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80A0475

MANUAL ULTRASONIC EXAMINATION PROCEDUES

FOR
VESSEL N0ZZLE SAFEEND AND CLOSURE HEAD
N0ZZLE-FLANGE WELDS

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.

PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 1 0F 32

MANUAL ULTRASONIC EXAMINATION PROCEDURES FOR

VESSEL N0ZZLE SAFEENDS AND CLOSURE HEAD

N0ZZLE-FLANGE WELDS

LONG ISLAND LIGHTING COMPANY

SHOREHAM NUCLEAR POWER STATION

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PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 2 0F 1

Rev. Prep'd
No. Date Description -

Reason By ' App'd By

1 7/27/ Changed; 2.1(4) & (5),5.2.3, General revision to incorporate F. T.

79 5.3.1, 6.1(2) & (3), 7.3.2, latest NES requirements. Carr
5.2.7, 7.3.3, and Figures ?.,5,
6, and 7. Incorporated Field Change 1
i
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g/7/11
Deleted; 2.3
Added; 5.1.3
CRA-972

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NUCLEAR ENERGY SERVICES, INC.
 .

PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 3 0F 32

MANUAL ULTRASONIC EXAMINATION PROCEDURES FOR

VESSEL N0ZZLE SAFEENDS AND CLOSURE HEAD

N0ZZLE-FLANGE WELDS

1.0 SCOPE

1.1 Area of Examination

This document covers the ultrasonic examination procedures for :

(1) Main Steam (N3) nozzle to transition

piece welds.

(2) Jet Pump Instrumentation (J P I ) (N8) nozzle to

safeend piece welds.

(3) Control Rod Drive (CRD) (N9) return nozzle to

cap weld.

(4) Core Differential Pressure ( AP) (NIO) nozzle

to safeend piece weld.

(5) Closure Head Vent (N7) and Instrumentation (N6)

nozzle to flange welds.

1.2 Type of Examination

1.2.1 Volumetric examination shall be performed using ultrasonic pulse

echo nominal 450 (or 25 ) angle beam shear wave and 00 long-
itudinal straight beam techniques applied to the outside surfaces
of the piping, safeends, transition pieces and flanges.
1.2.2 The examination shall be performed manually using contact search
units (transducers).
l.3 Time of Examination
i
These procedures shall govern the preservice examination and re-
examination of repaired areas of the pipe welds as required by the
ASME Boiler and Pressure Vessel Code, Section XI.

1.4 Weld Configuration

1.4.1 The nozzle and safeend/ transition piece / flange weld configurations
covered by this procedure are shown in Figures 1 through 6.

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NUCLE AR ENE AGY SERVICES. INC.

 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 4 0F 3L
1.4.2 Nominal weld thicknesses range from 0.28" to 1.78" and are
specified in Figures 1 through 6.
1.5 Materials
The nozzles, safeends and fittings are constructed of austenitic
stainless steel, carbon steel, or inconel, as designated in
Figures 1 through 6.
2.0 REFERENCES

2.1 Reference Documents

The following documents form a part of this examination procedure:

(1) ASME Boiler and Pressure Vessel Code, Section XI,
1971 Edition, and the Summer of 1972 Addenda.

(2) AStiE Boiler and Pressure Vesse1 Code, Section i11,

1971 Edition, and the Summer of 1972 Addenda.

(3) ASNT Recommended Practice, SNT-TC-1A, Supplement C,

Third Edition (1971).
(4) NES Procedure for Ultrasonic Instrument Linearity
Verification, 80A9053. b
(5) ConAm Procedure for Certifying Inspection Personnel,
CUTP-1, Rev. 5, August 1978. d
2.2 Applicable Drawings

The following drawings are part of this procedure:

(1) CE Assembly Drawing E-234-233

(2) CE Assembly Drawing E-234-229

(3) CE Assembly Drawing E-234-275

(4) CE Assembly Drawing E-234-245

(5) CE Assembly Drawing E-234-470

(6) GE Drawings 137C5644, 137C5632

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NUCLEAR ENERGY SERVICE'!.lNC.

 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 5 0F 32

3.0 PROCEDURE CERTIFICATION

The examination procedures described in this document comply with

Section XI of the ASME Boiler and Pressure Vessel Code, 1971 Edition,
including 1972 Summer Addenda, except where examination coverage is
limited by part geometry or access.
4.0 PERSONNEL CERTIFICATION

4.1 Personnel Certification Requirements

4.1.1 Each person performing ultrasonic examinati'on governed
by this procedure shall be certified in accordance with
References 2.1 (1) , 2.1 (3) and 2.1 (5) above.
4.1.2 An examination crew shall consist of one or two members
as needed. At least one member of each crew shall have a
minimum qualification of Level 11 in accordance with the
above referenced documents. The remaining member (s) shall
have a minimum qualification of Level 1.

4.2 Personnel Records

4.2.1 Records of personnel qualification shall be maintained by
the Examination Contractor.
4.2.2 A copy of the examiner's certification summary, and a current
eye test as required by SNT-TC-1A shall be filed with each
permanent examination record, with a copy submitted to the
plant owner or his agent, prior to performing examinations
per this procedure.

5.0 EXAMINATION REQUIREMENTS

5.1 Examination Frequency

5.1.1 The nominal examination frequency shall be 2.25 MHz for all
straight beam and angle beam examinations.
5.1.2 Other pulse frequencies shall be used if such variables as
material attenuation, grain structure, etc., necessitate
their use to achieve penetration or resolution. This informa-
tion shall be recorded on the data sheets.
5.1.3 5.0MHz may be used for straight beam examination in order to achieve
resolution of the side drilled holes in the calibration standards.
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5.2 Examination Angles and Coverage

5.2.1 The intent of this procedure is to provide maximum examination

coverage to ensure weld integrity. Each weld shall be scanned with
minimum 25% overlap of the transducer element width (Diameter)
for each scan pass.
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NUCLEAR ENERGY SERVICES. INO.
 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 6 0F 32

5.2.2 The rate of search unit movement shall not exceed six (6)
inches per second.

5.2.3 Each weld and the required volume (WRV) of metal for one (1)
wall thickness on each side of the weld shall be ultrasonically
examined using 45o angle beam techniques applied in two (2)
directions perpendicular to the weld axis and 30 angle beam /1s
(45 for steagCRD and AP nozzle piece welds only) in two (2)
directions parallel with weld axis and on both sides of the
weld where part geometry and access permit.
5.2.4 Straight beam techniques shall be applied, where part geometry
permits, to all parent material through which the angle beams
will pass during angle beam examinations. Indications
detected are to be recorded in accordance with Section 10.1.1
of this procedure, except in areas where no back echo can be
obtained. Indications detected shall be recorded and data
used during evaluation of angle beam examination results.

5.2.5 Other beam angles or longitudinal waves may be used as deter-

mined necessary: i.e. for evaluation of reflectors,to compen-
sate for geometric constraints, etc. All information shall
be recorded on the data sheets.
5.2.6 in addition, straight beam techniques shall be applied to the
weld and required volume where part geometry permits. Indica-
tions shall be recorded in accordance with Section 10.1.2 of
this procedure. This shall include straight beam examination
of parent material when no back echo is obtainable.

5.2.7 Where the examination surface, geometry, or other conditions

(weld, contour, access, etc.) do not permit a meaningful
ultrasonic examination to be performed, the examiner shall
record the area of non-examination and the particular inter-
fering condition in the space provided on the Weld Scan Data
Sheet. In addition, he shall make a sketch of the weld and ,

adjacent pipe and fitting conditions on a separate sheet of CD.

paper and attach to the Calibration Data Sheet. (See Figure 11)
Photos will be taken when possible and incorporated as part of
the report.
5.2.8 All examination weld / areas shall be entered in the space
provided on the Calibration Data Sheet. If there are no
recorda bl'e indications, it shall be so recorded.

5.2.9 Coverage for the welds specified in this procedure is shown in

Figures 1 through 6.

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NUCLE AR ENERGY SERV)CES. 8NC

 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WEL_D_S
PAGE 7 0F 32

5.3 Liquid Couplant

5.3.1 The ultrasonic couplant shall be suitable for use on nuclear

plant materials and be certified not to exceed 50 ppm halogen b
and 200 ppm sulfur.

5.3.2 The couplant shall be supplied in clean containers of

sufficient quantity to perform the examination.

5.3.3 The couplant shall be applied manually with a brush or other

suitable device.
5.3.4 Where required, the examiner shall be responsible for removing
couplant from the examination surface at the conclusion of
the examination.
5.4 Surface Preparation

All examination surfaces should be cleaned and free of dirt, weld

spatter, etc., or any 'other condition which would interfere with
the examination or impair proper transmission of the sound beam.

5.5 Weld identification

Each weld shall be located and identified per appropriate weld maps
in the Program Plan Book.

5.6 Datum Point

5.6.1 The examiner shall verify that there has been marked a
reference datum point on each weld from which all examination
data and reported indications shall be referenced.

5.6.2 Datum points shall be marked by the use of low stress stamps
or vibratooling and shall not be deeper than 1/32".

5.6.3 The datum point for all safeend/ transition piece welds in
horizontal lines shall be located on the top of the pipe at
weld centerline.

5.6.4 Closure Head nozzle to flange weld datum points shall be on

the weld centerline at Closure Head 0 .
N 5.6.5 Each weld datum point, along with respcctive weld reference
points and divisions, shall be shown on each examination
report.

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 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 8 0F 32

6.0 EQUIPMENT REQUIREMENTS

6.1 Examination Contractor's Equipment

The following test equipment or its equivalent shall be provided

by the Examination Contractor for examination of welds specified
in this procedure:

(1) Pulse echo ultrasonic instrument (in compliance

wi th Ref. 2.1 (1)) .
(2) Wedges ,45 and 30 -

1
(3) Search Units, 0 ; 1/4" - 1" dia., 2.25MHz
(4) Search Units, 2.25 MHz angle beam of a suitable size
(5) Couplant

(6) Camera

(7) Thermometer

6.2 Plant Owner's Equipment

The Plant Owner or his Agent shall provide the following service
facilities and equipment as required:
(1) Scaffolding
(2) Water, Air and Electricity
(3) Temporary Lighting
(4) Crane or Lifting Devices

(5) C;iibration Standard No. STEAM

(6) Calibration Standard No. JPl

(7) Calibration Standard No. CRD
(8) Calibration Standard No. AP
(9) Calibration Standard No. VENT
(10) Test Surface Preparation (cleaning and finishing)
(11) Drawings of Each Examination Area

(12) Post-Examination Cleanup of Test Area n1

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NUCLEAR ENERGY SERVICES. INC. - - -

 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 9 0F 32

7.0 CAllBRATION REQUIREMENTS

7.1 Calibration Standards

7.1.1 The calibration standards designated in 6.2.l(5) through (9)
shall be used for basic instrument calibration and for
establishing reference sensitivity levels for examination of
the piping welds specified in this procedure. Figures 1
through 8 provide a cross-reference between the welds to be
examined and the applicable standard.

7.1.2 The appropriate calibration standard corresponding to each

respective weld shall be recorded on each Calibration Data
Sheet. Figure 11 is an example of the Calibration Data
Sheet to be used with this procedure.

7.1.3 Calibration Data Sheets shall be numbered 475-1, 475-2,

475-3, etc., at the time of calibration a~nd shall be signed
by the examiner (s) upon completion.
7.1.4 Calibration procedures shall be performed using the 0.D.
surface of the calibration standard.
7.l.5 The temperature of the calibration standard shall be within
25 F of the part weld temperature. Calibration standard
and component temperature shall be recorded on the Calibra-
tion Data Sheet.
7.2 Reference Sensitivity Level

7.2.1 The reference sensitivity level shall be the distance-

amplitude curve initially obtained directly from the calibra-
tion standard and shall be the sensitivity level used for
evaluating and recording all indications.

7.2.2 During actual weld scanning, the reference sensitivity level

shall be increased at least 2X (6dB).
7.3 Times of Calibration
7.3.1 Basic instrument calibration shall be performed using the
appropriate calibration standard, search units and instru-
mentation immediately prior to the examination of the
welds specified in this procedure.

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NUCLEAR ENERGY SERVICES INC

 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 10 0F 32

7.3.2 Instrument vertical linearity checks shall be performed at the beginning

of each day of examination in accordance with the technique in the
procedure reference in para. 2.1(4) using an angle beam search unit ,

applied to a code calibration standard. (11

7.3.3 Examination system calibration checks shall be performed at

least at the beginning and at the completion of each four
(4) hour period of examination and/or at the change of Levelli
examination personnel, equipment, search units, coupler shoes, etc., ,

and at the completion of the examination of each similar series of <L

_

welds in accordance with Sections 8.2 and 8.4 of this procedure.

7.4 Calibration Response

7.4.1 Calibration response shall be checked at the primary
reference sensitivity level.

7.4.2 Signal response obtained during calibration check shall be

within plus or minus 20% of that established during basic
instrument calibration.

7.4.3 If any point on the Distance Amplitude Correction (DAC)

curve is below the 20% limit, the examiner shall:

(1) Mark all weld data sheets since previous

calibration " void".

(2) Recalibrate examination system.

(3) Re-examine voided areas.

7.4.4 If any point on the DAC curve is above the 20% limit, the
examiner shall:

(1) Recalibrate examination system.

(2) Re-evaluate $11 indications recorded since the

previous calibration at the corrected sensitivity
level.

7.4.5 If any point on the DAC curve has moved horizontally more
than 5% of the sweep line from its original settings, the
examiner shall-

(1) Correct the sweep calibration and note it on the

Calibration Data Sheet.

(2) Void any data sheets made since the previous calibration
which have recorded indica t ions and re-examine those
areas.
O20.09
NUCLEAR ENERGY SERVICES. INC.
 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE I1 0F 32

8.0 EXAMINATION SYSTEM CAllBRATION

8.1 Straight Beam Calibration

Straight beam calibration shall be performed as follows and as shown

in Figure 9 for STEAM, VENT, AP and Figure 10 for CRD and JPl .
(1) . Adjust the instrument sweep controls so that tne
examination area is displayed on the CRT screen.
Mark the horizontal screen positions selected
.for the hole or holes directly on the CRT screen
and on the chart on the Calibration. Data Sheet.
(2) Position search unit to obtain maximum response
from the side drilled (1/4T if T y l" or 1/2T 'I f
T <1") calibration hole. Adjust sensitivity
control to provide a signal amplituce of 80% of
Full Screen Height (FSH) and mark location and
amplitude on CRT screen.

(3) This is the primary reference sensitivity. Re-

cord all sensitivity control settings on the
appropriate Calibration Data Sheet.

(4) This completes calibration for thicknesses of under

one (1) inch. (No DAC is necessary for weld
thicknesses under one (1) inch).
NOTE: In bi-metallic calibration blocks (CRD and JPI)
the gain setting shall be checked against the
equivalent response from the weld hole (.L or =).
If the gain setting is different, it shall be so
recorded and used as the primary reference response.
The difference in gain settings will establish a
gain correction factor to be applied when evaluating
and recording indication found during the examination.

(5) For weld thikknesses one (1) inch and greater a

distance amplitude correction (DAC) curve shall be
established as follows and as shown in Figures 9 and 10.

(a) Without changing the sensitivity obtained in

(2) above, position the search unit for
maximum response from the 1/2T and 3/4T holes
and mark amplitudes on the CRT screen.

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NUCLEAR ENERGY SERVCES. INC

 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 12 0F 32

(b) If the instrument is equipped with an

electronic DAC device, the primary reference
response shall be equalized at 80% of FSH over
the distance range to be employed in the
examination.

(c) Plot a DAC curve by connecting the signal

response positions with a continuous line
extending over the full examination range.

(6) Record all data and instrument setting on the Calibration

Data Sheet, and sign and date upon completion.

(7) Repeat steps (1) through (6) for each different weld
thickness just prior to examination.

8.2 Straight Beam Calibration Check

Straight beam calibration check as required by Section 7.3.3 shall

be performed as follows:

(1) Adjust the sensitivity control settings to those

recorded for the calibrated reference sensitivity.
See Section 8.l(2).
(2) Reposition search unit at each respective test hole
and observe maximum signai response amplitudes.

(3) See Section 7.4 for signal response requirements

during calibration check.

8.3 Angle Beam Calibration

,
Angle beam calibration shall be performed as follows and as shown
in Figure 9 for STEAM, VENT, AP,and Figure 10 for CRD and JPl.
(1) Adjust thejnstrumentsweepcontrolssothat the
examination area is displayed on the CRT screen.
Mark the horizontal screen positions selected for
the hole or holes directly on the CRT screen and
on the chart on the Calibration Data Sheet.

(2) Position search unit to obtain maximum response from the

calibration hole (3/4T if T 3 1" or 1-1/2T if T < 1").
Adjust sensitivity control to provide a signal amplitude
of 80% of FSH and mark location and amplitude on CRT
screen.
Note: Calibration shall be performed for both axial
and circumferential scans using appropriate
holes,
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NUCLE AR 'JNERGY $ERVICES. INC.

 PROCEDURE NO. 80A0475
GUBJECT: MANUAL SAFEEND WELDS
PAGE 13 0F 32

(3) This is the primary reference sensitivity. Record

all sensitivity control settings on the appropriate
Calibration Data Shect.
(4) DAC curves for angle beam examinations shall be
established as follows and as shown in Figures 9
and 10:

Weld Thickness Less than One (1) Inch

(a) Position the search unit for maximum response
f rom the calibration hole at the 1-1/2T
position. Adjust the instrument sensitivity
controls to provide a signal amplitude of
60% of FSH and mark location and ampiitude
on the CRT screen. (See 8.3 (2)) .
(b) Without changing sensitivity, position the
search unit for maximum responses from the
calibration hole at 1/2T, 2-1/2T and 3-1/2T
positions respectively and mark location and
amplitudes on the CRT screen.

NOTE: Due to the high attenuation of the stainless steel /

inconel material or stainless steel cladding, it
may be necessary to divide calibration into two
zones. Use an additional Calibration Data Sheet
to record this information.

(c) If the instrument is equipped with an electronic

DAC device, the primary reference response shall
be equalized at 80% of FSH over the distance
range to be employed in the examination.

(d) Plot a DAC curve by connecting the signal response

positions with a continuous Iine extending over
thg full examination range.
NOTE: In bi-metallic calibration blocks (CRD and JPI) the
gain setting shall be checked against the equivalent
response from the weld hole (.L or =). If the gain
setting is different, it shali be so recorded and
used as the primary reference esponse. The difference
-
'in gain settings will establish a gain correction
factor to be applied when evaluating and recording
indication found during the examination.

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 FROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 14 0F 32

(e) Note position and amplitude of ID and OD notch

responses through 3T calibration range, (1D
at IT and 3T, OD at 2T).

Weld Thickness One (1) Inch and Greater

(a) Position the search unit for maximum response
from the calibration hole at the 3/4T position.
Adjust the instrument sensitivity controls to
provide a signal amplitude of 80% of FSH and
mark location and amplitude on the CRT screen.
(See 8.3 (2)) .
(b) Without changing sensitivity, position the
search unit for maximum responses from the
calibration hole at the 1/4T, 1-1/4T and 1-3/4T
positions respectively and mark location and
cnplitudes on the CRT screen.

(c) If the instrument is equipped with an electronic

DAC device, the primary reference response shall
be equalized at 80% of FSH over the distance
range to be employed in the examination.

(d) Plot a DAC curve by connecting the signal response

positions with a continuous line extending over
the full examination range.

(e) Note position and amplitude of ID and OD notch

responses through 2T calibration range, (ID at
1T, OD at 2T).

(5) Record all data and instrument settings on the Calibration

Data Sheet, and sign upon completion.

(6) Repeat steps (1) through (5) for each different weld
thickness just prior to examination.
j

8.4 , Angle Beam Calibration Check

Angle beam calibration check as required by Section 7.3.3 shall be
performed as follows:

(1) Adjust the sensitivity control settings to those

recorded for the calibrated reference sensitivity.
(See Section 8.3 (2)).
(2) Reposition search unit at each respective test hole
and observe signal response amplitudes.

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 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 15 0F 32

(3) See Section 7.4 for signal response requirements

during calibration check.

9.0 EXAMINATION PROCEDURES

9.1 Straight Beam Examination of Base Material for Laminations

9.1.1 Straight beam examination of all base material through

which the angle beams will pass during angle beam examination
shall be performed at a sensitivity level which gives a
minimum back reflection signal amplitude of 80% of FSH.
9.1.2 A rectilinear scan pattern shall be used allowing a minimum
of 25% overlap of the transducer element width (diameter)
for each scan pass.

9.1.3 See Table 1 and Figures 1 throu6h 6 for examination summary and
scan path distances. Refer to the Preservice inspection Program
Plan for detailed weld locations and iden t i f i ca t ions .

9.1.4 Continue scanning sequences until all base material has been
examined. Examination shall not be considered complete until
all recordable indications have been evaluated per Section
10.1.1.
9.2 Straight and Angle Beam Examination

9.2.1 Straight beam and angle beam examination of the weld and
required volume zone shall be performed at a minimum scanning
sensitivity level of 2X (6dB) greater than the calibrated
reference sensitivity level.

9.2.2 A rectilinear scan pattern shall be used allowing a minimum

of 25% overlap of the transducer element width (diameter)
for each scan pass.

9.2.3 See Table 1 and Figures I through 6 for examination summary

and scan path diptances. Refer to the Preservice Inspection
Program Plan for detailed weld locations and iden t i f i ca t i on s .

9.2.4 Continue scanning sequences until all welds have been examined.
Examination shall not be considered complete until all recordable
indications have been evaluated per Section 10.1.2.

10.0 EVALUATION CRITERIA

10.1 Recording of Indications

10.1.1 For straight beam examinations of base metal for laminations,

all areas giving indications equal to or greater than the remain-
ing back reflection shall be recorded on the appropriate data
sheet prior to angle beam examination of the weld and required
volume.
31b EM'
NUCLEAR ENERGV SERVICES. INC.
 PROCEDURE N0. 80A047F
SUBJECT: MANUAL SAFEEND WELDS
PAGE 16 0F 32

(1) Each recorded area shall be identified as to distance

from surface, length and position relative to the
weld datum point.

(2) Recorded data shall be taken on each parallel scan

pass at increments not to exceed that permitted by the
25% overlap of transducer element diameter (width).
10.1.2 For straight beam and angle beam examinations of weld and re-
quired volume, all Indications showing a signal amplitude
response equal to or greater than 50% of the reference response
shall be recorded on the appropriate data sheet at the time of
weld examination and prior to removino the equipment.

(1) Each recorded indication shall be identified as to depth

(as percent of thickness), distance from surface, length,
signal amplitude and location relative to the weld datum
point.

(2) Recorded data shall be taken on each parallel scan

pass at increments not to exceed that permitted by the
25% overlap of transducer element diameter (width).
10.1.3 Indications from all welds shall be reported in inches forward
(towards the vessel or closure head) or backward (away from
the vessel or closure head) from the weld centerline and in
inches CW or CCW from the weld datum point when looking at
the vessel or the top of the closure head.

10.2 Evaluation of Indications

10.2.1 Evaluation of all indications shall be made at the reference

sensitivity and in accordance with the requirements of the
ASME Boiler and Pressure Vessel Code, Section XI, 15-300.
All evaluations shall be performed by a Level || or Level lit
examiner.
/
10.2.2 Results of this evaluation shall be reported to the Plant
Owner or his Agent in accordance with the requirements of the
ASME Boiler and Pressure Vessel Code, Section XI, 15-600.
Disposition of evaluation results shall be made in accordance
with the Owner's Plant Procedures,

11.0 EXAMINATION RECORDS

11.1 Certification of Records

The Examiner shall complete and sign all data sheets immediately upon
the completion of each weld examination. The data sheets may be
reviewed by the authorized Code Inspector.

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 PROCEDURE NO. 80A0475
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PAGE 17 0F 32

11.2 Filing of Records

The examiner shall be responsibic for submitting to the Plant Owner,

or his Agent, a completely documented set of examination records
including certification of personnel qualifications with a current
eye test report in accordance with SNT-TC-1A.

11.3 Procedure Corrections and Additions

11.3.1 All procedure corrections and/or additions required during
the preservice examinations shall be made in accordance
with requirements of NES QA Program Plan #.NES 80A0448.
11.3.2 The examiner shall contact the LILC0 representative on site
to initiate all changes. AlI changes shall be documented in
the record of revisions section of this procedure.

<>i .- - -
s * A t .b a ' llP

NUCLE AR ENERGY SERVICES. INC.

 PROCEDURE NO. 80A0475
SUBJECT: MANUAL EEND WELDS
PAGE 18 0F ."~

LEGEND

i Perpendicular to Weld
= Parallel to Weld
* Base Material

WRV Weld and Required Volume

As Fa r As G eome t ry _._
Permits

W + 6"

2" W 2 " __

"
/ / /
~

1.78" 45 .. u/ 45$
O WRV ,
0 * ,
0 WRV 0 *
g g"
45
f
/ 45 =

a
g
.
/ /: \

\Carbon Steel
21" ID
Transition Piece Carbon Steel
A-508 CL 1 N zzle
A-508 CL I
N
24-9/16" OD

Figure 1 - Ultrasonic Examination Procedures for Main Steam (N3) Nozzle

toTransitionPieceWelds(Cal. Block" STEAM"]

>'"*
r, * h b
kf, '

O
NUCLE AR ENERGY SERVICFs. INC.
 .

PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 19 0F 32
LEGEND

1 Perpendicular to Weld Calibrated _

= Parallel to Weld On SS Side of

* Base Material
" '"
h WRV Weld and Required
Volume = Calibrated on cladded CS
side of "JPl"

W + 3"

W + 3" -

Stainless Steel
Safeend A-182 TP 1" W 1"
304

'
o
.813" 45S
'|
'

"o 30 45 .L
g
[
0 * 30 =
& ' /1
I/ v/>
o*!
i

5/16"
Carbon Cladding
3-3/16" ID Steel Nozzle
A-508 CL 2
5-7/16" OD
w

Figure 2 - Ultrasonic Examination Procedures for Jet Pump Instrumentation (N8)

Nozzle to Safeend Welds [ Cal. Block "JPl" ]

Ol.h.dO.O

P ~ucum~, a.smica,~c .
 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 20 0F 32

LEGEND

.L Perpendicular to Weld
= Parallel to Weld
* Base Material
, Calibrated on Cladded CS Side
WRV Weld and Required Volume of "CRD"

Calib rated On inconel Side

of "CRD"

W + 3"
inconel Cap W + 3"

1" .W 1"
|

N 45 1 '
Y/ '
' o/ ' /
45 .L
75" 0'* O WRV o 0 *
4
,5
=
I///A
, 45 =,
i
/ {

,
/
Carbon Steel
t

3-7/8" ID Nozzle A-508 CL 2

5-3/8" OD

Figure 3 - Ultrasonic Examination Procedures for Control Rod

Drive (N9) Nozzle to Cap Weld ( Cal . Block "CRD"]

3Jb5.kb

o NUCLEAR ENERGY SERVICES.INC

e
 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 21 0F 32
LEGEND

1 Perpendicular to Weld
= Parallel to Weld

* Base Material

} WRV Weld and Required Volume

Vessel Wall

N
W + 1"
-
11
4 gtt

_1/21! W. 1/2'1

.28" |
/[0'o WRV b Ib ^"
'

45 1
/0o* 00 WRV /
J. \ 45 = //45 - /

Stainless Steel inconel

Safeend A-182 TP 304 Nozzle
1-15/16 ID

2.5" OD

Figure 4 - Ultrasonic txamination Procedures for Pressure

Differential (N10) Nozzle to Safeend Weld
[ Cal . Block " AP" ]
Olo;;r0
o NUCLEAR ENERGY SERVICES lNC
.

PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 22 0F 32
LEGEND

1 Perpendicular to Weld

= Parallel to Weld

* Base Material
WRV Weld and Required Volume
]
Carbon Steel Flange A-508 CL 2
\
| : N
t
|
3 0 JRV

7 '/ 30
=

Examine As
/ 5 /
Far As Geometry /
Permits

5 J.'

RV
30 =
d
1.2R"- -

3-11/16 ID
6-1/4" OD

/
/ x

\ /
Closure Head
N # "
A-508 CL 2

Figure 5 - Ultrasonic Examination Procedures for Closure Head Vent (N7)

Nozzle to Flange Weld [ Cal . Block " VENT" ]

fj[o l) -

~ cu.. ,~ .c se - es,~c
 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 23_ 0F 32
LEGEND

1 Perpendicular to Weld

= Parallel to Weld

* Base Material

/ WRV Weld and Required Volume

Flange A-508 CL 2

| | /'
/
! !
! | 0
3 WRV
/ 30 0 =
/ '
Examine As Far
5/
y
As Geometry
Permits

RV
.30 =
A
/ 1.69"- . 5-5/8" ID

9" OD
I

Closure Head #

p Nozzle A-508 CL2

Figure 6 - Ultrasonic Examination Procedures for Closure Head instrumentation

(N6) Nozzle to Flange Welds [ Cal . Block " VENT" )
'
.D
4} 'O u d ? **

O
? NUCLE AR ENERGY SERVICES.INC
.

I
PROCEDURE NO. 80A0475~
SUBJECT: MANUAL SAFEEND WELDS
PAGE 24 0F 32
Exaraination Surface
/
o c::: I =a/
:::= o ,O TI
C'
[-s
- c==:n
/ O
- i
'
;

o c:= ='
?
VENT ap

Examination Surface
Examination Surfac
l'. '
/T
,
n T
6' ^ Qh
0 b'') f) |j
STEAM

Cal. Block No. Block Hole Hole Notch

T OD ID ,1/4T 1/2T 3/4T Dia. Depth Depth b
STEAM l.78" - -
.445" .89" 1.335' 1/8" 3.0" 2%T

VENT 1.30" 6.25" 3.25" 375" 75" 1.125' 3/32" 1.5" 2%T

AP .28" 2.5" 1.94" .070" .140" .210" 3/32" 1.5" 10%T

Figure 7 - Ul trasonic Calibration Blocks " STEAM", " VENT", and " AP"

ij,hSN,-n
UU

O
NUCLEAR ENERGY SERVICES INC.
.

PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 25 0F 32

's Examination Surface

'
T g,

g .,

5/16"
SS Cladding _
'
O O :o

Side 1
Side 2

Cal. Block Block Hole Hole Notch Side 1 Side 2

No. T OD ID 1/2T Dia. Depth Depth MAT. MAT.

\
C5 + 55
CRD 75" 5-3/8' 3-7/8' 375" 3/32" 1.5" 10%T Clad. Inconel

n CS + SS
JPI .81" 5-7/16 3-13{6 .405" 3/32" 1.5" 10%T Clad. SS

Figure 8 - Ultrasonic Calibration Blocks "CRD" and "JPl"

31'oi[5'b

a
> NUCLEAR ENERGY SERvlCES. INC.
 PROCEDURE NO. 80A0475
SUBJECT: MANUAL SAFEEND WELDS
PAGE 26 0F 32
1

, z ..~. R , .u . ..a . t s,~ u

. -----'s t i af Sov. u *va x Si t P'
3
f
_t A 2
,
3
., 1 | l \x N 4

V -( >:';'x.' .. '~ i.
| Ij ,

s
M || || fl
ton mcus.tss s iwH on ttis p p
2
3 "*^a RUER W EAE N E
1 23 4 5 6
| f l_ i ----- se i ar s'ow or rua. .Ccr t

I 6
. /
#

|1 I' ||
m Teca<utss cvta t iscs t! f, H [ |
jr jT fr ijr 4T 1}r
SEARCH UNIT LOCATIONS f, DAC CURVES FOR ANGLE BEAM CAllBRATION

E
r *n* *a'r' : E e e .xt
h [, _ _ _ _ _s' ',.' E *E "" s*c ="m "____
i

jr "YE '/ T
} ;
7^
3 h ;
T r ,
__
,

o
.

n
3
i
x
'e
il
SEARCH UNIT LOCATIONS F DAC CURVE FOR {T jT jT
STRAIGHT BEAM CAllBRATION.
NOTE: For straight beam calibration on Welds under 1" thick, use 1/2T hole only, no
DAC required.
Step 1 - Adjust sweep controls so that the entire examination are is displayed on CRT
screen.

Step 2 - Adjust sensitNity to provide 80% FSH indication from hole giving maximum
response. Mark position on screen.
Step 3 - Position search unit for maximum response f rom remaining holes. Mark
position on screen.
Step 4 - Plot DAC by connecting points marked on screen with line extended to cover
entire examination range.
Step 5 - Record all sweep and sensitivity control settings on respective data sheets.
Step 6 - Position search unit for maximum responses from the surface notches and "X"
mark screen and'dati sheet to indicate amplitude.
Figure 9 - Reference Sensitivity and DAC Calibration Procedures for Ultrasonic
Examination of Welds. Using Cal. Blocks " STEAM", " VENT" and "dP".
< r m
s. % A'

O
i .
NuCL ear (NERGV SERV'CES t%C

E1
.

PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 27 0F 32

Gain Correction
Weld Hole
1

2 Po*ua9f RtitSt
j ---- so a r so-~ u w'<f:usen
,
5
m m m
2 I
m
2
n n n
3 g . R! 3PCCE
I /
X 4
\ ,
. I x ~
re
e
s I.i n
II Il j
.'|
Cladded 3 N fl H
SS Or 3jr
inconel CS QT lit 2ir

Search Unit Locations and DAC Curves For

Angle Beam Calibration

Step 1 - For straight beam calibration use 1/2T hole only with 80% FSH as
primary reference response. No DAC necessary.

Step 2 - Adjust sweep controls so that the entire examination area is displayed
on CRT screen.

Step 3 - Adjust sensitivity to provide 80% FSH indication from hole giving
maximum response. Mark position on screen.

Step 4 - Position search unit for maximum response from remaining holes. Mark
position on screen. Divide into two zones, if high attenuation makes
it necessary.

Step 5 - Plot DAC by connecting points marked on screen with line extended to
cover entire examination range. Check gain setting against equivalent
response from the weld (gain correction) hole.
Step 6 - Record all sweep and sensitivity control settings on respective data sheets.
Step 7 - Position segrch unit for maximum response from the surface notches and "X"
mark screen and data sheet to indicate amplitude.

Figure 10 - Reference Sensitivity and DAC Calibration Procedures for Ultrasonic

Examination of Welds using Cal. Blocks "CRD" and "JPl".

g., , .., r: c
s) y (? .ta. s PJ

b '=

>#UCLEAR ENERGY SERVtCESu l%C

 PAGE 28 0F 32

Plant / Unit Data Sheet No.

Comp / System CALIBRATION DATA SHEET Procedure No.
Subject
Rev/ Change No.
INSTRUMENT SETTINGS SEARCH UNIT Calibration
Block No.
'ifg/Model No.- Scan Angle: Mode: Surface
Serial No. : Fixturing (if any): Block Temp 'F

Sweep Length : Style or Type No. :

DEPTH AMPL. ATTEN.
Sweep Delay : Size & Shape : In n:T in. 4 dB
Pulse Length / Damping: Frequency *

-' req . : Rep. Rate: Serial No/ Brand :

Filter: Video: Jack: Measured Angle :
DEC/ Gate Switch: Range: Cable Type & Length:
'4 ode Select: Reject: Couplant Brand:
3ain (coarse): (fine)? Couplant Batch:

3;c w. DAC PLOT

INSTR. LINZARITY CAL. I 1 2 3 4 5
90
Icplitude
ao|
i
|High!La.- |High| low i
70'
60 ;
'' ' I '
SCAN s. s i . , I |
|

1 ; |5 | i
3U
40
: i - ; - | 4 4 |
, , ' O ' i RV | -

, _ | + ,
! O '
co * 3 t ' ;l
.
$g i i t i l i | I
7
3 | |
ito !?eldj
! b I, ' ' I I I I
'l ,. h , . ! . o I . i ,,! . . . ,l i . . . l . , ,lii,.
4 | |8 !
= to Wey.I
O 1 2 3 4 5 6 78 9 10
AMPL. CO:;TRCL LINEARITY

Initial | 6 dB fResult EXA'IINATIO:!

PSCORDABLE
n;g;c;7;gy CO:02NTS/ REASON FOR
80 -6 | '5ZLD/AREls , INCOMPLETED SCAN (S)
Yes i' No
80 -12 | ,
'
40 +6
20 +12
\ |

CALIBRATION CHECKS TItiE

Initial Cal.
Intermediate
Intermediate
Intermediate
Final Cal.

ADDITIONAL SHEETS? (CHECK BOX) EXAMINERS 1 Date Level

Continuatiorj Beam Plot 2 Date Level
Supplements Non REVIE;7ER O
Sj NUCLE AR ENWY, SERV %ES INC,
FIGURE 11 CAllBRATION DATA SHEET d^"""''
. PAGE 29 of 32

SUPPLEMENT A
@
INDICATION REPORT SHEET
_ _ III --

, STRAIGHT BEAM

.-. . . . _ .- Datum Procedure No.

. O Subject
k Weld No.
A X A Page of
-d- __.
'

b Attached to Cal. |
Data Sheet No.

_
~
,- i Notes :
I

f~ Y (1) X-axis increments not to exceed

b''nr'f allowable scan increments.
D
" (2) End points shall bc :(a) 50% of DAC
[ "
-
'
(6db) for WRV Straicht Beam exam
y (b)equal to Remaining Back Re-
flection (RBR) for base material
t
'- y2 ~\. 1 amination exam.
! (3) This column for WRV Straight Beam
Section A-A exam only.
(4) This colu.n for base material lam-
ination exam onlv.
| , FORWARD BACK
INCI- ."O '3) Y 0 !:AX (f) (b)
g,) (4)
CATION SIDE OF D X S P 04 g DAc x9por;;7g,DPOINT
NO. WELD (in T/3s) (:db) 1 FSH y (g) y (g)

COMMENTS EXAMINERS
1. Date Level

b1DNhb
"
| .
REVIEWER () Date
*
NUCLE AA ENERGY SERV:C ES. lNC.
 -
PAGE 30 0F 32
.

SUPPLEMENT B
Weld
k INDICATION REPORT S!!EET
I .l. ANGLE BEAM
,
,---
..p
i Procedure No.
--- - - -
--Datum O Subject
X
Weld No.
A m A Page of
'-
U--- ------ --
Attached to Cal.
I Data Sheet No.
F-- y -- - '
{
Notes.
E

(1) X-axis increments not to exceed

I k' n .f, allowable scan increments
jJ 's N 's . (2) End points shall be 50% of DAC
D N -
s
-
f
,2 I _ _. T-L _4 |
(3) Data nust be recorded from both
t ___.6.__ _ h i sides. If. indication cannot be
:g y1,e found from the opposite side, so
W Y2H state.
Section A-A

otDE
MAXIMUM INDICAT!!N FORWAP.D (f) BACK (b) CALC.
INDI- g,) y
D 9 IGX i 3
-% '' ' ' " . . . O I E gg) L
.
CATIC:; CFt3) X IG.X
NO. WELD (in) % DAC ;7/33) , ,
D, |y1(in) D2 in. %T
,g3 Y2 (in)
f |

EXAMINERS
O.s O J ?: .
COMMENTS o1
v)<
1 Date Level

2_ Date Level

REVIEWER Date
O
NUCLE AR ENERGY SE AvtCES INC
 PAGE 31 Of 32

SUPPLE!4ENT C
Datum 0
b '
INDICATION REPORT SHEET
' = ANGLE BEAM
A (l) Hx A
i Procedure No.
g a,

-
._ I -0-- g- - ----- Subject
| , Weld No.
Y Page of
Weld Attached to Cal.
- -" 3 ( Data Sheet No.

N Notes :
:
(1) Y-axis increments not to exceed
b f allowabic scan increments
p1
"
s 9" (2) End points shall be 50% of DAC
D 1 s 's \ \ 8 ,
'

( 6db)
D 23[ ~ I ~~ ~[ ~ "
__ (3) Data must be recorded from both
[ ~ ~ }[ g --- A_ ~ I
~~ ]4X1
s
6
sides. If indication cannot be
found from the opposite side, so
6
state.
X
F 2*
Section A-A

" - -
D
I'AXI.*O! I!' DICA-~:0:; FCP.EWARD (f) BACK (b) CAIL .
(t) E:'OPOI::7 (2) E:;2 POI!;T III L
CATIC:4 CF (3) y MAX 3 g g'.j g f,; . v . . - - -

NO. GLD (in) % DAC (T/Sc}| (ir. ) Di X 3 (in) D3 X, (in) in. %T

l
CO:01ENTS EXM!INERS (M 'j'[jyh
c
1. Date Level

2. Date Level

REVIEWER Date
O
9' NUCt,E AR ENERGY SERvlCES NC

M
 '
.
l
.. .

PROCEDURE NO. 80A0475

SUBJECT: MANUAL SAFEEND WELDS
PAGE 32 0F 32

TABLE 1

WELD IDENTIFICATION

WELD NO. DESCRIPTION REFERENCE BLOCK REFERENCE FIGURE NOTES

14-316A Main Steam Nozzle (N3A STEAM 1, 7

through through D) to transition
D piece welds.

10-303A Jet Pump Instr. Nozzle JPl 2, 8

and B (N8A and B) to Safeend
Weld

2-303 Control Rod Drive Nozzle CRD 3, 8

(N9) to Cap Weld

6-315 Core Differential Pres- AP 4, 7

sure Nozzle (N10) to
Safeend Weld

1-317A Closure Head instr. VENT 6, 7

and B Nozzle (N6A and B) to
Flange Weld

3-317 Closure Head Vent Nozzle VENT 5, 7

(N7) to Flange Weld

rs ,rs U a .'1'^
sf ^}-

0
NUCLEAR ENERGY SERVICES, INC.
 ,
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l I n !
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2
_
,
,
,