ML050830350

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E-Mail B. Kemp, NMC, to H. Chernoff, NRR, May 11 Rev 2. Ppt W/Att Slides Conference Call, May 11, 2004
ML050830350
Person / Time
Site: Point Beach NextEra Energy icon.png
Issue date: 05/11/2004
From: Kemp B
Nuclear Management Co
To: Chernoff H
NRC/NRR/DLPM/LPD3
References
FOIA/PA-2004-0282
Download: ML050830350 (37)
v • d • e


Text

Harold Chernoff - May 11 rev2.pt 1%.

Pace 1 i From:

'Kemp, Brian" <Brian.Kemp~nmcco.com>

To:

<hkc~nrc.gov> -

t-, -

f Date:

Tue, May 11, 2004 1:07 PM

Subject:

' May 11 rev2.ppt

Harold, Attached is the outline of the discussion we would like to have with the staff at 3 pm EDT today.

<<May 11 rev2.ppt>

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I Harold Chernoff - May I11 rev2.ppt Page 1 1Z I HarcId Chrnoff-May11 rev2.ppt Page 1 I Point Beach Nuclear Plant Unit I -

2004 RPV Head Inspection Results Spring

.1 Conference Call Tuesday May 11, 2004 I

r to Nclear Excellence

I HarpJd Cheirnoff - May 1 1 rev2.ppt Page 210 I HarcJd Cherrioff - May 11 rev2.ppt Page2

Purpose 1

."ReView RPV inspection results from the

>PBNP-1 refueling outage (U1 R28)

- Limitation in coverage of Nozzles 32 & 33

- Relaxation of NRC Order EA-03-09 is requested Discuss Repairs being performed on Nozzle 26 8<t-Areva's ID Temperbead (IDTB) repair process

..- Revised relief requests required for this repair

?due to A52 to A82/182 weld overlap Committed to Nuclear Excellence

I Harold Chernoff - May 1 1 rev2.ppt Page 31" I Harcd Chernoff - May 11 rev2.ppt Page 3 Ii PBNP-1 General RPV Design Information

  • Fabricated by B&W
  • EDY 15.5 - high susceptibility category of NRC Order EA-03-09 Committed to Nuclear Excellence

I Hardd Chernoff - Mav 1 1 rev2.ppt Page 412

Harold Chernoff May.

_.re.

t.P_.

PBNP-1 Inspection History & Plans

  • Eddy current exam performed in 1994

- No indications (95% coverage)

  • Bare-metal visual (BMV) exam performed in Fall 2002 (no indications)
  • .UT examination performed in Fall 2002 (no indications)

- Greater than 90% coverage

  • RPV head will be replaced during U1R29 (18 months - Fall 2005)

Committed to Nuclear Excellence

I Harod Chernoff - May 11 rev2.ppt Page 5 CRDM Penetration Configuration

  • 16 open housings
  • 1 vent line Committed to Nuclear Excellence

I Harold Chernoff - May 1 1 rev2.ppt Page 61l I HarQId Chernoff - May 11 rev2.ppt Page 6 I CRD Penetration Layout 270 pc Pt

'0 VbeW Fromt Abort touc l

i Committed to Nuclear Excellence

I Harald Chernoff - May i I rev2.ppt Page 71 I HarQId Chernoff - May 11 rev2.ppt Page 7 I U1R28 Inspection Results

  • BMV exam essentially complete w/ no indications
  • Overall > 95% UT coverage
  • Limitations

- All thermal sleeved locations (33) have minor area of lack of OD coverage of 0.4" at bottom of tubes due to probe design

- Nozzles 32 & 33 have inaccessible areas due to weld distortion

  • Nozzle 26 Repair

- UT and surface indications Committed to Nuclear Excellence

I Haro!d Chernoff - May 1 1 rev2.ppt Page 81 I Haro!d Chernoff - May 11 rev2.ppt Page 8 q UT Limitations - Tube Bottom at OD Due to design of blade type UT probes, a small area on the bottom OD of tubes is unexamined

  • Generic issue with UsandArea the Areva blade tool Committed to Nuclear Excellence

I Hardd Chernoff - Mav 1 1 rev2.ppt Page 9 1 I

Ha~d Cernff

-May 1

rv2.DtPae 9II UT Limitations - Tube Bottom at OD Flaw assumed in the unexamined area (L flaw) and grows axially through the scanned area L axial (minimum is 0.41")

C L axial

,L flaw Committed to Nuclear Excellence

I Hardd Chernoff - May 1 1 rev2.ppt Page 10 q I HarQd Chernoff - May 11 rev2.,Dt Page 1Qj UT Limitations - Tube Bottom at OD (cont.)

  • Using conservative PBNP crack growth rate data (2 x 10- in/yr) derived from MRP-55, this worst-case flaw will take over 2.3 years to reach the J-groove weld
  • Relaxation to Order EA-03-09 will be requested Committed to Nuclear Excellence

I Harold Chernoff - May i 1 rev2.ppt Page 11 I I Harold Chernoff - May 11 rev2.ppt Page 11 UT Limitations - Nozzles 32 & 33

  • Weld distortion limits blade-probe access
  • Sleeves were removed in 2002 for full access (3 man-Rem per sleeve expended)
  • No indications seen in 2002 Committed to Nuclear Excellence

Harold Chernoff - May 11 rev2.ppt Page 12 UT Limitations - Nozzles 32 & 33 2004 Results (w/o sleeve removal)

- Nozzle 32

  • 3600 of coverage above and in the weld zone
  • 990 coverage below the weld

- Nozzle 33

  • 3000 of coverage above and in the weld area
  • 570 coverage below the weld
  • Ability to remove and reattach thermal sleeve to support additional inspections is difficult Committed to Nuclear Excellence

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I Harald Chernoff - Mav 1 1 rev2.ppt Paqe 151 I Haro.!d Chernoff - May 11 rev2.pDt Page 151 UT Limitations - Nozzles 32 & 33 (cant.)

Circumferential flaw above the Nozzle 33 J-groove weld assessed Initial flaw size of 600 (i.e., 3000 of UT coverage)

Using WCAP-14000 and MRP-55 crack growth rate data, it would take an undetected flaw 30 years to grow to a allowable length (3000)

Committed to Nluclear Excellence

Harold Chernoff-May 11 rev2.ppt Page 16 UT Limitations - Nozzles 32 & 33 (cont.)

  • Thermal sleeve removal is very difficult for these nozzles due to the removal and welding process performed in 2002
  • Relaxation from EA-03-09 will be sought for the limitation in coverage

- Structural Integrity Associates (SIA - Riccardella) analysis supports minor limitations in coverage

- This work was presented to NRR in February 2004 in preparation for the outage Committed to Nuclear Excellence

I Harc~d Chernoff - May 1 i rev2.ppt Page 17 11 I Harold Chernoff - May 11 rev2.pDt Pane 17

UT Limitations - Nozzles 32 & 33 (cont.)

  • The SIA analysis assumed only 80%

coverage during U1R28 (actual - 95%)

- The SIA analysis assumed only 50% coverage in outer ring nozzles 26 - 33

  • The results indicate an insignificant difference in the probability of leakage compared to that of full coverage

- Differences do not warrant additional man-Rem required for thermal sleeve removal Committed to Nuclear Excellence

IHarod Chernoff-May11 rev2.ppt Page 181 PBNP Results Probability of Leakage (per vessel year) 2.OOE 1.80E-01 No Ins p.

1.60E01 -

-Part.lnsp.Cmerage O

g-Ins p. Per NRC Order la

.E 1420E-1 I

  • l 1.00E-01

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lo\\Planned Head D 6 0E42X l

ReDi. F-05 4.00142 F402 Il 2.OOE42 4.OOE+00 0

5 10 15 20 25 EFCYs o N c

e Commnittedto Nuclear Excellence

I -H -a rd d-Che-r-n-off -- May 11 re-v2.p-pt Page 191" Harod Chernoff - May 11 rev2.ppt Page 19

Nozzle 26 Indications L1 he (e*g) h@4M

"-'-'

2 @211 l., at IL 

  • Large UT signal detected at the weld root (downhill location -

1800)

  • Signal attributed to a fabrication weld repair performed during construction Committed to Nuclear Excellence

Harold Chernoff - May11 rev2.ppt Page 20 

IH.rc~d Chernoff - Ma~y 1 1 rev2.ppt Page 20 1 Nozzle 26 Indications (Cont.)

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  • weld repair performed at this location
  • 1969 inspection report

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Committed to Nuclear Excellence

I I Harodd Chernoff - May 1 1 rev2.ppt Page 21 j I

HaoldCheroff-Ma 11rev2pptPag 21- -i Nozzle 26 Indications (cont.)

Several PTs revealed J-groove surface indications at the 90° and 2700 locations (see following diagrams)

,*i I. <-

Based on grinding and subsequent PTs depth is

> 3/16 inch

- Conservative repair of nozzle being performed due to high dose involved with flaw excavation Committed to Nuclear Excellence

I 7 -

I I HarQld Chernoff - Mav I I rev2.DDt Page 22 HarQ d *hernoff Nozzle 26 Indications (Cont.)

i

WHILA,
  • PT and UT signals superimposed t j
  • Correlation

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.lbetween UT and

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PT signals

  • Additional repair stresses (illustrative diagram)

Committed to Nuclear Excellence

I Harold Chernoff - May 1 1 rev2.ppt Page 231 I Harold Chernoff - May 11 rev2.ppt Page 23 I Nozzle 26 Repair

  • Areva IDTB repair is in progress
  • Simplified repair process outline follows Committed to Nuclear Excellence

I Harald Chernoff - Mav 1 1 rev2.ppt Page 2413 Hrold Chenf - Ma.1 _rev.D

_Pa,_,

Step 1 - Thermal Sleeve Removal NUT L.

1,

  • Sever existing thermal sleeve STEP I THERMAL SLEEVE CuTTnNG NI Committed to Nuclear Excellence

I Hardd Chernoff - May I 1 rev2.ppt Page 251 I Harold Chernoff - May 11 rev2.ppt Paje 25 II Step 2 - NDE &Roll Expansion

  • Perform baseline rotating UT
  • Using UT, take as-built

%G~m measurements

  • Roll expand nozzle IJELD ROOT STEP 2 ROLL EXPANSION M

Committed to Nuclear Excellence

Haerold Chernoff- _May I1 rev2.ppte Page 26 l Step 3 - Machining of Nozzle

  • Locate cut-line Sfifl
  • Machine the lower nozzle and form weld prep
  • Etch the original J-groove weld to locate fusion line
  • PT and UT the original J-TE groove weld in the area of the overlap STEP 3 NOZZLE REMOVAL AND WELD PREP MACHINING N1iI Committed to Nuclear Excellence

I HaLrold Chernoff - May 1 1 rev2.ppt Pa-ge 27 1 I Harold Chernoff - May 11 rev2.ppt Page 27 4 Step 4 - Welding

  • 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> Hold STEP 4 WELDING Committed to Nuclear Excellence

3 I Harold Chmoff - May 1 1 rev2.ppt Page 281 I Haol,hrnf

- May. 11. rv.pp Pag 2811...

Step 5 -Machining of Weld & NDE

/7

  • Machining of weld surface suitable for NDE during 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> X Perform UT and PT of weld after the 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> hold STEP 5 GRINDING, MACHINING, AND NDE Committed to Nuclear Excellence

I Harold Chernoff - May 1 1 rev2.pi)t Paqe 291 I Harold Chernoff - May 11 rev2.pDt Paie291 Step 6 - Chamnfer Grinding

  • v Grind chamfer on existing structural weld STEP 6 ORIGINAL WELD GRINDING Committed to Nuclear Excellence

I I Harold Chernoff - May 1 1 rev2.ppt Page 301q

, Hao. Chrnf. Ma.1.....................................

1 rv.pp Pag 30 Step 7 - Thermal Sleeve Installation T

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Dl Committed to Nuclear Excellence 2tA STEP 7 THERMAL SLEEVE REATTACHMENT

I Harald Chernoff - May 1 1 rev2.ppt Page 31 14 I.aQ~

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Nozzle 26 Weld Overlap Condition

  • With small diameter Weld ligament (132") heads, the repair A52 weld will come into contact with the existing A182 J-groove weld
  • Unique design challenge for the IGNDINCACNW.

Westinghouse 2-loop AND NDE plants Committed to Nuclear Excellence

Ha~r.ld Chernoff - May 11 rev2.ppt Page 32G Nozzle 26 Weld Overlap Condition (cont.)

  • NMC met with NRR on October 6th 2003 &

February 1gth 2004 to discuss this issue Nce E Committedto Nuclear Excellence

I arold Chernoff - May I11 rev2.Dpt Pagie 331l I Harold Chrnoff

- May 11 rev2.ppt Paae33i Nozzle 26 Weld Overlap Condition (cont.)

  • Crack growth rates (CGRs) in the Alloy 52 material are very low
  • The analysis therefore conservatively assumed Alloy 600 CGRs (MRP-55)
  • Analysis demonstrated that a worst-case flaw in the A82/182 would take in excess of 1.5 EFPY to go through the remaining Alloy 52 weld (0.26" weld ligament assumed)
  • Separation via grinding was considered but determined to not be appropriate due to very high dose C Nuax Committed to Nuclear Excellence

I Harald Chernoff - May 11 rev2.ppt Pg34IS Nozzle 26 Weld Overlap Condition (cont.)

  • Actual weld ligament will be - 0.44 inches &

the worst-case flaw would take over 2 years to pass through the A52 fusion zone

  • Revised IDTB relief request will be processed using actual dimensions NIc Committed to Nuclear Excellence

HarId Chernoff-_May11 rev2.ppt Page 35 I Fkrrold Chernoff - May 1 1 rev2.ppt Page 35 0 Summary

  • An NRC Order EA-03-09 relaxation request will be immediately submitted using actual coverage data
  • A revised IDTB relief request will be submitted on Thursday May 13th using actual weld overlap data Committed to Nuclear Excellence

IFtHarald Ctrernoff - May I11 rev2.ppt Page 36 8 p HarId CIirnoff

- May 11 rev2.ppt Page 36 Summary / Questions Committed to Nuclear Exccllence

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