ML17228A693
| ML17228A693 | |
| Person / Time | |
|---|---|
| Site: | Saint Lucie  |
| Issue date: | 08/09/1994 |
| From: | FLORIDA POWER & LIGHT CO. |
| To: | |
| Shared Package | |
| ML17228A692 | List: |
| References | |
| PSL-200-RAI-94, PSL-200-RAI-94-R, PSL-200-RAI-94-R00, NUDOCS 9408290067 | |
| Download: ML17228A693 (148) | |
Text
FLORIDA POWER AND UGHT COMPANY NUCLEAR ENGINEERING DEPARTMENT P.O. Box 14000 Juno Beach, Florida 33408 ST. LUCIE NUCLEAR PLANT, UNIT 2 SECOND INSERVICE INSPECTION INTERVAL USNRC REQUEST FOR ADDITIONALINFORMATION Prepared by Component, Support and Inspection Department Code Programs Group For St Lucle Nuclear Power Plant 6501 South Hwy. A1A Jensen
- Beach, Florida 34957 Commercial Service Date:
USNRC Docket Number.
Document Number.
Revision Number.
0 Date:
August 8, 1983 50-389 PSL-200-RAI-94 August 9, 1994
'F4082'Poob7 940808 PDR ADOt K 05000389 p
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ST. LUCIE UNIT 2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION ABSTRACT On August 4, 1993, Florida Power and Ught Company (FPL) submitted the St. Lucie Nuclear Power Plant, Unit 2, Updated Inservice Inspection (ISI) Program Plan and Schedule for the Second Inservice Inspection interval, which begins on August 8, 1993 and ends on August 8, 2003.
The ISI Program was developed and prepared to meet the latest ASME Boiler and Pressure Vessel Code,Section XI 1989 Edition, incorporated by 10 CFR 50,55a(b)(2), except for design and access provisions and preservice examination requirements set forth in 10 CFR 50.55a(g)(4).
The United States Nuclear Regulatory Commissions (USNRC), with assistance from their contractor, have determined that the need for additional information is required, in order to complete the staffs review of the St. Lucie Nuclear Power Plant, Unit2, updated Second Ten-Year Inservice Inspection Program Plan and Schedule for the Second Inspection Interval.
On June 17,
- 1994, (TAC NO. M87208), the USNRC submitted a request for additional information.
FPL has reviewed the USNRC staffs request for additional information, and Included within this document are the response's to the information requested.
Section 1.0 of this document provides the scope and status of the USNRC review as submitted to FPL in the request for additional information.
Section 2.0 of this document provides the additional information that the USNRC requested of FPL.
Section 3.0 of this document provides the FPL responses to the information requested in Section 2.0.
Attachment s are provided, when required to supplement the responses in Section 3.0.
File PSL2RAI.94.
Page 2
ST. LUCIE UNIT 2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION 1.0 SCOPE/STATUS OF REVIEW Throughout the service life of a water-cooled nuclear power facility, 10 CFR 50.55a(g)(4) requires that components (including supports) that are classified as American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Class 1, Class 2, and Class 3 meet the requirements, except design and access provisions and preservice examination requirements, set forth in ASME Code Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components, to the extent practical within the limitations of design, geometry, and materials of construction of the components.
This section of the regulations also requires that inservice examinations of components and system pressure tests conducted during successive 120-month inspection intervals comply with the requirements in the latest edition and addenda of the Code incorporated by reference in 10 CFR 50.55a(b) on the date 12 months prior to the start of the successive 120-month interval, subject to the limitations and modifications listed therein.
The components (including supports) may meet requirements set forth in subsequent editions and addenda of the Code that are incorporated by reference in 10 CFR 50.55a(b) subject to the limitations and modiTications listed therein. The licensee, Florida Power and Light Company, has prepared the St. Lucie Nuclear Plant, Unit 2, Second 10-Year Interval Inservice Inspection (ISI) Program Plan and Schedule to meet the requirements of the 1989 Edition of Section XI of the ASME Code.
As required by 10 CFR 50.55a(g)(5),
if the licensee determines that certain Code examination requirements are impractical and requests relief, the licensee shall submit information to the Nuclear Regulatory Commission (USNRC) to support that determination.
The staff has reviewed the available information in the St. Lucie Nuclear Plant, Unit 2, Second 10-Year Interval ISI Program Plan and Schedule, Revision 0, submitted August 4, 1993, and the requests for relief from the ASME Code Section XI requirements that the licensee has determined to be impractical.
2.0 ADDITIONALINFORMATIONREQUESTED Based on the above review, the staff has concluded that the following information and/or clarification is required to complete the review of the ISI Program Plan and Schedule.
Address the degree of compliance with augmented examinations that have been established by the USNRC when added assurance of structural reliability is deemed necessary.
Examples ofdocuments that address augmented examinations are listed below; where (1) and (2) may be applicable based on licensee commitments, and (3) is applicable to all licensees.
(1)
Branch Technical Position MEB 3-1, "High Energy Fluid Systems, Protection Against Postulated Piping Failures in Fluid Systems Outside Containment";
(2)
Regulatory Guide 1.150, Ultrasonic Testing of Reactor Vessel Welds During Preservice and Inservice Examinations; File PSL2RAI.94.
Page 3
ST.'LUCIE UNIT 2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION (3)
As required by the Code of Federal Regulations, Part 10, 50.55a(g)(6)(ii)(A),
effective September 8,
- 1992, all licensees must augment their reactor vessel examinations by implementing once, during the Inservice inspection interval In effect on September 8,
1992, the examination requirements for reactor vessel shell welds specified in Item B1.10 of Examination Category B-A of the 1989 Code.
In addition, all previously granted relief for Item B1.10, Examination Category B-A, forthe interval in effect on September 8, 1992, is revoked by the new regulation.
For licensees with fewer than 40 months remaining ln the Interval on the effective date, deferral of the augmented examination is permissible with the conditions stated in the regulations. It has been noted that, based on the date of the subject regulation and the August 8, 1993 starting date of the second 10-year interval of the St. Lucie Nuclear Plant, Unit 2, the required augmented reactor pressure vessel examinations must be performed during the first period of the second 10-year interval.
Please provide the staff with the projected schedule and a technical discussion describing how the regulation will be implemented for these welds at St. Lucie Nuclear Plant, Unit 2, during the second interval.
Describe the intended approach and any specialized techniques or equipment that will be used to complete the required augmented examinations.
(4)
Discuss these and any other augmented examinations that may have been incorporated in the St. Lucie Nuclear Plant, Unit 2, Second 10-Year Interval Inservice Inspection Program Plan.
B.
Review of the pressurized water reactor systems designed by Combustion Engineering has noted stay cylinder welds in the steam generator lower head. It appears that the Code has not addressed the unique design and function of these welds, which appear to function as both a primary pressure-retaining boundary (similar to a nozzle-to-shell weld) and as a component support.
Based on the design and function of these welds, appropriate examinations and subsequent scheduling for these welds should be considered.
FPL has designated Weld SG-2A-109-251, as an Examination Category B-H weld (Support Skirt-to-Stay Base) and has scheduled a surface examination. Review of this weld shows that it is a full penetration, pressure-retaining weld. Other Class 1 vessel, full penetration vessel welds require a volumetric examination. To apply examination Category B-H requirements to the subject weld, the weld configuration should be similar to a support skirt integral attachment type weld (Figures IWB-2500-13, -14, and -15). Please discuss the classification of the stay cylinder welds and include a technical position forthe assignment of Code examination categories and the application of Code examination requirements for these welds. Include information on the extent of examinations performed during the first 10-year interval.
- Also, please include a
revised examination schedule for the implementation of examinations on these welds, as determined to be applicable.
File PSL2RAI.94.
Page 4
ST.-LUCIE'UNIT2 SECOND INSERVICE INSPECTION INTERVAl REQUEST FOR ADDITIONALINFORNIATION C.
Paragraph 10 CFR 50.55a(b)(2)(iv) requires that appropriate ASME Code Class 2 piping welds in the Residual Heat Removal (RHR), Emergency Core Cooling (ECCS), and Containment Heat Removal (CHR) systems be examined.
Portions of these systems are critical to the safe shut down of the plant and should not be completely excluded from inservice volumetric examination based on piping wall thickness. It appears that because ofthe piping wall thickness at St. Lucie Nuclear Plant, Unit 2, a large percentage of piping welds (all thin-walled welds in the systems or 644 of 1362 C-F-1 welds) have been excluded from examination. The licensee should review these systems and select welds (7 1/2 percent) in those portions of lines excluded from examination to ensure that the integrity of the complete flow path of these systems is assured.
Discuss the review and provide a list of welds selected to augment the program.
D.
Request for Relief No. 1 addresses the examination requirements for Examination Category B-A, Items 81.11, 81.12, 81.21, 81.22, 81.30, and 81.40. It appears that Examination Category B-D, Item 83.90 examination areas are also Included in this relief request.
Please cianfy the scope of the Relief Request No.
1 and revise it accordingly.
E.
In Relief Request No.
4, the licensee proposes to eliminate the surface examination on Class 1 and 2 longitudinal piping welds beyond the examination area of the associated circumferential weld. In addition, the, licensee proposes to enhance the volumetric examination of the longitudinal weld at the intersection of the circumferential weld. Is it the intent of the proposed alternative to perform volumetric examination in lieu of the surface examination for the length of longitudinal weld required by Code'?
F.
Relief Request No. 5 lists Weld Nos. RC-121-901-771 and RC-112-1066-771 as receiving 100% Code coverage. Why is relief requested if full Code coverage is achieved' G.
Relief Request No. 14 addresses a change to the established scheduled of successive component examinations on a generic basis. The licensee's proposed rescheduling of examinations is considered acceptable provided that there is no more than 10 years between successive examinations. It should be noted that the performance of components in other nuclear plants should not be considered a
basis for assuming component integrity for St. Lucie Nuclear Plant, Unit 2, as service conditions do differ. Verifythat the proposed rescheduling of examinations does not result in a period between examinations that exceed 10 years.
H.
Relief Request No. 17 addresses the scheduling ofexaminations forCategory B-D, Item 83.90 welds. The licensee is requesting to examine the nozzle-to-shell welds coincident with the reactor pressure vessel weld examinations. The nozzle-to-shell welds and nozzle inner radius sections are typically examined during the same outage.
Provide a technical position for rescheduling the nozzle-to-shell welds when rescheduling of the inner radius examinations (Item 83.100) is not required.
File PSL2RAI.94.
Page 5
'ST. LUCIE UNIT 2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION In Section 1.3, the licensee stated that Code Case N~O is applicable to the program plan. Code Case N-460 provides an alternative to 100% Code coverage.
Included in Relief Request 1 are examination areas that appear to meet the 90%
Code coverage criteria. Please discuss how the alternative coverage requirement, as allowed by Code Case N-460, is being implemented. A revision to the relief request to address only those examination areas that do not receive the minimum 90% Code coverage is acceptable.
J.. Verifythat there are no additional relief requests required at this time. Ifadditional relief requests are required, the licensee should submit them for staff review.
The schedule for timely completion of this review requires that the licensee provide, by the requested date, the above information and/or clanTication with regard to the St. Lucie Nuclear Plant, Unit 2, Second 10-Year Interval Inservice Inspection (ISI) Program Plan and Schedule.
3.0 RESPONSES TO USNRC REQUESTS FOR ADDITIONALINFORMATION Based on review of the above requests for additional information, FPL is providing the following information and/or clarification to the USNRC's requests. Responses to particular requests will be identified with the same designation as the information requested in section 2.0 above.
A.
Section 6.0 of the updated St. Lucie Unit 2 ISI Program, provides a summary description of the augmented examinations Included within the updated program.
Addressed below is a reiteration of Section 6.0, and, where required, cianfication and/or additional information is provided.
A(1)
HIGH ENERGY FLUID SYSTEMS OUTSIDE CONTAINMENT Branch Technical Position MEB 3-1, "High Energy Fluid Systems, Protection Against Postulated Piping Failures in Fluid Systems Outside Containment",
required FPL to demonstrate that essential systems and components, are protected against the effects of postulated piping failures in fluid systems outside containment.
FPL completed a detailed analysis, and performed the appropriate protective methods required to mitigate the consequences of postulated pipe failure. The high energy piping systems considered for pipe rupture analysis outside containment were as denoted in the Giambusso Letter and the attachment to the December 1972 letter sent by A. Giambusso, Deputy Director for Reactor Projects, Directorate of Licensing to applicants and licensees, entitled "General Information Required for Consideration of Effects of a Piping System Break Outside Containment" and the results of this action is documented in the St. Lucie Unit 2 -, Final Safety Analysis Report (FSAR).
The applicability of this criteria for St. Lucie Unit 2 was accepted during the USNRC staff review as delineated in the Safety Evaluation Report (November 1974).
File PSL2RAI.94.
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'ST. LUCIE UNIT 2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORNIATION The St. Lucie Unit 2 Inservice Inspection Program incorporates augmented examinations on welds selected for examination that fallwithin the following criteria:
a.
Code Category C-F boundary was extended past the Code class boundary (MSIV)to the first restraint providing at least two degrees of restraint to piping thermal expansion; b.
Pipe-to-pipe welds and longitudinal weld seams located within these boundaries are also subject to augmented examination; c.
Welds selected for examination are as defined in the 1989 Edition of Section XI; For those welds selected in high energy fluid system piping between containment isolation valves, the extent of examination is 100% volumetric examination of circumferential and intersecting longitudinal pipe welds within the boundary of these portions of piping.
The welds and supports thus affected are specifically identified through Examination Notes in the Main Steam and Boiler Feedwater examination Tables.
A(2)
REGULATORY GUIDE 1.150 FPL was one of the first utilities to implement the regulatory guide when it was still in the draft mode. FPL along with its vendor, SwRI held several meetings with the USNRC prior to implementation.
The last St. Lucie mechanized Reactor Pressure Vessel Examination activity,was conducted during the 1989 refueling outage, and FPL implemented Regulatory Guide 1.150, Rev.
- 1. Appendix A, provides FPL's position for compliance with Regulatory Guide 1.150.
A(3)
NEW REGULATION 10 CFR 50.55a(g)(6)(II)(A)
The change in the regulation does not effect the St. Lucie Nuclear Piant, Unit 2, Second 10-Year Inservice Inspection Interval schedule, as FPL performs 100% volumetric examination of all our reactor pressure vessels.
The last examination activity was during the 1989 refueling outage.
(a)
FIRST INSPECTION INTERVAL During the 1989 refueling outage, Southwest Research Institute (SwRI) using their Enhanced Data Acquisition System performed the Reactor Pressure Vessel mechanized ultrasonic examinations.
These examinations covered the entire volume of all Reactor Vessel shell welds, to the extent practical within the design, geometry and materials of construction.
File PSL2RAI.94.
Page 7
ST. LUCIE UNIT 2
'SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONAL'NFORMATION These examinations met the requirements of the 1989 Edition of Section XI and 10 CFR 50.55a (g)(6)(II)(A) for full volumetric examination.
Areas not receiving at least 90% coverage are the subject of a request for relief no.
1.
(b)
SECOND INSPECTION INTERVAL The projected schedule for performance of the mechanized ultrasonic examination of the PSL-2 reactor pressure vessel shell welds during the Second Inspection Interval, is currently scheduled to be performed within the Second Inspection Period (August 8, 1996 through August 8, 2000). The entire volume, essentially 100%
of each shell weld length on the Reactor Pressure Vessel will be examined by the mechanized (automated) ultrasonic examination method.
A near surface examination technique will be used to interrogate the difficultto examine inner surface.
Indications willbe characterized to determine the size, shape and orientation, and compared against the acceptance criteria of Section XI, to determine acceptance.
In addition to the Code required examinations, FPL will be implementing the requirements of Regulatory Guide 1.150 Rev.
1 during the next reactor pressure vessel mechanized examination activity. Attachment A summarizes how FPL plans to comply with the Regulatory Guide, A(4)
REACTOR COOUNIT PUMP FLYWHEEL As required by Plant Technical Specification 4.4.11 each Reactor Coolant Pump Flywheel is examined per the requirements of Regulatory Guide 1.14, "Reactor Coolant Pump Flywheel Integrity", Position C.4.b as follows:
a.
A volumetric examination by ultrasonic method of the areas of higher stress concentration at the bore and keyway of each Reactor Coolant Pump flywheel, once each period (approximately 3-year intervals), during the refueling or maintenance shutdown coinciding with the inservice inspection schedule.
Removal of the flywheel is not required.
b.
A surface examination utilizing a ultrasonic surface wave of all exposed
- surfaces, and 100% volumetric examination (Ultrasonic methods) at or near the end of each Inspection 10-year Interval, during a plant shutdown coinciding with the inservice inspection schedule.
Removal of the flywheel is not required.
A(5)
PRESSURIZER SURGE UNE'FPL will conduct a Visual (VT-3) examination of the entire pressurizer surge line during the second inspection interval, to determine the general mechanical and structural condition.
This examination will require examiners to pay particular attention to component supports, for evidence File PSL2RAI.94.
Page 8
ST. LUCIE UNIT2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION of gross physical damage.
Reference:
USNRC Bulletin 88-11, Pressurizer Surge Line Thermal Stratification A(6)
LER 5089-93W4 Per LER 50-389-93-04, FPL committed to perform visual (VT-1) examination of the alloy 600 instrumentation nozzles, during the second inspection interval for evidence of leakage.
A(7)
FEEDWATER AUGMENTED EXAMINATIONS As a result of previous Feedwater replacement activities, FPL has determined that augmented inservice examinations are warranted. Previous USNRC issued documents that address this subject are USNRC Bulletin 79-13, and USNRC Informational Notice 93-20, "Thermal Fatigue Cracking of Feedwater Piping to Steam Generators".
FPL will perform a continuous enhanced ultrasonic examination starting at the Feedwater Nozzle ramp and extending out to a point, on the horizonai pipe run, to a point of 1 pipe diameter on the first elbow. Examinations are conducted in conjunction with the Code required examinations as Identified within the examination Tables. The augmented examinations are performed with an ultrasonic examination procedure specifically qualified for locating thermal fatigue cracking.
B.
STAY CYUNDER STAY CYUNDER WELDS The stay cylinder performs two basic functions: 1) structural support for the tube sheet; and 2) limit the movement of the steam generator tube bundle.
(a)
Allwelds associated with the stay cylinder on each steam generator were examined during the first inspection interval as required by Section XI, 1980 Edition through the Winter 1980 Addenda. It should also be pointed out that the same Edition and Addenda of Section XI also Identified examinations for successive inspection intervals to consist of 1 weld per head.
(b)
The current 1989 Edition of Section XI essentially requires the following examinations be performed on the primary side of the steam generator.
- 1) one weld per head;
These examination requirements are essentially the same as the earlier Edition of Section XI.
File PSL2RAI.94.
Page 9
ST. LUCIE UNIT 2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION Based on our review, FPL, has concluded that inservice examination of the stay cylinder welds are not required, nor are they warranted based on previous examination results of no reportable indications. No additional examinations are required and/or scheduled at this time.
2.
STAY BASE The function of the stay base is to support the weight of the steam generator.
Examination Category B-H designation of weld SG-2A-109-251 is correct, in that the support skirt-to-stay base weld is as shown in Figure IWB-2500-13.
Categorizing this weld other than B-H, as your staff has suggested, would, under current Code requirements, require a volumetric examination, but would also eliminate this weld from examination altogether.
FPL willon the other hand add to its current schedule, allowance to perform either a volumetnc or surface examination as required by IWB-2500-1.
Previous examinations conducted on this weld during the first inspection interval consisted of a volumetric examination. See Appendix B for revised examination schedule.
C.
CLASS 2 EXEMPT WELOS FPL has reviewed the history of the thin-wall piping systems in question.
Surface and/or Volumetric examinations performed as part of subsequent ISI Programs have not revealed any indications that exceeded the acceptance criteria.
Plant personnel perform periodic Reactor Auxiliary Building (RAB) walk-downs of accessible areas of the Low Pressure Safety Injection, High Pressure Safety Injection, Shutdown Cooling and Containment Spray systems outside containment with the system in operation. These walk-downs are documented and maintained in accordance with applicable St. Lucie Plant operating procedures and plant Technical Specifications. These RAB walkdowns concentrate primarily on identifying leakage associated with normal operation and the identification of unexpected and/or abnormal leakages in the system pressure-boundary.
Those areas inside containment that are inaccessible during plant operation are monitored by leak detection devices.
FPL has determined that additional examinations on systems that are currently exempt from the applicable Code requirements are not warranted. These systems have been continually monitored without observing any inservice related problems.
The system walk-downs performed by plant personnel, and system pressure tests conducted as part of the normal ISI Program, coupled with a lack of inservice related problems provide adequate assurance of the integrity of the complete flowpath. Additional surface and/or volumetric examinations would increase radiation exposure and costs without providing a compensating increase in the safety margin.
File PSL2RAI.94.
Page 10
ST.. LUCIE'UNIT2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION FPL will on a periodic basis, consult with plant personnel to determine if augmented and/or additional examinations are required to supplement the current plant ongoing inspection programs.
D.
REUEF REQUEST 1 Examination Category B-D, Item 83.90, Nozzle to Vessel weld is also addressed within this request for relief. The scope of relief request 1 has been changed to add Examination Item 83.90. See Attachment C for addition to Relief Request 1.
E.
REUEF REQUEST 4 No, the intent of the relief request is to perform volumetric and/or surface examinations (as applicable) on intersecting longitudinal welds, to the extent required, coincident with the circumferential weld examination.
F.
RELIEF REQUEST 5 Relief request 5, weld nos. RC-121-901-771 and RC-112-1066-771 received 100% Code coverage as identified within the request. Weld nos. RC-121-901-771 and RC-112-1066-771 have both been removed from this request. Attachment D provides the corrected request for relief.
G.
REUEF REQUEST 14 The USNRC staff stated that the proposed rescheduling of examinations is considered acceptable provided that there is no more than 10 years between successive examinations.
The 10 years between successive examinations denoted by the USNRC staff is the optimum condition, and may not always be achievable. FPL should point out that Section XI as currently wntten and endorsed by the USNRC, recognizes this situation, and allows successive examinations to exceed 10 years by as much as 3 to 4 years within a given inspection period.
With the exception of the examinations that may be deferred until the end of an inspection interval as specified in Table IWX-2500-1, and those examinations which specifically address percentages to be accomplished in a specific period ( example: Items 81.30, 83.90), all other required examinations in each examination category shall be completed during each successive inspection interval in accordance with Table IWX-2412-1.
Inspection periods as defined by Section XI are 3 years, 4 years, and 3 years. Inspection periods by themselves, allow successive examinations to exceed 10-year intervals by as much as 4 years.
Examples of allowances are provided below, utilizing the identified assumptions below:
File PSL2RAI.94.
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ST. LUCIE UNIT2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION Assumptions:
For St. Lucie Unit 2 the following assumptions are used:
a.
Commercial Service Year.
1983 b.
1st. Period:
Years 1984, 1985, 1986 c.
2nd. Period:
Years 1987, 1988, 1989, 1990 d.
3rd. Period:
Years 1991, 1992, 1993 Examples:
If an examination was initially performed during the first inspection Interval at the first outage of the first period, year 1984, then successive examination could be performed in the second inspection interval, first period, outage year 1994 through outage year 1996. Exceeding 10 years by 2 years, and be in compliance with Section XI.
(1996 -1984
= 12years)
If an examination was initially performed in the first inspection interval at the first outage of the second period, year 1987, then successive examination could be performed in the second inspection interval, second period, outage year 1997 through outage year 2000. Exceeding 10 years by 3 years, and be in compliance with Section XI~
(2000 - 1987 = 13 years)
Add the extension of plus or minus 1 year as allowed in IWX-2412(b) to the examples 1 and 2 above and successive examinations during a given inspection period, could exceed 10 years by as much as 3 years for examinations conducted in the first and third periods, and 4 years for examinations conducted in the second period, and be in compliance with Section XI.
Verification of the rescheduling of examinations for the components addressed in this Request for Relief, resulted in a period of successive examinations as defined below:
Reactor Pressure Vessel welds, including the closure head - Five of the nine items would exceed the successive 10-year interval by 1 year.
Steam Generator 2A Primary Side - With all required examinations on Steam Generator 2A, several welds examinations would exceed the successive 10-year interval by 5 to 7 year on the primary side.
Steam Generator 2B Primary Side - If all required examinations were performed Steam Generator 2B, examinations would exceed the successive 10-year interval by 1 year on the primary side.
File PSL2RAI.94.
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ST. LUCIE UNIT 2 SECOND 1NSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION c.
Steam Generator 2A Secondary Side - With all required examinations on Steam Generator 2A, several weld examinations would exceed the successive 10-year interval by 1 to 5 years.
Steam Generator 2B Secondary Side-Ifall required examinations were performed on Steam Generator 2B, the examinations would be performed for the first time, as all examinations during the initial interval were performed on 2A.
c.
All Pressurizer examinations willnot exceed the 10-year interval.
d.
All Reactor Coolant Pump examinations willnot exceed the 10-year interval.
FPL has revised Request for Relief 14 to include only those examinations that would exceed the current time frame allowed by Section XI (13 years or 14 years) as discussed above.
Appendix E provides the revised request for relief for those examinations that would exceed the current Code requirements.
H.
REUEF REQUEST 17 Relief Request 17 has been corrected to include Examination Category B-D, Item B3.100.
As your staff stated both the nozzle to shell weld and the nozzle inner radius on the reactor pressure vessel are performed at the same time. Appendix F provides the corrected request for relief.
CODE CASE NQ60 Because of the recent change in the regulation concerning the reactor pressure vessel, FPL assumed that the USNRC would be interested in the exact coverage that was achievable on each weld by examination angle.
Code coverage requirements, as allowed by Code Case N460 is implemented as follows; 1.
The 0'amination scan is intended to be utilized once to identify conditions which may interfere with the examination of the weld and the required volume (1/2t).
Coverage with this search unit is not factored into the overall calculation of weld coverage.
The required examination angles are 0', 45'/2 vee path, and 60'/2 vee path.
Of these, the two angle beams applied in two directions parallel with the weld and in two directions perpendicular to the weld are factored into the calculation. Except in cases where the beam is oriented essentially perpendicular to the plane of postulated flaws, the 0'xamination contributes nothing to the examinations, therefore, it is not factored into the calculation.
File PSL2RAI.94.
Page 13
ST. LUCIE UNIT 2
- SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION 3.
FPL elected to add enhancements to the overall examination of the reactor pressure vessel, as follows:
a.
A full vee path 45'o enhance the examination of the area directly under the cladding and to reduce areas of non coverage due to scan limitations.
b.
A special bi-modal scan of the cladding-base metal interface and 1/4 t under the cladding. This was not factored into the coverage calculations.
The overall coverage calculation consists of an average of the 45'nd 60'xaminations in all four directions.
FPL has revised the request for relief no.
1 to include only those examinations where coverage of that weld is less than 90%.
Appendix C provides the revised request for relief.
J.
ADDITIONALREQUESTS FOR RELlEF There are no additional request for relief from Code requirements at this time.
File PSL2RAI.94.
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ST. LUCIE UNIT'2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION ATTACHMENTA IMPLEMENTATIONOF REGULATORY GUIDE 1.150 FHe PSL2RAI.94.
Page 15
NUCLEAR ENGINEERING DEPARTMENT CoMPoNENT, SUPPoRT AND INsPEGTIQNs DEPARTMENT P.O. Box 14000 JUNO BEACH, FLORIDA 33408 St. Lucle NucIear Power PIant Unit 2 SECOND INSERVICE INSPECTION INTERVAL SECOND INSPECTION PERIOD IMPLEMENTATIONOF REGULATORY GUIDE 1.150 Prepared by Florfda Power and Ught Company Code Programs Group For St. Lucie Nuclear Power Plant 10 Miles South of Ft. Pierce on A1A Ft. Pierce, Florida 33034 Commercial Service Date:
NRC Docket Number.
Document Number.
Revision Number.
August 8, 1983 50-389 PSL-RG 1.150 0
Date: August 10, 1994
'ECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 19S4 ABSTRACT This document provides a summary of how Florida Power and Light Company (FPL),
implements the requirements ofRegulatory Guide 1. 150. FPL has complied, to the extent practical with the requirements of this regulatory guide for over 10 years. FPL, and our vendor Southwest Research Institute (SwRi), has conducted examinations on the n:actor pressure vessels at both sites (St. Lucie and Turkey Point), and on all four units (PSL-1 and 2, PTN 3 and 4).
Mere required in this document SwRi is inserted, in place ofFPL, fo make a distinction between equipment, techniques, or documentation unique to SwRI.
The mechanized ultrasonic examinations for the St. Lucie Nuclear Power Plant, Unit 2, Reactor Pressure Vesselis cunenfly scheduled to be performedin the Second Inspection Period, of fhe Second Inspection Interval.
The examinations will be conducted in accordance with the American Society of Mechanical Engineers Boiler and Pressure Vessel Code,Section XI, 1989 Edition, no Addenda, and the additional requin:ments of Regulatory Guide 1. 150 as stated within.
This document is wriffenin a format that firstidentifies the regulatory guide requirement, followed by a summary ofhow FPL willimplement that requirement.
File RG1.150 Page 2
SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1994 INTRODUCTION Ultrasonic examination of the St. Lucie, Unit 2 reactor pressure vessel welds, including the closure head will be performed during the upcoming Second Inservice Inspection Interval, in accordance with the 1989 Edition of the American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code (B&PVC),Section XI, and as supplemented by the additional requirements of Regulatory Guide 1.150, Revision 1. This document summarizes the additional requirements that Florida Power and LightCompany (FPL) implemented during previous examination activities in order to comply with the Regulatory Guide requirements.
FPL expects that these additional requirements willnot change.
1.0 INSPECTION SYSTEM PERFORMANCE CHECKS The conduct of nondestructive examinations require that the performance characteristics of the inspection system used be well defined and documented.
This is particularly true for situations which require comparisons of examination results generated during successive examinations on the same components. An inspection system comprises of the following:
a.
a transducer (search unit);
b.
a single-channel instrument or each channel of a multichannel instrument; and c.
a given cable type and length.
The checks described in paragraphs 1.1 and 1.2 should be made forany ultrasonic (UT) system used for inspection of reactor pressure vessel (RPV) welds.
The field performance checks described in 1.2 (with the possible exception of 1.2.c) should be conducted on a basic calibration block that represents the thickness range to be examined.
FPL agrees with the need to define and document the performance characteristics ofUT systems, and we have been, and requiring our vendors (SwRI) to do so formany years.
Most of the checks identified herein are considered standard operating practice. FPL applies these requirements to all reactor vessel weld examinations, whether the examinations are manual, or automated (Mechanized) from the inside surface. Since the results of the field performance checks described in 1.2 are independent of calibration block design, FPL approved vendor's procedures are required to allow the use of any calibration block that willprovide the signal responses needed forthe performance check.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1984 1.4 Preexamtnatton Performance Chectcs a.
Frequency of Checks These checks should be verified within six (6) months before reactor pressure vessel examinations performed during one outage. Pulse shape and noise suppression controls should remain at the same settings during calibration and examination.
b.
RF Waveform Arecord ofthe RF (radiofrequency) pulse waveform from a reference reflector should be obtained for each search unit used in the examination in a manner which will provide frequency amplitude information. At the highest amplitude portion of the beam, the RF return signal should be recorded before it has been rectified or conditioned for display. The reflector used in generating the RF return signal as well as the electronic system (i.e., the basic ultrasonic instrument, gating, and form of gated signal) should be documented.
These records should be used for comparison with previous and future records.
FPL requires vendors nof only to record RF pulse waveform asidenfified above, but also requires the determination of the frequency spectrum and distance amplifude curve for each search unit used. Search unifs fhaf do not meet stnct performance tolerances are prohibited from use. Documentation ofthis analysis is submitted to FPL priorto the performance offhe examinations and areinciuded as part of the final report of the examination activity.
In addition to the analysis described above, FPL also requires phofographs ofthe RF waveform in the fieldduring initialand finalcalibrations. This provides a record ofthe RF waveform obtained using the specific sysfem components (transducer, instrument, and cable) that are used for calibration and examination.
1.2 Field Performance Checks aO Frequency of Checks As a minimum, these checks should be verified on site before and after examining all the welds that need to be examined in a reactor pressure vessel during one outage.
Pulse shape and noise suppression controls should remain at the same settings during examination and calibration.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1984 b.
Instrument Sensltlvlty Durfng Uneartty Checks The initial instrument sensitivity during the performance of 1.2.e should be such that it falls at the calibration sensitivity or at some point between the calibration sensitivity and the scanning sensitivity.
RF Waveform Arecord ofthe RF (radiofrequency) pulse waveform from a reference reflector should be obtained and recorded in a manner that will permit extraction of frequency amplitude information. At the highest amplitude portion of the beam, the RF return signal should be recorded before it has been rectified or conditioned for display. This should be determined on the same reflector as that used in 1.1.b above. This record should be retained for future reference.
Screen Height Unearity Screen height linearity of the ultrasonic instrument should be determined according to the mandatory Appendix I to Article 4,Section V of the ASME Code or Appendix I to Section XI of the ASME Code.
e.
Amplitude Control Linearity Amplitude control linearity should be determined according to the mandatory Appendix II of Article 4,Section V, of the ASME Code or Appendix I of Section XI of the ASME Code.
Angle Beam Profile Characterfzatlon The vertical beam profile should be determined for each search unit used during the examination by a procedure similar to that outlined in nonmandatory Appendix B0, Article 4,Section V, of the ASME Code or Appendix I to Section XI of the ASME Code, Beam profile curves should be determined at different depths to cover the thicknesses of materials to be examined. Interpolation may be used to obtain beam profile correction for assessing flaws at Intermediate depths for which beam profile has not been determined.
Beam profile measurements should be made at the sensitivity required for sizing. For example, sizing to 20-percent DAC criteria requires that the beam profile be determined at 20-percent DAC.
File RG1.150 Page 5
.SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGUIATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1994 The field performance checks described above are performed as fo//ows:
(1)
RF Wavefbnn - Photographs ofthe RF waveform in the feld during each initial and final calibration. This provides a record of the RF waveform obfained using the specNc system components (transducer, instrument, and cable) that are used forcalibration and examinafion.
(2)
Sneen he)ght Linearity - Screen height linearity checks are performed for each insfrumenf in accordance wifh the Regulatory Guide requirements. These checksare performedimmediateiybefore and after complefion of the examinations.
(3)
Ampfifude Conthxf Lineanty - Amplitude control linearity checks establish a linear relationship befween an adjusfmenf ofthe gain, or sensitivity, confrols (knobs orswitches) and fhe conesponding signal amplitude change observed on the CRT.
In the case ofmanual examinations in accordance wifh Regulatory Guide 1.150, amplitude control linearity is determined for each instrument in accordance with fhe Regulatory Guide requirements.
These checks are performedin conjunction wifhthe screen height linearity checksimmediatel before and after complefion of the examinations.
Paragraph 1.2.b above requires that the insfrumenf sensitivity during fhe performance of amplitude control linearity checks should be at the calibration sensitivity or scanning sensitivity. However, the calibration sensitivity levels (and scanning sensitivify levels) vary wifh the different techniques used during vessel examinations.
Therefore, vendors are required to perform these linearity checks at fhe extreme upper and lower ends of the sensitivity range.
This ensures that the instrument is linear across a wide range of calibrafion and screening sensitivity levels.
In the case ofautomated examinations, Gain Control circuify electronically compensates for the normal signal affenuation that causes a sloping DAC curve and provides a vanable gain adjustmenf across the CRT screen such that a constant, horizontal DACcurveis attained. Gain Control pertormance is periodically verified on site during examinations to assure that a straight horizonfal DACis maintained. In essence, whenever the amplitude controls are used forindicafion amplitude measurements, amplitude control linearity checks are performed.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 Avgust 10, 1884 (4)
A~Beam PsuSe Charactenzation-Abeam profile foreach single element pulse-echo angle beam search unitis determined on site in accordance with the Regulatory Guide requirements.
These profiles are generated using the 1/4, 1N, and 3/4T side-drilled holes in a calibrafion block that is as thick or thicker thari the component to which the search unit will be applied.
Since Appendix A of the Regulatory Guide permits sizing at either 2096 or 5096 of DAC, Vendors are required to take both 2096 and 5096 beam profiles.
With the use of tandem dual-refracted longitudinal wave units for near surface examinafion, fypical sizing methodologies are not applicable because of the unique search unit perfonnance.
Therefore, when near surface indicafions are observed with these techniques, special supplemenfal sizing techniques may be required depending upon the observed characteristi of the fiaw. These special supplemental sizing techniques have been substantiafed and qualified using mockups, fieldexperience, and research project data over many years.
2.0 CAUBRATION System calibration should be performed to establish the DAC curve and the sweep range calibration in accordance with Article 4,Section V, of the ASME Code or Appendix I to Section XI. Calibration should be confirmed before and after each RPV examination, or each week in which the system is in use, whichever is less.
Where
- possible, the same calibration block should be used for successive inservice examinations of the RPV.
FPL requires system calibration be performed on sife in accordance with Regulatory Guide requirements on the applicable basic calibrafion block.
Calibration confirmafion during manual examinafions is performed pnor to fhe examination; at least every four hours during the examinations; with any subsfitution of search unit, cable, or power source; and upon complefion ofthe examinations.
For mechanized examinations, FPL requires calibration confirmation prior to the start of a series of examinations (a seriesis considered to be similar examinations perl'armed using the same examination techniques and the same equipment configuratio); with any substitution ofsearch unit, cable, orpower source; whenever the device is removed from the examination area; at least every week during the examinations; and at the completion of a series of examinations.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1994 NOTE:
While this calibration confirmation frequency is consistent with the Regulatory Guide, itsometimes does not comply withthe 12-hour frequency requirements of paragraph T-432.1.2 of Section V. The acceptability of exceeding the Section V 12-hour calibration check can be demonstrated as allowed in paragraph IWA-2240 of Section XI.
2.1 CaHbratlon for Manual Scanning For manual sizing of flaws, static calibration may be used if sizing is performed using a static transducer. When signals are maximized during calibration, they should also be maximized during sizing. For manual scanning for the detection of flaws, reference hole detection should be shown at scanning speed and detection level set accordingly.
As required above, vendors are required to use static calibrafion and static sizing techniques formanual examinafions, maximizing both calibrafIon and flawsignals.
Reference hole defection is verifi'ed by scanning over fhe calibration block at the maximum scanning speed and verifying that the signal meets or exceeds the recording level.
2.2 Calibration for Mechanized Scanning When flaw detection is to be done by mechanized equipment, the calibration should be performed using the following guidelines:
a.
The DAC curve should be established using either a moving transducer mounted on the mechanism that will be used for examination of the component or a mechanism that duplicates the critical factors (e.g.,
transducer
- mounting, weight, pivot points, couplant) present in the scanning mechanism.
b.
Calibration speed should be at or higher than the scanning speed, except when correction factors established in 2.2.d are used, C.
The direction of transducer movement (forward or backward) during calibration to establish the DAC curve should be the same direction during scanning unless it can be shown that a change in scanning direction does not reduce flaw detection capability.
One of the following alternative guidelines should be followed to establish correction factors if static basic calibration is used:
(1)
Correction factors between dynamic and static response
. should be established using the basic calibration block or, File RG1.150 Page 8
SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1984 (2)
Correction factors should be established using models and taking scaling factors into consideration (assumed scaling relationship should be verifie) or, (3)
Correction factors should be established using full-scale mockups.
FPL complies with these requirements forcalibration formechanized scanning in accordance with 2.2.d(1) in that we have repeatedly required SwRI to demonstrate equivalency between the scanning with the PaR devices and the stafic calibration techniques.
FPL also requires SuvRi fo provide a report documenting this equivalency using the equipment pertinent to FPL's application.
2.3 Calibration Confinna5on Calibration confirmation performed as midshift or interim confirmation between onsite calibrations should comply with stability requirements in T-433, Article 4,Section V, of the ASME Code.
When an electronic simulator is used foronsite calibration confirmation after a Code required block calibration performed off site, the following should also apply:
Complete system performance should be maintained stable prior to offsite calibrations and onsite calibration confirmation by use oftarget reflectors. The target reflectors should be mounted with identical physical displacement in both the offsite calibration facilities and the onsite mechanized equipment.
Each onsite periodic calibration should be preceded by complete system performance verification using a minimum of two (2) target reflectors separated by a distance
representing 75 percent of maximum thickness to be examined.
b.
Written records of calibrations should be established for both target reflector responses and Code calibration block DAC curves for each transducer. These written records may be used to monitor driftsince the original recorded calibration.
c.
Measures should be taken to ensure that the different variables such as temperature, vibration, and shock limits are minimized by controlling packaging, handling, and storage.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1994 FPL requires calibration confirmation be performed at the frequency specifie in paragraph 2 above and in compliance with the stability requirements of the Regulatory Guide. Vendors are required to perl'Orm fhe calibration confirmatio on site during using the basic calibration block, nof an electronic block simulator. As such, the additional requirements identified in this paragraph for the use of an elecfronic block simulator do not apply.
In addition to periodic calibration confirmafions functional checks of the UT instruments and the gain control circuitry system are typically perl'Ormed at shift changeover.
These checks uti%ze electronic signal generators to monifor for changesin sweep and amplitude displays. The stabi%fy criteria ofparagraph T-433 ofArticle 4 are used for acceptabi%ty of these functional checks.
For full vessel examinafions using the SeRi Fast PaR
- systems, two Data Acquisitions Systems are ufi%zed in parallel.
While one system is used for scanning and data acquisifion, the ofher system is being calibrated for the next series of examinafions.
In effect, two separafe cable system are used, one for calibration and another forexaminations. SwRI's Remofe Cable Calibrator system allows comparison of the difference in cable performance and also provides electronic signal generation forperiodic verificatithat the perl'Ormance ofthe fwo cable systems has not changed.
These cable performance checks are performed at the same time, and using the same criteria, as the electronic functional checks described above.
2.4 Calibration BIocks Calibration blocks should comply with Appendix I to Section XI or Article 4,Section V of the ASME Code. When an alternative calibration block or a new conventional block is used, a ratio between the DAC curves obtained from the original block and from the new block should be noted (for reference) to provide for a meaningful comparison or previous and current data.
The calibration side-drilled holes in the basic calibration block and the block surface should be protected so that their characteristics do not change during storage. These side-drilled holes or the block surface should not be modified in any way (e.g., by polishing) between successive examinations.
Ifthe block surface or the calibration reflector holes have been polished by any chemical or mechanical means, this fact should be recorded.
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- SECOND INSPECTION INTERVAL
'IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSLWG 1.150 REVISION 0 August 10, 1994 3.0 HULMINATlON The scope and extent of the ultrasonic examinations should comply with IWA-2000,Section XI, of the ASME Code.
If electronic gating is used to define the examination volume within which indications are recorded the start and stop control points should Include the entire required thickness including the material near each surface.
If a single gate is used, it should be capable of recording multiple indications appearing in the gate. Alternative means of recording may be used providing they do not reduce flaw detection and recording capability.
Examination should be done with a minimum 25-percent scan overlap based on the transducer element size.
The scope and extent ofmanual examinations are addressedin the examinafion plan and examinafion procedure in accordance wifh IWA-2000.
In order fo assure that the scope and extent ofautomafed examinations comply with IWA-2000 of Section XI, FPL requires the vendor to prepare a detailed Scan Plan for each'utomated examination activityin addition to typical examinafion procedures.
This plan addresses device configuration, scanning parameters, calibration parameters, gate seffings, and other specificinformation needed to perform fhe work. Implementation of the scan plan, as prepared for a specific application, willensure that the full volume of the ASME examination area are examined to the extent allowed by fhe vessel configuration. Coverageis accomplished using a combination ofseveral beam angles and examination techniques as specified in the scan plans.
The electronic gating system utilized by vendors does nof limitthe examination volume within whichindications are recorded. When the sfandard dafa acquisition systemis used, a video recording is made of the actual UT instruments CRT presentations with the search unit positional information superimposed in real time.
The SwRI enhanced data acquisifion system has oveHapping electronic gating foreach UTchannel such that a fullvolume examinafionis digitized, recorded, and displayed. The enhanced data acquisition system gating is capable of recording multiple simultaneous indicafions.
Allexaminations performed in accordance with the regulatory guide are performed using a 25-percent overiap, unless a greafer overiap is required.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1884 3.1 INTERNALSURFACE The capability to effectively detect defects at the internal clad/base metal interface shall be considered acceptable if the examination procedures(s) or techniques meet the requirements of section 6.0 of this document and demonstrates the following:
a.
procedure for examination from the outer surface, or when using full vee from the inside surface, should include the use ofthe 2-percent notch which penetrates the internal (clad) surface of the calibration blocks, defined by Section XI, Appendix I, Figure !-3131, or Section V, Article 4, T-434-1.
Procedures forexamination from the internal surface when not using the full vee should conform to paragraph 3.1.b below.
b.
an alternate reflector, other than the 2-percent notch described above, may be used provided (1) that it is located at the cladibase metal interface or at an equivalent distance from the surface, (2) that it does not exceed the maximum allowable defect size, and (3) that equivalent or superior results can be demonstrated.
c.
the examination procedures should provide the volumetric examination of at least 1 inch of metal as measured perpendicular to the nominal location of the base metal cladding interface.
Procedures forexamination from the outside surface ofthe vessel walluse the 2-percent notch forreference as specifiedin paragraph 3.1(a). These procedures alsoinclude a half vee calibration with the notch used for calibration of allindications which appear at the inside surface of the examination area.
Procedures for tandem examinations from the inside surface ufi%zes 1/16inch diameter side-drilled holes at the clad/base metal interface as described in paragraph
- 3. 1(b). In both cases, procedures provide for volumetric examination ofgreater than 1-inch depth below the claddinginterface as required byparagraph 3.1(c). SwRI has demonstrated that the reference sensitivity established on the 1/16inch diameter side drilled holes meets or exceeds that specified in Section XIofthe ASME Code. This technique has also been demonstrated to have the capability of detecting flaws with good signal-to-noise discrimination at depths ofat least 2-3/4 inches below the clad-to-base metal interface, thus overiapping the through-wall zone ofcalibrated sensitivity ofthe 45 degree and 60 degree beams. Using the tandem beam transducers, SwRI has detected flaws ofminute size in the area between the clad-to-base metal interface and the first 45 degree and 60 degree dac point.
FIIe RG).150 Page 12
'SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150
'PSLWG 1.150 REVISION 0 August 10, 1994 FPL has also used 70 degree dual (side-by-side mounted piezoelectric element) search units for underclad examinations; however, the useful range is limited to approximately 1 inch of depth below the cladding with no discernible improvement over the tandem beam search unit at the clad-to-base metal interface.
3.2 Scanning Weld-Meta( Interface The beam angles used to scan welds should be based on the geometry of the weld/parent metal interface. Where feasible for welds such as those identNed in Section T-441.4.2 of Article 4,Section V, of the ASME Code, at least one angle should be such that the beam is perpendicular
(+ or - 15 degrees to the perpendicular) to the weld/parent metal interface, or should be demonstrated that unfavorably orientated planar flaws can be detected by UT technique being used.
lfthis is not feasible, use of alternative volumetric NDE techniques, as permitted by the ASME Code, should be considered.
For RPV shell seam welds, FPL uses the nominal Code-specified O-degree, 45-degree, and 60-degree, beams to examine the full volume of the wall section except for the volume ofmaterial near the beam entry point, forwhich we use the previously mentioned tandem search units.
Section T-441.4.2 (or T-441.3.2.2 ofArticle 4,Section V, states that beam angles other than O-degree, 45-degree, and 60-degree should be used for the examination of (a) flange welds when the examination is conducted from the flange face, (b) nozzle and nozzle welds when the examination is conducted from the nozzle bore, (c) attachment and support welds, and (d) examination ofdouble taperjunctions. FPL has employed this approach for many years.
FPL and FPL approved vendors procedures, however, often provide more than Code-specified coverage where feasible. Each ofthe unique weld configurations noted above is evaluated to determine the best and most comprehensive coverage attainable. Mfhere necessary, other angle and straight beam examinations are pei1'ormed to assure complete coverage ofnozzle-to-shell, vessel-to-flange, and attachment welds. Previouslymentioned tandem beam techniques are also uti%'zed to provide the required near surface coverage when nozzle bore examinations are performed.
4.
BEAM PROFILE Delete entire paragraph.
This section included in Recommended Change 1.2.f, Angle Beam Profile Characterization.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1984 6.
SCANNING WELD-METALINTERFACE Delete entire paragraph.
This section Included in Recommended Change 3.2, Scanning Weld-Metal Interface.
6.
RECORDING AND SIZING The capability to detect, record, and size the flaws delineated by Section XI, IW8-3500, should be demonstrated. The measurement tolerance established should be applied when sizing flaws detected and recorded during scanning (see paragraph 7.a).
The difference between joint configurafions, plate thicknesses, fiaw locations within the weld, fiaw orientations, and acousfic characferisfics of fhe component matenal all contribute to fhe inherent variabi%tyofsizing techniques. FPL has used and willcontinue fo use, Code and non-Code sizing techniques, the use ofsupplemental NDE techniques ifpractical, mockups of the particular configurafion, and'when required, consultants to fullyevaluate the examination and fhe results.
6.1 Geometric indications Indications determined to be from geometric sources need not be sized.
Recording of these indications should be at 50-percent DAC. When indications are evaluated as geometric in origin, the basis for that determination should be described. Afterrecording sufficient information to identify the origin of the geometric indication, further recording and evaluation are not required.
Indication analysis and sizing are performed by FPL or FPL approved vendors. All the examination data is given an administrafive and technical review by a FPL qualified NDE Level IIan&or Level III, certified in that particular method.
Indications that are geomefricin origin are recorded at 50-percent DAC and the nature of each such indicafion is documented.
6.2 indications wtth Changing Metal Path a.
Indications that change metal path distances (including through-wall dimension), when scanned in accordance with the requirements of ASME Section XI for a distance greater than that recorded from the calibration reflector, should be recorded.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 'I.150 PSLWG 1.150 REVISION 0 August 10, 1984 b.
Reflectors which are at metal paths representing 25 percent and greater of the through-wall thickness of the vessel wall measured from the inner surface should be recorded in accordance with the requirements of the ASME Section XI and characterized at 50-percent DAC.
C.
Reflectors which are within the inner 25 percent of the through-wall thickness should be recorded at 20 percent DAC. Characterization should be in accordance with the demonstrated methods under paragraph 6.0. When the indication is sized at 20 percent DAC, this size may be corrected by subtracting the beam width in the through-thickness direction obtained from the calibration hole (between 20 percent DAC points) which is at a depth similar to the flaw depth. If the indication exceeds 50 percent DAC, the length should be recorded by measuring the distance between 50 percent DAC levels.
The determined size should be the larger of the two.
FPL believes that the intent ofthis paragraph is to require the examiner to determine and document the most accurate size of a refiector having through-wall dimension, to the extent practicable.
FPL typically requires bofh 20 percent and 50 percent beam spread measurement at the time of calibration in case the information is required during data analysis.
For tandem beam search units, the use ofbeam spread correction forsizing is not normally applicable because of fhe unique beam profile characteristics.
IArhen near surfaceindications are observed during a vessel examination, FPL routinely applies one or more special sizing techniques, before comparing the size fo the accepfance criferia of Secfion XI.
In general, FPL concurs with the specified approach, buf also requires application ofselected alternate sizing techniques when necessary based upon a
case-by-case evaluation in determining which technique is considered most appropriate for the anticipated flaw type and orientation.
6.3 indication Without Changing INetal Path a.
Indications which do not change metal path distance when scanned in accordance with the requirements of ASME Section XI and are within the outer 75 percent of the through-wall dimension should be recorded when any continuous dimension exceeds 1 inch.
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SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSLWG 1.150 REVISION 0 August 10, 1994 b.
Ifthe indication falls within the inner 25 percent of the through-wall dimensions, it should be recorded ar 20 percent DAC and evaluated at 50 percent DAC.
C.
Precautionary note: Indications lying parallel to welds may appear nontraveling (without changing metal path) when scanned by parallel moving transducers whose beams are aimed normal to the weld, l.e.,
at 90 degrees.
Multiple scans,
- however, may reveal that these indications are traveling indications. If so, recording and sizing are to be done in accordance with paragraph 6.2.
To fhe extent pracficable, evaluation ofnontravelingindicationsis pert'armed in accordance with these requirements, along with fhe use of additional sizing techniques where appropriate.
The precautionary note ofparagraph 6.3.cis appropriate.
To alleviate this concern, scanning is performed in the direction of the beam component wherever possible.
In those insfances when this preferred mode of scanning cannot be ufilized, NDE procedures address this concern by requiring additional scans (along the sound beam direcfion) of any nongeomefric angle beam indication observed during scans made parallel to the weld. Additionalscans are performed using small scanincrements (or large fransducer overiap) in order to develop a very accurate data set.
6.4 Additional Recording Criteria The followinginformation should also be recorded forindications that are reportable according to this regulatory position:
a, Indications should be recorded at scan intervals no greater than 1/4 inch.
b.
The recorded information should Include the indication travel (metal path distance) and the transducer position for 20 percent (where applicable), 50 percent, and 100 percent DAC and the maximum amplitude of the signal.
Page 16
SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSLWG 1.150 REVISION 0 August 10, 1984 When multichannel equipment is used in the examination system such as that all examination displays are not available for simultaneous viewing, an electronic gating system should be used which will provide on-line, reportable, recorded information regarding metal path, amplitude, and position of all indications exceeding a preset level. The preset level should be the minimum recording level required. To ensure that all recordable indications are
- recorded, a preferred method would incorporate multigates in each channel or a single gate for each channel with multi-indication recording capability.
In reference to Paragraph 6.4.a, inifial scanning is at 25 percent overfap as specifiedin Paragraph 3. However, data to be utilized for specific sizing or invesfigafion of indications that exceed the allowable limits of Section XIis acquired at 1/4 inch scan intervals.
The information required in Paragraph 6.4.his fypicallyrecorded for all vessel examinations, whefher the examination is perl'Ormed manually or using automafed equipment.
In reference fo Paragraph 6.4.c which addresses the use of mulfi-channel equipment,.the standard data acquisition system utilized by SwRI safisfies fhis requirement by virtue ofthe video recordr'ng ofthe instrument screens. Since fhe enfire screen presentationis recorded, simultaneous multiple signals an: recorded as encountered.
The data analysis process also includes review of all of the video tape data thereby ensuring that each recon/ed signal is reviewed and analyzed.
7.
REPORTING OF RESULTS Records obtained while followingthe recommendations of regulatory position 1.2, 3, and 6, along with discussions and explanations, ifany, should be kept available at the site. Ifthe size of an indication, as determined in regulatory position 6.2 or 6.3, exceeds the allowable hmits of Section XI of the ASME Code, the indications should be reported as abnormal degradation of reactor pressure boundary in accordance with the recommendation of regulatory position 2.a(3) of Regulatory Guide.1.16.
File RG1.1 50 Page 17
SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1984 Along with the report of ultrasonic examination test
- results, the following information should also be included:
a.
The best estimate of the tolerances in sizing the flaws at the sensitivity required in Section 6 and the basis for this estimate.
This estimate may be determined in part by the use of additional reflectors in the basic calibration block.
b.
A description of the technique used to qualify the effectiveness of the examination procedure, including, as a
- minimum, material, section thickness, and reflectors.
The best estimates ofthe portion ofthe volume required to be examined by the ASME Code that has not been effectively examined such as volumes of material near each surface because of near-field or other effects, volumes near interfaces between cladding and parent metal, volumes shadowed by laminar defects, volumes shadowed by part geometry, volumes inaccessible to the transducer, volumes affected by electronic gating, and volumes near the surface opposite the transducer.
Sketches and/or descriptions ofthe tools, fixtures, and component geometry which contribute to incomplete coverage should be included.
d.
Provide sketches of equipment (i.e., scanning mechanism and transducer holders) with reference points and necessary dimensions to allow a reviewer to follow the equipment's indication location scheme.
e.
When other volumetric techniques are used, a description ofthe techniques used should be included in the report.
ln reference to Paragraph T.a, FPL feels that the sizes obtained using Code sizing techniques should be used consistently tor comparison to Code acceptance standards whenever possible.
Based on experience, Code sizing techniques appear to be somewhat conservative; however, there is little evidence to support the feasibi%ty ofdeveloping specific tolerances or conection factors forCode sizing techniques. Noris there significant evidence ofimproved accuracy and consistency resulting from the use of any one alternate sizing technique. Alternate sizing methods must be used carefully and, in effect, should be used only when it can File RG1.150 Page 18
SECOND INSPECTION INTERVAL IMPLEMENTATIONOF REGULATORY GUIDE 1.150 PSL-RG 1.150 REVISION 0 August 10, 1994 be determined that fhe Code sizing techniques are, forsome reason, inappropriate for the specific type of flaw encounfered.
These statements do point out that flaw sizes based on UT are estimates.
- FPL, ofcourse, has varying degrees ofconfidencein flawsize estimates depending on pertinent examination variables. Since fhe ramificafions ofour flaw size estimates are very great, FPL willtypicallyrecommend certain actions to our vendors which can increase our confidencein flawsize esfimation. These recommendations may include actions such as:
(a) placing additional holes in fhe calibration block (b) constructing mockups of the examinafion area (c) using other NDE equipment (d) applying alternate NDE methods (e) performing certain laboratory tests (fl calling in specialists with particular experience in similar problems.
In reference fo Paragraph T.b, procedure qualifications are required and the documenfationis reviewed byFPL priorfoperformance ofthe examination activity.
Documentationis available forreview bythe enforcement and regulatory authority, and the aufhorizedinspecfion agency at any time.
In reference to Paragraph T.c, FPL requires a detailed limitafions report for all reactor vessel examinations.
The report is usually a combination of tables and sketches that quantify the various limitations to the Code required volume.
The information identifiedin Paragraph T.dis required by FPL to be included in a final report of the examination acfivity.
In reference to Paragraph T.e, when alfemafe techniques are ufilized, either for examination or sizing purposes, a complete descriptio of the application and results is included within fhe final report.
File RG1.150 Page 19
ST. LUCIE UNIT2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION ATTACHMENTB STAY CYLINDER EXAMINATIONSCHEDULE File PSL2RAI.94.
Page 16
DATE:
08/11/94 REVISION:
0 ST. LUCIE IRJCLEAR PLANT UNIT'2 USMRC REQJEST FIMI ADDITIONAL INFORMATION CLASS 1
SCHEDULED IXBIPONENTS PAGE-37 STEAk GENERATOR 2A PR JQAR S DE ZONE MQIBER: 003 SIWMARY EXAHIMATION AREA NUMBER IDENTIFICATION INSPECTION INTERVAL ASHE SEC. Xl CATGY MDE ITEM NO NETH
(
PLAN STATUS FIRST SECOND THIRD PERIOD PERIOD PERIOD
- - - - - - 0 U T A G E - --
1 2
3 1
2 3
4 1
2 INSTRUCTIONS
~CALIBRATION BLOCK REF.
DUG. NO.02-003 013000 SG-2A-109-251 8-H HT SUPPORT SKIRT-TO STAY BASE 88.30 IJT 2 -
X RCB EXAH LIHITED TO 1
STEAN GENERATOR, VolIsaetric or surfece ex'ay be perforaed, per IM8-2500.13 UT-7A~
013100 SG-2A-109-251-SP SUPPORT SKIRT RCB F-A VT-3 F1.30S 2-X PLATE AMD SHELL TYPE SUPPORT
&M/Atl 013200 SG-2A-101-251 STAY BASE-TO-PRIMARY HEAD RCB 8-8 UT 82.31 2
X UT-27 013400 SG-2A-101-254-8 HERIDIONAL 8 108 DEGREES RCB B-B UT 82.32 2
X EXAJI HOVED FROH 1ST PERIOD TO 3RD PERIIXJ, SUBJECT TO RR 0 14.
UT-27 013800 SG-2A-202-271 PRIHARY EXT. RING TO HEAD RCB 8-8 UT 82.31 2
X EXAM HOVED FROH 1ST PERIOD TO 3RD PERIIXJ, SUBJECT TO RR 8 14.
UT-27 013900 SG-2A-201-246 B-B UT PRIHARY EXT. RING-TO-TUBESHEET 82.40 RCB 2
X EXAH MOVED FROI 1ST PERIOD TO 3RD PERIIXJ ~
SUBJECT TO RR B 14.
IJT-27 014000 SG-2A-104-251 INLET NOZZLE-TO.HEAD RCB 8-D UT 83.130 2
X EXAH HOVED FRQI 1ST PERIOD TO 3RD PERIIm, SUBJECT TO RR 0 14.
UT-2W
DATEs 08/11/94 REVISION:
0 ST LUCIE NUCLEAR PLANT UNIT 2 USNRC REQUEST FOR ADDITIONAL INFORHATION CLASS 1
SCHEDULED CQ(PONENTS PAGE:
38 STEAH GENERATOR 2A PRIMARY SIDE ZONE NQ(BER: 003 SORRY EXAHINATION AREA NS(BER IDENTIFICATION INSPECTION INTERVAL ASKE SEC, XI CATGT NDE ITEH NO NETH PLAN STATUS FIRST SECOND THIRD PERIOD PERIOD PERIOD
- - - - - - 0 U T A G E - - - - --
1 2
3 1
2 3
4 1
2 3
INSTRUCTIONS
~CALIBRATION BLQX REF.
DUG.
MO.02-003 014100 SG-2A.102-251-A OUTLET NOZZLE-TO-MEAD 8 45 DEGREES RCB 8-D UT 83.130 2
X EXAH HOVED FROH 1ST PERIOD TO 3RD PERI(X), SUBJECT TO RR 8 14.
UT-27 014200 SG-2A-102-251-8 OUTLET NOZZLE-TO-MEAD 8 315 DEGREES RCB 8-D UT 83.130 2-X EXIH HOVED FRQH 1ST PERIOD TO 3RD PERI(m, SUBJECT TO RR 0 14.
UT-27 014400 SG-2A-101-244-8 EXT. RING LONG OLD 8 90 DEGREES RCB t014700 SG-2A-IN-IR INLET NOZZLE INNER RADIUS RCB 8-8 UT 82.32 8-D UT 83.140 2
X 2
X EXAH HOVED FROH 1ST PERIOD TO 3RD PERI(X), SUBJECT TO RR 0 14.
UT-27 EXAH HOVED FROH 1ST PER100 TO 3RD PERIQ),
SUBJECT TO RR 8 14.
UT-F 014800 SG-2A-OM-IR-A OUTLET NOZZLE (45D)
INNER RADIUS RCB B.D UT 83.140 2
X EXAH HOVED FROH 1ST PERIOD TO 3RD PERICO, SUBJECT TO RR f 14.
UT-2
- 014900 SG-2A.OM-IR.B OUTLET NOZZLE (315D)
INNER RADIUS RCB BD UT 83.140 2
X EXAH HOVED FROH 1ST PERIOD TO 3RD PERIOD SUBJECT TO RR 0 14.
UT-2 015300 SG-2A-PHS-A PRIHARY HAMNAT STLSS 8 0 DEGREES RCB 8-G-2 VT-1 87.30 2 X
~N/A~
'DATE:
08/11/94 REVISION:
0 ST.
LUCIE NUCLEAR PLANT UNIT 2 USNRC REQUEST FOR ADDITIONAL INFORNATION CLASS 1
SCHEDULED IXWPONENTS PAGEi 39 F-'
STEAN GENERATOR 2A PR WAR S
D 2ONE NMER: M3 SQBIARY EXAIII NATION AREA NINBER IDENTIFICATION INSPECTION INTERVAL ASIDE SEC. XI CATGY NDE ITEN NO NETH I
FIRST PERIOD PLAN STATUS SECOND THIRD PERIOD PERIOD
- - - - - - 0 U T A G E - - - - --
1 2
3 1
2 3
4 1
2 3
INSTRUCTIONS CALIBRATION BLOCX REF DVG NO 0.003 015400 SG-2A-PHN.A PRIHARY NANNAY NUTS B 0 DEGREES RCB B.G-2 VT-1 87.30 2 X N/A~
015500 SG-2A-PHS-8 e-0-2 Vr-1 PRINARY KAÃNAY STUDS B 112D30'7.30 RCB 2 X
~N/A~
015600 SG-2A.PNN-B 8 G-2 VT-1 PRIHARY NANMAY NUTS B 112030'7.30 RCB 2 X
~N/A~
e 015700 TUBE BUNDLE 8,411 U-TUBES RCB B-Q ECT B16.20 2C X
X THE EXTENT AND FREQUENCY OF EXANINATION IS DETERNINED BY PLANT TECHNICAL SPEC IF ICATIONS
~LATER~
ST. LUCIE'UNIT,.2
'SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION ATTACHMENTC REVEF REQUEST NO. 1 File PSL2RAI.94.
Page 17
-,ST. LUCIE-UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 1 A.
COMPONENT IDENTIFICATION:
Class:
1 Reactor Pressure Vessel and Closure Head Pressure Retaining Wetds B.
EXAMINATIONREQUIREMENTS:
EXAM CAT.
ITEM NO.
EXAMINATIONREQUIREMENTS B-A B1.10 B1.11 B1.12 Essentially 100% volumetric examination of all longitudinal and circumferential shell welds (does not include shell to flange weld).
8-A 8-A B-A 8-D B1.20 B1.21 B1.22 B1.30 B1.40 B3.90 Essentially 100% volumetric examination of accessible length of circumferential and meridional head welds, Essentially 100% volumetric examination of the shell to flange weld.
Essentially 100% volumetric and surface examination of head to flange weld ncludes nozzles with full penetration welds to vessel hell (to head)
C.
RELIEF REQUESTED:
Relief is requested from the ASME Boiler and Pressure Vessel Code required volume due to the following:
1)
Configuration and permanent attachments prohibit essentially 100%
ultrasonic examination coverage of the required examination volume.
Additional ultrasonic techniques are employed, where practical, to achieve the code required volume.
See attached table summary of coverage achieved and limitations.
2)
Component geometric interference with the scanning equipment and/or geometric shadowing of examination areas.
Page C 1
ST. LUCIE UNIT2
- SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 1 D.
BASIS FOR REUEF:
10 CFR 50.55a (g) (4), recognizes that throughout the service life of a nuclear power facility, components which are classified as ASME Code Class 1 shall meet the requirements, except design and access provisions requirements, set forth in Section XI, to the extent practical within the limitations of design, geometry and materials of construction of the components.
2.
NDE procedures implemented during the St. Lucie Unit2 RPV examinations utilize full vee path calibration of the 45'hear wave scans to compensate for limitations encountered in the near surface and those due to geometric shadowing.
Those examination volumes which receive other than 90% of the ASME Code required coverage are identled within this Request for Relief. It should be noted that electronic gating does not result In any examination limitations since the entire instrument screen presentation is monitored during the examinations, video
- taped, and reviewed independently following the examinations.
Described below, coupled with the Tables and Figures, are details of the examination limitations by weld description.
The accompanying Figures graphically depict the locations and extent of the limitations with respect to weld metal and associated base material.
The Table quantifies the limitations in terms of present code required volume which is effectively covered.
RPV LOWER HEAD MERIDIONALWELDS Mechanized scanning of the Lower Head Meridional weids 101-154A through F is limited due to interference from the core support lugs and flow skirt.
Figure 1.1 is a roll out inside view showing inside surface scan limitations. Figure 1.2 provides a side section view of peel segment welds showing limitations caused by core support lugs and flow skirt support.
Figure 1.3 provides a graphic view of a typical meridional weld showing transverse scan limitations in the area behind the flow skirt.
RPV CIRCUMFERENTIALSHELL WELDS The mechanized examination of the Lower Shell-to-Lower Head weld 201-141 is limited due to interference from the core support lugs and anti-rotation lugs.
Figure 1 ~ 1 is a roll out view showing the inaccessible scan surfaces from the vessel inside surface and shows the volume of material not examinable from the inside surface where scanning was limited by lug interference.
File RR-01.TR1 Page C 2
ST-LUCIE UNIT-2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 1 Examination ofthe Middle Shell-to-Lower Shell weld 101-171 is limited due to interference from the surveillance specimens.
Figure 1.1 is a roll out view ofweld 101-171 depicting areas where parallel examination scans can not be performed.
The Upper Shell-to-Flange weld 101-121 is examined from the shell side and from the flange seal surface. Beams directed nearly perpendicular to the weld plane from the flange seal surface compensated for the straight beam and angle beam examination limitations on the flange side of the weld. Due to the flange configuration, no transverse examination scans can be performed on the flange side of the weld. Figure 1.6 shows the limitations to the shell side examination and depicts the coverage obtainable from the seal surface examination.
Also shown is the tapered surface where transverse examination is prohibited.
RPV LONGITUDINALSHELL WELDS The examinations of the Lower Shell Vertical welds 101-142A, B and C are limited due to the core barrel antI-rotation lugs in the case of welds 101-142B and C.
Figure 1.1 shows the limitation of the 45 vee path examination.
The examination of weld 101-142C is also limited due to interference of the surveillance capsules.
This volume is effectively examinable by the 45'ull vee path beam. The 0 and 60'eam limitations are shown on Figure 1.5.
The 60'xamination ofthe Middle Shell Vertical welds 101-124C, is limited by interference from the surveillance capsules as shown on Figure 1.1.
Examination of the Upper Shell Vertical wetds 101-122A, is limited by interference from the outlet nozzle integral extension as shown on Figure 1.1. However, the examinations are complemented by the Nozzle-to-Shell weld examinations.
RPV NOZZLE TO SHELL WELD The inlet and outlet Nozzle-to-Shell welds are examined from the shell side and from the nozzle bore.
The Nozzle Bore examinations are limited due to near surface interface noise; however, surface wave examinations are performed on the nozzle inner radius sections which effectively compensates for the interface noise problem. The shell side transverse examinations of the outlet nozzles are limited due to interference from the nozzle integral extensions.
Limitations to the Inlet Nozzle examinations are shown on Figure 1.7 and limitations to the Outlet Nozzle examinations are shown on Figure 1.8.
File RR-01.TR1 Page C 3
ST. LUCIE UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 1 RPV CLOSURE HEAD E.
The Closure Head-to-Flange weld 101-101 is examined from one side due to flange.
Figure 1.10 provides the scan path for this weld.
The Closure Head Dome weld 102-101 is limited due to instrument nozzles, penetrations, and CEDM's, see Figure 1.13.
The extent of examination volume achieved ultrasonically and the alternate scans performed (see Examination Coverage Table) coupled with the system pressure tests provide assurance of an acceptable level of quality and safety.
ALTERNATIVEEXAMINATIONSOR TESTS:
1)
Periodic System Pressure tests per Category B-P, Table IWB-2500-1 2)
Inservice Hydrostatic tests per Table IWB-2500-1 3)
Conduct Mechanized Ultrasonic Examinations to the extent practical.
4) 50/70'i-modal ultrasonic examination of the inner 25 percent t.
F.
IMPLEMENTATIONSCHEDULE:
Second Inservice Inspection Interval August 8, 1993 to August 08, 2003 G.
ATTACHMENTSTO THE RELIE:
- 1) Examination Coverage Table
- 2) Examination Limitation Drawings.
File RR-Ol.TRl Page C 4
ST. -LUCIE UNIT.2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 1 Summa'umber Examination Atea Idenifcaffon Beam Dlmcthn Percent Coverage Figure No.
Description of Examlnaffon Coverage and Umlta5ons 000020 Bottom Head Peel Segment WeldI30 Deg.
N0.101 154A 45'0'onoRV 45'T 60'T sonow GWICCW CWICGW GWICCW UP/DN UP/DN UP/DN 62%
62%
62%
62%
69%
70%
72%
182 Examination of IWB-2500-3 E+~ volume limited along length ofweld near flowsldNower head attachment Claimed coverage Is 65%
overall 000030 000040 Bottom Head Peel Segment WeldI 90 Deg.
No. 101-154B Bottom Head Peel Segment Weld fe150 Deg.
No. 101 154C 45'0'ono.
O'RV 45'T 60'T sonow 45'0'ono O'RV 45'T 60'T 50/70'T GWICGW CWICCW GWICGW UP/DN UP/DN UP/DN CWICCW GWICCW GWICCW UP/DN UP/DN UP/DN 54/62%
54/62%
54/62%
62%
69o%%d 70%
72%%d 62%
62%
62%
62%
69%
70o%%d 72%
1g,3 182 Examination of IWB-2500-3 EW~ volume limited along length ofweld near flowsidrtdower head attachment and at flow sldrt support bracket Claimed coverage Is 64%
overall Examination of IWB-2500-3 E-FW-H volume limited along length ofweld near flowsldttdower head attachment. Claimed coverage is 66% overall 000050 000060 Bottom Head Peel Segment Weld 210 Deg.
No. 101-1 54D Bottom Head Peel Segment Weld 1270 Deg.
No. 101-1 54E 45'0'ono O'RV 45'T 60'T 50/70'T 45'0'ono O'RV 45'T 60'T sonow CWICCW CWICGW CWICCW UP/DN UP/DN UP/DN CWICCW CWICCW CWICCW UP/DN UP/DN UP/DN 54/62'/o 54/62o/o 54/62%
62o%%d 69/o 70o/o 72%
62%
62%
62%
62/o 69 70%
72o/o 1+,3 182 Examination of IWB-2500-3 E-F~H volume limited along length of weld near flowskirtdower head attachment and at flow skirt support bracket.
Claimed coverage ls 64%
overall Examination of IWB-2500-3 E-FW-H volume limited along length ofweld near flowskirtdower head attachment. Claimed coverage is 66% overall File RR-Ol.TR1 Page C
ST.;LUCIE UNIT 2'ECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 1 Summary number Examination Area Identificatbn Beam Dlcecfbn Percent Coverage Figure No.
Descrtptbn of Examlnatbn Coverage and Umitations 000070 000120 000150 Bottom Head Peel Segment Weld O 330 Deg.
No. 101-1 54F Lower Sheil-to-Intermediate Shell Circ.
Weld No. 101-171 Intermediate Shell Long.
Weld 255 Deg.
No. 101-124C 45'0'0/70RV 45'T 60'T sonow 45'0'ono O'RV 45'T 60'T sonow 45'0'ono 0'Rv 45'T 60 T 50/70'T CWICCW CWICCW GWICGW UP/DN UP/DN UP/DN GWICCW CWICCW GWIGGW UP/DN UP/DN UP/DN CWICCW GWICCW CWICCW UP/DN UP/DN UP/DN 544%%d/62%
54%/62%
54%/62%
63%
69%
70%
72%
92%
92%
92%
85%
85%
85%
83%
100%/70%
100%/55%
100%%d/74%
100%
100%
100o%%d 1005 1g,3 185 Examination of IWB-2500-3 EW~ volume limited along length ofweld near flowskINower head attachment and at flow sldrt support bracket.
Calmed coverage Is 64%
overall Examination of IWB-2500-2A~volume limited along length ofweld near vessel material specimen tubes. Claimed coverage is 8S% overall Examination of IWB-2500-2 A-MH)volume limited along length ofweld near vessel mater/al specimen tubes. Claimed coverage is 81% overall 000170 Upper Shell Longitudinal Weld O15 Deg.
No. 101-122A 45'0'ono.
O'RV 45'T 60'T sonow GWIGGW CWICGW CWICCW UP/DN UP/DN UP/DN 100/o/96%
1004/4964%%d 100/4/99%
97%
79%
74%
95%
Examination of IWB-2500-2 A-BC-Dvolume limited at intersection with the adjacent outlet nozzle integral extension.
Claimed coverage is 87%
.overall 000200 Upper Shell-to-Flange Circumferentia I Weld No. 101-'I21 45'0'ono O'RV 45'T 60'T sono~
GWICGW CWICGW CWICCW UP/DN UP/DN UP/DN 87%
80%
70'/o 50%
50%
50%
504/o 186 Examination of IWB-2500-2 A-EC-D volume for Transverse flaws Is limited above the weld by the inside surhce taper.
Claimed coverage ls 67%
overall 000210 Outlet Nozzle O 0 Deg.
Nozzle-to-Shell Weld.
No. 105-121 a 0'RV 45'T 60'T 50/70'T Shell Shell Shell Shell 28o%%d 2S4%%d 28%
28o%%d Examination of IWB-2500-7-A, B, C, D,E, F, G, H,I and M-N~P volumes transverse examination I'rom shell is limited by the integral extension.
File RR-01.TR1 Page C
ST. LUGIE UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 1 Summary number Beam Direction Percent Coverage Figure No.
Descrfptlon of Examination Coverage and umltatlons 000240 000790 000840 Outlet Nozzle 180 Deg.
Nozzle4o-Shell Weld No. 103-121B Flange to Torus Weld No. 101-101 Dome Weld No. 102-101 O'RV 45'T 60'T 50now O'RV 45'A 60'A 45'0'5'0'5'0'hell Shell Shell Shell Flange Shroud UP/DN UP/DN CWICCW GWICGW UP/DN UP/DN 28%
28%
28%
28%
80%
1oono%
70/60%
100/50%
100/100%
35/90%
25/80%
20/35%
10/80%
9,10,11 98 13 Examination of lWB-2500-7~B,C,D,E,F,G,H,I and IIAAGPvolumes transverse examination from shell ls limited by the integral extension.
Examination of IWB-2500-5 volume limited at intersection of flange flex radius, shroud, shroud hold down lugs, and head liltinglugs. Claimed coverage is 75% overall Examination of IWB-2500-3 volume limited by location of shroud and at intersection of adjacent weld 101-101 and shroud.
Claimed 46% overall File RR-01.TR1 Page C 7
0'5' I
60'0' I
120'35 I
I I
180' I
240'55'70'01-121 8
300 '
I 360'REA Of IO TAPER NOZZLE INTERFERENCE NTH VERTICAL WELD TRANSVERSE SCANS
~ 101-122A
~ 101-1228
~ 106-121 ~ 101-122C RPV MATERIAL SPECIMEN TUBES
~ 101-124A
~ 101-1248 10'I-124C~
33
'I53'3
~ 101-171 FLOW SKIRT SUPPORT 0
~ 101-142A 0
60'3 97'I04 120' 101-1428 O
18Q'40'20
-141 277 284'63' 101-142C 360'ORE BARREL ANTI ROTATION LUG 10'0 101-154A 40'5 9Q'01-1548 130 150'01-154 C
160'05'10'OI-1540 250'70'01-154E 280'25 330'01-154F FLOW SKIRT UPPER EDGE FLOW SKIRT LOWER EDGE 101-151 ROLL OUT IIISGE VIEW INACCESSIBLE SCANNING SURFACES FIGURE 1.1
PLOD SKlgT SUPPORT GORE SUPPORT LUGS TL05 SKID'T Eggs ljjhiTATlOH SOE SECTlOH +At PEEL SEGNEHT %CLOS 79.82 TELOS 10'l 154A THOU f RGURE 1.2
PARALLEL EXAM SECTION AT BOTTOM OF WELD TRANSVERSE EXAM r
FLOW SKIRT SUPPORT r
EXAM UMITATION SECTION AT SKIRT SUPPORT I I I I II I I IIIIII I I I SECTION AT TOP OF WELD PEEL SEGMENT WELDS AT 90', 210',
AND 330 AZIMUTH TOP VIEWS WELDS 101-154A THRU F FIGURE 1.3
CORE BARREL ANTI ROTATION LVG (TYP 6 PLACES)
I/2 4
PARALLEL EXAMINATION UMITATION.
TRANSVERSE EXAMINATION UMITATION 1/2 t CORE SUPPORT LUGS FlOW SKIRT SUPPORT LOSER HEAO TO LOWER SHELL CIRCUMFERENTIAL YELD RGURE I.4
RPV MATERIAL SPECIMEN INTERMEDIATE AND LOWER SHELL VERTICAL WELDS AT 255 VESSEL AZIMUTH PARALLEL EXAMIHATIOH UMITATIOH (0,'5',
60', 50/70'CW BEAMS)
WELD 101-124C FIGURE 1.5
FROM SEAL SURFACE FLANGE IO TAPER (seo')
PARALLEL EXAMINATION LIMITATION NO TRANSVERSE EXAMINATION uMITATION SHELL WELD 101-121 FIGURE 1.6
INLEI'IOZZLES NO UMITATION TRANSVERSE EXAMINATION
~
~
~
~
0,'5', 60'AND 50/70'FROM SHELL) 50/70 FROM BORE) 15'EAM UMITATION AT 90'NO 270'OZZLE AZIMUTH 45 BEAM UMITATION AT 0 AND 180'NOZZLE AZIMuTH PARALLEL EXAMINATION (15'AND 45'FROM BORE)
FIGURE 1.7
TRANSVERSE EXAMINATIOII (a'45',
SO', arfrd'FROM SHELL)
NO EXAMINATIONFOR 360'NOZZLE AZIMUTH OUTLET NOZZLES EXAMINATION FROM BORE ON PREVIOUS OUTAGE TELOS 105-121A + B FIGURE 1.8
I02-101 101-101 FROM O.D.
OF I.D.
SECTION A-A flCURE I.9
WELD REQUIRED VOLUME AND SCAN PATHS FOR CLOSURE HEAD WELD AND PEEL WELDS O.D. SURFACE SCAN PATH LEGEND II PARRALLEL SCAII J pERpENDICULAR scan O'- CAUBRATED LONGITUDINAL 23 60'J 45 J 45'J 6 J 6"
ULTRASONIC EXAMINATION OF RPV FLANGE CLOSURE HEAD WELD 10 4
V, II II I.D. SURFACE 101-104 A-D O'RV 6"
23" 101-101 FLANGE 45'I, 60'll 23" CLAD (
I.D. SURFACE 6 PRESSURE RETAINING SURFACE CLAD 60'J 4S'J 0.0. SURF'ACE PSL RPV CLOSURE HEAD WELDS FIGURE 1.10
SHROUD LOCATION SCAN DIRECTION 1/2 T
HCW 6.2" SCAN DIRECTION I/2 T FLANGE FLEX AREA 60 45 45 60 M.D NO. 101-101 FIGuRE 1.11
FLANGE flEX AREA LIMITATIONS (TYPICAL)
SHROUD LUG WELD CROWN 18" 6 I/4' 2/10 FLANGE UP 2 5/10 RPV STUD HOLE
~ LUGS LGCATEO AT STUD HOLES; LUG SHROUD 38" LUG i 3O If 8 If 3S
$ 12 g 39
$ 17 f44 If 21 g 48 If 25 g 53 NOTE: LUGS ARE SPACED 38" APART LOCATED BY ADJACENT RPV STUD HOLES.
EXAMINED FROM STUD HOLE 0 THROUGH 28 CLOCKWISE LOOKING DOWN.
FIGURE 1.12
101-104-C
~pS "A
90 ooo o 0 o 73 0 oo 630 o
0 35021 72 015 520 02007 610 02811 60 0190 510 014 o o 043 0
62QQO Q6Q 26Q ooo 0
O'o 580 ooo o
o 0
740 0
o0o 022 0
o 160 23 I5 4 Q6 Q2l Q66
,Q Q,4Q66 Ol 48
'6Q26 P
0 O
Q Q46<<6 Oo 57 0
ss ooo
, OQpo ooo 270 101-104-A FlGURE 1.13
ST. LUCIE UNIT.2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION ATTACHMENTD REUEF REQUEST NO. 5 File PSL2RAI.94.
Page 18
ST. LUCIE UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 5 A.
COMPONENT IDENTIFICATION:
Class:
1 Reactor Coolant Pump Suction and Discharge Safe end to pipe welds.
Pressure Retaining Dissimilar Metal Welds, Pressure retaining welds in Piping.
B.
EXAMINATIONREQUIREMENTS:
EXAM CAT.
ITEM NO.
EXAMINATIONREQUIREMENTS B-J B-F B9.11 B5.130 Essentially 100% volumetric and surface examination of Circumferential welds for >4" nominal pipe size.
Essentially 100% volumetric and surface examination of nozzle-to-safe end butt welds NPS 4 or larger.
C.
REUEF REQUESTED:
Relief is requested from the ASME Boiler and Pressure Vessel Code required volume as identified in Figure IWB-2500-8.
D.
BASIS FOR REUEF:
Configuration and permanent attachments prohibit 100% ultrasonic examination coverage ofthe required examination volume. The attached Table summarizes the percent of coverage achieved and reference specific, Figures included within the request identifying typical configurations Both the pump casing and the safe-end are fabricated from SA-351-CFSM material, which is centrifugally'ast stainless steel.
This material consists of relatively large grains in columnar structures that are aligned radially.
INLET The geometry of the welds varies considerably.
Figure 1 illustrates the inlet safe-end configuration in that the wall thickness of the elbow is 6/10" thicker than the safe-end.
Thus, the elbow-to-safe-end weld tapers down to the safe-end, and within a short distance another taper is caused by the joining ofthe safe-end to the pump.
The configuration of the safe-end weld conditions provide essentially no Page D 1
'ST. LUCIE.UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 5 access limitations on the shop weld from the elbow side, but are significantly more prohibitive from the safe-end side Including the surface conditions on the field weld. Most ofthe OD surface is not sufficientlyflat to permit adequate search unit contact. The taper is often so steep that the ultrasonic beam either changes to an ineffective angle or misses the area of interest entirely. The transition between weld taper and flat base material is so abrupt that search unit liftoffoccurs, causing substantial gaps in the beam coverage.
OUTLET The outlet safe-end configuration Figure 2 tapers gently upward from the pipe to the safe-end and further into the pump casing which is of an even greater thickness.
The geometric configuration poses no significant access limitation except for the safe-end to pump field weld where beam interrogation is possible from one side only.
SUPPLEMENTARY TECHNIQUE FPL has employed a full scale mock-up in lieu of the standard code calibration block. The mock-up was constructed of identical material with a duplication of the construction field weld and a duplication of the shop weld welding parameters considered necessary for this application. (See Figure 3)
This mock-up is considered invaluable toward the understanding and the qualification of acoustical interfaces that 'could cause beam
- scatter, beam redirection, mode conversion and verification of sound beam penetration.
The mock-up design accommodates a calibration from the carbon steel side to be used for the shop weld and a calibration from the safe-end material to be utilized for field weld examinations.
The examination technique essentially complies with the provisions of Section XI.
The shape and slope of the distance amplitude curve (DAC) is established using side drilled holes while examination sensitivity is established by ID notch (10%)
response.
In both cases, the ultrasonic beam passes through weld metal during calibration.
The extent of examination volume achieved ultrasonically (see Examination Coverage Table) coupled with the system pressure tests provide assurance of an acceptable level of quality and safety.
ALTERNATIVEEXAMINATIONSOR TESTS')
Surface examination per categories B-F and B-J.
RR 05. TXV Page D-2
ST.;LUCIE.UNIT.2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 5 2)
Ultrasonic examinations willbe performed to the maximum extent possible.
3)
Periodic system pressure tests.
F.
IMPLEMENTATIONSCHEDULE:
Second Inservice Inspection Interval August 8, 1993 to August 08, 2003 G.
ATTACHMENTSTO THE RELIEF:
- 1) Examination Coverage Table
- 2) Typical limitation figures.
- 3) RR-5 attachment ultrasonic examination technique and preservice inspection results.
File RR-05.TXt'age D - 3
.ST.,LUCIE UNIT-2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 5 Examlnatlon Area Idenbtication 2A2 Inlet Field Weld Safe end to Pump weld No. RC-115-4 2A2 RCP Inlet shop weld Elbow-to-safe end weld Number RC-115-1501-771-A Beam Angle 45'5'xamination Coverage Coverage (CRY) 20% from Safe End 0% from Pump side 100%
from Elbow 0% from safe end Descrfption of Umltatlons Examination limited by configuration.
Examination limited by configuration.
2A2 RCP Outlet Field weld, Safe end to Pipe weld Number RC-115-701-771 2B1 RCP Inlet shop weld elbow-to-safe end weld No.
RC-115-1501-771-B 2B1 RCP Outlet Field weld, Safe end to Pipe weld No.
RC-121-5 2A1 RCP Inlet shop weld Elbow-to-safe end weld no.
RC-112-1501-771-C 2B2 RCP Inlet shop weld Elbow-to-safe end weld No.
RC-124-1501-771-D 45 45 45 45 45'00%
from pipe 30% from safe end 100%
from Elbow 0% from safe end 100%
from Elbow 0% from safe end 100%
from elbow 20% from safe end 100%
from Elbow 0% from safe end Examination limited by configuration.
Examination limited by configuration.
Examination limited by configuration.
Examination limited by configuration.
Examination limited by configuration.
Pile RR-OS.IXX'age D
ST. LUCIE UNIT.2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 5 ExamlnatIon Area Beam IdenNhathn Angle Examination Coverage Coverage Flg.
DescrfptIon of Umltations (CRY) 282 RCP Inlet Shop 45 weld safe end to Pipe weld No.
RC-124-1301-771 100'rom pipe 304k from safe end 1
Examination limited by configuration.
Pi1e RR-05.TXX'age D 5
INI.E T CONF IGVRATION nGVRE I IIICONEL BVTTERING TTPICAL CONTOURS ELBOW SA-35 I CFSM r
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OUTLET CONFIGURATION FIGURE 2 PUMP CASING FIELD MELD
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SAFE END SHOP VELD PIPE SUBJECT OF RELIEF REQUEST 5
0 FULL SCALE HOCK-UP FIGURE 3 SA-516 GR 70 INCOtlEL MELD
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SA-351 CFSH VELD
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SA-351 CFSH AXIAL SCAN CALIBRAT ION CIRCUHFRENTIAL SCAN CALIBRATION IHPINGHENT 40 IHPINGHENT INCIDENT 40 POOR
RESPONSE
40 INCIDENT GOOD
RESPONSE
SUBJECT OF RELIEF REQUEST 5
NUCLEAR ENGINEERING DEPARTMENT CoMPoNENT, SUPPQRT AND INsPEcTIoNs P.O. BOX 14000 JUNO BEACH, FLORIDA 33408 St. LucIe Nuclear Power Phnt Unit 2 SECOND INSERVICE INSPECTION INTERVAL ULTRASONIC EXAMINATIONTECHNIQUE AND RESULTS FROM PRESERVICE INSPECTION OF REACTOR COOLANT PUMP SAFE END WELDS Prepared by Florida Power and Light Company Code Programs Section For St. Lucie Nuclear Power Plant 10 Miles South of Ft. Pierce on A1A Ft. Pierce, Florida 33034 Commercial Service Date:
NRC Docket Number.
Document Number.
Revision Number.
August 8, 1983 50-389 PSL-200-RR-5 Date: August 10, 1994
SECOND INSPECTION'NTERVAL ULTRASONIC EXAMINATIONTECHNIQUE FOR RCP SAFE END WELDS PSL400~%
REVISION 0 July 28, 1894 1.0 EXAMINATIONITEMS Each Reactor Coolant Pump Safe End area consists of two welds; Pump-to-Safe End and Safe End-to-Pipe or Elbow (as applicable). Figure 1 shows the weld materials, geometry and the adjacent components. Each Pump has an Outlet Safe End and an Inlet Safe End.
Both the Pump Casing and the Safe End are fabricated from SA 351 CF8M material, which is centrifugally cast stainless steel. This material consists of relatively large grains in columnar structure that are aligned radially. The piping connected to the Outlet Safe End consists of a carbon steel (SA-516 Grade 70) pipe with 304 stainless roll bonded cladding on the interior. The pump inlet differs in that an elbow exists on the pipe side. Although the elbow is fabricated from pipe material, it is thicker, 3.6 inches as opposed to 2.8 inches for the straight pipe. All other fabrication parameters are essentially the same.
The geometry of the completed weld varies considerably. The Outlet Safe End configuration tapers gently upward from the pipe (2.8 inches thick) to the Safe End (3.2 inches thick) and further into the pump casing which is of an even greater thickness. The Inlet Safe End differs in that the wall thickness ofthe elbows is 6/10 inches thicker than the Safe End. Thus, the Elbow-to-Safe End Weld tapers down to the Safe End, and within a short distance another taper is caused by the joining of the Safe End to the pump. (See Figure 1).
2.0 EXAMINATIONACCESS 2.1 RCP INLET SAFE END WELDS (SHOP AND FIELD)
The geometric configuration of the Safe End Weld conditions provide essentially no access limitations on the examinations of the shop welds from the elbow side, but are significantly more prohibitive from the safe end side including the surface conditions on the field weld.
(See Figure 1)
The geometric configurations ofthe Safe End welds have significant access limitations on the examinations of the field welds from the Safe End side, and are essentially prohibitive from the pump side.
Most of the outside (OD) diameter surfaces is not sufficiently flat to permit adequate search unit contact. The taper is often so steep that the ultrasonic beam either changes to an ineffective angle or misses the area of interest entirely. The transition between weld taper and flat base material is so abrupt that search unit liftoffoccurs, causing substantial gaps in beam coverage. The two welds are so dose together that limited space frequently File RR%5.R0$
Page 1
.SECOND INSPECTION INTERVAL ULTRASONIC EXAMINATIONTECHNIQUE FOR RCP SAFE END WELDS PS LAO~&5 REVISION 0 July 28, 1004 exists in between for the required search unit positioning.
2.2 RCP OUTLET SAFE END WELDS (SHOP AND FIELD)
The geometric configuration poses no significant access limitation except for the Safe End-to-Pump field weld where beam interrogation is possible from only one side (see Figure 2). The beam focus range is sufficiently wide to accommodate the mildtaper upward with respect to scan direction, inside (ID) diameter reflector detection ability is enhanced by increasing the beam impingement angle. (See Figure 3A AND 38) 3.0 SUPPLEMENTARY ULTRASONIC TECHNIQUE - FULLSCALE MOCK-UP Considering the variety of materials employed in the weld joints (Figure 1), a full scale mock-up was deemed necessary in lieu of the Code calibration block (see Figure 3). The mock-up is constructed of identical materials with a duplication of as much of the welding parameters as possible. The benefits of the mock-up are two fold:
3.1 There are six distinct acoustical interferences that willcause beam scatter, beam redirection and mode conversion. A mock-up is invaluable toward the understanding and the quantification of such phenomena, and verification of sound beam penetration; 3.2 The original calibration block, although fabricated from Safe End material was not acoustically similar to the actual weld area. A welded mock-up essentially duplicates all parameters, particularly heat input.
The mock-up design accommodates a calibration from the carbon steel side to be used for the shop weld examination and a calibration from Safe End material to be utilized for field weld examinations (see Figure 3).
The examination technique is substantially in compliance with the provisions ofASME Section XI,Appendix III, Supplement 7. The shape and slop ofthe distance amplitude curve (DAC) is established using side drilled holes while examination sensitivity is established by the inside (ID) diameter notch (10%) response.
4.0 ULTRASONIC EXAMINATIONPERFORMANCE Examination calibration consists of a triple distance amplitude correction (DAC) to effectively accommodate all conceivable examination conditions (see Figure 3).
File RR<5.R01 Page 2
- SECOND INSPECTION INTERVAL
,uLTRASONIC EXAMINATIONTECHNIQuE FOR RCP SAFE END WELDS PSL<00%54 REVISION 0 July 28, 1004 4.1 FIRST CAUBRATION The first calibration comprises contact on the carbon steel surface with the sound beam aimed toward side drilled holes aligned in the centerline ofthe inconel weld. The response from these three holes are used to establish the shape and slope of the DAC. The search unit is then positioned to maximize a response from the inside (ID) diameter notch located in the Safe End (beam passing through the inconel weld). This response,
- ideally, should be adjusted to the level of the DAC; however, the notch yields only a 20% full screen height (FSH) signal. At that cathode ray tube (CRT) distance, the DAC level would be about zero. Since DAC points below 20%
FSH are of little value, the notch response is simply marked, as is, without a sensitivity adjustment.
4.2 SECOND CAUBRATION The second calibration comprises search unit contact on the opposite end of the block with the sound beam aimed at the side drilled holes aligned parallel with and adjacent to the 308 stainless weld. This calibration establishes the shape and slope of the DAC through SA 351 CF8M Safe End material. In this case, the notch signal is "gained-up" (+ 6 db) to meet the DAC level.
4.3 THIRD CAUBRATION The third calibration is performed in the same manner but in this case the search unit is rotated 180 degrees to aim at the same holes with the sound beam passing through the 308 stainless weld prior to impinging on the holes. This is performed to determine the extent of acoustic differenc, if any.
Scanning is performed on the carbon steel side at twice the calibration sensitivity. Scanning on the austenitic materials utilizes the straight 351 material calibration as this is the more sensitive of the two. Material noise levels prevent the usual double sensitivity (+ 6 db); scan speed is reduced accordingly.
5.0 BACKGROUND
The centrificaily cast stainless Safe End material is renowned, within the industry for it's high acoustic impedance.
Consultations with Combustion Engineering, Southwest Research institute and Nuclear Energy Services confirmed that the "State of the Art" techniques involved the use of special search units. Florida Power and Light Nondestructive Examination (NDE) staff evaluated four different File RRZ5.R01 Page 3
-SECOND INSPECTION INTERVAL ULTRASONIC EXAMINATIONTECHNIQUE FOR RCP SAFE END WELDS PS L<0045%
REVISION 0 July 28, 1004 search units designed forthis application and retained foruse that which exhibited the superior performance.
Industry research has shown that refracted longitudinal wave interrogation of cast stainless structure achieves the greatest penetration.
Further, beam incident angles are limited to the 40 to 45 degree range.
The search unit is contoured to enharice the beam focus. Additional contouring is not a viable option because the conical weld surfaces are Insufficiently uniform (the surfaces have been smoothed by hand grinding). We cannot utilize other examination angles for the technical reasons cited earlier. We cannot miniaturize the search unit because the low (1.0 Mhz) examination frequency would cause deleterious beam divergence and smaller search units do not provide sufficient power to penetrate the materials.
6.0
SUMMARY
OF EXAMINATIONVOLUMEACHIEVED (PRESERVICE)
ELBOW SIDE SHOP WELD*
FIELD SAFE END WELD SIDE SAFE END SIDE FIELD WELD PUMP SIDE A-1 INLET A-2 INLET 8-1 INLET B-2 INLET 100 100 100 100 20 30 20 10 10 30 SAFE END WELD SHOP WELD*
PIPE SIDE e/o SHOP WELD*
FIELD SAFE END WELD**
WELD SAFE END SIDE FIELD WELD PUMP SIDE A-1 OUTLET 100 100
'IOO A-2 OUTLET 100 B-1 OUTLET 100 B-2 OUTLET 100 30
'IOO 30 50 100 50 File RR<5.R01 Page 4
SECOND INSPECTION INTERVAL uLTRAsoNic EXAMINATIQNTEGHNIQUE FOR RCP SAFE END WELDS PSL<00~%
REVISION 0 July 28, 1994 Indudes examination from Field Weld surface, where possible Indudes examination from Shop Weld surface, where possible 7.0 CONFlGURATlON PROFlLES The actual achievable examination coverage of the lower one-third volume of the Safe End welds is illustrated by a sectional view as viewed along the weld axis with the volume coverage achieved consistent with the. configuration profile at that location. Further, the actual examination coverage achieved by sound transmission through the Safe End welds is illustrated by a cross-sectional of each weld consistent with the configuration profile at that location as illustrated by sketches.
Examination Coverage Examination Area Identification 2A2 Inlet Field Weld Safe end to Pump weld No. RC-RC-115-4 2A2 RCP Inlet shop weld Elbow-to-safe end weld no.
RC-1 15-1501-771-A 2A2 RCP Oufiet Field weld, Safe end to Pipe weld No.
RC-1 15-701-771 Beam Angle 45'5'5o Coverage (CRV) 20% from Safe End 0% from Pump side 100% from Elbow 0% from safe end 100% from pipe 30 4%%d from safe end Flg.
1 3
4 5
6 7
8 9
10 2
3 4
5 6
7 8
9 10 11 12 13 14 15 Descrfpthn of Llmltathns Examlnafion limited by configuration.
Examination limited by configuration.
Examination limited by configuration.
File RR%5.R01 Page 5
SECOND INSPECTION INTERVAL ULTRASONIC EXANJIINATIONTECHNIQUE FOR RCP SAFE END WELDS PSL~L6 REVISION 0 July 28, 1094 ExamInatIon Coverage ExamInatIon Area IdentIIIcathn Beam AngIe Coverage (CRV)
Fig.
DescdptIon of UmItatIons 2B1 RCP Inlet shop weld Elbow-t~fe end weld No.
RC-115-1501-771-B 2B1 RCP Outlet Field weld, Safe end to Pipe weld No.
RC-121-5 2B1 RCP Outlet Shop weld, Safe end to Pipe weld No.
RC-1 21-901-771 2A1 RCP Inlet shop weld Elbow-to-safe end weld no.
RC-112-1 501-771-C 2A1 RCP Outlet Shop weld, Safe end to Pipe weld No.
RC-112-1 066-771 2B2 RCP Inlet shop weld Elbow-to-safe end weld no.
RC-1 24-1 501-771-D 45'5'5'5'5'5'00%
from Elbow 0% from safe end 100% from Elbow 0% from safe end 100% f'rom Pipe and 100o/o Safe, end 100% from elbow 20% from safe end 100% from Pipe and 100% Safe end 100/o from Elbow 0% from safe end 16 17 18 19 20 21 22 23
'4 25 27 28 29 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Examination limited by configuratio.
Examlnafion limited by configuration.
Examination limited by configurafion.
Examination limited by configurafion.
Examination limited by configuratio.
Examinafion limited by configurafion.
File RR-05.R01 Page
'SECOND INSPECTION INTERVAL ULTRASONIC EXAMINATION'TECHNIQUE FOR RCP SAFE END WELDS PSL<00~<
REVISION 0 July 26, 4904 Examlna5on Coverage Examlnatlon Area Beam Coverage Fig.
Descrfptfon of Umltathns Idenllfica5on Angle (CRV) 282 RCP Inlet Shop weld safe end to Pipe weld No.
RC-124-1301-771 45'00% from pipe 30 %
from safe end 50 Examination limited by contigvration.
51 52 53 54 File RR-05.R01 Page 7
PARTIAL COVERAGE FRON SAFE END SIDE 375~
CODE VOLUME
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I PUMP WELD NO. 124-5 AND 1301-771 RCP 2B2 OUTLET SAFE END WELDS, PRORLE AND EXTENT OF COVERAGE AT 140 FIGURE 5.52
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WELD NO. 124-5 AND 1301-771 RCP 282 OUTLET SAFE END WELOS, PROFILE AND EXTENT OF COVERAGE AT 160 FIGURE 5.S3 I
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PUMP WELD NO. 124-5 AND 1301-771 RCP 282 OUTLET SAFE END WELDS, PROFILE AND EXTENT OF COVERAGE AT 180 FIGURE 5.54
ST. LUCIE UNIT2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION ATTACHMENTE RELIEF REQUEST NO. 14 File PSL2RAI.94.
Page 19
I
-ST.'UCIE'.UNIT 2
-SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 14 A.
COMPONENT IDENTIFICATION:
Class:
Component Identification:
Reactor Pressure Vessel and Closure Head Steam Generator - Primary Side Pressurizer Reactor Coolant Pump Steam Generator - Secondary Side B.
EXAMINATIONREQUIREMENTS:
Exam Cate o
Exam Item No:
Exam Descri tion:
B-D B3.90 B3.100 B3.110 B3.120 B3.130 B3.140 RPV Nozzle - Vessel Weld RPV Nozzle Inside Radius Pressurizer Nozzle - Vessel Weld Pressurizer Nozzle Inside Radius Steam Generator Nozzle -Vessel Weld Steam Generator Nozzle Inside Radius B-B B2.1'I B2.12 B2.31 B2.32 B2.40 Pressurizer Shell - Head Welds Pressurizer Long Welds Steam Generator Circ Head Welds Steam Generator Meridional Welds Steam Generator Tubesheet
- Head Welds B-F B-G-1 B5.40 B6.50 Pressurizer Nozzle - Safe End RPV Threads ln Flange B-G-2 B7.20 B7.30 B7.50 Pressurizer Bolts, Studs, Nuts Steam Generator Bolts, Studs, Nuts Pressurizer Bolts, Studs, Nuts B-H B8.20 B8.30 Pressurizer integral Attachments Steam GeneratorlntegralAttachments B-J B9.11 Circumferential Pipe Welds File RR-14.TR2 Page E 1
,ST. LUCIE UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 14
~ECt:
E II N:
8 D
6 ~
C-A C1.40 C4.20 C1.30 Shell Clrcumferentlal Welds Head Circumferential Welds Tubesheet to Shell Welds C<>101-251 Stay base to Primary Head SG-2A-101>>254-B Meridional N 108 deg.
SG-2A-202-271 Primary Ext Ring to Head SG-2A-201-246 Primary ext. ring to Tubesheet SG-2A-'I04-251 Inlet Nozzle to Head SG-2A-102-251-A Outlet Nozzle to Head SG-2A-102-251-B Outlet Nozzle to Head SG-2A-101-244-B Ext. Ring Long Weld
@90 deg.
SG-2A-IN-IR Inlet Nozzle Inner Radius SG-2A-ON-IR-A Outlet Nozzle Inner Radius SG-2A-ON-IR-B Outlet Nozzle Inner Radius 1st 1st 1st 1st 1st 1st 1st 1st 1st 1st 1st 3rd 3I'd 3rd 3I'd 3rd 3I'd 3rd 3I'd 3rd 3I'd 3rd File RR-14. TR2 Page E 7
.ST. LUCIE UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 14 ITEM IDENTIFICATION SG-2A-203-246 2nd Ext. Ring to Tubesheet SG-2A-101-241 2nd Ext. Ring to Lower Shell SG-2A-102-221 Intermediate Shell to Cone SG-2A-1 03-221-A Key Bracket @0 deg SG-2A-104-221-A Clevis Bracket @45 deg STEAM GENERATOR TABLE SECONDARY SIDE RESCHEDULED FROM 1st 1st 2nd 1st 1st NEW SCHEDULE 31'd 3rd 31'd 3rd 3!'d File RR-14. TR2 Page E 8
ST. LUCIE UNIT2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 14 PIPING WELD CONNECTED TO PRESSURE VESSELS ITEM IDENTIFICATION RESCHEDULED FROM NEW SCHEDULE RC-114-201-258 Nozzle Extension to S/G Nozzle RC-114-2 Elbow to Nozzle Ext 1st 1st 3I'd 3I'd File RR-14. TR2 Page E 9
ST. LUCIE UNIT'2 SECOND INSERVICE INSPECTION INTERVAL REQUEST FOR ADDITIONALINFORMATION ATTACHMENTF REUEF REQUEST NO. 17 File PSL2RAL94.
Page 20
ST.'LUCIE UNIT'2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 17 A.
COMPONENT IDENTIFICATION:
Class:
1 Reactor Pressure Vessel Nozzle-to-Vessel Welds Nozzle Inner Radius Section B.
EXAMINATIONREQUIREMENTS:
EXAM CAT.
ITEM NO.
EXAMINATIONREQUIREMENTS B-D B3.90 At least 26%, but not more than 60% (credited) of the nozzles shall be examined by the end of the first period, and the remainder by the end of the Inspection interval.
B-D B3.100, At least 26%, but not more than 50% (credited) of the nozzles shall be examined by the end of the first period, and the remainder by the end of the inspection interval.
C.
RELIEF REQUESTED:
Relief is requested from the ASME Code requirements to examine at least 25% of the Vessel-to-Nozzle welds and Nozzle Inner Radius Section during the first examination period.
FPL proposes to conduct the entire Reactor Pressure Vessel examination requirements during the Second Inservlce inspection Period.
D.
BASIS FOR RELIEF'uring the First 10 Year interval the vessel-to-nozzle and nozzle Inner radius sections, that were examined during the first period, as Identified above, were reexamined during the second
- period, in conJunction with the automated Reactor Pressure Vessel examinations.
Page P - 1
ST. LUCIE UNIT 2 SECOND INSPECTION INTERVAL RELIEF REQUEST NUMBER 17 The Intent of the ASME Code Is to assure the structural integrity of safety related components.
This Is accomplished by performing nondestructive examinations, as required by Table IWB-2500-1, over the extent of a specific inspection interval.
Performance ofthe examlnatlon requirements Inthe first an third Inspection perIods provides an undue cost burden.
Performance of the 25% to 50%
examination requirements, as specified in the Code, by the automated examination technique, cost in excess of4300,000,00 to 4400,000.00 dollars more than performance of the entire vessel examinations of $700,000.00.
FPL, during the first 10 Year Interval, performed a reexamination ofthe 25%
to 50% code examinations, In conjunction with the remaining vessel examinations, In order to establish an examination Interval consistent with the entire Reactor Vessel requirements.
E..
FPL believes that since these welds will still be examined at 10 year intervals, an acceptable level of quality and safety Is assured.
I ALTERNATIVEEXAMINATIONSOR TESTS:
Conduct 100% Nozzle-to-Vessel Welds and Nozzle Inner Radius Section Examinations during Second Examination Period, In conjunction with the Mechanized Reactor Vessel examinations.
F.
IMPLEMENTATIONSCHEDULE:
Second lnservice Inspection Interval August 8,1993 to August 08,2003 File RR-17. TXT Page P - 2
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