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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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Aco'd BvPrep'dRev. - ,No. Date Description Reason - By Ngs t t i_ r n

./ @A' 'c -q x.$1 11/78 Revise: LILCO Cor.ments, CRA-569 a i[ 8 f( 7'''

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 . , ' . . r

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(2) BWR Vessel Scanner, Operating and Maintenance *,

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Manual No. 80A0658.' - '

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(3) Data Analysis System, instruction Manual No. 85A096. /h,'

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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