ML043060591
| ML043060591 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 10/13/2004 |
| From: | Duke Power Co |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| CNC-2201.01-00-0006 | |
| Download: ML043060591 (26) | |
Text
I CATAWBA NUCLEAR STATION UNIT 2 EVALUATION OF 2EOC13 ISI FLAW IN SG2C TO HOT LEG WELD CNC-2201.01-00-0006
Form 101.1 (ROO-04)
CERTIFICATION OF ENGINEERING CALCULATION Station And Unit Number Catawba Nuclear Station, Unit 2 Title Of Calculation Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld Calculation Number CNC-2201.01-00-0006 Total Original Pages 1
Through 8_
Total Supporting Documentation Attachments I tA) Total Microfiche Attachments Total Volumes I
Active Calculation/Analysis Yes Dl No 13 Microfiche Attachment List E Yes 1 No If Active, is this a Type 1 Calculation/Analysis Yes El No El (See Form 101.4)
These engineering Calculations cover QA Condition 1 Items. In accordance with established procedures, the quality has been assured and I certify that the above Calculation has been Originated, Checked, or Approved as noted below:
Originated By Date la.o JR 04 Checked By b
AL 4Jz Date lo -1.2 - V4
' Verification Method:
Meth d Method 2 Method 3 Other Approved By L J e G
t Jo4!
Date
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Issued To Document Management 8
I Date I
)
-13 Received By Document Management Date l -
I --t-3 4 Complete The Spaces Below For Documentation Of Multiple Originators Or Checkers Pages Through Originated By Date Checked By Date Verification Method:
Method 1 0 Method 2 0 Method 3 0 Other El Pages Through Originated By Date Checked By Date Verification Method:
Method 1 El Method 2 E Method 3 E Other El Pages Through Originated By Date Checked By Date Verification Method:
Method 1 Method 2 El Method 3 El Other E PR1O.-2
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Form 101.2 (R3-03)
File/Calculation No. CNC-2201.01-00-0006 REVISION DOCUMENTATION SHEET Revision Revision Description Number
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Statement of Problem / Purpose This calculation has been performed to address an indication discovered on the 2C Steam Generator to Hot Leg weld during 2E0C13. This particular weld is located between the cast low alloy steel primary channel head of the steam generator and the cast austenitic stainless steel elbow. Typically, the volumetric examination under Section XI of the ASME Code would be performed using an ultrasonic examination. However, the cast austenitic stainless steel material of the reactor coolant loop piping precludes the use of the ultrasonic examination methodology. The ultrasonic examination was replaced with a radiographic examination.
QA Condition This calculation is QA Condition I because it serves as the basis for continued qualification of a Duke Class A, ASME Class I component.
Analysis Methodology This calculation verifies that the structural integrity of the steam generator 2C nozzle to hot leg weld is maintained under all operating and design loading conditions, even with the identified flaw. The verification has been performed by conservatively bounding the flaw characteristics and comparing this bounding flaw against allowable flaw depths provided by a Westinghouse flaw evaluation handbook [7] specific to this reactor coolant loop location.
Other Evaluation Criteria No other evaluation criteria have been used.
Applicable Licensing References L. 1 Catawba UFSAR, September 27, 2003 issue date, Sections 3.9 and 5.2 L. 2 Catawba Selected Licensee Commitments 16.5.5, Reactor Coolant System, Structural Integrity, Rev 0 Assumptions/Engineering Judgments As noted in body of calculation Catawba Nuclear Station, Unit 2 Orig: WOC 10/12/04 Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld Check: JFW 10/13/04 CNC-2206.01-00-0006, Rev. 0 Page IL
References I
ASME Code,Section III, Subsections NB and NC, 1974 Edition with Summer 1974 Addenda.
2 ASME Code,Section XI, 1989 Edition, No addenda 3
Westinghouse sketch EDSK 380335B, from CNM-2201.01-0217 4
Westinghouse sketch EDSK 380329B, from CNM-2201.01-0217 5
CNM-1201.01-0076, Rev 0, ESCO drawing AA-43234,, Weld Bevel Detail, 31.00 I. D. Elbows, Nozzle Ends 6
CNM-2201.01-0008, Rev B, ESCO drawing AD-22321, Machining - 31.00 I.D. x 29.00 I.D. Long Radius 50° Reducing Weld Elbow 7
WCAP-15658-P, September, 2004, Flaw Evaluation Handbook for Catawba Unit 2 Steam Generator Primary Nozzle Weld Regions.
8 CN-2553-1.0, Rev 22, NC Flow Diagram.
9 CN-2NC-00 13, Rev 13, Weld Isometric.
10 PIP C-04-5421 Catawba Nuclear Station, Unit 2 Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld CNC-2206.01-00-0006, Rev. 0 Orig: WOC 10/12/04 Check: JFW 10113104 Page Z?
Calculation/Evaluation This calculation was performed by determining the bounding characteristics of the indication and comparing parameters associated with this indication to values in the Westinghouse supplied flaw analysis handbook [7].
Nozzle Configuration The nozzle connection consists of a low alloy steel casting that forms the channel head of the steam generator. This casting has been buttered with a low carbon, stainless steel weld metal. The piping to buttering field weld is made after post weld heat treatment of the steam generator channel head. The Duke weld number is 2NC-13-2 and the weld process control from the original fabrication is included as Attachment A. This weld is a full penetration, compound V groove weld made from the outside of the pipe. The GTAW (TIG) process was used for the first inch, followed by a "courtesy" radiograph (RT). Subsequent welding was performed using the SMAW (stick) process to finish out the weld. After completion of welding, a final RT was performed and accepted on the weld. In addition, liquid penetrant tests (PT's) were performed on the interior and exterior surfaces of the weld.
Flaw Geometry The flaw is located at the bottom of the pipe in the C hot leg. It is approximately at bottom dead center of the pipe. Based on the radiographic data, the flaw is 1" long and oriented in the circumferential direction. Since the examination was performed using RT, a limited amount of information was available to characterize the flaw. The location of the flaw relative to the OD surface was established using parallax radiographic shots.
These shots support a minimal flaw depth. However, because of the uncertainty in flaw depth, a bounding case has been reviewed herein.
Catawba Nuclear Station, Unit 2 Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld CNC-2206.01-00-0006, Rev. 0 Orig: WOC 10/12/04 Check: JFW 10/13/04 Page.. >
Radiography Evaluation 2-is-tU I1 i
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Duiing the Si radiographic exainnaon (FT) od Steam Generator Charlie v Wet Nozzle to Sale End and Sale End to Pipe welds QS1 item numbers a
l 805070.005 and 9051 30.010 respedrveA eons ich (l.00 x.1251 ineor dicatonwas deteced atti RTnumber 0.The RT rrlocated on te appecuimate heel ofi be elbow The lowcornasitindicationwes chiamctedzed tbe consistentih o slag type dcationwith esmail troughwel dimension bThe labication Mim was viewed in the analog and digital bfoers for comparisons. The fobication radiographs did olx record the idication. The detection of the hdicetion in 2004 and not durdng tab ication i contributed lo te piane of b e
lowein rotion o te kw n
change inthe plane of radiation from the owce A paralxR FT eposure wa perfomed to dete.rine hoe dept aoft e slag indication. The dept wes determined a be I.01 from be OD udaca. A srmple plot based on the two source locations during the parallax exposure in relation to the image shit and location from the weld edge supports the 1.01 depth caiculation and plots the indicabon to be located wi the SS material at or near the interlace of tie Safe End material and the Duk oield weld.
'The parallax exposure and calculations were veritied by Level I Radiographer J.L Smith.
tiLTucder RT Upvl
.Bodlyoftmessege In addition to the radiography shots made to characterize the flaw, both the original construction film and the 2EOC13 film (non-parallax shots) wNere digitized. The original construction film was digitized to determine if the indication could be seen from initial fabrication welding. Digitization of the film can greatly enhance the visible interpretation of the film in some cases. Next, the 2EOC13 film was digitized and reviewed to determine if the linear indication was actually separated into multiple flaws.
In both of these cases, there was no conclusive evidence from the digitization process that changed the film interpretation or flaw characteristics.
Based on the conclusions provided from the radiography review above, a best estimate characterization of the flaw has been provided. The flaw is located 1.01" from the outside surface of the piping in the stainless steel weld material. The flaw is oriented circumferentially with a length of 1.0". The flaw is most likely the result of a slag inclusion during fabrication. It has very little contrast that indicates a limited depth. It is located at the interface between the stainless steel buttering and the Duke stainless steel field weld.
Catawba Nuclear Station, Unit 2 Orig: WOC 10/12104 Evaluation of 2EOC13 IS1 Flaw in SG2C to Hot Leg Weld Check: JFW 10/13/04 CNC-2206.01-00-0006, Rev. 0 Page A_
The flaw location from the OD surface of 1.01" was considered from three positions relative to the flaw depth (top, center & bottom). The three positions were considered for two different aspect ratios. All six cases were found to be acceptable. Based on the method used to determine location, the center position is the most appropriate and is used in the documented flaw calculation below.
For the initial evaluation, the flaw depth will be assumed as l/2 of the length and evaluated as an embedded flaw. From the flaw handbook, several parameters are necessary to determine the acceptability of the indication. These are provided below. The appropriate figure for the purposes of evaluation from reference [7] for a circumferential embedded flaw in the stainless steel material is Figure A-3.7.
a
=
half flaw depth (in)
=
0.25 in.
l =
length of flaw (in)
=
1.0 in.
t wall thickness (in)
=
3.25 in.
Note: The wall thickness is based on profiling of weld using UT probe.
Value of 3.25" is conservative and represents the lowest reading throughout the weld region of interest. See page a for the LIT profile readings at the location of interest.
6
=
distance to flaw centerline
=
1.01 in.
6/t
=
1.01/3.25
=
0.311 a / t
=
0.25 /3.25
=
0.077 The 6/ t and a /t parameters may be plotted on Figure A-3.7 to determine the acceptability of the flaw. This point (A) is shown on the attached sketch.
In addition to the above evaluation, the flaw depth was increased to 1" yielding an aspect ratio of 1:1. In this case, the parameters change as noted below:
a
=
half flaw depth (in)
=
0.50 in.
I
=
length of flaw (in)
=
1.0in.
t
=
wall thickness (in)
=
3.25 in.
6
=
distance to flaw centerline Catawba Nuclear Station, Unit 2 Orig: WOC 10/12/04 Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld Check: JFW 10/13/04 CNC-2206.01-00-0006, Rev. 0 Page S.
=
1.01 in.
6lt 1.01 /3.25
=
0.311 alt
=
0.50/3.25
=
0.154 Again, the 6 I t and a I t parameters have been plotted on Figure A-3.7 as point (B) to determine the acceptability of the flaw.
Results In both cases evaluated above, it is clearly evident that the flaw is within the bounds of the acceptability provided by Figure A-3.7 of reference [7]. As a result, the piping containing this flaw is acceptable for continued service for the design life of the plant.
The figure in reference [7] indicates 10, 20 and 30 year acceptance lines. These lines are related to the design number of occurrences of transients used in the fatigue crack growth calculation. As such, this indication is acceptable for life of plant provided a prorated value (30/40 = 75%) of the design number of occurrences are not exceeded between now and end of plant life. This limit on fatigue cycle counts will be tracked under our fatigue management program.
Conclusion The flaw discovered during 2EOC13 is acceptable without repair for the life of plant.
Acceptance by the performance of analytical evaluation as allowed by ASME XI, IWB-3132.4 has been validated. Additional examinations have been performed during 2EOC13 to satisfy IWB-2430. Successive examinations for the SG2C hot leg weld number 2NC-13-2 will be necessary in the subsequent three ISI periods as required by IWB-2420.
Catawba Nuclear Station, Unit 2 Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld CNC-2206.01-00-0006, Rev. 0 Orig: WOC 10/12/04 Check: JFW 10/13/04 Page.6
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G; Source Location 21.25" from back of nozzle dam ring 24.77" from back of nozzle dam ring Reference Drawings:
- 1) CNM-2201.01-0008
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Problem Investigation Process Catawba Nuclear Station PIP erialNo:
Action Category:^ a 'LER-No:
. - OtherReport:
IC-04-05421 3
Problem Identification Discovered Time/Date:
10:33 10/111/2004 Occurred Time/Date:
10/07/2004 Unit(s) Affected:
Unit Mode
%Power Unit Status Remarks 2
NOMODE System(s) Affected:
NC Reactor Coolant Affected Equipment (No Equipment Affected)
Location or Problem:
Bldg: RX Column line:
Elev:
Location Remarks:
S/0 'C Method Used to Discover Problem:
RT (ISI) of S/G'C' Inlet/outlet nozzle weld 1
tief Problem
Description:
Inear indication of I inch found in S/G 'C' on Hot leg during RT(radiography)
Detail Problem
Description:
Linear indication of I inch found in S/G 'C' hot leg nozzle weld duirng RT.Linear indication of I inch exceeds the acceptance standards of NDE-12, ASME Code Sections III and XI.(Procedure NDE 12 Rev. I1. Appendix A, ASME Code Xl IWB-3514, ASME Code Section 111 NB-5320).
Slag indication of I inch in length located at RT film interval number 0. The indication was not visible on the construction radiographs. A change in the source position in relation to the plane of the flaw was determined to be the basis for the flaw detection in 2004 and not during the fabrication RT. This is a reportable indication.
Originated By: JFB8158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/1112004 Other Units/Components/Systems/Areas Affected(YNU): U Industry Plants Affected(Y.NU): U Immediate Corrective Actions:
Engineering to perform Fracture Mechanics Analysis.
Originated By: JFB8158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/1 112004 Immediate Corrective Action Documents I Work Orders:
Problem Identified By:
Problem Entered By:
Indiv Team JFB8158 JLW3805 JFB8158 JLW3805 Group IWS IWS Date 10/1112004 10/1112004 Screening Action Category: 3 Root Cause performed? No 10/1112004 11:33 Page 1 PIP No: C-04.05421 101120 Ino1.-33 Page I PP PNo: C-04-05421
Problem Investigalion Process Catawba Nuclear Station K
3EP No:
Other Report Nos:
Event Codes:
F8 Testing Screening Remarks:
Originated By: MLS9465: STANDRIDGE. MICKEY L Team: PAM7334 Group: SRG Date: 10/1 1/2004 Assignments:
Responsible Groups(s) for Problem Evaluation:
Responsible Group for Present Operability:
Responsible Group for Report Support Info:
Responsible Group for Reportability:
Responsible Group for Overall PIP Approval:
MCE N/A N/A N/A
[WS Mechanical/Civil Eng INSPEC. & WELD. SERV.
Si attreene By d,
ni M S 946nPA733 SRO 10111roup2004 i.;.
A9Daiet lScreened By:
MLS9465 PAM7334 SRG 10/11/20041 Present Operability
)esponsible Group:
Status:
Required Mode:
Comments:
No Current Signatures For This Section Reportability Responsible Group:
Status:
Problem Reportablc(Y.N,E):
Reportable Per:
Comments:
No Current Signatures For This Section Investigation Report:
Iesponsible Group:
Jvestigator:
Act Date:
Group:
Due Date:
10/11I2004 11:33 Page 2 PIP No: C-04.05421 PIP No: C-04-0.5421 onmoo704 11..33 Page 2
Problem Investigation Process Catawba Nuclear Station D')ate Due to VP or Sta. Mgr:
\\,atc Rcgulatory or Agency Rpt Duc:
bate Investigation Report Approved:
NRC Cause Codes:
Report Support Info:
Responsible Group:
Status:
No Current Signatures For This Section Problem Evaluation Problem Evaluation From: Resp. Group: MCE Status: ReadyForAccept OEDB Checked: No OEDB Comments:
Remarks Comments:
Assigned To:
MCE 10/1 l/2004 Due Date:
I 1/10/2004 Corrective Actions CA Seq. No: 1
- pW-irWWO'}.,
a44 a~CCusCo I ROC Open IWS FB A2 YYY Proposed Corrective Action:
Notify the NRC of the Reportable indication.
Originated By: JFB8158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/1 1/2004 No Current Signatures For This Section General:Outage:
Mode:
Other Tracking Processes Type Number Text Actual Corrective Action:
priority: N Actual CAC:
Status:
Due Date:
1I11t12004 HZ.-3.
Page 3 PIP No: C-04-05421
Problem Investigation Process Catawba Nuclear Station
'rSignature Type mdiv Ta
- Group' Date' i.
AssignedTo:
RGC 10/1112004 CA Seq. No: 2 lResp Group
-Stats O..'nrig Gfroup Event.Code&
- p. Prop CAC
?..CaUse C
IRGC
--- f L
IWS F8 A2 YYY Proposed Corrective Action:
Provide Fracture Mechanics Analysis data to the NRC for their review prior to unit re-start.
Originated By: JFB8 158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/11/2004 No Current Signatures For This Section General:Outage:
Mode:
Other Tracking Processes Type Number Text Actual Corrective Action:
Priority: N Actual CAC:
Status:
Due Date:
\\EssigneTo:
RGC 10/111/2004 Final and Overall PIP Approval Responsible Group: IWS Status: Screened 0
"idSl,i'te Type"~_
'al't-il-.ws,
>.W T
ia"O p
,;iH.>
7e
.;,e l Assigned To:
IWS 10/111/2004 Any Supplemental Concurrence Signatures Above Do Not Affect PIP Closure.
Closure Document Type Closure Document No Attachments Generic Applicability Responsible Group:
Status:
GO PIP No:
Assessment Remarks:
No Current Signatures For This Section
-Pailure Prevention Investigation No FPI Records for this PIP.
101f11200411:33 Page 4 PIP No: C-04-05421
Problem Invesligalion Process Catawba Nuclear Station KJRetnarks No Remarks for this PIP.
Maintenance Rule No Maintenance Rule Records for this PIP.
End of the Document for PIP No:
The status of this PIP is:
The duration of this PIP was:
C-4-542 1 Screened 0 days 10/ll/2004 11.33 Page 5 PIP No: C-04-05421
I QA-516 A I Revision 4 Indication Evaluation Report STATION Catawba UNIT 2
ISI PLAN ITEM NUMBER B05.070.005 rf! 130.010 I
ISI PLAN ID NUMBER 2SGC4lNLET-SE
,qmrin-0q NDE METHOD NDE PROCEDURE USED INDICATION SERIAL NUMBER Radiography NDE 12 REV. 11 S/N I (located at RT# 0)
DESCRIPTION OF ITEM CONTAINING INDICATION DATE INSPECTED EVALUATION NEEDED BY DATE Steam Gen Inlet Nozzle to Safe End Weld 1010712004 1011112004 Steam Gen Nozzle Safe End to Pine weld COMMENTS: Slag Indication 1.00" In length located at RT film interval number "O". The Indication was not visible on the construction radiographs. A change in source position in relation to the plane of the flaw was determined to the basis for the flaw detection in 2004 and not during the fabrication RT.
A ORIGINATED BY: T.L Tucker DATE: 1011112004 ACCEPTANCE STANDARD USED: Procedure NDE 12 Rev 11 Appendix A, ASME Code Sect. Xl IWB-3514, ASME Code Sect. III NB-5320.
CALCULATIONS/COMMENTS: Unear indication length of 1.00" exceeds the acceptance standards of NDE 12, ASME Codes Sect. III and Sect. Xl.
EVALUATION STATUS = Reportable B
Evaluated By (NDE LEVEL Ill): T.L Tucker DATE: 10/11/2004 PIP SERIAL No:
E - 0 c-5721 C
ISI COORDINATOR:
DATE:
ADDITIONAL INSPECTIONS El NOT REQUIRED El REQUIRED: ISI PLAN ADDENDA S/N:
D SURVEILLANCEINSPECTIONS 0 NOTREQUIRED O REQUIRED: ISI PLAN ADDENDA SIN:
ISI PLAN MANAGER lDATE DISPOSITION El ACCEPTABLE IN ACCORDANCE WITH IWB-3600 (FMA)
El REPAIRED El REPLACED E
COMMENTS:
DISPOSITIONED BY (ISI Plan Manager)_
DATE