Ultrasonic Inspection of Pressure Housing Welds

for Part Length Control Rod Drive Mechanisms

J. P. Lareau

ABB Combustion Engineering

March 13, 1998

Background

The part length control drive mechanisms for a Westinghouse design PWR have two

bimetalic welds connecting a section of 403 ferritic stainless to adjacent sections of 304

austenitic stainless steel. A leak was detected in a part length CRDM housing at Prairie

Island 2 and it was determined to be a throughwall crack in the lower dissimilar metal

weld in a transition taper. Ultrasonic inspection techniques were developed for the part

length housings to ascertain their condition. As reported in Reference 1, the

Westinghouse Owners Group response to the NRC, the crack was determined to be a

manufacturing flaw at the interface between the 403 base metal and the 309 weld butter

and was caused during the welding process. The approximate location of the flaw is

shown in Figure 1 &om Reference 1.

Although accurate component drawings were not available, actual components, both

spare housings and removed housings, were available and mechanical measurements

were made in order to develop drawings depicting the geometry to assist in the

development and qualification of the ultrasonic techniques. These measurements were

JPL/CRDM UT 3/9898052601 14 9'805i 5PDR ADOCK 050002759 , PDR

made in a hot cell during the destructive examination of both the lower (cracked) weld

and the upper weld. The resultant drawing showing both welds is provided in Figure 2.

From these drawings, mockups of the actual geometry were made from 304 stainless

steel. At the time of this project, type 403SS material was not available in a suitable

product form to fabricate a mockup. It was also believed that the special heat treatment

of the component after applying the butter could have changed the sound velocity. Also,

the type 304SS material was shown to be more attenuative and ultrasonically noisier than

the type 403SS, which makes the choice of the 304SS material the conservative option.

Both these effects ofattenuation and noise were observed in the field testing. From direct

observation of the ultrasonic data, it was noted that the background noise in the 304SS

was approximately 6 dB higher than in the 403SS for both the shear wave and

longitudinal wave responses. To compensate for the material differences between the twoF

types of stainless steel, the longitudinal velocity was measured for both materials in the

hot cell using removed housings. As expected, the 403SS velocity was higher than the

304SS (measured at 240 and 223 mils/microsec, respectively). It turned out that the

slight change in metal path due to the refracted angle shiA was offset by the change in

velocity for the particular set of inspection parameters used for the primary inspection

with the 45 degree longitudinal wave technique. The manual ultrasonic system employed

allows the operator to enter the actual refracted angle and sound velocity and the

instrument calculates the depth and metal path values. The automated system has an

algorithm that calculates depth based on time of flight data entered for known flaws in a

calibration sample and is self correcting for wedge delays, angle and velocity. For the

inspections, the appropriate velocities and calculated or measured angles were used for

analysis. In these mockup/calibration blocks, EDM notches were machined to establish

both the detection and sizing capability of the inspection techniques, as described below.

To date, the part length CRDM pressure housings have been inspected at two operating

plants, Prairie Island 2 and Diablo Canyon 2 for a total of twelve housings, eleven

inservice and one spare. Of these, the twelve lower welds and seven upper welds were

JPL/CRDM UT 3/98

4

I

inspected with the techniques described below. Only the isolated flaw in housing G9

from Prairie Island 2 has been recorded. A combination of destructive, visual and

penetrant testing has been used to confirm the ultrasonic results on four lower welds and

three upper welds, as reported in Reference 1.

Ultrasonic Inspection Method

As a basis for the ultrasonic inspection qualification for the CRDM pressure housings, the

techniques that had been previously qualified for IGSCC inspections through the

EPRI/BWROG program and the later Performance Demonstration Initiative Program

were chosen as the starting point. Certain transducer designs and automated ultrasonic

imaging systems were selected from the components that had been successfully used in

the EPRI programs for closely related applications. It must be noted that the neither the

IGSCC or the PDI programs addressed this specific weld type and consequently the exact

combinations of transducers and instruments developed for the CRDM inspection have

not been used in the PDI program. It should be emphasized that the underlying concepts

ofcorner trap detection and tip diffraction were used as the basis for both the IGSCC/PDI

and CRDM qualifications. The experience gained from qualifying for austenitic weld

inspections including IGSCC along with the methodology of Appendix 8 of the ASME

Code were the basis of the technique selection. One of the prime considerations for this

application was the specific geometry of the welds that included restrictive scanning

conditions due to tapers and step changes in the cross sections. These details will be

discussed below. The data analysts used for the actual field inspections have been

certified to PDI requirements for austenitic piping with IGSCC.

From the PDI program, the transducers qualified for detection and sizing in manual

inspections for small diameter piping ((6") were determined to be the best selection for

the CRDM geometry. For the CRDMs, it was necessary to use a small footprint

transducer in order to couple to the conical tapered sections of the component. For the

consideration of remote, automated CRDM inspections, the IntraSpect Automated

JPL/CRDM UT 3/98

Ultrasonic Imaging System inspection techniques, which had been qualified in the PDI

program for thicker wall pipes with diameters )6", were used. Accordingly, the same

concepts of corner trap detection and tip diffraction sizing were used, but with

correspondingly different transducer sizes and frequencies. For the specific set of

conditions for the CRDM housing welds, a combination of the IntraSpect Automated

Ultrasonic Imaging System was used with the transducers qualified for the manual

inspections of smaller diameter, thinner wall piping. EPRI maintains a table of the

transducers and instruments qualified for various aspects of PDI (reference 3) and

specific transducers and instruments were selected from these composite tables. The PDI

results for the various techniques are given on a pass/fail basis. The specific RMS sizing

error is not recorded for each individual technique and the technicians are allowed to use

a judgment based on a composite of responses using multiple techniques.

P

The PDI requirements for austenitic piping with IGSCC are separated into detection,

length sizing and throughwall depth sizing, as identified in Supplement 2 ofReference 2.

Among these requirements, the detection consideration was considered the most critical

with depth and length sizing a lower priority. To satisfy the detection criteria of a

minimum of 5 out 5 grading unit detections, a combination ofEDM notches and the real

crack was used. Similarly, to satisfy the 0 out 10 false positive calls, a combination of

upper and lower welds in unflawed housings were used. These results were confirmed by

penetrant testing and selected sectioning of the welds, as reported in Reference 1. For

calibration purposes, an EDM notch was used to set the sensitivity for the detection

scanning. For the lower weld, a notch depth of 0.030" was used, which corresponds to

6.6% of the cross section at the weld centerline thickness (0.45"). In addition, a refracted

longitudinal wave test was performed using tip diffraction sensitivity, which is higher

than corner trap testing. For these inspections, the tip signals from the depth sizing

notches were used to establish the scanning sensitivity. In general, this technique uses

the highest gain possible, limited only by electronic and material grain noise. For the

upper weld, a 0.026" notch, which is 5% of the cross section, was used to establish

detection scanning sensitivity. In both cases, this exceeds the sensitivity normally used

JPL/CRDM UT 3/98

for ASME code exams established with a 10% notch, and thus provides added

conservatism to the detection, capability of the inspection. In comparison, the critical

crack size, as reported in Reference 1, is greater than 40% throughwall based on the most

conservative of the various scenarios evaluated.

The length sizing requirement is +/-1". This aspect was not addressed in much detail,

other than with EDM notches. The actual cracked housing was evaluated as 360 degrees,

so length sizing was irrelevant. The length sizing was not considered to be a critical item

at this time, but this could be addressed at a future date.

For depth sizing, a series of EDM notches were used for both the upper and lower weld

geometries. In addition, a limited amount of destructive evaluation data from the cracked

housing was made available from Prairie Island. The PDI requirement is <0.125" RMS

error. The dual element longitudinal wave transducer was used for depth measurements

using back scattered tip diffraction techniques. For the lower weld manual inspection

technique, an RMS error of 0.042" was calculated and for the automated inspection, an

RMS error of 0.015" was calculated, in both cases using EDM notches. For the actual

crack, six local depth measurements &om the destructive testing were compared to the

manual inspection results. The actual crack had a black oxide coating on the crack face.

The depth to the limit of the black oxide, as reported in the Prairie Island preliminary

data, was subtracted from the cross section thickness calculated for the fusion line of the

weld at the 403/309 interface. (The actual physical measurements of the sectioned piece

was not used because of distortion from pulling the crack apart.) An RMS error was

calculated for the five non throughwall locations, and this was 0.036". A graph of the

remaining ligament measurements from the manual ultrasonic inspection, along with the

destructive test measurements for the black oxide depth is given in Figure 3. It must be

noted that the preliminary destructive test results report two zones within the flaw: the

black oxide coated section and a "mixed mode" section. As reported in Reference 1, the

"mixed mode" section has islands of good metal interspersed with localized oxides. The

ultrasonic results, as expected, correlate with the black oxide coated zone. The mixed

JPL/CRDM UT 3/98

mode zone is mostly transparent to the sound beam due to the good metal transmission

paths. It was also reported that this zone also is expected to have substantial remaining

strength.

For the upper weld geometry, no depth sizing was attempted. In this case, the location of

the end of the taper on the 403SS side precluded depth measurements because the

transducer would not couple properly in the specific location necessary to obtain tip

diffracted signals. At this writing, no sizing attempt has been made from the 304SS side,

although this may be possible if required. At this time, the upper weld inspection is

considered to be a detection only inspection.

Although the PDI guidelines specify the use of actual flaws, the use of EDM notches is

considered valid to augment this qualification. The basis of this position is from a study

performed by Battelle Northwest for the NRC, as described in Reference 4, "Natural vs.

Machined Defects: Differences in Ultrasonic Responses" by L. J. Busse et al. In this

report, it is concluded that EDM notches are a good representation ofopen cracks that are

not under compressive stresses that would close the crack face and thus make them

partially transmissive to sound. The oxidized face of a weld manufacturing flaw that is

caused in part by tensile loading is considered to satisfy this condition. This report also

addressed the effect of a tilt angle on the flaw and how it affected the shear wave

response. For tiltangles <15 degrees, either positive or negative relative to the beam, the

effect was <5 dB relative to the perpendicular notch. Since the weld fusion line was

measured to be approximately 15 degrees relative to the inner surface, this effect was

compensated by using a 5% notch and increasing the scanning sensitivity over reference

sensitivity. The actual corner trap response from the cracked housing was several dB

above reference relative to the notch response, except in a few local areas. The

automated ultrasonic image for a 120 degree section of the failed housing weld is

provided in Figure 4.

JPL/CRDM UT 3/98

Lower Weld Inspection

For the lower weld, as shown in Figure 2, a total of four inspections were performed. A

45 degree shear wave, 2.25 MHz, 1/4 inch diameter element, was scanned from both

sides of the weld using the 0.030" notch to establish corner trap sensitivity. In addition, a

45 degree re&acted longitudinal wave, dual element 4 MHz (0.14" x 0.3" elements) was

scanned from both sides, using tip diffraction sensitivity. The combination provided

optimum coverage for both corner trap and tip diffracted signals. The longitudinal beam

also provided coverage for the corner trap from the 403SS side inspection. The scanning

coverage for the two sided inspections is depicted in Figure 5. The calibration block is

shown in Figure 6, showing both the detection sensitivity notch (0.030") and the depth

calibration notches for the tip diffraction technique. Note that the beam angle is defined

from the entry surface. At the inner surface, the effective angles are 32 degrees and 57

degrees for the 304SS side and 403SS side examinations, respectively. The scanning

from the 304SS side was limited by the obstruction from the canopy seal weld. From this

side, the inner surface of the fusion line is just covered by the beam divergence. Complete

coverage of the weld inner surface was confirmed by the detection of faint interface

signals common for the inspection ofaustenitic welds.

Other than the known failed weld, no indications were detected in any lower weld from

any of the four inspection methods. At this writing, a total of twelve lower welds have

been inspected using these techniques In addition, for the entire circumference, the

random scattering noise from the weld metal was detected providing additional assurance

that there were no flaws that would have obscured the weld metal &om the sound beam.

All the images from the seven lower welds at Diablo Canyon as well as the four non

flawed welds at Prairie Island appeared virtually identical, other than for isolated low

amplitude spot reflectors that are common in austenitic weld inspections. The

calibration response images for the longitudinal and shear wave inspections are depicted

JPLlCRDM UT 3/98

in Figures 7 through 10, typical images from the inspected welds are shown in Figures

11 through 14. For comparison, the response from the cracked G9 housing using the

shear wave and longitudinal wave inspections from the 403SS side are shown in Figure

15.

Upper Weld Inspection

The cross sectional view of the upper weld and the ultrasonic coverage are shown in

Figure 16 and the corresponding calibration block is shown in Figure 17. For this

calibration block, the geometry had been measured in the hot cell from a sectioned

portion of the Prairie Island G9 housing upper weld. For detection sensitivity, a 5%

notch (0.026") was used. The location of the calibration notch was at the measured

location of the 403SS to 309SS fusion line. To account for any variation or uncertainty,

three notches of 5% depth were used with 1/8" axial offset for added assurance that there

was sufficient coverage relative to the location of the end of the taper on the 403SS side.

Allthree notches were readily detectable with one calibration set up. For this inspection,

the coverage from the 403SS side was performed with a 60 degree longitudinal wave

beam dual element transducer. Due to the taper, the effective beam angle at the weld

inner surface was approximately 48 degrees. The response to the calibration notches and

a typical weld response are shown in Figures 18 and 19, respectively. As in the case for

the lower weld, the unobstructed penetration of the sound beam into the weld metal is

evident in the image as an increase noise background response.

For the weld inspection &om the 304SS side, the same transducer was used as above.

This design transducer actually produces a 60 degree longitudinal wave and a shear wave

at approximately 26 degrees, simultaneously. This transducer design is often referred to

as "multimode" due to the presence of both longitudinal and shear wave components in

the beam. The two beams can be easily separated in analysis due to the approximate 2:1

difference in velocity between longitudinal and shear waves. The reason for using the

steeper shear wave component was due to the scanning restriction from a small step

JPL/CRDM UT 3/98

change on the outer surface, as shown in Figure 2. Although not identical to methods

used in PDI, a similar approach has been qualified using a transducer referred to as "30-

70-70" that uses 70 degree longitudinal and 30 degree shear wave multimode beams. The

26 degree shear wave was calibrated using the same 5% notches, with the results shown

in Figure 20. A typical weld response is shown in Figure 21. Again, in addition to direct

sensitivity to the 5% notch, the unobstructed penetration into the weld metal is also

evident from the imaged scattering noise in the weld metal itself.

A total of seven upper welds were inspected using the above techniques with no

reportable indications. Only isolated. low amplitude weld fusion line signals were

identified in the inspection data. These signals are typical for dissimilar metal weld

inspections. An additional five upper welds were inspected at Prairie Island 2, but with a

different inspection technique. It is planned that these welds willbe reinspected with the

new technique at the earliest convenience to increase the data base.

Conclusion

Based on the laboratory qualification efforts and the inspection of the failed pressure

housing (G9) from Prairie Island 2, the ultrasonic inspection methods described above

provide a high degree of confidence for the detection of welding flaws induced during

fabrication for both the lower and upper transition welds between the 403SS and 304SS

components. The detection sensitivity of this inspection (5% notch) provides significant

margin below the flaws sizes ofconcern ()40%) based on ASME code calculations.

Depth sizing using tip diffraction provides an accurate measure of the open crack depth,

based on the limited sample base from the failed housing destructive examination.

The implementation of the inspection can be performed completely remotely in a

reasonable amount oftime and with minimum radiation exposure to the crew.

JPL/CRDM UT 3/98

References

1) WOG letter to the NRC, OG-98-037, dated March 6, 1998, with attachments

2) ASME Code Section XI, Appendix 8, Performance Demonstration for Ultrasonic

Examination Systems, 1989 Addenda

3) Table 1 from PDI, dated February 19, 1997 for PDI-UT-2, PDI-UT-3 and

UNIXDETC

4) "Natural versus Machined Flaws: Differences in Ultrasonic Response", L. J. Busse et

al. Battelle Memorial Institute

JPL/CRDM UT 3/98 10

Figure I Schematic of Weld Configuration forPart length CRDMS,showing the location

of the flaw in Prairie island Unit 2

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~Y0,4

8,0O 100F 12.0

14 0u 16,0

18~0c ',20 0

22 024 0

Y Axise 1.300 X Axis 12 100 DTOF+ 6 800 us Meas'NA C

SY Axis 1,565 SX Axis+ 12 100AMP+ '57'OF: 11.800 us MP, 0.375 in Dpth+ 0,265 Thcknss+ 31.21'

0 8 1 2 156Peak (X)

120

100„-.'0-I

60,

0

I;:JWi .-.;:---40'Ih

Z00N

I ' ' '

6 0 10 0 14 0 18 0Co ri ht (C) 1997 ABB AMDATA

s I I

22 0 <- TOF <usec)

Figure 11

Typical Ultrasonic Inspection Results,45 S, Scanning Down

~ ~ ) ) I

File Channel Gate C-Scan B-Soan A-Scan Tools Display Settings HelpFile, DC-D10-1-45S-UP Exam Date,'03''045'98 Time 00:02 — 00;09Channel 1 Gate 'M 1 Hode; Max Video Hode; Full Video Filter 'Gain, 46,0 dB Dac, OFF Offsete 0.0 db PulseI Voltages 400

e ~ e ~ ~ ~ tet A te ' ~ ~ ~\ ~ eeet t ~ ~ ~ t\ ~ t ~ et\ t t tel

Axi

6 350, Y Axis'. 1,550TOF: 15,080 us dB+ 4 6

X Ax>stAHP 68Ijl MP 0,577 in Dpth; 0,408 9 ir'2 V P

I> Peak (X)120M t

)60'oom

20 .

(- X Axis100 jt0 0

I I I1200 14tO 1600

I

2,0I I I I

0.0 60 8 0 100Zoom Y Axis: 1.550 X Axis. 6 350 DTOF. 10.080 us Heas; W

SY Axise 1,142 SX Axist 6 350AHPt 68@ TOF; 15,080 us HP 0+577 in Dpth~ 0,408 Thcknss+ 47+99

8 0

O 10F 12,0

14,0u 160

18 020.022,024 0

0 4 07 10 13 165 Peak

120

100

80 )

60]

20-I0~

100~!!I!'. — .ct

40-10-Z00N

60 1001 I e I e I ~

14 0 18 0 22 0 <- TOP <usee1Co ~r i ht (C) 1997 ABB AHDATA

Figure 12Typical Ultrasonic Inspection Results,

45 S, Scanning Up

esetee I

rIe Iea Fa ~

ee w'4 . ! nina

g'i.le

Channel Gate 'C-Scan B-Scan A-Scan Tools Display Settings Help

File+..DC-D10-1-45L-DN,Exam .Date,'W04r'98 Time 00;34 - 00;42'Channel .

1" Gate; SM 1 Modes Max Video Mode: Off Video Filter: 2'Gain;, 64,0 SB Dao: OPF OFFset: 0.0 Sb Pulser Voltage: 000

AX

0 6Zoom

X Axis, 6 150, Y Axis; 0,600AMP, 448 TOF; 9,940 us dB 0,8 MP, 0,569 in

a hg

Dpth. 0,402 8 1FF2 V PoPeak (X)

90+ j60-,30-:

1 00

Zoom

e 7

0,0600

0 7 0F 8.0

9 0

s 10e 11,0

12.013,01400

Y Axis. 0 600 X Axis+ 6 150SY Axis. 10002 SX Axiss 6 150

AMPe 44'OFe 9,940 us MPt 0,569 in

0 4 0 8 it2 if6

I I

0~0 2 0 4,0 6,0 8,0 10 0 12 0 14,0I

16,0 <- X Axis

Dpth, 0,402 Thcknss 40,22

Peak (X)120 j100 g

80

60-'-"'0>

g-

20-,'

I

DTOF0 7,440 us Meas. ~8

10070401h

I II I I I

~

30 50 70 90 110Co r i ht (C) 1997 ABB AMDATA

I I I

13 0 <- TOF (usec)

Figure 13

Typical Ultrasonic Inspection Results,45 L, Scanning Down

PAG~ >+'F ~gD

-P a

File Channel Gate C-Scan B-Scan A-Soan Tools Display Settings kelpFile DC-D10-1-45L-UP, Exam Date.'OW04r'98 Time, 00.51 — 00;58Channel: 1 Gate'SW 1 Hade; Max Video Mode: Off Video Filter; 2Gain. 64,0 dB Dao,''OFF Offset: 0,0 db Pulser Voltage', 400

< ~ ~ A t ~ ~ ~ I% ~ hl P I IA ~ A Pal

X Axis. 0,000, Y Axis'0,900AHP: 79II'OF: 11.280 us dB: 5.9 HP; 0.730 in Dpth: 0,516 9 1/2 V

Ax 1,0-

Q.%—Zoom

1.OO ] I0 0

Zoom

I

2.0

Peak (X)120>90$ . =-

60-,8'-'0-'

I0~i2,0 14~0 16+0 <- X Axis

I I I I4+0 6,0 8,0 10~0

DTOF; 8 780 us Heas; 0,;t-.

Dpth; 0,516 Thoknss'i,tY Axis 0.900 X Axis+ 0 000

SY Axis 0,384 SX Axist -0,000AHP; 791 TOF! 11,280 us MP; 0,730 in

7,08,09 0

10,011,0

e 12,013,014.015 0

100 5704010

Zoom

2'O

0 0 Of3 Ot6 0 9

P - ~ tc,.

I I I I I I I I ~ I I

5 0 7 0 9 0 ii 0 13 0

Peak

120 a100 j2O-

60)40-

J 20)0

'-

TOF <usec)Co r i ht (C) 1997 ABB AHDATA

/.4'„te ~ I Ãr)2 an( fiIv&':"1fh.C>~<I

J'p

i I BIO cLfll<~ 2~ ~4''~~I

Figure 14Typical Ultrasonic Inspection Results,

45 L, Scanning Up

I I ~ I .ASI ~~Hjl ~

.'Fi',le "Charinel -Gate -::,C.-;Scan. B=Scan . A=S'c'an,- Tools -'3)ispl'aj", '* 'Settings'Fi;,1'e -'PI'-„G9.=.45L'='„PAART'xam„..Date."-. 02Ã20r,',98'-:, Tinie.'' 19;4'0*'=-'i9, 43,-'Chanrie'17 "i::„- . GaKe .-'-'SW;"...i-. ':Hade'Max,';"--."Video:„'.diode"" GFf'"" Vi'deo'"Fi'1'ter 2

Ga'xn'"''-60"0,"'dB:;~Dao" „OFF='-" Offset'0 .0'. db"'Pu'Iser."'Vol'tage.".2"400''.'",lne ~ ~ 'I' ~ 'I+ ~ ASA (ee ex,~ -Ph I 5 SX ee 7 ~ ~ 'ee 0 2 2 'e 0 '* ~ e 'e,ee ) I ~ pb eet ~ Ilee e ex I

"4R

'X'Axis.:... "-'0;650.;,'.Y Axis',. -.I'.750:,"-AMP.'"-"'i'i'*.7'-T0F.'ii"':720'..us'dB:». 9,""5;~..lIE,-':, 00782 i''Dpth: 0,553'O i/2.V .Power NA

Peak (Z>120 ~90;~~I I

- ~ IJ<- X'Axle

/

A:10i .. I

„x'- C;9.:~B0 7'-; ~, ~ eeeI II' eee e e

20051I'4

'-2.0,;:—,'1;0..., 0'xe '' .';,*.8..-0' "'2.'0:.

12ooN

~Ce pi Hb <C) 1507"ABBTAHBATA

:Yj".Axis'.'::, 0'",7050.,<,"X Axis';:.';650 'TOF<: 9,220 us - Heas.'.369"C-: SY Ax<'i:I',"' 1 303 'SX::AXTB".'~650

I4 ~~5 5 be 0- 'S~~g;F!Pie;Cha'nn<el'".'Cate..-<,-~G-,.Scan. <B='.Sc'an'A-Soan To'ols 'DisplacJ Settings

'F i'.le,'P I -;G9 "45S;-,.;DN ';-":"'TExaijip'Date.',"'02''20r<987! I.Tinie+ . i9;52 '-., i9,'54Chanriel: 1.."";Gate;"xSW li"- Ho<de,'""I!ax",",:Vi<deo'ade '."Qf'f,': Video Filter; 2Gai:n,"".52,'.0,,dB DaC,'';OFF XeOFFSet; ':0,0 "db.':Ful'S'eI. VOltage," 400

*

Help

".X;Axis; .'.'0 650,,:~XYBAxeis,„.,AHP. * 187X ATQF..

i2'660,5us"'.x

i,0.—'n 4.

0 "870dB'6-,,7 HPi™0 466 in Dpth;

.,e ele,

ei xe

i.- Co r,i~ht <C)'997 "ABB 'AHDATA

2oonI .1", 3 I I . I ~ I 0

I I , I I I

-2 0 -'.1 0;.".-'0;0 '.''i '1';0: . 2,0

0.329 9 ir'2 V Power NAPeak <X)J.'20%„~ ~

WI IX Axis

Figure 15Ultrasonic Test Results for G9,

4S 8 and 45L

Ultf

Figure 16

onic Scanning Coverage for Upper WeldREM ECN

R NS

fTESCRIP TICN PREP CHECK ENGR LIGR

26'S DN SCAN.900

309 BUTTER-

308 VELD

403SS

304SS

26'0

60'.000

,700

60L SCAN

A.OSOJIX A.OI0.XXX a S.OOS~XXXX R.OCOS

AAL FVASHTD SVRF ACTS SS MCRO INCHCSALL OWCNSNWS APC Ml INOICS

DAIOISICNS APPLY Al SSY (TOX') RCAATIYC IAAIYXTYAOX

DIMCNSICNWC R TOLCRANCWC PIR AND YIFSM 1944VIAISS OTHCRMSC SPCOHCO

TOIR AN CfS.

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gL I~ Iy COM CHO CC WC VOSAR OPC f7+/%III~ AMDAIA FRoovcls wwOsoL ccfwccXcvf 0409$ ~~CRDM PRESSURE HOUSINGUPPER WELDINSPECTION SCANNING

DZL 0 STD PROD D . IIO.

A BEARD PRLTD QQQ5Q20 OCTDTS DRAMNC d THC FROPCRTY Of NIB AAOATA WC. YANOSCR Cl. AHD IS NOT TO

~I P ROOM(SO OR VlfD TO FLIAIASH AHY PPORMAllOW FOR MAXWC CP DRAIANCSCR APPARATVS TXCCPT WNCRf PROIACCD fOR BY AOITCMCNT WTH SAD COMPANY

R V,

A

~ ~

0

~ ~ ~

~P

o ~ ~)

~ ~0

~ L l ~

~ ~S

~ ~ I ~ ~

)I ~ I

File Channel Gate C-Scan B-Scan A-Scan Tools Display Settings HelpFi le0 DC-60L-2-UP-CI Exam Date0 03''05/98 Time+ 18:03 — 18006Channel: 1 Gate.'SW 2 Mode, Max Video Hode, OFF Video Filter, 2Gain. 65.0 dB Dac. OFF Of'8set: 0.0 db Pulser Voltage'400

~ I ~ ~ ~ ~ AA tt ' ~ ~ ~\ ~ ~ ~ ~ t\ ~ t% f ~ ~ ~ P% ~ A J%

>< Axis4AMP; 798

Ax1

0 40,10 2 4

h Bt ~

Zoom

2~

I—~ -3.0 -2.0

0,000dB; 5 9 HP.

2,050, Y AxistTOF'3,240 us

4 +I

I I I I

0,0 1.0 2.0 3 0I

-1,0

0,852 in Dpth; 0,400 9 1r'2 VW

I

Power HAPeak (Ã)

Zoom Y Axis. 0 000 l( Axis. 2.050SY Axist -0 752 SX Axis. 2.050

AMP+ 79X TOFA 13,240 us MP; 00852 inDTOF'.240 us Heas',379 C

Dpth: 0.400 Thcknss 39.998 e ir'2 V

T 8 00 9 0F 100

11 0u 12,0-s 13,0e 14,0c 15,0

1640>r ~j

-0,8 -0,,4 -0,0.I,, I I, ~ „.0 4f.

II'

Peak (X)120 ~

100 ~i-- I

80-,60-

I

40 A

100 =70-40-10

Zoom~g

60 80 100 120 . 14,0Ct r I ht <0> 1997 ABB AI DATA

I I

160 180 <- TOF (usec)

Figure 18

Ultrasonic Calibration Response,

45 L, 5% Notch, Scanning UpPl~&'F ~ QF ~~

File Channel Gate C-Scan B-Scan A-Scan Tools Display Settings HelpFile', DC-D6-2-60L-UP Exam Date,'03/05/98 Time0 19+39 — 19;48Channel; 1 Gate'W 1 Hode: Hax Video Hode, OI'F Video Filter: 2Gain; 68,0 dB Dac, OFF OFFset: 0,0 db Pulser Voltage 400

~ ~ ~ A Ã ~ ~ ~ \ % w ~ IP4 0 AP~ I ~ ~ ~ l AA P\ ~

Ax 0 4i -0,24t9n

ZooN

0,0 2,0I I I I

4,0 6',0 8,0 10,0 12,0 14 0 16,0

X Axis; 0,000 Y Axis: 0.900AHP; 16M TOF 8,240 us dB "8.0 HP; 0,247 in Dpth; 0,116 e 1/2 V Power NA

Peak (X)120 q~

90 „-":-60 - i~ 9t

300= "'-

X AxisZOON Y Axis, 0 900 X Axis'0 000 DTOF; 1.100 us Heas'NA C

SY Axis'0,804 SX Axis'-0.000AHP 4X TOF: 7,100 us HP. 0 109 in Dpth; 0.051 Thcknss; 54111 e 1/2 V

T 8,00 9,0F 10,0

11,0u 12.0s 13,0e 14,0

8;8

-0,8 -0,4 -0,0 0 4Peak (X)120 ~

100 qj

80

60 ~;,,"

100 =70 =.

40 .10-ZOON

II<~—

I I I I I I I I I60 6~0 1~00 120 140 1.60 160Ca right1C> 1997 ABB AMDATA

4k~" -*-

6'-

TOF (usec)

Figure 19

Typical Ultrasonic Test Results,45 L, Scanning Up PAGF < PF Z7

' 4~, g 'I Qgl ~j I. Itt I F -III'~~W

File Channel Gate C-Scan B-Scan A-Scan Tools Displas Settings HelpFile,'DC-60L-2-DN-CI Exam Date,'3/05/98 Time 18:14 — 18e17Channel; 1 Gate', SW 1 Mode Hax Video Mode: OI'f Video Filter'2Caine 58,0 dB Dac; OFF Offset+ 0,0 db Pulser Voltage: 400

~ ~ e\ a JeI

X Axisa -2 750, Y AxisAHP. 858 TOF 14,880 us

-0.1-.-0 4-0,7 .~en-

Z00N

2 I I I—4 -4.0 -3 0I I

-2.0 -1,0

L,

I I

0,0 1,0I I I

2,0 3,0 4,0

S

II

-0,600dB, 6,5 HP, 1,050 in Dpth, 0.493 9 fr'2 V Power NA

Peak (X)

Bc 4:=-1

30 -;

<- X Axis iZoom Y Axis. -0 600 X Axis', -2.750

SY Axisi 0,327 SX Axis'2.750AMPi 85Ã TOFi 14,880 us HPi 1,050 in

DTOF; 8,880 us Meas; 0.379 C

Dpthi 0,493 Thcknss: 49,31Ã 9 1/2

-1,0

T 10,0O 110F 120

13,0 $u 14,0qs 15,0e 16,0c 17,0

18 0

58:8~i<

-0,7 -004 -0,,1

I'I

It

itg

Peak (Ã)

120'00

~I .IISc- aaa'p

40-;g ."

i20-,':

10070-.40-.10-

Zoom

I ' I I I I I I ~l6 0 8 0 10 0 12 0 14 0 16 0 18 0 20 0i

Co ~ni ht iCI IBB7 ABB AlIDATA<- TOF (usec)

Figure 20Ultrasonic Calibration Response,

45 L, 5% Notch, Scanning Down

PAGE s OF

4 + i V.

File Channel~, ., ~ i v 'PR \

Gate C-Scan B-Scan A-Scan Tools DisplaiJ Settings HelpF i 1 e DC-D6-2-60L-DN Exam Date+ 03''05''98 Time 19 53 — i9+58Channel+ i Gate+ SW i Mode+ Max Video Mode+ OFf'ideo Filter+ 2Gain. 64,0 dB Dac'OFF Off'set; 0,0 db Pulser Voltage+ 400Pulse Width i00 Pulser Type+ Sq Have 'amping,'50 Filters LP,+ OFF HP, 0,25

Y

XAxis'MP+

27K0 000, Y Axis,TOF'5 400 us

-0 900dB: -3.4 MP i,ii3 in Dpth: 0 523 e ir'2 V

Peak (X)

i0080

-0 ~ A4Zoom

i,00,II'0 0 20 4~0

I I I I

6 0 8 0 10 0 12,0~%i i * *ilAA

I I

14 0 i6.0

40

20-I

(- X

gC'i

Axi»

Figure 21

Typical Ultrasonic Test Results,45 L, Scanning Down +I"lL BQF 2'7

7