ML20141M285

Rev 0 to NDE-620, Nondestructive Exam Program

ML20141M285
Person / Time
Site:	Mcguire, McGuire
Issue date:	07/29/1992
From:	DUKE POWER CO.
To:
Shared Package
ML20141M268	List: ML20141M266 ML20141M285
References
NDE-620, NUDOCS 9208110036
Download: ML20141M285 (25)

Text

i

.- .- 1 l

l PROCEDUfnDE-620 PAGE 1 REVISION 0 DUKE POWER COMPANY OUALITY ASSURANCE DEPARTMENT NONDESTRUCTIVE EXAMINATION PROGRAM 4

1.0 SCOPE l This procedure shall be used for the ultrasonic examination of welds in ferritic

pressure vessels using the following wave modes and angles with a manual i pulse-echo, contact technique

a. Wave mode--shear 2.0 Appl! CATION This procedure applics to the following materials, product forms, weld types, l configurations and thickness range:

! a. Material--ferritic steels j b. Product forms--rolled and forged j c. Weld types--full penetration butt welds

! d. Configurations--circumferential, longitudinal, meridional,

! tubesheet-to-shell or head and nozzle-to-shell or head welds,

e. Thickness range--nominal wall thickness greater than 2.0 inches, i

3.0 REFERENCED DOCUMENTS 3.1 ASME Boiler and Pressure Vessel Code Section V, Nondestructive Examination,

1980 Edition with addenda through Winter 1980 and Winter 1981.

ASME Boiler and Pressure Vessel Coda Section XI, Rules for Inservice 3.2 Inspection of Nuclear Power Plant Components, 1980 Edition with Addenda l through Winter 1980 and Winter 1981.

4.0 RESPONSIBILITY i

4.1 The NDE level III UT is responsible for review, approval and qualification

of this procedure.

4.2 The -Quality Assurance Director, Operations at each nuclear site is responsible for assuring that the ' requirements of this procedure are implemented during preservice and inservice inspections.

5.0 PERSONNEL QUALIFICATION All ultrasonic examiners shall be qualified in accordance with Duke Power Company Procedure NDE-B, " Training, Qualification and certification of NDE Personnel."

9208110036 920729 PDR ADOCK 05000369 O PDR

PROCEDUftfDE-620 PAGE 2 REVISION 0 i OUKE POWER COMPANY OUALITY xSSURANCE DEPARTMENT NONDESTRUCTIVE EXAMINATION PROGRAM ',

l I 6.0 EQUIPMENT 6.1 Ultrasonic Instruments One of the following ultrasonic instruments shall be used:

a. panametrics Et 2002

b. Krautkramer USD-10

c. Krautkramer USK-7, USK-7S or USK-6

d. Stavley NOT-136

e. Tokyo Keikei SM-1000 6.2 Search Units 6.2.1 Search units shall contain single transducer elements. The nominal search unit frequency shall be 2.25 Mhz. The maximum nominal searcn / T unit size for square, circular, or rectangular active elements shall i be 1.0 inch.

6.2.2 Wedges shall be fabricated to produce the required refracted shear wave angles + 2 degrees.

6.2.3 The wedge used for the examination shall be the same as those used

, when calibrating.

l l

6.3 Search Unit Cables l

l 6.3.1 The cables used for the examination shall be the same' cables that j were used during calibration, l

6.3.2 Search unit cable types shall be either RG58, RG62 or RG174 with lengths from 4 ft. through 50 ft. '

6.3.3 Search unit ' cables used with the pulso-echo mode shall have two connectors.

6.4 Couplant l

6.4.1 Ultragel, Sonotraco, glycerine or deionized water shall be used as a couplant.

6.4.2 Couplant materials except deionized water shall be tested for sulfur and halogen content in accordance with ASME Section V, Article S.

The results of such tests shall be maintained by site QA.

PROCEDufMOE-620 PAGE 3 REVISION 0 OUKE POWER COMPANY OUAL.lTY ASSUR ANCE OEPARTMENT NONDESTRUCTIVE EXAMINATION PROGRAM i

6.5 Reference Blocks 6.5.1 Reference blocks used for beam angle measurements, screen distance calibration or calibration verification simulator shall be one of the following:

a. IIW type one or type two

b. Min'ature Angle Beam Block (Rompas)

c. AWd type DC Block (screen distance calibration only) 6.5.2 Reference blocks shall be made of the same nominal type of material as the vessel to be examined, i.e., wrought ferritic steel.

• • Note: applies to 6.5.2**

Other reference blocks may be used with Level III approval.

6.6 Basic Calibration Block 6.6.1 The material from which the block is fabricated shall be from one of the following:

a. Nozzle drop out from the component

b. A component prolongation

c. Material of the same material specification, product form and heat treatment as one of the materials being joined.

6.6.2 Where the component is clad, the basic calibration block shall be clad to the component clad nominal thickness + 1/8 in. Deposition -

of cladding shall be by the same welding procedure as the component.

When the automatic method is impractical, clad deposition shall be by the manual method.

6.6.3 Basic calibration block configuration is shown in Figure 1.

• • Note: applies to 6.6.3**

Alternate block designs may be substituted provided similar beam paths are used.

6.6.4 For examination of welds in pressure _ vessels where the diameter is greater than 20 inch ~ a -block of the same curvature or flat basic calibration block shall be used, When a flat basic calibration block is used, adjust the instrument gain in accordance with ASME Section V, Article 5, Appendix A.

PROCEDUREN0E-620 PAGE 4 REVISION 0 OUKE POWER COMPANY OUALITY ASSUR ANCE DEPARTMENT NONDESTRUCTIVE EXAMINATION PROGRAM 6.6.5 The finish on the surfaces of the basic calibration block shall be representative of the surface finishes of the pressure vessel.

l 7.0 CAllBRATION 7.1 Screen Distance Calibration 7.1.1 Calibrate the instrument sweep in inches of metal path. The metal path displayed on the screer shall be the shortest distance that will extend 1/8 V-path beyond the last calibration reflector.

7.1.2 Use screen distances of 2.0" through 50.0" in one inch increments when . calibrating other ultrasonic instruments.

• • Note: applies to 7.1**

When the Epoch 2002 or USD-10 are used, screen distances may be calibrated with any convenient metal path distance that meets the requirements of 7.1.1.

7.2 Sensitivity Calibration from the Unclad Side

}

l 7.2.1 Maintain the REJECT control in the "0FF" position.

! 7.2.2 Construct a distance-amplitude-correction curve (DACI 9 9 9 side l drilled holes.

7.2.3 The temperature difference between the examination and basic cali-bration block surfaces shall not exceed 25 degrees F.

7.2.4 Position the search unit on the basic' calibration block and obtain a peak response from the hole that produces the , highest amplitude.

Keep the center line of the search unit at least 1 1/2 inches- from -

the nearest edge of the block. Rotating the sound beam into the corner formed by the hole and the edge of the block may produce i signals at innger metal paths and higher amplitudes'. D_o not use

theu signal _s for calibration.

7.2.5 Adjust the gain controls to set the maximum amplitude point at 80%

, full screen height (FSH).

l 7.2.6 Mark the metal path and amplitude on the cathode ray tube (CRT) screen.

7.2.7 Obtain peak responses from the two other holes.

7.2.8 Mark each response at the metal path and' amplitude on the CRT.

l l

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t PROCEDURRDE-620 PAGE 5 REVISION O I DUKE POWE R COMPANY

. QUALITY ASSURANCE DEPARTMEN1 NONDESTRUCTIVE EXAMINATION PROGRAM 7.2.9 If the basic calibration block is not cladded, then proceed to 7.2.14.

7.2.10 Position the search unit on the clad side of the block.

7.2.11 Determine d0 change in amplitude between the 3/4T and the 5/4T holes.

7.2.12 Return to the unclad side of the block and position the search unit to obtain a maximum amplitude signal from the 3/4T hole.

7.2.13 Decrease the gain by the dB amount deturmined in 7.2.11 above.

7.2.14 Mark the amplitude of the peak signal at the 5/4T hole position.

7.2.15 Connect all of the screen marks 'cith a smooth curved line.

7.2.16 Obtain a maximum amplitude respon.se from the notch on opposite surface.

7.2.17 Mark the peak of the signal with an "X" on the CRT. ,

7.3 Beam Spread 7.3.1 After establishing the OAC, measure the beam spread in the vertical plane before each period of extended use or every 3 months, whichever is less. Record the measurement on the Ultrasonic Beam Spread Measurement Sheet.

7.3.2 Increase the instrument gain + 6dB so that the OAC curve represents the 50% DAC limit.

7.3.3 Obtain a oeak response from the 1/4T hole. Move the search unit toward the hole until the indication drops to the DAC line. Record the metal path.

7.3.4- Move the search unit away from the hole until the indication drops to the DAC 1ine. Record the metal path.

7.3.5 Repeat the above steps fer the.1/2T and 3/4T holes.

7.3.6 Plot the beam spread on the Beam Spread Measurement Sheet, NDE-6200.

7.4 Calibration Checks.

7.4.1- Verify instrument sensitivity and sweep range calibration using the basic calibration block or'a simulator block at the following times:

a. At the start and finish of each examination. or scriss of i examinations for which the calibration applies; L - - . - - - r~. . .. . - - . . - - - . . -. . - , . . - . . _ - . . - ,, -.

. . _ _ _ _ . . . - _ _ . . . - __ .m_-- . , _ _ _ . - _ _ _ - _ _ _ _ _ - . __ . .

PROCEOUfWDE-620 PAGE 6 nEVISION O DUKE POWER COMPAf4Y OUAllTY ASSURANCE DEPARTMENT tJON06STRUCTIVE EXAMINATION PnOGR AM #}

-_ _ l

b. When substituting coaxial cables with cables of the same type and length;

c. At intervals not to exceed 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br />;

d. With any change in examination personnel;

e. Any change in power source, or loss of power to the instrument;

f. When the examiner suspects equipment malfunction.

7.4.2 Initial and final calibration checks shall be made on the basic calibration block.

7.4.3 If any point on the OAC curve has decreased 20% or 2dB of its '

amplitude, void all examination data sheets since the last calibra-tion check. Prepare a new calibration record and reexamine all welds listed on the voided examination data- sheets (Forms NDE-620A and 6208).

7.4.4 If any point on the ' AC 0 curve has increased more than 20% or 2dB of its amplitude, adjust the gain settings to the original calibration and reexamine all recorded indications since the last calibration check, Change the recorded indication values as necessary on the examination data sheet.

7.4.5 If any point on the OAC curve has moved on the sweep line more -than 10% of the sweep reading, adjust the sweep controls to the original calibration and note the change on the calibration record. If recordable indications are noted. on the examination data sheets-since the last calibration check, void those data sheets, prepare a new calibration record, and reexamine all welds listed on the voided l examination data sheets.

7.5 Recalibration l

If any of the following changes are made to the ultrasonic examination systcm, prepare a nes callbration record:

( a. Any cnange in search unit, wedges, or cable type _or length;

b. Change in UT instruments; l -c. Any change in couplant type.

1 l

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l PHOCEDUlWDC-620 PAGE 7 REVISION 0 OUKE POWCR COMPANY OUAL.lTY ASSURANCE DEPARTMENT NONDESTRUCTIVE EXAMINATION PROGRAM 8.0 EXAMINATION 8.1 Surface Condition The examination surface shall be free of irregularities, loose material, or coatings which interfere with ultrasonit wave transmission or free movement of the search unit. The weld surface and base material shall comply with the requirements of Procedure QCH-3, " Weld Preparation for Inservice Inspections."

8.2 Examination Volume 8.2.1 The examination volume is the weld and the adjacent base mater,ial on each side of the wold. See Figures 2 through 10.

8.2.2 In order to determine th'e examination volume for a given weld, use

the weld detail drawings or preservice examination profiles. If this data is not available, p.ofiles shall be taken at Ln using a weld contour gage and 0 degree ultrasonic thickness measurements.

The 0.0. contour and thickness measurements shall cover a miniinum distsnce of 2t from the weld edge on each side of the weld as access permits. Ultrasonic thickness measurements shall..be taken at intervals no greater 0.5 . inch. Use Procedure NDE-90, " Reference System for Identification Layout of Welds and System Components," to determine LO '

• • Note: applies to'd.P**

"t" is the nominal vessel wall thickness.

I 8.3 Scannino Requirements 8.3.1 Use nominal beam angles of 45 and 60 degrees.

8.3.2 In order to detect reflectors parallel to the weld seam, place < the search on the vessel adjacent to the weld on the outside surface.

Direct the sound beam at right angles to the weld and scan the surface to cover the required volume in two beam path directions.

Perform the examination from two sides of the weld, where practical.

8.3.3 In order to detect reflectors transverse to the weld seam, place the search unit on the vessel adjacent to the weld on the outside surface. Direct the' sound beam parallel to the weld and. scan the surface to cover the required volume. Perform the examination in two opposite directions.

l PROCEDUfWDE-620 PAGE 8 REVISION O DUKE POWER COMPANY f r

OVALITY ASSURANCF DEPARTMENT NONDESTHUCTIVE EXAMINATION PROGRAM i 8.3.4 Scan with a gain setting of +14dB above the primary reference level.

If .the noise level is such that a 3 to 1 signal-to-noise racio or higher in the OAC area cannot be maintained, reduce the scanning gain until the 3 to 1 signal-to-noise level is achieved. Record the actual dB setting used for scanning as a limitation on the Examination Data Sheet if the scanning sensitivity is less than

+14dB above the reference sensitivity.

8.3.5 Overlap the search unit at least 25% of the active elem nt dimension.

8.3.6 Do not exceed 3 inches per second scannino speed. .

8.3.7 When scanning in the circumferential direction, a 60 degree refracted angle may not_ strike the inside surface. The NDE Examiner shall determine the maximum useable refracted angle by th following formula:

-1 Sin 1.0. \

(0.0.j Sin = maximum useable refracted angle I.D. = vessel inside diameter 0.0. = Vessel outside diameter 8.3.8 When the maximum useable refracted angle is less than 60 degrees.

l

.ne circumferential scan shall be conducted with 45 degree and 35 degree shear waves.

9.0 RECORDING CRITERIA 9.1 Record the following data for all indications that produce a response equal

to or greater than 20% of DAC at the primary reference level

I

a. Peak amplitude as a percent of DAC;

b. Metti path reading to the reflector (Mpmax);

l c. Search unit location (Lmax), search unit position.(Wmax) and sound beam direction;

d. Search unit locations (L 3) and (L )2 at the 20% DAC end points;

e. Minimum metal path (Mp3), position (W1 ) at the 20% DAC limits; 1

. , , , , , . . . . - 4 ,. ... - ---

._- - -- - -.- - - . _ _ - _- .. __ . - = _ . . - _ .. . .

PROCEDUREN0E-620 PAGE 9 REVISION 0 OUKE POWER COMPANY GUALITY ASSURANCE DEPARTMENT NONDESTRUCTIVE EXAMINATION PROGRAM t

f. Maxiraum metal path (Mp2), p sition (W 2 ), at the 20% DAC limits.

9.2 For indications exceeding 100% DAC, use the 50% maximum amplitude limits for the data required in 9.le and f.

• • Note: applies to 9.1 and 9.2**

1. When searching for the upper and lower boundaries over the . length of the flaw, overlap the search unit minimum of 0.1 of the transducer active element measered perpendicular L, the direction of search unit movement, ,

2. Clad-to-base metal interface signals are not conaidered recordable indications.

10.0 INDICATION INTERPRETATION AND EVALUATION 10.1 Interpretation 10.1.1 Investigate all recordable indications to determine the 1 e,c a ti on ,

shape and identity of the refl9ctor.

10.1.2 Plot the true position of all recorded indications on . a cross-sectional sketch snowing 0.0. profile and I.D. geometry.

10.1.3 Follow the steps below in order to classify .an indication as-geometric or metallurgical:

a. Review weld detail drawings;

b. Use supplemental NDE methods or techniques such :as alternate beam angles and wave modss, review- of radiographs, 'and ,

additional profiling.

10.1.4 All indications not determined to be geometric or metallurgical shall be considered flaws.

10.2 Esaluation-10.2;1 Flaws identified as occurring from the fabrication process shall be

< evaluated' .in accordance with the construction code-=for that component.

10.2.2 Evaluate all other w indications in. accordance with the accep-tance standards of Aii Section Y.I, IWA-3000,

~ + ,

PROCEDUllfDE-620 PAGE 10 REVISION 0 DUKE POWER COMPANY QUALITY ASSURANCE DEPARTMENT NONDESTRUCTIVE EXAMINATION PROGRAM 10.2.3 Compare inservice exemination results with the records of the preservice examination or previous inservice examination records.

10.2.4 The evaluation and disposition of all recordable indications shall be documented on Form QA-516A, " Quality Assurance Department Evaluation Report."

)

PROCEDURE N0b62C FIGUnE 1 HEVISION 0 1 1 NONDESTRUCTIVE EXAMINATION PROGRAM oVAU CE D PA MENT

.Na-2 in. long 1/8 to 1/4 in, d>e. flat end; rnill notches 2% Tdeep (Note 131) 1p Through cted thicknese 2% Tdeep into the base inetal 2

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Over 2 in. through 4 in. 3 in or t 3/16 in, Over 4 in, thre h 6 in. 5 in or t 1/4 in.

Over 6 in. throven 8 in. 7 in or t $/16 in.

Over 8 ;n. through 10 in. 9 in. or t 3/8in.

Over to in. through 12 in. 11 in. or t 7/16in.

Over 12 in, through 14 in. 13 in, or t 1/2 in.

Over 14 in. (Note (2)] (Note (*ll NOTE S:

(t1 Minimum dimenesone .

(t) For each incroses in thicknees of 2 in, or fract6on thereof, the hole diameter shall Irwreese 1/18 in.

(3) The tolerences for the hole diameters shallbe 1/32 in. tolerances on notch depth ehell be +10 and -20%; '

to4erence on hole fwion through the thicknees eheil be 1/8 in.; perpendicular tolerance on notch reflecting surf ace shell be : 2 dog.; tolerance on notch length shall be : 1/4 Itt.

(4) Cted shall not be included in T.

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l BASIC CAllBRATION BLOCK FIGURE 1-

i 4 8 PROCEDURE NDE-620 FIGURp 2 REVISION 0 DUKE POWER COMPANY '

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. CLASS - 1 N0ZZLE-TO-VESSEL WF.LDS

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FIGURE 10

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roRM NDE UT-i DUKE POWER C0t1PANY ,

1-J RcvisioN o ULTRASONIC CAllBRATION SHEET f Station: Unit: Date: Sheet number:

Procedurt. Rev: Couplant: Batch No:

Level: Calibration Block ID: Pyrometer S/N:

Examiner:

Level- Calibration Block Temp:

Examiner-.

9EFERENCE DLOCK INSTRUMENT TRANSDUCER SIMULATOR BLOCK ID: Digital O O Anaiog Type: Single O Duai O iD: Coarse e al N<. Reflector Type: Gain.

Model: Mhz Type: Frequhn s:

Serial No: Signal Amp: Fine SIZE: ..

Gain.

Material: Manufacturer: Manufacturer: Metal Path: _

CALIBRATION ,. METHOD CABLES INSTRUMENT SETTINGS Reject 100 g 3 j

Measured Wave Mode: AG62 0

. Damping 90 t5 Beam Angle shear: O no33 Delay 60 longitudinal: O noi74 g surface: Length:

Range 70 .

Frequency 60 + Type Reflector initial Calibration Gain / Coarse holes: axlai cire Tim e-50 nytch; axial cir" CAL CHECKS Gain / fine 40 o her Time filter , 30 initials _

20 CompnenWem % _, _

Pelse/ Echo Thru u ans ]

10 _

Jack Used: T ' /R O 1 2 3 4 5 6 7 8 9 10 -

Rep Rate 'l MJJor Screen Div- Inches _

REMARKS:

REVIEWED BY: LEVEL- DATE: ANil REVIEW: DATE:

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DUKE POWER COMPANY Exam Start: FORM NDE 629 A PRESSURE VESSEL WELD ULTRAS 0illC EXAt11 NATION DATA SHEET Exam Finish: Revision 0 Station:~ Unit: Weld identification: , Date:

Nominal Material Thickness (In.): Weld Length (In.): Surface Temperature: deg F Surf ace Condition: Lo: oyrometer S/N:

Examiner: ,

Level: SCANS: 4S O 50 0 Configuration:

Calibration sheet No:

Examiner: Level: 45T O 60T ACCEPTABLE /NO RECORDABLE INDICATIONS: O IND Msx W L MP L1 L2 Mp2 Beam Exam W1 Mp1 W2 Scan Damps REMARKS No. %DAC Max Max Max 20% 203 Dir Surf.

I 4

Limitations: If none , write "none".

sheet of 9 Miewed By: Level: Date: ANil Review Date item No:

P DUKE POWER COMPANY FORM NDE 620 6 PRESSURE VESSEL WELD ULTRASONIC EXAMINATION DATA SHEET (Continuation) Revision O Station: Unit: Weld identification: Date:

IND Max W L MP Li L2 W1 Mp1 W2 Mp2 Exam Deam Scan Damps REMARKS NO. %DAC Max Max Max 20% 20% Surf. Dir l l

\

i Limitations: If none ,' write "none".

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Examiner: Level: Calibration Sheet No:

Examiner: Level: sheet of Reviewed By: Level: Date: ANil Review Date item No:

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' DUKE POWER COMPANY FORM NDE 600 C ULTRASONIC WELD PROFILE SHEET , Rtvision o Station: Unit: Date: Couplant: Datch No:

Examiner: Level: '" " " " "^"

Examiner: Type:- Type: Single O ouci O Level:

Model:

Serial No.

Calibration Block ID: Frequency: MhZ Serial No: -

337,;

Manufacturer: Manufacturer:

0 Configuration:

To Flow .

270 90 Weld -

Centerline 100 Profile taKen at:

REMARKS:

Sheet of REVIEWED BY: LEVEL: DATE: ANil REVIEW. DATE: ITEM NO:

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