ML20236W741
| ML20236W741 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley |
| Issue date: | 12/30/1996 |
| From: | Sheffel B DETROIT EDISON CO. |
| To: | |
| Shared Package | |
| ML20236W737 | List: |
| References | |
| NUDOCS 9808060178 | |
| Download: ML20236W741 (115) | |
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I PERFORMANCE DEMONSTRATION INITIATIVE (PDI)
PROGRAM DESCRIPTION RE' VISION 1, CHANGE 1 December 30,1996 i
Approved By: ~
Bpacd/$heffel #
M PDI Committee Chairman 9808060178 980729 PDR ADOCK 05000410 G PDR
PDI Program Descripdon List of Effecdve Pages Coversbeet Rev.1 Change 0 List of Effective Pages Rev.1 Change 0 (04-26-96)
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l PDI Program Description List of Effective Pages I (Continued) !
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Appendix A Specimen Fabrication Rev.1, Change O Page1of1 Performance Demonstration Process Rev.1. Change O Page1of1 Quality Assurance Program Performance Demonstration Process Rev.1, Change 0 Page1of1 Quality Assurance Instructional Manual Appendix B PDI Position No. 94-001R1 Rev.1, Change 0 PDI Position No. 94-002R1 , Rev.1, Change O PD1 Position No.94-003 Rev.1. Change 0 PDI Position No. 94-004R1 Rev.1, Change 0 PDI Position No.94-005 Rev.1, Change 0 PDI Position No. 94-006R1 Rev.1. Change 0 PDI Position No. 94-007R1 Rev.1, Change O PDI Position No.94-008 Rev.1 Change 0 PDI Position No. 94-009R1 Rev.1. Change 0 PDI Position No. 94 010 Rev.1, Change 0 PDI Position No.95-001 Rev.1. Change 0 PDI Position No.95-002 Rev.1, Change 0 PDI Position No.95-003 Rev.1 Change 0 PDI Position No.95-004 Rev.1, Change O PDI Position No.95-005 Rev.1, Change 0 PDI Position No.95-006 Rev.1, Change O PDI Posidon No.95-007 Rev.1. Change 0 PDI Position No.95-008 Rev.1, Change 0 PDI Position No.95-009 Rev.1, Change 0 PDI Position No.95-010 Rev.1, Change 0 PDI Position No.95-011 Rev.1, Change 0 PDI Position No.95-012 Rev.1. Change 0 PDI Position No.95-013 Rev 1, Change O PDI Position No.96-001 Rev.1, Change 1 Appendix C PD1 Program Qualification Rev.1, Change 0 Sample Size Ranges Rev.1, Change 1 (12-30-%) 4
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ASME SECTION XI, APPENDIX VIII PERFORMANCE DEMONSTRATION FOR ULTRASONIC EXAMINATION SYSTEMS ARTICLE VIII-1000 SCOPE REQUIREMENT PDI IMPLEMENTATION '
VIII-1100 GENERAL:
(a) His Appendix provides requirements for performance (a) PDI has developed a written practice (Protocon that demonstration for ultrasonic examination procedures, Prescribes a method for implementation of these equipment, and personnel used to detect and size flaws. requirements.
(b) Each organization ( c.g., Owner or vendor ) shall have a (b) PDI has developed a program that provides a vehicle to written program that insures compliance with this meet all Appendix VIII requirements. Member utilities Appendix. >
may adopt the PDI program as their written program to satisfy ASME Appendix VIIIrequirements.
Each organization that performs ultrasonic examinations shall qualify its procedures, equipment, and personnel in accordance with this Appendix.
He organization may contract implementation of the program. -
(c) Performance demonstration requirements apply to (c) De PDI Program is designed to qualify personnel for the personnel who detect, record, or interpret indications or scope of examination task being performed (i.e.,
size flaws in welds or components. detection, recording,orinterpretation). See Appendix A and the Protocol for further information.
(d) He performance demonstration requirements specified (d) Appendix-A and the Protocol provides further details on in this Appendix do not apply to personnel whose this subject, involvement is limited to mounting a scanner device, marking pipe, or other situations where knowledge of ultrasonics is not important.
(e) Any procedure qualified in accordance with this (e) PDI monitors qualification of procedures and documents Appendix is acceptable. results. The qualification documentation is available to member utilities upon request.
(f) Instrument characterization described in Supplement I to (f) PDI Program Instruction PDP 1-012.1, provides for this Appendix. is ootional. Supplement I characterization. Some characterizations have been performed by PDI. PDI also maintains a list When Supplement I is selected, both the original and of equipment utilized during qualifications of manual substituted equipment shall be characterized. piping procedures as an aid to owners and vendors who may substitute equipment in the future (Ref. Procedure Nos. PDI-UT-1,2 & 3).
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ARTICLE VIII 2000 GENERAL EXAMINATION SYSTEM REQUIREMENTS REQUIREMENT PDI 13fPLENfENTATION VIII-2100 PROCEDURE REQUIREMENTS:
(a) De PDI Program requires that procedures specify the (a) ne examination procedure shall contain a statement of scope that specifically defines the limits of procedure limits of applicability in the Scope section. ,
applicability ( e.g. materials, thickness, diameter, product form). He PDI Program uses the Scope section of the Candidate Registration Form to assemble test sets required to demonstrate the limits of the specific procedure.
PDI generic procedures (PDI-UT 1,2 & 3) contain scope statements which specifically define the limits of each procedure's applicability including such items as materials, thickness, diameter, and product form.
(b) De examination procedure sha21 specify a single value (b) PDI has developed an instruction (PDP-I-009.1) which or a range of values for the variables listed in VIII- contains a checklist that specifically addresses all 2100(d). essential variables, ne instruction and checklist are used during the procedure review process to assure that procedures specify a single value or range of values for each essential variable.
He checklist will be used to verify suitability of procedures to be demonstrated for qualification.
(c) Any calibration method may be used provided it is (c) PDI has developed an instruction (PDP-I-009.1) which described and complies with VIII-2100(d)(5). contains a checklist that specifically addresses essential elements of calibration. The checklist is used during the procedure review process to assure that procedures contain the required elements for repeatable calibrations.
Du candidate fills out calibration forms which are used during the surveillance process of the demonstration.
(d) The examination procedure shall specify the following (d) PDI has developed an instruction (PDP-I-009.1) which essential variables: contains a checklist that specifically addresses all essential variables [(d)(1) through (d)(10)]. De instruction and checklist are used during the procedure review process to assure that procedures specify a single value or range of values for each essential variable.
The checklist will be used to verify suitability of procedures to be demonstrated for qualification.
(1) instrument or system, including manufacturer and model or series of pulser, receiver, and amplifier; (2) search units, including:
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ARTICLE VIIIo2000 GENERAL EXAMINATION SYSTEM REQUIREMENTS REQUIREMENT PDI IMPLEMENTATION (a) center frequency and either bandwidth or waveform duration as defined in VIII-4000; ,
I (b) mode of propagation and nominalinspection angles; (c) number, size, shape, and configuration of active elements and wedges or shoes; (3) search unit cable, including:
(a) type; (b) maximumlength; a (c) maximum number of connectors (4) detection and sizing techniques, including:
(a) scan pattern and beam directions; (b) maximum scan speed; (c) minimum and maximum pulse repetition rate; (d) minimum sampling rate (automatic recording systems);
(e) extent of scanning and action to be taken for access restrictions; (5) methods of calibration for detection and sizing (e.g.,
actions required to insure that the sensitivity and accuracy of the signal amplitude and time outputs of the examination system, whether displayed, recorded, or automatically processed, are repeated from examination to examination);are repeated from examination to examination);
(6) inspection and calibration data to be recorded; l
(7) method of data recording;
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ARTICLE VIII-2000 GENERAL EXAMINATION SYSTEM REQUIREMENTS (8) recoriling egoignent (e.g., strip chart, analog tape, digitizing) when used; (9) method and criteria for the discrimination of indications (e.g., geometric versus flaw indications .
and fo'r length and depth sizing of flaws); ,
(10) surface preparation requirements ARTICLE VIII-3000 QUALIFICATION REQUIREMENTS REQUIREMENT PDI IMPLEMENTATION VIII-2200 PERSONNEL REQUIREMENTS Personnel shall meet the requirements of Appendix VII and It is the owners responsibility to comply with this shall be qualified in accordance with VIII-3000. requirement. He PDI Program requires candidates to provide documentation that they have been %fied to at least Level II in UT per their employers wn practice.
PDI will not review the employers written practice.
VIII-3100 QUALIFICATION TEST REQUIREMENTS:
VIII 3110 DETECTION:
(a) Qualification test specimens shall meet the requirements (a) PDI has fabricated samples that meet all of the of the appropriate Sapplement listed in Table VIII 3110- requirements of Supplements 2 through 8 and 12
- 1. identified in Table VIII-31101 (below).
PDIis not addressing cast austenitic piping welds because the requirements are in the course of preparation. Supplement 10 " Dissimilar Metal" and Supplement 1I " Overlay," are not included in the scope of the PDI Program at this time.
(b) ne examination procedure, equipment, and personnel (b) PDI Procedures PDP-Q-009.1 and PDP-Q-018.3, require are qualified for detecting flaws upon successful that surveillance be conducted by qualified personnel to completion of the performance demonstration specified determine that combinations of procedures, equipment, in the appropriate Supplement listed in Table and personnel can detect the prescribed number and type VIII-3110-1. of test set flaws during the qualification demonstration.
(c) For piping welds whose requirements are in course of (c) PDIis not addressing implementation of Appendix III.
preparation, the requirements of Appendix III, as supplemented by Table I 20001, shall be met.
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ARTICLE VIII-3000 QUALIFICATION REQUIREMENTS REQUIREMENT PDI IMPLEMENTATION VIII 3110 DETECTION: (Condnued)
TABLE VIII 31101 ,
COMPONENT QUALIFICATION SUPPLEMENTS .
Component Type Applicable Supplement Piping Welds Wrought Austenitic 2 Ferritic 3 Cast Austenitic [ Note (1)]
Dissimilar Metal , 10 Overlay 11 Vessels Clad / Base MetalInterface Region 4 Nozzle Inside Radius Section 5 Reactor Vessel Welds Other Than Clad / Base MetalInterface 6 Nozzle-to-Vessel Weld 7 Bolts and Studs 8 NOTE:
(1) In course ofpreparation. The PDI Program meets Supplements 2, 3, 4, 5, 6, 7, 8 and 12 (12 inadvenently left out of the
'93 Addenda to Appendit Vill).
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ARTICLE VIII-3000 QUALIFICATION REQUIREMENTS REQUIREMENT PDI IMPLEMENTATION l
i i VIII 312(, SIZING:
(a) Qualifi:ation test specimens shall meet the requirements (a) All PDI fabricat,ed samples meet a!! of the requirements of the a) propriate Supplement listed in Table VIII-3110- of the specific supplements identified in Table VIII -
1.
3110-1 above except Supplements 10 and 11.
Supplements 10 and 11 are not included in the current scope of the PDI effort.
(b The examination procedure, equipment, and personnel (b) The PDI Program provides for monitoring and are qualified for sizing flaws upon successful completion determination of acceptable values of essential variables of the performance demonstration specified in the in accordance with Procedure PDP-Q-018.3 during the appropriate Supplement listed in Table VIII 3110-1. conduct of performance demonstreions.
(c) For piping welds whose requirements are4n course of (c) PDIis not addressing implementation of Appendix III.
preparation, the requirements of Appendix III, as supplemented by Table I-2000-1, shall be met.
VIII 3130 ESSENTIAL VARIABLE RANGES:
(a) Any two procedures with the same essential variables (a) The PDI program provides for monitoring of acceptable
[VIII-2100(d)] are considered equivalent. Pulsers, essential variables in accordance with Procedures PDP-search units, and receivers that vary within the tolerances Q-018.3 and PDP-Q-009.1. The Program also provides specified in VIII-4100 are considered equivalent. When for documentation of Performance test results. It is the the pulsers, search units, and receivers vary beyond the responsibility of the owner / vendor to determine tolerances of VIII-4100, or when the examination equivalency of procedures.
procedure allows more than one value or range for an essential variable, the qualification test shall be repeated The PDI program, in accordance with Instruction PDP-I-at the minimum and maximum value for each essential 009.1, and procedures PDP-Q-009 and PDP-Q-009.1, variable with all other variables remaining at nominal provides measures whereby changes to essential values. Changing the essential variable may be variables may be accomplished during successive accomplished during successive personnel performance personnel performance demonstrations. Each examiner demonstrations. Each examiner need not demonstrate need not demonstrate qualification over the entire range qualification over the entire range of every essential of every essential variable.
variable.
(b) When the procedure does not specify a range for (b) Procedures are reviewed in accordance with PDI essential variables and establishes criteria for selecting Instruction PDP-I-009.1 to determine if it is criteria values, the criteria shall be demonstrated. based. A successful demonstration by a candidate qualifies the procedure.
VIII 3140 REQUALIFICATION When a change in an examination procedure causes an Procedures are requalified at the request of owner / vendors.
essential variable to exceed a qualified range, the PDI generic procedures are requalified when essential examination procedure shall be requalified for the revised variable changes exceed the qualified range.
range.
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ARTICLE VIII 4000 ESSENTIAL VARIABLE TOLERANCES REQUIREMENT PDI IMPLEMENTATION VIII 4100 PROCEDURE MODIFICATIONS In lieu of the requirements specified in VIII-4110(a)-(h) PDI will qualify component substitutions in generic procedures by including any new components into personnel demonstrations. -
Satisfactory personnel demonstrations using components different than originally specified will qualify the new component.
VIII-4110 PULSERS, RECEIVERS, AND SEARCH UNITS ne qualified procedure may be modified to substitute or Owners or vendors may qualify equipment for substitution replace pulsers, receivers, or search units without , using PDI personnel demonstration or as described in VIII.
requalification when the following conditions are met. 4110 (a)-(h).
(a) Instruments with reject, damping, or pulse tuning controls, have discrete settings specified in the prrxedure.
(b) Pulsers and receivers shall be evaluated using ASTM E 1324, Guide for Measuring Some Electronic Characteristics of Ultrasonic Instruments, with the following exceptions:
(I) De lower (FJ and upper (Fu) limits for receivers shall be determined between frequencies that are 6 dB below the peak frequency.
(2) The receiver center frequency (Fe) shall be determined by:
Fc = FL + Fu 2
(3 De receiver band width (BW)shall be determined by:
BW = Fu - Ftx100 Fc (c) Search units shall be evaluated using ASTM E 1065 Evaluation of the Characteristics of Ultrasonic Search Units.
(d) Examination systems shall be evaluated using Supplement 1.
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ARTICLE VIII-4000 ESSENTIAL VARIABLE TOLERANCES
. REQUIREMENT PDI IMPLEMENTATION (e) Replacements of tl s instrument or the pulser section of the instrument system shall be within the following tolerances of the original equipment as measured into a 50 ohm, noninductive, noncapacitive, resistive load: ,
(1) pulse amplitude, ,,10%;
(2) pulse rise time, .10%;
(3) pulse duration. 10 %
(f) Replacements of the instrument or the receiver section of the instrument system shall be within the following tolerances of the original equipment:
(1) lower and upper frequency limits at the -6 dB point. 0.2 MHz:
(2) center frequency for instrument receivers with bandwidths less than 30%, 5%;
(3) center frequency for instrument receivers with bandwidths equal to or greater than 30%, 10%.
(g) Replacements of search units shall be within the following tolerances of the original search units:
(1) propagation mode is the same (2) measured angle, 3 deg.
(3) center frequency for search units with bandwidths less than 30%, 5%
(4) center frequency for search units with bandwidths equal to or greater than 30%, 10%
(5) waveform duration, ty cycle or 20%, whichever is greater (measured at -20 dB), or bandwidth, i 10 (h) As an alternative to (e) through (g) above, equipment replacement is acceptable if the examination system is within the following tolerances of the original system:
(1) system center frequency for examination systems with bandwidths less than 30%, 5%
(2) . system center frequency for examination systems with bandwidths equal to or greater than 30%,
10% ,
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(3) system bandwidth,t10%
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I l ARTICLE VIII 4000 ESSENTIAL VARIABLE TOLERANCES l
REQUIREMENT PDI IMPLEMENTATION
( VIII4120 SEARCH UNIT CHARACTERIZATION Characterization measurements of the search unit shall be l made using either a sinusoidal tone burst technique or shock ,
i excitation. When using shock excitation, the characterization l
pulser and UT instrument pulser shall be the same within the limits of VIII4110(e).
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ARTICLE VIII-5000 RECORD OF QUALIFICATION REQUIREMENT PDI IMPLEMENTATION VIII 5100 GENERAL The organization's performance demonstration pregram shall Each OwnerNendoc has the responsibility to describe in their specify the documentation that shall be maintained as performance deinonstration program, the docum,entation to qualification records. Documentation sha!!ir.clude be maintained as qualification records. PDI Program identification of personnel, NDE procedures, and equipment documentation may be adopted by the OwnerNendor, as and specimens used during qualification, and results of the applicable, to satisfy a portion of their program requirements.
performance demonstration.
PDI Program Prorocol will generate the following as qualification records: identification of personnel, NDE procedures, and equipment and specimens used during qualification, and results of the performance demonstration.
In accordance with Procedure PDP-Q-017 each qualification shall be documented on a performance demonstration
. qualification summary which meets the requirements of PDI Procedure PDP-Q-009.1.
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APPENDIX VIII- SUPPLEMENTS l
SUPPLEMENT 1 {
EVALUATING ELECTRONIC CHARACTERISTICS OF ULTRASONIC INSTRUMENTS REQUIREMENT PDI IMPLEMENTATION 1.0 PULSE RISE TIME, DURATION, AND .
AMPLITUDE -
1.1 The pulser evaluation shall be performed with a 50 ohm 1.1 PDI performed a few electronic characterizations in noninductive resistive load. Additionalloads, including accordance with Instruction No. PDP-I-012.1 written to search units, may be used. However, significant meet this supplement. It is the owner / vendor's impedance mismatches may occur, which can cause responsibility to implement this supplement if they variable results. A description of any additional loads choose to do so. PDI will not use this supplement to shall be included in the report. substitute equipment listed in a PDI generated examination procedure.
1.2 Connect the ultrasonic instrument, cables, attenuator, 1.2 terminators, and oscilloscope as shown in* Fig. VIII SI-1.
CAUTION: Pulser circuits can produce very high pulse voltages that may exceed attenuator maximum voltage limits. Choose an attenuator that can handle the peak pulser voltage.
Set the pulser modulefrequency cpntrol to thefrequency ofinterest. (This is only necessary if the instrument has a tunedpulse shape. An example ofa tunedand broadbandpulse are shown in Fig. Vill-Si 2.) Set the pulse shape modification controls (e.g., pulse length, pulse tuning, damping) to obtain a minimum pulse length and adjust the oscilloscope to obtain a display as shown in Fig. Vill SI-3 or Fig. Vill SI-4.
NOTE: In order to obtain a display that clearly shows the leading edge of the pulse, it may be necessary to trigger the oscilloscope externallyfrom the clock logic signal or utslize an oscilloscope with built in delay.
1.3 The interconnection between the ultrasonic instrument 1.3
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and the oscilloscope shall be made such that a ;
characteristic impedance of 50 ohms is maintained. The cable length shall be kept as short as possible.
CA UTION: Pulser circuit output pulses can exceed maximum oscilloscope input levels. Use protective probes where necessary.
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SUPPLEMENT 1 EVALUATING ELECTRONIC CHARACTERISTICS
- OF ULTRASONIC INSTRUMENTS REQUIREMENT PDI IMPLEMENTATION 1.4 Pulse Rise (a) ne pulse rise time T R for a broadband pulse is the 1.4(s) '
time interval (in ns) between the 10% and 90%
points (relative to the peak amplitude) on the leading edge of the pulse shape as shown in Fig.
VIII-SI 3.
(b) TR or f a tuned pulse is the time interval between 1.4(b) the 10% and 90% points (relative to the peak amplitude) on the leading edge of the pulse shape as shown in Fig. VIII-SI-4.
(c) The PULSE RISE TIME - MIN for,the 50 ohm 1.4(c) load is the TR with the pulse shape modification controls set for the minimum pulse length, ne PULSE RISE TIME - MAX for the 50 ohm load is the TR with the pulse shape modification controls set for the maximum pulse length. Rese values shall be recorded.
1.5 Pulse Amplitude (a) ne pulse amplitude for a broadband pulse with a 1.5(a) specified pulse load is the peak amplitude of the pulse (in volts) as shown in Fig. VIII-S t-3.
(b) For the tuned pulse, the pulse amplitude is 1.5(b) determined by measuring the peak amplitude of the positive and the negative portions of the pulse as shown in Fig. VIII-SI-4 and summing these two values. De amplitude of the positive and the negative peaks shall be reported separately.
(c) The PULSE AMPLITUDE - MIN for the 50 ohm 1.5(c) load is the pulse amplitude with the pulse shape modification controls set for minimum pulse length. De PULSE AMPLITUDE - MAX for the 50 ohm load is the pulse amplitude with the pulse shape modification controls set for maximum pulse length. Rese values shall be recorded.
1.6 Pulse Duration (a) The pulse duration TD for a broadband pulse with 1.6(a) the 50 ohm pulse load is the time (in microseconds) corresponding to the time interval between the 10%
point on the leading edge of the pulse shape and the 10% point on the tailing edge of the pulse shape (relative to the peak amplitude) as shown in Fig. VIII-S t-5.
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SUPPLEMENT 1 EVALUATING ELECTRONIC CHARACTERISTICS OF ULTRASONIC INSTRUMENTS REQUIREMENT PDI IMPLEMENTATION 1.6 Pulse Duradon (Cont'd) ,
(b) For a tuned pulse. Ta'is determined by super 1.6(b) ,
imposing curves representing the envelope of the '
pulse as shown in Fig. VIII S t-6. The pulse duration is determined in the following manner:
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Pomer supply -
section t
so a so n p, no n "A setenuator
"" wrminseer ',
tion w ametion FIG. VIII-511 PULSE RISETIME, DURATION, AND AMPLITUDE MEASUREMENT l
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- ,sw (a) Tened Puhe (b) armedhand Pulse FIG. VI!!-$12 PULSE DISPLAY l
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l FIG. VIII-513 BROADBAND PULSE EVALUATION ro .ia. - -w -in* .
nesstive .ies empetume i u
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lI f p nw Il ll u w eihuse j i. _ _ _ _ l_Ii _ _ __ __ _ V I Nosstive I
- l snplitude a _____
_______________ 9 FIG. VIII-SI 4 TUNED PULSE EVALUATION t
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a .__: ______ _______
FIG. VI!! SI 5 BROADBAND PULSE EVALUATION FOR PULSE DURATI0h To I I I / 's l I
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i FIG.VIII-514 7UNED PULSE EVALUWG0N FOR PULSE DURATION j 16 Revision 1, Change 0
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SUPPLEMENT 1 EVALUATING ELECTRONIC CHARACTERISTICS OF ULTRASONICINSTRUMENTS REQUIREMENT PDI IMPLEMENTATION 1.6 Pulse Duration (Continued)
STEP 1: Construct lines on the positive ar.d negative sides ,
of the 7.ero voltage line at an amplitude equal to .
10% of the respective peak amplitudes.
STEP 2: To is the maximum time interval between the points where the 10% lines from Step 1 intersect the pulse envelope as shown in Fig. VIII S t-6.
(e) ne PULSE DURATION - MIN for this pulse load 1.6(e) is To with the pulse shape modification controls set for minimum length. De PULSE DURATION
- MAX for this pulse load is To with the pulse shape modification controls set for maximum pulse length, nese values shall be recorded.
2.0 RECEIVER SECTION FREQUENCY CHARACTERISTICS 2.1 Connect the ultrasonic instrument, protective circuit, 2.1 variable delay gate generator, function generator, oscilloscope, step attenuator, and terminator, as shown in Fig. VIII SI-7. De variable delay gate generator is used to provide a function generator trigger which is time delayed. The oscilloscope is used to monitor the function generator output, which is the unattenuated input signal to the ultrasonic instrument receiver section.
the ultrasonic instrument CRT is used to monitor the receiver output. De impedance of each ponion of this system shall be matched.
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2.2 CAUTION
De ultrasonic instrument shall be in the 2.2 through-transmission mode to isolate the pulser circuit from the receiver section. This is to avoid possible damage to the step attenuator and/or function generator.
The protective circuit is a diode clamp or voltage divider that keeps the high pulse voltage from damaging the variable delay gate generator input.
(a) For instruments that have a substantial portion of 2.2(a) l the receiver located before the through-l transmission input, set the pulse length controls in l
their maximum position, disable the pulse output, and set the instrument in the pulse-echo mode.
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SUPPLEMENT 1 EVALUATING ELECTRONIC CHARACTERISTICS OF ULTRASONIC INSTRUMENTS REQUIREMENT PDI IMPLEMENTATION
2.2 CAUTION
(Continued)
(b) If the receiver provides variable signal filtering, the 2.2(b) .
signal filtering control shall be set for minimum or zero filtering. Set the receiver reject control to minimum or OFF. Set the receiver frequency control to the frequency range ofinterest and adjust the gate generator and function generator to provide a five-cycle sine wave whose frequency corresponds to the ultrasonic instrument frequency setting. However,if the ultrasonic instrument will amplify and detect a single-cycle burst instead of a five-cycle, this may be used. Set the calibrated attenuator to O dB attenuation and adjust the variable delay gate generator to provide a signal located midway across the CRT, (The ultrasonic instrument sweep rate is irrelevant to these measurements.) Adjust the receiver section gain controls and the function generator output amplitude to 80% full scale. (A preliminary scan of the frequency range may be desirable to determine the frequency of maximum response.)
(c) Repeat the above measurements, varying the 2.2(c) function generator frequency in 0.5 MHz increments above and below the receiver module frequency control setting until the CRT indication i decreases to 10% ofits maximum value. At each frequency increment, the function generator output amplitude shall be adjusted as required to maintain a constant amplitude input to the receiver Section.
At each frequency increment, record the CRT amplitude (in present full scale) versus frequency measured with the oscilloscope. Plot the results as shown in Fig. VIII-St 8.
NOTE: The 0.25 MHz and 20 MHz points shall normally be the extent ofmeasurement necessary to determine the frequency characteristics ofthe receiver. These limits may be reachedbefore the CRTindication decreases to 10% ofits maximum value.
(d) If the ultrasonic instrument is to be operated with 2.2(d) filtering, the measurements described shall be repeated at the corresponding filtering levels.
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SUPPLEMENT 1 EVALUATING ELECTRONIC CHARACTERISTICS OF ULTRASONIC INSTRUMENTS l
REQUIREMENT EDI IMPLEMENTATION 2.3 Receiver Frequency Results (a) Lower Frequency Limit FL. De lower 2.3(a) ,
frequency limit (in MHz) at a specific frequency control setting is the lowest frequency at which the instmment CRT indication is 6 dB below the maximum amplitude as shown in Fig. VIII-St 8.
(b) Center Frequency FC. He center frequency (in 2.3(b)
MHz) at a specific frequency control setting is the frequency at which the instrument CRT indication is maximum, as shown in Fig. VIII S t-8. The center frequency shall be determine within 10.1 '
MHz by decreasing the increment of frequency change in the region near the center frequency. {
q (c) Upper nequerev Limit FU. De upper 2.3(c) frquency limit (m MHz) at a specific frequency control setting is the highest frequency at which the instrument CRT indication is 6 dB below the maximum amplitude as shown in Fig. VIII.SI-8.
(d) ne measurements described in 2.3(a) through 2.3(d) 2.3(c) shall be repeated for each receiver module frequency control setting to determine the LOWER FREQUENCY LIMIT (in MHz) for eac.' setting.
Rese values shall be recorded.
I l
19 Revision 1, Change 0
A To test symem I I
-m A 6 .A.AAAA
' w eer Manipulator Search unit n
i:,
U l [ Glass block I l FIG. VI!!-SI18 TEST CONFIGURATION ,
20 Revision 1, Change 0
I to .
I F
l r. . _L ,+ F,
__3 4.__ __._ _ __ __ _ ____ _
. \
-4 dB l
l Ft F, 4 I
. , _ __ t _ _ __ __ _ ____ _ _ _ _ . _ _ _ _ _ _ _ _ _
l l I I l
l !
2 _
l i
I I l l l
.I I I II I i l I I l1 I i 1 2 3 ,E 6 7 . 9 10 11 12 rmuency,MHz FIG. VI!!-SI 2A FREQUENCY RESPONSE CURVE l
l l
i 21 Revision 1, Change 0
SUPPLEMENT 2 QUALIFICATION REQUIREMENTS FOR WROUGHT AUSTENITIC PIPING WILDS REQUIREMENT PDI IMPLEMENTATION 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the requirements 1.0 ne PDI Progra'm test specimens have been designed to listed herein, unless a set of specimens is designed to meet all requirements of Supplement 2 as delineated accommodate specific limitations stated in the scope of the below. A wide range of specimen sizes and geometric examination procedure (e.g., pipe size and access configurations is available to demonstrate owner / vendor lirr.itations). He same specimens may be used to procedures.
demonstrate both detection and sizing qualification.
1.1 General. De specimen set shall conform to the following requirements.
(a) Specimens shall have sufficient volume to minimize 1.1(a) Specimens have been designed and fabricated with spurious reflections that may interfe,re with the sufficient volume to minimize spurious reflections that interpretation process. may interfere with the interpretation process.
(b) The specimen set shall consist of at least four 1.l(b) PDI performed an industry-wide survey on the range specimens having different nominal pipe diameters of sizes and geometric ccaditions and sizes that exist and thicknesses. ney shall include the minimum within the industry. (i.e.: counter bore, weld crown and maximum pipe diameters and thicknesses for widths and weld roots.) For list of sizes see Appendix -
which the examination procedure is applicable. If C.
the procedure is applicable to pipe diameters of 24 in. or larger, the specimen set must include at least The PDI Program has provided an adequate quantity of one specimen 24 in. or larger in diameter with the samples to address piping ranges found in member maximum thickness covered by the procedure, but utility facilities, need not include the maximum diameter.
PDI will allow a .1 inch tolerance on minimum thickness, a .5 inch tolerance for maximum thickness on austenitic piping, and a 1.0 inch tolerance for the maximum thic~kness qualified on ferritic piping during the demonstration. (See PDI Position 94-001)
(c) ne specimen set shall include examples of the 1.1(c) PDI performed an industry. wide survey on the range following fabrication condition: of sizes and geometric conditions that exist within the industry. (i.e.: counter bore, weld crown widths and weld roots.) For list of sizes see Appendix - C. PDI samples encompass a range of fabrication conditions which fully meet (c)(1) through (c)(4) requirements.
(1) unround weld reinforcement (crowns); 1.1(c)(1) PDI has developed general and specific design requirements that provide for samples with flat-topped reinforcement. Weld crowns will be masked if the procedure requires examination through unground Crowns.
(2) wide crowns, such that the total crown width is 1.1(c)(2) PDI has developed general and specific design i 1/2 to 2 times the nominal pipe wall requirements that provide for samples with wide crowns.
thickness:
22 Revision I, Change 0
SUPPLEMENT 2 QUALIFICATION REQUIREMENTS FOR WROUGHT AUSTENITIC PIPING WELDS 1.1 General. (Continued)
(3) geometric conditions that normally require 1.1(c)(3) PDI has developed general and specific design discrimination from flaws (e.g., counterbore, requirements that provide for samples having various weld root conditions such as excessive I.D. internal geometric conditions..
reinforcement); '
(4) typicallimited scanning surface conditions, 1.1(c)(4) PDI has developed generai and specific design (e.g., diametrical shrink, single-side eccess due requirements that provide for samples having scan to safe ends or fittings), limitations.
l l
i 23 Revision 1. Change 0
SUPPLEMENT 2 QUALIFICATION REQUIREMENTS FOR WROUGHT AUSTENITIC PIPING WELDS REQUIREMENT PDI IMPLEMENTATION 1.1 General. (Continued)
(d) All flaws in the specimen set shall be cracks. 1.1(d) All flaws in the PDI specimen sets are cracks.
(1) Mechanical fatigue cracks and either IGSCC or 1.1(d)(1) All flaws are cracks. Field removed IGSCC thermal fatigue cracks shall be used. Atleast specimens are being used in the performance 75% of the cracks shall be either IGSCC or demonstration process. Non-!GSCC test sets include the thermal fatigue cracks required amount of mechanical and thermal cracks.
(2) At least 50% of the cracks shall be coincident 1.1(d)(2) PDrs test administration instruction (PDP with areas described in 1.0(c) above 009.4.1) ensures that these conditions are addressed and documented.
1.2 Detection Specimens The specimen set shallinclude 1.2 He PDI detection specimens meet the following detection specimens that meet the following requirements.
requirements:
(a) Specimens shall be divided into grading units. Each 1.2(a) The PDI Program designed and fabricated specimens grading unit shall include at least 3 in. of weld which contain flawed and unflawed areas (grading units) length. If a grading unit is designed to be unflawed, which fully comply with the requirements of 1.2(a). In at least 1 in. of unflawed material shall exist on addition, PDI applied a Quality Assurance program to either side of the grading unit. The segtnent of weld verify compliance with specimen design and fabrication length used in one grading unit shat! not be used in requirements.
another grading unit. Grading units need not be uniformly spaced around the pipe specimen.
TABLE VIII-S21 PERFORMANCE DEMONSTRATION DETECTION TEST ACCEPTANCE CRITERIA Detection Test False Call Test Acceptance Criteria Acceptance Criteria l
No. of Flawed Grading Minimum Detection No.of Unflawed Grading Maximum Number of
, Units Cdteria Units False Calls 1
1 5 5 10 0 6 6 12 1 7 6 14 1 8 7 16 2 9 7 18 2 10 8 20 3 !
11 9 22 3 12 9 24 3 l 13 10 26 4 14 10 28 5 j 15 11 30 5 '
16 12 32 6 17 12 34 6 18 13 36 7 19 13 38 7 24 iuvision 1, Change 0
SUPPLEMENT 2 QUALIFICATION REQUIREMENTS FOR WROUGHT j AUSTENITIC PIPING WELDS l REQUIREMENT PDI IMPLEMENTATION 1.2 Detection Specimens (Continued)
(b) Detection sets shall be selected from Table VIII S2- 1.2(b) PDI prot'ocol requires a minimum of 5 flpwed grading
- 1. The number of unflawed grading units shall be at units and 10 unflawed grading units to be included in a least twice the number of flawed grading units. test for procedure qualification. For personnel l
qualifications, a minimum of 10 flawed and 20 unflawed i Frading units shall be included in a test set. Detection test sets are selected from Table VIII.S2-1.
(c) Flawed grading units shall meet the following 1.2(c) Flawed and unflawed grading units are randomly criteria for flaw depth, orientation, and type, placed through the specimen (s) circumference.
(1) A minimum of 1/3 of the flaws, rounded to the 1.2(c)(1) A PDI computer software program was especially nex. higher whole number, shall have depths developed to aid the administrator in selecting specimens between 5% and 30% of the nominal pipe wall which meet the requirements of paragraphs 1.1,1.2, and thickness. At least 1/3 of the flaws, rounded to 1.3 in assembling test sets. He exceptions to ti.is rule the next higher whole number, shall have depths are IGSCC specimens and independently administered greater than 30% of the nominal pipe wall length sizing test.
thickness.
Due to the fact that the IGSCC flaws in the piping test specimens are service induced and were removed from operating power plants, compliance with the through wall sizing distribution requirements are not mandatory.
Also paragraph 3.8.1.C of Instruction PDP-I-009.4.1 states,"When length sizing tests are administered independently the flaw through wall depth requirements do not apply."
(See PDI Position 95-001)
(2) At leas: one and a maximum of 10% of the 1.2(c)(2) PDI Specimen Test Sets assure that at least one and flaws rounded to the next higher whole number, a maximum of 10% of the flaws are oriented axially. In-shall be oriented axially. De remainder of the process verification and receipt inspections were flaws shall be oriented circumferentially. performed to ensure that flawed and unflawed areas were fabricated in accordance with the requirements of ASME Section XI, Appendix VIII, and PDI specification requirements for flaw orientation.
i (3) Service-induced flaws shall be included when 1.2(c)(3) PDI samples include piping welds with flaws that available, were removed from operating nuclear power plants.
l f
, 25 Revision 1. Change 0 l
l
SUPPLEMENT 2 QUALIFICATION REQUIREMENTS FOR WROUGHT AUSTENITIC PIPING WELDS REQUIREMENT PDI IMPLEMENTATION 1.3 Sizirg Speelmens De specimen set shall contain 1.3 Ihe PDI sizing specimens meet the following sizing specimens that meet the following requirements: requirements. ,
(a) He minimum number of flaws shall be ten. 1.3(a) De PDI Program provided for a minimum of ten j flaws which are used for both depth and length sizing. !
(b) Flaws in the sample set shall be distributed as 1.3(b) PDI Program depth sizing flaws are distributed in follows: accordance with the Table in Section 1.1(b). See Section 1.2(c)(1) for length sizing specimens when length sizing is performed with detection examinations.
Flaw Depth Minimum
(% Wall Thickness) Number of Flaws 5 30% 20 %
31 60 % -
- 20%
61 - 100 % 20%
ne remaining flaws shall be in any of the above categories.
2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS De specimen inside surface and identification shall be All specimens are mounted or capped to conceal the concealed from the candidate. All examinations shall be inside surface. All specimens are constantly under direct completed prior to grading the results and presenting the monitoring, video surveillance, or in locked storage.
results to the candidate. Divulgence of particular PDI has developed a security program to safeguard and specimen results or candidate viewing of unmasked hold in confidence the specimens, the manufacturing data specimens after the performance demonstration is and the results of the performance demonstration prohibited. qualifications. Grading results are presented to the candidate after the examination is completed.
- 2.1 Detection Test. Flawed and unflawed grading units 2.1 In-process verification and receipt inspections were l shall be randomly mixed. performed in accordance with the PDI Q.A. Prog., to ensure that flawed and unflawed grading units were fabricated in accordance with the requirements of l
ASME Section XI, Appendix VIII, and PDI specifications 2.2 Length and Depth Slzing Test.
(a) For the length sizing test, the regions of each 2.2(a) De length sizing test is administered in conjunction specimen containing a flaw to be sized shall be with the detection test. See comment 1.2.(c)(1). When identified to the candiate. The candidate shall retest are performed for length sizing only, the flawed determine the length of the flaw in each region. regions are identified to the candidate, except for IGSCC i
flawed specimens.
Due to the security of the IGSCC specimens, flawed regions are never identified to the candidates, ne candidate must detect and length size the flaw as in the detection demonstration.
(See PDI Position 95-002) 26 Revision 1, Change 0
SUPPLEMENT 2 QUALIFICATION REQUIREMENTS FOR WROUGHT AUSTENITIC FIPING WELDS REQUIREMENT @LNPLEMENTATION (b) For the depth sizing test,80% of the flaws shall be 2.2(b) Depth sizing flaws are identified to the candidate. All sized at a specific location on the surface of the depth sizing is performed in a two inch window. This is specimen identified to the candidate. For the done to ensure that depth sizing is performed in the remaining flaws, the regior.s of each specimen region where the true flaw depth is known rnost containirg a flaw to be sized shall be identified to accurately (see PDI Position 94-006).
the candidate. The candidate shall determine the maximum depth of the flaw in each region.
3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria. Examination 3.1 All of the requirements of paragraph 3.1 and 3.2 are procedures, equipment, and personnel are qualified for being met. Additionally,during the demonstration detection when the results of the performance process, the candidate's ability to discriminate between demonstration satisfy the acceptance criteria of Table flaw and geometric responses in accordance with the VIII-S2-1 for both detection and false calls, procedure essential variables,is verified during the surveillance activities.
3.2 Sizing Acceptance Criteria. Examination procedures, 3.2 UT Systems are qualified for sizing when the following equipment, and personnel are qualified for sizing if the requirements are met:
results of the performance demonstration satisfy the following criteria:
(a) flaw lengths estimated by ultrasonics are within 1 3.2(a) The i 1 inch error tolerance is replaced by a .75 inch in. of the true length; Root Mean Square (RMS) error from flaw true sizes.
PDI considers the RMS error to be a more fair and truer evaluation of examiner capability. Justification for this Code variance is provided in PDI Position 94-002, and 94-005 contained in Appendix B to this program description.
(b) The RMS error of the flaw depths estimated by 3.2(b) The formula in paragraph 3.2(b)is used to calculate ultrasonics, as compared with the true depths, is the RMS error. Sizing results are acceptable when the less than 0.125 in. RMS error shall be calculated as RMS error is equal to or less than .125 inch. 'Ihis follows: change is necessary so that Supplement 12,2.0(c) and this paragraph agree.
u2
[(mi-ti)*
RMS= "
n
. . I l
where l
I mi = measured flaw depth ti = true flaw depth n = number of flaws measured 27 Revision 1, Change 0 1
SUPPLEMENT 3 QUALIFICATION REQUIREMENTS FOR FERRITIC PIPING WELDS l
REQUIREMENT PDI IMPLEMENTATION 1
Qualification of examination procedures, equipment, and PDI procedure PDP-I-009.4.2 requires that qualification personnel for ferritic pipe examination shall be accomplished for ferritic pipepnly shall be accomplished by satisfying by satisfying the requirements of Supplement 2, except that the requirements of Supplement 2 except that the sample the sample material shall be ferritic and 75% of the sample material shall be ferritic and 75% of the sarsple set set defects [ Supplement 2, para.1.0(cX2)] shall be defects shall be mechanical or thermal fatigue cracks.
mechanically or thermally induced fatigue cracks. (See PDI Positions94-004 and 94-007 in Appendix-B to this document).
28 Revision I, Change 0
LINE A. Uneer regression linef A B y = a + Ar, gMng the best fit of
- )
n date points (n1,I ri .... (an , or l c4ptained by the least squero rnethod vehere, , fy,,
E ""
t ZYj Ks; 80 =
a - r inieram - -- 6 on 7 (,,, ril !
, _ , o b = slope of the regression line M dt 20 -
I N Espf - (Esg)(Iril NIs/I -(Es/ 2 l l l l l
- 20 40 60 to 100 n = number of date points True % Through Well 2 i
LINE B: Ideal line, y = a (perfect UT rnessuremental.
CORR E LATION COEF F ICIENT: Correlation coefficient. defined es nEspj -(sm)(Iy j l r = y Ming,,2. gg,j2) (ntr/ -(Irjl 2) is a measure of "how wer* the least4guere repression line tits the date with rMpect to the ideal of y = a.
MEAN DEVI ATION: Meen devletion is en Indicator of escuracy of the measurements defined as ldi j + ld 2] + . . . ldnl n
NOTES:
(II Seenderuf Ade$emer/ col TeWes,26th ed., William H. Seyer, Ph. O,, Ed., CRC Press, Inc., Socs .9eton, FL.1979 (2) Percent through+ ell unha spoly to supplements 2 and 3. Fleer depth units apply to suppiaments 4 through 7.
l I FIG. Vill S4-1 DEFINITION OF STATISTICAL PARAMETERS l
29 Revision 1 Change 0 i
SUPPLEMENT 4 QUALIFICATION REQUIREMENTS FOR THE CLAD / BASE METAL INTERFACE OF REACTOR VESSEL REQUIREMENT PDI IMPLEMENTATION 1.0 l 1.0 SPECIMEN REQUIREMENTS:
l Qualification test specimens shall meet the requirements PDI Test specinkens meet all of the requirements of Appendix listed herein unless a set oispecimens is designed to VIII, Supplement 4, as described hereafter and will be used accommodate specific limitations stated in the scope of the to demonstrate both detection and sizing qualifications examination procedure. The same specimens may be used to demonstrate both detection and sizing qualifications.
1.1 Detection Specimens - Detection specimens, which may 1.1 PDI Program detection specimens are full scale mock-be full-scale mock ups, shall conform to the following ups manufactured from materid removed from cancelled requirements: BWR and PWR Reactor Pressuce Vessels.
(a) Specimens shall have sufficient volume to minimize (a) Spurious reflections are minimized by the use of full size spurious reflections. Specimen length and width mockups. The minimum specimen length and minimum shall be at least 12 in. There shall be at least 10 width is greater than the 12 in. minimum requ' ired.
square feet of clad surface in the specimen set.
PDI Program Implementing Instruction No.
PDP-I-009.4.3, recuires that each specimen set used for performance demoortration will include a minimum of 10 sq. ft.-of clad surface.
(b) (1) When the examination procedure requires the (b)(1) Demonstration of examination procedures applied examination to be performed from the vessel from the vessel ID (clad surface) will be performed from I.D. (clad surface), the specimen minimum the clad surface of the PDI specimens. He PDI thickness shall be 3 m. or the maximum minimum specimen size is 6.75 in. nominal thickness, thickness of the vessel (whichever is less), and will be used to satisfy the minimum thickness requirement.
(2) When the examination procedure requires the (b)(2) He PDI Program requires via Instruction No.
examination to be performed from the vessel PDP-I-009.4.3, that demonstrations of examination O.D. surface, the specimen shall be at least 90% procedures from the OD be performed from the OD of the maximum thickness to be examined. surface. The test specimens used for performance demonstration will be a minimum of 90% of the maximum thickness to be examined in accordance with Instruction No. PDP-I-009.4.3.
(c) he performance demonstration shall be on the (c) he performance demonstration examination volume of same type cladding as that to be examined, with the PDI Program test specimens has been clad using a following exceptions: shielded metal are weld (SMAW) single wire procedure, which is transferable to cladding applied by other methods per Code paragraph 1.1(c)(1). ,
)
(1) demor.stration on shielded metal arc weld (c)(1) ne demonstration will be on SMAW and is (SWAW) single-wire cladding is transferable to transferable to multiple-wire or strip clad components, multiple-wire or strip-clad processes; (2) demonstration of multiple-wire or strip-clad are (c)(2) Demonstrations of multiple-wire or strip clad are not considered equivalent but is not transferable to possible using PDI specimens.
SMAW-type clad.
30 Revision 1. Change 0
SUPPLEMENT 4 QUALIFICATION REQUIREMENTS FOR THE ;
CLAD / BASE METAL INTERFACE J OF REACTOR VESSEL i 1
l REQUIREMENT PDI IMPLEMENTATION 1.1 Detection Specimens: (Continued)
(d) The surface condition of the test specimens shall be (d) ne surface condition of the test specimens is considered representative of the general condition of the vessel by the PDI to be generally representative of the surface scanning surface. conditions found in the majority of United States operating nuclear reactor pressure vessels.
(e) The detection test matrix shallinclude flaws with the (e) ne PDi Program detection test matrix contains flaws of following description. the following description.
(1) Flaw Type. At least50% of the flaws shall be (e)(1) Greater than 50% of the PDI Program flaws M the i cracks. He balance of flaws may be cracks, Supplement 4 examination volume of the test specimens j fabrication defects (e.g., slag inclusions), or are cracks. Within any individual test set at least 50% of I machined notches. Machined nbtches shall the flaws shall be cracks. By PDI Program Instruction meet the following requirements: No. PDP-I-009.4.3, the balance of flaws may be a combination of cracks, fabrication defects such as slag inclusions or machined notches.
(a) notches shall be perpendicular to the (e)(1)(a) where notches are used they are perpendicular to surface within 2 deg.: the surface within +/-2 deg.;
l (b) notches shall have a maximum width of (e)(1)(b) notches in PDI test specimens have been !
0.010 in. and shall be plugged to their full manufactured using procedures that have repeatedly depth with an insert of the parent material shown the notch tip dimension to be less than 0.010 in.
prior to cladding. De actual width of the notch at the clad to base metal interface may be greater than 0.010 in. All notches were j plugged to their full depth prior to cladding. Justification for this deviation is provided in PDI Position 94-003. .
(2) A!! flaws shall emanate from the clad base (e)(2) All flaws in the Supplement 4 examination volume metalinterface and shall propagate emanate from the clad base metal interface and predominately into the base metal. A minimum propagate into the base material.
of 40% of the flaws shall be oriented parallel to the clad direction (within i 10 deg.) and a 50% of the flaws in the Supplement 4 examination minimum of 40% shall be oriented vohune of PDI test specimens are oriented parallel to the perpendicular to the clad direction (within 10 clad direction (within +/- 5 degrees). He remaining deg.). 50% are oriented perpendicular to the clad direction (within +/-5 degrees). Each Procedure demonstration test set will have a minimum of 40% of flaws oriented Parallel and a minimum of 40% presented perpendicular to the clad ditcction. Gh versonneldemonstration test set will contain e representative distribution of flaw orientation sizuandlocationr.
(See PDI Position 9f,-011)
(See also PDI Positins95-004 and 95-005) 1 31 Revision 1, Change 0
SUPPLEMENT 4 QUALIFICATION REQUIREMENTS FOR THE CLAD / BASE METAL INTERFACE OF REACTOR VESSEL REQUIREMENT PDI IMPLEMENTATION l
l 1.1 Detection Specimens: (Continued) '
TABLE VIII 541 i PERFORMANCE DEMONSTRATION DETECTION TEST ACCEFTANCE CRITERIA i Detection Test l _
Acceptance Criteria j No.of Flaws Minimum Detection Criteria 7 7 8 8 9 9 10 10 11 11 12 11 13 12 14 13 15 14 16 14 17 15 18 16 l 19 17 20 18 l
l (3) The flaw sizes shall be uniformly distributed in (e)(3) Flaws selected for detection test will be from the four through-wall depths (inches) among the ranges: categories (a, b, c, d) as specified, except that:
(a) 0.075-0.200 a. Flaws smaller than the 30% of allowable Raw size. as (b) 0.201-0.350 deRned in IWB-35101. will not be included as detection (c) 0.351-0.550 Raws. For crocedures anolied from the inside surface.
(d) 0.551-0.750 use the minimum thickness soeciRed in the Scove of the crocedure. to calculate aft. For crocedures coolied No flaw shall have an aspect ratio from the outside surface. the actual thickness of the test (deptMength)less than 0.1. antign is used to calculate ar PD! Program test specimen flaws do not have aspect ratios (deptMength)less than 0.1 (See PDI Position 95-003)
(f) The number of flaws in the detection test matrix shall (f) The number of flaws used for grading of the detection be selected from Table VIII S4-1. The rules of test set will be a minimum of 7 for procedure IWA-3000 shall be used for determining whether qualification. For versonnel analiReation. the total of closely spaced flaws should be treated a separate sunalement 4 and 6 Raws shall be at least 10. and at flaws. least 50% of these shall be Sucolement 4 Raws. Other flaws may be present in the examination area.
The rules ofIWA 3000 shall be used for determining whether closely spaced flaws should be treated as separate flaws.
(See PDI Position 95-004) 32 Revision 1, Change 0 1
SUPPLEMENT 4 QUALIFICATION REQUIREMENTS FOR THE CLAD / BASE METAL INTERFACE OF REACTOR VESSEL REQUIREMENT PDI IMPLEMENTATION 1.2 Sizing Specimens 1.2 .
(a) The sizing test matrix shall contain a minimum of (a) For procedure qualification, PD1 Program Implementing ten flaws, at least half of which shall be cracks. Instruction PDP-1-009.4.3 requires that the sizing test matrix will be selected to contain a minimum of ten flaws. For versonnel cualiReation. the total of sucolement 4 and 6 sirins Raws shall be at least 10. and that at least 50% of these shall be Suvolement 4 Raws.
At least half of the flaws in any sizing test matrix will be cracks.
, (See PDI Position 95-005)
(b) Sizing specimens shall conform with the (b) The detection specimens meet the specified requirements requirements of 1.l(b),1.l(c),1.l(d), and 1.l(e). of Supplement 4 Code paragraphs 1.l(b),1.l(c),1.l(d),
and 1.l(e). The detection specimens will also be used for sizing.
2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS:
2.1 Detection Test 2.1 (a) Specimen identification and flaw locations shall be (a) A specimen identification will be provided to the obscured so as to maintain a " blind test." All candidate. The flaw locations within the test specimens examinations shall be completed prior to grading the are obscured providing a " blind test."
results and presenting the results to the candidate.
Divulgence of particular specimen results or PDI procedures require that all detection examinations candidate viewing of unmasked specimens is (analysis of data) will be completed prior to grading the prohibited. results. The individual flaw results will not be divulged; however,information on the type of errors made, for example, Missed Detection, False Calls etc. will be provided. Candidates will be able to view specimens since all flaw locations are disguised. (See PDI Position 94-007).
I l
l 33 Revision 1, Change 0
SUPPLEMENT 4 QUALIFICATION REQUIREMENTS FOR THE CLAD / BASE METAL INTERFACE OF REACTOR VESSEL REQUIREMENT PDI IMPLEMENTATION 2.1 Detection Test (Continued) 2.1 (b) When a flaw is reported within 1/2 in. ofit true (b) A Raw will be considered detected when reoorted within location (x and y)it shall be considered detected. 1.0 inch of the true X, Y and Z location or the error All other reported flaws shall be considered false allowed by Code Case N-545 whichever is larger calls, location accuracy is for tradine curvoses oniv.
Mathematical errors. systematic location errors. and other errors which exceed the allowable detection criteria. may be accroted by the PDA. orovided:
- 1. There is no doubt that the recorted indication is related to the actual Raw.
- 2. The error did not result from misinterpretation of the ultrasonic stenals
- 3. The results of the investigation is documented and justiRed.
(See PDI Position 95-004) 2.2 Length and Depth Siziny Test 2.2 (a) For the length sizing test, the inside surface and (a) Access for sizing will be based on the exam technique specimen identification shall be obscured. The (i.e. ID or OD.) Since flaws are buried,inside surfaces regions of each specimen containing a flaw to be are obscured with cladding. A specimen identification sized shall be identified to the candidate. De will be provided. He candidate will be required to size candidate shall determine the length of the flaw in the length of each intended flaw reported during the each region. detection test. If required, scan areas containing additional flaws for length sizing will be identified to the candidate.
(b) For the depth sizing test,80% of the flaws shall be (b) For depth sizing, the candidate will be required to size sized at a specific location on the surface of the the depth (thru-wall) of each intended flav reported specimen identified to the candidate. For the during the detection test. If required, scan areas remaining flaws, the regions of each specimen containing additional flaws for depth sizing will be containing a flaw to be sized shall be identified to identified to the candidate. The candidate shall the candidate. The candidate shall determine the determine the gnaximum depth.
maximum depth of the flaw in each region.
l 1
34 Revision 1 Change 0
SUPPLEMENT 4 QUALIFICATION REQUIREMENTS FOR THE CLAD / BASE METAL INTERFACE OF REACTOR VESSEL REQUIREMENT PDI IMPLEMENTATION 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria 3.1
- Examination procedures, equipment and are qualified for Examination procedures, equipment, and personnel are detection if the results of the performance demonstration qualified for detection if the combined results of the satisfy the acceptance criteria of Table VIII-S4-1. performance demonstration satisfy the acceptance criteria of Table VIII-S4-1 or VIII-S6-2 where combined sucolement 4
& 6 demonrrrations are verformed. Additionally, during the demonstration process, the candidate's ability to discriminate between flaw and geometric responses in accordance with the procedure essential variables is verified during the surveillance activities, using instruction PDP-Q-018.3.
(See PD1 Position 95-004)
Additionally, the number of false calls shall not exceed A/10 The acceptable number of false calls is determined by the rounded to the next whole number where A is the total scan surface area scanned in the performance demonstration area of specimens in the test measured in square feet. sample set. A false call is defined as reporting a non flawed area as flawed. False calls in excess of the allowed number will result in an unsuccessful performance demonstration.
False Calls s A/10 (Rounded to the next Larger Whole Number)
A = Total Area Scanned (Square Feet) .I The total area scanned "A" is defined as the cumulative scan area for the examination volume (total x-scan axis length X ,
total y-scan axis length) for scans performed perpendicular to the area of interest and scans performed parallel to the area of
)
interest.
3.2 Sizing Acceptance Criteria Examination procedures, equipment and personnel are It has become necessary for PDI to adopt sizing acceptance qualified for sizing if the results of the performance criteria which differ from those specified in the Code. Refer demonstration satisfy the following criteria: to PD1 Position 94-005 and 94-010.
(a) no flaw is undersized for depth by more than 0.2 in.t (a) Critical miscall requirements have been removed from PD1 Sizing Acceptance Criteria, see PD1 Position 94-010.
(b) flaw lengths estimated by ultrasonics shall be the (b) An RMS method of grading will be used. The RMS true length -1/4 in., + 1 in.t error of the ultrasonic flaw length measurements, l
compared to the true flaw length, must be equal to or less '
than O.750in. Refer to PDI Position 94-005 for
! justification for this deviation.
l l
35 ,
Revision 1, Change 0 I
SUPPLEMENT 4 QUALIFICATION REQUIREMENTS FOR THE CLAD / BASE METAL INTERFACE OF REACTOR VESSEL REQUIREMENT PDI IMPLEMENTATION l 3.0 ACCEITANCE CRITERIA (Continued) 3.2 Sizing Acceptance Criteria (Continued) 3.2 (c) performance demonstration results reported by the (c) The criteria of 3.2(c)(1)-(3), are replaced by an candidate, when plotted on a two-dimensional plot equivalent RMS criteria. The measured flaw depth, as (Fig. VIII-S2-1) with the depth estimated by compared to the true depth shall be equal to or less than ultrasonics plotted along the ordinate and the true an error of 0.15 inch RMS. Refer to PDI Position 94-depth plotted along the absci, sa, satisfy the 010 forjustification of this deviation.
following statisticalparameters:
For combined Suvolement 4 and 6. versonnel aualiRection. the accrotance criteria for Suvolement 4 will be avolied to Suvolement 4 Raws and Suoviement 6 for Suoviement 6 flaws (See PDI Position 95-005)
(I) slope of the linear regression line is not less than 0.7; (2) the mean deviation of flaw depth is less than 0.25 in.:
(3) correlation coefficient is not less than 0.70.
36 Revision 1, Change 0
SUPPLEMENT S QUALIFICATION REQUIREMENTS FOR NOZZLE INSIDE RADIUS SECTION REQUIREMENT PDI IMPLEMENTATION Demonstrations on clad / base metal interface of reactor vessel The PDI Program is designed to qualify examination plate specimens (Supplement 4) qualifies examination procedures, equipment and personnel for nozzle inside radius ,
procedures, equipment and personnel for nozzle inside radius section examination'when the following requirements are !
section examination when the following requirements are met: '
met.
(a) For detection, a minimum of three additional flaws (a) PDI has fabricated two full size PWR nozzle mockups, at the inside radius section in one or more full scale simulating both inlet and outlet configurations. Five nozzle mock-ups (supplement 7) shall be added to BWR mockups are available if they are needed to the test set. expand the scope of a procedure performed from the inside surface. For procedure qualifications, applicable to PWR RPVs, a minimum of three flaws sill be j,
included in both the inlet and outlet nozzles. Eat t
- " analysis oniv" versonnel cualincations. the following shall acolv:
- 1. Where the analysis eautoment and the ultrasonic techniaue are basically the same as the Suvolement 4 annlication. no funher demonstrations will be reauired.
- 2. Where the techniques differ substantially, a demonstration set of a minimum of three flaws will be provided. These will be distributed in either the ir.let or outlet configuration or both as appropriate.
(See PDI Position 95-008)
The specimens shall comply with Supplement 4,1.1, 'Ihe specimens comply with Supplement 4,1.1. Flaw but flaws may be either notches or cracks, types will generally be cracks. However, some notches may be used.
Flaws shall be located in the radial axial plane of the All flaws are located within the radial axial plane of the nozzle inside radius section shown in Fig. IWB- nozzle inside radius section as illustrated by Fig.IWB-2500-7. 2500-7.
If the examination procedure requires the The PDI BWR nozzle specimens have been designed to examination to be performed from the vessel OD facilitate OD examination surface procedures. The surface, at least one nor.zle in the specimen set shall dimensions of the specimens were developed to include be at least 90% of the inaximum thickness ta2i n Fig dimensions suitable that these requirements can be met i IWB 2500-7, to be examined and the ratio of the for most BWR RPV's.
l nozzle thickness to sisell thickness shall be within 130% of that ratio fer the vessel nozzles to be l examined.
i 37 Revision 1 Change 0
f-SUPPLEMENT 5 QUALIFICATION REQUIREMENTS FOR NOZZLE INSIDE RADIUS SECTION REQUIREMENT PDI IMPLEMENTATION (a)(Continued) (a)(Continued)
If the examination procedure requires the ne PDI PWR inlet nozzle specimen has an internal examination be performed from the inside surface, diameter of 28 inches, which is sufficient for the specimen shall have the minimum nozzle demonstrations for PWR inlet and outlet nozzles. BWR diameter covered by the procedure. mockups are available for smaller nozzles.
Due to the limited sample base it is not possible to provide the same test set diversity as is donefor Supplement 4 and 6. As a minimum the PDA will do the following to insure the integrity of the demonstrations:
e Require procedures depnitively spectfy criteriafor detection and sizing,
- Require that candidates provide specipc evidence that their decisionsfollowed the procedure directions, without aprioriinformation, e No information as to the true size, location or orientation will be divulged to the candidates, and e To the extent possible candidates will be assigned separate areas of the test specimens or dsferent specimens.
Candidatesfor personnel demonstrations will be .
provided a sampling of the essential variables qualsped by the procedure.
Each of the flaws presented for demonstration shall Each of the flaws in the examination test set shall be be correctly identified in accordance with correctly identified. False calls shall not execed the Supplement 4,2.1 with no false calls. value established by carasraoh 4. Ha) of Code Case N-Demonstrations on Clad nozzle mockups may be E used for examination of unciad nozzles.
Demonstrations performed on unciad nozzle mockups shall not be used for examinations of clad nozzles.
(b) For length sizing, a minimum of three additional (b) PDI will not implement this requirement, see Code Case flaws as in (a) above shall be added to the test set. N-542.
All flaws shall be sized to the acceptance standards of Supplement 4.
- (c) For depth sizing, a minimum of three additional (c) For depth sizing a minimum of three flaws will be added j flaws as in (a) above shall be added to the test set. to the test set. The depth range of these flaws will be i neir depths shall be evenly distributed over the distributed over the range required by Supplement 4.
ranges of Supplement 4,1.l(eX3Xa),1.1(eX3Xb), ne sizing results will be combined with the clad / base and 1.l(eX3Xc). ne sizing results from these flaws metal interface qualification, ne acceptance criteria shall be combined with the sizing results from the shall be the same as is applied for Supplement 4.
clad / base metal interface qualification, and combined results shall meet the acceptance criterik of Supplement 4,3.2.
l 38 Revision 1. Change 0 l
J
SUPPLEMENT 5 NOZZLE INSIDE RADIUS FROM THE OUTSIDE SURFACE REQUIREMENT PDI IMPLEMENTATION Code Case N 552 PDI WILL ADOPT THIS CODE CASE FOR THE ALTERNATIVE METHODS - QUALIFICATION FOR DEMONSTRATION OF NOZZLE INSIDE RADIUS ,
NOZZLE INSIDE RADIUS SECTION FROM THE EXAMINATIONS FROM THE OUTSIDE SURFACE.
OUTSIDE SURFACE Section XI, Division 1 1.0 PROCEDURE REQUIREMENTS 1.0 PROCEDURE REQUIREMENTS De examination procedure shall include or provide for the ne examination procedure shall include or provide of the following following:
(a) A computational model that calculates (a) The capabilities of the proposed model are verified as a disorientation angles and the maximum metal path part of the initial procedure review and ase validated distance to the required inspection volume. during the demonstration process. Models which have Disorientation angle is shown in Figure N552-1. previously been validated will be used for comparison.
(b) A scope statement that specifies the maximum (b) De Scope statement is verified as a part of the acceptable disorientation angle and metal path for procedure review and must be accepted before the examinations, proceeding with the demonstration.
(c) Division of the surface of the required examination (c) Operation of the model will be verified as part of the volume into grids of 1.0 inch or less in the noule demonstration.
axis direction and 10 degrees or less of azimuth.
(d) Documenting the disorientation angle and metal (d) The capability of the model will be compared to path distance in each grid cell location for each previously validated models.
search unit or scan.
(e) Documenting the search unit or scan that produces (e) Operation of the model will be verified during the the minimum disorientation angle when multiple procedure review and modeling phase of the search units are used.
demonstration. The results will be compared to those from previously validated models.
2.0 SPECIMEN REQUIREMENTS 2.0 SPECIMENREQUIREMENTS Demonstration specimens shall meet the requirements of Demonstration specimens shall meet the requirements of Supplement 4, except as permitted by (a) through (d) below. Supplement 4, except as permitted by (a) through (d) below.
l (a) One or more full size noule mockups or sections of (a) Five nozzles, covering the typical range of BWR l full size nozzle mockups shall be used. applications, are available for demonstrations.
(b) Nozzle mockup material and configurations shall be (b) Nozzle (s) most appropriate to demonstrate the stated representative of nozzles installed in operating so)pe of the procedure will be selected. Others may be reactor vessels, but need not match exact thickness, j used to perform personnel demonstrations. <
diameter, or radius.
38a Revision 1, Change 0
SUPPLEMENT 5 l NOZZLE INSIDE RADIUS FROM THE OUTSIDE SURFACE REQUIREMENT PDI IMPLEMENTATION l
2.0 SPECIMEN REQUIREMENTS (Continued) 2.0 SPECIMEN REQUIREMENTS (Continued)
(c) Flaws shall be uniformly distributed in examination (e) The required distribution will be verified for each l zones A and B of Figure N552-2. At least half of procedure demonstration. Personnel demonstrations will l the flaws shall be located within 45 degrees of employ a selection of these flaws. )
nozzle azimuth angles 90 or 270.
(d) All flaws shall be located in the required inspection (d) Flaws within the mockups meet this requirement.
volume and shall be oriented in the radial axial plane of the nozzle inside radius section as shown in Fig. IWB-2500-7.
(e) Flaw depths shall be distributed ov'er the range of (e) Flaw depths shall be distributed over the range of depths depths required by Supplement 4. required by Supplement 4, for procedure demonstrations.
For personnel demonstrations, a selection of flaws will be selected.
3.0 CONDUCT OF PERFORMANCE 3.0 CONDUCTOFPERFORMANCE DEMONSTRATIONS DEMONSTRATIONS 3.1 Procedure Qualificadon Demonstradons 3.1 Procedure Qualificadon Demonstrations Procedure qualification demonstrations shall be conducted according to the following:
(a) The qualification shall demonstrate the following: (a) De qualification shall demonstrate the following:
(1) Examination surfaces to be used,i.e. vessel (a)(1) Examination surfaces to be used, i.e. vessel plate, plate, outer blend radius, and nozzle boss; outer blend radius, and nozzle boss; (2) Maximum metal path length; and (a)(2) Maximum metal path length; and (3) Maximum disorientation angles. (a)(3) Maximum disorientation angles.
(b) De demonstration shallinclude a minimum of 10 (b) The demonstration shall include a ndnimum of 10 flaws flaws for detection and sizing, in one or more for detection and sizing, in one or more mockups. A mockups. portion of these will be distributed among the examination to be demonstrated.
38b Revision 1, Change 0
SUPPLEMENT 5 NOZZLE INSIDE RADIUS FROM THE OUTSIDE SURFACE REQUIREMENT PDI IMPLEMENTATION 3.1 Procedure Quatincados Demonstradons (Continued) 3.1 Procedure Qualincadon Demonstradons (Continued)
(c) De initial demonstration shall be a blind test. (c) De initial demonstration sha:1 be a blind test.
Due to the limited sample base it is not possible to provide the same test set diversity as is done for Supplements 4 and 6. As a minimum the PDA will do the following to insure the integrity of the j
demonstrations:
- Require procedures definitively specify criteria for
, detection and sizing.
- Require that candidates provide specific evidence 1 that their decisions followed the procedure directions, without the aid of apriori information, e No information as to the true size, location or 1
orientation will be divulged to the candidates, and
- To the extent possible candidates will be assigned separate areas of the test specimens or different specimens (d) After a successful initial demonstration, the scope of (d) After a successfulinitial demonstration, the scope of the the procedure may be extended by (1) additional procedure may be extended by (1) additional demonstrations on additional mockups, or (2) non demonstrations on additional mockups, or (2) non blind blind demonstrations on at least one flaw using scan demonstrations on at least one flaw using rean parameters calculated to provide the desired parameters calculated to provide the desired maximum maximum path length or disorientation angles. path length or disorientation angles. Detection will be Detection shall be demonstrated to specific criteria demonstrated to specific criteria listed in the examination listed in the examination procedure for any procedures for any extension of procedure scope, beyond extension of procedure scope. that demor.strated in the initial blind demonstration.
3.2 Procedure Qualineados Documentation 3.2 Precedure Qualincados Documentadoa De examination procedure, modeling program and methods, he examination procedure, modeling program and methods, and the qualification results shall be documented to the extent and the qualification results shall be documented to the extent necessary to determine that exam %ations, performed on necessary to determine thai examinations, performed on reactor vessel nozzles, produce equivalent or smaller reactor vessel nozzles, produce equivalent or smaller miserientation angles, than the procedures demonstrated. disorientation angles, than the procedun.s which were demonstrated.
38c Revision 1, Change 0
1 SUPPLEMENT 5 NOZZLE INSIDE RADIUS FROM THE OUTSIDE SURFACE l'
i BEOUIREMENT PDI IMPLEMENTATION 3.3 PersonnelQualificatson 3.3 PersonnelQualificadon (a) Individuals previously qualified to the requirements (a) Individuals previously qualified to the requirements of
. of Appendix VIII Supplement 4, for the same type Appendix VIII Supplement 4, for the same type of of procedure (manual vs. automated), from the procedure (manual vs. automated), from the out.;ide outside surface, using the same type ofinstrument surface, using the same type of instrument and data and data recording and analysis equipment, shall be recording and analysis equipmer, shall be qualified as qualified as follows: follows:
(1) Successful demonstration shall include at least (1) Successful demonstration shall include at least three three additional flaws. additional flaws.
(2) Examinations shall be conducted from each of (2) Examinations shall be conducted from each of the the scan surfaces covered by the procedure. scan surfaces covered by the procedure.
(3) The candidate shall demonstrate a selection of (3) De candidate will demonstrate a selection of essential variables covered by the procedure, essential variables covered by the procedure, but but need not demonstrate the full range, need not demonstrate the full range. De demonstrations may be performed on mockups different than those used to qualify the procedure or other personnel.
(b) Individuals not previously qualified to the (b) Individuals not pmviously qualified to the requirements requirements of Supplement 4 shall be qualified as of Supplement 4 shall be qualified as follows:
follows:
(1) The candidat shall demonstrate the procedare (1) The candidate shall demonstrate the procedure on one or on one or more mockups. more mockups.
(2) De demonstration shall contain at least the (2) De demonstration shall contain at least the minimum minimum number of detection and depth sizing number of deteedon and depth sizing flaws specified in flaws specified in Supplement 4. Supplement 4.
(3) The demonstration shallinclude examinations (3) he demonstrados shallinclude examinadons from from each of the scan surfaces described in the eneb of the sean surfaces described in the procedure.
procedure (4) De danaastration need not cover the full range (4) De demonstration need not cover the full range of all the of all.the essential variables. essential variables. De demonstrations may be performed on mockups different than those used to qualify the procedure or other personnel.
38d Revision 1, Change 0
SUPPLEMENT 5 NOZZLE INSIDE RADIUS FROM THE OUTSIDE SURFACE REQUIREMENT PDI IMPLEMENTATION 4.0 ACCEPTANCE CRITERIA 4.1 Detection Acceptance Criteria 4.1 Detection Acceptance Criteria (a) Examination procedures and equipment are (a) Examination procedures and equipment are qualified qualified when each flaw is detected and identified.
when each flaw is detected and identified. He number ne number of false calls shall not exceed D/10 of false calls shall not exceed D/10 rounded up to the rounded up to the next whole number, where D is next whole number, where D is the nominal nozzle inside the nominal nozzle inside diameter, in. If only a diameter,in. If only a portion of a nozzle is examined, portion of a nozzle is examined, proportional credit proportional credit for false calls shall be allowed.
for false calls shall be a!! owed.
(b) Personnel previously qualified to Supplement 4, as (1,) &rsonnel oreviousIv analined to Sunalement 4. as described in 3.3(a) above, are qualified if each of described in 3.3(a) above. are aualined if each of the the flaws presented are detected and identifled with flaws cresented are detected and identined. The number no false talls. of false calls allowed shall be the same as in 4.1(a) above.
(See PDI Position 95-011)
(c) Personnel not previously qualified to Supplement 4 (c) Personnel not previously qualified to Supplement 4 are are qualified for detection if the results of the quali,fied for detection if the results of the demonstration demonstration meet the requirements of Table meet the requirements of Table VIII-S4 1. Additionally.
VI11-S41. Additionally, the number of false calls the number of false calls shall not exceed the number shall not exceed the number specified in 4.!(a) specified in 4.l(a) above.
above.
4.2 Depth Sizing Acceptance Criteria 4.2 Depth Sizing Acceptance Criteria (a) Examination procedures and equipment are (a) Examination procedures and equipment are qualified for qualified for depth sizing if the results of the sizing depth sizing if the results of the sizing demonstration demonstration meet the requirements of Appendix meet the requirements of Appendix VIII Supplement 4 VIII Supplement 4, paragraph 3.2. paragraph 3.2.
l l
38e Revision 1, Change 0
j SUPPLEMENT 5 l NOZZLE INSIDE RADIUS FROM TIIE OUTSIDE SURFACE l
REQUIREMENT PDI IMPLEMENTATION l 4.2 Depth Sizing Acceptance Cdteria (Continued) 4.2 Depth Sizing Acceptance Cdteria (Contim:ed)
(b) Personnel previously qualified to Supplement 4, as (b) Personnel previously qualified to Supplement 4, as j described in 3.3 (a) above, are qualified if the results described in 3.3 (a) above, are qualified if the results i from the sizing tests, when added to the candidate's from the sizir.g tests, when added to the candidate's results from Supplement 4, meet the acceptance results from Supplement 4, meet the acceptance criteria critesia of Supplement 4, paragraph 3.2. of Supplement 4, paragraph 3.2.
(c) Personnel not previously qualified to Supplement 4, (c) Personnel not previously qualified to Suppkment 4, are are qualified for depth sizing if the results of the qualified for depth sizing if the results of the sizing sizing demonstration meet the sizing acceptance demonstration meet the sizing acceptance requirements requirements of Supplement 4. ,
. of Supplement 4.
5.0 FIELD EXAMINATIONS 5.0 FIELD EXAMINATIONS The computational model shall be applied in conjunction ne computational model shall be apolied in conjunction with each field examination, to demonstrate that the proposed with each field examination, to demonstrate that 19 proposed examination variables are within the bounds of the examination variables are within the bounds of the qualification demonstration. qualification demonstration. His statement will be included in the procedure PDQS.
(a) Documentation showing coverage and (a) This item is beyond the Scope of the PDI Program. It disorientation angle shall be provided for each will be the responsibility of the utility, the Inspector, nozzle examination application performed. He regulatory authorities to assure these requirements are documentation shall be used to demonstrate that the fulfilled.
examination performed will achieve disorientation angles that do not exceed the disorientation angles for which the procedure was qualified.
(b) Modeling need not be applied for repeated (b) The PDA can provide assistance in performing scoping examination of the same or identical nozzles. studies to assist in these determir.ations.
Nozzle geometry changes that do not result in an increase in the disorientation angles or loss of coverage area need not be calculated.
(c) If the disorientation angle or metal path of the field (c) his item is beyond the Scope of the PDI Program. It examination exceeds that of the qualification, will be the responsibility of the utility, the Inspector, additional probe angles and directions may be regulatory authorities to assure these requirements are applied to examine these areas without need for fulfilled.
requalification, provided the demonstrated disorientation angle or path length can be achieved.
(d) If an area can be examined by addition of new (d) This item is beyond the Scope of the PDI Program. It search unit angles, orientations, or scan areas that will be the responsibility of the utility, the Inspector, produce disorientation angles or path length in regulatory authorities to assure these requirements are excess of the qualified values, a new procedure fulfilled.
qualification shall be performed.
ma ruvn'am 11Eurm n
SUPPLEMENT 5 NOZZLE INSIDE RADIUS FROM THE OUTSIDE SURFACE REQUIREMENT PDI IMPLEMENTATION l 5.0 FIELD EXAMINATIONS (Continued) 5.0 FIELD EXAMINATIONS (Continued)
(e) If neither 5.0(c) nor (d) can be met, the area shall be (e) This item is beyond the Scope of the PDI Program. It declared an area of no coverage.
will be the responsibility of the utility, the Inspector, regulatory authorities to assure these requirements are fulfilled.
l l
I
)
38g Revision I, Change 0 u_______________________
SUPPLEMENT 5 QUALIFICATION REQUIREMENTS FOR NOZZLE INSIDE RADIUS SECTION REQUIREMENT PDI IMPLEMENTATION Demonstrations on clad / base metalinterface of reactor vessel De PDI Program is designed to qualify et ination plate specimens (Supplement 4) qualifies examination procedurts, equipment and personnel for nozzle inside radius procedures, equipment and personnel for nozzle inside radius section examination when the following requirements are section examination when the following requirements are met:
met.
(a) For detection, a minimum of three additional flaws (a) PDI has fabricated two full size PWR nozzle mockups, at the inside radius'section in one or more full scale simulating both inlet and outlet configurations. Five nozzle mock-ups (supplement 7) shall be added to BWR mockups are available if they are needed to the test set. , expand the scope of a procedure performed from the inside surface. For procedure qualifications, applicable to PWR RPVs, a minimum of three flaws will be included in both the inlet and outlet nozzles. Eg
" analysis oniv" versonnel cualiReatior.r. the followine shallacolv.
- 1. Where the analysis eauinment and the ultrasonic technfaue are basically the same as the Sucolement 4 acclimation. no further demonstrations will be reauired.
- 2. Where the techniques differ substantially, a demonstration set of a minimum of three flaws will be provided. Rese will be distributed in either the inlet or outlet configuration or both as appropriate.
(See PDI Position 95-008)
He specimens shall comply with Supplement 4,1.1, ne specimens comply with Supplement 4,1.1, Flaw but flaws may be either notches or cracks. types will generally be cracks. However, some notches may be used.
Flaws shall be located in the radial axial plane of the All flaws are located within the radial axial plane of the nozzle inside radius section shown in Fig. IWB- nozzle inside radius section as illustrated by Fig.IWB-2500-7. 2500-7.
If the examination procedure requires the ne PDI BWR nozzle spximens have been designed to examination to be performed from the vessel OD facilitate OD examination surface procedures. The surface, at least one nozzle in the specimen set shall dimensions of the specimens were developed to include be at least 90% of the maximum thickness t.2i n Fig dimensions suitable that these requirements can be met i
IWB 2500-7, to be examined and the ratio of the for most BWR RPV's.
nozzle thickness to shell thickness shall be within 30% of that ratio for the vessel nozzles to be er=M 38h Revision 1, Change 0
SUPPLEMENT 5 QUALIFICATION REQUIREMENTS FOR NOZZLE INSIDE RADIUS SECTION REQUIREMENT i PDI IMPLEMENTATION l (a)(Continued) (a)(Continued)
If the examination proceeire requires the The PDI PWR inlet nozzle specimen has an internal examination be performed from the inside surface, diameter of 28 inches, which is sufficient for the specimen shall have the minimum nozzle demonstrations for PWR inlet and outlet nozzles. BWR diameter covered by the procedure. mockups are available for smaller nozzles.
Due to the limited sample base it is not possible to provide the same test set diversity as is donefor Supplement 4 and 6. As a minimum the PDA willdo the
, following to in.rure the integrity ofthe demonstrations:
e Require procedures definitively spectfy criteriafor detection andsizing, e Require that candidates provide specific evidence that theh decisionsfollowed the procedure direct'ons, without aprioriirtformation.
- No information as to the true size, location or orientation will be divulged to the candidates, and e To the extent possible candidates will be assigned separate areas of the test specimens or dgerent spe6 mens.
Candidatesfor personnel demonstrations will be provided a sampling of the essential variables qualified by the procedure.
Each of the flaws presented for demonstration shall Each of the flaws in the examination test set shall be be correctly identified in accordence with correctly identified. False calls shoII not exceed the Supplement 4,2.1 with no false calls. value established by narerraoh 4.1(a) of Code Case N.
Demonstrations on Clad nozzle mockups may be J.R used for examination of unclad nozzles.
Demonstrations performed on unciad nozzle mockups shall not be used for examinations of clad l nozzles.
l (b) Forlength sizing, a minimum of three additional (b) PDI will not implement this requirement, see Code Case flaws as in (a) above shall be added to the test set. N-542.
All flaws shall be sized to the acceptance standards of Supplement 4.
(c) For depth sizing, a minimum of three additional (c) For depth sizing a minimum of three flaws will be added r
flaws as in (a) above shall be added to the test set. to the test set. The depth range of these flaws will be
'Iheir depths shall be evenly distributed over the distributed over the range required by Supplement 4.
ranges of Supplement 4,1.l(c)(3Xa),1.l(eX3Xb), J The sizing results will be combined with the clad / base and 1.l(eX3Xc). The sizing results from these flaws metal interface qualification. The acceptance criteria shall be combined with the sizing results from the shall be the same as is applied for Supplement 4.
clad / base metal interface qualification, and combined results shall meet.the acceptance criteria of Supplement 4,3.2.
38i Revision 1, Change 0
SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL WELDS OTHER THAN CLAD / BASE METAL INTERFACE REQUIREMENT PDI IMPLEMENTATION 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the requirements 1.0 PDI Test specimens meet the requirements of Appendix listed herein unless a set of specimens is designed to VIII as described hereafter and will be used to accommodate specific limitations stated in the scope of the demonstrate both detection and sizing qualifications.
examination procedure. The same specimens may be used to demonstrate both detection and sizing qualifications.
TABLE VIII 56-I DE'1ECTION AND SIZING TEST FLAWS AND LOCA'I1ONS Fis.w nrough Wall dimension,in.
Flaw Location 0.075-0.200 0.201 0.350 0.351 0.550 0.551 0.750 0.751 2.00 I
Inner 10% [ Note (1)] X X S S ...
Outer 10% X X S S ...
Il-30% T ... ... X X S 3160% T ... ... X X S 61-89% T ... ... X X S NOTE:
(1)Does not apply to clad vessels (see Supplement 4)
LEGEND:
X Applies to detection and sizing flaws.
S Applies only eo sizing flaws.
T Thickness of the thickest specimen in the specimen set.
1.1 Detection Specimens. Detection specimens, which may 1.1 Detection specimens are full scale mock-ups be full-scale mock ups, shall conform to the following manufactured from material removed from canceled requirements: BWR and PWR Reactor Pressure Vessels.
(a) Specimens shall have sufficient volume to minimize (a) Spurious reflections are minimized by the use of full size spurious reflections. Specimen length and width mockups. He minimum specimen length and minimum i shall be at least 12 in, width is greater than 12 in.
Dere shall be at least 10 sq ft of scan surface in the Instruction PDP-I-009.4.3 requires that the examination specimen set. surface area of each specimen set used for performance 1 demonstration will be a minimum of 10 sq. ft.
(b) ne specimen set shall contain at least one sample (b) Instmetion PDP-I-009.4.3 requires that the specimen set that is at least 90% of the maximum thickness to be will contain at least one sample that is at least 90% of the examined. maumum thickness to be examined.
He specimen set shall contain one or more flaws in ne flaws in the supplement 6 examination volume are each of the locations and size ranges shown in table positioned at depths within the locations shown in table VIII.S6-1. VIII-S6-1. De size of the flaws has also been selected from the sane table.
39 Revision 1. Change 0
i SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL WELDS OTHER THAN CLAD / BASE METAL INTERFACE l
REQUIREMENT PDI IMPLEMENTATION 1.1 Detection Specimens (Continued)
(c) When the examination procedure requires the (c) De performance demonstration examination volume of examination to be performed from the vessel I.D. PDI test specimens has been clad using a shielded metal
- (clad surface), the cladding on the mockup shall be are weld (SMAW) sin 61e wire procedure, which is i
of the same type as the cladding on the component transferable to cladding applied by other methods.
to be examined, with the following exceptions:
(1) Demonstration on shielded metal arc weld (c)(1) ID (clad surface ) demonstration will be on SMAW (SMAW) single wire cladding is transferable to cladding and is transferable to multi-wire or strip clad multiple-wire or strip clad processes; components.
(2) Demonstration on multiple-wire or strip clad (c)(2) Demonstrations of multiple-wire or strip clad are not are considered equivalent but is not transferable possible using PDI specimens, to SMAW type clad. .
(d) De surface condition of the test specimens shall be (d) De surface condition of the test specimens is considered representative of the general condition of the vessel by the PDI to be generally representative of the surface scanning surface. conditions found in most United States operating nuclear reactor pressure vessels.
(e) De detection test matrix shallinclude flaws with (e) De detection test matrix willinclude flaws of the the following description. following description.
(1) Flaw Type. At least 50% of the flaws shall be (e)(1) Flaws in supplement 6 test specimens are a cracks. De balance of flaws may be cracks, combination of cracks and fabrication defects such as fabrication defects (e.g., slag inclusions), or slag / lack of fusion. PDI procedures require that within machined notches. Machined notches shall any individual test set at least 50% of the flaws will be meet the following requirements: crach.
(a) Notches shall be perpendicular to the (e)(1)(a) Notches have not been used in manufacturing the surface withini 2 deg.: supplement 6 specimens.
(b)' Notches shall have a minimum width of (e)(1)(b) Not applicable 0.010 in. and shall be plugged to their full i depth with an insert of the parent material prior to cladding.
(2) No more than 10% of the flaws shall emanate (e)(2) PDIInstruction PDP-I-009.4.3 specifies that the test from the outer (unclad) surface. set will include no more than 10% of flaws, rounded to the next higher whole number, which are OD connected for procedure qualifications test sets.
' A weld direction shall be established whether or PDI specimens do not include a weld and the weld not the specunen contains a weld. direction will be considered circumferential which will be descr: bed as the "X" axis.
I' 40 Rev4 ion 1, Change 0
SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL WELDS OTHER THAN CLAD / BASE METAL INTERFACE REQUIREMENT PDI IMPLEMENTATION 1.1 Detection Specimens (Continued)
A minimum of 40% of the flaws shall be Flaws are evenly distributed between txing parallel and oriented parallel to the weld direction (within perpendicular to the stipulated weld direction within 5 10 deg.) and a minimum of 40% shall be degrees. Each Procedure demonstration test set will oriented perpendicular to the weld direction have a minimum of 40% of flaws oriented Parallel and a (within110 deg.). minimum of 40% presented perpendicular to the clad direction. Each neesonneldemonstration test set will contain a representative distribution ofRaw orientations. sizes and locations.
(See PDI Posit'on 95-011)
(See also PDI Positions95-004 & 95-005)
(3) Flaws for the detection test matrix shall be (e)(3) Flaws selected for the detection test will be as shown selected from the detection test flaws included in Table VIII S6-1 except that:
in Table VIII-56-1.
- a. Flaws smaller than the 50% ofallowable Raw site.
as deRned in IWB-35:0-L will not be included as detection Raws.
. b. Flaws eaual to or less than the allowable Raw size will be counted as detection Raws. without renard to their oosition in Table Vill-S6-1.
- c. 'The thickness of the demonstration test soecimen will be used to determine the a/t ratios in IWB-3510-1.
(See PDI Position 95-003)
The flaws selected shall provide a ne test set will include at least one flaw in the outer demonstration of the minimum and maximum 10% of the flaw location volume and at least one flaw metal path ranges to be demonstrated. within the 11-30% T iocation volume of Table VIII-S6-1.
as well as a uniform distribution of flaw sizes At least one of the specified flaw sizes in Table VIII-S6-and locations. I will be included in the test set. Rese flaws will be distributed throughout the specified flaw locations of Table VIII-S6-1.
(4) De number of flaws in the detection test matrix (e)(4) ne number of flaws used for grading of the detection shall be selected from Table VIII-S6-2. test set will be a minimum of 7 for procedure qualification. ForversonnelaualiReation. the totalof suoolement 4 and 6 sirina Raws shall be at least 10. and I
at *mt 50% of these shall be Sunoloment 4 Raws. Other flaws may be present in the examination area.
(See PDI Position 95-004) ne rules ofIWA-3000 shall be used for he rules ofIWA 3000 shall be used of determining determining whether closely spaced flaws whether closely spaced flaws should be treated as should be treated as separate flaws. separate flaws.
41 Revision 1. Change 0
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SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL WELDS OTHER THAN CLAD / BASE METAL INTERFACE REQUIREMENT PDI IMPLEMENTATION 1.2 Sizing Specimens 1.2 Sizing Specimens (a) He sizing test matrix shall contain a minimum of (a) For procedure q' qualification, PDI Program Implementing ten flaws, at least half of which shall be cracks. Instruction PDP-I-009.4.3 requires that the sizing test matrix will be selected to contain a minimum of ten ilaws. For versonnel cualiReation. the total of sunclement 4 and 6 siring flaws shall be at least 10. and that at least 50% of these shall be Suoviement 4 Raws.
At least half of the flaws in any sizing test matrix will be cracks.
(See PDI Position 95-005)
(b) Sizing specimens shall conform with,the (b) He detection specimens which meet the specified requirements of 1.l(b),1.!(c),1.l(d) and 1 l(e), Appendix VIII requirements will also be used for sizing, except that the test matrix shall be selected from de The flaws will be selected form the sizing and detection l sizing and detection flaws included in Table VIII- flaws included in Table VIII-S6-1 56-1.
I TABLE VIII.56-2 PERFORMANCE DEMONSTRATION DETECTION ITET -
ACCEPTANCE CRITERIA Detection Test Acceptance Criteria Minimum No. of Maws De'stion Criteria 7 7 8 8 9 9 10 l 10
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l1 11 12 11 13 12 14 - 13 15 14 16 14 17 15 18 16 19 17 20 18 42 Revision 1. Chage 0 l r
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SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL WELDS OTHER THAN CLAD / BASE METAL INTERFACE REQUIREMENT PDI IMPLEMENTATION 2.0 CONDUCT OF PERFORMANCE 2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS DEMONSTRATIONS 2.1 Detection Test 2.1 Detection Test. *
(a) Specimen identification and flaw locations shall be (a) A specimen identification will be provided to the obsc ied so as to maintain a " blind test."... candidate. The flaw locations within the test specimens are obscured providing a " blind test."
All examinations shall be completed prior to grading PDI procedures require that all detection examinations the results and presenting the results to the (analysis of data) will be completed prior to grading the candidate. Divulgence of particular specimen results results. The individual flaw results will not be fivulged; or candidate viewing of unmasked specimens is however,information on the type of errors made, for prohibited. example, Missed Detection, False Calls etc. will be
.' provided. Candidates will be able to view specimens since all flaw locations are disguised. (See PDI Position 94-007).
(b) When a flaw is reported within 1/2 in. ofits true (b) A flaw will be considered detected when reported within location (x and y) it shall be considered detected. LQ inch of the true X, Y and Z location or the error All other reported flaws shall be considered false allowed by Code Case N-545 whichever is larger.
calls.
Location accuracy is for grading ourooses oniv.
Mathematical errors. systematic location errors. and other errors which exceed the allowable detection criteria. may be accented by the PDA. orovided:
I. There is no doubt that the reported indication is related to the actual Raw.
- 2. The error did not result from misinterpretation of the ultrasonic signals.
- 3. The results of the investigation is documented and justined.
(See PDI Positi.>n 95-006) 2.2 Iength and Depth Sizing Test 2.2 (a) For the length sizing test, the inside surface and (a) Access for scanning will be based on the examination specimen identification shall be obscured. He technique. (i.e. ID or OD) since flaws are buried, regions of each specimen containing a flaw to be specimen surfaces need not be obscured. A specimen sized shall be identified to the candidate. He identification will be provided. He candidate will be candidate shall determine the length of the flaw in required to size the length of each intended flaw reported each region. during the detection test. If required, scan areas containing additional flaws for length sizing will be identified to the candidate.
I 43 Revision 1, Change 0
SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL WELDS OTHER THAN CLAD / BASE METAL INTERFACE REQUIREMENT PDI IMPLEMENTATION 2.2 Length and Depth Sizing Test (Continued)
(b) For the depth sizing test,80% of the flaws shall be (b) For oepth sizing,' the candidate will be required to size sized at a specific location on the surface of the the depth (through-wall) of each intended flaw reported specimen identified to the candidate. For the during the detection test. If required scan areas remaining flaws, the regions of each specimen containing additional flaws for depth sizing will be containing a flaw to be sized shall be identified to identified to the candidate. De candidate will deter.nine the candidate. The candidate shall determine the the maximum depth of the flaw in each region.
maximum depth of the flaw in each region.
3.0 ACCEPTANCE CRITERIA 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria. Examination 3.1 ne criteria of Table VIII S6-2 will be used to evaluate procedures, equipment, and personnelar*e qualified for the performance demonstration detection results.
detection if the results of the performance demonstration satisfy the acceptane: criteria of Table Vill-S6-2.
Additionally the number of false calls shall not exceed he number of false calls will not exceed A/10 rounded A/10 rounded to the next whole number where A is the to the next whole number where area A is calculated total scan area of specimens in the test measured in using the maximum Y surface dirnension scanned by the square feet. ultrasonic transducer multiplied by the X surface dimension scanned by the ultrasonic transducer.
3.2 Sizing Acceptance Criteria. 3.2 It has become necessary for PDI to adopt sizing Examination procedures, equipment and personnel are acceptance criteria which differ from those specified in qualified for sizing if the results of the performance the Code. Refer to PDI Position 94-005 and 94-010-RI.
demonstration satisfy the following criteria:
(a) No flaw is undersized for depth by more than 0.2 (a) Critical miscall requirements have been removed from in.; PDI Sizing Acceptance criteria, see PDI Position 94-010-RI.
(b) Flaw lengths estimated by ultrasonics shall be the (b) An RMS method of grading will be used. The RMS error true length -1/4in.,+1 in.t of the ultrasonic flaw length measurements, compared to the true flaw length, must be equal to or less than O.750in. Refer to PDI Position 94-005 forjustification for this deviation.
(c) Performance demonstration results reported by the (c) ne criteria of 3.2(c)(2) and (3), are replaced by an candidate, when plotted on a two dimensional plot equivalent RMS criteria. Refer to PDI Position (Fig. VIII-S4-1) with the depth estimated by 94-010-R1 forjustification for this deviation.
ultrasonics plotted along the ordinate and the true depth plotted along the abscissa, satisfy the following statistical parameters:
(1) Slope of the linear regression line is not less (1) Will not be utilized by the PDI Program.
than 0.7 (See PDI-Position 94-010-R1)
(2) ne mean deviat;on of flaw depth is less than (2) De measured flaw depth, as compared to the true depth, 0.25 in.; shall be equal to or less than an error of 0.25 inch RMS.
l 44 Revision 1, Change 0
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SUPPLEMENT 6 QUALIFICATION REQUIREMENTS FOR REACTOR VESSEL I WELDS OTHER THAN CLAD / BASE METAL INTERFACE I REQUIREMENT PDI IMPLEMENTATION 3.2 Sizing Acceptance Criteria. (Continued)
(3) Correlation coefficient is not less than 0.70. (3) Will not be utilited by the PDI Program.
(See PDI-Position 94-010-RI)
(4) For combined Sunclement 4 and 6. versonnel aualiReation. the accrotance criteria for Sucolement 4 will be avolied to Succlement 4 Raws and Suvolement 6 for Sunclement 6 Raws.
(See PDI Position 95-005) 45 Revision 1 Change 0
SUPPLEMENT 7 QUALIFICATION REQUIREMENTS FOR NOZZLE-TO VESSEL WELD REQUIREMENT PD1 IMPL MENTATION i
TABLE VIII S7 I Parallel to Weld Perpendicular to Weld I ID Surface X X OD Surface X X Subsurface X X l
i Demonstration on reactor vessel plate specimens The protocol to demonstrate the ultrasonic examination of '
(Supplement 6) qualifies examination procedures, equipment, nozzle to-vessel weld sections is in the process of and personnel for nozzle-to-vessel weld examination when preparation. For information the following is provided.
the following requirements are met.
(a) For detection, a minimum of three additional flaws (a) PDI has fabricated three full-size nozzle-to-shell in one or more full-scale nozzle mock-ups shall be mockups. One represents a BWR application from the added to the test set. outside surface. The remaining two represent a PWR and a small injection or core flood nozzle. PDI will imolement the requirements of Suvolement 7 for inside surface. clad-to-base metalinterface. ontv.
Due to limited sample base it is not possible to provide the same test set diversity as is donefor Supplements 4 and 6. As a minimum the PDA willdo thefollowing to insure the integrity of the demonstrations:
- Require procedures depnitively spectfy criteriafor detection and sizing, o Require that candidates provide specipc evidence that their decisionsfollowed the procedure directions, without apriori information, e No information as to the true si:e, location or orientation will be divulged to the candidates, and e To the extent possible candidates will be assigned separate areas of the test specimens or diferent specimens.
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SUPPLEMENT 7 QUALIFICATION REQUIREMENTS FOR NOZZLE TO VESSEL WELD REQUIREMENT PDI IMPLEMENTATION (a) (Continued)
For " analysis only" personnel qualifications, the following shall apply:
- 1. Where the analysis eautoment and the ultrasonic techniaue are basically the same as the Suvolement 4 avolication. no further demonstrations will be reaulted.
- 2. Where the techniques differ substantially, a demonstration set of a minimum of three flaws will be provided. Rese will be distributed in either the inlet or outlet configuration or both as appropriate.
For manual personnel qualification and all procedure qualifications, the rules listed below shall apply.
(See PDI Position 95-009)
He specimens shall comply with Supplement 6,1.1, ne flaws comply with the requirements of Supplement but flaws may be either notches or cracks. 4,1.1 He flaws are predominantly cracks.
Flaw locations and orientations shall be selected A combination of flaws parallel and perpendicular to the from the choices shown in Table VIII-S7-1. At least weld will be used. These Raws willinclude only inside one subsurface flaw shall be included and there shall sur/ ace Raws of this demonstration.
be no more than one flaw from each category.
(1) Fordet .urations performed from the vessel (a)(1) Demonstrations performed from the outside surface, shell,f ce specimen shall be at least 90% of the will use test specimens which are at least 90% of the maximum thickness to be examined. maximum thickness to be examined, as indicated in the Scope of the procedure.
(2) For examinations performed from the bore of (a)(2) Nozzle bore demonstrations are not included. The the nozzle, at least one flaw parallel to the weld Raws comolv with the requirements of Suvolement 4.1.1.
shall provide a metal path distance within 10% The Raws are predominant /v cracks.
of the equivalent path length to the weld centerline of the thickest component to be examined.
(3) Each of the flaws presented for demonstration (a)(3) Each of the flaws presented for demonstration shall be shall be correctly identified, in accordance with correctly identified, in accordance with the supplement 6,2.1, with no false calls. requirements of Supplement 4. False calls shall not exceed the value established by caranraoh 4.1(a) of Code Case N-552.
(b) For length sizing, a minimum of three additional (b) A minimum of three additional flaws as in (a) above will flaws as in (a) above shall be added to the test set. be added to the test set. The depth range of these flaws All flaws shall be sized to the acceptance standards will be distributed over the range required by of Supplement 6. Suvolement 4. The sizine results will be combined with the clad / base metalinterface aualiReation results. The accentance criteria. for the combination shall meet the requirements ofSuvolement 4.
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SUPPLEMENT 7 QUALIFICATION REQUIREMENTS FOR NOZZLE-TO VESSEL WELD REQUIREMENT PDI IMPLEMENTATION (c) For depth sizing a minimum of three additional (c) For depth sizing a minimum of three flaws will be added.
flaws as in (a) above shall be added to the test set. He depth range of these flaws will be distributed over Heir depths shall be evenly distributed over the the range required by Supplement 4. The sirins results ranges of Supplement 6,1.1. The sizing results will be combined with the clad / base metalinterface l from these flaws shall be combined with the sizing auoli&ation results. The acceorance criteria. for the results from the rector vessel weld qualification and combination shall meet the requirements ofSuvolement
)
{
the combined results shall meet the acceptance i criteria of Supplement 6,3.2. i 48 Revision 1, Change 0 l
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SUPPLEMENT 8 QUALIFICATION REQUIREMENTS FOR BOLTS AND STUDS REQUIREMENT PDI IMPLE' MENTATION 1.0 SPECIMEN REQUIREMENTS:
)
l' Qualification test shall meet the requirements listed herein, Specimens met the requirements listed below.
unless a set of specimens is designed to accommodate Owner / vendors will' provide specimens if their procedures specific limitations stated in the scope of the examination contain specific limitations.
procedure 1.1 Specimens shall conform to the following requirements:
(a) ne qualification process shall be performed with a (a) Qualification will be performed on full scale bolts or full-scale section bolt or stud that is sufficient to studs. A bolt / stud test set shall contain at least (3) contain the beam path and demonstrate the scanning different diameters and lengths, with sufficient beam path technique to demonstrate the scanning technique requested by the candidate. A survey of the utilities provided the information regarding the appropriate bolts and studs.
(See PDI Position 95-010)
(b) The qualification specimen shall be of similar (b) ne test specimens used in the performance chemical composition, tensile properties, and demonstration process are actual full scale bolts / studs metallurgical structure as the bolt or stud to be which were purchased from canceled units or spare parts examined. De scan surface of the qualification vendors.
specimen shall have a configuration similar to the bolt or stud to be examined. (See PDI Position 95-010) l TABLE VIII 581 MAXIMUM NOTCH DIMENSIONS Depth, in. Reflective Area, Bolt or Stud Size [ Note (1)] sq.in.
Greater than 4 inches diameter 0.157 0.059 2 in. diameter and greater, but not 0.107 0.027 over 4 in diameter NOTE:
(1) For threaded surfaces, depth is meassuredfrom the bonom of the thread root to bottom ofnotch.
(c) Circumferentially oriented notches shall be located (c) Circumferential notches are located at the minimum and in the qualification specimen at the minimum and maximum metal paths (within one diameter of each end maximum qualifled tnetal paths. Rese notches are for versonnel qualifications and within one diameter of required on the outside threaded surface and the the opposite endforprocedure quahfications) which a inner bore hole surface of bored studs with candidate request to demonstrate. ney are located on maximum depths and reflective areas as specified in the outside threaded surface, outer shaft, and the inner Table VIII-S8-1. bore hole surface of bored studs as specified in Table VIII SB 1. He minimum number of notches in a test set shall be five. PDI's design review (PDI-Q-002) verified that the size and location of the notches meet Table VIII-S8 1.
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SUPPLEMENT 8 I QUALIFICATION REQUIREMENTS FOR BOLTS AND STUDS REQUIREMENT PDI IMPLEMENTATION (c) (Continued)
Specimen identification and notch locations are obscured. The detection performance demonstration acceptance crite'ria consist of 2 parts; detection test and a false call test. A successful detection performance demonstration is achieved if the acceptance criteria of both parts are satisfied.
(See Code Case N-457)
Detection Test De minimum detection criteria, or minimum number of notches which must be detected, is determined by the number of notches included in the performance demonstration sample set.
(d) Additional notches may be located Within the range (d) Additional notches may be located between the notches specified in (c) above, provided they do not interfere in (c) which do not interfere with the detection of other with the detection of other notches. notches. Some bolts and studs may be unflawed.
i
!- 2.0 ' CONDUCT OF PERFORMANCE i DEMONSTRATIONS: I
- 2.1 Detection Test l
(a) Specimen identification and notch locations shall be (a) To receive credit for detecting a notch,it must be obscured so as to raaintain a " blind test." A flaw recorded correctly relative to the following criteria; shall be considered detected when the notch, as defined in 1.1,is found. The notch axial location Number of Minimum Number of correlation shall be i 1/2 in. or15% of the bolt or Notches in Set Detection False Calls stud length, whichever is greater.
5 4 0 6 5 1
- j. 7 6 1 8 7 2 9 8 2 10 8 2 False Call Test - De acceptable number of false calls is determined *oy the number of flaws in the test and in accordance with the table above.
l A false call is defined as exceeding the following limits:
De notch axiallocation correlation shall be 1/2" or 15% of the bolt / stud length, whichever is greater.
Notch circumferential position must be within 60 degrees of notch centerline location (within the appropriate third of the bolt / stud).
These requirements meet or exceed the requirements of Supplement 8.
50 Revision 1, Change 0
SUPPLEMENT 8 QUALIFICATION REQUIREMENTS FOR BOLTS AND STUDS REQUIREMENT PDI IMPLEMENTATION 3.0 Acceptance Criteria 3.1 Examination procedures, equipment, and personnel are 3.1 Examination systems are qualified for detection when qualified for detection when each qualification notch (as each notch has been detected and its response equals or described in 1.1) has been detected and its response exceeds the reporting criteria of the procedure. The equals or exceeds the reporting criteria specified in the surveillance of the demonstration will veriff detections procedure. The notch response shall have a minimum and that notch responses have a minimum peak signal to peak signal to peak noise ratio of 2:1. peak noise ratio of 2:1.
51 Revision 1 Change 0
SUPPLEMENT 9 QUALIFICATION REQUIREMENTS FOR CAST AUSTENITIC PIPING WELDS REQUIREMENT PDI IMPLEMENTATION (In the course of preparation) Supplement 9, Cast Austentic,is "In Course of Preparation" so PDI cannot implement.
52 Revision 1. Change 0 l
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SUPPLEMENT 10 QUALIFICATION REQUIREMENTS FOR DISSIMILAR METAL PIPING WELDS REQUIREMENT PDI IMPLEMENTATION 1.0 SPECIMEN REQUIREMENTS .
I Qualification test specimens shall meet the requirements Supplement 10 Dissimilar Metal,is not being implemented listed herein, unless a set of specimens is designed to by PDI at this tiine. .
accommodate specific limitations stated in the scope of the examinaiton procedure (e.g., pipe size, weld joint configuration, access limitations). The same specimens may be used to demonstrate both detection and sizing qualifications.
1.1 General .
(a) Specimens shall have sufficient volume to minimize spurious reflections that may interfere with the interpretation process. ,
(b) De specimen set shallinclude the minimum and maximum pipe diameters and thicknesses for which the examinaiton procedure is applicable. Pipe diameters within a range of 0.9 to 1.5 times a nominal diametershall be considered equivalent.
Pipe diameters larger than 24 in. shall be considered to be flat. When a range of thicknesses is to be examined, a thickness tolerance of 25% is acceptable.
(c) De specimen set shallinclude examples of the following fabrication condition:
(1) geometric conditions that normally require discriminadon from flaws (e.g., counterbore or weld root conditions, cladding, weld buttering, remnants of previous welds, adjacent welds in close proximity);
(2) typicallimited scanning surface conditions (e.g., diametrical shrink, single-side access due to nozzle and safe end external tapers).
(d) All flaws in the specimen set shall be cracks.
(1) At least 50% of the cracks shall be in austenitic material. At least 50% of the cracks in austenitic material shall be contained wholly in weld or buttering material. At least 10% of the cracks shall be in ferritic material. He remainder of the cracks may be in either austenitic or ferritic material.
53 Revision 1, Change 0
I SUPPLEMENT 10 l
QUALIFICATION REQUIREMENTS FOR DISSIMILAR METAL PIPING WELDS REQUIREMENT PDI IMPLEMENTATION (2) At least 50% of the cracks in austenitic base material shall be either IGSCC or thermal fatigue cracks. At least 50% of the cracks in ferritic material shall be mechanically or ,
3 l
thermally induced fatigue cracks. '
)
i (3) At least 50% of the cracks shall be coincident with areas described in (c) above.
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f I
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l l
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l 1
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SUPPLEMENT 11 1
! QUALIFICATION REQUIREMENTS FOR FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC PIPING WELDS REQUIREMENT PDI IMPLEMENTATION 1.0 SPECIMEN REQUIREMENTS 1.0 Qualillcation test specimens shall meet the Soecimens currentiv beinn used for the BWROG - IGSCC requirements listed herein, unless a set of specimens is Overlav Examination will be used for this demonstration. \
designed to accommodate specific limitations stated in the scope of the exanunation procedure (e.g., pipe size, weld joint configuration, access limitations). The same spectmens may be used to demonstrate both detection and sizing qualification.
1.1 General The specimen set shall conform to the following requirements. ,
(a) Specimens shall have sufficient volume to minimize spurious reflections that may interfere with the interpretation process.
(b) The specimen set shall consist of at least three specimens having different nominal pipe diameters and overlay thicknesses. "Ibey shallinclude the minimum and maximum nominal pipe diameters for which the examination procedure is applicable.
Pipe diameters within a range of 0.9 to 1.5 times a nominal diameter shall be considered equivalent. If ,
the procedure is applicable to pipe diameters of 24 in. or larger, the specimen set must include at least one specimen 24 in. or larger but need not include the maximum diameter. The specimen set must include at least one specimen with overlay thickness within -0.1 in. to +0.25 in. of the maximum nominal overlay thickness for which the procedure is applicable.
(c) The surface condition of at least two specimens shall approximate the roughest surface condition for which the examination procedure is applicable.
(d) Flaw Conditions (1) Base metalflaws. All flaws must be cracks in or near the butt weld heat affected zone, open to the inside surface, and extending at least 75% through the base metal wall. Flaws may extend 100% through the base metal and into the overlay material; in this case, intentional overlay fabrication flaws shall not interfere with ultrasonic detection or characterization of the cracking. Specimens containing IGSCC shall be used when available.
55 Revision 1, Change 1
SUPPLEMENT 11 QUALIFICATION REQUIREMENTS FOR FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC PIPING WELDS REQUIREMENT PDI IMPLEMENTATION 1.1 General (Continued)
(2) Overlayfabricationflaws. At least 40% of the flaws shall be non-crack fabrication flaws (e.g.,
side-wall lack of fusion or laminar lack of bond) in the overlay or the pipe-to-overlay interface. At least 20% of the flaws shall be cracks. The balance of the flaws shall be of either type.
(e) Detection Specimens (1) At least 20% but less than 40% of the flaws shall be oriented within 20 deg. of the pipe axial direction. The remainder shall be oriented circumferentially. Fldws shall not be open to any surface to which the candidate has physical or visual access. The rules of IWA-3300 shall be used to determine wbether closely spaced flaws should be treated as single or multiple flaws.
(2) Specimens shall be divided into base and overlay grading units. Each specimen shall contain one or both types of grading units.
(a)(1) A base grading unit shallinclude at least 3 in. of the length of the overlaid weld. The base grading unit includes the outer 25% of the overlaid weld and base metal on both sides. The base grading unit shall not include the inner 75% of the overlaid weld and base metal overlay material, or base i metal-to-overlay interface. l l
(2) When base metal cracking penetrates into the overlay material, the base grading unit shall include the overlay metal within 1 in. of the crack location. This portion of the overlay f material shallnot be used as part of any overlay grading unit.
l 56 Revision 1, Change 1
SUPPLEMENT 11 QUALIFICATION REQUIREMENTS FOR FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC PIPING WELDS REQUIREMENT PDI IMPLEMENTATION (3) When a base grading unit is design to be unflawed, at least 1 in of unflawed overlaid weld and base metal shall exist on either side of the base grading unit. The segment of weld length used in one base grading unit shall not be used in another base grading unit.
Base grading units need not be uniformly spaced around the specimen.
(b)(1) An overlay grading unit shall include the overlay material and the base metal-to-overlay interface of at least 6 sq. in. The overlay grading unit shall be rectangular, with minimum dimensions of 2 in *
(2) An overlay grading unit designed to be unflawed shall be surrounded by unflawed overlay material and unflawed base metal-to-overlay interface for at least 1 in. around its entire perimeter. The specific area used in one overlay grading unit shall not be used in another overlay grading unit. Overlay grading units need not be spaced uniformly about the specimen.
(3) Detection sets shall be selected from Table Vill-S2-1. The minimum detection sample setis five flawed base grading units, ten unflawed base grading units, five flawed overlay grading units, and ten unflawed overlay grading units. For each type of grading unit, the set shall contain atleast twice as many unflawed as flawed grading units.
1 (f) Si:.ing Specimen (1) The minimum number of flaws shall be ten.
At least 30% of the flaws shall be overlay fabrication flaws. At least 40% of the flaws shall be cracks open to the inside surface.
(2) At least 20% but less than 40% of the flaws shall be oriented axially. The remainder shall be oriented circumferentially. Flaws shall not be open to any surface to which the candidate has physical or visualaccess.
57 Revision 1. Change 1
SUPPLEMENT 11 QUALIFICATION REQUIREMENTS FOR FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC PIPING WELDS REQUIREMENT PDI IMPLEMENTATION (f) Si:ingSpecimen(Continued)
(3) Base metal cracking used for length sizing demonstrations shall be oriented circumferential!y.
(4) Depth sizing specimen sets shallinclude at least two distinct locations where cracking in the base metal extends into the overlay material by at least 0.1 in. in the through-wall direction.
2.0 CONDUCTOFPERFORMANCE 2.0 DEMONSTRATIONS The specimen inside surface and identification shall be The specimen inside surface and identification shall be concealed from the candidate. All examinations shall concealed from the candidate. All examinations shall be be completed prior to grading the results and presenting completed prior to grading the results and presenting the the results to the candidate. Divulgence of particular results to the candidate. Divulgence of particular specimen specimen results or candidate viewing of unmasked results or candidate viewing of unmasked specimens after
- specimens after the performance demonstration is the performance demonstration is prohibited. Performance prohibited. -
demonstrations will be conducted to the requirements of the existinn cronram. with the Mrional requirements of essentia! variable recording and monitoring. which is reauired by Accendix Villand the PD1 Protocol. Extension ofcrocedure Stone and essential variables. not demonstrated by the existing samoles. will be demonstrated on site soecific calibration blocks. durinn examinations.
2.1 Detection Test 2.1 Flawed and untlawed grading units shall be randomly The detection. length sizinn and death sizinn tests will be mixed. Although the boundaries of specific grading conducted according to the crotocol ofthe existing BWROG units shall not bs revealed to the candidate, the
- /GSCC Overlav Pronram. (See PDI Position 95-014) ,
candidate shall be made aware of the type or types of grading units (base or overlay) that are present for each l
j specimen.
j 2.2 Length Sizing Test 2.2 (a) The length sizing test may be conducted separately The detection. lensth sizinn and death si-inn tests will be or in conjunction with the detection test. conducted accordins to the orotocol of the existino BWROG i (b) When the length sizing test is conducted in conjunction with the detection test and the detected ,
flaws do not satisfy the requirements of para.1.l(f),
additional specimens shall be provided to the .
candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.
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SUPPLEMENT 11 QUALIFICATION REQUIREMENTS FOR FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC PIPING WELDS REQUIREMENT PDI LMPL'EMENTATION
{
2.2 Length Sizing Test (Continued) J (c) For a separate length sizing test, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.
(d) For flaws in base grading units, the candidate shall estimate the length of that part of the flaw that is in the outer 25% of the base wall thickness.
2.3 Depth Sizing Test. 2.3 For the depth sizing test,80% of the flaws shall be sized The detection. length sizine and deoth sizing tests will be at a specific location on the surface of the specimen conducted according to the crotocol of the existing BWROG identified to the candidate. For the remaining flaws, the IGSCC Overlav Program. (See PDI Position 95-014) regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.
3.0 ACCEPTANCE CRITERIA 3.0 Theacceotance criteria of the existing BWROG - IGSCC Overlav Program.
(See PDI Position 95-014) t 3.1 Detection Acceptance Criteria Examination procedures, equipment, and personnel are qualified for detection when the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls. The criteria shall be satisfied separately by the demonstration results for base grading units and for overlay grading units.
3.2 Sizing Acceptance Criteria Examination procedures, equipment, and personnel are qualified for sizing when the results of the performance demonstration satisfy the following criteria.
(a) Flaw lengths are estimated within 1 in. of the true length (the length of base metal cracking is measured at the 75% through-base-metal position).
(b) All extensions of base metal cracking into the overlay material by at least 0.1 in. are reported as being intrusions into the overlay material.
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SUPPLEMENT 11 QUALIFICATION REQUIREMENTS FOR FULL JTRUCTURAL OVERLAID WROUGHT AUSTENITIC PIPING %ILDS l REQUIREMENT PDI IMPLEMENTATION 3.2 Sizing Acceptance Criteria (Continued)
(c) The RMS error of the flaw depth mea:urements, as l compared to the true flaw depths, is less than or l equal to 0.125 in. RMS error shall be calculated as follows:
,, -in
[(mi-ti)
RMS=
n where my = measured flaw depth ff = true flaw depth n = number of flaws measured I
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SUPPLEMENT 12 QUALIFICATION REQUIREMENTS FOR C(X)RDINATED IMPLEMENTATION OF SELECTED ASPECTS OF SUPPLEMENTS 2, 3,10, AND 11 REQUIREMENT PDI IMPLEMENTATION.$
1.0 DETECTION AND LENGTH SIZING .
(a) Ferritic P@ing (a) PDI qualifies ferritic piping detection by adding at least three flawed ferritic grading units and six unflawed ferritic grading units to an austenitic test set. The grading unit includes at least 3 in. of continuous weld length. Surveillance verifies that t.Il 9 grading units are correctly identified.
(1) The requirements of Supplement 3 are satisfied (a)(1) PDI satisfies Supplement 3 requirements by adding by osmonstration on wrought austenitic piping ferritic piping specimens to wrought austenitic sample when the following requirements are met. sets of Supplement 2.
(a) For detection qualification,'at least three (e)(1)(a) PDI qualifies ferritic piping detection by adding at additional flawed grading units and six least three flawed ferritic grading units and six unflawed additional unflawed units in ferritic piping ferritic grading units to an austenitic test set. He shall be added to the test set. A grading grading uait includes at least 3 in. of continuous weld unit shall include at least 3 in. continuous length. Surveillance verifies that all ferritic grading weld length. All 9 ferritic grading units units are correctly identified.
5 hall be correctly identified.
(b) For length sizing qualification, at least (a)(1)(b) For length sizing, PDI includes at least three and three additional flaws in ferritic piping no more than four flaws in ferritic piping to the flaws in shall be added to the test set. All flaws Supplement 2. Ferritic sizing results are graded with the l shall be sized within the length criteria of Supplement 2 results. The RMS error must be equal to Supplement 2, para 3.2. or less than .75" for the combined test sets.
1 (2) Examinations of specimens during a successful (a)(2) PDI is not currently implementing dissimilar metal detection or length sizing demonstration on requirements.
l dissimilar metal welded piping may be applied toward a Supplement 3 demonstration when the following requirements are met.
(a) Grading units shall include at least 6 in. (a)(2)(c) continuous weld length. He grading unit l shall contain only the ferritic-side base metal and inside surface clad. He austenitic base metal, butt weld, and weld preparation buttering shall not be a part of the grading unit.
(b) ne examinations performed on the ferritic (a)(2)(b) side of the dissimilar metal weld specimens i
shall use the same ultrasonic procedure i essential variable values, or, when appropriate, the same criteria for selecting i values, as the examinat2ons performed on the ferritic specimens.
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SUPPLEMENT 12 QUALIFICATION REQUIREMENTS FOR I
COORDINATED IMPLEMENTATION OF SELECTED ASPECTS OF SUPPLEMENTS 2,3,10, AND 11 REQUIREMENT PDI IMPLEMENTATION (b) Austenitic Piping Examinations of specimens (b) PDIis not currently implementing dissimilar metal during a successful detection or length sizing requirements.
demonstration on dissimilar metal welded piping may be applied toward a Supplement 2 l demonstration when the following requirements are met.
(1) Grading units shall be defined as at least 6 in. (b)(1) continuous weld length. De grading unit shall contain only the austenitic-side base metal. The ferritic base metal, b<tt weld, and weld l preparation buttering shall not be a part of the grading unit. ,
(2) De examinations performed on the austenitic (b)(2) side of the dissimilar metal weld specimens shall use the same ultrasonic procedure j essential variable values, or, when appropriate, the same criteria for selecting values, as the examinations performed on the sustenitic specimens.
I 2.0 DEPTH SIZING 2.0 PDI coordinates the qualification of examinations for Examination personnel, equipment, and procedure
- qualification requirements for depth sizing for more than
, one of Supplements 2,3,10, and 11 are met by the
! following demonstration.
l (a) Specimens (1) De minimum number of flaws shall be ten. (a)(1) De minimum number of flaws is ten.
(2) De specimen set shall include at least four (a)(2) PDI uses 4 or 5 ferritic flaws for Supplement 3 in flaws from specimens specific to each of the coordination with at least 5 austenetic flaws (for a l Supplements addressed by the demonstration. minimum total of 10 flaws) from Supplement 2.
i If Supplement 3 is being addressed, the specimen set shall include no more than five Supplement 3 flaws.
(3) De overall flaw depth distribution shall meet (a)(3) The surveillance and computer program for making the requirements of Supplement 2, para. tests verify that overall flaw distribution meets the 1.0(e)(2). requirements of Supplement 2, para.1.3 ('93 Addenda)
(4) Of the flaws specific to each of.ns Supplements (a)(4) PDI surveillance and instructions ensure that no more addressed by the demonstration, no more than than half of the flaws in any one depth category come half, rounded to the next higher whole number, from supplement 2 or 3 flaws.
may be in any one of the depth categories of Supplement 2, para.1.0(c)(2).
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SUPPLEMENT 12 QUALIFICATION REQUIREMENTS FOR COORDINATED IMPLEMENTATION OF SELECTED ASPECTS OF SUPPLEMENTS 2, 3,10, AND 11 I
KEOUIREMENT PDI IMPLEMENTATION 2.0 DEPTH SIZING (Continued) ,
(b) ne demonstration shall be conducted in PDI conducts the depth sizing demonstration by proudag ,
accordance with the requirements of Supplement 2, region on the specimen where the maximum depth is para. 2.2.(b). measured. This is because the Code assumed that the IG5 Planar Sizing Program was measuring depths at a specific location 20% of the time. His has not been true for sem m years and the Code hasn't revised this paragraph until recently.
(c) De examination procedure, equipment, and PDI qualifies examination systems for depth sizing by personnel are qualified for depth sizing under each combining the results of Supplement 2 and 3 flaws and of the Supplements addressed by the demonstration determining the RMS error. Acceptable performance is when when the F.MS error of the flaw depth the RMS error is less than er equal to .125 in. (See PDI measurements, as compared to the true flaw depths, Position 94-002).
is less than or equal to 0.125 in. RMS error shall be calculated as follows:
, 1/2
[(mi-ri)*
RMS=
n where mi = measured flaw depth rf = true flaw depth n = number of flaws measured 63 Revision 1. Change a
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" APPENDIX A" PROGRAM IMPLEMENTING PROCEDURES
Specimen Fabrication Quality Assurance Program ,
NUMBER TITLE STATUS SFQAR PDI Specimen Fabrication Quality Assurance Requirements Proprietary SFQAP PDI Specimen Fabrication Quality Assurance Program Proprietary PDI-Q-002 Design Control Proprietary PDI-Q-003 PDI Test Specimen Pro /urement Proprietary PDI-Q-004 PDI Document Control Proprietary PDI-Q-005 Material Control and Identification for PDI Specimen Fabrication Proprietary PDI-Q-006 Qualification of Inspection, Examination and Test Personnel for PDI Proprietary Specimen Fabrication IA-301 Qualification and Certification of NDE Personnel Proprietary ADM-217 Calibration and Control of NDE Center Measurement and Test Proprietar/
Equipment PDI-Q-010 PDI Test Specimen and Information Security Proprietary PDI-Q-012 PDIControl of Nonconforming Items Proprietary PDI-Q-013 PDI Specimen Manufacturing and Examination Records Indexing Proprietary PDI-I-013 PDI Test Specimen Quality Records Review Instruction Proprietary PDI-Q-014 Quality Assurance Monitoring Proprietary PDI-G-001 Preparation. Use and Control of Process Cogi Sheets Proprietary Page 1 of 1 Revision 1 Change 0
i PDP-I-009 PDP Prerequisites Instmetion Proprietary l PDP-I-009.1 l Procedure Review Instruction l Proprietary l PDP-I-009.2 l Dispute Resolution Instruction l Proprietary ;
l PDP-I-009.3 l Candidate Registration and Scheduling Instruction l Proprietary l PDP-I-009.4 l General Test Specimen Selection Instruction l Proprietary Test Specimen Selection Instruction - Manual or Semi-Automated PDP-I-009.4.1 Austenitic Piping Examinations for Detecction, Length and Depth Proprietary Sizing (Supplement 3 & 12)
Test Specimen Selection Instruction - For Detection, Length, and Depth PDP-I-009.4.2 Sizing of RPV Clad / Base Material Interface examinations (Supplement Proprietary
- 4) and RPV Welds other than Clad / Base Material Interface (Supplement 6) l PDP-I-009.5 l Grading Instruciton for Piping and Bolting l Proprietary l PDP-I-009.5.1 l Grading Instmeiton for Reactor Pressure Vessel (Supplementsl Proprietary 4 & 6) I l PDP-I-009.6 l PDQS Expansion Instruction l Proprietary
~
l PDP-I-009.7 l Piping Qualification Retest Instruction l Proprietary l PDP-I-009.7.1 l RPV Qualification Retest Instruction (Supplements 4 & 6) l Proprietary l PDP-I-012.1 l Instrument and Search Unit Characterization l ~ Proprietary PDP-I-018 l Piping Surveillance Instruction l l Proprietary l PDP-I-018.1 l Automated Surveillance Instruction l Proprietary l l l l l l l l l l l l l l l Page 1 of 1 Revision 1, Change 0
PDPQAR Perfonnance Demonstration Process Quality Assurance Proprietary Requirements lPDPQAP l Performance Demonstration Process Quality Assurance Program Proprietaryl l PDP-Q-001 l Organization Proprietary l
l PDP-Q-005 l Procedures and Instructions Propr:etary l
l PDP-Q-006 l Document Control Proprietary l
l PDP-Q-008 l Security of Test Specimen Information Proprietary l
l PDP-Q-008.1 l Control and Security of Test Sp;.cimen Proprietary l
l PDP-Q-009 l Performance Demonstration Control Proprietary l
l PDP-Q-009.1 l Test Administration Proprietary l
IA-301 l Q' qualification and Certification of NDE Personnel Proprietary l l l ADM-217 Calibration and Control of NDE Center Measurement and Tests Proprietary Equipment l l l l PDP-Q-013 l Handling, Storage, and Shipping Proprietary l
l PDP-Q-015 l Control of Nonconformances Proprietary l
l PDP-I-015.1 l 10CFR21 Evaluation and Reporting Proprietary l
l PDP-Q-016 l Corrective Action and Root Cause Analysis Proprietary l
l PDI-Q-017 l QA Records Proprietary l
l PDP-Q-018 l Audits Proprietary l
l PDP-Q-018.1 l Qualification & Certification of Lead Auditors Proprietary l
l PDP-Q-018.2 l Qualification & Certification of Auditors Proprietary l
l PDP-Q-018.3 l Surveillance Proprietary l
Page 1 of 1 Revision 1, Change 0
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" APPENDIX B" PDI PROGRAM POSITIONS i
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PDI POSITION NO. 94-001R1 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII Supplement 2 " Qualification Requirements for Wrought Austenitic Piping Welds" Paragraph I.1(b) ,
"The specimen set shall consist of at least four specimens having different nominal pipe diameters and thicknesses. They shall include the minimum and maximum pipe diameters and thicknesses for which the examination procedure is applicable. If the procedure is applicable to pipe diameters of 24 in, or larger, the specimen set must include at least one specimen 24 in. or larger in diameter with the maximum thickness covered by the procedure, but need not include the maximum diameter."
II. PDI POSITION AND PROPOSED CODE CHANGE -
The specimen set shall consist of at least four specimens having different nominal pipe diameters and thicknesses. The set shall include pipe specimens not thicker than 0.1 inch more than the minimum thickness, nor thinner than 0.5 inch less than the maximum thickness for which the examination procedure is applicable. It shall include the minimum and maximum pipe diameters and thicknesses for which the examination procedure is applicable. If the procedure is applicable to pipe diameters of 24 inch or larger, the specimen set must include at least one specime: 24 inch or larger in diameter but need not include the maximum diameter.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-These changes were incorporated by the 95 Addenda. See also, PDI Position 95-013, which describes additional changes to Supplement 12.
{94-001 and 94-004 should be combined}
Revision 1 Change 0
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PDI POSITION NO. 94-002RI
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I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII Supplement 2 " Qualification Requ' irements for Wrought Austenitic Piping Weids" l
" Sizing Acceptance Criteria.
Examination procedures, equipment, and personnel are qualified for sizing if the results of the performance demonstration satisfy the following criteria: ,
l (a) flaw lengths estimated by
, ultrasonics are within 1 in. of the true length;"
II. PDI POSITION AND PROPOSED CODE CHANGE -
PDI will allow a Root Mean Square (RMS) error of .75 inch instead of the specified 1 inch tolerance. The Section XI Code Committee is currently evaluating changes to this l paragraph (Reference ISI 94-39). A change has been proposed to the ASME Section XI l Code Committee which reflects this position.
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IH. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE l CHANGE-The RMS Calculation is more fair to the examiner since it does not consider a single
! " critical miscall" error. The RMS Calculation provides a truer indication of an examiners actual ability. The use of the RMS value may also reduce any tendency to intentionally oversize to avoid a " critical miscall" error. Additionally, the overall capability for accuracy, when averaged over all measurements, will be better than the 1 inch tolerance could allow.
Code Case N-538 and a Code revision incorporating these changes have been accepted by the ASME Code, but have not yet been published as of February 1996.
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PDI POSITION NO.94-003 I. CODE REFERENCE / REQUIREMENT ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 4 -
" Qualification Requirements for the Clad / Base Metal Interface of Reactor Vessel" Paragraph 1.1(e) (1) (b).
" Notches shall have a maximum width of 0.010 in. and shall be plugged to their full depth with an insert of the parent material prior to cladding."
II. PDI POSITION AND PROPOSED CODE CHANGE Notches in PDI test specimens have been manufactured using procedures that have repeatedly shown the notch tip dimension to be less than 0.010 in. The actual width of the notch at the clad to base metal interface may be greater than 0.010 in. All notches were plugged to their full depth prior to cladding.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE It is important to make the notch tip less than 0.010 in. to control the notch radius which ,
has an effect on flaw response. The flaw manufacturers were required to demonstrate that they could meet the notch width requirement and it was demonstrated that they could not reliably make the notch opening width less than 0.010 in. However, they could control the notch tip width to less than 0.010 in. The notches required by the Code are beyond current fabrication capabilities and are not technically feasible.
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. PDI POSITJON NO,94-004R1 I. CODE REFERENCE REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 2 ,
"Qualineation Requirements for Wrought Austenitic Piping Welds" Paragraph 1.1(b).
"The specimen set shall consist of at least four specimens having different nominal pipe diameters and thicknesses. They shallinclude the minimum and maximum pipe diameters and thicknesses for which the examination procedure is gpplicable. If the procedure is applicable t'o pipe diameters of 24 in. or larger, the specimen set must include at least one specimen 24 in. or larger in diameter with the maximum thickness covered by the procedure, but need not include the maximum diameter."
Supplement 3 "Qualincation Requirements for Ferritic Piping Welds"
" Qualification of examination procedures, equipment, and personnel for ferritic pipe examination shall be accomplished by satisfying the requirements of Supplement 2, except that the sample material shall be ferritic and 75% of the sample set defects (Supplement 2, para.
1.0(c)(2) shall be mechanically or thermally induced fatigue cracks."
Supplement 12 " Requirements for Coordinated Implementation of Selected Aspects of Supplements 2,3,10, and 11" Refer to requirements of Supplements 2 and 3.
Revision 1, Change 0
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I PDI POSITION NO. 94 004R1 )
(Continued)
II. PDI POSITION AND PROPOSED CODE CHANGE - ,
Supplement 2,1.1, (b) The specimen set shall consist of at least four specimens having different nominal pipe diameters and thicknesses. The set shall include pipe specimens not thicker than 0.1 inch more than the minimum thickness, nor thinner than 0.5 inch less than the maximum thickness for which the examination procedure is applicable. It shall include the minimum and maximum pipe dinneters and thicknesses for which the examination procedure is applicable. If the procedure is applicable to pipe diameters of 24 inch or larger, the specimen set must include at least one specimen 24 inch or larger in diameter but need not include the maximum diameter.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE -
In developing a program for meeting the requirements of Appendix VIII, we find that there is a large diversity of needs by the various utilities which must meet these requirements. We find disagreements over the significance of 0.030 inch differences in wall thickness. Among the realm of things which are significant in regard to examination effectiveness, this is of minor importance. At the larger end of the pipe wall thickness spectrum we find that the maxunums are approximately 3.0 inches for wrought austenitic piping and 3.75 inches for ferritic piping. Material at these extreme sizes is extremely rare. We propose that there is no fundamental difference within the proposed ranges,0.5 for wrought austenitic and 1.0 inch for ferritic material. Methods of compensating for metal l path range and attenuation are a requirement of the demonstrations.
The last sentence of 1.l(b)is unnecessarily complicated. What the Code implies l is 24 inches is big enough, after that it doesn't matter. The requirement that the largest thickness is in the largest diameter, is also not necessary The most difficult case is where the maximum thickness is in the smaller diameter pipe. f 1
i l These changes were incorporated by the 95 Addenda. See also, PDI Position 95-013, which describes additional changes to Supplement 12.
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I. CODE REFERENCE REQUIREMENT .
ASME Section XI, Appendix VIII (92 Edition W/93 Addenda) Supplement 4 -
" Qualification Requirements for the Clad / Base MetalInterface of Reactor Vessel" Paragraph 3.2 Sizing Acceptance Criteria (b) 3 1
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" Flaw lengths estimated by l
ultrasonics shall be the true length - !
!/4 in. + 1 in."
II. PDI POSITION AND PROPOSED CODE CHANGE PDI will allow a Root Mean Square (RMS) error of 0.75 inch RMS.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE.
l It is the position of the PDI that this requirement is arbitrary and not based on need or a demonstrated capability to perform at this level. The following facts should be considered.
These requirements are in effect, critical miscall conditions, i.e., one error invalidates the entire examination. Where examination demonstrations are requiring 80 to 120 hours0.00139 days <br />0.0333 hours <br />1.984127e-4 weeks <br />4.566e-5 months <br /> or more this is just not acceptable, particularly in light of the relative importance of the length measurement. Critical miscall conditions tend to encourage testmanship (i.e.,
! candidates will tend toward over sizing rather than correctly sizing the indication). The results are therefore less descriptive of the technique or what will actually be performed l in the field. An acceptance criteria based on the overall or average performance is much
! more meaningful. The RMS criteria now accepted for through wall sizing in piping is an example of such a criteria.
l Them have been three documented studies which have looked at the question of flaw j length sizing in RPV test specimens. These include the PISC II Round Robin Test Trials (1), the Sizewell B Validations at the IVC (2) and a demonstration performed by TVA in the spirit of Appendix VIII(3).
The PISC II trials were the largest of the three demonstration trials. This large intemational trial was conducted in 1982 - 84 time frame and included manual and automated systems as well as " advanced or alternative systems." The PISC trial results have been the subject of a large number of studies which have been widely accepted. Of Revision 1, Change 0
PDI POSITION NO,94-005 (Continued) the specimens included in PISC II, Plate No. 2 is most appropriate to Supplements 4 and
- 6. PISC Plate No. 2 is a flat plate clad on one side and approximately 5 X 5 feet and 10 inches thick. The plate contained flaws which would be included in both Supplements 4 and 6. The error in sizing the length of these flaws, ESY, is shown in Figure 10, for 20%
~ ASME DAC procedures. The reported mean was 14 mm width and the standard deviation was 33.1. This is a very large error. It indicates that only 65% of the measurements were within 33 mm or 1.3 inches of the mean which is off by more than .5 inch.
The PISC data was collected up to 12 years ago. Considerable advances in training and equipment have been made since that time. In addition, the overall data is skewed considering that there were some teams with mean errors in length of up to 2 inches, with very large standard deviations. There were at least 8 teams which examined Plate No. 2, achieving standard deviations ofless than 19 mm for the length measurements.
The IVC trials for Sizewell B, were directed primarily at the RPV. However, other components of the steam generator, pressurizer and flywheel were also included. These trials included both manual and automated systems. Mr. Conroy, program administrator, concludes that many individuals with high capability would have failed to pass the - 1/4 inch criteria. Reported length sizing accuracy's in this trial ranged from 3.9 to 10.2 mm (0.15 to 0.4 inch) RMS. In terms of mean and standard deviation these were -1.9 t.3.4 mm for the low and 4.2 i9.3 mm for the high. These are extraordinary accuracy's.
However, many of these individuals would fail Appendix VIII due to the -1/4 inch requirement.
The TVA " Demonstration In the Spirit of Appendix VIII" (3) was led by Frank Leonard of TVA and assisted by NDE Center personnel. The demonstration contained both Supplement 4 & 6 test blocks. The demonstration used automated data collection systems. Four data analysis candidates took part in the demonstration. One prominent difference between Appendix VIII requirements and the test results was a failure to stay with the - 1/4 inch length sizing tolerance. Overall the length sizing performance was very good. The mean deviation for all length measurements including retests was +0.155 inch with a standard deviation of t 0.325 inch. The measurement data base included 102 measurements. The RMS Error for these same measurements was 0.359 inch. In one case the measurement exceeded the + 1.0 inch requirement when the error was 1.028 inch.
Adoption of a length sizing criteria of 0.75 inch RMS would provide a workable and achievable standard for this measurement. Examples of this criteria can be seen in the proposal for revising the length sizing criteria for piping. It is actually more descriptive of the sizing process, as opposed to i 1.0 inch. Candidates who can demonstrate highly accurate sizing should be given credit for this achievement. The - 1/4 inch has been shown to be impractical.
Revision 1. Change 0
PDI POSITION NO. 94-006R1 I. CODE REFERENCE REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 2 -
" Qualification Requirements For Wrought Austenitic Piping Welds" Paragraph 2.2 (b)
"For the depth sizing test,80% of the flaws shall be sized at a specific location on the surface of the specimen identified to the candidate. For the remaining flaws, the regions of each specimen containing a flaw to be sized shall be identified to the candidate; The candidate shall determine the maximum depth of the flaw in each region."
Supplement 4 " Qualification Requirements for the Clad / Base Metal Interface of Reactor Vessel" Paragraph 2.2(b)
"For the depth sizing test,80% of the flaws shall be sized at a specific location on the surface of the specimen identified to the candidate. For the remaining flaws, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region."
Supplement 6 " Qualification Requirements for Reactor Vessel Welds Other Than Clad / Base Metal Interface" Paragraph 2.2(b)
"For the depth sizing test,80% of the flaws shall be sized at a specific location on the surface of the specimen identified to the candidate. For the remaining flaws, the regions of each specimen containing a flaw to be sized shall be identified to the l candidate. The candidate shall determine the maximum depth of the flaw in each region."
Revision 1. Change 0 L.
PDI POSITION NO. 94-006R1 (Continued)
II. PDI POSITION AND PROPOSED CODE CHANGE - ,
For depth sizing tests the region of the specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in the region.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE -
This requirement originafed during the early days ofIGSC. It was found to be impractical and was dropped. It is not always possible to achieve the required signal responses at any specified location. The new requirement is: more conservative, needed to maintain security, and more similar to what is done in actual field practice.
Code Case N-537, published in the 95 Supplement, is applicable to this situation.
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Revision 1 Change 0
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PDI POSITION NO. 94-007R1 I. CODE REFERENCE REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Add'enda) Supplements 4 ,
" Qualification Requirements For The Clad / Base Metal Interface Of Reactor Vessel" Paragraph 2.1(a),2.2(a) and Supplement 6 " Qualification Requirements For Reactor Vessel Welds Other Than Clad / Base Metal Interface" Paragraph 2.1(a) and 2.2(a) 2.la " Specimen identification and flaw locations shall be obscured so as to maintain a j
" blind test".
2.la "For the length sizing test, the inside surface and the specimen identification shall be obscured."
II. PDI POSITION AND PROPOSED CODE CHANGE -
Supplements 4 and 6, paragraphs 2.l(a) and 2.2(a) )
2.1 Detection Test (a) Flaw locations shall be obscured so as to maintain a " blind test." All examinations shall be completed prior to grading and presenting the results to the candidate. Divulging particular specimen results or candidate viewing of unmasked specimens is prohibited.
2.2 Iength sizing test (a) For the length sizing test, the regions of each specimen containing a flaw to be l sized shall be identified to the candidate. The candidate shall determine the length I of the flaw in each region. '
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Revision 1, Change 0
. PDI POSITION NO. 94-007R1 (Continued)
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED ,
CODE CHANGE -
Steps have been taken to obscure flaw locations on both the inside and outside surface. Flaws on the outside surface are even more difficult to conceal than the clad inside surface. It would not be possible to conduct a demonstration under the original requirements.
These changes have been incorporated in Code Case N-541, which was published in the 95 Supplement. ,
Revision 1 Change 0
PDI POSITION NO.94-008 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition W/93 Addenda) Supplement 6 -
" Qualification Requirements for Reactor Vessel Welds Other Than Clad / Base -
MetalInterface" Paragraph 3.2 Sizing A.cceptance Criteria (b).
" Flaw lengths estimated by ultrasonics shall be the true length -
1/4 in., + 1 in."
II. PDI POSITION AND PROPOSED CODE CHANGE -
~
PDI will allow a Root Means Square (RMS) error of 0.75 inch RMS.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-It is the position of the PDI that this requirement is arbitrary and not based on need or a demonstrated capability to perform at this level. The following facts should be considered.
These requirements are in effect, critical miscall conditions, i.e., one error invalidates the entire examination. Where examination demonstrations are requiring 80 to 120 hours0.00139 days <br />0.0333 hours <br />1.984127e-4 weeks <br />4.566e-5 months <br /> or more this is just not acceptable, particularly in light of the relative importance of the length measurement. Critical miscall conditions tend to encourage testmanship (i.e.,
candidates will tend toward over sizing rather than correctly sizing the indication). The results are therefore less descriptive of the technique or what will actually be performed in the field. An acceptance criteria based on the overall or average performance is much more meaningful. The RMS criteria now accepted for through wall sizing in piping is an example of such a criteria. g There have, been three documented studies which have looked at the question of flaw length sizing in RPV test specimens. These include the PISC II Round Robin Test Trials (1), the Sizewell B Validations at the IVC (2) and a demonstration performed by TVA in the spirit of Appendix VIII(3).
The PISC II trials were the largest of the three demonstration trials. This large international trial was conducted in 1982 - 84 time frame and included manual and automated systems as well as " advanced or alternative systems." The PISC trial results have been the subject of a large number of studies which have been widely accepted. Of Revision 1, Change 0 w__-______-_________________-___ _ _ _ _ _ .
PDI POMTION NO.94 008 (Continued) .
the specimens included in PISC II, Plate No. 2 is most appropriate to Supplements 4 and
- 6. PISC Plate No. 2 is a flat plate clad on one side and approximately 5 X 5 feet and 10 inches thick. The plate contained flaws which would be included in both Supplements 4 and 6. The error in sizing the length of these flaws, ESY,is shown in Figure 10, for 20%
ASME DAC procedures. The reported mean was 14 mm width and the standard deviation was 33.1. This is a very large error. It indicates that only 65% of the measurements were within 33 mm or 1.3 inches of the mean which is off by more than .5 inch.
The PISC data was collected up to 12 years ago. Considerable advances in training and equipment have been made since that time. In addition, the overall data is skewed considering that there were some teams with mean errors in length of up to 2 inches, with very large standard deviations. There were at least 8 teams which examined Plate No. 2, achieving standard deviations ofless than 19 mm for the length measurements.
The IVC trials for Sizewell B, were directed primarily at the RPV. However, other components of the steam generator, pressurizer and flywheel were also included. These
. trials included both manual and automated systems. Mr. Conroy, program administrator, concludes that many individuals with high capability would have failed to pass the - 1/4 inch criteria. Reported length sizing accuracy's in this trial ranged from 3.9 to 10.2 mm (0.15 to 0.4 inch) RMS. In terms of mean and standard deviation these were -1.9 i.3.4 mm for the low and 4.2 9.3 mm for the high. These are extraordinary accuracy's.
However, many of these individuals would fail Appendix VIII due to the -1/4 inch requirement.
The TVA " Demonstration In the Spirit of Appendix VIII" (3) was led by Frank Leonard of TVA and assisted by NDE Center personnel. The demonstration contained both Supplement 4 & 6 test blocks. The demonstration used automated data collection systems. Four data analysis candidates took part in the demonstration. One prominent difference between Appendix VIII requirements and the test results was a failure to stay with the - 1/4 inch length sizing tolerance. Overall the length sizing performance was very good. The mean deviation {or all length measurements including retests was +0.155 inch with a standard deviation of 0.325 inch. The measurement data base included 102 measurements. The RMS Error for these same measurements was 0.359 inch. In one case the measuremer.t exceeded the + 1.0 inch requirement when the error was 1.028 inch.
Adoption of a length sizing criteria of 0.75 inch RMS would provide a workable and achievable standard for this measurement. Examples of this criteria can be seen in the proposal for revising the length sizing criteria for piping. It is actually more descriptive of the sizing process,'as opposed to i 1.0 inch. Candidates who can demonstrate highly accurate sizing should be given credit for this achievement. The - 1/4 inch has been shown to be impractical.
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PDI POSITION NO. 94 009R1 This position is deleted and replaced by PDI Position 95-001 i
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, PDI POSITION NO.95-004 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 4 ,
" Qualification Requirements for the Clad / Base Metal Interface of Reactor Vessel" Paragraph 1.1(f)
"The number of flaws in the detection test matrix shall be selected from Table VIII-S4-
- 1. The rules ofIWA-3000 shall be used for determining whether closely spaced flaws should be treated as separate flaws."
II. PDI POSITION AND PROPOSED CODE CHANGE -
1.l(f) The number of flaws used for grading of the detection test set will be a minimum of 7 for procedure qualification. For versonnel qualification. the total of sucolement 4 and 6 Raws shall be at least 10. and at least 50% of these shall be Suvolement 4 Raws.
Other flaws may be present in the examination area.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-PDI implementation experience has shown that, for personnel qualification demonstrations, many fewer flaws can be used to obtain reasonable assurance that the candidate can accurately apply the detection procedures. No change is recommended for procedure qualification. In automated RPV examination analyst qualification, the candidate is looking at the same information and following the same steps to arrive at the desired conclusion. These examinations have taken up to four weeks, for a test and a retest, according to the previous rules. This time and cost for these examinations are not justifiable based on the modest, if any gain in confidence one might achieve.
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PDI POSITION NO.95-003 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Add' enda) Supplement 4 ,
" Qualification Requirements for the Clad / Base Metal Interface of Reactor Vessel" Paragraph 1.1(e)(3)
"The flaw sizes shall be uniformly distributed in through-wall depths (inches) among the ranges:
(a) 0.075-0.200 (b) 0.201-0,350 (c) 0.351:0.550 (d) 0.551-0.750 No flaw shall have an aspect ratio (depth / length) less than 0.1."
II. PDI POSITION AND PROPOSED CODE CHANGE -
Paragraph 1.1(c)(3) Flaws selected for detection test will be from the four categories (a, b, c, d) as specified, except that:
- a. Flaws smaller than the 50% of allowable flaw size. as deRned in IWB-3510-1. will not be included as detection flaws. For orocedures avolied from the inside surface.
use the minimum thickness soeciRed in the Scooe of the crocedure. to calculate a/t.
For orocedures avolied from the outside surface the actual thickness of the test specimen is used to calculate a/t.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-This requirement in some instances results in flaws which are a small fraction of the allowable flaw sizes listed in Table IWB-3512-1. This forces examination vendors to increase examination sensitivities beyond what is required to detect unacceptable flaws.
This excessive sensitivity will require reporting and investigation of a large number of trivial indications. Including flaws ofless than 50% of the IWB 3500 requirements are counterproductive to the development of effective procedures. It is expected that this revision will be recommended to the ASME Code.
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PDI POSITION NO.95-006 I. CODE REFERENCE / REQUIREMENT -
l ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 4 .
" Qualification Requirements for the Clad / Base Metal Interface of Reactor Vessel" Paragraph 2.1(b)
"When a flaw is reponed within 1/2 in. ofit <
true location (x and y) it shall be considered detected. All other reponed flaws shall be i considered false calls."
l II. PDI POSITION AND PR POSED CODE CHANGE -
A Raw will be considered detected when recorted within 1.0 inch of the true X, Y and 2 location or the error allowed by Code Case N-545 whichever is lareer Location accuracy is for erading ourposes oniv. Mathematical errors, systematic location errors, and other errors which exceed the allowable detection criteria, may be l acceoted by the PDA. orovided:
- 1. There is no doubt that the reoorted indication is related to the actual Raw.
- 2. The error did not result from misinterpretation of the ultrasonic sienals
- 1. The results of the investigation is documented and justiRed.
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III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE l CHANGE- '
It is the position of the PDI that the positioning error in the X and Y dimensions are required in the Code only for the purpose of Grading. We have found that there i: little difficulty in deciding whether or not the candidate has detected the intended flaw. We also believe the candidate should not be penalized for errors of position resulting from plotting errors.
Code Case N-545, which has been accepted by the Main Committee of the ASME Code, allows a positioning error based on metal path distance. The PDI position incorporates this Code Case as well as using the description of the PDA which is subject to definitive rules and is open to audit at any time.
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I. CODE REFERENCF1 REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supi.5ement 4 ,
" Qualification Requirements for the Clad / Base Metal Interface of h3 actor Vessel" Paragraph 1.2(a)
"The sizing test matrix shall contain a minimum of ten flaws, at least half of which shall be cracks."
II. PDI POSITION AND PROP,OSED CODE CHANGE -
1.2(a) For procedure qualification, PDI Program Implementing Instruction PDP-I-009.4.3 requires that the sizing test matrix will be selected to contain a minimum of ten flaws.
For versonnel cualiRcation. the total ofsucolement 4 and 6 sizine Raws shall be at least
- 10. and that at least 50% of these shall be Sucolement 4 Raws. At least half of the flaws in any sizing test matrix will be cracks.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-PDI Performance Demonstration experience has shown that, for personnel qualification demonstrations, many fewer flaws can be used to obtain reasonable assurance the candidate can accurately apply the sizing procedure. No change is recommended for procedure qualification. In automated RPV examination analyst qualification, the candidate is looking at the same information and following the same steps to arrive at the desired ccnclusion. These examinations have taken up to four weeks, for a test and a retest, according to the previous rules. This time and cost for these examinations are not justifiable based on the modest, if any gain in confidence one might achieve. It is expected that this revision will be submitted to the ASME Code.
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PDI POSITION NO.95-007 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII Supplement 5 " Qualification Requirements for Nozzle Inside Radius Section" for demonstrations and examination from the outside surface Paragraph 4.1(b)
" Personnel previously qualified to Supplement 4, as described in 3.3(a) above, are qualified if each of the flaws presented are detected and identified with no false calls."
II. PDI POSITION AND PROPOSED CODE CHANGE -
The requirements of the 93 edition of the Code, are replaced by Code' Case N-552, for examination from the outside surface.
Supplement 5, Paragraph 4.1(b), Personnel previously qualified to Supplement 4, as described in 3.3(a) above, are qualified if each of the flaws presented are detected and identified. The number offalse calls allowed shall be the same as in 4.1(a) above.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-The program to be implemented meets or exceeds the requirements of Code Case N-552.
The demonstrations and examinations performed to this code Case are superior those which are described in the 93 Code. The failure to allow a proponional number of false calls was an oversight and will be corrected when the case is incorporated.
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4 PDI POSITION NO.95-008 (Continued)
The PDI BWR nozzle specimens have been designed to facilitate OD examination surface procedures. The dimensions of the rwans were developed to include dimensions suitable that these requirema can be met for most BWR RPV's.
The PDI PWR inlet nozzle specimen has an intemal diameter of 28 inches, which is sufficient for demonstrations for PWR inlet and outlet nozzles. BWR mockups are available for smaller nozzles.
Due to the limited sample base it is notpossible toprovide the same test set diversity as is donefor Supplement 4 and 6. As a minimum rise PDA will do thefcilowing to insure the integrity of the demonstrations; e
Require procedures definitively specify criteriafor detection and sizing, e
Require that candidatesprovide specific evidence that their decisionsfcflowed the procedure directions, without apriori information, e
No information as to the true size, location or orientation will be divulged to the candidates, and .
To the extent possible candidates will be assigned separate areas of the test specimens or di[ferent specimens.
Candidatesforpersonnel demonstrations will be provided a sampling of the essential variables qmlified by the procedure.
Each of the flaws in the examination test set shall be correctly identified. False calls shall not exceed the value established by caragraoh 4,1(a) of Code Case N 552.
(b) PDI will not implement this requirement, see Code Case N-542.
III.
TECHNICAL CHANGE-JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE The PDI implementation for the nozzle inside-radius, from the inside surfa_cs, meets or exceeds Code requirements with the exception of personnel qualification. .In addition, Code Cases N-542 and the false call calculations from Code Case N-552 are incorporated. All of these examinations, performed from the inside surface, are accomplished using automated systems and techniques which are nearly ide itical to those performed for supplement 4, except for slight adaptation for the curvature. it is the opinion of the PDI that these minor changes do not warrant an additional personnel qualification. The procedure will be thoroughly qualified.
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PDI POSITION NO. 95 008 1
I. CODE REFERENCE / REQUIREMENT-ASME Section XI, Appendix VIII Supplement 5 "Qualifica' tion Requirements for Nozzle Inside Radius Section" for applications applied from the inside surface, Paragraphs (a) and (b).
"(a) For detection, a minimum of three additional flaws at the inside radius section in one or more full scale nozzle mock-ups (supplement 7) shall be added to the test set."
"(b) For length sizing, a minimum of three additional flaws as in (a) above shall be added to the test set. All flaws shall be sized to the acceptance standards of Supplement 4."
II. PDI POSITION AND PROPOSED CODE CHANGE -
(a) PDI has fabricated two full size PWR nozzle mockups, simulating both inlet and outlet configurations. Five BWR mockups are available if they are needed to expand the scope of a procedure performed from the inside surface. For procedure qualifications, applicable to FWR RPVs, a minimum of three flaws will be included in both the inlet and outlet nozzles. For " analysis only" versonnel qualifications. the followine shall acolv:
- 1. Where the analysis eauioment and the ultrasonic techniaue are basically the same as the Suvolement 4 avolication. no further demonstrations will be reauired. .
- 2. Where the techniques differ substantially, a demonstration set of a minimum of three flaws will be provided. These will be distributed in either the inlet or outlet configuration or both as appropriate.
(See PDI Position 95-008)
The specimens comply with Supplement 4,1.1. Flaw types will generally be cracks.
However, some notches may be used.
i All flaws are located within the radial axial plane of the nozzle inside radius section as illustrated by Fig.IWB-2500-7.
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. PDI POSITION NO.95-010 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 8 ,
Qualification Requirements For Bolts And Studs II. PDI POSITION AND PROPOSED CODE CHANGE -
The PDI has developed a personnel qualification program which meets or exceeds the requirements of Supplement 8.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-This position satisfies the requirements of Appendix VIII Supplement 8. Additional flaws and false call requirements are in addition to the Code requirement for personnel qualifications. It is expected that exact ranges and essential variables specific to a particular plant will be qualified at the. .ime of calibration, at the site.
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II. PDI POSITION AND PROPOSED CODE CHANGE -
Supplement 7," Qualification Requirements For Nozzle-To-Vessel Weld,"
paragraphh (a)
PD1 will imolement the requirements of Suvolement 7 for inside surface. clad-to-base metal interface. only.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-The tecl.nical basis for revising the scope of this qualification is under development. The cost / benefit of performing the examination to the existing requirements is very poor. It was estimated that performing a fully qualified Appendix VIII examination would extend PWR RPV examinations for up to 5 days. It is our position that there is no active flaw mechanism in these areas and that we would be spending an inordinate sum for re-detecting insignificant manufacturing flaws if any.
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PDI POSITION NO. 95 012 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 8 ,
Qualification Requirements For Bolts And Studs, paragraph 1.1(c)
"Circumferentially oriented notches shall be located in the qualification specimen at the minimum and maximum qualified metal paths. These notches are required on the outside threaded surface and the inner bore hole surface of bored studs with maximum depths and reflective areas as specified in Table VIII-S8-1."
II. PDI POSITION AND PROPOSED CODE CHANGE -
Circumferential notches are located at the minimum and maximum metal paths (within one diameter of each end for versonnel qualifications and within one diameter of the opposite endforprocedure quahfications) which a candidate request to demonstrate.
They are located on the outside threaded surface, outer shaft, and the inner bore hole surface of bored studs as specified in Table VIII-SS-1. The minimum number of notches in a test set shall be five. PDI's design review (PDI-Q-002) verified that the size and location of the notches meet Table VIII-S8-1.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-Code Case N-457 allowed location of the circumferential notches within one diameter from the end of the bolt or stud. N-457 was applicable to Appendix VI. It has now been incorporated into the Code by the 94 Addenda. For personnel qualification,it is necessary to place notches at various locations to provide a blind test. The procedure and the essential variables are qualified using site specific calibration studs before each examination.
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I PDI POSITION NO.95-011 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII (92 Edition w/93 Addenda) Supplement 4 ,
" Qualification Requirements for the Clad / Base Metal Interface of Reactor Vessel" -
Paragraph 1.1(e)(2)
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"All flaws shall emanate from the clad base 1 metalinterface and shall propagate
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predominately into the base metal. A minimum of 40% of the flaws shall be ;
oriented parallel to the clad direction (within l 10 deg.) and a minimum of 40% shall be oriented per'pendicular to the clad direction (within 10 deg.)."
II. PDI POSITION AND PROPOSED CODE CHANGE -
All flaws in the Supplement 4 examination volume emanate from the clad base metal interface and propagate into the base material.
50% of the flaws in the Supplement 4 examination volume of PDI test specimens are oriented parallel to the clad direction (within +/- 5 degrees). The remaining 50% are oriented perpendicular to the clad direction (within +/-5 degrees). Each Procedure demonstration test set will have a minimum of 40% of flaws oriented Parallel and a minimum of 40% presented perpendicular to the clad direction. Each versonnel demonstration test set will contain a representative distribution ofRaw orientations. sizes and locations.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE i CHANGE-When administering a combined demonstration for personnel qualification it is not possible to meet all of the distribution requirements specified or implied by Appendix '
VIII. The PDI has concluded that these requirements should be considered'as objectives for guidance and not necessarily as requirements for personnel qualifications. A sampling of conditions are considered to be adequate to qualify personnel, provided that the procedure has previously been fully demonstrated. This sampling would include flaw 1 size, location, and orientation. l Revision 1, Change 0 t
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PDI POSITION NO.95-013 I. CODE REFERENCE / REQUIREMENT -
ASME Section XI, Appendix VIII Supplement 12," Qualification Requirements for i Coordinated Implementation of Selected Aspects of Supplements 2,3,10, and 11,"
paragraphs 1.3(b) & (c)
II. PDI POSITION AND PROPOSED CODE CHANGF,-
1.0 (a) (1) (b) The demonstration shall meet the requirements of Supplement 2, except l that for length sizing qualification, the minimum number of flaws shall be ten, and the specimen set shall include at least three, but not more than four, flaws in ferritic material.
III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-This revision to Supplement 12 was incorporated into the Code by the 95 Addenda. This revises length sizing to the same basis as has been the case for depth sizing.
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PDI POSITION NO. %-001 I. CODE REFERENCE / REQUIREMENT -
Supplement 11 Qualification Requirements for Overlaid Austenitic Piping Welds II. PDI POSITION AND PROPOSED CODE CHANGE -
1.0 Specimen Requirements Soecimens currentiv beine used for the BWROG - IGSCC Overlav Examination will be used for this demonstration.
2.0 Conduct of Perfromance Demonstrations The specimen irside surface and identification shall be concealed fann the candidate. All examinations shall be completed prior to grading the results and presenting the results to the candidate. Divulgence of particular specimen results or candidate viewing of unmasked specimens after the perfonnance demonstration is prohibited. Performance de.nonstrations will be conducted to the requirements of the existing ororrom. with the additional requirements of essential variable recordine and monitoring. which is reauiredby Avvendix VIlland the PD1 Protocol. Extension ofcrocedure Scoce and essential variables. not demonstrated by the existing samoles. will be demonstrated on site speciRc calibration blocks. durine examinations.
2.1 Detection Test The detection. length sizing and death sizine tests will be conducted according to the
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protocolof the existine BWROG -lGSCC Overlav Program.
2.2 Length Sizing Test The detection. length sizine and death sizine tests will be conducted according to the orotocol of the existine BWROG -lGSCC Overlav Prorram.
2.3 Depth Sizing Test The detection. length sizine and deoth sizine tests will be conducted according to the orotocol of the existine BWROG -lGSCC Overlav Program.
3.0 Acceptance Criteria The acceotance criteria of the existine BWROG - IGSCC Overlav Program will be avolied.
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PDI POSITION NO. % 001 .
(Continued)
L III. TECHNICAL JUSTIFICATION FOR PDI POSITION AND PROPOSED CODE CHANGE-PDI believes that the number of candidates and application justification the fabrication of a separate set of samples. The existing samples, used for the BWROG-IGSCC qualification program, differ from those required by Supplement 11 in the use of flawed and unflawed grading units, as well as the total number of grading units. The original program did not consider these factors and consequently many of the flaws and samples do not meet the requirements of Appendix VIII Supplement 11. PDI believes that the current samples coupled with the procedure and essential variables of Appendix VIII, are adequate to address the question of personnel and procedure qualification.
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" Appendix C" PDI PlibGRAM QUALIFICATION SAMPLE SIZE RANGES
I APPENDIX C PDI PROGRAM QUALIFICATION SAMPLE SIZE RANGES MM MM Sample Sample Nominal Outside Identity Description Thickness Diameter SS Detection 1
301 SS 2" SCH 160 0.344 2.375 302 SS 4" SCH 40 0.237 4.500 303 S 4" SCH 80 0.337 4.500 306 SS 12" SCH 80 0.688 12.750
, 307 SS 24" 1.45 14.000 308 Existing SS 29" BWROG 1.4-1.5 28.000 309 SS 27.5"ID 2.500 27.500 310 SS 30" + DIA 23.000 30.0 J
SS Sizing Set 311 SS 4" SCH 80 ~ 0.337 4.500 312 Existing SS 12" SCH 100 0.844 12.750 313 SS 14" SCH 160 1.406 14.000 Ferritic Set 421 FE 4" SCH 80 0.337 4.500 423 FE 12" SCH 80 0.688 12.750 424 FE 24" 22.000 24.000 525 CLAD 30"ID 3.125 36.25 526 CLAD 42" ID 3.750 49.5 l
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" Appendix D" !
CODE CASES AND REVISIONS BEYOND ADDENDA 1993 L
" Appendix D" CODE CASES AND REVISIONS BEYOND ADDENDA 1993 Code Case N-457 and Code Revision, Qualification Specimen Notch Location for Ultrasonic Examination of Bolts and Studs, Applicable to Supplement 8 This Code Case was incorporated in the 94 Addenda. The Code Case is only applicable to Appendix VI. The Code revision is applicable to Appendix VIII.
See also PDI Position 95-012.
Code Revision Supplement 2,95 Addenda, Paragraph 1.1(b) Thickness Tolerance for Piping Qualification Specimen Test Sets This revision was incorporated into Supplement 2 of the Code by the 95 Addenda.
This revision allows examination of piping components which are .1 inch thinner and .5 inch thicker than the specimens which were used in the qualification demonstration, for austenitic piping. For ferritic piping the upper limit is raised to 1.0 inches thicker than the demonstration sample set. This change is included in }
the PDI program and is justified in PDI Position 94-00lR1 and 94-004RI.
Code Case N 537, Location of Ultrasonic Depth Sizing Flaws, Supplements 2,4, & 6 Paragraph 2.2 This Code Case was published in the 95 edition. The Case allows the test administrator to point out the region where a flaw is located as opposed to the exact location. This difference is needed to assure test set security. See PDI Position 94-006R1.
Code Case N 538, and Code Revision, Revise Pipe Length Sizing Acceptance Criteria This Case and the Code revision have been accepted by the Main Committee of i
the Code, as of December 1995. These revisions establish a realistic length sizing acceptance criteria, which meets the needs of safety. See PDI Position 94-002RI.
I Code Case N 541, and Code Revision, Clarification of Surface Access Conditions, Supplements 4,5,6, & 7 This Case has been published in the 95 Code Case Supplement. The Code revision was incorporated in the 95 Addenda. These changes allow access to the surface where flaws are located provided their locations are properly obscured.
See PDI Position 94-007RI.
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" Appendix D" CODE CASES AND REVISIONS BEYOND ADDENDA 1993 (Continued)
Code Case N 542 and Code Revision, Deletion of Length Sizing Requirements, for the Nozzle Inner-Radius Examinations of Supplement 5 The Code Case was published in the 95 S-1 Supplement. The Code Revision was l
incorporated by the 95 Addenda. This revision deletes the requirements for length sizing inner-radius indications. The revision is based on the fact that flaw length is not used for determination of acceptability. See PDI Position 95-008.
Code Revision, Pipe Length Sizing Set Selection Rules for Supplements 2 Paragraph 1.3(b) & Supplement 12 Paragraph 1.0(a)(1)(b)
This revision has been incorporated in the 95 Addenda to the Code. This change provides a more appropriate description of the length sizing test set and allows length sizing tests to be performed on a combined test set, as is the case for depth sizing. See PDI Position 95-013 and 94-00lRI.
Code Case N 545, Revise Location Tolerance Requirements, Supplements 4,5,6, &7 i This Code Case has been accepted and will be published in the 95 S-2 supplement for Code Cases. This revision was needed to provide more realistic location tolerances. These location tolerances are only used to assist in the grading of the examination. See PDI Position 95-006.
Code Case N-552, Alternative Rules for Examination of the Nozzle Inner-Radius I from the Outside Surface This Code Case has been accepted by the Main Committee of the ASME Code.
Publication is expected in 1996. This Code Case simplifies the demonstration and provides a technical basis for the demonstrations as well as examinations performed in the field. A copy of the Code Case is included in the Program Description. See PDI Position 95-007.
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