ML20058C373
| ML20058C373 | |
| Person / Time | |
|---|---|
| Site: | Cooper  |
| Issue date: | 05/31/1992 |
| From: | Patricia Anderson, Clark J, Miller W GENERAL ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML20058C322 | List: |
| References | |
| GENE-527-012-10, GENE-527-012-1092, GENE-527-12-10, GENE-527-12-1092, NUDOCS 9312020435 | |
| Download: ML20058C373 (200) | |
Text
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b GENE 3"-012-1092 J
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NONDESTRUCTIVE EXAMINATIONS OF 3
l CLOSURE STUDS AT THE COOPER NUCLEAR STATION D
WADE NILLER D
PAUL ANDERSON MAY 1992 D
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APPROVED BY:
y'/ je. Clark P
Pro ct Manager l
Principal Engineer l
l GENE. NDE Technology l
9312O20435 931117 PDR ADOCK 05000298-a PM i
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IMPORTANT NOTICE REGARDING CONTENTS OF THIS REPORT
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l Please Read Carefully t
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The only undertakings of the General Electric Company respecting information
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in this document are centained in the Agreement Number 86a-NS2, Task No. 161, j
t Amendment No. 3 (GE Identification No.179-05D32 -HP1-91)between the Nebraska i
Public Power District and the General Electric Company, and nothing contained in this document shall be construed as changing that Agreement. The use of i
this information by anyone other than the Nebraska Public Power District, or for any purpose than that for which it is intended, is not authorized. With
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respect to any unauthorized use, the General Electric Company makes no representation or warranty, and assumes no liability as to the con:pleteness, l
accuracy, or usefulness of the information contained in this document, or that
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its use may not infringe on privately owned rights.
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ACKNOWLEDGMENTS GENE acknowledges the contributions of many individuals involved with the i
Cooper RPV stud inspection development program.
The field support that was provided by personnel from GENE NPPD and CECO, including labor through upper management, was superb and instrumental in the success of this program.
J Especially appreciated are the contributions of the following personnel; l
t Gerry Hicks (NPPD) - Gerry's direct interest and participation along with his l
diligence and perseverance helped make this program efficient and successful.
Tom Black (GENE - SSM at Cooper) - Tom's help in dealing with the day to day administrative matters kept many of the "small" obstacles from interfering with the job at hand.
John Nash (GENE - SSM at Dresden) - John was outstanding in the manner in which f
he made all the arrangements needed at Dresden.
He also provided escort and worked with the examination team through all of the entire job.
l NPPD and CECO Radiation Protection Personnel - These individuals did an excellent job in providing a safe environment.
Their attention to detail and communication skills helped to assure there were no radiological or other safety problems.
Both NPPD and CECO Maintenance Personnel - The efficiency anc ingenuity of t
these individuals, from the construction of the stud stand to the daily maneuvering of the studs to be inspected, helped keep everything on schedule and resulting in the completion of the project in a timely manner.
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TABLE OF CONTENTS TAB SUBJECT i
1.0 EXECUTIVE SUNNARY i
2.0 INTRODUCTION
I 3.0 ACTIONS TO RESOLVE INDICATIONS 4.0 DISCUSSION 5.0 RESULTS I
6.0 CONCLUSION
S 7.0 Appendix A - Agreement No. 86A-NS2, Task Authorization. Task No.
l 161, Amendment No. 3 l
l 8.0 Appendix B - Procedures i
9.0 Appendix C - Ultrasonic Examinations of a Cracked RPV Stud at the i
Dresden Nuclear Power Station
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i 10.0 Appendix D - Cooper Stud UT Calibration Standard j
i 11.0 Appendix E - Personnel Certifications j
12.0 Appendix F - Transducer Certifications i
13.0 Appendix G - Resolution of the Initial UT Indication Detected in Cooper Stud #26 14.0 Appendix H-GENE's SNART 2000 Ultrasonic Data Acquisition and Analysis System 15.0 References l
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i 1.0 EXECUTIVE
SUMMARY
During the Fall 1991 outage at the Cooper Nuclear Station, ultrasonic (UT) 4 indications were reported in 51 of 52 reactor pressure vessel closure studs.
The initial indication in one stud was reportedly detected with a 00 longitudinal wave (straight beam) directed frore the end of the stud (end shot).
Although this indication was 1 ster attributed to a problem with the automatic pulse repetition rate (which could result in false calls, but would not prevent indications from being detected), it resulted in a more extensive j
examination of all the studs.
l The more extensive examinations were conducted with a manually operated 600 shear wave bore probe, which was inserted into the stud's extensiometer hole.
Indications were reported in all but one of the other studs.
These studs all l
had corrosion and pitting in the thread areas, just below the nut area, at the vessel flange, and a few at the top of the nut area.
The UT indications were located in these corroded areas.
Efforts to evaluate these indications were l
unsuccessful in proving that they were not associated with circumferential cracking (similar to cracking, associated with corrosion, that had been i
previously reported at another plant).
One of the studs, which was believed to have the largest of the indications, was evaluated using extensive nondestructive examinations (NDE) and metallography at GENE's Vallecitos Nuclear Center (VNC).
No evidence of l
cracking was found.
Cooper replaced all of their studs and a decision was made to disposition the indications in the original studs after the plant was back in service.
A plan was developed and implemented to resolve the indications.
Five studs were selected for extensive NDE examinations.
The five studs were selected l
based on the following; two of these studs had large UT indications, one had a i
faint radiographic (RT) indication (in the area of UT indications), one had a faint penetrant (PT) indication and one had no indications reported. The five l
studs were examined using automated UT with both a 60 and a 700 bore probe and with an " enhanced end shot".
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i The studs were then cleaned using a glass bead blast to remove the corrosion I
products. The UT was repeated plus RT and magnetic particle examinations were performed.
Notches were also placed in the root of corroded threads on one stud and the UT was repeated proving that crack-like indications could be l
detected and evaluated in corroded areas.
It was shown that the 700 bore probe was least affected by the corrosion and that crack like indications (notches) could be detected, and a meaningful examination could be performed using that probe.
The enhanced end shot was also effective in detecting the notches in the corroded threads.
However, it l
is clear that if recordable indications are detected with an end shot
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l technique, a bore probe will have to be used for evaluating, sizing and characterizing the indications.
l Based on these results (assuming that these studs are representative of the other studs), and the NDE and metallography performed at VNC, it can be concluded that the UT indications were not due to cracking but were associated with corroded threads. Therefore, the remaining studs at Cooper are judged to be free from cracking and the UT techniques, procedure and equipment used are l
considered as qualified for field use on studs similar to Coopers. However, a training and qualification program will have to be established for field l
personnel prior to these examiners performing such examinations in the field.
.i An additional qualification was performed on a stud containing a real crack and a notch at the Dresden Nuclear Power Station.
All of the UT equipment used at Cooper was also used during these examinations.
In addition, a special developmental bore probe was used in the examinations of this stud.
This probe was not used at Cooper because it was still undergoing fabrication in a vendors shop and was not received until several weeks after the Cooper i
examination.
This probe contained two 450 and one 00 transducers, arranged for performing time of flight diffraction (TOFD) measurements to determine crack depths.
The probe worked very well and provides another good toc 1 for the evaluation of UT indications in studs.
The crack and the notch were readily detected and characterized, adding to the previous qualification on notches at the Cooper site.
With the-700 probe the EDM notches in the Cooper stud appear to have UT signal characteristics very l
similar to the indications from the Dresden stud crack, which further-validates the qualification at Cooper.
The only real difference between the signals from the notches and that from the crack is that the Dresden stud crack is very large resulting in very large signal responses.
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2.0 INTRODUCTION
i During the Fall 1991 outage, ultrasonic (UT) examinations were performed on reactor pressure vessel (RPV) closure studs at the Cooper Nuclear Power Station.
The UT and magnetic particle (MT) exams were conducted originally in accordance with Section XI of the ASME Boiler and Pressure l
Vessel Code.
One recordable UT indication was detected with a straight beam (00
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longitudinal wave) aimed down the length of the stud from the top. This l
type of technique is referred to as an "end shot".
The indication appeared to be located in an area of corroded threads in stud number 26.
Because of this, and other indications detected later, supplemental UT and NT examinations were performed on the remaining studs.
Radiographic (RT) and penetrant (PT) were also tried on so:ne of the studs for evaluation purposes.
t A spare Cooper stud was modified for use as a calibration standard for future UT examinations. This calibration standard meets the requirements l
of Appendix VI " Ultrasonic Examination of Bolts and Studs" of the 1989 l
Edition of Section XI of the ASME Boiler and Pressure Vessel Code.
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l The supplemental UT exams were performed using a 600 shear wave, bore probe from inside the extensiometer hole in the studs.
This probe j
contained an up-lookina and a down-looking 600 transducer, plus a surface j
wave transducer to dem t cracking inside the extensiometer hole.
The j
l 600 angle had been selected since the resulting sound beams are close to l
perpendicular to the side walls of the threads on the studs, thus maximizing the reflections from the threads.
There has been considerable work done (Reference 6.)that indicate that circumferential cracks initiating in the threads will block the sound beam from reaching the threads behind the crack, thus eliminating the reflections from those threads.
This being so, the loss of signals from the threads might be used in both the detection and sizing of cracks.
j There were UT indications reported in 51 of the 52 studs with this probe.
An " enhanced end shot" UT was also performed and small indications were J
reported in several of the studs.
It was noted by the examiners that corrosion appeared in bands located at areas corresponding to the bottom of the nut, in the bolted-up configuration, and at the top of the threads on the flange end of the studs. There was also some corrosion at the top of the nut (bolt up configuration) on several studs.
The corroded areas corresponded with the UT indications noted, i
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The indications detected with the 600 bore probe, were partially based on l
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the loss of thread signal response, due to the blocking effect that a planar flaw would have if it was initiating at the root of a thread. All recorded indications exhibited some loss of thread signals.
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A recent experience at another nuclear power plant (see Reference 3.)
l showed that severe cracking had initiated at corrosion pits in 2 studs.
i Preliminary evaluations at the Cooper site were not able to eliminate l
cracking as a possible cause of the UT indications.
During the
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evaluation of the UT indications, one of the studs was reported to have a J
faint PT indication and one had a faint RT indication.
The corroded i
surface could not be PT'd adequately due to the inability to clean the surface.
The corrosion products on the surface, being somewhat porous, j
absorbed the penetrant thus potentially masking any real penetrant j
indications The RT could also have been affected by the corrosion i
build-up on the surface, since deep scratches or other adnormalities in the corrosion layer could appear to be is the base material of the stud 1
i on a radiograph.
Of the four methods used, all seemed to be somewhat j
affected by the corrosion products.
l Replacement studs were obtained and installed due to the indeterminate condition of the existing studs.
Extensive examinations, which included 4
the 600 bore probe, the enhanced "end shot", PT and RT were conducted on i
stud no. 26 at GENE's Vallecitos Nuclear Center (VNC). The stud was then sectioned in the areas of the UT indications on one end of the stud and a metallographic av. amination was performed.
No cracking was observed on j
the metallurgical samples.
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On the other end of the stud, the threads in the area of the UT j
indications were removed by machining and the UT was repeated.
The UT indications were no longer detectable, indicating that they were related to the corroded threads.
1 The initial end shot indication in stud No. 26 is a false indication and j
has been attributed to a problem with the. pulse repetition rate of a UT
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instrument (See Appendix G to this report).
This type of problem can produce false or phantom indications over long metal paths but would not j
cause real indications to be missed.
References 1. and 2. document the work performed at VNC. Supplement 1 to reference 3 was issued to inform other GE/8WR plant owners of the problems that had been experienced at Cooper.
At that time, Cooper Nuclear Station and GE personnel determined that the activities for l
resolution of the indications would be performed after start-up.
This l
l report covers the joint GENE /NPPD activities toward resolution of the l
indications.
i Appendix C (tab 9) to this report documents the UT examination of a known cracked stud at the Dresden Nuclear Power Station.
All of the transducers used at Cooper were used during the Dresden examination plus an additional developmental bore probe.
This probe was not available during the Cooper examination because it was just designed shortly before the Cooper exam and was still undergoing fabrication in a vendors shop.
That probe contained two 450 and one 00 transducer arranged to provide' i
time of flight diffraction measurements for determining the depth of cracks and represents an advance in the technology for UT stud examinations.
It provides an additional tool for evaluating UT indications in studs.
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3.0 ACTIONS TO RESOLVE INDICATIONS During a joint GENE /NPPD lessons learned meeting, held at the Cooper Site on March 2, 1992, a plan of action was formulated to resolve the indications in the remaining studs'at Cooper.
This agreement is documented in Agreement No. 86A-MS2, Task Authorization. Amendment No. 3 (see tab 7, Appendix A).
j GENE had decided to develop new UT techniques utilizing special bore probes, which should help in the resolution.
An option that was chosen was to use an opposite approach to that previously mentioned.
That is, to select beam angles which would tend to minimize the reflections from the threads, while maintaining good sensitivity to vertical flaws.
A 70+0 bore probe was purchased.
This probe has specially shaped l
transducer elements designed to help overcome the focusing effect that j
results from the curved, inside surface of the extensiometer hole.
1 A 450 time-of-flight, bore probe was also designed and purchased.
Unfortunately, it was still being fabricated during the Cooper examination, but its use at another site is discussed later in this report.
l The agreed method of resolution was to select five studs for evaluation.
l Stud No. 39 was selected for the faint PT indication that was reported during the outage.
Stud No. 40 was selected because of the faint RT indication also reported during the outage.
Stud No. 44 was selected because it was reported to have no recordable UT indications. Studs Nos.
14 and 17 were selected because they appeared to have the largest number of UT indications. The studs were selected based on testing results from the outage.
The suspect areas of these five studs were subjected to the following:
l A)
Automated UT with a 60-degree bore probe (same as outage exam) both before and after glass-bead-blast cleaning.
B)
Automated UT with a 70-degree bore probe both before and after glass bead blast cleaning.
i The automated exams with these bore probes provide for complete data acquisition, with complete digitized A-scan data recorded for each inspection.
The GENE SMART 2000 System was selected because-of the great amount of data that needed to be collected and the relative l
ease with which the examination can be reconstructed during data l
analysis using color coded B and C-scans.
Automated exams are much preferred during difficult inspections and investigations for these reasons.
I C)
Aiternating current, magnetic particle (AC-MT) examinations with the Yoke ieshnique after glass-bead-blast cleaning.
D)
Electric discharge machined (EDM) notches were placed in a corroded area of Stud 14 after cleaning and were scanned with the 60 and f
70-degree bore probes.
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Visual examination (10X glass) of the corroded areas both before and after glass-bead-blast cleaning.
F)
Selected areas on studs 17, 39, and 40 were radiographed.
G)
The enhanced "end shot" technique used during the outage examinations was used on Stud 14.
This was to verify notch detection capability for the straight beam on corroded threads.
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4.0 DISCUSSION 4.1 SET UP FOR EXAMINATIONS Cooper personnel provided an area on the lower floor of the turbine building where most of the examinations were performed. The contaminated studs were set up in a room bounded by a plastic tent with step off pads to a clean area where all of the data acquisition equipment was located.
The UT data was obtained with the SMART 2000 System, described in Appendix G.
Automation of the system was achieved by modifying GENE's l
piping weld scanner to transport the bore probes in the extensiometer l
hole of the studs in a raster scan pattern.
The scanner operated from a track that was clamped around the upper part of the stud. The SMART 2000-equipment setup is shown in Figure 1.
The scanner setup in the tented l
room is shown in Figure 2 and the SMART 2000 location in Figure 3.
Figures 4, 5 and 6 show the UT beam geometries for the different bore l
probes. The areas of interest for the studs is shown in Figure 7.
4.1 EXAMINATIONS BEFORE BEAD BLASTING I
Automated UT examinations were performed with a 60-degree bore probe in areas that had recordable indications during the outage.
Calibration sensitivities were used that duplicated the manual exams performed during the outage (to the extent possible).
These exams served as a baseline i
for the investigation that followed.
Automated exam data included A-scan, B-scan and C-scan recordings for each channel.
Scans were performed with transducers aimed in both the up and down directions for each area examined.
This exam showed the same basic results as the outage's manual exams for all studs, except for stud No. 44, which was reported to be free from indications during the outage exams.
The automated examinations showed this stud to have indications similar to the indications in all other studs and was not significantly different from the other studs.
There were areas in all 5 studs that exhibited an apparent loss of thread response in the locations seen during the outage.
Typical UT data outputs are shown in Figures BA & 8B.
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There was also a geometric indication recorded that originated at the clamp holding the studs in place.
The geometric origin was confirmed using two methods.
Water was poured over the suspected area and signal amplitude increased as the water worked its way between the stud and the clamp.
The clamp was removed and the signal was not present.
This proved that this reflection was from the clamp and that the indication was geometric in origin.
This is relevant, since the fact that it can j
happen should be known by field examiners.
This knowledge could help to t
prevent false calls when studs which have been removed from the RPV are being examined.
l Automated UT examinations were performed with a 70-degree bore probe in 1
the same areas that were examined with the 60-degree probe.
The only exception to that is that the area of interest on the flange end of the stud. This area could only be examined with the 70-degree transducer that was aimed downward, towards the flange end of the stud.
The reason for this was that the probe bottomed out in the stud before the transducer that was aimed upwards, towards the top of the stud, could pulse sound I
into the area of interest.
Calibrations were used that ouplicated the 60-degree sensitivity, as closely as possible. These exams were intended to show whether the 70-degree probe was less affected by the thread corrosion than the 60-degree probe was.
They also served as a baseline l
for the investigation that followed.
Automated exam data included l
A-scans, B-scans and C-scans.
Scans were performed in both axial directions, where possible.
There is a geometric restriction on the l
vessel flange end of the studs that prevents scanning with the up-looking transducer on the 70-degree probe.
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The 700 exam showed that this probe was less affected by corrosion than l
l the 60-degree probe.
There was less amplitude change from the threads.
Calibration notches were easily detected with an excellent signal-to-noise ratio and moved in time (walked) well beyond the envelope of reflections from the threads.
There were no indications in the studs that exhibited characteristics similar to the calibration notches.
The 9eometric indication, from the clamp, noted during the 60 degree exam was also seen with the 70 degree probe. These indications from the clamp are shown in Figures 9A & 98.
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i 4.2 EXAMINATIONS AFTER GLASS-BEAD BLASTING i
i The corroded threads on studs 17, 39 and 40, after glass-bead blasting, l
are shown in Figures 10 through 17.
Note that the corrosion and pitting is more severe at the nut end of the stud than it is at the vessel flange
.l end.
There is also considerable pitting on the shank of the studs, adjacent to the threaded regions.
By visual inspection the pitting in all areas varies from about 0.010 inches to 0.035 inches.
Studs 39 and 40 are so called " cattle chute studs" which are removed every outage.
That is probably why they appear to be less corroded.
)
The 60-degree examinations were repeated on all five studs after bead blasting. Calibrations were the same as the preeleaning exams. The same areas were scanned.
The removal of corrosion products changed the UT j
response significantly.
There was less evidence of thread signal loss l
and the overall amplitude of the thread response was about 4-6 dB greater than the preeleaning amplitude. These effects are shown in Figure 18.
The 70-degree examinations were repeated on all five studs after bead blasting. Calibrations were the same as the precleaning exams. The same areas were scanned. As with the 60-degree exam, the removal of corrosion products changed the UT response significantly.
The results were the same as those described for the 60-degree exam.
These effects are shown in Figure 19.
MT was performed on all five studs using an AC Yoke technique.
A wet ere attemp ed du ng th IS examination.
The pitted areas wer detected easily.
There was no indication of cracking, even in heavily pitted areas.
RT was performed, in the areas containing UT indications on studs 17, 39, and 40.
RT showed the thread corrosion, but there was no evidence of cracking.
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Visual (VT) exams were performed on all five studs, using a 10X magnifying glass and ambient lighting.
A moderate amount of pitting was observed.
On the nut end of the studs, pitting was noted in the threads i
near the bottom of the nut extending onto the body of the studs below the threads. At the vessel flange end of the studs, pitting was noted in the first few threads engaged in the bushing.
Pits ranged in size from f
approximately 1/64" to 1/8" in diameter.
The pits were aligned in many l'
areas. Edge-to-edge distances were as small as 1/64".
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UT reflections from circumferential EDM notches provide the same basic UT response as circumferential cracks.
Therefore, EDM notches were placed l
in corroded threads on Stud No.14 to demonstrate that small crack like j
indications could be detected despite the corrosion.
The EDM setup is shown in Figure 20. Figures 21 and 22 are close ups of the EDM electrode l
being positioned to machine a notch in the corroded threads. Three notch sizes were targeted for use in the investigation.
One additional notch was machined due to a miscut on one of the target notches.
The miscut notch is shown in Figure 23, while one af the other notches is shown in Figure 24. EDM notch location and sizes are shown in Figure 25.
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Scanner Set Up For Performing Automated UT Examinations Of Cooper RPV Studs in An Enclosed Contaminated Area (Plastic Tent).
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Cornparison of signal charictoristics and amplitude between pre and post cleaning for the 60* probe e oown.cnn pnar e o.w*w B14onaio a, mto. p24ca lg x ! s4 4ml x l tos mal axi s4 4ael i v i e6el n
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EDM Equipment 5
i Set Up In Contaminated Area To Machine Hotches In The Corroded j
Threads Of Cooper Stud # 14.
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Figure 21 EDM Equipment 1
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Positioning Of EDM Electrode For Placing Notches In The Corroded Threads Of Cooper Stud # 14.
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I 1
NOTCH DEPTH LENGTH WIDTH 1
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ll Figure 25. Notch locations In Cooper Stud # 14.
COOPER RPV STUD
// 14 i u m,
i 5.0 RESULTS Evaluation of the test data shows that corrosion products had a higher than anticipated effect on the outage UT examination results.
The loss-of-thread signal response noted during the manual exams appears to have been caused by a combination of a damping mechanism (caused by the corrosion products) and scatter due to geometric effects from the pitting on the sides of the threads.
Exams performed after glass-bead blasting seemed to be affected only by the scatter mechanism.
f The PT and RT indications noted during the outage could not be found after blast cleaning.
Wet Florescent MT was used to examine the area f
where the PT indication was noted.
There were no MT indications.
This means that the indication was removed by the cleaning process.
It appears that the corrosion products caused the PT indication, possibly by separations within the build-up.
The area on Stud 40 that showed RT indications during the outage, showed no indications after cleaning. The l
indication was removed by the cleaning process.
The cause is probably similar to the PT indication.
The data recorded with the 600 and 700 bore probes on the calibration notch in the Cooper stud calibration standard are shown in Figure 26.
Figure 27 shows the data recorded using the 70 0 bore probe as it is traversed over this same notch and the reflection is seen to travel (walk) in time.
Figure 28 shows typical thread reflections ' from stud i 14 in unnotched and uncracked regions. Figure 29 through 32 provides the i
UT data on the detection of the notches that were machined into the corroded threads of stud i 14 (see Figure 25 for notch data).
- Clearly, there is no problem with the detection of these notches in the region of I
these corroded threads.
This data provided a qualification for both probes, it also shows that the interpretation of the data using the 700 probe is much easier than that obtained with the 600 probe.
The enhanced "End Shot" UT was able to detect the EDM notches placed in all of the corroded areas on Stud 14.
This is important since this
)
i technique was used for the baseline examination of the replacement studs.
The 70-degree bore probe was shown to be the most effective tool for both detecting and evaluating indications.
1
i It is believed that the MT and PT examinations of these studs would be l
ineffective without cleaning off the corrosion products.
The corrosion products tend to be very porous and absorb the fluorescent magnetic particle and penetrant solutions, which could mask any real indications Therefore, it is felt that a cleaning method needs to be developed for future MT or PT exams on studs.
Bead blasting, since it removes the l
Parkerized coating, may not be a viable option for inservice inspections.
It should be noted that ASME Section XI requires surface exams (MT or PT) on studs that are removed from the vessel flange.
Based on the examinations performed on the five (5) representative studs at Cooper, and the work performed on stud no. 26 at VNC, some conclusions regarding the condition of the remaining Cooper studs can be made.
The PT and RT indications, detected during the outage in studs 39 and 40 were j
related to the corrosion products in the threads and are of no concern.
With the assumption that these 5 studs are truly representative, and_that t
studs 14 and 17 represent the worst case with regards to UT indications, l
then the conclusion can be reached that the UT indications detected during the outage in the remaining studs are strictly related to the corroded threads and not to cracks.
The 450 TOFD probe used at Dresden has been shown to be another valuable tool for both detection and sizing.
The probe is usable for evaluating
)
indications in the areas where corrosion is known to occur on studs.
However, it would require at least two more transducers, if it were to be the only probe used to perform a complete Section XI UT examination, in accordance with Appendix VI of Section XI.
)
)
)
i l
l The data from the cracked stud at Dresden, presented in Appendix C (tab
- 9) to this report add to the qualifications of the UT techniques, procedures, and equipment obtained at Cooper.
A comparison of the data from the Dresden crack shows that the UT signals from the notches in the j
Cooper stud are very similar and have the same basic characteristics.
i l
Therefore, the work performed at Cooper resulted in a valid qualification in accordance with Appendix VI of Section XI of the Code.
Of course.
that is providing that the examiners are properly trained and qualified l
with the UT techniques, procedures and equipment.
This being the case, justification has been provided for use of the techniques, described in l
1 this report, on RPV stud inspections in the field, subject to the l
approval of customers and the ANI.
i h
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Calibration A-scans for the 60 and 70* probes.
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I Progression of 70' signal from notch A t
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Figure 27. Series Of A-Scans With The 70 Bore Probe l
Reflection From Notch A In The Cooper Stud Calibration Standard h
Are Shown To Travel In Time (Walk)
I
o i
i l
Signal cornparison of the 70* up and down scans in the area ofinterest in t
the top threads.
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Note there is no possitive signal response in the area ofinterestin both scans.
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Figure 28. Tygical A-Scans From Corroded Threads In Cooper Stud #14 With The 70 Bore Probe.
This Is In An Area Where There Are No Notches.
Therefore There Is No Direct Reflection Detected (as in the case of a notch or crack).
l
4 1
Figure 29.
i a
1 Signal responses from EDM notch # 1 with the 60* and 70* probes s
I i
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70' down scan
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Signal responses from EDM notch # 2 with l
l 60* probe.
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50.
l P
40, I
i w
se.
l.
i e
Y %,,.
O'(
h
\\ 'w hkux...
10.
Note negitive signal response (loss of thread roll) t behind the response from the notch.
I e0 down scan 3:14w2_. a, can pr.pa 133 x=l_ s4 4aaly,11aa ml al s4 4oel i f
v l-a.S.
te.
a ae 88.!
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wi
-n e 58.
s 40, g
30,
'!.l!
4 lj N
20,
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,_,__pAJ
'.. A_,
m _ ___
Figure 30.
Signal responses from EDM notch # 2 with b
the 70 probe.
gji4b7u3_4 A,7M1) D1*P1 l@
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~
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p M
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yg 33 9 g
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Figure 31
l l
t i
i
)
)
Signal responses from notch # 3 with the 60* probe.
j
)
i 80 upscan gg Xal 54 4MlXp l 188 000l AXl 54 42)@ X l 42 4 lYl 2% 2l 14 teu3 e
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i Note the negitive signal response (loss of thread roll) b3 hind the response from the notch.
)
l t
i co m seen
+
314eM3_4 4, sata p2.p2 lgg x i 54 4m} 41189 emj axl 54 4%)W n
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wt a.,
du 80.
notch # 3 g
33,9 j
Ch,
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48, l
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,e
- ^
%_-sh~.vA,.__._._..__.,__....._...
l
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Figure 32.
l t
i 1
4 1
i
(
Signal responses from EDM notch # 3 with the 70 probe.
1 i
a 5
1 l
gi4b?u34a A, TOLU P1*P1 l@@ Kn{ 1 Pit GM} Xe[ 217 e4Ml AXl 1i18 SoG}[
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2639 X,.
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%l 230 P2;
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)
m y * +rmcm ff -"
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- 8. 3.sii
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Figure 33 i
1
.m
6.0 CONCLUSION
S Conclusions based on the results of these examinations are as follows:
As previously reported, it is believed that the first UT indication (Stud No. 26) detected at Cooper was due to a problem with the automatic pulse repetition rate of the UT instrument being used (see Appendix G).
This type of problem only occurs when examining components with long metal paths.
The problem can only result in false calls and not cause a real.
indication to be missed.
.There should be no concern regarding indications that might have been missed when this instrument was used on i
other components (such as piping welds).
l t
l Indications of thread loss, which was thought to be one indication of j
possible cracking with the 60-degree bore probe, have been shown to be related to the damping and scattering effects of the corrosion products.
l The indications with the enhanced end shot werie probably related to the corroded threads (as the sider corrode away) becoming somewhat better reflectors from the end shot orientation.
i l
?
l Corrosion induced scattering does not affect notch detection capability l
to a great extent with a 70-degree probe.
l l
The 70-degree probe is less affected by corrosion and a build-up of l
corrosion products than the 60-degree probe and can be used to perform I
reliable examinations of RPV studs which have a design similar to Coopers.
In addition, it has been shown that the 70 degree probe is superior to both the 60-degree probe and the enhanced "end shot" for both j
detection and evaluation of indications.
l l
l The examination baseline on replacement studs was performed with the enhanced "end shot". The enhanced end shot has been shown to be a method j
capable of detecting Appendix VI size EDM notches in corroded threads.
l It can be used for the inservice inspection of studs.
However, if indications are detected, the 70-degree bore probe should be used for evaluation.
l
(
i
__.._.._,.___.,_..,.__...__..,,..,____,_-,._..-m...--
It is b311evsd that the MT and PT examinations of th:so studs would be ineffective without cleaning off the corrosion products.
The corrosion products tend to be very porous and absorb the fluorescent magnetic particle and penetrant solutions, which could mask any real indications Therefore, it is felt that a cleaning method needs to be developed for future MT or PT exams on studs.
Bead blasting, since it removes the Parkerized coating, may not be a viable option for inservice inspections.
It should be noted that ASME Section XI requires surface exams (MT or PT) on studs that are removed from the vessel flange.
Based on the examinations performed on the five (5) representative studs
]
at Cooper, and the work performed on stud no. 26 at VNC, some conclusions
}
regarding the condition of the remaining Cooper studs can be made.
The PT and RT indications, detected during the outage in studs 39 and 40 were related to the corrosion products in the threads and are of no concern.
j With the assumption that these 5 studs are truly representative, and that studs 14 and 17 represent the worst case with regards to UT indications, then the conclusion can be reached that the UT indications detected during the outage in the remaining studs are strictly related to the i
corroded threads and not to cracks.
The 450 T0FD probe used at Dresden has been shown to be another valuable tool for both detection and sizing.
The probe is usable for evaluating indications in the areas where corrosion is known to occur on studs.
However, it would require at least two more transducers, if it were to be the only probe used to perform a complete Section XI UT examination, in accordance with Appendix VI of Section XI.
The data from the cracked stud at Dresden, presented in Appendix C (tab 4
- 9) to this report add to the qualifications of the UT techniques, i
procedures, and equipment obtained at Cooper.
A comparison of the data from the Dresden crack shows that the UT signals from the notches in the Cooper stud are very similar and have the same basic characteristics.
Therefore, the work performed at Cooper resulted in a valid qualification in accordance with Appendix VI of Section XI of the Code.
Of course, j
that is providing that the examiners are properly trained and qualified with the UT techniques, procedures and equipment.
This being the case, justification has been provided for use of the techniques, described in this report, on RPV stud inspections in the field, subject to the approval of customers and the ANI.
i
APPENDIX A AGREEMENT NO. 86A-MS2. TASK AUTHORIZATION. TASK NO. 161. AMENDMENT NO. 3 i
l l
l I
IDG.W.
.020 i
Customer Order Transmittal t
l (Send to San Jose Order Service (M/C 397) or Field l
Finance and responsible organizations)
{
I)
Nebraska Public Power District - Cooper Customer / Plant l OSD32 H)
Task 161. Am. 3 Verbal Purchase Onder Number Written x
$ Value ISIS Number IH)
UT Inspection Program - RPV Studs Wod Scope Description l
i IV) Deliverables & Customer Schedule Requirements I
)
CustomertTitle V) Customer Egectations (not stated in Purchase Order)
(O/E/I) i I
i I
)
VI) Customer Agreed Checkpoints During Wort
)
VII) Reference Documents (proposals, contracts, etc. - attach if feasible)
Task Authorization - attached
)
a) Bradlev J. Erbes. NSM c) Send to: Finance'- ~ 1.. Marlow - Oak Brook Preaared by (name and title:
cc:
T. B1ack - CNS NSM, SSM, TPE, etc.)
J. Clark - M/C 777 - SJ H. Herzoa - Oak Brook b) 6/3/92 R. Hooner - Oak Rrook Transmittal Date bd1 f)
J. Clark c)
NSM Concurrence Job Leader (Pr. Mgr., TPE, Engineer, etc.) -
d) Pre-meeting or Kickoff Conference Call Plan (schedule, date & time, geple panicipating, cie.)
)
This Task is considered Routine Consulting Services in accordance with the l
Settlement Agreement between NPPD and GE, dated as of September 7,1989.
~
Page 1 of 4
)
AGREEMENT NO. 86A-MS2 i
TASK AUTHORIZATION
-l
)
Task No.161. Amendment No. 3 March 6,1992 Task Authorization Number Effective Date
\\
179-OSD32.HP1-91 GE Identification Number
)
This Task Authorization is issued pursuant to the Agreement effective September 1,1986, between NEBRASKA PUBLIC POWER DISTRICT (DISTRICT) and GE.^
I.
PROJECT
)
Inservice inspection (ISI) and Erosion-Corrosion (E-C) Services for Cooper Nuclear l
Station (CNS). This Amendment No. 3 provides the basis ofunderstanding regarding j
work on the RPV Stud Inspection Program. This Program was discussed during the l
1 lessons learned meeting at CNS on March 2,1992.
II.
SCOPE OF WORK 1
The primary objective of this Task Amendment is for GE to provide the necessary i
NDE documentation to support disposition of the UT indications found on 51 of the original CNS RPV studs. The following work will be performed by GE.
)
l 1.
Develop improved UT technique for examination of CNS RPV studs.
1 2.
Prepare a new UT procedure as a result of UT development activities.
j i
3.
Review previous (1991 outage) UT data for original RPV studs and select five _
(5) studs for further evaluation.
i i
4.
Conduct UT examination of the selected five (5) studs using new procedures.
5.
Conduct additional surface NDE exami:2ation, including penetrant (PT) or
)
magnetic particle (MT) as required to confirm presence or absence of surface breaking flaws.
6.
Machine notches in at least one (1) stud using electrical discharge machining j
(EDM) to simulate a surface breaking flaw and compare UT indication from this EDM notch to UT indications observed in CNS RPV studs.
)
7.
Provide a preliminary report of work performed to support disposition of
~
51 RPV studs and provide a final report after completion of all development activities. This final report shall include the results of all additional procedure and equipment development work to support initial disposition of.UT
)
indications.
i
== wo l
1 i
Page 2 of 4 I
l The performance of the above activities will entail several work segments and will generally follow the activities listed in Attachment A which is incorporated herem.
j l
In support of the Program objectives, the responsibilities of GE and the DISTRICT are listed below-l GE Responsibilities:
Provide any necessary procedures for applicable UT and EDM activities.
I Provide a list of GE personnel and expected arrival dates on site.
Provide EDM equipment.
Provide Smart 2000 UT equipment.
l Provide the needed transducers.
Return of the CNS UT calibration standard.
Provide the necessary NDE documentation to support disposition of the UT indications found on 51 of the CNS original RPV studs.
DISTRICT Responsibilities:
I l
Ship the CNS UT calibration standard to GE's San Jose or Vallecitos facility.
I Provide GOT for GE personnel at CNS.
Provide sufficient work space and access (including handling of the studs) to the RPV studs,(Contaminated, in RCA) approx.10" x 20".
j Provide the following miscellaneous items:
Power: 110 VAC; 15 amps.
Water.
Floor Drain.
HP Coverage.
l Power for EDM Machine.
Clean area for GE's Smart 2000 equipment.
Office Space with phone, access for local and long distance calls.
Provide radiographic testing (RT) of 4 or 5 studs.
Provide walnut shell blasting of studs.
Capability to machine threads off of selected studs.
Provide MT and PT materials, including yoke and perhaps fluorescent l
materials.
)
III.
SAFETY CLASSIFICATION The review of previous UT data, the performance of the additional examinations, and i
the machining of notches utilizing the EDM will be performed at CNS and are j
classified Essential (Nuclear Safety-Related) Working Under the DISTRICT.QA' Program. All such on-site work at CNS shall be performed in accordance with i
Section 4 ofArticle XXIII of the Agreement for Services and Equipment, No. 86A-MS2.
j The remaining work which is to be performed at GE facilities is classified Non-Essential (Nuclear Non-Safety Related). All such off-site work shall be performed
)
under the GE Quality Assurance Program and in accordance with Section 5 of Article XXIII of the Agreement for Services and Equipment No. 86A MS2.
)
1
_ _ ~ _ _
_. _. _ _. _., _ _ _.. _ - ~. _. _ _
l Page 3 of 4 IV.
SUPPLIER LIMITATIONS l
t Same as stated in Amendment No. 2 to this Task Authorization.
V.
PROJECT MANAGEMENT i
i The following individuals shall be the primary contacts for the DISTRICT and GE with respect to the performance of this Task:
l DISTRICT Mr. G. E. Hicks (402)825-5720 Mechanical Engineer Cooper Nuclear Station GE Mr. J. P. Clark (408) 925-6772 Program Manager
!'i i
I VI.
PROJECT TEAM j
This Amendment will require additional home office engineering consulting and analysis services to support the project team.
i
)
VII.
SCHEDULE Attachment A provides an estimated schedule for performance of the work hereunder.
VIII. ESTIMATED COST l
1
)
GE will perform the work described herein at no cost to the DISTRICT.
Any additional material or services not identified in this Amendment and purchased by GE at the request of the DISTRICT will be billed at cost. In addition, an amount of 20 percent of such costs shall be added to cover administrative costs.
j
)
i GE shall not incur additional costs under this Task Amendment without obtmning the 3
prior written approval of the DISTRICT.
l The total authorized amount of this Task Authorization is: $1,231,082.
j Summary Original Task
$ 975,000 Amendment No. I 114,082-l l
Amendment No. 2 142,000 t
h I
This Amendment -
l I
i
$1,231,082 -
j Total 1
i
)
i 1
c i
.... _.. ~,
.... _. ~ ~.. - -,,
Page 4 of 4 DL SPECIAL TERMS t
This Task Amendment No. 3 is considered Routine Consulting Senices under the Settlement Agreement between the parties dated as of September 7,1989, and is subject to the terms and conditions therein.
X.
TERMS AND CONDITIONS This Task Authorization, the performance of the services described herein and the i
righ+s and obligations of the parties with respect thereto are governed by the Agreement for Services and Equipment between the parties effective September 1, 1986, and such terms and conditions as are set forth in this Task Authorization pursuant to such Agreement. The terms and conditions set forth in such Agreement are hereby incorporated herein by reference and except as expressly provided in this Task Authorization shall be applicable hereto.
Accepted and Agreed to:
NEBRASKA PUBIJC POWER DISTRICT GENERAL ELECTRIC COMPANY By:
4-f Fc.
By:
57v2J42.-
J Date 1
Date
Title:
Title:
Division Manager, Nuclear Operations Nuclear Services Manager i
)
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I L
1 APPENDIX B - PROCEDURES i
1 l
l t
f i
l l
l i
r I
)
EIS IDENT:
TP 5 2 7-15 09 sw uo. 1 REV 1 REVISION STATUS SHEET DOC TITLE ACTOMATED ULTRASONIC PROCELURE FOR THE EVALUATION OF MANUALLv DETECTED CLTRASONIC INDICATIONS IN RPV CLOSURE STUDS LEGEND OR DESCRIPTION OF CROUPS TYPE:
TEST PROCEDURE FMF:
Y A.
MPL NO:
N.A.
THIS DOCUMENT IS OR CONTAINS A SAFETY RELATED ITEM YES g NO EQUIP CLASS CODE REVISION 1.
Revised to incorporate SPPD
& ANII comments.
u'~i" M29l92-S fz1/J&
i I
l PRINTS TO J.C.S.
TUNG J.P.
CLARK CENERAL ELECTRIC COMPANY MADE BY APPROVALS T
- Q 175 CURTNER AVENUE D-4 yq 97 j
SAN JOSE CALIFORNIA 95125 l
q CHKD BY R.W.
ANDERSON ISSUED
'A ) r[
- t. v g CONT ON SHEET 2 f <M
.'s NEO 908 (84V 389%
l
(
GENuclearEmwgy TP52 7-15 0 95H NO.
2 i
REV 1
l 1.0 SCOPE i
1.1 This procedure defines an automated ultrasonic (UT) method to be used for evaluation of ultrasonic l
indications previously detected in Reactor Pressure vessel closure studs by manual UT procedures.
1.2 The examination shall be a remote, automated, angle beam, pulse echo technique utilizing a shaft with l
attached ultrasonic probes.
1 1.3 The extent of the examinations is to cover a i
minimum of 1 inch of stud length on each side of the area or areas where the manual indications
)
were reported.
2.0 REFERENCES
l The following documents form a part of this procedure to the extent specified herein.
2.1 American Society of Mechanical Engineers (ASME),
Boiler and Pressure Vessel Code, Sections V and XI, 1980 Edition including Addenda through Winter 1981 2.2 GE Nuclear Energy procedure for qualification and certification of Nondestructive Examination personnel l
Specification 386HA480 and/or Field Quality Procedure FQP-03.
2.3 GE Nuclear Energy Procedure GE-UT-307, Revision 0,
" Procedure For Ultrasonic Examination of RPV Closure l
Studs including Field Revision Requests (FRR) numbered NPPD-91-16 and NPPD-91-35 i
I i
l 2.4 Stud drawings and/or a detailed identification and 1
l marking plan meeting the requirements of ASME Code Section XI.
i j
3.0 PERSONNEL 3.1 Personnel performing the ultrasonic examinations and evaluations to this procedure shall be certified to a minimum of Level II.
I l
i NEO 807 (REV 4/88)
..n.,
'"s GENacsearEmrgy TP527-15095H No.
3 l
REV 1
2 3.2 In addition personnel performing the examination shall have completed sufficient training in the use of the automated inspection system as applied to the stud calibration standard / mock-up.
The training shall be conducted by the GENE NDE personnel responsible for the development of the ultrasonic inspection system, the calibration standard /=ock-up, and the procedure for performing this inspection.
The training shall be conducted using the automated equipment and this procedure.
l 4.0 EQUIPMENT The equipment needed to perform the stud ultrasonic inspection is i
as follows:
I 4.1 The Smart 2000 digitized ultrasonic data acquisitia-system shall be used.
The automated equipment primarily consists of an ultrasonic pulser / receiver, analog to digital converter, console, optical disk drive for archiving data, high resolution color monitor and color printer.
l 4.2 A multi-element probe or probes are used to perform this examination.
The probe or probes are to contain i
a minimum of two contact, shear wave, angle beam l
transducers with the sound beams directed in opposite l
directions along the length of the stud.
The l
refracted angles shall not be less than 40 or greater l
than 80 degrees.
The active element for each transducer shall not exceed 1/2" diameter.
Nominal l
frequency of the transducers shall be in the range of 1 to 5 MHz.
4.3 In addition a contact, straight beam transducer (0 degree longitudinal) may be included to measure the studs effective wall thickness and to evaluate corroded areas.
4.4 other probes of different frequency and angle can be used for evaluations at the discretion of the examiner.
i l
l l
NEO 807 (AEV 4/88) l l
~
I l
C GENixiesEnergy i
TPS27-150fMNo-4 i
REV 1
l 4.5 Deionized water is to be used as the couplant and is to be supplied by the owner.
Other couplanta can be i
used at the discretion of the examiner providing they meet the specification from procedure GE-UT-307, paragraph 4.5.2 as revised by FRR NPPD-91-16, with the approval of the owner 1
4.6 The scanning equipment shall be designed to be remotely motor driven with the appropriate motor controller to assura that proper scanning can be achieved with the above ultrasonic probe.
The motor controller shall be capable of providing an index which results in 50% coverage overlap.
The scanner and the motor controller shall provide position information to the data acquisition system with 1
regard to the probe location.
4.7 A calibration mock-up fabricated from a real stud is i
required for calibrating the UT examination system.
See the figure attached to procedure GE-UT-307 as l
revised by FRR No. NPPD-91-35 as an example.
If the l
mock-up shown in this figure is used then the 1
i appropriate notch for. angle beam calibration is notch
{
A.
5.0 CALIBRATION 5.1 Calibration shall be performed and recorded prior to i
commencement of any examinations.
Calibration shall include the complete ultrasonic examination test I
system.
5.2 Assemble the inspection track on the calibration mock l
up and attach the scanner to it.
5.3 Using the automated scanner, position the angle beam transducers to the appropriate circumferential notch, and optimize the reference signal to approximate 80%
l full screen height.
5.4 If a straight beam traneducer is used it shall be calibrated such that the average back reflection over the threaded areas on the outside diameter of the stud is 80% of full screen. height.
5.5 Scan the required volume and record all data on optical disk.
l NEO 807(REV 4/88)
~ _.
GENudesEragy Te5 v-150 e ~a 5
REV 1
l 5.6 Calibration shall be verified at the start and finish of a series of examinations or at other time the examiner deems necessary.
6.0 EXAMINATION 6.1 The examination shall be performed from the inside surface of the center hole using the specially designed probe or probes as required to provide 100%
coverage of the area of concern from two different directions and with two different refracted angles.
l 6.2 The rate of transducer travel shall not exceed 3" per
{
second and shall be the same as used for system calibration in section 5.0.
6.3 The required examination volume shall be examined with a minimum scanning overlap of 50% of each search unit's active element size.
6.4 Probe And Scanner Positioning - Identify a zero location on the top of the stud for future referencing.
Position the probe with the elements indexed to this zero reference.
Lower the probe to the pre-determined position with respect to the indications to be evaluated.
Set scan limits a minimum of 1 inch on either side of the area where the sound beam will interrogate the previously recorded indication.
Set this position as vertical zero and angle zero.
Record this zero location identification for future reference.
6.5 All studs shall be scanned once initially at reference level, determined from equipment calibration, as a minimum.
Additional scanning with gain setting higher than reference level (+6dB) is recommended if base line noise permits.
Scanning l
below reference level due to excessive base line noise must be approved by the cognizant Level III.
6.6 Scan the required volume and record all data on optical disk.
6.6.1 UT examination of all studs shall be accomplished both before and after corrosion product removal.
NEO B07 s AEV 4/88)
I w
TP52 7-1509H No-6 REV 1
1 7.0 EVALUATION l
7.1 Review and evaluate each circumferentially oriented indication determined to be valid.
Nicks, scratches, i
corroded threads or changes in metallurgical i
properties in themselves may not constitute a defect.
Circumferential cracks and/or other circumferential1y oriented indications are considered to be relevant.
7.2 Carefully evaluate all signals emanating at the OD surface in order to determine each indication's length, depth, maximum signal amplitude and/or location /
orientation with respect to vertical position and the stud's zero.
7.3 Compare the results obtained from the two different directions and at the different refracted angles with the manual results which are under evaluation.
The straight beam results may also be used to help, determine if certain indications are related to geometry.
7.4 The lev?1 II or III performing the evaluation will base his results on this comparison and on the l
results of other NDE methods, such as magnetic particle, liquid penetrant, or radiography, if such data is available.
I 8.0 REPORT 8.1 Report all non-geometric relevant indications to the plant owner.
The owner is responsible for the final evaluation and disposition of all reported indications.
8.2 A preliminary report will be provided to the customer prior to departure of key examination personnel from t
the site.
8.3 A complete final report shall be completed and submitted to the customer for review within sixty days after returning to San Jose.
l NEO 907(AEV 4/88) l
h Field Revision Request i
Cooper Nuclear Station p,ge, TA161 hofect No.
pgg g NPPD-91-16 o,te __9 91
~
Document to Be Changed-te. Procedure for Ultrasonic Examinations of uu,no e CE-UT-307, Rev. O RPV Closure Studs Anson CNnge a f>ecuested.
To meet customer requirements.
l Proposed Chenge:
change the last sentence in paragraph 4.5.2 to raad:
Total residual sulfur and halogen content shall not exceed the following:
- Halogen change sentence in paragraph 5.5.1 to read:
Move the REnha away from the nocch until the emplitude of the signal is 50g (-6dB) from the maximum.
Add new Ultrasonic Calibration Data Sheet, Exhibit I.
Add new Ultrasonic Examination Data Sheet. Exhibit II.
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Field Revision Request a ject Coener Nucimar Station ro pg TA161 nWrho. NPPD-91-19 Dere 11-1%-91 Docwnent un Inn Chengmt Procedure for Uitrasonic Examination of N
GE 'R-307 RPV Closure Studs de*5D't Chey 4 Aegestd To Meet NPPD Requirements i
i i
hoposed Chavt di Delete Paragraphs 5.3.1, 5.3.2, 3 3.3, and 3.3.4.
Replace with new 5.3.1, 5 3.2, 5.3.3, 3.3.4, to read as follows:
5.3.1 Suesp Range Calibration. Using a suitable Calibration Block, adjust the instrument suesp to display a minimum of $0" of Metal Path.
5.3.2 System Calibration and construction of DAC's shall be performed using a 2 (two) Zone technique on a fu11 length stud Calibration Block.
Zone 1 (one) shall cover the estal path range from 0" - 14,7/16" minimum, as measured from the nut end of the block. Zone 2 (two) shall cover the metal path range from 24 7/16" - 48 7/8" minimum.
5.3.3 The Zone 1 (one) DAC shall be obtained using a 5.0 MMZ Nominal Frequency Transducer f rom the nut end of the block. Obtain signals f rom slots A and D in the Calibration Block. S t the higher amplitude h
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/PR Ma NPPN 91-33 Dete _11-15-91 5.3.3 (cont'd) response to 80% FSH.
Mark the signal's position and amplitude on the CRT.
Without changing gain, obtain a response from the remaining slot.
Mark the position and amplitude on the CRT.
Conneet these points and extrapolate them to cover the examination range. This is primary reference level for Zone 1.
Mark a second curvo 20% of primary reference level on the CRT. Record instrument settings and DAC's on the Calibration Data Sheet.
S.3.4 The Zone 2 DAC shall be obtained using a 10.0 MHZ nominal frequency transducer from the flange end of the block. Obtain signals from slots A and D in the calibration block. Set the higher amplitude response to 80% FSH. Mark the signal's position and esplitude on the CRT.
Without changing gain, obtain a response from the remaining slot.
Mark the position and amplitude on the CRT. Connect these points and extrapolate them to cover the examination ran6e, This is primary reference level for Zone 2.
Mark a second curve 20% of primary reference level on the CRT.
Record instrument settings and DAC's on the Calibration Data Sheet.
l I
l
- 2 Deiste 5.3.4.1, 5.3.4.2, 5.3.4.3, 5.3.4.4, 3.3.4.5, 5.3.4.6.
j
- 3 Change 6.1.1 to read as follows:
i i
For Zone 1, the examination should be performed with search units with a freguancy within the range of 2.25 MHZ - 5.0 MHZ. For Zone 2, the examination should be performed using search units with a frequency within the range of 3.0 MHZ - 10.0 MHZ.
i l
Change 6.1.2 to read as follows:
scon at a gain setting of twice-(2X) primary reference level.
Record at primary reference level.
(
Change 6.1.4toreadasfoliows:
The examinations shall be performed in Zones that correspond to to those established during' calibration.
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O GE Nuclear Energy TITLE nevision no.:
nnocsount no.:
GE-UT-307 0
FROCEDURE FOR ULTRASONIC EXAMINATION OF RPV CIDSURE STUDS e
P8&A8ED SP.
MVEMD tr:
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COMMENTS:
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9 NUMBER: CE.UT.307 REV. O TABLE OF CONTDJTS i
TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA-TION OF RFV CIASURE STUDS GE Nuclear Energy l
1 TABLE OF CONTF.NTS i
l l
SECTION DESCRIFTTON Igd; 1.0 SCOPE 1
l l
2.0 REFERENCES
1 l
3.0 FEK50lerEL 2
l 4.0 EQUIPIENT 2
5.0 "ALISRATION 4
6.0 EXAKINATION 9
7.0 RECORDINC 11 l
l 8.0 EVALUATION 12 9.0 RECORDS 13 EXHIBIT 1 14 EXHIBIT 2 15 FIGUEE 1 16 FIGURE 2 17 FIGURE 3 18 FICURE 4 19
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. _ _ _ e NUMEER: CE.UT.307 REV. O PACE 1 or 19 TITLE:
PROCEDURE FOR ULTF.ASONIC EXAMINA.
GE Nuclear Energy 1.0 SCOPE 1.1 The scope of this Precedure encompasses the manual, contact.
pulse echo, ultrasonie examination of the ASME Section XI.
Category 3.C.1, reactor pressure vessel closure studs.
l 1.2 This Procedure contains techniques for examination using a straight besa from one or both ends of the stud, using angle beams from the extensiometer hole, and using surface waves in the extensionster hole.
These techniques may be used singly or in combination as required by the Owner's program.
1.3 This Procedure is applicable to materials up to 70 inches in length.
1.4 This Procedure is applicable to RFV cleeure studa when the examination is performed with the stud left in place or removed.
I 1.5 This Procedure contains variances from ASME Section XI requirements. qualified in accordance with Paragraph IVA-2240.
j 1.6 This Frocedure does not delineaxe the acceptance and/or rejection of indications disclosed during testing.
Final i
evaluations will be the owner's responsibility.
l
2.0 REFERENCES
(
2.1 The following documents form a part of this Procedure to the extent specified herein.
2.1.1 Codes and Standards 2.1.1.1 American Society of Mechanical Engineers.
l (AsME), Boiler and Pressure vessel Code, Sections V and XI, 1980 Edition' including Addenda through Winter 1981.
i 2.1.2 Ceneral Electric Documents 2.1.2.1 FQF.03, or equivalent, Qualification and Certificacian of Nondestructive Examination Personnel.
I
i i -
O NUMBER: CE.UT.307 KEV. O PACE 2 0F 19 TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
GE Nuclear Energy 2.1.2.2 CE.ADM.1001, Procedure for Performing Linearity Cheeks on Ultrasonic Instruments 2.1.3 vessel Tabrication Documents 2.1.4.1 Detailed identification and marking plan meeting the requirements of ASME Code Section XI.
3.0 PERSONNEL 3.1 All personnel performing the ultrasonic examinations in accordance with this Procedura shall be qualified and f
I certified to at least Level 1 Level I individuals shall work under the direct supervision of a certified Level II or Level III individual.
A Level I individual shall not independently evaluate or accept the results of this examination.
3.2 Personnel performing examination in accordance with this Procedure shall receive instruction in its usa prior to the examination. This indoctrination shall be documented.
4.0 EOUlfliENT 4.1 m basic equipment shall be pulsa scho design and shall be equipped with a calibrated gain or attenuation control.
Braduated in units no larger than 2 dB.
4.2 Transducers 4.2.1 Straight boas examination from the and(s) of the stud shall be performed using a ceramic type lon5 tudinal vava search unit having a nominal 1
frequency in the range of 2.25 through 10.0 MHz.
l m search unit should be from 1/2 through 3/4 inch disseter.
The search unit shall be capable of detecting the qualification notches in the calibration blocks.
Detection of the ASME qualification notehas in both the near and far positions shall be deeusented on the Calibration Data Sheet.
i t
)
.A A
i i'
NUMBER: CE.UT.307 PIV. O PACE 3 OT 19 l
TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
TION OF RPV C145URE STUD 5 1
GE Nuclear Energy 1
I l
t 4.2.2 Angle basa examinations from the extensieseter hole shall be performed using a specially designed stud examination probe (s).
The probe (s) shall centain, j
as a minimum, forward and aft pointing s' arch units e
]
with a nominal frequency of 2.25 MHz.
The search unit's active element size shall not exceed 3/8" The grisarg inspection angle should be in diameter.
the range of 40 - 60. Probes containing more than i
i one beaming angle may be used.
More then ene probo l
may be required to accommodate the desired beaming an& es and the required scanning directions.
l i
]
4.2.3 Surface wave examinations in the extensiometer hole shall be performed usir.g a search unit designed to j
produce surface waves at a nominal frequency of 5.0 l
MHz.
The search unit's active element size shall j
not exceed 3/8" diameter.
The search units may be incorporated in a specially designed surface wave i
stud examination probe or placed in a probe designed 1
)
i for angle beam examinations.
j 4.2.4 Uith the approval of the responsible Level III.
I transducers of different sise, shape and frequency j
j may be used for examination, investigation of defcet sise, location and orientation.
The use of cther J
translucers shall be documented.
I J
)
4.3 Ultrasonic ex ataations should be performed usin5 coaxial eables & to 12 feet in length, longer cables may be used 1
i when necessary to facilitate access.
Thb cable used shall be documented on the Calibration Data Sheet.
Documentation I
shall include the cable type, length, and number of I
connectors.
4.4 Calibration blocks shall be supplied or approved by the Owner.
Figures 1, 2 and 3 show the CE recommended calibration block configurations.
4.5 Couplant 4.5.1 USF grade glycerine, deionised water, or Ultragel II should be used for calibration and examinations.
When required to maintain soupling, the couplant say be thinned with a suitable retucing agent.
.)
i 9
NUMBER: CI.UT-307 REV. O PACE 4 0F 19 i
l TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA-GE Nucles? Energy l
- 4. 5. i' All couplants other than deionized water shall be certified for total sulfur and halogen content in accordance with ASTM D.129 64 and D.804-63.
The I
total residual halogens and sulfur shall not exeeed 250 PPM.
Deionized water, when used, shall be l
supplied by the owner.
pu iM-93-'t j
i 4.5.3 Other couplants which meet the above specification j
may be used with owner approval.
i j
5.0 CALIBRATION j
+
l 5.1 ceneral Requirements for Calibration I
i 5.1.1 The surface temperature of the calibration block (s)
+
shall be within i 25 degree F of the component i
l surface comparatura.
The identification of the I
temperature measuring device shall be entered on both the calibration and Esamination Data Sheets.
5.1.2 Complete system calibration shall be made for the l
l l
applicable examination (s) prior to examination.
A l
calibration check shall be made when the examination l
is complete, each four hour interval, and when any l
l change is made in personnil er system combination.
(
System calibration and calibration checks shall be perf6tsed using the baste calibration block.
l i
5.1.2.1 If, during the system calibration cheek, l
any point on the DAC line has changed in amplitude by 201 (2dB) or changed on the sweep line by more than $1 of the sweep l
division reading, since the last system calibration or calibration check, a nov calibration shall be made and recorded.
l All data sheets since the last valid calibration or calibration cheek shall be marked void and the affected studs shall be re examined.
5.1.3 In addition to the requirements of Paragraph 5.1.2, system calibration shall be checked and DAC curve verified after any change in power supply (e.g.,
from AC to battery or vice versa).
L l
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9 NUMBER: CE.UT.307 REU. O PACE 5 or 19 TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
l TION OT RFV C145URE STUDS GE Nuclear Energy 5.1.4 For initial ASME XI examination, the reject and damping controle of the instrument shall be set at either minimum or off position.
Other settings may be used when approved by a Level III. ~Such approval shall be documented by the Level III by signature or initial and date on the Calibration Data Sheet.
If rej6ct or damping are used Instrument. calibration shall be verified. Verification shall be documented on the Calibration Data Sheet.
I 5.1.5 Calibration for the examination shall include the complete Ultrasonic Test System (s).
Alternate cables and search units singly and in combination that have been included in a prior system calibration may be later substituted in the system:
s.uch substitution shall not necessitate a calibration eheck.
When any other part of the ultrasonic test system is changed, a calibration check shall be made.
~
5.1.6 Calibration for examination shall be performed on the calibration block (s) applicable to the stud that is beirs examined.
5 1.7 The UT instrument frequency setting should be set as elese to the transducer frequency as possible.
(
5.2 Instweene Calibration 5.2.1 Instrument calibration shall be performed daily, in accordance with Reference 2.1.2.2.
5.3 Calibration for Straight Beam Examination of Full Length closure Studs (in place or when removed).
l 5.3.1 Sweep Range Calibration.
Using the L/8 through L calibration blocks, adjust the instrument sweep range to display the mone(s) of the stud that are being examined.
144: swo. v. n-I i
i I
i saursor n.
ut.,-u4 Ju/
M t. V. O PACE 6 Ol' 19 TITLE:
PROCEDURE FOR ULTPASONIC EXAM 2 tt a.
GE Nuclear Energy I
l 5.3.2 System calibration and construction of the DAC, i
shall be performed usins a zoned technique.
)
Examination sones shall be established by j
calibrating on the blocks that span the zone of the stud that is to be examined.
It is expected that i
the sones will be:
L/8 to L/4, L/4 to 1./2, I./2 te #,,,f,. p-
)
3L/4, and 3L/4 to L: however, sones may be combined l
if material attenuation permits.
5.3.3 The initial distance amplitude correction (DAC) curve shall be established by obtaining a peaked signal from the Flat Bottomed Hele (FEM) in the L/8 i
Calibration Block (see 7.1.2.1 for search unit recommandations).
Using the variable gain centrol, l
adjust this signal amplitude to 801 FSM.
Mark the sweep position and amplitude of this signal on the ###~ j g screen. Without changing th* Sain centrol, obtain a i
peaksd signal from the FSM in the L/4 Calibration Riock.
Mark the sweep position and amplitude of
(
this signal on the screen.
Join the marks obtained l
above with a straight line point.co. point.
Tais is
(
the primary reference level for the zone extending from the scanning surface to L/4.
Mark a second curve 20I of the primary DAC on the screen and record the data on the Calibration Data sheet.
red.df.W r
l 5.3.4 Extension of the initiar DAC to cover the other zones shall be performed (as necessary) as follows:
1 5.3.4.1 Determine the additional gain needed to incrassa the L/4 signal to 80% FSH and add l
this gain to the system.
Mark the tot amplitude on the sereen and reeerd the new l
gain setting en the Calibration Data mg, p r. s o.sr l
5.3.4.2 chtain a peaked signal from the FBH in the l
L/2 ealibration block.
Mark the sweep l
position and amplitude of this signal en the screen.
m.es.tr 5.3.A.3 Connect the L/4 tot FSM point and the L/2 yeak amplitude with a straight line point te.peint.
This line is the primary reference level for the sono extending from I/4 to 1/2.
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{
i i
NUMBER: CE.UT-307 RIV. O PACE 7 0F 19 j
TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
1 TION OF RPV CLOSURE STUDS i
GE Nuclear Energy 1
5 4
1 I
j 5.3.4.4 Mark a second curve 20% of this referene.
l level on the screen and record the data on e
the Calibration Data Sheet.
M #*#
4 l
S.3.4.5 Repeat steps 1-4 for the additional ranges i
of L/2 to 3L/4 and 3L/4 to L.
When DAC's j
for these senes have been established, add
{
an additional 12d5 gain.
This is the primary reference level for renes L/2 through L.
The ASME code flaws in the
]
near and far positions shall then be l
detected.
The notches shall be detected,.,,,
l se reference level with the equipment sat up for the range where the flaw lies. The l
3 amplitudes from the notches shall be
[
j marked on the Calibration Data Sheet. The l
near position flaws are to be detected by scanning from the threaded and (nut end) j of the calibration block containing the i
notoh.
The far position flaws are to be detected by scanning from the nut and of i
the full length (L) calibration block.
5.3.4.6 Combination of examination sones, if possible, shall be performed.
Three points shall be established, i.e.
L/8 to red * #
L/2 requires DAC points from the L/8. the L/4, and the 1/2 Calibration Blocks.
The DAC established in this case would be valid for the examination sone extending from the scanning surface to l/2.
5.4 Calibration for angle beam examinations performed from the extensiometer hele (in place or when removed).
5.4.1 sweep Range Calibration.
Insert the desired stud examination probe (see Figure 4) into the extenstemeter hele and detect the signal from the calibrated noteh in the stud threads.
Adjust the instrument's sweep eentrols to display the distance from the CD surface of the bore hele to the notch in metal path.
The sweep range is considered to be salibrated when the metal path displayed on the instrument is within i SE of the calibrated value.
Record the instrument settings en the Calibration Data Sheet.
l
1 9
NUMBER: CE.UT 307 REV. O PACE 8 OT 19 TITLE:
PROCEDURE POR UI.TRASONIC EXAMINA.
GE Nuclear Energy 5.4.2 Sys tem Calibration.
System calibration for this technique consists of establishing reference sensitivity only.
Insert the desired stud examination probe into the extensiometet hole and detect the signal from the calibration notch.
Maximize the signal and set the amplitude to 801 i St FSH.
This represents primary reference sensitivity, other notches, e.g.,
.5 a/s..05 e/e, etc. may be present for assistance in spring I
indlestions.
If present data should be recorded from these notches for future use.
Record the instrument settings on the Calibration Data sheet.
5.4.3 More than one examination probe may be required to complete examination of a stud.
When a single channel instrument is used, it is intended that all i
necessary calibrations be performed for each probe, e.g., fore and aft facing search units, fore er aft i
facing multi. angle search units, etc.
Sensitivity differeness between search units on the same stud examination probe shall be recorded on the Calibration Data Sheet.
Appropriate adjustments.
based on this data, shall be made to primary reference sensitivity during indiestion recording.
5.4.4 When primary reference sensitivity has been established, draw a horizontal line on the CRT screen representing the amplitude.
A secondary l
line, representing 20% of the primary amplitude, f
shall also be drawn on the CRT screen.
Both lines shall also be drawn on the Calibration Data sheet.
5.5 Calibration for Surface Wave Examination in the Extensio.
meter Hole 5.5.1 Sweep Range Calibration.
Insert the surface wave stud examination probe (see Figure 4) into the extensiometer hole and detect the ID surfdce notch on the stud.
Nove the probe toward and away from J
the notch and observe the signal's esplitude.
Determine the point where the amplitude peaks and the distance of the search unit from the notch at peak amplitude.
The distance from the notch will
)
n.---
NUMBER: CE.tTr.307 REV. O PACE 9 or 19 TITLE:
PROCEDURE FOR UI.*,RASONIC EXAMINA.
GE Nuclear Energy usually be short.
Adjust the sweep controls to display the determined distance from the notch in inches.
Nove the prove away from the notch untilr44-n8-*~
the amplitude of the signal is 501 (- 6 dB) from the maximum.
Determine the distance. Adj us't the sweep controle. if necessary, to display the minimum and maximum distances from the notch within i 51 of the measured values.
Mark the minimum and maximum points on the CRT screen and on the Calibration Date Sheet.
I Rough or parkerized surfaces can preclude a surface l
wave having a working distance.
If little or no l
probe movement is possible without losing the notch signal, determine the search unit distance from the notch and adjust the sweep controls to dispisy the distance within i SE of the measured distanee. Mark the point on the CRT seroen and the Calibration Data Sheet.
Note on the Calibration Data sheet that no probe movement was possible.
In this case, no DAC i
(see 5.5.2) is necessary.
5.5.2 System Calibration.
System calibration for this technique consists of establishing primary reference sensitivity and a BAC (see 5.5.1).
Move the probe to the minimum distance from the notch and detect I
the signal from the notch.
See this amplitude to 801 i 51 FSH. Mark the amplitude on the CRT screen.,
Nove the probe to the maximum distance from the notch and mark the signal amplitude on the screen.
Connect the points with a straight line.
This establishes the primary reference sensitivity and DAC for the working distance determined for the search unit. Construct a secondary DAC equal to 20%
of primary.
Record the instrument settings and CRT markings on the Calibration Data Shest.
If no working distance can be establishes for the search unit, no DAC is required.
In this case, set the notch response to 801 2 52 FSM and mark the position and amplitude on the CRT screen.
Mark a secondary point equal to 20% of primary. Record the instrument settings and CRT markings on the Calibration Data Sheet.
6.0 173!1 NATION l
6.1 Straight Beam Examination of Full 14ngth Closure studs (in place or when removed) l I
i l
NUKBER:
CE.UT.307 REV. O PACE 10 0F 19 TITLE:
PROCEDURE FOR Ui.TRt.5ONIC EXAMINA.
GENuclear Energy 6.1.1 ror zones L/8 through L/2, examination should be f,,. p se performed with search units in the range of 2.25 through.5.0 MHz.
For zones L/2 through !..
examination should be perforised with search units in the range of 5.0 throush 10.0 MH2. to miniaire beam l
spreading at the longer distances.
6.1.2 for zones L/8 through 1/2 scan at a gain setting of l
twice (2X) the primary reference level. Record with /d# ###.
the gain control set at the reference level (1X).
For sones 1/2 through L the scanning and recording levels shall be those established in Paragraph 5.3.4.5.
6.1.3 The studs shall be examined from one end.
Th e,,.p.
s, l
complace end surface shall be scanned.
The scan path of the search unit shall overlap adjacent scans by a minimum of 101 of the transducer active l
element.
The scanning speed shall not exceed 6 inches por second.
6.1.4 The examination shall be performed in zones that to the zones established during correspond The instrument Sain shall be set at 2X ',, s,.jf calibration.
l l
primary reference level and the zone from the scanning surface to L/4 examined.
The ins trume n3 gain shall then be set at the gain established for the next examination zone, i.e.,1/4 to 1/2 and that sono shall be examined.
This progressive examination shall be continued until the full length of the stud (all zones) has been examined.
ran.stn s.r 6.1.5 When the calibration zones display less than full
)
l stud length, occasionally verify search unit f
operation by obtainin5 a reflection *roa the radial l
dimension of the stud.
l 6.2 Angle team Examination from the Extensiometer Hole 6.2.1 select the desired stud examination probe and insert it ingo the extensiometer hole. Rotate the probe to the 0 axis of the stud.
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f NUKBER: CE.UT.307 REV. O PACE 11 0F 19 i
TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
)
TION OF RFV C145URE STUDS GE Nuclear Energy 1
i 6.2.2 Nove the probe to the end of the stud opposite the end of the scan was started at, observing the CET for indications. Sean speed shall not exceed 3" per second.
6.2.3 At the end of each scan, index the probe to the next scan location. Maintain a 50% overlap of the search unit active element. sean the length of the stud to the limits imposed by the probe design.
Repeat until the entire stud has been examined.
+
6.2.4 For single channel instruments, repeat 6.2.1 through 6.2.3 for each search unit in the probe.
If a multiplexed instrument with automated data recording is used, it will not be necessary to sean the stud more than once.
)
6.3 surface Wave Examination in the Extensiometer Hola 6.3.1 select the desired stud examination probe and insert itingotheextensiometerhole. Rotate the probe to the 0 axis of the stud.
t 6.3.2 Move the probe to the end.of the stud opposite the end of the scan was started at, observing the CRT for indications. Sean speed shall not exceed 3" per second.
6.3.3 At the end of each scan, index the probe to the next mean location. Maintain a 50% overlap of the search unit active element. fean the length of the stud to the limits imposed by the probe design.
Repeat until the entire stud has been examined.
6.3.4 For single channel instruments, repeat 6.3.1 through 3
6.3.3 for each search unit in the probe.
If a multiplexed instrument with automated data recording is used, it will not be necessary to sean the stud more then once.
7.0 RECORDING i
7.1 Record all indications which exceed 201 DAC at 11 sensitivity on the Examination Data Sheer. Indications caused by stud geometry shall only be reeerded once per j
i stud.
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l NUKBER: CE.UT-307 REV. O PACE 12 0F 19 l
TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA-GE Nuclear Energy 7.2 Tor straight and angle beam examinations, record maximum amplitude in percent DAC, transducer movement between 201 i
DAC points and metal path at the maximum amplitude. Include sketch showing the stud number and the location of any a
indications data reeerdad.
i 7.3 For surface wave examinations, record maximum amplitude and the surface distance shown on the CRT.
Include a sketch showing the stud number and the location of any indications recorded.
l 8.0 EVALUATION l
8.1 Data Review:
All data shall be reviewed by an individual certified' to Level III.to determine if further examination l
or evaluation is required.
l l
l 8.2 Evaluation of Indications:
All indications shall be
(
evaluated in accordance with the ultrasonic acceptance criteria specified in Paragraph IVB 3515 of ASME section XI.
l 8.3 Recordable indications that are determined not te be seemetric reflectors will be reported to the owner after preliminary evaluation.
8.4 Final evaluation will be the Owner's responsibility.
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i NUMBER: CE.UT.)07 REV. O PACE 13 or 19 4
TITLE:
PROCEDURE FOR UI.TRASONIC EXAMINA.
GE Nuclear Energy 9.0 RECORDS 1
i 9.1 Data sheets are rypteal; the format may change provided the minimum information shown in 9.2 and 9.3 is maintained.
I 9.2 Calibration Data Sheet i
a)
Calibration sheet identificatien, date and time period of calibration j
b)
Name(s) and ASNT Level (s) of examination personnel c)
Examination procedure number and revision l
d)
Rasic calibration block identification e)
Ultrasonic instrument identification and serial number f)
Been angle, couplant, and mode of wave propagation in the sacerial l
g)
Search unit identification frequency, size, manufacturer, and serial number h)
Reviewer's signature A$lff Level and date i)
Search. unit cable type, length, and number of connectors i
j)
Times of initial calibration and subsequent and final calibration checks 4
k)
Calibration reflector (s) and the instrument settings.
amplitudes, and sweep positions used to establish 4
primary referenes sensitivity-l 1)
Thermometer serial number and caltbration block temperatures 1
9.3 Examination Data sheet a)
Data sheet identity, examination date and time period of examination b)
Name(s). tad ASNT level (s) of examination personnel c)
Examination procedure and revision d)
Applicable calibration sheet identity i
.)
void identification f)
Record of indications or of volume free from indications g)
Examination surface, volume scanned, scan identification and sean limitations if any h)
Reviewer's signature. ASNT Level and date 1)
Search unit position and loestions of recorded indications j)
Thermometer serial number and examination surface temperature
l l
9 NUMBER: CE.UT-307 REV. O PACE ll. OF 19 TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
TION OF RPV CLOSURE STJDS GE Nucleer Energy l
h STUD UT CAUBRATIDN DATA SHEET 1
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PROCEDURE FOR ULTRASONIC EXAMINA.
TION OF RPV C14SURE STUDS j
GE Nuclear Energy GENf RR $ EL!CTRIC suu
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NUMBER: CE UT-307 REV. O PACE 16 OF 19 i
TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
I TION OF RFV CIDSURE STUDS 1
GE Nuclear Energy i
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i CALIBRATION BLOCK SET J
FOR STRAIGHT BEAM EXAMINATICN j
FROM THE END OF THE STUD l
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l NUMBER: CE UT-307 REV. O PACE 17 OF 19 TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
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GE Nuclear Energy l
C ALI?RATIDN ELCCK i
FOR ANGLE EEAM EXAMINATION FROM THE EXTENSIDMETER HDLE l
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.115" 2.003 FROM THREAI) RDOT i
NOTCH LENGTH i
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9 NUMBER: CE.UT.307 REV. O PACE 18 OT 19 i
TITLE:
PROCEDURE FOR ULTRASONIC EXAMI!! A.
b GE Nuclear Energy i
CALIBRATION BLOCK ji FOR SURFACE WAVE EXAMINATION 4
IN THE EXTENSIDMETER HDLE
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1 6
NUMBER: GE.UT-307 REV. O PACE 19 of 19 TITLE:
PROCEDURE FOR ULTRASONIC EXAMINA.
GE Nuclear Energy r}yTUEE TCD CXAMINATICHO PERTURMED l'RDt4 THE EXTEH5fDt4ETCR HOLE q
LOCKING CDLLAD 1
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. JULL COLLAR (TCP VICV)
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PAD CENTEREL OH TORC RACING ll SCARCH y
,V UNIT c
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j oo DN COLLAR ROTATED AND LCCKED 70 Ih[
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INCRCMENTS GRADUATED IN.P INCRE t;:3 HCHT5 VITH l' RINGS e.
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, rAC:NG
, rAC]NG 4
i 3PRING LDATED SCARCH UNITS FICURE 4 i
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9 GE Nuclear Energy s
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PROCE00RE FOR '.*ET FLUORESCENT MACNETIC PARTIC1E EXAMINATION i
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9 NO.
CE MT.101 R.EV. O PACE 1 0F 16 i
TITLE:
PROCEDURE FOR L'ET FLCRESCENT MACNE!!C j
PARTICLE EXAMINATICNS TA3LE OF CCNTENTS stCTION DESCRIP?t0N PME NO
.0 SCOPE 2
2.0 REFERENCES
2 I
- .0 PERSCNNEL 2
-0 EQUIPMENT 2
!.O CALIERATION
)
6.0 EXAMINATION
~.0 RECORDING 12 6.0 REPORTS 14 EXHIBIT I 15 FIGURE I lo l
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O NO.
CE.NT-101 REV O PACE 2 cr 16 TITLE:
PROCE0"RE TCR *'ET TLORES ENT M.AGNET:0
^ " "
GENuclear Energy 1.0 EQfi 1.1 This procedure describes the methods, requirements. and acceptance cri:erta for con:1nuous wet magnetic particle examinatten of ASME See: en XI co perents. including but not limited to RPV closure studs. nuts.
vesse',s anc other ferro-magnetic compenents.
I 1
2 0 REFEREMyli 2.1 Aserican Society of Mechanical Engineers (A$ME) Boiler and Pressure 7 esse'.
Code Sections V and XI.1980 Edition. includi"5 Addenda :nreugh in:er 1981.
l 2.2 Ceneral Electric Procedare FQP 03. " Qualification and Car:tficacten of Nondestructive Examination Personnel", which meets the requirements of :he
)
American See ety of Nondestructive Testing (ASNT) Recen. mended Prac: ice.
SNT TC 1A. 1975 and 1980 Editions.
)
2.3 Ceneral Electric Procedure CE ADM-1005. " Procedure for Zero Reference I
Location and Data Recording for Nondestructive Examinations" 2 0 FIFSTNEL 3.1 Personnel performing magnetic particle examination to this precedure sha'.
be qualif;ed and certified in accordance with paragrapn 2 2 3.2 Level : personnel may perform the examination under the direc: ton cf personnel certified to at least Level !!.
Personr.el rev:evi 5 or evaluating recorded cata shall be certified to Level 1: or Level II:.
e C E0"ISMEN'T 4.1 The magnetizing apparatus used shall be capable of indu:ing in the 1:em under examination, a eagnetic field of suitable ir.:ensity in the destre:
direction by either the circular or the longitudinal mathed.
4.2 Direct current obtained from DC generators, or full wave or half wave direct current obtained by rectifiers or diodes may be used to induce : c magnetic field.
12 4.3 Any suitable means may be used to establish the magnetic field (e.g.
yeWe central conductor, direct contact and proda).
Care must be taken when utilizing the prod and direct contact methods to preven: arcing.
The central conductor must be insulated to protect the par: being examire:
4.4 Marvetic Particles 4.4.1 Fluorescent magnetic particles suspended in a suitable liquid vehicle shall be used as the inspection medium. A vetting agen:
may be used to assure complete coverage.
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NO.
GE MT 101 REv. O PAGE 3 CT 16 TITLE:
PROCEDURE TCR *TET F'.4RESCENT F.ACNETIC
'^**
GENuclear Energy 4.4.2 The concentration of the fluorsscent magnetic particles 'shall be between 0.1 and 0.7 al in a 100 al sample of the bath.
Particle concentration shall be measured after allowing a thirty minute l
settling time.
i l
4.4.3 The bath stren5th shall be checked at least once every eight hours 1
or when a new solution is prepared. This shall be recorded on the Magnetic Particle Examination Sheet.
4.4.4 The bath shall be agitated in a manner which assares enat the 1
l magnetic particles are uniformly suspendec in the medium, i
l 4.4.5 The application of the magnetic perticles must be in such a fashien as to assure that li htly held particles are not washed away 5
NCTE:
Aerosol spray cans of fluorescent particles can be used.
if they meet the requirements of ASME section V. SE-138.
a$ tiCMTINC i
t 4.5.1 A darkened area shall be used to conduct the examination.
.5.2 A high intensity black light shall be used for tilumination.
It shall be equipped with a filter (Kopp No.
1 or equivalent) shicn passes 3650 angstros unit ultraviolet (black) light black light intensity at the surface under examinatien shal'. os measuree at least once every eight hours. and whenever the work location is changed, using a meter which is sensitive to light in the ultraviolet spectrum and centered on 365 nanometers (nm) (3650 angstrom units). Two readin5s shall be taken; the first without a filter and the second with an ultravioist 4365 nn) absorming filter placed over the sensing element of the meter.
The second readir.g i
j shall be subtracted from the first and the difference shall oe a minimum of 800 uV/cm2. The black light bulb shall be curred on and allowed to warm up for at least five minutes prior to use.
l 4.6 Thermometers calibrated and certified in accordance with manufacturer's standards shall be used to seasure the examination component surface l
temperature. Additionally, the serial number of the thermometer shall 26 I
recorded on the Examination Data Sheet (Exhibit 1).
5.0 CALI* RATION t
5.1 Each piece of magnetiti:, equipment shall be calibrated once a year er whenever the equipment i..
been subject to major electric repair. perto:::
overhaul or damage.
If equipment has not been in use for a voar or ecre, calibration shall be done prior to first use.
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l 8
NO.*
CE NT.101 REV. O PACE 4 or 16 TITLE:
FR0CEDi'RE FOR VET IERESCENT MAGNE!IO PARTICLE EXAMINATIONS l
GE Nuclear Energy 5.2 Each alternating current electronic yoke shall have lifting power of at i
a least 10 lb. (4.5) KO at the maximum pole spacing that will be used. Yoke spacing is defined as the shorte'st distance between yoke legs at the contact area and shall be frea 3.0" to 6.0" 53 Each direct current or permanent magnetic yoke shall have a lif ting power of at least 40 lb. (18.1) KG at the aa.ximum pole spacing that will be used. Yoke spacing is defined as the shortest distance eetween yoke legs at the contact area and shall be from 3.0* to 6.0*.
5.4 Magnetiring unit ammeters shall be calibrated at least on:e every cuelve
'12) =cnths or af ter each time it has been subjectec to major electrical l
repair, periodic overnaul or damage. The unit's meter reading shall not deviate by more than : lot of full scale, relative to the actual current value as shown by the test meter, r
6.0 T.XAWINATION l
l-6.1 M85netic particle examination provides for the detection of surface and i
sub surface discontinuities in ferromagnetic satarials.
Its sensitivity is greatest for surface discontinuities and diminishes rapidly with increasing sub surface depth of discontinuittes. tiagnetic yokes are to be used only for surface discontinuities.
6.2 It requires that the item under er.anination be appropriately ugnet red l
while finely divided fluorescent ferrosegnatic particles suspended in a
(
liquid medium are applied to the area under examination.
The leakage i
field associated with a discontinuity attracts anc holds these particles forming a visual indication of its locarion ani size.
6.3 Surface to be Exaeined 6.3.1 Minimum examination surface requirements for nuclear power plant components and their integral attachments:
6.3.1.1 Pfeier. Pween and Valves. The examination surf ace requirements for these components shall include the vele and.50* of base metal on both sides of the welds as a miniaun.
6.3.1.2 Re ac ter had.to-Tlanme. The examination surface requirements for this component shall include the vald and 1/2T of base metai from the toe of the veld and all l}
of the base metal between the weld and the stud holes on the flange side of the veld as a rainimwn.
6.3.1.3 Boltier brrer Than 2 0* in Diameter - The examination surface requirements for these components stell ncluce the total surface area of the threads as a ste mum.
l 1
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NO.
CE KT 101 REV. O PACE 5 0F 16 TITI.E :
PROCEDURE FOR UET FLCRESCENT MACNETIC PARTICI.E EXAMINATICNS l
6 3.1.4 Interral Attachments - The examination surface l
requirements for these components shall ine;ude the we;d i
and 1.0* of base metal on both sides of the weld as a l
minimum.
l 6.3.1.5 Heat Exchanner Norrla Welds. The examination surface requirements for this component shall incluce the veld and.50" of base metal on both sides of the weld as a minisua.
I 6.3.1.6 Reacter Coolant Puma Fivwbaal. The examination surface requirements for these components shall include all i
exposed surfaces.
J l
l 6.3.1.7 Remeter Pressure Vassel Sruds The examination surface requirementa for these components shall include all exposed surfaces.
6.3.1.8 Reactor Pressure Vassel Nuts. The examination surface requirements for these components shall include all j
exposed surfacea.
l 6.3.1.9 Raaetor Pressure vessel Skirt Va'.ds The examination surface requirements for these components shall include i
i the weld and 1.0" of base metal en both sides of the weld as a minimum.
6.3.1.10 Remeter Pressure Vassal Velds - The examination surface requirements for this component shall include the weld l
and 1/2T from the toe of the weld where "T" is the thickness of the thicker member being joined.
l 6.4 Process l
l 6.4.1 Parts shall be magnetized in more than one direction. Facilities must be provided for handling and holding the part so that the magnetizing field can be applied in the pector directicn in a l
uniform and controlled manner. Magnetizing shall te accompitshed in one or both of the following ways:
6.4.1.1 By the use of a central conductor. cirealar magnetization.
6.4.1.2 By the use of coils, longitudinal magnetizatten.
1 6.4.2 Surface Praearation 6.4 2.1 The surface of the product being examined may be in th.
as finished condition (Care shall be taken to min:r:re l
abrasion of the parkerized surfaces).
i 9
NO.
CE MT 101 REV. O PACE 6 OF 16 TITLE:
PROCEDURE FOR ET FLORE5 CENT MACNETIC PARTICLE EXAMINATIONS GENuclear Energy
\\
l 6.u.2.2 Prior to zagnetic particle e xamir.a c t o n. tne surface to se examined and any adjacent area within at least 1.0" of the surf ace to be examined. shall be cry and free of any dirt. grease. lint. scale, weldir.5 flux. spatter, cil, or other extraneous matter that would interfere with the I
examination.
6.. 2.3 Cleaning may be accomplished by cetergents, organic solvents. descaling solutions. paint remove rs. vapor degreasing, ultrasonic cleaning er staan cleaning notheds, any other surface conditioning er cleaning (1 e
grinding. flapping etc.) shall be approved by the clien:
l 1
6.5 Circular Marretiration Teebnieue 651 Mar etirarioa *v a central Ceeductor i
i 6.5.1.1 for this technique, a central conductor is used to examine the internal surfaces of ring or cylindrically i
shaped parts. 1he central conductet technique may also be used for examining the outside surfaces of these shapes
- here large diameter cylinders are to be examined, the conductor shall be oosittened close te :re internal surface of the cylincer.
han ene concuctor 14 not centered, the circumference of the cylineer shall be examined in increments and magnetic particle fiele indicator shall be used to detere:ne the extent of the are that may be examined for each conductor position.
Bars, or cables passed through the bore of a cylteder, say be used to induce circular magnetization.
6.5.1.2 Magnetizing Current - Direct or rectified (half-wava 1
rectified or full wave rectified) magnetiring current shall be used.
The required current shall be deter-irec using the following guidelines:
l a)
For parts with outer diancters up to 5* (125 mm).
t 700 to 900 anp/in. of disseter shall be used:
b)
For parts with outer diameters over 5* (125 mm. up to 10" (250 as). 500 to 700 amp /in. of diameter shall be used; i
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For parts with outer diameters over 10* (250 mm) up
{
)
to 15" (380 as). 300 to 500 asp /in. of diameter shall be used.
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d)
For parts with outer diameters over 15" (380 = ).
100 to 330 esp /in of outer diameters shall be use:
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OE MT 101 RIV. O PAGE 7 CT 16 TITLE.
PROCEDL*RE FOR *TT TLORESCENT KACNETIC l
PARTICLE EXAMINATIONS 1
GE Nuclear Energy I
6.5.2 Mazeetization By Direct Centact f.5.2.1 Magnetizing Procedure. For this technique. magne: raticn is accomplished by passing current through the part to be examined. This produces a circular magnetic field that l
1s approximately perpendicular to the direction of current flow in the part.
6.5.2.2 Magnetirins Current. Direct or rectif:ed (half-wave rectified or full-wave rectified) magnetizing current l
shall be used. The required current shall be deter =inet l
using the following guidelines:
j a)
For parts with outer diameters up to 5- (125 mm).
700 to 900 amp /in. of diameter shall be used.
b)
For parts with outer diameters over 5* (125==> up to 10" (250 mm). 500 to 700 amp /in of diameter j
shall be used.
t)
For parts with outer diameters over 10" (250.m).;
i to 15" (380 mm). 300 to 500 amp /in. of diaeeter l
shall be used, d)
For parts with outer diameters over 15- (380 m).
100 to 330 amp /in. of diameter shall be uses.
e)
For parts with geometric shapes other than round.
the greatest cross sectional diagonal in a plane at i
l ri ht angles to the current flow shall determine tne i
inches to be used in the above computations.
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f)
As an alternate, for non cylindrical parts only. the j
magnetizing asperage may be established using the Kagnetic Particle Tield Indicator l
6.5.3 Lorritudical F.arnetization Technicue l
l 6.5.3.1 For this technique, magnetization is accomplishes by I
passing current through a multi-tarn fixed coil (or cables) that is wrapped around the part or section of the part to be examined. This produces a lon5 tudinal L
magnetic field parallel to the axis of the coil. If a fixed, pre-wound coil is used, the part shall be placed near the side of the coil during inspection. This as of special importance when the coil opening is note than te-times the cross sectional area of the part 1
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9 No.
CE MT 101 RIV. O FACE ! Of 16 TITLE:
PROCEDGE FOR '.TET TLCRESCE.NT MACNETIC GENuclear Energy 6 5 3.2 Magnetic Field Strength Direct or rectifted current shall be used to sa5netize parts examtned by this technique. The required field strength shall be calculated based on the length (L) and the dia:eter (0:
of the part in accordance with (a) or (b). below.
Lcng parts shall be examined in sections not to exceed 18-(460 mm), and 18- (460 as) shall be used for the part (L) in calculating the required field strength. For non cylindrical parts. (D) shall be the maximum cross sectional diagonal, a)
Parts with L/D Ratios Equal To or Greater Than 4.
The magnetizing current shall be within : ICt of the ampere-turns value determined as fellows :
35 000 Ampere-curns (L/D) 2
+
Tor example, a part 10" (250 mm) long x 2* (50 ::)
diameter has an L/L ratio of.5 Therefore.
31 29.7 (5 + 2) 5000 Ampere-turns b)
Parts with L/D Ratios Less Than a but Not Less Than 2.
The magneti:ing ampere-turns shall oe witnin :
10% of the ampere-turns value determined as follows 11 G.Q2 Aspere-turns L/D 1
6.5.3.3 Magnetizing Current - The current required to obtain the necessary magnetizing field strength shall be determined by dividing the ampere turns obtained in steps (a) or ib' above by the number of turns in the coil as folievs :
l Asse r e - tu rn s Amperes (Meter Reading) turns For example. if a 5-turn coil is ased and the aspere-tures required are 5000 use:
}Q2Q = 1000 Amperes (
10%)
5 6.5.3.4 Optionally, an electromagnetic yoke may be used to establish a longitudinal field. The. yoke shall be 1
i calibrated in accordance with Paragraph 5.0.
The yoke technique shall only be used to detect discontinuit es that are open to the surface.
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NO.
CE MT 101 REV. O FACE 9 CF 16 TITLE:
PROCEDURE FOR VET FLORESCENT MACNETIL PARTICLE EXAMINATIONS GENuclear Energy 6.6 A magnetic particle field indicator shall be used to establish adequacy of the magne:ic field.
The magnatizing field shall be sufficient to cevelop i
a pa::ecn on the indicator clearly. The field indicatet shall be placed en the surface being examined while applying the requited current and ferromagnetic particles. The production of a pattern of discernible ferrome,tas :c particles indicates an adequate field strer6tn has been generatsc. This confirmation need only be performed on the first ::e= (of each shape) examined during a production shif t.
6.7 Te=perature During Test - Magnetic particle examination shall no: be performed ou parts whosa surface temperature is in excess of 135%F 6.8 Erasinet:en Secuence 6.8 1 For yokes having both AC/DC capabilities, position selector suitch to the desired moca.
6.8.2 Ver fath Technieue i
j a) Position the yoke on the surface to be examined l
t b) Agitate aerosol can to ensure particle suspension, c) Apply current te yoke, d) Apply particles thoroughly over the part to be examir.ed ar.d observe the formation of magnetic particle indicattens.
e) Suicch off current and remove yoke from surface or part.
f) Under adequate lighting conditions as detailed in Paragraph L
i 4.5.2. examine the part for indications.
g) Racord observed indications on the Kagnetic Particle Examinat r.
Report.
6.8.3 Studs 6.8.3.1 Circular Magnetization - Central Condue:or i
a)
Place stud so the serial number is at :ne 12 o'cle:k position.
i b)
I. ort central conductor through s:ud and cor. rec:
)
cau.es to central conductor.
c)
Apply the magnetizing current as determined from Paragraph 6.5.1 and confirm the adequacy of the current per Paragraph 6.6.
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9 NO.
CE-MT 101 REV. O PACE 10 0F 16 TIT:.E.
PROCEDURE FOR VET T1. CRESCENT V.AGNITIC PARTICLE EXAMINATI')NS GENuclear Energy d)
Apply the wet sagnetic particles by spraying or flowing in a uniform manner over the area of interest a!.d observe the formatten of magnet:c particle indications while the current remains on.
e)
Switch off the magnetiting.:urrert.
t t
f)
Under adequate lighting conditions as cetailed by Paragraph 4.5.2, inspect the surface for sognetic particle indications.
g)
Rotate part 90% so that serial nu2ber is at the 2 o' clock or 9 o' clock position.
h)
Repeat operations "c" through "g" 6.S.3.2 f.ongitudinal Magnetization coil Method
'T.en the coil is made of cable wound around the test a) part. the turns shall be insediately adjacent to each other. Normally, these coils will consist cf three to six turns.
b)
Position the coil 6" to 8-from one end of the part To ensure complete inspecticn. successive overlapping shots shall be used.
c)
Apply the magnetizing current as deters ned from I
Paragraph 6.$.3 and confirm the at.equacy of the i
current per Para 5raph 6.6.
t d)
Apply the wet magnetic particias by spraying er flowing in a uniform manner over the area of interest and obsetve the formation of magnetic particle indications while tne current remains on c)
Switch off the magnetiring current.
f)
Under adequate lighting, inspect the surface for magnetic particle indications.
l 6.8.4 Nuts 6.8 4.1 Circular Magnetization - Central Conductor a)
Place the nut so the serial number is at the 12 o' clock position.
b)
Insert central conductor chrough nur and parallel
- s the bere centerline.
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CE-KT.101 REV. O PAGE 11 Of 16 TITLE PROCEOURE FCK VET TMRESCENT MAONET GE Nuclear Energy l
l c)
Apply the magnetizing current as cetermined from Paragraph 6.5.1 and confirm the ac quacy of the I
current per Paragraph 6.6, d)
Apply the wet magnetic part cles by sprayirg or i
flowing in a light, uniform manr.or over the area ci interest and observe the formation of magnetit particle indications while the current remains on e)
Switch off the magnetizing current f)
Under adequate li hting, inspect the surface for 5
magnetic particle indications.
l g)
Rotate part 90% so that serial number is at the 3 o' clock or 9 o' clock position h)
Repeat operations "c" through "g-6 8.6.2 Lon51tudinal Magnetization Coil Methoc (Tigure 1) l 6.8.4.2.1 Outside Diameter Coil Methoc 4)
When the coil is made cf cable wound around ene test part, the turna shall be immediately adjacent to each other. Normally, these coils will consist of three to six turns.
b)
Position the nut so that the serial nu=ber is at the 12 o' clock position.
c)
Position the coil around the axial center of the nut.
d)
Apply the Eagnetizing current as determined from Paragraph 6.5.3 and confirm the adequacy of the current per Paragraph 6.6.
e)
Apply the wet magnetic particles by sprayirs or flowing in a uniform sanner over tne area of interest and observe the formation of magnet;t particle indications while the current r e r.a i r.s on.
I f)
Switch off the magnetizing current i
g)
Under adequate lighting. inspect the outsice diameter surface and both ends for sagret:c particle indications.
h)
Rotate part 180% so that serial numoer is a:
the 6 o' clock position.
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9 NO.
CE MT-101 R Ev. O PACE 12 OP le TITLE:
PROCEDURE FOR *='ET FLCRESCENT d. ACNE!!C GE Nuclear Energy i)
Repeat operations
- c" througn -h*
6.8.4.2.2 Inside Diameter Coil Magnetization a)
Position the nut so the serial nu.mber is at :ha 12 o' clock position, i
b)
Position the coil through the inside clameter of the nut.
Center the coil radially and i
exially with respect to the !.D.
j c)
Apply the magnetiting Outrent as ceterminec from para &raph 6.5.3 and confirm the adequacy of the current per Paragraph 6.6 l
d)
Apply the wet sagtetic particles by spraying er flowing in a uniform manner over :he !.D.
surfaces and observe the forea:icn of magnette particle indications vnile tr.e curren:
reca.ns on.
e)
Switch off the magnett:ing current anc rencve the coil from the nut.
f)
Under adequate lighting, inspect :ce inside diameter for magnetic particle Indications g)
Rotate part 904 so the seris.1 nuseer :s at
{
te 6 o' clock position.
I h)
Repeat operations "c" threugh "g-69 Posteleaning - All surfaces should be cleaned sufficiently te assure al; magnetic particles are removed from the part.
6.10 When residual magnetism in the part could interfere with subsequent processing or usage. the part shall be damagnetized in accoreance wi:n ASKE Section V after completion of the examination.
7 0 RECCFDING 7.1 Record all relevant indications and all examination boundaries inaccessible for examination on the Magnetic Parti:le Examina: ion Rep:r:
form, in accordance with reference Paragraph 2.3.
72 Indications shall be classified as either relevant or non-relevant and shall be evaluated accordingly.
The following definitions shall apply
?-
the review and evaluation:
1
8 k'O.
CE.MT-101 REV. O PAGE 13 CT 16 l
TITLE: PROCILURE FOR VET F1. CRESCENT ".A.ONETIO GENuclear Energy i
I
, 2.1 Relevant Indiestiers. are those indications causec by discontinuities.
If an indication cannot be icentified as either relevant or non relevant, it shall be assumed to be relevant until the indication is either eliminated by surface conditioning or it is re examined by the same or other non. destructive means and demonstrated to be non-relevant. Only those indicatiens exceedi 5 1/16" shall be considered relevant.
722 Nee-relevant Indicatters. are those indications created by design or geometric configuration that have no relation as to the integrity of the part under examination.
73 Provide accurate indication lengths and orientation measurements with regard to v ld centerlina and L or other applicaole benchmarks for all u
the following recordable indicakiens:
7.3.1 Record all single linear indications 1/16* and greater in length detected on compenent surfaces with a nominal wall thickness of i
less than 2.0" l
l 7.3.2 Record all single linear indications 3/16* and greater in lets h detected on component surfaces with a nominal vall thickness of 2.0" and greater.
7.3.3 Record all multiple indications 1/16" and greater in length whien j
i are separated by.50 or less in all components regarclass of l
nominal wall thickness. Provide a sketch with all tecorded j
multiple indications with dimensions.
7.6 All relevant indications shall be evaluated to the appropriate table, as specified by Table It'A.3410 1.
7.5 Indications extending beyond the examination boundaries, or separate indications that lie both within and beyond the examination bouncar es b.t are characterized as single indications shall be recorded with a sketch showing the total length.
7.6 The size of indications extending into a pressure retaining membrane of the component shall be governed by the standard applicable to the pressure retaining component.
7.7 All flaw indications shall be reported to the owner within twenty four hours of final sizing determination, or as required by contract.
7.8 Evaluation and disposition of flaw indications are the responsibility of the Owner.
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9 NO..
GE KT 101 REV. O PAGE 1. OF 16 TITLE-PROCEDURE FOR **ET TLORESCENT.".ACNETIO PARTICLI EXAMINATIONS GE Nuclear Energy
\\
8.0 REPcPTS 81 The format of data sheet exhibits are subjected to change as may be taquired The technical content of data sheets used stall contain as a minimum the following (see Exhibit I).
a)
Project and unit number identification b)
- ld seam or ites identification
- e c)
Examination procedure and revision number d)
Examiner's name and certification level e)
Examination results (including location av.d dimenston of all reportable indications) f)
Equipment make and serial number g)
Yoke spacing used h)
Yoke calibration date i)
Particles, manufacturer's name, color and batch number j)
Examination technique, wet bath, yoke, coil, central conducter, etc.
k)
Thermometer serial number 1)
Component temperature
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40.-
CE MT 101 REV. O PACE 15 0F 16 l
!IT!.E:
PROCEDL*RE FCR '.*ET FLCRESCENT MACNETIC PARTICLE EXAMINATIONS QENuclear Ensrgy 1
I WET MAGNETIC PARTICLE GE Avew twsr EXAMINATION REPORT
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NO..
CE MT.101 REV O PACE 16 CT 16 TITLE:
PROCEDURE TCR '.*ET TLORESIENT MAGNETIO PARTICLE EXAMINATIONS GENuclear Energy i
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IkSIDE DLAMETER MAGNETIC FIELD LON6ffu0lNAL MAGNETRAft0N 00st, METMOD i
FICURE I
i GE-NE-508-008-0492 REV 1 ELECTRICAL DISCHARGE MACHINING PROCEDURE Prepared by Brian D.
Smith General Electric Company Nuclear Energy Division 175 Curtner Avenue San Jose, CA 95125 For Nebraska Public Power District Cooper Nuclear Station P.O.
Box 98 Brownville, NE 68321 April 4, 1992 i
28!9E Approved By:
Date J
Clark r ncipal Engineer E Technology REV. 1 To incorperate NPPD comments.
l 4/29/92 BDS I
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EDM NOTCHING PROCEDURE l
l.0 SCOPE 1.1 This procedure describes the method to be used to I
create electrical discharged machined (EDM) notches, using a sink type EDM unit, on ferrous and nonferrous I
materials.
2.0 PERSONNEL 2.1 Personnel performing IDM notches with this equipment shall be familiar with the users manual.
3.0 EOUIPMENT i
3.1 The EDM Machine is a precision metal removing machine l
tool.
It Utilizes the principle of controlled electrical discharges to dissipate the material to be removed.
3.2 specific applications for this unit are:
- Forming of difficult shapes and contours.
- Cutting hardened tool steel, carbide, and exotic alloys.
]
- Generating micro slots and holes.
- Burr-free production jobs.
l 4.0 PREPARATION l
4.1 Determine the job application.
4.1.1 Verify the type of material to.be notched.
1 4.1.2 Verify specific settings for that material.
4.2 Create conceptual EDM application.
4.2.1 Have a review meeting for the application.
4.2.2 Design electrode head and probe supports as required.
4.2.3 Procure all hardware and accessories required i
for the job.
4.3 Use a sample piece of material that is the same type as the job piece.
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J I
I 4.4 Assemble electrode hardware.
{
4.4.1 Verify that all parts will work for the application.
l 4.4.2 Check fit and form of assemblies.
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4.4.3 Set up to the test piece for fit and function verification.
4.5 Set up and test D.I. Water flow system and water
[
trapping system.
I 4.5.1 Check conductivity of D.I. Water.
Should be.
[
less than 6.0 mS.
t 4.5.2 Insure that all feed lines and drainage lines.
do not create a possible trip hazard or i
interfere with the set-up.
5.0 TEST CUTS l
l 5.1 These cuts should be done to the deepest depth l
required for the specimen, on the sample piece, to-determine the burn ratio of electrode to material.
i 3
{
5.2 Record settings for the test cuts on the Burn Ratio Data Sheet.
j
- Finish Rate
- Cutting Rate
- Power: High, Low 2 or Low I
- Servo Gap
- Pos or Neg switch i
- Auto Flush - on or off
- Electrode material type l
a)
Thickness l
b)
Width j
c)
Height i
5.3 Record the depth results on the Burn Ratio Data Sheet.
5.3.1 After each cut, place the cutting electrode in l
the cut, manually.
5.3.2 Scribe a line at the interface of the electrode and parent material.
5.3.3 Measure the distance from the scribed line to the bottom of the electrode.
5.3.4 This can be done with dial calipers or a microscope with a distance readout installed.
This measurement will be within 1 003 of the actual depth.
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5.3.5 A depth gauge that will fit in the cut (watch for side wall interference) or an impression of the cut may be used for sizing 5.3.6 Continue this process until the depth required is achieved within the specified tolerances.
5.3.7 At that point, record good cut settings.
You can now establish the probe burn ratio.
6.0 JOB CUTS 6.1 Set up the job piece and D.I. Water system and verify all applications are acceptable to the project engineer.
Verify set up is identical to process parameters determined in 5.2.
6.2 Perform cuts.
6.2.1 Record all data on the EDM Data Sheet.
6.2.2 Record time of cut, set up specification; verify that these are identical to values determined in 5.3.
- Finish Rate
- Cutting Rate
- Power: high, low 2 or low
- Servo Gap position
- Pos or Ne3 switch
- Auto Flush; on or off
- Electrode material type
- Thickness of material
- Length of material
- Height of material 6.3 Record the depth results on the EDM Data Sheet.
6.3.1 After each cut, place the cutting electrode in
)
the cut, manually.
6.3.2 Scribe a line at the interface of the electrode and parent material.
6.3.3 Measure the distance from the scribed line to
)
the bottom of the electrode.
This can be done with dial calipers or a microscope with a distance readout installed.
This measurement will be within i of the actual depth.
Note:
Measuring equipment calibrated to NIST traceable standards is required.
All measuring
)
equipment tolerances shall be specified.
6.3.4 A depth gauge that will fit in the cut may be used to check depth.
Be sure that' gauge is not hanging up on the cut sides.
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6.3.5 An impression of the cut may be used for sizing by using the impression under a micro-scope with a distance readout installed.
7.0 CUT IMPRESSIONS
[
7.1 After all cuts are finished and documented, make replicas of each cut with an impression material.
l 7.2 Each of these impressions should be examined on an i
optical comparator.
7.2.1 Record the length of the impression.
l 7.2.2 Cut the impression in half and use'one of the t
cut sections to record the measurements for height and width of the cut.
7.2.3 An extra set of impressions should be.made for review at any required later date.
8.0 APPENDICES l
EDM Data Sheet I
l EDM Probe Burn Ratio Sheet s
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EDM DATA SHEET OPERATOR DATE TECHNICIAN CHARGE NUMBER SPECIMEN TYPE & I.D. NUMBER PROBE DATA PROBE MATERIAL THICKNESS PROBE APPLICATION PROBE FIXTURE:
DIRECT MAGNETIC CHUCK OR EXTENDED FLUSHING FIXTURE (CIRCLE ONE)
FLUSH SET-UP i
APPLICATION:
D.I.
WATER OR CUTTING OIL (CIRCLE ONE) l SYSTEM SET-UP FINISH RATE i
CUTTING RATE i
SERVO GAP POSITION POS / NEG SWITCH -
POSITIVE OR NEGATIVE (CIRCLE ONE)
POWER -
HIGH LOW 2 LOW (CIRCLE ONE) i AUTO FLUSH -
ON OR OFF (CIRCLE ONE) i NOTES i
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l CUT DATA DESIRED DEPTH EDGE DISTANCE SET DISTANCE SET DISTANCE i
RESULTS RECORDED CUT DATA i
)
RECORD NOTCH DEPTH, WIDTH AND LENGTH OF EACH NOTCH.
{
DEPTH WIDTH LENGTH MOTCH 1
2 3
4 5
6 7
8 9
)
10 METHOD OF MEASURMENT RECORDED BY DATE h
L
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EDM PROBE BURN RATIO SHEET l
OPERATOR DATE i
i TECHNICIAN CHARGE NUMBER SPECIMEN TYPE & I.D. NUMBER l
i PROBE MATERIAL THICKNESS FLUSH SET-UP:
D.I.
WATER CUTTING OIL (CIRCLE ONE)
SYSTEM SET-UP:
FINISH RATE CUTTING RATE SERVO GAP POSITION POS / NEG SWITCH -
POSITIVE OR NEGATIVE (CIRCLE ONE)
POWER -
HIGH LOW LOW 2 (CIRCLE ONE)
AUTO FLUSH -
ON OR OFF (CIRCLE ONE) l NOTES 1
I l
l CUT DATA DESIRED DEPTH DEPTH SET ACTUAL DEPTH CUT #
1 2
3 4
5 6
7 8
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10 11 12 METHOD OF MEASUREMENT RECORDED BY DATE N
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l APIENDIX C ULTRASONIC EXAMINATIONS OF A CRACKED RPV STUD AT THE DRESDEN NUCLEAR POWER STATION
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1.0 INTRODUCTION
l During the week of 6/21/92 ultrasonic (UT) examinations were performed on a reactor pressure vessel (RPV) closure stud (# 70) at the Dresden Nuclear Station. This stud had been found to be cracked during a previous outage.
Commonwealth Edision (CECO) personnel had maintained this stud as a l
calibration / qualification standard.
This stud also contains a notch, which l
was used by CECO to verify that cracks, exceeding the size determined to be acceptable to maintain the structural margin, could be detected.
A second stud, which was also reported to be cracked during the same outage, had been j
subjected to destructive metallography and the cracking was verified.
i The purpose of GENE performing examinations of this stud was to provide further qualification of UT techniques, procedures and equipment.
All of these UT techniques, procedures and equipment, with the exception of one bore probe, had been qualified on notches machined into the corroded threads in stud number 14 at Cooper.
That qualification, at Cooper, provided for the disposition of UT indications that had been reported in the Cooper studs i
during the previous outage.
This further qualification on a real crack (rather than on notches) should result in justification for updating field equipment and procedures and for providing direct recommendations to other utilities with regards to the UT examinations of RPV closure studs.
2.0
SUMMARY
l The UT examinations at Dresden on the cracked RPV stud # 70 were performed j
using the GENE SMART 2000 UT Data Acquisition and Analysis System and a special scanner to provide for a completely automated examination.
Examinations were performed with the 600 and 700 shear-wave, bore probes which had been used at Cooper to disposition the UT indications in the Cooper studs i
during the spring of 1992.
In addition examinations were conducted with a developmental 450, shear-wave, bore proba.
This probe contains 3 different transducers, so arranged to obtain time-of-flight-diffraction (TOFD) measurements to determine crack depths.
Data from these examinations were collected and analyzed to determine the extent of the cracking, its through wall dimension and its position within the stud.
All the probes detected the cracking in the stud and a compilation of this data was used in the final i
analysis.
l I
l 3.0 EXAMINATION SYSTEM l
l The same UT system and all of the equipment that was used at Cooper was used l
in performing the examination on stud #70 at Dresden. This included the 600 l
and 700 bore probes.
The 600 bore probe also contains a surface wave transducer for the examination of the surface of the extensiometer hole.
In addition, a 450 time-of-flight bore probe was used and is described below.
I The probe contains two 450 shear-wave transducers, facing each other in a geometric arrangement such that if one of the transducers is pulsed the resulting reflection from the outside surface of the stud can be received by the other transducer.
In addition a 00 straight-beam transducer is spaced half way between the angle beam transducers.
l This probe can be used in a number of combinations.
By assigning and i
calibrating each function on separate channels on the SMART 2000 Data Acquisition System all functions can be performed simultaneously.
That is.
all three transducers can be used in the pulse ~ echo mode on three separate channels while they are also being operated in a transmit / receive (pitch / catch) mode on other channels.
This transmit / receive mode results in l
time-of-flight diffraction (TOFD) capabilities for determining crack depths.
l The transducer arrangement on this probe is shown in figure 1.
I l
4.0 EXAMINATION To perform this examination the stud was placed upright in a stand with the automated scanner mounted at the upper (nut) end of the stud.
Because the original top of the stud had been removed by cutting, length measurements were j
referenced to the ground notch in the threads on the flange end of the stud.
l The area of the notch and cr:ck in the flange end were then scanned with the 450 time of flight bore probe (previously described), the 600 bore probe with the 600 pulse echo transducers and the 880 surface wave transducer and the 700 bore probe with its 700 pulse echo transducers and a 00 straight beam transducer.
l 5.0 RESULTS Scans of the notch and crack area revealed that the crack in stud # 70 has propagated through the stud wall for 1780 of its circumference (see Figure 2).
j Through wall confirmation, that the crack penetrated the inner surface of the extensiometer hole was obtained with the 700 transducers and the surface-wave transducer (which is mounted on the 600 probe).
Cross-sectional plots show that the crack is oriented at about a 230 angle in the stud (see Figure 3),
The UT data also indicates that branching has occurred and that it has multiple facets along it entire length.
All the probes used gave very good data and were able to define the difference between the crack and signal loss from corrosion products and pitting, which existed i
in this stud.
l Figures 4 through 7 provides the UT A-scan responses and the C-scan representations from both the notch and the crack for the 600 and 700 transducers.
I Figure 8 shows the results obtained with the 450 down looking transducer operated in the transmission mode and the 450 up looking transducer operating in the receiver mode.
Note that the notch tip (upper A-scan) is readily detectable while the tip from the crack (lower A-scan) can only be seen along an edge.
This is because the crack is through wall in other areas and there is no tip present to detect.
The A-scan in the middle simply shows the response from threads in an uncracked region.
Also note that in the C-scan complete transmission is lost over the crack indication area (black bands in the C-scan at the bottom of the figure) indicating that the size of the crack exceeds the size of the transmitted sound beam.
Figure 9 shows the response received from the tip of the notch with the 450, down looking transducer operating as the transmitter and the 00 transducer l
operating as the receiver. This shows that TOFD measurements can also be made in this fashion, since the diffracted (or the forward scattering of the beam from the notch tip) beam also propagates in the vertical direction.
l
I Figure 10 provides the response from the notch with the 00 transducer operating in the pulse-echo mode.
Note in the C-scan that the complete back reflection is lost in the area of the crack.
This is because the crack is oriented at an angle and completely blocks the sound beam from reaching the outer (or back) surface in this area.
Figure 12 provides verification with the 450, the M0 and the surface wave I
(mounted on the 600 probe) transducers, that the crac< has propagated through to the surface of the extensiometer hole.
r I
i i
l l
I l
I l
l l
I I
,._.m__
.. ~, _, _.
i I
6.0 CtFLUSIONS l
Based on the results of these examinations, plus the previous qualifications
)
i performed at Cooper, it can be concluded that the UT techniques, procedures and equipment, employed at Cooper for the disposition of previously reported i
UT indications in the Cooper RPV studs, are fully qualified for crack detection and characterization.
In addition, it has been shown that the 700 transducers are superior to the 600 transducers in evaluating indications in corroded threads.
Both the 700 and the surface-wave transducers have been shown to be effective in the detection of surface cracking in the extensiometer hole.
The 450 T0FD bore probe has also been qualified and offers another very useful tool for the evaluation and characterization of cracking in RPV studs.
l I
i 1
i I
l 1
l l
l t
l
( _ _.
i
I l
i I
i f
I i
45 TIME OF FLIGHT PROBE j
i i
r t
t 1
e i
o i
l t
i i
l 4
i I
4 i
I i
i l
i
(
45'looking down
)
i i
j l
j g,
^
i I
45'looking up i
i
[
Figure 1.
45 Time-Of-Flight Bore Probe With A Center 0* Transducer l
I I
e-t-
i i
CRACK AREA PLAN VIEW..
AREA OF CRACK D'
I i
i
)
~ _ _
I
._.C-l n_-
-y_.
l l
)
)
NOTCH
)
l Figure 2.
Circumferential Extent And Depth Of Cracking In The Dresden.RPV.
Stud # 70 j
k J
KmZA m.o a--Ah+Mi+
1
--MLW J-d-
Fu J,,--..si-u
-4 s--
+6-hhe a-2 2h_-:
..p_
w m
a s.,__,
,_m, 4
P h
h i
s l
APPENDIX C 5
ULTRASONIC EXANINATIONS OF A CRACKED RPV STUD i
AT THE DRESDEN NUCLEAR POWER STATION F
i I
' ti I
i i
.t l
l
)
i i
t i
)
f i
s
)
l
)
i t
?
i
,.... ~,.,4 m..
l i
\\
l CROSS SECTION OF NOTCH AND CRACK IN STUD # 70 l
l i
i i
i I
i 54' l
l NOTCH fromtOp of stud A
( Referanco point obtained from l
original report) l i
l 4
2.8"
......_.............. 7.._..._........_
m' GWY l
l Figure 3.
i l
60 UP SCAN
[Q!dse+M2 Ag e.atu Ps+p3 Xail i H Sf T FTil ^x L753'al [!
I Zij 90.
Yp { ~
~4 3.3 99.
notch response yg 33 9 7e.
=
,y, 60.
59.
40.
30.
l !
(' i 28.
.m ts.
._ s t.. A.. )
(
@Idst,OB2 4,60LU-P3+P3
@ J-Xa! 3 64a] Y4.[ 75 206) AXl 71.3t4l 4
)
D
)
,I v]
43.3 90.
n BO.
st 23.s
^
ll h,
! c' indadon response as signa! *velW into the initial pulse.
Wj
-9. 4 s.e.
l 48, 30.
i i
I 20.
I JA.,w%\\.....
s l
@ldssoa2 c, set o p3+P3
@@ x ! a 64aj 4l 7s Ptuj ax[ 71 wlT n
90.i th[
_43.3, 80-'
Thread response away from
%)
33 9 crack
.yj
-, 4 f 'i f
l Se, 40.
i dh4 4 u,_
C.
...n a
c iss6aa2 c, p, eamu ps+ pal xl to 044 16 1 e 03-n
_._ a sa y,g y34 g 4--
inc2 cation area 1
Wf. 367 D4 avl as W
)
Yk
,a#-imi==
g i
)
0 Figure 4.
60 Up-Looking Transducer C-Scan Display And Typical A-Scans From Dresden Stud # 70.
The 3 A-scans Show The Reflections From The Notch The Crack Indication
[
Near The Inside Surface, And From Corroded Threads In An Uncracked
)
Area.
60* DOWN SCAN 3 moas a, e,etc; pe.p2 i g a x=! 7 sei was s40! xL si eselm Wl 2+ 9 5
90.
vl a3 88.1 n
7e I
hirmnnn ww as signal wesa into the inmal pJse.
.v.
68.
,*y
$g, 48.
f '; )
38.
1;\\ {i(
20.
...,a se.
L1
@sseaai a em c pa+p?
l@@ x i 7 haj ml N 640)axl si Pf*J @
s n
mL e+1
)
S
+e.
v1 as 3, n
88.
78
.vi
-i ;
i l8 mponse aruuse along rowen.
n.l.
48.
t 38.
- }L A.
)
20.
1 '*-
x r 7..aimi m aux; si zaai[r]
gss+easa,6mc.ce+w IE r n
- l _
2*:9 Dj 9e.
88.j yni es y 78 l ba pans.*om wrceion.
.v1
-ie
,g 58.
- 48. j
)
- 38. f I\\
,),{
- q
)
C-SCAN REPRESENTATION 3 issbeBi:Cr P, tO D: P2+P2 }
Xa 14th 7.417 AX 5 95_
__e
+[ isTiii v t 2% 11, n
i avj i12 33
)
SIGNAL" WALKED
- FROM BASE TO IP.
m 3
ii$i w es
- o i e eee!
ve i e ee_4 m i im
)
0 Figure 5.
60 Down-Looking Transducer C-Scan Display And Typical A-Scans Of The Crack In The Dresden Stud # 70 As It Is Scanned From The Inside To The Outside Surface
)
Of The Stud.
l l
i i
l l
Appendix D i
l I
i Cooper Stud UT Calibration Standard i
t I
i l
1 l
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i l
I l
1 I
l l
l 1
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l l
l
- l l)!
~
~
3 D
E 1
1 H
1 L
C l
C l
l C
l l
i l
/'-
N N
_ i
/
_. C l
l.
_ lN
[
1_ P.
/
~
0 Y 6 T
\\
\\
/
I
'\\
M S
I B
/
l i
/
l i
C C
T K
I 0
F O
C N
4 O
f i
D E
LD l
C D
i i
B -
I 1
N L -
A1 9,
C 7
2 9
S 3,
DG U
H T #
6 6
6 8
7 7
T D
2 2
2 2
2 2
S D
I 0
0 0
0 0
0 I
W V
P R
A F
B H
3 5
T 2
9 8
1 i
i i
G 4
8 7
4 9
9 N
3 8
6 3
8 8
5 E
L 8
1 H
3 4
0 2
6 2
T P
6 7
5 5
5 5
E 1
0 0
1 0
0 D
5 0
1 H
C T
A D
C D
E F
O N
a0
l r
i CPRSTD1 l
l COOPER RPV HEAD STUB EDM RESULTS i
1 l
Notch A = Desire 155 1 010 Deep x.020 t.010 Wide x
.340 010 Length.
l i
1 Actual:
Verification by:
- 00 Depth QA i
- O Width QA 1
l N8 QA Length 1
Notch B = Des"-a W ;.010 Deep x.020 1 010 Wide x
.290
. 010 Length.
on by:
l A:tual:
Verificati 07 Depth QA Midth
/
Jesire 060 010 Deep ::.020 1 010 de x Notch'C
=
.680 ;.010 Length.
l Actual:
Verification by:
Depth 0 60 QA 4
Width ON QA Length
- 0 78 QA 213 2eep x.020 t.010 ide x l
Notch D = Desire. 14~
+
.240 010 Lengt.*..
Actual:
Verifica n by:
2epth M
QA Width ON
- A Q
L=ngtn WI QA
/
Page i pr2 y
w p
w g
9 y
m-
--g y
I
)
l I
CPRSTD2 l
l I
Notch E = Desire.055 1 010 Deep x.020 1 010. Wide x
)
.390 t.010. Length.
l t
Actual; Verifica 4 n by.
t
.0S%
Qa
+
_r.. ~...
Wi.th
\\
jf Notch F = Desire.055 ;.010 Jeep x.020 1 010 Wide x N
.290
.010 Length.
t
/
t c.c t u a, :
Depth O f8-QA _
)
Uldth
.d27 QA A
Length 86 QA A
7 b'
Date:
//*
/
- A l
)
p rin t. nana
{
8/ A A
si;natur7 T+st Instrunent:
C;;ical ::nparator
)
t Calibratten ID #
28570 i
Last !alibrstion:
9137 I
Calibrstic. Due:
9201 i
All
.easur.n aqu:.;.ent
.s
- r'ibrated and tracable to
)
- I.E.2. standards.
A;l nc :hes r+r teasure : cy replication.
Theses repl:.:ss have been neasured and have been found to be
)
dinensionally accurate.
All dimensions were recorded
-he nearest thousands of an inch.
)
rage 2 1
1 I
.._._..,._..__,,a_--...._._.-.,,~_..._.
LABORATORY TEST NO. O 7ff &
f METALLURGY LABORATORY f
METALL0 GRAPHIC TEST REQUEST Ext. cs;772 Mail Code m
Requestor J. P. CLARK Job Order No. ICGHT Date Submitted 11/a/o1 Date Required 3 7 f g,f oy DRF No.
EWA No.
P.O.No.
W.0.No.
Applicable Specification (s}
Sample Description Cooper vessel stud Check Desired Infomation:
SECT 10NING DIRECTICN MOUNTING MEDIA HARDNESS TEST PHOTOGRAPHY Macro (Rockwell)
Macro
~ Transverse Bakelite 4
~ icro (As Pol.)
M Longitudinal
~ Diallyl Phthalate (Cu)
Micro (KH)
~%nent rl
~ Epoxy
~ Micro (DPH)
~ Micro (Etched) i
[ Progress 1ve
[t.poxy+C23
.esired etchant(s) l desired photograpnic magnifications i
Requestor Exam. before photo number of Polaroid copies DATA REOUIRED Grain size Sensitization Nitride Case Eval.
f ASTM A252 Test Weld Penetration f
Inclusion Count Failure Mode
- Ferrite 0xide Thickness Rolling Direction Eutectic Phase Licuid Penetrant EPR SEM Eval.
Sigma Phase Perform hardness survey to determinett urface hardness of Special/0ther Instructions modified 4130 material l
Sketen or Sample Tabulation-Cooper stud:
Surface hardness with parkerizing removed is R 39.5 ave of 10 readings C
i surface hardness of end is R 34.7 near the I.D. to R 37.5 near the 0.D.
C C
31 ave of 10 readings Reference stud:
Surface hardness with parkerizing removed is RC Surface hardness of end is R 28.3 near de I.D. to 31.3 near the 0.D.
j C
L QA USE ONLY Results transmitted to Wade Miller 10.00 AM Analysis indicates Item (s) is (are):
R acceptable C unacceptable LAB USE ONLY f
Perfomed Byj AsuuaC i
2 Checked By:/n A
/
\\
Date:
(//4~f9f M ur5i----,,
-a
,--=-
anc.accrevec ce-.
- n 1
l 70* UP SCAN 1
i a
i
@ds7032:Ar 70LO: Pi+P1 l@@ &! 17 06Dl Ye( 27.520] aXl 9 926l 5 90.
h[
61.4 m
im BO. g $6.5 j j 70- i k Irdionikn response as signal walks tr$o the inlQi! pube .y 44T i 3 60.t j 975. g, ,; l J ff 40. \\ k k y m% n _ I Q s7002:C, P, 70.U: P1+P1 2 10 8431 1 _dW gl 281 43 4 VW 3e3 22 1 i { aV) ?et 79 u., k am or signes
- u E
76-gds 7032 4,70LU-Pi+P1 l@[ %{ ~4512O} Yel 74 BROj aXj PV7teji ElfE 98- % l.._ 1 4j i OO' l'. 't. Yg] 16.5! 'f, I dl D 6 00af M gyl 18.9: 3 i v.4 60. ] 2; 50, s. 40. Base response not obtarnable dJe (] l to stud length Smitatiort 30, j l ib h ,f ' k% w / v b A , m.,_ t ) bs7032 Cr D,78 U: Pi+P1 4 4 041 X, to 04% $X 67P' i -aa %l181??: 1 Ynl P A ] avl 74 e M ) a m.Iq rem or spal B 76. M ceg t' eic 1/1 1t. 33 1 ri 1ime ) Figure 6. 70 Up-Looking Transducer C-Scans And A-Scans Of Different Areas Of The Crack In The Dresden ) Stud # 70
70
- DOWN SCAN
) l l@@ XnI TM F%e} Ycj 217 600) aXl 103 f:60} i giss7aatAy 78DN P1+P1 wa ve.
- L e35
- x 80.
y w, in6 cation response as signal " walks
- Into irWtial pulse.
) 7e, t syl -16 e 6e. ,, y "W[lj 50. Y 40.! 30.l 4 20. ,.N.J J., ) l@@ x j tu finj r ] 217 sce) axl 1aa mel i igjjds7aat o 7ana ct+at n e r Al_ e35 ,a 9e, ) 89. y ws. 7e ', avl -16.6 response as signal ' walks' through indicaton. se k $i 50-l; % 4e.! l 30,1 ., te. l ) l'Qla Ld, u JJ... .t Se,
- i
, E $= 7aa' a 7ao"- c'* o$ 1[+]Enj xai a > =1x+4le':
- al xtr$4 ~ ! [
) 98.
- L 83A i
80, y u,, i I aYl -ib 6 w.c g.; se. 40. 3e.i - <-- response at tese atirdoation. ) 20. ,l p g 10. i 4 4 -! dlL >b <t. ) @ 5s7001:Cg_P, 703N Pi4 Di Xnl 8 Me) y, l 16 331 33 _e I'- Yp] 180 12; i Ya] 33324} ~ avi e ic i ulM ) N fM M4 x, T . O-n 'M1 g --gy 3; ) Figure 7, 70 Down Looking Transducer C-Scan Display And Typical A-Scans Of The Crack In The Dresden Stud # 70 As It Is Scanned From The Inside To The Outside Surface ) Of The Stud.
45' TIME OF FUGHT PROBE gds 4501 Ar 45D-P.450-R: lg XM 10 000l Tcl 61 Mel AXl 51.t>00l@ m 90, %l Ms0.0 MINA U M N ( m tip responSO M 0e aY, -10eO 60. t i m _. l J m' 59, fl W[zI k fI h 40. 9 % A + f0 S '*; V ,3 - m - sa4 a.4 - ~ -a-i xu wa %i 4=ixisi~ii a 90. ml. i* A 90. nespan tememeoutsm u er pans. M ee 70 m.inaca:ener. l cvl -'ae e 50 50, i y 40,
- 30. i YW _c N%
} w,J ) \\ < a m-,,, -,, e..m,, i ~,es,6 giss4sai a,4so-P 4so-a-j@ xr4[- ia aaalx l se weil xl 48 sesj i r jj
- L. 'ee e au 90.
88-M o e-I i nesponse from atip at tne ed;p 78 4 'P '"P"
- evi -ios e 9
40. I j ) ) fl 30, 2 Sh r JuvJa}&aO C - SCAN REPRESENTATION @dses01 Cr P, lR, XM e.50BlXe 81es Ax 1 657 i l j$$?N f ? W.h Y # ? [
- s '
l s ' ?T.1 D$$$b 1,
- p g
3'*2 3* 1 '~ T g W.2tjliv ': y#. ~ av: 14s 73 w q ."? J f f;l,' ". "'i gg d1.80f;7 ;:S. - -' %af c.? 3 7 '.71lT s... 't .S cat-?.;*;:. :: -... W...'....<,.,
- l. ; }
"l1 {gl'J {.( 'T,, ggg g,g y h:a: ' a y.w%. n n. e 195.14 deg i l' OUt11 1/2 l ti.165h t ri l 1tw Figure 8. 45 TOFD Bore Probe With The Down-Looking Transducer Pulsing And The Up-Looking Transducer Receiving j C-Scan Display Showing Both The Notch And Area Of Cracking In The Dresden Stud i 70. The A-Scans Show The Tip Signals From The ) Notch And From The Edge Of The Crack.
45 DOWN PULSE,0 RECEIVE gsusai.n,4so-o soc,-a. igg vor 7 eoa;y,I s4 n,1.xl er enim R
- 1 83A was 98.
80< Yn! 66 9 N:
- I -' 6
- noeh res;enas a
EM 58. J. p] 40. i [ k k ?)(1416 {%_/ h N f \\ y M ".: L w~ i t gausas.n,4so-o anc,-n-gg xs n sealy i 42amiai s w; a y [l mL_w2 m 98. a'- 80' i YW 0.0 3; throed respome avl -*2 l
- o so, s-40,
" "x QL 1 38. 20<
- k. : \\,,,.
-w-. % ~JJb w p u s i e oee!- v, mi sueell u. 1 im ac e4 as ) bsusai c, p, 13g xni a asj v t s.,8431 xi 7resig e ga g qg gy ,3, 33 a na - 1 '~ YW 16s 15' k .Yl 16 tid E . !g 6,, (-ima:= tion area M 39? 34 Figure 9. 45 T0FDgoreProbeWithThe45 Down-Looking Transducer Pulsing And The 0 Transducer Receiving. ) C-Scan Display And Resulting A-Scans Showing Typical Responses From The Notch Tip And From An Uncracked Area Of The Threads.
1 I l i i i 1 1 0* RADIAL SCAN t 1 i:!s7031:6.orODEG: P2+P2 l@@ Xal to 640]41 24.MOl ax[ 7.3t,0l@ r .j d 33 11 90, ~a 88. f y 23 e 70. 1 I4 Dd -9.5 :' aVj %a 69. i l
- g8 yn.
j b 40. not& response > i 9,h
- p 30.
20. <3. m ei I a 10 ag$ +.-. Y-, ..-P l Y b ~ @!ds7031:Cy P, EEG l@ J-Xn! 3 429} 4j 5471laXl 19W){ $ "~2 , l ,,, c EH W *W 1 v+-
- e, y
14e 44 a ne -
- m.
' N' -- .,7' J. @ '. ? aVi 9G 2 .. : L::.4 "3 ; m ' :;D : '%, ~ N,jid'7'Jm;bO@gl% l } '{-9 g,5l.. g. g.,,,,, g ' t 'r .y ~ 4 @2} > iyN g % N99; g i;GQ7 q_ & Q,. q' - <(& &} + - p ~ tlr9NlNOS \\ w. s s a um x,.. ..nW,/,... nm;';cg. n i 4 y .p -,,7
- M.k [',[
JNkY 'J N .: gg, 4 ? ^5f,, b%~Cif, YfkNhe.Yb f. =....,...... ,g h, o _x j ~ ,g 1% me a v,. w..., ., g,. s. a.7 g
- )..U, W2r
.,, /, b 7 5... g3t > n.) p r%,. v,, gg, n~ e .... c,,g-wu ,c.e.e .14+_"' ' ~'"LMA?0$i43-MZ7.'.P 378.56 OPQ l 0OW 'J d l
- 8. itbli 1 ri l
T irre Figure 10. 45 T0FD Probe With The 0 Operating In The Pulse Echo Mode. C-Scan Of The Dresden Stud # 70 And The Resulting A-Scan From The Area Of The Notch.
SIGNAL RESPONSE FROM THE INDICATION AT THE EXTENSIOMETER HOLE (THROUGH WALL) WITH THE 45' TOF PROBE AND THE 70* AND 88* TRANSDUCERS 86* SCAN BorMiat 4y 88-PHP3 l$@ Xni 64 60) >*cf1E975) aXl 54 400l 1 f 4l 83;5j 96. p. u .6., ( RBSPOTMIS frQTR the 1.h 411hD Surface aYl -166; E Of the extenslomertar hCde 50 l)[ }l I r j'Q 40. e t 3e. '..h:; 20. l 'h 10. A %., h s u. .s. ..A s s.n u_ _,.. 70*up scan giss7032: Ar 70LU: Pi+P1 l@@ Xnl 54 403) Yel 188 800] aXl 54.4f*}@ f M 91 q 90. 80' 33 I
- (
sesponse from indication watdng into the hitial pulse s' 4 aY -33.0 y;m
- 69. 1 W T 50.
%{. j 49. l ~ 30. I f se e J t 0 00 1/1 163. ps Time Ar: '6377 45' t.o.f. scan grssesat:n,4so-o.asu-a: 1[i, x l 34 wa] re} es ocel ax[ 34 oois!, m 90. eil; se ) g u., ) i 'Y; -16 6: I - lad of response due toinckstion i se. 40. ,m ~ 30. te, h ) o scan representation of 45' t.o.f. scan i s 4rs s o$6 gys c, o, l , of?sc.c,tc, 297 oc> E.,cgil 1 x7 12' \\ $ NiiS5:?f "Y 70
- l eehMr ut t
- 2%
l $M36 -~d i %21:+ l amm 372 3 S 'E l l Figure ll. VerificationThatTheCrack}nTgeDresdegStud#70IsThrough Wall By Data Obtained With 45, 70, And 88 Transducers i f
) Appendix E ) Personnel Certifications ) ) ) ) i i ) r
1 $$$$$Id[$d$E@$l$$$$$d$ bd C3RT::F::Cf3 07 Q"JLZCATON lDi!1 p :#y f+ $ \\ i,y i 1$ s l%9P jij THIS IS TO CERTIFY THAT PAUL S. ANDERSON IS QUAIJFIED IN ACCORDANCE M7TH THE f f b GE/NPSD ADEEDMIAATION & CERTlflCATION g,,f N N'f'i PROCEDURE FQP-03 THICHISIN COMPIJANCE RTTH THE REQUIRDIENTS OF 1* AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING RECOMMENDED PRACTICE. i .x >-4 a cenezrzearzow. xxeznz ru=== vaans rnos emnerrzearrow on. e. h i M D.i 7{ LIQUID PENETRANT TESTING LEVEL II i Bc .ur _ s.,. o, g CERTIFICATION DATE (02-15-92) ligy y tiAGNETIC PARTICLE TESTING g%g'lgg",j LEVEL I
- 6.,'((!}p u.r.
s,.o
- CERTIFICATION DATE ff;kh[ld (02-15-92)
'" 4 RADIOGRAPHIC TESTING LEVEL imour _ 1,.o iin ,a k ( CERTIFICATION DATE pfA j 38,#I li S ULTRASONIC TESTING. c .u.a. - to o, LEVEL II .h*
- CdtTIFICATION DATE 2'.T'h I
dij; VISUAL TESTING (VT-1) (02-15-92) .r e a s, z xx, LEVEL I [?,* a
- CERTIFICATION DATE VISUAL TESTING (VT-2)
(02-15-92 hg' 1 ,.e xz3 LE EL
- CERTIFICATION DATE N/A i
p,$ VISUAL TESTING (VT-3) 3 pkg%
- CERTIFICATION DATE N/A k* h
...,,,x xx, LEVEL f*
- y.h l
VISUAL TESTING (VT-4) LEVEL Ij ,h g3
- CERTIFICATION DATE N/A h eh
,m n= xz, h+g ! gifjlh W4-xtl ADDITIONAL REQUIREMENTS OR LIMITATIONS: h i a ,.e % ed .(.r 4 4 EPRI Manual Detection 01/10/92, Spec. 01/08/92 l Wi Systen Detection (ONLY) 06/15/90 L
- 1. @
Manual Overlay 02/13/92, Spec. 02/10/92 bNI I 2%fd " b. .e>4** System 2000 Detection / Analysis 01/31/92 ~ t u I f a,. t n e > g / glg ev. M um m tx6ss 1.a eu &mun issua-s pgl sAw:cmmcam nn k w ex.pm mn w=meewyE emtse:w.m.e n e ssaw w w b8.9> g o -w esw swo sww=w:m;w=w.u=sts m w w= m. w mm. -
~ r DATE: November xx, 1991 RS/91-TO: Don Yoder FROM: Rich Skalski l
SUBJECT:
Training For Ultrasonic Examination of RPV Studs i Cooper Nuclear Station f The following individuals have received 5 hours training in the use of 60 degree Shear and 88 degree Surface Wave Bore Probe Techniques i i Paul Anderson Jeff Kieffer l Kathy Ellis Vic Krueger L Mark Evich Judy Dusley C. E. Frakes Larry Vice Kent Gebetsberger Bobbi Kieffer ~ t GE-UT-307, Rev. O Procedure for Ultrasonic Examination of RPV Closure Studs, FRR-NPPD-91-16, and FRR-NPPD-91-35 was used to conduct the training. l This training consisted of a demonstration and practice detecting the known notches on the ID and OD of Cooper Nuclear Station Calibration Block 'CNS-116. These techniques included echo dynamics, signal repeatability, verification utilizing a I ) positive and negative response from a Megasonics 5 MHZ 60. degree Shear Wave l Transducer to verify the
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surface notches. The 88 degree Surface Wave l Transducer was utilized to verify the ID surface notch of Stud Calibration ~ Block. All individuals were instructed in the proper scanning techniques and proper l indexing of the probe while using the centering device. The training also covered the enhanced stud end technique using a 5 MHZ and 10 MHZ transducer. 7 ) Instructor: M8
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) Mike Heath Date, I t
GENERAL ELECTRIC CD TEL No. . 4 08 92531. 4_4 M_a,.y... 0. 6,,. 9. 2.... 8.. :.4. 4 P.02 ) TRAINING AND QUALIFICATION RECORDS ) PROCEDURE FOR ULTRA 50NIC EXAN1 NATION l RPV CLOSURE STUDS This is to certified that the following personnel have been trained and demonstrated practical proficiency in accordance with the General Electric ) Test Procedure TP-527-1509 Rev. 1: " Automated Ultrasonic Procedure for the Evaluation of Manually Detected Ultrasonic Indications in RPV Closure Studs" l and are qualified to perform this examinations. As a minimum, training included Smart 2000 operation, scanner setup, motor control setup, data collection, and data analysis. This training also included practice on the Cooper Nuclear Station Calibration Standard No.116. ) Training were performed at the GENE NDE Development Lab. in San Jose and in i Vallecito. I I NAME PROCEDURE HOURS COMPLETED ) Robert W. Anderson Above 40 Apr. 24, 1992. 1 Paul Anderson Above 40 Apr. 24, 1992. ) l 1 ) i P i ,1 1 1 ) Qualified by o l N,% 5 v- < 55 4'L. e1 ) k b James C.S. Tung (Level III) ,/ Sr. Engr., NDE Development fi w ) 4 a I ,) i , _. -~ _..
1 l i APPENDIX F i 1 i i Transducer Certifications i ) J l l I i i
ULTRAS 0: llc TRA:lSDUCER AilALYSIS i i I REFLECTOR TRA!1SDUCER 1.0" Thick Flat Plate. SERIAL NO: B 10 9 b O oia. steel sail. SERIES: Beve. Pel,e a i" Rachus FBH. FREQUENCY: EO MHz at Inch Water Path. SIZE: EN Dia. 70CUs: [>0 E U Widnch 1 4 5 WAVE FORM a FREQUENCY SPECTR bESNhd - N . 5..... FREQUENCY: ME MHz i j, BANDWIDTH: 2sM MHz s E RFfE R ElIN i b ~~ j S f,t h h : k / S i 7F 1. vertical Sensitivity /Div. I \\ D 2. Horizontal Sensitivity /Div. ' i\\'kh,T!.'.9Ilf }... sPECTRLiM ANALYZER SETTINGS: j ( ~ E-A MMMM ' ' ~ " 3. Scan Width /Div. I i Inp t untion 6. Resolution ___l i 6 3 2 1 The above data has been obtained with Megasonics Ultrasonic Transducer Analyzer, MUTA, Tektronix 7704A Main Frame with 7L12 Spectrum Analyzer, 7B92A I Dual Time Base, 7A18 Dual Trace Amplifier. 1 i, /0~30~7[ DATE: I l M E C K 4*]DI[eMll 'fMl:l="fo --[db BY: --r f L7R A S ONIC TRANSDUCERS (2031966-3404 i 4 i
} ULTRAS 0: llc TRA:lSDUCER A?1ALYSIS i l l REFLECTOR TRAilSDUCER 1 @ I.0" Thick Flat NCC (l Plate. SERIAL NO: 6lD N O _.__0ia. Steel sa11. l SERIES: E en Pmt,e 1 O FBH. FREQUENCY: 3.O MHz at. i Inch Water Path. SIZE: E D' l Dia. ) FOCUS: _ 39 5 94ce.Imw 1 4 5 l M aggg<g3 i E WAVE FORli a FREQUE!1CY S I BANDWIDTH: /. E MHz l OSCILLOSCOPE SETTINGS: y 7 m; 1. Vertical Sensitivity /Div. j 2. I Horizontal Sensitivity /Div. g j[ SPECTRUM ANALYZER SETTINCS: ) ~ " 3. Scan Width /Div. 5 e t ation 6. Resolution ) 6 3 2 The above data has been obtained with Megasonics Ultrasonic Transducer Analyzer, MUTA, Tektronix Dual Time Base,7704A Main Frame with 7L12 Spectrum Analyzer, 7B92A 7A18 Dual Trace Amplifier. DATE: /o-3d-9/ M E El M*R1[eMI
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/ BY: Wb l LTR AS ONIC TRANSDUCERS Q (203)956 3404 )
1 .~ F_C,AEDiCC3,;;C r;:,:. 203. 66 *I"'8 .i. w: e.. p,. i ygl{g 205 Benedict Hill Road Tel (203) 966-3404 ew a aan, G 06S40 h (203) EM8 u t.TR ASONIC TRANSDUCERS I FAX TRANSMITTAL FORM TO: b-ATTis: MM b"$ s FROM: eo DATE: [ l~ f S
REFERENCE:
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4 A AYA STAVELEY .AYAYA SENSORSINC A Subsidiary of Staveley NDT Technologics Inc HAR;SCn!C REEEARCH CENTER \\ i l l k h E, d)m b,,_ h,v e rd V Purchase Order No. 2 0 h72 (y $69 customer: )/ Transducer Type: /l8-7_Zl7 Frequency: [m#L Serial No. $10 2-7 h J Center Frequency: k'7 /hM Z h Diameter:.k3fN% Focus: Element Energy Level: 1 Test Material: 30.3 SS,E k /375'*g,O, Damping: 340O-Attenuation 30-T dB Gain 40 dB olt s /div. ,C5 H.P. Filter: / ft //2. Time Base . 7-u sec. Reference Gain: Test Equipment: Panametrics 5052 UA Pulcer; Hewlett Packard 8557A Spectrum Analyzer ) w .-y,. . :,.,,, w. [ "f.. l~' Q...,. k.."- % Q ,' Ne 1 :,q,, . b;. "*.t W. 4 e . i;;; !D '. Np'. b.- 4 9 ci _ _ .L (; ? ' & y...gs ; w ) .) sa.9 +- .5 ' ~~
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APPENDIX F Transducer Certifications l l I j a 1 I 1 I i l l
l ULTRAS 0: llc TRA:!SDUCER AilALYSIS \\ l REFLECTOR 1 TRA!1SDUCER C 1.0" Thick Flat Plate. SERIA'. NO: b lO N Dia. Steel Ball. SERIES: _ 8c nt P4 DS FBH. FREQUENCY:
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Inch Water Path. SIZE: _ 2W Dia. i FOCUS: _ so S Feedinen 1 4 5 EM < E2 WAVE FORii a FREQUENCY SPEC I BANDWIDTH: 2-. M MHz 5 2E h,3 J 1. Vertical Sensitivity /Div. j 2. Horizontal Sensitivity /Div. ~ SPECTRUM ANALYZER SETTINGS: MEM 3. Scan Width /Div. In t tt ation - ar 6. Resolution 6 3 2 l The above data has been obtained with Megasonics Ultrasonic Transducer Analyzer, MUTA, Tektronix i { 7704A Main Frame with 7L12 Spectrum Analyzer, 7392A Dual Time Base, 7A18 Dual Trace Amplifier. ) i DATE: /O -3d - T [ i i MEI:K4*)Di[aL1 2ofc;;ll== N BY: a j TRASONIC TRANSDUCERS (203)966 3404 i i 3 i'
_PPENDIX G A RESOLUTION OF THE INITIAL UT INDICATION DETECTED IN COOPER STUD # 26 i 1 i i l l l l I l i i l l I l l \\ l
Backcround On 10/9/91, an ultrasonic (UT) examination of 35 of the RPV studs at the Cooper Nuclear Station was performed. The examination was performed in l accordance with Section XI of the ASME B&PV Code and augmented by GENE recommendations in RICSIL Number 055, Revision 1. The UT examination technique that was used was a straight beam (00 L wave) with a 1 inch diameter 2.25 MHz. transducer, where the transducer is placed on the top of the stud. The sound beam generated by that transducer then travels the full length of the stud and is reflected at the bottom end of the stud, back to the same transducer. The purpose is to detect circumferentially oriented cracking anywhere along the length of the stud. A large indication was detected in 1 of the 35 studs examined, stud # 26. The data from this indication is shown in Attachment 1. Several examiners witnessed the indication and it was verified by the Level III, who showed ii; to the Project Manager, a representative from the Cooper Station, and the Authorized Nuclear Inspector (ANI). The cavity above the reactor was then filled with water, so that other outage work could be performed. This delayed further evaluation of the indication until the water level was again lowered. This took several weeks. When the cavity was drained, an attempt to verify the indication was not successful. Several examiners tried to verify the indication, including the examiner who initially detected it. The same transducer used initially was also tried, without success. The one item that could not be re-tried was the UT instrument, because it had been dropped and damaged during the period when the reactor cavity was flooded. That instrument was a Krautkramer/Branson Model USK-7, which is a battery operated, portable UT instrument. References 1 & 2 describe extensive work performed at the Vallecitos Nuclear Center (VNC) on stud # 26, which clearly shows that stud # 26 was not cracked. This then leads to the conclusion that the initial UT indication detected was a false, or a so called " phantom indication". The purpose of this appendix therefore, is to determine the probable cause of such a " phantom indication". s
Possible Causes Of The Phantom Indication One of the first thoughts, after it was found that the indication could not be verified, was that during the period that the reactor cavity was flooded, the crack had filled with water and had become transparent to sound. That would be very unlikely, and in fact it is believed that a large reflection would still be detected even with the crack full of water. It was known that this was not so, since it has been proven that there was no crack. Another possibility is operator error. This has been ruled out, since more than one operator, including the Level III verified the indication, and also I was witnessed by the Cooper representative and the ANI. l Still another variable is the transducer. However, the same transducer used to initially detect the indication was tried and the indication could not be verified with it. The transducer functioned normally during both the i calibration (pre and post exam) and the re-examination including (calibrations). Therefore, it is very unlikely that the transducer was at f aul t. This then makes the one item that could not be re-tried, the Krautkramer/Branson USK-7, portable UT instrument, highly suspect in causing the so called phantom indication. This particular instrument has an automatic pulse repetition rate (PRR) control. One of the things that can happen, if the PRR is to high, when examining thick or long metal components, is that the l sweep on the oscilloscope of the UT instrument may repeat itself, overlaying the initial sweep. This is sometimes referred to as " screen wrap around" and can result in phantom indications anywhere along the area of interest. This phenomena can be affected by the UT frequency, the metal path through which the sound travels, (in this case 8 feet of steel, including the round trip), the sweep range, the gain, the amplitude of reflections and of course by the PRR. Therefore, if the automatic PRR of the USK-7 was operating at too high a frequency, phantom indications might be expected. This type of phenomena is conservative in that it can result in false calls. due to the phantom indications. but would not prevent the detection of real cracks. l
l Work Performed To Evaluate The Effects of the PRR on Stud Inspections I t l l Work was performed in the GENE Nondestructive Examination Development l Laboratory to show the effect that the PRR can have on a stud examination. l 1 The experiments were conducted on a BWR/6 stud that was readily available. This stud is slightly longer than the Cooper studs (55 inches vs. 48 inches). However, this 7 inch difference in length only makes it easier to demonstrate the effect, since it means the sound beam has to travel 14 more inches on the round trip. A 1 inch diameter, 2.25 MHz. transducer was used in all cases since this is i the same type of transducer that was used at the site when the phantom indications were first detected. Three UT instruments were selected to perform the experiments since they all have variable PRR controls. The first two instruments included a Sperry Immerscope, Model 725 and a Krautkramer/ Branson, Model USM 35. Both of these instruments have a PRR which is variable in discrete steps. The third instrument was a Branson Sonoray, Model 600, which has a continuously variable PRR from about 55 Hz. to 831 Hz., as j measured with a LeCroy digital oscilloscope. 1 i The stud was then examined with all three instruments and the PRR was varied to demonstrate the effect. That effect is shown in attachment 2 (3 pages). At the lowest PRR for the Sperry Immerscope 725(125 Hz.) and the Krautkramer/ Branson USM35 (250 Hz.) normal back reflections were obtained from the stud, with no phantom indications. However, in both cases, wnen the frequency was increased, just one step to 500 Hz., the screen wrap around started to occur, and phantom indications were observed. In both cases, as the PRR was further l increased, more and higher amplitude phantom indications started to appear. l l
The Branson Sonoray 600 was then tried. The PRR was adjusted to the point just refere low level phantom indications were observed. That PRR was 139 Hz. The PR3 was then adjusted to 303.5 Hz. to simulate what may have been observed on stuC.* 26. That is, a high amplitude phantom indication located at about 13 inches from the top of the stud. It was then further adjusted to show that variations in the PRR could cause the phantom indications to appear to be located anywhere along the length of the stud. This only required an increase in the PRR to 337.5 Hz. Therefore, it has been shown that very slight changes in the PRR can have a large effect on the phantom indications over this long of a metal path. 1he examin= tion data sheets, in attachment 1, do not mention a loss of back reflection in the indication area of stud # 26, however the Level III later reported that it did occur. This being the case, the questions that to be answered are: 1) if the phantom indication was caused by a variation in the automatic PRR, then why was it not observed on the other 34 studs, and 2) why was there apparently no back reflection on stud # 26? These questions are more difficult to answer. However, the answer to the first question could be related to the amp 111tude of the back reflections, which can be related to how well the sound is coupled into the stud or to a number of other factors. In addition, studs do tend to act as a wave guide, and mode conversion can take place as the sound beam tries to spread and is reflected off of the sides of the stud. This could result in a shear wave, which could move the back reflection still farther out in time, such that it night not be observed on the scope. This apparent longer metal path could also aggravate the PRR problem. This of course could be influenced by the amount and location of corrosion on the sides of the stud. Another possibility is that as the PRR varied on this stud it caused a slight shift in the sweep delay (which sometimes happens with changes in the PRR, depending on the instrument). This then could move the back reflection slightly off the scope, such that it would not be observed. \\
Conclusions I. Since other variables, such as operator error and problems with the ) transducer have been shown to not be the cause of the phantom indication, then the instrument used has to be highly suspect.
- 2. It has been shown that problems with the instrument's automatic PRR could result in phantom indications such, as was detected on stud i 26.
- 3. There could be a number of other factors, such as mode conversion, a shift in the sweep delay due to the higher PRR, the amount of corrosion on the j
sides of the stud, and the coupling of sound into the stud, which contributed to the problem. It is impossible at this point to isolate those factors since the. instrument was damaged and since stud i 26 has been sectioned. )
- 4. Based on these facts, and the data presented in this appendix, it can be concluded that the cause of the phantom indication in stud i 26 is related to a problem with the instrument's PRR, plus possible other factors such as those mentioned above.
- 5. It can also be concluded that a Droblem of this tYDe is a Conservative problem. since it would only occur on boltina with lono metal paths and could result in _ false calls but would still be effective in the detection
) of any real flaws. Therefore. the effectiveness of the'use of this instrument on other comDonents (such as DiDinQ Welds 1 durinQ the outaQ9 is not in cuestion. ) ) )
t I l 1 l i Initial UT Data For Cooper Stud # 26 l I l l ) l ) ) )
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.. - Effects of the Pulse Repetition rate on RPV Stud UT Examinations
EFFECT OF THE PULSE REPETITION RATE (PRR) ON RPV STuo UT EXAMINATIONS USING A SPERRY IMMERSCOPE MODEL 725 b i ~ {j-Ii ~ ' ~ PRR=125Hz., Norma [iackEcitoes PRR=500hz.,ials'eIidications ~ ~ ' ~ ~ ~ ~ ~ y D i 1 i ~ l s ) PRR = 1250 Hz., False Indications PRR = 2500 Hz., False Indications This instrument has a PRR control that is adjustable in steps with a switch.
) EFFECT OF THE PULSE REPETITION RATE (PRRl DN RPV STuo UT EXAMINATIONS USING A KRAUTKRAMER/BRANSON MoDEL USM35 ) o ] i ) ~ ) _a_.[. A nat PliR = 250 Hz., Normal Back Echoes PRR = 500 Hz., False Indications l ) ) ) l l l4 \\ ~ -A n IJ Li .-__ _ A 1 8. A db ) PRR = 1000 Hz., False Indications PRR = 2000 Hz., False Indications This instrument has a PRR control that is adjustable in steps with a switch. )
EFFECT OF THE PULSE REPETITION RATE (PRR) ON RPV STuo UT EXAMINATIONS USING A BRANSON SONORAY MODEL 600 y ~ w n t i' l.- . mL m k- - - - - - mm I t ~ PRR = 139 Hz., Normal Back Echoes PRR = 303.5 Hz. False Indications Near Top of the Stud I i i 1 . J. a du. n a. _ _ _=. _.. :.u a PRR = 321.5 Hz., False Indications PRR = 337.5 Hz. False Indications Hear Center of the Stud Hear Bottom of the Stud This instrument has a PRR that is continually variable from 54.5 to 831.3 Hz. The control is by a potentiometer. The frequency was determined with a Lacroy digital oscilloscope. L____
APPENDIX H GENE's SMART 2000 ULTRASONIC DATA ACOUISITION AND ANALYSIS SYSTEM ( b _________m
GENE SMART 2000 The GENE SMART 2000 ultrasonic data acquisition and analysis system includes a motor controller, a position monitor and four (4) digital pulser / receiver channels. The motor controller permits control of two axes: two stepping-motors and encoders or two servo-motort and encoders..The entire. system is computer controlled, operating with an open UNIX based architetture, built around the high performance microprocessor,.the 32-bit 68030 with VME bus. The system digitizes all raw incoming P/F waveform and/or video A-Scan-presentations along with the appropriate X-Y positional information which can be from internal or external motor controller. This data is stored in a 64 megabyte RAM buffer and can be archived by an 800 megabyte optical disk for off line data analysis and for subsequent examination comparison. The system can perform multi-task functions. The main focus is on.the visual aspect, the " window principle" which has been employed so successfully.in many user friendly personal computers. Eth several windows,. different types of information such as A-Scan, B-Scan, C-Scan, UT parameters, Motor Control... etc. can be imaged on one color monitor. The system is controlled via the. console and screen. During off-line data analysis and review mode, C-scan : image can be reconstructed, for any area within the digitized zone, to display either depth, time of flight, or amplitude view. Additionally,. since 'all of - the raw UT data, regardless of amplitude has been recorded, the operator can adjust the amplitude threshold between 0 to 100% of full screen height, as well as the gate length, for the reconstruction of the C-Scan display. As a further evaluation tool,- the cross-sectional images (B-Scan) can be dis' played - to aid data analysis. Color coded hard copy prints of all.of these images can be made for use in the evaluation reports.
REFERENCES 1. GENE REPORT, " COOPER AUTOMATED REACTOR STUD EXAMINATION" Robert W. Anderson, November 1991 2. GENE REPORT NO. 689-007-1291. " COOPER REACTOR PRESSURE VESSEL CLOSURE STUD METALLURGICAL EVALUATION" Brian F. Frew, December 1991 3. GENE RICSIL NO. 055, REVISION 1. INCLUDING SUPPLENENT 1, "RPV HEAD STUD CRACKING" Technical Sources, J. P. Clark, J. G. Erbes, March 26, 1992 4. SECTION XI 0F THE ASME BOILER AND PRESSURE VESSEL CODE, 1989 EDITION 5. GENE FIELD QUALITY PROCEDURE, FQP-03, " PROCEDURE FOR QUALIFICATION AND CERTIFICATION OF NONDESTRUCTIVE EXAMINATION PERSONNEL" 6. " COMPUTERIZED UT SYSTEM FOR STUD BOLT - IMPROVEMENT OF ULTRASONIC INSPECTION TECHNIQUE", T. Kisanuki, K. Uchida of Keihin Product Operations, Yokahama, Japan and T. Fushimi, K. Onda of Chuba Electric Power Company, Inc., Nagoya, Japan, Presented At The 9th International Conference On Hondestructive Evaluation In The Nuclear Industry, Tokyo, Japan, April 1988
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