L-2007-045, In-Service Inspection Plans, Use of Structural Weld Overlays as an Alternative Repair Technique Third Ten-Year Interval Unit 2 Relief Request 10

In-Service Inspection Plans, Use of Structural Weld Overlays as an Alternative Repair Technique Third Ten-Year Interval Unit 2 Relief Request 10

ML070990062
Person / Time
Site:	Saint Lucie
Issue date:	03/29/2007
From:	Johnston G Florida Power & Light Co
To:	Document Control Desk, NRC/NRR/ADRO
References
L-2007-045
Download: ML070990062 (33)

Text

FPL Florida Power & Light Company, 6501 S. Ocean Drive, Jensen Beach, FL 34957 March 29, 2007 L-2007-045 10 CFR 50.4 10 CFR 50.55a U. S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, D.C 20555 Re:

St. Lucie Unit 2 Docket No. 50-3 89 In-Service Inspection Plans Use of Structural Weld Overlays as an Alternative Repair Technique Third Ten-Year Interval Unit 2 Relief Reqiuest 10 Pursuant to the provisions of 10 CFR 50.55a(a)(3)(i), Florida Power & Light (FPL) requests approval to use structural weld overlays (SWOLs) as an alternative repair method. Dissimilar metal welds (DMWs) have shown a propensity for primary water stress corrosion cracking (PWSCC) degradation. For the upcoming SL 17 refueling outage, six (6) DMWs located on the pressurizer and hot leg piping are currently scheduled to have SWOLs applied. Relief is requested on the basis that the relief request provides an acceptable level of quality and safety.

FPL requests approval of the relief request prior to entering Mode 4 during the fall 2007 St. Lucie Unit 2 refueling outage, SL2-17, tentatively scheduled for Mid December.

Please contact Ken Frehafer at 772-467-7748 if there are any questions about this submittal.

Very truly yours, Site Vice President St. Lucie Plant Attachment GLJ/KWF A04-7 an FPL Group company

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 1 of 32 Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i)

Alternative Provides Acceptable Level of Quality and Safety USE OF WELD OVERLAYS AS AN ALTERNATIVE REPAIR TECHNIQUE

1.0 ASME Code Components Affected

Code components associated with this request are six (6) Class 1 safe end-to-nozzle dissimilar metal welds (DMWs) with Alloy 82/1 82 weld metal that are believed to be susceptible to Primary Water Stress Corrosion Cracking (PWSCC). Preemptive full structural weld overlays (SWOLs) are planned to be applied to these DMWs. In addition, the SWOLs will extend across the six (6) adjacent stainless steel pipe/elbow-to-safe end similar metal welds. These welds are scheduled to have SWOLs applied during the upcoming St. Lucie Unit 2 (PSL2) SL-2-17 refueling outage.

1.1 Category and System Details:

Code Class:

Class 1 System Welds:

Reactor Coolant System Examination Categories:

R-A*

• As submitted and approved by St. Lucie Unit 2, 3rd 10-year ISI Program Relief Request 2 1.2 Component Descriptions:

The application of this alternative is to apply SWOLs on one (1) safe end-to-pressurizer surge nozzle weld, one (1) safe end-to-pressurizer relief nozzle weld, two (2) safe end-to-hot leg shutdown cooling outlet nozzle welds (one in each hot leg), one (1) safe end-to-hot leg B surge nozzle weld and one (1) safe end-to-hot leg A drain nozzle weld. The SWOLs will also extend outward from the nozzle across the adjacent stainless steel pipe/elbow-to-safe end welds. The applicable weld identifications are as follows in Table 1.

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 2 of 32 TABLE I Weld Nos.

Nozzle to Safe End Safe-End to Item Location Weld Pipe/Elbow 1

Pressurizer Surge Line Nozzle RC-514-671 RC-1 08-FW-1 2

Pressurizer Relief Line Nozzle RC-506-671 RC-101-FW-1 3

Surge Line to Hot Leg B Pipe Nozzle RC-301-771 RC-1 08-FW-3 4

Shutdown Cooling Outlet to Hot Leg 'A' Pipe RC-501-771 RC-162-FW-1 5

Shutdown Cooling Outlet to Hot Leg 'B' Pipe RC-302-771 RC-147-FW-1 6

Hot Leg 'A' Drain Nozzle RC-1 14-502-771 RC-145-FW-1.

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 3 of 32 1.3 Component Materials:

The specific materials are shown in Table 2:

TABLE 2 Materials Item Location Nozzle Safe-End Pipe/Elbow Buttering 1

Pressurizer Surge P-No. 3 Group 3 Low P-No.8 Cast P-No.8 Cast F-No. 43 Line Nozzle Alloy Steel SA-508 Stainless Steel Stainless Steel SA-Alloy CL2 SA-351 CF8M.

351 CF8M.

82/182 2

Pressurizer Relief P-No. 3 Group 3 Low SA-1 82 F316 P-No. 8 SA-312 TP F-No. 43 Line Nozzle Alloy Steel SA-508 304 Stainless Steel Alloy CL2 82/1 82 3

Surge Line to Hot P-No. 1 Group 2 P-No.8 Cast P-No.8 Cast F-No. 43 Leg 'B' Pipe Carbon Steel SA-105 Stainless Steel Stainless Steel SA-Alloy Nozzle Grade 11 SA-351 CF8M.

351 cF8M.

82/182 4

Shutdown Cooling P-No. 1 Group 2 P-No.8 Cast P-No. 8 SA-312 TP F-No. 43 Outlet to Hot Leg Carbon Steel SA-1 05 Stainless Steel 304 Stainless Steel Alloy

'A' Pipe Grade 11 SA-351 CF8M.

82/1 82 5

Shutdown Cooling P-No. 1 Group 2 P-No.8 Cast P-No. 8 SA-312 TP F-No. 43 Outlet to Hot Leg Carbon Steel SA-1 05 Stainless Steel 304 Stainless Steel Alloy

'B' Pipe Grade 11 SA-351 CF8M.

82/1 82 6

Hot Leg 'A' Drain P-No. 1 Group 2 SA-1 82 F316 P-No. 8 SA-312 TP F-No. 43 Nozzle Carbon Steel SA-105 304 Stainless Steel Alloy Grade 11 82/182

St. Lucie Unit 2 Attachment Third Inspection Interval Atachentof3 Relief Request Number 10Paef2 2.0

Applicable Code Edition and Addenda

PSL-2 is currently in the 3rd 10-year Inservice inspection (ISI) interval. The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (Code) of record for the current 10-year IS[ interval isSection XI, 1998 Edition, including Addenda through 2000 (Reference 1). This is also the version used for the Repair/Replacement Program.

3.0

Applicable Code Requirement

The applicable Code requirement for which the relief is requested is ASME Code Section Xl, 1998 Edition including Addenda through 2000 (Reference 1),

IWA-441 0(a), IWA-461 1.1 (a) and Appendix ViIl Supplement 11.

IWA-441 0(a) states in part the following:

"Welding, brazing, defect removal, and installation activities shall be performed in accordance with IWA-4420 or IWA-4430, and the other requirements of this Subarticle.....

IWA-461 1.1 (a) states in part the following:

"Defects shall be removed or reduced in size in accordance with this Paragraph."

Appendix ViII provides requirements for performance demonstration for ultrasonic examination systems. Supplement 11 provides qualification requirements for full structural overlaid wrought austenitic piping welds.

4.0

Reason for Request

Dissimilar metal welds (DMWs), primarily consisting of Alloy 82/1 82 weld metal are frequently used in pressurized water reactor (PWR) construction to connect stainless steel pipe and safe ends to vessel and pipe nozzles, generally constructed of carbon or low alloy ferritic steel. These welds have shown a propensity for PWSCC degradation, especially in components subjected to higher operating temperatures, such as the pressurizer. See EPRI MRP-169

'Technical basis for Preemptive Weld Overlays for Alloy 82/1 82 Butt Welds in PWRs," October 2005 (Reference 2).

For the upcoming SL-2-1 7 refueling outage, six (6) DMWs located on the pressurizer and hot leg piping are currently scheduled to have SWOLs applied.

Repair/replacement activities associated with SWOL repairs are required to

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 5 of 32 address the materials, welding parameters, ALARA concerns, operational constraints, examination techniques and procedure requirements for repairs.

ASME Code Section XI, 1998 Edition including Addenda through 2000 (Reference 1), IWA-441 0(a) and IWA-461 1.1 (a) do not address all the needed requirements for this type of repair since potential existing defects will not be removed or reduced in size, and weld overlay of potential existing flaws in DMWs will be performed. Also comprehensive and generic NRC approved criteria are not currently available for application of SWOL repairs to DMWs constructed of Alloy 82/1 82 weld material for mitigation of potential PWSCC.

In addition, ASME Code Section XI, 1998 Edition including Addenda through 2000 (Reference 1), Appendix VIII Supplement 11 cannot be implemented as written for ultrasonic examination of a structural weld overlay repair. Attachment 1 includes a discussion of the Performance Demonstration Initiative (PDI)

Program alternatives and their bases with respect to Appendix VI II Supplement 11 requirements.

The alternative described in Section 5.0 is proposed to permit the implementation of SWOLs at PSL-2, as an alternative for the repair/replacement requirements of the ASME Code Section Xl, 1998 Edition, including Addenda through 2000 (Reference 1), IWA-441 0(a), IWA-461 1.1 (a) and Appendix VIII, Supplement 11.

5.0 Proposed Alternative and Basis for Use

The ASME Subcommittee XI has recently approved Section XI Code Case N-740-1, Draft dated February 2007 "Dissimilar Metal Weld Overlay for Repair of Class 1, 2, and 3 Items," provided as Attachment 2. This Draft Code Case is the result of the industry's experience with weld overlay repairs for flaws suspected or confirmed to be from PWSCC and for the first time directly applies to the Alloy 52M weld material that is primarily being used for these overlay repairs.

This proposal requests the use of the Code Case N-740-1 Draft February 2007 (Attachment 2) for implementing the six (6) scheduled SWOLs for potentially PWSCC susceptible safe end-to-nozzle welds of the pressurizer and reactor coolant hot leg piping. These SWOLs will include the six (6) adjacent stainless steel pipe/elbow-to-safe end welds. This request applies to each of the welds listed in Section 1.2, which are generically depicted in Figure 1. The proposed alternative is scheduled to be performed during the SL-2-17 Fall 2007 refuel outage.

The ultrasonic and surface examinations will be performed on the temper bead portion of the SWOLs no sooner than 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> after completion of the third temper bead layer. Currently, Code Case N-740-1 Draft February 2007,

St. Lucie Unit 2 Attachment Third Inspection Interval Atachentof3 Relief Request Number 10Pgeo3 paragraph 3(a)(2), specifies that ultrasonic and surface examination be performed 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> after the completed weld has returned to ambient temperature.

The ultrasonic examination of the completed SWOLs will be accomplished with personnel and procedures qualified in accordance with ASME Code Section XI, 1998 Edition, including Addenda through 2000 (Reference 1) Appendix VIII, Supplement 11 (as specified in Code Case N-740-1 Draft February 2007, section 3 therein), with the alternatives used for complying with the P01 Program. See Attachment 1 for the PDI Program changes to Appendix VII I Supplement 11.

5.1 Structural Weld Overlay (SWOL) Design The SWOLs satisfy all the structural design requirements of the pipe assuming no strength contributed by the original safe end-to-nozzle welds nor the pipe/elbow-to-safe end welds, as if the welds were removed. As shown in Figure 1, the SWOLs will completely cover the existing Alloy 82/182 weld and will extend onto the ferritic nozzle and austenitic stainless steel material on each end of the weld, including the adjacent pipe/elbow-to-safe end weld. The SWOLs extend around the entire circumference of the nozzle. Alloy 52M and 52 filler metals are compatible with all the wrought and cast base materials and the DMW and similar metal welds that will be covered by the SWOL.

The SWOLs will be designed as full structural overlays (assumed worst case flaw) in accordance with ASME Section XI Code Case N-740-1 Draft February 2007 (Attachment 2), Section 2 therein. Note that the details surrounding the design analysis for the SWOLs are being developed to support the PSL2 Fall 2007 refueling outage and our vendor has committed to supplying this analysis to FPL. The analysis will be available at the plant for NRC review at the beginning of the SL-2-17 refuel outage.

5.2 Welding The welding will be performed in accordance with Code Case N-740-1 Draft February 2007 (Attachment 2) using a remote machine gas tungsten-arc welding (GTAW) process and using the ambient temperature temper bead method with ERNiCrFe-7A (Alloy 52M) weld metal. Manual OTAW, using ERNiCrFe-7 (Alloy 52) or Alloy 52M will be used if local repairs of weld defects are necessary or additional weld metal is required locally to form the final SWOL contour in locations at least 3/16 in. away from the low alloy or carbon steel nozzles.

For applicable cases where Code Case N-740-1 Draft February 2007 paragraph 1 (c)(1) applies, the final SWOL ultrasonic and surface examination will be performed after completion of welding since temper bead welding would not

St. Lucie Unit 2 L'2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 7of 32 be required. The clarifications in this paragraph are conservative with respect to the intent of the Construction Code post weld heat treatment (PWHT) exemption requirements [Table NB-4622.7(b)-1] since all weld overlays are deposited on the surfaces of the ferritic steel nozzles instead of partial or complete through thickness welds applicable for the cases described in the Construction Code.

5.3 Examination The ultrasonic and surface examinations will be performed on the temper bead portion of the SWOLs no sooner than 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> after completion of the third temper bead layer. Currently, Code Case N-740-1 Draft February 2007, Paragraph 3(a)(2), specifies that ultrasonic and surface examination be performed 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> after the. completed weld has returned to ambient temperature.

The 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> delay is intended to provide time for delayed hydrogen cracking occurrence. Code Case N-740-1 Draft February 2007, Appendix 1 requires the machine or automatic GTAW process to be used for temper bead welding thereby eliminating the use of welding processes requiring flux for arc shielding.

The machine OTAW temper bead process uses a welding process that is inherently free of hydrogen. The GTAW process relies on bare welding electrodes and bare wire filler metal with no flux to absorb moisture. An inert gas blanket provides shielding for the weld and surrounding metal, which protects the region during welding from the atmosphere and the moisture it may contain and typically produces porosity free welds. In accordance with the weld procedure qualification, welding grade argon is used for the inert gas blanket. To further reduce the likelihood of any hydrogen effects, specific controls will be used to ensure the welding electrodes, filler metal and weld region are free of all sources of hydrogen.

In addition, the use of the machine GTAW temper bead process provides precise control of heat input, bead placement, bead size and contour. The very precise control over these factors afforded by the machine GTAW process provides effective tempering of the nozzle ferritic steel HAZ resulting in achievement of lower hardness and tempered martensite. This further reduces susceptibility to hydrogen induced cracking.

EPRI Report 1013558, Temperbead Welding Applications, 48 Hour Hold Requirements for Ambient Temperature Temperbead Welding, Technical Update, December 2006 (Reference 3) provides justification for reducing the 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> hold time on P-No. 3 Group No. 3 ferritic steel base material to start after completion of the third temper bead layer instead of the currently specified hold time in Code Case N-740-1 Draft, February 2007. Report 1013558 addresses

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 8 of 32 microstructural issues, hydrogen sources, tensile stress and temperature, and diffusivity and solubility of hydrogen in steels.

The base materials studied in the EPRI report are primarily P-No. 3. The pressurizer nozzle base materials at PSL2 are P-No. 3 Group. No. 3 and the hot leg piping nozzle base materials are P-No. 1 Group No. 2. The concerns associated with hydrogen assisted cracking are generally more significant for P-No. 3 than P-No.1 base materials due to the P-No. 3 base materials increased hardenability. Also, post weld heat treat exemptions shown in ASME Section 111, Table NB-4622.7(b)-1 are provided for P-No. 1 Group No. 2 materials, including temper bead welding, whereas no post weld heat treat exemptions, other than temper bead welding, are permitted for P-No. 3 Group No. 3 materials.

Past industry experience with the use of the machine or automatic GTAW process has resulted in no detection of hydrogen induced cracking after the 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> hold NDE or subsequent in-service inspections.

There is currently an ASME XI Subcommittee action to incorporate the revised NDE hold requirement into Code Case N-740-1 Draft February 2007. Code Case N-638-3, "Similar and Dissimilar Metal Welding Using Ambient Temperature Machine GTAW Temper Bead Technique Section Xl Division 1,"

has been revised with Main Committee and Board of Nuclear Codes and Standards approval to specify NDE 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> after completion of the third temper bead IlIayer.

All examinations will meet the requirements of the Code Case N-740-1 Draft February 2007, excluding qualification of the ultrasonic examination for the completed SWOLs. The ultrasonic examination qualification will be in accordance with ASME Code Section XI, 1998 Edition including Addenda through 2000 (Reference 1), Appendix VIII1, Supplement 11 with the alternatives that are used to comply with the PDI Program. See Attachment 1 for the PDI Program changes to Appendix VIII Supplement 11.

The PDI Program allows closer spacing of flaws provided they don't interfere with detection or discrimination. The specimens used to date for qualification to the Tni-party (NRC/BWROG/EPRI) agreement have a flaw population density greater than allowed by current Code requirements. These samples have been used successfully for all previous qualifications under the Tni-party agreement program. To facilitate their use and provide continuity from the Tni-party agreement program to Supplement 11, the PDI Program has merged the Tni-party test specimens into their structural weld overlay program.

However, the cast stainless steel base material of the applicable safe ends and the surge line elbow at the pressurizer surge nozzle and the surge pipe at the hot leg B surge nozzle are not currently within the scope of PDI qualified ultrasonic

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 9of 32 examination procedures.

Qualified representative mockups are not currently available, and examination procedures and personnel have not yet been demonstrated for the cast material. In these cases, an Appendix Ill ultrasonic examination will be performed, using the existing PDI qualified personnel and procedures as shown in Attachment 1.

5.4 Conclusion Similar NRC approved requests have been used to produce acceptable weld overlays when applied to dissimilar metal welds with Alloy 82/1 82 weld material.

The proposed alternative uses ASME Section XI Code Case N-740-1 Draft February 2007 (Attachment 2) that has been developed to cover the most recent operating experience and NRC approved criteria that are associated with similar SWOL applications. Therefore FPL considers that this Case and the PDI Program provides an acceptable level of quality and safety, consistent with provisions of 10 CFR 50.55a(a)(3)(i).

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 10 of 32

6.0 Precedents

Similar requests have been submitted to address the issues that are contained in this request. These include requests from the Indiana Michigan Power Company's, 0. C. Cook Unit 2. NRC verbal approval was received on March 23, 2006, for their request, which included the application of full structural SWOLs applied to their pressurizer dissimilar metal butt welds.

Additionally, the following requests associated with weld overlay repairs have been approved by the NRC: AmerGen Energy Company, Three Mile Island Nuclear Station, Unit 1, on July 21, 2004;(1) Constellation Energy's Calvert Cliffs Nuclear Power Plant, Unit 2, on July 20, 2k05;1(2) Millstone Unit 3, on January 20, 2006;1 (3 and Indiana Michigan Power Company, Donald C. Cook Unit 1, on February 10, 2006. (4 (1) NRC letter, Safety Evaluation of Request for Relief from Flaw Removal, Heat Treatment and Nondestructive Examination (NDE) Requirements for the Third 10-Year Inservice Inspection Interval, Three Mile Island Nuclear Station, Unit 1 (TMI-1),

Docket No. 50-289, (TAC No. MC12O1), dated: July 21, 2004, (ADAMS Accession No. MLO041 670510).

(2) NRC letter, Safety Evaluation for Calvert Cliffs Nuclear Power Plant, Unit No. 2, Docket No. 550-318, Relief Request for Use Weld Overlay and Associated Alternative Inspection Techniques (TAO Nos. MC6219 and MC6220), dated July 20, 2005, (ADAMS Accession No. ML-051930316).

(3) NRC letter, Safety Evaluation of Relief Request IR-2-39 Pertaining to the Repair and Inspection of Nozzle to Safe End Weld, Weld No. 03-X-5641-E-T at Millstone Power Station Unit No. 3 (MPS3) Docket No. 50-423, (TAO No. MC8609), dated January 20, 2006, (ADAMS Accession No. ML-053260012).

(4) NRC letter, Safety Evaluation of Alternative Regarding Repair of Safe-End-To-Elbow Weld 1-RC-9-01F at the Donald C. Cook Nuclear Plant Unit 1, Docket No. 50-315, (TAO No.

MC8807),

dated February 10,

2006, (ADAMS Accession No.

ML-060240355).

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 11 of 32 7.0 Duration of Proposed Alternative The alternative requirements of this request will be applied for the duration of up to and including the last outage of the current 3rd 1 0-year ISI interval which includes inservice examination requirements of Code Case N-740-1 Draft February 2007 (Attachment 2) for any applied weld overlays. The use of Code Case N-740-1 Draft February 2007 is requested until the NRC publishes the Code Case as a future revision of Regulatory Guide 1.147. Future inservice examinations of weld overlays at PSL-2 beyond this inspection interval will be as required by the NRC in the regulations.

8.0 References.

1. ASME Code, Section Xl, 1998 Edition, including Addenda through 2000

2. EPRI MRP-169 "Technical Basis for Preemptive Weld Overlays for Alloy 82/182 Butt Welds in PWRs," October 2005.

3. EPRI Report 1013558, Temperbead Welding Applications, 48 Hour Hold Requirements for Ambient Temperature Temperbead Welding, Technical. Update, December 2006.

9.0 Attachments "PDI Program Modifications to Appendix VIII Supplement 11" Code Case N-740-1 "Draft Dissimilar Metal Weld Overlay for Repair of Class 1, 2, and 3 ItemsSection XI, Division 1 "

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 SS Pipe8(A481 &GFSM[

(PZR Surge =o10eI SS Pipe (SA4312 TP30-4 (Hot Leg Shuttdown OColbig Outlet Nozzles' Mot L4g A Draf " Nozzei 88Elbow (SA-8Sl CFSM[i; (Hot LegSure NxAw8 :

L-2007-045 Attachment Page 12 of 32 88Sat* hid (8A4161 CFSMj PZR Surge Nozzle& PZR Relief Nozzle Kb~ Leg B "eNk e&H ut Leg

/Shutdown Coc~ng Outlet Nozzles Nozzf Low Alloy Steud IS-SCas9 2

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St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 13 of 32 PDI Program Modifications to Appendix V1II Supplement 11 Appendix V1II, Supplement 11 PDI Modification 1.0 SPECIMEN REQUIREMENTS

1. 1 General (b) The specimen set shall consist of at least Modification: (b) The specimen set shall consist of at three specimens having different nominal pipe least three specimens having different nominal pipe diameters and overlay thicknesses. They shall diameters and overlay thicknesses. They shall include include the minimum and maximum nominal the minimum and maximum nominal pipe diameters for pipe diameters for which the examination which the examination procedure is applicable. Pipe procedure is applicable. Pipe diameters within a diameters within a range of 0.9 to 1.5 times a nominal range of 0.9 to 1.5 times a nominal diameter diameter shall be considered equivalent. If the procedure shall be considered equivalent. If the procedure is applicable to pipe diameters of 24 inches or larger, the is applicable to pipe diameters of 24 inches or specimen set must include at least one specimen 24 larger, the specimen set must include at least inches or larger but need not include the maximum one specimen 24 inches or larger but need not diameter.

include the maximum diameter. The specimen The specimen set shall include specimens with overlays set must include at least one specimen with not thicker than 0. 1 inches more than the minimum overlay thickness within -0. 1 inches to +0.25 thickness, nor thinner than 0.25 inches of the maximum inches of the maximum nominal overlay nominal overlay thickness for which the examination thickness for which the procedure is applicable, procedure is applicable.

Basis: To avoid confusion, the overlay thickness tolerance contained in the last sentence was reworded and the phrase "and the remainder shall be alternative flaws" was added to the next to last sentence in paragraph 1. 1 (d) (1).

(d) Flaw Conditions (1) Base metal flaws. All flaws must be cracks Modification: (1) Base metal flaws. All flaws must be in or near the butt weld heat-affected zone, open in or near the butt weld heat-affected zone, open to the to the inside surface, and extending at least 75%

inside surface, and extending at least 75% through the through the base metal wall. Flaws may extend base metal wall. Intentional overlay fabrication flaws 100% through the base metal and into the shall not interfere with ultrasonic detection or overlay material; in this case, intentional characterization of the base metal flaws. Specimens overlay fabrication flaws shall not interfere with containing IGSCC shall be used when available. At least ultrasonic detection or characterization of the 70% of the flaws in the detection and sizing tests shall be cracking. Specimens containing IGSCC shall cracks and the remainder shall be alternative flaws.

be used when available.

Alternative flaw mechanisms, if used, shall provide crack-like reflective characteristics and shall be limited by the following:

(a) The use of alternative flaws shall be limited to when the implantation of cracks produces spurious reflectors that are uncharacteristic of actual flaws.

(b) Flaws shall be semi elliptical with a tip width of less

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 14 of 32 Appendix V1II, Supplement 11 PDI Modification than or equal to 0.002 inches.

Basis: This paragraph requires that all base metal flaws be cracks. Implanting a crack requires excavation of the base material on at least one side of the flaw. While this may be satisfactory for ferritic materials, it does not produce a useable axial flaw in austenitic materials because the sound beam, which normally passes only through base material, must now travel through weld material on at least one side, producing an unrealistic flaw response. To resolve this issue, the PDJ program revised this paragraph to allow use of alternative flaw mechanisms under controlled conditions. For example, alternative flaws shall be limited to when implantation of cracks precludes obtaining an effective ultrasonic response, flaws shall be semi elliptical with a tip width of less than or equal to 0.002 inches, and at least 70% of the flaws in the detection and sizing test shall be cracks and the remainder shall be alternative flaws. To avoid confusion, the overlay thickness tolerance contained in paragraph 1. 1(b) last sentence, was reworded and the phrase "and the remainder shall be alternative flaws" was added to the next to last sentence. Paragraph 1. 1 (d)( 1) includes the statement that intentional overlay fabrication flaws shall not interfere with ultrasonic detection or characterization of the base metal flaws.

(e) Detection Specimens (1) At least 20% but less than 40% of the flaws shall be oriented within +20 degrees of the pipe axial direction. The remainder shall be oriented circumferentially. Flaws shall not be open to any surface to which the candidate has physical or visual access. The rules of IWA-3300 shall be used to determine whether closely spaced flaws should be treated as single or multiple flaws.

Modification: (1) At least 20% but less than 40% of the base metal flaws shall be oriented within +/-20 degrees of the pipe axial direction. The remainder shall be oriented circumferentially. Flaws shall not be open to any surface to which the candidate has physical or visual access.

Basis: The requirement for axially oriented overlay fabrication flaws was excluded from the PDI Program as an improbable scenario. Weld overlays are typically applied using automated GTAW techniques with the filler metal applied in a circumferential direction.

Because resultant fabrication induced discontinuities would also be expected to have major dimensions oriented in the circumferential direction axial overlay fabrication flaws are unrealistic. The requirement for using IWA-3300 for proximity flaw evaluation was excluded, instead indications will be sized based on their individual merits.

(2) Specimens shall be divided into base and (2) Specimens shall be divided into base metal and

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 15 of 32 Appendix V1II, Supplement 11 PDI Modification overlay grading units. Each specimen shall overlay fabrication grading units. Each specimen shall contain one or both types of grading units.

contain one or both types of grading units. Flaws shall not interfere with ultrasonic detection or characterization of other flaws.

(a)(l) A base grading unit shall include at least Modification: (a)(1) A base metal grading unit includes 3 inches of the length of the overlaid weld. The the overlay material and the outer 25% of the original base grading unit includes the outer 25% of the overlaid weld. The base metal grading unit shall extend overlaid weld and base metal on both sides.

circumferentially for at least 1 inch and shall start at the The base grading unit shall not include the inner weld centerline and be wide enough in the axial direction 75% of the overlaid weld and base metal to encompass one half of the original weld crown and a overlay material, or base metal-to-overlay minimum of 0.50 inch of the adjacent base material.

interface.

Basis: The phrase "and base metal on both sides," was inadvertently included in the description of a base metal grading unit, The PDI program intentionally excludes this requirement because some of the qualification samples include flaws on both sides of the weld. To avoid confusion several instances of the term "cracks" or "cracking" were changed to the term "flaws" because of the use of alternative Flaw mechanisms. Modified to require that a base metal grading unit include at least 1 in. of the length of the overlaid weld, rather than 3 inches.

(a)(2) When base metal cracking penetrates into Modification: (a)(2) When base metal flaws penetrate the overlay material, the base grading unit shall into the overlay material, the base metal grading unit include the overlay metal within 1 inch of the shall not be used as part of any overlay fabrication crack location. This portion of the overlay grading unit.

material shall not be used as part of any overlay grading unit.

(a)(3) When a base grading unit is designed to Modification: (a)(3) Sufficient unflawed overlaid weld be unflawed, at least 1 inch of unflawed and base metal shall exist on all sides of the grading unit overlaid weld and base metal shall exist on to preclude interfering reflections from adjacent flaws.

either side of the base grading unit. The Basis: Modified to require sufficient unflawed overlaid segment of weld length used in one base weld and base metal to exist on all sides of the grading grading unit shall not be used in another base unit to preclude interfering reflections from adjacent grading unit. Base grading units need not be flaws, rather than the 1 inch requirement.

uniformly spaced around the specimen.

(b)(1) An overlay grading unit shall include the Modification: (b)(1) An overlay fabrication grading unit overlay material and the base metal-to-overlay shall include the overlay material and the base metal-to-interface of at least 6 square inches. The overlay interface for a length of at least 1 inch.

overlay grading unit shall be rectangular, with Basis: Modified to require sufficient unflawed overlaid minimum dimensions of 2 inches.

weld and base metal to exist on all sides of the grading unit to preclude interfering reflections from adjacent

___________________________________flaws, rather than the 1 inch requirement.

(b)(2) An overlay grading unit designed to be Modification: (b)(2) Overlay fabrication grading units

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 16 of 32 Appendix VIII, Supplement 11 PDI Modification unflawed shall be surrounded by unflawed overlay material and unflawed base metal-to-overlay interface for at least 1 inch around its entire perimeter. The specific area used in one overlay grading unit shall not be used in another overlay grading unit. Overlay grading units need not be spaced uniformly about the specimen.

designed to be unflawed shall be separated by unflawed overlay material and unflawed base metal-to-overlay interface for at least I inch at both ends. Sufficient unflawed overlaid weld and base metal shall exist on both sides of the overlay fabrication grading unit to preclude interfering reflections from adjacent flaws. The specific area used in one overlay fabrication grading unit shall not be used in another overlay fabrication grading unit. Overlay fabrication grading units need not be spaced uniformly about the specimen.

Basis: Paragraph 1. 1 (e)(2)(b)(2) states that overlay fabrication grading units designed to be unflawed shall be separated by unflawed overlay material and unflawed base metal-to-overlay interface for at least 1 in. at both ends, rather than around its entire perimeter.

(b)(3) Detection sets shall be selected from Table VIII-S2-1. The minimum detection sample set is five flawed base grading units, ten unflawed base grading units, five flawed overlay grading units, and ten unflawed overlay grading units. For each type of grading unit, the set shall contain at least twice as many unflawed as flawed grading units.

Modification: (b)(3) Detection sets shall be selected from Table VIII-S2-1. The minimum detection sample set is five flawed base metal grading units, ten unflawed base metal grading units, five flawed overlay fabrication grading units, and ten unflawed overlay fabrication grading units. For each type of grading unit, the set shall contain at least twice as many unflawed as flawed grading units. For initial procedure qualification, detection sets shall include the equivalent of three personnel qualification sets. To qualify new values of essential variables, at least one personnel qualification set is required.

(f) Sizing Specimen (1) The minimum number of flaws shall be ten.

At least 30% of the flaws shall be overlay fabrication flaws. At least 40% of the flaws shall be cracks open to the inside surface.

Modification: (1) The minimum number of flaws shall be ten. At least 30% of the flaws shall be overlay fabrication flaws. At least 40% of the flaws shall be open to the inside surface. Sizing sets shall contain a distribution of flaw dimensions to assess sizing capabilities. For initial procedure qualification, sizing sets shall include the equivalent of three personnel qualification sets. To qualify new values of essential variables, at least one personnel qualification set is required.

(3) Base metal cracking used for length sizing Modification: (3) Base metal flaws used for length demonstrations shall be oriented sizing demonstrations shall be oriented circumferentially.

circumferentially.

(4) Depth sizing specimen sets shall include at Modification: (4) Depth sizing specimen sets shall least two distinct locations where cracking in include at least two distinct locations where a base metal the base metal extends into the overlay material flaw extends into the overlay material by at least 0. 1 inch

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 17 of32 Appendix V111, Supplement 11 PDI Modification by at least 0. 1 inch in the through-wall in the through-wall direction.

direction.

2.0 CONDUCT OF PERFORMANCE DEMONSTRATION The specimen inside surface and identification Modification: The specimen inside surface and shall be concealed from the candidate. All identification shall be concealed from the candidate. All examinations shall be completed prior to examinations shall be completed prior to grading the grading the results and presenting the results to results and presenting the results to the candidate.

the candidate. Divulgence of particular Divulgence of particular specimen results or candidate specimen results or candidate viewing of viewing of unmasked specimens after the performnance unmnasked specimens after the performance demonstration is prohibited. The overlay fabrication demonstration is prohibited.

flaw test and the base metal flaw test may be performed separately.

2.1 Detection Test. Flawed and unflawed Modification: 2.1 Detection Test. Flawed and unflawed grading units shall be randomly mixed.

grading units shall be randomly mixed. Although the Although the boundaries of specific grading boundaries of specific grading units shall not be revealed units shall not be revealed to the candidate, the to the candidate, the candidate shall be made aware of candidate shall be made aware of the type or the type or types of grading units (base metal or overlay types of grading units (base or overlay) that are fabrication) that are present for each specimen.

present for each specimen.

2.2 Length Sizing Test (d) For flaws in base grading units, the Modification: (d) For flaws in base metal grading units, candidate shall estimate the length of that part the candidate shall estimate the length of that part of the of the flaw that is in the outer 25% of the base flaw that is in the outer 25% of the base metal wall wall thickness.

thickness.

2.3 Depth Sizing Test. For the depth sizing test, 80% of the flaws shall be sized at a specific location on the surface of the specimen identified to the candidate. For the remaining flaws, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.

Modification: 2.3 Depth Sizing Test.

(a) The depth sizing test may be conducted separately or in conjunction with the detection test.

(b) When the depth sizing test is conducted in conjunction with the detection test and the detected flaws do not satisfy the requirements of 1. 1 (f), additional specimens shall be provided to the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.

(c) For a separate depth sizing test, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 18 of 32 Appendix V1II, Supplement 11 PDI Modification 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria. Examination Modification: 3.1 Detection Acceptance Criteria.

procedures, equipment, and personnel are Examination procedures are qualified for detection qualified for detection when the results of the when:

performance demonstration satisfy the (a) All flaws within the scope of the procedure are acceptance criteria of Table VIII-S2-1 for both detected and the results of the performance detection and false calls. The criteria shall be demonstration satisfy the acceptance criteria of Table satisfied separately by the demonstration results VIII-S2-l for false calls.

for base grading units and for overlay grading (b) At least one successful personnel demonstration has units.

been performned meeting the acceptance criteria defined in (c).

(c) Examination equipment and personnel are qualified for detection when the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls.

(d) The criteria in (b) and (c) shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.

3.2 Sizing Acceptance Criteria.

(a) The RMS error of the flaw length Modification: (a) The RMS error of the flaw length measurements, as compared to the true flaw measurements, as compared to the true flaw lengths, is lengths, is less than or equal to 0.75 inch. The less than or equal to 0.75 inch. The length of base metal length of base metal cracking is measured at the flaws is measured at the 75% through-base-metal 75% through-base-metal position.

position.

(b) All extensions of base metal cracking into Modification: This requirement is omitted.

the overlay material by at least 0. 1 inch are Basis: The requirement for reporting all extensions of reported as being intrusions into the overlay cracking into the overlay is omitted from the PDI material.

Program because it is redundant to the RMS calculations performed in paragraph 3.2(c) and its presence adds confusion and ambiguity to depth sizing as required by paragraph 3.2(c). This also makes the weld overlay program consistent with the Supplement 2 depth sizing criteria.

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 19 of32

~Caze~ W740-1

~

W~iZ~ tr Dissimflar iwetalel W~Overlay f o2d Injit-r-Asc ana eken~ve tm tile jvnvli5ionn of lWAý4iI 6 axd TkWA-$lw 1 for eui.r dtc t'C to LT anRcc cpibailc s~.zr, in nu -TrR-c w ith thicprvso kmor hc Ccxistruction Ca&e C< Secikon XI' i 1!1 mtlhL Zi.'

tdu~ee d J edt to a 1ft", of aceeptab[, S)7-e Iinvt;ing iic'walli~r fii

Ž'iju, I

J 4~~~~~p~~~~ki~~~~~~Dletd 2fuw vty6iie~~~xt~

Fteii~~iiio and IWA-46 Ii. &&I'ct in atnmffcni stainicsa sle r augtcnitic nickd aflly pipin._________

auic-coatic with FX13-364) by aJi' a-i rC n Lw~lddffly -AD =a L i cthcr Editi-,, atn A>ddiuda, raCýrr to TiINC ThC Wd~d CwIVCTaysh~

'C il~e by dciitj of wttd r~zfitbrrenwnt (l'f lialaviion 111wIIUý&

ou giurfa&x i ~ePpi or-'.'Cjexl Iotluding fer jae, arazv1fetN wlne~~y n

the' FTh4flItyig rcquirarni u T -I Pitfa 5P1.i4

-D~

ftI fee I_

I W Pfr

-7 'rERi 3~ApplicýI 3f'dý ftrnwsd Uir crcincu f ceio f fthe.~_________

iizn, lxm4 -ihqll bl ilkpm Izjus Urtg 4 W Pji.It FyiCV rfizqk-fVýýio g

Wv eidirnp qualified in amirdamze id the Cmtuci-nnd Codeaod Oivnr'ý the pogi weld h eat tyaml adjb4TI rerlmimLs of the Conmimeieon Code nnd nh~Mdtd 1M btjtfm Mal-I&

n~i t

U U I,-

',I miftui.

i~ ~~t~a ~t nd iib~quxt~ rek~

ini ai laItier.M

~d~on aS~edi, IX.

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 20 of 32 BC06-165I 1 Deleted: BcO4-1003

')-7-07 editing and review Final -

-CDeleted: 1-31-07 RPA (b) The base material thickness shall be as defined as the maximum

__tFomatted: Bullets and Numbering thickness of the ferritic material where the overlay is applied (2 pendix 1 may be used for ambient-temperature temper bead welding.-

Fratd:Idn:Lft

.3,N bullets or numbering (d) Prior to deposition of the weld overlay, the surface to be weld overlaid shall Deleted:

be examined by the liquid penetrant method. Indications larger than 1/16 in. (1.5

'(omte:Idn:Left:

0.5",

mim) shall be removed, reduced in size, or corrected in accordance with the

[pcBeo:12pNo bullets or folowig rquiemet

~-

1Deleted: repaired.

(1) One or more layers of weld metal shall be applied to seal unacceptableDetd:

indications in the area to be repaired with or without excavation. The

'Deleted::

thickness of these layers shall not be used in meeting weld reinforcement Inserted::

design thickness requirements. Peening the unacceptable indication prior to Formatted: Indent: Left: 0.74', No welding is permitted.

Ebulesonubrg 2L.)If.reair ofidctosietfed in 1gd) is required, the area where the iDeleted: correction weld overlay is to be deposited, including any local repairs or initial weld Deleted:.o overlay layer, shall be examined by the liquid penetrant method. The area

' Deleted:c shall contain no indications greater than 1/16 in. (1.5 mmn) prior to the application of the structural layers of the weld overlay.

(e) Weld overlay deposits shall meet the following requirements Jmeaustenitic nickel alloy weld overlay shall consist of at least two weld layers deposited from a filler material with a Cr content of at least 28%. Te fir st layer of weld metal deposited may not be credited toward the required thickness. Alternatively, for PWR applications, a diluted first layer may be credited toward the required thickness, provided the portion of the layer over the austenitic base material, austenitic filler material weld and the associated dilution zone from an adjacent ferritic base material contains at least 24% Cr andphe Cr content of the deposited weld. meta~l is d:etermined by chemical...

analysis of the production weld or of a representative coupon taken from a_-

mockup, prepared in accordance with the WPS for the production weld.

Alternatively, for BWR applications, a diluted first layer may be credited toward the required thickness, provided the portion of the layer over the austenitic base material, austenitic filler material weld and the associated dilution zone from an adjacent ferritic base material contains at least 20% Cr and the Cr content of the deposited weld metal is determined by chemical analysis of the production weld or of a representative coupon taken from-a_

mockup prepared in accordance with the M/PS for the production weld.

LfyThis Case is only for welding in applications predicted not to have exceeded*-

thermal neutron fluence of I x 1017 (E< 0.5 eV) neutrons per c M prior to welding.

(R),A new weld overlay shall not he installed over the top of an existing weld*-

- Deleted::

Formatte-d: Indent: Left: 0.49"% No bullets or numbering NDeleted: <10-The austeniliec saoinless steel wel d reinofrcement shalt consust of at lent two weld layers having ats-jdeposited delta ferrite content of at leant 7E N. The first layer of weld metal with delta ferrite content of atleast 7.5 N ahalt constitsste the first layer of the weld nerfsrcemeat that may he credited toward the required thickness.

Aiternutively, licst layers of at least 5 EN are acceptabl e, provided the carhon content of the deposited weldmetala is determined by chemnical ainalysis to he less than O.02q%.¶ 1Formatted: Indent: Left: 0.75', No 1bullets or numbering, Tabs: 0.75" Lest tab Deleted.........

Deleted:

1Deleted:

-- Formatted: Indent: Loft: 0.49", No bullets or numbering

-- Formatted: Buliets and Numbering

-. Deleted:¶ fForma tted:- Indent: Left: 0.49" overla-v that has be in service.

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 21 of 32 13C06-1 651 D-

-fDelete~d. B.C0.4..--I..00

.3

.2-7-07 editing and review Final Deleted: 1-31-07 RRA 2 Crac~k Growth and Design,~

Deleted: Consideration.

-Formatted:

Bullets and Numbering 6a

.,rack G row th - ----------------------------------------------

Deleted: Flaw character izto ad ievaluation requiremeato stshalat bbad on The size of all flaws detected or postulated in the original weidment shall be

!,h s-on la.Hwee.h projected to the end of the$expected life of the overlay. Crackgo to

{ Deleted: considerattions ej-

-- ~rcerztinFormatted: Indent: Lf:07,N both stress corrosion and fatigue,ýhafl b yoa uaQ.d-- law-carti'etzaio and b Iullets or numberingLet0.5,N evaluation shall he based on the ultrasonic examination resul.......

(1) For repair overlays, the initial flaw size for crack groxvth shall be based oniW' *'" Deleted: design the as-found flaw------------------------

Deleted:, indluding (2) For mitigative overlays. the initial postulated flaw size for crack growth I

Deleted: crack

growth, shall be assumed consistent with the examinations performed, either pre or Deeed vlutdinte aeiasi potoverlay. The axa-lwlnt hl estat15ice 3

i)o h

ý accordance with tWB-3640. If the flaw post ~ ~ ~ ~

~

~

~ ~ ~ ~ ~ ~ ~ ~ i aalfa nthsalbseat15ice 8 mmorte nator near thebaoudoaryofltwo different combined width of the weld olus butterinta. whichever is areater. The mateaials, evaluation of flaw growth in bothmrata'ial sis reqtdre Circumferential flaw length shall be assumed to be 360 dea.

Deee:cadred.

(a) If an examination is perfoirmed prior to application of the overlay.

Inete:00adee which is qualified in accordance witlLAppendix VIII Supplement I1 Deleted:

an

_oýnide surface connected planar flaws are discovered, initial

,Fomte:Idn:Lf:.7 flaws (orin-inated from the inside surface of the weldment) equal to

~'

Formatted: Ballets and Numbering1 10%)" of the origzinal wall thickness shall be assumed in both the axial Deleted:.11 and circumferential directions.,

Deleted: 3.0 below, (b) Ifno examination is performed prior to application of the overlay, Deleted: indicatioans initial uiaws equal to at least iyr-,, tnrougn the onigtnal wa1 tnic.nss shall be assumned, in both the axial and circumferential directions, consistent with the overlay inservice insr~ection volume in F4,a 2."

(c) There may be circumstances in which an overlay, examination is Performed usintt an ultrasonic examination procedure which is qualified in accordance with,&ppendix VIII. Supplement 11I for depths-gareater than the outer 25%, of the origtinal wall thickness (Fig. 2). For such cases, initial flaw sizes may he assumied consistent with the depth to which the examination procedure is qualified.

- Deleted: 3.0 below (d) Any inside surfice connected planar Tlawj[ound by the overlay Deleted: indication preservice inspection of paragaraph 3.11). which exceed the depth oif' -

Deleted:.

(a), (b) or (c) above, shall be used as the initial flaw depth in determining~ the expected life, of the overlay.- Overlays meeting this condition shall be considered a repair.

(b) Structural Desicm and Sizinp, of the Overlay The design of the weld overlay shall satisfy the following, using the assumptions and flaw characterization restrictions in 24:al. The following_

design analysis shall be completed in accordance with IWA-43 11.

'I Formatted: Indent: Left: O7,N bullets or numbering 3

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 22 of 32

________________________J (1) '11c axa ei~hn n slope offfc eld covlay s6Ha vover the eld

tntk the heat alfeed xitici

-7yc-n eade s

(&ofthe,,vcld.

4nd shallI proviLde tor totid rJisiri1Itiwn from the Itcm L'nto-, the, weld cwcilay and back into the ftom witout ~Tttu irjpphiable ste%5 limj~

fJB32Qr lh~t

~in

~tnfl~o An'y lfimin& Th~wfj indi; ck cIy hU bc ev~nka~tM ini the nimauiyau to zrtur.! that benid redistrdbuttie.n oipe.ies& with.

the aboive. Thcese rcqutiicments Will usually tV 81tisfied if theO weld o~1vtly full thtcemc-as 1tmvh extends nxially be-ioind tbc projc~ttd flaw by at Iet7ii'vRi, wlwr R r thi, oulf radrlý,,, Oft, Outm

ItdW noMII wall th cknc", of* dth ~item e2)

Uj~-spzi7c~yaniUyzhJ nacudazýexith Isit 0 -Ire if the n~vet1,w All not xc~d 'zt ~g \\Jeot~~a is rcconznendcd, (3) F4:r 6:1t-irminrig ffic cc-tbincxE bfnt~h bf aiiiyoon e

tws, n 7eýic

ý.nkcrvv rr

lnlt, I or ffairi.PlefawhC riigshl e trcatie ns one Rlaw of teni2h equaI [ o the sum ofthe lcri~ths of the' nivddual ilawsý dria-nclTtrzead in acof~dawe with RWA-33f).

4,)

entbifi lv y-ritmikdhw the viA'W~j ZI 113 4Slatbft I, Adq-v-ýt: Le&t4 Akgmd at; 075 + Tab iftu 1,+

Itetta mmlv 1rf wtk Uh w.udt urtmftitc Wgiroo 'W UWif o don~ rf~aattw3 ffiuok-ptis of Lthe item ffor -icthe cr-eircwTzfcirzgfte of fi L=n it iI I Ah f

H;ii k V r TI 1 tos hn e I (VQ% thu.tjugh the orilma1 w h c iiss'o the jttý for`

entire p~is]k~h of 11%.eflw~

v

~ontbined flaws, ;5a

~

eplcbei rhk Dsl~64~ Iaj~ - Lz fli~a

.im Defettdf I ------------

(6) t ~ ~

~

~

i -,,;zra avai d 11 in ti- 0eiiz~

L 30r 4ý OMW~w.s 11

TIt, iý to jh

'I" I f 1 I -

_ _M__

JT fle uod f t e 1 V t dfe ldg o v.e d a v bo kn e th O

n ~ r n M e,V ~ e it.

~deposit amdyi-as requirements of1 The conibned. wall i~cnes atbe~

fc:, n.11r itd 1o.v~rl,-y yr rcznf4roetticnt f& 'a btandi MMO:11,111') Mth

~itan n 2,~I fnetm tbeee i7 6thewI Kshal I 1-c uaitJ =id -aIA mtiect dtc toqutrinmkms oi'N -V34

~lhivT'oc;! af any vhuingý:in ;jpphvJd lojd,ý ri*iult a:f wldj ýJbIrt~k;tgw trrn) Liitfti verksv, on Ahe-EAcnj-in theplinsýeme~ sx~

lhimus & nd C kifimiinc ncvlt2~ka dhanE-- L-n -,v, ilsri ft~ibdily and W Jitl ueto the ý d

CM ra~ 41A1l e u~

Esin

Laks, Pmua: 4t fideirut 5nwJeu J, 3 rd4-trtli*e:

-s~rnt:

S~Left AffW a;0 ý5 TbLiti I

13e4 fl~bdL4tMa j

4

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 23 of 32 BLC06-1 651 ~-IDeleted: BC04-1003

.2-7-07 editing and review Final__

Deleted: 1-31-07 RRA previously accepted by analytical evaluation shall be evaluated in accordance with IWBM-3640, 1WC-3640,or PN-ý L s apicbl.

.. Leee Forma tted: Snap to grid 3JqYapr~nati --- ----

'IFormatted: Don't snap to grid In. lieu of all other examination requirements, the examination requirements of this Case 1Formatted: No bullets or shall be met. Nondestructive examination methods shall be in accordance with IWA-

"\\numberng J

2200, except as specified herein. Nondestructive examination personnel shall be

.\\Deleted:

.0 qualified in accordance with TWA-2300.

Ultrasonic examination procedures and Deleted; andinspectionI personnel shall be qualified in accordance with Appendix VIIýjýupplernent 11.

a edIn dent: F e-- ;--

(a) Acceptance Examination Cm~et ~g k oad (1) The weld overlay shall have a surface finish of 250 micro-in. (6.3 S upie n

SiP' micrometers) RiNS or better and a flatness that is sufficient to allow for

~

'tbeEPRIPDpIIO,,fl" i~inefl adequate examination in accordance with procedures qualified per Appendix

\\

'Deleted:

,section )a VIII. The weld overlay shall be examined to verify acceptable configuration.

et

.5,N (2) The weld overlay and the adjacent base material for at least '/2 in. (13 mm~)

bulj t

~orm d Inumerng:

from each side of the weld shall be examined using the liquid penetrant Formatted:

utIndenumerd:

method. The weld overlay shall satisfy the surface examination acceptance Level: 3 + Numbering Style: 1, 2, 3, criteria for welds of the Construction Code or NB-5300. The adjacent base

... + Start at: 1 + Alignment: Left +

metal shall satisfy the surface examination acceptance criteria for base AlIgndedt at: 0.75"+abfr0.5 material of the Construction Code or NB -2500. If ambient temperature temper bead welding is used, the liquid penetrant examination shall be conducted at least 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> after the completed overlay has returned to ambient temperature.

(3) The acceptance examination volumne, A-B-C-D. in Fig. I () shall be ultrasonically examined to assure adequate fusion (i.e., adequate bond) with the base metal and to detect welding flaws, such as interbead lack of fusion, inclusions, or cracks. The interface C-D shown between the overlay and the weld includes the bond and the heat affected zone from the overlay. If ambient temperature temper bead welding is used, the ultrasonic examination shall be conducted at least 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> after the completed overlay has returned to ambient temperatue.

Planar flaws detected in the weld overlay accentance examination shall meet the preservice examination standards of Table TWvB-3514-2. In applying the____________

acceptance standards.to planar indications within the volume, E-F-G-H-in -

Deleted:, wall lhidcnesU"W shall be Fi ~ ~~~

~

~

~

~

the th~ickness of the weld overly Fi. Il(b), the thickness "t, " shall be used as the nomiunal wall thickness 'in Table iWB`1-351 4-2. For planar indications outside this examination volume.

the nominal wvall thickness shall be "tj." as shown in Fig. l(c), for volumes A-R-H-D and F-B-C-G.

Deleted::

Laminar flaws shall meet the following ------------------------------

Formatted: Indent: Left: 0.5", First (Lj.Laminar flaws shall meet the acceptance standards of Table IXVB-3514-3

.~line:

0.25", No bullets or numbering with the additional limitation that the total laminar flaw shall not exceed Formatted: Outline numbered +

10% of the weld surface area and that no linear dimension of the laminar Level: 1 + Numbering Style: a, b, c,

..+ Start at: 1 +Alignment: Left +

Aligned at: 0.75" + Tab after: V" +

Indent at: 1" 5

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 24 of 32 BC06-1651

-Deleted:

BC04-1003 2)-7-07 editing and review Final_-

Deleted: 1-31-07 RRA flaw area exceeds 3.0 in. (76 ecu). or q0 f th

-oia

-ip

-Deleted-.......................-.......

).....

circumference, whichever is greater. ----------------------------

--- (Deleted:

percent (b)The reduction in coverage of the examination volume, A--C-in Fig.

I(Deleted:¶ l(a) due to laminar flaws shall be less than 10%. Thepininspectable Formatted: Outline numbered +

volume is the volume in the weld overlay, underneath the laminar flaw, for Level: 1 + Numbering Style: a, b, c, which coverage cannot be achieved withang

~

ea xminatiot,--.

+Start at: 1 +.Alinment: Left+

)_.Any uninspectable volume in the weld overlay shall be assumed to contain Algeat0.5+Tbatr:1+

Lc Indent at 1 the largest radial planar flaw that could exist within that volume. This 1Deleted: dimensees of the assumed flaw shall meet thelpreservice examination standards of Table Deleted: are dependet mn the IWB-3514-2. with nominal wall thickness as defined above for pl1anarDltdth flaws. Alternately, the assumed flaw shall be evaluated and meet the

-=--

1Deleted: of the overlay.

requirements of lWvB-3640, 1WC-3640, or IWD-364fl,as aLpplicable. Both axial and circumferential planar flaws shall be assunmed.

Deleted, I (4) Alter completion of all welding activities, affected restraints, supports, and Deleted: inservice snubbers shall be VT-3 visually examined to verify that design tolerances are

'jDeleted:

shall met.

Deleted:,

(b) Presetvice Inspection Formatted: Outline numbered +-

(1) The examination volume in Fig, 2 shall be ultrasonically examined. The angle Level: 3 + Numbering Style: 1, 2,3, beamshal b diectd prpenicuar nd aralelto te ppin axs, tth+

Start at: 1 + Alignment: Left +

beamshal b diectd prpenicuar nd aralelto te ppin axs, ithAligned at: 0.5" + Tab after.i 0.75" scanning performed in four directions, to locate and size any cracks that might

+ Indent at: 0.75' have propagated into the upper 25% of the base material or into the weld Formatted: Outline numbered +

Level: 2 + Numbering Style: a, b, c, overlay.

(2) The preservice examination acceptance standards of Table 1W~B-35 14-2 shall Alge at: 02"+ Ta Lefter 0.5 be met for the weld overlay. In applying the acceptance standards, wall

+Indent at: 0.5' thickness, t6, shall be the thickness of the weld overlay. Cracks in the outer

'Formatted: Outline numbered +

25% of the base metal shall meet the design analysis requirements of 2.lW._ _

I ee:3+Nmern tl:123 v+ Start at: I + Alignment: Left +

(3) The flaw evaluation rules of IWB-3640, IWC-3640 or, RYVID-3640 shall not be Aligned at: 0.5" + Tab after. 0.75" applied to indications identified during preservice examination which exceed

+ Indent at: 0.75" the preservice examination standards of Table 11171-3 514-1

{Deleted:.0 (c) Inservice Inspection FoRmattedM (1) The weld overlay examination volume in Fig. 2 shall be added to the Formatted inspection plan andu.dtrasonic ally examined during_ the first or second

---

Deleted: shatl be refueling outage following application.

(2) Alterrnatively, fCor Mitigative weld overlays, s.in which examinations are performed in accordance with 4a2Yq,)a), 34a). and 34b). and nolý2side surface Deleted:.0 connected planar flaws are discovered, the overlay may he placed directly into

'.Deleted:

ii the popul~ation to he examined in accordanice with (c)(5) below.

D-eleted:.0 (3) The weld overlay examination volume in Fig. 2 shall be ultrasonically Detd:.

examined to determine if any new or existing cracks have propagated into the Dltd eet upper 25% of the base material or into the overlay. The angle beam shall be directed perpendicular and parallel to the piping axis, with scanningFomte iiI performed in four directions.

'41 The inservice examination acceptance standards of Table 1WvB-3514--2 shall Detd:Atntityfrisi,-

be met for the weld overlay. jf the acceptance criteria of`Tabtle 1W13-35ý1-cannot bermeL the acceptance criteria ofl IWB-3600, IWC-3600, or IWD-360q etd:

6

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 25 of 32 J3C06-1 651,_-- IDeleted: BC04-1003 22-7-07 editing and review Final -

Deleted: 1-31-07 PEA asapiablsall bermet for the -weld -overlay.- Cracks -in the outer 25% of eee:

the base metal shall meet the design analysis requirements of Section 2(b). -

IDeleted:.0 i5'l Weld overlay examination volumes in Fig. 2 that show no indication of crack growth or new cracking shall be placed into a population to be examined on a sample basis. Twenty-five percent of this population shall be examined once (6)If inservice examinations reveal crack growth,4 or new cracking, wýhich meet D-e e

Dlte d: me eting the acceptance criteria ofJWVB-351.4, ]W13-3600, ]IC-3600. or TWID-3600 the-I-Delet :ed: :s :tandars, weld overlay examination volume shall be reexamined during the first or g1Deleted: Table second refueling outage following discovery of the growth or new cracking-

-ent-

-s-n tome

17) For weld overlay examination volumes with unacceptable indications thatithishod nbe repibed htif 4tccording to 3ikc)AJ, the weld overlay shall be removed, including the original Tirteidýin etteswdd

_____they cma be eviariitecl this ietrequ irla defective weld, and the item shall be corrected by a repair/replacement thouid al. apjy. I sget that we'd activity in accordance with 1WA-4000.

'\\

ometimfn20g likefir fl~

dxeptblbe.<,N (d) Additional Examinations. If inservice examinations reveal an unacceptable WOL ewoi na vorume..

indication according to 3,LcY4)) crack growth into the weld overlay desig

-l D

fleleted: asdesroibed in thickness, or axial crack growth beyond the specified examination volume,

'"eee:.

additional weld overlay examination volumes, equal to the number scheduled for

'eee:2 n(

the current inspection period, shall be examined prior to return to service, Ifom~Ouln umee additional unacceptable indications are found in the second sample, a total of 50%

Level: 2 + Numbering Style: a, b, c, of the total population of weld overlay examination volumes shall be examined

+ Start at: 1 + Alignment: Left +

prior to operation. If additional unacceptable indications are found, the entireAlgeatO2+Tbaer0.

+Indent at: 0.5" remaining population of weld overlay examination volumes shall be examinedDetd:0 prior to return to service.

_4.

,QPressure.Testin Deleted:

A system leakage test shall be perfre in accordance with 1WA-5000.

.Formatted:

No bullets or numbering 5.0 Documentation Formatted: No bullets or Use of this Case shall be documented on Form NIS-2.

numbering 7

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 26 of 32

'644 Firia O ohtudi 1

f r FTA-4 k Aft"Umft"IMM "U"Re" 4

4 II Ii Odutud;~

oMa&a.4i I I

I I

r... rici A

-4 tý V ýw Twt rMqw 9 FI~ ~1~fld~k~LLm1h2rXi

-(2) Th.o wald ificluzi!i IHLI 1."

ýId ý-nll 07V~t4 +

1,0-i~

9, h

75'

~

f~

k I

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 27 of 32 ILIl6 311 I -"

ftw V CM, Inueia"vke EammnplicVcum Fig Pieýwvic, ad liew~

F-ui~iin Vlmm 9

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 28 of 32 77)7cjbWrn& ýndI rni"w Fnl.w DCWW 1rd 14 -q, iwui Am'bient Tem ruiur'e'Te twr WadWeldiny-Fk -

12A, 12B, arD 1 ZC'rnater#ia and d'1t

~oeir amwavt n

tgjnn P-N~o or k~~

'Tnr"04 Tr; pe~t ~nntb use-d to reiper" MZ4e EIM-la tfs*

the mater~ia-ho bn rm~e M 4--lce Trqm Q,4%1* I Q% 11et fýqr tnd4 tnerr, r apwirThan or a nine pflin pructk"e (b) ~Tre r~n Tji areac;p'jlvd~

void ovtr Wood on"~b fn twdSua aC or the Acfý%-6ea~ksc n a d11nw~kr4RctaI -ewid in a.r iacewwit thi~s Apvmdbc gfe fi1mid to tho"*a

snr q""jn

~eo o~al~iik of~b a

Io "no -in fev,~

t~ ~ t~

m ~aj 'bL--e -jedor ed h a-=, ~

~

r I~ dk pr it-~d Ol eplcf YofU ree I T ba se wn rSI~G owa ot exft>I(2I ql1) f.

(e)

FT i o to i-ic!

e Ja reat be wewde and u te rid

~

era we afBej0rt kam i 1tvzliieu)d Cr.d,2 rjýtýe~j tnl VLfnteaim~

ft e

Cofuen tAl

,h.

(Q) Peenlpg may W L"Armxprtcm the Init an AIlye a

wfowi~e Thme fianr promvvi anih fl wethrtg gperatora Oml be qiJAlflhO In tCwQf~!Kewlth,OVe~f IX and lu rwjub~rsdnrtv

.1 wrid'2.2.

(a) Th, abase materIM Tarr the kIng procedure qMMIMh~a uJWaIbe WIN@h samte P6 Mumnlw, ond Gwup Wnu-mbr, is It..* n'@'"Wo t e

The rmwirals shs be pashheldl Feat treated to at least dhe time and temperature ttwt vvas applied in the (b) The rwt M= oWtclvde argIe cf fta cm"y in To tet asumt~y sag be n* grealar hnfuwirtmuwiiiipadidforthe remit, (g) Tbe noftum kflawJo MEmperulum tfr'r mei1rlI M~e layers at thle Magi asserriby 91ta (dI) the tes9t sasseMby Ca~ty d epthOail bel Mt east 1 lnt 45 mrn)ý t~he test asseMbly thlcintelb a D at wast Wwlei dw: Mawamb

~

cytdepm,. The t"a aem~ty shallII lw' enough to pefnti roval of Me, nmeqifaed test jcIpeM*M_ The, test gggmbly drarom rO u~ndIng the eevEy ghsAbe2 Wet etwt

~atseM0 i~~le~kiA!1 aM 1&~ni

~ (1~r SOiim). Tha qi~i1Arx6I6_ ilAat ýgtoll b& VL'jFed IA a0_CoC~ance~1U1 F)Q, 1-1i (ip} Fevt baz riae-i~ft pr~

r fi~ uls JLI ret meV Iijnpotlts rew~remneryt3of the8Gm B=aCode and: Ocwfe Reit~ilremeM.~ Ir¶3LrA wJ6trke attall be datefrMdn by Czaloy W-i6ehifivel Lifats aft?* Dettha quaA pba bw mto i, or ii;wt iholwmst scrvic teinpatue o f heem ta be repalrel. The kxalcmndafdorentatn ofemist spcimeresshall be Gtitiarto thoge required~t 211(2f) bcew-IM Omit be in Me. base moot, 10

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 29 of 32 L-(~i~ri U

v F

Ij Lea-i swtm p

!4Meamtw, as nohe ast metal tnet 21 4e bovum -NUMtr, laNon,1, antl coairtatian ot tests p____________beas______s Crnehzil the thi~kryeSS Of ttt deoositcd voel me~ta Thbe COIr [or tIAZ unraLct Speeffleng Sha be tAP11 tr~arrwer9P WD lte GpiS OT Meu varkt ao'ýC OW*We~

M dafI'e the HAZ. The notobi of the Charpy V-notch specimen shatl be cut aptfoxihiatqly no~mil to the m~n~ria1:sv~fa(r m *"

a n~rri nero-rs tIc tr-kd asovh HZ 3%s pgp~ci triii rcwTjr ft-ý,,Wv Jt n IftU m1w hlril tIhamo pWm it tho WSr of a ipedirnen shall te Wiined to alla Mia roimof be ncotch to aIwalWW Par%~e to fte If morl linM.

t.)I# lthe tixw ma!*d.I is -M tho forwm Ce a plta or~ a upn. theI axi of the weld shaii beR crlelfled pa-eiel to th pritr--aI dlrectioe Mf rdling 1ý o rge-shall be in awooodance wh &A.70, Fq. 11, Type A, The, tes sh-a a =oim wt of Meet fulI-ize 40 mm X 10 mm s er-nio he Nolaiurl wpmin, pamoiA hsair.ksewfbederiergy.

test v~pea~

~rs~cnand hxftmon of abi Icst e~cirerza 51nalbe feportad In the PmOce~lae QuWM tl~)n RecW____________

( Thea swrag@ lmuul exr)anslcen valie of tiw tiwek I1A C"a V-natth specrrnens pmmi1iu ~C4 e~iiI I orreebrthn te w 1-lterl o w

ansovaluo d the mmo NIl~ti i*z#ecteed baie me-A Ita4peciwne'rs, Hcroevv, lfi o*

vetage laliruI "'Pa Miao value wLafr~ectfld baen mneta I jpff1nen aml ifs JpocMure Cpialimlwi et5o ael UI at" requýTiew~ts of tis ipendri, a 1t-vr of ti-x fcawi~ng $Nil be lperformo-Off Thewb dn procwr uIhall be m-zaffd-1~2j AY,,di-t~ m eoITnperetwe F~a IJ porocedure qjiRIEaan s~phi b debet rmnrd

)

MAa~d

~

truAic In &;ewram-v wi th TrL a;V04-a Lie proynavef or N-4-3 2 dl SoCDtlo Ill, Z2Qai Edlen with 2002 AOterda, The RTq-. or bmu~t wwlce Wi-rpcatire of fth triller:5 I Ur flwwiVIt,, khe welIn proce lum 4-l I be M-rh~

~I I I be im~e aued by.

termperature equ~ta~e 6 ft'wt o~f the Ack~ustett Temipeiatire.

2.2ovr rn~ok GýAlti Nwnnilm~d' lndi Left QA*"

-- ~fo oprtr bolte qwi~Ned in acyrarotnoe wth Ewciir X (a) Tfi a v& "t mta & he 11 be f,' poaltIt" k uy In enstom e a

&Fi meeh m G TAW p wmse.

(b) 31saimlleg metal wmiids alnall be fna de usin A-No, 8 hwe Idr ntal I044 42)ý for P N o. 8 to P-No -1, 3, or 12 (A, B, wC) %w kJI

~o I s o r F -No -4 3 weld meaI {f4W-4~32? tot r -

No 6 or <3ttg P-ha 1,. r 12 (tN 8, or C wijoirrt:

(0) Thi oreq lo tbe weded StIOl be-biruTCC wiUt a deposiT ct at 10;W three 40%v to ZmNov&at.'*ae Vt~~t8 irl ý3mm) 6vsrlay ~IhVkfiuie MMt ViS heajt Iif!Kt 16of Een layer cortmietlle to within +/- 1 N of itial use~d in IN.- prcedurr~ 9ýialcetio4 tv.si The I-eet_______

im f ft firxt i~ictlay0~*hal nrl pri 4ýkLJ/li (1&+/-XinM) i~

_____any a uste~iIc &veriay fillet mua!lntal Lat tPA *56 of the oveftay to ensure MRa the HA2 aM eit ru bmw me tal:. er tIcm pered S-4 i,s q rix -w r- !;~~

mha be de PQ s tc;w, a fa jnprj -01 ex~yqqedr thiat VWý for 14)- i$t?-yr-thq tht V Ir fmth rqw (dl The mayarltwjm hnterlaga tomernpmture orw lield qpoIecttre be 3-RDF I BC) 1tbr all (e r byerp= remrde-aums ofi te te~ps dterwrnived use ofir iunlcbn (a)~r rd *_IT Wwm I1I

St. Lucie Unit 2 L-2007-045 Third Inspection Interval Attachment Relief Request Number 10 Page 30of 32 1h %

ek~ntin

~r ia ;

iceoJ,e such,,%en~ ae eh whe-n t~ere 01W) lAaUerrm cocuw and amnn~

i am ttw terw2 beng wmited (y) ame thme perwald part and dolay timew betw~en each pass t4;

~U are So~ t5 eampk% tM

~Ipiute of e we" efooxwedute eftll be u~ nthe weidhig at the trtmwr (f) Rr~cur m shall to, Oen to ensure that"e wo region Is ftm of all powwu~

aoreaa N Po&

Te mut~e tb be.%

MMOMrLd L~

12

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 31 of 32 2-1.4

~k1~

GENERAL NOTE: Rue rnetI:Chzrpy kmpmcl;tciminse

nriot,

'.i 1,

13

St. Lucie Unit 2 Third Inspection Interval Relief Request Number 10 L-2007-045 Attachment Page 32 of 32 Tal-I Y. h f

ý 'mAl-m v htj:

d Addvna~ of "cttumX1 2004-B itiOn With a"'

low, Adden" i r-o wil h thr 191S1 E& Vic 197,93M c,:-