ML20207F026
| ML20207F026 | |
| Person / Time | |
|---|---|
| Site: | Calvert Cliffs |
| Issue date: | 06/01/1999 |
| From: | BALTIMORE GAS & ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML20207F023 | List: |
| References | |
| PROC-990601, NUDOCS 9906080011 | |
| Download: ML20207F026 (88) | |
Text
ATTACHMENT (1)
THIRD INTERVAL INSERVICE INSPECTION PROGRAM PLAN FOR CALVERT CLIFFS NUCLEAR POWER PLANT UNITS 1 AND 2
[$hbbk[5$037 Baltimore Gas & Electric Company Docket Nos. 50-317 and 50-318 June 1,1999
THIRD INTERVAL INSERVICE INSPECTION PROGRAM PLAN FOR CALVERT CLIFFS NUCLEAR POWER PLANT UNITS 1 AND 2 i
BALTIMORE GAS AND ELECTRIC
h CCNPP Units 1 & 2 Third IntervalISI Plan
. TABLE OF CONTENTS SECTION DESCRIPTION PAGE Revision Summary Sheet iii 1.0 Introduction and Plan Description 1-1 1.1 Overview '
1-1 1.2 Basis ofInservice inspection Plan 1-1 l
1.3 System Classifications-1-3 1.4 Augmented Inservice Inspection Requirements 1-4 2.0 Inservice Inspection Program Drawings 2-1 2.1 Piping Classifications 2-1 2.2 Piping and Instrumentation Diagrams 2-1 l
. 3.0 Inservice Inspection Summary Tables 3-1 3.1 ASME Section XI Inservice Inspections 3-1 4.0 Alternative Requirements to ASME Section XI 4-1 4.1 Adoption of Code Cases 4-1 4.2 Use of Subsequent Editions of ASME Section XI 4-4 4.3 Inservice Inspection Requests for Alternatives and 4-4 l
ReliefRequests 5.0 Request for Alternatives and Relief Request Index 5-1 l
6.0 Request for Alternatives and Relief Requests 6-1 l
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CCNPP Units 1 & 2 Third IntervalISI Plan REVISION
SUMMARY
SHEET SECTION EFFECTIVE PAGE(S)
REVISION DATE 1.0 1-1 0
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CCNPP Units 1 & 2 Third IntervalISI Plan SECTION
1.0 INTRODUCTION
AND PLAN DESCRitTION 1.1 Overview 1.1.1 - This Inservice Inspection (ISI) Plan outlines the requirements for the inspection of Class 1,2, and 3 pmssure retaining components and their supports at Calvert Cliffs Nuclear Power Plant (CCNPP), Units 1 and 2.
1.1.2 This ISI Plan will be effective from July 1,1999, through and including June 30, 2008 for Unit 1, and June 30,2009 for Unit 2, which represents the third interval for CCNPP.
1.1.3 The key featums of this ISI Plan are the Introduction and Plan Description, List of Piping and Instrument Drawings, Summary Tables, Requests for Alternatives and Relief Requests. The details of the ISI Program referenced in this ISI Plan are contained in documents that are available at CCNPP. These documents include, but am not limited to, piping and instrument diagrams, piping isometric drawings, a database listing of each weld, valve, suppon, etc., in the ISI Program, and documents supponing implementation of the ISI Program.
1.2 Basis ofInservice Inspection Plan 1.2.1 This ISI Plan was developed in accordance with the requirements delineated in the August 15,1997, issue of 10CFR50.55a. CCNPP perfonned their reactor pressure vessel examinations in accordance with 10CFR50.55a(g)(6)(ii)(A) during the second inspection interval.
-1.2.2 This ISI Plan wr;. developed in accordance with the 1998 Edition of the American Sonety of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, Secthm XI, Subsections IWA, IWB, IWC, IWD, and IWF, for Inspection Prograrr B. During the third inspection interval, CCNPP will implement the i
criteria of the 1998 Edition of Section XI, except for Subsections IWE and IWL, and Appendix VIII. For these items, the following criteria will be implemented:
i 1.2.2.1 For Class MC and metallic liners of Class CC components, the mquirements ofIWE,1992 Edition with 1992 Addenda will be used.
j 1.2.2.2 For Class CC concrete components, the requirements of IWL,1992 Edition with 1992 Addenda will be used.
1.2.2.3 For ultrasonic examination requirements, the 1989 Edition will be used.
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CCNPP Units 1 & 2 Third Interval ISI Plan Accordingly, this ISI Plan provides the details necessary for performing the l
inservice inspection of the Class 1,2, and 3 components and their supports at l
Calvert Cliffs, Units I and 2.
'1.2.3 The following ASME Section XI,1998 Edition Subsections, Articles, or L
Paragraphs are not included or addressed in this ISI Plan.
I l
l 1.2.3.1 The inspection of containment stmetures and liners per Subsections l
l IWE and IWL is not included in this ISI Plan. The rules of Subsections IWE and IWL as invoked by 10CFR50 are included in a separate Program Plan.
1.2.3.2 The snubber inservice testing requirements of Article IWF-5000 are not addressed in this ISI Plan. The extent, frequency, and acceptance standards for snubber assembly testing and inspection will be in accordance with CCNPP Technical Requirement Manual, Section 15.7.2.
1.2.3.3 The steam generator tubing examination requirements of Table IWB-2500-1, Examination Category B-Q, are not addressed in this ISI Plan.
l As allowed by ASME Section XI, IWB-2413, the extent, frequency, and l-acceptance standards for steam generator tubing inspection and testing will be in accordance with CCNPP Technical Specification Section 5.5.9.
l 1.2.4 Alternative requirements to ASME Section XI are set forth in Section 4.0 of this ISI Plan. Alternative requirements are in accordance with 10CFR50.55a and ASME Section XI.
1.2.5 With the exception of examinations that may be deferred until the end of the inspection interval as specified in Table IWB-2500-1, inservice inspections shall be performed in accordance with Inspection Program B as outlined in IWA-2432, l
IWB-2412,IWC-2412,IWD-2412, and IWF-2410 of ASME Section XI. The l
inspection schedule for the third interval is divided into three periods such that approximately one third of the inspections will be completed every period.
Successive inspections shall be in accordance with IWB-2420, IWC-2420, IWD-2420, and IWF-2420. Deviations to inspection schedules may occur, but, in that l
event, compliance with related Code requirements shall be maintained.
1 1;2.6 The commercial service dates for CCNPP, Units 1 and 2, were May 8,1975, and April 1,1977, respectively. The second inspection interval for CCNPP, Units 1 and 2 began on April 1,1987 and was scheduled to conclude on April 1,1997.
The second inspection interval was extended from April 1,1997 to June 30,1998
' for Unit I and June 30,1999 for Unit 2, as allowed by a Nuclear Regulatory Commission letter dated May 2,1997, entitled " Notification of Extension of the Inservice Inspection and Inservice Test Program - Second Ten-Year Interval l-2 Revision 0 r-
rn 37
- 1.,
.I' CCNPP Units l'& 2 Third IntervalISI Plan Calven Cliffs Nuclear Power Plant, Units 1 and 2 (TAC Nos. M98251 and M98252)". The second inspection interval for Unit I was funher extended from June.30,1998 to June 30,1999, to coincide with Unit 2, as allowed by a Nuclear Regulatory Commission letter dated August 19,1998, entitled " Request for l-Extension of the Second Ten-Year Inservice Interval - Calvert Cliffs Nuclear i-
_ Power Plant, Unit No.1 (TAC No. MA 1680)".
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1.3 System Classifications 1.3.1 At the time CCNPP was constructed, the ASME Boiler and Pressure Vessel Code only addressed nuclear vessels and associated piping up to and including
' the first isolation valve. Themfore, the piping co&s of record were USAS B31.7,1%9 Edition for nuclear piping, and USAS B31.1.0 - 1%7 Edition for non-nuclear piping. Consequently, CCNPP piping is not designated by ASME Section III Code Class 1,2 and 3 systems.
l 1.3.2 The quality group classification system for water, steam, and radioactive waste containing components important to the safety of water-cooled nuclear power plants is' established by NRC Regulatory Guide 1.26, in conjunction with 10CFR50.55a. Regulatory G"Me 1.26," Quality Group Classification and Standards", defines the WW) t. oup Classification System consisting of four Quality Groups, A through D. M.e definition of Quality Group A is provided by 10CFR50.2 under " Reactor Coolant Pressure Boundary". The definitions of l
Groups B, C, and D (Class 2, Class 3 and ISI non-classed, respectively) are provided by Regulatory Guide 1.26.
l 1.3.3 Piping and components subject to inservice inspection are shown on the Piping and Instrumentation Diagrams listed in Section 2.2 of this ISI Plan. Pursuant to 10CFR50.55a, the inservice inspection requirements of ASME Section XI have been assigned to these piping lines and components within the constraints of l
existing plant design.
l 1.3.4 Piping, components and supports classified as exempt from examination requirements are defined in ASME Section XI, paragraphs IWB-1220,IWC-1220,IWD-1220 and IWF-1230.-In accordance with ASME Section XI, paragraph IWB-1220(a), piping may be exempted from the volumetric and surface examinations of ASME Section XI, provided that they are connected to the reactor coolant boundary and are of such size and shape that upon a i
j postulated rupture, the resulting flow of coolant under normal operating conditions is within the make-up capacity of the plant.
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CCNPP Units 1 & 2 Third IntervalISI Plan 1.4 Auemented Inservice Inspection Reauirements Augmented inservice inspection requirements are those examinations that are specified by documents other than the ASME Section XI Code. Typically, these augmented examinations are at the request of the Nuclear Regulatory Comrnission through such
- mechanisms as Bulletins, Notices and Regulatory Guides. The augmented examinations addressed by the CCNPP ISI Program during the third inspection interval are as follows:
1.4.1 Ultrasonic examinations on the reactor pressure vessel shall be conducted in accordance with U.S. Nuclear Regulatory Commission Regulatory Guide 1.150, Rev.1, " Ultrasonic Testing of Reactor Vessel Welds During Preservice and Inservice Examinations".
1.4.2 Examinations on Main Steam and Feedwater piping outside containment shall be performed in accordance with the CCNPP UFSAR, Appendix 10A, and Technical Requirements Manual, Section 15.4.3.
1.4.3 Surface and volumetric examinations of reactor coolant pump flywheels shall be conducted in accordance with Regulatory Guide 1.14, as stated in CCNPP Technical Specification 5.5.7.
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F CCNPP Units 1 & 2 Third IntervalISI Plan SECTION 2.0 INSERVICE INSPECTION PROGRAM DRAWINGS This section provides a listing of the various drawings applicable to the CCNPP ISI Program.
2.1 Pipine Classifications Piping classifications are as identified in CCNPP Specification M-601, " Piping Class Summary Sheets", Revision 43, dated December 1,1998.
2.2 Pipine and Instrumentation Diagrams Table 2.1 provides a listing of the Piping and Instrument Diagrams (P&lDs) that depict the piping subject to inservice inspection at CCNPP, Units I and 2.
TABLE 2.1 PIPING AND INSTRUMENTATION DIAGRAMS DRAWING SHEET TITLE NUMBER NUMBER 60712 i
Compressed Air: IA, PA 60712 2
Compressed Air: IA, PA 60712 3
Compressed Air:IA,PA 60712 4
Compressed Air:IA PA 60712 5
60712 6
Compressed Air:IA,PA 60712 7
Compressed Air: lA, PA 60714 i
Plant Fire Protection System 60714 2
Plant Fire Protection System 60714 3
Plant Fire Protection System 60714 4
Plant Fire Protection System 60714 5
Plant Fire Pmtection System 60714 6
Plant Fire Protection System 60714 7
Plant Fire Protection System 60716 na Spent Fuel Pool Cooling 60717 1
Demin Water, and Condensate Storage System 60717 2
Demin Water, and Condensate Storage System 60723 1
Ventilation Systems, Containment, Turbine Bldg.
60723 1
Ventilation Systems, Containment, Turbine Bldg.
60723 1
Ventilation Systems, Containment, Turbine Bldg.
l 60723 1
Ventilation Systems, Containment. Turbine Bldg.
60723 1
RCS and PASS Sampling Systems i
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CCNPP Units 1 & 2 Third Interval ISI Plan TABLE 2.1 j
PIPING AND INSTRUMENTATION DIAGRAMS (con't) i DRAWING SHEET TITLE NUMBER NUMBER 60723 2
RCS and PASS Sampling Systems 60723 3
RCS and PASS Sampling Systems 60726 na Nitrogen Generating and Blanketing System 60727 1
DG Cooling Water, Starting Air, Fuel, and Lube Oil 60727 2
DG Cooling Water, Starting Air, Fuel, and Lube Oil 60727 3
DG Cooling Water, Starting Air, Fuel, and Lube Oil 60728 1
Plant Heating System 60728 2
Plant Heating System 60728 3
Plant Heating System 60729 1
Reactor Coolant System, UI 60729 2
Reactor Coolant System, U1 62729 1
Reactor Coolant System, U2 62729 2
Reactor Coolant System U2 60730 1
Chemical and Volume Control System, UI 60730 2
Chemical and Volume Control System UI 60730 3
Chemical and Volume Control System UI 62730 1
Chemical and Volume Control System, U2 62730 2
Chemical and Volume Control System, U2 62730 3
Chemical and Volume Control System, U2 60731 1
Safety Injection and Containment Spray, U1 60731 2
Safety Injection and Containment Spray, UI 60731 3
Safety Injection and Containment Spray, UI 62731 1
Safety Injection and Containment Spray, U2 62731 2
Safety Injection and Containment Spray, U2 62731 3
Safety Injection and Containment Spray, U2 60733 1
Aux Bldg. Waste Processing 60733 2
Aux Bldg. Waste Processing 60733 3
Aux Bldg. Waste Processing 60733 4
Aux Bldg. Waste Processing 60734 1
Reactor Coolant Waste Processing 60734 2
Reactor Coolant Waste Processing 60734 3
Reactor Coolant Waste Processing 60734 4
Reactor Coolant Waste Processing 60734 5
Reactor Coolant Waste Processing 60735 1
Waste Gas and Waste Processing 60735 1
Waste Gas and Waste Processing 2-2 Revision 0
i CCNPP Units 1 & 2 Third Interval ISI Plan TABLE 2.1 P1 PING AND INSTRUMENTATION DIAGRAMS (con't)
DRAWING SHEET TITLE NUMBER NUMBER 60738 1
Steam Line Drains, UI 60740 2
Steam Line Drains, UI 62740 1
Steam Line Drains, U2 62740 2
Steam Line Drains, U2 62740 3
Steam Line Drains, U2 60741 1
Chemical Addition and Condenser Tube Bulleting 60741 2
Chemical Addition and Condenser Tube Bulleting 60741 3
Chemical Addition and CondenserTube Bulleting 60741 4
Chemical Addition and Condenser Tube Bulleting 60744 1
Gas Analyzing System 60744 2
Gas Analyzing System 60746 1
Plant Water and Service Air Systems 60746 2
Plant Water and Service Air Systems 60746 3
Plant Water and Service Air Systems 62749 na Steam Generator Blowdown Recovery System, U2 60761 na Steam Generator Blowdown Recovery System U1 60583 na Auxiliary Feedwater System, U1 62583 na Auxiliary Feedwater System. U2 1
62700 1
Main Steam and Reheat. U2 62700 2
Main Steam and Reheat. U2 62700 3
Main Steam and Reheat. U2 62700 4
Main Steam and Reheat, U2 60700 1
Main Steam and Reheat, UI 60700 2
Main Steam and Reheat. UI 60700 3
Main Steam and Reheat, UI 60700 4
Main Steam and Reheat, UI 60702 1
Condensate and Feedwater Systems, UI 60702 2
Condensate and Feedwater Systems, UI 60702 3
Condensate and Feedwater Systems, UI 60702 4
Condensate and Feedwater Systems, UI 62702 1
Condensate and Feedwater Systems U2 62702 2
Condensate and Feedwater Systems, U2 62702 3
Condensate and Feedwater Systems, U2 62702 4
Condensate and Feedwater Systems, U2 2-3 Revision 0 L
CCNPP Units 1 & 2 Third IntervalISI Plan TABLE 2.1 PIPING AND INSTRUMENTATION DIAGRAMS (con't)
DRAWING SHEET TITLE NUMBER NUMBER 60706 1
Service Water Cooling, U1 60706 2
Service Water Cooling, UI j
607 %
1 Service Water Cooling, U2 60706 2
Service Water Cooling, U2
-60706 3
Service Water Cooling, U2 60708 1
Cimulating Salt Water, UI 60708 2
Circulating Salt Water, UI 60708 3
Circulating Salt Water, UI 62708 1
Circulating Water Cooling System, U2 62708 2
Circulating Water Cooling System, U2 60710 1
Component Cooling System, UI 60710 2
Component Cooling System, U1 60710 3
Component Cooling System, U1 62710 1
Component Cooling System, U2 62710 2
Component Cooling System, U2 62710 3
Component Cooling System, U2 60711 na Containment Charcoal Filter Spray System UI 62711 na Containment Charcoal Filter Spray System U2 l
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f CCNPP Units 1 & 2 I
Third IntervalISI Plan l
SECTION 3.0 INSERVICE INSPECTION
SUMMARY
TABLES This section provides a summary listing of all items subject to inservice inspection during the Third Inspection Interval at CCNPP, Units 1 and 2.
3.1 ASME Section XI Insen ice Inspections The ASME Section XI Inservice Inspection Summary Tables 3.1 and 3.2, for Units 1 and 2, respectively, provide the following information:
}
3.1.1 Examination Category This column lists the examination category as identified in ASME Section XI, Tables IWB-2500-1, IWC-2500-1, IWD-2500-1, and IWF-2500-1. Only those l
examination categories applicable to CCNPP are identified.
3.1.2 Item Number and Description of Components Examined These columns list the item number and description as defined in ASME Section XI, Tables IWB-2500-1, IWC-2500-1, IWD-2500-1, and IWF-2500-1. Only those item numbers applicable to CCNPP are identified.
3.1.3 Number of Components This column lists the total population of components potentially subject to examination. The number of components actually examined during the inspection interval will be based upon the Code requirements for the subject item number (e.g.,7.5% of Examination Category C-F-1, Item Number C5.11 components will be examined during the inspection interval).
3.1.4 Examination Method The column lists the examination method (s) required by ASME Section XI, Tables IWB-2500-1, IWC-2500-1, IWD-2500-1, and IWF-2500-1.
3.1.5 Request Number This column provides a listing of applicable Requests for Alternatives or Relief j
Requests. If a request number is identified, see the corresponding Request for Alternative or Relief Request in Section 6.0.
3-1 Revision 0
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CCNPP Units 1 & 2 Third Interval ISI Plan SECTION 4.0 ALTERNATIVE REOUIREMENTS TO ASME SECTION XI:
1998 EDITION This section lists the alternative requirements to ASME Section XI,1998 Edition, being adopted for the Third Interval Inservice Inspection Program at CCNPP, Units I and 2. The alternative requirements presented are in accordance with ASME Section XI and 10CFR50.55a, as applicable.
4.1 Adoption of Code Cases This section addresses the adoption of Code Cases during the Third Inservice Inspection Interval at CCNPP, Units I and 2. Code Cases adopted for Inservice Inspection use during the Third Interval are listed in Tables 4.1 and 4.2 of this Inservice Inspection Plan. Code Cases for Repair / Replacement activities are also included in these tables, when applicable. In all cases, the use and adoption of Code Cases will be in accordance with ASME Section XI,IWA-2440 and 10CFR50.55a. Code Cases that have already been incorporated into ASME Section XI,1998 Edition, will be implemented via application of the Code. The methodology for adopting Code Cases is divided into the four categories clarified below.
4.1.1 Adoption of Code Cases Listed for Generic Use in Regulatory Guide 1.147 Code Cases that are listed for generic use in Regulatory Guide 1.147, Revision 11 and later, will be adopted for use during the Third Inservice Inspection Interval by listing them in Table 4.1 of this Inservice Inspection Plan. All conditions or limitations delineated in Regulatory Guide 1.147 for a particular Code Case will apply.
TABLE 4.1 LIST OF ADOPTED CODE CASES CODE REG. GUIDE DATE CASE TITLE 1.147 ADOPTED NUMBER REVISION N-460 Alternative Examination Coverage for 11 7/1/99 Class 1 and 2 Welds N-481 Alternative Examination Requhements for 11 7/1/99 Cast Austenitic Pump Casings 4-1 Revision 0
r CCNPP Units 1 & 2 Third IntervalISI Plan 4.1.2 Adoption of Code Cases Not Listed for Generic Use in Regulatory Guide 1.147 Adoption of Code Cases that have been approved by the Board of Nuclear Codes and Standards, but that have not been listed for generic use in Regulatory Guide 1.147, may be submitted in the form of a Request for Alternative in accordance with 10CFR50.55a(a)(3). Once approved, these Requests for Alternatives will be available for use at CCNPP, Units 1 and 2.
Table 4.2 lists those Code Cases that are not listed for generic use in Regulatory Guide 1.147. In addition to the requirements stated in the Code Cases, criteria may be stipulated in the Request for Alternative or may be agreed upon through subsequent correspondences with the NRC. BGE will implement these additional requirements as applicable.
TABLE 4.2 CODE CASES SUBMITTED THROUGH REQUESTS FOR ALTERNATIVES CODE CASE TITLE REQUEST NUMBER NUMBER N-307-2 Revised Ultrasonic Examination Volume for ISI-03 Class 1 Bolting, Table IWB-2500, Examination Category B-G-1, When the Examinations Are Conducted From the Center-Drilled Hole N-416-1 Alternative Pmssure Test Requirement for ISI-04 Welded Repairs or Installation of Replacement Items by Welding, Class 1,2 and 3 N-498-1 Alternative Rules for 10-Year System Hydrostatic ISI-05 Testing for Class 1,2, and 3 Systems I
N-532-1 Alternative Requirements to Repair and ISI-06 l
Replacement Documentation Requirements and Inservice Summary Report Preparation and Submission as Required by IWA-4000 and IWA-6000 N-533 Alternative Requirements for VT-2 Visual ISI-07 1
Examination of Class 1 Insulated Pressure-l Retaining Bolted Connections I
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Revision 0 i
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CCNPP Umts 1 & 2 Third Interval ISI Plan TABLE 4.2 CODE CASES SUBMITTED THROUGH REQUESTS FOR ALTERNATIVES (con't)
CODE CASE TITLE REQUEST NUMBER NUMBER N-555 Use of Section II, V, and IX Code Cases ISI-08 N-566 Corrective Action for 12akage Identified at ISI-09 Bolted Connections N-592 ASNT Central Cenification Program ISI-10 N-616 Alternative Requirements for VT-2 Visual ISI-l1 Examination of Class 1,2, and 3 Insulated Pressure-Retaining Bolted Connections 4.1.3 Adoption of Code Cases Listed for Generic Use in Regulatory Guide 1.147 But Subsequently Annulled by ASME Section XI Under certain circumstances,it may be necessary to adopt a Code Case that has been listed for generic use in Regulatory Guide 1.147, but subsequently annulled by ASME Section XI. Therefore, BGE endorses all revisions of Regulatory Guide 1.147 from Revision i1 up to and including the most recent revision.
Endorsement of these revisions of Regulatory Guide 1.147 does not commit BGE to all Code Cases listed therein, but rather allows for selection of a previously accepted Code Case. The purpose of this endorsement is to identify all Code Cases that could potentially be incorporated into this Inservice Inspection Plan in accordance with IWA-2441.
4.1.4 Adoption of Code Cases Issued Subsequent to Filing this Inservice Inspection Plan Code Cases issued by ASME Section XI subsequent to filing this Inservice Inspection Plan will be proposed for use in amendments to this Plan in accordance with ASME Section XI,IWA-2441(d).
4-3 Revision 0 j
CCNPP ' Units 1 & 2 Third Interval ISI Plan 4.2 Use of Subsequent Editions of ASME Section XI
)
In accordance with 10CFR50.55a(g)(3)(v), components, including supports, may meet
(
the requirements set forth in subsequent editions of Codes and Addenda, or portions thereof, which are incorporated by reference in 10CFR50.55a(b), subject to the limitations an6 modifications listed therein. This Section of the Inservice Inspection Plan provides for the documentation of alternative requirements from approved subsequent Code editions that may be adopted during the Third Inservice Inspection Interval. Should this occur, this Inservice Inspection Plan will be amended for adoption of subsequent Code rules at that time.
4.3 Inservice InSDection Requests for Alternatives and Relief Requests 4.3.1 Alternatives to examinations required by the Code may be authorized by NRC, as allowed by 10CFR50.55a (a)(3), provided that design, fabrication, installation, testing, and inspection performed in compliance with Codes and Section XI requirements would result in hardship without a compensating increase in the level of quality and safety, or provided that the proposed attemative examination j
will assure an acceptable level of quality and safety. Specific exceptions shall be documented in the form of a Request for Alternative and included in Section 6.0 of this inspection Plan.
4.3.2 - Section 6.0 of this Inspection Plan also includes Relief Requests written in accordance with 10CFR50.55a(g)(5) when specific ASME Section XI' I
requirements for inservice inspection are considered impractical. If examination requirements are determined to be impractical during the course of the interval, relief requests shall be submitted in accordance with 10CFR50.55a(g)(5).
4.3.3 Relief Requests for limited coverage examinations shall be submitted in accordance with 10CFR50.55a(g)(5)(iv) throughout the interval, as limitations are identified. Due to ongoing changes in nondestructive examination procedures, techniques and requirements, BGE considers that submitting Relief Requests for incomplete examinations when they are evaluated will provide a more accurate representation of the limitations.
4.3.4 For this Inspection Plan, the term " Request for Alternative" applies to those requests that are being submitted per 10CFR50.55a(a)(3)(i) or 10CFR50.55a(a)(3)(ii). These requests propose alternatives that provide an acceptable level of quality and safety, or address requirements that present a hardship without a compensating increase in the level of quality and safety. The term " Relief Request" will be reserved for those requests submitted per 10CFR50.55a(g)(5), for review per 10CFR50.55a(g)(6)(i). These requests address those examinations that are impractical to implement due to factors such as physical restrictions.
4-4 Revision 0
r 1
CCNPP Units 1 & 2 Third IntervalISI Plan l
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SECTION 5.0 REOUEST FOR ALTERNATIVES AND RELIEF REOUEST INDEX This section provides a summary listing and revision status of all Requests for Alternatives and Relief Requests related to the Third Interval Inservice Inspection Program at CCNPP, Units 1 8
and 2. The actual Requests for Alternatives and Relief Requests are provided in Section 6.0 of this ISI Plan.
1 TAHLE 5.1 INSERVICE INSPECTION REQUEST FOR ALTERNATIVES AND RELIEF REQUEST INDEX REQUEST PAGE(S)
REV.
DATE TOPIC NO.
ISI-01 6-2 to 0
7/1/99 Alternative Surface Examination Criteria 6-5 for Examination Category B-J Piping Welds Imated in the Reactor Vessel Annulus ISI-02 6-6 to 0
7/1/99 Alternative Surface Examination Criteria 6-8 for Control Rod Drive Housing Welds ISI-03 6-9 to 6-0 7/1/99 Alternative Examination Criteria for 10 Reactor Vessel Closure Studs and Reactor Coolant Pump Studs ISI-04 6-11 to 6-0 7/1/99 Alternative Pressure Test Requirement 14 for Welded Repairs or Installation of Replacement Items by Welding, Class 1, 2 and 3 ISI-05 6-15 to 6-0 7/1/99 Alternative Rules for 10-Year System 17 Hydrostatic Testing for Class 3 Systems ISI 06 6-18 to 6-0 7/1/99 Altemative Requirements to Repair and 20 Replacement Documentation Requirements and Inservice Summary Report Preparation and Submission as Required by IWA-4000 and IWA-6000 5-1 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan TABLE 5.1 i
INSERVICE INSPECTION REQUEST FOR ALTERNATIVES AND RELIEF REQUEST INDEX (con't) i REQUEST PAGE(S)
REV.
DATE TOPIC NO.
ISI-07 6-21 to 6-0 7/1/99 Alternative Requirements for Insulation 23 Removal During Class 1,2, or 3 Pressure Tests at Bolted Connections in Systems Borated for the Purpose of Controlling Reactivity ISI-08 6-24 to 6-0 7/1/99 Use of ASME Section II, V, and IX 25 Code Cases 1S1-09 6-26 to 6-0 7/1/99 Alternative Corrective Actions for 27 Leakage Identified at Bolted Connections ISI-10 6-28 0
7/1/99 Use of ASNT Central Certification Program ISI-l1 6-29 to 6-0 7/1/99 Alternative Requirements for VT-2 33 Visual Examination of Class 1,2, and 3 Insulated Pressure-Retaining Bolted Connections with Corrosion Resistant Bolting Materials ISI-12 6-34 to 6-0 7/1/99 Alternative Criteria for the Selection of 37 Examination Category B-J Piping Welds ISI-13 6-38 to 6-0 7/1/99 Examination of Class 2 Welds in 40 Stainless Steel Piping Less Than 3/8 in.
Nominal Wall Thickness ISI-14 6-41 to 6-0 7/1/99 Alternative Pressure Testing 44 Requirements for RPV Flange 1.cak Detector Piping 5-2 Revision 0 1
L
CCNPP Units 1 & 2 Third IntervalISI Plan SECTION 6.0 REOUEST FOR ALTERNATIVES AND RELIEF REOUESTS This section of the Third Interval Inservice Inspection Plan contains the Requests for Alternatives and Relief Requests submitted for the third interval at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2.
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l 6-1 Revision 0
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l-CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMHER: ISI-01 (Page 1 of 4)
COMPONENT IDENTIFICATION Code Class:
1
References:
Table IWB-2500-1, Second Interval ISI Relief Request No.1 Examination Category:
B-J Item Numbers:
B9.11
==
Description:==
Alternative Surface Examination Criteria for Examination Category B-J Piping Welds Located in the Reactor Vessel Annulus Component Numbers:
Reactor Coolant System Piping Welds Listed in Table ISI-01-1 (Unit 1) and Table ISI-01-2 (Unit 2)
TAHLE ISI-01 1 UNIT 1 EXAMINATION CATEGORY B-J WELDS LOCATED IN REACTOR VESSEL ANNULUS LINE NUMBER WELD NUMBER WELD TYPE 42-RC-11 1
Nozzle to Transition Piece 42-RC-11 2
Transition Piece to Pipe 42-RC-12 1
Nozzle to Transition Piece 42-RC-12 2
Transition Piece to Pipe 30-RC-11 A 12 Elbow to Transition Piece 30-RC-11 A 13 Transition Piece to Nozzle 30-RC-11B 12 Elbow to Transition Piece 30-RC-11B 13 Transition Piece to Nozzle 30-RC-12A 12 Elbow to Transition Piece 30-RC-12A 13 Transition Piece to Nozzle 30-RC-12B 12 Elbow to Transition Piece 30-RC-12B 13 Transition Piece to Nozzle 6-2 Revision 0
CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-01 (Page 2 of 4)
TAHLE ISI 01-2 UNIT 2 EXAMINATION CATEGORY H-J WELDS LOCATED IN REACTOR VESSEL ANNULUS LINE NUMBER WELD NUMBER WELD TYPE 42-RC-21 1
Nozzle to Transition Piece 42-RC-21 2
Tmnsition Piece to Pipe 42-RC-22 1
Nozzle to Transition Piece 42-RC-22 2
Transition Piece to Pipe 30-RC-21 A 12 Elbow to Transition Piece 30-RC-21 A 13 Transition Piece to Nozzle 30-RC-21B 12 Elbow to Transition Piece 30-RC-21B 13 Transition Piece to Nozzle 30-RC-22A 12 Elbow to Transition Piece 30-RC-22A 13 Transition Piece to Nozzle 30-RC-22B 12 Elbow to Transition Piece 30-RC-22B 13 Transition Piece to Nozzle CODE REOUIREMENT ASME,Section XI,1998 Edition, Table IWB-2500-1, Examination Category B-J, Item Number B9.11, requires a volumetric and surface examination of the circumferential welds of pressure retaining piping NPS 4 and larger.
HASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(g)(5), reliefis requested on the basis that compliance with the ASME Section XI requirements is impractical for the facility.
CCNPP has determined that it is impractical to perform a surface examination on the welds listed in Tables ISI-01-1 and ISI-01-2. The components for which relief is mquested are located in NPS 30 and NPS 42 piping that is in the mactor vessel cavity annulus. To perfomi the mquired surface examination on these welds, the examiners must gain access to the reactor vessel annulus ama that houses the reactor coolant piping welds. This area is extremely difficult to enter, is a very high radiation area, and provides very little room for maneuvering. Performance of sudace examination on the subject piping welds represents a hardship with no compensating increase in plant safety. For these masons, an ultrasonic technique was developed for examining the outside surface of the piping welds from the inside surface of the pipe. When combined with the volumetric examinations performed on the subject welds, each weld will undergo the following ultrasonic examinations:
6-3 Revision 0
e CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-01 (Page 3 of 4)
BASIS FOR AIITERNATIVE(con't)
- 1) A 45-degree examination of the outside surface,
- 2) A 50/70-degree examination of the lower one-third weld volume,
- 3) A supplemental full volume 45-degree examination, and
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- 4) A 0-degree examination of the entire weld volume.
To qualify the 45-degree ultrasonic examination technique for CCNPP, Southwest Research Institute developed a mock-up of the nozzle and pipe welds, then introduced cracks at specific locations on the inside and outside surfaces. The lengths and depths of these cracks were tightly contmiled in order to allow the cracks to be used for qualification purposes. Crack depths ranged from half the maximum allowable Code flaw depth for the given pipe thickness to the maximum allowable Code flaws depth. All flaws were less than the largest acceptable surface flaw in length. The cracks were then investigated with ultrasonic examination techniques to demonstrate that the largest acceptable surface flaw could be detected by this examination technique.
PROPOSED ALTERNATE EXAMINATIONS Surface Examination As an alternative to performing a surface examination, CCNPP will perform a 45-degree shear wave ultrasonic examination on the outside surface of the subject welds using mechanized ultrasonic equipment from the inside of the pipe or vessel. This examination technique has been qualified for the detection of unacceptable flaws on the outer surface that would otherwise be detected by performing a surface examination.
Volumetric Examinations The lower one-third volume of the subject welds and heat affected zones are examined using a 50n0-degree multibeam transducer. In addition, a full-vee path 45-degree shear wave j
examination is performed to supplement the 50n0-degree examination. Because of the proximity of the examination volume to the "near field" of the 45-degree transducer, only the second half of the 45-degree vee-path is calibrated. However, this examination is performed from two directions, thereby assuring Code required coverage. In addition to these examinations, a 0-degree ultrasonic lamination scan is performed on the subject welds.
i 6-4 Revision 0
CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-01 (Page 4 of 4)
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on
{
July 1,1999.
i l
6-5 Revision 0
L l
CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-02
)
(Page 1 of 3)
COMPONENT IDENTIFICATION Code Class:
1
References:
Table IWB-2500-1, Second Interval ISI Relief Request No. 3 Examination Category:
B-O Item Numbers:
B14.10
==
Description:==
Alternative Surface Examination Criteria for Control Rod Drive Housing Welds Component Numbers:
Control Rod Drive Housing Welds 1
CODE REOUIREMENT ASME,Section XI,1998 Edition, Table IWB-2500-1, Examination Category B-0, Item Number B14.10, requires volumetric or surface examination of pressure retaining welds on 10% of peripheral control rod drive (CRD) housings.
BASIS FOR AI,TERNATIVE Pursuant to 10CFR50.55a(g)(5), reliefis requested on the basis that compliance with the ASME Section XI requirements is impractical for the facility.
There are 28 peripheral CRD housings weLa on each of the mactor pressure vessels at CCNPP.
Sinw Ntion XI requires the examination of 10% of the peripheral CRD housing welds, three peripheral Cxi> housing welds on each reactor pressure vessel will require examination. Due to design geometry and limited accessibility, CCNPP has elected to perform surface examination.
Only a portion of each of these three welds is accessible for the surface examination, due to the configuration of the closure head. These welds are partially obstructed because they extend into the closure head. For details, see Combustion Engineering Drawing No. E233-415 which is shown in Figure ISI-02-1. Based on this configuration, examination on 100% of these welds cannot be completed.
PROPOSED ALTERNATE EXAMINATIONS As an alternative to performing 100% surface examinations on three CRD housing welds, CCNPP will perform surface examinations on additional peripheral CRD housing welds such that the cumulative weld length will be the equivalent of 100% of three welds. Therefore, j
surface examinations will be performed on 75% of three welds and 50% of two welds.
6-6 I
Revision 0
T:
CCNPP Units 1 & 2 Third Interval ISI Plan -
REOUEST NUMBER: ISI-02 (Page 2 of 3)
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice
. Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units I and 2, which begins on July 1,1999.
I i
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6-7 l
Revision 0 1'
CCNPP Units 1 & 2 Third Interval ISI Plan REQUEST NUMBER: ISI-02 (Page 3 of 3)
FIGURE ISI-021 REACTOR PRESSURE VESSEL CLOSURE IIEAD ASSEMBLY
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um-m 6-8 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-03 (Page 1 of 2)
. COMPONENT IDENTIFICATION -
Code Class:
1
References:
Table IWB-2500-1 Code Case N-307-1 Examination Category:
B-G-1 Item Numbers:
B6.20, B6.30, B6.180
==
Description:==
Alternative Examination Criteria for Reactor Vessel Closure Studs and Reactor Coolant Pump Studs Component Numbers:
All Reactor Vessel Closure Studs and Reactor Coolant Pump Studs CODE REOUIREMENT ASME Section XI,1998 Edition, Table IWB-2500-1, Examination Category B-G-1, Item No. B6.20 requires volumetric examination of reactor vessel closure studs in place; Item Number B6.30 requires volumetric and surface examination of reactor vessel closure studs when removed; and Item Number B6.180 requires volumetric examination on reactor coolant pump studs and bolts.
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(i), mlief is requested on the basis that the proposed alternatives provide an acceptable level of quality and safety.
Under the provisions of Code Case N-307-1, when conducting an ultrasonic examination from the center-drilled hole of bolts or studs to satisfy the examination mquimments of Section XI, Examination Category B-G-1, the examination volume may be limited to a cylindrical region of %
in, thickness, measumd from the outside minor diameter (i.e., thread root diameter). Code Case N-307-1 has been approved for use in Regulatory Guide 1.147, Rev. I1. However, Code Case N-307-1 also requires that the center-drilled bore hole surface be examined by a qualified supplemental ultrasonic, surface, or eddy current examination technique. This additional examination is being deleted in a revision to Code Case N-307-1 that is currently being approved i
by ASME Section XI. This revision of Code Case N-307-1 also allows the examination volume to be limited to the % in. thick cylindrical region when ultrasonic examinations are performed from the end of the bolt or stud.
I 6-9 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-03 (Page 2 of 2)
BASIS FOR ALTERNATIVE (con't)
Elimination of the surface examination of the center-drilled bore hole surface is justified because cracking, which is the degradation mechanism that would be detected, is more likely to initiate from the OD surface than from the center-drilled bom hole surface. This conclusion is supported by the following facts:
- 1) The stress is higher on the bolt's or stud's OD surface under combined axial and bending loads.
- 2) The geometry of the thread roots is a stress riser condition that would sharply increase the susceptibility of crack initiation.
- 3) An industry survey was performed as part of the justification for revising Code Case N-307-1. The survey results on the examination of mactor vessel studs at 57 domestic nuclear plants showed that reactor vessel stud cracking has been experienced at only one BWR plant. In that single case, the cracks were determined to be stress-corrosion cracking due to the exposure of the studs to oxygenated water under a loaded condition. These cracks were found to initiate from the outer edge of the studs at a pitted location near the thread roots. The msults of this survey are judged to be bounding on the condition of other bolts and studs, because the reactor vessel studs, which have the largest diameter, are typically subject to the most severe opemting conditions.
As stated, cracks on bolts and studs are most likely to initiate from t.he OD surface. Therefore, volumetric examination of the cylinder region adjacent to the OD surface, will focus examinations on the primary area of concern.
PROPOSED ALTERNATE EXAMINATIONS When performing an ultrasonic examination from the end, or from the center-drilled hole on Reactor Pressure Vessel Closure Studs and Reactor Coolant Pump Studs at CCNPP, Units 1 and 2, the examination volume shall be a cylindrical region of % in. thickness, measured from the outside minor diameter of the stud.
APPLICABLE TIME PERIOD i
Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
6 10 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-04 (Page 1 of 4)
COMPONENT IDENTIFICATION Code Classes:
1,2, and 3
References:
IWA-4540(a), IWA-4540(b), IWA-5120, IWA-5212, IWA-5214, IWB-5230, IWC-5230, and IWD-5222 Code Case N-416-1 Examination Categories:
Not Applicable Item Numbers:
Not Applicable
==
Description:==
Alternative Pressure Test Requirement for Welded Repairs or Installation of Replacement Items by Welding Component Numbers:
All Class 1, Class 2, and Class 3 Pressure Retaining Components Subject to Hydrostatic Testing per IWA-4700 CODE REOUIREMENT ASME Section XI, IWA-4540(a) requires a hydrostatic test to be performed per IWA-5000 after welded repair or replacement of classed components, except those exempted by IWA-4540(b).
IWA-5120 and IWA-5212 requims a pressure test per IWB-5230, IWC-5230, or IWD-5222, as applicable to the system which contains the repaired or replaced component.
IWB-5230, IWC-5230, and IWD-5222, System Hydrostatic Test, require a Test Pressure of 1.02 to 1.10 times Po for Code Class I components,1.10 or 1.25 times P., (or Po r Po, as applicable) for o
Code Class 2 components, and 1.10 or 1.25 times P., (or Po r Po, as applicable) for Code Class 3 o
components, where Po is the nominal operating pressure corresponding with 100% rated reactor power, P., is the lowest pressure setting among the safety or relief valves provided for overpressure protection within the boundary of the system to be tested, Pa is the system design pressure, and Pa is design pressure of vapor or gas space above liquid level within an atmospheric storage tank for which overpressure protection is provided by relief valves.
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(ii), relief is requested on the basis that compliance with Section XI requirements would result in a hardship without a compensating increase in the levels of quality and safety.
6-11 Revision 0 l
F CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI.04 (Page 2 of 4)
BASIS FOR ALTERNATIVE (coni)
Due to the additional preparation required to safely accomplish the required System Hydrostatic Tests (at pressures above normal operating levels) after welded mpairs and replacements on Code Class I,2, and 3 components, these tests pmsent unusual difficulties and often harc' ship situations for CCNPP, Units I and 2.
Some of the specific problems typically encountered when preparing and performing these tests include:
- Complicated or abnormal valve line-ups in order to properly vent, fill, and isolate the component requiring testing.
j i
- Relief valves with setpoints lower than the hydrostatic test pressure must be gagged or removed and blind flanged. This process requires the draining and refilling of the system both prior to the test and prior to system restoration.
- Valves that are not normally used for isolation (e.g., normally open pump discharge valves) are often required to provide pressure isolation for an elevated pmssure hydrostatic test. These valves fmquently requim time consuming seat maintenance in order to obtain a leak tight pressure boundary.
- The radiation exposure to plant personnel involved in hydrostatic tests is high in comparison to operational pmssure testing due to the large amount of time required to pmpare the volume for testing (i.e., installing mlief valve gags, performing appropriate valve line-ups, completing valve maintenance, filling and venting, etc.).
The difficuhies encountemd in performing a hydrostatic pmssure test are prohibitive when weighed against the benefits. Industry experience, which is supponed by Calven Cliff's experience, shows that most through wall leakage is detected during system operation as opposed i
to during elevated pressure tests such as ten-year or post-maintenance system hydrostatic tests.
No leakage detection benefit is gained from the added challenge to the piping system provided by an elevated pressure hydrostatic test as compared to a system operational test. The stresses experienced during a hydrostatic test do not include the significant stmsses associated with the thermal growth and dynamic loading seen during a system operational test. Thus, the system is mom likely to experience any through wall leakage at operating conditions due to the combination of dynamic / thermal loading and the normal operating pmssure parameters than during the careful, slow pressurization of a hydrostatic test.
6-12 Revision 0
CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-04 (Page 3 of 4) l l
BASIS FOR ALTERNATIVE (coni) 1 These arguments are also supported by Code Case N-498, " Alternative Rules for 10 Year Hydrostatic Pmssure Testing for Class 1 and 2 Systems,Section XI, Division 1". This Request for Altemative is a logical extension of Code Case N-498 which is approved for use in Regulatory l
Guide 1.147, Revision 11. In addition, the ASME Board of Nuclear Codes and Standards has approved Code Case N-416-1, "Altemative Pressure Test Requirements for Welded Repairs or Irctallation of Replacement Items by Welding, Class 1,2, and 3 Systems,Section XI, Division 1",
which incorporates the logic and Alternative Examinations contained within this Request for Altemative.
Based on the above, CCNPP, Units 1 and 2, requests relief from the ASME Section XI mquirements for performing elevated pressum hydrostatic tests on Class 1, Class 2, and Class 3 l
repaired / replaced components.
PROPOSED ALTERNATE PROVISIONS j
After welded repairs or installation of replacement items by welding, the following altcmative requirements will be met in lieu of performing the hydrostatic pressum test required per paragraph IWA-4700:
(1) NDE shall be performed in accordance with the methods and acceptance criteria of the applicable Subsection of the 1992 or later Edition of Section III.
(2) Prior to or immediately upon retum to service, a visual examination (VT-2) shall be performed in conjunction with a system leakage test, using the 1998 Edition of Section XI, in accordance with paragraph IWA-5000, at nominal operating pmssure and temperature.
(3) Use of this Request for Altemative shall be documented on an NIS-2 Form.
(4) When Section III requims a surface exam on a Code Class 3 component, an additional smface examination shall be performed on the root (pass) layer of butt and socket welds.
(5) When Code Class 3 repair or mplacement activities involve socket / fillet welds, a surface examination shall be performed on the subject socket / fillet welds.
l 6-13 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-04 (Page 4 of 4)
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calveit Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
6-14 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-05 (Page 1 of 3)
COMPONENT IDENTIFICATION
! Code Class:
3
References:
IWD-2500, Table IWD-2500-1, IWD-5222 -
Code Case N-498-1 Examination Category:
D-B i
Item Number:
D2.20
==
Description:==
Alternative R-les for 10-Year System Hydrostatic Testing for Class 3 Systems Component Numbers:
All Class 3 Pressure Retaining Components Subject to Hydrostatic Testing perIWD-5000 CODE REOUIREMENT
)
IWD-2500 states that Class 3 components shall be examined and pressure tested as specified in Table IWD-2500-1.
Table IWD-2500-1 requires a hydrostatic test to be performed on the pressure retaining boundary j
of all Class 3 systems and components each inspection interval.
i IWD-5222, System Hydmstatic Test, requires a Test Pressure of 1.10 or 1.25 times P,y (or P or j
4 Po, as applicable) for Code Class 3 components, where Po is the nominal operating pressure
. contsponding with 100% rated reactor power, P,y is the lowest pressum setting among the safety cr relief valves provided for overpressure protection within the boundary of the system to be tested, Po is the system design pressum, and Po is design pressure of vapor or gas space above liquid level within an atmospheric storage tank for which overpressure protection is provided by relief valves.
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(ii), relief is requested on the basis that compliance with Section XI requirements would result in a hardship without a compensating increase in the levels of quality and safety.
Due to the additional preparation requimd to safely accomplish the required System Hydrostatic Tests (at pmssums above normal operating levels) on Code Class 3 components, these tests present l
unusual difficulties and often hardship situations for CCNPP, Units 1 and 2.
l 6-15 i
Revision 0 L
e.
CCNPP Units 1 & 2 E
Third IntervalISI Plan l-REOUEST NUMBER: ISI-05 (Page 2 of 3)
BASIS FOR ALTERNATIVE (coni) 5-
' Some of the specific problems typically encountered when preparing and performing these tests include:
l
' Complicated or abnormal valve line-ups in order to properly vent, fill, and isolate the component requiring testing.
- Relief valves with setpoints lower than the hydrostatic test pressure must be gagged or i
removed and blind flanged. This process requires the draining and refilling of the system both prior to the test and prior to system testoration.
- Valves that are not normally used for isolation (e.g., normally open pump discharge valves) are often required to provide pressure isolation for an elevated pressure hydrostatic test. These valves frequently requim time consuming seat maintenance in order to obtain a leak tight pressure boundary.
- The radiation exposure to plant personnel involved in hydrostatic tests is high in comparison to operational pressure testing due to the large amount of time required to prepare the volume for testing (i.e., installing elief valve gags, performing appmpriate valve line-ups, completing valve maintenance, filling and venting, etc.).
The difficulties encountered in performing a hydrostatic pressure test are prohibitive when weighed against the benefits. Industry experience, which is supported by Calvert Cliff's experience, shows that most through wall leakage is detected during system operation as opposed
- to during elevated pressure tests such as ten-year or post-maintenance system hydrostatic tests.
No leakage detection benefit is gained from the added challenge to the piping system pmvided by an elevated pressure hydmstatic test as compared to a system operational test. The stresses experienced during a hydrostatic test do not include the significant stresses associated with the thermal growth and dynamic loading seen during a system operational test. Thus, the system is i
more likely to experience any through wall leakage at operating conditions due to the combination of dynamic / thermal loading and the normal operating pressure parameters than during the careful, slow pressurization of a hydrostatic test.
These arguments are supported by Code Case N-498, "Altemative Rules for 10 Year Hydrostatic
. Pressure Testing for Class 1 and 2 Systems,Section XI, Division 1", which has been approved for use in Regulatory Guide 1.147, Rev.11, and was incorporated into ASME Section XI in the 1993 Addenda.- In addition, the proposed alternate examinations are in accordance with the criteria for Class 3 system testing as presented in Code Case N-498-1, "Altemative Rules for 10 Year System Hydrostatic Testing for Class 1,2 and 3 Systems".
6-16 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-05 (Page 3 of 3)
PROPOSED AI, TERNATE EXAMINATIONS CCNPP, Units 1 and 2, will adopt the following rules in lieu of the 10-year hydrostatic pressure test required by Table IWD-2500 1, Category D-B:
(1)
A system pmssure test shall be conducted at or near the end of each inspection interval j
or during the same inspection period of each inspection interval of Inspection Pmgram B.
(2)
The boundary subject to test pressurization during the system pressure test shall extend to all Class 3 components included in those ponions of systems mquired to operate or suppon the safety system function up to and including the first normally closed valve, including a safety or relief valve, or valve capable of automatic closure when the safety function is required.
(3)
Prior to performing the VT-2 visual examination, the system shall be pressurized to nominal operating pressum for at least 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> for insulated systems and 10 minutes for noninsulated systems. The system shall be maintained at nominal operating pressure during the performance of the VT-2 visual examination.
(4)
The VT-2 visual examination shall include all components within the boundary identified in (2) above.
(5)
Test instrumentation specified for hydrostatic pressure test is not requimd.
APPI,1CABI,E TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
l I
l l
t 6-17 Revision 0
L CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-06 (Page 1 of 3) l l
COMPONENT IDENTIFICATION Code Classes:
1,2, and 3 l
Reference:
IWA-4180 and IWA-6200 Code Case N-532 Examination Categories:
Not Applicable Item Numbers:
Not Applicable
==
Description:==
Alternative Requimments to Repair and Replacement Documentation Requirements and Inservice Summary Repon Preparation and Submission as Required by IWA-4000 and IWA-6000 Component Numbers:
All Class 1,2, and 3 Components Subject to Inservice Inspection, Repair, or Replacement Activities CODE REOUIREMENT -
ASME Section XI, IWA-6200 requires the preparation of Inservice Inspection (ISI) Summary Repons which contain completed Form NIS-1, " Owner's Report for Inservice Inspection" and Form NIS-2, " Owner's Repon for Repair or Replacement". In accordance with IWA-6240, the ISI Summary Report is required to be submitted to the enforcement and mgulatory authorities having jurisdiction at the plant within 90 days of the completion of the inservice inspections conducted each refueling outage.
ASME Section XI, IWA-4180 reiterates the requirement of IWA-6200 to complete NIS-2 forms for repairs and replacements.
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(i), reliefis requested on the Mris that the proposed alternatives pmvide an acceptable level of quality and safety.
ASME Section XI has recently reevaluated the Code criteria for reporting inservice inspection results, repairs and replacements, and has concluded that the current requirements are no longer effective. To address this issue, ASME Section XI issued Code Case N-532, " Alternative Requirements to Repair and Replacement Documentation Requirements and Inservice Summary Report Preparation and Submission as Required by IWA-4000 and IWA-6000". Code Case N-532 provides an alternative to the current ASME Section XI repair and replacement documentation requirements as well as regulatory reporting requirements relating to inservice j
inspection. This alternative is intended to reduce the resources required to prepare NIS-2 6-18 i
Revision 0 I
E
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-06 (Page 2 of 3)
BASIS FOR AIII'ERNATIVE (coni) forms and prepare and submit the ISI Summary Repon required by ASME Section XI,1998 Edition, after each refueling outage. This is a significant reduction in the administrative burden required by ASME Section XI,IWA-6000. The use of Code Case N-532 only affects documentation and reporting requirements and does not affect the level of quality or safety provided by the Inservice Inspection Program.
Code Case N-532 was approved by the ASME Boiler and Pressure Vessel Code Committee on December 12,1994, but is not yet endorsed in the most recent listing of NRC approved code cases provided in Regulatory Guide 1.147, " Inservice Inspection Code Case Acceptability -
ASME Section XI Division 1".
i The NRC Staff has made recommendations supporting the development of Code Case N-532 in SECY-94-093, "NRC Staff Assessment of Reponing Requirements for Power Reactor Ucensees". The use of Code Case N-532 is consistent with the recommendations of SECY 093 and provides more meaningful documentation to the regulatory and enforcement authorities havingjurisdiction at the plant.
This request to use Code Case N-532 includes compliance with the Code Case, with the j
following clarification regarding reponing of " corrective measures". ASME Section XI uses the i
term " corrective measures" in two different ways. One use of the term involves Code required activities such as repairs and replacements. The other use of the term, as found in IWX-3000, involves maintenance activities that do not involve repairs or replacement.s. With this clarification, CCNPP proposes not to repon corrective measures which only include routine maintenance activities such as tightening threaded fittings to eliminate leakage, torquing of fasteners to eliminate leakage at bolted connections, replacing valve packing due to unacceptable packing leakage, tightening loosened mechanical connections on supports, adjusting and realigning supports, cleaning up con osion on components resulting from leakage, etc.
Including these routine maintenance activities in the Owner's Activity Repon Form OAR-1 required by Code Case N-532 would be a significant expansion of current requirements. In addition, it would be an unnecessary reporting and review burden which provides negligible benefit. Reporting of these minor maintenance corrective measures has no safety significance
. and clutters the reponing of meaningful information on repairs, replacements, and evaluations performed to accept flaws and relevant conditions exceeding Section XI acceptance criteria.
Corrective measures which refer to Code required activities, such as repairs and replacements, l
. will be reponed in compliance with Code Case N-532.
6-19 Revision 0 l
.=
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-06 (Page 3 of 3)
BASIS FOR ALTERNATIVE (coni)
CCNPP considers the alternative documentation and reponing requirements of Code Case N-532 to be a reasonable alternative and an improvement to existing requirements. Because the use of this alternative only affects documentation and reponing requirements, CCNPP considers this alternative to provide an acceptable level of quality and safety.
PROPOSED ALTERNATIVE CRITERIA The Calvert Cliffs Nuclear Power Station, Units 1 and 2, will use Code Case N-532 in its entirety with the clarification stated above regarding the provision in paragraph 2(c) of the Code Case for reponing corrective measures.
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
6-20 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-07 (Page 1 of 3)
COMPONENT IDENTIFICATION Code Classes:
1,2, and 3
References:
IWA-5242(a)
)
Examination Categories:
B-P, C-H, and D-B i
Item Numbers:
B 15.10, B 15.20, B 15.30, B 15.40, B 15.50, B 15.60, B 15.70 C7.10 and D2.10
==
Description:==
Alternative Requirements for Insulation Removal During Class 1, 2, or 3 Pressure Tests at Bolted Connections in Systems Borated for the Purpose of Controlling Reactivity
)
Component Numbers:
Bolted Connections in Systems Borated for the Purpose of Controlling Reactivity CODE REOUIREMENT IWA-5242(a) states "For systems borated for the purpose of controlling reactivity, insulation shall be removed from pressure retaining bolted connections for visual examination VT-2."
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(ii), reliefis requested on the basis that the original requirements would msult in hardship without a compensating increase in the level of quality and safety.
The systems which are borated for the purpose of controlling reactivity at CCNPP Units 1 and 2 include Reactor Coolant, Chemical and Volume Control, and Safety Injection. These systems encompass a large portion of the overall ISI program and physically cover a large expanse of the reactor building. Many areas in which this piping and the associated bolted connections are located are difficult to access (e.g., scaffolding and /or ladder installation is required) and many of these areas are located such that significant radiation exposures would be encountered.
In order to identify leakage to be repaired during the outage, the preferred time frame to perform this inspection is in the beginning of the outage, subsequent to depressurization of the reactor coolant system. To perform these inspections at pressure would involve holding the reactor coolant system at operating pressure and temperature for an extended period of time to allow for scaffold construction, insulation removal and VT-2 inspection.
6-21 Revision 0
CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-07 (Page 2 of 3)
BASIS FOR ALTERNATIVE (coni)
There is normally a relatively short time frame when the unit is transitioning to cold shutdown.
Holding the unit at normal operating temperature and pressure for an extended period of time would result in a significant delay in going to cold shutdown.
Performing this inspection at the end of the outage would be ineffective, since finding leakage at that time would constitute bringing the unit back to cold shutdown to perform the repair and then beginning the stan up process over again. Also,in order to reinsulate the reactor coolant system at the end of the outage, the unit would have to remain at hot standby while the insulation is reinstalled and the scaffolding is removed. Typically, the reinstallation of insulation and removal of scaffolding is performed prior to leaving cold shutdown.
In addition, the removal and reinstallation of insulation with plant equipment in operation at system pressure and temperature increases the risk of personal injury and presents a safety concern to plant personnel. The personnel risk and radiation exposure is significant for the removal and reinstallation of insulation at these bolted connections during pmssure testing activities.
A VT-2 visual examination with the system depressurized would still provide adequate detection ofleakage because boric acid residue can be easily detected with insulation removed at the bolted connection.
Based on the previously stated reasons, CCNPP, Units 1 and 2, requests relief from the inspection at operating pressure with insulation removed, as detailed in IWA-5242(a). In lieu of these requirements, CCNPP, Units 1 and 2, proposes the altemative examination requirements that follow.
NOTE: An additional Request for Alternative, Request Number ISI-11,is being submitted as pan of this ISI Plan to addn;ss the removal of insulation at bolted connections in systems borated for the purpose of controlling reactivity, when the bolting material is resistant to corrosion. In the event that Request Number ISI-l1 is approved by NRC, it will take precedence over Request Number ISI-07 for bolted connections with corrosion resistant bolting material.
l PROPOSED ALTERNATIVE EXAMINATION l
A system pressure test with a minimum 4 hour4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> hold time and VT-2 visual examination shall be i
performed each refueling outage without the removal ofinsulation on systems borated for the purpose of controlling reactivity.
6-22 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-07 (Page 3 of 3)
PROPOSED ALTERNATE EXAMINATIONS (con't)
Each refueling outage, the insulation shall be removed from the bolted connections in systems borated for the purpose of controlling reactivity, and a VT-2 visual examination shall be performed on each of the connections. During this VT-2 examination, the connections are not required to be pressurized. Any evidence of leakage shall be evaluated in acconiance with IWA-
'5250.
These alternative examination requirements are the same as those specified in ASME Section XI Code Case N-533 as approved by the Board of Nuclear Codes and Standards, with the additional 4 hour4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> hold time provision stated above.
t These alternatives provide reasonable assurance that safety and integrity will be maintained for bolted connections in systems borated for the purpose of controlling reactivity.
APPLICABLE TIME PERIOD
- Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
6-23 Revision 0
c CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-08 (Page 1 of 2) j l
COMPONENT IDENTIFICATION
' Code Classes:
1,2, and 3
References:
IWA-2440 Code Case N-555 Examination Categories:
Not Applicable Item Numbers:
Not Applicable
==
Description:==
Use of ASME Section II, V, and IX Code Cases Component Numbers:
All Cless 1,2, and 3 Components Subject to Inservice Inspection, Inservice Testing, or Repair / Replacement Activities CODE REOUIREMENT ASME Section XI, IWA-2440 establishes the criteria for the application of code cases.
{
ASME Section XI, IWA-2443 states that the rules for application of code cases from Code Sections other than Section XI are in the course of preparation.
HASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(i), relief is requested on the basis that the proposed alternatives provide an acceptable level of quality and safety.
ASME,Section XI, has pmpared the rules for application of code cases from other Code Sections. These rules appear in Code Case N-555, but have not been incorporated into ASME Section XI.
Section XI has evaluated the code cases of ASME Sections II, V, and IX and determined that if they were used in the constmetion of a component, then they are appropnate for use during repair /mplacement activities on that component. In addition,Section XI has evaluated additional code cases for use during Section XI activities, and has determined that several are suitable for use because they provide an acceptable level of safety. Code Case N-555 lists the specific code cases that may be used for inservice inspection, inservice testing, or repair / replacement activities in accordance with Section XI.
6-24 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-08 (Page 2 of 2)
PROPOSED ALTERNATIVE ASME Section 11, V, and IX code cases that were used in the construction of a component may be used at CCNPP, Units 1 and 2, for repair / replacement activities on that component. Also, the code cases specified in Code Case N-555 may be used at CCNPP, Units 1 and 2, for inservice inspection, inservice testing, or repair / replacement activities in accordance with Section XI. If a specific code case is going to be applied, BGE will inform the regulatory authorities having jurisdiction at the site of theirintention.
APPLICABLE TIME PERIOD Application of the altemative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
)
1 I
6-25 Revision 0 i
i
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-09 (Page 1 of 2)
COMPONENT IDENTIFICATION Code Classes:
1,2, and 3
Reference:
IWA-5250(a)(2)
Examination Categories:
Not Applicable Item Numbers:
Not Applicable
==
Description:==
Alternative Corrective Actions for Leakage Identified at Bolted Connections Component Numbers:
Class 1,2, and 3 Pressure Retaining Bolted Connections
, CODE REOUIREMENT ASME Section XI, Subparagraph IWA-5250(a)(2) states, "If leakage occurs at a bolted connection on other than a gaseous system, one of the bolts shall be removed, VT-3 examined, and evaluated in accordance with IWA-3100. The bolt selected shall be the one closest to the source of leakage. When the mmoved bolt has evidence of degradation, all remaining bolting in the connection shall be removed, VT-3 examined, and evaluated in accordance with IWA-3100 "
BASIS FOR ALTERNATIVE 1
Pursuant to 10CFR50.55a(a)(3)(ii), relief is requested on the basis that compliance with Section XI mquirements would result in hardship without a compensating increase in the levels of quality and safety.
The leaking environment at a bolted connection is one of many variables to consider when evaluating leakage at a bolted connection. Other variables to be considered are: bolting materials, leaking medium, duration of the leak, and orientation of the leak (not all the bolts may be wetted). These variables are important to consider before disassembling a bolted connection for a visual VT-3 examination. Removal of bolting at a mechanical connection may not be the most prudent action and may cause undue hardship without a compensating increase in the level of quality or safety.
6-26 Revision 0
F CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-09 (Page 2 of 2)
PROPOSED ALTERNATIVE CCNPP, Units 1 and 2, proposes an alternative to the requirements ofIWA-5250(a)(2) that will provide an equivalent level of quality and safety at Class 1,2, and 3 bolted connections.
I.cakage discovered at a bolted connection by visual VT-2 examination during system pressure test will be evaluated to determine the susceptibility of the bolting to corrosion and potential future failure. The evaluation will, as a minimum, consider the following variables:
- 1) Location ofleakage
- 2) Historyofleakage
- 3) Bolted connection materials
- 4) Visual evidence of corrosion with the connection assembled
- 5) Corrosiveness of the process fluid
- 6) History and studies of similar bolted material in a similar environment
- 7) Other components in the vicinity that may be degraded due to the leakage
- 8) Leakage monitoring capabilities When evaluation of the variables above indicates the need for further examination, the bolt closest to the source ofleakage will be removed, receive a visual VT-1 examination, and be evaluated in accordance with IWA-3100(a). If the leakage was identified with the bolted connection in service, and an evaluation supports continued service, the VT-1 examination may be deferred to the next outage of sufficient duration. When the removed bolt has evidence of rejectable degradation, all remaining bolts shall be removed and subsequently receive a visual VT-1 examination and evaluated in accordance with IWA-3100.
APPLICABLE TIME PERIOD Application of the altemative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units I and 2, which begins on July 1,1999.
6-27 Revision 0 A
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-10 (Page1of1) l COMPONENT IDENTIFICATION Code Classes:
1,2, and 3
References:
IWA-2300 Code Case N-592 Examination Categories:
Not Applicable Item Numbers:
Not Applicable
==
Description:==
Use of ASNT Central Certification Program Component Numbers:
All Class 1,2, and 3 Components Subject to Inservice Inspection CODE REOUIREMENT ASME Section XI,1998 Edition,IWA-2300, contains requirements for the qualification of NDE personnel. It states that NDE personnel shall be qualified and certified using a written practice that is prepared in accordance with ANSI /ASNT CP-189, Standard for Qualification and Certification of Nondestructive Testing Personnel, as amended by the requirements of Section XI, Division 1.
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(i), relief is requested on the basis that the proposed alternatives provide an acceptable level of quality and safety.
ASME,Section XI, has evaluated the qualification and certification requirements of the ASNT Central Cenification Program (ACCP) and concluded that they are equivalent to those of ANSI /ASNT CP-189. An ACCP cenificate with current endorsements obtained by examination satisfies the Basic, Method, Practical, and Demonstration Examination requirements for Ixvel III NDE personnel, and the General and Practical Examination requirements for Ixvels I and II NDE personnel. Application of the ACCP maintains an equivalent level of quality and safety.
PROPOSED ALTERNATIVE When applicable, CCNPP, Units 1 and 2, will use the ACCP as an alternative to the personnel examination requirements of Section XI,IWA-2300.
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units I and 2, which begins on July 1,1999.
6-28 Revision 0
CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-11 (Page 1 of 5)
COMPONENT IDENTIFICATION Code Classes:
1,2, and 3
References:
IWA-5242(a)
Examination Categories:
B-P, C-H, and D-B Item Numbers:
B 15.10, B 15.20, B 15.30, B 15.40, B 15.50, B 15.60, B 15.70 C7.10 and D2.10
==
Description:==
Altemative Requirements for Insulation Removal During Class 1, l
2, or 3 Pressure Tests at Corrosion Resistant Bolted Connections in Systems Borated for the Purpose of Controlling Reactivity Component Numbers:
Corrosion Resistant Bolted Connections Listed in Tables ISI-l1-1 and ISI-11-2 TA BLE ISI-11-1 UNIT 1 CORROSION RESISTANT BOLTED CONNECTIONS l
COMP.ID ASME XI DRAWING FASTENER CIIROMIUM l
CLASS NUMBER MATERIAL CONTENT (%)
1-SI-434 2
15102-0008 ASTM A194/8M (NUTS),
16.00-18.00 1-SI-446 A193/B8M (STUDS) 1-SI-215 1
12120-01 ASTM A453 GR 660 13.50-16.00 1-SI-225 (STUDS AND NUTS) 1-SI-235 1-SI-245 1-CV-100E 1
12121-0006 SA A453 GR 660 13.50-16.00 1-CV-100F (STUDS AND NUTS) l 1-CV-110P 3
12115-0002 ASTM A194/8M (NUTS),
16.00-18.00 l
1-CV-110Q A193/B8M (STUDS) 1-MOV-616 2
12116-ASTM A194/8M (NUTS),
NUTS:
1-MOV-617 0001SH0001 A193/B8 (STUDS) 16.00-18.00 1-MOV-626 STUDS:
1-MOV-627 18.00-20.00 l-MOV-636 l
l-MOV-637 1-MOV-646 1-MOV-647 l
6-29 Revision 0 p
L
o CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-11 l
(Page 2 of 5)
' COMPONENT IDENTIFICATION (con't)
TABLE ISI-11-2 UNIT 2 CORROSION RESISTANT BOLTED CONNECTIONS COMP. ID ASME XI DRAWING FASTENER CHROMIUM CLASS NUMBER MATERIAL CONTENT (%)
2-SI-215 1
12120-01 ASTM A453 GR 660 13.50-16.00 2-SI-225 (STUDS AND NUTS) 2-SI-235 2-SI-245 2-CV-100E 1
12121-0006 SA A453 GR 660 13.50-16.00 2-CV-100F (STUDS AND NUTS) i 2-CV-110P 3
12115-0002 ASTM A194/8M (NUTS),
16.00-18.00 2-CV-110Q A193/B8M (STUDS) 2-MOV-616 2
12116-ASTM A194/8M (NUTS),
NUTS:
2-MOV-617 0001SH0001 A193/B8 (STUDS) 16.00-18.00 2-MOV-626 STUDS:
2-MOV-627 18.00-20.00 2-MOV-636 2-MOV-637 2-MOV-646 2-MOV-647 l
CODE REOUIREMENT l
IWA-5242(a) states "For systems borated for the purpose of controlling reactivity, insulation shall be removed from pressure retaining bolted connections for visual examination VT-2."
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(ii), relief is requested on the basis that the original requirements would result in haniship without a compensating increase in the level of quality and safety.
The systems which are borated for the purpose of controlling reactivity at CCNPP Units 1 and 2 include Reactor Coolant, Chemical and Volume Control, and Safety Injection. These systems encompass a large portion of the overall ISI program and physically cover a large expanse of the reactor building. Many areas in which this piping and the associated 6-30 i
Revision 0 i
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L CCNPP Units 1 & 2
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Third IntervalISI Plan l
REOUEST NUMBER: ISI 11 (Page 3 of 5)
BASIS FOR ALTERNATIVE (con't) bolted connections are located are difficult to access (e.g., scaffolding and /or ladder installation l
is required) and many of these areas are located such th t ia s gnificant radiation exposures and l
cost would be encountered.
In addition, the removal and reinstallation ofinsulation with plant equipment in operation at system pressure and temperature increases the risk of personal injury and presents a safety concern to plant personnel. The personnel risk and radiation exposure is significant for the removal and reinstallation of insulation at these bolted connections during pressure testing activities, i
BGE believes that the factors described below, in addition to the proposed attemative examination criteria, provide an acceptable level of safety and quality for corrosion resistant bolted connections in systems borated for the purpose of controlling reactivity.
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- 1) In response to NRC Generic Ixtter 88-05, CCNPP established a program to inspect all boric acid leaks discovered in the reactor coolant pressure boundary, and to evaluate the impact of those leaks on carbon steel or low alloy steel components. All evidence of leaks, including boric acid crystals or residue, is inspected and evaluated.
Issues such as the following are considered in the inspection and evaluation: 1) evidence of corrosion or metal degradation,2) effect the leak may have on the j
pressure boundary,3) possibility of boric acid traveling along the inside ofinsulation j
on piping, and 4) possibility of dripping or spraying on other components. Based on 1
this evaluation, appropriate corrective actions are initiated to prevent reoccurrence of
{
the leak and to repair, if necessary, any degraded materials or components.
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- 2) For the purpose of resisting cormsion, the bolting material in the connections listed in Tables ISI-11-1 and ISI-l1-2 were mplaced with stainless steel or alloy components that are designed to be resistant to corrosion. Numerous industry repons, including EPRI Repon TR-104748, " Boric Acid Corrosion Handbook", have established that bolting materials with a chromium content greater than 10.5% are highly resistant to boric acid corrosion. As shown in Tables ISI-11-1 and ISI-11-2, the materials used at CCNPP all have chromium contents in excess of 13.5%. EPRI Report TR-104748 also identifies SA-453 as a superior fastening material. This alloy was designed for resistance to acid corrosion environments due to its high nickel and chromium content and the inclusion of molybdenum specifically designed to inhibit inorganic acids such as boric acid.
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rn CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMBER: ISI-11 (Page 4 of 5)
BASIS FOR ALTERNATIVE (coni)
The removal of insulation to inspect for corrosion on bolting material that was specifically installed due to its corrosion resistant properties is unwarranted. It places an undo burden on CCNPP, Units 1 and 2, yet does not enhance the safety or quality of the plant.
i PROPOSED ALTERNATIVE EXAMINATION For the third inservice inspection interval, CCNPP, Units 1 and 2, will implement the following criteria:
- 1) During the first outage of the interval, system pressure tests will be conducted, during which insulation will be removed on all bolted connections in Class 1,2, and 3 systems that are borated for the purposes of controlling reactivity. The pressure test and insulation removal will be conducted in accordance with Request Number ISI-07, that is based on ASME Section XI Code Case N-533.
- 2) A VT-2 visual examination will be performed on the uninsulated bolted connections to verify integrity. In addition, bolting material will be confirmed. The bolted connections listed in Tables ISI-l1-1 and ISI-11-2 will be verified as having corrosion resistant material, and any additional connections determined to have corrosion resistant bolting material will be added to the tables.
4
- 3) During pressure tests conducted in subsequent outages, insulation will be removed from bolted connections with non-resistant material in accordance with Request Number ISI-
- 07. However, insulation will not be removed during VT-2 examinations on those corrosion resistant bolted connections identified in Tables ISI-l1-1 and ISI-l1-2. (For bolted connections with corrosion resistant materials, Request Number ISI-11 will take precedence over Request Number ISI-07.)
- 4) VT-2 examinations will still be performed on all bolted connections in systems borated for the purpose of controlling reactivity. For those bolted connections that remain insulated, any leakage identified by the evidence of boron residue or an active leak, will be addressed by ASME Section XI criteria and the CCNPP Boric Acid Corrosion Inspection Program that was developed in accordance with NRC Generic Letter 88-05.
- 5) Ifinsulation is removed for planned maintenance, repair, or other inspection at a bolted connection in a system borated for the purpose of controlling reactivity, a visual examination shall be performed on the bolted connection prior to disassembly and, if evidence of leakage is discovered, evaluated in accordance with the corrective measures of Subarticle IWA-5250.
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(c CCNPP Units 1 & 2 ThirdIntervalISI Plan REOUEST NUMBER:ISI-11 (Page 5 of 5)
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
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CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER:ISI-12 (Page 1 of 4)
COMPONENT IDENTIFICATION Code Class:
1
References:
IWB-2500, Table IWB-2500-1 i
Examination Category:
B-J Item Numbers:
B9.11, B9.21, B9.31, B932, B9.40
==
Description:==
Altemative Criteria for the Selection of Examination Category B-J Piping Welds -
Component Numbers:
All Class 1 Piping Welds CODE REOUIREMENT ASME Section XI, IWB-2500 states that components shall be examined and tested as specified in Table IWB-2500-1.
- Table IWB-2500-1, Examination Category B-J requires the extent and frequency of examinations to be determined using Notes 1 and 2 which state the following:
i.
(1) Examinations shall include the following:
(a) All terminal ends in each pipe or branch run connected to vessels.
(b) All terminal ends andjoints in each pipe or branch run connected to other components i
- where the stress levels exceed either of the following limits under loads associated with specific seismic events and operational conditions:
(1) primary plus secondary stress intensity range of 2.4 S,,, for ferritic steel and austenitic steel l
(2) cumulative usage factor U of 0.4 (c) All dissimilar metal welds not covered under Category B-F.
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(d) Additional piping welds so that the total number of circumferential butt welds (or branch
~
connection or socket welds) selected for examination equals 25% of the circumferential butt l welds (or branch connection or socket welds)in the reactor coolant piping system. This total does not include welds excluded by IWB-1220. These additional welds may be located L
' in one loop (one loop is defined for both PWR and BWR plants in the 1977 Edition).
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o CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-12 (Page 2 of 4)
CODE REOUIREMENTS (coni)
(2) The initially selected welds shall be examined in the same sequence during successive inspection intervals, to the extent practical.
BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(i), niiefis requested on the basis that the proposed alternatives
, pmvide an acceptable level of quality and safety.
The commercial service dates for CCNPP, Units _1 and 2, were May 8,1975, and April 1,1977, respectively. During the time of constmetion, the ASME Boiler and Pressure Vessel Code only addressed nuclear vessels and piping up to the first isolation valve. Therefore, the designated code of secord for nuclear piping was USAS B31.7,1%9 Edition rather than Section III of the ASME
- Boiler and Pressure Vessel Code. Because the stress intensity range and usage factor described in Table IWB-2500-1, Examination Category B-J, Note 1(b) are parameters associated with ASME
- Section III piping designs, this information does not currently exist for the ISI Class 1 piping at CCNPP, Units 1 and 2, and would be cost prohibitive to obtain. Although the stmss data requimd by USAS B31.7 - 1%9 does exist for the ISI Class 1 piping at CCNPP, Units 1 and 2, it differs from that required by ASME Section III and does not correlate to specific weld locations.
As allowed by 10CFR50.55a(b)(2)(ii), the criteria used for the selection of Examination Category B-J welds during the first and second intervals at CCNPP, Units 1 and 2, were based on ASME Section XI,1974 Edition with Addenda through Summer 1975. This weld selection methodology requires the examination of a different 25% of the piping welds each inspection interval, such that 100% of the welds will be examined by the end of the 40 year licensing period. To continue i
selecting welds in this manner will result in considerable man-rem exposure to prepare new welds j
for examination each interval. Additionally, this method does not ensure that potentially high stressed welds are reexamined over the course of plant life to monitor for service induced degradation.
Use of the proposed altemate weld selection methodology described hemin will help to maintain the radiation expended for weld preparation "As Iow As Reasonably Achievable". In addition, L
this selection methodology has been designed to choose those welds which have a greater probability of being subject to higher stress levels. Putting emphasis on the inspection of l
potentially higher stressed welds will meet the intent of the Code and improve the overall quality L
- and safety levels of the ISI Program.
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- Based on these reasons, CCNPP, Units 1 and 2, requests relief from the ASME Section XI, Table IWB-2500-1, Note I and 2 requirements regarding the selection of Exarnination Category B-J welds
- for examination.
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-i CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-12 (Page 3 of 4)
PROPOSED' ALTERNATE CRITERIA '
CCNPP, Units 1 and 2, will select Examination Category B-J welds for examination such that r
25% of the total non-exempt welds are examined during the interval. These welds will then be reexamined during subsequent intervals per Table IWB-2500-1, Note 2. The weld population l
selected for inspection shall include the following:
(1) All terminal ends in each pipe or branch mn connected to vessels.
(2) All terminal ends in each pipe or branch run connected to other components.
(3) All dissimilar metal welds between combinations of:
(a) carbon or low alloy steels to high alloy steels (b) carbon or low alloy steels to high nickel alloys (c) high alloy steels to high nickel alloys (4) Additional piping welds so that the total number of circumferential butt welds (or branch connection or socket welds) selected for examination equals 25% of the total number of non-exempt cimumferential butt welds (or branch connection or socket welds)in the reactor coolant piping system. These additional piping welds shall be distributed as follows:
(a) The examinations shall be distributed among the Class I systems prorated, to the degree practicable, on the number of non-exempt welds in each system (i.e.,if a system contains 30% of the non-exempt welds, then 30% of the nondestructive examinations mquired by Examination Category B-J should be performed on that system);
(b) Within a system, the examinations shall be distributed among structural
- discontinuities prorated, to the extent practicable, on the number of non-exempt structural discontinuities in that system, and; (c) Within each system, examinations shall be distributed between line sizes peorated, to the degree practicable, on the number of non-exempt welda in each line size.
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CCNPP Units 1 & 2 REOUEST NUMBER: ISI-12 (Page 4 of 4)
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
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I
T CCNPP Units 1 & 2 Third IntervalISI Plan l
REOUEST NUMBER: ISI-13 (Page 1 of 3)
COMPONENT IDENTIFICATION Code Class:
2
References:
IWC-1220, IWC-2500, Table IWC-2500-1 Examination Category:
C-F-1 Item Number:
C5.11
==
Description:==
Examination of Class 2 Welds in Stainless Steel Piping Less than 3/8 in. Nominal Wall Thickness
- Component Numbers:
All Stainless Steel Class 2 Piping Welds CODE REOUIREMENT ASME Section XI, Table IWC-2500, Examination Category C-F-1, Note (2) states the following:
The welds selected for examination shall include 7.5%, but not less than 28 welds, of all dissimilar metal, austenitic stainless steel or high alloy welds not exempted by IWC-1220. (Some welds net exempted by IWC-1220 are not mquired to be nondestructively examined per Examination Category C-F-1. These welds, however, shall be included in the total weld count to which the 7.5%
sampling rate is applied.) The examinations shall be distributed as follows:
(a) the examinations shall be distributed among the Class 2 systems prorated, to the degree practicable, on the number of nonexempt dissimilar metal, austenitic stainless steel or high alloy welds in each system (i.e., if a system contains 30% of the nonexempt welds, then 30% of the nondestructive examinations required by Examination Category C-F-1 should be performed on that system);
(b) within a system, the examinations shall be distributed among terminal ends and structural discontinuities [See Note (3) of Table IWC-2500-1] prorated, to the degree practicable, on the number of nonexempt terminal ends and structural discontinuities in that system; and (c) within each system, examinations shall be distributed between line sizes prorated to the degree practicable.
6-38 Revision 0
l CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-13 (Page 2 of 3)
BASIS FOR ALTERNATIVE Pursuant to 10CFk50.55a(a)(3)(i), relief is requested on the basis that the proposed alternatives pmvide an acceptable level of quality and safety.
Code rules require that a 7.5% sampling rate be applied to all Examination Category C-F-1 piping welds not exempted by IWC-1220. The total weld count to which the sampling rate is applied includes both those welds required to be examined (i.e.,2 3/8 in. nominal wall thickness) and those welds for which examination is not required (i.e., < 3/8 in. nominal wall thickness). The total number of welds required to be examined are then distributed, in a prorated manner, among those systems requiring examination. Those piping welds less than 3/8 in, nominal wall thickness, while not requiring examination, will have an impact on the number of examinations required in systems with piping equal to or greater than 3/8 in, nominal wall thickness.
At the CCNPP, Units 1 and 2, a number of the stainless steel Class 2 systems have piping with nominal wall thickness less than 3/8 in. This includes ponions of the Shutdown Cooling, Containment Spray, and Safety Injection systems. In the past, the Nuclear Regulatory Commission has expressed concerns at a number of nuclear facilities about examinations not being performed on sections of piping because they were less than 3/8 in. nominal wall thickness. Applying a sampling rate of 7.5% to all Examination Category C-F-1 piping welds regardless of wall thickness will ensure that all Class 2 systems will undergo examinations. Based on this reason, the proposed alternative examinations will ensure that an acceptable level of quality and safety will be met.
PROPOSED ALTERNATIVE EXAMINATIONS A uniform 7.5% sampling rate will be applied to all Examination Category C-F-1 piping welds regardless of nominal wall thickness. The examination requirements shall be as follows:
q
- 1) Welds in piping 2 3/8 in. thick will be subject to volumetric and surface examinations as stated in ASME Section XI.
- 2) Welds in piping < 3/8 in. thick will be subject to a surface examination.
The piping welds selected for examination will still be subject to the distribution requirements j
stated in ASME Section XI, Table IWC-2500-1, Examination Category C-F-1, Note (2).
l 6-39 Revision 0 J
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CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI-13 (Page 3 of 3)
PROPOSED ALTERNATE EXAMsNATIONS (con't)
NOTE:CCNPP, Units 1 and 2, also contain a small number of Class 2 welds in Main Steam carbon steel piping that is less than 3/8 in. thick. This Request for Alternative is not being applied to these welds because they are already 'ubject to augmented examination in accordance with CCNPP high energy line break commitments.
APPLICABI.E TIME PERIOD l
Application of the alternative enteria is requested for the third interval of the Inservice I
Inspection Program at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
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640 Revision 0
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l-l CCNPP Units 1 & 2 Third IntervalISI Plan REOUEST NUMBER: ISI 14 (Page 1 of 4)
COMPONENT IDENTIFICATION 1
Code Class:
2
References:
IWC-2500, Table IWC-2500-1 Examination Category:
C-H Item Number:
C7.10
==
Description:==
Alternative Pmssure Testing Requirements for RPV Flange Leak j
Detector Piping Component Numbers:
Lines CC-9-1009 and CC-9-2002 CODE REOUIREMENT ASME Section XI, Table IWC-2500-1, Examination Category C-H, Code Item No. C7.10 requims the performance of a system leakage test each inspection period on Class 2 piping up to
)
the first normally closed valve, or valve capable of automatic closure.
I BASIS FOR ALTERNATIVE Pursuant to 10CFR50.55a(a)(3)(ii), relief is requested on the basis that compliance with Section XI requirements would result in hardship without a compensating increase in the levels of quality and safety.
The Reactor Vessel Head Flange leak Detector Piping is separated from the reactor pressum boundary by one passiv; membrane, which is an 0-ring located on the vessel flange. A second 0-ring is located on the opposite side of the tap in the vessel flange (See Figures ISI-14-1 and 151 2). This piping is requimd during plant operation in order to indicate failure of the inner flange seal 0-ring. Failum of the 0-ring would result in the annunciation of a High Level Alarm in the contml room. Failure of the inner 0-ring is the only condition under which this piping is pmssurized.
The configuration of this piping pmeludes system testing while the vessel head is removed because J
the odd configuration of the vessel tap (See Figure ISI-14-2) coupled with the high test pressure requirement, prevents the tap in the flange from being temporarily plugged or connected to other piping. The opening in the flange is only 3/16 of an inch in diameter and is smooth walled, making the effectiveness of a temporary seal very limited. Failum of this seal could possibly cause i
eiection of the device used for plugging or connecting to the vessel.
6-41 Revision 0
I l
CCNPP Units 1 & 2 l-Third IntervalISI Plan REOUEST NUMBER: ISI-14 (Page 2 of 4)
BASIS FOR ALTERNATIVE (coni)
)
The configuration also precludes pressure testing with the vessel head installed because the seal prevents complete filling of the piping, which has no vent available. Additionally, a pneumatic test performed with the head installed is precluded due to the configuration of the top head. The l
' top head of the vessel contains two grooves that hold the 0-rings. The O-rings are held in place by I
a sedes of retainer clips that are housed in recessed cavities in the flange face. If a pressure test was performed with the head on, the inner 0-ring would be pressudzed in a direction opposite to what it would see in normal operation. This test pressure would result in a net inward fome on the inner 0-ring that would tend to push it into the recessed cavities that house the retainer clips. The thin 0-ring material would very likely be damaged by this inward force.
In addition to the problems associated with the 0-ring design that preclude this testing,it is also questionable whether a pneumatic test is appropriate for this piping. The use of a pneumatic test performed at RPV nominal operating pressure would represent an unnecessary safety risk to personnel in the unlikely event of a test failure, due to the large amount of stored energy contained in pressurized air.
Opemtional testing of this piping is precluded because it will only be pressurized in the event of a failure of the inner 0-dng. It is extremely impractical to purposely fail the inner 0-ring in order to
. perform a test.
Based on the above, CCNPP, Units 1 and 2, requests the following alternative examination be performed on the Reactor Vessel Head Flange Izak Detector Piping.
PROPOSED ALTERNATIVE EXAMINATION A VT-2 visual examination will be performed on the Reactor Vessel Head Flange leak Detector Piping during flood-up of refueling pool during a refueling outage. The hydrostatic head developed due to the water above the vessel flange during flood-up will allow for the detection of any gmss indications in the piping. This examination will be performed with the frequency specified by Table IWC-2500-1 for an IWC-5220 test (once each inspection pedod).
]
APPLICABLE TIME PERIOD Application of the alternative criteria is requested for the third interval of the Inservice Inspection Pmgram at the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, which begins on July 1,1999.
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r::
CCNPP Units 1 & 2 l
Third IntervalISI Plan REOUEST NUMBER: 1S1-14 (Page 3 of 4)
FIGURE ISI-14-1 REACTOR PRESSURE VESSEL HEAD FLANGE LEAK DETECTOR PIPING i
See Figure ISI-14-2 For Details I
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i 6-43 Revision 0 L
l CCNPP Units 1 & 2 Third Interval ISI Plan REOUEST NUMHER: ISI-14 (Page 4 of 4)
FIGURE ISI-14 2 REACTOR PRESSURE VESSEL IIEAD FLANGE l
AND LEAK DETECTOR LINE DETAILS
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$ hie 07[o'nttNo Top s's r af,"
--i
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3pge i
See Detoll *A*
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/
rF NNNNN
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x j
x
\\
N Detail "A"
\\
/
Vessel Flonge Sectional View 6-44 Revision 0