ML063620060
| ML063620060 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 12/15/2006 |
| From: | Westinghouse |
| To: | Office of Nuclear Reactor Regulation |
| Mensah T | |
| Shared Package | |
| ML070050115 | List: |
| References | |
| NSD-EPRI-06-43 | |
| Download: ML063620060 (13) | |
Text
Wolf Creek - Pressurizer Alloy 600/82/182 Location Summary NSD-EPRI-06-43 December 15, 2006
Westinghouse Electric Company Page 1 of 13 NSD-EPRI-06-43 December 15, 2006 Wolf Creek - Pressurizer - Alloy 600/82/182 Location Summary The following summarizes the review of the design and fabrication information of the surge, spray, safety, and relief nozzles of the Wolf Creek pressurizer. For each location (Figure 1) the following information will be provided:
A sketch (not to scale) of the location with material identification A table detailing the weld location/material and if post-weld heat treatment (PWHT) was performed at the location.
A table detailing all readily available fabrication repairs at each identified location.
Figure 1 - Pressurizer Sketch A
A Safety/Relief Nozzles (PW3)
Figure 5 Spray Nozzle (PW2)
Figure 4 Surge Nozzle (PW1)
Figure 3 Figure 2 Nozzle C
Westinghouse Electric Company Page 2 of 13 NSD-EPRI-06-43 December 15, 2006 Figure 2-Pressurizer Upper Head Sketch (View A-A)
Nozzle A Nozzle B Nozzle D Nozzle E Spray Nozzle Manway
Westinghouse Electric Company Page 3 of 13 NSD-EPRI-06-43 December 15, 2006 Figure 3-Pressurizer Surge Nozzle Sketch (not to scale)
Table 1-Wolf Creek Pressurizer Surge Nozzle Fabrication Figure ID Letter Location Area Location Description Location Type (Weld, Buttering, Base Metal)
Material Post Weld Heat Treat?
(Yes, No) a Weld 1st Pass - Alloy 82 Weld - Alloy 182 No b
Safe End to Surge Nozzle Buttering Alloy 182 Yes c
Surge Nozzle Buttering to Nozzle Cladding Tie In Weld Alloy 182 Yes d
Surge Nozzle Cladding Weld Stainless Steel 309 Yes e
Surge Nozzle Safe End Fill In Weld Alloy 182 No 3
f Surge Nozzle SS Thermal Sleeve to Safe-End Weld Alloy 82 (45o of circumference affected)
No (f) Thermal Sleeve to Safe-End -
Weld - Alloy 82 - (PW1)
(b) Surge Nozzle - Buttering
- Alloy 182 - PWHT -
(PW1)
Safe-End (a) Safe End to Surge Nozzle-Weld - Alloy 82/182 - (PW1)
Thermal Sleeve Surge Nozzle C L (c) Surge Nozzle Buttering to Cladding Tie In - Weld -
Alloy 182 - PWHT - (PW1)
(d) Surge Nozzle Cladding -
Weld - Stainless Steel 309
- PWHT (e) Surge Nozzle Safe End Fill In - Weld - Alloy 182 -
(PW1)
Westinghouse Electric Company Page 4 of 13 NSD-EPRI-06-43 December 15, 2006 Table 2 - Wolf Creek Pressurizer Surge Nozzle Repair Information Reference Repair #
Part Description Defect Description Repair Description 1
Surge Nozzle Buttering The surge nozzle end build up (safe end prep) was insufficient. There was not enough weld build up to clean up during machining of the outside diameter.
Alloy 182 was welded to the nozzle end until the nozzle had sufficient weld buildup to support final machining. PWHT was completed during normal cycle operations.
2 Surge Nozzle Buttering During the Repair # 1 radiography test (RT) indications were identified:
- 1. Length 7/8 inch, Depth 9/16 inch OD.
- 2. Length 1 1/8 inch, Depth 1 inch OD Indication removed Dye Penetrate test (PT) excavations Preheat and prepare to weld Weld repair area using Alloy 182 PT repaired area Check nozzle dimensions PWHT normal cycle.
3 Safe End to Surge Nozzle Weld Radiography test (RT) rejection of safe end to surge nozzle weld.
- 1. Length 1 inch, Depth 13/64 to 7/16 inch - Inside Diameter (ID)
Remove indication Dye Penetrate test (PT) excavation Preheat and prepare to weld Weld repair area using Alloy 82 PT and RT repaired area PWHT normal cycle 4
Surge Nozzle Cladding A measurement of the surge nozzle cladding thickness was not taken during the proper operation. So three slots were cut into the surge nozzle cladding to the base metal to obtain clad thickness measurements. These slots were cut after intermediate post weld heat treat.
Weld repair area using 308L stainless steel PWHT normal cycle PT repaired area after PWHT
Westinghouse Electric Company Page 5 of 13 NSD-EPRI-06-43 December 15, 2006 Table 2 (continued) - Wolf Creek Pressurizer Surge Nozzle Repair Information Reference Repair #
Part Description Defect Description Repair Description 5
Surge Nozzle Cladding This repair is a result of Repair #4. PT of the repaired areas in the surge nozzle after PWHT was not completed. This was identified by a review of the feeder travelers. The unit was sealed, purged, and on rail car for shipment when this was identified.
Covers and gaskets were removed from the surge nozzle and manway.
The basket was cut from the surge nozzle. The cut was made as close to the weld clad as possible.
The thermal sleeve was then removed from the surge nozzle by grinding the connection welds.
It was then verified that he basket and thermal sleeve were removed without exposing base metal.
The surge nozzle outside diameter was then cleaned to remove paint residue.
The repair areas noted in Repair #4 were then removed via grinding.
The excavations were the inspected using dye penetrant examination (PT).
The affected areas were then weld repaired using 308L and 309L stainless steel.
Local PWHT of weld repair was then completed.
The repaired area underwent PT.
The thermal sleeve was the reinstalled using Alloy 82. The weld area was PT.
The basket was then reinstalled.
Replace all covers and gaskets.
Repaint area.
Westinghouse Electric Company Page 6 of 13 NSD-EPRI-06-43 December 15, 2006 Figure 4 - Pressurizer Spray Nozzle Sketch (not to scale)
Table 3 - Wolf Creek Pressurizer Spray Nozzle Fabrication Figure ID Letter Location Area Location Description Location Type (Weld, Buttering, Base Metal)
Material Post Weld Heat Treat?
(Yes, No) a Weld 1st Pass - Alloy 82 Weld - Alloy 182 No b
Spray Nozzle to Safe-End Buttering Alloy 182 Yes c
SS Liner to Nozzle Buttering Weld Alloy 82 No d
SS Liner to Nozzle Cladding Weld Stainless Steel 308L No 4
e Spray Nozzle SS Thermal Sleeve to Safe-End Weld Stainless Steel 308L (45 o of circumference affected)
No Spray Nozzle (d) Liner to Cladding - Weld
- Stainless Steel 308L Thermal Sleeve Liner (b) Spray Nozzle - Buttering -
Alloy 182 - PWHT - (PW2)
Safe-End (c) Liner to Nozzle Buttering Weld-Alloy 82 - (PW2)
(a) Spray Nozzle to Safe End -
Weld - Alloy 82/182- (PW2)
C L (e) Thermal Sleeve to Safe End - Weld
- Stainless Steel 308L - (PW2)
Westinghouse Electric Company Page 7 of 13 NSD-EPRI-06-43 December 15, 2006 Table 4 - Wolf Creek Pressurizer Spray Nozzle Repair Information Reference Repair #
Part Description Defect Description Repair Description 6
Spray Nozzle Buttering PT indications found in lip of weld build up and along weld bond line. The indications were identified prior to PWHT.
Indications removed.
Areas were weld repaired using Alloy 82 PT repaired area before PWHT PWHT normal cycle PT repair area after PWHT
Westinghouse Electric Company Page 8 of 13 NSD-EPRI-06-43 December 15, 2006 Figure 5 - Pressurizer Safety & Relief Nozzle(s) Sketch (not to scale)
Table 5-Wolf Creek Pressurizer Safety/Relief Nozzle Fabrication Figure ID Letter Location Area Location Description Location Type (Weld, Buttering, Base Metal)
Material Post Weld Heat Treat?
(Yes, No) a Weld 1st Pass - Alloy 82 Weld Alloy 182 No b
Safety/Relief Nozzle to Safe-End Buttering Alloy 182 Yes c
Safety/Relief Nozzle Cladding Weld Stainless Steel 309L Yes 5
d Safety/Relief Nozzles Safety/Relief Nozzle Buttering to Cladding Tie In Weld Alloy 182 Yes (a) Safety/Relief Nozzle to Safe End - Weld -
Alloy 82/182- (PW3)
(b) Safety/Relief Nozzle -
Buttering - Alloy 182 - PWHT -
(PW3)
Safe-End Safety/Relief Nozzle (c) Cladding - Stainless Steel 309L - PWHT C L (d) Safety Relief Nozzle Buttering to Clad Tie In
- Weld - Alloy 182 - PWHT (PW3)
Westinghouse Electric Company Page 9 of 13 NSD-EPRI-06-43 December 15, 2006 Table 6 - Wolf Creek Pressurizer Safety/Relief Nozzle Repair Information Reference Repair #
Part Description Defect Description Repair Description 7
Nozzle A Buttering After PT inspection of nozzle build up several grind outs were prevalent. The deepest grind out is 1/8 inch deep.
The build up Weld repair build up using Alloy 182 PT repaired areas.
PWHT during normal cycle.
8 Nozzle A Safe End to Nozzle Weld Radiography test indications at the following areas of the safe end to nozzle weld due to operator error.
- 1. Length 1-1/4 inch, Depth 11/32 inch ID
- 2. Length 7/8 inch, Depth 11/32 inch ID Indications removed PT excavations Weld repair area using Alloy 82 PT and RT repaired area 9
Nozzle B Safe End to Nozzle Weld Radiography test indications at the following areas of the nozzle to safe end weld due to improper cleaning of weld bead..
- 1. Length 2-1/2 inch, Depth 1/4 to 3/4 inch ID
- 2. Length 1 inch, Depth 1/2 inch ID
- 3. Length 1-1/2 inch, Depth 1/2 inch ID
- 4. Length 1 inch, Depth 1/2 inch ID
- 5. Length 2-1/2 inch, Depth 1/4 to 3/4 inch ID
- 6. Length 2-1/2 inch, Depth 1/4 to 3/4 inch ID Indications removed PT excavations Weld repair area using Alloy 82 PT and RT repaired area
Westinghouse Electric Company Page 10 of 13 NSD-EPRI-06-43 December 15, 2006 Table 6 (continued) - Wolf Creek Pressurizer Safety/Relief Nozzle Repair Information Reference Repair #
Part Description Defect Description Repair Description 10 Nozzle B Safe End to Nozzle Weld Indications identified during previous Repair #9.
Radiography test indications at the following areas of the nozzle to safe end weld due to improper cleaning of weld bead.
- 1. Length 1-1/2 inch, Depth 1/2 inch ID
- 2. Length 1-1/4 inch, Depth 1 inch ID
- 3. Length 3/4 inch, Depth 7/8 inch ID
- 4. Length 1-1/2 inch, Depth 3/8 inch ID
- 5. Length 1 inch, Depth 1-1/16 inch ID
- 6. Length 1/2 inch, Depth 1/2inch ID Indications removed PT excavations Weld repair area using Alloy 82 PT and RT repaired area 11 Nozzle B Safe End The safe end ID exceeded final drawing dimensions.
Using 308L stainless steel weld ID of nozzle. 1/2 inch from edge of safe end to approximately 2 inches inside of bore approximately 1/8 inch thick.
Blend taper of bore to 4:1 smooth transition PT machined area.
Remove and weld repair PT indications with 308L stainless steel PT area.
12 Nozzle D Buttering After removing all unacceptable PT indications from the nozzle cladding and nozzle build up some areas require repair. The nozzle was not PWHT.
Indications removed.
Areas were weld repaired using Alloy 82 and Alloy 182 PT repaired area before PWHT PWHT normal cycle PT after PWHT 13 Nozzle D Buttering and Cladding Linear indication present in the nozzle weld build up, RT rejected area.
- 1. Length 1/2 inch, Depth 7/16 inch ID
- 2. Length 1 inch, Depth 7/16 inch OD Indications removed PT excavations Weld repair area using Alloy 82 PT repaired area before PWHT PT and RT area after PWHT
Westinghouse Electric Company Page 11 of 13 NSD-EPRI-06-43 December 15, 2006 Table 6 (continued) - Wolf Creek Pressurizer Safety/Relief Nozzle Repair Information Reference Repair #
Part Description Defect Description Repair Description 14 Nozzle D Buttering Identified after Repair #13. Radiography test indication at the following area of the nozzle buttering. Indication is due to operator error.
RT failed, indication is still present. Excavated area to small.
Excavated area made wider via grinding.
RT excavated area - clear.
Weld repair area using Alloy 182 PT and RT repaired area PWHT buttering 15 Nozzle D Buttering Following PWHT defect areas were located that were not present prior to PWHT.
- 1. Length 3/4 inch, Depth 3/8 to 3/4 inch ID
- 2. Length 2-1/4 inch, Depth 3/8 to 3/4 inch ID
- 3. Length 1/2 inch, Depth 3/8 to 3/4 inch ID Indication removed PT excavations Weld repair area using Alloy 82 16 Nozzle D Buttering Identified after completion of Repair #15.
Following PWHT defect areas were located that were not present prior to PWHT.
- 1. Length 1 inch, Depth 3/8 to 3/4 inch OD
- 2. Length 2-1/4 inch, Depth 3/8 to 3/4 inch OD
- 3. Length 1/2 inch, Depth 3/8 to 3/4 inch OD Indication removed PT excavations Weld repair area using Alloy 182 PT and RT repaired area PWHT 17 Nozzle D Buttering and Cladding Occurred as a result of Repair #16. During the grinding of the RT indications noted previously the ID of the nozzle was damaged. PT of the nozzle ID revealed indications.
Clad weld repaired in defected areas using Alloy 82 Repaired areas were then cleaned up via grinding and PT inspected.
PT inspection was acceptable.
18 Nozzle D Safe End to Nozzle Weld Radiography test indication at the following area of the safe end to nozzle weld. Deposited weld not properly cleaned before subsequent weld layer deposited, due to operator error.
- 1. Length 1-1/4 inch, Depth 1/2 inch OD Indication removed PT excavations Weld repair area using Alloy 82 PT and RT repaired area
Westinghouse Electric Company Page 12 of 13 NSD-EPRI-06-43 December 15, 2006 Table 6 (continued) - Wolf Creek Pressurizer Safety/Relief Nozzle Repair Information Reference Repair #
Part Description Defect Description Repair Description 19 Nozzle D Safe End to Nozzle Weld Radiography test indication at the following area of the safe end to nozzle weld due to operator error. Lack of fusion between weld beads
- 1. Length 1/2 inch, Depth 1/2 inch ID Indication removed PT excavations Weld repair area using Alloy 82 PT and RT repaired area 20 Nozzle D Safe End The safe end ID exceeded final drawing dimensions.
Using 308L stainless steel apply weld build up to the ID of the nozzle. [1/2 inch from edge of safe end to approximately 2 inches inside of bore approximately 1/8 inch thick.]
Blend taper of bore to 4:1 smooth transition PT machined area.
21 Nozzle D Safe End PT indications found on the ID of nozzle safe end.
The indications were identified after final PWHT and hydro test.