ML20059D881

Justification of Weld Mods to Pressurizer Temperature Nozzles for TE-0101 & TE-0102

ML20059D881
Person / Time
Site:	Palisades
Issue date:	10/23/1993
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML18059A477	List: ML18059A476 ML18059A478 ML18059A479 ML18059A480 ML18059A481 ML18059A482 ML18059A483 ML20059D881
References
EA-SC-93-087-01, EA-SC-93-087-01-R01, EA-SC-93-87-1, EA-SC-93-87-1-R1, NUDOCS 9311030030
Download: ML20059D881 (145)

Text

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

-a's ressuust ENGINEERING ANALYSIS COVER SHEET Total Number of Sheets 144 l3 Title Justification of Weld Modifications to Pressurizer Temperature Nozzles for TE-0101 and TE-0102.

INITIATION AND REVIEW Calculation Status Preliminary Pending Final Superseded Initiated Init Review Method Technically Reviewed Reve y

See Appd Appd CPCo i

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r.amt...oa eou.et.ct,u.tir,c. ten 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 will prove that the " pad" modification to stop this leakage is acceptable per the ASME Code for at least one fuel cycle.

2.0 ANALYSIS INPllT 2.1 Vendor Information - ABB/ Combustion Engineering

" Nozzle Details for Consumers Power Pressurizer" - M1-L-A sh. 986 rev. 5 a.

b.

" Vessel Forming and Welding for Consumers Power Pressurizer" - M1-L-A sh.

982, rev. 9 c.

" Top Head Forming and Welding for Consumers Power Pressurizer" - M1-L-A sh.

983, rev. 6 d.

" Instruction Manual:

Pressurizer; Consumers Power Company - Palisades Plant"

- M1-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 III,1986 (no addenda).

9311030030 931027 C

PDR ADOCK 05000255 t

P PDR a

Cangeners Pmer rewouns PALISADES NUCLEAR PLANT EA-SC-93-087-01

-- - ns w u ANALYSIS CONTINUATION SHEET Sheet 2

Rev #

91 l'

Reference / Comment 2.3 Imoortant Desian Conditions a.

Press. - The modification 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 i

1214.

b.

Temp. -

The modification 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 1,

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 l e' 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 small Loss of Coolant Accident from the nozzle penetrations.

2.4 Desian Drawinas a.

CPCo sketch, SK-SC-93-087 sh. 1, "TE-0101 Modification" Attachment I O

and sh. 2, "TE-0102 Modification" b.

ABB/ Combustion Engineering Drawing

" Pressurizer Head 2 la Temperature Nozzle Weld Repair" - D-9417-C093-019, rev. 02 c.

ABB/ Combustion Engineering Drawing

" Pressurizer Shell 3 le Temperature Nozzle Weld Repair" - D-9417-C093-021, rev. 01 2.5 Existina Analyses a.

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

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

b.

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

c.

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

i 1

@,pner Consmus

,,onn, PALISADES NUCLEAR PLANT EA-SC-93-087-01 ma m sman russars ANALYSIS CONTINUATION SHEET Sheet 3

Rev #

91 18' Reference /Corment 2.6 References a.

ABB/ Combustion Engineering Nuclear Services Welding l@

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

b.

ABB/Conioustion Engineering Nuclear Power letter, MCC Attachment 4 lc 525, from J. F. Hall dated October 15, 1993 titled

" Corrosion of Palisades Pressurizer Material."

c.

ABB/ Combustion Engineering Nuclear Services Traveler No.

lc' 2003067-001, rev. 2.

d.

Consumers Power Company Internal Correspondence from lC 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 lt Procedure Specification - GTA-8.8-910, rev. 10.

f.

Consumers Power Company Internal Correspondence from lt JCNordby to SS0verway, JCN 93*029, dated October 18, 1993,

" Effects of Half Bead Welding on Base Metals."

g.

Consumers Power Company Internal Correspondence from leJ RBJenkins to Design Package File, RBJ 93*064, dated October 18,1993, " Nuclear Engineering and Construction Organization:

Potential for Circumferential Cracks in Modified Pressurizer Instrumentation Nozzles."

h.

" Engineering Specification for a Pressurizer Assembly", 0 le:

Specification No. 70P-001, Rev. 2 from Nuclear Power Systems, Combustion Engineering, Inc.

i.

ABB/ Combustion Engineering letter from Thomas U. Bipes to l&

Scott Cedarquist, dated October 16, 1993, " Preliminary Results of Nozzle TE-0101 Eddy Current Exam."

j.

ABB/ Combustion Engineering letter

" Construction Code 1 le Reconciliation for Consumers Power Company - Palisades Pressurizer Upper and Lower Temperature Nozzle Repair / Modification."

k.

ABB/ Combustion Engineering Nuclear Services Traveler No. 4 2003067-002, Rev. O.

1.

ABB/ Combustion Engineering Procedure of Electrical 5 g

Discharge Machining (EDM) Pressurizer Nozzle Severing, STD-100-207, Rev. O m.

ASME Code Interpretation, IX-1-89-70 6 i

i

@, paper Consents PALISADES NUCLEAR PLANT EA-SC-93-087-01

,, gen,

---=s we ANALYSIS CONTINUATION SHEET Sheet 4

Rev #

91 IF Reference /Conynent 3.0 ASSUMPTIONS 3.1 Ma.ior 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 0.D. are concentric.

c.

Assuine measured TE-0101 nozzle I.D. and 0.D. are representative of I.D. and 0.D. of whole nozzle, i.e. that the I.D. and 0.D. do not vary as a function of distance down the nozzle.

Conalm Mmer PALISADES NUCLEAR PLANT EA-SC-93-007-01

---=s resser.ss ANALYSIS CONTINUATION SHEET Sheet 5

Rev #

9l b-Reference /Consnent 4.0 ANALYSIS 4.1 Backaround 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 verified the leakage.

Operations commenced reducing PCS pressure. ABB/ Combustion Engineering (ABB/CE) was contracted to assist in correcting this

'le, problem, as were Systems Engineering and Nuclear Engineering and Construction Organization engineers.

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

problem.

l b.

A Project Team was established to evaluate the leakage, identify alternative solutions, and recommend a solution i

to management.

On October 11, 1993 the alternative were presented to management and the option to modify the temperature nozzle design by welding a "paa" 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. ABD/CE t

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.D. was acceptable. The modification design was then revised to EA-SC-93-087-04 incorporate this change.

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

=====s wu ANALYSIS CONTINUATION SHEET Sheet 6

Rev #

91 It Reference / Comment 4.2 Industry Experience i

To date, the Nuclear Power Industry has experienced leakage l

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 he 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 determinations 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 seme welding from the inside of the pressurizer.

Due to time considerations in planning the most ALARA effective method of l

replacement, Palisades management decided to pursue a method that would allow operation of the plant for at least or.e 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 n~ation for at least one fuel cycle draws on ABB/CE's experienc',ts for

.h other short term modifications at other U.S. nuclear p:

leaking Inconel 600 nozzles.

l Comuns pruer PALISADES NUCLEAR PLANT EA-SC-93-087-01

--rs russacss ANALYSIS CONTINUATION SHEET l

Sheet 7

Rev #

91 18 l

Reference /Coment 4.3 Reason for Chance The existing temperature nozzles for TE-0101 (Pressurizer Vapor Phase Temperature Element) and TE-0102 (Pressuriner 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 g

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 b

l weld on the interior surface of the pressurizer shell, called a l

"J" weld, with a new weld on the exterior surface of the shell, Ref 2.4.b Att 12 e

as indicated in the construction drawings.

This exterior weld Ref 2.4.c Att 13 l

is interded to re-establish the pressure boundary downstream of the origir,al "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 Desian 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 l

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 i

l letter from Consumers Power's Welding Codes and Materials EA-SC-93-087-02 y'

l Supervisor. The process is laid out in a qualified ABB/CE welding procedure.

Ref 2.5.b, Att 3 4

Commin Power PALISADES NUCLEAR PLANT EA-SC-93-087-01 pseums m um u ns - =<

ANALYSIS CONTINUATION SHEET Sheet 8

Rev #

91 18 Reference /Coment b.

The weld modifications will take the shape of a " pad" lccated 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 without having to build-up I

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 will 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 no7zle and the ASTM A-533, Grade B, Class I 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 It!

conclusion of this calculation and its addendum is that lei the nozzle for TE-0101, located in the upper head.of the pressurizer, needs to be partially severed within the l e. :

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 I

the thinned nozzle wall. The stress cal < dion addendum demonstrated that with a thinned wall. :ck:" is of 0.110 EA-SC-93-087-04 inches, the stress level in the press a bon dary will be within the Code allowables. The stre.

cel.ulation also EA-SC-93-087-03 verifies that the nozzle for TE-0102,. cated in the lower section of the pressurizer shell, does not need to be severed since it does not experience as large a transient g

loading due to being in a liquid environment.

The axial 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 16 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-e' least one fuel cycle.

(

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Consunem Ptwer sweetsus PALISADES NUCLEAR PLANT EA-SC-93-087-01

)

=m e' ANALYSIS CONTINUATION SHEET Sheet 9

Rev #

01 hi Reference /Coreent d.

The existing crack locations in both nozzles leads to another potential problem. That problem is one of t

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 I

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 l-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 g

intentional exposure of carbon steel to bt, rated primary coolant is not a corrosion concern can be focnd from industry experience with pressurizer leaks froa h n.ter sleeves and temperature and pressure nozzles and from CE0G 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.

l@

Consunn Pruer I

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

--ns russness ANALYSIS CONTINUATION SHEET Sheet 10 Rev #

01 Reference /Corinnent e.

The partial sever cut will occur per the design drawing Ref 2.4.b ttt 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 2.6.1 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 I

that would meet ASME Code requirements. 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 1 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 0.D. of Assumption 3.2.b EDM wand), and nozzle I.D. and 0.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 0.0. 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.

i Comunn l

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

---s manuss ANALYSIS CONTINUATION SHEET l

Sheet 11 Rev #

91 l'

l Reference /Corrrnent 4.5 Desian 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 is 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 sepport 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 l

actually mount inside a thermowell that provides the pressure I

boundary from the pressurizer to the TE. The thermowell is then welded to the safe end of the nozzle (the nozzle is welded lC 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 l

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 maintained.

@Pmer consumus PALISADES NUCLEAR PLANT EA-SC-93-087-01

- es w u ANALYSIS CONTINUATION SHEET Sheet 12 Rev #

91 l'

Reference /Corrrnent 4.6 Impact on Affected Evstem or Interfacina 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 lE 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 lt 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 g

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 l

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.

l Operational axial stress is not a concern at the TE-0101 l

nozzle due to the fact that it is being partially severed.

I This allows any stresses due to the thermal expansion stresses caused by the difference in expansicn between the inner and outer walls of the pressurizer and the nozzle It; material to plastically deform the nozzle in a known

I 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 i

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 lt Since the modification i's 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

Consunm Rwer PALISADES NUCLEAR PLANT EA-Sc-93-087-01

== =s -

ANALYSIS CONTINUATION SHEET Sheet 13 Rev #

91 l'

I Reference /Consnent 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 i

of stress only occurs during major changes in plant state i

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 i

that would lead to Loss of Coolant Accident. Another point to be considered with any cracking of the TE-0102 1

nozzle as a result of the high axial stress during heatup and cooldown is that any cracks that may occur due to the lei 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 ltl 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 Ref 2.6.i, Att 2 e

detected indications within them; it can be expected that Assumption 3.1 j

any PWSCC that will occur in the newly welded areas will i

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.

Consum power l

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

rs e=

ANALYSIS CONTINUATION SHEET 3

Sheet 14 Rev #

91 10 Reference /Cortynent 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 Inconel 600, and Inconel 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 i

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 gi 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.

@,MHrer Consuners wwsman PALISADES NUCLEAR PLANT EA-5C-93-087-01

-n -r ANALYSIS CONTINUATION SHEET Sheet 15 Rev #

91 18 Reference / Comment 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 p

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 l6 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 modification will not affect either the lC 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 EA-SC-93-087-03 e

calculation and also function as the replacement pressure 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.

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

- -s - =

ANALYSIS CONTINUATION SHEET Sheet 16 Rev #

31 lC Reference /Coment 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 b.

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 i

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 Specifications.. What this means is that the modification will have to be Palisades Technical pressure tested to the maximum pressure allowed in the S**"'****i "3" "

l 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

?

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 Attach. 12 & 13 C.

the creation of the weld build up " pad" is found as Reference 2.6.a.

The qualified weld procedure to reinstall the le thermowell after the modification to the temperature nozzle attachment is found as Reference 2.6.e.

Procedures for lE attachment of thermocouples for monitoring pre-weld and post-weld heat treatments and the procedure for the monitoring the heat treatments are called' for in Reference 2.6.c.

lC

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

--ns -=

ANALYSIS CONTINUATION SHEET Sheet 17 Rev #

91 le Reference /Corpent 4.10 Code Reconciliation The ASME Boiler and Pressure Vessel Code (B & PV) for the construction design of the pressurizer wasSection III of the lel 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 ld -

design of the pressurizer and the design of the modification are to the same edition and addenda 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 1 le 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, e'.

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 i

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.

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Proc No 9.11 TEC)GIICAL REVIEW CHECKLIST Revision 5 EA - - S C - 3 7- 0 " d' REV.

I page 1 of 1 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 coments on a 3110 Form.

Satisfactory resolution of comments and completion of this checklist is noted by the Technically Reviewed signature on the Initiation and Review record block of Form 3619.

, N, N/A) 1.

Have the proper input codes, standards and design principles been specified?

2.

Have the input codes, standards and design principles been

/

properly applied?

3.

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

q/

4.

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

'/

5.

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

6.

Are assumptions accurately described and reasonable?

'/

7.

Has the use of engineering judgement been documented and v

justified?

/

8.

Are all constants, variables and formulas correct and properly applied?

Y i

9.

Have any minor (insignificant) errors been identified? If yes; Identify on the 3110 Fors and justify their d

i insignificance.

(

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

1/

e Typeraf Weld e St of Wald e

al Being Joined e

s of Material Being Joined e Location of Weld (s) e Appropriate Weld Symbology

11. Has the objective of the analysis been met?

l

12. Have administrative requirements such as numbering and

[

format been satisfied?

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

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EA-SC-93-087-01 i

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ATTACHMENT 1

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EA-SC-93-037-01 Page 1 ot 2 TE-0101 MODIFICATION THERM 0WELL

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INCONEL N0ZZLE

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

EA-SC-93-087-01 Page 2 of 2 l

TE-0102 MODIFICATION i

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TEMPERATURE ELEMENT THERMDWELL x

WELD 5.5.$^FE END

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INCDNEL N0ZZLE 'N

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T-72 PRESSURIZEP SK-SC-93-087 Sheet 2

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ATTACHMENT 2 4

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Eddy Current Exam Results 1

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4 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 currer' 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 circumferentialindications 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.D. axial notch in the calibration standard.

The size of the largest axialindication 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. Bipes ABB/CE Eddy Current Levellil Combustion Engineering Nuclear Services 00mtNst ce EvneenN ine

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

WELDING PROCEDURE SPECIFICATION (WPS): ABB/CCMBUSTION ENGINEERING NUCLEAR SERVICES SHIELDED METAL ARC -- MANUAL OYB))N/D fo/M/ds i

Procedure Sponsor Date '

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TjrthficalReviewe[

Date '

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EA-SC-93-087-01 i

Attachoent 3

- i P AL T S ADE S NUCLEAR PLANT Page 3 pied ho 3,o7_

SAFETY REVIEW Revision 7 Page 1 of 1 PS&L Log No Item Identification:

No SHA-3.43-937 Rev 1

Title WELDING PROCESS SE Rev SPECIFICATION (WPSit ABB/CE ENG. NUC. SVCS.

SHIELDED HETAL ARC - HANUAL Describe Issue / Changes PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING Reason for Issue / Changes EBOCEDURE REOUIREMENT BY ADMINISTRATIVE PPOC. 5.06 Yes No 1.

Does the item involve a change to procedures as described in the FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10, 6.9, 7.4, l

9.1, TABLE 4-21, TABLE 4-22 2.

Does the item involve a change to the facility as described in the FSAR7 FSAR Sections affseted NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6.

5.8, 5.10, 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 FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10, 6.9, 7.4.

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

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, 4.0 f

Justify No Answers below if logic is not obvioues i

Although welding, post weld NDE testing and heat treating are discussed in the FSAR, the same processes 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 questions listed above are answered NO, written USQ Evaluation is not required. However, this Attachment shall accompany other review materials for the item to document that a safety Evaluation was not required.

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NUCLEAR SERVICES Page 1 or s !

i i

Company Name ABB Combustion Encineerina By: M[I~

WPS SMA-3.43-937 Date 10/15/93 Support. PQR(s)

SMA43.43-old88 SMA-12.43-105 gev.Np.g}matg0/18 /93 Wald Process (es) Shielded Metal Arc Type (s)

Manual y:

_ _7

=.-

JOINTS (QW-402)

Joint Design Buildues and Fillets / Half Bead Technicue Backing (Yes)

X No i

Backing Material (Type)

P-3 Base Material No Retainers

,a

. m.

i Metal Nonfusing Metal i

Nonmetallic Other rfffr I

IT l

m l

'

~ ;

The 1se two layers are temper band and need not l

.5 fuse inao aosr.ls. Subsequent layers shall fbes into nossles.

P. 3 p

g t

93 I

• BASE MBTALS (QW-403)

P-No.

3 Group No.

3 to P-No.

43 Group No.

N/C OR Specification Type and grade SB-166 or sB-168 Ince 600 to Specification type and grade s1533 - crade

'B'

- Cimas 1 i

OR Chem. Analysis and Mech. Prop.

Not Annlicable to Chem. Analysis and Mech. Prop.

Not Annlicable i

Thickness Range:

Base Metal:

Groove 3/16" minimum Fillet Unlimitad Pipe Dia. Ranger Groove Unlimitad Fillet Un14=ited other

• FILLER METALS (QW-404)

Spec No. (SFA) 5.11 coated Electrodam - See Electrode control. 3-(c)

AWS No. (Class) 15.11 ENicrFa-3 F-No.

42 Consumable Insert None A-No.

Elc Size of Filler Metals 3/32n and 1/a" dia=atars Deposited Weld Metals incanal - ins Thickness Range No sinale nana shrll ave =ad 1/2" thickness Groove Not Annliemble Fillet Unlimitad Electrode-Flux (Class)

None Flux Trade Name Mana other

• Eachbasemetalfillermetalop&ination should be reoorded Independent Reviewer kR h Date

/c -/d -9.1 C/

C*-13-1993 09'Y0 CM OES/CE Cbsttaro:gs TO 31616?6 b

.02 WELDING PROCEDURE SPECIFICATION (WPS)

ABB/ COMBUSTION ENGINEERING WPS NO.

SMA-3.43-937 Rev._1 NUCLEAR SERVICES Page 2 of 5 i l

l POSITIONS (QW-405)

POSTWELD BEAT TREATMENT (QW-407)

Position (s) of Weld All Temperature Range 500 50 dec. F Weld Progression: Up _X_ Down Time Range 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> minimum.

Position (s) of Fillet None Air cool to ambient temmarature gas (QW-40s) l PREEEAT (QF-406)

Percent Composition Preheat Temp. Min. 350 dec. F Gas (es)

(Mixtr)

Flow Rt Interpass Temp. Max. 450 dec. F Shield.

None l

Preheat Maintenance Yes Trail.

Nena (Continuous or special heating, Back.

None if applicable.)

See maan 4, 3(hi.

ELECTRICAL CEARACTERISTICS (QW-409) i Current AC or DC DC Polarity RP Pulsed No 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 Not Annlicable (Pure Tungsten, 2% Thoriated, etc. )

Mode of Metal Transfer for GMAW Not Annlicable (Spray arc, short circuiting arc, etc.)

Electrode Wire Feed Speed Range Manually controlled for sMA nrecess TECENIQUE (QW-410)

String or Weave Bead strinaar or Weave to 3Y cara diameter i

Orifice or Gas Cup Size Not Annliemble Cleaning Initial Jrinder or wire Brush Interpass sama Method of Back Gouging Nona Oscillation Not to awe--4 3Y cara dia=meme contact Tube to work Distance not Annliamble Multiple or single Pass (per side) multinia Multiple or single Electrodes sinale Travel Speed (Range)

Manually controlled Peening Not Allowed lOther

• - Mi n 4=== h--d lanath ner unit inch of alactrode 4

Filler

)

Metal Current

• Min.

Other Bead Type Amp.

Volt Bead

Remarks, No.(s)

Process Class Dia.

Polar.

Range Range Length Comments All SMA SFA5.11 3/32 DCRP 55-65 22-23

.42" 1/4 DCRP 75-90 23-24

.37"

=-ry7 p

-r

--w-7

_w--

et r---v-w---

,-,--m-

EA-SC-93-087-01 OcT-15-1993 09:n ::cM JEE CE C'rattene:ga To 91516 s.:5? age 6 of 12 i

WELDING PROCEDURE SPECIFICATION DWPS SMA-3.43 937 Date 10/15/93 Page _ 3 __ of 5

Rev.

1 Date 10/18/93 SPECIAL INSTRUCTIONS:

1.

This procedure allows for use on a limited basis as defined below. The repair may be accomplished on P-3 matenals 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 welding 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 welding in accordance with the written procedure.

(b)

'Ihe weld metal shall be deposited by the manual shielded metal are process using low hydrogen type electrode. 'Ibe maximum bend width shall be three times the electrode core diameter.

(c)

All covered electrodes shall be from tvM hermetically scaled packages or heated ovens maintained between 225' F and 357 F. Electrodes exposed to the atmosphere for more than twenty minutes shall be re-beated at a temperature between 225' F and 357 F for at least eight (8) hours before re-issued for use.

Electrodes W_ to the atme=he for longer than 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> shall be discarded.

(d)

The weld area shall be preha=*=d to a minimum of 357 F and maintained at that temperature for a minimum of 30 minutes prior to any welding. The width of the band to be preheated sha!! be 10 inches and shall be maintained at a minimum of 357 F during welding. 'Ihe minimum preheat, and subsequent heat treat temperature requirements shall be monitored by use of thermocouples and recording ar5;- = h-c-x-g' may be attached by welding or marhanial methods.

OCT-19-1993 29:52 :#CM

^ES/CE Chattare:30 TO l

Page 7 of 12 2

a>

i i

4 WELDING PROCEDURE SPECIFICATION DWPS SMA-3.43 937 Date 10/15/93

)

i Page 4

of 5

4 j

Rev.

1 Date 10/18/93 a

i j

(e) l The initiallayer 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 j

cr machining before depositing subsequent layers. The second layer shall be l

l deposited over the entire area as before with 1/8" diameter electrodes.

l Subsequent layers shall be deposited with 1/8" diameter electrode in a manner to j

ensure tempering of the prior beads and their heat affect zones. All subsequent j

layers shall be at least 1/8" hom the outer most edge of the ground first layer.

l 1

1 l

ff)

Examination of Repair Weld (See Below) 4 j

The completed weld (groove welds only) shall have the reinforcement of a groove j

weld including the finallayer removed substantially flush with the surface prior to Mwining the required nondestructive examinations, (irr). The finalIrr shall j

be j fwo.ed after the completed weld has been at ambient temperature for a t

minimum period of 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> to determine the presence of possible delayed j

crachng. See G) below.

l (g)

Heat input shall be controlled within the WW bend length per unit length of i

electrode, as given on page 2.

i j

(h)

The weld arm shall be maintained at a temperature of 454550' F for a minimum i

of four hours after completion of the weld repair.

4 i

(i)

The Mwa of the repair weld and all in process operations shall be I

witnessed by the authorized inspector ifindicated on the traveler by the inspector.

}

0)

Posthmet operations in (h) above may be performed after the second layer or 1/4" i

j minimum thicknans has been deposited.

a 4

1, I

i, w

=

v n

v

ocT-is-1993 29:53

=0M CEB CE Chattanooga TO EA-SC-93-08 -01 Page 8 of 12 i

WELDING PROCEDURE SPECIFICATION DWPS SMA-3.43-937 Date 10/15/93' Page 5

of 5

Rev.

1 Date 10/18/93

" TEMPER BEAD TECHNIQUE & AFFECTS OF APPLICATION" CW4.k,e_@ '9 g_y em4-@ &,,,,.,.-,.,...,.,,.,,._.,,'

7

,0visfey_ m, ff f f f f f f f f f f,f f 7-

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f, y.. +...

l N z' 4 Z. A f f r.c. O. d _ K e.ee c _ A k

x x

v o rm

+

BsAd.f.LClays?

y s

1.

Heat affect zone created by 1st layer of M 2.

75-80% overlap desired to achieve good tempering of ist layer band, and HAZ. outside bend of 2nd layer must mg touch base material Second layer deposit tempers the 1st layer, and large portion of HAZ, which causes refining and nonening of grain structure within the HAZ.

3.

Hardsmed area of outside bend of 1st layer. If outside bend of 2nd layer is allowed to toudt bass maanrial, than this hardened area is moved further out, and refinement does not happen.

4.

Overlap of layer 2 by layer 3 to be y-E ^ 'y the same as before, and thereby enhans the tempering affects on layer #1 and the HAZ.

5.

Subsequent layers may be deposiend as desired to anhanna outer edge configuration and reduce grinding thns (ALARA). Most of tempering affect has aheady occurred during layers 2e3, and any =Mittaa=1 temperins will take pleos from the prehest and interpass.

Complete cepping of beads to achieve a araight upside wiu encourags bend rollover and require more srindins tina.

l l

~ ~ ~ ~ ~ ]a

EA-SC-93-087-01 l

ABB/CE Chatter oega e

Page 9 of 17' WELDING PROCEDURE QUALIFICATION RECORD t 563 v.ia:n COXBUSTION ENGI2rEERING, INC.

Ps0CEDURE QUALIFICATION RD. 18A 3 43 011SB CATE 12-13-89 Editorist Cr,rrection(s) 3/5/93, 10/15/93 ouALIFIED 70 CODE SECT 10N(s) !!f lx & xi MATERIAL SPEC. & GRADE SA533 ce

't' Ct

't' T0 niteFe 1 eeeesit FOR WELDING P No 3

TO F Wo 43 BACE!NG EEGyltENENTS Ease Waterial la facties VELDING PROCIES thi.tded Metet Are Malf Beed Technicue THICENESS (8 DI A. IF PIPE) 3.58 thick etate TYPE VELD JOINT U Croove. 28 demo eroove F!LLER METAL F No 43 fneonel A Me N/C _

PO$1TICN TEST VELD vertient

( 30 I

$1NGLE or MULTIPLE PASS multicle SPEC. or ANALT518 SfA5.11 (N4Cr893 NO. OF LATER$ (IF CLAD) N/A NO. OF AR'C8 ene ELECTRODE SIZE 3/328 and 1/8. die.eters PRENEAT 350*

• ein. seat 3D. ins. before.etela.

MAX. INTER Pass 450'F Flux N/A MAlsTAIN PRENEAT UNTIL PWNT fen SW!ELDING GA$(ES) & CORPOSITION w/A POSTMEAT TREATNENT $00* F t 50' 8 f or 4 hee. min.

FLCW RATE N/A oost heat eerformed eft.e 2 tavers of butter TTPE CURRENT DCar OTNER:

war. v..ve width - 3x core of.. test block at deo. sit.d doe 1/48 ein, thickn.aa ametent t.en. for 48 keurs erfor to finet P.T.

• No sinate n..e deoosit thletne.a ereeeded 1/2"

• • Read tenetthlinch flectrode J01BT CE$1CN stas uo.

Ptocitt WIRE DIA.

AMPNKats Are votTS BEAD LtWCTW taver #1 smA 3/32. dia, 59-45 22-73

,42 =

taver #7 tmA 1/88 dia.

70 90 23-26

.37 m salance SMA 1/8" die.

70 90 23-26 I

.37"**

1 FEttlTE 15 AUSTEu! TIC CLAD DEP081T DEPOSIT ANALYSIS C

.051 Mn 7.73 P

.004 3

.010

$1

.46 CR 13.97 N1 67.3 No e.01 Co

.33 N2

.014 Other Cu -.02

. 01 ft..&S CB.TA - 1.74. 07 Fe 3.53 At GUIDED BEED TESTS CMARPY V-totCW f kPAC1' TFtTE DicP tTISMT Tf fTt ;

FACE:

tecAfton Trup FT/Las allt LAf trP TfwP ttsutts I 4D 9F 200T:

see Pese 2

• 3D 1F SIDE: 4 0.r. - John Arnold

-20 2WF MActor EDT

-30'F

.,w

_ e.............

itNe tt e f ttis a toem T..oerature I

wom.-erstrueffvY TttTs e.t.

0.r Tata/C.cartton SPEC.

O!NENfl0NE AREA ULT!KATE ULTIRATE CHAEACTEE AND

..ch 1/48 demanit WS.

WIDfN TNY.

te. 1N.

L O&B l R$

$Tittf Pf1 LOCATICW CP FAftU U,7.

Y9 1

.751 1.213 1.1414 122.100 94.400 Base metal w.T.

Pr e.r. - e. cartten ys 2

.797 1.798 1.3611 128.750 94.600 taae w t.t e

visual

0. r.

W. Cass i tn.,

att Weld Metat on Pase 7 Other Liould n = trant in-s ted aft.r..ch t/4. of d x:ft

. _.....................q Final furf ace P.T. - 0.f. W. Warley We certify that the statements in this record are correce and that the test welds are prepared, welded and tested ll VELDER fee Ref.w ITMBOL YW accordance with requirements of the AsKt Code.

DEPT res 9648 Su

" ^ p IRCINEERIES, IRC.

TEST No S1188 M

_9V TEST LA3. pet Lab

_ 3T:

T.E. toween - AKZ 8T OTNER dV.9 A I-- l

/

TITLE u

n E.L. Sw ten - A&R T L. Sellow - AN This Document is The Pesperty Of E.L. Eatth

• SLAI CDENTI(E ENEtuRKing, Inc., Wile >ttR, CENE.

And is not to se tepreemed, or used To Fwnish AnP In-i f.rustlen For mettre Of Draufres or apparutus Essept

%84's Pr*rleed for Dr Agreement With as(d Ceupery.

j

u aC-95-Oe NU1 c Yhcncesa To

~

Page 10 of 12 Ceense1mem)tessunsases PCYrER SYSTEMS CROUP F f ELD CCNSTRUCTION WELDING PROCEDURE SPECIFICATION OWPS -_M-3 43"21133 g g, 12/13/39 2

3 page 0

E ev,

p, i

4 Hardness - Rockwell

'C' All Weld Metal Tensile

.502 19J2 Thickness

=

Area

=.19792 MAZ

= 21,22,21 R'C Yield KSI

= 67.2 Yield Lbs.

= 13,30@

Bottom of Groove Tensile KSI

= 99.8 Tensile Lbs.

= 19,758 HAZ

= 25,23,24 R'C Elong.

'2' Inches

= 2.71 Elongation %

= 35.5 Reduct. Area Dia.

=.392 180*

=.429 Reduction %

= 33.3 CVN's Base Metal sarole i Test Tenn.

FT/Lbs Enerov t Shear Mils Lat. Exr XS-TA

+30 113 50 78 XS-TB

+30 96 40 70 XS-TC

+30 90 30 64 CVN's HA2: (Bottom of Wald)

Satenle e Test TapD.

FT/ Tim Enertry

% Shear Mils Lat. Ex:

XS-ZD

+30 88 80 73 XS-ZE

+30 89 90 78 XS-ZF

+30 88 90 74 Test block received QET, plus forty (40) hrs. 6 1100-1200*F heat treatment prior to welding.

Block dimensions vare 3.5" thick, x 18"!

wide, x 31" long.

3 13:01 FCCM ABB/CE Chatta cosa TO Page 11 of 12 sadnes5TIOWhtWsINEERIES POvvER SYSTEhet GROT #

FIELD CCN5TRUCTION WELDING PROCEDURE SPECIFICATION OWPS EE"3

• 43"Q1' 00 car.

12/13/59 j

l 3

Sage J

_ of Rev.

O Date ll

{

" TEMPER BEAD TECHNIQUE & AFFECTS OF APPLICATION"

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G. e ow Tsk/s BEAD.*I.ECLsyt!

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1.

Heat affect zone created by 1st layer of deposit.

2.

75-80% overlap desired to achieve good tempering of 1st layer bead, and HAE. outside head of 2nd layer must nas touch base material.

Second layer deposit tempers the 1st layer, and large portion of MAZ, which causes refining and

]

softening of grain structure within the HAZ.

3.

Hardened area of outside bead of ist layer.

If outside bead of 2nd layer is allowed to touch base material, then this

~

hardened area is moved further out, and refinement does not happen.

4.

Overlap of layer 2 by layer 3 to be approximately the same as before, and thereby enhance the tempering affects on layer

1. 1 and the HAE.

5.

I4yers 4, 5, E 6 may be deposited as desired to enhance outer edge configuration and reduce grinding time (ALARA).

Most of tempering affect has already occurred during layers 2&3, and any additional tempering will take place from the preheat and interpass.

Complete capping of beads to achieve a straight upside will encourage bead rollover and require more grinding time.

L

-~ _ _

EA-SC-93-087-01

_ t s- ?93 13:22 DOM AEB/CE CFattancego To n c i.w i nu e nw s w u n s. ww m..m....... ww..

Page 12 of 12*** "'m COMBUSTION ENGINEERING,INC.

20ce=oer 10, 1974 anocEcune oVALIFtCAT1oN No. 9! *I2

• 3"lC3

__ _ l OATE III

orial correc:1on October 15, '9934 OU AU PIE C To CODE SECT 1oNts)53-168 v ATE mi Al spec. a c mAoE SA-533 Gr. 3 C1. 1 CST To 2 1/2" 1

43

, Thickness ta ora.if aiPel FOR WELolNG P No To P No I

SinRle "I' Shielded..etal Ar-ry,e wELo a. i s

wEtmNG e nocEss I

3 A No POSITION TEST WELD _ M ond 2,g; g

FlLLER VETAL F No M11tiolc SPEC. or AN ALYS13 bFb"5.11 SNiCTfe*3 (.132)

SINGLE or MULT PLE 8 ASS N!b 1/8". 5/32" No. oF LAYERS OF CLAol ELEcTAcoE SIZE 1

Sin 8 e N/A No.oF AmCs sLUx N/A f PAEHE AT_ 60*F Minine SMIE LotNG GASCESI & COMPOSITION N/A

-_ i MAX IN'1 AJ A$$

350*F PLOW RAM N[b DC-RP MAINTAIN PREHEAT UNTIL PWHT TY;E CURRENT terbg WW ;_ 50*F bDI 9_Sf00YEd

. l PoSTNEAT TRE ATMENT BACK!NG RECulmEMENU g oTuEn. No sinele rams ekiekn....ve.aa.a 1/2" For 30 Hrs.

Fumace Cool to 600'F P-3 and P-12 are same per prey. ASME Code.

(Completed Joint as Welded)~

actNT ossiaN sE 4e wo. I Paocess Wine otA.

I Auesmes l Ame VOLTS INCHE$NIN, TcY I

9%

1/8" l

90 l

24 l

9%

5/32" i 125 t

24 30' I

I

[8"~~-.4' l

l l

l l

p.q

% FERRITE IN AUSTENITic CLAo otPOSIT DEPOSIT ANALYSIS C

_ Mn P

S

- St Ca-Nt

- Mo Co Na oeer GUIDED BEND TESTS CH ARPY VWOTCH IMPACT TESTS I

DROP-WElGHT TESTS FACE.__

"C ^ T '* "

vswe {

es I wits Lat exp TEMP l AESULTS_

1/4T HA2

+10*F (101.108.124 I

acct:

4 k"*"2M*

P

~3 %

.ti I

s oE:

a, 4

l MACRO:

l NDT F

O NON-DESTRUCTIVE TESTS TENSILE TESTS ee aesc =s=

wi-**s statss es. l c-*=acete e Locatioai or cauas Lieuto PENETRANT l Acceptable pacioGaAmc I Acceptable Trans.

95,300 IDuctile in Weld ULTRASONIC I

Trans.

93,300 IDuctile in Weld 1

i SAG.PanTicta 6

VISU A L i

i 3BE w., J,.+v an. %...

..<a so<c.** ~'

W. C. Jones

-syueot vELoaR Chattanooga, Tennessee

'],.,0,,*',,,",,*,O'IM [7 ** '** * '""""

oEPT E-7059-D eo=sustio-

~c mcca'ao-

'*c-Met R&D Dept.

' e v _-

d' f

sT As.

BY oTHE d A TITL 4

7 s m

>R-3.43-29 4

l l

l l

EA-SC-93-087-01 9

ATTACHMENT 4 Corrosion Letter e

,_---,--.--..,._yy-

._-e,--,,.,,

e ee,, ra

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

!-i= w c

.re i

October 15, 1993

)

MCC-93-525 i

Mr. Paul Gire Consumers Power Company Palisades Nuclear Plant 27790 Blue Star Memorial Highway Covert, MI 47043

Subject:

Corrosion of Palisades Pressurizer Material I

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 limited, but the results indicate there will be only minor corrosion 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 similar approach as described in the report.

Contact me if you need additional information.

Sincerely, N

J.

. Hall Supervisor, Corrosion Technology JFH/b cc:

S. W. Lurie K. Coe R. Taylor J. Amburn T. Nagee i

ABB Combustion Engineering Nuclear Power Crecusser Evwereg ec aceo Gas.1911

EA-SC-93-087-01.

Page 2 of 6' CORROSION OF PRIMARY PRESSURE SOUNDARY MATERIALS AT PALISADES l

1.0 INTRODUCTION

/"

There are several Alloy 600 pressure boundary penetrations at the Palisaces nuclear plant.

Typical applications include pressurizer heater ' sleeves, i

pressurizer temperature nozzles, hot and cold leg piping instrument /RTD nozzles, reactor vessel (RV) leakage monitoring

tubas, RV vent pipe and RV t

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 ID initiated stress corrosion cracks. During the 1993 refueling outage at Palisades, the pressurizer upper head and lower shall temperature instrumentation nozzles developed leaks.

Consumers Power Company elected to apply temporary leak repairs to return the plant to service.

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 I steel, a low alloy grade. Low alloy and carbon steels used as pressure boundary materials are clad with stainless steel or Alloy 600 weld metal to isolate the materials from the primary coolant, thereby minimizing corrosion and corrosion product generation. The objective of this evaluation was to deterisine and document the expected corrosion for SA-533 Grmie B steel. The results util also be applicable to other grades such as SA-508 Class 2 low alloy steel and SA-106 Grade B carbon steel used.for primary systas 1.iping.

2.0 LITERATURE DATA Reference (1) presents the only published literature data that are applicable to Palisades.

During the 1965 refueling outage at Yankee Rowe, inspections discovered two small areas where the reactor vessel cladding had been breached.,

e

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Page 3 of 6 l

The cladding defects wee mechanically produced after a surveillance capsu h lower became loose and dumped mechanical test specimens and other debris int The lower head base metal was A302B steel which h head of the reactor vessel.

been clad with Type 304 stainless steel plate using an intermittent This f abrication process resulted in large areas of the cladding-base Thus, the breach in the cladding exposed large technique.

metal interf ace being unbonded.

areas of tne underlying base metal to the reactor coolant.

d Because of concern about corrosion and hydrogen embrittlement, t 8 steel under initiated a test program to determine corrosion rates for A302 b

tion was a operating and shutdown conditions and to deter 70'F to ppe B) at temperatures ranging from concern.

solutions of boric acid (2000-2500 The specimens included both electrically insulated coupons o galvanic 500*F.

coupons electrically grounded to Type 304 sta For these conditions, the effects.

B aerated and derated solutions for up to 121 days.

t r vendor test program wsil characterized the corrosion rates of A302B. The rea 300-500*F in derated l

also conducted a few short term (6-14 days) tests at

/

I solutions containing 2000 ppe B.

d The results of the study showed that hydrogen absorption was no f about 3 mpy that the exposed A302B steel would corrode uniformly at a rate o ii (mils per year) which was sufficiently low to be of no conce 25 year lifetime of the plant.

t C-E re-examined the Reference (1) data in developing estima l will be i

applicable to the Palisades pressurizar applications in which t exposed to 640*F steam (low B 1evels) and water.

CORR 0SION RATE FOR PRESSURIZER MATERIAL 3.0 3.1 Ass'=ntions ble C-E used three basic assumptions in developing a corro

~

n au-n~vo1-J 1 Page 4 of 6

=

l to Palisades.

They were as follows:

1.

The corrosion of SA-533 Grade B Class I steel in boric acid solutions is 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 will not adversely affect corrosion. Similarly, there are only minor differences between A302B and SA-508 Class 2 ::r 3 and SA-106 Grade 8 and these differences will not significantly affect corrosion rates.

2.

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

3.

While operating, the coolant will be derated. While shut down, the coolant will be aerated.

3.2 Rates for Hiah Temperature Operation Palisades primary coolant temperature during operation.is approximately 640*F for the pressurizar. The maximum test temperature included in the Reference (1) program was 500'F. Data were obtained for six specimens of A3028 after only one week of testing in a refreshed autoclave with a 2000 ppe B solution.

For these specimens, the average corrosion rate was 0.6 For the specimen with the greatest observed weight loss, the apy.

corrosion rate was 1.0 mpy.

These values for corrosion rates, which are based on short term tests, are times been probably higher than would have been obtained had test significantly longer.

Carbon and low alloy steels usually follow a logarithmic or parabolic corrosion rate law. The time required to reach a steady-state condition may exceed 100 days.

Rates during the initial transient stage (which includes seven days) will be high compared to the steady-state corrosion rates.

3

EA-SC-93-087-01 Page 5 of 6 i

4 l

There are no corrosion rate data for low alloy steels in borated water at temperatures above 500*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 temoerature. Based on this, C-E judge that the (steady state) corrosion rate at 640*F will not be significantly greater than the rate at 500*F.

i In addition, the available data are from tests with B levels of 2000 ppe, significantly greater than expected at Palisades during the current fuei cycle, and, thus, they are conservative with respect to actual conoitions.

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 this analysis, 100*F was assumed to be of coolant temperatures during cold shutdown. The tests continued for 121 days with several interim. weight loss

.I determinations which showed that steady state rates had been obtained.

For the Reference (1) tests, the average corrosion rate for 100*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 steel clad or Alloy 600 nozzles in the pressurizer. The use of dissimilar metals will cause some concern about galvanic effects.

In the Reference (1) tests, the A302B specimens were both insulated from and connected to Type 304 stainless steel, which chemically is similar to the stainless steel used for cladding of the primary system. No difference in corrosion I

rates for the two types of specimens were observed and thus galvanic corrosion should not be a problem.

/

l The limited corrosion that will occur will not be a localized form of

-4

EA-SC-93-087-01 i

i Page 6 of 6 corrosion (deep pitting, stress corrosion cracking, etc.). C-E experience in aerated berated water indicates that the corrosion morphology will consist of the superposition of shallow pits with no deep penetrations.

Reference (1) also indicated that corrosion would be uniform with r.o localized forms of corrosion being observed.

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

4

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

7.9 mpy yr. x 0.2 - 2.4 mils / year 3.6 Additional Considerations 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 6 aduced boric acid levels.

4.^

RECOMMENDATION Fc nalysis purposes, ABS-CE recommends a corrosion rate of 3 mils / year for the Palisades pressure boundary material.

5.0 REFERENCE 1.

" Absorption of Corrosion Hydrogen by A3028 Steel at 70'F to 500*F," WCAP-7099, December 1, 1967.

..w--

i l

i EA-SC-93-087-01 4

i ATTACHMENT 5 4

i Traveler 2003067-001 1

1 l

i t

l

)

i 1

i 4

i l

EA-SC-93-087-01 i

j Page 1 of 18 j

Proc No 10.41 j

PROCEDURE TRAVELER Revision 17 i

Page 1 of 2 i

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Procedure No ;cetec 7-ce i Revision No

.2_.

Date Initiated

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g EA-SC-93-087-01 i

PALISMES NUCLEAR PLANT Proc No 3.07-SAFETY PEvIEW Page 2 of 18 Attachment i Revisten 7

.Page 1 o f.1 PS&L Log No

-Mh Item Identification:

No 2003067-001 Rev 2

Title ABB/CE NUCLEAR SERVICES SE Rev rRAVELER:

WELD REPAIR / MODIFICATION OF PRESSURIZER NOZZLEfS)

Describe Issue / Changes PPESSURIZER NOZZLE REPAIPS BY COMBUSTION ENGINEERING Reason for Issue / Changes PROCEDURE REOUIREMENT BY ADMINISTRATIVE PROC. 10.41 Yes No 1.

Does the item involve a change to procedures as described in the FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4.

5.1, 5.6, 5.8.

5.10, 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 FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10, 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 FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3.

4.4, 5.1, 5.6.

5.8.

5.10, 6.9, 7.4, 9.1, TAarE 4-21. TABLE 4-22 4.

Should the Technical Specifications or any of their Bases be changed in conjunction with this item 7 t

f TS Sections affected NONE TS Sections reviewed 3.0. 4.0 l

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 processes that are discussed will be followed for this Vendor support.

This traveler and the Palisades Work Order will control the work performed on the Pressurizer (T=72) temperature element nozzles and thermowell(s).

Rev. 2 changed drawing number and weld procedure revisions and added editorial l

clarification to several steps.

l i

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 is not required.

However, this Attachment shall accompany other review materials for the ites to document that a Safety Evaluation was not required.

Appr<sdek y 4ekens sath 4 kekM, tW14 (A d l0. Al 0 10ll9 l9 2

&CA.- i deM eI#

Prepared By Date 3eviewed ay Date

EA-SC-93-087-01 Page 3 of 18 Procedure No. 2003067-001 4

Revision No. 2 Issued Date 10/19/93 i

PALISADES NUCLEAR PLANT MAINTENANCE PROCEDURE e

TITLE:

ABB-COMBUSTION ENGINEERING NUCLEAR SERVICES TRAVELER NO. 2003067-001 WELD REPA!R/ MODIFICATION OF PRESSURIZER N0ZZLE(S) i h*

ll,

/ l0 l4 $ 8 Pr d e-S or(sor #

Date' j

/ /(.)ll9 9 3 ical Review Date' b

A.i b4f

/ /0 1 45/

1 User Reviewer Date' Rev #

j

EA-SC-93-087-01

' Attachment 3 ABB-COMBUSTION ENGINEERING PAGE f*bd $!i NUCLEAR SERVICES REVISION 2 TRAVELER NO. 2003067-001 DATE 10/19/93 WELD REPAIR / MODIFICATION OF PRESSURIZER N0ZZLE(S)

I UTILITY:

CONSUMERS POWER COMPANY SITE:

PALISADES N0ZZLE NO.

PRESSURIZER NO22LE REPAIR 1.0 TABLE OF CONTENTS AND LIST OF EFFECTIVE PAGES:

CONTENTS PAGE NO.

E COVER PAGE 1

0 REFERENCES 2-3 0

PREREQUISITES 4

0 PERFORMANCE 5-11 0

DATA SHEET 5.1 12-15 0

APPROVED BY:

lb'M-Of

• 1 l0 M 43 TASK W DATE OWNER REPRESENTATIVE DATE

/6'-/9-95

/0 ~ao -9 3 ALITY REPR1SENTATIVE DATE -

AUTHORIZED INSPECTION AGENCY DATE d#l

&&s ENQINEERING

/DATE

.EA-SC-93-08I-01f ABB-COMBUSTION ENGINEERING PAGE N'DE W'3-h NUCLEAR SERVICES

' REVISION 2 se > x 18 TRAVELER NO. 2003067-001 DATE 10/19/93 l

2.0 REFERENCES

NOTE? Ihe applicable revision 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.

I 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.

-i 2.4 ASME Code Section XI, 1983 Edition, Summer 1983 Addenda, i

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

[

(Materials) 2.6 ABB/CE Procedure No. DWPS SMA-3-.43-937, Rev. 1.

t 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.

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

2.10 ABB/CE Procedure No. 0.P.-9.4, Rev. 12.

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

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

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

l i

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

i l

2.15 ABB/CE procedure No.

0.P.-

9.8, Rev. 8 I

i f

m a

b r,

EA-5C-93-087-01 E

ABB-COMBUSTION ENGINEERING PAGE 39F T$" 3 NUCLEAR SERVICES REVISION 2 Page 6 of.38 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 - Supervisor /Vorker Q - Quality Operations 0 - Owner / Client A - Authorized Nuclear Inspector V - Witness l

I - Inspect H - Hold MPE - Magnetic Particle Examination UT - Ultrasonic Test WIR - Veld Inspection Record LPE - Liquid Penetrant Examination-UTE - Ultrasonic Test Examination ROI - Report of Inspection l

I l

i 1

)

l

+

ABB-COMBUSTION ENGINEERING

'PAGE:4^TW*f8"'3' "E*

NUCLEAR SERVICES REVISION 2 i

l TRAVELER NO. 2003067-001 DATE 10/19/93 l

l l

3.0

- PREREOUISITES 1

I 3.1 All requir'ed personnel have received training in Health Physics, Quality Control,' Radiation Control, and AIARA:

l procedures and have been trained in the work tasks.to be~

performed.

l 3.2 Prewelding ECT has been completed and the location of the, nozzle to be repaired has been identified by Consumers-Power j

Company in writing.

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

3.4 Scaffolding at the pressurizer where work isLto be perfermed-has been erected, if required 3.5 Insulation has been removed.

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

j

~

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

I 3.8 Assure that the pressurizer water level is below the nozzle i

I elevation prior to performing any. task.

3.9 Locate and record all information from the nozzle such as code l

numbers, heat numbers, and nozzle location. Report this.

_ j 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 i

tranferrod 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 sin shall'be dried at a I

temperature between 225'F and 350*F for at least 8 hrs before reissued for use. Electrodes exposed to the~ atmosphere for l

more than 4 hrs shall be rebaked at.550*F+/-50*F for 2 hrs.

l Electrodes shall not be rebaked more than once.

3.11 Welding materials shall be controlled during repair per ref.

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

i s

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-a v,,,-

,.,-,e

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 5^ Y 1T'3 Page 8 o'-

. e.,

NUCLEAR SERVICES REVISION 2 t

TRAVELER NO. 2003067-001 DATE 10/19/93 STP NO.

i 4.0 PERFORMANCE NOTE:

The following steps shall be performed in the sequence j

listed. Nozzles may be worked in parallel.

i 4.1 Verify satisfactory completion of prerequisites.

S E

REMARKS:

Q H

0 A

4.2 Layout and prepare for NDE the area required for S

E the weld buildup and 5" min. radius around the Q

H buildup.

O NOTE: Pay special attention to the annulus between A

the nozzle and vessel shell.

i REMARKS:

4.3 Perform magnetic particle test of base metal pad S

buildup area and 5" minimum radius Q

I 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-l l

l

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 6^ Y T$"'5 NUCLEAR SERVICES REVISION 2 age 9 or_ 18 TRAVELER NO. 2003067-001 DATE 10/19/93 l

4.4 Perform ultrasonic test of base metal pad buildup S

,1-l area per PAL-410-005, and 5" radius

(

Q p4N-Acceptance criteria:

O (1) Any area, where one or mo,gre disconti'nuities 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-1.X-900 and VS-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 H

450'F max. for a minimum of 30 minutes prior to o

start of welding.

A REMARKS:

u :

ABB-COMBUSTION ENGINEERING PAGE 7 OF 15Page 10 of 18 ;

NUCLEAR SERVICES REVISION 2 TRAVELER NO. 2003067-001 DATE 10/19/93 CAUTION: THE 350*F PREHEAT MINIMUM MUST BE MAINTAINED CONTINOUSLY THROUGHOUT THE WELDING OPERATION i

AND UNTIL INITIATION OF THE POST WELD HEAT TREATMENT OF STEP 4.12.

l 4.8 Deposit first layer of pad buildup per S

H WPS-SMA-3.43-937 using 3/32" dia electrode.

Q 1

Verify interpass temperature.

O l

Heat Input per SMA-3.43-937 (Bead length / unit length A I

of electrode) Shall be verified no less than once WIR d

per welder, i

REMARKS.

[

l l

4.9 Grind first layer to remove approximately 1/2 of S

E l

the deposited weld material.

Q I

~

Verify interpass temperature.

O REMARKS:

A i

4.10 Deposit second layer per WPS-SMA-3.43-937, S

H usin5 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

per welder. Verify interpass temperature.

WIR REMARKS:

i 1

4.11 Deposit the third layer and subsequent layers S

U using 1/8" dia. electrodes. Each of these weld Q

I j

deposit layers (third and subsequent layers) shall O

fuse to the nozzle at the weld / nozzle interface.

A h

Deposit sufficient number of layers to meet the (f

requirments of ref. 2.la or 2.lb. Ven4,Jerp~ecs WIR f

lawpra4we, 4.12 Perform postweld heat treat of pad buildup and 5" S

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

H STD-100-089.

O Hold temperature at 500* +/- 50*F for a minimum A

[

g of four (4) hours.

REMARKS:

j i

_.. _ s ; O, L.

ABB. COMBUSTION ENGINEERING PAGE gtteprT5' 5 NUCLEAR SERVICES REVISION 2 Page U of d TRAVELER NO. 2003067-001 DATE 10/19/93 I

1

l 4.13 Drop temperature and allow to cool to ambient S

y temperture.

Q W

l Record date and time buildup reaches ambient 0-temperture.

A Ambient temperture is defined as follows:

-i "That temperature the material reaches durin5 cooldown when the recorded temperature does not change by a ten (10) degree F increment during a period of two (2) hours".

j 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 <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />.

4.14 Remove preheat equipment and thermocouples.

S E

l Prepare surface of the weld buildup and all Q

'I l

attachment areas for non destructive testing.

O l

Weld buildup to be ground per ref.2.la or 2.lb.

A Mark areas where temporary attachments are removed j

with approved marker.

ROI

'l!

REMARKS:

I l

4.15 PT pad buildup per 0.P.-9.4 S

W t

l The following indications _are unacceptable:

Q 1

l

a. Any cracks or linear indications.

O i

f

b. Rounded indications with dimensions greater A E55 than 3/16 inch.

LPE

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

M REMARKS:

AY1 S Lh Deh 6 ;5 D 2 477041 3

To Mad,- & si' rfkeT' 73 eldAe1~ h r TT.

2 -20 5 F AwrxT eAmT ihc-MAD & M MA '/ Ot%c-O WsTN AC.T.diTi6.5.

NOTE:

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

I 4.16 Grind to remove indications. Notify CPCo S

E Engineering prior to grinding. Maximum grinding Q

E depth allowed is only to within 3/16" of the O

original base material.

A REMARKS:

l l

l

~

EA-SC-93-087-01 ABB-COMBUSTION ENGINEERING PAGE 9%Fehgnt 5 l

NUCLEAR SERVICES REVISION 2 Page 12 of 18.

TRAVELER NO. 2003067-001 DATE - 10/19/93 r

4.17 P.T. grindouts per 0.P.-9.4.

S W

r The following indications are unacceptable:

Q l.

a. Any cracks or linear indications.

0

b. Rounded indications with dimensions greater A

l i

than 3/16 inch.

LPE l

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

REMARKS:

l i

n 4.18 Weld repair grindout per WPS-SMA-43.43-909.

S.

H

[

REMARKS:

Q l

O A

j WIR 4.19 P.T. final surface per 0.P.-9.4.

S-W_

The following indications are unacceptable:

Q I

a. Any cracks or linear indications.

O

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:

I t

i i

EA-SC-9 3-08 7- 01 ABB-COMBUSTION ENGINEERING PAGE ltytg.ejo;tPage13M18{

5 NUCLEAR SERVICES REVISION 2 TRAVELER NO. 2003067-001 DATE 10/19/93 4.20 Ultrasonic test pad buildup,and.5" minimum radius per PAL-410-005.

S j

a The following acceptance. criteria shallcapply:.

Q 1

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.

for t from 3/4 in. to 2-1/4 in., inclusive (3) 3/4 in. for t over 2-1/4 in.'

- a 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.

amplitude.

k 4.21 M.T. 5" radius and attachment areas S

W per OP 9.2.

Q I

The following indications are unacceptable:

0

a. Any cracks or linear indications.

A-i

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

I

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

{

REMARKS:

j 1

NOTE:

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

4.22 Install thernovell and weld per WPS-GTA-8.8-910 S

W and Ref. 2.1, (a) or (b). P.T. root pass per Q

1 4.23.

O REMARKS:

A WIR

c;_gce.jpagp g ~ 7

' ABB-COMBUSTION ENGINEERING PAGE tyt g m 5-NUCLEAR SERVICES

_ REVISION 2 age M d 18,

~

TRAVELER NO. 2003067-001 DATE - 10/19/93.-

4.23 P.T. root and final weld per O.P.-9.4.

S tJ The following indications are unacceptable:

Q 1

0 l

-]

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 '

j all equipment. Return to as-found condition.

'O

'l REMARKS.

A i

1 I

4.25 QC complete Final Inspection Checklist in S

accordance with Reference 2.2.

-Q 1

REMARKS:

.O A.

I i

I i

1 l

l l

2 l

4 I

i

- ~_.

EA-SC-93 087-01:

}

ABB-COMBUSTION ENGINEERING PAGE lytegh=9 sit 5 l

NUCLEAR SERVICES REVISION 2 Page 13 of 18 TRAVELER NO. 2003067-001 DATE 10/19/93 i

DATA SHEET 5.1 - PRESSURIZER TOP HEAD N0ZZLE 1-I 4.1 S H 4.9 S E Q H Q

I_

O _

0 A _

A l

4.2 S H 4.10 S H.

Q H Q 1 0 _

O A

A VIR 4.3 S _

4.11 S E l

Q l Q I O _

0 _

A _

WIR_

A MPE 4.4 S

4.12 S. E i

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i EA-SC-93-087-01 l

ABB-COMBUSTION ENGINEERING PAGE 15tepegsy 5 j

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EA-SC-93-087-01 i

I i

ATTACHMENT 6 inconel 600 PWSCC Status Report l

4

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l EA-SC-93-087-01 Page 1 of 31 l

l l

To:

KVCedarquist From:

PDFitton Date:

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 Please find attached a status report of the work that has been completed to date on Primary Water Stress Corrosion Cracking of Inconal 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 inconal 600 in i

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.

i i

1

EA-SC-93-087-01 Page 2 of 31 STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL 1.0 EXECUTIVE

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 j

Inconal 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 J

understand and mitigate PWSCC in PCS penetrations.

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

Thase recommendations seek to balance risk with cost.

PWSCC of Inconal 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 pressurizar RTD'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 inconal 600 used at Palisades have Page 1 Revision C

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l EA-SC-93-087-01 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 4

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 Inconal 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 Inconal 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 i

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 Inconal 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 Inconal 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 Pressurizar Nozzle Evaluation B. CEOG Task 636 Pressurizar 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 Inconal 600 Penetrations Information Package Page 2 Revision C

i EA-SC 93-08 -01 i

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Page 4 of 31 OF INCONEL 600 PRIMARY SYST j

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CKING 5

TERIAL 3.

Support position that PWSCC is not a safety rel t d j

Concern.

(

ae A. CEOG Task 637 Pressurizar Shell Corrosion Te e

Provide _ inspection method.

}

i 4.

ng

[

A. CEOG Task 635 Qualification of Eddy Current Examination Techniques 3

the pressurizer heater sleeves during the 89Maout j

spection of and 90Refout.

sleeves was found.No evidence of leaking pressurizer heater 90Maout,

)

j i

3.0 GENERAL DISCUSSION Primary Water Stress Corrosion-Cracking (PWS l

of Inconel have Inconal 600 sleeves or nozzles. The widesp

- oncern.

i 2

at-Inconel 600 in Primary System penetrations make i

se of significant reliability and regulatory concern.s PWSCC a 4

The following identifies failures that have been id i

to date.

entified i

1.

Calvert Cliffs Unit 2 experienced through wall cra ki i

attributable to PWSCC in_20 out of 120 pressurizar heater

{

c ng sleeves.

2.

SONGS Unit 3 experienced PWSCC in 4 pressurizer i nozzles. The nozzle material had a very high yield 4

nstrument strength. The failure was attributed to a particular i

material heat number.

1 3.

St.

supplied to SONGS-3. Lucia inspected one nozzle of the same heat n j

nozzles of similar heat number.It was cracked. They replaced all'6-

' i e

4.

Calvert Cliffs Unit 2 inspected pressurizer heater nozzles. They found 1 leaking and cracked. The original i

material was of low yield strength but had been reworked

twice, j

5. The Navy has experienced PWSCC failures of forged I 600 at temperatures lower than CE pressurizar i

nconel temperatures. Navy nozzles are rolled into place and welded.

6. Edf (French) including circumferential indications. Edf nozzleshas exp j

l rolled and welded.

are t

7. Westinghouse has experienced PWSCC of forged In i

steam generator tube plugs.

conal 600

8. Westinghouse has experienced PWSCC of Inconel 600 generator tubes.

steam l

Page 3 1

Revision C

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EA--SE-9 3-08 7-01 Page 5 of 31 OF INCONEL 600 PRIMARY SYST 4

CRACKING a

MATERIAL 1

9.

Maine Yankee has experienced PWSCC of Inconel 600 generator tubing.

steam

10. Arkansas Nuclear, Unit 1 i

(B&W Plant) pressurizer nozzle in December of 1990. experienced a cracked Repairs of cracked Primary System boundary materi l 3

expensive, Stress Corrosion Cracking (PWSCC) dose intensive, and time a

are involves intergranular r

stress corrosion cracking of alloy steels in a primary wat environment. Three things are needed to develop PWSCC.

er are:

They

1. Residual or operating stress. In the ID of these and tubes the stress must be a tensile stress.

i nozzles thinking is about 40 ksi of tensile stress is requi Current i

initiate PWSCC in Inconel 600.

red to 2.

Temperature. PWSCC is highly temperature dependent believes based on literature for every(temperature increase) of 10C (18F)the corro j

CE the pressurizer is most vulnerable.

This is why

2. The material must be susceptible to PESCC.

and steam generator tubing) characteristics of Inconal 600 Desirable less is known about hot forged Inconal 600are well researched.

Much High material yield strength is undesirable (nozzles).

i Palisades Plant.PWSCC continues to pose a large economic risk to th l

plants with Inconel 600 penetrations. We should not beTh e

i surprised by the failure of any single Inconal 600 4

penetration. The probability of developing a PWSCC initiat d PCS leak is increased by i

j e

1. High service temperatures j

2.

High material yield strengthHigh residual stresses develo 3.

j

4. Service time PWSCC will not occur in inconel 600 without residu l CE has estimated the minimum stress to initiate a PWS a

stress.

at 40 kai. Higher residual stress levels will shorten the CC crack i

time to initiate a crack. Higher service temper t high material yield strength will shorten the time to a ures and initiate a PWSCC crack. It is unclear exactly what th minimum temperature is below which no cracks will occur e

estimates that material with a yield strength greater than 50

. CE i

ksi is unfavorable is more likely to crack. This general guidance helps prov;ide the basis for identifying penetrati with the highest susceptibility to PWSCC.

ons PWSCC will never occur in relatively low probabilitThis does not mean y

Page 4 Revision C

l 12-SC-93-087-01 Page'6 of 31 STATUS REPORT ON PRIMARY WATER STRESS CO i

OF INCONEL 600 PRIMARY SYSTEM PRESSURE CRACKING

' ATERIAL locations.

The probability is lower, but not zero i

l Temperature is a key factor in the development of PWS rate of PWSCC will double for every 18F increase in i

l CC. The temperature. It is therefore reasonable to expect initial problems to occur in the pressurizer

.i j

most of the installation processes used throughout the PCS ar The relationship between temperature and PWS e relatively j

. The helpful in developing an assessment.of areas most at i

is clear that most initial failures will occur i i

risk. It penetrations. As such, i

it is reasonable to focus mostn pressurizer inspection efforts in this area. It is important to n t plants provide a much larger data base to'make i

o e that

{

er from, and to continuously evaluate previous assumptio will be worthwhile to use this information to periodically

{

ns. It re-evaluate Palisades response to this issue.

One of the key points in determining that the PWSCC I

Inconal 600 penetrations is not a safety issue is th j

of orientation of the cracks. Circumferential cracking can i

e axial ejecting a nozzle or' sleeve. The residual stresse i

cause

{

present in the heat affected zone of the welds result in a e

hoop stress that may cause axial cracking, not circumferential cracking.

Some work done under CEOG Task 636 directly supp I

affected zone are directly dependent on the incon

}

orts this i

material properties. Pre-reaming results in high Welding then creates residual stresses that are z e.

the material properties at the surface. The residual m ted by e

govern material susceptibility. High stresses material is of slightly less concern, strength non-reamed is also under tensile stress due to weldingstill gove i

I t

exceed the yield strength of the material. susceptibility is

, but

}

Additional work determined most of the sleeve / nozzle actually under compressive stress. Tensile stress'is requir d area is-to develop PWSCC.

{

Lower stress levels are required to e

propagate a crack than to initiate one, so developing a high 3

enough tensile stress on the-ID of the sleeve / nozzle is critical in initiating a crack. Post weld' machining was i

i Page 5 Revision C i

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l EA-SC-93-087-01 Page 7 of 31 OF INCONEL 600 PRIMARY SYSTE 5

KING I

RIAL the highest tensile stress.actually beneficial in removing a layer o i

failures have occurred due to the failure of pressu i

heaters.

Both Arkansas Nuclear Unit 2 and San Onofre have zar experienced heater sleeve failures caused by the swelling of i

a failed pressurizar heater. The failed heater i

i extremely difficult to remove. As time goes on.can be i

swells and places enough pressure on the heater sleeve to the heater cause cracking. The prompt replacement of a failed i

pressurizar heater can prevent this problem.

1[

4.0 SUSCEPTIBILITY QE PALISADES PRESSURI j

PWSCC Q

}

worked form of Inconel 600. Pressurizer heater sleeve i

The susce Inconel 600 is reasonably well known.ptibility of cold worked has been done due to the widespread use of cold worked Significant research i

Inconel 600 in Steam Generator tubing. Combustion Engin completed CEN-393-1 titled " Evaluation of Pressurizar Heater eering Siseve Susceptibility to Primary Water Stress Corrosi Cracking". This was done.as.CEOG Task 631 k

on November of 1989. Additional work was comp,leted in CEOG T and completed.in i

636,

" Pressurizer Heater Sleeve Evaluations".

ask i

i Palisades pressurizar heater sleeves were categ

}

n the t

made based on the low yield strength of the material, absence i

s of pre-installation reaming of the sleeve, and the absence of i

rework on the heater sleeves. Plants having inconal 600 with I

a yield strength above 50 ksi i

installation roaming done were, categorized as moderate ri k or those having pre-i units. Plants having both a high yield strength material and i

s pre-installation reaming have been categorized as high j

susersptibility. The susceptibility ratings are relative measures of probability 1

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.

j a high susceptibility plant.

Calvert Cliffs Unit 2 was 1

4 j

i The development of PWSCC in the steam 1

i Maine Yankee is a cause for concern. generator tubing at pressurizar. The steam generator tubing installed in Steam generator tubing j

Maine Yankee plant has favorable properties:-is it is not i

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EA-S C-9 3-08 7-01 i

Page 8 of 31 STATUS REPORT ON PRIMARY WATER STRESS CO i

OF INCONEL 600 PRIMARY SYSTEM PRESSURE l

G 4

highly susceptible to PWSCC. Steam generator tubing is residual stresses at the tube sheet. explosively expanded in Yankee tubes cracked.

This is where the Maine 1

i The plants with unfavorable pressurizer heater sleeve to pressurizer heater sleeves cracking at Palisadesm i

the statistical nature of PWSCC,

. Due to 4

that may occur in installing individual sleevesand the minor differences a

not be surprised if a few failures occur in lower

, we should susceptibility tubing. As such, we should be prepared to respond to a small number of pressurizer heater sleeve failures.

5.0 SUSCEPTIBILITY QE PRIMARY SYSTEM INCONEL igg NO2 j

PWSCC 1

All Palisades Primary Coolant System nozzles contain some i

Inconel 600. All Inconel 600 forged products have some yield strength and PWSCC that helps classify cold w Inconal 600, (nozzles).

does not work very well for hot forged products i

have also been unsuccessful in quantifying the suscep of hot forged Inconel 600.

y the area of highest concern. All Inconel 600 nozzl ce have developed PWSCC to date are in the pressurizer a

The temperature runs about 50F hotter than the-r

. This is PCS.

This would increase the corrosion rate by a factor ofe by the fact that PCS nozzle cracking has not bee during the 10 year ISI inspections that are required by Section XI. If widespread'PWSCC was occurring at lower temperatures XI program, o,r a boric acid walkdown at some of the 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 necessar develop PWSCC in any Inconal 600 product. They are:y to

1. Susceptible material

2. Temperature 3.

Residual or operating stresses that produce a high tensile Page 7

' Revision C l

EA-SC-93-087-01 Page 9 of 31 STATUS REPORT ON PRIMARY WATER STRESS C OF INCONEL 600 PRIMARY SYSTEM PRESSURE I

G i'

{

stress in the material Combustion Engineering has unsuccessfully tried to id i

was done under CEOG' Task 633. nozzle characteristics related entify

(

This No evidence of chemical contamination was foundCE evalu supports the cracking being PWSCC.

. This produces more variations in yield strength, grain sizeHot worked Inconel I

that promote PWSCC much more difficult. carbide precipita

, and 1

steam generator tubing does not accurately predict thePrevious work done on j

susceptibility of hot forged nozzles.

I diameter (ID).The BG&E nozzle cracks were initiated on the The crack growth rate was very slow.

indicates a high tensile stress existed on the nozzle ID This was initially relieved by cracking. Crack growth slowed and because operating stresses are much lower than presumed j

residual stresses.

crack growth than to propagate growth. Higher stress is necessary to init j

external inspection. Boric acid crystals were present j

SONGS-3 found their leak due to steam leakage observed during

{

a startup walkdown.

j Due to the high probability that PWSCC that will occur fi i

in the pressurizer, each pressurizer nozzle was evaluated i rst i. A brief summary is provided below:

n Pressurizer Surge Line Nozzle Pressurizar Spray Nozzle

- moderate susceptibility PORV Nozzle

- moderate susceptibility j

Pressurizer Safety Valve Nozzle-high susceptibility-high susc 3

i Pressurizar Lower Level Nozzles-moderate s i

i 1

Pressurizar Temperature Nozzles-moderate susceptibility 6.0 SAFETY SIGNIFICANCE 1

e' safety concern for Combustion Engineering plants. All i

may result in through wall leakage, axial cracks will n

{

cause a catastrophic failure of the pressure boundary.

1 PWR's. EdF (French)Some circumferential cracking has been observe welding. This results in a stress riser at the rollplants roll nozzles i i

j Page 8

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1 EA-SC-93-08 7-O L 1

Page 10 of 31 OF INCONEL 600 PRIMARY SYST i

ACKING TERIAL 3

transition. PWSCC can develop at this location re i

They were slid into place and. welded. No ci i

sulting in a j

e.

indications have be'en found in CE nozzles.

~

I a

1 4

The leakage path through a sleeve or nozzle can be rath tortuous. This results.in relatively low leak rat.

er mockup of a pressurizar heater sleeve and meas es in.the 4

}

carbon steel base metal corrosion in the area of the simulated PWSCC initiated leak. This work was done l

i Task 637.

The corrosion rate was estimated for one full i

i operating cycle, It is important to note that if a leak remainsand the affected.

activa and undetected long enough, significant erosion / corrosion of the base metal may occur.

}

7.0 REPAIR OPTIONS a

.ii Cracked. pressurizer heater sleeves and nozzles'have b and Babcock and Wilcox have qualified repair te een

{

i procedures, and equipment available for pressurizer heater sleeves.

i a single heater sleeve. Combustion Engineering ha i

techniques, equipment, and procedures available for most PCS nozzle locations. The Inconal 600 Working Group is looking at i

future activities to assure materials and equipment ar available fot-penetration would probably take three to four weeks toa j

e i

repair. Repairing multiple failures would take longer.

Replacement material-is not presently readily available i i

significant quantit well over one year.ies. The Calvert cliffs Unit 2 repair took n

3 l

j 8.0 RECOMMENDED ACTIONS i

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

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

{

2. Minimise cost by accepting a reasonable me j

3. Appropriately address regulatory concerns.asure of risk.

4.

Ensure nuclear and personnel safety.

A. INSPECTION

1. Continue to perform boric acid walkdowns on the PCS I

2.

Continue to monitor the results of 10 year ISI inspections 1

Page 9 Revision C I

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EA-SC-93-087 '

Page 11 of 31 4

STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL i

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.

5.

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 j

pressurizer RTD penetrations.

C. REPLACE

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

1.

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

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

duration.

D.

PARTICIPATE IN INCONEL 600 INDUSTRY INITIATIVES 1.

Sponsur 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 is 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 Inconal 600 Working Group, and support the justification for restart after a single leak.

Page 10 Revision C

EA-SC-93-087-01 Page 12 of 31 l

STATUS REPORT ON PRIMARY WATER STRESS CORROSION CRACKING-OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL 4

)

3. Evaluate participation in zinc injection studies looking i

at reducing the susceptibility of Inconal 600 to PWSCC.

l

4. Participate in CEOG Inconal 600 Working Group activities.

1 This includes EPRI efforts on Inconal 600. This will also 1

help identify other failures that may occur at other plants. Experience within the industry will directly 4*

impact the measures taken to assure acceptable economic risks are taken at Palisades.

4 5.

Evaluate participation in CEOG efforts in the area of 1

remedial measures. This may include nickel plating, stress l

relief, etc.

l 9.0 ATTACHMENTS

; Summary Table of PWSCC Variables and Effects

; Summary of Palisades Pressurizer Nozzle Penetration Susceptibility to PWSCC ; Summary of CEOG Task 633 " Pressurizer Nozzle Evaluation"

, ; Summary of CEOG' Task 634 "Inconal 600 l

Penetration Information" i ; Summary of CEOG Task 635 " Qualification of Eddy Current Exam Techniques" j ; Summary of CEOG Task 636 "Pressurizar Heater i

Sleeve Evaluations" j ; Summary of CEOG Task 637 " Pressurizer Shell Corrosion Testing" i ; Summary of CEOG Task 639 " Pressurizer Heater j

Sleeve Thermal Analysis" J

l i

i I

j i

l 4

Page 11 Revision C a

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EA-SC-93-087 Attachment 6 Page 13 of 31 STATUS REPORT ON PRIMARY WATER. STRESS CORROSION CRACKING OF INCONEL 600 PRIMARY SYSTEM PRESSURE BOUNDARY MATERIAL ATTACHMENT 1 i

+__+_________________+-__________________+ _________________+

Variable Known Effects Corrective Action

/ Comments

+__+_________________+_________________y

+._________________+

E Primary Water Will result in N

PWSCC with stress V

& susceptible l

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

0 Temperature Increase of 18F in N

temperature M

doubles the PWSCC E

rate l

N T

+ _ _ + _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ + _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ +. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ +

S Stress Tensile stress of Higher stresses T

40 kai is believed increase R

to be the susceptibility E

threshold.above S

which PWSCC may S

occur

+-_+-________________+-__________________+__________________+

M Cold Drawn &

Low Temperature _

Westinghouse SG A

Annealed Anneal tubing more susc T

Higher yield E

strength higher R

susceptibility I

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

A High Temperature CE SG tubing L

Anneal more resistant but not immune

+.+-________________+-__________________+__________________+

Hot Forged No Apparent Screening criteria

+__+_________________+.__________________+__________________+

Page 12 Revision C

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EA-SC-9 3-48 7-01 Page 14 of 31 12-14-vu PRESSURIZER SURGE LINE NOZZLE (1) (ASSEMBLY 985-01)

Service : Pressurizer Liquid Space (653F) i Inconel 600 985-03 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 ring. assembly.

Discussion:

The safe end should be considered medium risk to-develop PWSCC. It has been exposed to a high service temperature and has been welded on both ends. The nozzle 1

risk applications. material is slightly above the 50 ksi guideline for high This particular nozzle is at the bottom of the liquid space. This should be the lowest temperature location in the pressurizar. PWSCC that has occurred to date has been in the pressurizer steam have unknown effects on the susceptibility of thespace. T nozzle. The fact a repair would involve two external-welds would be helpful if a repair is required.

(

It is unknown what the susceptibility of the ring l

assembly would be. The repair would be extremely difficult. The absence of operating differential pressure is helpful; this is not a pressure retaining One of the key requirements for PWSCC to component.

occur is either residual of operating stress. The lack i

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 page):

./-

4 e

< awccm3.

Eng e. 2.

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

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12-14-90 EA-SC-93-087-01 SPRAY NOZZLE (1) (ASSEMBLY 986-01)

Page 16 of 31 Service : Pressurizer Steam Space (653F)

I l

Inconel 600 l

986-03 Yield 77,500 psi l

986-05 Yield unknown psi Rework:

None Cold Work:

I 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 pressurizar spray liquid, the service temperature would be closer to the cold leg temperature than to the pressurizar temperature. This greatly reduces the risk of developing PWSCC at'this location. The nozzle material is well above the'50 ksi j

i 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'and will have unknown effects on the susceptibility of the nozzle. The fact a repeir on the safe and 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-1LA.SH 986)

"d M

Drawings:

,g M -3l

,,i'

.i*

.1*

J'

[

N y

l y

,e Q

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.7,f

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j f$-sc-93-087-01 2 416 f 31 f

9 12 l

RELIEF VALVE NOZZLE (PORV) ASSEMBLY (1) (986-11) 1 l

Service : Pressurizer Steam Space (653F)

Inconel 600 i

986-13 Yield 77,500 psi I

j Rework:

None identified. This nozzle was not reworked during the PORV Replacement Project.

I l

Cold Work: None identified.

i j

Source of Residual stress: welding both ends; Discussion: These nozzles-should be considered high risk to

}

develop PW5CC. They are exposed to a high service temperature and have been welded on both ends. The i

nozzle material is well above the 50 kai guideline 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 l

nozzle is located on top of the pressurizer would be helpful if a repair is required.

j l

References:

CEOG Task 634 CE Drawing E-231-966 (M-lLA SH 986) i Dravings:

,y p

..r.

,.,.p' h

h g

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A- 087-01 Page 18 of 31 l

12-14-90 SAFETY VALVE FLANGES (3) (ASSEMBLY 986-15)

Service : Pressurizer Steam Space (653F)

Inconel 600 986-16A Yield 77,500 psi 986-16B Yield 77,500 psi 986-16C Yield 77,500 psi Rework:

None identified Cold Work: None identified Source of Residual stress: welding one and only.

i Discussion: These nozzles should be considered high risk to develop PWSCC. They are exposed to a high service temperature and have been welded on one end. The nozzle material is well above the 50 kai guideline for high risk applications. The PWSCC that has occurred to date has been in the pressurizar 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-1LA SH 986)

Drawings:

i

,s*

nP

• E.fJ' J

a a

4/

e y

k w

g l

e 1

.v =

l

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May (,SC-93-087-01 EA-Page 19 of 31 12-14-90 i

TOP HEAD LEVEL. NOZZLES (4) (ASSEMBLY 985-09)

Service : Pressurizer Steam Spacs (653F) 1 1

Inconel 600 985-07A Yield 46,200 psi 985-07B Yield 46,200 psi 985-07C Yield 46,200 psi 985-07D Yield 46,200 psi 1

1 Rework:

None i

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 kai guideline for high risk applications.

References:

CEOG Task 634 CE Drawing E-231-985 (M-1LA SH 985)

Drawings:

,',,;c # < " W F a f $ -.ca+ C ' os -u..,2

?nt'

- t :- >%g' M' j,

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hirac.cmaT L F l.A-SC-93-087-01 1223869@ 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 j

985-07C Yield 46,200 psi 985-07D 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 kai guideline for high risk applications. PWSCC that has occurred to date has been in the pressurizar steam space.

References:

CEOG Task 634 CE Drawing E-231-985 (M-1LA SH 985) d*4 m g

Drawings:

5)

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I EA-SC-93-087-01 3

Page 21 of 31 12-14-90 TEMPERATURE NOZZLES (2) (ASSEMBLY 986-07/18)

Service: (Assembly 986-07) Pressurizer Liquid Space (653F)

(Assembly 986-18) Pressurizer Steam Space (C53F)

Inconel 600 i

986-08 Temperature Nozzle Yield 46,200 psi I

986-19 temperature Nozzle Yield 46,200 psi j

Rework:

None Source of Residual stress: Partial penetration welds done on the inside of the pressurizar. These nozzles have the same configuration as those that failed at other CE i

plants.

I 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 50 kai guideline for high risk applications. PWSCC that has occurred to date has been in the pressurizar 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) nr.

inys:

,e A,. ;,

i l

-4 j

. y."".y -

ax/'e EVgggI M k=.::n.T m i 'f /

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At t ac r.m:n t 3 j

Page 1 of 3 EA-SC-93-087-01 1

05/09/91 CEOC TASK 633 PRESSURIZER N0ZZLE EVALUATION OBJECT!VE Provide an assessment of susceptt ot tity to PWSCC of CE pressurizer inst rument nozzles faericated from forged Inconel 600.

STATUS This test is complete.

The final report was issued 02-18-91.

SCOPE

1. Compile manuf acturing data.

2. Complete destructive evaluatton of Calvert Cliffs-2 leaking pressurizer nozzle.

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

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

I

5. Complete report.

DISCUSSION There is very little published information on PWSCC susceptibility 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 workee Inconel 600.

Tubular products are cold worked.

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

1. 50NC5-3 experienced PWSCC of 4 pressuriser instrument nozzles. These nozzles had very high yield strength. The failure was attributed to a particular material heat n umbe r.

I

2. St. Lucie inspected 1 nozzle of the same heat number.

It was cracked.

They replaced all 6 nozzles of similar heat n umbe r.

3. Calvert Clif f s-2 inspected pressurizer nozzles. They found 1 leaking l

and cracked. The original material was of low yield strength but had been reworked twice.

4. The Navy has experienced PWSCC f ailures of f orged Inconel 600 at t empe ra t u re s l

lower than CE pressurizer temperatures.

Navy nozzles are rolled into place and welded.

Ic0591-182A-MiO5

i' i

A t t ac r. men t 3 Page 2 of 3 05/09/9; EA-SC-93-087-01 CEOC TASK 633 Page 23 of 31 PRESSURIZER NOZZLE EVALUATION i

DISCUSSION (centinued)

5. Edf nas expertenced PWSCC of f orged Inconel 600, including circumf erential indications.

Edf nozzles are rolled and welded.

EdF found two cracked nozzles and performed NDE 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 foand. A nozzle would be classified as ntgn 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. ANO-1

(

(B&W Plant) recently experienced a cracked Inconel 600 nozzle in the pressurizer.

I B&W performed stress relief of the pressurizer after the nozzle welding was done.

B&W had used this argument (stress relief) as the basis for saying i

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.

l

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 BC&E nozzle. CE concluded that:

1. The mechanism was Primary Water Stress Corrosion Cracking (PWSCC).

2. The material was typical f or forged material.

3. Low strength f orged Inconal 600 will crack.

l No evidence of chemical contamination was found. This supports the cracking l

being PWSCC. Hot worked Inconel 600 produces more variations in yield strength, l

grain size, and carbide precipitation. This makes evaluating characteristics l

that promote PWSCC much more dif ficult.

Previous work done on steam generator tubes (cold worked) probably will not accurately predict the susceptibility of l

hot forged nozzles.

CE is looking at tre affects of the J weld on the metal microstructure.

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 initially relieved by the cracking.

Crack growth' 1

slowed because operating stresses are much lower than presumed residual stresses, j

Higher stress is necessary to in'tiate 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 l

criteria for classifying the susceptibility ot forged Inconel 600 products.

IC0591-182A-MA05 l

Attacnment 3 Page 3 of 3 05/09/9; EA-SC-93-087-01 CELO TASK 633

)

Page 24 of 31

)

PRESSURI:ER N0ZZLE EVALUATION i

4 P

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 Group has coveloped the following draft criteria for identifying hign susceptibtitty 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 kai.

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. Rework 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 identif y the most likely new crack locations.

If PWSCC becomes widespread, the criteria may need to be broadened to ensure that all 1-tks are found. A nozzle is classified as high risk if it is in the pressurize r, and either has a high yield strength or has been reverned.

BUDCET Total:

5152,000

Participants:

9 Palisades Share:

$ 17,000 Authorized Per WBS:

43001

)

l I

i IC0591-182A-MA05 l

l Attaenment faf !

Page-1 :( 1 05/10/91 EA-SC-93-087-01 J

CEOC TASK 634 Page 25 of 31 INCONEL 600 PENETRATION INFORMATION 1

OBJECT'VE Define ene metallargical properties of Inconel 600 penetrations installed in CE plants.

SCOPE i

i

1. Provide the material and f acrt:ation history for all In:onel 600 primary l

pressure bouncary penetrations.

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

{

DISCUSSION L

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

STATUS Final report received 1-23-91.

Work is complace.

BUDCET T

Total:

5205,000

Participants:

8 Palisades Share:

S 25.600 Authorized Per WBS:

43001 1

l l

IC0591-182A-MA05 i

j

Attacament Jf

? age 1f; 05/13/9'.

EA-SC-93-087-01 CEDC TASK 635 i

Page 26 of 31 QUA'!FICAT!ON OF EDDY CURRENT EXAM TECHNIQUES Palisaces is not participattng in :nis task.

OBJECTIVE This task will provide a qualtfied eddy current technique for inspecting pressurizer neater sleeves.

If leatage were to develop in one sleeve this would provide a qualified method of inspecting the other sleeves.

STATUS i

This task is complete.

Palisades did not participate in this task.

SCOPE i

1. Develop heater sleeve standards.

2. Qualify NDE technique and procedure against known standards.

DISCUSSION The CEOC Working Croup felt it would be beneficial to have a qualified method available for inspecting pressurizer heater sleeves. This will allow all sleeves to be inspected if a leak occurs.

This will reduce the time needed to respond to a leaking penetration.

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

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

BUDCE.

i Total cost:

$36,000 *

Participants:

4 Palisades Cost 0 - Not participating

• St. Lucie is paying f or a majority of the project cost. This cost allows CEOC participants to use the technology.

i IC0591-182A-MA05 i

l Attachsent #$ -

Page 1 of 3 05/09/9; EA-SC-93-087-01 CEOC TASK 636 i

Page 27 of 31 PRESSURIEER HEATER SLEEVE EVALUATIONS OBJECT VES

1. Compare metallargt:a1 concition of Calvert Cliffs-2 heater sleeves that did not crack witn sleeves tnat cracked in service at Calvert Cliffs-2 and ANO.

l

2. Determine the magnitude and orientation of stresses in pressurizer heater sleeves.

l

3. Determine tne effects of Iccalized stress relief.

STATUS i

A draft copy of the final report was issued for comment on 05-01-91.

SCOPE

1. Destructively examine 8 Calvert Clif f s-2 (CC-2) sleeves and 2 ANO sleeves.

j

2. Evaluate data from failed sleeves and sleeves that did not fail.

Try to l

characterize failure.

1 DISCUSSION l

Task 1 is complete.

All 10 heater sleeves have been destructively examined.

The following are the resultst

1. CE found smeared metal on the ID of 9 of 10 sleeves.

1 sleeve from ANO was not smeared.

They f ound smeared metal in the non-machined / reamed area of 4 sleeves.

2. They found evidences of intergranular penetrations 1 grain deep on 1 sleeve in a non-reamed area. This was also observed in some new Inconal 690 i

tubing. This is probably due to the manuf acturing process.

3. No significant microstructure differences were observed.

Welding introduces many variables affecting sleeves. CE preliminary conclusien is that the CC-2 sleeves would all have cracked over time. There were no j

dif ferences in the metallurgy of the cracked and non-cracked sleeves.

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

IC0591-182A-MA05 i

l

Attacnment /G !

Page 2 of 3 05/09/9L EA-SC-93-087-01 CEOC TASK 636 PRESSUR12ER HEATER SLEEVE EVALUATIONS DISCUSSION (continued)

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

1. Reamed and then velded.

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 i

PWSCC crack.

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

Applying EPRI's predictive model concludes that the statistical life of the non preraamed sleeve is 4} times longer.

PWSCC is still predicted to occur.

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

5. 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-reaming results in high hardness /high yield strength at the ID of the sleeve. Welding then creates residual stresses that are limited by the meterials properties at the surface.

The residual stresses govern PWSCC susceptibility. High j

strength non reamed material is slightly less 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 stresses are governed by material properties. The present CE number for susceptibility is 40 kai residual stress.

6. All Inconel 600 sleeves are susceptible to PWSCC. The susceptibility is relative and time related.

Installation processes and material properties will affect the susceptibility of each plant and each sleeve. Many sleeves may not experience PWSCC during the 40 year life of the plant.

7. Post weld reaming did not produce tensile stresses. It actually appeared helpful in lowering the tensile stress on the inner sleeve diameter.

8. Reamed and non-reamed areas remote f rom the weld have compressive or low tensile stresses.

9. The original plant rankings -(CEN-393) of heater sleeve susceptibility should not be changed.

IC0591-182A-MA05 i

Attachment g6 j Page 3 of 3 05/09/91 EA-SC-93-087-01 CEOC TASK 636 PRESSURICER HEATER SLEEVE EVALUATIONS l

i DISCUSSION (continued)

Corrosion testing to determine tne minimum residual stress necessary to produce PWSCC was completed in May of 1991.

C-ring specimens were stressed to dif ferent 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.

l An analysis of a sleeve that failed at ANO-2 in 1987 determined that that failure was also due to PWSCC. Several heaters failed and swelled.

The heat er induced a large tensile stress on the heater sleeve which resulted in a PWSCC leak developing in the pressurizer heater sleeve.

BUDCET Total:

$256,000

Participants:

7 Palisades Share:

S 36,600 Authorized Per WBS:

43001 I

1 i

a i

l 1

l l

1 l

IC0591-182A-MA05 l

t

At.

Pags 05/05

^~ ~ ~

~

CEOC TASK 637 PRESSURIZER ShELL CORROSION TESTING

1. 8' I

OBJECTIVE To cemonstrate that the development of a leat on-line will not seriously erode the pressure boundary and jecparctze plant safety.

STATUS The task is complete.

The final report was issued 04-29-91.

SCOPE

1. Construct a mock up of a pressurizer heater sleeve. Measure corrosion rates of shell material associated with a PWSCC initiated leak.

DISCUSSION Existing corrosion data is very censervative. The corrosion that actually occurred at BC&E was minor.

Measuring 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 St.-533B 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 rssults are as follows:

1. There was no hiddeti corrosion damage. A visual inspection is an effective method of ascertaining damage.

2. The corrosion cons;.sted 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 corroced.

This test demonstrated 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 1.

BUDCET 1990 1991 Total:

$60,000

$28,500 (Supplement 1)

Participants:

9 7

Palisades Share:

$ 7,500 4100 Authorized Per WBS:

43001 43001 IC0591-182A-MA05

i A t t a c hmen t (9 Page 1 of ;

05/13/91 i

EA-SC-93-087-01 CEDC TASX 639 PRESSURIZER HEATER SLEEVE THERMAL ANALYSIS OBJECT!VE This task will help determ:ne why the PWSCC that occurred at Calvert Cliffs-2 occurred where it cid, and will help us understand where we should be most concerned.

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

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

SCOPE

1. Develop a computer model simulating expected thermal profiles.

DISCUSSION l

The area cracking that has occurred appears to be between 644'F and 647'F.

The i

temperature in this region of the sleeve is relatively independent of the l

insulation configuration.

BUDCET Total:

553,000

Participants:

7 Palisades Share:

S 7,600 Authorized Per WBS:

43001 IC0591-182A-MA05 l

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EA-SC-93-087-01 3

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Page 1 of 7 Proc No 10.41 PROCEDURE TRAVEL.ER Revision 17 Page 1 of 2 Watoio s F'ecce ou,1E 9ec p.c,4TecN (w X): r1 BR Me svi.3-; rica Ex.sv>&c-i Procedure Title Mut t easa S e=e.. c er 64 h6 C n=M dec -- M A Mv4<

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EA-SC-93-087 1 Page 2 of 7 a

Procedure No. GTA-8.8-910 Revision No. 10 1

Issued Date 7/19/93 PALISADES NUCLEAR PLANT WELDING PROCEDURES TITLE:

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

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EA-S C-93-08 i-01 PALISADES NUCLEAR PLANT Page frJTc po 3.07 SAFETY REVIEW Attachmsnt 1 Revision 7 Page 1 of 1

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PS&L Log No

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l Item Identification:

No GTA-8.8-910 Rev 10 Title WELDING PROCEDURE SE Rev 3PECIFICATION (WPS):

ABB/CE ENG. NUC. SVCS. GAS TUNGSTEN ARC - HANUAL Describe Issue / Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING l

Reason for Issue / Change: PROCEDURE REOUIREMENT BY ADMINISTRATIVT PROCEDURE 5.06 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.

5.8, 5.10, 6.9, 7.4.

/

7 l

9.1, TABLE 4-21. TABLE 4-22 2.

Does the item involve a change to the facility as described in i

the FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4.

5.1, 5.6, 5.8, 5.10, 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, 6.9, 7.4, 9.1. TABLE 4-21. TABLE 4-22

)

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, 4.0 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 processes 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 questions listed above are answered NO, written USQ Evaluation is not required.

However, this Attachment shall accompany other review matorisis for the item to document that a Safety Evaluation was not required.

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WELDING PROCEDURE SPECIFICATION (WPS)

" * " ' f ABB/ COMBUSTION ENGINEERING NUCLEAR SERVICES page 1 ce :

Company Name ABB Combustion Encineerino By:

W.

V.

Gwaltney WPS GTA-8.8-910 Date08/10/84 Support. PQR(s)

GTA-B.8-100 GTA-8.3-104 Rev. No.

'att07/19/93 Weld Process (es)Cas Tunosten Arc Type (s)

Manual ay: /4.

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JOINTS (QW-402)

Joint Design Single Grcove No Retainers Backing (Yes)

X No Backing Material (Type)

Araon Gas

....,....e...

Metal Nonfusing Metal 7g, A6 7 Ag Nonmetallic

_X Cther g

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j Sketches. Production Drswings. Weld S.nnn..is or Written Ocwrywn should show the general arrange:nsnt of the parts to he wclded W hers

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• BASE METALS (QW-403)

P-No.

8 Group No.

I to P-No.

8 Group No.

1 OR Specification Type and grade SA240 Tvoe 304 to Specification type and grade SA312 Tvoe 316 OR Chem. Analysis and Mech. Prop.

Not Aeolicable to Chem. Analysis and Mech. Prop.

Not Aeolicable Thickness Range:

Base Metal:

Groove 1/16" to 3/4" max.

Fillet Unlimited Pipe Dia. Range:

Groove 1" to Unlimited Fillet Unlimited Other

• FILLER METALS (QW-404)

Spec No. (SFA) 5.9 ER308/ER308L Stainless Bare Wire (solid)

AWS No. (Class)

ER308/ER308L F-No.

6 Consumable Insert None e

A-No.

8 i

Size of Filler Metals

.062" or.093" Diameters Deposited Wald Metals Not to exceed 1/2" thickness cer cass.

Thickness Range:

no min. to 3/4" max.

Groove no min. to 3/4"- 100% GTA Fillet Unlimited Electrode-Flux (Class)

None Flux Trade Name None l

Other oualified to weld arcoves. fillets, and recairs on P8 base materials with A8 stainless filler in all cositions.

ii SA312 "t" cualified =.375" SA240 "t" cualified =.187"

• Each base metal filler ondination sh uld a recorded Independent Reviewer d~

.e Date 7

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EA-SC-93-067-OL i

Attacnmenc WELDING PROCEDURE SPECIFICATION (WPS)" " 5 "

l ABB/ COMBUSTION ENGINEERING t

WPS NO.

no-e.a-910 aev.u NUCLEAR SERVICES Page 2 :e :

POSITIONS (QW-405)

POSTWELD HEAT TREATMENT (QW-407)

Position (s) of Groove All Tenperature Range None Weld Progression: Up X

Cown Time Range None Position (s) of Fillet All GAS (QW-408)

PREHEAT (QW-406)

Percent Composition Preheat Temp. Min. 60 dec. F Gas (es)

(Mixtr)

Flow Rt l

Interpass Temp. Max. 350 dec. F ! Shield.

Arcon 99.99%

10!] CFHj I

Preheat Maintenance None

! Trail.

None (Continuous or special heating, i Back.

Arcon 99.99%

5:2 TrH!

I if applicable.)

None

' Backing gas not applicaole to ifillet welds.

l ELECTRICAL CHARACTERISTICS (QW-409)

' Current AC or DC DC Polarity SP Pulsed No j

Amps (Range)

See Below

'/o l t s (Range) See Below (Amps and volts range should be recorded for each electrode size, l

position, and thickness, etc.

Tungsten Electrode Size and Type 3/32" Diameter EUTh-2%

(Pure Tungsten, 2% Thoriated, etc.)

Mode of Metal Transfer for GMAW Not Acolicable (Spray arc, short circuiting arc, etc.)

Electrode Wire Feed Speed Range Manually as Needed l TECHNIQUE (QW-410)

String or Weave Bead Stringer or Weave Orifice or Gas Cup Size 3/8" I.D.

max.

Cleaning Initial Grinder or S.S.

Wire Brush Interpass Same t

l' Method of Back Gouging None i

i Oscillation 1/4" max.

Contact Tube to Work Distance Manually Controlled to 3/8" max.

i i

Multiple or Single Pass (per side)

Sinole or Multiole Multiple or Single Electrodes Sincle I

Travel Speed (Range)

Manually I

Peening Not Allowed l

{

Other l

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Bead Type Amp.

Volt Speed

Remarks, 1

No.(s)

Process Class Dia.

Polar.

Range Range Range Comments I

All GTA SFA5.9

.062 DCSP 80-110 11-12 Manual

.093 DCSP 95-125 11-12 Manual I

i

WELDING PROCEDURE QUALIFICATION RECORD EA-SC-93-087-01'-M3n/=

COMBUSTION ENGINEERING. INC.

Page 6 of 7 f

OATE OV9* COT'1). 1

~IA" *$*'22 PROCEDURE QUALIFICATION NO Editorial Correction:

07/19/93 QJALIFIE D TO CODE SECTION(S)

III i

M ATE RI AL SPEC. & GRACE SA-2LO T: 3%

SA-2LO % 3Ch ro q

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80R WELDING P No TO P No

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tfe FILLE R METAL F No A No POSITION TEST WELD SPEC, of AN ALYSIS

??A ;.O O-309 SINGLE or MULTIPLE PASS Y'lltI'1 ELECTRODE S!ZE 1/lb M N-2

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NO. 0F LAYE RS 41F CLAD)

FLU X NO.0F ARCS EiUE1?

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SHIELDING GAS ES) & COMPOSITION E*Cn PREHEAT FLOW R ATE 10 CEE M A X. lN TE R.P ASS 300'F Max.

TYPE CURRENT UC-3E MAINTAIN P REHE AT UNTIL PWHT NOUO BACKING REOUIREMENTS POSTHE AT TRE ATMENT OTHER:

Aracn Back Purg f 5 CFH "T" range qualifies = 0.062" min. to 3.375 u

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Page 7 of 7 January 20, 1982 J ' "' a ' g "' 104

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=AOCEDURE OUALIFICATION NO ONED TO CODE SENS) lii' in W U l

Editorial Correction:

07/19/93 SA-312 Type 316 SA-312 Type 316 uATERIAL SPEC. & GRADE 7g FOR WELDING P No 3

to P No 3 BACKING AEQUIREMENTS Arrion purep a y r =".J WELDING PROCESS Ga S TunOS ten arc THICKNESS (& DIA. IF PIPE 375" Y N 00" 3 TYPE WELD JOINT U~2r00Ve

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2 FILLER METAL F No SINGLE or MULTIPLE PASS Mul ti DI e SPEC. or ANALYSIS SFA-5.9/RDT Mi-27 ER-16-8-2 NO. 0F LAYERS (IF CLAD) N/4 f

NO. OF AACS One 0

60 F EECTROCE SIZE 3/32" 0 BTH-2 PAEHEAT l

Fwx N/A 350"F max. INTER. PASS

& COMPOSITION Ar00n MAINTAIN PREHEAT UNTIL PWT AS weIded SHIEWING GAS (ES)2-15 CFH POSTHEAT TREATMENT i

AS we1ded FLOW RATE TYPE CURRENT D.C.-3.P.

Ili frecuency Start "T"

ranRe cualifies 1062"

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ATTACHMENT 8 l

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j Half Bead Welding Effects i

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Page 1 of 2 To SS0verway, Palisades From JCNordby, Palisades CONSUMERS l

POWER Date October 18, 1993 COMPANY Subject Effects of Half Bead Welding on Base Metals Internal 1

Correspondence l

JCN>3*029 l

CC DJVandeWalle, Palisades t

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) SHA-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 ASHE 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 coupens are prepared and destructively tested to establish ranges of variables which will l

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.

l 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 l

and therefore no adverse effects will occur.

The area of concern is the HAZ.

i 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 l

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 l

carbide precipitation (in fact, it is lower than operating temperatures).

l The ineonel 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 cdditions 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

,u

EA-SC-93-087-01 2

4 I

i intended application, the effects of welding using SMA-3.43-937 will not adversely affect the pressurizer and/or nozzles.

1 i

s 5

T l

i

1 i

EA-SC-93-087-01 i-ATTACHMENT 9 i

l i

l Circumferential Crack i

i 1

j Potential Memo l

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EA-SC-93-087-01 cs Page 1 of 4 Y. _ ~BY$

To Design Package File From RBJenkins, Palisades Fd E CONSUMERS POWER Date October 18, 1993 COMPANY l

l Subject NUCLEAR ENGINEERING AND CONSTRUCTION ORGANIZATION P0TENTIAL FOR CIRCUMFERENTIAL CRACKS IN MODIFIED PRESSURIZER INSTRUMENTATION N0ZZLES Internal CC Correspondence RBJ93*064 INTRODUCTION Modifications are currently being prepared for two temperature instrumentation nozzles in the Palisades Plant pressurizer. 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 modificat' ions 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.

f.A-SC-93-087-01 i

REVIEW OF INSTRUNENT LINE EXPERIENCJ 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 i

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 NDE and other test work showed that:

e Most cracks were axial e

Only axial cracks penetrated beyond half the wall thickness Weld residual stresses are higher in the circumferential direction e

than in the axial direction.

I 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:

e The J-weld construction can generate very high residual tensile hoop stresses adjacent to the weld e

Pre-installation reaming tends to result in higher residual stresses e

Axial stresses tend to be compressive or relatively low tensile e

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 I

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 l

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-93-087-01 3

For the PORY line condition, the load environment is very different.

The butt j

weld is through-thickness.

Therefore, it can shrink the pipe side (or nozzle l

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 j

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 N0ZZLE 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 stress 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 e

nozzle e

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 e

l 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 4

i CONCLUSION I

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.

.l l

REFERENCES 1.

Alter et al, " Stress Corrosion Cracking of Pressurizer Instrumentation Nozzles in the French 1300 MWe Units," Proceedinas on the Fifth International Symoosium on Environmental Dearadation 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 l

l 4.

Letter fr'om GBSlade to Nuclear Regulatory Commission, Palisades Plant -.

l l

Pressurizer Safe End Crack Engineering Analysis and Root Cause Evaluation, October 7,1993 1

'l

EA-SC-93-087-01 l

l l

ATTACHMENT 10 Pressurizer Specification b

i

4 1

A hren 0

Page 1 of 9 y3 3

By i Design Specification is certifie ion' No. 1f540' and complete and in Co o n #cerrue to be correct ecmpliance with the requirements of Date #ek ke 9'

/44/

j N-141 of the ASME Boiler and Pressure Voscel Code,Section III, Nuclear Vessels, i

1960 Edition, through Winter 1966 addenda.

,eIe&y ENGINEIRING SPECIFICATION O [

N 1

l.

FOR O

if i

]g A PRESSURIZER ASSEMBLY Ag D

SPECIFICATION NO. 70P-001

[

{'

Revision 2 op

{lVI}.

Nuclear Power Systems h

(

1 i

COMBUSTION ENGINEERING, INC.

k ir Windsor, Connecticut g

w 2 1 j

r l

I!

D 5 !

This document is the property of combustion Engineering, Inc.

and is to be used only for the (CE), Windsor, Connecticut, purpose of the agreement with CE pursuant to which it is 1

furnished.

4 l# b A '

?C*bb W M Date:

Prepared By: R.C. Who ler Cog

• ant Engineer

/0 'C[F/ _

l Date:

Approved By:.jK'idaundson, Supervisor, Fatigue Evaluation Date: ]D-t 0- 9 I d

j Approved Doney,VManager, Plant Mechanical Systems R.O.

f 0- t 0 -9 l Date:

id l bw Approved By: P.T. Hammet, Project Manager IO!I#/il' Issue Date: _

Page 1 of 17

EA-SC-93-087-01 C O.T JUSTION ENGINEERING, I h % g' 7",7'9

.... _ o m

.......o

.v.. m.

a % G C.

\\

/&

(3)/

Io:

W. 'd. Roberts, Chatt.

A?FRC7AL CF ASF21966 *CCER W. K.

Wilhe'.=

AOLE:i::A FCR FEISYJi~.ZER xc:

7. C.

Eall Febraarf 16, 1967 J. D.

Crawford O C' M *d F-SI-M2 F. P.

Faga e

F. J.

Hamzalek

,g T. L.

Fettles (2)

F. A.

Lcve, Chatt.

. h el*f E. W.. Woollacott

?roject Files hh f(/Jf6NT c

Reference:

(A)

V.W. Roberts T No. 9 to V.K. Wilhel dated Febraa:/ 2,1967 Approval is Sranted in response to reference ( A) to use the Vinter 1966 Adienda of the AEF2 Sciler sud Fressure vessel Code, F*ction III, Rules for Cc:stractics of Itclear Vessels.

This approval a;; lies 0:1y to the pressurizer contract, and is void if a=y increase in cost or extensics of deliver / results from its applicatics.

f k.

W. K.

W12.hels

'w"G/ LK/JDC:ds quWD ar Wel g$1 er

-we s R.

91

=*

g0 s

EA-SC-93-087-01

~

P~

COMBC ' TION ENGINEERI: ~ 3, IN CC'ST'9 i

4r. Stan Knight Censumers Pressurizer Nuclear Concra :-

Contract 236cc Engineering c::

Mr. J. Abel Mr. G. Carr011 March 2, 1967 Mr. R. Armstrong The folicwing list of governinu :pecifications are f.w"..-!

! un a preliminary basta for planning purposes.

The list will be c.c-firmed and/cr amended by shop order as socn a3. the 00ntr::: cas been finalized.

1.

CEND Specification No. 7CP-CC1 as tentatively ::dified by Pro-posal No. 4-12526-1, Contract 2C355 and later agreements.

2.

Section *:: of ASMI C:de including all Addenda thrt 'dinter 1966 l

Addenda.

l l

3.

Special Code Cases:

a.

Case 1338-3 UT of plate

(

b.

Case 1359-1 UT of fergings i

c.

Case 1332-2 Low Alloy forgings d.

Case 1339-2 Low Alloy Plate e.

Case 1336 "Inconel" forgings, plate and tube 4.

CE Furchase Specs:

a.

P3712(b )

Low alloy plate i

b.

P3C9(d)

Low alloy fersings c.

P4301

)

"Inconel" forgings d.

P4332 b)

"Inconel" pipe e.

P43F3 c)

"Inconel" plate f.

P1F11 b )

Carbon steel plate 5.

M&P Specs:

2. 4.1. 3 (a )

Radiographic Inspection er

2. 4. 2. 4 (c )

MT Inspection 2.4.3.9(c)

PT, Materials de 87 2.4.3.lo(a)

PT, seal surfaces gy 2.4.4.9(c)

UT, Clad Bond

2. 4. 4.15 (b )

UT, Plate 8*

5.3.1.4(c)

Quench and Temper A-333 Plate es 5.3.1.5(d)

A-516 Plate 5.5.2.S(d)

Fabricati:n cf Nuclear Shells 1

l i

EA-SC-93-067-01 0 Page 4 of 9 Mr. Stan Knight March 2, 1967 1

-)

5.

M&P specs:

(Cent id)

Contract Supplement 2966C-1(c) to 5.5.2;a(d)

5. 5. 2. 9(c )

Fabrica:icn of Carbon steel Contract Supplement 2965C-1(a) to 5.5.2.9(c )

5. 5. 3.1(a )

Cleaning Nuclear Vessels

5. 5.6. s (c )

Fabricatien or neaes Contract Supplement 2966C-1(a) to ; 5. 5.6.8 (c )

' 6.1.1. 2 (b )

General Welding Procedure.

i 14./h 1

W. W. Ro'certs

'I i

Y k 1h i

4

{

t i

e ee S

EA-SC-93-037-01 0 ContracC 2966C Sheet 1 of 2 pue 3g9 FORM N-1 MANUFACTURERS DATA REPORT FOR NUCLEAR VE5SELS As required by the Provisions of the AME Code Rules and the National Board l

. Mr.nafaetured by

.C.e.mbus tien E..n E.i..n...e.e.J.i..n..ga..:...n...e.... 911 W. Main Street, Chat t an c e I.a.,..T...e..n. n..e s s. e.e.

.l (Ndes and address of Wen octurer) ac k s en..M.-i ch i

• a..n...

l

2. 4anafsetured,.or.

.C. e..t.is. u:ner..s..P. o.w...e...r..

.C.o.._. 2. 2.12 W. Mi ch.i..g an Avenue t

t.

r

--.. Kind..N.8.a t Af,,,..,,,, y,,og 3 c,,5),$ee.e.n a addre.6 er puene ser)) Nat'l Ed. No. NO.51,,,,y, gg,;c. Q

(-

,0.1....-.._. ) (.. -

3. Type _

"U" (Hons. or vert ) (Tergs.J ecketed. Heat E s.)

(Wfre. Sertel No.)

(State b State No.)

Iteme 4-8 :.ncl. to se comp.etee for si.ngle weal vessels.,iserets of 'seketed vessels. or shells of best eschangers I

A-533 Cr. 3 01. 1 Cve:.u.eadd C orrosion,

- l /.,

Mstenal.All.;Y...htfal T.S.... 3.Qa.Q0.Q..._ No-tanalThickne s....{

.. in. gliowsne,.!}.@. in. Diam.?.....'ft....in. Len stu..Jt!..1#

a.

4. Shell:

No (Elad ag seee.d

.)

cuan. or rense spectriege,,s,,,,,,

. g, ;, i,,,,,,,,,,,,,,,

g,g, Y e s,,,,,,,,,

_,,,,,,,,,, g g g;,,,,, y,,,,,,,,,,,,

=e1de

5. Seama: Long (If C;ese S,i ed

.... H. T. L.

.......I *.!

....... X. R,.. 3. Y.* 8.....,......

.m.. N o. o i C ours e s ~. 2,

A G.:2

... 3e NJ wr. Y v......

A-03 Gr. 3 CA.

l

6. Heads: (a) Matenal.A1191 E.MAE

!.5 6S.,000 (b) Matenal.A112I_5. Mil. -

T.S.

.j C,,2;p,,

Locauos Cro wn Knuckle Elliptical Conical Hesiepheries!

Flat Side to Press:

(Top, bottom, enda) nickness Ra d.tu s Radius Raue Apu Angle Radius Diameter (Con ve x :r Ccoce <

/ 8."

T:p 4-1/ 8.

5. 5...5../. 8 ".._....

5 5... 5..T8y

.C...e n..:..a..v.e.

(e) sot:==

. 4.....U..Q..

n....y..6" M-5 cen: ave (b)

_. ~.....

Other faatoniog-Desenbe or ettsch saatch,

If removable, bolts used..

.(Me te rs el. Sp e c. No..

T. a.,

Siz e, Numbe r)

(

7. Jac h a t Cloe are............

(DesertDe es esee 4 ateld. bar. etc. If bor save dimenenene, describe er eesteh)

Charpy !mpact.

3Q.....

ft.1b N T

,,,,,,,o y, p ",,',,,,,, 3 ',

• 5,,,, p

8. Coastructod for 8 7 d' ' '

,g press.2,... 2. 5. 0.0....... psi et Ma x. teap. 7.QQ... ?.F at teep, of.

.. 40 Itst.:s 9 eEd 10 to be completes for tube sections.

Tabe Sheets: Stationary. Msterial.....

.. Diam. _ _ _ _

_ _ in. Thichaes a..

la. Attaehetot............-

(Kind as Spes. No.)

(31.bject te pro se.)

(Weided. B e:ted)

Floating. Metenal -

Diam.

. tn. Thiekness..._

. in. Att aeb.m ent..

(Kind h spec. No.)

inches

10. Tubea: M at ertal._.

O. D.-.-~.....in. Thic km ess

. or gage Hunbe t........... Type.........

(Kind a spec. No.)

(Streight er :

Items 11 to 14 incl. to be corripleted for inner charnbers of !acaeted vessels, or channels of beer exebasters.

Nominal Corrosien

11. Shell: Me teria!....

_ _... T. 5............. -... Thi c kn e s s

--in.

A!!owasce

.in. Diam..

. f t..

..n. Le ngc.. ft.

(Klad b Spes. No.)

(Min. of rests, speetties)

12. 5eems: L on s.=

~...H.T.'

..(Yee er No)--

-I.R...~.~.....--

.... E ffs c2 en c y...... l. '.in~ e..........

(I C s B)

(welded. Dbl.. single)

Girth H.T. J X.R..

.~... No. o f Co urs e s.

l

13. Heeds. (a) Mstartal...

T.S. ~~.-_ _ (b) Material

..-._ T.S.

-.. (c) Material.

T.S.

...._ l Crown Knuckle E!!!ptical Conical Hemisphenca!

Flat Side to Press.

Location Thieksess Radius Radius Ratio Apez Angle Radins Disa eter (Corives or Coned (a) Top, bottom. eade (b) Chaanel (c) Floatlag

.~

. (b).

(c) m.

.~ Otbei fa teein g..

If reaoyable holte used (a).-

.. -.. - ~

(Watertel Spee. No., T.s., sise, Nuester)

(seerg. er etisch sue CD Charpy Impe et............ ft-Ib Pnettmetie m

14 Const:ucted for specW Hydrostatic or Test overs ting pre s s.....g....... p si a t Max. temp.............'F at te mp. of................... O F Combinetion Press 5Fest-e1.ee.r,este.

het other internal or esternal pres sures with coincadent toaperature when appuceble.

i 9

EA-SC-93-087-01 0 FORM N.1 (back)

Page 6 of 9

• • • e below to be corspleted for all vessels ehere sp;1acatie.

'e ty Valv e out1e ts ; Number...I':.I.e e,,,,,[,,jj,,,,_,,,, Sig,,,_,,,j.... ~.....~ L o eaton T:o Head

1. 16.

.ssles:

4 Purpose (Islet.

Roseforcement How Outlet. Drais)

Naabet Diam. or size Type Material Dickness Matettal Attach e d ;

..f..........

~

..S...e..eA.:.~t a.c..h..n.. e n..:....

i

... ~....

~

......~..

1

17. Inspeetson Mscholea, No. -

_ 3 ;,,,,--

M",,,,,,,, g,,,g,,,,Eg,g H e a d,,,,,,,.

.e

.... j Openangs: H asdh ole s. No.

. Size.....

... Loc ation....-.....~.

.-~...

...............y Threa ded. No.

$1: e...~.

L oc a tion........

....,..~,,4Ed 30.O c"

• 0l M'-

v

18. Supports: $ktrt......:.8 8 Lugs....-- -.....- Lega

.-~

... Oth er.

.. _ Atta e h e d....I.22.:". ---..~.. ~ ~...

(ves erne >

cxuseers (nummer) coeserme) 4wher. a How)

... Pressuri..:e.r.. to be used in the primary syste= of a pressuri:ed 'a er nue ear

,9. Remarks.

1 a c-l

.r er E an:.

..._i

.. _.. ~ -

m.......

m

~...

. ~.

carset deseropsten er e.rvae. rer whien v.eeet wee seatsne4)

CERTIFICATION OF DESIGN Cenbustion Engineering, Inc., Chattanooga Tennessee Dssign information on file at

..... =

Stiess anslyaae teport on file et..C.h?.gs,3Ae,n.... -3,4ne e rigf,,,J33,;,,,Jhat *.anc oga, T e.ne s s e a,,,,,,,,,,,,_,,,,_,

a 3

O

.S..

State. b U Reg. No%[.{i..i.

D:siga s;ecific tions eerufied by....t.t

.?.Q.rse,3,s.es.

Prof. Eng..Y R

i

• W um Stress analysis report certified by ~ y. an -- :.t

?..-.

............. Prof. En g.

• e s S ta te."".e..r.=: *. Re g. No " ' "

=

ertsfy that the statements made in this report are correct and tha t att dotatle of material design,construcuca, and worsmansa.p o vessel conform to the ASME Code fer Naclest Vessels.

D:ts-Januarv 15 19.6 i.

Si gne d -.506C.g s 31og,,jgg in e e ring,,,.ES.t By.~.

.7a d w '

Certificate of Authorisation Expires

~ e..*e".:b.e..r 31..t. W*. "*"'.". ).

L N. 31asiddle "a

1 CERTIFICATE OF SHOP INSPECTION yESSEL MADE BY..Combustien. Enginee.r.in.g Inc.........

a t.

C. h a..:.a*.a...n...e..o..g a. J.....e. n.n..e..s...s..e.e.-..

9 l

...... ~...

I, tBeindersigned. holdang a valid commission issued by the National Board of Besler and Pressure Vessel inspectors and/or the Stat.

af. -

an d employed br.IAsli.0.I.d. 5.IR.am 3oM..e,E..JEg.:.) __;ns._C,g.,,,,,,,_,j_a rd e r(t C 5 * ~iC' I

have mspected the pressure ve seel described in this manufacturer's data report on m.Y8I*uaG,,,,[,,,,,_,,_,__,,,,_,,,,,,,,, g g,2,, agg state that to the best of my ' nowledge and belief, the manufacturer has constructed this pressure vessel as accortf ance with me A3ME a

Code for Nuclest Vessels.

By signing this ceruficate neither the Inspector nor has employer makes any warrasty, expressed or implied, concerning te pressura vessel described in this manufacturer's data report. Furthermore, neither the Inspector nor has employer shall be liable on any anne for any personal injury of property damage or a loss of say ktad artssng from or connected with this inspection.

Oete.. JUn' D 19.H.

National 3eard.923 b 4 977 e 4.Xans......

commis sions.....

6

....... -.. - =

! epeesere signature Nationat Bo.rd or State and No.

n.

we.a=

CERTIFICATE OF FIELD ASSEMBLY INSPECTION I

1. the undersagned, holding a valid comstission issued by the National Board of Scaler and Pressure Vesselinspectors and/or de Staly o f

.h..---

- an d em plo ye d by ~.....~.....

.~

. --.~..

.of

. ~. - -..

. - ~.. - -

have compare e statements in this manufseturer's data report with the desenbed pressare vessel and state that parts referred to at data items...

._...~....... eot included la the cortificate af sbop 4aspeetoe r.a vj i

hun inspect y me and that to the best of my knowledge and belief the manufacturer has ecostructed arMasembled 22s ;resser j l

vessel in se ance with the ASME Code for Nuclest Vessels. The descrsbed vessel was inspect?dca:nd subjected to a ht h

N atic test p a t.

By signing tMg;eertificate neither the Inspector nor his employer makes any warranty, expressed or implied ~concernag te pressurl tessel descrig in this tr.snufseturer's data report. Furthermore. netther the Inspector nor his employer shall be liable en say = anne; for any perseas tajury or property damage or a loss of any kind aristag from or esaaected with this inspectaost" 1

l Deie.-

.. 19...

(.1*8 I

Commaa1 e t s.. -..

I tnapectore $lg natur.

National Seare er Steu and No..-..

. - -.. ~~~

..m

Sheet 2 of 2 Contract

,6,C FORM N-1.

MANUFACTURERS DATA IEPORT FOR NUCLEAR VF.SSF.L Natl.. LID. No. 20051.

ATTACitMENT SilEET Noz7.lcs DIAMETER REINFORCEMENT U0tf I

PURPOS'd NO.

,0R SIZE TYPE MATERIAL TilICKNESS MATERIAL ATTACllED Q

_.=--_-_c.

&.,.c

_._c-. t. _.._ g Surge'Assceibly -

nody 1

Ll-13/16"ID. Forging A-508-64 C1. 2 1

1" Integral l Welded Extension 1

10-1/2" 1.D; Forging' SB-166 Inconel.

1-1/8" Integral

' Welded

~~5 iray Assembly

[

I i Body 1

4-1/2" 1.D.

Forging A-508-64 C1. 2 59/64" Integral

'We1.ted Extension 1

3-5/8" I.D.

Forging SB--166 Inconel 19/32" Integral Welded t

Relief Valve

!3"I.D.

Forging A-508-64 C1. 2 1-17/32" In t.c gral b'eiued Rody 1

Extension 1

3" 1.D.

Forging S3-166 Inconel 1-1/2" Integral

' Ueliicd l

I 1,evel Assembly H:dy L-7/16" I.D.

Forging A-508-64 C1. 2 l 1/2" Integral t'eldod

- ' nody F.xt.

8

.957" I.D.

Dar SD-166 Inconel 13/64" Integral Heide,d.

m>

mma

_, h-d

$"p Extension 8

l 957" I.D.

Bar SA-132 Tenn F-11 fi 11/ fi/4" i n t v e r:n 1 g

3g3 e

a ci v.,

-i-y 9- ?

Tcaperature u

4.1 Body 2

.815" 1.D.

Bar SB-166 Inconel

.250" in licad/Sliell

.Ucided

• y,!

n c Extension 2

.815" 1.D.

ila r SA-182 Type F-316

.250" N/A_,,__

l Helderi

?;

c> e E

j IIcater Assembly

~

In U"ad Ue d

ceves 120 1.158" 0.D.

Tubing SH-167 In.

ej

.17?a i Heaters 120 l.1175" 0.n.

' Tuli l n n

,r.n -163 Inconel l,.130",_

N/A

[ffgqjfth__ ____ _

EA-5C-93-087-01 0 l

Page 8 of 9

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Page 9 of 9 ss 3300 NB 3000 - DESIGN NB-3331 NB.3300 VESSEL DESIGN NB 3324.2 Spherscal Shells NB 3310 GENERAL REQl;1REMENTS FR

,, P3

,, 25. - !

2S.

1 j

NB-3311 Au ' " '" 7 The requirements for acceptability of a vessel design are as follows.

• B-3330 OPENINGS AND REINFORCEMENT (of The design shall be such that the requ.irements of NB 3100 and NB-3200 shall be satisfied.

NB.3331 General Requirements for Openings (b) The rules of this Subarucle shall be met. In cases (al For vessels or parts thereof which meet the re-of conflict between NB 3200 and NB 3300 the require-quirements of NB 3222.4(d), analysis showing satis-ments of NB 3300 shall govem.

facuon of the requirements of NB 3221.1, NB.3221.2.

NB 3221.3. and NB 3222.2 in the immediate viemity of the openings is not required for pressure loading if the rules of NB 3330 are met.

l NB 3320 DESIGN CONSIDERATIONS (b) For vessels or parts thereof that do not meet the f

requirements f NB 3222.4td) so that a fatigue analysis NB 3321 Design and Service Loadings is required, the rules contained in NB 3330 ensure sat-i The provisions of NB-3110 apply.

isfaction of the requirements of NB 3221.1, NB-3221.2. and NB 3221.3 in the vicinity of openings.

and no specific analysis showing satisfaction of those stress lim ts s it9uited f f Pensure loading. The re-NB-3322 Special Considerations quirements of NB 3222.2 may also be considered to The provisions of NB-3120 apply.

be saus6cd if. in the vicinity of the noule, the stress intenstry resulting from external noule loads and ther-mal effects. including gross but not local structural dis-conunnes. is sh wn by analysis to k kss man W..

NB 3323 General Design Rules In this case, when evaluating the requirements of NB-

]

The provisions of NB 3130 apply except when they 3222.4(e), the peak stress intensity resulting from pres-r confhet with rules of this Subarticle. In case of conflict.

sure loadings may be obtained by application of the

]

this Subanicle governs m the design of vessels.

stress index method of NB-333g or NS 3339.

i (c) The provisions of (a) and (b) above are not in-tended to restnct the design to any specified section thicknesses or ther design details, provided the basic i

NS-3324 Tentative Pressure Thickness l

stress limits are satis 6ed. If it is shown by analysis 4

The followmg formulas are given as an aid to the that all the stress requirements have been met, the rules designer for determinmg a tentative thickness for use of NS 3330 are waived.

m the design. They are not to be construed as formulas (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 j

regions (NB 3221.2). the wall thickness of a vessel citeutar or ellipucal cylinder with a vessel of the shapes shall never be less than that obtained from the formulas permitted by this Subsection. Additional restnenons j

m NB 3324.1 med NB 3324.2. in which:

given in NB 3338.2(d) are applicable if the Stress in-r= thickness of shell or head. in, dex Method is used. If fatigue analysis is not required.

P= Design Puseeure. psi

• the restnctions on hole spacing are applicable unless j

A=inside radive of shell or head, in.

there will be essentially no pipe reactions.

i R.= outside radius of shell or head. m.

(e) Openings are not litnited as to size except to the 5.= design stress intensity values (Section II Part extent provided in NS 3338.2(d).

D. Subpart 1. Tables 2A and 2B) psi (f) All references to dimensions apply to the (mished l

dimensions excluding matenal added as cortosion aj-l NS 3324.1 Cylindrical Shells lowance. Rules regarding metal available for reinforce-ment are given in NS-3335.

PR PR.

(g) Any type of opening permitted in these rules i

1. ~ S. - 0.5 7

1. ~ 5.

• 03 7 may be located in a welded joint.

89 J

EA-SC-93-087-01 ATTACHMENT 11 Code Reconciliation d

r

q EA-SC-93-087-01

' 1 Page I of g ABB ASEA BACWN GOVERJ October 19,1993 Southeast Nuclear Service Center CSE 93-381 Consumers Power Co.

Palisades Nuclear Plant 27780 Blue Star Memorial Highway Covert, MI 49043 Attention:

SUBJECT:

CONSTRUCTION CODE RECONClUATION FOR THE REPAIR / MODIFICATION OF TWO (2) PRESSURIZER TEMPERATURE NOZZLES Enclosure (1)

Construction Code Reconciliation for Consumers Power Company Pressurizer Upper and Lower Temperature Nozzle Repairs / Modification

Dear Mr. Overwe,

y, The Original Construction Code associated with the original CE supp!!ed Consumers Power Pressurizer is the 1965 Edition through Winter 1966 Addendum of the ASME Boiler and Pressure Vessel Code, Section 111.

A code reconciliation is provided as Enclosure 1 to meet code requirements in accordance with your Section XI program.

Sincerely, ABB COMBUSTION ENGINEERING K.E.Coe SNSC Engineering

, KEC:gt ABB Combustion Engineering Nuclear Services

EA-SC-93-087-01 1 Page 2 of 8 ENCLOSURE 1 CONSTRUCTION CODE RECONCILIATION FOR CONSUMERS POWER COMPANY Pall 8ADES 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 Pressurizeris the 1965 Edition through the winter 1

1966 Addendum of Section til of the ASME Boiler and Pressure Vessel Code (herein after referred to as the Original Construction Code). The ASME Section XI Program i

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 111 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 and 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 preventleakage of reactor coolant. The original nozzles will remain in place. The repair / modification activities will be done in accordance with i

ASME Section XI Code and provides for a weld buildup on the vessel outside diameter CSE 93 382

EA-SC-93-OS7-01

. 1

}

Page 3 of 8 l

Page 2 (OD) 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 i

the nozzle OD surface and the OD surface of the Pressurizer to provide the i

aforementioned new pressure boundary.

After the temporary repair weld is 1

completed, the top head temperature nozzle will be severed between the original weld J

i and the temporary repair weld to allow thermal expansion during heatup and cooldown l

during normal operations. This modification / weld buildup will become the vessel pressure boundary for each nozzle.

i i

This modification involves a repair activity in accordance with the A$ME Section XI 1983 Edition with Summer '83 Addenda. Article IWA-4120 states that repairs may be performed in accordance with "later editions of the Construction Code, or Section lil, either in its entirety or portions thereof" or the rules of Section XI, IWB-4000 for f

Class 1 Components may be use.d alternatively.

4 The Section XI Code (Article IWA-7210) specifies that replacements shall meet the r9quirements of the edition of the Construction Code to which the original component j

or part was constructed, unless the following alternative is adopted Article IWA-7210

]

l (c):

4 a

l'

"(c) Alternatively, replacements may meet all or portions of the requirements i

of later editions of the Construction Code, provided that the following requirements are met.

CSE 93-382 4

4

i tA-SC-93-037-01 i 1 Page 4 of 8 l

Page 3 (1)

The requirements aticcting the

design, fabrication and examination of the replacement are reconciled with the Owner's Specification.

(2)

Mechanicalinterfaces, 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 Analysis Report, Design Report, or other suitable method which demonstrates the satisfactory use j

for the specified design and operating conditions, whichever is i

l r

applicable.

(4)

Materials are compatible with the installation and system requirements."

The discussion below addresses each of the requirements:

]

I 1.

Raouirement

"(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 Attachment 11 Page'5 of 8 i

Page 4 Discussion f

The Owner's Specification specifies the Original Construction Cods at the 1965 Edition with Summer '66 Addendum of Section 111 of the ASME Code. The design, fabrication and examination requirements are specified in NB-3000',

NS-4000', and NS-5000' respectively.

A comparison of each of these requirements is provided below:

Design 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, Rev.1, " Structural Analysis of Temperature Nozzle Weld Repairs For Consumers Power Palisades Pressurizer".

Fabrication There are no fabrication activities associated with this modification activity.

i

'The sections of the 1965 Code for design are Article 4 (N 400), Article 5 (N 500) and Article 6 (N-600). The Articles correlate to NS-3000, NS-4000, and NS-5000 respectively in. current editions of Section Ill.

CSE 93 382 e,

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j EA-SC-93-087-01 j 1 i

Page 6 of 8 i

i Page 5 Examination The examination of the Replacement Nozzles is being performed under the 1986 edition of ASME Section ill, NS-5000 which provides current industry J

acceptance criteria. This criteria is at least as restrictive as 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.

i 2.

Raoulrement

"(2) Mechanical interfaces, fits, and tolerances that provide satisfactory performance are not changed by the later Edition of the Construction Code."

Discuss!an Mechanical interfaces, fits, and tolerances are not changed by the use of Section XI.

3.

Recuirement

"(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

) 1 Page 7 of 8 Page 6 j

Qiscunnlan The Design Report associated with this project is ABB/CE Engineering Calculation No. CR 9417 - CSE93 - 1121, Rev.1, " Structural Analysis of 4

Temperature Nozzle Wold Repairs for Consumer's Power Palisades Pressurizer".

1 This design report has analyzed and found acceptable this specific modification for the specified design and operating conditions o'the Owner's Specification.

The modified design is therefore reconciled with the Owner's Specification.

4.

Recuirement

"(4) Materials are compatible with the installation and system requirements".

Discussion The weld, pad is deposited with SFA 5.11 ENiCrFe-3 welding electrodes as specified in ASME Section 11, 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-10 composition weld pad of the side shell nozzle.

The welding filler material, SFA 5.11 ENiCrFe 3, conforms to the requirements of Section 11 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 and meets the strength requirements for design under ASME Section Ill.

CSE 93-382

EA-SC-93-087-01 i 1 Page 8 of 8 Page 7 j

The repair welds will be made in accordance with the requirements of IWA-(

4300 of Section XI.

Conclusidn The preceding discussions show the requirements for reconciliation to the Original Construction Code have been met for this modification.

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EA-SC-93-087-01 4 PWbc! NY1%.41 PROCEDURE TRAVELER Revision 17 Page 1 of 2 A68/Comsor,co Em wsewc N-"m seeom S v^se Nc Procedure Title suo fenoa/ mea r,em a premporge vmes - som. ecoacea-cez r Mcceu Procedure Nojcesc<.,7 ect Revision No C

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EA-SC-93-087-01 4 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 N0ZZLE(S)

ELECTRICAL DISCHARGE MACHINING (EDM) PROCESS f.

/ /C'h G3 Procedure Sponsor Date

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a x g_ge7 01 PALISADES NUCLEAR PLANT ; Proc No 3.07 SAFETY REVIEW Page 3 of 9 Attachmant 1 Revision 7 Page 1 of 1 PS&L Log No M 'lO5 Item Identification No 2003067-002 Rev 0

Title ABB/CE NUCLEAR SERVICES SE Rev FRAVELER: WELD REPAIR / MODIFICATION OF PRESSURIZER NOZZLE -- EDM PFOCEDURE Describe Issue / Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING Reason for Issue / Changes PROCEDURE REOUTREMENT BY ADMINISTRATIVE PPOC. 10.41 Yes No 1.

Does the item involve a change to procedures as described in the FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6.

5.8, 5.10, 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 FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10, 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 FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10, 6.9, 7.4, 9.1.

TABLE 4-21. TABLE 4-22 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, 4.0 i

i Justify No Answere below if logic is not obvious 1

Although material removal under the ASKE code is discussed in general terms in the FSAR, the EDM process does not deviate from code acceptable practices.

j 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 is not required.

However, this Attachment shall accompany other review materials for the item to document that a safety Evaluation was not required.

(N(dl?nQIolu/9s L M i whihs Prepared By Date deviewed By Date

EA-SC-93-087-01 l 4 Page 4 of 9 ABB

==

l FIELD CHANGE NOTICE FCN NO. 20030QCC[

DATE

/d -2 2. - 9.5 l

DOCUMENT NO. D-99/7-Cc93 -Ol 9 REV. NO.

Oz PAGE

/ ee/

STEP / PARA. NO. 2 cA/6 8 /c DESCRIPTION OF REQUESTED CHANGE:

kN'hofe: Se u \\ r-es 4 A)oT T o e A c c ed m;rleut 0;chosess 0 9 055"me. ADD nyoove depth of.200" mu)."

De /OdT'SE VER..

SEE f 92.,2. t h ($ FC 0 Di M kJq tv 1C be. rCU W C b ~

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REASON FOR CHANGE:

5 Re(lect fogain mexT.s o & Pn/;sApe s hc]ed"DNT seeet g corc,ocum3 e,cuoye 73gg y 4

APPRO D BY:

REVIEWED AND RELEASED BY:

GW 4//1

/0ZZO3 f

0$

5 Task Manager / /

Date nt Rep entative pv 4elam wiA;DateK L QQgg

'wWE

/ o-27-93 cL/k)1% O io/z2/U

' Quality Representative Date -

Authorized inspection Agency Data FQQ FtN (2/91)

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F1NAL SURFACE SST TYPE 316

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EA-SC-93-087-01

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i po,.-st-e

ABB-COMBUSTION ENGINEERING PAGE 1 OF 4 NUCLEAR SERVICES REVISION O EA-SC-93-087-01 TRAVELER NO. 2003067-002 DATE 10/20/93 Attach:nent 14 Page 6 of 9 i

WELD REPAIR / MODIFICATION OF PRESSURIZER N0ZZLE 1

UTILITY:

CONSUMERS POWER COMPANY 1

SITE:

PALISADES N0ZZLE NO.:

PRESSURIZER N0ZZLE REPAIR 1.0 TABLE OF CONTENTS AND LIST OF EFFECTIVE PAGES:

CONTENTS PAGE NO.

E COVER PAGE l'

0 REFERENCES 2

0 PREREQUISITES 3

0 PERFORMANCE 4

0 APPROVED BY:

/7 h-l 0 to/tif43 YS

//

lelo 93 TASK MANAGER A DATE OWNER REPRESENTA" JIVE DATE 0?r

/f-20 9s

&sf4 D& hh4tht-w A -

Vl Blake UAl.IYl'lLEPRESENTATIVE DATE' AUTif0RIZED INSPECTION AGENCY DATE p (j).yyl w Ich>/tg

/o - 2o4)

ENGINEERING 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 Attachnent 10 Page 7 of 9

2.0 REFERENCES

2.1

1. P4'v/ Combustion Engineering Dwg. No. D-9417-C093-019, Rev. 02.

ABB 7

eace #Chl *' rec 3co7-oos & ac4 cal ac scle c u+ e,p,, <. 4 6

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

guk 3l 101.

2.3 Instruction Manual:

Pressurizer; Consumers Power Company -

Palisades Plant.

2.4 ASME Code Seccion 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.0.

2.7 ABB/ Combustion Engineering 0.P-9.5. Rev. 9.

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

S - Supervisor / Worker Q - Quality Operations 0 - Owner / Client A - Authorized Nuclear Inspector V - 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

i ABB-COMBUSTION ENGINEERING PAGE 3 OF 4 NUCLEAR SERVICES REVISION O EA-SC-93-087-01 l

TRAVELER NO. 2003067-002 DATE 10/20/93 Attach.ent 14!

Page 3 of 9 3.0 PREREOUISITES l

3.1 All required personnel have received training in Quality Control, Radiation Control, and AIARA 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 j

has been erected, if required.

1 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,1f required.

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1 rev

ABS-COMBUSTION ENGINEERING PAGE 4 OF 4 NUCLEAR SERVICES REVISION O [91s 3-TRAVELER NO. 2003067-002 DATE 10/20

,e Page 9 of 9 STEP NO.

4.0 PERFORMANCE 4.1 Verify satisfactory completion of prerequisites.

S V

Q W

0 REMARKS:

A 4.2 Setup EDM equipment per the requirements of Ref.

S W

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.

i NOTIFY SHIFT SUPERVISOR PRIOR TO PUTTING WATER Id PRIMARY SYSTEM AT EXT. 0225/0252; SS.

name/date REMARKS:

4.3 EDM the Eroove in the nozzle approximately 1" (one)

S W

inch from the vessel I.D. per ref. 2.6. and 2.1.

Q y

r 12elavesce (=Ckl S 2cc3067-ecs Say ac. M I O

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wortle cu+ vguirh4M,

[O S

A REMARKS:

cjez!93

4.4 Verify nozzle groove by VT-3, per Ref. 2.7.

S W

and Drawing Ref. 2.1.

Q 1

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A REMARKS:

ROI -

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RETURN TO TRAVELER l

2003067-001 STEP 4.22 FOR INSTALLATION OF THE THERM 0WELL

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i EA-SC-93-087-01 i

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ATTACHMENT 15 i;

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i EDM Procedure

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1 Proc No 10.41 12 PROCEDURE TRAVEL.ER i

Revision 17 Page 1 of 2 4

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EA-SC-93-087-01 PALISADES NUCLEAR PLANT 3 Proc No 3.07 SAFETY REVIEW Page 2 of 12 Attachmant 1 Revision 7 Page 1 of 1 PS&L Log No k Y ~/L9N Item Identification:

No STD-100-207 Rev 0

Title PROCEDURE FOR SE Rev ELECTRICAL DISCHARGE MACHINING fEDM) PNESSURIZER NOZZLE SEVERING Describe Issue / Change: PRESSURIZER NOZZLE REPAIRS BY COMBUSTION ENGINEERING Reason for Issue / Change: PROCEDURE REOUIREMENT BY ADMINISTRATIVE PROC. 5.06 Yes No l.

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, 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 FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10, 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 FSAR7 FSAR Sections affected NONE FSAR Sections reviewed 4.3, 4.4, 5.1, 5.6, 5.8, 5.10, 6.9, 7.4, 9.1. TABLE 4-21. TABLE 4-22 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, 4.0 Justify No Answers below if logic is not obvious:

Although material removal under the ASME code is discussed in general terms in tre 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 according to Section 5.3.

If all Safety Review questions listed above are answered NO, written USQ Evaluation is not required. However, this Attachment shall accompany other review materials for the item to document that a Safety Evaluation was not required.

MA)difaD mkiks 6%LL whih>

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l Prepared By date Reviewed By Date

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EA-SC-93-087-01 5 i

Page 3 of 12

~

Procedure No. STD-100-207 1

i Revision No. O Issued Date 10/21/93 f

PALISADES NUCLEAR PLANT SPECIAL PROCESS PROCEDURES i

TITLE:

PROCEDURE FOR ELECTRICAL DISCHARGE MACHINING (EDM)

PRESSURIZER N0ZZLE SEVERING i

C/Jn 0/a1Di io/224s Procedure Sponsor Date

' syfI toIsa]a3 i

Tynnrcaiaeviewer Date '

Coha Gadv i io/u/9s i O User Reviewer

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Date Rev #

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EA-5C-93-087-01

' 3 Page 4 of 12 M EDID

^aa=re FIELD CHANGE NOTICE FCN NO. 2CO3CTrCC6' DATE

/d-22 -93 DOCUMENT NO. D-M/7-Cc93 -Ol 9 REV. NO.

Oz PAGE

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STEP / PARA. NO. 2 cA/6 8 -(o DESCRIPTION OF REQUESTED CHANGE:

kN:hofe: Re unt-es 4 AJoT To e xc e ed lymeNt }_h;cho ess 0 9. 05 5"mo. ADO 193 cove depth o f.200" Aw)."

DeAJcT'SEv5ft.

5EE f9 2,R. thIS YC0 hrM rWQ y)1( b c. ICU h Cb ~

REASON FOR CHANGE:

B Re9/ect QM me.47.s o & Pal;see s &cJes-PLar 5Peci Cicarico Chanye PacknSe #93 o B y APPRO D BY:

REVIEWED AND RELEASED BY:

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pv 4ef+ma w>Al Datex L QQy Task Manager / /

Date nt Rep sentative OYa0

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' Quality fiepresentative Date

/ uthorged Inspection Agency Date FQQ FCN ('2/91) lehb

THERMOWELL SST TYPE 316 s\\

F1NAL SURFAC@

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EA-SC-93-087-01

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'j Page 5 of 12 SA-182 TYPE F-316

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EXISTIN2

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TEMPER @

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N0ZZLE

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.06 GAP R.18 MIN

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AT FIT-UP p

._ BREAK CORNER

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SB-166 l

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( 019-01 )

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0 2.5 MIN 0 4.0 MAX f

.50 MIN.

.62 MAX.

12 REF.

THICK WELD 8

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(INCONEL 182)

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EA-SC-93-087-01 Attach: ent 15 Page 6 of 12 A ItIR M EDID 1"::=::.:

FIELD CHANGE NOTICE FCN NO. 2CO30@ O09 DATE

//-2 E-93 DOCUMENT NO.

@ - /00 - tO 7 REV. NO.

6 PAGE

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$TEP// PARA. NO. 5.83 DESCRIPTION OF REQUESTED CHANGE:

hle k: Yf S-S~pec)kcnb/wt) C}mya S Anye.

REASON FOR CHANGyg b

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REVIEWED AND RELEASED BY:

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Date Client Representative Date hl

/o-t%-0 Ys

/0 -M -93 uality Repr'iisentative' Date Authorized inspection Agency Date

'00 FCN (2/91)

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EA-3C-93-087-01 Attachr.ent 15 Page 7 of 12 A BR R

M ED D e? :::x FIELD CHANGE NOTICE FCN NO. 200J0/o7-Cod DATE

//- 2 E - 95 DOCUMENT NO. SM - /SC - 20 7 REV. NO.

O PAGE 6//5 STEP / PARA. NO. f /7 f_30 i

DESCRIPTION OF REQUESTED CHANGE:

Shrp 519) 6.30 CUEMa~ 'W L~ b N-A)O& & A)O E Coh W&

REASON FOR CHANGE:

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REVIEWED AND RELEASED BY:

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OCT-1?-1??3 15:04 ::CN

EB CE Chat t er..

..: 9 a TO 31 sis gag;gg -

e,g; EA-SC-93-087-01

-) 3 Page 8 of 12 i

1 PROCEDURE FOR ELECTRICAL DISCHARGE MACHINING (EDM)

PRESSURIZER NOZZLE SEVERING STD-100 207, REV. 0 l

L PREPARED BY:

A //

/A j DATE: /dMA.T r

r COGNIZANT SUPERVISOR APPROV m k<e- -

DATE: /*/M/93 a

f FIELD OPERATIONS APPROVAL:

ih DATE: lb (9 U e

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• i Q,A APPROVAL: V U

DATE:

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PAGE 1 OF 5 i

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253 cE crA.tanb a ccT-is-:3?3 15:e5 ::cn 3

To 91sisTs.:s2?s

~ 2.c2 STD-100-207. Rev. O Page 2 of 5 EA-SC-93-087-01 5 Page 9 of 12-1.0 ORIECIIVES 1.1 This document sequences the steps required for electrical discharge machining (EDM) of 1" pressurizer nozzle in the area of the nozzle between the I.D. and O.D. of the pressurizer shell. 'Ihis allows 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 for this process.

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2.0 REFERENCES

h g

2.1 Drawing No. D-9417-C093-019,Rev. 2.

ge h < u e-FCM 2cc 3c67-cc5 0

& Ackud (Pf u w0meds of nozzle c5 3.0 DEFINITIONS 3.1

'Its following services are available:

A.

480 VAC 3 phase (30 amp lines).

B.

Deminemlized water 60 psi minimum.

i i

C.

110 VAC 20 amp q

4.0 PROCEDURE

{

4.1 The EDM Control Cabinet and Power Supply should never be left unattended in l

the energized mods.

l 4.2 Ensure that the " Ram Mode" switch is in the " Edge" position any time the tool is not in use.

4.3 Do not operate the EDM tool without operating DI water flush system.

4.4 If any step cannot be completed haranw of equipment failure, or some other cause, inform the CE shift supervisor.

1 S.0 OPERATIONAL PROCEDURE 5.1 Visually check the cables, fixtures, and hoses for any obvious damage and be sure all connections are secure.

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STD-100-2M, Rev. 0 l

Pags 3 of 5 EA-SC-93-087 ' 5 Page 10 of 12 5.2 Install a new electrode in the EDM Tooling Head.

NOTE: Electrode is to be positioned such that the electrode is centered m i

Delrin wand and the D.I. water connection is rotated to its outermost position referenced to the Delrin wand. This is O' Ref.

5.3 Install the tooling holder such that the two 1/4" holes are facing the center line of the pressurizer.

5.4 Install the Delrin wand into the nozzle with O' Ref. aligned with the pressurizer and center line.

5.5 Adjust the tooling holder such that the two 1/4" holes are centered in line with the two set screws which att used to lock the electrode shaft.

5.6 Install eccentric caeUng on electrode shaft.

5.7 Install eccentric motor mount to the tooling holder.

5.8 Rotate the eccentric cacHag such that the egHag is aligned to the center of l

the motor tnount.

1 5.9 Install motor to motor snount and eccentric coupling.

I NOTE: Motor shaft and electrode shaft must not be in contact.

5.10 Tighten set screws in the eccentric coupling to the motor shaft and the electrode shaft.

5.11 P-h-Ir maa-dane at the tooling head.

5.12 Suggested EDM paramders.

Servo Up Mode Auto retract (during cut)

Edge (stand by)

Servo Speed 3-9 Gap Adjust 3-9 Ram Cycler Off Ram Feed Neutral Gap Initiation 150 Lands 1 or 2 Electrods Metallic - 2 Polarity Neg.

Peak Current Full

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cT-:3-t m 3:es

==ct1 255 cE :ns m r,::32-Tc 91616TE45aa s.ca l

STD-100 207, Rev. O Page 4 of 5 EA-SC-93-087-01 5 l

Page 11 of 12 i

% On Time 20-90

)

Art Duration 128 l

Capacitor Mode Off 5.13 Turn the EDM machine on while the Ram Mode switch is in the edge position.

5.14 Start D.I. water flow to the electrode.

5.15 Check Edge Mode by shoning between negative and positive, alarm on power supply should sound.

i If the electrode is in contact with the nozzle, the edge alarm will sound. Do not l

5.16 tum to auto retract until no alarm sounds.

5.17 If edge alarm is sounded due to electrode contact, adjust electrode to a position 4

that does not cause an alarm.

4 5.18 Turn mode to Auto Retract, press machine on and check that electrode is not shoned.

j 5.19 Open hydraulle line valve to begin cut and adjust control parameters for best cut.

j so y

Qg JC~CH

.20o 3067 -cog

• NCTTE: Do not cut above Wamps.

p/o/43 5.20 Continue cut until complete or w.iuc deems it necessary to change to new electrode. If new electrode is needed, repeat steps for electrode installation.

5.21 After eccentric cut is complete, remove electrode tooling and install new electrode which is.yr-My.20" thinner. In=r=11mhaa steps are same as for 1st electrode up to Step 5.6.

5.22 Install anarantric coupling to the electrode shaA. Do not tighten set screws.

5.23 Install concentric motor mount to the tooling holder.

5.24 Rotans electrode shaft approx.135* in a clockwise direction. ' Ibis should move electrode into the eccentric slot.

5.25 Tighten 2 set screws through Delrin wand to fix electrode shaft at 135*.

5.26 Install motor to the concentric motor mount and the concentric coupling.

Tighten coupling set screws.

5.27 Feheir enanactinas at the tooling head.

j bCT-19-i b 15:es :: m

[33 cs 77,3..,

70 3 g ggg g,

STD-100-207.Rev. O i

l Page 5 of 5 EA-SC-93-087-01

' 5-Page 12 of 12 l

a 5.28 If the edge alann sounds, slight adjustment of the electrode may be maanry e

l before beginning cut.

5.29 Turn mode to Auto Retract, press machine on and check that the electrode is i

not shorted.

l Open hydraulic valve to begin cut a' d adjust control parameters for best cut.

n 5.30 l

30 pA 6(f pcg*~zco 3c07-oc 6 i

NOTE: Do not cut above)4' amps, i

pp l

5.31 Continue until cut is complete or operator deems it m*=y to change 1

electrode. If a new electrode is needed, repeat steps for electrode installation.

1 i

If another concentric cut is required spent steps for concentric cutting but use

~

5.32 an electrode.20" thinner than the electrodes used for previous concentric cut.

d 5.33

=" 1;---=.

=;= & - :- 2== Mi :-i ;.=:4 by -:--It b

yd y 'D "2 2:::- ? ;r.

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@ g&yv7'004 NOTE: Graphite cutten may be used for last cuts.

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5.34 After cut verification disassemble and remove equipment from containment.

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EA-SC-93-087-01 ATTACHMENT 16 1

ASME Code Interpretation i

IX-1-89-70 J

1

^~

EA-SC-93-08h-01 I 6 Section XI - Interpretations No. 29

. XI t-89-69, XI-1-89-70 Page 1 of 1 Interpretation: XI 189-69 l

Subject:

Section XI, IWF-1300 and Table IWF 25001; Component Support Examination Boundaries (1980 Edition With Addenda Through Winter 1981) l Date Issued:

February 15,1991 File:

IN90-027 Question: For a nonintegral support whose boundary is identified in IWF-1300(c) with no I

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-l 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: XI 1-89 70

Subject:

Section XI, IWB-4212; Material Removal Process - Nonwelded (1983 Edition With Summer 1983 Addenda)

Date Issued:

February 15,1991 l

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.

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