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Non-proprietary Rev 0 to 1H61R, LGS - Unit 2 Core Shroud Ultrasonic Exam
	ML20207H833
Person / Time
Site:	Limerick
Issue date:	05/31/1999
From:	Hayden J; GENERAL ELECTRIC CO.
To:	;
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ML20137X937	List: ML20207H827; ML20207H833;
References
	1H61R, 1H61R-R00, NUDOCS 9907260037
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t Docket No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 14 of 92 Interim Report Limerick Generating Station - Unit 2 Core Shroud Ultrasonic Examination Prepared for PECO Energy Prepared by:

GE Nuclear Energy Report No.: 1H61R, Rev. 0 1

May 1999 )

Original Signed By:

Prepared By: Date:

John Hayden, GE Inspection Services, Sr. NDE Specialist I.evelll!- Ultrasonic Method Original Signed By:

Reviewed By: Date:

Richard Keck, GE Inspection Services, Project Manager Original Signed By:

Reviewed By: Date:

Thomas Anderson, PECOEnergy,ISIEngineer EROPRIETARYINFORMATION NOTICE The information contained in this document is not to be used for other than the purposes for which this document is fumished by GE Inspection Services, nor is this document (in whole or in part) to be reproduced or fumished to third parties (other than to carry out said purposes) or made public without the prior written permission of GE Inspection Services.

9907260037 990624 PDR ADOCK 05000353 p PDR

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Dock;t N2. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 15 of 92 1

Project Summary From 29 April 1999 through 8 May 1999, General Electric (GE) Inspection Services conducted ultrasonic examinations of Core Shroud Assembly welds at Limerick Generating Station - Unti 2. The scope of the examina; ions included selected portions of four circumferential welds, H3, H4, H5 and H7. The detection of flaw indications forced an expansion of the work scope to include the examination of accessible portions of welds H1, H2 and H6. )

J All welds were examined using the GE OD Tracker scanning device, while employing the conventional technique, which uses 45* shear wave,60* longitudinal wave and OD/lO Creeping wave search units in an integral housing.

This report contains specific details regarding the performance and results of the examinations.

References e

ASME Boiler and Pressure Vessel Code,Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components,1989 edition.

Note: The ultrasonic examinations described in this report are not addressed by the ASME Code. 1 The examinations were performed in accordance with the intent of ASME Sections V and XI with regard to the basic ultra',onic requirements, whenever possible.

BWRViP-03 ReactorPressure VesselandInternals Guidelines.

I e General Electric document GE-UT-503, Version 8, Procedure For Automated Ultrasonic Examination l Of Shroud Assembly Welds.

I Equipment i The capabilities of the MicroTomo* data acquisition system, TomoView Workstation and GE Trimodal search unit were successfully demonstrated in accordance with BWRVIP-03 " Reactor Pressure Vessel l and Internals Guidelines".

MicroTomo" Acquisition System The MicroTomoS data acquisition system was utilized for this examination. The MicroTomo is a

{

multiplexed, digital system. The system digitizes the entire A-scan or RF waveform at the rate of up to 120 MHz. The entire A-scan is digitized and archived to a one gigabyte optical disk or 2 gigabyte removable ]

l hard disk for off-line analysis and subsequent examination comparisons. '

0D Tracker Scanner This device rests upon and drives around the steam dam structure of the core shroud assembly.

Interchangeable vertical arms of appropriate length descend from the carriage of the GE OD Tracker to the elevation of each of the four welds examined. The search units are applied to the outside surface of the shroud, and are manipulated about the accessible ponions of the circe rference of the shroud.

Search units are also moved toward and away from each weld, in a raster scan pattern. This scanning motion generally provides full coverage of the BWRVIP-specified surface regions on both sides of the weld.

GE TriModalSearch Unit The GE Trimodal search unit was employed during the examinations of Weld H7. This device consists of a stainless steel housing for 45' shear wave, a dual-element 60* longitudinal wave and dual-element OD/lO Creeping wave transducers.

1H61R

u Docket No.' 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 16 of 92 TomoViewwData Analysis Workstation The TomoView* Workstation was used for the evaluation of ultrasonic data. The data is displayed with any combination of time or arnplitude in A-scan, B-scan, C-scan and D-scan views, with 1024 X 768 pixel resolution. Tho TomoView software permits any desired manipulation of the A, B, C or D-scan images.

An adjustable color palette is provided for image enhancement. Each image, or specific region therein, can be selectively enlarged. GE data analysts have used the TomoVie'.v software to successfully demonstrate complete flaw detection and sizing capabilities in the PDI Piping Program at the EPRI NDE Center.

TriModal Technique Examination Methodology The examinations employed 45* shear wave,60* longitudinal wave and OD/lD creeping wave transducers units which direct ultrasound to interrogate the regions of interest. The following sketch depicts the relationship between each search unit during scanning.

Looking Down - 3 Search Unit Coverage (Trailing) ODCr Start to (Leading) 45' Shear End l Scan End l l Scan Start j

% l45l [Nl

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! l l45l{lCrl pcan Direction - Facing Shroud l 45 {pi] UP Looking Up - 3 Search Unit Coverage (Trailing) 45' Shear Start to (Leading) ODCr End 1H61R

r Dock;t N3. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 17 of 92 Examination Results Numerous indications of intergranular stress corrosion were observed during the course of the examinations of welds H1, H2, H3, H4 H5 and H6. The examination of weld H7 did not reveal flaw indications. This document also contains a section of Examination Summary Sheets for each weld examined.

CircumferentialExamination Coverage This approach defines examination coverage as that length of weld scanned by the combined coverage of !

the 45* and OD/ID Creeping wave elements. This technique is considered to be satisfactory since both the 45* and OD/ID Creeping wave transducers have bee' 1emonstrated (in accordance with BWRVIP-03) to be effective for the detection of surface-breaking flaws at both the outside and inside surfaces )'

of the shroud.

{g5j @p] WDN l 1P l l Examination Personnel The examinations were conducted by the following GE Inspection Specialists:

MicroTomo /wCarousel /OO Tracker System Operators:

Martin Crane Level 11 Nicholas Labella Level 11 Terry Rockwood Level lit Michael Webster Level 11 Ultrasonic Data Analyst:

John Hayden Level lli James Halley Project Manager:

Richard Keck I

1H61R

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Docket N2. 50-353 GL 94-03 June 24,1999. 2R05 Final Report f

Page 51 of 92 1

s PECO ENERGY COMPANY LIMERICK GENERATING STATION UNIT 2 REACTOR PRESSURE VESSEL CORE SHROUD INSPECTIONS 2R05 INSPECTION FINAL REPORT May 1999 ATTACHMENT 3 Structural Integrity Associates Report Evaluation of the Limerick, Unit 2 Shroud Examination Results Report No. SIR-99-061, Revision 0 May 14,1999 (21 Pages) k I

l l

l 1

Docket No. 50-353 GL 94-03 June 24,1999 - 2R05 Final Report Page 52 of 92 May 14,1999 SIR-99-061 RAM-99-053 rmattson@structint.com Mr. Richard E. Clemlewicz PECO Energy Systems 965 Chesterbrook Blvd.,63B-3 '

Wayne, PA 19087-5691-

Subject:

Evaluation of Limerick, Unit 2 Shroud Examination Results

Dear Rich:

Structural Integrity Associates (SI) has performed an evaluation of the ultrasonic examination results recorded during the 1999 inspections of shroud circumferential welds H1 through H7 at Limerick, Unit 2, in order to determine acceptance for continual operation. The evaluations performed and documented herein were designed to justify operation without reinspection of these welds for at least onq two year operating cycle. The evaluations were performed following the approach used in the BWh Vessel and Internals Project (BWRVIP) shroud evaluation guidelines [1], based on limit load and linear elastic fracture mechanics (LEFM) techniques. The following sections of this report describe the methodology used to evaluate each weld, the resulting safety margins, and the recommended inspection intervals.

INSPECTION AND EVALUATION METHODOLOGY The inspection and evaluation approach employed at Limerick, Unit 2 provides the necessary information for determination of the required amount of unflawed material to meet specified safety margins, including the appropriate amount for postulated crack growth and nondestructive examination detection and sizing uncertainties. Ultrasonic examination (UT) techniques were utilized which provided complete through-thickness interrogation of all welds. Due to accessibility limitations, the circumferential extent of examination of these welds varied. However, sufficient weld length was adequately interrogated to quantifiably demonstrate the condition, and hence, the structural integrity of all welds evaluated. Because both limit load and LEFM assessments have been performed, evaluation methodologies will be addressed separately with respect to structural integrity evaluation.

ACCEPTANCE CRITERIA The core shroud is a core support structure which provides lateral support for the fuel. The applicable codes, standards and classification for the core shroud are as follows:

SIR-99-061/ RAM-99-053

r DoclCt No. 50-353 GL 94-03 June 24,1999 2R05 Final Repod Page 53 of 92

The core shroud is classified as a safety-related component.

The core shroud is not an ASME Code, Section lli component. However, the original design is in accordance with the intent of Section ill of the ASME Code.

. ' The evaluation of the core shroud was performed in accordance with the requirements of the BWRVIP's shroud evaluation guidelines [1].

FLAW EVALUATION RESULTS Based upon the inspection data reported in 1999, flaw evaluations were performed to justify continued operation, with the results documented herein. The analyses were performed using limit load as the failure criterion for each of the welds. The analyses performed take into account the distribution of good material at each weld around the circumference of the shroud. In addition, the H4 weld, which is the most highly irradiated, was evaluated using the LEFM methodology.

Substantial conservatisms were built into the evaluation to account for the weld area examined, the weld area which was not examined, evaluation guidelines' detection and sizing uncertainties, crack growth, and the evaluation guidelines' flaw proximity criteria as applied to adjacent flaws. The specific conservatisms utilized in this evaluation are as follows:

1. All areas not examined were considered cracked through-wall for all evaluations.

2. A bounding crack growth rate (5 x 10 4inches / hour) [1] in the length and depth directions was applied to all identified flaws, as well as to all the uninspected regions.

3. UT inspection uncertainty factors were applied to all identified indications, as well as to uninspected regions.

4. Two years of crack growth were included in the evaluation of all welds.

5. ASME Code,Section XI proximity criteria for adjacent flaws were applied, after accounting for crack growth and inspection uncertainties.

6. ASME Code,Section XI pressure boundary safety margins were applied to these evaluations even though the core shroud is not a primary pressure boundary,

7. Dead weight of the shroud and supported components was conservatively ignored.

The conservative assumptions described above were applied to each of the horizontal welds examined in this report. Table i documents tne input data. Tables 2 through 8 present the results of the ultrasonic examination for each of the horize lal welds evaluated in this report.

SIR-99-061/ RAM-99-053

Docket No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 54 of 92 The results of the limit load ana.yses for each of the horizontal welds examined are presented in Table 9, based upon tne strecses reported in Table 1, and the examiriation results reported in Tables 2 through 8.

Based upon the stresses reported in Table 1, the upset conuition governs for welds H2 through H7, while the faulted condition governs for weld H1. One observes from Table 9 that the factors-of-safety for the upset condition vary from 4.50 to 15.15, and for the faulted condition the factor-of-safety is 1.89. This compares to ASME Code minimum factors-of-safety of 2.77 and 1.39, respectively, specified for pressure boundary components [1]. One should note that the conservatisms utilized in this study are as described previously in this section.

Finally, an evaluation of the H4 weld was performed using the LEFM methodology to determine the applied stress intensity factor resulting from the bounding loading conditions. The results of this analysis demonstrate that the 150 ksiVinch material toughness which is presented in the evaluation guidelines [1]

as the acceptable fracture toughness for this material under irradiation embrittled conditions is met. Table 10 illustrates that the evaluation guidelines [1] minimum required factors-of-safety have been met for weld H4.

SUMMARY

Based upon a review of the examination data for circumferential welds H1 through H7, there is substantial margin for each of these welds under conservative, bounding conditions to allow for continued operation for at least one twenty-four month cycle. The analyses performed included limit load analyses under bounding design basis conditions, and LEFM evaluations for the postulated highest fluence weld. The evaluations were performed with the assumption that all regions uninspected, or reported with flaws, were cracked through-wall for all calculations. Additionally, all uninspected areas and areas with reported cracking were gre w in the length and depth directions at the bounding crack growth rate of 5 x 104 inches / hour, and increased in length and depth by UT uncertainty factort Required safety margins were used, and were exceeded in all cases.

Very truly yours, Prepared by: Reviewed by:

Original Signed Cy: OriO!nal Signed By:

R. A. Mattson, P. E. M. L. Herrera, P. E.

pq Attachments SIR-99-061/ RAM-99-053 l-.

Docket Ns. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 55 of 92 REFERENCES

1. BWR Vessel and Internals Project, *BWR Core Shroud Inspection and Flaw Evaluation Guidelino, Revision 2 (BWRVIP-01)," EPRI Report No. TR-107079, October 1996, SI File No. BWRVIP 201P.

2. Fax from Rich Ciemiewicz (PECO) to Dick Mattson (SI) with Attached Figure, May 9,1999, St File No. PECO-300-211.

3. GE Nuclear Energy

Evaluation of the Limerick Unit-1 Core Shroud inspections (Refuel Outage 6),"

Report No. GE-NE-B13-01805-16, February 1996, SI File No. PECO-300-202.

4. GE Nuclear Energy," Determination of Inspection Lengths for the Limerick Unit-1 Shroud," Report No. GENE-523-A037-0495, July 1995, St File No. PECO-300-205.

5. Structural Integrity Associates, *1mpact of RIPD's on the Shroud Evaluation for Limerick Generating Station, Unit 1," Report No. SIR-99-046, April 9,1999, St File No. PECO-300-401.

6. BWR Vessel and Intemals Project, " Reactor Pressure Vessel and Intemals Examination Guidelines (BWRVIP-03), Revision 1," EPRI Report No. TR-105696-R1, March 1999, St File No. BWRVIP 203P.

7. E-mail from Richard Ciemiewicz (PECO) to Dick Mattson (SI) dated May 13,1999,9:52 a.m., St File No. PECO-300-213.

8. Structural Integrity Associater, Software User Manual,"ANSC for Determining Net Section Collapse of Arbitrarily Thinned Cylinder," Report No. SIR-94-035, Revision 0, April 29,1994, SI File No. QA-1900.

9. Tada, H.,"The Stress Analysis of Cracks Handbook," Paris Productions Inc., Second Edition,1985.

10. Electric Power Research Institute, " Ductile Fracture Handbook," Report No. NP-6301-D, June 1989.

11. Rooke, D. P. and Cartwright, D. J.," Compendium of Stress Intensity Factc< s," The Hillingdon Press, 1976.

12. BWR Vessel and Internals Project," Evaluation of Crack Growth in BWR Stainless Steel RPV Internals (BWRVIP-14)," EPRI Report No. TR-105873, March 1996, SI File No. BWRVIP-01-214P.

SIR-99-061/ RAM-99-053

Yli (

Docket No. 50-353 GL 94-03 '

June 24,1939 2R05 Final Report Page 56 of 92

(

I 13.- Letter from Carl Terry (BWRVIP Chairman) to C. E. Carpenter (U.S. NRC), Project No. 704 -

CWRVIP Response to NRC Safety Evaluation of BWRVIP-14," November 24,1998, St File No. ;

EPRl-89-403.

{

1. Letter from Carl Terry (Vice President, Niagara Mohawk Power Corporation) to U a. NRC Docket Control Desk, Letter Number NMP2L 1803, July 9,1998, Si File No. PECO-300-214.

s1 J

SIR-99-061/ 99-053

m Dock;t No. 50-353 - GL 94-03

' June 24,1999 2R05 Final Report Page 57 of 92 Table 1 Design input!

V/ eld Shroud . Shroud Bending Moment- Pressure Differential Designatio~ Mean Thickness Stresses Stresses

-n Radius [2] [2] (ksi) (ksi)

Upset Faulted Upset Faulted H1 109.0" 2.0" 0.594[4] 1.045[4] 0.322 0.7773 H2 109.0" 2.0" 0.810[4] 1.377[4] 0.3225 0.777 H3 102.5625" 2.0" 0.935[3] 1.583[3] 0.300[3] 0.724[3]

H4 102.5625" 2.0" -1.471[3] 2.411[3] 0.300[3] 0.724[3]

H5 102.5625" 2.0" 2.740[3] 4.468[3] 0.300[3] 0.724[3]

H6. 99.375" 2.0" 2.9822 4.851 8 0.570[5] 1.000[5]

H7 99.375" 2.0" 3.746[3] 6.140[3] 0.570[5] 1.000[5]

Notes: 1. Other design input includes the following:

The shroud material is Type 304L stainless steel, with S equal to 14.4 ksi at 550 F [4].

The crack growth rate to be used is 5 x 104 inches / hour [1]. For purposes of this evaluation, it is assumed that Limerick, Unit 2 is on twenty-four month fuel

. cycles, with 16,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> per cycle.

The factors-of-safety to be considered are 2.77 for the upset condition, and 1.39 for the faulted condition [1].

2. The stress is calculated based upon the bending moment in Reference 4.

3. The stress is calculated based upon the pressure in Reference 4.

I i

SIR-99-061/ RAM-99-053

Docket No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 58 of 92 Table 2 Weld Designation H1 Flaw Detection Results 2.3 Flaw Starting Azimuth Ending Azimuth Number (*) (*)

1 0.00'

11.01

2 12.06' 39.46' 3 39.46 50.51 ' d 4 54.86' 59.81' 5 61.97 8 64.17' 6 65.27 70.57 7 72.22 73.32 8 74.97' 80.27' 9 84.47' 94.92' 10 98.02 99.12 11 99.67' 101.32' 12 101.67 103.32 13 103.87 106.62 14 107.17' 126.46' 15 126.46 190.51

16 206.01' 209.31' 17 212.18' 214.38' 18 215.48 217.13 19 219.88'* 233.56

20 238.46 240.11 21 243.07' 244.17' 22 261.92 264.67 23 277.47 280.57 24 294.36' 304.26' 25 305.36 306.46 26 306.46 360.00

Notes: 1. Flaws which cross over lug sets are increased in length by 0.5 at each end [6,7].

All uninspected regions are also increased in length by 0.5' at each end.

2. UT uncertainty factors for length are based upon the transducer which determines the length. For near side detection, the factor is 0.000" for both the creeping wave and 45 shear [6,7). The uncertainty factor is added to each end of the flaws.

3. All reported Indications are assumed to be through-wall, as are all uninspected regions.

4. Uninspected regions.

SIR-99-061/ RAM-99-053

Docket No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 59 of 92 Table 3 Weld Designation H2 Flaw Detection Results" i Flaw Starting Azimuth Ending Azimuth Depth

Number (') (') (inches) 4 1 0.00'd 10.98'd 2.0 l 2 12.72' 20.82' O.31 3 23.49 25.14 0.31 4 34.49 35.59 0.31 5 36.14 38.34 0.31 6 39.30'd 50.48'd 2.0 7 50.57' 57.33' O.31 8 64.28 70.88 0.31 9 72.33 73.98 0.31 10 74.53' 81.48' O.31 11 98.48 99.58 0.31 12 114.47 116.12 0.31 13 117.77 119.97 0.31 14 124.92 125.47 0.31 15 126.43'd 190.48'd 2.0 16 191.12' 155.52' O.31 17- _ , 201.72- 203.37 0.31 18 203.92 205.63 0.31 19 219.85'd 233.40'd 2.0 20 233.48 235.68 0.31 21 243.18' 261.48' O.31 22 278.13' 287.83' O.31 23 294.47 295.57 0.31

~

24 304.37 305.47 0.31 15 306.57'd 360.00'd 2.0 Notes: 1. Flaws which cross over lug sets are increased in length by 0.5' at each end [6,7). All uninspected regions are also increased in length by 0.5" at each end.

2. UT uncertainty factors for length are based upon the transducer which determines the length. For near side detection, the factor is 0.000" for 45 shear [6,7]. The uncertainty factor is added to each end of the flaws.

3. UT uncertainty factors for depth are based upon the transducer which determines the depth.

For near side detection, the factor is 0.106" for 60 longitudinal [6,7]. The maximum reported flaw depth is aesumed for all flaws. For analysis purposes, the entire shroud will be assumed to be flawed to the maximum reported flaw depth, in conjunction with through-wall flaws at the uninspected regions.

4. Uninspected regions.

SIR-99-061/ RAM-99-053

DockCt Ns. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 60 of 92 Table 4 Weld Designation H3 Flaw Detection Results 2.3 Flaw Starting Azimuth Ending Azimuth Depth

Number (*) (*) (inches) 1 0.00' ' 5.04 2.0 2 6.09' 39.91' 2.0 3 39.91 50.04 2.0 4 51.09' 80.94' 2.0 5 81.41 83.14 2.0 6 84.71' 89.46' O.39 7- 90.56 91.66 0.39 8 99.51' 109.96' O.39 9 109.96 110.04 2.0 10 110.04' 117.77' 2.0 11 124.84 126.49 0.39 12 126.49 182.66 2.0 13 186.46' 203.29' 2.0 14 208.79 210.56 0.33 15 212.21' 219.91' 2.0 16 219.91 233.46 2.0 17 233.49' 263.14' 2.0 18 263.69 265.89 0.33 19 266.24' 269.54' O.33 20 270.99' 281.24' O.33 21 282.34 286.19 0.33 22 291.09 292.19 0.39 23 292.27' 298.79' 2.0 24 301.07 302.17 0.33 25 303.27' 304.92' O.33 26 306.49 360.00 2.0 Notes: 1. Flaws which cross over lug sets are increased in length by 0.5* at each end [6,7]. All uninspected regions are also increased in length by 0.5* at each end.

2. UT uncertainty factors for length are based upon the transducer which determines the length. For near side detection, the factor is 0.000" for both the creeping wave and 45*

shear [6,7]. The uncertainty factor is added to each end of the flaws 1

3. UT uncertainty factors for depth are based upon the transducer which determines the depth.

For near side detection, the factor is 0.131" for 45* shear [6,7]. The maximum reported flaw depth on the applicable surface is assumed for all flaws. For cracking from both surfaces, a through-wall flaw is conservatively assumed.

4. Uninspected regions.

SIR-99-061/ RAM-99-053

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l Dock;t N2. 50-353 GL 94-03 June 24,1999 2R05 Final Repod Page 61 of 92 l l

l Table 5 Weld Designation H4 Flaw Detection Results2 Flaw Starting Azimuth Ending Azimuth Depth 8 Number () (') (inches) 1 0.00' ' 5.01 2.0 2 7.79 11.09 0.10 3 12.11 13.76 0.10 4 13.76 15.93'd 2.0 5 16.59 18.24 0.10 6 21.06 22.16 0.10 ;

7 23.03' 26.56' O.10 l 8 28.76 32.06 0.10 l 9 33.16' 35.91' O.10 10 36.46 50.01'd 2.0 11 51.13 52.78 0.10 l 12 53.33 55.53 0.10 j 13 57.68' 70.58' O.11 14 73.88 76.63 0.10 15 86.68 89.98 0.10 j 16 96.58 98.23 0.10 _

17 104.98 107.73 0.10 18 110.48 111.58 0.10 19 114.82' 118.12' O.10 20 119.22 120.32 0.10 21 126.37 126.92 0.10 22 126.92'd 163.67'" 2.0 23 166.20 167.70 0.10 24 170.77'" 182.58 2.0 25 186.06 187.71 0.10 26 189.91' 194.31' O.10 27 194.66 197.41 0.10 28 203.81' 208.76' O.10 !

29 219.88 234.50'* 2.0 l 30 236.94 239.69 0.10 1 31 244.35 246.00 0.10 32 248.20 249.30 0.10 33 253.40 256.70 0.10 34 258.35' 259.45' O.10 35 260.00 261.10 0.10 j 36 262.20 , 263.30 0.10 J SIR-99-061/ RAM-99-053

Dock:t No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 62 of 92 Table 5 (concluded)

Weld Designation H4 Flaw Detection Results:

Flaw Starting Azimuth Ending Azimuth Depth' l Number (') (*) (inches) 37 280.70' 282.70' O.10 38 294.93' 298.23' O.10 39 298.78 301.53 0.10 40 305.38 306.48 0.10 41 306.48 343.67' 2.0 42 343.70 344.70 0.10 43 350.77* 360/00 2.0 Notes: 1. Flaws which cross over lug sets are increased in length by 0.5' at each end [6,7].

All uninspected regions are also increased in length by 0.5 at each end, except those marked with a *, which are increased in length by 0.02' at each end.

2. UT uncertainty factors for length are based upon the transducer which determines the length. For near side detection, the factor is 0.000" for the creeping wave [6, 7]. The uncertainty factor is added to each end of the flaws.

3. UT uncertainty factors for depth are based upon the transducer which determines the depth. For near side detection, the factor is 0.131" for 45 shear [6,7]. For analysis purposes, the entire shroud will be assumed to be flawed to the maximum reported flaw depth, in conjunction with through-wall flaws at the uninspected regions.

4. Uninspected regions, j i

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SIR-99-061/ RAM-99-053

0 Docket No. 50-353 GL 94-03 June 24,1999 2R05 Final Repod Page 63 of 92 Table 6 Weld Designation H5 Flaw Detection Results2 Flaw Starting Azimuth Ending Azimuth Depth' Number () (a) (inches) 1 0.00 " 5.07" 2.0 2 39.94

50.07 " 2.0 3 58.4_4 59.97 0.05 4 77.01 80.31' 2.0 5 5 83.49 86.25 0.05 6 90.91' 94.76' O.05 7 97.51 100.26 0.05 8 109.49 112.82 0.05 9 121.62' 123.82' O.05 10 126.52 " 182.58 " 2.0 11 183.11' 184.21' O.05 12 219.33" 233.49 " ~ ~

2.0 13 306.52" 360.00" 2.0 Notes: 1. Flaws which cross over lug sets are increased in length by 0.5' at each end (6,7].

All uninspected regions are also increased in length by 0.5' at each end.

2. UT uncertainty factors for length are based upon the transducer which determines the length. For near side detection, the factor is 0.000" for the creeping wave and 45* shear [6,7]. The uncertainty factor is added to each end of the flaws.

3. UT uncertainty factors for depth are based upon the transducer which determines the depth. For near side detection, the factor is 0.131" for 45' shear (6,7]. For analysis purposes, the entire shroud will be assumed to be flawed to the maximum reported flaw depth, in conjunction with through-wall flaws at the uninspected region.

4. Uninspected regions.

5. For cracking from both surfaces, a through-wall flaw is conservatively assumed.

SIR-99-061/ RAM-99-053

l DockIt No. 50-353 GL 94-03 June 24,1999 2R05 Final Report l Page 64 of 92 l

Table 7 l

l Weld Designation H6 l Flaw Detection Results: l Flaw Starting Azimuth Ending Azimuth Depth 8 Number (") (') (inches) 1 0.00' ' 5.04' 2.0 2 6.09' 21.84' O.35 l 3 22.i9' 39.36' O.35 4 39.36 50.04 2.0 I 5 51.09' 63.11' O.35 6 65.86 68.61 0.35 7 69.16' 79.76' O.35 8 82.51 88.36' O.35 9 91.11' 96.96' O.35 10 97.51' 123.19' O.35 11 126.49 182.66'4 2.0 12 187.74' 193.24' O.35 13 204.39 205.49 0.35 14 209.34' 214.41' O.35 15 215.51 219.36 0.35 16 219.36 237.54 2.0 17 238.59 239.69 0.35 18 245.31 247.39 0.35 i 19 248.06 250.26 0.35 20 262.51 265.26 0.35 '

21 275.31 276.96 0.35 22 283.91' 294.94' _

0.35 23 296.04' 298.24' O.35 24 301.54' 304.29' O.35 25 304.29 360.00 2.0 Notes: 1. Flaws which cross over lug sets are increased in length by 0.5' at each end [6,7].

All uninspected regions are also increased in length by 0.5* at each end.

2. UT uncertainty factors for length are based upon the transducer which determines !

the length. For near side detection, the factor is 0.000" for 45 shear [6,7]. The uncertainty factor is added to each end of the flaws.

3. UT uncertainty factors for depth are based upon the transducer which determines

the depth. For near side detection, the factor is 0.131" for 45' shear [6,7]. For i analysis purposes, the entire shroud will be assumed to be flawed to the maximum reported fiaw depth, in conjunction with through-wall flaws at the uninspected regions.

4. Uninspected regions.

SIR-99-061/ RAM-99-053

Docket No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 65 of 92 Table 8 Weld Designation H7 Flaw Detection Results Flaw Starting Azimuth Ending Azimuth Depth Number (*) (') (inches) 1 0.00' ' 5.03'd 2.0 2 36.42'* 53.45 2.0 3 126.48'4 185.03' d 2.0 4 216.48'd 234.50'* 2.0 5 311.38 360.00'* 2.0 Notes: 1. Flaws which cross over lug sets are increased in length by 0.5" at each end [6, 7].

All uninspected regions are also increased in length by 0.5" at each end.

2. Uninspected regions.

SIR-9941/ RAM-99-053

Dock:t No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 66 of 92 Table 9 Limit Load Factors-of-Safety' 8 Weld Factor-of-Safety3^6 Designation Calculated Allowable H1 1.89 1.39 H2 15.15 2.77 H3 6.03 2.77 H4 12.19 2.77 HS 7.35 2.77 H6 4.50 2.77 H7 8.26 2.77 Notes: 1. Based upon one cycle (two years) of crack growth for all welds.

2. See Appendix B for the detailed ANSC [8] output.

3. The allowable factors-of-safety are 2.77 for the upset condition, and 1.39 for the faulted condition.

4. The factors-of-safety are calculated as follows, with all stresses in ksi:

S.F. =

P, + P, where: P. = bending moment stress from Table 1 P. = pressure differential stress from Table 1

= minimum failure bending stress from Appendix B output Pl

5. For weld H1, the faulted condition governs. For welds H2 through H7, the upset condition govems.

SIR-9h')61/ RAM-99-053

Docket No. 50-353 GL 94-03

. June 24,1999 2R05 Final Report Page 67 of 92 Table 10 Linear Elastic Fracture Mechanics Factors-of-Safety .2 Weld Factor-of-Safety

Designation K'3 H4 44 3.4 Notes: 1. Based upon one cycle (two years) of crack growth.

2. See Appendix C for the detailed calculations.

3. Units are ksi Vin.

4. The factor-of-safety equals the material toughness (Kc) i divided by the applied stress intensity factor (K,), where the material toughness is 150 ksi Vin [1]. The allowable factor-of-safety for upset conditions is 2.77.

SIR 99-061/ RAM-99-053

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Docket N3. 50-353 GL M-03 June 24,19PP 2R05 Final Report Page 68 of 92 APPENDlX A inspection Results (See ATTACHMENT 2 to the PECO Energy Report) r SIR-99-061/ RAM-99-053

Docket Ns. 50-353 GL 94-03

'Jur3e 24,1999 2R05 Final Report Page 69 of 92 APPENDIX B Flaw Evaluation Results Using the ANSC Software [8]

Basis for Analyses:

1. All reported indications are increased in length at each end by one cycle of crack growth (0.8 inches), and by the UT length sizing uncertainty shown in Tables 2 through 8, as appropriate.

2. All areate not examined are assumed to be flawed through-wall, and increased in length as stated above.

3. Flaws increased in length per Note 1 will be combined if closer than 4 inches (twice the shroud thickness) t'part [1].

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SIR-99-061/ RAM-99-053

r Docket No. 50-353 GL 94 June 24,1999 2R05 Final Report Page 70 of 92 APPENDIX C Linear Elastic Fracture Mechanics Evaluation

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' Docket N3. 50-353 GL 94-03

June 24,' 1999 2R05 Final Report Page 71 of 92 Weld H4 will be evaluated using linear elastic fracture mechanics techniques, and one cycle of operation for crack growth. The methodology to be utilized is as follows:

Those areas which have partial through-wall flaws wt be evaluated using the methodology of Tada [9].

' Those areas which are postulated to have through-wa3 flaws adjacent to partial through- !

wall flaws will be evaluated using the methods outlined by EPRI [10), and will consider !

flawinteraction per Rooke[11).

Partial Throuch-Wall Flaw Evaluation For evaluation of a partial through-wall flaw of depth equa! te t a4) inches (two years of crack growth at 5 x 104 inches / hour plus a depth uncertainty _ factor of 0.131 tnehos plus an initial crack depth of 0.11 inches), the stress intensity factor can be calculated uetg the methods of Tada [9):

K = ogna F(a/b)

I where the term F(a/b) accounts for the crack depth (a) as a function of plate depth (b).

From Tada, page 2.11:

4 0.752 + 2.02(a / b)+ 0.371 - sin ** 9 F(a/b)= tan "" e =3.0 V xa 2b **

cos {

2b K = (1.771)(3.0M(n)(1.041) = 10 ksid (upset conditions)

However, this value of stress intensity only accounts for applied stresses. The effect of residual stresses must also be taken into account. From the austenitic stainless steel crack growth report [12), the stress intensity factor due to weld residual stresses is negative for flaws deeper than about 45% through-wall.

Even considering the industry's latest position on this subject [13), the applied stress intensity factor for a flaw 52% through-wall is under 19 kslM. If this is added to the above value, the applied stress intensity factor is still well within any allowable value.

Throuch-Wall Flaw Evaluation For evaluation of postulated through-wall flaws adjacent to partial through-wall flaws in weld H4, methods outlined in the EPRI Ductile Fracture Handbook [10] will be used. ,

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l SIR-99-061/ RAM-99-053 m

DockGt No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 72 of 92 From Chapter 5, Section 1, the stress intensity factor (K) for a compound crack when subjected to a bending moment can be calculated as follows:

K = (o,F,) hM The terminology is provided in the referenced handbook. For stress, the total stress will be utilized for this evaluation.

For a total upset stress of 1.771 ksi (controlling condition), a through-wall flaw of length equal to 38.61*

(37.19' flaw length plus 0.9' for crack growth plus 0.52' for UT length sizing uncertainty), the stress intensity factor equals 39.1 ksi.

However, because of proximity to an adjacent through-wall flaw, this stress intensity must be increased by a factor. From Rooke [11), for a ligament of 6.16* (7.1" ligament minus 0.9* for crack growth minus 0.04' for UT length sizing uncertainty) and an adjacent flaw length equal to 15.66* (14.24* flaw length plus 0.9' for crack growth plus 0.52* for UT length sizing uncertainty), the flaw interaction effect can be calcu'ated per the methodology of Figure 76 [11]. For ai/b = 0.56 and a/b = 1.38, K/Koequals 1.12.

Therefore, the total stress intensity factor in the shroud equals 44 kslM.

One should note that the use of the methodoiogy described above is only applicable for bending moments applied to a cylinder with a radius to thickness ratio between 5 and 10. The validity of tile use of this method will be substantiated through the use of detailed finite element analyses. It should also be noted that the methodology utilized herein is consistent with that utilized by GE Nuclear Energy in the evaluation of the cracking at Nine Mile Point, Unit 2 [14].

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SIR-99-061/ RAM-99-053

i Docket No. 50-353 GL 94-03

. lune 24,1999 2R05 Final Report Page 73 of 92 PECO ENERGY COMPANY LIMERICK GENERATING STATION UNIT 2 REACTOR PRESSURE VESSEL CORE SHROUD 2R05 INSPECTION FINAL REPORT May 1999 ATTACHMENT 4 StructuralIntegrity Associates Report Evaluation of Shroud Vertical Welds at Limerick, Unit 2 Report No. SIR-99-063 May 14,1999.

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SIR-99-063/ RAM-99-055

Dock t No. 50-353 GL 94-03 June 24,1999 2R05 Final Report Page 74 of 92 May 14,1999 SIR-99-063 RAM-99-055 rmattson@structint.co Mr. Richard E. Ciemiewicz PECO Energy Systems 965 Chesterbrook Blvd.,63B-3 Wayne, PA 19087-5691

Subject:

Evaluation of Shroud Vertical Welds at Limerick, Unit 2

References:

1. GE Nuclear Energy," Shroud Vertical Weld inspection and Evaluation Guidelines," Report No. GENE-B13-01980-14 (Draft), March 1999.

2. Structural Integrity Associates," Evaluation of Limerick, Unit 2 Shroud Examination Results," Report No. SIR-99-061, May 14,1999.

3. Letter i, ' D Carl Terry (BWRVIP Chairman) to C. E. Carpenter (U.S. NRC),

" Project No. iG . - BWRVIP Response to NRC Safety Evaluation of BWRVIP-14," l November 24,1998, SI File No. EPRI-89-403.

Dear Rich:

Per your request, we have evaluated the allowable flaw depth for continuous flaws in the Limerick, Unit 2 ,

shroud vertical welds, assuming that the shroud horizontal welds are flawed through-wall for their entire '

length. The methodology utilized in this evaluation is contained in the shroud vertical weld evaluation guidelines [ ), with the design input obtained from the Reference 2 report.

]

The methodology utilized is that described in Section 4.2.1 of the guidelines. For the high fluence welds, the applied stress intensity factor can be calculated utilizing Equations (4) and (5). For an assumed 1.6" deep flaw, for the controlling faulted condition ([n = 1.448 ksi), the applied stress intensity factor (K) is:

K = o 6Ra / M 3

where: (n = 1.448 ksi a = 1.6"

= 12.0 F(a/b)

SIR-99-063/ RAM-99-055

n Docket N150-353 GL 94-03 June 24,1999 2R05 Final Report Page 75 of 92 or, the applied intensity factor equals 39 ksi M. However, the stress intensity factor due to residual stresses must also be taken into account. Utilizing the latest BWRVIP methodology for shroud horizontal welds (3), the stress intens:ty factor for a flaw 80% through-wall is approximately 7 kald. Therefore, the total stress intensity factor is 46 ksi, with an allowable value of 100 kslM [1].

For the welds which only need to be evaluated utilizing limit load techniques, Equation (6) can be solved.

. The allowable flaw depth (a), for the goveming upset condition below the core plate, is as follows:

a=t- (SF)(2to,,)/(2of) where: t = 2" SF .= 3.0

= 1.14 ksl ai c, = 43.2 ksi Therefore, a continuous 1.84" deep tiaw is allowed for all shroud vertical welds evaluated to limit load criteria.

In conclusion, all vertical welds in the Limerick, Unit 2 shroud can be flawed at the end of the next cycle to a depth of at least 1.6". Taking into account one cycle of crack growth (0.8") and a maximum UT depth sizing uncertainty factor (0.131"), the allowable flaw size at the beginning of the cycle is 0.67", which is deeper than any flaw measured in the horizontal welds in the current outage.

Very truly yours, Prepared by: Reviewed by:

Original Signed By: Original Signed By:

Richard A. Mattson, P. E. Marcos L. Herrera Associate Associate gav SIR-99-063/ RAM-99-055 '

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, DockQt No. 50-353 GL 94-03

- June 24,1999 - 2R05 Final Report Page 76 of 92 1

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i PECO ENERGY COMPANY LIMERICK GENERATING STATION UNIT 2 REACTOR PRESSURE VESSEL CORE SHROUD 2R05 INSPECTION Fli4AL REPORT May 1999 l

ATTACHMENT 5 General Electric Technical Services Report The Evaluation of Limerick Unit 2 Shroud Cracking For At Least One Cycle of Operation GE-NE-B13-02010-33 May 1999 (16 Pages) 1 i

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Proprietary Document ,

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ML20207H833

Contents

Text

Subject:

Dear Rich:

SUMMARY

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References:

Dear Rich:

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