ML20137F088

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Provides Description of Induction Heat Stress Improvement Performed on Recirculation Sys Welds,Reactor Water Cleanup Sys Pipe Replacement Program,Igscc Insp Program & Weld Overlay Repairs,Per 850226 Commitment
ML20137F088
Person / Time
Site: Brunswick  Duke Energy icon.png
Issue date: 08/16/1985
From: Cutter A
CAROLINA POWER & LIGHT CO.
To: Vassallo D
Office of Nuclear Reactor Regulation
References
NLS-85-288, NUDOCS 8508260144
Download: ML20137F088 (14)
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CD&L Carolina Power & Ught Company AUG 161985 SERIAL: NLS-85-288 Director of Nuclear Reactor Regulation Attention: Mr. D. B. Vassallo, Chief Operating Reactors Branch No. 2 Division of Licensing United States Nuclear Regulatory Commission Washington, DC 20555 BRUNSWICK STEAM ELECTRIC PLANT, UNIT NO.1 DOCKET NOS, 50-325 & 50-324/ LICENSE NOS. DPR-71 & DPR-62 IGSCC INSPECTION RESULTS

Dear Mr. Vassallo:

By letter dated February 26,1985, Carolina Power & Light Company (CP&L) apprised your staff of the Company's plans for performing mitigative actions and inspections for IGSCC on Brunswick Unit I during the 1985 refueling outage. These mitigative actions and inspections are nearing completion. This letter contains descriptions of: 1) the Induction Heating Stress improvement (IHSI) that has been performed on Recirculation System welds; 2) the Reactor Water Cleanup (RWCU) System piping replacement program; 3) the IGSCC inspection program, including post-lHSI UT inspection results; and

4) the weld-overlay repairs performed during the current refueling outage. A summary of the susceptible weld population describing mitigative actions applied, indications detected, and repairs is included as Table 1. In addition, this letter includes the basis for continued operation of Unit i until the next refueling outage, presently scheduled to begin in May 1987.

Mitigative Actions Induction Heating Stress Improvement (IHSI) was performed on 79 recirculation system weld joints as indicated on Table 1. The IHSI was performed by IHI, Inc., of Yokohama, Japan, in accordance with IHI Procedures. IHSI is not specifically addressed by codes, standards, or regulations. The time-temperature recordings were made in accordance with ASME Boiler and Pressure Vessel Code,Section III, Division 1, NB-4622.2, and capacitive discharge welding requirements for thermocouple settings were made in accordance with NB-4311.2 and NB-4311.3.

The entire Class 1,6-inch RWCU System (suction) piping was replaced from the RHR System tie-in to the outboard primary containment isolation valve,1-G31-F004. The piping was replaced with nuclear grade stainless steel. The RWCU primary containment penetration X-14 (suction side) was modified to eliminate the inaccessible weld inherent with the original flued head penetration design at Brunswick.

8508260144 850816 PDR ADOCK 05000324 G PDR 411 Fayettevine Street

  • P. O. Box is51
  • Raleigh, N C. 2)602

..c. \

, Mrc D. B. Vassello NLS-85-238, Page 2 Inspection Program UT examinations were performed by General Electric Company (GE). The IGSCC UT examinations performed during the March 1985 refueling outage are divided into the following categories:

1. Overlays made prior to October 1984
2. Reexamination of I-B32-RECIRC-28"-B-12
3. IE _ Notice 84-41 inconel butter welds
4. Welds subjected to Induction Heating Stress Improvement (IHSI)

The UT personnel were qualified in accordance with Generic Letter 84-11. Examination teams worked both in " master / slave" arrangement and in independent inspection teams.

The master / slave examinations were directed with the master located outside the drywell and the slave performing the actual scanning by communication with the master via headsets. Both slave and master were provided with duplicate oscilloscope displays.

IGSCC indications were plotted using weld-crown profiles, thickness readings, and radiographs.

The sizing of IGSCC indications was performed by EPRI-qualified personnel using 2.25 to 5 MHz, broadband, highly-damped shear, and refracted-longitudinal transducers. The sizing methods used were those taught at EPRI and included; Satellite Pulse Observation Technique (SPOT), Pulse Arrival Time Technique (PATT), dB drop method, and 70-degree creeping wave technique.

Forty-one welds were examined (approximately a 40-percent sample) using the automated GE SMART UT System to determine the correlation between manually and automatically accumulated data. Excellent correlation of results was obtained between manual and automated detection of circumferential IGSCC. The SMART UT System was superior in detection of short-axial indications.

The overlays made prior to October 1984 will be examined by manual and automated techniques developed by EPRI as outlined in the interim report dated April 1985, Examination of Weld-Overlayed Repairs. The inspection incorporates a 0-degree, 2.25 MHz scan for bond integrity and the use of 2.25 to 4 MHz refracted longitudinal 60-degree and 45-degree transducers for the overlay and base material. The overlayed welds to be inspected are listed in Table 2.

Weld 1-B32-RECIRC-28"-B-12 was reexamined, reevaluated, and determined to be free of IGSCC. Results of the November 1984 examination indicated that the weld had a 2.5-inch,10 percent through-wall circumferential indication. Recent examinations by several GE UT, Level III examiners have determined that the UT indications are caused by the geometry of the internal surface. This has been confirmed by a second-party inspection performed by Lambert, MacGill, and Thomas.

Examinations of inconel butter welds, as recommended in IE Notice 84-41, were performed using a 0-degree longitudinal,45-degree shear 2.25 MHz transducer. The welds in_spected are listed in Table 3. The only indications identified were those caused by the interface of the inconel buttering to carbon steel which were observed during the examination from the carbon-steel side. Three of the butter welds were also ewmined by EPRI in a research and development ef fort. The examinations were performed using various refracted longitudinal transducers and state-of-the-art techniques. The examinations all resulted in findings consistent wth those identified by CP&L.

Mr. D. B. Vassello NLS-85-288, Page 3 Seventy-nine welds that were subjected to the IHSI process were examined in accordance with the guidance provided in Generic Letter 84-11. The inspections were performed with a 2.25 MHz, single-element,45-degree, shear-wave tranducer using 1/2 "V" and 1-1/2 "V" examinations to ensure complete coverage. Scanning was performed in six directions (where geometry permitted)-two perpendicular, two parallel, and four tangential--with the search unit oscillated t 30 degrees. A scanning overlap of 50 percent was used in lieu of the ASME code-required 10 percent at a minimum sensitivity of 6 dB above calibration. Calibration was established from calibration holes only, which provides higher sensitivity than calibration notches. Post-IHSI IGSCC indications are included in Table 1. It should be noted that the pin-hole leak in Weld 1-B32-RECIRC-BRK2 was not detected ~ ultrasonically.

Disposition of Indications Twenty-three weld joints were found to contain IGSCC indications. Twenty-two of these joints were weld-overlay repaired. The overlay repairs were designed based on the indications' measured length and assuming the indications were through-wall. This design adequately satisfies the requirements of Article IWB-3640, ASME Code Section XI. A flawed piped analysis for the remaining weld joint (1-B32-RECIRC-28-A8) showed it will remain structurally sound until the next refueling outage. The design and installation of the overlay repairs were performed in accordance with Generic Letter 84-11.

Summary of Susceptible Weld Population The remaining susceptible weld population at Brunswick Unit No. I consis_ts of 110 welds. Mitigative actions taken, indications detected, and repairs performed on the remaining susceptible weld population are summarized in Table 1. IHSI has been applied to 79 of the 110 susceptible welds. Of the remaining 31 susceptible welds, l0 have weld-overlay repairs and 11 are solution annealed. Ninety-one percent of the susceptible weld population of Brunswick Unit No. l'have had IHSI, solution annealing, or weld-overlay repair performed as mitigative measures. Of 32 weld-overlay repairs on Brunswick Unit No.1,19 are on axial or pinhole indications only; the remaining 13 are on

~

c ircumferential indications.

Compensatory Actions The following special surveillance measures have been implemented at the Brunswick Plant:

~

1. As required by the Technical Specifications, plant shutdown shall be initiated for inspection and corrective action shall be taken when any leakage .

detection system indicates, within any period of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, an increase in the rate of unidentified leakage in excess of 2 gpm. For sump level monitoring systems with fixed-measurement interval method, the level shall be monitored at 4-hour intervals or less.

2. At least one of the leakage measurement instruments associated with each sump shall be operable, and the outage time for inoperable instruments shall be limited to 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />. Otherwise, an orderly shutdown will be immediately initiated.
3. A visual examination for leakage of the reactor coolant piping shall be performed during each plant outage in which the containment is deinerted provided that such an inspection has not been made in the previous 92 days.

Mr. D. B. Vassello NLS-85-288,' Page 4 provided that such an inspection has not been made in the previous 92 days.

The examination shall be performed consistent with the requirements of IWA-3241 and IWA-5242 of the 1980 Edition of Section XI of the ASME Boiler and Pressure Vessel Code. The system boundary subject to this examination shall contain the susceptible welds inside the primary containment.

These special surveillance measures are consistent with those given in Attachment I to Generic Letter 84-11 and CP&L's ALARA Program.

Conclusion CP&L has completed IHS1 on 79 susceptible weld joints and has replaced the 6-inch, Class l, Reactor Water Cleanup System piping. The Core Spray and Residual Heat Removal System piping is carbon steel. Mitigative techniques have been used on 91 percent of the susceptible weld population of Unit 1. These techniques include; IHSI, solution annealing, and weld-overlay repair.

UT examinations of inconel butter welds and welds subjected to IHS! are complete.

Preparations for UT examinations of weld-overlay repairs made prior to October 1984 are in progress. For those welds found to contain IGSCC indications, a conservative analysis has been performed to determine appropriate corrective action. Scheduled repairs have been completed on affected welds, and an analysis of the one remaining weld with IGSCC shows that it will remain structurally sound until the next planned refueling outage. In addition, existing stringent leak detection surveillance measures will remain in effect at Brunswick. Since (1) 91 percent of the susceptible weld population of Unit No. I have been mitigated, (2) comprehensive inspections have been performed on susceptible piping,(3) conservative repairs and analyses weie performed on welds containing IGSCC indications, and (4) enhanced surveillance requirements for drywell leakage detection will remain in ef fect, CP&L believes that start-up and continued operation of Brunswick Unit No. I until the next refueling outage (presently scheduled for.May 1987) is justified and will not adversely affect the health and safety of the public.

Results of the remaining overlay inspections and the design report on weld-overlay repairs made during the current outage will be submitted within 30 days af ter unit start-up. An inspection plan for the next refueling outage will be submitted 30 days prior to the start of that outage. Should you have any questions regarding this submittal, please contact Mr. S. R. Zimmerman at (919) 836-6242.

Yours_very truly,'

A. B. Cutter - Vice resident Nuclear Engineerirg & Licensing MAT /rtj (1831 MAT)

Enclosures cc: Mr. W. H. Rutand (NRC-BNP)

Dr. J. Nelson Grace (NRC-RII)

Mr. M. Grotenhuis (NRC) 1

1 a

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-TABLE 1 -

SUMMARY

OF SUSCEPTIBLE WELD POPULATION.

d BRUNSWICK UNIT 1 i

SOLUTION

t. SUSCEPTIBLE ANNEAL Y/N IHS1 Y/N ORIENTATION INDICATIONS LENGTH DEPTH WELD OVERLAY REPAIR DATE INSTALLED DESIGN NOTES

=

WELD JOINT 4" B32 A-1 N N None N/A N/A N/A N/A i

4" B32 A-10 N N Pinhole 0.06" 100% TW Nov '84 S 4" B32 B-1 N N None N/A N/A N/A N/A 4" B32 B-10 N N None N/A N/A N/A N/A d

4" C31 2 N None N/A N/A N/A N/A

j. N

! 4" C31 3 N N None N/A N/A N/A N/A

}

12" B32 AR-A-1 N Y None N/A N/A N/A N/A

} ,

12" B32 AR-A-2 N Y A O.3"

  • Ma r ' 85 L Pinhole leaks at this welc A O.3"
  • A O.4"
  • 12" B32 AR-A-3 N Y A O.3"
  • Ma r ' 85 S

! A O.75"

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. C 1.75" -35% TW i

j 12" Bj2 AR-A-4 N N C 1.6" 19% TW Nov '84 S (12" 332 AR-B-1 Y None N/A N/A N/A N/A

) N ,

-12" B32 AR-B-2 N N C 2.0" 20% TW Nov '84 S l i

I 12" B32 AR-B-3 N Y A O.25"

  • Ma r ' 85 L l A O.5" * .

I 12" B32 AR-B-4 N N~ C 1.0" 45% TW 'Nov '84 S 12" B32 AR-C-1 N Y None N/A N/A N/A N/A i

l 12" B32 AR C-2 N Y A O.5"

  • Ma r ' 85 S I A O.63" * ,

t i A O.75"

  • A O.63"
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TABLE 2 WELD OVERLAYS TO BE INSPECTED DURING MARCH 1985 0UTAGE 1-B32-12"-AR-E2 Riser Pipe to Elbow 1-B32-12"-BR-H4 Riser Pipe to Safe-end Extension 1-B32-28"-A-15 Discharge Elbow to Piping 1-B32-28"-A-14 Discharge Valve to Elbow 1-B32-28"-B-8 Valve to Elbow l

l 4

MSC/85-0184

TABIE 3 INCONEL BITITER WELDS INSPECTED DURING MARCH 1985 OUTAGE

  • 1-B32-RECIRC-28"-B-1 Nozzle to Safe-end Inconel Butter
  • 1-B32-RECIRC-12"-AR-A-6 Nozzle to Safe-end Inconel Butter
  • 1-B32-RECIRC-12"-AR-B-6 Nozzle to Safe-end Inconel Butter 1-B32-RECIRC-12"-AR-C-6 Nozzle to Safe-end Inconel Butter 1-B32-RECIRC-12"-AR-D-6 Nozzle to Safe-end Inconel Butter 1-B32-RECIRC-12"-BR-F-6 Nozzle to Safe-end Inconel Butter 1-B32-RECIRC-12"-BR-G-6 Nozzle to Safe-end Inconel Butter 1-B32-RECIRC-12"-BR-H-6 Nozzle to Safe-end Inconel Butter 1-B32-RECIRC-12"-BR-K-6 Nozzle to Safe-end Inconel Butter 1-B11-JPI-4"-N8B Nozzle to Safe-end Inconel Butter
  • Welds additionally inspected by EPRI.

e MSC/85-0184 i

.

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