ML20058K140
| ML20058K140 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 02/20/1990 |
| From: | Shelton D TOLEDO EDISON CO. |
| To: | NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| Shared Package | |
| ML20058K143 | List: |
| References | |
| 1768, NUDOCS 9003020254 | |
| Download: ML20058K140 (77) | |
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DONALD C. SHELTON u.c.nm w
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' Docket Number 50-346' License Number NPF,
Serial Number 1768 1 February 20, 1990 f
United States Nuclear Regulatory Commission Document Control Desk Vashington, D. C. 20555'
- Subj ec t
High Pressure Injection / Makeup Nozzle and Thermal. Sleeve. Program Gentlement-The'purpote of this letter is to docLment'two recent meetings with the NRC-Staff'regarding-the High Pressure Injection (HPI)/Hakeup_ nozzle program at G
' Davis-Besse Nuclear-Pover Station' Unit 1 (DBNPS).. A meeting to discuss-the
-developrent~of-enhanced ultrasonic testing (llT).for'the HPI/Hakeup nozzle was held'authe B&V Nuclear Service company (B&W) of fices. in Lynchburg, VA on
. January 18,fl990. -Another-meeting relating to Toledo Cdison's November 8,
_1989: request 1(letter Serial Number 1726) for NRC approval of veld overlay, if repair.of the HPI nozzle is necessary, vas held on' January 24, 1990'at the NRC of fices in Rockville, MD.' -Enhanced (TT of the HPI/Hakeup nozzle during the.
sixthitefueling outage'-(6RFO).is one of the'follovup activities resulting from
-discovery of the1 failed HPI/Hakeup nozzle thermal sleeve during-the fifth tefueling outage-(5RF0)..Since'3RF0, teveld overlay: design has been developed as a contingency should the enhanced UT disclose flavs necessitating tepair of' the no'zzle.
W. The1 thermal, sleeve,' which:had failed due to thermal' fatigue, allowed makeup -
4 vater lto impinge on the mouth of the nozzle.
Liquid _ dye penetrant._(PT)
,i
, inspection of'the nozzle revealed indications inLthe cladding in the. area
~
f vhere the thermal sleeve-had failed.
The manual UT examination performed at:
- that; time found no' evidence,of the 'i.lavs extending into the base metal.
Conservative analysiss indicated that signifIcant flav growth was not'expacted vith'an effective thermal' sleeve in place. The' failed thermal sleeve vas replaced,; minimum makeup flov'va. Increased, and control over makeup _flov vas
. improved to reduce thermal' cycling of the thermal sleeve. The NRC approved-c?'
restart'and operation for one cycle based on these actions and required Toledo i
. Edison to-identify follovup actions for 6RFO. Toledo Edison's June' 19, 1989
. letter-to the_NRC (Serial Number 1664) identifled planned actions for 6RFO.
jDR003020254 900220 ADOCK 05000346 p
PDR THE TOLEDO EDtSON COMPANY EDISON PLAZA 300 MADISON AVENUE TOLEDO. OHIO 43652 "J
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. 9 i* Dock 3t N'usbsr 50-346
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License Number NPF-3' 1
Serial Number-1768) 4 "2
Page 2 a
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?{l6 The 6T.FC-actions include re-routing ~ makeup flov to an-alternate HPI nozzle,
~
're inspec~ tion of the-thermal sleeve, and development of an enhanced UT technique to inspect the HPI/ Makeup nozzle and the alternate nozzle.
Although-Toledo Edison does not expectithese inspections to discover indications in the thermal sleeve or flav growth in the nozzle, plans for thermal sleeve i
replacement and. veld overlay repair of the nozzle have been developed as contingency measures, t
On1 January 18, 1990, Toledo Edison and B&V representatives met with the NRC Staff at the B&V offices in'Lynchburg, VA to review results of the. development program for enhanced.UT examination for the HPI/ Makeup nozzles.
This was a-follovup to an October 1989 meeting and the last planned for the enhanced UT development program.
A copy'of the meeting hendout and list of attendees is attached--(Attachment 1).
1The background relating to failure of the thermal sleeve and discovery of'PT indications in the nozzle was reviewed, and the intended use of UT data in nozzle structural evaluations to justify continued operation was explained.
The development program and results vere summarized and related to the intended use..It was shovn that the system can reliably detect flavs penetrating into the base metal by more than 0.125 inch which is well belov tne depth _vhere structural: integrity of the nozzle vould be compromised.
It was also shovn that flavs in most of the volume of the nozzle and adjacent reaccor ct'lant-piping can be adequately sized using time-based techniques.
However, lfor a small' zone inside the mot ti? of the nozzle, time-based' sizing of 1
1 axially-oriented flavs proved to be impractical and amplitude-based sizing was performed.
Should flavs be detected in this zone, locally augmented sizing
-technigtes vill be employed.
Mr. T. T. Taylor, of Battelle Pacific Northwest
- Laboratories ~(PNL), the NRC consultant, did not express any major concern with this approach.
j
=During the course of the meeting, Mr. Taylor' presented his evaluation of B&V's
" scanning results on-test-blocks previously supplied by PNL..The examination resulted.in 100 percent; detection of the flaws with_no unflawed locations reported as containing flavs.
Initially, it was_ thought that two flaws were reported.in one of the blocks that PNL' records indicated as having no' flaws.
- Following'the meeting, removal of the backing plate from the test block and close inspection revealed'the presence of two notches in the locations reported by B&V. These notches had apparently.been machined in the block and not recorded.
~
Based on the enhanced UT development program results, comments received at
'this meeting and in subsequent conversations with the NRC Staff, Toledo Edison conclude that the use of enhanced.tTr to assess the structural integrity of the HPI/ Makeup nozzle is' acceptable to the NRC.
As requested by the Staff a
' report documenting the results of the enhanced UT development program is being-prepared and' vill be' submitted under separate cover.
)
Dockot Nu:bar 50-346-License Number NPF-3 Serial Number 1768; Page-3' l
On~ January 14,:1990, Toledo Edison's' consultt3t, met with the Staff atToledo Edison and Structural Integrity Asso the NRC offices in-Rockville,-MD, to' review Toledo Edison's November 8, 1989 request (Serial
. Number 1726) for-NRC approval of veld overlay repair methodology for the
- HPI/ Makeup nozzle.
A list of attendees and copy of the meeting handout are attached (Attachment 2).
Toledo Edison had requested this meeting to resolve any St.aff questions regarding the fracture mechanics analysis used to determine the allovable flav
-size and-the' basis for the veld overlay design.
Toledo Edison does not expect the enhanced UT to discover flavs in the HPI/ Makeup nozzle necessitating a veld overlay repair.
However, in the event that a repair-is indicated, expeditious NRC approval for veld overlay vill be required to prevent delay of
-t the refueling outage schedule. A vindow of approximately eight veeks exists
- l Lbetween completion of the UT and planned refilling of the reactor coolant system.
The veld overlay meeting opened with a brief overview of the history of the HPI/ Makeup nozzle thermal sleeve issue and actions planned for 6RF0.
The Staff members present indicated their belief that the driving force for the flaws intthe cladding observed during 5RF0 vas thermal fatigue induced by the
-impingement of cold makeup water on the nozzle during the period of operation with the failed thermal sleeve.
The Staff indicated that NRC approval for restart from SRF0 was based primarily on replacement of the failed thermal sleeve, thereby protecting the nozzle from the effects of impingement of cold makeup _ vater.
The Staff indicated their belief that, with an intact thermal
-sleeve, the primary mechanism for flav grovth is precluded and no significant flav growth vill occur.
SIALdescribed the updated fracture mechanics-analysis which is the basis for Toledo Edison!s1 November 8, 1989 submittal (Serial Number 1726) and-explained the reasons for the difference in conclusions from the earlier fracture mechanics analysis-provided with Toledo Edison's September 15, 1988 submittal
-(Serial Number 1580). The earlier analysis vas intentionally based on a conservative simplified model in order to support restart of the unit following~ discovery of the failed thermal sleeve during SRFO. The model used at-that time vas a single edge flaved plate which assumed that the stresses were maintained' uniform across the section at their inside surface value. Use l
of this model resulted in an ASME Section XI allovable flav depth for brittle fracture prevention of 0.5 inch.
-The updated analysis vas. performed using the pc-crack code nozzle corner flev model which is more representative of the actual configuration than the flat plate model used in the earlier analysis. Vith the updated analysis, the ASME Section XI allovable flav depth for brittle fracture prevention is essentially j
.through-vall indicating that brittle fracture is not a concern.
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- Dockst1 Numbar 50-346
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l License _ Number NPF-3 r
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-because the total applied stress intensity curve.(pressure and thermal) for
.any fla'v size up to through-vall, for the limiting HPI:flov transient with an.
i effective thermal sleeve, does not exceed the material fracture toughness with the applied ASME_ Code safety factor.
.The pc-Crack ~ nozzle corner flav model results have been verified and found to E
be highly accurate with respect to experimental results of a study of pressure
- vessels containing nozzle corner flavs. A comparison of pc-Crack predictions for_ nozzle corner flaws with experimental results was presented. Two papers,
" Fracture Mechanics Analysis of Japan Atomic Energy Research Institute (JAERI).
Model Pressure Vessel Test," and " Fatigue Behavior of Nozzles of Light Vater Reactor Pressure Vessel Model," which support this conclusion vere provided to the' Staff._ Copies are attached (Attachments 3 and 4).
Based on the updated fracture mechanics analysis, Toledo Edison has concluded that brittle fracture is not a concern and.the limiting flav size is governed' by ASME Section III structural reinforcement requirements. The Staff identified no specific technical concerns, however, they indicated that.they would have to review the above referenced technical papers to assess the conservatism of Toledo Edison's conclusions.
The meeting proceeded to-a discussion of the veld overlay repair development.
-Since brittle fracture is not a. concern, the design approach is based on maintaining ~ASME.Section III structural reinforcement requirements. The nozzle design was analyzed to determine the amount of existing excess reinforcement.
Sufficient excess reinforcement exists to accommodate flavs up to 1.6 inches deep, beyond which additional reinforcement, i.e, veld overlay, vould-be required to maintain Section III margins.
The veld overlay-process using automatic gas tungsten are velding (GTAV) vas developed for.this application by Velding Services Incorporated.- The mockups and tooling to_ demonstrate the capability under field constraints, veld procedure development, procedure qualification, pre-and post-veld heat
-treatment requirements, and' post-veld non-destructive examination plans were
. discussed.~
Additionally, a study'of the potential for flav growth during application of the veld overlay was presented which concluded that'there vould be negligible flav growth during velding.
Staff attention focused primarily
.on the control of heat input during velding, the potential for flav growth and the model for heat _ transfer used in the study.
The Staff suggested that requirements on controls of heat input similar'to those in the pending Code Case for tempered bead veld overlay be implemented.
Additionally, the Staff indicated:that'the flav growth study vould have to-be reviewed before a' veld overlay repair could-be approved.
In summary, NRC approval of a veld overlay repair vould not be forthcoming L
prior to the availability of the HPI/ Makeup nozzle enhanced UT results.
The
?
Staff indicated that they share Toledo Edison's belief that, with an intact ther_ mal sleeve, no significant flavs vill be identified unless they were
-pre-existing and vere not detected during SRF0, or an undefined failure mechanism is involved.
If a large flav is discovered, the most significant problem may be explanation of its existence and justification of the adequacy of corrective actions. Toledo Edison indicated that the inspection plan included repeating the SRF0 manpal UT prior to the enhanced UT.
W
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.i' Do$kot Nu bir 50-346
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License Number NPF l,1 Serial-Number'1768-
-Page-5 Toledo' Edison believes that there are no significant technical issues r.
prohibiting the use of veld overlay in this specific application, should repair of~the nozzle be necessary.
Having considered a range of alternatives, F
it is Toledo Edison's judgment that veld overlay. reinforcement is the most.
appropriate'and prudent contingency plan.
Toledo Edison appreciated,the opportunity to discuss its plans with the NRC l
Staff.
Should you have any questions concerning this matter,-please call Mr.=R. V. Schrauder, Manager - Nuclear Licensing, at (419) 249-2366.-
i
.Very truly yours, f:
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'I PVS/ssg cc:
P. M. Byron, DB-1 NRC Senior Resident Inspector -
A. B. Davis, Regional Administrator, NRC Region III T.'V. Vambach, DB-1 NRC Senior Project Manager l
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4 SECOND-NRC REVIEW MEETING t
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- ENHANCED ULTRASONIC EXAMINATION POR HPl/M4KEUP NOZZLE m
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-SPECIFIC APPLICATION OF DEVELOPED ENHANCED ULTRASONIC EXAMINATION TECHNIQUES
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MOCKUP SCANNING DEMONSTRATION-DISCUSSION-CONCLUSION s
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HPl/ MAKEUP NOZZLE - A1 THERMAL SLEEVE FRAGMENTS FOUND 1
JULY 2,1988
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TWO PIECES PROM END FOUND BELOW REACTOR CORE:
FAILURE ATTRIBUTED TO THERMAL FATIGUE FAILURE EXPOSES END OF NOZZLE TO COLD -
MAKEUP WATER.
PT IP?DICATIONS SEEN IN NOZZLE IN. AREA EXPOSED lNDICATIONS-ATTRIEuYED TO THERMAL FATIGUE ANAYSIS INDICATES CRACK ARREST WITHIN CLAD LAYER UT FINDS NO EVIDENCE OF FLAWS i
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NRC APPROVED RETURN TO POWER BASED UPON SUBMITTAL l
SERIAL NUMBER 1580, SEPTEMBER 14,1988 l
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COMPLETED COMMITMENTS J
o INCREASED MINIMOM BYPASS MAKEUP FLOW l
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o REPLACEMENT OFTHERMAL S'.EEVE WITH NEW DESIGN o
UPDATE NRC ON:
PROGRESS OP FURTl1ER EVALUATIONS ACTIONS TO BE TAKEN IN STH REFUELING OUTAGE REMAINING COMMITMENT
" TOLEDO EDISON PLANS TO OPERATE UNTIL THE NEXT REFUELING OUTAGE AT WHICH TIME THE HPl NOZZLE WILL BE RE-EXAMINED, RE EVALUATED, AND REPAIRED AS REQUIRED."
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RECENT SUBMITTAL TO NRC EXPLAINS TOLEDO EDISON PLANS 1
SERIAL NUMBER 1664, JUNE 19,1989 1
o RE-ROUTE THE MAKEUP FLOW PATH TO HPl NOZZLE, A2 o
PIBER-OPTIC EXAMINATION OF HPl/ MOCKUP THERMAL SLEEVE l
o ENHANCED UT OF THE HPl/ MAKEUP NOZZLE (A1) FROM THE OUTSIDE i
o ENHANCED UT OF ALTERNATE NOZZLE (A2) TO PROVIDE BASELINE INFORMATION I
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o PLANT OFF LINE - JANUARY 31,1990
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o NOZZLE AND THERMAL SLEEVE EXAMINATIONS TO BEGIN AS SOON AS CONTAINMENT ACCESS l
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o OUTAGE DURATION IS DEPENDENT ON ALL i
HPI NOZZLE AND THERMAL SLEEVE i
INSPECTIONS AND RELATED REMEDIAL ACTIONS BEING COMPLETED BY APRIL 12,1990 4
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I O DEVELOP UT TECHNIQUES TO MONITOR AREAS AFFECTED BY THE FAILED THERMAL SLEEVE
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- DEMONSTRATE FLAW CHARACTERIZATION
- SUITABLE AS INPUT TO FRACTURE MECHANICS ANALYSIS 4
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DEVELOPMENT OBJECTIVES REQUIRED FOR SUBSEQUENT FIAW EVALUATION o
ABILITY TO DETECT AND LOCATE THERMAL FATIGUE FIAWS PENETRATING
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SIZING RESOLUTION ADEQUATE TO SHOW ANY FLAW GROWTH RENAINS WITHIN NOZZLE L
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PROVILE CONSISTENT AND REPEATABLE l
RESULTS, MINIMIZING ERRORS OF INTERPRETATION DESIRED BUT NOT MANDATORY o
ABILITY TO DETECT FIAWS WITHIN THE CIADDING 4
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45 s
1/2 2.25 1/2 5.0 Single-Flat Roh Scan on l
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HPI PROGRAM TEST RESULTS EPRI TEST BLOCKS BLIND SAMPLES EDM NOTCHES AND THERMAL PATIGUE CRACKS PLAW POPULATION:
34 8 CRACKS 26 NOTCHES DETECTION RATE:
100 %
SIZING RESULTS:
OVERALL PERPORMANCE RMS ERROR:
0.064" STD.DEV.:
0.062" l
CRACKS RMS ERROR:
0.062" STD. DEV.:
0.029" NOTCHES.
RMS ERROR:
0.060" STD. DEV.:
0.042"
=
'a HPI PROGRAM TEST RESULTS i
q BATTELLE BLOCKS u
BLIND SAMPLES THERMAL FATIGUE CRAOKS i
FLAW POPULATION:
9 l
- SIZING RESULTS:
TO BE SUPPLIED l.ATER BY BATTELLE f
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HPI PROGRAM TEST RESULTS HEI_HQZZIJLMQUEIIE EDM NOTCHES CIAD CRACKS FIAW-POPUIATION:
17 5 CIAD CRACKS 12 NOTcmts (8 NOTCHES => 0.125" PENETRATION INTO BASE METAL)
DETECTION-RATE:
100 % OF ALL FIAWS => 0.125" PENETRATION INTO BASE METAL SIZING RESULTS:
TIME-OF-FLIGHT SIZING RMS ERROR:
0.081 STD.
DEV.:
0.035
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1 TIME-OF-FLIGHT SIZING THROUGHOUT 1
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SUPPLEMENTAL SIZING TECHNIQUES WILL SE APPLIED ON A CASE BY CASE SASIS FOR ANY DETECTED FLAWS L
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7x ENHANCED UT DEVELOPMENT CONCLUSIONS o
SCANNING ZONE ENCOMPASSES AREA OF OBSERVED SURFACE INDICATIONS AND PREVIOUS EXPOSURE.TO COLD MAKEUP WATER WITH A MARGIN
(
n o
FIAWS PENETRATING INTO BASE METAL CAN BE RELIABI.Y DETECTED IN SIZES l
WELL BELOW DEPTli REQUIRING ADDITIONAL REINFORCEMEh"P c
FLAWS WITHIN REGIONS FOR TIME-RASED SIZING CAN BE RELIABLY SIZED
)
l o
SIZING OF FLAWS DETECTED IN OTHER l
REGIONS WILL BE SUPPLEMENTED BY l
LOCALIZED TECHNIQUES l
o LONGI"UDINAL WAVE SCAN WILL BE USED
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TO OBSERVE FLAWS IN CIADDING IN THE ZONE OF CONCERN l
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Docket Nurbar 50-346 g
License Number NPF-3 Serial Number 1768 iAttachment 2 DAVIS-BESSE NUCLEAR POVER STATION i
HPI/NAKEUP N0ZZLE PROGRAM
=
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PRESENTED TO:
NUCLEAR REGULATORY COMMISSION
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JANUARY 24, 1990
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.i DAVIS-BESSE NUCLEAR POWER S'i. VION n
4 HPl/ MAKEUP NOZZLEiPROGRAM q
l AGENDA-4 g
- l.- Brief Review of Overall Program f
L
- 11. -Fracture Mechanics Analysis Update
j
- A!iowable Crack Size x
- Experimental Verification of pc-CR ACK ' Model 3
l
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-lift Weld _ Overlay Repair Development e
- Design Approsch
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- _ Welding: Development Post Repair NDE L
- Study:of Potential for Crack Growth-l During W+1 ding 8hy
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BPI/ MAKEUP N0ZZLE
.Al-u THERMAL?SLERVE FRAGNENTS FOUND July 2,L1988-
- ,a;;
TWO PIECES FROM END FOUND BELOV REACTOR' CORE
'l FAILURE ATTRIBUTED T0 THERMAL
- FATIGUE I
FAILURE EXPOSES END 0F N0ZZLE-TO' COLD MAKEUP VATER I
.PT INDICATIONS SEEN'IN N0ZZLE IN AREA--EXPOSED t
- INDICATIONS ATTRIBUT
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,ANALYSISLINDICATES CRACK GROVTH NOT EXPECTED VITH EFFECTIVE
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THERMALISLEEVE IN PLACE-
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.UT! UTILIZED.AT THE TIMEcFOUND-NO EVIDENCE OF FLAVS IN BASE-il u
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NRC APPROVED RETURN.TO: POWER-BASED UPON SUBMITTAL i
SERIAL NUMBER 1580,= SEPTEMBER 14,:1988
~
i fa COMPLETED COMMITMENTS l' -
INCREASED MINIMUM-BYPASS MAKEUP FLOV s
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' IMPROVED CONTROL OVER MAKEUP FLOV--
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REPLACEMENT-0F THERMAL SLEEVE 1
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SERIAL NUMBER 1664, JUNE:19,1989 I
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- RE-ROUTE THE MAKEUl' FLOV PATH TOlBPI N0ZZLE,'A2 FIBER-OPTIC EXAMIN TICi 0F HPI/ MAKEUP THERMAL' SLEEVE ENHANCED UT OF THEcBPl/ MAKEUP N0ZZLE (A1) FROM THE-OUTSIDE t
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BASELINE INFORMATION 3
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NOMINAL.0UTAGE DURATION - FOUR MONTHS 1,
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'- N0ZZLE AND THERMAL SLEEVE EXAMINATIONS TO BEGIN-AS SOON AS CONTAINMENT ACCESS'IS POSSIBLE --END-0F-u 1ST VEEKTIN FEBRUARY
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" il.l FRACTURE MECHANICS ANALYSIS UPDATE.
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Reinforcement Requirements
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0.118in.
3 f
[
(3 mmi -
(3 nwn)
-(c) CROSS SECflON OF NOZZLE N3 (d) MACHINED FLAW TYPE ILLUSTMATED l '.
l 5
ii Flawed Nozzles Used in JAERI Crack Growth Experiment e
m n
ll
- i o
L o.
h-t ud
,+
4-. -.,,
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+- +
,4 e
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T f.'
~
CHACK LENGTH F f40a8 NOTCH T F (mmi
l
'- b
!E I
I I
I I
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I l-I I
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r=
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poo ij z
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g 555 O
e
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n 292 : Q* u
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g ES E
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n
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o m s-N g
t c-
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z z
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u 3.-
n a
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CRACK 1 ENGTes froes NOTCH TIP Na I
~
CitACK LENGTH FHOeA NOTC8t TIP (m i n
n Mo CRACK LENGilt F ROGA NOICat T8P immt F
.a e
>n 3
8 8
8 8
3
-n 8:
z.a
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1 I
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ee 2
- a 5=
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y
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b-43 zl E 5 - e>poo
= -
> 20
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Z z -4 e
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-4 uo' 5
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of f
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CHACK L'EteGTH FROBA NOTCH TIP (daJ k
. 9 :-
- 2.0 0:
b M
D l
3
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40 IJ 4
/
g
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=
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=
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20
. pf
- 5' pc-CRACK h[
^ '
Rtsutts 5'
h:.
k os..
I.
O-
.+
b 10
.==
g-EXPtmistNTAL-i Q'
j CAACKTv't4 1
y N0ZZitN1 NCZILE NJ
/
cmAct Tv't e s
A. No m tN2 Noz2LE Nt t
4
/
n U.5
,* 1 P;
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l o
p ao -
. NUMetR Of CYCLLS teneuses)
~
. Verification,of pc-CRACK Nozzle' Corner Crack Medel.
l l"-
7 With Respect.to,JAE2I Crack Crowth Experiments li m
l',
'a g
N i
i
^
.[
ni Ir i.
' r'
- '5
- ,i..; L.,
~,i i 7
d s
1 t
f i.
- Ill. WELD: OVERLAY. REPAIR DEVELOPMENT:
1 1
- De' sign Approach
.i
- Nozzle Reinforcement Requirements j
Reinforcement as a-Basis for Weld-3 j
Overlay Design
)
a 5
l'
. : Welding Procedure Development.
~
3
-- Mockup / Procedure Development f
- c
- Procedure Qualification 0
a 4
- Post-Repair NDE-i
^[
- Study of Potential for Crack ~ Growth During Weldbg
. w.
- d
- lib,
' f :,
4,
- nf' 1
7
.6..c....
g
- e.
'r s'
- ?i-r r.i 4
1
\\
l u
DAVIS-BESSE HPl NOZZLE T
REINFORCEMENT REQUIREMENTS m s OF RrINreRCrwrwT Greater.of L3 = 0 (or) D/2 + T,+Tb "C
-i I
h =.5 Q +.5 r I
I 2
I
~(r, = D/2 + T /2) l b
1 l\\
d'.h
,4 l
1 l
L j
Lu.
i o
i T-ampu _
a.
%r y n !
t v
A 5
s L
c, A
3 i.
AREA REOUTRED TO BE REPIACED:
1 1
At = Dtr AREA AVAIT.ABLE FOR REINFORCEMENT:-
-S,Nozz.
(A1+A2+Al S
Run 3
a where: A{ = 2 h.(Tb-t) b 2
2 2 ) " '43 #2 e
'A
= 2(r
~
A.= 2(L -D/2-g (T Nr) 3 g
r I
w.
q; l'
,. );,,,, j ;
?b:.
REINFORCEMENT REQUIREMENTS J
AS A-BASIS'FOR WELD-OVERLAY DESIGN L NITS OF REINFORCEMENT i
L'x = D/2 + T,+T ;+ 2t,1 gg b
y
" L ' N =. S Vr, ( T '*wd) b
.5r2 (r,=D/2'+ I b wel))
^
~
2 Awu l-
,/
A t
[.
ir'i r <
n
[
9 i
r; '-
- c. m u ua e
(f,,
l L$
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'L' L./
l.-
ARIA REOUTRED To-BE REPLACED:
1 1
A = Ot
+ ~ #rc!
r AREA AVAILABLE FOR RETNTORCEMENT:
,~
l A;.= 2'(L'N
) (T 'b) b'
= o otherwise A. = 2 (L'x - D/2-'- r ) (T;-t )
3 e
r i
A,1 = _tygt x-(L'y-(T-ty))+-tygy(L' - D/2 - Tb w d ), x 2 y
~t I
[\\
8 1
m
. - ~.
i-d'5. -~lk "L :4=.;3;is -.jf vi:q ;
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DAVIS ~-BESSE.:HPI NOZZLE E'
ct of Crocking _on Nozzle Reinf.
6-
~
5'
- 1 3 4
i x
1 u
0
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-1
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o
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l' x-
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1
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i l-
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8 8
8 8
8 8
8' 8'
I I
8 8
8
~8 ;
0' 0.4 0.8
.: 1.2 '
1.6
. 2' 2.4' 2.8 '
t.
i
~ Radius.of ' Crocked Zone. (in.)
i m
,(.,..-
. ~ ~ ~ -
.-rA,.
.~r r
- - - - - * - -v
.-m-
--m--
m-m-'
't-j.
Reg'd WOL Thicicnese (In.)
i o.
o o
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b k.
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- 1.,
WELDING PROCEDURE. DEVELOPMENT
- l T'
FOR HPl/ MAKEUP NOZZLE WELD OVERLAY REPAIR i
.i L
j u
l-Deveiopment of Welding Technique for l'
j Overlay Application i
l?
-j
- Automatic GTAW
' 3)
- Repair Using Carbon Steel Weld Metal
}
o 1
l
- Preheat and PWHT Per Se'ctions lil, j
IX and XI of Code 1
g l
.l p,
j
- Mockup and Tooling By. Welding Service's, Inc.
Ll:
i to Demonstrate Capability (including L
.I Field Constraints) 1 L
L'
- Weld Procedure Specification and 1
Procedure Qualification H
1 y
li;
['
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90-006PR
'l 6J H
- N-
,r t
'l i
SCHEMATIC OF HPI NOZZLE SHOWING INTERFERENCESJ l
AND CONSTRAINTS-1 1
l P\\PE WH1P R escrf: AiNT"'
(m-- ReuwAM.s.)
)
i
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duc.he ex/
u:emueu.S l
l' 90-007PR
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1 I
l WELD PROCEDURE SPECIFICATION AND J
PROCEDURE QUALIFICATION FOR AUTOMATIC l
GTAW PROCESS 1
a L
Develop For P-1 Group 2 Materials L
(Thickness > 1.5')
)
l-Heat Treat Qualification Plate to Simulate 1-Current PWHT Condition at Davis-Besse 1
l Perform Procedure Qualification Per Sections ill and IX of Code
- Tensile-Tests
- Bend Tests
- Toughness Tests Produce Qualified Procedure for Overlay Application I
.90-008PR I
L
. ~.....
.c.;
u N
DAVIS-BESSE HPl NOZZLE WELD OVERLAY--
POST-REPAIR NDE PLANG 1
+
. Inspection for Soundness of Weld Overlay-De;osit-(Qualifies Repair for Single Fuel Cycle)
- Straight Beam UT
- Shear-Wave UT
- Section V Calibration Blocks l
l l
-]
q i
l 90-009PR t
s 4
~
4
- c
4l l
l-STUDY OF POTENTIAL FOR CRACKLGROWTH-1 DURING OVERLAY WELDING
~
1 i
l-i
- Elastic-Plastic Weld 3
- i.
-l-i Stress Intensity Based Upon pc-CRACK Corner Crack Model I
i ASME'Section XI Fatigue I
2 Crack Growth Law l
l 9
+-Two Crack Depths Modeled j
j
- 1.6 inches
- 2.5 inches 1
i l-I-
i i
i p
r
[-
9 0 010 P R 1
l
t q
RESULTS OF CRACK GROWTH DURING OVERLAY WELDING STUDY-f l
- - Analysis Shows Kl < K IC j
For Both Crack Depths t
i i
- No Crack Growth Due to Crack l
Instability is Predicted i
i i
- 250 Fatigue Cycles Modeled To Simulate Weld Passes j
I j
- Negligible (17 Mils) Crack Growth I
Due To Fatigue is Predicted v
/!
t
'1 9 0 011P R
'1
1
)
, -e g :.>
- }i I
F, liilt h 4
li t i s ii A l
a
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+
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s N
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s v
+
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s Finite Element Model Used For Crack Growth Analysis
1 -..
.g
~'
L
=
t
~
g.
';s
' b.
.~A s' O 70 F 60 g, ^g 250 y g I e - conservattve 3rd order polyr.maial-for-7G F 50 I.A 40 l
B r
t l
3 l
t 30
.eo 20 b
l u,
-l ti o
lo ox I
O i
I I
S X
c-I I inter-face
- -[
?
-20
- 1. 0
- 1. 5
- 2. 0
- 2. 5
- 3. 0 O
~ D. 5 X (in)
Initial Stress from PWHT
.i I
9,g' g
%.=t-w swa y-M..gey.
.hs
- s____,
_y
_g g,
g,,
,,,,,g,
l
.,g l
- l...-
a fo I
.yggg._ _ _ _ _,_ _ _ _ _,- _ _ _ - -,-
-n 50 - Ae pone at C.L. co ylete i
e 8e first layer ~ complete
- g 40
~
Ae i Y C e-ot 1175 F
'lf E
8e cdoted to 1500 F 8
-- g ;- MFto @ F----'Tl
i 1600 m
De co,oled to 6M,1 F
'i 4, _ to.d r.t -
l 2a e
S
______3______p______;.
____q j
io e
e e
e o
e e
e o
g I
8 8
8 m
0
.I e
800
- - -- - - T - - - - - r - - - -
e -- - - - 7 a
l e
e e
S i
p i
e s
1 -10 l
4
- [
8 8
I t
e
-20 r
l-400 ------4------t--
4 l
e s.
a L-
.r-m a e C i
3 3
l
-30 l
.t e
e (Joes seet i.ecle.Je Ptuf f 8e 4 8 !al _ str ess) 8 l'
8 8
-48
^
^
O
^
^
D I
2 3
4 0
1 2
3 4
X (sn)
X (in)
Temperatere Due to Weldsng at. Crach C.t Croch C.L. hop Streme Behovser.
I
' b e
a I
4 m
.m
.m.
.E a...
m m
. o m - m:m.m-
.m
.:,______.me_m-_=
-~
y g: y
= ;
=-
^
~
,' ~ *'
,:.- :m.. -
l' 2*:. Q :-3
~
7
=
=
e.
_.e,_
a
-3;-
....=n 1
l.
50 - A e poee at C. L. complete 50
' A s paoe at C.L.. co m iete
'8 s first Jayer complete 8s faret layer complete 40 40 C u ot 1175'F' Cu at 1275 F.
M R
a n
a n
e 5
- g 10 10 m
0 m
0 2
a a
-10
-10
-20
-20
-30
-30 idoee not ' include PANT snitio1 etrese)
(does not Jnclude PnNT snitsosi etreee)-
--40
^
^
^
-40 H
I 2
3 T4-0 I
2 3-4 X Ord X (in)
Nozzle Surface Hoop Strees Behovlor
' Pipe Surface Hoop Strees Betwwler k
e i-
.r 2--
r:.m..
m.
e.-s.
m=
.m..=m.
m
.m..
m.
. m.
m..
=.
u
wi-
^
e-.
includes PNNT strese effect of 13 ksimin~D.5 incinnias PWHT stress effect ' of 9 kes *in~0. 5 40 40 30 30 r,- 27.
20
{
l 20 K
= 20 I
ak~=20 AKw -20 g
r a
r G
10 T
Q 10 f
f j
f (]r' p
?
r
\\
c I
M 7
0 f
c 7
0 F
(((;
5 5
s s
-10
-10 x
x
-20 crack depth = 2. 6 ist
_gg crack depth = 2.5 in.
-30
-30
-40 a-8 Q
29
-40 0
4
-9 12 16 20 24 28 0
4 9
12 16 2 11 24 Weld Pass (weld loyer 1)
Weld Pass (eeld icyer,1)
K llistory atJthe crack C.L.
M History at the crack center line t
b e
l L
1 l-.
v t
includes PwH etrese. effect of 13 hst ein~0. 5 40 newindes Pwll stress effect of 9 he ests D.5 r
40 3"
~
K=d
- O
~
p g;I 5
k
, - 28 :
211 p
p q
aK
-28 f
20 g
I A K.,,,, = 2 5 i
m 10 I
Gi 10
'd
?
'd i
y o
. fr
- c II c
[
y o
- -H
[
5 f
f e
0 5
-10 x
l
~10 f
.x f
)
-20 crach depth - I.6 in.
f crock depth - 2. 5 in.
g
-30
-48
^
^
-40
^
O 4
8 12 16
-20 24:
28 0
4 8
12 16 20 24 28 Weld Pass (weld loyer 1)
Wald Poss (weld layer 1)
K History hosed on nozzle surface stresses K History based on nozzle surface stresses i
f
=
- ~.-
. 2 2.'
' ~ ~
~
o
't i
6 includes PhNT etrese effect of 13 ksi*in~0.5 40 includes PVNT streee effect of 9 heinen~0.5 40 K
. ' 36
'I 3
g. =39' q
an 30 I
{
20 r
&%nas = 2Z 20 F
S"ees' h
~
~
~
~
~~
7 0
^
^
i 7
0
^
^
^
^
- e 5
x -10 Lx -10
(
_2,. crack depth - 1.6 in.
_z, crack depth - 2.5 in.
? r
- l t
........m j
0 4
8 12
,16 20 24 28 D-4 8
- 12 16 20 24' 28 WeId Pose (seId Ioyer I)
WeId Pues (eeid Ioyer 1) i M History based on pipe surface stresses M History based on pipe surface stresses I
..,... ~. -, _
...m
y l. g,,.,
i h h [-
i /
't kO.
UtW 4 k C A-s lh b
f
_ c%
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1 Pn. c-o sw...J,c u m m ~
6m.m fosW G MN#u wa!
Guem% Z.0w+pTv (40t) 77t-troo JOHW NL'v3Htm44 ZhL.K Po E.0Dcw.
(4/9) J AII-~ 8At,f
,duous Wow &
cEnrasuc s q ca.aume7n %s D,. t. w ~
L3 '.n c
- Tocec, e x,.a (419) ni. n 1
. w ik.:.'1
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