ULNRC-03863, Requests Relief from Requirements of 1989 Edition of ASME Section IX as Detailed in Encl Relief Requests ISI-13, ISI-14,ISI-15,ISI-17 & ISI-18.Relief Requests Detail Exam Limitations Encountered During Plant Refueling Outage 9

Requests Relief from Requirements of 1989 Edition of ASME Section IX as Detailed in Encl Relief Requests ISI-13, ISI-14,ISI-15,ISI-17 & ISI-18.Relief Requests Detail Exam Limitations Encountered During Plant Refueling Outage 9

ML20236Q726
Person / Time
Site:	Callaway
Issue date:	07/10/1998
From:	Passwater A UNION ELECTRIC CO.
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
ULNRC-03863, ULNRC-3863, NUDOCS 9807210007
Download: ML20236Q726 (13)

Text

....

a Union Electric one Ameren Plaza 1901 Chouteau Avenue Po flox 66149 St. Louis, Mo 63166-6149 samt.sm 8

s July 10,1998 U.S. Nuclear Regulatory Commission Attn: Document Control Desk Mail Stop PI-137 Washington, DC 20555-0001 ULNRC-03863 MI6 g

fggg DOCKET NUMBER 50-483 UNION ELECTRIC CALLAWAY REFUEL 9 REOUEST FOR RELIEF FROM ASME CODE in accordance with 10CFR50.55a(g)(5)(iii), Callaway is requesting relief from the requirements of the 1989 Edition of ASME Section XI as detailed in attached Relief Requests ISI-13, ISI-14, ISI-15, ISI-16, ISI-17, and ISI-18.

These Relief Requests detail the examination limitations encountered during Callaway Refueling Outage 9.

Please contact us if you have any questions concerning this information.

/

f Very truly yours, t'

G~4 A. C. Passwater Manager - Corporate Nuclear Sersices JAM /DSH/RDM Attachment (12 pages)

- {^

.-ouoa 9807210007 980710 PDR ADOCK 05000483-PDR 1

e subsidiary of Amoren Corporation

cc:

M. H.

Fletcher Professional Nuclear Consulting, Inc.

19041 Raines Drive Derwood, MD 20055-2432 Regional Administrator U.S. Nuclear Regulatory Commission Region IV 611 Ryan Plaza Drive Suite 400 Arlington, TX 76011-8064 Senior Resident Inspector Callaway Resident Office U.S. Nuclear Regulatory Commission 8201 NRC Road Stc, edman, MO 65077 Kristine M. Thomas (2)

Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission 1 White Flint, North, Mail Stop 13E16 11555 Rockville Pike Rockville, MD 20852-2738 Manager, Electric Department Missouri Public Service Commission P.O. Box 360 Jefferson City, MO 65102 i

i 1

l 4

m.

__m.-._

l CALLAWAY ISI RELIEF REQUEST ISI-13 System:

Reactor Coolant System (RCS) Pressurizer Surge Line Examination Category:

B-J ltem Number:

B9.11 Component

Description:

Pipe to Pressurizer Surge Line Nozzle Safe-End Weld. This weld is identified as 2-BB-01-F004.

Code Requirement:

ASME Section XI,1989 Edition, Table IWB-2500-1, Examination Category B-J, Item No. B9.11 requires volumetric and surface examination of the weld. This is a high stress location, therefore inspection of this weld once per 10-year interval is required.

Areas for Relief:

Weld 2-BB-01-F0')4 achieved a composite coverage of 82.47% of the weld volume when including the axial exam from the safe end side and the circumferential exam.

Basis for Relief:

The limitation to the axial scan is due to four lugs welded to the pipe within the examination volume. The lugs were formerly used as anchors for a snubber that has since been removed from this line under modification package CMP 94-1019. Actual coverage achieved in each direction is listed below.

2-BB-01-F004 1

Axial Scan Coverage in two directions 64.95 %

Circumferential Coverage in two directions 100 %

The code required surface exams were also performed on these welds at this time and yielded no indications with 100% coverage.

In addition to the code required 45 scan, a 60 shear wave scan was performed on both sides of the weld to compensate for the beam redirection. The estimated coverage achieved is conservatively based on this nominal 60' angle. With beam redirection, the actual examination angle is estimated to be closer to 45 and thus yields a greater weld volume examined than was recorded. Examination l

results can be found in Callaway file E170.0100 reports 6226-98-23 l

and 6106-98-23.

1 I

It is impractical to achieve any additional weld coverage at this time, therefore reliefis requested pursuant to 10CFR50.55a(gX5Xiii).

l

(_--

f Alternate Testing:

None. The best possible examination was performed using a combination of 60' and 45' shear wave transducers. The extent of

(

l, this ultrasonic examination, the liquid penetrant surface examination, the Section XI VT-2 (visual) examination for leakage performed once every refueling outage, and the reactor coolant leakage detection system verify weld integrity.

i' s

i i

i

' i

l.

i i

CALLAWAY ISI RELIEF REQUEST ISI-14 I

l System:

Reactor Coolant System Cast Piping (BB)

Examination Category:

B-F Item Number:

B5.130 l

Component

Description:

2-BB-01-F304 and 2-BB-01-F305 are Reactor Coolant System 'C' Loop piping to Steam Generator Nozzle Welds. 2-BB-01-F304 is the Steam Generator inlet nozzle to 50 elbow weld. 2-BB-01-F305 is the Steam Generator outlet nozzle to 40 elbow weld.

Code Requirement:

ASME Section XI,1989 Edition. Table IWB-2500-1, Examination Category B-F, Item No. B5.130 requires volumetric and surface examination of all dissimilar metal welds once per 10 year interval.

The Reactor Coolant System Loop piping is cast stainless steel (SA-351 CF8A) while the steam generator nozzle is carbon steel. ASME Section XI requires 100% volumetric examination of the inner 1/3 thickness of weld metal plus the inner 1/3 of adjacent base metal for a distance of 1/4" beyond the edge of the weld crown, in addition, Article 111, Paragraph 111-4420 requires that the ultrasonic examination for reflectors parallel to the weld scam be performed using a sufficiently long examination beam path to provide coverage of the required examination volume in two beam path directions.

Areas for Relief:

A composite coverage of 69.7% of the weld volume was achieved for weld 2-BB-01-F304 and 77% of the weld volume was achieved for weld 2-BB-01-F305 for both the axial and circumferential exams.

Basis for Relief:

Scanning of the subject welds is limited on the elbow side by a steep outside diameter taper on the steam generator outlet and inlet nozzles. The elbow material is cast stainless steel (SA-351 CF8A).

Due to the high attenuative nature of this material, a refracted longitudinal sound wave is necessary to get a meaningful ultrasonic examination. A longitudinal sound wave cannot be extended to provide coverage in two beam path directions.

..-_-_m

Basis for Relief (cont):

Achieved Coverage:

}

2-BB-01-F304 l.

Parallel Scan in Two Directions 71 %

Axial Scan in Two Directions 37.02 %

Axial Scan in One Direction 62.98 %

2-BB-01-F305 Parallel Scan in Two Directions 71.87 %

l Axial Scan in Two Directions 65.03 %

Axial Scan in One Direction 34.97 %

l These welds were approved for reliefin the first ten year interval l

under Callaway ISI Relief Requests P-2 and P-3 submitted May 20, i

1994.

i l

l Based on the fact that no indications were detected, the weld integrity has been assured. Furthermore, a liquid penetrant surface examination was performed over the entire surface of the weld, l

which yielded no relevant indications. It is impractical to achieve any additional weld coverage at this time, therefore reliefis request pursuant to 10CFR50.55a(gX5Xiii).

Alternate Testing:

None. The maximum possible volume was examined as practical.

The extent of this uhrasonic examination, the liquid penetrant surface examination, the Section XI VT-2 (visual) examination for leakage l.

performed once every refueling outage, and the reactor coolant l

leakage detection system verify weld integrity.

l l

l l'

i-i l

t i

l l

l l

CALLAWAY ISI RELIEF REQUEST ISI-15 System:

Reactor Coolant System Cast Piping (BB)

Examination Category:

B-J Item Number:

B9.11 Component

Description:

2-BB-01-F301 and 2-BB-01-F307 are Reactor Coolant System 'C' Loop piping to 'C' Reactor Coolant Pump Welds. 2-BB-01-F301 is the Reactor Coolant Pump inlet weld. 2-BB-01-F307 is the Reactor Coolant Pump outlet weld.

Code Requirement:

ASME Section XI,1989 Edition, Table IWB-2500-1 Examination Category B-J, item No. B9.11 requires 100% volumetric examination of the inner 1/3 thickaess of weld metal plus the inner 1/3 of adjacent base metal for a distance of 1/4" beyond the edge of the weld crown.

In addition, Article Ill, Paragraph 111-4420 requires that the ultrasonic examination for reflectors parallel to the weld seam be performed using a sufficiently long examination beam path to provide coverage of the required examination volume in two beam path directions.

Areas for Relief:

A composite coverage of 83% of the weld volume was achieved for weld 2-BB-01-F301 and 65% of the weld volume was achieved for weld 2-BB-01-F307 for both the axial and circumferential exams.

Basis for Relief:

Scanning of the subject welds is limited due to the weld profile and the large search unit footprint. The 1" 1 Milz longitudinal transducer required to project the sound through the cast stainless steel (SA-351 CF8A) is limited by the pump to pipe configuration. Furthermore, due to the high attenuative nature of this material, a refracted longitudinal sound wave is necessary to get a meaningful ultrasonic examination. A longitudinal sound wave cannot be extended to provide coverage in two bearn path directions.

Achieved Coverage:

2-BB-01-F301 Parallel Scan in Two Directions 84.28 %

Axial Scan in Two Directions 63.72 %

Axial Scan in One Direction 36.28 %

2-BB-01 F307 Parallel Scan in Two Directions 82.76 %

Axial Scan in Two Directions 4.19 %

Axial Scan in One Direction 86.57 %

t

. Basis for Relief (cont):

Based on the fact that no indications were detected, the wc'd integrity has been assured. Furthermore, a liquid penetrant surface examination was performed over the entire surface of the weld, which yielded no relevant indications. It is impractical to achieve

)

any additional weld coverage at this time, therefore relief is requested pursuant to 10CFR50.55a(g)(5)(iii).

Alternate Testing:

None. The maximum possible volume was examined as practical.

The extent of this ultrasonic examination, the liquid penetrant surface 1

examination, the Section XI VT-2 (visual) examination for leakage performed once every refueling outage, and the reactor coolant leakage detection system verify weld integrity.

i

]

t I

I C_

1 CALLAWAY ISI RELIEF REQUEST ISI-16 System:

Reactor Coolant System Cast Piping (BB)

Examination Category:

B-J Item Number:

B9.11 Component

Description:

2-BB-01-S302-3 is the Residual Heat Re noval suction-to-RCS loop I cold leg branch connection weld.

Code Requirement:

ASME Section XI,1989 Edition, Table IWB-2500-1, Examination Category B-J, item No. B9.11 requires 100% volumetric examination of the inner 1/3 thickness of weld metal plus the inner 1/3 of adjacent base metal for a distance of 1/4" beyond the edge of the weld crown.

In addition, Article 111, Paragraph 111-4420 requires that the ultrasonic examination for reflectors parallel to the weld seam be performed using a sufficiently long examination beam path to provide coverage of the required examination volume in two beam path directions.

Areas for Relief:

A composite coverage of 23.35% of the weld volume was achieved for weld 2-BB-01-S302-3 for both the axial and circumferential exams.

Basis for Relief:

Weld 2-BB-01-S302-3 can be examined from the RCS pipe side only due to the nozzle-to-pipe branch configuration. The RCS piping material is SA-351 CF8A (cast stainless steel). Due to the highly attenuative nature of this material, a refracted longitudinal wave is necessary to get a meaningful ultrasonic exarnination. A longitudinal sound wave can not be extended to provide coverage in two beam path directions.

Achieved Coverage:

2-BB-01-S302-3 Axial Scan in One Direction 93.4 %

Additionally, a 35 refracted longitudinal scan was attempted to detect reflectors transverse to the weld. Even though the weld itself could not be examined from this direction, no indications were l

detected.

l This weld was approved for reliefin the first ten year interval under Callaway ISI Relief Request S-1 submitted May 20,1994.

l l

l l

l l

Basis for Relief (cont.):

Based on the fact that no indications were detected, the weld integrity has been assured. Funhermore, a liquid penetrant surface j

examination was performed over the entire surface of the weld, which yielded no relevant indications. It is impractical to achieve tany additional weld coverage at this time, therefore reliefis requested

)

pursuant to 10CFR50.55a(g)(5)(iii).

i Alternate Testing:

None. The maximum possible volume was examined as practical.

The extent of this ultrasonic examination, the liquid penetrant surface examination, the Section XI VT-2 (visual) examination for leakage performed once every refueling outage, and the reactor coolant leakage detection system verify weld integrity.

i 4

1 l

CALLAWAY ISI RELIEF REQUEST ISI-17 I

System:

'A' Steam Generator (BB)

Examination Category:

B-B ltem Number:

B2.40 Component

Description:

2-EBB 01 A-SEAM-1-W is the 'A' Steam Generator Bottom Head-to-Tubesheet weld.

Code Requirement:

ASME Section XI,1989 Edition, Table IWB-2500-1, Examination Category B-B, item No. B2.40 requires 100% volumetric examination of the Steam Generator Tubesheet-to-Head Weld.

Areas for Relief:

100" of the 427.07" circumferential distance is obstructed by suppo-t lugs in four locations. The lugs are integral portions of the steam generator.

Basis for Relief:

Scanning of the subject welds is limited due to four lugs that obstruct 100" of the 427.07" circumferential distance of the weld.

Achieved Coverage:

2-EBB 01 A-SEAM-1-W 0 Scan 76.6 %

45 AxialScan 76.6 %

60 Axial Scan 76.6 %

45 Circumferential Scan 76.6 %

60 Circumferential Scan 76.6 %

This weld was approved for reliefin the first ten year interval under Callaway ISI Relief Request H submitted April 11,1988.

Based on the fact that no indications were detected, the weld integrity has been assured. It is impractical to achieve any additional weld coverage at this time, therefore reliefis requested pursuant to 10CFR50.55a(g)(5)(iii).

Alternate Testing:

None. The maximum possible volume was examined as practical.

The extent of this ultrasonic examination, the Section XI VT-2 (visual) examination for leakage performed once every refueling outage, and the reactor coolant leakage detection system verify weld integrity, h

l j

-)

CALLAWAY ISI RELIEF REQUEST ISI-18 System:

Reactor Coolant System Cast Piping (BB)

Examination Category:

B-J Item Number:

B9.11 l

Component

Description:

2-EP-02-F007 is a Loop 2 Accumulator Safety injection pipe to valve weld upstream of valve BB8948B (RCS Loop 2 Cold Leg Safety injection Accumulator Check Valve).

Code Requirement:

ASME Section XI,1989 Edition, Table IWB-2500-1, Examination Category B-J, item No. 89.11 requires 100% volumetric examination of the inner 1/3 thickness of weld metal plus the inner 1/3 of adjacent base metal for a distance of 1/4" beyond the edge of the weld crown.

In addition, Article III, Paragraph 111-4420 requires that the ultrasonic examination for reflectors parallel to the weld seam be performed using a sufficiently long examination beam path to provide coverage of the required examination volume in two beam path directions.

Areas for Relief:

A composite coverage of 59.8% of the weld volume was achieved for weld 2-EP-02-F007 for both the axial and circumferential exams and 70.42% coverage for the surface examination.

Basis for Relief:

Scanning of the subject welds is limited due to a permanent energy absorption chamber that obstructs 10.5" of the 35.5" circumferential distance of the weld.

Achieved Coverage:

2-EP-02-F007 Parallel Scan in Two Directions 70.5 %

I Axial Scan in Two Directions 28%

Axial Scan in One Direction 42.5 %

This weld also required a surface examination of 100% of the circumference. 70.42% of the surface could be examined using dye penetrant method due to the obstruction of the permanent energy i

absorption chamber.

This weld was approved for reliefin the first ten year interval under l

Callaway ISI Relief Request M submitted June 28,1991.

Basis for Relief (cont):

Based on the fact that no indications were detected, the weld integrity l'

has been assured. It is impractical to achieve any additional weld l

coverage at this time, therefore reliefis requested pursuant to j.

10CFR50.55a(g)(5)(iii).

L l

m___.

_a_____

l 4..

Alternate Testing:

None. The maximum possible volume was examined as practical.

The extent of this ultrasome exammation, the liquid penetrant surface examination, the Section XI VT-2 (visual) examination for leakage

(

performed once every refueling outage, and the reactor coolant leakage detection system verify weld integrity.

i 4

1 i.

t i

i o

I

_ _ - _ - _ _ -