ML19254F021
| ML19254F021 | |
| Person / Time | |
|---|---|
| Site: | Big Rock Point File:Consumers Energy icon.png |
| Issue date: | 09/12/1979 |
| From: | Heineman W CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| Shared Package | |
| ML19254F017 | List: |
| References | |
| SWRI-NDT-800-67, NUDOCS 7911050366 | |
| Download: ML19254F021 (16) | |
Text
SOUTHWEST RESEARCH INSTITUTE
'""II!-*~'7 August 1979 NUCLEAR PROJECTS 4
OPERATING PROCEDURE M
Page 1 of 16 i
$ Y MANUAL ULTRASONIC EXAMINATION OF BIG RCCK POINT 5
STUB TUBE-TO-LOWER HEAD WELD
- s SwRI-NDT-800-67
~
.l.0 PURPOSE This procedure provides the technical information and detailed steps l
necessary to ensure a complete and accurate manual ultrasonic examination of f
Big Rock Point stub tube-to-lower head weld in accordance with the appli-
, able ASME Boiler and Pressure Vessel C3 des.
2.0 SCOPE AND APPLICATION E]
N Manual, contact, shear-wave angle-beam, pulse-echo ultrasonic exami-nation techniques shall be conducted on the stub tube-to-lower head welds M specified in the applicable SwRI Examination Plan.
e]
2.1 Aeolicable Documente E
{
J The following documents form a part of this proceiure as 3
applicable:
8
--=i -o (1)
ASME Boiler and Pressure Vessel Code,Section XI, 1971 3 h,,
- l Edition, with Addenda through Winter 1972, " Rules for 3
Inservice Inspection of Nuclear Reactor Coolant Systems."
' e+
(2)
ASKE Boiler and Pressure vessel Code,Section III,1971 Edition, with Addenda through Winter 1972, " Nuclear Power 5
Plant Components," with the exception of the following:
)
i i
(a)
Subsubparagraph IX-3451.l(c)(3) of Appendix IX to 3
Section III states that transfer (attenuation com-pensation) be accomplished between the produelion material and basic calibration block and a correc-
,c tion made for the difference. No attempt. shall be rade by the examiner to determine differences in the acoustic properties between the basic calibratiou block and the production material.
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")s 1267 308 9
s.m,,, w.m 7911050
SOUTHWEST RESEARCH INSTITUTE Swal-NDT-soo-67 Revision 0 August 1979 NUCLEAR PROJECTS g
D OPERATING PROCEDURE Page 2 of 16 3 y (3)
SwRI Nuclear Quality Assurance Program Manuai (NQAPM).
3 (4)
AS1E Boiler and Pressure Vessel Code Section IX,1971 S'
Edition, with Addenda through Winter 1972, " Welding Qualifications."
3.0 RESPONSIBILITY (1)
The Director of the Department of Engineering Services, Quality C
} b.'
3 Assurance Systems and Engineering Division, shall be responsible for the preparation, review, approval, and control of this pro-e cedure.
4 (2)
The Manager of the Nuclear Field Services Section, Department of j,
Engineering Services, shall be responsible for the implementation
~ jp of this procedure in acccedance with the NQAPM in effect on the date this pr-edure is approved.
(3)
The examiner shal.1 be responsible for implementing the require-E ments of this proc (dure.
(4)
Thc Manager of Support Services, Nality Assurance Systems and j$
Engineering Division, shall be responsible for storage of re-tords generated in accordance with this procedure.
4.0 Con" wL PRCCIDURE RECUIRE>ENTS 2 g#
The require =ents listed below shall be applied when performing manual
, Jultrasonic er.ninations in accordance with this procedure.
Reauirements
,Section j
(1)
Configurations to be examined 7.0 s
~
(2)
Automatic defect alarm and recording j
equipment shall not be used l3 (3)
Search unit vedges, shoes, or saddles 5.0 (4)
Rotating, revolving, or scanning mechanis=s shall not be used f
i
=
i 1
(5)
Personnel certification 5.0 5'5%
(6)
The' examination surface or surfaces 7.0 I9 e,., u a. i 1267 309
SOUTHWEST RESEARCH INSTITUTE swr 1-NDT-800-67 Revision 0
^"8"**
h NUCLEAR PROJECTS R
OPERATING PROCEDURE
' ~
Page 3 of 16 y
m*
(7)
Surface finish 7.0 f
(8)
Couplant 5.0
'Qd (9)
Method used 2.0 g
(10) Technique used 2.0 PN t
I (11) Calibration nethod and method of correlating 5.0, 6.0, M
indications with defects 8.0, 9.0
{%
(12) Scanning 7.0 j
(13) Mode of transmission 2.0 (14) Type and size of search unit 5.0 (13) Examination frequency 3.0 C
3 y (16) Examinations shc11 be performed on welds in f N their completed condition
$N V
(17) Ultrasonic instrument 5.0 l\\
5.0 PERSONNEL AND ECUIPMENT 5 $
5.1 Personnel Certification
.4 e
1 Personnel performing examinations in accordance with this pro-
~!
cedure shall be certified in accordance with SwRI NQAP 11-1, "Special Process Control."
d 52 Reference Block N
The reference block used for screen distance calibration and g4 verification shall be an IW block (Sketch 1).
The ID bicek shall be carbon 3
steel.
,W
~
5.3 Basic calibration Block f
The basic calibration block shall be 3RP-CRD-25. It is a full-
- size nock-up of the bottom head assembly at control rod drive F-2.
Sketch ;
I shcwa the side-drilled holes to be used.
44
........1 1267 310
SOUTHWEST RESEARCH INSTITUTE SwxI-m -aoo-67 Revision 0
^" 3" * * " 9 h
NUCLEAR PROJECTS
% w?,
OPERATING PROCEDURE Page 4 of 16 I'
5.4 Search Units j' [
Search units size shall be 1.0" x 1.0" or 1.0" round.
Search unit vedges shall be f abricated to produce a 34.5*
1
{,
' ref racted shear wave as demonstrated on the II'4 block (Sketch 1).
M,g The nominal search unit frequency shall be 1.0 MH:.
! <d 5.5 Ultrasonic Instrument t A %
The examiner shall select an appropriate ultrasonic instrument rom the following:
s$
3 kAF (1)
Sonic FTS Mark I lea (2)
Sonic FTS Mark II y
(3)
Sonic U'4A Mark III i
}
Each instrument shall be aligned and display an align =ent cali-3 bration sticker as required by NQAP 10 '..
4 l
5.6 Couolant
- h (1)
USP grade glycerine, ultragel II, or deionised water (with 07 or without wetting agent) shall be used when performing ultrasonic calibrations and examinations in accordance
'i with this procedure.
g L:
(2)
Couplant materials used for examinations shall be the same i
}
as used for the calibration.
i (3)
Light oil or other compounds, which in the opinion of the
-p\\
lM Level II exa:: Liner provide adequate ultrasonic coupling, may be used upon concurrence of the section =anager respon-j $g sibl6 for the exacd.iation.
(4)
All couplants other than deionized water shall be carti-fied for sulfur content and total halogens in accordance J
with ASTM D-129-64 and ASTM D-808-63.
The residual amount 5
[
of total sulfur or halogens shall not exceed 1,. by weight.
3 Deicui:ed water, when used, shall be supplied by the l
j%
customer.
F A1
< 7 J) l
(
SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-a a-67 Re-ision 0 August 1979 m
.: afg NUCLEAR PROJECTS R
CPERATING PROCEDURE Page 5 of 16 5
6.0 CALIBRATION METHOD s'
cN 6.1 Calibration The complete ultrasonic examination system calibration sbill be per-
{
for: ed prior to the examination.
d s
g NOTE i
3 The " REJECT" control shall be maintained in the
(
"0" position during calibration and examination.
6.2 Distance Calibration I"
c An IIW reference block shall be used to construct a sound path
" distance of 12.5 inches. Each minor screen division will be.25 inch and each ciajor division will be 1.25 inches. The distance calibration shall be con-
% ducted as follevs:
5M 5
0 (1)
Position search unit on IIW reference block and observe
} k the radius echoes.
(2)
Adjust "MATERIAI, CALIBRATION," "RMGE," and " DELAY" g
controls to obtain a linear sound path distance of 12.5 inches displayed along the screen baseline.
- k,$
I If difficulty is encountered in obtaining multiple echoes, the distance calibration shall be conducted as shown in Sketch 3.
t i
l T 6.3 Zone Calibration 4
I
=
)
3 The three drilled holes located in the stub tube base material, j
as shown in Sketch 2, shall be utilized to construct a multiple point :ene alibration as follows:
C (1)
Obtain naximum amplitude from the hole with the highes
- $[:
3 amplitude.
(2)
Adjust this signal to 50%
3* full screen height (FS'd) and mark this amplitude on the instru=ent screen. The gain j
controls shall not be adjusted 3nce the pri= arf reference j
]
response has been established.
E J
i%
9 1267 312 a
.....-m.,
SOUTHWEST RESEARCH INSTITUTE SwRI-sur-sco-67 Revision 0
^" 8""
NUCLEAR PROJECTS CPERATING PROCEDURE y
Page 6 of 16 12 [
(3)
Position the search unit for maxi.:um response from the other two holes and = ark each amplitude on the screen.
%s 8
Each point shall '.e identified on the applicable SwRI C$
Instru=ent Calibration Record with respect to azimuth location (0*, 90', 180').
i s
6.4 Sween Range and DAC Curve Verification W
9 E
Sweep range calibration shall be verified on the appropriate keference block and the multiple point zone calibestion, if applicable, shall j
g
,be verified on the basic calibration block.
(1)
At the start of a series of examinations j
(2)
With any substitution of search unit cable r4 (3)
With any substitution of power source g
e (4)
At least every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during the examination 1 \\
(5)
At the finish of a series of examinations N
i
- E y (6)
At any ti=e when, in the opinion of the examiner, there is doubt as to the validity of the calibration.
6.4.1 Calibration Changes 3
(1)
Perform the following if any point in the =ultiple point zone calibration has changed sore than 20% or 2 d3 in l j amplitude, or any point has moved = ore than 5% of full screen widtr.
y g j
(a)
Void all examinations referring to the calibration 5
in qusstion and performed af ter the last valid vQ calibration verification.
(b)
Perform and record a new calibration.
Nl (c.
Reexa=ine the areas for which exasinations have been veided.
J g
j (2)
Perform the following if any point in the =ultiple point g
y zone calibration has soved on the sweep line = ore than 5%
jy of full screen width.
kd MI s.
o-ca.s 1267 313
SOUTHWEST RESEARCH INSTITUTE sw t-sur-soo-67 Revision c August 1979
-,b,'g..
OPERATING PROCEDURE NUCLEAR PROJECTS D
Page 7 of 16 12 g (a)
Correct the sweep range and record the change on the swr 1 Instrument Calibration Record.
s5' (b)
If any indications have been recorded with this cali-s bration, the SwRI Examination Record shall be voided, a new alibration perfor=ed, and the voided examination areas reexamined.
6.4.2 Recalibration 3
N Substitution of any of the following shall be cause for re-t s
% ^ c. bration:
,lg (1) search unit (vedge/ transducer) 2 0e H lia (2)
Couplant I
(3)
Ultrasonic instrument
{d (4)
Exanination personnel.
f 6.5 Calibration Data 2
Calibration data shall be recorded on the appropriate SwAI Instrument Calibration Record and shall include, but not be limited to:
L j[.
(1)
Serial number of the basic calibration block used n
(2)
Type and serial number of the reference block used
} g (3)
Type and serial number of the ultrasonic instrument
}
(4)
Type, size, beam angle, and serial number of the 2
i ultrasonic search uni A
(5)
Nominal search unit frequency p
l (6)
Couplant (which shall be the same type as used in the acts al examination)
/
(7)
Signature and ultrasonic certification level of the 2
{
examiner conducting calibration i
1 (8)
Date calibrated D
(9)
Time of calibration and verific*. tion.
tsi 126/
314 5..asterm Ga.k1
SOUTHWEST RESEARCH INSTITUTE SwRI- = -8*-67 Revision 0 NUCLEAR PROJECTS OPERATING PROCEDURE g
Page 8 of 16 7.0 E.U MINATION j.
7.1 Surface condition The contact surfaces must be free from weld spatter, roughness,
, or other conditions which interfere with free movement of the search unit or ja
. impair the transmission of ultrasound.
I j N 7.2 Examination Area i W
?
The stub tube-to-vessel lower head weld shall be examined f rom outer surface of the lower head (Sketch 4).
a4 7.3 Scanning Para =eters When practicable, scanning shall be performed at a =ini=um gain setting of 2 times the reference level sensitivity.
(
Instrument gain setting for scanning shall be determined on the basic calibration block as follows for esch pri=ary ref arence level utilized.
h a
(1)
With the instrument at the primary reference level, 3
position the search unit on the basic calibration block to M
obtain a signal from a calibration reflector (side-
[
drilled hole) of 40% FSH.
(2)
Add 6 d3 of gain by utilizing the 6 d3 swit.h, if present.
Observe the signal amplitude.
(If the 6 d3 switch is not present on the instrument, use the method in step (3) or g
(4) for scanning sensitivity.)
.g (3)
Add 6 d3 of gain by utilizing the fine gain controls.
Observe the signal amplitude.
j N
(4)
Add 6 d3 of gain by utilizing a combination of both fine and coarse gain controls. Observe the signal amplitude.
s S
,l (5)
Choose the =ethod above which yields a signal response closest to 80% FSH.
(
(6)
The method chosen shall then be used for all scanning at 2
{
j times the reference sensitivity.
E I
The examiner shall ensure that the signti response of the =ethod g
chosen is within t2 d3 of 80 FSH. Record this ampli' w,e and sethod on the g
.- SwRI Instrument Calibration Record.
.....,,,n.,.,
1267 315
SwRI-NDT-800-67 SOUTHWEST RESEARCH INSTITUTE nevi = ton o August 1979 b
NUCLEAR PROJECTS
/E OPERATING PROCEDURE Page 9 of 16 ig
.u.-.
M
,3 Instrument gain settings for scanning shall be recorded on the kppropriateSwRIExaminationRecord.
3c' The search unit =ove=ent rate for scanning shall not exceed 6 inches per second.
(\\
Scanning overlap shall be a sinimum of 10% of the search unit piezoelectric element di=ension perpendicular to the direction of scan.
c i
{
7.4 Angle-Beam Examination h
The angle-beam examination shall be conducted usftg a 34.5*
2*
shear-wave search unit. The search unit shall be placed on the outer surface
{ f of the lower head with the sound beam directed as nearly as pc_sible parallel to the control rod drive (CRD) ho. sing. This exasination snall scan completely C
3 around the CRD housing and extend minimum of 3 inches from the CRD housing.
g Calibration shall be in accordance eith Paragraphs 6.2 and 6.3.
7.5 Reference Points for Physical Measurements N
a h
"L" measurement shall be =casured by azi=uth location with j
respect to plant north.
l
"*J" =easurements shall be =ade from the edge of the CRD housing.
I 7.6 Postexamination Cleaning a3 Arrangements shall be made with the customer for postexamita-tion removal of couplant =aterials.
g t
j
,8.0 RECORDING CRITERIA i
i Ultrasonic reflectors producing a response 50% or greater of the reference level shall be recorded on the appropriate SwRI Exasination Record.
N
- D Indications producing a response 100% or greater of the reference level j [N sary to determine the shape,
. shall be investigated by a Level II or Level III examiner to the extent neces-identity, and location of the reflector.
Indications 100% or greater of the reference level investigated ana l
7; found to be other than geometrical la nature shall be reported to the custc=er i.
j for evaluation.
1267 316
- 2. i
SOUTHWEST RESEARCH INSTITUTE SwaI-sot-800-67 Revision 0 I **
b=
NUCLEAR PROJECTS t h OPERATING PROCEDURE Page 10 of 16 N9.0 EVALUATION 2'd 3
Evaluation of reportable indications shall be the responsibility of the tb ustomer, or th cr-comer's representative, and shall be conducted in accor-
'jdance with ASr.E Boiler and Pressure Vessel Code,Section XI Paragraph IS-311.
The applicable year of the Code and Addenda shall be as specified in Paragraph 2.l(1) of this procedure.
y AIN 10.0 RICORDS
$ Q!
I The customer shall receive copies of documents generated in accordance s
xw.
this procedure in the examination report.
h Permanent documents generated in accordance with this procedure shall be 33@ stored and retained as a portion of the exantnation report. The examination IN report shall be stored by the Manager of Support Services, Quality Assurance l
Syste=s and Engineering Divi; ion, in the Data Storage Facility for the period D specified by the contractual agreement with the custo=er.
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M NOTE L SUBTRACT THE MINIMUM METAL PATil ( WgMP) FROM Till M A XIMUM METAL PATH (W2MP) AND DIVIDE BY THE 4/8 NODE METAL PATil (4/8 MP)
s TilRU WALL DE PTil IN */. OF "T7 4 /8 MP M M NOTE 2.
SU8 TRACT Tile M A XIMUM METAL PATH (W2MP) FitOM Tile 4/8 NODE METAL PATil ( 4/8 MP ) AND COMPA R E TO THE MINIM JM METAL PAT H. ( WsMP). THE SMALLER OF Tile TWO NUM8ERS IS TilEH DIVIDEO BY Tile 4/C NODE METAL PATH (4/8 MP) 4/8 MP-W2 MP a DISTANCE FROM SUHFACE IN */. OF "T" 4/8 MP OR IF W MP IS 1.E SS Til A N 4/8 MP-W2MP 3
WgMP USE a DISTANCE FROM SUHFACE IN */o OF "TI 4/8 MP G
- -J L4 N
N
,