ML031340510

Relief, Request for Relief Number 02-002, Revision 1 Re Limited Weld Examinations for End of Cycle 13 Refueling Outage

ML031340510
Person / Time
Site:	Catawba
Issue date:	05/07/2003
From:	Gordon Peterson Duke Power Co
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
RR-02-002, Rev 1
Download: ML031340510 (32)

Text

Duke c SPower, A Duke Energy Company GARY R. PETERSON Vice President Catawba Nuclear Station Duke Power CNOI VP / 4800 Concord Rd.

York, SC 29745 803 831 4251 803 831 3221 fax grpeters@duke-energy. com May 7, 2003 U.S. Nuclear Regulatory Commission Attention:

Document Control Desk Washington, D.C. 20555

Subject:

Duke Energy Corporation Catawba Nuclear Station, Unit 1 Docket Number 50-413 Request for Relief Number 02-002, Revision 1 Limited Weld Examinations for End of Cycle 13 Refueling Outage

Reference:

Letter from Duke Energy Corporation to NRC, same subject, dated August 15, 2002 Pursuant to 10 CFR 50.55a(g)(5)(iii), please find attached Request for Relief 02-002, Revision 1. This request for relief is associated with limited weld examinations for the subject outage and incorporates a response to a Request for Additional Information previously discussed with members of the NRC staff.

The reference letter originally transmitted Revision 0 of this Request for Relief.

Revision 1 of this Request for Relief should replace Revision 0 in its entirety.

Please note that the number of welds included in Revision 1 is less than that included in Revision 0. Relief is no longer being requested for some of the welds included in Revision 0 because these welds will be examined again in a subsequent refueling outage in the interval using improved examination techniques.

The attachment to this letter contains all technical information necessary in support of this request for relief.

Duke Energy Corporation is requesting NRC review and approval of this request at your earliest opportunity.

There are no regulatory commitments contained in this letter or its attachment.

A04V7 www. duke-energy. com

Document Control Desk Page 2 May 7, 2003 If you have any questions concerning this material, please call L.J. Rudy at (803) 831-3084.

Very truly our Peterson LJR/s Attachment xc (with attachment):

L.A. Reyes, Regional Administrator U.S. Nuclear Regulatory Commission, Region II Atlanta Federal Center 61 Forsyth St., SW, Suite 23T85 Atlanta, GA 30303 E.F. Guthrie, Senior Resident Inspector U.S. Nuclear Regulatory Commission Catawba Nuclear Station R.E. Martin, Senior Project Manager (addressee only)

U.S. Nuclear Regulatory Commission Mail Stop 08-H12 Washington, D.C. 20555-0001

Request for Relief 02-002 Revision 1 Page 1 of 8 Proposed Relief in Accordance with 10 CFR 50.55a(g)(5)(iii)

Inservice Inspection Impracticality Duke Energy Corporation Catawba Nuclear Station - Unit 1 (EOC-13)

Second 10-Year Interval - Inservice Inspection Plan Second Interval Start Date - June 29, 1995 Second Interval End Date - June 29, 2005 ASME Section XI Code - 1989 Edition with No Addenda I

II & III IV V

VI VII Limited System /

Code Requirement from Which Relief is Basis for ReDef Alternate Justflcation for Implementation Schedule Area/Weld ID.

Component for Requested: 100% Exam Volume Coverage and / or Examinations Granting Relief Number Which Relef Is 4 Scan Directions or Testing Requested:

Exam Category Area or Weld to be Item No.

Examined Fig. No.

Limitation Percentage I PZR-W4ASE RC System Exam Category B-F See Paragraph "A" See Paragraph See Paragraphs "G and J" See Paragraph "K" Pressurizer Safety Item No. B05.040.004 -ASME Section XI.

"F' Nozzle-to-Safe End Appendix III, 111-4420, 1989 Edition with No Butt Weld Addenda. Coverage from two beam path directions (See note below) 77.28% Volume Coverage IPZR-W4BSE RC System Exam Category B-F See Paragraph "B" See Paragraph See Paragraphs "G and J" See Paragraph "K" Pressurizer Safety Item No. B05.040.005 -ASME Section XI, "F'

Nozzle-to-Safe End Appendix III, 111-4420, 1989 Edition with No Butt Weld Addenda. Coverage from two beam path directions (See note below) 86.00% Volume Coverage IPZR-W4CSE RC System Exam Category B-F See Paragraph "C" See Paragraph See Paragraphs "G and J" See Paragraph "K" Pressurizer Safety Item No. B05.040.006 -ASME Section Xl, "F'

Nozzle-to-Safe End Appendix 111,111-4420, 1989 Edition with No Butt Weld Addenda. Coverage from two beam path directions (See note below) 82.03% Volume Coverage IND38-1 ND System Valve Exam Category B-J See Paragraph "D" See Paragraph See Paragraph "H and J" See Paragraph "K" IND002A to Pipe Item No. B09.011.104 "F'

Circumferential IWB-2500-8(c), Volume C-D-E-P only Weld 61.23% Volume Coverage 1BRHRHX-5-9 ND System RHR Exam Category C-A See Paragraph "E" See Paragraph See Paragraph "I and "

See Paragraph "K" Heat Exchanger Item No. COI.00.002 "F'

Shell-to-Flange IWC-2500-l(a)

Circum. Weld 55.90% Volume Coverage NoA.;.t: h e

shall be n

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performed from two sides of the weld, where practicable, or from one side of the weld, as a minimum.

See Attachment I for a drawing of the RHR Heat Exchanger welds listed above See Attachment 2 for a drawing of the Pressurizer welds listed above svsswt

Request for Relief 02-002 Revision 1 Page 2 of 8 IV. Basis for Relief Paragraph A:

(The pressurizer safety valve nozzle material is SA-508 and the safe end is SA-182, Gr. F316L. The weld is 6.0 inches in diameter with a 0.96 inch wall thickness.)

Nozzle to Safe End Weld lPZR-W4ASE cannot be examined from two beam path directions because the nozzle taper limits scanning from the nozzle side. This is a dissimilar metal weld joining a carbon steel nozzle to a stainless steel safe end. Coverage is limited to 77.28% of the required examination volume. This percentage of coverage represents the aggregate from all scans performed on the weld. Each scan is considered 25% of the total examination volume because four scans are required. One axial scan from the safe end side covered 100% of the examination volume in one direction; one axial scan from the nozzle side covered 9.12%

of the examination volume; two circumferential scans covered 100% of the examination volume in two opposing directions. Thus, the required exam volume was fully scanned from three of the four required directions but the fourth scan from the nozzle side caused the limitation that resulted in less than 100%

aggregate coverage from all scans. In order to achieve more coverage, the nozzle would have to be re-designed to allow scanning from both sides of the weld. (See note in Paragraph C below.)

(Examination data is shown in Attachment A.)

Paragraph B:

(The pressurizer safety valve nozzle material is SA-508 and the safe end is SA-182, Gr. F316L. The weld is 6.0 inches in diameter with a 0.96 inch wall thickness.)

Nozzle to Safe End Weld PZR-W4BSE cannot be examined from two beam path directions because the nozzle taper limits scanning from the nozzle safe end. This is a dissimilar metal weld joining a carbon steel nozzle to a stainless steel safe end. Coverage is limited to 86.00% of the required examination volume. This percentage of coverage represents the aggregate from all scans performed on the weld. Each scan is considered 25% of the total examination volume because four scans are required. One axial scan from the safe end side covered 100% of the examination volume in one direction; one axial scan from the nozzle side covered 44.00%

of the examination volume; two circumferential scans covered 100% of the examination volume in two opposing directions. Thus, the required exam volume was fully scanned from three of the four required directions but the fourth scan from the nozzle side caused the limitation that resulted in less than 100%

aggregate coverage from all scans. In order to achieve more coverage, the nozzle would have to be re-designed to allow scanning from both sides of the weld. (See note in Paragraph C below.)

(Examination data is shown in Attachment B.)

Paragraph C:

(The pressurizer safety valve nozzle material is SA-508 and the safe end is SA-182, Gr. F316L. The weld is 6.0 inches in diameter with a 0.96 inch wall thickness.)

Nozzle to Safe End Weld PZR-W4CSE cannot be examined from two beam path directions because the nozzle taper limits scanning from the nozzle safe end. This is a dissimilar metal weld joining a carbon steel nozzle to a stainless steel safe end. Coverage is limited to 82.03% of the required examination volume. This percentage of coverage represents the aggregate from all scans performed on the weld. Each scan is considered 25% of the total examination volume because four scans are required. One axial scan from the safe end side covered 100% of the examination volume in one direction; one axial scan from the nozzle side covered 28.15%

of the examination volume; two circumferential scans covered 100% of the examination volume in two opposing directions. Thus, the required exam volume was fully scanned from three of the four required directions but the fourth scan from the nozzle side caused the limitation that resulted in less than 100%

aggregate coverage from all scans. In order to achieve more coverage, the nozzle would have to be re-designed to allow scanning from both sides of the weld. (Examination data is shown in Attachment C.)

Note: Variations in the calculated coverage from the nozzle side of the three Pressurizer welds were the result of differences in the OD weld contours. These differences caused the distance from the weld centerline to the search unit exit point to change from weld to weld as shown on the attached UT profile / plot sheet sketches.

Request for Relief 02-002 Revision 1 Page 3 of 8 Paragraph D:

[The residual heat removal (ND system) valve body and pipe material are both stainless steels. The weld is 12.0 inches in diameter with a 1.125 inch wall thickness.]

Valve ND002A to Pipe Weld 1ND38-1 cannot be examined from two beam path directions because the valve body taper limits scanning from the valve side. This is a similar metal weld joining a stainless steel valve to a stainless steel pipe. Coverage is limited to 61.23% of the required examination volume. This percentage of coverage represents the aggregate from all scans performed on the weld. One axial scan from the pipe side covered 54.88% of the examination volume in one direction; no axial scan was performed from the valve side.

Two circumferential scans covered 100% of the examination volume in two opposing directions. Thus, the required exam volume was fully scanned from only the two circumferential directions. The partial scan from one axial direction and none from the other caused the limitation that resulted in less than 100% aggregate coverage from all scans. In order to achieve more coverage, the valve configuration would have to be re-designed to allow scanning from both sides of the weld. (Examination data is shown in Attachment D.)

Paragraph E:

[The residual heat removal (ND system) heat exchanger shell material is SA-285-C and the flange is SA-105. The weld is 43.75 inches in diameter with a.875 inch wall thickness.]

This weld was radiographed to provide more exam volume coverage than was possible with ultrasonic examination. During the radiographic examination of Residual Heat Removal Heat Exchanger Shell to Flange Weld BRHRHX-5-9, 100% coverage of the required examination volume could not be obtained. The examination coverage was limited to 55.90%. Limitations were caused by the heat exchanger's shell-to-flange configuration. In order to achieve more coverage, the heat exchanger would have to be disassembled at the flange connection and the upper and lower sections of the vessel separated allowing access for the placement of the radiographic film on the inside surface of the weld, which is impractical. Ultrasonic examination of this weld and adjacent base metal would also require the disassembly of the flange connection; which is impractical.

(Examination data is shown in Attachment E.)

The limited radiographic (RT) examination of the Residual Heat Exchanger shell to flange weld was due to internal vessel divider plates, the external geometric configuration and limited access to the examination external surface due to the flange bolting material. Each of these specific exam interferences limited the radiographic examination of the required volume as discussed in the following paragraphs.

Internal Vessel Divider Plates The vessel's internal divider plates are designed in a "T" configuration as shown on Attachment 1-Sheet 2, Detail A, and the Radiographic Technique sheet, in Attachment E. The internal divider plates come in contact with the examination area in three separate locations, identified as points A, B and C, which completely obstruct examination coverage of the weld and the required 0.5 inch of base metal on each side of the weld.

At point "A", 4.5 linear inches of the circumferential examination area was obstructed (film interval OR - 10, Attachment E) by the divider plate thickness and the angle through which the radiation from the source had to penetrate the divider plate to image the examination area on the opposite side.

At point "C", 4.875 linear inches of the circumferential examination area was obstructed (film interval 5E - 6) by the divider plate thickness and the angle through which the radiation from the source had to penetrate the divider plate to image the examination area on the opposite side.

Request for Relief 02-002 Revision 1 Page 4 of 8 At divider plate contact point "B", 0.750 linear inches of the circumferential examination area was obstructed (film interval 8 - 8X) by the divider plate thickness and by the divider plate weld metal.

External Shell to Flange Configuration and Flange Bolting The flange weld is in close proximity to the flange bolting surface as shown on Attachment 1-Sheet 2, Detail B and has 52 flange studs with large heavy hex nuts. The close proximity of the studs and nuts to the outside surface of the vessel in conjunction with the nearness of the flange face restricted the placement of the RT film

for complete examination coverage. During the examination, the radiographic film holders and backing leads were placed behind the bolting material, on the outside surface of the vessel and then slide onto the flange taper to the fullest extent possible. This provided for examination coverage of the required 0.5 inch base metal on the shell side of the weld and - 0.625 inches of 0.875 inch wide weld. The required 0.5 inch of base metal on the flange side, and an average of - 0.25 inch of the weld were not recorded on the film. The area of examination coverage and the obstructed area is shown on Attachment 1-Sheet 2, Detail B.

V. Alternate Examinations or Testing Paragraph F:

The scheduled 1 0-year code examination was performed on the referenced area / weld and resulted in the noted limited coverage of the required ultrasonic volume. No alternate examinations or testing is planned for the area / weld during the current inspection interval.

VI. Justification for Granting Relief Paragraph G:

Beginning in 1990 Duke Energy Corporation changed to refracted longitudinal wave search units to examine dissimilar metal (DM) welds based upon NRC Information Notice 90-30, "Ultrasonic Inspection Techniques for Dissimilar Metal Welds". The procedure used for DM weld examination complied with the requirements of ASME Section XI, Appendix III, 1989 Edition. The procedure required the use of refracted longitudinal waves to examine the weld and buttered material and shear waves to examine the wrought nozzle and safe end base materials. Duke Energy-Corporation employed the best available manual techniques to examine DM welds prior to the implementation of Appendix VIII. Based on procedure development work using DM weld mock-ups containing thermal fatigue cracks, Duke Energy Corporation believes that ID initiated fatigue cracks exceeding the acceptance standards of IWB-35 14 would have been detected.

The refracted longitudinal wave search units have an inherent limitation in that the useful portion of the sound beam lies in the first beam path leg between the transducer and the inside surface of the pipe. Beam paths beyond the inside surface of the pipe cannot be used to extend the examination coverage because of mode conversion that occurs at the inside surface. However, refracted longitudinal wave search units have better penetration through stainless steel weld metal than shear wave search units. When calibrating in accordance with ASME Section XI, Appendix I, there is not enough sound energy available to establish a distance-amplitude-correction curve beyond the inside surface notch located in the basic calibration block.

There were no examination findings and no flaws were detected during any of the previous inservice inspections. This weld was initially inspected by radiography and liquid penetrant examination during construction and verified to be free from unacceptable fabrication defects.

These Pressurizer nozzle-to-safe end butt welds are located inside containment and are part of the reactor coolant system pressure boundary. General Design Criterion 30, "Quality of Reactor Coolant Pressure Boundary," of Appendix A to 10 CFR Part 50, "General Design Criteria for Nuclear Power Plants," mandates

Request for Relief 02-002 Revision 1 Page 5 of 8 that means be provided for detecting and, to the extent practical, identifying the location of the source of reactor coolant leakage. If a leak were to develop at these weld locations, the instrumentation available to the operators for detection and monitoring of leakage would provide prompt and qualitative information necessary to permit them to take immediate corrective action. If a leak should develop in these aforementioned locations, the only corrective action would be to shutdown and depressurize the reactor coolant system, since the components are non-isolable.

Plant Technical Specifications dictate that a reactor coolant system water inventory balance be performed on a regular basis. A normal operating practice is to perform this computer based mass balance on a daily frequency and/or whenever the operators suspect any abnormal changes to other leakage detection systems. Plant Technical Specification requires that if the leak rate cannot be reduced below 1 gpm unidentified that the plant be put in hot standby within 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> and in cold shutdown within the following 30 hours3.472222e-4 days <br />0.00833 hours <br />4.960317e-5 weeks <br />1.1415e-5 months <br />. Leakage as a result of a failed weld discussed in this section would show up as unidentified leakage and be subject to the 1 gpm limit.

Other leakage detection systems available to the operator and dictated per plant technical specifications are:

Containment Atmosphere Gaseous and Particulate Radioactivity Monitoring System (EMF monitors 38 & 39) which would detect airborne radiological activity; Containment Floor and Equipment Sump Level Monitoring Subsystem where unidentified accumulated water on the containment floor would be monitored and evaluated as sump level changes; Containment Ventilation Unit Condensate Drain Tank Level Monitoring Subsystem which collects and measures as unidentified leakage the moisture removed from the containment atmosphere.

Additionally, other indicators are also available to the operator that a leak exists:

Containment Atmosphere Iodine Monitor (EMF 40)

Charging / Letdown system mismatches; Containment humidity indications; Pre-Cycle walkdowns performed each outage while system is at operating temperature and pressure prior to criticality; Post-Cycle walkdowns performed at operating temperature and pressure performed during unit shutdown.

Potential Failure Mechanisms:

The pressurizer safety valve nozzle to safe-end butt weld joins two dissimilar metal components, a carbon steel vessel nozzle to a stainless steel forging safe end using inconel weld material. The weld is susceptible to two potential failure mechanisms, both of which are initiated from the inside diameter. The first is PWSCC due to wetted surface exposure to high temperature primary coolant system water. The second is thermal fatigue associated with high temperature differences experienced during unit heat-up and cool-down cycles.

The first mechanism, PWSCC, is eliminated by the existence of cladding material (SA-213, Gr. TP304) on the inside diameter of the nozzle that also covers the weld. The second mechanism, thermal fatigue, is not expected to result in cracking of the weld because it was accounted for by the number of acceptable unit heat-up and cool-down cycles within the primary coolant system design and is further minimized by the expected infrequent operation of the safety valves.

At the time of the inspection, Duke Power Corporation used the best available UT methodology to perform the weld examination such that evidence of thermal fatigue cracking would be expected to be detected in the areas covered by the sound beams.

Request for Relief 02-002 Revision 1 Page 6 of 8 See Paragraph J for additional justification information based on other code required testing.

Paragraph H:

Duke Energy Corporation does not take credit for the weld metal and far side examination volume when performing ultrasonic examination of similar metal austenitic piping welds where scanning is limited to one side of the weld. However, a best effort examination using a 600 refracted longitudinal wave search unit was conducted in one direction perpendicular to the weld covering 100% of the weld metal and 100% of the far side base. The near side was examined using a 600 shear wave search unit covering 100% of the base material volume. Circumferential scans using a 450 shear wave search unit were performed over 100% of the examination volume in two opposite directions.

ND system Valve ND002A to pipe weld ND38-1 is located inside containment. If a leak were to develop at this weld location discussed in this relief request, the instrumentation available to the operators for detection and monitoring of leakage would provide prompt and qualitative information necessary to permit them to take immediate corrective action. If a leak should develop in this aforementioned location, the probable corrective action would be shutdown and depressurize the steam generators, since the weld is non-isolable.

Other leakage detection systems available to the operator and dictated per plant technical specifications are:

Containment Atmosphere Gaseous and Particulate Radioactivity Monitoring System (EMF monitors 38 & 39) which would detect airborne radiological activity; Containment Floor and Equipment Sump Level Monitoring Subsystem where unidentified

-accumulated water on the containment floor would be monitored and evaluated as sump level changes; Containment Ventilation Unit Condensate Drain Tank Level Monitoring Subsystem which collects and measures as unidentified leakage the moisture removed from the containment atmosphere.

Additionally, other indicators are also available to the operator that a leak exists or may be developing:

Containment humidity indications; Low FWST Level annunciator; Pre-Cycle walkdowns performed each outage while system is at operating temperature and pressure prior to criticality; Post-Cycle walkdowns performed at operating temperature and pressure performed during unit shutdown.

See Paragraph J for additional justification information based on other code required testing.

Paragraph I:

Weld 1BRHRHX-5-9 on the ND Heat Exchanger is used to cool the water from the reactor coolant system (RCS) in Residual Heat Removal (RHR) mode or the Containment Sump in Containment Sump Recirculation.

The ND System is normally in standby during power operations. When the RCS is less than 350° F, the ND system is aligned to RHR mode and the ND Heat Exchanger is used to remove decay heat during shutdown operations. In emergency core cooling mode, the Heat Exchanger is used to remove the heat energy from containment prior to the ND system returning the water back to containment.

The area that contains this Heat Exchanger to flange weld is surveyed twice a day by Operations staff during their routine rounds. One of the items that must be checked off is the general condition of the room containing

Request for Relief 02-002 Revision 1 Page 7 of 8 the Heat Exchanger. It is reasonable for the operator making these rounds to detect any external leaks from this weld.

This same area is also surveyed once a week by a periodic test that is used to specifically look for radioactive leaks outside containment. This area must be surveyed and signed off. If a leak were encountered, it would be written up in a work request and Problem Investigation Process form filled out. The Fluid Leak Management Process then examines the leak. The leak is either repaired or set up for periodic monitoring. A leak in the ND system would also have to be entered into the Emergency Core Cooling System Leakage Program.

Potential Failure Mechanisms:

The residual heat removal heat exchanger shell to flange circumferential weld joins two carbon steel components using compatible weld material. The weld is susceptible to one failure mechanism, thermal fatigue, that is initiated from the inside diameter of the weld and is associated with high temperature differences experienced during unit heat-up and cool-down cycles. This mechanism is not expected to result in cracking of the weld because it was accounted for by the number of acceptable heat-up and cool-down cycles factored into the system design.

At the time of the inspection, Duke Power Corporation used the best available RT methodology to perform the weld examination such that evidence of thermal fatigue cracking, consistent with the fatigue type cracks that are introduced into Performance Demonstration Initiative (PDI) UT samples, should have been detected in the areas covered by the RT exam.

See Paragraph J for additional justification information based on other code required testing.

Paragraph J:

Duke Energy proposes to use the code required pressure test and VT-2 visual examination to compliment the limited examination coverage. The Code requires, for Class 1 Components (reference Table IWB-2500-1, Item Numbers B 15.20 and B 15.50) that a system leakage test be performed after each refueling outage.

Additionally, a system hydrostatic test (reference Table IWB-2500-1, Item Numbers B15.21and B 15.51) is required once during each 10-year inspection interval.

The Code requires, for Class 2 Components (reference Table IWC-2500- 1, Item Number C7. 10) that a system pressure test be performed each inspection period. Additionally a system hydrostatic test (reference Table IWC-2500-1, Item Number C07.020 is required once during each 10-year inspection interval. These tests require a VT-2 visual examination for evidence of leakage. This testing will provide adequate assurance of pressure boundary integrity.

VII. Implementation Schedule Paragraph K:

The scheduled second 10-year interval plan code examination was performed on the referenced welds resulting in limited volumetric coverage. No additional examinations are planned for the welds during the current inspection interval. The same welds may be examined again as part of the next (third) 10-year interval plan, depending on the applicable code year edition and addenda requirements adopted in the future.

Request for Relief 02-002 Revision I Page 8 of 8 VIII. Other Information The following individuals contributed to the development of this RFR:

Jim McArdle (NDE Level III Inspector) provided UT related information for Sections II through V Tim Tucker (NDE Level III Inspector) provided RT related information for Sections II through V David Goforth (CNS Systems Engineer) provided a portion of Section VI Mark Pyne (G.O. Engineering) provided a portion of Section VI.

Andy Hogge (Sponsor) compiled the remaining sections Sponsored By:

Approved By:

1 I JEza aX,;

Date Attachment A Attachment B Attachment C Attachment D Attachment E Weld PZR-W4ASE Examination Data Weld IPZR-W4BSE Examination Data Weld PZR-W4CSE Examination Data Weld ND38-1 Examination Data Weld lBRHRHX-5-9 Examination Data RHR Heat Exchanger Equipment Drawing Pressurizer Safety Nozzle & Weld Detail Drawing

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DUKE POWER COMPANY Exam Start:

0505 Form NDE-UT-2A ULTRASONIC EXAMINATION DATA SHEET FOR PLANAR REFLECTORS Exam Finish:

0532 Revision 4 S:Lation:

Catawba lUnit:

1 I Component/Neld ID: 1PZR-W4ASE Date:

4/29/2002 Weld Length (in.):

20.8 Surface Condition:

AS GROUND Lo: 9.1.1.4 Surface Temoerature:

81 0

F Examiner: David Zimmerman/)

I Level:

II Scans:

PyrometerS/N:

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A /2 Level:

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NOT WRIT IN T IS SP CE 50%dac 50%dac 50%dac 50%dac 50%dac 50%dac IN THIS SPAC 100%dac 100%dac 100%dac 100%dac 100%dac 100%dac NRI 45o Remarks: *FC 02-10, 01-03, 98-20, 97-01. **Scanned at 72dBdue to signal/noise ratio.

Limitations: (see NDE-UT-4) El 90% or greater coverage obtained: yes no 03 SheetL1 of L Reviewed Bv:

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DEG to Prepared By:

Level:

III Date: 4/29/2002 Sketch(s) attached El yes E no Sheet of_

Reviewed By:

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Revision 0 Examination Volume/Area Defined El Base Metal El Weld El Near Surface El Boltinq E Inner Radius Area Calculation Volume Calculation

.657 SQ. IN.

SEE ATTACHED Coverage Calculations Area Length Volume Volume Beam Examined Examined Examined Required Percent Coverage Scan # Angle Direction (sq.in.)

(in.)

(cu.in.)

(cu.in.)

1 450 CW

.657 20.8 13.7 13.7 2

450 CCW

.657 20.8 13.7 13.7 3

450 Si

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.657 20.8 13.7 13.7 42.35 54.8 77.28 Item No:

B05.040.004 Prepared By:

Level:

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DUKE POWER COMPANY Exam Start:

0508 Form NDE-UT-2A ULTRASONIC EXAMINATION DATA SHEET FOR PLANAR REFLECTORS Exam Finish:

0527 Revision 4 Station:

Catawba Unit:

1 ComponentAeld ID: 1PZR-W4BSE Date:

4/29/2002 Weld Length (in.):

20.8 Surface Condition:

AS GROUND Lo: 9.1.1.4 Surface Temoerature:

81 F

Examiner: David Zimmerman Level:

III Scans:

Pyrometer S/N:

, MCNDE 27228

,c ~ <,z,v t^Cal Due:

7/3/2002 Examiner: Gary J. Moss)%,

Level:

II 45 E 72**

dB 70 [

dB

~~~~~~~~~~~~~~~~~~Configuration:

CIRC. WELD Procedure:

NDE-610 kev 4

FC:

45T O 62 dB 70T O dB S2 Flow Si 60 dB NOZZLE to SAFE-END Calibration Sheet No:

60T

____dB Scan Surface: OD 0201046,E0201047 Applies to NDE-680 only 0201046, 0201047SkwAgeNA Other:

dB Skew Angle:

N/A IND #

° Max Max Max Li L2 Wi Mpi W2 Mp2 Beam Exam Scan Damps Ref 20%dac 20%dac 20%dac 20%dac 20%dac 20%dac N

DO 10T W} ITE HMA HMA HMA HMA HMA HMA Do NOT WRIT IN T ISt SP CE 50%dac 50%dac 50%dac 50%dac 50%dac 50%dac IN THIS SPAC IN T,lS SP CE 100%dac 100%dac 100%dac 100%dac 100%dac 100%dac NRI 450 Remarks: *FC 02-10, 01-03, 98-20, 97-01. ** Scanned at 72dB due to signal/noise ratio.

Limitations: (see NDE-UT-4) E 90% or greater coverage obtained: yes El no Sheet__L of Reviewed B:

Level:

Date:

rized Insoectoh Date:

Item No:

A

-E 7 5- */6Z SB2 tl 05.040.005 F e, /P /

R S

DUKE POWER COMPANY FORM NDE-UT-4 ISI LIMITATION REPORT Revision 1 Component/Weld ID: 1PZR-W4BSE Item No: B05.040.005 Remarks:

SURFACE BEAM DIRECTION NOZZLE CONFIGURATION Cl NO SCAN El LIMITED SCAN C 1 2

C E

2 cw ccw FROM L to L INCHES FROM WO 1.0 to BEYOND ANGLE:

0 45 l 60 C Other FROM 0

DEG to 360 DEG SURFACE BEAM DIRECTION O

NO SCAN a LIMITEDSCAN C

2 C I 0 2

cw ccw FROM L to L INCHES FROM WO to ANGLE:

0 45 C 60 C Other FROM DEG to DEG El NO SCAN SURFACE BEAM DIRECTION C NO SCANSUFC a

LIMITED SCAN C

C2 C 1C 2 0cw ccw FROM L to L INCHES FROM WO to ANGLE:

0 45 C 60 Cl Other FROM DEG to DEG SURFACE BEAM DIRECTION C

NO SCAN Cl LIMITED SCAN

-2 lC 1 i 2

cw ccw FROM L to L INCHES FROMWO to ANGLE:

C 0 l 45 C 60 Other FROM DEG to Prepared By:

Level:

[if Date: 4/29/2002 Sketch(s) attached C yes C no Sheet CL of Reviewed By:

Date:

r Z

Authorized Inspector:

yym Date:

DUKE POWER COMPANY l

NDE-91-1 l

Limited Examination Coverage Worksheet Revision Examination Volume/Area Defined O Base Metal E

Weld O Near Surface El Boltina EO Inner Radius Area Calculation Volume Calculation

.625 SQ. IN.

SEE ATTACHED Coverage Calculations Area Length Volume Volume Beam Examined Examined Examined Required Scan # Angle Direction (sq.in.)

(in.)

(cu.in.)

(cu.in.)

Percent Coverage 1

45° 2

450 3

45° 4

45° cw CCw S2 Si

.625

.625

.625

.275 20.8 20.8 20.8 20.8 13 13 13 13 44.72 13 13 13 13 52 86.00 r-Y3rD 3,r-4

DUKE POWER COMPANY NDE-UT-5 UT PROFILE/PLOT SHEET RevIslon.1 EXAMINATION SURFACE 1 A

Fil ATn Cl I:Ac ('

WfELD CM, -%I IYI I I

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q.

1 2

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1 1 1 1 I I I II lSlllI I i11I 1.5 C-~~~~~~~~~~~~~~-

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Component ID/Weld No.

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Item No:

,Revlewed By:

Q44I U ___'

t lLevel: Vi I Da te:

t _,Level:_

Date: -

/n-d I

Date:

C-22 -2 270 roFile taken 270 j1 :

} 90 180 SheetL.+/-of4 4

1111 I

.5 3

I jAuthorized Inspect6K

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P I

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DUKE POWER COMPANY Exam Start:

0512 Form NDE-UT-2A ULTRASONI,C EXAMINATION DATA SHEET FOR PLANAR REFLECTORS Exam Finish:

0522 Revision 4 Station:

Catawba Unit:

I Component/Weld ID: 1PZR-W4CSE Date:

4/29/2002 Weld Length (in.):

20.8 Surface Condition:

AS GROUND Lo: 9.1.1.4 Surface Temerature:

81 F

Examiner: Winfred C. Leepe 11 Scans:

Pyrometer S/N:

, MCNDE 27228 Examiner: Marion T. Weavr. ia Level:

II 45 El 72**

dB 70 dB Configuration:

CIRC. WELD Procedure: NDE-610 Rev:

4 FC:

45T El 62 dB 70T dB S2 Flow Si 60 E

___0_

dB NOZZLE to SAFE-END Calibration Sheet No:

60T dB Scan Surface: OD 0201046,0201047 Applies to NDE-680 only Other:

dB Skew Angle:

N/A Max Mp W

L Beam Exam IND# 4 Max Max Max Li L2 Wi Mpl W2 Mp2 Dir.

Surf.

Scan Damps Ref 20%dac 20%dac 20%dac 20%dac 20%dac 20%dac DO IOT W ITE HMA HMA HMA HMA HMA HMA Do NOT WRIT IN T IS SP ' CE 50%dac 50%dac 50%dac 50%dac 50%dac 50%dac IN THIS SPAC 100%dac 100%dac 100%dac 100%dac 100%dac 100%dac NRI 45 I

Remarks: *FC 02-10, 01-03, 98-20, 97-01. ** Scanned at 72dB due to signal/noise ratio.

Limitations: (see NDE-UT-4) E 90% or greater coverage obtained: yes no O Sheet of_

Reviewed B:

Level:

Date:

A orzed Inspector Date:

Item No:

@ > /

BL 5 / S0 7

/oJ->6 h'l 5 2c &Z B05.040.006 A M,co'Ze

-7#e2-ed 2 p II 6IJJ(1 W77 AVeC01Ev7-C

.A

DUKE POWER COMPANY FORM NDE-UT-4 ISI LIMITATION REPORT Revision 1 Component/Weld ID: IPZR-W4CSE Item No: B05.040.006 Remarks:

SURFACE BEAM DIRECTION NOZZLE CONFIGURATION El NO SCAN El LIMITED SCAN Ei 102 0l1 0E 2 0l cw ccw FROM L to L INCHES FROM WO 1.0 to BEYOND ANGLE:

El 45 0 60 0 Other FROM 0

DEG to 360 DEG SURFACE BEAM DIRECTION E NO SCAN E LIMITED SCAN i

2 El El 2 El cw El ccw FROM L to L INCHES FROM WO to ANGLE:

l 0 El 45 l 60 E Other FROM DEG to DEG SURFACE BEAM DIRECTION El NO SCAN E LIMITED SCAN l1 El2 E

1 l 2 l cw ccw FROM L to L INCHES FROM WO to ANGLE:

El 0 El 45 E 60 El Other FROM DEG to DEG SURFACE BEAM DIRECTION El NO SCAN E LIMITED SCAN E

El2 E 1El 2 cw El ccw FROM L to L INCHES FROM WO to ANGLE:

0 El 45 E 60 El Other FROM ___

DEG to Prepared By: z9L Level:

Ill Date: 4/29/2002 Sketch(s) attached El yes E no Sheet,..

of Y Reviewed By:

Date:

lAuthorized Inspector:

m,Y Date:

CZZ

DUKE POWER COMPANY NDE-UT-5 UT PROFILE/PLOT SHEET Revislon.1 I YAUIMAioxi cZI IDC A r I

rVA tl Artfn\\

Cl trA r

2 WE 1

q I I I I 1I I I I LD JAAMIINH I UIY OUKml8C: C 1

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Component ID/Weld No.

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Sc,,

,Revlewed BY: C 4,e-lAuthorlzed Ispector. /-,f, )f Level:_

Date: 4/1zqoz

, Level:

Date: 5 /I/o Z 2 gi' Date:

-22.

U Profile taken 270 at 1 O 90 180 Sheetof I I s> f I I lI Y I.J

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I 4

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I I.L-7/

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lExaminer JS?6

DUKE POWER COMPANY NDE-91-1 Limited Examination Coverage Worksheet Rvso Examination VolumelArea Defined Ol Base Metal El Weld El Near Surface ID Bolting E Inner Radius Area Calculation Volume Calculation

.675 SQ. IN.

SEE ATTACHED SKETCH Coverage Calculations Area Length Volume Volume Beam Examined Examined Examined Required Scan # Angle Direction (sq.in.)

(in.)

(cu.in.)

(cu.in.)

Percent Coverage 1

45o CW

.675 20.8 14.04 14.04 2

45° ccw

.675 20.8 14.04 14.04 3

45° S2

.675 20.8 14.04 14.04 4

450 Si

.19 20.8 3.95 14.04 46.07 56.16 82.03 Item No:

B05.040.006 Prepared By:

Level:

Date:

Reviewed By:

Level:

1LY Date: S74s6/o L

lA3 tcC

Catawba Unit #1 EOC13 Item #

Weld #

No Data Recorded. Reference Calibration Sheet #' s 0O a'2 () / 1) -z 7 6001-C,O62-ed2 e,K/

BSS A.o //. /d VI" D~~~~~P

//

111=01e CF q m 114101,

DUKE POWER COMPANY FORM NDE-UT-4 ISI LIMITATION REPORT Revision 1 Component/Weld ID: 1ND38-1 Item No: B09.011.104 Remarks:

0l NO SCAN SURFACE BEAM DIRECTION Valve Configuration El LIMITED SCAN 1

2 El 1 2 El cw El ccw FROM L to L INCHES FROM WO -

C/L to Beyond ANGLE:

0 45 60 El Other FROM 0

DEG to 360 DEG SURFACE BEAM DIRECTION El NO SCAN El LIMITEDOSCAN El 1Ea2 El 1El 2 El cwEl ccw.

FROM L to L INCHES FROM WO to ANGLE:

0 45 l 60 0 Other FROM DEG to DEG SURFACE BEAM DIRECTION El NO SCAN l

LIMITED SCAN 1El2 E 1El 2 El cwO ccw FROML toL INCHES FROM WO to ANGLE:

0 El 45 0 60 El Other FROM DEG to DEG El NO SCAN El LIMITED SCAN SURFACE El1 2

toL -_- -

Ir El 0 El 45 60 El Ohlr Prepared By. Jay A. Eaton

(

Level:

NCHES FROM BEAM DIRECTION El 1 2 [

cw El ccw WO to FROM DEG to IlIl Date: 5/2/2002 j Sketch(s)

Reviewed By:

)T4 uL

ti-zed Isetr

!Reviewed By:,,&-

/

g Dt

.S', O2 Authorized Inspector:

1/ J FROM L ANGLE:

-~~~~~

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DUKE POWER COMPANY NDE-UT-5

,/ 1 LT PROFILE/PLOT SHEET Revision.i EXAMINATION SURFACE 1 - QA4JlZ 4

1111 3

lii 11 1 I 17rtA%.

AC-CA 2

1 0

)

1,'

EXAMINATION SURFACE 2 WELD I

Lb 2

II1 I III 3

1 1I I I 4

1 II 3

,2___

7, 2.5.

3.

Component ID/Weld No.

0

Remarks:

I

/-\\

I l

Item No:

>as o

°

\\

I DL Examiner.

t I Level:

I Date: sI I loa Reviewed By: r-J; L vel:,

I Date: s-'oe.

1

.1 I

I I /

II IAUtorleed IRspector-.

/IerifjD5,Th v

.5 I eJv3S -I 2.

270

\\

4

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1-I I;C I

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D)a te: S 11 11 1 l t H4

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1 450 CW 2

450 CCW 3

60° Si 4

600 S2 Total 0.563 0.563 0.253 40.1 40.1 40.1 0

0 Aggregate Coverage 600L Wave Supplement Coverage 3

600L S1 0.309 40.1 22.58 22.58 10.14 0

55.3 12.391 22.58 22.58 22.58 22.58 90.32 22.58 100.00 100.00 44.91 0.00 61.23 54.88 54.88% of 1 scan (25%) = 13.72% of total weld.

~;5 f ~ L DUKE POWER COMPANY NDE-91-1 Limited Examination Coverage Worksheet Revision 0 Examination Volume/Area Defined I] Base Metal

[l Weld l Near Surface l Boltinci QI Inner Radius Area Calculation Volume Calculation 0.375' X 1.5 = 0.563 SQ. IN.

0.563 X 40.1" = 22.58 CUIN.

Coverage Calculations Area Length Volume Volume Beam Examined Examined Examined Required Percent Coverage Scan # Angle Direction (sq.in.)

(in.)

(cu.in.)

(cu.in.)

I FORM NDE-RTI l REVISION 5 DUKE POWER COMPANY RADIOGRAPHIC EXAMINATION REPORT ITEChNIQUE Weld / Component ID.

I BRHRHX-5-9 Project Catawba Nuclear Station Procedure NoJRcv.

NDE 12/11 Acceptance/Reporting StandardzE, K 5adiographe Level Date R.L.Gantt If 05-04-02 Code Reference ASME Sec. Xl Material:

CS ED SS L

Diameter 43.75" Thickness

.875" Source:

lr-192 -Size:

.142" Curies:

91 Estimated Weld Build-Up

.0625" SFD 21.937" IQI:

Film Side

[a Source Side E0 20 Size(s)

IQI Design:

Standard Hole-Type Film View:

Single l

Composite O

Number of Film Per Cassette:

2 Film Stand Off NA Film Brand/Type:

Front Fuji 80 Center NA Back Fuji 80 Shim Size(s):

NA Screen Thickness:

Front

.010" Center NA Back

.010" (Ug = Ft/D) Actual Ug:

.006" Exposure Time:

Hrs.

NA Min. X,fJE t41 gd.

Thicker member used as shim:

E TECIINIQUE SET UP J A C

E F

G G

H p§l Other ti;WiE~~~~~~~~~~~I I

tf0aS I ~ ~

Of s

S p

psd SigeWl Offset Double Double Exposure. Flm Draw Ske Single Wall View Wall View Wal View Inside Pipe FILM REVIEW Interval Date Indication Length/Size Reviewer Level Date Accept Reject Report Reshoot 0-1 05-04-02 8,12 5X4 7 III 05-04-02 1-2 05-04-02 8

6Q;(_

III 05-04-02 2-3 05-04-02 8

(4_

-III 05-04-02 3-4 05-04-02 8,12 e

/ 7 III 05-04-02 4-5 05-04-02 8

c/M 7 11 05-04-02 SE-6 05-04-02 Mah' 7 III 05-04-02 6-7 05-04-02 8

J III 05-04-02 7-8 05-04-02 III 05-04-02 8X-9 05-04-02 III 05-04-02 9-10 05-04-02 12 M____III 05-04-02 10 -OR 05-04-02

_III 05-04-02 V

_

Indication

1. Incomp. Fusion

4. Unconsumed Insert 7. Undercut

10. Convexity

13. Surface and flaw

2. Incomp. Pen.

5. Crack

8. Porosity I1. Concavity

14. Inclusion types:

3. Excessive Pen.

6. Slag

9. Tungsten

12. Film Artifact 15.

Exam Limitations:

Yes:

55

% Examined E] No: (100% Examined)

Comments:

Second Review

-/

Level III Date 05-04-02 ANI/ANII Review 5

Date 5-G<-

Item No.

C01.010.002 I-;

K I

tt,dl

IC&l.&iC14

.K 9

RADIOGRAPIUC TECHNIQUE I Date:

-4t-OZ Approved:

z

=1-2 1ZT LweJ 0

- 0 6

5E Exposure Times 0 -

- 2 9

2-3 3 - 4 ilm 4 S 5E-6

• 8X 6-7 7 - 8.

8X - 9 9 - 10 10 - OR 3 mw;^

5 j cM oscc.

@b4JOsc.

Sm,-AjS0sec-O5rŽ5sec

/0 A4i' 5Scc.

2 0

3

• 8 5

OR 0

DUKE POWER COMPANY NDE-91-1 Limited Examination Coverage Worksheet

. Revision 0 Examination Volume/Area Defined Base Metal Elz Weld E}" Near Surface

' Bolting El Inner Radius El.

Area Calculation Volume Calculation 45 q q7 T assst 5

7 X Se 4e eJoto..

Coverage Calculations Beam Area Length Volume Volume Scan i Angle eamn Examined Examined Examined Required Percent Coverage Directon (sq.in.)

(in)

(cu.in.)

(cu.in.)

/..

iŽe4frL~S

's-Fct C^xI

-LJuc':

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6/.6il e.6S Prepared. BY:

Level:

-LL Date: 5-4Xz Reviewed By:

.z.z Xt Level: _Z Date:.5--,a2

RFR 02-002 ATTACHMENT SHEET 2 NO COVERAGE NO COVERAGE

-NO COVERAGE DETAIL DIVIDER PLATES SCALEs NONE W

EXAMINATION COVERAGE NO COVERAGE DETAIL B -

FLANGE TO SHELL WELD.

SCALE' FULL 1

-SA-105 ISI ITEM NO.

CO le 0 10e 002

NOTES:

I: WELO PREP PER PWRSD OWG 271C500

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