ML19336A698
| ML19336A698 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 10/03/1980 |
| From: | William Jones, Keyes D OMAHA PUBLIC POWER DISTRICT |
| To: | |
| Shared Package | |
| ML19336A692 | List: |
| References | |
| NUDOCS 8010300508 | |
| Download: ML19336A698 (30) | |
Text
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^ January,1980, ISI '
Attachments, pg iii
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Part 1: pgs iv, y, and 1-19 , Part 2: pg i, 1-5 j l j FOlut NIS-1 OWNERS
- DATA ItEPORT FOR INSERV!CE INSPECTIONS As required by the Provisions of the ASME Code Rules 4
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. o wnet Omaha Public Power District, 1623 Harney. Omaha. NE 68_102
. (Name and Address of Owner) l i 2.eunt Fort Calhoun Station. P.O. Box 98. Eort Calhoun. NE 6&O23 . d (Name and AdJress of Phnt) j 3. Plant Unit No . 1 4. owner Certincate of Authorization (if required)
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- 5. Commercial Service Date 9-26-73 6. National Board Number for Unit i
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- 7. Components inspected i Manufacturer
] Component or Manufacturer or Installer State or National j Appurtenance or Installer Scrial No. Province No. Board No.
- l 3 RPV CF 66111 20828
- RPV Closure Head CF _66211 2nR7R 1
i RP_V Bolting CE l RC Pump Bolting Byron Jackson 671-N-0029 thru _P_iging_(see attachmentL fi
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1 i 4 l Notc; Supplement.d sheets in fome of lists, sketches, or drawings may 1.c used provided (1) sire is 8% in. x lI in.,
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(2) infornm;en in ittms I through 6 on this data repori :s included on cash sheet, and (3) rach sheet as numbered as.J the number of sheets is recorded at the top of this form. I
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Omaha Public Power District,1623 Harney St. , Omaha, NE 68102
. Fort Calhoun Station-Unit 1, P.O. Box 98, Fort Calhoun, WE 68023 Commercial Service Date - 9/26/73
! ABSTRACT An inservice examination (IS!) of selected components of Fort Calhoun Station Unit 1 was perfonned during the January-February 1980 refueling outage. This ISI was the third ISI of the second 40-month period of commercial operation. The coaponer.ts were examined in accordance with the " Project Plan for the 1980 Inservice Examination of Fort Calhoun Station Unit 1." PART 1 The nondestructive examinations were performed using visual (VT), liquid pene-trant (PT), magnetic particle (MT), manual ultrasonic (UT), and mechanized ultrasonic (Mech UT) techniques. The MT examinations revealed reportable indi-cations on one closure head stud and four closure head nuts. These indications were reported to Omaha Public Power District (0 PPD) on Customer Notification Forms (CNFs), and were evaluated and accepted "as is" by 0 PPD. The manual UT i examinations revealed only insignificant and geometric indications. The Mech UT examinations revealed only insignificant indications. The VT and PT exam-inations revealed no recordable indications. PART 2 In addition to the above examinations, SwRI was requested to perform VT, MT, and UT examinations of Reactor Coolant Pump Case Bolting by OPPD personnel. Several VT and MT indications were reported to OPPD personnel on CNFs. SwRI also performed VT, MT, and UT examinations on the spare and replacement bolt-ing. The examination results are contained in the special report " Reactor Coolant Pump Case Bolting Examination at Ft. Calhoun Station Unit 1", July 1980. iii
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Omaha Public Power District, 1623 Harney St., Omaha, NE 68102 .
. Fort Calhoun Station - Unit 1, P.O. Box 98, Fort Calhoun, NE 68023 Commercial Service Date - 9/26/73 PART 1 TABLE OF CONTENTS Page VOLUME I - FINAL REPORT WITH APPENDICES LIST OF ABBREVIATIONS.............................................. v I. INTRODUCTION................................................ 1 A. Examination Areas...................................... 1 B. Summary of Examination Results......................... 1 C. Mech UT Discussion..................................... 3 II. DETAILS OF THE INSERVICE EXAMINATION................. ...... 4 A. Equipment.............................................. 4 B. Radi a ti o n Exposu re . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 C. Explanation of Fie ld Data Records. . . . . . . . . . . . . . . . . . . . . . 6 D. Summary of Nondestructive Examinations. . . . . . . . . . . . . . . . . 7 E. Summary Table.......................................... 12
- 1. Reactor Pressure Vessel and Closure Head. . . . . . .. . . 13
- 2. Piping - Class 1.................................. 15
- 3. RC Pumps.......................................... 16
- 4. Piping - Class 2.................................. 17
- APPENDICES A. Class 1 Weld Identi fication Figures . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Class 2 Nonexempt Weld Identification Figures. . . . . . . . . . . . . . . . . C. Southwest Research Institute Nondestructive Testing Proceduras.................................................. D. Southwest Research Institute Nuclear Projects Operating Procedures........................................ E. Ultrasonic Calibration Block Drawings, Certifications and Sketches................................................ F. Certi fications of Personnel Quali,fications . . . . . . . . . . . . . . . . . . . . G. Material and Equipment Certifications......................... H. I E C i rcu l a r No . 76-06. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I. Mechanized Scan Plan (Text and Tables 0nly) . . . . . . . . . . . . . . . . . . .
- VOLUME II - FIELD DATA Class 1 Components and Systems..................................... I Reactor Pressure Vessel and Closure Head......................
Piping........................................................ Reactor Coolant Pumps......................................... Class 2 Piping..................................................... Ca l i b ra t i o n Reco rd s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- NOTE: Appendices A through I and Volume II - Field Data are not included in this report. They are available for inspection at the Fort Cal-houn plant site or the Operations Technical Support Services office.
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Omaha Public Power District,1623 Harney St., Omaha, NE 68102 .
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Fort Calhoun Station - Unit 1 0 P.O. Box 98, Fort Calhoun, NE 68023 Commercial Service Date - 9/26/73 PART 1 LIST OF ABBREVIATIONS ASME - The American Society of Mechanical Engineers ASNT - The American Society for Nondestructive Testing, Inc. CCW - Counterclockwise CNF - Customer Notification Form CRT - Cathode Ray Tube CSS - Containment Spray System Line CW - Clockwise OAC - Distance Amplitude Correction Deg - Degree (s) FSH - Full Screen Height HAZ - Heat-Affected Zone HPSI - High Pressure Safety Injection Line ISI - Inservice Examination Lo - Zero Reference Location mR - Millirem Mech UT - Mechanized Ultrasonic Examination MT - Magnetic Particle Examination NDT - Nondestructive Testing 0 PPD - Omaha Public Power District PT - Liquid Penetrant Examination QA - Quality Assurance RC - Reactor Coolant RL - Refracted Longitudinal . RPV - Reactor Pressure Vessel SDC - Shutdown Coolant Line SI - Safety Injection System SwRI - Southwest Research Institute ; l UT - Ultrasonic Examination VT - Visual Examination l l l l l v
Onaha Public Power District, 1623 Harney St.c Omahao NE 68102 A -
- Fort Calhoun Station - Unit 1, P.O. Box 98, Fort Calhoun, NE 68023 Commercial Service Date - 9/26/73 i
1 PART 1 I. INTRODUCTION During the January-February 1980 refueling outage, Southwest Research Institute (SwRI) personnel performed nondestructive examinations of selected Class 1 and Class 2 components in Omaha Public Power District's (0 PPD) Fort Calhoun Station Unit 1. These examinations constituted the third inservice examination (ISI) of the second 40-month period of commercial operation. ! A. Examination Areas The ISI was performed in accordance with the following documents: (1) Section XI of the American Society of Mechanical Engineers (ASME) . Boiler and Pressure Vessel Code, " Rules for Inservice Inspection of ' Nuclear Power Plant Components," 1974 Edition, including Addenda through Summer 1975. , (2) Fort Calhoun Station Unit 1 Technical Specifications. (3) " Project Plan for the 1980 Inservice Examination of Fort Calhoun Station Unit 1," prepared by SwRI. (4) IE Circular No. 76-06 " Stress Corrosion Cracking in Stagnant Low Pressure Stainless Piping Containing Boric Acid Solution at PWR's." Representative samples of the components and/or areas in the following list were examined with nondestructive testing (NDT) techniques: Class 1 (1) Reactor Pressure Vessel and Closure Head . (2) Reactor Coolant Piping (3) Reactor Coolant Pumps
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(4) Pipit.g Systems Class 2 (1) Pipirg Systems B. Summary of Examination Results The nondestructive examinations were perfonned using visual (VT), magnetic particle (MT), liquid penetrant (PT), manual ultrasonic (UT), and mechanized ultrasonic (Mech UT) techniques. The various examinations were conducted in accordance with standard SwRI NDT procedures which.were written to conform to the requirements of the applicable sections of the ASME Boiler and Pressure Vessel Code and the SwRI Nuclear Quality Assurance Program Manual. A copy of each applicable SwRI NDT procedure is included in Appendix C. The mechanized
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Omaha Public Power Districto 1623 Harney St., Omaha, NE 68102 Fort Calhoun Station - Unit, P.O. Box 98, Fort Calhoun, NE 68023 Cc:nmercial Service Date - 9/26/73 PART 1 examination equipment was operated in accordance with the SwRI " Plan for Mechan-ized Ultrasonic Examination of Selected Components at Fort Calhoun Station Unit 1," (Scan Plan) the text and tables of which are located in Appendix I. Five examination areas exhibited MT indications which were reported to OPPD personnel on Customer Notification Fonns (CNFs) for disposition. These MT in-dications were observed on closure head stud No. 17 and on closure head nut Nos. 3, 9, ll, and 13. They were evaluated and accepted "as is" by 0 PPD personnel . No other MT indications were observed. The mechanized UT examinations revealed insignificant indications in the nozzle inside radius sections. The manual UT examinations revealed insignifi-cant indications in one 12-inch containment spray system weld plus insignifi-cant and geometric indications in one 6-inch safety injection line weld. No other recordable ultrasonic indications were observed. The VT and PT examinations revealed no recordable indications. In addition to the above examinations, SwRI was requested to perform VT, MT, and UT examinations of Reactor Coolant Pump Case Bolting by OPPD personnel. Sev-eral VT and MT indications were reported to OPPD personnel on CNFs. SwRI also performed VT, MT, and UT examinations on the spare and replacement bolting. The examination results are contained in the special report " Reactor Coolant Pump Case Bolting Examination at Ft. Calhoun Station Unit 1", July 1980. Test data (instrument calibration records and examination data) for examina-tions were recorded on standard SwRI forms. A copy of each of the instrument calibration records and examination data sheets completed on site is included in the field data of this report. The SwRI examiners were qualified and certified in accordance with estab-lished SwRI personnel certification procedures and the SwRI Nuclear Quality Assur-ance Program Manual, which comply with the guidelines of SNT-TC-1 A, American So-ciety for Nondestructive Testing, Inc. Personnel Qualification Certifications are in Appendix F. , Operating Procedures governing the weld joint identification marking on nu-clear power plant components and measuring and recording search unit location and maximum signal amplitude data during ultrasonic weld examinations and data from VT, PT, and MT examinations are located in Appendix D. The SwRI Quality Assurance Section was represented on site by an SwRI Quality Assurance (QA) representative, who was present for approximately 50 percent of the examination period. The QA representative performed the appropriate duties outlined in Section 3.3.l(4), "0nsite Quality Assurance Activities," of the " Pro-ject Plan for the 1980 Inservice Examination of Fort Calhoun Station Unit 1."
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Omaha Public Power District,1623 Harney St., Omaha, NE 68102 l
- Fort Calhoun Station - Unit 1, P.O. Box 98 Fort 0 Calhoun, NE 68023 Commercial Service Date - 9/26/73 PART 1 l
C. tiech UT discussion The mech UT examinations were limited by structural obstructions in the examination areas plus some limitations caused by the extreme curvature of cer-tain areas of the nozzle-to-vessel blend areas where the device wall-following capability was exceeded, These mechanized equipment limitations have now been eliminated for future cutside surface examinations by additional equipment modification. In any case, none of these limita+ 'ns, structural or equipment, will apply to the mechanized examinations sched. +a to be performed from the inside surfaces of the RPV and nozzles during trie 1982 outage. Those examira-tions will provide complete coverage of all Code-required RPV examination areas
'for the first inspection interval.
The structural obstructions made the upper 1/8 and lower 1/3 of the nozzle-to-shell weld and inner radius sections and the lower 1/4 of the nozzle-to-safe end and safe end-to-pipe welds inaccessible. See the Scan Plan (Appendix I) and the field data sheets (Volume II) for details of the examina-tions performed. i i 1 1
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__ - Omaha Public Power District,1623.Harney St., Omaha, NE 63102 Fort Calhoun Station - Unit 1, P.O. Box 98 Fort0 Calhoun, NE 68023 Commercial Service Date - 9/26/73 1 l
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PART 1 1
- II. DETAILS OF THE INSERVICE EXAMINATION J
4 l This section of the report provides a description of the equipment used during - the ISI, a listing of approximate radiation exposure levels encountered during
- the ISI, and a summary of the nondestructive examinations.
i i A. Equipment l t 1. Ul trasonic !
- a. Manual. Sonic FTS Mark I ultrasonic instruments were used for the manual UT examinations. These instruments were also used as necessary for i thickness gauging or materials and as an aid in determining the acoustic characteristics / properties through measurement of the transmission and attenua-tion of ultrasound in the materials.
i ) b. Mechanized. Sonic Mark II UT instruments were used for the Mech UT examinations. Recording of the mechanized data was accomplished by j using the SwRI Data Acquisition System, which simultaneously recorded test data i from two separate ultrasonic search units. Gating and positioning circuits i were incorporated into the system to provide reflector location and amplitude information. These data were permanently recorded on a six-channel Brush 260 i strip chart recorder and an Ampex Model PR500 Recorder / Reproducer, while the ! CRT presentations of the three Sonic Mark II's were videotaped. The SwRI Data i Acquisition System is explained in more detail in the " Mechanized Examination Devices" section.
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- c. Transducers. Various brands, sizes, types, and frequencies of '
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ultrasonic transducers (search units) were used to perform the examinations. > Certification 1or the transducers used for the Fort Calhoun Unit 1 ISI can be found in Appendix G. For information on the actual transducer used for any , specific examination, consult the data sheets and referenced calibration sheets
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in the field data volume of this report.
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- 2. Mechanized Examination Devices
- a. Butt Weld Inspection Device. The SwRI Butt Weld Inspection Device (BWID) was used to examine the 24-in. nozzle-to-safe end welds adjacent to the reactor pressure vessel. The BWID, which operated on the pipe track, was placed onto the track manually and operated entirely by remote control. A module con-taining two ultrasonic transducers was utilized as required by specific scans.
- Scans were accomplished by setting the module a predetermined distance from the track and then driving the BWID around the pipe. Successive scans were then made in either the clockwise or counterclockwise direction around the pipe by moving the module a predetermined incremental distance alor. the pipe after
- each scan. The position of the device on the track was displayed on a digital counter to the operator and recorded by the Data Acquisition System. A zero reference at the top of the pipe was obtained from a sensitive leveling device i on the BWID itself. Deionized water (the acoustic couplant) was supplied through I
the control cable to the search units from a pressurized container. I 1 ! 4 i i
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_ l' Omaha Public Power District,1623 Harney St.o Omaha, NE 68102 ' Fort Calhoun Shtion - Unit 1, P.O. Box 98, Fort Calhoun, NE 68023 Commercial Serbice Date - 9/26/73 PART 1
- b. Nozzle-to-Shell and Nozzle Radius Inspection Device. The SwRI Nozzle-to-Shell and Nozzle Radius Inspection Devi:es were used to examine the attaching weld and the inside radius areas, respectively, of the two 24-in, reactor coolant inlet nozzles of the reactor pressure vessel. These devices were redesigned especially for use in the annulus between the reactor pressure vessel and its insulation at Fort Calhoun Station. They were mounted manually on the permanently installed pipe track on the nozzle and operated by rr te control. Each device was fitted with appropriate search unit modules fe, the specific examination being performed. The modules contact the examination area at a preselected reference point, and the required scans were accomplished by driving the device around the track; the module was moved a prescribed dis-tance (in or out) between scans. The positions of the device and its module were displayed to the operator and recorded by the SwRI Data Acquisition System along with the ultrascriic data. A zero-degree reference position with relation to the top of the nozzle was obtained from a sensitive leveling instrument on the h vice. Deionized water (the acoustic couplant) was supplied through the control cable to the search unit i.'odule from a pressurized container.
- c. SwRI Data Acquisition System. The SwRI Data Acquisition System is a portable, compact, modular system designed for rapid and accurate recording and/or processing of ultrasonic test infomation obtained during mechanized ex-aminations. The information may be either preliminary baseline data obtained during a preoperational examination or data gathered on an inservice examination to be used for comparison or correlation.
In general, information obtained from ultrasonic examinations was processed by the SwRI Data Acquisition System in the following manner. Signal information from each of the ultrasonic testing instruments was displayed on the appropriate CRT for each instrument. Amplitude and time analog infomation was channeled through electronic gates and examined according to preselected levels. For the signals which exceed these levels, calibrated voltages were generated which were analogous to the ultrasonic signal amplitude and the sound beam distance to the reflector. The time analog and amplitude analog voltages corresponded to the first triggering signal encountered along the sound beam and the signal with the largest amplitude, respectively. The SwRI Data Acquis-ition System processed information from three ultrasonic testing instruments si-mul taneously. This system produced the following types of examination records for the Fort Calhoun Station Unit 1 1980 ISI:
. Vidcotape
. Strip Chart Analog Tape A requirement of every test, the TV viodeotape recording provided a continuous record of all infomation displayed on the CRT units and the ana-log-to-digital display. Thus, it furnisbd an accurate record of the informa-tion which can be used as an interpretative tool for the other record forms, and it also orovided a redundant backup examination record.
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Omaha Public Power District,16?3 Harney St., Omahao NE 68102 Fort Calhoun Station - Unit 1. P.O. Box 98, Fort Calhoun o NE 68023 Commercial Service Date - 9/26/73 PART 1 The six-channel strip chart recording provided a "hard copy" of i test data for the gated regions of the three ultrasonic testing instruments. . Transducer module position was also recorded, providing correlation with other data record. Analog tape recording of test data allowed the largest degree of freedom for the SwRI Data Acquisition System. It may be used in place of, or in addition to, the strip chart recorder of tb 3 computer. Either of the latter two records can be generated from the analog tape recording. B. Radiation Exposure Radiation exposure encountered during the ISI was of fundamental concern to all SwRI personnel involved during the daily examination activities. SwRI personnel took the necessary precuations in order to minimize overall exposure and consequently received the minimum dosage practicable while performing the selected examinations. The following listing details the approximate radiation exposure levels associated with various examination areas. ' Radiation Exposure LE/els Area Exposure RPV Flange Ligaments 300 mR/hr RPV Nozzles (in sand boxes) 400-900 mR/hr
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RPV Head Interior (Cladding) 2-3 R/hr Containment Air Lock Level 5-20 mR/hr Containment Lower Level 10-25 mR/hr 12" LPSI Piping 100-150 mR/hr Reactor Coolant Pumps 80 mR/hr Auxiliary Building 5-50 mR/hr C. Explanation of Field Data Records The results of NDT examinations and calibrations performed by SwRI person-nel were recorded on standard SwRI forms. These completed documents consti-tute a portion of this Report. The original records are retained in the SwRI Data Storage Facility, and copies are provided herein for completeness.
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The field data records for each weld or area are assembled into a package preceded by a Sumary Sheet. The examination areas and summary sheet numbers l correspond to those listed in the Summary Table. A general explanation of the individual field data forms follows.
- All instruments used in performing UT examinations were calibrated prior to use, then verified again at specified intervals during the
examinations and upon completion of the examinations. The calibration parameters were recorded on the appropriate calibration record sheet as specified in the applicable NDT procedure. The documented calibra-tion and calibration verification provide immediate assurance that the examinations were performed using properly calibrated instrements. l 6 _
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! Omaha Public Power District, 1623 Harney St., Omahae NE 68102
- Fort Calhoun Station - Unit 1, P.O. Box 98o Fort Calhouna NE 68023 i
Commercial Service Date - 9/26/73 PART 1
- The results of manual UT examinations were recorded on the applicable data record sheets 3s specified in the appropriate NDT procedure. The information documented on these forms describes the parameters associ-ated with those indications which were greater than the recording levels specified in the applicable NDT procedures. Mech UT data was recorded manually and, also, as discussed in Paragraph 2.c. of Section A above.
- When required, the size, lcoation, and nature of reflectors were deter-mined analyzing the indication parameters recorded on the forms
- descr1Deu above. The analysis is documented on SwRI Indication Reso-i lution Record Sheets, which are included as a part of each affected data package.
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! Visual, Liquid Penetrant, and Magnetic Particle Examination Record Sheets were used to record the results of those examination. The
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equipment and/or materials used in VT, PT and MT examinations are also i identified on the record sheets.
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D. Summary of Hondestructive Examinations The following sections of the report are presented for explanation of the
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Summary of Nondestructive Examinations Table (Summary Table). The Summary Table provides infonnation and results for the nondestructive examinations per-i formed during the Janaury
- ebruary 1980 outage.
] 1. ASME Section XI Item No. and Category , The ASME Section XI Item No. and Category are listed in the first aA 7 second columns respectively. ,
- 2. Examination Area Identification Column a
In the column " Examination Area Identification," each area, component, , or weld is designated with a unique alphanumeric code. Each area, component, or weld which was examined is listed in the following manner.
- a. Pressure Retaining Vessels, Pumps and Valves i The examination areas for these components are listed by the gen-eric terms which specifically identify the area, component, or weld examined.
These terms, such as " Nozzle-to-Shell Weld at 2400," are self-explanatory and are exclusive to that area, component, or weld. In addition to genaric names, weld numbers are used wherever possible. ,
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! b. Class 1 Piping l i i The Class 1 piping welds examined during this ISI are identified i by nominal pipe size, function, and line number within the systems, which are abbreviated functionally as follows: RC - Reactor Coolant System i 7 '
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Omaha Public Power District,1623 Harney St.o Omaha oNE 68102
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Fort Calhoun Station - Unit 1 0 P.O. Box 980 Fort Calhoun, NE 68023 ' Commercial Service Date - 9/26/73 PART 1 Weld Identification Figures (Appendix A) identify component welds and piping weld locations along with other information pertinent to the perfonnance of the ISI. Line numbering and designations for Class 1 are un-changed from those used for the baseline examination and are exphined in the 10-Year examination plan, p f c. Class 2 Piping l l Weld Identification Figures (Appendix B) identify component welds and piping weld locations along with other information pertinent to the per-formance of the ISI. For the Class 2 piping systems, the designation system consists of several parts: (1) The first character set is one or two digits indicating nominal pipe size. (2) The second set, of two to four letters, identifies the j system by an abbreviation of its functional name. The abbreviations for the lines examined during this ISI are listed below: SDC - Shutdown Coolant System Line SI - Safety Injection System Line CSS - Containment Spray System Line i HPSI - High Pressure Safety Injection System Line (3) The tnird set consists of a unique line number. The first digit is a "2," signifying Class 2. The second digit is a "0." The third and fourth digits assure uniqueness. (4) The fourth set is usually a 1- or 2-digit number identify-ing a specific circumferential weld. Items such as pipe supper:s, etc., are identified by adding initials to the number of the circumferential wcld directly upstream. For example, PR is a pipe restraint downstream from circum-ferential weld No. 4. If there are successive components between circumferential welds, a /ifth set will be added to identify them sequentially ei'h clockwise from zero refer- l ence location (LO) or in the direction of flow, as appropri- 1 ate. 1 (5) R;, cesentative examples are as follows (see Appendix B, Figure B-36): (i) 24-SI-2001-6 is the sixth circumferential weld in sequence c n Class 2, 24-in. Safety Injection Line No. 2001. , l 8
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_. - _ _ _ _ _.- _ _ . _ . . _ _ _ ._. - __ ' Ouaha Public Power District, 1623 Harney St., Omaha, NE 68102 '
- Fort Calhoun Station - Unit 1, P.0 Box 98, Fort Calhoun, FE 68323 Commercial Service Date - 9/26/73 i
! PART 1 i I (ii) 24-SI-2001-6-PR-2A is the second pipe restrainst down- ', strea.n from weld No. 6 referred to in (i) above. Since this pipe restraint has two support components, j their numbers are PR-2A and PR-28,respectively. 4 l
- 3. Examination Method Column
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- a. Visual (VT)
' Areas requiring VT were examined in accordance with SwRI Proce- . dure NDT-900-1, R?v. 46, or NDT-900-4, Rev. 22. These SwRI procedures include l those guidelinas wtlined in Paragraph IWA-2210 of Section XI and specify
! methods of documenting indications,
- b. Liquid Penetrant (PT)
PT examinations were performed in accordance with SwRI Procedure NDT-200-1, Rev. 47, using a visible red-dye penetrant. PT material certifica-
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tions are in Appendix G.
- c. Magnetic Particic (MT)
MT examinations were perfonned in accordance with SwRI Procedure NDT-300-2, Rev. 27, using the fluorescent magnetic particle method. MT mater- ' ial certifications are in Appendix G. 4
- d. Ultrasonic (UT)
. The specific UT procedures employed in any particular examination
- covered in this report are found in Appendix C.
t i Each weld was subjected to examination scans as discussed in the following subsec. ions. Exceptions to these scans were usually due to area / component config reations and/or inaccessibility. l (1) ' ongitudinal Attenuatiori. The base metal adjacent to piping welds was examined with a straight-beam search unit in order to determine the , relative sound transmission characteristics of the base metal and the calibra-tion standard. Attenuation measurements were not taken on clad materials. ' (2) Examination Scans (a) Straight Beam Lamination Scan (00L). A 0-degree (deg)
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longitudinal wave was used to examine the base metal adjacent to the welds to determine the existence of any laminations or inclusions which, if present, j would cast " shadows" which could prevent sound beam access to all or part of the welds and/or could affect the interpretation of the examination results (see Paragraph I-2' 'd of Appendix I to Section XI,1974 Edition, and Paragraph t T-534.3 of Article 5, Section V). < 9
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Omaha Public Power District,1623 Harney St., Omaha WE o 68102 Fort Calhoun Station - Unit 1o P.O. Box 98, Fort Calhoun, NE 68023 Commercial Service Date - 9/26/73 l
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(b) Straignt Beam Longitudinal Wave Weld Scan (00W). Where physical configuration prohibited shear wave examinations from one side of piping welds, a 0-deg longitudinal wave examination was performed from the surface of the weld whenever poss*ble. 0-deg longitudinal wave examination was performed on vessel welds unless the accessibility and/or configuration prevented the examination. The examinations are used to determine the exis-tence of any reflectors in the weld positioned parallel to the weld surface (see Paragraph I-2310 of Appendix I to Section XI, and Paragraph T-536 of Article 5, Section V). The 00W scan requirement is not applicable to welds in material 0.40 inches or less in thickness, per SwRI's NDT procedure for thin wall pipe examinations.
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(c) Straight Beam Scan (00). In the case of the RPV flange ligaments, a 0-deg straight beam examination was performed from the RPV seal surface. This type of examination was also used for examination of the clos-ure head nuts. (d) Angle Beam Scans (450, iSOT, 600, 600T, 290RL, and 450RLT). Each weld was examined using 45- and 60-deg shear waves, as required, to determine the internal characteristics of the weld metal and, when required, the adjacent base metal for at least 1/2 thickness beyond the edge of the weld. Whenever possible, examinations were perfomed from both sides of the weld using the required test angles. In addition, a transverse scan (applied along the weld to detect any reflectors oriented " transverse to the weld") using a 45-deg shear wave search unit was performed whenever possible. The use of these techniques is denoted by "450T" in the Summary Table. For vessel welds a 60-deg transverse scan (600T) was also perfomed whenever possiMe. Optimum coverage of the RPV nozzle inside radius sections was obtained Ij use of a 290
- refracted longitudinal wave beam (290RL).
A 60-deg shear wave was used to examine the closure studs from the heater hole utilizing the SwRI stud probe. This technique is designed to detect radial flaws propagating from the outside surface of the studs in the threaded areas. i
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Procedure Identification Column
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The column titled "SwRI Procedure No./Rev." lists the SwRI NDT Proce-dure that was used for each examination.
- 5. Summary Sheet Column The column titlec. Summary Sheet No." references the summar s sheet pro-vided for each examination area. The summary sheets are included in the Field Data volumes. In addition to summarizing the results of the examinations, the i
summary sheets list the record sheet numbers, the SwRI examiners, dates of the examinations, and resolution sheet numbers.
, 6. Indications Columns The four columns under the general heading of " Indications" are "No Recordable," " Insignificant," " Geometric," and "Other." These columns were used as required, and their general description is provided below. .
10
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- .- . . _ -
Omaha Public Power District, 1623 Harney St.o Omaha, NE G8102 - Fort Calhoun Station - Unit 1, P.O. Box 98, Fort Calhoun, NE 68023 Commercial Service Date - 9/26/73 PART l The results for the VT, PT, and M examinations are indicated by an "X" in the appropriate column to be either "No Recordable" or "Other." The term "Other" is used when indications are observed that exceed the recording requirements of the applicable procedure. The results of the UT examinations are indicated by recording the angle of the ultrasonic search unit under the column heading which describes the test results for that angle, i.e., the "No Recordable," " Insignificant,"
" Geometric," or "Other" column.
In the performance of the UT examination, the uata recording level was established by the applicable NDT procedure. The term "No Recordable" was applied when no indications were observed greater than the recording level and no indications were observed between 20 percent of the Distance Amplitude Correction (DAC) curve and the recording level @ich were suspected by the Level II examiner to be other than geometric in nature.
" Insignificant" was applied when (1) the amplitude of any indication observed was equal to or greater than the recording level, but less than 100 percent of the DAC curve, or (2) nonrelevant indications, such as reflections due to standing waves, trapped glycerine, etc., were observed.
" Geometric" indications are (1) those indications whici. have an ampli-tt a equal to or greater than 100 percent of the DAC curve, and have been resolved and documented to be geometric in nature, or (2) indications that are less than 100 percent of the DAC curve but were suspected by the Level II exam-iners to be other than geometric in nature, and were then resolved and docu-mented to be geometric in nature.
Indications that are geometric in nature are those resolved as due to a reflection from a geometric feature of the wc.E ar component such as " root" geometry, " crown" geometry, "i..:ide surface" geometry, or "outside iurface" geometry. An indication due to " root" geometry is one in which the ultrasonic wave is reflected by the root geometry of the weld bead; " crown" geometry indications occur when the ultrasonic wave reflects off the inside surface of the examination area, strikes the crown of the weld, and .is returned to the transducer; "inside surface" geometric indications occur when the internal surface of the examination area of the weld fitup contains an angular plane sufficient to reflect a portion of the ultrasonic beam back to the transducer; and "outside surface" geometric indications occur when the ultrasonic wave reflects off the inside surface of the examination area, strikes the outside surface of the examination area, and is returned to the transducer. Figures 4 and 5 illustrate typical " crown" and " root" indication paths respectively.
"Other" indications include those indication 3 evaluated to be other than " Insignificant" or " Geometric" indications, as described above. No such indications were reported during this ISI.
The resolution of each " Geometric" and "Other" indication was docu- ' mented on SwRI Indication Resolution Records and included with the weld data l 11 i
._ _ - . _
._- _.__.._ ~- - . _ . , . _ . - - _ . - . - , , _ .
. _ . . _ _ _ _. _ . . _ _
I 0maha Public Power District,1623 Harney St., Omaha, NE 68102 i - Fort Calhoun Station - Unit la P.O. Box 98, Fort Calhoun, NE 68023 , Commercial Service Date - 9/26/73 PART 1 i l t package. These records are listed by serial number along with the appropriate examination data sheets on the summary sheet for that component. i ,
- 7. Remarks Column 4
The "Rcmarks" column is used to provide additional information perti-
- nent to the examination results
- When complete coverage of the examination area was not possible, I the " Remarks" column was used to indicate the limitations.
!
- For VT, PT, and t1T results reported in the "Other" column, a j brief description is given in the " Remarks" column. (Therewere no VT, PT, or UT indications reported in the "Other" column.)
!
- For UT examination results reported in the " Geometric" or "Other" columns, a brief description of the resolution of the indication is presented in the " Remarks" column.
- Reference is made in the " Remarks" column to CNFs used in the reporting of indications.
.
- The required UT calibration block number is listed in the
! " Remarks" column for the applicable examination.
]
) E. Summary Table The Summary Table is included from pages 13 through 19 of this report.
i i i
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;
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. _ _ . - ._ _ _ _ __ __ _ _ _ _ . _ . . _. -_
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' REACTOR PNFSSURE VESSFt. AND Cl.OSURE HEAD (See Figures A-1 and A-2a) M{
^ '" ^ " "U E x AMINATION E x Af. HEMARKS d. w C SLC al SEC xl PnOctDunE EX AM SUM I I E M NO CAIGY ARE A BOENIIFICAllON MElllOD NO /H E V. Sitt t f NO. t40 HECOnDADL E INS 8GNIF ICAN I GI OME I HIC OlllEH S,[ [
C
- m3 n N0ZZl.ES m 7MO n' Bl.4 D-D N-2-C Nozzle-to-P ell Weld at
, Mech L'T 700-6/4 300051 0*L,0*W,45*,
45*T,60*,60*1 Examination limited due to structural obstructions and area configuration. I$k QMq 240* Il-CSCI.-5-FCL o O3 0 b Bl.4 B-D N-2-C Hech UT 700 5/3 300002 29*RL Examination limited due to structure' ni N obstructions and area configuration. O M B ' In:iide Radius Section IR-CSCI-2-FCL M e h.)O. a o St.4 B-D N-2-D Hech UT 700-6/4 300053 0*L,0*W,45*, Examination limited due to structural k . {
'
Nozzle-to-Shell Weld at 45'T,60*,60*1 obstructions and area configuration. g" 300* I l -CSC L FCI. % m N *O N Bl.4 B-D N-2-D Hech UT 700-5/3 300004 29*RL Examination limited due to structural b Inside Radius Section obstructions and area configuration. *g IR-CSCL-2-FCL cu 5 O3 NOZZLE-TO-SAFE END WFl.DS *k to 8-F N-2-C at 240' PT 200-1/47 3000f>5 X F.xamination ilmited due to structural . Bl.6 (RC-24-30) Mech UT 700-5/3 0*L,0*W obstructions and nozzle configura- - 45*RL, ttou. [* 45*T RL 3-CSCL-8-FCI. and 24-SSCL-2.406-10-FCL
"{m 1
OT Bl.6 8-F N-2-D at 300* PT 200-1/47 300006 X Examination limited due to structurni ." (RC-12-18) Mech Ur 700-5/3 0*L,0*W, obstructtons an.1 nozzle contigura- g, 45*RL, tion. cR 45'T RL 3-CSCL-8-l'CI. and 3 24-S50L-2.40( 101. *$
=- -
rri O m _BO L.T l HC-Bl.8 B-C-1 Closure ficad Stude Pfr 300-2/27 300007 X Fxamined studs 3,6,7,R,9,10,11,14' O UT 600-13/20 60* 15,16,17,18,20,22,23 and 27. HT in- N
"
dications on stud No. 17, evaluated and accepted "as is" tiy OrfD per-annuel. See CNF 000). 6.125-1.125-8-0S-5 1:xa.alned nut e 3,6,7,8,9,1Q,11,14,15 c 83.6 8-C-l Closure licad Nute HT UT 300-2/27 100008 600-19/20 0*,45* X 16,17,18,20,22,23 and 27. HT in.ft-cations on nute 3 (5,e CNF 0001),9, y
-4 Dev. 2 11 and 21 (6ee CNF 0002). Evaluated ,
and accepted "as i s" ley Ol'i'D pe r - sonnel. 9.125-6-8-CS-5 and u 6.125-1.125-8-CS-5
-
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-- - - - . _ ~ - -. . _ . -~ _ . -- . . -. .- ~ . - - . .
FORT cal.IlullN STATION UNIT I 1980 INSERVICE EXf NINATION - CIASS I , SUlittARY OF NONDESTRUCTIVE EWIINATIONS lit %C10R COut. ANT PtfMPS - St C xi Stc. xi (M AMINATION (KAM PHOLEDuitL E X AM. SUM
~~
'
REMAHKS Oh g igg g gy AHt A 40tNilflCATION MEillOD NO /H LV SilECT tao. NO HL COttDAULE iNSIGrilF ICANI GE OME IHIC 01HEH g hh 6 9 a,O = OW {] RC l'tfHP NO. ItC-3A m :r cr 55.1 B-C-1 Case Bolttog Stude Ur 800-71/0 300306 0* All 16 studs examincJ in place. --* @ [ 3.5-X-8-CS-24-FC1. (n 3 n CD B5.3 8-C-1 Case Bolting VT 900-1/46 300307 X All 16 stuJe anJ nuts exa.sined in 2Nh g place.
"* % %
n B5.5 B-K-2 Support components VT 900-4/22 300015 X All 3 supports examined. @ m - a.
"O M B5.9 B-C-2 Flange Bolting VT 900-1/46 300016 X All 16 bolts examined in place. [8C1 g 7M RC PUMP NO. RC-3B I 3 "**
'
W ct ct g 85.1 B-G-1 Case Bolttug Studs UT 800-71/0 300017 0* All 16 stude exaluined in place. ]m.
- w B5.3 B-G-1 Case Bolting VT 900-1/46 300018 X All 16 stuJe and nuts examined in yQ place. w. to O
B%.5 B-K-2 Support Componente VT 900-4/22 300019 X All 3 supports examined.
- CD s h
55.9 B-C-2 Flange Bolting VT 900-1/46 300022 X All 16 botta examined in place. k5. w ,
& .Cu<+
.
th OO 73
<+ m
.T a
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- r2 O (T1 C
i 3 C)
- 3
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. . - . . - . . . - - . . - . - . - . - _ - - . - - . .. . -- - ~ . . ~ . . . .
- ., ~ . . - . . . . - . . - - -
. - . . . . - - ~ , - ~ -
.
-
FoltT cal.l!OUN STATION llNIT I 1980 INSERVICE EXAHINATION - CLASS 2 g,, yo SUHrtARY OF NONDESTRUCTIVE EXAMINATIONS
.
O,. - ct 7 y UE.I!!G (D > ' h ASME ASME S.st e witu INDICATIONS g ' E X AMINADON EXAM. HEMAnKS -d-dc SE C. x1 SEC, xl Pl JOUHE E X AM. SUM
.
EE18) ll E M NO
-
CAIGY. ARE A IDENilFICAT40N ME 16 tOD _ P. EV. SilE E I NO. f40 llE COftDADL E INSIGNIF ICANI GEOME TitlC 0111EH __
*[3 ,
c. 1
'
t.n 3 o " 12-SDC-2003 l rD . M
~
M gure B 12a) I
] %.xg '
i _
- C2.1 C-F 12-SDC-2003-6 UT 800-36/24 300050 0*L,4 5* ,4 5*T Examination extended to 2" from weld Qf+d Pipe-to-Elbow fusion line in accordance witle IE o
' (g
, ,
Circular 76-06. 12-SS-40S .375-18-FCL [ 3 C,, - c+ e un -
.,
(D c+ C2.1 C-F 12-SDC-2003-17 UT 800-36/24 300049 0* L,4 5* ,4 5*T Examination extended to 2-3/4" from o E3.
> Elbow-to-Pipe weld fusion line in acenrdance with g "'* ggO IE Circular 76-06. N .
h 12-SS-405 .375-18-FCL g-"'m + s Cn 24-SI-2001 NTN W. W g ure B-36) c-)
. T C2.1 C-F 24-SI-2001-3 UT 800-36/24 300023 0*I. ,4 5* ,4 5'T 20-SS-STD .375-23-FCL as $
Elbow-to-Pipe O:3 i W k
--* C2.6 C-E-2 24-SI-2001-6 PR-2A VT 900-4/22 300024 X N Pipe Restraint SIS-37T . , .
C2.6 C-E-2 74-SI-2001-6-PR-25 VT 900-4/22 300025 x [* j- Pipe Restraint SIS-378 5g 4 W 24-S1-2002 07 ' JFh ure B-17) 7
.
C2.1 C-F 24-SI-2002-2 UT 800-36/24 300026 0*L,45*,4T 5 Limited 45'trr from the upstream olde OM Pipe-to-Elbow due to pipe support interference. :3
!
20-SS-STD .375-23-FCf.
- 24
$
C-E-2 24-SI-2002-16-PR VT 900-4/22 300027 x mo l C2.6 m i Pipe Restraint SIS-34 m
Co 1 O j 20-51-2001 N W g igure B-36) i 3 j C2.5 C-F-1 20-51-2001-6 PT (See Remacks) Examinat inn perf ormed by til'I'D per-Seal Weld sonnel, j, m i >
;c C2.6 C-E-2 20-St-2001-6-SC VT 900-4/22 300029 X Support Componenta H i
! "
'
I2-CSS-2004 , iFigure B-38) j C2.1 C-F 12-CSS-2004-4 UT 800-36/2u 300010 0* L,4 5'T 45* 12-SS-40S .375-18-FCI. } II C12.-IOP' E
.
- . . -- .-..- -.- -- - . - . . _ - . _ --. . . - - -. - _ _ . . - . . . . . - .. _ - ~ , . . - . . . . .- - . . . . . - - - . . - . . . . - .
I 1 R)RT cal.llOUN STATION UNIT 1
. 1960 IN3ERUICE k.XArt.dAT10N - Cl. ASS 2 SutPtANY OF NONDESTRUCTIVE EXAtilNATIONS
.
I y G G (CunL'et)
^
E x AMitJ ATION EXAM O C3 SLC x1 SE C. N I PHOCE Dunt E x AM. SUM - HEMARKS g AHE A eutt4TIFICATION ME letOO OfflEH I I E M NO CATGV f40 /H LV. SHEEit40 NO ltECOHDAbi t itassGt4tf lCAt31 GEOME T H4C g-(D W
,n 12-CSS-2004 O. [
g gure 87 8) (Cont'J) A { C* . C - a. C2.6 C-E-2 12-CSS-2004-12-PR-1 VT 900-4/22 300031 X m3O Pipe Restraint kgy
< c+ O I2-C55-2005 $* ,", k (D - a. 5
& Efrure B-3H) O C2.6 C-E-2 12-CSS-2005-3-PR-2 VT 900-4/22 300032 X
* &
Pipe Restraint (D ' 8 12-CSS-20ll 3, n~ ; gtgre B-39) to r+ c+
% .
C2.6 C-E-2 12-CSS-20!!-2-PR-2 VT 900-4/22 300033 X $. . a Pipe Restratut Dy$ ta = La O 12-CSS-2012 i (Figure B-39) m , as s 4 C2.1 C-F 12-CSS-2012-8 UT 800-36/24 300034 Q*I,45*,45*T 12-SS-40S .375-18-FCI. Ob k ' I Pipe-to-Reducer LO CD LA m '
- M 12-CSS-20l3 l (Figure B-39) rl .
O C2.6 C-E-2 12-CSS-2013-4-PR-3 YT 900-4/22 300035 X hk *
.Spe Reetraint S!S-32 g,
,
, w~
'
8-HPSI-2001 y*
! (Fitore B-40) O2 Cm C2.6 C-E-2 3-11 PSI-2001-2-P R-2 VT 900-4/22 300036 X ." m Pipe Restraint SIS-23C 2 03, mO +
C2.1 C-F UT 800-36/24 300037 , 0*L,45*,45'T 8-SS-40S .322-20-FCL N j 8-ilrSt-2001-4 i Eltsou-to-Pipe m t
-
O
^
6-lH*5 I -200_I (Fleure B-41) , C2.6 C-E-2 6-IIPSI-2001-5-PR-A VT 900-4/22 300038 X P!pe Restraint S15-164 y
>
C2.6 C-E-2 6-IfrSI-2001-5-tR-n vt 900-4/27 300039 X y ripe Heaitraint SIS-16 I~
! *
- - _ _
_ _ _ . . _ _ _ _ . . - __ - _ . _ _- . . _ _ ._ . __ __ -- - _ _ . _ _ . _ . . . . --
.
FORT CAI.ll0UN STATION UNIT I . 1980 INSERVICE EXAMINATION - Cf. ASS 2
- SUtttARY OF NONDESTRUCTIVE EXAMINATIONS h,a g
y lif1 E _(Cunt.'d) m '+ [
" ^' T E F AMsN ATION EMAM SE C. x1 SEC. XI PHOCf DUHE E X AM. SUM REMARKS O.
w wC ARE A IDENilf tCATION MElllOD IIE M NO CAIGE NO /H EV. SilE E T NO. NOHECOHDADLE INSIGNIFICANI GCOME intC OillEn m{{ c 6-IIPSI-2002 (Figure B-40) [3O
-"; to *Q
< et O
" OD G C2.1 C-F 6-HPSt-2002-5 UT 800-36/24 300040 0* L,45* ,45*T '
6-SS-40S .280-21-FCL O ct (D Pipe-to-Elbow O8' a=a
,
m * " 6-HPSt-2003 i m' g gure B-40) (D r+
, e C -1 I sw C2.5 C-E-1 6-HPS I-200 3-7-l'S PT (See Remarks) Examination performed by OPPD per- "* O
'
, Pipe Support sonnel. k '* ,# N-* a C2.6 C-E-2 6-ilPS I-200 3-7-SC Support Components VT 900-4/22 300043 X Q* $ ' N.T W N W O 6-51-2002 . C M gure B-42)
- m5 t Os C-F 6-SI-2002-3 800-36/24 300044 0*I. 4 5* ,4 5*T 6-SS-40S .280-21-FCL XO c2.1 UT q PIre-to-Elbow
.o . et C2.6 C-E-2 6-SI-2002-8-PR-1 vt 900-4/22 300045 X .
} Pipe Restraint [* C2.6 C-E-2 6-SI-2002-8-PR-2 VT 900-4/22 300046 X C+g2, , Pipe Restraint StS-22 o s-mm C2.1 C-F 6-St-2002-17 UT 600-3/53 300047 0*L,0*W,45*T 45*,60* 45* 60* Seven 45* Indicat ions due to crown $* Pipe-to-Tee geometry. Ihree 60* ludications due @y to root geometry. Two 60* indica- s tions due to root geometry with mode
- m
, g , conversion. Four 60* indications 2 .-s due to instwe surface geometry. No examinations fram the downstream MQ' Ch < side due to the tee configuration. CD
, 6"-2501-2-S.160 m
, W l
.
! > n H a 6 ,
.
'
,
Omaha Public Power District, 1623 Harney St., Omaha, NE 68102 , Fort Calhoun Station - Unit 1, P.O. Box 98, Fort Calhoun, NE 68023 ' Commercial Service Date - 9/26/73 PART 2 REACTOR COOLANT PUPP CASE BOLTING EXAMINATION OF FORT CALHOUN STATION UNIT 1 TABLE OF CONTENTS SPECIAL REPORT
- ATTACHMENTS A. Isometric and Pump Drawings B. Southwest Research Institute Nondestructive Testing Procedures C. Southwest Research Institute Operating Procedures D. Certificates of Personal Qualifications E. Material and Equipment Certifications F. Ultrasonic Calibration Block Drawing and Certifications.
G. Bolting Photographs H. Field Data and Calibration Record
- NOTE: Attachments A through H are not included in this report. They are available for inspection at the Fort Calhoun plant site or the Oper-ations Technical Support Services office.
! l i
.
- 7
.
Omaha Public Power District,1623 Harney St., Omaha, NE 68102 Fort Calhoun Station - Unit 1 2 P.O. Box 98, Fort Calhoun oNE 68023
'
Commercial Service Date - 9/26/73 PART 2 REACTOR COOLANT PUMP CASE BOLTING EXAMINATIONS AT FORT CALHOUN STATION UNIT 1 During May 1980, Southwest Research Institute (SwRI) personnel examined Reactor Coolant (RC) Pump case studs and nuts at Fort Calhoun Station. These examina-tions were performed at the request of Omaha Public Power District (OPPD) per-sonnel and the results are reported herein. All examinations were conducted in accordance with the American Society of Mechanical Engineers Boiler and Pres-sure Vessel Code, Section XI " Rules for Inservice Inspection of Nuclear Power Plant Components," 1974 edition with addenda through Summer 1975, and Section V
" Nondestructive Examination," 1974 edition with addenda through Summer 1975.
All applicable terms of the SwRI " Project Plan for the 1980 Inservice Examina-tion of Fort Calhoun Station Unit 1" were met. During the January-February 1980 Inservice Examination (ISI) ultrasonic (UT) and visual (VT) examinations were performed by SwRI personnel on the 32 RC Pump studs and nuts (installed) in pumps A and B. These examinations were confined to the nuts and stud upper ends, which were visible and accessible from above the pump cover. No defe-t indications were recorded. Subsequently, during station pre-startup hydrotesting, OPPD personnel found coolant leakage and severe corrosion and erosion affecting several studs in each of pumps A, B and C in the area below the pump covers. This area is not visible from above and is not readily accessible. The upper pump case insulation must be removed for an effective in-place VT and to reduce radiation levels to reasonably tolerable values. OPPD immediately requested SwRI to investigate the problem and to detennine the reasons for failure of the ISI examinations to detect the severe stud damage. A rigorous reexamination of damaged and undamaged studs by SwRI personnel, using the same Code-specified methods (SwRI NDT-800-71/0) and the same type equipment as used during the ISI, demonstrated that (a) the ISI UT had been correctly performed and (b) the UT procedure applied was inherently incapable of detecting the type of damage exhibited by the corroded and eroded studs. At the request of OPPD, SwRI personnel remained on site to examine the sixteen spare reactor coolant pump studs and two sets of new replacement studs, using UT, VT and fluorescent magnetic particle-(MT) techniques. The following exam-inations were all performed by SwRI personnel; the repairs, evaluations and acceptances were by OPPD personnel. Two spare studs (S-8 and S-ll) were found to have linear MT indications which exceeded Code limits. These were reported to OPPD on Customer Notification Forms (CNFs) and were repaired, reexamined, and accepted for service. Numerous other VT and MT indications were reported, evaluated, and found to be acceptable for service. RC Pump D was de-insulated, the studs examined by VT and UT techniques and found to be suitable for continued service. Pumps A, B and C were disassem-bled and four studs from A, seven from B and six from C were removed from ser- . vice due to gross corrosion damage. The remaining studs from these three pumps were given VT, UT and MT examinatians by SwRI personnel. Two additional studs from Pump A and two additional studs from Pump B were removed from service due to indications recordad during these examinations. Numerous VT and MT indica-tions were reported, evaluated and accepted, some with and some without minor rework. Twenty-three studs were replaced for various reasons. 1
_ _ Omaha Public Power District,1623 Harney St., Omaha, NE 68102
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Fort Calhoun Station - Unit 1, P.O. Box 98, Fort Calhouno WE 68023 Commercial Service Date - 9/26/73 PART 2 Selected stud nuts were examined by SwRI personnel using VT methods and some indications were recorded; these indications were evaluated and accepted "as is" by 0 PPD personnel. All stud nuts on pumps A, B and C were visually exam-ined and accepted by 0 PPD QC personnel. As a result of the examinations outlined above, the following conclusions have been reached:
- 1. The January-February 1980 ISI VT and UT examinations were properly per-
; formed and met all Code requirements.
1
- 2. Currently available (Code-specified) UT techniques for examination of studs without center-drilled holes, while adequate and effective for detecting thread-root cracking, are not suited for detection of the type of corrosion damage suffered at Fort Calhoun Station as reflectors normal to the ultrasonic beam are not produced by the corroded areas.
- 3. Future ISI programs at Fort Calhoun should continue to include the examina-tions currently scheduled. In addition, pump case insulation should be removed periodically to permit VT of the stud areas affected by the corro-
, sion induced by leakage of the outer seal between the pump case and cover. The VT procedure is completely adequate for detection of this type of damage. The following Summary of Nondestructive Examinations table summarizes the exam-inations performed; copies of the SwRI examination data sheets (and associated CNFs) are included in Attachment H. Photographs of selected areas are in Attachment G. The Tables' columnar format is self-explanatory, but the following comments may be helpful:
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All ultrasonic examinations were performed using 0-deg longitudinal beam search units, and no recordable indications were observed; hence, all UT is shown by "00" entries in the "No Recordable" column.
- All other (VT and MT) examinations are recorded by an "k" in either the "No Recordable" column cc in the "Other" column. The "Other" column is used to indicate that indications requiring evaluation by OPPD were observed.
- The " Remarks" column contains brief explanations of the types of indi-cations, their final disposition, and relevant CNF references. The field data sheet and related CMF copies for each group of studs (or nuts) are filed under their respective Summary Sheets, as listed in the " Weld Exam. Sum. Sheet No." column.
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FultT cal.IltHIN STATION UNIT !
- HEAC'lON Cool.AH r Putir noLTING SUltilARY OF NONDESTHUCTiVE EXAMI NATIONS g- 3 9S 5a'ir os REACTOR COOI. ANT PllttPS
-' B ct 3-(- } 5.H f ifJOICAllOf 4S O A mMF ASME w[tp t._
g gg g ,, $tp y [X AMINAllOf4 L X AP.t PitOCE DUHE E XAM StJM P.t M AH KS b c AHI A tOf fJilFICAllOf4 MLIHOO r40 /H g y, FJO NECOHDAut [ s tJStGtH f lC At41 GEOMEllHC OTit[it 11 E M f 40 CAIGY sn[L paa
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b RC PUffP NO. RC-1A g g "* g B5.3 8-C-1 Case Bolting Studs VT 900-l/46 300504 X Vr indications (corrosion, p!tting, %g 85.2 8-C-1 (A-4 through A-15) tfr 300-2/27 X tool marks, and scratch) on 5 studs. . a. cs :E 0* bd UT 800-71/0 See CNFs $19, 541 through 544 Studs A-4 and A-15 were removed Q C. Q O W
#j from service. Reevalu.ition of O U 9.
"
stud A-9 after grinding revealed c+ e on no recordable indications. Studs
- A-Il and A-12 were evaluated and a c3a- $.
g u accepted "as is" by OPPD personnel. e c+ c+ N . HT in.llcations (round and linear) on
%
$. m a studs A-!! nnd A-12. See CNFs 550 NUN and 551. Evaluated and accepted "as w. w la" by UPPD personnel. f DJ J Studs A-1. A-2, A-3 and A-16 were rejected without ex.smination due to
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>< m gross corrosion damage.
- 1. 5 -X CS - 2 4 - FCI.
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B-G-1 VT 900-1/46 3000507 X vf indications (corrosion) on all H5.3 Case Bolting Nuts 'O rl fA-1 through A-16 nuts. See CNF 545 Evaluated .ind o accepted "as is" by OPFD personnel. rt B All 16 nuts were visually examined
- O r and accepted by OPPD QC personnel 03 03 per Haintenance Osier No. 5901. $*
O ::' 7:. Ps,_No. sC-in gm
= Cn 85.3 B-G-1 Case Butting Studs VT 900-l/A6 300505 x vr in s cattuns (tool marks, pitting, CD B5.2 B-G-1 (B-5, -7, -8, 11, tir 300-2/27 X scratches) on 6 studs. See CNFs 5)R, h o"
-12, -11 and -14) UT 800-71/0 0* 540, 545, 546, 547, and 549. Studs ,N fi-5 and B-14 were removed from ser- co vice. Studs a-12 and B-13 were eval- O uated and accepted "as is" by 0000 w pe r vionne l , ricenaminatton of studs B-7 and 8-11 after maintenance re-vealed no recordable indications.
o tff indications (round and linear) on y stud B-12. See CNF 552. Evaluated -i and accepted "as is" by UPPD per- g sonnel.
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_ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ - _ _ _ _ _
_ - _.._ _ __ _ . . _. ~ . _ . _ . _ _ . . . _ _ _ _ . _ __ _ _ . . . _ _ _ _ _ _ _ . . _ _ _ _ _. . _m_ - _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ._ m. ._ _ _ _ _ - _ FORT CAlllOUN STATION UNIT I ,
,
REACTOR CtxH. ANT PUNP UOLTING StnittARY OF NuNDESTRUCTIVE EEAftlNATIONS ("3 "M g !
--li rACT nit Cool.Attr pimps (Cont'd) _ $gy 2
$ "' '" ' ^ ' "$ O EXAM HfMAHKS E x AMIN ATION
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PHOcE puttE E x AM. SUM l gSIC. x1 51 C. 2 8 AH6 A IDENIlf tCAf tote MEIHOL) 0161EH -e Fit M NO CAIGY t407H E V. Sist EI NO. t40HECORDAHLE INSIGNti tCAt41 GEOMEineC Cu T CT , '
"g O C =* ".>
g i RC Pump No. RC-1B
) (cont J) m i
Stude 5-1, B-2, B-1, B-4, B-6, B-15 AYh
" o :E C2 and 8-16 were rejected without $ ",. @
-
) examination due to gross corrosion g Jamage. B-9 was visually examined m and accepted by 0000 QC personnel. ,r+ 8 C
c=#):2 1.5-I-8-CS-24-FCt. c- . M e s. 4 t
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300509 n-7 was examined by swr 1 personnel. @ ct et LI B5.3 B-G-1 Case Bolting Nuts VT 900-1/46 X
- All 16 nuts were visually emanined a (8-7) and accepted by OPro t)C personnel os. w
,
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per Halntenance order No. 5904. D y *m ) ha. () i O
, g-RC Plttir NO. RC-)C m '
1 co -s
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55.3 B-C-1 Case Bolting Studs Vf 900-1/46 300506 X vi indications (tool marbs) on stud os , p5.2 8-C-1 (C-5 through C-14) tir 300-2/27 0* X C-10 See CHF 516. Evaluated and accepted "as is" by OPPD personnel. XQ W
. '
trr 800-71/0 03 th
- e+
.
4 tir indications (linear) on studs C-10 an.1 C-11. See CNFs 535 arul [* Evaluated and accepted "as is" , a 517 by OPPD personnel.
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Studs C-1 through C-4, C-15 and C-16 . were rejected without examinatton g2 due to gross corrosion Jamage. C rn i 3 1.5-X-8-CS-24-FCI. m j co t 2 ~" , VT All 16 nuts were visually examined rn o RS.) B-C-l Case Bolting Huts --- --- N and accepted by OPPD QC personnel 1 per Itainterunce Order No. 5905 $ o N stC Pt!MP f40. RC-3D w ' 900-l/46 300501 X vt trulications (Boric AclJ butid-up) : B5.1 n-C-1 Case notting Studs vf I p5.1 B-C-1 (D-l through D-16) UT 800-71/0 0* on studs D-1 throuRh D-6 and D-14 through D-16. See CNF 501. Evalu- o ' ated and accepted "as is" 1.y OPI'D y personnel. All studs were examined --t d in place. m i
- 1. 5-X- 8-CS -2 4- I CL i i i
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FORT cal.it00N STATION UNIT I
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PEACTOR CtIOI. ANT l'Uttt' ROI.T ING SuttttARY OF NONDESTRUCTIVt; EXAHINATIONS REACTOR COOT. ANT PUMPS (Cont'd) bOk B ct 7 5m
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SwHI WC it) ItJDlCATIONS (D W ASMF ASME m r St C. x1 St C x E x AWNATION AR[ A lpf NilflCAf TON EXAM M[Ilf00 PHO(lII)UHL [ X AR,t. SUM lif M AHKS -bd. " C c
'l i E M NO CAIGY h0 /H E V. $ sit E I NO. tJO Ft[COHDADLE INSIGt41F ICANI GE OME T HIC OTHED w 3 Cr >
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sn , I SPARt; Bot. TING 7
, v. a ;
VT 900-1/46 300502 X vr indications (tool marks, plating <eto - 85.3 B-C-1 Case Rotting Studs spatter, pitting, arc strikes) on 7 *,, %
] B5.2 B-C-1 (S-1 througli S-16) Hr trr 300-2/27 800-71/0 0*
X mtuds S-1, S-2. S-3, 5-5 and S-8 (D 0 s 2 through S-16. See CNFs 502 through a2e 514. Evaluated azul accepted "as is" W *-
,
by Orro personnel. rp r+ g i-e 3 C -* -s. j tfr indications (linear) on all studs. - n ! See CNFs 515 through 530 Recua=Ina- R '+,rt r y tion of stuJ S-8 after light machin- N --* 7 ing revealed one Code-acceptable in- (* N ON
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Jication. Seemanination of stud S-Il d after light machining revealed no re-cordable indications. All remaining
"*
o"
* *E a MT indtrations were evaluated and czy " [
accepted "as lu" by OPFD personnel. Og t 3.5-X-8-CS-24-FCs. g s
.
to 85.3 R -(* i Case Dotting Nuts Vr 900-1/46 300508 X vi indications (tool manns) on nuts . (S-1 thrnur,h S-15) 5-1 through S-5. See CNFs 531 througt 534 EvaluateJ and accepted f O i'
"as is" by OPPD personnel.
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REPl.ACF.HCHT STUHS' m ,
--*.a t Q5.$ A-C-1 Case sulting Studs VT 900-1/46 300503 X tir indication (linear) on stud bi cm 85.2 R-C-l (MS 53550-1. IA, 2 Ifr 100-2/27 X NS-53550-7. See CNF 553 EvaluateI through 12, and 14 tTr 800-71/0 O* and accepted "as is" by OrrD g cr- ." m through 17. SS 53551-1, sonnel. 2 00, ;
IA, 2 through 15 and 17) mo N Ch O i O 1 N W i t 3:=
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