ML20151W335
| ML20151W335 | |
| Person / Time | |
|---|---|
| Site: | Limerick  |
| Issue date: | 04/10/1987 |
| From: | Matthew Mitchell BECHTEL POWER CORP. |
| To: | |
| Shared Package | |
| ML20151W267 | List: |
| References | |
| UT-HX-NIR, NUDOCS 8808240055 | |
| Download: ML20151W335 (19) | |
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BECHTEL CONSTRUCTION, INC.
MANUAL ULTRASONIC EXAMINATION PROCEDURE FCR RHR HEAT EXCHANGER N0ZZLE INNER RADIUS UT-HX-NIR April 10,dh7 REVISION 2 4 Date 4x vi MATERIALS AND (J A LIT Y ERV ES N \>
Prepared and Approved [O l&ll/ O Autho'rized s'e by DE Levelill Examin r Ddte pNs ~,\
Re vie wed A$l L -A'k' V ? W'N '
Date - < '_ & Mt>J. M p h/p7 Approved '
M #W4m - dM M gey/9,13'C6nstruction 'Date/
Manager,VA&OS[f J D'a t e ' g 4 j'b' Y
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("0R LIMERICK ONLY) s, s a TABLEkJ-ON*ENTS 1.0 SCOPE 2.0 . REFERENCES APR 2 01987 3.0 GENERAL REQUIREMENTS BECHTEL 4.0 CALIBRATION 5.0 EXAMINATION 6.0 EXAMINATION RECORDING REQUIREME.VIS 7.0 EVALUATION AND ACCEPTANCE CRITERIA 8.0 DOCUMENTATION AND RECORDS kyWYk W t* MY 22z.s/,<au' AM deu/.:;r 4 ara r i
3f, m, 2 04/10/87' 1
Incorporate FCR Nos. LP-610 and LP-737 t 1 ;i10/23/86; General Revision O J06/25/86) Initial Issue i NO. I OATE 3 REVtSa0NS 8000240055 080815 PDR ADOCK 05000353 G PNU
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i D7cument Ns. UT-HX-NIR Re v. 2 (For Limerick Only) i P 21 2 ef 19 l 1.0 SCOPE l
o 1.1 This procedure specifies the minimum requirements for manual ultrasonic 1
b-) e:: amination of the RHR heat exchanger nozzle inner radius areas, as indicated in Figure 1.
1.2 The RHR heat exchanger shell is constructed of carbon steel (SA516-70).
The RHR heat exchanger flange and nozzles are constructed of carbon steel (SA105, Class II).
a 1.3 This procedure was developed in accordance with ASME Section V, T-110(c) and ASME Section XI, paragraph IWA-2240.
2J REFERENCES 2.1 ASME Boiler and Pressure Vessel Code,Section XI,1980 Edition through Winter 1981 Addenda.
2.2 American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, 1980 Edition.
2.3 Bechtel Construction Procedure CP-W-4, Preservice Inspection of Nuclear Piping Systems.
3.0 GENERAL REQUIREMENTS 3.1 Personnel 3.1.1 Bechtel NDE Personnel shall be certified and certification records maintained in accordance with Bechtel's NDE Certification Standards, NEPQ 1 and NEPQ 2.
3.1.2 Subcontractor NDE Personnel shall be certified in accordance with their NDE Personnel Certification Procedure, which shall meet the requirements of the American Society of Nondestructive Testing Recommended Practice No. SNT-TC-1A, 1930 Edition ac well as AGFE Bofler and Pressure Vessel Code,Section XI,1980 Edition through Winter 1981 Addenda.
3.1.3 Complete certification records for the Subcontractor NDE personnel plus the Level III that certified the individual, shall be submitted to the designated Bechtel individual prior to performing final acceptance examination. Complete certification jobsite.
records for each individual shall be maintained on file at the 3.1.4 In addition to the above, ultrasonic technicians performing examinations in accordance with this procedures shall receive four hours of specific application training in the techniques specified in this procedure.
3.2 Equipment
,mE 3.2.1 A pulse-echo ultrasonic instrument with an A-scan presentation shall be 8M used. The instrument shall be equipped with a stepped gain control calibrated in units of 2 dB or less. The instrument shall be capable of generating and receiving frequencies of 1.00 to 5.00 MHz. Manufacturer's recommended d maintenmce checks of ultrasonic instruments shall be performed annually.
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e Document No. UT-HX-NIR Re v. 2 (For Lirarick Only)
. Pane 3 ef 19 3.2.2 Search units may contain either single or dual transducer elements.
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3.2.2.1 Transducers shall have a nominal f requency range of 1.0 to 5.00 MHz, 3.2.2.2 The maximum nominal transducer dimension for circular, squete, or rectangular active elements shall not exceed the following:
TABLE 1 Nominal Material Transducer Thickness Size 1/4" or less 1/4" x 1/4" or 1/4" Round 1/4" to 1/2" 1/4" x 1/4" or 1/4" Round to 1/2" x 1/2" or 1/2" Round 1/2" and above 1/2" x 1/2" or 1/2" Round to 1" Round .
Note: Other transducers may be used provided a Code calibration is documented.
3.2.3 Search unit cables shall be coaxial.
3.2.4 Contoured wedges shall be used to produce shear waves at a nominal 45-degree angle to the nozzle inner radius area.
3.3 General Examination Requirenents - Couplants 3.3.1 Any commercially available couplant may be used to couple the transducer to the part during calibration and examination. The same couplant shall be used during both processes.
3.3.2 Couplants shall be certified for total sulfur and halogen content in accordance with ASTM D-129-64 and D-808-63. The total residual halogens and sulfur shall not exceed 1 percent by weight, respectively.
3.3.3 Examination Frequency 3.3.3.1 The ultrasonic examination frequency for examinations performed in accordance with this procedure shall bei
- 1) Nominal 2.25 MHz for all angle beam examinations of carbon steel.
mE 2) Other frequencies may be utilized if deemed necessary, as 8?? dispositioned by a Level II.
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i Document N7- UT-HX-NIR g, y , 2 (For Liecrick Only) p; p 4 nf 19 3.3.4 Examination Angles and Coverage 3.3.4.1 v Nominal 45-degree angle beam shear wave technique shall be applied to the OD surface of the nozzle contour area (Figure 3) in two directions:
clockwise (CW) and counterclockwise (CCW).
3.3.5 Basic Calibration Block's)
A 3.3.5.1 be one ofThethe material from which the basic calibration block is fabricated shall following:
- 1) Nozzle dropout from the component
- 2) A component prolongation
- 3) Material of the same material specification, product form, and heat treatment as the nozzle being examined.
3.3.5.2 be used The nozzle inner for sensitivity radius calibration calibration (Figure 2).block shall contain three notches to 3.3.6 Reference blocks such as an IIW or a Rompas may be used for:
- 1) Search unit beam exit point location *
- 2) Angle verification
- 3) Sweep range calibration O 4) System calibration checks provided the blo:k is fabricated from acoustically similar material.
4.0 . CALIBRATION 4.1 Instrument Cs11bratio-
- 4. 2 d Instrument calibration for screen height and amplitude control linearities shall be verified prior to the start of each day's examinations.
4.1.2 Screen Height Linearity 4.1.2.1 The ultrasonic instrument shall provide screen height linearity within 5 percent of full range for at least 80 percent of the full screen height (FSH)
(baseline to maximum calibrated screen points).
4.1.2.2 To verify the capability of the ultrasonic instrument to meet the linearity requirements, position a search unit as shown in Figure 4 so that echoes can be observed from any two reflectors in a calibration block.
,,g 4.1.2.3 Adjust the search unit position to give a 2:1 ratio of amplitudes
!84 between the two echoes, with the larger set at 80 percent of FSH. Without moving a" the search unit, adjust only the calibrated gain control to successively set the larger echo from 100 percent to 20 percent of FSH, in 10 percent increments (or b
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5 Document No. UT-HX-NIR Re y, 2 (For Licorick Only) Page 5 et
. 19 2 dB steps if a fine control is not available), and read the amplitude of the
,_x smaller echo at each setting. The reading shall be 50 percent of the larger
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amplitude, within 5 percent of FSH. The settings and readings shall be estimated to the nearest 1 percent of full screen.
4 .1. 3, Amplitude Control Linearity 4.1.3.1 The ultrasonic instrument shall utilize an amplitude control, accurat(
over its useful range to + 20 percent of the nominal amplitude ratio, to allow measurement screen.
of indications beyond the linear range of the vertical display on the 4.1.3.2 To verify the accuracy of the amplitude control in the ultrasonic instrument, as required in paragraph 4.1.3.1, position a search unit so that an echo from one reflector in a calibration block is peaked on the screen. With the increases and decreases in gain (dB) shown in Table 2, the echo amplitude shall fall withia the specified limits.
TABLE 2 SPECIFIED LIMITS FOR ECHO AMPLITUDE Indication Set Indication Limits, at Percent dB Control Percent of
- of Full Screen Change Full Screen 80 percent -
6 dB 32 to 48 percent 80 percent - 12 dB 9 40 percent + 6 dB 16 to 24 percent 64 to 96 percent 20 percent + 12 dB 64 to 96 percent Note: A minus (-) denotes decrease in amplitude; a plus (+) denotes increase. Convenient reflectors from any calibration block may be used with antic or straight beam search units. The ser'ings and readinge shall be estimated to the nearest 1 percent of full screen.
4.1.4 Screen height and r.mplitude control linearity verification shall be decumented in the appropriate blocks on the Ultraronic Calibration Report, MQS-013.
4.1.5 Instruments that do not meet the requiremeuts of paragraphs 4.1.2 or 4.1.3 dhall not be used.
4.2 Search Unit Calibra: ion 4.2.1 Prior to performing system calibration (4.3), the search unit beam exit mE point shall be determined and marked on the wedge. In addition, the beam angle 8Os shall be determined and documented in the "measured angle" block on the Ultrasonic Calibration Report, MQS-013.
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f Document N% UT-HX-NIR Re v, 2 (For Lia rick Only)
Pmge 6 cf 19
_4.2.2 Prior to performing the examination, a plot to determine beam spread shall be derived as described is paragraph 4.2.2.1. The plot shall be ir.cluded in the examination data package.
V) 4.2.2.1 Utilizing the transducer and contoured wedge which will be used during the examination, construct a beaa spread plot as follows:
- 1) Obtain the peak amplitude response from notch #1 and set at 80 per;ent FSH.
- 2) Without changing the gain, move the search unit forward and then backwaid until the sigral drops to 50 percent of peak amplitude and mark the corresponding beam exit points on an indication location strip. Record the sweep reading of the left edge of the indication.
- 3) Repeat steps 1) and 2) with notches #2 and d3.
- 4) Utilizing the data from the indication location strip, draw a cross-sectional beam pict.
4.3 System Calibration 4.3.1 General Requirements 4.3.1.1 An ultrasonic calibration shall be performed and the data documented appropriately on the Ultrasonic Calibration Report, MQS-013 each day prior to the examination.
llh 4.3.1.2 Calibration shall include the search units, couplants, cables, ultrasonic instruments, and recording devices, as applicable. The initial and final calibration shall be performed on the basic calibration block.
Intermediate calibration checks may be t .cformed in tne same manner as the initial calibration or as an alternate as described in paragraph 4.6.
A 4.3.1.3 Th* maximum calibration indications shall be obtained with the sound beam oriented essentially perpendicular to the axis of the calibration reflector.
The canterline of the applicable calibrationofblock.
the search unit shall ride in the 3/4 inch radius (R tetion of the beam into a corner formed by the reflector and the side of the block may produce a higher amplitude signal at a longer beam path. This beam path shall not be used for calibration.)
4.3.1.4 Calibration shall be performed from the surface (clad or une lad) of the calibration block that corresponds to the component surface to be ext _ined.
4.3.1.5 The temperature of the calibration block surface shall be within 25'F of the temperature of the examination surfaces. These temperatures and the serial number of the temperature measuring device chall be documented in the appropriate blocks on the Ultrasonic Calibration Report, MQS-013.
4.3.2 System Calibration Check m aa 8?? 4.3.2.1 A system calibration check, which is the verification of the inatrument i sensitivity and sweep range calibration, shall be performed and documented on the SE. ultraaonic Calibrativa Report, xQS-ola, at tre following times:
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e-Document nn, UT-HX-NIR Re v . 2 (For Licorick Only) Page 7 ef 19
- 1) At the start and finish of each examination.
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With any change in the instruments, recording instruments, search units, shoes, couplants, or cables.
- 3) With any change in examination personnel.
- 4) At least every twelve hours during system use.
- 5) At any time when, in the opinion of the operator, there is doubt as to the validity of the calibration. !
4.3.2.2 If any calibration point has decreased 20 percent or 2 dB of its amplitude, all data sheets since the last calibration check shall be marked void. A new calibration shall be made and recorded, and the voided examination areas shall be reexamined. i 4.3.2.3 If any calibration point has increased more than 20 percent or 2 dB of its amplitude, recordet
'dications taken since the last valid calibration or calibration changed oncheck may the data be r examined with the correct calibration and their values sher .
4.3.2.4 If any calibration point has moved on the sweep line more than 10 percent of the sweep division reading, correct the sweep range calibration and" note the correction in the examination record. If recordable reflectors are noted on the data sheets, those data sheets shall be voided, a new calibration shall be recorded, and the examination areas r. hall be reexamined.
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(_j 4.3.2.5 Pulse shape (dampening), noise suppression (reject), and filter controls shall be at the same position during examination, calibration (verification), and system linearity checks. Adjusting or changing these controls while the instrument is calibrated for an examination is prohibited. The minimum or "off" position is t!e recommended position for these controls.
4.4 Angle Beam Calibration for Inner Radius Examination 4.4.1 The instrument horizontal linear range shall be calibrated for the 45-degree angle beam examination using a Rompas block as follows:
4.4.1.1 Obtain a maximum indication from the long radius reflection surface of the calibration standard (2-inch metal path).
4.4.1.2 Using the material calibration control and delay control, align this signal at CRT Position 2.
4.4.1.3 Increase the instrument gain control until secondary echoes occur.
4.4.1.4 Align the secondary echoes at CRT Positions 5 and 8.
4.4.1.5 The CRT is now calibrated in inches of metal path (each major division mE equaling 1 inch). Make no further adjustments to the sweep range or delay 8?t controls, s
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a Doc ueen t th. UT-HX-NIR Rev. 2 (For Lin rick Only) Pag; 8 cf 19 A 4.5 Utilizing notches #1, #2 and #3 on the inner radius calibration block (Figure 2), position the search unit at the notch which gives the highest g3 I
amplitude and adjust the gain to provide an 80 percent of FSH indication.
4.5.1 Without changing the gain, maximize the signals from the remaining notcheu and mark their peak amplitude and sweep positions on the CRT. This is the Distance Amplitude Curve (DAC).
A 4.5.1.1 Increase the gain setting 26 dB. This is the primary reference level.
4.5.2 Record all sensitivity control settings on the appropriate Calibration Data Sheet (MQS-013).
4.6 Intermediate calibration checks may be performed using one of the reference blocks, described in paragraph 3.3.6, provided tha following is documented in the appropriate blocks on the Ultrasonic Calibration Report, MQS-013:
- 1) Reference block type / serial number, i.e. Rompas S/N #953608.
- 2) Reference reflector used, i.e., 1-inch radius.
- 3) Gain setting establishing the signal peak amplitude at 50 percent FSH.
- 4) Horizontal sweep position of left side of signal base.
da a sheet Fr M 13 1)
Calibration sheet identification and date of calibration.
- 2) Names of examination personnel.
- 3) Examination procedure number and revision.
- 4) Basic calibration and reference block identification.
- 5) Ultrasonic instrument identification and serial number.
- 6) Beam angle, couplant, and mode of wave propagation in the material.
- 7) Orientation of search unit with respect to the nozzle (CW or CCW).
- 8) Search unit identification -- frequency, size, and manuracturer's serial number.
- 9) Special search units, wedges, shoe type _ or saddle identification, if used.
g 10) Search unit cable type and length, thoml 11) Times of initial calibration and subsequent calibration checks.
S 2e l _
Document N,, UT-HX-NIR Rev, 2 (For Linarick only) py g, 9 ef 19
- 12) Amplitudes and sweep readings obtained from the calibration reflectors.
- 13) Temperature measuring device serial number and temperatures of the salibration block (s) and part examined.
- 14) Instrument settings.
Note: If an electronic DAC curve is being used, a second recort ; hall be made of the resultant amplitudes and sweep readings obtained from the calibration reflectors.
5.0 EXAMINATION 5.1 Surface Conditions 5.1.1 The examination surface shall be free of irregularities, loose material, or coatings that interfere with ultrasonic wave transmission.
5.2 Scanning Sensitivity A
5.2.1 Angle Beam - Scanning sensitivity shall be at least 20 dB above the primary reference level. A 5- to 10 percent ID roll shall be maintained.
5.3 Scanning Speed 5.3.1 Scanning speed shall not exceed 3 inches per second.
(j 5.4 Coverage 5.4.1 Scan the examination volume utilizing three quadrants in both the CW and CCW directions (Figure 3).
5.5 Scanning for Reflectors - Angle Beam 5.5.1 The angle beam examination for reflectors shall be performed as described in paragraph 3.3.4.1. The examination volume shall be scanned in two beam path directions, CW and CCW.
A 5. 5. 2 follows:
The search unit shall be overlappe.1 10' to 15' to the left and right as Scan "A" - Beam normal at centerline of nozzle radius Scan "B" - Beam 15' to 20' to left Sean "C" - Beam 15' to 20' to right 5.6 Any obstruction or other condition preventing full coverage of the examination volume shall be documented on the Ultrasonic Examination Data Report, MQS-014 and on an Incomplete Examination Report (IER).
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. Document No. UT-HX-NIR Rev. 2 (For Lim rick Oniv) P'ge 10 rf 19.-.-
6.0 EXAMINATION RECORDING REQUIREMENTS
'1 6.1 Indication Recording A 6.1.1 All indications 20 percent of reference sensitivity level or greater shall be recorded.
6.1.2 All indications recorded per the requirements of paragraph 6.1.1 shall be investigated to the extent necessary to determine the shape, identity, and location of the reflector in terms of the acceptance criteria of paragraph 7.2.
6.1.5 The means used to identify an indication as geometric shall be recorded.
6.2 Examination Documentation 6.2.1 Report (FormThe following data shall be recorded on the Ultrasonic Examination Data HQS-014):
- 1) Data sheet identification, ' ate and time period of examination.
- 2) Names and certified levels of examination personnel.
- 3) Examination procedure (s) and revision (s).
- ) Applicable calibration report number.
- 5) Identification of nozzle examined.
- 6) Surface from which examination was conducted.
- 7) Record of indications (or of volume frue of indications).
6.2.2 For each nozzle inner radius examina. tion arta which is free of any recordable indications, the data report shall state "To Reco*dable Indications."
A 6.2.3 For each indication that equals or exceeds 2L percent of DAC, the following shall be recorded:
A 6.2.3.1 Peak amplitude dB setting when adjusted to the DAC (Ind. dB at DAC),
sweep reading to reflector (CRT Div. Peak), search unit position (S.U. POS),
search unit location (S.U. LOC), and sound beam direction, i.e., axial clockwise or ccunterclockwise (CW or CCW). (Abbreviations correspond with Form MQS-014 block headings.) Note: S.U. position is taken from 0 datum.
S.U. location is taken from centerline of outside radius.
A 6.2.4 For each indication, excluding geometric indications, greater than 50 percent of DAC, the following shall be recorded:
- 1) Peak amplitude dB setting when adjusted to the DAC (Icd. dB at DAC), sweep readings to reflector (CRT Div. Peak), search unit mE position (S.U. POS), search unit location (S.U. LOC), ani sound EN beam direction, i.e. , axial clockwise or co 2nterclockwise (CW or th CCW).
E, (Abbreviations correspond with Form PQS-014 block headings.)
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Docueent No. UT-HX-NIR Re v. 2 (For Lircrick Oniv) Pag, 11 cf
. 19
- 2) Search unit positions parallel to the reflector et the points where the reflector amplitude equals 50 percent of DAC for reflectors
~ .) greater than 50 percent DAC.
6.2.5 Indications that are recorded to the requirements of 6.2.3 and 6.2.4 and additional information generated during evaluation (paragraph 7.0) shall be recorded or referenced on Form MQS-014.
6.3 Reference System A 6.3.1 Indications shall be reported in inches and degrees CW or CCW from the datum point when looking towards the vessel and in inches from outside radius centerline of zone A, B, or C.
6.3.2 All position and location recordings shall be to the nearest 0.050 inch.
6.4 Examination Volume Profile 6.4.1 An examination volume profile shall be established for all indications recorded per the requirements of paragraph 6.1.1. Intermittent related indications determined to be of the same origin (i.e., geometrical) need only have a single examinatio. volume profile at the location of the peak amplitude of the composite indication. Examination volume profiles shall be taken from the applicable heat exchanger drawings. ,
6.4.2 Picts with profile data shall be drawn on the Form MQS-015 rad attached to the applicable Ultrasonic Examination Data Report, Form MQS-014. In addition,
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\s all reflectors recorded per paragraph 6.1.1 shall be plotted onto the profile at their cppropriate locations.
7.0 EVALUATION AND ACCEPTANCE CRITERIA 7.1 All recorded indication data shall be evaluated by the Lead PSI Technician.
7.1.1 Any additional examinations that are performed to further evaluate a recorded indication shall properly documented on Forms MQS-013, MQS-014 and MQS-315, as spplicable.
7.1.1.1 A description of the examination technique used shall be included on the Ultrasonic Examination Data Report, Form HQS-014.
7.1.1.2 The additional Ultrasonic Examination Data Report shall be cross referenced with the Ultrasonic Examination Data Report originally documenting the indication using the examination report numbers.
7.1.2 The following steps shall be applied when evaluating any indication recorded per the requirements of 6.1.1.
7.1.2.1 Verify that all examination documentation is complete in accordance gf with Section 6.2.
co m LA 7.1.2.2 Review specifications and/or drawings.
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Document Ho, UT-HX-NIR Re v . 2 (For Li : rick Oniv) Page 12 cf 19
_7.1.2.3 Interpret the indication from the area containing the reflector in accordance with the applicable procedure or by visual inspection.
i 7.1.2.4 As an option, other NDE methods or techniques such as alternate UT bean angles, UT profiling or radiography may be used.
7.1.2.5 The basis for classifying the origin of an indication as geometrical or metallurgical shall be recorded on the Ultrasonic Examination Data Report (Form HQS-014).
7.2 All recorded indications shall be evaluated in accordance with Article IWA-3000 through of the Winter ASME 1981 Boiler and Pressure Vessel Code,Section XI,1980 Edition Addenda.
acceptance standards of Table 3.
The examination results are then compared to the 8.0 DOCUMENTATION AND RECORDS 8.1 (Figure 5).Ultrasonic calibration data shall be documented on Form HQS-013 8.2 Indication recording shall be documented on Form MQS-014 (Figure 6).
8.3 Examination reports shall be reviewed by the Lead PSI Technician for completeness and conformity to the requirements of this procedure. ,
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Document rio. UT-HX-NIR Re v. 2 (For Littrick Only)
.- P"te 13 *f 19 1
TP3 RNR HEAT EXCHANGER N0ZZLE INNER RADIUS AREA ALLOWABLE PLANAR INDICATIONS Material SA-508 Class 2 and 3 forgings that meet the requirements of NB-2331 and the specified minimum yield strength of 50 kai or less at 100*F Aspect Surface Subsurface Ratio,1 Indications,2 Indications 2-4 A/ a/t, % a/t, %
0.00 1.8 2.3Y 0.05 1.0 2.4Y 0.10 2.2 2.6Y 0.15 2.4 2.9Y
- 0.20 2.7 3.3Y 0.25 3.1 3.7Y 0.30 3.5 4.1Y s
0.35 3.5 4.6Y 0.40 3.5 5.2Y 0.45 3.5 5.9Y 0.50 3.5 6.5Y Inside corner region 2.5 Not applicable NOTESt (1) Dimensions of a and are defined in IWA-3300. For intermediate flaw aspect ration a/ , linear interpolation is permissible. Refer to IWA-3200(b).
(2) See Table IWB-3512-1 for the appropriate component thickness t as a function of flaw location.
(3) The total depth of a subsurface indication is 2a.
(4) Y = (S/t)/(a/t) = S/a. If Y 0.4, the flaw Y
indication is classified as a surface indication. If 1.0, use Y = 1.0.
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Document N9. UT-HX-NIR _Rev. 2 (For Limarick Only)
Page 15 et 19 g1 Calibration i
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- 1 0.027 1.7
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