ML20213F019
| ML20213F019 | |
| Person / Time | |
|---|---|
| Site: | Hatch  |
| Issue date: | 11/06/1986 |
| From: | Gucwa L GEORGIA POWER CO. |
| To: | Muller D Office of Nuclear Reactor Regulation |
| References | |
| 0816C, 816C, SL-1427, TAC-56540, TAC-60943, NUDOCS 8611130420 | |
| Download: ML20213F019 (117) | |
Text
Georgia Fbwer Company 333 Piedmont Avenue Attanta. Georgia 30308 Telephone 404 526-6526 Mailing Address: A Post Office Box 4545 Atlanta, Georgia 30302 g Georgia Power L T. Gucwa the soutrerrr electre system Manager Nuclear Safety and Licensing SL-1427 0816C November 6, 1986 Director of Nuclear Reactor Regulation Attention: Mr. D. Muller, Project Director BWR Project Directorate No. 2 Division of Boiling Water Reactor Licensing U.S. Nuclear Regulatory Commission Washington, D.C. 20555 NRC DOCKET 50-321 OPERATING LICENSE DPR-57 EDWIN I. HATCH NUCLEAR PLANT UNIT 1 RESPONSE TO NRC REQUEST FOR ADDITIONAL INFORMATION RELATIVE TO SUBCONTRACTOR UT PERSONNEL Gentlemen:
Enclosed herein is Georgia Power Company's response to the NRC letter of September 5, 1986, which requested additional information concerning the qualifications of subcontractors who performed ultrasonic examinations of stainless steel piping and components during the Winter 1985-86 maintenance / refueling outage at Plant Hatch Unit 1. The subject letter indicated that the additional information was necessary to enable the NRC to assess its safety evaluation finding - of April 24, 1986, regarding the qualifications of subcontractor nondestructive examination personnel used during the Winter 1985-86 outage at Plant Hatch Unit 1.
Should you have any questions in this regard, p_ lease contact this office at any time.
Sincerely, y L. T. Gucwa JAE/lc 0 0\
\ I 8611130420 861106 1 DR ADOCK 0500
GeorgiaPower d Director of Nuclear Reactor Regulation Attention: Mr. D. Muller, Project Director BWR Project Directorate No. 2 November 6,1986 Page Two Enclosure
.c: Georc la Power Company U.S. Nuclear Regulatory Commission Mr. t . P. O'Reilly Dr. J. N. Grace, Regional Administrator Mr. J. T. Beckham, Jr. Mr. P. Holmes-Ray, Senior Resident Mr. H. C. Nix, Jr. Inspector-Hatch GO-NORMS 0816C 700775
. Georgia Power b ENCLOSURE ;
NRC DOCKET 50-321 OPERATING LICENSE DPR-57 EDWIN I. HATCH NUCLEAR PLANT UNIT 1 RESPONSE TO NRC REQUEST OF SEPTEMBER 5,1986, FOR ADDITIONAL INFORMATION RELATIVE TO SUBCONTRACTOR UT PERSONNEL USED DURING THE WINTER 1985-86 MAINTENANCE / REFUELING OUTAGE -
PLANT HATCH UNIT 1 NRC Question 1:
"Who were the contractors and what _ examinations were performed by each for SCS?"
Response
The subcontractors used by Southern Company Services,. Inc. (SCS) to perform the ultrasonic examination of stainless steel piping and components during the Winter 1985-86 maintenance / refueling outage at Plant Hatch Unit 1 were Lambert, MacGill, Thomas, Inc. (LMT) and Combustion Engineering (C-E). LMT and _C-E personnel, under the supervision of SCS personnel, performed ultrasonic examinations- on a sample of welds prior to the application of the induction heating stress improvement (IHSI) process and on all welds treated with IHSI, as well as any supplemental examinations for evaluation purposes. In addition, the subcontractors also performed ultrasonic examinations of weld overlays. '
During the subject outage, a total of seventeen LMT inspectors, one C-E-inspector, and four SCS employees completed the scope of IGSCC-susceptible piping and component examinations using SCS Procedure UT-H-400, Revision 5, Deviation 001.
Prior to performing examinations involving intergranular stress corrosion cracking (IGSCC), the subcontractors were given a written examination relative to SCS Procedure UT-H-400, Revision 5, Deviation 001.
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0816C E-1 11/06/86 i
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t g f Georgia Power d ENCLOSURE 7 RESPONSE TO NRC REQUEST OF SEPTEMBER 5,1986, FOR $
ADDITIONAL INFORMATION RELATIVE TO SUBCONTRACTOR UT PERSONNEL USED DURING THE WINTER 1985-86 MAINTENANCE / REFUELING OUTAGE - s ,;
PLANT HATCH UNIT 1 i
., ;. f NRC Question 2:
" Provide the procedures used by each contractor to qualify for IGSCC '
detection and/or evaluation at the NDE Center." ; c
Response
x The following procedures were used by the subcontractors at the EPRI NDE Center for the detection and/or evaluation of IGSCC:
1 EPRI Module 17, Revision 1.
- 2. LMT Procedure UT-10, Revision 11/ Field Change No. 9.
3 LMT Procedure UT-41, Revision 0.
A SCS Level III inspector used SCS Procedure UT-H-400, Revision 5 to qualify at the EPRI NDE Center for the detection and/or evaluation of IGSCC. Subsequent to the qualification, a deviation (Deviation 001 to SCS procedure UT-H-400, Revision 5) was initiated and required that Level II and Level III ul trasonic examination (UT) personnel performing examinations on IGSCC-susceptible piping and components be qualified through the EPRI NDE Center. The technical content of the SCS procedure was not changed as a result of the subsequent deviation to SCS Procedure UT-H-400, Revision 5. ,,
A copy of each of these procedures follows this page.
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ENCLOSURE t
sO RESPONSE TO NRC REQUEST OF SEPTEMBER 5,1986, FOR ADDITIONA G NFORMATION RELATIVE TO SUBCONTRACTOR UT PERSONNEL USED DURI 6 THE WINTER 1985-86 MAINTENANCE / REFUELING OUTAGE -
PLANT HATCH UNIT 1 3
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NRC Question 3:
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" Provide a comparison of the c'ontractor qualification procedures with those used for the examination's at Hatch 1 during the 1985 refueling j
@" outage."
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Response
- . e Ultrasonic examination procedures used by the subcontractors for l qualification at the EPRI NDE Center include the following:
- 1. LMT Procedure UT-10, Revision 11/ Field Change No. 9.
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i 2. LMT Procedure UTJ41 Revision 0.
As noted in the res'po'nse to NRC Question 1, SCS Procedure UT-H-400,
, Revision 5, Deviation ~ 001, was used for weld examinations. All of the "qforementioned procedures are manual contact ultrasonic examination prpcedures written generally to examine thickness ranges from 0.20 in. to i
6.0 in. The aforementioned procedures are all written to Section XI of the ASME Boiler and Pressure Vessel Code. SCS Procedure UT-H-400 and LMT
< Procedure UT-41 were written specifically to comply with the 1980 edition of the ASME Code. LMT Procedure UT-10 was written to comply with the 1977 edition of the Code, while EPRI Module 17 was written to comply with
, s the 1974 edition, plus later editions, of the Code.
- All of the aforementioned procedures reference American Society for Nondestructive Testing document SNT-TC-1 A for personnel qualification.
Equipment requirements vary but generally use an A-Scan presentation and manual search units with the principle angle of 45 degrees and frequencies of 1.5 to 2.25 MHz. SCS Procedure UT-H-400 also requires use of a supplemental 60-degree angle when the weld examination is limited to one side of the weld. . This requirement is to ensure complete coverage of the examination volume, A 2-Vee path calibration using a notch for sensitivity, with a minimum scanning level of +6 dB to +12 dB, is required by LMT Procedure UT-41.
LMT Procedure UT-10 requires using_ a notch for sensitivity with a
} scanning level of +14 dB. SCS Procedure UT-H-400 requires l
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i l 0816C E-3 11/06/86 7: -
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Georgia Power b ENCLOSURE RESPONSE TO NRC REQUEST OF SEPTEMBER 5,1986, FOR ADDITIONAL INFORMATION RELATIVE TO SUBCONTRACTOR UT PERSONNEL USED DURING THE WINTER 1985-86 MAINTENANCE / REFUELING OUTAGE -
PLANT HATCH UNIT 1 sensitivity to be set from the side-drilled holes and a scanning level of
+14 dB, when practical. The EPRI module allows use of side-drilled holes or notches and a scanning sensitivity from +6 dB to +14 dB. In general, the SCS procedure provides a more sensitive examination.
The scanning speed for all four procedures is generally 3.0 in to 6.0 in, per second, with a transducer oscillation of 30 degrees to 45 degrees. It should be noted that the two LMT procedures require a scan at 30 degrees to 45 degrees to the weld, in addition to parallel and perpendicular scans. Al so , transducer overlap is nominally 50 percent for LMT Procedures UT-10 and UT-41, 10 percent minimum overlap of the transducer's width for SCS Procedure UT-H-400, and 10 percent to 50 percent for EPRI Module 17.
Indications which cannot be attributed to noise or geometry are recorded for determination. LMT Procedure UT-41 requires the recording of any reflector greater than 25-percent distance amplitude correction (DAC) curve. SCS Procedure UT-H-400 requires the recording of any geometric reflector greater than 50-percent DAC. All of the procedures addressed in the response to NRC Question 2 require that any flaw, regardless of amplitude, be recorded.
As a general conclusion, all of the procedures discussed herein provide for a similar technique. The major difference between the SCS procedure and the other procedures discussed herein is that SCS Procedure UT-H-400 requires calibration on side-drilled holes which is generally a more sensitive calibration than one performed using the standard notch.
0816C E-4 11/06/86 700775
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Testing. Engineering Service. Training N3 515 Aldo Avenue Santa Clara, CA 95050 408-980-9333 PROCEDURE COVER SliEET AND QUALIFICATION RECORD Procedure No. UT-10 Revision No. 11 P; ocedure Title Ul tra sonic Examination of Nuclea r Coolant System Piping LMT, Inc. QA Review and Approval h o // -/3 - f 2.
(Obality Assurance Officer)
Client Approval Authorized Nuclear Inspector Approval Specific Qualification Record Job Site Component Examiners Date
Lombart o MccGillo Thamas,Inc. PROC. UT-10 Teshng
- Engineering
- Service
- Training PAGE 1 k 515 Aldo Avenue FOLLOWI:lG PAGE 2 i Santc Clara. CA 95050 REVISI0ft 11 408-980-9333 DATE 11/12/82 TITLE: ULTRASONIC EXAMINAT' ION OF NUCLE AR C00L AflT S YSTEM PIPINr, I. PURPOSE AND SCOPE A. Purpose This procedure sets forth the instructions for ultrasonic examination of f ull penetration welds and adjacent base metal in piping and fittings with nominal wall thicknesses of 0.2" through 6.0".
B. Scope
- 1. This procedure is applicable to full penetration circumferential, longitudinal, attachment and branch connection welds in ferritic and austenitic stainless steel materials where successful calibration is achieved .
- 2. This procedure is applicable when a minimum of 1/2 node metal path examination is utilized.
QUALIFICATION: Prepared by: T. G. Lambert Approved for use g
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[Omhj O MacGill o Thsmas,inc. PROC. UT-10
- Testing . Engineering . Service . Training
' 515 Aldo Avenue f[0INGPAGE3 l i Santa Clara, CA 95050 REVISION 11 408-980-9333 0 ATE 11/12/82 1 I. B. 3. This procedure is applicable when remote instrumen-tation is used.
II. REFERENCES A. This procedure is in compliance with the applicable portions of the following referenced documents:
- 1. American Society of Mechanical Engineers Boiler and Pressure Vessel Cods; a) Section V, "Nondestructiv.e Examination, 1977 edition, Sumner 1978 addenda; b) Section XI, " Rules for Inservice Inspection of Nuclear Power P1 ant Components", 1977 edition, addenda through Summer 1978, including Appendix III, " Ultrasonic Examination Method for Class 1 and 2 Piping Systems Made f rom Ferritic Steels."
- 2. American Society for Nondestructive Testing; a) Recommended Practice No. SNT-TC-1A , June 1975,
" Personnel Qualification and Certification in Nondestructive Testing."
- 3. a) LMT Procedure QA-6, " Qualification and Certifi-cation of NDE Personnel ."
b) LMT Operating and Quality Assurance Manual .
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Lombart o MacGill o Thsmos,Inc. PROC. UT-10 PAGE 3 Testing
- Engineering . Service . Training k 515 Aldo Avenue "I"O EA6E 4 1 Santa Claro. CA 95050 REVISION 11 408-980-9333 0 ATE 11/12/82 III. DEFINITIONS None.
IV. RESPONSIBILITY A. The Technical Manager, LMT, Inc., is responsible for the generation and control of this procedure and shall so indicate by a dated signature on Page 1.
B. The responsible Level III Field Supervisor, LMT, or hi s designated Level III alternate, LMT, shall qualify the procedure for a particular examination.
V. PROCEDURE QUALIFICATION The procedure may be qualified for specific examinations, personnel, and equipment by performing and documenting a s uc ces s f ul calibration.
l VI. PERSONNEL REQUIREMENTS A. Personnel shall be qualified and certified according to !
the requirements of ASME XI, SNT-TC-1 A, and LMT, Inc.
Procedure QA-6, " Qualification and Certification of NDE Personnel."
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^ Santa Clara, CA 95050 REVIS10N 11 408-980-9333 DATE 11/12/82 VI. B. Examiners shall be certified Trainee, level I, Level II, or Level III, by LMT, in ultrasonic testing. If Level I personnel are used for angle beam scanning, a Level II must be able to view the resul ts on t} ^ CRT. Trainees may be used to operate recorders and record data.
C. When using a remote ultrasonic master / slave tester system, examinations shall be controlled by a Level II using the master unit and performed by a Level I using the slave unit.
D. Personnel evaluating ultrasonic data or interpreting strip charts shall be certified a minimum Level II, by LMT, in ultrasonic testing.
E. LMT personnel reviewing examination reports for con-formity to the requirements of this procedure shall be certified Level III.
VII. EQUIPMENT AND MATERIAL REQUIREMENTS A. Ultrasonic testers shall be of the pulse echo type. In-struments shall have an amplitude display linear within 5% of calibrated screen height over 80% of that height; and an attenuator, stepped in increments of 2 dB or less, which is accurate over the range of the test to l
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Lombort o MacGillo Thsmas,Inc. "" c "'-to Testing . Engineering . Service . Training 0'. : M G P A G E 6 515 Aldo Avenue i Santa Clara, CA 95050 REVISION 11 408-980-9333 DATE 11/12/82 VII. A. 20% of nominal value. Instruments shall have had thei r internal alignment and calibration verified within 90 days of any impl ementation of thi s procedure.
- 1. A record of calibration shall be available at the jobsite for client audit.
B. The ultrasonic master / slave tester system shall be of the pulse echo type. The master unit shall house the control functions, and the slave unit shall house a scope dis play, telephone communication, and a transducer connection.
- 1. Vertical linearity of 5% of the full screen range over at least 80% of the calibrated screen height shall be required for both the master and slave units.
- 2. Amplitude control accurate over the useful range of the instrument to 20% of nominal value shall apply to the master unit.
- 3. Amplitude controls calibrated in units of 2 dB or less shall apply to the master unit.
- 4. A record of calibration shall be available at the j obsite for client a udit.
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Lomborto MccGillc Th mos,Ince PROC. UT-10 g Testing
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515 Aldo Avenue Santa Clara, CA 95050 REVIS10fl 11 408-980-9333 DATE 11/12/82 VII. C.
Connecting cables shall be coaxial, and their length limited to less than that at which significant signal degradation (2 dB) occurs, but shall not exceed 200 feet.
D. Electronic recording equipment, when used, shall be electronically aligned within 180 days of use.
E. Search units shall be certified by the manufacturer, or LMT, as to essential properties , incl uding bandwidth, damping, center frequency within 10% of nominal, and relative gain.
- 1. Transducers should be selected according to Tabl e 1. Additional search units may be used for evaluation or in unusual circumstances; however, such use shall be documented by an approved Field Change to this procedure as per LMT, Inc. Quality Assurance Procedure QA-5.
Material Angle Beam Thickness Max. Size Max Freq.
Op to .5" 3/8"x3/8" PE or P/C 5.0 MHz Over .5" 1/2 "x1/2" P /C 1.5 MHZ through 2" Over 2" 1"x1" PE or P/C 2.25 f1Hz Table 1
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Testing. Engineering Service. Training PAGE 7 1
FOLLOWING PAGE 8 515 Aldo Avenue l Santa Clara, CA 95050 REV15 ION 11 ,
408-980-9333 DATE 11/12/82 i
VII. E. 2. Angle beam transducer wedges shall provide refracted angles of 45 , 3*, in the calibration block.
a) Refracted angles shall be determined as fol-lows:
- 1) Using an IIW or Rompas block, determine the wedge exit point and angle.
- 2) Position the transducer on' the calibration block for naximum response from the f ar side notch.
- 3) Measure the distance along the block sur-f ace from the side of the notch nearest the transducer to the wedge exit point.
- 4) Calculate the refracted angle using the following fo rmul a :
0 = arc tan h, where t
G = refracted angle h = horizontal distance from notch to exit point t= block thickness b) Other angles or si zes may be used for evalua-tion, and when geometric and weld configuration or wall thickness impede effective use of 45 .
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\ Santa Claro, CA 95050 REVISION 11 408-980-9333 DATE 11/12/82 VII. E. 3. Search unit contact angle beam wedges shall meet the criterion of Table 2 for coverage of attachment weld root areas , as shown in Figure 1, when the ex amina-tion i s limi ted to hal f-node ( hal f-vee path) .
Required Index to Weld Beam Angle Centerline Distance A 45 .93T 60 1.6 T 70* 2.47T Table 2 F. Couplant materials shall be as low as practicable in s ulf ur and halogen content. Certi fication shall be pro-vided on a generic basis for each brand of couplant.
Analysis for halogens and sulfur shall be made according to ASTM D-129-64 and ASTM D-808-63.
- 1. Residual halogens and sulf ur shall not exceed 1% by weight.
- 2. LMT Gel and Ultra-Gel are satisfactory couplants.
G. Calibration blocks shall be of the form as described in ASME XI (1977), Appendix III, Summer 1978 addenda.
Calibration blocks shall be of the same nominal si ze ,
thickness, material, and surface finish as the area of
Lombart o MacGillo Thamos,Inc, Pa0C. uT-10 Testing
- Engineering
- Service
- Training F 0 ING PAGE 10 <
515 /udo Avenue '
i' Santa Claro, CA 95050 REVISION 11 408-980-9333 OATE 11/12/32 VII. F. m aj o r interest in the material to be ex amined (Fig-ure 2).
- 1. Calibration notches shall be one inch long, not more than one-quarter inch wide, and a depth selected according to Table 3.
Nominal Pipe Wall Notch Depth Thickness, t, in. (d) in. Tolerance Less Than 0.312 .05t +10%
-20%
0.312 to 6.0 .05t +10%
-20%
Table 3
- 2. Calibration holes for use in half-node examinations only shall be drilled perpendicular to the ends of the block to the centerline of the pipe, one and one- hal f inches deep. The diameters and location shall conform to Table 4.
Lombart o MacGillo Thrmas,inc. "" ' "'-
Testing
- Engineering Service
- Training fo 011 NG PAGE 11
' 515 Aldo Avenue Santa Claro, CA 95050 REVISION 11 408-980-9333 DATE 11/12/82 VII. F. 2.
Pipe Wall (T) Hole G Hole location 1 i n. or Less 3/32" 1/2T over 1 in. 1/8 " 1/4T and 3/4T through 2 in.
over 2 in. 3/16" 1/4T, 1/2T and through 4 i n. 3/4T over 4 in. 1/4" 1/4T, 1/2T and through 6 in. 3/4T Table 4
- 3. Other reflectors may be included in block designs for informational purposes.
VIII. PREPARATION A. Documentation
- 1. The following preliminary documentation requirements shall be reviewed by the examiner with the client for review before beginning any examination program:
a) Procedure Qualification b) Calibration Sheets i
c) Inspection Reports d) Material and Equipment Certifications
Lombart o MocGillo Thsmas,Inc. "" ' "'-
Testing . Engineering . Service . Training 515 Aldo Avenue $0WNGPAGE12 1' Santa Clara, CA 95050 REVISION 11 408-980-9333 DATE 11/12/82 VIII. A. 1. e) Personnel Certifications f) NRC Form 4 (Operating Nuclear Plants Only) g)
NRC Form 5 (Operating Nuclear Plants Only) h) Status Indicators (Hold Tags) i) Radiation Work Permits (when applicabl e)
- 8. Physical Preparation
- 1. The following physical preparation requirements shall be reviewed by the examiner with the client before specific examinations are performed:
a) Ins ul ation removal b) OSHA requirements (ladders, lighting, fresh air, scaffolding, etc.)
c) Cleanup requirements d) Sa fety precautions (other work in area, etc.)
C. Surf ace Preparation
- 1. Responsibility It shall be the responsibility of the Level II ex aminer to determine the need for surf ace prep-aration.
- 2. Surface shall be suf ficiently smooth and clean so that a meaningf ul examination may be performed.
- 3. Welds shall be identified and all required marking procedures completed before performing any examina-tions.
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Lombart o MacGillo j
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Testing
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- Service Training PAGE 12 FOLLOWING PAGE 13 515 Aldo Avenue Santa Clara, CA 95050 REVISION 11 408-980-9333 0 ATE 11/12/82 IX. LIMITATIONS
- 1. This procedure i s based on ASME Nuclear Requirements; it may not be applicable to military, API, or AWS require-ments without modification.
- 2. The procedure is limited to carbon and austenitic steels unless specifically qualified for other materials.
X. CALIBRATION A. Test calibration is performed on a complete system. Any change in the ultrasonic instrument, transducer cabl e, or transducer requires test recalibration. A change in qualified personnel, recording instrumentation, or recorder connection cable requires a calibration check; however, instrument alignment veri fication need not be made with the transducer used for testing.
B. Instrument alignment verification for screen height and amplitude control linearity shall be performed before the initial examination in any given series and repeated on a daily basis. '"
- 1. Instrument Linearity Verification a) Position the angle beam search unit on a cali-bration block to obtain two echoes with a 2:1 amplitude ratio.
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Lombart o MccGillo Th2 mas,Inc. "R oc "-t o Testing
- Engineering . Service . Training 515 /udo Avenue
[L[0 NG PAGE 14 1
Santa Clara, CA 95050 REVISION 11 408-980-9333 DATE 11/12/82 X. B. 1. b) Set the larger echo to 80% of calibrated screen-height.
c) Vary the amplitude of the larger echo from 100%
to 20% of calibrated screen height in 10% incre-ments.
d) Note that at each increment the smaller echo remains 1/2 the larger within a tolerance ' band of 5% of f ull screen height.
e) Record s uccessf ul performance of the verifica-tion on a Calibration Report form (Figure 3).
- 2. Attenuator Linearity Verification a) Position the search unit to obtain an 80% of f ull scale echo on the calibrated screen.
b) Adjust the sensitivity control to decrease the system gain by 6 dB and 12 dB. Compare the response with Table 5 and determine its accept-ability. Estimate system response to 1% of calibrate full scale.
c) Position the search unit to obtain a 40% of full scale echo on the calibrated screen.
d) Adjust the sensitivity control to increase the system gain by 6 dB. Compare the response with Table 5 to determine its acceptability. Esti-l I
i Lambort o MacGillo Thamas,lnc. ea C. uT-10 '
Testing Engineering. Service. Training 515 Aldo Avenue f0L0 NG PAGE 15 '
i' Santa Clara, CA 95050 REVISION 11 408-980-9333 DATE 11/12/82 X. B. 2. d) mate system response to 1% of calibrated f ull screen.
e) Position the search unit to obtain a 20% of f ull scale echo on the calibrated screen.
f) Adjust the sensitivity control to increase the system gain by 12 dB. Compare the response with Table 5 to determine its acceptability.
Estimate system response to 1% of calibrated f ull scale.
g) Record successful performance of the verifica-tion on a Calibration Report fo rm (Figure 3) .
Indication Gain Indication Tolerance Set Change Limits 80% -6 dB 32% to 48%
80% -12 dB 16% to 24%
40% +6 dB 64% to 96%
20% +12 dB 64% to 96%
Table 5
- 3. The remote ultrasonic matter / slave tester system instrument performance shall be verified before each day's examination.
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' Lombart o MccGillo Thsmos,Inc. "" c "'-
Testing . Engineering . Service . Training F 0 NG PAGE 16 515 Aldo Avenue 1' Santa Clara, CA 95050 REVISION 11 408-980-9333 DATE 11/12/82 X. C. Examination Calibration
- 1. Straight beam examination scans are optional. When used, straight beam ex amination scans shall be cal-ibrated at the same time of examination on a repre-sentative sample of the material ex amined by pl ac-ing the first back reflection at 80% amplitude and four sweep divisions.
- 2. Angle Beam Examination (Axial Scarning)
Calibration is performed on a complete system on an appropriate basic calibration block at the begin-ning of each day's testing of the material.
a) Calibration shall be performed on a calibration block whose temperature is within 25 F of the material to be examined, b) Set the sweep range on the calibrated tester screen according to Table 6.
Thickness I.D./0.0.
(T) Metal Path Points Up to 1/2" 2-1/2 Vee Paths 2,4,6,8,10 Div.
1/2 " - 1 " 2 Vee Paths 2.5,5,7.5,10 Div.
1"-2" 1-1/2 Vee Paths 3,6,9 Div.
>2" 1 Vee Paths 4,8 Div.
Cast Stain- 1/2 Vee Path 8 Div.
less - or Clad Pipe Table 6
Lomb3rt o MccGillo Thomas 5 Inc.
Testing. Engineering Service. Training PAGE 16 F O L LO*.II rlG P A G E 17 1' 515 Aldo Avenue Santa Claro, CA 95050 REVIS10N 11 408-980-9333 0 ATE 11/12/82 X. 2. c)
C. For ex aminations utilizing metal paths greater than one-half node, test sensitivity at any range is established by setting the amplitude of the nearest circumferential notch echo to 80% of f ull calibrated scale. The responses from the remaining circumferential notch echoes in the test region shall then be obtained at this sensitivity, joined together in a smooth DAC curve on the tester f ace, and similarly recorded on the Calibration Report form (Figure 3). The DAC curve so generated is the Primary Re ference Level .
d) For examinations utilizing a half-node metal path, DAC curve shall be generated using the side drilled holes in a basic calibration block so that the maximum hole response is set to 80%
calibrated screen height. This response shall be obtained with the transducer centerline aligned with the hole half length and the beam perpendic ular to the SDH, to prevent possible erroneous corner responses. The DAC shall be clearly marked on the tester face and smoo t hl y extrapolated to cover the full examination
Lambort o MccGillo Thsmos,inc. "R oc "-t o Testing Engineering. Service. Training 515 Aldo Avenue F$0tlINGPAGE18 l Santa Clara, CA 95050 REVISION 11 408-980-9333 D ATE 11/12/82 X. C. 2. d) range, 0 to T inches. The DAC shall also be recorded on the Calibration Report form (Figure 3). The DAC curve is the Primary Reference Level, e) After the Primary Reference Level has been es-tablished on the basic block, a calibration reference response may be established on a Rompas or other standard reference block. The response should include both sweep and ampli-t ude calibration points and should be recorded as a calibration check response on the Calibra-tion Report f o rm . This response may be used for calibration check when an appropriate basic block is not ava il abl e.
- 3. Angle Beam Examination (Circunferential Scanning)
The angle beam calibration required for axial scan-ning, (X.C.2), i s considered acceptable for circum-ferential scanning if the amplitude of the axial l calibration is within 2 dB of the the amplitude obta.ined from the axial notch echoes and its sweep i location is within 10% of the calibrated reference l
response value recorded on the calibration sheet.
If these tolerances cannot be met, a compl ete new l
l i
Lambert o MacGill
- Thomas,Inc. PROC. UT-10 i Testing
- Engineering
- Service
- Training PAGE 18
%5d2 515 Aldo Avenue FOLLOWING PAGE 19 IV Santa Claro, CA 95050 REVISION 11 408-980-9333 0 ATE 11/12/82 X. C. 3. calibration is required following the requirements of X.C.2 of this procedure.
- 4. When using the remote ultrasonic master / slave test-er system amplitude peak responses on the slave unit shall agree with the master unit within 20% of f ul l scale height and within 5% of sweep range full sc al e .
XI. PERFORMANCE A. Straight Beam Scan
- 1. The material through which angle beam sound will travel during the examinations may be examined with l ongi tud i nal beams for thickness information, geom-etry, weld locations and l aminations to supplement the angle beam examinations.
- 2. A Rectilinear scan pattern shall be used.
B. Calibration Check
- 1. A calibration check is required before and after each examination and with any change in test per-sonnel. In no case shall a calibration check exceed four hours.
2.
The calibration check shall as a minimum consist of verification of the DAC curve by a two-point am pl i-t'ude and range check using the basic calibration block or a portable block such as the calibration
Lambcrtc MacGilloTh mas,Inc. PR OC . H-10 PAGE 19 Testing
- Engineering
- Service
- Training hd2 FOLLOWIf4G PAGE 20 515 Aldo Avenue 1' Santa Clara. CA 95050 REVIS10ft 11 408-980-9333 0 ATE 11/12/82 XI. B. 2. block or a portable block such as the Rompas whose response has been related to that of the basic block.
a) The amplitude response of the reference reflec-tor during the calibration check shall be with-in 2 dB, and its sweep location within 10%
of the calibration reference response value recorded on the calibration sheet to be accept-abl e, b) An unacceptable calibration check shall be cause for f ull examination of the test system to determine the reason for the calibration change. Typical causes for calibration change are ambient temperature effects on transducers and electronics, control settings inadvertently changed, and loss of couplant between the transducer and wedge. If, in the judgment of the examiner, the cause of the calibration change has been corrected or may be compensated for by a change in control settings, calibra-tion may be restored using the calibration check response.
/
Lombert o MacGill c Thomas,Inc. "oc "'-t o l l Testing
- Engineering . Service . Training F $0W tlG PAGE 21 ,
' 515 Aldo Avenue Santa Clara, CA 95050 REVIS10ti 11 408-980-9333 DATE 11/12/82 XI. B. 2. c) Any examination that has been performed in a non-calibrated condition shall be repeated.
C. Sensitivity The scanning sensitivity shall be a minimum of 2x (6dB) greater than the reference sensitivity level.
D. Coverage
- 1. Each area shall be scanned with a nominal 15%
overlap of the transducer width (diameter) for each scan path. In no case shall transducer overlap be less than 10%.
- 2. For angle beam examinations the search unit shall be oscillated + and - 45 degrees to ensure maximum coverage.
- 3. Any obstruction or other condition preventing full coverage of the examination shall be recorded on the examination report.
E. Scanning Speed Scanning speed shall not exceed four inches per second.
F. Limitations Physical or other limitations that prevent f ul l c om-pliance with the requirements of this procedure shall be recorded on the Examination Report form, Figure 4.
~ Lomb rto MacGilloThrmas,Inc. PROC. UT-10 Testing . Engineering . Service . Training N tV 515 Aldo Avenue Santa Claro, CA 95050 0 NG PAGE 22 REVISION 11 408-980-9333 DATE 11/12/82 XI. G. Automatic Alarms Automatic alarms or recording may be used as an aid to the examiner.
XII. EVALUATION A. Recording of Indications
- 1. Evaluation shall be at the Primary Reference (DAC)
Sensitivity.
- 2. Evaluate and record all reflectors.
a) Indications shall be evaluated and recorded to the extent that the examiner can determine their si ze, shape, identity and location.
- 3. Any indication determined to be non-geometric shall be recorded, regardless of si ze, on the form shown in Figure 5.
B. Reference System for Reportina Indications The reference system of Figure 6 shall be used to 10-cate indications.
C. Acceptance Criteria The acceptance criteria contained in Paragraph IWB-3514 of ASME XI,197 7, Summer 1978 addend a , and s ummari zed in the tables drawn in Figures 7 and 8 may be used as a guide for acceptance.
~ Lambort o MacGillo Thsmos,Inc. "" c "'- o Testing
- Engineering
- Service
- Training OW flG PAGE 23 515 Aldo Avenue 1 l Santa Clara, CA 95050 REVISI0ft 11 i 408-980-9333 DATE 11/12/82 XIII. RECORDS A. A Report of Visual and Ultrasonic Examination (Fig-ure 4) shall be prepared for each item examined, and shall be related to a Report of Ultrasonic Calibration (Figure 3).
B. Oscillograph chart records shall be made of all angle beam examinations.
- 1. Chart records used 'in indication analysis shall utilize two channels, one corresponding to vertical deflection of the tester signal and the other to hori zontal . These channels shall be calibrated to match the oscilloscope display. That is, an indi-cation 90% of vertical amplit ude appearing at five divisions on the tester screen should have a nine division deflection on one chart channel and a five division deflection on the other.
- 2. Chart records shall include pre and post test cali-bration checks made at the same scanning speed as the test.
- 3. Location and other pertinent information shall be manually noted on each chart.
Lombart o MccGillo Thamos,Inc. PROC. UT-10 E
Testing
- Engineering . Service . Training 515 Aldo Avenue LO NG PAGE 24 i Santa Clara, CA 95050 REVISION 11 408-980 9333 DATE 11/12/82 XIII. B. 3. a) Pertinent in formation incl udes , but is not limited to date, time, item, equi pme n t , exam-iners, scans, gain, and recorder settings and speed.
C. Alternate Recordings Other types of recording, such as event or alarm moni-toring and magnetic taping may be used as an aid to the examiner where feasible.
XIV. REVIEW A. Examination Reports shall be subject to review by an assigned LMT Level III examiner for conformity to the requirements o f t hi s procedure.
B. Foll owing the final LMT review, the reports will be transmitted for review by the client and the Authorized Nuclear Inspector.
XV. DOCUMENTATION STORAGE AND DISTRIBUTION A. Original examination documentation shall become the property of the client upon sign-of f by the ISI Field Coordinator. Additional reports which may incl ude examination documentation as reference material shall be generated from copies.
1
Lambart o MacGill o Thsmas,Inc. "" c-
,,,s ,"'-
Testing
- Engineering
- Service
- Training
'FOLLOWING PAGE 25 515 Aldo Avenue 1 Santa Claro, CA 95050 REVISION 11 408-980-9333 0 ATE 11/12/82 XV. B. Field storage facilities shall provide a safe storage area, and access to files shall be limited to the LMT Field Supervisor, his designated representatives, client representatives and the Authorized Nuclear Inservice Inspector.
i l
Lambort o MacGill o Thomas,Inc. PROC. U -10 Testing
- Engineering
- Service
- Training ,]GL Ok 515 Aldo Avenue iG PAGE 26 )
1' Santa Clara, CA 95050 REVIS10ft 11 i
1 408-980-9333 0 ATE 11/12/82 i
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Page of REPORT OF ULTRASONIC CALIBRATION S
Examiner / Level Examiner / Level Review / Level N Authorized Inspector Customer Instrument S/N ReCal Due Cable Recorder S/N ReCal Due E Recorder S/N ReCal Due Vertical Linearity Check Check Completed _.
sional 1 !100 on an 7n sn sn an 20 U in 10 Sional 2 i I
Signal 2 shall equal 50% of Signal 1 f5% of full scale Attenuator Linearity Check Check Completed P
To.cor n2in c.* '
-6 -12 lsat +12 Signal Amp. set +6 80% 32 to 48 16 to 24 !20% 64 to 96 40% 64 to 96 Actual Value M M >DO<
E Signal amplitude must fall within listed values Transducers N
S/N Mfg. Type Size Freq.
T Index Angle S/N Mfg. Type Size Freq. Index Angle S/N Mfg. Type Size Freq. Index Angle S/N Mfg. Type Size Freq. Index Angle P
R Procedure O Rev. Date C
Cal. Block Type S/N Ref. Refl.
C Temp.
l Verification /Ref. Blk. S/N Ref. Refl. Temp.
A L
DAC Cal. Check I Instrument Settings Time 10 B
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R Gain A sweep T Delay I Reject 4 O Damp.
2 N
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PROC . UT -10 PAGE 28 FOLLOWING PAGE 29 LMT-uTx2 10/79 i Location Lambert
- MacGill
- Thomas,Inc.
'T' Repo,t No.
Testing Engineering
- Service Training c,1,3,, 71,,
515 Aldo Avenue I i Santa Clara, CA 95050 Job No-408-980-9333 o,t, Page of
, REPORT OF V77UAL AND ULTRASONIC EXAMINATION f
E Description Size Material S/N ( s)
M Location Preparation Temp S
I Examiner / Level Examiner / Level Review / Level G
N Authorized Inspector Customer E
g Tester 1 S/N 2 S/N U Recorder 1 S/N 2 S/N I
p Transducer 1 2 M 3 4 E
Couplant Cable Marker Photo P Calibration Procedure Rev.
R Examination Procedure Rev.
C Recording Procedure Rev.
C g Calib. Blk. Temp. Ref. Amp. Sweep L Ref. Gain Damp. Reject Gate Alarm Mag. Tape Count Chart Cal. Check Time Cal. Ref. Blk. Ref. Refl. Amp. Sweep Position Scan Gain Ref. Dwg. Reject Level Report Level E
NAD = No Apparant Disc. L = Linear G = Geometry S = Spot M = Multiples X '
i Scan Type Disp. Scan Type '
A Disp. Scan Type Disp.
I O PT i l
M 1 visual 7 ! 13 I Base Metal 8 , 14 3
9 l 15 N 4 i 10 ! 16 5
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12 l 18 T _
Scan Description of Indications I
O N
Sketch Figure 4
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Lamborto MacGillo Thamas5 Inc.
Testing. Engineering Service Training Report No.
515 Aldo Avenue Job No.
1 Santa Clara, CA 95050 Date 408-980-9333 Patie o' ULTRASONIC INDICATION DATA TABULATION I. INDICATION NO. SCAN NO.
II. MAXIMUM AMPLITUDE DATA
- 1. Ampl itude i
- 2. Percent DAC
- 3. Sweep Metal Path
- 4. Transducer Position III. INDICATION LENGTH
- 1. Length measured between % DAC limits
- 2. Indication length
- 3. Transducer position IV. INDICATION CROSS SECTION DATA AT INTERVALS ALONG THE INDICATION'S LENGTH BETWEEN % DAC POINTS
- 1. Reference is from weld O' and weld centerline (or)
Reference is
- 2. Transducer perpendicular to indication.
TRANSDUCER M[N SWEEP MAX AMPLITUDE MAX SWEEP POSITION DISTANCE ALONG SWP MP POSIT AMP SWP MP POSIT SWP MP POSIT DEPTH FROM l INDICATION l SURFACE l
1 1
Figure 5 Examiner Contractor Review signature LeveT Asst. Examiner Signature Level l
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TABLE IWG-3514 2 ALLOWABLE P1 ANAR INDICATIO*.S Material: Femt.c steels ti .it mi et the reamrrm.nts (t N 12300 and speofeed fusnamum yet to strt ngth ef 50 ku or less at 400 F I
Voauenetric Enem.. .t on Method .
Surface Nominal Wall Theckness i b arn.na tion
- t. In . 0 312 or less8 10 2.8 38 4 8 and ovee Method Aspect Ratso, Surface Subsurface Surface Sutmerface Surface Subsurface Surface Subsurface Surface Subsurface Nom Wall Indic louecation, Indicateon. Indecateon. Ind cat.on. Indicatson. Ind cation. .todecation. Indecatson. Indication. Indica tion.
af/' a tt. % at %8 at % at %8 Thech ness. Length, at % at %8 at % at. %8 at % at %8 f. in. I. in.'
Preservice Eaamination 0 7.4 92 6.7 to 5.7 7.2 4.7 58 3.7 0 05 79 96 7.2 46 87 62 7.5 50 6.1 0 10 8.7 10 4 79 40 48 0 312 or iess is 95 68 81 55 66 0.15 96 11 5 88 43 52 10 5 7.5 90 61 7.3 0 20 96 11 5 v3 48 58 10 . 3.16 11 8 C4 10 1 69 82 54 65 0 25 96 11 5 39 11 8 95 0 30 11 4 78 93 61 73 20 14 96 11 5 99 11 8 95 0 35 11 4 88 10 5 69 82 96 11 5 99 11 8 95 11 4 0 40 88 11 8 69 93 30 14 96 11 5 39 11 8 95 11.4 88 11 8 69 10 4 0 45 9.6 11.5 99 11 8 95 0 50 11.4 88 11.8 6.9 11.6 4 0 and over 14
. 96 11.5 99 11 8 9.5 11 4 88 11.8 69 11.6 basernce Examination
- 0. 11.1 13 8 10 0 12 6 85 10 8 70 87 55 69 0 05 11 8 14 4 10 8 13 0 93 0 10 11.2 75 9.1 60 7.2 0.312 or iess 02 13 0 15 6 11 8 14 2 10 2 12.1 8.2 99 64 78 0 15 14 4 17.2 13 2 15 7 11.2 13 5 91 10 9 7.2 8.7 10 03 0 20 14 4 17 2 14 8 17 7 12 6 15.1 10 3 12 3 81 97 0 25 14 4 17 2 14 8 17 7 14 2 17.1 11 7 13 3 91 10 9 20 030 14 4 17 2 14 8 17 7 06 ,
14 2 17.1 IJ 2 15 7 10 3 12 3 0 35 14 4 17 2 14 8 17 7 14 2 17.1 13 2 17.7 10 3 13 9 30 0 40 14 4 17 2 14 8 17 7 08 14 2 17.1 13 2 17.7 10 3 15 6 0 45 14 4 17 2 14 8 17 7 14 2 17.1 13 2 17.7 10 3 17 4 0 50 14 4 17 2 14 8 4 0 and over 08 17 7 14 2 17.1 13 2 17 7 10 3 17 4 NOTES:
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-+ # Testing
- Engineering
- Service Training i '. 515 Aldo Avenue Santa Clara, CA 95050 408 980-9333 PROCEDURE COVER SHEET AND QUALIFICATION RECORD Procedure flo. 41 Revision No. O Procedure Ti tle ULTRASONIC EXAMINATION OF NUCLEAR COOLANT SYSTEM PIPING FOR INTERGRANULAR STRESS CORROSION CRACKING (IG LMT, Inc. QA Review and Approval < 2- ,
(Qualf ty AIsurance Of ficer) f Client Approval Authorized Nuclear Inspector Approval Specific Quali fica tion Record Job Si te Component Examiners Date i
LOmhj O MccGill o Thamas,Inc. ea0C. Ur-41 Testing . Engineering . Service . Training PAG F 515 Aldo Avenue Santa Clara. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 TITLE:
ULTRASONIC EXAMINATION OF NUCLEAR C0OLANT SYSTEM PIPING FOR INTERGRANULAR STRESS CORR 0SION CRACKING (IGSCC)
I. PURPOSE AND SCOPE A. Purpose This procedure provides instructions for the implementa-tion of NRC Bulletin 83-02 (March 4, 1983) for the con-tact angle beam ultrasonic examination of full penetra-tion butt welds in stainless steel piping, including heat affected zones near attachment welds.
B. Scope The procedure is applicable to austenitic steels and in-conel where successful qualification is achieved. This procedure is further limited to piping systems having nominal wall thickness of 0.35" to 2.0". The examina-tions shall be performed from the outside surfaces, and may be performed manually or with automatic scanning devices.
II. REFERENCES A. This procedure is in compliance with the applicable por-tions of the following reference documents:
QUALIFICATION: Prepared by: .E.L. Thomas Approved for use hx e'
Lombarto MccGillc;Th mas,Inc. "" c "'-4 y Testing
- Engineering. Service Training
= NGE AE 515 Aldo Avenue Santa Clara, CA 95050 REVISION 0 ,
408-980-9333 DATE 07/23/85 II. A. 1.
, NRC IE Bulletin 83-02 " Stress Corrosion Cracking in large Diameter Stainless Steel Recirculation System Piping at BWR Plants".
- 2. ASME Boiler and Pressure Vessel Code,Section XI, 1980 Editien, including Addenda through Winter 1981.
- 3. American Society far Nondestructive Testing; a) Recommended Practice No. SNT-TC-1A, " Personnel Qualification and Certification in Nondestruc-tive Testing" 1975 and 1980 editions.
- 4. a) LMT Procedure QA-6, " Qualification and Certifi-cation of NDE Personnel."
b) LMT Operating and Quality Assurance Manual.
III. DEFINITIONS None.
IV. RESPONSIBILITY A. The Technical Manager, LMT, Inc., is responsible for the generation and control of this procedure and shall so indicate by a dated signature on Page 1.
B. The responsible Level III Field Supervisor, LMT, or his designated Level III alternate, LMT, shall qualify the procedure for a particular examination.
~ Lombart o MccGillo Thsmas,Inc. " Roc "T-u Testing
- Engineering
- Service
- Training PAGE 3 0F 515 Aldo Avenue 38 PAGES IV Santa Claro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 V. PROCEDURE QUALIFICATION The procedure may be qualified for specific examinations, personnel, and equipment by performing and documenting a successful calibration.
VI. PERSONNEL REQUIREMENTS A. Personnel evaluating tests results shall be qualified and certified according to the rules of SNT-TC-1A, LMT, Inc. Procedure QA-6, " Qualification and Certification of NDE Personnel", and must have succesfully completed the EPRI IGSCC Detection Practical examination.
B. Personnel used for scanning shall be certified a mini-num level I, by LMT, in ultrasonic testing, and shall have demonstrated proficiency in scanning and measuring techniques. An EPRI qualified Level II or Level III must be in full view of a CRT at all times during exami-nations, except in cases of initial IGSCC qualification or for purposes of demonstration.
C. LMT Personnel reviewing examination reports for conform-ity to the requirements of this procedure shall be cer-tified i.avel III.
Lombart o MacGillo Thomas,Inc. ""
y Testing
- Engineering
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- Training
,,f,"o';"
m 38 PAGES 515 /udo Avenue Santa Cloro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 VII. EQUIPMENT AND MATERIAL REQUIREMENTS A. Instruments shall be of the pulse echo type. Instru-ments shall have an amplitude display linear within 5%
of calibrated screen height over 80% of that height; and an amplitude control, stepped in increments of 2 dB or less, which is accurate over the range of the test to 20% of nominal value. Instruments shall have had their internal alignment and calibration verified within three months of any implementation of this procedure.
1.
A record of calibration shall be available at the jobsite for client audit.
B. Connecting cables shall be coaxial, and their length limited to less than that at which significant signal degradation (2 dB) occurs, but shall not exceed 200 feet.
C. Electronic recording equipment, shall be electronically aligned within 180 days of use.
D. Search units shall be certified by the manufacturer or LMT as to essential properties, including bandwidth, damping, center frequency within 10% of nominal, and relative gain.
- 1. The nominal beam angle for full vee-path examina-tions shall be 45*.
' Lemborto MccGilloTh mas,Inc. PROC. UT-41 Testing
- Engineering
- Service
- Training P GE F ,
515 Aldo Avenue Santa Clara, CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 VII. D. 2. A record of search unit properties shall be availa-ble at the jobsite for client review.
- 3. The angle beam search unit wedges shall be checked prior to each day's use to determine actual beam angle when checked in the calibration blockby using the formula:
Beam Angle = Arc Tan A T
(where A==Depth (whereT surf ace distance to reflector) of reflector)
The actual beam angle shall be recorded and shall be within 2 of the required angle to be acceptable for initial or further use.
- 4. The results of examinations performed with angle beam search units which meet the above requirement are acceptable provided the search unit beam angle on subsequent checking is within 3 of the required angle. Should this tolerance not be met on subse-quent checking, determination of the need for re-examination shall be made and the basis for the decision documented.
' Lombart o MccGill o Thsmas,Inc. ""c"'"
" GE Testing
- Engineering
- Service
- Training 3g AE 515 Aldo Avenue Santa Cloro CA 95050 REVIS10tl 0 l 408-980-9333 DATE 07/23/85 ll VII. D. 5. Search units shall be selected according to Table 1.
In general, angle beam shear waves shall be used for this procedure; however, refracted longitudinal waves may be used as an aid in detection or evaluation.
Additional search units may be used for evaluation or in unusual circumstancas; however, such use shall be approved by the Supervising LMT Level III and the reasons documented.
Material Angle Beam Exam.
Thickness Size and Freo.
.25" each element
.35" to .50" (Round or Square)
(P/E or P/C) 2.25 MHZ Maximum .50" each element
.50" to 1.2" (Round or Square)
(P/E or P/C) i 1.5 to 2.25 MHZ Maximum .75" each element 1.2" to 2" (Round or Square)
(P/E or P/C) 1.5 to 2.25 MHZ l
Table 1 l
Lombart o MacGillo Thomas,Inc. "" c "'-4 I Testing Engineering
- Service Training P^
38 PAGE 515 Aldo Avenue Santa Clara CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 1 VII. D.,6. Search unit contact angle beam wedges shall meet the criterion of Table 2 for coverage of attachment weld root areas, as shown in Figure 1, when the examina-tion is limited to a half vee-path.
Required Index to Weld Beam Angle Centerline Distance A 45* .9 T 55* 1.3 T 60* 1.6 T 70 2.5 T Table 2 E. Couplant materials shall be as low as practicable in sul-fur and halogen content. Certification shall be provided on a batch basis for each brand of couplant. Analysis for halogens and sulfur shall be made according to ASTM D-129-64 and ASTM D-808-63.
- 1. Residual halogens and sulfur shall not exceed 1% by weight.
- 2. LMT Gel and Ultra-Gel are satisfactory couplants.
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Lambcrt o Mo3 Gill o ThEmas,Inc. "" c "'-4 Testing
- Engineering Service. Training 38 AE 515 Aldo Avenue Santa Claro, CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 VII. F.
Calibration blocks shall be of the form as described in ASME XI (1980), Appendix III. Calibration blocks shall be of the same nominal size, thickness , material, and surface finish as the area of major interest in the mate-rial to be examined (Figure 2).
- 1. Calibration notches shall be one inch long, not more than one-quarter inch wide, and with a depth no greater than 10% of the nominal pipe wall thickness. l 2.
Calibration holes for use in half-node examinations only, shall be drilled perpendicular to the ends of the block and parallel to the centerline of the pipe.
a) A minimum of two holes, each of the same diame-ter, located at 1/4t and 3/4t, shall be used.
3.
Other reflectors may be included in block designs for informational purposes.
- 4. Calibration blocks shall be retained by and be the responsibility of the client.
VIII. PREPARATION A. Documentation 1.
The following preliminary documentation requirements shall be reviewed by the examiner with the client for review before beginning any examination program:
I
Lombart o MccGillo Thomas,Inc. "" c "- 4 Testing
- Engineering
- Service
- Training yG AE 515 Aldo /M/enue Santa Clara. CA 95050 REVISION 0 408 980-9333 DATE 07/23/85 VIII. A. 1. a) Procedure Qualification; b) Calibration Sheets; c) Inspection Reports; d) Material and Equipment Certifications; e) Personnel Certifications; f) NRC Form 4 (operating nuclear plants only);
g) NRC Form 5 (operating nuclear plants only);
h) Status Indicators (Hold Tags);
i) Radiation Work Permits (when applicable).
B. Physical Preparation
- 1. The following physical preparation requirements shall be reviewed by the examiner with the client before specific examinations are performed:
a) Insulation removal; b) 0SilA requirements (ladders, lighting, fresh air, scaffolding, etc.);
c) Cleanup requirements; d) Safety precautions (other work in area, etc.).
C. Surface Preparation
- 1. It shall be the responsibility of the Level II or Level III examiner to determine the need for sur-face preparation.
- 2. Surfaces ? hall be sufficiently smooth and clean so 1
that a meaningful examination may be performed.
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Lombart o MacGillo Thomas,Inc. " '
^
Testing . Engineering . Service . Training 38 A S 515 Aldo Avenue Santa Claro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 VIII. C. 3. Welds shall be identified and all required marking procedures completed before performing any examina-tions.
- 4. Low stress stamps or vibratooling, or both, may be used to permanently identify each weld. The marking shall not interfere with the examination or be any deeper than 3/64 of an inch.
IX. LIMITATIONS This procedure is limited to austenitic steels and inconel unless specifically qualified for other materials.
X. CALIBRATION A. Examination calibration is performed on a complete sys-tem. Any change in the ultrasonic instrument or search unit requires recalibration. A change in qualified per-sonnel, search unit, recording instrumentation, or in-strument recorder interconnect cabling requires a cali-bration check. Instrument alignment verification need not be made with the search unit used for testing.
Lombcrto MacGillo Thsmas,Inc. " c P
Testing
- Engineering Service. Training 3 A S 515 Aldo Avenue Santa Claro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85.
X. B. Instrument alignment verification for screen height and amplitude control linearity shall be performed before the initial examination in any given series and repeated with each system calibration.
- 1. Instrument Linearity Verification a) Position the angle beam search unit on a cali-bration block to obtain two echoes with a 2:1 amplitude ratio.
b) Set the larger echo to 80% of calibrated screen height.
c) Vary the amplitude of the larger echo from 100%
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to 20% of calibrated screen height in 10% incre-ments.
d) Note that at each increment the smaller echo re-mains 1/2 the larger within a tolerance band of 5% of full screen height.
e) Record successful performance of the verifica-tion on a Calibration Report form (Figure 3).
- 2. Verification of Amplitude Control Accuracy a) Position the search unit to obtain an 80% of full scale echo on the calibrated screen.
b) Adjust the amplitude control to decrease the sys-tem gain by 6 dB and 12 dB.
1 Lambcrt o MacGillc> Thrmas,Inc. "" c "'-4 N6hgy3 "
Testing
- Engineering . Service . Training '
515 /udo Avenue Santa Cloro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 X. B. 2. b) Compare the response with Table 3 to determine acceptability. Estimate system response to 1%
of calibrated full screen.
c) Position the search unit to obtain a 40% of full scale echo on the calibrated screen.
d) Adjust the amplitude control to increase the sys-tem gain by 6 dB. Compare the response with Table 3 to determine acceptability. Estimate system response to 1% of calibrated full screen.
e) Position the search unit to obtain a 20% of full scale echo on the calibrated screen.
f) Adjust the amplitude control to increase the sys-tem gain by 12 dB. Compare the response with Table 3 to determine its acceptability. Estimate system response to 1% of calibrated full scale.
g) Record successful performance of the verifica-tion on the Calibration Report form.
Indication Gain Indication Tolerance Set Change Limits 80% -6 dB 32% to 48%
80% -12 dB 16% to 24%
40% +6 dB 64% to 96%
20% +12 dB 64% to 96%
Table 3
' Lombart o MacGillo Thsmos,lnc. "" c "'-*
^
Testing
- Engineering Service
- Training 38 AGES 515 Aldo Avenue Santa Cloro CA 95050 REVISION 0 408 980-9333 DATE 07/23/85 X. C. Examination Calibration 0
- 1. Angle Beam. Examination (Axial Scanning) Calibration is performed on a complete system on an appropriate basic calibration block at the beginning of each day 's testing of the material .
a) Calibration shall be performed on a calibration block whose temperature is within 25*F of the material to be e'x amined, b) Set the sweep range on the calibrated instrument screen according to Table 4:
Thickness I.D./0.D.
(T) Metal Path Points
< 1/2" 2-1/2 Vee Paths 2,4,6,8,10 Div.
1/2" to 1.2" 2 Vee Paths 2.5,5,7.5,10 Div.
1.2" to 2" 1-1/2 Vee Paths 3,6,9, Div.
Table 4 l
l l c) For examinations utilizing metal paths greater than one-half node, test sensitivity at any range is established by setting the amplitude of the nearest circumferential notch echo to 80% of full calibrated scale.
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' Lombart o MccGilloThsmos,Inc. "" '
^
Testing
- Engineering
- Service Training 38 A S 515 Aldo Avenue Santa Clara. CA 95050 REVISION 0 408 980-9333 DATE 07/23/85 X. C. 1. c) The responses from the remaining circumferential notch echoes in the examination region shall then be obtained at this sensitivity and joined to-gether in a smooth DAC curve on the tester face, and similarly recorded on the Calibration Report form (Figure 3). The DAC curve so generated is the Primary Reference Level.
d) For examinations utilizing a half-node metal path, the sweep range shall be 1 vee-path. DAC curve shall be generated using the side drilled holes (to 1-1/4T) in a basic calibration block so that the maximum hole response is set to 80%
calibrated screen height. This response shall be obtained with the transducer centerline aligned with the hole half length and the beam perpendic-ular to the SDH, to prevent possible erroneous corner responses. The DAC shall be clearly marked by connecting the hole responses on the tester face with a smooth line and extrapolated to cover the full examination range. Next, es-tablish the reference sensitivity from the inside diameter surface notch by setting the indication amplitude at the level of the DAC curve.
' Lombart o MccGillo Thsmas,Inc. PROC. UT-41 Testing
- Engineering . Service . Training P^
38 A S 515 Aldo Avenue Santo Claro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 X. C. 1. d) The DAC shall also be recorded on the Calibra-tion Report form.
The DAC curve is the Primary Reference Level.
e) Af ter Primary Reference Level has been estab-lished on the basic block, calibration reference responses may be established on a Rompas or other adaquate reference block. The responses should include both sweep and amplitude calibration points and should be recorded as calibration check responses on the Calibration Report form.
These responses may be used for calibration checks when an appropriate basic block is not practical.
2.
Angle Beam Examination (Circumferential Scanning)
The angle beam calibration required for axial scan-ning, (X.C.1), is considered acceptable for circum-ferential scanning if the amplitude of the circumfer-ential half-yee path notch is within 2 dB of the amplitude obtained from the same axial notch echo and it's sweep location is within 10% of the calibrated reference response value recorded on the calibration sheet. If these tolerances cannot be met, a new cal-ibration is required following the requirements of X.C.1. of this procedure using axial notch reflect-ors.
Lombcrt o MccGillo Thrmas,Inc. "" c "'-4 Testing
- Engineering
- Service . Training NGE A S
' 515 Aldo Avenue Santa Claro, CA 95050 REVISION 0 408 980-9333 DATE 07/23/85 X. C. 3. Angle Beam Examination (0blique Scanning)
Additional scans at approximately 45* to the pipe ax-is and from the weld perpendicular (Figure 4) shall be performed in the clockwise and counterclockwise directions. Examinations shall be conducted from both sides of the weld, where possible. The Calibration requirement of X.C.1, is considered acceptable for oblique scanning.
XI. PERFORMANCE A. Calibration Check
- 1. A calibration check is required before and after each examination, and at intervals not to exceed
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twelve (12) hours and with any change in examination personnel, except when using mechanized equipment.
2.
The calibration check shall as a minimum consist of verification of the DAC curve by a two point ampli-l tude and range check using the basic calibration block or a portable block such as the Rompas whose response has been related to that of the basic
, block.
a) The amplitude response of the reference reflec-tor during the calibration check shall be within 2dB and the sweep location within 10% of the calibration reference response value recorded on i
the calibration sheet to be acceptable.
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' Lombcrt o MccGillo Th: mas,Inc. "" c "-4 i Testing . Engineering . Service . Training ^
38 A S 515 Aldo Avenue 1
Santo Claro, CA 95050 REVIS10ft 0 408 980-9333 DATE 07/23/85 XI. A. ,
- 2. b) An unacceptable calibration check shall be cause for full examination of the test system to deter-mine the reason for the calibration change. Typ-ical causes for calibration change are ambient temperature effects on search units and electron-ics, control settings inadvertently changed, and loss of couplant between the search unit and wedge. If, in the judgment of the examiner,the cause of the calibration change has been correct-ed or may by compensated for by a change in con-trol settings, calibration may be restored using the calibration check response, c) Any examination that has been performed in a non-calibrated condition shall be repeated.
B. Sensitivity The scanning sensitivity shall be a nominal 12db (4x) greater than the reference sensitivity level wherever possible.
- 1. Where signal-to-noise ratios are greater than 4:1 at the +12db scan level, the scanning sensitivity shall be that sensitivity at which the CRT baseline noise equals 10% FSH, but in no case shall scanning sensi-tivity be less than 6dB above Reference Level.
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Lambert o MacGill o Thomas,inc. n C. uT-41 Testing
- Engineering
- Service
- Training NGEA S 515 Aldo Avenue IV Santa Claro, CA 95050 REVISION 0 408 980 9333 DATE 07/23/85 XI. C. C _o v e ra g e 1.
Each a ea shall be scanned with a nominal 50% over-lap of the search unit width (diameter) for each scan path.
- 2. For angle beam axial and circumferential examina-tions the search unit shall be oscillated 30* to ensure maximum coverage.
- 3. No search unit oscillation is required for oblique scanning.
- 4. The entire examination volume comprising the weld and adjacent base metal, as shown in Fig. 4, shall be examined with the beam normal to the weld for at least a full vee-path from one side or a half vee-path from both sides. Where practical, welds shall be examined from both sides with a full vee-path.
5.
Axial examinations shall be performed using a suffi-ciently long examination beam path to provide cover-age of the required examination volume.
- 6. Circumferential coverage shall be a minimum of the weld and one pipe thickness (T) as measured from the weld centerline, where practical.
- 7. Should variables preclude obtaining coverage of the examination volume as shown in Figure 4, steps may be taken that include one or more of the following:
Lambcrt o MccGill o Thsmas,Inc. ea0c. u1 41 Testing
- Engineering . Service . Training PAGE 19 0F 515 Aldo Avenue 38 PAGES IVI Santa Clara. CA 95050 REVISION 0 DATE 07/23/85 XI. C. 7. a) Reducing the dimension of the wedge front face to beam exit point; b) Reducing search unit size; c) Increasing the beam angle; d) Conditioning the weld surface (client responsi-bility).
D. Scan Directions
- 1. Scan directions and numbering sequances shall be as shown in (Figure 5) and in the following order where possible and applicable:
a) Perpendicular to the weld axis from both direc-tions.
b) Parallel to the weld in the clockwise and coun-terclockwise directions.
c) Oblique to the pipe axis (approximately 45 from normal to the weld) in the clockwise and coun-terclockwise directions from both sides of the wel d. Oblique scans may not be appropriate for purposes of demonstration or qualification.
E. Scanning Speed Scanning speed shall not exceed three inches per second.
F. Restrictions Maximum effort should be made to ensure full coverage to the requirements of this procedure.
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kmh][{ O MacGill o Thomas,Inc. PROC. UT-41 Testing
- Engineering
- Service
- Training yG A S 515 Aldo Avenue Santa Claro, CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 XI. F.
Physical or other limitations that prevent full compli-ance with the requirements of this procedure shall be recorded on the Examination Report form, (Figure 6).
G. Automatic Alarms Automatic alarms or recording may be used as an aid to the examiner.
H. Overchecking A total of five (5) percent minimum of welds examined to this procedure shall be re-inspected using different examiners. The welds to be overchecked may be selected at random or by client preference, but should be repre-sentative of the total inspection. Overchecking is not appropriate for purposes of personnel qualification or demonstration.
XII. EVALUATION A. Recording of Indications
- 1. All indications regardless of amplitude in the HAZ or base metal, or any known flaw, shall be investigated by a Level II or Level III examiner to determine the shape, identity, and location of the reflector.
- 2. All indications 25% of DAC or greater shall be inves-tigated by a Level II or Level III examiner to deter-mine the shape, identity, and location of the reflec-tor.
Lombcrto MmGilloTh mas,Inc. ls"cs'2"';l Testing
- Engineering . Service
- Training 38 PAGES 515 Aldo Avenue Santa Cloro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 XII. B. Reflector Determination
- 1. The determination of geometric or flaw situations shall be based on data plots, review of previous UT or RT data or the use of additional examinations.
Weld profile data may be used to record information to aid in plotting (Figure 7).
- 2. Contour gauges may be used to obtain 0.D. surface profiles. Digital thickness readirgs may be utilized for thickness measurements. Calibration is deemed acceptable if the digital readings are correct for at least two (2) istablished depth extremities in a given calibration standard.
- 3. The basis for reflector determination shall be docu-mented in the examination report.
C. Non-geometric Indications
- 1. The following must be recorded on the indication sheet (Figure 8) for all non-geometric indications:
a) Peak amplitude (% reference DAC) with correspond-ing range to indication (inches, search unit position from weld centerline, sweep location, metal path and search unit direction).
b) Minimum sweep reading to reflector and position of search unit at 50% and 10% peak amplitude points.
. -1 Lombcrt o MocGillo Thsmas,inc. ""' "'"
Testing
- Engineering
- Service
- Training 515 Aldo Avenue N6 HAGS i
Santa Clara, CA 95050 REVISION 0 l 408 980 9333 DATE 07/23/85 I XII. C. ,
- 1. c) Maximum sweep reading to reflector and position of search unit at 50% and 10% peak amplitude poi nt s.
d) Search unit positions or locations parallel to the reflector at the end points where the reflec-tor amplitude disappears (length of reflector).
D. Geometric Indications
- 1. The following must be recorded on the indication sheet (Figure 9) for all geometric indications:
a) Peak amplitude (equal to/ greater than 50% refer-ence DAC) with corresponding range to indication (inches, search unit position from weld center-line, sweep location, metal path, and search unit direction).
b) Minimum sweep reading to reflector and position of search unit at the 50% Reference Level point.
c) Maximum sweep reading to reflector and position of search unit at the 50% Reference Level point.
d) Search unit position or locations parallel to the reflector amplitude f alls to 50% reference amplitude (length of reflector).
[OmhCd O MacGill o Thsmos,lna. "" c "'-4
$g fgh3 "
A0 Testing
- Engineering
- Service
- Training 515 Aldo Avenue Santa Claro. CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 t
i XII. E. Reference System for Reporting Indications A reference system shall be established to locate the search unit along the weld and to determine its posi-tion in reference to the weld centerline. This shall be accomplished in accordance with Figures 10 through 12.
F. Acceptance Criteria Non-geometric indications shall be reported as cracks.
Any examined part contai'ning cracks shall not be accepta-ble under this procedure. The client or his designated representative shall be notified within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> of crack conditions.
G. Sizing (Through-wall Dimensions)
An additional approved sizing procedure (s) shall be used to determine through-wall dimensions of cracking, as re-quired by the client.
XIll. RECORDS A. A Report of Ultrasonic Examination (Figure 6) shall be l
prepared for each item examined, and shall be related to a Report of Ultrasonic Calibration (Figure 3).
B. Oscillograph chart records may be made of all angle beam examinations.
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0 Lombart o MacGillo Thsmos,Inc. " Roc m-4t Testing
- Engineering
- Service . Training yG l A S 515 Aldo Avenue Santa Clara, CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 XIII. B. 1. Chart records used in indication analysis shall uti-lize two channels, one corresponding to vertical de-flection of the CRT signal and the other to horizon-tal.
These channels shall be calibrated to match the oscilloscope display. That is, an indication 90% of vertical amplitude appearing at five divisions on the instrument screen should have a nine division deflec-tion on one chart channel and a five division deflec-tion on the other.
- 2. Chart records shall include a pre and post test cali-bration check-made at the same scanning speed as the test.
- 3. All indications on a strip chart record shall be identified.
- 4. Location and other pertinent information shall be manually noted on each chart, a) Pertinent information includes, but is not limi-ted to date, time, item, equipment, examiners, scans, gain, and recorder settings and speed.
C. Additional Recording Other types of recording, such as event or alarm monitor-ing, magnetic taping and computer enhanced printouts may be used as an aid to the examiner where feasible. This procedure may be used with automatic scanning devices.
. I Lombort o MccGillo Thomas,Inc. PROC. UT-41 y Testing
- Engineering . Service . Training yG m A S 515 Aldo Avenue Santa Cloro CA 95050 REVISION 0 408-980-9333 DATE 07/23/85 XIII. D. ALARA-I Scanner When the ALARA-I remote automatic scanner is used in conjunction with this procedure, a separate count sheet shall be included with each report.
XIV. REVIEW A. Examination Reports shall be reviewed by an assigned LMT Level III examiner for conformity to the require-ments of this procedure.
- 1) All strip charts when used, shall be reviewed and signed off by the LMT qualified Level III.
B. Following the final LMT review, the reports will be transmitted for review by the client and the Authorized Nuclear Inspector.
XV. STORAGE AND DISTRIBUTION A. Original examination documentation shall become the property of the client upon sign-off or his designated representative, and shall not be removed from the site.
- 1. Additional reports which may include examination documentation as reference material shall be generated from copies.
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~ [OmDCd O MacGillo Thrmas,Inc. PROC. UT-41 Testing
- Engineering
- Service . Trotning 0F 515 Aldo Avenue }G l Santa Cloro. CA 95050 REVISION 0 408 980 9333 DATE 07/23/85 I XV. B.
Field storage facilities shall provide a safe storage area, and access to files shall be limited to the client, his designated representatives, and the LMT Supervisor and his designated representatives.
XVI. REVISION AND FIELD CHANGE A. Revisions This procedure may be revised to remain current with changing requirements of the reference documents and or job conditions.
B. Field Changes
- 1. This procedure may be modified to allow changes for specific circumstances i
by issuing Field Changes.
- 2. Field Changes shall be prepared by the LMT Field Supervisor.
- 3. Prior to implementation, Field Changes shall be approved by the authorized client representative.
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- Engineering
- Service
- Training 0F m $$GE A
515 Aldo Avenue Santo Claro. CA 95050 REVISI0tl 0 408-980 9333 DATE 07/23/85 e
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Lambort o MacGillo Thsmas,Inc. "" l y ,,ff;l Testing
- Engineering
- Service
- Training W 38 PAGES 515 Aldo Avenue Santa Claro. CA 95050 REVIS10tl 0 408-980-9333 0 ATE 07/23/85 l
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PROC. UT-41 PAGE 29 0F 38, REVISION 0, DATE 0//23/a5
. LMT.uTC.i 9n Loc Lambert
- MacGill
- Thomas,Inc. ca,.ation N. 1,m e Testing . Engineering e Service . Training ;oo no.
515 Aldo Avenue Santa Claro, CA 95054
408 980-9333 Pace et REPORT OF ULTRASONIC CAllBRATION Z Examiner / Level Examiner / Level Review / Level N Authorized Inspector Customer Instrument __ SIN ReCal Due SU Cable Instrument SIN ReCal Due Recorder S/N ReCal Due Recorder S/N ReCal Due VERTICAL LINEARITY CHECK Check Completed by b SIGNALt 100 90 80 70 so 50 40 30 20 2 SJGN AL 2 to W
Signal 2 shall equal 50% of Signal I within 2 5% of full scale.
Q. AMPLITUDE CONTROL LINEARITY CHECK t., heck Completed by D S E N Sa fivs T V SET ~4 - 12 SET + 12 Q ACCEPT II ANGE 80 % 32 to 44 18 to 24 20 % 44 to to SET 40 %
+4 64 to te W ACTUAL VALUE .W M Xh Signal amphtude must fall witnin listed values.
SEARCH UNITS SIN Mfg. Type Size Freq. Inder Angle SIN Mfg. Type Size Freg. Index Angle O
g Procedure Rev. Date Field Change Date Q.
Ca!. Block Type SIN Ref. Ref t. Temp.
Verification / Ref. Bf k. SIN Ref. Refl. Temp.
DAC CAL. CHECK INSTRUMENT SETTINGS '
10 s
^"9 '
O 0* Beam D'9'tal a . _ _ _ _ . _ _ . . _ _ . _ _ _ . . _ _
08'"
a: 6 '
CD Sweep '
U Delay 4 4 .
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O Freo. 2 4 6 8 10 Video /Filt. IRD Rep. Rate MP FIGURE 3
- Lambart o MacGillo Thsmas,Inc. "" c "- ' t Testing Engineering. Service. Training yGEPAGES 515 Aldo Avenue Santa Claro, CA 95050 REVISION 0 408-980 9333 DATE 07/23/85 l
Required Perpendicular Scan ' Required Parallel Coverage Measured from the Scan Coverage Beam Weld Centerline for Full V Measured from the with Weld Width T Weld Centerline 45*
60*
The lesser of 3r or 2.5T+1" T 70*
The lesser of 4.5T or 4T+1" T The lesser of 6.5T or 6T+1" T pl INNER , "/ PROFILE OF
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PROC . 01 -41 PAGE 32 UF JB, HLV1510N U, UAlt U//44/0D 2 la/79 Location Lambert
- MacGill
- Thomas,Inc. Report No.
Testing e Engineering e Service e Training c,1,yo, 71,,
' 515 Aldo Avenue Santa Clara, CA 95050 J b No.
408-980-9333 Date Page of REPORT OF VISUAL AN D ULTRASONIC EXAMINATION f Description Size Material S/N(s)
E M
Location Preparation Temp S
I Examiner / Level Examiner / Level G Review / Level N Authorized Inspector Customer i E
Tester 1 S/N 2 S/N U Recorder 1 S/N 2 S/N p Transducer 1 2 M 3 E 4 N Couplant Cable Marker Photo P Calibration Procedure Rev.
R Examination Procedure Rev.
C Recording Procedure _,
Rev.
A Calib. Blk. Temp. Ref. Amp. Sweep L Ref. Gain Damp.
I Reject Gate g Alarm Mag. Tape Count Chart Cal. Check Time Cal. Ref. Blk. Ref. Refl. Amp. Sweep Position Scan Gain Ref. Dwg. Reject Level Report Level E
NAD = No Apparant Disc. L = Linear G = Geometry S = Spot M = Multiples X
Scan Type Disp. Type lI Scan A l Scan Disp. Type Disp.
O PT !
M 1 visual 7 13 g 2 Base Metal 8 14 3 9 N 15 4 ! 10 16 5 11 A i
! 17 6 12 l 18 T
Scan Description of Indications I
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38 PAGES 515 Aldo Avenue Santa Clara. CA 95050 REVISi3N 0 :
408-980-9333 DATE 07/23/85 I
- 1. l All measurements to be taken in a positive (+) clockwise, or negative (-) counterclockwise direction, as measured from 12:00 ;
and weld centerline.
- 2. REFERENCE ARROW - is direction of system flow.
- 3. HORIZONTAL RUNS - 12 is TDC
- 4. VERTICAL RUNS -
a) If the weld is an elbow-to pipe, pipe-to elbow, tee-to-elbow, etc.; 12 is the centerline of the outside radius of the elbow.
b) "If the weld is a pipe-to pipe, pipe-to-tee, elbow-to-elbow, etc.; 12 is the centerline of c) the outside radius of the elbow above the weld.
If in rule (b) there is no elbow above, use an extension of the centerline of the outside radius of the elbow below the weld.
d) If rule (b) or (c) cannot be used because no elbows are visible, choose and note the most c o n v'e ni e n t location, such as; long seam, point nearest Reactor vessel, etc.,
e) 12:00 on saddle welds will be located on the up-stream side of the saddle at the intersection of the saddle weld with the saddle centerline -
which is parallel the pipe axis.
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(flow down)
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Rev. 1 9/85 I
M gledRe**p mcx_s TITLE: Generic Procedure for Detection and Discrimination of IGSCC PURPOSE: To provide a procedure for the student to perform a practical examination based on the ASME Code and state-of-the-art ultrasonic parameters for detection and discrimination of IGSCC.
The student will be able to:
OBJECTIVES: 4 Successfully perform an ultrasonic examination of welds for detection and discrimination of IGSCC using a procedure.
O Score 80% or better on the specific and practical examinations.
l l
DIVISION COMPETENCY AREA LEARNING MODULE PAGE 1 9 1 0 1 7 1 0' 15
l l
I INFZRMATION SHEET .
I Learning Activities Resources
- 1. Read information sheets Attached 1
- 2. Attend lecture Classroom
- 3. Perform practical examination Instructor will provide Module Prerequisites: Level II Ultrasonic Examination Training and Experience i
Legal Notice This r port was prepared by J.A. Jones Applied Research Company as an account of work sponsored by the Electric Power Research In.
statuts, Inc. (EPRI). Neither EPRI, members of EPRI, J.A. Jones Applied Research Company, nor any person acting on their behalf: a. makes any wtrranty expressed or impiled with respect to the accuracy, completeness, or usefulness of the information contained in this report, or I thIt the use of any information, apparatus, method, or process disclosed in this report may not infringe on privately owned rights, or b.
assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, or process disclssed in this report.
DIVISION COMPETENCY AREA LEARNING MODULE PAGE
.. i i i I i i i .I l l 1 I
I INFORMATI2N SHEET INTRODUCTION This modu?e may be used to complement existing procedures used for ultrasonic examination of nuclear power plant piping in accordance with the ASME Boiler and Pressure Vessel Code,Section XI,1974 and later editions.
The present state-of-the-art parameters above the ASME Code requirements to increase the probability of detection and discrimination of IGSCC have been included.
This procedure shall be used by the student as a bas.is for performing the practical examination. Successful completion of the practical examination shall be considered as a basis for qualification of the procedure and the student's ability to perform within its parameters. In addition, the student is required to supply a detailed summary of their examination parameters which are actually used during their practical examination. This information is to be provided on Form 3 " Summary of Performance Qualification Variables" and will become an integral part of the qualification.
GENERIC PROCEDURE FOR DETECTION AND DISCRIMINATION OF IGSCC 1.0 PURPOSE 1.1 To establish the requirements for manual ultrasonic examination of full penetration butt. welds and adjacent base metal subject to intergranular stress corrosion cracking in nuclear power plant piping systems.
2.0 SCOPE 2.1 This procedure is applicable to austenitic piping systems having a nominal wall thickness of 0.400 inches to 2.5 inches.
2.2 The examination shall be performed from the outside surface.
3.0 REFERENCES
3.1 Coordination Plan For NRC/EPRI/BWROG Training And Qualification Activities Of NDE Personnel.
3.2 ASME Boiler and Pressure Vessel Code,Section XI,1974 and later Edition and Addenda.
l l 3.3 UT Operator Training for Intergranular Stress Corrosion Cracking, Competency Area 910, developed by the EPRI NDE Center.
4.0 PERSONNEL QUALIFICATION 4.1 Personnel performing ultrasonic examinations in accordance with this procedure shall be qualified and certified to the requirements of a procedure based on the requirements of References 3.1, 3.2 and 3.3 above.
OlVISION COMPETENCY AREA LEARNING MODULE PAGE L l_1 U LLLI ,n,,, _
I INFORMATION SHEET 5.0 EQUIPMENT l
5.1 ULTRASONIC INSTRUMENT 5.1.1 A pulse-echo ultrasonic instrument with an A-scan presentation shall be used. The instrument shall be capable of generating and receiving frequencies of 1 to 5 MHz.
5.2 ULTRASONIC SEARCH UNIT 5.2.1 Search units may contain either single or dual transducer elements.
5.2.1(a) Transducers shall have a nominal frequency of MHz.
5.2.1(b) Transducer element size shall be in the range of inch to inch either round or square.
5.2.2 The primary search unit shall contain a wedoe to produce shear waves at a nominal degrees in austenitic stainless steel.
In those cases where complete coverage of the weld and adjacent base metal cannot be obtained or detection and discrimination is questionable, other angles of degrees may be used in conjunction with the primary search unit.
5.2.2(a) Wedges shall meet the following criterion for coverage of the weld root as shown in Figure 1, when the examination is limited to half-V examination.
a-
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Figure 1 If these variables are such that the dimension A on f Figure 1 is greater than:
l 0.93t for e = 450 1.6t for e = 600 2.St for e = 700 DIVISION COMPETENCY AREA LEARNING MODULE FAGE l_I_I_I L l -- l --- l - - .- 1 I I_l 1 _ - -
l INFORMATION SHEET Rev. 1 9/85 The interference shall be eliminated by one or more of the following:
(1) reducing the dimension of the wedge edge-to-beam entry point; (2) reducing search unit size; (3) increasing beam angle.
5.2.2(b) Contoured contact wedges may be used to aid ultrasonic coupli ng.
5.2.2(c) Calibration shall be done with th'e contact wedges used during the examination.
5.3 COUPLANT 5.3.1 USP-grade glycerine or commercially available couplants shall be used for calibration and examination.
5.3.2 Couplants shall be certified for total rulfur and halogen content in accordance with ASTM D-129-64 and D-808-63. The total residual halogens and sulfur shall not exceed 1% by weight.
5.4 8ASIC CALIBRATION BLOCKS 5.4.1 The basic calibration block shall be manufactured in accordance with the applicable edition and addenda of Section XI of the ASME Boiler and Pressure Vessel Code.
5.4.2 Where practical, calibration blocks should be made from material of the same nominal diameter and nominal wall thickness or pipe schedule as the pipe to be examined.
5.4.3 Material Specification 5.4.3(a) The calibration blocks shall be fabricated from one of the materials specified for the piping being joined by the weld.
5.4.3(b) Where the examination is to be performed from only one side of the joint, the calibration block material shall be the same specification as the material on that side of the joint.
5.4.3(c) If material of the same specification is not available, material of similar chemical analysis, tensile properties, and metallurgical structure may be used.
5.4.4 The finish on the block surfaces shall be representative of the surface finishes of -the piping.
5.4.5 Calibration Reflectors shall be in accordance with 5.4.1 above.
OlVISION COMPETENCY AREA LEARNING MODULE PAGE 1 11_1L _1_ _7_ R OF 19
1 INFORMATION SHEET l
6.0 CALIBRATION 6.1 ULTRASONIC INSTRUMENT 6.1.1 Instrument calibration for screen height and amplitude control linearity shall be verified at intervals not to exceed three months.
6.1.2 Screen Height Linearity 6.1.2(a) The ultrasonic instrument. shall provide screen height linearity within 5% of full range for at least 80% of the full screen height (FSH) (base line to maximum calibrated screen points).
6.1.2(b) To verify the ability of the ultrasonic instrument to meet the linearity requirement of 6.1.2(a),
position an angle beam search unit as shown in Figure 2 so that echoes can be observed from any two reflectors in a calibration block.
( )
AA % l
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legenaud Figure 2 Adjust the search unit position to give a 2:1 ratio of amplitudes between the two echoes, with the larger set at 80% of full screen heignt. Without moving the search unit, adjust sensitivity (gain) to successively set the larger echo from 100% to 20% of FSH, in 10%
increments (or 2 dB steps if a fine control is not available), and read the amplitude of the smaller echo at each setting. The reading shall be 50% of the larger amplitude, within 5% of FSH. The settings and readings shall be estimated to the nearest 1% of full screen. Alternatively, a straight beam search unit may be used on any calibration block that will provide the signal differences.
OlV;SION COMPETENCY AREA LEARNING MODU 1.E PAGE
__1 R_ _5L _/5t_ _ _ _ ___________ ___ _5L _2__ _______. __ 2 @ F___t a__ ___
1 INFORMATION SHEET l
6.1.3 Amplitude Control Linearity 6.1.3(a) The ultrasonic instrument shall utilize an amplitude ,
control, accurate over its useful range to + 20% of )
the nominal amplitude ratio, to allow measurement of i indications beyond the linear range of the vertical display on the screen.
6.1.3(b) To verify the accuracy of the amplitude control in the ultrasonic instrument, as required in 6.1.3(a),
position a search unit so. that an echo from one reflector in a calibration block is peaked on the screen. With the increases and decreases in atte-nuation shown in Table 1, the echo amplitude shall fall within the specified limits.
Table 1 Specified Limits For Echo Arrplitude Indication Set at Indication Limits, dBContrgl
% of Full Screen Change % of Full Screen 80% - 6 dB 32 to 48%
80% -12 dB 16 to 24%
40% + 6 dB 64 to 56%
20% +12 dB 64 to 96%
NOTE:
(1) Minus denotes decrease in amplitude; plus denotes increase.
Convenient reflectors from any calibration block may be used with angle or straight beam search units. The ' settings and readings shall be esti-mated to the nearest 1% of full screen.
6.2 SEARCH UNIT CALIBRATION 6.2.1 Prior to performing system calibration, the search unit beam exit point and beam angle shall be determined. This shall be verified using an appropriate reference block.
OlVISION COMPETENCY AREA LEARNING MODULE PAGE t_- -- 1 IIL l_1LI __ m , n,
INFORMATION SHEET 6.3 SYSTEM CALIBRATION 6.3.1 General Requirements 6.3.1(a) Calibration shall include the complete ultrasonic examination system. Any change in search units, shoes, couplants, cables, ultrasonic instruments, recording devices, or any other parts of the examina-tion system shall be cause for calibration check.
The original calibration shall be performed on the basic calibration block. . Calibration checks may be -
performed on either a basic calibration block simula-top or the basic calibration block, but must include a check of the entire examination system.
6.3.1(b) The maximum calibration indications shall be obtained with the sound beam oriented essentially perpen-dicular to the axis of the calibration reflector.
The center line of the search unit shall be at least 3/4 in. (19mm) from the nearest side of the block or pipe. (Rotation of the beam into a corner formed by the reflector and the side of the block may produce a higher amplitude signal at a longer beam path; this beam path shall not be used for calibration.)
6.3.1(c) For contact examination, the temperature dtfference between the examination and b ibration block surfaces sha' degreesCentgrade) exceed 250gs l not 6.3.1(d) Calibration shall be performed from the surface (clad
- or unclad) of the calibration block which corresponds '
to the component surface to be examined.
6.3.2 System Calibration Confirmation 6.3.2(a) Complete ultrasonic examination system calibration, establishing the DAC curve, shall be performed within one day prior to use of the system for examination of those welds for which the calibration is applicable, and at least cnce each week during the examination.
6.3.3 System Check 6.3.3(a) A system calibration check, which is the verification of the instrument sensitivity and sweep range calibration, shall be performed:
(1) at the sta.t and finish of each examination; (2) with any change in examination personnel; and (3) at least every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during an examination.
J DIVISION COMPETENCY AREA LEARNING MODULE PAGE
_ _ _ _st ___________# __ st - a - __._ _ _ _ _ _ _ _ __ 9 57 - R - @C3 1%-
INFORMATION SHEET Rev. 1 9/85 6.3.4 Corrective Actions 6.3.4(a) If any point on the DAC curve has decreased 20% l or 2 dB of its amplitude, all data sheets since the last calibration check shall be marked void.
A new calibration shall be made and recorded and the voided examination areas shall be reexamined.
I 6.3.4(b) If any point on the DAC curve has increased more than 20% or 2 dB of its amplitude, recorded indications taken since the last valid calibration
- or calibration check may be reexamined with the correct calibration and their values changed on the data sheets.
6.3.4(c) 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 calibration and note the correction in the examination record.
If recordable reflectors are noted on the data sheets, those data sheets shall be voided, a new calibration shall be recorded, and the examination areas shall be reexamined.
6.4 ANGLE BEAM CALIBRATION 6.4.1 Reflectors in the appropriate basic calibration block described in 5.4 shall' be used for angle beam calibration.
6.4.2 Examination Greater Than One-Half Vee Path 6.4.2(a) Side-drilled holes or notches, as appropriate, shall be used to construct the DAC curve. Position the search unit for maximum response from the reflector (ID notch or 3/4 t side-drilled hole) on the opposite side of the calibration standard; then position the search unit to obtain the maximun response from the next appropriate reflector (OD notch or 1/4 t side-drilled hole) to obtain the metal path determined in 7.4 below.
6.4.2(b) Adjust the sweep control to display the indication from the calibration reflectors at convenient intervals on the screen and record them on the calibration data sheet. The sweep range shall be adjusted to display a maximum of 12/3 vee-paths.
6.4.2(c) The side-drilled hole or ID notch, as appropriate, shall be used to establish the primary reference level sensitivity at 80% FSH.
DIVISION COMPETENCY AREA LEARNING MODULE PAGE o _ _ _ _ _ _ _ _ _ _ _ _ _ @ 9 8 9 W e @D M
INFORMATION SHEET Rev. 1 9/85 -
6.4.2(d) When side-drilled holes are used to establish the primary reference level, the scanning level sensitivity shall be at least 6dB above the primary reference level.
6.4.2(e) When 10%' notches are used to establish the primary reference level, the scanning level sensitivity shall be at least 14dB above the primary reference level.
6.4.2(f) The above referenced 6.4.2(d) and 6.4.2(e) scanning level sensitivities may not be adequate in some highly attenuative materials. A 5 to 10%
baseline noise level as a minimum should be observed in addition to the above dB levels.
6.4.3 One-Half Vee Path Examination 6.4.3(a) Side-drilled hole (s) shall be used to construct a DAC curve. The side-drilled hole or ID notch, as appropriate, shall be used to establish the primary reference level sensitivity at 80% FSH.
The sweep range shall be adjusted to display a maximum 1 1/2 vee-paths.
6.4.3(b) When side-drilled holes are used to establish the primary reference level, the scanning level sensitivity shall be at least 6dB above the primary reference level .
6.4.3(c) When 10% notches are used to establish the primary reference level, the scanning level sensitivity shall be at least 14dB above the primary reference level .
l 6.4.3(d) The above referenced 6.4.3(b) and 6.4.3(c) scanning level sensitivities may not be adequate i
in some highly attenuative materials. A 5 to 10%
baseltae noise level as a minimum should be observed in addition to the above dB levels.
7.0 EXAMINATION 7.1 SURFACE CONDITIONS The examination surface shall be free of irregularities, loose material, or coatings which interfere with ultrasonic wave transmission.
DIVISION COMPETENCY AREA LEARNING MODULE PAGE
_ _ _ I _ l-- 1 ] -_____ _ _ __ I _ l l I I I I l l __
l
I INF3RMATION SHEET 7.2 SCANNING SPEED Scanning speed shall nct exceed 3 inches per second and lower scan speeds may be necessary.
7.3 COVERAGE To assure complete coverage of the examination area, each pass of the search unit should overlap 50 percent of the search unit's i width. Overlap shall be a minimum of 10 percent. '
7.4 SCANNING FOR REFLECTORS 7.4.1 To detect reflectors oriented parallel to the weld seam, scan the applicable examination volume by either a full vee-path examination from one side, or by a one-half vee-path examina-tion from both sides. Aim the search unit about 90 degre.es to the weld and manipulate it laterally and longitudinally so that the beam passes through all the required examination volume.
7.4.2 To detect reflectors oriented transverse to the weld seam, the one-half vee-path examination shall be used. Examine the weld root by making a scan from the base metal adjacent to the weld.
Repeat with the search unit aimed parallel to the-weld in the opposite direction. The weld shall be examined from both sides where practical. When it is not practical to examine the weld root from the base metal, the weld root should be examined by a single scan along the weld crown with the search unit aimed approximately parallel to the weld length. Repeat the scan in the opposite direction.
7.4.3 In both 7.4.1 and 7.4.2 above, the search unit shall be oscillated approximately 45 degrees to aid in detecting reflec-tors oriented in a direction not normally expected.
8.0 INVESTIGATION OF INDICATIONS All indications shall be investigated to the extent that the examiner can determine the shape, identity and location.
9.0 RECORDING 0F INDICATIONS All indications that are determined not to be screen noise and are not OD geometry shall be recorded.
[
10.0 RECORDS AND REPORTS Examination results shall be recorded on Form 1 " Ultrasonic Calibration Sheet", Form 2. " Ultrasonic Test Data Report" and Form 3 " Performance Qualification Parameters".
OlVISION COMPETENCY AREA LEARNING MODULE PAGE
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INFORMATION SHEET j ,
I supetARY OF PERFORMANCE QUALIFICATION VARIABLES NAME S.S. NO. DATE PROCEDURE TITLE:
PROCEDURE NO,. REV. NO. DATE COMPANY ADDRESS SEARCH UNIT (S):
pu1Q IF MORE THAN ONE SEARCH UNIT IS USED, YOU MUST RECORD DATA FOR EACH ONE.
Primary Search Unit (No.1): Monitor Verifies and Initials Manufacturer: Model: ( )
Serial No: Frequency: ( )
Size: Single / Dual: ( )
B:aa Angle: Wave Mode: ( )
Supplemental Search Unit (No. 2):
Manufacturer: Model: ( )
Serial No: Frequency: ( )
Size: Single / Dual: ( )
Beam Angle: Wave Mode: ( )
Supplemental Search Unit (No. 3):
Manufacturer: Model: ( )
Serial No: Frequency: ( )
Size: Single / Dual: ( )
Beam Angle: Wave Mode: ( )
DIVISION COMPETENCY AREA LEARNING MODULE PAGE 1
9__3 @ 1 7 14 OF 15
' Rev. 1 INFORMATION SHEET 9/85 f
Monitor Verifies
' and Initials INSTRUMENT (S):
Primary Instrument: (Used in combination with search unit (s) , , ). ( )
Manufacturer: Model: ( )
Supplemental Instrument (s): (Used in combination with search unit (s)_,_,_). ( )
Manufacturer: Model : ( )
Supolemental Instrument (s): (Used in combination with search unit (s) ,___,___).( )
Manufacturer: Model : ( )
CABLES:
Primary Cable (No.1)
Length: No. of Connectors: Type of Connectors: to ( )
Supplemental Cable (No. 2) ( -)
Length: No. of Connectors: Type of Connectors: to ( )
Supplemental Cable (No. 3)
Length: No. of Connectors: Type of Connectors: to ( )
THE FOLLOWING ITEMS ARE TO BE WITNESSED BY THE MONITOR 0 Scanning Level Sensitivity Used: dB .
4 Scan Speed (Less Than 3 Inches /Second)..................
0 Overl ap (50% of Transduce r Width) . . . . . . . . . . . . . . . . . . . . . . .
O Cal i bration Wi thin The Procedure Limi ts . . . . . . . . . . . . . . . . .
(Note any exceptions below in remarks section)
REMARKS:
OlVISION COMPETENCY AREA LEARNING MODULE PAGE 1 9 1 0 1 7 15 OF 15
Request For Deviation ADM . H/F/V . FOR M 206 Document ID/Rev. No. Date Requested Document Page No. Deviation No. l UT-H-400/05 12-30-85 1 of 15 001 l page 1 ,, 1
- 1. Examination Areas Affected by Deviation (List each area or component to be examined in accordance with this ceviation (state Component identif Catson, weld identeflCation, etc.). If change is to plan or program, state "None".):
The manual ultrasonic examination of austeni tic welds which are susceptible to Inter-granular Stress Corrosion Cracking performed at Plant Hatch Unit I during the 1985/86 outage using SCS NDE Procedure UT-H-400, Rev. 5.
- 2. Deviation:
Add paragraph 4.3 to read:
4.3 Personnel performing manual ultrasonic examination of IGSCC austenitic welds shall successfully demonstrate their ability at the Electric Power Research Institute NDE Center upon completion of the required course.
- 3. Justification:
This is added to clarify the personnel requirements imposed upon Georgia Power Company.
f UE-30-1985 ,'j ,"*[ l'k*-30-1985 LetelJd.M l
111 Approvah y Date x
@anager N.[oes Approval LJMA 12-30-1985 Operating C@pany Abigsval' // / Date SEE PRB ftEETING filNUTES N/A Remarks:
Ptem (e. 91380 A
SCUTHERN CCMPANY SERVICES INSPECTION, TESTING AND ENGINEERING MANUAL ULTRASONIC EXAMINATION OF FULL-PENETRATION WELDS (GREATER THAN O.400 INCH)
UT-H-400 REVISION: 5 b.- O. un DATE: 9-20-84 PREPAREp~SY~ )
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Np LEVEL III APPROVAL APPROV//
UT-H-4C0 TABLE OF CONTENTS Section Title Page 1.0 Purpose 1 2.0 Scope 1 3.0 Applicable Documents 1 4.0 Responsibilities 1 5.0 Qualification of Ultrasonic 2 Examination Personnel 6.0 Ultrasonic Equipment 2 7.0 Search Unit (Transducer) 5 Verification 8.0 Equipment Calibration 5 9.0 Examination Areas 3 10.0 Surface Preparation 8 11.0 Examination Procedure 9 12.0 Inves".igation of Indications 11 13.0 Recording of Indications 11 14.0 Evaluation and Disposition of 12 Indications 15.0 Records 12
UT-H-400 1.0 PURPOSE This procedure provides the requirements for manual ultrasonic examination of full-penetration butt welds, branch connection welds, support attachment welds, and the adjacent base material in accordance with the applicable American Society of Mechanical Engineers, (ASME) Boller and Pressure Vessel Codes.
2.0 SCOPE This procedure is applicable for piping whose nominal thickness is greater than O.400 inches and less than 5.0 inches. In addition, vessels whose nominal wall thickness is less than 2.5 inches may be examined using this procedure. Examinations may be performed outside these ranges provided nondestructive examination (NDE) Level III concurrence is obtained. Other examinations may be performed using portions of this procedure upon NDE Level III concurrence.
3.0 APPLICABLE DOCUMENTS This procedure is written in compliance with the following documents:
- 1. ASME Boiler and Pressure Vessel Code,Section XI, 1990 Edition with Addenda through Winter 1980, " Rules for Inservice Inspection of Nuclear Power Plant Components."
" Nondestructive Examination."
In addition, this procedure is written in compliance with earlier editions of the ASME Boiler and Pressure Vessel Code and may be used as necessary when deemed acceptable by an NDE Level III examiner.
4.0 RESPONSIBILITIES 4.1 The manager - inspection, testing, and engineering shall be responsible for the approval and control of this procedure.
4.2 An NDE Level III certified in ultrasonic examination is responsible for having ultrasonic examination procedures and techniques developed and approved, and for assuring that this procedure, when correctly followed, will detect discontinuities which do not meet the applicable acceptance standards.
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UT-H-400 5.0 QUALIFICATION OF ULTRASONIC EXAMINATION PERSONNEL 5.1 All NDE personnel performing ultrasonic examinations in accordance with this procedure shall be qualified and certified to the requirements of a procedure (written practice) written and approved in accordance
, with the American Society of Nondestructive Testing (ASNT) SNT-TC-1A.
5.2 The ultrasonic examination may be performed by a Level I examiner under the direct supervision of a certified Level !I or Level III in ultrasonic examination; however, all interpretation of the results of the examinations shall be performed by a Level II or Level III examiner certified in ultrasonic examination. In addition, a trainee may assist in the performance of the ultrasonic examination provided the trainee is directly supervised by a Level II or Level III examiner.
6.0 ULTRASONIC EQUIPMENT 6.1 The Ultrasonic Instrument 6.1.1 A pulse-echo type ultrasonic instrument with an A-Scan presentation and operating frequencies '
of 1 to 10 MHz shall be used to perform examinations in accordance with this procedure. Screen height linearity, horizontal linearity, and amplitude control linearity (dB) shall be verified in accordance with Procedure UT-H -4 5 0 6.1.2 The following ultrasonic instruments shall be used in accordance with this procedure:
e KrautKramer Branson USL-38.
e Nortec 131.
e Sonic Mark I.
e KrautKramer USK-7.
Other instruments may be used provided Level III concurrence is obtained.
6.2 The Ultrasonic Search Unit (Transducer) 6.2.1 Search units having a nominal frequency of 2.25 MHz shall be used for examination in accordance with this procedure. However, for angle beam examination of austenitic piping, a search unit having a nominal frequency of 1.5 MHz shall be
.used.
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"T-H-400 6.2.2 Other frequencies may be used upon Level III concurrence when variables such as production material grain structure require their use to ensure adequate penetration or resolution.
6.2.3 The search unit size shall be in accordance with the following tables; however, other sizes may be used upon Level III concurrence.
STRAIGHT BEAM Nominal Material Nominal Search Unit Thickness (t) Size 0.401 to 1.999 in. 1/4- or 3/8-in.
round 2.000 to 2.999 in. 3/8- or .1/2-in.
round 3.000 to 3.999 in. 1/2 , 3/4 , or 1-in. round 4.000 to 4.999 in. 3/4- or 1-in.
round ANGLE BEAM Nominal Material Nominal Search Unit Size Thickness (t) Round Rectangular O.401 to 1/4 or 1/4 x 1/4 or O.999 in. 3/8 in. 3/8 x 3/8 in.
1~.000 to 3/8 or 3/8 x 3/8 or 1.999 in. 1/2 in. 1/2 x 1/2 in.
2.000 to 1/2 or 1/2 x 1/2 or 3.999 in. 3/4 in. 1/2 x 1 in.
4.000 to 3/4 in. 1/2 x 1 in.
4.999 in.
Notes: 1. For angle beam examination of large diameter (i.e., greater than 10 inches) austenitic piping, a 3/8-inch search unit shall be used for all material thicknesses.
- 2. For dual element search units, the dimension applies to one of the two elements.
6.2.4 The beam angle shall be 45 (nominal) refracted shear wave. When the examination can be conducted from only one side of the weld (e.g.,
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UT-H-400 pipe to valve, etc.), a 60* (nominal) or other appropriate angle (s) shall be used.
6.3 Couelant 6.3.1 USP-grade glycerine or deionized water shall be used when performing calibrations and examinations in accordance with this procedure.
6.3.2 Other compounds may be used upon the concurrence of an NDE Level III.
6.3.3 Couplants other than deionized water shall be certified for total sulfur and halogen content in accordance with American Society for Test ng and Materials (ASTM) D-129-64 and D-808-63.
The total residual amount of sulfur and halogen shall not exceed 1 percent by weight.
6.4 Reference Blocks Reference blocks (e.g., IIW Block, Rompas), if used, should be of the same material (e.g., carbon steel, stainless steel) as the component to be examined.
6.5 Basic Calibration Blocks 6.5.1 Drilled holes in a production material block of similar metallurgical structure and having the same or equivalent P-number grouping as the finished component shall be used as basic i
calibration reflectors. For the purpose of this function P-1, P-3, P-4, and P-5 are considered equivalent.
6.5.2 The basic calibration block shall be manufactured .in accordance with Section V,
' Article 5 of the ASME Boiler and Pressure Vessel Code.
6.5.3 Where different thicknesses are involved in j examination, the calibration block thickness is determined from the nominal thickness of the weld or component to be examined.
6.5.4 Flat basic calibration blocks or blocks of essentially the same curvature as the part to be examined may be used for examination of components with contact surface curvatures greater than 20 inches in diameter.
6.5.5 .Maen the contact surface curvature of the component is 20 inches or less, a single curved basic calibration block may be used to 4 of 15
UT-H-400 calibrate the examination on component contact surfaces in the range of curvatures from 0.9 to 1.5 times the basic calibration block diameter.
7.0 SEARCH UNIT (TRAMSDUCER) VERIFICATION 7.1 Prior to calibration of the ultrasonic system, the search unit beam exit point and nominal angle of refraction shall be verified using an appropriate reference block.
7.2 Angle beam search units used during ultrasonic calibration and examination shall comply with the following:
7.2.1 Angle beam search units shall produce a sound beam within 23 of the nominal angle.
7.2.2 Each search unit wedge shall be marked to clearly indicate the nominal angle of refraction and the beam exit point.
8.0 EQUIPMENT CALIBRATION 8.1 Prior to the beginning of each day of examination, the complete ultrasonic examination system shall be calibrated on the basic calibration block for the particular examination to be performed. The examination system includes the ultrasonic instrument (and battery pack, if applicable), search unit, coaxial cable, couplant and any other apparatus, instrument, or circuit used.
8.2 A change to any part of the system will require recalibration or at least a check of the calibration (subsection 8.7).
8.3 The reject control shall be placed and remain in the "O" (off or minimum) position during calibration and examination.
8.4 The temperature of the calibration block shall be within 25 F (14*C) of the component to be examined.
8.5 The equipment calibrations shall be performed in accordance with the following and the results documented on Ultrasonic Instrument Calibration Record, UT-H/F/V-Form 400C (Figure 400-1).
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UT-H-400 8.6 Angle Beam Calibration 8.6.1 Reflections from drilled holes in the appropriate basic calibration block shall be used for angle bea:n calibration. Note: Sweep range may be established using reflections from notches, corners, or an appropriate reference block.
8.6.2 For the examination of circumferential welds, responses from holes oriented perpendicular to the axis of the basic calibration block shall be used to construct a distance amplitude cor-rection (DAC) curve. The sweep range (screen distance) shall be adjusted to display at least the minimum number of vee-path as follows:
Thickness Sweep
, (t) Nominal Range t
.401 in.-l.999 in. 1 1/2 vee-paths (3t) 2.0 in.-4.999 in. 1 vee-path (2t) 8.6.3 For the examination of longitudinal welds, support attachment welds, and branch connection welds, a DAC curve shall be constructed by utilizing the responses from the hole (s) oriented axially with the basic calibration block. The sweep range shall be adjusted to display at least 1 full vee-path (2t); however, this sweep range may be extended for 1/2t hole calibration.
8.6.4 A DAC curve shall be constructed by utilizing responses from the basic calibration block holes. As a minimum, the DAC curve shall be accomplished by performing the following:
- 1. Position the search unit to obtain the maximum response from the applicable calibration block hole (s) and vee-path positions as follows:
Cal Block Vee-Path Hole (s) Positions 1/2t hole only 6/8, 10/8 1/4t, 3/4t 3/8, 5/8, i
holes 7/8, 9/8, i 11/8 l
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UT-H-400
- 2. Adjust the gain control so that the response from the first vee-path position is 80 percent of full screen height (FSH).
This 80-percent amplitude response shall be the primary reference response.
- 3. Check the vertical linearity of the test system by reducing the gain control setting by 6 dB. The resulting primary reference response signal amplitude should be reduced to 40 percent of FSH 15 percent. If the signal falls either above or below this range and if adjustment of the instrument controls fails to provide a satisfactory check, the transducer and/or the transducer cable shall be changed and the calibration repeated. If this change does not correct the vertical linearity, the instrument shall be changed.
- 4. Reestablish the primary reference response to 80 percent of FSH by adding back the 6 dB gain. Without further changing the gain, establish the maximum response from the other applicable reflectors. Mark each amplitude on the cathode ray tube (CRT).
These points shall be joined by a smooth line whose length covers the examination range, forming the DAC curve. This shall be the primary reference level.
8.6.5 Calibration Check A calibration reference response may be established using an appropriate reference standard, (e.g., Rompas, IIW Block). This reference response shall include both sweep and amplitude calibration points and shall be recorded on the CRT and Figure 401-1. This response may be used for calibration checks (section 8.6) when the basic calibration block is not available; however, final calibration
(" cal out") shall be performed on the basic calibration block.
8.7 Calibration Check 8.7.1 A calibration check on at least one of the basic reflectors in the basic calibration block or a check using a simulator or reference block (e.g., Rompas or DSC block) shall be made at the finish of each examination, every 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> 7 of 15
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UT-H-400 of examination, or when examination personnel are changed. If a simulator or reference block is used, it shall be identified on the applicable calibration sheet.
S.7.2 If, in the opinion of the examiner, there is doubt as to the validity of the calibration, a calibration check shall be performed.
8.7.3 If any point of the calibration check has moved on the sweep line by more than 10 percent of the sweep division reading, correct the sweep range calibration and note the correction on the applicable calibration sheet. If recordable indications are noted, the examination is voided, and a new calibration (section 8.0) shall be recorded and the voided examinations shall be reexamined.
8.7.4 If any point of t'he calibration check has 1
decreased more than 20 percent or 2 dB of its amplitude, all data and/or calibration sheets since the last calibration or calibration check shall be voided. A new calibration (section 8.0) shall be recorded and the voided examinations shall be reexamined.
3.7.5 If any point of the calibration check has increased more than 20 percent or 2 dB of its amplitude, all recorded indications since the last valid calibration or calibration check may be reexamined with the corrected calibration and their values shall be recorded on the applicable calibration and data sheet.
9.0 EXAMINATION AREAS 9.1 Unless otherwise specified (e.g., program, plan, etc.)
the examination volume shall be the inner inside :
diameter 1/3t (where t is the nominal wall thickness) '
and 1/4-inch base material from the toe of the weld, e.g., see Figure 400-2.
9.2 When conditions limit the area of examination, the limitations shall be recorded and an approximate percentage value assigned governing the area examined.
10.0 SURFACE PREPARATION i
The finished contact surfaces shall be free from weld spatter and any roughness that would interfere with free movement of-the search unit or impair the transmission of ultrasonic vibrations.
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UT-H-4CO 11.0 EXAMINATION PROCEDURE 11.1 When all required search unit verifications and equipment calibrations have been completed, the following procedure shall be used to perform the ultrasonic examination and the data recorded on Ultrasonic Weld Examination Record, UT-H/F/V-Form 400E (Figure 400-3).
11.1.1 The required volume of weld and base material shall be examined by the angle beam method from two sides of the weld, where practical. When the examination can only be conducted from one side of the weld (e.g.,
pipe to weld), then a 60 (nominal) or other appropriate angle shall be used to ensure the required examination volume is covered.
11.1.2 To assure complete coverage of the examination area, each pass of the search unit shall overlap a minimum of 10 percent of the search unit's width.
j 11.1.3 Scanning speed shall not exceed 6 inches per second; however, when examining austenitic material, slower scanning speeds may be necessary.
11.1.4 When practical, scanning shall be performed at a minimum of 2 times (6 dB) the primary reference level sensitivity; however, for the examination of austenitic material, scanning shall be performed at a minimum of 5 times (14 dB) the primary reference level sensitivity. If 14 dB scanning is impractical, e.g. noise, etc., lower scanning levels are permitted provided upon Level III concurrence. (Note: However, !
investigation and recording of indications shall be performed at the primary reference level.)
11.1.5 While scanning the search unit shall be scillated approximately 20* left and 20 l
t right and progressively indexed along the weld such that the entire scan follows a l zig-zag pattern. For austenitic material this oscillation shall be increased to t
approximately 30'.
11.1.6 Straight Beam Examination of the Base Material When required, (e.g., preservice i
examination) the volume of base material I
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UT-H-4CC through which the sound beam will travel in angle beam examination shall be examined by a straight beam transducer in accordance with the following:
- 1. The straight beam transducer shall be coupled to the production material at a location free of indications. The sensitivity of the instrument shall be adjusted as required to maintain the first back reflection at an amplitude of 50 to 80 percent of ESH.
- 2. Indications that have an amplitude equal to or greater than 50 percent of the initial back reflection and accompanied by a 50 percent loss of back reflection shall be recorded. If total loss of back reflection occurs, even if unaccompanied by an intermediate echo, the total area of back reflection loss shall be recorded.
11.1.7 Angle Beam Examination: Reflectors Parallel to the Weld 11.1.7.1 When practical, welds shall be examined (45 nominal) from both sides so that at least 1 1/2 vee-paths pass through the weld, the heat-affected zone, and the required volume of the base material on each side of the weld. When 1 1/2 vee-paths examination is impractical, a half-node examination may be performed.
3 11.1.7.2 Scanning shall be accomplished by placing the search unit on the
- contact surface with the beam aimed perpendicular to the weld and by manipulating the search unit laterally and longitudinally so that the ultrasonic beam passes through the required volume of weld and base material.
11.1.8 Angle Beam Examination: Reflectors Transverse to the Weld The angle beam examination (45* nominal only) shall be conducted by coupling the applicable search unit to the weld with the 10 of 15
UT-H-4C0 sound beam directed into and parallel with the weld and the required amount of base material. The entire length of the weld shall be scanned in this manner. The search unit shall then be rotated 180 and the scan completed in this direction. (Note: For austenitic materials only, the weld and 1/2 inch of the adjacent base material shall be scanned in this manner.)
11.1.9 Thickness Measurement Examination When indications are required to be recorded in accordance with section 13.0, thickness measurements should be recorded in the approximate area of the indications on the base material upstream and downstream and at the weld centerline. These measurements may be used to assist the examiner for evaluation of the indications.
11.1.10 Post-Examination Cleaning Upon completion of the ultrasonic examination, the couplant should be removed from the mrea of examination to the extent practical.
12.0 INVESTIGATION OF INDICATIONS All indications shall be investigated to the extent the examiner can determine the shape, identity, and location of all such indications.
13.0 RECORDING OF INDICATIONS 13.1 For austenitic piping welds, indications shall be recorded as follows:
Indication Indication Amplitude Evaluation Abbreviation O- to 49-percent Geometry NRI DAC disregard 50-percent DAC Geometry RI or greater Any Amplitude Flaw RI 13.2 For all other welds, the following requirements apply:
13.2.l' All indications that produce a response greater than 20-percent DAC and are 11 of 15
UT-H-400 interpreted by the examiner to be other than geometry shall be recorded.
13.2.2 All indications that produce a response greater than 20-percent DAC but are less than 50-percent DAC and are interpreted by the examiner to be geometry shall be disregarded.
13.2.3 All indications that produce a response 50-percent DAC or greater and are interpreted by the examiner as geometry shall be recorded and documented as geometrical indications.
13.2.4 A summary of the recording criteria is as follows:
Indication Indication Amolitude Evaluation Abbreviation O- to 20-percent Disregard NI DAC 21- to 49-percent Geometry, NRI DAC Disregard 50-percent DAC Geometry, RI or greater Record 21-percent DAC Other than RI or greater Gecmetry, Record 14.0 EVALUATION AND DISPOSITION OF INDICATICNS 14.1 It shall be the responsibility of a Level II or Level III certified in ultrasonic examination to review, evaluate, and disposition all recordable indications to determine their reportability requirements.
14.2 Reportable indications or other indications i determined to be significant by the Level II or Level l
III shall be reported to the operating company in accordance with Procedure ADM-H/F-205.
15.0 RECORDS Permanent documents generated in accordance with this procedure shall be included in the examination report. The examination report shall be submitted to the operating l company in accordance with Procedure ADM-H/F-207.
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ENCLOSURE RESPONSE TO NRC REQUEST OF SEPTEMBER 5,1986, FOR ADDITIONAL INFORMATION RELATIVE TO SUBCONTRACTOR UT PERSONNEL USED DURING THE WINTER 1985-86 MAINTENANCE / REFUELING OUTAGE -
4 PLANT HATCH UNIT 1 NRC Question 3:
" Provide a comparison of the contractor qualification procedures with those used for the examinations at Hatch 1 during the 1985 refueling outage."
Response
Ultrasonic examination procedures used by the subcontractors for qualification at the EPRI NDE Center include the following:
- 1. LMT Procedure UT-10, Revision 11/ Field Change No. 9.
- 2. LMT Procedure UT-41, Revision 0.
- 3. EPRI Module 17, Revision 1.
As noted in the response to NRC Question 1, SCS Procedure UT-H-400, Revision 5, Deviation 001, was used for weld examinations. All of the aforementioned procedures are manual contact ultrasonic examination procedures written generally to examine thickness ranges from 0.20 in. to 6.0 in. The aforementioned procedures are all written to Section XI of the ASME Boiler and Pressure Vessel Code. SCS Procedure UT-H-400 and LMT i Procedure UT-41 were written specifically to comply with the 1980 edition of the ASME Code. LMT Procedure UT-10 was written to comply with the 1977 edition of the Code, while EPRI Module 17 was written to comply with the 1974 edition, plus later editions, of the Code.
' All of the aforementioned procedures reference American Society for Nondestructive Testing document SNT-TC-1A for personnel qualification.
Equipment requirements vary but generally use an A-Scan presentation and manual search units with the principle angle of 45 degrees and frequencies of 1.5 to 2.25 MHz. SCS Procedure UT-H 400 also requires use of a supplemental 60-degree angle when the weld examination is limited to one side of the weld. This requirement is to ensure complete coverage of
- the examination volume.
A 2-Yee path calibration using a notch for sensitivity, with a minimum scanning level of +6 dB to +12 dB, is required by LMT Procedure UT-41.
LMT Procedure UT-10 requires using a notch for sensitivity with a scanning level of +14 dB. SCS Procedure UT-H-400 requires l
- 0816C E-3 10/31/86 4
- ~ . _ , _ . - , . , . . ,, --_ , . . . , _ . . . , - _ - . . , _ . , - - . , - _ . . . . _ . . . , _ . . , , . -
ENCLOSURE RESPONSE TO NRC RE0 VEST OF SEPTEMBER 5, 1986, FOR ADDITIONAL INFORMATION RELATIVE TO SUBCONTRACTOR UT PERSONNEL USED DURING THE WINTER 1985-86 MAINTENANCE / REFUELING OUTAGE -
PLANT HATCH UNIT 1 sensitivity to be set from the side-drilled holes and a scanning level of
+14 dB, when practical. The EPRI module allows use of side-drilled holes or notches and a scanning sensitivity from +6 dB to +14 dB. In general, the SCS procedure provides a more sensitive examination.
The scanning speed for all four procedures is generally 3.0 in, to 6.0 in, per second, with a transducer oscillation of 30 degrees to 45 degrees. It should be noted that the two LMT procedures require a scan at 30 degrees to 45 degrees to the weld, in addition to parallel and perpendicular scans. Al so , transducer overlap is nominally 50 percent for LMT Procedures UT-10 and UT-41,10 percent minimum overlap of the transducer's width for SCS Procedure UT-H-400, and 10 percent to 50 percent for EPRI Module 17.
Indications which cannot be attributed to noise or geometry are recorded for determination. LMT Procedure UT-41 requires the recording of any reflector greater than 25-percent distance amplitude correction (DAC) curve. SCS Procedure UT-H-400 requires the recording of any geometric reflector greater than 50-percent DAC. All of the procedures addressed in the response to NRC Question 2 require that any flaw, regardless of amplitude, be recorded.
As a general conclusion, all of the procedures discussed herein provide for a similar technique. The major difference between the SCS procedure and the other procedures discussed herein is that SCS Procedure UT-H-400 requires calibration on side-drilled holes which is generally a more sensitive calibration than one performed using the standard notch.
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0816C E-4 10/31/86