ULNRC-05219, Pressure and Temperature Limits Report, Revision 4, Incorporating Changes Associated with the Replacement Steam Generator Program

Pressure and Temperature Limits Report, Revision 4, Incorporating Changes Associated with the Replacement Steam Generator Program

ML053050444
Person / Time
Site:	Callaway
Issue date:	10/21/2005
From:	Keith Young AmerenUE, Union Electric Co
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
ULNRC-05219
Download: ML053050444 (28)

Text

Union Electric PO Box 620 Callaway Plant Fulton, AIO 65251 October 21, 2005 U. S. Nuclear Regulatory Commission Attn: Document Control Desk Mail Stop P1-137 Washington, DC 20555-0001 Ladies and Gentlemen: ULNRC-05219 wAmeren DOCKET NUMBER 50483 UE CALLAWAY PLANT UNIT 1 FIGURE 14.9 CALLAWAY PLANT PRESSURE AND TEMPERATURE LIMITS REPORT Attached is the Callaway Plant Pressure and Temperature Limits Report (PTLR), Revision 4. Revision 4 incorporates changes associated with the Replacement Steam Generator Program. This report is provided to the NRC Staff for information. It has been prepared in accordance with the requirements of Technical Specification 5.6.6.c.

If you have any questions concerning this report, please contact us.

Very truly yours, Keith D. Young Manager, Regulatory Affairs DJW/jdg

Attachment:

Callaway Pressure and Temperature Limits Report, Revision 4 00l a subsidiary of Ameren Corporation

ULNRC-05219 October 21, 2005 Page 2 Mr. Bruce S. Mallett Regional Administrator U.S. Nuclear Regulatory Commission Region IV 611 Ryan Plaza Drive, Suite 400 Arlington, TX 76011-4005 Senior Resident Inspector Callaway Resident Office U.S. Nuclear Regulatory Commission 8201 NRC Road Steedman, MO 65077 Mr. Jack N. Donohew (2 copies)

Licensing Project Manager, Callaway Plant Office of Nuclear Reactor Regulation U. S. Nuclear Regulatory Commission Mail Stop 7E1 Washington, DC 20555-2738 Missouri Public Service Commission Governor Office Building 200 Madison Street PO Box 360 Jefferson City, MO 65102-0360 Mr. Ron Reynolds Director Missouri State Emergency Management Agency P.O. Box 116 Jefferson City, MO 65102

E1 70.0130

• FIGURE 14.9 CALLAWAY PLANT PRESSURE AND TEMPERATURE LIMITS REPORT Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT Table of Contents Section Page 1.0 Reactor Coolant System (RCS) PRESSURE AND 1 TEMPERATURE LIMITS REPORT (PTLR) 2.0 Operating Limits 1 2.1 RCS Pressure and Temperature Limits 1 2.2 Cold Overpressure Mitigation System 1 3.0 Reactor Vessel Material Surveillance Program 9 4.0 Reactor Vessel Surveillance Data Credibility 9 5.0 Supplemental Data Tables 16 6.0 References 16 Callaway Plant i Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT List of Figures Figure Page 2.1-1 Callaway Plant Reactor Coolant System Heatup Limitations 3 (Heatup Rates of 60° and 1000F/hhr) Applicable to 20 EFPY (With Margins for Instrumentation Errors) 2.1-2 Callaway Plant Reactor Coolant System Cooldown Limitations 5 (Cooldown Rates of 0, 20, 40, 60 and I 00F/hr) Applicable to 20 EFPY (With Margins for Instrumentation Errors) 2.2-1 Maximum Allowed PORV Setpoint for the Cold Overpressure 7 Mitigation System List of Tables Table Page 2.1-1 Callaway Plant Heatup Data at 20 EFPY With Margins for 4 Instrumentation Errors 2.1-2 Callaway Plant Cooldown Data at 20 EFPY With Margins for 6 Instrumentation Errors 2.2-1 Callaway Plant COMS Maximum Allowable PORV Setpoints at 20 8 EFPY Callaway Plant il Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT 1.0 Reactor Coolant System (RCS) Pressure and Temperature Limits Report (PTLR)

This PTLR for Callaway Plant has been prepared in accordance with the requirements of Technical Specification (TS) 5.6.6. The TS addressed in this report are listed below:

LCO 3.4.3 RCS Pressure and Temperature (PIT) Limits LCO 3.4.12 Cold Overpressure Mitigation System (COMS) 2.0 Operating Limits The parameter limits forthe specifications listed in Section 1.0 are presented in the following subsections. The limits were developed in accordance with the NRC-approved methodology specified in Specification 5.6.6 (Ref. 1). NRC approval of this methodologywas received in Amendment No. [134], (Ref. 3).

The methodology listed in WCAP-14040-NP-A, Rovision 2 was used with one exception:

a) ASME Code Case N-514 was used.

The revised P/T Limit curves account fora requirement of 10 CFR 50, Appendix G, that the temperature of the closure head flange and vessel flange regions must be at least 120 0F higher than the limiting RTNDT for these regions when the pressure exceeds 20% of the preservice hydrostatic test pressure (3107 psig).

2.1 RCS Pressure and Temperature (PIT) Limits (LCO 3.4.3) 2.1.1 The RCS temperature rate-of-change limits are:

a. A maximum heatup of 10OPF in any 1-hour period.

b. A maximum coo!down of 100GF in any 1-hour period.

c. A maximum temperature change of 10F in any 1-hour period during inservice hydrostatic and leak testing operations above the heatup and cooldown limit curves.

2.1.2 The RCS P/T limits for. heatup, cooldown, inservice hydrostatic and leak testing, and criticality are specified by Figures 2.1-1 and 2.1-2.

2.2 Cold Overpressure Mitigation System (COMS) Setpoints (LCO 3.4.12)

The pressurizer power-operated relief valves (PORVs) shall each have lift settings in accordance with Figure 2.2-1. The (COMS) arming temperature is 2750F. These lift setpoints have been developed using the NRC approved methodologies specified in Technical Specification 5.6.6.

Callaway Plant 1 Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT 2.2 (continued)

The maximum allowed PORV setpoint for COMS is derived by analysis which models the performance of the COMS assuming limiting mass and heat input transients with incorporation of 10% relaxation of the Appendix G limits in accordance with ASME Code Case N-514. Operation with a PORV setpoint less than or equal to the maximum setpointensures that Appendix G criteria will not be violated with consideration for (1) pressure and temperature instrumentation uncertainties; (2)single failure of one PORV; and (3)effects of reactor coolant pump operation.

To ensure mass and heat Input transients more severe than those assumed cannot occur, Technical Specifications place limitations on the number of safety injection pumps and centrifugal charging pumps that are capable of injecting, unisolating accumulators, and starting reactor coolant pumps during the appropriate COMS MODES. These limitations are outlined in TS LCO 3.4.6, LCO 3.4.7, and LCO 3.4.12.

Callaway Plant 2 Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT AATURIAL PROPERTY BASIS UMTING MATERIAL LOWER SHELL PLATE R2708-3 .

LMTING ART VALUES AT 20 EFPY: 114T, 10A'F 3/4T. 42.2F 2500 482314"53143 -

t* 2 2 5 0 i iI ! i i MITI

$M 2000 1750.1 UKACC PTABLZI 5-8 QP11AT ION 1500 VP jPTo ze r.I 1250 - ACCE IOF I PTADI AT! ONit I I up Tot as /X1.1 r'sT. "33 Is CrA 1 000 -

cst~. Ziki is "L3,

-. , ;y.

R:

'-4 750 500 I

250 II ATI "I I .II I

I1-r Il. T-1LI 1 r~

I LI]

IIr-w I I rrIiI !Ii4t 111ril"I"TIM A I I 3 0 . - . . . .

a 50 Ic0 150 200 250 300 350 400 45o soo I n d i c a ILe d Temperature ( D e g . F )

FIGURE 2.1-1 Callaway Unit I Reactor Coolant System Heatup Limitations (Heatup Rates of 60 and 100°F/hr) Applicable for the First 20 EFPY (With Margins for Instrumentation Errors). Includes vessel flange requirements of 170°F and 561 psig per 10CFR 50, Appendix G.

Callaway Plant 3 Revision 4

-!'$,3; ',i Figure 14.9 .;

PRESSURE AND TEMPERATURE LIMITS REPORT TABLE 2.1-1 Callaway Plant Heatup Limits at 20 EFPY With Marains for Instrumentation Errors 60°F/hr 60 °F/hrCrit. Limit I100°F1hr I 00lFhrCriL Limit Leak Test Limit Temp. Press. Temp. Press. Temp. Press. Temp. Press. Temp. Press.

('IF) (psig) (OF) (psig) (OF) (psig) (OF) (Psig) (OF) l psig) 60 0 245 0 60 0 245 0 225 2000 60 500 245 544 60 494 245 546 245 2485 65 507 245 533 65 494 245 531 70 516 245 527 70 494 245 519 _

75 524 245 524 75 494 245 509 80 524 245 524 80 494 245 502 85 524 245 527 . 85 494 245 497 90 524 245 533 90 494 245 494 95 524 245 541 95 494 245 494 100 524 245 551 100 494 245 495 105 524 245 563 105 494 245 499  :

110 524 245 577 110 494 245 504 115 527 245 593 115 494 245 511 120 533 245 611 120 494 245 520 125 541 245 631 125 49.4 245 531 =

130 551 245 653 130 495 245 543 135 561 245 677 135 499 245 557 140 561 245 703 140 504 245 574 145 561 245 732 145 511 __245 592 - X 150 561 245 763 150 520 245 612 155 561 245 796 155 531 245 - 634 160 561 245 832 160 543 245 658 165 561 245 871 165 557 245 685 170 561 245 912 170 561 245 714 170 703 245 957 170 574 245 745 175 732 250 1006 175 592 250 779 .

180 763 255 1058 180 612 255 816 185 796 260 1113 185 634 260 856 190 832 265 1173 190 658 265 899 195 871 270 1238 195 685 270 946 200 912 275 1306 200 714 275 996 _

205 957 280 1381 205 745 280 1049 210 1006 285 1460 210 779 285 1107 215 1058 290 1544 215 816 290 1169 220 1113 295 1636 220 856 295 1236 _ _ _

225 1173 300 1732 225 899 300 1307 230 1238 305 1837 230 946 305 1384 235 1306 310 1948 235 996 310 1467 240 1381 315 2066 240 1049 315 1555 245 1460 320 2193 245 1107 320 1649 250 1544 325 2328 250 1169 325 1750 255 1636 330 2472 255 1236 330= 1858 X 260 1732 260 1307 335 1973 265 1837 265 1384 340 2096 270 1948 . 270 1467 345 2227 275 2066 _ 275 1555 350 2367 280 2193 . 280 1649 .

285 2328 285 1750 290 2472 290 1858

. . 295 1973 1300 2096 .

= _ _ _ _ 305 2227 _ _ l 310 2367 Callaway Plant 4 Revision 4

Figure 14.9.

PRESSURE AND TEMPERATURE LIMITS REPORT I'

MUATERIAL PROPERTY BASIS TIWNGMATEAL LOWER SHELL PLATE R2708-3 ULMTING ART VALUES AT 20 EFPY: 114T. 100.4-F 3/4T, 842 OF 2500 I I I

2250 _ __ __ __ __ __

" '2000 I 750 ______UNACCEPT-ABLE

______OPERATION C,

= 1500 cn w 1250 IACCEPTA:LEI OPERATI ON 1 000.I a-750- c C aLI RsT F C) 500 -

250 0

6 50 1i00 t50 i

200 *250 d

300 350 400 450 s6 Indicated T-emp e r a ture (Deg . F FIGURE 2.1-2 Callaway Unit 1 Reactor Coolant System Cooldown Limitations (Cooldown Rates of 0, 20, 40, 60 and 100 °F/hr) Applicable for the First 20 EFPY (With Margins for Instrumentation Errors). Includes vessel flangerequirements of 170°F and 561 psig per 10CFR 50, Appendix G Callaway Plant 5 Revision 4

- . . -7.

ale,,

' Figure 14.9 K to PRESSURE AND TEMPERATURE LIMITS REPORT.

TABLE 2.1-2 Callaway Plant Cooldown I-mits at 20 EFPY With Ma gins for Instrumentation Errors 0 0 i 1000Fhr Steady State l 2O Fhr 4O F1hr 60F/hr Temp. Press. Temp. Press. Temp. Press. Temp. Press. Temp. Press.

(OF) (psig) (°F) (psi) ° F(Psig) (OF) (psig) ('IF) (psI) 60 0 60 0 60 0 60 0 60 0 60 500 60 468 60 427 60 386 60 302 65 507 65 468 65 427 65 386 65 302 70 516 70 476 70 436 70 396 70 313 75 525 75 486 75 446 75 406 75 325 80 534 80 496 80 457 80 418 80 338 85 544 85 506 85 468 85 430 85 351 90 555 90 518 90 481 90 443 90 366 95 561 95 531 95 494 95 457 95 382 100 561 100 544 100 508 100 472 100 400 105 561 105 559 105 524 105 489 105 419 110 561 110 561 110 540 110 506 110 439 115 561 115 561 115 553 115 526 115 461 120 561 120 561 120 561 120 546 120 485 125 561 125 561 125 561 125 561 125 511 130 561 130 561 130 561 130 561 130 539 135 561 135 561 135 561 135 561 135 561 140 561 140 561 140 561 140 561 140 561 145 561 145 561 145 561 145 561 145 561 150 561 150 561 150 561 150 561 150 561 155 561 155 561 155 561 155 561 155 561 160 561 160 561 160 561 160 561 160 561 165 561 165 561 165 561 165 561 165 561 170 561 170 561 170 561 170 561 170 561 170 899 170 885 170 873 170 864 170 856 175 937 175 925 175 917 175 911 175 910 180 977 180 969 180 963 180 961 180 969 185 1020 185 1015 -185 1014 185 1016 190 1066 190 1065 195 1116 _ _ _ X X - X 200 1170 205 1228 210 1289 215 1355 220 1426 225 1503 .

230 1584 235 1672 _ _ _

240 1766 245 1866 250 1973 255 2088 X _

260 2211 265 2342 .

270 2482 _ _ -

Callaway Plant 6 Revision 4

1 -.

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT CALLAWAY COMS Maximum Allowable PORV Setpolnts 2500 I 4-2000 .. I. . . . I I I I I I I I. I I . I l/t .

cn 81500 c

CL 0.

U, 1000 I II I I I§ I I I I I I I I I I iI I 1 1~.11 1 1 1- 1 1 1 1 0

rL 500 0 I" 0 50 ' 100 150 200 250 300 350 400 RCS Temperature (degree F)

-High PORV Setpoint -- - - Low PORV Setpoint Figure 2.2-1 Maximum Allowed PORV Setpoint for the Cold Overpressure Mitigation System Callaway Plant 7 Revision 4

i w * @

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT TABLE 2.2-1 CALLAWAY PLANT COMS MAXIMUM ALLOWABLE PORV SETPOINTS AT 20 EFPY Maximum Allowable Function Generator Setp nts (Breakpoints)

Breakpoint Number Temperature - High Setpoint Low Setpoint (psig)

RCS (OF) (psig) 1 70 496 466 2 80 496 466 3 90 496 466 4 180 527 497 5 230 558 512 6 250 750 597 7 270 750 597 8 280 750 597 9 350 2335 2185 Note: Setpoints assume'that all 4 or less RCPs are in operation.

Callaway Plant 8 Revision 4

Figure 14.9  :: t PRESSURE AND TEMPERATURE LIMITS REPORT 3.0 Reactor Vessel Material Surveillance Program The reactor vessel material surveillance program is in compliance with Appendix H to 10 CFR 50, entitled "ReactorVessel Material Surveillance Program Requirements' and Section 5.3 of the Callaway Final Safety Analysis Report. The surveillance capsule withdrawal schedule is presented in FSAR Table 5.3-10. The surveillance capsule reports are as follows:

1. WCAP-1 1374, Revision 1, June 1987, "Analysis of Capsule U from the Union Electric Company Callaway Unit 1 ReactorVessel Radiation Surveillance Program.*

2. WCAP-12946, June 1991, 'Analysis of Capsule Y from the Union Electric Company Callaway Unit 1 Reactor Vessel Radiation Surveillance Program."

3. WCAP-14895, July 1997, "Analysis of Capsule V from the Union Electric Company Callaway Unit 1 Reactor Vessel Radiation Surveillance Program."

4. WCAP-1 5400, June 2000, "Analysis of Capsule X from the AmerenUE Callaway Unit I Reactor Vessel Radiation Surveillance Program."

4.0 Reactor Vessel Surveillance Data Credibility Regulatory Guide 1.99, Revision 2, describes general procedures acceptable to the NRC staff for calculating the effects of neutron radiation embrittlement of the low-alloy steels currently used forlight-water-cooled reactorvessels. Position C.2 of RegulatoryGuide 1.99, Revision 2, describes the method for calculating the adjusted reference temperature and Charpy upper-shelf energy of reactor vessel beltline materials using surveillance capsule data. The methods of Position C.2 can only be applied when two or more credible surveillance data sets become available from the reactor in question.

To date four surveillance capsules have been removed and analyzed from the Callaway Plant reactor vessel. To use these surveillance data sets, they must be shown to be credible. Inaccordance with the discussion of Regulatory Guide 1.99, Revision 2, there are five requirements that must be met for the surveillance data to be judged credible.

The purpose of this evaluation is to apply the credibility requirements of Regulatory Guide 1.99, Revision 2, to the Callaway Plant reactorvessel surveillance data and determine ifthe Callaway Plant surveillance data is credible.

Criterion 1: Materials in the capsules should be those judged most likelyto be controlling with regard to radiation embrittlement.

The beltline region of the reactor vessel is defined in Appendix G to 10 CFR Part 50, "Fracture Toughness Requirements," as follows:

"the reactorvessel (shell material including welds, heataffectedzones, and plates or forgings) that directly surrounds the effective height of the active core and adjacent regions of the reactor vessel that are predicted to experience sufficient neutron radiation damage to be considered in the selection of the most limiting material with regard to radiation damage.'

Callaway Plant 9 Revision 4

Figure 14.9 r PRESSURE AND TEMPERATURE LIMITS REPORT The Callaway Plant reactor vessel consists of the followirg beltline region materials:

- Intermediate shell plate R2707-1,

- Intermediate shell plate R2707-2,

- Intermediate shell plate R2707-3,

- Lower shell plate R2708-1,

- Lower shell plate R2708-2,

- Lower shell plate R2708-3, and

- Intermediate shell longitudinal weld seams, lower shell longitudinal weld seams, and a intermediate to lower shell circumferential weld seam All vessel beltline weld seams were fabricated with weld wire heat number G0077. The intermediate to lower shell circumferential weld seam 101-171 was fabricated with Flux Type 124 Lot Number 1061.

The intermediate and lower shell longitudinal weld seams were fabricated with Flux Type 0091 Lot Number 0842.

The Callaway Plant surveillance program utilizes longitudinal and transverse test specimens from lower shell plate R2708-1. The surveillance weld metal was fabricated with weld wire heat number 90077, Flux Type 124 Lot Number 1061.

At the time when the surveillance program was selected it was believed that copper and phosphorus werethe elements mostimportanttoembrittlementofreactorvessel steels. Since all plate materials had approximately the same content of copper and phosphorus, lower shell plate R2708-1 was chosen forthe surveillance program since it had the highest initial RTNDT and the lowest initial upper shelf energy of the plate material. In addition, the current pressurized thermal shock (PTS) evaluation shows that if surveillance data is not used, lower shell plate R2708-1 is the plate that is predicted to have the highest embdttlement rate.

Per Regulatory Guide 1.99, Revision 2, "weight-percent coppert and "weight-percent nickel* are the best-estimate values for the material, which will normally be the mean cf the measured values for a plate or forging or for weld samples made with the weld wire heat number that matches the critical vessel weld. Since the surveillance weld metal was made with the same weld wire heat as all of the vessel beltline weld seams, it is representative of the limiting beltline weld metal.

Based on the above discussion, the Callaway Plant surveillance materials are those judged most likely to be controlled with regard to radiation embrittlement and the Callaway Plant surveillance program meets this criteria.

-Criterion 2: Scatter in the plots of Charpy energy versus temperature for the irradiated and unirradiated conditions should be small enough to permit the determination of the 30 ft-lb temperature and upper shelf energy unambiguously.

Plots of Charpy energy versus temperature for the unirradiated and irradiated condition are Callaway Plant 10 Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT presented in WCAP-15400, June 2000, Analysis of Capsule X from the AmerenUE Callaway Unit I Reactor Vessel Radiation Surveillance Program.

Based on engineering judgement, the scatter inthe data presented in these plots is small enough to permit the determination of the 30 ft-lb temperature and the uppershelf energy of the Callaway Plant surveillance materials unambiguously. Hence, the Callaway Plant surveillance program meets this criterion.

Criterion 3: When there are two or more sets of surveillance data from one reactor, the scatter of ARTNDT values about a best-fit line drawn as described in Regulatory Position 2.1 normally should be less than 280F for welds and 170F for base metal. Even if the fluence range is large (two or more orders of magnitude), the scatter should not exceed twice those values. Even if the data fail this criterion for use in shift calculations, they may be credible for determining decrease in upper shelf energy if the upper shelf can be clearly determined, following the definition given in ASTM E185-82.

The functional form of the least squares method as described in Regulatory Position 2.1 will be utilized to determine a best-fit line for this data and to determine if the scatter of theA RTNDT values about this line is less than 28°F for welds and less than 1 F for the plate.

Following is the calculation of the best-fit line as described in Regulatory Position 2.1 of Regulatory Guide 1.99, Revision 2.

Callaway Plant 11 Revision 4

(,Sl: Figure 14.9 - r-PRESSURE AND TEMPERATURE LIMITS REPORT Table 4.0-1 CallawavPiantSurveillance Capsule Data Material Capsule Capsule Fia) FF°b ARTNT(c) FF X ARTNDT FF2 Lower Shell U 0.331 0.696 0.0(e) 0.0 0.48 R2708-1 Y 1.27 1.07 25.15 26.91 1.14 (Longitudinal) V 2.52 1.25 16.45 20.56 1.56 X 3.33 1.32 25.71 33.94 1.74 Lower Shell Plate U 0.331 0.696 25.86 18.00 0.48 R2708-1 Y 1.27 1.07 46.39 49.64 1.14 (Transverse) V 2.52 1.25 44.82 56.03 1.56 X 3.33 1.32 30.77 40.62 1.74 Sum: 8.6411 215.15 245.7 9.84 Surveillance Weld C 05 =7(FF* R DT)+(F 2 ) = (245.70) - (9.84) =25.0 0 F _

Materiald _U 0.331 0.696 68.53d' 47.70 0.48 Y 1.27 1.07 36.92(d) 39.50 1.14 V 2.52 1.25 48.21 (d) 60.26 1.56 X 3.33 1.32 51.81(d) 68.39 1.74 Sum: 4.32 205.47 215.85 4.92 CF Surv.YUI = I(FF

• RTNDT) d -(FF 2) (215.850F) + (4.92) =43.90 F Notes:

(a) f = calculated fluence from capsule X dosimetry analysis results, (x 19 n/cm 2 , E>1.0 MeV).

These values were re-evaluated as part of capsule X analysis. (See Section 6 of WCAP-15400).

(b) FF = fluence factor = fO.28s0.1-ito.

(c) ARTNDT values are the measured 30 ftlb shift.

(c) These measured ARTNDT values do not include the adjustment ratio procedure of Reg. Guide 1.99 Revision 2, Position 2.1, since this calculatbn is based on the actual surveillance weld metal measured shift values and based on the copper and nickel content the ratio would be 1.

In addition, the only surveillance data available is from the Callaway Unit I reactor vessel, therefore, no temperature adjustment is required.

(e) The actual value is -7.33, but for conservatism a value of zero is considered.

The scatter of ARTNDT values about the functional form of a best-fit line drawn as described in Regulatory Position 2.1 is presented in Table 4.0-2.

Per the 27t Edition of the CRC Standard Mathematical Tables (page 497), for a straight line fit by the method of least squares, the valuesb. and b1 are obtained by solving the normal equations nbo + blXx1 = Eyi and boY:x1 + bDi 2 = FAyi Callaway Plant 12 Revision 4

I. Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT These equations can be re-written as follows (b,= a and b,= b):

n n xyi = an + bcx, and i=1 i=1 n n n 7xiYi = + bxi2 1=1 1=1 i=1 Lower shell plate R2708-1:

Based on the data provided in Table 4.0-1 these equations become:

215.15 = 3a + 8.6411b and 245.70 = 8.6411 + 9.84b Thus, b = 24.8405 and a = 0.1669, and the equation of the straight line which provides the bestfit in the sense of least squares is:

Yr = 24.8405 (X) + 0.1669 The scatter in predicting a value Y corresponding to a given X value is:

e=Y-Y' Table 4.0-2 Callaway Plant Lower Shell Plate R2708-1 Base Material FF Measured Best Fit(a) Scatter of <17*F (Base ARTNDT ARTNDT (0F) ARTNDT (OF) Metals)

(30 ft-lb)(OF)

Lower Shell 0.696 0.00 17.4 -17.4 NO Plate R2708-1 1.07 25.15 26.75 -1.6 Yes (Longitudinal) 1.25 16.45 31.25 -14.8 Yes 1.32 25.71 33.0 -7.29 Yes Lower Shell 0.696 25.86 17.4 8.46 Yes Plate R2708-1 1.07 46.39 26.75 19.64 NO (Transverse) 1.25 44.82 31.25 13.57 Yes

__ 1.32 30.77 33.0 -2.23 Yes NOTES:

(a) Best Fit Line Per Equation 2 of Reg. Guide 1.99 Rev. 2 Position 1.1.

Callaway Plant 13 Revision 4

.. -. - -1 Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT Table 4.0-2 indicates that one measured plate ARTNDT value is below the lower bound I a of 17O1F by less than 1OF. Meaning the best fit line is slightly over predicting this measured ARTNDTvalue. Table 4.0-2 also indicates that one measured plate ARTNDTvalue is above the upper bound 1a of 170 F by less than 30F. From a statistical point of view + 1a (170F) would be expected to encompass 68% of the data. Therefore, it is still statisticallyacceptable to have two of the plate data points fall outside the + 1a bounds. The fact that two of the measured plate ARTNDTvalues are outside of 1a bound of 170F can be attributed to several factors, such as 1)the inherent uncertainty in Charpy test data, 2) the use of a symmetric hyperbolic tangent Charpy curve fitting program versus an asymmetric tangent Charpy curve fitting program or hand drawn curves using engineering judgment, and/or 3) rounding errors.

In summary, all measured plate is within acceptable range. Therefore, the plate data meets this criteria.

Weld Metal:

Based on the data provided in Table 4.0-1 the equations become:

205.47 = 3a + 4.321b and 215.13 = 4.321a + 4.897b Thus, b = 60.9 and a = -19.3, and the equation of the straight line which provides the best fit in the sense of the least squares is:

Y = 60.9 (X) - 19.3 The scatter in predicting a value of Y corresponding to a given X value is:

e=Y-Y' Table 4.0-3 Callaway Plant Surveillance Weld Metal FF Measured Best Fitf) Scatter of <28°F (Weld ARTNDT 0 ARTNDT ( F) ARTNDT (OF) Metal)

(30 ft-lb) (OF) 0.696 68.53 30.55 37.98 NO 1.07 36.92 46.97 -10.05 Yes 1.25 48.21 54.88 -6.67 Yes 1.32 51.81 57.95 -6.14 Yes NOTES:

(a) Best Fit Line Per Equation 2 of Reg. Guide 1.99 Rev. 2 Pcsition 1.1.

One measured weld ARTNDT Is below the lower I a at 280F. The fact that one of the measured weld ARTNDT is out of la bound of 280 F can be attributed to several factors, such as 1) the inherent uncertainty in Charpy test data, 2) the use of a symmetric hyperbolic tangent Charpy curve fitting program versus an asymmetric tangent Charpy curve fitting program or hand drawn curves using engineering judgement, and/or 3) rounding errors.

Callaway Plant 14 Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT Criterion 4: The irradiation temperature of the Charpy specimens in the capsule should match the vessel wall temperature at the cladding/base metal interface within +/ 250F.

The capsule specimens are located in the reactor between the neutron pads and the vessel wall and are positioned opposite the center of the core. The test capsules are in baskets attached to the neutron pads. The location of the specimens with respect to the reactor vessel beltline provides assurance that the reactor vessel wall and the specimens experience equivalent operating conditions such that the temperatures will not differ by more than 25 0F. Hence this criterion is met.

Criterion 5: The surveillance data for the correlation monitormaterial in the capsule should fall within the scatter band of the data base for that material.

The Callaway Plant surveillance program does not contain correlation monitor material. Therefore, this criterion is not applicable to the Callaway Plant surveillance program.

Based on the preceding positive responses to all five criteria of Regulatory Guide 1.99, Revision 2, Section B, the Callaway Plant surveillance data is credible.

Callaway Plant 15 Revision 4

, Figure 14.9 , zi

.1 PRESSURE AND TEMPERATURE LIMITS REPORT 5.0 Supplemental Data Tables Table 5.0-1 Comparison of Callaway Plant Surveillance Material 30ft-lb Transition Temperature Shifts and Upper Shelf Energy Decreases with Regulatory Guide 1.99, Revision 2, Predictions.

Table 5.0-2 Calculation of Chemistry Factors Using Surveillance Capsule Data.

Table 5.0-3 Provides the unirradiated reactor vessel toughness data. The boltup temperature is also included in this Table.

Table 5.0-4 Provides a summary of the pressure vessel neutron fluence values at 20 EFPY used for the calculation of ART values.

Table 5.0-5 Provides a summary of the adjusted reference temperature (ARTs) for reactor vessel beltline materials at the Ye-T and 3/-T locations for 20 EFPY.

Table 5.0-6 Shows the calculation of the ART at 20 EFPY for the limiting reactor vessel material (lower shell plate R-2708-3).

Table 5.0-7 Provides RTpTs values for 35 EFPY.

6.0 References

1. Technical Specification 5.6.6, *Reactor Coolant System (RCS) PRESSURE AND TEMPERATURE LIMITS REPORT (PTLR)."

2. NRC letter dated [March 24, 2000], [CALLAWAY PLANT, UNIT I - ISSUANCE OF AMENDMENT RE: PRESSURE TEMPERATURE LIMITS REPORT]

3. License Amendment No. [134], dated [March24,2000], from [Jack Donohew, Senior Project Manager, Section 2] to [Garry L. Randolph, Vice President and Chief Nuclear Officer].

4. WCAP-14040-NP-A, Revision 2, "Methodology Usedto Develop Cold Overpressure Mitigating System Setpoints and RCS Heatup and Cooldown Limit Curves," January, 1996.

5. WCAP-16140, July 2004, 'Callaway Replacement Steam Generator Program NSSS I Engineering Report' Callaway Plant 16 Revision 4

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT

, -.. Z i' V, Table 5.0-1 Comparison of Callaway Unit I Surveillance Material 30 ftlb Transition Temperature Shifts and Upper Shelf Energy Decreases with Regulatory Guide 1.99,Revision 2,

- Predictions 30 ft-lb Transition Upper Shelf Energy Temperature Shift - Decrease Materials Capsule Fluence Predicted Measured Predicte Measured (X 1 0 19n/cm2 ) (OF) (a) (,F) (b) d (%) (a) (%) (c)

Lower Shell U 0.331 30.62 o.o0) 14.5 0 Plate R2708-1 Y 1.27. 47.08 25.15 20 6 V 1.252 55.0 16.45 23.5 0 (Longitudinal) X 3.33 58.08 25.71 25 5 Lower Shell U 0.331 30.62 25.86 14.5 11 Plate R2708-1 Y 1.27 -47.08 46.39 20 13 V -1.252 55.0 44.82 23.5 3 (Transverse) X 3.33 58.08 30.77 25 5 Weld Metal U 0.331 22.13 68.53 14.5 11 Y 1.27 34.02 36.92 20 14 V 1.252 39.75 48.21 23.5 8 X 3.33 41.98 51.81 25 8 HAZ Metal U 0.331 _ 65.93 - 0 Y 1.27 56.38 _ 14 v 1.252  : 56.1 _ 0 X 3.33 - 42.11 0 NOTES:

(a) Based on Regulatory Guide 1.99, Revision 2, methodology using the mean weight percent values of copper and nickel of the surveillance material.

(b) Calculated using measured Charpy data plotted using CVGRAPH, Version 4.1 .

(c) Values are based on the definition of upper shelf energy given in ASTM E18582.

(d) Actual measured value forARTNDT is -7.33. This physically should not occur, therefore for conservatism a value of zero will be used.

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• t, h VS Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT Table 5.0-2 Calculation of Chemistry Factors Using Surveillance Capsule Data Material Capsule Capsule ) FFWbl ARTNDT(C) FF x ARTNDT FF Lower Shell U 0.331 0.696 0.0(e) 0.0 0.48 PlateR2708-1 Y 1.27 1.07 25.15 26.91 1.14 V 2.52 1.25 16.45 20.56 1.56 (Longitudinal) X 3.33 1.32 25.71 33.94 1.74 Lower Shell U 0.331 0.696 25.86 18.00 0.48 Plate Y 1.27 1.07 46.39 49.64 1.14 R2708-1 V 2.52 1.25 44.82 56.03 1.56 X 3.33 1.32 30.77 40.62 1.74 (Transverse) SUM 245.70 9.84 C 0f 5 = X(FF

• RTNDT) + XiFF2) = (245.70) (9.84) =25.00 F Surveillance UL 0.331 0.696 68.53(') 47.70 0.48 Weld Material(d) Y 1.27 1.07 36.921(' 39.5 1.14 V 2.52 1.25 48.21'g' 60.26 1.56 X 3.33 1.32 51.81() 68.39 1.74 SUM 215.85 4.92 CF surv wee = E(FF

• RTNDT) + X(FF 2 ) = (215.85"F) + (4.92) =43.90F NOTES:

(a) f = calculated fluence from capsule X dosimetry analysis results, (Id9 n/cm2, E > 1.0 MeV).

All updated fluence values from the Capsule X analysis (Table 01 of WCAP 15400).

(b) FF = fluence factor =

(c) ARTNDTvalues are the measured 30 flb shift.

(d) These measured ARTNDT values do not include the adjustment ratio procedure of Reg.

Guide 1.99 Revision 2, Position 2.1, since this calculation is based on the actual surveillance weld metal measured shift values and based on the copper and nickel content the ratio would be 1. In addition, the only surveillance data available is from the Callaway Unit 1 reactor vessel, therefore, no temperature adjustment is required.

(e) The actual value is -7.33, but for conservatism a value of zero is considered.

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Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT eats * '~SA o TABLE 5.0-3 Reactor Vessel Beltline Material Unirradiated Toughness Properties Material Description l Cu Ni(%) Initial RTNDT Closure Head Flange R2704-1 l l 300F(c)

Vessel Flange R2701-1 l l - l 400F(c)

Intermediate Shell Plate R2707-1 0.05 0.58 400 F Intermediate Shell Plate R2707-2 0.06 0.61 10'F Intermediate Shell Plate R2707-3 0.06 0.62 -10F Lower Shell Plate R2708-1 0.07 0.58 500F Lower Shell Plate R2708-2 0.06 0.57 10F Lower Shell Plate R27083 0.08 0.62 200F Intermediate and Lower Shell . 0.06 -600 F Longitudinal Weld Seams___

Intermediate to Lower Shell 0.04 0.06 60°F Circumferential Weld Seam046 The Initial RTNDT values for the plates and welds are based on measured data (WCAFL 12948).

All vessel beltline weld seams were fabricated with weld wire heat number 90077. The intermediate to lower shell circumferential weld seam 101-171 was fabricated with Flux Type 124 Lot Number 1061. The intermediate and lower shell longitudinal weld seams were fabricated with Flux Type 0091 Lot 0842. The surveillance weld metal was fabricated with weld wire heat number 90077, Flux Type 124 Lot number 1061. Per Regulatory Guide 1.99, Revision 2, 'weight-percent copper *and "weight-percent nickel, are the best-estimate values for the material, which will normally be the mean of the measured values for a plate or forging or for weld samples made with the weldwire heat number that matches the critical vessel weld. The surveillance weld metal was made with the same weld wire heat as all of the vessel beltline weld seams and is therefore representative of all of the beltline weld seams.

l') These values are used for considering flange requirements for the heatup/cooldown curves. Per the methodology given in WCAP-1404O-NP-A (Ref. 4), the minimum boltup temperature is 60"F.

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Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT TABLE 6.0-4 Fluence (109 nlcm2 , E > 1.0 MeV) on the Pressure Vessel CladlBase Metal Interface for Callaway Plant EFPY 00 150 l 300 450 12.40 0.445 0.649 0.756 0.768 16 0.565 0.822 0.956 0.964 24 0.832 1.21 1.40 1.40 32 1.10 1.59 1.85 1.83 54 1.83 2.64 3.07 3.02 Callaway Plant 20 Revision 4

t J 1I I

,., I. :I ' -. W I  ; -

Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT TABLE 5.0-5 Summary of Adjusted Reference Temperature (ART) Mlues at the 4/-T and

%-T Locations for 20 EFPY 20 EFPY ART(a)

Material 1

%-T ART  %-T ART

._, (OF) ('F)

Intermediate Shell Plate R2707-1 96.4 79.0 Intermediate Shell Plate R2707-2 77.4 56.6 Intermediate Shell Plate R2707-3 57.4 36.6 Lower Shell Plate R2708-1 124.0 105.4 Using Surveillance Capsule Data 90.9 83.2 Lower Shell Plate R2708-2 77.4 56.6 Lower Shell Plate R2708-3 100.4A' 84.2(t)

Intermediate & Lower Shell Longitudinal Weld Seams 101- -15.4 -30.8 124A & 101-142A (900 Azimuth)

Using Surveillance Capsule Data 0.8 -17.2 Intermediate & Lower Shell Longitudinal weld Seams 101-124B&C and 101-142B&C (2100 & -6.6 -23.2 3300 Azimuth)

Using Surveillance Capsule Data 7.3 -5.8 Intermediate to Lower Shell Circumferential Weld Seam 101- -6.0 -22.6 171 .

Using Surveillance Capsule Data 7.8 -5.0 ART = Initial RTNDT + ARTNDT + Margin (OF)

(b) These ART values are used to generate the heatup and cooldown curves.

Note:When two or more credible surveillance data sets become available, the data sets may be used to determine ART values as described in Regulatory Guide 1.99, Revision 2, Position 2.1. If the ART values based on surveillance capsule data are larger than those calculated per Regulatory Guide 1.99, Revision 2. Position 1.1, the surveillance data mist be used. If the surveillance capsule data gives lower values, either may be used.

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I ,

i I Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT

l .~

TABLE 5.0-6 Calculation of Adjusted Reference Temperature Values at 20 EFPY for the Limiting Callaway Plant Reactor Vessel Material (Lower Shell Plate R270&3)

Parameter [ ART Value Location 1/4-T l _ _ _-T Chemistry Factor, CF CF) 51.0 51.0 Fluence, f (10'9 n/cm2 )(a) 0.7174 0.2547 Fluence Factor, FFH) 0.91 0.63 ARTNDT = CF x FF, eF) 46.4 32.1 Initial RTNDT, I (CF) 20 20 Margin, M f)c) 34 32.1 ART = I + (CF x FF) + M eF) 100.4 84.2 per Regulatory Guide 1.99, Rev. 2 (a

Fluence, f, is based upon fe (10o' rnicm', E > 1.0 MeV) = 1.204 at 20 EFPY. The Callaway Plant reactor vessel wall thickness is 8.63 inches at the beltline region.

(b)

Fluence Factor (FF) per Regulatory Guide 1.99, Revision 2, is defined as FF = f0.28-0.1019ogo (C) Margin is calculated as M = 2,2+ a02)0 5. The standard deviation for the initial RTNDT margin term a,, is 0F since the initial RTNDT is a measured value. The standard deviation for ARTNDT term A, is 17 0F for the plate, except that a, need not exceed 0.5 times the mean value of ARTNDT.

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Figure 14.9 PRESSURE AND TEMPERATURE LIMITS REPORT TABLE 5.0-7 RTpTS Calculations for Callaway Plant Beitline Region Materials at 35 EFPPd Material l Fluence (1019 FF n/cm2 , E >1.0 MeV)I 1CF (OF)

ARTpTs(

(O 1 ). Margin F)

RTNOT(U)(a)

(OF)

RTpTs b

('F)

Intermediate Shell 2.074 1.20 31.0 37.2 34.0 40 111 Plate R2707-1 Intermediate Shell 2.074 1.20 37.0 44.4 34.0 10 88 Plate R2707-2 Intermediate Shell 2.074 1.20 37.0 44.4 34.0 -10 68 Plate R2707-3 Lower Shell Plate 2.074 1.20 44.0 52.8 34.0 50 137 R2708-1 Using S/C Data 2.074 1.20 26.3 31.6 17.0 50 99 Lower Shell Plate 2.074 1.20 37.0 44.4 34.0 10 88 R2708-2 Lower Shell Plate 2.074 1.20 51.0 61.2 34.0 20 115 R2708-3 Inter. and Lower Shell 1.167 1.04 29.7 30.9 30.9 -60 2 Long. Weld Seams101-124A &

101-142A (90° Azimuth)

Using S/C Data 1.167 1.04 43.7 45.4 28.0 -60 13 Inter. and Lower Shell 2.042 1.19 29.7 35.3 35.3 .-60 11 Long. Weld Seams101-124B&C &

101-142B&C (210° &

3300 Azimuth)

Using SIC Data 2.042 1.19 43.7 52.0 28.0 -60 20 Intermediate to Lower 2.074 1.20 29.7 35.6 35.6 -60 11 Shell Circumferential Weld Seam 101 -171

.................... i .... .................... .......... .............. ............ .............. ......

Using SIC Data 2.074 1.20 43.7 52.4 28.0 -60 20 (a) Initial RTNDT values are measured values (b) RTpTs = RTNDT(u) + Margin + ARTmrn (c) ARTps= CF

• FF (d) Projected no. of EPFY at the EOL.

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