ML17286A571
| ML17286A571 | |
| Person / Time | |
|---|---|
| Site: | Columbia  |
| Issue date: | 04/10/1987 |
| From: | WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | |
| Shared Package | |
| ML17286A569 | List: |
| References | |
| QCI-6-13, NUDOCS 9102050185 | |
| Download: ML17286A571 (54) | |
Text
APPENDIX I Procedure QCI 6-4., Revision 5 Pr ocedure QCI 6-13, Revision 4
9102050185 910123 PDR ADOCK 05000397 Q
WASNINO'fON PIJNSIC tOWCR 4N, SUPPLY SYSTEM NDE & I INSTRUCTION QCI 6-13 REVe NOe CttKCTIVCDATK 4-10-87 Q ALITYAttKCTINQ Q]VK5
@NO ULTRASONIC EXAMINATION OF PIPING WELDS (t1ANUAL) 1.0 PURPOSE AND SCOPE 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 ASME 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 Qualifications 3.'l.l Supply System personnel shall be certified in accordance with Reference 6.2.
3.1.2 3.1.3 Contractor personnel shall be certified to the contractor's Quality 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.
Personnel designated as trainees may assist the Level II or III in performance of the examinations to this instruc'tion.
3.1.4 Level I individuals shal] perform only specific setups, calibrations, tests or record data to the 'requirements 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.
WRI Y
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QCI 6-13 Rev.
4 3.2 The pulse-echo, ultrasonic flaw detection instruments shall be equipped with a stepped gain control, grad-uated in units no larger than 2 dB.
Instruments considered accept-able for examination are listed.below; other instruments may be used if the model ape is qua'lified.
Krautkramer USIP-ll Krautkramer USL-48 Nortec ADT-131 or 131D 3.3 Single'r dual element ceramic. type trans-ducers having an area from 0.049 to 1.0 square inch shall be used.
Base material examinations and thickness measurements will nor'mally be conducted using a 2.25 or 5.0 HHz longitu-dinal wave transducer; however, other frequencies may be used where metallurgical characteristics prevent effective use of 2.25 or 5.0 HHz transducers.
3.3.2 hng3~~
Single or dual element iceramic type transducers having an area from 0.049 to 1.0 square inch shall be used.
The initial examination will normally be conducted using 2.25 HHz shear wave transducers with a beam angle of 43 to 47 degrees.
Other angles and wave modes may be used for evaluation of 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 metal-lurgical characteristics prevent effective use of 2.25 HHz shear wave transducers.
The transducer exit point and beam angle shall be verified, prior to examin'ation, using an IIW (International Institute of Welding) or Rompas calibration blook.
3.4 g~l Q Ultragel II or an equivalent shall be used as the liquid 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 ASTH D129-64.
The sulfur content of the residue shall not exceed 1% by weight.
(b)
Couplants shall. be analyzed for chloride content in accor-dance with ASTH D808-63.
The chloride content of the residue shall not exceed 1X by weight.
Page 2 of 19
e QCI 6-13 Rev.
4 3.5 ~Ii 3-Clip Cl bl 3
I lib 5 \\3\\3\\
Section 14 of the Inservice Inspection Program Plan or as specified by the Responsible Technical Organization (RTO).
3.6 r
P The finished contact surfaces shall be free from weld splatter 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 5
n i
qn - The ultrasonic instrument linearity shall be checked each day prior to its use and documented on the Cali-bration Data Sheet shown in Attachment 7.2.
Linearity shall be determined in accordance with the requirements of Paragraphs (a) and (b) below.
(a) ri
- 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 cali-bration block.
Ad)ust the search unit position to give a 2 to 1 ratio of amplitudes between the responses, with the larger set at 80'L of full screen height (FSH).
Hithout moving the search. unit, ad]ust the gain control to succes-sively set the larger signal from 100K to 20K FSH in 10'/
increments or in 2 dB increments if the instrument is equipped with a stepped gain control.
The sma1'ler signal amplitude mu'st be 50K of the larger.amplitude signal within
~
5/. FSH.
Instruments that do not meet this requirement shall not be used.
(b) r 1
h
- To verify the accuracy of the amplitude control in 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 ampli-tude shall be brought as near as possible to &OX FSH with the
. dB control. If necessary, the final ad)ustment to
&OX FSH can be made with the variable gain control.
Using only the dB control, the dB changes indicated below shall be made and the resulting amplitude compared with the allowable amplitude limits.
The procedure shall'be repeated for 40K and 20'L FSH amplitudes.
The initial settings and readings shall be esti-mated to the nearest 1/ of full screen.
Instruments that do not meet this requirement shall not be used.
Initial Amplitude X F
&0 80 40 20 dB Control
~i~(g
-6
-12
+6
'12 Amplitude Limits
'/
H 32 to 48 16 to 24 64 to 96 64 to 96 Page 3 of 19
0
QCI 6-13 Rev.
4 e
3.8 3.8.1 Calibration shall be performed from the surface of'he cali-bration block which corresponds to the component surface to be examined.
3.8.2 3.8.3 3.8.4 3.8.5 The calibration block'temperature shall be within 25'F of the component being examined.
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.
Calibration shall be performed at the beginning of each day prior to use with each calibration block and shall be checked at the following intervals:
(a)
At least every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during an examination; (b)
At the start and finish of eaCh completed examination; (c)
At each change of examiners; (d)
In 4he event of loss of.power; and (e) If any'art of the examination system has been changed; such as, search units,,cabl,es-'or ultrasonic instruments; (f). If the operator.suspects:a malfunction.
Calibration checks may be performed on a secondary reference, such as an IIN, Rompas block or equivalent, provided the
. response from the block has been referenced after initial calibrati'on.
The tolerances of 3.&.7 and 3.8.8 shall apply for this operation.
3.8.6 Final cal.ibration shall be performed on the calibration block used for initial calibration.
3.8.7 w
- If the indication from any of the calibration reflectors has moved on the sweep line more than 1(C, correct the sweep range calibr'ation and note the correction on the Calibration Data Sheet.
If recordable indications were noted on the Examination Data Sheets, those data sheets shall be voided.
A new calibration shall be made and recorded and the voided examination areas shall be reexamined.
Page 4 of 19
e QCI 6-13 Rev.
4 3.8.8
- If the amplitude of any of the calibration reflectors has changed by more than 2 dB, all data sheets since the last acceptable calibration check shall
'e marked void.
A new calibration shall be made and recorded and the voided examination areas r'eexamined.
3.8.9 All required.calibration data shall be recorded on the Ultra-sonic Calibration Data Sheet,.2.
9.9 ~-Pi t
Ptll i
t tl,tt lit ti techniques in 4.0 shall be demonstrated in the presence of an Autho-rized Nuclear Inspector.
The successful completion of these cali-brations shall be documented on Calibration Sheets,.2.
These calibrations shall serve as a generic qualification for record purposes only as the instruction is essentially qualified upon each successful calibration used during the course of the weld examinations.
4.0 ZEXJMK 4.1
- 4. 1. 1 Calibrate the'instrument sweep to the required sound path distance using an IIW, Rompas or an equivalent block having
. known dimensions.
The sweep calibration shall be sufficient to include all reflectors required to construct the distance-amplitude correction (DAC).curve.
.4.1 2-For the examination of piping welds u'sing the 1/2 "V" 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 ampli.tude 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.
Ad)ust the instrument gain to set this signal at 80'4 of full screen hei.ght and mark the location and amplitude of the signal on the screen.
(b)
Without changing the instrument controls, maximize the signal of the two remaining holes and mark their ampli-tudes and locations on the screen.
Page 5 of 19
QCI 6-13 Rev.
4 (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
'he amplitudes and locations o'n 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 con-struction 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 "V" path location.
Adjust the ampli-tude of the notch to be equal to the DAC curve.
This is the primary DAC reference level.
(f)
Record and plot all calibration data on the appropriate areas of the Calibration Data Sheet.
(g)
After the primary DAC reference level has been estab-
'ished on the pipe calibration standard, a calibration reference response may be's'tablished 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 informa-
, tion 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 "V" 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 circumferential notch on the opposite side of the cali-bration block and adjust the instrument gain to set the response at 80/. of full screen height.
Hark the loca-tion and amplitude on the screen.
Page 6 of 19
QCI 6-13 Rev.
4 (b)
Without adjusting the gain, obtain responses from the notches at 1
and 1-ll2 or greater "Y" path locations.
Hark 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 appropriate areas of the Cal.ibration Data Sheet as shown in.2.
(e)
After the primary DAC reference level has been estab-lished 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 apd amplitude calibration points and the gain setting used to establish them.
This informa-tion shall be recorded on the appropriate area of the Calibration Data Sheet.
This reference response may then be used to perform calibration checks.
Final calibratton,
'however, shall be'erformed on the pipe calibration standard.
4.2 B
i r
-P v
4.2.1 Calibrate the instrument sweep to a distance sufficient to include the 'thickness of the 'material being examined using an IIW, Rompas or an equivalent block having known dimensions.
4.2.2 For the examination of piping, fabricated from plate mate-rial, for laminar reflectors, calibration shall be performed according to the following:
4.3 r i (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 80K full screen height.
(b)
Record and plot all'calibration data on the appropriate areas of the Calibration Data Sheet.
B m
in p
v 4.3.1 This examination shall be performed only on pipe and/or fittings fabricated from plate material.
Page 7 of 19
QCI 6-13 Rev.
4 4.3.2 4.3.3 For detection of laminar reflectors in plate material, the search unit shall be placed on the base material and manipu-lated to ensure coverage of the entire area through which the sound must pass during the angle beam"examinati,on.
The instrument gain shall be ad)usted during the examination to maintain a back reflection of at least 50K full screen height while scanning.
4.4 n
1 8
m in i
f W 1
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 "V" 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 exam)-
nation cannot be performed from the weld crown, the search unit shall be placed directly ad)acent to the weld edge.
The sound beam shall be directed parallel to the weld and the search unit manipulated laterally and longitudinally.
Physical or other limitations which prevent complete examina-tion of the weld area shall be documented on the Examination Data Sheet.
4.4.4 Welds that cannot be examined from at least one side using the angle beam technique shall be examined by another volu-metric method.
4.5 ~ in 4.5.1 4.5.2 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.
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 1/2 or 1 or greater "V" path examination technique whichever is applicable.
Page 8 of 19
QCI 6-13 Rev.
4 4.5.3 For examination 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 per-formed in both directions. along the weld.
4.5.4 For longitudinal weld seams ad)acent to circumferential welds the entire weld length shall be examined during preservice examination.
For inservice examination only the first 1 foot of the weld from each adjacent circumferential weld need be examined.
4.5.5 The angle beam coverage for examination of 'reflectors paral-lel to the weld using the 1/2 "V" 'path examination technique shall be sufficient to permit the sound beam to cover the inner 1/3 T of the weld and at least 1/4 inch of the adjacent base material on both sides of the wel.d edge.
Manipulation of the search unit over the weld crown may be required to achieve this coverage using the. 1/2 "V" examination technique.
4.5.6 For 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 1/3 of the weld and 1/4 inch of the base material ad)acent to the weld.
'I 4 Beam Requ)red Scan Distance Measured from the
~Al hi IITII
\\
45 At least 3-1/2 T
60 At least 5
T 4.6 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 lOX of the transducer piezoelectric element dimension perpendicular to the direction of scan.
v For angle beam examination, scanning shall be performed at"a minimum of 2X (6 dB) above the primary reference level.
Six dB increases the signal amplitude by a factor of approximately '2,'making the primary reference curve a
50K, DAC curve.
Recording of indications requires the signal to be ad)usted to the point where it is equal to the DAC curve using the dB con-trol.
Signal amplitude can then be determined from the following chart using the observed change in the dB control.
Page 9 of'9
l 4
QCI 6-13 Rev.
4 0
100
-1
112 125 141
-4
159 178 200
-7
224
-8
251
-9
282 316
-11
355 400 447
-14 501
-15 562
-16 631 708
-18 794
-19 891
-20 1000 0 -
100
+1
90
+2 -
80
+3
70
+4 -
63
+5 -
56
+6
50
+7 -
45
+8
40
+9 -
36
+10 32
.'ll 28
+12 25
+13 -
22
+14 20
+15 18
+16 16
+17 -
14
+18 -
13
+19 11
+20 -
10 klk t
yk tk 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 locati'on of the pipe counterbore trans)-
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.
4.8 f r ftk f
the laminar reflector exceeds the remaining back reflection response in an area exceeding 3/4" in its longest dimension, the following data shall be recorded on the Examination Data Sheet.
Assign a number, beginning with 1, to each individual indication which is recorded.
Page 10 of 19
QCI 6-13 Rev
~
4 (b)
M~i~nfg~v Record the search unit location interval with respect to the stamped degree location numbers on the weld.
(c)
(d)
(e)
(g)
QHzLhngla Record the search unit beam angle (0 ).
5UUL5y~fKR Record the surface (1 or 2) on which the'earch unit is being applied.
See Attachment 7.3 5gglg P~ Record the sound path distance to the reflector.
~c~
Record the major dimension of the reflector in the lOOX DAC length column.
Prepare a sketch showing the area in which the reflector exceeds the remaining back reflection and attach it to the Examination Data Sheet.
4,9 i
n I
1 H~l'f the maximum signal amplitude equals or exceeds 50'/ of the primary reference level, the following data shall be recorded on the Examination Data Sheet.
(a)
Lng~ign ~io pr Assign a number, beginning with 1; to each individual indication which is recorded on each weld.
(b)
II d th h
lt I
tl
\\
t'ith respecto the stamped degree location numbers on the weld.
(c)
(d)
(e)
(g)
(h)
~agre~~ - Record the search unit beam angle, typically 45 or 60'.
1d~-
dth f
I tl I\\tth search unit is being applied.
See Attachment 7.3.
dl
- Il d
I tl I
It orientation with respect to the weld.
Beam direction will be A, B, C or D.
See Attachment 7.4 5gllnd ~ - Record the sound path distance to the indication at the peak amplitude location.
Q~; This information, recorded in degrees, is used to describe the extent of intermittent or continuous geometric indications.
If a more thorough description's
- required, this blank may be used to reference the notes section.
Jhl~l~l - If an indication is dampable on the surface of the part, it should be stated in this column.
Page 11 of 19
QCI 6-13 Rev.
4 e
(i)
~Lli~ly.- Record the maximum amplitude of the signal as a
percentage of the primary reference level.
())
~n II - Record the 50'L to 50K and 100% to 100'L DAC length of each indication.
(t)d~fll -Rd,l
) I.tt dlt (I) from the search unit to the smaller stamped location number and the distance from the exit point to the weld centerline.
(W) for longitudinally oriented indications or the distance from the search un.it centerline to the weld centerline (H) for transversely oriented indications.
These measurements shall be taken at the maximum amplitude location.
See.5.
(1)
Thr W
11 m n If the maximum signal'mplitude equals or eXceeds 100K 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 measurements shall be taken at the 100'A 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 s'arne scan line.'ach indication shall be fully investigated to determine the points at which the minimum and maximum readings occur.
I )D M R
DID((RD~RI I DIR.ID RL I~ RDR((D mil r 1
W 1
Any crack-like indication; regardless of amplitude',
shall be recorded and investigated to determine its
- shape, identity and location.
All indications 50'X DAC or greater determined to be geometrical or metallurgical in origin shall be recorded.
Any other indications determined not to be geometrical or metallurgical in origin shall be recorded if they are 20K of the distance amplitude correction (DAC) curve or greater.
(a)
~~n~qbyZ.- Assign a number, beginning with 1, to each individual indication which is recorded.
(I)
I~
d I I
(t I t
with respect to the stamped degree location numbers on the weld.
. (c)
~~glp Record the search unit beam angle (0').
Page 12 of 19
QCI 6-13 Rev.
4 (d)
(e) d h
t h
h search unit is being applied.
See Attachment 7.3.
d\\
t.t d
th h
tt orientation with respect to the weld.
Beam direction will be A, 8, C or D.
See Attachment 7.4.
(f)
,'~~P 4 - Record the sound path distance to the reflector.
(g)
~~n
- 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) gag~ - If an indication fs dampable on the surface of the part, it should be state'd in this column.
(i)
~m~i.Sh - Record the maximum amplitude of the signal as a
percentage of the primary reference level.
(]>
~d(th Record the 202 to 202 (when re(>e>red>,
SO% to 50'L and 100K to 100K DAC length of each indication.
(k) h ni P
Record, in inches, the distance (L) from the search unit to the smaller stamped location number and the distance from the exit point to the weld centerline (N) for longitudinally oriented indications or the distance from the search unit centerline to the weld centerline (W) for transversely oriented indications.
These measurements "shall be taken at the maximum amplitude location.
See.5.
4.11 m
r 1
- Ifthe maximum signal amplitude
. equals or exceeds 100K 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 measurements shall be taken at the 100'L DAC level.
The minimum and maximum sound path readings may not necessarily be at the point of maximum signal amplitude, nor dothey 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.
4.11.1 A Calibration Data Sheet (Attachment 7.2) shall be prepared for each calibration.
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.
Page 13 of 19
QCI 6-13
.Rev
~
4
- 5. 0 i'YALAYA~
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 tn accordance with Paragraph IHB-3514 of ASME Section 'XI, 1980 Edition Hinter 1980.
Addenda (Reference 6.1.1).
5.2 Any area where complete examination cannot be performed due to obstructions, configuration of we'Id, 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 fg~F~N I
6.1 American Society of Mechanical Engineers Boiler and Pressure Yessel
- Code, 1980 Edition through Hinter 1980 Addenda.
6.1.1 Section XI - "Rules, for Inservice Inspection of Nuclear Power Plant Components".
6.2 The Supply System "Program Manual for Qualification and Certification of Examination, Testing and Inspection Personnel HMC-034".
7.0 7.1 Examination Data Sheet 7.2 Calibration Data Sheet 7.3 Examination Surfaces 7.4 Beam Directions
'.5 Search Unit Location and Orientation Page 14 of 19
i e
OCI 6-13 Rev.
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gCI 6-13 Rev.
4 O
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P WASNINOSOA ~ UALIC tOWSA 4P SUPPLY SYSTEM NDE & I INSTRUCTION QCI 6-4 RCVo NO+
CFI'CCTIVC DATC 3/28/89 A
T ARRKCTIN4 g VKK PNO ULTRASONIC EXAMINATION FEEDHATER'NOZZLE INNER RADII 1.0 2.0 1.1 This procedure defines the requirements for manual, pulse-echo ultrasonic examination of the feedwater nozzle inner
- radius, (Zones 1,
2, and 3),
ASME Section XI, Category B-D.
Scanning by this procedure is done from the reactor vessel O.D. wall and nozzle surfaces using refracted shear wave search units.
Figure 1
illustrates 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 Hinter 1980).
1.4 BHR Calibration Data listed in Table I have been predetermined from the Supply System's feedwater nozzle mockup so the qualified exam-iner need only use the vessel calibration block representing the shell course containing the nozzle.
None.
3.0
- 3. 'I I
3.1.1 Personnel performing examinations to the requirements of this instruction shall be a certified to at least Level II, in ultrasonics in accordance with the requirements of Refer-ence 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 BHR feedwater nozzle mockup and this ultrasonic examination procedure.
91020S0187.
910123 PDR ADOCK 05000397 f;"
9 PDR 7&~y'HCCKK KV/D T I C 4 III/DAT
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ROYAL/DATK 5 ZV-8 W~O5 R4 5UtCRSKDK5 155UCs Revision 4
~AOC 1
21 OIs
QCI 6-4
.Rev.
5 0
3.1.2 Personnel not specifically qualified on the BHR feedwater nozzle mock-up, but designated as Trainee, Level I, II or III UT may assist a qualified examiner in performance of examinations to this instruction.
3.1.3 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 of (b) above.
3.2 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 Xauimaai
/
3.3.1 The pulse-echo, ultrasonic, flaw d'etection instrument shall be equipped with a fine gain or attenuation control graduated in units no larger than 2 dB.
Instruments considered accept-able for this examination are listed below;
- however, other instruments may be used if the model type has been qualified.
Krautkramer VSIP-11, USL-48, USD-10 Nortec NDT 131 or 131D, 132D 3.3.2 Single element'eramic transducers, having an area of'44 to 1.0 square inch, with a nominal frequency of 2.25 HHz shall be used with specific
- wedges, Figure 5.
The refracted angle within the material shall be within the limits shown in Table I.
Additionally, data may be taken with other sizes, frequencies, and angles, after completing the examination to the above requirements.
3.3.3 Ultragel II or its equivalent shall be used as the liquid couplant; 3.3.4 The vessel calibration standard listed in Table I shall be
-used.
This standard corresponds to the shell thickness containing the sub)ect nozzle.
3.3.5 IIN-2 ROMPAS or modified Type DC (square ended semicircle) sweep calibration reference blocks.
3.3.6 Flashlight for reading instrument control knobs.
Page 2 of 21
QCI 6-4 Rev.
5 3.4 f
3.5 The contact surface shall be
<lean and, free of dirt, dust, weld
- spatter, loose paint, or other material which would interfere with free movement of the transducer or impair transmission of ultra-sonic energy into the material.
The scanning speed shall'not exceed 3 inches per second.
3 '
1 fi i
Prior to the examination, the nozzles shall be marked and identi-fied in accordance with a nozzle marking plan as illustrated in Figure 6.
'Sanford's "Sharpie" black tip marker is the accepted pen device.
3.7 Calibration shall include the complete ultrasonic examination system.
Any change in couplants,
- cables, or ultrasonic instruments shall be cause for recalibration.
Sweep calibrations may be made with 'a'tandard angle beam wedge using the IIH or similar curved
- block, and must be representative of the metal path expected for the zone to be examine'd, reference Table I..
3.7.1 Instrument Calibration --Prior to the initiation of scheduled examinations, the ultrasonic instrument shall be checked for screen height and amplitude control linearity per paragraphs 3.7.2 and 3.7.3.
3.7.2 Screen Height (per ASHE) Linearity Check
. An angle beam s'earch unit shall be positioned on a calibration block and signals obtained from two reflectors.
The search unit posi-tion shall be ad)usted to give a
2:1 ratio of amplitudes between the two reflectors.
The gain control (sensitivity) shall be ad)usted and the larger signal brought to 80K of full screen height (FSH), ad)usting position if necessary to maintain the 2:1 signal ratio.
Hithout moving the search unit, ad)ust the gain control to successively set the larger signal from 'lO(C to 2N'.
FSH in lOX increments or 2 dB steps.
The smaller amplitude must be 50K of the larger amplitude within SX 'of FSH.
Instruments that do not meet these requirements
'shall not be used.
3.7.3 Amplitude Control Linearity Check The angle beam search unit shall be positioned on a calibration block and a peaked signal amplitude obtained.from a hole or notch.
The indi-cation shall be brought as near as possible to 80K FSH with Page 3 of 21
OCI 6-4 Rev.
5 the dB control. If necessary, the final adjustment to 80K FSH is 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 amplitude compared with the allowable amplitude limits as specified below.
Instruments that do not meet these limits shall not be used.
The proce-dure shall be repeated for 40K and 2N! FSH amplitudes.
Set of 'A FSH Change (X FSH) 80 80
'40 20
-12
+
6
+12 32 to 48 16 to 24 64 to 96 64 to 96 3.7.4 R'ecal'ibration (Sweep Only) If the indication from the cali-bration reflector has moved on the sweep line more than one inch of metal path, correct the sweep range calibration and note the correction on the calibration data sheet. If record-able reflectors are noted on the examination data.sheets, those data sheets shall be voided.
A new calibration shall be made and recorded, and the voided examination areas shall
~
be re-examined.
3.7.5 Recalibration (Amplitude Only) - If the amplitude of the calibration notch has changed by more than 10'A FSH when a
check is made on the reference block, all data sheets since the last positive calibration check shall be marked void.
A new calibration shall be recorded and the voided examination areas re-examined.
The voided sheets may be discarded.
Calibration shall be performed at the beginning of each series of examinations.
A calibration verification shall be made at intervals not exceeding four hours during the examinations.
4.0 An initial instrument sweep calibration shall be made for shear wave velocity by using the examination search unit with a conventional angle beam shear wave wedge and the IIW, Rompas or modified DC type curved calibration block.
Sweep calibration data is listed in Page 4 of 21
~I OCI 6-4 Rev.
5 Table I for each nozzle.
The oscilloscope's
'screen shall read directly in inches of metal path and the data entered on the cali-bration 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.
Ad]ust the "Range"'nd "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 9.
Next, delay the signal at 6 to zero.
Signals should again appear at zero, 3,
6 and 9. If they do not, make minor ad)ustments so they do.
The CRT is now calibrated for 14 to 24 inches of metal path.
4.1;2 Zone 2 Using the transducer with <he wedge, obtain peaked signals from the 1
calibration block No.
120.
Ad]ust-the obtain reflection signals at positions the signal at 5.4 to the 0.4,position.
calibrated for 5 to 15 inches of metal
- 4. 1.3
. Zone 3 - Using the transducer with the calibrate as in 4.1.2.
convex 25'hear
/2 to 3/4 "T" holes in range and sweep to 3.5 and 5.4.
Delay The CRT is now path.
flat 25 shear
- wedge, 4.2 Basic calibration gain sensitivity shall be determined by both the applicable vessel calibration block and the transfer sensitivity gain as shown in Table l.
Basic calibration shall be established with sufficient gain so that 2X scanning can be performed without changing the variable gain control.
To determine the basic sensitivity level, the search unit shall be held on the applicable vessel calibration block with the signal amplitude from the 3/4 T-hole maximized.
The instrument gain con-trols shall then be ad)usted so that the 3/4 T-hole signal amplitude is brought to 50K FSH.
This basic sensitivity level shall then be ad)usted for each zone according to Table 1's "Transfer Sensitivity dB Gain Increase."
After ad]usting to the transfer sensitivity gain
- increase, the gain setting shall now be the primary reference level of 1X.
Examination scanning shall be at 2X (+6 dB) above the pri-mary reference level.
SEE:
As shown in Table 1, Zone 1 requires no additional gain ad-
]ustment after the 3/4 T-hole is maximized at 50'L FSH to achieve the Page 5 of 21
QCI 6-4 Rev.
5 4.3 primary reference level (see Note 4).
Transfer sensitivity gain is 0 for Zone 1.
However, for Zones 2 and 3 the primary reference gain level is an additional 12 dB over the 3/O'-hole maximized at 5(C FSH.
MQQQH:
Care must be exercised during calibration to assure the shear wave component is used for calibration since there is 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 approximately 5.7 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 approx-imately 4-3/4 inch metal path at a surface distance of 6-1/2 inches.
A Level 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 num-bered in sequence with calibration data sheets.
Scanning shall be performed at 2X above the primary gain level (1X).
Measurement and recording of ultrasonic indications shall be done at the 1X level.
The inner radius Zone 1 shall be scanned in two directions (CW and CCW) from the vessel plate as shown in Figure 9.. Scanning shall be done in a circumferential or radial motion with a minimum overlap of 0.5 inches.
The moveable pointer on the transducer wedge shall be positioned in the groove marked "CCW" for scanning counter clockwise and "CW" for scanning clockwise.
While scanning, the pointer shall be aimed at the nozzle bore to the extent practical with the trans-ducer oscillated slightly.
The examiner shall reference Figure 9
for transducer orientation.
The scan boundaries extend from the end of the blend radius to a
distance of 9 inches out on the shell wall.
The operator shall occasionally rotate the wedge toward the bore axis to obtain a
direct reflection signal from the'nner radius as a check to confirm penetration.
=
P 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 (CW) and counterclockwise (CCW) (Figure Il).
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.
Page 6 of 21
OCI 6-4 Rev.
5 The nozzle forging and the inside bore shall be examined to the maximum extent possible using the cylindrical surface for scanning (Figure 12).
The scan path of'he search unit shall overlap the adjacent scan by a minimum of 0.50 inch.
The search unit shall be scanned circumferentially around the nozzle forging so the angle beam shear wave covers all 360'f the circumference in both the clockwise and counterclockwise directions.
4.4 4.5 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 ti'me position on the CRT shall be investigated to determine maximum amplitude.
Indications in the region of the blend radius which exceed 25K 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 (CH) or counterclockwise (CCW), and search unit position.
f P
f Reference points for physical measurement of azimuth shall be in accordance with the nozzle reference plan shown in Figures l0, 11, and 12.
4.6 D
P 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.
2.
3.
4.
5.
Report No.
ISI Drawing No.
Zone No.
Sweep Distance Indication No.
5.0 5.1 5.2 The recorded data shall be reviewed by a level III Examiner to determine if additional examination and/or interpretation is required.
Recorded indications shall be plotted on a scale no less than quarter size and reviewed by the Level III Examiner.
Page 7 of 21
OCI 6-4 Rev.
5
- 6. 0 ggQ'f~N 6.1 American Society of Mechanical Engineers Boiler and Pressure Vessel
- Code, 1977 Edition through Summer 1978 Addenda.
- 6. 1. 1 Section XI - "Rules for Inservice Inspection of Nuclear Power Plant Components".
6.1.2 Section V - Nondestructive Examination".
6.2 American Society for Nondestructive
- Testing, June 1975 Edition.
Recommended Practice SNT-TC-lA "Nondestructive Testing Personnel Qualification and Certification".
6.3 The Supply System "Program Manual for Qualification and Certifica-tion of Examination, Testing and Inspection Personnel HMC-034".
6.4 Nozzle forging drawings - General Electric/CBI Nuclear Page 8 of 21
QCI 6-4 Rev.
5 TABLE I ULTRASONIC CALIBRATION DATA FOR EXAMINATION OR BHR NOZZLE INNER RADII NOZZLE TYPE '- N4 FEEDHATER ACOUSTIC AN9LES DEGREES' B
C CRT DISPLAYED SHEEP CAL STANDARD
¹ TRANSFER SENSITIVITY dB GAIN INCREASE Zone 1
22 70 70 Zone 2
22 25 63-'70 Zone 3
0-10 25 63 5" to 15" UT 120 5" to 15" UT 120 14" to 24" UT 1202 0
12 12 2.
3.
4.
See Figures 2A, 2B, 3 and 4 The 5/16 in. dia.,
3/4 T hole (5.06 in.
below the contact surface) shall be used for calibration.
Convex shoe NOTE:
The following is in reference to Zone 1
transfer sensitivity.
Gain setting for 5(C FSH indication is 6
dB less for RFW nozzle mock-up notch (Notch A) than for 3/4 T-hole of cali-bration standard
. UT-120.
Therefore, as a
conservative
- measure, the 3/4 T-hole gain setting has been accepted as the primary gain level.
Page 9 of 21
OCI 6-4 Rev.
5 3
NOZZLE EXAMINATIONZONES FIGURE 1
Page 10 of 21
OCI 6-4 Rev.
5 Vessel Plate Scan Width Scan Start Dimension ~
4e
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~ 1I~ ~
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Nominal Entry Point For Sound Beam for Zone t A
Skew Angle (Offset)
B Refracted Angle G
Intercept Angle Ultrasonic Search Unit Assembly with Compound Angle
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2B. SOUND BEAMGEOMETRY IN NOZZLE FOR ZONE'1 FIGURES 2A and 2B Page 11 of 21
OCI 6-4 Rev.
S SCAN AREA C
SECTIONALVIEW OF NOZZLE BODY FIGURE 3 SOUND BEAMGEOMETRY ZONE 2 FIGURE 4 SOUND BEAM GEOMETRY, ZONE 3 SECTIONALVIEWOF NOZZLE CYLINDER FIGURES 3 and 4
Page 12 of 21
OCI 6-4 Rev.
5 SIDE VIEWS END VIEWS ZONE 1, FLATCONTACTSURFACE
/
/
ZONE 2, CONVEX CONTACTSURFACE
/
/
ZONE 3, CONCAVE CONTACT SURFACE FIGURE 5 TRANSDUCER HEDGE CONFIGURATIONS Page 13 of 21
4 P
OCI 6-4 Rev.
5 NOZZLE NUMBER LOCATED ON TAPER l
4-LINES MARKED ON NOZZLE BODY I
t 3454 3
0'454 I
300' 00 ZONE 1 CIRCLE RADIALLINES EXTEND AT LEAST2 PAST REF CIRCLE 304 2854 27po 54 904 X DISTANCE ~
24 05D 2100 195'80'04 354 (BOTI'OM)
FIGURE 6 NOZZLE MARKING PLAN Page 14 of 21
OCI 6-4 Rev.
5 ULTRASONICCALIBRATIONSHEET
~AOJECTs KXAMINKRs KXAMIMKRs LKVELs LEVELs 4% SUPPLY SYST"M DATEs INSTRUCTIONNox SHEET NO
'HE AMOMKTER8/Ns CASLKTYPE RKVISIONs TEMPEAATVRK CHART RECORDER TYtts SIM THAt IEW WIEEE F
CAIN IN sAs IN. SIZE IEEE IEI ACTUALAMOLK INSTRUMENTCAI.ISRATION
~
EW WEVEWEEE tRKVIOUSLYttRFOAMKDON CALISRATIONSHEET NUMSKR SCREEN HEIGHT LDIKAAITY FOR CONTINUOUS0*INCONTROL IQ 100 90 80 70
$0 50 10 20 20 SCRKEN HEIOHTLINEARITY FOR 2EAs STEt CAINCONTROL Alltl.ITUOECOMTAOLLRIEAAITY LITUOK%
80 12 sAs
+2 0
-2 W
M W 12 1$
sSs CHANCE
-8 HIGH 80
+'12 ITIALCALTIMts INSTRUMENT SKTTINOS wAASKRANCE w COARSE DELAY IIANOECALIS SLAYCALIS FREQUENCY 0*ININA OAlltINO IS NOOK
/8 NOOK itNOOK IS NODE n NOOE IS MODE AMPLITUDE RFSH SYSTEM CAU8RATION SWEEP READINO IN INCHES LIMITS%
FINALCALTIMts SCREEN DACtAESKMTATION 1$ ~ 24
$$ ~ 9$
CALCHECKS RClECT FILTER KA cAs SEARCH UNIT OAIKMTATIOM AXIAL SS USE A
TIELOS Oh tAATStXAMIMKD REVIEWED SY LEVELIlls SM 102' OATKs 0
1 2
2 8
0 7
FUI.LSCREEN SWEEP AtVIEWEDSYs 8
10 IN.
OATS s FIGURE 7 Page 15 of 21
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3154 Q4 PO 3454 154 QO REFER NCE CIRCLE QCI 6-4 Rev.
5 3004 600 2850 50 2700 PO 255 054 240 200 354 180'IXED AZIMUTHCIRCUMFERENTIAL SCAN TECHNIQUE '
SECONDARY 654 MOVINGAZIMUTH
$CAN TECHNIQUE PRIMARY CIRCIJNFERE?ITI,'L,NO RADIAL SC,",II?IIt!G ZONE 1 REFERENCE CIRCLE ZONE 1 REFERENCE CIR LE SCAN PATHS
~
~
Xdcr eoInter Toward Bore Xdcr Bet. lt+< y einter Toward Bore SCAN PATHS SCAN IN CW AND CCW DIRECTION CIRCUMFERENTIALSCANNING MOTION SCAN IN CW AND CCW DIRECTION RADIALSCANNING MOTION FIGURE 9 SCANNING NOTIONS FOR TKE ZONE 1
EXAMINATION Page 17 of 21
ocr 6-a Rev.
5 po 15'04 ZONE 1 REFERENCE CIRCLE 604 54 a
a e
a ww 90 604 DIST NCE(D)
AZIMUTH(A)
REFERENCE CIRCLE NOTE:
ALI.(A) MEASUREMENTS SHALLBE IN COUNTER CLOCKWISE DIRECTION FROM NEAREST RADIALUNE.
ALL(D) MEASUREMENTS SHALLBE FROM REFERENCE CIRCLE RADIALLYOUTWARD.
FIGURE 10 MEASUREMENT CRITERIA FOR RECORDING UT Page 18 of 21
OCI 6-4 Rev.
5 004 At(CCW) 270'or "0"distance measurement See Figure 12 Mid Radius Scan Width (x360')
adius End NOZZLE CROSS SECTION FIGURE 1 1 REQUIRED SCAN PATHS AND HEASUREHENT CRITERIA FOR ZONE 2 EXAMINTIONS Page 19 of 21
OCI 6-4 Rev.
5 CIRCUMFERENTIALSCANS SHALL BE MADEIN TWO DIRECTIONS AROUNDTHE CYLINDRICALSECTION OF THE NOZZLE FORGING (TOP)
'EASURE D DISTANCES FORM BREAKPOINT ON NOZZLE FORGING BETWEEN CONICALANDCYUNDRICAL SECTIONS 2700 gp4 SIDE VIEWOF NOZZLE 1800 Reference Az Snes are each l5'round the nozzle. AllAz measurements are made in counter~ckwise direction hom these Knes to the index mark on the search unit., View made kroking toward the vessel.
FIGURE 12.
ZONE 3 SCANNING AND LOCATION REQUIREMENTS Page 20 of 21
OCI 6-4 Rev.
5 315 330 0
15 30 270 105 120 21 19 180 1 0 Pkc olhd~<)
Icf QSI NL lNpHHa:
ScW 1:4 FIGURE 13 Page 21 of 21