ML20092D392

Forwards Supplemental Response to Notice of Violation in IE Insp Repts 50-438/83-24 & 50-439/83-24,per NRC 840404 Request to Admit Part A.3 & Revise Schedule for Parts A.4 & A.5 Re Questionable Ultrasonic Exams

ML20092D392
Person / Time
Site:	Bellefonte
Issue date:	05/02/1984
From:	Kammer D TENNESSEE VALLEY AUTHORITY
To:	James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
Shared Package
ML20092D390	List: ML20092D392 ML20092D399 ML20092D405 ML20092D409
References
NUDOCS 8406210572
Download: ML20092D392 (43)

Text

. ..

g ,

TENNESSEE VALLEY AUTHORITY

, CHATTANOOGA. TENNESSEE 374ot j 400 Chestnut Street Tower II May 2,1984 U.S. Nuclear Regulatory Commission g 'IAI 8 P f ,. g 4 Region II Attn: Mr. James P. O'Reilly, Regional Administrator 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30303

Dear Mr. O'Reilly:

BELLEFONTE NUCLEAR PLANT UNITS 1 AND 2 - SUPPLEMENTAL RESPONSE TO VIOLATION 50-438/83-24-01, 50-439/83-24 QUESTIONABLE ULTRASONIC EXAMINATIONS This letter is in response to R. C. Lewis' letter to H. G. Parris dated April 4,1984 on violation 83-24-01 in which TVA was requested to admit part A.3 and revise our schedule for parts A.4 and A.S. The enclosed information, which delineates our position on these items, was discussed with NRC representatives in an April 17, 1984 telecon.

If you have any questions concerning this matter, please get in touch with R. H. Shell at FTS 858-2688.

To the best of my knowledge, I declare the statements contained herein are complete and true.

Very truly yours, TENNESSEE VALLEY AUTHORITY

~

D S Gm

, D. S. Kammer Nuclear Engineer Ecolosure oc (Enclosure):

Mr. Richard C. DeYoung, Director Office of Inspection and Enforcement U.S. Nuolear Regulatory Commission Washington, D.C. 20555 Records Center Institute of Nuclear Power Operations 1100 circle 75 Parkway, Suite 1500 Atlanta, Georgia 30339 8406210572 840607 DRADOCK05000g 1983-TVA 5OTH ANNIVERSARY An Equal Opportunity Employer

/0 l

,- .i-ef a '

Process Specification: 3.M.7.l(R2) r

• (;3 Date: March 2, 1984 Sheet: 1 of 20 l

TENNESSEE VALLEY AUIHORITY

'? j SPECIFICATION FOR ULTRASONIC EXAMINATION OF WgLD JOINTS 1.0 SCOPE F

This procedure defines the requirements for ultrasonic examination of welds in accordance with the following codes:

ASME Section I, Power Boilers,1974 edition ASNE Section III, Nuclear Power Plant Components, 1974 edition ANSI B31.1, Power Piping, 1973 edition through Smaner 1974 g addenda 1.1 The welding engineering or welding qualic- control unit at .

each site shall demonstrate this procedic a and each revision or addendum-to the satisfaction of the Authorized Nuclear Inspe'ceor. This demonstration shall be documented on a form similar to Appendix A.

k 2.0 EXTENT AND METHOD OF EXAMINATION 2.1 Unless otherwise specified, the entire volume of the weld '

and heat affecend zone shall be examined to detect, locate,  !

and evaluate defects oriented both parallel and perpendicular to the weld.

2.1.1 Where practical the weld shall be examined from both sidas by the angle beam method.

2.1.2 Where geometry or base metal reflectors (section 2.2) do not permit angle beam examination from both sides (from either or both surfaces) a combination of  !

angle beam and straight beam examination or straight beam ' examination from two perpendicular directions shall be used.

E44062.05 (L:

i.

's g m

, --,-a , . - - - - , ,- - ,- -. ,

l BELLEFONTE NUCLEAR PLANT UNITS 1 AND 2 SUPPLEMENTAL RESPONSE TO SEVERITY LEVEL IV VIOLATION 50-438/83-24-01, 50-439/83-24-01 d a QUESTIONABLE ULTRASONIC EXAMINATIONS Part A.3 4

' The NRC stated in the April 4,1984, letter that "although the ASME Code was not cited in this violation, the Code does mquire recording of 'any significant changes in subsequent rechecks,' thereby, implying the performance of calibration checks" and that the " licensee provided

, no documented criteria for periodic checks of calibration of ultrasonic examination equipment."

i TVA still maintains that our procedure meets the minimum 1974 ASME Code requirements. We disagree that the Code requires the " recording" of any significant change (s) in subsequent mehecks when recalibrating ultrasonic examination equipment. However, as a matter of good practice, we periodically check the integrity of the calibration in 4

process of examination by the use of a portable "rompas" field calibration block. Furthermore, as agmed upon during the December 20, 1983 telecon with NRC representatives, we have improved our program by revising the G-29M process specification 3.M.7.1 to include

, scanning rate limitations, detailed information regarding calibration (recalibration), the use of transfer . techniques, and calibration rechecks. Per NRC's mquest in the April 17, 1984 telecon, we are submitting the attached revision to the G-29M process specification 3.M.7.1 as evidence of and further delineation of our improvement in the program.

However, we still deny the violation occurred as stated.

Parts A.4 and A.5 We agree that the schedule for achieving ft211 compliance is excessively long for mvising the construction ultrasonic testing procedum QCP 7.2. The construction testing procedure QCP 7.2 will now be revised by June 1,1984, to incorporate all of the citanges that have been made to the G-29M process specification 3.M.7.1.

A

%r t

e 3

h J - g g y -.e- l'w r 4 , ---, a m, y .-, , - , - --wcr -e -+vy - - , - - ,,n-- n

/ 6 l

t Process Specification: 3.M.7.1(R2)

Date: March 2, 1984 3 ; C:'t? Sheet: 2 of 20 t.

. +

ll 2.2 The entire volume of base metal through which the sound will travel during angle beam examination of the weld shall be examined by the straight beam method to detect reflectors which would interfere with the angle beam examination.

(This examination shall be used only to locate areas which would interfere with angle beam examination and shall not be

, used as an acceptance examination.)

2.3 An example of weld area scanning is given in Figure 1. '

t 5~

W 2a 4

1 -

3

, 2

/3

/

I 2b

(:-). h

, 6 e

\ / "

l m

+

4 FIGURE 1 EXAMPLE OF WELD AREA SCANNING Exams 1,2,3, and 4 denotes angle beam examination and shall be per'ormed whenever possible.

• Exams 1,3,4, and 5 are acceptable when access perries examination from only one side of the weld.

Exams 5 and 6 denotes straight beam examination per Section.

( 9.0 of this procedure.-

' If exams 1 and 2 are not possible, exams 3,4,5, and 6 are i !

acceptable ,

i E44062.05 I

i

Process Specification: 3.M.7.1(R2)

Date: March 2, 1984 Sheet 3 of 20 3.0 EQUIPMENT i

3.1 Pulse-echo ultrasonic equipment generating frequencies over the range of 1-5 MHz shall be used. A nominal frequency of 2.25 MHz shall be used for most examinations and 1.5 MHz is l recommended for stainless steel, unless factors such as material grain size require the use of other frequencies.

3.2 The equipment shall have a calibrated attenuator (gain  ;

control) accurate to + 2 dB or 20 percent over its range. }

The range shall be sufficient to allow comparison of j indications beyond the viewable portion of the cathode ray tube display.-

I '

3.3 For angle beam examiskation, the system shall produce a beam in the material at an angle of 40 to 75 degrees with respect to the perpendicular to the entry surface. l 3.4 For straight beam examination the search unit shall produce a beam in the material which is nominally perpendicular to the entry surface. ,-

3.5 Ultrasonic testing couplants approved for use on nuclear systems and components are glycerine, Vaseline, Exosen, 3

Ultragel, or nuclear grade water. Couplant purchase

! requirements are listed in Purchase Specification PF-1059.

3.6 Instructions to verify the ability of the ultrasonic instrument to meet the linearity requirements, and to verify the accuracy of the amplitude control of the ultrasonic ,

instrument are found in Appendix B, and shall be documented similar to Appendix D. I If the ultrasonic instrument does not meet these linearity requirements the instrument should be repaired.

4.0 CALIBRATION BLOCK 4.1 The flat calibration block shall be as shown in Figure 2. l 4.1.1 The material of the block shall be of similar.

metallurigical structure and have the same or equivalent P-number (Section IX, QW 420) as the material to be examined. P-numbers 1, 3, 4, and 5 shall'be considered equivalent.

E44062.05

.D l

e i

I; i

.)

i l

_ - - - ~ . . . _ , _ _ _ _ - - _ _ . . . . - _ . _ . . . . .

e a g

j. . Process Specification: 3.M.7.1(R2)

O Date: March 2, 1984 Sheet 4 of 20 4.2 For examination of circumferential welds or any longitudinal welds with a contact surface curvature cf 20 inches in diameter or less, the calibration bloc,k contact surface shall also be curved. 'The curved calibration block shall be as shown in Figure 3.

4.2.1 The diameter of the part to be examined shall be no less than 90 percent nor more than 150 percent of the calibration block diameter.

4.2.2 Listed below are six curved blocks which will cover a 0.94- to 20-inch-diameter range.

Block Diameter, Inches Contact Surface Diameter, Inches 1.04 .' 0.94-1.56 .

1.7 l.56-2.6 2.9 2. 6-4. 3 4.8 4. 3-7. 2 8.0 7.2-12.0 .

13.33 12.0-20.00 ID E44062.05

. Process Specification: 3.M.7.1(R2)

Date: March 2. 1984 O. .

sw c= 5 e zu t.

If' MIN (NOTE 2 L a- .

f't, Ij" MIN s g n . "

• ~

L (es reevived )

k a A

HOLE LOCATION

{ 4 (SEE Ta8LE) 1 .

d. .

T s

O -

T g i 8 6 la l A }.otS }

. I Figure 2 FLAT CALIBR ATION SLOCK l L = Length of block determined by the angle of seart h unit and the vee-path used.

• T = Thickness of basic calibration block (see table below).

d = Diameter of side-drilled hole (see table below).

t = Nominal production material thickness.

Nominal Production Calibration Hole Hole )

Material Thickness (t), In. Block Thickness (T), In. Location Diameteter (d), In. 1 Up to 1 inel 3/4 or t 1/2 T 3/32 Over 1 thru 2 1-1/2 or t 1/4 T 1/8 Over 2 thru 4 3 or t 1/4 T 3/16 over 4 thru 6 5 or t 1/4 T 1/4 Over 6 thru 8 7 or t- 1/4 T 5/16 over 8 thru 10 9 or t 1/4 T 3/8 l Over 10 t 1/4 T See Note 1 i

Note 1 - For each increase in thickness of 2 inches or a fraction thereof, the hole O diameter shall increase 1/16-inch.

Note 2 - For block sizes over 3 inches in thickness (T), the distance from the hole [i 4

to the end of the block shall be 1/2 T min. t E44062.05 i

1

.l

- a 'l

/

Process Specification: 3.M.7.1(R2)

, Date: March 2, 1984 O Sheet: 6 of 20 '

Hole Location l See Table 1 i

l f

e \

\\ '#,

\\

\\

g \\

I Y,

s i

e 2. ,.

Y Q ,* 4

%e $%

e U,

• FIGURE 3 CURVED CALIBRATION BLOCK i

Refer to Table in Figure #2 for necessary information. g W

1 I

E44062.05 l,

\

t Procass Spacification: 3.M.7.l(R2)

Date: March 2, 1984

~s Sheet: 7 of 20 5.0 STRAIGHT BEAM CALIBRATION 5.1 When straight beam examination is used to detect, locate, and evaluate defects in material of 1 inch or greater thickness, a distance-amplitude correction curve shall be constructed, or compensation created electronically.

5.2 The curve shall be constructed as follows using the basic calibration block: 1 1

, 5.2.1 The search unit shall be positioned to obtain a' maximum , response from the calibration hole at 1/4 T.

This is the primary reference response.  :

I!

5.2.2 The signal shall be adjusted to produce a response of 1/2 of full scale on the cathode ray tube.

5.2.3 Without changing the gain control, the maximum response from the calibration hole at 3/4 T shall be determined.

5.2.4 The points representing the response from 1/4 T and 3/4 T shall be joined by a straight line extended to include the complete test range (Figure 4). I 5.3 An electronic distance amplitude device (if used) shall be adjusted such that the maximum response from the calibration hole is equalized over the distance range to be used.

5.4 The reference level for examination shall be the primary reference response corrected for distance.

6.0 ANGLE BEAM CALIBRATION 6.1 A distance-amplitude correction curve or electronic compensation shall be used.

6.2 A distance-amplitude correction curve (if used) shall be constructed as follows using the basic calibration block.

6.2.1 The search unit shall be placed as near as possible to the calibration hole and positioned for maximum res pons e. The approach distance shall not be less than 2 inches or 3/8 node whichever is less.

E44062.05 0) s.

V w- , e - ~ - -

r -- ^w- w

e ,

Process Specification: 3.M.7.1(R2)

Date: Ma.ch 2, 1984 A Sheet: 8 of 20 U {

i l

ea,=a=, acrenc=ct ass o=sc sci at sa W .._

..y, -os- _avs6 scacem N

l T T FIG. 4 TYPICAL DISTANCE AMPLITUDE I CORRECTION CURVE: STR AIGHT BEAM ,

METHOD ,, - '

?

N\.~

~,

,o' N ." .,

TT

. en.=an, arrene=cc mescovse g ---- scs at ny.or av66 scacam i.v. or ,

,,,* e,CrtnguCE LCvtk N

=..-hi5.

.--+. ...n..... b:a:-i- N j g .....-p.......

I S F tienTMS of a wtt-Pain i FIG. 3 TYPICAL DIST NCE AMPLITUDE 3 CORRECTION CURVE: ANGLESEAM METHOD i

E44062.05 i O i l-

'C Proc 3so Sp3cification: 3.M.7.1(R2)

Date March 2, 1984 il Sheet 9 of 20 l l

1 6.2.2 The response shall be adjusted using the gain control to produce a response of 75 percent of full screen height. This is the primary reference response.

6.2.3 Without changing the gain control, the search unit shall be positioned at other locations covering the 1

examination distance range to be used.

6.2.4 The corresponding responses shall be noted on the cathode ray tube screen.

~

1 6.2.5 These points shall be connected with a smooth curve (see Figure 5 ,for a typical example) .

6.3 Electronic distance ansplitude correction, if used, shall produce a primary reference response of 50 percent of full

• j screen height over th'e distance range to be used in examination.

6.4 A transfer method shall be used to correlate the response from the calibration block and the component. A description

! of the transfer method is found in Appendix C.

6.4.1 For piping circumferential welds, the transfer method f shall be used at least once for each veld in pipe 10 1 inches in diameter and under, and at least once for i each 5 feet of weld in larger pipe.

! 6.4.2 I*or other welds, the transfer method shall be used at i 1 east once for each 10 feet of weld. -

.; 7.0 SURFACE PREPARATION 4 7.1 The wald shall have a surface such that it cannot mask, or be confused with, reflections from defects.

~ 7.2 The contact surfaces for the search unit shall be free from any roughness or veld spattex which would interfere with scund transmission or movement of the search unit.

, 8.0 ANGLE BEAM SEARCH 8.1 The refersace level for monitoring defects shall be the primary reference level (6.2.2) corrected for distance (6.1) and corrected by the transfer method (6.4).

E44062.05 O i o

9 F

f

, - - y - _ . . , _, _ - - - - - .

, , - . . , - - , , . - . - - , . _ _-.,m - . - - , . , ,. - - - , . , . , w ,

a Process Specification: 3.M.7.1(R2)

Date: March 2. 1984

() Sheet: 10 o f 20 8.2 Wh n possible, scanning shall be performed at a gain setting of 6 dB above the reference level.

8.3 Defects parallel to the weld shall be detected as follows:

8.3.1 The angle beam search unit shall be p1' aced on the contact surface with the beam approximately perpendicular to the weld.

8.3.2 The search unit shall be moved laterally and longitudinally so that the beam passes through the entire volume of weld metal in two different approaches. Each pass of the search unit shall

, overlap a minimum of 10 percent of the transducer width.

8.3.3 The rate of search unit movement for exasination shall not exeed 6 in/sec unless calibration is verified at the higher scanning speed.

8.3.4 Double welded joints may be examined using two search units to detect lack of penetration (Figure 6) .

8.4 Defects perpendicular to the weld shall be detected as follows:

8.4.1 Two search units shall be placed astride the veld.

8.4.2 They shall form an angle of less than 45 degrees with the weld (Figure 7).

8.4.3 The search units shall be manipulated such that the entire volume of weld metal is examined. Each pass i of the search unit shal1 overlap a minimum of 10 percent of the transducer width.

8.4.4 Alternatively, if the weld surface is suitably prepared, one search unit may be placed on the weld with the beam parallel to the weld. The unit shalL be manipulated such that the entire volume of weld metal is examined. Each pass of the search. unit shall overlap a minmum of 10 percent of the transducer (piezoelectric element) dimenalon perpendicular to the direction of the scan.

E44062.05 O i 9

_ _ , , , _ _ . - - " ~ * - - '

4-Process Sp3cificcticn: 3.M.7.l(R2) i Date March 2, 1984

, Sheet: 11 of to s

set mof t '

~ ~

. \, .,

• Seg aseTC 1

, l., 2 6

. Nett II The SeatCM Umtl potshen well vaey.

FIG.E TYPICAL DOUBLE SEARCH UNIT I TECHNIQUE FOR DETECTING LACK OF j

PENETRATION IN DOUBLE WELDED JOINTS i O 1

- .. . 0.

b iii? 4 I h f_ f r i i il .

C Li (i~ [1 \ \* \ \ v\ V* \\ \* i i l\ t \ *i\\\

. g.-

O  !

4 V .

FIG. 7 TYPICAL TWO SEARCH UNIT TECH. g NIQUE FOR DETECTING TRANSVERSE DISCONTINUTIES IN WELDED JOINTS

-i E44062.05 0 -

t 4

., .-- -- .- -w- , . - . .- - - - , .+--,.--w . ---e _ . - - --

Process Specificction: 3.M.7 1(R2)

. . Date: March 2, 1984 Sheet: 12 of 20 i ,

i 8.5 Reflectors producing a response greater than 20 percent of j the reference level shall be evaluated with the gain control at the refemnce level corrected with transfer. l l

i 8.6 The reflectors shall be evaluated to determine their shape, identity, and location in relation to the acceptance criteria of section 10. ,

8.7 Calibration check shall be made when any part of the examination system is changed, at the finish of each examination or series of similar examinations, every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br />  ;

during the. examination, and when examination personnel are changed . The calibration check shall verify the sweep range calibration and distance amplitude correction.

)

1 3 8.7.1 For sweep range correction, if a point on the DAC '

curve has moved on the sweep line more than 10 percent of the sweep reading or 5 percent of fbli sweep, whichever is greater, correct the sweep range calibration and note the correction in the examination record.

If reflectors am recorded on the data sheets, those data sheets shall be voided, a new calibration shall be recorde1. All recordes indications since the last valid calibration er calibration deck shall be reexamined wi.th tue cormated calibration and their values shall be enanged on the data sheets.

1 8.7.,2 For distance amplitude correction, if a point on the distance-emplitude cermotion (DAC) curve has decreased 20 percent or 2dB of its amplitude, all data sheets since the last oelibration or calibration j check shall be marked void. A nt.w calibration shall be made and moorded and the area covemd by the voided data shall be reexamined. If any point of the distance amplitude correction (DAC) curve has I increased more than 20 percent or 2dB of its amplitude, all recorded indications since the last valid calibration er calibration deck shall be reexamined with the corrected calibration and their l values shall, be changed on the data sheets. I i

i 1

. . _ - _ _ _ , . , . ..,.. _ ~ , - l

Sheet: 13 of 20 1 9.0 STRAIGHT BEAM SEARCH 9.1 When possible, scanning shall be performed at a gain setting of twice (6 dB) the primary reference level.

9.2 The weld shall be scanned by moving the search unit along and across a sufficient contact area to examine the entire weld. Each pass of the search unit shall overlap a minimum of 10 percent of the transducer width.

9.3 The rate of search unit movement for examination shall not exceed 6 in/see unless calibration is verified at the higher scanning speed.

. 9.4 Penetration of the sound beam shall be verified by obtaining a back reflection from a parallel surface opposite to the

. contact surface. Alternatively, the back reflection may be

, obtained on a metallurgically similar material using approximately the same sound travel distance.

9.5 Reflectors which produce a response greater than 20 percent of the refemnce level shall be evaluated with the gain control at the reference level corrected with transfer. .

9.6 The evaluation shall be sufficient to determine the shape, identity, and location of the reflectors in relation to the i acceptance criteria of Section 10.

9.7 calibration check shall be made when any part of the examination system is changed, at the finish of each examination or series of similar examinations, every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during the e.xarinaticu, and when examination persor.nel are changed. The calibration dieck shall verify the sweep range-calibration and distance amplitude correction. See ssotions 8.7.1 and 8.7.2 if corrections are necessary.

10.0 ACCEPTANCE CRITERIA 10.1 Any mflector inteepreted to be a crack, lack of fusion, or incomplete penetration is unacceptable.

• 10.2 Any reflector is unacceptable if its maponse exceeds the refemnce level and its length exceeds:

i l

3 4 i

.. . :- ,, . . .- .a . . . .

l l

a . .

• ~'

Process Specification: 3.M.7.1(R2)

Date: March 2, 1984 Sheet: 14 of 20 1/4 inch for t up to 3/4 inch, inclusive; 1/3 e for c from 3/4 inch to 21/4 inch, inclusive; 3/4 inch for t over 2 1/4 inch  !

where e is the thickness of the thinner _of the two materials being joined at the weld.

11.0" RECORDS The minisans records requirements shall be as follows:

1. Identification (including sketch if necessary) of the veld.

2. Operator.

3. Date. '

Description of ultrasonic equipment and probe.

4.

5. Scan directions and distances.

. 6. Sketch of any unacceptable reflectors. I

7. Calibration data.

a) all DAC points and point maplitudes, and b) transfer data See Appendix D for Record and Calibration and Data Sheet examples.

12.0 Personnel performing nondestructiva examination shall be #

qualified in accordance with SNT-IC-1A and supplements,

" Recommended Practice for Nondestructive Testing Personnel qualification and Certification.'- The SNf-TC-1A reting of the personnel interpreting the examination shall be included in the examination report.

Prepared by M . /J. "1tm 3-f4-84 Reviewed by [ [_ b > > - / . py SNT-TC-1A, X.evel III ,

Approved by

~m .[ y.3-/4-F/

1 E44062.05 '

p i

i

- - - ~

Process Spacification: 3.M.7.1 (R2)

Dace: March 2, 1984

, Sheet: ' 15 of 20 TENNESSEE VALLEY AUTHORITY DIVIS!ON OF CONSTRUCTION 4

NDE DE 10NSTRATION RECORD 1 ASME No'ndestructive Examination method performed to the requirements of process specification Rev. and addendas

~ has been demo'nstrated to the utisfaction of the Authorized Nuclear inspector. '

i e

Technician .

Level Date ANI -

Date f

9 -

e l

l

!h Fem TVA 10131 (CON.2 79) w w - - --, w..- - , - - - ,

Proogss Specificztion: 3.M.7.1(R2)

Date: March 2, 1984 Sheet: 16 of 20 l

APPENDIX B EQUIPMENT CALIBRATION Screen Height Linearity h To verify the ability of the ultrasonic instrument to meet the linearity, position an angle beam search unit as shown in Figure 1 so that indications can be observed from both the 1/2 and 3/4T holes in a basic calibration block. Adjust the search unit position to give a 2 to 1 ratio of amplitudes between the two indications, with the larger set at 80 percent of full screen height. Without moving the search unit, adjust sensitivity (gain) to successively set the larger indication from 100 percent to 20 percent of full screen height, in 10 percent increments (or 2 dB steps if a fine control is not available),

and read the smaller indication at each setting. The reading must be 50 percent of the larger amplitude, within 5 percent of full screen height. The settings and readings must be estimated to the nearest 1 percent of full screen. Alternatively, a straight beam search unit may be used on any calibration block which will provide amplitude differences.

Amplitude Control Linearity To verify the accuracy of the amplitude control of the ultrasonic instrument, position an angle beam search unit as shown in Figum 1 so that the indication Orom the 1/2T hole in a basic calibration block is peaked on the screen. With the increases and decreases in attentuation shown in the following table, the indication must Gall within the specified limits. Other convenient mflectors from any calibration block may be used with angle or straight beam search units.

Indication Set at dB Control Indication Limits

% of Full Screen Change  % of Foll Screen _

80% -6dB 32 to 48%

80% -12dB 16 to 24%

40% +6dB 64 to 965 20% +12dB 64 to 96%

The settings and madings must be estimated to the nearest 1 percent of full screen.

1

-rocess spacitication: 3.M./.1(R2)

.#' Data: March 2, 1984 Shsot: 17 of 20

.O .

APPENDIX B EQUIPPENT CALIBRATION 9

I e 4a

_3 j 12 4 llis e to V

- r 1O FIG. I LINEARITY i

• I l

l I

I

• l O

e l

l l .

l

,-- _ _ - _ _ _ w -- n, . , - - - - ,,,,...,v y ., -,,, --_- . ..- ,- y e

l

. , I e Process Specification: 3.M.7.1(R2)-

Date March 2, 1984 Sheet: 18 of 20 1

1 APPENDIX C TRANSFER TECHNIQUE A. Establish basic callbration per the instructions in either section 5.0 or 6.0 of the procedure. .

B. ' Pitch-Catch (through transmission) Technique

a. With the controls set as they were during basic calibration, connect a second transducer to the UT instrument and switch the instrument to through transmission testing. The second transducer may be of the same angle as thi transmitting transducer or a variable angle type.

b. Manipulate the two't'ransducers on the calibration block

until a maximum response is shown on the CRT. Mark this point on the CRT.

c. Repeat step b on the material to be examined.

. d. Adjust the gain control to bring the response established in c to the saae level as established in b.

e. The basic calibration curve can then be used for evaluation of signals.

f. 'Then exneining pipe, the transfer technique shall be applied in both the axial and circumferential directions.

I l

E44062.05 f

l l

l l

S5$$$'t$'lUE2b I

-4 4

, , APPDTDIX D

, SAMPLE INSTRUCTIONS .

IIL"."L.ASO::tc T::ST :....0;;T STRUCTURF/SYSTDI Exsmole:

Base Plates' - Mainstosm Restrainse /R4 h::IT0, l.or 2 DATE:

k*ELDI.D.,Examn[c: 1R4 00074 UT EQPT. SNS 6' Machine PROBE -

TREQ Actual Freo.1-5 MhZ

_ PRO 15E SI'/.E Dimoneinne - width II DAC 75? mee.,n1_ s,,i l e r -n n a inneeh & _ d.0BE A::CLC(S) Actuni L-40*

T.'LLNSFER :!ECIfA : ISM Plastic Wedge or search unic COUPLANT Ultra-cel TT' cre. CALILRATION ELOC: _ Block SN# & material, size, & dimenn

)

CALIBRATION DATA amount of DBs required to ohenin 75% of full screen r.

& transfe!

. TEST METHOD (S) A-scan, b-scan, or C-scan l i'

.s.

CODE CLASS SCAT 1, III 3 III NF, et

• 1 COVERACE entire volume 100%

SCA:: MET!!OD(S) contact, immersion. continuous, with AMPLITUDE SpTTIiG _75% of full mereen overls C'?SACE CO::DITIO!! smooth. flush. eroun EQUIPPI::T LINEARITY __ Acceptable nor RNP-OCP 7. 2 *etc.

O sxzica or cu^cczrr^>t trtectoas:

si . 1e=sta. aenen. evne - 11 1 41c=ti a-

! roccived abovo 50% of DAC ,

i t

l l coe.v_.:TS . -

O Results of the above examination: ACC:: PIED

• • OPERATOR RUEm 4 ASNT CERT. LEVEL

- Process Specificacien: 3.M.7.l(R2)

Date: March 2,1984

, Sheet: 20 of 20 l

(

I . .

APPENDIX D .

l

- * . .. l 1

... . . . . l s.0 Mot %T auCTtvt t z. e.ATSQft PnOC EDuat t .L 'u * ' .0"' "a Tv A . D.wt%N I 83. ugg.( At sos.(a

. . . ~ l au. n..it e weeve. _ n.'v e l

.e_

UL I asateessC CAk rea At ause QA 3 A t..Lg i *

. i

) . t. a.arwes _ , _ , , _ . ._ *. es e.sa va n ,. . . . _. . . .

i .

• .octow r .rw f tv.t=a r ws e .

- - , e. . ....,_ s,.

e u . .. .

e is .tCO.ed. 1,. '

e f

• I .

p 8 4utt. 1A. 3:3 g _ s .te. skt

?, 8 net. b .f r. .( ts, tg e *p

,( .

ur nec. s,. .o ces  :: r l .

e m.,*uas i

s I iv.i ..

- . . ~

. O .su O t. .'= n a -' O -u e - '.-

-. - - . 1 . i 1. . e 4 .. l 6 i i. . a i_i.

. 4=i 6 i 8 1 6-l'i

. . - - . . . . ~ . .

l ...-. - I u, '

. l., i ut i ... I u, i i-- i .- n . a .~ ,. e # w . 1 .- I u .

.E I i i l I l l

...._.....a.......................

e v es s.,=<co.vc i, .-.. s e, i .

a f 8l 8 I I i i

4. O u o w a b o . -..J u . .; . ,r . . . .u 1

= l I II I I I t  !

. 4 e I e;i; e -~ '**""

Iii l l I i . . = , . .

.. I i t i, e e-<see n.c.6.-

. .. I i #a e ' oe w,

~

~ ,. i 6I esvi. Cor.

. i i O, ,

• ,, F i i i .e ,ec t One, .

l l

, , i i ##  : ( ... ..,, '

..'.'.. s. o s . . . . . , o.,a . , 0 . O , ,*s. .

, uns. ..r. a e..c o e . ore Tv. B ft . M e

g w

• j

< l

- Process Specification: 3.M.7.1(R2)  !

h Date: March 2, 1984 l 5 Sheet: 1 of 20 4

TENNESSEE VALLEY AUTHORITY SPECIFICATION FOR ULTRASONIC EXAMINATION OF WELD JOINTS 1.0 SCOPE F

This procedure defines the requirements for ultrasonic examination of welds in accordance with the following codes:

ASNE Section I, Power Boilers, 1974 edition ASME Section III, Nuclear Power Plant Components, 1974 edition 4 ' ANSI B31.1, Power Piping, 1973 edition through Summer 1974 g addenda 1 1.1 The welding engineering or welding quality control unit at each site shall demonstrate this procedure and each revision or addendum to the satisfaction of the Authorized Nuclear Inspector. This demonstracian shall be documented on a fcts

, similar to Appendix A.

i l ,

j

' 2.0 EXTENT AND METHOD OF EXAMINATION 2.1 Unless otherwise specified, the entire volume of the weld and heat af facted zone shall be examined to detect, locate, and evalerte defeces oriented both parallel and perpendicular ec tre weld.

2.1.1 Where practical the weld shall be examined fram both sides by the angle besa method.

• I 2.1.2 Where seemetry or base metal reflectors (section

2.2) do not pruit angle beam exarnination from both sides (fres either or both surfaces) a combination of angle beam and straight bens examination or straight besa examination from two perpendicular directions shall be used.

E4e.062.05

( ..

9 g-

BELLEFONTE NUCLEAR PLA T UNITS 1 AND 2 SUPPLEMENTAL RESPONSE TO SEVERITY LEVEL IV VIOLATION 50-438/83-24-01, 50-439/83-24-01 QUESTIONABLE ULTRASONIC EXAMINATIONS Part A.3 -

The NRC stated in the April 4,1984, letter that "although the ASME Code was not cited in this violation, the Code .does require recording of 'any significant changes in subsequent rechecks,' thereby, implying the performance of calibration checks" and that the " licensee provided  ;

no documented criteria for periodic checks of calibration of ultrasonic examination equipment."

]

TVA still maintains that our procedure meets the minimum 1974 ASME  !

Code requirements. We disagree that the Code requires the "re_ cording" (

of any significant change (s) in subsequent mohecks when recalibrating ultrasonic examination equipment. However, as a matter of good '

practice, we periodically check the . integrity of the calibration in  !

process of examination by the use of a portable "rompas" field calibration block. Furthermore, as agreed upon daring the December 20, 198 3 telecon with NRC representatives, we have improved our program by mvising the G-29M process specification 3.M.7.1 to include scanning rate limitations, detailed information regarding calibration (recalibration), the use of transfer techniques, and calibration rechecks. Per NRC's request in the April 17, 1984 telecon, we are submitting the attached revision to the G-29M process specification 3.M.7.1 as evidence of and further delineation of our improvement in ,

the program.  !

However, we still deny the violation occurred as stated.

Parts A.4 and A.5 We agree that the schedule for achieving full compliance is j excessively long for revising the construction ultrasonic testing '

procedure QCP 7.2. The construction testing procedure QCP 7 2 will  ;

now be revised by June 1, 1984, to incorporate all of the dianges that i have been unde to the G-29M process specification 3.M.7.1.  ;

l 9

6

. . g

Process Specification: 3.M.7.1(R2)

Date: March 2, 1984 E.,1 sheet 2or2o 1 .

2.2 The entire volume of base metal through which the sound will travel during angle beam examination of the weld shall be examined by the straight beam method to detect reflectors which would interfere with the angle beam examination.

(This examination shall be used only to locate areas' 'which 4 would interfere with angle beam examination and shall not be

} , used as an acceptance examination.)

i j. 2.3 An example of weld area scanning is given in Figure 1.

I' l

I 5' '

e 2a 9 7 1 - -

2 3 i

I 3,

l 1

(.'.,) T 2b h

,' 6 p -

m '

arm i

i YICUPE 1 EXAMP!E OF WEI.D AltEA SCANNING i.

Exams 1,2,3, and 4 denotes angle beam examination and shall be performed whenever possible.

!. ' Exame 1,3,4, and 5 are acceptable when access pern'its t

examination from only one side of the weld.

i Exams 5 and 6 denotes straight been examination per Section 9.0 of this procedure.-

k If esses 1 and 2 are not possible, exams 3,4,5, and 6 are L acceptable.

E44042.05

4-Process Specification: 3.M.7.1(R2)

Dates March 2, 1984 Sheet: 3 of 20 l l

3.0 EQUIPMENT 3.1 Pulse-echo ultrasonic equipment generating frequencies over the range of 1-5 MHz shall be used. A nominal frequency of 2.25-MHz shall be used for most examinations and 1.5 MHz is recommiended for stainless steel, unless factors such as l material grain size require the use of other frequencies.

, , 3.2 The equipment shall have a calibrated attenuator (gain control) accurate to + 2 dr or 20 percent over its range. )

The range shall be sufficient to allow comparison of  ;

indications beyond the viewable portion of the cathode ray

} tube display.-

3.3 For angle beam examination, the system shall produce a beam in the material at an angle of 40 to 75 degrees with respect to the perpendicular to the entry surface. l 3.4 For straight beam examination the search unit shall produce a beam in the material which is nominally perpendicular to the entry surface.

l 3.5 Ultrasonic testing couplants approved for use on nuclear systems and componenta are glycerine, Vaseline, Exosen, Ultragel, or nuclear grade water. Couplant purchase requirements are listed in Purchase Specification PF-1059.

3.6 Instructions to verify the ability of the ultrasonic instrument to meet the linearity requirements, and to verify the accuracy of the amplitude control of the ultrasonic w instrument are found in Appendix B, and shall be documented similar to Appendix D. I If the ultrasonic instrument does not meet these linearity requirements the instrument should be repaired.

4.0 CALIBRATION BLOCK 4.1 The flat calibration block shall be as shown in Figure 2. l 4.1.1 The material of the block shall be of similar metallurigical structure and have the same or equivalent P-number (Section II, QW 420) as the material to be examined. P-numbers 1, 3, 4, and 5 shall be considered equivalent.  !

~

E44062.05 0 .

I f

i I _ , , _ _ _ _ _ , , ,_ __, _

~ _ _ ._. . _ , , , _ . - . . , _ _ _ . . _ . . . - . . , -

i

~

j. . Process Specification: 3.M.7.l(R2)

O Date: March 2, 1984 Sheet: 4 of 20 4.2 For examination of circumferential welds or any longitudinal welds with a contact surface curvature of 20 inches in diameter or less, the calibration block contact surface shall also be curved. 'The curved calibration block shall be as shown in Figure 3.

4.2.1 The dieneter of the part to be examined shall be no less than 90 percent nor more than 150 percent of the calibration block diameter.

4.2.2 Listed below are six curved blocks which will cover a 0.94- to 20-inch-diameter range.

Block Diameter. Inches Contact Surface Diameter, Inches 1.04 ,, 0.94-1.56 .

1.7 1.56-2.6 2.9 2.6-4.3 4.8 4.3-7.2 8.0 7.2-12.0 13.33 12.0-20.00 l

4 E44062.05 l

)

l l

Process Specification: 3.M.7.1(R2)

Sh e o l

a.

l IfMIN (NOTE 21 , l 4* .

l

. r -

1[ MIN

, , m . "

m L ( as reevired )

k a M

HOLE LOCATION l .

1 y (SEE TABLE) j A. .

+

i O

T g'\ l 86846 A 4.otSi Figure 2 FLAT CALIBRATION BLOCK I L = Length of block determined by the angle of search unit and the vee pith used. "

T = Thickness of basic calibration block (see table below).

d = Diameter of side-drilled hole (see table below).

t = Nominal production material thickness.

Nominal Production Calibration Hole Hole Material Thickness (t), In. Block Thickness (T), In. Location Diameteter (d), In.

Up to 1 inci 3/4 or t 1/2 T 3/32 over 1 thru 2 1-1/2 or t 1/4 T 1/8 over 2 thru 4 3 or t 1/4 T 3/16 over 4 thru 6 5 or t 1/4 T 1/4 Over 6 thru 8 7 or t 1/4 T 5/16 over 8 thru 10 9 or t 1/4 T. 3/8 Over 10 t 1/4 T See Note 1 Note 1 - For each increase.in thickness of 2 inches or a fraction thereof, the hole diameter shall increase 1/16-inch.

O. Note 2 - For block sizes over 3 inches in thickness (T), the cistance from the hole p to the end of the block shall be 1/2 T min. t E44062.05 I

, 4 -

e , ., , - -

sl Process Specification: 3.M.7.l(R2)

, Date: Phrch 2, 1984 l Sheet: 6 of 20 Hole Location See Table

/ \\ '#,

is

\\

g \\

l

• 5

, i V6 eo Ae S.

D 'Sd.

FIGURE 3 CURVED CALIBRATION BLOCK Refer to Table in Figure #2 for necessary information.

O D

E44062.05

. - - , - ~ , --- - - - - - - - - - - - ~ ,. r- ,.-, - - - - . -c- , - ey.- ,.--c

t- Process Specification: 3.M.7.1(R2)

,_ Date: March 2, 1984 Sheet: 7 of 20 5.0 STRAICHT BEAM CALIBRATION 5.1 When straight beam examination is used to detect, locate, and evaluate defects in material of 1 inch or greater thickness, a distance-amplitude correction curve shall be constructed, or compensation created electronically.

5.2 The curve shall be constructed as follows using the basic calibration block:

, 5.2.1 The search unit shall be positioned to obtain a maximum response from the calibration hole at 1/4 T.

This is the primary reference response.  !

l 5.2.2 The signal shall be adjusted to produce a response of 1/2 of full scale on the cathode ray tube.

5.2.3 Without changing the gain control, the maximum response from the calibration hole at 3/4 T shall be determined.

5.2.4 The points representing the response from 1/4 T and '

i 3/4 T shall be joined by a straight line extended to include the complete test range (Figure 4) . I 5.3 An electronic distance amplitude device (if used) shall be adjusted such that the maximum response from the calibration hole is equalized over the distance range to be used.

5.4 The reference level for examination shall be the primary -

reference response corrected for distance.

6.0 ANCLE BEAM CALIBRATION 6.1 A distance-amplitude correction curve or electronic compensation shall be used.

t 6.2 A distance-seplitude correction curve (if used) shall be constructed as follows using the basic calibration block.

i 6.2.1 The search unit shall be placed as near as possible i

to the calibration hole and positioned for maximum re s po nse. The approach distance shall not be less than 2 inches or 3/8 node whichever is less.

E44062.05 O r l

s 4

D v ~ ,.n,n ---- - .- -. , . . , - - . - - e , - - , ----r , -

Process Specification: 3.M.7.1(R2)

Date: March 2, 1984 O Sheet: 8 of 20

,arunne scarmence masse =se sciavso onav66scacan h .____.__v ____________ . .

. N *

]

T T FIG. 4 TYPICAL DISTANCE AMPLITUDE I CORRECTION CURVE: STR AIGHT BEAM  ;

METHOD ., - '

?

'g ,s

,8 , *

% # s, T

l i PA t atFt*I"" RCS

.- stt gy, $I # SC##I"

,, we feisN=ct'5"' ,

i

,Yg E N

g,,. 9....".

88 "I"

/ .....=)******

I 3 $ 7 f!GMfMSOF &vttepafn FIG.3 TYPICAL DISTANCE AMPLITUDE I CORRECTION CURVE: ANGLE SEAM METHOD 1

E44062.05 l O i

. _ _ . . , - . . . . . . - . . - , , . .--_# , _ _ . _ - - . . _ . _ , . . . . , . ~ . ., ,. . . . . .

• Pracccc Sp3cificctign 3.M.7.1(R2)

Date: March 2, 1984 I

()

• Sheet: 9 of 20 6.2.2 The response shall be adjusted using the gain control to produce a response of 75 percent of full screen height. This is the primary reference response.

6.2.3 Without changing the gain control, the search unit shall be positioned at other locations covering the examination distance range to be used.

6.2.4 The corresponding responses shall be noted on the cathode ray tube screen.

6.2.5 These points shall be connected with a smooth curve (see Figure 5 ,for a typical example). I 6.3 Electronic distance amplitude correction, if used, shall produce a primary reference response of 50 percent of full "

screen height over th'e distance range to be used in examination.

6.4 A transfer method shall be used to correlate the response from the calibration block and the component. A description of the transfer method is found in Appendix C.

6.4.1 For piping circumferential welds, the transfer method shall be used at least once for each weld in pipe 10 inches in diameter and under, and at least once for i each 5 feet of weld in larger pipe.

6.4.2 For other welds, the transfer method shall be used at least once for each 10 feet of weld.

7.0 SURFACE PREPARATION ,

7.1 The weld shall have a surface such that it cannot mask, or be confused with, reflections from defects.

7.2 The contact surfaces for the search unit shall be free from any roughness or weld spattar which would interfere with sound transmission or movement of the search unit.

8.0 ANCLE BEAM SEARCH

' 8.1 The reference level for monitoring defects shall be the primary reference level (6.2.2) corrected for distance (6.1) and corrected by the transfer method (6.4).

E44062.05 4 ,-

o 9

..n - -- , - . -- . . - . . - , .-, -. ,. --- .. .,

Process Specification: 3.M.7.1(R2)

Date: March 2. 1984 O Sheet: 10 of 20 8.2 When possible, scannidg shall be performed at a gain setting of 6 dB above the reference level.

8.3 Defects parallel to the weld shall be detected as follows:

8.3.1 The angle beam search unit shall be pl' aced on the contact surface with the beme approximately

, perpendicular to the weld.

8.3.2 The search unit shall be moved laterally and longitudinally so that the beam passes through the entire volume of weld metal in two different approaches. Each pass of the search unit shall overlap a minimum of 10 percent of the transducer width.

8.3.3 The race of' search unit movement for exasination shall not exeed 6 in/see unlesa calibration is verified at the higher scanning speed.

8.3.4 Double velded joints may be examined using two search units to detect leek of penetration (Figure 6) .

O 8.4 Defects perpendicular to the veld shall be detected as follows:

8.4.1 Two search units shall be placed astride the weld.

3.4.2 They shall form an angle of less than 45 degrees with the weld (Figure 7).

8.4.3 The search units shall be manipulated such that the entire volume of weld metal is examined. Each pass of the search unit shall overlap a minimum of 10 perc6at of the transducer width.

8.4.4 Alternatively, if the veld surface is suitably prepared, one search unit may be placed on the veld with the beam parallel to the veld. The unit shall be manipulated such that the entire volume of weld metal is examined. Each pass of the search. unit shall overlap a minmum of 10 percent of the transducer (piezoelectric element) dimension perpendicular to the direction of the scan.

E44062.05 i

I 8

.- Procsss Sp2cificaticn 3.M.7.1(R2)

Date March 2, 1984 P) e Sheet: 11 of 20

\.) -

4 sec worc i -6

,b *

. '\ , .,

g3 sec= ores , ,

\ ,

(e) . .'

. Note 1: The searen unets position w.n vaey.

i FIG. 6. TYPICAL DOUBLE SEARCH UNIT I

TECHNIQUE FOR DETECTING LACK OF PENETRATION IN DOUBLE WELDED JOINTS i O N

O veto.s* j.

~

i s 'i t n t_ 1 i i irie in *

<*f+ ( t11 et t 4 s n,s t e t t et t u b -

FIG. 7 TYPICAL TWO SEARCH UNIT TECH. I NIOUE FOR DETECTING TRANSVERSE DISCONTINUTIES IN WELDED JOINTS .

l E44062.05 i

t

a

Prootss Specification: 3.M.7.1fR2)

. . . Date: March E, 1984 i

Sheet: 12 of 20 I

8.5 Reflectors producing a response greater than 20 percent of the reference level shall be evaluated with the gain control at the refemnce level corrected with transfer. a I 8.6 The reflectors shall be evaluated to determine their ' shape, identity, and location in relation to the acceptance criteria of section 10.

8.7 Calibration check shall be made when any part of the examination system is changed, at the finish of each examination or series of similar examinations, every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> i during the examination, and when examination personnel are changed. The calibration check shall verify the sweep range calibration and distance amplitude correction.

8.7.1 ' For sweep range correction, if a point on the DAC j curve has moved on the sweep line more than 10 percent of the sweep mading er 5 percent of fbil sweep, whichever is greater, correct the sweep range calibration and note the correction in the j examination moord.

i If reflectors are recorded on the data sheets, those

data sheets shall be voided, a new calibration shall l be recorded. All recorded' indications since the last l valid calibration or calibration check shall be reexamined with the corrected calibration and their values shall be &anged on the data sheets.

i 8.7.2 For distance amplitude correction, if a point on the distance-amplitude correction (DAC) curve has j decreased 20 percent or 2dB of its amplitude, all data sheets since the last calibration or calibration check shall be marked void. A new calibration shall j be made and moorded and the area covered by the

voided data shall be reexamined. If any point of the distance amplitude correction (DAC) curve has increased more than 20 percent or 2dB of its

amplitude, all recorded indications since the last valid calibration or calibration check shall be reexamined with the corrected calibration and their values shall be sanged on the data sheets.

)

i I i

i 4

l

, s , . - . . . . . . _ , . . ,

. . ,, ,_,;.-.-- _. .. - . - - . - . . _ - - ~ , . , - . - - ,, - , . . _ - - - . - -

Sheet: 13 of 20 9.0 STRAIGHT BEAM SEARCH 9.1 When possible, scanning shall be performed at a gain setting of twice (6 dB) the primary reference level.

92 The weld shall be scanned by moving the search unit along and across a sufficient contact area to examine the entire weld. Each pass of the search unit shall overlap a minimum of 10 percent of the transducer width.

9.3 The rate of search unit movement for examination shall not exceed 6 in/sec unless calibration is verified at the higher scanning speed.

9.4 Penetration of the sound beam shall be verified by obtaining a back reflection from a parallel surface opposite to the contact surface. Alternatively, the back reflection may be

, obtained on a metallurgically similar material using approximately the same sound travel distance.

9.5 Reflectors which produce a response greater than 20 percent of the reference level shall be evaluated with the gain control at the referwnee level corrected with transfer.

9.6 The evaluation shall be sufficient to determine the shape, identity, and location of the reflectors in relation to the acceptance criteria of Section 10.

9.7 Calibration check shall be made when any part of the examination system is changed, at the finish of each examination or series of similar examinations, every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during the examination, and when examination personnel are changed. The calibration dieck shall verify the sweep range calibration and distance amplitude correction. See sections 8.7.1 and 8.7.2 if corrections are necessary.

10.0 ACCEPTANCE CRITERIA 10.1 Any reflector interpreted to be a crack, lack of fusion, or incomplete penetration is unacceptable.

10.2 Any reflector is unacceptable if its response exceeds the

. reference level and its length exceeds:

l 4

w 7 m _ < , % - ,6._,.. p9-_.. ,.~ _ ,_m_,, y g..-. gg ._-. p..- 7

l Process Specification: 3.M.7.I'R2) (

Date: March 2,1984 s*

O e= t' of 2o 1/4 inch for t up to 3/4 inch, inclusive; 1/3 e for e from 3/4 inch to 21/4 inch, inclusive; 3/4 inch for e over 2 1/4 inch where t is the thickness of the thinner of the two materials being joined at the weld.

11.0" RECORDS l 1

The minima records requirements shall be as follows:

1. Identification (including sketch if necessary) of the veld.

2. Operator.  ;

3. Date.

4. Description of ultrasonic equipment and probe.

5. Scan directions and distances.

. 6. Sketch of any unacceptable reflectors. . 1

7. Calibration data, a) all DAC points and point amplitudes, and b) transfer data See Appendix D for Record and Calibration and Data Sheet examples.

12.0 Personnel performing nondestructive examination shall be qualified in accordance with SNT-TC-1A and supplements,

" Recommended Practice for Nondestructive Testing Personnel Qualification and Certification." The SNT-TC-1A rating of the 4 personnel interpreting the examination shall be included in the examination report.

Prepared by Ae v. . // "lLN 3.l6 -d4 Reviewed by [ I d 4. py SNT-TC-1A, 4.evel III ,

Approved by

/

m .[ '

3 3-/6-F/

R44062.05 O o 1

_ . . , _ ._ _ . - - _ . . _ . . _ , , _ - l

. Procsca Specificacion: 3.M.7.1 (R2)

Dace: Farch 2, 1984 e'

• Sheec:'15 of 20 APPENDIX A TENNESSEE VALLEY AUTHORITY DIVISION OF CONSTRUCTION NDE DEMONSTRATION RECORD ASME No'ndestructive Examination method ,

performed to the requirernents of process specification Rev.

• and addendas

~

. has been demonstrated to the satisfaction of the Authorized

Nuclear Inspector, .

i 6

• x .

Technician Level. Date ANI ,

Date D .

t t9 I

Nm TVA 10131 (CON.2 79) 1 1

_. ._ . - _ _ _ _ - ._ _ _ _ - - ~. _ _._ _ _ _ _ _ ._ . _ _ . _ . _ _ _ _ _ _ ____ _ _ _ _

1 i ,.

Proo:ss Specific tient 3.M.7.1(R2)

Datet March 2,1984 j ^ . Sheet: 16 of 20 I

APPENDIX B EQUIPMENT CALIBRATION 5

i 4 Screen Height Linearity ,

o l

To verify the ability of the ultrasonic instrument to meet the

! linearity, position an angle beam search unit as show in Figum 1 so I

that indications can be observed from both the 1/2 and 3/4T holes in a basio calibration block. Adjust the search unit position to give a 2

. to 1 ratio of amplitudes between the two indications, with the larger

set at 80 percent of full screen height. Without moving the search I unit, adjust sensitivity (gain) to successively set the larger indication from 100 percent to 20 percent of full screen height, in 10 i percent increments (or 2 dB steps if a fina control is not available),

i and read the smaller indiostion at each setting. The reading must be i 50 percent of the larger amplitude, within 5 percent of full screen I height. The settings and medings must be estimated to the nearest 1

, percent of full somen. Altematively, a straight beam search unit j may be used on any calibration block which will provide amplitude l diffemnoes.

Aeolitude Control Linearity i

To verify the accurney of the amplitude control of the ultrasonio j instrument, position an angle beam search unit as shown in Figum 1 so i that the indication from the 1/2T hole in a basio calibration block is peaked on the somen. With the increases and doomases in 1 attentuation shown in the following table, the indication mast finil within the specified limits. Other convenient mflectors from any i calibration block any be used with angle or straight beam search

units.

Indication Set at dB Control Indication LiaLts 5 of Full Screen Chanas i of Full Screen 805 -6e ~ 32 to 485

! 805 -12e 16 to 245

405 +6m 64 to 965 l 205 +12e 64 to 965 i

f The settings and medings must be estimated to the nearest 1 percent of full screen.

i t

I

crococo specitiestion: J.M./.1(R2) 7 Data March 2, l')84 Shsot 17 of 20 APPENDIX B EQUIPPENT CALIBRATION e

.w t .

L

_. . ..s .

. I

?

lg ,,

PlG. I LINEARITY se e

I t

9 O

o ee-8

e Process Specification: 3.M.7.1(R2)

Date March 2, 1984 g Sheet: 18 of 20 APPENDIX C TRANSFER TECHNIQUE A. E4tablish basic calibration per the instructions in either section 5.0 or 6.0 of the procedure. .

3. ' Pitch-Catch (through transmission) Technique

a. With the controls set as they were during basic calibration, connect a second transducer to the UT instrument and switch the instrument to through transmission testing. The second transducer may be of the same angle as the transmitting transducer or a variable angle type.

Manipulate the two"t'ransducers on the calibration block b.

until a maximum response is shown on the CRT. Mark this point on the CRT.

Repeat step b on the material to be examined.

c.

g d. Adjust the gain control to bring the response established y in c to the same level as established in b.

e. The basic calibration curve can then be used for evaluation of signals.

f. When examining pipe, the transfer technique shall be applied in both the axial and circumferential directions.

I E44062.05

Sik$$t$ 17 E 2b 4-O.

v o.e APPENDIX D

, SMIPLE INSTRUCTIONS liLTMSO !II: T*:ST :' :.' ORT STRUCTURF/SYSTD1 Example:

Base Places' - Mainsteam Restrainse/R4 I?.:IT 0 1.or 2 DATE:

k' ELD 1.D.Examnie IR4 00024 UT EQPT. SMS &' Machine PROBE FREq. Actual Frea.1-5 Mhz width enout SI'/.E Dimon. inn - D Inneeh &_ ?.=.00E A :CLC(S) Aceuni L-40*

DAC 7s? meenst #n t i e r s.n o, 75*

• TMNSFER ItEC!fA :IS)! _ Plastic _ wedge or search unit COUPIANT Ultra-cel TT1 cre.

CALIBRATION OLOCK Block SN# & material, size, & die.enn CALIBRATION DATA _ amount of DDs reouired to obtain 75% of fu .

. TEST METHOD (S) .A-scan, b-scan, or C-scan CODE CIASS SCAT 1, III 3. _III NF, et -

C0VERACE entire volume 100% SCAN !!ET110DfS) contact, immersion, enneinuous, with AMPLITUDE SFITING 35% of full mereen overls

_ C'.T5 ACE CO::DITIO:! smooth. flush. erotm EQUIP'CT LINEARITY _Accentabic nor BNP-0CP 7.2 *etc.

O sxzTca or cu^cczrrist: ^=rtecroas: si 1==stu. eenca. eve - 11 1aaic==1 a=

i received above 50% of DAC ,

i CD E TS:

I Results of the above examination: ACC:PTED I

• OPERATOR REJECTED 4

t Ash *r CERT. LEVEL t

r

Procssa Specificacicn: 3.M.7.1(R2)

Date: March 2,1984 e . , . .,

Sheet: 20 of 20 O

APPENDIX D ,. .

, ... . ~ . .

p.08 0LSt NuCTewt i14.s..aA780se '*'

PROCtavat e a um . . . .a= =a Tv A. Dewttss ass uckf aa powf A . . .. c a. .e

. . . . I

.u, .n e r. _

..J.,

l . *[ .

. UtiesA60seeC CAkewAAf ause QAs A west #

.mm .r e s .

g 1

} . saa ne age.tt .

.._ .es, *

-eenswet _ . .

octow.t mo ____ etw I e t w.gwes t .s e ._. _

e .

t. erow eme ,,, '

i, sa. 4me6a ... ,.

e w stComeda ns. i

. ,e faa eeugt. *  ! .

1A. ssat f aCa. a 464 4* begets se.

,0 .,

Y

. .tr. egrg,

.. . .u s ts

• p i ' '

us i

i.

6 O uw-Ose.-- n we . O ...<* .

'. -, t .. i i.i 6 6-i 6=I i. -

1

-. t=1 6 # I i 1!,

.......~-...un.

. . . . I ur l.. I ut i .: 1 ut i

. '. -- p= n .e e.em e 1 # . a e i

- - i i l i 1 Defas.ttm tstungguaws restaw e.' if f u.

, ,., ... ,..s. O u o u. O = 0 ~ -

t 8l i l i i i I w . .;.,

m

. . _.u I i li l ! ) f

, , g i ; ,

9 g . . so.aw a.

i I i j ..-se . .

.. I1 6 i ; i e sweer rs t.6. -

. I t

.. 1 6 , i onkar -

3. I 6 1 i t e.6 st a Cor.

, 4 6 ee Coe

,, 1 i f I es,ec t

• i Ocre .

. )) 6 u

! g. .s e .. e

.. . . ...... . ,0

• O ' **- ** -

u nsem.or a .s*a r.se o c. ora .

ha u na **=* 6.* -

g

+

- _ - , ,- # .