ML20148K565
| ML20148K565 | |
| Person / Time | |
|---|---|
| Issue date: | 05/02/1997 |
| From: | Naujock D NRC (Affiliation Not Assigned) |
| To: | Sullivan E NRC (Affiliation Not Assigned) |
| References | |
| NUDOCS 9706180176 | |
| Download: ML20148K565 (100) | |
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WASHINGTON, D.C. 3061 6 0001 o
8 k..... p May 2, 1997 MEMORANDUM T0: Edmund J. Sullivan, Jr., Chief Section B Materials and Chemical Engineering Branch Division of Engineering FROM:
Donald G. Naujock, Metallurgist Section B Materials and Chemical Engineering Branch Division of Engineering
SUBJECT:
SUMMARY
OF MEETING HELD ON APRIL 23 AND 24, 1997 WITH THE PERFORMANCE DEMONSTRATION INITIATION TO DISCUSS THEIR PROGRAM DESCRIPTION DOCUMENT, REVISION 1 Introduction On April 23 and 24, 1997, the staff held a public meeting with representatives from the Performance Demonstration Initiative (PDI) at the Electric Power Research Institute (EPRI) Non-destructive Examination (NDE) Center in Charlotte, North Carolina. The purpose of the meeting was to discuss changes that occurred since the NRC assessment of PDI Program Description Document (PDD) Revision 0.
PDI provided the NRC staff with 4 copies of their Program Description Document, Revision 1 before the meeting began, and the NRC staff returned the 4 copies at the close of the meeting. A list of attendees and their affiliations is provided as Attachment 1.
A PDI representative began the meeting with an overview of the agenda that was followed by a presentation on meeting objectives. A major objective of PDI was to develop an understanding of NRC's view regarding the acceptability of the PDI program.
The handout used with the presentation is Attachment 2.
Reaulatory Isutel PDI expressed concern with regulatory uncertainty surrounding the rulemaking of Appendix VIII, and the acceptance of the PDI program.
PDI is searching for a way to receive generic acceptance of their program from the NRC. The NRC
- i siaff suggested that PDI submit their program as a topical report (topical).
/
Tru topical will have to identify applicable Appendix VIII supplements, any v
exceptions to these supplements, and any other lin,itation that may affect utilization of the program by utilities.
The topical will define the PDI program at the point in time of its submittal.
After the NRC evTluates the topical, licensees may reference it in their request for relief as an p) alternative.
Items not contained in the topical or that are plant-specific will have to be addressed separately by each licensee. The NRC staff suggested that the topical PDI submits uses a PDD that satisfies the 1995 0"7. / > 9 Edition with 1996 Addenda of Section XI of the ASME Code.
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The NRC staff stated that rulemaking is referencing the 1995 Edition with 1996 Addenda of Section XI of the ASME Code. Rulemaking is progressing on schedule and is expected to be issued in July 1998. The NRC staff requested that PDI provide a list identifying the changes necessary to bring the PDI program into compliance with the 1995 Edition with 1996 Addenda along with the appropriate supplements, exceptions, and implementation times for each supplement.
PDI will have to resolve any differences between the PDI program and ASME Code.
A PDI representative stated there was confusion with ANII and NRC inspections on the acceptability of the PDI program as an alternative to Regulation Guide 1.150 and/or the ASME Code. The inspectors were not accepting the PDI program as an alternative according to IWA-2240 without first witnessing a performance demonstration.
PDI staff believed that the IWA-2240 approach appeared reasonable and hoped that the NRC staff would accept Appendix VIII as implemented by the PDI program as an acceptable alternative to Article 4 of Section V and Appendix III requirements. The NP,C staff stated that as long as Appendix VIII is not part of the regulations, Appendix VIII or PDI qualified procedures that differ from those contained in the licensee's specified approved edition and addenda of the ASME Code will have to be handled as an alternative. The staff informed the attendees that requests for relief to use PDI qualified procedures as alternatives to ASME Code have been authorized according to the 10 CFR 50.55a(a)(3)(i). These requests for relief explained the differences between ASME Code and PDI qualified procedures. The ensuing discussion used Braidwood Nuclear Power Station, Units 1 and 2 request for i
relief NR-29 as an example on submitting an alternative to ASME Code and the staff's response to the submittal.
PDI staff requested that the NRC provide a person as a point of contact. At the meeting, Robert A. Hermann (301) 415-2768 was identified as this contact person.
Currently, PDI is planning on rewriting Appendix VIII and then submitting it as a code case to ASME.
Because of funding limitations, PDI has made little progress with the rewrite.
The IGSCC Coordination Plan was terminated in January 1997. All IGSCC and weld overlay qualifications are being conducted by PDI.
PDI has taken an exception to the staff's request for the continued maintenance of the IGSCC register. PDI believes that eliminating the IGSCC register is justified buause the performance demonstration qualification summary (PDQS) sheet states '..nen an examiner is IGSCC qualified. The qualifications can easily be verified by calling PDI. The NRC staff requested that PDI provide their explanation in writing.
RPV Specimens PDI staff gave a presentation on reactor pressure vessel (RPV) specimen design and fabrication. The specimens being used for RPV performance demonstration testing are the same ones that were seen by the NRC staff during the assessment performed in early 1995. The handout used with this presentation is Attachment 3.
7 E. J.
Sullivan 3
A second RPV presentation was given on the RPV demonstration process.
PDI l
stated that most of the equipment and personnel performing UT with automated equipment have been qualified through PD!.
PDI staff discussed the differences between their program and Supplements 4, 5, 6, 7, 11, and 12 to Appendix VIII.
In the opinion of the NRC staff, most of these differences should be taken up with ASME Code and sent to the NRC as exceptions.
The handout used with this presentation is Attachment 4.
l The third RPV presentation was given on single side RPV shell weld examination i
performance demonstration. This presentation was in response to the NRC concerns that the specimens being used for the performance demonstration test did not adequately challenge the UT technique being used. The NRC staff believes that single-side RPV examinations were not part of the 1995 assessment and requested that PDI provide a written response to this NRC concern for review.
The handout used with this presentation is Attachment 5.
The following NRC questions were submitted to PDI before the meeting. During the meeting, PDI provided their answers.
1.
How will PDI resolve the open Issues 95-01-04 and 95-01-09 from the NRC Assessment Report on the PDI program?
Answer: The NRC issued a letter to Carl Osman (PDI) dated April 23, 1997, that provided recommendations for closing these two issues. At the end of the meeting, PDI provided a response to the NRC letter which contained wording l
similar to the NRC staff's recommendation. The NRC staff believes that PDI's response to the NRC letter should resolve the outstanding issues from the 1995 assessment of the PDI program.
2.
ASME has asked PDI to make a side-by-side comparison of Appendix VIII to Section XI requirements with PDI's implementation of these requirements. What is the status of this request?
Answer: PDI state they have completed this task and submitted it to the ASME working group.
3.
ASME has asked PDI to stop inundating the subcommittees with large numbers of code cases at each working meeting.
Instead, PDI was asked by ASME to l
rewrite Appendix VIII and submit it to the subcommittee for review. What is the status of this task?
Answer: ASME has not formally asked PDI to stop inundating the subcommittee with large numbers of code cases.
4.
PDI's implementation of Appendix VIII has resulted in many changes. Some of these changes involve moving from deterministic bounded criteria to statistical bounded criteria. Where have these changes occurred in the latest revision of PDI's Program Description Document (PDD), Revision 1, and where does PDI anticipate these type of changes to occur in the Appendix VIII l
rewrite?
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Sullivan 4
Answer: These have occurred in PDD Revision 1.
PDI has not looked ahead in the rewrite to determine if and where these kinds of changes will occur.
5.
The NRC staff has received input from NDE personnel that flaw and blank implants installed in vessel specimens are recognizable with UT.
There is concern that some candidates are developing techniques for finding the implants before finding the flaws.
Explain what PDI is doing to aeter this type of testmanship.
Answer: The discussioris during the meeting and NRC staffs' observation of specimens and the test demonstration answered the question of testmanship.
The NRC staff considered the specimen security provided by the PDI program as reasonaole and effective.
6.
There are inferences that candidates who have taken the PDI PD tests are collaborating with each other to develop flaw maps of the test specimens.
This type of information sharing may not be preventable, and therefore, should be expected.
Explain what PDI is doing to protect the integrity of the PD sxaminations, Answer: PDI does not believe that their specimens are being compromised. The PDI program exhibited a high level of specimen integrity that would hinder any i
efforts to map flaws.
7.
How does Appendix VIII, as implemented by PDI, embrace Appendix III and j
Section V, Article 4.
Answer: PDI does not embrace Appendix III or Section V, Article 4.
8.
Appendix VIII, VIII-2100(d)(9) states that procedures shall specify l
methods and criteria for the discrimination of indications.
- However, procedures are being qualified that use amplitude gates (20% distance amplitude correction (DAC) curves, etc).
Amplitude gates do not contribute to the discrimination of indications, i.e., geometric versus flaws.
Explain how amplitude gates and other similar restrictions are supported by Appendix VIII.
Answer: The 20% DAC developed for calibration according to ASME Code is not the same 20% DAC in procedures being used for the performance demonstration tests. Any procedure that is able to pass the performance demonstration is acceptable.
PDI considers the use of gates to be out of the scope of the PDI program.
9.
Appendix VIII, VIII-2100(d)(9) states that procedures shall specify methods and criteria for the discrimination of indications.
Indications determined to be flaws have ASME Code acceptance criteria based on flaw characterization (IWB-3600).
Explain how the PD examination is ensuring that procedures and examiners are capable of finding and sizing flaws down to the minimum recordable flaw sizes set by ASME Code.
Answer: PDI has at least one flaw at this depth in the test set.
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10.
PDI's cladded vessel specimens have a cladded surface finish that represents approximately 90% of the reactor pressure vessels in the field.
For the 10% of the vessels that are not being represented by PDI specimens, explain what method is being used to indicate their exclusion from the PDI prcgram.
Answer: This is a plant specific problem and will have to be handled by those plants. The NRC staff suggested that the program descriptions clearly state what is covered and what is not covered.
11.
PDI has been allowing candidates to qualify to Appendix VIII, Supplements 4 and 6 with only one performance demonstration test.
Explain how PDI is satisfying the minimum number of flaws and flaw depth distribution for both supplements in the one PD test.
Answer: PDI staff observed that shallow flaws on the OD and ID are the hardest to find and medium to larger depth flaws are being found all (100%) of the time. So by keeping the shallow flaws from Supplement 4 and 6 and dropping some of the medium and larger depth flaws, PDI staff believes that the abbreviated performance demonstration test is as challenging as a performance demonstration of the two supplements separately. The NRC staff suggested that PDI bring this consolidation of supplements up with ASME Code.
Since this consolidation is being used by PDI, NRC staff requested that PDI provide a detailed justification that included a statistical basis similar to the statistical analysis used to establish the acceptance criteria for these supplements.
Attachments: As stated cc:
J. R. Strosnider Distribution File Center EMCB RF KRCotton DOCUMENT NAME: G:\\NAUJ0CK\\ TRIP 4 23.PDI
- See privious concurrence To receive a copy of this doctanent, indicate in the box C= Copy w/o attachment / enclosure EmCopy with attachment / enclosure N a No copy l
OFFICE DE:EMCB*
C DE:EMCB*
E DE:EMCB N
NAME DGNaujock:adl RAHermann EJSullivan h DATE 5/22/97 5/22/97 l., /1/97 OFFICIAL RECORD COPY j
4
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Sullivan 5
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10.
PDI's cladded vessel specimens have a cladded surface finish that represents approximately 90% of the reactor pressure vessels in the field.
For the 10% of the vessels that are not being represented by PDI specimens, explain what method is being used to indicate their exclusion from the PDI program.
Answer: This is a plant specific problem and will have to be handled by those plants.
The NRC staff suggested that the program descriptions clearly state what is covered and what is not covered.
11.
PDI has been allowing candidates to qualify to Appendix VIII, Supplements 4 and 6 with only one performance demonstration test.
Explain how PDI is satisfying the minimum number of flaws and flaw depth distribution for both supplements in the one PD test.
Answer: PDI staff observed that shallow flaws on the OD and ID are the hardest i
to find and medium to larger depth flaws are being found all (100%) of the time. So by keeping the shallow flaws from Supplement 4 and 6 and dropping some of the medium and larger depth flaws, PDI staff believes that the abbreviated performance demonstration test is as challenging as a performance demonstration of the two supplements separately.
The NRC staff suggested that PDI bring this consolidation of supplements up with ASME Code.
Since this consolidation is being used by PDI, NRC staff requested that PDI provide a detailed justification that included a statistical basis similar to the statistical analysis used to establish the acceptance criteria for these supplements.
j Attachments: As stated l
cc:
J. R. Strosnider Distribution f
File Center V EMCB RF KRCotton DOCUMENT NAME:
G:\\NAUJ0CK\\ TRIP 4 23.PDI
- See privious concurrence To receive a copy of this doctanent, indicate in the box C= Copy w/o attachment / enclosure E= Copy with attachment / enclosure N = No copy I
0FFICE DE:EMCB*
C DE:EMCB*
E DE:EMCB N
EJSullivan h NAME DGNaujock:adl RAHermann DATE 5/22/97 5/22/97 l, /L/97 OFFICIAL RECORD COPY l
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Sullivan 5
J 9.
Appendix VIII, VIII-2100(d)(9) states that proceceres shall specify methods and criteria for the discrimination of indications.
Indications determined to be flaws have ASME Code acceptance criteria based on flaw
{
characterization (IWB-3600).
Explain how the PD examination is ensuring that procedures and examiners are capable of finding and sizing flaws down to the minimum recordable flaw sizes set by ASME Code.
Answer: PDI has at least one flaw at this depth in the test set.
3
- 10. PDI's cladded vessel specimens have a cladded surface finish that represent approximately 90% of the reactor pressure vessels in the field.
For i
i the 10% of the vessels that are not being represented by PDI specimen, explain what method is being used to indicate their exclusion from the PDI program.
Answer: This is a plant specific problem and will have to be handled by those pl ants. The NRC staff suggested that the program descriptions clearly state what is covered and what is not covered.
i 11.
PDI has been allowing candidates to qualify to Appendix VIII, Supplements 4 and 6 with only one performance demonstration test.
Explain how PDI is satisfying the minimum number of flaws and flaw depth distribution for both supplements in the one PD test.
i Answer: PDI staff observed that shallow flaws on the OD and ID are the hardest j
to find and medium to larger depth flaws are being found all (100%) of the time. So by keeping the shallow flaws from Supplement 4 and 6 and dropping j
some of the medium and larger depth flaws, PDI staff believes that the abbreviated performance demonstration test is as challenging as a performance demonstration of the two supplements separately. The NRC staff suggested that PDI bring this consolidation of supplements up with ASME Code.
Since this consolidation is being used by PDI, NRC staff requested that PDI provide a
)
detailed justification.
i Attachments: As stated cc:
J. R. Strosnider Distribution File Center EMCB RF KRCotton DOCUMENT NAME: G:\\NAUJ0CK\\ TRIP 4 23.PDI To receive a copy of this document, indicate"In the box C= Copy w/o attachment / enclosure E= Copy with attachment / enclosure N = No copy OFFICE DE:EMCBdh C
DE:EMCB I
DE:EMCB N_
NAME DGNaujock:adl RAHermann EJSullivan DATE f //2 /97
[/7#97
/ /97 0FFICIAL RECORD COPY
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Single Side RPV Shell l
Weld Examination i
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Discussions t
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April 23-24,1997 i
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l ASME Section XI Requirements
- Article I-2000 Examination Requirements I-2100 Vessels Great Than 2 in, In
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Thickness
. I-2110 Reactor Vessels
- (a) Ultrasonic examination procedures, equipment and personnel used to detect and size flaws in reactor vessels greater than 2 in. in thickness shall be qualified by performance demonstration in accordance with Appendix VIII for the following specific examinations and no other I-2000 requirements apply.......
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Requirements of
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Appendix VIII/PDI d
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l Article V111-2000 General Examination System 1
Requirements VIII-2100 Procedure Requirements j
- (a) The examination procedure shall contain a statement of scope that i
specifically defines the limits of j
procedure applicability.
- (d) (4) detection and sizing techniques, meluding (a) scan pattern and beam directi on..............................................
(e) extent of scanning and action to be taken for access restrictions; l
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Vendor Procedures Vendors UT procedures for performance demonstration included " single side" applications within the scope or application of the procedure l
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P 31-ISI-Shell Rev. Q REMOTE INSERY10E EXAMINATION OF REACTOR VESSEL SHELL WELDS 1
1.0 PURPOSE 1.1 This document describes the equipment, examination techniques, sensitivity calibration, data recording and data interpretation requirements i
for mechanized inservice examination of the Reactor Vessel shell welds.
l The methodologies 3escribed herein are intended to satisfy the volumetric l
examination requirements of the ASME Code Section X1,1992 Edition, i
1994 Addenda including Appendix Vill, Supplements 4 and 6.
]
2.0 REFERENCES
AND APPENDICES i
1 2.1 ASME Boiler and Pressure Vessel Code,Section XI,1989 Edition.
2.2 ASME B&PV Code,Section XI. Appendix Vill, 1992,1993 Addenda.
2.3 Appendix 1
- Essential Hardware, Software and Operations input Parameters
- 2.4 WesDyne document "RV lSi System Operations Manual, Rev. 0".
2.5 Examination Program Plan.
2.6 Dynspulser Qualification Procedure 96-QA.1113 Rev. O.
3.0 SCOPE 31 This document provides general requirements for ultrasonic examinations of stainless steel clad carbon / low alloy steel shell full penetration welds of the Reactor Vessel and required volumes 4* through 12.3" in thickness.
Complete access to one side of the weld for perpendicular and parallel beam directions shall be considered a minimum recuirement. Where access to the examination volume is limited by component geometry, scanning wil!
be performed to the extent practical from the available surfaces.
Eh 06 01 96 3 of 41 a' = 8 01 31 97 om em tw 4 4i95 Weltinghou$e trectric LQrporation
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SOUTHWEST RESEARCH INSTITUTE SwRJ-PDI AUTl NUCLEAR PROJECTS Rev. 2. Ch i
3'",*'Y 3'g 0 OPERATING PROCEDURE p 9oris
.(2) Examinations performed where access from both sides of the weld exist shall be conducted as fouows Examiaations shall be perfurmed using two 55-degree shear-wave search units and two SUC-40 search units looking in opposite direcuons. A 0-degree search unit i
may also be used as described in Subsecuan 7.6 to detect lammar reflectors which may interfere with angle beam examinadon and to determine component I
thickness.
(3) Examinations perfonned where access is limited to one side of the weld sha?1 be conoucted as follows.
Examinadons shall be perforzned using two SUC-40 search urjts. one 45-degree shear-wave search unit, and one 55<$egree shear-wave search unit a' looking in the l
J same direction. A Hegree search unit may be used as described in Paragraph 7.3(2).
i 7.4 Examination Limitations When the specific 5wRIScan Plan n,
- cannot be met. the "as perforrre.d" scanura parameters and the reason for the scanning limitations shall be.' -
=-
7.5 Surfsee Condition The contact surfaces shall be free from weld spaner. roughness, or other conditions which interfere with free movement of the search tait or impair the transmission r5 ultrasound.
7.6 Base Materint Lamination Senn (1) A straight-beam lammanon exammation may be performed during the initial angle-beam examination of welds and adyacent base material covering the entire area through which the angle beamis :o be passed.
(2) In areas where no backwall reflection can be observed (such as tapered secdons etc.).
obtain a backwall signal from the adjacent base material with parallel surfaces and adjust the signal to 80% 55 of FSH.
8.
RECORDING CRITERIA Exarrunations performed in accordance with this procedure shall be recorded using EDAS. The EDAS parameters shall conform to this procedure with the EDAS storing all digidzed A-scans from the acdve channels. Data will be stored on the system disk array and archived to 4-mm tape (see Figures 4 and 5).
8.1 Detection Criteria (1) Indications must exhibit the foDowing attributes to be cocsidered a detected flaw:
(a) The indication reust have a echo <ivnamic present: tion indicauve of target movement through the sound beam.
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l INFORMATION l
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MSEIMCE WSPECTioN PRoCEDURf REMOTE ULTRASONIC EXAMihATioN OF REACTOR VESSEL WElos IN PRocEcuRE. so Is!-400 03 ACCoRoANCE WTTH AsME sEcTioN x!, APPEMotx vt!! SUPPL 1htENTs 4 ANo 5 se.PO400 01,03 i
1.0 SCOPE This procedure shal govem the automated remote contact ut*Jasonic examination of full penetration clad-femtic metal circumferential, longitudinal, and meridional welds in reactor vessels. Wall thicknesses ranging from 4 inches up to 12.3 inches with a minimum diameter of 142 inches (lD) may be examined with this procedure.
The welds mayjoin forgings or plates or combinations thereof. The clad type may consist of SMAW, multiple wire, or strip clad or combinations of these. The objective of this procedure is to detect and sire flaws within the examination volumes described from the inside surface of the component This procedure is intended to be implemented by scannino the examination volurnes from est least one perpendicular and one paralsel direction for flaw detection. However, subsurface indications may be detected that cannot be confirmed by both transducers from y
the same side. When this condition exists, the suspect area shall be scanned from both sides in order to disposition the suspect indication. Half-node examination techniques will be used. Where geometnc configurations preclude complete coverage from one direction.
scanning from the opposite direction may be used to increase coverage. Flaw sizing techniques shall be applied from each side of the flew where the configuration permits.
The exarr.ination of vessel welds described by this procedure meets the minimum 4
requirements of ASME Boiler and Pressure Vessel Code,Section XI,1992 Edition, Apperxfix Vill, Supplements 4 and 6.
2.0 SURFACE PREPARATION: The exarnination surface shall be free of dirt, loose scale, machining or grinding particles, weld spatter, or other loose foreign roaterial or coatings which interfere with ultrasonic wave transmission. The surface shall be so'ficient!y smooth to maintain acoustic coupling and minimize surface noise. These requirernents apply on O
all areas through which the sound beams pass. Generally, the condition of the vesselID meets these requirements and no further surface conditioning is required.
3.0 PERSONNEL QUAlfFIC ATIONS: There are three besic categories of personnel involved in performing this examination. They are data acquisition operator, calibration personnel, and data analysis personnel described as follows:
3.1 Data Aceuismen Ooerator Personnel operating the data acquisition system do not require training or certification in the ultrasonic method because their activity is limited to operation of equrpment only and they do not make decisions conceming system configuration or the ultrasonic data itself. Their activity is limited to operation of the system controls which execute preestablished scan plans. All Fage i of n INFORMATION l
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i Considerations for Performance Demonstration i
Appendix VIII does not l
c escribe access conditions but 1
l states... "Any procedure j
qualified in accordance with l
this Appendix is acceptable"
- Article V111-1000 Scope ll VIII-1100 General:
- (e) Any procedure qualified in j
accordance with this Appendix is j
acceptable i
PDI Program Requirements Test Administration PDP-Q-009.1
- Paragraph D. The candidate organization and the PDA shall agree on any special1 imitations on the scope of the demonstration
................or a demonstration with examination access from only one side of the weld.
PDI Considerations 0
PDI RPV Technical working group developed a description of Sing..e Side to address the j
limitation for the purpose of performance demonstration
- An ultrasonic procedure only allowing for ultrasonic data to be collected (and later analyzed) from only one perpenc.icular and transverse axis to the intended Saw volume. The surface must allow for the complete examination volume thickness to be examined by the ultrasonic beams......
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- Article V111-3100 Qualification Test Requirements i
VIII-3110 Detection
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- (b) The examination procedure, equipment, and personnel are qualified j
for detecting flaws upon successful l
completion of the performance demonstration specified in the i
appropriate Supplement listed in Table l
VIII-3110-1 l
= VIII-3120 Sizing l
- (b) The examination procedure, j
equipment, and personnel are qualified j
for sizing flaws upon successful l
completion of the performance
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demonstration specified in the appropriate Supplement listed in Table VIII-3110-1
Other PDI Test Considerations
- Test Specimens and Flaws Considered to be equally challenging from either side of the examination volume
- Flaw manufacturing methodology does not favor any access
- Flaw orientation is realistic
- Test Protocol
- Shall be the same as that used for procedures without access limitations
Procedure Performance
,l Procedures which have been demonstrated as " Single Side" have been shown to be equally effective as the procedures which require " double side" access.
Conclusions
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- Single Side RPV Examination
)
procedures are qualified in accordance with Code requirements
- Test specimens contain realistic flaw types, location & orientation Procedures which have been demonstrated as " Single Side" have been shown to have code required flaw detection capability as have the procedures which require " double side" access.
4 RPV Demonstration Process Automated RPV Procedure Demonstrations to PDI's Implementation of Appendix Vill, Supplement 4 and 6 PDI, EPRI & NRC Discussions April 23-24,1997
Organization of l;
Performance Demonstrations Responsibilities j
Demonstration Rules (Protocol) j
=
Procedure & Personnel Perfonnance j
Demonstrations I
- Essential variables
- Test Set Selection l
- Grading
- Documentation I
Key to Successful RPV Demonstrations
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l Responsibilities - EPRI l
EPRI XDE Center is Performance l
Demonstration Administrator (PDA)
- Develop Program
- Develop Technical Basis
- Administer and supervise demonstrations
- Document results
- Resource to assist utilities 1
PDI provides guidance and oversight to PDA through the protocol Authorized Inspection Agencies (ANI) l
- Witness relevant portions of demonstrations
- Review and UT procedures
- Assure field implementation is to same standard l
as was demonstrated 1
i
Demonstration Rules Protocol Prepared by PDI (Utilities) as instructions and interface document to all participants, includes
- Perquisites for Performance Demonstration
- PDA's Role in Procedure Review
- Scheduling Criteria
- Test Specimen Selection
- Security
- Administration of the Performance Demonstrations
- Documentation for Performance Demonstrations
- Grading Requirements
- Retesting
- Dispute Resolution
Performance Demonstrations 4
i The PDA - Performance Demonstration 4
l Administrator is responsible for all 4
l performance demonstration activities in accordance with PDI program procedures
- Procedure review j
- Verification of personnel and procedure technique, equipment & essential variables 4
l
- Develop and maintaining auditable records
- Surveillance during the demonstration l
- Grading & Issue of demonstration results ANI may participate in PDA's administration of combined procedure / personnel demonstrations
-- Review UT procedures
- Witness relevant portions of demonstration
Performance Demonstrations Candidate prerequisites
- All candidates shall have completed the following Signed a corporate and/or personnel a
use agreement Registered for performance demonstration
- Provided a performance demonstration
~
plan and security plan
- Procedure & essential variables
- Provided statement of LevelII certification Prior to demonstration
- Equipment certification (hardware and transducers)
- Operating manuals l
- Copy of Software
k J
j Performance Demonstrations l
PDA prerequisites i
L
- The PDA shall have reviewed &
l accepted the candidates procedure
}
- Selected the test specimens and
)
l developed test sets
- Developed a detailed demonstration plan including security requirements j
- Demonstration facility l
Specimen integrity j
Personnel l
Computer systems
- Preparec al: demonstration forms,
{
checklists and grading sheets
e j
~
PDA's Role in Procedure Review Procedure Review
=
- Level III with nuclear plant ISI experience
- Evaluates procedure to Appendix VIII requirements Identify essential variables
- Determines Range or Criteria based
- Provide feedback to candidates on procedure revisions or improvements
- Develops checklist for use during performance demonstrations Expenence
- Procedures typically need 2-3 revisions before acceptance for performance demonstration
c PERFOnMANCE DEMONSTRATIOA, INITIATIVE i
AUTO VESSEL DETECTION PROCEDURE ESSENTIAL VARIABLE REVIEW CHECKLIST
',. ;y A. t y A B&W Nuclear Technologies
_gg=gg 1S1800 h
..>r:.
.C
--a=---
0 2-95 J M.. r n 79 Remote Ultrasonic Fmnination of Reactor Vessel Welds in Accordance with ASME Section XI, Appendix W7 J > '
I VIII Supplements 4 and 6 w===E 134GM--TMNSESSikMEROG!DURnIHTEM5fGMt%8DTi6fsi$3!satEfMW ~RESUlmif 1.0 SCOPE A
Verify that the procedure contains a statement of scope that specifically defines the limits of procedure
[*]1 applicability (e.g. essential variables and range of qualification).
Material: Clad Ferritic Metal Product Form: RPV circumferential. loncitudinal. and meridional welds
[Y]
Thickness Range:
4.0" to 12.3" Diameter: Min..142.".
Max.
B Also, verify that the procedure list the weld types and configurations to be examined. (e.g., ASME
[Y]
Section XI, Supplements 4,5,6 & 7, etc.)
Procedure Location: 1.0 Full Penetration Welds. Sucolement 4 & 6 C
LIMITATIONS D Dual side access required for we: examination INF0HATION
[mA)
O Single side access required for welds exammatio n.
.[ Y ]
Clad Type: SMAW. Multiole Wire. and Stric Clad Clad roughness:
?
[*]5 List any additionallimitations: 1.0 The examination volumes will be scanned from at least one peroendicular and one carallel direction for flaw detection. Where reometric conficurations ereclud.t
[Y]
comolete coverace. scannine from the ocoosite direction or the use of a full-node techniaue may be used to increase coverace Flaw sizine technioues will be acclied from each side of the flaw where the conficuration oermits.
D PERSONNEL REQUIREMEST i
Ensure that the procedure addresses provisions for personnel qualiScations and duties for each classification.
[y)
Procedure Location:.3 Q 2.0 SURFACE PREPARATION A
Verify the procedure adequately addresses surface preparation.
[Y]
Procedure Location: _2.0 Ensure that the procedure specifies the examination scanning surface (e.g. ID, OD, Nozzle bore, etc.).
B
[Y]
i Procedure Location: 1.0 (ID) l Notes: Candsdale's procedure comphes with AsME secton XI. Appenix VUI. Arucle VUI.2000: Y = Yes N = No N/A = Not Apphcable.
- a see Comment rrsoo.0: ooc I Page 1 of 5
(
(.
E
..i.i.l ai ; J v.c s l M*: A _1
.i 1__ h. if W 3.0 EQUIPMEh"r Instrinments or Systems A
Ensure that the procedure identifies the instrument or system, includes the manufacturer and model or l
series of pulser, receiver, and amplifier, as well as display and processing Hardware Rev. Table A & ]L
[Y]
Software Rev. Table A & B. and algorithms.
Procedure Location: 4.1. and Table A & B Search Unit Cables B
Ensure that the procedure identifies the Search Unit Cable (s), including, Type, Maximum Length, and
[Y]
.; d.... ;; i : Of r - ' -
List Procedure Location: 4.3 and Table C i
INFORMATION s o rch U nits C
Ensure that the procedure identifies the nn:nber, size, shape, and con 5guration of active elements and
[Y]
wedges or snoes Procedure Location: 4.4 and Table D & E D
Verify that the procedure specifies a nommal value or a range of values for search units, Center
[Y]
Frequency, Bandwidth, or Wave-form Duration.
Procedure Location: 4.4 and Table D & E l
E Verify that the procedure describes any rotating, revolving, or scanning mechanisms, if used.
[Y]
Procedure Location: M l
F Verify that the procedure describes any special equipment,if used.
Procedure Location: N/A
[N/A]
l G
Verify that the procedure identifies the couplant to be used.
Procedure Location: M
[Y]
4.0 CALIBRATION l
A Verify that the procedure provided a description of the calibration method for detection and sizing (e.g.
action required to insure that the sensitivity and accuracy of the signal amplitude and time outputs of
[Y]
the exammation system, whether displayed, recorded, or automatically processed, are repeated from l
examination to examination).
List Procedure Location: 7.1. 7.2. 7.3. 7.4. 7.5. 7.6. 9.1. 9.2. 9.3. 9.4 & 9.5 l
B Ensure th t the calibration technique includes the establishment of reference sensitivity levels, instrument controls to be used, and acceptance standards for the calibrated condition.
[Y]
List Procedure Location: 7.2. 7.5. 7.6. 9.2. 9.3. 9.4 & 9.5 C
List Procedure Location: Verify that the procedure addresses calibration block selection.
[Y]
List Procedure Location: 4.6.1. 4.6.2 & 4.6.3 D
Verify that the procedure identifies the calibration data to be recorded.
[*]2 List Procedure Location: 14.0 Notes: Canidate's procedure comphes with AsME seccon XI. Appendix VUI. Amcle Vm.2000: Y = Yes N = No N/A = Not Apphcable,
- a see Comment msDaboc Page 2 of 5
(
-7 '
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. G QQ,_ _ _ y_ _
vM
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.....L 5.0 CALIBRATION DATA RECORD A
Ensure that the procedure requires, as a mmimum, the following data orded on a cal. data sheet:
(1) Calibration sheet identification and date of calibration.
IYI i
(2) Names of ernmmation personnel.
I Yl (3) Examination procedure number and revision.
IYI (4) Basic calibration block identification.
I I
. (5) Ultrasonic instrument identification and serial number.
I I
i (6) Beam angle, couplant, and mode of wave propagation in the material.
[ *]
2 i
(7) Search unit identification - frequency, size, and manufacturer's serial number.
I I
l (8) Special search units, wedges, shoe type, or saddle's identification,if used.
[N/A]
(9) Search unit cable type, length, and number of intermediate connectors.
(10) Times ofinitial calibration and subsequent calibration checks.
1 (11) Amplitudes and sweep readings obtamed from the calibration reflectors.
[Y]
(12) Software version,if applicable ProcedureLocation 14J If an electronic DAC curve is being used, a second record shall be made of the resultant amplitudes and IN/A]
B sweep readings obtained from the calibration reflectors.
List Procedure Location: N/A 6.0 EXAMINATION TECHNIQUE A
Verify that the procedure specifies a single value or a range of values for the following:
1.
Mode of Propagation.
Procedure Location: 10.1 and Table D & E
[Y]
2.
Nominalinspection angle.
Procedure Location: 7.1.7.2.8.1.10.1 and Table D & E
[Y]
3.
Detection and Sizing techniques, including:
Scan psttern and beam direction.
Procedure Location: 8.1 - 8.13 and 10.3 - 10.14
[Y]
4.
Maximum scan speed.
Procedure Location: 8.2 & 10.2
[Y]
l l
5.
Minimum and Maximum pulse rep rate.
Procedure Location: ?
[N]3 l
6.
Minimum sampling rate (automatic recording systems)
Procedure Location: 8.5 & 10.5
[Y]
7.
Extent of scanning and action to be taken for access restrictions.
[Y]
Procedure Location: 5 1.5.2.6.0.8.0.10.0.12.0 & 14.0 No:es: Cardidate's procedun complies with AsME Scenen XI. Appenix VUI. Amcle VIU-2000- Y = Yes N = No N/A = Not Apphcable. * = *.iec Comment Page 3 of 5
t,
. E
_ _ 7..
3,..
1,. e. :
1 r.
7.0 EYAMINATION DATA RECORDING i
A Verify that the procedure addresses the following namination data recording criteria:
i
- 1. Examination Data to be recorded.
1
- a. GeometricIndications Procedure Location: 11.3.1
[Y]
- b. FlawIndications Procedure Location: 11.3.2 & 11.3.3
[Y]
- 2. Method of data recording.
Procedure Location:.41.
[Y]
- 3. Recording equipment (e.g., strip chart, analog tape, digitizing) 3 when used.
Procedure Location: 4.1 & Table B
[Y]
4 B
Ensure that provisions are made for recording the following information on the exammation data sheet:
i (1)
Data sheet identification and date and time period of examination;
[Y]
j (2)
Names and certi5 cation levels of exammation onnel;
[Y]
t i
(3)
Examination procedure and revision;
[Y]
[/g (4)
Calibration sheetidentification;
[Y]
(5)
Identification and location of the weld and volume scanned;
[*] 4 (6)
Surface from which the examination is conducted and
[*]4
?
a (7)
Examination results.
ProcedureI.ocation: 14A
[Y]
8.0 INDICATION EVALUATION A
Verify that the procedure provides a method and criteria for the discrimination ofindications (e.g.,
geometric versus flaw indications and for length and depth sizing of flaws.
[Y]
Procedure Location: 11.1,11.2.11.3.12.1 & 12.2 COMMENTS PROCEDURE EVALUATION I
This procedure as writtenis: D Acceptable li5 Unacceptable Reviewed By:
Date: 10/10/95 Dave Holthaus Additional Review:
Additional Review:
(Organization)
(Organization) e Reviewed Bv:
Reviewed Bv:
Notes: Candidate's procedwe comphes with AsME secuon XI. Appendix Vm. Anicle VUI.2000: Y = Yes N = No N/A = Not Applicable. * = see Comment m oo:. ooc Page 4 of 5
1 &W Nuclear Technologies ISI l
Remote Ultrasonic Evamination cf Recctor Vessel Welds in Accordance with ASME Section XI, Appendix
~
VIII, Supplements 4 and 6 i
A procedure change will be required to address comments _1 through 1 prior to participation in the Performance Demonstration Process..
Comment # 1 (Checklist No. l.A)
Checklist item # 1.A required the procedure to contain a statement of scope that specifically defines the limits of procedure applicability (e.g. essential variables and range of qualification).
The scope, as it in presently written, is inadequate. The scope needs to be more specific with regards to limitations, applicability, coverage, etc.
C:mment # 2 (Checkhst No.4.D & 5.A)
Checklist item # 4.D requires the procedure to identify the calibration data to be recorded and checklist item # 5.A provides a listing of the mtmmum information which needs to be recorded.
Paragraph 14.0 provides a listing of reporting information which includes most of the required calibration data with the exception of the examination couplant. This item need to be added to the procedure.
C:mment # 3 (Checklist No. 6.A.5)
Checklist item # 6.A.5 requires the procedure specify the mmtmum and maxiomm ym6 me. im.
The procedure needs to be revised to include this information.
INFORMATION C:mment # 4 (Checklist No. 7.B)-
Checklist item # 7.B, requires the procedure to identify the examination data to be recorded Paragraph 14.0 provides a listing of reporting information which includes most of the required exammation data with the exception of, (1) time period of examination, (2) Weld identification, and (3) Surface from which the examination is conducted.
The procedure needs to be revised to include this information.
The following comment (s) are provided as recommendations and don't necessarily require a procedure change.
C:mment # 5 (Checklist No.1.C)
Checklist item # 1.C addresses clad roughness.
Insofar as the procedure does not address this item, the PDQS will reflect cladding roughness as " ground".
l l
Nczes: Candidate's procedure comphes with AsME secuan XI. Appendtx Vm, Amele VHl.2000: Y = Yes N = No N/A = Not Apphcable. * = see Comment Page 5 of 5
Essential Variables Appendix VIIIidentifies essential variables PDA review procedure and equipment for additional essential variables
- Custom hardware
- Software
- Techniques All essential variables are confirmed during performance demonstration
Test Specimen Selection Responsibility of PDA to develop specimen test set
- Computer programs are used and test sets are reviewed for program compliance.
- Min.. and Max. range of essential variables must be covered
- Procedure limitations have to be considered Limited access
- Responsibilities of personnel for automated procedures Specimen Integrity is addressed
9 I
Test Set Requirements 4
l Combined Supplement 4 & 6 test set will j
include a minimum of 14 flaws for Detection and 20 for sizing Detection min 7 flaws per supplement Sizing min 10 flaws per supplement
)
Size & Orientation distribution per code requirements Test sets for personnel demonstrations may l
be smaller using a qualified procedure!
i 4
9 Development of RPV
' Test Set l
Specimens contain supplement.
L & 6 f"aws (detection and sizing; s
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Development of RPV Test Set Specimen is divided into scan areas.(patches)
PDA selects different patches to make up test set I
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When combined with scan areas from other test specimens the number of flaws meet PDI program test set requirements
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RPV TEST
SUMMARY
- PROCEDURE Demonstration Performance Demonstration Qualification Test Set Information Test Set Prepared for Test Set Prepared on UT Procedure Type of Test inspection Surface OD ID Initial Test ist Retest 2nd Retest Single Sided Extension Scan Areas (patches) Used Specimen R Specimen R "hD Sneci nen R Specimen R Fmm To Used Area Fmm To Used Area Fmm l To Used Area From To Used Area From To Used Area I
~
'J as maas 8P35 C RPR Total Area of l
Test Set sub total area sub total area sub total area sub at area sub total area
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<*= wy,= =
,8 Number of Flaws and Application In Test Set Supplement 4 Supplement 6 Supplement 6 Supplement 6 Supplement 6 Inner 10%T 11-30% T 31-60% T 61-89% T Outer 10% T gojcl
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. Loc 3)
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- Supplement 6 l
ASME Cmle Requirement l
Detection l
Sizing l
Detection l
Sizing l
Total Number of Flaws to be Used for Grading Purposes l
l l
- Dewoien amn k equel er seesw $se W sMar must be earmel mew een to )
% of Flaws Used Which are Cracks two *e re== *== m1
% of Flaws Used Which Emanate from the Clad / Base Metal Interface
% of Flaws Used Which are OD Connected w, e.. ir m,
% of FI2ws Used Which are Parallel to the Exam Volume (Skew = 0 deg) er w. w.= *. = >
% of Flaws Used Which are Perpendicular to the Exam Volume (Skew =90 deg) l l
l l
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l Test set prepared by Date Form revision 6: 2/6/96
Specimen Integrity i
4 Specimen Integrity is Maintained l
- Specimen are given an alias
- Actual orientation is concealed i
j
- All data files are j
given unicue names collected with a local datum point of l
0/0 l
header information is identical The candidates can not develop knowledge of the specimen truth!
4 a
I
Planning for a Performance
~
Demonstration All demonstrations are be carried out to a performance demonstration plan.
Planning begins at least 3 months before 1
l The plan is important to achieve successful and efficient demonstrations & considers j
- Number of ultrasonic procedures / personnel
- Location & facility requirements
- Type of UT equipment to be used
)
- Security plan
- Demonstration specimens & calibration blocks
- Schedules - Guided Practice - Demonstrations -
Retesting 1
i i
Administration of Performance
~
Demonstrations
'l Preparation
- PDI provides candidates with practice specimens
- PDA visit candidate facility to review, UT system, final UT procedure revisions and security requirements
- Scan areas of the test specimens are provided to candidates for the preparation of scan plans
9 i
Demonstration Activities Set -Up Set-up i
- PDA facilities are secured, change locks, install video equipment, post signs etc....
- Indoctrination of candidate personnel l
- Test specimens are shipped to arrive l
when PDA are on site
- Demonstration area and equipment are secured All equipment configurations are venfied, (model/ serial numbers are recorded)
Software is loaded ( from back up copy)
Computer systems are logged.
l Demonstration Activities Surveillance
- Surveillance All performance demonstration activities are carried out under direct surveillance by PDA staff a Procedure demonstrations require 3 staff
- Utility personnel may also participate Checklists developed by PDA from procedure review are used to document procedure compliance Additional surveillance by CCTV 1
-y.s
,_6
.y-y w
Demonstration Activities Calibration l
Calibration
- Any calibration method may be used but must be cLescribed in the procedure
- The UT system and each transducer is calibrated in accordance with the procedure
= ANI witness calibration
- Calibration documents are retainec. on file 4
4 Demonstration Activities Data Collection Data Collection l
- PDA provides candidate with j
instructions where to collect data.
- Checklists are used to verify data is collected in accordance with procedure essential variables.
- Candidates may only access data in accordance with the procedure and equipment changes are not permitted without procedure criteria or technical justification
3rd STAGE SIZING DATA COLLECTION INSTRUCTIONS Patch Name TASK INITIAL 1
Verify the specimen is and the orientation is correct 2
Notify the Operator that the Patch data file name will be and the start location is at inches from the specimen zero.
CIRCtDGERENTIAL SCAN 3
Verify the scanner is zeroed correctly on the test Specimen 4
Provide the Operator with the scan sheet 5
Verify the transducers are in the 0 degree orientation 6
Verify the operator has selected the correct scan plan from the scanner control plan menu 7
Verify the operator has selected the correct UT Set UP plan from the ACCUSONEX plan menu 8
Verify the operator has selected set up #2 8A Channels -Toggle RF Switch 8B Apply Button 8C OK Button 9
Verify the operator has turned on the UT system 9A Verify Scan Screen Display Peak & RF 10 Verify the scanner moved to the patch zero and offset 11 During Data Collection verify scan speed in log book.
12 Record the status of the UT data in the following table LOCATION FR.E NAME STATUS OPERATOR PDA A
/
\\
CoMMExrs Completed by:
Date Time Page 1 of 4
a Demonstration Activities 1
Data Analysis Data Analysis Automated demonstrations
- UT Data from 2-4 test sets is collected.
- 2-4 analysts review data (4-5 files of data j
full test set) j
- Reporting requires
- Completion of all procedure requirements l
& plotting on full size PDI top and side l
view sheets j
- PDA interview to verify compliance with the procedure
- Every flaw reported must be demonstrated to the PDA in accordance with the criteria of the procedure.
3
.. ~.
OBJECTIVE EVIDENCE WORKSHEET f;r FLAW EVALUATION i
C&WNT DEMONSTRATIM 1
CANDIDATE:
INFORMATION TESr Sert l
l l
The f4-c techniques were used by the candidate for initial buvu analysis of the indications in their test i
set ac m.c d by the PDA.
l Indications are first separated into 2 categoric.s 1) Geometry 2) Non-Geometry.
For recording a Non-Geometry indication, the following should apply:
l Indication Number Does this indication exhibit target motion ad peak amplitudes greater than the background noise.
YES O NO O What transducer was used for Initial recording 45'L D 45's D It's Maximum amplitude
>10% DAC D
>20% DAC D 1
What Transducer was used for verification 45'L D 45'S D l
It's Maximum amplitude
>10% DAC D
>20% DAC D For single side flaw detection, was this flaw verified with both the 45'L and the 45*S.
YES D NO D A " Suspect" Indication is a flaw that could NOT be verified from one direction with both the 45'L and 45'S wave detection transducers.
Is this flaw defined 4 a " Suspect" Indication.
YES O NO O Did the candidate ask for "Relook Data" from the opposite direction.
YES O NO O Was this indication confirmed from the oppose direction.
YES D NO O Does the indication exhibit target motion from the opposite direction.
YES D NO O Does the indication plot in the same approximate location fmm this opposite direction.
YES D NO O Is the amplitude of the indication of sufficient strength to be resolved from the background noise.
YES D NO O What Transducer was used for confirmadon 45'L D 45'S O It's Maximum amplitude
>10% DAC D
>20% DAC D Any needed COMMENTS, for clarification, will be wrinen on the back of this form.
i
l 5 '
OBJECTIVE EVIDENCE OF FLAW EVALUATION PER PROCEDURE Remt te Ultrasonic Fnminarian of Reactor Vessel Weids in Accordance with ASME Section XI, Appendix VIII, t
SUPPLEMENT'4 PROCEDURE NO.: '...
REV. I FMD GE: 95-001,95-002, 5-003 and 95-004 CANDIDATE:
TEST SET:
/g
'-s h The following techniques were used by the candidate to size the indications in their t.
Flaw sizing is accomplished utilizing two (2) separate sizing techniques with three (3) tiers of an the acceptance criteria ofIWB-3500:
- 1 Sizing with the original coarse detection data.
i
- 2 Sizing with fine detection data.
W3 Sizing with the Backward Scatter technique.
If tip signals are not appare.nt. sizing will be accomplished using satellite signals if present or the dB drop technique.
Step taken prior to establishing the length and TWE were as follows:
Identify those profiles which are related to the upper and lower extremities, tip signals, of the flaw at maximum amplitudes (if available).
Each scan line should be examined over the length of the flaw.
i Use the same manner of depth measunng as was used during analysis of the calibration block data.
Increment through the data in both directions to the flaw edges where the amplitude fall to the appropriate t:chnique for the length dimension.
All credible length and depth measurements, from the actual sizing techniques, shall be averaged for the final flaw dimensions.
The following sizing measurements were performed during 3al STAGE ANALYSIS (referenced above).
Flaw AA/BB TWE was measured using the lower tip signal (-) the clad for both 45L and 55L Izngth sizing measured @ noise w/both 45L and SSL
-All measurements were averaged for final flaw dimensions.
Flaw CC TWE was measured using the lower tip signal (-) the clad for both 45L and 55L Iength size measurement was takes from the 2nd stage sizing results which were measured @ noise w/both 45L and 50% DAC w/ both 70L The candidate considered the 2nd stage length a more credible value.
-All TWE measurements were averaged for final flaw dimensions.
Flaw DD/EE TWE was measured using the lower tip signal (-) the clad w/both 45L and (1) 55L.
The other 55L TWE was not consistant with the other channels and believed not to be credible.
Length sizing measured @ noise w/both 45L and 55L
-All but one TWE measurement was averaged for the final flaw dimensions.
Flaw C TWE was measured using the lower tip signal (-) the clad for both 45L and 55L.
Length sizing measured @ noise w/both 45L and 55L
-All measurements were averaged for final flaw dimensions.
Flaw F 1WE was measured using the lower tip signal (-) the clad for both 45L and SSL Length sizing measured @ noise w/both 45L and 55L and averaged with 2nd stage sizing result.
-All TWE measurements were averaged for final flaw dimensions.
Flaw G
'IWE was measured using the lower tip signal (-) the clad for both 45L and SSL Length sizinF measured @ noise w/both 45L and SSL and averaged with 2nd stage sizink result.
-All TWE matements were averaged for final flaw dimensions.
l
~
$ Tlaw S TWE was measured usi g the lower tip signal (-) the clad for both 45L and 55L.
Length sizing measured O noise w/both 45L and 55L and averaged with 2nd stage sizing result.
-All TWE measurements were averaged for final flaw dimensions.
l l
Baw Y TWE was measured using the lower tip signal (-) the clad for both 45L and 55L Length sizing measured @ noise w/both 45L and SSL and averaged with 2nd stage sizing result.
-All TWE measurements were averaged for final flaw dimensions.
TNE was measured hsing the lower tip signal (-) the clad for both 45L and 55L l
Raw N l
Length sizing measured @ noise w/both 45L and SSL
-All measurements were averaged for final flaw dimensions.
RawI TWE ws measured using the lower tip sipal (-) the clad for both 45L and 55L l
Length sizing measured @ apise w/both 45L and 55L.
-All measurements were averaged for final flaw dimensions.
FiawZ TWE was measured using the lower tip sipal (-) the clad for both 45L and 55L.
q l
Length sizing measured @ noise w/both 45L and 55L.
g
-All measurements were averaged for final flaw dimensions.
Haw B TWE was measured using the lower tip sipal (-) the clad for both 45L and 55L.
Length sizing measured @ noise w/both 45L and 55L i
-All measurements were averaged for final flaw dimensions.
i Raw A TWE was measured using the lower tip sipal (-) the clad for both 45L and 55L l
Length sizing measured @ noise w/both 45L and 55L
-All measurements were averaged for fm' al flaw dimensions.
All data was taken in a scan direction that was perpendicular to the flaw so an y
'c pattern would be created for the use of flaw tipinformation All flaws were scanned from both sides (perpendicular) to flaw orientation O/M N REVIEWED BY:
DATE:
'/
]
l INFORMATION l
l Techniques used by INFORMATl0N 2nd Stage Sizing:
TFNGTH All length sizing with the 70L transducers were done with the 50% DAC criteria All length sizing with the 45L transducers were done with the @ noise level criteria.
CD NOTE:
(If the flaw was below the recording criteria, a dimension was not "lt:p obtained.)
M "J:S TWE For all (13) flaws, the tip signals were used for thruwall sizing.
NO 1/2 Max. Amplitude points were used for sizing NO satellite signals were used for TWE
-All measurements obtained per flaw were averaged for final flaw dimensions-3rd Stage Sizing:
TFNGTH All length sizing with the 45L and 55L transducers were done with the @ noise level criteria.
Five (5) out of the (13) flaws used the 2nd stage length result to' help in the determination of the final 3rd stage result.
~
IMi For all (10) of the flaws, tip signals were used for thruwall sizing.
NO 1/2 Max. Amplitude points were used for sizing NO satellite signals were used for TWE
-All measurements obtained per flaw were averaged for final flaw dimensions-ATI0g 1
pu suum i tuu s i
9 enfication of
- O Equipment
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4 Demonstration Activities Grading Program description incluc es the grading criteria for Procedure & Personnel demonstrations
- Detection
- Number of flaws / False calls
- Location accuracy Length & through wall sizing
- RMS
- Final grading is carried out using report I
overlays and computer programs.
- Results are presented as Acceptable or Unacceptable
Demonstration Activities Retesting Results of gradmg
- Procedure demonstrations results are withheld until all candidates have completed the demonstration
- Personnel demonstrations results are available immediately following the demonstration
- PDA provides candidates with objective feedback on performance Trending Procedure revisions Additional training
- Procedure retests require full demonstration test set
- Personnel demonstrations may be limited to category type
l-i Demonstration Activities Documentation l!
Preparation, completion, processing, &
l retention of records is by EPRI NDE Center
)
PDA staff keep log books of all demonstration activities
)
PDA archives all documentation in an organized file system l
UT Procedure
[l Hardware & software equipment certification j
Essential variables
- Ultrasonic data
- All results & grading PDA compiles Perfonnance Demonstration Qualification Summary (PDQS) document
Example of RPV Procedura
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- 1; Addends: 0 2
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Ranges Detnoastrated:
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Seyyimuuut 4 es ASME AspeedEx VIII TeeeDatr 05-May.95 hard==ses 6of ASME Arr==^= VIII TemeDnee:
0540my-95 Mmeertet:
Ferrisie wish 5 MAW as Genul,tsaa g Moserfah Fewide wlih 5 MAW m Ground.r%demy n
Surface:
Inner Diameter Surface-Inner Denneter p
Access:
DumiSided Access:
DumiSided I
Eh Detection lleichmans Range: 0.000 to 0.000 Emendannum. Detectant TMelemas Range: 4.000 to I2.290 i
- Awess:
Single 5 mind Access:
Single Sided I
Eh Detection TWckmens Rouge: 0.000 so 0.000 Emmmenselom Detection TWetusems Range: 4.000 to 12.290
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/%AM Performance Demonstration Initiative Program i
V FDQ5 tese 347 4... e!;h.yN 'Mrh j +fp'h
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01-Jan-96 Airshielem SW Typester:
AUT4'A1.SoAware. l.37
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EDA 5 Sotwese, t.0
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Y When 'Thseech Wall threensten* E haar===d 'en 0.230 Rh45 med 0.7 Slaye M creurin per e pDE Program Descripdom has been schieved. M 24 i casussents.
I The specimes ser used so domesmerase me proceene hecluded spechnen wth a manimumm ehickness of 6 38* and i1.06"(exclutug ciudL 2 Bened on the spechnen ses esckness tem commust el.ee " Thickness Ramse* specined above hicludes the '90s of htenhamm1bar*= es* anowance ps Appenas vitt.
3 line adminum ramee of ee supplemein 4 vehene sure a me *cind e bene muest ineertmee* (0. cop) sud extends inee she base mireal (siipplemein 6 vetusme).
1Jensensions.
I This praraa=e is gusNeed for desereiam enly. See proceduse SwRI-FDI-AUT2sishg.O for lange and TWE sising.
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- mrcir Performance Demonstration Initiative Program l
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In A 2..a with the PDIL f./." of Secthe XI, Appendix VIII ogg,nes
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T Speelfic DetaE ef QueEllcations Owner:
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n, Procedure:
- Revision
- 1; Addenda: 0 E,.
w, e b$f$!Q Automated Inside Seeface Ultrasonic Exannnetlen of Fer:1 tic Vessel Wall greater than 4.0 Inches Q~" ! W
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feitiative's " 4 -
^'n of The American Society of Mechanical Engineers BeNer and Pressem Tessel Code Section XI. Appendix VIII se sieted in this document.
F.J. A4wle
{
i Forfeewomuce Deressmerstlen inIIIstive Rescler Presure Vessel Supervleer/tsvel HI l
t i
Date F.I.Becker Performance Denseestration Inisistive Ashnenherseer
[
This derussent b not suchemele wethset a reasse seat.
Page 3 et 3 a
ov. -.s,_
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s.
Candidate and Procedure PDOS Use Guide for Pinine and RPV(Manual & Automatici & Boltine '
I t
- .The following items are; designed to describe the,'infofination foundlo'rithe PDOS Certificate for Manual or Automated. Piping,' RPV, and Bolting. t
~
. Much of the information'is common to all five,typeshf qualificatiori;The_ Manuel Piping qualification is the. base ~ document and contains many@
i common fields that'willinfound'on alfother'qualificationEThicommon fields will not be preceded by a letter, if the number below is' preceded.
~
by a "p, " it is unique to Piping quellfications. !f the number is preceded by an "r," it is unique to RPV qualifications. If the number is proceded by an "a," it is unique to Automate <f Piping or RPV qualifications.'ll the number is preceded by a "b," it is unique to Botting qualifications. Many of the items below describe both the Candidate and Procedure qualifications and will be designated, " candidate / procedure," where they both apply or where only one applies it will be designated as either " candidate" or " procedure."
i 1)
Candklaterprocedure qualified; Procedure PDOS wiH specify Owner's name.
- 13) The date the PDOS document was printed.
Persor nel PDOS will specify Candidates' name.
14)
For a procedure, this is a unique identifying number for each procedure PDOS l
2)
Candidates'ID or Social Security Number. This wlN be blank for a Procedure For a candidate, this is a unique identifying number for that candidate if a
~
- PDOS, candidate has multiple q=_Wlans, this unique number wEl appear on he/her PDOS documents ~
3)
Procedure number, revision number, and addenda number
- 15) This is an intemal PDI tracidng number l
4)
Title of demonstrated Procedure This is the date the candidate procedure was demonstrated with the rances r
16) 5)
Candidaterprocedure PDOS Revision number, specified in numbers p17, and p18 for piping, r36 for RPV, and b31 for bolting
(
6)
For a candidate PDOS this will specify the owner of the procedure that was used p17) This is the minir9um and maximum diameters quellfied during the demonstration.
I by the candidate during the demonstration.
For Tolerances to the stated values see item p25.
a7) The type of automated system utlHzed for the collection and analysis of UT data p18) TNs is the minimum and maximum thickness quagfied during the demonstration.
(Tomoscan, P-Scan, I-98, GERIS-2000, EDAS, etc.).
For Tolerances to the stated values see item p25.
f i
8)
Type of component carxtdate/ procedure was demonstrated on (Bolting, Piping,
- 19) This is an intemal PDI tracking number j
RPV).
i
- 20) The type of material qualified (Austenitic with or without IGSCC, Fe ritic or Ferritic 9)
Candidate / Procedure PDOS "Date of Issue * (associated with.rr.-ber 5). This w/SMAW as ground cladding).
date win not precede 1-Jan-96 and wiR be updated with an* rsrv%rs to the
?
PDOS (i.e. Changes in " Ranges Demonstrated," Technical %as information,
- 21) This describes the examination appucation that the ai- _ _ b,(-:+f =e has
" ' ^
orTypographical errors).
successfuny demonstrated (Detecten, Length Sizing, Through WaN Sizing), if an examinaten type was not qualified it will not be Ested.
a10) This is the Automated systems analysis software type or name and its revision number.
- 22) Type of access restnctions the candidaterprocedure is quaHfied to perform. For Piping this specines weld access (Double Sided. Single Sided, Limited Single all) This is the Automated systems data acquisition software type or name and its Sded) revision number.
For RPV this speci'ies volume access i
DueLSilled - Fug examinshon coverage by opposing beam directions in both a
- 12) Type of scan application ( Manual Fully-Automatic, Semi-Automatic).
perpendicular and parallel scan path.
[
Single Sided - fur examination coverage by only one (1) beam drection in both NOTE: For en RPV procedure PDQS the altove holds true. For an RPV a: perpendicular and parallel scan path.
l automated candidele PDQS refer to 't=staMt.
Page 1
Cendidate end Procedure PDOS Use Guidefor Pioine end RPV(Manual & Automatic) & Boltint i
The following items are designed to describe the information found on the PDOS Certificate for Mariual MAutofneted Piping lRff/ind Boltind.Q
[
Much of the information is common to all five types of qualification."The.Maridal Npiniq0alifidatiori}s tti5 bass docufNnht andcontairis hian common fields that will be found on all other qualifications. The common fields will not be preceded b p'
i by a "p, " it is unique to Piping qualifications, if the number is preceded by artM it Is' unique 16 RPV gbalif uallliclillbfi b
(
e N
an "a," it is unique to Automated Piping or RPV' qualifications! if thd 60inbdl5 'priceded i
idate9 6r$.m.w mm"@@#png$_;fca"wp M g i i jnd.lwilllidesigliated,
~
~ j 68di
'tems below describe both the Candidate and Procedum
.vhere only one applies it ivill b6_de_sagriated as'64theE ". cit.h,qualificat or s i oc6d6E Mr 4
.vt
. MM-@NGW~%W__."".
....m 1
p23) Types of weld crown conditions the candidate / procedure is quellfied to b31) This is the minimum and maximum metal path demonstrated during a perform (Ground Flush, Flat Topped, As.We ded).
Bolting = %v.
n
- 24) This is the acceptance criteria es specified by Appendix Vill.
b32) If a condidate was successful with the Appendx A of Procedure PDI-UT-5 I
(Straight Beem for Bolts / Studs) they received the " Bore Hole Endorse-p25) This is the " Tolerances" that are to be applied to the minimum and mext-ment." Canddeles' with a " Bore Hole Endorsement" may snhr mum diameter and thicimess ranges (p17 & p18).
Sweluete bolting Indications that were recorded prevleuely with the Streight Beem tecimique. If a condidate was successful with Proce-l
- 26) This statement refers to the requirements of Appendix VII. A candidate who dure PDl-Ui-4 (Bore Hole Examir:etion on Bolts / Studs) they do not successfup demonstrated en Appendix Vill Detection qLN;vi with no require the " Bore Hole Endorsement" to evaluate Indcollons detected
[
y more then 3 ettempts in a one year period, meets the requirements of with the Straight Beam technique Appendix Vll. The expiration date of Appendix VII is three years from the i
date (number 16) the candidate received their quellfleetion. Only Appendix b33) Type of Bolting access restrictions the
-_ " -,------he is queeled to Vllt. Supplements 2 & 3 examinations for Piping and Supplements 4 & 6 perform (Top, Bottom, or Both). If a candidate has access to the " Top" or
{
examinettons for RPV meet the " Practical" requirements of Appendix Vll.
" Bottom" they are quellfled to perform the examinellon on eNher end of i
the bolt or stud or with the bolt or slud in-place. If "Both" is Ested then the l
1 NOTE: For Ploing. e Supplement 12. Ferrflic addam enemination cardidate must have access to both ends of the bolt or stud.
does not meet the requirements of Appendix Vll.
r34) This specifies a supplement that is defined by Apperdix Vill as e' unique l
- 27) This is where any comments about the car.Jd :J,nucessre wRI be located-examinellon volume.
P
- 28) This section will have any candidate / procedure limitations which apply to r35) This speelfles which surface the examinellon was queNfied from (Inside the queHfication. This "E ~ ^- -," sectiotts_houki be reviewed very or Outside).
[
carefull%
}
r36) This defines the thicimess range that was queRfled, which incluoes the 29)
Authenticity of the "Origine!" document has been established with the
'90% of Maximum Thicimess" adjustment per Appendix Vllt. From the ID 3
applicaten of a raised seal to the " Signature" page. All pages preceding the for Sgpiement 4 e maximum thicimess is not applicable. From the 00
- Signature
- page must be present for the quellfications to be valid.
for Supplement 4 e minimum thicimess is not appNeeble. For Supple-l ment 8 the minimum thicimess is specific por the procedure scope.
I e30) This field wls state whether a candidate has Automt.'ed Date Acquisition, Automated Data Analysis, or both.
Summary.gl.Egroonnel QueWicalloris -This is e ommage summary of a
{
cand'dete's quellfications to be used as a carivenient queHfication determinellon.
i This summary document is not officiel without supporting documemellon.
i Page 2 i
now. 0-WB6 i
t
.. -, ~. --
Keys to Successful RPV Demonstrations Written Instructions
=
- Protocol
- Technical basis document
- Written imp.ementing procedures
- Experienced staff Preparation & planning
=
- Schedule
- Training & practice by candidates
- Participation by utility, & ANIin demonstrations
Keys to Successful RPV Demonstrations Realistic Specimens
- Full size specimens & realistic flaws
- High quality & No ambiguous conditions Experienced & expert staff
=
- Dedicated PDA staff ISI experience Participated in specimen fabrication program Familiar with state of the art equipment and techniques Knowledgeable in the Program requirements Cooperation
=
- Utility -Administrator - Candidates
i
}
i RPV Specimen Design l
& Fabrication Process I
j PDI Program i
Appendix VIII -
Supplements L,5,6 & 7 i
I i
PDI-Specimen Design EPRI XDE Center
- Responsible for Technical Basis Design & Procurement of Specimens.
- NDE Center Experience
>15 Years Experience Recruited 2 Specimen Design Engineers (ex IVC gogram)
Facilities
- Material
- Welding & Fabrication
- Metalography
- NDE
Design Objectives
- Guidelines To Test Specimen Design.
- Comply with Appendix Vill.
- Apply to as Many Utility Applications as Possible
- Full Size
- Realistic Flaws I
- Portable
- Provide Diversity in Test Sets
- Quality
i' US Plant Survey i
J Survey of All Plants l
- Based on Appendix Vill Criteria 4
l
Response
- Approx. 90% by July 91 l
62 PWR Units l
- 8 BW /11CE / 43 WE
= 32 BWR Units 3
l AdditionalInformation
]
- Drawings / Weld Configurations j
Established a Comprehensive j
Data Base for Specimen Design 4
i
Paga No. 146
' 05/16/91 A
' oe*****ppendix VIII Industry Survey 1991 - Reactor Vessel. Configurations I
i Plant Name: SUSQUEHANNA Unit 2
Type BWR Sequence No.: 4!-
Da'te:
04/05/91 Revision No.:
O Code Update Year: 1994 BWR Reactor Nozzle Configurations Diam.
Thick.
Plate Ratio Number Function 4
ID Nom Tn2 Ts Tn2/Ts N1 Recirc. outlet 26.20 9.77 6.44 1.52 N2 Recirc. inlet 12.00 7.13 6.44 1.11 N3 Steam outlet 23.64 8.13 7.25 2,12 N4 Feedwater 12.00 7.13 6.44 13 '1 N5 Core spray 12.00 7.13 6.44 1.11 N6 Head spray and spare N7 Vent 5.75 3.50 3.63 0.97 N8 JPI 3.83 2.65 3.63 0.73 5.13 4.31 6.44 0.67 <
N9 CRD Hyd.
5.13 4.31 6.44 0.67 N10 Core diff press. - penet.
2.65 0.00 0 00 0.00 N11 Instrument - penet 1.94 0.00 0.00 0.00 N12 Instr. - penet.
N13 N/A 1.94 0.00 0.00 0.00 N14 N/A 0.00 0.00 0.00 0.00 i 0.00 0.00 0.00 0.00 '
N15 Drain _ penet.
1.79 0.00 0.00 0.00 N16 Instr. - penet.
l N17 N/A 1.94 0.00 0.00 0.00 !
N18 N/A 0.00 0.00 0.00 0.00 N19 N/A 1 00 0.00 0.00 0.00 N20 N/A 0.00 0.00 0.00 0.00 N21 N/A 0.00 0.00 0.00 0.00 j 0.00 0.00 0.00 0.00 R marks:
Drawings are provided.
Plate Thicknesses (PWR or BWR) i Nozzle belt line or maximum vessel thickness:
7.25 l
Core belt line shell course or minimum thickness:
6.19 Closure head:
5.13 Lower head 8.25 oce**************************************************************************
EPRI NDE Center /PDI Appendix VIII Industry Survey - 1991 l
Pag 3 No. 141 05/15/91 Appendix VIII Industry Survey 1991 - Piping Configurations coo ************************* **********************************************
Plant Names SUSQUEHANNA Unit 2
Type: BWR Seq. No.:
45 Date: 04/05/91 Revision No.:
0 Wrought Austenitic Piping (NOT including main coolant loop)
Minimum Diameter piper 4.00 Thickness:'
O.38 Material:
SA312 304L Maximum Diameter piper 28.00 Thickness:
2.54 Material:
SA240 304 Minumum Thickness pipe:
0.38 Diameter:
4.00 Material:
SA312 304L Maximum Thickness pipe 2.54 Diameter:
28.00 Material:
SA240 304 Special conditions:
Taken from calibration block list.
PWR Wrought Austenitic Main Cool #Lnt Loop Piping (Does NOT include surge line or safety injection)
Minimum Diameter pipe 0.00 Thickness:
0.00 Material:
Maximum Diameter pipe 0.00 Thickness:
0.00 Material:
Minumum Thickness pipe:
0.00 Diameter:
0.00 Materials Maximum Thickness pipe:
0.00 Diameter:
0.00 Material:
Are the elbows cast (Y/N)?
N Are the elbows team-welded (Y/N)?
N Safe end material:
Wrought or cast (Y/N)?
Special conditions:
Taken from calibration birck list.
l I
i ooo************************************************************************
EPRI NDE Center Industry Survey 1991 by: J.A. Jones Applied Research Company
i' Peg 3 No. 142 05/15/91 1',
'i i!.
Appendix VIII Industry Survey 1991 - Pipin'g Configurations 3
ooo***************************************************************************i !
t i
a Plent Name SUSQUEHANNA Unit 2
Type: BWR Seq. No.:
45 Date: 04/05/91 Revision No.:
0 Ferritic Piping (NOT including PWR main coolant piping)
Minumum Diameter pipe:
6.00 Thickness:
0.27 Material: SA106 Gr B Maximum Diameter piper 24.00 Thickness:,
2.58 Material: SA106 Gr B Minumum Thickness pipe 0.27 Diameter:
6.00 Materials SA106 Gr B Maximum Thickness pipe:
2.58 Diameter:
24.00 Material: SA106 Gr B Special conditions:
eTaken from calibration block list.'
PWR Clad Ferritic Main Coolant Piping Minimum Diameter pipe 0.00 Thickness:
0.00 Materials Maximum Diameter pipe:
0.00 Thickness:
0.00 Material:
Minumum Thickness pipe 0.00 Diameter:
0.00 Material:
Maximum Thickness pipe:
0.00 Diameter:
0.00 Material:
Are the elbows Cast (Y/N)?
N Are the elbows seam-welded (Y/N)?
N Safe end material:
Wrought or cast?
Type of clad?
Special conditions?
'Taken from calibration block list.
l 1
vooo***************************************.
EPRI NDE Center Industry Survey 1991 by: J.A. Jones Applied Research Company l
l
P;g3 No. 135
\\
05/13/91 i
Appendix ooooooooooooo*******VIII Inductry Survey 1991 - Bolting Configurstion3********
Plant Names SUSQUEHANNA Unit:
2 Type: BWR Sequence No.:
Date:
04/04/91 Revision No.:
0 RPV Closure Head Studs Diameter:
5.63 Length:
58.16 Heater hole diameter:
0.63
~
M a t e r i a l s f.,s. 1..
Head Design:
Slotted L.
u Calibration standard available (Y/N)?
N If so, does it meet the requirements of Appendix VIII (Y/N)?
N Remarks:
RCP Bolts i
Diameter:
2.99 Length:
23.50 Heater hole diameter:
0.00 Material: 540 Gr B24 Head Design:
Calibration standard available (Y/N)?
N If so, does it meet the requirements of Appendix VIII (Y/N)?
N l
Remarks:
1 i
l l
0000***************************************************************************
l EPRI NDE Center Industry Survey 1991 by: J.A. Jones Apllied Research Company i
I
l Paga No. 109 05/13/91 Ap gooooooooooo*pendix VIII Industry Survsy 1991 - Bolting Configurations i
l PlF.nt Name: R.E. GINNA Uniti:
1 Type: PWR Sequence No.:
26 Date:
04/01/91 Revision No.:
0 RPV Closure Head Studs Diameter:
6.00 Length:
57.00,
Heater hole diameter:
1.00 i
Mattrial SA320 L43 Head Design:
Hex Calibration standard available (Y/N)?
l 1
Y l
l If co, does it meet the requirements of Appendix VIII (Y/N)?
i
)
l N
Remarks:
Cal standard meets Appendix VI.
l
- o****
RCP Bolts i
Diameter:
3.50 Length:
30.56 Heater hole diameter:
0.75
(
l
, Material SA320 L43 Head Design:
Threaded cylinder i
i l Calibration standard available (Y/N)?
1 Y
l If co, does it meet the requirements of Appendix VIII (Y/N)?
l N
Remarks:
Cal standard meets Appendix VI.
l l
l i
l l
I l
1 l
'=ooooo*************************************************************
EPRI NDE Center Industry Survey 1991 by: J.A. Jones Apllied Research Company i
'Paga Ns. 110 05/13/91 Appendix VIII Industry Survey 1991 - Piping Configurations coce****************************************************************************!
PlEnt Name R.E. GINNA Unit: 1 Type PWR Seq. No.:
26 Date: 04/01/91 Revision No.:
0 Ferritic Piping (NOT including PWR main coolant piping)
Minunum Diameter pipe:
0.00 Thickness:
,0.00 Material:
Maximum Diameter pipe:
0.00 Tliickness:
0.00 Material:
Minunum Thickness pipes.
0.00
. Diameter:
0.00 Materials Maximum Thickness pipe:
0.00 Diameter:
0.00 Materials Special conditions:
PWR Clad Ferritic Main Coolant Piping Minimum Diameter pipe:
0.00 Thickness:
0.00 Material Maximum Diameter pipe:
0.00 Thickness:
0.00 Material Minumum Thickness pipe:
0.00 Diameter:
0.00 Material:
Maximum Thickness pipe:
0.00 Diameter:
0.00 Material:
Ara the elbows Cast (Y/N)?
N Are the elbows seam-welded (Y/N)?
N Safe end material:
Wrought or cast?
Type of clad?
Special conditions?
1 i
ee******************************************************************************
EPRI NDE Center Industry Survey 1991 by: J.A. Jones Applied Research Company
P:g3 No. 109 05/13/91 Appendix VIII Industry Survey 1991 - Piping Configurations oocoo****************************************************************
1 Plent Name: R.E. GINNA Unit 1
Type: PWR Seq. No.:
26 Date: 04/01/91 Revision No.:
0 t
Wrought Austenitic Piping (NOT including main coolant loop)
{
Minimum Diameter pipe WOOL Thickness:
'O.44 Material:
3 04 JS,.
I Maximum Diameter pipe 10.00 Thickness:
1.00 Material: 504.,[SSj Minumum Thickness pipes (0;135 Diameters 6.00 Material: 104..SS; Maxbnum Thickness pipe 1.00 Diameter:
10.00 Material: ;304 SS -
Specici conditions:
PWR Wrought Austenitic Main Coolant Loop Piping (Does NOT include surge line or safety injection)
)
Minimum Diameter pipe:
27.46 Thickness:
2.40 Material: 304 SS2 Maxbnum Diameter pipe 28.92 Thickness:
2.50 Material: 304 SS :
!Minumum Thickness pipe 2.40 Diameter:
27.46 Material: 3047S i Maximum Thickness pipe 2.50 Diameter:
28.92 Material: 304 SS' Ar3 the elbows cast (Y/N)?
Y
.Are the elbows seam-welded (Y/N)?
Y Snfo end material:
None Wrought or cast (Y/N)?
N/A Special conditions:
Inconnel buttering on safe end to piping welds.
l oooooo*************************************************************
EPRI NDE Center Industry Survey 1991 by: J.A. Jones Applied Research Company
~ _ -
P;g] No. 121 l
05/16/91 Appendix VIII Industr j
ooooo**********************y Survey 1991 - Reacto'r Vessel Configurations 1
PlCnt Names R.E. GINNA Units 1 Type PWR Sequence No.: 26 Date: 04/05/91 Revision No.:
0 Code Update Year: 2000 PWR Reactor Pressure Vessel Configurations Nozzles Inlet Outlet Safety Injection Nozzle ID Maximum 36.18
.33.96 3.44 Nozzle ID Minimum (3
- '33.00'*
3.44 (At the Section XI Boundary fbr'4.25 inner radius examination)
Nozzle Extension ID 27.46 28.92 3.44 (Pipe end side)
OD 34.00 35.00 5.40 Metal path to weld Maximum 11.00 10.93 6.19 centerline:
Minf=um 8.57 7.71 6.19 Nozzle bore taper (degrees) 6.00 10.00 0.00 Plate Thicknesses (PWR or BWR)
Nozzle belt line or maximum vessel thickness:
9.16 i
Core belt line shell course or minimum thickness:
6'.50
{
Closure head:
5.38 Lower head:
4.13 i
l i
l
\\
l I
\\
i l
ocooo***********.*************************.
EPRI NDE Center /PDI Appendix VIII Industry Survey - 1991 j
VesselPlate Thicknesses (94 Plants - July 29,1991) 5F 45--
g ap 35--
[l g
i.l l
e 3F 8
i s
O 25--
O 2F 5(,((t {tl l lljlll
[t c
t t g, t
t t
t Plate Thickness (inches)
$$$8 PWR's (62)
BWR's less Lwr Hd BWR Lwr Hd Only
Vessel Plate Thicknesses (62 PWR Plants - July 29,1991) 45-42-39-36-
.I y/
g 3*
k 2
8
/
A W
o 24-4 l
k fk w
21_
we
.D 18-NN
~
15-/
Ji I* _2 3
12 9-h-
3 ' 3.5 ' 4 ' 4.5 ' 5 ' 5.5 ' 6 ' 6.5 ' 7 7.5 ' 8 ' 8.5 9 9.5 10 '10.5' 11 11.5' 12 '12.5' 13 '13.5' 14 '14.5' 15 '
Plate Thickness (inches)
BWR RPV Nozzle Ratios (32 Plants -July 29,1991) 42-
/
':/
34-
- '/ I f l
- s!)
.i
!If !!
'i
?
- ,*~/ if A
i ti; 1s-k
$/
ao$ us' 'ad 'ad 'ad 'ad ad ' avl 'O.sl '0.95 R.0$ '1.1
'1.25 '13$ 1.45 '1.5$
'1.d
'1.75 '1.85 '1.9$ ' '
Ratios
PWR RPV Nozzle Metal Paths (62 Plants -July 29,1991)
~
34_ -
31-48-'
1 u-j
[
~
m i
g_
l-
?
s::
i
~'
~
I
~
betal Path (inches)
e App. VIII Design Requirements Supplement 4&6
- May be Full Scale
- Length & Width Shall be at 12 inches
- Maximum Thickness of Vessel (within 90%)
= Test Specimens are Full Scale Sections ofRPVPlate and cover up to 12.3 inches T
- Clad With Same Type Cladding SMAW Clad is Applied in the Examination Volwne S
d App. VIII Design l
Requirements 50% of the flaws Shall be Cracks Balance may be Cracks, Fabrication Defects (e.g.. Slag Inclusions) or Machined Notches
= Approx. 200 Flaws
= 80% are Cracks 14% are Fabrication Defects (Slag /LoF)
= <6% are EDMNotches Notches Shall Be Perpendicular to Surface 2 deg.
Maximum Width of Of),010 inch
l l
App. VIII Design Requirements.
l o
j
- At Least 40% of the Flaws Shall l
be Parallel & 40% Perpendicular to the Clad Direction (Supp. 4) or Weld Direction in (Supp 6.)
i Flaws are Evenly Distributed i
l Supplement 4 & 6 Specific
- Flaws Shall Emanate from the Clad Base MetalInterface Flaws Emanate From the Clad
- No More Than 10% Emanate from the Outer Surface
- Approx. 5% Are OD Connected 4
1 l
Test Specimen R2031 to 3 l
RPV Welds Less Than 12.5" Thick (Base Material) i l
i e
1
-i:-
-i}-
4 I
i 45.875" 11.25" m
i 3
m j
91.75"
^
i e
i e
i A
A i
30.0" L
i Y __.. _ _
i i
l 60.0" j
j i
1 4
Y 9
9 I
Automated Inspection from the Internal (Clad) Surface Manual & Automated Inspection from the External (Unclad) Surface (Thick Section BWR)
Seam Welds Clad Base Me'tal Interface Detection & Sizing Demonstration PDH
App. VIII Design l.
Requirements J
Supplement 5 Nozzle Inner Radius j
- Flaws May Be Either Notches or i
Cracks Approx. 90 Flaws
\\
>90% are Cracks
}
<10% are Notches j
- For OD Techniques Nozzle to l
Shell Ratio Shall Be Within 30%
4 Specimens Cover the Range of
'\\
Ratiosfor BWR Plants i
}
i App. VIII Design Requirements Supplement 7 Nozzle to Shell
- Flaws May Be Notches or Cracks
- Approx. 40 Flaws
= 85% are Cracks 15% are Fabrication Defects (Slag /LoF)
Notches are not Used con tinued........
4 App. Vill Design Requirements Supplement 7 Nozzle to Shell
- For OD Examinations the Thickness of the Specimen Shall be 90% of the Maximum Thickness to be Examined PWR Covers 12.3 inches
= BWR Covers 7.5 inches
- For Bore Examinations the Specimen Shall Provide at Least 1
. Flaw Parallel to the Weld Within 10% of the Maximum Metal Path Metal Paths up to 19" are Included.
I i
i Test Specimen R201 PWR Nozzle-to-Shell Welds J
' Up to 12.5" Thick 4E--- 11.25" i
A
/
-~~ M L
A 71.0" M 42.0" 2
\\
v l
v ggr
\\_._
s Automated Inspection from inside Surface Bore Shell Inner Radius inspection (Corner Only)
Metal Path 6-19" Detection & Sizing PDH
App. VIII Design
~
Requirements
- Flaw Size & Location
- Through Wall Extent in 5 Ranges Described as "a,b,c,d, e"
- Length Requirements No Flaw Shall Have An Aspect Ratio (depth / length) Less than 0.1
- Depth Location (Z) and Applica: ion Described for Each l
Supplement...........
i
s Size and Location of PDI Specimen Appendix VIII Flaws TWE - Size a
b c
d e
0.075 - 0.200 0.201- 0.350 0.351 -0.550 0.551-0.750 0.751-2.00 Application Supp. 4 & 5 X
X X
X Supp. 6 & 7 Inner 10%
Does not apply to clad vessels / specimens (see supplement 4)
Outer 10%
X X
S S
11-30% T X
X S
31-60% T X
X S
61-89% T X
X S
Legend X Applies to Detection and Sizing Flaws S Applies to Sizing Flaws T Thickness of the Thickest Specimen in the Specimen Set
9 Full Size, Realistic and Portable Full Size
- All Specimen Designs Used MaterialRemoved From Canceled US RPV's Realistic
- Material Selected based on Size, Availability, & Quality.
- Flaw Designs Based on PDI TechnicalBasis & Appendix VIII Portability
- Size ofSpecimens Had to ConsiderISI Vendor Facilities
1 i
i Provide Diversity in Test Sets
~
i l
Conceptual Drawings and I
Applications Were Developed
)
for PDI Approval
)
- Modular Design of Test Sets l
- Specimen Security
)
- Design Reviews of Final i
Manufacturing & Flaw Specifications Includes
)
= PDI & Code Requirements 4
Application of Specimens 4
4 i
Beam Plots of Flaw Locations l
= Example Test Sets i
j.
l l
Quality i
i
- PDI Developed Specimen j
Fabrication QA Program Requirements j
- QA Requirements Were Applied to Specimen Design and Fabrication i
l
- All QA Requirements Were i
Passed on to Specimen Sub-y contractors.................
Specimen Fabrication QL Requirements Design Control PDI Test Specimen Procurement PDI Document Control Material Control and Identification for PDI Specimen Fabrication
- Q.ualification ofInspection, Examinstion and i
Test Personnel for PDI Specimen Fabrication
- Qualification and Certification of NDE
{
Personnel
)
Calibration and Control of PDA Measurement and Test Equipment l
- PDI Test Specimen and Information Security
- PDI Control of Nonconforming Items PDI Specimen Manufacturing and Examination Records Indexing PDI Test Specimen Quality Records Review Instruction 4
- Quality Assurance Monitoring
- Preparation, Use and Control of Process Control Sheets
)
Procurement of Specimens Vendor Information Meeting January 1992
- Provided All Prospective Vendors With PDI Program Requirements Security ofInformation Timetable
= Quality Assurance
- Prerequisites for Bidding
- All Vendors Required to Sign Non-Disclosure Statements & Submit Procedures to Guarantee 1
Confidentiality of Test Specim.en Flaw Truth
Procurement of l
Specimens j
Initial RPV Practice Specimen i
Bids Invited From i
- Ansald0/NP.P (Italy /E SA) j
- Ensa (Spain)
- Inqual/Sonospection (L'SA/UK) i
- SwRI (L'SA)
- Westinghouse (E SA) e
- The Welding Institute (E K)
- L~ddcomb Engineering (Sweden) l Provided Overview of Flaw Technology & Capability
+
i-i Bid Evaluation Process l
l Procedure was Established to Evaluate Proposals
)
- Evaluation Process Weighted j
- QA, Security, Technical, Facilities, l
Experience, and Schedule 60%
- Cost 40%
l
- Contracts Were Placed With A l
Contingency that the Vendor l
Demonstrated Repeatability &
Quality of the Proposed Flaw Manufacturing Method to PDI i
Program Requirements.
6 Vendor Qualification Requirements
- Used to Qualify Flaw Method, Welding Procedures and Welders i
for the Application l
- Manufacture 4 Flaws of Each Type l
- Working to Controlled Procedures.
- Meet or Exceed PDI Specifications &
l Tolerances l
Reporting
- Full Manufacturing Documentation, NDE and Destructive Evaluation of 3 Flaws.
4 i
1 Vendor Flaws l
Vendors Proposed 3 Flaw l
Manufacturing Methods 2
- Crack Implants i
Flaws are Generated in Small Piece
~
of Material and Then Implanted into i
the Test Specimen 1
- Directly Induced. Cracks
- Flaws are Generated Directly in a the Test Specimen (Weld Solidification)
- Slag / Lack of Fusion
- Flaws are Fabricated Directly in the I
Test Specimen
d lJddcomb "5cc
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- Nondestructive Evaluation of 4 Flaws Verified
- NDE Response & Characteristics of the Flaw
- Weld Implant Quality to Identify Satellite UT Indications from
~
Welding Process.
- One Flaw Was Kept as an Archive Example for Future NDE Evaluation l
e
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i DEMONSTRATION OF MANUFACTl1 RING PROCFnUREE.
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$M INFORME TECNICO urTAtcacico j
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EQUIPOS NUCLEARES, C.A.
EM. N' 3396 NI"!
EXAMEN METALOGRAFICO DEPAGTACENTO CETALUR!lCO METALLOGRAPHIC EXAM.
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4 10 LABORATORIO METALOGRAFICO Sheet of CLIENTE CONTRATO N*
CUPON FECHA EPRI 1CD9 W 6294 25-03-93 Customer Job.ri*
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METALLOGRAPHY OF WELDER QUALIFICATION a
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The welder qualification block was weldedin accordance with Drawing No. C-4988-610. This i
involves using the GTAW process (Procedure PDI-SQOP-17-4988(42)} for the botaxn 1/2 inch j
of deposit, the SMAW process (Prvccius PDI-SQOP-17-4988(41)} for the imerm~hta 3/4 inch, and the FLAW process (Procedure PDI-SQOP-17-4988(43)} for the final 3/4 inch. After ultrasonic and MT examinations, the block was sectioned et the transverse mmerline and polished l
and etched. Figure 1 shows the cross secnon for welder Frank Garcia.
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i Figure 1. Cross Section of Welder Qualification Block for Frank Ganna.
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I Summary of Flaw Manufacturing i
Crack Implants.
- Flaw Dimension Accuracy Acceptable
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- Weld Implant Quality i
Unacceptable Directly Induced Cracks &
S:.ag/LoF
- Flaw Dimension Accuracy Acceptable
- Weld Quality Acceptable i
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Specimen Fabrication l
Material Supplied by EPRI &
- From Canceled RPV Vessels
- Subject to High Sensitivity l
Base:ine NDE Examinations
- Higher than Normal Code Exams
- MaterialIdentification was Established
- QA Records Sampling
- >200 Tons!
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PDI Technical Specifications l
and Drawings
- Manufacturing Drawings General Arrangement Manufacturing Scheme Flaw layout
- Technical Specifications Manufacturing and Quality Requirements Flaw Requirements
l Specimen Fabrication I
l
- Vendor Drawings, Procedures, l
and QA
- All Drawings & Procedures Were Reviewed Before Fabrication
- Hold Points Were Established for Vendor QA and EPRI Staff QA
- Vendor Personnel Were Required to Sign Non-disclosure Forms for Security of Flaw Truth
- QA Audits and Surveillance's Were Required
Specimen Fabrication Manufacturing
- Each Fabrication Step was Identified on Work Instruction Sheets
- Vendor Personnel Signed Off at Each Stage
- QA and EPRI Staff Verified Flaw Locations
- Full Documentation Was Kept
Specimen Fabrication Vendor Inspection
- Specimen was Subject to Final Inspection Before Delivery Visual 4
NDE-Surface and Volumetric
- All Specimen Manufacturing Records Recovered & Delivered.
As Built Drawings 1
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Receipt Inspection by EPRI VisualInspection Review Manufacturing Records
- Line by Line Review of All Fabrication Records
- Fabrication Records Are Used to Establish Flaw Truth Tables l
Develop Dimensional j
Certificate of Conformance
- Prepare Application Drawings Ultrasonic Fingerprint i
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Ultrasonic Fingerprint l
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Very High Sensitivity and Scan l
Resolution Objective's
- Specimen Quality Meets PDI Specifications
- Uninten1:ionalIndications Do Not Preclude Satis: factory Performance Demonstration Signals Do Not Draw Attention to A Flaw and/or Signals Should Not Be Interpretec. as Flaw Tips
- Flaw is Suitable for Test Sets I
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PDI Specimen Ultrasonic Fingerprint APPLICATION TASK ten w a nn m.i.u em a j
Detection l
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1993 AnnualInfonnation Meeting i
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i PDI RPV Specimen i Summary i l
- Meet All ASME Section XI, i
Appendix Vill Requirements
- Apply to Most Utility Applications
- Full Size and Contain Realistic Flaws
- Manufactured to Highest Quality Requirements
- Provide Diverse and Challenging Test Sets
A12adrent 2 I PERFORMANCE DEMONSTRATION PROGRAM i PDI, EPRI AND NRC DISCUSSIONS APRIL 23-241997 l PROGRAM OBJECTIVES Uniform implementation of a high quality program Reduced cost through pooling of resources Maintain competitive environment for ISI vendors Provide focal point for communications l with NRC and others i i
PDI PROGRAM TIMELINE Ad Hoc Committee established in 1989 PDI established Jan.1991 a 5 year funding Funding utilities 91-96, Presentation of PDI plans and schedules to NRC, Feb.1991 NRC requests accelerated implementation (complete by 1995),1991 Piping demonstrations start April 1994 PDI PROGRAM TIMELINE First RPV demo Nov.1994 NRC Assessment Jan.1995 Assessment Report Aug.1995 NRC/PDI Coordination meeting March 96 NRC Accepts PDI for IGSCC Qualification March 1996 l Four Assessment Items remain open Three Party Agreement terminated Jan 1997 l
i i PDI PROGRAM STATUS Piping Supplements 2 & 3 fully implemented,330 Candidates 292 Qualified Overlay Supplement 11 implemented with exceptions Bolting Supplement 8 fully implemented RPV Supplements 4&6 fully impleniented 5 Vendors and 50 Analysts qualified Manual RPV qualifications initiated PDI PROGRAM STATUS Program and Samples ready for Nozzle Supplements 5&7: activity on hold as a l result of regulatory uncertainty l IGSCC Piping demos transitioned to PDI PDI qualified RPV are being attempted, meeting with acceptance difficulty e
l \\ l PROGRAM DESCRIPTION l DOCUMENT (PDD)
- Objective
- Provide Utilities a line-by-line comparison between Appendix VIIi and the PDI implementation of Appendix VIII - The document would be referenced by utilities in their Inspection programs Expenence - The 89 version of Appendix VIII required many revisions PDD continued - Code Cases and Code Revisions presented to ASME - Most have been accepted and incorporated - Program Description Document (PDD) developed to assure all parties are aware of the program program actually being implemented. - First efforts identified sample fabrication, and administration problems with appendix VIII l i i
PDD continued
- Rev 0 September 1994 addressed:
- Sample fabrica' tion requirements and tolerances i - Piping flaw length acceptance criteria - RPV length and depth acceptance criteria - Administrativedetails
- Rev 0 Basis for 1995 NRC Assessment s
PDD continued i Code Revisions - 15 Code revisions or Code Cases processed and i necepted - Addresses most but not all of the Rev 0 differences
- Rev 1: based on RPV experience
- Rev 1 Change 1, incorporated BWROG Overlay program
l l l PDD REV.1 CHANGE 1-
SUMMARY
SUPPLEMENT 2 - Revisions incorporated to maintain security of IGSCC samples SUPPLEMENT 4 - Personnel demonstration willinclude a distribution of flaws size, orientations, and locations PDD REV.1 CHANGE 1-
SUMMARY
Supplement 4 continued - Flaws less than 50% of IWB-3500 not scored for detection -Combined Supplement 4 & 6 personnel examinations allowed -Flaw location tolerance of Code Case 1 l l
i PDD REV.1 CHANGE 1-
SUMMARY
SUPPLEMENT 5 - Adopted Code Case N-552 for examination from outside surface -For examination from inside surface:
- Personnel qualification not required where techniques are the same as Supplement 4
- Allowed false calls as in Code Case N-552 PDD REV.1 CHANGE 1-
SUMMARY
SUPPLEMENT 6 - Same revisions as Supplement 4 - Plus allowed that all flaws between 50 and 100% ofIWB are counted as detection flaws without regard to position in Table VIII-S6-1 i
l l l 1 l PDD REV.1 CHANGE 1-
SUMMARY
l
- SUPPLEMENT 7
- PDI will implement clad to base metal portion only, of Supplement 7 - Personnel qualifications not required where techniques are same as Supplement 4 - Procedure qualification will exceed the Code minimum requirements. PDD REV.1 CHANGE 1-
SUMMARY
- SUPPLEMENT 8
- Meets or exceeds Code requirement for personnel qualifications a Incorporated Code Case N-457, (notch location)
- SUPPLEMENT 11
- Overlay added, Sample requirements and acceptance criteria are from the BWROG IGSCC Program.
l l l PDD REV.1 CHANGE 1-
SUMMARY
- SUPPLEMENT 12
- Addedclarifications - Added combined length and depth sizing as revised by 95 & 96 Code Addenda CODE ACTIVITIES Rewrite of Appendix VIIIin progress - Separation of personnel and procedure Qualifications -Incorporation of Code Cases - Incorporation of differences between PDD and Code - Clarifying procedure requirements and essential variables
l l l CLOSURE OF OPEN ITEMS \\ 95-01-4 Demonstration of each technique described in procedure 95-01-09: Number ofIGSCC and far side flaws in personnel demonstrations l TECHNICAL BASIS FOR RPV DESIGN
- Key design criteria for samples:
- Sound material representative of PWR and BWR fabrication - Sample matrix to meet needs of all utilities - Representative conditions e.g. curvature, geometry, roughness, material type - Sufficient for sample diversity and security - Code Compliant I l
TECHNICAL BASIS FOR RPV Key sources ofinformation: - Sample and wsid geometry detennined by survey ofinstalled configurations, - Realistic flaw types and responses = PISC II and m Under-Clad cracking experience TR NP2841
- Destructive evaluation of Midland RPV samples TR102074 TECHNICAL BASIS FOR RPV FLAWS Crack tip radius less than 20 micron Notches will be held to absolute minimum Ultra-clean welds are required around flaws Imbedded flaws are fabrication type flaws Flaw tilt up to typical weld prep angles Typical flaw roughness required Conservative aspect ratios used, i.e. short l
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