3F0308-07, Relief Request 08-001-RR, Revision 1: Reports of Weld Overlay Examination Results

Relief Request 08-001-RR, Revision 1: Reports of Weld Overlay Examination Results

ML080940470
Person / Time
Site:	Crystal River
Issue date:	03/26/2008
From:	Cahill S Progress Energy Florida
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
3F0308-07
Download: ML080940470 (10)

Text

Progress Energy Crystal River Nuclear Plant Docket No. 50-302 Operating License No. DPR-72 Ref: 10 CFR 50.55a March 26, 2008 3F0308-07 U.S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, DC 20555-0001

Dear Sir:

Crystal River Unit 3 - Relief Request #08-001-RR, Revision 1: Reports of Weld Overlay Examination Results Crystal River Unit 3 to NRC letter, 3F0308-04, dated March 12, 2008, "Crystal River Unit 3 - Relief Request #08-001-RR, Revision 1" As committed to in the referenced document, Florida Power Corporation (FPC), doing business as Progress Energy Florida, Inc., is hereby submitting reports of weld overlay examination results for the structural weld overlay that was applied to the Decay Heat (DH) drop line at Crystal River Unit 3 (CR3) during the March 2008 outage.

Engineering acceptance of the Ultrasonic Examination results for the DH drop line weld overlay occurred on March 19, 2008.

This submittal is being made within fourteen days of CR3 Engineering acceptance of the results and fulfills three regulatory commitments made in the referenced document.

This submittal contains no new regulatory commitments.

If you have any questions regarding this submittal, please contact Dennis Herrin, Acting Supervisor, Licensing and Regulatory Programs at (352) 563-4633.

Sincerely, Stepng e

Cahill Engineering Manager 63eiv 3".

r/ca C SJC/dar Attachments: 1. Relief Request #08-001-RR, Revision 1: Reports of Weld Overlay Examination Results

2. Phased Array Ultrasonic Examination and Calibration Records (Five Pages) xc:

NRR Project Manager Regional Administrator, Region II Senior Resident Inspector Progress Energy Florida, Inc.

Crystal River Nuclear Plant 15760 W. Powerline Street Crystal River, FL 34428 ADLr7

PROGRESS ENERGY FLORIDA, INC.

CRYSTAL RIVER UNIT 3 DOCKET NUMBER 50 - 302/ LICENSE NUMBER DPR - 72 RELIEF REQUEST #08-001-RR, REVISION 1:

REPORTS OF WELD OVERLAY EXAMINATION RESULTS Relief Request #08-001-RR, Revision 1:

Reports of Weld Overlay Examination Results

U.S. Nuclear Regulatory Commission 3F0308-07 Page 1 of 2 Relief Request #08-001-RR, Revision 1: Completed Commitments Relief Request #08-001-RR, Revision 1, was submitted to the Nuclear Regulatory Commission (NRC) to support the application of a structural weld overlay to the Decay Heat (DH) drop line at Crystal River Unit 3 (CR3). During a maintenance outage that commenced on March 1, 2008, an indication of Primary Water Stress Corrosion Cracking (PWSCC) was detected on the DH nozzle Alloy 82/182 weld. PWSCC has been identified as a degradation mechanism for Alloy 82/182 welds and weld buttering.

To ensure the integrity of the reactor coolant pressure boundary, Florida Power Corporation (FPC) concluded that the application of a full-structural weld overlay over this weld was the most appropriate course of action. However, ASME Code Section XI, 1989 Edition, no Addenda, provides no rules for the design of weld overlays or for repairs without removal of flaws. Additionally, Code Case N-504-3, "Alternate Rules for Repair of Classes 1, 2, and 3 Austenitic Stainless Steel Piping," which has been approved by the NRC for use, does not provide the methodology for overlaying nickel alloy welds joining austenitic and ferritic base materials. Therefore, FPC proposed this weld overlay as an alternate repair in the referenced document. Verbal approval from the NRC of this alternate repair was provided in a phone call on March 13, 2008.

As part of Relief Request #08-001-RR, four regulatory commitments were made.

FPC committed to providing a response to three of these regulatory commitments within fourteen days after CR3 Engineering accepted the Ultrasonic Examination results of the DH drop line weld overlays. Since Engineering accepted these results on March 19, 2008, the response to these regulatory commitments is due by April 2, 2008. These are provided below.

FPC committed to providing a response to the fourth regulatory commitment within sixty days after entry into Mode 4 start-up following the March 2008 maintenance outage. Since entry into Mode 4 start-up occurred on March 19, 2008, the response to this regulatory commitment will be provided by May 18, 2008, in a separate letter.

Commitment 1 Provide a report of the weld overlay examination results including a listing of indications detected.

The recording criteria of the ultrasonic examination procedure to be used for the examination of the overlays requires that all indications, regardless of amplitude, be investigated to the extent necessary to provide accurate characterization, identity, and location. Additionally, the procedure requires that all indications, regardless of amplitude, that cannot be clearly attributed to the geometry of the overlay configuration be considered flaw indications.

Response 1 During the examinations, no suspected flaw indications such as lack of bond, weld flaws, planar flaws, or laminar flaws, were observed. The Pre-Service Inspection examination covered 99% of the Code Required Volume in the circumferential direction and 100% in the axial direction. The Inservice Inspection examinations covered 100% of the Code Required Volume in both the circumferential and axial directions.

Please refer to the Phased Array Ultrasonic Examination Record in Attachment 2.

U.S. Nuclear Regulatory Commission 3F0308-07 Page 2 of 2 Commitment 2 Provide a report documenting the disposition of indications using the standards of ASME Section XI, IWB-3514-2 and/or IWB-3514-3 criteria and, if possible, the type and nature of the indications. The ultrasonic examination procedure requires that all suspected flaw indications are to be plotted on a cross-sectional drawing of the weld and that the plots should accurately identify the specific origin of the reflector.

Response 2 There were no suspected flaw indications observed during the examinations. No disposition was necessary.

Commitment 3 Provide a report discussing any repairs to the weld overlay material and/or base metal and the reason for the repairs.

Response 3 There were no repairs necessary to the weld overlay material or base metal.

PROGRESS ENERGY FLORIDA, INC.

CRYSTAL RIVER UNIT 3 DOCKET NUMBER 50 - 302 / LICENSE NUMBER DPR - 72 RELIEF REQUEST #08-001-RR, REVISION 1:

REPORTS OF WELD OVERLAY EXAMINATION RESULTS Phased Array Ultrasonic Examination and Calibration Records (Five Pages)

V 4 ictural Integrity Associates, Inc.

PHASED ARRAY ULTRASONIC EXAMINATION RECORD Examination Data Sheet No.: CR3-HL DECAY HEAT-WOL-08-01 Calibration Data Sheet No.: See Comments Section Date: 03/18/08 Time:

0830 through 1201 Plant:

Crystal River Unit:

3 Procedure No.:

SI-UT-126 Revision:

3 Examination Scans Performed Yes No Component: P Vez'sl Hot Leg Decay Heat Nozzle Weld Overlay (1) Axial (Facing Downstream) 0 El Component Configuration:.0°-

08 Weld Overlay Weld Overlay No.: CR3 ISI Summary Number B4.1.27 (2) Axial (Facing Upstream)

Weld Overlay Regions:

JNozzle/DMW/Pipe (3) Circumferential (Clockwise Flow('))

Ei E

Weld Overlay Thickness:

Nominal 0.76 Inch Examination Angles (4) Circumferential (Counterclockwise ())

[]

LII Examination Surface:

Surface of Weld Overlay Axial Circumferential Notes:

00 through 830 (2) 00 through 690 (2)

( As Viewed Facing Downstream E]

[]

(2) Examination angles are generated in 1 0 increments.

Examination Sensitivity:

44.0 dB 39.0 dB Comments:

No suspected flaw indications, such as lack of bond, weld flaws, planar flaws, or laminar flaws, were observed during the examinations. The examination gain was adjusted to maintain the procedure-specified baseline noise level from 5% to 20% of full screen height. The lower range of examination angles detected responses from the inside surface of the component which were useful for monitoring search unit contact / coupling effectiveness during the examination.

PSI exam with 99% (CRV.)in the Circ direction / 100% in the ax direction, ISI exams with 100% (CRV ) in the CIRC and AX directions. (Code Required Volume).

L The applicable Calibration Data Sheets are listed below:

CR3-08-DH-AX, CR3-08-DH-WBM-CIRC, CR3-08-DH-ZIZ2-CIRC & CR3-08-DH-Z3-CIRC

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Examiner:

Level:

II Date:

03/18/08 Examiner Level:

II Date:

03/18/08 Reviewer:

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l Level:

III Date:

03/19/08 I'

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VStructural Integrity Associates ULTRASONIC PHASED ARRAY CALIBRATION RECORD Customer: Progress Energy Calibration File Name: CR3-08-DH-AX Plant/Unit: Crystal River - Unit 3 Procedure No: SI-UT-126, Rev.3 Component/System: Hot Leg Decay Heat Nozzle Weld Overlay Wedge Manufacturer:

SI Refracted Angle Verification Model:

8.1" Radius WOL Focal Law Angle Measured Index Material:

Rexolite Angle Offset Velocity:

0.228 X 106 in/sec 600 620 0.45" Wedge Angle:

160 450 45° 0.50" Scan Direction:

Axial 300 29o 0.65" WOL Nominal OD:

15.20" Instrument Search Unit Integral Cable Manufacturer:

R/D Tech / Olympus Type:

32 conductor, 38 gauge coaxial Model:

OmniScan MX Length:

8' Serial Number:

OMNI-6171 Connectors:

Hypertronics Phased Array Module:

OMNI-M-PA32 / 128PR Intermediate Cable PA Module Serial No.:

OMNI-1983 Type:

32 conductor, 38 gauge coaxial Software Revision:

1.4R3 Length:

18" Instrument Settings:

Electronic Record Connectors:

Hypertronics / OmniScan Search Unit Manufacturer:

GE Element Length:

2.70 mm Transmit Model:

115-000-404 Element Width:

1.20 mm Transmit Serial Number:

01ML7V Elements (Primary Axis):

16 Receive Model:

115-000-405 Elements (Secondary Axis):

2 Receive Serial Number:

01MLLN Inactive Element-Transmit:

0 Frequency (MHz):

2.0 Inactive Element - Receive:

0 Calibration Data Files Focal Law: CR3 08 DH AX.Law Angles Generated: 00 through 830 (1 ° Increments)

Wave Mode: Longitudinal Set-up File: CR3-08-DH-AX-36.ops!

Focal Sound Path: 36mm Couplant / Batch Ultragel 11 02220 Calibration Block(s): S1-13-AX-03 Calibration Reflector Data Comments:

Calibration.

Reference

% FSH Ref. Gain Wedge Applies for the axial examination of the Reflector Angle Delay Weld Overlay Material -and the Weld and 0.40" Deep SDH WOL 70-81 46.2 dB 0.10 psec Base Material of the Dissimilar Metal 0.50" Deep SDH WOL 700 83 44.7 dB 0.00 Vsec Nozzle-to-Safe End weld.

0.70" Deep SDH WOL 600 84 49.2 dB 0.53 psec 1.00" Deep SDH WOL 600 84 46.7 dB 1.0o psec 0.10" Deep SDH WOL 800 80 44.7 dB 1.52 psec 1.20" Deep SDH WOL 450 81 44.2 dB 1.02 pe 0.80" Deep SDH WOL 00 83 39.2 dB 0.00 pseC Calibration Performed Examiner Level Date - Time Initial:

Michael Kleinjan t11,,i.

I 03/17/2008 @ 1439 Final:

Michael Kleinjan 4vd1._.

II 03/18/2008 @ 1309 Reviewed:

III 03/19/08 0P-t4 D E LECVE L :j RVC&

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Structural Integrity Associates ULTRASONIC PHASED ARRAY CALIBRATION RECORD Customer: Progress Energy Calibration File Name: CR3-08-DH-WBM-CIRC Plant/Unit: Crystal River - Unit 3 Procedure No: SI-UT-126, Rev.3 Component/System: Hot Leg Decay Heat Nozzle Weld Overlay Wedge Manufacturer:

SI Refracted Angle Verification Model:

8.1" Radius WOL FocalLaw Angle Measured Index Material:

Rexolite Angle Offset Velocity:

0.228 X 106 in/sec 600 600 0.60" Wedge Angle:

160 450 450 0.65" Scan Direction:

Circumferential 300 310 0.70" WOL Nominal OD:

15.20" Instrument Search Unit Integral Cable Manufacturer:

R/D Tech / Olympus Type:

32 conductor, 38 gauge coaxial Model:

OmniScan MX Length:

8' Serial Number:

OMNI-6171 Connectors:

Hypertronics Phased Array Module:

OMNI-M-PA32 / 128PR Intermediate Cable PA Module Serial No.:

OMNI-1983 Type:

32 conductor, 38 gauge coaxial Software Revision:

1.4R3 Length:

18" Instrument Settings:

Electronic Record Connectors:

Hypertronics / OmniScan Search Unit Manufacturer:

GE Element Length:

2.70 mm Transmit Model:

115-000-404 Element Width:

1.20 mm Transmit Serial Number:

01ML7v Elements (Primary Axis):

16 Receive Model:

115-000-405 Elements (Secondary Axis):

2 Receive Serial Number:

01MLLn Inactive Element-Transmit:

0 Frequency (MHz):

2.0 Inactive Element - Receive:

0 Calibration Data Files Focal Law: DH Circ DMW.Law Angles Generated: 0° through 69° (1° Increments)

Wave Mode: Longitudinal Set-up File: CR3-08-DH-DMW-CIRC-50.ops Focal Sound Path: 50mm Couplant I Batch Ultragel Il1 02220 Calibration Block(s): SI-13-CIRC-03 Calibration Reflector Data Comments:

Calibration Reference

% FSH Ref. Gain Wedge Applies for the circumferential Reflector Angle Delay examination of the Weld Overlay and the 1.00" Deep SDH WOL 440 83.0 40.0dB 1.4O psec Weld and Base Material of the DMW Nozzle to Pipe weld Calibration Performed Examiner Level Date - Time Initial:

Michael Kleinjan

)

II 03/17/2008 @ 1544 Final:

Michael Kleinjan II 03/18/2008 @ 1321 Reviewed:

I, 03/19/08 P6 ýJ N DC Lr vEL 171' X r:,/ t D,911*J PA ie3 ri-,6y 3ý/

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Structural Integrity Associates ULTRASONIC PHASED ARRAY CALIBRATION RECORD

.Customer: Progress Energy Calibration File Name: CR3-08-DH-Z1Z2-CIRC Plant/Unit: Crystal River - Unit 3 Procedure No: SI-UT-126, Rev.3 Component/System: Hot Leg Decay Heat Nozzle Weld Overlay Wedge Manufacturer:

SI Refracted Angle Verification Model:

8.1" Radius WOL Focal Law Angle Measured Index Material:

Rexolite Angle Offset Velocity:

0.228 X 106 in/sec 600 600 0.65" Wedge Angle:

160 450 450 0.60" Scan Direction:

Circumferential 300 310 0.55" WOL Nominal OD:

15.20" Instrument Search Unit Integral Cable Manufacturer:

R/D Tech / Olympus Type:

32 conductor, 38 gauge coaxial Model:

OmniScan MX Length:

8' Serial Number:

OMNI-6171 Connectors:

Hypertronics Phased Array Module:

OMNI-M-PA32 / 128PR Intermediate Cable PA Module Serial No.:

OMNI-1983 Type:

32 conductor, 38 gauge coaxial

. Software Revision:

1.4R3 Length:

18" Instrument Settings:

Electronic Record Connectors:

Hypertronics / OmniScan Search Unit Manufacturer:

GE Element Length:

2.70 mm Transmit Model:

115-000-404 Element Width:

1.20 mm Transmit Serial Number:

01ML7V Elements (Primary Axis):

16 Receive Model:

115-000-405 Elements (Secondary Axis):

2 Receive Serial Number:

01MLLN Inactive Element-Transmit:

0 Frequency (MHz):

2.0 Inactive Element - Receive:

0 Calibration Data Files Focal Law: DH CIRC Z1Z2.Law Angles Generated: 0O through 690 (10 Increments)

Wave Mode: Longitudinal Set-up File: CR3-08-DH-Z1Z2-CIRC-31.ops Focal Sound Path: 31mm Couplant I Batch Ultragel It / 02220 Calibration Block(s): SI-13-CIRC-03 Calibration Reflector Data Comments:

Calibration Reference

% FSH Ref. Gain Wedge Applies for the circumferential Reflector Angle Delay examination of the Weld Overlay.

0.40" Deep SDH WOL 530 82 36.1dB i.9 -osec 0.70" Deep SDH WOL 500 81 39.2dB 1.61 psec Calibration Performed Examiner Level Date - Time Initial:

Michael Kleinjan 11 e

I 03/17/2008 @ 1501 Final:

Michael Kleinjan 1.)

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II 03/18/2008@ 1333 Reviewed:

I 03/19/08 P6A* P41L LIVL2T P~ic'w D911q011 1

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VStructural Integrity Associates ULTRASONIC PHASED ARRAY CALIBRATION RECORD Customer: Progress Energy Calibration File Name: CR3-08-DH-Z3-CIRC Plant/Unit: Crystal River - Unit 3 Procedure No: SI-UT-126, Rev.3 Component/System: Hot Leg Decay Heat Nozzle Weld Overlay Wedge Manufacturer:

SI Refracted Angle Verification Model:

8.1" Radius WOL Focal Law Angle Measured Index Material:

Rexolite Angle Offset Velocity:

0.228 X 106 in/sec 600.

600 0.60" Wedge Angle:

160 450 450 0.65" Scan Direction:

Circumferential 300 310 WOL Nominal OD:

15.20" 0.70 Instrument Search Unit Integral Cable Manufacturer:

RID Tech / Olympus Type:

32 conductor, 38 gauge coaxial Model:

OmniScan MX Length:

8' Serial Number:

OMNI-6171 Connectors:

Hypertronics Phased Array Module:

OMNI-M-PA32 / 128PR Intermediate Cable PA Module Serial No.:

OMNI-1983 Type:

32 conductor, 38 gauge coaxial Software Revision:

1.4R3 Length:

18" Instrument Settings:

Electronic Record Connectors:

Hypertronics / OmniScan a

Search Unit Manufacturer:

GE Element Length:

2.70 mm Transmit Model:

115-000-404 Element Width:

1.20 mm Transmit Serial Number:

01ML7V Elements (Primary Axis):

16 Receive Model:

115-000-405 Elements (Secondary Axis):

2 Receive Serial Number:

01MLLN Inactive Element-Transmit:

0 Frequency (MHz):

2.0 Inactive Element - Receive:

0 Calibration Data Files Focal Law: DH CIRC Z3.LAW Angles Generated: 00 through 690 (10 Increments)

Wave Mode: Longitudinal Set-up File: CR3-08-DH-Z3-CIRC.ops Focal Sound Path: 20mm Couplant / Batch Ultragel Il/ 02220 Calibration Block(s): SI-13-CIRC-03 Calibration Reflector Data Comments:

Calibration Reference

% FSH Ref. Gain Wedge Applies for the circumferential Reflector Angle Delay examination of the Weld Overlay 0.50" Deep SDH WOL 520 80 37.0dB 2.00 psec material.

1.00" Deep SDH WOL 480 82 42.9dB 0.30 psec Calibration Performed Examiner Level Date - Time Initial:

Michael Klienjan 4.,

II 03/17/2008 @ 1531 Final:

Michael Klienjan 4 0.

1I 03/18/2008 @ 1345 Reviewed:

111 03/19/08

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