ML20076E205

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Rev 1 to Task V Radiographic Confirmation Rept
ML20076E205
Person / Time
Site: Zimmer
Issue date: 03/24/1983
From:
CINCINNATI GAS & ELECTRIC CO.
To:
Shared Package
ML20076E200 List:
References
NUDOCS 8305260338
Download: ML20076E205 (10)
v • d • e


Text

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Task V Radiographic Confirmation Report 1/31/83 3/24/83 Rev. 1 This report outlines the , method used to fulfill the requirements of "The Quality Confirmation Program" concerning the re-review of Pullman Power Product pipe welds and the reradiography of - -

selected samples of those welds.

The evaluation of this program by CG&E has demonstrated that the absence of shims has a negligible effect upon the required radiographic sensitivity when the film density in the area of interest is maintained within Code requirements. For the broad range of pipe sizes and thickness included within the program, the results confirm that radiographs with properly shimmed penetrameters do exhibit the Code required images of the penetrameter outline and essential hole or slits when the 4

radiography is performed using the same technique as the original l but unshimmed radiograph. For those cases Where it was not possible to utilize the same technique as the original and an alternate Code acceptable but less favorable radiographic technique was used, the program still demonstrated essentially equivalent sensitivity as the original radiography.

The results of the OCP Task V program indicate that the .

existing radiographs of those welds which were not re--

radiographed as part of this program can be relied upon to have sufficient radiographic sensitivity to evaluate and interpret the 1 weld quality even though the penetrameters on these radiographs were inadequately shimmed.

Concerning Radiographs Problem (as stated by the NRC)

Radiographic technique did not meet the ASME code in that the penetrameters were not adequately shimmed in approximately 180 out of 600 radiographs reviewed by the NRC.

Action

1. Demonstrate that the existing radiographs of large bore -

piping supplied by the CG&E piping fabricator are adequate to identify weld deficiencies by:

a) Review the shop radiographs to identi.fy those radiographs that are either unshimmed or inadequately shimmed to determine, for each pipe size and thickness, the films Which contain the least sensitive penetrameter images (essential hole or slit) where the density of the penetrameter is the same or greater than the density of the area of interest. ,

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Resolution ,

'Mathod Used to Compile List of Pipe Diameters and Wall Thickness A review was performed of all Pullman Power Product pipe weld -

radiographs (18003) to determine the density of the weld and the density of the penetrameter. Only film where the density of the penetrameter was greater than the lightest area of the weld became subject to final review (Reference QCP Procedure 19-QA-01, .

para. 6.5). In the final review, the Level III determined and

, recorded the sensitivity levels of each radiograph by noting the cost sensitive penetrameter characteristic that could be clearly ,

detected.

In addition, he noted the least sensitive penetrameter characteristic (Reference QCP Procedure 19-QA-01, para. 6.9) and also noted whether or not a shim was. used (Reference QCP Procedure 19-QA-01, para. 6.3). All of the above information was listed in the computer. When all weld radiographs had been reviewed as indicated above, utilizing the computer they were grouped by pipe size and wall thickness. This formed the list of pipe size and wall thickness of which there were 62 categories listed. These categories are listed on Attachment #1.

NOTE: The category thickness is based upon the nominal pipe size. The actual pipe wall thickness.*and weld thickness may be greater than the nominal pipe size.

The initial review revealed that a group of 153 film relating to 19 welds did not fall within the scope of the program but needed further review to determine acceptability to all aspects of the Code. This subsequent review found eleven welds tc be code acceptable and eight welds that did not meet the requirements of IX 3334.5 of the Code. These eight welds are identified on Nonconformance Report #Q-QAD-83-0586-N.

1 Action (CG&E) b) Reradiograph the weld identified above, if accessible, using, as nearly as possible, the original technique plus the penetrameter shimmed to at least the total weld thickness

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including reinforcement, all in accordance with the code.

l Resolution t

l Selection of Welds to be Reradiographed After the list of pipe size and wall thickness was formulated one weld of each pipe size and wall thickness was selected, from each group of those radiographs judged to be least sensitive, and was reradiographed. Attachment #5 delineates the sensitivity classification and the number of Radiographs falling within those ~

classifications.

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Deletions of dategories From The Original 62 After additional input from Pullman Power Products and upon -

further investigation sixteen (16) of the 62 categories were deleted from the confirmation program. See Attachment #2.

1. Twelve (12) categories were penetration plates or flued -

head plates which meet requirements of ASME Section III Article IX sub-paragraph IX 3110 and paragraph NB-5277 _

special exceptions, Summer of '72 addenda. See Attachment #3

2. Two (2) categories (10" .719 and 4" .531) were re-reviewed and were found to meet all shimming and density requirements therefore are not required to be part of the program.
3. One (1) category (18" . 438) included only one weld.

This weld had been cut out and replaced by a HJK field weld. Reference HJK Equipment Trouble Report 397-9931-9397. ,

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4. One (1) category is 1.500 Plate. The program is designated for pipe welds not plate welds.

Changes In Pipe Sizes / Thickness Categories -

Prior to each category being reradiographed the original film was re-reviewed for correct pipe size / wall thickness designation.

After this review nine (9) categories were changed to reflect the correct size or wall thickness. These are listed as #5 on Attachment #2.

Final List of Pipe Size / Wall Thickness After all changes and/or deletions, a list of forty six (46) different pipe sizes and wall thicknesses was formulat.ed. These categories are listed on Attachment #4. Along with each pipe size and wall thickness, the PSK line number and weld number that identified the welds that were reradiographed, are also listed.

e (3)

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. Inaccessible Wald Categorico and Reasons For Inaccessibility After a thorough field walkdown of the original 62 categories ,

four (4) categories were determined to be inaccessible.

They are:

1. 14"STD/WT X 8" SCH/40 weldolet to 14" STD pipe weld. '

The installed configuration does not permit radiography. . .

2. 18" .375. All welds are on service water lines that cannot be properly radiographed due to silt settling in -

the lines when drained.

3. 27".875. (rolled plate) This category is the longitudinal weld on downcomer support sleeves. The installed condition does not permit radiography due to concrete interference. (See Dwg. S401).
4. 30" .375. All welds are on service water lines that cannot be properly radiographed due to silt settling in the lines when drained.

Mock-up of Inaccessible CcAegories Mock-ups have been fabricated, per paragraph 6.16 of CG&E Procedure 19-QA-Ol, which states: The original technique may be qualified by use of a mock-up weld sample of nearly identical diameter and wall thickness. .

The four mock-ups were constructed using exis' ting approved weld procedures, employing TIG root and first pass and SMAW completion. These weld mock-ups were subjected to normal inspection prior to being serialized and stamped.

Note: After the final review, 85 welds were identified as l

i not meeting the minimum density requirements of 2.0 H.D. as l stated in ASME Section III Appendix IX, Article IX 3000 sub paragraph IX 3334.3. These welds were subsequently identified on 20 Nonconformance Reports and are in the NR system for disposition.

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., ATTACHMENT #1 ORIGINAL LISTING,OF PIPE SIZE / WALL THICKNESS CATEGORIES Pipe Size Wall Thickness Pipe Size Wall Thickness .

  • WR .625 20" ' .375
  • 2 1/2 .120 20" 1.031 2 1/2 .203 20" 1.500 2 1/2

.276 *20" 1.969 .

  • 3 1/2 .120 22" .375 3 1/2 .226 *22" .969 3 1/2 24" .375

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.318

  • 4" .120 24" .969 4" .237 24" - 1.812 4" .337 28" .375 4" .438 28" .625
  • 4" .531 30" .375
  • 6" .134 36" .750 6" .280 6" .432 6" .562
  • 8" .148 ~
  • 8" .322 8" .406 8" .500 $r
  • 8" .719 8" .875
  • 10" .165 -
  • 10" .365

, 10" .594

  • 10" .719 ,

10" .844

  • 12" .180 12" .375 12" .406 12" .500
  • 12" .562 12" .688 12" 1.00
  • 14" .188 14" .375 14" .438 14" .750 14" .938 14" 1.094 16" .375 16" 1.031 -

16" 1.219 -

18" .375

  • 18" . .438 18" .938 -

18" 1.156

. 18" 1.375

  • 18" 1.781
  • These categories changed as reflected on Attachment #2.

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.' . ATTACHMENT #2 CATEGORIES DELETED FROM ORIGINAL LIST Pipe Size Wall Thickness ,

(1)*WR .625 Penetration Plate or Flued Head Plate

. 2 1/2" .120 Penetration Plate or Flued Head Plate ,

3.1/2" .120 Penetration Plate or Flued Head Plate .

4" .120 Penetration Plate or Flued Head Plate 6" .134 Penetration Plate or Flued Head Plate 8" .148 Penetration Plate or Flued Head Plate

, 20" 1.969 Penetration Plate or Flued Head Plate After film review changes were made to the following categories and the category were deleted.

(2) 10" .719 All welds met density requirements.

4" .531 All welds met density requirements (3) 18" .438 Weld was replaced by HJK field weld (4) Plate 1.500 Program is for pipe welds not plate welds NOTE: The pipe size and thickness categories listed above have resulted in elimination of 16 categories from the original 62.

See Attachment #4 of the Task V Radiography Confirmation Report for a corrected list of categories.

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Attachment #2 cont'd After review changes were made to the following categories: .

(5) A. 28" Changed to 27" .875 wall i

I Reason for Change: Computer entry error 27" is special order but was originally entered as 28"

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B. 3 1/2" . Changed to 3" .120 wall.

j 3 1/2" Changed to 3" .226 wall 3 1/2" Changed to 3" .318 wall Reason for Change: O.D. Dimensions were entered in computer in error

. I.D. dimension are correct entry C. 36" Changed to 1.336 wall Reason for Change: Computer entry error was entered as .750 Re-entered correct 1.336 D. 12" .562 Changed to 10" . 594 wall

  • 8" .406 Changed to 8" .322 wall i

Reason for Change: Computer entry error actual size or

wall thickness reflects l

(for the 8" counter bore)

(for the 12" 12"x8" reducer.)

E. 22" .969 Changed to 24" .894 wall Reason for Change: The I.D. Dimension was entered in computer in error.

The O.D. Dimension is the correct entry for pipe size.

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.969 Dimension = Wall Thickness (.894)

I + Shim Thickness 1

I .894 is correct entry for wall thickness.

F. 8" .719 Changed to 14 STD/WT x 8" SCH/40 weldolet to 14".375 pipe Reason for Change: The weld in this category is a branch line connection of a 14" x 8" weldolet to 14" pipe.

Not 8" pipe to weldolet.

ATTACHMENT #3 JUSTIFICATION FOR ELIMINATION OF PENETRATION PLATES AND FLUED HEAD PLATES FROM LIST OF CATEGORIES (Includes Exerpts from ASME Section III Article IX-3000)

It was determined that the welds within 12 categories received a volumetric examination according to ASME Appendix IX -

Article IX-3110. Article IX-3110. states in part's methods as described are applicable to most geometric (a)"..... The configurations and materials encountered in fabrication and shall be applied for normal conditions. However, special configurations and materials may be encountered that require modified methods and techniques......" and

"(b) Such special procedures may be modifications or combinations of methods described in IX 3000 and shall be proven by demonstration to result in an examination. capable of detecting '

discontinuities to the same extent that applicable normal "; '

techniques, as included in IX 3000, would result in detection of '

discontinuities under normal conditiohs......"_ and -

Summer of 1972 Addenda NB-5277 Special Execeptions /

When the joint detail does not permit radiographic ~ -e examination to be performed in accordance with procedures of ~this Section of the Code for joints attaching penetrations assemblies, which are fabricated as appurtenances or of the closing seam within an electrical penetration assembly, not necessarily I fabricated as an appurtenances, ultrasonic examination plus liquid penetrant or magnetic particle of the completed weld may be substituted for the radiographic examination. The absence of l auitable radiographic equipment shall not be justification for auch substitution. The substitutien of ultrasonic examination ,

can be made provided the examination is performed using a detailed written procedure which has been proven by actual demonstration to the satisfaction of the Inspector as capable of detecting and locating discontinuities described in this Code. '

, The nondestructive examination shall be in accordance with l Appendix IX and meet the acceptance standards of NB-5530 for the I

ultrasonic examination, NB-5340 for the magnetic particle examination and NB-5350 for_the liquid penetrant examination.

These welds have received.ra'diographic, ultrasonic and magnetic particle, and/or liquid' penetrant examinations.

Therefore, these welds were deleted from the program.

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i . . .' . . 's. . .. .ak ATTACHMENT #4 ,

FINAL PIPE SIZE / WALL THICKNESS CATEGORIES Pipe Cize Wall Thickness Line Number Weld Radiographed 2 1/2" .203 1-RE-40A2 1/2-1277 B -

2 1/2" .276 1-MS-29AB2 1/2-198 F 3" .226 1-RH-04AA14-137 E 3" .318 1-MS-49A3-85A B 4" .237 1-RH-04AB14-152 D 4" .337 1-RI-20C4-3 A g4 " .438 1-HP-06B4-20 A

'6" .280 1-FC-39CA6-21 B 6" .432 1-MS-33A6-78 s C 6" .562 1-MS-33A6-282 L 8" .322 1-RI-02A8-37 L 8" .500 1-HP-05AlO-24 C 8" .875 DB-15 ~

J 10" .365 1-MS-08AC10-304R B 10" .594 / l-RD-28CA10-10 B 10" .844 1-FW-04AAll-00-66 B 12" .375 - 1-RI-02B12 A 12" .406 1-FC-14CA8-48 C 12 ' .500 1-MS-07BC12-3AH A l-MS-08BB12-6B A 12" -f '

.688 <

1-FW-02FAl2-43A C 12" l.00 14" .375 1-RH-09A14-161 E 34" .438 1-WR-07A14-195 C 14" .750 1-HD-02AA8-39 ZZ 14" .938 1-HP-03A14-9 B 14" 1.056 1-FW-05A13-94-74 B 16" .375 1-RH-02BB20-19 DE i

l 16" 1.031 1-FW-OlB23-83-4 F 16" 1.250 1-FW-02DB16-95-45 A 18" .375 Mock-up WS-17A18-53 E 18" .'938 1-RH-OlB18-34 D 18 C / 1.156 1-FW-02GA18-39 D l

18"~' l.375 1-FW-02GB18-49 C 20" .375 1-LP-OlA20-21 G l

l 20" 1.031 1-HD-12AA20-63-PC2 ILS 20" 1.411 1-FW-OlAA19-30-17 A l D

! 22" .375 1-DG-09AA22-9 24" .894 1-MS-OlBD24-24 B 24" .375 1-WS-02LA24-29 C 24" .969 l-MS-OlBB24-8 A 24" 1.812 1-FW-02C23-83-28 C

.27" '

.875 Mock-up J-7936-20A A 28" .375 1-DG-10AC28-13 C l

30" .375 Mock-up WS-02KB30-556 A

.36" 1.336 1-MS-OlCA36-33 J 14" std/wt x 8" sch/40 to 14".375 pipe ,

Mock-up WR54D14-54 D d'

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Attcchment #5 e

' RADIOGRAPHIC SENSITIVITY CLASSIFICATION AND PERCENTAGES Percent Percent of Views of Description Views Total Reshot Category Sensitivity 4 Grade 2 Shimmed 392 2.1 83 21.1 Sensitivity 4 Grade 2 Not Shimmed 226 1.2 25 11.0 ,

~ Sensitivity 4, Grade 1 Shimmed 1,447 8.1 8 .5 Sensitivity 4 Grade 1 Not Shimmed 322 1.8 22 5.8 Sensitivity S Grade 2 Shimmed 939 5.2 .0 Sensitivity S Grade 2 Not Shimmed 1,067 5.9 .0 Sensitivity S Grade 1 Shimmed 1,204 6.7 .0 Sensitivity S Grade 1 Not Shimmed 1,257 7.0 .0 Sensitivity 2 Grade 2 Shimmed 4,176 23.3 23 .5-Sensitivity 2 Grade 2 Not Shimmed 1,509 ,

8.4 26 1.7 Sensitivity 2 Grade 1 Shimmed 3,872 ._21.6 8 .2

' Sensitivity 2 G'rade 1 Not Shimmed 1,137 6.3 6 .5 l

Sensitivity 1 Grade 2 Shimmed 189 1.0 .0 Sensitivity 1 Grade 2 Not Shimmed 31 . 1 .0 Sensitivity 1 Grade 1 Shimmed 62 . 3 .0 Sensitivity 1 Grade 1 Not Shimmed 20 . 1 .0 Sensitivity not evaluated (ref: Pg 2) 153 Total film reviewed l8,003 (Film within Program)

Under Shimmed 9,440 Unshimmed 4,753 Total 14,193 Film Code Acceptable +3,810 Total Film 18,003 rw e -e -- .'* * ' - - - - - - - - - - - 'w--- ~ - - - " " " - '- - - - - -

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