ML20064F126

Acoustic Emission Insp of Reactor Coolant Pump Motor Flywheel

ML20064F126
Person / Time
Site:	Arkansas Nuclear
Issue date:	12/09/1982
From:	ARKANSAS POWER & LIGHT CO.
To:
Shared Package
ML20064F116	List: 1CAN128210, Forwards Acoustic Emision Insp of Reactor Coolant Pump Motor Flywheel, Per 820914 Request ML20064F126
References
APL-82-01, APL-82-1, NUDOCS 8301060257
Download: ML20064F126 (41)

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TEST PROCEDURE APL-82-01

" ACOUSTIC EMISSION INSPECTION OF THE REACTOR COOLANT PUMP MOTOR FLYWHEEL" Prepared by:

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Approved by:

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l REV:

DATE:

APPROVED BY:

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8301060257 821223 PDR ADOCK 05000313 o

PDR HAFA FORM 110 a

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INDEX 1.0 SCOPE

2.0 REFERENCES

3.0 PREREQUISITES 3.1 Test Personnel 3.2 Equipment Required 3.3 Temporary Site Facilities 4.0 PREPARATION 5.0 PRECAUTIONS 6.0 PROCEDURE 7.0 TEST REPORT APPENDICES A.

AEI-82-154 (Test Procedure)

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B.

Equipment Checklist l

C.

Temperature Sensor Location D.

Ileater Assembly Position 6 Sequence E.

Data Sheet F.

Removal of Sensor Fixtures b.

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1.0 SCOPE Q. C.

Verification g,

This procedure when used in conjunction with AEI Procedure 82-154 (Appendix A) shall govern the volumetric examinaticn by acoustic emis-sion of the Reactor Coolant Pump Motor Flywheels.

This procedure deals with the application of thermal stress to the flywheel while it is monitored for acoustic emissions.

NOTE: Each flywheel is tested in two axes. Test "A" is conducted by heating two spokes which are selected for texture mainly to accommodate attachment of temperature sensors and heater assemblies. When Test "A" is complete and equipment is removed the flywheel is rotated 90 CW or CCW to the two adjacent spokes and the process repeated as Test "B".

2.0 REFERENCES

Nuclear Regulator Guide 1.14 (9/75) 25 modified by 2.1 Code of Federal Regulations - 10 paragraph 50.55a, subpara-graphs (a)(2)(i) 6 (ii) 2.2 ASME Section XI paragraph IWA 2240 and the guidelines of IWA-6000 3.0 PREREQUISITIES 3.1 Test Personnel Personnel performing this portion (stress application) of the test shall be qualified to Level II in accordance with the HAFA Certification Procedure and ANSI N45.2.6 guidelines.

3.2 Equipment Required a.

Heater Assemblies w/ Lanyards b.

Clamps w/ Lanyards c.

Temperature Sensors (prenumbered and wired to recorder) d.

Power Supplies c.

Strip Chart Temperature Recorder f.

Spa res g.

Adhesives and Tools necessary for mounting Sensors and making Equipment Modifications or Adjustments y-

3. 3 Temporary Site Facilities a.

Temporary scaffolding allowing access to all upper fly-j-

wheel inspection ports l

b.

Scaffolding or brackets to support power supplies and l

instrumentation in the vicinity of the East access port l

c.

Temporary 120 VAC, 30 AMP, 60Hz power at the test location for two power supply units and 5 AMP outlets for recorder and work light d.

Craft support to remove and stow access port covers and to position flywheel (rotate as required) for test NOTE: See AEI-82-154 for modifications and additional requirements BAFA FORM 110

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2 4 19 82 Page: 4 of 8 4.0 PREPARATION The following measures whall be taken prior to entering containment.

4.1 The strip chart recorder shall be adjusted to the chart paper for 0 C & 100 C ensuring that all temperature sensors including spares are. reading within a 30C band.

Chart paper used will have a range of 00 through 3000 and will have reference numbers placed along one edge to permit reference notations without writing directly on the chart.

4.2 The recorder shall be set to record only those channels in use with one channel recorded each 10 seconds at a chart speed of.25 inches /

minute. With all controls in position unplug unit and place in clear plastic bag front end first. Seal bag around unit leaving back of unit accessible thorugh open end of bag.

Bag is normally closed except to replace sensors.

Power cord and sensors shall be left protruding when bag is sealed.

NOTE: Once in containment, the recorder will be operated by plugging or unplugging power cord. Plastic bag must bc transparent and positioned to permit reading of the strip chart.

4.3 Power supplies shall be similarly bagged with power cord and connection plugs protruding. Prior to bagging switches will be placed in "0FF" position and adjustment knobs lef t in desired operating position.

Switch and minor knob adjustments can be made through the loose fitting bag.

4.4 Multimeter shall be bagged with Amp-Clamp or voltage probes protruding.

Operation while in bag presents no problem.

Battery shall be fully charged.

4.5 Equipment shall be verified as complete and in accordance with " Equipment Checklist" (Appendix "B") and Section 4.0.

Q.C.

5.0 PRECAUTIONS The following precautions will be taken when in the vicinity of the Reactor Coolant Pump Fotors.

5.1 No tools or equipment shall enter the motor housing unless they have a lanyard or similar safety device attached which has been secured to a piece of equipment or structure outside the hausing.

5.2 No items placed in the motor housing shall have loose parts which can become detached.

5.3 No glass items shall be placed within the motor housing.

Flashlights lens shall be plastic.

Mirrors shall be polished steel.

5.4 Eyeglasses, if exposed, shall be secured with elastic strap headband.

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6.0 PROCEDURE

'Ihis procedure will commence af ter the acoustic emission sensors have been placed in position and the flywheel has been positioned to give equal access to two adjacent spokes through the East inspection port.

6.1 Ascertain that all motor systems are of f and it is safe to enter the flywheel housing.

6.2 Examine area for debris, oil, nicks or any other blemishes Q.C.

which will prevent tempetature sensors from adhering or heaters from fitting properly.

6.3 Prepare sensor contact areas as required.

6.4 Install sensor plate with sensors #6, #8, 6 #10 on lef t spoke pulling the plate tightly against the flywheel I.D. (see. Appendix "C" for position of sensors).

NOTE: When installing sensors the assistant will apply the necessary adhesive before handing it to the installer. The installer will mount the sensor holding it in position as long as neces-sary to insure adhesion.

6.5 Install heater assembly #1 on the lef t spoke pulling it against the flywheel I.D. (see Appendix "D").

The heater clip with the lanyard will always be toward the flywheel.

NOTE: When installing heater assemblies the assistant will ensure that the lanyard is attached to a solid structure then place the assembly into the access hole and the hands of the installer.

6.6 Install heater assembly #2 behind #1 and immediately against it.

6.7 Install clamps #16 #2 in that order being careful to position heater wires out of the way to avoid pinching.

Clamping pressure shall be the maximum achieved manually.

6.8 All wires and lanyards shall be positioned as far to the left as possible to avoid interference.

6.9 Install sensor plate with sensors #1, #3, 6 #5, heater assem-hlies #3 6 #4 and clamps #3 6 #4 on the righthand spoke in a manner l

similar to the above.

6.10 Install remaining sensors as indicated in Appendix "C".

Sensors to be mounted on curved surfaces have matching curves and must be positioned accurately for proper adhesion.

6.11 Inspect installation for correctness i.e.

l o Wires not pinched against heater strips or sharp edges o Heater clips fit flat against sides of spokes l

o Clamps are in proper position on clamping bracket o All temperature sensors are in position and firmly af fixed.

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" - ' 2982 Page: 6 of _8 6.12 Remove all non-essentia1 tools and equipment from the housing area.

6.13 Start recorder by plugging into power supply. Heater power Q.C.

units not plugged in.

6.14 Attach heater wires to heater power supplies in numerical sequences.

6.15 Inform Acoustic Emission personnel of intention to commence heating. Obtain their concurrence.

6.16 Plug in heater power supplies. Turn switches "on".

Adj ust potentiometers to obtain 50% power. Note time of start and strip chart reference.

6.17 Monitor all temperature readings recording pertinent data on the " Data Sheet" (Appendix "E").

6.18 The following shall be cause to stop the heating process.

6.18.1 Heater temperature (Sensor #11) exceeds 250 C.

Abort to protect paint.

6.18.2 Loss of critical temperature indications dependent upon time into test and the discretion of the test conductor.

6.19 Initial power supply settings will apply heat to the spokes at 25% capacity.

If spoke temperatures are not rising at the desired rate the heating rate may be increased slowly to avoid overheating the painted surfaces (see 6.18.1). until a satisfactory temperature gradient has been achieved.

6.20 When both test conductors (HAFA & AEI) affirm data completion the heater supplies are switched "0FF".

Temperature recorder and acoustic equipment shall remain "0N" until acoustic sensing is no longer useful.

. 6.21 Unplug temperature recorder and heater power supplies.

Q.C.

6.22 Secure all equipment in area for cool-down period. Acoustic and temperature data are analyzed during cool-down period.

The results of this analysis will be as follows with necessary action indicated:

a) No defects indicated.

Continue with paragraph 6.23.

b) Defect indicated, all or portion of test must be repeated.

Repeat steps from paragraph 6.11.

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c) Defect indicated, must relocate acoustic sensors and repeat test.

Continue with paragraph 6.23 then restart after sensor relocation.

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d) De fect located.

Continue with paragraph 6.23 till housing is cleared.

Conduct alternate examination of suspect area to determine severity of defect.

6.23 Remove heater clamps #4, #3, #2, & #1 and stow in carrier.

6.24 Remove heater assemblics #4 & #3 in order and stow.

6.25 Remove heater assemblies #2 & #1 in order and stow.

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6.26 Remove temperature sensors using pry bar if necessary.

Stow.

NOTE: See Appendix "F" for removal of sensor fixtures from spokes.

6.27 Insure all tools and equipment are removed from motor housing.

Q.C.

6.28 Identify spokes tested with non-permanent marking or other means of reference.

Describe method of identification below Identification of Spoke / Flywheel Position:

1 6.29 General Information I.D. of Unit Tested:

Date of Test:

Test Conductor / Level:

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Other Test Personnel / Level:

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Q.C. Inspector:

Temperature Recorder S/N:

Calibration Due Date:

Tenperature Sensor Couplant:

NOTE:

Indicate Unit I.D. and Test designation "A" or "B" on cover page of this procedure.

7.0 Test Report 7.1 A test report shall be submitted for the testing of each of the four(4) units and shall include the following:

a.

General information (paragraph 6.29) b.

Temperature Data ( Appendix "E")

c.

Data generated by AEI in accordance with Test Procedure AEI-82-154 (Appendix "A")

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Summation and Analysis of Data e.

Conclusion NOTE: Information listed in a, b & c above will be submitted for both Test "A" 6 Test "B" for each unit (see Note with 1.0 Scope).

7.2 HAFA shall supply to AP&L the information for submittal to the NRC per their request and in accordance with the guidelines of ASME Section XI, Article IWA-6000, Records & Reports.

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i HAFA FORM 110

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ATTACH'. TAT "A" To APL-82-01 (33 Pages) i A E INTERNATIONAL 640 G JADWIN AVE., RICHLAND, WA 99352 = (509) 943-2371

• TLX 152315 AEl HSB RCLD AEl-8 2-154 REY.1 - 12/82

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TEST PROCEDURE A.E. INSPECTION OF NUCLEAR REACTOR COOLANT PUMP FLYWHEEL OCTOBER 1982

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Prepared by:

M Approved by:

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@ A DIVISION OF THE HARTFORD STEAM BOILER INSPECTION A

' AEI-82-154 INDEX 1.0 SCOPE

2.0 REFERENCES

3.0 INSTRUCTIONS 4.0 PREREQUISITES 4.1 Procedure for the Application of Stress 4.2 Permanent Plant Equipment 4.3 Temporary Site Facilities 4.4 A.E. Inspection Test Equipment 5.0 PERSONNEL 6.0 PREPARATION 6.1 A.E. Inspection Equipment Setup 6.2 Transducer / Preamplifier Placement 6.3 A.E. Inspection System Application 6.4 Communications 6.5 Calibration Using an Artificial Source 7.0 TEST CONDUCT 7.1 Energy Release Monitoring 7.2 Active Acoustic Source Location Analysis 7.3 Passive Acosutic Source Location Analysis 7.4 Confirred Acoustic Source Investigation 8.0 POST-TEST ACTIVITY 8.1 Transducer / Preamplifier Removal 8.2 Preparation for Transit APPENDIX A - Coordinate System Description APPENDIX B - AEI Forms

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1.0 SCOPE A E International (AEI) will conduct an Acoustic Emission (A.E.)

Remarks Inspection of a coolant pump flywheel.

This inspection is to be conducted in conjunction with the appli-cation of thermal stress to the flywheel.

The analytical techniques will utilize an appropriate number of transducers in conjunction with

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the A.E. test system to maintain continuous energy release and defect location monitoring capability. Stress will be applied by use of heaters located in the hub region of the flywheel.

This test procedure establishes and documents the step-by-step activities of the A.E. Inspection personnel in the preparation for and conduct of the nondestructive inspection.

2.0 REFERENCES

2.1 Recomended Practice for Acoustic Emission Monitoring of Structures During Controlled Stimulation, ASTM E569.

2.2 Definition of Tenns Relating to Acoustic Emission, ASTM E610.

2.3 ECH0-1000 Calibration Procedures, A E International Confi-dential, AEI-000 Rev.1982.

2.4 Proposed Standard for Acoustic Emission Examination During Application of Pressure, ASME B-1137.

2.5 Inspector Qualification and Certification Manual, El-TP-08.

2.6 'ASME Seqtion XI, Para. lWA 2240.

2.7 10 CFR, 50.55a (2)(a)(i) and (ii).

2.8 Proposed Position Paper, PTEB, NRC, Circa 1977.

3.0 INSTRUCTIONS As each step in the procedure is completed, it will be signed and dated by the personnel completing the activity.

If Nonconformance Re-ports or Field Change Requests, Forms AEI-0019, Rev. I and AEI-0021, are initiated as a result of the test procedure activities, each report or request number will be noted in the " Remarks" margin, opposite the procedure step involved, each report or request so generated, and noted.

will become part of the test procedure as Appendix A.

A single copy of the approved test procedure will be designated asi the record copy and will be used as the sign-off copy for all test ac-tivities.

Custody of the record copy is assigned to the principal A.E.

Inspector for the A.E. Inspection team at the Customer's site.

3 4.0 PREREQUISITES The following conditions or activities must be completed prior to Remarks the arrival of A.E. Inspection equipnent at the Customer's site.

4.1 Procedure for the Application of Stress H. A.F. A. International (H. A.F. A.) shall prepare an applica-tion of stress procedure that describes in detail the method and mechanical considerations involved in the test configuration, and also describes the sequence of stress control during the ap-plication of thermal stress.

The test procedure will be submitted to the principal A.E. Inspector for review.

Such review will be directed at evaluating the conpatibility of the stress control sequence with data acquisition requirements of the A.E. Inspec-tion program.

Test Procedure

Title:

Date Rev. #

Doc. #

Accepted by principal A.E. Inspector Date 4.2 Permanent Plant Equipment The Customer shall provide support and restraints for all equipment that is a part of or mechanically attached to the fly-l l

wheel, such that no loose parts, brackets, or other mechanical noise sources exist which may mask the acoustical energy release from discontinuities.

The Customer shall visually inspect the above equipment prior to commencement of site A.E. Inspection testing activities to verify the condition of the equipment.

l In addition, prior to the commencement of the field cali-(

bration activities described in Section 6.0 of this procedure, all temporary scaffolding, hoses, cables, supports, or insulation which may act as noise sources during the test will be removed l-from contact with equipment which is part of or mechanically at-tached to the flywheel to be inspected.

4.3 Temporary Site Facilities The Customer shall arrange for the following f acilities to be available during the activities described in this test pro-cedure.

4.3.1 Suitable A.E. system set-up area in close proxi-l mity to the flywheel under test.

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4.3.2 Temporary power in the form of 117 VAC at 30 Amps, Remarks 60 Hz continuous power feed capable of reaching the A.E.

equipment.

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4.3.3 Temporary scaf folding or other means of access to allow A.E. Inspection personnel to measure, install and calibrate acoustic transducers.

4.3.4 Craf t support for the stringing of signal cables or preparation.of transducer mounting surfaces, if appli-cable.

Verify that all required site facilities are available:

By Date 4.4 A.E. Inspection Test Equipment The A.E. Inspection personnel shall prepare the A.E. Inspec-tion equipment as follows:

4.4.1 The A.E. Inspection system shall bd ~ thoroughly.

checked for equipment damage.

4.4.2 The A.E. Inspection system shall be stocked with sufficient supplies to permit conduct of test activities; i.e., film, recorder paper, teletype paper, adhesives, test leads, batteries, repair parts, etc.

Verified by Date 5.0 PER SONNEL List all A.E. Inspection personnel involved in the test program.

At least one principal inspector must be qualified in AEI Inspection technology.

The principal inspector for this test program is respon-sible for the supervision of all A.E. Inspection personnel on-site.

Principal A.E. Inspector Level / Method

• D. L. Robinson III A.E.

11. L. Avel i s I

A.E.

M. J. Overhauser Trainee A.E.

Reference form AEl-0024 " Certificate of Personnel Qualification",

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• A.E.

Acoustic Emission or other NDE Method l

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6.0 PREPARATION

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Remarks Af ter the A.E. system and.teste personr:*1.arhive et the Customer's site, the following activities in preparation for calibration 'and test-y ;

ing will be completed.

1 6.1 A.E. Inspection Equipm'ent Setup 6.1.1 Positiun the A.E. system in the appropriate area per para. 4.3.1, st that pMsonnel access may be mainteihed and so that signal and power cables may be properly installed.

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Complete Date 6.1.2 Connect the A.E. system to the temporary power cir-cuit provided per arra. 4.3.2. and confirm that power supply requirements have been satisfied for A.E. Inspection system.

N Complete

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Date 6.1.3 Check all interconnecting cables fo'r'the A.E. In-J spection equipment, including'tihe connections it -the test equipment rack, tape decks, digital computer, 'etc.

Connect cables as necessary.

Complete

' ' ' D ate 6.2 Tr an sd uce r/ P re amp l i f i er P l ac'emen t 6.2.1 Prepare transducer /prearreplifier placement map.

The flywheel shall be measured per the requirements of the data sheet and transducer placement shall be documented in terms of the coordinate system illustrafed in Appendix A.

Mark the measured transducer lodation's on the structure surface.

This application may be witt,essed by a representative'of the Custor.

Qeality Control.

Date 5

Cor:p1"^,

ct the required number of transduce-asserbiies 6.2.0 plus spares for use in this test program.

Check'odt the con-dition of each transducer assembly as follows:

a)

Visually inspect each tran;ducer assembly for damage to connections and insulatfor..

b)

Verify transducer by attach.'.ig to a preamplifier aqd monitoring preamplifier output.

Assign a location to each transducer assembly.

Those not assigned lecetions shall be designated as spares. Record the location and the assembly identification number on the System Appli-cation Table, AEl-003 /A.

is 6.2.3 Select the preamplifiers for use in the test pro-pg3 gram.

Using a checkout procedure for A.E. system preampli-fier as detailed in document AEI-000, verify the operation of each preamplifier selected as per Form AEl-001/A.

Assign a location to each preamplifier assembly.

The remaini'ng preamplifiers shall be designated as spares. Re-a cord the preamplifier identification number for each assigned location symbol on the System Application Table, AEI-003/A.

Complete D ate 6.2.4 At each transducer location. record all infoma-U' tion required on the System Application Table, AEI-003/A.

a)

A.E. Inspection personnel will attach the transducer assembly to the prepared flywheel surface, using the y

proper adhesive dictated by the test program tempera-3 ture.

Customer Quality Control representatives may witness the transducer placement.

Documentation con-cerning chemical content of the transducer adhesive will be provided, if requested.

Verify installed trans-ducer assembly operation and identification number.

b)

Position the preamplifier adjacent to the transducer and connect the transducer assembly to the preamplifier input (BNC) connection.

Verify the preamplif'ier identi-fication number.

c)

Connect a preamplifier cable between the preamplifier output connector and the A.E. Inspection system.

Verify that the transducer / preamplifier signal cable has been connected to the A.E. Inspection system input as per the System Application Table, AEl-003/A.

d)

Using background activity as a signal source, and with the entire signal input patch established, verify that the transducer is active by monitoring the output from each channel as displayed on the oscilloscope. Use

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the monitor selector switch to isolate the signal dis-played. Momentarialy disconnect the transducer signal cable from the preamplifier, while monitoring the back-ground activity, to provide positive identification i

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of the transducer and the test chassis input match.

Remarks Verify installed transducer assembly operation on the System Application Table, AEI-003/A.

e)

In areas of moisture, contamination, etc., protect the transducer / preamplifier as required to prevent damage to equipment and/or loss of test signals during the test program.

6.3 A.E. Inspection System Application For the A.E. Inspection system, the following checkout pro-gram shall be followed. Record all information required on the System Operation Check, AEI-004/A.

6.3.1 Verify that the minimum number of the designated D

modules are installed in the test racks on System Operation Check, AEI-004/A. Record the identification number on each module as required.

If, at any time during the A.E. Inspec-tion program, a module becomes inoperative or unacceptable for usage and is subsequently replaced in the rack, the equipment type and identification number of the replacement module shall be recorded on the appropriate form.

6.3.2 Each rack module or group of modules used as a subsystem shall be performance tested in accordance with AEI-000 crieckout procedure; i.e., checkout and/or calibrate system /s and subsystem /s to be used and log on Forms AEI-001/A 004/A, 008/A, 0010, 0039, and 0060.

After each module or subsystem has been tested, comple-tion of testing shall be noted as verified on the System Operation Check, AEI-004/A.

Assure that computer parameters have been calculated and tabulated on Form AEI-0012.

Verify that all system rack interconnections have been returned to their normal configuration and that no temporary jumpers or cabling have been lef t in place in each system rack.

Complete Date

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6.4 Communications Remarks Communication systems shall be established as follows:

6.4.1 Install a cable between the A.E. Inspection system and the thermal stress control center; locate a remote in-tercom station at the control center. Connect and checkout the intercom station between the control center and the A.E.

Inspection unit.

Complete Date 6.5 Calibration Using an Artificial Source Reference AEI-000, ECH0-1000 Calibration Procedures.

Complete Date 7.0 TEST CONDUCT Af ter all A.E. Inspection equipment has been checked out and after the final system calibration procedure has been performed as per Section 6.5 above, the Customer shall be notified that the A.E. Inspec-tion system is ready for data acquisition.

During the thermal stress test, -the Test Director shall inform the principal A.E. Inspector of all changes in stress applied to the flywheel and of all changes in equipment operation status.

In turn, the principal A.E. Inspector shall notify the Test Director of any indications of discontinuities which appear as acoustic emission sources monitored by the A.E. Inspection system.

Communication be-tween the Test Director and the principal A.E. Inspector shall be es-tablished and maintained.

Two concurrent test conduct activities will be undertaken during the thermal test:

Energy Release Monitoring and Active Acoustic Emit-ter location.

The following test conduct procedures shall be applied to the A.E. Inspection system.

7.1 Energy Release Monitoring Proceed to establish energy release monitoring activity as f ollows:

-g-7.1.1 With the flywheel in its thermal test configuration, p

adjust each signal conditioner gain to a background level as determined by the principal A.E. Inspector conducting the analysis.

7.1.2 At each plateau or hold point, it may be necessary to readjust the signal conditioner gains.

The principal A.E.

Inspector will make this determination.

7.1.3 Establish the patch connection sequence indicated in the Relative Energy Monitoring Patching Sequence, AEI-005, included in Appendix B.

Set strip chart recorder speed and adjust ratemeter to provide the appropriate deflection.

7.1.4 If during the test, the signal conditioner /s acting as an input for a ratemeter is readjusted for background noise level as per para. 7.1.2, subsequently readjttst the ratemeter for appropriate strip chart deflection and note readjustment on strip chart.

7.1.5 Label the leading edge of the strip chart with the project designation, date of test, monitoring location and transducer numbers involved.

l 7.1.6 The magnetic tape recorder, if used, shall be in I

operation recording all amplified transducer signals during periods of stress; i.e., during temperature increase or as otherwise deemed advisable by the principal A.E. Inspector.

7.1.7 A log of magnetic tape usage will be maintained using the Running Log, AEI-002/A included in Appendix A for the inspection system.. Each reel and its storage box will be labeled with the tape reel number.

7.2 Active Acoustic Source Location Analysis During the conduct of the acoustic emission test, active or live acoustic source analysis shall be detected by the A.E. In-l spectors using the computer analysis systems.

The choice of trans-

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ducers for input to the computer for each data point shall be made by the principal A.E. Inspector or other A.E. Inspectors based on consideration of cross-correlation and dictated by possible sources

-of significant acoustic emission signals.

The start and stop of each data point being analyzed is dic-RmM tated by the stress increment set by the principal A.E. Inspector and is recorded on the Running Log, AEl-002/A. At the end of each data point analysis, data point termination is noted on Running

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Log, AEl-002/A.

All digitized. data are recorded on digital mag-netic disk storage.

The following procedure applies to the active acoustic source location analysis for one such data point, and shall be repeated for each data point for which active acoustic source location analysis is performed.

7.2.1 Establish a patching sequence connecting the appro-priate signal conditioner output to the corresponding com-puter input.

Record the data point number, transducer se-quences, stress, reel number, reel count, and.the time on the Running Log, AEI-002 7.2.2 Establish patch connections from the monitor bus to the input of the monitor scope.

7.2.3 Select signal conditioner #1 to be displayed on the monitor scope by use of the monitor thumbwheel index.

7.2.4 Set the signal conditioner controls to allow dis-criminator to trigger on acoustic emission signals (as seen on monitor scope).

The discriminator control sett'ings will i

be determined by the principal A.E. Inspector conducting analysis and may change as test progresses (dependent on background levels).

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7.2.5 Repeat Steps 7.2.3 and 7.2.4 for all signal con-ditioner channels.

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7.2.6 Input the structural parameters and transducer locations for the structure to be analyzed. Read table from previously generated disk.

Check computer display for veri-fication of proper parameters input.

Set computer to "Ac-quire" data.

7.2.7 Continually monitor all signal conditioners via the monitor bus to insure all data input channels remain active.

Readjust discriminator threshold verniers as re-quired or place in automatic mode.

7.2.8 When ia'ta has been acquired over the set stress Remarks increment determined by the principal A.E. Inspector, visually scan each memory section output trace to verify that data has been collected. Record the memory section with the project designation, data point number, and the memory section of the trace / s.

Record stop acquisition time of data point and other pertinent data on Running Log, AEl-002/A.

7.2.9 After each of the memory sections have been re-corded, read data peaks via cursor function for ECHO analysis.

Transfer all data to magnetic disk and log storage index num-ber.

Print out geometric display on hard-copy and reset com-puter system to analyze and display flywheel.

7.2.10 The principal A.E. Inspector responsible for ccm-puter analysis shall initiate the ECHO analysis activity by use of AEI ECHO programs.

Time-to-Digital Conversion (TDC) and Real-time Source Display (RSD) functions occur simul-taneously on-line as data is being collected.

The ECHO pro-gram is a statistical program and works with data resultant from the TDC function af ter the data is collected.

7.2.11 Upon completion of the ECHO computations, the com-puter will cause the terminal to print out a structural source

~

location map. A valid discontinuity location of high proba-bility will be. indicated by a range of " significance" numbers from

• through 4.

7.2.12 After a recordable location probability map is generated, the appropriate structure transparency shall be placed over the map for the data point. All emitter locations will be marked on the transparency. Emitter locations iden-tified as a

• on the structural source location map shall be considered as the most predominant indications of disconti-nuities and shall be noted as a (O) on the transparency.

Emitter locations identified as a 1 on the structural source significance layout shall be considered ag less prominent indications of discontinuities and shall be noted as a O) on i

the transparency.

The (Er) value of maximum count number

shall be noted at the top of each computer layout.

The results Remarks of the Source Analysis Computer (SAC) layout should be cross-checked with the video displayed results of the RSD.

The RSD data should be printed in hard-copy if desired.

7.2.13 The entire teletype printouts from the RSD and SAC, including the print routine and the structural source signifi-cance layout shall be filed in the permanent data file.

NOTE:

In the event that a significant or critical disconti-nuity is detected during the inspection, the A.E. Inspector should immediately print out the location and intensity using the RSD video; he should intnediately transfer the data for this source to the SAC for statistical analysis and printout of results.

7.3 Passive Acoustic Source Location Analysis After the acoustic emission test has been completed, passive or post-test acoustic source location analysis shall be conducted by the A.E. Inspector /s using the data acquired on-line during the test and recorded.

Data point selection shall be based on cross-correlation requirements and on active acoustic source location analysis activities of the possible sources of significant acoustic emission energy release signals.

At a minimum, the flywheel under test shall have two acoustic emission location analysis procedures, either active or passive, performed using two unique data points (transducer combinations).

As each data point is analyzed and the corresponding Location Anal-ysis Data Sheet package is completed, a sequential data point num-ber will be assigned.

The following procedure applies to the passive acoustic source location analysis of one data point and shall be repeated for each data point for which passive acoustic source location analysis is performed.

7.3.1 Load the appropriate magnetic tape reel /s onto the tape deck /s and advance the tape /s to the index point corrcs-ponding to the data point.

r

' 7.3.2 Establish a patching sequence connecting the ap-Remarks propriate tape recorder output to the corresponding signal conditioner. Record the data point number, the stress range to be analyzed, description of the area to be analyzed, date of analysis and the A.E. Inspector performing the analysis.

Record the reel number /s and tape index number /s of the magnetic tape /s from which the acoustic emission signals will be reproduced, and the clock setting of the TDC func-tions.

If desired, set the RSD functions to display the structure being analyzed.

7.3.3 Place the tape deck /s in the playback mode.

Pro-ceed to adjust the signal conditioner, acquire data, read the TDC display and analyze the data as per 7.2.2 through 7.2.14.

Transfer all TDC data to magnetic disk for record storage.

7.3.4 Tabulate all identified sources, their exact geo-metric location, their statistical data, the stress range over which each source was analyzed and the recommended sig-nificance grade of each source.

7.4 Confirmed Acoustic Source Investigation **

Af ter SAC source cross-correlation and analysis is completed, cross-check all results. Tabulate on Fo.rm AEI-0031.

Present all test results in an on-site test report to the Customer and discuss with the Customer Test Director.

Grade A - Significant to Physical /Structrual Integrity (a) Acoustic energy release rate - positive and at least 20 percent increase per unit' stress increment.

l (b) Source significance nunber (Er) = "*" or "1".

l (c)

Cros s-correla tion:

(1)

Stress correlation required over two or ricre stress in-crements encompassing stress range from at least 10 percent below normal operating stress to at least 10 percent above normal operating stress.

(2) Cross-correlated by three or more transducer set combi-nations.

l

• • Severity index and innocuous signal explanation is presented in Appendix C.

r (3) For cyclic testing data source detected energy output R

s should increase by relative energy number of at least seven on each pressure cycle.

(d) Relative energy number (Er) = 10 to 20.

(1) Er = 10 to 15 if cross-correlated by three additional data sets with location accuracy of 95 percent.

(2) Er = 15 to 20 if cross-correlated by two additional data sets.

i Grade B - Predominant but Insignificant to Structural Integrity Under Conditions of Imposed Test (a) Acoustic energy release rate - stable and less than 10 percent increase per unit stress increment.

(b) Source significance number (Er) = "*",

"1", or "2".

(c) Cross-correlation:

(1) Stress increment correlation required by one or more stress increment data sets in stress range from at least 20 percent below to at least 10 percent above normal operating stress.

(2) Cross-correlation by at least two or more transducer set combinations.

(d) Relative energy number (Er): 7 to 10.

(1) Cross-correlated with Er of 7 to 10.

Grade C - Minor and Insignificant to Structural Integrity (a) Acoustic energy release rate-stable and less than 10 percent increase per unit stress increment.

(b) Source significance number (Er):"1",

"2", or "3".

(c) Cross-correlation:

(1)

Stress increment correlation required by one or more stress increment data sets.

(2) Cross-correlated by at least two transducer set combi-nations.

(d) Relative energy number (Er)- 4 to 7.

(1)

Cross-correlated with location accuracy of at least 93 percent and Er of 4 to 7.

l l

e 8.0 POST-TEST ACTIVITY Remarks Af ter the acoustic emission test program is completed and the site test conduct activities described in Section 7.0 have been per-formed, the A.E. Inspection equipment shall be removed from its test location and prepared for transit as follows.

8.1 Transducer / Preamplifier Removal At each of the transducer locations, the following removal procedure shall be followed.

8.1.1 Turn off the preamplifier power supply.

8.1.2 Remove any protective coverings from each trans-ducer and disconnect the transducer lead from the preampli-fier input.

A.E. Inspection personnel will remove each transducer from the surface of teh structure under test by breaking the adhesive bond.

Quality Control

• representative /s may witness the removal of all transducers.

8.1.3 Disconnect the signal cable from each preamplifier.

Renove the transducer and preamplifier from the test area.

8.1.4 Remove the signal cables from the test area.

8.1.5 Coil and store all cables in their transit compart-ments.

Store all transducers and preamplifiers in their shipping cabinets.

Complete Date 8.2 Preparation f'or Transit Prepare the A.E. Inspection system for transit as follows.

8.2.1 Disconnect and remove the remote intercom station from the thermal test control center. Coil and store the interconnecting cable.

Complete Date 8.2.2 Disconnect and remove interconnecting signal patch cables from the equipment rack /s.

Coil and store the inter-

~'

connecting cables.

Date Comp!etc 8.2.3 Disconnect all temporary power circuits.

Complete Date 8.2.4 Secure the test equipment in its transit container.

Complete Date

APPENDIX A

~ ~

COORDINATE SYSTEM DESCRIPTION The Y axis is established as the vertical reference line of the rectangular geometry; it coincides with the tangent line through the edge of the flywheel located at 2700 The limit of Y axis is deter-mined by the diameter of the flywheel.

The X axis is established as the horizontal reference line which coincides with the tangent line located at 00 on the flywheel.

The limits of the X axis is determined by the diameter of the flywheel.

4 8

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PORT SECTION A

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APPENDIX B AEI FORMS e

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PERFORMANCE AND CAllBRATION DATA SHEET PREAMPLIFIER MODEL PREAMPLIFIER SER. NO.

CAllBRATION CAPACITOR SER. NO.

OSCILLOSCOPE MDL. NO.

SER. N0.

FUNCTION GENERATOR MDL. NO.

SER. NO.

ATTENUATOR MDL. NO.

SER. NO.

COUNTER MDL. NO.

SER. NO.

Peak Response Frequency (30 kHz)

Peak Response Frequency (100 kHz)

Frequency kHz Frequency kHz Gain dB

Gain, dB Band Pass (-3dB)

BandPass(-3 dbl High Frequency kHz High Frequency kHz Low Frequency kHz Low Frequency kHz Rolloff Rolloff

.25 Fc dB

.25 Fc dB 4 Fc dB 4 Fc dB Ry Pass Circuit Mechanical Inspection Resistance ohms Noise figure Comments mV P-P Relay Pickup VDC Supgly Current MA@22VDC Supply Current MA??9VDC Inspected by Date Form AEI-001 Reviewed by

__Date

RUiii41NG I OG Sheet #

103 CODf.

Date:

TIMF STR E ss

goo, Indav nD TOC COMMENTS

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? viewed by Date:

Fom AEl-002/A

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ECH0-2000 SYSTEM OPERATION CHECKS JOB CODE MINIMUM CHANNELS REQUIRED D

APPLICABLE

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EQUIPMENT CHECXOUT DESCRIPTION PROCEDURE #

INITIAL f COMMENT Transducers Preamplifiers Signal Co6ditioner Linear Ratemeter Strip Chart Recorder Audio Analog Recorder Multi-Trace Scooe 3

Reviewed by Date Form AEl-004/A

9 EtiERGY M0filTORIriG PATCHlf4G SEQUENCE JOB CODE STRUCTURE XD CHANNEL CHART #

RATEMETER COMMENTS 1

l Reviewed by Date Fom AEl-005

ECH0-2000 SOURCE DIGITAL COMPUTER SUBSYSTEM PERFORMANCE CHECK SHEET JOB CODE REFERENCE ACTIVITY BY Terminal I/N RSD Programs Status SAC Programs Status Conments:

F Reviewed by Date Form AEl-008/A i

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PERFORMANCE DAlA SHEET 1 APE MACHINL J03 CODE TAPE MACHINE I/N MODE FREQUENCY kHz I

CHANNEL PERFORMANCE l CHANiiEL Fi RF0F31 alice NO.

rnh (b!tc.

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VERIFIED 1

17 2

18 3

19 4

20 5

21 6

22 7

23 8

24 9

25 10 26 11 27 12 28 13 29 14 30 15 31

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16 32 Coments :

Reviewed by Date Form AEI-0010 l

I

COMPUTER PARAMETERS JOB CODE STRUCTURE DATA xM YM GR VT A

CD TC R

RT y

XDucer Transducer w Measurements Actual Comouter X

Y Delay Remarks r

l Reviewed by Date Fom AEl-0012

1 JOB NO.

JOB NAME NONCONFORMANCE REPORT g,7g.

ESCRIPTION OF NONCONFORMANCE:

i IEM PLACED ON HOLD RED HOLD TAG NO.

ATTACHED TO ITEM BY:

DATE ECOMMEND DISPOSITION:

BY:

DATE:

o USE AS IS O REPAIR a REWORK O REJECT REJECT - RETURN TO VENDOR D

EPOSITION REVIEW o AECEPTED a REJECTED 5.O OA/0C MGR CONDITIONAL RELEASE ATTACH T0 ITEM TAG NO.

Y:

QA/QC MGR DATE C

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EVIEWED BY:

DATE ECOMMENDED DISPOSITION COMPLETED:

0A/0C DATE 151 RIBUi l0N:

8. CORRECTIVE ACTION REQUt51 155ULU: CJ YES.

O NO O QA/QC MANAGER CAR NO.

DATE:

C PRESIDENT / GENERAL MANAGER D SYSTEMS & ELECTRONICS SUPERVISOR QA/QC D RESEARCP 3 DEVELOPMENT MANAGER VENDOR DEFICIENCY NOTICE ISSUED:

O YES O NO

(*

C FIELD SERVICE SUPERVISOR VDN a l

D PURCHASING MANAGER P/M OA/0C i

lEMARKS:

Form AEI-0019, Rev. I

l f1 ELD LllAf4GE RLQ' JEST JOB CODE REPORT CODE flLLD CilAliGE IS HEREBY REQULSTED TO PROCEDURE #

SEC110!i PARAGRAPH DESCRIPTIOli 0F CHAfiGE RLA50li FOR REQUEST REQUESTED BY DATE APPROVAL OF FIELD CHAf4GE BY___

DATE COMMEfiTS BY CUS10MLR CUS10MER APPROVAL BY DATE Received by _

Date Form AEl-0021

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CERTIFICATE OF PERSONNEL QUALIFICATION NAME 500. SEC. NO.

SUMMARY

OF TECHNICAL TRAINING:

VISUAL TEST CERTIFICATION:

TEST DATE TEST DATE TEST DATE TEST DATE TEST DATE TEST DATE NONDESTRUCTIVE TEST METHOD CERTIFICATION:

TEST METHOD QUALIFICATION STANDARD CERTIFIED - LEVEL I BY DATE

/

/

CERTIFIED - LEVEL II BY DATE

/

/

TEST METHOD QUALIFICATION STANDARD CERTIFIED - LEVEL I BY DATE

/

/

CERTIFIED - LEVEL 11 BY DATE

/

/

TEST METHOD QUALIFICATION STANDARD CERTIFIED - LEVEL I BY DATE

/

/

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CERTIFIED - LEVEL 11 BY DATE

/

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TEST METHOD QUALIFICATION STANDARD CERTIFIED - LEVEL 1 BY DATE

/

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CERTIFIED - LEVEL !! BY DAT E

/

/

Form AEl-0024

PERFORMANCE AND CAllBRATION DATA SHEET SIGNAL CONDITIONER MODEL SIGNAL CONDITIONER SER. NO.

OSCILLOSCOPE - MDL.#

SER. NO.

FUNCTION GENERATOR - MDL.#

SER. NO.

ATTENUATOR - MDL.#

SER. N0.

FREQUENCY COUNTER SER. NO.

SIGNAL CONDITIONER SIDE A SIGNAL CONDITIONER SIDE B x10 Gain Ref. 4. 8 dB x10 Gain Ref. 4. 8 dB Band Pass Ref. 4.9 BandPassRef.4.5

-3dB Hi kHz

-3dB Hi kHz

-3dB Lo kHz

-3dB Lo kHz

~30 kHz Filter Ref. 4.11 kHz

~30 EHz Filter Ref. 4.11 kHz Ref. 4.12 dB Ref. 4.12 dB 100 kHz Filter Ref. 4.14 kHz 100 kHz Filter Ref. 4.14 kHz Ref. 4.15 dB Ref. 4.15 dB dB x100 Gain Ref. 4.16 dB x100 Gain Ref. 4.16 x1000 Gain Ref. 4.17 dB x1000 Gain Ref. 4.17 dB Vernier Linearity Vernier Linearity Ref. 4.18 dB Ref. 4.18 dB Disc. Check Ref. 4.20 Disc. Check Ref. 4.20 Auto Check Ref. 4.21 dB Auto Check Ref. 4.21 dB Energy Scaler Checks Energy Scaler Checks Ref. 4.22 - 4.28 Ref. 4.22 - 4.28 PCI-11-1 AEl-0060 l

l I

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APPENDIX "B"

""2-'

H.A.F.A.

TEST 3

E InternatlC>rlal, Revision:

0 inc.

PROCEDURE

"" t " "

2 ' " 8 2 Page: 1 of 1

EQUIPMENT CHECKLIST Item Quantity Description 1.

1 Strip Chart Recorder (bagged with cord and 12 numbered sensors available) 2.

1 Multineter (bagged wi th Amp-Clamp or probes available) 3.

2 Power Supplied (bagged with cords and connector plugs available) 4.

As Reg ' d Spare Sensors (with blank tags) Bagged Individually 5.

4 Clamps with Lanyards 6.

4 Heater Assemblies with Lanyards 7.

1 Spare Heater Clip (bagged) 8.

1 Sensor Adhesive, Tube 9.

1 Sanding Block 10.

1 1/2" Diam. Pry Bar w/ Lanyard 11.

1 Flashlight with Lanyard 12.

1 Inspection Mirror with Lanyard 13.

1 ea.

1/2" & 3/8" Open End Wrench or Small Cresent Wrench 14.

1 Flat Screwdriver (1/4")

t l

l 15.

1 Pliers 16.

As Req ' d Rope (equip. hoisting) If Req'd 17.

1 Knife 18.

1 roll Tape 19.

1 Flat File 20.

I roll Lanyard Wire (bagged) 21.

1 Copper Crimp Tube F

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PERFORMANCE AND CALIBRATION DATA SHEET ENERGY RATEMETER RATEMETER MDL. NO.

SER. NO.

OSCILLOSCOPE MDL. NO.

SER. NO.

FUNCTION GENERATOR MDL. NO.

SER. NO.

FREQtlENCY COUNTER MDL. N0.

SER. NO.

Upper Ratemeter Lower Ratemeter Threshold Lincarity Threshold Linearity input Signal 1 V P-P, Disc Input Signal 1 V P-P, Disc Input Signal 5 V P-P Disc Input Signal 5 V P-P, Disc Input Signal 10 V P-P, Disc Input Signal 10.V P-P, Disc Verify 6 Inputs Active Verify 6 Inputs Active Initial Initial Calibration Range Calibration Range 30 kHz, Meter

, Output 30 kHz, Meter

, Output 600 kHz, Meter

, Output 600 kHz, Meter

, Output Linearity Check Linearity Check Output at 450 kHz Output at 450 kHz Output at 300 kHz Output at 300 kHz Output at 150 kHz Output at 150 kHz 4

Mechanical Inspection Date Comments d.

Form AEl-0039

-~-

l APPEKDIX "C" H.A.F.A.

TEST J

t internatlOnal, Revision:

0 inc.

PROCEDURE "t**-

2'

" 82 Page: 1 of 1

TEMPERATURE SENSOR LOCATION (EAST PORT)

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I APPENDIX "D"

^"'-82-o' M.A.F.A.

TEST C InternatlOnal, aey1,1on: o

~

i

'"c-PROCEDURE

" " =

24 1982 Page: 1 of 1

.=

HEATER ASSEMBLY POSITION & SEQUENCE N

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1

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l 0

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l HAFA FORM 110

l APPENDIX "F"

• ' ^"-*-'

M.A.F.A.

TEST D

c International, Revision:

o inc.

PROCEDURE D8M W v. 24. 1982 Page: 1 of 1

(

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Insure sensor wires are not bent

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or kinked in vicinity of fixture and

's

/

are free to slide through.

y 2.

Slowly lift fixture until it clears the edge of

[.

the flywheel then, 3.

Slide fixture along wires toward access port while lifting until sensors are available for removal.

(

HAFA FORM 110