Text

Rev 0 to NDE Procedure NDT-C-38, Ultrasonic Exam of Full Penetration Butt Welds in Cast Stainless Steel Components
	ML20209H288
Person / Time
Site:	Byron, Braidwood, 05000000
Issue date:	06/30/1986
From:	; COMMONWEALTH EDISON CO.
To:	;
Shared Package
ML20209H286	List: ML20209H281; ML20209H288;
References
	NDT-C-38, NUDOCS 8609150204
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A TTA CHMENT 2 i

Commonwealth Edison Co's NDE Procedure l

NDT-C-38, for UT Examination of Cast l

Stainless Steel Components.

8609150204 860902 PDR ADOCK 05000455 G

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e NDT-C-38 ROY 0 Juco, 1986 Page 1 of 23 COMMONWEALTH EDISON COMPANY NONDESTRUCTIVE TESTING PROCEDURE FOR ULTRASONIC EXAMINATION OF FULL PENETRATION BUTT WELDS IN CAST STAINLESS STEEL COMPONENTS BYRON AND BRAIDWOOD STATIONS A.

Scope The ultrasonic methods described in this procedure are for A.1 the examination of full penetration butt welds in statically cast stainless steel material, SA-351 Grades CF8A and CF8M in PWR Reactor Coolant systems. The cast stainless steel (CSS) welds are of different types such as:

forged pipe-to-cast elbows, pumps or valves and cast elbows-to-cast pumps or valves.

A.2 This procedure reflects the lates.t state of the art and to meet ASME code requirements as provided by "best effort" and is specifically designed for detection of IWA-2240, planar indications in the lower 25% to 50% of the component to wall thickness for materials from approximately 2.0" 4.0" thick.

A.3 This procedure utilizes straight beam (0#) and angle beam (approx. 40 ) refracted longitudinal wave techniques.

B.

Applicable Documents and Codes The following codes and standards form a part of this B.1 examination procedure to the extent specified herein.

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NDT-C-38 R;v 0 Jcto, 1986 Page 2 of 23 B.2 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, section II, Rules for Inservice I

Inspection of Nuclear Power Plant Components, and section V. Nondestructive Examination, 1977 Edition, Summer of 1978 addenda.

B.3 American Society for Nondestructive Testing (ASNT)

Recommended Practice for Mondestructive Testina Personnel i

Qualification and Certification SNT-TC-1A, Supplement C, l

1975 or 1980 Edition.

B.4 Electric Power Research Institute (EPRI) Report, Ultrasonic Examination of Cast Stainless Steel Components In Main Coolant Pipina Systems At Byron Nuclear Power Plant, December 18, 1985.

C.

Application C.1 The objectives of the methods given herein is the detection and recording of indications within the weld, the heat

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affected zone, and the base material adjacent to the weld.

The indications that are located from 25% to 50% through wall depth are to be evaluated and identified by the inspector.

1 C.2 The examination shall be performed from the outside of the component by means of contact ultrasonic testing.

l l

EDT-C-38 I

goy 0 Juno, 1986 i

Page 3 of 23 I

Examination areas shall include the entire circuaterence of C.3 the weld, the heat-affected zone and the cast stainless steel base material, to the extent possible, adjacent to the weld.

When the afore mentioned volume cannot be examined due to surface contours and other restrictions (valves and pumps etc.) the maximum possible area shall be I

examined.

The area examined and type of restrictions shall be documented on the report form.

l Reflectors parallel to the weld shall be detected by angle C.4 l

beam scanning from the cast side / sides with the beam directed toward and perpendicular to the weld, to extent possible.

' Reflectors transverse to the weld shall be detected by C.5 angle beam scanning on the weld surface and the cast base material side / sides with the beam directed parallel to the weld, in two directions, 180 to each other, where possible.

A straight beam examination shall be performed on each weld C.6 for angle beam interference, for attenuation measurements, to obtain exact component wall thickness measurements at the counterbore area.

Further more, straight beam I.D.

geometry examination is required to profile and plot and to assist in determining examination coverage and signal evaluation.

NDT-C-38 Ocv 0 June, 1986 Page 4 of 23 D.

Beauirements D.1 Personnel D.1.1 All personnel performing and evaluating this ultrasonic examination (s) shall be certified to at

,least Level 11 in accordance with SNT-TC-1A, Supplement C, 1975 or 1980 Edition.

D.l.2 All personnel shall familiarize themselves with the objectives of this procedures by practicing on a mock-up or cracked specimens before performing an actual examination.

D.2 Equipment D.2.1 Ultrasonic instruments shall be used with contact search units.

The ultrasonic instrument shall be accurate equipped with a dB calibrated gain control, over its range to i 20 percent or i 2dB.

D.2.2 The ultrasonic instrument and specified angle beam 1

search unit combination shall be capable of resolving l

the 10% deep I.D. notch on the calibration block with 1

a minimum 2:1 signal noise ratio.

It may be necessary to adjust the instrument to a lower or different frequency setting, than the transducer in 1

1 1

EDT-C-30 ROY 0 June, 1986 Page 5 of 23 i

order to obtain satisfactory resolution.

Documentation of certification for the ultrasonic instruments and transducers used shall be supplied when requested.

D.2.3 The modern digital microprocessor controlled f

ultrasonic instrument, such as the EPOCH 2002 is

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recommended to be used when doing this cast stainless I

steel component examination for the following good low frequency resolution, multiple reasons:

calibration memory, material velocity readout and i

direct printer hookup.

l D.2.4 The straight beam transducers shall be nominally 1.0 MHE and.750" to 1.o= in diameter.

The following specific set of angle beam search units, designed for notches optimum results on the 10% and 25% deep I.D.

in the calibration blocks, were used in developing this procedure: KBA, Alpha type,

.5 and 1.0 MHZ x 1.0" diameter transducers, mounted on axial and circumferential contoured wedges that produce an approximate 40 dual focused refracted longitudinal wave mod'e.

Other search unit f requencies, sizes and angles may be used, for performing and assisting evaluations or accomodating geometry problems, if l

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l NDT-C-38 ROY 0 Juno, 1986 Page 6 of 23 equal or better results are obtained on the 1

calibration standard.

I D.2.5 The search unit cable shall be of the coaxial type and shall not exceed 12 feet in length.

D.2.6 Glycerine or ultragel 11 are normally used as a couplant but other couplants may also be used if l

l comparable results are obtained.

All couplants used aust have a certified analysis of halogen content of

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less than 300 pga.

D.3 Calibration blocks D.3.1 There are two calibration blocks (one thinner for 29" I.D. pipe and one thicker for 31" I.D.

Pipe) f or each station that meet the recommended design and The blocks requirements of ASME Section V Article 5.

have additional notches nachined in them.

D.3.2 The calibration blocks have the same mater.ial similar diameter specification, cast structure type, and wall thickness and a representative surf ace finish as the components being examined.

D.3.3 There shall be documentation certifying the calibration block material.

l D.3.4 Additional calibration blocks shall meet the same above requirements of this procedure.

l

NDT-C-38 ROY 0 June, 1986 Page 7 of 23 l

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D.3.5 Other reference blocks (IIW-2 DSC, Rompas, Etc) may be used for calibration verification checks.

D.3.6 Calibration Block Holes and Notches i

The calibration blocks contain both axial and circumferential side drilled holes (S.D.H.) and I.D.

notches.

The S.D.H.'s are 3/16" dia. x 3"

long, located at depths of 1/4, 1/2 and 3/4 vall thickness and.are primarily used for sweep range (F.3.2) calibration.

The I.D. notches are 2" long and 25% and 50% depths and are primarily machined to 10%,

used for sensitivity (F.3.3) calibration.

Other holes and notches may be present and used for aiding

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l calibration if they don't interfere, f

E.

Surface Preparation The examination surface shall be free of irregularities, E.1 loose material or coatings which interfere with ultrasonic l

wave transmission.

l surface temperature shall be within i 25 F E.2 The component of the calibration block temperature.

Surface preparation shall include the weld and component E.3 for a surface either side of the weld, where possible, sufficient distance to allow examining the required volume.

i

NDT-C-3s a;v o June, 1986 Page 8 of 23 F.

Calibration of Equionent Instrument Linearity Verification F.1 F.1.1 Screen Heicht Linearity The ultrasonic instrument shall provide screen height least 80% of linearity within 5% of full range for at the full screen height (FSH) (base line to maximum calibrated screen points).

The screen height linearity check shall be made in accordance with Attachment #1 of this procedure and the results

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recorded on Form NDT-CF-2.

F.1.2 Amplitude Control Linearity The ultrasonic instrument shall utilize an amplitude 20%

control, accurate over its useful range to i i

of the nominal amplitude ratio, to allow measurement indications beyond the linear range of the of Vertical display on the screen.

The amplitude l

control linearity check shall be made in accordance with Attachment #1 of this procedure and the results recorded on Form NDT-CF-2.

1 l

l 1

MDT-C-38 Ccv 0 June, 1986 Page.9 of 23 F.1.3 Instrument calibrations for screen height and the amplitude control linearity shall be performed at beginning of each period of extended use or every 3 months, whichever is less.

F.2 Calibration General l

F.2.1 Calibration shall include the complete ultrasonic l

examination system.

Any change in search units, wedges, couplants, cables, ultrasonic instruments, recording devices, or any parts of the examination system shall be cause for recalibration, except when using a digital microprocessor controlled instrument (EPOCH 2002) several calibrations may be made at one time and recorded.

These digital calibrations may be recalled or reprogrammed at any time within four hours of the original calibration or recalibration, that day.

The initial calibration shall be made on The the proper designated calibration block.

calibration verification shall be made on either the proper designated calibration block or the reference blocks listed in D.3.5.

The calibration block and data shall be recorded on the calibration form.

i NDT-C-38 R;v 0 June, 1986 Page 10 of 23 F.2.2 Calibration shall be performed at the beginning of l

each day of examinations.

A calibration verification l

shall be made at least every four hours during t

examinations, at the finish of each shift and whenever a change in examination personnel occurs.

F.2.2.1 Recalibration. Amplitude Only If the amplitude on the CRT screen has changed by I

i more than 20% of its criginal amplitude when a check is made on the calibration standard, all data I

forms since the last positive calibration check shall be marked void and destroyed.

A new calibration shall be made and recorded and the voided examination areas shall be re-examined.

F.2.2.2 Recalibration. Sweep Only

)

If there is any indication that the sweep position has moved on the sweep line more than ten percent of the calibration sweep, correct the sweep range calibration and note the correction in the examination record.

If recordable reflectors are noted on the data sheets, those data sheets shall l

be voided and destroyed.

A new calibration shall be completed and recorded, and the voided examination shall be repeated.

EDT-C-38 R;v 0 June, 1986 Page 11 of 23 F.3 Calibration. Specific F.3.1 Calibration Block Selection: The 29" 1.D.

calibration block shall be used when calibrating for examination of the 27 1/2" and 29" I.D. components and the 31" 1.D. calibration block for examining the 31" 1.D.

components.

F.3.2 Sweep Rance Calibration: A 5.0" depth full screen range, using the 1/4, 1/2 and 3/4 T S.D.H.'s shall be established for both the straight beam and angle beam calibrations.

Measure the depth of each S.D.H.

from the calibration block O.D. surface, and with the search unit positioned for maximum hole signal response, from each hole, adjust the signal to it's corresponding 5.0" screen position.

Repeat this process on each hole until the screen range is linear.

The back reflection and the signals from the bottom of the notches may also be used for the straight beam calibration.

If an accurate corner reflection signal is obtained from the 10% deep I.D.

notch, it should also be used when calibrating the Use the staggered holes for angle beam screen range.

the straight beam calibration and the in line holes for the angle beam calibration.

A separate (Axial and Circumferential) calibration shall be performed

NDT-C-38 R;v 0 June, 1986 Page 12 of 23 for each angle beam scan.

If the hole signals do not line up exactly as stated, adjust them as best as possible with the greatest accuracy at the lower 50%

block wall thickness.

F.3.3 Reference Sensitivity: The straight beam reference sensitivity shall be established by adjusting the minimum and maximum amplitude, 1st back reflections of the calibration block to 80% F.S.H.

and recording both gain settings on the calibration form.

During actual examination and scanning, the 1st back reflection shall be maintained at approximately 80%

F.S.H. by read justing the gain setting.

The angle _

beam reference sensitivity, shall be established by 25%

maximizing the tip signal response of the 50%,

and 10% deep I.D.

notches Adjust the maximum peak At this signal to 80% F.S.H. and mark on UT screen.

gain setting mark the maximum amplitudes of the other two notches.

Draw a DAC curve by connecting the three marked peaks and on the calibration form record their amplitudes and sweep positions.

It should be noted that the notch depths do not always compare l

1

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NDT-C-38 R;v 0 June, 1986 Page 13 of 23

Also, exactly with their corresponding hole depth.

i reference sensitivity record the screen height at During actual angle beam examination noise level.

and scanning, a desired noise level (10 to 30% FSH) i shall be maintained by raising or lowering the calibration gain setting.

F.4 Calibration Data Record J

F.4.1 The following data shall be recorded on the calibration data Form.

Calibration sheet identification and date of a.

calibration; b.

Names of examination personnel; Examination procedure number and revision:

c.

Basic calibration block identification and

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d.

temperature:

identification and serial Ultrasonic instrument e.

number; f.

Bean angle, couplant, and mode of wave propagation in the material:

l Orientation of search unit with respect to the j

g.

pipe (longitudinal or circumferential) l identification - frequency, size and l

h.

Search unit Manufacturer's serial number; i.

Special search units, wedges, shoe type, or saddle's identification, if used; j.

Search unit cable type and length:

k.

Times of initial calibration, subsequent calibration checks and final calibration.

Amplitudes and sweep readings obtained form the 1.

calibration reflectors.

4 NDT-C-38 ROY 0 June, 1986 Page 14 of 23 2

G.

Examination Procedure i

G.1 Scannino G.l.1 Scannina Coverage: Scan the examination volume with the sound beam path overlapping each scan by at least 10% of the transducer dimension measured perpendicular to the scan path.

G.1.2 Scannina Speed: The rate of search unit movement shall not exceed six inches per second.

G.l.3 Scannina Sensitivity: When performing straight beam examinations per paragraph C.6 it is recommended to maintain a 80% F.S.H. first back reflection.

Angle beam scanning shall be performed at the relative reference amplitude (Para. F.3.3.) to the extent possible.

Different cast material properties may require raising or lowering the gain to maintain a 10% to 30% F.S.H. noise level which is necessary to ensure a good examination.

The scanning sensitivity (gain) used on each weld shall be recorded on the examination data form.

G.1.4 Scannina Motion: When straight beam examining per paragraph C.6, the search unit shall be moved progressively along and around the weld.

For angle i

s NDT-C-38 I

ESV 0 June, 1986 Page 15 of 23 beam axial and circumferential scanning for coverage oer paragraphs C.3, C.4 and C.5 the search unit shall be moved towards and away from the weld and progressively around the diameter, where possible.

The angle beam search unit should be oscillated slightly (as much as the curved wedge allows) during scanning.

i H.

Recording H.1 Straight beam thickness measurements, and I.D./O.D.

profiling shall be made every 90 (0

90 180*

f and 270 ) around the component diameter and the results recorded on the data sheets with profile plots attached,.

When using the straight beam examination for the detection 1

H.2 of indications which might effect the angle beam examination, the noted indication, other than noise, that have an amplitude equal to or greater than 50% of the initial back reflection and accompanied by a 50% reduction of the initial back reflection shall be recorded.

Also, record the minimum and maximum gain settings needed to l

maintain an 80% FSH initial back reflection.

If there are areas, due to high noise and attenuation, that preclude resolution of the initial back reflection these areas shall be noted in the data report.

i

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s NDT-C-30 R;v 0 June, 1986 Page 16 of 23 For angle beam examination, all indications other than H.3 material noise, that equal or exceed 50% reference (DAC) level shall be recorded.

Also, any indication of any amplitude that the operator believes to be a planar flaw shall be recorded.

For the purpose of establishing sound beam penetration and H.4 geometry indications that are detected below

coverage, I.D.

recording level shall be noted on the data report as a general comment.

I.

Examination Data Record The following data shall be recorded on the examination 1.1 data sheet:

a.

Data sheet identification and date of examination; b.

Names and level of examination personnel; Examination procedure and revision; c.

d.

Applicable calibration sheet identification; Identification and location of weld or volume scanned e.

(for example, marked up drawings or sketches);

f.

Surface from which examination is conducted:

Record of indications or of volume free of indications; g.

Type of examination performed and orientation of search h.

unit with respect to the pipe:

i.

Couplant identification:

).

Pipe size, schedule and material type; k.

Unit and/or pipe system identification:

1.

Pipe temperature.

1

NDT-C-38 R;v 0 June, 1986 Page 17 of 23 1.1.1 For each recordable indication, the following information shall be recorded on the examination data sheet:

a. Give the indication a number and identify the scan in which detected.

b. For each recordable indication, the recording points j

f or the minimum and maximum sweep distances, linear extent and surface distances will be 50% of the maximum signal amplitude at reference sensitivity

c. The reflectors maximum amplitude, as percent of the DAC curve at reference sensitivity.

With the search unit still positioned at this maximum amplitude point, record the sweep distance to the reflector and surface distance (in inches) from the designated reference point (possibly, weld center line) to the search unit exit point.

Again, at this location, record the sweep distance to the reflector and the surface distance from the designated reference point to the search unit exit point, when the signal drops 50% of its maximum amplitude as the search unit is moved toward and away from the reflector.

NDF-C-38 R;v 0 June, 1986 Page is of 23

d. The search unit locations (possibly, distance around the pipe from top dead center) parallel to the 1

reflector at its maximum and start and end points, when the signal amplitude drops to 50% of its maximus amplitude.

This will establish the location and j

linear extent of the reflector.

The examiner shall evaluate, to the best of his ability, 1.2 I

what's causing the recordable reflectors and try to determine their linear extent.

Reflectors, such as possible I.D. geometry, root bead and weld grain boundaries, that are continuous or intermittent (proven by l

raising or lowering the gain) for a given length, shall be recorded as a single indication, with comments.

The examiner shall supply any additional data obtained on indications that are evaluated as planar flaws.

The reference points (usually two) used for locating and I.3 plotting indications shall be designated by the station and the examiner shall identify these points on the data sheet.

The examiner or agency performing ultrasonic examinations I.4 in accordance with this procedure, shall be responsible for filling out the calibration and data sheets correctly and submitting them to the station ISI/ PSI coordinator, within his designated time period.

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I I nenector Fig. 1-1 Linearity AMPLITUDs CONTROL LINEARITT_

SCREEN HEIGHT LINEARITY To verify the ability of the ultra-To verify the accuracy of the sonic instrument to meet the linearity amplitude control of the ultrasonic instrument, as required in F.1.2, requirement of F.1.1, positido as angle beam search unit is shown ja Fig. 1-1 position an angle beam search unit as so that indicatit.n;. can be observed from shouu in Fig. I-1 so that the indication both the 1/2 and 3/4 7 holes in a basic from the'1/2 Y hole in a basic calibrs-calibration block. Adjust the search tion block is peaked on the screen.

unit position to give a 2 to 1 ratio of.

With the increases and decreases in attenuation shown in the following table, amplitudes between the two indications, the indicatica must fall within the with the larger set at SOE of full screen height. Without moving the specified limita. Other convenient reflectors from any calibratico block search unit, adjust sensitivity (sain) any be used with angle or straight beam to successively set the inrger indication from 1001 to 25 et fall search units.

screes height in 101 incr==ames (or fl 2 dB steps if a fine control is not Indicatio available), and read the smaller ladication indication at each setting. The Set at I of d5 Control Limits I i-Ft:11 Screen Chamae Fta11 Scre reading must be SOE of the larger amplitude, within 51 of full tersom 802

- 6ds 32 to 482 height.

The settings sad readings 801

-12 dB 16 to 243 a.ust be estimated to the nearest II

+ 6 dB' 64 to 963 of full screen. Alternatively, a 40E 202

+12 dB 64 to 963 straight beam search unit may be I

used on any calibration block which will provide amplitude The settings and readings must be differences.

estimated to the nearest II of full scree

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NDT-C-38 UI.TRA50NIC CALIBRATION FORM MDT-CF-2 s

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Thio calibration fora wao us:d with precedaro HDT-3 1986 s

Page 20 Date

__ Unit

_ Inspection Calibration Sheet No.

Examiner

_ Level Calibration Standard No.

Transducer S/:I UT Instrument S/N Couplant (lot #):

BEAM SPREAD CAI.CULATIO?l (Hade once per search unit / calibration standard combination 100% DAC 50% DAC-T 50% DAC-A Hole Depth W

Sweep W

Sucep W

Sweep y

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E j

1/4 T A/ //

T = liovina toward reflec.coi

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fkf [/b 0

1/2 T A = Moving away from Jy J

re ector 0

3/4 T

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W = Distance, on the surface, between the transducer index point 100% DAC 50% DAC'-T 50% DAC-A and the center line Hole Depth of the holes U

Sweep W

Sucep Po A // /

lY//

ll T 3/4 T CONTROL LINEARITY CHECK AMP 1,ITUDE T.INEARITY CHECK 100% FSit

-%FSil 50% FSil

%FSH 80% FSit

-6dB (32-48) 90% FSil

%FSH 40% FSH

%FSH 80% FSH -12dB (16-24) j 80% FSH

_%FSH 30% FSH- -

%FSH, 40% FSH

+6dB (64-96) 70% FSil

%FSil 20% FSil

_ZFSil 20% FSII +12dB (64-96) 60% FSil ZFSH AI Reviewed by:

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2_ 2 Juno, 1986 Pogo 21 e

_Rev.

This c:libration form was used with Proceiere NDT-Straight team agle Beas: Asial Cire Calibration Sheet No.

00it No. & Inspectico Dato Level

-Calibration Standard No.

Calibration Standard Thickness Couplant (Lot f):

Temperature TRANS N-DAC CRID Fuv DETECTION U. IT V

10 Size Man:facture; 9

s

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Mod 21

- Freq.

g

_ Serial No._

7 f

Serial No.__

Ang1(_

6 Cable:

Type 5

Length 4

CALIBRA110H DATA 3

l l Reflector I

Hode/Back Rf 3

Sm eM 0

1 2 3

4 5 6 7 8 9 to 0

Calibration Checked:

"P11tude Time E Amp.

ESt88eP Oper.

u gg, "A" Distance PT M.

M. A Dist. b

~ Foint of Block Used _-

TWSTRUWENT CONTW4 Incidence Shee No.

Weld so.

start finish r ns.in. rw.tmen CAIE Reflector Suesp

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Attettu.a150 n _

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Delay Wh 3

SEM ITIVI1T L*

CAIM Demeins Noise. Level

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This date obeet was used with Procedure Ert-Bate Osit No. 4 Inspectime Data Sheet No.

Syetami Wald Type Wald No.

Schedule, Material Pipe Sise tsaminer Level CouplantQat f)

Calibration Sheet Nos IAleve Angle Seeng Asimi

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Pipe Temperatura

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Angle Bean-Along Wald 6) 1Aleve of,Wald 8"**

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PROCEDURE CERTIFICATION Revision:

0 Date: June. 1986 Procedure Number:

NDT-C-38 ProcedureTit15:

Ultrasonic Ernminneinn nf ri,1 1 Panerene4nn Butt Welds in Cast Stainless Components Byron and Braidwood Stations This is to certify that the above titled procedure is in compliance with the

Edition, requirements of the ASME Boiler and Pressure Vessel Code,1977 Summer 1978 Addenda, Section (s) V & XL This procedure has been reviewed, witnessed and approved by:

A A A /A d*-/7 N

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Date Signatur fA NT-T R A Level

Il l-19-Ed hMA

/ % 6? A Date AutheMzEa QA Department 51ghature I, the undersigned, of the holding a valid certificate issued by the National Board of Boiler and Pressure \\

Vessel. Inspectors and/or the State of Illinois, have reviewed the above procedure and find it acceptable.

Date

& No.

Signature of Authorized Inspector 1

u A TTA CHMENT 3 Byron Unit-2 and Braidwood Unit-1 UT Inspection Results Summery Report.

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1 ATTACHMENT B BYRON UNIT 2 RELIEF REQUESTS:

NR-1 Limited ultrasonic examinations were performed on cast stainless steel elbow-to-cast pump or valve welds.

NR-2 Limited ultrasonic examinations were performed on cast stalonless steel elbow-to-reactor vessel nozzle safe-end welds.

NH-3 Limited ultrasonic examinations were performed on cast stainless steel elbow-to steam generator nozzle welds.

NR-12 Limited ultrasonic examinations were performed on cast stainless steel; elbow, pump or valve-to-pipe welds.

J 8360b-5

{

NR-1 Rev. O O

RELIEP REQUEST NR-1 1.

SYSTEM:

Reactor Coolant 2.

NUMBER OF ITEMS:

8 i

Cast Stainless Steel SA-351-CF8A (Elbow) a to Cast Stainless Steel SA-351-CF8 (Pump)

Line Number Weld Number Attachment Numbers 1

2RCO2AA-31" J-8 1&2 2RCO2AB-31" J-8 1&2 2RCO2AC-31 J-8 1&2 2RCO2AD-31 J-8 1&2 Cast Stainless Steel SA-351-CF8A (Elbow)

I to l

Cast Stainless Steel SA-351-CF8N (Valve) i Line Number Weld Number Attachment Numbers 29C01AA-29" J-4 1&3 2RC01AB-29" J-4 1&3 2RC01AC-29" J-4 1&3 2RC01AD-29" J-5 1 &' 3 4

1 3.

ASME CODE CIASS:

1 1

4.

ASME CODE SECTION XI REQUIRBEENTS: Table INB-2500-1, Examination Category B-J, Item 89.11 requires a surface and volumetric examination of the regions described in Figure I W 2500-8 for piping 4 in nominal pipe size and greater.

In addition, Examination Category B-P, Item B15.50 requires a system leakage test in accordance with INB-5221 each refueling outage for all pressure retaining components. Article IWB-2200, "Preservice Examination" states thatt i

a.

Examinations required by this Article shall be completed prior to initial plant startup. In addition, the preservice examinations shall be extended to include essentially 100% of the pressure retaining welds in all Class 1 components except in those components exempted from examination by INB-1220 (a), (b),

or (c).

b.

Shop and fleid examinations may serve in lieu of the on-site preservice examination provided:

1)

In the case of vessels only, the examination is performed after the hydrostatic test required by Section III has been completed; 2) such examinations are conducted under conditions and with O

equipment and techniques equivalent to those that are expected to be employed for subsequent inservice inspections; (0946M/0095M)

i NR-1 Rev. 0 l

3) the shop and field examinations records are, or can be, j

documented and identified in a form consistent with those required in IWA-6000.

5.

BASIS FOR RELIEF: All of the welds listed above are cast austenitic stainless steel to cast austenitic stainless steel. Acceptable radiographic examinations of these welds have been completed to meet the preservice volumetric inspection requirement. However, we do not intend i

to use radiography as the inservice voltanetric examination method.

A "best effort" ultrasonic examination, consisting of the code required i

axial 1/2 V-path scan from both sides of the weld and circumferential 1/2 l

V-path scan along the weld, was completed for each of the above listed i

welds. However, the code required sensitivity was not attainable due to I

the attenuation characteristics of cast austenitic stainless steel. In l

addition, the unwieldy characteristics of the contoured wedge search unit l

and the valve body contour on the O.D. surface presented some limitations j

during the axial scans (except weld J5 on line 2RC01AD-29" which had no j

examination restrictions). Circumferential scans were limited a, short I

distance from the edge of the weld crown for both the valve and pump welds because of the search unit dimensions and the physical shape of these castings. These restrictions precluded the 100% examination coverage as required by the procedure.

l 6.

ALTERNATE TEST METHOD: None.

l 7.

JUSTIFICATION: The examinations perforised on the above listed welds represent the state-of-the-art, best effort, technique available for the l

inspection of cast austenitic stainless steel. The ultrasonic inspection j

technique utilises two 1.0 inch diameter x 1.0 lets transducers, mounted on a contoured wedge search unit, that produce an approximate 41 degree, dual, refracted longitudinal wave focused near the calibration block I.D.

surface. The calibration standards were machined from a representative cast stainless steel elbow. The ultrasonic examination technique was proven capable of penetrating ultrasound to the weld I.D. and detecting large flaws (25% or greater through wall dimension) in the cast material.

Despite the reported limitations, both axial and circumferential scans were capable of locating flaws within the counterbore region as verified by the identification of root and counterbore signals. This counterbore region (See Attachments) closely resembles the ASME Code required examination voltase and thus is the primary area of interest for volumetric flaw detection. The combination of acceptable radiographic examinations and these state-of-the-art ultrasonic examinations assures an acceptably high level of structural integrity for these welds.

O (0946M/0095N)

O O

O 1

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i NR-2 Rev. O RELIEF REQUEST NR-2 1.

SYSTm:

Reactor Coolant 2.

NUMBER OF ITEMS:

4 Cast Stainless Steel SA-351-CF8A (Elbow) to Stainless Steel SA-182 GR-F316 (Safe-end)

Line Number Weld Ntamber Attachment Number 2RC03AA-27.5" J-12 1&2 2RC03AB-27.5" J-12 1&2 2RC03AC-27.5" J-13 1&2 2RC03AD-27.5" J-12 1&2 3.

ASME CODE CLASS:

1 4.

ASME CODE SECTION XI REQUIRMENTS: Table IW3-2500-1, Examination Category B-J, Item B9.ll requires surface and volumetric examination of the regions described in Figure IWB-2500-8 for piping 4 in, nominal pipe size and greater. In addition, Examination Category B-P, Item B15.50 requires a leakage test in accordance with IWB-5221 each refusling outage for all pressure retaining components.

Article IWB-2200 "Preservice Examination" states that:

a.

Examinations required by this Article shall be completed prior to initial plant startup. In addition, the preservice examinations shall be extended to include essentially 100% of the pressure retaining welds in all Class I components except in those components exempted from examination by IWB-1220 (a), (b) or (c).

b.

Shop and field examinations may serve in lieu of on-site preservice examination provided:

1)

In the case of vessels only, the examination is performed after the hydrostatic test. required by Section III has been completed:

2) such examinations are conducted under conditions and with equipment and techniques equivalent to those that are expected to be employed for subsequent inservice inspections; 3) the shop and field examination records are, or can be, documented and identified in a form consistent with those required in IWA-6000.

i Ultrasonic examination requirements from Mandatory Appendix III, Article l

III-4000, require examination for:

a.

reflectors parallel to the weld seam. The angle beam examination for reflectors parallel to the weld seam shall be performed by a full V path from one side or a one-half V path from two sides of the weld, l

where practicable.

I

! (0946M/0095M)

NR-2 O

Rev. O b.

reflectors transverse to the weld seam.

1)

The angle beam examination for reflectors transverse to the weld seam shall be perfcrmed on the weld crown on a single scan path to examine the weld root by one-half V path in two directions along the weld.

2)

For inservice examination, only those welds showing reportable preservice indications need be examined for transverse reflectors.

l 5.

BASIS FOR RELIEF: The welds listed above are all cast austenitic stainless steel to Reactor Vessel nozzle safe-ends. These welds have received radiographic and surface examinations to meet the preservice volumetric and surface examination requirements. However, we do not

(

intend to use radiography as the inservice volumetric examination method.

Ultrasonic examinations were performed circumferentially in both directions for transverse reflectors, and axially for parallel reflectors, from the safe-end side only, on each of the above listed welds.

In addition, a "best effort" ultrasonic examination, consisting of circumferential 1/2 V-path scans of the elbow side base metal, was I

performed. The unwieldy characteristics of the contoured wedge search unit and the as-cast transition on the elbow 0.D. surface prevented O

performance of an axial scan from the elbow side. The elbow side circumferential scans were limited a short distance from the edge of the weld crown due to the inability of the search unit to maintain sufficient coupling while scanning over the weld to base metal transition. The code required sensitivity was, also, not attainable on the elbow side due to the attenuation characteristics of cast austenitic stainless steel. These restrictions precluded the 100% examination coverage as required by the procedure.

6.

ALTERNATE TEST MrrHOD: None.

7.

JUSTIFICATION: The examinations performed from the cast (elbow) side of the above listed welds represent the state-of-the-art, best effort, l

technique available for the inspection of cast austenitic stainless steel. The ultrasonic inspection technique utilizes two 1.0 inch diameter x 1.0 leis transducers, mounted on a contoured wedge search unit, that produce an approximate 41 degree, dual, refracted longitudinal wave focused near the calibration block I.D. surface. The calibration standards were machined from a representative cast stainless steel elbow.

The ultrasonic examination technique was proven capable of penetrating ultrasound to the weld I.D. and detecting large flaws (25% or greater through wall dimension) in the cast material. The circumferential scans were capable of locating flaws in the volume of metal adjacent to the weld, near the I.D. surface. Having performed acceptable radiographic and one-sided ultrasonic (from the safe-end side) examinations as well as the state-of-the-art ultrasonic examination (from the elbow side), an O

acceptably high level of structural integrity for these welds is assured. 60946M/0095JM

OU

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O WELD DETAIL ATTACHMENT 2 NR-2

NR-3 Rev. O O

RELIEF REQUEST NR-3 1.

SYSTEM:

Reactor Coolant 2.

NUMBER OF ITEMS:

8 Cast Stainless Steel SA-351-CF8A (Elbow) to Cast Carbon Steel SA-216 GR-WCC (Nozzle)

Line Number Weld Number Attachment Numbers 2RC01AA-29" F-2 1&2 2RCO2AA-31" F-1 1&2 2RC01AB-29" F-2 1&2 2RCO2AB-31" F-1 1&2 2RC01AC-29" F-2 1&2 2RCO2AC-31" F-1 1&2 2RC01AD-29" F-2 1&2 2RC02AD-31" F-1 1&2 3.

ASME CODE CLASS:

1 1

4.

ASME CODE SEC' TION XI REQUIRFMENTS: Table IWB-2500-1, Examination Category B-F, Item B5.30 requires surface and volumetric examination of the regions D

described in Figure IWB-2500-8 for all Steam Generator nozzle-to-safe end V

welds. In addition, Examination Category B-P, Item B15.30 requires a system leakage test in accordance with IWB-5221 each refueling outage for the steam generator pressure retaining boundary.

Article IWB-2200, "Preservice Examination", states that:

a.

Examinations required by this Article shall be completed prior to initial plant startup. In addition, the preservice examinations shall be extended to include essentially 100% of the pressure retaining welds in all Class 1 components except in those components exempted from examination by INB-1220 (a), (b) or (c).

b.

Shop and field examinations may serve in lieu of on-site preservice examinations provided:

1)

In the case of vessels only, the examination is performed after the hydrostatic test required by Section III has been completed; 2) such examinations are conducted under conditions and with equipment and techniques equivalent to those that are to be employed for subsequent inservice inspections:

3) the shop and field examination records are, or can be, documented and identified in a form consistent with those required in IWA-6000.

Ultrasonic examination requirements from Mandatory Appendix III, Article III-4000, require examination f6r: (0946M/0095M)

NR-3 Rev. O O

e a.

Reflectors parallel to the weld seam. The angle beam examination for reflectcrs parallel to the weld seam shall be performed by a full V path from one side 'or a one-half V path from two sides of the weld, where practicable.

b.

Reflectors transverse to the weld seam.

1)

The angle beam examination for reflectors transverse to the weld -

seam shall be performed on the weld crown on a single scan path to examine the weld root by one-half V path in two directions along the weld.

2)

For inservice examination, only those welds showing reportable preservice indications need be examined for transverse reflectors.

l 5.

BASIS FOR RELIEF: The welds listed above are cast austenitic stainless steel SA-351-CF8A to cast carbon steel SA-216 GR-WCC with austenitic stainless steel cladding. Acceptable radiographic examinations of these welds have been completed to meet the preservice volumetric inspection requirement. However, we do not intend to use radiography as the i

i inservice volumetric examination method.

Ultrasonic examinations were performed circumferentially in both l

directions for transverse reflectors, and axially for parallel reflectors, from the steam generator nossle side with a 1/2 V-path scan. In addition, a "best effort" ultrasonic examination, consisting of the code required axial 1/2 V-path scan from the elbow side and circumferential 1/2 V-path scans along the weld, was completed for each of the above listed welds.

However, the code required sensitivity was not attainable on the elbow side due to the attenuation characteristics of cast austenitic stainless steel. The elbow side circumferential scans were limited a short distance from the edge of the weld crown due to the inability of the search unit to maintain sufficient coupling while scanning over the weld to base metal transition. These restrictions precluded the 100% examination coverage as required by the procedure.

6.

ALTERNATE TEST METHOD: None. (0946M/0095M)

NR-3 Rev. 0

-)

7.

JUSTIFICATION: The examinations performed from the elbow side of the above listed welds represent the state-of-the-art, best effort, technique available for the inspection of cast austenitic stainless steel. The ultrasonic inspection technique utilizes two 1.0 inch diameter x 1.0 MHz transducers, mounted on a contoured wedge search unit, that produce an approximate 41 degree, dual, refracted longitudinal wave focused near the calibration block I.D. surface. The calibration standards were machined from a representative cast stainless steel elbow.

The ultrasonic examination technique was proven capable of penetrating ultrasound to the weld I.D. and detecting large flaws (25% or greater through wall dimension) in the cast material. Despite the reported limitations, both axial and circumferential scans were capable of locating any flaws within the counterbore region as verified by the identification of root and counterbore signals. This counterbore region (See Attachments) closely resembles the ASME Code required examination volume and thus is the primary area of interest for volumetric flaw detection. The combination of acceptable radiographic examinations, acceptable ultrasonic examinations from the steam generator side, and these state-of-the-art ultrasonic examinations from the elbow side assures an acceptably high level of structural integrity for these welds.

/~

l t

' O (0946M/0095M)

O O

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NR-12 Rev. O RELIEP REQUEST NR-12 1.

SYSTEM:

Reactor Coolant 2.

NUMBER OF ITENS:

36 Cast Stainless Steel SA-351-CF8A (Elbow) to Stainless Steel SA-376 Type 304N (Pipe)

Line Number Wald Ntunbers Attachments Numbers 2RCO2AA-31" J-1, J-2, J-3, J-7 1&2 2RCO2AB-31" J-1, J-2, J-3, J-7 1&2 2RCO2AC-31" J-1, J-2, J-3, J-7 1&2 2RCO2AD-31" J-1, J-2, J-3, J-7 1&2 2RC03AA-27.5" J-11 1&2 2RC03AB-27.5" J-ll 1&2 2RC03AC-27.5" J-12 1&2 2RC03AD-27.5" J-11 1&2 Cast Stainless Steel SA-351-CF8 (Pump)

'O to Stainless Steel SA-376 Type 304N (Pipe)

Line Number Weld Numbers Attachment Numbers 2RC03AA-27.5 J-1 1&3 2RC03AB-27.5 J-1 1&3 2RC03AC-27.5 J-l 1&3 2RC03AD-27.5 J-l 1&3 Cast Stainless Steel SA-351-CF8M (Valve) to Stainless Steel SA-376 Type 304N (Pipe)

Line Number Weld Number Attachment Ntspber 2RC01AA-29" J-3 1&4 2RC01AB-29" J-3 1&4 2RC01AC-29" J-3 1&4 2RC01AD-29" J-4 1&4 2RC03AA-27.5" J-5, J-6 1&4 2RC03AB-27.5" J-5, J-6 1&4 2RC03AC-27.5" J-5, J-6 1&4 2RC03AD-27.5 J-4, J-5 1&4 3

ASME CODE CLASS: 1 0 (0946M/0095M)

NR-12 Rev. 0 4.

ASME CODE SECTION XI REQUIREMENTS: Table IWB-2500-1, Examination Category B-J, Items B9.11 and B9.12 require surface and volumetric examination of the regions described in Figure IWB-2500-8 for piping 4 in, nominal pipe size and greater.

In addition, Examination Category B-P, Item B15.50 requires a system leakage test, IWB-5221, each refueling outage for all pressure retaining components.

Article IWB-2200, "Preservice Examination" states that:

Examinations required by this Article shall be completed prior to a.

initial plant startup. In addition, the preservice examination shall be extended to include essentially 100% of the pressure retaining welds in all Class 1 components except in those components exempted from examination by IWB-1220 (a), (b), or (c).

b.

Shop and field examinations may serve in lieu of on-site preservice l

examinations provided:

1)

In the case of vessels only, the examination is performed after the hydrostatic test required by Section III has been completed; 2) such examinations are conducted under conditions t.nd with equipment and techniques equivalent to those that are expected l

to be employed for subsequent inservice inspections; 3) the shop and field examination records are, or can be, documented and identified in a form consistent with those required in IWA-6000.

Ultrasonic examination requirements from Mandatory Appendix III, Article III-4000 require examination for:

a.

Reflectors parallel to the weld seam.

l The angle beam examination for reflectors parallel to the weld seam shall be performed by a full V-path from one side or a one-half 7-path from two sides of the weld, where practicable.

b.

Reflectors transverse to the weld seam 1)

The angle beam examination for reflectors transverse to the weld seem shall be performed on the weld crown on a single scan path to examine the weld root by one-half V-path in two direction along the weld.

2)

For inservice examination, only those welds showing reportable preservice indications need be examined for transverse reflectors. (0946M/0095M)

b O

NR-12 Rev. 0 5.

BASIS FOR RELIEF: The welds listed above are all cast austenitic stainless steel to stainless steel pipe. We have completed acceptable radiographic and surface examinations to meet the preservice volumetric and surface requirements. However, we do not intend to use radiography as the inservice volumetric examination method.

Ultrasonic examinations were performed circumferential1y in both directions for transverse reflectors, and axially for parallel reflectors, from the pipe side with a 1/2 V-path scan. In addition, a "best effort" ultrasonic examination, consisting of the code required axial 1/2 V-path scan from the component (elbow, pump, or valve) side and circumferential 1/2 V-path scans along the weld, was completed for each of the above listed welds. However, the code required sensitivity was not attainable on the component side due to the attenuation characteristics of cast austenitic stainless steel. The axial scans of welds J1 and JS, on lines 2RC02AB-31" and 2RC03AB-27.5" respectively, were limited by 3% due to base metal concavity (J1) and a permanent support (J5). The unwieldy characteristics of the contoured wedge search unit and the valve body contour on the O.D. surface presented some limitations during the axial scans of the pipe-to-valve welds. Circumferential scans were limited a short distance from the edge of the weld crown for all the pipe-to-valve welds, all the pipe-to-pump welds, and three of the pipe-to-elbow welds O

(2RCO2AA-31"/J1, 2RCO2AB-31"/J1, and 2RCO2AC-31"/J3) because of the inability of the search unit to maintain sufficient coupling while scanning over the weld to base metal transition. These restrictions 4

precluded the 100% examination coverage as required by the procedure.

6.

ALTERNATE TEST MFTHOD: None 1

7.

JUSTIFICATION: The examinations performed from the component side of the above listed welds represent the state-of-the-art, best effort, technique available for the inspection of cast austenitic stainless steel. The ultrasonic inspection technique utilizes two 1.0 inch diameter x 1.0 MHz transducers, mounted on a contoured wedge search unit, that produce an approximate 41 degree, dual, refracted longitudinal wave focused near the calibration block I.D. surface. The calibration standards were machined from a representative cast stainless steel elbow. The ultrasonic examination technique was proven capable of penetrating ultasound to the weld I.D. and detecting large flaws (25% or greater through wall dimension) in the cast material. Despite the reported limitations, both axial and circumferential scans were capable of locating flaws within the counterbore region as verified by the identification of root and counterbore signals. This counterbore region (Sec Attachments) closely resembles the ASME Code required examination volume and thus is the primary area of interest for volumetric flaw detection. The combination of acceptable radiographic examinations, acceptable ultrasonic examinations from the pipe side, and these state-of-the-art ultrasonic examinations from the component side assures an acceptably high level of structural integrity for these welds. (0946M/0095M)

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ATTACHMENT C BRAIDWOOD UNIT 1 RELIEF REQUESTS:

INR-2 Limited ultrasonic examinations were performed on cast stainless steel elbow-to-cast pump or valve welds.

1NR-5 Limited ultrasonic examinations were performed on cast stainless steel elbow-to-steam generator nozzle welds.

1NR-6 Limited ultrasonic examinations were performed on cast stainless steel elbow, pump or valve-to-pipe welds.

INR-7 Limited ultrasonic examinationc were pdrformed on cast stainless steel elbow-to-reactor vessel nozzle safe-end welds.

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RELIEF REQUEST INR2 Rev. 2 1.

SYSTEM: Reactor Coolant 2.

NUMBER OF ITEMS: 8 Line Number Weld Number IRCO2AA-31 3RC-01-17 1kC02AB-31 1RC-02-31 1RCO2AC-31 1RC-03-17 1RC02AD-31 1RC-04-18 1RC01AA-29 1RC-01-4 1RC01AB-29 1RC-02-18 1RC01AC-29 1RC-03-4 1RC01AD-29 1RC-04-5 3.

A.S.M.E. CODE CLASS: 1 4.

A.S.M.E. CODE SECTION XI REQUIREMENTS: Table IWB-2500-1, Examination Category B-J, Item B.9.ll requires surface and volumetric examination of the regions described in Figure IWB-2500-8 for piping 4 in nominal pipe size and greater, this examination includes essentially 100% of the weld length.

In addition, Appendix III, Supplement 7, requires that ultrasonic examination sensitivity be established using I.D.

notches with a depth of 10% wall thickness.

5.

BASIS FOR RELIEF: The above listed welds are cast stainless elbows to either cast pumps or cast valves.

The optimized ultrasonic technique used for the statically cast stainless steel welds will detect large flaws (25% or greater through the wall) therefore this sensitivity in less than that required by code.

In addition, due to the unwieldly characteristics of the contoured wedge search units and variations in the machined surfaces, the welds listed above experienced axial and circumferential scanning limitations.

6.

ALTERNATE TEST METHOD: None.

7.

JUSTIFICATION: The structural integrity of these welds has been assured by:

a.

Having performed a best effort ultrasonic exam, based on state of the art techniques, of the cast stainless welds.

b.

Having performed acceptable radiographic and surface examinations.

4 l

0322m(082886) 0885A

RELIEF REQUEST INR-5 Rev d 1.

SYSTEM: Reactor Coolant 2.

NUMBER OF ITEMS:

8 Cast Stainless Steel SA 351-CF8A (Elbow) to Cast Carbon Steel SA-216 GR-WCC (Nozzle)

Line Number Weld Number 1RC01AA-29" 1RC-01-8 1RC02AA-31" 1RC-01-9 1RC01AB-29" 1RC-02-19 1RC02AB-31" 1RC-02-23 1RC01AC-29" 1RC-03-8 1RCC2AC-31" 1RC-03-9 1RC01AD-29" 1RC-04-9 1RC02AD-31" 1RC-04-10 3.

ASME CODE CLASS:

1 l

4.

ASME CODE SECTION XI REQUIREMENTS: Table IWB-2500-1, Examination Category B-F, Item B5.30 requires surface and volumetric examination of the regions described in Figure IWB-2500-8 for all Steam Generator nozzle-to-safe end welds. This examination includes essentially 100%

of the weld length. In addition, Appendix III Supplement 7, requires that ultrasonic examination sensitivity be established using I.D.

notches with a depth of 10% wall thickness.

5.

BASIS FOR RELIEF: The welds listed above are cast austenitic stainless steel SA-351-CF8A to cast carbon steel SA-216 GR-WCC with austenitic stainless steel cladding. The techniques used to examine the cast stainless side of these welds will detect large flaws (25% or greater through the wall) therefore this sensitivity is less than that required by code.

In addition, Weld IRC-02-23 had limited circumferential scans near the weld toe area. This limitation is due to the transducer system's inability to maintain coupling while scanning over the weld-base metal transition.

6.

ALTERNATE TEST METHOD: None.

7.

JUSTIFICATION: The structural integrity of these welds has been assured by:

a.

Having performed a best effort ultrasonic exam, based on state of the art techniques, from the cast stainless side, b.

Having performed an acceptable ultrasonic exam from the carbon steel side, c.

Having performed acceptable radiographic and surface examinations.

0322m(082886) 0885A

l RELIEF REQUEST INR-6 Rev. 2 i

j 1.

SYSTEM: Reactor Coolant 2.

NUMBER OF ITEMS: 36 s

Cast Stainless Steel SA-351-CF8A (Elbow) to i

Stainless Steel SA-376 Type 304N (Pipe)

I Line Number Weld Number 4

1RC02AA-31" 1RC-01-10, 11, 12, 16 IRC02AB-31" 1RC-02-24, 25, 26, 30 1RC02AC-31" 1RC-03-10, 11*, 12, 16 1RCO2AD-31" 1RC-04-ll, 12, 13*, 17 1RC03AA-27.5" 1RC-01-30 IRC03AB-27.5" 1RC-02-12 1RC03AC-27.5" 1RC-03-31 1RC03AD-27.5" 1RC-04-31 Cast Stainless Steel SA-351-CF8 (Pump) to Stainless Steel SA-376 Type 304N (Pipe) 1 l

Line Number Weld Number i

IRC03AA-27.5 1RC-01-18*

1RC03AB-27.5 1RC-02-l*

1RC03AC-27.5 1RC-03-18*

1RC03AD-27.5 1RC-04-19*

Cast Stainless Steel SA-351-CF8M (Valve) to Stainless Steel SA-376 Type 304N (Pipe)

Line Number Weld Number e

1RC01AA-29" 1RC-01-3 1RC01AB-29" 1RC-02-17*

4 1RC01AC-29" 1RC-03-3*

i 1RC01AD-29" 1RC-04-4*

1RC03AA-27.5" 1RC-01-22, 23*

1RC03AB-27.5" 1RC-02-5*, 6*

1 1RC03AC-27.5" 1RC-03-22, 23 1RC03AD-27.5" 1RC-04-23, 24 4

3.

ASME CODE CLASS:

1 I

0322m(082886) i 0885A i

i

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4.

ASME CODE SECTION XI REQUIREMENTS: Table IWB-2500-1, Examination Category B-J, Item B9.ll requires surface and volumetric examination of the-regions described in Figure INB-2500-8 for piping 4 in. nominal pipe size and greater, this examination includes essentially 100% of the weld length. In addition, Appendix III, Supplement 7, requires that ultrasonic examination sensitivity be established using I.D.

notches with a depth of 10% wall thickness.

5.

BASIS FOR RELIEF: The above listed welds are cast stainless steel to wrought stainless pipe. The optimized ultrasonic technique used for the statically cast stainless steel welds will detect large flaws (25%

or greater through the wall) therefore this sensitivity is less than that required by code.

In addition, due to the unwieldly characteristics of the contoured wedge search units and variations in the machined surfaces those welds listed with a asterik, experienced axial and circumferential scanning limitations.

6.

ALTERNATE TEST METHOD: None.

7.

JUSTIFICATION: The structural integrity of these welds has been assured by:

a.

Having performed a best effort ultrasonic exam, based on state of the art techniques, from the cast stainless side, b.

Having performed an acceptable ultrasonic exam from the non cast side.

c.

Having performed acceptable radiographic and surface examinations.

s J

i i

0322m(082886) 0885A

1, -

RELIEF REQUEST INR-7 Rev. 2 1.

SYSTEM: Reactor Coolant 2.

NUMBER OF ITEMS:

4 Cast Stainless Steel SA-351-CF8A (Elbow) to Stainless Steel SA-182 GR-F316 (Safe-end)

Line Number Weld Number 1RC03AA-27.5" 1RC-01-31 1RC03AB-27.5" 1RC-02-13 1RC03AC-27.5" 1RC-03-32 1RC03AD-27.5" 1RC-04-32 3.

ASME CODE CLASS:

1 4.

ASME CODE SECTION XI REQUIREMENTS: Table IWB-2500-1, Examination Category B-J, Item B9.11 requires surface and volumetric examination of the regions described in Figure IWB-2500-8 for piping 4 in, nominal pipe size and greater, this examination includes essentially 100% of the weld length.

In addition, Appendix III, Supplemental 7, requires that ultrasonic examination sensitivity be established using I.D.

notches with a depth of 10% wall thickness..

5.

BASIS FOR RELIEF: The above listed welds are all cast austenitic stainless steel to Reactor Vessel nozzle safe-ends. The optimized ultasonic technique used for the statically cast side of these welds will detect large flaws (25% or greater through the wall) therefore this sensitivity is less than that required by code.

In addition, due to the unwieldly characteristics of the contoured wedge search units and variations in the machined surfaces, the welds listed above experienced axial and circumferential scanning limitations..

6.

ALTERNATE TEST METHOD: None.

7.

JUSTIFICATION: The structual integrity of these welds has been assured by:

a.

Having performed a best effort ultrasonic exam, based on state of the art techniques, from the cast stainless side, b.

Having performed an acceptable ultrasonic exam from the non-cast steel side.

c.

Having performed acceptable radiographic and surface examinations.

0322m(082886) 0885A

ML20209H288

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