Text

Rev 5 to Administrative Procedure 9.11, Engineering Analysis.
	ML18059A478
Person / Time
Site:	Palisades
Issue date:	10/27/1993
From:	; CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	;
Shared Package
ML18059A477	List: ML18059A476; ML18059A478; ML18059A479; ML18059A480; ML18059A481; ML18059A482; ML18059A483; ML20059D881;
References
	9.11, NUDOCS 9311030020
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PALISAQES NUCLEAR PLAHT Proc No 9.11 AQMINISTBAIIVE PROCEDURE Revision 5 Page 2 of 18 TITLE: ENGINEERING ANALYSIS

4.2 INITIATOR The initiator is responsible for preparation, rev1s1on and filing of the analysis in accordance with the requirements of this procedure.

Any EA's which effect pipe stress/serial packages including pipe supports shall be documented in accordance with EM-18-03.

{Ref. 3 . 2. a) .

4.3 TECHNICAL REVIEWER The Technical Reviewer is responsible for the technical adequacy of the analysis and documenting the review on the Technical Review Checklist.

5.0 DEFINITIONS 5.1 ENGINEERING ANALYSIS (EA)

Engineering Analyses are documented technical determinations involving one or more engineering disciplines and/or plant system design bases or expectations. EA's are typically performed to ascertain such things as: System/equipment design margin, system/equipment operability, system/equipment failure modes and

effects, systems/equipment response to plant accidents, appropriate rating for new or modified equipment, plant/area environmental conditions, equipment material capability/compatibility, capability of structural supports, and personnel safety/performance.

Engineering Analysis may cover any subject and are not limited to these subjects.

5.2 VENDOR INFORMATION Technical data, design or recommendations provided by either the Vendor or Manufacturer of equipment or services. When this information is pertinent, it shall be listed in the analysis as design input. If this information is not being filed separately such that it is retrievable, a copy shall be included as an attachment to the EA. The information shall be provided by either a vendor drawing, vendor correspondence, or other published material.

Documenting vendor data by telephone record is not acceptable.

5.3 PRELIMINARY ENGINEERING ANALYSIS Engineering Analyses prepared with information that has not been finalized shall be identified as *Preliminary* in the calculation status block. When Preliminary data is used in an EA, that data shall be identified on the cover sheet (form 3169) of the EA. An Attachment shall be contained in the EA which lists individually the items which are preliminary, if they are too numerous to be identified on the cover sheet .

PALISADES NUCLEAR PLAHI Proc No 9* 11 AQMINISTBATIYE PROCEDURE Revision 5 Page 3 of 18 TITLE: ENGINEERING ANALYSIS 5.4 PENDING EN&INEERIN& ANALYSIS An EA that has been developed in support of a modification or a design drawing which has yet to be implemented in the plant shall be identified as *Pending* in the calculation status block.

5.5 FINAL ENGINEERING ANALYSES A completed and approved EA which does not contain any major assumptions requiring later verification, which reflects the

as-installed* configuration of a modification, or is a *stand alone" analysis may be identified as *Final* in the calculation status block.

5.6 .SUPERSEDm ANALYSES Analyses which have been filmed by the Palisades DCC and contain design information which is no longer valid because of a more recent analysis having been performed will be superseded. These analysis are to be identified as described in Section 6.6.4. The original analysis if available, shall be revised to reflect the superseded status and the EA which supersedes it. EA's superseded in their

5.7 entirety need not be microfilmed.

VENDOR &ENERATm ANALYSIS Analyses generated by an outside vendor/contractor shall conform to the administrative requirements of Section 6.1.3 and 6.1.4, and shall be indexed in accordance with Section 6.6.3.

5.8 STRESS PACKAGES OR SERIAL PACKAGES A collection of analysis of piping and its components, pipe support analyses, drawings, sketches, tables, piping system input parameters and/or computer output associated with individual Palisades Plant piping systems, or subsystems. (See reference 3.2.8).

6.0 PRQCEQURE 6.1 ADlllNJSTRATIYE REQUIREMENTS 6.1.1 Ident1f1cat1on of Need The need for an Engineering Analysis is often identified during the performance of the engineering design phase of the modification process as in Palisades Administrative Procedures 9.03, *facility Changes* and 9.04, *specification Changes.* Per AP 9.04, Engineering Analyses are required for the performance of specification changes and additional requirements are delineated. The need for an EA may also be identified during the Corrective Action, Maintenance, Procurement processes, etc, or through management direction.

ATTACHMENT Consumers Power Company Palisades Plant Docket 50-255 ENGINEERING ANALYSES FOR MODIFICATION OF PRESSURIZER TEMPERATURE NOZZLES October 27, 1993

PALISADES NUCLEAR PLANT EA-SC-93-087-01

.,_. *.,,..mar ENGINEERING ANALYSIS COVER SHEET Total Nt.ll'i>er of Sheets 144 I 1 itle JustificatiQn of Weld Modifications to Pressurizer Temgerature Nozzles for TE-0101 ang TE-0102.

INITIATION AND REVIEW Calculation Status Preliminary Pending Final Superseded c c c Initiated Init Review Method Technically Reviewed Revr Rev Appd Appd CPCo '

I Description By Detai 1 Qual By Appd. ~

Bv Date Alt Cale Review Test Bv Date ~

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~av':f 1 add industry repairs, clarify hydro reqmts, add EDM effect justification SSOverwo(} )

10/23/93 4 I JCWong

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1.0 OBJECTIVE The purpose of this Engineering Analysis is to document the justification for modifying the design of the Pressurizer Temperature Nozzles for TE-0101 and TE-0102 to include a*

weld built-up "pad" to stop Primary Coolant System (PCS) leakage caused by axial cracking of the nozzles interior to the exterior surface of the pressurizer. This EA wi 11 prove that the "pad" modification to stop this leakage is acceptable per the ASME Code for at least one fuel cycle. I '1 2.0 ANALYSIS INPUT 2.1 Vendor Information - ABB/Combustion Engine~ring

a. "Nozzle Details for Consumers Power Pressurizer" - Ml-L-A sh. 986 rev. 5

b. "Vessel F~rming and Welding for Consumers Power Pressurizer* - Ml-L-A sh.

982, rev. 9

c. "Top Head For~ing and Welding for Consumers Power Pressurizer" - Ml-L-A sh.

983, rev. 6

d. "Instruction Manual: Pressurizer; Consumers Power Company - Palisades Plant"

- Ml-L-A sh 862, rev. 1.

2.2 Codes and Standards

a. Initial Design - ASME Section III, 1965 with Winter 1966 addenda.

b. Modification Design - ASME Section III, 1965 with Winter 1966 addenda.

c. Modification Installation - ASME Section XI, 1983 with Summer 1983 addenda.

d. Weld Material Procurement - ASME Section Ill, 1986 (no addenda).

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PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet _2_ Rev # II 1

11 Reference/Conment 2.3 Important Design Conditions

a. Press. - The ~odification must be able to function as the pressure boundary between the PCS and the Containment Atmosphere. Pressurizer Design Pressure - 2500 psia, Pressurizer Design .

Transients per CE Report Nos. CENC 1114 and CENC EA-SC-93-087-03 1214.

b. Temp. - The mod~fication must take into account the differential temperature along the nozzle and through the pressurizer shell thickness during plant heatup and cooldown, as well as steady state conditions. Pressurizer Design Temperature - 700°F, Pressurizer Design

Transients per CE Report Nos. CENC 1114 and CENC EA-SC-93-087-03 1214.F ,

c. Stress - The modification must account for the thermal expansion stresses that will be set up in the nozzle and pressurizer shell due to having dissimilar metals constrained to the same EA-SC-93-087-03 le dimension by internal and external welds fixing both points of the nozzle to the pressurizer shell. The modification must also take into account the residual stresses in the nozzles and Ref 2.6.g, Att 9 le the pressurizer base metal caused by the welded "pad". This is a concern for reoccurrence of the cracking. Also orientation of residual stresses in the nozzles is a concern from the standpoint that excessive axial stress could lead to circumferential cracking of the nozzles and thus present a potential for a smalJ Loss of Coolant Accident from the nozzle penetrations.

2.4 Design Drawings

a. CPCo sketch, SK~SC-93-087 sh. 1, "TE-0101 Modification" and sh. 2, "TE~Ol02 Modification" Attachment 1 le

b. ABB/Combustion Engineering Draw1ng - "Pressurizer Head Attachment 12 Ie.

Temperature Nozzle Weld Repair" - D-9417-C093-019, rev~ 02

c. ABB/Combustion Engineering Drawing - "Pressurizer Shell Attachment 13 le Temperature Nozzle Weld Repair" - D-9417-C093-021, rev. 01 2.5 Existing Analyses

a. "Structural Analysis of Temperature Nozzle Weld Modifications for Consumers Power Palisades Pressurizer",

EA-SC-93-087-03, Rev. 0.

b. "Half Bead Welding for Modifications to TE-0101 and TE-0102" - EA-SC-93-087-02,. Rev. 0.

c. "Acceptability of Partial Severing of TE-0101 Nozzle", EA-SC-93-04, Rev. 0.

PALISADES NUCLEAR PLANT EA-SC-93-087-01

. . . . . ...,. JllllllS:liRUS ANALYSIS CONTINUATION SHEET Sheet _3_ Rev # 11 1 I1 Reference/Conrnent 2.6 References

a. ABB/Combustion Engineering Nuclear Services Welding Attachment 3 1~

Procedure Specification - SMA-3.43-937, rev. 1.

b. ABB/Combustion Engineering Nuclear Power letter, MCC Attachment 4 1~

525, from J. F. Hall dated October 15, 1993 titled "Corrosion of Palisades Pressurizer Material."

c. ABB/Combustion Engineering Nuclear Services Traveler No. Attachment 5 I~

2003067-001, rev. 2.

d. Consumers Power Company Internal Correspondence from Attachment 6 IC.

PDFitton to KVCedarquist, PDF 91*019, dated May 22, 1991, "Palisades Plant Inconel 600 Primary Water Stress Corrosion Cracking Status Report."

e. ABB/Combustion Engineering Nuclear Services Welding Attachment 7 I~

Procedure Specification - GTA-8.8-910, rev. 10.

f. Consumers Power Company Internal Correspondence from Attachment 8 I~

JCNordby to SSOverway, JCN 93*029, dated October 18, 1993, "Effects of Half Bead Welding on Base Metals."

g. Consumers Power Company Internal Correspondence from Attachment 9 I~

RBJenkins to Design Package File, .RBJ 93*064, dated October 18, 1993, "Nuclear Enginee~ing and Construction Organization: Potential for Circumferential Cracks in Modified Pressurizer Instrumentation Nozzles."

h. "Engineering Specification for a Pressurizer Assembly", Attachment 10 le Specification No. 70P-001, Rev. 2 from Nuclear Power Systems, Combustion Engineering, Inc ..

i. ABB/Combustion Engineering letter from Thomas U. Bipes to Attachment 2 le Scott Cedarquist, dated October 16, 1993, "Preliminary Results of Nozzle TE-0101 Eddy Current Exam."

j. ABB/Combustion Engineering letter - "Construction Code Attachment 11 le Reconciliation for Consumers Power Company - Palisades Pressurizer Upper and Lower Temperature Nozzle Repair/Modification."

k. ABB/Combustion Engineering Nuclear Services Traveler No. Attachment 14 2003067-002, Rev. 0.

1. ABB/Combustion Engineering Procedure of Electrical Attachment 15 Discharge Machining (EDM) Pressurizer Nozzle Severing, STD-100-207, Rev. 0

m. - ASME Code Interpretation, IX-1-89-70 Attachment 16

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet _4_ Rev # ~ 1 11 Reference/Corrment 3.0 ASSUMPTIONS 3 .1 Ma.for Cracks in the pressurizer temperature nozzle for TE-0102 can be characterized as axial and thus the cracks in both temperature nozzles are similar with respect to location and orientation to previous industry experience with Inconel 600 Pressurizer Penetrations experiencing Primary Water Stress Corrosion Ref 2.6.d, Att 6 Cracking (PWSCC) i.e. the only cracks in the nozzles are axially oriented and are located in the vicinity of the partial penetration "J" weld.

3.2 Minor

a. Assume effects of borated primary coolant on the pressurizer base material is bounded by the results of the laboratory tests provided by ABB/Combustion Engineering. Ref 2.6.b, Att 4

b. Assume TE-0101 nozzle I.D. and O.D. are concentric.

c. Assume measured TE-0101 nozzle I.D. and 0.0. are representative of I.D. and O.D. of whole nozzle, i.e. that the I.D. and O.D. do not vary as a function of distance down the nozzle.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet _5_ Rev # "' 1 I1 Ref erence/Coarnent 4.0 ANALYSIS 4.1 Background

a. On October 9, 1993 at approximately 0900 insulators working on the upper head of the pressurizer (T-72) re-installing insulation that had been removed to allow repair to the leaking PORV line observed water leaking from the upper head around the base of the TE-0101 temperature nozzle. (Operations department personnel were also scheduled to inspect the TE-0101 temperature nozzle prior to pressurizer insulation re-installation, but had not yet gotten to that location in their inspections.) At that time the pressurizer was filled solid with water, the PCS was cold and at 250 psia. Palisades Systems Engineering, Mechanical Maintenance, and Operations departments veri fi e_d the 1eakage. Operat i ans commenced reducing PCS pressure. ABB/Combustion Engineering (ABB/CE) was contracted to assist in correcting this problem, as were Systems Engineering and Nuclear Engineering and Construction Organization engineers.

Event Report, E-PAL-93-032, was initiated to correct the problem.

b. A Project Team was established to evaluate the leakage, identify alternative solutions, and recommend a solution to management. On October 11, 1993 the alternative were presented to management and the option to modify the temperature nozzle design by welding a "pad" to the exterior surface of the pressurizer to re-establish the structural support and pressure boundary was chosen.

c. On October 12, 1993 a detailed inspection of the other pressurizer temperature nozzle (for TE-0102) was completed and leakage from around that nozzle was also noted. The modification scope was then expanded to include both pressurizer temperature nozzles.

d. A structural analysis of the modification was performed by ABB/CE. It determined that the upper nozzle must be severed between the new and old welds due to thermal stresses that develop during heatup and cooldown of the pressurizer. However, as the modification design continued to develop, it became apparent that complete severing of the nozzle had technical drawbacks. ABB/CE was then directed to determine the maximum amount of nozzle that could remain and still have the nozzle meet ASME Code requirements. ABB/CE developed a calculation showing a remaining "ligament" of the nozzle 0.0. was acceptable. The modification design was then revised to EA-SC-93-087-04 incorporate this change.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet _6_ Rev # ~ 1 11 e/Cooment 4.2 Industry Experience To date, the Nuclear Power Industry has experienced leakage from similarly designed nozzles, especially in high temperature environments like the pressurizer. In fact, a special Combustion Engineering Owner's Group (CEOG) Working Group was formed in November of 1989 to address the PWSCC of Inconel 600 that had been determined to be the cause of previous similar leaks. The results of a comparison of this working group's d~terminations indicated that the Palisades Pressurizer Temperature Nozzles were moderately susceptible to PWSCC. As a Ref 2.6.d, Att 6 result inspections of the pressurizer temperature nozzles, using VT-2 methods with the insulation installed have been performed as part of the pre-startup inspections during each subsequent refueling. The industry in the United States has, so far, experienced cracking in instrument nozzles and heater sleeves in pressurizers. These leaking penetrations have all shared a common cause for the stress that sets up the conditions to promote PWSCC - they were all attached to the inner surface of the pressurizers with partial penetration welds. The Palisades temperature nozzles are attached with a partial penetration "J" weld. Permanent repairs at the other U.S. plants that have experienced penetration cracking have involved replacement of the nozzles which has involved some welding from the inside of the pressurizer. Due to time considerations in planning the most ALARA effective method of replacement, Palisades management decided to pursue a method that would allow operation of the plant for at least one fuel cycle while not being overly dose expensive to install. This approach would allow plant operation while the planning and engineering needed for the potentially high dose replacement of the nozzles occurs. The modification chosen to allow operation for at least one fuel cycle draws on ABB/CE's experience with other short term modifications at other U.S. nuclear plants for leaking lnconel 600 nozzles.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet _7_ Rev # II 1 11 Reference/Corrment 4.3 Reason for Change*

The existing temperature nozzles for TE-0101 (Pressurizer Vapor Phase Temperature Element) and TE-0102 (Pressurizer Water Space Temperature Element), located on the pressurizer upper head and lower shell respectively, are currently exhibiting leakage from between the Inconel 600 nozzle and the carbon steel base material of the pressurizer at the outer surface of the pressurizer. Eddy Current Testing has been used to characterize the cracks in the upper nozzle as axial. These Ref 2.6.i, Att 2 cracks are similar to cracks found in Inconel nozzles at other Pressurized Water Reactors. The typical Inconel 600 cracks have been caused by PWSCC and are not considered to be a safety e problem due to the fact that they occur axially rather than Ref 2.6.d, Att 6 circumferentially (this implies they are not likely to fail catastrophically without leaking for a sufficient amount of time to be detected). The modification for these leaks, as proposed by the Nuclear Steam Supply System (NSSS) vender for Palisades, ABB/CE, is to replace the original pressure boundary le.

weld on the interior surface of the pressurizer shell, called a "J" weld, with a new weld on the exterior surface of the shell, Ref 2.4.b Att 12 as indicated in the construction drawings. This exterior weld Ref 2.4.c Att 13 is intended to re-establish the pressure boundary downstream of the original "J" welds and replace the structural support that may have been weakened by the cracks, thereby bypassing the faulted (cracked) portion of the nozzles.

4.4 Design Considerations

a. The weld modification design is governed by Section XI of the ASME Boiler and Pressure Vessel code, 1983 edition with the summer 1983 addenda, The Code. ABB/CE has Reference 2.2.c provided a letter that details how the Code applies to Ref 2.6.j Att 11 this modification. The letter indicates that IWB-4000 will be used by the modification. By using IWB-4000 methods the modification avoids the difficulties encountered with welding to the pressurizer - post weld heat treatment of the entire pressurizer, since the methods specify a self-tempering weld process. The justification for choosing the specific processes of IWB-4000 as prescribed by the Traveler is presented in a Ref 2.6.c, Att 5 letter from Consumers Power's Welding Codes and Materials EA-SC-93-087-02 Supervisor.

The pro.cess is laid out in a qualified ABB/CE welding procedure. Ref 2.5.b, Att 3

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet ~ Rev # @1 I1 Reference/Comnent

b. The weld modifications will take the shape of a "pad" located around each nozzle on the outer surface of the pressurizer shell. The diameter of the pads, as Refs 2.4.b & c, specified, is designed to take into account the Att 12 & 13 replacement of the nozzles in the future by allowing a large enough area to weld on withriut having to build-up additional pad area. At the same time it also provided a large area for the stresses on the weld pad to be spread over. The thickness of the pad is designed as part of the stress analysis of the modification. The pads establish EA-SC-93-087-03 the pressure boundary and structural support between the nozzles and the pressurizer shell. This modification wi.11 re-establish the leak-free condition that is the design condition for the nozzle/pressurizer shell interface.

c. Welding the nozzles to the pressurizer shell at both the interior surface and the exterior surface, however, sets up the potential for high stresses in the nozzle due to the different thermal expansion experienced by the Inconel 600 nozzle and the ASTM A-533, Grade B, Class 1 steel plate pressurizer. This stress, caused by having the nozzle fixed at two locations to the pressurizer shell, is evaluated in the modification stress analysis. The EA-SC-93-087-03 I~

conclusion of this calculation and its addendum is that Ie.

the nozzle for TE-0101, located in the upper head. of the pressurizer, needs to be partially severed within the Ie.

thickness of the upper head to prevent the stresses caused by differences in thermal expansion during heatup and

cooldown from exceeding the ASME code allowable stresses.

The nozzle will be partially severed using the procedure Ref 2.6.k Att 14 laid out in a second traveler. By partially severing the nozzle, the thermally induced loads on the welded pressure boundary is bounded by the material's collapse loads in the thinned nozzle wall. The stress calculation addendum demonstrated that with a thinned wall thickness of 0.110 EA-SC~93-087-04 inches, the stress level in the pressure boundary will be within the Code allowables. The stress calculation also EA-SC-93-087-03 verifies that the nozzle for TE-0102, located in the lower section of the pressurizer shell, does not need to be severed since it does not experience as large a transient loading due to being in a liquid environment. The axial le.

stresses developed on the lower nozzle due to accident transients are still within ASME code stress and fatigue allowables even with the nozzle constrained at the inner EA-SC-93-087-03 Ie.

and outer surface of the pressurizer. The calculation also confirms that, since the modification design meets ASME code requirements for all stress and fatigue allowables, the modification will allow operation for at least one fuel cycle.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet _9_ Rev # '1 1 I1 Ref erence/COf111lent

d. The existing crack locations in both nozzles leads to another potential problem. That problem is one of corrosion of the carbon steel pressurizer by the borated primary coolant that will come in direct contact with the steel. Due to the exterior weld build-up, the modification will allow the known axial cracks at the TE-0101 and TE-0102 temperature nozzles to potentially place borated primary coolant in contact with the carbon steel pressurizer. The NSSS vender indicates that, per an industry study, corrosion of low alloy steel relating to PWSCC failures in Inconel 600, the Palisades pressure Ref 2.6.b, Att 4 I*

boundary material can expect a conservative maximum corrosion rate of 3 mil/year. This corrosion rate would.

not significantly effect the integrity of the pressure boundary during one fuel cycle, thus this modification is

acceptable for installation for at least one fuel cycle from a corrosion standpoint. Other proof that this intentional exposure of carbon steel to borated primary Ie coolant is not a corrosion concern can be found from industry experience with pressurizer leaks from heater sleeves and temperature and pressure nozzles and from CEOG Task 637. Actual expected corrosion for the Palisades Ref 2.6.d, Att 6 le pressurizer base metal is probably undetectable due to the fact that the areas exposed to borated primary coolant will not experience any flow past them (and therefore no erosion effects) and thus will experience an even slower total rate of metal loss.

PALISADES NUCLEAR PLANT EA-SC-93-087-01

- rm*.s l'mr&&S.S ANALYSIS CONTINUATION SHEET Sheet 10 Rev # ¥' 1 I1 Reference/COl!lllent

e. The partial sever cut will occur per the design drawing Ref 2.4.b Att 12 and the second traveler with the EDM procedure. The Ref 2.6.k Att 14 design is based on a desire to cut enough of the nozzle Ref 2.6. l Att 15 material to meet the Code allowables, as ABB/CE has shown in a supplement to the original design stress calculation, EA-SC-93-087-04 while ensuring that enough "ligament" is left of the nozzle wall thickness to prevent a through-wall penetration by the EDM process to the pressurizer shell.

The reason for the concern with EDM cutting the pressurizer shell is that the EDM process has not been interpreted to be usable on low alloy carbon steels without post-removal surface smoothing by mechanical methods and, due to PCS foreign material exclusion concerns, that mechanical methods are not a prudent choice of method for this application. To design a ligament size, ABB/CE determined the maximum nozzle wall thickness EA-SC-93-087-04 that would meet ASME Code re~uirements. The dimension calculated was a maximum of 0.110 inches. To ensure that the nozzle would break at the cut notch in the unlikely event of an excessive transient loading and not somewhere else, the desired ligament size was chosen as 0.055 inches. This ligament size, taken along with the cutting accuracy of approximately +/- 0.002 inches, the concentricity accuracy of the EDM wand versus the nozzle I.D. being approximately+/- 0.005 inches (based of I.D. of nozzle, constriction at the modification weld, and O.D. of Assumption 3.2.b EDM wand), and nozzle I.D. and O.D as measured in the Assumption 3.2.c field, ensures that a sufficient amount of nozzle.will be removed to control stress levels while still ensuring that the O.D. of nozzle will not be penetrated. Thus with this ligament size specified, no pressurizer base metal will be affected by the EDM process and this portion of the modification will also meet ASME Code.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet 11 Rev # ~ 1 11 Ref erence/Conment 4.5 Design Basis Function The design basis function of the pressurizer system is to control PCS pressure and volume through the use of a saturated steam bubble and stored water volume. Pressure control is performed by the saturated steam bubble. It controls PCS pressure reductions by expansion of the steam bubble and some of the stored water flashing to steam, thus reducing the pressure drop for a given PCS contraction. It controls PCS pressure increases by compressing the steam bubble and condensing some of the steam into water. (There is also a spray system to control rapid pressure increases.} The stored water volume also acts as a means of controlling the PCS water volume. The pressurizer water level is the controlling input to the Chemical and Volume Control System for letdown and charging. The pressurizer level ~s controlled automatically to maintain the appropriate PCS water volume. The design basis functions of the nozzles for TE-0101 and TE-0102 are to: (1}

provide a pressure boundary from the pressurizer to the containment atmosphere and (2} provide structural support to the thermowells and temperature elements. The Temperature Elements (TEs} provide the plant operators with indication of the steam and water temperatures within the pressurizer to help control operation of the plant. The TEs, however, are not Q-Listed and do not provide any input into automated systems; they are just for indication. The nozzles for the TEs are provided to create the proper geometry and structural support for the mounting of the TEs to the pressurizer. The TEs actually mount inside a thermowell that provides the pressure boundary from the pressurizer to the TE. The thermowell is then welded to the safe end of the nozzle (the nozzle is welded Attachment 1 I~

to the safe end during nozzle fabrication, prior to installing the nozzle in the pressurizer shell}. The nozzle is then welded, via the "J" weld to the pressurizer shell and the interior cladding of the pressurizer to provide the pressure boundary to atmosphere. The proposed modification will retain the original "J" weld inside the pressurizer but will not rely on it to prevent the nozzle (and thus thermowell and TE} from being ejected from the pressurizer. For TE-0101, since the nozzle is intentionally being partially severed outside of the le "J" weld, the modification will assume both the design functions of pressure boundary and structural support. For TE-0102, even though the nozzle will remain intact, the "J" weld will not be relied on for any structural support. The modification will replace the pressure boundary and structural support aspects of the "J" weld with the "pad" on the exterior of the pressurizer. The modification, thus, moves the structural support point and the pressure boundary from the interior surface to the exterior surface of the pressurizer.

Therefore the original design basis functions of the temperature nozzles are m~intained.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet 12 Rev # ~ 1 I1 Re nce/Conment 4.6 Impact on Affected System or Interfacing Systems

a. The proposed modification will not have any noticeable effect on the pressurizing system, PCS, or the pressurizer temperature indicating system.

b. Each pad's weight is less than 10 pounds which is Ie..

insignificant compared to the dry weight of the pressurizer vessel which is 202,000 lb. {including heaters) and thus is not a weight concern.

c. The method by which the pads are deposited on the exterior le_

of the pressurizer assures that they are not a residual stress concern for the vessel itself or the temperature Ref 2.6.g, Att 9 nozzles. The modification will not adversely affect the e pressurizer base metal due to any metallurgical changes Ref 2.6.f, Att 8 caused by the weld process. This is the prime reason for the selection by the ASME Code for the weld procedures

{Half Bead Technique) specified in paragraph IWB-4000 of the Code. The residual stresses created by this weld Ref 2.6.g, Att 9 modification have been evaluated and determined that the residual stresses caused by the modification can be determined to be hoop stresses, just as was seen in the original design. The fact that the residual stresses are in the hoop direction, and not in the axial direction, implies that any cracking of the nozzle that might occur as a result of these stresses would again be axial and not circumferential. Also it is likely that the operational hoop stresses as a result of the modification will be substantially less than for the original "J" weld. This is due to the fact that nozzle exterior at the original "J" weld only saw only the tensile residual stresses caused by the shrinkage of the weld material, whereas the nozzle exterior at the pad weld will also see exterior pressure due to the cracks upstream on the nozzle pressurizing the bore of the pressurizer shell penetration. This exterior pressure is compressive and e tends to lessen the total tensile stress on the nozzle.

Operational axial stress is not a concern at the TE-0101 nozzle due to the fact that it is being partially severed.

This allows any stresses due to the thermal expansion stresses caused by the difference in expansion between the inner and outer walls of the pressurizer and the nozzle material to plastically deform the nozzle in a known orientation and location. Operational axial stress is a potential concern in the TE-0102 nozzle, though, since it is remaining intact. This concern is mitigated by the fact that the corrosion mechanism that is producing the nozzle cracking is PWSCC and it is very time dependent. Ref 2.6.d, Att 6 Since the modification is intended to only be installed one fuel cycle, it is highly unlikely that enough time would be available for PWSCC to produce a through-wall crack. The concern is also mitigated by the fact that the

I PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet 13 Rev # ~ 1 I1 Ref erence/Comnent axial stress in question is also self-limiting, due to its cause. The stress is highest during high differential temperatures between the interior and exterior walls of the pressurizer. This is a relatively uncommon occurrence, especially for the water space of the pressurizer, other than during plant heatup and cooldown.

The intensity of the axial stress during steady state operation is likely to be much below the threshold stress required for the onset of PWSCC. Since the highest level of stress only occurs during major changes in plant state and the modification is only intended for installation during one fuel cycle, there will be little time spent with the nozzle at its maximum axial stress. Thus, there still is not a realistic threat of a circumferential crack that would lead to Loss of Coolant Accident. Another point to be considered with any cracking of the TE-0102 nozzle as a result of the high axial stress during heatup and cooldown is that any cracks that may occur due to the IE::

stress would occur between the "J" weld and the pad weld and thus would still be within the new pressure boundary.

As regards new cracks in the nozzle wall beyond the new pressure boundary, it has been the industry experience that PWSCC requires significant time to develop into through wall cracks. Since the areas of the nozzles to be welded by the modification were not highly stressed prior to the modification, and currently have no eddy current detected indications within them; it can be expected that Ref 2.6.i, Att 2 Assumption 3.1 1~

any PWSCC that will occur in the newly welded areas will be minimal and will not likely cause through wall cracks prior to the replacement of the nozzles. With no pre-existing flaws to accelerate the process, the time this Assumption 3.1 modification is intended to be installed is insufficient to develop PWSCC. Because a Code authorized weld process e.

was used to form the new pressure boundary and the stresses created in the lower nozzle are within Code allowables, the modification will not adversely affect the pressurizer or nozzle at the TE-0102 nozzle.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet 14 Rev # "' 1 11 Reference/Cotrment

d. Operational axial stress is not a concern with TE-0101 due to the fact the nozzle is being partially severed. This cutting operation is being performed by Electrical Discharge Machining (EDM}. The EDM process is being used due to the fact that it produces only a residue that may be allowed to enter the PCS, thus simplifying the cutting operation by not requiring that the cutting be prevented from entering the PCS. The EDM process only produces residue in the consistency of talcum powder since it essentially vaporizes the metal it 'is being used to cut through. Since the EDM process is going to be used to cut lnconel 600, and lnconel 600 includes trace amounts of Cobalt, one of the concerns with releasing this residue to the PCS is the activation of the Co-60. The fact that the modification would introduce this Cobalt bearing powder to the PCS was brought to the attention of Palisades Reactor Engineering department. Allowing the EDM residue from Inconel 600 to enter the PCS was evaluated by Reactor Engineering as not being a concern to fuel integrity or PCS activation due to the fine consistency of the residue and the extremely small amounts of it being created.

Another concern with EDM is that it produces a very thin Heat Affected Zone (HAZ}. Per paragraph IWB-4212, if a Reference 2.2.c thermal process is used to remove metal from a P-No. 43 material, 1/16" of material must be removed after the thermal removal process is complete. (Inconel 600 is grouped as a P-No. 43 material.} However, per ASME Code Ref 2.6.m Att 16 Interpretation XI-1-89-70, the requirements of paragraph IWB-4212 do not apply to the EDM process when used on P-No. 43 material; Thus no post-removal surface smoothing will be required after the EDM process is used to partially sever the TE-0101 nozzle. Yet another concern with using the EDM process is ensuring that only the nozzle be cut. This is because there is no Code

interpretation for cutting the P-No. 3 base metal.

Without the Code interpretation the modification would have to take into consideration the requirement to mechanically remove whatever little HAZ may be created by the EDM process operating on the base metal. However, due to the design, as indicated above in Section 4.4.e, the probability of contacting the base metal is minimized by leaving a 0.055 inch ligament of the nozzle behind. This ligament has been evaluated as acceptable per the ASME EA-SC-93-087-04 Code. Because the modification to the nozzle is being performed within the Code allowables, and because a Code authorized weld process was used to form the new pressure boundary, the modification will not adversely affect the pressurizer or the portion of the TE-0101 nozzle being relied on as a pressure .retaining component.

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet 15 Rev # ~ 1 I*

Reference/ omnent

e. The modification will not adversely affect the PCS due to the entry of foreign materials. As discussed above, the only materials to enter the PCS are a small amount of EDM residue of powderized Inconel and the demineralized water used by the EDM process for cooling and dielectric. The residue has been evaluated by Reactor Engineering to not pose either a fuel damage risk or an activation problem.

The demineralized water has been estimated at 120 gallons (6 gal/hr

20 hrs) and has been evaluated as not being a boron dilution problem. Therefore the modification will not have an adverse effect on the PCS.

f. In addition, the weld modification will not affect the temperature elements because they are not affected by the location of the structural support or pressure boundary, as long as they are not exposed to PCS pressure. The leaks are not in an area that threatens to expose the TEs to PCS pressure, thus the modification will have no effect, in this regard, on the TEs. The TEs will be removed from the thermowells prior to the weld modification, thus the actual installation of the

modification will not affect the TEs either.

g. Overall, the modifi~ation will not affect either the system it is installed on or any interfacing systems except to restore the structural .support that may have been weakened by the cracks in the nozzles and to re-establish the pressure boundary that has been bypassed.

4.7 Critical Features The critical features that the modification must meet are that it must re-establish the structural support and the pressure boundary between the pressurizer and the containment atmosphere while not detrimentally affecting the structural integrity of the pressurizer or the nozzle. The temperature elements and thermowells that are installed in the nozzles must continue to function normally. The original "J" weld had two critical physical functions - (1) to provide structural support for the thermowell and thus the temperature element, and (2) to provide a pressure boundary between the pressurizer and the containment atmosphere. The modification weld "pad" will function as the replacement structural support as determined the stress calculation and also function as the replacement pressure

EA-SC-93-087-03 le boundary due to its location. Because the temperature elements will be removed during the welding and because the thermowells will not be damaged during the modification, there will be no adverse effects on the temperature elements, so the TEs will continue to function normally.

PALISAD~S NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet 16 Rev # II 1 I1 Ref erence/C nt 4.8 Critical Feature Verification

a. The critical features of the weld will be verified by following the traveler, which calls for the use of non- Ref 2.6.c, Att 5 destructive testing after the pad is installed by weld build-up on the pressurizer as required by section IWB-4344 of the Code.

b. The critical features of the modification will be verified, as required by the Code, via a leak check and visual inspections at normal operating conditions. Per paragraph IWA-4500 (a) of the Code, an examination of the repaired area using the same technique as originally detected the flaw must be performed. For the temperature element nozzles, this means that a visual inspection for leakage, with the insulation off, must be performed at 250 psig. Per paragraph IWA-4400 (a) after repairs by welding on the pressure retaining boundary, a system hydrostatic test shall be performed per IWA-5000. IWA-5214 requires that the replacement component (in this case the pressure boundary) be pressure tested to comply with the system pressure test specified in IWB-5222. IWB-5222 (b) states that when a system hydrostatic test is conducted for a reactor vessel containing nuclear fuel and the vessel in within the system test boundary, the test pressure shall not exceed the limiting conditions specified in the plant Technical Specifications. Since the pressurizer is unisolable from the reactor vessel, and the reactor vessel will contain nuclear fuel during the performance of the hydrostatic test, this paragraph indicates that the test pressure shall not exceed the limiting conditions specified in the plant Technical Specification~; What this means is that the modification will have to be Palisades Technical Specs, Section 3. 1. 1 pressure tested to the m~ximum pressure allowed in the Technical Specifications, 2100 psia, and visually inspected at this pressure.

c. The critical function of normal indication observed on TE-0101 and TE-0102 will be verified by the plant operators e.

during plant startup.

4.9 Weld Characteristics Weld characteristics for the modification are indicated on the Ref 2.4.b & c, design drawings. The qualified weld procedure to be used for the creation* of the weld build-up "pad" is found as Reference Attach. 12 & 13 le 2.6.a. The qualified weld procedure to reinstall the Attachment 3 le thermowell after the modification to the temperature nozzle attachment is found as Reference 2.6.e. Procedures for Attachment 7 1~

attachment of thermocouples for monitoring pre-weld and post-weld heat treatments and t~e procedure for the monitoring the heat treatments are called for in Reference l.6.c. Attachment 5 IC!

PALISADES NUCLEAR PLANT EA-SC-93-087-01 ANALYSIS CONTINUATION SHEET Sheet 17 Rev # ~ 1 I1 R eren I nt 4.10 Code Reconciliation The ASME Boiler and Pressure Vessel Code (B & PV) for the construction design of the pressurizer wasSection III of the 1965 edition with the winter 1966 addenda. Per the Palisades Ref 2.6.h Att 10 Nuclear Plant Final Safety Analysis Report, Section 4.3.7, the pressurizer was built to ASME Section III 1965 edition with winter 1965 addenda. The original engineering specification Ref 2.6.h Att 10 for the pressurizer, on pages 2 and 3, states that the winter 1966 addenda is approved for the Palisades pressurizer. Based on this fact an FSAR Update.will be submitted to correct this error. The design of the modified connection for the temperature nozzles is to the Section III of the ASME B & PV Code, 1965 edition with the winter 1966 addenda. Since the EA-SC~93-087-03 design of the pressurizer and the design of the modification are to the same edition and addend~ of the Code, no reconciliation is required. The modification-installation is to the ASME B & PV Code, 1983 edition with the summer 1983 addenda. This particular edition and addenda of the Code has been approved as Palisades' Inservice Inspection (ISI) Code, and thus all welding to Section XI components at Palisades is done to this edition and addenda without the need for reconciliation to the Construction Code - the reconciliation was performed when this edition and addenda were approved as the ISI code. (See Reference 2.6.j for a more detailed code Attachment 11 reconciliation.) Thus the modification design and installation are properly reconciled to the Construction Code.

5.0 CONCLUSION

Ref 2.4.b &c, The modification as specified in design drawings and installed per Attach. 12 & 13, the Travelers is an acceptable modification to the Palisades Ref 2.6.c & k, Pressurizer Temperature Nozzles per the ASME. Boiler and Pressure Attach. 5 & 14 Vessel Code,Section XI. The modification is being performed per the Code and thus will provide adequate structural support and a sufficient pressure boundary to continue operation of the Palisades Nuclear Plant for at least one full fuel cycle.

NUCLEAR OPERATIONS DEPARTMENT Document Review Sheet Document Title Ju<; ;..&c~t;--oh ,.J- ~dJ fatoJ i:o Pz.r<. Tu......P Al,...~_, I es: fG -0/01 I

TE -f) /o l Document Number SA- - Sc- c;'.3- o s 7- 0/

I Re111s1on Number I

IPi!ge / ot I Item P1ge and/or Number Section Number Comments Response or Resolution N~ri..e Reviewer J. c..

CA)

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IDate (D-1...)-15 I Review Coordm1tor I Date I Document Sponsor IDate form3110 10-91

Proc No 9.11 TECHMICAL REVIEW CHECKLIST Attachment 5 EA - s (_ - C\ s - 0 ~ 7 -cJ I REV. Revision 5 Page 1 of l This checklist provides guidance for the review of engineering analyses.

Answer questions Yes or No, or N/A if they do not apply. Document all corrments on a 3110 Form. Satisfactory resolution of connents and completion of this checklist is noted by the Technically Reviewed signature on the Initiation and Review record block of Form 3619.

1. Have the proper input codes, standards and design

@, N, N/A) principles been specified?

2. Have the input codes, standards and design principles been Y properly applied?

3. Are all inputs and assumptions valid and the basis for y their use documented?

4. Is Vendor information used as input addressed correctly in the analysis? y

5. If the analysis argument departs from Vendor Information/Recommendations, is the departure justification documented?

6. Are assumptions accurately described and reasonable? 'I

7. Has the use of engineering judgement been documented and justified? I

8. Are all constants, variables and formulas correct and properly applied? y

9. Have any minor (insignificant) errors been identified? If yes; Identify on the 3110 Fon1 ancMjustify their insignificance. \

10. Does analysis involve welding? If Yes; verify the following infor9ition is accurately represented on the analysis drawing (Output docW1ent). y

TJIWtf Veld

SfW~*f Veld

*IYlal Being Joined

Tit*a1s of Material Being Joined

Location of Weld(s)

Appropriate Weld S,Yllbology

11. Has the objective of the analysis been met?

y

12. H*av1 adllinistrat1v1 requir11111nts such as numbering and f fon11t been satisfied?

EA-SC-93-087-01 ATTACHMENT 1 CPCo Sketches

EA-SC-93-087-01 Attachme:nt 1 Page 1 of 2

TE-0101 MODIFICATION S.S. SAFE ENO INCONEL NOZZLE PROPOSED EXTERIOR WELD "PAO" ADDITION C.S. PRESSURIZ::?

INTERNAL "J" WELD S.S. CLADDING

T-72 PRESSURIZER SK-SC-93-087 Sheet 1

EA-SC-93-087-01 Attachment 1 Page 2 of 2 TE-0102 MODIFICATION ELEMENT THERMOWELL ~

S.S. SAFE END

C.S. PRESSURIZER\

\ PROPOSED EXTERIOR WELD "PAO" ADDITION EXISTING PAD BUILD-UP (P-3 MATERIAU INTERNAL "J" WELD S.S. CLADDING T-72 PRESSURIZER SK-SC-93-087 Sheet 2

EA-SC-93-087-01 ATTACHMENT 2 Eddy Current Exam Results

EA-SC-93-087-01 AttachmE:nt 2 PagE: 1 of 4 jl 1111 Jll'll919

October 16, 1993 Scott Cedarquist Consumers Power Co.

Subject:

Preliminary results of Nozzle TE-0101 Eddy Current Exam On October 16 1993, ABB/Combustion Engineering performed an eddy current examination of Nozzle TE-0101 located on the top of the pressurizer at Palisades Unit 1 Nuclear Plant. The inspection utilized the rotating 3-coil eddy current probe to aid in distinguishing an axial or circumferential orientated indication.

The results of the examination indicated four axial crack indications emanating from the inside of the pressurizer with a length of approximately one half inch. The examination was performed utilizing a calibration standard with axial and circumferential indications of various sizes located on the ID of the standard.

To indicate the approximate size of the crack indications, a voltage setting of five volts was established on the 0.018" deep 1.0. axial notch in the calibration standard.

The size of the largest axial indication in the nozzle was approximately nineteen volts.

This indicates the axial indications are larger than the calibration standard notches.

Details of this inspection will be included in the final report to be issued at a later date. Graphic presentations and other documentation will be included in the final report.

Sincerely, ABB/Combustion Engineering Thomas U. Sipes ABB/CE Eddy Current Level Ill

Combustion Engineering Nuclear Services Combustion Engineering. Inc P 0 Box 500 Telepnone 203-285-9519

000 Prospect Hill Road Fax 203-285*9530

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EA-SC-93-087-01 ATTACHMENT 3 SMA Welding Specification

Attachment 3 Page 1 of 12 Proc No 10.41 Attachment 4 PROCEPUBE TBAYELER Revision 17 Page 1 of 2

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EA-SC-93-087-01 Attachment 3 Page 2 of 12 Procedure No. SMA-3.43-937 Rev i s ion No. 1 Issued Date 10/19/93 PALISADES NUCLEAR PLANT WELDING PROCEDURES TITLE:

WELDING PROCEDURE SPECIFICATION (WPS): ABB/COMBUSTION ENGINEERING NUCLEAR SERVICES SHIELDED METAL ARC -- MANUAL 7

Date I I User Reviewer Rev #

EA-SC-93-087-01 Attachment 3 PALISADES NUCLEAR PLANT Page 3 ~d-4io 3.07 SAFETY REVIEW Attachment 1 Revision 7 Page 1 of 1

Item Identification: No SM.A-3.43-937 Rev ___

PS&L Lag Na 1_ Title WELDING PROCESS PECIFICATION WPS : ABB CE ENG. NUC. SVCS. SHIELDED MET.AL ARC - MANUAL Describe Issue/Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING SE Rev Reason for Issue/Change: PROCEDURE RE UIREMENT BY ADMINISTRATIVE PROC. 5.06 Yes Na

1. Does the item involve a change to procedures as described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5. 6' s.a 1 5.10, 6.9, 7.4, 9.1, TABLE 4-21, TABLE 4-22 x

2. Does the item involve a change ,to the facility as described in the FSAR?

FSAR Sections affected ~N~O~N~E--------------------------------------

FSAR Sections reviewed 4.3, 4.4, 5.1 1 5.6, 5.8, 5.10 1 6.9, 7.4, 9.1 1 TABLE 4-21, TABLE 4-22

3. Does the item involve a test or experiment not described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.a, 5.10, 6.9, 7.4, 9.1, TABLE 4-21, TABL~ ~-~~

4. Should the Technical Specifications or any of their Bases be changed in conjunction with this item?

TS sections affected ~N~O~HE----------------------------------------~

TS Sections reviewed ~3~*~0.a-~4~*~0'-------------------------------------

Justify No Answers below if logic is not obvious:

Although welding, post weld NOB testing and heat treating are discussed in the FSAR, the same proceaae* that are discussed will be followed for this Vendor support.

Rev. 1 added clarification on the weld process that will be used for the Pressurizer (T-72) temperature element nozzles and thermowell(s) *.

If any safety Review question listed above is answered "YES", perform a written USQ Evaluation according to Section 5.3.

If all Safety Review question& listed above are answered NO, written USQ Evaluation i* not required. However, thi* Attachment shall accompany other review materials for the item to document that a Safety Evaluation was not required.

Prepared By Date

__________________________________ - - - - - .. " *** ____ - - - - - -- __ . -- - - - - - - - - - - - - - - - EA- SC- 9 3-0 8 7 -0 1 OCT-19-1993 0g:49 FROM AEB/CE Chattanooga TO 31616764~~ent P.22 Page 4 0 t i1 I WELDING PROCEDURE SPECIFICATION (WPS)

ABB/COMBUSTION ENGINEERING

Company Name WPS SMA-3.43-937 NUCLEAR SERVICES ABB Combustion Engineering Date 10/1S/93Support.

Page l of 5 JOIH'l'S (QW-402)

Joint Design Buildups and Fillets/Half Bead Technique Backing(Yes) X No Backing Material (Type) P-3 Base Material No Retainers (a.tir ID balll lloalliol ... ~

Metal Nonfusing Metal Nonmetallic _ Other The 1.i two layen are temper bead and need aot fuse into nozzle. Sublequcnt layen lhall ftJM into ncmJa. p.. 3 p

¥3

BASS IUITALS (QW-403)

P-No. 3 Group No. 3 to P-No. 43 Group No. N/C OR Specitication Type and grade SB-166 or SB-168 Inco 600 to Specif !cation type and grade SA533 - Grade 'B' - Class 1 OR Chem. Analysis and Mech. Prop. ~N~o.-t....1A11.1DK..1P11..il...i1o:1cgaub&.11ll.:li1L.. -_ _ _ _ _ _ _ _ _ __

to Chem. Analysis and Mech. Prop. ~N.-.ot.-.A.,.p~p.1...i~cgaub1.11la.;:1*1.----------

Thickness Range:

Basa Metal: Groove 3/16" minimum Fillet Unlimited Pipe Dia. Ranqe: Groove Unlimitld Fillet Unlimited Other

~ILLBa ~AI.8 (QW-404)

Spec No. (SFA) ,.11 Coated Elec;trodes - See Electrode Control. 3-Ccl AWS No. (Cla**> A5.11 EHiCrFe-3 F-No. 43 Consumable Insert __,N~o~n~*-------~--------~

A-No.

Size of Filler Metal* 3/32" and 1/8" diam,1t1r1 D1poait1d Wald Metal* __.Inuc~o~nw*~l.....,;;-;.....il~S~a~-----~---------=-~---~-

Thickne** Range: No single pa11 1hall exceld 1/2" thickness Groove Hgt Applicable Fill1t Unlimited, Electrode-Flux (Class) --~N~onua.__ _________________ ~

Flux Trade Name -0.Hwonua.________________________ ~--

other

Bach !)&** ..

Independent Reviewer ,%

tal f illar **tal

'?:J'4=1e c~ina~ion *hoald 1'e racor4a4 Data /D-/4-9,3

r:.n.-.:H.. - J J-uo 1-l.J l Attachment 3 QCT-18-1993 g9:50 ~?OM ABE/CE Chatta~ooga TO *31s1 s '764~~P:fu75.:.P f 16 . n WELDING PROCEDURE SPECIFICATION (WPS)

ABB/C01\1BUSTION ENGINEERING

WPS NO. SMA-3.43-937 Rev._l NUCLEAR SERVICES Page 2 of 5 POSITIONS (QW-405) POS'l'WELD BEAT TllllTXEN'l' (QW-407)

Position(s) of Weld All Temperature Range 500 += 50 deg. f Weld Progression: Up -1L Down Position(s) of Fillet tl2DI

-- Time Range ~ bs;n.u;:11 minimYm Ai~ cooi tQ ambient timai,stY'i GAS (QW-408)

PR EB EAT (QW-40<<5) Percent Composition Preheat Temp. Min. J~Q dea. [ Gas(es) (Mixtr) Flow Rt Interpass Temp. Max. ~SQ gi9:1 f Shield. H2D~

Preheat Maintenance ~§!5 Trail. li2DI (Continuous or special heating, Back. Hgne if applicable.) ~~I :RASI ~'

J (bl I ELBCTRICAL CJIARACTBKISTICS (QW-409) current AC or oc c~ Polarity Bf Pulsed H2 Amps (Ranqa) ~!HI iU: l S2lf Volts (Range)* Belo!!

~-*

(Amps and volts ranqe should l::>e recorded for each electrode size, position, and thicknesa, etc.

Tunqsten Electrode Size. and Type Hgt A12glic1bl.1 (Pure Tunqsten, 2' Tho~iated, etc.)

Mode ot Metal Tranef er for GMAW lfgt Ali2li211s=Ablta (Spray arc, short circuitinq arc, etc.)

Electrode Wire Feed Speed Range HADYAll~ cgnt~gll1g !g~ ~D li2:t!i!'1~1i T2CJDllQ03 (QW*410)

Strinq or Weave Bead St~ing1~ g~ ilAXI tg ~x '12&:1 dia.m1t1~

orifice or Gas cup size Hgt A1212lis;;1lal1 Cleaninq Initial ~~indl~ g~ ii~I B;ci.1b Interpass ~Ami Method ot Back Gouqinq li'2DI oscillation Hgt tg 1xs;;11d JX cg~* di1m1t1£ Contact Tube to Work Diatance Hgt A.a,,l.;1;1bl1 M\lltiple or Sinqle Paaa (per side) ~lti12l*

Multiple or Sinqla Electrode* &1nszl*

Travel Speed (Ranqe). H11m1llx ~gnt,gll.1d Paeninq llQt 6llmr:1d I other

- 11DiJllUlll b11d lmtatb li2*~ YDit incb gf 1l1s;;t,gs;l*

Piller M*tal eurrant

Min. Other Bead Type Amp. Volt Bead Remarks, No. (a) Procesa Claaa Dia. Polar. Range Rang* Lenqth comments All SMA SFA.5.11 3/32 DCltP !5!5-6!5 22-23 .42" 1/8 DCRP 75-90 23-24 .37"

EA-SC-93-087-01

- - - - - - - - - .. - - . . - - - . . - - - - - - - - - - - - - - - - - - - - .. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - * - A.t tac hrne n t 3

JCT-18-1993 89=51 FROM ABB/CE Chattanooga TO '31616764E.?age 6 of 12 WELDING PROCEDURE SPECIFICATION DWPS SMA-3.43-937 Date 10/15/93 Page 3 of 5 Rev. _J_ Date 10/18/93 SPECIAL INSIRUCTIONS:

1. This procedure allows for use on a limited basis as defined below. The repair may be accomplished on P-3 materials made without PWHT or after the final PWHT.

2. Prior to repair, the area shall be examined by magnetic particle or liquid penetrant methods in accordance with the acceptance standards on the specific code edition. This shall be defined by Quality Assurance. Each layer of deposit shall be visually inspected for uniformity prior to depositing subsequent layer*

3. All weldin& shall be in accordance with ASME Section XI and IX and shall include the requirements listed below:

(a) The repair area shall be suitably prepared for weldin& in accordance with the written procedure.

(b) The weld metal shall be deposited by the manual shielded metal arc process using low hydroaen type electrode. The maximum bad width shall be three times the electrode core diameter.

(c) All covered electtudes shall be from unopened hermetically sealed packages or heated ovens maintained between 225° F and 350' F. Electrodes exposed to the atmosphae for more than twenty minutes shall be re-heated at a temperature between 225° F and 35<1 F for at 1eut ei&ht (8) houn before re-issued for use.

BlecUodes exposed to the atmosphere for longer than 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months shall be discarded.

(d) The weld ma shall be preheated to a minimum of 350' F and maintained at that tempenture for a minimum of 30 minutes prior to any weldina. The width of the band to be pieheated shall be 10 inches and shall be maintained at a minimum of 3500 F durin& weldina. 'Ibe minimum preheat, and subsequent heat treat temperature requirements shall be monitored by use of thermocouples and recordina equipment. The:nnocoupla may be attached by weldin& or mechanical methods. >

EA-SC-,:-,_ *JB 7-01 OCT-18-1993 09:52 FROM ABB/CE Chattanooga TO Attachment 3 Page 7 of 12

WELDING PROCEDURE SPECIFlCA TION DWPS Date SMA-3.43-937 10/15/93 Page 4 of 5 Rev. _l_ Date 10/ 18/93 (e) The initial layer of weld metal shall be deposited over the entire area with 3/32" diameter electrode. The weld bead crown surface shall be removed by grinding or machining before depositing subsequent layers. The. second layer shall be deposited over the entire area as before with 1/8" diameter electrodes.

Subsequent layers shall be deposited with 11s* diameter electrode in a manner to ensure tempering of the prior beads and their heat affect zones. All subsequent layers shall be at least 1/8

from the outer most ed1e of the around first layer.

(t) Examination of Repair Weld (See Below)

The completed weld (groove welds only) shall have the reinforcement of a groove weld including the final layer removed substllntially flush with the surface prior to performing the required nondestructive examinations, (Pl'). The final PT shall be performed after the completed weld has been at ambient temperature for a minimum period of 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months to determine the presence of possible delayed cracking. See {j) below.

(J) Heat input shall be controlled within the specified bead length per unit length of electrode, u &ivm on paae 2.

(h) The weld area shall be maintained at a temperature of 4SO-SSO' F for a minimum of four houn aftm completion of the weld repair.

(i) 'Iba performance of the repair weld and all in proceu operations shall be witne11ed by the authorized inspector if indicated on the traveler by the inspector.

(j) Poltheat operations in (h) above may be perfonned after the second layer or 1/4*

minimum thicJcnrm has been deposited.

I.

/

OCT-18-19g3 0g:53 FROM ABB/CE Chattanooga TO EA-SC-93-08/-01 Attachment 3 Page 8 of 12

WELDING PROCEDURE SPECIFICATION DWPS Date Page SMA-3,43~937 10/ 15/93

_...s__ of 5 Rev. _l_ Date 10/ 18/93

.TEMPER BEAD TECHNIQUE & AFFECTS OF APPLICAnoN*

_t).,,_~AL~,e_~ * !-----------------~-----._----~~~-;-.;-rA~--~

a~<~l*p-~--r!---,,-?""'"'!/~~~~~~~~~~~!:".:==--".,..::::::.._~~~

~* ). I I ,,_..,.-,JJ19""'tm.,.~,,......,_~i--..,__,,~jo....,__,.~~.,_

-. ~.c

~

-"'P- ...,*-*'*~ _,""'-,_"'""~,..-.~---,_~-,_.~~,......,.-"';-""',_ _____

1~~~--i:o,...'-....c;,.~,..-,__~~.......;;---..,_..::;....-"'....c;.-

"- *"' o.... T.s1"dc

~BaAJ;;-i~-L,Ay~~*---------------------------------_.

1. Heat affect mne creaaed by 1st layer of deposit.

2. 1S-80~ overlap desired to achieve &ood temperi.na of 1st layer bead, and HAZ. outside bead of 2nd layer must mt touch base material.. Second layer deposit tempers the 1st layer, and large portion of HAZ, which causes refinin1 and softening of grain structure

within the HAZ. .

3. Hardened uea of outside bead of 1st layer. If outside bead of 2nd layer is allowed to touch bue material, thm this hardened area is moved further out, and refinement does not . . . . .

4. Overlap of laJW 2 by layer 3 to be apprmimatl!Jy tbe same II before, and thereby enhance the temperina affects on layer 11 and the HAZ.

s. Subsequent layers may be deposited u desim:l to eahanc:e outer ed1e confipration and reduce grinding time (AI.ARA). Most of temperina affect bas already occurred during layers 2"3, and any additicnal tempering will take place from the preheat and interpus.

Complece c:appin& of bads to achieve a straight upside will encourap bead rollover and require more pindina time.

EA-SC-93-087-01 TO Attachment 3 Page 9 of 12 WELDING PROCEDURE QUALIFICATION RECORD COKBUSTIO* JDIGXB2ERI5G, IHC.

DAT! 12.*13*19 P~OCEDURI QUALIFICATION 110. SMA*3*43*9ll!§ Edftor!1l Correction<*>

3/5/93, 10/1!/9J 9UAL1,llD TO CODI llCTIOllCS> ({(, IX A XI "ATE~IAL S,!C. & GRA9! SA53l*Gr 'i'

Ct '1' TO EliCrft*3 Dtpo1ft FOil WELDING P No TO F No ... 41_ __ 8.ACiIMG lEQUlllMIMTS i l l ! M1ttci1l i* i@Cklpa WE~ClllG P*OCISS lhjrld!d Mttll Arc Hllf ***d Tesbnjque THIClNESS Cl DIA. If PIPE> J.s* $hjck plltt TTPE WELD JOINT U Gcooye, 2* dtep gcooye FI LLElt l'ETAL F No _4::..:l,.__,l""'"n..,.c,,._on,,.t,..L_ _ _ _ _ _ l 110 ...!US- POSITION TEST WELD .:.Vt,,,,r.;..,t,,,.i..,c.1.,l_ _ _ _ _ _ _ _ ( :S*~

S lllGLE or MULTI PLi PASS ""'Mu.,.l..,t,..j..p..,l,.,1_ _ _ _ _ _ __

SPEC. or AllALTS1S SfA5.11 EH1Ccft*3 NO. OF LA TERS <1 F Cl.AD) -'N""/..,'A.____ _ _ _ _ _ _ __

110. OF AlrCI - - - - - - - - - - - - - - - - - - -

ELECTRODE SIZE 3/32* and 1/8* dla111tt!CS PREHEAT 3SQ* E mjn,*soak 30 mjn1. before ~*lding FLUX _,,.N....__ _ _ _ _ _ _ _ _ _~-~~----- MAX I INTER PASS ..,;4;o.c5:,:0;...".i..f_ _ _ _ _ _ _ _ _ _ __

I SM IElD ING GAS(IS) & CO*.,OSlTIOlf__..M~l.-l_ _ _ _ _ __ ~AlllTA Ill PH NEAT UllT IL PWHT _ , _ h : . : * - - - - - - - - -

FLOW RATE ....,.lli.;;A..__ _ _ _ _ _ _ _ _ _ _ _ _ _ __

POST HE:Af TREATMEIT SQQ* F ; SO* F foe 4 Ors. min.

TTP! C\JHEIT .. Dc,..B..,P_ _ _ _ _ _ _ _ _ _ _ _ _ __ po*t*bttt ptcfoc!fdtft1c 2 L1y1r1 of bytter OTK!l: d1991jtgt fgr 1t4* min. thisin***

e.T. *!o 1in1L1 Pl dtpo1!S tb!c!sntJ* CXC!tdfd 1/Z*

.ID11T DHIGI

~~':,,I]

I FllllTE II AUITEllTIC CLAD Dl,OIJT S************************************************************************************************************

DIPOllT ANALTSll c .05] .QQt II' s _,.,0...1,.g_*-*- - - sf I 46 Cl 13.57 .........i.._____ Co

QJ 112 .Q.l* Othtc Cu * .02

"' 67.3 ft

1.U Al * <.Ql Tl * .41 GUIDED l!MD TllTI FACI:

ltOOT:

SIDE: 4 o.r.

Jqbn Arnold MACIOz

.........................................................................................................~=='

Other Ljqyfd ptQttCM!t intptstti 1ft1r 11sb 1/4* gt dtpttf\

Ftn1L lurf1s1 p.T.

q.K. v. Vttlty

.......................................................................................................... ~~'

we oertf fy that th* st1t...nC* ta this rtcacd art earcect VELDEI SH 11'91 X...

ITllllO\. ...* - - - llnd thH th* , .., vel* *r* prepered, welded 1nd ttsted ;,

DE'T CC1*944f accordance ~tch cequirt111nc1 af th* Al'llle Code.

THT IC ....:Sla.:1u1'-l!H-------------- IUI l*GIIE!llll, IIC

THT I.Al. g,Mt ..s._.L..*1mb----------1 --~~

T.!. lo.,_n

AXZ IT OTKll ~L.&.a~"".mlAl:Mlll'------.:---- TJTl.I - - - - - - - -

.L. IU'tcn

All T.1.. lallw

AO.I T1'f1 D~ Is Tiie 'rGptrty Of E.\.. CtUll

1W ~ICll UGIJllDUIG, llC., WlllDa, cml.

And It"°' TO ...... ~:ilad, or UM To *umflll,,,, Irr fCMWMten For Mitt~ Of Dfr111f... Qr ._.,.CUI b..,c

....... l'NridM For ly Afl I ZIC Wtttl ..fd Ccllilllnr*

TO EA-SC-93-087-Gl Attachment 3 Page 10 of 12 POWER SVSJEMS GROUI' FIELC CCNST"UCilON WELDING PROCEDURE SPECIFICATION DWPS ___ <::::-1A_-_3_.4_3_-Q-=.::.l.;;;.l8;;,.;8:;._,__ _

Date ---=1~2"'--/~13:.t.l....::8~9_ _ _ __

?aqe _ _....;;;;., 2 _ _ ot - -

Rev.--~-- 0 Date _ __

Hardness - Rockwell 'C' All Weld Metal Tensile Thickness ... .502 Area "" .19792

= 21,22,21 R'C 'f.ield KSI = 67.2

'iield tbs. = 13,300 Bottom of Groove Tensile KSI "" 99.a Ten*il* Lbs. = 19,750 HAZ .. 25,23,24 R'C Elonc;. '2' Inches a 2.7l Elonc;ation t ""'35.5 Reduct. Area Dia. ,.. .392

" iso* = .429 Reduction t = 33.3 cyH's Ball MttaJ.

sampl1 t Test Ttmp. rI'/Lba j:narqy Sh1ar Mils Lat. E'XI1 XS-TA +30 113

' 50 78 XS-TB +30 96 40 70 XS*TC +30 90 30 64 CYN 1 1 QZ: (Bottom of Weld) s1mpl*

T11t Tpp, fT/Lb* En*m l shear Mils I,at. Ex7 73 XS*ZD +30 88 80 xs-zs +30 89 90 78 xs-zr +JO 88 90 74 Test block received Q*T, plu* torty (40) hrs. @ i100-12oo*F h*at treatment prior to welding. Block cu.mens ion* ware 3.5" thick, x 18" wide , x Jl" lone;.

~-'< 13:01 FROM ABB/CE Chattanooga TO EA-SC-93-087-01 Attachment 3 Page 11 of 12 COMamOtl~lllGUllEE..M POWER SYSTEMS GROUP FIELD CONSTRUCTION WELDING PROCEDURE SPECIFICATION DWPS 5:>lA-3

43~ll.88 Date 12/13/89 Page 3 of -=-3-----

R@v. a D~te "TEMPER BEAO TECHNIQUE & AFFECTS OF APPLICATION"

~V.l:/f../_~?--@_ * :l___ - - - --* ti:_-;-;-f'A;}

l j

~I OY'CIC /.A?_\:J:/....., _. :so .,.. == - >=:::!:><:sos I

I I

- 0vc,e)Ad

@ - r- ~ ~

"--I

/ ~ < _ , . ? ;a<:JG £ -> > S= s- s- s- 'S>=

@I.. ***~** *~*;,;;i;*~:r "A_-r.f£..eJ.< d_z;_,,_~1:_/])1__________ ~-

~ it. * .;. o .. r~.,~

I

J 1--~ Bu*d.r.:1..

- !.-1.At*

l. Heat affect zone created by lst layer ot deposit.

2. 1s-1ot overlap desired to achieve qood temperinq of 1st layer bead, and KAZ. outside bead of 2nd layer must ~ touch base material. Second layer deposit te=pers th* lst layer, and larqe portion of HAZ, which causes refininq and 50fteninq of qrain structure within the HAZ.

3. Hardened area of outside bead of 1st layer. If outsid* bead of 2nd layer is allowed to touch base material, then this hardened area is moved further out, and refinement do** not happen.

4. ov.rlap of layer 2 by layer 3 to ba approximately the.same a* before, and thereby enhance the tamperinq affect.a on layer

1 and the HAZ.

5. Layara 4, 5, ' 6 may be deposited a* desired to enhance outer edqe configuration and reduce qrindinq time (A.LARA).

Mo*t of tempering atfect has already occurrac:l durinq layers 2*3, and any additional temperinq will take place troa the

preheat and interpasa. Complete eappinq of beads to achieve a straight upaide will *encouraq* bead rollover and require more grinding time.

~ .

13:02 FROM R88/CE Chattanooga TO EA-SC-93-087-01 V'fCL.l.111'11\.:I rnv'-'~&.1vni;;. .,....,l"'\._ 11 '""""" , ................... _ Attachment 3 Page 12 of 1{-~"'J \\tr~1 COMBUSTION ENGINEEFUNG. INC.

OAT! Dec.ember 10, 19i4 PROCEDURE QUALIFICATION NO ~-1.: * ..J.3-1C5 torial correction October 15, 1993'* C!.JALIF1EC TOCOD! SICTIONISl _ _ _I_I_I_____

ATER1A1..SPec.&GAAoe SA-533 Gr. B Cl. l Q&T FOR W'eLDING P No 12 iO p No 43 THICKNESS!& CIA, IF PIPEI _ _ 2_l/ ..__2"_ _ _ _ _ _ _ __

'h'ELD1NG PROCESS Shielded .'.'*1etal .~re TYPE WELD JOINT Single "V" FILLER M!TAl. F No _ _ _4 3 ____ A No -------1 POSITION T'EST WELD _f_1o_r_1_*z_o_n_tal ________ ( 2 -Gl SPEC. or ANALYSIS SFA-5.11 F};iCrF_e-3 ll82..._____ \ S1NGLE or MULTIPLE PASS_...;~;..;;h:.:ll=-t=in:::.:l::.;C~--------

ELECT~OOE SIZE 1/8

5/32 NO. OF LAYERS{IF Cl.AO! _ __,N_./_;A-=------------

NO. oF A~cs Single s~ Ie\. OIN G GAS <ESI & COMPOSITION -----'~'-"/'-'A'-'-------- ?REHEAT_

FLOW RA TE _ _N ___/_A__~------------- i MAX. IN-:-!A.PASS 350 °F__________

iYPE CURRENT _ __,OC .....-_,RP,,_______________ M.AINTAIN PFICHEAT UNTIL PWHT _N._/R I _________

BACKING ReOUIMMENTS Strip Ranoved - I POSTH!AT TREATMENT Buttering 1150°F + 50°F

OTHER: No sinal1 pa11 tbickn111 exceedad 1/2" For 30 Hrs. Furnace Cool to 600°F

_ _ _P_-_3_a_n_d_P_-1_2_a_re.o......;s_a""""m_e_.p...,,e....r......i::;.pr'""'"... e v....._A""'"'S;;..;.M=E-....Co'"'"'d"""e-=-.--""""'(Completed Joint as Welded___ )'_ _

JOINT OISIGN BE.AO NO. PROCISS WllllE CIA. .0.MP!lllES ARC VOLTS INCHES/MIN

P*3 . J..tUP~**

..,..,---"' .,.,,,(, *3 g.(4. 1/8" 90 24

~~-*-*>:--

_._' ~MA S/32" 125 24

~

.3 I*" -*

- ****--. -.it.

'30.

?-43 . -

..... _..... '!ft FERRIT! IN ~USTENITIC CL.AD D!POSIT DEPOSIT ANALYSIS C-----

Mn _ _ _ __ p _ _ _ _ __

5------ s. ______

C" NI------- Mo------ Co------Nz------ 01tler - - - - -

GUIDED BEND TESTS CHAAPY V-NOTCH IMPACT TESTS CROP-WEIGHT TESTS FACE: L.OCATION T*MP "1'/U* "'ILS LAT ex* TEMP ~ESUL TS ROOT: l/4T HAZ +10°F 1101. 108.124 SIDE: 4 4.-..-~~l2h1 (!It p_:; ~;ri ..

MACll'O:

NOT OF NON-OESTRUCrt'IE TESTS TENSILE TeSTS LIQUID PINETIIANT .& - - -ble .,.,..,. 111',(;IWI~ \J~?l"A*~ tT"ll._..,, '="'**a.c.Tt'fll'. LOt:ATION or t"'AIL.U,.C RAOIOOAAPHIC Acc:mtable Trans. 95.300 Ductile in Weld ULTRASONIC Trans. 93,300 Ductile in Weld MAG. PARTICLl VISUAL eLo!PI W. C. Jones SYMBOL _ _B_BE __*~-~-

I Wt1 c.ftity That 1i.. ,,,,,.....,tt ;,, *kit. r.c0td '"' corre<*, *nd '"*'

11w _ , -ldl were o...-per.d, welCltcl end 1nted ln ~ccordel"<:t Chattanooga, epT ~----....;;.;. ......_.._....,.___Tennessee

~--..-....-----~------

with requir-ft of I~ AW! Code.

TEST NO ___E:..~-...7--0~5..;.9_,-D....__ _ _ _ _ _ _ _ _ __ N c; l N t I!:" IN 0. I NC.

r!ST I.AB. Met R§D Dept,

~fA-3.43*29

EA-SC-93-087-01 ATTACHMENT 4 Corrosion Letter

EA-SC-93-087-01 Attachment 4 Page 1 of 6

October 15, 1993 MCC-93-525 Mr. Paul Gire Consumers Power Company Palisades Nuclear Plant 27790 Blue Star Memorial Highway Covert, MI 47043

Subject:

Corrosion of Palisades Pressurizer Material

Dear Mr. Gire:

Attached for your use/review is a draft evaluation of the corrosion of primary pressure boundary materials exposed to borated water. Admittedly, the data are limitedl but the results indicate there will be only minor eorrosion over the next fuel -cycle at the repaired nozzle locations. These data have been previously used to assess corrosion at Arkansas-2, Palo Verde-1, etc. using a s1m1lar approach as described in tha report.

Contact ma if you need additional 1nformat1on.

d s;~:~~

Y-Hall Supervisor, Corrosion Technology JFH/b.

cc: S. W. Lurie K. Co*

R. Taylor J. Mburn T. Matlt I

i ABB Combustion Engineering Nuclear Power

EA-SC-93-087-01 Attachment 4 Page 2 of 6

CORROSION OF PRIMARY PRESSURE BOUNDARY MATERIALS AT PALISADES

1.0 INTRODUCTION

There are several Alloy 600 pressure boundary penetrations at the Palisades nuclear plant. Typical applications include pressurizer heater sleeves, pressurizer temperature nozzles, hot and cold leg piping instrument/RTD nozzles, reactor vessel (RV) leakage monitoring tubes, RV vent pipe and. RV instrumentation. All of these* nozzles are welded to the primary system components by J-groove partial penetration welds. In recent years, a number of these Alloy 600 penetrations in several ABB-CE plants have developed leaks as a result of IO initiated stress corrosion cracks. During the 1993 refueling outage

at Palisades, the pressurizer upper head and lower shell temperature instrumentation nozzles developed leaks. Consumers Power Company elected to apply temporary leak repairs to return the plant to sarv;ca.

The temporary leak repairs at Palisades will result in non-clad pressurizer shell material being exposed to borated water or steam. The pressurizer shall is SA-533 Grade B Class 1 steel, a low alloy grade. Low alloy and carbon steels used as pressure boundary materials ar1 clad with stainless steel or Alloy 600 weld metal to isolate the *1t1rials from the priury cool ant, thereby mi n1mi zing corrosion and corrosion product generation. The objecttve of th1s evaluation was to dete,..1n* and docU11ent the expected corroston for SA-533 Grade B steel. The results wtll also b1 applicable to other gr1d1s such as SA-508 Class 2 low alloy steel and SA-101 Grade B carbon steel used for primary system piping.

2.0 LITERATURE DATA

.Reference (1) presents the only published literature data that are applicable to

Pa1i sades. During the 1965 refue 11 ng outage at Yankee Rowe, 1nspect1 on s discovered two small areas ~ere the reactor vessel cladding had been breached.

EA-SC-93-087-01 Attachment 4 Page 3 of 6 The cladding defects wee mechanically produced after a surveillance capsule became 1oose and dumped mechanical test specimens and other debris into the lower head of the reactor vessel. The lower head base metal was A302B steel which had been clad with Type 304 stainless steel plate using an intermittent spot welding technique. This fabrication process resulted in large areas of the cladding-base metal interface being unbonded. Thus, the breach in the cladding exposed large areas of the underlying base metal to the reactor coolant.

Because of concern about corrosion and hydrogen embr1tt1 ement, the reactor vendor initiated a test program to determine corrosion rates for A302B steel under operating and shutdown conditions and ta determine if hydrogen absorption was a concern. In this program, specimens of A302B were exposed to aerated and derated solutions of boric acid (2000-2500 ppm B) at temperatures ranging from 70'F to soo*F. The specimens included both electrically insulated coupons of A302B and coupons electrically grounded to Type 304 stainless steel to assess galvanic effects. Most of the testing was at low temperatures (70' to 140.F} in 2500 ppm B aerated and derated solutions for up to 121 days. For these conditions, the test progra11 we 11 charactari z1d the corros 1on rates of A302B. The reactor vendor also conducted a few short term {6-14 days) tests at 300-SOo*F in derated solutions containin9 2000 PP" B.

The results of tha study showed that hydrogen absorption was not a concern and that the exposed A3028 steel would corrode uniformly at a rate of about 3 mpy (mils per year) which was sufficiently low to be of no concern over the re11a1n1ng 25 year 11f1t1me of the plant.

C-E re-ex1111n9d the Reference (1) data in developing asti*ated corrosion rates applicable to th1 Palisades pressurizer applications in which the steels will be exposed to 640'F steam (low B levels) and water.

3.0 CORROSION RATE FOR PRESSURIZER MATERIAL I

3.1 Assyeptions C-E used three basic assumptions in developing a corrosion rate app1icab1a

2-

cA-.:iG-';iJ-uo, -0 i Attachment 4 Page 4 of 6 to Palisades. They were as fallows:

1. The corrosion of SA-533 Grade B Class 1 stee1 in bor1c acid solutions 1s equivalent to that of A302B. Both grades are low alloy steels but there are minor compositional differences, with the most significant being higher Ni in the SA-533 Grade B Class 1 material.

The presence of Ni w1ll not adversely affect corrosion. Similarly, there are only minor differences between A302B and SA-508 Class 2 or 3 and SA-106 Grade B and these differences will not s1gnificant1y affect corrosion rates.

2. During the upcoming cyc1e, Palisades will operate 80 percent of the time.

3. While operating, the coolant will be darated. While shut down, the coolant will be aerated .

3.2 Rates for High Temperature Operation Palisades pr1mary coolant temperature during operation.is approximately 64o*F for the pressurizer. The maximw1 test temperature included in the Reference (1) progr111 was soo*F. Data were obtained for six specimens of A302B after only one week of tasting in a refreshed autoclave with a 2000 ppm B solution. For these specimens, the average corrosion rate was 0.6 mpy. For the sp1cimen with the greatest observed weight loss, the corrosion rat* was l;O llPY*

Th*te valu*s for corrosion rates, which are based on short t1n11 tests, are probably higher than would have been obtained had tast times been significantly longer. Carbon and low alloy steels usually follow a logarithmic or parabolic corrosion rate law. The tilll required to reach a steady-state condition 111y exceed 100 days. Rates during th* in1tia1 transient stage (which includes seven days) will be high ca11Pared to the

/

steady-state corrosi'on rates.

EA-SC-93-087-01 Attachment 4 Page 5 of 6 There are no corrosion rate data for low alloy steels in borated water at temperatures above soo*F. However. the Reference (1) program did include tests at 300'F and 400'F in derated borated water. These tests showed decreasing corrosion rates with increasing temperature. Based on th1s, c~

E judge that the (steady state) corrosion rate at 640°F wi 11 not be significantly greater than the rate at SOO'F.

In addition, the available data are from tests with 8 levels of 2000 ppm, significantly greater than expected at Palisades during the current fuel cycle, and, thus, they are.conservative with respect to actual conditions.

This is especially true for the steam spare nozzle location since boric acid has limited volatility.

3.3 Rates for Low Temperature Conditions During any unscheduled outage, the material may be exposed to low temperature aerated borated water. Reference (1) presented data for tests at 70, 100 and 140 F in aerated water with 2500 ppm B. For th1s analysis, 1

ioo*F was assumed to be of coolant temperatures during cold shutdown. The tests continued for 121 days with several 1nterim, weight loss determinations which showed that steady state rates had been obtained.

For the Reference (1) tests, the average corrosion rate for lOO'F was 7.0 mpy with an upper bound of the data indicating a worst case corrosion rate of 7.9 mpy.

The non-clad pressurizer or material will. be coupled .to the stainless stee-1 c1ad or Alloy 600 nozzles in the pressurizer. The use of dissimilar metals will causa some concern about galvanic effects. In the Reference (1) tests, th1 A302B specimens were both insulated from and connected to Type 304 stainless steel, which chemically 1s similar to the stainless steel used for cladding of the primary system. No difference in corrosion rates for the two types of specimens were observed and thus galvanic corrosion should not be a problett. I

/

The limited corrosion that will occur will not be a local 1zed form of

-4*

EA-SC-93-087-01 Attachment 4 Page 6 of 6 corrosion (deep pitting, stress corrosion cracking, etc.). C-E experience in aerated borated water indicates that the corrosion morphology will consist of the superposition of shallow pits with no d~ep penetrations:

Reference ( 1) a1 so indicated that corrosion would be uniform with no localized forms of corrosion being observed.

3.5 Overall Corrosion Rates Based on a split of 80 percent hot ope rat i ans and 20 percent cold shutdown, corrosion rates for the pressurizer material at Palisades were determined as follows using the rates described above:

"Worst case" corrosion rate - 1.0 mpy x 0.8 +

7.9 mpy yr. x 0.2 ~ 2.4 mils/year 3.6 Additional Cons1derat1ons The corrosion rate cited above is most applicable to situations where the material is exposed to water environments. In areas of steam, the cited rate will be conservative because of reduced boric acid levels.

4.~ REC°"'ENDATION Fe nilysis purposes, ABB-CE rec0111ends a corrosion rate of 3 mils/year for the Palisades pressur9 boundary 111at1rial.

S.O REFERENCE

1. *Absorption of Corrosion Hydrogen by A302B Steel at 70'F to soo*F," WCAP-7099, Dtcellber 1, 1967.

I

EA-SC-93-087-01 ATTACHMENT 5 Traveler 2003067-001

EA-SC-93-087-01 Attachment 5 Page 1 of 18 Proc No 10.41 Attachment 4 PROCEl)URE TBAYELER Rev; s ion 17 Page l of 2 f\g.g/Cc*"'1B;iS fic.....a £E,.l~ *.,ee:;:.1M: f\J..,~L.E.+I!- Si=tzv ,,e;s TF.Avt!~ No. Z.co ~r.,,,7-c;,.-,,

rocedure Tit 1e *Ne'-P ~PA1fZ. //".,:::<<F*ce..,..,cN Oc .Pe.Es~,J~1~E~ tJrc:2.L...E.(s.)

Procedure No ~CC3t:.&7-co / Revision No .2.. Date I n i t i at ed / c /; t; I Ci 3 Return to Initiator By 10/~/q.~

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rPrint N*t"ne & .n1t1*ll Urgent ReV1110n (hud I r\*r I H ...... "'

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EA-SC-93-087-01 P~ISADES NUCLEAR PLANT Attachment s Proc No 3.07 SAFETY REVIEW Page 2 of 18 Attachment l Revision 7 Page l of 1 93-1~~~

PS&L Log No I Item Identification: No 2003067-001 Rev _2_ Title ABB/CE NUCLEAR SERVICES SE Rev

.,RAVELER: WELD REPAIR/MODIFICATION OF PRESSURIZER NOZZLEISI Describe Issue/Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING Reason for Issue/Change: PROCEDURE REDUIREMENT BY ADMINISTRATIVE PROC. 10.41 Yes

1. Does the item involve a change to procedures as described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5. 6, 5. 8, 5.10 1 6.9, 7.4, 9.1, TABLE 4-21. TABLE 4-22

)(

2. Does the item involve a change to the facility as described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4. 4*, 5.1, 5.6, 5.8, 5.10 1 6.9, 7.4,

9. l , TABLE 4-21. TABLE 4-22 x

3. Does the item involve a test or experiment not described in the If lX FSAR?

FSAR Section* affected NONlj FSAR Sections reviewed 4.3, i.4, 5.1, 5.6, 5.8, 5.10, 6.9, 7.4,

9. l , TABLE 4-21, TABLE 4-22

4. Should the Technical Specifications or any of their Bases be v changed in conjunction with this item?

TS Sections affected NONI TS Sections reviewed 3.0. 4.0 Justify No Answer* below if logic is not obvious:

x Although welding, po*t weld NOB te*ting and heat treating are discussed in the FSAR, the same proc***** that are di*cu*sed will be followed for this Vendor support.

Thia traveler and th* Pali*ad** Work Order will control the work performed on the Pressurizer (T-72) temperature element nozzles and thermowell(s).

Rav. 2 changed drawing number and weld procedure revision* and added editorial clarification to **veral *tep*.

If any*safety Review que*tion listed above i* answered "YES", perform a written USQ Evaluation according to Section 5.3.

If all Safety Review qu**tion* li*t*d above are anmwered NO, written USQ Evaluation i* not required. However, thi* Attachment *hall accompany other review materials for th* item to document that a Safety Evaluation wa* not required.

Appr'"<<l by ~l-tCt\\ \..0 r4\c, J* ~\£~ 1o/1q/C,J

&w.rr~ 10/1q I/q_3

~

~a. 11ofzofcr~ i.1,,.1-Prepared By Date eviewed By Date

EA-SC-93-087-01 Attachment 5 Page 3 of 18 Procedure No. 2003067-001 Revision No. 2 Issued Date 10/19/93 PALISADES NUCLEAR PLANT MAINTENANCE PROCEDURE TITLE:

ABB-COMBUSTION ENGINEERING NUCLEAR SERVICES TRAVELER NO. 2003067-001 WELD REPAIR/MODIFICATION OF PRESSURIZER NOZZLE(S)

Date 93 Datr ' Rev #

EA-SC-93-087-01 Attachment 5 ABB-COMBUSTION ENGINEERING PAGE ~ago~ ~~ 18 NUCLEAR SERVICES REVISION 2 TRAVELER NO. 2003067-001 DATE 10/19/93

WELD REPAIR/MODIFICATION OF PRESSURIZER NOZZLE(S)

UTILITY: CONSUMERS POWER COMPANY SITE: PALISADES NOZZLE NO.: PRESSURIZER NOZZLE REPAIR 1.0 TABLE OF CONTENTS AND LIST OF EFFECTIVE PAGES:

CONTENTS PAGE NO. REV.

COVER PAGE 1 0 REFERENCES 2-3 0 PREREQUISITES 4 0 PERFORMANCE 5-11 0 DATA SHEET 5.1 12-15 0 APPROVED BY: 7,;f__

~~ /0 .. /'1-9,f DATE a.Jw. ~ 10/J,,fo OWNER REPRESENTtiVE DATE

~ /o-~o-'l3 AUTHORIZED INSPECTION AGENCY DATE

EA-'SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE :ft~hlf~t s NUCLEAR SERVICES REVISION 2 Page 5 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93

2.0 REFERENCES

NOTE: The applicable rev1s1on for each procedure, drawing, etc.

shall be released by SNSCE to the Task and Quality Assurance Managers.

2.1 DRAWINGS

2.la ABB/Combustion Engineering Dwg. No. D-9417-C093-019, Rev. 02.

2.lb ABB/Combustion Engineering Dwg. No. D-9417-C093-021, Rev. 01.

2.2 ABB/Combustion Engineering Nuclear Services Quality Assurance Manual, QAM-100, Fourth Edition, Rev. 1.

2.3 Instruction Manual: Pressurizer; Consumers Power Company -

Palisades Plant.

2.4 ASME Code Section XI, 1983 Edition, Summer 1983 Addenda.

2.5 ASME Code Section II and III, 1986 Edition with no Addenda.

(Materials) 2.6 ABB/CE Procedure No. DW'PS SMA-3.43-937, Rev. 1.

2.7 ABB/CE Procedure No. O.P.-9.2, Rev. 7.

2.8 ABB/CE Procedure No. WPS SMA-43.43-909, Rev. 2.

2.9 ABB/CE Procedure No. STD-100-089, Rev. 7.

2.10 ABB/CE Procedure No. O.P.-9.4, Rev. 12.

2.11 ABB/CE Procedure No. PAL-410-005, Rev. 0.

2.12 ABB/CE Procedure No. DWPS GTA-8.8-910, Rev. 10.

2.13 ABB/CE Procedure No. KSM-1.X-900, Rev. 0.

2.14 ABB/CE Procedure No. WS-TC-900, Rev. 1.

2.15 ABB/CE procedure No. O.P.- 9.8, Rev. 8

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE' :f~~~nt 5 NUCLEAR SERVICES REVISION 2 Page 6 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93

2.16 Designated sign-offs/abbreviations in this traveler shall be in accordance with the following legend.

S -

Q -

0 -

Supervisor,IW'orker Quality Operations Owner/Client A - Authorized Nuclear Inspector W- Witness I - Inspect H - Hold MPE - Magnetic Particle Examination UT - Ultrasonic Test WIR - Weld Inspection Record LPE - Liquid Penetrant Examination UTE - Ultrasonic Test Examination ROI - Report of Inspection

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 4A~~~nt 5 NUCLEAR SERVICES REVISION 2 Page 7 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93 3.0 PREREQUISITES 3.1 All required personnel have received training in Health Physics, Quality Control, Radiation Control, and Al.ARA procedures and have been trained in the work tasks to be performed.

3.2 Prewelding ECT has been completed and the location of the nozzle to be repaired has been identified by Consumers Power Company in writing.

3.3 Special tooling is on hand in sufficient quantity for the intended program.

3.4 Scaffolding at the pressurizer where work is to.be performed has been erected, if required.

3.5 Insulation has been removed.

3.6 Cover nozzle opening, to preclude debris from entering RCS.

3.7 Provide a system of tool and material accountability for all items entering the primary system, if applicable.

3.8 Assure that the pressurizer water level is below the nozzle

3.9 elevation prior to performing any task.

Locate and record all information from the nozzle such as code numbers, heat numbers, and nozzle location. Report this information to SNSCE for evaluation. Obtain Consumers Power approval/concurrence for the nozzle to be welded prior to proceeding.

3.10 All covered electrodes shall be baked before use at a temperature of 550+/- 50° F for two hours. The temperature of the oven shall not exceed 300° F, when the electrodes are placed in the oven. After baking and before the electrodes are allowed to cool below 225°they shall be tranferred to a holding or drying oven operating at a temperature between 225°F and 350°F.

During the repair, the electrodes may be maintained in heated ovens in the repair area. The oven temperature shall be maintained between 225°F and 350°F. Electrodes exposed to the atmosphere for more than 20 minutes min shall be dried at a temperature between 225°F and 350°F for at least 8 hrs before reissued for use. Electrodes exposed to the atmosphere for more than 4 hrs shall be rebaked at 550°F+/-50°F for 2 hrs.

Electrodes shall not be rebaked more than once.

3.11 Yelding materials shall be controlled during repair per ref.

2.15 so that they are identified as acceptable material until consumed .

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE SAU~c~nt S Page 8 of 18 NUCLEAR SERVICES REVISION 2 TRAVELER NO. 2003067-001 DATE 10/19/93 STP NO.

4.0 PERFORMANCE NOTE: The following steps shall be performed in the sequence listed. Nozzles may be worked in parallel.

4.1 Verify satisfactory completion of prerequisites. s H ____

REMARKS: Q H ____

0 A

4.2 Layout and prepare for NOE the area required for s H the weld buildup and 5" min. radius around the Q H-__-- _-

buildup.

0 NOTE: Pay special attention to the annulus between A the nozzle and vessel shell.

REMARKS:

Perform magnetic particle test of base metal pad s 4.3 buildup area and 5" minimum radius Q l _ _ __

around pad area per OP-9.2, (yoke) 0 The following indications are unacceptable: A

a. Any cracks or linear indications. MPE b; Rounded indications with dimensions greater than 3/16 inch.

c. Four (4) or more rounded indications in a line separated by 1/16 inch or less, edge to *edge.

REMARKS:

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE ~15f'2~nt 5 NUCLEAR SERVICES REVISION 2 Page 9 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93 4.4 Perform ultrasonic test of base metal pad buildup s area per PAL-410-005, and 5" radius - ; Ji! Q l ____

Acceptance criteria: 4.

I\\ tt'\ IW\1AW\

~,,&11'1?

1CI 0

(1) Any area, where- one or more discontinuities A produce a continuous total loss of back reflec- UTE- - - - -

tion accompanied by continuous indications on the same plane that cannot be encompassed with a circle whose diameter is 3 inches or 1/2 of the plate thickness, whichever is greater, is unacceptable.

(2) In addition, two or more defects smaller than described in (1) shall be unacceptable unless separated by a minimum distance equal to the greatest diameter of the larger defect or unless they may be collectively encompassed by the circle described in (1).

REMARKS:

4.5 Clean all areas where UT and MT testing was per- s E _ _ __

formed using approved cleaning solution. Q NOTE: Pay special attention to the annulus 0 between the nozzle and the vessel shell.

A REMARKS:

4.6 Set up preheat equipment on pressurizer per s E _ _ __

STD-100-089 and KSM-l.X-900 and WS-TC-900. Q Thermocouples shall be located between 0 5"to 10" from the edge of the weld pad A build-up.

REMARKS:

4.7 Preheat pad buildup area and 5" radius s E _ _ __

per WPS-SMA-3.43-937. Hold preheat at 350 F min. Q E _ _ __

450°F max. for a minimum of 30 minutes prior to 0 start of welding. A REMARKS:

Attachment 5 ABB-COMBUSTION ENGINEERING PAGE 7 OF 1 sPage 10 of 18 NUCLEAR SERVICES REVISION 2 TRAVELER NO. 2003067-001 DATE 10/19/93 CAUTION: .THE 350°F PREHEAT MINIMUM MUST BE MAINTAINED

4.8 CONTINOUSLY THROUGHOUT THE WELDING OPERATION AND UNTIL INITIATION OF THE POST WELD HEAT TREATMENT OF STEP 4.12.

Deposit first layer of pad buildup per WPS-SMA-3.43-937 using 3/32" dia electrode. Q s H ____

l ____

Verify interpass temperature. 0 Heat Input per SMA-3.43-937 (Bead length/unit length A of electrode) Shall be verified no less than once WIR per welder. ------ IG REMARKS:

4.9 Grind first layer to remove approximately 1/2 of s H ____

the deposited weld material. Q I _ _ __

Verify interpass temperature. 0 REMARKS: A 4.10 Deposit second layer per WPS-SMA-3.43-937, s H using 1/8" dia. electrode. Q 1 Heat Input per SMA-3.43-937 (Bead length/unit length 0 of electrode) Shall be verified no less than once A

/e

4.11 per welder. Verify interpass temperature.

REMARKS: .

~

Deposit the third layer and subsequent layers WIR s w using 1/8" dia. electrodes. Each of these weld Q I deposit layers (third and subsequent layers) shall 0 e

fuse to the nozzle at the weld/nozzle interface.

Deposit sufficient number of layers to meet the requirments of ref. 2. la or 2. lb. Vt.,i-ft 1.Jtrp4cs

~~<~1e, A

WIR I ~l

,01 1*

4.12 Perform postweld heat treat of pad buildup and 5" s :!!

radius area around the pad per WPS-SMA-3.43-937 and Q :!!

STD-100-089. 0 Hold temperature at 500° +/- 50°F for a minimum of four (4) hours.

R.EKARics:

A le

...._.., '. . -* _; '-' - . .: -* - ._, 0 I -lJ 1 ABB-COMBUSTION ENGINEERING PAGE gttef31IllfSt 5 NUCLEAR SERVICES REVISION 2 Page 11 of u TRAVELER NO. 2003067-001 DATE 10/19/93 4.13 Drop temperature and allow to cool to ambient s temperture. Q Record date and time buildup reaches ambient 0 temperture. A Ambient temperture is defined as follows:

"That temperature the material reaches during cooldown when the recorded temperature does not change by a ten (10) degree F increment during a period of two (2) hours".

REMARKS:

NOTE: Final nondestructive testing is not to be performed until after pad buildup areas have remained at ambient for a minimum of 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months .

4.14 Remove preheat equipment and thermocouples. s H ____

Prepare surface of the weld buildup and all Q I _ _ __

attachment areas for non-destructive testing. 0 Weld buildup to be ground per ref.2.la or 2.lb. A Mark areas where temporary attachments are removed with approved marker. ROI REMARKS:

4. 15 PT pad buildup per 0. P. - 9. 4. S W _ _ __

The following indications are unacceptable: Q 1 ____

a. Any cracks or linear indications. 0

b. Rounded indications with dimensions greater A ~H____

than 3/16 inch. LPE

c. ~~ur (4) or more rounded indications in a

~e separated by 1/16 inch or less, edge

. edge.

~RF.MARKS: A-!:I.H~Ll\~Hf :=*u:~Eaio.J lffe Yi-<j 3 Tu MAJG ~g- Jro~T....:ri) a2~~~r &a;z. ~~ ...

~ E 62NV""-T CAf:4b(aT Rx; MADS <r'a<.+ MA 'z' p12.D4<=u W1IU f\Cci~i1"1'C.S. .

NOTE: Should unacceptable indications be encountered, proceed with the following repair cycle.

4.16 Grind to remove indications. Notify CPCo s H _ _ __

Engineering prior to grinding. Maximum grindin~ Q H ____

depth allowed is only to within 3/16" of the 0 original base material. A REMARKS:

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE gA~ftC~nt 5 NUCLEAR SERVICES R':VISION 2 Page 12 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93

4.17 P.T. grindouts per O.P.-9.4.

The following indications are unacceptable:

a. Any cracks or linear indications.

b. Rounded indications with dimensions greater than 3/16 inch.

c. Four (4) or more rounded indications in a s

Q 0

A LPE w

l ----

line separated by 1/16 inch or less, edge to edge.

REMARKS:

4.18 Weld repair grindout per WPS-SMA-43.43-909. s H REMARKS: Q l 0

A WIR 4.19 P.T. final surface per,O.P.-9.4. s w The following indications are unacceptable: Q l

a. Any cracks or linear indications. 0

b. Rounded indications with dimensions greater A than 3/16 inch. LPE

c. Four (4) or more rounded indications in a line separated by 1/16 inch or less, edge to edge.

REMARKS:

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 1~teJli1m,ist 5 NUCLEAR SERVICES REVISION 2 Page 13 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93 4.20 Ultrasonic test pad buildup,and 5" minimum radius per PAL-410-005. S The following acceptance criteria shall apply: Q l ____

All indications which produce a response greater 0 than 20% of the reference level shall be investi- A gated to the extent that the operator can determine UTE the shape, identity, and location of all such reflectors and evaluate them in terms of the acceptance standards given in (a) and (b) below.

(a) Discontinuities are unacceptable if the amplitude exceeds the reference level, and discontinuities have lengths which exceed:

(1) 1/4 in. for t up to 3/4 in., inclusive (2) 1/3 t. fort from 3/4 in. to 2-1/4 in., inclusive (3) 3/4 in. for t over 2-1/4 in.

where t is the thickness of the weld being examined; if a weld joins two members having different thicknesses at the weld, t is the thinner of these two thichnesses.

(b) Where discontinuities are interpreted to be cracks, lack of fusion, or incomplete penetration, they are unacceptable, regardless of discontinuity or signal

4.21 amplitude.

M.T. 5" radius and attachment areas per OP 9.2.

The following indications are unacceptable:

a. Any cracks or linear indications.

S Q

0 A

W'

b. Rounded indications with dimensions greater MPE than 3/16 inch.

c. Four (4) or more rounded indications in a line separated by 1/16 inch or less, edge to edge.

REMARKS:

NOTE: If the nozzle(s) is required to be severed continue on Nuclear Services Traveler 2003067-002.

4.22 Install thermowell and weld per WPS-GTA-8.8-910 s w and Ref. 2.1, (a) or (b). P.T. root pass per Q l _ _ __

4.23. 0 REMARKS: A W'IR;__ __

t:A-.::iC-9 _)-ucf/:._v i ABB-COMBUSTION ENGINEERING PAGE 1itt~m~Ii;f: s NUCLEAR SERVICES REVISION 2 Page 14 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93 4.23 P.T. root and final weld per O.P.-9.4. s w_____

The following indications are unacceptable: Q l ____

0

a. Any cracks or linear indications. A

b. Rounded indications with dimensions greater LPE - - - - -

than 1/16 inch.

REMARKS:

4.24 Remove all tools and equipment from the pressurizer. S H ~---

QC. inspect for final housekeeping and removal of Q H ~---

all equipment. Return to as-found condition. 0 REMARKS: A 4.25 QC complete Final Inspection Checklist in S accordance with Reference 2.2. Q l ____

REMARKS: 0 A

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 1~ t(?Jfhm,~ 5 NUCLEAR SERVICES REVISION 2 Page 15 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93 DATA SHEET 5.1 - PRESSURIZER TOP HEAD NOZZLE 4.1 s i 4.9 s R Q R Q I 0 0 A A 4.2 s R 4.10 s R Q R Q l 0 0 A A TNIR 4.3 s - 4.11 s R Q l Q I 0 0 A A MPE

- TNIR 4.4 s - 4.12 s li Q l Q li 0 0 A A UTE 4.5 s li 4.13 c li Q Q y 0 0 A A 4.6 s R 4.14 s y Q Q 0 0 A A 4.7 s i 4.15 s li Q i- Q I 0 0 A A LPE 4.8 s i 4.16 s y Q I Q y 0 0 A A YIR

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 1'3:tEJFim'~ 5 NUCLEAR SERVICES REVISION 2 Page 1o of 18 TRAVELER NO. 2003067-001 DATE 10/19/93 4.17 s ~ 4.24 s . w Q l Q w _ __

0 0 A A LPE _ __

4.18 s w 4.25 s Q l QI _ __

0 0 A A WIR 4.19 s w Q l 0

A LPE 4.20 s -

Q l 0

A UTE 4.21 s i Q l 0

A MPE 4.22 s w Q l 0

A -

WIR.

4.23 s i Q i 0

A LPE- _ _ __

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 14t t0fhmt5t 5 NUCLEAR SERVICES REVISION 2 Page 17 of 18 TRAVELER NO. 2003067-001 Dt1TE 10/19/93 DATA SHEET 5.1 - PRESSURIZER VESSEL SIDE NOZZLE

4.1 s H:

Q 0

A E

4.9 s H Q

0 A

I 4.2 s H 4.10 s H Q H Q l 0 0 A A WIR 4.3 s - 4.11 s H Q l Q I 0 0 A A -

MPE WIR 4.4 s - 4.12 s H:

Q l Q H:

0 0 A - A UTE 4.5 s H: 4.13 s H:

Q Q w 0 0 A A 4.6 s H: 4.14 s w Q Q 0 0 A A 4.7 s i 4.15 s H:

Q i Q I 0 0 A

A LPE 4.8 s H: 4.16 s w Q l Q w 0 0 A A WIR

........"1.-.)\..1-:,:...1-...,*..:;;, - v '-

Attachment 5 ABB-COMBUSTION ENGINEERING PAGE 15 OF 1 &>age 18 of 18 NUCLEAR SERVICES REVISION 2 TRAVELER NO. 2003067-001 DATE 10/19/93

4.17 s i Q I A

0 LPE

4. 24 s w Q

0 A

w _ __

4.18 s w 4.25 s Q l -

Q I----

0 0 A - A WIR 4.19 s w Q l 0

A LPE 4.20 s -

Q l 0

A UTE._ __

4.21 s li Q l 0

A MPE 4.22 s w Q l 0

A -

WIR 4.23 s i Q i 0

A -

LPE _ _ __

EA-SC-93-087-01 ATTACHMENT 6 lnconel 600 PWSCC

Status Report

I

EA-SC-93-087-01 Attachment 6 Page 1 of 31

To:

From:

Date:

KVCedarquist PDFitton ?J'JJ~.:)}:;;.

May 22, 1991

Subject:

PALISADES PLANT INCONEL 600 PRIMARY WATER STRESS CORROSION CRACKING STATUS REPORT cc KEOsborne, Palisades MGKlyver, Palisades JRSchepers, Palisades DJMalone, Palisades RPMargol, Palisades BVVanWagner, Palisades

. *BM £ll.~ll!ha Please find attached a status report of the work that has been completed to date on Pr'imary Water Stress Corrosion Cracking .of Inconel 600. This is not intended to be a final report; additions or deletions may be appropriate as additional information becomes available. I have attempted to capture what I know on the subject of PWSCC of inconel 600 in this document.

Please review the attached status report. I will provide the status of the recommendation section at your convenience. I will remain available to support your efforts in this area as you see fit. I suggest we both attend the next Inconel 600 Working Group meeting in late August at CE in Windsor. I will leave that to your judgement and management approval

EA-SC-93-087-01 Attachment 6 Page 2 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL

1.0 EXEC!JTIVE

SUMMARY

The Nuclear Power Industry has begun to see a significant number of occurrences of Primary Water Stress Corrosion Cracking (PWSCC) of Inconel 600 in NSSS penetration applications. Palisades has 241 Inconel 600 Primary Coolant System penetrations. The new steam generator tubing is Inconel 600. The development of PWSCC in a Primary system boundary can significantly impact plant availability and be expensive to repair. Calvert Cliffs required over one year to repair the first pressurizer heater sleeve cracks.

The recommended actions have been developed to meet the following objectives:

1. Avoid mid-cycle shutdowns via an inspection/replacement program.

2. Minimize cost by accepting a reasonable measure of risk.

3. Appropriately address regulatory concerns.

4. Ensure nuclear and personnel safety.

Alternatives range from doing nothing to replacing all Inconel 600 PCS boundary material. A summary of the recommendations is as follows:

1. Perform additional visual inspections of pressurizer penetrations each refueling outage.

2. Develop contingency plans to repair leaking pressurizer penetrations.

3. Continue to participate in industry initiatives to understand and mitigate PWSCC in PCS penetrations.

4. Replace high risk Inconel 600 material in the pressurizer.

These recommendations seek to balance risk with cost.

PWSCC of Inconel 600 will be a life extension issue.

PWSCC is dependent on a susceptible material, temperature, stress, and time. The relationship between these factors is not very well defined. As plant life increases within the nuclear industry, we may begin to see PWSCC at some lower temperature PCS locations. If that occurs, additional measures will be appropriate.

A single PWSCC initiated PCS pressure boundary leak will take at least 2 to 4 weeks to repair. This excludes additional time that may be required to perform additional inspections, address licensing/regulatory concerns, and find replacement material. The two pressurizer RTO's may be particularly difficult to repair quickly. In general, Palisades nozzle design is.easier to repair than newer plants, and the particular lots of inconel 600 used at Palisades have Page 1 Revision c

EA-SC-93-087-01 Attachment 6 Page 3 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL

relatively favorable material properties. Operating time is a factor, so this will *become more of a concern as the plant ages. Combustion Engineering has qualified equipment and procedures available for most repairs.

2.0 INTRODUCTION

A special CEOG Working Group was formed in November of 1989 to address Primary Water Stress Corrosion Cracking (PWSCC) of Inconel 600. This Working Group agreed to the following objectives:

1. Identify the susceptibility of Inconel 600 penetrations to PWSCC.

a. Understand what contributed to Calvert Cliffs-2, SONGS-3, and st. Lucie failures.

b. Assess the susceptibility of installed components.

2. Address NRC concerns.

3. Investigate options to mitigate PWSCC in Primary system pressure boundary components.

In January of 1991 the Inconel 600 Working Group agreed to investigate PWSCC concerns related to steam generator tubing.

This was due to the discovery of PWSCC in the Maine Yankee

steam generator tubing in December of 1990. The scope of this effort is undefined.

As a participant, Consumers Power also had the following objectives:

1. Share expertise, cost, and resources in dealing with PWSCC of Inconel 600. PWSCC could have a large impact on plant availability.

2. Assess the susceptibility of Palisades to PWSCC in Inconel 600 PCS penetrations.

3. Develop plans to mitigate PWSCC concerns (if necessary).

The Inconel 600 Working Group developed a series of tasks aimed at accomplishing the objectives. A summary of each task is provided in Attachment 2. The tasks are listed below:

1. Determine root cause of pressurizer heater sleeve PWSCC.

A. CEOG Task 633 Pressurizer Nozzle Evaluation B. CEOG Task 636 Pressurizer Heater Sleeve Evaluations

c. CEOG Task 639 Pressurizer Heater Sleeve Thermal Analysis

2. Determine material properties of nozzles and sleeves installed in plants.

A. CEOG Task 631 Pressurizer Heater Sleeve Information Package B. CEOG Task 634 Inconel 600 Penetrations Information Package

Page 2 Revision c

Attachment 6 Page 4 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL

3. support position that PWSCC is not a safety related concern.

A. CEOG Task 637 Pressurizer Shell Corrosion Testing

4. Provide inspection method.

A. CEOG Task 635 Qualification of Eddy current Examination Techniques system Engineering performed a visual external inspection of the pressurizer heater sleeves during the 89Maout, 90Maout, and 90Refout. No evidence of leaking pressurizer heater sleeves was found.

3.0 GENERAL DISCUSSION Primary Water Stress Corrosion Cracking (PWSCC) of Inconel 600 products has become a nuclear power industry concern.

Palisades has 241 Primary Coolant System penetrations that have Inconel 600 sleeves or. nozzles. The widespread use of Inconel 600 in Primary System penetrations makes PWSCC a significant reliability and regulatory concern.

The following identifies failures that have been identified to date.

1. Calvert Cliffs Unit 2 experienced through wall cracking attributable to PWSCC in 20 out of 120 pressurizer heater sleeves.

2. SONGS Unit 3 experienced PWSCC in 4 pressurizer instrument nozzles. The nozzle material had a very high yield strength. The failure was attributed to a particular*

material heat number.

J. St. Lucie inspected one nozzle of the same heat number supplied to SONGS-3. It was cracked. They replaced all 6 nozzles of similar heat number.

4. Calvert Cliffs Unit 2 inspected pressurizer heater nozzles. They found 1 leaking and cracked. The original material was of low yield strength but had been reworked twice.

5. The Navy has experienced PWSCC failures of forged Inconel 600 at temperatures lower than CE pressurizer temperatures. Navy nozzles are rolled into place and welded.

6. Edf (French) has experienced PWSCC of forqed Inconel 600, includinq circumferential indications. Edf nozzles are rolled and welded.

7. Westinghouse has experienced PWSCC of forged Inconel 600 steam generator tube plugs.

s. Westinghouse has experienced PWSCC of Inconel 600 steam generator tubes.

Page 3 Revision c

Page 5 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL

9. Maine Yankee has experienced PWSCC of Inconel 600 steam generator tubing.

10.Arkansas Nuclear. Unit l (B&W Plant) experienced a cracked pressurizer nozzle in December of 1990.

Repairs of cracked Primary System boundary material are expensive, dose intensive, and time consuming. Primary Water Stress Corrosion Cracking (PWSCC) involves intergranular stress corrosion cracking of alloy steels in a primary water environment. Three things are needed to develop PWSCC. They are:

1. Residual or operating stress. In the ID of these nozzles and tubes the stress must be a tensile stress. Current thinking is about 40 ksi of tensile stress is required to initiate PWSCC in Inconel 600.

2. Temperature. PWSCC is highly temperature dependent. CE believes (based on literature) the corrosion rate doubles for every temperature increase of lOC (18F). This is why the pressurizer is most vulnerable.

2. The material must be susceptible to PWSCC. Desirable characteristics of Inconel 600 tubing products (sleeves and steam generator tubing) are well researched. Much less is known about hot forged Inconel 600 (nozzles) .

High material yield strength is undesirable *

PWSCC continues to pose a large economic risk to the Palisades Plant. This risk is shared by all operating nuclear plants with Inconel 600 penetrations. We should not be surprised by the failure of any single Inconel 600 penetration. The probability of developing a PWSCC initiated PCS leak is increased by

l. High service temperatures

2. High residual stresses developed during installation

3. High material yield strength

4. Service time PWSCC will not occur in inconel 600 without residual stress.

CE has estimated the minimum stress to initiate a PWSCC crack at 40 ksi. Higher residual stress levels will shorten the time to initiate a crack. Higher service temperatures and high material yield strength will shorten the time to initiate a PWSCC crack. It is unclear exactly what the minimum temperature is below which no cracks will occur. CE estimates that material with a yield strength greater than so ksi is unfavorable; ie more likely to crack. This general guidance helps provide the basis for identifying penetrations with the highest susceptibility to PWSCC. This does not mean PWSCC will never occur in relatively low probability Page 4

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Attachment 6 Page 6 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL locations. The probability is lower, but not zero .

Temperature is a key factor in the development of PWSCC. The rate of PWSCC will double for every 18F increase in temperature. It is therefore reasonable to expect most of the initial problems to occur in the pressurizer. The installation processes used throughout the PCS are relatively similar; as such the residual stresses should be similar. The relationship between temperature and PWSCC rates is very helpful in developing an assessment of areas most at risk. It is clear that most initial failures will occur in pressurizer penetrations. As such, it is reasonable to focus most inspection efforts in this area. It is important to note that ongoing inspection programs at other commercial nuclear power plants provide a much larger data base to make conclusions from, and to continuously evaluate previous assumptions. It will be worthwhile to use this information to periodically re-evaluate Palisades respo~se to this issue.

One of the key points in determining that the PWSCC of Inconel 600 penetrations is not a safety issue is the axial orientation of the cracks. Circumferential cracking can cause a catastrophic failure of the pressure boundary, potentially ejecting a nozzle or sleeve. The residual stresses that are present in the heat affected zone of the welds result in a hoop stress that may cause axial cracking, not circumferential cracking.

Some work done under CEOG Task. 636 directly supports this conclusion. The residual stresses created near the heat affected zone are directly dependent on the inconel 600 material properties. Pre-reaming results in hi9h hardness/high yield strength at the ID of the sleeve/nozzle.

Welding then creates residual stresses that are limited by the material properties at the surface. The residual stresses govern material susceptibility. High strength non-reamed material is of slightly less concern, but residual stress is still governed by material properties. Low strength material is also under tensile stress due to welding, but susceptibility is lower because residual stresses cannot exceed the yield stren9th of the material.

Additional work determined most of the sleeve/nozzle area is actually under compressive stress. Tensile stress is required to develop PWSCC. Lower stress levels are required to propagate a crack than to initiate one, so developing a high enough tensile stress on the ID of the sleeve/nozzle is critical in initiating a crack. Post weld machining was Page 5 Revision C

Attachment 6 Page 7 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL actually beneficial in removing a layer of the material under the highest tensile stress.

It is also worth noting that pressurizer heater sleeve failures have occurred due to the failure of pressurizer heaters. Both Arkansas Nuclear Unit 2 and San Onofre have experienced heater sleeve failures caused by the swelling of a failed pressurizer heater. The failed heater can be extremely difficult to remove. As time goes on the heater swells and places enough pressure on the heater sleeve to cause cracking. The prompt replacement of a failed pressurizer heater can prevent this problem.

4.0 SUSCEPTIBILITY Q.[ PALISADES PRESSURIZER HEATER SLEEVES TO PWSCC Pressurizer heater sleeves are fabricated from a tubular cold worked form of Inconel 600. The susceptibility of cold worked Inconel 600 is reasonably well known. Significant research has been done due to the widespread use of cold worked Inconel 600 in Steam Generator tubing. Combustion Engineering completed CEN-393-1 titled "Evaluation of Pressurizer Heater Sleeve Susceptibility to Primary Water Stress Corrosion Cracking". This was done as CEOG Task 631, and completed in November of 1989. Additional work was completed in CEOG Task 636, "Pressurizer Heater Sleeve Evaluations".

Palisades pressurizer heater sleeves were categorized in the low susceptibility range for PWSCC. This determination was made based on the low yield strength of the material, absence of pre-installation reaming of the sleeve, and the absence of rework on the heater sleeves. Plants having inconel 600 with a yield strength above 50 ksi, or those having pre-installation reaming done were categorized as moderate risk units. Plants having both a hiqh yield strength material and pre-installation reaming have been categorized as high susceptibility. The susceptibility ratings are relative measures of probability, not absolute measures that PWSCC will or will not occur. Two units were identified as high susceptibility, six units as moderate susceptibility, and seven units as low susceptibility. Calvert Cliffs Unit 2 was a high suaceptibility plant.

The development of PWSCC in the steam generator tubing at Maine Yankee is a cause for concern

Steam generator tubing sees lower service temperatures than those experienced in the pressurizer. The steam generator tubing installed in the Maine Yankee plant has favorable properties: ie it is not Page 6

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Attachment 6 Page 8 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL highly susceptible to PWSCC. Steam generator tubing is explosively expanded into place, which may introduce high residual stresses at the tube sheet. This is where the Maine Yankee tubes cracked.

The plants with unfavorable pressurizer heater sleeve material should provide a valid indication of concern prior to pressurizer heater sleeves cracking at Palisades. Due to the statistical nature of PWSCC, and the minor differences that may occur in installing individual sleeves, we should not be surprised if a few failures occur in lower susceptibility tubing. As such, we should be prepared to respond to a small number of pressurizer heater sleeve failures.

5.0 SUSCEPTIBILITY Ql PRIMARY SYSTEM INCONEL §.QQ. NOZZLES TO PWSCC All Palisades Primary coolant System nozzles contain some Inconel 600. All Inconel 600 forged products have some susceptibility to PWSCC. The relationship between material yield strength and PWSCC that helps classify cold worked Inconel 600, does not work very well for hot forged products (nozzles). Evaluations of grain boundary and carbide location have also been unsuccessful in quantifying the susceptibility of hot forged Inconel 600.

The relationship between PWSCC and temperature helps reduce the area of highest concern. All Inconel 600 nozzles that have developed PWSCC to date are in the pressurizer. This is what we would expect based on system operating temperature.

The temperature runs about SOF hotter than the rest of the PCS. This would increase the corrosion rate by a factor of eight compared to the rest of the PCS. This is also supported by the fact that PCS nozzle cracking has not been identified during the 10 year ISI inspections that are required by Section XI. If widespread PWSCC was occurring at lower temperatures, it would have been detected by the ASME Section XI program, or a boric acid walkdown at some of the many nuclear plants that are in service. section XI inspection criteria apply to all plants, presenting a large data base of information.

It remains clear that three conditions are necessary to develop PWSCC in any Inconel 600 product. They are:

1. Susceptible material

2. Temperature

3. Residual or operating stresses that produce a high tensile Page 7

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Page 9 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL stress in the material Combustion Engineering has unsuccessfully tried to identify nozzle characteristics related to PWSCC susceptibility. This was done under CEOG. Task 633. CE evaluated the BG&E nozzle.

No evidence of chemical contamination was found. This supports the cracking being PWSCC. Hot worked Inconel 600 produces more variations in yield strength, grain size, and carbide precipitation. This makes evaluating characteristics that promote PWSCC much more difficult. Previous work done on steam generator tubing does not accurately predict the susceptibility of hot forged nozzles.

The BG&E nozzle cracks were-initiated on the internal diameter (ID). The crack growth rate was very slow. This indicates a high tensile stress existed on the nozzle ID, and was initially relieved by cracking. crack growth slowed because operating stresses are much lower than presumed residual stresses. Higher stress is necessary to initiate crack growth than to propagate growth.

Calvert Cliffs Unit 2 found the leaking nozzle during an external inspection. Boric acid crystals were present.

SONGS-3 found their leak due to steam leakage observed during a startup walkdown.

Due to the high probability that PWSCC that will occur first in the pressurizer, each pressurizer nozzle was evaluated in Attachment l. A brief summary is provided below:

Pressurizer Surge Line Nozzle - moderate susceptibility Pressurizer Spray Nozzle - moderate susceptibility PORV Nozzle - high susceptibility Pressurizer Safety Valve Nozzle- high susceptibility Pressurizer Upper Level Nozzles- moderate susceptibility Pressurizer Lower Level Nozzles- moderate susceptibility Pressurizer Temperature Nozzles- moderate susceptibility 6.0 SAFETY SIGNIFICAHCE PWSCC of Inconel 600 nozzles and sleeves is not a nuclear safety concern for Combustion Engineering plants. All cracking that has occurred to date has been axial. While this may result in through wall leakage, axial cracks will not cause a catastrophic failure of the pressure boundary.

Some circumferential cracking has been observed in French PWR's. EdF (French) plants roll nozzles into place prior to welding. This results in a stress riser at the roll Page 8 Revision c

Page 10 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL transition. PWSCC can develop at this location resulting in a circumferential crack. CE nozzles are not rolled into place.

They were slid into place and welded. No circumferential indications have been found in CE nozzles.

The leakage path through a sleeve or nozzle can be rather tortuous. This results in relatively iow leak rates in the surrounding area. Combustion Engineering has constructed a mockup of a pressurizer heater sleeve and measured actual carbon steel base metal corrosion in the area of the simulated PWSCC initiated leak. This work was done as CEOG Task 637. The corrosion rate was estimated for one full operating cycle, and the pressure boundary integrity was not affected. It is important to note that if a leak remains active and undetected long enough, significant erosion/corrosion of the base metal may occur.

7.0 REPAIR OPTIONS Cracked pressurizer heater sleeves and nozzles have been replaced at a number of plants. Both Combustion Engineering and Babcock and Wilcox have qualified repair techniques, procedures, and equipment available for pressurizer heater sleeves. The Combustion Engineering technique can be used on a single heater sleeve. Combustion Engineering has qualified techniques, equipment, and procedures available for most PCS nozzle locations. The Inconel 600 Working Group is looking at future activities to assure materials and equipment are available for all likely repairs. A single cracked PCS penetration would probably take three to four weeks to repair. Repairing multiple failures would take lonqer.

Replacement material is not presently readily available in significant quantities. The Calvert cliffs Unit 2 repair took well over one year.

8.0 RECOMMENDED ACTIONS The recommended actions have been developed to meet .the following objectives:

1. Avoid mid-cycle shutdowns via an inspection/replacement progra11.

2. Minimize cost by accepting a reasonable measure of risk.

3. Appropriately address regulatory concerns.

4. Ensure nuclear and personnel safety.

A. INSPECTION

1. continue to perform boric acid walkdowns on the PCS.

2. continue to monitor the results of 10 year ISI inspections Page 9 Revision c

EA-SC-93-087-01 Attachment 6 Page 11 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL on PCS nozzles.

3. Install a small piece of removable insulation on each pressurizer nozzle location. This will permit a bare metal visual examination. An ESSR has been submitted for a cost estimate of this task.

4. Perform and document visual external inspections of every pressurizer nozzle/sleeve each refueling outage. This should be done and documented as a VT-2 exam with the insulation removed.

s. Develop a PT process for inspecting the internal heat affected zone of the pressurizer safety valve nozzles, if they are not replaced.

B. REPAIR

1. Be prepared to repair Inconel 600 leaks that may develop.

a. Determine the lead time for replacement PCS penetrations material. Evaluate advance purchase of selected material, possibly within the CEOG program.

b. Purchase replacement nozzles for the pressurizer safety valve flanges. These should eventually be replaced.

c. Evaluate the cost benefit of paying to modify vendor equipment and procedures to repair Palisades pressurizer RTO penetrations.

C. REPLACE

1. Determine the most appropriate replacement material(s) for inconel 600 PCS penetrations.

1. Replace high strength incon.el 600 material in the pressurizer. ESSR's have been submitted to replace five pressurizer nozzles with a yield strength of 77 ksi.

2. Replace pressurizer heaters promptly if they fail. This should occur during the next outage of acceptable duration.

D. PARTICIPATE IN INCONEL 600 INDUSTRY INITIATIVES

1. Sponsor an effort to define the stress characteristics of butt welds on safe ends. The stress characteristics of these welds has significant implications for Palisades.

Palisades nozzle joint design is relatively unique. This task i* extremely important; if residual stress is not present PWSCC will not occur, even in highly susceptible material. CE will be quoting this task before June 14, 1991. .

2. Participate in the CEOG Task to develop a justification for operation with an unknown PWSCC initiated leak. This document will support the inspection recommendations that will be made by the CEOG Inconel 600 Working Group, and support the justification for restar,t after a single leak .

Page 10 Revision c

EA-SC-93-087-01 Attachment 6 Page 12 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL

3. Evaluate participation in zinc injection studies looking at reducing the susceptibility of Inconel 600 to PWSCC.

4. Participate in CEOG Inconel 600 Working Group activities.

This includes EPRI efforts on Inconel 600. This will also help identify other failures that may occur at other plants. Experience within the industry will directly impact the measures taken to assure acceptable economic risks are taken at Palisades.

5. Evaluate participation in CEOG efforts in the area of remedial measures. This may include nickel plating, stress relief, etc.

9.0 AIIA~HM;EHI~

Attachment l; Summary Table of PWSCC Variables and Effects Attachment 2; Summary of Palisades Pressurizer Nozzle Penetration Susceptibility to PWSCC Attachment 3; summary of CEOG Task 633 "Pressurizer Nozzle Evaluationn Attachment 4; Summary of CEOG Task 634 "Inconel 600 Penetration Information" Attachment 5; Summary of CEOG Task 635 "Qualification of Eddy current Exam Techniques" Attachment 6; Summary of CEOG Task 636 "Pressurizer Heater Sleeve Evaluations" Attachment 7; Summary of CEOG Task 637 "Pressurizer Shell Corrosion Testing" Attachment 8; summary of CEOG Task 639 "Pressurizer Heater Sleeve Thermal Analysis"

Page 11 Revision c

EA-SC-93-087-01 Attachment 6 Page 13 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM. PRESSURE BOUNDARY MATERIAL

ATTACHMENT l

+--+-----------------+-------------------+------------------+

Variable Known Effects Corrective Actionl I I I /Comments

+--+-----------------+-------------------+------------------+

I Primary Water Will result in

PWSCC with stress

& susceptible

~I material R +-----------------+-------------------+

0 Temperature Increase of l8F in N temperature M doubles the PWSCC E rate N

T

+--+-----------------+-------------------+------------------+

s Stress Tensile stress of Hiqher stresses T 40 ksi is believed increase R to be the susceptibility E threshold above s which PWSCC may s occur

+--+-----------------+-------------------+------------------+

M Cold Drawn & Low Temperature Westinqhouse SG A Annealed Anneal tubinq more susc T Hiqher yield E strenqth hiqher R susceptibility I

A

+-------------------+------------------+

.Hiqh Temperature CE SG tubinq L Anneal more resistant but not immune

+--+-----------------+-------------------+------------------+

Hot Forqed No Apparent Screeninq Criteria

+--+-----------------+-------------------+------------------+

Paqe 12 Revision C

?a~ I EA-SC-93-087-01 Attachment 6 Page 14 of 31 l2-l4-':IU

PRESSURIZER StJRGE LIN-E NOZZLE ( l)

Service :

Inconel 600 Pressurize~ Liquid Space (653F)

(ASSEMBLY 985-01) 985-03 Safe End Yield 51,200 psi 985-12 Ring Assembly Yield unknown psi Rework: None Cold Work:

source of Residual stress: Welding both ends of safe end.*

Welding on one end of rinq assembly.

Discussion: The safe end should be considered medium risk to develop PWSCC. It has been exposed to a hiqh service temperature and has bee'n welded on both ends. The nozzle material is slightly above the 50 ksi guideline for high risk applications. This particular nozzle is at the bottom of the liquid space. This should be the lowest temperature location in the pressurizer. PWSCC that has occurred to date has been in the pressurizer steam space. The thickness and geometry of the safe end will have unknown effects on the susceptibility of ,the nozzle. The tact a repair would involve two external, welds would be helpful if a repair is required.

It is unknown what the susceptibility of the ring assembly would be. The repair would be extremely difficult. Th* absence of operating differential pre**ure is helpful; thia is not a pres*ure retaining component. one o! the key requirements tor PWSCC to occur is either residual of operating stress. The lack of differential pressure eliminates operating stress as a source of stress. '

References:

CEOG Task 634 CE Drawing E-231-985 (M-lLA SH 985) ___/

Drawings (See attached paqe):

"P15c. 2..

EA-SC-93-087-01 Attachment 6 Page 15 of 31

.tr<e .,

_6_,_., .

-..*1*.... _

.- :- " "3.

" -~ ,*.... ) .... -..

,, l'i ii c - l""\.fJ1° 2.

"P.!5c. :3 12-14-90 EA-SC-93-087-01 SPRAY NOZZLE (1) (ASSEMBLY 986-01) Attachment 6 Page 16 of 31 Service Pressurizer Steam Space (653F)

Inconel 600 986=03 Yield 77,500 psi 986-05 Yield unknown psi Rework: None Cold Work:

Source of Residual stress: welding two ends of safe end (986-03); welding on one end of ring (986-05).

Discussion: The safe end nozzle should be considered moderate risk to develop PWSCC. It is welded on both ends. Due to the steady stream of pressurizer spray liquid, the service temperature would be closer to the cold leg temperature than to the pressurizer temperature. This greatly reduces the risk of developing PWSCC at this location. The nozzle material is well above the 50 ksi guideline for high risk applications. PWSCC that has occurred to date has been in the pressurizer steam space. The thickness and geometry of the safe end will have unknown effects on the susceptibility of the nozzle. The tact a repair on the safe end would involve only external welds, and that it is located on top of the pressurizer would be helpful if a repair is required. The susceptibility of the ring is unknown at this time.

References:

CEOG Task 634 CE Drawing E-231-986 (M-lLA SH 986)

Drawings:

(aee.ltz-3!

I

. ~-

I

'II"

@4JJJ,1.- - ,.**

A Ho J. """.d* 1..

"Palt-~-93-087-01 Attachment 6 12 l':n~gld of 31

RELIEF VALVE NOZZLE (PORV) ASSEMBLY (l) service : Pressurizer Steam Space (653F)

Inconel 600 (986-11) 986-13 Yield 77,500 psi Rework: None identified. This nozzle was not reworked during the PORV Replacement Project.

Cold Work: None identified.

Source of Residual stress: welding both ends; Discussion: These nozzles should be considered high risk to develop PWSCC. They are exposed to a hiqh service temperature and have been welded on both ends. The nozzle material is well above the so ksi quideline for high risk applications. PWSCC that has occurred to date has been in the pressurizer steam space. The thickness and geometry of the pipe will have unknown effects on the susceptibility of the nozzle. The fact that this nozzle is located on top of the pressurizer would be

helpful if a repair is required.

References:

CEOG Task 634 Drawings:

CE Drawing E-231-986 (M-lLA SH 986)

M 1"T ac.11 ~..,;t" "'2..

'D.it-~-93-087-01 Attachment 6 Page 18 of 31 12-14-90

SAFETY VALVE FLANGES (3) (ASSEMBLY 986-15)

Service : Pressurizer Steam Space (653F)

Inconel 600 986-16A Yield 77,500 psi 986-l6B Yield 77,500 psi 986-16C Yield 77,500 psi Rework: None identified Cold Work: None identified Source of Residual stress: weldinq one end only.

Discussion: These nozzles should be considered high risk to develop PWSCC. They are exposed to a hiqh service temperature and have been welded on one end. The nozzle material is well above the 50 ksi guideline for hiqh risk applications. The PWSCC that has occurred tQ date has been in the pressurizer steam space. The thickness and geometry of the flange will have unknown effects, but will probably reduce the susceptibility of a through

wall crack developing. The fact that a repair would only involve one external weld, and that it is located.on top of the pressurizer, would be helpful if a repair is required.

References:

CEOG Task 634 CE Drawing E-231-986 (M-lLA SH 986)

Drawings:

I o l-H:!!fr-1-r

=.:--**7

'!--!1--..,..~-r-....:.*.I

I I

Hn-ci.""4...iT 2.

-P1&' ~

EA-SC-93-087-01 Attachment 6 Page 19 of 31 12-14-90 TOP HEAD LEVEL.NOZZLES (4) (ASSEMBLY 985=09)

Service : Pressurizer Steam Space (653F)

Inconel 600 985-07A Yield 46,200 psi 985-07B Yield 46,200 psi 985-07C Yield 46,200 psi 985-070 Yield 46,200 psi Rework: None Cold Work:

Source of Residual stress: welding; both ends Discussion: These nozzles should be considered medium.*risk to develop PWSCC. They are exposed to a high service temperature and have been welded on both ends. The nozzle material is below the 50 ksi guideline for high risk applications.

References:

CEOG Task 634 CE Drawing E-231-985 (M-lLA SH 985)

Drawings:

HTrec.a.....,..iT' '2.

'Ya,_.. 1:A-SC-93-087-01 Attachment 6 .

12~i~ia.92@ of 31 BOTTOM HEAD LEVEL NOZZLES (4) (ASSEMBLY 985-05)

Service : Pressurizer Liquid Space (653F)

Inconel 600 985-07A Yield 46,200 psi 985-07B Yield 46,200 psi 985-07C Yield 46,200 psi 985-070 Yield 46,200 psi Rework: None Cold Work:

Source of Residual stress: weldinq; both ends Discussion: These nozzle* should be considered medium risk to develop PWSCC. They are exposed to a high service temperature and have been welded on both ends. The nozzle material is below the 50 ksi guideline for high risk applications. PWSCC that has occurred to date has been in the pressurizer steam space.

References:

CEOG Task 634 CE Drawing E-231-985 (M-lLA SH 985) ,*~.

Drawings:

.. ."-~ : -.':':'* .

~ ...... . .. *.-*.- ,

~,,*** .

I **i..'

i.- ** . . .

e_.-

Olmll

A~ .. ,L...* ...rr L.

"K~ ~

EA-SC-93-087-01 Attachment 6 Page 21 of 31

TEMPERATURE NOZZLES ( 2) (ASSEMBLY 986-07/18) 12-14-90 Service: (Assembly 986-07) Pressurizer Liquid Space (653F)

(Assembly 986-18) Pressurizer Steam Space (653F)

Inconel 600 986-08 Temperature Nozzle Yield 46,200 psi 986-19 temperature Nozzle Yield 46,200 psi Rework: None Source of Residual stress: Partial penetration welds done on the inside of the pressurizer. These nozzles have the same conf iquration as those that failed at other CE plants.

Discussion: These nozzles should be considered medium risk to develop PWSCC. They are exposed to a high service temperature and have been welded on one end. The nozzle material is below the so ksi guideline for high risk applications. PWSCC that has occurred to date has been in the pressurizer steam space. The internal J weld geometry makes repairs more difficult than on other Palisades nozzles.

References:

CEOG Task 634 CE Drawing E-231-986 (M-lLA SH 986)

D1***1:\w:i.nq~:; ::

1-----

A:.::achmen: 3

?age l of 3 EA-SC-93-087-01 05/09/91 Attachment 6 Page 22 of 31 CEOG TASK 633 PRESSURIZER NOZZLE EVALUATION OBJECTIVE Provide an assessment of susceptibility to PWSCC of CE pressurizer instrument nozzles fabricated from forged Inconel 600.

STATUS This test LS complete. The final report was issued 02-18-91.

SCO?E

1. Compile manufacturing data.

2, Complete destructive evaluation of Calvert Cliffs-2 leaking pressurizer nozzle.

J. Evaluate the Calvert Cliffs-2 nozzle and SONCS-3 leaking nozzles.

4. Develop susceptibility criteria for hot forged Inconel 600, or identify additional activities.

5. Complete report

DISCUSSION There is very little published information on PWSCC 1u1ceptibility of hot forged Inconel 600. It is likely that additional work will be required in this area. Preliminary information indicates hot forged Inconel 600 is different than cold worked Inconel 600. Tubular products are cold worked.

Pressurizer heater sleeves are tubular materials. Other PCS nozzles were produced from hot for1ed Inconel 600. The following sumnarize1 information known to date:

l. SONCS-3 experienced P\llSCC of 4 pre11urizer instrument nozzles. Th***

nozzles had very hi&h yield 1tren1th. The failure wa1 attributed to a part ic1Jlar material heat number.

2. St. Lucie inspected l nozzle of the same heat number. It was cracked. They replaced all 6 nozzles of similar heat number.

3. Calvert Cliffs-2 inspected pressurizer nozzles. They found l leaking and cracked. The oriainal material was of low yield strength but had been reworked twice.

4. The Navy ha1 experienced PWSCC failures of forged Inconel 600 at temperatures lower than CE pre11urizer temperatures. Navy nozzle* are rolled into place and welded *

I C059 l-182A-HA05

At:.t:.achnient: 3 Page 2 of 3 05/09/91 EA-SC-93-087-01 CEOG TASK 633 Attachment 6 Page 23 of 31 PRESSURIZER NOZZLE EVALUATION DISCUSSION (continued)

5. EdF nas experienced PWSCC of forged Inconel 600, including circumferential indications. Edf nozzles are rolled and welded. EdF found two cracked nozzles and performed NOE on some additional pressurizer nozzles. They found 40 additional nozzles that were cracked but not yet leaking.

It is expected that: these criteria will identify the most likely new crack locations. If PWSCC becomes widespread, the criteria may need to be broadened to ensure that all leaks are found. A nozzle would be classified as high risk if it is in the pressurizer, and either has a high yield strength or has been reworked.

6. B&W and Westinghouse have forged Inconel 600 nozzles in their NSSS. AN0-1 (B&W Plant) recently experience~ a cracked Inconel 600 nozzle in the pressurizer.

B&W performed 1tres1 relief of the pressurizer after the nozzle welding was done. B&W had used this argument (stress relief) as the basis for saying PWSCC would not occur on B&W plants. The nozzle material has a yield strength of 46 ksi, and a microstructure typical of low temperature annealed forged alloy 600. *

7. Both B&W and Westinghouse have experienced PWSCC of forged Inconel 600 tube plugs. Both companies cold work the material during installation~

CE nozzles are not rolled. They were slid into place and welded. It is presently believed that the rolling introduced a stress that has led to circum-ferential cracking.

CE has evaluated the BG&E nozzle. CE concluded that:

l. The mechanism was Primary Water Stress Corrosion Crackina (PWSCC).

2. The material was typical for forged material.

3. Low strength forged Inconel 600 will crack.

No evidence of chemical contamination was found. This supports the cracking being PWSCC. Hot worked Inconel 600 produces more variations in- yield strength, grain size, and carbide precipitation. This makes evaluating characteristics that promote PWSCC much more difficult. Previous work done on steam generator tubes (cold worked) probably will not accurately predict the susceptibility of hot forged nozzles. CE is looking at the affects of the J weld on the metal mic:roscruc:ture.

The BC&E nozzle cracks initiated on the internal diameter (ID). Crack growth indicated the rate was very slow. This indicates high tensile stress existed on the nozzle ID, and was initi&lly relieved by the cracking. Crack growth slowed because operating stresses are much Lower than presumed residual stresses.

Higher stress is necessary to in:~iate a crack than to propagate one *

CE also evaluated a failed SONC-3 nozzle. The material properties were very different than the Calvert Cliffs Unit 2 nozzle. There are no clearly defensible c:riceria for classifyin1 the susceptibility ot for1ed Inconel 600 product1.

IC059l-l82A-MA05

Attachment 3 Page 3 of 3 05/09/91 EA-SC-93-087-01 CEOC TASK 633 Attachment 6 Page 24 of 31 PRESSURIZER NOZZLE EVALUATION Calvert Cliffs-2 found their Leaking nozzles during an external inspection.

Boric acid crystals were present. SONCS-3 found their leak due to steam Leakage observed during a startup walkdown.

All Inconel 600 forged product has some susceptibility to PWSCC. The CEOC Inconel 600 Working Croup has developed the following draft criteria for identifying high susceptibility Locations: ~

1. Service temperature. All cracks found to date have been located in the pressurizer. The service temperature is 50° higher than the PCS temperature.

2. Material yield strength. All cracks found to date have been in nozzle materials with a yield strength greater than 50 ksi. The one Calvert Cliffs Unit 2 nozzle that is an exception was reworked twice. It was repaired with stick welding, not tig welding as originally done by CE.

3. iework or cold work. Reworking a.nozzle can introduce higher residual stresses. CE did not roll or expand nozzles during installation.

It is expected that these criteria will identify the most likely new crack locations. If PWSCC becomes widespread, the criteria may need to be broadened to ensure that all leaks are found. A nozzle is classified as high risk if it is in the pressurizer, and either has a high yield strength or has been reworked.

BUDCET Total: $152,000

Participants:

9 Palisades Share: $ 17,000 Authorized Per WBS: 43001

IC059l-l82A-MA05

Attaci'unent 2'1i Page l of 05/10/91 EA-SC-93-087-01 CEOC TASK 6J4 Attachment 6 Page 25 of 31 INCONEL 600 PENETRATION INF'ORMATION OBJEC7IVE Define the metallurgical properties of Inconel 600 penetra:ions installed tn CE plants.

SCOPE

l. Provide the material and fabrication history for all Inconel 600 prunary pressure boundary penetrations.

2. Identify non-conformance that were identified during construction.

DISCUSSION This task is being done to help understand the metallurgical properties of the material currently installed in CE planes. This is a long lead time cask chat will help us assess the susceptibility of individual penetrations to PWSCC.

STATUS Final report received 1-23-91. Work is complete.

BUDGET To cal: $205,000

Participants:

8 Palisades Share: $ 25,600 Authorized Per WBS: 43001 IC0591-182A-HA05

Accachznenc /')

Page l of 05/13/91 EA-SC-93-087-01 CEOC TASK 635 Attachment 6 Page 26 of 31 QUALif ICATION Of EDDY CURRENT EXAM TECHNIQUES Palisades is not participating in this task.

OBJECTIVE This task will provide a qualified eddy current technique for inspeccing pressurizer heater sleeves. If leakage were co develop in one sleeve this would provide a qualified mechod of inspeccing the other sleeves.

STATUS This task is complete. Palisades did noc participate in this task.

l. Develop heater sleeve standards ..

2. Qualify NOE technique and procedure against known standards.

DISCUSSION The CEOC Working Group felt it would be beneficial to have a qualified method available for inspecting pressurizer heater sleeves. This will allow all 1leeve1 to b* inspected if a leak occurs. This will reduce the time needed to respond to a leaking penetration.

This technique was used at Maine Yankee in the spring of 1990. 4 sleeves were inspected in 18 hours2.083333e-4 days 0.005 hours 2.97619e-5 weeks 6.849e-6 months . No defects were found.

Palisades elected not to participate in this task due to budgetary considerations.

BUDCET Total cost: $36,000

Pa rt ici pants: 4 Pali sadu Co st : 0 - Not participatin1

St. ~ucie i1 paying for a majority of the project cost. This cost allows CEOC participants to use the technology *

IC0591-182A-HA05

At:.t:.achment:. I(#

Page l of J 05/09/91 EA-SC-93-087-01 GEOG TASK 636 Attachment 6 Page 27 of 31 PRESSURIZER HEATER SLEEVE EVALUATIONS OBJECTI'/ES

l. Compare metallurgical condition of Calvert Cliffs-2 heater sleeves t:.hat:. did not crack with sleeves that cracked in service at Calvert Cliffs-2 and ANO.

2. Determine the magnitude and orienc:ation of stresses in pressurizer heac:er sleeves.

3. Determine the effects of localized stress relief.

STATUS A draft copy of the final report was issued f~r comment on 05-01-91.

l. Desc:ructively examine 8 Calvert: Cliffs-2 (CC-2) sleeves and 2 ANO sleeves.

2. Evaluate data from failed sleeves and sleeves that did not fail. Try to characterize failure *

DISCUSSION Task l is complete. All 10 heater sleeves have been de1tructively examined.

The following are the re1ults:

l. CE found smeared metal on the ID of 9 of 10 sleeves. 1 sleeve from ANO was not smeared. They found smeared metal in the non-machined/reamed area of 4 sleeves.

2. They found evidence1 of intergranular penetration* l &rain deep on l sleeve in a non-reamed area. This was also ob1erved in 1ome new Inconel 690 tubing. Thia is probably due to the manufacturin1 process.

3. No significant microatructure differences were ob1erved.

Welding introduces many variables affecting sleeves. CE preliminary conclusion is that the CC-2 sleeves would all have craclited over time. There were no dif ference1 in the metallurgy of the cracked and non-craclir.ed sleeves.

CE constructed a mockup to determine if the tensile 1tres1 required for PWSCC waJ caused by welding. Destructive examination of the heat affected zone demonstrated that the welding process does produce the necessary ten1ite hoop 11tre11. The 1tre11 wa1 found where it was predicted, confirming previous thoughts on the mechanism *

IC059l-l82A-MA05

Attachment ~~

Page 2 ~f J 05/09/91 EA-SC-93-087-01 CEOC TASK 636 Attachment 6 Page 28 of 31 PRESSURIZER HEATER SLEEVE EVALUATIONS DISCUSSION (continued)

CE examined four pressurizer heater sleeve mockups to determine the affects of welding on residual stress. The four mockups were:

l. Reamed and then welded.

2. Welded in a non-reamed area.

3. Welded in non-reamed area and then reamed.

4. Welded in reamed area and then stress relieved.

CE concluded:

1. Stress relief may lower residual stress, but may actually change the Inconel 600 structure to make it more susceptible to PWSCC, *

2. There are high tensile stresses near the heat affected zone at the inner surface. These stresses are circumferential which would produce an axial PWSCC crack,

3. The non-prereamed welding also produced high stre11e1, but not as high.

Applying EPRI's predictive model conclud11 that the stati1tical life of the non-prereamed sleeve i1 4t times longer. PWSCC i1 1till predicted to occur.

4. Residual stress values are not absolute number1. They are relative measures of residual stress.

S. This work directly supports the earlier conclusions with some engineering basis. The residual stresses caused near the Heat Affected Zone by welding are directly dependent on the material properties. Pre-r1amin1 results in high hardne11/hi1h yield 1trength at the ID of the 1leev1. Weldin1 then creates residual 1tr11111 that are limited by the material* properties at the surface. The re1idual stresses 1overn PWSCC 1u1c1ptibility. High strength non-reamed material is 1lightly le11 concern, but residual stress is still governed- by material properties. Low strength material is tensilly stressed due to welding, but susceptibility is lower because residual 1tr11111 are 1overn1d by material properties. The present CE number for susceptibility is 40 ksi residual stress.

6. All Inconel 600 sleeves are susceptible to PWSCC. The susceptibility is relative and time related. Installation proces111 and material properties will affect the susceptibility of each plant and each 1l11ve. Many sle1ve1 may not experience PWSCC during the 40 year life of the plant.

7. Post weld reaming did not produce tensile 1tre11es. It actually appeared helpful in low1rin1 the tensile 1tre1s on the inner sleeve diameter.

8. Reamed and non-reanNd area1 i*~mote from the weld have compre11iv1 or low tensile 1tresse1

9, The original plant rankings *(CEN-393) of heater sleeve 1u1ceptibility should not be changed.

IC059l-l82A-MA05

Attachment l~

Page 3 of 3 05/09/91 EA-SC-93-087-01 CEOC TASK 636 Attachment 6 Page 29 of 31 PRESSUR1ZER HEATER SLEEVE EVALUATIONS DISCUSSION (continued)

Corrosion testing to determine the m1n1mum residual stress necessary to produce PWSCC was completed in May of 1991. C-ring specimens were stressed to different stress levels to determine the affects on PWSCC initiation. The maximum induced stress was 80 ksi. Testing did not produce PWSCC initiated cracks.

This may be due to the yielding of the C-ring specimen, resulting in a lower stress being present. The test results do indicate that the welding process induces a tensile stress greater than 80 ksi.

An analysis of a sleeve that failed at AN0-2 in 1987 determined that: that failure wa1 also due to PWSCC. Several heaters failed and 1welled. The heacer induced a large tensile stress on the heater sleeve which resulted in a PWSCC leak developing in che pressurizer heater sleeve.

BUDGET Total: $256,000

Participants:

7 Palisades Share: $ 36,600 Authorized Per WBS: 43001 IC059l-l82A-HA05

At.

Pag1.

05/ 0';.

EA-SC-93-087-01 CEOC TASK 637 Attachment 6 PRESSURIZER SHELL CORROSION TESTING Page 30 of 31 OBJECTIVE To demonstrate that the development of a leak on-line will not seriously erode the pressure boundary and jeopardize plant safety.

STATUS The task is complete. The final report was issued 04-29-91.

SCOPE

l. Construct a mock-up of a pressurizer hea~er sleeve. Measure corrosion rates of shell material associated with a PWSCC initiated leak.

DISCUSS ION Existing corrosion data is very conservative. The corrosion that actually occurred at BC&E was minor. Meuuring corrosion under actual leakage conditions will accurately represent what we would expect in the plant. This supports the position that a PWSCC initiated leak will not jeopardize plant safety.

The testing that was performed is conservative. The erosion/corrosion test began with a significant crack, and utilized steam generator tubing. Steam generator tubing is thinner than pressrizer heater sleeves. CE used SA-5338 base material, five inches thick, with a two to eight mil clearance between the tube and base material. Test temperature was 600F with 800 PPM boron.

The preliminary test results are as follows:

l. There was no hidden corrosion damage. A visual inspection it an effective method of ascertainin1 damage.

2. The corrosion consisted primarily of pitting, with very little base metal erosion.

3. Very Little base material was removed during the test. Most of the base metal inner bore was not corroded.

This test d..onstrated that previously published erosion/corrosion data is excessive for this application.

STATUS Testing has been completed. The test report will be issued on 2-1-91. CPCo voted yes on Supplement l.

BUDGET 1990 1991 Total: $60,000 $28,500 (Supplement l)

Participants:

Pali HdH Share:

Authorized Per WBS:

ICOS91-l82A-HA05 9

$ 7,500 43001 7

4100 43001

Atcachsnent 19

!?age l of 05/13/91 EA-SC-93-087-01 CEOG TASK 639 Attachment 6 Page 31 of 31 l?RESSURIZER HEATER SLEEVE THERMAL ANALYSIS OBJECTIVE This task will help determ~ne why the PWSCC that occurred at Calvert Cliffs-2 occurred where it did, and will help us understand where we should be most concerned.

l. Develop a temperature profile of a typical pressurizer heater sleeve.

STATUS This task is complete. The final report was issued 04-29-91.

1. Develop a computer model simulating expected thermal profiles.

DISCUSSION The area cracking that has occurred appears to be between 644°F and 647°F. The temperature in this region of the sleeve is relatively independent of the insulation configuration.

BUDGET Total: $53,000

Participants:

7 Palisades Share: $ 7,600 Authorized Per WBS: 43001

IC059l-l82A-HA05

EA-SC-93-087-01 ATTACHMENT 7 GTA Welding Spec

EA-SC-93-087-01 Attachment 7 Page 1 of 7 Proc No 10. 41 Attachment 4 PROCEDURE TRAVELER Revision 17 Page 1 of 2

\ ;:Loi u 6 Pizcct:P\.ijt.E s*;>E(1f=1CAT1DN (w;:>'"~):- ABB/Cc:tw1~..,:.nt:.;....J f;.µ(:,1/ut,;Gf"1f>..;(J Procedure Tit 1e k/u.c.Lgs1z. S'~tz.v .c1:s* G4S TqJG<;re:=N nee - .. .118"3U4L Gn~- e.e Procedure No -110 Revision No 10 Date Initiated 10/)5/9 _?

Sponsor C?lu rf .1 Jc, I v.t Return to Initiator By Aurgned Act1~1ty Act:1v1tv Comp1etea Ac!J'ollty Perton Bv rv'l Re...,.wer Hourt Print ~1m* & n1t1a11 1

Urgent Revi11on

= Urgent Editonel Applicability Review

= Retain-No Revi1ion =

JJIt!ft.1 :J lnec:tiv8te ~ Retain-Revise

Cancel

ReplKed by: = Ret1in-Editori81 Cancel Drtft Development Stan Cate: I I Completion 01te: /() I /S-1 '1 3 T1cnnic1I Review*

Comment*: C YH l(No .j ev.,t .s Review Co""'letMI: { 0 I I (p I CJ 3 Comment Reeolutlon: tJ*! rJby AL.ARA Review' Comment1: 0 YH 0 No Cepy f>Y0°'1d~d Review ~letecl: I to ALAtz.A fff Comment Reeolution: I

~--~o.J Envirann.nt!i Rtview

Comment1: 0 YH 0 No Review Comt11eted:

Comment RelOlution:

U !!' Reyj!w

PtfJR ~~ Cormo1ent1: av.. ~No

-F.." ~ ~ftion Pwiomled: ~.. ONo C a-p('\><< * .P* -

Re"liew ~: JO I If, /'9l

~ Re1a>ldon: I fl/JAi PStl Rtvi!w *

.I .

v S!19f!tM Rtytnr

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DCC Comrpt t P'et::"

In:

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EA-SC-93-087-01 Attachment 7 Page 2 of 7 Procedure No. GTA-8.8-910 Revision_No. 10 Issued Date 7/19/93 PALISADES NUCLEAR PLANT WELDING PROCEDURES TITLE:

WELDING PROCEDURE SPECIFICATION (WPS): ABB/COMBUSTION ENGINEERING NUCLEAR SERVICES GAS TUNGSTEN ARC -- MANUAL Date I /o

{jserReVfewer Date Rev #

EA-SC-93-08/-01 Attachment 7 PALISADES NUCLEAR PLANT Page :ft(RC 'Jlo 3.07 SAFETY REVIEW Attachment 1 Revis.ion 7 Page l of l PS&L Log No _ _,_12_0_-_/r...;;;Q-....,<'-f Item Identification: No GTA-8.8-910 Rev ...1Q_ Title WELDING PROCEDURE SE Rev SPECIFICATION tWPSl: ABB/CE ENG. NUC. SVCS. GAS TUNGSTEN ARC - MANUAL Describe Issue/Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING Reason for Issue/Change: PROCEDURE REOUIREMENT BY ADMINISTRATIVE PROCEDURE 5.06 Yes No Does the item involve a change to procedures as described in the x

1.

FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.*31 4.41 5.11 5. 61 5.8 1 5.101 6.91 7.41 9.1, TABLE 4-21. TABLE 4-22

2. Does the item involve a change to the facility as described in 3.

the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.41 5.11 5.6 1 5.8 1 5.10, 6.91 7.4, 9.1. TABLE 4-21. TABLE 4-22 Does the item involve a test or experiment not described in the x

FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.31 4.4, 5.1, 5.6, s.0, 5.101 6.91 7.4, 9 .1, TABLE 4-211 TABLE 4-22 v

~

4. Should the Technical Specifications or any of their Bases be changed in conjunction with this item?

TS Sections affected NONE TS Sections reviewed 3.0 1 ~.o Justify No Answers below if logic is not obvious:

Although welding, post weld NDE testing and heat treating are discussed in the FSAR, the same proces*e* that are discussed will be followed for this Vendor support.

If any Safety Review question listed above is answered "YES", perform a written USQ Evaluation according to Section 5.3.

If all Safety Review queations listed above are anawered NO, written USQ Evaluation i* not required. However, thi* Attachment shall accompany other review material* for

~~a item to document that a Safety Evaluation was not required.

i4cG'l'p-k~ by J,f QLC,._S#';\_ f"'V ~Je C°"'- Jo/1"'/<i3 ('.U. '1

~- f~ JO-l~-93 ~~~

... v7ewed By l 1o[tg}j_~

Date Prepared By Date

EA-SC-'JJ-Utl/-\.ii WELDING PROCEDURE SPECJFICA TION (WPS) Page 4 of I ABB/COMBUSTION ENGINEERING NUCLEAR SERVICES Page l of 2 Company Name ABB Combustion Engineering By: W. v. Gwaltney WPS GTA-8.8-910 Date08/10/84 Support. PQR(s) GTA-8.8-100 GTA-8.8-104 Manual JOINTS (QW-402)

Joint Design Single 'V' Groove No Retainers Backing(Yes) X No Backing Material (Type) Argon Gas Metal Nonfusing Metal Nonmetallic _K Other Skctchc~. Production Drawin!!s. Weld Symh11ls 11r Wrill..:n D..:s..:ripti11n should show the gcncrnl arran~cmcnt 11f th..: parts l11 he w..:IJ..:d. Wh..:r..:

applicable:, the root spacin!! and the d..:tails 111' weld ~r1u1v..: 1r1:1y h..:

'peci1ied.

BASE METALS (QW-403)

P~No. 8 Group No. 1 to P-No. 8 Group No. 1 OR Specification Type and grade .......;::S~A=2~4~0.._T~v~oi==e--=3~0~4,__~~~~~~~~~~~~~~

to Specification type and grade --=S~A=3~1=2:........:T~v~o~e~=3~1-6..._~~~~~~~~~~~~~

OR Chem. Analysis and Mech. Prop. ......:.;N_o_t~A~o~P~l--=-i=c~a=b-l~e=--~~~~~~~~~~~~~

to Chem. Analysis and Mech. Prop. ~~N~o~t::,....;A~P-P..-..:.l~i-c~a=b~l~e.._~~~~~~~~~~

Thickness Range:

Base Metal: Groove 1/16" to 3/4" max. Fillet Unlimited Pipe Dia. Range: Gr.cove l" to Unlimited Fillet Unlimited Other

FILLER METALS (QW-404)

Spec No. (SFA) 5.9 ER308/ER308L stainless Bare Wire (solid)

AWS No. (Class) -=E~R~J~0~8~/aER:.=..3~08~L=-----------------------~--------~------

F-No. 6 Consumable Insert ~~~N~o~n~e=-~~~~~~~~~~

A-No.

Size of Filler Metals .062" or .093" Diameters Deposited Weld Metals Not to exceed 1/2" thickness per pass.

Thickness Range: no min. to 3/4" max.

Groove no min. to 3/4"; 100% GTA Fillet Unlimited Electrode-Flux (Class) ~~N~o~n~e=---~~~~~~~~~~~~~~~~~~~

Flux Trade Name ~~N~o~n~e=-~~~~~~~~~~~~~~~~~~~~~~~

Other Qualified to weld grooves. fillets. and repairs on PS base materials with AS stainless filler in all positions.

SA312 "t" qualified = . 375". SA240 "t"* qualified = .187" I:

Each base metal tiller ination ~h_9uld

recorded Independent Reviewer ,,,..-:- tr. Date

EA-SC-9.3-087-01 WELDING PROCEDURE SPECIFICATION (WPS)Page 5 of A.BB/COMBlTSTION ENGINEERING WPS NO. ---'G=-=T.....,A_-8=-:....,.,8_-9~1!::;.,':0~-Rev. lQ NUCLEAR SER VICES Page 2 of 2

POSITIONS (QW-405)

Position(s) of Groove Weld Progression: Up _x_ Down Position(s) of Fillet PREHEAT (QW-406)

All All POSTWELD HEAT TREATMENT (QW-407)

Temperature Range ~N~o~n~e-~--

T ime Range -:..:N-=o~n=e'----------

GAS (QW-408)

Percent Composition Preheat Temp. Min. 60 deg. F Gas (es) (Mixtr) Flow Rt i Interpass Temp. Max. 350 deg. F Shield. Argon 99.99% ~1=0=+=3---=C~F~Hj Preheat Maintenance ~N~o~n~e'---- Trail. None (Continuous or special heating, , Back. Argon 99.99% ---=-5=~~2-=C~F~HI if applicable.) -""'-'N-=o~n=e'------ !Backing gas not applicable to i jfillet welds. !

I ;

ELECTRICAL CHARACTERISTICS (QW-409)

current AC or DC DC Polarity SP Pulsed ~N~o_______

Amps (Range) See Below Volts (Range) See Below (Amps and volts range should be recorded for each electrode size, position, and thickness, etc.

Tungsten Electrode Size and Type 3/32" Diameter EWTh-2%

(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW -~N~o~t~*~A~p~p~l~i~c~a~b~l~e=---------------------

(Spray arc, short circuiting arc, etc.)

Electrode Wire Feed Speed Range Manually as Needed TECHNIQUE (QW-410)

String or Weave Bead _.::S~t~r~i~n~g~e~r:-::o~r:.-!W~e~a~v~e=-----------------------------

Orif ice or Gas Cup Size --~3~/~8~"---=I~*~D~-~m~a~x~*~-----------------------,------

Cleaning Initial Grinder or S.S. Wire Brush Interpass Same Method of Back Gouging _:.;:N~o~n~e,__ ________________________________________

Oscillation ~l~/~4~"---l.m~a~x~*----------------------------------------------~

Contact Tube to Work Distance Manually Controlled to 3/8" max.

Multiple or Single Pass (per side) Single or Multiple Multiple or Single Electrodes _.::S~i~n~g~l~e"-----------------------------~

Travel Speed (Range) ~M~a~n~u~a~l~l~y..______________________________________

Peening Not Allowed Other Filler Metal current Travel Other Bead Type Amp. Volt Speed Remarks, No. ( s) Process Class Dia. Polar. Range Range Range Comments i

All GTA SFA5.9 .062 DCSP 80-110 11-12 Manual I

.093 DCSP 95-125 11-12 Manual I I

~

WELDING PROCEDURE QUALIFICATION RECORD EA-SC-93-087-01 Attachment 7 E-S6J (117:

COMBUSTION ENGINEERING. INC. Page 6 of 7 ov_e_~_c_e_r-;-"

. '- l"1 _* ~1?.

1 -~-~~*---=~?:;...:...~-----

OATE ___ p ROCE OU RE au AL IF ICA TION NO _ _....;:;..;.7;;.;;A..;;.-_'..;;.3..;;.* ..:::S_--=:..c.:::~,::...__ _

1 Editorial Correct(oR: 07/19/93 CIJALIFIE D TO cooe SECTIONISl _ _ _--="'"-=--=1"_ _ __

MATERIAL SPEC. & GRADE FOR WELDING P No _ _ _ _

'NE LOING p ROCESS SA-240 '!';i 30 4 9_____ TO p No _ _ _8______

_.....;:_-a_s__rro.. .; .*.; ; :.m=g..: s:. ;t: .;e:.:n: . . . :A:. :.:. r.: ;c_ _ _ _ _ _ __

FI U.E R METAL F No - - - - - - ' " ' - - - - A No _ _ _ _...;.7_ _ __

TYPE POSITION TEST TO _ _ _ _ _ _ _

SA-240 Tp 304

....;-=-------------

2 "1'11 THICKNESS (& 01 A. IF PIPE I -~-'!l.------.---..."'---------

we LO JOINT _ _ _S_i_n_,g'-l_e_'_'*_r_"_ _ _ _ _ _ _ __

x 3/'_. 6" we LO __::_o_r_1_*z_._&_V_e_r_..._~_. ......:...?..:i.:.:x..:e..:d:___ d SPEC. or AN AL YSIS ___ :.!-.--'..:::0:.::8:..__________

S.._F._A:....--5._..'-9"--E:R,..* SINGLE or MULTIPLE PASS ----'~~4ul=...::t...::i:.:n:.:l:..:e=--------

ELECTRODE SIZE _ _ :_/_1_6_'-'~'--~-W'I'_H.;;..-....;2;;,,*_ _ _ _ _ _ _ __

NO. OF LAYERS OF CLAOI - - - - - - - - - - - - - - -

NO. OF ARCS Single FLUX - - - - - - - - - - - - - - - - - - - - - - - -

SHIE LO ING GAS (ESI & COMPOSITION _ __._A--..-rg._.o...n__________ PREHEAT ____6_0:....c_F........~-*1;;.;;*n ___* _____________

FLOWRATE _ _ _ _1_o __c~F~H;;,;;__ _ _ _ _ _ _ _ _ _ _ __ MAX. INTER.,ASS ____3_0_0__F_~_ax_._ _ _ _ _ _ _ _ __

0 TYPECURRENT _ _ _ ~_C_-_S_P______________

MAINTAIN PREHEAT UNTIL PWHT BACKING REQUIREMENTS POSntEATTREATMENT _ _ _N_o_n_e _ _ _ _ _ _ _ _ ___

OTHER: Argon Back Purge@ 5 CFH "T" range qualifies ,. 0.062" min. to 0.375 JI<

Y'o '°"',:.' "'"' ~"\.w, *tt , ".z. lz.+/u JOINT DESIGN BEAD NO. PROCESS WIRE DIA. AMPERES ARC VOLTS INCMESJMIN.

-- -~~

All GTA 1/16"95-105 ll-13

.r I~ .*

/ ~

y L

DEPOSIT ANALYSIS

~**

I~

-*- L.~~H c ______ Mn _ _ _ _ __

% FERRITE IN ALIS-raNITIC CLAD DEPOSIT p _ _ _ _ _ __ s _______ 5, ______

CA NI------- M o - - - - - - - C o - - - - - - - Nz - - - - - - - O t h e r - - - - -

GU I DED BEND TESTS OofARPY V-NOTO-f IMPACT TESTS DAOP*WEIGHT TESTS FACE:

!. Acceo cab 1.r:> LOCATION TEMP n'/US MILS LAT EXP TEMP RE SUL TS

.:. Acceptable ROOT:

,. ... - TM--*-

II ' oc11*1** I

-~ ... -

fMl

,,O,llTT

\Ml&.lft~

"" r"IMll

!:IDE:

He .. *Of TO II 11Pft9U CH.

HHl*HT o* llHD

-- ro *-,.,**- ~~ co*,.n.

WIT* I& 1

&_~'_~~

MACRO: WWl81 I* ,H "

NOT OF NON-DESTRUCTIVE TESTS TENSILE TESTS LIQUID PENETRANT I T'Y*t: S~CCIMCN Ul..TIWAT[ STlll~l.....-SI C:MA*ACTIR

L.OCATION 0,. '*11..ullll RADIOGRAPHIC I Trans. 86,200 Base Mater::.u ULTRASONIC I Trans. 84.800 Base Material MAG. PARTICLE l Trans. 84.200 Base Material -

VISUAL I Acce"Otable Trans. 85.000 Base Material I

WELDER c. Overby SYMSOL _ __..}11__.__ ___ Ne cen1fv lh*r 1he ll**e.....,,. in 1hi1 record ue corrK?. ind "'"'

rhe 1e1i weldl were grejMreci. welded and 1111ed '" 1cc0ta*"Ce

,EPT Chattanooga .. irh rlQ,.iremenn of the ASMI! Coae.

TEST NO G::rR-ii.B .. \QO

~ ~:'""'¥--"""'" ... "' ** :_,~

TEST LAS.

WAS IA-88-7,8

-'.et ~&D De"Ot.

BY OTHER <:::Z rt:'-. c?oc: ~~"TITLE t::¥t~ee,,-

WELDING PROCEDURE QUALIFICATION RECORD EA-SC-93-087-01 Attachment 7 Page 7 of 7 lt-llJ 1*110 l

COMBUmON ENGINEERING, INC.

January 20, 1982 PROCEDURE QUALIFICATION NO. GTA-8. 8-104 lATE - - - - - - - - - - - - - - - - - - - - - - -

QUALIFIED TO cooe SECTION<Sl II I, IX and ROT Editorial Correction: 07/19/93

. "'4ATERIAL SPEC. & GRADE SA-312 Type 316 SA-312 Type 316 8 TO P No --'8____ TO -----------~---------------------

FOR WELDING P No BACKING REQUIREMENTS Argon Purge @ 5 CfH

..-.ac1NGPROCESS Gas Tungsten Arc THICKNESS (&DIA. IF PIPE)

375" X 8 00" 2l TYPE WELD JOINT U-Groove .

POSITION TEST WELD Hori zonta 1 Fj xed ( 2 .(

SINGLE or MULTIPLE PASS -..:.M....y..,,l_,,t"'"i.... p...,;le..._____________

SPEC. Of ANALYSIS _....;S...;..F.;..;.A_-5;;;..;*:..;:9._/..:. :R.:.DT.:. . .:. M;..:.1_-2:.T:.,____:E:.:.R:.. .-. :. 16:: . -. .: :8:. . .:2- NO. OF LAYERS (IF Cl.AO) __.:.,N"'"/.._A.._________________

NO.OFARcs~O~n~e=------------------------

El..ECTROOE SIZE _3/_,3.....2._"_.0.,___=EW..;..;TH~-= - - - - - PREHEAT 60 F FLUX ___N~A.;._..,___________________~

MAX. INTER-PASS ---.:3=:.:5:.:::fP:.. .;. .F_ _~---=--:--:-----

SHIElOING GAS(~ & COMPOSITION _A_r_g_o_n__________ MAINTAIN PREHEAT UNTIL PWHT ~A..;.::s:......;.w;..;:e:...;l...:d:.:::e:.:d'----------

FLOW RATE 12-1 5 CFH POSTHEAT TREATMENT . .:.A. ;.:s;. . .;.;w_e.. ;. 1d=e=d=----------

TYPE CURRENT D. c. -S. p. Iii frequency start "T" range qualifies :II 0.062" mjp Co a iSO" T OTHER: -Pure maintained for at least the 3/16" thickness of weld de sit.

y Y't ... .1.-...*.11 "'-~* -

JOINT DESIGN BEAD NO. PROCESS WIRE DIA. AMPERES ARC VOLTS INCHES/MIN Al I lJ If\ I/ IO" li::::J-IJU ll-12

~*

) ~-~- \?~ :-1.

4'.z":f. "'*'~ . J~ .. ,. FERRITE IN AUSTENITIC Ct.AO DEPOSIT EPOSIT ANAL. YSIS C 0.043 Mn l .61 p 0.014 S 0.014 Si --0_*. . ;. 4. ; .6___

CA 16.32- Ni 9.69 Mo 1.85 co -=o.....o,,..,4,..____N2 0.045 °"* Cu - 0.

V - 0.04 Ti-(0.0l Cb+Ta-<O.Ol Tungsten - ?0.01 GUIDED BENO TESTS CHARPY V-NOTCH IMPACT TESTS DROP-WEIGHT TESTS FACE; _________________-++-_L_OCA __T_10N_-+__ Ts_M_P-+---"-'-L.9-*--+--M1_Lm_..LA_T_u_,.-++___ Ts_M_,._-+-__-~_a_u_~_n____

ROOT: - -.......--,..,........,..,_.....______,___~------+----+-------+------~-------+---------

SIDE: _ _4_~01.,;_K(~T....;r~a~n~s~v~e~rs~e~!).____,+-------i----+------+-----++-----+--------

MACRO:

Acceptable Full Penetration) NDT NON* -OESTRUCTIVE TESTS TEii.Si LE TESTS P. T. Ok H.Patr1ck (8-25-8 ) SPEC. CllM*NSIONS A"*A ULTIMATI U~Tl"U*TI CHA"ACTI!:" AND R. T. Ok C.S.Matthews (8-3 -81) NO. WIDTH THK. SQ. IN LOAD .... 81 ST"Kll-HI LOCATION 0,. ,.AILUF U. T. JB-A .785 .376 .2951E 27550 93.3 Base Metal-Du M. T. JB-8 .110 .406 .3126~ 29500 94.4 Ba"e Metal-Du VISUAL OTHER Lhem.Ana lys1 s-Base Mat' C-0.049, Mn-1.77, P-O.n24. 5-0.012. Si-0.61. Ni-13.16.

Cr-17.07, Mo-2.96, Ti-<..01, Cb- <..01 V- 0.05, Co-0.07. Cu- 0.14. N?- 0.12 WELDER _..,'1°"._t~_. .;. R_a_.g._o....n'--________ svMBOL AUK we cen1ty tnat tne 118tefNll* in mis recora ,,. correct. anc '"" "

tnt wetct1 ,,. or90.,.., welded lftCI tested '" ac:coraance .,,,, ,..

DEPT __....;C;;..;.h..;.;:a:..:t:....:t;;::a:.;;n:.=O~O_.g~a:....,___________________ quiremena ot tne ASME Code.

'ST NO _9_,6..,..0;...,0,_o....1___.....-__..,....-.---....----------- c~o M ~o N e NGIN E ERIN G. I N c.

. c:sTL.AB. Metallurgical R&O lab. Bv g.__:_ ~"" ~4 BY OTHER ~<' - - ~ 44!( TITLE *

v-e_

l'<.'7. "M/,_.

T*ll Decu*l*T 11 r** "***1*T* O*

COMIUSTION lNGINIHlllNG. INC** WINDIO*. CONN *

... * ..., ,. n .. _ ,.. ** van "' , , , _ *** -.

--*** ........*u-

, .. . ._ . *H HAWI. . . ** AHAMIW UCIPf

EA-SC-93-087-01 ATTACHMENT 8 Half Bead Welding Effects

EA-SC-93-087-01 Attachment 8 Page 1 of 2 To SSOverway, Palisades From JCNordby, Palisades CONSUMERS POWER Da,te October 18, 1993 COMPANY Subject Effects of Half Bead Welding on Base Metals Internal Correspondence JCN93*029 cc DJVandeWalle, Palisades Modifications will be made to TE-0101 and TE-0102 on the pressurizer using the half bead welding technique as an alternative to conventional postweld heat treatment (PWHT). However, a question was raised as to what effect this welding technique will have on pressurizer and/or nozzles. As a result I am writing this letter to inform you that, for the intended application, there will be no significant adverse effects on the pressurizer and/or nozzle resulting from the use of ABB/Combustion Engineering welding procedure specification (WPS) SMA-3.43-937 (half bead welding).

Essentially, the reason there will be no adverse mechanical effects on the pressurizer and/or nozzle is the fact that all of the WPSs have been qualified in accordance with ASME Section IX and the half bead welding rules of ASME Section XI. Because there is no way of nondestructively evaluating the mechanical properties of a production weld, WPS qualification test coupons are prepared and destructively tested to establish ranges of variables which will produce sound welds. This qualification has been done for SMA-3.43-937 .

No significant adverse metallurgical effects on the pressurizer and/or nozzle are assured basically through control of preheat, interpass and PWHT temperatures. From the standpoint of the pressurizer base metal, the qualification tests described above assure a sound microstructure. The inconel nozzle is a different case.

Inconel is a nickel alloy. Corrosion resistance is one of its more important properties. Outside of the heat affected zone (HAZ) from welding, the inconel nozzle will only see temperatures well under its maximum design temperature and therefore no adverse effects will occur. The area of concern is the HAZ.

The corrosion resistance of the heat affected zone (HAZ) is not verified by the mechanical tests required by WPS qualification. Although far less vulnerable to the effects of temperature on corrosion resistance than austenitic stainless steel, the amount of carbide precipitation resulting from welding temperatures is limited by the 450°F interpass temperature. In addition, the 500°F +/-50°F PWHT temperature is far below that required for carbide precipitation (in fact, it is lower than operating temperatures).

The inconel weld metal itself is of least concern. Aside from the qualification tests described above and the inherent as-welded toughness of nickel alloys, the carbon in this weld metal is stabilized. Because of additions of columbium and tantalum, this material will not experience additional carbide precipitation resulting in possible lowering of corrosion resistance, either from the heat of subsequent beads or PWHT.

In conclusion, it should be noted that this modification has been performed at other plants with success. While welding will always have an effect on base metal properties, the question is not simply will the effect be detrimental, but will the effect be detrimental for the intended application. For this

EA-SC-93-087-01 Attachment 8 2

intended application, the effects of welding using SMA-3.43-937 will not adversely affect the pressurizer and/or nozzles .

EA-SC-93-087-01 ATTACHMENT 9 Circumferential Crack Potential Memo

EA-SC-93-087-01 Attachment 9 Page. l of 4

==----~-

==-=

=-- .

--* To From Date Design Package Fils RBJenkins, Palisades;,ut/FrlZ October 18, 1993

~Br JUal.U1fCll .mu -

CONSUMERS POWER COMPANY

~

Subject NUCLEAR ENGINEERING AND CONSTRUCTION ORGANIZATION POTENTIAL FOR CIRCUMFERENTIAL CRACKS IN MODIFIED PRESSURIZER INSTRUMENTATION NOZZLES Interna 1 CC Correspondence RBJ93*064 INTRODUCTION Modifications are currently being prepared for two temperature instrumentation nozzles in the Palisades Plant pressu~izer. The modifications are being conducted in order to eliminate primary coolant system leakage through what are believed to be axial cracks in the temperature instrumentation nozzles.

The axial cracking phenomenon in these Inconel 600 sleeves, while new at Palisades, has been experienced in the nuclear power industry at many installations over the last several years. In addition, the modifications being contemplated for the instrumentation nozzles have been successfully completed at other plants. The difference between the modifications being considered at Palisades from those completed at other plants is that the Palisades modifications are being planned very shortly after circumferential cracking was discovered in the PORV line. The recent PORV line cracking experience has raised awareness of the potential for circumferential cracking in Inconel 600.

It is the purpose of the discussion below to explain how the PORV line cracking and temperature instrumentation line cracking are different in some very significant aspects and why the differences can explain why circumferential cracking in the temperature instrumentation nozzles is not expected.

EA-SC-93-087-01 Attachment 9 2

REVIEW OF INSTRUMENT LINE EXPERIENCE Reference (1) summarizes relevant pressurizer instrumentation cracking experience in France. The nozzle configurations are not unlike those of current concern at Palisades. The welding is a partial penetration/fillet weld detail. The impact of the weld shrinkage is to constrict the instrument tube circumferentially. The instrumentation lines see little in terms of axial loads. Detailed NOE and other test work showed that:

Most cracks were axial

Only axial cracks penetrated beyond half the wall thickness

Weld residual stresses are higher in the circumferential direction than in the axial direction.

Reference (2) is a very comprehensive discussion of pressurizer instrumentation and weld configurations very similar to those of current concern. The conclusions of that work scope include the following:

The J-weld construction can generate very high residual tensile hoop stresses adjacent to the weld

Pre-installation reaming tends to result in higher residual stresses

Axial stresses tend to be compressive or relatively low tensile

Based upon service experience, laboratory studies and stress analysis, the initiation and propagation of circumferential cracks is unlikely Reference (3) reviews control rod drive and incore instrumentation nozzle cracking via detailed analysis work. Although the specific application is the reactor vessel, the conclusions apply to the pressurizer instrumentation configurations as well. Those conclusions note that hoop stresses in those systems are greater than axial stresses and that weld residual stresses are significantly higher than externally applied or other operational loads.

REVIEW OF THE PORV LINE EXPERIENCE Reference (4) and its enclosures document the PORV line/nozzle cracking. The cracking actually occurred in the Inconel 600 side of the safe end-to-pipe weld. The metallurgical work shows cracks growing radially from the pipe inner diameter and fanning lightly to the outer diameter. While there may have been some axial cracks, joint leakage was clearly a circumferential rather than an axial cracking phenomenon.

The primary difference between the PORV line phenomenon with respect to the instrumentation cracking both at Palisades and elsewhere is that the PROV line weld is a full butt weld and not a partial penetration weld, J-weld or fillet weld. All of these types of welds will provide circumferential weld shrinkage and the resultant potential for axial cracks. The instrumentation line welds, when shrinking axially, see little resistance or restraint to shrinkage from the instrumentation configuration. The instrumentation element is essentially free to be shrunk by the weld. Very near the weld, there may be some axial compressive stress as noted in Reference (2). However, this lack of axial restraint results in an essentially "plane stress" load environment .

EA-SC-93-087-0l Attachment 9 3

For the PORV line condition, the load environment is very different. The butt weld is through-thickness. Therefore, it can shrink the pipe side (or nozzle side) very efficiently. If the pipe side was free and the nozzle side was free during weld shrinkage, it would be very difficult to produce significant axial stress in the pipe or safe end as the pipe could deflect to accommodate the weld shrinkage much as the temperature element would. However, during the field welding of the joint of concern, the nozzle end is fixed by the vessel.

The pipe end, while not as rigidly confined as the nozzle end, is well supported if only to support its weight. Therefore, the load environment in the area of the field weld is more akin to "plane strain" because axial movement of the pipe/nozzle is very limited. This constrained configuration permits the development of an axial residual stress field that simply could not have been achieved in the typical temperature instrumentation element configuration.

The design of the PORV line can result in high axial residual weld stresses if the fabrication process (to include welding) does not reduce them due to heat treatment etc. The joint fitup and root configuration can make the joint vulnerable to these residual stresses.

PALISADES TEMPERATURE NOZZLE MODIFICATION The modifications to the temperature instrumentation nozzles incorporate pressurizer pad-to-sleeve welds that are essentially the same as the existing J-welds as far as their impact on residual stress fields is concerned. The new welds have the appearance of a fillet weld .. As noted, these welds are not as efficient as butt welds in inducing axial stress into the instrumentation

nozzle.

For the modification where the nozzle is cut, the temperature element will be essentially free on either side of the exterior weld when the pipe is cut.

The cut may reduce axial residual weld stresses induced by the weld shrinkage with the restraint of the element by the inside J-weld. With the cut, the above discussion applies directly with regard to the lack of a mechanism for developing residual axial stress (potentially leading to circumferential cracks).

For the modification where the nozzle is not cut, an axial residual stress field between the new weld (outside) and the J-weld (inside) may exist due to the existing restraint during the welding process. No similar residual stress field will exist external to the new weld. Therefore, an undesirable residual stre~s loading exists between the welds while all the axial operational loads (internal pressure) will be reacted by the new weld only. While any potential axial residual tensile stress loading is undesirable, that resulting from the current modification is not of immediate concern. The reasons are as follows:

There are essentially no externally applied mechanical loads to the nozzle

The potential axial stress distribution from the modification will be new and will require time for the initiation and propagation of the cracks

The potential axial stress between the welds would be totally self limiting as it is caused by stiffness (restraint) and any local

cracking between the pressurizer inner and outer diameter would relieve the load which caused it to occur

EA-SC-93-087-01 Attachme:nt 9 4

CONCLUSION

-* Joint configuration and the fabrication process combine to limit the impact of any deleterious effects of weld residual stress in the design of the temperature instrumentation nozzle modification. These considerations along with an awareness of the time limitation of the duty cycle for the joint combine to provide assurance that a catastrophic failure due to circumferential cracking will not occur.

REFERENCES

1. Alter et al, "Stress Corrosion Cracking of Pressurizer Instrumentation Nozzles in the French 1300 MWe Units," Proceedings on the Fifth International Symposium on Environmental Degradation of Materials in Nuclear Power Systems - Water Reactors, American Nuclear Society, August 1991

2. "Evaluation of Pressurizer Penetrations and Evaluation of Corrosion After Unidentified Leakage Develops, CE-NPSD-690-P," Combustion Engineering Owner's Group, January 1992

3. Safety Evaluation of the Potential For and Consequence of Reactor Vessel Head Penetration Alloy 600 ID Initiated Nozzle Cracking," CEN-607, Combustion Engineering Owner's Group, May, 1993

4. Letter from GBSlade to Nuclear Regulatory Commission, Palisades Plant -

Pressurizer Safe End Crack Engineering Analysis and Root Cause Evaluation, October 7, 1993

EA-SC-93-087-01 Pressurizer Specification

/

EA-SC-93-087-01 Attachment 10 Page 1 of 9 ENGINEER.ING SPECIFICATION FOR A PltESSUlUZER ASSEMBLY SPECIFICATION NO. 70P-00l Revision 2 Nuclear Power systems COMBUSTION ENGINEERING, INC.

Windsor, Connecticut This document is the property ot Combustion Enqineerinq, Inc.

(CE), Windsor, Connecticut, and is to be used only for the purpose of the agreement with CE pursuant to which it is furnished..

Prepared Date: _1o_l_'f_l_'1_r_

Approved Date: l~o,/?1 Evaluation Approved 10-10--q,/

Date=--------~-

Doney, Manaqer, Plant M*chanical Systems Approved By- ~ I b-

P.~~e,Prdjact Mana9*r Cate: 10-10 -qi ssue Date:

Paqe l of l7

EA-SC-93-087-01

~

I ~'Pa~

Attachment 10 CO~. JU~TION ENGINEERI~G, 2 of 9

'iU8JllCT ~ROM-OAT<;

. j~~ c.

w /4-

w. w. Roberts, Chatt. ~"ffiOV AL OF As.r:: 1966 'r'l'DrTER W. K.

ADDE11DA 10R FRESS'JR!ZE:;R xc: v. c. Ha.11 Fe'bru.Ary 16,

, rr"-.

.-./C{

J. D.

F. p.

Crawl'ord Fagan c (. /~~ P-SE-442 F. J. ~a1ek T. L. Kettles (2)

F. A. L ow-e , Cb.at t . lcUJ-~

~,r/

(D E. W** Woollacott Project Files /(/Jf610

,~

Reference:

(A) W.W. Rooerts TI' No. 9 to W.K. wµ_helz:t dated Febr~a.ry 2, 1967.

- 1 Approval is granted in res~nse to re:!'erence (A.) to use the T,ol'inter 1966 Add.end.a of the Aa.m Boiler ~nri Pressure Vessel Code; P.-ction III, RUles tor Co~structiou of Nuclear Vessels. *

'!'his ap~oval a~~lies only to the pres!urizer contract, and is void i~ ari:y increase in cost or extension of delivery resul.ts fr~ its a~l1cgtion.

W. K. Wilhelm WIOT/TLK/ ,JDC: d.s

EA-SC-93-087-01

.., , ~ttachment 10 CO~HBt TIO:\ ENGI~EERI: -' ' 1* '"17 ~~age 3 of 9 4001U551:£

~-- ---------------------

~r. Stan lCni,;:Ot / Consume~s P:-essu:-izer Nuclear Cor.tra~:

Contract 2966c Enginee:-:!.:ig cc: Mr. J. A~el Mr.* G. car:"~ 11 March 2, lJ67 Mr. R. Ar~strong The !'ollcwing list of governi:iL:; ~:pec!.fications a.re :'*.:-~**:i:L~*,; * ~ '-!"'l a p::-elimi:iar:r bas:.s ~or pla:i~:.ng pi.;r'poses. i::::e 1!.st will':!:! c.;*:ri-

!'irmed and/or amended. by step order as socn as the cont:*.::.~": i1c.3 been £inal.:Lzed.

l. CEND Specification No. 7CP-001 as tentatively ~cdif~ed by P!'Q-posal No. 4-12526-l, Contract 20355 and later agree~ents.

2. Sect.ion III of ASriIE Code ~ncl 1..:ding all Adde!'lda th.::...l 1.iinter 1966 Addenda.

3. Special Coae Cases:

a. Case 1339 ... 3 UT of plate

b. Case 13 59-:L UT of f'org:tngs

c. Case 1332-2 I.ow Alloy forgings

d. Case 1339-2 tow Alloy ?late 1

e. case 1336 ' Inconel forgir.gs, plate and tube

4. CE Purchase Specs: ...

a. P3Fl2 ('o J !low alloy plate b ** P3C9(d) Low alloy fcrsings

c. P43Cl ( c) "I.nconel forgings

d. P43B2f b) "Inconel'r pipe 1

e. P43F3 c) tinconel 11 plate

f. PlFll b) ca~bon steel piate

5. M&P Specs:

2.4.l.3~a) 2.4.2.4 c) 2.4.3.9(c)

Radiog~apr.~c MT Inspection PT, Materials

!~spection 2.4.3.lO(a.) FT, Seal S~rfa~es 2.4.4.9(c) UT, Clad Eond

2. 4. 4. l5 (b ) UT, Plate e 5.3.l.4(c) Que~ch and Te~pe~ A-533 ?late 5.3.l.5(d) 1 r If " A-516 Plate 5.5.2.8(d) Fabrication ~~ ~rucl~ar Shells

EA-SC-93-087-01 Attachment 10 Page 4 of 9 Mr. Stan K.1igh t March 2, 1967

-* 5. M&P Specs: (Cont'd)

Contract Supplement 2966c-1(c) to 5.5.2.8(d) 5.S.2.9(c) Fabrication of Carbon Ste~l Contract Supplement 29~6C-l(a) to 5.5.2.9(~)

5.5.3.l(a) Cleanin~ Nuclear Vessels 5.5.6.a(c) Fabrication of heads Contract Supplenent 2966c-1(a) to 5.5.6.S(c) 6.l.l.2(b) General Weld.1.ng Procedure.

-~v<,J~

W. W. Roberts WWR/lh

-D

EA-SC-93-087-01 Contract Z966C Attachment 10 Sheet l of 2 Pages of 9 FORM N-l MANUFACTIJRERS DATA REPORT FOR NUCLEAR VESSELS

i. As req11ired by tbe Provision* of the A~E Code Rulee aad tbe Satioul Board

- .aAu!acm:.d b1*....... ~~.~!~l:~~....ss.~.:!!!If.~S.1..*;n~.:..a~.~}J...l!.:.-~!.~I!...~.~~~.!._ft1.!E-~.'¥.:.~?..&~.z.._~.~.::~~.~.~.~~.......... ~.-..

<N'-* *ncl *ddre u ot M*n'j*ctunr)

2. M~ufactur.d fot ... " ...~9.;}.lll.la.'r.!... ~.2~~!. ...~~.:..i ... ~.*f.... !:i:.~ ...!:!J:S:h.:!J~.~...~.~~.B~~.1-*... ~.~!;~.C?-~.?....~~.~E.!.i!'.~ ............. _,,_ ..................... .

v t H t E

3. Type...... :...~~....: ......... Kind ... -~.~ ........~.~ ........ Veseel No. ( ,..~ .......

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J:........... ) (................................) Nat'l Bd. No ...~.9.~.~*~***** Y'r. Built..~.?.~.... .

9 (HQn~. ar Vert.) (T11nk.Jtcketecl.He11t lh.) Oilfrt. Seri*1 No.) (9t11ce *State No.)

Item1 4-8 UicJ, to be codlpleted !or :iiJlgle 111eU veutla, jackets of jacketed -.*esull, or sbe1!1 of beat ezchacitr1.

A-533 Gr. B Cl. l I Over ~eads

. . All. S. ,., an non No:ni1:ial . Corrg*ioa 1 /l 6 . . 2-l 2. S-l/

4. Shell. M1tenal.

(Jtlnd asrde'cf QY. ** ~:!Mt- T.S ..... K.V..a.¥....~ ******* Tluckceu .....6__... u1. Allowancr..........

D,) (Mlft, of NDH tpedfle~ .

5. Seams: Loac ..... - .... !:... -~.............-............... R. T. !...........-...!!...................... X.R .. - .... -!~.~

1n. Diam.~ .. -.ft ......... ui. LenlthZ.6. .. !t ...... _

.............................. EHicitacy ....... _ .................. .

Welded Yes Yes ' 1'2Cln* a*

A-~ "t;r*:-*B""t:'I":***1-**................... H. T. \ ........... -................................. ~~~.:f3'"(;t-':""jf"cI"."1'""'""* No. of Co1u1es ...................... .

6. Heads: (a) llateri1l ..~ll,q,Y. ...§.~.~.~*-................... T.S ..... §.R.1.9.9.Q._ ........ (b) Meteri11.aJ.lQY. ...§.~.~-~l .................. T.S ...... ~9 ...i.9.9.9. .............. .

Locatioa Cro.ni ltauckle Elliptical Conical Hemispherical Flat Sid* to Prell (Top, bottom, tada) Thickness Radiua R1di111 R&tiD Apex Ni&l* Radiua Diameter (Coavex or Coaea

<*> ... ~.~:e................. ...~.:.Y.~...... ~.?.:.21..~" ................ .. ....-........_.......................- ...~.~.:.?.~~~~-... .................. ..~.9.:::~.~.'.'{-~ .........

(bl ... ~.E.t:-.e.?!1.......... ....~.::.+.L.~....... ~~.~.~1.~" ................ .........___ .,,..... ........................ .2.~..:.~_!....... *-*-*-*-..... ..~.9.r*.s.~:-.:.'?......-.

IC rmovable, bolts used ..................................................................................... -........................... Other futeni111 .................................................. .

CM*terta!, Spee. No.. T .a,, Si:1e, l'(wnber) (Ce*eribe or attac:h *k*tds

7. Jaclcet Cloaure ................................................................................ :~ ............................... " ............................................................................................ ..

CC**c:r'b* ** "I** a. **ld, ber, etc:. U tl*r 11v1 d1m*R*ion11, de*cnbe gr *ic*teh)

8. Coaatructed lor 0. Cbarpy Impact ........ ~~........ -..ft*lb t ' : a ' : c orl Test ,,, 5

.~~~I pre11.z .................. 250 p1.i at . .z. tesp .. 7.0.0..... ~.F et te'lllp. or ..................................0 P. Cl**""* {Pre**iue ...... 3 7'.~......... p complteed or tu HCt oas.

Statioaary. Materi&l .....- ............................. otam...._......................... in. Tl:aic&A"* ....._....... ,_. ia, Attaclm1eut ..........................

CX1n4

91"C:* No.) (IS~j.oi to pNH.) (WeldeG. Solt*d)

'1oatia1. Material................. .".................. Diam. , _.........._........... ia. ThicknHI ,_ .. _ ......... in. Attachmeot ...................... _

(Xlnd 81 S"c:. Ko.)

Number.............. Type .................... .

(Str11111:ht 01' t nems ll to n uicl. to St completed for inner c&ambetl Of Jacketed YHHh, or cheaaels of &eac exdiaacers.

Nomuael Corro1ioa

11. Sh*ll: Meterial.................................. T.S .......... _... ,........... Thickll*** .......... i.4. Allowaace .......... ia. Oiam ........ ft ........ Jn. t..eaeth ...... ft ..... ..

CK.led 8' Spec:. No.) C1Un. of r*n1e 1peoiliecl)

12. seam*: Loe& .... '"(#;i<;;;cct>i 7:.Sl"q°ier"***** a. T. J_ ..........(Y;i**;;i;;)'............ x.R .........._............._................... Efficiency.. *****circ*iiisii"s)'

Gi.rt!a .........................._. .........- .............. 8. T. J...... - ... *.. *---***--***************** X.R .... ".... _ ................................. N'o. of Cou.raes ................*-*-

13. Heads: (e) Mattrial ............... _........... T.s ................... (b) Mat11iel *-...................... T.S ......... - ..... (c) Material .............. _ ........... !.s ............ -

Cro1n1 IUiuckle Elliptical Ccmi.cal Hemispherical Flat Side to Pr~u Locatioc 1(s) Top, bottom, (b) Cham1e1 eDds ............. _ ................

Radius Radiu* Ratio Apex A.Dile Radius Di.aautter (Convex or Coac1 (c) Floati111 -*****. . -!S_. .

1r~111ovable, 'boltt 11aed (a) ............................... _............. lb).-.................................. (c) ....................... _,_,Qther fs1tettia1 .. :**-***** ............._... .

Clil*'*ri411, IP*** Mo., T.11 .. IUle, Zlfllllllter) (C**i;Q* "r ettaeh 1lre

14. Couu,acttd ror Ip~-

0 Oaarpy I~ct ................ ft-U1 PlteumaUc Bydto.*ta&_ic Qf

}

Teat ~

°"'

c."'\J opwraUac pre*** ............. psi at Max. temp ............. F _ac iemp. of .................... OF Combuaatioa Prt**;:................. ..

Poeiwel4 H**i-Tr*aCed.

fll;et other lnt.l'ftel or *sternal pree1un1 witli coiaci.dea.t temperature *l\ea epplic:eble.

..,c:;g

EA-SC-93-087-01 Attachment 10 FORM :\-1 (back) Page 6 of 9

**-1 ':>*low to be complet*d !or all vessels whue ap;illcablt.

'ety Valve Outlets: Nwzab.r ** ..:.~:J.~.~............. -....... Size ........................... _..... Loca401:1 .....!£E...!t~.'!~..........................._._ .................... -

.sales:

PIU~ae (IAlet, Reid orcemea t How Outlet, OraiA) Nimhr Ciam. or ~n Type Material l'hiclaUIH JbteriMl AttAched

17. !n1ptctioa liaiibolta, No . ..... 9.'f:.~ ........ Si.ze ..........~~.:'. ....... Locatioa 1£-e... ~.~~~ ....................... ~..... ......................... -..... - .. -.....................

Opwc&s: Haadhol.,1, No ..................... Size ........................ Lcx:atioa ... _.. _, .............................._....... ... -.......................... ..._ .......................

Threaded, No ................. ~ .. Size ........................ Locatiou ,_, ........................................ ,__ ............................ - ................. _...... _

** ~e~ded co ~o:~o

18. Support&: Skirt, .....!~~............ L11,s .......................... L1g1 ............................ Other,_ .................... ~ ......... Attacbed ..... ~i!aC.. ...........................

(YH or No) (Nwaber) (:lumber) (Oucri?>.) (Wh*re Iii How)

P=essurizer to ~e used in the ~ri~ary system of a pre&surized ~ace~ ~uclear

19. Remarks: .........................................................................................._ .............................................- ............................................--*--********* ......... .

.. ................... .E.9.::.~E... E.*.~;)..£.: .....................................-.........................-.........................-............ _,_.-.. -........-...................... __ .......................

~

CERTIFICATION OF DESIGN

. . . Combustion :::i.gineering, Inc., Chat'tanooga, !ennessee Des1i111nCormauon on file at ._., ..................................................................................................................................................- *. ---................... _.

Stress 11ialy1i1 ntl)Ort on file 1t .... ~.9.r.'.IE.~.~-~J~.~ ...~2.~.~;.~~.;.~.~~}.. ,.f.~f.:..1:.. ~.~!~.S~.~~£~i.!.? .. J~~E'.~~.~~.C:. ........................................... .

,. L K i y ~ v O"c-"'o Oeslp 1peci!icatiou certified by ......~.:...... :. ......!E.~;7.~.~ .................................... Prof. En'- '\Y~*.;i.. " ........ State.:;:~ ..~.:-..~.- Rei. So.~*~*~*{~*~*-*

. ... .*. d"" Frank P. Hi... 1 pc.,._ .es st tre11 aaa l ys11 report ceni.1e .. y ......................................................................... ro ....... ,. **-*-.. -....... a e .............. - e *. ;-.0 ..... t -.en::i. R,,,., )1..1 ..

ti ertify tllal the atatemmlts made i.u this rtport art correct aAd that all del.lila of material, d"iip:i, coa1U'IZ~tioa, "d workma1u~ip o

_

vessel coaform to I.he ASllE Code Cor N~c:lear Vessels. *

Date ..l.!~1::..~U-JJ......... 1g j.?.- Si1tled.-...~:?.lJ:E.!-:~~l:?.n ...;FlS.!!:.~-~~!':L ..l:lS.:.. Sy .._ .* ~~*...c-"~ ............ !

H. N .,... . idd~

Certillcate of A11tbonzatioa

. . December 31, OIUD)iffQC:tUNr) J.~ /U E¥;nre1 ............ _ .. - .................... -**-***---* .......... - - -.......................- ...... .

~ * ..,i;iTJ -e CERTIFICATE OF SHOP INSPECTION VESSEL MADE BY ....... ~.?..::~~~.~~-~-:1.'...~.?..~.~::.:.~ ~.~~-~.:..-~.:'.'.7::. ......... _........... - ............,_ .......~.. at. ....<::.!°l~!:.~~.~!?.9.&~.1.-;-.~~:::.~.~.~.~-~.. ~.~*-

l, tbe -W\dersiped, holdi.ni a valid commission iasued by the National Soard of Boiler "d Pressure Vessel Tnapeetors and/or t!le Stat.

"".. ave U'lspecte

d'"'

of .............- ........................... asid eniployed by .4ii>:f..~J.9..;.~ .*. ~.~~-~~ .. R.~t~.~.~.~...~F:.~.P.:.... JP.~.:....~ *.............f:.f:E.~~2..'.~.!....£9.::':::.~;:.?.::..~;.

Janua:-v 12

... e pressure vesee ld esc:n'b e d'1n th.11 masi~ fac turer

s data report on .................................................................. :r<...... . a.a d 1,,:..o state that to the best of iny knowled&* 1Ad belief, th* manu!actlif9r hn coutructtd thia preuure vuul ia accorda:ice with I.he ASKE Code far N11clea: Vuuls.

By li!l;Di.ai thia ctrtiCicate aeitber th* IA1pector nor bi& emp!oyer mikes any warruty, u:presaed or implied, coucerui.tlg ?hi! ;iressiire vnu1 d11cribed iA this maDufacturer's data report. Furthermore, neither the !Zlspeetor aor his employer shall be liable ~i:. aoiy ~allnrr Cot my perso4-l inj11ry or property damn* or a loss of IAY kUld uisinc from or c:oaucted with this inspection.

Cite ......~.':!:l~ ...!.9.............- ..- .................. 19.9.~-**

~ational Board 2928

...9.n.:.r:f.\ ..9.71. ri£~~~*r:w; ..............................."... Commi11iocs .......................... - ............................................................... .

N'atlonal Board or State and No.

CERTIFICATE OF FIELD ASSEMBLY INSPECTION I, the 1'Adtrsip1d, holdlil1 *valid con11niuion issued by tbe NAtioaal Board oC Boiler aad Press1u*1 Veuel l.aspectors ~nd/or ~e S:att

~~~:;**~*~;~~-;;*@;*~..~~*~*;~~adi~m~ii'~~~i~~;;;;~;*d~t~**;;;,..rt ..;.;;*~...tb~~d~~~rib;d-p~*~*~*;~;;-~!!;*~i**;d-*~*;~~..tl;~~**;~*~~f~;;~d*~~-*~;

data items ..... ~ ......................................................................... - .............................. _., aot iGcludtd iA tile certificate oC shop i1is11ec tooo 'oa v beea U&spect~y me 1Dd. lh.t to I.he 'best oC my knowledr* and ~li*f the "l&Aufactu:er lias eoasi:ructtd an?4nembled :.bis. ~reuiir vessel ha 1cad*ace with th* ASME Code !or Nuc:lear Ve111l1. The duc:rib.d v1111l 1va1 insp*ctedc::a:ad subjected :o a !I.,.

atic test~ ................ ~ ... pai. . t"'U f Y *iilliAi ~ertific:ate neitb.or th* In1pector nor !\is employer ma Iles aay warraaty, ezpresaed or implied:' conc:emi..ni ~e ~reut1r veuel dHcr~ in this inanu!acturer'a data report. FurthenDON!, aeither the IAspector 11.or bia employer ~l be liable in lllY i:ian11e Car any peraOA&r"i.aJIUY or propert1 damaist or a 1011 of a!lY kind ari1in& from or couected with this iupectioa:--

Oate ................ -*-*-.. -.......... _.... - ................ 19..........

0:1

- - - - -**********************..************************************ Commi11ioa1 .......................................................................................... ..

Ohtlon.,l 8o&td or Ste\" iln.:l ~o.

Contrac Sh*.!Ct 2 of 2 FORM N-1 MANU.FACTiJRERS DATA FOR NUCLEAR V~SSiL Natl.. BD. ~o. 208.5 l.

ATTACHMENT SHEET

.... ~

DIAMF:TER REINFORCEMENT HOW PURPOSE .NO. PR SIZE TYPE MATERIAL 'THICKNESS MATERIAL ATTAcmm

~--::::::*-===;::::=.=~;:-r::r==~u==:!E..._E"*::J-E5*'~;£===:i~""!?"'":=::::c.~

.* ~.. -=***:::::--::.-:::*=*

--:..:5*::=::::--.-:'.:=* ~::::====*::::::**=* *=***~*.:;::-=1*~

.. -~--*rz=**~*~.--:=====r - - - *- ~;i==.";-=-=*=*=-**--~T::-:=--==,,_ """°!

~-::* -~;=;;/!&~? Vorg:-nr. LoS-64

=* **:&::!!:* ==. *

O\sse*WlY . 1 CL 2 1" l Inter.ml I Woldod --i Extension 1 10-1/2 11 I ._D Forging* SD-166 Inconel. 1-1/6 j Integral Helcicu I

!:;pray A-s-se-m~1b~,1~y-~-'-'-~--l--~--~-1--~~~---1-~---~---~-_~-i--~--~~l---~~-~~~-t-~~--~t I

I Body 1 Iw~! lcle<l Extension 1 I Hellied

~~---'*-~-t~~1~~---.__J1~-~~-- -

I'I Rclicf Valve --,

I r-B_o_d...::.y_ _ _ _ _ _ _ _...__l_ .,_'3_'_'_I_._D_._ _...._1 Poq~itig ,\-508-64 Cl. 2 I 1-17/32" Int;cr.ral

\,\~hied l SB-166 Inc_o_n_e_l~~-~-,~-lT_l_/_2_'_'~-+~-In-..:....tcr,ral II Extension 1 13" I.D. Farr.in&* I He Ldi" a

! I1 I

& 1-7/16" I.D -1 1/2" . Intecral \*.'cldt'!tl 13/6/t" loter.ral IHcldcd1 SJecves

+--------!

120 1.1~8" O. D. 'fut>ing . SB-167 In* e::..l:-.....*_ _ ___..__.....,1....,7""""'>11__ _-1 _ _} " Head

I-'~ '~---

120 1

B75" O. n.

Tuhinp, - _.<>_n-1~-~_Tnc~~cl __ _.JJQ.:._____ --~l~--------- ~~ciJ. ..*&~1a __

EA-SC-93-087-0l Attachment 10 Page 8 of 9

C.n-.)l..-1..)-\)CJ 1-\) L Attachment 10 Page 9 of 9 NB-3000 - DESIGN NB-JJJt NB*3300 V~EL DESIGN NB-3324.2 Spherical Sbelll NB-3310 GENERAL REQlJIREMENTS I ..

PR er ,,,._

PRO N

1 A is.. - P 2s.

The rcquircmenta for ac:ceptability of a vessel design are as follows.

(a) The design shall be such that the rcquiremenu B-3330 OPENINGS AND REINFORCEMENT of NB-3100 and NB-3200 shall be satisfied. NB.Jl31 General Requirements for Opeainp (b) The n.iles of this Subarticle shall be met. In case.o; (a) For vessels or parts thereof which meet the re*

of conftict between NB-3200 and NB-3300 the require- quiremcnts of NB-3222.4(d), analysis showing satis-ments of NB-3300 shall govern. faction of the requirements of NB-3221.1, NB-3221.2, NB-3221.3. and NB-3222.2 in the immediate vicinity of the opening!; is noc required for ~urc loading if the rules of NB-3330 are met.

SB*3320 DESIGN CONSIDERATIONS fb) For vessels or pans thereof that do not meet the requirement.~ of NB-3222.4{.d) so that a fatiiue analysis

~B-3321 Desian and Service Loadings i!i required. the rules contained in NB-3330 ensure sat*

The provisions of NB-3110 apply. isfaction of the rcquirl:ments of NB-3221.1. NB*

3221.2. and NB*3221.3 in the vicinity of openings.

and no specific analysis showing sati5faction of t~

NB-3322 Special Comiderations stras limits i~ required for Pfe$Sure loading. The re*

quirements of NB-3222.2 may ali;o be consid~ to The provisions of NB-3120 apply. be satisfied if. in the vicinity of the nozzle. the stress intensity resulting from external nozzle loads and ther*

maJ effects. includin1 1fOSS but not local suuctural dis-NB*3323 General Desip Rules continuities. is shown by analysis to be las than I .5S...

ln this case. when evaluating the requirements of NB-The provisions of NB-3130 apply except when they 3222.4(e), the peak 5b'eSS intensity re,;ulting from pres-conflict with rules of this Subarticle. In case of conftict. sure loadings may be obtained by application of the this Subarticle governs in the design of vessels. 5tn:ss index method of NB-3338 or NB-3339.

(c) The provisions of (a) and (b) above arc not in-tended to restrict the design to any specified section NB-3324 Tentative Pressure Thickness thicknesses or other design details. provided the basic stre5S limits are satisfied. If it is shown by analysis The following formulas are given a.o; an aid to the that all the stress requirements have been met. the rules designer for determining a tentative thickness for use of NB-3330 are waived.

in the desii"* They a~ not to be consmicd as fotmulas (d) Openings shall be circular. elliptical. or of any for acceptable thicknesses. However. except in local other shape which results from the intersection of a regions (NB-3221.2), tbe wall thickness of a vessel circular or elliptical cylinder with a vessel of the shapes shall never be less than that obtained from the formulas pennitted by this Subsection. Additional rcsaictions in NB-3324. I and NB*3324.2. in which: given in NB-3338.2(d) are applicable if the Stress In*

t=- tbicknea o( shell or head. in.

dex Method is .used. If fatigue analysis is not required.

P-::a Design Pttmure. psi

the restrictions on hole spacing ~ applicable unless R:::: inside radius of shell or head. in. there will be essentially no pipe reactions.

R,,= ouuidc radius o( shell or head, in. ( e) Openings are not limited as to size except to the S,,.* design stress intensity values (Section II. Part extent provided in NB-3338.2(d).

0, Subpart 1. Tables 2A and 28), psi (j) All references to dimensions apply to the finished dimensions excluding material added as corrosion aJ.

NB-3324.1 Cylindrical Shells lowance. Rules n:gardin1 metal available for reinforce-ment are given in NB-3335.

t ,,. PR or t=---- PR,, (g) Any type of opening pennitted in these rules S,. - O.SP S,. + O.,P may be located in a welded joini.

89

EA-SC-93-087-01 I

I ATTACHMENT 11 Code Reconciliation

EA-SC-93-087-01 Attachment 11 Page 1 of 8 All

AS!A !ROWN BOVERI October 19, 1993 Southeast Nuclear Service Center CSE-93*381 Consumers Power Co.

Palisades Nuclear Plant 27780 Blue Star Memorial Highway Covert, Ml 49043 Attention:

SUBJECT:

CONSTRUCTION CODE RECONCILIATION FOR THE

Enclosure ( 1 )

REPAIR/MODIFICATION OF TWO (2) PRESSURIZER TEMPERATURE NOZZLES Construction Code Reconciliation for Consumers Power Company Pressurizer Upper and Lower Temperature Nozzle Repairs/Mod ificatlon

Dear Mr. O'itf'wo..y,

The Original Construction Code associated with the original CE supplied Consumers Power Pressurizer is the 1965 Edition through Winter 1966 Addendum of the ASME Boiler and Pressure Vessel Code, Section Ill.

A code reconciliation Is provided as Enclosure 1 to meet code requirements in accordance with your Section XI program.

Sincerely, ABB COMBUSTION ENGINEERING f5;6C1 K. E.Coe

. KEC:gt SNSC Engineering ABB Combustion Engineering Nuclear Services 1201 lll...,.,rom' ~ TeleehOM ~151 752-2590 CNttariQOOa.ienneueoP4C2 TOii Free 1<<1Gin*56

EA-SC-93-087-01 Attachment 11 Page 2 of 8 ENCLOSURE 1 CONSTRUCTION CODE RECONCILIATION FOR CONSUMERS POWER COMPANY

PALISADES PRESSURIZER UPPER AND LOWER TEMPERATURE NOZZLE REPAIR/MODIFICATION In accordance with the Owners Specification "Engineering Specification for a Pressurizer Assembly, CE Specification No. 70P*001, Revision 2," the original construction code for the Palisades Pressurizer is the 1965 Edition through the winter 1986 Addendum of Section Ill of the ASME Boiler and Pressure Vessel Code (herein after referred to as the Original Construction Code). The ASME Section XI p*rogram at Consumers Power is governed by the 1983 Edition through Summer '83 Addendum

of Section XI (herein after referred to as the Section XI Code). This modification will be designed under ASME Section Ill rules and implemented under ASME Section XI, 1983 edition with Summer '83 Addenda.

Two instrumentation nozzles of (1 .3) inch diameter located in the pressurizer require modification to prevent leak paths due to axial cracks in the nozzle base material.

The subject nozzles are temperature nozzles, one located in the top head end the other located In the lower shell of the Pressurizer. These nozzles provide a pressure boundary and structural support for thermowells and RTD devices. The nozzles will be modified by welding to prevent leakage of reactor coolant. The original nozzles will remain in place. The repair/modification activities will be dona in accordance with ASME Section XI Code and provides for a weld buildup on the vessel outside diameter CSE-93-382

EA-SC-93-087-01 Attachment 11 Page 3 of 8 Page 2

(00) surface. No repair of the original nozzle attachment weld (partial penetration) on the inside of the vessel will be made. The weld buildup will be made to incorporate the nozzle OD surface and the OD surface of the Pressurizer to provide the aforementioned new pressure boundary. After the temporary repair weld is completed, the top head temperature nozzle will be severed between the original weld and the temporary repair weld to allow thermal expansion during heatup end coo Id own during normal operations. This modification/weld buildup will become the vessel pressure boundary for each nozzle.

This modification involves a repair activity in accordance with the ASME Section XI 1983 Edition with Summer '83 Addenda. Article IWA-4120 states that repairs may be performed in accordance with 0 later editions of the Construction Code, or Section Ill, either in its entirety or portions thereor or the rules of Section XI, IWB-4000 for Class 1 Components may be use.d alternatively.

The Section XI Code (Article IWA-7210) specifies that replacements shall meet the requirements of the edition of the Construction Code to which the original component or part was constructed, unless the following alternative is adopted Article IWA* 7210 (cl:

"(c) Alternatively, replacements may meet all or portions of the requirements of later editions of the Construction Code, provided that the following

r~quirements are met.

CSE*93*382

EA-SC-93-087-01 Attachment 11 Page 4 of 8

(i) The requirements affecting the design, Page 3 fabrication examination of the replacement are reconciled with the Owner's and Specification.

(2) Mechanical Interfaces, fits and tolerances that provide satisfactory performance are not changed by the later edition of the Construction Code.

(3) Modified or altered designs are reconciled with the Owner's Specification through the Stress Analy1i1 Report; Design Report,

or other suitable method which demonstrates the satisfactory use for the specified design and operating conditions, whichever is applicable.

(4) Materials are compatible with the installation and system requirements *.*

The discussion below addresses each of the requirements:

1. Becyjrement

" (1) the requirements affecting the design, fabrication and examination of the replacement (modification) are reconciled with the Owner's Specification".

CSE-93-382

EA-SC-93-087-01 Attachment 11 Page 5 of 8 Page 4 Discussion The Owner's Specification specifies the Original Construction Code as the i 965 Edition with Summer '66 Addendum of Section Ill of the ASME Code. The design, fabrication and examination requirements are 1pecifled In NB-30001, NB-4000 1 , and NB-5000 1 respectively.

A comparison of each of these requirements is provided below:

Oesjgo The design of the modification is consistent with the Original Construction Code, i.e., the rules of NB-3000 (N-400). The "Requirements for Acceptability" (NB-3211} for the design are met for this modification in ABB/CE Engineering Calculation No. CR-9417

CSE93

1121, Rav. 1, "Structural Analysis of Temperature Nozzle Weld Repairs For Consumers Power Palisades Pressurizer".

Eabrjcatjo.o There are no fabrication activities associated with this modification activity .

1The sections of the 1965 Coda for design are Article 4 (N-400), Article 5 (N-500) and Article 6 (N-600). The Articles correlate to NB-3000, NB*4000, and NB-5000 respectively in .current editions of Section lll.

CSE-93-382

EA-SC-93-087-01 Attachment 11 Page 6 of 8 Page 5 Exemlnatlon The examination of the Replacement Nozzles is being performed under the 1986 edition of ASME Section Ill, NB-5000 which provides current Industry acceptance criteria. This criteria is at least as restrictive 111 the requirements in the 1965 ASME Section Ill.

In light of the above, the reQuirements affecting the design, fabrication and examination of this modification are considered reconciled with the Owner's Specification.

2. Begyjrement

"(2) Mechanical interfaces, fits, and tolerances that provide satisfactory performance are not changed by the later Edition of the Construction Code."

pjscyssion Mechanical interfaces, fits, and tolerances are not changed by the use of Section XI.

3. Requirement

(3) Modification or altered designs are reconciled with the Owner's Specification through the Stress Analysis Report, Design Report, or other suitable method which demonstrates the -satisfactory use for the specified design and operating conditions, whichever is applicable".

CSE-93-382

EA-SC-93-087-01 Attachment 11 Page 7 of 8

Ojscusslgn The Design Report associated with this project is ABB/CE Engineering Paga 6 11 Calculation No. CR-941 7 - CSE93 - 1121, . Rev. 1, Structural Analysis of Temperature Nozzle Weld Repairs for Consumer's Power Palisades Pressurizer*.

This design report has analyzed and found acceptable this specific modification for the specified design and operating conditions of the Owner's Specification.

The modified design is therefore reconciled with the Owner's Specification.

4. Bcgujrement 11 (4) Materials are compatible with the installation and system requirements" .

Qjscyssjon The weld, pad is deposited with SFA 5. 11 ENiCrFe-3 welding electrodes as specified in ASME Section II, Part C. This filler material (F-43) Is compatible with both the alloy 600 (P43) nozzle and the vessel base material, SA-533 Grade B Class 1 for the top head nozzle and the A-1 O composition weld pad of the side shell nozzle.

The welding filler material, SFA 5. 11 ENiCrFe-3, conforms to the requirements of Section II and Ill 1986 Edition and is compatible with the materials being joined. This weld material (ENiCrFe-3) provides corrosion resistance in the primary water environment end meets the strength requirements for design under ASME Section Ill.

EA-SC-93-087-01 Attachment 11 Page 8 of 8 Page 7 The repair welds will be made in accordance with the requiramants of IWA-4300 of Section XI.

Conc!uajcio The preceding discussions show the requirements for reconciliation to the Original Construction Code have been met for this modification .

CSE-93-382

EA-SC-93-087-01 ATTACHMENT 12 TE-0101 Drawing

2 ~l L______ ~ ----- - *- ----*--- ~ -- - ***-* _ l!>______ *-- - ~- -- ------* J_________~ -*- --*- __j__ ---- ... - D-9417-C093-019 01 Added Sf'Ver between welds. f101ci~9J J.~

IDR [l(l)"'h' I0/1~/9J SMA J 4J 9J7 wos SJ..AA-J 4 }-918 Added rrn1!~ri<lls I

.Arldrd 06 CJGP di!llension wr OOl(JI

[OCR No C09J*OJ7 . !

02 rirn LUCR rJO.cogJ OJB: 1*0./1B/ 9 J J /\ Py.p.,J.l so MIN1.s2 MAX wAS .2sMrN1 Js J;~ qOu-

~~ ~

- --*----f~'-

MAX /Pf/'{.j't' 0

-*{6j~:@

THERHOWELL

PT ROOT ANO SST TYPE 316 '* FINAL SURF ACE

>*11, 1*8

- ~-*--~-~_1; EXISTING I" TEMPERATURE NOZZLE c c

-- --------- .-- SB-166

(

.50 MIN.

CERTIFIED FOR

) .62 MAX.

THICK WELD BUILD UP

<INCONEL 182)

CONSTRUCTION

~J PT FINAi. SURF ACE UT FINAi. BUILD UP

. VERIFICATION STATUS: COMPLETE 0

~~:..!:~!9~~~e~::d v~~~rr.d ~b~ ~0~...~°;:,: ::~; 01:'

1 1 1

--HEAD MATERIAi.'

SA-533 Gr- 8 Cl I 0.*1gn Rev1a" using Checkh*'tl*} ~of DAM-101.

N- d~ "'.)~,,_ S1gnotur-e (}:3e. d~-"-< Oat. '~/.e(._~

Independent Rav1ower-B ~--------------------

B UNLESS OTHERWISE SPECIFIED:

/ 1. TOLERANCES

.x - +/-.1 *

.xx - +/--01*

.xxx - +/--003~

ANGLES - +/-10' CHA~ERS - +/- l*

2. BREAfC. All I NTERNAl ANO EXTERNAL CORNERS WITH APPROX.

OJ* RAO 1US OR CHAt.FER J. MACH I NEO SURF' ACES TO BE 125 AA OR BETTER

... All DIMENSIONS ARE IN INCHES PRESSURIZER HEAD TEMPERATURE A

EA-SC-93-087-01 19* .....

NOZZLE WELD REPAIR ro*---*.,..,.

. , _ .. _t\lllltC>'I A

-~!'.!"!':.~"!"'-~~

llll!IW ITrVlt.l..Ji DATE* 10/t2/93 Attachment 12 D£lXUI IT1 ~JI 8~t.t DATE* lf!/11/f?

llf'F'RO'IED srt.J/l ,....,,.,of../ DAT[*l?1l/V TASK NO. 2003097 FU NIPEI ~fDlOlll~

ASEA BROWN BOVERI D-9417-C093-019 02 8 7 6 5 4 3 2

EA-SC-93-087-01 ATTACHMENT 13 TE-0102 Drawing

4 3 2 - - D-9417-C093-021 ~l

____s ___ ____l _______ 7.____ _l _____~------'----5-----"---

D

'- __ /'-- _____ __;~- .

.50 MIN

.62 MAX 5.5 MIN REF.-* THICK WELD BUILO-UP llNCONEL 182l PT FINAL SURF ACE c c UT rlNAL BUILD-UP UT, MT BASE MAT'l -R .18 MIN BEFORE WELDING-- -

--BREAK CORNER

-- SA-182, TYPE f-316

-THERMOWELL CERTIFIED FOR SST TYPE 316 EXISTING CONSTRUCTION VERIFICATION STATUS* COMPLETE

~.!:!:!°~~~oi::d . :.~}f-d1't,b~":°':-.ooo;~1';,9.'!_.!~ o~I*

Oca1gn R*v1ew uung Checkh1tf1I _L__ of aAH-UJI.

EXISTING I' Nw 4.A . ..t!'"'- S1~ett.r* gr..~ Onto 1 o/t .a/rJ TEMPERATURE Jndep.nden'l R....*1G.,.,.

-SB-166 NOZZLE B

B UNLESS OTHEA\lflSE SPECIFIED:

1. TOLERANCES

.x - +/-.1 *

-EXISTING P-3 WELD BUILD-UP

.xx - +/-.01 *

.xxx - +/-.003*

ANGLES - +/-10' CHA~ERS - +/- 3*

2. BREAK All INTERNAL ANO

~---- ---SHELL EXTERNAL CORNERS WI TH MATERIAL= APPROX *

03* RADIUS OR '

SA-533 G.- B Cl 1 CHAMFER

"-..,------\..._......-

3. MACHINED SURF ACES TD BE 1 25 AA OR BETTER

.!Ill. All DIMENSIONS ARE IN INCHES PRESSURIZER SHELL TEMPERATURE NOZZLE WELD REPAIR A A ~--~--.-M-~~-.---~----------l EA-SC-93-087-01 * ...,n......,_w_i.,.

- .. - l \ l l f c . 1 0Alf:010/15/IS Attachment 13 -~~'!"_!!_~~~

DElllD IT1 llS.ORltll DATt* 10/15/IS llf'PRMD 1T1J.A.lllllR4 DATt* 10/15/93 TA.SK NO. 2003087 fl.I Wll6 ~Sl BlO_<_o_ -c_~~-'

ASEA BROWN BOVERI 6 5 4 3 2 8 7

EA-SC-93-087-01 ATTACHMENT 14 Traveler 2003067-002

EA-SC-93-087-01 Attachment 14 P~c1 ffil l'tJ. 41 Attachment 4 PROCEDURE TRAVELER Revision 17 Page 1 of 2 tl~S7c.,me~*~ric,A..J £3).J'=-,~~*t...!G ;:J . . . cL..:,.it, suv1&.F-s ~-=uae. Ne. ZC1o:Jo~-r-ooz. ~

ocedure Tit 1e we:.i..o (..EP.411Z../trtcu1~1cn1cN ~r ege~wJ?1zr:g µcz.ues. - EOrrl fJe.ocss.s Procedure No )co*?of., 7 *()OZ. Revision No 0 Date Initiated 10J'zz,.Je;3 Sponsor cliuf ma 1'.1 I Return to Initiator By !O/z2/93 AlllQMC2 Acuvrtv Act1v1tv Comg1eted Ac11vrtv Penon Bv*

v'l Activrtv Re..,..wer Houn 'Print ~ 1me & *nit1111 Urgent Re11111on

/ 1 -

c.ht<<f /!!a ,*rt {ti,4, V I = Urgent Editonal t/v..Jb), J},~., 10/u1q3

'N Jr ~:.~;,~~::-* ~ ~""*:*.::::~~*-* -J\~i'. ** '

/ St8tt 08!8: I I Completion Cate: f () I Z.Z. I '/ 'J recnntctf R*vi!* *

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~ Aeealutlon:

eomrnem*= av...a:.No JU I Z.Zt .,3 IJ "Y" t t.J..,y~foj r-I I ~AJorJ ~1* 1 *'

A!.!AA f!lm!!

ColNMtlla: 0 YH 0 No Rellinw~:

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EA-SC-93-087-01 Attachment 14 Page 2 of 9 Procedure No. 2003067-002 Revision No. 0 Issued Date 10/21/93 PALISADES NUCLEAR PLANT MAINTENANCE PROCEDURE TITLE:

ABB-COMBUSTION ENGINEERING NUCLEAR SERVICES TRAVELER NO. 2003067-002 WELD REPAIR/MODIFICATION OF PRESSURIZER NOZZLE(S)

ELECTRICAL DISCHARGE. MACHINING (EDM) PROCESS

{Ur{/.

Colr~ /0 22 4~ 0 User Reviewer Date Rev #

EA-SC-':iJ-087-01 PALISADES NUCLEAR PLANT Attachment i4Proc No 3.07 SAFETY REVIEW Page J of 9 Attachment l Revision 7 Page l of l PS&L Log No

r----------------~

Item Identification: No 2003067-002 Rev ___

RAVELER: WELD o_ Title ABB c NUCLEAR SERVICES PAIR MODIFICATION OF PRESSURIZER NOZZLE -- EDM PROCEDURE SE Rev Describe Issue/Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING Reason for Issue/Change: PROCEDURE RE UIREMENT BY ADMINISTRATIVE PROC. 10.41 Yes No

1. Does the item involve a change to procedures as described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.a, 5.10 1 6.9, 7.4, 9.L TABLE 4-2L TABLE 4-22 x

2. Does the item involve a change to the facility as described ih the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5:11 5.6, 5.8, 5.10 1 6.9, 7.4, 9.1, TABLE 4-21, TABLE 4-22

3. Does the item involve a test or experiment not described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10 1 6.9, 7.4, 9.1, TABLE 4-21, TABLE 4-22

4. Should the Technical Specifications or any of their Bases be chanqed in conjunction with this item?

TS Sections affected ~N~O~N;E--------------------------------------~

TS Sections reviewed ~3_.~o..__4~*~0..___________________________________~

Justify No Answers below if loqic is not obvious:

Althouqh material removal under the ASME code is discussed in qeneral terms in the FSAR, the EDM process does not deviate from code acceptable practices.

If any Safety Review question listed above is answered "YES", perform a written USQ Evaluation accordinq to Section 5.3.

If all Safety Review questions listed above are answered NO, written USQ Evaluation i* not required. However, this Attachment shall accompany other review materials for the item to document that a Safety Evaluation wa* not required.

I 10/z.1 Jt:;~

Date

EA-SC-93-087-01 Attachment 14 Page 4 of 9 Jl 1111

,.,11119 ASEA BROWN BOVERI Cerra-.&..-. .......

FIELD CHANGE NOTICE FCN NO. 2003o<o}oos= DATE ;

/0-22..-93 DOCUMENT NO. D-~~l'Y-Ca93 -019 REV. NO. O 2-.

PAGE _......._........_....._ __________ -~=----------

STEP I PARA NO. 2 0416 G * (e DESCRIPTION OF REQUESTED CHANGE:

4cld:'A.Jore : Re'Z.tAir-es Q. ~oT l'o e...x.c.12.eq ).!j"91?/eJ1Jt {~;c.kiUe.ss or .055"/\1'9)(. flAJD /9-_jroov-e de.p'!:J.i af:' .:<_Oo" htOJ,"

D<!) !UcT SE VER..

SEE f;; ~ o ..<.. "tl, ;.s Fe.tu T>/~f';s1.Jt1 w~tLL b~ f"6V~ c;d - k ~

REASON FOR CHANGE:

To R.ef:'lect R-e'/..llir-c.>1'1e.N1.S of. ?1+/;sl4P5 ;{)<.ic..leJ4r-Pl.>9AJT SPee.i ~.*c1111.* o.c.J Ch14~-e.. f!JC.k~-e #Cf 3 0 ~ j APP~D BY: ~ - i

~ r,~ 11/49.~;;J;Hj;J?W REVIEWED AND RELEASED BY: .

~ nAI 1J-zz~~3 rg;f aJ. m~ 10/zz.-/9__75 Task Manager

~ - /YJ Date C~ent Reprpsenta~~/

/ip"prtN~ .~ '-t< -et"a-1 (,V 10

oate 1-,.-... /<. L 8 I.A._ /t: .iZ b ~vLAif r USfitY9Presentative Lo-27-.-92.

Date -

C?£w. maC7 'o!!-

Author}Zed Inspection Agency

._,19.3 Date

QO FClll (2/91)

- --- -------T-HE_R_M_O_W_E_L_L_~------;-~-\:'--=:p~fii!!R!::050;iiT~AiiN~--.

SST TYPE 316 _ ~ FINAL SURFACE

~ EA-SC-93-087-01

) 1/ 4 V ~ Attachment 14 Page 5 of 9

A-182 _TYPE F-316-------- ~----;~ EXISTIN TEMPER1 NOZZLE

.06 GAP R .18 MIN AT FIT-UP BREAK CORNER 019-01

--.i.__0 2.5 MIN 04.0 MAX

.50 MIN.

--.62 MAX.

THICK WELD 8 CINCONEL 182)

PT FINAL SURI UT FINAL BUil HEAD -

.12 APPROX. SA-533 1ATERIAL IG I 1 APPROX.

fl.dd Pc:.- Fc!V ;i_poJo" 7-00S

/Joie: f<ielV\;i--cs a. JJ~TTb.ExC.eE.DLiJl'fmeAJi "ti,; c.k t\.).ess- (!) ~. 0~5 ,, M.4,A' 17-#J D ft3 roove.. ,

de.pt~ 0 ~ * ~CJo "llliAJ .. Do ,.()or 5-e11er-.. /

ABB-COMBUSTION ENGINEERING PAGE 1 OF 4 NUCLEAR SERVICES REVISION 0 EA-SC-93-087-01 TRAVELER NO. 2003067-002 DATE 10/20/93Attachrnent 14 Page 6 of 9

WELD REPAIR/MODIFICATION OF PRESSURIZER NOZZLE UTILITY: CONSUMERS POWER COMPANY SITE: PALISADES NOZZLE NO.: PRESSURIZER NOZZLE REPAIR 1.0 TABLE OF CONTENTS AND LIST OF EFFECTIVE PAGES:

CONTENTS PAGE NO.

COVER PAGE 1 0 REFERENCES 2 0 PREREQUISITES 3 0 PERFORMANCE 4 0 APPROVED BY: ~

~<{~ tna~

TASK MANAG~ DATE

~-11/aQ 10/z.1/q OWNER REPRESENTATIVE DATE 3

g'fot~J ftpY ..fel~c~ w~ KL Bla.~e UA I PR.ESENTATIVE DATE A~ORIZED I~ECTION AGENCY DATE

~a cLJw.m~ ,0;~2/13 1*-2'-'IJ NEERING DATE

ABB-COMBUSTION ENGINEERING PAGE 2 OF 4 NUCLEAR SERVICES REVISION O EA-SC-93-087-01 TRAVELER NO. 2003067-002 DATE 10/20/93 Attachment 14 Page 7 of 9 2.0 REF!RENCES 2.1 ABB/Combustion Engineering Dwg. No. D-9417-C093-019, Rev. 02. (~

~..(izvei...ce s=:'CN 4= ~'3o4:>(-005 -~ o.ckia.I ~c ~..:..1~ c:"'-+- ,...""~'-' 111-wi~"-+<-.:. .._

2.2 ABB/Combustion Engineering Nuclear Services Quality Assurance ,

Manual, QAM-100, Fourth Edition, Rev. 1. ~i*( /"*3

?'!- ....,

/0 / ~

2.3 Instruction Manual: Pressurizer; Consumers Power Company -

Palisades Plant.

2.4 ASME Code Section XI, 1983 Edition, Summer 1983 Addenda.

2.5 ASME Code Section II and III, 1986 Edition with no Addenda.

(Materials) 2.6 ABB/Combustion Engineering STD-100-207, Rev.a.

2.7 ABB/Combustion Engineering O.P-9.5. Rev. 9.

2.8 Designated sign-offs/abbreviations in this traveler shall be in accordance with tne* following legend.

S - Supervisor/Worker Q - Quality Operations 0 - Owner/Client A - Authorized Nuclear Inspector W- Witness I - Inspect H - Hold MPE - Magnetic Particle Examination UT - Ultrasonic Test WIR - Weld Inspection Record LPE - Liquid Penetrant Examination UTE - Ultrasonic Test Examination ROI - Report of Inspection

ABB-COMBUSTION ENGINEERING PAGE 3 OF 4 NUCLEAR SERVICES REVISION 0 EA-SC-93-087-01 TRAVELER NO. 2003067-002 DATE 10/20/93 Attachment 14

Page 8 of 9 3.0 PREREQUISITES 3.1 All required personnel have received training in Quality Control, Radiation Control, and Al.ARA procedures and have been trained in the work tasks to be performed.

3.3 Special tooling is on hand in sufficient quantity for the intended program.

3.4 Scaffolding at the pressurizer where work is to be performed has been erected, if required.

3.5 Insulation has been removed.

3.6 Provide a system of tool and material accountability for all items entering the primary system, if applicable.

3.7 Install water plug,if required .

_J

ABB-COMBUSTION ENGINEERING PAGE 4 OF 4 NUCLEAR SERVICES REVISION 0 TRAVELER NO. 2003067-002 DATE 10/2of91\.3SC-93-087-01

Attachment 1~

Page 9 of 9 STEP NO.

4.0 PERFORMANCE 4.1 Verify satisfactory completion of prerequisites. s w ___

Q w____

0 REMARKS: A 4.2 Setup EDM equipment per the requirements of Ref. s H ____

Ref. 2.6. Q EDM machine settings shall not exceed the following: 0 Amperage- Shall not exceed 30 Amps. A CAUTION: Any time the. EDM equipment is not operational make sure the D.I. water source is shut off to minumize the dilution of the primary water.

NOTIFY SHIFT SUPERVISOR PRIOR TO PUTTING WATER X~

PRIMARY SYSTEM AT EXT. 0225/0252; SS. _ _ _ _ _ _ _ _ __

name/date

REMARKS:

RETURN TO TRAVELER 2003067-001 STEP 4.22 FOR INSTALLATION OF THE THERMOWELL

EA-SC-93-087-01 ATTACHMENT 15 EDM Procedure

EA-SC-93-087-01 Attachment 15, Page 1 Pree No 10.41 12 Attachment 4 PROCEDURE TRAVELER Revision 17 Page l of 2 ocedure Title PtulcE"tx't-E.. fOrz Et.ECT'f!!l{A-L.. D, 1;n+pee;;.~ .Nf4of1J.J1t-.J6 P2e. ~cz-z~.

Procedure No Srr:J-100-z..07 Revision No CJ Date Initiated Jo/zz./q~

Sponsor L {u;.j) ma. ~ 1 Return to Initiator By 10/zz/95 I

I A111gned Act1vn:y ActMtV Cam;1eted Act1vn:y Per1on Bv*

IV') Activity Re,,..wer Haun :Print ,..,.tm* & 1ri1t1111 v7 = Urgent Editonal N ~ ~*==-~~=:. -M =.....:,::~::.~,:-" - -~l::

/ or*n O*xmamem eomD:;: ~::; 10 ; ;~ ; 9 3 !!!11\1[.lll~,f!lllJ,[~r~ . . . *.................. *****~*~*****

j-erft ~d "I Ttchn!sf! Rtvifw

Comment*: a v .. s No

! I

,(

\.-/ Review Comoi.tM:

Comment ReecMution:

/u (l..2 I '1'~ ~ardb I~

"LARA Rtmw*

Co~: CJ YH CJ No Review~: I I e o - t Anolutioft:

Envin!nm!ntlf Atftw

ColftlMntl: CJ YH CJ No Review Co"""9nd:

CoftWNftt Reeoluborl:

U!!! f!ty;tw*

~Ill) ~yHolJ.S p;¢U L jz...f ,,vrJ Commenn: CJ Y** CI No CI v.. CI No I I

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EA-SC-93-087-01 PALISADES NUCLEAR PLANT Attachment 15 Proc No 3. 07 SAFETY REVIEW Page 2 of 12 Attachment 1 Revision 7 Page 1 of 1 PS&L Log No Item Identification: No STD-100-207 Rev ___o_ Title PROCEDURE FOR SE Rev LECTRICAL DISCHARGE MACHINING EDM PRESSURIZER NOZZLE SEVERING Describe Issue/Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING Reason for Issue/Change: PROCEDURE RE UIREMENT BY ADMINISTRATIVE PROC. 5.06 Yes

1. Does the item involve a change to procedures as described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.a, 5.10 1 6.9, 7.4, 9.1, TABLE 4-21, TABLE 4-22

2. Does the item involve a change to the facility as described in the FSAR?

FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, *5 .1 1 5.6, 5.a, 5.10 1 6.9, 7.4, 9.1, TABLE 4-21 1 TABLE 4-22 x

3. Does the item involve a test or experiment not described in the FSAR?

FSAR Sections affected NONE FSAR s'ections reviewed 4.3, 4.4, 5.1, 5.6, 5.a, 5.10 1 6.9, 7.4, 9.1, TABLE 4-21 1 TABLE 4-22

4. Should the Technical Specifications or any of their Bases be changed in conjunction with this item?

TS Sections affected ~N~O~NE=-----------------------------------------

TS Sections reviewed ~3~*~0...__4~*~0..____________________________________

Justify No Answers below if logic is not obvious:

Although material removal under the ASME code is discussed in general terms in the FSAR, the EDM proceas does not deviate from code acceptable practices.

If any Safety Review question listed above is answered "YES", perform a written USQ Evaluation according to Section 5.3.

If all Safety Review questions listed above are answered NO, written USQ Evaluation i* not required. However, this Attachment shall accompany other review materials for the item to document that a Safety Evaluation was not required.

(Z,(fy. tllaJ::J I 10/~1 /q3 Prepared By D'ate ' Date

EA-SC-93-087-01 Attachment 15 Page 3 of 12 Procedure No. ST0-100-207 Revision No. 0 Issued Date 10/21/93 PALISADES NUCLEAR PLANT SPECIAL PROCESS PROCEDURES TITLE:

PROCEDURE FOR ELECTRICAL DISCHARGE MACHINING (EDM)

PRESSURIZER NOZZLE SEVERING Date 0

Date 0

User Reviewer Rev #

EA-SC-93-087-01 Attachment 15 Page 4 of 12 Jl 1111

,.,191 ASEA BROWN BOVEAI C'AINlulllll ~ ~ ....

FIELD CHANGE NOTICE FCN NO. 2003o<oJoo!T DATE ;

/{)-;}.2--9..3 DOCUMENT NO. D-94'1'7-C093 -019 REV. NO. 02...

-=--=------------'--

PAGE 6

4z

---..-.....------------ STEP I PARA. NO. 2 0416 DESCRIPTION OF REQUESTED CHANGE:

,L/j,J:'A.Jore : Re't.t.1 1r-es Q. AJoT l"o e.xc.ee.q ).i)--9/7/BAJt {~;c.k,..,ecss o.f' . 055 /\1~)(. r1AJD 19--3r-~ov~ dep"t:>,

11 "t .2,0o" .1r11..v,"

Dd) /\Jcl SE //£R..

SEE f9 ~ o ..<. "tl, is, Fc.f0 JJ,~,'6011 w~~.L- b~ rc-vK. CJd - k -

REASON FOR CHANGE:

To R, e ~le t:t R-ei<Jir-c. h'!eAJ1.S o}. ?1+/i s ,q.r:>e S t<Jt(c..leJ4r PlJ9AJT SPee( ~.*c~;,* oAJ Ch14~ flJC.k'!:f-e :i;:9'3 O '8 /

R. p.~ /?7H6 APP~D BY: ~

i

~~ /Vdl (J?l.I() .

REVIEWED AND RELEASED BY: .

~ ndJ IJ-zz~~3 rg:J'UJ. ma;_O 10/z~h_:s Task Manager Date Cj\ent Reprpsentati\j! f pate r;9 - /Y1 /fpprtN<<{ . ~ 'f< -eta-1 10 W l""f"" /<.. L 84 Jc~

. ~Vf..,JRif t_o-ic-9; C4fkJ*n1ae7 10/l.i./?3 (lJafity8i)resentatlve Date. Author;zed Inspection Agency Date FCJI (2/91)

THERMOWELL ~

p;.*~~OT AN SST TYPE 316 _ ~

>1/4 v & I

/

/ FINAL SURFAC EA-SC-93-087-01 Attachment 15 F-316~

Page 5 of 12

A-182 TYPE

~--1~ EXIST IN TEMPER~

NOZZLE R .18 MIN .06 GAP AT FIT-UP BREAK CORNER SB-166 019-01

-..c..._0 2.5 MIN 04.0 MAX

.50 MIN.

--.62 MAX.

THIC'.{ WELD 8 (INCONEL 182)

PT FINAL SURF UT FINAL BUil

.12 APPROX. HEAD

SA-533 1ATERIAL G

I 1 APPROX.

EA-SC-93-087-01 Attachment 15 Page 6 of 12 jl 1111

~1\1919 ASEA BROWN BOVERI ClllMllllaa ~ - - , _

FIELD CHANGE NOTICE FCN NO. 2oa3o0l oot.t DATE._ _ _/_/-_~_z:_-_~-=>3 _ _ _ __

DOCUMENT NO. 5/Z) - /0 ('),... Z tJ J REV. NO. _...;;;0;.___ _ _ _ _ _ __

PAGE §_TE~/ PARA. N0._5.-=-i-.3~3.....___ _ __

DESCRIPTION OF REQUESTED CHANGE:

u~le h ~k,P ~ !38.

REVIEWED AND RELEASED BY:

~fu.)~O 1ofai,/cts Client Representative Date a~ /o--Jd-9-3 Date Authorized Inspection Agency Date FCN (2/91)

EA-SC-93-087-01 Attachment 15 Page 7 of 12 Jl 1111

,.,191 ASEA BROWN BOVERI

~~--

FIELD CHANGE NOTICE FCN NO. 2. 003o b '7 - oo<<G DOCUMENT NO. S!D - /tJ1) - Z'OV/ REV. N O . - . : . : : : . . . . - - - - - - - -

PAGE _....._f___._~_5

_ _ _ _ _ _ __ STEP I PARA. NO. 7J. I Cf

5: ,.3 ()

DESCRIPTION OF REQUESTED CHANGE:

0 !z:,.-p 5.'fq; 5.30 (!h~E" /V()fc h riead.

AJo ~ .* bv A.Jo f eut tdw~ ~ /tff?lp~ :

APPROVED BY: f4- ~ 'J-1 UO-t:J~ /0

7 7

~~ REVIEWED AND RELEASED BY:

/I - 'Z "Z. --9_ U0f!u. fllaO 10Jz~/q3 Date Client Repr9sentative ' Da!Et

1-pp;ov~d P.-Y' J.e {~cuY\ VJ .-ttA i<' L. Bl ~\!.-e Io/~ '?.../q 3 Author,iZed Inspection Agency ,,.1 ~te

()~ uI Yh~

I o/-i z,/q3 .

TO 916167S4a2sa ?.a 1 EA-SC-93-087-01 Attachment 15 Page 8 of 12 PROCEDURE FOR ELECTRICAL DISCHARGE MACHINING (EDM)

PRESSURIZER NOZZLE SEVERINO STD-100-207,REV. 0 PREPARED BY: /}L 4 4~ .: DATE:/~.f COGNIZANT SUPERVISOR APPROV~ e..,

DATE: /~/fef

/f:f.3 PAGE 1 OF 5

llCT-19-lq_q_....,J

~ le:;_: ri_c:;_ FPr_,M -BB ~-"E Chattanooga H TO 316167S482Sa ~.a2 STD-100-2r:r7, Rev. 0 Page 2 of 5 EA-SC-93-087-01 Attachment 15 Page 9 of 12

1. 0 Q&JEC'J]YFS

1. 1 This document sequences the steps required for electrical discharge machining (EDM) of l" pressurizer nozzle in the area of the nozzle between the I.D. and O.D. of the pressuri:zer shell. This al.lows for the removal of material in a manner so as to limit the debris from entering the pressurizer and reduce the total manrem for the project by controlling the process remotely. Both copper tungsten and graphite electrodes may be used foi' this process.

3.1 The followin1 services are available:

A. 480 V AC 3 phase (30 amp lines).

B. Demineraliud wattt 00 psi minimum.

C. 110 V AC 20 amp 4.0 PRQCEDt,TBE 4.1 The EDM Control Cabinet and Power Supply should never be left unattended in the enqi.zc:d mode.

4.2 Ensute that the "Ram Mode* switch is in the "Edp" position any time the tool a~m~

4.3 Do not operate the EDM tool without operatin& DI water flush system.

4.4 If any step cannot be completed because of equipment failure, or some other cause, inform the CB shift supervimr.

5.0 OPEBADONAL PBngmpp;

! .1 Visually check the.. cables, fixtures, and holes for any obvious damage and be sure all connections are secure.

316167648258 P.03 STD-100-2(]7, Rev. 0 Page 3 of 5 EA-SC-93-087-01 Attachment 15 Page 10 of 12 5.2 Install a new electrode in the EDM Toolin1 He.ad.

NOTE: Electrode is to be positioned such that the electrode is centered in Delrin wand and the D.I. water connection is rotated to its outennost position referenced to the Delrin wand. This is O" Ref.

5.3 Install the tooling holder such that ihe two 1/4" holes are facing the center line of the pressurii.er.

5.4 Install the De1rin wand into the no7.Zle with 00 Ref. aligned with the pressurizer and center line.

5.S Adjust the tooling holder such that the two 114* holes are centered in line with the two set screws which are used to lock the electrode shaft.

S. 6 Install eccentric couplin& on, electrode shaft.

S. 7 Install eccentric motor mount to the tooling holder.

s. 8 Rotate the eccentric couplina such that the couplina is aliped to the center of the motor mount.

S.9 Install motor to motor mount and eccentric couplin1.

NOTE: Motor shaft and electrode shaft must not be in contact.

S.10 Ti&hten set screws in the eccenttic coupling to the motor shaft and the electrode shaft.

S.11 Recheck connections at the toolin& head.

S.12 Sugested EDM para.met.en.

Saw Up Mode Auto retract (during cut)

Edge (stand by)

Servo Speed 3-9 Gap Adjust 3-9 Ram Cycler Off Ram Feed Neuual Gap Initiation lSO Leadl 1 or2

Electrode Metallic - 2 Polarity Neg.

Peak Current Full

TO 916167648258 P.a4 STD-100-207, Rev. 0 Page 4 of 5 EA-SC-93-087-01 Attachment 15 Page 11 of 12

5.13

~On Time Arc Duration capacitor Mode 20-90 128 Off Tum the EDM machine on while the Ram Mode switch is in the edge position.

5.14 Start D.l. water flow to the electrode.

5.15 Check Edge Mode by shorting between negative and positive, alarm on power supply should sound.

5 .16 If the electrode is in contact with the nozzle, the edge alarm will sound. Do not tum to auto retract until no ala.rm sounds.

5.17 If edge alarm is sounded due to electrode contact, adjust electrode to a position that does not cause an alarm.

S.18 Tum mode to Auto Retract, press machine on and check that electrode is not shorted*

- 5.19 Open hydraulic line valve to begin cut and adjust control parameters for best

~

o NOTE: Do not cut above..J4'"amps.

Cu/II 10/.,,i-/q3

~e FCN

~

200 sor;;,7 -oo~

S.20 Continue cut until complete or operator deems it necessary to change to new electrode. If new electrode is needed, repeat steps for electrode installation.

S.21 After eccentric cut is complete, remove electrode toolina and .install new electrode which is approximately .20" thinner. Installation steps are same as for 1st electrode up to Step !5.6.

S.22. InstaJJ concentric couplin1 to the electrode shaft. Do not ti&htm set screws.

S.23 TnstaJJ concentric motor mount to the tooling holder.

S.24 Rotaae electrode shaft approx. 135* in a clockwise dhection. This should move electnxle into the eccentric slot.

S.25 npten 2 set screws throughDelrin wand to fix.electrode shaft at 13S".

S.26 Install motor to the concentric motor mount and the concentric couplin1.

TI&hten couplin1 set screws. /

5.27 Recheck connections at the tooling head.

TO 3161676~s2s 8 P.as STD-100-2<J7. Rev. 0 Pages of 5 EA-SC-93-087-01 Attachment 15 Page 12 of 12

S.28

5. 29 If the edge alarm sounds, slight adjustment of the electrode may be necessary before beginning cut.

Turn mode to Auto Retract, press machine on and check that the electrode is not shorted.

S.30 Open hydraulic valve to begin cut and adjust co~trol parameters for best cut.

!J (~

NOTE: Do not cut above,. amps. i o/z,i/ci? 5*e-e f{f./~-200 30'-'7- ocb S. 31 Continue until cut is complete or operator deems it necasary to change electrode. If a new electrode is needed, repeat steps for electrode installation.

5. 32 H anothet" concentric cut is required repeat stepS for concentric cutting but use an electrode .20* thinner than the electrodes used for previous concentric cut.

NOTE: Graphite cutters may be used for last cuts.

After cut verification disassemble and rmnove equipment from containment.

/

EA-SC-93-087-01 ATTACHMENT 16 ASME Code Interpretation IX-1-89-70

EA-SC-93-087-01 Attachment 16 Section XI - Interpretations No. 29 XI-1-89-69, XI-1-89-70 Page 1 of 1 Interpretation: Xl-1-89-69

Subject:

Section XI, IWF-1300 and Table IWF-2500-1; Component Support Examination Boundaries (1980 Edition With Addenda Through Winter 1981)

Date Issued: February 15, 1991 File: IN90-027 Question: For a nonintegral support whose boundary is identified in IWF-1300(c) with no mechanical connections buried within the insulation, is it a requirement of Section XI that the examination be extended from a mechanical connection to the surface of the pipe, therefore, re-quiring removal of the insulation to complete the visual examination?

Reply: No, if there are no examinations required per Section XI, Table IWF-2500-1, then removal of the insulation is not required.

Interpretation: Xl-1-89-70

Subject:

Section XI, IWB-4212; Material Removal Process - Nonwelded (1983 Edition With Summer 1983 Addenda)

Date Issued: February 15, 1991 File: IN91-005 Question: If electric discharge machining (EDM) or metal disintegration machining (MDM) are used on P-8 or P-43 materials, in an area where defect removal or repair welding is not required, does the requirement of Section XI, IWB-4212, for additional material removal apply?

Reply: No.

233

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References:

References:

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