ML20067A961
| ML20067A961 | |
| Person / Time | |
|---|---|
| Site: | Brunswick  |
| Issue date: | 01/24/1991 |
| From: | Vaughn G CAROLINA POWER & LIGHT CO. |
| To: | NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
| Shared Package | |
| ML19310E585 | List: |
| References | |
| RTR-NUREG-0313, RTR-NUREG-313 NLS-91-017, NLS-91-17, NUDOCS 9102080068 | |
| Download: ML20067A961 (43) | |
Text
--._
k Carolina Power & Light Company P.O. Box 1551 e RaMgh, N C 27002 SERIAL:
gg G.E.VAUGHN Vee Preendent Nuclear Servkee Department United States'Huclear Regulatory Commission ATTENTION:
Document Control Desk Washington, DC 20555 BRUNSWICK STEAM ELECTRIC PLANT, UNIT NO.J1 DOCKET.NO.:50-325/ LICENSE NO. DPR-71 IGSCC INSPECTION RESULTS -JREFUELING OUTAGE-7
References:
1.
NRC Inspection Report No. 50-325/89-35, dated December 7, 1989 2... Letter from G. E. Vaughn (CP&L) to Nuclear Regulatory' Commission dated January'7, 1991, " Examination / Evaluation Results:for. Weld No. 1B21N4D-5-SW1-2 Refueling Outage 7" i
3.
. Letter from E.
G. Tourigny.(NRC).to L. W. Eury (CP&L)' dated-December 21, 1989, " Generic. Letter 88-01, NRC, Position'on
.IGSCClin' BWR Austenitic' Stainless SteeliPiping -(TAC Nos; 69128 and 69129)"
4.
Letter from-L.
I. Loflin (CP&L)' to Nuclear. Regulatory Commissioti dated June 29, 1989,;" Response _to Staff's Request for Additional Information Pertaining tofCarolina Power &
l Light Company's Response-to Generic Letter 88-01, Units 1 and 2 (TAC Nos.- 691281and 69129)"
Gentlemen:-
Carolina Power &- Light Company :(CP&L) has completed th'e BSEP.
i Unit 1 Refueling Outage 7 activities 5 associated with:
- (1)1the i
replacement of-the Reactor Coolant Recirculation System (RCRS) and Core Spray System piping and safe-ends.and (2) the NUREG 0313,~ Revision 2. inspections of piping susceptible to
@g Intergranular Stress Corrosion Cracking-(IGSCC).
?
emo MS'
. Enclosure 1 contains:
(1) -a description of, the NUREG 0313, 1
13 8 Revision 2 Inspection Scope and Results, including.the' Scope of Examinations,;UT Process used, UT Results, and a; discussion of-
'So the inspection results of RHR valve welds 1B32RD2B2-84-FWB33 and ex
$8 1B32RD2A2-87-FWA33;-(2) a description of the replacement of the' i
gg RCRS and Core Spray piping and safe-ends; (3) an updated classification of the BSEP Unit 1 IGSCC' susceptible welds based o$g upon the RCRS and-Core Spray. piping:and safe-end replacement
-Ag completed during the BSEP Unit 1 Refueling Outage 7 (Table 1);
$0h t8 ho g)y&#.)
8f'l-
/.
/
1 p
l d
Document Control-Dask
-(NLS-91-017)t/ Page.2 l
l and_(4)-a conclusion that includes a-basis for the continued l
operation of BSEP-Unit 1 until theLnext refueling--outage currently scheduled for September 1992.- ' Enclosure 2.contains the analysis reports from Structural. Integrity-Associates,. Inc.
regarding modification of-the RHR valves 1E11-F060A and F060B; Enclosures 3 and-~4' provide'the SMC O'Donnell &. Associates, Inc.
(ODAI) report on the Mechanical Stress ~ Improvement Frocess-application on_the'RCRS and Core Spray _ piping and safe-ends (proprietary) and the ODAI affidavit-transmitting that-report,-
respectively.
Pleaso. refer any questions regarding-this submittal to Mr. M. R.
Oates at (919) 546-6063.
- Yours very :truly G.
E. Vaughn-DBB/jbw (958BNP)
Enclosures
ENCLOSURE 1 BRUNSWICK STEAM ELECTRIC PLANT, UNIT _NO.
1 NRC DOCKET 50-325/ LICENSE No. DPR-71 IGSCC INSPECTION RESULTS - REFUELING OUTAGE 7 (1) NUREG 0313, Revision 2, INSPECTION SCOPE AND RESULTS ScoDe of Examinations CP&L's approved (Reference 3) NUREG 0313 IGSCC Inspection Program was extensively revised because of the RCR9 and Core Spray piping / safe-end replacement, and the commitment (Reference 1) made by CP&L to inspect the eleven * (11) dissimilar metal, and four (4) similar metal.(Inconel) welds in BSEP Unit 1 that had' not previously been inspected using transducers that produce a refracted longitudinal (RL) sound wave.
Table 1 illustrates the revisions to the NUREG 0313 Inspection Program.-
- Two (2) of the eleven dissimilar metal welds (1E21FF FWRNA18 and 1E21FF-8-FWRNB18) were replaced as part of the core Spray piping / safe-end replacement.
TABLE 1 - BSEP 1 IGSCC Inspection Categories STATUS A
B C'
D E
G TOTAL Prior to Refueling 122 0
58 31 46 13 270 Outage 7 hefueling Outage 7 40 10 8-11 5
13 87 Inspe tions
( 7)
(17)
(16)
(24)
Current Population 150 10 42 25 11 1
239 The inspections indicated in parenthesis (XX) above are the number of welds in each category that were originally scheduled to be inspected in accordance with the NUREG 0313 Inspection Program.
The variations in actual inspections performed versus scheduled inspections were caused by the elimination or replacement of welds by the RCRS and Core Spray piping and safe-end replacement.
Table 2 (attached) provides a complete listing of the BSEP Unit 1, NUREG 0313, Revision 2, IGSCC Inspection Classifications, including weld numbers, IGSCC Category, joint configuration, system and inspection schedule.
i Enclosuro 1 - Page 2 of 6 W
]
UT Process-The UT examinations of the eighty-seven (87)_ welds identified in Table 1 were performed by General Electric (GE) UT personnel who are qualified in accordance with the EPRI/BWROG/NRC requirements, including the latest requalification program.
The examination of these welds incorporated the use of two fully automated GE UT systems.
One system was the GE " SMART UT" System, which uses the
" Ultra Image III" computer driven data acquisition system with the ALARA remote scanning device.
The second system used was GE's recently qualified " SMART 2000" System which also uses the ALARA remote scanning device.
The " SMART 2000" System is a l
multi-channel system which digitizes the entire A-scan, and is
[
able to perform examinations in approximately half the time required by the " SMART" System.
The data retained by the " SMART f
2000" is also far superior to the existing automated systems.-
Manual examinations were performed where automated equipment could not be used, and as required to supplement the automated system examinations.
UT Results As indicated in Table 1, eighty-seven (87) wolds were inspected per CP&L's approved (Reference 3) NUREG 0313, Revision 2, ICSCC Inspection Program.
During the examination of the welds in the scope of inspections, an indication was identified in IGSCC Category
'G' Feedwater System (FWS) weld no. 1B21N4D-5-SW1-2.
This indication, the resulting evaluation of the indication, and the inspection results of the remaining eight (8) FWS welds were discussed in detail in the Reference 2 submittal, dated January 7, 1991.
Of the remaining seventy-eight (78) inspections completed during BSEP Unit 1, Refueling Outage 7, indications were identified in two (2) of the remaining four (4) Category
'G' welds.
These indications are discussed in detail below (see RHR Valve Welds J
1B32RD2B2-84-FWB33 and 1B32RD2A2-87-FWA33).
As stated in the f
Reference 2 submittal, the thirteen (13) Category
'G' welds being inspected during Pufueling Outage 7 represented 100% of the
^
Category
'G' welds, thus no sample expansion was required.
No other flaws were identified in any of the remaining inspections, in any of the IGSCC inspection categories.
BHR Valve Wolds 1832RD2B2-84-FWB33 and 1B32RD2A2-87-FWA33 Welds 1B32RD2B2-84-FWB33 and 1B32RD2A2-87-FWA33 (ISI Ref Nos.
24A12 and 24B13 respectively) were-inspected as part of a commitment made by CP&L in Reference 1, and in response to the NRC Staff's Request for Additional Information (Reference 4) concerning the limited inspections occurring on welds which were part of the IGSCC Inspection Program.
In order to inspect these welds it was necessary to provide a surface suitable for ultrasonic examination.
Several alternative inspection techniques were considered.
2nclo2uroL1'- Pago 3 of 6 j
Howavor, it was impossible to improve.the inspectability with the l
application of alternate examination techniques only, and it-was l
determined that the method of choice was to machine the valveL body at the point nearest the weld joint in order to provide a
" flat land" large enough to accommodate a 100% inspection from i
ono side of the weld._ This machining.was accomplished in accordance with the design analysis performed by Structural Integrity Associates, Inc. (Enclosure 2).
An ultrasonic examination.was performed of these: welds with the
" SMART UT" System utilizing O' longitudinal wave, 45' shear wave, and 45' and 60' RL transducers.
During-the inspection of these welds, indications _which were not contained in the weld metal or i
heat affected zone, were identified.
These indications were determined not to be related to IGSCC (see-Enclosure 5 for complete GE UT Reports).
The valves were cast from A216'WCB i
carbon steel. material, and because of the orientation _and-location of-the indicatiots, were suspected of containing inclusions typical of a cast component.
A review of available data related to the manufacturing of~the two RHR valves-(1 Ell-:
F060A & 1E11-F060B) was performed.
The results of~that:
investigation.are as follows.
RHR Valve 1E11-F060A tWeld No. 1B32RD2B2-84-FWB33)
Five (5) indications were detected during the Ut examination
.of weld 1B32RD2B2-84-FWB33.
The parameters oflthese-indications are listed below.
UT Ind.
Distance from
_ Distance from-Number Zero Reference Lenath Weld Centerline 1
23.4" 0.40" 2.00" 2*
24.0" 10.80":
1.40" 3*-
25.0" 0.35" 2.'00" 4
46.4"
- 1.30"
-1.20" 5*
48.3" 0.45" 1.50" Flaws are imbedded in the base material and show no discernable connection to the ID surface by-UT examination Valve geometry prohibited complete measurements A complete review of the base metal '(as-cast) radiographs (RT) and original documentation packages generated during the valve' manufacturing process resulted in the identification of several inclusions which were acceptable by RT.
A comparison of these base metal inclusions to the UT indications identified five inclusions with. remarkably-similar parameters.
The parameters of the five base metal inclusions most closely related to the identified'UT-indications are listed below.
RT Ind.
Distance from Distance from Number Zero Reference Lenath Weld Centerline l
1 23.6" 0.25"
-1.75" 2
24.1" 0.50" 1.50" 3
25.1" 0.25" 1.75"-
4 46.8" 1.25" 1.70" 5
49.0" 0.25" 1.30" l
l
- Enclosurs 1
'Page 4 of 6-RHR Valve 1E11-F060B (Weld No. 1B32RD2A2-87-FWA33F Two (2) indications were detected during the UT examination-of weld 1B32RD2A2-87-FWA33.
The parameters of these-indications are listed below.
UT Ind.
Distance-from Distance from-Number Zero Reference Lenath Weld Centerline 1*
7.6"-
- 1.50" 1.30" 2
65.7"
- 1.50" 1.20" Flaw is~ imbedded in the base material and shows no-discernable-connection to the ID surface by'UT examination Valve geometry prohibited complete measurements A complete review of the-base metal _(as-cast) radiographs (RT) and original-documentation packages _ generated during the valve manufacturing process resulted in the identification of an inclusion which was icceptable. by: RT. in-
-)
the area of UT Indication 1.
The parameters ofLthis inclusion:are listed below.
^
Indication Distance from Distance from
'4 Number Zero-Reference Lenath
-Weld-Centerline-1 8.25" 1.75" 1.00" In regards to UT Indication 2, thel review of the radiographs and documentation revealed that in the area;fromi65.34" to 68.00" circumferentially, and from 1.00" to 6.50" from the ensuing weld centerline, there wereitwo_(21 rejectable RT indications and one (1)- rejectable MT indication which were subsequently. ground out and weld-repaired..
A flaw evaluation of the-deepest flaw was performed by Structural i
Integrity Associates, Inc._(see Enclosure.2), in accordance with ASME Code, Section.XI, 1986. Edition, and demonstratesnthat the valves can'be returned to service for at least one operating cycle.
Based upon our thorough review of-the original documentation and radiographs,.CP&L has' concluded that the five (5) UT indications that have.been' identified on 1E11-F060A valve, I
and IED Indication 1 identified in the 1E11-F060B valve, are existing base metal flaws,.and are not servicelinduced.
.In regards to UT Indication 2 in the-1E11-F060B valve, CP&L has concluded.that it is a base metal / weld metal acoustic interface signal produced by the extensive base' metal repairs in the same area during the manufacturing process, and is'also not service induced.
Based cn1 the acceptable flaw evaluation and the overwhelming evidence that these indications are not service induced, and-thus have no crack growth = mechanism, CP&L's position 1
is'that the valves can be-returned to service without adverse effect to the health and safety of the public for at least one 1
operating cycle.
CP&L has also determined that the flawed areas of both valves will be scheduled for reinspection during the next BSEP Unit 1 Refueling-Outage.
i I
Enclosura 1-- Pagn 5 of 6 (2)
REPLACEMENT OF REACTOR COOLANT RECIRCULATION ANDLCORE SPRAY I
-SYSTEM PIPING AND SAFE-ENDS The replacement of the RCRS and Core Spray System piping and safe-ends was performed by General Electric Company during this l
j refueling outage.
The modification of the RCRS consisted of thecreplacement of the existing 304 SS risers and Inconel 600 safe-ends with'316NG SS material.
In addition to the material-change, the new scfe-ends were designed to eliminate the, thermal sleeve attachment weld and the crevice condition inherent'to the old design which was-a~
l IGSCC initiation site.
The existing Inconel 182 nozzle-butter and cladding was removed and replaced with ER309L'SS weld material.
i The modification of the Core Spray System consisted of the replacement of the existing Inconel 600_ safe-ends with 316NG.SS material and the replacement of the existing carbon steel _
transition _ piece with a new forged carbon steel transition piece.
The existing Inconel 182 nozzle butter.and cladding was also removed and replaced with ER309L SS weld material.
The replacement materials were selected in accordance with the recommendations of NUREG 0313, Revision.
2.
In addition, the replacement SS materials were electropolished and received' preoxidation treatments.
The welding process used to complete the replacement controlled the heat input in the weld _below 1.8 megajoules, which reduces the residual welding stresses'and-enhances the materials resistance to IGSCC.
Further'IGSCC-mitigation was accomplished by the application of the Mechanical-Stress Improvement Process (MSIP) to all= replacement welds except the two (2) carbon steel transition piece to carbon. steel pipe welds on the Core Spray System.
_The MSIP was performed by SMC -
O'Donnell and Associates, Inc.
A pre and post-MSIP1 ultrasonic examination was performed on all welds which received MSIP with no rejectable indications being observed._ As a result =of the RCRS and Core Spray System piping and safe-end replacement, thirty-five (35) weld overlay repairs were removed from the NUREG 0313 Inspection Program.
(3)
UPDATED CLASSIFICATION OF IGSCC SUSCEPTIBLE WELDS An updated classification of the BSEP Unit 1 IGSCC susceptible welds is contained in Table 2.
The table has been revised to reflect the new welds which are part of the RCRS and Core Spray piping and safe-end replacement, as well as any other required updates.
The table has also been revised to reflect the actual weld numbers rather than ISI reference (abbreviated) weld numbers.- Table 3 provides a cross-reference for those weld numbers which have cnanged as a result of this revision.
Table 4 provides a list of welds that have been replaced or eliminated as a result of the RCRS and Core Spray System piping / safe-end replacement.
]
I Enclocuro 1 - pegs 6 of 6 (4)
CONCLUSION Caro 3ina Power & Light Company has completed the IGSCC inspections and the replacement of the RCRS discharge risors, safo-ends, and nozzle butter, and the Core Spray transition pieces, safo-onds and nozzle butter.
The Mechanical Stress Improve 5ent Process was successfully applied to thirty (30) RCRS welds, and four (4) Core Spray System wolds.
Pro and post-MSIP ultrasonio examinations were completed on those thirty-four (34) welds with no rejectable indications observed.
Ultrasonic examinations were performed on eighty-seven (87) welds in IGSCC categories
'h',
'B',
'C',
'D',
'E' and
'G' of NUREG 0313, Revision 2, employing the GE " SMART UT", " SMART 2000", and Manual UT techniques.
The scope of examinations were in accordance with Carolina Power & Light Company's approved NUREG 0313 Inspection Program.
Based on the results of the mitigative actions taken and the
" state-of-the-art" inspections performed, Carolina Power &= Light company believes that the start-up and continued operation of BSEP Unit 1 until the next refueling outage, currently scheduled for September 1992, is-justified and will not adversely affect the health and safety of the public, and Carolina Power & Light Company intends to proceed with the start-up of BSEP Unit i as currently scheduled on February 14, 1991.
1 1
1 l
1 1
e
3 TAB E a Page 1 of 10 BSEP UNIT 1 - IGSCC INSPEOTION CLABSIIISATIONS ICSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGOR1 CONFIG.
RFO 7 RFO 8 RFO 9 RF010 RPO11 1B32RECIRC-22AM3BCA A
SWEEPOLET RCRS 1832RECIRC-22AM3BCD A
SWEEPOLET RCRS 1B32RECIRC-22AM5BCA A
SWEEPOLET RCRS 1B32RECIRC-22AM5BCB A
SWEEPOLET RCRS
~
1832RECIRC-22BM1BCA A
SWEEPOLET RCRS 1832RECIRC-22BM1BCD A
SWEEPOLET RCRS X
1832RECIRC-22BM3BC A
SWEEPOLET RCRS X
1B32RECIRC-22BM4 A
SWEEPOLET RCRS 1832RECIRC-22BM4BC A
SWEEPOLET RCRS I
1B32RECIRC-4A2 A
PIPE /ELBO RCRS X
1 I
1B32RECIRC-4A3 A
RLBO/ PIPE RCRS IB32RECIRC-4A4 A
hkPE/ TEE RCRS 1832RECIRC-4A5 A
TEE /FLG RCRS 1B32RECIRC-4A6 A
TEE / VALVE RCRS 1832RECIRC-4A7 A
VALV/ PIPE RCRS 1B32RECIRC-4A8 A
PIPE /ELBO RCRS 1832RECIRC-4A9 A
ELBO/ PIP't RCRS 1B32RECIRC-4B2 A
PIPE /Ei'10 RCRS
=
1B32RECIRC-4B3 A
ELBO/ PIPE RCRS 1832RECIRC-4B4 A
PIPE / TEE RCRS X
1832RECIRC-4B5 A
TEE /FLG RCRS 1B32RECIRC-4B6 A
TEE / VALVE RCRS X
IB32RECIRC-4B7 A
VALV/ PIPE RCRS X
l 1832RECIRC-4B8 A
PIPE /ELBO RCRS l1B32RECIRC-4B9 A
ELBO/ PIPE RCRS M
I TABLE 1
-Page 2 of 10
__ BSEP QRIT 1 - IGSCC INSPECTION Cfkm81FICATIONS w_
IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CONFIG.
RFO 7 RFO 8 RFO 9 RF010 RF011 G31PC7-1-FWRWCU949A A
ELBO/ PIPE RWCU f
1G31PC7-1-SWRWCU950 A
PIPE /ELBO RWCU 1G31PCI-1-FWRWCUC2A A
PIPR'VALV RWCU IG31PC2-1-FWRWCUC3A A
VALV/ PIPE RWCU
~~~
1G31PC2-1-FWRWCU932 A
PIPE /ELBO RWCU 1G31PC3-1-SWRWCU933 A
ELBO/ PIPE RWCU 3.
1G31PC3-1-FWRWCU934 A
PIPE /ELBO RWCU X
1G31PC4-1-SWRWCU935 A
ELBO/ PIPE RWCU 1031PC4-1-FWRWCU936A A
PIPE /ELBO RWCU 1G31PC6-1-FWRWCU937A A
ELBO/ PIPE RWCU 1G31FF-1-FW1G311110 A
PIPE /ELBO RWCU 1G31FF-1-Fif1G311109 A
ELBO/ PIPE RWCU 1G31FF-1-FW1G311108A A
PIPE / PIPE RWCU 1G31FF-1-FW1G311105 A
PIPE / PIPE RWCU 1G31FF-1-FW1G3110928 A
PIPE /VALV RWCU 1031FF-1-FW1G311093 A
VALV/ PIPE RWCU X
IG31PCB-1-FW1G311094
-A PIPE /VALV RWCU i
. VALV/ PIPE RWCU I.PE/ELBO RWCU 1G31-999A A
i X
ELBO/ PIPE RWCU X
PIPE /ELBO RWCU I
SLBO/ PIPE RWCU l
PIPE /ELBO RWCU X
DESIGNATES PRESERVICE INSPECTION OF NEW-WELD
j i
TABLE 2 Page 3 of 10 j
__.RREP UNIT 1 - IOSCC INSPECTION CLASSIFICATIONS i
IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CONFIG.
RFO 7 RFO 8 RFO 9 RF010 RF011 1031-1009 A
PIPE /ELBO RWCU X
.A ELBO/ PIPE RWCU X
TEE / RED RWCU 1
l 1G31-1014 A
TEE / RED RWCU i
?
-A RED / PIPE RWCU 1G31-1016 A
VALV/ PIPE RWCU g
PIPE /ELBO RWCU:
3 l
ELBO/ PIPE ' RWCU X
PIPE /ELBO RWCU l
ELBO/ PIPE RWCU X
PIPE /ELBO RWCU I
PIPE /ELBO RWOU X
1G31-987 A
TEE /VALV' RWCU i
l 1G31-988 A
TEE / PIPE RdCU~
4 I
{
1G31-989 A
PIPE /ELBO RWCU X
PIPE /ELBO RWCU-
m.____
_ _ _. ~..... _
TABLE 2 Pege 4 of 10 BSEP UEIT 1 - IGSCO INSPECTION CL&5SIFICATIONS
+
IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CONFIG.
RFO 7 RFO 8 RFO 9 RF010 RF011 1G31-992 A
PIPE /ELBO RWCU
~
1G31-981 A
ELBO/ELBO RWCU j
1G31-984 A
PIPE /EXCH RWCU-1RWCU-90A A
EXCH/ELBO RWCU d
PIPE /ELBO RWCU X
PIPE /ELBO RWCU X
g 1G31-1034 A
PIPE /ELBO RWCU 1G31-1037 A-ELBO/ELBO RWCU.
X 1G31-1038 A
PIPE /ELBO RWCU X
i 1G31-1043 A
ELBO/ PIPE RWCU
=l
_..,. _.. ~.
.--.--m
TAELE 2 Paga 5 of 10 DSEP UNIT 1 - LQJ_qQ_1HRFIQTIQH _QJAD.SIElQhTIONS
_m m,,
IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CONFIG.
RFO 7 RTO 8 RTO 9 RTO10 RTO31 3
PIPE /ELBO RWCU X
ELBO/ PIPE RWCU iG31-1058 A
PIPE /ELBO RWCU X
PIPE /ELBO RWCU X
ELBO/ PIPE RWCU X
ELBO/ PIPE RWCU X
ELBO/ PIPE RWCU X
1G31-34C A
PIPE /VALV RWCU 1RWCU-675B A
EXCH/ELBO RWCU 1G31FF-14-FWRWCUB4B A
VALV/ PIPE RWCU X
v
1 TARLE_1 Page 6 of 10
__DBEP_3NLT 1 - 19800 INSPIQ"! ION CLABBIPICATIONS r-IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CONFIG.
RFO 7 RFO 8 RFO 9 RF010 RF011 m=
1G31FF-14-FWRWCUB3B A
PIPE /VALV RWCU X
X 1832FFA-12-FW701 A
PIPE /SE RCRS 1832FFB-12-FW702 A
PIPE /SE RCRS ID32FFC-12-FW703 A
PIPE /SE RCRS 1B32FFD-12-FW704 A
PIPE /SE RCRS 1832FFE-12-FW705 A
PIPE /SE RCRS l
IB32FFF-12-FW706 A
PIPE /SE RCRS X
1832FFG-12-FW707 A
PIPE /SE RCRS IB32FFH-12-FW708 A
PIPE /SE RCRS IB32FFJ-12-FW709 A
PIPE /SE RCRS 1832FFK-12-FW710 A
PIPE /SE RCRS l
1811N2A-RPV-FWABA A
SE/ NOZZLE R :9 (X) 1B11N2B-RPV-FWABA A
SE/140ZZLE RCRS (X) 1B11N2C-RPV-FWABA A
SE/NOZZ LE RCRS (X) 1811N2D-RPV-FWABA A
SE/ NOZZLE RCRS (X) 1811N2E-RPV-FWABA A
SE/ NOZZLE RCRS (X) 1811N2F-RPV-FWABA A
SE/ NOZZLE RCRS (X) 1811N2G-RPV-FWABA A
SE/NOZZ LE RCRS (X)
Ib11N2H-RPV-FWABA A
SE/ NOZZLE RCRS (X)
IB11N2J-RPV-FWABA A
SE/ NOZZLE RCRS (X) 1811N2K-RPV-FWABA A
SE/ NOZZLE RCRS (X)
IB11NSA-RPV-FWRNA-16A A
SE/ NOZZLE CS (X)
IB11N5B-RPV-FWRNO-16A A
SE/ NOZZLE CS (X) 1E21FF-4-FW1E2180 A
TRANS/SE CS (X) 1E21FF-8-FW1E2183 A
TRANS/SE CS (X)
DESIGNATES PRESERVICE INSPECTION OF NEW WELD (X) DESIGNATES SECTION XI INSPECTION OF WELD THAT WILL ALSO MEET THE REQUIREMENTS OF NUREG 0313, REV 2.
TABLF, 2 Page 7 of 10 RSEP UNIT 1 - 10B00 INEEECTION CLASSIFICATIONS wa-IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMEER SYS CATEGORY CONFIG.
RFO 7 RFO 8 RFO 9 RPO10 RF011 1B32FFA-12-rWRRB10A B
SWPL/ PIPE RCRS l1B32FFB-12-PWRRB11A B
SWPL/ PIPE RCRS L
1832FFC-12-rWRRB12A B
SWPL/ PIPE RCRS (X)
IB32FFD-12-FWRRB13A B
SWPL/ PIPE RCRS (X)
IB32FFE-12-TWRRB14A B
SWPL/ PIPE RCRS IB32FFF-12-TWRRA10A B
SWPL/ PIPE RCRS H
1B32FFG-12-FWRRA11A B
SWPL/ PIPE RCRS IB32FFH-12-FWRRA12A B
SWPL/ PIPE RCRS IB32FrJ-12-rWRRA13A B
SWPL/ PIPE RCRS (X) 1B32FFR-12-FWRRA14A B
SWPL/ PIPE RCRS I B 3 2 RECIRC-28 A2 (IHSI)
C PIPE /SE RCRS X
t 1872RECIRC-28A3(IHSI)
C PIPE /ELBO RCRS X
1832kECIRC-28A5(IHSI)
C PIPE / TEE RCRS X
1832RECIRC-28A6(IHSI)
C TEE / PIPE RCRS X
1832RECIRC-26A9(IHSI)
C VALV/ PIPE RCRS X
1832RECIRC-28A10(IHSI)
C PIPE /ELBO RCRS X
IB32RECIRC-28A11(IHSI)
C ELB0/ PUMP RCRS X
IB32RECIRC-28A12(IHSI)
C.
PUMP / PIPE RCRS X
1B32RECIRC-28A13(IHSI)
C PIPE /VALV RCRS X
IB32RECIRC-28A16(IH31)
C PIPE / TEE RCRS X
1832RECIRC-28A17(IHSI)
C TEE / CROSS RCRS X
1B32RECIRC-28A18(IHSI)
C CROSS / RED RCRS X
1832RD2B2-84-FWB33(IHSI)
C TEE /VALV RCRS X
DESIGNATES PRESERVICE INSPECTION OF NEW WELD (X) DESIGNATES SECTION XI INSPECTION OF WBLD THAT WILL ALSO MEET THE REQUIREMENTS OF NUREG 0313, REV 2.
TABLE.2 Page 8 of 10
,__R31P UNIT 1 - IGJ.Q.Q INSPJQTION C.L&#SIFICATION8 IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CONFIG.
RFO 7 RFO 8 RFO 9 RF010 RF011 I B32 RECIRC-28 B2 (IllSI)
C PIPE /SE RCRS 1B32RECIRC-28B3(IHSI)
C PIPE /ELBO RCRS 183 2 RECIRC-28B5 (IllSI)
C PIPE / PIPE RCRS X
X 1832RECIRC-28B9(IHSI)
C VALV/ PIPE RCRS 183 2RECIRC-28B10 (IllSI)
C PIPE /ELBO RCRS X
1B3 2RECIRC-28 B11 (IllSI)
C ELBO/ PUMP RCRS X
l 183 2RECIRC-28B12 (IllSI)
C PUMP / PIPE RCRS X
IB3 2 RECIRC-28 B13 (IllSI)
C PIPE /VALV RCRS X
183 2RECIRC-28 B14 (IHSI)
C VALV/ELBO RCRS X
I B32 RECIRC-28 B15 (IllSI)
C ELBO/ PIPE RCRS X
183 2RECIRC-28 B16 (IllSI)
C PIPE / TEE RCRS.
X 1832RECIRC-28 B17 (IllSI)
C TEE / CROSS RCRS X
1832RECIRC-28B18(IHSI)
C CROSS / RED RCRS X
183 2 RD2 A2-87-FWA3 2 (IllSI)
C TEE /VALV RCRS X
X l
1832RECIRC 22AM1(IllSI)
C VALV/ PIPE RCRS X
1832RECIRC-22AM2(IHSI)
C PIPE /VALV RCRS X
II332 RECIRC-22 AM4 (IllSI)
C PIPE /CRSS RCRS 1B32RECIRC-22AM5(IHSI)
C CRSS/ PIPE RCRS X
1832RECIRC-22AM6(IHSI)
C PIPE / CAP RCRS X
1832RECIRC-22BM1(IHSI)
C-CAP / PIPE RCRS-1B32RECIRC-22BM2(IHSI)
C PIPE /CRSS RCRS X
1832RECIRC-22BM3(IHSI)
C CRSS/ PIPE RCRS X
c 1832RECIRC-22BM5(IHSI)
C PIPE /VALV RCRS X
1832RS2B2-10-FWB39(IHSI)
C TEE / PIPE RCRS X
1E1110-1-10-FWRHRC1(IllSI)
C-PIPE /VALV RHR X
- a
TABLE _1 Page 9 of 10
__ JEEP UNIT 1 - IQBCC INSPECTIQ1L_CMESif1 CAT 10118 r
IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CONFIG.
RFO 7 RFO 8 RFO 9 RF010 RF011 183 2 RECIRC-2 8 A1 (MSIP)
C NOZZ LE/SE RCRS X
X 1B32RECIRC-20B1(MSIP)
C NOZZLE /SE RCRS X
1B11NBA-RPV-SWAB (MSIP)
C NOZZLE /SE JPI X
1811N8 B-RPV-SWAB (MSIP)
C NOZ 2 LE/SE JP1 X
X 1B32RECIRC-28A7(IHSI)
D PIPE /ELBO RCRS X
X X
1B32RECIRC-28B6(IHSI)
D PIPE / TEE RCRS X
X X
1B32RECIRC-28B7(IHSI)
D PIPE /ELBO RCRS X
X X
IB32RECIRC-28A9BC1 D
WOL/ PIPE RCRS X
X X
1B32RECIRC-28A12BC D
WOL/ PIPE RCRS X
X X
1812RECIRC-28A15BC1 D
WOL/ PIPE RCRS X
X IB32RECIRC-28B9BC D
WOL/ PIPE RCRS X
X X
1832RECIRC-28B12BC D
WOL/ PIPE RCRS X
X X
IB32RECIRC-28B15BC D
WOL/ PIPE RCRS X
X X
PIPE /WOL RHR X
X X
1G31PCI-1-FWRWCUC1A D
WOL/ PIPE RWCU X
X X
1G3115-1-15-FWRWCUB2A D
VALV/ PIPE RWCU X
X 12B11N8A-JPI-FWRI22-1 D
SE/PNSEAL JPI X
X 12B11N8B-JPI-FWRI22-2 D
SE/PNSEAL JPI X
X X
1821N4A-2-FWN4A45-3 D
EXT /SE FW X
X X
1821N4A-2-SW1-2 D
SE/SE. EXT FW X
X 1B21N4A-2-SW2-3 D
TRANS/ EXT FW X
X 1821N4B-3-FWN4B135-3 D
EXT /SE FW X
X X
1821N4B-3-SW1-2 D
SE/SE. EXT FW X
X X
j l
TABLE _2.
Pago.10 of 10
_,_1) SIP __EHIT 1 - I0000 IRSPECTION CLMSIFICATIOi (,.,
__,.m IGSCC JOINT SCHEDULED INSPECTIONS WELD NUMBER SYS CATEGORY CO!1 FIG.
RFO 7 RFO 8 RFO 9 RTO10 RF011 IB21tJ48-3-SW2-3 D
TRANS/ EXT FW X
X X
IB21N4C-6-FWN4C225-3 D
EXT /SE FW X
X X
IB21N4C-6-SW1-2 D
SE/SE. EXT FW X
X X
IB21N4C-6-SW2-3 D
TRANS/ EXT FW X
X X
1821114 D-5-FWN4 D315-3 D
EXT /SE FW X
X X
IB21N4D-5-SW2-3 D
TRANS/ EXT FW X
X 1832RECIRC-28A4(O' LAY)
E ELBO/ PIPE RCRS X
X X
ID32RECIRC-28A14(O' LAY)
E VALV/ELBO RCRS X
X 1832RECIRC-28AIS(O' LAY)
E ELBO/ PIPE RCRS X
X X
ID32RECIRC-28B4(O' LAY)
E ELBO/ PIPE RCRS X
X X
183 2 RECIRC-28 B8 (O 'IAY)
E ELBO/VALV RCRS X
X 1B32RECIRC-22AM3(O' LAY)
E VALV/ PIPE RCRS X
X 1832RECIRC-4A1(O' LAY)
E WOL/ PIPE RCRS X
X F
183 2 RECIRC-4 A10 (O ' LAY)
E PIPE /WOL RCRS X
X I D3 2 RECIRC-4 81 (O 'IAY)
E WOL/ PIPE RCRS X
X X
IB32RECIRC-4B10(O' LAY)
E PIPE /WOL RCRS X
X 1B32RECIRC-28A8(IHSI)
E ELBO/VALV RCRS X
X
~
1821N4D-5-SW1-2 G
SE/SE. EXT FW X
X X
X X
pago 1 of 2 Th1LR_1 10000 SUSCEPTLD14 WELD NUMBER CROBD REFEEERGE "OLD" IST "NEW" WELD "OLD" ISI "NEW" WELD REF. NO.
NUMBEB REF. NO.
NUMBER 22AM3BCA 1B32RECIRC-22AM3BCA 28A9 1B32RECIRC-28A9 22AM3BCB ID32RECIRC-22AM3BCB 28A10 1B32RECIRC-28A10 22AM5BCA 1B32RECIRC-22AM5BCA 28A11 1B32RECIRC-28A11 22AM5BCD 1B32RECIRC-22AM5BCD 28A12 1B3 2 RECIRC-2 8 A.12 22BM1BCA 1B32RECIRC-22BM1BCA 28A13 1B32RECIRC-28A13 22BM1BCD 1B32RECIRC-22BM1BCD 28A16 1B32RECIRC-28A16 22BM3BC 1832RECIRC-22BM3BC 28A17 1B32RECIRC-28A17 22BM4 1B32RECIRC-22BM4 28A18 1832RECIRC-28A18 22BM4BC 2B32RECIRC-22BM4BC 24A12 1832RD2B2-04-FWB33 4A2 1832RECIRC-4A2 28B2 1B32RECIRC-28B2 4A3 IB32RECIRC-4A3 28B3 1D32RECIRC-28B3 4A4 1832RECIRC-4A4 28B5 1832RECIRC-28B5 4A5 1B32RECIRC-4A5 28B9 1B32RECIRC-20B9 4A6 1B32RECIRC-4A6 28B10 1B32RECIRC-28B10 4A7 1B32RECIRC-4A7 28B11 1B32RECIRC-2B811 4A8 1B32RECIRC-4A8 28B12 1B32RECIRC-28B12 4A9 1B32RECIRC-4A9 28813 1B32RECIRC-28B13 4B2 1B32RECIRC-4B2 28814 1B32RECIRO-28B14 4B3 1R32RECIRC-4B3 28B15 1B32RECIRC-28B15 4B4 lu32RECIRC-4B4 28B16 1B32RECIRC-28B16 4B5 1B32RECIRC-4B5 28B17 1B32RECIRC-28B17 4B6 1B32RECIRC-4B6 28B18 1B32RECIRC-28B18 4B7 1B32RECIRC-4B7 24B13 1B32RD2A2-87-FWA33 4B8 1B32RECIRC-4B8 22AM1 1B32RECIRC-22AM1 4B9 1B32RECIRC-4B9 22AM2 1B32RECIRC-22AM2 1RWCU-949A 1G31PC7-1-FWRWCU949A 22AM4 1832RECIRC-22AM4 1RWCU-950 1G31PC7-1-SWRWCU950 22AMb 1B32RECIRC-22AMS 1RWCU-C2A 1G31PCI-1-FWRWCUC2A 27AM6 1832RECIRC-22AM6 1RWCU-C3A 1G31PC2-1-FWRWCUC3A 22BM1 1B32RECIRC-22BM1 1RWCU-932 1G31PC2-1-FWRWCU932 22BM2 1B32RECIRC-22BM2 1RWCU-933 1G31PC3-1-SWRWCU933 22BM3 1B32RECIRC-22BM3 1RWCU-934 1G31PC3-1-FWRWCU934 22BM5 1832RECIRC-22BM5 1RWCU-935 1G31PC4-1-SWRWCU935 20A1 1832RS2B2-10-FWB39 1RWCU-936A 1G31PC4-1-FWRWCU936A 20A2 1E1110-1-10-FWRHRC1 1RWCU-937A 1G31PC6-1-FWRWCU937A 28A1 1B32RECIRC-28A1 1RWCU-1110 1G31FF-1-FW1G311110 28B1 1B32RECIRC-2831 1RWCU-1109 1G31FF-1-FW1G311109 4NBA 1B11NBA-RPV-SWAB 1RWCU-1108A 1G31FF-1-FW1G311108A 4N8B 1B11N8B-RPV-SWAB 1RWCU-1092B 1G31FF-1-FW1G311092B 28A7 1B32RECIRC-28A7 1RWCU-1093 1G31FF-1-FW1G311093 28B6 1B32RECIRC-28B6 1RWCU-1094 1G31PC8-1-PW1G311094 28B7 1832RECIRC-28B7 1RWCU-1095A 1G31-1095A 28A9BC1 1B32RECIRC-28A9BC1 1RWCU-B4B 1G31FF-14-FWRWCUB4B 28A12BC 1B32RECIRC-28A12BC 1RWCU-B3B 1G31FF-14-FWRWCUB3B 28A15BC1 1B32RECIRC-28A15BC1 28A2 1B32RECIRC-28A2 28B9BC 1832RECIRC-28B9BC 28A3 1832RECIRC-28A3 28B12BC 1B32RECIRC-28B12BC 28A5 1B32RECIRC-28A5 28B15BC 1832RECIRC-28B15BC 28A6 1B32RECIRC-28A6 20A1BC 1E1110-1-10-SWA
A l
t 1
pags 2 of 2 TABM.1 i
IG8CC 8USCEPTIBLE _ WELD.MUMBER_ CROSS...REFERFNCE HOLD" ISI "NEW" WELD "OLD" ISI "NEW" WELD REF. NO.
N. UMBER REF. NO._
H.Q}iBER 1RWCU-C1A 1G31PC1-1-FWRWCUC1A 28B4 1B32RECIRC-28B4 l
1G31-B2A 1G3115-1-1!,-FWRWCUB2A 28B8 1B32RECIRC-20B8 i
JPI-22-1 12 B11N8 B-J PI-TWRI22-1 22AM3 1B32RECIRC-22AM3 JPI-22-2 12B11N8B-JPI-FWRI22-2 4A1 1B32RECIRC-4A1 28A4 1B32RECIRC-28A4-4A10 1032RECIRC-4A10 28A14 1B32RECIRC-28A14 4B1 1B32RECIRC-4B1 j
28A15 1D32RECIRC-28A15 4B10 IB32RECIRC-4B10 28A8 1B32RECIRC-28A8 l
i I.
l 3
4 a_
d i
i
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i I
i 4
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l i.
p
- f -
1 f
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,,,_,..,,-,..-.a,.-
,~......-,,--~.-i.
,~..-,-~.m....
page 1 of 1 TABLE 4 1G800 SQBCEPTIBLE WELD 8. REPLACED / ELIMINATED BY ECRS AND CORE SPRAY. PIPING /8 AFB END REPLACEMENT 12ARAl*
12ARE1*
12BRJ1*
[
12 ARA 2 12ARE2=
12BRJ2 12 ARA 3 12ARE3 12BRJ3' 12 ARA 4 12ARE4 12SRJ4:
12 ARA 5*
12ARE5* -
12BRJ5*
12 ARA 6*
.12AREG*
12BRJ6*
12ARBl*.
12BRFl*
!12BRK1*
12ARB2 12BRF2 12BRK2 12ARB3 12BRF3
.12BRK3 12ARB4 12BRF4-12BRK4 12ARB5*
12BRF5*
-12BRKS*
12ARB6*
12BRF6*'
12BRK6*
12ARCl*
12BRGl*
1811NSA-RPV-FWRNA16*
i i
12 ARC 2 12BRG2 1E21FF-4-FWRNA18*
~
12 ARC 3 12BRG3
-1E21FF-4-FW1CS15*-
12 ARC 4 12BRG4-1B11N5B-RPV-FWRNB16*
12 ARC 5*
12BRGS*-
-1E21FF-8-FWRNB18*
d 12 ARC 6*
12BRG6*
1E21FF-8-FW1CS31*
12ARDi*
12BRH1*-
12ARD2 12BRH2 12ARD3 12BRH3 12ARD4
' 12 BRH4 -
12ARD5*'
'12BRH5*-
12ARD6*.
,12 BRH 6 *.-
WELDS-REPLACED AS PART.OF.THE-RCRS/ CORE' SPRAY REPLACEMENT >
(REMAINING WELDS - WERE: ELIMINATED) -
i l
L i
1.
s
,w-wem,-*w**
y-
-e-er w - -w a o,ev._
ENCLOSURE E
,j,
BRUNSWICK STEAM ELECTRIC PIANT, UNIT No.1
~ S/f74/ /
L NRC DOCKET 50-325 / LICENSE No. DPR-71 yh(
IGSCC INSPECTION RESULTS - REFUELING OUTAGE 7 p4p DM4 Yt ANALYSIS REPORTS - STRUCTURAL INTEGRITY ASSOCIATES, INC.
fa SIR-90-003 -
" Redesign of Area Between the RHR System Return g( c((L Valves and Reactor Recirculation System Tees,"
j/
dated January 12, 1990 f/2 f/9 /
RAM-91-004 -
" Redesign of Area Between the RHR System Return
{*-
Valves and Reactor Rocirculation System Tees -
As-Built Reconciliation for Unit 1," dated
.f #f
January 14, 1991 I
" Evaluation of Flaw Indications in RHR Valves SIR-91-003 F060A and F060B - Brunswick Steam Electric Plant, Unit 1," dated January 21, 1991 i
1 y+.-
+
STRUC115ULL A rra cy/4 co 7' 2 INTEGRITY ASSOCIATES,INC.
m ml 31E0 Almeden Erpressway l' ossa Plant Operetiou l SWte :26 January 12, 1990 06 South Mt11er Road San Jose. CA 95118 pygg.9 o.o 04 SWie10 (406) 978 8200 SIR-90-003, Rev. O D *S N '4313 Trirx insit m3 (216) 8%BBBB tu aw rtMM rumm wata,!
Mr. Terry Pitchford Carolina Power & Light Company Brunswick Steam Electric Plant Leonard Street Extansion Southport, 11C 28461
Subject:
Redesign of Area Between the RHR System Return Valves and Reactor Recirculation System Tees
References:
1.
" Design Report-- Recirculation Piping -
Loop A and B - B31.1 Power Piping Code",
General Electric Company, Revision 0, October 1, 1985.
2.
Carolina Power & Light Company Drawing No.
0-FP-06014, Revision A, January 18, 1989.
- 4. ASA B16.10-1957, " Face-to-Face and End-to-End Dimensions of Ferrous Valves", American Standard.
- 5. ASME Boiler.and Pressure Vessel Code,Section III, 1986 Edition.
- 6. ANSI B16.34-1981, " Valves - Flanged and l
Buttwelding End", American National Standard.
5
Dear Terry:
Carolina Power Light Company (CP&L) is undertaking more extensive in-service inspection of the reactor. recirculation (RR) and residual heat removal (RHR) systems at the' Brunswick Steam Electric Plant, Unit 2, in order to comply with the requirements of U.S.
NRC NUREG-0313, Revision 2.
In order to ultrasonically (UT) examine the weld between the reactor recirculation system tees and the residual heat removal system return valves, the valve bodies must be reduced in thickness at the weld location in order to provide at least a
2-1/2 inch
" flat" land for manipulating the transducer.
Structural Integrity Associates (SI) was contracted by CP&L to provide the technical justification for reducing the valve body thickness at this location.
The General Electric Company (GE) performed a reanalysis of the RR system in 1985, and documented their results in the Reference l
1 Design Report.
Although the purpose of the GE Design Report l
Page 2 January 12, 1990 T.
Pitchiord RAM-90-004 was to qualify the RR system, it also provided stress information at the location currently being evaluated.
Per Figure 14 (1),
nodes 769 and 509 (Loops A and B) are of interest herein.
Pages i
234 and 283 (1) report the maximum stress ratio (i.e.,
computed i
stress / allowable stress) for all reported load combinations of 0.511, with a mode:.ed thickness of 1.388 inches.
Therefore, if a wall thickness of 1,388 inches is maintained, modification of the GE Design Report is not required.
Drawing number 0-FP-06014 (2) provides a general arrangement of the valves to be examined.
Per note number 1, they were designed to B16.5 (3).
Since the Reference 2 drawing was initially l
issued in
- 1971, the 1968 version of the standard is the
Code-o f-r ec o rd ".
Reference 3 further references B16.10-1957 (4) for face-to-face and end-to-end dimensions.
These two documents, therefore, form the basis for the original design of the valves.
Per Reference 3, Table 27, the minimum thickness required is 2.28 inches for the 24 inch 900 pound gate valves.
This is confirmed per the Reference 2 drawing, that states "2-1/2 min. vall (2.280 min. wall USAS B16.5)".
Per Reference 4, Table 5,
the standard end-to-end dimension is 61
- inches, or 30.5 inches from the centerline of the valve to the edge of the weld preparation.
The geometry of the veld preparation is governed by Figure 10 of Reference 3 (included here as attached Figure 1).
Reviewing the drawing for the subject valves, however, indicates that the actual end-to-end dimension is 59 inches.
It is not clear from this review what the original basis was for this exception to the design Code.
However, at this time, the current standards governing valve design can be applied to determine a less restrictive length requirement.
The 1986 version of Section III of the ASME Boiler and Pressure Vessel Code was chosen (5).
The design for the valve body is as follows:
Per NB-3512.1, hStandard Design Rules" are contained in l
NB-3530 through NB-3550.
l NB-3542 references B16.34 (6) for minimum body thickness.
This standard requires a minimum thickness of 2.28 inches.
NB-3544.8 provides weld transition and contour requirements similar, to those required in Reference 3,
but does not
(
provide specific requirements on end-to-end dimensions.
NB-3545 provides limits on primary and secondary stress to ensure that basic ASME Section III safety margins are maintained.
STRUCTURAL INTEGRITY ASSOCIATESINC
Page 3 January 12, 1990 T. Pitchfora RAM-90-004 Primary membrane stresses are limited by the.. body-neck crotch
- region, which is stated to be the most highly stressed portion of the valve body under internal pressure.
The only effect of thickness reduction at the weld joint on this stress limit is whether the " area" in the pressure area method used to calculate crotch general primary membrane stress has been reduced.
Per NS-3545.1(a)(3) and Figuro NB-3545.1(a)-1 (included here as Figure 2),
L
= 0.5d - Tb = 9.16" g
where:
L
= the reinforcement limit along the g
valve body from the outside surface of the neck d
% 24" T
% 2.84" (average) 3 Per the attached as-built sketch (Figure 3), the length of full thickness valve wall available for "L " epals 2-9/16" g
+9"+0.5",
or 12-1/16".
Therefore, 2-1/2" can be removed in order to provide a flat land for UT inspection, witbout violating the above L requirement.
3
' concerns regarding secondary stresses. are again focused in the crotch region.
There is-no apparent effect of valve end-to-end length or thickness of the ve2 d E r.J..
in these l
calculations.
Therefore, the modification described herein will have no effect on secondary stresses or the associated fatigue evaluation.
It is, therefore, acceptable to machine the valve body per the attached Figure 4,
provided that a minimum length of 9.5 inches is maintained from the outside diameter of the neck to the top of the transition contour.
STRUCTURAL m
ASSOCUGTSINC
Page 4 January 12, 1990 T. Pitchford RAM-90-004 If you have any questions on the information contained in this
' letter report, please do not hesitate to contact us.
Very truly yours, R. A. Mattson R
.t e
.d
/
Y F.
C.
Riccardsli'aV' Approved by:
D#/
A. Jf'Giannutti
/'
i Proy2ct Manager f
/mc cci CPL-09Q Project File
/
+
b
-% g g INTEGRITY
/ ASSOCIATESINC i
J
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l M Ek TE' DNG DDS
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s INO*,VOlV1. IN$10[ ;DNT;gA E 02 V$[ Wi*H 4
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PlG. ll INSIO! *0NTOVE 809 VS! Wl*H REOTANGV' AA S ACA!NO RINO FIG.12 tNsi;E 00NT0VR 80R VSE Wl?M TAPER BAOKING RING A e Nemanal outsiee eWmetet of weldant erut.
_]
B e Nemmat sne sse enametet of pipe.
C
- A
- 0.03l
- 1. tit. 0.010
.)
1
- Nemma4 went inseeness of pipe.
i 3
0.031 = Minus toleranee en 00 of pipe to ASTM Soestficatten A 104. etc.
1.*$ = Mmsmw. m all of It tm. of nominal well (permittes by ASTM $seelf 6est6en A t0 4, eted mwme.ee by t, to s eavert itste terme of elemet et.
6.010 = Ptwa toneeenee en siemetee C (See Pet. ?.4.3)
Note 1 Runeut of a meanined suriaee to tnsise diametet of valve Mete 4 See Pae. 4.4 ens t.4 fee setails the totetanees.
to have no sorwet thante an eestaen taoise 616melet of i
valve mor se oather tartet er smallet tnen pipe snesee diamenet.
Note $ % W sem b6eed on vte of Ye in. wies betung nat.
Note 3 The outenee and ansies el enet of volves shall be es.
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INTEGRITY ASSOCIATES,INC.
3150 Almoden Erpressway rosed Mom Operchone stuie226 00 8 """ "* d January 14,1991 02 RAM 91004
- Akron, 44313 iAx me)m en (216) 064 8000 FAX W6) 809-M01 Mr. Roy R. Johnson, Project Manager Carolina Power & Light Company Brunswick Steam Electric Plant leonard Street Extension Southport, NC 28461
Subject:
Redesign of Area Between the RHR System Return Valves and Reactor Recirculation System Tees As Built Reconciliation for Unit 1
Reference:
StructuralIntegrity Associates Report SIR 90 003, Revision 0, dated January 12,1990
Dear Roy:
The referenced report provided Carolina _ Power & Light Company (CP&L) with the technical justification for reducing the valve body thickness at the subject location. The modifications described in the report have been implemented, and CP&L has forwarded Unit 1 as built data for both the Loop "A" and Loop "B" locations (Attachments 1 and 2, respectively). All of the geometric requirements contained in the referenced report were satisfied for Loop "A", and most were satisfied for Loop "B", For Loop "B", the actual "B" and "C" dimensions did not meet the requirements of Figure 4 of the referenced report. In addition, a localized thin spot on the valve body was required in order to remove PT indications (see Attachment 2).
The requirement for the "C" dimension to be set to 21/2" was in order to allow UT examination of the tee to valve weld. Since CP&L approved the difference, we assume that the dimension is acceptable (see the first paragraph of the referenced report).
Based upon a review of Figure 1 of the referenced report, which forms the basis for the specified "B" dimension, it is felt that use of a "B" dimension of 11/4"in lieu of the 11/2" requirement is acceptable.
Per Attachment 2, a cavity has been removed from the valve body in order to remove PT indications. The distance from the end of the machined area to the outside surface of the neck is 8.0" (9.75" - 1.75"), versue the 91/2" minimum dimension shown in Figure 4 of the referenced report. However, the actual distance from the edge of the grind out area to the outsidt of the neck is 10.50" per Attachment 2. Therefore, this requirement is satisfied.
i MM*22%IDlD*ET2%!2212501hu % f?1MMT5I%LTAa.wi*n*.*.%% MUTE 2CEm"Ta4WEnELt.a4.E. Elf 2.UUIES.M E2 M a T R TE E
i-Page 2 January 14,1991 Mr. R. Johnson
_ - RAM 91004 Based upon thti above review,'the as bullt configuratioriisin compliance with the referenced -
~
report.
t If you have any questions on this letter, or the attachments thereto, please do not hesitate to contact us, it is suggested that this letter be filed with CP&L's records pertaining to the Unit 1 RHR and reactor recirculation systems.
Very truly yours, l
[
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R. A. Mattson t
Re
1 Approved by:
P. C Riccardella W A. JgGiffnnuzzi f'
Project Manager
/11 attachment cc:
' CPL-160102 -
CPI-160 401
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FLANT MOD 89-094 D A _. A S, 41 E \\
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p hTT6CH AWT 2, u m xmrry ASSOCIATES,INC.
3150 Almaden Expressway see 22s Tossil Plant ceperations sen Jo.e. CA 95118 January 21,1991 se south Maler nood 3,, in (4 ) s78 8200 JFC-91-006 ru n a m Akron,oh; 44333 SIR-91003 (216) 864 8886
)
r u : m e m usi Mr. Roy R. Johnson, Project Manager i
Carolina Power & Light Company Brunswick Steam Electric Plant Leonard Street Extension 1
Southport, NC 28461 l
Subject:
Evaluation of Flaw Indications in RHR Valves F060A and F060B -
Brunswick Steam Electric Plant, Unit 1
References:
1.
General Electric Company, Brunswick Steam Electric Plant Unit 1 ISI Report, Report Nos. R 111 and R-112.
s 2.
ASME Boiler and Pressure Vessel Code,Section XI,1989 Edition with 1990 Addendum,IWB 3600 and Appendices H and A.
l l
3.
" Evaluation of Flaws in Ferritic Piping", Novetech Corporation, EPRI
{
Report NP-6045, October,1988
Dear Roy:
Carolina cower & Light Company (CP&L) is undertaking more extensive inservice inspection of the reactor recirculation (RR) and residual heat removal (RHR) systems at the Brunswick Steam Eectric Plant (BSEP), Unit 1, in order to comply with the requirements ot' U.S. NRC NUREG 0313, Revision 2. During tne process of ultrasonically (UT) examining the welds between the reactor recirculation system tees and the residual heat removal system return valves, flaw indications were detected in the valve bodies away from the welds [1]. StructuralIntegrity Associates (SI) was contracted by CP&L to provide the technicaljustification for accepting the flaw indications as-is, Figure 1 shows the geometry in question, and was provided by CP&L The Reference 1 report describes the flaw indications detected during inservice inspection. This letter report and attached appendices documents the flaw analyses performed in order to justify plant startup and continued operation.
l'
_J
Page 2 January 21,1991 Mr. R. Johnson JFC-91-006/ SIR 91003 Structural Evaluation Based upon the geometry shown on Figure 1, an axisymmetric solid of-revolution finite element model was developed for evaluation of stresses caused by internal pressure-(1000 psig) and steady state temperature (532'F, with 70'F being stress-free). The Algor SUPERSAP Program was used for analysis. Appendix A contains the detailed calculations documenting the stress analysis performed. Since an arisymmetric analysis was performed, the reactor recirculation system piping was modeled as an equivalent sphere of radius equal to the pipe diameter. Material properties were chosen at 550 F. Since all reported flaws were oriented in the axial direction, only hoop stresses are of interest in the flaw evaluation.
All hoop stresses in the area of interest are provided on pages 9,10, and 11 of Appendix A for the 1000 psig pressure load, and on pages 14,15, and 16 for the steady state thermal analysis. Appendix B summarizes the stresses of interest which will be used in the flaw evaluation. These stresses were adjusted for the maximum operating pressure of 1250 psig, and to include ASME Code safety factors.
Fracture Mechanics Flaw Evaluation The preceding geometry and stress results for the BSEP, Unit 1 RHR valve were employed to perform fracture mechanics flaw evaluations. The worst cae (deepest) axial flaw l
indication,1.1 in. deep, with the length in the valve undetermined because of geometry, was l
evaluated in accordance with ASME Section XI [2].
In accordance with IWB-3650, Appendix H, for evaluating ferritic piping, safety factors of three on hoop pressure stress and one on hoop thermal stress were applied. Because of the distance of the flaw indications from the weld center line, weld residual stresses were assumed to be negligible.
Material properties were derived from CMTR's (certified material test reports) for the "B" valve, which contained the deepest indication, for both clastic plastic (EPFM) and linear elastic fracture mechanics (LEFM) analyses. Charpy toughness values of 21,32, and 31 ft lb l
were reported for tests at -20aF, indicating relatively good toughness for this A216-WCB casting material. Using Section XI, Appendix H methods for correlating Jac and K ci with Charpy upper shelf, and an assumed minimum upper shelf of 35 ft lb (based on the -20*F results), a Jc value of 350 in lb/in and a Kc value of 102.1 ksiVi n were justified. A 2
i i
corresponding J Resistance curve from Reference 3 was employed for the EPFM analysis, with a Ramberg-Osgood stress-strain curve derived from the CMTR results.
EPFM analyses show that an infinite length axial crack in the reduced section of the valve, using average stresses in that section, is acceptable for a depth in excess of the 1.1 in.
l maximum reported indication depth. LEFM was used as a cross check, with the stress distributions at the valve cross section corresponding to the deepest indication location, to l
show that an axial crack 1.1 in. deep would be acceptable over the length of the valve l
reduced section and taper. An infinitely long axial flaw 1.25 in. deep was found to be STRUCTWIAL DITEGMTY ASSOCIATESINC
) W pi ?
Page 3 January 21,1991 Mr. R. Johnson JFC-91-006/ SIR-91-003 acceptable for the adjacent thicker section of the valve which was not inspectable because of the configuration. Fatigue crack growth for the deepest portion of the indication, due to 117 startup/ shutdown cycles and corresponding pressure and thermal stress cycles over the life of the plant, was predicted by using the ASME Section XI fatigue crack growth law to I
be on the order of 0.01 inches. This amount of predicted growth is assumed negligible, and is consistent with the conclusion that these flaw indications are original fabrication discontinuities, and are not service induced.
In summary, ASME Section XI safety margins are met for the largest indication, which envelopes the other indications. The reported indications are considered acceptable as is.
Detailed flaw evaluation calculations are found in Appendix C to this letter report.
Summarv _.;d Conclusions Based upon the information provided herein, coupled with that provided by CP&L, it is concluded that the UT flaw indications found on RHR valves F060A and F060B are not service induced, and are acceptable as is for one more refueling cycle. It is recommended that these flaws be reinspected at the next refueling outage to confirm that there is not a crack growth mechanism.
Should you require further information, and have questions on the attached, please contact us, Very truly yours, J. F. Copeland R. A. Mattson Associate Associate
/1)
Attachment cc:
Dale Bates - CP&L STRUCTURML DITEGRETY ASSOCIATESINC
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APPENDIX A Stress Analysis of RHR Valve to Recirculation System Tee
- SIR-91003 STRUCTURAL DITEGRITY ASSOCIATESINC L
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