ML031830187

(BFN) - Units 2 and 3 - American Society of Mechanical Engineers (ASME)Section XI, Inservice Inspection (ISI) Program - Requests for Relief 2-ISI-21 and 3-ISI-17 for Examination of Piping Weld Overlays

ML031830187
Person / Time
Site:	Browns Ferry
Issue date:	06/30/2003
From:	Abney T Tennessee Valley Authority
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
Download: ML031830187 (51)

Text

June 30, 2003 10 CFR 50.55a(a)(3)(i)

U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Mail Stop: OWFN P1-35 Washington, D.C. 20555-0001 Gentlemen:

In the Matter of ) Docket Nos. 50-260 Tennessee Valley Authority ) 50-296 BROWNS FERRY NUCLEAR PLANT (BFN) - UNITS 2, AND 3 - AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM - REQUESTS FOR RELIEF 2-ISI-21, AND 3-ISI-17 FOR EXAMINATION OF PIPING WELD OVERLAYS In accordance with 10 CFR 50.55a(a)(3)(i), TVA is requesting relief from certain inservice inspection (ISI) requirements in Section XI of the ASME Section XI, Appendix VIII, Supplement 11 for BFN Units 2 and 3. The specific requirements for which relief is requested relate to the qualification requirements for inspecting piping weld overlays using ultrasonic testing (UT). The enclosure to this letter contains BFN Units 2, and 3 requests for relief 2-ISI-21, and 3-ISI-17 for NRC review and approval.

ASME Section XI, Appendix VIII requirements are mandated and supplemented by 10 CFR 50.55a(b)(2)(xiv), (xv), and (xvi).

Appendix VIII of ASME Section XI, 1995 Edition with 1996 Addenda is specified in the CFR. The BFN Units 2 and 3 Inservice Inspection (ISI) Programs for nondestructive

examination complies with the 1995 Edition, 1996 Addenda of ASME Section XI, and supplemented as required to incorporate ASME Section XI, Appendix VIII.

U.S. Nuclear Regulatory Commission Page 2 June 30, 2003 TVA recently was advised by the Electric Power Institute (EPRI), staff that prior to performing ultrasonic examination of Class 1 Reactor Coolant System (RCS) weld overlays (reference NRC GL 88-01, and Boiling Water Reactor Vessel and Internals Project (BWRVIP)-75), relief from ASME Section XI, Appendix VIII, Supplement 11 requirements is necessary.

TVA was also informed that two options exist: (1) adopt ASME Code Case N-653, Qualification Requirements for Full Structural Overlaid Wrought Austenitic Piping Welds,Section XI, Division 1, with some modifications, or, (2) use the EPRI Performance Demonstration Initiative (PDI) Program in lieu of the ASME Code Section XI, Appendix VIII, Supplement 11 requirements. EPRI has worked with the NRC staff to develop a sample request for relief, using option 2 above, to ensure sufficient information is submitted for NRC review. of this letter contains BFN Unit 2 request for relief 2-ISI-21 for NRC review and approval. Enclosure 2 of this letter provides BFN Unit 3 request for relief 3-ISI-17.

The technical content each of the requests for relief is consistent with the EPRI sponsored PDI model including updates resulting from requests for additional information issued to other utilities (i.e., Southern Nuclear Operating Company (SNC), for Plant Hatch and Carolina Power and Light, for Brunswick Steam Electric Plant).

TVA requests approval of these requests for relief by January 16, 2004, to support resource planning for the Unit 3, Cycle 11 (Spring 2004) refueling outage.

U.S. Nuclear Regulatory Commission Page 3 June 19, 2003 There are no new regulatory commitments in this letter. If you have any questions, please contact me at (256) 729-2636.

Sincerely, Original signed by:

T. E. Abney Manager of Licensing and Industry Affairs Enclosures cc (Enclosures):

(Via NRC Electronic Distribution)

Mr. Stephen J. Cahill, Branch Chief U.S. Nuclear Regulatory Commission Region II Sam Nunn Atlanta Federal Center 61 Forsyth Street, SW, Suite 23T85 Atlanta, Georgia 30303-8931 NRC Resident Inspector Browns Ferry Nuclear Plant 10833 Shaw Road Athens, Alabama 35611-6970 Mr. Kahtan N. Jabbour, Senior Project Manager U.S. Nuclear Regulatory Commission One White Flint, North (MS 08G9) 11555 Rockville Pike Rockville, Maryland 20852-2739

U.S. Nuclear Regulatory Commission Page 4 June 30, 2003 DTL:JWD:BAB Enclosures cc (Enclosures):

A. S. Bhatnagar, PAB 1E-BFN M. J. Burzynski, BR 4X-C A. L. Ladd, PEC-2A-BFN J. E. Maddox, LP 6A-C D. C. Olcsvary, LP 6A-C C. M. Root, PAB 1G-BFN J. R. Rupert, NAB 1A-BFN K. W. Singer, LP 6A-C M. D. Skaggs, POB 2C-BFN E. J. Vigluicci, ET 11A-K R. E. Wiggall, SAB 1A-BFN NSRB Support, LP 5M-C EDMS-K s:\lic\submit\subs\Units 2, & 3 Weld Overlay Relief Request.doc

ENCLOSURE 1 TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)

UNIT 2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (THIRD TEN-YEAR INSPECTION INTERVAL)

REQUEST FOR RELIEF 2-ISI-21 (See Attached)

TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)

UNIT 2 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (THIRD TEN-YEAR INSPECTION INTERVAL)

REQUEST FOR RELIEF 2-ISI-21 Executive Summary: In accordance with 10 CFR 50.55a(a)(3)(i),

TVA is requesting relief from inservice inspection requirements of the 1995 Edition through 1996 Addenda of ASME Section XI, Appendix VIII, Supplement 11, Qualification Requirements For Full Structural Overlaid Wrought Austenitic Piping Welds, of the ASME Boiler and Pressure Vessel Code. The Performance Demonstration Initiative (PDI) Program for implementing the Supplement 11 qualification program for overlay welds is not in strict compliance with the requirements of Supplement 11 of the 1995 Edition through the 1996 Addenda. TVA proposes to use the PDI Program for implementation of Appendix VIII, Supplement 11 as amended in the attachment to this request for relief. The amendments to Supplement 11 as shown in the attachment were coordinated with PDI, NRC, and Pacific Northwest National Laboratory (PNNL).

Unit: Two (2)

System(s): Recirculation (RECIRC), Core Spray (CS),

and Reactor Water Clean Up (RWCU) Systems Components: Piping Welds with Structural Weld Overlay ASME Code Class: ASME Code Class 1 ASME Section XI Edition: 1995 Edition, 1996 Addenda E1-2

Code Table: Westinghouse Owners Group (WOG) topical Report WCAP-14572, Revision 1-NP-A, Table 4.1-1 Examination Category: R-A, Risk-Informed Piping Examinations Examination Item Number: R1.16, Elements Subject To Intergranular Stress Corrosion Cracking (IGSCC)

Code Requirement: The 1995 Edition of ASME Section XI, with addenda through 1996, WCAP-14572, Revision 1-NP-A, Table 4.1-1, Examination Category R-A, Item No. R1.16, requires a volumetric (UT) examination of the pipe weld including the overlay. The UT examination must be performed using personnel, procedures, and equipment qualified in accordance with Appendix VIII, Supplement 11.

Code Requirements From Which Relief Is Requested: Relief is requested from the requirement to qualify personnel, procedures, and equipment in accordance with Appendix VIII, Supplement 11 as stated in the 1995 Edition through the 1996 Addenda of the ASME Section XI Code.

List Of Items Associated With The Relief Request: BFN Unit 2 Weld Overlays in the Risk-Informed ISI Program that require examination:

WELD # SYSTEM PIPE SIZE CATEGORY GR-2-15 RECIRC 12.0 E DSRWC-2-03 RWCU 6.0 E DSRWC-2-04 RWCU 6.0 E DSRWC-2-05 RWCU 6.0 E E1-3

Weld Overlays in the BFN Unit 2 Risk-Informed ISI Program that currently do not require examination:

WELD # SYSTEM PIPE SIZE CATEGORY TCS-2-421 CS 12.0 E GR-2-45 RECIRC 12.0 E GR-2-59 RECIRC 28.0 E GR-2-61 RECIRC 28.0 E GR-2-64 RECIRC 28.0 E Basis For Relief Request: The requirements of ASME Section XI, Appendix VIII, Supplement 11, as stated in the 1995 Edition through the 1996 Addenda are not practical to implement. The requirements were amended to improve the implementation process. The amended requirements are contained in the attachment to this relief request. The EPRI sponsored PDI amendments to Supplement 11, as shown in the attachment, were coordinated with PDI, NRC, and PNNL.

The proposed amended requirements of Supplement 11 for the qualification of personnel, procedures, and equipment will provide an alternative with an acceptable level of quality and safety.

Alternate Requirement: TVA proposes to utilize personnel, procedures, and equipment qualified in accordance with ASME section XI, Appendix VIII, Supplement 11, as amended by the attachment, which is the EPRI administered PDI Program.

Justification For The Granting Of E1-4

Relief: The proposed amended criteria (as shown in the attachment) to the requirements of the ASME Section XI, 1995 Edition with addenda through 1996, Appendix VIII, Supplement 11, which were coordinated through PDI, NRC, and PNNL, provides an alternative with an acceptable level of quality and safety.

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NOTE: This request for relief (RFR) is consistent with one submitted by Brunswick Steam Electric Plant to the NRC by letters dated July 16, 2002, and February 11, 2003.

The NRC approved the request for relief by letter dated March 26, 2003.

Implementation Schedule: This request for relief is applicable to the BFN Unit 2, ASME Section XI Third Ten-Year ISI inspection interval which expires on May 24, 2011.

Attachment:

Table - Comparison of ASME Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E1-6

ATTACHMENT 2-ISI-21 Comparison of ASME Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E1-7

SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the No Change No Change requirements listed herein, unless a set of specimens is designed to accommodate specific limitations stated in the scope of the examination procedure (e.g., pipe size, weld joint configuration, access limitations). The same specimens may be used to demonstrate both detection and sizing qualification.

1.1 General. The specimen set shall conform No Change No Change to the following requirements.

(a) Specimens shall have sufficient volume to No Change No Change minimize spurious reflections that may interfere with the interpretation process.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) The specimen set shall consist of at least No Change (b) The specimen set shall consist of at least three specimens having different nominal pipe three specimens having different nominal pipe diameters and overlay thicknesses. They shall diameters and overlay thicknesses. They shall include the minimum and maximum nominal include the minimum and maximum nominal pipe diameters for which the examination pipe diameters for which the examination procedure is applicable. Pipe diameters within procedure is applicable. Pipe diameters within a range of 0.9 to 1.5 times a nominal diameter a range of 0.9 to 1.5 times a nominal diameter shall be considered equivalent. If the shall be considered equivalent. If the procedure is applicable to pipe diameters of procedure is applicable to pipe diameters of 24 inches or larger, the specimen set must 24 inches or larger, the specimen set must include at least one specimen 24 inches or include at least one specimen 24 inches or larger but need not include the maximum larger but need not include the maximum diameter. The specimen set must include at diameter.

least one specimen with overlay thickness The specimen set shall include specimens with within -0.1 inches to +0.25 inches of the overlays not thicker than 0.1 inches more than maximum nominal overlay thickness for which the minimum thickness, nor thinner than 0.25 the procedure is applicable. inches of the maximum nominal overlay thickness for which the examination procedure is applicable.

(c) The surface condition of at least two No Change No Change specimens shall approximate the roughest surface condition for which the examination procedure is applicable.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (d) Flaw Conditions (1) Base metal flaws. All flaws must be (1) Base metal flaws. All flaws must be in or (1) Base metal flaws. All flaws must be in or cracks in or near the butt weld heat-affected near the butt weld heat-affected zone, open to near the butt weld heat-affected zone, open to zone, open to the inside surface, and extending the inside surface, and extending at least 75 the inside surface, and extending at least 75 at least 75 percent through the base metal percent through the base metal wall. percent through the base metal wall.

wall. Flaws may extend 100 percent through Intentional overlay fabrication flaws shall not Intentional overlay fabrication flaws shall not the base metal and into the overlay material; in interfere with ultrasonic detection or interfere with ultrasonic detection or this case, intentional overlay fabrication flaws characterization of the cracking. Specimens characterization of the base metal flaws.

shall not interfere with ultrasonic detection or containing IGSCC shall be used when Specimens containing IGSCC shall be used characterization of the cracking. Specimens available. when available. At least 70 percent of the containing IGSCC shall be used when (a) At least 70 percent of the flaws in the flaws in the detection and sizing tests shall be available. detection and sizing tests shall be cracks. cracks and the remainder shall be alternative Alternative flaw mechanisms, if used, shall flaws. Alternative flaw mechanisms, if used, provide crack-like reflective characteristics shall provide crack-like reflective and shall be limited by the following: characteristics and shall be limited by the following:

(1) Flaws shall be limited to when implantation of cracks precludes obtaining a realistic (a) The use of Alternative flaws shall be limited ultrasonic response. to when the implantation of cracks produces spurious reflectors that are uncharacteristic of (2) Flaws shall be semi-elliptical with a tip actual flaws.

width of less than or equal to 0.002 inches.

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

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (2) Overlay fabrication flaws. At least 40 No Change No Change percent of the flaws shall be non-crack fabrication flaws (e.g., sidewall lack of fusion or laminar lack of bond) in the overlay or the pipe-to-overlay interface. At least 20 percent of the flaws shall be cracks. The balance of the flaws shall be of either type.

(e) Detection Specimens (1) At least 20 percent but less than 40 (1) At least 20 percent but less than 40 (1) At least 20 percent but less than 40 percent of the flaws shall be oriented within percent of the base metal flaws shall be percent of the base metal flaws shall be

+20 degrees of the pipe axial direction. The oriented within +20 degrees of the pipe axial oriented within +20 degrees of the pipe axial remainder shall be oriented circumferentially. direction. The remainder shall be oriented direction. The remainder shall be oriented Flaws shall not be open to any surface to circumferentially. Flaws shall not be open to circumferentially. Flaws shall not be open to which the candidate has physical or visual any surface to which the candidate has any surface to which the candidate has access. The rules of IWA-3300 shall be used physical or visual access. physical or visual access.

to determine whether closely spaced flaws should be treated as single or multiple flaws.

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

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

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

(a)(2) When base metal cracking penetrates (a)(2) When base metal cracking penetrates (a)(2) When base metal flaws penetrate into into the overlay material, the base grading unit into the overlay material, the base metal the overlay material, the base metal grading shall include the overlay metal within 1 inch of grading unit shall not be used as part of any unit shall not be used as part of any overlay the crack location. This portion of the overlay overlay fabrication grading unit. fabrication grading unit.

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

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

segment of weld length used in one base grading unit shall not be used in another base grading unit. Base grading units need not be uniformly spaced around the specimen.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b)(l) An overlay grading unit shall include the (b)(l) An overlay fabrication grading unit shall (b)(l) An overlay fabrication grading unit shall overlay material and the base metal-to-overlay include the overlay material and the base include the overlay material and the base interface of at least 6 square inches The metal-to-overlay interface for a length of at metal-to-overlay interface for a length of at overlay grading unit shall be rectangular, with least 1 inch least 1 inch.

minimum dimensions of 2 inches.

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

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

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

To qualify new values of essential variables, at To qualify new values of essential variables, at least one personnel qualification set is least one personnel qualification set is required. required.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (f) Sizing Specimen (1) The minimum number of flaws shall be ten. (1) The minimum number of flaws shall be ten. (1) The minimum number of flaws shall be ten.

At least 30 percent of the flaws shall be At least 30 percent of the flaws shall be At least 30 percent of the flaws shall be overlay fabrication flaws. At least 40 overlay fabrication flaws. At least 40 overlay fabrication flaws. At least 40 percent of the flaws shall be cracks open to percent of the flaws shall be cracks open to percent of the flaws shall be open to the inside the inside surface. the inside surface. For initial procedure surface. Sizing sets shall contain a distribution qualification, sizing sets shall include the of flaw dimensions to assess sizing capabilities.

equivalent of three personnel qualification sets. For initial procedure qualification, sizing sets To qualify new values of essential variables, at shall include the equivalent of three personnel least one personnel qualification set is qualification sets. To qualify new values of required. essential variables, at least one personnel qualification set is required.

(2) At least 20 percent but less than 40 No Change No Change percent of the flaws shall be oriented axially.

The remainder shall be oriented circumferentially. Flaws shall not be open to any surface to which the candidate has physical or visual access.

(3) Base metal cracking used for length sizing No Change (3) Base metal flaws used for length sizing demonstrations shall be oriented demonstrations shall be oriented circumferentially. circumferentially.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (4) Depth sizing specimen sets shall include at No Change (4) Depth sizing specimen sets shall include at least two distinct locations where cracking in least two distinct locations where a base metal the base metal extends into the overlay flaw extends into the overlay material by at material by at least 0.1 inch in the through-wall least 0.1 inch in the through-wall direction.

direction.

2.0 CONDUCT OF PERFORMANCE DEMONSTRATION The specimen inside surface and identification The specimen inside surface and identification The specimen inside surface and identification shall be concealed from the candidate. All shall be concealed from the candidate. All shall be concealed from the candidate. All examinations shall be completed prior to examinations shall be completed prior to examinations shall be completed prior to grading the results and presenting the results to grading the results and presenting the results to grading the results and presenting the results to the candidate. Divulgence of particular the candidate. Divulgence of particular the candidate. Divulgence of particular specimen results or candidate viewing of specimen results or candidate viewing of specimen results or candidate viewing of unmasked specimens after the performance unmasked specimens after the performance unmasked specimens after the performance demonstration is prohibited. demonstration is prohibited. The overlay demonstration is prohibited. The overlay fabrication flaw test and the base metal flaw fabrication flaw test and the base metal flaw test may be performed separately. test may be performed separately.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS 2.1 Detection Test.

Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be randomly mixed. Although the boundaries of randomly mixed. Although the boundaries of randomly mixed. Although the boundaries of specific grading units shall not be revealed to specific grading units shall not be revealed to specific grading units shall not be revealed to the candidate, the candidate shall be made the candidate, the candidate shall be made the candidate, the candidate shall be made aware of the type or types of grading units aware of the type or types of grading units aware of the type or types of grading units (base or overlay) that are present for each (base metal or overlay fabrication) that are (base metal or overlay fabrication) that are specimen. present for each specimen. present for each specimen.

2.2 Length Sizing Test (a) The length sizing test may be conducted No Change No Change separately or in conjunction with the detection test.

(b) When the length sizing test is conducted in No Change No Change conjunction with the detection test and the detected flaws do not satisfy the requirements of 1.1(f), additional specimens shall be provided to the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (c) For a separate length sizing test, the No Change No Change regions of each specimen containing a flaw to be sized shall be identified to the candidate.

The candidate shall determine the length of the flaw in each region.

(d) For flaws in base grading units, the (d) For flaws in base metal grading units, the (d) For flaws in base metal grading units, the candidate shall estimate the length of that part candidate shall estimate the length of that part candidate shall estimate the length of that part of the flaw that is in the outer 25 of the flaw that is in the outer 25 percent of of the flaw that is in the outer 25 percent of percent of the base wall thickness. the base metal wall thickness. the base metal wall thickness.

2.3 Depth Sizing Test.

For the depth sizing test, 80 percent of the The candidate shall determine the depth of the (a) The depth sizing test may be conducted flaws shall be sized at a specific location on the flaw in each region. separately or in conjunction with the detection surface of the specimen identified to the test.

candidate. For the remaining flaws, 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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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) When the depth sizing test is conducted in conjunction with the detection test and the detected flaws do not satisfy the requirements of 1.1(f), additional specimens shall be provided to 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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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria.

Examination procedures, equipment, and Examination procedures are qualified for (a) Examination procedures are qualified for personnel are qualified for detection when the detection when all flaws within the scope of detection when:

results of the performance demonstration the procedure are detected and the results of satisfy the acceptance criteria of Table VIII- the performance demonstration satisfy the S2-1 for both detection and false calls. The acceptance criteria of Table VIII-S2-1 for criteria shall be satisfied separately by the false calls. Examination equipment and demonstration results for base grading units personnel are qualified for detection when the and for overlay grading units. results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls. The criteria shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.

(1) All flaws within the scope of the procedure are detected and the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for false calls.

(2) At least one successful personnel demonstration has been performed meeting the acceptance criteria defined in (b).

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) Examination equipment and personnel are qualified for detection when the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls.

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

3.2 Sizing Acceptance Criteria.

Examination procedures, equipment, and No Change No Change personnel are qualified for sizing when the results of the performance demonstration satisfy the following criteria.

(a) The RMS error of the flaw length No Change (a) The RMS error of the flaw length measurements, as compared to the true flaw measurements, as compared to the true flaw lengths, is less than or equal to 0.75 inches. lengths, is less than or equal to 0.75 inches.

The length of base metal cracking is measured The length of base metal flaws is measured at at the 75 percent through-base-metal position. the 75 percent through-base-metal position.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) All extensions of base metal cracking into This requirement is omitted. This requirement is omitted.

the overlay material by at least 0.1 inches are reported as being intrusions into the overlay material.

(c) The RMS error of the flaw depth (b) The RMS error of the flaw depth (b) The RMS error of the flaw depth measurements, as compared to the true flaw measurements, as compared to the true flaw measurements, as compared to the true flaw depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inch.

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ENCLOSURE 2 TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)

UNIT 3 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (SECOND TEN-YEAR INSPECTION INTERVAL)

REQUEST FOR RELIEF 3-ISI-17 (See Attached)

TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)

UNIT 3 AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) SECTION XI, INSERVICE INSPECTION (ISI) PROGRAM (SECOND TEN-YEAR INSPECTION INTERVAL)

REQUEST FOR RELIEF 3-ISI-17 Executive Summary: In accordance with 10 CFR 50.55a(a)(3)(i),

TVA is requesting relief from inservice inspection requirements of the 1995 Edition through 1996 Addenda of Section XI, Appendix VIII, Supplement 11, Qualification Requirements For Full Structural Overlaid Wrought Austenitic Piping Welds, of the ASME Boiler and Pressure Vessel Code. The Performance Demonstration Initiative (PDI) Program for implementation of the Supplement 11 qualification program for overlay welds is not in strict compliance with the requirements of Supplement 11 of the 1995 Edition through the 1996 Addenda. TVA proposes to use the PDI Program for implementation of Appendix VIII, Supplement 11 as amended in attachment to this request for relief. The amendments to Supplement 11 as shown in attachment were coordinated with PDI, NRC, and Pacific Northwest National Laboratory (PNNL).

Units: Three (3)

System(s): Recirculation (RECIRC), and Residual Heat Removal (RHR) Systems Components: Piping Welds with Structural Weld Overlay ASME Code Class: ASME Code Class 1 Section XI Edition: 1995 Edition, 1996 Addenda E2-2

Note: The ASME Section XI Code of record (component selection) for BFN Unit 3 is the 1989 Edition, No addenda. However, TVA has adopted the 1995 Edition, 1996 Addenda for nondestructive examination at all of its nuclear plants. Reference TVA letter to NRC dated August 10, 2001. The NRC approved TVAs request by letter dated May 24, 2002.

Code Table: Westinghouse Owners Group (WOG) Topical Report WCAP-14572, Revision 1-NP-A, Table 4.1-1 Examination Category: R-A, Risk-Informed Piping Examinations Examination Item Number: R1.16, Elements Subject To Intergranular Stress Corrosion Cracking (IGSCC)

Code Requirement: The 1995 Edition of ASME Section XI, with addenda through 1996, WCAP-14572, Revision 1-NP-A, Table 4.1-1, Examination Category R-A, Item No. R1.16, requires a volumetric (UT) examination of the pipe weld including the overlay. The UT examination must be performed using personnel, procedures, and equipment qualified in accordance with Appendix VIII, Supplement 11.

Code Requirements From Which Relief Is Requested: Relief is requested from the requirement to qualify personnel, procedures, and equipment in accordance with Appendix VIII, Supplement 11 as stated in the 1995 Edition through the 1996 Addenda of the ASME Section XI Code.

List Of Items Associated With The Relief Request: Weld Overlays that currently require examination in the Unit 3 Risk-Informed ISI Program WELD # SYSTEM PIPE SIZE CATEGORY E2-3

GR-3-53 RECIRC 28.0 E DSRHR-3-11 RHR 20.0 E Weld Overlays in the BFN Unit 3 Risk-Informed ISI Program that currently do not require examination:

WELD # SYSTEM PIPE SIZE CATEGORY GR-3-03 RECIRC 28.0 E GR-3-27 RECIRC 28.0 E GR-3-54 RECIRC 28.0 E GR-3-57 RECIRC 28.0 E GR-3-59 RECIRC 28.0 E GR-3-60 RECIRC 28.0 E GR-3-64 RECIRC 28.0 E Basis For Relief:

The requirements of ASME Section XI, Appendix VIII, Supplement 11, as stated in the 1995 Edition through the 1996 Addenda are not practical to implement. The requirements were amended to improve the implementation process. The amended requirements are contained in the attachment to this relief request. The EPRI sponsored PDI amendments to Supplement 11, as shown in the attachment, were coordinated with PDI, NRC, and PNNL.

The proposed amended requirements of Supplement 11 for the qualification of personnel, procedures, and equipment will provide an alternative with an acceptable level of quality and safety.

Alternate Requirement: TVA proposes to utilize personnel, procedures, and equipment qualified in accordance with ASME section XI, Appendix VIII, Supplement 11 as amended by the Attachment, which is the EPRI administered PDI Program.

Justification For E2-4

The Granting Of Relief: The proposed amended criteria (as shown in the attachment) to the requirements of the ASME Section XI, 1995 Edition with addenda through 1996, Appendix VIII, Supplement 11, which were coordinated through PDI, NRC, and PNNL, provides an alternative with an acceptable level of quality and safety.

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NOTE: This request for relief (RFR) is consistent with one submitted by Brunswick Steam Electric Plant to the NRC by letters dated July 16, 2002 and February 11, 2003.

The NRC approved the request for relief by letter dated March 26, 2003.

Implementation Schedule: This request for relief is applicable to the Unit 3 second Ten-Year ISI inspection interval which expires on November 18, 2005.

Attachment:

Table - Comparison of ASME Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E2-6

ATTACHMENT 3-ISI-17 Comparison of ASME Section XI, Appendix VIII, Supplement 11, Code Case N-653, and PDI Alternative E2-7

SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS 1.0 SPECIMEN REQUIREMENTS Qualification test specimens shall meet the No Change No Change requirements listed herein, unless a set of specimens is designed to accommodate specific limitations stated in the scope of the examination procedure (e.g., pipe size, weld joint configuration, access limitations). The same specimens may be used to demonstrate both detection and sizing qualification.

1.1 General. The specimen set shall conform to the following requirements. No Change No Change (a) Specimens shall have sufficient volume to No Change No Change minimize spurious reflections that may interfere with the interpretation process.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) The specimen set shall consist of at least No Change (b) The specimen set shall consist of at least three specimens having different nominal pipe three specimens having different nominal pipe diameters and overlay thicknesses. They shall diameters and overlay thicknesses. They shall include the minimum and maximum nominal include the minimum and maximum nominal pipe diameters for which the examination pipe diameters for which the examination procedure is applicable. Pipe diameters within procedure is applicable. Pipe diameters within a range of 0.9 to 1.5 times a nominal a range of 0.9 to 1.5 times a nominal diameter shall be considered equivalent. If the diameter shall be considered equivalent. If the procedure is applicable to pipe diameters of procedure is applicable to pipe diameters of 24 inches or larger, the specimen set must 24 inches or larger, the specimen set must include at least one specimen 24 inches or include at least one specimen 24 inches or larger but need not include the maximum larger but need not include the maximum diameter. The specimen set must include at diameter.

least one specimen with overlay thickness The specimen set shall include specimens with within -0.1 inches to +0.25 inches of the overlays not thicker than 0.1 inches more than maximum nominal overlay thickness for which the minimum thickness, nor thinner than 0.25 the procedure is applicable. inches of the maximum nominal overlay thickness for which the examination procedure is applicable.

(c) The surface condition of at least two No Change No Change specimens shall approximate the roughest surface condition for which the examination procedure is applicable.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (d) Flaw Conditions E2-3

SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (1) Base metal flaws. All flaws must be (1) Base metal flaws. All flaws must be in or (1) Base metal flaws. All flaws must be in or cracks in or near the butt weld heat-affected near the butt weld heat-affected zone, open to near the butt weld heat-affected zone, open to zone, open to the inside surface, and extending the inside surface, and extending at least 75 the inside surface, and extending at least 75 at least 75 percent through the base metal percent through the base metal wall. percent through the base metal wall.

wall. Flaws may extend 100 percent Intentional overlay fabrication flaws shall not Intentional overlay fabrication flaws shall not through the base metal and into the overlay interfere with ultrasonic detection or interfere with ultrasonic detection or material; in this case, intentional overlay characterization of the cracking. Specimens characterization of the base metal flaws.

fabrication flaws shall not interfere with containing IGSCC shall be used when Specimens containing IGSCC shall be used ultrasonic detection or characterization of the available. At least 70 percent of the flaws in when available. At least 70 percent of the cracking. Specimens containing IGSCC shall the detection and sizing tests shall be cracks. flaws in the detection and sizing tests shall be be used when available. Alternative flaw mechanisms, if used, shall cracks and the remainder shall be alternative provide crack-like reflective characteristics flaws. Alternative flaw mechanisms, if used, and shall be limited by the following: shall provide crack-like reflective characteristics and shall be limited by the (1) Flaws shall be limited to when implantation following:

of cracks precludes obtaining a realistic ultrasonic response. (a) The use of Alternative flaws shall be limited to when the implantation of cracks produces (2) Flaws shall be semi-elliptical with a tip spurious reflectors that are uncharacteristic of width of less than or equal to 0.002 inches. actual flaws.

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

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (2) Overlay fabrication flaws. At least 40 No Change No Change percent of the flaws shall be non-crack fabrication flaws (e.g., sidewall lack of fusion or laminar lack of bond) in the overlay or the pipe-to-overlay interface. At least 20 percent of the flaws shall be cracks. The balance of the flaws shall be of either type.

(e) Detection Specimens (1) At least 20 percent but less than 40 percent of the flaws shall be oriented within (1) At least 20 percent but less than 40 (1) At least 20 percent but less than 40

+20 degrees of the pipe axial direction. The percent of the base metal flaws shall be percent of the base metal flaws shall be remainder shall be oriented circumferentially. oriented within +20 degrees of the pipe axial oriented within +20 degrees of the pipe axial Flaws shall not be open to any surface to direction. The remainder shall be oriented direction. The remainder shall be oriented which the candidate has physical or visual circumferentially. Flaws shall not be open to circumferentially. Flaws shall not be open to access. The rules of IWA-3300 shall be used any surface to which the candidate has any surface to which the candidate has to determine whether closely spaced flaws physical or visual access. physical or visual access.

should be treated as single or multiple flaws.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (2) Specimens shall be divided into base metal (2) Specimens shall be divided into base metal (2) Specimens shall be divided into base and and overlay fabrication grading units. Each and overlay fabrication grading units. Each over-lay grading units. Each specimen shall specimen shall contain one or both types of specimen shall contain one or both types of contain one or both types of grading units. grading units. Flaws shall not interfere with grading units. Flaws shall not interfere with ultrasonic detection or characterization of ultrasonic detection or characterization of other flaws. other flaws.

(a)(1) A base grading unit shall include at least (a)(1) A base metal grading unit shall include (a)(1) The base metal grading unit includes the 3 inches of the length of the overlaid weld. at least 1 inch of the length of the overlaid overlay material and the outer 25 percent of The base grading unit includes the outer 25 weld. The base metal grading unit includes the the original overlaid weld. The base metal percent of the overlaid weld and base metal on outer 25 percent of the overlaid weld and base grading unit shall extend circumferentially for at both sides. The base grading unit shall not metal on both sides. The base metal grading least 1 inch and shall start at the weld include the inner 75 percent of the overlaid unit shall not include the inner 75 percent of centerline and be wide enough in the axial weld and base metal overlay material, or base the overlaid weld and base metal overlay direction to encompass one half of the original metal-to-overlay interface. material, or base metal-to-overlay interface. weld crown and a minimum of 0.50 of the adjacent base material.

(a)(2) When base metal cracking penetrates (a)(2) When base metal cracking penetrates (a)(2) When base metal flaws penetrate into into the overlay material, the base grading unit into the overlay material, the base metal the overlay material, the base metal grading shall include the overlay metal within 1 inch of grading unit shall not be used as part of any unit shall not be used as part of any overlay the crack location. This portion of the overlay overlay fabrication grading unit. fabrication grading unit.

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

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (a)(3) When a base grading unit is designed to (a)(3) Sufficient unflawed overlaid weld and (a)(3) Sufficient unflawed overlaid weld and be unflawed, at least 1 inch of unflawed base metal shall exist on all sides of the grading base metal shall exist on all sides of the grading overlaid weld and base metal shall exist on unit to preclude interfering reflections from unit to preclude interfering reflections from either side of the base grading unit. The adjacent flaws. adjacent flaws.

segment of weld length used in one base grading unit shall not be used in another base grading unit. Base grading units need not be uniformly spaced around the specimen.

(b)(l) An overlay grading unit shall include the (b)(l) An overlay fabrication grading unit shall (b)(l) An overlay fabrication grading unit shall overlay material and the base metal-to-overlay include the overlay material and the base include the overlay material and the base interface of at least 6 square inches. The metal-to-overlay interface for a length of at metal-to-overlay interface for a length of at overlay grading unit shall be rectangular, with least 1 inch. least 1 inch.

minimum dimensions of 2 inches.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

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

E2-8

SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

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

To qualify new values of essential variables, at To qualify new values of essential variables, at least one personnel qualification set is least one personnel qualification set is required. required.

E2-9

SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (f) Sizing Specimen (1) The minimum number of flaws shall be ten. (1) The minimum number of flaws shall be ten. (1) The minimum number of flaws shall be ten.

At least 30 percent of the flaws shall be At least 30 percent of the flaws shall be At least 30 percent of the flaws shall be overlay fabrication flaws. At least 40 overlay fabrication flaws. At least 40 overlay fabrication flaws. At least 40 percent of the flaws shall be cracks open to percent of the flaws shall be cracks open to percent of the flaws shall be open to the inside the inside surface. the inside surface. For initial procedure surface. Sizing sets shall contain a distribution qualification, sizing sets shall include the of flaw dimensions to assess sizing capabilities.

equivalent of three personnel qualification sets. For initial procedure qualification, sizing sets To qualify new values of essential variables, at shall include the equivalent of three personnel least one personnel qualification set is qualification sets. To qualify new values of required. essential variables, at least one personnel qualification set is required.

(2) At least 20 percent but less than 40 No Change No Change percent of the flaws shall be oriented axially.

The remainder shall be oriented circumferentially. Flaws shall not be open to any surface to which the candidate has physical or visual access.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (3) Base metal cracking used for length sizing No Change (3) Base metal flaws used for length sizing demonstrations shall be oriented demonstrations shall be oriented circumferentially. circumferentially.

(4) Depth sizing specimen sets shall include at No Change (4) Depth sizing specimen sets shall include at least two distinct locations where cracking in least two distinct locations where a base metal the base metal extends into the overlay flaw extends into the overlay material by at material by at least 0.1 inches in the through- least 0.1 inches in the through-wall direction.

wall direction.

2.0 CONDUCT OF PERFORMANCE DEMONSTRATION The specimen inside surface and identification The specimen inside surface and identification The specimen inside surface and identification shall be concealed from the candidate. All shall be concealed from the candidate. All shall be concealed from the candidate. All examinations shall be completed prior to examinations shall be completed prior to examinations shall be completed prior to grading the results and presenting the results to grading the results and presenting the results to grading the results and presenting the results to the candidate. Divulgence of particular the candidate. Divulgence of particular the candidate. Divulgence of particular specimen results or candidate viewing of specimen results or candidate viewing of specimen results or candidate viewing of unmasked specimens after the performance unmasked specimens after the performance unmasked specimens after the performance demonstration is prohibited. demonstration is prohibited. The overlay demonstration is prohibited. The overlay fabrication flaw test and the base metal flaw fabrication flaw test and the base metal flaw test may be performed separately test may be performed separately.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS 2.1 Detection Test.

Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be Flawed and unflawed grading units shall be randomly mixed. Although the boundaries of randomly mixed. Although the boundaries of randomly mixed. Although the boundaries of specific grading units shall not be revealed to specific grading units shall not be revealed to specific grading units shall not be revealed to the candidate, the candidate shall be made the candidate, the candidate shall be made the candidate, the candidate shall be made aware of the type or types of grading units aware of the type or types of grading units aware of the type or types of grading units (base metal or overlay fabrication) that are (base metal or overlay fabrication) that are (base or overlay) that are present for each present for each specimen. present for each specimen.

specimen.

2.2 Length Sizing Test (a) The length sizing test may be conducted No Change No Change separately or in conjunction with the detection test.

(b) When the length sizing test is conducted in No Change No Change conjunction with the detection test and the detected flaws do not satisfy the requirements of 1.1(f), additional specimens shall be provided to the candidate. The regions containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (c) For a separate length sizing test, the No Change No Change regions of each specimen containing a flaw to be sized shall be identified to the candidate. The candidate shall determine the length of the flaw in each region.

(d) For flaws in base grading units, the (d) For flaws in base metal grading units, the (d) For flaws in base metal grading units, the candidate shall estimate the length of that part candidate shall estimate the length of that part candidate shall estimate the length of that part of the flaw that is in the outer 25 of the flaw that is in the outer 25 percent of of the flaw that is in the outer 25 percent of percent of the base wall thickness. the base metal wall thickness. the base metal wall thickness.

2.3 Depth Sizing Test.

For the depth sizing test, 80 percent of the The candidate shall determine the depth of the (a) The depth sizing test may be conducted flaws shall be sized at a specific location on the flaw in each region. separately or in conjunction with the detection surface of the specimen identified to the test.

candidate. For the remaining flaws, 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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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (b) When the depth sizing test is conducted in conjunction with the detection test and the detected flaws do not satisfy the requirements of 1.1(f), additional specimens shall be provided to 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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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS 3.0 ACCEPTANCE CRITERIA 3.1 Detection Acceptance Criteria.

Examination procedures, equipment, and Examination procedures are qualified for (a) Examination procedures are qualified for personnel are qualified for detection when the detection when all flaws within the scope of detection when:

results of the performance demonstration the procedure are detected and the results of satisfy the acceptance criteria of Table VIII- the performance demonstration satisfy the S2-1 for both detection and false calls. The acceptance criteria of Table VIII-S2-1 for criteria shall be satisfied separately by the false calls. Examination equipment and demonstration results for base grading units personnel are qualified for detection when the and for overlay grading units. results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls. The criteria shall be satisfied separately by the demonstration results for base metal grading units and for overlay fabrication grading units.

1) All flaws within the scope of the procedure are detected and the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for false calls.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (2) At least one successful personnel demonstration has been performed meeting the acceptance criteria defined in (b).

(b)Examination equipment and personnel are qualified for detection when the results of the performance demonstration satisfy the acceptance criteria of Table VIII-S2-1 for both detection and false calls.

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

3.2 Sizing Acceptance Criteria.

Examination procedures, equipment, and No Change No Change personnel are qualified for sizing when the results of the performance demonstration satisfy the following criteria.

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SUPPLEMENT 11 - QUALIFICATION CODE CASE N-653 PDI PROGRAM:

REQUIREMENTS FOR FULL The Proposed Alternative to STRUCTURAL OVERLAID (Provided for Information Only) Supplement 11 Requirements WROUGHT AUSTENITIC PIPING WELDS (a) The RMS error of the flaw length No Change (a) The RMS error of the flaw length measurements, as compared to the true flaw measurements, as compared to the true flaw lengths, is less than or equal to 0.75 inches. lengths, is less than or equal to 0.75 inches.

The length of base metal cracking is measured The length of base metal flaws is measured at at the 75 percent through-base-metal position. the 75 percent through-base-metal position.

This requirement is omitted. This requirement is omitted.

(b) All extensions of base metal cracking into the overlay material by at least 0.1 inches are reported as being intrusions into the overlay material.

(c) The RMS error of the flaw depth (b) The RMS error of the flaw depth (b) The RMS error of the flaw depth measurements, as compared to the true flaw measurements, as compared to the true flaw measurements, as compared to the true flaw depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inches. depths, is less than or equal to 0.125 inches.

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