ML20236D245

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Submits Descriptions of Listed Items,Including post-overlay Insp Program & Weld Overlay Repairs on Reactor Recirculation Safe Ends,Per 890208 Telcon Re Final IGSCC Insp Results for Refueling Outage 6
ML20236D245
Person / Time
Site: Brunswick 
Issue date: 03/14/1989
From: Loflin L
CAROLINA POWER & LIGHT CO.
To:
NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
NLS-89-061, NLS-89-61, NUDOCS 8903230018
Download: ML20236D245 (16)


Text

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.s CASA Carolina Power & Light Company _

MAR I 41989 SERIAL; NLS-89-061 United States Nuclear Regulatory Commission ATTENTION: Document Control Desk Washington, DC 20555 BRUNSWICK STEAM ELECTRIC PLANT, UNIT NO. 1 DOCKET NO. 50 325/ LICENSE NO. DPR-71 FINAL IGSCC INSPECTION RESULTS - REFUELING OUTACE 6

References:

1.

Letter from Mr. L. W. Eury (CP&L) to Nuclear Regulatory Commission dated July 18, 1988, " Response to Generic Letter 88-01 and IGSCC Inspection Plans -- BSEP-1 Refueling Outage 6" 2.

Letter from Mr. L. I. Loflin (CP&L) to Nuclear Regulatory Commission dated December 28, 1988, " Evaluation and Mitigation Measures for Reactor Recirculation and Core Spray Inlet Nozzle to-Safe End Weldments" 3.

Letter from Mr. R. B. Richey (CP&L) to Nuclear Regulatory Commission dated January 13, 1989, " Reactor Recirculation and Core Spray Inlet Nozzle to-Safe End Weld Overlays" l

l 4.

Letter from Mr. L.

I, Loflin (CP&L) to Nuclear Regulatory Commission dated January 27, 1989, "ICSCC Inspection Results -

l Refueling Outage 6" Centlemen:

i As discussed in our previous letter (Reference 4), Carolina Power &

Light Company (CP&L) apprised the NRC Staff of the IGSCC inspection results from the current refueling outage for Unit 1.

Because post-overlay ultrasonic testing (UT) examinations were in progress at the time the January 27, 1989 letter was submitted, CP&L committed to provide within 30 days after start-up an updated weld overlay design.

report.

These inspections and the subsequent repairs applied as a result of indications detected in adjacent weldments have been completed.

9903 p

E" h0 1

s 411 Fayetteville Street e P. O. Box 1551

  • Raleigh. N C 27602 e-- - -

D Document Control Desk I

NLS-89-061 / Page 2 l

l l

On February 8, 1989, technical representatives from CP&L and the NRC-Staff held a telephone conference to discuss these results.

Based on these discussions and the documents referenced above, this letter contains descriptions of the following:

1.

the post-overlay inspection program 2,

weld overlay repairs made on reactor recirculation safe ends l

3.

a revised summary of the susceptible weld population 4.

a conclusion that includes a revised basis for continued operation and an economic analysis to justify the schedule for permanent Unit i repairs during the next refueling outage, presently scheduled to begin in April 1990 5.

an updated classification of the service sensitive weldments into the seven categories defined in NUREG-0313, Revision 2 based on the final results of these Unit 1 inspections (Tables 1 and 2).

POST-0VERLAY (Nozzle-to-Safe End) INSPECTION PROGRAM UT Process The UT examinations were performed by general Electric (CE) UT personnel who have been qualified in accordance with the EPRI/BVROG/NRC q

requirements, including the latest requalification program. An additional second party UT examination was performed on a selected nozzle overlay by Universal Testing Laboratories (UTL) UT personnel who have received training and have been qualified at the EPRI Center.

The GE examinations incorporated the use of the fully automated GE

" SMART UT" System as described in Reference 4 Manual examinations were performed to supplement the SKART UT examinations. The UTL examinations incorporated the use of a KKB-USD10 Flaw Detector, a modified Siemens-KWU Stutzen Manipulator and Siemens-KVU Probes.

Four different probes were used to locate and characterize the indications.

Indications in the area inspected were "hard-copied" and data was recorded onto a video cassette.

Scono of Examinations The original scope of the post-overlay examinations consisted of the nine (seven reactor recirculation and two core spray nozzle-to-safe end weld) overlays applied (see Reference 2) and two thermal sleeve-to-safe end weldments.

1

Document Control Desk NLS-89-061 / Page 3 J

During the examination of the 12 ARC 6 overlay, several indications were detected in the area of the thermal sleeve to safe end weld. This area was not part of the original examination scope.

Following completion of the overlay examination, the "C" thermal sleeve-to-safe end weld (which j

along with "H", was one of two thermal sleeve-to-safe ends originally j

selected) was examined. The inspection was performed using the 45 degree shear wave as per procedure ar.d could not verify the flaws detected during the overlay examination.

Supplemental examinations were i

then performed using refracted longitudinal (RL) transducers of l

31 degrees, 36 degrees, and 45 degrees that confirmed the presence of

]

the flaws.

Based on these results, the scope of examinations was increased to include seven additional thermal sleeve-to-safe end joints (five on reactor recirculation nozzles that were overlaid, one on an unoverlaid reactor recirculation nozzle, and one on a core spray nozzle that was overlaid).

Indications were detected in all of these except for the core spray safe end.

The inspection scope was then further expanded to include the remaining two reactor recirculation thermal sleeve-to-safe end welds.

The remaining core spray thermal sleeve-to-safe end, which is not a welded connection, was not included based on results of the other core spray examination.

UT Results As previously described in the January 27, 1989 letter, UT examinations were performed on 92 weldments in Categories A, C, D, and E of NUREC-0313, Revision 2.

The results of those inspections are described in our previous letter (Reference 4).

Results of the post-overlay examinations which were not previously submitted are as shown in Table 3 and as follows:

l 1.

Nozzle-to-Safe End Overlays UT examination of the nine nozzle-to-safe end overlays revealed areas of lack of bond, interbead lack of fusion, and limited growth of previously detected indications following application of the overlay. A summary of these results is contained in Table 3.

Analysis of recorded indications has been performed by Structural Integrity Associates, Inc. (SIA).

The results of these analyses will be provided in Volume II of the final overlay design report for BSEP-1, which will be submitted to the NRC within 30 days following start-up of BSEP-1 from the current refueling outage.

Examinations of weld overlays on 12ARD6 and 12BRH6 detected growth in previously detected indications.

No definite end point or length could be determined due to the indications extending to the edge of the full structural portion of the overlay. Additional machining was performed on the nozzle end of the overlay to expand the examination area.

Both CE and UTL 1

~e 1

1 Document Control Desk NLS 89-061 / Page 4 performed UT scans of:the machined surface with'the following

'j results:

The GE examinations of both overlays determined the ehd 0.8 inches (12BRH6) from the' downstream edge of the overlay.

point of the indications was 0.9 inches (12ARD6) and' This confirmed a growth of.approximately 1.0 inches (12ARD6) and 0.8 inches-(12BRH6) of the original indications.

.The UTL examination (12ARD6 only) revealed that no

'I

. indications-were detectable from the machined-surface q

l downstream'of indications detected by GE, thereby confirming-the results obtained by GE.

I i

2.

Thermal Sleeve-to-Safe End Weldments t

l Results of these examinations revealed varying. degrees of axial

,l and circumferential indications in all. ten of the reactor I

recirculation safe ends a shown in the. summary (Table 3).

Structural Integrity Associates has, as described above, analyzed these indications and'the results'are'provided in the final design report.

A metallurgical (boat) sample was removed from the N2D safe end to confirm the presence of.the detected indications.

Results of this sample were able to confirm the accuracy of the UT examination, but not the crack mechanism.

SAFE END WELD OVERLAY i

As a result of the telephone conference. held on February 8, 1989 and a subsequent call made on February 13, 1989, CP&L presented to.the. Staff our proposed plans to apply " limited service" weld overlays (for one cycle oi operation) to those safe ends that,. by analysis, required structural reinforcement.

The analysis of these welds'and the design of the weld overlay repairs was performed by Structural' Integrity Associates, Inc.

Based on this analysis, weld overlay repairs were applied to all ten (10) reactor recirculation safe. ends.

The weld overlay application was performed as follows:

Prior to welding, the area to be welded and one inch of the base material on either side was liquid penetrant (LP) examined. The weld overlay was then applied in accordance with the. design i

dimensions provided by Structural Integrity Associates.'

The final weld overlay surface was liquid penetrant examined.

A description of the weld overlay repairs, including details of the repair process, design criteria and analysis,:and stress calculations, will be provided by separate submittal'to the NRC no later than 30 days following start-up of Unit 1 (currently scheduled for March 26, 1989).

i

__m

_. a m_ _ _ _. _ _ _. _ _

w Document Control Desk NLS-89-061 / Page 5 l

l

SUMMARY

OF THE SUSCEPTIBLE WELD POPUIATION j

The susceptible weld population, as defined by NUREG-0313, Revision 2, l

for the Brunswick Plant, Unit 1 is summarized below and included in j

Tables 1 and 2.

[

]

Welds replaced with esistant marnrial 113 Solution annealed welds 9

Welds mitigated by IHSI 55 Wolds mitigated by MSIP 7

l Unmitigated welds 22 j

Flawed welds mitigated by IHSI 1

Welds repaired by weld overlay 45 Limited Service weld overlays 10 Total number of IGSCC welds 262 l

CONCLUSION j

Carolina Power & Light Company has completed IGSCC examinations and repairs on the Brunswick Plant, Unit 1.

SUMMARY

As precented in our previous submittal (Reference 4), and as contained l

herein, the total scope of work performed during this refueling outage consisted of the following:

1.

Mechanical Stress Improvement Process (MSIP) was performed on selected inconel butter reactor pressure vessel nozzle q

welds (core spray, reactor recirculation suction and i

discharge, and jet pump instrumentation).

2.

Remaining portions of the reactor water clean-up (RWCU) l system (excluding the weldolet connections to the RHR and reactor recirculation systems ) that contained susceptible 304 stainless steel material, have been replaced with resistant 316L stainless steel material.

3.

Ultrasonic examinations were performed on ninety-two (92) weldments, and on one (1) core spray thermal sleeve to safe I

end attachment area (unwelded slip fit), in categories A, C, 1

D, and E of NUREG-0313, Revision 2.

l 4.

Inconel ("temperbead") weld overlays were applied to nine (9) reactor pressure vessel nozzle-to-safe end weldments. These overlays meet the standard design requirements as defined in NUREG-0313, Revision 2.

v e

Document Control Desk NLS-8'9-061 / Page 6' 5.

Ten'(10) " limited service" overlays were applied to reactor recirculation system discharge safe ends in response to l

indications detected. These overlays were designed by SIA and have been shown by analysis to meet the ASME Boi?er and Pressure Vessel Code,Section XI safety margins for one additional 18 month fuel cycle.

As a result of the mitigative actions taken, the " state-of-the-art" UT 9

examinations that'were performed, and the continuing enhanced surveillance requirements for drywell leakage detection, CP&L believes that the start-up and continued operation of BSEP-1 until the next refueling outage (presently scheduled for. April 1990) is justified and l

will not adversely affect the health and safety of the public.

Based on the results of the UT examinations and mitigative actions taken during the Refuel 6 outage, the Company intends to proceed with the start-up of BSEP-1, which is currently scheduled for March 26, 1989. Volume II of the final overlay design report for BSEP-1, which is being prepared by Structural Integrity Associates, will be submitted to the NRC within 30 days following start-up of BSEP-1.

An inspection plan will be submitted three (3) months prior to the start of the next BSEP-1 refueling outage (currently scheduled for April 1990).

Please refer any questions regarding this submittal to Mr. Stephen D.

Floyd at (919) 546-6901.

Yours very truly,

/

Leonard I. Lo lin Manager Nuclear Licensing Section BK/WRM/wrm

(\\cor\\igscc ul)

Enclosures cc:

Mr. S. D. Ebneter Mr. W. H. Ruland Mr. E. G. Tourigny l

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l TABLE 2 4

BSEP I -IGSCC SUSCEPTIBLE WELD LIST I " ' ' ' '

i ISI OP WELD DE:CPIPTION IGSCC PROCESSES OVERLA YS _ L A S T g y,pg3 NUMBEP SY3 JOlHT DIAM.

CAT.

TYPE RF CPIG.

UPGRD. /HSR 28AI B32 t'~ SE 23" C.

%I:t P 6

6 28A2 SE - P C

IHSI 4

5

\\

28A3 P-E C

IMSI 4

5 4

28A 4 E-P E

IHSI 4

4 5

5 N

k 28A5 p-T C

IHSI 4

5 29AG T-P C

IMSI 4

5-

)

28A7 P-E

'C lHSI 4

5 1

28A8 E - V.

E G

29A3 V-P

.C IHSI d'

5' 23A9BCl W

l D.

5

)

29AIO P-E C

IHS I 4

5 23All E-PJ !P I

C IH51 4'

5 I

y 22A l ':

P).IP -P C-lHSI 4

5 23Al2?:

W G

5 25A13 P-V

'C

'IHSI 4

5 29A14 V-E E

34 d e5 G.

29Als E-P E

3 4+5 6

26AISBCl W

D G-29AIG P-T C

IHS I 4

5 29Al7 T-C C

IHSI 4~

5 29Al8 C-R f

C IHSI 4

5 24Al2 T-V 24'

.C IHSI 4

5 22AMI V-P 22*

C IHSI 4

.S 22AM2 P - V' C

IHSI 4

_5 22AM3 V-P E

5 N/A 6

22AM3BCA S

A SA 5

22AM3BCB S

A SA 5

22AM4 P-C C

IHSI 4

6 22AU S C-P C

IHSI 4

S 22AM5BCA S

A SA' 5

22AM5BCS S

A SA 5'

22AMG P-CAP N

C lHSI 4

5 20A l Y

T-P 20' C

IHSI 4

5 20A IBC Eli S

D 5

20A2 t

P-V N

C IHSI 4

5 12APAl B32 5-P 12" C

IHS1 4

5 12APA 2 P-E E

IHSI 4

4 5

5 12APA 3 E-P E

IHSI 4

4 5

5 12APA 4 P-P E

3-4 5

6 12APA5 P-SE D

5 A THERM SL.

SE - TS F

6 6

L.S.

12AR A G SE-N E

6 N/A 6

12ARBI S-P C

IHSI 4

5 I2ARB2 P-E E

3-4 5

G I2APB 3

_E-P E

IHSI 4

4 5

5 I2APB4 P-P E

3-4 5

6 12APB5 P -SE D

5 B THERM SL.

SE -TS F

G G

L. S.

12ARBG SE - N E

6 N/A G

12APCI

$-P C

IHS) 4 6

12APC2 P-E E

IHS) 4 4

5 6

I2APC3 E-P E

IHSI 4

4 5

G 12 ARC 4 P-P C

IHSI 4

6 12 ARC 5 M SE D

G C THERM SL.

SE-TS F

6 G

L.S.

12ARCG SE - N h,E S

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TABLE 2 (CONT'O.)

"l l PAGE 2 OF 8 IS l' OR WELD DESCRIPTION IGSCC PFOCESSES O VERLA YS LAST AWA NUMBER SYS.

JOIN T DIAM.

CAT.

TYPE PF ORIG UPGPO. INSP.

12APDI B12 5-P 12' C

IHis 4

5 J2APD2 P-E E

IMSI 4

4 5

'S 12APD3

.E - P E.

lHSI 4

4 5

5 12APO4 P-P E

!H51 4

'4 5

5 12APD5 P -iE D

5 O THEFhl :L.

I SE-TS F

.6 G

L.S.

12 APD 6 SE -N E

MSIP G

.6 6

I APEI S-P C

IHil 4

5 12 APE 2 P-E E

3 4-5 G-I: APE 3 l

E-P E

lHil 4

4 5

G I. APE 4

'P-P C

IMSI 4

6 1., APES P-lE C

-5 E THEPM :L.

E-TS F

6 6

L. S.

I ANE6

E-H E

6'

'E JAl W-P 4"

E 5

5 4A2 P-E A

PEPL Q

O i

4A3 l

_ E-P A

PEPL O

O 4/4 l

P-T

.A PEPL 0

3 4A5 s

T-P A

PEPL Q

O 4AG l

T-V A'

PEPL Q

G 4A 7 V-P A

PEPL Q^

't 4A 3 P-E A

PEPL Q

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4A9 E-P A

PEPL O

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4AIO P-W Y

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'G 2881 N-Sc~

28' C

MSIP G

6 2982 SE-P C

IHSI 4

6 l

2983 P-E C

IHSI 4

6' 2984 E-P E

IHSI 4

4' 5

5 2385 P-P C

IHSI 4

5 23RG P - P-C IMSI 4

5 2387 P-E C

IMSI.

'4 5

2285 E-V E

3-4 4+5 6

28 8 )

V-P C

IHSI 4

6 2883BC W

D 5

28810 P-E C

IHSI 4

5 2BB ll E-PLAIP C

IHSI 4

5 28B12

% IMP -P C

IHSI 4

5 28812 BC W

D 5

28813 P-V C

IHFI 4

5 288/4 V-E C

IHEI 4

5 l

28 BIS E-P C

IHSI 4

5 l

298/ 5 BC W

D

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5

)

28 BIG P-T C

IHSI 4

5 1

28BI7 T-C C

IHS!

4 5

288/8 C-R C

IMS) 4 5

248/3 T-P 24' C

IHSI 4

5 228M I CAP - P 22*

C

/ HSI 4

6 228MI BCA S

A SA 5

22BkliBCB S

A 5A 5

22BAI 2 P-C C

IMSI 4

5 22 Bali C-P C

INSI 4

5 228AIBC S

A SA 22BAI4 P-P A

5A 5

22BAI4 BC S

A SA 5

22BAI S E

~P--V C

IHS) 4 5

l

v.

4; o

. TAGL E 2 (CON T 'DTD l PAGE 3 OF 6

'Y ISI OP WELO

~ DESCPIPYlON IGSCC ' PMCESSES -

OVERLAYS LAST

^

NUMBEP i fS JOIN T DI A kl.

CAT.

TYPE PF CPIG. UPGPO. INSP.

12BRFI B32 5-P

'12 *

'C IHSI 4

6 12BPF2

)

'P-E E:

IHil 4-4 5'

5' 122PF3 t.

E-P C'

IHSI

'4 5

12BPF4

.\\

~P-P E

3-4 5.

'5 l

12BPF5 P-3E D.

5 h

F THERAI :L.

E-T:

.F' 6

G L. S.

12RPFG SE-N

.C bli/P G

G l2BPG l

- S -P C

IH:l[

4 5

122PG2 P-E i

E

'lH:/

4 4

5 5

12EPG3 E-P l

E.

lHCl 4

4

'5 5

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IH31 4

4 5'

5 128PG 5 P-:E D

5 l '

3 THEPhi 3l..

JE-TS F.

6 G'

L.:.

il8PGG ZE - ll j

E AISIP 6

N/A G

122PH I

$~P C

I hil,

4 5

128PH 2 P-E E

!h l 4

4 5

5 12EPH 3 E-P E

IHit 4

4 5>

5 12BHM 4 V - P.

E 3

de5 6

12BI;H 5 P--- ZE l

C i

H THEPkt 3L 3E-T:

_ F 6

6 L.S.

12BRHG

E-N E

N/A 6

12BRJl 5-P IHSI 4

5^

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122RJ 2 P-E E.

lHSI 4

4 5

6 12BPJ 3 E-P E

IHSI 4

.4 5

6 12BRJ4 P-P G

IHS 4

5 12EPJ 5 P

SE D

6 J THERAI SL.

SE-TS '

F GI G

L.S.

12BRJ6 SE-N C^

AISIP 6

6 12BPKI S-P C

IHSI J

5 128PK2 P-E E

IHSI 4

4 5

5 liePK ?

E-P E

IH l 4

4 5

6 IdePK 4 p-P E

IH:1 4

4 5

6 128PK 5 P-SE C

6 K THEPAl SL.

SE-TS F

G L. S.

12BRKG SE~ N C

AISIP 6

5 i

46)

W-P 4'

E 5

~N;A 5

482 P-E A

REPL C

5 48.3 E-P A

REPL G

-5 484 P-T A

REPL 0

5 e

485 T-P A

PEPL C

5 deG T~V A

PEPL C

5 487 V-~P A

PEPL C

5

-l B 8 P-E A

PEPL 0

4 489 E-P A

PEPL 0

4 4 BIO Y

P-W E

N !A 6

i

i TABLE 2 (CCNT'O.)

l PA GE 4 - OF G 151 OR WELD DESCRIPTION IGSCC PROCESSES OVERLAYS L A ST 'REMAPKa, 1

NUMBEP S YS.

JOIN T DIA M.

CAT.

TYPE PF ORIG. UPGRO. INSP x

IPWCU :(A-S31 W-P 6"

O REPL 4

'D I RYCU C2A i

P-V A.

PEPL 4

.4 i RYCU :3A V-P

A.

PEPL 4

4 iRVCU 932

. P-E l

A PEPL 4

4 i RV:J 933 E-P i

', A PEPL 4

4 IPWCU 934 P-E l

A PEPL 4

4 iPW:V 935 E-P

_l A

PEPL 4'

4' IPNCV 93GA P-E.

l

.A PEPL 4

4 I RVCJ 937A E-P A.

REPL 4

4 IRVCJ 951 P-E A

PEPL 4

G l

l l %:V 952

. E-P A.

PEPL 4

G l

!R'r:J' :GA P-V A

REPL 4

-4

~

[

'lR;:J C78 VP A

PEPL 4

4 l

lPa:) 250 P-E A

PEPL 4

4 i Pa:J 949A E - P.

A PEPL 4

4 I RY:V CSC P - V.

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