Dissimilar Metal Weld

Configuration Management Database

1012087

Dissimilar Metal Weld Configuration

Management Database
1012087

Technical Update, December 2005

EPRI Project Managers

C. Latiolais
R. Bouck

ELECTRIC POWER RESEARCH INSTITUTE

3420 Hillview Avenue, Palo Alto, California 94304-1395 PO Box 10412, Palo Alto, California 94303-0813 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS
AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER
RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY
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ANY OF THEM:
(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)
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METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.
ORGANIZATION(S) THAT PREPARED THIS DOCUMENT
Electric Power Research Institute (EPRI)

This is an EPRI Technical Update report. A Technical Update report is intended as an informal report
of continuing research, a meeting, or a topical study. It is not a final EPRI technical report.

NOTE
For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or email askepri@epri.com.
Electric Power Research Institute and EPRI are registered service marks of the Electric Power
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Copyright 2005 Electric Power Research Institute, Inc. All rights reserved.

CITATIONS
This report was prepared by
Electric Power Research Institute (EPRI)
NDE Center
1300 W.T. Harris Blvd.
Charlotte, NC 28262
Principal Investigators
C. Latiolais
R. Bouck
EPRI Solutions
3420 Hillview Ave.
Palo Alto, CA 94304
Principal Investigator
R. King
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Dissimilar Metal Weld Configuration Management Database. EPRI, Palo Alto, CA: 2005.
1012087.

iii

ABSTRACT
This report provides an update on the progress of the Dissimilar Metal Weld (DMW)
Configuration Management Database. This database is being created to support the nuclear
power industry by enabling better access to the documentation and information on Alloy
600/182/82 dissimilar metal welds. The contents of the database will support synergistic
approaches and cost sharing in the solutions to problems that may occur when implementing the
Primary System Piping Butt Weld Inspection and Evaluation Guideline (MRP-139). The
database will contain information that will allow users to capture their site-specific DMW
configurations and analyze them as they relate to other DMW configurations across the nuclear
fleet. The DMW Configuration Management Database will also support analysis, inspection,
repair, and mitigation approaches.

CONTENTS

1 DISSIMILAR METAL WELD CRACKING BACKGROUND................................................... 1-1

2 DEFINING THE NEED............................................................................................................ 2-1
3 DATABASE DESIGN ............................................................................................................. 3-1
4 DMW CONFIGURATION ANALYSIS .................................................................................... 4-1
5 CONFIGURATION MANAGEMENT DATABASE REPORTING ........................................... 5-1
Report 1: Welds by System Identification.............................................................................. 5-1
Report 2: PDI-Qualified Welds .............................................................................................. 5-1
Report 3: Welds That Have Had Repairs .............................................................................. 5-2
Report 4: Dynamic Query Builder.......................................................................................... 5-2
6 SUMMARY ............................................................................................................................. 6-1
A PROJECT PLAN................................................................................................................... A-1
A.1 Introduction .................................................................................................................... A-1
A.1.1 Purpose .................................................................................................................. A-1
A.1.2 Applicability ............................................................................................................ A-1
A.1.3 Document Overview ............................................................................................... A-2
A.1.4 Acronyms, Abbreviations, and Terms .................................................................... A-2
A.1.5 Attachments ........................................................................................................... A-3
A.1.6 References ............................................................................................................. A-3
A.2 The Project Plan ............................................................................................................ A-3
A.2.1 Project Description ................................................................................................. A-3
A.2.2 Deliverables ........................................................................................................... A-6
A.2.3 Project Assumptions .............................................................................................. A-7
A.2.4 Project Organization and Contacts ........................................................................ A-8
A.2.5 Assets Required ..................................................................................................... A-8

vii

A.2.6 Potential Risks ....................................................................................................... A-9

A.2.7 Documentation ..................................................................................................... A-10
A.2.8 Schedule .............................................................................................................. A-10
A.2.9 Technical Information ........................................................................................... A-11
A.2.10 Configuration Management ................................................................................ A-12
A.2.11 Quality Assurance .............................................................................................. A-12
A.2.12 Testing ............................................................................................................... A-13
B DMW CONFIGURATION MANAGEMENT DATABASE WEB APPLICATION: USER
INTERFACE REQUIREMENTS AND DESIGN ........................................................................ B-1
B.1 Introduction .................................................................................................................... B-1
B.1.1 Purpose .................................................................................................................. B-1
B.1.2 Applicability ............................................................................................................ B-1
B.1.3 Document Overview ............................................................................................... B-2
B.3.4 Acronyms, Abbreviations, and Terms .................................................................... B-2
B.1.5 Attachments ........................................................................................................... B-2
B.1.6 References ............................................................................................................. B-3
B.1.7 Assumptions ............................................................................................................... B-3
B.1.8 Responsibilities ........................................................................................................... B-3
B.2 User Interface Requirements (Web) .............................................................................. B-3
B.2.1 User Interface Plan ................................................................................................ B-3
B.2.2 SPW2 Common Pages .......................................................................................... B-4
B.2.2.1 Login Page ..................................................................................................... B-4
B.2.2.2 SPW2 Application Selector Page ................................................................... B-4
B.2.2.3 SPW2 User Information Page ........................................................................ B-4
B.2.2.4 SPW2 Administrator Page(s).......................................................................... B-5
B.2.3 Web Interface: DMW Configuration Management Database Web ApplicationSpecific Pages ................................................................................................................. B5
B.2.3.1 DMW Configuration Management Database Home Page.............................. B-7
B.2.3.2 DMW Configuration Management Database Main Page................................ B-7
B.2.3.3 DMW Settings Page ....................................................................................... B-9
B.2.3.4 DMW Select Reports Page........................................................................... B-17
B.2.3.5 DMW Reports Page...................................................................................... B-18
B.2.3.6 Plant Information Page ................................................................................. B-19
B.2.3.7 The Applications Help Page ......................................................................... B-20
B.2.3.8 Weld Mockups Main Page............................................................................ B-21

viii

B.2.3.9 Weld Mockups Settings Page....................................................................... B-22

B.2.3.10 Weld Mockups Reports Page ..................................................................... B-23
C GUIDANCE FOR ESTABLISHING DMW QUALIFICATION................................................ C-1

ix

LIST OF FIGURES
Figure B-1 Web User Interface Page Flow Diagram................................................................. B-6
Figure B-2 Home Page ............................................................................................................. B-7
Figure B-3 Applications Main Page........................................................................................... B-8
Figure B-4 DM Weld Settings Page ........................................................................................ B-10
Figure B-5 Weld Attributes Tab............................................................................................... B-11
Figure B-6 PDI and Inspection Attributes Tab ........................................................................ B-14
Figure B-7 Attachments Tab ................................................................................................... B-16
Figure B-8 DM Weld Select Reports Page ............................................................................. B-18
Figure B-9 DM Weld Reports Page ........................................................................................ B-19
Figure B-10 Plant Information Page........................................................................................ B-20
Figure B-11 Applications Help Page ....................................................................................... B-21
Figure B-12 Mockups Main Page............................................................................................ B-22
Figure B-13 Mockups Settings Page ...................................................................................... B-23
Figure B-14 Mockups Reports Page ....................................................................................... B-24
Figure C-1 Example RPV Hot Leg ........................................................................................... C-3
Figure C-2 Example Pressurizer Nozzle .................................................................................. C-4
Figure C-3 DM Weld Configuration Data Form ........................................................................ C-5

xi

LIST OF TABLES
Table A-1 Record of Revision ................................................................................................... A-1
Table A-2 References for the Project Plan ............................................................................... A-3
Table A-3 Contact Information for Project Personnel ............................................................... A-8
Table A-4 Documentation to Be Created as Part of This Project............................................ A-10
Table A-5 Project Schedule and Associated Efforts ............................................................... A-11
Table B-1 Record of Revision of the User Interface Requirements and Design ....................... B-1
Table B-2 References for the Web Application: User Interface Requirements and Design...... B-3
Table B-3 DMW Configuration Management Database User Types and Permission............... B-9

xiii

DISSIMILAR METAL WELD CRACKING BACKGROUND

Primary water stress corrosion cracking (PWSCC) of Alloy 600 nozzles and penetration
locations in PWR plant primary system pressure boundaries has been observed, primarily in
steam generator tubing, since the mid-1980s. During the second half of 2000, cracks were
discovered in Alloy 182 welds joining low-alloy steel reactor vessel hot leg nozzles to stainless
steel pipes at Ringhals 4 (Sweden) and VC Summer (United States). At VC Summer, a throughwall leaking flaw was found in the Alloy 82/182 weld between the low-alloy steel reactor vessel
outlet nozzle and the stainless steel primary coolant pipe. Although cracking was primarily
axially oriented, at VC Summer a short and shallow circumferential crack was also discovered in
the inside diameter (ID) region of the Alloy 182 weld clad beneath the low-alloy steel nozzle
material. This circumferential crack arrested when it reached the low-alloy steel base material.
Although not a significant flaw in terms of structural integrity, the VC Summer circumferential
flaw heightened the concern regarding the potential for the existence of circumferential flaws
and their impact on structural integrity.
In 2003, a small leak was discovered from an Alloy 182/82 butt weld on a pressurizer relief
nozzle at Tsuruga 2 (Japan). This leak was from an axial crack in the butt weld between the
low-alloy steel nozzle and the stainless steel relief valve line.
In spring 2005, Calvert Cliffs Nuclear Power Plant (United States) identified indications in a
2-in. (51-mm) diameter hot leg drain nozzle DMW. There were two axial indications contained
entirely within the weld and butter closely associated with the ID, located approximately 180
apart. There was also one circumferential indication connected to the ID, extending
approximately 100 in circumference, with one end oriented near one of the axial indications.
The circumferential indication has been determined to be construction related; the axial
indications are being attributed to PWSCC.
Axial cracks without associated leaks have been discovered in butt welds at Ringhals 3 and 4,
VC Summer, Tsuruga 2, and Three Mile Island Unit 1 (United States). The only circumferential
crack reported to date was the short, shallow crack at VC Summer.

1-1

Cracking in Alloy 182 welds has been observed since 1977 in similar Alloy 182 welds in BWR
plants. Alloy 182 welds are typically found in BWR plants between dissimilar metals in welds
between nozzles and safe ends and between safe ends and piping system. Alloy 182, supplied
exclusively as an electrode for use with the shielded metal arc welding process, was used in the
fabrication of plant components and in weld repairs during fabrication and construction. The
discovery of cracking in these welds in reactor coolant pressure boundary components after years
of operating service has resulted in the replacement or repair of the affected components as well
as the monitoring of other Alloy 182 welds with ultrasonic examination techniques as part of the
in-service inspection program at each plant.

1-2

DEFINING THE NEED

Appendix A describes the software project plan for the DMW Configuration Management
Database Web Application, and Appendix B describes the user interface, which will be designed
and developed.
The DMW Configuration Management Database not only serves as a common resource for
DMW data, but it also assists in meeting the following objectives:

To serve as a focal point for the data being collected (see Appendix C) in compliance with
Materials Reliability Program (MRP) and Boiling Water Reactor Vessel Internals Program
(BWRVIP) guidelines

To provide the ability to determine, analyze, and group like DMW configurations

To obtain weld specifics that can be used in determining the best approaches for weld repair,
mitigation techniques, pre-emptive weld overlay application, and weld examination
techniques

To design and fabricate realistic mockups, which leads to the ability to demonstrate DMW
inspection capabilities

To develop improved examination techniques using realistic replications of the actual DMW
configurations

To improve ultrasonic transducer development and design specifications

To share mockup costs across plants with similar configurations

To share previously manufactured mockups with plants that are now collecting configuration
data

To aid in determining whether specific DMWs have qualified ultrasonic testing (UT)
procedures

2-1

DATABASE DESIGN

The DMW Configuration Management Database is designed to capture all of the information
that will be gathered in response to recommendations that are detailed in BWRVIP-2005-014,
MRP 2003-039, and MRP 2004-05. When issued to the industry, these letters referenced a
guideline (see Appendix C) for obtaining the pertinent information relative to DMW
configuration data. The database will be a common holding area for the following types of
information:

Weld identification

Weld conditions

The presence of remnant welds

Adjacent welds

Weld crown conditions

Weld repairs

Weld preparation type

Critical dimensions of weld configuration

Critical reference points

The presence of tapers

Obstructions present

Materials used

Performance Demonstration Initiative (PDI) qualification attributes

ASME Code classification

Classification according to MRP-139

Inspection attributes

Area dose rates

Links to previous examination data

Photographs

Suitability for automated inspection

Surface conditioning attributes

3-1

Summaries of radiograph data review

Digitized radiograph files

Thickness and contour images

Reconstructions of DMW geometry images

Images of coverage calculations

PDI Table 1 data

Site-specific transducer availability

As-built and design drawings

Plant-specific data

The data will be populated into the database by both plant and EPRI personnel.

3-2

DMW CONFIGURATION ANALYSIS

Having the data collected in a database allows an analysis of the inspectability of the weld to be
performed. The process (a description of which is beyond the scope of this report) consists of
multiple steps with many variables. Like welds within the same system that may have unique
properties, whichwhen taken into considerationmay require independent demonstrations in
accordance with PDI-developed site-specific mockup criteria.
When the PDI program was developed, DMW configuration information was collected, but (to a
large degree) the actual configurations in the plant were either not known or not submitted for
incorporation into the PDI program sample library. In addition, inspection attributes (such as
weld crown conditions, the location of adjacent welds, scanning access, and modifications to the
design during fabrication) taken into account in the configuration analysis were not known. In
order to perform a configuration analysis, the actual configuration parameters must be known.
Coverage plots are performed during the analysis to determine the expected coverage and the
dispositioning of the DMW. Actual DMW walkdown thickness and contours are used for
the plots.
Transducer applicability is also considered for welds that are qualified under the PDI
program. For welds that require a site-specific mockup, transducer specifications and designs
are developed.
In summary, the data collected are used to perform detailed evaluations on the welds. The
analysis includes the following:

Development of the scan plan

Selection of proper search units

Calculations of expected achievable coverage

Recommendations for alternative examinations

Determination of whether the welds are covered by the existing qualified procedure

Recommendations on additional mockups

4-1

CONFIGURATION MANAGEMENT DATABASE

REPORTING

The DMW Configuration Management Database will be capable of creating both standardized
and ad hoc reports. Reports 13 (described next) are standardized reports, and Report 4 allows
users to customize the report based on their specific needs.

Report 1: Welds by System Identification

This report allows the user to see all of the DMWs, sorted by system, for the plant under
evaluation. Currently, the user is limited to the data for which they are responsible at their plant.
Future revisions of the application will allow end users to look across the industry at like
configurations. The data populated in the database must be screened for validity prior to being
included in fleetwide reports. In Report 1, the following fields are reported:

System

Weld ID

ID at weld centerline

OD at weld centerline

T1: upstream thickness

T2: downstream thickness

Report 2: PDI-Qualified Welds

This report allows the user, within the scope of the PDI-qualified procedures, to look at each
DMW at their plant(s) and determine which have been PDI qualified. A default response of
unknown must be entered in the PDI-qualified field if an analysis has not been performed. It is
the intent that all welds be dispositioned as to their inspectability and captured by the database.
In Report 2, the following fields are reported:
Weld ID
T1: upstream thickness
T2: downstream thickness
PDI qualified

5-1

Report 3: Welds That Have Had Repairs

This report allows the user to quickly see which DMWs have had repairs performed. Several
DMW flaws that have been reported are coincident with weld repairs. In Report 3, the following
fields are reported:

Weld ID

System

Weld repairs

T1: upstream thickness

T2: downstream thickness

PDI qualified

Report 4: Dynamic Query Builder

The dynamic query builder can be used to conditionally query any of the fields within the
database. Currently, the user is limited to the data for which they are responsible at their plant.
Future revisions of the application will allow end users to look across the industry at like
configurations. The data populated in the database must be screened for validity prior to being
included in fleetwide reports.

5-2

SUMMARY

The DMW Configuration Management Database is scheduled to be released for beta testing in
January 2006. The application is in the final stages of programming and is ready for submission
to EPRIs Software Quality Assurance group for testing.
The DMW Configuration Management Database Web Application will meet the requirements
for storing and retrieving DMW data used in preparation for examination, repair, or mitigation of
DMWs.
MRP is leading an initiative on Alloy 600/82/182 piping butt welds to determine the best course
of action on a per-component basis. It has become apparent that many of the actual
configurations in a plant vary greatly from the design information used to qualify procedures and
personnel in accordance with ASME Section XI, Appendix VIII. MRP has therefore
recommended the following as good practices:

That all PWR utilities collect data on the actual configuration of Alloy 600/82/182 butt welds
that exist in their plants.

That the actual configuration be compared to the PDI test set to determine if the
configuration is covered by currently qualified procedures.

That all utilities send these field data to the EPRI NDE Center for evaluation to determine
whether additional samples are required to expand existing procedures or to perform
additional R&D as needed to address gaps in the technology. The same request and need
applies to the BWR fleet.

The database will be used to house the data collected by these initiatives.
The DMW Configuration Management Database has cross functionality that can be applied to
several functional areas. The MRP, BWRVIP, PDI, NDE Center, and Materials Technical
Advisory Group (MTAG) initiatives all share a need for access to field and design information
on DMWs. The DMW Configuration Management Database will likely be integrated with other
Web-based fleet health assessment tools.

6-1

PROJECT PLAN

The following personnel are responsible for the preparation, review, and approval of the project
plan for the Dissimilar Metal Weld (DMW) Configuration Management Database Web
Application:
Prepared by Dinesh Bangari on May 20, 2005
Reviewed by Andrew Han on May 20, 2005
Approved by Ron King on May 20, 2005
Table A-1 presents a format for maintaining a record of changes made to this project plan.
Table A-1
Record of Revision
Date

Revision

5/20/2005

Section

Description

All

Original release

A.1 Introduction
A.1.1 Purpose
The purpose of this document is to define the software project plan for the DMW Configuration
Management Database Web Application project. This document is the first revision of the
original plan.
A.1.2 Applicability
This document is applicable to all EPRI Solutions Engineering Services personnel working on
software projects. This includes contractor personnel working as members of the EPRI Solutions
Engineering Services team as well as third parties working as subcontractors to EPRI Solutions.

A-1

A.1.3 Document Overview

This project plan is a high-level document that describes the plan for working on the DMW
Configuration Management Database Web Application software project. It provides information
such as the project description, deliverables, required personnel, and estimated costs.
This document is a general overview for the entire project and is intended to be a reference for
all project stakeholders. It acts as a simple view of the overall project; many of the items in this
document will be covered in more detail in additional project documentation.
The project has been divided into three tasks. Task 1 includes the creation of this document, a
requirements document, and a user interface document. Task 2 includes completion of a detailed
design document and programming the database and the Web application culminating with a
beta release. Task 3 includes making changes to the application based on feedback on the beta
release, creating a user manual and making the final release of the software.
This project plan meets the requirements of the EPRI Software Development Plan as defined in
references A.1.6.2 and A.1.6.3. Review and approval by the EPRI Software Engineering Team
for EPRI projects is required.
A.1.4 Acronyms, Abbreviations, and Terms
ADO.NET

ActiveX Data Objects for .NET (database components)

ASP.NET

Microsoft Active Server Pages for the .NET platform

ASPX

Microsoft Active Server Pages for .NET

CCPR

EPRI Cost to Completion Progress Report

Elementool

A bug- and defect-tracking database in use by EPRI Solutions

EPRI

Electric Power Research Institute

EPRI Solutions

A subsidiary of EPRI

IE

Microsoft Internet Explorer, Version 5.5 or above

IIS

Microsoft Internet Information Server

ITA

EPRI Family of Companies Inter-Company Task Agreement

MRP

EPRI Materials Reliability Program

.NET

The Microsoft .NET framework for managed software

A-2

PDI

Performance Demonstration Initiative

SPW2

SMART PlantWorks 2 for Power Delivery

SQL

Structured Query Language

TR

An EPRI-published technical report

UI

User Interface

VB.NET

Microsoft Visual Basic for the .NET platform

VS.NET

Microsoft Visual Studio .NET developer Environment

Win2K

Microsoft Windows 2000 Server operating system

A.1.5 Attachments
None.
A.1.6 References
Note: Unless a date or revision level is specified, the most current revision should be considered
the reference. Table A-2 lists the references used for this aspect of the project.
Table A-2
References for the Project Plan
Reference
No.

Document
No.

EPRI Solutions Document

A.1.6.1

PR20020003

Software Development Requirements, EPRI Solutions

A.1.6.2

N/A

Process Guide for Software Development: Requirements and Guidelines

A Roadmap, EPRI

A.1.6.3

N/A

EPRI Software Development Guidelines on the Internet:

http://www.epri.com/eprisoftware/index.html, EPRI

A.2 The Project Plan

A.2.1 Project Description
The EPRI Materials Reliability Program (MRP) is leading an initiative relative to Alloy 82/182
piping butt welds to determine the best course of action on a per-component basis. It has become
apparent that many of the actual configurations in the plant vary greatly from the design
information used to qualify procedures and personnel in accordance with ASME, Appendix VIII.
A-3

MRP has recommended as a Good Practice that all PWR utilities collect data on the actual
configuration of Alloy 600/82/182 butt welds that exist in their plants. They recommend that the
actual configuration be compared to the Performance Demonstration Initiative (PDI) test set to
determine if they are covered by current qualified procedures. MRP has recommended that all
utilities send these field data to the EPRI NDE Center for evaluation to determine whether
additional samples are required to expand existing procedures or additional R&D is needed to
address gaps in the technology. The same request and need applies to the BWR fleet. The
database will house the data from both the PWR and the BWR plants.
If these data were assembled into a usable database, it would make for a very powerful tool in
assisting several of the ongoing industry initiatives for managing the ever-growing materials
issues. These data are expected to help the MRP Executive Committee understand the risk
associated with approving the MRP Butt Weld I&E Guidelines (that is, how many welds do not
have PDI-qualified procedures?). In addition to narrowing or closing the existing inspection
technology gaps, the information would be very valuable in other areas such as mitigation,
repair, or replacement planning. The goal is to eventually tie this database in with other
databases already being used to manage Alloy 600/82/182 materials issues to determine the best
inspection solution and also provide guidance on inspection, repair, replacement, and mitigation
methods.
Some of the key components of the dissimilar metal weld configuration data collection effort are
the following:

To ensure that the information collected is in the format requested or in a format that is
deemed useful in completely assessing the inspectability attributes of the weld, including the
weld profile

To collect all significant data in support of MRP 2004-05

To develop the physical database infrastructure to perform the necessary data collection and
analysis and reporting

To be able to identify and group all inspection issues with Alloy 600/82/182 weldments

To provide the necessary reports as needed to support questions as to the inspectability of

DMW configurations and assist with designing realistic mockups to support the industry

In order to support these data collection effortsas well as other Materials Technical Advisory
Group (MTAG) and MRP projects that are focused on resolving the examination issues relative
to DMWsit has been determined that a DMW Configuration Management Database should be
developed. It is intended that this database, which will be Web based, be used to collect, store,
and retrieve information on DMWs in PWRs. The results of the data collected will be used to
determine where there is overlap in the design configurations and where similar inspection
solutions can be applied. By way of this project, all configurations can be addressed in terms of
the appropriate actions to be taken: inspection, repair, replacement, and/or mitigation. The same
request and need applies to the BWR fleet. The database will house the data from both the PWR
and the BWR plants.

A-4

The software development portion of the project is intended to be a two-year project. The project
will be divided into the following three major tasks:

Task 1: The initial scope in 2005 includes development of the software project plan,
functional and non-functional requirements, and user interface (UI) design documentation,
according to the EPRI Software Quality Assurance group requirements.

Task 2: Following the development of this documentation, the detailed design will be
completed for the software and database; and a beta version of the software, including the
actual database and Web-based software, will be developed.

Task 3: In 2006, the software will be updated based on lessons learned from the beta testing
phase. In addition, all final documentation, such as a users manual, will be developed.

The overall requirements for the project are as follows:

Design a database to hold data for DMWs. Data can be in the form of documents, drawings,
photographs, and user entries identifying the weld and weld characteristics.

Design a Web-based application that will assist the user in data entry into the DMW database
(including uploading of documents and photographs).

The Web application should enable users to:

Determine if a site-specific mockup exists that is applicable to their configuration by use

of a library of mockups entered by users and EPRI.

Provide sufficient information for an individual to determine if a configuration warrants a

site-specific mockup or if it is covered by the PDI program.

Determine the best inspection solution and also provide guidance on inspection, repair,
replacement, and mitigation methods.

Group similar configurations for the purpose of cost sharing in the development of
mockups and demonstrations.

Be able to report on butt weld specifics such as counterbores, weld root, cladding, weld
buttering, remnant welds, adjacent welds, and weld repairs. Reports would be generated
through the use of a criteria builder and one or more predefined reports.

Be able to use the application to determine design parameters for site-specific mockups.

The Web application should also enable users to create detailed reports about the welds such
as the total number of DMWs by plants, group or count by diameter or thickness, and other
parameters.

Users will be provided with access rights on a per-plant basis. User login and access may be
managed under the SMART PlantWorks 2 application framework and/or under the EPRI
login, which will be determined before the start of Task 2.
Help and user documentation will be provided through a user manual (in the EPRI software
manual format) downloadable from the Web site.

A-5

In addition, some future requirements are also identified and listed here. Although these
requirements are not part of the current project, they are listed here so that the software can be
designed in order to scale easily for future product developments.

The database needs to have information on ID contours: profilometry data.

The application should be capable of determining like configurations to determine the

specific mockup availability.

The application would enable users to identify the gaps in qualified procedures relative
to documented configurations.

The application would be able to make some limited amounts of data available across
the industry.

The application would enable users to identify and group all inspection issues.

The application will be capable of determining examination coverage.

A.2.2 Deliverables
The following items are contractual deliverables for this project:

Task 1

This project plan.

A software requirements document.

A UI document.

A revised estimate for Tasks 2 and 3, if necessary.

Task 2

A detailed design document.

A beta version, running on the EPRI Solutions servers, with all planned features
incorporated.

Completed EPRI software testing forms for the beta release.

The beta release software will pass through the EPRI software testing process.

Regular reports and CCPRs as required by the finalized ITA.

Task 3

A final version, running on the EPRI Solutions servers, with all planned features
incorporated.

Completed EPRI software testing forms for the final release.

An online, downloadable user manual in the EPRI software manual format.

A-6

 All EPRI Solutions created software.

The final release software will pass through the EPRI software testing process.
Regular reports and CCPRs as required by the finalized ITA.
Noncontractual (primarily internal) deliverables for this project are listed here:
Task 1
There are no additional internal deliverables.
Task 2
Completed EPRI Solutions software release control forms for the beta release.
Task 3
Completed EPRI Solutions software release control forms for the final release.
EPRI Solutions project closeout documents.
A.2.3 Project Assumptions
The work scope and cost estimates for this project are based on several assumptions as described
in greater detail as follows:
EPRI will provide all necessary inputs, documents, and material requested by EPRI Solutions
for completing the project.
This software application is proposed as a Microsoft .NET application. As such, it makes use
of the new ASP.NET and Visual Basic .NET software platforms and languages.
The database server for storing the application data will be Microsoft Windows 2000 Server.
As a .NET application, the software will require Microsoft Windows 2000 Server, Microsoft
Internet Information Server 5, and possibly additional third-party items.
The login method for user authentication is still to be finalized. The following four options
for hosting the DMW Configuration Management Database Web Application have been
identified:
On the customers site at EPRI Charlotte not using the EPRI login but only the EPRI
Solutions login for user authentication.
On EPRI Solutions Web servers at Palo Alto using EPRI login for user authentication.
On a separate server machine at the EPRI Data Center at Palo Alto using EPRI login for
user authentication.
On the EPRI Web servers at Palo Alto using EPRI login for user authentication.
One of the tasks for Task 1 of the project will be to identify the location for the final
application release.

A-7

The implementation cost estimate is based on the project schedule set out in this plan. An
accelerated schedule would require a re-evaluation of costs. The cost estimates are for the
required features and do not cover the optional database features planned for the future.

The DMW Configuration Management Database Web Application will fit within the
SMART PlantWorks 2 application framework. This framework provides a common set of
functions to handle logins and manage users (through role-based security), plant properties,
and user-application-plant access.

A.2.4 Project Organization and Contacts

Table A-3 lists the personnel who will be involved in this project and provides their e-mail
addresses and phone numbers for reference.
Table A-3
Contact Information for Project Personnel
Name

Title and Function

Phone

E-Mail

EPRI Solutions
Ron King

Manager, Engineering Services

650.855.2647

rking@eprisolutions.com

Tina Taylor

Director, Engineering Services

650.855.2819

ttaylor@eprisolutions.com

Dinesh Bangari

Application Developer

650.855.2423

dbangari@eprisolutions.com

Andrew Han

Application Developer

650.855.1037

ahan@eprisolutions.com

Carl Latiolais

EPRI Manager

704.595.2140

clatiola@epri.com

Bob Bouck

EPRI Project Manager

704.595.2117

rbouck@epri.com

EPRI

A.2.5 Assets Required

This scope of work will require several personnel, hardware, and software assets, as listed in the
following:

Personnel assets required include the following:

Ron King will act as the project manager. He will need to be able to provide adequate
technical input and review throughout the course of this project.

Dinesh Bangari will act as the lead developer for the project. He will be primarily
responsible for the design and implementation of the software.

Testing personnel will be required. It is expected that EPRI will be able to procure
qualified testers for the beta and final versions of this software.

A-8

 Hardware assets required include the following:

Each developer will need their own desktop or laptop computer capable of being
connected to the network and running the necessary applications. Development machines
must be capable of running the developer version of IIS and SQL Server.
For integration testing, a development server to host the Web site and SQL database will
be required. This server must be capable of running the required new software as well as
the Web and database software.
Test client machines will be required for testing the browser capability.
Additional internal network resources may be required.
Software assets required include the following:
All developers will require the following:
o Microsoft Windows 2000
o Microsoft Office
o Microsoft Outlook
o SQL Server 2000 for development and testing
o Microsoft IIS5 for development and testing
o Visual Studio .NET for Web-based development
Some developers and team members may also require one or more of the following
applications:
o Microsoft Visio for system modeling
o Microsoft Project for scheduling and tracking
All developers will need access to the following services during the development project:
Visual Source Safe for source code control, Elementool for bug and defect tracking, and
the EPRI Solutions Engineering Services portal server for document control.
Software for the application host server will be required. This includes, but is not
necessarily limited to: Win2K, SQL Server, IIS5, IE, the .NET Framework, Microsoft
XML Extensions for SQL Server, and additional third-party .NET components (if
needed).
A.2.6 Potential Risks
It is possible that during the design phase, the information provided for the welds may not
translate into a straightforward data format that can be used for both information retrieval and
analysis. If the data formats become too complex, cost and schedule overruns could result. To
mitigate this potential problem, it will be necessary to prioritize the software features and design
the software so that future requirements are more easily met.

A-9

The overall data for the welds, which include large files and photographs, could consume an
excessive amount of computer disk spacethus affecting performance, especially if stored in the
form of binary large objects (BLOBS) in the database. To mitigate this potential effect on
performance, it is better to store the information as disk files in secure folders. It will be
necessary to take care of this feature in the design phase.
Some delays could result from communication difficulties because personnel at the EPRI NDE
Center and EPRI Solutions are geographically distant from one another. To mitigate these
potential delays, timely communication will be achieved through face-to-face meetings to gather
information, timely e-mail, and other exchanges and monthly project reports. This should not
pose a significant problem because EPRI Solutions has successfully executed several such
projects for EPRI.
A.2.7 Documentation
The documentation listed in Table A-4 will be created as part of this project.
Table A-4
Documentation to Be Created as Part of This Project
Item

Title or Description

Project plan (this document)

DMW software requirements document

DMW user interface document

DMW software design document

Release control form(s)

DMW software user manual

Project closeout report

The first three documents are deliverables for Task 1 of this project.
A.2.8 Schedule
Table A-5 is a tentative schedule for the project. The schedule is relatively conservative and has
some flexibility. EPRI Solutions is committed to completing Tasks 1 and 2 in 2005 and Task 3 in
2006. The beta software is to be submitted to EPRI Software Engineering Team (SET) for testing
and approval by November 1, 2005. The final release is due for testing and approval by EPRI
SET no later than November 1, 2006.

A-10

Table A-5
Project Schedule and Associated Efforts
Description

Start

Duration
(Weeks)

End

Developer
Time
(Hours)

4/7/2005

5/17/2005

120

- Complete project plan

4/7/2005

4/13/2005

15

- Complete requirements document

4/14/2005

4/27/2005

50

- Complete user interface document

4/20/2005

5/9/2005

45

- Submit documents to EPRI

5/9/2005

5/9/2005

- Refine and revise documents

5/16/2005

5/17/2005

10

5/23/2005

22

12/31/2005

720

- Complete design document

5/23/2005

6/15/2005

100

- Develop alpha version

6/16/2005

8/12/2005

280

- Develop beta version

8/15/2005

9/14/2005

200

- Beta documentation (user manual)

9/15/2005

9/28/2005

40

- Build beta install and test

9/28/2005

10/14/2005

70

- Beta release

10/20/2005

10/28/2005

30

Task 1: Application documentation

Task 2: Design and development of beta software

Task 3: Software final release

23

300

- Develop final version

2/1/2006

15

4/28/2006

120

- Develop final documentation

5/1/2006

5/26/2006

90

- Build final install and test

5/29/2006

6/13/2006

60

- Submit final release to EPRI SET

6/14/2006

6/20/2006

30

Project complete

6/20/2006

A.2.9 Technical Information

This will be a Web-based project. The software will run over the Web and be hosted on a server
identified during Task 1 of the project. The software will have the following features:

Database holding information on DMWs in a plant with the ability to sort, determine overlap
between configurations, and determine inspection solutions.

Detailed reporting capabilities for DMWs.

Detailed specifications will be available in the Software Requirements document, which is a

deliverable for Task 1 of the project.

A-11

This application will be designed as a multi-tiered application. The user views and interacts with
the information from a Web browser (Internet Explorer [IE]). Processing will be completed on a
Web server (IIS5), using presentation and business logic implemented in ASP.net. The Web
server will process data based on user requests and generate Web pages that are viewable by the
user in the Web browser. The user interacts with the Web server only via the Web browser; only
the business layer on the Web server will interact with the database.
When running under the .NET framework, the Web server will make use of Microsoft Active
Server Pages for .NET (ASP.NET). These Web pages will be preprogrammed by the developer
to dynamically create data views for the user.
ASPX pages will be created using VS.NET. These Web pages will use the new ASP.NET
technology for creating Web pages and will be written in VB.NET using code behind.
Communications with the SQL database will be done through the ADO.NET components and
through stored procedures.
A.2.10 Configuration Management
Revision control, change control, and release control shall be according to the requirements of
the EPRI Solutions software development program as defined in reference A.1.6.1.
A.2.11 Quality Assurance
This project will be performed in accordance with the EPRI Solutions software development
program as detailed in reference A.1.6.1.
This project plan and all requirements documents will be provided to the EPRI project manager
and the EPRI Software Engineering Team for review according to the requirements of references
A.1.6.2 and A.1.6.3.
The application will be made available through the Web (as it will normally run) for access by
beta testers.
The software will be made available through the Web interface to the EPRI Software
Engineering Team for beta and final-release testing.

A-12

A.2.12 Testing
Informal testing will be performed by the developers while constructing the various portions of
the application. The developers will log and fix their own bugs and defects.
Additional EPRI Solutions testers will perform informal checks during integration testing. Bugs
and defects will be logged into the Elementool bug- and defect-tracking database.
Formal testing will be completed during integration testing. Test plans are considered
noncontractual internal deliverables. Bugs and defects will be logged into the Elementool
bug- and defect-tracking database.
The EPRI Software Engineering Team will complete the final functional testing.

A-13

DMW CONFIGURATION MANAGEMENT DATABASE

WEB APPLICATION: USER INTERFACE
REQUIREMENTS AND DESIGN

The following personnel are responsible for the preparation, review, and approval of the
Dissimilar Metal Weld (DMW) Configuration Management Database Web Application: User
Interface Requirements and Design:

Prepared by Dinesh Bangari on July 6, 2005

Reviewed by Andrew Han on July 6, 2005

Approved by Ron King on July 6, 2005

Table B-1 presents a format for maintaining a record of changes made to this aspect of the
project.
Table B-1
Record of Revision of the User Interface Requirements and Design
Date

Revision

Section

Description

6/16/2005

00

All

Original release

B.1 Introduction
B.1.1 Purpose
This document defines the user-interface requirements for the DMW Configuration Management
Database Web Application.
B.1.2 Applicability
This document is applicable to all EPRI Solutions Engineering Services personnel working on
this software project. This includes contractor personnel working as members of the EPRI
Solutions Engineering Services team. It also includes third-party contractors who are working on
software projects for EPRI Solutions as subcontract vendors.

B-1

B.1.3 Document Overview

The purpose of this document is to define the user-interface requirements for the DMW
Configuration Management Database Web Application.
The DMW Configuration Management Database Web Application implements a design that
meets the requirements for storing and retrieving DMW data, and it reports on DMWs to assist in
formulating guidance on the inspection, repair, replacement, and mitigation method.
The detailed business and nonfunctional requirements for the DMW Configuration Management
Database Web Application are defined in reference B.1.6.6.
This document, along with reference B.1.6.6, completely defines the software requirements for
the DMW Configuration Management Database Web Application.
B.3.4 Acronyms, Abbreviations, and Terms
EPRI Solutions

A subsidiary of EPRI

SPW2

SMART PlantWorks 2 for Power Delivery

UI

User Interface

B.1.5 Attachments
None.

B-2

B.1.6 References
Note: Unless a date or revision level is specified, the most current revision should be considered
the reference. Table B-2 lists the references used for this aspect of the project.
Table B-2
References for the Web Application: User Interface Requirements and Design
Reference
No.

Document
No.

EPRI Solutions Documents

B.1.6.1

PR20020003

Software Development Requirements, EPRI Solutions

B.1.6.2

N/A

Process Guide for Software Development: Requirements and Guidelines

A Roadmap, EPRI

B.1.6.3

N/A

EPRI Software Development Guidelines on the Internet:

http://www.epri.com/eprisoftware/index.html, EPRI

B.1.6.4

SW20020048

Functional and UI Requirements for SMART PlantWorks 2 for Power

Delivery (Web Tools and Data Transfer Tool)

B.1.6.5

SW20050076

DM Weld Configuration Database Web Application: Project Plan

B.1.6.6

SW20050078

DM Weld Configuration Database Web Application: Software Requirements

B.1.7 Assumptions
None.

B.1.8 Responsibilities
For primary responsibilities, see reference B.1.6.1. The author will ensure that this document is
approved by the manager of technology development. It is important that this document be
reviewed and approved by the customer.

B.2 User Interface Requirements (Web)

B.2.1 User Interface Plan
The application will be designed to operate best with a screen resolution of 1024 x 768. It will be
designed to generally work (using scroll bars, if needed) at a screen resolution of 800 x 600.
Resolution below 800 x 600 will not be supported or tested. There is no real limit to the
maximum resolution other than the users ability to view and maneuver around the UI.
The application will be designed for full color mode. The application will be useable at 256
colors. Color settings below 256 will not be supported.
B-3

Text is intended to be black on a white background. Use of color other than what is described
here will be limited to menu bars, buttons, and header texts. Cascading style sheets will be used
so that these setting can be easily adjusted, as necessary, in a central location.
The primary font will be Arial 12-point type. Cascading style sheets will be used so that these
settings may be adjusted as necessary.
The general look and feel of the DMW Configuration Management Database Web Application
will follow that of the existing SMART PlantWorks 2 (SPW2) user interface.
Users will be required to explicitly commit data changes to the database (using a Save button
or the like) to help avoid unintentional modification of data or settings. The user will be notified
whether the Save operation has succeeded or failed.
Data validation will take place at the Submit level when the user attempts to commit a change
to the database. The use of the new features in the .NET platform will allow for some level of
client-side validation at the control and form levels. Appropriate feedback will be given to the
user, indicating any validation problems with input data.
B.2.2 SPW2 Common Pages
The DMW Configuration Management Database Web Application is based on, and sits inside,
the SPW2 framework. Because of this, a few Web pages are common to all SPW2 applications.
B.2.2.1 Login Page
Users will be routed to www.epri.com for entering their login information. If the user is
authenticated, the applications home page will display.
B.2.2.2 SPW2 Application Selector Page
The SPW2 Application Selector page allows the user to select an application and/or plant from
all applications and plants for which the user has access rights. Under the SPW2 framework, it is
possible for users to have access to multiple applications and to multiple plants. See reference
B.1.6.4 for more information.
B.2.2.3 SPW2 User Information Page
Under the SPW2 framework, all of a users information, particularly their user name and
password, plus some contact information, is contained in a single location. This information is
accessed from the SPW2 User Information Page. See reference B.1.6.4 for more information.

B-4

B.2.2.4 SPW2 Administrator Page(s)

Under the SPW2 framework, access to administrative functions is through a common link
available on all pages. This link is available only to SPW2 administrators (currently only EPRI
Solutions personnel).
B.2.3 Web Interface: DMW Configuration Management Database Web ApplicationSpecific Pages
This section describes the application specific pages used to enter and save DMW data and to
generate reports for several purposes such as providing guidance on inspection, replacement,
repair, or mitigation methods or for the purpose of cost sharing in the development of sitespecific mockups and demonstrations.
All pages will have the corporate and application menu identifying the application as an SPW2
application. Access to these pages follows the authentication rules for all SPW2 applications (see
reference B.1.6.4). In addition, there are DMW Configuration Management Database Web
Application-specific links to other application Web pages.

B-5

Figure B-1 shows the Web pages navigation map for the DMW Configuration Management
Database Web Application.
EPRI Login
page

SPW2 Login
page

Plant
Information

Select Submit

For All Pages

Select
Applications

DM Weld Home
Page
(list of plant-units)

Select
Edit Plant Info

DM Weld
Help

Select
Help

Select
Save or Cancel

SPW2
Application
Selector

Select
My Info
Select
Admin

Select
Mockup
Library

SPW2 User
Information

Select
Working Plant

Mockup
Library

SPW2
Admin
Functions
Select
Report

Select
Add, Edit or View
Mockup
Report

DM Weld Main
Page
(list of welds)

Mockup
Page

Select
Cancel

Select
Delete

Select
Report

Select
Add, Edit or View

Weld Page
(list of weld
parameters)

Select
Save or Clear

Weld Report Select

(criteria builder to
customize report)

Select
Weld Page

Figure B-1
Web User Interface Page Flow Diagram

B-6

Select
Submit

Weld Report

B.2.3.1 DMW Configuration Management Database Home Page

Figure B-2 shows the Home page, which displays a welcome message and allows the user to
select a working plant to access. For each plant, the page displays the plant name, the plant
description, and the users rights for accessing that plant. The users functionality while working
with that plant is determined by their rights. Clicking on the Mockup Library hyperlink navigates
to the Mockup Main page described in Section B.2.3.8. Clicking on the Help link navigates to
the Applications Help page.

Figure B-2
Home Page

B.2.3.2 DMW Configuration Management Database Main Page

This is the page that the user sees after logging into the SPW2 and selecting the appropriate plant
for DMW Configuration Management Database Web Application. It is divided into two sections:
one displays a list of DMWs whose configurations have been saved; the other displays plant
information and has a button for editing it. Users can navigate from here to another page where
they can add new weld information, edit or delete any weld information, or view reports on
welds. The page will look similar to the one shown in Figure B-3.
B-7

Figure B-3
Applications Main Page

Working with DMW:

A user can add data for a new DMW configuration by clicking on the Add button. This will
bring up a page where users can enter information on weld data. A user can also edit a weld
configuration after selecting one from the list and clicking on the Edit button. The page also
provides a View button that brings up a page where weld information can be viewed but not
modified. Clicking on the Delete button prompts the user to confirm that the selected weld
should be deleted. If the Report button is clicked, it brings up the Reports Select Page where
users can select criteria to generate a report.

B-8

It should be noted that not all users would be able to perform all these actions. Table B-3 lists the
user types and their level of permission.
Table B-3
DMW Configuration Management Database User Types and Permission
User Type

Permission

Superuser

Add, edit, view, delete, and report

Editor

Edit, view, and report

Reader

View and report

Only SPW2 administrators have the access rights to create other user types. Details on user types
and permissions are available in reference B.1.6.4.
Editing Plant Information:
The Edit Plant Information button displays a page where users can edit plant information as
described in Section B.2.3.6.
Links to Other Pages:
There is a Help link that takes the user to the Help page described in Section B.2.3.7.
B.2.3.3 DMW Settings Page
The DMW Settings page provides the means for entering weld information into the applications
database. The main body of the page contains three tabs, each of which contains a number of text
boxes and combo box control to provide or data entry. There are also buttons and hyperlinks to
help the user to navigate through the application. The page will look similar to the one shown in
Figure B-4.

B-9

Figure B-4
DM Weld Settings Page

The user will typically navigate through the tabs entering all relevant information on the selected
DMW using the text boxes and combo box control on the tabs. Clicking the Save button will
validate the users inputs and then save the data about the weld in the applications database.
Clicking the Cancel button navigates the user back to the Main page without saving the data.
Clicking the Clear button will reset all the Web controls used for data entry on the page. When
an existing DMW is being edited or viewed, its name will appear above the tabs to identify the
weld. For new welds being added, this name will not display until the DMW configuration
information is saved.
The DMW Main hyperlink navigates back to the Main page, and the Help link will navigate to
the Help page.
There are four tabs on the tabbed form for the user to enter information for each weld. The
screen shot in Figure B-4 displays the Weld Identification tab of the DMW Settings page. The
information on this tab is presented as follows.

B-10

Weld Identification Tab:

Name
Record number
ISO drawing number
Photograph index
Component ID/weld number
System
System line number
Notes
Figure B-5 shows the Weld Attributes tab of the DMW Settings page.

Figure B-5
Weld Attributes Tab

B-11

The information on this tab is presented in the following lists.

Weld Attributes Tab:

Counterbores

Weld root

Cladding/buttering on nozzle or both sides of the weld

Weld buttering

Remnant welds

Adjacent welds

Weld crown condition of adjacent weld

Weld crown height of adjacent weld

Weld repairs

Weld crown height

Circumference

ID at weld centerline: calculated

OD at weld centerline: calculated

D1: nozzle taper to buttering

D2: buttering width

D3: buttering to DM weld tangent/weld toe

D4: DM weld tangent to safe-end

D5: safe-end width

D6: weld width

D7: weld to BM restriction (if any)

D8: DM weld tangent to toe (at surface)

D9: weld width (at surface)

A1: DM weld surface angle

A2: weld surface angle

T1: nozzle thickness

T2: Safe-end thickness

T3: elbow thickness

Taper 1 description

Taper 1 reference point

B-12

 Start of taper 1 to reference point

Stop of taper 1 to reference point
Taper 1 angle
Taper 2 description
Taper 2 reference point
Start of taper 2 to reference point
Stop of taper 2 to reference point
Taper 2 angle
Thickness at weld
Thickness upstream
Thickness downstream
Safe-end material
Weld material
Repair material
Downstream butter material
Upstream butter material
Nozzle material

B-13

Figure B-6 shows the PDI and Inspection Attributes tab of the DMW Settings page.

Figure B-6
PDI and Inspection Attributes Tab

The information on this tab is presented as follows.

PDI and Inspection Attributes Tab:

Current code classification

Code classification per MRP: XXX

PDI qualified

Is a site-specific mockup required?

Has site-specific mockup been developed?

Site-specific mockup ID

Next scheduled inspection year

Most recent inspection year

B-14

 Indications detected
Percent coverage: increments of 10%
Area dose rates
Contact dose rates
Qualitative assessment of previous data: H/M/L
Obstructions
Suitable for automated inspection
Upstream scanning surface RMS
Downstream scanning surface RMS
Can surface conditioning alone make the component inspectable?
Has any surface conditioning been done to date?
Review of radiographs performed?
Summary of radiograph review
Can meaningful examinations be performed on the weld as is?
Are the required probes on Table 1?
Are site-specific probes available?

B-15

Figure B-7 shows the Attachments tab of the DMW Settings page.

Figure B-7
Attachments Tab

The Attachments tab allows users to upload files, documents, photographs, images, and other
electronic attachments for the DMW configuration.
Attachments Tab:
For each attachment, users will enter the following information:

File Title: will uniquely identify the attachment.

File Name: the file name of the attachment.

B-16

 File Type: identifies the type of the attachment. The following types are currently available:
Weld photograph
Mockup drawing
Obstruction photo
Radiograph
Thickness and contour image
Geometries image
Scan plan/coverage plot
Link to previous examination
General document
Procedure
Calculations
Design drawing
Other
Users can add new documents by clicking on the Add button. For each attachment that is added
to the attachments table, users can choose to view the attachment by clicking on File Title or
delete the attachment using the Delete button.
B.2.3.4 DMW Select Reports Page
The Select Reports page (see Figure B-8) enables users to generate reports for several purposes
such as determining the best inspection solution and providing guidance on inspection,
replacement, repair, or mitigation methods. Users can generate two types of reports:
Customized reports based on search criteria: The upper section of the page has Web controls
whereby the user can select the criteria for generating customized reports. Users can select
the plant for the report from a dropdown menu that lists all the plants that they have access
to, including an option of All Plants.
Predefined reports: The lower section has links to some predefined reports. These reports are
based on predefined criteria that are used for generating reports on DMWs.

B-17

Figure B-8
DM Weld Select Reports Page

B.2.3.5 DMW Reports Page

The DMW Reports page (see Figure B-9), will display a table with weld information based on
the criteria selected by the user. The tables columns display some basic weld information such
as Weld Name, System Name, Attachments, and Notes. To view the detailed information on any
weld in the report, users can click on any weld name in the Weld Name column or click on View
Attachments to jump straight to the attachments page for that weld.

B-18

Figure B-9
DM Weld Reports Page

B.2.3.6 Plant Information Page

The Plant Information page displays the plant information and provides controls for editing plant
information, such as NSSS Supplier, plant type, company name, and measurement units used at
that plant. The page will look similar to the one shown in Figure B-10.

B-19

Figure B-10
Plant Information Page

B.2.3.7 The Applications Help Page

The Help page (see Figure B-11), shows typical About information, links to manuals in PDF
format, support information with contact links, and license and disclaimer information.

B-20

Figure B-11
Applications Help Page

B.2.3.8 Weld Mockups Main Page

This page will list all the available DMW mockups whose configurations have been saved. Users
can navigate from here to another page where they can add new mockup information, edit or
delete any mockup configuration, or view reports on welds. The page will look similar to the one
shown in Figure B-12.

B-21

Figure B-12
Mockups Main Page

B.2.3.9 Weld Mockups Settings Page

The Weld Mockups Settings page provides the means for entering weld mockup information into
the applications database. The main body of the page contains a number of text boxes and combo
box controls to provide or data entry. There are also buttons and hyperlinks to help the user to
navigate through the application. The page will look similar to the one shown in Figure B-13.

B-22

Figure B-13
Mockups Settings Page

B.2.3.10 Weld Mockups Reports Page

The Weld Mockups Reports page (see Figure B-14), will display a table with all the weld
mockup information available in the database. The tables columns display some basic mockup
information such as Mockup Name, System Name, Attachments, and Notes. To view the detailed
information on any mockup in the report, users can click on mockup name in the Mockup Name
column.

B-23

Figure B-14
Mockups Reports Page

B-24

GUIDANCE FOR ESTABLISHING DMW

QUALIFICATION

Items 112 in the following list should be performed during walkdown. Items 1320 address
what to do with the data obtained and what other steps should be performed.
1. Take pictures of the general area for obstructions. If obstructions such as hangers or whip
restraints, adjacent valves, or components are present, determine the maximum vertical
clearance available and the available surface distance available to mount scanners.
2. Take picture of DMW with 6-in. (15.24-cm) scale.
3. Take OD weld profile contour at zero degrees using pen gauges or other contouring devices.
4. Take ultrasonic examination (UT) thickness at zero degrees. (Additional weld contours and
thickness may be taken at 90, 180, and 270 if the configuration is not uniform.)
5. Identify weld toes and carbon steel/stainless steel (SS) interface.
6. If weld toes are not visible, acid etching may be performed or eddy current surface probe
may be used to identify Inconel/SS interface.
7. Take required measurements, using the example in Figures C-1 through C-3 as a guideline.
8. Take circumference measurements on the parallel surfaces for each different diameter
(nozzle, safe-end, and elbow).
9. Provide comments (such as weld crown conditions). The weld crown and scan surface must
allow unimpeded access across the weld and butter. Waviness, tapers, and exposed weld toes
that cause search unit liftoff must be addressed. The general surface condition should either
be machined or ground smooth to an RMS finish approximately 250 RMS. The long-range
waviness can be measured by placing the required search units on the examination surface to
ensure that there are no gaps between the surface and the bottom of the probe greater than
approximately 1/32 in. (0.08 cm) over the entire scanning surface.
10. Document any areas that show evidence of weld repairs.
11. If possible, obtain dose rates in the area of the weld and on contact; or at a minimum, review
the dose rates from previous outages.
12. Previous examination data should be reviewed to determine actual coverage obtained. If any
indications were reported, identify which limitations (weld crowns, tapers, or other physical
limitations) may be present. These data will also aid in determining the adequacy of previous
examinations.

C-1

13. Fabrication data and radiographs should be reviewed to determine the location and type of
any weld repairs. Digitization of the construction radiographs may be useful if weld repairs
have been performed or if previous UT examinations showed indications.
14. Design and as-built data should be reviewed and compared to the as-found conditions. A
reconstruction of the actual configuration should be developed using this information.
15. From Step 14, the examiner should compare the configuration to samples included in the PDI
test set and review the applicable procedure and the PDI site-specific mockup criteria. This
evaluation must be performed one refueling outage prior to the required examination in order
to allow sufficient time for fabrication of mockups and qualification of the procedures and
personnel.
16. If the as-found configuration is determined to be outside of the qualified procedure, a
feasibility evaluation should be performed to determine if meaningful UT could be
performed. If it is determined that a meaningful UT cannot be performed, alternative or
supplemental examinations should be considered.
17. If the weld is covered by the qualification or is determined to be examinable, a scan plan
should be developed based on the actual coverage obtainable. This scan plan should include
the selection of the optimum search units based on the criteria included in the applicable
procedure. A plot should be developed to show the areas of coverage in both the axial and
circumferential directions.
18. One should check the available search unit instrument combination available to determine if
the required equipment has been qualified and available.
19. If the weld is covered by the qualification, but the desired equipment is not on the PDI
Table 1, the equipment should be sent to the NDE Center for qualification. Vendor, utility,
or PDA personnel can perform this demonstration.
20. If a site-specific mockup is required, it must be fabricated and the required demonstrations
performed in accordance with the PDI site-specific mockup criteria.

C-2

Plant ID:

Unit:
Component:
RPV Hot Leg (Example)

B-F Weld

B-J Weld

Nozzle Butter

RPV Nozzle

Safe-End

Figure C-1
Example RPV Hot Leg

C-3

CSS Pipe

Plant ID:
Unit:
Component: Pressurizer Nozzle
11201-V6-002-W18 @ 0 (Type 360) (example)

D1

D2

D3

D4

D5

D6

D7

D8
D9
A2
A1

T1

T2
PZR Nozzle

#
D1
D2
D3
D4
D5
D6
D7
D9
A1

Description
Nozzle taper to buttering
Buttering width
Buttering to DM weld tangent
DM weld tangent to safe end
Safe-end width
Weld width
Weld to BM restriction (if any)
DM weld tangent to toe (at
surface)
Weld width (at surface)
DM weld surface angle

A2

Weld surface angle

D8

T3

Safe-End

Dim
0.75 in.
0.50 in.
0.15 in.
0.45 in.
1.10 in.
0.90 in.
3.00 in.
0.65 in.

#
T1
T2
T3

Description
Nozzle thickness
Safe-end thickness
Elbow thickness

B-F (DM) Weld ground flush.

B-J Weld flat-topped. Crown height: 0.05 in.

Note: 1 in. = 2.54 cm

Figure C-2
Example Pressurizer Nozzle

C-4

Dim
1.25 in.
1.05 in.
0.85 in.

Comments:

1.05 in.
13
15

Elbow

Plant/Unit/Component:
Weld ID/Location:
Insert photograph.

Insert contour and thickness info. Use additional sheet, if necessary.

Refer to example.

#
D1
D2
D3
D4
D5
D6
D7
D8
D9
A1
A2

Description
Nozzle taper to buttering
Buttering width
Buttering to DM weld tangent
DM weld tangent to safe-end
Safe-end width
Weld width
Weld to BM restriction (if any)
DM weld tangent to toe (at surface)
Weld width (at surface)
DM weld surface angle
Weld surface angle

Dim

#
T1
T2
T3

Description
Nozzle thickness
Safe-end thickness
Elbow thickness

Comments:

Figure C-3
DM Weld Configuration Data Form

C-5

Dim

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