ML051290122
| ML051290122 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 04/22/2005 |
| From: | Fadel D Indiana Michigan Power Co |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| AEP:NRC:5055-04 | |
| Download: ML051290122 (12) | |
Text
Indiana Michigan Power INDIANA Cook Nuclear Plant MICHIGAN P One Cook Place BridgmanMI 49106 PCWR AEP~com A unit of American Electric Power April 22, 2005 AEP:NRC:5055-04 10 CFR 50.55a Docket No. 50-315 U. S. Nuclear Regulatory Commission ATTN: Document Control Desk Mail Stop O-P1-17 Washington, DC 20555-0001 Donald C. Cook Nuclear Plant Unit 1 REVISION TO PROPOSED ALTERNATIVE TO THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS CODE, SECTION XI REPAIR REQUIREMENTS
References:
- 1. Letter from D. P. Fadel, Indiana Michigan Power Company (I&M), to Nuclear Regulatory Commission (NRC) Document Control Desk, 'Donald C. Cook Nuclear Plant Unit 1, Proposed Alternative to the American Society of Mechanical Engineers Code,Section XI Repair Requirements," AEP:NRC:5055-01, dated April 12, 2005.
- 2. Letter from D. P. Fadel, I&M, to NRC Document Control Desk, "Donald C. Cook Nuclear Plant Unit 1, -Proposed Alternative To The American Society Of Mechanical Engineers Code,Section XI Repair Requirements - Response To Request For Additional Information," AEP:NRC:5055-02, dated April 15, 2005.
In Reference 1 and supplemented by Reference 2, Indiana Michigan Power Company (I&M) proposed an alternative to the requirements of the American Society of Mechanical Engineers Code,Section XI, to repair a flaw in a pressurizer nozzle to safety valve inlet piping weld. I&M proposed using a weld overlay that would be applied using a machine gas tungsten arc welding (GTAW) process. Following the completion of the repair, I&M determined that the configuration of the overlay weld would not allow at least 90 percent coverage when performing the required post-repair volumetric examination. Therefore, additional weld material was required to be manually applied to the overlay weld to achieve a weld contour that would allow 90 percent volumetric examination coverage. Since the proposed alternative transmitted by the referenced letter involved only machine welding, I&M has revised the alternative to include manual GTAW. This need to utilize manual welding was discussed with members of the U. S. Nuclear Regulatory Commission (NRC) staff on April 20, 2005. The revised proposed alternative is provided in the attachment to this letter.
U. S. Nuclear Regulatory Commission AEP:NRC:5055-04 Page 2 Revision bars in the right margin of the attachment indicate the changed portions of the text. To support the current Unit 1 outage schedule, this request was verbally approved on April 20, 2005.
I&M has had no previous experience in the use of this process on the nozzle to safety valve inlet piping weld, or on similar configurations. The volumetric examination was performed after the application of several layers of weld material using the GTAW machine. Therefore, the need to perform manual welding was not identified until the later stages of the repair, and I&M could not have reasonably foreseen that the machine applied weld would result in a contour that would preclude the required volumetric examination coverage.
Verbal relief was requested because completion of the nozzle to safety valve inlet piping weld repair process, including post repair non-destructive examination (NDE), was, at the time of discussion, the critical path for restart following the current Unit 1 refueling outage. The repair and NDE must be completed prior to the transition to operational Mode 4, which is currently scheduled to occur on April 22, 2005. Therefore, the unit restart schedule does not provide adequate time for the administrative processes involved in preparation and issuance of written approval. The need to perform manual welding was not identified until April 20, 2005, and, as described above, could not have reasonably been anticipated.
During a telephone conversation with NRC personnel regarding an inspection follow-up question on April 21, 2005, it was noted that following completion of the overlay weld, it was discovered that impact requirements (Charpy V-Notch) were required for the qualification of the vendor welding procedure. The vendor developed a Welding Procedure Specification (WPS) with inputs that bounded those used for the production weld based on a review of the vendor bead log. The vendor conducted the required tests and documented them in a Procedure Qualification Record (PQR). The revised PQR and WPS have been satisfactorily completed, and they satisfactorily bound the parameters for the production weld. This issue has been entered into I&M's corrective action program.
There are no new commitments identified in this letter. Should you have any questions, please contact Mr. John A. Zwolinski, Director of Safety Assurance at (269) 466-2428.
Sincerely Daniel P. F Engineering Vice President RV/rdw
Attachment:
10 CFR 50.55a Relief Request - ISIR-15, Revision 1, Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i)
U. S. Nuclear Regulatory Commission AEP:NRC:5055-04 Page 3 C: R. Aben - Department of Labor and Economic Growth J. L. Caldwell - NRC Region III K. D. Curry - AEP Ft. Wayne, w/o attachment J. T. King - MPSC, w/o attachment C. F. Lyon - NRC Washington DC MDEQ - WHMDJHWRPS, w/o attachment NRC Resident Inspector
Attachment to AEP:NRC:5055-04 I 10 CFR 50.55a Relief Request -ISIR-15, Revision 1 I Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i) 1.0 ASME CODE COMPONENTS AFFECTED Code Class: Class I
Reference:
ASME Section XI, 1989, no addenda ASME Section XI, Case N-504-2 ASME Code Case N-416-1 ASME Section III, 1965 Edition, Winter 1966 Addenda ASME Section III, 1992 Edition Exam-ination Categories: B-F Item Number: B5.40
==
Description:==
Alternative Welded Repair For the Pressurizer Safety Nozzle To Safety Valve Inlet Line Component Number: 1-PRZ-23.
2.0 APPLICABLE CODE EDITION AND ADDENDA ASME Section XI 1989 Edition, no addenda 3.0 APPLICABLE CODE REQUIREMENTS IWA-4000 and IWB-4000 of ASME Section XI require repairs to be performed in accordance with the Owner's Design Specification and the original construction Code of the component or system.
4.0 REASON FOR REQUEST During the Unit 1 Cycle 20 refueling outage, an ultrasonic examination of 1-PRZ-23 identified an axial flaw (see Figure 1) within the Alloy 82/182 weld material. The flaw was most likely caused by Primary Water Stress Corrosion Cracking (PWSCC). 1-PRZ-23 is a nozzle-to-safe end weld containing Alloy 82/182 weld material connecting a carbon steel nozzle to an austenitic stainless steel safe end. The Code acceptable repair method would require complete removal of the PWSCC flaw.
The nozzle material is SA-216 WCC carbon steel. The safe end is austenitic stainless steel SA-182 F316. The nozzle weld material connecting the carbon steel nozzle to the austenitic safe end is Alloy 82/182.
Pursuant to 10 CFR 50.55a(a)(3)(i), an alternative is requested on the basis that the proposed alternative repair will provide an acceptable level of quality and safety.
Attachment to AEP:NRC:5055-04 Page 2 5.0 PROPOSED ALTERNATIVE AND BASIS FOR USE A full structural weld overlay repair is proposed for the nozzle-to-safe end weld. ASME Code Case N-504-2 allows a flaw to be reduced to an acceptable size by deposition of weld reinforcement (weld overlay) on the outside surface of the pipe without flaw removal.
The nozzle material is SA-216 WCC carbon steel. The safe end is austenitic stainless steel SA- 182 F316. The nozzle weld material connecting the carbon steel nozzle to the austenitic safe end is Alloy 82/182.
The weld overlay has been designed consistent with the requirements of ASME Code Case N-504-2, "Alternative Rules for Repair of Classes 1, 2, and 3 Austenitic Stainless Steel Piping,"
with the exceptions noted below. The weld overlay will extend around the full circumference of the nozzle-to-safe end weld location as required by Code Case N-504-2. The specific thickness and length have been computed according to the guidance provided in Code Case N-504-2. The overlay will completely cover the indication with Alloy 52 material. Alloy 52 material is highly resistant to PWSCC.
In order to perform this repair, it is necessary to weld to the carbon steel nozzle material. The Code of Construction allows welding to the carbon steel nozzle without post weld heat treatment.
The Code of Construction exemption for post weld heat treatment is based on the pressurizer safety nozzle material (SA-216 WCC, P-No.1 Group 2 material) thickness being less than 1.25 inches and the carbon content being less than 0.30%. The nozzle thickness is 1.22 inches and the maximum specified carbon content is 0.25%.
'The Code of Construction does not require pre-heat or post-weld heat treatment for a component 1.25 inches thick or less with a maximum carbon content of 0.30%.
Code Case N-504-2 was approved for generic use in Regulatory Guide 1.147, Revision 13, and was developed for austenitic stainless steel material. An alternate application for nickel-based and carbon materials is proposed due to the specific configuration of the subject weld.
Therefore, the methodology of Code Case N-504-2 shall be followed with the following exceptions:
- 1. Paragraph (b) of Code Case N-504-2 requires that the reinforcement weld material shall be low carbon (0.035% maximum) austenitic stainless steel. In lieu of the stainless steel weld material, a consumable welding wire highly resistant to PWSCC has been selected for the overlay weld material. This material is a nickel-based alloy weld material, commonly referred to as Alloy 52, and will be applied using primarily a machine gas tungsten arc welding process. Also, limited manual gas tungsten arc welding may be required when the machine welding is completed. Alloy 52 contains about 30%
chromium that imparts excellent corrosion resistance to this material. This material is
Attachment to AEP:NRC:5055-04 Page 3 suitable for welding over the carbon steel nozzle, Alloy 82/182 weld material, stainless steel safe end, stainless steel weld material, and stainless steel piping as it is compatible with the existing weldment and base materials. Accordingly, this alternative provides an acceptable level of safety and quality.
- 2. Paragraph (e) of Code Case N-504-2 requires as-deposited delta ferrite measurements of at least 7.5 Ferrite Number for the weld reinforcement. Delta ferrite measurements will not be performed for this overlay because the deposited Alloy 52 is 100% austenitic and contains no delta ferrite due to the high nickel composition (approximately 60% nickel).
Accordingly, this alternative provides an acceptable level of safety and quality.
- 3. Paragraph (h) of Code Case N-504-2 requires a system hydrostatic test of the completed repair if the flaw(s) penetrated the original pressure boundary or if there is any observed indication of the flaw penetrating the pressure boundary during repair. In lieu of hydrostatic testing, a system pressure test and an ultrasonic examination of the weld overlay shall be performed in accordance with the Third Interval ISI Program and ASME Code Case N-416-1. This alternative requirement is sufficient to demonstrate that the overlay is of adequate quality to ensure the pressure boundary integrity. Accordingly, this alternative provides an acceptable level of safety and quality.
The repair, pre-service inspection, and inservice inspection (ISI) examination of the weld overlay repair shall be performed in accordance with the ISI Program, NUREG-0313, Revision 2, Generic Letter 88-01, and approved plant procedures as specified by the ISI Repair/Replacement Program. The weld overlay shall be examined in accordance with the industry-developed Performance Demonstration Initiative procedure. As required by Code Case N-416-1 (Alternative Pressure Test Requirement for Welded Repairs or Installation of Replacement Items by Welding, Class 1, 2, and 3), nondestructive examination shall be performed to ASME Section III, 1992 Edition, Subsection NB requirements to the extent practical. A description of the required examinations is provided in Tables 1, 2, and 3. The acceptance criteria for the volumetric examinations shall be ASME Section XI, Paragraph IWB-3514, "Standards for examination Category B-F, Pressure Retaining Dissimilar Metal Welds, and Category B-J, Pressure Retaining Welds In Piping."
The use of overlay filler material that provides excellent resistance to PWSCC develops an
- effective barrier to flaw extension by corrosion processes. The design of the overlay for the nozzle-to-safe end weldment uses methods that are standard in the industry. There are no new or different approaches in this overlay design which are considered first of a kind or inconsistent with previous approaches. The overlay has been designed as a full structural overlay in accordance with Code Case N-504-2. I&M concludes that the alternative repair approach described above presents an acceptable level of quality and safety to satisfy the requirements of 10 CFR 50.55a(a)(3)(i).
Attachment to AEP:NRC:5055-04 Page 4 During a telephone conference on April 20, 2005, NRC staff personnel requested that I&M provide the following information regarding the use of manual gas tungsten arc welding:
Howv will the material condition be maintained?
The filler material used for the manual gas tungsten arc welding process is in the form of 1/8 inch diameter by 36 inch long rods composed of ERNiCrFe-7 (Alloy 52). The filler material used for the machine gas tungsten arc welding process is 0.035 inch diameter wire, also composed of ERNiCrFe-7. These materials are found in ASME Section II, Part C, SFA-5.14 and are purchased in accordance with Section II, Part C and ASME Section III, Sub-section NB requirements per the contractor's welding and quality control programs.
Controls for heat input The average heat input for the machine weld was 27,174 joules per inch. The maximum heat input for the machine weld was 33,480 joules per inch on the final layer of the overlay. The manual weld was 22,000 joules per inch, which was within the heat input range of the machine
'weld. The heat input was monitored by the contractor's quality control personnel and is documented in the overlay bead log.
Sketch Figure 2 shows the location of the manual weld.
Area and volume of manually applied weld material The low area of the machine weld that was required to be manually applied extended from approximately 90 degrees to approximately 270 degrees, looking toward the pressurizer, with 0 degrees being the top of the nozzle. To achieve a smooth circumferential contour, the manual weld was applied to the entire 360 degrees on Alloy 52 weld metal only. The manual weld area is approximately 3/8 inch wide. The manual weld area is not in the portion of the overlay that covers the dissimilar metal weld, 1-PRZ-23.
6.0 DURATION OF THE PROPOSED ALTERNATIVE This alternative repair is requested for the remaining service life of the component.
7.0 PRECEDENT Similar requests have been approved for the Three Mile Island, Unit 1, Nuclear Station (Reference 1) and the Cooper Nuclear Station (Reference 2).
Attachment to AEP:NRC:5055-04 Page 5
8.0 REFERENCES
- 1. Letter from Richard J. Laufer, NRC, to Christopher M. Crane, AmerGen Energy Company, 'Three Mile Island Nuclear Station, Unit 1 (TMI-1) Request for Relief from Flaw Removal, Heat Treatment, and Nondestructive Examination Requirements for the Third 10-Year Inservice Inspection (ISI) Interval (TAC No. MC1201)," dated July 21, 2004.
- 2. Letter from Allen G. Howe, NRC, to Randall K. Edington, Nebraska Public Power District, "Cooper Nuclear Station - Re: Request RI-35 for Relief from the Requirements of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (Code) (TAC No. MC4954)," dated March 4, 2005.
Attachment to AEP:NRC:5055-04 Page 6 TABLE 1 IN-PROCESS NONDESTRUCTIVE EXAMINATION REQUIREMENTS Examination Description Method l Technique Refercnce Acceptance Standards Safe end, weld, and nozzle Surface Liquid Penetrant N-504-2 N-504-2, Paragraph (c) overlay surface preparation exam I" layer of deposited weld Surface Liquid Penetrant N-504-2 N-504-2, Paragraph (c) reinforcement Thickness measurement of Volumetric UT-0OL N-504-2, Per weld overlay design the deposited weld Repair Plan reinforcement TABLE 2 PRE-SERVICE INSPECTION REQUIREMENTS Examination Description Method Technique Reference Acceptance Standards Completed weld overlay Volumetric UT-0OL N-504-2 Per weld overlay design for complete bonding and minimum thickness Examination of completed Surface Liquid Penetrant N-504-2 N-504-2, Paragraph (i) weld overlay and examination of the "band" 0.50 inches outward from the toe of the weld around the entire circumference of the nozzle Completed weld overlay Volumetric UT angle beam per PDI N-504-2 N-504-2, Paragraph (i) and outer 25 percent of procedure original nozzle and safe end thickness
Attachment to AEP:NRC:5055-04 Page 7 TABLE 3 INSERVICE INSPECTION REQUIREMENTS Examination Method Technique Reference Acceptance Reinspection Description Standards Frequency Weld overlay Volumetric UT-Angle ASME Section No planar flaw Exam next two and upper 25 beam per PDI XI, Appendix extending into refueling outages, and percent of procedure, VIII the structural reevaluate based on original nozzle and exam weld overlay inspection results and safe end base volume per material PDI procedure Surface Surface Liquid ASME, N-504-2, Exam next two examination of Penetrant Section XI Paragraph (i) refueling outages, and complete weld reevaluate based on overlay surface inspection results .
Attaclm-lent to AEP:NRC:5055-04 Page 8
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Attachment to AEP:NRC:5055-04 Page 9 FIGURE 2 Manual Weld 0 Degrees Pressurizer 180 Degrees