ML20064E486
| ML20064E486 | |
| Person / Time | |
|---|---|
| Site: | Monticello  |
| Issue date: | 10/14/1982 |
| From: | NORTHERN STATES POWER CO. |
| To: | |
| Shared Package | |
| ML20064E467 | List: |
| References | |
| FOIA-82-514 NUDOCS 8301060024 | |
| Download: ML20064E486 (36) | |
Text
,
v NSP - NRC MEETIrlG AGENDA OCTOBER 10 1982 REVIEW NSP INSPECTION PROGRAM 22" RECIRC RING HEADER EfiD CAP INDICATIONS 12" RECIRC RISER INDICATI0t!S SUMilARY t
8301060024 821117 S
R 514 PDR
f MONTICELLO NUCLEAR GEilERATING PLANT 1982 AUGMENTED ISI EXAM PROGRAM
~
NUMBER OF SYSTEMS llELDS EXAM.
A.
REACTOR RECIRCULATIOM SYSTEM 28" LOOP A 16 LOOP B 17 22" MAi!IFOLD 23 12" RECIRCULATION RISER 50 (INCLUDING S.E. ilELDS) 4" BYPASS 8
B.
REACTOR WATER CLEAN-UP SYSTEM (4" DIA) 3 C.
RESIDUAL HEAT REMOVAL TW20 - 18" / 16" 2/5 7
TW30 - 18" / 16" 2/5 7
REW10 - 18 4
_A 135 G
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7 g- -
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E Prinury Contairrent Vessel i
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Reactor Pressure s
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f Riser
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RECIR ULATION RISER Q RMAJ-2 WELD 4.
SWEEPOLET 33/4"
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22" DIA RECIRCULATION MANIFOLD Schematic of Loop A Recirculation Manifold at the Repair Location
1982 ISI RESULTS
~
INDICATION DESCRIPTION WELD SYSTEM ID ORIENTATION DEPTH LENGTH LOCATION EMAT REW32-22" RMBd-2 3-AXIAL 4-11%
1.0" 12:00-CAP (MANIFOLD) 0.5" 0.5" REW21-12" RRCJ-3 2-AXIAL
<2%
0.41 7:30-S.E.
(RISER) 0.20 8:00-S.E.
2-CIRC.
3.5%
0.25 ROOT-LACK OF FUSION REW20-12" RRDJ-5 1-AXIAL
<2%
0.43 3:30-ELB0W (RISER)
REW19-12" RREJ-3 3-AXIAL
<2%
0.34 12:00-PIPE (RISER) 0.30 12:00-PIPE 0.28 12:00-S.E.
1-CIRC.
9%
1.06 12:00-R00T REW14-12" RRFJ-3 1-AXIAL
<1%
0.32 12:00-PIPE (RISER)
=
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WELDI'iG PROCEDURE SOUi!D h' ELD iiETAL CRACK RESISTAi!CE C0f1PRESSIVE STRESS W
G
t CRACK RESISTANCE 30SL WELD METAL 6 FERRITE MEASUREMEi!TS LOM SEi!SITIZATI0t!
- WATER BACKING
- LIlilTED BEAD SIZE
- LIMITED ELECTRODE SIZE
- LIMITED AMPERAGE
- LIllITED PREHEAT /II;TERPASS TEMPERATURES SMALL BEADS TRA!!SVERSE TO INDICATIONS t
l l
i t
~
HIGH CORPRESSIVE STRESS WATER BACKING HIGH llEAT INPUT AFTER 2 LAYERS i
- MAXIMUM PRACTICAL AMPERAGE
- MAXIMUM PRACTICAL WEAVE WIDTH i
I 9
i l
,., - ~., - -. - -.. -.
. ~,.. -.
I OVERLAY REPAIR SunMARY 1.
MOCK-UP TRAINING 2.
VERIFY SYSTEM PREREQUISITES 3,
MARK OVERLAY AREA 4.
PENETRANT TEST 5.
INSTALL ARC STRIKE SHIELDS At!D WELDING GUIDE 6.
VERIFY QUALIFIED WELDERS AND FILLER METAL 7.
HELD FIRST LAYER 8.
FERRITE F.EASUREMENT 9.
HELD SECOND TO SIXTH LAYERS 10.
FERRITE HEASUREMENT 11.
GRIND 12.
PENETRA!!T TEST 13.
RADIOGRAPH TEST 14.
ULTRASONIC TEST 15.
HYDROSTATIC TEST l
A!'ALYTICAL BASIS FOR 22" CAP WELD OVERLAY REPAIR DESIGN STRESS ANALYSIS ASf'.E SECTIO!l III ANSI B31.1 FRACTURE MECHANICS CRACK PROPAGATIOi; At?ALYSIS LIMITIliG CRACK DEPTH TEARIliG MODULUS l
l
ANSYS MODEL OF 22"END CAP WELD OVERLAY l
2:9/\\
LIMITING SECTION 3
N,
.h__._-l l
SWEEP 0LET 6__
6__
l unghuq__
usammum__
_huusd_
/ PREP 7
APPLIED STRESS PROFILE THAOUGH LIMITING SECTION 22" END CAP 10-8-
PRESSURE 6-
.D 4-g E
t;i 2.
THERMAL TRANSIENT 0
- S 1.5 DISTANCE CR K (INCHES)
OUTSIDE OF WELD OVERLAY.
9 J
F CODE STRESS ALLOWABLES 22" END CAP ACTUAL CATEGORY EQUATION STRESS SECTION III B31.1 NUMBER OR NB ALLOWABLE ALLOWABLE THICKriESS S
NA S,=16,900 PSI S =14,427 PSI h
S =18,750 PSI c
REQUIRED (1) 1.308" 0.826" 0.952" THICKNESS PRIMARY (9) 5,470 PSI
(10) 12,060 PSI 50,700 PSI 49,765 PSI SECONDARY
~
PEAK (11)
(15,150)5 NA NA USAGE
<0.01 1.0 1.0 FACTOR (40 YR)
- FINITE ELEMENT MODEL GIVES 9920 PSI FOR MAXIMUM STRESS INTENSITY, EQUATION (9) CALCULATES AXIAL STRESS WHICH IN THIS CASE IS NOT LIMITING AS MOMENTS = 0.
l
I TOTAL APPLIED STRESS J
PRESSURE +
10 CYCLES RESIDUAL + THERMAL _
k If!'f l
l l.
lfff PRESSURE + RESIDUAL -
10 hl)
[ ( [f (
i l
RESIDUAL -
lJll MONTHS
)
b2 MONTHS m
1 YEAR 1 YEAR C
=
n
=
=
TIME
'N.s
9 4
9 e
6
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CRACK GROWTH RESIDUAL STRESS 22" END CAP 30 20 -
A (N0 STRESS) 10 -
o s
ID OD mg E
m EC 8 '
G B (BEST W
ESTIMATE)
C (WORST CASE) -40 O
e X - P. Ford, 1.5 ppm 02
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0 - R.
I!orn, 0.2 ppm 0 2
10" E
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( 10 I
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cc f
dt=1.843 X 10 K*
-12 Upper Bound
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Lower Bound
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,1 Stress Intensity Factor (Ksi /Ili)
CRACK GROWTH CASES b
^
d CASE GROWTH LAW R
dt
-12 4
g.615*
Al A
1.843 x 10 A2 A
4.116 x 10-12 g.615**
4 4
-12 g.615 B1 B
1.843 x 10 4
-12 g.615 B2 B
4.116 x 10 K.615 4
-12 C1 C
1.843 x 10 t
K.615 4
C2 C
4.116 x 10-12 BEST ESTIMATE EPRI NP 2423-LD JUNE 1982 0.2 ppm DATA.
UPPER BOUND EPRI NP 2423-LD JUNE 1982 0.2 ppm DATA.
G
70 STRESS INTENSITY FACTOR, K VS CRACK DEPTH, a
---E=*
60 -
1 = 2 inches
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3 k T = 1.0 in.
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L 50 -
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PIPE DIAMETER = 22 in.
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/
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/
/
40 -
7
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5 30 -
/
/
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20 -
/
/
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10 -
0.
0 0.1 0.2 0.3 0.4 0.5 0.6 l
a,(inches)
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1
o CRACK GROWTH 22" END CAP
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ORCED
- 1. 2 -
. OVERLAY.OF.MELDA s
30.9-c-
C2 5
LIMIT FOR b
0.6 -
UNREINFORCED PIPE C1
- 0. 3 -
CASE A1,A2,81,B2 i
i 0
1 2
3 4
5 TIME (years)
Cl,C2 ARE RESPECTIVELY THE BEST ESTIMATE AND UPPER BOUf4D IGSCC CURVES FOR A FINITE LENGTH SEMI-ELLIPTICAL SURFACE CRACK.
I CRACK GROWTH 22" END CAP 1.2 -
WELD OVERLAY 0.9 _
n U
__L_LOWANG_E D _EPTH__._ _ _ _ _
_Al __
A
.c E
70% OF WALL B2 0.6 _
B1 A2
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5 0.3 -
1 0
0 1
2 3
4 5
TIME (years) i I
i
{
Y
TEARING MODULUS 22" END CAP 240 -
200 -
160 -
in1b "o
J ~14,000 C
in2 x
N
.5 120 -
2 PRESSURE =
inib 5
JIC=6000 4000 PSI in2 80 -
PRESSURE =
6300 PSI PRESSURE = 6000 PSI PRESSURE = 5000 PSI 0
0 40 80 120 160 200 240 T
OVERLAY WELD
/
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WELD ANNEALED CAP 1" RADIUS FLAW
22" CAP WELD OVERLAY ANALYSIS
SUMMARY
OF RESULTS REPAIR MEETS ALL DESIGN STRESS ANALYSIS REQUIREMENTS CRACK PROPAGATION ANALYSIS SHOWS:
NO CRACK PROPAGATION WITH EXPECTED RESIDUAL STRESS IMPROVEMEllT ACCEPTABLE CRACK PROPAGATIOM FOR MORE THAN Ol'E FUEL CYCLE EVEN WITH WORST CASE RESIDUAL STRESS ASSunPTION TEARING t;0DULUS ANALYSIS SHOWS NO LOSS IN DESIGN SAFETY MARGIt! WITil CRACK ASSUMED ENTIRELY THROUGH ORIGIt!AL PIPE THICKNESS i
A
--4..
A!!ALYTICAL BASIS FOR ACCEPTANCE 0F 12" RISER INDICATIONS WITHOUT REPAIR ASME SECTION XI ACCEPTANCE STANDARDS FRACTURE MECi!A!!ICS At!ALYSIS CRACK PROPAGATION LIlllTING CRACK DEPTH TEARING MODULUS I
j
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9 i
TABLE IWB-3514-3 s
ALLOWABLE PLANAR INDICATIONS tld Material: Austenstic steels tilat meet the requirements for the specilled sninunum yield strength Of 35 ksi Or less at 100'F y
t Volumetric Examination Method, Nommal Walt Thickness,' 8 r, in.
Surface e,.
Esaminatson 0.312 1.0 2.0 3.0 Method Avect Surface Subsurface Surface Subsurface Surface Subsurface Surface Subsurface Nom. Wall Indecation Ratso,'-
Indication, Indication" Indication, Indication" Indication, Indicatiun" Indication, Irwhcation8e Thickness,s.:
- Length, a //
alt, %
alf, %
alt, %
olt, %
alt, %
o I8, %
alt, %
ale, %
- , in.
d', en.
Pre <,ervice Emanunation 0 00 94 94Y 8.5 8.5Y
- e..e 8.0Y 7.6 7.6Y 0.312 or less
'/.
0.05 96 9.6Y 86 8 6Y 82 82Y 7.7 7.7 Y 0.10 98 9 8Y 88 8.8 Y 8.3 8.3Y 7.8 7.8 Y 1.0
'/..
0.15 9.9 9.9Y 8.9 8 9Y 8.4 8 4Y 7.9 7.9Y 0 20 10 0 10.0Y 9.1 9.1 Y 86 8.6Y 8.1 8.1 Y 20
'/.
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0 25 10 0 10.0Y 9.2 9 2Y 8.7
- 8. 7 Y H.2 8.2 Y 0 30 10 0 10 OY 9.4 9.4 Y 8.9 8 9Y 8.3 8.3Y 3 0 and over
'/.
x 0.35 10 0 10 0Y 9.5 9.5 Y 9.0 9.0 Y 85 8.5Y 040 10 0 10.0Y
- 9. 7 9.7 Y 9.1
- 9. I Y 86 h 6Y l
045 10.0 10 OY 9.8 9 8Y 9.3 9.3 Y 8.7 8.7Y O
3 O 50
- 10.0 10.0Y 10.0 10 OY 94 9.4 Y 8.9 8.9Y m
inservice Esamination 5
0 00 11.7 11.7 Y 10 6 10 6Y 10 0 10 OY 95 9.5Y 0.312 or less 0.2 Z
0 05 12 U 12.0 Y 10.7 107 Y 10.2 lu.2Y 96 9 6Y
==
0 10 12.2 12.2 Y 11.0 l l.0 Y 10.4 10.4 Y 9.7 9.7Y 1.0 0.25 0 15 12.4 12.4 Y 11.1 11.lY 10.5 10.5Y 9.9 9.9Y 0 20 12.5 12.5Y I 1.4 I I.4 Y 10.7 10 7Y 10.1 101Y 2.0 0.45 0 25 12.5 12.5Y 11.5 ll.5 Y 10.9 10.9 Y 10.2 10.2Y O.30 12.5 12.5Y 11.7 II.7Y 11.1 11.1 Y 10.4 10.4Y 3.0 aixf over 0.65 0.35 12.5 12.5Y 11.9 I I.9 Y 11 2 11.2 Y 10.6 10 6Y 0.40 12.5 12.5Y 12.1 12.l Y 11.4 I I.4 Y 10.7 lo.1Y 0 45 12.5 12.5Y 12.2 12.2 Y 11.6 11.6Y 10 9 10 9Y 0 50 12.5 12.5Y 12.5 12.L Y 11.7 II.7Y 11.1 II.lY NOT E S:
.i..
(11 7 or mtermediate flaw aspect ratios o // and thickness f, linear interpolation is pernussible.
(21 r b nomnui a.ill thickiirw of.sclual wall thidness as determused by U I enamenation.
I H lhe total depth of a sht5urface mdicatmn is 20 (41 Y = t5 ifI/to !#l = $ lo. Il y < 0.4, u= flaw mdication is clasufied as a surfas e indic.stion. If Y > 1.0, use Y = 1.0.
s e
ANSYS MODEL 12" PIPE CRACKS l
l kb
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LIMITING j__
SECTION l
LENGTH = 1" DEPTH =.07"
~~-
D.dMelMEd Mud.
O p.
Equi
_ul
_i.msum bud
_b.I bema l
I
.=__
l l
l
/ PREP 7
{
12" SCHEDULE 80 16 12 -
AXIAL STRESS PRESSURE + THERf1AL +
WEIGHT (WORST CASE) 8-m
~
l0 HOOP STRESS PRESSURE m
4-0 l
j ID BASE 0.2 0.4 0.6 OD 0.8 0F CRACK DEPTH (inches) 9
CODE STRESS ALLOWABLES 12" SCHEDULE 80 PIPE ACTUAL CATEGORY EQUATION STRESS SECTION III B31.1 NUMBER OR NB ALLOWABLE ALLOWABLE THICKNESS S
NA S =16,900 PSI S
=1,427 PSI m
h S =18,750 PSI REQUIRED (1) 0.606" 0.462" 0.538" THICKNESS PRIMARY (9) 8646 PSI
(10) 19,110 PSI 50,700 PSI 49,765 PSI SECONDARY PEAK (11)
(34,330)5 NA NA USAGE 0.2 1.0 1.0 FACTOR (40 YR)
- FINITE ELEMENT MODEL GIVES 9506 PSI FOR MAXIMUM STRESS INTENSITY.
THE DIFFERENCE IS DUE TO THE NOTCH.
I l
t i
r eu.
CRACK GROWTH RESIDUAL STRESS 12" PIPE AXIAL AND HOOP 40 36 -
30 -
20 -
i A (N0 STRESS) 10 -
5
$uu 0
ID OD a
Ee C
cc B (BEST ESTIMATE)
C (WORST l
CASE)
_2 0 -
~~
CRACK GROWTH 12" SCHEDULE 80 AXIAL CRACK 2
0.8 OD -
- 0. 6 -
70% WALL = 0.48" 7
.E C2 C1 A2 Al
.$ 0.4 -
iEb 0.29 Q
- 0. 2 -
S t_05 o.03 yg 8
i i
1 2
3 4
5 TIME (years) i l
~,
I CRACK GROWTH 12" SCHEDULE 80 CIRCUMFERENTIAL CRACK 0.8 OD -
- 0. 6 -
O E
en 0.4 -
I a.g 42% WALL = 0.29" 7
0. 2 '-
A1, A2 C2 C1 ID 1
2 3
4 5
TIME (years) m e
TEARING MODULES 12" PIPE AXIAL FLAW a = 0.48"
~
240 -
200 -
160 -
m3 JIC=6000 x
N
.5 120 -
4 x NORMAL LOAD 3
5 x NORMAL LOAD 5
80 -
J =7500 g,,
g NORMAL LOAD 40 -
f=31.5 0
40 80 120 160 200 240 T
e e
we
_. = - _. - _ _
h TEARING MODULES 12" PIPE CIRCUMFERENTIAL FLAW a = 0.20*
240 -
200 -
160 -
~2 x
JIC=6000
^
~
.c 120 -
2 "c
C 3
80 -
3.8 x NORMAL LOAD f=19.0 40 -
0_
i i
i i
0 40 80 120 160 200 240 T
O h
9 t
EVALUATION S'!4RRY 12" RISER HELD INDICATIONS WELD
~
INDICATION' DESCRIFFION ASME SECTION XI ALLOWABLE INDICATION IDENTIFICATION ORIENTATION DEPTH 11NGTH ALIDWABLE INDICATION DEPTH DEFIH BY ANALYSIS RRCJ-3 AXIAL (2)
<2%
.41 IN.
11.3%
12.8% % 50%
i CIRC.(2) 3.5%
.25 IN.
11.5%
10% % 35%
RRDJ-5 AXIAL
<2%
.43 IN.
11.3%
12.8% % 50%
RREJ-3 AXIAL (3)
<2%
.34 IN 11.3%
12.8% 4 50%
CIRC 9%
1.06 IN 11.1%
10% % 35%
RRFJ-3 AXIAL
<1%
.32 11.3%
12.8% % 50%
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N11 CLEAR HLGULA10RY COMMISSION
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- g ' w DCT 191982 Docket No. 50-263
~
Northern States Power Company ATTN:
Mr. C. E. Larson Director of Nuclear Generation 414 Nicollet Mall
. Minneapol is, MN 55401 Gentlemen:
This refers to the discussions between Mr. G. Neils and others of your staff and Mr. W. S. Little and others of the Region 111 and NRR staffs during a meeting at the Region li t office, on October 14, 1982, regarding your proposed corrective actions for the crack indications found in the welds on the Monticello Nuticar Generating Plant recirculation system piping. With. regard.to the matters discussed, we understand that you will:
1.
Submit a report to the NRC for review.
This report will include:
A summary of your 1982 augmented ISI examination program, a..
b.
A' description of any repairs, c.
The basis for establishing the accuracy of UT measurements including the depth of indications, r
d.
A description of the methods and analysis used, load comb.inations, and results of analysis using updated loads, An evaluation of reactor reci rculation system stresses e.
resul ting f rom repai rs, and s
e 4
9
/
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_-CONFIRMATORY ACTION LETTER
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OCT 191982 Northern States Pwer Company 2-f.
The basis for Justifying continued operation with existing Indications and repairs.
2.
Not return the unit to service without NRC concurrence.
The above Information was confirmed in a telephone conversation between Mr. Little and Mr. Nells on October 15, 1982.
Picase inform us 'innediately if your understanding of this matter is di f ferent from that stated above.
Sincerely, Original signed by A. Bert Davis James G. Keppler Regional Administrator cc:
W. A. Shamla, Plant Manager DJtS/ Document Control Desk (RIDS)
Resident inspector, Rlli Monticcilo Resident inspector, Rlli Prairie Island John W. Ferman, Ph.D., Nuclear Engineer, HPCA CONFIRMATORY ACTION LETTER al.!.st)8....R ' '.l...
R.!'.'..0%.... R ' ' ! AN...".,'fL....-.."'.$............-
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1,I, u s,,,,,,,,Dav,! s,,,,,,,,,,f f,?,PP,I er 10/18/82
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O'FFICIAL RECORD COPY oc eomu ne no em nacw ono
LIMINARY NCTIFICATION OF EVENT OR UNUSUAL OCCURRENCE--PSO-III-82-103-A Date: October 22, 1982 s prelicinary notifiestien constitutes EARLY notice of events of POSSIBLE safety or lic interest significance. The information is as initially received without veri-ction or evaluation, and is basically all that is known by the staff on this date.
Bility: Northern States Power Company Licensee Emergency Classification:
Monticello Nuclear Plant Notification of Unusual Event Alert Docket No.
50-263 Site Area Emergdney Monticello, MN 55362 General Emergency Not Applicable' v.
Dject: RECIRCULATION LOOP CAP CRACKING (UPDATE)
Additional ultrasonic testing of recirculation cooling system piping has identified crack indications in four riser pipes leading to the reactor.
The cracks previously identified were in the "A" Loop end cap which has now been replaced.
One new riser crack indication was about 9% of the wall thickness and the remaining were determined to be less than 3.5%.
The Licensee had proposed repair of the 9% indication by a weld overlay process and no action on the other cracks at this time.
During surface preparation for the overlay repair, two pinhole through-wall cracks were discovered in the riser pipe. Ultrasonic testing had previously identified the pinhole crack as stag-inclusions or pipe geometry reflections.
The licensee is currently evaluating the pinhole cracks to determine what repair actions are needed.
The resident inspectors and a Region III (Chicago) piping specialist have been reviewing the licensee's activities at the site.
Region III issued a Confirmatory Action Letter or. 10/21/82 requiring the licensee to submit repair information and its analysis of the cracking phenomenon.
NRC staff authorization must be obtained before the unit returns to operation after its present refueling outage.
The licensee has notified the news media that pipe repair activities are under way and Region III has responded to news media inquiries.
Region III was notified of the pinhole cracks on 10/21/82.
'This information is current as of 10 a.m. October 22, 1982.
$Cf y' V
Contact:
C. Brow R. Walker '
J Streeter 612/295-2066 384-2565 384-2541
's,
'STRIBUTION:
St.
MNBB Phillips E/W Villste sirman Palladino EDO NRR IE NMSS mm. Gilinsky PA OIA RIS
=m. Ahearne MPA AECD cm. Roberts ELD Air Rights MAIL:
omm. Asselstine SP INPO ADM:DMB GCY
( s NSAC DOT: Trans Only (p*
CRS D
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8R Regions I
, II
, IV
,V Licensee (Corporate Office)
.m rum