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PROCEDURE NO. 80A0480'
SUBJECT: AUTO RPV WELDSPAGE 1 0F 29
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AUTOMATED ULTRASONIC EXAMINATION PROCEDURES ,' :
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FOR REACTOR VESSEL WELDS . l',-- :, ,
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. .LONG ISLAND LIGHTING COMPANY . ..,
SHOREHAM NUCLEAR POWER STATION -
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2" G~7 bPrep'd by. .
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Project M r. Y Date
Z- 9 -WREV. NO. DATE NES - 'Mgr. ISI Level 111 Date
L.A U = ~//rs =/ir/7i~_ 0 2-15-78 NES. ISIPro6ramMgr. Level |Ii
Date
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7 9 0 3 2 9 0 0c2e Ei NUCLEAR ENERGY SERVICES. INC.
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PROCEDURE NO. 80A0480f ,SUBJECT: AUTO RPV WELDSPAGE 2 0F g
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. '. :IJ , 3, yRECORD OF REVISIONS
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Aco'd BvPrep'dRev. - ,No. Date Description Reason - By Ngs t t
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./ @A' 'c -q x.$1 11/78 Revise: LILCO Cor.ments, CRA-569 a i[ 8
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5.6 &5.6.1-5.6.5 _ _ . ,, . .
Add: -
2.3 (2) Manual I;o.
80A0658 .,2.2 (3) Manual tio. .
Y'- 85A096- -
" 7.5. 3 (1) the word " check' -'
7.54(2) the word " check' .75.5(1) the word " check"
'8.1.l(3)"In the 0
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straight beam...._
calibration." .
8.2.l(3)" Verify that allpoints on the sweep .
line are within plusor minus St. of the ful:equalized
response
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sweep lino."
8.2.2 (1)" . . .and horizon- .tal positions."
8. 2. 2 (2) " . . . and thehorizontal displacementis within the
require. - .
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plus or minus 5%." i1<
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Delete: . _ . . _, ...: _
8.1. l (3) " . . . entire . . .- --
(0-8 horizontal divi-sions).
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PROCEDURE NO. 80A0480SUBJECT: AUTO RPV WELDSPAGE 5 0F 29
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(1) Nuclear Reflectoscope, Data Acquisition and ~ 'Control
System, 854100-1, operating and . _
';'Maintenance Manual, No. TM-73-14N, Rev. O,November, 1973 . ,
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(2) BWR Vessel Scanner, Operating and Maintenance *,
d t th^
Manual No. 80A0658.' - '
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(3) Data Analysis System, instruction Manual No. 85A096.
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3.0 PROCEDURE CERTIFICATION~
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The examination procedures described in this document comply
with SectionXI of the ASME Boiler and Pressure Vessel Code, 1971
Edition includingSummer 1972 Addenda, except where examination
coverage is limited by partgeometry or access. - .
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4.0 PERSONNEL CERTIFICATION , ,.
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4.1 Personnel Certification Requirements
4.1.1 Each person performing ultrasonic examination governed
bythis procedure shall be certified in accordance with the
~~ References 2.1 (1) , 2;.1 (3) and 2.1 (4).,
4.1.2 An examination crew shall consist of three or more
membersas needed. At least one member of each crew shall have
aminimum qualification of Level 11 in accordance with theabove
referenced documents. The remaining member (s) shallconsist of one
with a minimum qualification of Level I and
a mechanical / electronic technician.. .
4.2 Personnel Records
4.2.1 P.ecords of personnel qualification shall be maintained
byExamination Contractor. - -
4.2.2 A copy of the examiner's certification summary and a
currenteye test as required by SNT-TC-1A shall be filed with
each
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permanent examination record, with a copy submitted to the
-~plant owner or his agent, prior to performing examinationper this
procedure.
5.0 EXAMINATION REQUIREMENTS _4
5.1 . Examination Frequency
5.1.1 The nominal examination frequency shall be 2.25 MHz for
allstraight beam and angle beam examinations.
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PROCEDURE NO. 80A0480
SUBJECT: AUTO RPV WELDS' PAGE 13 OF 29
8.2.2 Performance checks of search units and cables as required
by'
Section 7.4.4 shall be performed as follows:. ,
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(1) Re-position search unit on the Calibration Standard at-
each test hole and observe maximum signal response
amplitude21sand horizontal positions. q. ,
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PROCEDURE NO. 80A0480'
SUBJECT. AUTO RPV WELDSPAGE 12 OF 29
(5) Program a TUC card to match the Distance Amplitude
Curveestablished in (2) above.
(6) Program a DAC card to electronically equalize all TUC
responsesto the specified (80% FSH) amplitude over the entire depth
rangeto be used during the examination. The sensitivity
establishedhere is the reference sensitivity.
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(7) Record all information required on the Calibration Data
Sheet (s).The ultrasonic examiner or examiners shall sign the
completedCalibration Data Sheet (s) noting their applicable
SNT-TC-1A levels.
(8) Assign each TUC card a sequential I.D. number from the TUC
CardLog and properly store each calibrated TUC Jard and
DACCalibration Data Sheet for subsequent use.
(9) Repeat steps (1) thru (9, for each of the instrument
receiversections used.
(10) Adjust amplitude recording gate levels to trigger at
thespecified limits (40% to 80%) if examinations are to be
performedimmediately.
8.2 System Calibration Check
8.2.1 Calibration checks of the examination system as required
by Section7.'4.3 shall be performed as follows:
(1) If not already running, equipment shall be allowed a minimum
of15. minutes warm-up.
(2) Refer to the proper Calibration Data Sheets for
requiredinstrument settings.
(3) Use appropriate TUC cards and DAC settings and perform a
checkof the examination instrumentation system including
sensitivitylevel, depth gate function and position, and digital
print system.Verify that the amplitude response is within plus or
minus 20% ofthe- Equalized Response obtained during initial
calibration. Verify.that all points on the sweepline are within
plus or minus 5% of dhthe full equalized response sweep line.
(4) If the response is beyond the allowed tolerance, refer
toSection 7.5.
OAle NUCLEAR ENERGY SERVICES, INC.
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PROCEDURE NO. 80A0480SUBJECT: AUTO RPV WELDS
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7.5.5 If any point on the Equalized Response has moved
horizontally morethan 5% of the sweep line from its original
settings, the examinershall
(1) Mark all Weld Scan Data Sheets " VOID" since previous
calibration
check which have recorded indications. /h
(2) Recalibrate examination system.
(3) Re-examine voided areas.
8.0 EXA*1IMATION SYSTEM CALIBRATION
8.1 Basic System Calibration for Anale and Straight Beam
8.1.1 Basic examination system calibration settings and
parameters mayLe established at any time prior to the examination
of reactorvessel welds. Initial calibration shall consist of the
following:
(1) Adjust instrument sweep range to correspond with the areato
be covered during the examination. For initial calibration,
the 1/4T hole indication from the calibration standard
shalloccur at the second horizontal screen position; the 1/2Tand
3/4T indications shall occur respectively at the fourthand sixth
horizontal screen positions. For angle beamexamination where
detection is possible, the far surfacenotch shall occur at or near
the 8th position.
(2) Establish actual Distance Amplitude Curve for each angle
andexamination depth combination by plotting the signal
responseamplitudes from the 1/4T, 1/2T and 3/4T reference holes
whilethe highest response hole indication is set at 80% of
FullScreen Height (FSH) as shown in Figure 7.
(3) Adjust depth gate positions to cover the examination
range.~
In the O straight beam channel, water path indications existdue
to the construction of the search unit. Normally the firstwater
path indication occurs at or near CRT position zero (0) .This
position of the water path indication will vary depending 7on
examination thickness. Normal examination practice is tomonitor
(set gates) from the trailing edge of the water path(entry echo) to
the leading edge of the thickness back reflection.As this is not
necessarily CRT positions 0-8, the precisesetting is best left to
the examiner (s) at the time of systemcalibration.
(4) Connect TUC to proper channel and place one TUC pulse in
eachdepth gate.
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PROCEDURE NO. 80A0480SUBJECT: AUTO RPV WELDSPAGE 10 0F 29
7.4.2 Instrnment vertical linearity checks for each of the
receiversused shall be performed at the beginning of each day of
examina-tion in accordance with the applicable sections of the
procedurereferenced in paragraph 2.1 (5). Data shall be recorded
asrequired within the Check Sheet, Figure 10.
7.4.3 Examination system calibration checks using the TUC shall
be. performed at least at the beginning and at the completion of
ecch4 hour period of examination and/or at the change of
examinationpersoanel, and at the completion of the examinations of
eachsimilar series of welds. Checks shall be made in accordancewith
Section 8.2.1 of this procedure.
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7.4.4 Performance of the search unit sleds and coaxial cables
shallbei verified each time the sled and cables are removed f
romthe examination area. Should an examination scan overlap
twoshifts, these checks should not interrupt the scan but shallbe
performed as soon as possible after the scan is completed(Refer to
paragraph 8.2.2). (No less than one check every 24 hrs)
75 Calibration Response
7.5.1 Calibration response shall be checked at the Equalized-
Response Level.
7.5 2 Signal response obtained during calibration check shall
bewithin plus or minus 20% of that established during basicsystem
calibration.
7 5.3 If any point on the Equalized Response has decreased by
morethan 20% of its amplitude, the examiner shall:
(1) Mark all Weld Scan Data Sheets " VOID" sinceprevious
calibration check. z@s
(2) Recalibrate examination system..
(3) Re-examine voided area. _'7.5.4 If any point on the
Equalized Response has increased by more
than 20% of its amplitude, the examiner shall:
(1) Recalibrate examination system.
(2) Re-evaluate all indications recorded since theprevious
calibration check at the corrected equalizedresponse level.
O.c/ NUCLEAR ENE ACY St AviCEi+NC.
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PROCEDURE NO. 80A0480SUBJECT: AUTO RPV WELOSPAGE 7 0F 29
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5.3 Liquid Couplant
5.3.1 The ultrasonic couplant shall be demineralized water or a
mixtureof demineralized water and a suitable wetting agent such
asKodak Photo-Flo solutions or other and shall be recorded on
theWeld Scan Data Sheet.
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5.3.2 The couplant shall be supplied in clean containers of
suf-ficient quantity to perform the examination- 7
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5.3 3 The couplant shall be pumped from the container to the
trans-ducer fixtures through flexible tubing.
5.4 Surface Preparation .
All examination surfaces should be clean and f ree of dirt, weld
spatter,etc., or any other condition which would interfere'with the
examir.ationby impairing proper transmission of the sourd beam, or
by preventingfree movement of the search unit along the examination
surface.
5.5 weld identification
Each weld shall be located and identified per the appropriate
weld
. . .map located in the Program Plan Book.
5.6 Reference point-
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5.6.1 Reference Points have been marked in accordance with Stone
andWebster Specification SHI-397 to provide identification and
locatio 2of pressure boundary welds of the reactor vessel and
closure head.
5:6.2 The RTV vertical and meridional reference points start at
thehighest point on the weld centerline.
Ib5.6.3 The RPV circumferential weld reference points start at
the 0
(CE Vessel) orientation of the vessel at the weld
centerline.
5.6.4 The scanner assembly vertical and circumferential
positions are
- - --specified in Table 2. ._ . _ ,-
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5.6.5 The transducer vertical and horizontal starting positions
arespecified in Table 2.
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