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Feedwater Nozzle Insp Rept for Refueling Outage RF89A Spring 1989.
	ML17285A963
Person / Time
Site:	Columbia
Issue date:	12/27/1989
From:	Jones O; WASHINGTON PUBLIC POWER SUPPLY SYSTEM
To:	;
Shared Package
ML17285A962	List: ML17285A961; ML17285A963;
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WASHINGTON PUBLIC POWER SUPPLY SYSTEM NUCLEAR POWER PLANT NO. 2 FEEDWATER NOZZLE INSPECTION REPORT FOR REFUELING OUTAGE RF89A SPRING, 1989 Prepared by: VER li/~ 7 l1 II Engine D e I

Reviewed by:

Manager, Engineeri g Systems Support Date

.n 'iI p nager, Ge ~tion Engineering Date Manage , Plan" Technical Daze Approved by: . ~/~ 4- (z/wipe Plan Manager Da=e 900ig90882 891228 05000397 PDR AGOCK PDO

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SUMMARY

2: This report addresses reactor vessel feedwater nozzle .inspections cj for WNP-2 performed during the fourth refueling outage (April

."4 1989) . This report is required by NUREG-0619, Section 4.4.3.

Ultrasonic Examination of one reactor feedwater nozzle was performed during the refueling outage. No recordable. indications

'4) were found. The plant experienced. 10 startup/shutdown cycles during this inspection period.

The low-flow control valves RFW-FCV-10A and RFW-FCV-10B, installed during RF87A (Spring 1987), cont'inued to perform well. These valves replaced the RFW-FCV-10 valve to minimize thermal cycling

-3 of the RFW nozzles caused by the on/off mode in which the -10 valve controlled RFW level during low-flow/startup conditions.

The Supply System plans to continue its augmented feedwater nozzle inspection at the next refueling outage as committed in the WNP-2 Program Plan.

NDE EXAMINATION During WNP-2 refueling outage RF89A, the Supply System performed

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ultrasonic examination of one reactor feedwater nozzle safe-end, bore and inner radius from the vessel OD.

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) satisfies -part of WNP-2's commitment described in FSAR Section 5.2.4.10 and Inservice Inspection Program .Plan Section 5.3.2 to

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) ultrasonically examine one. feedwater nozzle from the OD each r4

t refueling outage for the first six refueling outages.

I4 The Supply System has developed an angle'eam shear wave technique V

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that is unique to the WNP-2 feedwater nozzle design. The procedure was qualified on the WNP-2 feedwater mock-up, which is a feedwater N nozzle from the scrapped Douglas Point Unit 1 reactor vessel. The inner radius, Zone 1, of the nozzle is scanned using a 72 degree angle transducer. The inner radius, Zone 2, and bore region, Zone 3, are scanned using a 25 degree angle transducer. The UT pro-cedures used for examination, QCI 6-4 and QCI 6-13, are contained in Appendix I. Any changes to procedures that affect UT scanning

'rt techniques are verified on the feedwater nozzle mock-up.

Calibration data for reactor feedwater nozzle inner radius 4

examinations have been predetermined using the WNP-2 feedwater nozzle mock-up. This allows the examiner to use the reactor vessel calibration block representing the shell course containing the feedwater nozzle for calibration. 'The transfer data is contained rI in Table I of procedure QCI 6-4. Indications that exceed 25% full

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I sc een height(FSH) are recorded and indications that. exceed 50% FSH are evaluated.

ho examirfh ions we e performed by Supply Sys em and Gene examiners 4

cer-ified to either Level II or Leve'II UT. a'lect=ic 1

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REFERENCES Vg 1. Feedwater Nozzle Inspection Report for Refueling Outage RF86A, issued November 25, 1986.

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2. Feedwater Nozzle inspection Report for Refueling Outage RF87A, issued December 7, 1987.

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3. Feedwater Nozzle inspection Report for Refueling Outage RFSSA, issued December 14, 1988.

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4I APPENDIX I Procedure QCZ 6-4, Revision 5 Procedure QCI 6-13, Revision 4

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EFFECTIVK DATE NDE 8 I IHSTRUCTION 3/28/89 QUALITYAFFECTING Q YES @NO TITLE ULTRASONIC EXAMINATION FEEDHATER NOZZLE INNER RADII 1.1 This procedure defines the requirements for manual, pulse-echo

.ultrasonic examination of the feedwater nozzle inner radius, (Zones I, 2, and 3), ASHE Section XI, Category 8-D. Scanning by this procedure is done from the reactor vessel O.D. wall and nozzle surfaces using refracted shear wave search units. Figure I illustrates the Zones which can be effectively scanned from the outside surfaces of the vessel plate and nozzle.

1.2 This procedure covers the angle beam shear wave technique that is unique to the nozzle design. Specific refraction angles have been determined by. individual nozzle geometry as depicted in Figures 2, 3 and 4.

1.3 This instruction is intended to meet the requirements of Sections V and XI of the ASHE Boiler ~nd Pressure Vessel Code (1980 with Addenda through Hinter 1980).

1.4 BHR Calibration Data listed in Table I have been predetermined from the Supply System's feedwat<<r nozzle mockup so the qualified exam-iner need only use the vessel calibration block representing the shell course containing the nozzle.

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I 3.0 3.1 r nn1 ifi i n 3.1.1 Personnel performing examinations to the requirements of this instruction shall be a certified to at least Level II, in ultrasonics in accordance with the requirements of Refer-ence 6.2 and (b) below. Supply System personnel shall be (a) certified to at least Level II in accordance with Reference 6.3 and (b) qualifie'd using the Supply System BHR feedwater nozzle mockup and this ultrasonic examination procedure.

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Rev. 5 3.1.2 Personnel not specifically qualified on the BHR feedwater nozzle mock-up, but designated as Trainee, Level I, II or III UT may assist a qualified examiner in performance of .

examinations to this instruction.

3.1.3 At'least one person responsible for reviewing the results of the ultrasonic examination shall be a Supply System person certified as an ultrasonic Level III in accordance with Reference 6.3 in addition to tneeting the requirements of (b) above.

3.2 The thermal insulation should be clear of the nozzle and vessel to create a free space 12 inches out from the nozzle cylinder outer surface.

3. 3 F~~m 3.3.1 The pulse-echo, ultrasonic, flaw detection instrument shall be equipped wi th a fine gain or attenuation control graduated in units no larger than 2 dB. Instruments considered accept-able for this examination are listed below; however, other instruments may be used if the model type has been qualified.

Krautkramer USIP-ll, USL-48, USD-10 Nortec NDT 131 or 131D, 132D 3.3.2 Single element ceramic transducers, having an area of .44 to 1.0 square inch, with a nominal frequency of 2.25 MHz shall be used wi th specific wedges', Figure 5. The refracted angle within the material shall be within the limits shown in Table I. Additionally, data may be taken with other sizes, frequencies, and angles, after completing the examination to the above requirements.

3.3.3 Ultragel II or its equivaIent shall be used as the liquid couplant.

3.3.4 The vessel calibration standard listed in Table I shall be used. This standard corresponds to the shell thickness containing the subject nozzle.

3.3.5 IIH-2 ROMPAS or modified Type DC (square ended semicircle) sweep calibration reference blocks.

3.3.6 Flashlight for reading instrument control knobs.

Page 2 of 21

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QCI .6-4 Rev. 5 3.4 ur a Pr r The contact surface shall be clean and free of dirt, dust, weld spatter, loose paint, or other material which would interfere with free movement of the transducer or impair transmission of ultra-sonic energy into the material.

3.5 nin d imi The scanning speed shall not exceed 3 inches per second.

3.6 H zzl In n ifi a ion Prior to the examination, the nozzles shall be marked and identi-fied in accordance with a .nozzle marking plan as illvstrated in Figure 6. Sanford's "Sharpie" black tip marker is the accepted pen device.

3,7 n ral R iremen fr ali r i n Calibration shall inclvde the complete ultrasonic examination system. Any change in couplants, cables, or ultrasonic instruments shall be cause for recalibration. Sweep calibrations may be made with a standard angle beam wedge using the IIH or similar curved block, and must be representative of the metal path expected for the zone to be examined, reference Table I:

3.7.1 Instrument Calibration Prior to the initiation of scheduled examinations, the ultrasonic instrument shall be checked for screen height and amplitude control linearity per paragraphs 3.7.2 and 3.7.3.

3.7.2 Screen Height (per ASHE) Linearity Check - An angle beam search vnit shall be positioned on a calibration block and signals obtained from two reflectors. The search unit posi-tion shall be adjusted to give a 2:1 ratio of amplitudes between the two reflectors. The gain control (sensitivity) shall be adjusted and the larger signal brought to 80% of full screen height (FSH), adjusting position maintain the 2:1 signal ratio. Without moving the search if necessary to unit, adjust the gain control to successively set the larger signal from 100% to 20/. FSH in 10% increments or 2 dB steps.

The smaller amplitude must be 50% of the larger amplitude within 5% of FSH. Instrvments that do not meet these requirements shall not be used.

3.7.3 Amplitude Control Linearity Check The angle beam search unit shall be positioned on a calibration block and a peaked signal amplitude obtained from a hole or notch. The indi-ca.ion shall be brovgh, as near as possible to 80'/ FSH with Page 3 of 21

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've'CI 6-4 Rev. 5 the dB control. If necessary, the final adjustment to 80K FSH is made with the variable gain control or dB,switch.

Using only the dB control, the dB changes indicated below shall be made and the resulting amplitude compared with the allowable amplitude limits as specified below. Instruments that do not meet these limits shall not be used. The proce-dure shall be repeated for 401. and 20'4 FSH amplitudes.

nitial Am li d dB n r 1 Amoli d imi Set of / FSH Change (X FSH) 80 32 to 48 80 -12 16 to 24 40 64 to 96 20 +12 64 to 96 3.7.4 Recalibration (Sweep Only) - If the indication from the cali-bration reflector has moved on the sweep line more than one inch of metal path, correct the sweep range calibration and note the correction on the calibration data sheet. If record-able reflectors are noted on the examination data sheets, those data sheets shall be voided. A new calibration shall be made and recorded, and the voided examination areas shall be re-examined.

3.7.5 Recalibration (Amplitude Only) - If the amplitude of. the calibration notch has changed by more than lOX FSH when a check is made on the reference block, all data sheets since the last positive calibration check shall be marked void. A new calibration shall be recorded and the voided examination areas re-examined. The voided sheets may be discarded.

Calibration shall be performed at the beginning of each series of examinations. A calibration verification shall be made at intervals not exceeding four hours during the examinations.

4.0 A BRATI N AND H NATI N An initial instrument sweep calibration shall be made for shear wave velocity by using the examination search unit with a conventional angle beam shear wave wedge and the IIH, Rompas or modified DC type curved calibration block. Sweep calibration data is listed in Page 4 of 21

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s1 Table I for each nozzle. The oscilloscope's screen sha31 read directly'in inches of metal path and the data entered on the cali-bration data sheet; Figure 7.

4.1.1 Zone 1 - Using a Rompas block, direct the ultrasonic beam toward the large radius, with the exit point of the trans-ducer at the radius center mark on the block, maximize the CRT signals by moving the transducer forward and back.

Adjust the "Range" and "Delay" controls until the first reflection signal is at "2" on the horizontal graticule line on the CRT and the following signals appear at "5" and "8".

Lock the range control knob and de1ay the signal at "8" to zero position. Signals should now appear at zero, 3, 6 and

9. Hext, delay the signal at 6 to zero. Signals should again appear at zero, 3, 6 and 9. If they do not, make minor adjustments so they do. The CRT is now calibrated for 14 to 24 inches of metal path.

4.1.2 lone 2 Using the transducer with the convex 25'hear wedge, obtain peaked signals from the 1/2 to 3/4 "T" holes in calibration block Ho. 120.. Adjust the range and sweep to obtain reflection signals at positions 3.5 and 5.4. Delay the signal at 5.4 to the 0.4 position. The CRT is now calibrated for 5 to 15 inches of metal path.

4.1.3 Zone 3 Using the transducer with the flat 25 shear wedge, calibrate as in 4. 1.2.

4.2 m li u li ra i n Basic calibration gain sensitivity shall be determined by both the applicable vessel calibration block.and the transfer sensitivity gain as shown in Table l. Basic calibration shall be established wi th sufficient gain so that 2X scanning can be performed without changing the variable gain control.

To determine the basic sensitivity level, the search unit shill be'-

held on the applicable vessel calibration block with the signal amplitude from the 3/4 T-hole maximized. The instrument gain con-trols shall then be adjusted so that the 3/4 T-hole signal amplitude is brought to 50/. FSH. This basic sensitivity level shall then be adjusted for each zone according to Table 1's "Transfer Sensitivity dB Gain Increase." After adjusting to the transfer sensitivity gain increase, the gain setting shall now be the primary reference level of 1X. Examination scanning shall be at 2X (+6 dB) above the pri-mary 'reference level.

~N T : As sho~n in Table 1, 2one 1 requires no additional gain ad-

'justment atter the 3/4 T-hole is maximized at 50K FSH to achieve the Page 5 of 21

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~ r primary reference level (see Note 4). Transfer sensitivity gain is 0 for Zone 1. However, for Zones 2 and 3 the primary reference gain level is an additional 12 dB over the 3/4 T-hole maximized at 5(C FSH.

C~A TIO : Care must be exercised during calibration to assure the shear wave component is used for calibration since there is also a ti strong longitudinal wave component generated by the angle beam transducer, especially for Zone 2 aid 3 calibration. A peaked shear

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wave signal from the 3/4 T hole should appear at approximately 5o7 inches metal path when the transducer is approximately 2-3/8 inches surface distance from a line normal to the hole centerline. The sl refracted longitudinal wave should produce a peaked signal at approx-imately 4-3/4 inch metal path at a surface distance of 6-1/2 inches.

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1 A Level II or III UT examiner shall view the CRT display during the t

I examination. A record of each nozzle inner radius examination shall h

be made on examination data sheets (Figure 8), which shall be num-h bered in sequence with calibration data sheets. Scanning shall be performed at 2X above the primary gain level (1X). Heasurement and recording of ultrasonic indications shall be done at the 1X level.

~n - 1 The inner radius Zone 1 shall be scanned in two directions (CH and CCH) from the vesse'1 plate as shown in Figure 9. Scanning shall be done in a circumferential or radial motion with a minimum overlap of 0.5 inches. The moveable pointer on the transducer wedge shall be positioned in the groove marked "CCH" for scanning counter clockwise and "CH" for scanning clockwise. Hhile scanning, the pointer shall be aimed at the nozzle bore to the extent practical with the trans-ducer oscillated slightly. The examiner shall reference Figure 9 for transducer orientation.

The scan boundaries extend from the end of the blend radius to a distance of 9 inches out on the shell wall. The operator shall occasionally rotate the wedge toward the bore axis to obtain a direct reflection signal from the inner radius as a check to confirm gt penetration.

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'id ~tne-The inner surface of the nozzle shall be scanned from the exterior

't surface of the nozzle using the appropriate search units in two ti directions: 'clockwise (Cll) and counterclockwise (CCll) (Figure 11).

c A circumferential scannina pattern spaced at intervals not exceeding 0.25 in'. (3/4 in. overlap) shall be followed around the nozzle body to obtain full coveraae of the inner surface Zone 2.

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Rev. 5 The nozzle forging and the inside bore shall be examined to the maximum extent possible using the cylindrical surface for scanning (Figure 12). The scan path of'he search unit shall overlap the adjacent scan by a, minimum of 0.50 inch. The search unit shall be scanned circumferentially around the nozzle forging so the angle beam shear wave covers all 360'f.tlie circumference in both the clockwise and counterclockwise directions.

4.4 rdin Indications in the region of the blend radius which have an ampli-tude greater than 50K FSH at the 2X scanning level and which travel

.'in time position on the CRT shall be investigated to determine maximum amplitude.

Indi cations in the region of the blend radius which exceed 257. FSH at the primary reference level (1X) and which travel in time posi-tion on the CRT, shall be recorded on the examination data sheet.

Report signal amplitude in X FSH, metal'path in inches, search unit direction as clockwise (CH) or counterclockwise (CCH), and search unit position.

4.5 Reference points for physical measurement of azimuth shall be in accordance with the nozzle reference plan shown in Figures 10, ll, and 12.

4.6 RT Di la Ph of the CRT

'hotos di.splay shall be taken at the option of the Level III Examiner to further document the ultrasonic signal character.

Pertinent data shown below shall be recorded on the back of each photo.

1. Report No.

2. ISI Drawing Ho.

3. Zone Ho.

4. Sweep Distance

5. Indication Ho.

5.1 The recorded data shall be reviewed by a level III Examiner to determine if additional examination and/or interpretation is required.

5 2 Recorded indications sha11 be plotted on a scale.no less than quarter size and reviewed by the Level III Examiner."

Page 7 'of 21

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.OCI 6-4 Rev. 5

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6.1 American Society of Mechanical Engineers Boiler and Pressure Vessel Code, 1977 Edition through Summer 1978 Addenda.

6.1.1 Section XI - "Rules for Inservice Inspection of Huclear Power Plant Components".

6.1.2 Section V Hondestructive Examination".

6.2 American Society for Hondestructive Testing, June 1975 Edition.

Recommended Practice SHT-TC-lA "Hondestructive Testing Personnel Qualification and Certification".

6.3 . The Supply System "Program manual for. Qualification and Certifica-tion of Examination, Testing and Inspection Personnel HMC-034".

6.4 Hozzle forging drawings - General Electric/CBI Huclear Page 8 of 21

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~ .'0 TABLE I ULTRASONIC CALIBRATION DATA FOR EXAHINATION OR BHR NOZZLE INNER RADII.

NOZZLE TYPE N4 FEEDHATER ACOUSTIC ANglES CRT CAL TRANSFER DEGREES' DISPLAYED .STANDARD SENSITIVITY 8 C SHEEP ¹ dB GAIN INCREASE Zone 1 22 70. 70 14" to 24" UT 1202 0 Zone 2 22 25 63-70 5" to 15" UT 120 12 Zone 3 0-10 25 63 5" to 15" UT 120 See,Figures 2A, 28, 3 and 4

2. The 5/16 in. dia., 3/4 T hole (5.06 in. below the contact surface) shall be used for calibration.

3. Convex shoe NOTE: The, following is in reference to Zone 1 transfer sensitivity.

4. Gain setting for 50/..FSH indication is 6 dB less for RFH nozzle mock-up notch <Notch A) than for 3/4 T-hole of cali-bration standard UT-120. Therefore, as a conservative measure, the 3/4 T-hole gain setting has been accepted as the primary gain level.

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OCI 6-4 Rev. 5 SIDE VIEWS END VIEWS

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ZONE 1, FLAT CONTACT SURFACE ZONE 2, CONVEX CONTACT SURFACE ZONE 3, CONCAVE CONTACT SURFACE FIGURE 5 TRANSDUCER HEDGE CONFIGURATIONS Page 13 of 21

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'OCI 6-4 Rev. 5 NOZZLE NUMBER LOCATED ON TAPER LINES MARKED ON NOZZLE BODY I 4-I I

3 345'ADIAL 04 LINES EXTEND AT LEAST 2 PAST REF CIRCLE 0'154 30'5'ONE 1 CIRCLE I

300' 60'850 50 24 2700 90'55 05'40 204 225 210'0 5 4 180'0'654 35'BOTTOM)

FiGURi 6 N022LE HARl'IHG PLAN Page 14 of 21

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ULTRASONIC CALIBRATIONSHE:"T ROJKCTI SYSTKMI XAMI HER: I.EVE LI ND.'HERMDMETEASINI DF XAMIMERI LEVEL: IMSTAUCTIDM RKVISIOMl CABLE TYPE KRIALNUMBER TEMP F ~ IM WEDEMDD~ IEIIEFII HICKNESS SWEEP III SIZE FIIED Mll EDIDIZIW KMPERATURE CAIN IN dls ACTUALANCLE BATCH NO.

HART RECOROKA TYPEI UT INSTRVMKNTTYPKI )SIMI INSTRUMENT CALIBRATION PAEVIOUSLY PKRFOAMED ON CALIBAATIOMSHEET NVMSKR SCREEN HEICHT LINEAAITY SCREEN HEICHT LINEARITY AMPLITUDE CO MTADL LINEARITY, FOR CONTINUOUS CAIN CONTAOL FOR 2db STEP CAIN CONTROL MPLITVDEX 60 40 I 20

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AIAPLITUDE SWEEP READINC CAL CHKCKS RUMEMT SETTINCS RKFLKCTOAS 'XFSH VI INCHES SCREKN DAC PRESKN1'ATIOM RANCE IB NODE COARSE DELAY IS NODE SO ANCE CALIB IS NODE 4

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270'0'4 300'854 04 255 05'40 20'804 165'OVING FIXED AZIMUTHCIRCUMFERENTIAL AZIMUTH SCAN TECHNIQUE SCAN TECHNIQUE SECONDARY PRIMARY CIRCUt4FF ?ITI,>L AHD @DIAL SC"~ttttIt G ZONE 1 REFERENCE CIRCLE ZONE 1 REFERENCE CIRCLE SCAN SCAN PATHS Xdcr Pointer PATHS Xdcr ReL %+

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FIGUR 9 SCAHHIHG HOTIOHS FOR THE ZONE 1 EXAHIHATIOH Page 17 of Zl

OCI 6-4 Rev. 5 QO 15'ONE 1 REFERENCE CIRCLE 50 Qpt gpss 60'IST NCE(0)

AZIMUTH(A)

REFERENCE CIRCLE NOTE:

DIRECTION FROM ALL(A) MEASUREMENTS SHALL BE IN COUNTER CLOCKNSE NEAREST RADIALLINE.

RADIALLY OUTWARD.

ALI (D) MEASUREMFNTS SHALL BE FROM REFERENCE CIRCLE FIGURE 'lO HEASUREHENT'CRITERIA FOR RECORDING UT Page 18 of 21

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Radius End NOZZLE CROSS SECTION FIGURE 11 REQUIRED SCAN PATHS AND MEASUREMENT CRITERIA FOR ZONE 2 EXAMINTIONS Page 19 of 21

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OCI 6-4 Rev. 5 CIRCUMFERENTIALSCANS SHALL BE MADE IN TWO DIRECTIONS AROUND THE CYUNDRIGAL SECTION Or THE NOZZLE FORGING MEASURE D DISTANCES FORM BREAK POINT ON NOZZLE FORGING BETWEEN CONICALANDCYLINDRICAL SECTIONS (TOP)

D Az 270'gO SIDE VIEW OF NOZZLE 180'eference Az lines are each 15'round the nozzle. All Az measurements are made in a counter-chckwise direction from these lines to the index mark on the search uniL View made looking toward the vessel.

FIGURE 12. ZONE 3 SCANHIHG AND LOCATION REQUIREHEHIS Page 20 of 21

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EFFECTIVE DATE HDE S. I INSTRut:TlON 4-10-87 QUAUTY AFFECTNG

@YES @NO TITLE ULTRASONIC EXAMINATION OF PIPING MELDS (ftANUAL) 1.0 PURPOSE AHD SCOPE 1.1 This instruction defines the method for manual contact ultrasonic examination of similar and dissimilar metal welds in piping systems 0.2 to 6.0 inches in thickness. The methods outlined in this instruction meet the requirements of the.ASllE Boiler and Pressure Yessel Code,Section XI, 1980 Edition through Minter 1980 Addenda and Appendix III.

1.2 . These examinations may be performed by Supply System personnel or by a Supply System Contractor under Supply System supervision.

2.0 DEFINITIONS None 3.0 PROCEDURE 3.1 Personnel Qualifications 3.1.1 Supply System personnel shall be certified in accordance with Reference 6.2.

3.1.2 Contractor personnel shall be certified to the contractor's Quality Assurance. Program provided the program has been approved by the Supply System. As an alternative, the contractor personnel shall be certified in accordance with Reference 6.2.

3.1.3 Personnel designated as trainees may assist the Level II or III in performance of the examinations to this i ns tructi on.

3.1.4 Level I individuals shall perform only specific setups, calibrations, tests or record data to the requirements of this instruction and shall implement this instruction only with the direct particjpation of a Level II or higher individual. The Level I shall not independently evaluate or accept the results of the examinations performed to thi s instruction.

3.1. 5 Examination teams shall include at least one Level II or Level III UT examiner.

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I i gCI 6-13 l Rev. 4 3.2 Ultrasonic Instruments - The pulse-echo, ultrasonic flaw.'detection instruments shall be equipped with a stepped gain control, gradu-ated in units no larger than 2 dB. Instruments considered accep-table for examination are listed below; other instruments may be used if the model type is qualified.

Krautkramer USIP-1 1 KRautkramer USL-48 Hortec HDT-131 or 1310

-s 3.3 Transducers a" 3.3.1 55i5 ducers having an area from 0.049 to 1.0 square inch shall P

1 be used. Base material examinations and thicknes's measurements will normally be conducted using a 2.25 or 5.0 MHz longitudinal wave transducer; however,,other fre-quencies may be used where metallurgical characteristics prevent effective use of 2.25 or 5.0 MHz transducers.

3.3.2 ~An le Beam - Single or dual element ceramic type trans-ducers having an area from 0.049 to 1.0 square inch shall The initial examination will normally be con-

"I be used.

ducted using 2.25 MHz shear wave transducers with a beam angle of 43 to 47 degrees. Other angles and wave modes may be used for evaluation or indications and where wall thickness or geometric configuration impedes effective use of the 45 degree angle. The tolerance for other angles shall be +3 degrees. Transducers of other frequencies and wave modes may also be used for evaluation of indications or where metallurgical characteristics prevent effective use of 2.25 MHz shear wave transducers. The transducer exit point and beam angle shall be verified, prior to examination, using an IIM ( International Institute of Melding) or Rompas calibration block.

3.4 ~Cou lant - Ultragel 11 or an equivalent shall be used as the liquid couplant. Certification of acceptable sulfur and halogen content shall be obtained and made available for each lot or batch number.

(a) Couplant shall be analyzed for sulfur content in accordance with ASTM D129-64. The sulfur content of the residue shall not exceed 1% by weight.

(b) Couplants shall be analyzed for chloride content in accordance with ASTM D808-63. The chloride content of the residue shall not exceed 1% by weight.

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Page 2 of 19

QCI 6-13 Rev. 4 gaby 3.5 Calibration Blocks -. Calibration blocks shall be as specified in Section 14 of the Inservice Inspection Program Plan or as specified the Responsible Technical Organization (RTO).

3.6 Surface Pre aration - The finished contact surfaces shall be free from we d sp atter ar any roughness that would interfere with free.

movement of the search unit or coatings which would impair the transmission of ultrasonic vibrations.

3.7 Instrument Cali bration - The ultrasonic instrument linearity shall be checked each day prior to its use and documented on the Cali-bration Data Sheet shown in Attachment 7.2. Linearity shall be determined in accordance with the requirements of Paragraphs (a) and (b) below:

( a) Screen Hei ht Linearity Check - To verify the ability of the ultrasonic i nstrument to meet screen height linearity requirements, position an angle beam search unit so that responses can be observed from any two reflectors in a calibration block. Adjust the search unit position to give a 2 to 1 ratio of amplitudes between the responses, with the larger set at 80% of full screen height (FSH).

Mithout moving the search unit, adjust the"gain control to successively set the larger signal from 100>>. to 20% FSH in 10~ increments or in 2 dB increments if the instrument is equippe'd with a stepped gain control. The smaller signal amplitude must be 50>> of the larger amplitude signal within 5~ FSH. Instruments that do not meet this requirem nt shall not be used.

(b) Am litude Control Linearity Check - To verify the'accuracy of the amplitude control in the ultrasonic instrument, position a search unit so that a response from a reflector in the calibration block is peaked on the screen. The signal amplitude shall be brought as near as possible to 80 FSH with the dB control. 'If necessary, the final adjustment to 80% FSH can be made with the variable gain control. Using only the dB control, the dB changes indi-cated below shall be made and the resulting amplitude compared with the allowable amplitude limits. The proce-dure shall be repeated for 40% and 20 FSH amplitudes.

The initial settings agd readings shall be estimated to the nearest 1 of full screen. Instruments that do not meet this requirement shall not be used.

Page 3 of 19

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,4 ~ OCI 6-13 Rev. 4 Initial Amplitude dB Control Amplitude Limi ts Set at 5'FSH ~Chan e .in 5 FSH 80 '0

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4 40 +6 64 to 96

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I 3.8 General Requirements for fxamination Calibration

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Calibration shall be performed from the surface of the

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} calibration block which corresponds to the component e

surface to be examined.

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3.8.2 The calibration block temperature shall be within 25 F of the component being examined.

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}4 3.8.3 Calibration shall include the complete ultrasonic examina-

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tion system. Any change in couplants, cables, transducers, wedges, ultrasonic instruments, or any other parts of the exami nat 'on, system shall be cause for a calibration check.

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~ l (a) At '.east every 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> during an examination; 4

(b) At-'.he start and finish of each completed examination;

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' (c) At -".ach change of examiners; (d) In 'he event of loss of power; and

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(e) If any part of the examination system has been changed, such as, search units, cables or ultrasonic ji instruments; h

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}2 (f) If the operator suspects a malfunction.

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i 3.8.5 Calibration checks may be performed on a secondary refer-

<<4 ence, such as an IIM, Rompas block or equivalent, provided

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the response from the block has been referenced after ll initial calibration. The tolerances of 3.8.7 and 3.8.8 shall apply for this operation.

3.8.6 Final calibration shalI be performed on the calibration block used for initial calibration.

4',4 3.8.7 Recalibration (Swee Only) - If the indication from any 4Q e

o the ca ibration reflectors has moved on the sweep line 4

I more than 10, correct the sweep range calibration and note the'correc.ion on the Calibration Data Sheet. If Page 4 of 19

i QCI 6-13 Rev. 4 (b) ldithout changing the instrument controls, maximize the signal of the two remaining holes and mark their amplitudes and locations on the screen.

(c) As an alternate, if the calibration block is designed such that it only contains a 1/2 T side drilled hole, position the search unit for maximum response from this hole. Then adjust the instrument gain to set this signal at 80 of full screen height and mark the, location and amplitude of the signal on the screen.

Mithout changing the instrument controls, maximize the signal from this hole at the 6/8 node position and mark the. amplitudes and locations on the screen.

(d) Connect these points on the screen with a line and extrapolate the curve an additional 1/4 T to cover the full examination thickness. This completes the construct~on of the DAC curve only.

(e) To determine the primary reference level, position the search unit to obtain the maximum response from the notch at the 1/2 "Y" path location. Adjust the amplitude of the notch to be equal to the DAC curve.

This is the primary DAC reference level.

(f) Record and plot all calibration data on the appropri-ate areas of the Calibration Data Sheet.

(g) After the primary DAC reference level has been established on the pipe calibration standard, a cali-bration reference response may be established on a Rompas or other standard reference block. The response shall include both sweep and amplitude calibration points and the gain setting used to establish them. This information shall be recorded on the appropriate area of the Calibration Data Sheet.

This reference response may then be used to perform calibration checks. Final calibration, however, shall be performed on the pipe calibration standard.

4.1.3 For the examination of piping welds using the 1 "Y" path or greater technique, /he calibration shall'be performed in accordance with the following to detect reflectors parallel or transverse to the weld:

(a) Position the search unit for maximum response from the circumferrential notch on the. opposite side of the calibratioh block and adjust the instrument gain to set the response at 80>> of full scr'een heigh:.

Nark the location and amplitude on the screen.

Page 6 of 19

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QCI 6-13 Rev. 4 (b) Without adjusting the gain, obtain responses from the

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notches at 1 and 1-1/2 or greater "V" path locations.

l gh Mark the locations and amplitudes on the screen.

I (c) Connect the points with a line. Thi s is the primary

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DAC reference level.

(d) Record and plot all calibration data on the appropri-

'I ate areas or the Calibration. Data Sheet as shown in Attachment 7.2.

Ii (e) After the primary DAC reference level has been established on the pipe calibration standard, a calibration reference response may be established on a Rompas or other standard reference block. The response shall include both sweep and amplitude calibration points and the gain setting used to establish them. This information shall be recorded on the appropriate area of the Calibration Data Slieet.

This reference response may then be used to perform

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'I cal ibration checks. Final calibration, however, I shall be performed on the pipe calibraiion standard.

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4.2 Strai ht Beam Calibration - Preservice Inspection Only 4.2.1 Calibrate the instrument sweep to a distance sufficient to include the thickness of the material being examined using an IIW, Rompas or an equivalent block having known dimensions.

4.2.2 For the exami nati on of piping, fabricated from plate material, for laminar. reflectors, calibration shall be performed according to the following:

(a). Position the search unit on the part to be examined using sufficient gain to produce a back reflection from the part of at least 80>> full screen height.

(b) Record and plot all calibration data on the appropri-ate areas of the Calibration Data Sheet.

4.3 Strai ht Beam Examination of Plate Material - Preservice ns ection Only 4.3.1 - This examination shall be performed only on pipe and/or fittings fabricated from plate material.

.I Page:7 of 19 hl I ~

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QCI 6-13

'ev. 4

} 4.3.2 For detection. of laminar reflectors in plate material; the

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search unit shall be placed on the base material and mani-t pulated to ensure coverage of the entire,'area through which the sound must pass during the angle beam examination.

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4.3.3 The instrument gain shall be adjusted during the examina-tion to maintain a back reflection of at least 50K full

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screen height while scanning.

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4.4 An le Beam Examination of Melds r>

4.4.1 For detection of reflectors parallel to the weld, the search unit shall be placed on the contact surface with the beam essentially perpendicular to.the weld centerline.

The search unit shall be manipulated to ensure the sound beam passes through the entire area. of interest using the 1,/2 or l-l/2 or greater "V" path examination technique 4(

>'.I from both sides of the weld. Physical or other limitations

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which prevent complete examination of the area of interest shall be documented on the Exhni nation Data Sheet.

4.4.2 For detection of reflectors transverse to the weld, the search unit shall be placed on the weld with the beam di rected along the weld in two opposite directions.

4.4.3 As an alternate, if the weld contour is such that the examination cannot be perform>ed from the weld crown, the search unit sh'all be placed directly adjacent to the weld edge. The sound beam shall be directed parallel to the N

weld and the search unit manipulated laterally and longi-tudinal')y. Physical or other limitations which prevent

'i r complete examination of the weld area shall be documented on the Examination Data Sheet.

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4.4.4 Welds that cannot be examined from at least one side using the angle beam technique sha)1 be examined by another

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volumetric method.

4.5 Scannin Requirements for An le Beam Examination Area of Interest - The area of interest is the volume of r>

4.5.1 material which is to bg. examined and shall include the

~ 4 inner 1/3 T of the weld and 1/4 inch of adjacent base material on both sides of the weld as measured from the weld crown edge.

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4 gCI 6-13 Rev. 4 4.5. 2 The area of interest shall be examined from both sides, when possible, with the search unit directed normal to the weld for detection of reflectors parallel to the weld using the 1/2 or 1 or greater "V" path examination technique whichever is applicable. 4.5.3 For examination of reflectors transverse to the weld, the search unit shall be placed on the weld crown when possible, and directed parallel to the weld. Scanning shall be performed in both directions along the weld. 4.5.4 For longitudinal weld seams adjacent to circumferential welds the entire weld length shall be examined during preservice examination. For inservice examina~ion, only the fi rst 1 foot of the weld for Class 1 and 2-1/2 T for Class 2, need be examined. All other welds shall be examined for their full length. 4.5.5 The angle beam coverage for examination of to the weld using the 1/2 "Y" path examination reflectors'arallel technique shall be sufficient to permit the sound beam to cover the inner 1/3 T of the weld and at least 1/4 inch of the adjacent base material on both sides of the weld edge. Manipulation of the search unit over the weld crown may be required to achieve this coverage using the 1/2 "Y" examination technique. 4.5.6 For the l-l/2 "V" path technique; the minimum coverage shall .be in accordance with the chart below and in all cases shall be sufficient to cover the lower 1/3 of the weld and 1/4 inch of the base material adjacent to the weld. Beam 'equired Scan Distance Measured from the

            ~An  le      Weld Centerline - Pi    e Thickness  is                   "T" At least 3-1/2   T At least 5 T 4.5.7    The. manual scanning rate shall not exceed 6.0 inches per second.      Each pass of the search unit shall overlap a of 10~ of the transducer piezoelectric element                       'inimum dimension perpendicular to the direction of scan.

4.6 Scannin Sensitivity - For angle beam examination, scanning shall be performed at a minimum of 2X (6 dB) above the primary reference level. Six dB increases the signal amplitude by a factor of approximately 2, making the primary reference curve a 50 DAC curve. Recording of indica ions requires the signal to be adjusted Page 9 of 19

gCI 6-13 Rev. 4

l to the point where it is equal to the DAC curve using the dB i

01

 ~              control. Signal amplitude can then be determined from the

% ~ following chart using the observed change in the dB control. "1

 'I dB Gain - % DAC                    dB Gain - 5 DAC 0  -     100                       0  - 100
                    -1  -     112                      +1  -  90
                    -2  -     125                      +2  -  80
                    -3  -    141                       +3  -  70
                    -4  -     159                     '+4  -  63
                    -5  -    178                       +5  -  56
                    -6  -    200                       +6  -  50
                    -7  -     224                      +7  -  45
                    -9  -    282                       +8  -  36
                    -10   -   316                      +9  -  32
                    -ll -    355                       +10 -  28
                                                     -

400 447

                                                       +12
                                                       +13 -'225 J~

501 +14 - 20 562 +15 - 18 631 +16 - 16 708 +17 - 14 794 +18 - 13 891 +19 -

ll 1000 +20 10 4.7 Meld Thickness Measurement - Thickness measurements may be taken at or near the 0 degree reference point and at 90 degree interva'is around each weld on which a data plot is performed. The measure-ments will be made on: (a) The weld centerline; (b) In the heat affected zone as near as possible to each edge of the weld; and (c) On the base material on each side of the weld. 4.7.1 In addition, the location of the pipe counterbore transi-tion should be determined when possible and the distance from the weld centerline documented on the Examination Data Sheet. 4.7.2 All measurements shall be documented on the appropriate area of the Examination Data Sheet shown in Attachment 7.1. Page 10 of 19

I~ ( ()CI 6-13 ( Rev. 4 Is 4.8 Data Recordin for Strai ht Beam Examination - If the response from the laminar reflector exceeds the remaining back reflection response in an area exceeding 3/4" in its longest dimension, the following data shall be recorded on th'e Examination Data Sheet.'a) Indication Number - Assign a number, beginning with 1, to II I i

(b) Location. Interval numbers on the weld. I<< Record the search unit location (c) ~Beam An le - Record the search unit beam angle (0'). (d) Scan Surface Record the surface (1 or 2) on which the V ay search unit is being applied. See Attachment 7.3.

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( e) Sound Path - Record the sound path distance to the rer(actor. (f) Len th - Record the major dimension of the reflector in the 0 DAC length column. (g) Prepare a sketch showing the area in which the reflector exceeds the remaining back reflection and attach it to the Examination Data Sheet. I 4.9 Data Recording for An le Beam Examination of Ferritic Steel Melds-

   ,a     If the  maximum     signal amplitude equals or exceeds         50>> of the I:
.I primary reference level, the following data shall              be recorded on la
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the Examination Data Sheet. (a) Indication Number - Assign a number beginning with to 1 each individual indication which is recorded on each weld. I I~ i (b) Location Interval - Record the search unit location ca interval with respect to the stamped degree location

a ( numbers on the weld. (c) ~Beam An le - Record the search unit beam angle, typically 45 or 60". (d) Scan Surface - Record the surface (1 or 2) on which the

                 'earch unit is         being applied. See  Attachment 7.3.

(e) Beam Direction - Beam direction documents the search unit orientation with respect to the weld. Beam direction will be A, B, C or D. See At.achmen. 7.4. Sound Path - Record the sound path distance to the indica-tior; at the peak amplitude )ocation. Page ll of 19

     . QCI 6-13 Rev. 4 (g)       Extent - This information, recorded in degrees, is used to describe the extent of i'ntermittent or continuous geometric indications. If a more thorough description is required, this blank may be used to reference the noles section.

(h) ~Dam able - If an indication is dmapable on the surface of the part, it should be stated in this column. (i) ~Am litude Record the iaaximum amplitude of the sional as a percentage of the primary reference level. rs. (j) 50'nd

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                             ~Len   th  Record the        50     to           100  to  100  DAC  length s

of each indication. s

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s (k) Search Unit Position - Record, in inches, the distance (L) a from the search unit to the smaller stamped location riumber and the distance from the exit point to the weld center-

-t                            line (M) for longitudinally oriented indications or the distance from the search unit centerline to the weld 5

centerline (M) for transversely oriented indications.

,a These measurements          shall be taken at the mwimum amplitude
)j                            location.        See  Attachment 7.5.

( 1) Throu h Mall Dimension - If the maximum signal amplitude equa s or exceeds DAC, record the minimum and maximum sound path dis ance and search unit location as the search sx unit is moved toward and away from the reflector. These

<< measurements shall be taken at the 100 DAC level. The mi'nimum and maximum sound path'eadings may not necessarily be at the point of maximum signal amplitude, nor do they x'

have to be on the same scan line. Each indication shall be fully investigated to determine the points at which the minimum and maximum readings occur. 4.10 Data Recording for An le Beam Examination of Austenitic and Oissimi ar Metal Welds - Any crack-like indicatson, regardless of amplitude, shall be recorded and investigated to determine it' shape, identity and location. All .indications 50 DAC or greater determined to be geometric'al ><< in origin shall be recorded. or'etallurgical

                                                             'a Any   other indications determined not to be geometrical or metallurgical in origin shall be recorded if they are 20 of the f<<

distance amplitude correction (DAC) curve or greater.

 ,i                (a)       Indication Number - Assign a number, beginning with 1, to 9                             each individual indication which is recorded.

(b) Location Interval - Record the search unit location inter-val with respect to the stamped degree location numbers on the weld. Page 12 of 19

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r emt: t y ', 0 wa< h ~ t ga*".stree ~ v "c t mfc 0 4I v 7 R m's ~ m rf V~ r ~ ~ QCI 6-13 Rev. 4 (c) Beam An<ele - Record the search unit beam angle (0 ). (d) Scan Surface - Record the surface (1 or 2) on which the search. unit is being applied. See Attachment 7.3. (e) Beam Direction - Beam direction documents the search unit orientation with respect,td the weld. Beam direction will be A, B, C or D. See Attachment 7.4. (e) Sound Path - Record the sound path distance to the reflector. ' (g) Extent This informationr,e corded in degrees, is used to describe the extent of intermittent or continuous geometric indications. If a more thorough description is required, this blank may be used to reference the notes section. (h) ~gam able - If an indication is dampable on the surface of the part, it should be stated in this column. Amolitude - Record the maximum amplitude of the signal os a percentage of the primary reference level. Len th - Record the 20>> to 20 (when required), 50 to 50>>

  '                                                       and           0 to 100>> DAC length of                     each indication.
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(k) Search Unit Position - Record, in inches, the distance (L) vrom one search un>t to the smaller stamped location number and the distance from the exit point to the weld center-line (M) for longitudinally oriented indications or the e distance from the search unit centerline to the weld centerline (M) for transversely oriented indications. These measurements shall be taken at the maximum amplitude location. See Attachment 7.5. Throu h Mall Dimension - If the maximum signal amplitude equals or exceeds 100 DAC, record the minimum and maximum sound path distance and search unit location as the search unit is moved toward and away from the reflector. These measurements shall be taken at the 100>> DAC level. The minimum and maximum sound path readings may not necessarily be at the point of maximum signal amplitude, nor do they have to be on the same scan line. Each indication shall be fully investigated to determine the points at which the minimum and maximum readings occur. 4.11 - Examination Records 4.11.1 A Calibration Data Sheet (A tachment 7~2) shiall be prepared for each c al i b ra a on. Page 13 of 19

'CI 6-13 Rev. 4 4.11.2 An Examination Data Sheet shall be prepared for each weld examined and shall be related, by number, to a Calibration Data Sheet. 5.0 EVALUATION 5.1 All indications detected i n the area of interest which produce signal amplitudes greater than 100~'f the DAC refererce level shall be individually reported and an evaluation made in accordance with Paragraph IMB-3514 of ASHE Section XI, 1980 Edition Minter 1980 Addenda (Reference 6.1.1). 5.2 Any area where complete examination cannot be performed due to obstructions, configuration of weld, etc., shall be recorded and reported. 5.3 All data shall be submitted to the Supply System UT Level III for review. The Level III shall evaluate the examination data and indicate the status of the indication in the Evaluation column of the Ultrasonic Examination Data Sheet. The Level III shall also complete the Data Evaluation Form in accordance with NDEEI Instruction 12-8.

6.0 REFERENCES

     ~  6. 1    American Society of Mechanical Engineers Boiler and Pressure Yessel Code, 1980 Edition through Minter 1980 Addenda.

6.1.1 Section XI - "Rules for Inservice Inspection of Nuclear Power Plant Components". 6.2 The Supply System "Program Hanual for gualification and Certifica-tion of Examination, Testing and Inspection Personnel MHC-034". 7.0 ATTACHMENTS 7.1 Examination Data Sheet 7.2 Calibration Data Sheet 7.3 Examination Surfaces

       .7.4     Beam  Directions 7.5     Search Unit Location and Orientation Page 14      of 19

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QCI 6-13 Rev. 4 t WASHHIGTON PVBLIC POWER SVPPLY SYSTEI I L>> ULTRASONIC EXAMINATIONDATA SHEET REPORT NO.. RCU-001 fnolEcTI IHIp svsTEMI RC ISI ORAWINC NO;. RC ]P] ] wELo/PART oEscRIPTICNt p]pe go e] how WELotfanT rto.: RC-42-501-3 MATERIALTYPE: cAL sTAtIOARO No.: UT-126 2 HICK NESS I 3.6 No.OF sCAN olnacvloNs: 4 LIMITEO EXAM: QXNO C3 YES ACCEPTANCE CRITERIAt IN-3514 INSTRUCTION No.: 6-20 REVISION: 0 ANCLal 0 ANCLEI 45 AttCLEt ExAMINERt T. Smi th LEVELI II oATat 12-28-82 oATat 1-1-83 CATE: ExAMINant LEVELt I TIME STARTI 8:40 TIME STAR'Tl 9;QQ ff4 TIME STARTI

8. JoneS am THICKNESS IIEASURahhaNIS TIME STOP 1 rZUS Wal,o WIDTH >~ >" TIME svof1 9: 50 am TIME STOPI ]PIQQ aol WELO HEICHT SVRFACETWO 0'l SVRFACE ONF. PART TEMP: 72 PART TaMF: ~

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W a COUNTER R M cAL SHEET NO.: TS-001 CALsHEETNo.t 75-002 CAL SHEET No.t 3.6 N/A 3.6 3.6 3. 6 H/A 3.7 CHART No:.'t/A ARTNo.: RCU-001 CHART No.l 3.7 N/A 3.6 3.7 3.5 N/A 3.6 190 . tI/A 3.5 3.6 3. 6 H/A 3.5 220'.6 3.6 N/A 3.6 3.6 3~ 7 H/A 3.7 LOCATION 100 50 20 EVAL 0 c I Iht UNIT THROUCHIVALLCATA M UAT loll m INTERVAL X hu U 2 P Z D U To To To SIT I ON AT O I 5 2 A 4 tv t 100 SO 20 MAXIMUMAh1 f MAXlh'IUM MINIhIUhth U I U cv c PART NO th O vl R

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6.0 REFERENCES

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