ML20197K080

Summary Rept on Ultrasonic Exams Performed at Seabrook Station Unit 1 on Statically Cast Fitting to Component Weldments

ML20197K080
Person / Time
Site:	Seabrook
Issue date:	05/15/1986
From:	King D, Lance J, Rennell T PUBLIC SERVICE CO. OF NEW HAMPSHIRE
To:
Shared Package
ML20197K063	List: ML20197K058 ML20197K080
References
YAEC-1543, NUDOCS 8605200252
Download: ML20197K080 (42)

Text

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SUMMARY

REPORT ON ULTRASONIC EIAMINATIONS I PERFORMED AT SEABROOK STATION UNIT ONE ON STATICALLY CAST FITTING TO COMPONENT WELDMENTS I

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8 /Y/ 76 I

Prepared By:

D. B'. King [ D ]p ' (Date)

Mechanical Services u Reviewed By: //ly ~77) I &/ "8h T. M. Rennell (Date)

I Mechanical Service roup Approved By:

/ 'O b/b <

J.J/Cance/ Manager (Date)

MecKanicalfervicesGroup Yankee Atomic Electric Company I Nuclear Services Division 1671 Worcester Road Framingham, Massachusetts 01701 8605200252 860515 l PDR ADOCK 05000443  ;

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DISCLAIMER OF RESPONSIBILITY I This document was prepared by Yankee Atomic Electric Company

(" Yankee"). The use of information contained in this document by anyone other lI

. than Yankee, or the Organization for which the document was prepared, is not authorized and with respect to any unauthorized use, neither Yankee nor its officers, directors, agents, or employees assume any obligation, responsibility, or liability or makes any warranty or representation l

concerning the contents of this document or its accuracy or completeness.

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[ ABSTRACT

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This report summarizes the elements involved with the ultrasonic examination of weldments joining statically cast SA-351 CF8A fittings to <

various components in the heavy wall Reactor Coolant Piping System at Seabrook Station, Unit 1. The referenced welds were examined from the casting side of the weldment where applicable with both 0 and 41 refracted longitudinal

{ wave probes. These examinations were performed by the Westinghouse Electric Company Nuclear Services Integration Division Inspection Service, under the direction of the Yankee Atomic Electric Company during the period of April 9 through April 17, 1986. The examination procedure / technique was successfully demonstrated to members of the NRC on April 15, 1986 at the Seabrook site.

This demonstration consisted of identifying flaw indications in samples

( provided by both Westinghouse and Pacific Northwest Laboratories. l C

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I TkBLE OF CONTENTS DISCLAIMER OF RESPONSIBILITY..................................... 11 ABSTRACT......................................................... iii LIST OF FIGURES.................................................. v

1.0 INTRODUCTION

..................................................... 1 2.0 BACKCROUND....................................................... 3 l

3.0 COMPONENTS EXAMINED..............................................

I 6 l 4.0 METHOD ANu EXTENT OF EXAMINATION................................. 11 5.0 METHOD OF RECORDING REFLECTORS................................... 12 6.0 EXCEPTIONS....................................................... 13

7.0 CONCLUSION

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I LIST Oh' FIGURES I Number Title Page A.1 FB-RC-5 Detail Drawing 4-A.2 Loop 1 Weld Map 7 A.3 Loop 2 Weld Map 8 i A.4 Loop 3 Weld Map 9 A.5 Loop 4 Weld Map 10 A.6 14 1 Detail of Reactor Coolant Pump Discharge Nozzle to Pipe Weld I .

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1.0 INTRODUCTION

The cost and corrosion resistance of cast stainless steel products has resulted in their use throughout commercial PWR Main Coolant Piping Systems.

At Seabrook Station the use of cast stainless steel is limited to statically cast fittings in the primary coolant loops.

L ASME Section XI requires a full volumetric inspection of all Safety y Class 1 welds which, at Seabrook Station, include the welds and adjacent heat affected zones of the cast fittings.Section XI requires that during preservice inspection a technique is used which will be capable of performing u the inservice inspections. Ultrasonic inspection and radiography are the only possibilities, however, because of the large section thickness and the r

i possibility of water filled pipe, radiography is impractical.

Ultrasonic inspection remains as the only method to perform the volumetric examinations of the cast fitting welds. UT, however, is restricted r by severe attenuation, noise, scattering, and beam redirection of energy due to the material microstructure.

s In-house work at Yankee Atomic for NHY, and in conjunction with Westinghouse Nuclear Services Inspection Division, developed an inspection methodology for the cast stainless steel components. This report details the work performed, the inspection methodology, and the exemptions to Section XI

[ requirements which are necessary. The performance of this activity is d

required by ASME Section XI and NUREG-0896, Supplement No. 3, Paragraph 7 5.2.4.3, Item (1) as follows:

L y (1) FSAR Table 5.2-2, " Material Specifications Class 1 Primary l Components," shows the use of cast stainless steel (SA-351,

' Gr CF8A) fittings. Paragraph 2.2, Table 2.2, in the PSI program for examination of the reactor coolant system (Document 80A8983) discusses exceptions from the ASME Code-required ultrasonic examination of cast austenitic stainless steel fitting and component welds in the primary piping systems. Table 2.2 stat'ss that the wrought pipe-to-cast elbow or cast pump stainless steel welds will be examined with a one-side, 1/2-vee ultrasonic examination from the pipe side, and the cast side may not be examined because of metallurgical constraints (large grain structure that produces a high degree of scatter and attenuation of ultrasound). This table also states that the cast B

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I elbow-to-cast pump welds will not receive an ultrasonic examination because of these constraints.

A one-side, 1/2-vee examination does not meet the Code requirements. The staff recognizes that the ultrasonic examination of cast stainless steel fittings and components may be i difficult. However, a preservice inspection with the best available instrumentation with straight beam and angle beam I

techniques should be attempted and documented on all welds in (

accordance with Section II requirements. A technical justification is required if the examination is performed from the pipe side only.

In Table 2.4, which lists reference calibration standards, only SA-376, Gr 304N calibration blocks have been identified. The I program tables indicate that the cast stainless steel fittings to pipe welds will be examined with these wrought stainless steel calibration standards. Calibration blocks for fitting to nozzle h

E safe end welds are to be identified "later." Calibration blocks should be available for each type of material (i.e., ferritic, cast, or wrought) that is representative of both sides of the j weld. The applicant should describe the measures that were taken

! (i.e., using the best available refracted longitudinal waves transducers) to determine that a meaningful ultrasonic examination could not be performed from the cast side of these welds. Copies I of the ultrasonic testing procedures for the primary piping welds should be provided for staff review.

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2.0 BACKGROUND

,I In an effort to comply with the NRC recommendation, the Mechanical Services Group, Nuclear Services Division of the Yankee Atomic Electric Company undertook a research program; the goal of which was to develop a reliable technique to ultrasonically examine weldments of a statically cast i fitting to component configuration from the statically cast side of the weldment.

A 13" x 13" x 3" (nominal) section of SA-351 CF8A material was obtained I from Car) lina power and Light. This material was cut from a spare fitting at the Shearon Harris plant. The section was machined to provide an appropriate calibration block subsequently identified as SB-RC-5 (Figure 2.1). The search unit that was used in the Yankee study was a KBI dual element 1" diameter round pitch / catch 45 refracted longitudinal wave transducer.

I The basic objectives of the study were to:

a. Identify ability to penetrate weld reqsired volume in various areas I of the same fitting and relative areas in other fittings.

b. Identify / compare base line noise levels between various fittings.

c. Determine a reliable threshold of detection for flaw indications.

I Calibration was made utilizing the 1/4, 1/2, and 3/4t holes in the calibration block. Noise levels in the block at reference gain settings were nominally 15 - 25% FSH.

The objectives were accomplished by testing several weldments in SA-351 CF8A fittings in Seabrook Units 1 and 2. In addition, welded samples provided by the Westinghouse Electric Corporation were tested. Welds selected for the test were in various stages of completion, i.e., fit-up and tacked, root welded, approximately 1/2 volume welded, and completely welded. Emphasis here was to identify base line noise levels and attempt to verify penetration by B observing ID geometric reflectors, such as counter bore e r root georotry.

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I Noise levels observed in the samples were consistent with those of the calibration block (15 - 25% FSH nominal). Fourteen welds in Unit 2 and two

. welds in Unit 1 were examined. No evidence of ID geometry / penetration was observed. Four samples containing mechanically and thermally induced cracking were examined at the Westinghouse Research and Development Center in Monroeville, Pennsylvania. The samples were fabricated as part of the owner's Group Study on centrifugally cast piping weldment inspection. These samples were centrifugally cast pipe to statically cast SA-351 CF8A fittings. Testing I was performed from the statically cast side. Surface preparation was similar to the welds in Seabrook Units 1 and 2 fittings, i.e., machined and ground.

a Noise levels observed were again 15 - 25% nominal. No geometric reflectors were observed, and only one sample exhibited a relevant flaw type indication.

I Based on the above results, it was felt that a consistently reliable inspection could not be performed on the subject weldments with currently available procedures and techniques. This position was discussed with NRC -

I NRR and Region One officials. The NRC position at the time was that every weldment in the plant should be evaluated individually to determine whether or not a meaningful exam could be performed. It was at this point that Seabrook I Management elected to contract Westinghouse Inspection Services to perform the examinations on the subject weldments based on the fact that the Westinghouse technique had been successfully demonstrated to the NRC at several other utility locations, including Wolf Creek, Commanche Peak, Caloway, and Hillstone III. Prior to awarding Westinghouse the inspection contract, Yankee sent a UT Level III to the Westinghouse R&D Center to evaluate the Westinghouse technique and compare it with the technique previously tried in I the Yankee study. The results of the comparison seemed to indicate that although both techniques would find flaws, the Westinghouse technique appeared I to detect both geometric and flaw responses with more consistency and higher amplitudes. Further, at the request of Yankee, two Westinghouse NDE UT Level III engineers came to the Seabrook Station to evaluate the welds in the Unit 1 fitting material. After testing a representative sampling of welds in Loop 1, they felt that they could perform a meaningful examination such as had previously been done at the aforementioned plants.

I Based on these facts, Westinghouse was contracted to perform the referenced examinations.

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I 3.0 COMPONENTS EXAMINED i

The following ASME Class 1 weldments were examined. See Figures 3.1 through 3.4 for locations.

Loop 1 Loop 2 Loop 3 Loop 4 1-1-2 4-1-2 7-1-2 10-1-2 I 1-1-3 4-1-3 7-1-3 10-1-3 I

2-1-1 5-1-1 8-1-1 11-1-1 2-1-2 5-1-2 8-1-2 11-1-2 2-1-3 5-1-3 8-1-3 11-1-3 2-1-4 5-1-4 8-1-4 11-1-4 2-1-5 5-1-5 8-1-5 11-1-5 2-1-6 5-1-6 8-1-6 11-1-6

• 3-1-1 *6-1-1 *9-1-1 *12-1-1 3-1-2 6-1-2 9-1-2 12-1-2

• 3-1-3 *6-1-3 *9-1-3 *12-1-3 I

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4.0 METHOD AND EXTENT OF EXAMINATION The listing of wcldments identified in Section 3.0 were examined from the statically cast fitting side only with the exception of welds 3-1-1, -

6-1-1, 9-1-1, and 12-1-1. These welds are located at the reactor coolant pump to discharge pipe junction and were scanned from both the pump and pipe sides; however, due to geometric and metallurgical considerations, a complete ,

examination could not be performed. See Section 6.0 of this report for details. It should be noted that where applicable, the above referenced welds were scanned from the pipe side using shear waves during the normal PSI program.

I The examination method was ultrasonic tested utilizing both 0 longitudinal and 41 refracted longitudinal waves. The O scans were l

performed on the weld and applicable base material for the following purposes:

a. Clear angle beam scan path.

b. Verify angle beam reflectors such as counterbore and ID geometry.

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• c. provide assurance of penetration when angle beam reflectors were not present.

The Al refracted longitudinal wave inspections were performed in the axial and circumferential (both CW and CWW) directions.

L The Westinghouse technique was satisfactorily demonstrated to representatives of the NRC at Seabrook Station on April 15, 1986. The demonstration consisted of applying the 41 refracted L-wave technique to cast stainless steel samples supplied by Westinghouse and Tom Taylor of L

pacific Northwest Labs. The technique was able to detect cracking in all of the samples to the satisfaction of all concerned parties.

5.0 METHOD OF RECORDING REFLECTORS In an effort to demonstrate penetration on each weld utilizing the 41 refracted L-wave, the scanning area was extended to obtain a reflection from counterbore, if it existed. If a reflection was observed from root ID geometry, that would also serve as evidence of penetration. If no ID geometric reflectors were noted, O data was compared with welds exhibiting ID geometry in an effort to evaluate dB difference as evidence that penetration was achieved.

Reflectors identified in the 41 RL were verified by either 0 plotting, review of the applicable radiographs, or both. Reflector data concerning sweep readings, surface distances, etc., were recorded in accordance with Westinghouse Procedure ISI-206, Revision 1 (Appendix A).

Straight beam data was also recorded to verify / confirm the presence of ID geometry.

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6.0 EXCEPTIONS The welds listed below were not completely examined due to either I metallurgical or geometric configurations. Formal request for relief of inspection requirements will be made at the time of submittal of relief requests for the PSI Program.

B Weld Reason for Exclusion Remarks 1-1 Geometrical / metallurgical Scanned from pipe side with 00, 450 See Figure 6.1 refracted shear and 410 refracted L-waves. Scan on pump side with 410 RL resulted in essentially 00 at ID due to OD l geometry.

6-1-1 Geometrical / metallurgical Scanned from pipe side with 0 0, 45 0 l See Figure 6.1 refracted shear and 410 refracted I

L-waves. Scan on pump side with 410 RL resulted in essentially 00 at ID due to OD geometry.

9-1-1 Geometrical / metallurgical Scanned from pipe side with 00, 450 g See Figure 6.1 refracted shear and 410 refracted l L-waves. Scan on pump side with 410 RL resulted in essentially 00 at ID due to OD geometry.

12-1-1 Geometrical / metallurgical Scanned from pipe side with 0 0, 45 0 See Figure 6.1 refracted shear and 410 refracted L-waves. Scan on pump side with 41 0 RL resulted in essentially 00 at ID due to OD geometry.

3-1-3 Geonetrical Surface Preparation l

6-1-3 Geometrical Surface Preparation 9-1-3 Geometrical Surface Preparation 12-1-3 Geometrical Surface Preparation l

Further, relief from the requirements of IWB-3514 shall be requested, l due to the nature of the examination sensitivity and recording criteria.

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7.0 CONCLUSION

S The referenced examinations were performed in accordance with the applicable requirements of ASME Section 11 1977 Edition through Summer of 1978 Addenda with the noted exceptions. In addition, reference sensitivity and scanning levels were established from the side drilled holes rather than the 10% notch. This level of sensitivity was sufficient to detect flaws in the samples supplied by Westinghouse Owner's Group and pacific Northwest Laboratories.

Inspections, witnessing, and surveillance of the examinations and related activities were conducted by personnel from: Factory Mutual Engineering Arkwright Boston Insurance, the United States Nuclear Regulatory Commission, New Hampshire Yankee, and Yankee Atomic Electric Company.

It is the licensee's belief that adequate penetration was achieved on all welds based on the fact that even on welds where a significant dB difference was noted (reference Table 1, Weld 1-1-3 + 10 dB and 4-1-3 + 12

% dB). ID geometric reflectors were observed.

I No relevant indications were noted during the inspections. A relevant L

indication would be that resulting from a flaw. Approximately 48% of the welds examined did exhibit geometric reflectors.

The Westinghouse final report, including all inspection data, is f

N availabic for review at Seabrook Station.

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E TABLE 1 Comparison of Relative Penetration Base Metal Weld Numbers Calibration Block / Fitting Evidence of Penetration List dB dB Counterbore/ Root Geometry Loop 1 1-1-2 50 46 1-1-3 55 65 I 2-1-1 59 62 X 2-1-2 55 57 X 2-1-3 59 52 X X f

2-1-4 59 55 X X 2-1-5 59 58 l

L 2-1-6 53 61 P 3-1-1 50 56 3-1-2 55 60 F

l 3-1-3 55 60 Loop 2 4-1-2 55 65 X X H 4-1-3 55 67 X 5-1-1 55 66 s

5 2 55 65 5-1-3 57 58 I

- 5-1-4 57 59 K X H 5-1-5 57 64 5-1-6 57 71 .

6-1-1 55 66 6-1-2 55 60 6-1-3 55 60

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Comparison of Relative Penetration l Base Metal Weld Numbers Evidence of Penetration 5 List Calibration Block / Fitting dB dB Counterbore/ Root Geometry Loop 3 l 7-1-2 50 56 I I 7-1-3 50 53 X j 1

l 8-1-1 50 51 X I

1 8-1-2 50 58 X 8-1-3 50 51 X g l 8-1-4 50 56 X 3 e-1-5 Se 5, 8-1-6 58 60 9-1-1 58 69 X 9-1-2 55 59 X X 9-1-3 55 59 Loop 4 10-1-2 53 57 10-1-3 53 59

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11-1-4 59 60 X X 11-1-5 59 62

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I APPENDIX A I

em:.ct ova . +. e t a Nucleaf INSPECT 80N SERVICES 7

W SeTVices Integration 151 206 Rev.)

I. Divisio.n NONDESTRUCTIVE EX AMihATION PROCEDURE I

TITiE I

MANUAL ULTRASONIC EXAMINATION OF WELDS I.

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l l E Prepared By: ' q-B.J.Dfebvre[{evel III l

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Approved By l W.,u

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D.C.Adamonis, Manager  !

Inspection Services l l

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\ l oUd '" October 19,1984 Ede" October 2,198 l  !

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APPENDIX A W NSD u v.

ISI-206 1 i

Change No. 01 i Sheet 1 of 1 I

SERVICE ACTIVITY PROCEDURE FIELD CHANGE PLANT: Seabrook Plant Unit No. 1 PURPOSE: To clarif y recording and calibration Change Paragraph 5.5.1 to read as follows:

Establish a calibration from calibration block ,

f rom the back surf ace at 50% to 80% nominal.  ;

Note as part of examination data (paragraph 9.1) the sensitivity adjustment required to maintain +

examination volume back surface at 50% to 80% i amplitude shall be noted for each fitting. i i

g Add new paragraph 7.5 as follows- i l For P.S.I. Pipe welds responses from internal H surfaces that can serve to demonstrate as evidence of sound beam penetration shall bc ,

notes to the extent that the response area can  !

., be reproduced. If unable to verify any penetration with angle beam and straight beam on fitting side, angle beam examinatt on shall be performed on wrought side and not 2d on data sheet ,

e CONCURRENCE / SIGN AND PRINT FOR WESTINGHOUSE M DATE l\ a - (- 'i~ i%t

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H TITLE OR POSITION iTN Ce e-u h m. te DATE /\l , s. C 'l I'I %.

FOR THE UTILITY .

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DATE //c/> o

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TITLE OR POSITION sn e ,,..c ;r DATE -/hd AUTHORIZED INSPECTOR f" " M -- DATE v- a (IfAppropriate) 5 '-- A' d ,, /

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APPENDIX A W NSID .

.3127W:42A/100584  !!S1-206Rev.1 K I. . , .

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l MANUAL ULTRASONIC EXAMINATION OF WELDS 1.0 SCOPE 1.1 This procedure defines requirements for manual ultrasonic -

examination of full penetration circumferential and longitudinal .

butt welds, and adjacent base materials of these and fillet or  :

corner welds. It is applicable to such welds in piping systems '

, (.25" to 6" thick) and vessel materials (.25 to 2" thick), in ferritic or austenitic steels of either wrought or cast product - .

forms. Technical contents are based on the ASME Code, including i F Section XI, IWA-2240, when dictated due to Code omissions and to 3 implement upgraded technology or good practice. ,

a 1.2 Procedure OPS-NSD-101, Preservice and Inservice Documentation, and .

the Examination Program Plan noted therein are considered part of this procedure and are to be used as applicable. l 1.3 Examinations in accordance with this procedure are intended to  ;

15tisfy volumetric examination requirements based on the applicable L edition and addenda of ASME' Boiler and Pressure Vessel Code specified in the Examination Program Plan.

2.0. GENERAL REQUIREMENTS .

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2.1 Personnel perfoming examinations to this procedure shall be certified to at least LEVEL 11 for ultrasonic examinations, based on a written procedure prepared in :..cordance with SNT-TC-1 A, as may be l{- l l

modified by the applicable ASME Section XI. Personnel certified to

any LEVEL for ultrasonic examinations may be employed as assistants.

- 2.2 Ultrasonic flaw detecti*on instruments shall be of the pulse echo I -

type with an A-Scan presentation and shall be qualified to the '

j requirements of NSD-ISI-10 at the beginning of each period of

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extended use. Qualifications may be valid for a period not to l exceed three months.

2.3 Piezoelectric transducers shall be in accordance with TABLE 1 and l shall be capable of providing the applicable calibration as required l

herein.

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. 2.4 Couplant shall be a suitable liquid, semi-liquid or paste, such as

' Echogel, Exosen, Sonctrace, Trim, Ultragel or glycerin, that is certified as containing not more than 1% oy weight, of residual

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sulphur and halogens.

H 2.5 The item to be examined, including the required extent of adjacent volume to be examined, shall be as defined in the Examination

, Program Plan. This infomation shall be provided to the examiner i assigned to conduct the examination. Examination of the required i volume shall be to the maximum extent practical. For preservice examinations only, the extent tnat cannot be examined shall be noted. See 9.0.

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( i:ct October 19,198 ,,,, 1 of 15 'ca r October 2.19S:

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APPENDIX A l h NSID 3127W:42A/100584 151-206 Rev. 1 i ,- i li '2. 6 Transducer scan surf aces including the weld crown, shall be l .

l essentially free of dirt, spatter, paint, coatings and

. irregularities that impair smooth uninterrupted contact of the i i search unit and coupling of the sound beam into the material.

I 2.6.1 Surface condition, and access support (e.g., scaffolds, , t I lighting, etc.) if required, shall be the responsibility of '

I the utility. ]

(. 2.7 Generally the examinations conducted in accordance with this i procedure will be done from the 0.D. surface. When examinations are j to be conducted from an I.D. surf ace, calibration must be ,

l accomplished on the I.D. of the appropriate calibration block and  ;

noted on the report.  ;

2.8 CAllBRATION BLOCKS .

l 2.8.1 Calibration blocks shall be f abricated from the same product i l

form and the same material specification as one of the I

l materials in the weld assembly to be examined.

Alternatively, for welds in austenitic materials, material of equivalent P-number pr P-number grouping may be used.

l Calibration blocks ar.d the general items for which they are applicable shall be as listed in the Examinaton P'rogram Plan.  ;

I 2.8.2 Calibration blocks shall be of the same nominal diameter and  !

I nominal wall thickness as the item to be examined, and shall l ,

contain notch refie ctors. Notch depth shall be in accordance I with the applicatl . code.  ; ,

( Alternatively, for austenitic material and for vessels; (1)  !*

I I

reflectors may be side drilled holes, (2) for materials witn diameters greater than 20", the block may be flat, (3) fer materials with diameters of 20" and less, the examination surface may be within the range of .9 to 1.5 times the block l diameter.

I l l l

When orilled holes are provided, nominal depth (length) shall ,

be 1 1/2" minimum if end or side drilled; and thru-wall or I

1 1/4" minimum if drilled on a chord line. Diameter and ,

I location shall be based on nominal thickness, as follows:

l l THICKNESS (T) DIAMETER LOCATION (T) 3/32" 1/2 lor 1/4 & 3/4)

I Up to 1" Incl.

Over 1" thru 2" 1/8" 1/4 & 3/4 ,

i Over 2" thru 4" 3/16" 1/4 & 3/4 l l Over 4" thru 6" 1/4" 1/4 & 3/4 i Primary RC Loop 3/16" 1/4,1/2 & 3/4 I

i 2.8.3 Temperature difference between the surface of the block on i t which calibration is acccmplished and the surf ace of the item

! to be examined shall not exceed 25'F. Devices for deter-

! . mining this difference are not considered as MT&E equipment.

j 2.8.4 Where the component is clad, the block shall be clad by the j same welding procedure. If icpractical, welding may be by

' manual procedure.

l g a s t c.wg g ,. .,y 3g ;;

. :m October 19,198: I ,.m 2 of 15 icau October 2.1984  ;

I  % 01M4wtv ?. i S J I

l.

- - - - APPENDIX A ,

[ h NSID 312N:42A/1005E4 151-205 Rev I r' s 2.8.5 Surface finish of blocks shall be representative of surface .l

, finish of examination scan surf aces.  ;

~

r' 3.0 SYSTEM CAllBRATION L  !

3.1 Prior to conducting examinations, the complete system to be utilized .

shall be calibrated on the applicable calibration block (See 2.8.1)  !

f for the examinations to be conducted. The system is defined as; the L ultrasonic instrument (and battery pack if applicable), cable (s),  !

i transducer, couplant, and any other apparatus, instrument or circuit i eriployed between the instrument and the calibration block surface.  !

Once calibration has been established, any change to any part of the  !

l system will require at least a verification of the calibration. i 3.2 Sweep range calibration shall be sufficiently long so as to allow l examination of the entire required volume by a: full " vee path"  : ,

from one side of the weld; half " vee path" from each side of the  !

weld; or a combination of such coverage so that the entire volume i required to be examined is covered by at least 2 sound beam i i

j direction.s. See Figures 1 ;hru 4.

L  : ,

3.2.1 A " vee path" is composed of a downward and an upward path or j leg of the calibrated sound beam in the material through  ;

which it is traveling. .

A 1/2 vee path is either a downward or an upward leg. i Example: for 11/2 Y (or 3T) calibration where the volume I required to be completely ccvered by the first 1/2 V from one ,

L side and by the last (3rd 1/2V) from the opposite side,1/2 i  :

vee path coverage from both sides has been satisfied.' A  ; l 11/2 vee is composed of 3 half vees and 2 full vees, one of  !

I l which is inverted.  ;

L l I

i 3.2.2 Sweep shall be calibrated to provide equally spaced i  ;

increments of the appropriate reference reflectors. Table 2 , I specifies specific sweep limitations. i  :

i 3.3 Reference sensitivity shall be established from notch reflectors i except, for vessels, castings,1/2 node techniques, and f or austenitic materiais greater than 1.7 inches thick, drilled holes j may be used. Primary reference sensitivity shall be established  ;

j from not nearer (in sweep time) the applicable reflector that  ;

provides the highest amplitude response. For primary loop reactor I coolant piping, sensitivity shall be established from the 3/4 T ,

b hole. For pressure boundary base metal adjacent to and underneath integrally welded supports, sensitivity shall be established on an 0.D. notch or on holes representing an up-leg.

!' 3.4 Reference sensitivity shall be established by adjusting the peaked

signal from the applicable calibration reflector to 80 of FSH (Full '

Screen Height).

l i

i 1

i t

• 81C% t l lmseSt:

! omit Octeber 19. 1984 m et 3 of 15 Imt October 2, IcSc u: m4 -ev : s sa r'

k e

[ _ _ ____

l L,

APPENDIX A NSID f  ;

3127W:42 A/100584 l151-206 Rev. I 8

I 1 3.4.1 Without moving the scarch unit from this peaked signal  ;

location point, check vertical linearity of the system by ,

decreasing signal amplitude 6dB, and then by an additional . ;

i 6dB. The resulting signal decrease must be within 32% to 48*.  ;

I FSH and 16 to 24% FSH respectively.

3. 4.' 2 If either signal f alls outside of its' range, such controls j

as reject, clipping, damping, filtering, etc. , shall be

, adjusted such that this check can be accomplished l' sati sf actorily. If adjustment of controls f ails to provide a satisfactory check, the transducer and/or cable shall be 8 changed and calibration repeated.

j i

I If the system continues to f'all outside of the acceptable .  !

range, the instrument shall be changed. Once adjustment of i i controls that affect linearity is established, if necessary, , j they shall remain fixed for the period of the examinations. 3 3.5 Return primary reference signal to 80% FSH and without changing gain contr61, determine peak indipation amplitude from the remainiag -

)

applicable reflector positicns in the examination region. Construct i I a distance amplitude curve (DAC) on the screen by a curved line connecting each of the peaked points. The DAC may be extrapolated at either end for a distance of 1/2 T.

j I

i' i

I -

3.5.1 Khere the primary reference sensitivity is established from a notch reflector, signals from the 1/4 T and 3/4 T boles may be used to establish slope of the DAC when 1/2 node examination is used. Alternatively, the next two' notch l,

i

?

I l

l reflector positions may be used to extrapolate the DAC slope to cover the examination range. Holes shall not be used to establish a DAC for examinations requiring a calibration block of less than .8" thick.

I l

3.5.2 For primary loop RC piping, slope of the DAC shall be  ! .

established with the peaked signal from the 1/4 T hole set to

• l 80% FSH and connecting the resulting peaks from the 1/2 i and I

f 3/4 i holes with a curved line. With the peaked signal from the 3/4 T hole adjusted to 80% FSH reference sensitivity, the DAC curve shall be drawn as a line parallel to the line established above. The line shall extend through the 80%

I 1

reference point and through a vertical line of the screen that represents a minimum of 1 1/4 T or 100% of sweep. ,

3.5.3 Reference points at 50% and 20% of DAC shall also be I

j established on the screen by decreasing each DAC curve reference point by 6dB and then by an additional 6dB. The resulting 50% and 20% points shall be connected by curved lines drawn on the screen.

I ,

t a r t:t.vt I j ar vst.,

Att October 19, 1984 1,icL 4 of 15  ;:. t October 2,1984

%: m at :s n I

l - - _ _ _ _ _ _

l I APPENDIX A I NSID l ;151-206 Rev. 1 3127W:42A/100584 l l 3.5.3 (cont'd)

To minimize screen clutter, lines connecting 50% points may i

be deleted, provided the points are clearly defined and are j separated by not more than approximately one major screen division. Unen investigating indications which may or are ,

'I

• required to be recorded at the 50*. DAC level, a line connecting the applicable adjacent points must be considered or, alternatively, 2X reference sensitivity may be used, with I

the 100% DAC curve then representing the 50*. DAC line. {

3.6 When calibrating for angle beam examination of primar loop reactor i f coolant piping system and for cast austenitic meteria s, a primary reference DAC shall be established by adjusting the 1/4 T hole I

l reflector to 80% FSH and another DAC established by adjusting the  ;

i 3/4 T hole reflector to 80t FSH. DAC curve for the 3/4 T shall parallel the 1/4 T curve. Examinations shall be conducted once for each DAC.

3.7 Calibration for reflectors , transverse to the weld'shall be based on ,

l 1/2 V.

3.8 Straight beam calibration for welds, in vessels shall be as follows:

t i

r

a. Welds Tess than .8" thick

~

The signal amplitude from the 1/2 i hole shall be set at 80 percent of full screen. A DAC curve is not required.

b. Welds .8" thick and greater The signal amplitude frem 1/4 T hole shall be set at 80 .

percent of full screen. Mark the amplitude of both the 1/4 T and 3/4 T holes to establish a DAC. ,

4.0 SYSTEM cal.lBRATION VERIFICATION Calibration shall be verified at the beginning of each day of

,I  !

examination, and at the end of examinations for which calibration is applicable or every four hours, whichever is less, and with any change in l

examination personnel.

4.1 A DECREASE in sensitivity of more than 20B shall require recalibration and re-examination of all items examined since the previous acceptable calibration or check. An INCREASE in sensitivity of more than 2 DB shall require recalibration and I a re-examination and data correction of all indications recorded since the previous acceptable calibration or check.

i 1( i t ut em loatt October 19, 1984 t

!,eg 5 of 15 Iarcst:

tatt October 2.1984 iE s. e. i m . . n .

5 I

E 1

APPENDIX A l NSID 312N:42A/100584 151-206 Rev. 1 3

I - 4.2 If any point on the DAC curve has moved on the sweep line more than 10% of the sweep division reading, correct the sweep range

,I calibration and note the correction in the examination record. If recordable reflectors are on the data sheets, those data shall be ,

l voided, a new calibration established, and areas relative to the i l

I 5.0 EXAMINATION voided data shall be re-examined. ,

5.1 Extent of Examination l

j 5.1.1 Examination for reflectors parallel to the weld shall be conducted to achieve coverage of the required volume to the ',

extent described in 3.2, f ro.n one side of the weld. As necessary, examination shall be conducted from both sides and  !

the "second" side examination may be limited solely to l

coverage of that volume in which the rec,uired coverage was -

f I [

not achieved from the "first" side, 5.1. 2 Calibrated straight b'eam (see 3.8) examinatien when required 1 in the Examination Program Plan, shall be accomplished to examine all of the volume required to be examined, to the

,I extent practicable. i, g 5.2 Examinations utilizing more than one DAC curve shall be accomplished -

g once for each curve.

( 5.3 Rate of search unit movement shall not exceed 6" per.second. .

5.4 Scanning sensitivity shall be at least twice the primary reference i

sensitivity.

f 5.5 Base Metal Straight Beam Examination 5.5.1 Prior to performing angle beam examination the base material through which the angle beam will cass shall be completely scanned with a straight beam search unit to detect reflectors l

I which might interfere with the angle beam examination. This examination is to be done for preservice only.

5.5.2 Sensitivity of the instrument shall be adjusted at a location free of indications so that the first reflection from the

I back surf ace will be 50 to 80 percent of full screen height.

Sensitivity as adjusted above shall be continuously monitored during the examination, and adjusted as necessary to maintain at least this minimum amplitude. Alternatively, calibration j in accordance with 3.8 may be used, i

1 i j a m: ,vt f :o*u October 19.19Bt iner -

6 of 15 barrsts att Octcber 2,1984 s.e m -tv. : i es _

I

APPENDIX A E NSID 3127W:42A/100584 l151-206 Rev.1  ;

I' l s- 5.5.3 Areas containing indications (principally laminar) that i

af fect angle beam examinations shall be noted, considered  ;

l during that examination, and recorded on the data sheet if i they are confirmed as interfering. See 9.0.

l 5.6 Angle Beam - Reflectors Parallel to the Veld l

5. 6.1 The scan pattern shall start with* the search unit transmitting an agle beam perpendicular to and towards the I .

wel d. The search unit shall be moved towards and away from the weld such that a necessary amount of the beam path passes through the maximum accessible volume of weld and base metal i

{  !

to be examined. Concurrent with this scan, the search unit  ; I shall be angled right and lef t and progressively indexed .  !

o along the length of the weld such that the whole scan pattern i follows a "saw-tooth" pattern. The " pitch" of the  :  ;

^

"saw-tooth" shall be such that the beam covers at least 10 }  ;

percent of the area covered by the previous adjacent pass. . i The weld and required amount of adjacent base metal is to be i fully scanned by thip method. When necessary and practicable ,

i examination shall be accomplished from both sides of the j i wel d. This relates to examination directions 2 and 5 in .

OP S-NSD-101.

I 5.7 Angle Beam - Reflectors Transverse to the Veld I

i 5.7.1 This examination is to be accomplished only where ,

satisfactory sound beam coupling into the weld can be achieved and maintained. Crowns should be flat 'for at least i i 90% of width. l 5.7.2 The search unit shall be placed on one edge of the ' weld directing the angle beam into the material parallel to the '

l. weld axis. From this position, the search unit shall be i

! moved parallel to the weld and indexed toward the opposite l a j si.de such that the next scan will cover at least 10 percent -

i of the area covered by the previous adjacent scan. Parallel l l' t scans snall be. repeated in this manner until the length and I

• width of the required volume under this surf ace has been i scanned; and then repeated in the opposite direction. This '

relates to examination directions 7 and 8 as described in -

OPS-NSD-101.  !

6.0 INTERPRETATION AND INVESTIGATION f 6.1 The examiner shall interpret all indications tnat exceed 20% of the l primary reference DAC such that he can assess their source and cause

in terms of their being either valid or non-valid. Indications f rom or naar the root of welds may require other aids. See 6.3.

[A j aniews Got October 19, 1994

% .e 7 of 15 pr.,sto

nr October 2,19Sc m : iou -u : : :: _g, l

l __

I APPENDIX A W NSID ,

312 T.!:42A/100584 l 151-206 Rev.1 lI[ t 6.1.1 Valid indications are reflectors caused by flaws, such as cracks, lack of penetration or fusior, inclusions and

'I porosity. - All other indications are considered non-valid, including those due to: scanning noise, grain structure, beam redirection, internal liquid levels, clad interface, f

straight beam back surface and geometric reflectors.

6.2 Valid indications that exceed 20% of primary reference DAC shall be investigated by the examiner, in terms of the recording requirements of 7.0.

6.3 Other transdLcers, search units, f requencies, techniques, etc., may be used to aid interpretaton and investigation.

6.3.1 If such aids necessitate use of any control that cannot be positively returned to its calibrated position, (such as a potentiometer control on sweep, damping, uncalibrated gain, Il- 7.0 RECORDING INDICATIONS etc.) primary reference calibration shall be verified before use and re-established prior to continuing examinations. >

7.1 Prior to recording indications that require dimensioning, complete I primary reference calibration, including linearity check shall be j verified. Scribe /Ref. line data shall be recorded or verified. ,

• 7.2 Valid flaw indications which provide a response equal to or greater i

'{ than 50% of primary reference DAC shall be censidered as--recordable  ;

l indication--and noted as RI.

7.2.1 For each such indication, peak amplitude, sweep positien, and search units location and direction shall be' recorded. , The indicatien shall also be dimensioned to record, as a minimum, sweep positions and search unit locations representing

,I minimum and maximem 50% DAC points, parallel and i i perpendicular to t he length axis of the indication.

7.3 Valid flaw indications which provide a response between and 50%

W of primary reference DAC shall be considered as--non-recordable '

indication--and noted as hRI.

l I 7.3.1 For preservice examination of pipe welds only, where primary reference sensitivity was established from a notch, each such indication shall be noted on an R1 data sheet. As a minimum, I peak amplitude, sweep position, search unit location and direct, and scanning side thickness shall be noted.

l >

I I(

I tart:mt j lar.-sto ont October 19, 1984 . ,,ar 8 of 15 :cet October 2 m1984

%: :m cv in I

I ~~

APPENDIX A h NSID 3127W:42A/100584 !I51-206Rev.1 7.4 Non-valid indications, and the absence of valid indications shall be considered as--no indication--and noted as N1. .

8.0 POST CLEANING  ;

I 8.1 Examined areas shall be dry-wiped to remove excess wet couplant, if necessary.

9.0 EXAMINATION RESULTS AND DOCUMENTATION I '

9.1 All data relative to examinations shall be recorded in accordance with OPS-NSD .101.

l I l i

I '

i I i I .

I .

I i i

I l I

l tRh:52

[ 18 8t c7n t l 9 of 15 la.it October 2,1984 '

( cart October 19, 1984 - I..cr

~r ie:4 =cv su ,y3, I

I

l APPENDIX A h NSID .

!151-206 Rev. 1 3127W:42A/1005B4

~

j l' TABLE 1 ANGLE BEAM EXAMINATION l NOMINAL T R A N S 0 U C E R (1) '

I-1 .

MATERIAL THICKNESS MAX.

SIZE MINIMUM FREO. MHz NOMINAL ANGLE i

.250" to .750" 1/4" 2.25 45*S

.751" to 1.000" 1/2" 2.25 45*5  !

l 2.25 45*5 t 1.001" to 1.200" 3/4" I 1.201" and Greater 1" ,

2.25 45*S Main Coclant Piping -

Forged 1" , 1.0 41 *L/45'S i

1  ;

Centrifuga11y Cast 1" 1.0 41

• L or cast  ;

STRAIGHT BEAM EXAMINATION  !

l ,

S1IE $

MIN. MAX. MAX. FREO. MHz .

l[ Main Coolant Piping 1" 1.25" 2.25 I

All. other to 1,2" Dia. 1/4" 1/2" 5.0 12" Dia. and greater 1/4" 1" 5.0 l

I -

NOTES:

(1) Other transducers may be used where metallurgical characteristic or geometry impede effective use of the above listed angle beams or l

- frequencies. Size is the element viewed f rom the side and shall not be l -

increased.

1 1

t"temt l larrst:

10 of 15 October 2.1984

(  :"1 October 19. 1984 ..ist lect NWO 10.4estv ;183

. l l

.I L - _ - - -

APPENDIX A NSID 3127W:42A/100584 151-205 Rev. 1 I

I

~

~

TABLE 2 1/4 T = 1/8 Node = 1/8V 1 1/4 T = 5/8 Node = 5/8V  ;

1/2 T = 2/8 Node = 1/4 V i 1/2 T = 6/8 Node = 3/4 V I, 3/4 T = 3'8 / Node = 3/8 Y 1 3/4 T = 7/8 Node = 7/8 Y 1 T = 4/8 Node = 1/2 V -

2 T = 8/8 Node = 1 V ,

ETC.

i' SWEEP RANGE CALIBRATION

' i FOR SWP. RANGE CAL. OF: MAX. LAST LEG % SWP. LOCATION ())

1T 70 l 75  !

2T 3T 75 i 4T 75 (1) Applicable for "T" calibration point from notch reflector, or last I  ;

"T" point as extrapolated or extended from calibration hole reflectors. Maximum last leg location indicated is based on piping .

calibration block at minimum "T" and of volume to be examined at maximum "T". Last leg positions indicated abov'e may be changed if  ;

thickness of calibration block and the examination grea are determined to be other than this basis. Calculate for maximum last ,

leg position as follows:

.". = HAX. %5WP. LOCATION FOR L AST LEG. ',

100 :- B {

I I '

i i af vss ,

E s r!C1wt October 2,1954 oct October 19, 1984 I,, r _ 11 of 15 U ct I *st O80;4dtv Fi83 I

I APPENDIX A .

W NSID 151-206 Rev.1 i i

filustrathe Only Ir .

'!6 &~ ~, s, s

'/

SIDE 1 SIDE 2 k N i

b

t.  %  ! \ /\ t I*

I 'eNw%\\\% ys r fMe'JW f IT Cal., Crown Flat & Flush i j I .

A A~

q w.- _

_NN l

• \ s

'sN\\ % l

/

NN'\%V##A '

l 1T Cal., Crown Obstructing Crown Obstructing

/. M _- _

- NN s ';,x/

x v'/  :

i I

n%s, .

2T Cal., Crown Obstructing '

I M /L

• l j

i s ,

~

e'

/ 's \ /

\ ,W6 9 W 4,\N 9$6%%X;A '

// i 3T Cal., Crown Obstructing i[

i

/ / . - .

I

. 's '

[Y y \ Coverage from Side 1 is 100% "

's

~

. 's/ hj\,_ Sied 2 Exam. Not Reouired l i

4T Cal. . j l l i

Broken Beam = Exam. Start Solid Beam = Exam completion or Maximum access.  ;

ALL BEAM ANGLES-45'  ;

SEE FIGURE 2 FOR COMMENTt.RY FIGURE 1 j I 5f3

. Et s t CT".1 October 19,1984 l,,t 12 of 15  ;! oav "I s October 2,1984 (oist s.c ie u .t v i2 l

1 I l

n APPENDIX A s

{ h NSID 151-206 Rev.1 -

s

" tilus!ra.tive Only .

SIDE I SIDE 2 i

+j'd*- '

f , s 3 -M'- k k i

's ' AN% \MI hint _

+ X/

/r$Mv5pL '

/  !

{

+

IT Cal. , Crown flat & Flush

• y qw z T +

N ! / An nk k' l

s WWM N . /

VMAY&, '

l l

C IT Cal., Crown Obstructing Crown Obstructing '

i L

l +

r A A - NN g

u/ X-L s. -

mswA -  :

l 2T Cal. , Crown Obstructing , j i

/ A -

p L

\ s L'

' A

\

's>% M M /

Coverage from Side is 100t Side 2 Exam _ Not Recuired l

l 3T Cal. i l

L Broken beam = Exam. start. Solid beam = Exam. completion or maximum access. i a

r ALL BEAM AMLES-60* ' j l -

L i ri9ures and views illustrate extent or examination volume coverase'that is obtained based on parameters depicted. Actual parameters existing for or i during each examination alter significantly the depicted coverage. I i  !

Key parameters depicted are: .

1. Search unit is essentially minimum size j .

2. Nominal beam angle (in the part) is achieved and maintained .  ; i

3. Eeam has zero spread j ,

F 4. Beams reflect from parallel planes equal to T at 1.0. and crown areas L 5. Width of obstructing crown is equal to T

6. Scan access is available on both sides. i Where weld crown is not obstructing, 2T cal, range or greater can satisfy 8 recuired coverage from one side. {

I Cal. range and transducer or angle shall be such that examination and '

data required (see 2.5) can be satisfied. Maximum extent of recuired  :

l coverage achieved during examination is, that volume that has been

" cross-hatched" by calibrated beams, as perceived solely by the examiner. I i

E I F1GURE 2 ,

i i

October 19,1984 l,,n, 13 of 15 $'.N'" October 2,1984  !

,'cIts _

u.c :ou -i v :a'

L APPENDIX A W NSID 151-206 Rev.1 l L .

Illustrative Only .

I SIDE 1 SIDE 2 i l _L . i' M'h r A k k t

k I

1T Cal., Crown Flat & Flush bhbIh k b l i q .... .I i

- A A- ]_ N N  !  ;

N _, ,,'

1T Cal., Crown Destructing Crown Obstructing

/ /, ,-k  %

• _ ' '. , , ' f ,f* , ' ,,

2T Cal. , Crown Obstructing '

l l / / -- - k k 3T Cal.

'% ,' ' ~

h _

l l A A -

'7

,' \ Coverage from Side 1 is .1007, '

\

s '

's,',/ y b.u

.,r'4w.l /

Side 2 Exar.. Not Recuired  ;

4T Cal.

i 6

- i I 1 i

~

Broken Beam = Exam. Start Solid Beam = Exam. Completion or .

' +

_ Maximum Access  ;

i

- ALL BEAM ANGLES- 45' SEE FIGURE 4 FOR COCENTARY FIGURE 3 I. .

i ,act. t  !

=ct October 19,loJ4 - ! ,,;, 14 of 15 lasesc:

=ce October 2,1954 l I #w s i 3 314 es t y ?-I.e 3 L --

m L

APPENDIX A

~~

[ - V.! NSID 151-206 Rev.1 {

{ 111ust'rative Only SIDE 1 SIDE 2 1 / k k

/  !

'N, L IT Cal. , Crown Flat & Flush dw..r w A ,k k I

/

j

- / '

1T Cal., Crown Obstructing Crown Obstructing r -N N e /L --- - -

L /

I i

. j

'hT4 gg,g' j I l2TCal., Crown Obstructing '

" t

! A An Coverage from Side 1 is 100%

7 L

i

f g %jy*/

'u- M Stee 2 Exam. Not Recuired_ ,

l

,. 3T Cal. '

r,-  ! t N

" ~ Broken beam = Exam. start. Solid beam = Exam. completion or maximum access. I i ALL BEAM ANGLES-60' l Figures and views illustrate extent of examination volume coverage that is j obtained based on parameters depicted. Actual parameters existing for or

' during each examination alter significantly the depicted coverage. ,

Key parameters depicted are:  :

7 1. Search unit is essentially minimum size I

- 2. Nominal beam angle (in the part) is achieved and maintained'

3. Beam has zero spread -

4. Beams reflect from parallel planes equal to T at 1.D. and crown areas

• m 5. Width of obstructing crown is ecual to T i  !

' 6. Scan access is available on both sides j Where weld crown is not obstructing, 2T cal range or greater can satisfy

~ required coverage from one side.

l u

Cal. range and transducer or angle shall be such that examinatier. and data required (see 2.5) can be satisfied. Maximum extent of required coverage achieved during examination is, that volume tnat has been j

cross-hatched" by calibrated beams, as perceived solely by the examiner.

{

iP F1GURE a u

• i 3E v:SE 2 l o

October 19,1984 I

15 of 15 Icart October 2,1984 .

l . .e,,

[toyt 68 t CTiv t

• • OC 1014 = t v 22BJ

~

F L

W

_ _ _ _ _ _ _ _ _ _ __