ML20082G704
| ML20082G704 | |
| Person / Time | |
|---|---|
| Site: | Calvert Cliffs  |
| Issue date: | 02/28/1993 |
| From: | ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY, ASEA BROWN BOVERI, INC. |
| To: | |
| Shared Package | |
| ML20082G697 | List: |
| References | |
| CE-NPSD-906, NUDOCS 9504130362 | |
| Download: ML20082G704 (22) | |
Text
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I CE-NPSD-906 t
CHEMICAL CONTENT OF WELD DEPOSITS FABRICATED USING r
HEATS A8746 AND 34B009 i
PREPARED FOR THE COMBUSTION ENGINEERING OWNERS GROUP FEBRUARY 1993 ABB COMBUSTION ENGINEERING NUCLEAR POWER COMBUSTION ENGINEERING, INC.
WINDSOR, CONNECTICUT 00**!O3$$o!O$$$17 P
Combustion Engineering, Inc.
TABLE OF CONTENTS Section No.
Title Pagg i
Introduction 1
II
Background
1 III Scope 3
IV Results 4
V Conclusions 9
VI References 10
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LIST OF TABLES Number Title Engs -
-1 Nickel Content for Colled Wire Electrode' Weld Deposits 11 2
Weld Seams and Consumables Using Adcom Heat #A8746 12 3
Copper Analysis Results for Weld Wire Heat #A8746 13 4
Weld Deposit Copper Content for Adcom Wire Heats 14 5
Weld Seams and Consumables Using Reid Avery Heat #34B009 15 6
Copper Content Analysis Results for Weld Wire Heat #34B009 16 7
Weld Deposit Nickel Content with Cold Nickel Feed 17 8
Nickel Content for Heat #34B009 with Cold Nickel Feed and Linde 1092 Flux 18 9
Best Estimate Copper and Nickel Content for Vessel Welds 19
Combustion Engineering, Inc.
I.
INTRODUCTION i
This report presents the results of a task undertaken for the Combustion Engineering
. Owners Group (CEOG) to provide the basis for the copper and nickel content of reactor pressure vessel welds made using two specific heats of weld wire. These heats are common to beltline welds in several reactor vessels fabricated by ABB/CE in Chattanooga, Tennessee. The as-deposited welds were not always analyzed explicitly for copper or nickel during fabrication because the significance of those chemical elements to irradiation embrittlement was not then recognized. Subsequent efforts to estimate the as-deposited weld chemistry from limited data sometimes have resulted in different values for the same weld consumables. The purpose of this evaluation is to utilize a broad set of chemical analysis results in conjunction with information from material specifications to establish a consistent and viable basis for the as-deposited weld chemical content for four specific reactor pressure vessels -
involving two heats of weld wire, i
II.
BACKGROUND Submittals were made in December 1991 to the Nuclear Regulatory Commission (NRC) in response to 10 CFR 50.61, " Fracture Toughness Requirements for -
Protection Against Pressurized Thermal Shock (PTS) Events" (Federal Register, j
v.5694, page 22304, May 15,1991). The NRC expressed concern regarding the consistency and credibility of data used as the basis for PTS submittals, especially with respect to chemical content. Two or more licensees have reported different copper or nickel contents for reactor vessel welds for which an identical heat of weld wire was used. These differences arose in part because of the way multiple analyses were handled, the type of estimation methods used by licensees, or the degree to which data traceability was established.
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n The PTS submittal of one CEOG licensee was questioned by the NRC regarding the l
copper and nickel content of a vessel beltline weld formed using weld wire heat number A8746. This same weld wire heat was also used for two other CEOG:
licensees' vessel beltline welds. The same copper content (a single measurement, not
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an average) was reported by all three licensees, but different nickel contents were reported. An initial response to the question was prepared based on a review of fabrication records, procedures and specifications as described in the results section.
This report builds upon that initial review using chemical analysis data representative of weld wire specifications and weld procedures employed by ABB/CE.
NRC guidance for determination of copper and nickel content is contained in'10 CFR
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50.61, " Fracture Toughness Requirements for Protection Against Pressurized Thermal Shock Events". Four alternatives are available to obtain best-estimate copper and nickel values for the plate or forging, or for weld samples made with the weld wire heat number that matches the critical vessel weld as follows:
(1)
The mean of the measured values, or, if these values are not available, -
(2) the upper limiting values in the material specifications to which the vessel was built, or if not available, (3) conservative estimates (mean plus one standard deviation) based on generic data from reactor vessels fabricated in the same time period to the same material specifications, if justification is provided.
(4)
If none of the first 3 alternatives are available,0.35% copper and 1.0% nickel must be assumed.
The preceding guidance was employed in this evaluation.
Combustion Engineering, Inc.
Ill.
SCOPE The objective of this evaluation is to provide best estimate values of copper and nickel content for weld deposits produced using the following materials:
1.
Adcom HiMnMo weld wire heat A8746 and Linde 124 flux 2.
Reid Avery HiMnMo weld wire heat 34B009 and Linde 124 or 1092 flux 3.
Reid Avery HiMnMo weld wire heat 34B009 with Ni-200 cold wire feed and Linde 1092 flux The preceding materials were used to fabricate reactor vessel beltline welds in Calvert Cliffs Unit 2, St. Lucie Unit 1, Millstone Unit 1, and Millstone Unit 2. The guidelines contained in 10 CFR 50.61 are followed to provide those best estimates.
The approach taken is to review ABB/CE welding procedures and specifications, to'
. collect chemical analysis results specific to the three weld materials noted, and to collect chemical analysis results for comparable and contrasting weld materials. This information is then evaluated to determine the best estimate value for:-
1.
the nickel content of HiMnMo wire weld deposits, specifically heats
- A8746 and 34B009, 2.
the copper content of Adcom wire weld deposits, specifically heat
- A8746 3.
the copper content of Reid Avery heat #34B009 weld deposits, and 4.
the nickel content of Reid Avery heat #34B009 plus Ni-200 cold wire feed weld deposits.
In this evaluation, chemical analysis results were obtained from weld deposits fabricated using Linde 0091,1092,124 and 80 fluxes. The toughness properties of welds made using Linde 0091,1092 and 124 fluxes have been previously shown to be
. Combustion Engineering, Inc.'
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m comparable. Flux type is known to affect certain chemical elements, but nickel and copper contents in the weld deposit have not been found to be substantially affected m
by flux type for Linde 0091,1092 and 124 for a given heat of weld wire. There is -
insufficient information from ABB/CE fabrication records to draw similar conclusions -
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.regarding Linde 80 flux welds. Therefore, copper and nickel analysis results from i
Linde 80 flux welds will be ' onsidered for information only.
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L IV.
RESULTS a
1.
Welding Procedures and Specifications l
ABB/CE fabricated many reactor pressure vessels using automatic submerged are welding. Type Mil-B4 electrode wire specifications (see MIL-E-18193A, Military Specification, " Electrodes, Welding, Carbon Steel and Alloy Steel,'
i Base, Colled," July 23,1957) were used as the basis for ABB/CE procurement of the filler wire. In this report, the terminology " wire type" is used to represent the broad classification of weld filler material: Mil-B4 of Mil-B4 Modified (Mil-B4 Mod). The terminology " specification" is used to represent the specific classification of weld filler material: HiMnMo, MnMoNi, MnMo, or Low Cu-P. The terminology " supplier designation" is used to represent the specific compositional classification of wire provided by the supplier to meet the CE specification: HiMnMo, MnMoNi or Low Cu-P. ABB/CE purchase specifications in place between 1965 and 1971 called for several groups of coiled electrodes differentiated by the manganese (Mn), molybdenum (Mo) and nickel (Ni) content:
ABB/CE Specified Supplier Wire Tyne Specification Nickel Content Designation Mil-B4 Mod HiMnMo HiMnMo Mil-B4 Mod MnMoNi 0.90 to 1.10%
MnMoNi Mil-B4 MnMo HiMnMo Mil-B4 Mod MnMoNi 0.65 to 0.85%
MnMoNi Mil-B4 Low Cu-P Low Cu-P 1 i
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Only in the case of the wire designation MnMcNi was any nickel required-
- (specified by CE) to be included in the wire. Note also that Mil-B4 Modified was originally specified by CE as either HiMnMo or MnMoNi, In subsequent' specifications, Mil-B4 Modified referred only _to MnMoNi wires with nominally 0.75% or 1.00% nickel, and Mil-B4 referred only to HiMnMo, MnMo, or Low Cu-P wires which all had no nickel specified.
The suppliers of coiled wire electrodes typically'used the designations as indicated above on their certifications. Supplier certifications and weld material release reports (generated by ABB/CE upon receipt of the wire) -
included nickel content only for the MnMoNi wires, i.e., the nickel was determined only where it was specified. Weld material certification tests (weld deposits) and actual vessel weld deposit analyses generally included an analysis for nickel only when MnMoNi wires were utilized or when the vessel equipment specification called for a nickel analysis. Nickel _was not intentionally added to a heat because of the extra expense to the wire supplier.
Therefore, the nickel content for a HiMnMo or a MnMo wire is expected to be low (significantly less than 0.75%).
2.
Observed Nickel Content of HiMnMo and MnMoNi Coiled Wire Electrode Weld Deposits 1
The nickel content of welds deposited using HiMnMo heats #A8746 and
- 34B009 is not available from ABB/CE weld deposit analysis records.
However, nickel content was determined for other HiMnMo heats and for many MnMoNi heats. [ Note: welds fabricated using a Ni-200 cold wire addition are not included in the discussion which follows.] A search was performed of ABB/CE weld receipt and weld deposit analysis records for the j
1 years 1965 to 1971, and a list was compiled of each analysis that included nickel content. For each analysis with a reported value of nickel, the supplier Combustion Engineering, Inc.
designation and wire supplier is noted as shown in Table 1; multiple analyses on a single heat are grouped together. The mean and standard deviations described below are based on the average nickel for each heat, whereas the ranges reflect all reported nickel values within each set of wires.
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The MnMoNi wires fall within two ranges of nickel,0.59 to 0.82% Ni and 0.89 to 1.10% Ni. The corresponding mean and standard deviation are:
mean = 0.706% Ni, o = 0.051% Ni mean = 0.990% Ni, o = 0.069% Ni These correspond well to the two specification levels of 0.75% and 1.00% Ni discussed in the previous section.
For the HiMnMo wires, nickel content is in the range of 0.01 to 0.16%. The mean nickel value for the 16 heats is 0.058% with a standard deviation of 0.037% Ni.
It is clear from the HiMnMo dam that nickel was not intentionally added to the original heats from which the electrode wires were drawn. Therefore, for the HiMnMo heats #A8746 and #34B009, a conservative best estimate (mean plus one standard deviation) of the nickel in the weld deposit is 0.10% Ni.
3.
Copper Content of Weld Deposits Using Wire Heat #A8746 Weld wire heat #A8746, a HiMnMo coiled electrode supplied by Adcom, was used to fabricate the weld seams described in Table 2. In each case, the submerged arc welding was performed using Linde 124 flux.
Two separate weld deposit chemical analyses were performed which involved heat #A8746 as described in Table 3. Only one of the analyses relates directly to the four weld deposits listed in Table 2. Each of the vessel welds were.
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- deposited using Linde 124 flux, whereas only one of the chemical analyses i
reflected a Linde 124 flux weld. Therefore, the Linde 80 weld deposit I
analysis can only be used for information.
1 The Linde 124 flux weld deposit analysis resulted in a copper content of 0.12% using Adcom weld' wire heat A8746. In order to judge.the viability of -
the 0.12% copper value, a compilation was made of weld deposit copper contents of other Adcom heats which is given in Table 4. Treating each copper analysis as independent (i.e., assuming that each reflects results from a l
unique coil), the mean copper content is 0.20%, the standard deviation is 0.036%, and the range is 0.12 to 0.27%. The data include seven different heats or combinations of heats, four different types of flux, two different. wire i
specifications, and a 29 month time period over which wire was procured and analyses were performed. Therefore, the 0.036% standard deviation for copper reflects heat-to-heat and coil-to-coil variations as well as the influence -
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of weld flux and the time dependence of the copper coating process on weld'-
deposit copper content. In other words, since the sta'ndard deviation represents
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many Adcom wire heats and other factors, the 0.036% copper (one standard deviation) should conservatively represent the copper variability of welds deposited using a single heat of Adcom. wire, heat #A8746.
Comparison of the data from Table 3 and Table 4 indicates that the range of available measurements specific to heat #A8746,0.12 to 0.17% copper, is within the range of the seven different Adcom supplied heats and combinations of heats. Furthermore, the mean of the two A8746 analyses,'0.145% Cu, is within one standard deviation of the single Linde 124 weld deposit analysis 1
(0.036% plus 0.12% equals 0.156% Cu). Therefore, a conservative best i }
Combustion Engineering, Inc.
estimate of the copper content of the welds described in Table 2 is 0.16%
based on the heat-specific measurement and the standard deviation for generic Adcom wire heat data.
4.
Copper Content of Weld Deposits Using Wire Heat #34B009 Weld wire heat #34B009, a HiMnMo coiled electrode supplied by Reid Avery, was used to fabricate the weld seams described in Table 5. The submerged arc welding was performed using either Linde 124 or Linde 1092 Oux.
Nine chemical analyses involving heat #34B009 are described in Table 6. The first two entries are laboratory experiment results and, therefore, are not representative of production weld deposits. Four entries are analysis results from samples extracted from a II.B. Robinson Unit 2 (HBR-2) reactor vessel head weld. Three entries are analysis results for the Millstone Unit 1 (MP-1) surveillance weld performed for EPRI and General Electric. The seven representative measurements were from welds deposited using Linde 1092 flux, and the two experimental analysis results were from welds deposited using Linde 1092 or Linde 124.
The Linde 1092 flux weld deposit analyses resulted in a mean copper content of 0.19%. This mean of measured values is directly applicable to the Millstone Unit I weld described in Table 5. Given that the weld flux does not affect the copp;r content significantly (see Section III), the 0.19% mean copper is also applicable to the 1
St. Lucie Unit I weld described in Table 5 which was deposited using Linde 124 flux.
L 5.
Nickel Content of Weld Deposits Using Wire Heat #34B009 and a Cold Nickel Wire Feed The Millstone Unit I weld described in Table 5 was fabricated using a cold nickel wire feed in addition to the electrode wire heat #34B009. Therefore, the nickel
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content of that weld would be greater than normal for a HiMnMo wire weld deposit without the nickel feed wire (as discusse'd in Section IV.2).
Table 7 presents 24 sets of data on the nickel content of. welds deposited using RACO-3 (Reid 'Avery) wires, Ni-200 wire (cold nickel feed) and Linde 1092 flux.
Only two different wire heats, singly or in tandem, were used. The mean nickel:
content is 1.065% and the range is 0.72% to 1.21% Ni.
Table 8 presents nickel content associated with the Table 6 data in which heat-
- 34B009 was used with Ni-200 wire and Linde 1092 flux. All but two of the nickel contents specific to heat #34B009 are within the range of the data from Table 7. The average of the three MP-1 surveillance weld values is 0.94% Ni, and the range is 0.81 to 1.03% Ni. The average of the MP-1 and the two in-range HBR-2 values is 0.88% Ni, and the range is 0.75 to 1.03% Ni for the. welds deposited with heat
- 34B009. The 0.88% Ni represents the mean of measured. values for weld deposits fonned using heat #34B009 with a cold nickel wire feed. However, given the higher mean of the generic data (Table 7), a more conservative estimate of the heat-specific -
weld nickel content is 1.03%, the upper bound of the data from Table 8.
V.
CONCLUSIONS 1.
Welds deposited by Combustion Engineering using HiMnMo coiled wire electrodes _
yield a mean nickel content of 0.058% with a standard deviation of 0.037%.
Therefore, a conservative estimate (mean plus one standard deviation) of nickel content in such welds is 0.10% Ni.
2.
Welds deposited using 'Adcom Heat #A8746 (HiMnMo) and Linde 124 flux are conservatively estimated to contain 0.16% Cu and 0.10% Ni.
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3.
The welds deposited using Reid Avery Heat #34B009 (HiMnMo) with' Linde 124 or Linde 1092 flux are estimated to contain 0.19% Cu based on the mean of measured values, and conservative estimates of nickel content are 1.03% Ni with a Ni-200 wire n
addition and 0.10% Ni without a Ni-200 wire addition.
These best estimate chemical contents are summarized in Table 9 for the welds described in l
Tables 2 and 5.'
VI.
REFERENCES 1.
" Evaluation of Pressurized Thermal Shock Effects due to Small Break LOCA's with Loss of Feedwater for the Combustion Engineering NSSS," Combustion Engineering.
Report CEN-189, December 1981.
2.
" Application of Reactor Vessel Surveillance Data for Embrittlement Management,"
Combustion Engineering Owners Group Report CEN-405-P (Draft Revision 2),
December 1992.
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Combustion Engineering, Inc.
TABLE 1 Nickel Content for Coiled Wire Electrode Weld Deposits Supplier Wire Nickel i
Designation --
Sunolier Content %
HiMnMo Page 0.03, 0.05 HiMnMo Page 0.02, 0.02 L
HiMnMo -
Page 0.01, 0.03, 0.03 l
HiMnMo Page 0.03, 0.03, 0.04, 0.04, 0.05, 0.07, 0.11 i
HiMnMo Page 0.02, 0.03, 0.03, 0.03, 0.03, 0.04, 0.04, 0.05 HiMnMo Page 0.02, 0.03, 0.03, 0.03 (Not Reported)
Page 0.03, 0.03
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HiMnMo (Not Reported) 0.05 l]
liiMnMo Page 0.06
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HiMnMo Reid Avery 0.08, 0.09 i
HiMnMo Reid Avery 0.07, 0.08, 0.12
)
HiMnMo Reid Avery 0.16, 0.16 HiMnMo Reid Avery 0.04 HiMnMo Reid Avery 0.03, 0.06, 0.07 HiMnMo Reid Avery 0.10, 0.11 liiMnMo Reid Avery 0.05, 0.05, 0. %
MnMoNi Adcom 0.74 MnMoNi Adcom 0.73, 0.74
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MnMoNi Page 0.64, 0.68, 0.68, 0.70, 0.71 I
MnMoNi Adcom 0.59, 0.61, 0.72, 0.72 MnMoNi Reid Avery 0.59, 0.60, 0.62, 0.64, 0.64 MnMcNi Reid Avery 0.64, 0.64, 0.64, 0.66 MnMoNi
.Adcom 0.73 MnMoNi (Not Reported) 0.69 MnMoNi Reid Avery 0.73, 0.74 MnMoNi Reid Avery 0.69, 0.72, 0.72, 0.73, 0.74, 0.76, 0.81 MnMoNi Reid Avery 0.75, 0.78, 0.79, 0.80, 0.82 MnMcNi Adcom 1.00, 1.01 MnMoNi Adcom 1.02, 1.03, 1.03, 1.04, 1.04, 1.05, 1.05, 1.05, 1.08 MnMcNi Adcom 0.96, 1.00(4), 1.02(2), 1.06(2), 1.10 MnMoNi (Not Reported) 0.89...
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' l TABLE 2 '
Weld Seams and Consumables Using Adcom Heat #A8746 (HiMnMo)
. Weld Procedure -
Reactor Vessel Weld Seam No. (Note 1)
Weld Flux Tvoe Specification Calvert Cliffs Unit 2 2-203 A,B,C Linde 124 SAA-4-0
'St. Lucie Unit 1 2-203 A,B,C (Note 2)
Linde 124 SAA-4-0 Millstone Unit 2 2-203 A,B,C Linde 124 SAA-4-0 3-203 A,B,C Linde 124 SAA-MA-501-2 t
Note 1:
All of the weld seams listed were deposited without a cold nickel wire feed.
Note 2:
Weld wire heat #34B009 (Reid Avery) was also used with heat #A8746 to deposit the weld seams in a single are process.
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TABLE 3 P
Copper Content Analysis Results.
for Weld Wire Heat #A8746 (Adcom HiMnMo)
Iyne of Analysis Date Flux Tyne/ Lot No.
Cooper (%)
l Weld Deposit 8/19/69 Linde 80/#8651 0.17 Weld Deposit 8/27/69 Linde 124/#3878 0.12 i
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I TABLE 4 Weld Deposit Copper Content for Adcom Wire Heats
' Supplier Flux Copper Designation Iype Content (O IliMnMo Linde 124 0.12 (Note A)
IliMnMo Linde 80 0.17 (Note A)
MnMoNi Linde 0091 0.16 MnMoNi Linde 1092 0.16, 0.20 MnMoNi Linde 1092 0.18, 0.19, 0.20(2), 0.21(2), 0.22(2), 0.24, 0.25 MnMoNi Linde 1092 0.22 MnMoNi Linde 1092 0.22 (Note B)
MnMoNi Linde 1092 0.27 (Note B)
Note A - From Table 3
. Note B - Combination of two Adcom heats in weld deposit.
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TABLE 5 Weld Seams and Consumables Using Reid Avery Heat #34B009 (HiMnMo)
Weld Procedure Reactor Vessel Weld Seam Ng Weld Flux Type Specification St. Lucie Unit 1 2-203 A, B, C (Note 1)
Linde 124 SAA-4-0 Millstone Unit 1 3-073 (Note 2)
Linde 1092 SAA-33-J(1) -
Note 1:
Weld wire heat #A8746 (Adcom) was also used with heat #34B009 to deposit the weld seams in a single arc process. A cold nickel wire feed was not used.
Note 2:
The weld process included the addition of a cold nickel wire feed.
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TABLE 6 Copper Content Analysis Results for Weld Wire Heat #34B009 Tyne of Analysis Elux Tyne Conner Content (%)
Source
-i' Weld Deposit Linde 1092 0.15 CE Lab Experiment i
Weld Deposit Linde 124 0.17 CE Lab Experiment Weld Deposit Linde 1092 0.180 HBR-2 Head Sample Weld Deposit Linde 1092 0.182 HBR-2 Head Sample.
Weld Deposit Linde 1092 0.183 HBR-2 Head Sample
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Weld Deposit Linde 1092 0.202 HBR-2 Head Sample Weld Deposit Linde 1092 0.18 MP-1 Surveillance Weld (EPRI)
Weld Deposit Linde 1092 0.19 MP-1 Surveillance Weld j
(EPRI)
Weld Deposit Linde 1092 0.18 MP-1 Surveillance Weld (GE Report NEDC-30299) j l
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TABLE 7 Weld Deposit Nickel Content with Cold Nickel Feed -
Source Nickel Content (O Mixed Reid Avery Heats, Linde 1092 1.06, 1.03, 1.15, 1.16, 1.15, 1.08, flux and Ni-200 wire 1.03, 1.06, 1.06, 1.04, 1.10, 1.01, 1.04, 1.15, 1.07 Single Reid Avery Heat, linde 1092 0.99,1.12, 0.92, 0.94 (Note 1),
- flux and Ni-200 wire 1.115 (Note 2),1.05,1.20, 0.97 j
Note 1: Average of 20 analyses from single weld, with a range of 0.72 to 1.08% Ni.
Note 2: Average of 2 analyses from one surveillance program weld (1.02 and 1.21% Ni).
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i TABLE 8 Nickel Content for Heat #34B009 with Cold Nickel Feed and j
Linde 1092 Flux Nickel Content
'(M Source 0.75 HBR-2 Head Sample 0.32 HBR-2 Head Sample 0.84 HBR-2 Head Sample 0.43 HBR-2 Head Sample -
O.81 MP-1 Surveillance Weld (EPRI) 0.98 MP-1 Surveillance Weld (EPRI) 1.03 MP-1 Surveillance Weld (GE Report NEDC-30299)
Combustion Engineering, Inc.
TABLE 9
. Best Estimate Copper and Nickel Content for Vessel Welds Content (%)
Reactor Vessel Weld Seam No.
_C_u Ni Calvert Cliffs Unit 2 2-203 A,B,C 0.16 0.10 St. Lucie Unit 1 2-203 A,B,Cm 0.16 0.10 2-203 A,B,Cm 0,19 o,10 Millstone Unit 2 2-203 A,B,C 0.16 0.10 3-203 A,B,C 0.16 0.10 Millstone Unit l 3-073 0.19 1.03 i
Notes (1)
Chemical content contribution from wire heat #A8746
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(2)
Chemical content contribution from wire heat #34B009 ll I
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