ML110200193
| ML110200193 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 01/14/2011 |
| From: | Faulhaber H Omaha Public Power District |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| LIC-11-0004 | |
| Download: ML110200193 (149) | |
Text
Omaha Public Power District 444 South 16th Street Mall Omaha, NE 68102-2247 January 14, 2011 LIC-1 1-0004 U.S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, D.C. 20555
References:
SUBJECT:
- 1. Docket No. 50-285
- 2. Letter from OPPD (H. J. Faulhaber) to NRC (Document Control Desk), "10 CFR 50.55a Request Number RR-12, Omaha Public Power District (OPPD) Request for Relief from Code Case N-722 Visual Examination (VE) of the Reactor Vessel Hot Leg Nozzle to Safe End Dissimilar Metal Welds," dated August 16, 2010 (LIC 0065) (ML102300641)
- 3. Letter from NRC (Lynnea Wilkins) to OPPD (D. J. Bannister), "Fort Calhoun Station, Unit No. 1 - Request for Additional Information Re:
Request for Relief From Code Case N-722 Visual Examination of the Reactor Vessel Hot-Leg Nozzle-to-Safe End Dissimilar Metal Welds (TAC No. ME4541)," dated October 25, 2010
- 4. Letter from OPPD (H. J. Faulhaber) to NRC (Document Control Desk), "Response to Request for Additional Information (RAI)
Regarding Request for Relief from ASME Code Case N-722 Requirements for Visual Examination of Reactor Vessel Hot Leg Nozzle to Safe End Welds," dated November 4, 2010 (LIC-1 0-0095)
Withdrawal of Response to Request for Additional Information (RAI)
Regarding Request for Relief from ASME Code Case N-722 Requirements for Visual Examination of Reactor Vessel Hot Leg Nozzle-to-Safe End Dissimilar Metal Butt Welds In Reference 3, the NRC requested that the Omaha Public Power District (OPPD) provide additional information in order to complete its review of OPPD's Reference 2 Relief Request. OPPD provided the requested information in Reference 4.
OPPD wishes to clarify a portion of its Reference 4 response to NRC Question No. 1 pertaining to securing shutdown cooling and resolve issues regarding proprietary, material inadvertently enclosed with that submittal. Therefore, OPPD hereby withdraws Reference 4 and supersedes it in its entirety with this submittal.
4ow Employment with Equal Opportunity
U. S. Nuclear Regulatory Commission LIC-1 1-0004 Page 2 To provide additional support for the requested relief, Wesdyne has normalized eddy current test (ECT) pancake coil data from the 2009 examination of the two reactor pressure vessel (RPV), hot leg nozzle-to-safe end, dissimilar metal (DM) butt welds that are the subject of the relief request. The data was collected from the inside diameter of the RPV hot leg nozzles and is therefore much more definitive than a qualitative outside diameter visual exam.(VE).
The report characterizes and compares the material condition of the two DM butt welds by analyzing permeability variations. As shown in of the Attachment, the ability to identify material degradation using this technique is based on over a decade of work performed at FCS on the control element drive mechanism (CEDM) seal housings.
The report shows that there are no significant permeability changes (a known precursor to stress corrosion cracking) in either of the welds. As a result, the initiation of stress corrosion cracking in either of these welds during the fourth 10-year inservice inspection interval (ISI) ending on September 25, 2013, is considered very unlikely.
No commitments to the NRC are contained in this submittal.
As an enhancement, prior to the start of the 2011 refueling outage, OPPD is revising Surveillance Test (ST) QC-ST-MX-3003, which currently requires a visual inspection under the RPV and surrounding areas for signs of leakage or boric acid accumulation.
The enhancement will require that the RPV nozzles be inspected for the presence of leakage and/or boric acid accumulation on the containment floor underneath them, the bio-shield wall near them, or on the bottom of the nozzle insulation.
If you have any questions regarding this submittal, please contact Mr. Bill Hansher at (402) 533-6894.
Sincerely, Harry J. Faulhaber Division Manager-Nuclear Engineering HJF/BL/mle
Attachment:
OPPD Response to NRC Request for Additional Information c:
E. E. Collins, NRC Regional Administrator, Region IV (w/o Enclosures)
L. E. Wilkins, NRC Project Manager J. C. Kirkland, NRC Senior Resident Inspector (w/o Enclosures)
LIC-1 1-0004 Attachment Page 1 OPPD Response to NRC Request for Additional Information
LIC-1 1-0004 Attachment Page 2 REQUEST FOR ADDITIONAL INFORMATION The NRC staff has reviewed and evaluated the information provided by the licensee and has determined that the following information is needed in order to complete its review of the relief request.
NRC Request
- 1. The NRC staff requests the licensee's basis for not performing a visual, volumetric or inside surface examination of each weld necessary to meet the inspection requirements of 10 CFR 50.55a(g)(6)(ii)(E).
If visual, volumetric or inside surface examinations could be performed on each penetration nozzle to meet the current inspection requirements, the NRC staff finds insufficient basis to grant relief under 10 CFR 50.55a(a)(3)(i), as not performing the examination does not provide the same level of assurance as the current inspection requirements. However if there is a hardship, NRC staff requests the licensee's basis for relief to not perform the inspection under 10 CFR 50.55a(a)(3)(ii).
OPPD Response
Background
10 CFR 50.55a(g)(6)(ii)(E) requires visual inspections of the reactor coolant pressure boundary in accordance with American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Code Case N-722. Code Case N-722, Table 1, Examination Categories requires inspection of reactor pressure vessel (RPV) hot leg nozzle-to-pipe connections each refueling outage (RFO). A direct visual examination (VE) of the bare-metal surface with the insulation removed or, a remote visual inspection with the insulation in place (provided the resolution of the component surface is equivalent to a bare-metal VE) is required. An alternative to the VE is to perform an ultrasonic examination from the inside or outside surface in accordance with the requirements of Table IWB-2500-1 and Appendix VIII (1995 Edition with the 1996 Addenda or later).
As explained below, OPPD has previously demonstrated the hardship and less than satisfactory results that a direct VE of these welds would provide.
An ultrasonic examination greatly increases the impact on utility and vendor resources, outage duration, and expense that few other plants with similar welds must incur. An ultrasonic examination exposes personnel to radiation and the plant to possible damage from the intrusion of foreign material into the reactor coolant system (RCS) with no commensurate increase in plant safety.
Conclusive data and photographic evidence from three inspections since 2003
LIC-1 1-0004 Attachment Page 3 and as recent as the fall 2009 RFO show that no flaws exist in either weld.
Based on the characteristics of the weld, combined with favorable operating parameters and the addition of zinc, cracking is very unlikely to occur during the requested period of relief.
The Westinghouse deterministic crack growth analysis, submitted with Reference 1, shows that it is technically justifiable to deviate from the requirements of Code Case N-722 by not performing the examinations required by Code Case N-722 on these welds before the spring 2014 RFO.
The existing visual inspections performed each RFO coupled with favorable data from the 2003, 2008, and 2009 weld examinations and supported by deterministic crack growth analysis, and planned normalization of ECT data provide an acceptable level of quality and safety to the requirements of Code Case N-722.
Visual Examination Hardship At Fort Calhoun Station (FCS), Unit No. 1, a direct VE of these welds would require significant resources to construct scaffolding as well as to remove and replace insulation, nozzle cover plates, and the sand above the nozzles (sandboxes encase the nozzles).
Due to its age, it is likely that the insulation contains asbestos, which would greatly increase the inspection hazard and difficulty in such a confined area. In addition, scaffolding has not previously been constructed in this area. As such, the potential to encounter unexpected hazards or difficulties is much greater and this could result in personnel injury, equipment damage, or outage delay.
Finally, in addition to high radiation levels, the environmental conditions in this area include high heat and humidity. Thus, stay times would be low and multiple crews would be required to complete the work on schedule. The area dose rate with the head on the reactor pressure vessel (RPV) is 120 millirem per hour while the dose rate near these welds is approximately 40 millirem per hour.
OPPD estimates that due to the issues described above, the total dose for performing a VE from the outside diameter (OD) surface for these two nozzle-to-safe end dissimilar metal (DM) welds is approximately 6 man-rem.
OPPD has previously received NRC relief (Reference 2) from the inservice inspection (ISI) requirements of Section Xl of the ASME BPVC, (1989 Edition, no Addenda), for surface examination of Class 1, RPV nozzle-to-safe end DM butt welds including welds MRC-1/01 and MRC-2/01, the subject of the current relief request. In its relief request, OPPD noted that a surface inspection of the outside weld surfaces would be difficult due to the confined space and limited access from the close proximity of the sandbox wall to the surface of the pipe/nozzle.
LIC-1 1-0004 Attachment Page 4 Such an inspection would allow only 60% of the weld to be inspected from the OD surface whereas the alternative ultrasonic examination conducted during the 2003 RFO from the inside diameter (ID) allowed 100% of the weld to be inspected at a much lower dose. The NRC approved OPPD's relief request concluding that the alternative (ultrasonic examination) provided reasonable assurance of the structural integrity of the welds for an entire 10-year ISI period (i.e., for the third ten-year ISI interval that ended October 31, 2003), and did not require further testing until September 25, 2013.
Although OPPD's current relief request is from a different requirement of the ASME BPVC than that granted in 2004, the conclusion that ultrasonic examination provides reasonable assurance of a weld's structural integrity for a considerable length of time (i.e., 10 years) is still valid.
In comparison, the current relief request (Reference 1) is only asking for relief for the remainder of the fourth 10-year ISI interval on September 25, 2013, or approximately 4 years since the last ultrasonic examination.
Ultrasonic Examination Hardship Of the 31 U. S. pressurized water reactors (PWR) that have PWSCC-susceptible DM butt weld configurations on RPV primary nozzles, the vast majority can perform the Code Case N-722 VE each outage with little difficulty, as their nozzles are easily accessible and not covered by insulation. Discussions with industry peers show that at those plants, with minimal preparation time, a single person can perform the VE in as little as a half an hour per nozzle. Such short VE inspection times meet the intent of Code Case N-722 for a qualitative assessment of cracking initiated from the inside surface by observation of the outside surface. Therefore, at the majority of these plants, the corresponding impact on outage duration, resources, dose, and cost is justifiably minimal.
In contrast, at FCS, approximately 1000 man-hours are required to prepare for an ultrasonic examination and 150 man-hours are required to conduct it. If the FCS RPV hot leg nozzle-to-safe end DM butt welds were highly susceptible to primary water stress corrosion cracking (PWSCC), an ultrasonic examination of these welds each refueling outage might be warranted. However, Westinghouse has determined that of these 31 PWRs, FCS is ranked near the bottom in terms of susceptibility to PWSCC. Thus, it is not credible to assume that cracking will initiate and progress to a significant depth over one cycle. Therefore, requiring FCS to conduct an ultrasonic examination each refueling outage is not necessary or justifiable.
LIC-1 1-0004 Attachment Page 5 OPPD intends to implement an extended power uprate (EPU) following the 2012 RFO; therefore, the Westinghouse deterministic crack growth analysis (Enclosure 2 of Reference 1) considered a hypothetical crack for PWSCC growth due to pre-and post-EPU conditions. The Westinghouse analysis determined that the hypothetical crack would not exceed the ASME maximum allowable end-of-evaluation period flaw size (75% through-wall) before the spring 2014 RFO, which is 51 calendar months after the fall 2009 RFO.
Considering the FCS availability factor (0.85) over the last 5 years, the required service life (to reach 75% through-wall cracking) is 60 effective full power months (EFPM), which is equivalent to about 70.6 calendar months. This is well past both the period of relief requested (i.e., the end of the fourth 10-year ISI interval on September 25, 2013) and the spring 2014 RFO.
In comparison to the VE conducted at most of the other PWRs with PWSCC-susceptible DM butt welds on RPV primary nozzles, the performance of an ultrasonic examination at FCS would require a significant amount of equipment and personnel to be brought to the site, staged, and in-processed. During the inspection, the location of the equipment above the RPV cavity is a foreign material exclusion (FME) concern as evidenced by several instances in the industry (none of which happened at FCS) of debris falling into the cavity during the examination.
For example, during one ultrasonic examination, a leveling bracket fell into the RPV cavity, during another, a bolt from an end effector was left in a RPV nozzle, and once the entire 300-pound robot fell into the RPV cavity when a bracket failed.
Current Methods of Leak Detection Although not as specific as the VE required by Code Case N-722, Surveillance Test (ST) QC-ST-MX-3003, Visual Inspection (VT-2) of Piping Areas of Limited Access, includes a visual inspection under the RPV and surrounding areas each RFO for signs of leakage or boric acid accumulation. Thus, a crack in one of the RPV hot leg nozzle-to-safe end DM butt welds would be discovered by this inspection through the accumulation of boric acid on the containment floor, the bio-shield wall, or the bottom of the nozzle.
In addition, two other procedures performed each RFO would also be likely to discover any leakage. Operating Instruction OI-CO-1, Containment Closeout, is performed at the end of an RFO prior to resuming power operations and requires documentation of the location of water droplets or puddles on the containment floor. As an example of the ability to detect leaks using this procedure, in October 2000 (Reference 3), a small leak from TE-108 (a temperature element on the pressurizer) was found during a
LIC-1 1-0004 Attachment Page 6 containment walkdown prior to startup from a forced outage. (Such a leak is no longer a concern as the pressurizer was replaced in 2006 and the weld from which the leak emanated no longer exists.)
Operating Procedure OP-ST-RC-3007, Periodic Reactor Coolant System Integrity Test, is another visual examination designed to locate leakage from pressure retaining components in the RCS prior to startup from an RFO. OP-ST-RC-3007 requires that the RCS be pressurized to at least 2150 psia with a 4-hour hold time for pressurized components. Under such conditions, it is unlikely that a RPV hot leg DM butt weld leak would go undetected.
During plant operation, should a leak occur, FCS has access to several leak detection systems that indicate loss of RCS integrity (Reference 3).
These include:
- 1. Radiation Monitors
- 2. Fire Detectors
- 3. Daily RCS Leak Rate Test Increased leakage would be detected by changes in:
- 1. Containment Sump Level
- 2. Volume Control Tank Level
- 3. Pressurizer Pressure and Level
- 4. Containment Temperature and Pressure
- 5. Containment Dew Point Monitor As evidence of the effectiveness of the detection of increased leakage during plant operations, in late 1990, the FCS daily reactor coolant leak ratetest (OP-ST-RC-3001) consistently indicated that the leak rate had increased by 0.2 gpm (Reference 3). The RCS engineer entered containment and found a small leak on a spare control element drive mechanism (CEDM) upper housing (note, a similar leak is not a concern because the RPV head was replaced in 2006).
Therefore, OPPD is confident that the daily leak rate procedure is capable of finding RCS leaks during plant operation.
Thus, the performance of an ultrasonic examination every refueling outage is not justifiable when the likelihood of discovering a leak using current visual inspection methods is weighed against the risks of an ultrasonic examination not
LIC-1 1-0004 Attachment Page 7 expected to show any significant change from the ultrasonic examination conducted in 2009.
Finally, shutdown cooling must be secured during the ultrasonic examination.
This limits the ability to filter and purify the RPV cavity water and can have a negative impact on outage duration, as fuel movement cannot proceed until sufficient clarity is achieved.
Recent History of RPV Nozzle-to-Safe End DM Butt Weld Inspections As stated above, OPPD conducted an ultrasonic examination from the ID surface of RPV hot leg nozzle-to-safe end welds MRC-1/01 and MRC-2/01 during the 2003 RFO. OPPD examined these welds again in 2008 and 2009. During the 2008 RFO, welds MRC-1/01 and MRC-2/01 were examined from the inside surface using eddy current testing (ECT) and photographs were taken (Enclosure 1). The photographs of nozzle N1A show the MRC-2/01 (180 degrees) weld and the photographs of nozzle N1B show the MRC-1/01 (0 degrees) weld.
The football shaped objects in some of the photos are water droplets on the camera lenses. The photographs clearly do not show the presence of any surface cracks and are a better indicator of weld integrity than an external VE as cracks generally begin on internal surfaces before becoming through-wall cracks visible on external surfaces. Thus, an external VE can only confirm that through-wall cracks exist. The lack of cracks on the internal surfaces of welds MRC-1/01 and MRC-2/01 means that the possibility of external surface cracking during the period of relief requested (per the Westinghouse deterministic crack growth analysis) is not credible.
The volumetric examinations performed during the 2009 RFO utilized Wesdyne's SUPREEMTM delivery system to examine the RPV nozzle weld configurations for cracking by using a combination of ultrasonic, ECT plus-point, and ECT pancake probes. No indications of cracking were found in either of the RPV hot leg nozzle DM butt welds. The prime objective was to determine the material condition of each nozzle.
However, material characterization and susceptibility to PWSCC were also assessed by using an ECT pancake probe. The mechanism for using permeability to assess PWSCC susceptibility is described in a paper presented at the ASME 2010 K-PVP Conference, July 18-22, 2010 in Bellevue, WA.
The paper (Enclosure 2) titled Determining the Onset of Stress Corrosion Cracking in Austenitic Stainless Steel with Permeability Change, finds a correlation between zones of ferromagnetic surface layers and stress corrosion cracking (SCC).
The paper shows that abrupt, highly positive changes in
LIC-1 1-0004 Attachment Page 8 localized permeability were in zones where SCC initiated. This paper is based on over 10 years of empirical data taken at FCS, Unit No. 1, and Palisades Nuclear Plant and is mechanistically applicable to the RPV hot leg nozzle-to-safe end DM butt welds.
In 2009, the Nuclear Energy Institute (NEI) awarded the methodology of using permeability to determine the onset of SCC "Best of the Best" as a top industry practice in nuclear power.
NRC Information Notice 2002-21, Supplement 1, Axial Outside-Diameter Cracking Affecting Thermally Treated Alloy 600 Steam Generator Tubing, describes the work at Seabrook using ECT to screen for OD SCC in Alloy 600 SG tubing. This was a qualitative assessment of residual stress by using ECT pancake coils. FCS has advanced this process with normalization of ECT signal amplitude as a more reliable means of determining the onset of SCC initiation.
Wesdyne has normalized ECT data from the 2009 examination of these two RPV hot leg Alloy 600 nozzle-to-safe end DM welds.
The analysis (Enclosure 3) provides additional support for the case that cracks in the RPV hot leg nozzle-to-safe end DM butt welds do not exist and that the onset of SCC during the period of requested relief is very unlikely.
Weld examination data has remained consistent during the period from 2003 to 2009. Indeed, the ultrasonic examinations conducted in 2003 and 2009 achieved 100% coverage of the RPV hot leg nozzle-to-safe end DM butt welds and when the welds were last inspected during the fall 2009 RFO, there were no data interpretation issues. This indicates that both welds have remained extremely clean and free of flaws, which is expected, as the welds are heat treated and clad with stainless steel in the vicinity of the welds on both internal and external surfaces (see Figure 1). Cracks have not been found at plants where RPV hot leg nozzle-to-safe end DM butt weld geometries are similar to those at FCS.
These features, in conjunction with low hot leg operating temperatures (averaging 591.8 0F over the last two cycles) make these welds much less likely to develop flaws or cracks as evidenced by the 2003, 2008, and 2009 inspection results.
LIC-1 1-0004 Attachment Page 9 Figure 1 - FCS RPV Hot Leg Nozzle to Safe End DM Butt Weld Geometry Therefore, based on favorable design and operating parameters as evidenced by recent examination results, the likelihood of a through-wall crack developing in these welds during the relatively short period of relief requested (i.e., to end of the fourth 10-year ISI on September 25, 2013) is not credible.
OPPD is planning to mitigate both RPV hot leg nozzle DM butt welds during the 2014 RFO. Mitigation will credit the zinc injection program that has reached and exceeded the threshold value of 300 ppb-months, which is where most of the benefits of PWSCC mitigation are achieved. OPPD is also working with Westinghouse to plan for RPV nozzle weld inlay to mitigate both hot leg nozzle DM butt welds. This will enable OPPD to perform the RPV hot leg nozzle-to-safe end DM butt weld ultrasonic examination at a less frequent interval.
Proposed Alternative 10 CFR 50.55a(a)(3) allows licensees to demonstrate either that (1) the proposed alternative provides an acceptable level of quality and safety or (2) the requirement results in hardship or unusual difficulty without a compensating increase in the level of quality and safety.
As such, OPPD's basis for not performing a visual, volumetric, or inside surface examination of each weld is based not only on hardship but also on the following alternative measures that provide an acceptable level of quality and safety:
The augmented examinations described above from the 2003, 2008, and 2009 RFOs.
re Deterministic analyses of hypothetical crack growth that result in a long period of time to reach ASME maximum allowable 75% through-wall cracking.
W The addition of zinc to the reactor coolant system (RCS) to mitigate PWSCC.
LIC-1 1-0004 Attachment Page 10 Visual examinations currently performed each RFO, one of which is being enhanced to require that the RPV nozzles be inspected for the presence of leakage and/or boric acid accumulation on the containment floor, the bio-shield wall, or the bottom of the RPV hot leg nozzles.
Postulated Flaw Results As stated above, it is highly unlikely that a flaw has developed or will develop in either RPV hot leg DM butt weld prior to the end of the requested relief on September 25, 2013.
Nonetheless, OPPD requested that Westinghouse postulate such a flaw to determine whether it could propagate to a size that exceeds the allowable flaw depth (75% through-wall). Since no indications were detected at these welds during the 2009 RFO, Westinghouse conservatively postulated an initial flaw depth of 0.125 inch and an initial flaw length of 0.25 inch as a hypothetical undetected flaw. Both pre-and post-EPU piping loads were used in the Westinghouse analysis.
For additional conservatism, a hypothetical 25% inside surface weld repair was assumed in the residual stress profiles used in the Westinghouse analysis even though fabrication records show that there are no previous weld repairs. The Westinghouse deterministic crack growth analysis concluded that the total crack growth due to PWSCC based on the pre-and post-EPU conditions at the RPV hot leg nozzle DM butt weld locations would not exceed the ASME maximum allowable end-of evaluation period flaw size (75% through-wall) until well after the spring 2014 RFO.
In fact, Enclosure 2 of Reference 1, shows that a hypothetical crack does not reach 75% through-wall until 70.6 months after the fall 2009 RFO (i.e., until December 2015). This is well past both the period of relief requested (i.e., the end of the fourth 10-year ISI interval on September 25, 2013) and the spring 2014 RFO.
In 2008, Indian Point 2 submitted a similar deterministic flaw analysis to justify deviating from the MRP-139 VE requirement, which is the predecessor to the Code Case N-722 VE requirement.
The Electric Power Research Institute (EPRI) subsequently approved Indian Point 2's request.
Zinc Addition OPPD has been adding zinc to the RCS since January 23, 2003. Laboratory and test reactor results have shown that the addition of zinc reduces corrosion and is beneficial in mitigating the effects of PWSCC (Reference 4). The benefits are such that since the end of 2005, the number of U.S. PWRs adding zinc has more
LIC-1 1-0004 Attachment Page 11 than doubled (Reference 5).
As of October 19, 2010, the cumulative total addition of zinc at FCS is 379.6 ppb-months, which is above the level (300 ppb-months) at which significant PWSCC mitigation is achieved (Reference 5). To maintain the positive effects of this program, OPPD continues to add zinc at a level of 6.1 ppb/month.
Observation of Leakaqe and/or Boric Acid Accumulation As stated above, Surveillance Test QC-ST-MX-3003 includes a visual inspection under the RPV and surrounding areas for signs of leakage or boric acid accumulation. Thus, a crack in one of the RPV hot leg nozzle-to-safe end DM butt welds would be discovered by this inspection through the accumulation of boric acid on the containment floor, the bio-shield wall, or underneath the RPV hot leg nozzles. Prior to the start of the 2011 RFO, OPPD is enhancing the ST to require the RPV nozzles to be inspected for the presence of leakage and/or boric acid accumulation.
Operating Instruction OI-CO-1, Containment Closeout, is performed at the end of an RFO prior to resuming power operations and requires documentation of the location of water droplets or puddles on the containment floor.
Operating Procedure OP-ST-RC-3007, Periodic Reactor Coolant System Integrity Test, is another visual examination designed to locate leakage from pressure retaining components in the RCS prior to startup from an RFO. OP-ST-RC-3007 requires the RCS to be pressurized to at least 2150 psia with a 4-hour hold time for pressurized components. Under such conditions, it is likely that a leaking RPV hot leg nozzle would be detected. These three visual inspections conducted each RFO meet the intent of Code Case N-722 for a quick, qualitative examination of the two RPV hot leg nozzle DM butt welds.
Due to the configuration of FCS, Unit No. 1, any other type of VE examination would impose significant hardship as described above.
Conclusion The performance of an ultrasonic examination of these two RPV hot leg DM butt welds greatly increases the impact on utility and vendor resources, outage time, and expense that few other plants with similar welds must incur. Conducting the examination exposes personnel to radiation and the plant to possible damage from the intrusion of foreign material into the RCS with no commensurate increase in plant safety. Conclusive data and photographic evidence from three
LIC-1 1-0004 Attachment Page 12 inspections since 2003 and as recent as the fall 2009 RFO show that no flaws exist in either weld.
Based on the characteristics of the weld, combined with favorable operating parameters and the addition of zinc, cracking is very unlikely to occur during the requested period of relief. Nevertheless, the presence of a hypothetical flaw has been postulated under both pre-and post-EPU conditions and the results show that it will not exceed the ASME maximum allowable end-of evaluation period flaw size (75% through-wall) until well after the spring 2014 RFO. At that time, OPPD plans to either undertake mitigation measures or perform an ultrasonic examination.
In the interim, several visual inspections that meet the intent of Code Case N-722 are conducted each RFO and provide additional assurance that a leak from an RPV hot leg nozzle-to-safe end DM butt weld would be detected.
Additionally, normalization of the 2009 ECT data (Enclosure 3) has verified that cracks are not present and are very unlikely to start during the requested period of relief.
Since there were no recordable indications in the fall 2009 RFO inspection, it is highly unlikely that any leakage will occur before the spring 2014 RFO. As a result, degradation of the pressure boundary is not expected and the safety of the nuclear facility as well as the health and safety of the public is maintained.
Therefore, based on the results of the Westinghouse deterministic crack growth analysis, it is technically justifiable to deviate from the requirements of Code Case N-722 by not performing any additional examinations of the RPV hot leg nozzle DM butt welds before the spring 2014 RFO. OPPD concludes that the existing visual inspections performed each RFO coupled with favorable data from the 2003, 2008, and 2009 weld examinations and supported by deterministic crack growth analysis and planned normalization of ECT data provide an acceptable level of quality and safety to the requirements of Code Case N-722.
NRC Request
- 2. NRC staff requests the following references used in the Westinghouse calculation; numbers 3, 5, 6, 8, 9, 10 and 11.
NRC staff will need these references quickly to have sufficient time to perform verification calculations and support the licensee's schedule.
LIC-1 1-0004 Attachment Page 13 OPPD Response Reference 5 from the Westinghouse calculation is OPPD calculation FC06945 titled "FCS RSG -
RCS Structural Analysis." It contains information from Westinghouse, Areva, and Mitsubishi Heavy Industries that is subject to an agreement restricting its disclosure. Westinghouse and a third party jointly own References 3, 6, 8, 9, 10, and 11.
To avoid complications involved in obtaining approval to release these documents from the various companies, all parties have agreed to make them available for NRC review at the Westinghouse Rockville, Maryland office located near NRC headquarters (Enclosure 4 is a map to the Westinghouse Office).
Please contact Ms. Leslie Collins at (301) 881-7040 to make an appointment to review the documents.
This will allow Westinghouse and OPPD technical personnel to be on standby in the event that questions arise during the review.
The office hours are 9 a.m. until 5 p.m. eastern time. To ensure that adequate space is available, drop-in visits are not recommended. It should be noted that the documents or any portion thereof cannot be-copied, faxed or removed from the office.
NRC Request
- 3. NRC staff requests the 2003, 2008, and 2009 inspection data of welds designated Items 1 and 2 in Table 1 of the August 16, 2010 relief request. NRC staff requests the inspector's summary reports to verify previous inspection results, and verify basis for initial starting flaw size in flaw analysis calculations.
For example, reports documentation the inspection stating "No Reportable" or "No Recordable" indications are requested.
OPPD Response contains the 2008 weld inspection data. Enclosure 5 contains the 2009 weld inspection data. contains scanning information and results from 2003. Please note that the 2003 information as reported by Areva for welds MRC-1/01 and MRC-2/01 simply show "No Recordable," which was industry practice at that time.
However, other supporting information from the 2003 inspection is enclosed.
NRC Request
- 4. In order to support the licensee's use of zinc as a mitigation method, NRC staff requires supporting technical basis documents for review. Specifically, NRC staff
LIC-1 1-0004 Attachment Page 14 requests those documents that address the mitigation effectiveness of the zinc addition history at Fort Calhoun Station, Unit 1, at the current levels at 300 ppb-months, and the rate of addition of 6 ppb/month. Also, provide projected rates of addition during the period of requested relief and projected accumulated concentration-time levels over the period of requested relief.
OPPD Response Electric Power Research Institute (EPRI) Technical Report (TR) No. 1013420, Pressurized Water Reactor Primary Water Zinc Application Guidelines, Final Report, December 2006 (Reference 6), describes the positive benefits of zinc injection for PWSCC mitigation that continues to emerge through laboratory tests and field experience. Reference 6 is available to the public at EPRI's website (www.epri.com).
The original zinc PWSCC studies are documented in WCAP-13223 (Reference 7). Testing was performed out to zinc exposures of 390 ppb-months and 500 ppb-months where a distinct benefit to PWSCC initiation in highly stressed steam generator Alloy 600 specimens was observed. Under some extreme conditions, PWSCC initiation started at low zinc exposures but tended to stall at an exposure of approximately 160 ppb-months with little initiation seen after 310 ppb-months.
Reference 7 is proprietary to Westinghouse and has been sent to the Westinghouse Rockville, Maryland office where it is available for NRC review in accordance with the response to question 2 above.
After one cycle, zinc was shown to be incorporated into the Farley steam generator tubing primary oxide after approximately 310 ppb-months exposure, (Reference 6, Figure 2-5).
Based on the 2006 dose rate reduction analyses documented in the EPRI report, about 75% of the dose rate reduction achieved following a 2000 ppb-month exposure was available after 300 ppb-months indicating that the primary oxide film had been substantially improved.
As of October 19, 2010, the cumulative total addition of zinc is 379.6 ppb-months.
FCS has been adding zinc for 6 operating cycles most recently averaging 6.1 ppb/month.
With approximately 36 months until the end of the requested relief (i.e., September 25, 2013), an additional 219.6 ppb-months of zinc is projected to be added.
Cumulative zinc addition at that time will be approximately 599.2 ppb-months.
LIC-1 1-0004 Attachment Page 15 References
- 1. Letter from OPPD (H. J. Faulhaber) to NRC (Document Control Desk), "10 CFR 50.55a Request Number RR-12, Omaha Public Power District (OPPD) Request for Relief from Code Case N-722 Visual Examination (VE) of the Reactor Vessel Hot Leg Nozzle to Safe End Dissimilar Metal Welds," dated August 16, 2010 (LIC 0065) (ML102300641)
- 2. Letter from NRC (S. Dembek) to OPPD (R. T. Ridenoure), "Safety Evaluation for Fort Calhoun Station, Third 1 0-year Inservice Inspection Interval, Request for Relief (RR) 9 (TAC No. MC1 115)," dated June 8, 2004 (NRC-04-0072)
- 3. Letter from OPPD (D. J. Bannister) to NRC (Document Control Desk), "Response to NRC Bulletin 2002-01 Request for Additional Information," dated January 17, 2003 (LIC-03-0008)
- 4. 2009 PWROG Farley Zinc Program Summary Presented at the NRC-MRP Meeting (ML092250675)
- 5. 2010 PWROG Farley Zinc Program Summary Presented at the NRC-MRP Meeting (ML102020675)
- 6. EPRI Report 1013420, "Pressurized Water Reactor Primary Water Zinc Application Guidelines," Final Report, December 2006
- 7. WCAP-13223, "Corrosion Control and Dose Rate Reduction Program," @1992 Westinghouse Electric Corporation Enclosures
- 1. Letter from Westinghouse (G. D. Auld) to OPPD (B. Lisowyj), "2008 RFO Reactor Vessel Hot Leg Nozzle Eddy Current Inspections Transmittal of RPV Outlet Nozzle Material Characterization Report," dated June 19, 2008 (CFTC-08-35)
- 2. PVP2010-25984, "Determining the Onset of Stress Corrosion Cracking in Austenitic Stainless Steel with Permeability Change," (B. Lisowyj & Z. Kuljis) as presented at ASME K-PVP Conference, July 18-22, 2010, Bellevue, Washington
- 3. Wesdyne Report No. 1305120-Rpt.1, "Fort Calhoun RPV Outlet Nozzle Eddy Current Data Normalization," dated December 2010
- 4. Map to Westinghouse, Rockville, Maryland Nuclear Regulatory Affairs Office
- 5. 2009 Weld Inspection Data
LIC-1 1-0004 Attachment Page 16 Enclosures (Continued)
- 6. 2003 Weld Inspection Data
LIC-1 1-0004 Letter from Westinghouse (G. D. Auld) to OPPD (B. Lisowyj), "2008 RFO Reactor Vessel Hot Leg Nozzle Eddy Current Inspections Transmittal of RPV Outlet Nozzle Material Characterization Report,"
Dated June 19, 2008 (CFTC-08-35)
Westinghouse Westinghouse Electric Company Nuclear Services P.O. Box 355 Pittsburgh, Pennsylvania 15230-0355 USA CFTC-08-35 June 19, 2008 Dr. Bob Lisowyj Omaha Public Power District Fort Calhoun Nuclear Station P.O. Box 550 Fort Calhoun, NE 68023-0550 OMAHA PUBLIC POWER DISTRICT FORT CALHOUN NUCLEAR STATION 2008 RFO Reactor Vessel Hot Leg Nozzle Eddy Current Inspections Transmittal of RPV Outlet Nozzle Material Characterization Report
Reference:
- 1. OPPD Contract 00083453 Release 33
Dear Dr. Lisowyj:
Please find attached the following document for your use in support of Reference 1:
- WDI-PJF-1304009-FSR-001, OPPD Fort Calhoun Station RPV Outlet Nozzle Material Characterization Report If you have any questions or need of any additional information, pleases do not hesitate to contact me at 412-374-3392 or Dante Barlow at 724-722-5403.
Very truly yours, Gregg D. Auld Customer Projects Manager cc:
Chuck Bloyd OPPD Ken Erdman OPPD Joy Grachen W
Chris Burton W
Dante Barlow W
Zoran Kuljis W
Don Adamonis W
Electronically Approved Records are Authenticated in the Electronic Document Management System
WESDynE A Westinghouse NDE Company FIELD SERVICE REPORT INTERNAL REVIEW SHEET DOCUMENT NUMBER: WDI-PJF-1304009-FSR-001 REVISION NUMBER: 0 TITLE:
OPPD Fort Calhoun Station RPV Outlet Nozzle Material Characterization Report ORIGINATOR (Printed Name)zoa u~s*
7*
May 29,2008
/',.
QUAILITY ASSURANCE (Printed Name)
REPORT CONTENTS:
X Usting of applicable procedures and revisions NIA Procedure changeslFleld Change Requests X
Personnel qualificationsicertifications X
Receipt Inspection Reports, Installed material quality releases, other supporting documents X
Calibration certificates NIA Load test certificates X
NDE reports X
Data sheets including verification signatures NIA Issue Reports (CAPs)
NIA Westinghouse Plant Anomaly letters N/A Supplemental inspection reports (other than NDE) or procedures NIA Signature log sheet for personnel (e.g., Signing off of procedures, inspection reports)
NIA Customer documents/work orders/requests (when signatures and/or data !have been Input)
NIA Certification documentation for controlled consumables NIA Software documentation NIA C of C (when required by contract)
NIA NDE Certification Submittal Letter WDI-FSRIRS Rev I Date 8/6/07
mi w!spyl Projects & Application Engineering OPPD Fort Calhoun Station RPV Outlet Nozzles Material Characterization Report (OPPD Contract No. 00083453; Wesdyne SAP No. 1304009)
Prepared by:*"
Z~afn Kuljii
,',rincipal Engineer Principal ET Level III Date: May 29, 2008 Approved bA
.ý Don Adamonis General Manager Products & Applications Engineering Date:
r Wesdyne International, Inc May 2008 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 1 of 95
mWESDyynE INT E R NAT IO NAL Projects & Application Engineering OPPD Fort Calhoun Station RPV Outlet Nozzles Material Characterization Report Table of Content:
I Summary II Material Characterization on Outlet Nozzles DMW (Butt Weld) at Fort Calhoun Station - Inspection Program III Inspection Results Appendix-1:
Appendix-2:
Appendix-3:
Appendix-4:
Appendix-5:
Appendix-6:
Appendix-7:
Appendix-8:
Appendix-9:
Appendix-10:
Nozzle N IA, Still Images from Visual Inspection at 45" from Core barrel ID Surface, (Location with DMBW)
Nozzle N IA, Still Images from Visual Inspection at 52" from Core barrel ID Surface, (Location with FW)
Nozzle N I B, Still Images from Visual Inspection at 45" from Core barrel ID Surface, (Location with DMBW)
Nozzle NIB, Still Images from Visual Inspection at 52" from Core barrel ID Surface, (Location with FW)
Nozzles: NIA & NIB, Eddy Current Inspection with Pancake & Plus-Point Probes - Test Result Graphics Nozzles: N IA & N I B, Eddy Current Inspection with Low Frequency Probes - Test Result Graphics ET Testers and ET Probes Certificates Personnel Certificates Calibration Standard Certification ET Inspection Procedure: WDI-SSP-1150, RO " Eddy Current Inspection Procedure: WDI-SSP-1150, RO "Eddy Current Material Characterization Along ID Surface on RPV Nozzle Safe End DM Weld at OPPD's Fort Calhoun Station" OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 2 of 95
WESDyI1E Projects & Application Engineering OPPD Fort Calhoun Station RPV Outlet Nozzles Material Characterization-Report I - Summary:
Material characterization inspections at Fort Calhoun on RPV's two outlet nozzles were performed by Wesdyne International during the scheduled outage on May 1, 2008.
The combined visual and eddy current inspections were executed with full scope as originally planned in the inspection program for this task. These inspections were performed with the submersible robotic manipulator "SQUID", equipped with special eddy current probes that were selected for this application. These probes and the inspection techniques were earlier qualified for this application at Wesdyne facilities, using actual DMW (Butt Weld) samples and one actual RPV nozzle with similar DMW (Butt Weld) material configuration (S/S Cladding and Inconel Weld). Eddy Current (ET) scanning was accomplished axially, and locations are defined by value "X" (the axial distance from the Core Barrel ID) and value "Y" (angular location measured in clock-wise direction when looking in to the nozzle from inside RPV, with the 00 orientation at 12 o'clock position).
Visual inspection results confirmed the existence of DMW (Butt Weld), on both outlet nozzles (N-I-A, nozzle connecting to RC-2A and N-I-B, nozzle connecting to RC-2B) at a distance of 45.0 inches from the Core Barrel ID surface (this has confirmed the distance extracted from the original RPV manufacturing drawings).
Also the second characteristic field weld, located between the nozzles Safe End and the RCS Pipe, was clearly confirmed at a distance of 52.0 inches from the Core Barrel ID surface (this has confirmed the distance extracted from the original RPV manufacturing drawings).
The eddy current inspections have confirmed a distinguishable permeability boundary on both sides of the DMW (Butt Weld) on two inspected outlet nozzles. The weld location measured with a robotic manipulator with the eddy current probes has confirmed characteristic distance of 45.0 inches from the Core Barrel ID surface. The characteristic transitions between the inconel weld (DMW (Butt Weld)) and the adjacent S/S Claddings (one over the C/S Nozzle and the other over the S/S Safe End Spool forgings), were clearly detectable, with adequate Signal-to-Noise ratio (S/N ratio > 10) with Pancake and Low Frequency (LF) probes. This has confirmed the expected results based on the earlier process qualifications at Wesdyne's facilities.
The result with Plus-Point probe provided inconclusive signals, from these transitions, with inadequate Signal-to-Noise ratio. This relatively inadequate performance with Plus-Point probe has confirmed the earlier conclusions obtained in the qualification testing.
Based on these inspection results, both outlet nozzles at Fort Calhoun Station were characterized with clearly detectable Inconel Welds (DMW (Butt Weld)) exposed to primary coolant along the nozzle ID surface.
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Page: 3 of 95 Material Characterization for DMW-Final Report
Fn WESDyfEom Projects & Application Engineering I N TER N A T I0NA II-Material Characterization on Outlet Nozzles DMW (Butt Weld) at Fort Calhoun Station - Inspection Program Following is the list with short descriptions of nondestructive inspection (visual and eddy current) that are required to be completed on both outlet nozzle (N-1-A and N-I -B) at Fort Calhoun Station:
II-A) Initial Calibration Sequence The initial calibration sequence shall be performed per procedure:
WDI-SSP-1050, RO.
11-B) Visual Inspection Sequence on the Ist nozzle (N-i-A):
Goal for this evolution:
Identify and locate two characteristic geometries expected along this location that are expected based on manufacturing drawings. These expected geometries are 1/32" deep by 3/4" wide counter-bore at the DMW (Butt Weld) location, and irregular surface finish at the field made weld between safe ends to centrifugally cast Reactor Coolant Pipe (RCS Pipe).
The visual inspection shall be performed to include full nozzle circumference and to include both, the DMW (Butt Weld) and the safe-end field weld to centrifugally cast Pipe. This distance will be defined based on tool mounting position and expected location for these two location extracted from RPV manufacturing drawings (see sketch 1).
This location will be verified with RPV manufacturing drawing. Any significant deviation from expected distance based on manufacturing drawings (see sketch 1) exceeding the distance of +/- 2.0 inches will be brought to the customer attention for final resolution.
If visual inspection provides inconclusive results, the reference location of the DMW (Butt Weld), or the field weld on the transition of the centrifugally cast Pipe will be established with the LOW FREQUENCY eddy current probe.
The 1st and the 2 nd video inspection sequence shall have camera objectives centerline positioned at DMW (Butt Weld) centerline (X2=45.0 inches;
+/- 1.0 inch, see sketch 1).
The 3rd and the 4h video inspection sequence shall have camera objectives centerline positioned at 7.0 inches further away from DMW (Butt Weld) centerline (X2 + 7.Oinches = 52.0 inches; +/- 1.0 inch, see sketch 1).
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Page.- 4 of 95 Material Characterization for DMW-Final Report
W ESDylnE INTER NAT I ONA Projects & Application Engineering r~ 7
-- T TýFF-rrTTT Camera "B" CW Rotation 3d & 4 Visual Scan Coverage Camera "A" CCW Rotation I-L L I
I
- 1 f 70' 90,
[
1800 Camera "B" CCW Rotation Sketch-1 Visual InsDection Scans #12 and #34 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 5 of 95
WESDyr1E Projects & Application Engineering IN T ER NAT 1$0 A
II-C) Low Frequency ET Inspection Sequence on the 1st nozzle (N-i-A):
Goal for this evolution:
Define the transition between Stainless Steel Cladding over Carbon Steel nozzle and DMW (Butt Weld).
C-1) 1st LF ET Probes Inspection Sequence Position the inspection sleds for 1st and 2 nd scans on locations I and 2 (00 and 1800, see sketch 2).
Inspections with Low Frequency Probes will start at the distance of 40.0 inches from the Core Barrel ID (between X3 and X2, see sketch 3).
The extent of this I" axial scan with the Low Frequency probe moved away from the RPV centerline shall be minimum 18.0 inches long.
C-2) 2 LF ET Probes Inspection Sequence The 2nd scan shall start from the end of the 1st scan (40.0 + 18.0 inches=
58.0 inches) and theprobes will be moved toward the RPV centerline.
The extent of this 2n axial scan with the Low Frequency probe shall be minimum 18.0 inches long.
C-3) 3 rd LF ET Probes Inspection Sequence Position the inspection sleds for 3rd and 4 th scans on locations 3 and 4 (900 and 2700, see sketch 2).
Inspections with Low frequency Probes will start at the distance of 40.0 inches from the Core Barrel ID surface (between X3 and X2, see sketch 2).
The extent of this 3rd axial scan with the Low Frequency probe moved away from the RPV centerline shall be minimum 18.0 inches long.
C-4) 4 th LF ET Probes Inspection Sequence The 4 th scan shall start from the end of the 3rd scan (40.0 + 18.0 inches =
58.0 inches) and the probes will be moved toward the RPV centerline. The extent of this 4 th axial scan with the Low Frequency probe shall be 18.0 inches long.
Following completion of all four inspection sequences with the Low Frequency probes the actual DMW (Butt Weld) location will be defined.
Any significant deviation from expected distance based on manufacturing drawings (see sketch 1) exceeding the distance of +/- 2.0 inches would be brought to customer attention for final resolution.
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Page.: 6 of 95 Material Characterization for DMW-Final Report
FmwEspyflE IN TE R
NAT L
Projects & Application Engineering It and 2d LF ET Scans 0.
1800 3r and 4th LF ET Scan I1
-1A 190o Sketch-2 Low Frequency ET Inspection Scans #12, and #34 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 7 of 95
W-E SDyflE Projects & Application Engineering IN T ER NATIONAL II-D) ET Inspection Sequence on the 1st nozzle (N-i-A):
Goal of This Evolution Define the characteristic eddy current signals that represent transition between stainless steel cladding and inconel weld (DMW (Butt Weld)).
II-D-1) 1st ET Probes Inspection Scans on the 1 st Nozzle (N-I-A):
After the DMW (Butt Weld) position information is confirmed (evolutions B and C above) the two-inspection sled with the ET Probes (Plus-Point and Pancake Coils) will be moved to staring position (DMW (Butt Weld) centerline minus 6.0 inches), this should be at approximately 39.0 inches from the Core Barrel ID surface (between X3 and X2, see sketch 1). The sleds will be oriented at inspection locations I and 2 (00 and 1800, see sketch 3).
The first scan will be performed in outbound direction, away from RPV centerline. The scan length shall be minimum 12.0 inches long.
II-D-2) 2nd ET Probes Inspection Scans on the 1st Nozzle (N-I-A):
The 2nd scan shall start from the end of the 1st scan (39.0 + 12.0 inches=
51.0 inches) and the probes will be moved in inbound direction, toward the RPV centerline.
The extent of this 2 nd axial scan with the ET Probe shall be minimum 12.0 inches long.
II-D-3) 3 rd ET Probes Inspection Scans on the 1st Nozzle (N-I-A):
Position the inspection sleds for 3rd and 4th scans on locations 3 and 4 (90' and 2700, see sketch 3).
Inspections with ET Probes will start at the distance of 39.0 inches from the Core Barrel ID surface (between X3 and X2, see sketch 3).
The extent of this 3rd axial scan with the ET Probe shall be minimum 12.0 inches long.
II-D-4) 4th ET Probes Inspection Scans on the 1st Nozzle (N-I-A):
The 4th scan shall start from the end of the 3rd scan (39.0 + 12.0 inches =
51.0 inches) and the probes will be moved toward the RPV centerline. The extent of this 4 th axial scan with the ET Probes shall be minimum 12.0 inches long.
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Page.: 8 of 95 Material Characterization for DMW-Final Report
FWESDyynE INTE R NATI ON AL Projects & Application Engineering f I
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View "A"
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-39.0" 3 rd and 4th ET Scan 900
-lr Sketch-3 ET Inspection Scans #12. and #34 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 9 of 95
FWESDylnE i NT E R NATI O NAL Projects & Application Engineering II-D-5) Inspection Completion on the 1st Nozzle (N I A)
This evolution will complete data acquisition process on one nozzle.
Recorded data will be evaluated and accepted before the "SQUID" tool will be disengaged and prepared for move to the second nozzle position.
At the second nozzle position complete evolution defined for the first nozzle will be repeated. Following completion of full inspection scope on the second nozzle the final inspection technique calibration process will be completed. Preliminary report with result presentation will be prepared and after accepted by customer representative the "SQUID" tool will be prepared for removal from the RPV.
Essential information for eddy current inspection arrangement are provided in Table-I "Eddy Current Calibration data Sheet", and Table-2 "Eddy Current Calibration and Inspection Information".
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 10 of 95
FnWimpynlE IN TE R NAT 1 0 A
Projects & Application Engineering III) Inspection Results:
111-1) Eddy Current Inspections Results:
III-l-1) Nozzle N-1 -A:
DMW (Butt Weld) with Detected Inconel Weld Exposed to Primary Coolant.
111-1-2) Nozzle N-i-B:
DMW (Butt Weld) with Detected Inconel Weld Exposed to Primary Coolant.
111-2) Visual Inspections Results:
111-2-1) Nozzle N-i-A:
DMW (Butt Weld) detected at 45.0 inches from the Core Barrel ID surface.
111-2-2) Nozzle N-i-A:
Safe End to RCS Pipe Weld detected at 52.0 inched from Core Barrel ID surface.
111-2-3) Nozzle N-I-B:
DMW (Butt Weld) detected at 45.0 inches from the Core Barrel ID surface.
Local surface irregularity observed at 2700 circumferential orientation 111-2-4) Nozzle N-i-B:
Safe End to RCS Pipe Weld detected at 52.0 inches from the Core Barrel ID surface.
Prepared by:
Zoran Kuljis Principal Engineer Principal ET Level. III Wesdyne International, Inc.
Date: May 29, 2008 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 1 of 95
FWESDyynE IN T E R NAT I 0 AL Projects & Application Engineering Table-i Eddy Current Calibration data Sheet Utility: OPPD Plant: Fort Calhoun Unit: 1 Outage: RF024 Procedure No: WDI-SSP-1150 Procedure Rev. No.: 0 Inspection Area (s):
Outlet Nozzle DM Weld Applicable PARAGON Session(s): ET Inspection Nozzle N1A and NiB PARAGON Operator Signature: Corey Adamonis Date: 05/01/2008 ET Examiner Signature: Zoran KulJis Date: 05/01/2008 Equipment Information PARAGON SAP #: 102285 ET Instrument Model: Zetec PCI Board PARAGON ET. Software Release No: 5.5.0 ET Instrument S/N: (EC Boards 026,021)
Calibration Blocks: Standard DWG# 6031204 SAP #: 105799 Cable Type Cable Length(s)(ft)
No of Intermediate Connectors Probe Extension Cable-Pancake 2 - 25ft (50ft) 2 Probe Extension Cable-+Point 1 - 75ft 1
ET Probe Information Probe ET Probe Serial ET Probe Type Phase Volt %
No.
Number 260 kHz / 500 kHz 260 kHz / 500 kHz 1
P22153
+ Point @ 0° 265/267 100/100 2
P22160
+ Point @ 180' 270/270 100/100 3
362894 Low Freq @ 0' 89/86 100/100 4
362895 Low Freq @ 1800 89/93 100/100 5
P22165 Pancake @ 01 166/166 100/100 6
P22166 Pancake @ 180° 165/165 100/100 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 12 of 95
-- W ESDyO l E Projects & Application Engineering Table-2 Eddy Current Calibration and Inspection Information ET Calibration & Inspection Information Cal IN & Scans on Nozzle A Filenames:
Cal Out & Scans on Nozzle B Filenames:
INT CAL PP1A, 1NT CAL PP 2A END CAL PP1A, END CAL PP 2A INT CAL LF IA, INT CAL LF 2A END CAL LF IA, END CAL LF 2A Scans on Nozzle # NIA:
Scans on Nozzle # NIB:
PP Scans: FC DMW NIA PP12A, FC DMW N1A PP34A PP Scans: FC DMW NIB PP12A, FC DMW NIB PP34A LF Scans: FC DMW NIA LF 12A, FC DMW NIA LF34A LF Scans: FC DMW NiB LF 12A, FC DMW NIB LF34A OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 13 of 95
FqiWEspyflE I NT E RN A TO10 Projects & Application Engineering Appendix 1 Nozzle N IA Still Images from Visual Inspection at 45" from Core barrel ID Surface (Location with DMBW)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 14 of 95
nWEspyflE IN T ER N AT 1 ONA Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 00 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 15 of 95
~WESDy1nE IN T E RN AT I ONAL Projects & Application Engineering iNOZZie IN IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 300 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 16 of 95
0WESDynlE I NTE R NATI ONAL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 600 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 17 of 95
~WESDynE I NTE RNAT I ON AL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 900 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 18 of 95
FWESDylnE INTERNATIO L
Projects & Application Engineering Nozzle NIA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 1200 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization/for DMW-Final Report Page.- 19 of 95
FnW EspyfE Projects & Application Engineering IN TE R
AT L
Nozzle N IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 1500 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 20 of 95
FWESDylnE INTERNTONAL Projects & Application Engineering Nozzle N 1A Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 1800 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 21 of 95
Fn W ESDyrlE Projects & Application Engineering INTERN AT IONA Nozzle N IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 2100 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 22 of 95
M WEspynlE IN T ER N A T 1 ONA Projects & Application Engineering INUZZIC IN IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 2400 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 23 of 95
FWEsDynlE I NTE R ATN I ON A Projects & Application Engineering Nozzle N1A Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 2700 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 24 of 95
FnWEspyflE INT ERNMAT 1NAL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 3000 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 25 of 95
FWESDyynE INT E RNAT ION AL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 3300 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 26 of 95
FWESDyynE INTERN AT 10NAL Projects & Application Engineering Appendix 2 Nozzle N IA Still Images from Visual Inspection at 52" from Core barrel ID Surface (Location with FW)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 2 7 of 95
FWESDynfE I NT E R NAT 10NAL Projects & Application Engineering INOZZIe IN IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 00 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization/for DMW-Final Report Page: 28 of 95
FWESDylnE INTERNATIONAL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 30' OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization.for DMW-Final Report Page: 29 of 95
n
,WESDyfnE Projects & Application Engineering IN TE R
NAT L
Nozzle N IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 600 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 30 of 95
FWESDyynE INTERN AT I ONAL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 900 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 31 of 95
~WESDynlE INTERN AT ION AL Projects & Application Engineering Nozzle N 1A Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 1200 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 32 of 95
FWESDfynE INTERNATIO AL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 1500 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 33 of 95
FWESDyynf INTER NATI ONAL Projects & Application Engineering INozzie IN IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 1800 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 34 of 95
5WESDylnE INTERNATIONAL Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 2100 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 35 of 95
FWESDylnE I NTOE R NAT 0
A Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 2400 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page.- 36 of 95
n W ESDyIlE Projects & Application Engineering I NT ER N AT 1 0NA NOZZle IN IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 2700 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 37 of 95
Fq1WESpyn1E I
NTE R
AT Projects & Application Engineering Nozzle N IA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 3000 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 38 of 95
F WEspy n,E Projects & Application Engineering INTE RN ATI ON AL Nozzle N I A Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 3300 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 39 of 95
n wnAsOyn A
IN NTE R N AT 1 ONA Projects & Application Engineering Appendix 3 Nozzle N IB Still Images from Visual Inspection at 45" from Core barrel ID Surface (Location with DMBW)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page.- 40 of 95
nWEsDynfE I NTE RNATI ONA Projects & Application Engineering Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 0' OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 41 of 95
n W EspynlE Projects & Application Engineering I NTE R HAT IQNA Nozzle N 11B Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 300 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 42 of 95
FWESDyynE INTERN ATI ON Projects & Application Engineering Nozzle N IB Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 600 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 43 of 95
1,511WEspynlE I N TE RN A T 1 0NA Projects & Application Engineering Nozzle N its Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 900 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 44 of 95
Fn W ESDynE Projects & Application Engineering IN?
T ISRNAT 1 ON. ALI Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 1200 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 45 of 95
FnWEsDyflE INTERNATIO Projects & Application Engineering Nozzle N 1B Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 1500 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization/for DMW-Final Report Page: 46 of 95
n W.spyfl=
Projects & Application Engineering I NT ER N A T 1 ONA Nozzle N IB Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 1800 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 47 of 95
~WESpyflE Projects & Application Engineering Nozzle N I B Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 2100 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 48 of 95
W EspyfE Projects & Application Engineering INT E R MAT 1 ONA Nozzle N IB Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 2400 OPPD Fort Calhoun RP V Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 49 of 95
"WESDynE I NTE R NATI 0NAL Projects & Application Engineering Nozzle NIB Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 2700 (Local surface irregularity above the DMBW centerline)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 50 of 95
FWESDyflE INTERN ATI ONA Projects & Application Engineering Nozzle N I1B Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 3000 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 51 of 95
FWEspynrE I NTE R NAT 1 N
Projects & Application Engineering N ozzle N 115 Visual Inspection Still Frame from Location, Axial: 45"; Circumferential: 3300 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 52 of 95
FnWEspyflE I N TE R NA TO10 Projects & Application Engineering Appendix 4 Nozzle NIB Still Images from Visual Inspection at 52" from Core barrel ID Surface (Location with FW)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 53 of 95
FWESDyynE I NTE R ATI ON AL Projects & Application Engineering Nozzle N IB Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 0' OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 54 of 95
Fq1WESpynE IN T ER NAT 1O 0A Projects & Application Engineering Nozzle N I B Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 30' OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization/for DMW-Final Report Page: 55 of 95
FWEsDynfE I NTE R NATI ON AL Projects & Application Engineering Nozzle N IB Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 600 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 56 of 95
,W ESDynE Projects & Application Engineering I N TER NA TIO AL Nozzle N IB Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 900 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization/for DMW-Final Report Page: 57 of 95
S W ESpynE Projects & Application Engineering I N TE R MATI 1 0L Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 1200 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 58 of 95
n W EspyflE Projects & Application Engineering i NT E RN AT 1 ONA Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 1500 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page.- 59 of 95
nWEspyflE Projects & Application Engineering INOZZle IN 113 Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 1800 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Page: 60 of 95 Material Characterization for DMW-Final Report
FIRWESpyflE IN TE R
NAT L
Projects & Application Engineering Nozzle N IB Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 2100 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page.- 61 of 95
FnTW ESDyfnE Projects Application Engineering INTER NATIG N
Nozzle N IB Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 2400 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 62 of 95
rWESDylnE INTERNATONA Projects & Application Engineering iNOZZie iN i3 Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 2700 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 63 of 95
F W EspyflE Projects & Application Engineering INTERNAT NA ALI Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 3000 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization/for DMW-Final Report Page: 64 of 95
W ESDyn=E Projects & Application Engineering INTERN AT IONA
- IIULLiZ1, I
II)
Visual Inspection Still Frame from Location, Axial: 52"; Circumferential: 3300 OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 65 of 95
mWESDylnE I NTE R NAT N AL Projects & Application Engineering Appendix 5 Nozzles: NIA & NIB Eddy Current Inspection with Pancake and Plus-Point Probes -Test Result Graphics OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 66 of 95
oWESpynE Projects & Application Engineering For 0105 iW_ Test& 1*
iý F 0
I IV26K 2V 260K Proe 1 260 Kh z 0.021,
Probe2 2s60bz 0.199%
97.53% 265" F _F Probe 1 50 Khz 0.081%
Pro 2 580 Krz 0.397%
C 0.5w 0.185 h~,e obc. t47 260 SeW' AR547 Initial Calibration for Pancake (#1) and Plus-Point (#2) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 67 of 95
Fm W ESDynE Projects & Application Engineering INT ERNAT IQ Fie edt Vitm TeM "NO G$
F d) 0I 1 V 2UK 2V 260K P.obe 1 260 K1iz 021%
he 1 500 Khiz 300%
Pobe 2 260 Khz 0.202%
I 0.(
Probe 2 500 Khz 0.423%
96.05% 267' Draw 0.1W3 Final Calibration for Pancake (#1) and Plus-Point (#2) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 68 of 95
rmWEspyflE INT E RNATIO1A0 Projects & Application Engineering
=77I Fk M
%m TetW H*
3V 2C0K 4V 20K Prolbe 3 260 Khz 021%
Probe 4 260 Khz 0.204%
C
- 00Khz Probe 4 500 KIhz 0.415%
(
-Th Drw 0413 Initial Calibration for Pancake (#3) and Plus-Point (#4) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 69 of 95
mWi wsDnfl I NT E R NATO1 AL Projects & Application Engineering F_
7171 -- I; I i o r,ý _ýJEIFX f l bt w
Taw d
I~ýF (5 05 0
)
3V 26K 4V 260K I
Probe 3 260 Kiz 0.021%
Probe A4250 Ki 0.201%
(
Probe 350S KIhz 0.970M Probe 4 500 Kbz 0.401%
(
Drw.
1 1~de4 x199.4 y4.84 Swe~1 O.t~t 119 Final Calibration for Pancake (#3) and Plus-Point (#4) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 70 of 95
MNWESATynE I N TE R N ATIONA0 Projects & Application Engineering
-fm;m
-xi fed em *w'eI d
19 01 IV 28K 2V 260KI Probe 1 260 Khz 0.022%
Proe 3 260 Khz
-0.022%
P0.be 20260 Kh 0.201%
- 6 Probe
- 260 Kb3 0.203%
0
~-
o.1~
Nozzle N IA Scan along DMBW at 900 Orientation - Pancake (#1) and Plus-Point (#2) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 71 of 95
FWESDylnE I NTE R NATI ON AL Projects & Application Engineering r x Fit Oft AM. T-t*
a F (b 0
3V260K 4V26Kk Probe 1 260 Khz 0.0221%
Probe 3 260 Khz
-.Z2 Probe 226 Khz 0.201%
I Probe 4250Khz 0.203%*
x) t..0.431 Nozzle N IA Scan along DMBW at 270' Orientation - Pancake (#3) and Plus-Point (#4) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 72 of 95
FWi wsDyflE INT ER MATIO1AL Projects & Application Engineering
ýý, i 1, " 1%
t4 I ý N, ý V, ý I ý,J,
ý,[ r ý ý I,
, ý I r_:ý - r !xi Flb Edt view IV 260K TU~
2V 266K Nobel 260 Khz 0.020%
Probe 2 2850 Kz 0.200%~
Probe 30260 Kh 0.020%
Probe 40201 Vi 0.201%
Or.0,172 J
Probe I x 0.6-Y 4001 Svl I DaUR 275 Nozzle NIA Scan along DMBW at 0' Orientation - Pancake (#1) and Plus-Point (#2) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 73 of 95
FWESDylnE I NTE R NATI ON AL Projects & Application Engineering r- -
Fk Eft ftw Telle H*
GO F 6
1 3V260K 4V 260K Probe 1 260 Khz 0.020%
Probe 2260 Khz 0.200%
99~
Probe 3 260 lhz 0.020%
Probe 4 250 Klz 0.201%
IDmw 0.429 J
Proe 0X
ý46.81
,S*weec I De0t~t275 Nozzle N IA Scan along DMBW at 1800 Orientation - Pancake (#3) and Plus-Point (#4) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 74 of 95
~WESDyflE INTERNATI ONAL Projects & Application Engineering 2i IV 250K 2V 2UK Probe1 2608Khz 0.021%
Probe 260 Khz M
0.021%~
Probe 2 260 Khz 0.200%
279.36% 270" 293.29%*
273" Probe4 260Khz 0.202%
38.04% 239' 55.82% 221" r
0.144 Nozzle N IB Scan along DMBW at 00 Orientation - Pancake (#1) and Plus-Point (#2) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 75 of 95
Fm W ESDyynEE Projects & Application Engineering I NT ERNATI1ON 3V 260K Tes4V 26 4V 260K Probe 1 2606Khz 0.026%
Probe 2266 Khz 0.202%
2 2860Khz Probe 4 260 Kh0 0.200%
Dr9 0.099
-ob*3.100.0-y45.91 S.We09 I
Data't vs9 Nozzle N I B Scan along DMBW at 1800 Orientation - Pancake (#3) and Plus-Point (#4) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 76 of 95
rWESDyynE I NTE R NATI ON AL Projects & Application Engineering F_7 r- -!ý;;_,.x IV 260K 2V 260K Pro 9.0 Pro e01 260 Khz Prob. 20205hz 0.211M~
9 260 5hz Prob. 4260 Khz 0.201%
&o.M iep612 Nozzle N IB Scan along DMBW at 900 Orientation - Pancake (#1) and Plus-Point (#2) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 77 of 95
FW SDyynE I NTE R NAT 1 NAL Projects & Application Engineering i "T,
','1 711- -
r-- " - m ý x Fre 5m Viw Telow HM 9; F 4b 0 0 3V 260K 4V260Kt Prbe1 260 Khz 0.0241%
Prtobe3 260 Khz
-0.020%
Pro.
2 260 KhZ 0.200%
/
Prbe 4260Khz 0.201%
2 9
Swepm Soe 612 Nozzle NI B Scan along DMBW at 2700 Orientation - Pancake (#3) and Plus-Point (#4) Probes OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 78 of 95
mWEsDynmE INTERN ATR I N AL Projects & Application Engineering Appendix 6 Nozzles: NIA & NIB Eddy Current Inspection with Low Frequency Probe -Test Result Graphics OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 79 of 95
FWESDfynl INTE R NATI ON AL Projects & Application Engineering 1',1 ýol-x PF* em vow Teow I*
9;F4 09 f?
IV 2K IV20K Probe 1 2 Khz 0.4711%
rbe.1 20Khz 0.493%
laO "t *ql£ RG*
0raw 0.191 Initial Calibration for Low Frequency Probe (#1)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 80 of 95
Fm W ESDynf Projects & Application Engineering I N T E RNAT 10 Fie m~ m*w TeSts M 2V 2K~
ZV 20K Probe2 lKbz 0.525%
Pobe2 20Khz 0.632%
0.30%
82" 0.30% 79" V..m 0.1IN Initial Calibration for Low Frequency Probe (#2)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 81 of 95
m oWESDyInE Projects & Application Engineering INTERNATI ON F4 I rt To m
90 00~
IV
?K
- v20r, Pi be1 2 Kbz
- 0. 495W 0.493,'
F I
1rids *PJ*
Qd*e KL Dý0.177{
Final Calibration for Low Frequency Probe (#1)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 82 of 95
Fq1WESpyflE I NT E PNAT 1NAL Projects & Application Engineering 7,
77ý x
r em EiWew TeRW mm Q9Fd 0 9
ý 2V 2K V 20K Pfebe 2 2 Khz 0.519%
P0be2 209Khz 0.559%
j
[
1*1 7*IL RG*
ln*
ROIk[ 7Q" 0r* 0.207 Final Calibration for Low Frequency Probe (#2)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 83 0f 95
mWESDyynE I NTE R NATI ON AL Projects & Application Engineering
ý 1 ( :, VV, ý ý 1 ý ý 1 1 " "
I ý" I "i,
f, )! ý, ýý 11 r", !- 7!,x 1 Fie em viw 2;F d>
IV 2K IV 20K Prbe1 2Khz 0.030%
Probe1 20 Khz IWM6 Nozzle NIA Scan along DMBW at 4.5' Orientation - Low Frequency Probe (#1)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 84 of 95
M WESDynIE I NTE R NATI ON AL Projects & Application Engineering F117 71 ý 11
", ! 4 ý "I ý i - ; -1 ý r --, 0 ri -_, :i -N Fie Edo New~
ZY 2K Testf Help ZV 20K Probe* 2 2Khz 0.0 31%
Probe12 20 1h 0.101%~
SweeSiXe917 Nozzle N IA Scan along DMBW at 184.50 Orientation - Low Frequency Probe (#2)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 85 of 95
W ESDynfE Projects & Application Engineering I NTERNAT ON1 AL Net Efft Miew Testw tdp 19 019 IV 2K IV20K Probe1 2 Khz 0.031%
Prbe1 20Khz 0.101%~
dr..
Daw 0.21 2831.06% 276' 1543.75% 179' Nozzle N IA Scan along DMBW at 94.5' Orientation - Low Frequency Probe (# 1)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 86 of 95
M WESDynfE Projects & Application Engineering I N E"NA'"
Fit NEf vew TeAW I*
2V 2K 7V 20K PNpbe 2 2 Kbz Pmbe! 2 2Khz 9Wm ~ee917 Nozzle N IA Scan along DMBW at 274.50 Orientation - Low Frequency Probe (#2)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 87 of 95
~WEsoynlE I NTE R NAT I ON AL Projects & Application Engineering F -117
- It - -17 ý 7 7 1 -t, 1 11 r, - 7 ),
me Edo View Teste "0 9; F~
01 Probe1 2 Khz 0.032%
Prob10 20 hz 0.100%
2904.83%
286 1626.83%
181' Orm 0.222 Nozzle N IB Scan along DMBW at 0' Orientation - Low Frequency Probe (# 1)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 88 of 95
~WESDynlE SNTIERN AT I ON AL Projects & Application Engineering "A 4 1 ý: 1 i, 1ý1;,
ýt r 1:ý x
Fit Eckt Ya 2V 2K 2V 20K Prbe2 2Ehz 0.028%
Probe2 20 Khz 0.102%
)
10.31% 279' 4.41% 176' D 0.249 Nozzle N IB Scan along DMBW at 1800 Orientation Low Frequency Probe (#2)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 89 of 95
W ESDyHlE Projects & Application Engineering INTER NAT I NA GrF 0 0 IV 2K IV20K Po.be31 2Khz 0.030%
P0b.1 20Khz 0.106%
DmGW 0.261 2874.50% 276" 1584.16% 177' Nozzle N IB Scan along DMBW at 94.50 Orientation - Low Frequency Probe (#1)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 90 of 95
Fm W ESDyHE Projects & Application Engineering I NT E RN A T 6 ONA 7V 2K 2V 20K 0roe22 Khz 0.038%~
P0.102 20Khz 01.1 O2%
D-.223 3155.67% 283' 1441.79%
176' Nozzle N IB Scan along DMBW at 274.50 Orientation - Low Frequency Probe (#2)
OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page. 91 of 95
m wEmsyflE I
N E R N AT1 Projects & Application Engineering Appendix 7 ET Testers and ET Probes Certificates OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 92 of 95
Zetec C15 C.D. Howe Drive Z ETE.C Deep River, Ontario KOJ 1PO Canada Tel.
Fax.
Web.
(613) 584-1440 (613) 584-1441 www.zetec.corm Certificate of Conformance This certifies that quality system standard ISO 9001:2000 has been met or exceeded in the manufacture of this product.
P# 22153 Model Spot Probe Drawing # 5-S1-022 Rev RO Job Number 2855 Zetec Catalog ID Number W
Miz8O Check Out W' TC7700 Check Out Signed: c*
"6..
Date: j//f
//07
ZETEC Zetec 15 C.D. Howe Drive Deep River, Ontario KOJ IPO Canada Tel.
Fax.
Web.
(613) 584-1440 (613) 584-1441 www.zetec.com Certificate of Conformance This certifies that quality system standard ISO 9001:2000 has been met or exceeded in the manufacture of this product.
P# 22160 Model Spot Probe Drawing # 5-S1-022 Rev RO Job Number 2855 Zetec Catalog ID Number W
Miz8O Check Out TC7700 Check Out Signed: r,.
1 D-te Date:
I 0/ý <tI6 t -
ZETEC Zetec 15 C.D. Howe Drive Deep River, Ontario KOJ IPO Canada Tel.
Fax.
Web.
(613) 584-1440 (613) 584-1441 www.zetec.com Certificate of Conformance This certifies that quality system standard ISO 9001:2000 has been met or exceeded in the manufacture of this product.
P# 22165 Model Spot Probe Drawing # 5-S1-021 Rev RO Job Number 2855 Zetec Catalog ID Number Miz80 Check Out TC7700 Check Out Signed: *._
Date:
[(2//
s7
Zetec 15 C.D. Howe Drive ZLI A S Deep River, Ontario KOJ IPO Canada Tel.
Fax.
Web.
(613) 584-1440 (613) 584-1441 www.zetec.com Certificate of Conformance This certifies that quality system standard ISO 9001:2000 has been met or exceeded in the manufacture of this product.
P# 22166 Spot Probe Model Drawing # 5-S1-021 Rev RO Job Number 2855 Zetec Catalog ID Number ZMiz80 Check Out
.L7 TC7700 Check Out Signed:______
Date:
Date:.10//
4/07
Zetec Certificate of Conformance Delivery:
16870 Contract/Purchase Order Number:
4500085467 Page 1 of 2
ZETEC 8226 Bracken Place SE, Suite 100 Snoqualmie, WA 98065 Tel: (425) 974-2700 Fax: (425) 974-2701 Certificate of Conformance Delivery:
16870 This certifies that, to the best of our knowledge, the material delivered under this purchase agreement is in accordance with the terms of the Contract/Purchase Order.
Customer:
WESTINGHOUSE ELECTRIC COMPANY-LLC Contract/Purchase Order Number:
4500085467 Certificate Date of Issue: "
27-MAR-02 Specific Contract/Purchase Order requirements:
Where Rev. 6 testing is specified, EPRI Pressurized Water Steam Generator Examination Guidelines, Rev. 6 (section 6.5.1 Probe Quality Parameters) apply.
Exception specific to Zetec X-Probes Rev. 6 testing - Zetec X-Probes have been tested and verified to meet the requirements of EPRI Report 1003138 Rev. 6 section 6.5.1 for probe quality parameters as amended by Zetec Document 05-1039 for 360 degree coil coverage.
Zetec Certificate of Conformance Delivery:
16870 Contract/Purchase Order Number:
4500085467 Page 2 of 2
Line Itm1scito I tern/Description 10014093-1 DP-.500-SP 4PA Catalog Item Qty Rev6 Z0001653-1 8 No 362893 362896 S/N 362891 362894 362897 362892 362895 362898
WD[-SAP
-ECR ZETEC Doculentn 03-1008 CALIBRATION CERTIFICATE COMPANY NAME: WESDYNE INTERNATIONAL LLC c.-c -s Zetec, Incorporated hereby certifies that the following instrument meets or exceeds all manufacturer's specifications.
INSTRUMENT: PCI EDDY CURRENT CARD SERIAL NUMBER: &I
- OI.)
The calibration of this instrument has been performed using a documented, controlled Zetec procedure which meets or exceeds the requirements of ASME Section XI, Appendix IV and ASME Section V Article 8, Appendix III through the 2003 Edition Calibration has been performed using standards whose accuracies are traceable to the National Institute of Standards and Technology. This Certification complies with ISO/IEC 17025 and ANSI/NCSL Z-540. This certification may not be reproduced or distributed except in whole without written authorization from Zetec.
N.I.S.T. TRACEABILITY:
Standard Instrument Serial Number Calibration Date Expiration 7678 OSCILLOSCOPE B036119 04/10/2007 04/10/2008 CALIBRATION DATE:
1 5-a Ot CALIBRATED BY:
JAMES LARSEN TECHNICIAN CERTIFICATION DATE: I C-,3.A)09 O
EXPIRATION DATE:
%9 A"- 0* 1 CERTIFIED BY:
JAMES LARSEN PROCEDURE #: ESP-COP PCI ECC REV.2 COMMENTS:
QUALITY MANUAL: Z-QA-001 REV.I ID CERTIFICATION NUMBER 03-1008: 72193 www.zetec com Pare 1 of 1 Zetec, Inc.
& 8226 Bracken Place SE, Suile 100
- Snoqualmie, WA 98065 USA Phone 425-974-2700 Fax 425-974-2701
,y WD1-SAPjOqq?6-ECR ZETEC Documcnt 0.-IC08 CALIBRATION CERTIFICATE COMPANY NAME: WESDYNE INTERNATIONAL LLC C.c-L A Zetec, Incorporated hereby certifies that the following instrument meets or exceeds all manufacturers specifications.
INSTRUMENT: PCI EDDY CURRENT CARD SERIAL NUMBER:
Cl 07-4,1 The calibration of this instrument has been performed using a documented, controlled Zetec procedure which meets or exceeds the requirements of ASME Section XI, Appendix WV and ASME Section V Article 8, Appendix I/ through the 2003 Edition Calibration has been performed using standards whose accuracies are traceable to the National Institute of Standards and Technology. This Certification complies with ISO/IEC 17025 and ANSI/NCSL Z-540. This certification may not be reproduced or distributed except in whole without written authorization from Zetec.
N.I.S.T. TRACEABILITY:
Standard Instrument Serial Number Calibration Date Expiration 7678 OSCILLOSCOPE B036119 04/10/2007 04/10/2008 CALIBRATION DATE:
I I D CALIBRATED BY:
JAMES LARSEN TECHNICIAN CERTIFICATION DATE:
S I_-
4 OS EXPIRATION DATE:
iS 5,A-,-
Oc CERTIFIED BY:
JAMES LARSEN PROCEDURE #: ESP-COP PCI ECC REV.2 COMMENTS:
QUALITY MANUAL: Z-QA-001 REV.]
a CERTIFICATION NUMBER 03-1008: 72192 www.zetec.com Page 1 of I Zetec, Inc.
9 8226 Bracken Place SE, Suite 100
- Snoqualmie, WA 98065 USA Phone 425-974-2700 Fax 425-974-2701
mwEspynE INTERN AT 10NAL Projects & Application Engineering Appendix 8 Personnel Certification OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 93 of 95
mimW.sDynE WesDyne Intemational Page Iof I Inspection Services Certificate of Qualification for Zoran R. Kuljis 18814 This individual is certified in accordance with WesDyne International QA Procedure WDP-9.2 "Qualification and Certification of Personnel in Nondestructive Examination", which follows the guidelines of ASNT Recommended Practice SNT-TC-1A, CP-1 89, and ASME Section Xl.
WesDyne Written Practice WDP-9.2 Rev. 11 Interim CERTIFICATIONS I
Method Level Certification Date Proficiency Date Expiration Date I Eddy Current III.
5/8/2007 N/A 4/12/2012 Umitations/
None.
Restrictions:
Test Techniques:
ET: Absolute and Differential.
EYE EXAMS Not valid without current eye exam attached.
ADDITIONAL CERTIFICATIONS / QUALIFICATIONS Revi~ewem NDEAdminisr at
WESDynF Qualification and Certification Summary WesDyne International Name:
Zoran R. Kuljis Badge: 18814 CURRENT CERTIFICATION EXAMINATIONS Method Level Gen./Basic SpeciMethod Pract./Spec.
Demo.
Practical Score Examiner Score Score Score Score Score LT ET Ill.
83 83 97.5 96 96 91.10 C. Wyffels, L-I11 MT PT RT UT VT VT-1 VT-2 VT-3 EDUCATION M. S. Mechanical Engineering-University of Zagreb - Zagreb, Croatia, 1973 TRAINING CLS LAB 80 16 24 8
32 Hours - ECT Data Analysis for S/G Tubing, EPRI Hours - ECT of Non-Ferromagnetic Tubing, Zetec Hours - Data Analysis of Non-Ferromagnetic Tubing, Zetec EXPERIENCE Initial Method Certification Date LT ET MT PT RT UT V'T J VT-1 VT-2 V'-3 5/1/1975 This individual is certified in accordance with WesDyne International QA Procedure WDP-9.2 "Qualification and Certification of Personnel in Nondestructive ExalNation 7, 5 ich follows the guidelines of ASNT Recommended Practice SNT-TC -IA, CP-189, and ASME Section XA.
NDEAdministat. ML Whv-sel/
Date NDEAdministlat'6r. AIL Whvisell Date
w...S.Dynr Individual Experience Summary Record WesDyne International Documented records are maintained on file and meet at least the minimum WesDyne International requirements for File Date each certification discipline. These and additional records (when referenced) provide objective evidence supporting 3/712008 Qualification and Certification.
Name: Zoran R. Kuljis Badge: 18814 Prior Certification:
This individual has been performing NDE related activities since 1975 in power plant, bridge fabrication, and/or structural steel inspection performing visual, surface and/or volumetric examinations on vessels, structural supports, heat exchangers, piping and related components. Previous experience documentation available upon request.
Documented Experience LT ET MT PT RT UT VT VT-I VT-2 VT-3 Date Company Level Ill.
05/75 to 12/07 Upon Request NIA 0
5674 4200 4200 0
5155 0
0 0
0 Total Experience 0
5674 4200 4200 0
5155 0
0 0
0 The supporting documented records have been reviewed and are true and correct to the best ofmy knowledge.
NDEAdwinstrt K Whytsell Date
F-18.3-2 Rev. 4
- Westing0ouse VISION ACUITY EXAMINATION RECORD Name
- SAP No, Date of Exam 0Do W use Social Security Number or passport number.
Note: Fill in the actual numerical results for each reading, e.g.; NearVision, R# I or Far Vision, L 20 / 20 Near Vision - Jaeger' R] Snellen 0 Other:
Accept.
Unaccept.
ENatural R# _
L#
B#
Corrected R#
L#
B#
- Qualified Jaeger Card Serial Number (if applicable):
/:3*
-t*.
Far Vision - Sneilen K1 Other:
Accept.
Unaccept.
Natural (R201 (L20/
B20 1 Corrected R 20/ 1'."
L20/ J,..
.20/
Color Vision Accept.
Unaccept.
- Ishihara, Other (Describe)
Corrective Lenses Required While Conducting Inspections Yes No Near Vision X
I Far Vision Eye examinations shall be performed by a Level Ill, designate or medical personnel.
Eye Examination Administered By:.
kst-
),I Signature.
Title Date This Vision Acuity Examination is acceptable for NDE, Inspection and Test.
- Yes, No fi This Vision Acuity Examination also meets the requirements of ASME Section Xl, Yes;v No fi 1992 edition, 1992 Addenda and later editUns.
/
Accepted By:
,'o A lyram*lnatio IIIord d
aTitle Date ForrnB\\sllon Acuity Examilnationl Recor4-f18-32.,doc
FWEsDynfE I NTE R NAT A
OT AL Projects & Application Engineering Appendix 9 Calibration Standard Certification OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 94 of 95
Quality Release & Certificate of Conformance Westinghouse Electric Company LLC Nuclear Services Haymaker and Northern Pike Road Monroeville, PA 15146 QR- 08-32 Rev: 0 Business Unit: NS Date:
02-11-08
- 1. Customer Name:
2-Plant Site:
- 3. Customer Order No. and Latest Rev
- 4. W Network Number WesOyne International Waltz Mill N/A N/A
- 5. Westinghouse Sales Order Number:
- 6. W Purchase Order Number
- 7. Item #:
- 8. W P.O. C/N #:
- 9. PAR:
- 10. Supplier S.O. #:
N/A 45600254870 001 N/A N/A 52-9204
- 11. Materal Specification:
- 12. Rev:
- 13. Drawing No:
- 14. Rev:
- 15. Basic Component N/A N/A 6D31204 0
Yes 09 No IN
- 16. ASME Code Section:
- 17. ASME Code Class
- 18. ASME Code Edition and Addenda:
- 19. Code Cases:
N/A N/A N/A N/A
- 20. Item Name:
- 21. Part Number:
- 22. Quantity Released:
Calibration Block N/A 1
- 23. Serial Number:
- 24. Heat Numbers:
- 25. Other:
SAP 105799 Heat Number 51142D-02 N/A Trace Number 22539 The attributes listed below were reviewed and approved by Quality as noted by an A" In the status column. "N/A" indicates Non-Applicable items. Records are available for review. Contingent items are identified by a "C" In the status column and are explained In the Remarks section.
Status Status Status A
A Supplier C of C A
Cleanliness N/A ASME Data Report Form(s) Attached 0 u
A Material Certifications N/A Operating Electrical Test Records N/A Certified Stress Report d
I N/A Heat Treat Records N/A Non-Operating Elec. Test Records N/A Special Handling, Storage, Install Instruct.
N/A RT Film and Records N/A Pressure Test Records N/A Instruction Books h
WA PT Records N/A Seat Tightness Test Records N/A Westinghouse C of C 0
N/A MT Records WA Performance Test Records N/A Westinghouse C of Q k
N/A UT Records N/A NDE Personnel Qual. Cert.
A TSI Data Package I
A Visual Inspection Records N/A Painting A
Dimensional Inspection A
Packaging Customer QA Data Package Required? 0 Yes or [I No
- 27. Contingent QR
- 28. Deviation Notices
- 26. Remarks:
[ Yes or 10 No 0 Yes or 0 No iR Released for Shipment to the WesDyne International, LLC, Waltz Mill Site, Madison PA.
List Applicable DNs:
m a
r kIS (Copies are attached to this document.)
Weslnghouse Electric Company LLC Quality certfies that for the equipment and material released, oil
- 29. Supplier-contractual quality requirements have been met.
The equipment supplier has certified that the equipment above meets all requirements of the purchase Tolling Specialists, Inc.
order, dreedngs and specifications. Westnghouse has reviewed evidence supporting this release and, rept as specified above, has detected no devrations from such requirements. This release does not 30, Suppl r Signature:
- 31. Date:
verve any rights Westinghouse may have under the purchase order, including Westrighores ight
.tol Jh I
reject the equipment upon dicovery of any such deviations after arrival at destination
)(
02-11-08
- 32. 0 This order has been processed in accordance with the Westinghouse Quality John Kunicky 02-11-08 Management System (QMS) Revision 5 dated 10-1-02.
- 33. C1 This order has been processed under the Westinghouse ASME Code Program l
(WCAP)-1 2308) Revision dated
. Westinghouse ASME Certificate inghouse Quality R N-11 49 (expiration date
)applies.
SPECIALISTS k~l.
IXORPORATED MACHINE TOOL BUILDERS -
SPECIAL MACHINING -
DIES -
ENGINEERING SERVICE P.O. Box 828, LATROBE, PA 15650-0828 Phone (724) 539-2534 FAX: (724) 537-4960 CERTIFICATION OF COMPLIANCIE February 11, 2008 Westinghouse Electric Corporation Nuclear Energy Systems P.O. Box 355 Pittsburgh, PA 15230 Gentlemen:
This is to certify that the products shipped to you, per the information fisted below, comply to the requirements of this order. All required tests and inspections have been performed. Documented evidence of compliance supporting this certification is available at our facility for review.
Items have been manufactured and inspected I.A.W. Tooling Specialists, Inc. Quality Assurance Program Manual Rev. K dated 03/27/98, which meets the requirements of ASME NCA3800 and the applicable portion of IOCFR50 Appendix B, as audited and approved by Westinghouse on 04/27/07.
Westinghouse Purchase Order Number:
4500254870 NSDN Number:
N/A TSI Shop Order Number:
52-9204 Westinghouse Q.R1 #: a8e-e, -
tz o
==
Description:==
PO Item 001, (1) Each, Calibration Block for Ft. Calhoun, Per 6D31204 Rev 0 SAP #: 105799 ery truly yours, Quality Assurance
Tooling Specialists, Inc.
P.O. Box 828 Latrobe, PA 15650 Material Release N!
1 6 9 8 6 Work Order No:
Purchase Order No.
Q.C. Release:
Customer:
c4-,& 4)
'(Signature)
(Date)
Cust.'s O.C. Rel. No:
Date:
Customer Furnished Material:
Customer's Q.C. Rel. Representative Yes (X)
No ( )
Material Specification:
Material
Description:
Material Supplier:
Order No:
Heat No:
Special Test No:
.5"-//5.,2 <0 -.
.no-a.
Material Quantity Released:
Material Weight Released:
Drawing No:
==
Description:==
Item No:
==
Description:==
No. of Pieces Required:
/
Make:
(piece-)
Drawing No:
==
Description:==
Item No:
==
Description:==
No. of Pieces Required:
Make:
/
(pieces)
Drawing No:
==
Description:==
Item No:
==
Description:==
No. of Pieces Required:
Make:
Remarks:
REF: WORK ORDER CONTROL SHEET-REV.
TSI FORM 184 REV. 1 (2-7-96 HF)
900 INDUSTRIAL DRIVE /1 CLINTON, NC 28328 Certificate of Conformance/Compliance/CMTR
'I/
Customer:
WESTINGHOUSE ELECTRIC CO.
WESDYNE 1-70 MADISON EXIT S4 GATE-D MADISON, PA 15663 Description Item Pieces Specification 5
3 1/4" THICK X 16" X ASTM B168-01 Date 7/28/04 Serial No.
217215 D Our DC No.
217215 This material meets the requirements of your PO number 4500142038 Grade/Type 24" PLATE N06600 HRAP ALLEGHENY Heat 4 /
Heat Code 511420-02 COIL#
04204N084 TR# 22539 LTI This material..has been supplied in accordance with DuBose National Energy Services, Inc. Quality System Program Rev.0O, dated 01-08-02 in compliance with IOCFRSO APP. B.
The contents of the report are correct and accurate and the results are in compliance with the material specification, the code, and the customer purchase order.
10CFR21 APPLIES DEDICATION PERFORMED IN ACCORDANCE WITH DNES QUALITY SYSTEM PROGRAM THIS MATERIAL SHIPPED FROM AN APPROVED VENDOR.
PHYSICAL INSPECTION PERFORMED BY THAT DNES APPROVED VENDOR.
Date L,
PA " - 0 vi
'Tre-pp Form D-19 Rev. 7
C2 0.
0 (44 a
CD 0
L, U)
C',
Lo 0i) +
I Co.
0 0
-'4, NOTICE OF 814PRAF.WT
.WATA IdI.
CERTIFICATE OF TEST PACMGO UST
- tIIAdnG2=
T47483 02/0/04 773550BRAC-KEt4IDE, PIAJ101620 131020101,060000 152-024-058 0//4
~~1i~~~m 1~
Ti
-1 12354 IfR~vDtr~IPA 1333 SOLD TO PRIME SEC.
SHIP TO ROLLED ALLOYS INC.
DSO DSO ROLLED ALLOYS INC.
P.O.
BOX 310 594 125 WEST STERNS ROAD TEMPERANCE MI 48182 TEMPERANCE MI 48182 TRACER#
122 1-GRADE AND SPECIFICATIONS CARRIER - P.I.
& I.
MOTOR EXP.FINC.
"ALTEMP"
- ALLOY, "AL 600" PLATE-HOT ROLLED COILS AMNEALED PICKLED 3 EDGE --
(ANS 5540L) (ASME-SB-168 A02 NON-DDQ)
(ASTM-B-168-01)
(S-1000 REV E)
(S-400-E}
(AMCI-1 REV A)
(UNS R06600) --
TWO GOOD SIDES REQUIRED ITEM PCS DIMENSIONS W/GIL 001A 1 48./.250/1.
C CUST IDENTITY 125022740021 1
SKID HEAT f COIL #
511420 -02 04204N084 TEST f GROSS 3701172 11175 11175 TARE NET THEO 50 11125 50 11125 TAG Of CD SKID 010363.
GAUGE TOL: + 0.01500 0.01000 TYPE HEAT/TEST
-- C--
.MN--
-- P
-- S-.
.SI-- -- CR--
-- AL-- -- CU-- -- CB-- -- TA-- --. TI--
HEAT 511420-02
.05
.24 IO
.010
.0001
.19 16.19 73.34
.17
.01
.04
.003
.17
-- CO--
-- tFE--
HEAT 511420-0,2
.06 9.27 YIELD TENSILE *. ELONG GRAIN rTE1 TEST NO PSI PS1I5 IN22--
% A/A HARDNESS SEND SIZE HARDENABILITY 001A 3707172 T 48600.
96500.
- 42.
85.HRB T PASS 7.
Y.S.
BY 0.2% OFESET METHOD WESTINGHOUSE 0thSOSE MELT A REVIEW ITEM TEST NO SOURCE MACROETCH PON 4500142038
- SFACTORY, 001A 3707172
- 1.
FASS IT# S PASS METALLOGRAPHIC MAGNIFICATION:
0O0X ETCHANT USED: HC1/NITRIC/ACETIC MIXED ACID I
AXE PAGE 01 -
CONTINUED ON PAGE 02 05/17/04 13:11:19 a oc" t m two IUUrUSU
- 1.
Do cmws ecw on N.
9.--;
-rl 7t i 9 3 c) 1 0
0)bb tx 0
ul)
U, m
0 0)
-4
+
02 0D Cl AL DIISA? at KOaiCE OF SHIPMMNI Ar RIPATOFTS PACKMIN UST
- AnICEIInCAE OF TEST I
A%00.I I I
T47483 02/02/041 77.3550 1PC~R
'9E, P'A 14031620 131020).01060000 1B2-024-058Os1/4
~ 1'tF'~i I176573-2 1IO Y 12354 IDRACKENRIDGE IPA 1033631 SOLD TO PRIME SEC.
SHIP TO ROLLED ALLOTS INC.
DSO 030 ROLLED ALLOYS INC.
P.O. BOX 310 584 125 WEST STERNS ROAD TEMPERANCE MI 48182 TEMPERANCE MI 48182 GRADE AND SPECIFiCATIONS CARRIER - P.I.
& 1.
MOTOR EXP.,INC.
- ALTEMP" ALLOY, hAL 600" PLATE-HOT ROLLED COILS ANNEALED PICKLED 3 EDGE --
(AHS 5540L)
(ASNE-SB-169 A02 NON-DDQ)
(ASTM-B-168-01)
(S-000 REV E)
(S-400-E) (AICI-l REV A)
(UNS N06600)
TWO GOOD SIDES REOUIRED --
ALLEGHENY LUDLUM DOES NOT USE MERCURY IN THE TESTING OR PRODUCTION OF ITS PRODUCTS.
TO THE BEST OF ALLEGHENY LUDLUMS KNOWLEDGE, UNDERSTANDING, AND BELIEF, THIS MATERIAL WAS HOT CONTAMINATED SY MERCURY WHILE IT WAS BEING PRODUCED IN OUR FACILITIES.
DuBOSE EQUIPMENT, MATERIALS AND SERVICES ARE OF U.S.
ORIGIN WESTINGHOUSE 4ATREVIEW NO WELD REPAIRS.
IT#
5 S1B 0L NITIt DATE THE MATERIAL WAS HEAT TREATED AT APPROPRIATE TEMPERATURES TO MEET THE DESIGNATED PROPERTIES Or THE REFERENCED SPECIFICATION.
7HE NUMERIC COP*E SHOWN UNDER MELT SOURCE CAN BE INTERPRETED AS FOLLOWS:
R1.E AILOYL=g1A111ASSUMJR
- 1.
DOMESTIC MELT AND ROLLED
- 2.
FOREIGN MELT AND DOMESTIC ROLLED
- 3.
FOREIGN MLT AND ROLLED DATE THIS CERTIFICATE OF TEST SHALL NOT BE REPRODUCED EXCEPT IN FULL.
MATERIAL WAS MANUFACTURED IN ACCORDANCE WITH THE ALC QUALITY MANUAL REVISION 13 DATED 07/07/2003.
EN 10204 -
3.1B ALLEGHENY LUDLUM Is APPROVED AS A MANUFACTURER ACCORDING TO AD-MERKXLATT WOITRD 100 AND ThE PRESSURE EQUIPMENT DIRECTIVE P6D 97/23/EC.
TESTING WAS PERFORMED AT ALC MAOCAP AND ISO/IEC 17025 APPROVED LABORATORIES LOCATED AT TECHNICAL CENTER -
NATRONA HTS, BRACKENRIDGE, AND LEECHBURG, PA FACILITIES OR A NADCAP AND ISO/IEC 17025 ACCREDITED LABORATORY.
ISSUNgD BY ALLEGHENY LUDLUM S/17/04 14i
07/28/04 14:21 PAX1 Boo 21g90ggq LAB TrESTING DUBOSE 0001 IMII ORATORY I
TESTING INC.
2331 Tbpaz Duive, Hatfield, PA 19440 TEL-800-219-9095, FAX: 500-219-IC SOLO TO Oubose National Energy Svcs.
P.O. Box 499 Clinton, NC 28328 9 70 W1ý6 ý ý j 4 ý DSIDOI 07-18531-1
~,,tVCUrO1.ULW~4 W&W, TWkq uwnn WVT Pq ME A Lq)
HIP TO.
Westinghouse FJec. Corp.
Off 1.70 Madison Exit 54 Gate-D Madison, PA 15663 AT'tN: Mark Weatherly (QA)
CUT210MR P.O.
53629-65 CERTIFICA IONPAATE 07/28/04 SHIP ViA Customer Pick~-Up 3 pos.
I PC.
1 PC.
%1/4 Thick x W6Vide x 25' Lopg Plates, ASTM B-168, UNS N06600, Alloy 600,'Heat #511420-02, Coil #04204N084., Trace #22539, -
PO item M5, DC #217215, Vendor - Rolled Alloy, PO #53528-6
'" Sch. 80 x 6'0" Long Pipe, ASTM B-1 67rJNS N06600, Alloy 600, Heat #905018, Trace #2254" rPo Item 92, DC #217216, Vendor -
Prudential Stainless, PO #53530-65 V4' Sch. 160 x 4' 0" Long Pipe, ASTM B-167, UNS N06600, Alloy 600, Heat #08B2906,"lrace #22541, PO Item #1, OC #217216, Vendor -
Prudential Stainless. PO #53530-65
Reference:
Customer-Westinghouse Electric Corp., PO #.4500142038 Three pieces of the above material (PLATES-TRACE #22539) were 100% Ultrasonically Inspected for laminations only In accordance with Customer's Instructions using L.T.I, Procedure UT-V-L, Rev. 0, dated 3/28189 and (3) pieces were found to be acceptable to those requirements.
Testing performed by Mark Tiemey, SNT-TC-1A, Level I(1.
Two pieces of the above material (PIPES-TRACE #22.540 & #22541) were 100% Ultrasonically Inspected for laminations only in accordance with Customer's Instructions using L.T.I. Procedure UT-VZLý Rev. 0, dated 3/26f89 and (2) pieces representing (7' 4") were found to be acceptable to those requirements.
Testing performed by Mark 7-emey, SNT-TC-IA, Level Ill.
IWESTIIIGOUSE P~O#
41500142038 IT# 1,2 & 5 Page 1 of 3
07/2 8/04 14:21 RUl 800 21fl 9096 LA 72STING D
IUBOSE Q__
00O2
/3QILAWORATORY
__.JTEISTING INCa DSI001.04-07-18531 -1 b
101741.Aa. N lKt ('. UT. AT. uV 2331 Topaz Drtve, Hatfialdi, PA 1 944U)
TEL 8OG-219.S9095 a FAX; 8O0-219-9090 One piece of the referenced samples (PLATE) was subrhitted to chemical content evaluation and It was found to be In conformance to ASTM B-168. UNS N06600 with the following results:
ELEMENT C
REQUIREMENTS MIN 0.
0.15 Cr 14.0 Cu 17.0 0.5 10.0 1.0 TRACE
- 753ý 0.04%
16.5%
- e0.1%
9.0% "
0.3%
74.5% "
<0.001%
0.2% -
Fe Mn 6.0 NI 72.0 S
Si 0.015 0.5 WESTINGHOUSE PO# 4500142038 rT# 1,2"9 5 Two pleces of thQ referenced samples (PIPES) were submitted to chemical content evaluation and (2) pieces were found to be In conformance to ASTM B-167, UNS N06600 with the following results:
REQUIREMENTS
... -- TRACE -M..
ELEMET*IT C
Cr Cu Fe Mn Nj S
SI MIN 14.0 6.0 72.0 MM~
0.16 17.0 0.5 10.0 1.0 0.015 0.5 0.01%"
15.4%
0.2%
8.4%-'
0.2%
-I 75.0%
<0.001%"
0.2% -"
- 2_2541 0.03% -
16.0%I
<0.1% "
9.4%--
0.3%'""
73.4% -
<0.001%
0.3% -
A Tensile-test was performed on (1) piece of the submitted Test Specimens (PLATE) and It was found to be in conformance to ASTM 8-168, UNS N06600, Hot Rolled, Annealed & As-Rolled with the following results:
TRACgNO.
REQUIRED - ANNEALED REQUIRED. AS.ROLLED TENSILE STRENGTH YIELD (.2%)
3TRENGTH ELONGATION (IN 40)
OD SPECIMEH SIZE 80,000 PSI 35,000 PSI 85,000 PSI 35,000 PSI 30%
30%
22539 99,000 PSI /
49,700 PSI 44% -.
0.1606" Page 2 of 3
07/28/04 14: 21 FAX 800 219 909D LaB T*STrNG DUBOSE Q003 ABORATOR DSi001-04-07-118531-1 TESTING INC.
2331 Topaz Drive, Hatfield, PA 19440 TEL 800-219-8095, FAX: 800-219-909e CatIOUT-@1 ~
G4 U¶ ptt REI.
UPD Tensile test was performed on (2) pieces of the submitted Test Specimens (PIPES) and (2) pieces were found to be in conformance to ASTM B-167, UNS N06600, Hot & Cold Worked, Annealed with the fol(owing results:
TENSILE YIELD (.2%)
STRENGTH ELONGATION (IN Z OD x WALL THK.
SPECIMEN S19E TRACE NO.
REQUIRED - HOT REQUIRED - COLD 80,000 PSI 30,000 PSI 80,000 PSI 35,000 PSI 35%
30%
22540 22541 96,000 PSi 95,000 PSI 43,'800 PSI 43,700 PSI /
47%
1.0485"xO.1470" 50%
1.0510' x 0.2170" WESTINGHOUSE
ýPO#
45001420.38 IT// 1,2,& 5 FINAL SHIPPING QUANTITY; 3 pcs.
3 pcs.
2 pcs.
%" Thick x 16' Wide x 24" Long Plates, Trace #22539 I" Sch. 80 x 12" Long Pipes, Trace #22540 I° Sch. 160 x 12" Long Pipes, Trace #22541 The above material was processed in accordance with Laboratory Tafting, Inc. Procedure No. QC-I.-MC, Rev. 4 dated 12/13101.
The provisions of 10CFR21. 10CFRSO, Appendix B and NCA-3600 apply to this order.
All testing performed in accordance with L.T.I. CA Program Rev. 16 dated 9/1101 as audited and approved by Ou~ose National Energy Services, Inc.
The se*'eiso performed above were dlone In accordance with LTI'a Quality Syatem Program Manual Revision 1I dfad 9/1/01 and ISOll1C Guide 17028. These rubu. rIelate only to the items tested and this report stall not be reproduced. except In full, without tie wit!en apRrovMl ol Laboratory Toftl,. Inc. LTJ. is accredliad by A21LA In me Chlemical, Mechanical and NondestuJctive Fields of Tesdng. LT.]. is ac=redfted by NADCAP In the Matertal's Testing and NOT. MT. PT, RT and UT.
MERCURY CONTAMINATiON: During the tatrig and inspecton, fte product did 10 come In d(ract =nact wth rmercury or any of It compounds nor with any MrG*ury containing devkcs employing a slgte boundary of contatnment.
NOTE; The recording of faite, gclitflouS or frauduwent taternenUt or nitfies on lhLt docurnent May be punished as a fodony iunder Federal Statutes including Feieral Law, TIta 18, Chapter 47.
Donald J. DiFillppo QA Manager Sy.
"B Page 3 of 3
07/26/04 14:21 PA ag0 219 9096 LAB TESTING DUBOSE Q004
/JJLABORA70RY TESTING INC.
2331 Topaz Drive, Hatfield, PA 19440 TEL: 800-219-9095 - FAX: 600-21gg-096 Ct(E~h1,4.@.U.*
Msu, Td ULTRASONIC INSPECTION REPORT
'1 ~'
'2 CUSTOMER Oubose National Energy
-CUSTOMER P.O.; 53529-65 LAB NO.:' DSO11-04-0T-18531-1 DATE RECEIVE:
07/26/04 QTY RECEI'VED: 3-
-s ACC.: 3xcs.
REJ.: 0 APPROVED TEST PROCEDUm:-
APPLICABLE SPECS:
(JU7-V-L. Rev. 0. dated 3128/89 Cusbomer's lnstruclorts (No Lamlnatons)
DESC UPTION4 OF MATERIAL? STAGEif OF MATER~IAL AT TIME OF TEST-.
'A' Thick x 16" Wide x 24' Long Plates. ASTM 8-168. UNS N06600. Alloy 600, Host #511420-02, Coil #04204N084, STrce¢ #VS*39, PO RtemT #5 M
rEST 'OtR. SURFACE Lon Me or IMODE ANGLE 3.8.B 0*
E.QU IP.. &MFG:
Krau'dmarer OuSOSE WSTNfOUSE IMODEL NO.:
USN-62R SATI'SFACTORY
,POQ 450014'2031 SERIAL NO.;
O07NHC iN-"r__.__
IT# 5 TRANS. MFG.:
Hafsonlo MODEL NO.:
CM0512-S SERIAL NO.:
920396 SIZE:
.750' 0ia.
FRMQ.
IAIN (d8) 5 MHz 1 49 CABLE LENGTH: W CAUBRATION NO.,:
N/A CAUBRATION STD FINISH:
NIA TYPE:
RG-.174 DESCRIPTION; Production Material DAMPING CONTROL-REJECT CONOL.
PRoDUCTION FINISH:
I IMMERSION 0
0
<250 RMS CONTACT 3
LuAC-=C 7s)
SCANNIN Sp:
COUPLANT:
REFERENCE LEVEL:
R -xosen*20 80%
F.S.H, AREA GATED:
RECORDING EQUIP. (IF U'SED):
N/A N/A NIA AUDI'OMALINFORMATION (IF NEC$SeAR8)*i' "ATE OF INSPECr ON:
07f27/04 ULTrASONIC INSPECTOR-TIME OF INSPECTION:
4.00 pm PAGE 1 OF 3
07/28/04
.14:21 FPA 800 219 9096 LAB TESTING 4 DUDOSE
_005 T IILADORA TORY LJLTESTIG INC.
2W33 Topaz Drive. Hatfleld, PA 19440 r.,um nl U"M" TEL: 800-219-9095 - FAX: 800-219-9096 UT-TECH1.4 ULTRASONIC INSPECTION REPORT CUSTOMER:
OubOSe Nalonneyr CUSTOMER P.O.: 53529-"5 LAB NO_:
DS1001-G4-07-18531-1 DATE RECE1VED; O7/26104 QTY RECEiVED: 1 K.4' 8")
ACC. 4' 8" REJ,; 0 APPROVED TEST PROCEDURE:
APPUCASLE SPECS:
UT-V-L, Rev. 0. datad 3=28/89 Customer's Instruonors (No Laminations)
DESCRIPTION OF MATERIAL I STAGE OF MATERiAL AT TIME OF TEST:
Y- -Sch. 80 x 4 8* Long Pipe. ASTM 8-167. UNS N066aO, Altoy 600. Heat #905018, Trace #22540, PO Item #2 TEST DIR.
SURFACE Radial 1
0 1
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FWESDylnE I HTOE R NAT 1 0AL Projects & Application Engineering Appendix 10 Eddy Current Inspection Procedure: WDI-SSP-1 150, RO "Eddy Current Material Characterization along ID Surface on RPV Nozzle Safe End DM Weld at OPPD's Fort Calhoun Station" OPPD Fort Calhoun RPV Outlet Nozzle-2008 Outage Material Characterization for DMW-Final Report Page: 95 of 95
LIC-1 1-0004 PVP2010-25984 "Determining the Onset of Stress Corrosion Cracking in Austenitic Stainless Steel with Permeability Change" Presented at ASME K-PVP Conference, July 18-22, 2010, Bellevue, Washington
Proceedings of the ASME 2010 Pressure Vessels & Piping Division / K-PVP Conference PVP2010 July 18-22, 2010, Bellevue, Washington, USA PVP2010-25984 DETERMINING THE ONSET OF STRESS CORROSION CRACKING IN AUSTENITIC STAINLESS STEEL WITH PERMEABILITY CHANGE Dr. Bob Lisowyj RE. C.Eng. FIMMM Omaha Public Power District Omaha, Nebraska, USA ABSTRACT After two decades of operation, austenitic stainless steel Control Element Drive Mechanism (CEDM) seal housings at a Pressurized Water Reactor (PWR) nuclear plant experienced Transgranular Stress Corrosion Cracking (TGSCC).
In order to prevent the same cracking from occurring at the Fort Calhoun Nuclear Plant, a preventative program was initiated in 1999. All 37 CEDM seal housings have been inspected by using WesDyne Intraspect pancake and plus point eddy current probes.
Examination of the eddy current data found that TGSCC was associated with localized areas of higher permeability (confirmed with a magnetometer).
In order to quantitatively analyze the data, the normalized value from signal amplitude was defined as the arithmetic ratio between the absolute measurement of local permeability value (amplitude) and the eddy current signal value (amplitude) for the calibration standard axial notch. The data showed that in failed seal housings the normalized amplitudes were about three times greater than in non-cracked housings. Higher permeabilities were associated with cracked locations.
The eddy current methodology therefore provides an empirical criterion to monitor when locally higher surface material permeability changes occur in order to determine the onset of TGSCC.
INTRODUCTION Stress Corrosion Cracking (SCC) consists of two stages, an incubation stage followed by a crack propagation stage. The crack propagation stage can be determined fairly accurately by using Arrhenius energy values.
However, the incubation stage can take long periods of time (20 years is not uncommon), and is far less predictable with no indication of how incubation is Zoran Kuljis Principal Engineer Westinghouse Windsor, Connecticut, USA progressing. Currently, there is no method for assessing when the transition from incubation to cracking will occur, or if it is occurring. Stress corrosion cracking is therefore difficult to control and is usually found only after through-wall cracking has produced a leak.
This problem is particularly applicable to stainless steel and inconel alloys in the Reactor Coolant System (RCS) where risk assessments are more critical to safe plant operations.
In the nuclear industry, SCC has occurred in inconel alloys and stainless steel alloys. However, at Fort Calhoun Station, the specific areas of concern were the 304 stainless steel CEDM seal housings. These seal housings contain the control rods, which are used for reactivity control during reactor start-up and operations.
The control rods provide a means for rapid reactor shutdown when limiting conditions are reached. Fort Calhoun Station needed to assess the status of its own seal
- housings, and decide whether preventative replacement was necessary or cost effective.
The inspection goals were to: define the material condition, and to reduce operational risk by better understanding the incubation period prior to the onset of SCC.
Eddy Current Testing (ECT) was chosen as the NDE technique, because of its high sensitivity to surface changes.
In fact ECT is hampered by material permeability variations, which challenge the detection capabilities of a sensor by limiting the resolution of flaw signatures. It is this ability to find permeability variations that has made ECT so promising in characterizing the SCC process.
ECT acquisition and impedance output is proportional to field driver orientation, sensor pickup type, probe lift-off, and the voltage/frequency settings.
Material conditions I
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such as surface effects from cold working may cause the production of martensite or material non-homogeneities, both of which can be detected by ECT.
Tool Access Plug Tool Access Tube
-Drive Shaft j
Motor Drive Vapor Seal Seal Housing Inspection Area Leak-Off Port Mechanical Seals Cooling Jacket Figure 3. Appearance of CEDM Seal Housing (lower opening next to dowel pin is CEDM housing, upper 4
Lower Flange opening is tool access housing) j Drive Shaft Figure 1 shows a schematic representation of the CEDM
. Support Tube seal housing. The ECT inspection area is circled. The temperature in this vicinity was estimated at 150° F to "a
Upper Housing 2000 F. The CEDM seal housings are relatively stagnant with no flow during power plant operation.
Figure 2 is a representation of the material properties Reactor Coolant and physical dimensions of the CEDM seal housings.
Figure 1. Schematic of CEDM Seal Housing The CEDM seal housing is made from forged and heat treated ASTM A-182 Type 304 stainless steel. A J-weld next to the CEDM seal housing places the ID surface of the housing under the requisitory tensile load for SCC to originate.
Figure 3 is a photograph of an actual CEDM seal housing. The dowel pin is used as a reference point for the collection of ECT data. The internal diameter of the CEDM housing is 2.063".
LABORATORY MATERIAL INVESTIGATION Failed CEDM seal housings were sectioned at the EPRI NDE Center and then sent to Battelle Pacific Northwest Laboratories for an Analytical Transmission Electron Microscopy (ATEM) and Scanning Electron Microscopy (SEM) study. Prior to sectioning, ECT was performed on the housings, and four zones of high permeability were 0-,,..M So-found with all the cracking being associated with these AS"M V~d zones of high permeability. The work at Battelle Pacific
,*,rM SA:3 TNorthwest Laboratories focused on identifying aging-induced changes of the material responsible for the ECT indications.
Microstructural characterizations were AS°M712 F-30performed at varied depths below the inner surface (ID
-oc T
.-..r..,
surface) on several different samples from regions with and without indications.
SEM examinations were also Figure 2. Material and Physical Dimensions of CEDM performed on samples that contained an axial crack.
o(*I Ui.,.-.
Seal Housing.
2 Copyright © 2010 by ASME
The SEM examinations showed that the general microstructure consisted of equiaxed grains with sizes from 20 pm to 100 pm. The grains and grain boundaries were clearly defined by crystallographic orientation contrast in the SEM/BSE (Backscattered Electrons) images.
Up to 30% of the grains contained annealing twins, recognized by their straight-edged or zigzagged shapes within the normal grains.
The observations indicated an annealed, unstrained material with a -50 pm wide layer of deformed material along the ID surface.
Apart from widely scattered metallurgical inclusions in the alloy, the microstructure revealed by SEM contained no significant second phases and was precipitate free along the grain boundaries.
There was no microstructural difference between the regions with or without ECT indications.
Three SEM panels in Figure 4 show the entire crack along its -2,000 pm length (0.08") from the ID surface of the CEDM housing.
Small metallurgical inclusions appear by using average atomic contrast.
This micrograph shows the transgranular character of the crack and the branching along its length. An oxide-filled notch was found at the crack initiation point on the ID surface. However, the surface oxide was not preserved in the TEM cross-section samples.
SEM/EDS (Energy Dispersive X-ray Spectrometry) of the inclusions in the CEDM housing were identified mainly as MnS (Manganese Sulphide). The analyses also found a few spheroidal 0.5 to 1.0 pm diameter particles of 6-ferrite in the body centered cubic (bcc) structure alloy regions with nickel below the stability range for the face centered cubic (fcc) austenitic matrix structure. Minor 6-ferrite is commonly produced in austenitic stainless steels during alloy processing. Based on image areas in the SEM, the maximum volume fraction of inclusions in the CEDM housing was estimated as 0.2%.
SEM/EDS examinations also showed that areas of the transgranular crack were filled with chromium enriched (relative to the alloy matrix) iron chromium nickel oxide containing other impurities.
Figure 5 shows an oxide filled region of the crack as well as the tendency of the crack to fine scale branching. The impurities varied locally at different points along the crack, but included sodium,
Examples of the SEM/EDS spectra are given in Figure 6. The top spectrum with chloride came from near the crack tip, and confirms that the transgranular cracking of the CEDM housing is chloride induced. However, the chloride was observed only in a few spots, and sulphur was a more common impurity in the crack oxide. The bottom spectrum was typical of the EDS analysis away from the crack tip.
Figure 4. Typical Transgranular Cracking in the CEDM Seal Housings.
Figure 5. Oxide F Scale Branching gion with Cracking and Fine 3
Copyright © 2010 by ASME
in the near-surface regions. No significant microstructural differences were seen in the regions with or without ECT Fe Cr Fe eindications.
The shallowest regions of the deformed layer examined by ATEM in this study were 50 pm from the surface, Gt Ni which is significantly less than the sampling depth of the C SiECT
(-1,000 pm).
It is therefore possible that Sl K,
T transformed structures close to the surface might have Al ^ p Tiescaped observation.
Detected chloride near the crack tip supported a
mechanism of TGSCC caused by impurities in low oxygenated water in the stagnant CEDM housing space.
Fe CrC eFe Si S
~Ni Ni Figure 6. SEM/EDS Spectra. Top Spectrum from Near Crack Tip. Bottom Spectrum Away from Crack Tip.
ATEM microstructural characterization in the base metal outside of the locally strained regions along the ID surface found a structure of equiaxed grains with an austenitic structure, low densities of dislocations, and precipitate free grain boundaries.
No significant second phases such as carbides or martensite, and rarely any &-
ferrite was found in the base metal. Selected Area Electron Diffraction confirmed the matrix structure was Figure 7. 6-Ferrite in Austenitic Matrix.
fcc. There was no evidence of any weld microstructures or precipitation that might be expected in the heat-affected zone from welding. Figure 7 shows an example of 6-ferrite in the austenitic matrix with a distinctive diffraction pattern from the bcc ferrite given in Figure. 8.
EDS analyses of these particles in the ATEM gave an 9
average composition of 0.5% silicon, 28.45 % chromium, 1.6% manganese, 4.8% nickel and the remaining balance was iron.
The matrix composition was 0.6% silicon, W
20.2% chromium, 2.0% manganese, 9.2% nickel, with the remaining balance being iron.
ATEM cross sections were also produced to study the near surface microstructures with samples ranging from 50 pm to 700 pm below the ID surface. Figure 9 gives Figure 8. Selected Area Diffraction Pattern from 5-examples of dislocation structures near the ID surface Ferrite [011].
and 700 pm below the ID surface. No deformation twins, martensite, or other transformation products were found 4
Copyright © 2010 by ASME
To date, little change of permeability has been observed in the retested Fort Calhoun Station housings. During the 2008 outage, the eight highest normalized ECT CEDM seal housings were retested to find out if any changes in permeability were occurring.
No cracking was found at any of the Fort Calhoun Station CEDM seal housings, and the normalized permeability values were unchanged.
This lack of change shows that no active progression towards TGSCC failure was occurring in any of the CEDM seal housings at Fort Calhoun Station. This data also provides good justification for less frequent examinations at Fort Calhoun Station.
The almost identical CEDM seal housings at another plant failed after 19 years of operation.
It may well be that the failed CEDM seal housings contained initially higher, localized permeability values, however the advantage of this methodology is that it provides a mechanism for tracking the change in permeability with time and finding areas that are susceptible to SCC. The change in permeability at the plant that had failures in their CEDM seal housings would have been a good indicator that incubation was progressing, and that SCC failure was likely. This is the essence of the proposed methodology, which provides a way of enhancing plant safety by predicting SCC susceptibility, and avoiding early and costly replacement of expensive plant components resulting in savings and productivity increases.
The methodology is fully transferable to other plants.
Figure 9. Dislocation Structures Near Surface (right) and 700 pm Deep (left) in the CEDM Seal Housings.
FORT CALHOUN STATION PROGRAM A voluntary program at Fort Calhoun Station using WesDyne Intraspect pancake and plus point ECT technology was started in 1999.
In order to directly compare local permeability, normalized pancake ECT values have been used. The normalized value is defined as an arithmetic ratio of the absolute measurement of local permeability (amplitude) to the ECT signal value (amplitude) for the same characteristic calibration standard notch.
The same axially oriented notch was used for all the Fort Calhoun Station measurements, and on the failed CEDM seal housings. For the permeability measurements a lower frequency (100 kHz) was used because it is more sensitive to local permeability changes.
All 37 Fort Calhoun Station 304 stainless steel CEDM seal housings have been inspected by the ECT methodology since 1999 (see Figure 10).
The raw pancake coil data for cracked and uncracked housings is shown in Figures 11 and 12.
No indication of cracking was found in any of the housings or nozzles at Fort Calhoun Station. The highest normalized ECT value from the Fort Calhoun Station housings is less than half the ECT normalized value from cracked housings at another plant (see Figure 13). If any normalized ECT values at Fort Calhoun Station were to show a progressive increase, then that housing would be recommended for replacement by an available Fort Calhoun Station spare rigure wu.
vvesuyne iniraspeci iesung r-quipmeni at Fort Calhoun Station housing.
5 Copyright © 2010 by ASME
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CEOM Seal Housing Normalized Permeability Effect on, Eddy Current Signal On high permeability
- plant I 4W0i'ti~
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Correlation Between Area of Cracking and High Permeability Pancake ECT Display.
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Permeability Ele-t on 4 Eddy Current Signal -
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Zone with Dectected Degradation Figure
- 13.
Schematic Comparing Normalized Permeability Changes with Location in CEDM Seal Housings for High and Low Permeability Plants.
MAGNETOMETER STUDY In order to confirm that the source of the high signals from ECT pancake testing of the CEDM seal housings was due to increased permeability, further data was taken using a magnetometer. A Foerster Magnetoscop 1.069 magnetometer read the relative permeability values in the critical surface area, which is the area where detectable degradation was found.
This area (zone) is shown in Figure 13 and represents the surface area 0.5" to 1.5" below the flanged surface of the CEDM seal housings. All the detected cracking has been found in this area.
Figure 14 and Figure 15 depict a 3-D plot of the relative permeability (Pr) across the surface of CEDM seal housings with low and high permeability.
The high permeability trace in Figure 15 was obtained from the CEDM seal housing with TGSCC.
The relative permeability was -30% higher in Figure 15 than in Figure 14. Note, higher permeability spikes are visible in Figure 15 at the area 0.5" to 1.5" below the flanged face
£.w4p*f01UMAWAMD Figure 12.
Correlation Between Low Permeability Pancake ECT Display and the Incidence of No Cracking.
6 Copyright © 2010 by ASME
of the CEDM seal housing.
The higher permeability spikes found in the magnetometer study are in the same location as the higher permeability areas found in ECT and displayed in Figure 11. The magnetometer traces conclusively show that the high values from pancake ECT are produced by higher permeability.
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concentrations, and no areas of martensite, which could explain the high permeability detected by ECT.
However, surface oxidation will alter the orbital spin in materials such as stainless steels and inconel alloys creating magnetic dipole alignment. This local magnetic dipole change at the surface of the 304 stainless seal housing would change the material from a paramagnetic to a ferromagnetic state. The zones of ferromagnetic surface layers found by ECT are anodic areas from which SCC will initiate. All cracking has been found to emanate from these anodic, high permeability areas.
The mechanism of transitioning to a ferromagnetic state is described in Reference 1.
Further work is clearly necessary to fully understand why ECT pancake testing finds high permeability areas in stainless steel housings, which are indicative that SCC is initiating.
A major benefit of the described technology is the simplicity and speed in performing SCC assessments, which make it a very valuable material tool.
CONCLUSIONS A methodology is presented for early detection of SCC in vulnerable components by using a correlation between high permeability and the incidence of SCC. The eddy current methodology provides an empirical criterion to monitor when locally higher surface material permeability changes occur in order to determine the onset of TGSCC.
The advantages of this methodology are that no special tooling is required, ECT is widely available, and ECT is fast and easy to use. The methodology has reduced inspection frequency at Fort Calhoun Station, improved plant reliability, and avoided costly component replacements. The ECT discussed in this paper is fully transferable to other plants, and could be used not only on stainless steel components, but also on inconel alloy components.
ACKNOWLEDGEMENTS Kirby Woods, Innotech Engineering Solutions LLC helped to develop the theory behind the proposed mechanism for tracking SCC. Special thanks to Brian Chee of Iowa State University for graphics help.
Figure 14.
Relative Permeability Change Versus Distance from CEDM Seal Housing Flange Face for a Low Permeability Housing.
penn 1.14 113"...........
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Relative Permeability Change Versus Distance from CEDM Seal Housing Flange Face for a High Permeability Housing.
DISCUSSION Failed CEDM seal housings were sectioned at the EPRI NDE Center and then sent to Battelle Pacific Northwest Laboratories for an ATEM and SEM study.
Prior to sectioning, ECT was performed on the 304 stainless steel housings, and four zones of high permeability were found with all the cracking being associated with these zones of high permeability. The study at Battelle found no unusual material conditions, such as changes in precipitate density, no abnormally high dislocation REFERENCE Reference 1.
Ferromagnetic Performance, Lisowyj.
"Transitioning from Surface Oxidation,"
November 2003, K.
Paramagnetic to NACE Materials Woods and B.
"7 Copyright © 2010 by ASME