ML20064M651

Forwards Response to 821108 Request for Addl Info Re 810707 Response to Generic Ltr 81-04 Concerning Bwr/Coolant Pressure Boundary Piping (NUREG-0313,Rev 1)

ML20064M651
Person / Time
Site:	Brunswick
Issue date:	02/08/1983
From:	Utley E CAROLINA POWER & LIGHT CO.
To:	Vassallo D Office of Nuclear Reactor Regulation
References
RTR-NUREG-0313, RTR-NUREG-313 GL-81-04, GL-81-4, LAP-83-14, NUDOCS 8302150602
Download: ML20064M651 (97)

Text

r-Form 244 LAP-83-14 Carolina Power & Light Company

-m FEB 08 1983 Company Correspondence Director of Nuclear Reactor Regulation Attention:

Mr. D. B. Vassallo, Chief Opc ating Reactors Branch No. 2 Division of Licensing United States Nuclear Regulatory Commission Washington, DC 20555 ERUNSWICK STEAM ELECTRIC PLANT, UNIT NOS. 1 AND 2 DOCKET NOS. 50-325 AND 50-324 LICENSE NOS. DPR-71 AND DPR-62 REQUEST FOR ADDITIONAL INFORMATION GENERIC LETTER 81-04:

IMPLEMENTATION OF NUREG-0313, REV. 1

Dear Mr. Vassallo:

This is in response to your November 8, 1982 letter which requested additional information concerning NUREG-0313, Rev. 1 for the Brunswick Steam Electric Plant (BSEP).

Your questions (attached) are in regard to Carolina Power & Light Company's (CP&L) July 7,1981 response to NRC's Generic Letter 81-04 concerning BWR/ coolant pressure boundary piping.

The enclosures to this letter provide CP&L's response for BSEP Unit No. 1, which is presently shutdown for refueling.

Information for Unit 2 is currently being compiled and will be provided by March 1983.

Please contact us should you have any questions regarding this information.

Yours very truly, E. E. Utleyl Executive Vice President Power Supply and Engineering & Construction JAM / mag (6024C11T2)

Enclosure cc:

Mr. D. O. Myers (NRC-BSEP)

Mr. J. P. O'Reilly (NRC-RII)

Mr. S. D. MacKay (NRC)

EG&G Idaho, Inc.

f, P. O. Box 1625 Idaho Falls, Idaho 83415 p

l i 0302150602 830200 PDR ADOCK 05000324 p

PDR

l Brunswick Steam Electric Plant, Unit Nos. 1 and 2 Implementation of NUREG-0313, Rev. 1 NRC Request for, ditional Information Carolina Power &- Light Company Responses 1.

Refer to Table 1 (attached) 2a. and 2b. During the augmented Inservice Inspection (ISI) of the non-conforming Service Sensitive Pipe Southwest Research Institute (SWRI)

NDT procedures 600-31 Revision 9 deviation 3, entitled " Manual Ultrasonic Examination of Austenitic Pressure Piping Welds" and SWRI-NDT-700-5/7 with deviation 4 entitled " Mechanized Ultrasonic Examination of Vessel Components, Vessel Welds and Piping Welds" will be used (copy attached).

The methods and techniques of these procedures specify the use of 3/8" round 1.5 MHz single element tranducers and use 45 and 60 degree refracted shear waves for angle beam scanning of the weld volume. The procedures also employ an additional 45-degree tangential scan to ensure the i

detection of axial undercrown which may have initiated at the inside surface of the piping. The 45-degree tangential scan is performed from the adjacent base material with the 45-degree search unit adjacent to the weld crown and skewed approximately 45-degrees into the weld to detect cracks axial to the pipe, at the inside surface beneath the weld crown.

The procedures require the recording and investigation of all ultrasonic reflectors producing a response greater than 50 percent of the reference level. Additionally, they require recording and investigation of any ultrasonic reflectors not readily attributable to geometry by the j

examiner, regardless of amplitude.

Scanning is to be performed with a minimum overlap of 10 percent of the search unit piezoelectric element dimension perpendicular to the direction of scan.

The basic calibration blocks conform to the requirements of ASME Boiler and Pressure Vessel Code,Section V, Article 5,1977 edition with addenda through Summer 1978.

2c. The ultrasonic examiners for the augmented ISI will be certified to Level I or Level II.

A Level II examiner (in accordance with the guidelines of Recommended Practice SNT-TC-IA) will be performing each 1'

examination.

He may be assisted by a Level I examiner (in accordance with the guidelines of SNT-TC-IA).

However, a Level I examiner may not independently carry out any calibrations, examinations, or evaluations. A Level III examiner will be provided, as necessary, for those indications which may be interpreted as crack-like.

All examiners will have met the i

minimum training requirements specified in SNT-TC-IA.

Additionally, all examiners will have received additional training in the detection of axial cracking including a laboratory session with welded specimens containing machined reflectors.

Each examiner will have also satisfectorily demonstrated his/her ability to detect simulated cracking in a welded specimen. As available, examiners receive training on any available cracked specimens at their disposal.

i

During the augmented ISI of the nonconforming service sensitive pipe,,

procedure SWRI-NDT-600-31, Revision 9 entitled " Manual Ultrasonic Examination of Austenitic Pressure Piping Welds" will be used.

This procedure incorporates an additional scanning technique over the procedure which was satisfactorily demonstrated at Battelle Memorial Institute in Columbus, Ohio. The procedure (600-31, Revision 9) requires recording and investigation of all ultrasonic reflectors producing a response greater than'50 percent of the reference level. Additionally, it requires recording and investigation of any ultrasonic reflectors not readily attributable to geometry by the examinec, regardless of amplitude.

The procedure further specifies the use of a 3/8-inch round,1.5 MHz, single-element transducer and the use of bcth 45-degree and 60-degree refracted shear waves for the angle-beam examination of the weld volume.

The basic calibration blocks conform to the requirements of ASME Boiler and Pressure Vessel code,Section V, Article 5,1977 Edition with Addenda through Summer 1978.

The scanning is to be performed at a minimum gain setting of two times the reference level sensitivity with scan overlap a minimum of 10 percent of the search unit piezoelectric element dimension perpcadicular to the direction of scan.

The search unit movement rate for scanning shall not exceed 6 inches per second.

An additional 45-degree tangential scan will be employed to ensure the detection of any axial undercrown cracking which may have initiated at the inside surface of the piping.

This 45-degree tangential scan is performed from the adjacent base material with the 45-degree search unit adjacent to the weld crown and skewed approximately 45-degrees into the weld in order to detect any cracks which may be axial to the pipe and located at the inside surface beneath the weld crown.

2d. Twenty-seven welds out of a total of 46 will be inspected.

2e. A portion of all the non-conforming service sensitive pipe welds on each a

system are inspected at each refueling outage.

2f. The welded joints and their associated Stress Rule Index Numbers for Unit 1 are listed in Tables 2 and 3.

3a. The methods used for nonconforming nonservice sensitive piping are the same as for nonconforming service sensitive piping (see 2a).

3b. Attachment 1, SWRI-NDT-600-31 Revision 9 will be used for the augmented ISI.

3c. See response 2c.

3d. Eight welds out of a total of 63 will be inspected on Unit 1.

3e. See response 2f.

3f. At least 25 percent of the welds in the nonconforming non-service sensitive piping in each system will be inspected within the 80-month interval as required by NUREG-0313 Rev. 1.

(6031R13T1)

TABLE 1 INFORMATION REQUESTED ON LEAK DETECTION SYSTEM (1)

(2)

(3)

(4)

(5)

(6)

(7)

Type of Is Leak Time Is Control Calibration Document System System Rate Required System Room or Testing Reference Operable Sensitivity To Achieve Functional Indications During for (1)

(yes/no)

(gpm)

Sensitivity After SSE (alarms)

Operation Thru (6)

(hours)

(yes/no)

(recorders)

(yes/no)

Primary Containment yes NA 0

yes Alarm &

yes PT4.1.6 Atmospheric Parti-Recorder SD-24 culate Radioactivity Monitoring System Primary Containment yes NA 0

yes Alarm &

yes PT4.1.6 Gaseous Radioactiviry Recorder SD-24 Monitoring System Primary Containment yes I gpm 1-8 hrs no Alarm &

yes PTS.lPC Sump Flow Recorder SD-47 Integrating System Drywell Pressure yes NA 0

yes Alarm &

yes PTS.1PC Recorder SD-47 Average Drywell yes NA 0

yes Alarm f no SD-24 Temperature Recorder

TABLE 2 BRUNSWICK - 1 B-32 RECIRCULATION SYSTEM PIPE WELDS LOOP A SERVICE SENSITIVE WELD NO.

(Yes or No)

SRI 28-A-2 N

1.080 28-A-3 N

1.464 28-A-4 N

1.410 28-A-5 N

0.948 28-A-6 N

0.974 28-A-7 N

1.379 28-A-8 N

1.408 28-A-9 N

1.068 28-A-10 N

1.584 28-A-11 N

1.522 28-A-12 N

1.123 28-A-13 N

1.128 28-A-14 N

1.513 28-A-15 N

1.421 28-A-16 N

0.979 28-A-17 N

1.019 28-A-18 N

0.950 28-A-9BC N

1.200 28-A-12BC N

1.039 28-A-15BC N

0.984 22-AM-1 N

1.148 22-AM-2 N

1.112 22-AM-3 N

1.027 22-AM-4 N

1.240 22-AM-5 N

1.175 22-AM-6 N

1.144 4

.r

_...e,_,.,

..c_-*-,.

e y

4 TABLE 2 (Continued) i BRUNSWICK - 1 B-32 RECIRCULATION SYSTEM PIPE WELDS LOOP A SERVICE WELD NO.

SENSITIVE SRI 12-AR-Al Y

1.081 12-AR-A2 Y

1.479 12-AR-A3 Y

1.458 12-AR-A4 Y

1.273 12-AR-B1 Y

1.005 12-AR-B2

~

Y 1.393 12-AR-B3 Y

1.505 12-AR-B4 Y

1.362 12-AR-C1 Y

1.571 12-AR-C2 Y

1.579 12-AR-C3 Y

1.544 12-AR-C4 Y

1.599 12-AR-D1 Y

1.081 12-AR-D2 Y

1.457 12-AR-D3 Y

1.436 12-AR-D4 Y

1.348 12-AR-El Y

1.142 12-AR-E2 Y

1.565 12-AR-E3 Y

1.528 12-AR-E4 Y

1.584 4-A-1 Y

1.222 4-A-2 N

1.553 4-A-3 N

1.535 4-A-4 N

1.177 4-A-5 N

1.159 4-A-6 N

1.299 i

4-A-7 N

1.268 I

4-A-8 N

1.420 4-A-9 N

1.449 4-A-10 Y

1.194

-3m._y m

-w

TABLE 3 BRUNSWICK - 1 B-32 RECIRCUIATION SYSTEM PIPE WELDS LOOP B SERVICE WELD NO.

SENSITIV2 SRI 28-B-2 N

1.028 28-B-3 N

1.341 28-B-4 N

1.324 28-B-5 N

0.925 28-B-6 N

0.935 28-B-7 N

1.361 28-B-8 N

1.364 28-B-9 N

1.051 28-B-10 N

1.514 28-B-11 N

1.462 28-B-12 N

1.116 28-B-13 N

1.121 28-B-14 N

1.484 28-B-15 N

1.400 28-B-16 N

0.972 28-B-17 N

1.011 28-B-18 N

0.951 28-B-9BC N

1.200 28-B-12BC N

1.035 28-B-15BC N

0.984 22-BM-1 N

1.144 22-BM-2 N

1.204 22-BM-3 N

1.214 22-BM-4 N

1.248 22-BM-5 N

1.135 l

l l

TABLE 2 (Continued)

BRUNSWICK - 1 B-32 RECIRCULATION SYSTEM PIPE WELDS LOOP B 4

SERVICE WELD NO.

SENSITIVE SRI 12-BR-F1 Y

1.116 12-BR-F2 Y

1.526 12-BR-F3 Y

1.450 12-BR-F4 Y

1.456 12-BR-G1 Y

1.096 12-B4-G2 Y

1.506

~12-BR-G3 Y

1.526 12-BR-G4 Y

1.418 12-BR-H1 Y

1.592 12-BR-H2 Y

1.569 12-BR-H3 Y

1.534 12-BR-H4 Y

1.528 12-BR-J1 Y

1.058 12-BR-J2 Y

1.410 12-BR-J3 Y

1.450 12-BR-J4 Y

1.300 12-BR-K1 Y

1.070 12-BR-K2 Y

1.420 12-BR-K3 Y

1.381 12-BR-K4 Y

1.248 4-B-1 Y

1.224 4-B-2 N

1.556 4-B-3 N

1.538 4-B-4 N

1.176 4-B-5 N

1.159 4-B-6 N

1.298 4-B-7 N

1.268 4-B-8 N

1.417 4-B-9 N

1.451 4-B-10 Y

1.195 e--

w w

R2 quest for Additional Information Implementation of NUREG-0313. Rev.1 Brunswick Steam Electric Plant, Units 1 and 2 Docket Nos. 50-324 and 50-325 1.

Unidentified Leakage Monitoring (IV.B.1 of NUREG-0313, Rev. 1),

a.

Identify the methods to detect and monitor unidentified leakage in the pressure boundary piping of your BWR.

Some of these metho'ds are enumerated in Regulatory Guide 1.45, Paragraph 3.

b.

Please fill out the attached table of information regarding the systems identified in the above paragraph.

2.

Augmented ISI of Nonconforming Service Sensitive Pipe a.

Please identify the methods for augmented ISI of the nonconforming service sensitive pipe (IV.B.3 of NUREG-U313

~

Rev. 1).

b.

Provide a copy of the specifications for the augmented ISI method or methods (IV.B.3 of NUREG-0313 Rev. 1).

Identify each of the. augmented ISI methods used and the training c.

and certification levels the individuals using those methods received.

Indicate if cracked specimens are used in your training (IV.B.3 of NUREG-0313 Rev. 1).

d;-

Identify the proportion of the nonconforming service sensitive pipe that is being inspected (IV.B.2.b of NUREG-0313 Rev. 1).

Identify the inspection interval of each system of the e.

nonconforming service sensitive pipe (IV.B.2.b of NUREG-0313 Rev. 1).

f.

Identify the Stress Rule Index Numbers for the welded joints in the nonconforming service sens'itive pipe-(IV.B.1.b (6) of NUREG-0313 Rev. 1).

3.

Augmented ISI of Nonconforming Nonservice Sensitive Piping a.

Please identify the methods for augmented ISI of the nonconforming nonservice sensitive piping (IV.B.3 of NUREG-0313 Rev. 1).

b.

Please provide a copy of the specifications for the augmented ISI method or methods (IV.B.3 of NUREG-0313 Rev. 1),

Identify each of the augmented ISI methods used and th5 training c.

and certification levels the individuals using those methods received.

Indicate if cracked specimens are used in your training (IV.B.3 of NUREG-0313 Rev. 1).

d.

Identify the proportion of the nonconforming nonservice sensitive piping that is being inspected (IV.B.2.b of NUREG-0313 Rev. 1).

em e

.:o e.

Identify the Stress Rule Index Numbers for the welded joints in the nonconforming)nonservice sensitive piping (IV.B.l.b (6) of NUREG-0313 Rev. 1.

~

f.

Ident!ify the proposed inspection interval for each system of nonconfonning nonservice sensitive piping (IV.B.l.b of NUREG-0313 Rev. 1).

\\

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SOUTHWEST RESEA RCH INSTITUTE SwRI-NDT-600-31 Revision 9 NUCLEAR PROJECTS December 1982 OPERATING PROCEDURE Page 1 of 26 Title MiO{UAL ULTRASONIC EXAMINATION OF AUSTENITIC PRES $URE PIPING WELDS EFFECTIVITY AND APPROVAL 12/22/82

. Other revisions of the base document may 9

of this procedure became effective on Revision be effective concurrently.

SA Approvals Written By Date Technical Review Date bfD m

Manager of Q.A.

Oaje Cogni nt Director Date

$Y

'[

/

I k

/

The following information may be used for convenience. Corrbietion of this pcrtion is not mandatory.

Deviation No.

Cate Effective Procedure Section(s)

Affected Notes:

SOUTHWEST RESEARCH INSTITUTE 8""'J""',-6 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 2 of 26 l'.

MANUAL ULTRASONIC EXAMINATION OF AUSTENITIC PRESSURE PIPING WELDS SwRI-NDT-600-31 1.

JURPOSE This procedure provides the technical information and detailed steps required to ensure a complete and accurate manual ultrasonic examination of similar or dissimilar metal welds and adjacent base material in 'cla; or unclad austenitic pressure piping in accordance with the applicable ASME Boiler and Pressure Vessel Codes.

2.

SCOPE AND APPLICATION Pressure piping welds and the adjacent base material in the nominal thickness range of greater than 0.4 inch to 5.0 inches shall be examined.

Manual, contact, pulse-echo, shear-wave angle-beam, and longitudinal-wave straight-beam ultrasonic techniques shall be utilized for the examination of welds and adjaceat base material in extruded austenitic preaaure piping.

Similar and dissimilar metal circumferential and longitudinal pipe welds and branch pipe connection butt welds to be examined shall be as specified in the applicable SwRI Examination Plan.

3 APPLICABLE DOCUMENTS, (1)

ASME Boiler and Pressure Vessel Code,Section XI, 1977 Edition',' with Addenda through Summer 1978, " Rules for Inservice Inspection of Nuclear Power Plant Components" (2)

ASME Boiler and Pressure Vessel Code,Section V, 1977 Edition, with Addenda through Summer 1978, "Nondest.ructive Examination," with the ext.eptirm of the following:

(a)

Subparagraph T-533.1 of Article 5,Section V, requires the basic calibration block for production material thickness (t) up to and including 1 inch to be 3/4 inch or t.

Paragraph 5.3 of this procedure requires the basic calibration block to be either t, no more than 25% less than t, or closer in thickness to the production material than the 3/4-inch alternate SwRI Form OA 3 2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-6% -31 Revision 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 3 of 26 thickness allowed by Article 5 for production material thick-nesses up to and including 1 inch.

This exception will assure a more accurate calibration than the Article 5 basic calibra-tion block design allowed by Code.

(b)

Subparagraph T-535.1 of Article 5 states that transfer (atten-untion compensation) be accomplished between the production material and basic calibration block and a correction made for the difference.

Paragraph 7.5.2 of this procedure describes the method used to conduct attenuation measurements.

These attenuation measurements shall be recorded and considered during analysis and evaluation of in'd'ication's. No attempt shall be made by the examiner to compensate for observed differences before or during the examinations.

(3)

ASME Boiler and Pressure Vessel Code,Section IX, 1977 Edition with Addends through Suumer 1978, " Welding and Brazing Qualifications" (3)

SwRI Nuclear Quality Assurance Program Manual (NQAPM) 3.1 Calibration and Examination Records SwRI-NDTR Form No.

Revision Date 17-18 7-31-75 17-19 7-10-80 17-25 7-10-80 17-37 2-16-80 17-86 7-25-80 17-87 7-25-80 4.

RESPONSIBILITY (1)

The Director of the Department of Engineering Services, Quality Assurance Systems and Engineering Division, shall be responsible for the preparation, review, approval, and control of this procedure.

(2)

The Project Manager shall be responsible for the implementation of this procedure in accordance with the NQAPM specified in the applicable SwRI Project Plan.

(3)

The examiner shall be responsible for implementing the require-ments of this procedure.

SwRI Fwm OA 3 2

l S""I- " -6

-3 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 t'

NUCLEAR PROJECTS OPERATING PROCEDURE Page 4 of 26

-n (4)

The Manager of the Support and Administration Section, Quality Assur-ance Systems and Engineering Division, shall be responsible for stor-age of records generated in accordance with this procedure.

5.

PERSONNEL AND EOUIPMENT 5.1 Personnel Certification Personnel performing ultrasonic examinations shall be certified in accordance with SwRI NQAP 11-1, "Special Process Control."

52 Reference Block Reference blocks used for screen distance calibration and veri-fication shall be cf the same material as the production material, i.e.,

stain-less steel or carbon steel, and shh11 be one of the following:

(1) SwRI Half-Round, (2) AWS Type DC, or (3) IIW.

5.3 Basic Calibration Block for Circumferential, Longitudinal, and Branch Pipe Connection Welds Side-drilled basic calibration hole reflectors, in accordance with Section V of the ASME Boiler and Pressure Vessel Code, shall be placed in a block manufactured from material of similar metallurgical structure and of the same or equivalent P-number grouping as the production material, as identi-fied in Section IX of the ASME Boiler and Pressure Vessel Code. The calibra-tion material shall be determined by the production piping material to which the search unit is applied.

The basic calibration block thickness shall be determined by the thickness of the production piping material to which the search unit is applied and Article 5 of Section V.

When a basic calibration block of the same thick-ness as the production piping material is not available and where the produc-tion piping material thickness is 1 inch or less, the basic calibration block thickness shall be no more than 25% thinner than the production material thick-ness or shall be closer to the production material thickness than the 3/4-inch thick alternate calibration block allowed by Article 5.

Appreved drawings of basic calibration blocks to be used in acccrdance with this procedure are contained in the applicable SwRI Examination Plan.

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 Revision 9 December 1982 R

NUCLEAR PROJECTS OPERATING PROCEDURE j

Page 5 of 26 The surface finish of the basic calibration block shall be representative of the surface finish of the piping.

Flat basic calibration blocks or blocks of essentially the same curvature as the part to be examined may be used when contact surface curva-tures are greater than 20 inches in diameter.

A curved basic calibration block shall be used to establish distance amplitude correction (DAC) curves for examinations on contact surfaces in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter, when contact surface curvature is 2:0 inches in diameter or less.

The curvature of the mein run pipe shall be used to establish the requirements for the basic calibration block curvature for the examination of branch pipe connection welds.

1 5.4 Search Units (1)

The search unit size shall be selected according to the following:

Straight-Beam Nominal Production Material Thickness Nominal Search Unit Size 2.0" or less 1/4" Round 1.0" to 3.0" 3/8" Round 2.0" to 4.0" 1/2" Round 3.0" to 5.0" 3/4" to 1" Round Angle-Beam The search unit size for carbon steel shall be selected according to the following:

Noninal Production Material Thickness Nominal Search Unit Size 1.0" or less 1/4" x 1/4", 1/4" Round 0.4" te 2.0" 3/8" x 3/8", 3/8" Round 0.75" to 4.0" 1/2" x 1/2", 1/2" Round 2.0" to 5.0" 1/2" to 1", 3/4" Round (2)

The nominal search unit size for austenitic materials shall bc 3/8" round or 3/8" x 3/8".

SwRi Ftwm QA 3 2

SwRI-ET-600-31 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 Jl}*

NUCLEAR PROJECTS OPERATING PROCEDURE Page 6 of 26 1

(3)

The exit point of the sound beam and the actual refracted beam angle of shear-wave search units shall be determined on an IIW block.

The exit point shall be marked on the search unit wedge.

(4)

The nominal angle-beam shear-wave search unit frequency for examination of austenitic piping shall be 1.5 MHz.

(5)

The nominal straight-beam longitudinal-wave search unit frequency for austenitic piping shall be 1.5 MHz or 2.25 MHz.

(6)

The nominal search unit frequency for the carbon steel side of dissimilar piping welds shall be,2.25 MHz.

(7)

The longitudin,al-wave search unit frequency for attenua-tion measurements shall be 2.25 MHz to simulate a 1.5 MHz shear mode, and 5.0 MHz to simulate a 2.25 MHz shear mode.

(8)

For examination of circumferential piping welds, search unit wedges shall be fabricated to produce 45' i2* and 60* t2* refracted shear-waves.

(9)

For examination of longitudinal piping welds or branch pipe connection welds to piping, search unit vedges shall t

be fabricated to produce 45' +2' refracted shear waves.

55 Ultrasonic Instrument The examiner shall use a Sonic FTS Mark I ultrasonic instrument which shall be aligned and shall display an alignment calibration tag as required by NQAP 10-1.

5.6 Couplant (1)

USP grade glycerine or deionized water (with or without wetting agent) shall be used when perf orming ultrasonic calibrations and examinations in accordance with this procedure.

l (2)

USP-grade glycerine shall be certified for sulfur content and total halogens in necordance with ASTM D-129-64 and ASTM D-808-63.

The residual amount of total sulfur or halogens shall not exceed 1% by weight. Deionized water, when used, shall be supplied by the customer.

l SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 Revision 9 December 1982

'h NUCLEAR PROJECTS OPERATING PROCEDURE Page 7 of 26 1

(3)

Couplant materials used for examinations shall be the same as used for the calibration.

5.7 Thermometer Quicktemp thermometer Model SX-666, calibrated and certified in accordance with the applicable revision of SwRI Nuclear Projects Operating Procedure XII-FM-104 shall be used to measure calibration block and component surface temperature.

6 CALIBRATION METHOD 6.1 Instrument Linearity The ultrasonic instrument shall be verified at the beginning of each day for amplitude linearity and amplitude control linearity in accordance with Paragraphs 6.1.1 and 6.1.2.

Data required shall be recorded on the SwRI Instrument Linearity Verification Record and the sheet number shall be refer-enced on the applicable SwRI Sonic Instrument Calibration Record.

6.1.1 Amplitude Linearity (1)

Position a shear-wave search unit on a calibration block to obtain indications from the 1/2T and 3/4T holes.

(2)

Adjust the search unit position to give a 2:1 ratio between the two indications, with the larger indication (1/2T hole) set at 80% of full screen height (FSH) and the smaller indication (3/4T hole) set at 40% of FSH.

(3)

Without moving the search unit, adjust the instrument I

sensitivity (gain) to set the larger indication to 100% of l

FSH.

i (4)

With the larger indication at 100%, record the' amplitude of the smaller indication, estimated to the nearest 1% of FSH.

(5)

Successively set the lar8er indication from 100% to 20% of FSH in 10% increments (or 2 dB steps if a fine control -is not available); observe and record the smaller indication estimated to the nearest 1% of FSH at each setting. The reading must be 50% of the larger amplituda within 5% of FSH.

SwAl Form QA 3-2

-3 SOUTHWEST RESEARCH INSTITUTE CRI-"T-6 o

December 1982 Lk NUCLEAR PROJECTS OPERATING PROCEDURE Page 8 of 26 e _;ny 6.1.2 Amplitude Control Linearity (1)

Position a shear-wave search unit on a calibration block to obtain maximum amplitude from the 1/2T hole.

(2)

Without moving the search unit and according to the fol-lowing table, set the indication to the required percent of FSH and increase or decrease the dB as specified.

The signal shall be estimated and recorded to the nearest 1%

of FSH and shall fall within the limits of the following table:

Indication Indication Set at % of dB Control Limits, % of Full Screen Change

• Full Screen 80%

-6dB 32 to 48%

80%

-12dB 16 to 24%

40%

+6dB 64 to 96%

20%

+12dB 64 to 96%

• Ninus denotes decrease in amplitude; plus denotes increase.

6.2 Calibration The complete ultrasonic calibration shall be performed prior to the examination.

l NOTES l

The REJECT control shall be maintained in the O position during calibratio'n and examination.

The nominal piping production material thickness shall be used to determine the correct calibration block and search units for the examination of piping components which may be thicker than the nominal pipe size and welded to the pipe. The Level II examiner shall ensure that complete coverage of the thicker piping component is obtained.

Additional calibration vee path positions and larger screen sizes may be required to assure this coverage.

The additional calibration vee path positions and larger screen size shall be used for the examination from the thicker component and the nominal pipe side of the weld.

The FREQ MHz control shall be turned to 1 when a 1.5 MHz search unit is used, to 2 with a 2.25 MHz search unit, and to 5 with a 5.0 MHz search unit.

swr! Fem CA 3-2

SOUTHWEST RESEARCH INSTITUTE R"I-""'-6 1,

December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 9 of 26 The type and length of the search unit cable shall be recorded on the SwRI Sonic Instrument Calibration Record.

The centerline of the search unit shall be at least 3/4 inch from the nearest side of the block.

Rotating the beam into the corner formed by the bole and the side of the block may produce a higher amplitude at a longer beam path.

This beam path shall not be used for calibration.

l All spaces on the SwRI Sonic Instrument Calibration Record shall be filled in.

l 6.2.1 Temperature i

The temperature of the calibration block shall be within 25'F of the component temperature and shall be recorded on the SwRI Sonic Instrument Calibration Record for the initial calibration and each verification.

The surface tsaperature of the component to be examined shall be taken prior to performing an examination and shall be recorded on the appli-cable SvRI Examination Record.

t 6.3 Calibration for Circumferential Butt Welds 6.3.1 Straight-Beam Distance Calibration The screen distance chosen shall be the shortest applicable size to include at least 1/4e beyond the thickast production material to which the search unit is applied.

Observing back reflections from the applicable reference block, adjust the MAT'L CAL, RANGE, and DELAY controls to obtain the required linear sound path distance displayed along the screen baseline.

6.3.2 Angle-Beam Distance Calibration i

The screen distance chosen shall be the shortest applicable size to include at least 1/8 vee path past the anticipated examination range.

Observing radius echoes from the applicable reference block, adjust the MAT'L CAL, RANGE, and DELAY controls to obtain the required linear sound path distanca displayed along the screen baseline.

l When the same instrument is used for both 45* and 60* examina-l

• tions, the screen distance calibration shall be conducted in the following manner:

(1)

The screen distance size shall be determined by the angle-beam search unit requiring the longer examination range.

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE R"'-",',-6

-3 December 1982 Rt NUCLEAR PROJECTS OPERATING PROCEDURE Page 10 of 26 (2)

Position the 45' 12* search unit on the appropriate refer-ence block and record all required reference block entries on the appropriate SwRI Sonic Instrument Calibration Record.

(3)

Without changing the MAT'L CAL, RANGE, or DELAY controls, repeat step (2) with the 60* i2' search unit.

(4)

No attempt shall be made to compensate for the delay difference between 45* t2* and 60* t2* screen distance calibra,tions. This difference shall be considered when resolving indications.

6.3.3 Straight-Beam Distance Amplitude Correction A DAC curve shall be established by utilizing responses from the basic calibration holes.

6.3.3.1 Production Material 1 Inch or Less in Thickness (1)

Position the straight beam search unit to obtain maximum response from the 1/2T hole.

(2)

Adjust instrument gain controls to obtain the primary reference response at an amplitude of 50% iS% of FSH.

(3)

Draw a straight horizontal line on the instrument screen l

at the primary reference amplitude to extend a distance equal to the nominal thickness of the production material.

(4)

Signal amplitudes for indications recorded shall be refer-enced as a percentage of this line.

6.3.3.2 Production Material Greater Than 1 Inch in Thickness (1)

Position the straight-beam search unit to obtain maximum j

response from the calibration hole selected from the following, which produces the highest amplitude:

j Hole 1/4T 1/2T (if present) 3/4T i

SwAI Fam 0A 3-2

8"*'-" T-6

-3 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 11 of 26 1-(2)

Adjust the instrume'nt gain controls to obtain a primary reference response at 50% iS% of FSH and mark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining calibration holes and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall extend 1/4T beyond the last qualified. calibration point.

6.3.4 Angle-Beam Distance Amplitude Correction If a curved block is used, DAC curves for the examination of circumferential welds shall be constructed by utilizing the responses from the holes oriented perpendicular to the axis of the basic calibration block.

6.3.4.1 Material 1 Inch or Less in Thickness 45* and 60* DAC (1)

Position the 45*

2* search unit to obtain maximum response from the calibration hole and vee path position, selected from the following,.which produces the highest amplitude:

Hole Vee-Path Positions 1/2T 2/8, 6/8, 10/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% 5% of FSH and mark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

l l

(5)

Repeat steps (1) through (4) using a 60* i2* search unit.

SwRI Fam 0A 3-2

SwRI-NDT SOUTHWEST RESEARCH INSTITUTE n

December 1982 R

NUCLEAR PROJECTS OPERATING PROCEDURE Page 12 of 26 EXCEPTIONS If the configuration of the weld is such that the 60* t2' search unit sound-beam is not directed into the A-B-E-F intersect (as depicted in SKETCH 1) on the straight pass, a 14/8 vee path calibration shall be accomplished with a 45* i2* search unit.

6.3.4.2 Material Greater Than 1 Inch to 3 Inches in Thickness 45* and 60* DAC (1)

Position the 45* +2' search unit to obtain maximum response from the calibration hole and the vee path position, selected from the following, which produces the highest amplitude:

Hole Vee-Path Positions 1/4T 7/8 1/2T (if present) 2/8 3/4T 3/8, 5/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% iS% of FSH and mark this ampli-tude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search un.c to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

l (5)

Repeat steps (1) through (4) using a 60* t2* search unit.

EXCEPTION If the configuration of the weld is such that a 60*

• 2' search unit beam is not directed into the veld root, a 13/8 vee path calibration shall be accomplished with a 45* *2' search unit.

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE

[*'-"",',-6 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 13 of 26 1

6.3.4.3 Material Greater Than 3 Inches to 5 Inches in Thickness 45' and 60* DAC (1)

Position the 45* +2' search unit to obtain maximum response from the calibration hole and the vee path position, selected from the following, which produces the highest amplitude:

Hole 45' Vee-Path Positions 1/4T 7/8 1/2T (if present) 2/8 3/4T 3/8,3/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% 5% of FSH and mark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

(5)

Repeat steps (1) through (4) with a 60* i2* search unit utilizing the following vee path positions:

Hole 60* Vee-Path Positions 1/4T 1/8 1/2T (if present) 2/8, 6/8 3/4T 3/8, 5/8 6.3.4.4 Clad Piping 45' and 60* DAC (1)

Position the 45' t2* search unit to obtain maximum response from the calibration hole and the vee path position, selected from the following, which produces the highest amplitude:

SwRI Fam OA 3-2

SOUTHWEST RESEARCH INSTITUTE U"',"',- 6 December 1982

h. y NUCLEAR PROJECTS OPERATING PROCEDURE Page 14 of 26 e

Hole Vee-Path Positions 1/4T 1/8 1/2T (if present) 2/8 3/4T 3/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% iS% of FSH and mark this amplitude on the screen. The gain controls shall rot be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall extend 1/8 vee path beyond the last qualified calibratica point.

(5)

Repeat steps (1) through (4) with a 60* i2* search unit.

6.4 Calibration for Branch Pipe Connection and Longitudinal Seam Welds 6.4.1 Straight-Beam Distance Calibration The straight-beam distance calibration shall be the same as that described in Paragraph 6.3.1.

I 6.4.2 Angle-Beam Distance Calibration The screen distance chosen shall be the shortest applicable size to include at least 1/8 vee path past the anticipated examination range.

Observing the radius echoes from the applicable reference block, adjust the MAT'L CAL, RANGE, and DELAY controls of the instrument to obtain the required linear sound path distance displayed along the screen baseline.

6.4.3 Straight-Beam Distance Amplitude Correction

(

The straight-beam distance amplitude correction shall be the same as that described in Paragraph 6.3.3.

SwRI Fam OA 3 2

8"*I-"T-6

-3 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 R'

NUCLEAR PROJECTS OPERATING PROCEDURE Page 15 of 26 6.4.4 Angle-Beam Distance Amplitude Correction If a curved block is utilized, DAC curves shall be constructed by utilizing the responses from the basic calibration holes oriented axially with the basic calibration block.

6.4.4.1 Material 1 Inch or Less in Thickness 45' DAC (1)

Position the 45' +2' search unit to obtain maximum response from the calibration hole and vee path position, selected from the following, which produces the highest amplitude:

Hole Vee-Path Positions 1/2T 2/8, 6/8, 10/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% tS% of FSH and mark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Iosition the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

6.4.4.2 Material Greater Than 1. Inch to 5 Inches in Thickness 45* DAC (1)

Position the 45' f2* search unit to obtain maximum response f rom the calibration hole and the vee path position, selected from the following, which produces the highest amplitude:

l SwRI Fam OA 3 2

l SwRI-WT-600-31 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 Ry NUCLEAR PROJECTS OPERATING PROCEDURE Page 16 of 26 Hole Vee-Path Positions 1/4T 7/8 1/2T (if present) 2/8 3/4T 3/8, 5/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% iS% of ?SH and mark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

6.4.4.3 Clad Piping 45' DAC This calibration shall be the same as that described in Para-graph 6.3.4.4, steps (1) through (4), using the 45* i2' cearch unit only.

t 6.5 Secondary DAC Calibrations If all points on the DAC curve do not appear at 20% of FSH or l

greater, a secondary DAC curve shall be constructed as follows:

l l

(1)

All secondary DAC curves shall contain at least 2 points.

l (2)

The DAC point at 2 lines or greater in amplitude and adja-cent to a DAC point that falls below 2 lines of amplitude shall be brought to the primary reference level by manip-ulating the gain controls. This point shall be marked on the instrument screen.

The adjacent point (s), previously at less than 2 lines of amplitude, shall be marked on the screen and all points connected with a smooth curved line.

The gain setting for this secondary DAC curve shall be recorded on the appropriate SvRI Sonic Instrument Caliera-tien Record.

SwRI Fwm OA 3 2

S""'-""T-6

-3 SOUTHWEST RESEARCH INSTITUTE Rsvision 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 17 of 26 EXCEPTIONS When the first DAC point is the only point above 2 lines of amplitude, the next highest point shall be brought to the primary reference level. This point shall be marked on the instrument screen. The other points previously at less than 2 lines of amplitude shall be marked on the screen and all points con-nected with a smooth curved line.

The gain setting for this secondary DAC curve shall be recorded on the appropriate SwRI Sonic Instrument Calibration Record.

It shall not be necessary to construct a secondary DAC when the calibration consists of a 2/8, 6/8, and 10/8 vee path.

66 Calibration verification 6.6.1 Sweep Range and DAC. Curve Verification Sweep range calibration shall be verified on the appropriate reference block; and DAC curve calibration, if applicable, shall be verified on the appropriate basic calibration block:

(1)

At the start of a series of examinations (2)

With any substitution of the same type and length of search unit cable (3)

With any substitution utilizing the same type of power source; e.g.,

a change from one direct current to another direct current source (4)

At least every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during the examination (5)

At the fitish of a series of examinations I

(6)

Whenever the validity of the calibration is in doubt 6.6.2 Calibration Changes (1)

Perform the following if any point on the DAC curve has decreased more than 20% of FSH or 2 dB in amplitude, or any point on the sweep line has moved more than 10% of the sweep reading or 5% of full sweep, whichever is less:

SwAI Fwm OA 3 2

SwRI-M-6M-31 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 18 of 26 (a) Void all examinations referring to the calibration in question and performed after the last valid calibra-tion verification.

(b) Conduct a new calibration.

(c) Reexamine the areas for which examinations have been voided.

(2)

Perform the following if any point on the DAC curve has increased in amplitude more than,20% of FSH or 2 dB:

(a) Correct the calibration.

(b) Reexamine, all indications recorded since the last valid calibration verification.

(c) Enter proper values on a new SwRI Examination Record.

6.6.3 Recalibration Substitution of any of the following shall be cause for recali-bration:

(1)

Search unit (vedge/ transducer)

(2)

Couplant (3)

Ultrasonic instrument (4)

Examination personnel (5)

Cable type of length (6)

Change in type of power source; e.g.,

a change from alternating to direct. current SwRI Form QA 3 2 o

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 Revision 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 19 of 26 7.

EXAMINATION 4

7.1 Examination Areas 7.1.1 circumferential and Longitudinal Butt Welds in Piping Circumferential and longitudinal full penetration butt welds with a nominal thickness of greater than 0.4 inch to 5.0 inches shall be examined from the outside surface of the pipe.

Scanning of the weld and base material shall be adequate to ensure compl'ete coverage for 1/3t f rom the inside surface of the pipe as shown in SKETCH 1.

The base material shall be examined for a distance of a 1/4 inch as measured from the outside surface fusion line on each side of the weld.

Class 1 longitudinal welds shall be examined along the entire length of the weld during the preservice examination and for at.least one pipe-diameter length or 12 inches, whichever is less, from the fusion line of the intersecting circumferential weld during inservice examinations.

Class 2 longitudinal welds shall be examined for at least 2-1/2t length from the fusion line of the intersecting circumferential veld during preservice and inservice examinations.

7.1.2 Butt Welds of Branch Pipe Connections Full penetration butt welds of branch pipe connections in pressure piping greater than 0.4 inch to a maximum of 5.0 inches nominal thickness shall be examined f t om the outside surface of the pipe.

l Scanning of the weld and base material shall be adequate to ensure complete coverage for 1/3t from the inside surface of the pipe. The base material shall be examined for a distance of a 1/4 inch measured from the outside surface fusion line on the main run pipe side of the weld.

7.2 Surface Condition The contact surfaces shall be free from weld spatter, roughness, or other conditions which interfere with free movement of the search unit or impair the transmission of ultrasound.

SwRI Fwm 0A 3-2

s 8""I-" T-6

-3 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 1

l NUCLEAR PROJECTS OPERATING PROCEDURE Page 20 of 26 t

7.3 Indication Length Zero Reference (Lo) Location Areas to be examined in accordance with this procedure shall have an Lo marked in accordance with the applicable revision of SwRI Nuclear Projects Operating Procedure IX-FE-103.

74 Scanning Parameters When practicable, scanning shall be performed at a minimum gain setting of 2 times the reference level sensitivity.

i Instrument' gain setting for scanning shall be determined on the basic calibration block as follows for each primary reference level utilized:

(1)

With the instrument at the primary reference level, manip-ulate the seatch unit on the basic calibration block to obtain a signal of 40% of FSH from a calibration reflector (side-drilled hole).

(2)

Add 6 dB of gain by utilizing the 6 dB switch (if present), the fine gain control or a combination of the fine,and coarse gain controls and choose the method which yields a signal response closest to 80% FSH.

(3)

The signal response of the method chosen shall be within

• 2 dB of 80% FSH.

This amplitude and method shall be recorded on the Ultrasonic Instrument Calibration Record.

The method chosen above shall be used during the valid calibra-tion period for all scanning at 2 times the reference level sensitivity.

7.4.1 Scanning Scanning overlap shall be a minimum of 10% of the search unit piezoelectric element dimension perpendicular to the direction of scan.

The search unit movement rat'e for scanning shall not exceed 6 inches per second.

7.5 Attenuation and Thickness Measurements 7.5.1 Longitudinal Attenuation Measurements A straight-beam search unit as described for a,ttenuation measure-ments (Paragraph 5.4) shall be placed on the appropriate basic calibration block. Obtain a backwall reflection, setting this signal between 50% and 90%

SwRI Fonn OA 3-2

=.

SOUTHWEST RESEARCH INSTITUTE 8",RI-NDT

,,,n December 1982 Rh NUCt. EAR PROJECTS OPERATING PROCEDURE Page 21 of 26 l_Y of FSH.

Record the signal amplitude and instrument gain settings on the appro-priate SwRI Sonic 7.nstrument Calibration Record for Attenuation / Lamination Examination. Adjust the instrument gain controls to display the next backwall reflection at the same amplitude at which the preceding backwall reflection was recorded. Record the signal amplitude, instrument gain settings, and the dB difference required to obtain the adjacent backwall reflections at an equal amplitude.

Place the straight-beam search unit on the examination surface and determine the dB difference required to obtain signals of equal height from two adjacent backwall reflections.

Record this dB difference on the appropri-ate SwRI Exa'mination Record. The search unit for attenuation measurements shall be placed adjacent to Lo on the base material away from the heat-affected zone (HAZ).

If attenuation measurements cannot be taken adjacent to Lo, the location of the measurements shall be recorded on the appropriate SwRI Exami-nation Record. Measurements shall be taken at least at the following locations:

(1)

Two positions for circumferential and longitudinal welds, one on each side of the weld (2)

One position adjacent to Lo on the main run pipe base mate-rial for branch connection welds NOTE Attenuation measurements shall not be conducted for longitudinal or branch connection welds if measurements have been conducted in the applicable piping base material.

No attenuation measurements shall be conducted on clad piping.

)

7.5.2 Thickness Measurements Thickness measurements shall be taken at a minimum of' three points adjacent to Lo for longitudinal and circumferential welds (on the

~

centerline of the weld and at one point in the base material on each side of the weld).

Ihickness measurements shall be taken at a minimum of two points adjacent to Lo for branch pipe connection welds (one on the base material of the main run pipe, and one on the base material of the branch connection).

If these measurements cannot be taken adjacent to Lo, the location of the measure-ments shall be recorded on the appropriate SwRI Examination Record.

SwAl Form QA 3-2

S"*I-""T-6

-3 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 t

i R3 NUCLEAR PROJECTS OPERATING PROCEDURE Page 22 of 26 I"i Screen distance calibration for this examination shall be con-ducted in accordance with Paragraph 6.3.1.

Measurements shall be taken by placing the straight-beam search unit in the appropriate position on the examination surface and observing the position of the back wall reflection on the instrument screen. These measurements shall be recorded on the appropriate SwRI Examination Record.

7.6 Examination of Circumferential and Longitudinal Butt Welds in Piping 7.6.1 Angle-Beam Examination for In'dications Parallel with the Weld Angle-beam examinations for circumferential welds shall be accom-plished using 45' 2* and 60* i2* refracted shear-waves from both sides of the veld.

For this examination, the sound-beam shall be directed perpendicularly into the weld to detect indications parallel with the weld. Calibration for these examinations shall be in accordance with Paragraphs 6.3.2 and 6.3.4.

i Angle-beam examinations for longitudinal welds shall be accom-plished using a 45' i2* refracted shear wave from both sides of the weld.

For this examination, the sound-beam shall be directed perpendicularly into the veld to detect indications parallel with the weld.

Calibration for this exami-nation shall be in accordance with Paragraphs 6.4.2 and 6.4.4.

7.6.2 Alternate Examination A 45' t2' and 60* 12* shear-wave examination shall be conducted as required to assure complete coverage from both sides of the circumferential weld.

A 45' +2* shear-wave examination shall be conducted as required to assure complete coverage from both sides of the longitudinal weld.

Any areas of the weld not receiving complete coverage from both sides shall be examined from one side of the weld with the required shear-wave (s) and a straight-beam longitudinal-wave applied to the surface of the weld crown in the affected areas. Calibration for the longitudinal-wave search unit shall be in accord-ance with Paragraphs 6.3.1 and 6.3.3.

7.6.3 Angle-Beam Examination for Indications Perpendicular to the Weld An angle-beam examination shall be conducted on each weld using a 45* 12* shear-wave. This examination shall be conducted by placing the secrch unit on the weld with the sound beam directed into and parallel with the weld to detect indications perpendicular to the veld. The entire length and width of the weld shall be scanned with the search unit beam directed in this manner, once in a clockwise and once in a counterclockwise direction.

SwRI Fam OA 3 2

8""I- " -6 *-3 SOUTHWEST RESEARCH INSTITUTE savisicn 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE g

Page 23 of 26 ls-For austenitic materials, the search unit shall then be placed on the base metal with the search unit vedge touching the edge of the weld crown and the sound beam directed tangential into the weld at a 45* *10* angle.

The entire length of the weld shall be scanned with the search unit beam directed in this manner on each accessible side of the weld. The search unit shall then be turned 90* and the scans repeated.

Calibration for these examinations shall be in accordance with Paragraphs 6.3.2 and 6.3.4 for cir-3 cumferential welds, and Paragraphs 6.4.2 and 6.4.4 for longitudinal welds and branch pipe connection welds.

Geometric root ripple echoes occurring at the same metal path distance as flaws adjacent to the weld root are to be expected.

A flaw must be distinguished from root ripple by the greater echo amplitude of a flaw compargd to the amplitude of the, root ripple at the same location.

A flaw indication adjacent to the weld root tends to mack out several facets of the root ripple and travels along the baseline through the root ripple package.

7.6.4 Angle-Beam Examinati.on for Indications in Austenitic Base Material Perpendicular to the Weld An angle-beam examination shall be conducted on it of base material adjacent to each weld using a 45'

+2' shear-wave. This examination shall be conducted by placing the search unit on the base material with the

. sound beam directed parallel to the weld to detect indications perpendicular to the weld. The base material within it of the weld shall be scanned with the search unit directed in this manner, once in a clockwise direction and once in a counterclockwise direction.

Calibration for these examinations shall be in accordance with Paragraphs 6.3.2 and 6.3.4 for circunferential welds, and Paragraphs 6.4.2 and 6.4.4 for longitudinal welds and branch pipe connection welda.

7.7 Examination of Butt Welds of Branch Pipe Connections 7.7.1 Straight-Beam Examination of Welds A straight-beam examination shall be performed on the surface of the weld crown when possible.

Calibration for the straight-beam examination shall be in accordance with Paragraphs 6.3.1 and 6.3.3.

7.7.2 Angle-Beam Examination for Indications Parallel with the Weld An angle-beam examination shall be accomplished using a 45* 12' refracted shear-wave from the main run pipe side of the weld.

For this examina-tion the sound beam shall be directed perpendicularly into the weld to detect indications parallel with the weld.

Calibration for these examinations shall be in accordance with Paragraphs 6.4.2 and 6.4.4.

SwRl Fam OA l-2 1.

-3 SOUTHWEST RESEARCH INSTITUTE

%"I7,-6 1

December 1982 q

NUCLEAR PROJECTS OPERATING PROCEDURE Page 24 of 26 w

4 7.7.3 Anale-Beam Examination for Indications Perpendicular to the Weld The angle-beam examination for indications perpendicular. to the weld shall be the same as the examination described in Paragraph 7.6.3.

7.8 Postexamination Cleaning Arrangements shall be made with the customer for postexamination removal of couplant materials.

8.

RECORDING CRITERIA Ultrasonic reflectors producing a response greater than 50% of the ref-erence level shall be recorded on the appropriate SwRI Ultrasonic Examination Record.

Any ultrasonic reflectors not readily attributable to geometry by the examiner shall be recorded on the appropriate SwRI Ultrasonic Examiantion Record and investigated by a Level II or Level III examiner to the extent necessary to determine the shape, identity, and location of the reflector.

Examples of non geometric reflectors (which may. occur at any ampliutde) are those which are slightly removed from the weld root and/or chaefer, mask the.

j root indications, are transverse to the weld, or have linear dimensions with side branches.

The end points of the indication as determined by 100% DAC shall.be recorded.

l Indications shall be recorded in accordance with the techniques outlined in the applicable revision of SwRI Nuclear Projects Operating Procedure IX-FE-117.

Indications investigated and found to be other than geometrical in nature, regardless of the amplitude, shall be reported to the customer for evaluation.

Scanning limitations shall be recorded.

9.

EVALUATION Evaluation of reportable indications shall be the responsibility of the customer, or the customer's representative, and shall be conducted in accor-dance with ASME Eoiler and Pressure Vessel Code,Section XI, Article IWA-3000.

The applicable year and Addenda of the Code shall be as specified in Para-graph 3. of this procedure.

l SwAl Form OA 3-2

SOUTHWEST RESEARCH INSTITUTE S""I * -6

-3 Revision 9 December 1982 w

NUCLEAR PROJECTS OPERATING PROCEDURE Page 25 of 26 26 10.

RECORDS The customer shall receive copies of documents generated in accordance with this procedure in the examination report.

Documents generated in accordance with this procedure shall be stored and retained as a portion of the examination report. The examination report shall be stored by the Manager of the Support and Administration Section, Quality Assurance Systems and Engineering Division, in the Data Storage Facility for the period specified by the contractual agreement with the customer.

l d

j SwAl Foem QA 3 2

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'v.. C1. IIvMUR. a am reementee %et finie songgruste - le fesh dmove peeeeture / eve =usam es[ai arnas

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-=nes n,teeed, eveonesee

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4 at a.e++e.cr n Add the following as the third and fourth paragraphs of 7.3.3:

For austenitic materials, the eedreh uu1t shall he placed on the bene ratal with the searca unit wedge touching the edge of the veld crown and the r.nund bes= directed Ni tsny,cntial into r.he weld at a 45* 1 10* angle.

The entire length of the veld siae11 g

be sesu :*d with the scarch unit beam directed la this manner ou each secessihic side I;of:new1d.

The seerch unit shall then he turned 90* and the nennn repeated.

Cenmetric root ripple echoes occurring at the same s tal path distanen as flava adiacent to the vald root are to be exuetted.

A flav meu;t be distin uiehed fror g

t g

root ripple by the greater echo amplitude of a flaw co= pared to the emplitude u>

the 4

root ripple at the 4ame location. A flaw indicatir,n adjacent to the veld root tena,

[I to r. ash out several' facets of the root ripple and travels along the bannline through Q, the root ripple package.

'J

$ l

[,.,.4J an angle-beam ex9mination shall be conducted on It of asu:tenitic baee =aceris t l ~ ? odjacent to cach austecitie veld using a 45* i 2* shear-wsve.

This examination shall he conducted by placlog the search unit on tFe base material with the suuud

_h

'N) heam directed parallel to the vs.2d to detect Indications perpendicular to the w Id.

ne bane raterin3 vithin it of the weld snall he nc. nned with the search tmir directed l %

in this ranner, onen in a clockwlee direction and a cc in a counterclockwise dir4-crion l 31 sy'

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6 I*

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.t D. y Y* FEC 4 T f;)3,_, jg 3'tG49 W IE S'WWWWWPf7 EEEe

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-,3 this chans:e i= neceeesty to incorporate chanEcs rer;msted bv Cnolins Pow r a f.tpr C'Ip Ally.

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l Sw21-N1JTR-700-5/ 9 Deviation 4' Fage 2 of 2 Change 8.0 to read as follows:

Ultrasonie reflectors producing a response greater than 50% of the reference level shall be recorded and investigated by a Lr,el 11 cr Level 111 eraniner to the extent necessary to define tic shape, identity, and location of the reflector. Additionally, all ultrasonic reflectors (regardless of signal amplitude) noe readily attributable to geometry by the examiner shall be recorded and investigated by a Level II or Level III eraminer to the extent necessary to determine the shape, identity, and location of the reflector.

Eraep;es of non 7.cometric reflectors (which osy occur at any aunlitude) are those which are slightly removed from the veld root and/cr charfer, maak the root indications. are transverse to the veld, or have linear dimensions with, side branches.

3

~

Indications not readily attributable to geometry by the examiner, when scanning in the}K direction (length of indicatien), shall require scans in the Y direction (vidth of ; indication), extending to loss of signal along the I exis.

The scans in the Y direction shall extend to loss of signal along the Y 2xis.

3 Y scan increments shall be one-tenth inch. All T scans shale run in the sen* direction. upon corpletion of which an X-scan shall be run at the maxi = = saplitude location.

Indicstions investigated sud found to be other than geometrical in nature shall be reported to the custoner for evslustion.

Scarning limitations shall be recorded.

1

PROCEDURE DEVIATION R '

f s3TE' PROCEDURE / AEVISICN NC.

M l

Brunswick, Unit 1 700-5/9 SECTICNs PAE QEYtATIO N NO.

PAGE CATE RECOc.a. c J.

X N 2

1 er 1 November 30,1982-7.

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Piping examinations required to be perforned during the 1982 hservice Examination at Brunswick Steam Electric Plant, Unit 1 shall be affected y

by this deviation.

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j' Delete the last two paragraphs of 7.3 when examinations are to be perfor=ed on piping Components which received a base material lamination scan during a s a previous examination.

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This deviation is necesaary to make a change at the request of l

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Carolina Power & Light Co=pany.

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.,wRI-NDT-700-5 SOUTHWEST RESEARCH INSTITUTE N'UC1. EAR PROJECTS

," 9 1931 OPERATING PROCEDURE Page 1 of 23 MECHANIZED ULTRASONIC EXAMINATION OF VESSEL COMPONENTS, VESSEL WELDS, AND PIPING WELDS EFFECTIVITY AND APPROVAL O

Revision 9 of this procedure became effective on Otner revisions of the t:ase document may be effective concurrently.

SA Approvals Written 3y Date Technical Review Date W

lfh 8I 4pj 7

Manager of 0.A.

Date Co i nt Director Date l

l

((

., ll f/

)

l c

M The following information may be used for convenience. Cd,moietion of this portion is not mandatory.

Deviation No.

Date Effective Procecure Sectioniss Affected M400ET); hk H3-83 Bstpfoy p site Swat Form CA4cA.o

SwRI-NDT-700-5

)

SOUTHWEST RESEARCH INSTITUTE Revision 9

/

December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 2 of 23 MECHANIZED ULTRASONIC EXAMINATION OF VESSEL COMPONENTS, VESSEL WELDS, AND PIPING WELDS SvRI-NDT-700-5 1.0 PURPOSE This procedure provides the technical information and' detailed steps required to ensure proper mechanized ultrasonic examination of nonwelded pressure vessel c;sponents, vessel and piping welds and adjacent base mate-rials in accordance with the applicable ASME Boiler and Pressure Vessel Code.

2.0 SCOPE AND APPLICATION Mechanized ultrasonic examinations shall be performed using surface waves, shear-vave angle-beam and longitudinal-wave angle-and straight-beam, immersion or contact pulse echo techniques on pressure " vessels or piping.

N nvalded pressure vessel components greater than 0.4 inch to 12.0 inches

')

o in vall thickness, pressure vessel welds and adjacent base =aterial greater

/

than 0.4 inch to 2.0 inches in wall thickness, and pressure piping welds and adjacent base material greater than 0.4 inch to 5.0 inches in vall thickness shall be examined in accordance with this procedure. Welds or components to be examined shall be as specified in the applicable SwRI Scan Plan and Examination Plan.

Examinations may be conducted on clad or unciad components.

2.1 Apolicable Documents The following documents, as applicable, form a part of this procedure:

(1)

ASME Boiler and Pressure Vessel Code,Section II,1977 Edition, with Addenda through Summer 1978, " Rules for Inservice Inspection of Nuclear Power Plant Components" (2)

ASME Boiler and Pressure Vessel Code,Section V, 1977 Edition, with Addenda through Summer 1978, " Nondestructive Exanination," with the exception of the following:

(a)

Subparagraph T-333.1 of Article 5 requires the basic calibration block for production material thicknesses up to and including 1 inch to be 3/4 inch or "t."

Paragraph 5.3 of this procedure requires the basic SwRI Fonn CA 3 2

SOUTHWEST RESEARCH INSTITUTE Ev"C" 'n-7 December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 3 of 23 q

calibration block to be either "t," no more than 25%

less.than "t," or closer in' thickness to the produc-tion material than the 3/4-inch alternate thickness allowed by Article 5 for production material thick-nesses up to and including 1 inch. This exception will assure a more accurate calibration than the Article 5 basic calibration block design allowed by Code.

(b)

Subsubparagraph T-535.1 (d) of Article 5 states that transfer (attenuation cocpensation) be accomplished between the production material and basic calibration block and a correction made for the difference. No I

attempt shall be made by the examiner to compensate l

for observed difference in the acoustic properties between the basic calibration block and the produc-tion material, as refere'nced in 7.1.

(3)

ASME Boiler and Pressure vessel Code,Section IX, 1977 Edition with Addenda through Summer 1978 " Welding and Brazing Qualifications" (4)

SwRI Nuclear Quality Assurance. Program Manual (NQAPM) 3.0 RESPONSIBILITY (1)

The Director of the Department of Engineering Services within the Quality Assurance Systems and Engineering, Division shall be responsible for the preparation, review, control, and approval of this procedure.

(2)

The Project Manager shall be responsible for the implementation of this procedure in accordance with the NQAPM specified in the applicable SwRI Project Plan.

(3)

The examiner shall be responsible for i=plementing the require-ments of this procedure.

(4)

The Manager of the Support and Administration Section of the Quality Assurance Syste=s and Engineering Division shall be responsible for storage of records generated in accordance with this procedure.

)

SO.UTHWEST RESEARCH INSTITUTE S"*I;l"'n~;

e December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 4 of 23 I

m-4.0 CODE AND PROCEDURE REQUIREMENTS The requirements listed' below shall be applied when performing mecha-nized ultrasonic examinations in accordance with this procedure.

Requirements Section (1)

Weld type's and configurations to be 7.0 examined, including thickness dimensions, materials, and product form (2)

The examination surface (s) 7.0 (3)

Surface condition 7.0 (4)

Couplant 5.0 (5)

Technique used 2.0 (6)

Angles and mode of, wave propagation 5.0 in the material (7)

Type and size of search unit 5.0 (8)

Examination frequency 5.0 (9)

Search unit wedges, shoes, or saddles 5.0 (10) Ultrasonic instrument 5.0 (11) Calibration method used 6.0 (12) Scanning 7.0 (13) Recording of data 8.0 (14) Automatic defect alarm and recording equipment 5.0 (15) Rotating, revolving scanning 5.0 mechanisms (16) Personnel qualification 5.0 (17) Type and length of search unit cable 6.0

SOUTHWEST RESEARCH INSTITUTE 8","l2?-7

-5

,e December 1981 5

NUCLEAR PROJECTS OPERATING PROCEDURE Page 5 of 23 q

5.0 PERSONNEL AND EQUIPMENT 5.1 Personnel Certification Personnel performing examinations in accordance with this procedure shall be certified in accordance with SwRI NQAP 11-1, "Special Process Control."

52 Reference Block Reference blocks to be used for screen distance calibration and verification shall be as follows:

(1)

SwRI Half-Round (Sketch 1)

(2)

AWS Type DC (Sketch 2)

(3)

IIW (Sketch 3)

The reference block shall be of the same basic material as the production material; i.e., carbon steel or stainless steel.

5.2.1 Reference Block Selection Reference blocks sh'all be used as follows for screen distance calibration:

l (1)

Straight Beam Screen Block Distance Block Tyne Dimension 1.0", 2.0" SwRI Half-Round 1.0" AWS Type DC 0.5" or 1.0" IIW l.0" 2.5", 5.0", 10.0" SwRI Half-Round 1.0" AWS Type DC 1.0" IIW l.0" 20.0" IIW 4.0" swAI Form 0A 3 2

SwRI-NDT-700-5

}

SOUTHWEST RESEARCH INSTITUTE Ravision,

/

December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 6 of.23 (2)

Angle Beam Screen Block Distance Block Type

, Dimension

~

2.0", 2.5", 5.0" SwRI Half-Round 1.0" Radius AWS Type DC 1.0" and 2.0"

Radii, 10.0" SwRI Half-Round, 1.0" Radius AWS Type DC 1.0" and 2.0" Radii IIW Block 4.0" Radius 20.0", 40.0" IIW Block 4.0" Radius 5.3 Basic Calibration Block If examinations are to be conducted on a clad component from the clad surface, the basic calibration block shall be clad to the nominal thick-ness of the component cladding il/8 inch. Deposition of clad shall be by the automatic method used on the inside of the component. Where the automatic method is impractical, deposition of clad shall be by the manual method used to cover the circumferential velds of the component.

The basic calibration block, except for inner radii examinations, shall contain side-drilled basic calibration hole reflectors, in accordance with Article 5 of Section V.

The reflectors in the inner radius basic cali-bration block shall be notches. The reflectors shall be placed in a block manufactured from material of the same or equivalent P-number grouping as the production material, as identified in Section IX of the AS E Code.

P-numbers P-1, P-3, P-4, and P-5 shall be considered to be equivalent for the purpcses of this examination. When two different P-number materials are involved, the calibration material shall be determined by the production material to which the search unit is applied.

The basic calibration block thickness shall be determined by the thickness of the production material to which the search unit is applied and by Article 5.

When a basic calibration block of the same thickness as the produc-tion material is not available and where the production material thickness is 1 inch or less, the basic calibration block thickness shall be no more than 25%

thinner than the production material thickness or shall be closer to the production material thickness than the 3/4-inch thick alternate calibration block allowed by Article 5.

Approved drawings of the basic calibration blocks to be used in accordance with this procedure are in the applicable SwRI Scan Plan.

SwRI-NDT-700-5 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1981 NUCLEAR PROJECTS OPERATING PROCECURE Page 7 of 23 A flat basic calibration block or blo'ck of essentially the same curvature as the part to be examined shall be used for examinations on contact surface curvatures greater than 20 inches in diameter.

For contact surfaces 20 inches or less in diameter, a single curved basic calibration block may be used to establish sensitivity ' calibration for examinations conducted on contact surfaces in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter.'

5.4 Search Units The size of search units shall be selected according to the following table:

b2 (1)

Angle Beam Nominal Production N minal Search Unit Size Material Thickness o

0.4" to 1.0" 1/4" x 1/4",1/4" Round 0.4" to 2.0" 3/8" x 3/8", 3/8" Round 0.75" to 4.0" 1/2" x 1/2", 1/2" Round 2.0" to 7.0" 1/2" x 1", 3/4" Round 5.0" to 12.0" 1" x 1", 1" Round, 1-1/8" Round 4

(2)

Straight Beam Nominal Production Material Thickness Nominal Search Unit Size 0.4" to 2.0" 1/4" Round 1.0" to 3.0" 3/8" Round 2.0" to 4.0" 1/2" Round 3.0" to 7.0" 3/4" or 1" Round 5.0" to 12.0" 1" Round or 1-1/8" Round The exit point of the sound beam and the actual refracted beam angle of shear-wave search units shall be determined on an IIW block.

The exit point shall be marked on the search unit wedge.

Search unit wedges shall be fabricated to ensure that the proper angle of refracted shear-or longitudinal-waves are produced in accordance with the appropriate SwRI Scan Plan.

$wm Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE

)

December 1981 NUC(EAR PROJECTS OPERATING PROCEDURE Page 8 of 23 The nominal search unit frequency for examination of carbon steel piping welds, vessel welds, nozzle-to shell welds, nozzle inner radil, and integral extensions shall be 2,.25 MHz.

The nominal shear-wave search unit frequency for examination of austenitic piping shall be as fellows:

Nominal Frequency Search Unit Size 2.25 MHz 1/4" x 1/4",1/4" Round 1.5 MHz 3/8" x 3/8"', 3/8" Round 1.5 MHz 1/2" x 1/2",1/2" Round 1.5 MHz 3/4" Round, 1/2" x 1" The nominal longitudinal wave search unit frequency for austenitic piping shall be 1.5 MHz or 2.25 MHz.

5.5 Ultrasonic Instrument and Scanning Mechanisns The examiner shall select an appropriate ultrasonic instrument

'T from the following:

,/

(1)

Sonic FTS Mark II (2)

Sonic WA Mark III (3)

Branson Sonoray Series 600 Retating, revolving, or scanning mechanisms used when perfor=ing mechanized ultrasonic examinations shall be described in the SwRI Scan Plan.

Automatic def ect alarm and recording equipment to be utilized is specified in the applicable revisions of SwRI Nuclear Projects Operating Procedures XII-FM-106, XII-FM-108-4, and XII-FM-129.

Each instrument shall be aligned and shall display an alignment calibration sticker as required by NQAP 10-1.

5.6 coualant (1)

USP grade glycerine or deioni:ed water (with or without wetting agent) shall be used when performing ultrasonic calibrations and examinations in accordance with this procedure.

(2)

Couplant materials used for examinations shall be the sane as used for the calibration.

SwAI Form QA J-2

SOUTHWEST RESEARCH INSTITUTE

[v"C""',-*-5 December 1981 NUCLEAR PROJECTS OPERATING PFiOCEDURE Page 9 of 23 q

(3)

Light oil or other compounds which, in the opinion of the Level II examiner, provide adequate ultrasonic couplir4 may be used upon concurrence of the Project Manager respon-sible for the examination.

(4)

All couplants other than deionized water shall be certified for sulfur content and total halogens in accordance with ASTM D-129-64 and ASTM D-808-63.

The residual amount of total sulfur or halogens shall not exceed 1% by weight.

Deionized water, when used, shall be supplied by the customer.

5.7 Thermometer Quicktemp thermometer Model SX-666, calibrated and certified in accordance with SwRI Nuclear Projects Operating Procedure XII-PM-104 shall be used as required to measure basic calibration block and component surface temperature.

6.0 CALIBRATION METHOD Calibratica details such as vee-path positions and sweep distance shall be described in the applicable SwRI Scan Plan.

The complete ultrasonic examination system calibration shall be per-formed prior to the examination.

NOTES The " REJECT" control shall be maintained in the "0" position during calibration and examination.

The nominal piping production material thickness shall be used to deter-mine the correct calibration block and search units for the examination of piping components which may be thicker than the nominal pipe size and welded to the pipe. The Level II examiner shall ensure that complete coverage of the thicker piping component is obtained. Additional cali-bration vee-path positions and larger screen sizes may be required to assure this coverage. The additional calibration vee-path positions and larger screen size shall be used for the examination from the thicker component and the nominal pipe side of the weld.

The "FREQ MHz" control shall be turned to "1" when a 1.5 MHz search unit is used and to "2" with a 2.25 MHz search unit.

Swm Form cA 3-2 '

~

i SOUTHWEST RESEARCH INSTITUTE

'"*EN -'

)

Re December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 10 of 23 The crew leader of the crew conducting the initial calibration.for a group of examinations shall sign the calibration sheet in one of the spaces provided, preferably the top space. He shall also date the sheet and enter the time of completion of the calibration in the time space on the sheet.

Each subsequent shift shall verify the calibration at the beginning of each shift following the initial calibration. The crew leader shall at that time sign his name to' the calibration sheet and enter the date and time of that verification adjacent to his signature. He shall also enter the time and his initials in the calibration verification section of the sheet.

The temperature of the basic calibration block during calibration and verifications shall be within 25*F of the component temperature. For examina-tions from the inside surface of the vessels, water temperature inside the ves-sel may be used for component temperature. Under no circumstances shall exami-nations be performed if the temperature of the basic calibration block is not within 25'F of the component to be examined. The temperature of the basic calibration block during the initial calibration and the temperature during each verification shall be recorded on the applicable SwRI Instrument Cali-bration Record. The component temperature prior to performing the examination

)

and upon completion of the examination shall be recorded on the applicable SwRI

./

Examination Record.

6.1 Instrument Linearity The ultrasonic instrument shall be verified for amplitude lin-earity and amplitude control linearity in accordance with Paragraphs 6.1.1 and 6.1.2.

This verification shall be conducted at the beginning of each day.

Data required shall be recorded on the "SwRI Instrument Linearity Verification" Record and the sheet number referenced on the applicable SwRI Instrument Calibration Record.

6.1.1 Amplitude Linearity (1)

Position a shear-wave search unit on an SwRI Ealf-Round reference block and obtain at least two radius echoes.

(2)

Adjust the search unit position to give a 2-to-1 ratio between two radius echoes with the larger indication set at 80% of full screen height (FSH) and the smaller indication 4

set at 40% of FSH.

(3)

Without moving the search unit, adjust the instrument sensitivity (gain) to set the larger indication to 100% of FSH.

SOUTHWEST RESEARCH INSTITUTE 8"*'2',-*-5 December 1981 NUCLEAR PROJECTS OPER ATING PROCEDURE rage 11 of 23 (4)

With the larger indication at 100%, record and the positica of the smaller indication, estimated to the nearest 1% of FSH.

(5)

Successively set the larger indication from 100% to 20% of FSH in 10% increments (or 2 dB steps if a fine control is not available). Observe and record the smaller indication, e'stimated to the nearest 1% of FSH, at each setting. The reading must be 50% of the larger amplitude within 5% of FSH.

6.1.2 Amplitude Control Linearity EXCEPTION An amplitude control linearity check is not required if an electronic DAC is utilized and/or the gain controls are not to be manipulated.

(1)

Position a shear-wave search unit on an SwRI Half-Round reference block to obtain maximum amplitude from the radius.

(2)

Without moving the search unit and according to the following table, set the indication to the required percent of the FSH and increase or decrease the dB as specified.

The signal shall be estimated and recorded to the nearest 1% of FSH and shall fall within the limits of the following table:

Indication Indication Limits, % of Set at % of dB Control Full Screen Change

• Full Screen 80%

-6 dB 32 to 48%

~

80%

-12dB 16 to 24%

40%

+6dB 64 to 96%

20%

+12dB 64 to 96%

• Minus denotes decrease in amplitude; plus denotes increase.

6.2 Straight-Beam Distance Calibration j

Distance calibration for circumferential welds and longitudinal velds shall be constructed by observing the back reflections from an applicable reference block and adjusting the " MAT'L CAL," " DELAY," and " RANGE" controls i

)

O SOUTHWEST RESEARCH INSTITUTE S""C""n$-5 December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 12 of 23 l

to obtain a linear sound path distance displayed along the screen baseline.

In all cases, the screen distance chosen shall be the shortest applicable size to

(

include at least 1/4t beyond the nominal production material thickness.

l Distance calibration for integral extensions shall be constructed by observing the back reflections from an applicable reference block and adjust-ing the " MAT'L CAL," " DELAY," and " RANGE" controls to obtain a linear sound path distance displayed along the screen baseline. In all cases, the screen distance chosen shall be the shortest applicable size to include at least 25%

of the wall thickness beyond the anticipated examination distance.

6.3 Angle-Beam Distance Calibration Distance calibration for circumferential welds and longitudinal l

welds shall be constructed by observing the radius echoes from an applicable reference block for the material and thickness involved and adjusting the

" MAT'L CAL," " DELAY," and " RANGE" controls to obtain a linear sound path dis-tance displayed along the screen baseline.

In all cases, the screen distance chosen shall be the shortest applicable size to include at least 1/8 vee path beyond the anticipated examination distance.

Distance calibration for integral extensions shall be constructed by observing the radius echoes from an applicable reference block for the mate-rial and thickness involved and adjusting the " MAT'L CAL," " DELAY," and " RANGE" l

controls to obtain a linear sound path distance displayed along the screen base-line. In all cases, the screen distance chosen shall be the shortest appli-cable size to include at least 25 of the wall thickness beyond the anticipated examination distance.

1 l

The search unit wedge shall be re=oved prior to the preliminary l

distance calibration for nozzle inner radius from the outer blend radius and I

for other examinations utilizing angle-beam longitudinal-wave search units.

l Observing the back reflections from an applicable reference block, adjust the

" MAT'L CAL," " DELAY," and " RANGE" control to obtain a linear sound path dis-tance displayed along the screen baseline. After the preliminary distance calibration, remount and couple the search unit wedge to the search unit.

Posi-tion the search unit for the maximum response from a reflector in the basic calibration block. Physically ceasure the metal path distance to this reflec-tor and adjust the signal to the appropriate location on the screen baseline, only using the " DELAY" control.

This completes the distance calibration.

6.4 Straight-Beam Distance Amolitude Correction for Material 1.0-Inch or Less in Thickness Straight-beam DAC for =aterial 1 inch or less in thickness shall be n one point zone calibratien which does not use electronic DAC.

Swm Form QA 3-2

\\

l SOUTHWEST RESEARCH INSTITUTE

[*CE"'n~l~'

December 1981 NUCLEAR PROJECTS OPERATING PROC' DURE Page 13 of 23 E

4 Position the search unit to obtain maximum response from the basic calibration hole at 1/2T. Adjust this amplitude to the primary reference level at 50% *S% of full screen height (FSH) and mark the amplitude on the A straight horizontal line shall then be drawn en the instrument screen.

screen at the amplitude of the primary level. The line shall extend a distance equal to the nominal thickness of the production material. All indications recorded shall be referenced as a percentage of this line for signal amplitude.

6.5 Electronic Distance A=plitude Correction Electronic DAC is used to set reflector responses from a cali-bration block equal in amplitude regardless of the distance of the reflector from the search unit.

6 5.1 Angle Beam cnd Straight Beam for Welds Electronic DAC curves shall be constructed by utilizing the responses from the basic calibration hole (s). The initial point on the DAC curve is established by manipulating the search unit to obtain maxinum response from the nearest suitable position. The instrument gain is then adjusted so that this response is 50% iS% FSR. This is the primary reference response and shall be marked on the instrument screen. The search unit shall be placed similarly at other required positions. Using the electronic DAC controls, adjust remaining responses to the primary reference level and. mark their amplitudes on the screen. These points shall be joined by a straight hori-zontal line, not to extend more than 1/8 vee-path or 1/4T beyond the last qualified calibration point.

6.5.2 Multiple-point Zone Calibration Maximum response from the nearest suitable reflector obtained by manipulating the search unit. Adjust the instrument s-4 - t response at 50% i3% FSH. This is the primary reference response se marked on the instrument screen. The search unit shall be placed

...a maximum response from the other required reflectors. Using the electronic DAC controls, adjust their maximum responses to the primary reference level and mark their amplitudes on the screen. These points shall be joined by a straight horizontal line, not to extend more than 20% of the wall thickness to either side of the calibrated zone.

6.5.3 Single-Point Zone Calibration for Inner Radius Without Using Electronic Distance A=clitude Correction Examination of the inner radius from the inside surface shall bc conducted without using the electronic DAC controls. Two search units shall be Seal Form QA 3-2

m SOUTHWEST RESEARCH INSTITUTE

'""I!"'n~'

~'

Rv December 1981

~

NUCLEAR PROJECTS OPERATING PROCEDURE Page 14 of 23 q

~

used for this examination. One search unit will act as an ultrasonic mirror and the other search unit will be connected to the instrument. Submerge the basic calibration block in deionized water. Position the search units to reflect the sound beam off the radius in the basic calibration block and to obtain the signal back from the ultrasonic mirror. Adjust the instrument

" MAT'L CAL," " DELAY," and " RANGE" controls so the reflection from the ultra-sonic airror is displayed on the instrument screen. Position the search units to obtain the first reflection from the notch in the. radius of the basic cali-bration block. This signal will appear on the instrument screen between the initial pulse and the signal obtained from the ultrasonic mirror. Adjust the

" MAT'L CAL," " DELAY," and " RANGE" controls to set the signal from the notch to approximately the center of the screen while retaining the signal from the ultrasonic mirror on the instrument screen. Adjust the gain controls to set the signal amplitude to 75% tS% FSH. This is the primary reference level and shall be marked on the instrument screen. A line shall be drawn on the instru-1 ment screen through this point not to extend more than 20% of the wall thick-ness to either side of the point.

6.6 Calibration Verification 6.6.1 Frequency of Instrument Calibration Verification (1)

Sweep range calibration shall be verified on the appropri-ate reference block and DAC curve calibration, if appli-cable, shall be verified on the appropriate basic cali-bration block:

(a)

At the start of a series of examinations (b)

With any substitution of the same type and length of search unit cable (c)

With any substitution utilizing the same type of power source; e.g., a change f rom one direct current source to another direct current source.

(d)

At leart every 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> during the examinat' ion ~ ~ '

~~'

(e)

At any time when, in the opinion of the examiner, there is doubt as to the validity of the calibration (2)

When a group of examinations has been coupleted using a given calibration, the final verification shall be initialed by the crew leader in charge.

SwAI Fown CA 3 2

\\

SOUTHWEST RESEARCH INSTITUTE

["l;l"',;*3 December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE q

Page 15 of 23 (3)

The last calibration verification at the end of a shift shall be conducted during the interface period and in conjunction with the oncoming crew. The two crew leaders shall verify the calibration together as a handoff. Both

~

crew leaders' initials should appear on che calibration sheet for verification conducted in this manner.

NOTES The mechanized positioning equipment calibration shall be verified in conjunction with the instrument calibration verification or at least every 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> during the exami-nation. Device counts per increment shall be verified to coincide with counts per increment as specified in the Sean Plan examination tables. The "0" position and linearity of the X and Y readout shall be verified in accordance with the appropriate Operating Guide.

Ultra. sonic instrument functional checks shall be conducted every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during scanning to determine if any apparent functional changes have occurred in the instrument.

If any reflector from the function block has moved on the sweep line more than 5% of full screen width or changed in ampli-tude more than 20% or 2 dB, the instrument calibration

~

shall be verified on the appropriate reference and basic calibration blocks.

6.6.2 Calibration Changes (1)

Perform the following if any point on the DAC curve has decreased more than 20% or 2 dB in amplitude, any point on the DAC has coved on the sweep line more chan 5% of full screen width or : ore than 10% of the sweep division reading, whichever is less:

(a)

Void all examinations referring to the calibration in question and performed af ter the last valid calibra tion verification.

(b)

Conduct a new calibration.

(c)

Reexamine the areas for which examinations have been voided.

SOUTHWEST RESEARCH INSTITUTE Uv"Cl"'n-'

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December 1981

~

NUCLEAR PROJECTS OPERATING PROCEDURE Page 16 of 23 (2)

Perform the following if any point on the DAC has increased in amplitude more than 20% or 2 dB:

(a)

Correct the calibration.

(b)

Reexamine all indications recorded since the last valid calibration verification.

(c)

Enter proper values on a new SwRI Examination Record.

6.6.3 Recalibration Substitution of any of the follewing shall be cause for recalibration:

(1)

Search unit (wedge / transducer)

(2)

Couplant (3)

Ultrasonic instrument (4)

Examination personnel (substitution of examination person-nel shall be defined as any substitution of the Level II or the Level III crew leader during a shift) 1 l

(5)

Cable type or length (6)

Change in type of power source; e.g., a change from alternating to direct current 6.4 Calibration Data Calibration data vill be recorded on the appropriate SwRI Instru-ment Calibration Record and will include, but not be limited to:

(1)

Serial number of the reference block (2)

Serial number of the basic calibration block (3)

Type, manufacturer, and serial number of the ultrasonic instrument l

l (4)

Type, size, beam angle, and serial number of the ultra-sonic search unit 3

SwAl Form CA 3-2

SOUTHWEST RESEARCH INSTITUTE U"[f',-7 December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 17 of 23 (5)

Nominal search unit frequency (6)

Couplant (0hich shall be the same as used in the actual examination)

(7)

Signature and ultrasonic certification level of examiner making calibration (8)

Date calibrated (9)

Time of calibration and calibration verification 7.0 EXAMINATION 7.1 Examination Areas The following are specific areas on which mechanized ultrasonic examination of pressure vessel welds, piping welds, adjacent base material, and 1

components from the inner or outer surface of pressure vessels shall be performed:

(1)

Piping welds and adjacent base material in a thickness range of greater than 0.4 inch and up to 5.0 inches (2)

Vessel welds and adjacent base material in a thickness range of greater than 0.4 inch and up to 2.0 inches (3)

Nonwelded vessel components (i.e., nozzle inner radius, and integral extensions) in a thickness range of greater than 0.4 inch and up to 12.0 inches Attempts to determine differences in the acoustic properties between the basic calibration block and the production material which would j

result in an instrument gain change are not permitted.

7.1.1 Vessel Welds i

I Examinations shall be perf ormed on components in their complaced condition. Examination of vessel welds shall include the veld and base mate-rial for 1/2t from the fusion line of the weld. The required 1/2t examination area on base material thicknesses that differ on each side of the veld shall be determined by the nominal thickness of the base material on the side of the weld from which the examination is to be performed. The 1/2t to be examined shall be measured from the outside surf ace fusion line at the veld crown.

The examination of vessel velds and adjacent base material shall be conducted with a 45* t2* and a 60*

2* search unit. The 45' 2* and the

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SOUTHWEST RESEARCH INSTITUTE E"CE"'n~'

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December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 18 ot' 23 60* *2' search units shall be used to direct the sound beam perpendicularly into the weld. This examination shall be conducted from both sides of the weld, when practicable. The 45' t2' search unit shall also be utilized to conduct a trans-verse examination of the veld and 1/2t of base material on each side of the veld.

The sound beam shall be directed parallel to the veld to conduct the examina-tion; then the search unit shall be turned 180* and the examination repeated.

7.1.2 Nonwelded Vessel Consonents Examinations shall be performed on components in their completed condition. The examination area for nonwelded components shall be as speci-fied in the applicable SwRI Sean Plan.

Inner radius examinations from the outer blend radius shall use refracted longitudinal waves which strike the inner radius at 45' *10*.

Inner radius examinations from inside the vessel shall be conducted at 1/4-inch increments with an angle-beam search unit producing a nominal 45' in water and surface waves along the inner radius section.

7.1.3 Piping Welds The examination area for piping walds shall be the lower 1/3e of the weld and base material. The piping base material shall be examined for 1/4 inch, as measured from the outside surface fusion line on each side of the weld.

Piping welds shall be examined with a 45* *2' and a 60*

2*

search unit. The 45' *2* and 60* *2* search units shall be used to direct the sound beam perpendicularly into the weld. This examination shall be conducted from both sides of the veld. The 45*

2* search unit shall also be utilized to conduct a transverse examination of the veld. The sound beam shall be directed I

parallel to the weld to conduct the examination; then the search unit shall be l

turned 180* and the examination repeated.

7.2 Surface condition The contact surfaces shall be free from weld spatter, roughness, or other conditions which interfere with free movement of the search unit or impair the transnission of ultrasound.

I 7.3 Scanning Scanning overlap shall be a minimum of 10% of the transducer piezoelectric element dimension perpendicular to the direction of scan.

Scan-ning coverage for velded vessel components shall be adequate to examine the i

veld and 1/2t of base material from the fusion line of the veld.

Scanning Swns F9tm QA 3-2

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-5 SOUTHWEST,RESEARCH INSTITUTE

'"*'2'-7 ge December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 19 of 23 coverage for piping welds shall be adequate to examine the required portion of the weld and base material fon 1/4 inch, as measured from the fusion line on each side of the weld. Scanning coverage for nonwelded components shall be specified in the applicable SwRI Scan Plan.

Examination techniques including search unit angles, contact surface and examination coverage will be described in the detailed swr 1 Scan Plan for the particular examination. The SwRI Scan Plan shall be approved by the Director of the Department of Engineering Services.

Scanning shall be performed at the primary reference level sensitivity.

The search unit movement rate for scanning shall not exceed 6 inches per second.

Before the angle-beam examination of welds, a lamination scan using straight-beam shall be performed, covering as much as practical of the area through which the angle beam is later to be passed.

Screen distance cali-bration for this examination shall be conducted in accordance with Paragraph 6.2 of this procedure.

0;.nning sensitivity shall be as required to maintain back reflection at an amplitude of between 50% and 90% of FSH.

This lamination scan is performed by noting whether back echoes are lost or intermediate echoes are observed in any of the areas to be examined

~

I with an angle-beam search unit. Intermediate echoes having an amplitude equal to or greater than 50% of the initial back reflection shall be recorded.

To record an intermediate indication, obtain a back reflection signal from an f

indication-free area and adjust the instrument gain control until this signal l

is at 75% =5% of FSH. Record the intermediate indication when its amplitude is equal to 50% of the initial back reflection and accompanied by a 50% loss of back reflection. If total loss of back reflection accompanies the inter =ediate echo, the area of total loss of back reflection shall be recorded.

7.4 Postexamination Cleaning Arrangsments shall be made with the customer for postexamination i

removal of couplant materials.

8.0 RECORDING CRITIRIA Ultrasonic reflectors producing a response greater than 50% of the refer-ence level shall be recorded. Indications found to be greater,than 50% of the ref erence level and not readily attributable to geometry by the examiner, when scanning in the X direction (length of indication), shall require scans in the

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SOUTHWEST RESEARCH INSTITUTE 8","l-l"'-7

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,e December 1981 NUCLEAR PROJECTS OPERATING PROCEDURE Page 20 of 23 Y direction (width of indication), extending to the 20% limits along the I axis. The scans in the Y direction shall extend to the 20% limits of the indication along the Y axis.,

Y scan increments shall be one-tenth inch (when incrementing with the SwRI rotator, the increments shall be one-half degree). All Y scans shall be run in the same direction, upon ecmpletion of which an X-scan shall be run at the maximum amplitude, location.

Indications 100% or greater of the reference level shall be investigated by a Level II or a Level III examiner to the extent necessary to determine the shape, identity and location of the reflector.

Indications 100% cr greater of the reference level investigated and found to be other than geometrical in nature shall be reported to the customer for evaluation.

Scanning limitations shall be recorded.

9.0 EVALUATION Evaluation of reportable indications shall be the responsibility of the customer, or the customer's representative, and shall be conducted in accor -

dance with Article IWA-3000 of the ASME Boiler and Pressure Vessel Code,Section II.

':he applicable year and Addenda of the Code shall be as speci-fled in Paragraph 2.1(1) of this procedure.

10.0 RECORDS I

The custoner shall receive copies of documents generated in accordance with this procedure in the examination report.

l l

Documents generated in accordance with this procedure shall be stored and retained as a portion of the examination report.

The examination report shall be stored by the Manager of the Support and Administration Section, cuality Assurance Systems and Engineering Division, in the Data Storage Facility for the period specified by the contractual agreement with the custoner.

SwAl Form OA 3-2

3wRI-NDT-700-5 Revision 9 December 1981 Page 21 of 23 N_

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s. i lumpection shall be afincted by this deviation...

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Change the first paragraph of.8. to read as follows:

Ultr.uonic railectors producing a responsa greater. chan 50% of tbc j

reference level shall be recorded on the appropriate swr 1 Ultrasonic Erd-in*Liun record and investigated.

g ChunEc the second paragraph of 8. to read s's follows:

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4 h AArlitionally ell ultrasonic reflectors fressedleau of signal amplitude),

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act readily attributable to gr.ametry by the examiner shall be recorded 1.

on the appropriate SwRT Ultrasonic r.xamination Record and investigated by a Lavel II or Level III examin r to tM extent necessary to w

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determine the shape. identity, and loca len of the reficctor. Examples 5M of non-geometric reflectors (which may occur at any amplitude) are chose M

which are siir,htly removed from the weld root sad /or chamier, mask the y/

root indicstions, are transverse to the veld, ur.have linear dimensic w with side branches.

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.. Add the following as the third Paragraph of 8.i 4l When the sepHtude cf an indication fluctuates above and below the j,I required recording eJaplitude along f ra length, the total length of the indicatinn will be determined by the end points where the sign.s1 9

is discernible from the anise.

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Brunswich, Unit I

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PAGK DATE 17MJicTJ '

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1 on. 3 7 January 1983

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1 9 Calibration and F' aMnat, on, R,ecords f

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change 7.4 to read as follows:

g When practicable, scanning shan be performed at a nd.ninum gain -

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setting of 5 tices the refercuce level sensitivity.

w Instrument gain uutting for scanning shall be decernined on the w

basic calibration block as follows for each primary reference g

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level utiliced.

at the prf wiry reference level position

,yN With the instrument the nearch unic.on che basic c'alibration block to obtain a j

R (1) signal from a calib.ation reflector (side-drilled hole) of N

20; FSL E

$p siensweaser ( gre, escrivses riesete is as messesser *e4 ' stet it ts ada. doe to S. MTtN e t" *1 A+eese cheoge Ph This chann.c is necessary to incorpordte chang,cn rc'quer.ted by

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600-31/9 Deviation 2 7 January 1963 Page 2 of 3

.c (2) Ada 14 dB of gain by utilizing the 14 d3 switch, if present.

Observe the sigus) msplitude (If the 14 dE switch is not present on the instmat, use the method in step (3) for scanning sensitivity).

(3) Add 24 dB of gain by utilizing a combination of both fins and coarse gain controls.

observe the signal amplitude.

(4)

Choose the setthod,above which yields a eignal response closest to 1001 of IS11.

($) The asthod chosen = hall then be use;d for all sesnuing st 5 times the reference level sensir.ivity.

e examiner shall ensure that the signal. response of the method chosan is within.e2dB of 100 ISH.

Record this suplitude End r.hthod,ou the Sw21

,(

~ Instrument Calibration Recotd.

Instrument gain settings for scanning shall be recorded on the appropriate SvRI h=ination

• Record.

Chsuge 6. to read as follows:

Ultrasonic reflectors producing a response greater than 20% o.f the reference level ahall be recorded on the appropriate SwE.E Ultrasonic h*=i= tion Record.

/-

Any ultrasonic reflectors not readily attributable to geometry by the

,raminer shall be recorded on the appropriate SwRI Ultrasonic Examination Escord and Investigsteed by a Level II or Level III cxaminer to the extent necessary to determine the shape, identity, and location of the reflector.-Examples of non-geonetric reflectors (which usy occur at say anpiltade) are those which are slightly removed from the weld root and/or chamfer, mask the root indications, are transverse to the veld,.

or have linear dimensions with side braneben.

Indications 100% or g'reater of the reference level shall be investigated by a Level II or Level III examiner to the extent necessary to determine the shape, identity, and location of ' the reflector.

The end points of the. indication is deternioed by 100% MC shall be recorded.

6

600-31/9 Devinsion 2 7 Jannsry 1983 Page 3 af 3 Indications shall be recorded in accordsnee with the techniques outlined in the applicable revision of $wn Enclear Projects Operating Procedure IX-FE-ll7, except es awdified by this procedure;.

Indicatione investigated and found to be other than geometrical in nature, regardless.cf the amplitude, shall be reported to the custoiner for evaluation.

Scanniu6 liBitatiOne shall he recorded.

When the amplitude of.an indication fluctuates. above and below the required recording amplitude siong its length, the total Iergth of the' indication will be determined by the'end points where the signal is disc,ernible from the noise.

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SOUTHWEST RESE ARCH INSTITUTE POST OFFICE DR AWER 20S10 8220 CULEBR A RO AD S AN ANTONIO, TEX AS 78284 15123684 5111

.A oyAuTV ASSURANCE SYST5h s TELIX Wrme psUC EfeGa SNT A Afe0 GBeeseesteeG OfvtS40es TELEX N7579 feUC SeeGR SNT TELaCOMen mwelt November 9, 1982

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ghf WY Mr. C.R. Diets M[#

General Manager Brunswick Steam Electric Plant 6*

Ef7N Carolina Power & Light Company p.,

P.O. Box 10429 Southport, North Carolina 28461-0429 g/V.

SUBJECT:

Base Material Lamination Scan Requirements k

(

REFERENCE:

BSEP Letter October 18, 1982, File B10-10056

/

Base Material Lamination Scan Requirements

/

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Dear Mr. Dietz:

The requirement for base material laminatiqn scans prior to each angle beam aramination has been the subject of many discussions. The laminations of concern are fabrication imperfections which are present from time of manufacture and will not CU appear during service. To fully address the subject it must divide into three areas

~

of interest; vessels over two inches thick, ferritic piping and austenitic piping.

Each of these components are addressed differently by the Code.

(1) Vessels over two inches thick: Tha Summer 1978 Addenda to Section II (IWA 2232) refers to Article 4 of Section V for examinations of vessels over two inches thick. Article 4 T-451.3, requires straight beam scanning for planar reflectors (which are defined in Section II IWA 3000). Article 4, T-451.3 requires evaluation of laminar reflectors to determine their interference with angle beam examinations.

SwKI position is that since straight beam scanning for both i

planar and laminar indications is done with the same search unit and screen distance calibration, although amplitude cali-brations differ, there is little gained by deleting the lami-nation scan. In the case of mechanized vessel examintions where a three transducer module (45 degrees, O degree, 60 degrees)

~~

is used, there is even less reason to delete the lamination scan since the entire area is being covered for angle beam, and the data is available without extra collection effort.

(2) Ferritic piping: The Suommer 1978 Addenda to Section II (IWA 2232) refers to Appendix III for ultrasonic examina-

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Mr. C.R. Dietz November 9, 1982 Page 2 i

tion of Class 1 and Class 2 ferritic piping. Appendix III makes no mention of scanning for 1==inar defects. Although Section Y is not referenced for the examination of ferritic piping,Section V, T-534.3 scates "the volume of base material through which the sound will travel in angle beam examitation shall be completely scanned with a straight beam search unit to detect reflectors which might affect interpretation of angle beam results." Although Section V guidance is not specified, good practice dictates that the affect of laminar interference should be checked before performing an engle beam scan.

SwRI's position is that if PSI or previous examination data is available to determine that no laminations exist in the area of concern which would affect angle beam scans; the lam-ination scan may be deleted for that veld.

(3) Austenitic piping: No specific mention of austenitic materials

'is made in Section II except in Appendix III, Supplement 7 which does not address the requirement for lamination areas. Again, we refer to SectionY, T-534.3 as being a logical and conservative g

practice.

c. :.w Sw11's position for austenitic piping is the same as for ferritic piping; if previous examintion data can be researched and the examiner assured that there will be no laminar inter-farence with angle beam scans, the lamination scan may be omitted without a deleterious affect on the examination.

In summary, lamination scans should continue to be performed on ferritic vessels over two inches in thickness, particularly when examined with mechanized techniques.

Tamination scans may be deleted for examinations of ferritic and austenitic piping if sufficient previous data is available to ensure the absence of laminations which would interf are with angle beam scans. It is recommended that the concurrence of the local athorized nuclear inspector and NRC representative be obr.ained.

y...

"~

Mr. C.R. Dietz

J November 9, 1982 Page 3 If we may be of further assistance in this or other matters, please contact us.

Sincerely, J.R. Inganells

, Research Engineer Inspection Engineering Section Department of Engineering Services

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SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 Revision 9 NUCLEAR PROJECTS ecem er 1982 OPERATING PROCEDURE Page 1 of 26 Title MANUAL ULTRASONIC EXAMINATION OF AUSTENITIC PRESSURE PIPING WELDS EFFECTIVITY AND APPROVAL 12/22/82

. Otner revisions of the base document may Revision 9

of this procedure became effective on be effective concurrently.

SA Approvais Written By Date Tecnnical Review Date Otj Manager of Q.A.

Da e Cogn' t Director Date

'P 53/g

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The following information may be used for convenience. Corroietion of this portion is not mandatory.

Deviation No.

Date Effective Proceoure Sect:on(s)

Affected Notes:

e%

F F-'

,W W

O i

SOUTHWEST RESEARCH INSTITUTE C"'1-""',-6 o

~

December 1982 i

NUCLEAR PROJECTS OPERATING PROCEDURE Page 2 of 26 MANUAL ULTRASONIC EXAMINATION OF AUSTENITIC PRESSURE PIPING WELDS SwRI-NDT-600--31 1.

PURPOSE This procedure provides the technical information and detailed steps required to ensure a complete and accurate manual ultrasonic examination of similar or dissimilar metal welds and adjacent base material in clad or unclad austenitic pressure piping in accordance with the applicable ASME Boiler and Pressure Vessel Codes.

2.

SCOPE AND APPLICATION Pressure piping welds and the adjacent base material in the nominal thickness range of greater than 0.4 inch to 5.0 inches shall be examined.

Manual, contact, pulse-echo, shear-wave angle-beam, and longitudinal-wave straight-beam ultrasonic techniques shall be utilized for the examination of welds and adjacent base material in extruded austenitic pressure piping.

Similar and dissimilar metal circumferential and longitudinal pipe welds and branch pipe connection butt welds to be examined shall be as specified in the applicable SwRI Examination Plan.

3 APPLICABLE DOCUMENTS (1)

ASME Boiler and Pressure Vessel Code,Section XI, 1977 Edition, with Addenda through Sutuner 1978, " Rules for Inservice Inspection of Nuclear Power Planc Components" (2)

ASME Boiler and Pressure Vessel Code,Section V, 1977 Edition, with Addenda through Summer 1978, " Nondestructive Examination," with the exception of the following:

(a)

Subparagraph T-533.1 of Article 5,Section V, requires the basic calibration block for production material thickness (t) up to and including 1 inch to be 3/4 inch or t.

Iaragraph 5.3 of this procedure requires the basic calibration block to be either t, no more than 25% less than t, or closer h thickness to the production material than the 3/4-inch alternate SwRl Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE S"nI-"ot-6 *-3t Revision 9

~1 December 1982 i

/

NUCLEAR PROJECTS OPERATING PROCEDURE Page 3 of 26 thickness allowed by Article 5 for production material thick-nesses up to and including 1 inch. This exception will assure a more accurate calibration than the Article 5 basic calibra-tion block design allowed by Code.

(b)

Subparagraph T-535.1 of Article 5 states that transfer (atten-tation compensation) be accomplished between the production material and basic calibration block and a correction made for the difference.

Paragraph 7.5.2 of this procedure describes the method used to conduct attenuation measurements. These attenuation measurements shall be recorded and considered during analysis and evaluation of indications. No attempt shall be made by the examiner to compensate for observed differences before or during the examinations.

(3)

ASME Boiler and Pressure Vessel Code,Section IX,1977 Edition with Addenda through Summer 1978, " Welding and Brazing Qualifications" (3)

SwRI Nuclear Quality Assurance Program Manual (NQAPM)

Ti.b 3.1 Calibration and Examination Records zr SwRI-NDTR Form No.

Revision Date 17-18 7-31-75 17-19 7-10-80 17-25 7-10-80 17-37 2-18-80 17-86 7-25-80 17-87 7-25-80 4.

RESPONSIBILITY (l'

The Director of the Department of Engineering Services, Quality Assurance Systems and Engineering Division, shall be responsible for the preparation, review, approval, and control of this procedure.

(2)

The Project Manager shall be responsible for the implementation of this procedure in accordance with the NQAPM specified in the applicable SwRI Project Plan.

(3)

The examiner shall be responsible for implementing the require-ments of this procedure.

SwRI Form QA 3 2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 Revision 9 l

l December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 4 of 26 Qv (4)

The Manager of the Support and Administration Section, Quality Assur-ance Systems and Engineering Division, shall be responsible for stor-age of records generated in accordance with this procedure.

5.

PERSONNEL AND EQUIPMENT, 5.1 Personnel Certification Personati performing ultrasonic examinations shall be certified in accordance with SwRI NQAP 11-1, "Special Process Control."

52 Reference Block Reference blocks used for screen distance calibration and veri-fication shall be of the same material as the production material; i.e.,

stain-less steel or carbon steel, and shall be one of the following:

(1) SwRI Half-Round, (2) AWS Type DC, or (3) IIW.

5.3 Basic Calibration Block for Circumferential, Longitudinal, and

<g Branch Pipe Connection Welds fy' Side-drilled basic calibra: ion hole reflectors, in accordance with Section V of the ASMI Boiler and Pressure Vessel Code, shall be placed in a block manufactured from material of similar metallurgical structure and of the same or equivalent P-number grouping as the production material, as identi-fied in Section IX of the ASME Boiler and Pressure Vessel Code. The calibra-tion material shall be determined by the production piping material to which the search unit is applied.

The basic calibration block thickness shall be determined by the thickness of the production piping material to which the search unit is applied and Article 5 of Section V.

When a basic calibration block of the same thich-ness as the production piping material is not available and where the produc-tion piping material thickness is 1 inch or less, the basic calibration block thickness shall be no more than 25% thinner than the production material thick-ness or shall be closer to the production material thickness than the 3/4-inch thick alternate calibration block allowed by Article 5.

Approved drawings of basic calibration blocks to be used in accordance with this procedure are contained in the applicable SwRI Examination Plan.

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE swaI-unt-6oo-31 Revision 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 5 of 26 The surface finish of the basic calibration block shall be representative of the surface finish of the piping.

Flat basic calibration blocks or blocks of essentially the same curvature as the part to be examined may be used when contact surface curva-tures are greater than 20 inches in diameter.

A curved basic calibration block shall be used to establish distance amplitude correction (DAC) curves for examinations on contact surfaces in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter, when contact surface curvature is 20 inches in diameter or less.

The curvature of the main run pipe shall be used to establish the requirements for the basic calibration block curvature for the examination of branch pipe connection welds.

5.4 Search Units (1)

The search unit size shall be selected according to the following:

G' Straight-Beam Nominal Production Material Thickness Nominal Search Unit Size 2.0" or less 1/4" Round 1.0" to 3.0" 3/8" Round 2.0" to 4.0" 1/2" Round 3.0" to 5.0" 3/4" to 1" Round Angle-Beam The search unit size for et bon steel shall be selected according to the following:

Nominal Production Material Thickness Nominal Search Unit Size 1.0" or less 1/4" x 1/4",1/4" Round 0.4" to 2.0" 3/8" x 3/8", 3/8" Round 0.75" t o 4.0" 1/2" x 1/2", 1/2" Round 2.0" to 5.0" 1/2" to 1", 3/4" Round (2)

The nominal search unit size for austenitic materials shall be 3/8" round or 3/8" x 3/8".

s 1

I l

SwRt Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE S"*I-""T-6

-3 Revision 9 December 1982 i

NUCLEAR PROJECTS OPER ATING PROCEDURE Page 6 of 26 (3)

The exit point of the sound beam and the actual refracted beam angle of shear-wave search units shall be determined on an IIW block. The exit point shall be marked on the search unit vedge.

(4)

The nominal angle-beam shear-wave search unit frequency for examination of austenitic piping shall be 1.5 E z.

(5)

The nominal straight-beam longitudinal-wave searen unit frequency for austenitic piping shall be 1.5 Ez or 2.25 Ez.

(6)

The nominal search unit frequency for the carbon steel side of dissimilar piping welds shall be 2.25 M z.

(7)

The longitudinal-wave search unit frequency for attenua-

Lon measurements shall be 2.25 Mz to simulate a 1.5 Ez shear mode, and 5.0 Ez to simulate a 2.25 MHz shear mode.

(8)

For examination of circumferential piping welds, search

. 3.

unit wedges shall be fabricated to produce 45* t2' and 60* 12' refracted shear-waves.

(9)

For examination of longitudinal piping welds or branch pipe connection welds to piping, search unit wedges shall be fabricated to produce 45' t2' refracted shear waves.

5.5 Ultrasonic Instrument The examiner shall use a Sonic FIS Mark I ultrasonic instrument which shall be aligned and shall display an alignment calibration tag as required by NQAP 10-1.

5.6 couplant (1)

USP grade glycerine or deionized water (with or without wetting agent) shall be used when performing ultrasonic calibrations and examinations in accordance with this procedure.

(2)

USP grade glycerine shall be certified for sulfur content and total halogens in accordance with ASTM D-129-64 and ASTM D-808-63.

The residual amount of total sulfur or halogens shall not exceed 1% by weight.

Deionized water, when used, shall be supplied by the customer.

SwRt Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 Revision 9 December 1982 NUCLEAR PROJECTS OPER ATING PROCEDURE Page 7 of 26 (3)

Couplant materials used for examinations shall be the same as used for the calibration.

i 5.7 Thermometer Quicktemp thermometer Model SI-666, calibrated and certified in accordance with the applicable revision of SwRI Nuclear Projects Operating Procedure XII-FM-104 shall be used to measure calibration block and component surface temperature.

6 CALIBRATION METHOD 6.1 Instrument Linearity The ultrasonic instrument shall be verified at the beginning of each day for amplitude linearity and amplitude control linearity in accordance with Paragraphs 6.1.1 and 6.1.2.

Data required shall be recorded on the SwRI Instrt. ment Linearity Verification Record and the sheet number shall be refer-enced on the applicable SwRI Sonic Instrument Calibration Record.

f 6.1.1 Amplitude Linearity t

(1)

Position a shear-wave search unit on a calibration block to obtain indications from the 1/2T and 3/4T holes.

(2)

Adjust the search unit position to give a 2:1 ratio between the two indications, with the larger indication (1/2T hole) set at 80% of full screen height (FF") and the smaller indication (3/4T hole) set at 40% of FSH.

(3)

Without moving the search unit, adjust the instrument sensitivity (gain) to set the larger indicatico to 100% of TSH.

e (4)

With the larger indication at 100%, record the amplitude of the smaller indication, estimated to the nearest 1% of i

FSH.

(5)

Successively set the larger indication from 100% to 20% of FSH in 10% increments (or 2 dB steps if a fine control is not available); observe and record the smaller indication estimated to the nearest 1% of FSH at each setting.

The reading must be 50% of the larger amplitude within 5% of FSH.

l l

SwRI Form QA 3.2 l

-3 SOUTHWEST RES EARCH INSTITUTE S""Ifo'n-6 1

December 1982

.,s NUCLEAR PROJECTS OPERATING PROCEDURE Page 8 of 26 6.1.2 Amplitude Control Linearity (1)

Position a shear-wave search unit on a calibration block to obtain maximum amplitude from the 1/2T hole.

(2)

Without moving the search unit and according to the fol-lowing table, set the indication to the required percent of FSH and increase or decrease the dB as specified. The signal shall be estimated and recorded to the nearest 1%

of FSH and shall fall within the limits of the'following table:

Indication Indication Set at % of dB Control Limits, % of Full Screen Change

• Full Screen 80%

-6dB 32 to 48%

80%

-12dB 16 to 24%

40%

+6dB 64 to 96%

20%

+12dB 64 to 96%

e.. i

+

• Minus denotes decrease in amplitude; plus denotes increase.

6.2 Calibration The complete ultrasonic calibration shall be performed prior to the examination.

NOTES The REJECT control shall be maintained in the O position during calibration and examination.

The nominal piping production material thickness shall be used to determine the I

correct calibration block and search units for the examination of piping components which may be thicker than the nominal pipe size and welded to the pipe. The Level II examiner shall ensure that complete coverage of the thicker piping component is obtained. Additional calibration vee path positions and larger screen sizes may be required to assure this coverage. The additional calibration vee path positions and larger screen size shall be used for the examination from the thicker component and the nominal pipe side of the weld.

The FREQ MHz control shall be turned to 1 when a 1.5 MHz search unit is used,

• o 2 with a 2.25 MHz search unit, and to 5 with a 5.0 MHz search unit.

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-p-,

SOUTHWEST RESEARCH INSTITUTE

%"I-""'-6 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 9 of 26 The type and length of the search unit cable shall be recorded on the SwRI Sonic Instrument Calibration Record.

j l

The centerline of the search unit shall be at least 3/4 inch from the nearest side of the block.

Rotating the beam into the corner formed by the hole and the side of the block may produce a higher amplitude at a longer beam path.

This beam path shall not be used for calibration.

All spaces on the SwRI Sonic Instrument Calibration Record shall bc filled in.

6.2.1 Temperature The temperature of the calibration block shall be within 25*F of the component temperature and shall be recorded on the SwRI Sonic Inscrument Calibration Record for the initial calibration and each verification.

The surface temperature of the component to be examined shall be taken prior to performing an examination and shall be recorded on the appli-cable SwRI Examination Record.

Q(xi 6.3 Calibration for Circumferential Butt Welds 6.3.1 Straight-Beam Distance Calibration The screen distance chosen shall be the shortest applicable size to include at least 1/4t beyond the thickest production material to which the search unit is applied.

Observing back reflections from the applicable reference block, adjust the MAT'L CAL, RANGE, and DELAY controls to obtain r.he required linear sound path distance displayed along the screen baseline.

6.3.2 Angle-Beam Distance Calibration l

The screen distance chosen shall be the shortest applicable size to include at least 1/8 vee path past the anticipated examination range.

Observing radius echoes f rom the applicable reference block, adjust the MAT'L CAL, RANGE, and DELAY controls to obtain the required linear sound path distance displayed along the screen baseline.

When the same 'nstrument is used for both 45' and 60* examina-tions, the screen distance ca..iration shall be conducted in the following manner:

(1)

The screen distance size shall be determined by the angle-beam starch unit requiring the longer examination range.

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE

["I-*'J

-3 6

December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 10 of 26 i

(2)

Position the 45* t2* search unit on the appropriate refer-ence block and record all required reference block entries on the appropriate SwRI Sonic Instrument Calibration Record.

(3)

Without changing the MAT'L CAL, RANGE, or DELAY controls, repeat step (2) with the 60* t2* search unit.

(4)

No attempt shall be made to compensate for the delay difference between 45' t2* and 60* 12* screen distance calibrations.

This difference shall be considered when resolving indications.

6.3.3 Straight-Beam Distance Amplitude Correction A DAC curve shall be established by utilizing responses from the basic calibration holes.

6.3.3.1 Production Material 1 Inch or Less in Thickness b

(1)

Position the straight beam search unit to obtain maximum response from the 1/2T hole.

(2)

Adjust instrument gain controls to obtain the primary reference response at an amplitude of 50% 5% of FSH.

(3)

Draw a straight horizontal line on the instrument screen at the primary reference amplitude to extend a distance equal to the nominal thickness of the production material.

(4)

Signal amplitudes for indications recorded shall be refer-enced as.a percentage of this line.

6.3.3.2 Production Material Greater Than 1 Inch in Thickness (1)

Position the straight-beam search unit to obtain maximum response from the calibration hole selected from the following, which produces the highest amplitude:

l Hole l

1/4T 1/2T (if present) 3/4T l

l l

l l

SwAI Fwm 0A 3-2

SOUTHWEST RESEARCH INSTITUTE S"*I-""'-6

-3 Revision 9 December 1982

~

NUCLEAR PROJECTS OPERATING PROCEDURE Page 11 of 26 (2)

Adjust the instrument gain controls to obtain a primary reference response at 50% iS% of FSH and mark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining calibratica holes and mark e - amplitude on the screen.

(4)

Join these points with a smooth' curved line which shall extend 1/4T beyond the last qualified calibration point.

6.3.4 Angle-Beam Distance Amplitude Correction If a curved block is used, DAC curves for the examination of circumferential welds shall be constructed by utilizing the responses from the holes oriented perpendicular to the axis of the basic calibration block.

6.3.4.1 Material 1 Inch or Less in Thickness rI.T Q$

45* and 60* DAC (1)

Position the 45' i2* search unit to obtain maximum response from the calibration hole and vee path position, selected from the following, which produces the highest amplitude:

Hole Vee-Path Positions 1/2T 2/8, 6/8, 10/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% 5% of FSH and mark this amplitude on the screen.

The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each suplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

(5)

Repeat steps (1) through (4) using a 60* t2* search unit.

SwRI Form QA 3-2

g"I""T-6

-3 SOUTHWEST RESEARCH INSTITUTE J,

December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 12 of 26 EXCEPTIONS If the configuration of the weld is such that the 60* t2' search unit sound-beam is not directed into the A-B-E-F intersect (as depicted in SKETCH 1) on the straight pass, a 14/8 vee path calibration shall be accomplished with a 45* +2' search unit.

6.3.4.2 Material Greater Than 1 Inch to 3 Inches in Thickness 45' and 60* DAC (1)

Position the 45' t2' search unit to obtain maximum response from the calibration hole and the vee path position, selected from the following, which produces the highest amplitude:

Hole Vee-Path Positions 1/4T 7/8

.:3, 1/2T (if present) 2/8 e-3/4T 3/8, 5/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% iS% of FSH and mark this ampli-tude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

(5)

Repeat steps (1) through (4) using a 60* 12* search unit.

EXCEPTION If the configuration of the weld is such that a 60* *2' searen unit beam is not directed into the weld root, a 13/8 vee path calibration shall be accomplished with a 45* t2' search unit.

SwRI Form QA 3-2

SOUTHWEST RESEARCH INSTITUTE

[^'-""',-6 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE g

Page 13 of 26 6.3.4.3 Material Greater Than 3 Inches to 5 Inches in Thickness 45' and 60* DAC (1)

Position the 45' *2* search unit to obtain maximum response f rem the calibration hole and the vee path position, selected from the following, which produces the highest amp 1.itude:

45' Vee-Path Positions Hole 1/41 7/8 1/2T (if present) 2/8 3/4T 3/8, 5/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% 5% of FSH and mark this amplitude on the screen. The gain controls shall not be adjusted once the primary reference response has been established.

R,

• d" (3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

(5)

Repeat steps (1) through (4) with a 60* *2' search unit utilizing the following vee path positions:

Hole 60* Vee-Path Positions 1/4T 1/8 1/2T (if present) 2/8, 6/8 3/4T 3/8, 5/8 6.3.4.4 Clad Piping 45* and 60* DAC (1)

Position the 45* 12* search unit to obtain maximum response from the calibration hole and the vee path position, selected f rom the following, which produces the highest amplitude:

s. - -

SwRI Form QA 3 2

-3 SOUTHWEST RESEARCH INSTITUTE

["C""',-6 December 1982

,9 NUCLEAR PROJECTS OPERATING PROCEDURE Page 14 of 26 u

Hole Vee-Path Positions 1/4T 1/8 1/2T (if present) 2/8 3/4T 3/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% tS% of FSH and mark this amplitude on the screen.

The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall extend 1/8 vee path beyond the last qualified calibration point.

(} }

(5)

Repeat steps (1) through (4) with a 60* t2' search unit.

6.4 Calibration for Branch Pipe Connection and Longitudinal Seam Welds 6.4.1 Straight-Beam Distance Calibration The straight-beam distance calibration shall be the same as that described in Paragraph 6.3.1.

6.4.2 Angle-Beam Distance Calibration The screen distance chosen shall be the shortest applicable site to include at least 1/8 vee path past the anticipated examination range.

Observing the radius echoes from the applicable reference block, adjust the MAT'L CAL, RANGE, and DELAY controls of the instrument to obtain the required linear sound path distance displayed along the screen baseline.

6.4.3 Straight-Beam Distance Amplitude Correction The straight-beam distance amplitude correction shall be the same as that described in Paragraph 6.3.3.

SwRI Fcan OA 3-2 a

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31

~

Revision 9 December 1982 i

NUCLEAR PROJECTS OPERATING PROCEDURE g

Page 15 of 26 4"

6.4.4 Angle-Beam Distance Amplitude Correction If a curved block is utilized, DAC curves shall be constructed by utilizing the responses from the basic calibration holes oriented axially with the basic calibration block.

6.4.4.1 Material 1 Inch or Less in Thickness 45' DAC (1)

Position the 45'

• 2' search unit to obtain maximum response from the calibration hole and vee path position, selected from the following, which produces the highest amplitude:

Hole Vee-Path Positions 1/2T 2/S, 6/8, 10/8 (2)

Adjust the instrument gain controls to obtain a primary yg, Ofp reference response at 75% i3% of FSH and mark this amplitude on the screen.

The gain controls shall not be adjusted once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

6.4.4.2 Material Greater Than 1 Inch to 5 Inches in Thickness l

45' DAC (1)

Position the 45*

2* search unit to obtain maximum response from the calibration hole and the vee path position, selected from the following, which produces the highest amplitude:

l l

l SwRI Form CA 3-2[

SOUTHWEST RESEARCH INSTITUTE S"*I-""T-6

-3 Revision 9 a-December 1982

' ~

NUCLEAR PROJECTS OPERATING PROCEDURE ig Page 16 of 26 Hole Vee-Path Positions 1/4T 7/8 1/2T (if present) 2/8 3/4T 3/8, 5/8 (2)

Adjust the instrument gain controls to obtain a primary reference response at 75% iSZ of FSH and mark this amplitude on the screen. The gain controls shall not be adjustad once the primary reference response has been established.

(3)

Position the search unit to obtain maximum response from the remaining vee path positions and mark each amplitude on the screen.

(4)

Join these points with a smooth curved line which shall not extend more than 1/8 vee path beyond the last qualified calibration point.

6.4.4.3 Clad Piping 45' DAC W

This calibration shall

• .,e the same as that described in Para-g aph 6.3.4.4, steps (1) through (4), using the 45* 12* search unit only.

6.5 Secondary DAC Calibrations If all points on the DAC curve do not appear at 20% of FSH or greater, a secondary DAC curve shall be constructed as follows:

(1)

All secondary DAC curves shall contain at least 2 points.

l (2)

The DAC point at 2 lines or greater in amplitude and adja-cent to a DAC point that falls below 2 lines of amplitude shall be brought to the primary reference level by manip-tlating the gain controls. This point shall be marked on

~

the instrument screen.

The adjacent point (s), previously at less than 2 lines of amplitude, shall be marked on the screen and all points connected with a smooth curved ~ line.

The gain setting for this secondary DAC curve shall be recorded on the appropriate SwRI Sonic Instrument Calibra-tion Record.

J SwRI Form QA 3-2

-3 SOUTHWEST RESEARCH INSTITUTE P,'"I-"'-6 1,,

7 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 17 of 26 EXCEPTIONS When the first DAC point is the only point above 2 lines of amplitude, the next highest point shall be brought to the primary reference level. This point shall be marked on the instrument screen. The other points previously at less than 2 lines of amplitude shall be marked on the screen and all points con-nected with a smooth curved line.

The gain setting for this secondary DAC curve shall be recorded on the appropriate SwRI Sonic Instrument Calibration Record.

It shall not be necessary to construct a secondary DAC when the calibration consists of a 2/8, 6/8, and 10/8 vee path.

6.6 Calibration Verification 6.6.1 Sweep Range and DAC Curve Verification Sweep range calibration shall be verified on the appropriate reference block; and DAC curve calibration, if applicable, shall be verified on the appropriate basic calibration block:

@4.49 s

(1)

At the start of c series of examinations (2)

With any substitution of the same type and length of search unit cable (3)

With any substitution utilizing the same type of power source; e.g., a change from one direct current to another direct current source (4)

At least every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during the examination (5)

At the finish of a series of examinations (6)

Whenever the validity of the calibration is in doubt 6.6.2 Calibration Changes (1)

Perf orm the following if any point on the DAC curve has decreased more than 20% of FSH or 2 dB in amplitude, or any point :.a the sweep line has moved more than 10% of the sweep reading or 5% of full sweep, whichever is less:

i l

SwRI Fonn QA 3-2

SOUTHWEST RESEARCH INSTITUTE SwRI-ET-600-31 Revision 9 December 1982

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NUCLEAR PROJECTS OPERATING PROCEDURE

,,g Page 18 of 26 (a) Void all examinations referring to the calibration in question and performed after the last valid calibra-tion verification.

(b) Conduct a new calibration.

(c) Reexamine the areas for which examinations have been voided.

(2)

Perform the following if any point on the DAC curve has increased in amplitude more than 20% of FSH or 2 dB:

(a) Correct the calibration.

(b) Reoxamine all indications recorded since the last valid calibration verification.

(c) Enter proper values on a new SwRI Examination Record.

6.6.3 Recalibration Substitution of any of the following shall be cause for recali-bration:

(1)

Search unit (wedge / transducer)

(2)

Couplant (3)

Ultrasonic instrument (4)

Examination personnel (5)

Cable tyme of length (6)

Change in type of power source; e.g., a change from alternating to direct current SwRt Form QA 3 2

SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 Revision 9 j

December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE

,g Page 19 of 26

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7, EXAMINATION 7.1 Examination Areas 7.1.1 Circumferential and Longitudinal Butt Welds in Piping Circumferential and longitudinal full penetration butt welds with a nominal thickness of greater than 0.4 inch to 5.0 inches shall be examined from the outside surface of the pipe.

Scanning of the weld and base material shall be adequate to ensure complete coverage for 1/3t from the inside surface of the pipe as shown in SKETCH 1.

The base material shall be examined for a distance of a 1/4 inch as measured from the outside surface fusion line on each side of the veld.

Class I longitudinal welds shall be examined along the entire length of the weld during the preservice examination and for at least one pipe-diameter length or 12 inches, whichever is less, from the fusion line of the intersecting circumferential weld during inservice examinations.

d.m Class 2 longitudinal welds shall be examined for at least 2-1/2t length from the fusion line of the intersecting circumferential weld during preservice and inservice examinations.

7.1.2 Butt Welds of Branch Pipe Connections Full penetration butt welds of branch pipe connections in pressure piping greater than 0.4 inch to a maximum of 5.0 inches nominal thickness shall be examined from the outside surface of the pipe.

Scanning of the weld and base material shall be adequate to ensure complete coverage for 1/3t from the inside surface of the pipe.

The base material shall be examined for a distance of a 1/4 inch measured from the outside surface fusion line on the main run pipe side of the weld.

7.2 Surface Condition The contact surfaces shall be free from weld spatter, roughness, or other conditions which interfere with free movement of the search unit or impair the transmission of ultrasound.

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SwRI Form QA 3-2

SwRI-NDT-600-31 SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982

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NUCLEAR PROJECTS OPEH ATING PROCEDURE Page 20 of 26 7.3 Indication Length Zero Reference (Lo) Location Areas to be examined in accordance with this procedure shall have an Lo marked in accordance with the applicable revision of SwRI Nuclear Projects Operating Procedure IX-FE-103.

7.4 Scanning Parameters When practicable, scanning shall be performed at a minimum gain

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setting of 2 times the reference level sensitiv1ry.

Instrument gain setting for scanning shall be determined on the basic calibration block as follows for each primary reference level utilized:

(1)

Wich the instrement at the primary reference level, manip-ulate the search unit on the basic calibration block to obtain a signal of 40% of' FSH from a calibration reflector (side-drilled hole).

(2)

Add 6 dB of gain by utilizing the 6 dB switch (if

$3}

present), the fine gain control or a combination of the fine and coarse gain controls and choose the method which yields a signal response closest to 80% FSH.

(3)

The signal response of the method chosen shall be within t2 dB of 80% FSH.

This amplitude and method shall be recorded on the Ultrasonic Instrument Calibration Record.

The method chosen above shall be used during the valid calibra-tion period for all scanning at 2 times the reference level sensitivity.

7.4.1 Scanning Scanning overlap shall be a minimum of 10% of the search unit piezoelectric element dimension perpendicular to the direction of scan.

The search unit movement rate for scanning shall not exceed 6 inches per second.

7.5 Attenuation and Thickness Measurements 7.5.1 Longitudinal Attenuation Measurements A straight-beam search unit as described for attenuation measure-ments (Paragraph 5.4) shall be placed on the appropriate basic calibration block. Obtain a backwall reflection, setting this signal between 50% and 90%

SwRI Form QA 3 2 f

l SOUTHWEST RESEARCH INSTITUTE SwRI-NDT-600-31 l

Revision 9 l

December 1982 l

NUCLEAR PROJECTS OPERATING PROCEDURE Page 21 of 26 of FSH. Record the signal amplitude and instrument gain settings on the appro-j l

priate SwRI Sonic Instrument Calibration Record for Attenuation / Lamination Examination. Adjust the instrument gain controls to display the next backwall reflection at the same amplitude at which the preceding backwall reflection was recorded. Record the signal amplitude, instrument gain settings, and the dB difference required to obtain the adjacent backwall reflections at an equal amplitude.

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Place the straight-beam search unit on the examination surface and determine the dB difference required to obtain signals of equal height fros' two adjacent backwall reflections.

Record this dB difference on the appropri-ate swr 1 Examination Record.

The search unit for attenuation measurements shall be placed adjacent to Lo on the base material away from the heat-affected l

zone (HAZ).

If attenuation measurements cannot be taken adjacent to Lo, the location of the measurements shall be recorded on the appropriate SwRI Exami-l nation Record. Measurements shall be taken at least at the following j

locations:

(1)

Two positions for circumferential and longitudinal welds, one on each side of the weld

-E (2)

One position adjacent to Lo on the main run pipe base mate-rial for branch connection welds NOTE Attenuation measurements shall not be conducted for longitudinal or branch connection welds if measurements have been conducted in the applicable piping base material.

No attenuation measurements shall be conducted on clad piping.

7.5.2 Thickness Measurements Thickness measurements shall be taken at a minimum of three points adjacent to Lo for longitudinal and circumferential welds (on the centerline of the weld and at one poinc in the base material on each side of the weld).

Thickness measurements shall be taken at a minimum of two points adjacent to Lo for branch pipe connection welds (one on the base material of the main run pipe, and one on the base material of the branch connection).

If these measurements cannot be taken adjacent to Lo, the location of the measure-ments shall be recorded on the appropriate SwRI Examination Record.

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S""I-""'-'

SOUTHWEST RESEARCH INSTITUTE Revision 9 December 1982 l

NUCLEAR PROJECTS OPERATING PROCEDURIi!

Page 22 of 26 Screen distance calibration for this summination shall be con-ducted in accordance with Paragraph 6.3 1.

Measurements shall be taken by 4

placing the straight-beam search unit in the appropriate position on the examination surface and observing the position of the back wall reflection on the instrument screen. These measurements shall be recorded on the appropriate SwRI Examination Racord.

7.6 Exanination of Circumferential and Longitudinal Butt Welds in Piping 7.6.1 Angle-Beas Examination for Indications Parallel with the Weld Angle-be.sm examinations for circumferential welds shall be accom-plished using 45* t2' and 60* t2* refracted shear-waves from both sides of the weld.

For this examination, the sound-beam shall be directed perpendicularly into the veld to detect indications parallel with the weld.

Calibration for these examinations shall be in accordance with Paragraphs 6.3.2 and 6.3.4.

Angle-beam examinations for longitudinal welds shall be accom-plished using a 45* t2* refracted shear wave from both sides of the weld.

For

.c%

this summination, the sound-beam shall be directed perpendicularly into the "E

weld to detect indications parallel with the weld.

Calibration for this exami-nation shall be in accordance with Paragraphs 6.4.2 and 6.4.4.

7.6.2 Alternate Examination A 45' t2' and 60* t2' shear-wave examination shall be conducted as required to assure complete coverage from both sides of the circumferential weld. A 45' *2' shear-wave examination shall be conducted as required to assure complete coverage from both sides of the longitudinal weld.

Any areas of the weld not receiving complete coverage from both sides shall be examined from one side of the veld with the required shear-wave (s) and a straight-beam i

longitudinal-wave applied to the surface of the weld crown in the affected areas. Calibration for the longitudinal-wave search unit shall be in accord-ance with Paragraphs 6.3.1 and 6.3.3.

7.6.3 Aagle-Beam Examination for Indications Perpendicular to the Weld An an3 e-beam examination shall be conducted on each weld v % p 1

a 45* 12* shear-wave. This examination shall be conducted by placing the search unit on the weld with the sound beam directed into and parallel with the weld to detect indications perpendicular to the weld.

The entire length and width of the weld shall be scanned with the search unit beam directed in this manner, once in a clockwise and once in a counterclockwise direction.

l

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swr 1 Form QA 3 2

SOUTHWEST RESEARCH INSTITUTE S""'-*'-6

-3 Revision 9 i

December 1982 1

NUCLEAR PROJECTS OPERATING PROCEDURE Page 23 of 26 For austenitic materials, the search unit shall then be placed on the base metal with the search unit wedge touching the edge of the veld crown and the sound beam directed tangential into the weld at a 45* *10* angle.

The entire length of the weld shall be scanned with the search unit beam l

directed in this manner on each accessible side of the weld. The search unit shall then be turned 90* and the scans repeated.

Calibration for these examinations shall be in accordance with Paragraphs 6.3.2 and 6.3.4 for cir-cumferential welds, and Paragraphs 6.4.2 and 6.4.4 for longitudinal welds and branch pipe connection welds.

Geometric root ripple echoes occurring at the same metal path distance as flaws adjacent to the weld root are to be expected.

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A flaw mast be distinguished from root ripple by the greater echo amplitude of a flaw compared to the amplitude of the root ripple at the same location. A flaw indication adjacent to the weld root tends to mask out several facets of the root ripple and travels along the baseline through the root ripple package.

7.6.4 Angle-Beam Examination for Indications in Austenitic Ease Material Perpendicular to the Weld, An angle-beam examination shan be conducted on it of base material adjacent to each weld using a 45' r2' shear-wave. This namination h.

shall be conducted by placing the search unit on the base material with the sound beam directed parallel to the weld to detect indications perpendicular to the weld. The base material within it of the weld shall be scanned with the search unit directed in this manner, once in a clockwise direction and once in a counterclockwise direction. Calibration for these examinations shall be in i

accordance with Paragraphs 6.3.2 and 6.3.4 for circumferential welds, and Paragraphs 6.4.2 and 6.4.4 for longitudinal welds and branch pipe connection welds.

7.7 Examination of Butt Welds of Branch Pipe Connections 7.7.1 Straight-Beam Examination of Welds A straight-beam examination shall be performed on the surface of the weld crown when possible.

Calibration for the straight-beam examination shall be in accordance with Paragraphs 6.3.1 and 6.3.3.

7.7.2 Angle-Beam Examination for Indications Parallel with the Weld An angle-beam examination shall be accomplished using a 45* 12' refracted shear-wave from the main run pipe side of the weld.

For this examina-tion the sound beam shall be directed perpendicularly into the weld to detect indications parallel with the weld.

Calibration for these examinations shall be in accordance with Paragraphs 6.4.2 and 6.4.4.

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SOUTHWEST RESEARCH INSTITUTE M*I-""'j

-3 e n December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 24 of 26 7.7.3 Angle-Beam Examination for Indications Perpendicular to the Weld The angle-beam examination for indications perpendicular to the weld shall be the same as the examination described in Paragraph 7.6.3.

7.8 Postexamination Cleaning Arrangements shall L2 removal of couplant materials.

made with the customer for postexamination 8.

RECORDING CRITERTA JF "[^,2 l2mK*

Ultrasonic reflectors producing a response greater than 50% of the ref-3y Record.erence level shall be recorded on the appropriate SwRI Ultrasonic Examination 3

Any ultrasonic reflectors not readily attributable to geometry by the examiner shall be recorded on the appropriate SwRI Ultrasonic Examiantion Record and investigated by a Level II or Level III examiner to the extent

,cu necessary to determine the shape, identity, and location of the reflector.

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Examples of non geometric reflectors (which may occur at those which are slightly removed from the weld root and/or chamferany ampliutde) are indications, are trannverse to the weld, or have linear dimensions with

, mask the root side branches.

M The end points of the indication as determined by 100% DAC shall be recorded.

Indications shall be recorded in accordance with the techniques outlined in the applicable revision of SwRI Nuclear Projects Operating Procedure IX-FE-117.

Indications investigated and found to be other than geometrical in nature regardless of the amplitude, shall be reported to the customer for evaluation.

Scanning limitations shall be recorded.

9.

EVALUATION Evaluation of reportable indications shall be the responsibility of the customer, or the customer's representative, and shall be conducted in accor-dance with ASME Boiler and Pressure Vessel Code,Section XI, Article IWA-3000 The applicable year and Addenda of the Code shall be as specified in Para-graph 3. of this procedure.

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SwAI Form QA 3-2

~ SOUTHWEST RESEARCH INSTITUTE S""I- " -6

-3 Revision 9 December 1982 NUCLEAR PROJECTS OPERATING PROCEDURE Page 25 of 26 u

10.

RECORDS The customer shall receive copies of documents generated in accordance with this procedure in the examination report.

Documents generated in accordance with this procedure shall be stored and retained as a portion of the examination report. The examination report shall be stored by the Manager of the Support and Administration Section, Quality Assurance Systems and Engineering Division, in the Data Storage Facility for the period specified by the contractual agreement with the customer.

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