Text

Forwards Response to NRC Bulletin 88-005, Nonconforming Matl Supplied by Piping Supplies,Inc at Folsom Nj & West Jersey Mfg Co at Williamstown,Nj. Matls Installed in Facility Meet ASME Code Requirements
	ML20248D920
Person / Time
Site:	Limerick
Issue date:	03/31/1989
From:	Kemper J; PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC
To:	; NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
	IEB-88-005, IEB-88-5, NUDOCS 8904120082
	Download: ML20248D920 (119)
	v • d • e

{{#Wiki_filter:- _ _ _ _ _ _ _ _ _ _ _ _ t; i. .w PHILADELPHIA' ELECTRIC COMPANY 2301 M ARKET STREET P.O. BOX 8699 PHILADELPHIA. PA.19101 (215)841 450o-JOHN S. KEMPER l ezNion viCa.ensstDENT NUCL.E AR March 31, 1989 U.S. Nuclear Regulatory Commission Docket No. 50-353 Attn: Document Control Desk Washington, DC 20555

Subject:

Limerick Generating Station (LGS) Unit 2 NRC Bulletin 88-05, dated May 6, 1988 " Nonconforming Material Supplied by Piping Supplies, Inc. (PSI) at Folsom New Jersey and West Jersey Manufacturing Company (WJM) at Williamstown, New Jersey" Supplement 1 to Bulletin 88-05, dated June 15, 1988 Supplement 2 to Bulletin 88-05, dated August 8, 1988 Gentlemen: The enclosed report comprises our complete response to the requirements delineated by NRC Bulletin 88-05 and subsequent supplements. The subject Eulletin required holders of construction permits to provide a written response of the results of the document review, testing and analysis prior to the planned fuel date. Limerick Generating Station (LGS) Unit 2 plans to load fuel in June of 1989. Philadelphia Electric Company (PECo) received the. Bulletin on May 18, 1988. Upon receipt of the Bulletin, PECo initiated the records search for suspect components and joined the industry-wide Nuclear l Management and Resources Council (NUMARC) Bulletin 88-05 program. The I NUMARC program was designed to incorporate and evaluate data from multiple sources on a statistical basis in order to provide a consistent response to the Bulletin. PECo actively participated in the NUMARC Program and contributed to the generic test program. We followed the guidelines established by NUMARC and developed a three phased program for LGS, Unit 2. The three phase approach included the following: (1) Document Review - The safety-related and installed materials procured from West Jersey Manufacturing (WJM), Piping Supplies Incorp. (PSI) and Chew Landing Metal Manufacturing Company (CLM) were identified by review of documents. 8904120082 890331 PDR ADOCK 05000353 O PDC l' (

' e (2) Testing - In-situ hardness testing was conducted on the installed suspect components; and chemical testing was conducted on representative material samples of heat numbers installed in LGS Unit 2. (3) Analysis - Testing data and completed stress analysis were evaluated to verify acceptability of material in a manner consistent with the technical rationale used in the NUMARC Program. Upon evaluation of the testing data, PECo concludes that the suspect WJM/ PSI /CLM materials installed in LGS Unit 2 meet the ASME Code requirements. The enclosed rep:vt contains the technical bases, developed in accordance with NUMARC guidelines, for the conclusion. Additionally, our Authorized Inspection Agency (Kemper Group, Lumbermen's Mutual Casualty Company) concurs with our rationale and has concluded that the Code requirements are met. A letter from Lumbermen's Mutual Casualty Company has acknowledged the LGS Unit 2 Bulletin 88-05 Program and accepted the approach. The letter is included as Appendix A. If you have any questions or require additional information, please do not hesitate to contact us. Sincerely, fAsx - SAT 1000D Copy to: W. T. Russell, Administrator, Region I, USNRC T. J. Kenny, Senior Resident Inspector LGS-2, USNRC R. J. Clark, Project Manager, NRR, USNRC Enclosure i i

-s; ~.s PHILADELPHIA ELECTRIC CG4PANY (PECo) RESPONSE TO NRC BULLETIN 88-05 FOR l 1 LIMERICK GENERATING STATION (LGS), UNIT 2 -~. ( ) ,a l l l March, 1989 l

4 W.c ' [ TABLE OF CONTENTS zm 1.0 PURPOSE...:.................... 3 '2.0. EXECUTIVE

SUMMARY

3 3.0

SUMMARY

DESCRIPTION OF LGS UNIT 2 RESPONSE TO NRC. BULLETIN 88-05 I ~ 3.1' Documentation Review Activities...... 4 3.2 Testing Program Activities 4 3.3 Analysis Activltles........ 5 4.0 GENERAL CONCLUSIONS.................. 5 5.0 RESULTS 5.1. - Docunentat ion Revi ew 6 5.2 Testing General 6 Comparison Testing 7 In-Situ Hardness Testing 7 I Chenical Anal ys i s............. 7 Stress Analysis 7 5.3 Analysis General 7 Product Tests............... 8 AISI Evaluation 9 LGS Unit 2 Laboratory Testing Analysis. 9 LGS Unit 2 In-Situ Testing 10 LGS Unit 2 Chemical Analysis 11 f: NUMARC Laboratory Testing 11 [ PECo Met. Lab (PML) S LTI Testing Comparisons............... 12 LGS Unit 2 Stress Analysis 13

6.0 CONCLUSION

S 13 Carbon Steel.................. l Stainless Steel 14 15

7.0 REFERENCES

16 U 8.0 TABLES....................... 16 FIGURES. O. 17 APPENDICES..................... RESPONSE TO MC BULLETIN 88-05 FOR LGS UNIT 2 V(7 - I l 1.0 PURPOSE This report provides a complete response to the requirements set forth by NRC Bulletin 88-05 and Supplements 1 and 2 to the Bulletin. Bulletin 88-05 and subsequent supplements required holders of construction permits to review purchasing records to determine the presence of materials supplied by Piping Supplies, Inc. (PSI), West Jersey Manufacturing Company (WJM) and Chews Landing Metal Manufacturing (CLM), and to provide assurance that the suspect materials meet the Code and specification requirements or are suitable for their intended service or replace unsultable nnterials. 2.0 EXECUTIVE

SUMMARY

The NRC 1ssued Bulletin 88-05 and subsequent supplements regarding the alleged falsification of material. documentation by three piping material suppliers: West Jersey Manufacturing (WJM), Piping Supplies Incorporated (PSI), and Chews Landing Metal Manufacturing (CLM). The Bulletin required specific actions to be undertaken by utilities to resolve this issue. In an effort to aid the Industry, NUMARC, through a consortiun of thirty-three utilities, developed a generic Industry wide program 3 addressing the guidelines for documentation review, testing, and analysis.. Philadelphia Electric Company (PECo), as a member utility, actively participated in the development and Implementation of the guidelines established by NUMARC. The final NUMARC report " Response to NRC Bulletin 88-05" was transmitted to the Comnission for review and approval in December, 1988. Based on the NUMARC guidelines, PECo developed a three-phase program to address the Bulletin for Limerick Generating Station (LGS), Unit 2. During Phase 1 of the Program, PECo completed a review of the purchase records for LGS Unit 2 to determine the presence of material supplied by PSI /WJM/CLM. Secondary suppliers such as General Electric (GE) also reviewed their LGS Unit 2 purchase documents for WJM/ PSI /CLM supplied materials. Upon review of the material documentation, PECo has concluded that suspect materials were furnished and Installed at LGS Unit 2. Upon discovery of suspect materials, those components determined to be in the warehouse were irrmediately segregated and placed on hold. During Phase II of the Program, PECo, in conjunction with NUMARC, developed and performed the testing phase of the 88-05 program. PECo tested the safety-related WJM/ PSI /CLM materials installed in LGS Unit 2 and used the results of the NUMARC and PECo testing programs to demonstrate that the materials meet Code requirements.

_4_ r~% PECo contributed 47 flanges fran stock to the NUMARC laboratory (_) For comparison purposes, PECo Metallurgy Lab (PML) and an progran. Independent testing laboratory (LTI) tested thirty-seven (37) flanges that were conmon to the NUMARC Laboratory Testing Program. During Phase III of the progran, PECo evaluated and analyzed the results of the tensile, hardness and chemical tests. The conparison between NUMARC, PML, and LTI test data yleided a good correlation between the results. Thus, PECo used the NUMARC-developed di rect hardness number to tensile strength correlation to determine strength of carbon steel material Installed at LGS Unit 2. PECo also used the American Iron and Steel Institute (AISI) report on product testing to determine the acceptance of the variability in test results. The analysis indicates that the test results for WJM/ PSI material are typical for product tests of SA-105 material. This report outilnes the PECo LGS Unit 2 88-05 Program, describes the test nethods used for carbon steel and stainless steel and evaluates the results of these tests. The report provides the technical bases and rationale used by PECo to conclude that the WJM/ PSI /CLM naterials installed at LGS Unit 2 meet Code requirenalts. 3.0

SUMMARY

DESCRIPTION OF LGS, UNIT 2, NRC BULLETIN 88-05 PRDGRAM The Limerick Generating Station, Unit 2 NRC Bulletin 88-05 O Program is a three-phase program which addresses the following: Phase I: Documentation Review Phase II: Testing Phase III: Analysis of Test Results and Conclusions 3.1 DOCUMENTATION REVIEW ACTIVITIES 1) Review of purchasing records for bulk naterial purchase of PSI /WJM/CLM manufactured / supplied piping materials. 2) Revlea of piping subassemblies and ASME Section III in-line conponents purchase specifications. 3) Review of skid mounted components purchase specifications. 4) Review by General Electric of the piping related purchase orders for LGS Unit 2. 5) Detennine installation status (i.e., location) via review of N-5 packages for ASME Section III piping, spool installation records and other pertinent installation docurcentation. 3.2 TESTING PROGRAM ACTIVITIES (~l 1) Develop site specific in-situ testing guidelines in A-accordance with NUMARC developed guidelines.

/; 2) Conduct hardness testing on the safety-related, insta11ed' canponents. 3) Conduct chemical testing on representative material s9mples of heat nunters of components installed in LGS Unit 2.

4). For comparison purposes,. conduct testing in-house (through

.PECo Metallurgy Lab) and through an independent testing lab -(LTI) on 37 flanges corrmon to the NUMARC program. 3.3 ANALYSIS ACTIVITIES 1) Determine reliability of PECo test methods by developing and evaluating the correlation between PECo test data and NUMARC test data. .2) Evaluate hardness test results to screen non-conforming materials. 3) Evaluate chemical test results to determine chemical composition and acceptability of components. 4). Perform stress analysis to determine whether LGS Unit 2 installed flanges meet Code pressure design rating or stress allowables estabilshed.per NUMARC Generic Report. 4.0' GENERAL CONCLUSIONS The review of the data generated from the testing performed at LGS Unit' 2 permits the following conclusions to be drawn: 1. The LGS Unit 2 In-situ hardness test results are above the L 350 hardness value threshold established by the NUfMRC D study. 2. With one exception, the chemistry of carbon steel materials tested meet the requirements of SA-105. The exception, a bilnd flange with heat Code 6X11375, has been renoved and replaced. 3. LGS Unit 2 stress analysis on Installed WJM/ PSI /CLM flanges meet the Code pressure design rating and/or stress ) allowables established by the NUMARC generic report. 4. The thirteen stainless steel items received from WJM/ PSI /CLM and installed at LGS Unit 2 were identifed as austenitic f stainless steel using the Texas Nuclear Alloy Analyzer. I 5. The LGS Unit 2 Equotlp hardness test results, chemical l analysis, the stress analyses coupled with the technical reasoning provided in the NUMARC, demonstrate conclusively ~ that the material tested is acceptable ASME Code Material, w ___ _

_. ( ~ 5. 0 RESULTS_ 5.1. DOCUMENTATION REVIEW ) 1 In response to NRC Bulletin 88-05 and Supplements, PECo, I identified the safety-related materials that were purchased fran ) West Jersey Manufacturing (WJM), Piping Supplies Incorporated I (PSI) and Chews landing Metal Manufacturing Ccmpany (CLM) for the Limerick Generating Station, (LGS) Unit 2. The search consisted of a detailed review of the following categories: a) Bulk Purchase of Suspect Material b) ASME Section III, ANSI B31.1 Q-IIsted Systans, Piping Subassemblies and In-Line Components c) Skid Mounted Components and Secondary Suppliers d) GE Supplied Piping Subassemblies and Components The review of the first two categories indicated that 4076 Items were purchased for LGS Units 1 and 2 during the time frame established by the Bulletin. Upon discovery of the suspect components, those components determined to be in the warehouse were immediately segregated and placed on hold. Further investigation revealed that 312 carbon steel items and 13 stainless steel items were received from WJM/ PSI /CLM and installed in safety-related systems at LGS Unit 2. The 312 carbon steel and 13 stainless steel items were composed of 51 heats and 4 O heats respectively. The review of the last two categories has identified no additional suspect materials that were purchased for LGS Unit 2. Table 1 includes the total scope of WJM, PSI & CLM conponents at LGS Unit 2. Table 2 includes the Installed items at LGS Unit 2. The database was fonnatted in accordance with NUMARC established 'fle1ds. 5.2 TESTING The Bulletin and supplements required utilities to provide assurance that PSI /WJM/CLM supplied materials meet the Code and specification requirements or are suitable for their Intended service or replace unsultable materials. NUMARC developed an Industry-wide generic testing program and established guidelines for testing of carbon steel and stainless steel components. The guidelines established by NUMARC and accepted by the NRC include the use of: The Equotlp Portable Hardness Tester to screen non-conforming carbon steel material Installed in the j I plant. Magnetic test for confirming austenitic stainless steel. l t

.;. r) The Texas Nuclear Alloy Analyser (TtMA) to determine m (_ the correct mettalic alloy composition of stainless steel naterials. The NUMARC Program included comprehensive laboratory testing of PSI /WJM ltens contributed by the utilities; and in-situ testing of installed itens. LGS Unit 2 contributed 47 stock flanges for the NUMARC Laboratory Testing. The test results fran the NUMARC Laboratory Testing for the LGS Unit 2 supplied noterial are shown on Table 3. Comparison Test For comparison purposes, PECo Metallurgy Lab (PML) and an Independent testing laboratory (LTI) conducted hardness, tensile and chemical tests on 37 flanges cannon to the NUMARC Laboratory Test Program. The results of the PML and LII test are included in Table 4. IN-Situ Hardness Test PECo tested the safety related WJM/ PSI /CLM carbon steel flanges installed at LGS Unit 2 with the Equotip Portable Hardness Tester. The results of the test are tabulated on Table 5. l Chemical Analysis 1 f)\\ PECo also conducted chemical analyses on samples of stock (_ j material corresponding to heat nunbers of installed flanges that fell below 396 L. Three heats, 12432, J5G, and F70080 were not available from s90ck and samples were removed from the installed flanges. Chemical analysis was also conducted on samples of naterial fran heats that fell above 396 L. Credit for previously D tested samples from representative heats was taken from LGS Unit 1 testing and NUMARC testing database. The results are provided on Table 6. Stress Analysis Stress analysis was perforned on the installed flanges found to have Equotip hardness readings of less than 396 LD (137 BHN). l Analysis was based on line design pressure and tanperature conditions. The stress analysis report is included as Appendix B. 5.3 ANALYSIS The purpose of the various test prograns was to confirm that the installed naterials net Code and to identify any items that may need to be replaced. The methods selected for in-situ testing were Intended to screen out nonconforming material and verify that the specified naterials were furnished. In-situ test values are not expected to natch those on existing CMTRs. For ferritic steels, such as SA-105, the principal attribute is strength, which can be evaluated by hardness testing. Generic laboratory chemical analysis of a large sanple of the WJM/ PSI /CLM

__ _ _ _ _ - _ _ _ - _ /~ carbon steel naterial demonstrated that the naterial furnished, kTJ except for sone bilnd flanges, was within the expected range for the product test of the naterial. The principle eierents, carbon and manganese provide strength and they are controlled to facilitate weldability. Silicon, phosphorus and sulfur are also controlled to facilitate weldability. The specific composition requirements of ASME SA-105 have changed in various editions, whereas the tensile requirement has remained the same. Thus, by demonstrating an appropriate tensile strength through hardness testing, an item satisfactorily tested and inspected after welded Installation would be considered to neet Code. For stainless steels, such as SA-182, the principal attributes are sufficient corrosion resistance and weldability as indicated by the proper alloy content. The detennination of alloy content using the Texas Nuclear Alloy Analyzer (TNAA) is appropriate for testing in-situ stainless steel itens. Product Tests Tests of finished products produce different results than the original test upon which the CMTR was based. ASTM atx! ASME have long recognized this and in some editions of some specifications have provided allowance for such differences. Allowances, tolerances or variations are to be expected and are based on test accuracy and gg upon metallurgical fundamentals. V The alloying elenents in steel segregate within an Ingot as do nonmetallic Incluslais. This causes the composition to vary. The strength will also vary due to the amount of work or size reduction given to the Ingot and due to the heat cycle. The heat cycle includes specific heat treatnents such as norna1Izing a completed part, as well as heat cycles involved in extrusion, rolling and forging. Peak temperatures and cooling rates are very important and affect strength and hardness. An additional source of variation is that it is permissible to test a specially forged blank rather than cut up and test a finished product. For SA-105 material which is not required to be heat treated, one test blank nay represent an entire heat of steel which could be 75 tons or more, nany different Ingots, worked and forged to different diameters (such as 1/2 to 24 inches), ratings (150 or 300 pound), and forns (blinds, slip-ons, weld necks). In addition to the inherent chemical segregation, the great differences in the amount of shaping and fonning, temperature cycles, recrystallization and cooling rates often cause mechanical tests results of finished products to be different than original CMTR values, and could cause test results to be outside nominal specification values. The American Iron and Steel Institute (AISI) has provided an evaluation of these effects as discussed below. O Lh_---_..-m________m______.__________._m__m___.____

_ - - _ - _ _ - _ _ _ _ _ _ _ _ - _ _ _ - _ _ _ _ _ _ - _ _ - _ __ - - -AISI Evaluation The AISI published a study In 1974 which quantified the variances in chemical analyses and mechanical test results. The AISI study is entitled, "The Variation of Product Analysis and Tensile Properties Carbon Steel Plates and Wide Flanges Shapes". This paper indicates that shapes (In study SU 19) which are similar to SA-105 carbon steel forgings in the amount of forming work, chemical composition and strength levels, will vary by 10 to '20% from CMTR values. Figures' 33 and 37 In the AISI study docunent. the magnitude of the product test variation, minus-6 ksi to 15 ksi and minus 2 ksi to minus 18 ksi, and also the frequency of occurrence. Figure 33, Line c, shows that approximately one-third of the values were found to be 7 ksi below the CMTR value (approximately 10 percent variance), and one-half percent of the values would be 14 ksi below CMTR value (approximately 20 percent variance). Line C In_both Figures 33 and 37, excerpted from the AISI study, represent material similar to SA-105. Figure 33 represents the flange product test data compared to the official web tests (CMTR's). Figure 37 represents the web product tests compared to the official web test (CMTR's). From these test it is obvious, by comparing the two lines labeled c in each Figure, that webs and flanges in the same piece of steel do not compare to CMTR values in the same way. This is because the amount of work and cooling rates are different'even within the g same piece of steel. .s g The appilcation of a conservative allowance of variances in the laboratory data developed by the generic testing program makes it understandable that these materials could all have been properly certified as Code material. This fact is important to a program designed to screen out deficient material and thereby confirm that material is in accordance with the specification to which it was certified. The important feature of the AISI work is not the specific values for variation of the percentages of variant material, but rather the independent documentation of a real and comronly recognized fact that product test results will be different than CMTR test results. It is readily seen that the NUMARC and LGS, Unit 2 mechanical test data exceed nominal values or are in a range similar to the variances docunented by AISI. Analysis - LGS, Unit 2 Laboratory Testing Of the 43 SA-105 tests performed on LGS, Unit 2 material for inclusion in the NUMARC test program, 39 exceeded the SA-105 specification required minimum tenslie strength of 70 ksi. The four tests showing tensile strengths below 70 ksi, had values of 68.4, 68.0, 69.6 and 66.3 ksi, respectively, which are consistent with the anticipated variance for product testing. In addition, O L i l ~

_ _ _ _ _. Equotip laboratory testing yleided results In excess of LD (] whereas, L 350 is the 1mer bound cut-off established in the o i V NUMARC test progran. Table 3 lists the NUMARC laboratory test results for LGS, Unit 2 supplied carbon steel naterial. When laboratory EquotIp hardness test results are converted to Brinell hardness (BHN),17 of the flanges show a result less than 137 BFN, which is the minimun BHN required by SA-105 for CMTR's in lieu of tenslie tests. Thirteen of these seventeen flanges showed tensile strengths over 70 ksi. However, this is consistent with the overall NUMARC test results which show that DHN conversions are conservatively low when canpared to material with acceptable mechanical properties. In addition, all but three of the LGS, Unit 2 SA-105 flanges supplied for laboratory testing exhibited chemical properties meeting the latest requirements of SA-105. The three flanges, representing two heats, exhibited slightly low manganese contents of 0.30, 0.50 and 0.51 percent, respectIvely, which compares to the present SA-105 requirement of 0.60 percent minimtm. The slightly low manganese content in the three flanges may be explained If the stock was procured to the pre 1974-edition of SA-105 which required 0.90 percent manganese maximum but no minimum. Thus, the manganese in these three flanges is not a technical concern. Analysis - LGS Unit 2 In-Situ Testing q Equotip hardness testing in the fleid yleided results similar to V the NUMARC laboratory test program except that no values fell below L 350. The lowest value from the field Equotip hardness D testing was L 371. Figure 1 depicts the distribution of field D Equotip hardness testing. The Equotip hardness distribution from field testing peaked at L 396-409 which compares to the nut %RC laboratory program peak 09 405 for laboratory and a peak of 417 for field hardness categories. The remainder of the LGS, Unit 2 Equotlp hardness distributions were also similar to the NUMARC program hardness distributions for both laboratory and fleid hardness categories. The field Equotlp hardness data Indicated that inconsistent test results were obtained for nine flanges. Test results were considered to be inconsistent when the difference between the highest and lowest L value exceeds 15 points. The L 15 range in hardness D D values is a procedure imposed requirement end is conservative when compared to the manufacturer's recommendation of a range of L 30. If the less conservative but fully acceptable L 30 range recommended by the manufacturer is applied, eight of thO nine D flanges meet the criteria for valid tests. These eight tests are considered acceptable with a lowest Equotip hardness reading of L 419. When this result is compared to the corresponding tensile skrengthof74ksi it is clear that the eight flanges are acceptable. The remaining flange with heat Code 'GDFR' had a reading outside the L 30 range (i.e., L 32). This flange was considered O accephable based on nut %kC laboratory tests results on the same V heat. I i

.. - - _ - _ _ _ - _ _ ('T Four stainless steel flanges representing two heats from LGS, Unit 2 k/ were included in the NUMARC laboratory testing progran. The results are shown in Table 3A. As indicated in Table 3A, two LGS, Unit 2 flanges meet the mechanical and chemical property requirements of SA-182, F316L and two flanges neet the nechanical and chemical property requirements of SA-182, F304L. The field testing using the TNAA shows the 13 flanges tested to be austenttic stainless steel, i Analysis - LGS Unit 2 - Chemical Analysis The results of the laboratory chanical analysis on representative samples of nuterials corresponding to heat nunbers of installed canponents at LGS Unit 2 is tabulated on Table 6. Chemical analysis was perforned on samples of material corresponding to heat nuTbers of installed flanges that fell below 396 L

D Seventeen (17) heats of WJM/ PSI /CLM Supplied carbon steel naterials installed at LGS Unit 2 fell below 396 L. Three heats of those D

flanges that fell below 396 Q were not available from stock and sanples were removed fran installed flanges. Chemical analysis was also installed perforned on twenty-two (22) heats of Installed j flanges that tested above 396 L Credit for previously tested naterial sanples of representatkv.e heats was taken from LGS Unit 1 testing and nut %RC testing database. ('T (_/ The results Indicate that, with one exception, chenical canposition of the sanples meet the specification requirements or are within the acceptable variance for product testing. The exception noted is heat code 6X11375 which exhibited low carbon and manganese content, 0.07% and 0.26% respectively. This naterial is suspect per NRC Bulletin 88-05 requirements. Thus, the 3" dianeter raised face blind flange with heat code 6X11375 is being renoved and replaced with one that neets SA-105 speelfication and Code requirements. Procurement docunents indicate that the two six inch dianeter spectacle blind flanges with heat code 'F70080' were required to be SA-515 material. The chemistry of sample representing heat code 'F70080' neets the SA-515 naterial specification. Thus, with the exception of a blind flange with heat code '6X11375', all other components tested neet the chemical specification requirements. Analysis - NUMARC Laboratory Testing j The SA-105 tensile test results exceed 70 ksi or are consistent l with the anticipated variance for product testing. The tensile l results histogram has a nornel distribution with a nean at I I approximately 77 ksi, well above specification requirements. l S There are approximately 13 percent of the Itens with less than ] l l the normal strength and these are within the anticipated variance I described in the Paragraph on AISI evaluation on page 9 of this f report. A histogram of the sane itens' hardness values is also a bell shaped histogram but has a broader distribution. A plot

_ _ _ _ - LQ of these same laboratory tenslie 'results and EquotIp hardness v; expressed as BHN data shows that almost all the hardness data points fall at or below the ASTM A370 BHN-tenslie conversion correlation. Thus, Indicating that this is a conservative approach, and that a more accurate correlation is required for this acceptance evaluation. In fact, the Equotip manufacturer;recormends that product specific correlations be established in such cases. It is noted that there are man,c acceptable tenslie values below the nominal acceptance criteria of 137 BHN. LGS, Unit 2 field tests were performed with EquotIp tests and the data converted to BHN. The conversion from Equotlp to BHN is an approximation, as are all hardness conversions. It Is apparent that the Equotip-BHN-tensile conversion approach Is not well suited to this appilcation. The ASTM A370 BHN-tensile conversion is also an approximation. The double conversion / double approximation requires a more direct approach. It should be noted that the lowest Equotip hardness measured at LGS, Unit 2 was greater than the lower hardness nunbers measured in the NUMARC laboratory testing program, that is, L 371 for LGS, Unit 2 In-situ testing program as opposed to b 348 for the NUMARC test program. TheNUfMRCtenslievaluescorhespondingtoL 350 and greater are considered acceptable; therefore, the LGS,DUnit 2 Items subject to Equotip testing also have acceptable strength. A For austenitic stainless steel, laboratory chemical analysis V verifled the expected carbon, chrom!un, nickel, molybdenum, etc., composition for the specified materials. The principle concern for these materials is to have sufficient alloy for corrosion resistance. Any metal which had sufficient alloy to be non-magnetic and which was also inspected after welding a stainless steel system would be substantially verifled as being acceptable material. Analysis - PECo Metallurgy Lab (PML)/An Independent Testing Lab (LTI) Testing The comparison tests conducted by PML/LTI of the 37 comnon carbon steel flanges that were part of the NUMARC laboratory test program Indicate good correlation with the results of NUMARC laboratory test program, the LGS, Unit 2 fleid testing data, and between FML and LTI testing data. The PML Equotlp hardness test data exceeded 350 as did the NUMARC laboratory and LGS, Unit 2 hardness tlsts.GoodcorrelationwasshownbetweenactualBrinellhardness l testing performed by PM'. and Brinell hardness values converted from actual Rockwell B hardness test performed by LTI. The tenslie test performed by PML had uitImate tenslie strength values 1 greater than 63 ksi as was also the case in the NUMARC laboratory test program for LGS, Unit 2 Items. The results of the chemica; analysis between PML and LTI revealed U^ cortparable results for those elements analysed in comnon by the two groups, that is, carbon, manganese and silicon. Although l some difference in the alloy content is noted, none are greater than would be expected from testing at two or trore laboratories.

, M-Both PML and LTI agree that three carbon steel flanges h' ave less v than the 0.60 percent manganeso required by.the present SA-105. which is the same result obtained in the nut %RC specimens LIM-2-13, LIM-2-27 and LIM-2-28 (Table 3). The PML/LTI conparison-tests provide a verification of the accuracy of the LGS, Unit 2 fleid - testing ~ and the NW1 ARC laboratory testing by showing good correlation of the results of tests on caninon items within the accuracy to be expected of the varicus test methods. LGS Unit 2 - Stress Analysis for Installed Flanges Stress Analysis was performed on all installed flanges.found to have Equotlp hardness readings less than L 396. Analyses were D based on IIne design pressure and temperature conditions. All. flanges were found to meet the Code. pressure design rating and/or stress allowables established in the NUMARC Generic Report. The Stress Analysis report is included as Appendix B. 6.0 CONCLUSICL", Review of the data generated from the testing performed at LGS, Unit 2 in response to NRC Bulletin 88-05 permits the following conclusions to be drawn. Carbon Steel la The distribution of LGS, Unit 2, fleid Equotip hardness test results shows a bell-shaped curve very similar to the distribution curve generated by the NUMARC t'st program. It -Is concluded; therefore, that the test results and conclusions from the nut %RC test program are appilcable to LGS, Unit 2 for SA-105. 2. The LGS, Unit 2, field Equotip hardness test distribution shows all Installed material to have an L value greater than n 350 (63 ksi ultimate tenslie strength equTvalent). This is the threshold above which replacement or further Investigation of the material need not be considered based on a NUMARC test program findings. See Figure 1 for the distribution of the LGS, Unit 2, Equotlp hardness test results. 3. The NUMARC laboratory tests on carbon steel material supplied by LGS, Unit 2 exceeded the lower bound values of 63 ksi ultimate tensile strength and the L 350 Equotlp D hardness estabitshed by the NUMARC test program. The chemistry of carbon steel materials met the requirements of SA-105, except for three flanges, representing two heats, l.- which were slightly low in manganese content. However, these three flanges met the pre-1974, SA-105 requirement of q 0.90 maximtm manganese. Refer to Table 3 for the laboratory ) test results for carbon steel materials. l

.- ( ; J /] - 4. A comparison between the 37 connon flanges ' included in tho NUMARC laboratory test : program and the PML/LTI comparison . tests shows good correlation. No Equotip hardness values less than L 350 and no uitImate tenslie strengths less than ~j D 63 ksi were shown in the PML/LTI conparison tests...The PML/LTI comparison tests also revealed the same three carbon steel flanges with a s11ghtly low manganese content to present SA-105 requi rements. j q With one exception, a blind flange with heat code 6X11375, the -i chemical composition of heat codes of installed WJM/ PSI /C W material at LGS Unit 2 meet the chemical composition requirements of SA-105 and SA-515 specifications..The flange with heat code 6X11375 is being removed and replaced. 5. The LGS, Unit 2 fleid Equotip hardness test results, chemical analysis, the NUMARC-laboratory test results and the PML/LTI comparison tests, coupled with the technical reasoning provided in the NUMARC report, demonstrate conclusively that the material tested is acceptable ASME Code material. 6. The generic stress analysis performed as part of the NUMARC program is appilcable to LGS, Unit 2. This generic stress analysis demonstrated that materials with an asstrned room temperature, ultimate tensile strer.gth of 56 ksi were satisfactory. LGS Unit 2 stress analysis on installed O WJM/ PSI /CLM flanges mee* the Code pressure design rating and/or stress allowables established by the NUMARC Generic Report. Stainless Steel 1. The thirteen stainless steel items received from WJM/ PSI /C W and installed at LGS Unit 2 were identifled as austenitic stainless steel using the Texas Nuclear Alloy Analyzer (TNAA). 2. The laboratory testing of all stainless steel material received from LGS Unit 2 met the mechanical and chemical properties of SA-182 for the appropriate grade. O i

_________-_ _ I REFERENCES (_-) ' 1. NUMARC Report 88-01, " Response to NRC Bulletin 88-05", October 1988, prepared by Bechtel Group, Inc., for EPRI. 2. The Variation of Product Analysis and Tenslie Properties Carbon Steel Plates and Wide Flanges Shape, AIS1, September 1974. 3. Chemical Test Analysis Results, File No. TCW-019-01, Bechtel Poaer Corporation. 4. General Electric Report, DCN 236644. 5. PECo Metallurgical Laboratory Note No. 88-423-3, " Metallurgical Examination of Thirty-Seven (37) ASTM A105 Flanges and Fitting nede by Piping Supplies, Inc., or West Jersey Manufacturing Company" prepared by PECo Metallurgy Laboratory. AU SAT /vvg/03088902 1 i

.. LIST OF ILLUSTRATIONS b('S ' TABLES TABLE 1 Stock and Installed WJM/ PSI /CLM supplied noterials at LGS Unit 2 TABLE 2 Installed WJM/ PSI /CLM noterials at LGS Unit 2 TABLE 3 NUMARC Laboratory Testing of 43 carbon-steel PSI /WJM/Cl)4 flanges from LGS Unit 2 TABLE 3A - NUMARC Laboratory testing of four (4) stainless steel ) PSI /WJM/CU4 flanges fran LGS Unit 2. l TABLE 4 PECo Metallurgy Lab (PML) and an independent testing lab (LTI) testing of 37 flanges connon to the NUMARC Laboratory testing. (Metallurgical Laboratory Note No. 88-423-3). TABLE 5 LGS Unit 2 in-situ hardness test results on installed WJM/ PSI /CLM flanges. TABLE 6 Chemical analysis of installed WJM/ PSI /CLM flanges at LGS Unit 2 TABLE 7 Stainless steel Texas Nuclear Alloy Analyzer results for 13 Installed stainless steel canponents at LGS Unit 2. FIGURES FIGURE 1 - IN-SITU hardness test distribution. ) 1

7 L. - 17: - O. APPENDICES u Letter from Authorized Nuclear Inspector, Kemper ' APPENDIX A Group, Ltsnbermen's Mutual Casualty Company to. W. -E. Mourer, Bechtel Western Power Corporation, U^ I dated November'9, 1988. 1 APPENDIX B' - Bechtel Power Corporation, Final Report Revision 2 '" Response to NRC Bulletin 88-05", dated March, 1989. APPENDIX C LGS Unit 2 --Stress Analysis, for installed flanges with hardness less than 396 L

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M3t.<L2b. No. 88-423-3 Pagef20 of 24 .e= '%s/ PART IDENTIFICATION NUMBERS PECO FLANGE STAMPED. SPECIMEN -NO. . IDENTIFICATION V 1 10" WJ 150-SA105-l ETPG STD 2 4" WJ 600-SA105 l E1321 XH 3 4" WJ 150-SA105-CL2 i AAY84 B-16-5 STD . g]) 4 8" WJ 300-SA105-CL2 ~ .STD 2358 5 '14" WJ 600-SA105-CLII 217538 S/100 B16.5 6 24" 150 WJ-SA105 STD l 1800 CLD i 7 24" WJ-150-SA105 15533 STD 8 16" PS-150-SA105 GL2 STD 6X11237 B16.5 9 18" PS-300-SA105-CL2 (}/- 1753 STD B16.5 i Sheet 1 of 5 4

y,, <. i M3t. Lib. No. 88-423-3 'Pcga 21 of 24 }Q k/ PART IDENTIFICATION NUMBERS l PECO FLANGE STAMPED-SPECIMEN NO. IDENTIFICATION 10: 10" WJ 600-SA105-CLII 225868 S100 B16.5 11~ 6" PS 300-SA105-CL2" l AAR84 S/40 12 ~6" WJ 300-SA105 CLL2 160 STD / 13 18" 300 PS-SA105 CLII 19040 STD e 14 14" WJ 600-SA105 CL2 1858 XH B16.5 15 12"'WJ 300-SA105 T604843 STD 16 8" WJ 900-SA105 ETHZ S/120 l 17 6" WJ 900-SA105 ETNF XH 18 18" WJ 150-SA105 i( ') 3991 STD Sheet 2 of 5

r s i M;t. Lab. No. 88-423-3 Psgs 22 of 24 l [) ) PART IDENTIFICATION NUMBERS PECO FLANGE STAMPED SPECIMEN NO. IDENTIFICATION 19 12" WJ 150-SA105 M763401 STD 20 8" WJ-900-SA105 M763401 STD 21 12",300-SA105-CL2 2793 STD B16.5 16 22 12" WJ 300-SA105 CL2 2774 STD 23 10" WJ 600-SA105 CLII 217538 S/100 B16.5 24 8" WJ 900-SA105 ETRD S/120 25 6" 150-SA105 114A9 STD 26 10" WN 150-SA105 22865 STD 27 6" WJ 900-SA105 ETNF XH -{ v Sheet 3 of 5

Met. Lab. No. 88-423-3 Page 23 of 24

C)

PART IDENTIFICATION NUMBERS '~ PECO FLANGE STAMPED SPECIMEN NO. IDENTIFICATION 28 8" WJ 150-SA105 GDJX STD 29 8" WJ-900-SA105 ETRD S/120 30 2" WJ-150-SA105 GDFR XH ggf 31 14" WJ 150-SA105 CL2 82337 STD 32 6" WJ 300-SA105 H455X STD f 33 6" WJ 300-SA105 H455X STD 34 6" WJ 300-SA105 GDJE STD l 35 6" WJ 300-SA105 l GDJE STD 36 6" WJ 300-SA105 ,n;) () GDJE STD Sheet 4 of 5 ._________a

~ s M rs t. L:b. No.~88-423-3 Pcg3 24 of 24 i PART IDENTIFICATION NUMBERS i PECO FLANGE STAMPED SPECIMEN NO. IDENTIFICATION 37 6" WJ 300-SA105 GDJE STD W i l r4 Sheet 5 of 5

^ '

'* 1 Met". Lab.cNo.-. 88-423-3, Page 5 of 24 ') TABLE NO. 1 i j r ASTM'A105 Chemical Composition Results 3 1 l i i ASTM:A105; Forgings, Carbon' Steel', for Piping domponents Chemical Requirements Element Composition Percent Note 1: For each1 reduction of 0.01% below the specified. carbon . Carbon 0.35 Max'. maximum (0.35%), an increase Manganese 0.60 1.05-of 0.061 manganese above.the Phosphorus 0.040 Max.. specified maximum (1.05%) Sulfur 0.050 Max. will be permitted up to a Silicon 'O.45 Max. maximum'of 1.351. PML _ PECo Metallurgy. Laboratory LTI - Laboratory Testing, Inc. PECo SPECIMEN PML LTI PML LTI LTI LTI PML LTI: NO. CARBON CARBON MANGANESE MANGANESE PHOSPHORUS SULFUR SILICON SILICON 1-0.18 0.20 1.30 1.21 0.019 0.015 0.30 0.30 2 0.17 0.20 1.28 1.19 0.017 0.014 0'32 0.29 3 0.31 0.31 0.84 0.81 0.035 0.019 0.17 0.22 4 0.21. 0.21 1.35 1.24 0.023 0.009 0.19 0.23~ 5 0.25 0.25 1.22 1.19 0.019 0.014 0.34 0.27 6-0.20 0.22 1.31 1.26 0.017 0.017 0.37 0.29 7 0.19. 0.20 1.23 1.17 0.016 0.010. 0.26. 0.27 8 0.21 0.22 0.92 0.97 0.020 0.019 0.15 0.22 9 0.23 0.23 1.23 1.13 0.017 0.016 0.11 0.21 10 0.21 0.25 0.99 0.94 0.017 0.012 0.38 0.26 11 0.18 0.20 1.33 1.26 0.015 0.012 0.23 0.30 12 0.21 0.23 0.91 0.94 0.015 0.012 0.30 0.23 13 0.17 0.'19 1.28 1.23 0.019 0.018 0.47* 0.21 14 0.19 0.20 1.31 1.16 0.014 0.018 0.47* 0.26-15 0.22 0.24 0.79 0.83 0.022 0.013 0.20 0.25 16 0.17 0.18 1.44* 1.30 0.030 0.022 0.21 0.26 17 0.22 0.23 1.20 1.11 0.020 0.013 0.27 0.27 18 0.23 0.25 0.68 0.73 0.029 0.025 0.18 0.30 19 0.22 0.23 0.23* 0.31* 0.024 0.018 0.16 0.25 l

Does not meet chemistry requirements.

I I

A . Mat.. Lab.'No. 88-423-3 ' Paga 6 of 24 [' ~ TABLE NO. 1-I ASTM A106 Chemical: Composition Results (Continued)_ 4 PMLL_ PECo Metallurgy Laboratory LTI - Laboratory Testing, Inc. .PECo SPECIMEN PML LTI PML LTI LTI. LTI PML-LTI NO. CARBON CARBON MANGANESE MANGANESE PHOSPHORUS SULFUR SILICON SILICON 20 0.17 0.20 1.38*. 1.24 0.027 0.027 0.19 0.23 21 0.22 0.22 0.90 0.87 0.013 0.010 0.22 0.22 22 0.21 0.22 0.95 0.88 0.014 0.013 0.19 0.2.3 23 0.24 0.28 1.35 1.12 0.013 0.013 0.19 0.24 24 0.18 0.20 1.12 1.08 0.015 0.015 0.30 0.28 25 0.24 0.28 0.87 0.76 0.061* 0.008 0.31 0.37* 26 0.33 0.36* 0.99 0.91 0.019 0.017 0.30 0.34 27 0.11 0.23 1.21 1.10 0.022 0.011 0.25 0.27 28 0.30 0.32 0.91 0.92 0.031 0.025 0.20 0.21 29 0.17 0.20 1.05 1.03 0.009 0.015 0.26 0.25 ) 30 0.28 0.30 0.99 0.92 0.021 0.017 0.14 0.23 ll 31 0.22 0.24 1.09 1.04 0.031 0.030 0,22 0.22' 32 0.25 0.29 0.42* 0.50* 0.032 0.022 0.16 0.19 33 0.25 0.32 0.41* 0.50* 0.029 0.018 0.13. 0.20 34 0.29 0.32 0.90 0.91 0'.029 0.022 0.24 0.21 '35 0.31 0.34 0.98 0.91 0.030 0.024 0.26 0.21 36 0.29 0.31 0.97 0.91 0.025 0.022 0.20 0.21 37 0.29 0.31 0.98 0.97 0.028 0.020 0.24 0.23

Does not meet chemistry requirements.

(g /

Met. Lab. Nu. 88-423-3 Page 7 of 24 ] TABLE NO. 2 \\ ASTM A105 Hardness The hardness by ASTM A105 specification shall be Hardness Brinell 137 minimum to Hardness Brinell 187 maximum. Each component was measured for hardness by the Equotip Model D portable hardness tester, Brinell using a 3000 kg

load, Hardness Rockwell B, and Hardness Rockwell B converted to Brinell.

Specimens that failed the tensile or yield strength requirements are marked FTY: PML _ PECo Metallurgy Laboratory LTI - Laboratory Testing, Inc. TABLE OF HARDNESS NUMBERS 1 PML L VALUE LTI PECo PML CONVERTED PML BRIUZLL PML SPECIMEN EQUOTIP TO ACTUAL FROM ACTUAL NO. L VALUE** BRINELL*** BRINELL HRE HRB i 1 405.8 144.0 158.0 156.0 84.0 2 395.8 137.0 148.0 159.0 81.0 l 3 429.1 160.5 155.8 153.0 81.1 4 419.0 153.0 158.3 150.0 81.5 5 407.4 145.0 155.0 147.0 81.5 6 396.3 137.0 145.0 153.0 80.3 7 398.4 139.0 150.7 153.0 80.1 8 FTY 394.7* 136.0* 138.0 144.0 77.5 9 417.9 159.0 163.0 162.0 84.3 10 390.1* 134.0* 138.0 137.0 75.3 l 11 405.0 143.5 150.0 150.0 78.9 l 12 401.1 140.5 148.3 159.0 80.3 l 13 402.5 141.5 143.5 144.0 77.1 14 394.0* 136.0* 144.0 144.0 78.0 l l

The actual Bri:it 1 and HRB values were taken from a minimum of three measureinents on component cross-sections.

The Equotip L Value reported was obtained by taking two sets of 5 measurements, deleting the highest and lowest measurements and averaging the three remaining L numbers. X() The 1 Converted to Brinell number is an averaae of the two sets of L Values obtained by the Equotip Model D portable hardness tester.

R, .Mst.. Lab. No. 88-423-3 Page 8 of'24 ) 1 TABLE NO. 2 ~ ~' ASTM A105 Hardness (Continued) L PML _ PECo Metallurly Laboratory LTI - Laboratory Testing, Inc. TABLE OF HARDNESS NUMBERS PML L VALUE LTI PECo PML CONVERTED PML BRINELL PML SPECIMEN EOUOTIP HTO ACTUAL FROM ACTUAL NO. L VALUE** BRINELL*** BRINELL HRB HRB 15 FTY 391.7*' 134.5*- 133.0* 137.0 74.4 16 FTY 379.6* 125.5* 131.0* 132.0 72.9 17 416.3 152.5 - 163.0 165.0 83.9 18 398.5-139.0 143.0 153.0 78.0 19 395.8 137.5 143.3 141.0 77.1 20 395.0* 136.0* 142.0 144.0 78.0 21 408.9 145.5 151.3 144.0 80.4 22 398.4 138.5 146.3 144.0 78.0 23 .408.9 146.0 154.7 162.0 77.8 24 395.5 137.0 142.6 147.0' 76.0 25 413.2 150.0 161.7 156.0 79.1 26 448.4 174.5 181.7 176.0 89.1-j 27 420.2 154.5 161.7 159.0 82.3 28 422.5 156.0 169.0 159.0 86.4 29 388.3* 132.0* 145.0 144.0 78.1 30 420.3 154.5 158.0 165.0 80.1 31 415.3 150.5 165.7 159.0 88.4 32 PTY 391.6* 135.0* 137.0 137.0 71.0 33 PTY 388.3* 132.0* 128.3* 137.0 75.6 34 432.2 163.0 161.7 169.0 84.6 35 441.3 169.5 165.7 169.0 87.3 36 427.8 160.0 167.0 162.0 85.4 37 408.0 145.5 154.7 159.0 83.5 e l 1

The actual Brinell and HRB values were taken from a minimum of three. measurements on component cross-sections.

The Equotip L Value reported was obtained by taking two sets of 5 measurements, deleting the highest and lowest measurements and averaging the three remaining L numbers. ( The L Converted to Brinell number is an average of the two sets of L Values obtained by the Equotip Model D portable hardness tester. l lU

' Met. Lab. No.,88,423-3 P ge 9 of 24 t s 3 TABLE NO. 3 O. Tensile Test Results to ' ASTM A105 Table 2, Mechanical Requirements PECo-SPECIMEN TENSILE YIELD (.2%) REDUCTION NUMBER STRENGTH STRENGTH ELONGATION OF AREA 70,000 psi-36,000 psi 22.0% 30.0% Minimum Minimum Minimum Minimum ' Required Required Required Required 1 79,855' psi 42,443 psi 27.5% 59.5% 2 73,585 psi 44,708 psi 31.0% 70.4% 3 80,428 psi 45,306 psi 25.0% 52.6% 4 79,660 psi 43,312 psi 31.0% 67.4% 5 74,000 psi 45,000 psi 33.5% 164.7% 6 '72,681 psi 40,082 psi 34.1% 68.3% 7 76,421 psi 42,192 psi 36.4% 67.5% 8

69,369 psi
33,505 psi
21.5%

46.9%' 9 76,942 psi 43,456 psi

13.4%
27.2%

10 '70,927 psi 42,606 psi 34.3% 61.2% Il 76,714 psi 45,306. psi 32.0% 72.8% f-h, 12 74,734 psi 42,653 psi 32.0% 66.9% (;) 13 72,180 psi 38,095 psi' 27.3% 53.5% 14 72,044 psi 38,559 psi 31.2% 52.4% ~15

69,115 psi
32,842 psi 36.5%

60.8% 16

66,416 psi
35,087 psi
21.1%
23.8%

17 80,154 psi 49,331 psi 31.4% 67.1% 18 73,154 psi 38,469 psi 28.2% 54.0% 19 71,161 psi 38,848' psi 23.5% 37.6% 20 -73,566 psi. 44,647 psi 27.0% 58.0% 21 74,439 psi 39,465 psi 29.7% 62.3% 22 72,476 psi 38,232 psi 29.6% 63.0% 23 78,005 psi 48,081 psi 30.7% 66.1% 24 71,716 psi 36,487 psi 31.6% 60.6% 25 82,211 psi 45,019 psi 25.5% 63.9% 26 94,327 psi 50,000 psi 25.0% 46.2% 27 79,773 psi. 49,845 psi 31.0% 55.1%. 28 85,686 psi 48,529 psi 27.0% 57.6% 29 71,633 psi 40,951 psi 32.8% 59.3% 30 82,712 psi 48,380 psi 27.0% 55.3%

9.2%
25.9%

31 79,825 psi 43,165 psi 32

65,714 psi
30,918 psi 30.0%

69.5% 33

66,510 psi 56,938 psi
19.0%

33.4% 34 84,551 psi 46,122 psi 28.0% 58.0% 35 85,506 psi 46,153 psi 29.0% 57.4% 36 82,968 psi 45,684 psi 27.0% 58.8% 37 80,225 psi 47,227 psi 27.0% 57.8% O'

Under minimum specification requirements.

w . Met.' Lab. No'. 88-423-3.- 'Paga'10 of 24 i TABLE NO. 4-W ' Table of Portable Hardness J Versus ] Laboratory Brinell Hardness j BRINELL HARDNESS , PORTABLE HARDNESS CONVERTED PECo from the LABORATORY ABOVE (+) SPECIMEN EOUOTIP-BRINELL .or BELOW (-) NO. L VALUE HARDNESS ACTUAL BRINELL 1 144.0 158.0 -14.0 2 137.0 148.0 -11.0 3 160.5 155.8 + 4.7 4 153.0 158.3 - 5.3 5 145.0 155.0 -10.0 6 '137.0 ~ 145.0 - 8. 0 7 139.0-150.7 -11.7 8 136.0 138.0 - 2.0 FTY 9 359.5 163.0 - 3.5 10 134.0 138.0 - 4.0 11 143.5 150.0 - 6.5 12 140.5 148.3 - 7.8 13 141.5 143.5 - 2.0 14 136.0 144.0 - 8.0 15 134.5 133.0 + 1.5 FTY 16 125.5 131. - 5.5 FTY 17 152.5 163.v -10.5 18 139.0 143.0 - 4.0 19 137.5 143.3 - 5.8 20 136.0 142.0 - 8.0 21 145.5 151.3 - 5.8 22 138.5 146.3 - 7.8 23 146.0 154.7 - 8.7 24 137.0 142.6 - 5.6 25 150.0 161.7 -11.7 26 174.5 181.7 - 7.2 27 154.5 161.7 - 7.2 28 156.0 169.0 -13.0 29 132.0 145.0 -13.0 30 154.5 158.0 - 3.5 31 150.5 165.7 -15.2 32 135.0 137.0 - 2.0 FTY 33 132.0 128.3 + 3.7 FTY 34 163.0 161.7 + 1.3 35 169.5 165.7 + 3.8 36 160.0 167.0 - 7.0 l 37 145.5 154.7 - 9.2 FTY: Failed Tensile or Yield Strength _ _______.-_____ - _ a

U PHILADELPHIA ELECTRIC COMPANY L.T.I. Lab Report #TC-4850.3 P.O. (TS271511-AN / 947013 -Page t A. SPECTROCHEMICAL ANALYSIS RESULTS - ASTM A-105 SERIAL # CARBON MANGANESE PHOSPHORUS SULFUR SILICON REQUIRED 0.35 max. 0.60-1.35 0.040 max. 0.050 max. '0.35 max. 1 0.20 1.21 0.019 0.015 0.30 2 0.20 1.19 0.017 0.014 0.29 3 0.31 0.81 0.035 0.019 0.22 4 0.21 1.24 0.023 0.009 0.23 5 0.25' 1.19 0.019 0.014 0.27 6 0.22 1.26 0.017 0.017 0.29 7 0.20 1.17 0.016 0.010 0.27 8 0.22 0.97 0.020 0.019 0.22 9 0.23 1.13 0.017 0.016 0.21 10 0.25 0.94 0.017 0.012 0.26 11 0.20 1.26 0.015 0.012 0.30 12 0.23 0.94 0.015 0.012 0.23 13 0.19 1.23 0.019 0.018 0.21 N. 14 0.20 1.16 0.014 0.018 0.26 W 15 0.24 0.83 0.022 0.013 0.25 16 0.18 1.30 0.030 0.022 0.26 17 0.23 1.11 0.020 0.013 0.27 18 0.25 0.73 0.029 0.025 0.30 19 0.23

0.31 0.024 0.018 0.25 20 0.20 1.24 0.027 0.027 0.23 21 0.22 0.87 0.013 0.010 0.22 22 0.22 0.88 0.014 0.013 0.23 23 0.28 1.12 0.013 0.013 0.24 24 0.20 1.08 0.015 0.015 0.28 25 0.28 0.76
0.061 0.008
0.37 26
0.36 0.91 0.019 0.017 0.34 27 0.23 1.10 0.022 0.011 0.27 28 0.32 0.92 0.031 0.025 0.21 29 0.20 1.03 0.009 0.015 0.25 30 0.30 0.92 0.021 0.017 H0.23 31 0.24 1.04 0.031 0.030 0.22 32 0.29
0.50 0.032 0.022 0.19 33 0.32
0.50 0.029 0.018 0.20 34 0.32 0.91 0.029 0.022 0.21 35 0.34 0.91 0.030 0.024 0.21 36 0.31 0.91 0.025 0.022 0.21 37 0.31 0.97 0.028 0.020 0.23 4
Does not meet specification requirements.

L.h

4 ~{bs PHILADELPHIA ELECTRIC COMPANY. L.T.I. Lab Report #TC-4850.3 P.O..(TS271511AN / 947013 Page 'B. TENSILE TEST RESULTS - ASTM A-105 TENSILE YIELD (.2%) REDUCTION SERIAL # STRENGTH STRENGTH ELONGATION OF AREA REQUIRED 70,000 PSI 36,000 PSI 22.0% 30.0% 1 79,855' PSI 42,443 PSI 27.5% 59.5% 2 73,585 PSI 44,708 PSI 31.0% 70.4% 3 80,428 PSI 45,306 PSI 25.0% 52.6% 4

79,660 PSI 43,312 PSI 31.0%

67.4% 5 74,000 PSI 45,000 PSI 33.5% 64.7% 6 72,682 PSI 40,082 PSI 34.1% 68.3% 7 76,421 PSI 42,192 PSI 36.4% 67.5% 8

69,369 PSI
33,505 PSI
21.5%-

46.9% 9 76,942 PSI 4,3,456 PSI

13.4%
27.2%

10 70,927 PSI 42,606 PSI 34.3%- 61.2% 11 76,714 PSI 45,306 PSI 32.0% 72.8% 12 74,734 PSI 42,653 PSI 32.0% 66.9% 13 72,180 PSI 38,095 PSI 27.3% 53.5% M, 14 72,044 PSI 38,559 PSI 31.2% 52.4% W 15

69,115 PSI
32,842 PSI 36.5%

60.8%- 16

66,416 PSI
35,087 PSI
21.1%
23.8%

17 80,154 PSI 49,331 PSI 31.4% 67.1% 18 73,154 PSI 38,469 PSI 28.2% 54.0% 19 71,161 PSI 38,848 PSI 23.5% 37.6% 20 73,566 PSI 44,647 PSI 27.0% 58.0% 21 74,439 PSI 39,465 PSI 29.7% 62.3% 22 72,476 PSI 38,232 PSI 29.6% 63.0% 23 78,005 PSI 48,081 PSI 30.7% 66.1% 24 71,716 PSI 36,487 PSI 31.6% 60.6% 25 82,211 PSI 45,019 PSI 25.5% 63.9% 26 94,327 PSI 50,000 PSI 25.0% 46.2% 27 79,773 PSI 49,845 PSI 31.0% 55.1% 28 85,686 PSI 48,529 PSI 27.0% 57.6% 29 71,633 PSI 40,951 PSI 32.8% 59.3% 30 82,712 PSI 48,380 PSI 27.0% 55.3% 31 79,825 PSI 43,165 PSI

19.2%
25.9%

32

65,714 PSI
30,918 PSI 30.0%

69.5% 33

66,510 PSI 56,938 PSI
19.0%

33.4% 34 84,551 PSI 46,122 PSI 28.0% 58.0% 35 85,506 PSI 46,153 PSI 29.0% 57.4% 36 82,968 PSI 45,684 PSI 27.0% 58.8% 37 80,225 PSI 47,227 PSI 27.0% 57.8%

Under minimum specification requirements.

l l l

1 i r O TABLE 5: IN-SITU HARDNESS TEST RESULTS.ON INSTALLED FLNT,ES O i. O l 4

soume: MATEPJAL CONTROL g NRC BlLLETIN 88-45 E/; Ab HARNESS TEST DATA gggd. f J22 - 8 f ~ BY EAT MaeER L1ERICK LMIT 11 MARCH 22,1989 PLANT U LIE EAT NRREET N ITEM CODE 'L' I MMBER T LSS 2 001 12 G 414 l i L8S 2 002 12 G 441 LBS 2 003 12 G 417 LSS 2 004 12 G 389 i L66 2 005 14184 436 LSS 2 006 14184 430 L6S 2 007 15533 447 L6S 2 000 15533 421 L66 2 009 15533 441 LSS 2 010 15533 425 LSS 2 til 15533 446 l LSS 2 012 15533 419 rs L6S 2 013 15533 447 LBS 2 014 16758 482 LSS 2 015 16758 423 LGS 2 016 12,00 396 L66 2 017 1800 420 L6S 2 018 1800 392 L6S 2 819 21492 416 LBS 2 820 21492 422 LSE 2 021 21492 409 LSE 2 022 2168 447 LGS 2 023 2164 389 LS6 2 024 2168 414 LSS 2 025 2154 390 LGS 2 026 2164 448 LGS 2-027 2168 395 LSS 2 028 2160 422 LSS 2 029 2168 447 LBS 2 830 2164 416 L6S 2 031 2160 445 LBS 2 E 217538 445 L6S 2 333 217538 414 LSS 2 434 218516 436 L5S 2 135 218516 461 LSS 2 336 2258 All LBS 2 037 5 78 419 LSS 2 438 2578 397 O '3S a a = ma L 2 M4 5 78 4 ' 5S 2 M1 578 429 l L5S 2 442 2578 399 ' 35 2 M3 5 78 410 LSS 2 M4 2793 4 ) LSS 2 MS 2733 415 l j

LGS 2 84 2793 398 L6S 2 847 2793 414 L66 2 848 2793 489 LBS 2 849 2793 419 LSS 2 850 2793 43 LBS 2 851 2793 399 L6S 2 852 2793 489 LSS 2 853 2793 411 LGS 2 854 2793 411 L86 2 855 2793 399 LGS 2 856 '2793 485 LGS 2 857 2793

1 LGS 2

858 2793 413 LSS 2 859 2793 444 LES 2 860 2793 487 LOS 2 861 2793 484 L66 2 862 2793 41 LOS 2 863 2793 488 LSS 2 864 2793 418 LBS 2 ' 865 2793 486 LGS 2 866 2793 486 L6S 2 867 2793 481 LGS 2 868 2793

4 7

2. 869 2793 487 '(d LOS LBS 2 878 2793 404 LGS 2 871 3991 483 LGS 2 872 3991 398 LGS 2 673 3991 486 L6S 2 874 3991 395 LBS 2 875 44266 421 LGS 2 876 44266 392 LGS 2 877 44266 43 LES 2 878 44266 419 L6S 2 879 44266 413 L8S 2 888 44266 385 LSS 2 881 44266 434 L66 2 882 44266 485 LSS 2 483 44266 397 l LSS 2 884 45265 424 LGS 2 885 45285 424 LGS 2 386 58816 422 LGS 2 387 58816 449 LGS 2 888 54616 482 LSS 2 489 '8816 412 LSS 2 398 58816 128 l LSS 2 391 '8816 44 LSS 2 392 58816 445 LSS 2 893 '4816 49 LSS 2 394 54816 413 O =!E 2

= L 2 896 2 816 444 LSS 2 397 'J1816 432 LOS 2 898 '8816 421 LSS 2 899 58816 436 LSS 2 188 58816 658 LGS 2 181 535 % 4.18

.s I) v LG6 2 182 535 % 432 LG6 2 103 535 % 444 LSS 2 184 53596 424 LDS 2 185 535 % 416 LOS 2 106 535 % 425 LBS 2 107 535 % 485 LG6 2 108 535 % 411 LGS 2 109 53596 413 LES 2 110 535 % 426 L9S 2 til 535 % 409 LG6 2 112 535 % 404 LOS 2 113 535 % 421 L86 2 114 535 % 424 LG6 2 115 535 % 411 LS6 2 116 535 % 423 LG6 2 117 535 % 425 L96 2 118 53596 439 LSS 2 119 535 % 433 L86 2 120 53596 424 i L9S 2 121 535 % 431 L86 2 122 tJ596 448 i L86 2 123 535 % 418 i LGG 2 124 535 % 411 LBS 2 125 53596 447 l (~} k L86 2 126 535 % 425 I LBS 2 127 535 % 436 LES 2 128 53596 428 l LOS 2 129 535 % 418 LS6 2 138 53596 415 LOS 2 131 535 % 447 LG6 2 132 535 % 425 LOS 2 133 53596 447 LG6 2 134 53596 429 L6S 2 135 53596 425 L86 2 136 535 % 449 LOS 2 137 53596 441 LBS 2 138 535 % 418 LG6 2 139 535 % 423 L66 2 148 5F 44tl LGS 2 141 64C 443 LS6 2 142 64C 415 LS6 2 143 676114 49 LSS 2 144 670"'t 319 LSS 2 145 65 't 47 LSS 2 146 6111375 26 LBS 2 147 74271 44 ) LGS 2 148 74279 385 LS6 2 149 74279 22 LS6 2 150 74278 23 i LSS 2 151 74278 21 LSB 2 152 74279 24 LSS 2 153 7479 371 LSS 2 154 74271 29 LSS 2 155 7479 376 LS6 2 15 74279 23 LGS 2 157 74278 371

( i v LOS .2 158 74278 373 LS6 2 159 74270 377 l LOS 2 16G 74270 372 LOS 2 161 74278 375 LGS 2 162 9271 412 LOS 2 163 9271 488 LBS 2 164 9271 417 LG6 2 165 9271 449 LGB 2 166 9271 397 LBS 2 167 9271 488 LBS 2 168 9271 429 L6S 2 169 9271 397 166 2 179 9856 398 LBS 2 171 9856 483 L86 2 172 A79 432 LOS 2 173 MY-84 415 LES 2 174 MZ84 447 LGS 2 175 MZ84 398 LOS 2 176 MZ84 383 LBS 2 177 '9Z84 389 LE6 2 178 MZ84 397 LSS 2 179 MZ84 443 LG6 2 180 MZ84 390 (~' 3 LGS 2 181 MZ84 488 U L9S 2 182 BLN 393 LS6 2 183 BLN 389 L86 2 184 BLN 395 LSS 2 185 BLN 398 LOS 2 186 TY 430 LSS 2 187 GY 398 L9S 2 188 UY 389 L6S 2 189 GY 391 LGE 2 190 DN 381 LOS 2 191 00 426 LSS 2 192 00 427 LGS 2 193 00 449 LG6 2 194 00 448 LOS 2 195 00 437 LGS 2 1% 00 425 LGS 2 197 00 447 LG6 2 198 00 428 L95 2 199 OG 447 LG6 2 290 00 409 LSS 2 291 00 439 LGS 2 292 00 4 LG6 2 213 00 423 LSS 2 294 00 416 LSS 2 295 00 429 I L2 2 296 04 44 O em 3

un L2 2 298 06 G LG6 2 299 00 4 LSS 2 214 00 411 LSS I 211 De 413 lab 2 212 De G . LBS 2 213 00 47

I O-i uiS 2 214 De 424-i L6S 2 215 De 434 UiS 2 216 De 415 ) LfiS 2 217 00 420 uiS 2 218 DG 409 UiS 2 219 COI 458 LGS 2 220 CDI 438 LOS 2 221 COI 433 . LOS 2 222 COI 44 LGB 2 223 COI 437 LfiS 2 224 COI 429 ) L6S 2 225 COI 436 LOS 2 226 CDI 432 LOS 2 227 COI 450 ) L6S 2 228 COI 434 ) LBS 2 229 COI 439 UiS 2 230 COI 430 LSS 2 231 E1321 391 LOS 2 232 E1321 389 LGE 2 233 E!321 388 LSS 2 234 E1321 394 L66 2 235 E1321 386 LGS 2 236 E1321 394 L6S 2 237 ETPR 415 LGS 2 238 ETPR 425 LBS 2 239 ETPT 397 LBS 2 248 F70000 390 LBS 2. 241 F70000 413 uiS 2 242 GDOW 406 LES 2 243 GDBW 408 LBS 2 2% GDDE 47 LfiS 2 245 6DDE 43 LBS 2 2% GDDE 476 L5ii 2 247 GDDE 4% LBS 2 248 GDIE 436 LGS 2 249 SDDE 477 L85 2 250 SDDE 473 LSS 2 251 GDDF 481 LSS 2 252 GDOF 40 LOS 2 253 GDOF 487 LGS 2 254 GDDM 427 L66 2 255 GDET 383 L86 2 256 EDET 407 LSS 2 257 SDFR 657 UiG 2 258 3DFR 44 LSS 2 259 GDFR 428 LSS 2 258 3DFR 41 LSS 2 261 SDFR 453 UiG 2 32 50FR 43 O =36 a

L 2 254 NR a33 ' LGS 2 255 3DFR 426 L3S 3 256 3DFR +50 LSS 2 257 NR 474 L35 2 258 3DFR 44 j tsS 2 39 m es a

l I ~ LGS 2 270 SDFR 43 l LSS 2 271 GDFR 437 L86 2 272 GDFR 461 LBS 2 272 SDFR 473 LBS 2 274 GDFR 448 LES 2 275 GDFR 435 LSS 2 276 GDFR 451 LSS 2 277 GDFR 418 LGB 2 278 60FR 426 LOS 2 279 GDFR 437 LSS 2 280 GDFR 412 L6S 2 281 SDFR 409 LSS 2 282 6DFV 438 LBS 2 283 6D19 432 L6S 2 284 6DKD 419 LGS 2 285 SDKD 428 LSS 2 286 GDKD 441 L6S 2 287 SDKD 427 LSS 2 288 GDKD 438 L6S 2 289 GDK6 424 LSS 2 290 SDHS 418 LBS 2 291 SDHS 45 L6S 2 292 SDKS 433 L6S 2-293 GDK6 435 LSS 2 294 GDHS 421 LOS 2 295 GDHS 430 LSS 2 296 6DKS 436 LSS 2 297 GDKS 439 LBS 2 298 GDHS 427 LBS 2 299 GDKS 436 LSS 2 300 SDHS 423 L66 2 301 GDK6 418 LfB 2 302 J56 380 L93 2 303 J56 382 LSS 2 304 E4978 382 LSS 2 305 54978 392 L6S 2 306 T3 399 L9S 2 307 T3 402 LSS 2 308 T3 413 LGS 2 309 T3 413 L6S 2 310 T504843 386 LOS 2 311 VP 417 LSS 2 312 W 428 O

O l TABLE 6: CHEMICAL TEST RESULTS FROM LGS UNITS 1 & 2 AND PU%RC DATABASE FOR HEATS INSTALLED AT LGS UNIT 2 O i O

CHEMICAL TEST RESULTS ~ Item No. Heat No. C Mn -P S1 S 1 6X11375 0.07 0.26 0.010 0.03 0.010 2 74270 0.20 0.86 0.019 0.21 0.020 3 CHV 0.22 0.92 0.013 0.21 0.027 4 BLN 0.28 0.74 0.008 0.19 0.020 5 GDET 0.27 0.87 0.006 0.21 0.018 6 45285 0.16 1.13 0.012 0.24 0.021 7 50816 0.31 0.87 0.007 0.21 0.015 8 53596 0.18 1.11 0.013 0.27 0.029 9 58F 0.32 0.84 0.011 0.20 0.027 10 64C 0.34 0.75 0.008 0.21 0.032 11 676914 0.28 0.82 0.032 0.15 0.027 12 GDBW 0.29 0.95 0.013 0.23 0.021 13 GDDF 0.28 0.87 0.017 0.20 0.026 14 GDFV 0.28 0.96 0.015 0.24 0.015 15 T3 0.19 1.12 0.010 0.21 0.016 16 AAZ84 0.29 0.68 0.016 0.21 0.012 17 CFY 0.33 0.74 0.012 0.20 0.015 18 OK4978 0.21 0.80 0.009 0.18 0.016 19 A79 0.31 0.75 0.007 0.21 0.022 20 COX 0.30 0.68 0.020 0.22 0.017 21 GDDE 0.32 0.68 0.020 0.23 0.022 22 GDDM 0.28 0.93 0.012 0.24 0.029 23 GDKD 0.32 0.91 0.013 0.22 0.019 24 GDKG 0.25 0.87 0.008 0.28 0.019 25 VP 0.30 0.75 0.013 0.24 0.021 - p 26 2358 0.22 1.13 0.015 0.23 0.007 V 27 12432 0.22 1.20 0.020 0,28 0.018 1 28 J5G 0.22 0.74 0.015 0.29 0.019 29 F70080 0.29 0.91 0.023 0.22 0.019 30 15533 0.180 1.240 0.012 0.270 0.008 31 1800 0.180 1.240 0.010 0.270 0.016 32 2160 0.200 0.960 0.011 0.240 0.011 33 217538 0.230-0.240 1.12-1.28 0.12.015 0.24.28 .011.016 34 3991 0.230 0.750 0.023 0.320 0.031 35 AAY84 0.300 0.800 0.030 0.210 0.018 36 E1321 0.170 1.280 0.010 0.270 0.013 37 GDFR 0.270 0.970 0.016 0.250 0.015 3 38 T604843 0.220 0.860 0.017 0.270 0.013 39 44266 0.270.28 0.71-0.76 0.14-0.17 x 40 Cto 0.210.280 0.82-1.13 0.007.013 0.19-0.20 0.007.013 41 PAGC 0.013 1.210 0.028 0.480 0.003 I 42 B20 0.029.033 1.19-1.20 0.022 0.32-0.36 0.005 43 CRT 0.013.015 1.57-1.58 0.022 023 0.56 0.019 1 Notes: Items 1 - 26: Chemical Analysis frcm representative material samples of heat nuThers of installed flanges at LGS Unit 2. Items 27 - 29: Chemical Analysis on samples removed from installed flanges. Items 30 - 43' Chemical results frcm LGS Unit I testing and/or NUMARC testing database. "The percentage of Phosphorus (P) and Sulphur (S) were not determined, l SAT /vvg/03158907 f

0 STN 2 EN T O I P N M U OC SG M L LC RO E F I A S T P AD M R J E W S Y L L E A E N T A S O Y S O S L E L L A N I R A A T E S LC D U E N LL S A A T X S E N T I 7 EL BAT O l

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\\ l O I i a APPENDIX A: LETTER FROM AUTHORIZED NUCLEAR INSPECTOR, f KEMPER GROUP LUMBERMEN'S MUTUAL CASUALTY COMPANY TO W. E. MOURER, BECHTEL WESTERN I POWER CORPORATION, DATED NOVEMBER 8, 1988 1 m)

I Ii Lumbermens Mutual Casualty Company

Americ.in Motorists Insur::nce Ccmpany American Manufactur:rs Mutual Insurance Cernp.iny e American Prot 2ction insurance Company Long Grove, IL 60049-0001 312!540 2000 (d.,h m r.? Gn November 9, 1958 Mr. W. E. Moue:

Bechtel Western Power Co. t P.O. 3cx 3965

.i i;

San Francisco, CA 94119 Daar tir. Mouer: On November 7, 1988 representatives from the Kemper Group Authorized Inspec. tion Agency attended a presentation at your Pottstown, PA office to revisw Philadelphia Electri:. Company's response to NRC Bulletin 88-05. The presentation was bs.. sed upon the industry guideline established by NUMARC which consists c.f material chemical analysis and Equotip

tatist.. cal analysis. The Kemper Group evaluated the results as presented to c!etermine if there was a basis to.further questior. the suspect material or the existing meterial documentation.

It was cetermined the material documentation is representative of the material and there war. no reascn, based upon the tests performed, to furthe: question the :uspect material. We believe, therefore, that the O e Pece teriet i im::o 911'"ce ita the ^snt ceae. If we can be of any fur:her ansistance in this matter please contact me at your convenience. Very truly yours, I LUMBERP.IHS MUTUAL CASUALTY COMPANY Codes & Etandards Manager (312) 54C-2883 Bechtel Kemper Group cc: e M. Iycr R. E. Muise H. LilUgh J. E. Ayotte K. Stout R. V. Wielgoszinski A. Sidhu A. E. Callope R. Pslaniswamy K. V. Golosh H. Linsin %fgler D. H.tekney F. Breismeistor I1

'? 3 .V APPENDIX B BECHTEL POWER CORPORATION - FINAL REPORT, REVISION-2 " LIMERICK UNIT 2 RESPONSE TO NRC BULLETIN 88-05" O u i 'O

i Bechtel Power Corporation Engineers-Constructors ,q Fif ty Beale Street -U San Francisco, California Mall Address: P.O. Box 3965. San Francisco, CA 94119 In reply please reference: BLP - Doc. Control No. gL 9 '7W Mr. D. B. Fetters Philadelphia Electric Co. 2301 Market Street Philadelphia, Pennsylvania 19101 MAR 171989

Subject:

Job No. 18240, Philadelphia Electric Co. Limerick Generating Station, Unit 2 NRC Bulletin 88-05, Final Report, Rev. 2 Startup System #Cen. IMPACT: Fuel Load 1 Commercial OP J

Reference:

BLP-46448, Jan. 19, 1989 Enclosures Bechtel National Letter to M. S. Iyer, CCN 239623 [Jl Dear Drews Please find enclosed the letter from Bechtel National M & QS which includes revision 2 of the subject report. Should you have any questions please call Frank Grajo at (215) 327-5788. Very truly yours, N = M. Iyer Sr. Project Engineer Written Response Req'd: NO TP/FLG(RP):al cci Mr. R. J. Stipcevich, w/a Mr. P. Tutton, w/o Philadelphia Electric Co. Philadelphia Electric Co. 7 s. S. Thomas, w/a Mr. J. Fedick, w/o M Philadelphia Electric Co. Philadelphia Electric Co. [ Mr. J. Brightman, w/a Philadelphia Electric Co. 5026

QL10 00 Tb2 3cAS9 Nf Bechtel National, Inc. Systems Engineers - Constructors Fifty Beale Street V San Francisco, Cahfornia Mad Address: PO Bon 3965. San Francisco. CA 94t19 To: M. S. Iyer Date: March 3, 1989

Subject:

Evaluation of Test Data From: B. D. Hackney (BDH-039-01) in Response to NRC Bulletin 88-05, Final Report Of: R&D/ Materials and Quality Rev. 2, Limerick Services Job No. 18240-000 Copies: F. Breismeister/R. A. Manley w/a At: 50/15/A34 768-2873 C. Barton w/a F. Grajo w/a W. E. Mourer w/a A. Sidhu w/a B. Wells w/a DCC 07871 w/a Please find enclosed revision 2 of the subject report. The revision consists of a rewrite of paragraph 3 on page 6 concerning flanges with inconsistent g field hardness ranges. If you should have any questions, please do not g hesitate to call. l Y. B. D. Hackney BDH/TCW:g f 4 V i usme k

gt*> 9' 7W O t'"za1cx u"rr 2 *zsro sz ro "ac auttzr1 88-os l Final Report f Revision 2* March 1989 Prepared for M. S. Iyer and A. Sidhu I By / 4[. B. D. Hackney A h a*o O Averev a ~.* C. 6teismeis te r F I-Approved Ik#Nh d<c_ l R. A. Manliy- [/ i Manager i Materials and Quality Services Research and Development i l BECHTEL NATIONAL, INC. SAN FRANCISCO O 3 6 "e 182'o-ooo reca a vere "e 881o-o1 tv

Rev. 1 - Revised Table I
Rev. 2 - Revised p. 6 as noted

1 c9 3 9 747 I o ABSTRACT Field test data from 312 SA-105 carbon steel flanges and 13 SA-182 stainless steel flanges supplied to Limerick, Unit 2 by the West Jersey Manufacturing Company, Piping Supplies, Inc. or Otews Landing Metals Manufacturing Company and which were subsequently installed have been evaluated. In addition, laboratory test data have been evaluated from 47 stock flanges, 43 carbon steel and 4 stainless steel, supplied from the same source (s) and which was included in the NUMARC industry wide generic test program.. In addition, 37 o f the same 43 carbon steel stock flanges that were factored into the NUMARC laboratory test program were tested for comparison purposes by the Philadelphia Electric Company Metallurgical Laboratory (PML) and an independent test laboratory (LTI). All of the data have been evaluated in a manner consistent with the technical reasoning and rationale used in the industry wide NUMARC test program. The field, NUMARC and comparison test data for carbon steel and stainless steel materials indicates that all installed items are acceptable and verifies that the correct ASME Code materials have been used. Carbon steel stock items should be Equotip hardness tested and those items showing an Lp value equal to or greater than 350 should be released for plant use. Stainless steel stock items should be given a chemical analysis including carbon content and those items having chemical properties meeting the appropriate grade of,SA-182 should be released for plant use, O l l O 4 1284m 1

4 o LIMERICK UNIT 2 RESPONSE TO NRC BULLETIN 88-05 CONTENTS E.*K2 ABSTRACT................................................................ i CONTENTS................................................................ ii .j L I S T O F ILL U ST RAT IO N S................................................... iii

1.0 INTRODUCTION

g 2.0 CO NCLU S I O N S.................................................. 2 3.0 RE CO MME NDAT I ONS.............................................. 3 4.0 D I SC U S S I ON.......................................,,,,,,,,,,,,, 3 e 1284m 4 i

OLM 7N9 LIST OF ILLUSTRATIONS FIGURES ?*K *. Figure ! Distribution o f Equotip Hardnes s Test Results................. 9 TABLES Table I Laboratory Test Results for LCS, Unit'2 Su St ee l Ma terials........................... pplied Carbon 10 Table II Laboratory Tes; Results for LGS, Unit 2 Su Stee l Materials............................pplied Stain 1-e 12 O O ~ 1284m I'

SM7%

1.0 INTRODUCTION

In response to NRC Bulletin 88-05 and Supplements, Bechtel Construction proceeded to identify all safety related materials that were purchased from West Jersey Manufacturing (WJM), Piping Supplies Incorporated (PSI) and Chews Landing Metal Manufacturing Company (CLM) for the Lintrick Generating Station, (LGS) Unit 2. The search consisted of a detailed review of all document packages that were determined to have the potential fet perchase of material from these three manufacturers. ne presence of any materials from the three sources was recorded. In this manner, the total quantity of the materials, including heat codes or heat numbers, was determined. Once the material was identified, all ASME Section II'I and ANSI B31.1 systems were reviewed for the presence of WJM/ PSI /CLM supplied materials. As a separate but concurrent activity, all stock / warehouse material was reviewed and any WJM/ PSI /CLM supplied material was removed from stock and segregated. The results of these thorough searches indicated that 312 carbon steel and 13 stainless steel items had been received fec,m WJM/ PSI /CLM and installed. h e 312 carbon steel items were composed of 51 heats while the 13 stainless steel items came from 3 heats. i Having identified and located all WJH/ PSI /CLH materials, the items were tested in accordance with the guidelines established by NUMARC for field conditions. The NUMARC program is an industry wide, cooperative one consisting of both field and laboratory testing and is designed to q incorporate and evaluate data from multiple sources on a statistical V basis in order to provide a consistent response to NRC Bulletin 88-05. The testing performed at LCS, Unit 2 on WJM/ PSI /CLM materials consisted of Equotip hardness testing on carbon steels and a verification of alloy l content using the Texas Nuclear Alloy Analyzer for stainless steel items. ne documentation and field testing was centro 11ed and integrated into the quality program by means of Field Procedure I 18240-2-FG-004. In addition, LGS, Unit 2, contributed 47 flanges from stock to the laboratcy testing portion of the NUMARC program. From these flanges, laboratory tests were conducted on 43 carbon steel flanges and on 4 stainless steel flanges. Also 37 carbon steel flanges common to the FUMARC laboratory test program were tested by PML/LTI for comparison purposes. he number of hest:, represented in the NUMARC laboratory testing were 34 for carbon steel items and 2 for the stainless steel items. De laboratory and comparison testing of the LGS, Unit 2 material consisted of tensile tests, hardnese tests, and chemical analysis. The field test data was collected, compiled and submitted to Project Engineering for review. he laboratory test results performed on LGS, Unit 2 was also compiled and provides additional data for review. The comparison test results were also submitted and have been included in the overall evaluation. The purpose' of this report is to evaluate the data from the field, laboratory and comparison testing and present the appropriate conclusions and reconunendations. 1294m

'l l an 7M i

2.0 CONCLUSION

S. Cm ' Review of the data generated from the testing performed at LCS, Unit 2, in response to NRC Bulletin 88-05 permits the following conclusions to , 1 be drawn. Carbon Steel 1. The distribution of LCS, Unit 2, field Equotip hardness test results shows a bell shaped curve very similar to the distribution' curve generated by the NUMARC test program.. It is concluded; therefore, that the test results and conclusions from the NUMARC test program are applicable to LGS, Unit 2 for SA-105. 2. he LCS, Unit 2 field Equotip' hardness' test distribution shows all of the material with an La value greater than 350 (63 kai ultimate tensile strength equivalent). This is the threshold above which replacement or further investigation of the material need not j t be. considered based on the NUMARC test program findings..See Figure 1 for the distribution of the LGS, Unit 2, Equotip hardness test results. 3. All of the NUMARC laboratory tests on carbon steel material supplied by LCS, Unit 2 exceeded the lower bound values of 63 kai ultimate tensile strength and the LD 350 Equotip hardness . established by the NUMARC test program. The chemistry of carbon steel mate-lais met the requirements of SA-105, except'for three flanges,. representing two heats, which were slightly low in manganese content. However, these three flanges met the pre-1974, - SA-105 requirement of 0.90 maximum manganese. Refer to Table I for ' the laboratory test results for carbon steel tasterials. 4. A one on one comperison between tha 37 co==an flengee included in the NUMARC laboratory test program and the PML/LTI comparison tests shows good correlation. No Equotip hardness values less than Lp 350 and no ultimate tensile strengths less than 63 kai were shown in the PML/LTI comparison tests.- The PML/LTI comparison tests also revealed the same three carbon steel flanges with a slightly low manganese content to present SA-105 requirements. 5. The LCS, Unit 2 field Equotip hardness test results, the NUMARC laboratory test results and the PML/LTI comparison tests, coupled with the _ technical reasoning provided in the NUMARC report, demonstrate conclusively that the material tested is acceptable ASME Code material. 6. The generic stress analysis performed as part of the NUMARC program is applicable to LCS, Unit 2. This generic stress analysis demonstrated that materials with an assumed room temperature, ultimate tensile strength of 56 ksi were satisfactory. 7t'ere fore, no LGS, Unit 2 unique stress analysis is required. J l 0 1284m

(. &M74f Stainless Steel 1. All thirteen stainless steel items received from WJM/ PSI /CLM and ' installed were positively identified as austenitic stainless steel using the Texas Nuclear Alloy Analyzer. a 2. The laboratory testing of all stainless steel material received f rom LCS, Unit 2 met the mechanical and chemical properties of - SA-182 for the appropriate grade. Refer to Table II for the laboratory test results for stainless steel materials. 3.0 RECOMMENDATIONS 1 Based on the conclusions reached above, the following reconenendations are offered. 1. Carbon steel materials exhibiting a field Equotip hardness test result greater than LD 350 should be used as-is without further testing, evaluation or snalysis. 2. Those materials that were determined to be austenitic stainless steel by testing with the Texas Nuclear Alloy Analyzer should be used as-is without further testing, evaluation or analysis. 3. Any carbon steel materials in stock / warehouse that were supplied by WJM/ PSI /CLM should be tested. Carbon steel materials showing an Equotip hardness test result greater than LD 350 should be considered acceptable for use. Any stainless steel materials in hf stock / warehouse that were supplied by WJM/ PSI /CLM should be given a full chemical analysis including carbon content and should meet the requirements of SA-1:82 for the appropriate grade. Any stock material not meeting the requirements stated above can be further ~ evaluated by chemical analysis or replication in the case of carbon steels or by magnetic tests in the case of si:alnless steels or the i material can be discarded depending on which method appears to be l the most desirable. 4.0 DISCUSSION 4.1 General The purpose of the various test programs were to confirm that the installed materials met Code and to identify any items that may need to be replaced. The methods selected for in-situ testing were intended to screen out nonconforming material and verify that the specified materials were furnished. It was not intended to recertify the material. In-situ test values are not expected to match those on existing CETRs. For ferritic steels, such as SA-105, the principal attribute is strength, which can be evaluated by hardness testing. Generic laboratory chemical analysis of a large sample of the WJM/ PSI /CLM carbon = steel material demonstrated that the material furnished, except for some 0 1284m

c9 M 74'? 4. blind flanges, was within the expected range for the product test of the material. We principle elements, carbon and manganese, are to provide qQ strength and are controlled to facilitate weldability. Silicon, phosphorus and sulfur are also controlled to facilitate weldability. The specific composition requirements of ASME SA-105 have changed in l various editions, whereas the tensile requirement has remained the i hus, by demonstrating an appropriate hardness, an item same. i satisfactorily tested and inspected after welded installation should be considered to meet Code. For stainless steels, ouch as SA-182, the principal attribute is sufficient corrosion resistance and weldability as indicated by the l proper alloy content. The NUMARC test program indicates that l determination of alloy content using the Texas Alloy Analyzer is j appropriate for testing in-situ items; however, in order to be responsive to NRC Generic letter 88-01, NUMARC is recommending that stock items be given a full chemical analysis including a determination of carbon content, at least for material that may be used in RPV coolant piping systems in order to confirm that the item is an IGSCC resistant material. 4.2 Product Tests Tests of finished products will almost always give different results l than the original test upon which the CNTR has been based. ASTM and ASME have long recognized this and in some editions of some specifications have provided some allowance for such differences. i A Allowances, tolerances or variations are to be expected and are based on U test accuracy and upon metallurgical fundamentals. The alloying elements in steel segregate within an ingot as do nonmetallic inclusions. B is causes the composition to vary. Le { strength will also vary due to the amount of work or size reduction given to the ingot, billet or bloom, and due to the heat cycle. Se f heat cycle incluse: specific heat treatments such as normalizing a completed part, as wed as heat cycles involved in extrusion, rolling y i and forging. Peak temperatures and cc,oling rates are very important and affect strength and hardness. An additional source of variation is that it is permissible to test a specially forged blank rather than, cut up and test a finished product. For SA-105 material which is not required to be heat treated, one test blank may represent an entire heat of steel which could be 75 tons or more, many different ingots, worked and forged to different diameters (such as 1/2 to 24 inches), ratings (150 or 300 pound), and forms (blinds, slip-ons, weld necks). In addition to the inherent chemical segregation, the great differences in the amount of shaping and forming, i temperature cycles, recrystallization and cooling rates often cause i mechanical tests results of finished products to be different than original CMIR values, and could cause test results to be outside nominal specification values. We American Iron and Steel Institute (AISI) has provided an evaluation of these effects as discussed below. O v, l 1284m

l i ~ 4.3 AISI Evaluation h' ' The AISI published a study in 1974 which quantified the variances in chemical analyses and mechanical test results. %e AISI study is entitled, "The Variation of Product Analysis and Tensile Properties Carbon Steel Plates and Wide Flange Shapes". This paper indicates that the shapes (in study SU 19) which are similar to SA-105 carbon steel forgings in the amount of forming work (which varies widely within a single completed item), chemical composition and strength levelt, will vary by 10 to 20% from CHIR values. Figures 33 and 37 in the AISI study document the magnitude of the product test variation, minus 6 kai to 15 kai and minus 2 kai to minus 18 kai, and also the frequency of Figure 33, Line e, shows that approxir.ately one-third of occurrence. the values were found to be 7 kai below the CMTR valu~e (approximately 10 percent variance), and one-half percent of the values would be 14 kai below the CHIR value (approximately 20 percent variance). Line c in both Figures 33 and 37, excerpted from the AISI study, represent material similar to SA-105. Figure 33 represents the flange product test data compared to the ' official web tests (CMTR's). Figure 37 ) represents the web product tests compared to the official web test (CMTR's). From these tests it is obvious, by comparing the two lines labeled c in each Figure, that webs and flanges in the same piecs :- f I steel do not compare to CMIR values in the same way. This is because the amount of work and cooling rates are different even within the same piece of steel. The application of a conservative allowance for variances in the laboratory data developed by the generic testing program makes it O understandable that these materials could all have been properly certified as Code material. This fact is important to a program designed to screen out deficient material and thereby confirm that material is in accordance with the specification to which it was certified. The important feature of the AISI work is not the specific values for variation or the percentages of variant material, but rather the independent documentation of a real and commonly recognized fact that product test results will be different than CMTR test results. It is readily seen that the NUMARC and LGS, Unit 2 mechanical test data all exceed nominal values or are in a range similar to the variances documented by AISI. 4.4 Analysis - LCS, Unit 2 Testing i Of the 43 SA-105 tests performed on LGS, Unit 2 material for inclusion in the NUMARC test program 39 exceeded the SA-105 specification required minimum tensile strength of 70 ksi. The four tests showing tensile strengths below 70 ksi, had values of 68.4, 68.0, 69.6 and 66.3 kai, respectively, all of which are consistent with the anticipated variance for produce testing. In addition, Equotip laboratory testing yis!ded results in excess of Lp 364, whereas, LD 350 is the lower bound cut-off established in the NUMARC test program. Table I lists the laboratory test results for LGS, Unit 2 supplied carbon steel material. O l 1 1284m ,I i i l 4

~ o?M797 When laboratory Equotip hardness test restits are converted to Brinell hardness (BMN) 17 of the flanges show a result less than BHN 137 which .d is the minimum BHN required by SA-105 for CMIR's in lieu of tensile j p hirteen of these seventeen flanges showed tensile strengths tests. over 70 kai. However, this !s consistent with the overall NUMARC test results'which show that BHN conversions are conservatively low when compared to material with acceptable mechanical properties. In addition, all but three of the LGS, Unit 2 SA-105 flanges supplied for laboratory testing exhibited chemical properties meeting the latest requirements of SA-105. %e three flanges, representing two heats, exhibited slightly low manganese contents of 0.30, 0.50 and 0.51 percent, respectively, which compares to the present SA-105 requirement of 0.60 percent minimum. The slightly low manganese content in the three flanges may be explained if the stock was procored to the pre 1974-edition of SA-105 which required 0.90 percent manganese maximum with no minimum. he slightly low mangenese in these three flanges is not a technical concern. These data are also shown in Table I. Equotip hardness testing in the field yielded results similar to the NUMARC laboratory test program except that no values fell below LD 350. he lowest value from the field Equotip hardness testing was L l 364. Figure 1 depicts the distribution of field Equotip hardness D testing. Note that the Equotip hardness distribution from field testing peaked at Lp 396-409 which compares to the NUMARC laboratory progran peak of 405 for laboratory and a peak of 417 for field hardness categories. We remainder of the LGS, Unit 2 Equotip hardness distributions were also strikingly similar to the NUMARC program hardness distributions for both laboratory and field hardness categories with the one exception, as noted previously, that none of LCS, Unit 2 V field h::rdness values fell below LD 350. %e field Equotip hardness data indicated that inconsistent test results were obtained for nine flanges. Test results were said to be inconsistent when the difference between the highest and lowest LD value exceeds 15 points. h e Le 15 range in hardness values is a procedure imposed requirement and is conservative when compared to the manufacturer's recommendation of a range of Lp 30. If the less conservative but fully acceptable LD 30 range recommended by the manufacturer is applied, eight (8) of the flanges meet the criteria for g valid tests. These eight tests are considered acceptable with a lowest Equotip hardness reading of Lo 419. When this result is compared to the corresponding tensile strength of 74 ksi it is clear that all eight flanges are acceptable. %e remaining flange had readings outside the Lp 30 range (i.e., Lp 32). This flange was considered acceptable based on NUMARC laboratory test results on the same heat. 1 1 Four stainless steel flanges from LCS, Unit 2 were included in the NUMARC laboratory testing program. The results are shown in Table II. As indicated in Table II, two LCS, Unit 2 flanges meet the mechanical and chemical property requirements of SA-182, F316L and two flanges meet the mechanical and chemical property requirements of SA-182, F304L. he field testing using the TNAA is consistent with Table II and shows all 13 flanges tested to be austenitic stainless steel. O, 1284m 6

3, d2377M 4.5 Analysis - NUMARC Laboratory Testing All SA-105 tensile test results exceed 70 kai or are consistent with the anticipated variance for. product testing. He tensile results histogram - has a normal distribution with a mean at approximately 77 kei, well above specification' requirements. Bere are approximately 13 percent of the items with less than the nominal strength and these are within the ~ anticipated variance described in paragraph 4.3. A histogram of the same items' hardness values is also a bell shape histogram but has a broader distribution because hardness testing has more variance than tensile testing. A plot of these same laboratory tensile results and Equotip hardness expressed as BHN data (from the Equotip manufacturer's conversion table) shows that almost all the hardness data points fall at or below the ASTM A370 BHN-tensile conversion correlation, indicating that this is a conservative approach, and that a more accurate correlation is required for this acceptance evaluation. In fact, the Equotip manufacturer recommends that product specific correlations be established in such cases. It is noted that there are many acceptable tensile values below the nominal acceptance criteria of 137 BHN.. LGS, Unit 2 field tests were performed with Equotip tests and the data converted to BHN. The conversion from Equotip to BHN is an approximation, as are all hardness conversions. It is apparent that the Equotip-BHN-tensile conversion approach is not well suited to this-application. We ASTM A370 BHN-tensile conversion is also an approximation, he double conversion / double approximation requires a more direct approach. It should be noted that the lowest Equotip hardness measured at LGS, Unit 2 was greater than the lower hardness O numbers measured in the NUMARC laboratory testing program, that is, LD 364 for LGS, Unit 2 as opposed to La 348 for the NUMARC test program. Se NUMARC tensile values corresponding to Lp 350 and greater are considered acceptable; therefore, the LCS, Unit 2 items subject to Equotip testing also have acceptable strength. For austenitic stainless steel, laboratory chemical analyses verified the expected carbon, chromium, nickel, molybdenum, etc. composition for the specified materials. Se principle concern for these materials is to have sufficient alloy for corrosion resistance. Any metal which had sufficient alloy to be nonmagnetic, and which was also inspected after welding a stainless steel system would be substantially verified as being acceptable material. 4.6 Analysis - PML/LTI Testing The comparison tests conducted by PML/LTI of the 37 coamson carbon steel flanges that were part of the NUMARC laboratory test program indicates good correlation with the NUMARC laboratory test program, the LCS, Unit 2 field testing data and between PML and LTI. Se PML Equotip hardness test data all exceeded Lp 350 as did the NUMARC laboratory and LCS, Unit 2 hardness tests and good correlation was shown between actual l Brinell hardness testing performed by PML and Brinell hardness values L converted from actual Rockwell B hardness tests performed by LTI. All of the tensile tests performed by PML had ultimate tensile strength values greater than 63 kai as was also the case in the NUMARC laboratory l test program for LCS, Unit 2 items. > 1284m p

c?37797 The results of the. chemical analysis between PML and LTI revealed comparable results for those elements analyzed in common by the two - v groups, that is, carbon, manganese and silicon. Although some difference in the alloy content is noted, none are greater than would be expected from testing at two or more laboratories. It is interesting that both PML and LTI agree that three carbon steel flanges have less than the 0.60 percent manganese required by the present SA-105 which is the same result obtained in the NUMARC laboratory test program, and were obtained on the same specimens. These specimens were PECO specimen No.s 19, 32 and 33 and NUMARC specimens LIM-2-13, LIM-2-27 and LIM-2-28, respectively. The PML/LTI comparison ests provide a verification of the accuracy of the LGS, Unit 2 field testing and the NUMARC laboratory testing by showing good correlation of the results of, tests on common items within the accuracy to be expected of the various test methods. References 1. Unpublished Final Report, NUMARC Ret,,anse to NRC Bulletin 88-05, October 1988, prepared by Bechtel Group, Inc. for EPRI. 2. The Variation of Product Analysis and Tensile Properties Carbon Steel Plates and Wide Flanges Shape, AISI, September 1974. i O l l I O 1284m l

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.._m.. ,- %)' 1 APPENDIX C LGS UNIT 2 - STRESS ANALYSIS FOR INSTALLED FLANGES AT LGS UNIT 2 WITH HARDNESS LESS THAN 396 LD 'l O 1 J i.

/ inter &A U>dA 2 I a 2_ 4 o ,,,c,,,,, g g r A g so. No. ,Ro;EcT SUBJECT h I h b FILE NO. O uaxa W r w 296 t.s c cc... istgo-sse g 20 Sb ph NO. OF $HEETS I Ceuw SLnt 4 I T O C. RECORD OF ISSUES No. DESCRIPTION BY DATE CHKD DATE APPR D DATE ASN Fntal J.sha Y+/89 A YA 1 Vskv au stse ^ I A \\ ^^ A 22 incDug i cever ebet, u I rabl Sectsteto: tom. = a of <a a m of ca aw O 9 i j l t O l l SFP 20220. REV 7/81 ED 1 AEV 5 (7 81)

t STRESS ANALYSIS FOR INSTALLED FLANGES WITH HARDNESS LESS Calc. No.1s240-S$0s, Rev.0 THAN 396 LD PER LDe(ERICK 'OFF PROJECT WORK REQUEST

DATED January 4,1989 11/29/sa, DOC #23sss4 Pasei Table of Contents Pages 1.0 PURPOSE 1

2.0 SCOPE 1 3.0 EVALUATION PROCEDURE AND CALCULATIONS 1 (1) Pressure Design Evaluations 2 (2) Moment Loadinn Qualification 3 4.0 RESULTS AND SUMMARIES 4 (1) Pressure Design Evaluations - 4 (2) Moment Loadina Qualification ' 5

5.0 CONCLUSION

5

6.0 REFERENCES

7 Tables O e=8e> TABLE 1.0 - Limerick Unit 2 (NRCB 88-05) Flange (Hardness Less Than 396) Pressure / Bolt Up Qualification By Derating Per TABLES B1 & C1 In Reference 2 8 TABLE 1.0A - Pressure Design For Blind Flanges (Carbon Steel) 10 Flange Evaluation 11 TABLE 2.0 - Limerick Unit 2 (NRCB 88-05) Stress Analysis For Installed Flanges With Hardness Less Than 396 LD 13 TABLE 2.0A - Limerick Unit 2 (NRCB 88-05) Stress Analysis For Installed Flanges With Hardness Less Than 396 LD 15 l TABLE 3.0 - Approximate Hardness Convension Number v.s. Approximate Ten-slie Stress, Mat'l = A370 16 TABLE 4.0 - Limerick Unit 2 (NRCB 88-05) Comparison of " Actual Moment" v.s. " Moment In Generic Report" For Installed Flanges With ) Hardness Less Than 396 LD 17 { I TABLE 4.0A - Limerick Unit 2 (NP.CB 88-05) Moment Comparison For Installed Flanges With Hardness Less Than 396 LD 19 O SIGNATURE DATE a:\\;inear A&e k V+/81 Crcser Vt)ALLc iK41 (/

. STRESS AN ALYSIS FOR INSTALLED FLANGES WITH HARDNESS LESS Cde. No.18240-SSos, Rev.0 THAN 396 LD PER LIMERICK 'OFF PROJECT WORK REQUEST" DATED January 4,1989 11/29/88, DOC #2s5864 Page 1 (O \\.) I.CPURPOSE Based on NRC Bulletin No. 88-05 dated May 6,1988, the materials supplied by Piping Supplies, i Incorporated (PSI) at Folsom, New Jersey and West Jersey Manufacturing Company (WJM) at Williamstown, New Jersey contain false information in the use of the nuclear industry. The purpose of this evaluation is to qualify the components supplied by PSI or WJM, scoped in the next section by following the procedures provided in the Bechtel" Report on Generic Analysis and Evaluation of Suspected Material Identified in NRC Bulletin 88-05" dated July 21,1988 (Ref.2). 2.0 SCOPE All the evaluated flanges are identified on the isometrics with the Limerick Project "OFF PROJECT WORK REQUEST" dated 11/29/88, Document Control No. 235854 (Ref.3). This evaluation is performed for all the installed flanges with hardness less than 396 LD per the requests from the project and the documentation in Reference 11 for the Limerick Unit 2 only. ] There are a total of fifty-two (52) flanges in the scope of this analysis, in which forty-six (46) are made of carbon steel and six (6) are made of stainless steel. 3.0 EVALUATION PROCEDURE AND CALCULATIONS In compliance with the requirements addressed in Bechtel's Generic Report (Ref 2), two -(2) evaluations are required to qualify the flanges with the suspected materials. These are (I) Pres-sure Design Evaluations : TABLE B1 and TABLE C1 (Ref.2) are the basis of this evaluation for the blind flanges and the other flanges, respectively. In case that it is not met, either of NC-3325 and Appendix XI of ASME Section III is used to qualify this flange;

m. 2 (2) Moment Loading Qualification : TABLE C4 (Ref.2) and TABLE C6 (Ref.5) are the basis of this evalu-ation for the large bore and the small bore flanges, respectively. In case that the large bore does not meet the requirements, the given moments in TABLE C5 (Ref.2) will be the allowables for Normal, Upset, Emergency and Faulted conditions. The following is the detailed evaluation procedures and calculations for this subject analysis.

SJONATURE DATB Originator )qfjdA W/89 p V Checker flgi, CA </ff37

1 l STRESS ANALYSIS FOR INSTALLED FLANoES WITH HARDNESS LESS Cale. No.18240-SSos, Rev.o THAN 396 LD PER LIMERICK 'OFF PROJECT WORK REQUEST" DATED January 4,1989 11/29/88, DOC #2s5864 Page2 (J) \\ l (1) Pressure Desian Evaluations j i j (a) The pressure-temperature rating tables, TABLES B1 & C1 (Ref.2) were generated I based on ANSI B16.5 Table 2. To qualify, the flange should be evaluated for the internal design pressure. All the required data, such as flange ID, pressure class, material, isometric no., system design pressure and temperature, tested yield - strength ( assumed to be half of tensile strength bared on field LD number ), etc. l are provided in TABLE 1.0. ) I Using the system design temperature, the pressure class of the analyzed flange., and the calculated S value, the pressure from TABLE B1 or TABLE C1 (Ref.2) was j y ' derated and the adjusted maximum allowable pressure for suspected material was I established. Since the tested S value is lower than 36,000 psi, the Maximum y Allowable Pressure for S = 36,000 psi may be linearly interpolated for in:?rmedi-I y ate S values. The adjusted maximum allowable pressure is obtained using the y following equation : o 4 Adjusted Maximum Allowable Pressure =( Pressure From 1 TABLE Bl / Cl ) l (36,000) / (b) Compare the adjusted maximurn allowable pressure to the system design pressure. Acceptability is established when the system design pressure is equal to or less than the adjusted maximum allowable pressure. The results are given in the last column of TABLE 1.0. (c) If any of the above ratios is greater than unity, the sub-section NC-3325 and the Appendix XI of ASME Code, Section III,1971 Edition up to and including 1972 Winter addenda will be applied to qualify the blind flanges and the other flanges for the pressure design evaluations, respectively. The results are presented in the last column of TABLE 1.0A. SIGNATURE DATE , Q Originator MydA W.jgp G Checker Qtj3 g ,,r g y l / l 1 1

i '

'l]!l.l 'A STRESS ANALYSIS FoR INSTALLED FLANGES WITH HARDNESS LESS . Calc. No.18240 SS05, Rev.0 p^ > THAN 396 LD PER LDdERICK 'oFF PROJECT WORK REQUEST" DATED January 4,1989 .11/29/84, DOC #338464 Page s (2) Moment Loadine Qualification (a) Using the applicable data similar to those identified in Section 3.0.(1) and the connecting pipe schedule and size, determine the available ratio provided in - TABLE C4 (Ref.2) or TABLE C6 ( Ref.5 ) for the material S = 20,000 psi. Since l y SIF value = 1.08 for large bore and SIF value = 1.3 for small bore have been generically used in the project, the equivalent tested S should be the flange tested y yield strength, S finearly interpolated by a factor of (1.08/1.90) or (1,30/2.10), y 1 respectively. The RATIO is calculated as below : y { Ratio From TABLE C4 / C6. Sy 20 ksi ) R ATIO = = [ ( 20.000 ) } y \\( Equnualent Tested Sy }.] 3 in which, Equivalent Tested S = ( Tested S ) x ( l.08 /1.90 ) for large bore above 2 y y inches; .- ~.. p Equivalent Tested S = ( Tested S ) x ( l.30 / 2.10 ) for small bore 2 y y inches and below; (b) Acceptability is the RATIO equals to or less than unity. The results are presented l in TABLE 2.0.- .a I (c) If any of the above ratios is greater th:n unity, the Equations (12) for Level A, (13) for Level B, and (14) for Levels C and D based on TABLE 5 (Ref.2) will be applied to qualify those flange joints using the actual given moments in Reference

3. Levels A, B, C and D represent Normal, Upset, Emergency and Faulted condi-tions. ' The results are presented in the last column of TABLE 2.0A.

{( R ATIO = \\ Maxtmum Allonied Moment ( TABLE CS } } } ( ( 20.000 ) ) ,J( rested sy ) / Acceptability is the RATIO equals to or less than unity. The results are presented in the last column of TABLE 2.0A. O SIGNATURE DATE Originator fMosh V4/87 Checker Yfi/e?_\\M /84,1

STRESS ANALY318 FOR INSTALLED FLANGES WITH HARDNESS LESS Cale. No.18240 SS05, Rev.0 THAN 396 LD PER LIMERICK 'OFF PROJECT WORK REQUEST

DATED -

. January 4,1989 ' 11/29/88, DOC #236864 Page 4 4.0 RESULTS AND SUMMARIES 1 The followings are the results and the summaries of the above analyses : (1) - Pressure Dggign Evaluations I (a) From TABLE 1.0, the ratios for thirty-seven (37) out of forty-six (46) flanges with carbon steel material are less than unity. The ratios for nine (9) flanges - exceed unity. The pre:;sure ratings of all of these 9 flanges are 600 lbs, and the flange design pressure ranged from 1,115 psig to 1,325 psig. For these 9 flanges, the maximum RATIO in TABLE 1.0 is about 15.7% over the allowable. It requires qualification by Appendix XI or NC-3325. They are: Isometric No. Pc No Gasket Type Isometric No. PeNo Gasket Type 3* BF RF 600 lbe S.S. 4' W N 600lbe S.S. (1) SP EBB 242 K37 22 Flexitallie (6) 8031-EBB 2331 4 Ring Joint 4* WN 600 lbe S.S. 4' WN 600 lbe S.S. (2) 8031-EBC-208 1 9 Ring Joint (7) 8031-EBB 233-1 5 Ring Joint 4* WN 600 lbs S.S. 4' WN 600 the S.S. (3) 8031.EBC-208-1 10 Ring Joint (8) 8031-EBB-233-1 16 Ring Joint i 4' WN 600 the S.S. 4" WN 600 lbe S.S. I (4) 8031 EBC-208-1 11' Ring Joint (9) 8031-EBB-2331 17 Ring Joint 4* WN 600 lbe S.S. (5) 8031 EBC-2081 13 Ring Joint (10) N/A N/A N/A The properties of ring joint gasket are obtained from ANSI Code B16.20 (Ref.9). I SGNATURE DATE 0:idnator Mk V4/89 Checker

WLe,

//c/@ f

STRESS ANALYSIS FOR INSTALLED FLANGES WITH HARDNESS LESS Cale. No.18240 SS05, Rev.0 THAN s96 LD PER LIMERICK "OFF PROJECT WORK REQUEST" DATED January 4,1989 j 11/29/84, DOC #236864 Page 5 (b) The above nine (9) flanges are evaluated and the results are shown in TABLE 1.0A. Eight (8) out of these 9 flanges are 4" WN 600 lbs flanges. They are l qualified per Appendix XL One (1) out of them is 3" RF 600 lbs blind flange also met the requirements of NC-3325. (2) Moment Loadinn Qualification (a) Moment evaluations are shown in TABLE 2.0. There are three (3) flanges whose RATIOS are greater than unity. All of them are welding neck flanges. (b) For those three (3) flanges, the actual moments at the flange joints are compared with the allowable moment provided in TABLE CS (Ref.2). All the results are l presented in TABLE 2.0A and found to be acceptable, since the ratios of ( maxi-mum required S )/( tested S ) are less than unity. j y y

5.0 CONCLUSION

l There are a total of six (6) flanges of stainless steel material and forty-six (46) flanges of carbon O steel material in this subject scope. Only the installed flanges 'of carbon steel material were evaluated, since the stainless steel material has been accepted per NUMARC Generic Testing i Program Response (Ref.10). l All of these evaluated flanges which have been installed in field meet the Code requirements, j The individual evaluations of these qualified flanges are listed in the following : l (1) PRNURE DESIGN EVALUATIONS Total Number of Acceptance per Acceptance per Acceptance per Acceptance per Flanges ( < s96 D ) Generic Report ASME NC-ss25 Appendix XI NUMARC (S.S.) 52 37 1 8 6 1 The maximum ratio of (abnormal pressures) / (design pressure) for the installed flanges within this scope is about 1.20. The peak pressure for Level C shall not exceed 1.5 of design pressure. The peak pressure for Level D shall not exceed 2.0 l of design pressure. Therefore, the abnormal pressure are far below Code i allowable, j O SIGNATURE DATE j Originator h 4M9 Chocker /}}t2 fl //5/?? I f j

1 - STRESS ANALYSIS FOR INSTALLED FLANGES WITH HARDNESS LESS Calc. No.18240-SS05, Rev.0 THAN s96 LD PER LIMERICK 'OFF PROJECT WORK REQUEST" DATED January 4,1989 f 11/s9/48, DOC #3s4454 Page 6 O 'k) i _ (2) MOMENT LOADING OfIAI IFI('ATION Total Number of Acceptance per Acceptance per Acceptance per-Flanges ( < s96LD ) Generic Report TABLE C5 NUMARC (S.S.) i 52 43 3 6 A comparison of " Actual Moments in the Normal condition' given by the Limerick project" v.s. " GENERIC moments assumed in TABLE C5 of the GENERIC report" has been made. It indicates that the basic assumed moments in the GENERIC report (Ref.2) are adequate and applicable to the Limerick Project. The assumptions for those moments are. (1) In determining the moment loads, piping stress is limited to 60% (or 100% for pressure rating of 900s and greater) of the thermal expansion' allowable stress, Sa = 1.5S, plus assumed 3,000 psi for deadweight. h (2) Bending and torsional moments are assumed to be equal in magnitude. Each is assumed to be square root of 2 of resultant moment. The results are presented in TABLE 4.0. All the RATIOS are less than unity except for two (2) flanges ( item no's 11 & 49 ) which are slightly over the GENERIC moments by 1% and 3%, respectively. In order to accept this small de'viation and to expand the acceptance from the Normal condition to the Upset, Emergency and Faulted conditions, TABLE 4.0A has been established. TABLE 4.0A is the analysis to use the actual moments in the Normal, Upset, Emergency and Faulted conditions from the project to check l against the established allowable moments based on Equations 12,13 and 14. The results in the last column of TABLE 4.0A show that they are lower than the i allowables. { This is concluded that the GENERIC moment allowables in the GENERIC report are adequate for the Limerick Project. Therefore, the flanges with hardness less than 396 LD are found to be acceptable for this project. SJQNARJRE DATE Q Originator $dfelh J/4./M Chocker W&jg e/s/f7, j

l 4 STRESS ANALYSIS FOR INSTALLED FLANGES WITH HARDNESS LESS Cale. No.18240 SSos, Rev.o - THAN 896 LD PER LIMERICK 'OFF PROJECT WORK REQUEST

DATED January 4,1989 11/29/88, DOC #385854 Page 7

~

6.0 REFERENCES

(1) Limerick Project " Piping Material & Instrument Piping Standard " Document No. 8031-P-300, Rev.35. (2) Bechtel" Report on Generic Analysis and Evaluation of Suspected Material Identified in NRC Bulletin 88-05" dated July 21, 1988. 1 (3) Umerick Project " OFF PROJECT WORK REQUEST " (OPWR) from A. Sidhu to M. Khlafallah, dated November 29, 1988. Document Control No. 235854. (4) ASTM Material A370, TABLE 28, Approximate Hardness Conversion Number for-t4onaustenitic Steels (Rockwell B to other Hardness Number). (5) heneric Analysis and Evaluation of Suspect MaterialIdentified in NRC Bulletin No. 88-05 dated May 6,1988. Stress Staff Calculation Np. SGGS-04, Rev.l. n (6) '5SME Code, Section III,1971 Edition up to and including 1972 Winter addenda, sub-section NC-3325. l (7) ASME Code, Section III,1971 Edition up to and including 1972 Winter addenda, A'ppendix XI. .x (8) ASME Code, Section III,1977 Edition up to and including 1979 Summer addenda, l O sud-section NC-3658. t (9) A'NSI B16.201973 Edition, Ring-Joint Gaskets and Grooves for Steel Pipe Flanges. - (10) NUMARC GENERIC TESTING PROGRAM RESPONSE To NRC Bulletin 88-05, FINAL REPORT, October,1988. Section 5.: Stainless Steel and Low Alloy Steel. r a (11) Memorandum from Chuck Bradford to Distribution, dated 11/11/88. Subject : NRC Billietin 88-05 Status and Final Report. L .e s o .[ .. b. i a 3. S!GNATURE DATE Originator h V4/8f Chocker M/ d (/5/$[ O U

_m i <l BECHTEL POWER CORPORATION .i Interoffice Memorandum g Distribution T File Shj NRC Bulletin 88-05 Status & { Final Report Date I November 11, 1988 From C. Bradford d 1 of SF Engineering Ce plesq B. G. Markowitt (all W/c) At . H. Hollingshaus 45/4/D39 Ext 8-1284 A. Langmo 4 i i Th3 pui 'erid response to NRC Bulletin 88-05. pose of this memo is tok i gal fiz al risport. of the This memo transmits the _Bacause of its size, bagng sent to one contact point in each offics* port is only the final re j Neq$tiaionswiththeNationalBoardresultedin { end ersi g the NW. ARC program on September 28 a latter acc epta ility for unstampad plants was left as an , 1988. Code b1ve res ins e to be pect n agencias. d, thrt que NTOL presentationsThe generic program provided input to the e pl&Ut u aB htal'NTOL's have now re. It is my understanding that all that rJ solved this issue favorably with s and AIA's. l A.cIose t maating was held with the NRC on October 27 Their e pense was ganarally favorable and it looks as,if this issup; a 1988. be resolved soon in the form of Suppiament 3 meetti ith NRC strass analysis people is planned for Novemb 16-1, One more ' t the list of questions does not indicate significant pro er The key recommendations,of the ganarie program are sur. i d as follows: 1. 1 pan issues, ased on this report and further data eclisctioninc a u a ng and/or analysis should not be required. 2. ns lied items should be acce arvice for the long term.pted as technically adequate or 3. 11 ellow forged carbo esptable for use. n steel material in warehouses should a 4. arb steel blind flanges in varahouses should be hardness est before use. Equotip (Ld) readin ou be aces; table for installation. gs of 351 or higher /

_-_--_-----__x

[ 'YMed e ~1L Tg g g~ ~' ~~ ~ ~ ~ ~ ~ ~ ~~ P< tgo 2, u Do

t. hse withoutStainless steel items in warehouses should be accep resistant materialtesting unless the application recuires IGscC or (e.g. NRC Generic Letter 88-01).

1

ctse, chemical analysis should be performed to confirn that In that l

the item (s) are_ resistant. , app [ tars likely that the.NRC will place more stringent 11 ntions on the use of warehouse material relativa stri rd r*H g., recommendations.1 .ea u o. feedback from Vogtle indicates that thd I~NF

is t,cMil usine the 137BMN (converted Ld=396) 11 nit.

As an alternate, NRC noted that they woul_d acceps c.__ as_a lower l ga per.u d up by one standard deviation (19 14 points). progra adtjustr -. ~ It 'is a eric stress analysis for installed items, perhaps o th t gen p s a' npling basis or for items wh.ig:h tested below 1375HN (c1 nverhed), before allowing cperating plants to close out this isnue. 3 To clos <a, h.s effert the success I think it has bsen.I'd like to thank a mate th bot h th n project team and those outside the team who providedThis includes in :alua ole information and support. All the feedback I have got, ten ! rom the-NRC, NUMARC and EPRI has been very positive and cc:1plimantary to Bechtel. Bre;ismehster who was the principal author of the final reportSpe Kh.tafallah who put together the generic stress analysis, and O Dartnis Brown who pulled the data base together. Me adfica nd statistical analysis and Lee Anderson's counsel and Tony Mark's support also played an i=portant role in the program. 4& i . Bradfo d Disf,' ion: B. N. ers* R. Tosse L. Memula K. e4 iger*

5. Freid R. Miller I.

V@enh

R. Henderson X. Morgan e*

E. R. dagel;s* C. Hogg E. Nelson L. MidWrien N. Howard

c. Reid P. Huber A. Sidhu

2" S. 1Fernbpn D. Kansal A. Wilk F. Eyeisgeister M. Khlafallah D. Igo R. Manley D. Cupi i

T. Mark C. < bilf :r T. Mprah

Rehortf attached t

h '. I' u

enev ornie,e erence e Document Controi No. LIMERICK GENERATING STATJON PHILADELPHIA ELECTRIC COMPANY OFF PROJECT WORK REQUEST (}~ro M. katsFALLsa of ses o Po srsff From: M. b/ONd v 2 91988 Date: COPIES TO: M.S. Iyer-a.w. (Unit 1 only) R. Knickerbockers (Unit 2 only) Umt 1 O Unit 2 8

SUBJECT:

h/RC blLLETi^t 88.Os: Srness ANALYs/s Atw Insrrusa FLAAJGGS w/ /7 H HARDAIESS LESS 'rHA st . goo /b

REFERENCES:

cp C. 6 RAD Fogo ///// /82 I57728 .6) F/AtAL A5POG DATED lol82 : R%/se 70 NRC BuMNiv 28.05 ENCLOSURES: 50 METRICS k/ /7H FLAA/G ES /DENTIFIGO (bY YE!InL<)A4A.Rxgg} AS N A VING /1A/L^A/ESS REASIAl6 3 4 doo [p, ACTION REQUESTED: O Furnish Data, information O Approval E Perform Analysis / Design / Calculation-0 Other inputs are: Final, Commited or Prehmanary O Study and Report O Review and Comment O Concurrence / Agreement 10CTR21 APPLIES: YES V NO REMARKS: Paxem smass - i-r. sis s m eie. rv rane,c s l / C E AtTI Fl e o Pent. 77te e Alct.csuxc. L 0% ), v M, 2 dd86 I. I [ Signed: Date: ' Project Eng ne( 8

Eng'r.

Contact:

4. 8/C#ff ! F M 70 Charge Number: Job /8 2 4-0 Sub M Phonehd 3'27-5"78f Activity Code df T E M N 7/[

/#!ZT c ( f, )ra! ApprovaM//41 Date: Authorized IBudget) MH RS 840 - ~ Written Response Reo'd: YES / NO Other Costs Due Date: /O! Ole!$f (Project Approval Required to Exceed Budgeti Advise Eng't. Contact if Response will be later Per Telecon with: Date: vev. 2 (1/f 8)

Stcht und Stzhlguss Act:r ct fbnte d'acirr (E-Modul 210000 N/mm8) Steel and cast stesi O Le HV HS HMS HRC H00 Le NY HS HR9 HMC HSD (N3 cog (4300g 300 80 38.4 400 148 73,3 302 E,1 30.4 401 141 73.3 304 82 40.3 404 143 77.4 308 83 41.3 400 144 78.0 308 84 42.3 408 145 78,8 310 SS 43.2 410 147 79.0 312 88 44.2 412 148 79.8 6 314 ST 45.1 414 100 80.0 Sig SS 48.0 416 151 80.8 318 80 44.9 418 ISS 81.0 320 90 47.8 420 184 81.5 322 91 48.T 422 ISS 82.9 324 93 49.8 424 157 82.4 328 M 80.4 424 I SS. 82.9 328 SS S t.3 425 te0 83.4 330 98 52.2 430 182. 83.8 332 97 53.0 432 tes 84.3 334 98 53.8 434 fee. 84.7 334 99 54.8 434 186 58.1 338 100 55.5 438 ASS SS.S 340 102 SS.S 440 100 80.0 342 103 57.1 442 171 88.4 344 104 57.8 444 171 88.8 348 105 58.8 444 174 87.2 0 348 100 88.4 448 175 87.7 q 300 107 80.1 480 177 88.1 l 362 100 80.0 452 179 88.4 354 110 S t.S 454 100 88.8 398 111 82.4 4SS 102 80.2 3SS 112 83.1 458 184 St.S 300 114 83.4 463 ISS 80.0 342 115 M.S est ISF 90.3 384 116 SS.2 464 ISS 80.7 348 117 08.9 des ISO 91.1 384 119 88.8 488 192 91.4 370 120 87.3 470 1H 91.8 l 372 121 87.9 472 198 92.1 374 122 84.0 474 197 92.5 378 124 80.2 478 1# 92.8 370 128 88.4 475 200 93.2 -- 380 128 70.5 480 202 93.5 set its 71.1 482 204 93.8 384 128 71.7 444 200 M.2 388 138 72.3 484 207 M.S 388 138 72.9 448 200 M.S i 390 138 73.5 480 211 H.S 392 134 74.1 492 218 95 8 394 I SO-74.7 494 218 98.4 398 137 78.2 4M 218 98.1 398 138 78.8 498 218 98.4 l 400 140 70.3 500 v 220 M.7 ODie Worte sind gD!tig fur unlegierten und niedriglegierten Stahl und Stahlguss im warmgewalzten oder geschmiedeten und wermebehandelten Zustand. Les valeurs sont valables pour les eclers et les fontes d' acier non allies et felblement aill6s. forg6s ou I temin63 6 chaud et eyent subi un traitement thermique.

OAm 16.1.3 A range of hardness can pmperty be ar='A=8 only 16.1.4 Brtnen hardness may be requiMd when % for quenched and tempered or nonnaha0d and tempered properties are not spectaed. When agreed upon, hardness O material. For anasalad material a maximum ages only tems can be subsatuted for tenson tests in order to expedite should be apar,A-t For nonnahand matanal a minimum or tunas of a large number of dupbcsas puces kom the same 188-a maximum hardaneB may b8 spac Sed by agreement. In general, no hardaens regaressents abound be appbed to 16.2 Apparatie-Equipment shan most the fouowtag l untreated antarlal. (158f l S. s 4 TAaLE ss Apposenses Maesse comeraten Bemuhere der 90ensestedte Obsole (Restree8 5 to amor Monkees Itseers) Redmus testem MsW=es 4 l l Roemed 8 M gg,,,, 4 ' Reshmal A Rasmus P 157 t,aga. 307 t,apa, 457 Seas. 4 a===.10Mv v==.

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1A EF 37.7 to (MEl M

114 $A4 114 1rF 41A SLA MA ISA 38.7 es 113 85 118 15 40A MA 81.1 K4 EF et 110 SM 119 1M 40A M2 SES 87.7 34.7 81 100 85 1# 13 40A M.7 00A S7A EF 80 10F EN 1er 130 NA M.1 80.1 K4 E7 80 100 S.78 18 tit NA SOA MA E7 31.7 es 1M E77 1M 117 3BA SOA 79A SSA E.7 37 10s SA1 15 118 38.1 884 MA M4 EF 101 85 1M 114 3F.7 884 78A 817 EF 36 1m SAF 1W 112 37 2 ER 78.8 SSA F7.7 54 111 SSA 87.7 782 88.4 E7 33 110 agJ SBA 77.9 St.7 35.7 g 18 EJ 082 77.8 S12 H.7 31 100 NA 08.4 773 80J 31.7 90 10F MA M3 75A 40.7 33.7 de 109 34 2 MJ FSA 40 2 21.7 de 15 M.1 EF 7EA 483 E7 47 104 33.7 88.1 78 3 47.7 117 O 46 10B SSJ 75.0 47A 18.7 14 256.. Y% A= , g - r. .e .c i

LIMERICK GENERATING STATION PHILADELPHIA ELECTRIC COMPANY - OFF PROJECT WORK REQUEST M. kut.Arvttra of seso po srAFr ro: From: b/O#d Date: COPIES TO: H.S. Iyer o w. (Unit 1 only) R. Knickerbockers (Unit 2 only) Unit 1 O unit 2 E

SUBJECT:

NRC &llICYtAt 88-os : Srness Anstysis me Insraum FLAkJG SS witrH +1ARDMESS 1ESS THAM 400 La

REFERENCES:

cp C. MADFORD //////82 I.ET7ER .!d FtriAL ADPORT DATED /O]88 : RkspcNsc rc NMC Muumig 88 4 5-ENCLOSURES: SOMETRICS VIITH FLAA/GES IDENTIFIGO (bY YE!1% iAjggggp} AS HAVING //AIt4 NESS A!EASIN43 4 doD /,,o, ACTION REQUESTEO: O Furnish Deta, information O Approval @ Perform Analysis / Design / Calculation-0 Other inputs are: Final, Commited or Preliminary O Study ano Report O Review and Comment O Concurrence / Agreement 10CFR21 APPLIESt YES V NO REMARKS: Paaron.m. smass m Y. Sis s e e m e. ro ,ame s I D E AITI Fl & O PGA THE F-M CLO SUKE, Jl cou. J ) ^ d[* llb8/86 I [ Signed: Date: oroiec c s n.y e Eng't.

Contact:

4, BOW //Fa04MO Charge Number: M /$240 Sub d hO Phone:(B/d 327-578f Activity Code 13TE NM 7// EGS ApprovaT.N Date: /M Authorized (Budget) MH RS 840 4 Vritten Respon Reg' YES / _ NO Other Costs Sue Date: /M 87 (Project Approval Required to Exceed Budget' . Advise Eng'r. Contact if Response wa be v. ar Per Telecon with: Date: i sev. 2 (1/86) {

c9ATY6Y ~ ~ O - c ~-

7~

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V TABL (CARBON STEEL) O.........E1.0A-PRESSUREDESIGNFORBLINDFLANGES ' SIZE : 3" / FLEXITALLIC STYLE CG GASKET, SPIRAL-WOUND STAINLESS STEEL PRESSURE RATING 150#' 300#. 600#~ 900# 1500#- INT.. PRESSURE 1250 1250 1250 1250 1250-GAFP/ET O.D. 4.75 4.75 4.75 4.75 4.75 GASKET I.D. 4 4 4 3.75 3.625 m= 3 3 3 3 3 ( yu 10000 10000 10000 10000 10000 5 C= 6 G.625 6.625 7.5 8 t= 0.875 1.0625 1.25 1.5 1.875-Ab= 0.808 2.416 2.416 3.352 5.544 i Sa= 25000 25000 25000 25000' 25000 l Sb= 25000 25000 25000 25000 25000 4 c= 0.200 0.200 0.200 0.200 0.200 l N= 0.375 0.375 0.375 0.500 0.563 bo= 0.188 0.188 0.188 0.250 0.281 d= 4.375 4.375 '4.375 4.250 4.220 b= 0.188 0.188 0.188 0.250 0.265 hg= 0.813 1.125 1.125 1.625 1.890' Am= 1.525 1.525 1.525 1.711 1.754 j H= 18791 18791 18791 17733 17481 Hp= 19328 19328 19328 25035 26364 Wal= 38119. 38119 38119 42767 43844 Wm2= 25771 2577.1 25771 33379 35152 Sfo= 17993 15266 11030 11237 8361 Sfa= 8983 14250 10296 13658 14761 Sf= 17993 15266 11030 13658 14761 1.5* Allowable N/A N/A 20250 N/A N/A 9 Design 1.0* Allowable N/A N/A 13500 N/A N/A Temp. 1.0* Allowable N/A N/A 13500 N/A N/A 450 F MAXIMUM RATIO = N/A N/A 0.817 N/A N/A Note : It is acceptable only if the RATIO <= 1.0. l O. IbA40~5Soffo l SlGNATURE DAT2 OrlGinator WQ (yffgg Checker ggp,g,g g7g= $ /0 1

TABLE 1.0A FLANGE EVALUATION j

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PIPE SIZE: 4.00 " UNITS: IN, LBS & IN-LBS O PIPE THICKNESS: 0.337 (SCH 80) FLANGE TYPE: WELDING NECK W/ RING JOINT TYPE GASKET FLANGE RATING: 600 DESIGN PRESSURE: 1290 FLANGE MATERIAL: CARBON STEEL SA105 TUBE TURNS FLANGE PROPERTIES: BOLT CIRCLE: 8.500 FLANGE OD 0: 10.750 HUB DIA X: 6.000 GAP: 0.000 FLANGE THK Q: 1.500 HUB LENGTH Y: 4.000 Sa( Cold ) : 25000 R.F. DIA R: 6.188 BORE DIA J: 3.830 Sb ( Hot ) : 25000 FLANGE PROPERTIES PER ASME ARTICLE XI-3000 NOMENCLATURE: A= 10.750 g0= 0.335 h= 1.998 B= 3.830 g1= 1.085 R= 1.250 C= 8.500 t= 1.500 GASKET INFORMATION: GASKET TYPE: RING JOINT STYLE GASKET - RING & GROOVE NO. R37 STAINLESS STEEL O.D.= 6.313 IF bO<.25 b= 0.055 IF bO>.25 b= 0.117 4 I.D.= 5.438 IF bO<.25 G= 5.813 IF bO>.25 G= 6.078 m= 6.500 w= 0.438 b= 0.055 y= 26000 bo= 0.055 G= -5.813 BOLT LOADS: Wm2= 25964 H= .34230 O wm1= 50977 Am= 2.039 w= e73ee Hp= 16747 Ab= 3.352 Gasket M. m= 23643 FLANGE LOAD AND MOMENTS: Hd= 14862 hd= 1.793 Md= 26640 Hg= 16747 hg ' 1.344 Mg= 22504 Ht= 19368 ht= 1.839 Mt= 35625 Mp= 84769 SHAPE CONSTANTS FROM FIG. XI-3240 AND STRESS FORMULA FACTORS: K= 2.807 g1/g0= 3.239 alpha = 1.779 T= 1.254 h/ho= 1.763 beta = 2.038 Z= 1.291 F= 0.588 gamma = 1.419 Y= 1.994 V= 0.047 delta = 0.569 U= 2.192 f= 1.000 lamda= 1.988 ho= 1.133 e= 0.519 Pres. Moment M= 22133 d= 5.93 t= 1.500 Max. moment = 23643 STRESS CALCULATIONS: Ratio A Ratio B LONGITUDINAL HUB STRESS Sh= 13789 0.681 0.584 RADIAL FLANGE STRESS Sr= 10771 0.798 0.684 TANGENTIAL FLANGE STRESS St= 7053 0.522 0.448 Note: Ratio A = Sh/(1.5 of allowable stress, (1.5*15000*63/70) psi) = Sr (or St)/(1.0 of allowable stress, (15,000*63/70) psi) O Ratio B = Sh/(1.5 of allowable stress, (1.5*63000/4) psi) = Sr (or St)/(1.0 of allowable stress, (1.0*63000/4) psi)

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SIGNATURE DATE CM U"..g ( M 4 h Orlainator kM& % V88 W II checker MM 12/:1!!

TABLE 1.0A FLANGF EVALUATION

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1 PIPE SIZE: 4.00 " UNITS: IN, LBS & IN-LBS ()PIPETHICKNESS: 0.337 (SCH 80) ~ FLANGE TYPE: WELDING NECK W/ RING JOINT TYPE GASKET FLANGE RATING: 600 -DESIGN PRESSURE: 1325 FLANGE MATERIAL: CARBON STEEL SA105 TUBE TURNS FLANGE PROPERTIES: BOLT CIRCLE: 8.500 FLAh0E OD 0: 10.750 HUB DIA X: 6.000 GAP: 0.000 FLANGE-THK Q: 1.500 HUB LENGTH Y: 4.000 Sa( Cold ) : 25000 R.F. DIA R: 6.188 BORE DIA J: 3.830 Sb ( Hot ) : 25000 FLANGE PROPERTIES PER ASME ARTICLE XI-3000 NOMENCLATURE: Aes 10.750 g0= 0.335 h= 1.998 B= 3.830 gl= 1.085 R= 1.250 C= 8.500 t= 1.500 GASKET INFORMATION:- GASKET TYPE: RING JOINT STYLE GASKET - RING & GROOVE NO. R37 STAINLESS STEEL O.D.= 6.313 IF bO<.25 b= 0.055 IF bO>.25 b= 0.117 I.D.= 5.438 IF bO<.25 G= 5.813 IF bO>.25 G= '6.078 m= 6.500 w= 0.438 b= 0.055 y= 26000 bo= 0.055 G= 5.813 /~5 BOLT LOADS: Wm2= 25964 H= 35159 \\/ Wm1= 52360 Am= 2.094 W= 68080 Hp= 17201 Ab= 3.352 Gasket M. m= 23886 FLANGE LOAD AND MOMENTS: Hd= 15265 hd= 1.793 Md= 27363 Hg= 17201 hg= 1.344 Mg= 23114 Ht= 19893 ht= 1.839 Mt= 36591 Mp= 87068 SHAPE CONSTANTS FROM FIG. XI-3240 AND STRESS FORMULA FACTORS: K= 2.807 g1/g0= 3.239 alpha = 1.779 T= 1.254 h/ho= 1.763 beta = 2.038 Z= 1.,291 F= 0.588 gamma = 1.419 Y= 1.994 V= 0.047 delta = 0.569 U= 2.192 f= 1.000 lamda= 1.988 ho= 1.133 e= 0.519 Pres. Moment M= 22733 d= 5.93 t= 1.500 Max. moment = 23886 STRESS CALCULATIONS: Ratio A Ratio B LONGITUDINAL HUB STRESS Sh= 13993 0.698 0.599 RADIAL FLANGE STRESS Sr= 10882 0.815 0.698 TANGENTIAL FLANGE STRESS St= 7126 0.533 0.457 Note: Ratio A = Sh/(1.5 of allowable stress, (1.5*15000*62.334/70 psi) = Sr (or St)/(1.0 of allowable stress, (15,000*62.3/70) ps () Ratio B = Sh/(1.5 of allowable stress, (1.5*62334/4) psi) = Sr (or St)/(1.0 of allowable stress, (1.0*62334/4) psi)

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