ML20133H622

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Summary of 850723 Meeting W/Util,State of Il,Impell & Nutech Re Proposed long-term Resolution of IGSCC Concerns. Viewgraphs Encl
ML20133H622
Person / Time
Site: Quad Cities Constellation icon.png
Issue date: 07/26/1985
From: Bevan R
Office of Nuclear Reactor Regulation
To:
Office of Nuclear Reactor Regulation
References
NUDOCS 8508090425
Download: ML20133H622 (24)


Text

  • -

July 26, 1985 Docket No. 50-265 LICENSEE: Comonwealth Edison Company FACILITY: Quad Cities Nuclear Power Station, Unit 2

SUBJECT:

SUMMARY

OF MEETING WITH COMMONWEALTH EDISON COMPANY REGARDING ITS PROPOSED LONG-TERM RESOLUTION OF INTERGRANULAR STRESS CORROSION CRACKING (IGSCC) CONCERNS FOR QUAD CITIES UNIT 2 The NRC staff met with Commonwealth Edison Company (CECO) on July 23, 1985 to hear and discuss its proposal for long-term resolution of IGSCC concerns for Quad Cities Unit 2. Enclosure 1 is a list of attendees. Enclosure 2 is selected handout material used in CECO's presentation.

CECO proposed a detailed integrated program as an alternative to complete replacement of IGSCC-susceptible pipe. The program included augmenting the existing weld overlays to " full structural" condition, applying full structural weld overlays or " pipe-lock" (if appropriate) to future flaws not currently overlaid, stress improvement (IHSI) of all accessible welds not already treated with IHSI, implementing hydrogen water chemistry, and doing some s More extensive ultrasonic (pool-piece pipe replacement where appropriate.UT) examination would b automated techniques to enhance flaw detection capabilities. In summary, CECO presented a table of IGSCC-susceptible weld profiles projected after implementation of the integrated program, and a comparison of total pipe replacement cost with cost of the integrated program for all IGSCC-susceptible welds.

The proposed program elicited discussion between NRC and licensee participants regarding staff concerns related to technical, regulatory and other aspects of the proposed program. As a result of the meeting, CECO apparently intends to proceed in measured steps and with due regard to NRC staff comments and admonitions.

/

Roby B. Bevan, Project Manager Operating Reactors Branch #2 Division of Licensing

Enclosures:

As stated cc w/ enclosures:

See next page DISTRIBUTION See next page DL:0RF DL2.0Rd#2 R8evar. js DVassallo 07/ 85 07/p85 0500090425 850726 PDR ADOCK 05000265 g PDR

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DISTRIBUTION

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NRC POR Local PDR ORBf2 Reading j ORB #2 Mtg Sum File DVassallo RBevan ELJordan BGrimes ACRS(10)

NRC Participants

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Mr. Dennis L. Farrar Commonwealth Edison Company Quad Cities Nuclear Power Station cc:

Mr. B. C. O'Brien James G. Keppler President Regional Administrator Iowa-Illinois Gas and Regic'd III Office Electric Company U. S. Nuclear Regulatory Commission 206 East Second Avenue 799 Roosevelt Road Davenport, Iowa 52801 Glen Ellyn, Illinois 60137 Robert G. Fitzgibbons, Jr.

Isham, Lincoln & Beale Three First National Plaza Suite 5200 Chicago, Illinois 60602 -

Mr. N'ck Kalivianakis Plant Superintendent Quad Cities Nuclear Power Station 22710 - 206th Avenue - North

' Cordova, Illinois 61242

, Resident Inspector U. S. Nuclear Regulatory Commission 22712 206th Avenue North Cordova, Illinois 61242 Chairman Rock Island County Board of Supervisors Rock Island County Court House Rock Island, Illinois 61201 The Honorable Tom Corcoran United States House of Representatives Washington, D. C. 20515 Mr. Gary N. Wright Nuclear Facility Safety Illinois Department of Nuclear Safety 1035 Outer Park Drive, 5th Floor Springfield, Illinois 62704 0

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l EhCLOSURE 1 ATTENDANCE LIST FOR JULY 23, 1985 MEETING WITH COMMONWEALTH EDISON COMPANY ON QUAD CITIES, UNIT 2 PIPE REPLACEMENT Name Affiliation R. Bevan NRR/DL/ ORB #2 C. Reed Ceco, VP Nuclear Operations D. Farrar CECO, Nuclear Licensing B. Rybak CECO, Nuclear Licensing E. Zebus Ceco, Recirc Pipe Replacement W. Johnston NRR/DE B. D. Liaw NRR/DE/MTEB R. M. Bernero NRR/DSI J. A. Zwolinski . NRR/DL/0RB#5 W. J. Collins IE/DEPER W. Hazelton NRR/DE/MTEB A. W. Dromerick IE/DEPER ,

J. Wojnarowski CECO, Nuclear Licensing J. C. Renwick CECO, Recire Pipe Replacement S. W. Swartz Illinois Dept. of Nuclear Safety J. Gavula IMPELL J. Famiglietti IMPELL J. S. Abel Ceco, Station Nuclear Engr.. Dept.

R. J. Tamminga Ceco, Maint. Staff W. W. Witt Ceco, Corp. Lev. III D. Pitcairn NUTECH R. H. Buchholz NUTECH R. Vollmer IE

ENCLOSURE 2 COMMONWEALTH EDIS0N COMPAllY -

00AD CITIES NUCLEAR POWER PLANT - UNIT 2 LONG-TERM RESOLUTION OF IGSCC CONCERNS

JULY 23, 1985 BETHESDA, MD 4 e e

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a MEETING OBJECTIVES INFORM NRC 0F INTEGRATED PROGRAM PROPOSED FOR LONG-TERM IGSCC RESOLUTION AT QUAD CITIES UNIT 2 ,

o UPDATE NRC ON RECENT INSPECTION RESULTS AND TECHNICAL DEVELOPMENTS' 7 o PROVID'E BASIS FOR CONSIDERING AN ALTERNATE TO COMPLETE SYSTEM REPLACEMENT o PRESENT PROPOSED INTEGRATED PROGRAM OBTAIN INITIAL NRC REACTION TO PROPOSED PLAN AND IDENTIFY ANY AREA WHERE ADDITIONAL DISCUSSION SHOULD TAKE PLACE.

\ . .

MEETING AGENDA RYBAK o INTRODUCTION o RECENT INSPECTION / DEVELOPMENT UPDATE RYBAK UNIT 2 ISI INSPECTION RESULTS NUTECH OVERLAY EFF_ECTIVENESS EVALUATIONS (PITCAIRN)

EPRI -

HYDR 0 GEN WATER CHEMISTRY RESULTS (J0NES)

EPRI -

OVERLAY UT INSPECTION TECHNIQUES (J0NES)

ZEBUS o PROPOSED PROGRAM FOR LONG-TERM RESOLUTION

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PROGRAM DESCRIPTION

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COST-BENEFIT

SUMMARY

ALL o- GENERAL DISCUSSION

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RYBAK o' MEETING

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UNIT 21GSCC-RELATED ISIINSPECTION RESULTS (Com1NUED)

SUMM ARY CONCLUSIONS.

O PERF0RMED 100% INSPECTION IN 1983

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4 o APPR0XIM ATELY 25% INSPECTED IN 1985 A ND RESUL NO ADDITIONALIGSCC -

0 IGiCC SITUATION HASSTAELIZED AT yee--2a%6r%LL,0g;D CITIES UNIT 2y.m-%J: ,

o 410% IGSCC FLAWED WELDSIN QU AD CITIES UNIT 2 a

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& ?k O OVERLAY EFFECTIVENESS EVALUATIONS NUTECH OVERLAY DESIGN BASIS 0 WELD DVERLAY DESIGNED TO PROVIDE AT LEAST FULL IWB-3640 MARGINS, e.-

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0 MATERIAL IS PROVEN TO ARREST IGSCC PROPAGATION, 0 DEMONSTRATED BENEFICIAL RESIDUAL STRESSES FROM WELD OVERLAY PROCESS. ARRESTS IGSCC PROPAGATION BEFORE FLAW REACHES DEPOSITED MATERIAL, O ACTUAL SHRINKAGES MEASURED AND ANALYZED FOR EFFECT ON _

PIPING SYSTEM AND UNREPAIRED FLAWED WELDS, 0 CONSERVATIVE ANALYSES PERFORMED TO ADDRESS LOW FRACTURE TOUGHNESS WEL-D METAL- ISSUE OF EXISTING WELD OVERLAYS, i

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NUTECH WELD OVERLAY PROCESS SPECIFICATION 0 USE OF CONTROLLED WELD METAL CONTROLLED DELTA FERRITE (>7.5 FN) - MEASURED IN FIRST LAYER .

LOW CARBON GRADES OF TYPE 308 OR 308L

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0 AUTOMATIC GTAW PROCESS USED O TIGHTLY CONTROLLED WELDING PARAMETERS ASSURE HEAT INPUT NECESSARY TO ACHIEVE RESIDUAL STRESS IMPROVEMENT 0 OTHER CONTROLS ON WELDER QUALIFICATION, SIZE AND SHRINKAGE MEASUREMENTS, EXAMINATION AND IN-PROCESS INSPECTIONS -

0 CONTROLS RESULT IN ASSURANCE THAT DESIGN BASIS IS MET

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LABORATORY AND IN-PLANT VERIFICATION 0 BENEFICIAL RESIDUAL STRESS IMPROVEMENT DEMONSTRATED IN GEORGIA POWER / NRC / NUTECH TESTS ON 12-INCH PIPE CONFIRMS ANALYTICALLY PREDICTED RESIDUAL STRESS IMPROVEMENT BENEFITS DUE TO WELD METAL SHRINKAGE AND "IHSI EFFECT" FROM WELDING HEAT  :

0 EPRI SPONSORED PROGRAMS AT NDE CENTER IN 1983/198f1 ON LARGE 11AMETER PIPE VERIFY ANALYSES USING WELDS II PROGRAM 0 TESTS ON 28-INCH PIPE BY GEORGIA POWER SHOW SAME EFFECT AND ABILITY OF WELD OVERLAY TO ARREST EVEN DEEP CRACKING DUE TO RESIDUAL STRESS EFFECT 0 FULL-SCALE EPRI PIPE TESTS AT GE AND BATELLE-NORTHWEST DEMONSTRATE THE EFFECTIVENSS OF THE WELD OVERLAY AS A -

LONG-TERM REPAIRS FOR IGSCC CURRENTLY INDICATE LIFE OF AT LEAST 5 FUEL CYCLES W-ITH EXRERIEMENT PROGRESSING ANTICIPATE CONFIRMATION OF AT LEAST 15 FUEL CYCLES BY MID-1986 O e e

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l HYDR 0 GEN W ATER CHEMISTRY UPD ATE W85) 0 VERIFICATION PROGRAM AT DRESDEN-2 CYCLE 9 EX AMINATION RESULTSINDIC ATE NO FUEL -

PERFORM ANCE PROBLEMS AFTER ONE HWC CYCLE HYDR 0GENINICTION AND WATER CHEMISTRY  :

CONTROL CONTINUEDINTO. CYCLE 10 UPGRADED INICTION SYSTEM PERFORMING WELL AND WATER QU ALITY CONTINUES EXCELLENT OPERATING IN IGSCC-IMMUNITY REGIME CLOSE TO 100% OF TIME AT POWER 0 SHORT-TERMINJECTION TESTS AT OTHER PLANTS PEACH BOTTOM 3

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PILGRIM SEVER AL SWEDISH PLANTS ALL PLANTS TESTED HAVE ACHIEVED IGSCC-IMMUNE CONDITIONS DURING POWER OPER ATION 0 HWC IS PRACTICAL MEANS TO MITIGATEIGSCC ,

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OVERL AYINSPECTION PROGR AM UPDATE

, PROGR AM OBJECTIVE DEVELOP A TECHNICAL BASISFOR NDE OF WELD OVERLAY REPAIRED JOINTS

,,_ APPROACH T DEMONSTRATE NDE TECHNIQUES CAPABLE OF PROVIDING DETAILED AND ACCURATE INFORMATION TO SUPPORT ANALYSIS OF WELD OVERLAY REPAIRED JOINTS FOR LONG TERM SERVICE EXAMIN ATION OBJECTIVES

, 0 DETERMINE WHETHER THE OVERLAY IS FREE OF UNACCEPTABLE FABRICATION FLAWS TO JUSTIFY STRUCTURAL CREDIT FOR STRENGTH OF OVERLAY METAL

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0 MONITOR AT LEAST THE UPPER PORTIONS OF THE ORIGINAL PIPE WALL AND OVERLAY METAL O CHARACTERIZE REMAINING, SOUND PORTION OF PIPE WALL IN DETAlb SUFFICIENT TO SUPPORT ANALYSIS OF LONG TERM OPERATION OF THE JOINT O

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M ANU AL UT RESULTS 0 DETECTION, LENGTH, AND DEPTH MEASUREMENT CAPABILITIES

. ARE DEMONSTRATED FOR DEEP CRACKS, USING MANY DIFFERENTINSTRUMENTS AND TRANSDUCERS 0 DETECTION OF SH ALLOW, TIGHT CR ACKSIS DIFFICULT -

,,_ AUTOM ATED UT RESOLTS  ?

O DiTECTION, LENGTH, AND DEPTH MEASUREMENT CAPABILITIES ARE DEMONSTR ATED FOR DEEP CRACKS, USING TWO DIFFERENT SYSTEMS AND VARIOUS TR ANSDUCERS 0 EXCELLENT POTENTIAL FOR MONITORING CR ACKS 0 DETECTION OF SHALLOW CR ACKS NOT RELIABLE SURFACE CONDITION i

, 0 SOME DEGREE OF SURFACE SM0OTHING IS REQUIRED FOR ANGLE BEAM EXAMINATION 0 EXTREME SM0OTHING PROVIDES LIMITED BENEFIT

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0 IF NECESSARY, NORMAL BEAM EXAMINATIONS COULD BE

, . PERFORMED ON THE UNPREPARED SURFACE -

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CONCLUSIONS

. O CRACKS REACHING TO WITHIN THE UPPER 25 PERCENT OF THE ORIGINAL PIPE WALL, AND POSSIBLY SHALLOWER CRACKS ALSO, C AN BE EFFECTIVELY DETECTED AND SIZED 0 DETECTION OF SHALLOW, TIGHT CRACKS IS PRESENTLY DIFFICULT ,

0 CODE-UNACCEPTABLE OVERLAY FLAWS AND . CRACKS PENETRATING INTO THE OVERLAY ARE GENERALLY DETECTABLE 0 SURFACE PREPARATION IS REQUIRED FOR EFFECTIVE ANGLE-BEAM EXAMINATION FOR MOST FLAWS OF CONCERN O

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TION OF ALL AVAILABLE REMEDY TECHNIQUES, INCLUDING MATERIALS REPLACEMENT  ?

RESIDUAL STRESS IMPROVEMENT WATER CHEMISTRY CONTROL o IMPLEMENT AN ISI PROGRAM ON A WELD SPECIFIC BASIS DEPENDENT ON REMEDIES APPLIED. THUS, PROVIDES A UNIFORMLY HIGH LEVEL 0F ASSURANCE FOR EVERY WELD, o INTEGRATED PROGRAM IS DESIGNED TO APPLY TWO _

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o ENLARGE ALL EXISTING 0 OVERLAYS T0 " FULL STRUCT 9 (100% DEPTH X 360 CIRCUMFERENTIAL LENGTH FOR A LOAD) -

o APPLY A " FULL STRUCTURAL"0VERLAY OR A PIPELOC EXISTING (OR FUTURE) FLAWS NOT CURRENTLY OVERLA o

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IS' "' b CONSIDER OPTION OF SP0OL PIECE REPLACEMENT WH PROVES TO BE COST EFFECTIVE o

IMPLEMENT HYDR 0 GEN WATER CHt!MISTRY AS AN ADD REMEDY - A RELATIONSHIP BETWEEN ISI SAMPLE SIZE AN SYSTEM AVAILABILITY WILL BE ESTABLISHED S

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IN-SERVICE INSPECTION PROGRAM o OVERLAID WELDS - 100% UT INSPECTION OF OVERLAY MATERIAL AND OUTER 25% OF BASE METAL FOR 2 CYCLES,

,,. THEN RETURN TO SECTION XI INSPECTION FREQUENCY:

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2. REMEDIES - RETURN TO SECTION XI INSPECTION FREQUENCY

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MEETING

SUMMARY

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, o PROPOSED PROGRAM ADDRESSES STAFF CONCERNS REGARDING LONG TERM IGSCC RESOLUTION BY MEANS OTHER THAN PIPE REPLACEMENT o INTEGRATED APPROACH ALLOWSSELECTION 0F MOST PRUDENT COST EFFECTIVE (DOLLARS AND REM) RESOLUTION ON- WELD :

SPECIFIC BASIS o CURRENTLY PROJECTION OF REMEDY DISTRIBUTION 0

80% OF WELDS >200 F H AVE 2 REMEDIES 100% OF WELDS >2000F H AVE AT LEAST 1 REMEDY o WILL SUBMIT PROPOSED PLAN TO NRC FOR INFORM ATION W

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