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Responds to 830826 Intergranular Stress Corrosion Cracking Order Confirming Shutdown & 830304 IE Bulletin 83-02 by Providing Results of Ultrasonic Test Insp of ASME Code Class I Stainless Steel Piping.Work in Progress on Overlay Repair
	ML20082H397
Person / Time
Site:	Brunswick
Issue date:	11/28/1983
From:	Howe P; CAROLINA POWER & LIGHT CO.
To:	Harold Denton; Office of Nuclear Reactor Regulation
References
	REF-SSINS-6820 BSEP-83-3748, IEB-83-02, IEB-83-2, NUDOCS 8312010143
	Download: ML20082H397 (25)
	v • d • e

_ _ _ _. -

CD&L

~

Carolina Power & Light Company M

s Brunswick Steam Electric Plant P. O. Box 10429 Southport, NC 28461-0429 November 28, 1983 FILE: B09-13510A SERIAL: BSEP/83-3748 Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation United States Nuclear Regulatory Commission Washington, DC 20555 BRUNSWICK STEAM ELECTRIC PLAN'T, UNIT NO. 2 DOCKET NO. 50-324 LICENSE NO. DPR-62 IGSCC INSPECTION RESULTS

Dear Mr. Denton:

In response to your letter of August 26, 1983, transmitting an IGSCC Order Confirming Shutdown and IE's letter of March 4, 1983, transmitting IE Bulletin 83-02, Carolina Power & Light Company shut down Brunswick Unit No. 2 on November 2, 1983, to perform IGSCC inspections on required piping. This report contains the results of those UT inspections of ASME Code Class I stainless steel piping.

It also describes the corrective actions and provides a basis for continued operation for a period of up to six months after startup. The inspections are complete, with work in progress on overlay repairs.

Scope of Inspection ASME Code Class I nonconforming stainless steel weld joints that are 4" or greater were inspected during the current outage. Table 1 lists these joints, along with materials and fabrication information.

Isometric sketches showing the location of these welds are attached. Those welds that involved austenitic stainless steel for which the carbon content is greater than 0.04%

were considered to be nonconforming. Only the recirculation pump discharge valve bypass lines, the recirculation 12" safe-end transition pieces, and the recirculation 28" safe-ends are conforming stainless steel material. The weld filler metal used in Class I stainless steel piping at Brunswick was stainless steel Type 308, 308L, 316, or 316L. The stainless steel pipe is Type 304.

The only weld joints that were solution annealled at Brunswick are the seam welds and the recirculation sweepolet to discharge manifold welds.

T:te recirculation system piping was purchased from General Electric (GE) with the shop welds being made by Aesociated Piping and Engineering (AP&E) of Compton, California and field erection performed by GE.

For the stainless steel joints in the Residual Heat Removal (RHR) System, the field welds were made by Brown and Root, and the shop welds by M. W. Kellogg Company of Williamsport, Pennsylvania. The Class I reactor water clean-up piping vas also fabricated by the M. W. Kellogg Company and erected by Brown & Root.

8312010143 831128 0\\

DR ADOCK 05000324 PDR i\\

Mr. H. R. Denton Inspection Program Inspections conducted on Brunswick Unit No. 2 were performed by GE and LMT.

Examination teams were divided into a master / slave arrangement. The master directing the examination was located outside the drywell and communicated with the slave with headsets with a duplicate oscilloscope display. The slave performed the actual scanning under the direction of the master.

The "masterc" were Level II or Level III personnel qualified per IEB 83-02 and graduates of the 40-hour EPRI course on IGSCC which was under the auspices of an NRC representative. The " slaves" were Level I/II personnel qualified per IEB 83-02 (except for the length of cracked pipe on which the proficiency demonstration was performed). This length was limited by the availability of cracked specimens. The Level II slaves who were graduates of the 40-hour EPRI course on IGSCC were deemed qualified to scan without further demonstration.

Other Level I/II slaves were required to demonstrate scanning ability by demonstration on a Nine-Mile Point Plant pipe sample containing known areas of IGSCC.

Details of the methods used for the ultrasonic inspections are listed below:

1.

Calibration was established from calibration holes only. This provides higher sensitivity than using calibration notches.

BSEP Unit No. 2 did not exhibit abnormally high noise levels.

2.

Scanning sensitivity was a minimum of 6 dB above calibration.

3.

Scanning speed was sufficiently slow to ensure careful observation of the reflected ultrasonic signals.

In no case was it permitted to exceed 4 inches /second.

4.

A scanning overlap of 50% for each successive scan was used in lieu of the code required 10% overlap on 124 of the 131 welds inspected.

5.

Applicable welds were examined from ten directions; two perpendicular, four parallel, and four oblique for the different pipe sizes.

Additionally, during the scans, the search unit was oscillated 30.

The pipe-to pipe and pipe-to-elbow welds were examined for both sides-other welds were accessible for examination from one side only.

6.

A one-half node examination was performed on the welds. Weld crowns permitted examination to the root.

7.

Relevant reflectors originating in HAZ or base metal were recorded regardless of amplitude.

8.

Final evaluations were performed by a Level III examiner.

Indications were plotted using previous thickness data and weld joint preparation drawings. Additionally, weld crown heights and widths were measured.

Mr. H. R. Denton 9.

Signal characteristics and plots of the indications determined evaluation methodology. Evaluation could require:

a.

Thickness readings in the indication area.

b.

Confirmation of root /counterbore geometry using radiographs.

c.

Examination of the indication using different angles.

d.

Field evaluation by the Level III.

e.

Review of previous UT data 10.

Initial sizing is performed using the amplitude drop method. The drop points were the transducer position where the IGSCC indication signal rose and fell into the general noise level on the oscilloscope.

11.

For IGSCC indications that are not repaired, an alternate sizing technique using a crack-tip method is being used. This provides a higher confidence level than a single sizing methodology. The sizing method which results in the largest indication sizing is used for each indication when performing analyses.

Welds in which IGSCC indications have been detected and the characteristics of the indications are listed in Table 2.

Disposition of IGSCC Indications A flawed pipe analysis in accordance with ASME Code,Section XI, Article IWB-3640 was performed for unrepaired weld joints that contained IGSCC indications. The highest value of primary stress in the recirculation system is 15,300 psi which corresponds to a stress ratio of 0.91.

Most of the cracks are short; however, for the crack growth rate analysis, the circumferential cracks were assumed to extend 360 around the pipe at the UT measured depth. A crack growth rate corresponding to severely weld sensitized material was used for a period of six months. The value of steady-state stress used for the bounding crack growth analysis is 9,680 psi.

The crack growth analysis will be performed agcin after the value of shrinkage-induced stress is known. None of the end-of-period predicted depths approached two-thirds of the allowable depth given by IWB-3640 for cracks 0.5" longer than the measur:d lengths. The initial crack depth corresponding to the end-of period depth limit was in each case greater than twice the depth estimated by UT measurements. This highly conservative approach ensures the integrity of the system for the proposed operating period of six months.

The overlay repair designs are based on through-wall cracks with a length equal to the measured crack length plus 0.5".

The design thicknesses are adequate to satisfy Article IWB-3640.

Mr. H. R. Denton Attachment C to SECY-83-267C, dated November 7,1983, gives criterion for weld overlay repairs. This document was made available to CP&L after the Unit No. 2 program was initiated and was implemented as practicable in the last portion of our program. The repairs on joints 2-B32-12"-K2, 2-B32-12"-J2, 2-B32-12"-G4, 2-G31-6"-10, 2-G31-6"-15, and 2-G31-6"-16 have sufficient thickness to conform to the criteria given in Attachment C.

For the other joints, the actual average thicknesses are 0.22" for 2-B32-12"-J3 and 0.28" for 2-B32-12"-K3, compared to 0.30" for conformance to Attachment C.

The penetrant test of the first overlay layer was done for 2-B32-12"-J2, 2-B32-12"-K2, 2-B32-6"-15, and 2-G31-6"-16, and all indications detected were repaired. All overlays had at least three layers.

Specific information, including analysis methods and results which envelope all crack propagation analyses used to justify interim operation for a period of six months, was being presented to your staff November 22, 1983. This presentation included methods and results for the weld overlay repairs. Prior to startup, as-built analyses will have been completed. The final design report giving details of the fracture mechanics evaluations, weld overlay designs and evaluations of the shrinkage stresses due to the weld overlays will be subm!tted within 45 days of the unit startup.

Compensatory Actions To provide additional assurance of safe operation, CP&L commits to the following limits and actions on the primary containment leakage and monitoring instrumen-tation.

1.

The Reactor Coolant System leakage shall be limited to a 2 gpm increase in unidentified leakage within any 24-hour period (leakage shall be monitored and recorded once every 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months ).

Should this leakage limit be exceeded, the unit shall immediately start an orderly shutdown. The unit shall be placed in at least hot shutdown within the next 12 hours1.388889e-4 days 0.00333 hours 1.984127e-5 weeks 4.566e-6 months and in cold shutdown within the following 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months .

2.

At least one primary containment sump collection and flow monitoring system shall be operable. With the primary containment sump collection and flow monitoring system inoperable, restore the inoperable systems to operable status within 24 houre or immediately initiate an orderly shutdown and be in at least hot shutdown within the next 12 hours1.388889e-4 days 0.00333 hours 1.984127e-5 weeks 4.566e-6 months and in cold shutdown within the following 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months .

Mr. H. R. Denton In conclusion, CP&L feels that it has complied with the requirements of the August 26, 1983, order and IE Bulletin 83-02 sufficiently to allow startup and continued operation on Brunswick Unit No. 2 until its planned Spring 1984 outage. Conservative analyses have been performed on welds with indications to determine appropriate corrective actions. Based on very conservative criteria, repairs have been or will be made on eight welds prior to startup, with the analysis showing that the remaining welds will remain structurally sound beyond the Spring 1984 outage. Additionally, existing stringent drywell leakage limits will continue to be in effect until total resolution is' completed in the 1984 outage.

Since 1) the indications identified were small in size, 2) conservative analyses show that propagation between now and the Spring 1984 outage is not a technica. concern, and 3) the continued enhanced surveillance requirements in effect on drywell leakage will be maintained, CP&L feels that startup and continued operation of Brunswick Unit No. 2 until April 30, 1984, will not adversely affect the health or safety of the public.

CP&L will submit a plan for. future weld inspections and disposition of the unrepaired indications on or before February 15, 1984 Very truly yours, Q. C<)) M P. W. Howe, Vice President Brunswick Nuclear Project JGT/RMP/pms/ LETCH 2 Attachments j

P. W. Howe, having been first duly sworn, did dispose and say that the information contained herein is true and correct to his own personal knowledge or based upon information and belief.

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My commission expires: 3-Mk-E 7 cc:

Mr. R. C. DeYoung Mr. J. P. O'Reilly NRC Document Control Desk

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BSEP-83-3748, Responds to 830826 Intergranular Stress Corrosion Cracking Order Confirming Shutdown & 830304 IE Bulletin 83-02 by Providing Results of Ultrasonic Test Insp of ASME Code Class I Stainless Steel Piping.Work in Progress on Overlay Repair

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Dear Mr. Denton:

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BSEP-83-3748, Responds to 830826 Intergranular Stress Corrosion Cracking Order Confirming Shutdown & 830304 IE Bulletin 83-02 by Providing Results of Ultrasonic Test Insp of ASME Code Class I Stainless Steel Piping.Work in Progress on Overlay Repair

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Dear Mr. Denton:

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