ML063560358

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Industry Presentation Slides: MRP-139 Analysis Basis
ML063560358
Person / Time
Site: Wolf Creek Wolf Creek Nuclear Operating Corporation icon.png
Issue date: 11/30/2006
From: Kammerdeiner G
Electric Power Research Institute
To:
Office of Nuclear Reactor Regulation
Mensah T
References
Download: ML063560358 (17)


Text

MRP-139 Analysis Basis MRP / NRC November 30, 2006 Greg Kammerdeiner, First Energy Chairman, Assessment ITG

Purpose

  • Provide overview of analysis documents that support required butt weld inspections in MRP-139
  • Summarize the purpose, method and main conclusions from each document
  • Review supporting analysis documents in light of Wolf Creek inspection findings

© 2006 Electric Power Research Institute, Inc. All rights reserved. 2

Roadmap to Butt Weld Analysis Documents

  • Document preparation spanned five year period from June 2000 through August 2005

© 2006 Electric Power Research Institute, Inc. All rights reserved. 3

MRP-21: Crack Growth of A182 in PWRs

Purpose:

To determine crack growth rates in A182 weld metal used to join A600 CRDM nozzles to vessel heads

  • Methodology: Sample welds prepared using typical materials and procedures were then tested in autoclave
  • Main

Conclusions:

- The crack growth rates in A182 welds were up to five times higher than for A600

- A preliminary crack growth model was developed Superseded by MRP-115

© 2006 Electric Power Research Institute, Inc. All rights reserved. 4

MRP-44.1: Preliminary Butt Weld Safety Assessment

Purpose:

To prepare a preliminary safety assessment to address butt weld cracks such as occurred at Ringhals 3/4 and leak as occurred at VC Summer

  • Methodology: Prepared a survey of A182 butt weld locations and assessed operating experience, crack orientation, flaw tolerance, leak detection, boric acid corrosion, and structural margin
  • Main

Conclusions:

- Plants have adequate margin to continue operation

- Identified short-term inspection guidance Superseded by MRP-113

© 2006 Electric Power Research Institute, Inc. All rights reserved. 5

MRP-57: A182 Experience in BWRs

Purpose:

To assess A182 butt weld cracks in BWR plants

  • Methodology: GE reviewed public and proprietary crack data
  • Main

Conclusions:

- There are more axial cracks than circumferential cracks

- Axial cracks can grow long if not arrested by resistant material

- Circumferential cracks were all less than 90º arc length (and some deep) except Duane Arnold

- 360º crack at Duane Arnold caused by crevice environment not present in PWRs. Nevertheless, showed leak before rupture

© 2006 Electric Power Research Institute, Inc. All rights reserved. 6

MRP-33: RPV Nozzle Weld Stresses

Purpose:

To determine effect of weld geometry (single vs double V) and repairs on residual stresses to help understand Ringhals 3/4 and VC Summer cracks/leak

  • Methodology: Prepared elastic-plastic finite element models of welds and repairs
  • Main Findings:

- Hoop stresses exceed axial stresses at ID surface such that most cracks should be axial

- Through-wall hoop stresses are high suggesting potential for rapid crack growth

- Welds finished on the ID, or repaired on the ID, have high tensile stresses on inside surface

© 2006 Electric Power Research Institute, Inc. All rights reserved. 7

MRP-106: Residual and Operating Stresses in A182 Butt Welds

Purpose:

To determine residual/operating stresses for full range of butt weld sizes (1 to 30) and ID repairs for larger (5 to 30) butt welds

  • Methodology: Elastic-plastic finite element analyses for multi-pass welds and 30º, 60º, and 90º partial-arc ID repairs
  • Main

Conclusions:

- For normal welds without repairs, tensile stresses at ID are low, consistent with small number of cracks/leaks

- Weld repairs to the ID create high tensile hoop and axial stresses of similar magnitude

- Many butt welds too small for ID repairs

- Adding weld deposit to OD can reduce ID tensile stress

© 2006 Electric Power Research Institute, Inc. All rights reserved. 8

MRP-109: Safety Assessment for Westinghouse and CE Plant Butt Welds

Purpose:

To assess safety of A182 butt welds in Westinghouse and CE plants

  • Methodology: Calculated:

- Size of critical axial and circumferential flaws,

- Time for cracks to grow through wall and circumferentially using generic residual stresses and MRP-21 crack growth model, and

- Potential to detect leaks before rupture

  • Main

Conclusions:

- Axial flaws not a concern due to crack arrest at carbon and SS material

- Times for partial-arc cracks to grow through-wall can be <1 yr

- Time between leak detection and rupture >2 yr

© 2006 Electric Power Research Institute, Inc. All rights reserved. 9

MRP-112: Safety Assessment for B&W Design Plants

Purpose:

To assess safety of A182 butt welds in B&W design plants

  • Main

Conclusions:

- Axial flaws not a concern

- Time for part-arc cracks to grow thru-wall can be <4 yr

- Some time between detectable leakage and rupture except for PZR relief nozzle

© 2006 Electric Power Research Institute, Inc. All rights reserved. 10

MRP-114: Effect of Weld Repairs

Purpose:

To assess the effect of partial-arc weld repairs on circumferential cracking

  • Methodology: Fracture mechanics crack growth calculations based on:

- As-welded and repaired residual stresses in MRP-106,

- PVP-365 K algorithm (superposition method) and

- Crack arrests for K < 0

  • Main

Conclusions:

- Regions of high crack growth are limited to approximately the arc length of the weld repair region

- Even for cases of 360º ID repairs, uniform initiation is highly unlikely (i.e., Duane Arnold)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 11

MRP-116: Probabilistic Risk Assessment

Purpose:

To assess the probability and consequences of rupture of butt welds due to PWSCC

  • Methodology: Probabilistic model based on standard Westinghouse approach considering crack initiation, crack growth, crack detection, leakage detection, rupture and core damage
  • Main

Conclusions:

- Probability of leak due to axial crack is 2 orders of magnitude higher than for circ cracks

- Total risk (CDF or LREF) within Reg. Guide 1.174 guidelines for 40 year plant life

© 2006 Electric Power Research Institute, Inc. All rights reserved. 12

MRP-115: A82/182 Crack Growth Rates

Purpose:

To develop A82/182 crack growth model considering worldwide data

  • Methodology: All available data collected and screened by panel of international experts, including NRC and NRC contractors
  • Main

Conclusions:

- Recommended deterministic curve at 75th percentile of data

- MRP-115 curve for A182 similar to MRP-21 but with no stress intensity threshold

- Curve for A82 between A600 base metal and A182 weld metal (closer to A600)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 13

MRP-113: Final Butt Weld Safety Assessment

Purpose:

To integrate all MRP safety assessment work into one overall summary document

  • Methodology: Same as described for other reports
  • Main

Conclusions:

- Most cracks expected to be axial and will arrest at carbon and SS material

- Deep partial-arc circ cracks should be limited to region of weld repairs with leak detection before rupture except at one location

- 360º part-depth circ cracks unlikely to occur

- BMVs should be performed within next two outages

- Inspection plan is being developed

© 2006 Electric Power Research Institute, Inc. All rights reserved. 14

MRP-139: Butt Weld Inspection Requirements

Purpose:

To develop mandatory inspection intervals for A82/182 butt welds

  • Methodology: Inspection intervals based on MRP-113 and BWRVIP approach
  • Main

Conclusions:

- Characterize all weld profiles by end of 2007

- Inspect PZR welds by end of 2007

- Inspect HL welds 4-14 NPS by end of 2008

- Inspect HL welds >14 NPS by end of 2009

- Inspect CL welds by end of 2010

- MRP Letter 2004-05 requires BMV of welds by 2007

© 2006 Electric Power Research Institute, Inc. All rights reserved. 15

Review Based on Wolf Creek Inspections

  • MRP-113/114 address partial-arc circ cracks caused by weld repairs

- Repairs known to be detrimental with potential for circumferential flaws

- Crack growth rate can be high

- Crack growth limited to approximate repaired region

  • Unknown to what extent WC indications align with repairs

- Critical flaw size is large

  • 144-166º for safety/relief from existing analyses
  • Realistically much larger (remove SSE and thermal loads)

- Maximum Wolf Creek flaw is estimated at 26% thru-wall and 155º extent.

  • Depth vs arc length is unknown

- Palisades and Duane Arnold confirm margin for large circumferential flaws

© 2006 Electric Power Research Institute, Inc. All rights reserved. 16

Opportunities for Improvement

  • Establish less conservative critical flaw size
  • Better estimate of K vs crack depth with stress relaxation
  • Probabilistic considerations

© 2006 Electric Power Research Institute, Inc. All rights reserved. 17