ML20197B713

Forwards Info Re IGSCC Insp Program,For Reload 7/Cycle 8 Refueling Outage,Per 850524 Request.Based on Comprehensive Review of IGSCC Insp Data,Welds Categorized in Accordance W/ Guidance in Draft Rev 2 to NUREG-0313

ML20197B713
Person / Time
Site:	FitzPatrick
Issue date:	10/28/1986
From:	Brons J POWER AUTHORITY OF THE STATE OF NEW YORK (NEW YORK
To:	Muller D Office of Nuclear Reactor Regulation
References
RTR-NUREG-0313, RTR-NUREG-313 JPN-86-49, NUDOCS 8610300385
Download: ML20197B713 (17)

Text

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123 Mrn stret White Plains. New York 10601 914 681 6240

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1. > NewYorkPower 1# Authority 2"CC"eEN$"'

October 28, 1986 JPN-86-49 Director of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Attention: Mr. Daniel R. Muller, Director BWR Project Directorate No. 2 Division of BWR Licensing

Subject:

James A. FitzPatrick Nuclear Power Plant Docket No. 50-333 Intergranular Stress Corrosion Cracking Inspection Plan for the Reload 7/ Cycle 8 Refuel Outace

Reference:

1. NRC letter, D. B. Vassallo to J. P. Bayne, dated May 24, 1985, requested inspection plans.

Dear Mr. Muller:

Reference 1 requested that the Authority provide plans for piping inspection and/or modification which will be completed during the next refueling outage. This letter is the Authority's response to that request.

The Authority is engaged in an aggressive program of detection and mitigation of Intergranular Stress Corrosion Cracking (IGSCC) which includes comprehensive inspections of susceptible welds. It also includes induction heat stress improvement (IHSI) of most of the recirculation system, planned selective replacement or removal of piping, and hydrogen water chemistry (water chemistry upgrade, hydrogen addition system, ,

and crack arrest verification (CAV) system.)

Since the last submittal to the Nuclear Regulatory Commission (NRC), the Authority has been involved in a comprehensive review of all the IGSCC inspection data for the FitzPatrick plant. Based on this review, the welds at the i FitzPatrick plant have been categorized in accordance with the '

guidance in Draft NUREG-0313 Revision 2. The weld summary computer printout is shown in Attachment 1. This summary supersedes and replaces summaries previously provided to the ob!

8610300385 861028 PDR ADOCK 05000333

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NRC. The Authority is also developing an updated inspection history summary. This summary is scheduled to be completed six weeks following the end of the Reload 7/ Cycle 8 refuel outage, currently planned to begin in January 1987.

As part of the IGSCC program, IHSI was applied to 98 welds I

in the Reactor Water Recirculation and Residual Heat Removal (RHR) Systems during two maintenance outages in 1984. The

! Authority plans to take credit for these inspections as part of

the IGSCC program. In most cases, an ultrasonic examination was performed both before and after the IHSI application. Qualified personnel from EBASCO Services Incorporated, the New York Power

, Authority, and Universal Testing Laboratories /Kraftwerk Union performed the required ultrasonic examinations. Personnel and i procedures were qualified in accordance with Inspection and Enforcement Bulletin 83-02. The total radiation exposure to personnel from these two outages was 441 rem. Of this total, 62 rem was received by inspection personnel. It should be noted that according to Draft NUREG 0313, these inspections would not be valid, since they were not performed in accordance with the upgraded 1985 Electric Power Research Institute (EPRI) program.

If these inspections are not accepted, the significant radiation exposure incurred would have to be repeated.

During the upcoming Reload 7/ Cycle 8 refueling outage i

(scheduled to begin in January 1987), the Authority has scheduled removal or replacement of 27 IGSCC susceptible welds.

This includes removal and capping of the Reactor Water Recirculation System bypass lines and the replacement of the stainless steel portions of the RHR and Reactor Water Cleanup (RWCU) suction piping with carbon steel. This will reduce the number of stainless steel welds within the scope of Draft NUREG 0313 Revision 2 requirements from 173 to 146. The Authority also plans to implement a stress improvement method on the only two welds in the Reactor Water Recirculation System which have not been treated with a stress improvement process. Six welds in the RHR system which are not intpectable by ultrasonic means i

will be inspected using the portable linear accelerator system known as MINAC.

Another facet of the FitzPatrick IGSCC program is water chemistry upgrade. Improved water chemistry has been found to decrease susceptibility to IGSCC. During the last two fuel cycles, the FitzPatrick plant has operated with excellent water quality. In addition, the Authority is in the process of implementing the BWR Chemistry Guidelines which were developed by the Boiling Water Reactors Owners Group for IGSCC in

, conjunction with EPRI. As recommended in these guidelines, a chemistry data management system will be installed to monitor plant water chemistry.

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In addition to the above, the Authority is installing hydrogen addition and CAV Systems. The CAV system consists of two autoclaves. One will be used to monitor the electrochemical potential (ECP). The other will maintain three tensile specimens representative of reactor materials under load. A data acquisition system is designed to continuously monitor the i

reactor water conductivity, dissolved oxygen, ECP, and crack growth rates. Since the CAV system will be operational during reactor operation with both normal water chemistry and with hydrogen water chemistry, differences between crack growth rates in the two environments will be observed.

Attachments 2 and 3 discuss alternate inspection programs as detailed in the weld summary total for Category C and G welds.

The Authority considers that the program described in this letter is sufficient to monitor IGSCC at the FitzPatrick Plant.

Should you or your staff have any questions regarding this response, please contact Mr. J..A. Gray, Jr. of my staff.

Very truly yours, sg Jo n C. Brons Senior Vice President Nuclear Generation Attachments

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cc: Office of the Resident Inspector U.S. Nuclear Regulatory Commission Post Office Box 136 Lycoming, New York 13093 i

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ATTACHMENT I TO JPN-86-49 WELD

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1 ATTACHMENT II TO JPN-86-49 IGSCC INSPECTION PROGRAM i

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l JAMES A. FITZPATRICK NUCLEAR POWER PLANT DOCKET NO. 50-333

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- - - - - _ , . _ ~ . _ _ - _ _ . - _ _ _ - _ _ . . _ . . _ . . , - - _ , _ . _ _ _ _ _ - _ . . _ _ , . , - . . , _ _ _ _ _ - _ _ . . _ _ _ - - - _ _ _ _ _ _ . . . _ _ . , _ _ . - _ - - .

The following table addresses the total number of welds that are within the scope of NUREG-0313 Revision 2 guidance. This comparison between NUREG-0313 Rev. 2 requirements and Authority plans is provided for information only, since the NUREG is only in draft form at this time. Welds scheduled for replacement (27 total) have not been included in the totals. The inspection schedule is assumed to begin at the start of the Reload 7/ Cycle 8 refueling outage. All Category E welds will be inspected during the next refueling outage. Category E includes those welds which have IGSCC indications and were either overlayed or treated with IHSI.

WELD

SUMMARY

TOTAL CATEGORY # OF WELDS (%) NUREG 0313 # OF WELDS SCHEDULED FOR INSPECTION DURING RELOAD 7/ CYCLE 8 A (Resistant 17 25% in 10 yrs 1 Materials)

B (Nonresistant NA - -

Materials-SI within 2 yrs of operation)

C (Nonresistant 78 100% in 7 yrs 11 Materials- (5 refuel outages)

SI after 2 yrs of operation)

D (Nonresistant 10 100% in 7 yrs 2 Materials-No (5 refuel outages)

SI)

E (Cracked- 9 100% in next outage 9 Overlayed or SI)

F (Cracked- N/A - -

Inadequate or No Repair)

G (Nonresistant-Not Inspected) 32 Next Outage 19 Reference Att. #3 Total 146 42 1

All inspection personnel will be qualified in accordance with the Non-Destructive Examination (NDE) coordination plan agreed upon by the NRC, EPRI, and the BWROG as upgraded in September 1985. Personnel inspecting weld overlays will have attended the weld overlay workshop at the EPRI NDE Center. The sample expansion program to be used if IGSCC indications are found in the sample being inspected, is the following:

1. Welds will be selected from the same or a more susceptible category and will be equal in number to the initial sample examined.

2. Welds selected will be from the same system and of a similar pipe size, construction history, weld detail, weld parameters, etc.

3. If any IGSCC indications are found in the second sample, all welds within that system, pipe size and category will be examined.

As detailed in the cover letter, the Authority performed Inductive Heating Stress Improvement (IHSI) on 98 welds of the Reactor Water Recirculation and Residual Heat Removal Systems during two outages in 1984. For 88 of the welds, an ultrasonic examination was performed both before and after IHSI. The remaining ten welds were examined only after the IHSI treatment. The inspections were performed by EBASCO Services and Universal Testing Labs /Kraftwerk Union (UTL/KWU) . Personnel and procedures were qualified in accordance with Inspection and Enforcement Bulletin 83-02. Radiation exposure to inspection personnel was approximately 62 rem. Total personnel radiation exposure was 441 rem.

During the 1985 refueling outage, 40 welds were inspected by ultrasonic examination. Personnel and procedures were qualified in accordance with Inspection and Enforcement Bulletin 83-02.

Of these 40 welds, 14 that had received the IHSI process were examined by EBASCO inspectors. The UTL/KWU inspections, using automated P-SCAN-ultrasonic testing equipment, were performed on 10 of the 14 welds that EBASCO had inspected. Two of the welds were manually examined, because access did not allow the installation of the automatic manipulator. One weld, 22-02-2-22 was confirmed to have intergranular stress corrosion cracking, and a weld overlay was applied. The history of this weld is described in a Authority letter to the NRC JPN-85-42, dated May j 9, 1985.

Because of the near term implementation of hydrogen water chemistry, the inspection schedule will be lengthened by a factor of two for Category B, C and D welds. All Category E j

welds will be inspected during the upcoming refueling outage.

Based on the planned implementation of a hydrogen injection system, the radiation exposure to inspection personnel as j detailed above, and the previous inspections, the Authority i plans to implement the following schedule for Category C welds.

j The inspection program begins at the next scheduled refueling

! outage (1/15/87).

1. OF WELDS (%)NUREG REQUIRED (%) PROPOSED PROGRAM 78 100% IN 7 YEARS 100% IN 10 YEARS (5 refueling outages) (7 refueling outages) 16 welds in Reload 7/ Cycle 8 Refuel 11 welds in Reload 7/

Cycle 8 Refuel Outage

refuel outage)

During the 1987 refueling outage, the Authority proposes to inspect 11 welds that have previously undergone IHSI.

I

ATTACHMENT III TO JPN-86-49 EXCEPTIONS TO INSPECTION PROGRAM NEW YORK POWER AUTHORITY JAMES A. FITZPATRICK NUCLEAR POWER PIR;T DOCKET NO. 50-333 DPR-59

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Category G, comprising 32 welds, includes 17 bimetallic, safe end to nozzle welds. These 17 welds are the 12 Reactor Water Recirculation welds, two Core Spray welds, one Control Rod Drive (CRD) cap weld and two Jet Pump Instrument nozzle welds.

The safe ends were fabricated to a low carbon specification

(<0.025% carbon content) and are thus considered 304L. These welds contain Inconel 182 weld metal. The Authority will inspect eight of these 17 welds during the upcoming refueling outage. This decision was based on the low incidence of IGSCC at the FitzPatrick Plant to date and high radiation exposure to inspection personnel and craft support personnel that would be received if all welds were inspected. It is estimated that approximately 2 person-rem is required for craft support and inspection of each weld. Additionally, the implementation of a hydrogen injection system will protect these welds from IGSCC.

The CRD cap is estimated to require 0.75 rem of exposure to personnel for its inspection. Since it is a new Inconel 182 weld (installed and inspected in June, 1983, the Authority decided not to inspect the weld at this time. The nine welds not inspected will be inspected during the next scheduled refueling outage.

The jet pump nozzle assemblies contain eight Category G welds. Four welds will be inspected during the upcoming refueling outage. Based on past radiation surveys, the Jet Pump Instrument Nozzle has a general area dose rate of 1 R/h with some contact area levels in excess of 4 R/h. If only 50% of the welds are inspected, the radiation exposure saved during the upcoming outage is estimated to be approximately 6 person-rem.

The remaining 4 welds will be inspected during the 1988 refueling outage.

The remaining seven Category G welds will be inspected. This includes six RHR welds and one Core Spray weld.

The total number of inspections for the upcoming refueling outage for Category G welds is 19. This total is obtained by delaying until the 1988 refuel outage a total of 13 welds (9 bimetallic welds and 4 jet pump nozzle assembly welds) out of the 32 Category'G welds.

.