ML15253A196

Request for Approval of Relief Request (PRR)-53, Proposed Alternative in Accordance with 10 CFR 50.55a(z)(1) to ASME Section XI, Appendix Viii, Supplement 11 for Qualification Requirements for Full Structural Overlaid Wrought Austenitic

ML15253A196
Person / Time
Site:	Pilgrim
Issue date:	09/01/2015
From:	Perkins E Entergy Nuclear Operations
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
2.15.063
Download: ML15253A196 (19)

Text

Eniegyi Nuclear OPoer SationsIc

~ En tigj.'600 Rocky Hill Road PyotMA 02360 September 1, 2015 U.S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, DC 20555-000 1

SUBJECT:

Request for Approval of Pilgrim Relief Request (PRR)-53, "Proposed Alternative in Accordance with 10 CFR 50.55a(z)(1 ) to ASME Section Xl, Appendix VIII,

• Supplement 11 for Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds" Entergy Nuclear Operations, Inc.

Pilgrim Nuclear Power Station Docket No.:

50-293 License No.:

DPR-35 LETTER NUMBER: 2.15.063

Dear Sir or Madam:

Pursuant* to 10 Code of Federal Regulations (CFR) 50.55a(z)(1), Pilgrim Nuclear Power Station (PNPS) hereby requests an alternative to specific portions of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code,Section XI, "Rules for In-service Inspection of Nuclear Power Plant Components," on the basis that the prop~osed alternatives provide ah acceptable level of quality and safety. The request is summarized below. More specific details are provided in Attachment 1.

For the Fifth 10-Year Inspection Interval, Entergy is required to update the PNPS 120-month (10-Year Interval) Inservice Inspection Program in accordance with 10 CFR 50.55a(g)(4) with the latest Section XI Edition and Addenda incorporated by reference in 10 CFR 50.55a(a)(1)(ii)

Which is the Section XI, 2007 Edition with the 2008 Addenda of the ASME Boiler and Pressure Vessel Code, (Code of Record). Section Xl repair/replacement, pressure testing and nondestructive testing activities at PNPS are being maintained to the 2001 Edition through the 2003 Addenda for the Fifth 10-Year Interval until December 31, 2017 using Alternative Request PRR-26, which was NRC approved on June 19, 2015 (TAC NO. ME5432). As such, 10 CFR 50.55a(b)(2)(xv) requires that PNPS apply the 2001 Edition, no Addenda, in lieu of the 2001 Edition through the 2003 Addenda for Appendix VIII Supplement 11 qualification requirements.

This alternative request is being submitted for authorization because the current Entergy fleet procedures that implement ASME Section XI at PNPS will not be updated from the 2001 Edition through the 2003 Addenda until after December 31, 2017. Implementation of Appendix VIII Supplement 11 requirements of the 2001 Edition using the alternatives based on the use of the Performance Demonstration Initiative Program requirements in this request are still needed at PNPS when using the 2001 Edition through the 2003 Addenda of Section Xl.

PNPS Letter 2.15. 063 Page 2 of 2 Pursuant to 10 CFR 50.55a(z)(1 ), PNPS requests approval to implement an alternative to ASME Section XI, Appendix VIII, Supplement 11 for Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds. See Attachment 1 for additional details.

There are no new commitments included in this document.

If you have questions concerning this letter, please contact me at 508-830-8323.

Sincerely, Everett (Chip) P. Perkins, Jr.

Manager, Regulatory Assurance EPP/mw

Attachment:

1. Pilgrim Nuclear Power Station 10 CFR 50.55a Request No. PRR-53, "Proposed Alternative in Accordance with 10 CFR 50.55a(z)(1 ) to ASME Section Xl, Appendix VIII, Supplement 11 for Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds" (16 Pages) cc:

Mr. Daniel H. Dorman Regional Administrator, Region I U.S. Nuclear Regulatory Commission 2100 Renaissance Blvd., Suite 100 King of Prussia, PA 19406-2713 Mr. Richard V. Guzman, Project Manager Division of Operating Reactor Licensing Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Mail Stop O-8-F2 11555 Rockville Pike Rockville, MD 20852 USNRC Senior Resident Inspector Pilgrim.Nuclear Power Station

ATTACHMENT 1 TO LETTER 2.15.063 Pilgrim Nuclear Power Station 10 CFR 50.55a Request No. PRR-53, "Proposed Alternative in Accordance with 10 CFR 50.55a(z)(1) to ASME Section XI, Appendix VIII, Supplement 11 for Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds" (16 Pages)

Pilgrim Nuclear Power Station 10 CFR 50.55a Request No. PRR-53, "Proposed Alternative in Accordance with 10 CFR 50.55a(z)(1) to ASME Section XI, Appendix VIII, Supplement 11 for Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds"

1. ASME Code Component(s) Affected Code Class:

1 Component Numbers:

Various for Piping Welds Code

References:

Appendix VIII, Supplement 11 Examination Category:

Various for Piping Welds Item Number(s):

Various for Piping Welds

==

Description:==

Alternative requirements to ASME Section XI, Appendix VIII, Supplement 11 Unit/Inspection Interval:

Pilgrim / Fifth 10-Year Interval July 1, 2015-June 30, 2025

2. Applicable Code Requirement

10 CER 50.55a(g)(6)(ii)(C) Augmented ISI requirements: Implementation of Appendix VIII to Section XI; provides the requirements for the implementation of Appendix VIII and the Supplements to Appendix VIII to Section XI, Division 1, 1995 Edition with the 1996 Addenda. For the Fourth 10-Year Interval Pilgrim Nuclear Power Station (PNPS) met these requirements using the 2001 Edition of Section Xl for Appendix VIII that was required in accordance with 10 CER 50.55a(b)(2)(xv) with an authorized alternative request for the Supplement 11, "Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds," in accordance with Reference 1.

For the Fifth 10-Year Inspection Interval, Entergy is required to update the PNPS 120-month (10-Year Interval) Inservice Inspection Program in accordance with 10 CFR 50.55a(g)(4) with the latest Section XI Edition and Addenda incorporated by reference in 10 CFR 50.55a(a)(1 )(ii) which is the 2007 Edition with the 2008 Addenda of the ASME Boiler and Pressure Vessel Code, (Code of Record).Section XI repair/replacement, pressure testing and nondestructive testing activities at PNPS are being maintained to the 2001 Edition through the 2003 Addenda for the Fifth 10-Year Interval until December 31, 2017 using Alternative Request PRR-26, Reference 2 which was NRC approved on June 19, 2015 (TAC NO. ME5432). As such, 10 CFR 50.55a(b)(2)(xv) requires that PNPS apply the 2001 Edition, no Addenda, in lieu of the 2001 Edition through the 2003 Addenda for Appendix VIII Supplement 11 qualification requirements. - Page I of 16

3. Reason for Request

This alternative request is being submitted for authorization because the current Entergy fieet procedures that implement ASME Section XI at PNPS will not be updated from the 2001 Edition through the 2003 Addenda until after December 31, 2017 in accordance with Reference 2. Implementation of Appendix VIII Supplement 11 requirements of the 2001 Edition using the alternatives based on the use of the Performance Demonstration Initiative (PDI) Program requirements in this request are still needed at PNPS when using the 2001 Edition through the 2003 Addenda of Section XI.

The industry utilizes the PDI program for the qualification of equipment, procedures and personnel. The PDI Program does not meet all aspects of the Code requirements identified in ASME Section Xl, Appendix VIII, Supplement 11 of the 2001 Edition or the latest edition and addenda referenced in 10 CFR 50.55a(a)(1)(ii). As a result, other alternative requests have been authorized throughout the industry for the implementation of the PDI Program requirements in lieu of Supplement 11 and PNPS needs the authorization of this request to use the requirements of the PDI program, which have been incorporated into the PNPS alternative requirements to Supplement 11 in Table 1 of this Attachment.

4. Proposed Alternative and Basis for Use

Proposed Alternative Pursuant to 10 CFR 50.55a(z)(1 )this alternative request is being submitted for authorization because it represents an acceptable level of quality and safety for the requirements associated with Qualification for Structural Overlaid Wrought Austenitic Piping Welds covered under the 2001 Edition of Section Xl, Appendix VIII, Supplement 11. The PNPS

.... alternative requirements in this request provide qualification requirements for detection and length and depth sizing for both service-induced and fabrication-induced flaws. They are applicable for wrought austenitic, ferritic or dissimilar metal welds, overlaid with austenitic weld material. The alternative requirements to be used in accordance with this request are outlined below with their technical bases and are shown in Table 1 of this Attachment.

Basis for Use Compliance with the proposed alternatives in this request, versus those in the 2001 Edition of ASME Section Xl, Appendix VIII, Supplement 11, are needed to support qualification requirements for the examination of weld overlays if overlays are applied during the proposed duration of this request. - Page 2 of 16

The title of ASME Section Xl, Supplement 11 in the 2001 Edition is "Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds." When originally written, this was accurate for the extent of usage of weld overlay "Full Structural Weld Overlay" repairs. However, the use of weld overlays has broadened. Weld overlays are now being designed that are not intended as full-structural replacements "Optimized Weld Overlays" to the original weld and base material. In addition, weld overlays are now being applied in the industry over cast austenitic stainless steel piping welds, as well as those in wrought material. Therefore, the PNPS alternative requirements in Table 1 have been broaden to include the PDI Program requirements that would now be applicable for these new covered conditions.

PNPS has no optimized weld overlays at this time and has no plans to apply any full structural weld overlay or optimized weld overlay repairs for the duration of this request.

However, there are three full structural weld overlays that have been applied at PNPS and they will be examined with qualified and demonstrated, personnel, equipment, and procedures that are to be used based on the alternatives contained in this request. If any new optimized or full structural weld overlays are needed to be applied, then the alternative requirements in this request will be used.

The PNPS alternative requirements to be used in accordance with this request are outlined below with basis statements that support the changes as follows and they are shown in Table I of this Attachment.

1) A scope statement has been added to reflect the applicability of Supplement 11.

The 2001 Edition, Supplement 11 has no scope statement. This would lead one to believe that the title contained the scope of the Supplement. However, In order to provide a true description of the content of the PNPS alternative a Scope statement has been added which reflects the new content of the pr'oposed requirements.

2) The names of the grading units were changed from base metal and overlay fabrication to inservice and preservice, respectively.

Originally, Supplement 11 was written to cover the examination of weld overlay repairs of Boiling Water Reactor (BWR) recirculation piping welds, which were applied due to Stress Corrosion Cracking (SCC). At the time, SCC cracking was only occurring in the base metal adjacent to the weld (in the heat affected zone). Therefore, for qualification purposes, it was appropriate to refer to the grading units intended to contain cracking in the original pipe as "base metal" grading units.

Although PNPS is a BWR, mechanisms have been discovered, subsequently, that cause cracking not only in the base metal, but also in the weld and buttering of these types of welds. Overlays are being applied to welds in Pressurized Water Reactors, as well, where the cracking is primarily found in the weld and buttering material. - Page 3 of 16

Therefore, it is now more appropriate to call the grading unit for the original piping as an "inservice" grading unit, which is a broad enough term to encompass flaws in the base material or weld material. Since the term for grading units in the original piping.was being changed to "inservice", it is appropriate to change the term for grading units intended to contain fabrication related discontinuities in the weld overlay (i.e. bonding and weld cleanliness) to "preservice." It is during the preservice inspection that these indications are expected to be discovered.

3) The term base metal flaws was changed to service-induced flaws and the term overlay fabrication flaws was changed to fabrication-induced flaws in this This alternative request proposes using "service-induced flaws" as an alternative to the term "base metal flaws" and "fabrication-induced flaws" as an alternative to "overlay fabrication flaws" to describe the flaw types to make them broad enough to encompass all currently recognized degradation mechanisms.

4) Provisions have been added for qualification of "Optimized" weld overlays.

The qualification requirements provided in ASME Section Xl, Appendix VIII, Supplement 11, were written strictly for weld overlay repairs designed as full structural replacements for the original weld and base material beneath them. The volumetric examination coverage

• required for full structural weld overlays was the thickness of the overlay, plus the outer 25%

of the original weld and base material. Since that time, the industry has begun to use overlay repairs on larger piping systems, for which full structural overlays are not practical, due to the weight they would add to the piping system and the time it would take to install them. These new "Optimized" weld overlays are thinner and are designed as a partial structural replacement to the original piping. They are only designed as a repair for up to a 75% through-wall circumferential crack, instead of a 100% through-wall crack. Because of this, the volumetric examination requirements have also been increased to include the outer 50% of the original base material (a 25% increase over the previous requirement). The proposed alternatives contain provisions to allow for qualification of this extended examination volume.

5) Qualification for width sizing of laminar flaws is now addressed.

The acceptance criteria for laminar flaws in a weld overlay repair are based upon, among other things, the total area of the flaw. However, Supplement 11 only contains provisions for length sizing and is silent on qualification for width sizing. The common technique for both length sizing and width sizing of laminar flaws is to map the edges of the flaw using a 00 (straight beam) transducer. There is virtually no difference in these measurements in terms of axial versus circumferential directions. Therefore, this alternative request includes a clarifying sentence for the qualification for both length and width sizing of laminar flaws. - Page 4 of 16

5. Duration of Proposed Alternative

This request will apply to a portion of the Fifth 10-Year Interval, which starts on July 1, 2015 and will continue to December 31, 2017, which coincides with the proposed duration of the Alternative Relief Request PRR-26, Reference 2.

6. Precedents

NRC Letter to NextEra Energy, "St. Lucie Plant Unit No. 2 - Fourth 10-Year Inservice Inspection Interval Relief Request No. 3, Revision 0 (TAC NO. MF4398)," dated June 3, 2015 [ADAMS Accession No. ML15111A357]

7. References

1. NRC Letter to Entergy, 'Pilgrim Nuclear Power Station Relief Request No. PRR-9 (TAC NO. MC8292)," dated March 22, 2006 [ADAMS Accession No. ML060240055]

2. NRC Letter to Entergy, "Pilgrim Nuclear Power Station Re: Request for Alternative (PRR)-26, Fifth 10-Year Inservice Inspection Interval (TAG No. ME5432)," dated June 19, 2015 [ADAMS Accession No. ML15166A401]

8. Attachments Table 1: Section XI, 2001 Edition, Appendix VIII, Supplement 11 Requirements vs.

PNPS Alternative Requirements. - Page 5 of 16

Section Xl,200:1 *Edition, Appendix: VlllI, Supplemenet 1 NSAtraieRqirmnst upeet1 NONE 1 SCOPE This alternative provides qualification requirements for detection and length and depth sizing for both service-induced and fabrication-induced flaws. It is applicable for wrought austenitic, ferritic, or dissimilar metal welds, overlaid with austenitic weld material.

1.0 SPECIMEN REQUIREMENTS 2 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the requirements listed Qualification test specimens shall meet the requirements listed herein, herein, unless a set of specimens is designed to accommodate unless a set of specimens is designed to accommodate specific specific limitations stated in the scope of the examination procedure limitations stated in the scope of the examination procedure (e.g., pipe (e.g., pipe size, weld joint configuration, access limitations). The size, weld joint configuration, and access limitations). The same same specimens may be used to demonstrate both detection and specimens may be used to demonstrate both detection and sizing sizing qualification, qualification.

1.1 General. The specimen set shall conform to the following 2.1 General. The specimen set shall conform to the following requirements.

requirements.

(a) Specimens shall have sufficient volume to minimize spurious (a) Specimens shall have sufficient volume to minimize spurious reflections that may interfere with the interpretation process.

reflections that may interfere with the interpretation process. - Page 6 of 16

(b) The specimen set shall consist of at least three specimens (b) The specimen set shall consist of at least three specimens having having different nominal pipe diameters and overlay thicknesses, different nominal pipe diameters and overlay thicknesses. They shall They shall include the minimum and maximum nominal pipe include the minimum and maximum nominal pipe diameters for which diameters for which the examination procedure is applicable. Pipe the examination procedure is applicable. Pipe diameters within a diameters within a range of 0.9 to 1.5 times a nominal diameter shall range of 0.9 to 1.5 times a nominal diameter shall be considered be considered equivalent. If the procedure is applicable to pipe equivalent. If the procedure is applicable to pipe diameters of 24 in.

diameters of 24 in. (610 mam) or larger, the specimen set must (600 mam) or larger, the specimen set must include at least one 24 in.

include at least one specimen 24 in. (610 mam) or larger but need not (600 mam) or larger but need not include the maximum diameter. The include the maximum diameter. The specimen set must include at specimen set must include at least one specimen with overlay not least one specimen with overlay thickness within -0.1 in. to +0.25 in.

thicker than 0.1 in. (2.5 mm) more than the minimum thickness, and at

(-2.5 mm to +6 mm) of the maximum nominal overlay thickness for least one specimen with overlay not thinner than 0.25 in. (6 mam) less which the procedure is applicable.

than the maximum thickness for which the examination procedure is applicable.

(c) The surface condition of at least two specimens shall (c) The surface condition of at least two specimens shall approximate approximate the roughest surface condition for which the the roughest surface condition for which the examination procedure is examination procedure is applicable.

applicable. - Page 7 of 16

TABLE 1:SECTION X,2001 EDITON, ScinX,01EiinApedxVISplmnPNSAlternative Requ~irements to Supplement 11i,:.,: ! ': ;* ii inspection (PSi) grading units.

(1) [SI Grading Unit. A grading unit designed to include a portion of the original weld and base material and the weld overlay material above it and designed to contain service-induced flaws (cracks).

(2) PSI Grading Unit. A grading unit designed to include a portion of the weld overlay, including the interface between the weld overlay and the original weld and base material, and designed to contain fabrication-induced flaw types (e.g.,

interbead lack of fusion, laminar lack of bond, cracks).

(1) Base metal flaws. All flaws must be cracks in or 2.2 Service-Induced Flaws. Service-induced flaws shall be in or near the weld, near the butt weld heat-affected zone, open to the inside buttering, or heat-affected zone, and open to the inside surface. The examination surface, and extending at least 75% through the base procedure shall specify the examination volume. If the examination procedure metal wail. Flaws may extend 100% through the base specifies an examination volume greater than the outer 25% of the base metal wail metal and into the overlay material; in this case, thickness, the detection and sizing test sets shall include at least five representative intentional overlay fabrication flaws shall not interfere flaws suitable to demonstrate the procedure capability in this extended volume.

with ultrasonic detection or characterization of the Intentional fabrication-induced flaws shall not interfere with ultrasonic detection or cracking. Specimens containing IGSCC shall be used characterization of service-induced flaws. At least 70% of the flaws in the detection when available.

and sizing tests shall be cracks. Specimens containing stress corrosion cracking (SCC) shall be used when available.

If implantation of actual cracks produces spurious reflectors not characteristic of actual flaws, alternative flaws may be used but shall comprise not more than 30% of the total service-induced flaws. Alternative flaw mechanisms, if used, shall provide crack-like reflective characteristics. The shape of the alternative flaw is intended to simulate the growth pattern of actual flaws and may be semi-elliptical. The tip width of the alternative flaws shall not exceed 0.002 in. (0.05 mm). - Page 8 of 16

APEDXVISPLMN iRQIEET S NSATRNATiVE REQUIREMENTS:

.;:,;::*section XlI, 2001: Edition, Appendix VIII, *Supplement 11 PP AtrntveRqurmet t uplmet1 (2) Overlay Fabrication Flaws. At least 40% of the flaws shall be 2.3 Fabrication-induced Flaws. At least 40% of the flaws used in non-crack fabrication flaws (e.g., sidewall lack of fusion or laminar detection and length sizing test sets shall be noncrack fabrication flaws lack of bond) in the overlay or the pipe-to-overlay interface. At least (e.g., interbead lack of fusion or laminar lack of bond) in the overlay or 20% of the flaws shall be cracks. The balance of the flaws shall be the pipe-to-overlay interface. At least 20% of the flaws shall be cracks of either type.

wholly contained in the overlay. Depth sizing test sets shall contain only planar flaws, such as interbead lack of fusion or cracks that have a major dimension perpendicular to the overlay surface.

(e) Detection Specimens 2.4 Detection Specimens (1) At least 20% but less than 40% of the flaws shall be oriented (a) At least 20% but less than 40% of the service-induced flaws shall within +20 deg. of the pipe axial direction. The remainder shall be be oriented within 20 deg. of the pipe axial direction. The remainder oriented circumferentially. Flaws shall not be open to any surface to shall be oriented circumferentially. Flaws shall not be open to any which the candidate has physical or visual access. The rules of surface to which the candidate has physical or visual access.

IWA-3300 shall be used to determine whether closely spaced flaws should be treated as single or multiple flaws. - Page 9 of 16

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i TABLE 1: SECTION XI, 2001 EDITION, APPENDIX VIii,, SUPPLEM~ENT 11: REQUIREMENTS VS. PNPS ALTERNATIVE REQUIREMENTS

• i 'Section XI, 2001 Edition, Appendix VIiI, Supplement 11:...

PNPS-Alternative Requirements to Supplement 11 (Requirements).

(Based on PDI Program Requirements) - See Note (1)

(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 shall include at least 3 in. of 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 metal-to-overlay interface.

(2) When base metal cracking penetrates into the overlay material.

The base grading unit shall include the overlay metal within 1 in. (25 mm) of the crack location. This portion of the overlay material shall not be used as part of any overlay grading unit.

(3) When a base grading unit is designed to be unflawed, at least 1 in. (25 mm) 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. (3871 mm2).

The overlay grading unit shall be rectangular, with minimum dimensions of 2 in. (51 mm).

(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. (25 mm) 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.

(b) 1SI Grading units include the overlay material and the examination volume specified in the examination procedure. ISI grading units shall extend circumferentially for at least 1 in. (25 mm) and shall start at the weld centerline and shall be wide enough in the axial direction to encompass one-half of the original weld crown and at least 1/2 in. (13 mm) of the adjacent base material. The grading units shall be of various sizes. For an axially-oriented discontinuity, the axial dimension of the 1SI grading unit may encompass the original weld crown and at least 1/ in. (13 mm) of both adjacent base materials.

(1) If service-induced flaws penetrate into the overlay material, the 1SI grading unit shall not be used as part of any PSI grading unit.

(2) Sufficient unflawed area shall exist on all sides of the grading unit to preclude interfering reflections from adjacent flaws.

(c) PSI grading units shall include the overlay material and the overlay-to-component interface for a length of at least 1 in. (25 mm).

(d) PSI grading units designed to be unflawed shall be separated by u nflawed overlay material and unflawed overlay-to-component interface for at least 1 in. (25 mm) at both ends. Sufficient unflawed overlaid weld and base metal shall exist on both sides of the PSI grading unit to preclude interfering reflections from adjacent flaws. The specific area used in one PSI grading unit shall not be used in another PSI grading unit. PSI grading units need not be spaced uniformly about the specimen. - Page 10 of 16

TABLE 1: SECTION XI, 2001 EDITION, APPENDIX VIII, SUPPLEMENT 11 REQUIREMENTS VS. PNPS ALTERNATIVE REQUIREMENTS (3) Detection sets shall be selected from Table VIII-S2-1. The (e) Detection sets shall be selected from Table V111-82-1. For PSi and minimum detection sample set is five flawed base grading units, ten ISI grading units, the sets shall contain at least twice as many unflawed unflawed base grading units, five flawed overlay grading units, and as flawed grading units.

ten unflawed overlay grading units. For each type of grading unit, (1) If PSI and ISI qualifications are performed in combination, the the et hal conainat eas twie a may uflawd a flweddetection sample set shall contain at least ten flawed ISI grading units grading units.

and five flawed PSI grading units.

(2) If PSI or ISI qualifications are performed separately, the detection sample set shall contain at least ten flawed ISI grading units or ten PSI grading units, as applicable.

(f) Sizing Specimen 2.5 Sizing Specimens (1) The minimum number of flaws shall be ten. At least 30% of the (a) Sizing sample sets shall contain at least ten flaws. At least 30% of flaws shall be overlay fabrication flaws. At least 40% of the flaws the flaws shall be fabrication-induced flaws. At least 40% of the flaws shall be cracks open to the inside surface.

shall be service-induced flaws and shall be open to the inside surface.

Sizing sets shall contain a representative distribution of flaw dimensions that cover the examination volume specified in the examination procedure.

(2) At least 20% but less than 40% of the flaws shall be oriented (b) At least 20% but less than 40% of the service-induced flaws shall axially. The remainder shall be oriented circumferentially. Flaws be oriented axially. The remainder shall be oriented circumferentially.

shall not be open to any surface to which the candidate has physical Flaws shall not be open to any surface to which the candidate has or visual access.

physical or visual access.

(3) Base metal cracking used for length sizing demonstrations shall (c) Flaws used for length sizing demonstrations shall be oriented be oriented circumferentially, circumferentially.

(4) Depth sizing specimen sets shall include at least two distinct (d) Depth sizing specimen sets shall include at least two distinct locations where cracking in the base metal extends into the overlay locations where a service-induced flaw extends into the overlay material by at least 0.1 in. (2.5 mm) in the through-wall direction.

material by at least 0.1 in. (2.5 mm) in the through-wall direction. - Page 11 of 16

I,:TABLE 1: SECTION: Xl, 2001 EDITION,:

APPENDIX VIII, SUPPLEMENT 11 REQUIREMENTS VS. PNPS ALTERNATIVE REQUIREMENTS o : Section Xl, 2001 Edition, Appendix VIII, Supplementl;,,

11

• ,i;.~ ;i:i PNPS Alternative *Requirements to Supplement 11".

(Requirements)

'

i.';* i*i":/: ;,(Based on PDiProgram Requiremnents) -See Note (1) 2.0 CONDUCT OF PERFORMANCE DEMONSTRATIONS 3 PERFORMANCE DEMONSTRATION The specimen inside surface and identification shall be concealed The specimen inside surface and identification shall be concealed from from the candidate. All examinations shall be completed prior to the candidate. All examinations shall be completed prior to grading the grading the results and presenting the results to the candidate, results and presenting the results to the candidate. Divulgence of Divulgence of particular specimen results or candidate viewing of particular specimen results or candidate viewing of unmasked unmasked specimens after the performance demonstration is specimens after the performance demonstration is prohibited. PSI and prohibited.

ISI detection tests may be administered separately. When administered separately, the criteria in 3.1 shall be satisfied separately by the demonstration results for ISI grading units and for PSI grading units.

2.1 Detection Test. Flawed and unflawed grading units shall be 3.1 Detection Test randomly mixed. Although the boundaries of specific grading units

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nlwdgaiguissalb admymxd shall not be revealed to the candidate, the candidate shall be made altog thaed bondarniwesdfseii grading units shall no be r evealymi ed.

aware of the type or types of grading units (base or overlay) that are to the candidate, the candidate shall be made aware of the type or present for each specimen.

types of grading units (ISI or PSI) in each specimen.,

(b) Examination equipment and personnel shall be considered qualified for detection if the results of the performance demonstration satisfy the acceptance criteria of TableVlII-S2-1 for both detection and false calls.

(c) If the procedure is intended to be used to examine greater than the upper 25% of the original pipe volume, a candidate for personnel qualification shall not fail to detect more than one of the flaws located in

____________________________________________the extended volume. - Page 12 of 16

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2.2 Length Sizing Test 3.2 Length Sizing Test (a) The length sizing test may be conducted separately or in (a) The length sizing test may be conducted separately or in conjunction with the detection test.

conjunction with the detection test.

(b) When the length sizing test is conducted in conjunction with the (b) When the length sizing test is conducted in conjunction with the detection test and the detected flaws do not satisfy the requirements detection test and the detected flaws do not satisfy the requirements of of 1.1(f), additional specimens shall be provided to the candidate.

2.5, additional specimens shall be provided to the candidate. The The regions containing a flaw to be sized shall be identified to the regions of the additional specimens containing flaws to be sized shall candidate. The candidate shall determine the length of the flaw in be identified to the candidate provided it does not compromise the eachhofth region.h egon (c) For a separate length sizing test, the regions of each specimen (c) For a separate length sizing test, the regions of each specimen containing a flaw to be sized shall be identified to the candidate, containing flaws to be sized shall be identified to the candidate The candidate shall determine the length of the flaw in each region.

provided it does not compromise the sample or data set confidentially.

The candidate shall determine the length of the flaw in each region.

(d) For flaws in base grading units, the candidate shall estimate the (d) For flaws in ISI grading units, the candidate shall estimate the length of that part of the flaw that is in the outer 25% of the base wall length of that part of the flaw that is in the examination volume thickness.

specified in the examination procedure.

(e) Examination procedures, equipment, and personnel are qualified for length sizing if the RMS error of the circumferential flaw length measurements, as compared to the true circumferential flaw lengths, is not more than 0.75 in. (19 mam). The length of a service-induced flaw is measured in accordance with 3.2(d).

(f) Examination procedures, equipment, and personnel qualified for length sizing in accordance with 3.2(a) through 3.2(e) are considered qualified for both length and width sizing of laminar flaws. - Page 13 of 16

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-See Note (,1)*,i 2.3 Depth Sizing Test. For the depth sizing test, 80% of the flaws 3.3 Depth Sizing Test shall be sized at a specific location on the surface of the specimen

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ea hcns bv h identified to the candidate. For the remaining flaws, the regions of flaw (ie.,h remining liamnsit) and meayuin be codeda shckeparatoel ori each specimen containing a flaw to be sized shall be identified to the conjuncion. weaiith thegdeetioand test.odctdspaaey r

candidate. The candidate shall determine the maximum depth of cnucinwt h eeto et the flaw in each region.

(b) If the depth sizing test is conducted in conjunction with the detection test, and the detected flaws do not satisfy the requirements of 2.5, additional specimens shall be provided to the candidate. The regions of the additional specimens containing flaws to be sized shall be identified to the candidate provided it does not compromise the sample or data set confidentiality. The candidate shall determine the maximum depth of the flaw in each region.

(c) For a separate depth sizing test, the regions of each specimen containing flaws to be sized shall be identified to the candidate provided it does not compromise the sample or data set confidentiality.

The candidate shall determine the maximum depth of the flaw in each region.

(d) Examination procedures, equipment, and personnel are qualified for depth sizing if the RMS error of the flaw depth measurements, as compared to the true flaw depths, is not more than 0.125 in. (3.3 mam). - Page 14 of 16

3.0 ACCEPTANCE CRITERIA ACCEPTANCE CRITERIA has been incorporated, revised or no longer addressed in the requirements above as compared to Section Xl, 2001 Edition, Appendix VIII, Supplement 11.

3.1 Detection Acceptance Criteria. Examination procedures, Incorporated in 3.1 and specifically revised in 3.1(b).

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, Incorporated in 3.2 and specifically revised in 3.2(b).

equipment, and personnel are qualified for sizing when the results of the performance demonstration satisfy the following criteria.

(a) The RMS Error of the flaw length measurements, as compared to the true flaw lengths, is less than or equal to 0.75 inch (19 mam).

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 Incorporated and revised in 2.4(b)(1 ) and 2.5(d) with no requirement to by at least 0.1 in. (2.5 mm) are reported as being intrusions into the report intrusions into the overlay material, but to address them under overlay material, the current detection and sizing specimen requirements.

(c) The RMS error of the flaw depth measurements, as compared to Incorporated and revised in 3.3(d).

the true flaw depths, is less than or equal to 0.125 in. (3.2 mm).

_____________________________ - Page 15 of 16

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AP. PENDIX VIII, SUPPLEMEN 11REQUIEMNT V.PNPS *AETERNAT!VE REQUIREMENTS;.*i!i;:i.,= ;%.i

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NONE 4 PROCEDURE QUALIFICATION In addition to the requirements of 2 and 3, procedure qualification shall satisfy the following:

(a) The specimen set shall include the equivalent of at least three personnel performance demonstration test sets. Successful personnel performance demonstrations may be combined to satisfy these requirements.

(b) Detectability of all flaws in the procedure qualification test set within the scope of the procedure shall be demonstrated. Length and depth sizing shall meet the requirements of 3.2 and 3.3.

(c) At least one successful personnel demonstration shall be performed.

(d) To qualify new values of essential variables, the test set shall include the equivalent of one personnel test set. The acceptance

_______________________________________________criteria of 4(b) shall be met.

Notes: (1) The "italicized" PNPS alternative requirement is the same as the Section XI, 2001 Edition, Appendix VIII, Supplement 11 requirement and no change has been made. - Page 16 of 16