ML17333A564

Final Rept, Reactor Vessel Nozzle Bore Data Evaluation

ML17333A564
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Site:	Cook
Issue date:	08/31/1996
From:	SOUTHWEST RESEARCH INSTITUTE
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DONALD C. COOK NUCLEAR PLANT, UNIT 2 REACTOR VESSEL NOZZLE BORE DATA EVALUATION FINAL REPORT SwRI Project 7S04 Prepared for American Electric Power Service Corporation 1 Riverside Plaza

Columbus, Ohio 43216-6631 Prepared by Nondestructive Evaluation Science and Technology Division August 1996 SOUTHWEST RESEARCH INSTlTUTE SAN ANTONIO HOUSTON D ETR 0 IT WASHINGTON, DC 9609i80296 9609i0 PDR ADOCK 050003ih I

, P PDR

DONALD C. COOK NUCLEAR PLANT, UNIT 2 REACTOR VESSEL NOZZLE BORE DATA EVALUATION FINAL REPORT SwRI Project 7804 Prepared for American Electric Power Service Corporation 1 Riverside Plaza

Columbus, Ohio 43216-6631 Prepared by Nondestructive Evaluation Science and Technology Division August 1996 Written by Approved by Alfr d R. Anderson Project Manager NDE Engineering Section Department ofNDE Services Br acob Director Department ofNDE Services

TABLE OF CONTENTS I.

INTRODUCTIONAND

SUMMARY

II.

ENHANCEDDATAANALYSIS III.

ANALYSISRESULTS APPENDICES A

Indication Location Plots B

EDAS-IIEvaluation Data

I.

INTRODUCTION AND

SUMMARY

The 1996 reactor vessel examinations (April-Mayrefueling outage) at Donald C. Cook Nuclear Plant, Unit2 (Cook 2), were performed to satisfy the requirements for the second 10-year interval of plant operation per American Society of Mechanical Engineers (ASME)Section XI (1983 Edition) as well as the augmented examinations required by 10CFR50.55.

The examinations were conducted by Southwest Research Institute (SwRI) using SwRI's Fast PaR device and Enhanced Data Acquisition System-II (EDAS-~). The reactor vessel shell welds were examined using procedures qualified under the Performance Demonstration Initiative (PDI) guidelines which implement ASME Appendix VIIIrequirements.

Examinations ofthe nozzle-to-shell welds, nozzle inner radius sections, and the nozzle-to-safe end welds from the nozzle bore were performed using procedures (DCC-AUT14/1/0 and DCC-AUT15/1/0) written to ASME 1983 Edition ofSection XI requirements.

The nozzle-to-shell weld examinations conducted from the nozzle bore were performed using an incorrect pulser preamp switch setting. This caused the actual examination sensitivity to be lower than the calibration sensitivity.

This error was not discovered until after the completion of examinations, and at that time it was determined that a reexamination effort would have an adverse impact on the outage schedule.

After conferencing with regulatory personnel, the plant staff decided to request relief for those examinations and investigate the opportunity to perform a meaningful analysis ofthe data as acquired.

Afterconducting a detailed and enhanced analysis ofthe existing data, it was determined that itwas possible to identify those indications which exceeded the Code and Regulatory Guide equivalent evaluation thresholds.

The existing data does not allow a complete sizing evaluation using Code or Regulatory Guide criteria. However, since a known flaw, detected from the bore and sized from the vessel outside surface during previous examinations, was also detected at the reduced sensitivity, itis possible to draw some inferences about the indications that were identified. Again this outage, the known flaw was sized independently from the outside surface ofthe vessel, and it displayed the same dimensions as it did in 1988 and 1990. Allof the remaining indications identified during the enhanced analysis of the detection data were lower in amplitude than the known acceptable flaw, and after applying Code-style sizing calculations to the existing enhanced detection data, all of the measured dimensions were less than the similar measurements for the known flaw.

The existence ofslag-type nozzle fabrication flaws is fairlywell known within the nuclear industry with several documented cases of these flaws having been discovered through preservice and inservice inspection. The nozzle joint design is such that arc control is difficultand one ofthe most common outcomes is the accumulation ofslag along the side walls ofthe joint. While itis difficult to precisely characterize ultrasonic indications with respect to the exact type offlaw, our experience in conducting these nozzle bore examinations is that such fabrication flaws are relatively common and that, in most cases, the indications have been documented for many years. In the case of the Cook 2 vessel, CB&Ireport "Investigation of Nozzle Weld Repairs On AMP Reactor Pressure Vessel", dated October 11, 1972, documents the existence of nozzle weld repairs made during vessel fabrication and also states that some fabrication flaws were accepted and left in the welds.

Six of the nozzle-to-shell welds at Cook 2 have been examined from the bore twice previously (once preservice and once inservice) using similar techniques and two of the nozzles have been examined three times previously (once preservice and twice inservice). Each ofthese examinations revealed some indications which required evaluation, but only one indication was determined to be unacceptable based on the initialevaluation results. This was the indication that was sized in 1988 (and again in 1990) using a tip-diffraction technique from the outside surface of the vessel and determined to be acceptable.

Based on SwRI's experience with nozzle bore examinations over the past 25 years, it is believed that, although the 1996 examinations were not performed at the proper gain setting, the enhanced analysis (as described in Section II)provided the opportunity to review the data in a manner that provided a high level of confidence.

It is also felt that the results of these examinations are consistent with other examination experiences and that there is no reason to suspect that any new or unusual flaws exist in the Cook 2 nozzle welds.

II. ENHANCED DATA ANALYSIS While it was known that the examination data was not acquired at the required gain settings, it was felt that the characteristics ofthe EDAS-IIsystem were such that an effective data review could be accomplished even at the lower gain setting. In order to perform an effective review of the data, SwRI performed the followingtasks.

Upon return to SwRI, the entire examination system was reconstructed in the same configuration as used at Cook 2. The appropriate calibrations were downloaded to the system and verifications were performed to assure that the system was operating as it did at the plant.

An empirical approach was used to determine "equivalent 50% and 20% thresholds" for each acquisition channel used during the examination.

These thresholds were determined by (1) obtaining 50% and 20%

reference signals through the entire examination system at calibration sensitivity, and then (2) recording the corresponding signal amplitude after the switch was changed to the incorrect setting used for examination.

Since EDAS-IIdigitizes and records the fullvideo waveform at 10-bit resolution, it was possible to enhance the data display and then compare the recorded data to the derived thresholds to identify the indications that exceeded those thresholds.

The enhanced data display provided improved amplitude resolution and allowed the analyst to view the data in a manner more consistent with normally acquired data sets.

Although the data were acquired using detection scan increments which are larger than typical sizing increments, length and throughwall sizing calculations were made for each indication forevaluation purposes.

III. ANALYSIS RESULTS ASME Section XIand Regulatory Guide 1.150 require that all indications exceeding 50% DAC located in the outer 75% of the vessel shell be recorded and evaluated.

Table A identifies 11 indications (including the known fiaw) located in the outer 75% ofthe vessel shell which exceeded the equivalent 50% threshold.

Information on indication location and correlation with previous examination data is also provided foreach indication. See Figure 1 for azimuth locations.

Indications located in the inner 25% ofthe vessel shell are required to be recorded and evaluated if they exceed 20% DAC. No indications were observed in the inner 25% of the vessel shell that exceeded the equivalent 20% threshold.

Table B provides the amplitude-based throughwall and length sizing information that was calculated for each indication that exceeded the equivalent appropriate threshold.

Although it is well known that throughwall measurements based upon amplitude are not typically accurate with respect to true fiaw size, these calculations were made primarily for comparison purposes to the known flaw. Also, while the throughwall measurements may not be absolutely conservative, the length measurements are conservative because ofthe technique used for the calculations.

While the fact that the indications did not receive complete evaluation may be ofsome concern, it should be noted that 5 of the 11 were within 2 dB (normal Code calibration tolerance) of the 50%

threshold (see Figure 2). Due to the normal variances that occur when applying Code procedures, it is quite possible that some of these would not have exceeded the evaluation threshold ifthe examinations had been performed at the proper gain setting. Also, due to the normal probability of false calls, had the indications been completely evaluated, it is likelythat some, particularly those that could not be correlated with previous data, would have been determined to be nonrelevant (e.g., caused by transducer liftoff).

Based on the analysis performed, SwRI is confident that any recorded indication which would have exceeded 50% DAC (or 20% DAC for the inner 1/4T) has been identified. Although it is not possible to complete the required evaluation steps for the identified indications, itis felt that, based on SwRI's experience, the enhanced initial detection data presentation and results obtained are comparable to other nozzle examinations at Cook 2 and other plants.

Appendix Acontains indication plots and Appendix B contains EDAS-IIevaluation data for the 11 indications reported.

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0 DONALDC. COOK UNIT 2 DETECTION EVALUATIONI CORRELATION OF PREVIOUS DATA Table A

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DONALDC. COOK UNIT 2 1996 ISI - SIZING EVALUATION Table B

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APPENDIX A INDICATIONLOCATION PLOTS

Exa rn 44 Indication 334 2.66 Indication 81

Exam 44 Indication 357'.70 Indication g2

Exam 44 Indication

'I 56'.64 Indication 83

Exam 44 Indication

'I 76'.10 Indication 84

Exon 48 Indications O93'ndication 81

Exam 48a Indication 1

1 6'ndication 81

Exon 48o Indicotion 6

299'.75 Indication 82

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Exon 48'ndication 352'ndication 83

Exam 49rr Indication

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Exam 49rr Indications 1 74 Indication f!2

Exam 50rr Indication O

293'ndication 81

APPENDIX B EDAS-II EVALUATIONDATA

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~am Number Exam 44

~ Page 1 of 7

DC Cook Unit 2 2-N4-0 Outlet Noz. Bore 8 22 deg.

Looking TWD Cursor Box 1 of 5 Scan Axis Inc. Axis Depth In Material 16.45 - 17.69 211.67

- 222.47.

3.93 5.02 Module Coordinates Inc. Axis Scan Axis Channel 1

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- 24.81 Module Coordinates Inc. Axis Scan Axis Channel 2

20.33 - 21.57 Module Coordinates Inc. Axis Scan Axis Channel 3

33.73 - 44.62 23.57 - 24.81 Module Coordinates Inc. Axis Scan Axis Feature Analysis Comments Channel 4

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Summary Enhanced Analysis

.xam Number Exam 44

~ Page 2 of 7

Cursor Box 2 of 5 Scan Axis Inc. Axis Depth In Material 20.45 22.29 329.27

- 340.07 12.81 - 13.41 Module Coordinates Inc. Axis Scan Axis Channel 1

36.45 38.29 Module Coordinates Inc. Axis Scan Axis Channel 2

25.89 - 27.73 Module Coordinates Inc. Axis Scan Axis Channel 3

151.33

- 162.13 36.45 38.29 Module Coordinates Inc. Axis Scan Axis Feature Analysis Reference Points Inc. Axis Location Surface Location Scan Axis Location Depth In Material Metal Path Time DAC Separation Inc. Axis Values Scan No. Limits Inc. Axis Limits Depth Length Maximum Point DAC Inc. Axis Location Surface Location Scan Axis Location Depth In Material Metal Path Time Comments Channel 4

146. 61 - 157. 34

25. 89 - 27. 73 Channel 4

Planar 335.21 23.29 21.01 12.99 13.19 118.4 38 122 332.91 1.26 13.17 2.38 66 334.00 24.33 22.01 13.17 13.37 120.0 334.00 24.57 22.25 13.20 13.40 120. 3 39 126 337.58 Ind g 1 with Enhanced Evaluation

'xam NumSer Exam 44

.Page 3 of 7

Cursor Box 3 of 5 Scan Axis Inc. Axis Depth In Material 20.13

- 21.93 168.48

- 179.28 14.50 14.95 Module Coordinates Inc. Axis Scan Axis Channel 1

170.53

- 181.33 37.81

- 39.61 Module Coordinates Inc. Axis Scan Axis Channel 2

165.72 - 176.52 25.89 27.69 Feature Analysis Reference Points Inc. Axis Location Surface Location Scan Axis Location Depth In Material Metal Path T3.me DAC Separation Inc. Axis Values Scan No. Limits Inc. Axis Limits Depth Length Maximum Point DAC Inc. Axis Location Surface Location Scan Axis Location Depth In Material Metal Path Time Comments 175.60 23.73 21.13 14.74 14.97 134.4 39 140 174.41 0.36 14.78 1.29 46 175.60 23.85 21.25 14.78 15.01 134.7 175.60 24.09 21.49 14.78 15.01 134.7 43 142 176.80 Channel 2

Planar

xam Number Exam 44

~ Page 4 of 7

Ind ¹ 4 Enhanced Analysis Module Coordinates Inc. Axis Scan Axis Channel 3

37.81 - 39.61 Module Coordinates Inc. Axis Scan Axis Channel 4

25.89

- 27.69 Cursor Box 4 of 5 Scan Axis Inc. Axis Depth In Material 24.65

- 26 '3 155.28

- 158'.88 14.88 - 15.44 Module Coordinates Inc. Axis Scan Axis Channel 1

157.34 160.92 42.73

- 44.61 Module Coordinates Inc. Axis Scan Axis Channel 2

152.54

- 156.12 30.49 32.37 Feature Analysis Reference Points Inc. Axis Location Surface Location Scan Axis Location Depth In Material Metal Path Time o

DAC Separation 156 '0 28.13 25.45 15.13 15.36 137.9 41 0.16 156.40 28.29 25.61 15.17 15.40 138.2 41 Channel 2

Planar

~am Number Exam 44 Page 5 of 7

Inc. Axis Values Scan No. Limits Inc. Axis Limits Depth Length Maximum Point DAC Inc. Axis Location Surface Location Scan Axis Location Depth In Material Metal Path Time Comments 124 155.22 15.13 1.29 41 156.40 28.13 25.45 15.13 15 '6 137.9 126 157.59 Ind 4 3 Enhanced Analysis Module Coordinates Inc. Axis Scan Axis Channel 3

42.73

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30.49 32.37 Cursor,Box 5 of 5 Scan Axis Inc. Axis Depth In Material 20.09 21.77 350.87 1.67 12.46

- 13.34 Module Coordinates Inc. Axis Scan Axis Channel 1

35.77 37 '5 Module Coordinates Channel 2

~am Number Exam 44

.Page 6 of 7

Inc. Axis Scan Axis 25.49 27.17 Module Coordinates Inc. Axis Scan Axis Channel 3

172.92

- 183.71 35.77 37.45 Module Coordinates Inc. Axis Scan Axis Channel 4

168.12

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DAC Separation Inc. Axis Values Scan No. Limits Inc. Axis Limits Depth Length Maximum Point DAC Inc. Axis Location Surface Location Scan Axis Location Depth In Material Metal Path Time Comments 356.79 23.13 20.85 12.85 13.05 117.1 41 141 355.59 Channel 4

Planar 356.79 23.49 21.21 12.95 13.15 118.1 41 0.37 143 358.00 12.92 1.22 49 356.79 23.41 21.13 12.92 13.12 117.8 Ind g 2 Enhanced Evaluation

-'xam Number Exam 44 Page 7 of 7

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