ML19254F020

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Manual Ultrasonic Examination of Big Rock Point Reactor Vessel Control Rod Drive Housing
ML19254F020
Person / Time
Site: Big Rock Point File:Consumers Energy icon.png
Issue date: 08/24/1979
From: Heineman W
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML19254F017 List:
References
SWRI-NDT-800-66, NUDOCS 7911050364
Download: ML19254F020 (22)


Text

{{#Wiki_filter:SOUTHWEST RESEARC!: INSTITUTE Sgt5-8 -66 August 1979 Ng NUCLEAR PROJECTS 4 OPERATING PROCEDURE Page 1 of 22 'I ~ ' - ~ NY MANUAL ULTRASONIC EXAMINATION OF 3IG ROCK POINT REACTOR VESSEL CONTROL RCD DRIVE HOUSING ~h s i ' SwRI-NDT-800-66 mp 1.0 PURPOSE y' This procedure provides the infor=ation and detailed steps necessary to i ensure a complete and accurate manual ultrasonic exaMnation of the Big Rock I ne reactor vessel control rod drive (CRD) housings in accordance with the applicable ASME Boiler and Pressure Vessel Codes. I SCOPE AA APPLICATION 3 f^.] 2. 0 2 pd This procedure has been prepared for the =anual, contact, pulse-echo shear-wave angle-beam, and longitudinal-wave straight-beam, ultrasonic excsi-nation of stainless steel reactor vessel CRD housings at Big Rock Point. 3 A GE MK I search unit holder shall be utilized for the examination of j, l the CRD housings. The areas to be examined shall be as specified in the i hl ;;plicable SwRI E:camination Plan. a 3 l 2.1 Aeolicable Documents

!Aip The following documents form a part of this procedure as

= l 's applicable: t (1) ASME Soiler and Pressure Vessel Code, Section XI, 1971 f; Edir. ion, with Addenda through Winter 1972, " Rules for l jg In,ervice Inspection of Nuclear Reactor Coolant Syste=s." l i' j J (2) ASME 3 oiler and Pressure 7essel Code, Section III, 1971 2; Edition, with Addenda through Winter 1972, " Nuclear Power g,4 Plant Components," with the exception of the following: .hn (a) Subsubparagraph IX-3451.1(c)(3) of Appendix IX to i )q Section III states that transfer (attenuation con-i pensation) be accceplished between the production sacerial and basic calibration block and a corree-tion =ade for the difference. No attempt shall be made by the exaciner to determine differences in the j acoustic properties between the basic calibration i block and the producti]gagg p g i g UUR Un L1 Hnl l n@ i s..e, y-, a 4 2 2 7911o3o @(; 1267 285

SOUTHWEST RESEARCH INSTITUTE "$I;f"7$~" August 1979 k.Nrg* NUCLEAR PROJECTS OPERATING PROCEDURE Page,- of,, ._.u 3: (3) SwRI Nuclear Quality Assurance Progras Manual (NQAPM). w 2 d 3.O RESPONSIBII.ITY I (1) The Director of the Department of Engineering Services, Quality Assurance Systems and Engineering Division, shall be responsible y i f or the preparation, review, approval, and control of this pro-cedure. s ") (2) The Manager of the Nuclear Field Services Section, Department of { Engineering Services, shall be responsible for the implementation e of this procedure in accordance with the NQAPM specified in the applicable SwRI Project Plan. I b (3) The examiner shall be respansible for imple=enting the require-ments of this procedure. d A N (4) The Manager of Support Services, Quality Assurance Systems and h Engineering Division, shall be responsible for storage of re-3 I cords generated in accordance with this procedure. E ij 4.0 CODE AND PROCEDURE REQUIREMENTS

  • he requirements listed below shall be applied when perfor=ing =anual g ultrascnic examinations in accordance with.this procedure.

Recuire=ents Section T (1) Configurations to be exasined, 7.0 j, including thickness dimensions il g (2) Autoc:atic defect alarm and recording j equipeent shall not be used -M il (3) Search unit vedges, shoes, or saddles 5.0 24 3 4 (4) Rotating, revolving, or scanning =echanis=s ~ Mi shall not be used l l (5) Personnel certification 5.0 I{' (6) The examination surface or surfaces 7.0 I i..l 6 7 2 8 6 e .~,,>~.31 P00R ORBiML

SOUTHWEST RESEARCH INSTITUTE U"I I '-* " August 1979 NUCLEAR PROJECTS J OPERATING PROCEDURE page 3 of 22 '._LLW a s + (7) Surface finish 7.0 f (8) Couplant 5.0 (9) Method used 2.0 (10) Technique used 2.0 (11) Calibration method and method of correlating 5.0, 6.0, indications utch defects 8.0, 9.0 (12) Scanning 7.0 ( Qe. (13) Mode of trans=ission 2.0 C ha (14) Type and size of search unit 5.0 Mt (15) Examination frequency 5.0 (16) Examinations shall be perfor=ed on components in their completed condition h (17) Ultrasonic instru=ent alignment 5.0 l !Y M, 5.0 PERSONNEL AND EQUIPMENT 5.1 Personnel Certification c Personnel performing examinations in accordance with this pro-3 cedure shall be certified in accordance with SwRI NQA1 11-1, "Specisi Process Control." f' 5.2 Reference Bicek t s

  • d Reference blocks used for screen distance calibration and verification shall be as follows:

Al (1) SwRI Half-Round (Sketch 1) (2) AWS Type DC (Sketch 2) The reference block shall be of the same basic =aterial as the j s h production =aterial, e.g., stainless steel. '9 1267 287 d ...._.m P00R ORGM

SOUTHWEST RESEARCH INSTITUTE CI!"T" August 1979 9g NUCLEAR PROJECTS OPERATING PROCEDL.'P'- (+j yj. Page 4 of 22 Q n3 5.2.1 Reference Block Selection Reference blocks shall be used as follows for screen distance calibration. (1) Straight-3eam E5M Screen Block Distance Block Tyce Dimension j-l 1.0" SwRI Half-Round, 1.0" AWS Type DC 0.5" or 1.0" i

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(2) Angle-Beam Screen Block Distance Block Tyce Di=ension 's 10.0" SwRI Half-Round 1.0" Radius } AWS Type DC 1.0" and 2.0" Radii AM 5.3 Basic Calibration Block { The calibration reflectors shall be notches nachined on the ,O d outside surface of basic calibration block 3R15A. Basic calibration block 4 3RISA is a sinulated CRD housing and is shot.n in Sketch 4 Notches "I" and "H" shall be utilized for examinations scanning j an axial direction. Notch "I" has a depth of.116 inch (20%t) and notch "H" has a depth of.058 inch (10:t). 3% Notches "7" and "E" shall be utilized for examinations scanning 3 in a circumferential direction. Notch "H" has a depth of.116 inch (20 t) and c notch "E" has a depth of.058 inch (10%e). I ? I h An approved drawing of the basic calibration block shall be contained in the applicable SwRI Examinatica Ilan. / 5.4 Search Units l

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The si:e of search units shall be selected according to the following table: i6 1267 288 Lm $

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SOUTHWEST RESEARCH INSTITUTE S$1 $'-') August 1979 h NUCLEAR PROJECTS !8 OPERATING PROCEDURE Page 5 of .3., E 3-(a) Straight-Beam 3 Nominal Search Unit Size Examination Tyce [ 3/8" dual ele =ent Thickness =easurenents (b) Angle-Beam m i Nominal Search Unit Size Examiration Tyce j 3/8" x 3/8" circunferential g 1/2" x 1/2" Axial .p (2) The exit point of the sound beam and the actual refracted 3 d >N beam angle of angle-beam search units shall be determined on an IIW block (Sketch 3). The exit point shall be marked on the search unit wedge. j (3) The nominal angle-beam search unit frequency for exami-1 nations shall be 2.25 MHz. b N ( (4) The nominal straight-beam search unit frequency shall be 3 5.0 MHz. (5) For examination of CRD housings, search unit wedges shall .^l be fabricated to produce 45' 2' refracted shear-waves. 3 -2 ty j 5.5 Ultrasonic Instrument fg The exa=iner shall select an appropriate t.ltrasonic instru=ent

l'4 from the following:

)N 24 (1) Sonic FTS Mark I -Is Q (2) Sonic FTS Mark II jlg'# (3) Sonic UWA Mark III i3 Each inst:cunent ?s all be aligned and display an alignment calibrationstickerasrequirep[yNQAP10-1. l .(

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SOUTHWEST RESEARCH INSTITUTE !""CE"'-* -" August 1979 hq. NUCLEAR PROJECTS y - M OPERATING PROCEDURE Page 6 of 22 '1 D 5.6 Couplant a (1) A trickle of reactor vessel water normally occurs through

S the seal device at the upper end of the CRD housing. This shall be used as the ultrasonic couplant, when practical.

3 i (2) Deionized water shall be used when the trickle of reactor / vessel water is insufficient to provide adequate couplant. $*b i Tubing shall be attached to the plant deionized water { supply piping to provide the necessary couplant. 5.7 Search Unit Holder M The search unit holder, Sketch 5, shall be a GE MK 1. The GE a

l/ MK I, stored at the Big Rock Point site, consists of a spcing-loaded mount for the search unit, sectional tubular handle, coax cable approximately 13 feet f

long, and plastic tubing for ecuplant supply. 4 5 5.0 CALIBRATION METHOD l' I f y l The complete ultrasonic examination system calibration shall be per-y formed prior to the examination. NOTES hi l The " REJECT" control shall be =aintained in the "0" position j g j! during calibration and examination. in The "FREQ MH2" control shall be turned to "2" when a 2.25 MH: rlq l search unit is used, and "5" when a 5.0 MH: search unit is used. 6.1 Distance Calibration iF -g 6.1.1 Scraight-Beam 's e A 1.0-inch screen distance size shall be utill:ed for straight- - j beam. Observing back reflections from the applicable reference block, adjust the

  • MATERIAL CALI3 RATION," " RANGE," and " DELAY" controls of the I instru=ent to obtain the required linear sound path distance, displayed along j

j the screen baseline. %;. s 1267 290 w ,.+.,,,u.,., P00R BRGEL

I SOUTHWEST RESEARCH INSTITUTE '""l;i"'-*3 /2 gust 1979 h NUCLEAR PROJECTS /. OPERATING PROCEDURE 4-Page 7 of 22 m t 6.1.2 Angle-Beam o' ds The screen distan:e size for angle-beam shall be 10 inches. Observing radius echoes from the applicable reference block, g adjust the " MATERIAL CALI3 RATION," " RANGE," and " DELAY" controls of the instru=ent to obtain the required linear sound path distance, displayed along yg, the screen baseline. n g 6.2 Angle-Beam Distance Amolitude Correction Distance amplitude correction (DAC) curves shall be constructed by utilizing the responses from the notches in basic calibration block 3R15A. ir = p 6.2.1 DAC Curve Calibratien for Axial Scanning A 1/2" x 1/2" 45' search unit shall be =cunted in the GE MK I search unit holder for axial scanning. = 3i (1) Position the search unit ti ob*ain =ax1=um response from (' the notch and nodal position producing the highest ampli-g tude from the following: l Nc*ch Nodal Positions Jc qp "I" (?0~t) 4/8, 12/8, 28/8 (2) Adjust instrument gain controls to obtain the pri=ary lc reference response at 852 t32 of full screen height (PSH) and = ark this a=plitude on the screen. The gain controls $lj shall not be adjusted cnce the pri=ary reference response )p has been established. 1 2 (3) Position the search unit to obtain =axi=us response from i N the remaining nodal positions and = ark each a=plitude on l Jt* the instrue:ent screen. j !) ~ hl (4) Join these points with a s=occh curved line. (5) '41th the instrument gain set at the pri=ary reference l level, position the search unit to obtain =aximum responsej 'f. from the 12/8 node using notch "H." Mark the signal I 5 i amplitude with an I. h 1767 291 m j Gl i ,..,.~.u a \\ l

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-800-66 aevisio# 0 August 1979 g NUCLEAR PROJECTS M OPERATING PROCECURE Page 8 of 22 N ? 6.2.2 DAC Curve Calibration for Circumferential Scanning sog A 3/8" n 3/8" 45' search unit shall be mounted in the GE MK I for circumferential scanning. 3 N (1) Position the sea .h unit to obtain maximum response from j% the notch and nodal position producing the highest ampli-J tude from the following: f%g Notch Nodal Positions M "F" (20 t) 4/8, 12/8, 28/8 s f (2) Adjust instrument gain controls to obtain the primary [ reference response at 85% 5% of FSH and = ark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established. E ? (3) Position the search unit to obtain raximum response from the two other nodal positions and mark each amplitude on j y the instrument screen. (4) Join these points with a smooth curved line. j P (5) With the instrument gain set at the pri=ary reference ~T le'rel, position the search unit to obtain maximum response T from the 12/8 node using notch "?.." Mark the signal ampli-g c ide with an I. -i, A 6.3 Secondary DAC Calibrations s P. sil If all points on the DAC curve do not appear at 20% of FSH or greater, a secondary DAC curve shall 1,e constructed as follows: iw (1) All secondary DAC curves shall contain at least 2 paints. M (2) The DAC point at 2 lines or greater in amplitude and adja-cent to a DAC point that fal.ls below 2 lines of amplitude shall be brought to the pri=ary raference level by anipu-lating the instru=ent gain controls. This point shall be j i marked on the instrucent screen. The adjacent point (s), E ( $5y 1267 292 $.v50 earm Ga.31 P00R O H M ~

-. + - SwRI-NDT-800-66 SOUTHWEST RESEARCH INSTITUTE Revision 0 August 1979 NUCLEAR PROJECTS OPERATING PROCEDURE +7 Page 9 of 22

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previously at less than 2 lines of amplitude, shall be marb d on the screen and each point connected with a s 3 3-smooth curved line. The instrument gain setting for this secondary DAC curve shall be recorded on the appropriate s SwRI Instru=ent Calibration Record. 5 i EXCEPTIONS E li , j When the first DAC point is the only point above 2 lines of amplitude, the ner-highest point shall be brought to i{ the primary reference level. This point shall be marked on the inst.a=ent screen. The other points previously at less than 2 lines if amplitude shall be marked on the

h screen and each point connected with a smooth curved line.

n 1 te inst ument gain setting for this seconJay '.'." curve N shall be recorded on the appropriate SwRI Instru=ent Calibration Record. 6.4 Calibration Verification 1' } 6.4.1 Sween Range and DAC Curve Verification St.eep range calibration shall be rerified on the appropriate i l reference block s.7d DAC curve calibration, if applicable, shall be verified on q the basic calibration block. a 5 (1) At the start of a series of examinations (2) With any substitution of search unit cable ,d 'I (3) With any substitution of power source _f (4) At least every 4 hours during the exa=ination l g d (5) At the finish of a series of examinations .c 3 (6) At any ti=e when, in the opinior of the exa:.iner, there is doubt as to the validity of the calibration. .3 6.4.2 Calibration Changes I i (1) Perform the following if any point on the DAC curve has j [ decreased = ore than 20% or 2 d3 in a=plitude, or any point i has moved on the sweep line = ore than 5* of full screen i. width: NQ .,,- u.u P003 BRMA mm

SOU THWEST RESEARCH INSTITUTE '""l27*~" August 1979 hsg NUCLCAR PROJECTS g CPEHATING PROCEDURE Page 10 of 22 = 3 (a) Void all examinations referring to the calibration d-in question ari perfor ed after the last valid calibration v:.rification. (b) Conduct a ne, calibration. m. V 5 f (c) Reexamine the areas for which examinatiom, have been j voided. } ^f 1 (2) Perform the following if any point on the DAC curie has increased in amplitude more than 20% or 2 d3: (a) Correct the calibration. d (b) Reexamine all indications recorded since the last valid calibration verification. (c) Enter proper values on a new SwRI Exa=ination 3 Record. i h

i i

6.4.3 Recalibration 9 q Substitution of any of the fellowing shall be cause for re- ~~ ] calibration: (1) Sa. arch unit (vedge/ transducer) g (2) Couplant -i s4 (3) U..trasonic instrument sj (4) E7teination personnel. z, M 6.5 Calibration Data M j - Q Calibration data shall be recorded on the appropriate SwRI tl Inr.ru=ent Calibration Record, and shall include but not be limited to: (1) Serial number of the basic calibration block used j (2) Type and serial number of the reference block used (3) Type and serial number of the ultrasonic instrument M 1767 294 o $WAl #Jf " )d= 3*l P00RBRTdM

S"l-l"'-8 J SOUTHWEST RESEARCH INSTITUTE n 3 August 1979 Ng NUCLEAR PROJECTS R' OPERATING PROCEDURE ' l +W-

  • Page 11 of 22 T

^* (4) Type, size, beam angle, and serial number of the v ultrasonic search unit Y (5) Couplant (which shall be the same type as used in the actual examination) C f (6) Signature and ultrasonic certification level of the d' examiner conducting calibration i L{ (7) Date calibrated (8) Time of calibration and verification (s). 2 7.0 EXAMINATION $ 6 d Angle-beam examination shall be conducted on the accessible portions of % the CRD housing. The examinations shall be conducted from the inside surface of the CRD housings using a CE MK I search unit holder. C k 7.1 Surface Precaration The control rod drive mechanism shall be removed by plant personnel to provide access to the interior of the CRD housing to be examined. The interior surface will not require additional preparation. I _ rt 7.2 Scanning Parameters j pW When practicable, scanning shall be perfor=ed at a =inimum gain setting of 2 ti=es the reference level sensitivity. g b

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Instru=ent gain setting for scanning shall be determined on the jg basic calibration block as follows: i g (1) Manipulate search unit on the basic calibration block to obtain a signal from a calibration reflector (notch) ef a SO: FS'd. (2) Add 6 dB of gain by adjusting the instru=ent fine gain control only. Observe the rignal amplitude. (3) Add 6 dB of gain by ad >stieg a combination of both fina }[ and coarse gain contro?s. Observe the signal amplitude. 5 s: w 1267 295 d ,__._.m P00R OWL

SOUTHWEST RESEARCH INSTITUTE C"';"-8 3 August 1979 NUCLEAR PROJECTS OPERATING PROCEDURE Page 12 of 22 8h (4) Add 6 dB of gain by =anipulating the instrument 6 dB switch, if present. Observe the signal amplitude. ,L % (5)

hoose the =ethod above which yields a signal response closer to 100% FSH.

+p (6) The c:etho i chosen sna11 then be used during the valid gy j calibration period for all scanning at 2 times the re-g h ference level sensitivity. 1 ) The examiner shall ensure that the signal response of the method ' h sen is within 2 dB of 100% FSE. Instrument gain settings for scanning shall be recorded on the d ap. r iate SwRI Exa=1 nation Record. The search unit =ovement rate for scanning shall not ext. ed 6 inches per second. a q Scanning overlap shall be a minimum of 10% of the search unit piezoelectric element dimension perpendicular to the direction of scan. 2 % 7.3 Thickness Measurements The wall chickness of the accessible portions of the CRD housing shall be verified to be.58 t.1 inch. Areas of reduced thickness and the ~ 2 I thickness of the CRD housing shall be recorded on the applicable SwRI Exami- ? nation Record. The a:i=uth '.ocation with respect to the plant north and the distance from the flange sur face shall be recorded for areas of reduced ! d, thickness.

t 5

M 7.4 Angle-Beam Examination M = 4 3 The thermal slee a on the inside of the CRD housing will limit the exa=ination area (Item 2 in Sketch 5). The accessible portions of the CRD f housing shall be examined using a 45' t2' search unit. Sb

Ei The angle-beam examinations shall be conducted with the search unit directed in two directions. One examination shall be conducted with the sound beam directed circumferentially and another with the sound beam directed axially to the CRD housing icoking toward the thermal sleeve.

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SOUTHWEST RESEARCH INSTITUTE """Ci"'n~' August 1979 NUCLEAR PROJECTS hp OPERATING PROCEDURE Paga 13 of 22 $ t RECORDING CRITERIA 8.0 As L Ultrasonic reflectors producing a response SC% or greater of the - reference level shall be recorded on the appropriate SwRI Examination Record. [ Indications producing a response 100% or greater of the reference level I aaA shall be investigated by a Level II or Level III examiner to the extent m( sssary to determine the shape, identity, and location of the reflector. nec 3 g Indications 100% or greater of the reference level investigated and nd to be other than geometrical in nature and areas with a change of a thickness greater than t.1 inch from the nominal.58-inch thickness shall be reported to the customer for evaluation. s s _5 l4 0 9.0 EVALUATION Evaluation of reportable indications shall be the responsibility of the I customer, or the customer's representative, and shall be conducted in accor-dance with ASME Boiler and Pressure Vessel Code, Section XI, Paragraph 15-311. o i' The applicable year of the Code and Addenda shall be as specified in Paragraph ) 2.l(1) of this procedure. 10.0 RECCRDS ,a The customer sitall receive copies of documents generated in accordance M with this procedure in the examination report. Per=anent documents generated in accordance with this procedure shall be 3 h stored and retained as a portion of the examination report. "he examination f [t J report shall be stored by the Manager of Supoort Services, Quality Assurance Syste:r.s and Engineering Division, in the Data Storage Facility for the period o j specified by the contractual agree ~ent with the customer. 14 = - 1 1267 n97 = z W NG

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M NOTE I. SU8 TRACT Tile MINIMUM METAL PATH ( WgMP) FROM Tile M AXIMUM METAL PATal (W2MP) AND DIVIDE BY Tile 4/8 NODE METAL PATil (4/8 MP) W 2MP-W MP g a TilRU WALL DEPTH IN */. OF "T7 4 /8 MP W W NOTE 2. SUBTRACT Tile M A XIMUM METAL PATH (W2MP) FROM THE 4/8 NODE METAL PATH ( 4/8 MP ) AND COMPARE TO Tile MINIMUM METAL PATH ( WgMP). Tile SMALLER OF Tile TWO HUMBERS IS TliEN DIVIDED BY Tile 4/8 NODE METAL PATH (4/8 MP) 4/8 MP-W2 MP = DIST ANCE FROM SURFACE IN */. OF "TI 4/8 MP OR If W MP IS LESS Til AN 4/8 M P - W2MP g W3 MP DIST AllCE FROM SURFACE IN % OF "T" USE a CN N LN O N}}