ML19208A625

Responds to IE Bulletin 79-17 Re Pressurized Water Reactor Facilities W/Ol.Forwards Flow Diagrams or Makeup & Purification,Decay Heat,Spent Fuel & Bldg Spray Sys

ML19208A625
Person / Time
Site:	Crystal River
Issue date:	08/27/1979
From:	Stewart W FLORIDA POWER CORP.
To:	James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
IEB-79-17, NUDOCS 7909170094
Download: ML19208A625 (81)

Text

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Power i

C O n F O n a T O 8e August 27, 1979 File:

3-0-3-a-3 Mr. J. P. O'Reilly Director U.S. Nuclear Regulatory Commission Office of Inspection and Enforcement Suite 3100 101 Marietta Street Atlanta, Ga 30303

Subject:

Crystal River Unit 3 Docket No. 50-302 Operating License No. DPR-72 I.E.Bulletin 79-17

Dear Mr. O'Reilly:

Enclosed is our response to Item 1 of I.E.Bulletin 79-17.

Please contact this office if you require any additional discussion concerning our response.

Very truly yours, FLORIDA 10WER (DRPORAT/0N 1

~.5LUQO W. P. Stewart Manager, Nuclear Operations WPSemhD77 g <. 3 y_ o a.-

e cc: Directot Division of Operating Reactors Office of Inspection and Enforcement U.S. Nuclear Regulatory Coctmission Waahington, D.C. 20555

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omcra eseg; 790917 e oqq General Office 32o1 Tnirty.iourtn street soutn. P O Box 14042. st Petersburg. Fionda 33733 e 813-866-5151

IE BULLETIN 79-17 RESIUNSE For All Pressurized Water Reactor Facilities with an Operating License:

1.

Conduct a review of safety related stainless steel piping sy ems within 20 days which contain stagnant oxygenated borated watpr. These systems typically include ECCS, decay / residual heat remova l, spent fuel pool cooling, containment spray and borated w. iter stor. ige tank (BWSE-RWSr ) piping.

RESPON SE :

Stagnant systems are those which do not normally function dnring routine plant operation.

At Florida Power's Crystal River Unit 3, the systems (or portions of systems) which contain stagnant oxygenated borated water are the following:

(1) Makeup and Purification (lligh Pressure Injection) MU (2) Decay lleat (Low Pressure Injection) Dil (3) Spent Fuel SF (4) Building Spray H Flow diagrams of each system are attached:

MU:

FD-30 2-661 Dil:

FD-30 2-641 SF.

Fu-30 2-6 21 BS:

FD-30 2-711 r.n r o Sd6xdO WPSemhD77

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1(a) Provide the extent and dates of the hyd rotes ts, visual and volumotric examinations performed per 10 CFR 50.55a(g) (Re:

IF Circular 76-Oh enclosed) of identified systems.

Include a description of the non-des t ruct t ve examinatton procedures, procedure qua1ificatlons.iad acceptance crit eria, the sampling plan, result s of the exam attoon and any related corrective actions taken.

RESPON SE :

Florida Power performed examinations per IE Circular 76-06 as outlined in our 28 February 1977 letter, attached.

During January 1977, FPC discovered two through-wall cracks in the Building Spray system, 8" TP 304 Stainless Steel, Schedule 40 pipe.

See LER 77-1 and 77-6.

Cracked sections were removed and replaced with TP 304 SS, same size.

Volumetric examinations per IF. Circular 76-06 were pe r f o rme.I in.' 7 l, ot the Buildind Spray welds and 11% of the Decay lleat welds.

NDC procedures used were Babcock and Wilcox Procedures ISI-101 (Revision 11) ari e ISI-102 (Revision 7), attached. No procedure qualifications are available since Florida is not a code state, but the procedures are certified by B6W's Level 111 examiner as meeting or exceeding requirements of Section XI (1971 edition through Winter 1972 addenda).

Random selection of welds was made per MIL-STD-105D Sampling Procedures and Tables for Inspection by Attributes.

Results of the examinations, as summarized in the FPC 28 Februarf 1977 letter: no findings indicative of chloride stress corrosion cracking.

Corrective action taken by FPC:

(a) Monthly hydrostatic test of Building Spray, Makeup and Decay llcat systems (by SP-340, ECCS Pump Operability).

(b) Monthly draining of Building Spray system, prior to and af ter monthly operability tests.

(c) Volumetric examination of area of Buttding Spray cracks in addition to Section XI requirements during 23 April 1979 ref ueling outage.

Indications were acceptable.

(d) Volumetric examination of area of Building Spray cracks during next ref ueling outage.

FPC letter of 5 April 1979, attached, modifies the earlier 28 February 1977 letter to eliminate tests of Building Spray and Decay lleat welds other than scheduled IS1 examinations.

WPSemhD77

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60 DAY LTE t.te-79 T'

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28 February 1977 h

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Crystal P.ive r Unit 3 Mr. Nornan C. Moseley, Director Docket I o.

50 002 Of fice of Inspectien cv! Enforecinent U. S. !!uclec r R;;t< c to., Ce remis s ion License C PT.-72 2 30 Peachtree St.,

Suite 818 Kef:

LEP's 77-1 and 77-G At3anta, Geert,a 3'> 3 D 3 Dear Mr. Moscicy-results of our study precipi-Yne. purpore of this letter is to su=arire the (2) th rci.t;h wall crack.' in eight-inch, Type 30 '., s t ai n -

tated by finding pro less steel, SchcJule 40 pipe in the P,uilding Spray Systen as reported in a

Licersee Event Kercrts 77-1 and 77-6.

the sections including the 'relds Upen discovery of the through call cracks,

and metallurgical examination to deterrinc c aus p

were renoved fcr replacenent to a metallurgical Inboratory f or exc- -

L' of failure.

! rice sag: tant uns scnt nation.

The report received conclude.d the failure uns due to chloride ctre.

The peint of entry of the chlorides cannot be satisfactorily corrosion.

n.:y have been ESV-26 uhich was disassembled during the tes:

accounted for but and erectica progrcm.

The report suggests' chloride contamination by storage of t.he Building Spray Systcm in the marinc environmant of the Gulf Coast.

We do not concur with this speculation.

Stagnation of water is likely Figure 1 (enclosed shows the a'rea of concern. the Reactor Luilding and th:

to have occurred bctween closed BSV-4 outside Iligh chloride content isolated upward bend in the pipe inside the building.

that both to this area is strongly suggested by the configuration and the fact f ailures' occurred nearly simultaneously, in similar veld heat affected zones Both failures occurred in areas of ucids which had under-in Schedule 40 pipe,.

four (4) wcld repairs which amplifics the problem or sensitina-gone at least affected zone of thin wall stainless pipe and induces high t' ion in the heat We stress, both conditicas being necessary for chloride stress corrosion.

chloride entry occurred during the Building Spray Puttp Runout suspect.that flow path.

Test pregram uhen BSV-26 was disassembled to provide a temporary A sictilar piping configuration exists on the "B" Bui(ding Spray Train, but Ultrasenit Exanination,'which effectively identified the cracks in the "A" We believe, there-Train, demc,astrated the integrity of similar zones in "B".

and that it is b

foru, that these two (2) failures really constitute one event l

an isolated insrance.

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Vnin..:t ri. en.Iv ri ens verc ' performed in ucld zonce in erc.

where st a~n ent -

'liqu;d.

e,u : r.b l e as.sucrected in IE Circular 76-06.

cc

y-seven (2 7%)

of.he t ot al velds in the Building Spray Systct-and ejcycn (11%)

p:rcent pM cc ut c f d,e total.c1ds in the Deca;. I! cat System vete examined uith no f i t.w :i gn.m.. t._ tive of chloride strecs corrocion crackir.g.

Upon receipt of IE Circular No. 76-06, it did not pertain te our facility as tm had oc,r received our Operating License.

Houever, due to the crackiag ue have experienced, ue are naking, preparations to arct t h e "!.c t i c a n t o b e t.'k e n by Licenace" listed en pages 2 and 3 of IE Circular 76-06.

These are as fol-louc:

1.

Florida Pcuer Corporation will hydrostatically tect, code class 2 and 3 systers, in accordance with the AS:2 Code Sectica X1, 19 74 throuch Su me; 1975 Addcada, wi th cxcepti cac r.cted in the waiver for 1.hich uc are apply-ing.

Specifically, it is' nur interpretaticn of Sectica XI, Subsection IL'C-5000 th

' Florida Pe. cr is meeting hydrostatic test parnineters menth]:

in operability verificatica of both the Building Sprcy 3ystem and the Oc-cay Heat System.

The procedure for operability chechs for any systen Ice; HovcVer, both f ailures in the Building Spray Syster hav.,

during this test.

occurred in areas of the line doenstrec= of the shut-of f valve for pressun These arcas shall be drained acnthly pricr to and af ter system tests.

operability checks to prevent accun.ulatien of non-ficcing water.

2.

As previcusly stated, Florida Fe. cr has already comuleted volumetric cx-aminati:ns on randenly selected veldn in twenty-seven (27%) percent of the Building Spray System and cleven (11%) percent of the Decay Heat Systen on 3-inch and larger thin walled stainless steel pipe with no adverse finds.

In the future, we shall volumetrically examine five (5%) percent of the total velds in the Bui] ding Spray and Decay Heat Sve ter.s at each refueling outage, in addition to our recuired commitment in Section X1, 19 74 through Sue.mcr 1975 Addenda of the ASME Codes.

3.

During the course of the hydrostatic or volumatric examinations, should any adverse findings occur, your. office vill be notified within twenty -

four (24) hours.

Very truly yours, FLORIDA POWER CORPORATION -

W. P. Stewart (h)

Director, Poqcr Productfon DRP/fch

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...t lNSERVICE INSPECTION PROCEDURE SU DEC T ULTRASONIC EXAMINATION OF SIMILAR tCTAL WELD SEAMS AND ATTACH:CNT WELDS ISI-101, REV.11 l

g r ' l.

_SCO PE :

This procedure shall goverr. the maneal ultrasonic oxamination of similar weld seams and attachmgnt welds for,

.. inservice inspection in accordance with ASME Eiler anB

' Pressure. Vessel Code, Sections III and XI.

Ckkele,' longi-

'tudinal and attachment weld seams in piping and vessel welds up to 15 inches thick are covered by. this procedure.

The timing of the examination shall be in accordance with Section XI requirements.

2 EOUIPMENT:

Ultrasonic examination equipment shall consist of an cl.ectronic appara tus capable of producing, receiving and displaying high frequency electrical pulses at the required frequencies and energy levels.

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3.

OPERA. TOP. OUALIFICATION:

The operator performing tho examincticn shall be qualified to Level II in acecrdance with BrJ' Con-struction Company Ounlity Control Administrativc Procedu rc

'9A-lG9.

The assistant shall be qualified to at least Le' el ~

a in accordance with BEM Construction Comcany Ouality Control Administra tive Procedurc 9A-169.

n.

4.

SURPACE PEE PA FMION:

The examination surface.sha 1 ne free of dirt, loose scalc, machining or grinding particles, weld spatter, or other loose foreign matter.

The surface finish'shall be sufficiently smcoth to maintain accurt:cci bond and minimize surface noise.

A mill finish mav be

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adequate for testing.

Whenever necessary, surface condit-ioning shall be accomplished by available mechanicc1 processe.

such as machining, grinding, sand blasting, or belt sanding

,to provide a suitable surface finish.

Surface preparation

. shall-be performed on an arca which includes the weld and the arca for a 2T (2 times thickness)on both sides of the weld.

The ultrasonic testing operator shall inspect the surface for suitability for performing the examination.

Surfaces shall be prepared in accordance with ISI-50.

5.

COUPLANT:

A suitable liquid, semi-liquid, or pasto.couplant Med ium, such as water, oil, glycerin, grease or Hamiklcer shall be applied to the examination surface.

.o r.,S,.)

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(CVISED HY RCVISIOt1 PAGE 110.

y' CRH j,

1 OF HEVIStou DATE SECTIONS 8.1, 0.2.1, 9.4, 12.0, 7 g_,

12.M,

9. 2. 2, 9.5 105UE DATE 1/30/76 4-16-73 a

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INSERVICE It15PECT!Ott PROCEDURE

' ULTRASONIC EXN4INATIOti OF SIMILAR METAL SU N CC T ISI-101, REV,ll WELD STN1S AND ATTACll:1ENT WELDS s

stcols or nickcl

(

Each batch of materials"used on stainicss based alloys shall have been tested for residual amounts of total halogen and total sulfur in accordance with ISI-60.

Thc1 total residual amount ofhalogensandsuljhrshallnot exceed the requirements of ISI-60.

The couplapt batch number shall be recorded on the report data,fo'rm.

AREA OF INTEhEST:

The examination shall include the weld, 6.

weld fusion line and one plate thickness on both sides of the wcld beyond the fusion line in the case of welds in pressure boundaries and two plate thicknesses beyond the fusion line in the case of attachment or support welds.

7.

CALIBRATI ON BLCCK :

The calibration block material shall be of an 7.1

[1aterial-thickness and P-Number to the material being equivalent P-numbers 1, 3,

4, and 5 materials as listed in cxamined.

Table Q-ll.1 of Section IX of the ASME Boilcr and Pr'ccrui'.

Vessel Code are considered to be equivalent.

7.2 clnddinc

When an examination is to be performed from the cladded side of a component, the block shall contain cladding of the same nominal thickness and type as the ccmp-

7.3 Conficuration

The calibration block shall meet the minimur requirements of the basic calibration block.as shown in Figure 1.

7.3.1 Flat Blocks:

For examination of circumferential or-longitudinal welds on vessolc or piping with contact

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curvatures equal to or greater than 20 inch diameter, a flat block or blocks of essentially the same curva.ture as the part to be examined shall be used.

7.3.2 curved Blocks-The calibration block contact surface surface shall be curved for vessel or piping contact curvatures less than 20 inch diameter.

A single curved basic calibration block may be used to cali-brate the examination on vessel or piping contact O

9521fM PAGE NO.

1 2

OF20 J,

rp 3:e3 a BABCOCK & WILCOX D&W Construction Company

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INSERVICE lH5PECTION PROCEDURE

_( SU DJ ECT ULTRASONIC EXAMINATION OF SIMILAR METAL

[h -

WELD SEAMS AND ATTACHMENT WELDS ISI-101, REV. 11

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d surfaces in che range of curvatur.c from 9/10 to ESh[

i 1-1/2 tiras the basic calibration'blo diameter.

E5h For example, the 8 inch diameter curve block may be C "};

used to calibrate the examination on v snel or piping g

surfaces in the range of curvature from 7.2 contact g;y

(;{p=

,to 12 inch diameter.

The curvature range froc 0.94 inch to 20 inch diameter requires six block curva-CQ:

tures as indicated in Figure 2.

Curved vessel or C[';;

piping blocks may contain the basic reference holes C ;)

in a piece of vessel or piping of the same nominal CO;L;}

, thickness or pipe schedule.

7.4 Size:

The length and width of the calibration block shall at least the minimum requirements of Figure 1.

The meet 1 for thickness of the block shall be as allowed in Figure the material thickness examined.

Where two (2) or more ccm-ponent thicknesses are joined, the block shall be selected to cover the largest thickness.

7.5 Hole (s):

The calibration holes shall be drilled parallel to the contact surface for flat blocks and for loncitudinal holes in curved blocks and tangent to the surface in curved fg4 blocks for circumferential holes when used.

The diameter of these holes shall conform to those stated in Figure 1 for the block thickness.

The holes may be drilled to greater depths than the lh inch stated in Figure 1.

8.

SEARCH UNITS:

Straioht Beam:

Either ceramic, lithium sulfate or barium 8.1 titanate 2.25 or 5.0 MHz dual element er 2.25 MHz single element search units, having an effective area of 0.049 to 1.0 square inch inclusive, shall be used for the straight

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beam longitudinal wave weld examination.

If grain structure is such that 2.25 MHz cannot penetrate, a 1.0 MHz search Other unit of the types listed above may be substituted.

search units; may be used upon approval of the B&W Constructio:

Company Level III Examiner,

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8.2 Angle Deam:

.0.2.1 Type:

Either ceramic, lithium sulfate or barium titanate 2.25 or 5.0 MHz, 45 and 60 degree (

2 angle beam, single or dual element search degrees) units shall be used as stated below. The effective area of the transducer shall bc 0.049 to 1.0 square g3 inch inclusive.

A wedge shall be used to give the

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INSERVic'. INSPECTION PROCEDURE j g ly

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SU DJ ECT ULTRASONIC EXAMINATION OF SIMILAR META O'.

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desired angic in the material"to be p. tamine 5. '

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If grain structure is such that listed above may be substituted.a 1.0 MHz s penetrate, I ty 4

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units may be used upon approval of the B&W Con-3 ib.

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struction Company's Level III Examiner.

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8'2.1.1 Shear Wave:

eM On materials two (2) inches Af and over in thickness, both 45 and 60 A.cgr beams shall be used.

two (2) inches, On materials less tF i..

required.

only a 45 degree beam is

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8.2.1.2

_ Longitudinal Wave:

where adequate On austenitic material.

penetration and sensitivitj cannot be achieved with a shear uave bea:c.,

an angle longitudinal wave beam

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(s) shall be used.

'8.2.2 E>:it Point :

before examinations are performed cach day

.g er correct the ex.tt point on the transducer shoe.

8.2.3 Beam Angle:

beam anglc shall be checked with the IIW g.

.th2 confirm that the transducer meets the angle ranges specified in S.2.1.

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,B.2.4 Wedge Rework:

C"-"

the angle tolerances specified in 8.2.1 shall beAn

,._ and 8.2.3 repeated until the unitreworked and the

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is satisfactory.

9.

CALIBRATION:

clad or unclad side of the component,When t shall be performed through e the calibration material in the same manner.ither the clad or base c-Calibration blocks may have one side partially or fully clad depending y

intent of the calibration isupon the application and/or d The

-ials that to duplicate the mater-

as possibic.the ultrasonic beam will encounter as near

.9.1 straight Beam:

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O.

9.1.1 Syeep Range Calibration:

( j may be performed using an IIW block to calibrate the tion block itself. sweep range or by using the calibra p3cc,40 The back reflect ion.should appear on

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B&W Cohmuction Company 9-

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INSERVl[ INSPECTION PROCEDURE SU DJ ECT ULTRASONIC EXMINATIO!! OF-SI'4ILAR MCTAL-ISI-101,,R"EVj[.1j,',.

[ps WELD SEAMS A11D ATTACllMcNT WCLDS tv.

IIW Block ' Mett$od r:"., ' -

9.',1,1.1 J,

+-.

9.1.1.1.1 Select the range.d'ec rej on the depth control, to includ'c' the-thickness being examined.

i.'e'.,

2, 5, 10, 50 inches or.etc.

9.1.1.1.2 Connecting the Search Unit to the instrument should result in an initial pulse being displayed on the CRT; if not, it may be found by adjusting the sweep delay ccn-trol.

9.1.1.1.3 Place the point when the initial pulse first breaks the time basa-line, on the division.'abeled G on the CRT face.

D@.O 9.1.1.1.4 Place the Search Unit on the 1 mch

( 25ra:n) thickness of the IIW bicc:

O using sufficient couplant to ent :re cound transmission into the picre.

Other unclad ASMC blecks of knv.-

thickness may be used.

9.1.1.1.5 To determine schere the first bar'-

reflection should appear, find the value of each increment, engrared on'the CRT face, for the thickness

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range you have selected.

To do thi use the follouing formula:

I=

P/'100 for screens divided int 100 increments I=

1. 50 for screens divided int

~...'. ".

50 increments Where I = the value of each incremt

~

Where R = the range you have selec-

.N$b*d @

~

PAGE tJO.

S I-5 OF20 l

t

.ru pena DADCOLLc. mLCOA B&W Construction Company INSERVICE lHSPECTION PROCEDURE

'[5UDJECT ULTRASONIC EXAMINTiTION OF SIMILAR METAL WELD SEAMS At;D ATTACl!MCtM WELDS ISI-101, REV. 11 9.1.1.1.6 For example:

To ins ect a piece 8

" ~'

inches thick, selec a screen range I

that will include thb thickness, 10 inch range, and divide the screen into 100 increments:

I = 10 = 0.1" the value of each increment

'100 hen placing the Search Unit on the 1 inch (25mm) thickness of the II.

block, the first back reflection should break the baseline at 1 inch

/

(10 increments) and 2 inches (20 incremen ts) erc., thru 10 inches (100 increments).

This is accen-plished using the material cali-bration and sweep delay controls alternately.

1:cx t olace the Scarc' a

Unit on the 8 inch piece you cis examining.

The first back ref2c.:-

p should appear at 8 inches (00 increments) on the CRT facc.

9.1.1.2 Calibration.Bloch Method:

9.1.1.2.1 Position the search unit for the maximum first indication f ro:. ti.e 3/.4 T sido drilled hole.

Adjust the lef t edge of this indication to line 2 on the screen with the delay control.

9.1.1.2.2 Position the search unit ~for the maximum indication from the 3/4 T ho Adjust the left cdge of this indi-cation to line 6'on the screen with the range control.

9.1.1.2.3 Repeat' delay and range control adjustments until the 1/4 T and 3/4 T hole reflections start at sweep lines 2 and 6.

.Ti., l68 9.1.l.2.4 All measurements of depth should

()

be made where the signal first

, breaks the baseline on the CRT Scrc..

PAGEtJO.

OF 20 )

6

.,su

.m 9 w ~~

w ~ ~' %ptty % ymygx~ ~ gy,,g.,

I-

'553"3" DABCOCK & WILCOX B&W Construction Company INSERVICE INSPECTION PROCEDURE d

lSUDJsCT 1

ULTRASONIC EXAMINATION OF SIMILAR ' METAL WELD SEAMS AMD ATTACIIMENT WELDS ISI-101, REV.ll h,

1' 9.1.2 Distance-Amplitude Correction:

s 9.1.2.1 Position for maximum response from the hole which gives the highest amplitude.

Adjust the sensitivity control to provide and 80%

of full screen indication from the hole.

Mark the peak of the indication on the screen with a grease pencil or other suit-

,j able marker.

I..

9.1.2.2 Position the search unit'for maximum responsc from another hole (if available) indication.

Mark the peak of the indication on the screc:

9.1.2.3 Position the search unit for maximum ampli-tude from the third and other (if avn11able) hole indications and mark the peaks on the screen.

)9.1.2.4 Connect the screen marks and extend tF.rcugh the thickness to provide the distance

{g s amplitude curve for the side drilled holes.

If only one (1) hole is available, this is the primary reference level for the thick-s _

ness range.

9.2 Angle Beam:

9.2.1 Sweep Range Calibration:.The hweep range calibration may be performed using an IIW block to calibrate the

- sweep range or by using the calibration block itself.

The sweep range should be set to cover the range of i

thickness to be examined for a maximum of 80 percent of the full. screen sweep.

The use of half, full or multiples of full neN: will determine the desired thickn'ess to be cc;O: jd.

For examinations from a convex surface

'cs*

the curvature perpendicular to the vessel or s ' i.c d.s, the examination distance must be calculated _ ~ curved calibration blocks are not uset The following formu.la shcold be used to calibrate the necessary sweep range:

-1 SR = (R-T) sin (0

- sin (n sin 0 R - T )) cot 0

[NUd.i.6.9 u

j.

P A G C l4 0.

lNSERYlCE INSPECTION PROMDURE

'SU DJ EC T

'UL.^. SONIC EXAMINATION OF SIMILAR, METAL WELCS SEAMS AND ATTACllMENT KELDS' '- ~~

.LSI-10~1. RTN. 7. 7." *,'

~

r r

s.

I hw SR,= Sweep Range ( I n c h e s ),,..,,,,

r..,

R,= Radius.of Curvature for' Out' side Sur,f ace,(Inches)-

+ -.

O = Refracted Beam Angle from N'ormal to u.rface T = Wall Thickness (Inches)

• r Several sweep ranges have been calcul'ated for vario.us

~

component radii and thicknesses in Figure ~3'.

Note, somc beam angles can not cover th'c full depth at smaller radii.

9.2.1.1 IIW Block Method:

9.2.1.1.1 Select the range desired, on the depth control, to include the thickness being examined.

i.

e.

2, 5,

10, 50. inches and etc., and the wave node.

9.2.1.1.2 Connecting the angle beam search unit to the UT instrument chculd result in an initial pulse being displayed on the CRT, if not it lI

. may be found by adjusting the sweep delay control.

9.2.1.1.3 Place the point where the front face reflection first breaks

. r__ -...

the time baseline on the division

~

labeled.0 v" the CRT face.

. =_

9.2.1.1.4-Place the search unit on the 1 inch (25mm) thickness, just below the 2

~

inch diameter hole, perpendicular v-

.n

...to the'4~ inch side of the IIW block.

Using enough couplant to ensure good F ;'

,,. sound coupling, slowly move the

{';,-

~

search unit away from the edge unti]

a bach reflection shows on the CRT.

RN

~;

i-Maximize the signal by oscillating

~

the transducer and moving it slight.'

back and forth.

3G:d.t.90

/

PAGE llO.

8 OF20

. " INSERVICE ItfwcGTION PROCEDURE SUBJECT ULTRASONIC EXAMINITION 'OF SIMILAR METAL WELD SEAMS AND ATTAC!! MENT PELDS '- -

-ISI-101,.13dV., 11.

r,--**

9.2.1;1.5 To. determine where the fi'rst b.ack tw -

-reflec~ tion should apptar,, find t.h e value of' ecch',incr gent,"engrava9..

• ~ ' "

"' ~

=

on the CRT f ace,. d2

.d'd'."' To,d.o tNe thitkness range you have seldht j

this, use the fullpwing formula:

l I=

R/100 for screens divided int 100 increments I

I=

R/50 for screens divided int 50 increments where I = the value of each increre l

where R = the range you have selec 9.2.1.1.6 For example:

To examine a plate 3 inches thick, selec,t a screen rang that will include that thickness; 5 inch rango.

(ks The screen is divided into 100 increments.

I = 5 = 0.05" = the value of

(;

100 each increment.

%y%y

~M

D3 Then, using sufficient couplant, place the scarch unit on the 1 inch (25mn) thick side of the IIW

^

block, perpendicular to the corner as stated in 9.2.1.1.4.

Alternate using the material calibration and sweep delay controls bring the pip to correspond with 1 inch in depth on the CRT (20 increments).

Since no multiple back cchoes will be

" displayed

'ove the search unit away from the corner until another pip occurs which represents the to corner of the IIW block, (2 inches After maximizing the signal, alter e

nately adjust the material calibra

~

tion and sweep delay ~ controls to bring the signal to correspond wit

,2 inches in depth on the CRT.

i PAGE NO.

l 3.7.,9 m,1 9

or 20 '

u. <.

j'-

u. o su u B&W.Constivction Company INSERV}C INSPECTION PROCEDURE i-

l SU DJ ECT ULTRASONIC EXhMINATION OF SXMILAR METAL ISI-101,REV((.i,3l':,';

3 WELD SEAMS AND ATTACHMENT WELDS I

r

.s

. ".c n -(40 increments).

Alternating. bd,-

~

,,Q, tween this, full nodg_and thu pre-

~ ' "

vious 1/2 node pos'iMon, bring th'e signals to their cojFdspUnding positions on the screen using 'the material calibrati'on and sweep dc -

lay controls.

Once this is accom-plished move the search unit still farther to another half or full node position and make fine adjust-ments using this (N) node position and the first half node position.

~

Check the result on the curved IIW block end; the first signal should a

occur at 2.8 inches for a 45 degrec angle beam and at 2.0 inches for a 60 degree angle beam uhe placing the crystal index mark over the 4 inch (100mm) position.

All measur; ments of depth should be made wher:

the signal first breaks the basaln 0

on the CRT screen.

9.2.1.2 calibration Block Method:

9.2.1.2.1 Position the search unit for the maximum first indication from the 1/4 T side drilled hole.

Adjust the lef t edge of this indication to line 2 on the screen with the delay control.

~

-9.2.1.2.2 Position the scarch unit for the maximum indication from the 3/4 T hole.

Adjust the lef t edge of this

~

indication to line 6 on the screen with the range control.

9.2.1.2.3 Repeat delay and range control adjustments until the'l/4 T and 3/4 T hole ref1cctions start at sweep lines 2 and 6.

~

c....

J ' M y..,,<m g

j

%s

-P A G E t1 0.

~

10 OF20

ros 32 32'

, BACCOCK d WILCOX BL. Construction Company INSERVICE INSPECTl0t4. PROCEDURE

.m.

',$ ' * )['

l

',u aJ EC T ULTRASONIC EXAMINATION OF SIMILAR METAL PEV., - < 1 1

J-

ISI2101,

,,f* WELD SEAMS AND ATTACHMENT WELDS s

s,

+c..

9.2.1.2.4 Position the search nit for.

maximum response 'frpm b 'cc.ner of -

the block on the.opposir^ aurface.

The indication will ap-nr near sweep line 8, Two divisons on the sweep equals 1/4T.

9.2.2 Distance-Amplitude Correction:

9.2.2.~1 Calibration From the Clad Side:

9.2.2.1.1 Position the search unit for maximum response from the hole which gives the highest amplitude.

9.2.2.1.2 Adjust the sensitivity control to provide an 80% of full screen indication from the hole.

Mark the peak of the indication on the screen.

D 9.2.2.1.3 Position the search unit for the maximum amplitude from any remain-ing holes and mark the peaks on the screen.

9.2.2.1.4 Position the search unit for the maximum amplitude of additional nodal indications from the hole (s) such that the DAC Curve can be defined beyond the full range to

~

be examined.

Mark the indication peaks on the screen.

9.2.2.1.5 Connect the screen marks to Tj provide the distance amplitude curve.

If only one (1) hole is available, this amplitude is the primary reference level for the

~

thickness range.

9.2.2.2 Calibration from the Unclad Side of Full Clad 3..

, r; n Dlock:

.c3.

3

. s <..>

~~--

9.2.2.2.1 - From the clad side of the block,

(ff determine the dB change in ampli-i PAGE No.

OF20 3,

B&W C4nstrvction bompany INSERV' E INSPECTION PROCEDURE "

SUBJECT'

-~

'e ULTRASONIC EXAMINATION OF SIMILAR METAL

'(,

WELD SEAMS AND ATTACl! MENT WELDS ISI-101,REV.-li" N.: -

. a G.- m.,:...~..

i

~._ r

~..

. -.r.

tudebetweenthe3h.y..,

..pd 5/4T positions (StepA)}

9.2.2.2.2 From the unclad s1de,. perform

~

calibrations as noted in 9.2.2.1.1 thru 9.2.2.1.4.

~

~

9.2.2.2.3 To determine the amplitude for the 5/4 T hole, position the transducci

~

for maximum amplitude from the 3/4 T hole.

Decrease the signal ampli-tude by the number of dB determinec in Step A.

Mark the height of this signal amplitude at sweep line 10 (5/4T).

(Performed only if 9.2.2.1 is possible.)

9.2.2.2.4 Connect the screen marks to procidc the distance - amplitude curve.

This will permit evaluation of in-dications down to the clad surface w

(near sweep line 8).

9.2.2.3 Calibration from Unclad or Half Clad Elec'n-Perform callcrations as noted in 9.2.2.1.1 thru 9.2.2.1.5.

9.3 Change in Equipment:

Any change in search units, shoes, couplants, cables, ultrasonic instruments, or any other parts of the examination system shall be cause for recali-bration.

'9.4 Calibration Confirmation:

Sweep range and DAC shall be verified:

A.

At the beginning of each day of examination.

B.

At least every four hours of examination.

C.

With every change of examination personnel.

D.

At the finish of cxaminations for each thickness range.

E.

If the operator suspects any malfunction of the UT. system.

F.

In the event of any power loss.

n.,, g >-(e'a d i x.A.

t

' \\w.

~+r----

V PAGE NO.

12 OF20

on..-

B8.W Construction Company

,f INSERVICE INSPECTION PROCEDURE SUBJECT < ULTRASOMIC EXAMINATION OF SIMILAR METAL

[_ h iWELD SEAMS AND' ATTACILIENT WELDS ISI-lOl, REV.ll The original and final calibration must be performed on the basic calibration block.

Intermediate calibration checks ator.

If a

. may be performed on a calibration block sim

~~

calibration block simulator is used, it sha be able to -

The simulator.

produce known amplitude and sweep readings.

produced amplitude and sweep readings shall be recorded on the calibration sheet at initial calibration and each cali-bration check.

If multiple DAC curves are used for differ'er types of examinations, the ca.l.ibration block simulator shall gs be used for each type.

g 9.5 Calibration Chances:

If any point on the distance amnlitud.

correction (DAC) curve has changed by more than 20% ('2 dD )

c-its amplitude, all data sheets since the previously success-A new calibrat

,ful calibration check shall be. marked void.

shall be made and recorded and'the voided examination areas shall be reexamined.

10.

SCANNING REOUI RI'4ENTS -

10.1 Movement Rate: The rate of search unit movement shall not exc.

.j 6 in./sec. unless calibration is verified at scanning speed.

10.2 Search Unit coverace:

Each pass of the scarch unit shall ove.

a minimum of 10% of the transducer piezoelectric element dimc:

perpendicular to the direction of scan.

10.3 Application:

The welds and heat-affected zones shall be exa:a from.both sides of the weld by a straight beam and two angle beams where practical and where required.

The beams shall pa through all of the weld material on each of the scans where practicable.

The beams need not pass through all of the adjai base material.

Direct the angle beams normal to the weld fro i

~

both sides of the weld and parallel to the weld in both dirce The volume o'f base material through which the beam '

travel in angle beam examination shall be examined with a str beam search unit in accordance with ISI-102.

10.4. Scanning sensitivity:

Scanning may be performed at a gain se 2 times the reference level (6dB increase in amplitude) using 100%, 50% and 20% DAC curves drawn on the sprcen.

The record of~ indications shall be carried out with the' gain control at i

e

,t)5 3J75 2

l reference level.

~

./'.

PAGE No.

~

8 20 13 op

s-BABt.uCK & WILCOX Pos 32s324

. B* d Construction Cornpony INSERYltE INSPECTION PROCEDURE

~

.'U.,.'

SUBJECT ULTPASONIC EXAMINATION OF SIMILAR METAL

-s WELD SEAMS AND ATTACHMENT WELDS

,ISI-10 ', i'.R@7. it 1

.~

5.C. As..an alhernate method, scanning'idhy be' performed afte.Cincrea.

the gain 14dB above the reference leve'1. ' Thi5hr)c,rease.s signa.

amplitude by a factor of five, making the primprp iceference cu:

a 20% DAC curve.

The recording of the peah inBicaticas/ using this method, requires that the signal amplitu'de.b.c adjusted to the 100% DAC curve using the dB contro]..

True signal amplitude shall be obtained from thci following chart using the observed c in: the dB control.

l sore !

%D^c g

-- y..---

en o

too 100 o

-1 st2 90

-+ 3

-2

1. 25 50 c2

-3 gag 40 t)

• 4 159 6)

,. 4 g.

/~~

-Il 355 2C ell

~5 17s 56

+5

-6 200 50

+6

=)

22A 45

+1 5

258 40

<t

[.

-9 Jr2 J6 e9

-10 336 32 rt o

-12

<co 25 r:2

~ '

' ' ' ~

~22 p3 3

-13

• 18 50t 23 r!4

-15 562 38 el 5

.a-.

-16<

3 33 16 gg

~

.. ~ ~

a-

....l'...

7_

-..C.

~ ' ~ -

11 gog

, 14 _. _.

f3 y

-'Ci.,.

"I8 714 rJ L

....u.

19 893 ll ef 9 20 1000 30

'20 4

.h..

': 2.

t:',

For recording 20% to 20% lengths the:dB control will be sc t at higher gain than.the reference level..For 50% to 50% lengths, dB-control will.be set 6dB 1-igher gain than the~ reference leve:

for 100% to 100% lengths, the dB control.will be at the. refere:

level.._..-

~

.o.

10.5' Penetration' Verification:' Penetrationshall be verified"by ob

~

ing a reflection from an opposite parallel surface of the material when available in straight beam' scanning.

10.6 Deviationc:

Where the configuration of the. weld being examincc or surrounding structures do not permit scanning.ns required i:

Section'10, the examination deviations shall be recordcd on the data sheets.

._f,..

. y;; g n PAGE No.

20 14 0F e

e

,,'n DAUy _rc.61LCOX B&VI Construction Cornpany INSERVied INSPECTION PROCEDURE s' SU DJ ECT m

ULTRASONIC EXAMINATION OF SIMILAR METAL r

.. 4'..

~..

)

WELD SEAMS AND ATTACHMENT HELDS ISi-101,.

. -R sV. i_1_ _

4

11. [hECORDIt!G STANDARDS:

All indicatidnu wh,ich produce aire 6ponse,.

'. greater than 20 percent of the DAC reference,levc shall he

. investigated to the extent that the operator can eten. tine the shape, identity and location of all such reflectofs and ava'lbate

- them in accordance with the following :

11.1 The serrch unit shall be..placed in a~ position which producet the maximum amplitude.

If.the maximum amplitude equals or

~~

excceds 50 percent of the DAC reference calibration curve, the amplitude and its position shall be recorded.

The length'of.the transducer travel between 50 to 50 and 100 to

.i 100 percent of the DAC reference level shall be recorded.

The through thickness dimension shall be determined by measuring the 50 to 50 percent of DAC signal locations on the CRT face.

These measurements for the thickness shall be repeated at one-half (h) the transducer active dimension or one-half (h) inch increments on either side

~

of the maximum signal position, starting touard position A or surface one, until the signal drops below 50 percent DI.C.

11.1.1 Multiple indications, related in depth and dictance r*

from surf aces one er two, which can De damped at the examinaticn surface, having amplitudes frcm 50 to 100% of DAC shall be recorded in one data entry as intermittent or co-tinuous.

Such data entry shall show the ampllsm

'nd depth ranges, y

and the distance from the appropriate surface.,

Such indica tions. sha..l..l..._sta te" "D AMPS ".

11.1.2 Multiple indications as in paragraph 11.1.1 which

Or r'_:

... cannot be damped from the examination surface sha21 r.

also be recorded as in paragraph 11.1.1, except c..-,.

.that the. data-entryL shall state. "DOES NOT DAMP".

'.,[.11'.1.3 For indications having pAak amplitudes excceding

" ~ ' "

the DAC reference calibration curve, the thru wall

.n. :.

c m.- dimension corresponding.to.the_ peak amplitude shall u

. :.._, be.undorlin.ed t.

~

~11.2 All' indications detected. in the area of interest which

j.._ produce signal amplitudes. greater than the DAC refcronce

-.. calibration curvo and that have a linear dimension equal to or exceeding that given in Table 1 shall lx1 recorded and reported individual 2y and an evaluation made to the

~

acceptance =tandards involved in the original construction.

SU'd.D 7

.s I

PAGE NO.

15 OF 20 g

e I

./ M y'*

DABCOCK & WILCOX B&W Construction Company INSERVICE INSPECTION PROCEDURE

. s.

SUDJECT ULTRASONIC EXAMINATION OF SIMILAR METAL

(

g WELD SEAMS AND ATTACHMEN'I WELDS ISI-101, REV.11

- TABLE 1

..., l...

e 1

MATERIAL LINEAR f

THICKNESS RANGE DIMENSION (INCHES)

O thru 3/4 1/4 inch

- O'ver 3/4 thru 2-1/4 1/3 of thickness

'Over 2 1/4 -

~ /4 inch 3

N 11.2.1 'An indication in a weld or weld fusion none shall c

- evaluated using the fabrication radiographs, wherca an indication in base material shall be evaluated

-- to the radiographic or ultrasenic acceptance standards for the base material.

The separation

- between the weld / weld fusion zone and tha base material shall be based en the parameters-of 2

the fabrication welding procedure.

11.2.2 If there is any doubt regarding the proper interpretation of ultrasonic indic~rions in the area of interest, such doubt may be resolved by

~

radiography.

11.3 The examination cata shall show the location, size, and depth of' indications.

The amplitude of discontinuity indications shall be recorded to the_nearcst 10 percent increment.

..i

. :.. -. : '... : '.. E.~. :..

..: "~..

11.4.Any area where best effort inspection uas performed due to configurat-icn shall b,e recorded and reported.

12.

RECORD OF EXAiI ATION'RESULTS:

A copy o'f the examination data (Fig. 4) shall be provided to the customer with the following information:

....=

a u.

~.....

'A.; 'ContYa'ct" Huinber'

'B'. - Examination Personnel

-C.

Instrument D.

Method of Test E.

Couplant N-F.

Calibration Sheets

' ~

-G.

Weld Identification and Location

"- ~

H.

Type, Size, and Frequency Search Unit 1.

Ultrasonic Wave Mode J.

Calibration Block Number K.

Chart of Results

'j L.

Procedure c

. < 7p#

M.

Date (s) of Examination N.

Examination. Surface PAGE No.

L$yout of. wold seams as detail-16 oF 2 0 O.

c

.in ISI-360, ISI-3 61, or ISI-362.

...._....s.. t...-..v..

......-.a SU DJ EC T. - UL' imSONIC EXAMINATION OF SIMILAR META 1 T

WELD SEAMS AND ATTACIIMENT WELDS ISI-101, REV. 11

).._.

. If,, MIN (SE E NOTE 23 a*

i k II

{

D ll t

s r

W L

7c"h" C".E"I C3c'"

C""3 LOCATION OF HCLE FROM

^ ~

CONTACT SURFACE DETERI.41NED D

FROM THE TABLE DELOW 1

~

- DA$tO C AllBRATION HOLE OF DIAMETER'd.

SIDES PARALLEL T

WITl!!N t. 0.015 IN./ F T

?{C\\

d 12' \\

' ~

C ".~.

L = Length of block determined by t*se inste of search unit end the vec-path u ed

.T= Thickness of basic cabbration block (see table below)

D = Dcpth of sicc drille:.f ho'e (see table below) d = Diameter o' side drated hole (see tab!c belowl u,...

t

• Nominal production material thickness

.' T... ;.'..... '.....

, Nominat Production Basic Calibration Hofo Hoto Minimum H a

e Materi:1 Thickness (t) in.

- BlockThickness (TI,.n.

Loca tion

- Diamoter (dl. in.

D e p th (.D )..:..

Up to 1 incl.

84 or t

'A T

'4 l'4 Over I thru 2 I'/, or s

'A T

'4 l '/.

Over 2 thru 4 3 or t

'/.T

• /,.

l'4 Over 4 thru 6

_.~'

5 or i

'A T

'/.

I'4 Over 6 thru 8 1 o~

'/. T 8/..

I'4 Orca 8 thau 10

'A T

• /.

I'4

'9 c. t Orcr10

't

'A T See Note I l'4 Note 1-For cach increase in thict.ncis of 2 in., or a fraction thereof. the hoic diameter shalt inciesse '/.. in.

Note 2-l'or lilo6k sitesince 3 in. in thickness (T). the distance fronithe hole to the end of the block shall be %T min, to prevent coincialent reflections (som the hole and the corner in the '/. th uc path position. filocks fabricated with a 1%.iii.tninimum dimension need not be mc=hfied if the corner and hole indications cais tse c:.sily resolved.

Figtire 1 BASIC CALIBRATION BLOCK Sfid' j,79 f

._ /

p.

PAGE NO.

17 OF20 1

J

D&W Conuruction Company

~

4 f

INSERYlCE INSPECTION PROCEDURE r,.

~~

c SU DJ EC T ULTRASONIC EXAMINATION OF SIMILAR METAL

~

h NELD SEAMS AND ATTACIU4ENT' WELDS ISI-101, REV.ll i

'O.04 l.56

-LIMITS 2.6 4.3 7.2 12.2 I

20 20 ii g g

g g

OLOCKS 1i ;

i I

g Ii l

1 l.

I

[l I

l

-l I

1l l

1 l

lII l

l c

l I

w V

l lI l

--h 5

Ib

!l 1

l 1

t l

l

[

13.3 I

4 il l

l l

$[

ou m xy I l :l l

1 c

5 v

l g

a l

i 10 ll lll l

I jf/

r L

hd ll l l

0 f

! 5 I I I

i

/

l u

li l I /

l u

I iA E

5 4.0

/ w '_. _

8 4 "3

I l la

~

i i

I v

I ). I _ _ _.

2.3 i,7 i

l O

S 10 IS 20 VESSEL ColiTACT SURFACE CURVATURE O!AIAETER litCHES i

r.

i

1. Plot curvature of basic catebration block on diagonal (45') fine.

2. Draw liorizontalline through that point from the '/,. to the l'/a limit line.

3.The ends of this line read on the horizontal scale gives the sange of vessel contact susface curvatures which may be examined with a system cal.brated.on this btuck.

Note: thickness <ange ser4uirements shatt also be satisfied.

t I

Fi uro 2 RATIO LIMITS FOR CURVED SURFACES l

.~

9[$I.s.SD 1

l P A G E I4 0..

18 or 20 u

1 I

. n omPEIM

B&W Construc6on Company v

}

INSERV!CF NSPECTION PROCEDURE I

i-M ECT ULTRASONIC EXAMINATION OF SIAILAR METAL l ',.iF "

T WELD SEAMS AND ATTACHMENT WELDS ISI--101, REV..,1),.] ]..

TThe following data have been calculated for use in sc;, ting the twei t

ra n gc.T.o..,n. the ultrasonic CRT screen ~when' uiiin'J 'a.ngle bearp exam. na tion.'

,u, s.

(0-sin ~1(R sin 6 )

SR = (R-T) sin cot 0

^

s

)

.c

=

SR= Sweep Range (Inches)

' ~

R= Radius of Curvature for Outs'ide Surface (Inches) 0= Refracted Beam Angle from Normal to Surface T= Wall Thickness (Inches)

- 177 Fuel Assembly Units Calibration Based on Dm 1/2 Node M;.nn.c Full i

~'COMPO"ENT RADIUS OF CURVATURE THICKNESS SWEEP FJ.::G E S ?.7 E E  :

(Inches)

(Inches)

(Inches)

( I r.c r. 2.-

450 600 450 Reactor Vessel:

Closure Head 94.25 7.0 7.3 8.2 10

-Nozzle Belt 96.125 12.0 13.0 18.0 20 Core Belt 94.25 9.0 9.5 11.3 20

~~

~

'5.375 5.6 6.0 10 i >; -

Lower ~ Head- ~~~

92.675

' team Generator:

Upper & Loucr Heads 68.5 -

~

9.0 -

9.8 14.8 20

____.._Shell 76.6 6.625 7.0 8.0 10 1

I

--Pressurizer:

_ __..._ __ U pp e r & Lower Heads

. _.. _ _ _. 5 0

.__...-....-.5.0--

5.3 6.4 10 l

Shell Region 48.5 6.5~

7.1 12.0 10

. Heater Delt Region 55.0 13.0 16.3

• 27.5 20 i

Main Loop Piping:

~

~

~ ~ " ~ ' '

~~~ ' ~ ~

Inlet Piping

- - - 15. 0 4.0 5.5

• 8.0 10 t

Outlet Piping '.-

.. -. 19. 0 - - - - -- -.

4.0 4.8

• 10.0 10 I

- -- -- Inle t Piping 14.0 3.0 3.6

• 7.0 5

Outlet Pa.p.tng

~~~'~18.0 ~

~~~

' ' 3. 0 3.4

• 9.0 5

-- FBeam does not reach in~ternal surface because of curvature.

~~ "

The last two (2) columns provide even sweep ranges for full screen calibration which are convenient to use.

Figur

e 3 SWEEP RANGE SETTINGS FOR VARIOUS CURVATURE AND THICKNESS VESSELS.

'_ ; __ N.Y...

q

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5.*io ?

BADCOCK & WILCOX D&W Construction Company INSERVICE INSPECTION PROCECURE

~

f "nJECT ULTRASONIC EXN4INATION OF TIIE DASE b b ffA N N T[h b.b bS ISI-lO2, REV. 7 1

SCOPE:

This procedure shall govern the ultrasonic examination of the base metal arcas bordering welded seams knd base metal

~

repairs for inservice inspection as required by ASME Boiler and Pressure Vessel Code, Sections III and XI.

Materials up to,15 inches thick are covered by this procedure.

2.

EQ UI PM ENI_'L Ultrasonic cxamination equipment shall consist of an electronic apparatus capable of producing, receiving and

~

displaying -high frequency electrical pulscs at the required frequencies and energy levels.

3 opER7go R__ QUALIFICATION :

The operator performing the inspection shall be qualified to Level II in accordance with B&W Can-struction Company Quality Control Administrative Procedure 9A-169.

The assistant shall be qualified to at least Level :

in accordance with B&W Construction Company Quality Contrcl Administrative Procedure 9A-169.

s SURPACE PRE?APATI C;T -

The examination surface shall be free to dirt, y

loose scale, machining or grinding particles, ucld spatter, C

or-other loose forcign matter.

The surface finish shall bc Z

sufficiently smooth to maintain acoustical bond and minin.ne

~c surface noise.

A mill finish may be adequate for testing, g

Whenever necessary, surface conditioning shall be accomslicb-a by'available mechanical processes, such as machining, g rir.di:

sand blasting, or belt sanding to provide a suitable surface Cd finish.

Surface preparation shall be performed on an area D

which includes the weld and the area for 2T (2 times thichnc$

plus 2 inches on both sides of the weld.

The ultrasonic testing operator shall inspect the surface for suitability fc performing the examination.

Surfaces shall be prepared in accordance with ISI-50.

"e -

COUPIANT :

A suitable liquid, semi-liquid, or paste couplant medium, such as water, oil, glycerin, grease or Hamiklocr shall be applied to the examination surface.

3.,w..., t3 3

.u 3

Each batch of materials used on stainless stcels or nickcl based alloys shall have been tested for residual amounts of 6

UI VISED DY REVISIOtt P A G E t1 0.

CRII SECTIONS 7.,11.,

8.3, FIGURE 1 1 OF G 3

hl VISIO*J DATE S.1, 8.4, 10.3 ISSUE DATE 1/30/76 11/27/72

l B& Construction Company w.

INSERVICE INSPECTION PROCEDURE b

~5UDJECT ULTRASONIC EXAMINATION OF THE BASE METAL

1. 84 AREAS BORDERING WELDED SEAMS AND BASE 3

,,l METAL REPAIRS ISI-102, REV. 7

- total halogen and total sulfur in accordance with ISI-60.

The total residual amount of halogens and sulfur shall ndt exceed the requirements of ISI-60.

the couplant batch.

i

, --number shall be recorded on the report data form.

6.

AREA OF INTEREST:

The examination shall include the weld fusion line and all of the area on both sides of the weld beyond the fusion line through which. angle beams will pass.

This

~

includes 1.5 times the thickness for 45 degree, and 1.8

- times the thickness for 60 degree angle beams.

7.

STRAIGHT BEAM SEARCH UNITS:

Either ceramic, lithium sulfate or barium titanate 2.25 or 5.0 MHz dual element or 2.25 Fir

" ~ ~ ~

single element search units,having an effective area of 0.049 to 1.0 scuare inch inclusive, shall be used for the straight beam longitudinal wave examination.

If the

~~ grain structure is such that 2.25.MHz cannot penetrate, a "1.0 MHz search unit of the types li..ed above may be s u 'n -

~

stituted. 'Other search units may be used upon approcal of I

the B&'.! Construction Company Level III Examiner.

FA '.,

8._.. CALIBRATION:

f 8.1 ~ Instrument Calibration:, t' hen the examination is to be

'"*4

._. performed frca the clac or unciad side of the componen,

~

' 'the calibration shall be performed through'either the cl1.'

==

' -or base material in the.same manner.

The search unit srs_

be' coupled.to the examination material to produce a.m:nint t.

gg_,

d-50 percent to a maximum 75. percent full scale signal resp _

c

(;jy s._from. the. opposite... side.of a defect frec area of the plate.

,3

~

C(pg=

If' cladding conditions, nonparallel. surfaces or other Qgy 1.,, material properties'cause calibration from the opposite side -(back reflection) of the component to be unreliable i

or impossible, the opposite side calibration shall be este tr.:lish'ed using a. basic calib~ ration block as defined in ISI-l

:.ISI-10 6, or_ ISI-10.9...

)

y,.

,7 -- 8.2 Change in Equipment:

Any change in search units, shoes, couplants, cables, ultrasonic instruments, or any other

~~-" "

"' parts of the examination system shall' be cause for recali-f bration.

8.3 Calibration Confirmation:

The back reflection shall be verified.:

,f).E"d.l.84

["

.f.. _.

A._:At the beginning of each day of examination.-~

~~

l B.

'At least every four hours of examination.'

P A,G E N o.,,

OF 6 e l -..

i 2

m 3202' BABCOCK & WILCOX B&W Constructior. Company INSERVICE INSPECTION PROCEDURE ULTRASONIC EXAMINATION OF' THE BASE METAL

. -r

'UBJECT 3

AREAS BORDERING WELDED SEAMS AND BASE MEIAL REPAIRS ISI-102, REV. 7 With every change of examination personnel.

e C..

D}

At the finish of examinations for each thickness range.

If the operator suspects any malfunction of the UT syste E.

F.

In the event of any power loss.

s 1

..---- The original and final calibration must be performed on Intermediate the component or the basic calibration block.

calibration checks may be performed on a calibration block simulator.

If a calibration block simulator is used, it shall be able to produce known amplitude and sweep readings.

The simulator produced amplitude and sweep readings shall bc L_

recorded on the calibration sheet at initial calibration a:.C cach calibration check.

If calibration amplitude has changed 8.4 Calibration Chances:

20% (2dB) of its original amplitude, all data by more than since the,revious' calibration check shall be marked t

sheets void.

A new calibration shall be made and recorded and the v'oided. examination areas.shall be reexamined.

9.

SCANNING REOUIREMENTS:

~

9..L.

Movement Rate:

The rate of search unit movement shall not cxceed 6 in./sec. unless calibration is verified at scannir v

speed.- ; - -

---f 9.2 Search Unit Coverace:

Each' pass of the search unit shall o.verlap a minimum of 105 of the transducer piezoelectric element-dimension perpendicular to the direction of scan.

~

.n 9.3 Scanning Sensitivity:

Scanning shall be performed with an instrument adjustment that will produce a back reflection to 90t fi-Em-the opp 6 site side of the base metal of from 50%

of. full scale.- Minor sensitivity adjustments may be made t:

accomodate for surface roughness.

[.

9'. 4 Penetration Verification:

Verification of sound penetratio:

.through the base metal shall be accomplished by maintaining a 50t back reflection from'the opposite parallel surface

,during scanning.

It may not be possible to maintain a back reflect' ion due to the clad interface conditions.

In these the sensitivity shall not be adjusted.

cases,

9.5 Deviations

Where the configuration of the weld being ex-amined or surrounding structurcs do not permit scanning as

.. required in Section 9, the examination deviations shall be

/

recorded.on the data sheets.

.e.3 n.1.? ~;.>

~

3

10. RECORDING STANDARDS:

PAGE No.

n g

3 oF 6

• L 2 oADU

..... L u e.

B&W Conitrucdon Company

. p.

INSERVILilNSPECTION PROCEDURE

...y ' q';.l l SuaJECT ULTRASONIC EXAMINATION OF Ti!E' BASE ~-

u

,' ? :

[

}

METAL AREAS BORDERING WELDED SEAMS c

2'*

AND BASE METAL REPAIRS IST-102 -E2V. 7

~~.M O.1, plate:i

~

W " " " '? '.'. -

g..

10.1.1 Any area, where a discontinuity produq'es.,a total loss of back reflection accompanied by a cont 5nuous indication on the same plane that cannot be containc within a 3 inch diameter circle or 1/2-the plate

$. g :

thickness, whichever is greater, shall be reported.

j 10.1.2 Single discontinuitles that do not exceed the requirements of 10.1 but are separated from a sim-

~'

il.ar discontinuity by a distance less than the dia-meter of the larger shall be reported unless both can be contained within a 3 inch diameter circle c 1/2 plate thickness, whichever is greater.

10.1.3 All areas deemed acceptable to the above require-ments but that cannot be contained in a 2 inch diameter circle shall be recordpp.

p'g% qgj gg

[( M{\\' U A

%B4 L 10.2 Forgings:

[

r i

10.2.1 All areas which exceed 50 percent of the resultant back reflection shall be investigated with the search unit in a position which produces the maximm amplitude.

If the maximum amplitude equals or exc:

100 percent of the resultant back reflection, it sh.

be recorded to those levels, 10.3 Areas which contain nonparallel surfaces shall be examined by establishing a minimum of 50 percent to a maximum of 75 percent back reflection from a calibration block which is c the nominal thickness and acoustically similar to the part being examined.

Indications which exceed 100 percent of th-original back reflection and cannot be contained in a2 inc.

diameter circle shall be recorded to those levels.

10.4 The record shall show location, Septh, s.ize and amplitude of the discontinuity. Discontinuity amplitude shall be in l' percent increments.

10.5 If a base material condition exists which exceeds the limit.

of Sections 10.1.1 and 10.1.2 or 10.2.1 the shcar wave inspections as required by subsequent ISI specifications shall be. performed from both inside and outside surfaces wherever possible.

If the opposite side is not accessible, these areas shall be charted and the inspection performed o a best effort basis.

~

.c. r p.gr.,

I.

m c.

PAGE No.

l 4

OF 6 l

r,,, v s.

.-~

a.

B&W C.o.....ve. tion Company t

1,.

INSERVIC". INSPECTION PROCEDURE

~

s.

su o.! ECT ULTRASONIC EXMIINATION OF THE BASF.

p' METAL AREAS BORDERING WELDUD SEMIS -

...m*'s

~

IST..lO2,

REU.7.

AND BASE METAL REPAIRS t

• • .rs'. -

• 3 e

A copy'o.5. he examinatiort-da+.a t

11. RECORD OF EXAMINATION RESULTS:

TFig. 1) shall be prov.tded to the customer Uith thc/following information:

-. f, '<....

.f,.

j A.

Contract Number B.

Examination Personnel

~-

C.

Instrument

1. D.

Method of Test E.

Couplant

..f'c F.

Calibration Sheets G.

Item Identification and Location H.

Type, Size, and Frequency Search Unit I.

Ultrasonic Wave Mode J.

Calibration Block Number or Back Reflection (BR)

..K.

Chart of Results L.

Procedure

.. ~....

M.

Date (s) of Examination N.' Examination Surface i...

~' Layout of Item as detailed in ISI-360, ISI-361

-O.

or ISI-362.

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('S good O

W. P. STEWART, DIR E CTOR er POWER PRCDUCTION c o n eo n a r.o =

April 5, 1979 Mr. Robert W.

Reid, Chief Operating Reactors Branch #4 Division of Operating Reactors U.S. Nuclear Regulatory Com=ission Washington, D.C.

20555 0 0 0145 - !

b h

g

Subject:

Crystal River Unit No. 3 Docket No. 50-302 Operating License No. DPR-72

Dear Mr. Reid:

The purpose of this letter is to update Florida Power Corporation's letter dated February 28, 1977, regarding inspections of stagnant, low pressure og stainless piping containing boric acid solutions.

The February 28, 1977, letter described the actions we took as a result of two cases of intergran-ular stress corrosion cracking (ICSCC) in the Crystal River Unit 3 building spray piping, and in response to IE Circular No. 76-06.

In su==ary, the actions we took were as follows :

1.

Ultrasonic examinations were performed of 27% of the building spray system welds and 11% of the decay heat system welds.

No def ects we re found.

2.

Procedures were initiated to perform periodic system operability / leak tests as required by our in-service inspection test program.

No leaks have been found during these tests.

We intend to continue these tests as required by our in-service inspection and test program.

3.

Procedures were revised to require the building spray piping where the two cracks occurred to be drained following each test.

This ensures that the stagnant water conditions which led to the cracking will not recur.

The February 28, 1977 letter also indicated we would volumetrically examine 5% of the total welds in the building spray and decay heat systems at each refueling outage.

However, we have performed a reevaluation to determine' the extent of inspections which are justified.

Experience at CR-3'and other PWRs indicates that cracks in the subject piping may occasionally I")

occur.

However, in no cases have these cracks threatened the system opera-(/

bility -- in all cases, small leaks have resulted in detection prior to the c r:* ? { a%; n J, * ~ s.

u General Office 320i wty.eurm street soum. P.O. Box 14042, St. Petersburg. Flonda 33733 813-866-5151

)

Mr. Robert W. Reid Page 2 April 5, 1979 cracks-propagating completely around the circumference of.the pipe.

In this regard, it is noted that the NRC has indicated that " failure of austenitic stainless steel pipes in nuclear plants, without prior leakage, is considered to be extremely unlikely".

(See Page 7 of NUREG-75/067, Investigation and Evaluation of Cracking in Austenitic Stainless Steel Pip-ing of Boiling Water Reactors Plants, October, 1975.)

Based on the above experience and NRC position, we consider it suitable to rely on periodic pressure tests and leak detection to monitor the condition of the subject piping for detection of intergranular chloride stress corrosion cracking.

Therefore, in lieu of the volumetric inspections of 5% of the welds, in the decay heat and building spray systems we proposed to perform:

1.

Volumetric inspections and pressure tests in accordance with Sec-tion XI of the ASME Boiler and Pressure Vessels Code, 1974 Edition through Sum =er 1975 Addenda. This inspection program is defined by Florida Power Corporation's submittals dated April 14, 1977, Novem-ber 21, 1977, August 17, 1978, and March 28, 1979.

2.

At the forthcoming refueling outage we will ultrasonically inspect the building spray system welds at either side of the Reactor Building p

pe ne t rations to insure that there has been no recurrence of cracking.

The area to be examined will cover a distance of approximately six times the pipe wall thickness (not less than 2 inches) on each side of the welds.

If you require any further discussion concerning our proposal, please con-tact this office.

Very truly yours, FLORIDA POWER CORPORATION 1

W. P. Stewart ECSekcR05 D24 File: 3-0-3-a-3 D.

Sfi4130 a

)

STATE OF FLORIDA COUNTY OF PINELLAS d

W.P. Stewart states that he is the Director, Power Product' ion, of Florida Power Corporation; that he is authorized on the part of said company to sign and file with the Nuclear Regulatory Commission the information attached hereto; and that all such statements made and matters set forth therein are true and correct to the best of his knowledge, information and belief.

h

,l r-sU i LQmV\\

W.P.

Stewart O

Subscribed and 5-orn to bef ore ce, a Notary Public in and for the State and County above named, this 5th day of April,1979.

/

t Notary Pubiic Notary Public, State of Florida at Large,

~

My Coc!missien Expires:

July 25, 1980 (Notary 1 D12)

+

asa.31 a

1(b) Provide a description of water chemistry controls, sumiaary of chemistry data, any design cha nges and/or act ions t.ike n, such as periodic flushing of recirculation procedures to maintain required water chemistry with respect to pil, B, CL, F, 02'

/

RESPON SE :

Crystal River Unit 3 water chemistry controls are covered by procedures SP-710 and SP-713, attached.

In general, the following water chemistry limits are maintained :

System Building Spray Spent Fuel Decay lleat pil See Note 1 4.8 - 8.5 4.8 - 8.5 B ppm 0 - 2300 0 - 1300 Cl pp's

<50 - 200

<50 - 200 F-p,ib

<50

<50

~

02 p pt.'

6-8~

10 ppb-8 ppm NOTE 1.

' me parts of Building Spray are operated on water fron BWST which is maintained in range of Spent Fuel water chemistry limits.

.o)J G.4 c]omN r.o WPSemhD77

Rev. 7 6/h9/78 C

Document section 1

NFORM ATION ONL C. R. Nuclear o

SURVEILIANCE PROCEDURE SP-710 FLORIDA POWER CORPORATION CRYSTAL RIVER UNIT 3 RC, DECAY HEAT RDf0 VAL, AND RC MAKEUP SYSTEMS' CHDf1STRY SURVEILLANCE PROGRAM 952133 REVIEWED BY: Plant Revi mittee v

--$M a

Date bA Y

/

~/

Meeting No.

[-

o APPROVED BY: Nuclear Plant Manager 2

'nnnf u.

/

1.0 SURVElLLANCE REQUIRDENTS 1.1 The reactar coolant (RC), decay heat (DH) removal, and makeup systems shall be determined to be withL the limits described on Enclosure 1 (Surveillance Table).

NOTE:

Requirements listed on Enclosure 1 may include, but are not limited to, Standard Technical Specifications (STS), Environmental Techn' cal Specifications (ETS),

and FSAR specifications.

1.2 DEFINITIONS 1.2.1 Surveillance Table Compiled information needed to schedule, implement, accept, and document surveillance activities.

1.2.2 Specified Criteria as outlined by STS, ETS, FSAR, B & W, etc. in publi-cations.

1.2.3 Administrative Criteria as ou' lined by the ChemRad Section.

1.2.4 Action References References to action required when "Specified Acceptance Cri-teria" cannot be met.

1.2.5 Implementation References References needed to perform surveillance task.

1.2.6 Documentation Florida Power Corporation (FPC) form on which surveillance results are to be recorded for review and tranraittal to plant files.

3[5"d.It.O I

(-

e 1.2.7 LLD (Lower Limit of Detection)

{

1.2.8 FUR (Form 912915, ChenRad Follow-Up Report) 2.0 ACCEPTANCE CRITERIA See Enclosure 1 (Surveillance Table).

3.0 REFERENCES

NEEDED TO COMPLETE PROCEDURE See "Coupletion" colunn of Enclosure 1 (Surveillance Table).

4.0 SPECIAL CONDITIONS OR L:.0UIRDfENTS None 5.0 EQUIPMENT REQUIRFD Per " Implementation Reference" column of Enclosure 1 (Surveil-lance Table).

6.0 PROCEDURE 6.1 Consider ste a l conditions or requirements per Section 4.0 of this procedure.

6.2 Perform " Surveillance Requirements" as outlined on Enclosure 1 (Surveillance Table).

6.2.1 Form 912915, ChemRad Follow-Up Report, shall be initiated describing deficiencies that prevent the scheduled completion of a surveillance task; ChemRad supervision and/or the Shif t Supervisor shall be notified per " Documentation" form; and the applicable " Action Reference" shall be reviewed for required action.

6.3 Restore the affected system or component per the "Implemen-tation Reference".

bE52-(

9 6.4 Record surveillance results on the form designated in the

" Documentation" column of Enclosure 1 (Surveillance Table).

6.5 Circle in red on the " Documentation" form each result outside the limits on the form.

6.6 Notify ChemRad supervision and/or the Shif t Supervisor per the " Documentation" form of all items circled.

6.6.1 Refer to the applicable " Action Reference" for required action when "Specified Acceptance Criteria" on Enclosure 1 (Surveil-lance Table) are exceeded.

6.6.2 When the Shift Supervisor must be notified of unsatisfactory surveillance results or when restorative and/or corrective actions require follow-up on a later date, a ChemRad Follow-Up Report (Form 912915) shall be initiated and referenced in the

" Remarks" section of the " Documentation" form.

6.7 Route the completed " Documentation" form (s) per Section 5.6 of AI-400, Plant Operating Quality Assurance Manual Control Document.

6.7.1 A copy of Form 912915 (initiated above) shall be transmitted in the documentation package wherein the Follow-Up Report referenced.

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Document Section

'. N FO R M ATIO N O N L ik j

C. R. Nu: lear Y

SURVEILLANCE PROCEDURE SP-713 FLORIDA POWER CORPORATION CRYSTAL RIVER UNIT 3 RC SUPPORT SYSTDG' CHDfISTRY SURVEILLANCE PROGRAM 95Z205 REVIEWED BY t Revi m=ittee Yr 3

n/ah9 D-.

/

I Meeting No.

hk-APPROVED BY: Nuclear P nt Manager

_J ouza, :t.

.u, u,,s.

1.0 SURVEILLANCE REQUIRDENTS 1.1 The reactor coolant (RC) support systems' chemistry shall be determined to be within or equal to the administrative accep-tence criteria as described on Enclosure 1 (Surveillance Table).

NOTE:

Requirements listed on Enclosure 1 may include, but are not limited to, Standard Technical Specifications (STS),

Environmental Technical Specifications (ETS), and FSAR specifications.

1.2 DEFINITIONS 1.2.1 Surveillance Table Compiled information needed to schedule, implement, accept, and document surveillance activities.

1.2.2 Specified Criteria as outlined by STS, ETS, FSAR, B & W, etc. in publi-cations.

1.2.3 Administrative Criteria as outlined by the ChemRad Section.

1.2.4 Action References References to actisu required when "Specified Acceptance Criteria" cannot be met.

1.

3 Implementation References References needed to perform surveillance task.

1.2.6 Documentation Florida Power Corporation (FFC) form on which surveillance results are to be recorded for review and transmittal to plant files.

Sfi2206 Page 1 SP-713 Date 10/8/76

1.2.7 LLD (Lower Limit of Detection) 1.2.8 FUR (Form 912915, ChemRad Follow-Up Raport) 2.0 ACCEPTANCE CRITERIA See Enclosu-(Surveillance Table).

3. 0 REFERENCES NEEDED TO COMPLETE PROCEDURE See " Completion" column of Enclosure 1 (Surveillance Table).

4.0 SPECIAL CONDITIONS OR REQUIREMENTS None P00R DEM 5.0 EQUIPMENT REQUIRED See " Implementation Reference" column of Enclosure 1 (Sur-veillance Table).

6.0 PROCEDURE 6.1 Consider special conditions or requiremer ts per Section 4.0 of this procedure.

6.2 Perform " Surveillance Requirements" as outlined on Enclosure 1 (Surveillance Table).

6.2.1 Form 912915, ChemRad Follow-Up Report, shall be initiated describing deficiencies that prevent the scheduled completion of a surveillance task; ChemRad supervision and/or the Shif t Supervisor shall be notified promptly per " Documentation" form; and the applicable " Action Reference" shall be reviewed for required action.

6.3 Restore the affected system or component per the "Implemen-

-tation Reference".

Sfi'd207 Page 2 SP-713 Date 10/8/76

6.4 Record surveillance results on the form designated in the

" Documentation" colu=n of Enclosure 1 (Surveillance Table).

6. 4.' l Circle in red on the " Documentation" form each result outside the limits on the form.

6.4.2 Promptly notify ChemRad supervision and/or the Shif t Supervisor per the " Documentation" form of all items circled.

6.4.3 Refer to the applicable " Action Reference" for required action when "Specified Acceptance Criteria" on Enclosure 1 (Surveil-lance Table) are exceeded.

6.4.4 When the Shif t Supervisor must be notified of unsatisfactory surveillance results or when restorative and/or corrective actions require follow-up on a later date, a ChemRad Follow-Up Report (Form 912915) shall be initiated and referenced in the

" Remarks" section of the " Documentation" form.

6.5 Route the completed " Documentation" form (s) per Section 5.6 of AI-400, Plant Operating Quality Assurance Manual Control Document.

6.5.1 A copy of Form 912915 (initiated above) shall be transmitted in the documentation package wherein the Follow-Up Report referenced.

35L:208 Page 3 SP-713 Date 1/13/77 Rev. 2

k}4 r

SffkVFTI.I.AWR TAhlP.

ST8T2lN (8) Emergency Core Cooling 70!!:S

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LLD 0.1 ppe CH-104/142 RS-M2/l-4 01 ailoride(8 II/M Admin.

LID 0.1 ppe CH-105 RS-M2/l-4 04 Turbidity II/M Main.

LIA __

1 NTU CH-125 RS-M2/l-4 W'-

05 Sp. Cond. at 25'c II/M Main.

0.056 20 Ta CH-107/126 RS-M2/1-4 CF TANK 33 CH-155 STS 4.5.!!

07 toron(I II/M(8 BAW 1385 Part 4 2270 1500 2400 1400 ppe CH-101 RS-M2/1-4 STS 3.5.1, 6.9 08 FlsoridaI8 II/M Admin.

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11D 0.1 ppe CH-105 RS-M2/l-4 10 Turbidity II/M Main.

LLD 1

NTU CH-125 RS-M2/l-4 8

11 So. Cond. at 25'c II/M Admin.

0.056 20 cm CH-107/126 RS-H2/l-4 (I Pequi ennt shall not be =A=inistratively relaxed as per Al-400 - Fl)Jt? OPERATIIOC QUALITY ASSURAllCE MANUAL. CONTROL DOCUHFJtT.

(2 Within et.a inours of volume increase 3 80 gale. and II/D until AB e 100 ppmB.

Special frequency initiated by Q

SP-300. Operating Dallw Surveillance log, and OP-401. Cars Flooding System. Section 7.0.

p

() Limits are established aince dissolved osymen in tanks is e function of cover gas and makeup solution

,l composition swl is not cantrolled readily.

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1(c) Describe the preservice NDE performed on the weld joints of identified systems. The description is to include the applicable ASME Code sections and supplements (addenda) that were followed, and the acceptance criterion.

/

RESPON SE :

Preservice inspection at Crystal River Unit 3 was performed per ASME Section XI (1971 edition through Winter 1972 addenda).

Inspection was conducted for FPC by B&W.

Acceptance criteria are listed in the attached Summary Report.

In general, PSI included these examinations:

Class 1 Piping:

60 Decay Heat welds examined by (Jr (0*/45*) and LT 310 Makeup welds examined by (Jr (0*/45*) and NT Class 2 Piping:

354 Decay lleat welds examined by (Jr (0*/45*) ani! \\T 88 Makeup welds examined by lJr (0*/45*) and Vr All PSI data was reviewed by 1MW and FPC Level 111 examiners and found acceptable.

99 WPSemhD77 352220

REV.

O D/.TE l b - A 4 - 7 c PAGE l-1 r

SUMMARY

REPORT INTRODUCT70'd 1.0 This report describes the 1975-76 Preoperatio'nal Inspection of the Class 1 and 2 portions of the ::aclear Steam Supply System for Florida Power Corporation, Crystal River Unit f3, located near Crystal River Florida.

This Inspection uas performed in conformance with the 1971 Edition (through the '!ir.ter 1972 Addenda) of Section "F.ules for Inservice Inspection of Nuclear Reactor Coolant Systems" XI of the ASME B&PV Code.

All pressure boundary welds and adjacent base metal were examined to the extent that the system design and non-destructive testing technology permitted.

This report describes the areas examined, the type of examinations, the examination standards and procedures, and the test data accumulated for comparison in Manual and remote ultrasonic examination future Inservice Inspections.

techniques were used in conjunction with visual, liquid penetrant and magnetic particle examinations.

The technical data and examination results summarized in Volume 3 through 8.

1 of this report are documented in detail in Volumes It may be noted that the data forms u~ sed are not exact duplicates of those shown in the procedures contained in the Preopera-Those shown in the procedures are intended tional Inspection Manual.

only as e::amples, and the forms used in this report comply with the recording requirements of said procedures.

i I

h 1.1 EXAMINATION METHODS All nondestructive examinctions were performed in accordance

(

with the detailed procedures contained in the Preoperational Inspection ms For easy reference, a list of these procedures is presented in Manual.

Mil 2.M Section 2 of volume 1.

REV.

O

_T DATE PAGE fr. ~~

[*

The devels,= _st of examination methods, the f.s. paration of examinatior.

me thod s,

t'.-+ ; reparation of examination procedures, the performance of examinations, and the interpretation and evaluation of examination results were performed by qualified personnel.

The c:::~ination procedures were written by personnel qualified to at least the requirements of SMT-TC-1A (1968 Edition) Level II ar.d were reviewed and approved by personnel qualified to Level III.

Tnese procedures conform to the requirements of the 1971 Editions, (through Winter 1972 Addenda) of ASME B&PC Code Sections XI, V and III where applicable.

The preoperational inspection examinations were performed by technicians qualified to SNT-TC-1A (1968 Edition) Level II, assisted by technicians qualified to at least Level I.

Each of the examination data figures in Volume 3 through 8 lists the specific equipment, materials and procedures that were used.

All pieces of equipment were calibrated in accordance with the specific procedures and ISI-80, Revision 4, " Administrative Procedure for Preventive Maintenance of NDE Equipment", and were standard production models-having no changes or modifications.

In like manner, the materials used for the examinations were those reqrired in the procedures and were recorded in the data figures.

q l

1.2 DATA REVIEW AND EVALUATION 5

The Class 1 and Class 2 systems preoperational inspection examination data, except for the Class 2 piping, were reviewed and evaluated at B&W construction company, Copley, Ohio by personnel qualified to S,NT-TC-1A (1968 Edition) Levels II or III.

The criteria used during-the evaluations are as follows:

l 3522l?2

REV t,

D?.TE l

PAGE l _.

f' l.2.1 Pecordable Indicationc:

Any.*isui,1, magnetic particle, or liquid penetrant indications with size or namber exceeding the amount allotted by Paragraph NB5342 and NB5352 of the ASME B&PV Code Section III, 1971 Edition, through Winter 1972 1.ddendt.

Ultrasonic indica:1ons with signal amplitude exceeding 20 or 50 percent (depending on the specific procedure) of the calibration reference level.

1.2.2 Reportable Indication:

Visual, magnetic particle, liquid penetrant and ultrasonic indications with shape, size, number, or signal amplitude exceeding the amount allowed by ASME B&PV Code Section XI, 1971 Edition, through Winter 1972 Addenda.

i The results of all Class 1 and Class 2 system nondestructive examinations, except for the Class 2 piping examinations, were reviewed and certified by perscnnel qualified to SNT-TC-1A (1968 Edition) Levels II and III.

Indications were evaluated and/or correlated to the original f abrication acceptance standards or the acceptance standards in ASME B&PV Code Section XI.

The results of all Class 2 piping nondestructive examinations

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were reviewed and certified by Mr. J. C. Hicks, the Leve1 III examiner for Florida Power Corporation.

?0011URBl%L Frank J.lsattler B&W Construction Company Level III Examiner j

%2223

AzV.

DATE UJ.

PAGE 6.0 CLASS 1 PIPI!:G S'J,. _ L*.F.Y C'

For clarity, the results are summarized in groupr of simi1L:

welds or components.

I:o reportable indicationr were found by ultrasonics.

Several reportable indications were found by visun_

and liquid penetrant.

These areas were repaired, re-examined cr.d found to be clecr.

6.1 Reactor Vecsol Core Flood Nozzle to Safe End Welds The core flood nozzle to safe end welds joining MK89 to 17

.were examined with ultrasonics and liquid penetrants.

Several 1ct:

amplitude recordable indications were found as documented on the various data sheets.

6.2 Surge Mozzle to Safe End Weld The surge nozzle to safe end weld joining MK8 to MK37 was examined visually and with liquid penetrants and ultrasonics.

One lo-amplitude recordable signal was found as documented on the data sheet This indication resulted from the ID geometry of the nozzle.

6.3 Pressurizer Relief Nozzle to Safe End Welds The pressurizer relief nozzle to safe end welds were examined visually and with liquid penetrants and ultrasonics.

However, scme low amplitude recordable indications were found as noted on the data sheet.

These signals were due to nozzle geometry.

6.4 Flow Meter RTE-Mounting Boss-Vent Connection Pressurizer Tap, Decay Heat and Drain Nozzle to Safe End Welds These nozzle welds were examined visually and with liquid penetrants and ultrasonics.

No recordable indications wcre found.

6.5 Reactor Vessel Inlet and Outlet Nozzle to Pipe Welds The inlet and outlet nozzles to primary piping velds were j

examined and two low amplitude recordable indications were found as docomented on the data sheets.

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10-15-76 P.'. " O L _

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6.6 Circumferential :-d Longitudinal Welds 7

The circumferentir.1 and longitudinal weld seams were examined visually and with ultraronics.

Three hundred and twelve recordable indications were found.

C.7 Branch Connection ' elds Exceeding 4 inches Nomincl Pipe Size The branch connection welds were examined visually and with ultrasonics.

No recorddble irdications were found by ultrasonics.

Pecordable indications were found by visual examinations in four areas on the MX51 to MK49 pressurizer spray nozzle to pipe weld.

6.8 Socket Welds The socket welds were examined visually and with liquid penetrants Numerous recordable indications were found as noted on the data sheets.

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6.9 Pranch Connection Welds, 4 Inches Nominal Pipe Size and Less The branch connection welds were examined visually and with liquid penetrants and ultrasonics.

Several recordable indications were found visually and with liquid penetrants, as documented-on the data sheets.

No recordable indications were found by ultrasonics.

6.10 Circumferential and Longitudinal Welds and Branch Connection Feld:

The welds were examined visually.

Florida Power personnel performed this examination.

No recordable indications were found.

6.11 Integrally 1.'elded Piping Supports Twenty-six integrally welded piping supports were examined visually and with either liquid penetrants or ultrasonics.

No reportable indications were found.

For nineteen of the supports,

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the geometric structure prohibited the effective use of ultrasonics for the examinations.

Liquid penetrant examinations were performed 8022%Ti

~ O REV

-.2 15-76 DNIE PAGE 673 f

cn t'a.ese supports as a:a alternative.

The re. ining seven supports were examined with ultrasonics.

Several ' recordable indications were found, as documented on the data figures.

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1 DATE__l-70 ~

PAGE 2 '; i T

10.0 CLASS 2 PIPING WELDS For clarity, the results are summari.ed in groups of similar welds or components.

10.1 Circumferential and Longitudi;.sl Welds The circumferential and longitudinal welds were examined with ultrasonics.

Numerous indications were found.

These indications were evaluated by Mr. J. C.

E.cks Florida Power Corporation Level III examiner.

Mr. Hicks' evaluation follows this summa 2J.

10.2 Sucport and liangers The piping supports and hangers were exauined visually and with magnetic particles and liquid penetrants.

No reportable or recordable indications were found.

10.3 Bolts and Nuts The bolts and nuts were examined visually and with ultrasonics.

No reportable or recordable indications were found.

10.4 Valves The valves were examined visually.

No reportable indications were found.

Four recordcble indications were found.

10.5 Valve Bolts The valve bolts were examined visually and with ultrasonics.

No reportable or recordable indications were found.

10.6 Penetration Welds The pene.tration welds were examined with either liquid penetrant or magnetic particle.

No reportable indications were found.

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EVALUATION OF CLASS II ULTRASONIC TEST RESUL13 DURING PRESERVICE INSPECTION f

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Prepared by:

J. C. Hicks FPC - level III Quality Programs Department.

OUA'AUS O

s PROBLD1 E:: tensive ultrasonic indications were identified during preservice inspecticn of feedwater (EF) welds.

minstemn f}5), feedwater (FW), and emergenc/

Tr.e subject indications appear on a large portion of the MS, FW and EF welds;

~&.ey both shop and field, which were examined as part of preserv cf the reference curves and have lengths pater than those acceptable under the applicable inspection precedures conducted c. der Plant Surveillance Procedure SP-304.

A detemination of the physical cause of the indications was needed to evaluate the possible effect the cause of the indications might have on the integrity of the welds.

4

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L*:T T1:D The Crystal. liver Unit #3 Main Stea::,, Feedwater, and E.crgency Feedwater syste=

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censist prir=:-ily of SA-106 GrB and SA-182 piping materials which were, designed and fabricate.d to ANSI B31.1 - 1969 as rodified by Require. Tnt Outline, RO-2891.

These docu e.m s do not recognize the ccaduct of ultrasenic examinations; and further, wer:. promulgated prior to the existence of sny requirements for the conduct of i tservice examinations of pressure containing equipment.

Because of t-.e foregoing no clearly defined basis existed upon which to evaluate the ultrascr..: (UT) indic:tions.

Mditic 21 backgrec.. is as fo11cus:

steam line 2, inch direter by 0.94 inch nominal wall SA-106 GrE.

1.

Mai:

Feec: eater line IS inch dia eter by 0.937 inch nominal wall SA-106 Gr3.

2.

Shc-welds were made by M. W. Kellogg to weld procedure F1-K1-F6-SAW-14-1G 3.

(ccpy attached).

4.

Fie~ d welds were rade by J. A. Jones to weld procedure CS-1-TIG-SMA and 3-2-BR-SMA (attached).

5.

Welds wre visually inspected and radiographed to a nominally 2-2T sensitivity after post weld heat treatment (PhWT).

6.

Preservice inspection was conducted under procedure SP-304 (attached).

7.

Ult asonic inspecticas were in accordance with procedures ISI-101 and 102.

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. T.ETIGATION o

?..e first step of the investigation was an attempt to asce f.e subject welds.

Similar layouts were made for UT data taken as folloss:

1.

FG-17 weld A prior to hydrotest 2.

LG-17 weld A after hydrotest 3.

FG-4 weld A prior to hydro *est 4.

FS-4 weld A after hydrotest 5

FG-18 prior to hydrotest 6.

Partial FG-18 after hydrotest 7.

FW-347 prior to hydrotest Examples of the layouts from FG-17A are attached.

All of the layouts exhibited certain characteristics as follows:

Indications we m linear and circumferential in nature.

1.

Many indications h:d apparent through wall distances of 0.10 to 2.

0.30 inches.

Most indications we m at or very near the weld I.D. surface.

3.

The iHdications were 1/8 to 3/16 inches off the root centerline.

4.

Many indications were not detectable from both sides of the weld.

5.

In an atterpt to cl.aracterize the cause 6f the UT indications, Pittsburg Testing Lab (PTL) radiographed FS-17A both prior and subsequent to hydrotest with a The indications present nigte which produced radiographs to a 2-1T sensitivity.UT indications were found to were mapped.in the same manner as the Ur data.

correspond to most of the slight RT indications, but no RT indications corre-lated with the significant linear root UT indications.

Based on the foregoing, it was decided to conduct an experinent to try to dupli-Pipe material, which had been cut from cate the indications in a sample weld.the Main Steam lines to pemit insta From the and had weld preps machined in accordance with drawing (attached).

preservice inspection records and construction records it was determined FS-18 was a field weld with a typical pattern of UT indications.

Weld Data Sheet, it was determined that a censumable insert of th

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ntrber as used on MS-18 Insert.

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U.VESTICAi!C:. Lon 'dj o

Using the above information and materials, '.'.c sa.ple weld was made as similar 3

f to M5-18 as practical. The weld was subject to quality control similar to the field wcld :nd was docurrented on a Field '::Id Data Sheet (attached).

A battery of nca-destructive and destructivc exa=inations werd conducted on the sa..ple weld, as listed below, in order to p:mide a mnM n data base from which to evaluate the problem.

NDE ON SM9LE h?_LD - AS hT_LDED 1.

O. D. Visual 2.

I. D. Visual 3.

UT fmm O. D. both 0* and 45* shear.

4.

RT to a 2-1T sensitivity on Kodak 'N' film NDE CN SMPLE KELD - AFTER PhWT ft 1.

O. D. Visual s//Jf 2.

I. D. Visual w/ macro-photos 3.

UT from O. D. both 0* and 45* shear.

4.

RT to a 2-1T sensitivity or better on both Kodak 'M' and "R" films.

5.

Fltorescent liquid penetrant (LP) of the I. D. of the weld root area.

6.

Magnetic Particle (MT) by the drf D. C. yoke method on the I. D. and O. D. weld area.

Fmm this range of tests there appeared to be a series of linear indications coin-cident with I. D. weld prep machining narks Wich were visible close-up, confirmed 5,.r_ey. etic particle and liquid penetrant e:rinations, panially correlated with fine indications in high resolution radiographs and partially corresponding to Ur indications greater than 1001 DAC showing tbmugh wall distances of 0.10 to 0.30 inches.

Based on the NDE results it was then decided to section the sample weld at locations where nultiple EDE techniques all showed indications.

This was done and the result-ing six cross-sectiens were polished and examined both as-polished and etched. The sample from the location of greatest UT response was sent to Dr. William F. Smith at Florida Technological University for an independent analysis.

His resultant re-port is attached.

None of the cmss-section.s examined showed any macro or micro discontinuities in or near the weld zone which would relate to the Ur indications.

The machining marks were determined to be less than three mils deep.

Further consideration of the sample weld showed that sharp changes of the I. D. con-(

tour, resulting from both the machined weld prep and the root bead configtnation, were present that might act as geometric UT reflectors. To demonstrate if this was

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If.'C"~.*T* TIC (Cont'Q s

the cre.c a one foot section of the sagle weld was re-exami i by UT, again verify-('

ing the indications as present, and then the I. D. was care ly handgrotr.d to produce a scoothly transitioned contour with a minimun ret-e.. oval.

Exaatination by the sane UT technique after contouring showed all apparc. indications had been eliminated.

As a final investigation visuil exa-inntions of field welds 1-17A and FG-17L were accomplished using a fiber-cptic bcresc:pe.

Viewing condi

-s were marginal, but it was verified that a sitilar root bead ccatour was'preser.

ut no weld prep con-tcurs could be distinguished.

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rom the results of this 6xtensive investigation it has been concitded th.t:

c 1.

A w Id contour is produced which acts as a geometric reflector during ultrasonic examination; causing apparent linear rtiot indications.

2.

Removal of the root bead contour eliminates the indications.

3.

No radiographic indications are present in the accepted constn:: tion radiographs kitich correlate with the UT indications.

4.

Remote visual examination of two main steam welds confirred the presence of root bead contours co parable to the sample weld.

5.

Macro and micro examinations of areas with significant ultrasonic indications shcwed no related discentinuities.

6.

The results and conclusions of this investigation have received the re-view and concurrence of the architect engineer, Gilbert Associates. Inc.

(letter FPC - 13544 attached).

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.. i EiU:i'234

ACHON 'IO :S 'LE!

F Based upon the conclusic.s of this evaluatica and the rn%:ir cf the norida Po ict Corporatica Ievel III B=:iner, s.s shall:

1.

Ibke no attest to sliminate the wcld I.D. ultrasonic indice.t rs frcc the 2i sten, feet:ater, and e::crgency feedwater systrs.

2.

Id.itor the s:ru:tural integrity of the subject systens in service by u:c of an a::cptchle radiographic technique.

3.

F.2: sir. in file all present radiographic and ultrasonic exci.: tion rc ords nada to date on the subject systems.

4.

Perfor ulra:r.ic err c.inations on the see one quadrant of tha fol-Ic-dng rainster elds during three (3) inservice inspections v."_th a minirt=1 of 9 en:hs operation between exa:ninations: ES-17A, 1'S-4, 6 MS-18.

Should no deg adation b' discov= red upon cccparison of.results to past data, no further c.= inat.as will be made other than those ccmitted to in our Standard ' 2hnical Specificaticas.

~

3(*W19 9 9 V-e ef de)

a 1(d) Facilities having previously experienced cracking identified systems, Item 1, are requested to identify (list) the new materials utilized in repair or replacement on a sys tem-by-sys tem basis.

Jf a report of this information and that requested above has been previously submitted to the NRC, please re.ference the specific report (s) in res ponse to this bulle t'in.

RESPON SE :

Florida Power Corporation experienced through-wall crackin;; in two areas of Building Spray welds as discussed in our 28 February 1977 letter, attached.

In both cases, TP 304 SS piping was replaced with TP 304 SS.

The initial crack was repaired and radiographed per Work Request 01876 and Modification Approval Record 77-1-8.

The second and final crack was repaired and radiographed per WR 2181, MAR 77-1-31.

Both areas were again volumetrically examined (iTT and !G) during the refueling outage commencing 23 April 1979.

Ir.dicaticas were acceptable.

1. 0 04@p61 Ot~y)*3#

WPSemhD77