ML061740350

American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code,Section XI - Preemptive Weld Overlays on Alloy 600 Pressurizer Nozzle-To-Pipe Welds

ML061740350
Person / Time
Site:	Watts Bar, Sequoyah
Issue date:	06/16/2006
From:	Morris G Tennessee Valley Authority
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML061740350 (59)

Text

Tennessee Valley Authority, Post Office Box 2000, Soddy-Daisy, Tennessee 37384-2000 June 16, 2006 10 CFR 50.55a U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, D.C. 20555-0001 Gentlemen:

In the Matter of ) Docket Nos. 50-327 Tennessee Valley Authority ) 50-328 50-390 SEQUOYAH NUCLEAR PLANT (SQN) UNITS I AND 2 AND WATTS BAR NUCLEAR PLANT (WBN) UNIT 1 - AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

BOILER AND PRESSURE VESSEL CODE, SECTION XI - PREEMPTIVE WELD OVERLAYS ON ALLOY 600 PRESSURIZER NOZZLE-TO-PIPE WELDS AND ASSOCIATED ALTERNATIVE REPAIR TECHNIQUES - GENERIC REQUEST FOR RELIEF G-RR-1 Pursuant to 10 CFR 50.55a(a)(3)(i), TVA requests approval for use of alternatives to the requirements of the ASME Code,Section XI, for the specified Edition and Addenda, Article IWA-4000, for repair and replacement activities related to the performance of preemptive weld overlays (PWOL), and/or needed weld overlay repairs at SQN and WBN. TVA plans to perform surface examinations and where practical, volumetric examinations of pressurizer surge line, spray line, and safety and relief valve header nozzle-to-pipe dissimilar metal (DM) weld areas to address potential primary water stress corrosion cracking (PWSCC) associated with Alloy 600 arid Alloy 182/82 welds. Where the full examination of nozzle-to-pipe weld areas cannot be practically obtained, or evidence of indications is discovered that precipitate repairs in the existing welds, TVA plans to use weld overlays as a repair technique. In addition, TVA plans to use PWOLs as a mitigation technique for potential PWSCC degradation and as a practical means to improve nondestructive examination results and to obtain full coverage during future inservice inspections (ISI).

The status of the SQN and WBN ISI Program intervals are as follows:

SQN Units 1 and 2 Units 1 and 2 are in the third 10-year ISI Program intervals. Since June 1, 2006, SQN performs repairs and replacements utilizing the ASME Boiler and Pressure Vessel Code, Section Xl, 2001 Edition through the 2003 Addenda.

VCI4-7 Printed on recycled paper

U.S. Nuclear Regulatory Commission Page 2 June 16, 2006 Watts Bar Unit 1 Unit 1 is in the third period of the first 10-year ISI Program interval. WBN utilizes the 1989 Edition of Section XI, but intends to transition to the ASME Boiler and Pressure Vessel Code Section XI, 2001 Edition through the 2003 Addenda on December 27, 2006 at the start of the second 10-year interval.

TVA requests approval for G-RR-1 prior to TVA's fall 2006 refueling outages. TVA intends to install PWOLs during the SQN Unit 2 fall 2006 refueling outage and then install PWOLs on SQN Unit 1 during the fall 2007 refueling outage. TVA plans to conduct examinations at WBN during the Unit 1, Cycle 7, fall 2006 refueling outage. Based upon potential ISI findings at WBN, use of PWOLs for repairs would be on a contingency basis. provides Generic Request for Relief No. G-RR-1.Section VIII of G-RR-1 lists nine similar industry examples that have either been approved by NRC or are pending NRC approval as indicated therein. Enclosure 2 lists the TVA commitments.

TVA's schedule has been discussed with Mr. Doug Pickett, NRC Senior Project Manager.

If you have any questions, please contact Rob Brown at (423) 751-7228.

Sincerely, G. W. Morris Manager Corporate Nuclear Licensing & Industry Affairs

Enclosures:

cc: See page 3

U.S. Nuclear Regulatory Commission Page 3 June 16, 2006 Enclsoures cc (Enclsoures):

U.S. Nuclear Regulatory Commission Sam Nunn Atlanta Federal Center 61 Forsyth Street, SW, Suite 23T85 Atlanta, Georgia 30303-8931 NRC Senior Resident Inspector Sequoyah Nuclear Plant U.S. Nuclear Regulatory Commission 2600 Igou Ferry Road.

Soddy Daisy, TN 37379 NRC Senior Resident Inspector U.S. Nuclear Regulatory Commission Watts Bar Nuclear Plant 1260 Nuclear Plant Road Spring City, TN 37381 Douglas V. Pickett, Senior Project Manager U.S. Nuclear Regulatory Commission Mail Stop 08G9A One White Flint, North 11555 Rockville Pike Rockville, Maryland .20852-2739

ENCLOSURE 1 TENNESSEE VALLEY AUTHORITY (TVA)

SEQUOYAH NUCLEAR PLANT (SQN) UNITS 1 AND 2 THIRD 10-YEAR INTERVAL WATTS BAR NUCLEAR PLANT (WBN) UNIT 1 FIRST AND SECOND 10-YEAR INTERVAL AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

SECTION XI REPAIRS AND REPLACEMENTS (R&R) PROGRAM GENERIC REQUEST FOR RELIEF NO. G-RR-1 EXECUTIVE

SUMMARY

Pursuant to 10 CFR 50.55a(a)(3)(i), TVA requests approval for use of alternatives to the requirements of the ASME Code,Section XI, for the specified Edition and Addenda, Article IWA-4000, for repair and replacement activities related to the performance of preemptive weld overlays (PWOL), and/or needed weld overlay repairs. TVA plans to perform surface examinations and where practical, volumetric examinations of pressurizer surge line, spray line, and safety and relief valve header nozzle-to-pipe dissimilar metal (DM) weld areas to address potential primary water stress corrosion cracking (PWSCC) associated with Alloy 600 and Alloy 82/182 welds. Where the full examination of nozzle-to-pipe weld areas cannot be practically obtained, or evidence of indications is discovered that precipitate repairs in the existing welds, TVA plans to use structural weld overlays (SWCOLs) as a repair technique. In addition, TVA plans to use PWOLs as mitigation for potential PWSCC degradation and as a practical means to improve nondestructive examination results and coverage during future inservice inspections.

TVA intends to install PWOLs during the planned SQN Unit 2 fall 2006 refueling outage and then install PWOLs on SQN Unit 1 during the planned fall 2007 refueling outage.

TVA plans to conduct examinations at WBN during the Unit 1, Cycle 7, fall 2006 refueling outage. Based upon examination findings and potential for repairs, the WBN utilization of PWOLs for repairs will be on a contingency basis.

G-RR-1 is similar to several prior NRC approvals.Section VIII of this enclosure lists nine industry examples. These examples are either approved or pending NRC review/approval. TVA proposes the use of PWOLs where it is known that full Code examination coverage of the nozzle-to-pipe DM weld areas is impractical, as well as, the use of weld overlays as a repair technique where full coverage can be obtained, but unacceptable indications are discovered. In addition, TVA requests the option to install SWOLs/PWOLs to mitigate potential PWSCC areas where full coverage can be obtained, but no indications are detected. The PWOLs and repair overlays performed at SQN and WBN will use the provisions of ASME Code Cases N-504-2, "Alternative Rules for Repair of Classes 1, 2, and 3 Austenitic Stainless Steel Piping,Section XI, Division 1'," and N-638-1, "Similar and Dissimilar Metal Welding Using Ambient Temperature Machine GTAW Temper Bead Technique,Section XI, Division 1," with modifications as El-1

shown in this request. In addition, TVA will follow the requirements of 10 CFR 50.55a(g)(6)(ii)(c) and comply, to the extent practical, with the provisions of ASME Section XI, Appendix VIII, Supplement 11, of the 2001 Edition of ASME Section XI for the performance of volumetric examinations of the welded areas following the application of the completed full structural weld overlays. TVA meets these requirements utilizing the approved Electric Power Research Institute (EPRI)

Performance Demonstration Initiative (PDI) techniques and the procedures as outlined in the attachments.

The successful use of these techniques and approved alternatives at other utilities have demonstrated that the weld overlay processes provide an acceptable level of quality and safety in accordance with the requirements of 10 CFR 50.55a(a)(3)(i).

I. SYSTEM/COMPONENT(S) FOR WHICH RELIEF IS REQUESTED:

Tables 1-3 provide the lists of nozzle-to-pipe DM weld areas (six welds for each unit) to be considered for the application of SWOLs/PWOLs. These tables list the specific weld designations, description, the associated weld and component configuration detail drawings, the corresponding weld overlay design drawings, and the associated base materials and the existing weld materials associated with the potential weld overlay areas. Attachment 1 provides Inservice Inspection (ISI) Program drawings. Attachment 2 provides a typical drawing of a weld overlay design.

The deposited material for the weld overlays will extend to cover the regions from the low-alloy steel nozzle, nozzle end weld buttering, DM weld, existing stainless-steel nozzle safe-end (SE) transition piece, the transition piece-to-pipe stainless steel weld area, and a portion of the stainless steel process piping. The tables are collated using the number designations for the SE DM welds, as the primary area of focus. For each SE DM weld, there is a corresponding stainless steel SE to stainless steel process pipe field weld with a unique weld number that is listed in Table 4. As stated above, these stainless steel welds will also be covered by the overlay process.

Because these SE welds are Alloy 600 DM welds, examinations of the welds are on an accelerated augmented schedule in accordance with the guidelines of the EPRI Material Reliability Program Primary System Piping Butt Weld Inspection and Evaluation Guideline (MRP-139).

For all three units, each of the six pressurizer nozzle-to-safe end DM welds are ASME Code Class 1 (or equivalent) welds within the Reactor Coolant System (RCS) which are all analyzed under the Risk-Informed Inservice Inspection Program (RI-ISI) processes and assigned the Code Category R-A, as appropriate. The examination volume coverage and the acceptance standards are defined by the RI-ISI Program as that analysis is applied to the standard ASME,Section XI, ISI Program requirements. For the SQN units, the six DM welds were all recently reevaluated as part of the ISI Program's third interval update to meet the 2001 Edition through the 2003 Addenda (2001A03) Code requirements and as part of the revision to the existing RI-ISI Program that is also reevaluated to accompany the ISI Program update. In the case of the SQN units, five of the six welds remain classified as low safety significant piping components.

The SQN surge lines were reclassified as High Safety Significant (HSS) piping segments and the surge line nozzle safe end-to-process piping weld selected to be examined as E1-2

part of the RI-ISI program weld population. In the case of the initial WBN RI-ISI Program, the six pressurizer [)M welds were categorized as low safety-significant (LSS) welds and were to be examined as part of the augmented ISI program in accordance with the agreed upon industry Alloy 600 program mitigation responses in MRP-139. In all three units, the augmented accelerated examinations will continue to be performed, as stated above, until weld overlays are in place and the examination schedule can be relaxed, if appropriate.

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Table 1 Sequoyah Unit 1 Weld No. Description TVA Overlay Nozzle Nozzle Nozzle to Safe- Safe-End to Pipe Process Drawing Design Material End Safe-End End Weld Filler Material Pipe

[Ref. ISI- Drawing Buttering Weld Material Material 0394-C- No. Material Material 01, for J__location]

RCW 1 14" Surge ISI-0394- 10056C56 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, A-376, TP SE Line C-05 Class 2 82/182 82/182 Grade ER308 316 F316L SCH. 160 RCW 4" Spray ISI-0394- 10056C57 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, SE Line C-02, Class 2 82/182 82/182 Grade RCW 6" Relief Detail D ISI-0394- 10056C58 SA-508, I Alloy F316L ER308 TP 316 SCH. 120 600 Alloy 600 SA-182, Stainless Steel, SA-376 SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 TP 316, Detail C F316L SCH. 160 RCW 6" Safety ISI-0394- 10056C59 SA-508, Alloy 600 Alloy 600 SA-1 82, Stainless Steel, SA-376 SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 TP 316, Detail C F316L SCH. 160 RCW 6" Safety ISI-0394- 10056C60 SA-508, Alloy 600 Alloy 600 SA-1 82, Stainless Steel, SA-376, SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 TP 316 Detail C F316L SCH. 160 RCW 6" Safety ISI-0394- 10056C61 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 TP 316, 1 1 Detail C , I _ I F316L , SCH. 160 E1-4

Table 2 Sequoyah Unit 2 Weld No. Description TVA Overlay Nozzle Nozzle Nozzle to Safe- Safe-End to Pipe Process Drawing Design Material End Safe-End End Weld Filler Material Pipe

[Ref. ISI- Drawing Buttering Weld Material Material 0396-C- No. Material Material 01, for location]

RCW 14" Surge ISI-0396- 10056C67 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, A-376, SE

.. Line 0-0.3 Class 2 812 A0 82/182 ' .Grade ER308/E308 TP3 16 F316L SCH. 160 RCW 4" Spray ISI-0396- 10056C66 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, TP SE Line C-02, Class 2 82/182 82/182 Grade ER308 316 SCH.

Detail D F316L 120 RCW 6" Relief ISI-0396- 10056C62 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376 TP SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 316, SCH.

Detail C F316L 160 RCW 6" Safety ISI-0396- 10056C64 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376 SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 TP 316, Detail C F316L SCH. 160 RCW 6" Safety ISI-0396- 10056C65 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, TP SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 316 SCH.

Detail C F316L 160 RCW 6" Safety ISI-0396- 10056C63 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, TP SE Valve Line C-02, Class 2 82/182 82/182 Grade ER308/E308 316, SCH.

I Detail C I I I F316L , 160 E1-5

Table 3 Watts Bar Unit 1 Weld No. Description TVA Overlay Nozzle Nozzle End Nozzle to Safe-End Safe-End to Process Drawing Design Material Buttering Safe-End Material Pipe Weld Filler Pipe

[Ref. CHM- Drawing No. Material Weld Material Material 2570-C-01, Material for location] I I I WP-10-SE 14" Surge CHM-2570- 10056C74 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, Line C-05, Class 2 82/182 82/182 Grade ER308/E308 TP 316, Detail E F316L SCH.

160 WP-1 1-SE 4" Spray CHM-2570- 10056C75 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, Line C-06, Class 2 82/182 82/182 Grade ER308 TP 304 Detail D F316L SCH.

160 WP-12-SE 6" Relief CHM-2570- 10056C76 SA-508, Alloy 600 Alloy 600 SA-1 82, Stainless Steel, SA-376 Valve Line C-06, Class 2 82/182 82/182 Grade ER308/E308 TP 304, Detail C F316L SCH.

160 WP-1 5-SE 6" Safety CHM-2570- 10056C77 SA-508, Alloy 600 Alloy 600 SA-1 82, Stainless Steel, SA-376 Valve Line C-06, Class 2 82/182 82/182 Grade ER308/E308 TP 304, Detail C F316L SCH.

160 WP-1 3-SE 6" Safety CHM-2570- 10056C78 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, Valve Line C-06, Class 2 82/182 82/182 Grade ER308/E308 TP 304 Detail C F316L SCH.

160 WP-14-SE 6" Safety CHM-2570- 10056C79 SA-508, Alloy 600 Alloy 600 SA-182, Stainless Steel, SA-376, Valve Line C-06, Class 2 82/182 82/182 Grade ER308/E308 TP 304, Detail C F316L SCH.

S1_ 1_ 1_ 1 160 E1-6

Table 4 Sequoyah Sequoyah Unit 1 Unit 2 Weld No. Description TVA Drawing Process TVA Weld Weld No. Description TVA Drawing Process TVA Weld

[Ref. ISI-0394- Pipe Map [Ref. ISI-0396- Pipe Weld Map C-01, for Weld Drawing C-01, for No. Drawing location] No. No. location] No.

RCW-29-SE 14" Surge ISI-0394-C-05 RC-35 ISI-0482- RCW-29-SE 14" Surge ISI-0396-C-03 RC-35 ISI-0008-Line C-01 Line C-01 RCW-24-SE 4" Spray ISI-0394-C-02, RCF-23 ISI-0369- RCW-24-SE 4" Spray ISI-0396-0-02, RCF-23 ISI-0013-Line Detail D C-02 Line Detail n C-01 RCW-26-SE 6" Relief ISI-0394-C-02, RCF-24 ISI-0369- RCW-27-SE 6" Relief ISI-0396-C-02, RCF-24 ISI-0013-Valve Line Detail C C-03 Valve Line Detail C C-03 RCW-27-SE 6" Safety ISI-0394-C-02, RCF-36 ISI-0369- RCW-28-SE 6" Safety ISI-0396-C-02, RCF-45 ISI-0013-Valve Line Detail C C-03 Valve Line Detail C C-03 RCW-28-SE 6" Safety ISI-0394-C-02, RCF-42 ISI-0369- RCW-25-SE 6" Safety ISI-0396-C-02, RCF-42 ISI-0013-Valve Line Detail C C-03 Valve Line Detail C C-03 RCW-25-SE 6" Safety ISI-0394-C-02, RCF-45 ISI-0369- RCW-26-SE 6" Safety ISI-0396-C-02, RCF-36 ISI-0013-Valve Line Detail C C-03 I Valve Line Detail C C-03 E1-7

Table 4 (Continued)

Watts Bar Unit 1 Weld No. Description TVA Process TVA Weld Drawing Pipe Weld Map

[Ref. CHM- No. Drawing 2570-C-01, No.

for location]

WP-1 0-SE 14" Surge CHM-2570- RCF-H3-5 CHM-Line C-05, Detail 2547-C-01 E

WP-11-SE 4" Spray CHM-2570- RCF- ISI-0365-Line C-06, Detail D233-07 C-02 D

WP-12-SE 6" Relief CHM-2570- RCF- ISI-0365-Valve Line C-06, Detail D232-01 C-01 C

WP-1 5-SE 6" Safety CHM-2570- RCF- ISI-0365-Valve Line C-06, Detail D232-12 C-01 C

WP-13-SE 6" Safety CHM-2570- RCF- ISI-0365-Valve Line C-06, Detail D232-10 C-01 C

WP-14-SE 6" Safety CHM-2570- RCF- ISI-0365-Valve Line C-06, Detail C I D232-11 0 C-01 E1-8

II.CODE REQUIREMENTS:

The following table lists the applicable ISI Program 10-year interval, the period of ASME Section X1 ISI Code of Record (Code Edition, or Edition with Addenda) for the given plant and unit, the ISI/Nondestructive examination (NDE) program Code of Record for the overlay examinations, and the ASME Section XI Repairs and Replacements Code of Record, and the ASME Section III Code of Record to be used for the design of the weld overlay.

Plant/Unit ISI Program ISI Overlay NDE R&R Code Overlay Interval / Program Code* Design Code Period Code (i.e., PDI)

SQN / 3IdY1st 2001A03 2001A03; 2001A03 2001A03 2001, no addenda, for use of PDI SQN / 2 3rd/1st 2001A03 2001A03; 2001A03 2001A03 2001, no addenda, rd_ for use of PDI WBN / 1 1 st/ 3 rd 1989, No 2001A03; 1989, No 2001A03

[2nd / lst, as Addenda 2001, no addenda, Addenda of 12/27/06] [2001A03 for use of PDI [2001A03 as of as of 12/27/061 12/27/06]

• Note that TVA recently received permission to update its ISI/NDE procedures to meet the 2001A03 Code as part of an effort to standardize NDE procedures across all of TVA's units [reference NRC letter dated May 5, 2006 (ML060880207)]. Note also that the third 10-year ISl program interval for SQN Units 1 and 2 started on June 1, 2006.

Watts Bar Unit 1 is in the third period of its first 10-year interval and currently plans to transition to its second 10-year interval on December 27, 2006, with the ASME Section XI Programs written to meet the 2001A03 Code.

In accordance with the ASME Section Xl Program requirements, repairs and replacements activities must meet the Owner's requirements in that a repaired or replaced/modified item must meet the Construction Code to which the original item was constructed. Accordingly, consideration was given to the respective units' original codes of record in the weld overlay designs and the development of the individual repairs and replacements plans and associated installation of the weld overlay activities. The original plant component and piping design, and fabrication and installation, Codes-of-Record are:

Plant f Unit - Original Design Codes of Record SQN Unit 1 SQN Unit 2 WBN Unit 1 Pressurizer (Nozzle) ASME Section III, 1968 ASME Section III, 1968 ASME Section III, Design & Fabrication Edition with Code Case Edition with Code Cases 1971 S71 with Code Code: 1401 1401 & 1459 Case 1493-1 Piping Primary Design USAS B31.1.0, 1967 USAS B31.1.0, 1967 ASME Section III, Code: 1971S73 Fabrication and USAS B31.7, 1969 with USAS B31.7, 1969 with ASME Section III, Installation Code: Addenda a, b, & c Addenda a, b, & c 1971S73 E1-9

Alternatively, the given unit-specific repairs and replacements plan may meet all or portions of the requirements of different Editions and Addenda of the Construction Code, or Section III when the Construction Code was not Section III, provided the Code to be used for the activities is reconciled with the Owner's requirements, in accordance with the reconciliation requirements of IWA-4000 (or IWA-7000) of the applicable ASME Section XI Repairs and Replacements Program Code of Record.

In a standard ASME Section XI ISI program, TVA would classify the safe-end welds as Class 1, Subsection IWB, Table IWB-2500-1, Category B-F pressure retaining DM welds in vessel nozzles, with item number B5.40, as Pressurizer nominal pipe size 4 inch (NPS

4) or larger Nozzle-to-Safe End Butt Welds. Table IWB-2500-1, of the units' respective ASME Section XI Codes-of-Record, would require that these welds receive volumetric and surface examinations using Figure IWB-2500-8 with acceptance standards as shown in IWB-3514, for the given Edition/addenda of the Code. The nozzle safe-end to process pipe stainless steel welds, which will also be covered by a portion of the overlay, would be classified as Category B-J welds with item numbers of B9.1 1, and would have to meet the same examination volume and acceptance standards as the Category B-F welds. Examinations performed prior to the application of the weld overlays will meet these requirements.

In accordance with the requirements of 10 CFR 50.55a(g)(6)(ii)(c), the provisions of ASME Section XI, Appendix VIII, and its applicable supplements, must be used for the performance of volumetric examinations of the welded areas following the application of the completed full structural weld overlays over the DM welds. TVA plans to meet those requirements by using the EPRI PDI techniques and procedures. TVA understands that in the case where licensee's NDE programs are generally written to meet the 2001 Edition and later addenda of ASME Section XI (e.g., the 2001A03 Code), 10 CFR 50.55a(b)(2)(xxiv) restricts the incorporation of the PDI processes to the use of certain ultrasonic examination criteria that is shown in the 2001 Edition.

In addition to the examination requirements discussed above, application of the repair welding requirements, or the performance of weld overlays in areas where it is not practical to preheat and post-weld heat treat a component, the applicable ASME Section Xl Codes, Articles IWA-4000, allow the use of temper bead (or half-bead) weld techniques to accomplish proper repairs and replacements.

Along with the IWA-4000 repairs and replacements requirements, the ASME Code allows the use of approved alternatives in ASME Section XI Code Cases N-504-2, "Alternatives Rules for Repair of Classes 1, 2, and 3 Austenitic Stainless Steel Piping, Section Xl, Division 1 ," and N-638-1, "Similar and Dissimilar Metal Welding Using Ambient Temperature Machine GTAW Temper Bead Technique,Section XI, Division 1."

However, Regulatory Guide (RG) 1.147, "Inservice Inspection Code Case Acceptability, ASME Section Xl, Division 1," Revision 14, also imposes additional limitations of the use of these Code Cases. TVA has incorporated consideration of these limitations into the proposed weld overlay processes and plans shown in this enclosure.

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III. CODE REQUIREMENTS FROM WHICH RELIEF IS REQUESTED:

Relief is requested from meeting the following Code of Record requirements during the performance of these weld overlays.

1) For SQN Units 1 and 2, relief is requested for welding performed in accordance with the requirements of IWA-4610(a) of the 2001 Edition, with the 2003 (2001A03)

Addenda, of ASME Section Xl.

2) For WBN Unit 1, relief is requested for welding performed in accordance with the requirements of IWA-4500 of the 1989 Edition, with no Addenda, of ASME Section Xl.

3) For SQN Units 1 and 2 and WBN Unit 1, relief is requested for examination of the completed weld overlay(s) in accordance with the requirements of 2001 Edition of ASME Section XI, Appendix VIII, Supplement 11.

4) For SQN Units 1 and 2 and WBN Unit 1, relief is requested from meeting the full provisions of the alternative ASME Code Case N-504-2 with the use of ASME Section XI 2005 Addenda Non-mandatory Appendix Q, as required in NRC RG-1.147.

5) For SQN Units 1 and 2 and WBN Unit 1, relief is requested from meeting the full provisions of the alternative ASME Code Case N-638-1 including examination of the weld overlay area and the associated maximum limit for the surface area for the given overlay to 100 square-inch.

IV. BASIS FOR RELIEF:

During future refueling outages scheduled to start fall 2006 for WBN Unit 1, fall 2006 for SQN Unit 2, and the fall 2007 for SQN Unit 1, TVA plans to perform surface examinations of the subject pressurizer nozzle-to-safe end DM welds; and, where practical, volumetric examinations, as part of the industry initiatives on the investigation and mitigation of Alloy 600 and Alloy 82/182 PWSCC issues. Where unacceptable indications of weld flaws are found, TVA plans to use weld overlay techniques as a repair process and to mitigate the impact of any such indications on the unit's future operation. The application of weld overlays will also facilitate the performance of future examinations of these nozzle areas by providing a more consistent outer surface configuration from which volumetric examination scanning can be performed. In addition, TVA proposes to take a proactive approach on these DM weld areas and apply PWOLs, as necessary and as schedules permit, on the pressurizer nozzle-to-safe end DM weld areas on all three units, and/or use the SWOL/PWOL process outlined in this request where DM weld repairs, are needed in the pressurizer nozzles.

Currently, there is no comprehensive ASME Code or industry standard criteria for a licensee to apply a structural weld overlay repair to a DM weld that is constructed of Alloy 82/182 weld material susceptible to PWSCC. The ASME Section XI Code Committee recently approved Code Case N-740. However, this code case is not published and has not been reviewed and approved for general industry use by the NRC Staff, nor incorporated into RG 1.147. In addition, the current effective Code edition and addenda requirements for the ASME Section XI Repairs and Replacements Programs in place at SQN and WBN [i.e., the 2001A03 Code for SQN (the latest 10 CFR 50.55a approved Code), and the 1989 Edition for WBN] do not have the needed process requirements. The repairs and replacements activities associated with a structural weld overlay DM weld repair (or use of a PWOL) are required to address the materials involved, the welding parameters, ALARA concerns, operational constraints, El-11

examination techniques, and procedure requirements. The need for a viable mitigation process with the Alloy 600 DM welds and a ready approved methodology to repair any potentially unacceptable indications found in these types of welds, during the near-term TVA outages, has prompted this relief request.

V. PROPOSED ALTERNATIVES:

TVA proposes to use a full structural weld overlay as a repair process for any unacceptable examination indications found in these welds and as a PWOL process to mitigate the impact of potential future degradation of the SQN Units 1 and 2 and the WBN Unit 1 pressurizer nozzle-to-safe end Alloy 82/182 DM welds (six welds each unit).

As part of the preparation for these weld overlays, prior to the start of the weld overlay process, TVA plans to perform, as a minimum, surface examinations of the planned overlay weld areas. In addition, ultrasonic (UT) volumetric examinations of some of the DM weld areas for all three units (e.g., in the surge line nozzles) will be performed for those components where a full code coverage (i.e., greater than 90 percent) can be obtained. Where it has been determined that full code coverage cannot be obtained, by physical measurements of the areas and access investigations, WVA will evaluate the need for the performance of a weld overlay, as a means to mitigate the potential weld degradation and any need for more frequent successive examinations.

The materials associated with each of the SQN and WBN weld areas are as shown in Tables 1, 2 and 3 above. The nozzle material is a ferritic, low alloy steel (P3 Group 3).

The process piping material is an austenitic stainless steel (P8). The existing DM weld filler materials are Alloy 82/182 (F43, considered equivalent to P43). The overlays will be designed as full structural overlays in accordance with the requirements of ASME Section XI Code Case N-504-2, with certain modifications, and Nonmandatory Appendix Q of the 2005 Addenda to ASME Section XI, as required by Table 2 of NRC RG-1.147, Revision 14. The proposed modifications to the processes in N-504-2 are discussed in .

For application of the weld overlays, an automatic or machine gas tungsten-arc welding (GTAW) ambient temperature temper bead welding technique will be implemented in accordance with ASME Section XI Code Case N-638-1, also with certain modifications.

Use of Code Case N-638-1 is required for support of the PWOL process at WBN as that unit's Repairs and Replacements Program must meet the requirements of the 1989 Edition of ASME Section XI. As currently planned, beginning December 27, 2006, the WBN Repairs and Replacements Program will be updated to meet the 2001A03 Code, unless the current 1 st 10-year ISI Program interval is extended in accordance with the provisions of the Code. If the current interval is extended for WBN as allowed by the Code, WVA plans to apply the provisions of this request to the ASME Code programs that are currently in effect. When the WBN ISI and Repair and Replacements Program is updated, WVA plans to apply the provisions of this request as appropriate to the WBN programs that are updated to meet the new 10-year interval requirements. For the SQN Units 1 and 2, automatic or machine GTAW is allowed in accordance with the provisions of the 2001A03 Code, Articles IWA-4633.2(a) through (e), which is the SQN Repairs and Replacements Program code-of-record for this request. However, Code Case N-638-1 is also appropriate to be used with the 2001A03 Code in order to allow the qualification and use of the ambient temper bead weld techniques. Use of N-638-1 for the SQN E1-12

pressurizer overlays, as it is proposed in this request, is compatible with the ASME Section XI 2001A03 Code provisions in Article IWA-4623.2. In addition, manual GTAW may be used if local repairs of base metal defects and/or weld defects are necessary, or additional weld metal is required to be deposited locally (in non-temper bead areas only) to form the final PWOL contour. However, manual GTAW will only be permitted in areas that do not affect the tempering region adjacent to the low alloy steel nozzle. The proposed modifications to Code Case N-638-1 are discussed in Attachment 4 of this enclosure. Depending upon the diameter of the nozzle(s) and process pipe to be overlaid and the axial extent of the overlay, the 100 square inch limit of surface covered by the overlay imposed by Code Case N-638-1 may be exceeded. Additional weld material may need to be deposited, in the axial directions, onto the ferritic nozzle in order to facilitate the required post-overlay ultrasonic examination and/or to ensure that a final smooth nozzle area is obtained. As part of this request, TVA proposes to keep the maximum weld overlay surface areas to less than, or equal to, 300 square inch on the ferritic nozzle surface area.

In accordance with the provisions of ASME Section IX Code Case 2142-2, the welding metal to be used as the overlay filler wire will be either ERNiCrFe-7A (Alloy 52M, UNS06054), or ERNiCrFe-7 (Alloy 52, UNS06052). Use of these weld filler materials is supported by ASME Code Case 2142-2, "F-Number Grouping for Ni-Cr-Fe Filler MetalsSection IX (Applicable to all Sections, including Section III, Division 1, and Section Xl),"

which was approved for use with Section IX on August 7, 2003. Use of this filler metal is also discussed in Attachment 4. These temper bead weld techniques in accordance with the requirements of N-638-1 will be applied to the ferritic nozzle base material using the modifications shown in Attachment 4 also. During the performance of the overlay in accordance with N-638-1 monitoring of the weld preheat and interpass temperatures is required to meet the requirements of Article IWA-4000 of the applicable unit's Repairs and Replacements Program [e.g., IWA-4533(b) for the 1989 Code, IWA-4610(a) for the 2001A03 Code]. The IWA-4000 requirements stipulate that the temperatures are to be monitored with the use of thermocouples. In lieu of the thermocouples, contact pyrometers and manual records of the temperatures will be used to document the monitoring of these temperatures in order to preclude the need of attaching the thermocouples, thereby reducing the amount of personnel radiation exposure. The pyrometers will be calibrated in accordance with TVA's, or the contractor's, measuring and test equipment programs and will be capable of monitoring at least the required process temperature range from the minimum preheat temperatures of 50 degrees Fahrenheit (F) to the maximum interpass temperatures of 350 degrees F. In addition to the requirements of N-638-1 (with its modifications), the weld overlay methodology for the use of Code Case N-504-2 (with its modifications) will be used to install the overlays.

These aspects are also discussed in the attachments.

Following the completion of the overlay process, volumetric examinations of the completed overlay weld areas will be performed. In accordance with the requirements of 10 CFR 50.55a(g)(6)(ii)(c) and the restrictions of 10 CFR 50.55a(b)(2)(xxiv), the ultrasonic (UT) examination of these weld areas will be accomplished in accordance with the requirements of the 2001 Edition of ASME Section XI, Appendix VIII, Supplement

11. TVA will meet these requirements using the approved EPRI PDI techniques and procedures also outlined in Attachment 5. It is TVA's expectation that full ASME code coverage (i.e., greater than 90 percent) of the weld overlay areas will be obtained in the UT examinations of the overlaid areas. However, in some cases for a specific pressurizer nozzle, there is the potential of encountering practical examination limitations E1-13

as the result of the physical component contours in the transition areas from the surface of the overlay material onto the existing nozzle, or piping material, at the ends of the overlay areas. If any such practical limitation is encountered during the performance of the post-overlay examinations such that the full (greater than 90 percent) coverage of the overlay area cannot be obtained, TVA understands that a separate request for relief to address these issues may be required.

Any applicable requirements not addressed in Attachments 3, 4 and 5, will be met as described in the provisions/requirements of the applicable Edition and Addenda of ASME Section XI, Article IWA-4000; Appendix VIII, Supplement 11; Code Case N-504-2; and Code Case N-638-1.

TVA proposes to apply the provisions of this request, when approved, during the current 10-year ISI Program intervals as indicated above. In the case of WBN, TVA requests that this relief also be granted for use during the 2 nd 10-year ISI Program interval that is scheduled to start December 27, 2006.

VI. JUSTIFICATION FOR GRANTING RELIEF:

Attachments 3, 4, and 5 of this enclosure, when used with the applicable ASME Section XI Edition and Addenda Article IWA-4000 requirements, provide a comprehensive package of proposed detailed criteria with requirements, proposed alternatives, methodologies, modifications, and the basis for these differences, to support the use of G-RR-1.

Application of the weld overlays provides a residual axial and hoop stress field (in compression) which is favorable to the mitigation of potential PWSCC degradation in the original Alloy 82/182 DM weld and buttering areas. The overlay weld filler material (52/52M) is resistant to PWSCC in the pressurized water reactor (PWR) environment and provides a suitable replacement for the Alloy 82/182 properties. The proposed overlay design provides for the minimum dimensions to meet ASME Code Case N-504-2, the Appendix Q of the 2005 Addenda to Section XI, and the associated Section XI, Article IWB-3640, and Section III requirements. The overlay will be designed for access to meet the ASME Section XI inspection requirements, including coverage for the stainless steel nozzle safe end-to-process pipe weld, for each specific nozzle area. The weld overlay thickness and length of the overlay has been determined in accordance with the requirements of Code Case N-504-2 and included the assumption of a 100 percent through-wall circumferential flaw. The design thickness also meets the flaw stability criteria of ASME Section XI Article IWB-3640. The overlay length was also designed such that the length is sufficient to transmit loads onto the adjoining pipe material. However, consideration for the inspection requirements of the completed weld overlay generally controlled the design lengths. A rigorous finite element analysis (FEA) evaluation was performed in developing the overlay design and to determine the post-overlay residual weld stresses. This analysis included consideration of the system conditions (i.e., piping/nozzles wet or dry) under which the overlay is to be applied.

Thermal stratification and its effects were taken into account, where applicable. Industry standards on crack growth principles with the currently accepted data for PWR environments and the Alloy 600, or stainless steel, materials were used in the FEA evaluation. The design report for these PWOLs will be provided to the NRC Staff as part of the supporting information for this request. A final structural integrity evaluations E1-14

(including analysis of any indications found during the pre-overlay examinations) which support this relief request will be provided to the NRC Staff, prior to the restart of the unit (prior to entry into Mode 4) during the outage in which the overlays are performed.

Over the SQN and WBN units' operating life, various NDE methods (visual, surface, and volumetric) have been performed on the DM welds and associated nozzle-to-safe end process piping welds as part of the Section XI ISI Program requirements, augmented examinations, or as information examinations. The ISI program examinations have been performed during the current, or previous, ISI program intervals. Some of these volumetric examinations have been performed in accordance with the PDI processes.

To date, no reportable indications have been found with volumetric examinations that have been performed on the welds that may be subjected to overlays in the SQN and WBN units. For SQN Unit 1, no reportable indications have been found in DM weld RCW-26-SE and in DM weld RCW-28-SE. In two instances, minor indications were found during the performance of routine dye penetrant (PT) examinations performed as part of the Unit 1 ISI Programs. In both cases, the indications were satisfactorily dispositioned. In the September 1985 case with the RCW-26-SE weld examination, the indication was removed by minor surface polishing of the area and a follow-up examination found to be satisfactory. In the case of the RCW-28-SE weld, the minor surface indication in the weld was evaluated as acceptable to leave as-is. For the RCW-28-SE weld, the preliminary surface examination and preparation of the weld surface prior to the application of PWOLs will effectively remove these indications. For SQN Unit 2, there were also no reportable surface or visual indications in the examinations that have been performed. For WBN Unit 1, the surface or visual examinations of the subject welds have resulted in no reportable indications.

Consequently, the application of the PWOLs to these nozzle areas will be performed under optimum conditions of integrity for the subject DM and their associated stainless steel welds. TVA considers the process described herein to result in high-quality weld areas that can be readily examined and expects that the post-overlay examinations of the welds will show that there are no recordable indications in the deposited metal. For the completed overlays that meet these expectations, TVA may choose to revert to the examinations and schedules required by the integration of the applicable unit's standard ASME Section XI ISI Program, any associated RI-ISI Program, and any added requirements of Nonmandatory Appendix Q , Article Q-4000, of the 2005 Addenda to ASME Section XI, imposed in RG-1.147, Table 2. The resulting frequency of required examinations may not necessarily be on a frequency that is equivalent to those imposed with the current version of the EPRI MRP-139 guidelines. However, as industry experience evolves, TVA intends to adjust monitoring of weld overlays as appropriate.

This request follows the provisions of ASME Code Cases N-504-2 and N-638-1, with the modifications shown in the attachments. Both of these Code Cases are approved for generic use by licensees through the guidelines in RG-1.147, Revision 14, as approved September 29, 2005. Both Code Cases have stipulations on their generic use, shown in Table 2 of RG-1.147.

In developing the weld overlay designs, the potential for exceeding the maximum allowed limit of 100 square inches for the surface areas, in accordance with the unmodified requirements of Code Case N-638-1, was encountered, especially in the design of the 14 inch NPS surge line nozzle overlay areas. TVA proposes to maintain the completed weld overlay area over the ferritic nozzle material to less than the 100 square inches wherever practical and still meet the optimum reliability of the completed E1-15

overlay. Where the completed overlay exceeds 100 square inches over the ferritic material, TVA will maintain the completed area to less than or equal to 300 square inches. Weld overlays in excess of 100 square inches have been supported by numerous precedents in other utility relief requests that are similar to this request.

Relaxation of the 100 square inches surface area in overlays is also the subject of an ASME Code Committee white paper which supported the revision of Code Case N-638-1 to revision N-638-2. A copy of this white paper has been submitted to the Staff as information in an attachment to Enclosure 1 of the Calvert Cliffs Nuclear Power Plant relief request submitted January 18, 2006. See the cited precedent, item 6, below.

In addition to the above attributes, TVA's ASME Section XI repairs and replacements Program procedures will precipitate a rigorous review, by TVA, of the welding procedures used to perform the overlays to ensure that the procedures are compatible with the plant/unit base design requirements and safety margins. With this review, the suitability of these overlays will also be ascertained through the TVA design change process. Both the scheduled PWOLs and any applied SWOL repairs will require post PWOL or SWOL repair UT examination that will serve as the Code required preservice examinations, as appropriate. These preservice examinations will be performed in accordance with the alternative PDI requirements that are shown in Attachment 5. TVA personnel, or supplemental contract personnel will also perform the post-overlay NDE under TVA's NDE programs and procedures to ensure that the examinations are high quality, complete, and thorough with coverage obtained to the maximum practical extent.

Along with the performance of the required post-overlay NDE, the associated components and weld areas will receive a visual VT-2 examination conducted as part of the routine post-refueling outage RCS nominal temperature and pressure system leakage test performed in accordance with the requirements of IWB-2500 and Table IWB-2500-1, Category B-P. A system leakage test is also routinely performed, following repairs and replacements that require the performance of a hydrostatic pressure test, in accordance with the requirements of ASME Code Case N-416-3, "Alternative Pressure Test Requirement for Welded or Brazed Repairs, Fabrication Welds or Brazed Joints for Replacement Parts and Piping Subassemblies, or Installation of Replacement Items by Welding or Brazing, Classes 1, 2 and 3,Section XI, Division 1." Code Case N-416-3 is approved in RG-1.147, Revision 14, unconditionally, for generic use. Code Case N-416-3 will be used here to support other ASME Code Class I pressure boundary repairs and replacements activities within the RCS, if so required. Note that the application of the weld overlays is performed in a manner such that the pressure boundary wall materials inside the outer 10 percent of the pressure vessel nozzle and associated piping wall thicknesses are not penetrated beyond the 10 percent thickness. Since this welding is applied to the outer surfaces of the existing components, the overlay activities are exempt from the hydrostatic pressure test requirements of IWA-4700 of the 1989 Edition of the Code, or the hydrostatic pressure test requirements of IWA-4540 of the 2001A03 Code.

In summary, the combined effects of deposition of PWSCC resistant weld reinforcement on the outside surface of the DM weld; the resulting favorable axial and hoop residual compressive stresses produced on the inside diameter of the primary areas of interest due to the overlay weld shrinkage, and the facilitation of high quality NDE of the overlays, will result in a plant/unit condition that is safe and will improve protection of the general public from the consequences of design basis accidents. In accordance with the requirements of 10 CFR 50.55a(a)(3)(i), the proposed alternatives provide an acceptable level of quality and safety for use at SQN and WBN.

E1-16

VII. IMPLEMENTATION SCHEDULE:

TVA will apply the provisions G-RR-1 following approval, for the remainder of the current 10-year ISI Program intervals as indicated in the table above. In the case of WBN, TVA also plans to apply the provisions of this request during the 2 nd 10-year ISI Program interval which is scheduled to start December 27, 2006. Once the structural weld overlays are installed, the overlays will remain in place for the design life of the repair that is defined in accordance with the evaluation requirements in paragraph (g) of Code Case N-504-2 and the corresponding requirements of Appendix Q of the 2005 Addenda to ASME Section XI. Appropriate inservice examinations will continue to be performed in accordance with TVA's integrated IS[ and RI-ISI Program, and if required by Appendix Q, paragraph Q-4300.

VIII. PRECEDENTS:

Numerous precedents regarding the use of full structural weld overlays on DM welds, including those where weld flaws or indications have been found in the DM weld material and in cases where preemptive weld overlays are used to mitigate the potential degradation of the DM welds. A partial list of these precedent submittals or associated safety evaluation reports (SER) is as follows:

1) Three Mile Island, Unit 1, Docket No. 50-289, SER dated July 21, 2004

[MIL041670510]

2) Cooper Nuclear Station, Docket No. 50-298, SER dated March 4, 2005

[ML050670165]

3) Susquehanna Steam Electric Station, Unit 1, Docket No. 50-387, SER dated June 22, 2005 [ML051220568]

4) D. C. Cook Nuclear Plant, Unit 1, Docket No. 50-315, SER dated June 27, 2005 [ML051720006]

5) Calvert Cliffs Nuclear Power Plant, Unit 2, Docket No. 50-318, SER dated July 20, 2005 [ML051930316]

6) Calvert Cliffs Nuclear Power Plant, Units 1 and 2, Docket Nos. 50-318 & 50-318, Submittal dated January 18, 2006 [ML060240110], with enclosed copy of ASME Code Committee white paper on 100 square inch limitation, (reference Committee Tracking #BC04-1000); written approval pending

7) Millstone Power Station, Unit 3, Docket No. 50-423, SER dated January 20, 2006

[ML053260012]

8) San Onofre Nuclear Generating Station, Unit 2, Docket No, 50-361, Submittal dated February 22, 2006 [ML060550423]; written approval pending E1-17

9) Davis Besse Nuclear Power Station, Docket No. 50-346, Submittals dated March 29 and March 31, 2006 [ML060900374 and ML060940424, respectively];

written approval pending E1-18

ATTACHMENT 1 TVA ISI PROGRAM DRAWINGS OF PRESSURIZER DM WELD AREAS SQN Unit I SQN Unit 2 WBN Unit 1 ISI-0369-C-02 ISI-0008-C-01 CHM-2570-C-01 ISI-0369-C-03 ISI-0013-0-01 CHM-2570-C-05 ISI-0394-C-01 ISI-0013-C-03 CHM-2570-C-06 ISI-0394-C-02 ISI-0396-C-01 CHM-2547-C-01 ISI-0394-C-05 ISI-0396-C-02 ISI-0365-C-01 ISI-0482-C-01 IS1-0396-C-03 ISI-0365-C-02 Al-I

6 'X4 - REDUCER?

rvp.

69.>

IlL

'6.

RCF-22 RCF-21 PCs-oJ4

- RCS-039 RCW- 14 Ill RCS-046 6 "X4'- REDUCER -

RCF-20 "Ooo RCF-)4 AI-2

REFERENCE DRAWINGS A-7263 A-7264 MATERIAL SPECIFICATIONS

• '*0 PIPE SA 376 TP J16 0.6' SCH 160

- RCF-24C SA-376 TP-304 3J SCH 160 RCF-248RC-2B*.-f

• FRCF-240 FI TTINGS IRCS 056 SA-403 WP-316 6' SCH 160 RCF-25 SA_403 WP-J04 RCF -24G--.< -/ FCV 32 " SCH 160 R -FCV D8. FLANGES RCF-24E -- RCF-26 SA-182 F-316 FCF298-33 FRCF-25A 6" SCH 160 S - * >2 SA-182 F-304 3' SCH 160 i-FCV-68-333B :6 RCF-24A RCF -30 3-BC .,,o t, ASME CC-I (EQUIVALENT)

(SEE NOTE "p RC-29A7 . 1*9 CF,-258 "NF24 (SEE NOTE 4) RS10--68-565 (SEE NOTE 4)

~,tIRCF -298 4 ,RCF-29-BC 68-565-&C)

MANWAY( N / C1./w *.. RCF-42 */*./" *NOTES. THESE YIELDS ARE DRAW BEAD WELDS.

/~~~ \. . / -,*/\ RCS-089 2. THIS DRAWING SUPERCEDES DRAWING

/

I *,,*.* %0*' SPRAY 1,",'< CHM-2JJ4 -C SH. 7 C -24. I~ .... 5N. ,1 61/* J.. SEE ISI-0394-C NOZZLE IELDS. FOR PRESSURIZER 1I RCS-069-**/* * -RCS-090 4. 1NCLUDE VALVE SERIAL NO. ON

- I "oRCS-,. / *..*.* "l*/'.EXAMINATION E TO UNIT REPORT 2 DRAING WHEN EXAMS 6" *'*(" .,ARE PERFORMED ON THIS,s,-oo,0-C-o3 COMPONENT.

RCS. ... I RIf746 /S768-564 NOZL ' 3. LC-3 SEE S-3I4-.2t (SEE NOTE FO PR-4)ESSURIZE (SEE NOTE 4) "6RC- .d A RCS-0 2.- TSC94 RCS-072 7 C -RCC*C4 VILVE fRS-p856 g

VAUVE sER NOTE 2ooN-o.7 4)No(S5," 0002,4 #00)

ITSE RCS-074R 0 -- CS0 -CHANRE NOUE PIR FCOI2000-10. Rf -

ViCAN VALVE NUWC~RS PER FC*OF96-29 PESRCS-O7I R0 AOD TEDC- N-CICNS PER FC 96- It R V6 R 86 I CfCSE9 I S4TEI APPROVEI A,f TENNESSEE VALLEY Ag*[lRl~rf SEQUOYAH NUCLEAR PLANT UNIT I REACTOR COOLANT SYSTEM WELD LOCATIONS ORAIN: RP DoArT: #-25.-90 SCALE, NOT 10 SCALE C9ECKOEDEOC i APPROVED CLR CAD L03691NnOORAUIRL SURWIIIED,: KEC ISi-036'9-t'27T 3 10 A1-3

IREFERENCE DRAWINGS 1-47W465-SERIES CONTRACT NO, 68C60-91934 (N2M-2-6)

SEISMIC LUG PRESSURIZER MANUAl. IFIGS.5-1. 5-7)

(TYP. 4 PLACES) MATERIAL SPECIFICATIONS ALL VESSEL SHELL AND HEAD SECTIONS ARE FABRICATED OF SA-533 CLASS 2 MANGANESE-MOLYBDENUM STEUL AND ARt RCW-23A CLAD WITH AUSTENITIC STAINLESS STEEL, THE NOZZLES ARE FABRICATED OF SA-5D8.

INSTRUMENT NOZZLES CLASS 2. MANGANESE-MOLYBDENUM STEEL.

(4 IN LINE AROUND SAFE END CONNECTIONS ARE SA-182.

PZR AT SAME ELEV.) CR. F-316L FORGINGS DETAIL A SECTION 3-B THE SUPPORT SKIRT IS APPROXIMATELY 1.5 INCHES THICK AND IS FABRICATED OF 2 (SEE NOTE 4) SA-516. CR.70. CARBON STEEL PLATE.

ASME (CC-I) EQUIVALENT

-WP-5 2.5" NOMINAL HEAD THIQKNESS I-TYP. 4 NOZZLES

-RCW-15 RCW-15-IR

-RCW-24-SE RCW-2 9-SE RCW-20D-WP- WP-2 (EXCLUDED WELD)

WP-3 6" THIS VIEW I:S NOT A TRUE ORIENTATION NOTES:

FOR TRUE 0 RIENTATION SEE TOP VIEW I THIS DWC SUPERCEDES BOTH CHM-2362-A 3.0" NOMINAL INSTRUMENT NOZZLES AND CHM-2363-A.

HEAD THICKNESS (5 IN LINE AROUND PZR AT 2 FOR UNIT 2 DWC SEE ISI-0396-C SAME ELEVATION) 0 ' IS f OF MANWAY AND MEASURED CLOCKWISE IN THE TOP VIEW

-INSTRUMENT NOZZLE 4 . SUPPORT CLASSIFIED AS PZR RIGID (TYP. 4 PLACES) SUPPORT AT THIS LOCATION SEE DRAWING 48N428 FOR CONFIGURATION.

RCW-28-SE (PIPING TO VALVE 68-564) VESSEL INSIDE SURFACE CLAD 0.190" NOM r RCW-179- SEE TABLE BELOW:

AS BUILT DIMENSIONS

[EWEL WELD DENO. O, ]IN A" TOP IS AT VIEW 90' WP-6 -60" WP-9 I -45"

- .~

J-40 L- wcL L

NO'TE P-IL rO _L rO WEtD5 L J-JJl-LOCAlE I'-=- PIPINGC CONVIJLUA.t1N - J -"J1 *D,'y

'ER EoV 2&7S-.07

' I ..................

RCW-18-IR -1*L _RP___L- c_

465

.. L _.G-i__ _

WlOIt0 VIEI. -LUC NOS.S INS. IARwI NOZZLES G1

• .__JJ-*-z i

W. 000 6OtE A REF. oGS PER? rCor 200m.01 SUPPORT BRACKET-- Z LLUG NO.4 -REV NV CHIECKE I SUVIAIM EO APPROVED DATE NOT IN THE SCOPE OF TENNESSEE VALLEY AUTOMRITY THE SUPPORT BOUNDARY L MANWA Y (TYPICAL 4 PLACES) SEQUOYAH NUCLEAR PLANT UNIT I BOTTOM VIEW TOP VIEW (LOOKING UP) (LOOKING DOWN) PRESSURIZER DRAIN: RFG I OArE:A I1 SCALE!mOr ro SCALE OCLTCKEO _P11 FAPPROV(Oý RUE CAO MAINAINED DRAvriNcoCk SU'Wirrf r"C r ý'ýfl-0394-C-O A1-4

I .................. (Cs

><SA AFETY & RELIEF NOZZLE MATERIAL] 6.62 SPRAY NOZZLEMATERIAL RhEEhRENCE WEST INHOUSE OWG AWIINA2. EDSK-J793488 POS/DWG NO. ASME NO. - ITEM T PDS/DIG N0. ASME NO.

2656A90 SA 533 CR.A.CLASS2 5-.37DIR. I 2656A90 SA 533 C*R.A. CLASS2 109749 I 802A 2 393A708 SA 506 CLASS 2 2 393A708 SA SO CLASS2 1099J91 7960527

, 0 EVSK-J793468 3 I14:O(LOtt0 1098J04 1 2656A96 SARI2 GRAOD r3161. / 4 2656A96 SA 8s2 GRADEF316L ASME (CC-I ) EQOUI VALENT 39BA009 5 398A009 SA 2tJ GRADE)IP 30o4 SA 1R AD e T~ 304 4 6 398A009 SA 3 CASTP ,104 NOTE: THE DIMENSION 6 398A009 SO 32 OARE S ON THIS DRAWING FOR INFORMATION ONLY.

7 SST CLADOCIG 8 *oINCOoE.

VELDBUILO-UP COO 4 IA

- O3.53 .IA9_-

o t4RPRCX.0A.6 1.A

-UAPPROX.1 .6 9.00 DIA I 0.12 PRIESSURIZER SAFETY & RELIEfi NOZZLE DETAIL C l

7 5.29 VIA 6

180" 10 7.300 01 A.

X SAFETY NOZ.

SEE S DETAIL C I'12.720 0IA.

SPRAY NOZZLE PRESSURIZER SPRAY NOZZLE SEE DETAIL 90" w 0_

-* - Y 270' DETAIL D SROD SPRAYNO??LfOffAllj L L !21 1.AS - I -

J 6R ADO

_L Ff RfVf$f SAFfTr i RCLIfr ALVILENIVES000610! rF631206-p.AC.o 12-12-98 fffV SI I CKI CRES ISUBVIFT rOI APPROVEDI DA411 rEAPIISS(E V.4(017 AUTHORITY RELIEF NOZZLE SEE DETAIL C SEQUOYAH UNI NUCLEAR PLANT T

PRESSUR I ZEER Z SPRAY, SAFETY & RELIEF NOZZLE DETAILS 0* RP SRAO OAE~ 0? SI A satt Aor 70 SCAt 040 CIO~

11( t PSRV(0RJ9V CADlRIlS!A#Mfl1OAWVMC{!ii

-EG 4

-"'.I 11 ~ I J 0'~'

AI-5

REFERENCE DRA WINGS MEMO RIMS BJ8 960527 802 1097J91 099IJ91 350894 -A I 0998J04 ASHE (CC-1) EOUIVALENT NOTE THE DIMENSIONS ON THIS DRAWING ARE FOR INFORMATION ONLY SLURGE NOZZLE MATERIAL ITEM ASME NO 1 SA 533 GR A. CLASS 2 2 SA 508 CLASS 2 NtMNEL WELD

4. SA 1B2 GRADE F316L 5 SST CLADOING 6 SA 240 7 INCONEL WELD, INCONCLWELD BUILD-UP

+/-.-L_ .L -_ L _-_- - _ L _ -

REV] BY W I StAITTEOI o AsO*

, OI DATE TEAAESSECVALLEY Aur7ImIrT SEOUOYAH NUCLEAR PLANT UNI T I PRESSURIZER SURGE NOZZLE DETAILS AWJ PPG ID 21raT U I scALE Aor ro scALE 4ee- AAP9AOWOj~

• I!

I ICAOM4INTIAP(CRAVIAEEV~

sýirrm"llin - -JTJE*

- .,- - - I Al-6

REFERENCE DRAWINGS 471304-I 47W465-1 I-RC-O01, I -RC-O02 7-RC-O03, I -RC-004 MATERIAL SPECIFICATIONS PRESSURIZER SURGE LINE 14' SCH 160 A-376 HOT LEC 19"10, A-351 C:BM. N.Y. 2.84' CROSSOVER LEfG 31"}D, A-351 CrSM, N.Y. 2.99" COLD LEG 27.5*ID. A-331 CrOM. N.Jr. 2.69" ASME CC-1 (EOUIVALENT)

NOTES:

I. THIS DWD REPLACED C041-2333-C.

3. REACTOR VESSEL NOZZLE TO SAFE END WELD 1D'S ARE SHOWN ON RV OWC CMI-2343-C.

THESE ARE ASME SECTION XI EXAM CATEGORY B-F. DISSIMILAR METAL WELDS.

4. STEAM GENERATOR NOZZLE TO SAFE END WELD ID'S ARE SHOWN ON SC DONGISI-0399-C.

THESE ARE ASME SECTION XI EXAM CATEGORY I.

• B-F. DISSIMILAR METAL WELDS.

5. FOR TEMPERATURE ELEMENTS SEE RC-34-SY SHEET 2, TAG I THRU 13.

6. THE EXAMINATIONS OF THESE WELDS ARE RC-35 INCLUDED IN THE EXAMINATION Of THE NOZZLE TO SAFE END WELDS. THE IDENTIFIER FOR THE NOZZLE TO SAFE END WELD IS USED FOR THE EXAMINATION.

THESE WELDS ARE NOT INCLUDED IN THE B-J OR S-F POPULATION BECAUSE 15 1 . THEY ARE INCLUDED IN THE NOZZLE TO PRESSURIZER SAFE END EXAMINATION. DURING UICI2 SHS NT AS REMOVE FROM WELDS rNo DUE TO REPLACEMENT STEAM GENERA TOR A_4 SAFE ENDS.

7. THESE WELDS WERECUT OUT AND REMADE CHABURNGO THE STEAM GENERA TOR SLRPr' ,c ME AM

.,Js-5 CHANCERUSNOTE D(COPER 7 Y 200 3-01 CJLDLi.)i MANCftI NOTW 6-PPER Ac-fGO7 2

-I-sR- -I E00-03 I

-EBB 1-3

-A fflO i YAR NCT FitrACv' r srr--m--nt¥om-'* w-ris P coEr-E-,y-"oz ..

RiEV BE CE*C*OeltD 1 I APPROV n~o VlE e

UNUNI IT of YEANESSEEVALLEYAUTHOITY

- , SEQUOYAH NUCLEAR PLANT UNIT I REACTOR COOLANT PIPING WELD LOCATIONS 78 -"78o. DRAMN;RPC DAlE: 1-16-$5 SCAlE; NOY 10 SCAlE 1 REACTOR CEERED: EC APPROVEDO: 1EV LAD -AMAINAINED DARANACIREV BUILDING SuWIFTrEtE: icc ISIr-0482-C-017 In3 icI ISI-- . 8. . . T iF.

BULDNGIsaltro AI-7

REFERENCE DRAWINGS 47W304-1 2-RC-005N (LOOP 1) 2-RC-0061 (LOOP 2) 2-RC-0079 (LOOP J) 2-RC-OOaW (LOOP 4) 47W465-1 CONTRACT: 91934 DRA WING: 9392- TEN SHOP STS: T5W-I TFRU TEN-18F MATERIAL SPECIFICATIONS PRESSURIZER SURGE L INE 1f" SCH 160 A-376 HOT LEG 29°1D, A-351 CF8M. N.Y. 2.84" CROSSOVER LEG 31"1B. A-351 CF8M. N.f. 2.99° COLD LEG 27.5-10. A-351 CF8M. N.. Z.69" ASME CC-I (E*OIVALENT)

NOTE 2) NOTES:

2. INACCESSIBLE

3. REACTOR VESSEL NOZZLE TO SAFE ENO WELD ID'S ARE SHOWNON RV DWG 15-OZ98-C. THESE ARE ASME SECTION XI EXAM CATEGORY 8-F.

DISSIMILAR METAL WELDS.

4. STEAM GENERATOR NOZZLE TO SAFE END WELD TES ,D1S ARE SHOWN ON S/C DWG ISI-0401-C.

THESE ARE ASME SECTION XI EXAM CATEGORY 8-F. DISSIMILAR METAL WELDS.

5. FOR TEMPERATURE ELEMENTS SEE SHEET 2 TAGS 1-13.

r6. THE EXAMINATIONS OF THESE WFELDS ARC INCLUDED IN THE,'EXAMINATION OF THE NOZZLE TO SAFE END WELOS.

L**. TEU IENTOIFIER FOR THE NOZZLE TO SAFE END FELD I USD FR THE EXAMINATION.

NOE 2) THESE WELDS ARE NOT INCLUDED IN THE 9-J OR 6-F POPUATN "EUSE THE-Y ARE 0NDE N H 7" NOZ Z LE T O ,

PRESSUR IZER L i - ICE -- I _ I _e -_ _

5-EACTORU TOWeER CONTAINMENTTLDING NHAAICCNOD[ 6 PCR fCOF 200!1-0.

s-L n- -fl ICE I-+/-$- -I - -A +/-!

!. L rE INCA!-iED SIZ - 2's - ID -C.+/-

L ER. SON fV C - A Aff.!S-At 8SANH CONN.LOCATIONI !N*$

'I. CVRDECT REr DNCS.

ADO SýC SVI1. A ADO)51.4 Rev.l ar Dc(cxo I Si, io I,,,APPROWo I oAr UNIT of TENNESSEE VALLEYAUTIffITS Z _

"SEOUOYAH NUCLEAR PLANT UNIT 2 REACTOR COOLANT PIPING WELD LOCATIONS f-REACTOR EctERED. (DC AP'RDVE: d CAD 11AI*

IIAL IDAnI, DiP gfo BUILDING (DC ISI-0008-C-_1 _slI*,I.! T J7 A1-8

RCS-050 REFERENCE ORA WINGS 47W465 SERIES 6"X4' CONC RED NAVCO A-7547

- 2-RC-005W 2-RC-006W RCS-049 RCF-23 HA TERIAL SPECIFICA TIONS PIPE SEAMLESS STAINLESS STEEL ASTM A-376 TP-316 6" SCH 160 RCS-048--- 4" SCH 120 ASTM A-376 TP-304 3" SCH 160 2" SCH 160 FITTINGS SEAMLESS STAINLESS STEEL-BUTT WELDED ASTM A-403 WP-316 6" SCH 160

\- RCS-047 4 SCM 120 3" SCH 160 RCS-040ý FORGED STAINLESS STEEL-SOCKET WELDED ASTM A-182 F-304 RCS-205 *-. -"-RCF-16 2" BORED To MATCH SCM 160 PIPE HRCW-I13 FLANGES (SEE NOTE 2) /'"-RCF-22 FORGED STA lNLESS STEEL ASTM A-182 F-316 6' SCH 160 3" SCH 160 2" SCH 160 RCF- 16A ASME CC-I (EOUIVALENT)

RCF- I 7 NOTES I WELD CVCW-4 IS TO BE INCLUDED IN THE CVCS SYSTEM FOR PRISIM RCS-044"-

2 WELD PCW-13 IS SAME AS 2-RC-65S ON 2-RC-005W 3 WELD RCW-14 IS SAME AS 2-RC-10JS ON 2-RC-O06W REF- 1.')---RCF-21 I....

EL 697"-4 1/16"-

PCV-68-3400

-EF-19 [RCS-035 RS0iRF03

- / CS-02 (2' W-BSS 1

SEE NOTE' I

- RF-4 FRoM *RC-I CONTINU-ED 1SI-0009-C SH 2 RCS-046 RF RW-Id PE (SEE NOTE 3J)--'I

[I 64 RS RCS COLD LEG RC-0 .- ---c-PCF-20 6-'"X" CONE RED DRLý__.&'_-

LOOP NO.2 "F " -*"_t* VIA/

RCIG~r MJTE FUGEVALVESPC&-U-340lo*: -JAC PC 7C.Dr REVTEE AT ICCKE0 SU8MITED APWVE. I If TEMNESSEEVALLEYAUrTo~Jrr RCF- 14

\" / PCV-8-34B t/

SEOUOYAH NUCLEAR PLANT --

op~'TUNIT 2 PCV-66-340, REACTOR COOLANT SYSTEM PCV-68-J4orr-aC WELD LOCATIONS PROWM REV IDATE SCALE NIT TO SCALE RC-3swUOTTED -~- EF-1 D~T3W n roc APAC3E ~55CAD ISIOOI-EZ-O, A)NAICV LWAVbPCRfl' 08 A1-9

I nrrLnr.CL.c arrrnr ,,nr ur~,iwLyi.,.,

r.na 47W465 SERIES NAVCO A-7548 NAVCO A-7549 MATERIAL SPECS.

SEE SHEET I ASME CC-I (EQUIVALENT)

NOTE:

1. FOR NOZZLE LOCATIONS SEE RN"-S5 ISI-0396-C.

2. INCLUDE VALVE SERIAL NUMBER ON EXAMINATION REPORTS WHEN EXAMINATIONS ARE PERFORMED ON THIS COMPONENT REFER TO TABLE A FOR PRESERVICE EXAMINATIONS.

\

PCV-U334 RCS-OSSA(SEE AIOrE TABLE A PSI EXAMINATIONS ON WELDS IN THE VALVE ASSEMBLIES FOR VALVES PCV-68-334 AND PCV-6B-340A

- RCs-072 BY VALVE SERIAL NUMBER SERIAL NO. REPORT NO.

2 R5879 (U2C8) (PT)

SPRAY NOZZLE 3 R7638 (UICIO) (PT)

IfI 7 IR92-02314 (U2CSA) (PT) 8 R7644 (U1C1O) (PT)

REACTOR BUILDINIG 9 IR95-04021 (U1C7) (PT)

LOWER CO/iTA IN*ENT 10 R5875 (U2C3) (PT) 1 R6607 (U2C12) (UT)

A RCS-j03 tWD PRESSURIZER rfit ORIER71AF10M PEA fSO2'/"

NfAAC TABLEA PER ELDI 20DB-Ot CHAACEM VALVE W. PER FCT 2"-07

.$ REF, 53 2 ALAOL-"

AM TAKE A. 4-E OMAC - IsEf ULLft" A I -WLflAsEL PER LOrT200& -0 RE10VE

_v -J--L.NOTEFRN .jg VALLWS fLV-Ei-JJ

_L _qJ -UT2 Y

_-L A-R--_L2 PER rT.- Y]* !-to

-RCS-106 RCS-090 ADONOE 5A7TV A' rECTUIDERT~IffLNRa-SI-5 T 2E PER ADOr 2JJA-FL .JA"c-L -M.LJIl/L amc rREC wCAFray Or VALVWE WO.S ADO EALPTIGN fWSC. ADONOTEON S APG RA reE I Sau1 7-B-*1 PL9-5ADRELITOR COOZELABTSYTE

& RENOVW REV MOIS.

BV orV DCKED ISUavIrito APPROAEDIDA IE TENNESSEEVALLEY AIJBWRITY SEQUOYAJH NUCLEAR PLANT-UNIT 2 REACTOR COOLANT 5ssTEM WELD LOCATIONS SALE, MOSCALE UABA, KEY DATE:

L)EEO L A-pPRmOV: a B. LAO UIRTAIBEDMIN f SvmrfltTEO ECO I IST~ -ni I i-tC-r)i1 I Al-10

PZRH- I 2-4 7 W465 -SERIES REFERENCE DRA WINGS f NOTE 5\'%

SEE CONTRACT NO. 68C60-91934 (N2M-2-6)

SUPPORT SKIRT SEISMIC LUG PRESSURIZER MANUAL (FIGS. 5-1. 5-7)

Ui\ WELD (TYP. 4 PLACES)

• • PRE*SUR IZER MATERIAL SPECIFICATIONS ALL VESSEL SHELL AND HEAD SECTIONS ARE FABRICATED OF SA-533. CLASS 2.

SHHE.L MANGANESE -MOL YBDENUM STEEL AND ARE RCW-23 CLAD WITH AUSTENITIC STAINLESS STEEL.

INSTRUMENT NOZZLES THE NOZZLES ARE FABRICATED Or SA-508.

(4 IN LINE AROUND CLASS 2. MANGANESE-MOL YBOENUM STEEL.

PZR AT SAME ELEV.)

DETAIL A iON B-B SAFE END CONNECTIONS ARE SA-182.

CR. F-J16L FORGINGS PZRH IA (TYP 4 PLACES.

SE IS .MIC LUGS) THE SUPPORT SKIRT IS APPROXIMA TEL Y PZRH (TYP -2 (SEE NOTE 5) 1.5 INCHES THICK AND IS FABRICATED OF RC2 3.75" NOMINAL

• 4 PLACES)

THICKNESS SA-516. GR.70. CARBON STEEL PLATE.

RCW-21-IR I--TRUNNION SEE DETAIL A (TYP. 2 PLACES) 6"I---ASME (CC-?)

B.

EQUIVALENT WP-5 TYP. 4 NOZZLES 1/2..'['l P,,,

SEE DETAIL SHEET 3 6)1 RCW-15 RCW-15-IR WP-6 CLADDING (SEE NOTE 6) Wp-7 0.190" NOMINAL WP-9 RCW-24-SE (SEE NC TE 6)2.5" NOMINAL HEAD THICKNESS 7 D===

RCW-2 9-SE RCW-20 WP-2 V WP-3 WP-4 (EXCLUDED WELD) 3.0" NOMINAL 6T NOTES.

HEAD THICKNESS THIS VTRUE 0EWIO0 S NOT A TRUE ORIENTATION k FOR RIENTATION SEE TOP VIEW

1. THIS DWG SUPERCEDES ISI-0308-A, (S EE NOTE 3) WP-I - INSTRUMENT NOZZLES ISI-0323-A. AND ISI-0299-0.

(5 IN LINE AROUND PZR AT SAME ELEVATION) 2. FOR UNIT I DWG SEE S1-0394-C.

'NSTRUMENT NOZZLE & SAFETY NOZZLE 3. O IS f OF MANWAY AND MEASURED TYP. 5 PLACES) RCW-25-SE INSTRIUMENT NOZZLE A (PIPING TO VALVE 68-564) (TYP. 4 PLACES) A PRESSURIZER CLOCKWISE IN THE TOP VIEW.

MANW,

'Y 4. VESSEL INSIDE SURFACE CLAD - 0. 190' NOMINAL.

LUG NO.2 RCW-28-SE PING TO VALVE 68-565, 5. SUPPORT CLASSIFIED AS PZR RIGID x RCW-16 ROWPI RCW-16-IR ROW -19 IR 15

_0 SUPPORT AT THIS LOCATION SEE DRAWING 4SN428 FOR CONFIGURATION.

SPRAY NOZZLE L UG NO.3 ,,

6. SEE TABLE BELOW:

RELIEF 07 AS BUILLT DIMESIONS 30"

-NOZZLE 270 AELD NO. "A" IS AT 90-Y 270' zu-

-1 +w EE 90" w WP-6 -60'

.I - SAFETY NOZZLE 30* Wp-9 -45' A I. .

RCW-2 6-SE -- , wol - - , .. ý f - Pý . -

(PIPING TO VALVE 68-563) .L'E.LR"2:1 JLL LJ I *J. -i r /1 DA 00DVOTE 'f6 BELOS TO LOCATECONTINUJA riWil P

~'--~'--"-ROW-I17 'FR Eeor 2005.02 RCW-17-IR Z LUC PZR ID 2-MI OB-YY -7LL .6.L - ia -7 L__M. -. YN.

.oREucr sAFETY A RELIEF NOTRIE LL)Z4Tiav PER EcOF 200.02 LUG NO.-1 SUPPORT BRACKET MANN UNIT r o- T NEVI BY I CHECKED I suWTrrEDo I APPROVED I TENNESSEE VALLEY AUTPWRIFY DATM NOT IN THE SCOPE OF BOLTING 1(01-,6)

BOTTOM VICP)Ew THE SUPPORT BOUNDARY TOP VIEW SEQUOYAH NUCLEAR PLANT (TYPICAL 4 PLACES) (LOOKING DOWN) UNIT 2 (LOOKING Ui DETAIL B PRESSUR IZER DRAIN- RPC ChErCKE:D:

su - - -

PH

,rc I Dar~o, I DATE: 12.1-$I IAPPROVED: CLS 1CAO I

rTSI-0*0...r-SCALE, Nfr WA4NTAIND

- 1 ro SrAiE RAIIACIREY N

V7l Al-I1

SAFETY & RELIEF NOZZLE MATERIAL 6.62 SPRAY NOZZLE MATERIAL REFERENCE DRAWINGS WESTINHOUSE 0WG NO. EDSK-J793488 ITEM IfPDS/5YWGNO. ASME NO. 0.06 ITEM IF PDS/DWG NO. ASME NO.

MEMO RIMS NO. 838 960527 802 1 2656A90 SA $33 GR.A. CLASS 2 5.327 DIA. 1 2656A90 SA 533 CR.A, CLASS 2 1097J9l 2 393A708 SA 505 CLASS 2 2 393A708 SA 508 CLASS 0 1099J91 EDSK-379346B 3 INCONEL. WELD 3 ONELWELD C IR~2 1098J04 4 2656A96 SAIS2 GRADEF316L 4 2656A96 SA 182 GRADEF316L ASME (CC-1) EQUIVALENT 5 3A009 SA 213 GRADE 22' 304 4 5 396A009 SA 213 GRADEIP 304 6 SS2 CLADGISO NOTE: THE DIMENSIONS ON THIS DRAWING 6

F 398A009 S 312 GRADE22 304 ARE FOR INFORMATION ONLY.

7 INCONELWELDBUILD-uP I SlI CLADOIIIG 8a INCORELWELDOUILD-UP

}2 . .00 DI o

I PRESSURIZER SAFETY & RELIEF NOZZLE DETAIL C o iA PRESSURIZER SPRAY NOZZLE DETAIL 0 ELL n.i -ics-I- t - -R

,:L-9I-wC CGRRtCfE ,I lCfa PERECOT2000-11

..... . ... . ... I ... . .....

iL R-ru i. L-~ .uL - Krq-iL .. aw

+/-'¶...A P!L ADDfMiA-r ýgjj-f -DiFAIL h W0IWA(Si&i-PiR rcor-gi-i7

"? *" J ......... f ....... "- I ......... I ....

TERMESSEEVALLEY AUTANNITy

~CLIUC.JFAfl NUUL~AI% I-'LI6NI SEQ(,U(JYAH NUC..LE'AR¢ -LANI PRESUR ZER SPRAY, SAFETY & RELIEF NOZZLE DETAILS Al-12

CJ REFERENCE URAWINGS MEMO RIMS BJ8 960527 802 1097J91 1099J91 J50894-A 1098J04 ASUC (CC-I) EOUIVALENr NOT, THE O *IMENSIONSON THIS DRAWING ARE FOR INFORMATION ONLY.

<-- SURGE NOZZLE UAAIIRIAL I rIM ASUE NO.

SA 533 CR.A, CLASS 2 211 SAA CLASS C0 A 2 3

4 6

?

I INCONEI WELD SA 182 GRAOE F3I1L SS , CLAWOING SA '40 INCONEL WELD a INCONEL WEL0 BUILD-UP

.L1~1~.J--

frvi or I O(CcXO I SE*FIID I APPOPOVIOI ODAI IrmWtSSre viAter AUIURMIIr SEQUOYAH NUCLEAR PLANT UNII PRis.li SURGE NOM17£ o~rAI(S fftA cwAA-; qP*0 OAlf,4 J2 I ¶IS~

ITSC ~

IS~a.lWItoIA/I*I I R I -0i96 -C-fl I I&,f"l is- Ilia I -z I -n 39& -f---n i i0cl Al-13

REFERENCE DRAWINCS 47V465-2 REFERENCE DIMENSIONS VENDOR MARUAL WBN-VTM-WI20-0550 "B " FIGURES 5-1. 5-3. 5-6, 5-2s. 5-1. 5-7) r i f LE SEAM NO. 'A I 56.44 MATERIAL SPECIFICATIONS 2 19J.25* NOZZLE SAFE ENDS GIRTH 322.12' SURGE 14' SCII. 160 SA- 1a2OR F-JI6 t WELDS 450.87' SPRAY 4' SCH. 160 SA-182 OR F-316t 5 588.12 "

/A SAFETY 6' SCIt. 160 SA-182 OR F-JIft 6 #30' RELIEF 6' SCH. 160 SA-I2 OR F-JI6L LONGITUDINAL 7 -29 NOZZLE A MANWAY FORGINGS WELDS a 11351 SA-508 CLASS S 2 9

S #47, StfEL L BARREL to 0. SA 53J CR. A CL. 2 SURGE NOZ.

It 0. UPPER & LOWER HEAD SPRAY NOZ.

SA-5JJ CR. A CL. 2 RELIEF NOZ. 12 #81, SAFETY NOZ. 13 .146- 59' SAFETY noz. 14 -)47 7' ASME CC-I (EQUIVALENT)

SAFETY NOZ. 15 NOTE:

I-.SUPPORT BRACKETS NOT USED WP-IO W- ID-NIR N

NOZZL Ey WP- 10-SE FOR SKIRT SUPPORTJ

& WELD SEE DETAIL A SHEET 4 ASAFETY NOZZLE WP-13-SE PZRLUG-2 WP- 13 WP- I -NIR RELIEF NOZZLE-WP- 12-SEW jl L".

EAPJC 1 - £cI.

'2op.,uNC - L .. CC.- i -

r.O, A SIME 10 C SIZE.

lq!

014 (If 01

~ )SII

• MNSAY. ADD AMATRIAL SPECIfICAPIIWS. *EC. SOCIRIA011 A

WP-12NI WP-12-NIR J LLqziu I -i i§

• [V#St kffE*Cwr S8A"IC A fillf stoo

!-I- rft-I---+/--I--

11 .I Or I MfO I SWs.IIE# I AhVCLO I " itE PZRLUG-I rEAWESSEE IALLEE AUlmIyr WATTS BAR NUCLEAR PLANT UNIT I PRESSURIZER 09-N NEr DAFE,12-t*O I SCALE,.ý 10~ SC44E TOP VIEW aoEED IE fRWC. 04 IIE MCA 5-1rpi- 2-s-CQ Al-14

HE1 £&EN(* DNAWINU5 MEMO RIMS (WON) WAT-D-IO911 YMEMORIMS (SON) 838 960527 802 1097JgI 1099J91 350894-A 1098J04 ASME (CC-I) EQUIVALENT NOTE: THE DIMENSIONS ON THIS DRAWINC ARE FOR INFORMATION ONLY.

SURGE NOZZLE MATERIAL ITEM ASME NO.

I SA 533 GR.A, CLASS 2 2 SA 508 CLASS 2 3 INCONEL WELD

4. SA 182 GRADE F316L 5 SST CLADDING 6 SA 240 7 INCONEL WELD a INCONEL WELD BUILD-UP sycv r I ctcxfo I sumirt1 oI APPROVEDI DAf TENE.SSEE VALLEY AUTHOITY WATTS BAR NUCLEAR PLANT

,RRIVJuIJER SURGE NOZZLE DETAILS DRAIN; PHO DARE: 1.1J-03 SCALE, .r o sCALE ChTECKEDf KEC APPIDVEDHMALOCAD M06NItI1AD DRAIFN7RCA u,*ro t IA CHM-2570-C-05 VO Al-15

EVFERENCE DRAWINCS WESTINHOUSL OWC NO. EDSK-379348B MEMO RIMS NO. WAT-D-10911 (W8N)

MEMO RIMS NO. 838 96052J 802 (SON) 1097J91 1099J97 EDSK-3793468 1098J04 DIMENSIONS ON THIS DRAW!

FOR INFORMATION ONLY.

PRESSURIZER SAFETY & RELIEF NOZZLE DETAIL C 180" x

PRESSURIZER SPRAY NOZZLE DETAIL D Y 270' Al-16

NOTES: REFERENCE DRAWINCS

1. SE DETAIL A ON DW. 4-18hiO-C WfErT I SK.JO4-I SHEETS I THRU 12 FORS INT STEAM E APr OtNCINCATOR TAILS t0 O DELD PIPIG AtD IhMtE IEtDS RADIUS SECTIGI. Tt PIPE P0O SAF 4£00 OtDtO A1O 5G SUE £00 IL) $0 MAUZL( IS ID E$NT£ITrIED As *0W AM) CA TEOOIJE0 AS Aflf nT-CTIO'4 XI EXAd C4AT[OY NJ. DISSJIWlLAA **1rAL WELD.

MATERIAL SPECIFrCATIONS PRESSI5R*1 SUR"E Imk

2. SEE DRAWIN4 ISt-0427-C MRIVSArt AE D IEnEW MON.PIPE SIZE-14" ANDlNAER RADIUS SECTIONS SM. I1O SA-J7?f "'S

3. SEE DRAPIN,CM043M-O-CFGR PRESSURIUER WS'E NOTLEG EMDNEWSAAV INNERRADIUS SECTIONS 230 A 3if. 2.33' M.N.

cri-z ma- SA331 *-&4 RCS-,-2 CMSOtVR LEG J)-ID, 2.48- A.#.

mr-flI-3 SA-JI C0-&A y( ,- RCS-I-J CC% LEV

• .119. 0r-U 2.))' u.N.

SA-351 BRA,1 CU*IECTIDWE 9' S04. t90 S4 403 VP 3045 to* SOY. 140 SA 40J R? 3)5 b0S W4SM 140 SA 403 rS 310 S AS'_E CC-I rEQUIVALENT) to OWN L EC nu I 0o4-07 -04

$cor 04-01 R-ViSE (-UI1wW-"I

• rToE PCr*rOT00-04

-- J--L .... LM - L -L . . . ......

41YIN hOriv mproif RET I &SANDRR51 4 AM SF ROAR ffies , t&-j-. MW S rLss WAM.001 1 IRAWI M. IlOW -I" -A To I. -C

'l.0* m L- - - _.L._. _

^W4

.*05 sTr1I#-$. CO 11 m WEN 94i o Meg SSEENoTr I (MT.)

2-rriM Lr - CIL+,, I -*~r fE -*wr I "

TENNESSEEYALLEY AU7TMITV WATTS BAR NUCLEAR PLANT UNIT 1 MECHANICAL REACTOR COOLANT PIPING WELD LOCATIONS CRAM0, 0 IEV - U47- -0 49 tse1

-wrp I CHPJf-2547-tO IIc Al-17

REFERENCE DRAWINGS 82UU-001 WBN-E-2879 IC-232 C,,. SK-465-2 SH. t

• IVA ,SK-465-2 SHo.2

'P 'c. kP P

"V.

o,

&V. /w MATERIAL SPECIFICArIONs CLASS I

.b I~, SEAMLESS STAINLESS STEEL

-o o .,A. SA 376 TP 304

- 4 ., . 77SCH. PCV 58-4 160 3SCH. 160 RC l 0;62- ,A .. RC,-15 FLTTINGES

-0t. \ 'RC-02-9C SEAMLESS STAINLESS STEEL oI V R- 2 RCt-A-T129-06 SA 403 WP304

~~G0 ~ FCV-68-332 6.SCH. 160 3 SCH. 160 RCF-0232-CA 0FLANGES RCS-016 SA 182 F316

• >,ao*- 6'SCH.160 RCS01 SA 182 F304

[ 3'SCHI 160 RCS-015 RCS-022 NOZZLEN-IJuo RCF-D232-0l,1 NOZZLE 11-12 6-5

-0""-T RRCN-01UCEA LARC-OJ-BC RCF-D32-1 2-D RCS-0W<Z 8-5NCFI. RCS-021 HOP NMBER

- RCS-008 RCS-O NO-El.780- 15116' NOZZLE ANI-15 "SR-F-52C2-11 RCS-0l 0 A C-221 /6-6 NOTES.

RCS-00212 /68-56-O RCS-OI 6 -564 '---z~nRCS-01 1. SHOP WELD NUMBERS RUNIT THRU RCS-025 I

RCS-002K- RG-04-BC 2. THIS DRAWING REPLACES RCS-014ýISI-0017-C SHEET 1 RCS-013R4-0 6856 RC-0 RCS-O..i RCS01 RCS-Ol Isc RC-04 EMVEftTE CNWlfRCS-01 l3-E~E-J RCS-007 JJ!Bm- - ~f - I- +/-rff.-I -~P -!o-i- v RCS-OO' 0 ,(ISE VALK!AVIAfIC P0* fWI 81-01. NEVIS( Fr1fl .IXK EL 777 10 15116 EV. 1 gr ISCECED cr I 1r(OI APPROW O I AIt RCS-O6~' /

1,16'TCNNESSEEEL 77rlO VALLEY AuTHO9irr RCS-005 WATTS BAR NUCLEAR PLANT UNIT REACTOR COOLANT SYSTEM 1

WELD LOCATIONS D*AVN: 4AA ODr: S.:!-j XUE 10Sc..

toD O"CKEV: PW APPROWD. #~

.fi *11 CWDA150DANIAD lsvwirr1Eo ; - ISI-0365-C-01 vfli Al-18

REFERENCE DRA WINGS WBN-E-2879 IC-233 MATERIAL SPECIFICATIONS PIPe SAJ76 TP304 4"SCH 160 RCS-042 6"SCH 160 RCP-0233-l13 FIzTTINGS SA 403 WP J04 4"SCH 160 6"SCH 160 6"X6"XJ" TEE ASUE CC-1 (EQUIVALENT)

J

- RCF-023J-12 RCF-D233 THESE WELDS ARE 3/8"APART RCF-L3233-1I 233-09 7:-6 :-340D RCS-OJ3 RCF'-L123 e-68-J400-BC RCP-02 j3-08 RCS-046 NOTE:

1.THIS DRAWING REPLACES ISI-OO1-C SHEET 2

- RCS-047 2.ALL MATERIAL SEAMLESS STAINLESS STEEL RCS-0J5 J.SHOP WELDS RCS-031 THRU RCS-032 RCS-047. RCS-036A.

RCS-112.AND RCS-t J

->. - RCS-I2 PCV 68-3408 PCV-68-J408-BC

-. 0.

_O*JH_ L _.c - (-NM- 3 S__ J _ J0-GJ -_

AD0 PRES$URZIR ROZ~tE LABEL N-SIt UPDATETltLE BLXK A0Ofi 0 O r-'023j".-*ftI,rtOf 0{RCS-10.REPtACV r1L0$R'S-03 A RC$JSA firm *O-o*Jj-.D -16 *SPEC4IWLT. A 1*4xj AM fff cvI B, C I cmcYro I SuelITrrr a I APPROEO I OAtE TENNESSEE VALLEYAUTHORITY WATTS BAR NUCLEAR PLANT UNI T I REACTOR COOLANT SYSTEM WELD LOCATIONS ORAI,: JAA O!DIf0-2iOS-S0- CADOL NOt rO SCALE CHECKEO:PHB APPROVEDeCLB A I CAD A INIAIMBL OBIIRNCOREV suvwriro - ISI-0365-C-02 02 Al-19

ATTACHMENT 2 PIPE (SS)

SE/PIPE OR INSPECTION BLEND SE/ELBOW WELD (SS)

SAFE END (SS)

END WELD STRUCTURAL OVERLAY WELD (52/52M)

BUTTER (82/182)

NOZZLE TRANSITION CLADDING Typical Weld Overlay Configuration

ATTACHMENT 3 Modifications To Code Case N-504-2 and Corresponding Non-Mandatory Appendix Q Requirements Code Case N-504-2 Modification/Basis Reply: It is the opinion of the Committee that, in lieu of the Modification. Code Case N-504-2 will be used for weld overlay requirements of IWA-4120 in Editions and Addenda up to and repairs to the ferritic (P3) and nickel alloy (F43/P43) base including the 1989 Edition with the 1991 Addenda, up to and material as well as the austenitic stainless steel (P8) base including, the 1995 Edition, and in IWA-4410 in the 1995 Edition material.

with the 1995 Addenda and later Editions and Addenda, defect in Basis: Code Case N-504-2 is accepted for use along with austenitic stainless steel piping may be reduced to a flaw of Nonmandatory Appendix Q in the current NRC Regulatory Guide acceptable size in accordance with IWB-3640 form the 1983 1.147 Rev. 14. For the weld overlay of the identified welds at Edition with the Winter 1985 Addenda, or later Editions and TVA, the base material will be ferritic material (P3) with existing Addenda, by deposition of weld reinforcement (weld overlay) on nickel alloy weld metal (F43/P43) to which an austenitic stainless the outside surface of the pipe, provided the following steel (P8) safe-end is welded. Industry operational experience requirements are met. [Essentially same as Scope of Appendix has shown that PWSCC in Alloy 82/182 will blunt at the interface Q]: with stainless steel base metal, ferritic base metal, or Alloy 52/52M weld metal, TVA plans to apply a 360 degree structural weld overlay to control growth in any PWSCC crack and maintain weld integrity. The weld overlay will induce compressive stress in the weld, thus impeding growth of any reasonably shallow cracks. Furthermore, the overlay will be sized to meet structural.

requirements independent of the existinc weld.

(b) Reinforcement weld metal shall be low carbon (0.035 percent Modification. In lieu of austenitic stainless steel filler material, max.) austenitic stainless steel applied 360 degrees around the the reinforcement weld metal will be a nickel alloy.

circumference of the pipe, and shall be deposited in accordance Basis: The weld metal used may be ERNiCrFe-7A (alloy 52M, with a qualified welding procedure specification identified in the UNS N06054) or ERNiCrFe-7 (alloy 52 UNS N06052). This weld Repair Program. [Same as Q-2000(a)] metal is assigned F43 by ASME per Code Case 2142-2. The requirements of ASME Section III, NB-2400 will be applied to all filler material. The chromium content of Alloy 52M is 28 - 31.5 percent identical to that of Alloy 52. The main difference in Alloy 52 vs. Alloy 52M is a higher Niobium content (0.5 - 1 percent).

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ATTACHMENT 3 (continued)

Modifications To Code Case N-504-2 and Corresponding Non-Mandatory Appendix Q Requirements The difference in chemical composition between Alloy 52 and Alloy 52M improves the weldability of the material and pins the grain boundaries thus reducing the likelihood of separation between the grains and hot tearing during weld puddle solidification. These filler materials were selected for their improved resistance to PWSCC. Alloys 52 and 52M contain about 30 percent chromium that imparts excellent corrosion resistance, The existing alloy 82/182 weld and the Alloy 52/52M overlay are nickel base and have ductile properties and toughness similar to austenitic stainless steel piping welds at pressurized water reactor operating temperature. These filler materials are suitable for welding over the ferritic nozzle or pipe Alloy 82/182 weld and the austenitic stainless steel pipe or safe-ends.

(e) The weld reinforcement shall consist of a minimum of two Modification: Delta ferrite (FN) measurements will not be weld layers having as-deposited delta ferrite content of at least performed for weld overlay repairs made of Alloy 52/52M weld 7.5 FN. The first layer of weld metal with delta ferrite content of metal.

least 7.5 FN shall constitute the first layer of the weld Basis: Welds of alloy 52/52M are 100 percent austenitic and reinforcement design thickness. Alternatively, first layers of at contain no delta ferrite due to the high nickel composition least 5 FN may be acceptable based on evaluation. [Same as Q- (approximately 60 percent nickel).

2000(d)]

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ATTACHMENT 4 Modification To Code Case N-638-1 Code Case N-638-1 Modification/Basis 1.0(a) The maximum area of an individual weld based on the Modification: In certain cases (e.g. with surge line nozzles) it finished surface shall be 100 square inches, and the depth of the will be necessary for the weld overlays to exceed the 100 square weld shall not be greater than one-half of the ferritic base metal inches limitation.

thickness. Basis: Use of Code Case N-638-1 is primarily focused on application of the weld filler material on ferritic portion of the pressurizer nozzle base metal extending onto the existing Alloy 82/182 nonferritic buttering (in accordance with N-638-1 1.0(b).

Depending upon the diameter of the nozzle's) and process pipe to be overlaid and the axial extent of the overlay, the 100 square inches limit of surface covered by the overlay imposed by Code Case N-638-1 may be exceeded. Additional weld material may need to be deposited, in the axial directions, onto the ferritic nozzle and onto the stainless steel process pipe in order to facilitate the required post-overlay ultrasonic examination and/or to ensure that a final smooth nozzle area contour is obtained. As part of this request, TVA proposes to keep the maximum weld overlay surface areas on the ferritic nozzle base materials to less than, or equal to, 300 square-inches. In support of this modification to the N-638-1 limitation is an ASME Code Committee white paper which supported the revision of the Code Case to revision N-638-2. This Code Committee white paper is under NRC review as part of the Calvert Cliffs Nuclear Power Plant, Units 1 and 2, Docket Nos. 50-317 & 50-318, Submittal dated January 18, 2006 [ML060240110]. The use N-638-2 has not been approved, by the regulator, for generic application and published in RG-1.147. However, the ASME Code Committee white paper indicates that the 100 square inch limitation was arbitrarily established and repair areas of up to 500 square inches would have no adverse effects. (Reference ASME Code Committee action item # RRA 00-04, tracking #BC04-1 000)

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ATTACHMENT 4 (continued)

Modification To Code Case N-638-1 (Referenced below in 4.0(b) para. 1.0(d) Prior to welding the area Modification: In lieu of the required ultrasonic examination of to be welded and a band around the area of at least 1-1/2 times 4.0(b) only the required liquid penetrant examination will be the component thickness or 5 in., whichever is less shall be at performed. The ultrasonic examination will be in accordance with least 50'F.) N-504-2 and Appendix Q.

Basis: For the application of the weld overlays or repairs, for 4.0(b) The final weld surface and a band around the area defined some of the DM welds addressed in this request, it is not in para. 1.0(d) shall be examined using a surface and ultrasonic possible to perform a meaningful ultrasonic (UT) examination of methods when the completed weld has been at ambient the required band of base material because of the existing nozzle temperature for at least 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />. The ultrasonic examination configurations shown in the TVA drawings contained in shall be in accordance with Appendix 1.3 Attachment 1. This occurs with the SQN safety and relief valve nozzle and the spray line nozzle areas. This Code Case applies to any type of welding where a temper bead technique is to be 3 Refer to the 1989 Edition with the 1989 Addenda and later employed and is not specifically written for a weld overlay repair.

Editions and Addenda However, it is believed that for this type of repair any major base material cracking would take place in the heat affected zone (HAZ) directly below the weld overlay or in the underlying 82/182 weld deposit and not in the required band of material out beyond the overlay. Therefore, it is assumed that if this cracking were to occur it would be identified by the ultrasonic examination of the weld overlay and not performing the required base material ultrasonic examination should be considered acceptable.

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ATTACHMENT 4 (continued)

Modification To Code Case N-638-1 4.0(c)requires temperature monitoring by welded thermocouples Modification: Preheat and interpass temperatures for the weld per IWA-4610(a) pad will be measured using a contact pyrometer. Interpass temperature will be monitored for the first three layers at each repair location. On the first repair location, the interpass temperature measurements will be taken every three to five passes. After the first three layers, interpass temperature measurements will be taken every six to ten passes for the subsequent layers. The heat input for layers beyond the third layer will not have a metallurgical affect on the low alloy steel HAZ.

Basis: Due to the location of the repair and area radiation dose rate, the placement of welded thermocouples for monitoring weld interpass temperatures determined to be not beneficial based on dose costs. Therefore, welded thermocouples are not planned for use to monitor interpass temperature during welding.

(1) Regulatory Guide 1.147, Rev. 14, Page 14, Table 2, Modification: In lieu of the ultrasonic examination acceptance "Conditionally Acceptable Section XI Code Cases," special criteria of the Construction Code in the condition for the use of condition for Code Case N-638-1: Code Case N-638-1, the acceptance criteria of ASME Section XI Nonmandatory Appendix Q, as stipulated in the Conditions of "UT examinations shall be demonstrated for the repaired volume RG-1.147, Rev. 14, for the use of Code Case N-504-2 will be using representative samples which contain construction type applied for the entire structural weld overlay.

flaws. The acceptance criteria of NB-5330 of Section III edition Basis: As an approved alternative to the requirements of ASME and addenda approved in 10 CFR 50.55a apply to all flaws Section XI, the use of the approved RG-1.147 stipulations with identified within the repaired volume." use of Code Case N-504-2 is appropriate in order to reduce the possibility of conflicting acceptance criteria and provides an acceptable level of quality and safety.

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ATTACHMENT 5 Alternatives to Appendix VIII, Supplement 11 Appendix VIII of Section XI cannot be used for NDE of a structural weld overlay repair. Relief is requested to use the PDI program implementation of Appendix VIII. A detailed comparison of Appendix VIII and PDI requirements is summarized below.

Relief is requested to allow closer spacing of flaws provided they don't interfere with detection or discrimination. The specimens used to date for qualification to the Tri-party (NRC/BWROG/EPRI) agreement have a flaw population density greater than allowed by current Code requirements. These samples have been used successfully for all previous qualifications under the Tri-party agreement program. To facilitate their use and provide continuity from the Tri-party agreement program to Supplement 11, the PDI program has merged the Tri-party test specimens into their weld overlay program.

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 - QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements 1.0 SPECIMEN REQUIREMENTS 1.1 General. The specimen set shall conform to the following requirements.

(b)The specimen set shall consist of at least three specimens Alternative: (b) The specimen set shall include specimens with having different nominal pipe diameters and overlay thicknesses. overlays not thicker than 0.1 in. more than the minimum They shall include the minimum and maximum nominal pipe thickness, nor thinner than 0.25 in. of the maximum nominal diameters for which the examination procedure is applicable, overlay thickness for which the examination procedure is Pipe diameters within a range of 0.9 to 1.5 times a nominal applicable.

diameter shall be considered equivalent. If the procedure is Basis: To avoid confusion, the overlay thickness tolerance applicable to pipe diameters of 24 in. or larger, the specimen set contained in the last sentence was reworded and the phrase "and must include at least one specimen 24 in. or larger but need not the remainder shall be alternative flaws" was added to the next to include the maximum diameter. The specimen set must include last sentence in paragraph 1.1(d)(1).

at least one specimen with overlay thickness within -0.1 in. to

+0.25 in. of the maximum nominal overlay thickness for which the procedure is applicable.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 -QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements (d) Flaw Conditions (1) Base metal flaws. All flaws must be cracks in or near the butt Alternative: (1) ... must be in or... intentional overlay fabrication weld heat-affected zone, open to the inside surface, and flaws shall not interfere with ultrasonic detection or extending at least 75 percent through the base metal wall. Flaws characterization of the base metal flaws. Specimens containing may extend 100 percent through the base metal and into the intergranular stress corrosion cracking shall be used when overlay materials; in this case, intentional overlay fabrication available. At least 70 percent of the flaws in the detection and flaw sh,*dl nut :Inteere with ultrasonic detection or sizing tests shall be cracks and the remainder shall be alternative characterization of the cracking. Specimens containing IGSCC flaws. Alternative flaw mechanisms, if used, shall provide crack-shall be used when available. like reflective characteristics and shall be limited by the following:

(a)The use of alternative flaws shall be limited to when the implantation of cracks produces spurious reflectors that are uncharacteristic of actual flaws.

(b)Flaws shall be semi elliptical with a tip width of less than or equal to 0.002 inches.

Basis: This paragraph requires that all base metal flaws be cracks. Implanting a crack requires excavation of the base material on at least one side of the flaw. While this may be satisfactory for ferritic materials, it does not produce a useable axial flaw in austenitic materials because the sound beam, which normally passes only through base material, must now travel through weld material on at least one side, producing an unrealistic flaw response. To resolve this issue, the PDI program revised this paragraph to allow use of alternative flaw mechanisms under controlled conditions. For example, alternative flaws shall be limited to when implantation of cracks precludes obtaining an effective ultrasonic response, flaws shall be semi elliptical with a tip width of less than, or equal, A5 -2

ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 - QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements (d) Flaw Conditions to 0.002 inches, and at least 70 percent of the flaws in the detection and sizing test shall be cracks and the remainder shall be alternative flaws.

To avoid confusion, the overlay thickness tolerance contained in paragraph 1.1(b) last sentence, was reworded and the phrase "and the remainder shall be alternative flaws" was added to the next to last sentence.

Paragraph 1.1 (d)(1) includes the statement that intentional overlay fabrication flaws shall not interfere with ultrasonic detection or characterization of the base metal flaws.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 -QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements (e) Detection Specimens (1) At least 20 percent but less than 40 percent of the flaws shall Alternative: (1) At least 20 percent but less than 40 percent of be oriented with +20 degrees of the pipe axial direction. The the base metal flaws shall be oriented within + 20 degrees of the remainder shall be oriented circumferentially. Flaws shall not be pipe axial direction. The remainder shall be oriented open to any surface to which the candidate has physical or visual circumferentially. Flaws shall not be open to any surface to access. The rules of IWA-3300 shall be used to determine which the candidate has physical or visual access.

whether closely spaced flaws should be treated as single or Basis: The requirement for axially oriented overlay fabrication multiple flaws. flaws was excluded from the PDI Program as an improbable scenario. Weld overlays are typically applied using automated GTAW techniques with the filler metal applied in a circumferential direction. Because resultant fabrication induced discontinuities would also be expected to have major dimensions oriented in the circumferential direction axial overlay fabrication flaws are unrealistic.

The requirement for using IWA-3300 for proximity flaw evaluation was excluded. Instead indications will be sized based on their individual merits.

(2) Specimens shall be divided into base and overlay grading Alternative: (2) Specimens shall be divided into base metal and units. Each specimen shall contain one or both types of grading overlay fabrication grading units. Each specimen shall contain units. one or both types of grading units. Flaws shall not interfere with ultrasonic detection or characterization of other flaws.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 - QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements (a)(1) A base grading unit shall include at least 3 in. of the length Alternative: (a)(1) A base metal grading unit includes the of the overlaid weld. The base grading unit includes the outer 25 overlay material and the outer 25 percent of the original overlaid percent of the overlaid weld and base metal on both sides. The weld. The base metal grading unit shall extend circumferentially base grading unit shall not include the inner 75 percent of the for at least 1 in. and shall start at the weld centerline and be wide overlaid weld and base metal overlay material, or base metal-to- enough in the axial direction to encompass one half of the overlay interface, original weld crown and a minimum of 0.50" of the adjacent base material.

Basis: The phrase "and base metal on both sides," was inadvertently included in the description of a base metal grading unit. The PDI program intentionally excludes this requirement because some of the qualification samples include flaws on both sides of the weld. To avoid confusion several instances of the term "cracks" or "cracking" were changed to the term "flaws" because of the use of alternative Flaw mechanisms.

Modified to require that a base metal grading unit include at least 1 in. of the length of the overlaid weld, rather than 3 inches.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 - QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements (a)(2) When base metal cracking penetrates into the overlay Alternative: (a)(2) When base metal flaws penetrate into the material, the base grading unit shall include the overlay metal overlay material, the base metal grading unit shall not be used as within 1 in. of the crack location. This portion of the overlay part of any overlay fabrication grading unit.

material shall not be used as part of any overlay grading unit.

(a)(3) When a base grading unit is to be unflawed, at least Alternative: (a)(3) Sufficient unflawed overlaid weld and base 1 in. of unflawed overlaid weld and base metal shall exist on metal shall exist on all sides of the grading unit to preclude either side of the base grading unit. The segment of weld length interfering reflections from adjacent flaws.

used in one base grading unit shall not be used in another base Modified to require sufficient unflawed overlaid weld and base grading unit. Base grading units need not be uniformly spaced metal to exist on all sides of the grading unit to preclude around the specimen. interfering reflections from adjacent flaws, rather than the 1 inch requirement.

(b)(1)An overlay grading unit shall include the overlay material Alternative: (b)(1) An overlay fabrication grading unit shall and base metal-to-overlay interface of at least 6 in2 . The include the overlay material and the base metal-to-overlay dimensions of 2 in. interface for a length of at least 1 inch.

Modified to define an overlay fabrication grading unit as including the overlay material and the base metal-to-overlay interface for a 2

length of at least 1 in, rather than the 6 in Requirement.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 - QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements (b)(2) An overlay grading unit designed to be unflawed shall be Alternative: (b)(2) Overlay fabrication grading units designed to surrounded by unflawed overlay material and unflawed base be unflawed shall be separated by unflawed overlay material and metal-to-overlay interface for at least 1 in. around its entire unflawed base metal-to-overlay interface for at least 1 in. at both perimeter. The specific area used in one overlay grading unit ends. Sufficient unflawed overlaid weld and base metal shall shall not be used in another overlay grading unit. Overlay exist on both sides of the overlay fabrication grading unit to grading units need not be spaced uniformly about the specimen. preclude interfering reflections from adjacent flaws. The specific area used in one overlay fabrication grading unit shall not be used in another overlay fabrication grading unit. Overlay fabrication grading units need not be spaced uniformly about the specimen.

Basis: Paragraph 1.1 (e)(2)(b)(2) states that overlay fabrication grading units designed to be unflawed shall be separated by unflawed overlay material and unflawed base metal-to-overlay interface for at least 1 in. at both ends, rather than around its entire perimeter.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 -QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements (b)(3) Detection sets shall be selected from Table VIII-S2-1. The Alternative: ... base metal grading units, ten unflawed base minimum detection sample set is five flawed base grading units, metal grading units, five flawed overlay fabrication grading units, ten unflawed base grading units, five flawed overlay grading and ten unflawed overlay fabrication grading units. For initial units, and ten unflawed overlay grading units. For each type of procedure qualification, detection sets shall include the grading unit, the set shall contain at least twice as many equivalent of three personnel qualification sets. To qualify new unflawed as flawed grading units, values of essential variables, at least one personnel qualification set is required.

(f) Sizing Specimen (1)The minimum number of flaws shall be ten. At least 30 Alternative: (1) The .... Least 40 percent of the flaws shall be percent of the flaws shall be overlay fabrication flaws. At least 40 open to the inside surface. Sizing sets shall contain a distribution percent of the flaws shall be cracks open to the inside surface, of flaw dimensions to assess sizing capabilities. For initial procedure qualification, sizing sets shall include the equivalent of three personnel qualification sets. To qualify new values of essential variables, at least one personnel qualification set is required.

(3) Base metal cracking used for length sizing demonstrations Alternative: (3) Base metal flaws used ... circumferentially.

shall be oriented circumferentially.

(4) Depth sizing specimen sets shall include at least two district Alternative: (4) Depth sizing specimen sets shall include at locations where cracking in the base metal extends into the least two distinct locations where a base metal flaw extends into overlay material by at least 0.1 in. in the through-wall direction. the overlay material by at least 0.1 in. in the through-wall I direction.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 -QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements 2.0 CONDUCT OF PERFORMANCE DEMONSTRATION The specimen inside surface and identification shall be Alternative: The specimen..... prohibited. The overlay concealed from the candidate. All examinations shall be fabrication flaw test and the base metal flaw test may be completed prior to grading the results and presenting the results performed separately.

to the candidate. Divulgence of particular specimen results or candidate viewing of unmasked specimens after the performance demonstration is prohibited.

2.1 Detection Test Flawed and unflawed grading units shall be randomly mixed. Alternative: Flawed.... (base metal or overlay fabrication)

Although the boundaries of specific grading units shall not be ... each specimen.

revealed to the candidate, the candidate shall be made aware of the type or types of grading units (base or overlay) that are present for each specimen.

2.2 Length Sizing Test Alternative: (d) For ... base metal grading ... base metal wall thickness.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 -QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements 2.3 Depth Sizing Test For the depth sizing test, 80 percent of the flaws shall be sized at Alternative: (a) The depth sizing test may be conducted a specific location on the surface of the specimen identified to the separately or in conjunction with the detection test.

candidate. For the remaining flaws, the regions of each (b) When the depth sizing test is conducted in conjunction with specimen containing a flaw to be sized shall be identified to the the detection test and the detected flaws do not satisfy the candidate. The candidate shall determine the maximum depth of requirements of 1.1(f), additional specimens shall be provided to the flaw in each region. the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.

(c) For a separate depth sizing test, the regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the maximum depth of the flaw in each region.

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ATTACHMENT 5 (continued)

Alternatives to Appendix VIII, Supplement 11 SUPPLEMENT 11 -QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria Examination procedures, equipment, and personnel are qualified Alternative: Examination procedures are qualified for detection for detection when the results of the performance demonstration when:

satisfy the acceptance criteria of Table VIII-S2-1 for both a. All flaws within the scope of the procedure are detected and detection and false calls. The criteria shall be satisfied separately the results of the performance demonstration satisfy the by the demonstration results for base grading units and for acceptance criteria of Table VIII-S2-1 for false calls.

overlay grading units. b. At least one successful personnel demonstration has been performed meeting the acceptance criteria defined in (c).

c. Examination equipment and personnel are qualified for detection when the results of the performance demonstration satisfy the acceptance criteria of Table VIII-$2-1 for both detection and false calls.

d. The criteria in (b) and (c) shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.

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ATTACHMENT 5 (continued)

Alternatives to Appendix 'VIII, Supplement 11 SUPPLEMENT 11- QUALIFICATION REQUIREMENTS FOR PDI PROGRAM:

FULL STRUCTURAL OVERLAID WROUGHT AUSTENITIC The Proposed Alternative to PIPING WELDS Supplement 11 Requirements 3.2 Sizing Acceptance Criteria (a) The RMS error of the flaw length measurements, as Alternative: (a) The ... base metal flaws is ... position.

compared to the true flaw lengths, is less than or equal to 0.75 inch. The length of base metal cracking is measured at the 75 percent through-base-metal position.

(b) All extensions of base metal cracking into the overlay material Alternative: This requirement is omitted.

by at least 0.1 in. are reported as being intrusions into the overlay material. Basis: The requirement for reporting all extensions of cracking into the overlay is omitted from the PDI Program because it is redundant to the RMS calculations performed in paragraph 3.2(c) and its presence adds confusion and ambiguity to depth sizing as required by paragraph 3.2(c). This also makes the weld overlay program consistent with the Supplement 2 depth sizing criteria.

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Enclosure 2 TVA Commitments

1. The design report for these preemptive weld overlays will be provided to the NRC Staff as part of the supporting information for this request.

2. A final structural integrity evaluation (including analysis of any indications found during the pre-overlay examinations) which support this relief request will be provided to the NRC Staff prior to the restart of the unit (prior to entry into Mode 4) during the outage in which the overlays are performed.