ML20086B541

Transmits Info Re Flaws in Both Nozzles on Both Heat Exchangers Which Require Fracture Mechanics Evaluation & Forwards MMDT-SMT-193, Fracture Mechanics Evaluation, Braidwood,Unit 2 Residual Heat Exchanger Tube Side..

ML20086B541
Person / Time
Site:	Braidwood
Issue date:	11/13/1991
From:	Simpkin T COMMONWEALTH EDISON CO.
To:	Murley T NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM), Office of Nuclear Reactor Regulation
Shared Package
ML20086B542	List: ML20086B541 ML20086B548
References
NUDOCS 9111200231
Download: ML20086B541 (18)

Text

_ _ _ _ _ _ _ _ - - - - _ - - . _ _ - - - - - . _ _ _

Commonwealth Edison C } 14.X) Onos Place oownero Grove, Illinois 60$15 November 13.1991 Dr. Thomas E. Murley Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Attn: Document Control Desk

Subject:

Braidwood Station Unit 1 Flow Evaluation Report for RHR Heat Exchanger Nozzle to Shell Wolds NBC Docket No. 50-450- __

Dear Dr. Mudoy:

Pursuant to the Braidwood Station Unit 1 inservice inspection Program, a best effort UT exam was conducted on the subject welds. These exams resulted in the identification of flaws in both nozzles on both heat exchangers which require a fracture mechanics svaluation to demonstrato continued acceptability.

Enclosed for your review is the aforementioned evaluation. Please direct any questions you may have concerning this matter to this cifice.

Sincerely, iuv,ues-lb p/nqb "

T.W. Simpkin Nuclear l.icensing Administrator cc: S. DuPont - Braldwood R. Pulsifer - NRR W. Shafer - Rlli J. Jacobsen - Rlli 9111200231 911113 POR 0

ADock 0S000456 FOR -U[

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DW/91-0072 Terrence Dimpkin l Huclear Licensing Administrator j Subjecta liraldwood Unit 2 Rouldual liest Homeval Heat Exchanger Nozzle to. Vessel Welds Inservice Inspection. Results During ASME Section XI Inses vice Inspection of the Hraldwood Unit 2 Residual Heat Removal heat exchanger nozzio to vosso1 wolds, ultrasonic teflectors-gieater thar allowable by ASME Section XI Subarticle IWH-3500 were  !

detected. This prompted on analysis in accordance with Subarticle IWH-3600 *

(Fractur e Hechanics) which was .perictined by Westinghouse Electric Corpor ation.

-As chown in the attached report all. indications fall within ASME Section XI acceptance standards act'forth In either Subarticle IWD-3500 or IWB-3600. Those ludications found acceptable analytically by Fracture ,

Hechanics analysis will be monitored by inspections during future Draidwood  ;

-Unit 2 outages'as required by ASME Section X1, tWC-2420._

11 ease transmit. this report to t he _ regulatory authorities. This requirernent is steted in ASME Section XI Paregraph IWB-3125 and IWD-1610.  !

If there are any questions regarding this information please contact Hike Sears on extension 2251. l l

/s  ?

K.L.Kofron/g l Station Hanager '

Braldwood Nuclear Power Station

' FLK/MS/ach l (318/ZD700)

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.o s I. DACKGROUND

• During the Draidwood Unit 2 preservice inspection (1984 through 1988) a request was submitted to the NRC asking relief from the ultrasonic examination ruquirements for the Residual Heat Removal heat exchanger nozzle inner radii and nozzle to vessel welds. This was due the inherent geometric constraints limiting the ability to perform a meaningful ultrasonic examination. This relief request (Relief Request 2f1R12 of the Braidwood Unit 2 preservice Inspection program) was granted by the NRC in Braidwood SSER 5 page 6-2.

A similar relief request (Relief Request NR-12 of the Droidwood Inservice Inspection Program) was submitted to the flRC in December 1988. This relief asked for the same code testing exemptions which had been granted during preservice inspection. The NRC. granted inservice inspection relief for the nozzle lnner radii examination but requested a best effort-ultrasonic examination be conducted on the nozzle to >

vessel welds. This is documented in the NRC Safety ,

Evaluation of the Braidwood Unita 1 and 2 First Ten Year Interval Inservice Inspection program, (TAC No. 64038 and -

64065 issued October 4,-1991).

11. 1DIR0utlCTlnN At the direction of the NRC, as stated in their review of Draidwood Station's inservice Inspection program, a best effort ultrasonic examiaation was performed on the Braidwood Unit 2 Residual Heat Removal heat exchangers nozzle to vessel ,

welds,- These nozzles are welded to the tube side (ASME Class 2 portion) of the heat exchanget vessels.. Figure I shows the

-inservice inspection weld locations.

The original inspection schedule for this outage called for i ultrasonic inspection of the nozzle to vessel welds on the ,

unit 2 "A" heat exchanger. Ultrasonic reflectors found during these~ examinations which were greater than 100%

i reference level and exhibited definable depth, were evaluated in accordance with ASME Section XI 1983 Edition, Summer 1983 Addenda, Subarticle IWB-3500. The indications did not meet

• IWD-3500 acceptance criteria. At this point the inspection was expanded to include the nozzle to vessel weldas on the unit 2 *D"' Residual Heat Removal heat < exchanger. -

The nozzles on this-heat exchanger.also revealed indications which exceed '

code allowable limits. -Those reflectors shown not to meet the'. acceptance standards of IWB-3500 were subjected to further evaluation in accordance with ASME Section XI

-Subarticle IWB- 3600 (Fracture Mechanics Analysis) and found

'to be acceptable for continued service.

l (1).

318(111291) l: ZD70G I

", 3 Ultrasonic data indicated that none of the indicationa are 4

open to the internal or external surface. This indicates 4 that these reflectors are caused by slag and/or lack of fusion in the lower bevel weld which is a result of t he fabrication process and not service induced.

As shown in this report all indications fall within ASME Section XI acceptance standards set forth in either Subarticle IND-3500 or IWB-3600. Those indications found acceptable analytically by a Fract.ure Mechanics analysis will be monitored by inspections during future Braidwood Unit 2 outages as required by ASME Section XI, IWC-2420.

III. EADRI. CATION _INE0BMATION The subject nozzles are on the tube side of the Residual Heat Removal heat exchangers. These heat exchangers were '

manufactured by Joseph Oats Corporation in 1975 por the requirements of ASME Section III, NC-3200, Alternate Design Rules for Vessels. The heat exchanger vessel tube side is ASME Class 2 and the shell side is ASME Class 3. The nozzles are 3/8 inch nominal thickness (actual measured ultrasonic ,

thicknese: is 0.4 inch), 13.875 inches outside diameter, SA-240 Tp 304 rolled plate welded to the 1 inch thick SA-240 Tp e - 304 rolled plate of the tube side vessel wall.  :

The weld joint configuration as shown in Figure 2 is E double bevel groove weld-with an external 3/8 inch fi'.let weld. Holding was performed using the shielded metal arc  !

process with E308 electrode. Joseph Oat Corporation

- personnel have stated that the groove weld was backgouged at the root during the welding operation. The inside diameter

! and outside diameter of the weld joints.were examined by '

! liquid. penetrant examination at completion of welding and had acceptable results. These: welds did not receive radiographic examination during fabrication. This was due to

- the-joint configuration. ASME Section 111, 1974 Edition, Subsection NC, paragraph NC 3352 does not require radiographic. examination of angle joints between the shell and nozzle which exceed 30 degrees. The ultrasonic testing performed during this outage was the first volumetric examination of^these welds.

IV. ULTRAERN1C IECliNIDDE The Residual'Ileat Removal heat exchanger Nozzle to Vessel welds were examined using a procedure that required a

. calibration which would produce an examination that meets the intent of ASME Section XI, Appendix III requirements.

The examinations were performed using C.E.Co. procedure NDT-C-2, Rev. 18 utilizing a 70 degree, 5.0 Mhz., 0.250"

- dia. chear wave transducer. The 70 degree transducer was necessary to obtain the best examination coverage and sensitivity possible. The instrument sweep r. ge was calibrated to represent a 1.0" depth range.

. . (2) 318(111291)

ZD70G

. ; .- . = . . . . = ~ = = w;u = = . = = = - . - . - .-- - - - . . - - . - . - . - . ..

3 v. l The instrument sensitivity was established using the 3/32" l

- dia, 1/2 "T" side drilled hole in calibration block BY-113.  ;

. The first point on the DAC was to set the signal amplitude ,

of the side drilled hole at 1/4 node to 80% Full Screen ,

lleight (FSil) and then mark the signal amplitude of the hole .

at the 3/4 node position. It should be noted that with this calibration sensitivity, a 10-20% FSil noise level is .

displayed on the. screen. This is the maximum sensiLivity '

and noise level that the operator can utilize while performing the examination. ,

, t in conjunction with this procedure, depth sizing of the '

flaw indications was performed in accordance with C.E.Co. ,

procedure NDT-C-41, Rev. O. This procedure allows the use ,

of liigh Angle Dual Refracted 1.ongitudinal Wave transducers -

to detetmine thru-wall dimensions of the flaw indications.

The following requirements applied while using the above referenced procedures:

1. The circumference of the nozzle welds were marked off into 1-.0"-increments.

2. All flaw indications that were detected at 50% DAC or  !

greater amplitude within each inch of weld were recorded.

3. If the flaw indication was not detected at 50% DAC level within each inch of weld, it was considered terminated.

4. If the Claw indications appeared continuous or intermittent between termination points, this was noted or recorded. ,

5. Flaw indications 100% DAC or greater were length sized.in accordance with ASME Section XI Code or 100% DAC end points and their depth were sized in accordance with  !

C.E.Co. procedure NDT-C-41, Rev. O.  !

6. The 70 degree. shear wave transducer was used to size the length and to record the indications around the

-cireumference.

- 7 ~. 2idicat.ans which exceeded 100% DAC were sized using the

7) degree sheer, 70R1,.and 60 degree shear transducer. .-

L P Indications which exceed IWB-3500 acceptance critoria will be monitored.

i 6

ll i

i (3) 318(111291)'

' ' 2DT1T 2 , - _ . . _ _ . . _ . _ _ . _ , - . - . _ . . . , . . , , , - _ _ . . _ . _ _ . _ , . . . _ . , . _ . , . _ . _ _ _ . _ .

V. ULTMS0111C_ EXAM U! AT I Qji S.JE SULTS

' Attachment A summarizes, for each nozzle, t.hu recordable indications detected during ultrasonic examinations. All the indications are subsurface flaws, not open to the internal or external sutface. Iloweve r , following the methodology of ASME Section XI, IWA-3310(b),_several flaws have been considered as surface flaws and are so reported in these tables. The a/t column values have been developed using the actual nozzle wall thickness of 0.400 inches, as measured by ultrascule examinations.

VI . EVALUAT10lLDEJJLIRASDlilC_EXAMll1ATl01LRESULTS A Fracture Mechanics analysis has been performed by Westinghouse in accordance with t.he methodology and criteria of ASME Section XI, IWD-3600. This evaluation developed maximum allowed flaw dimensions for normal operating conditions and emergency and faulted conditions. The results of the Fracture Mechanics analysis have been used to construct an upper boundary flaw chart for the detected-indications. _The complete Westinghouse evaluation-which developed this chart is provided in Attachment D. Figure 4-1 in Attachment D shows the developed chart.

-All the indications from section V which exceeded the acceptance criteria of _IWB-3500 have been found to be withiri the boundary of the upper boundary flaw chart. The indications for each nozzle have been plotted on separate flaw evaluation charts. Th m charts are provided in Figure 3,_4, 5, and 6 for the 2A outlet, 2A inlet, 2D outlet and the 20 inlet nozzle respectively. The 1/C values for these charts have been developed using the outsido pipe diameter of 13.875 inches resulting in a circumference of 43.6 inches.

Several corservatisms have been applied by Westinghouse in the development of the maximum allowable flaw sizes:

(a) The loads applied to the heat exchanger nozzles were taken from the equipment specification loading criteria.

The actual loads for the Braidwood Unit 2 RHR heat ,

exchangers are approximately 60 percent of the design loads.

(b).The residual' stresses ured in the analysis were taken for a 10-inch schedule 160 pipe. This smaller pipe diameter and larger thickness (1.125; inches) result in_a extremely _ conservative stress distribution relative to the heat = exchanger nozzle.

(c) The indications depths have been analyzed taking into account the thickness of the pipe, no credit was taken .

-for the additional thickness of the fillet wold on the outsile surface of the nozzle.

(4) 318(111291)

'ZD70G

,- '. l V11. ERIMilY_CQDLAllLMATEILCllEMISTRY  !

l The HilR heat exchangers tube side nozzles are exposed to ,

only primary coolant water. The Chemistry requirements for l primary coolant water are given in section 3/4.4.7 of the Braidwood Technical Specifications. These limits are 100 ppb-dissolved oxygen when the temperature is greater than 250 degrees Farenheit and 150 ppb for Flotaride and Chloride at all. temperatures. A detailed discussion Jn Stress Corrosion-Cracking and related parameters is provided in-Appendix A, section 3.4.

VIII. C011CLUS10N 1 i

All the indications detected on the nozzle ta pipe welds for the 2A and 2B RHR heat exchangers, tube side, have been found acceptable in accordance with ASME Section XI rules, 1HB-3500-or IWD-3600 as applicable. -- These flaws which have -

been dispositioned by a Fracture Mechan 4cs analysis will be +

monitored by inspection during future 9taidwood Unit 2 outages as required by ASME Section XI, IWC-2420.

The Ultrasonic Examinations indicated that the t>ubsurface flaws detected are not open to the Internal or external surface.- This points to slag and/or lack of fusion induced discontinuities rather than service induced flaws.

In light of the evaluations perf.stmed, all the indications detected are acceptable for fut'.ner service without repair.

i P

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'. . Page 1 of-4 ATTACHMENT A Component: 21tl102AA Wold No: 2RHXS-1 Outlet Nozzle A total of 16 indications above 50*5 DAC were recorded. Those indications having amplitude greater than 100's DAC and defin ble depth are summarized below.

11KL .._ _LK._._ __._ Max ._Ac ,_ _._19.t h. . a12s)** aLl__* . alt _

6 16.125" 112% .125" .09 .72 22.5 7 16.5" 125% .625 .11 .176 27.5 9 18.5" 200's 2.0 .16 .08 40 l

20 21.125" 224% 1.0 (.09) .045 11.25 11 23.25" 125% .50 (.10) .10 12.5

_13 -_ 31" 125% 1.75 .06 .034 15 Tliese indications exceed ASME Section XI Article IWB-3500 acceptance standards.

a a/t represents through wall percentage of indication

• • Denotes ASME Section XI (Article IWA-3000) characterization (i.e. a - surface, 2a - subsurface).

Note: All flaws were found to be not open to the surface by ultrasonics.

l l

l l (12)

- 318(111291)

ZD700

Page 2 of-4 ATTACitMENT A 4

Componen t. : 2RIIO2AA Weld No: 2RIIXN-2 Inlet Nozzle A total of 26 indications above 50% DAC were recorded. Thos.:

indications having amplitude greater than 100% DAC and definable depth are summarized below.

Indt _Los. M aL_ Amp.t. Lgth< a12 a) *

• _aLLJ_a/L 23 37.5" 125% 0.375" .13 .346 33 This indication exceeds ASME Section XI Article IWIi-3500 acceptance standards.

• a/t represents through wall percentage of indication

• • Denotes ASME Section XI (Article IWA-3000) characterization (i.e. a - surface, 2a - subsurface).

Note: All flaws were found to be not open to the surface by ultrasonics.

l~

t l

l l (13)

!- 318(111291)

! ZD70G l

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ATTACilMENT A Page 3 of 4 Component: 2Ril02An Weld No: 2RilXN-1 Outlet Nozzle A total of 37 indications above 50% DAC were recorded. Those indications having amplitude greater than 100% DAC and definable depth are summarized below.

Ind._ Loc. _.liax._Amn._ Lg tlu aL2a)** all

• azt.

03 8.0" 282% 5.5" .16 .029 40 21 27.75" 158% 1.0 (.06)- .03 7.5 22 29.0" 125% 0.25 (.03) .06 3.75 31 37.5" 178% 1.5 .15 .10 37.5 37 43.375" 125% 1.25 .24 .192 60 These indications exceed ASME Gection XI Article IWB-3500 acceptance standards.

• a/t represents through wall percentage of indication Denotes ASME Section XI (Article IWA-3000) characterization (i.e. a - surface, 2a - subsurface).

Note: All flaws-were found to be not open to the surface by ultrasonics.

I A

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I (14) 318(111291)

ZD70G

Page 4 of 4 ATTACilMENT A Component: 2Ril02AU Wold No: 2 HilXN-2 Inlet Nor.zle A total of 32 indicactions above 50% DAC were recorded.

Those indications having amplitude greater than 100% DAC and definable depth are summarized below.

Inti,_ LOL liaX._l miu igth. a(?JJ ALL_

• aft _

08 6.875" 125% .875" (.05) .0285 6.25 09 8.0" 158% .875" .16 .182 40 14 13.5" 112% 0.25" (.07) .14 8.75 24 34.5" 158% 0.625" ( 04) .032 5.0 These indications exceed ASME Section XI Article IWB-3500 acceptance standards.

• a/t represents through wall percentage of indication

• • Denc'es ASME Section XI (Article IWA-3000) characterization (i.e. a - surface, 2a - subsurface).

Note: All flaws were found to be not open to the surface l by ultrasonics.

l l

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(15) 318(111291)

ZD70G l

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ATTACllMENT 1)

Fracturo Mechanics Evaluation l

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