catawba nuclear station, unit 2, evaluation of 2eoc13 isi ... · generator to hot leg weld during...

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CATAWBA NUCLEAR STATIONUNIT 2

EVALUATION OF 2EOC13 ISIFLAW IN SG2C TO HOT LEG WELD

CNC-2201 .01-00-0006

. .-

Form 101.1 (ROO-04)

CERTIFICATION OF ENGINEERING CALCULATION

. . Station And Unit Number Catawba Nuclear Station, Unit 2

Title Of Calculation Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld

Calculation Number CNC-2201.01-00-0006

Total Original Pages 1 Through 8_

Total Supporting Documentation Attachments I tA) Total Microfiche Attachments -

Total Volumes I Active Calculation/Analysis Yes Dl No 13

Microfiche Attachment List E Yes 1 No If Active, is this a Type 1 Calculation/Analysis Yes El No El(See Form 101.4)

These engineering Calculations cover QA Condition 1 Items. In accordance with established procedures, thequality has been assured and I certify that the above Calculation has been Originated, Checked, or Approved asnoted below:

Originated By - Date la.o JR 04

Checked By b AL 4Jz Date lo -1.2 - V4

' Verification Method: Meth d Method 2 Method 3 Other

Approved By L J e Gt Jo4! Date /0_ -3__

Issued To Document Management 8 I Date I ) -13

Received By Document Management

_ _ _ _ _ _ _ _ Date l - I --t- 3 4

Complete The Spaces Below For Documentation Of Multiple Originators Or Checkers

Pages Through

Originated By Date

Checked By Date

. Verification Method: Method 1 0 Method 2 0 Method 3 0 Other ElPages Through

. . . Originated By Date

Checked By Date

Verification Method: Method 1 El Method 2 E Method 3 E Other ElPages Through

Originated By Date

Checked By Date

Verification Method: Method 1 Method 2 El Method 3 El Other E

PR1O.-2

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O a1 A A n_. -^.

Form 101.2 (R3-03)

File/Calculation No. CNC-2201.01-00-0006

REVISION DOCUMENTATION SHEET

Revision Revision DescriptionNumber

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Statement of Problem / Purpose

This calculation has been performed to address an indication discovered on the 2C SteamGenerator to Hot Leg weld during 2E0C13. This particular weld is located between thecast low alloy steel primary channel head of the steam generator and the cast austeniticstainless steel elbow. Typically, the volumetric examination under Section XI of theASME Code would be performed using an ultrasonic examination. However, the castaustenitic stainless steel material of the reactor coolant loop piping precludes the use ofthe ultrasonic examination methodology. The ultrasonic examination was replaced with aradiographic examination.

QA Condition

This calculation is QA Condition I because it serves as the basis for continuedqualification of a Duke Class A, ASME Class I component.

Analysis Methodology

This calculation verifies that the structural integrity of the steam generator 2C nozzle tohot leg weld is maintained under all operating and design loading conditions, even withthe identified flaw. The verification has been performed by conservatively bounding theflaw characteristics and comparing this bounding flaw against allowable flaw depthsprovided by a Westinghouse flaw evaluation handbook [7] specific to this reactor coolantloop location.

Other Evaluation Criteria

No other evaluation criteria have been used.

Applicable Licensing ReferencesL. 1 Catawba UFSAR, September 27, 2003 issue date, Sections 3.9 and 5.2L. 2 Catawba Selected Licensee Commitments 16.5.5, Reactor Coolant System,

Structural Integrity, Rev 0

Assumptions/Engineering Judgments

As noted in body of calculation

Catawba Nuclear Station, Unit 2 Orig: WOC 10/12/04Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld Check: JFW 10/13/04CNC-2206.01-00-0006, Rev. 0 Page IL

ReferencesI ASME Code, Section III, Subsections NB and NC, 1974 Edition with Summer

1974 Addenda.2 ASME Code, Section XI, 1989 Edition, No addenda3 Westinghouse sketch EDSK 380335B, from CNM-2201.01-02174 Westinghouse sketch EDSK 380329B, from CNM-2201.01-02175 CNM-1201.01-0076, Rev 0, ESCO drawing AA-43234,, Weld Bevel Detail,

31.00 I. D. Elbows, Nozzle Ends6 CNM-2201.01-0008, Rev B, ESCO drawing AD-22321, Machining - 31.00 I.D. x

29.00 I.D. Long Radius 50° Reducing Weld Elbow7 WCAP-15658-P, September, 2004, Flaw Evaluation Handbook for Catawba Unit

2 Steam Generator Primary Nozzle Weld Regions.8 CN-2553-1.0, Rev 22, NC Flow Diagram.9 CN-2NC-00 13, Rev 13, Weld Isometric.10 PIP C-04-5421

Catawba Nuclear Station, Unit 2Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg WeldCNC-2206.01-00-0006, Rev. 0

Orig: WOC 10/12/04Check: JFW 10113104

Page Z?

Calculation/Evaluation

This calculation was performed by determining the bounding characteristics of theindication and comparing parameters associated with this indication to values in theWestinghouse supplied flaw analysis handbook [7].

Nozzle ConfigurationThe nozzle connection consists of a low alloy steel casting that forms the channel head ofthe steam generator. This casting has been buttered with a low carbon, stainless steelweld metal. The piping to buttering field weld is made after post weld heat treatment ofthe steam generator channel head. The Duke weld number is 2NC-13-2 and the weldprocess control from the original fabrication is included as Attachment A. This weld is afull penetration, compound V groove weld made from the outside of the pipe. TheGTAW (TIG) process was used for the first inch, followed by a "courtesy" radiograph(RT). Subsequent welding was performed using the SMAW (stick) process to finish outthe weld. After completion of welding, a final RT was performed and accepted on theweld. In addition, liquid penetrant tests (PT's) were performed on the interior andexterior surfaces of the weld.

Flaw GeometryThe flaw is located at the bottom of the pipe in the C hot leg. It is approximately atbottom dead center of the pipe. Based on the radiographic data, the flaw is 1" long andoriented in the circumferential direction. Since the examination was performed using RT,a limited amount of information was available to characterize the flaw. The location ofthe flaw relative to the OD surface was established using parallax radiographic shots.These shots support a minimal flaw depth. However, because of the uncertainty in flawdepth, a bounding case has been reviewed herein.


Orig: WOC 10/12/04Check: JFW 10/13/04

Page .. >

Radiography Evaluation

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B 1ill.Duiing the Si radiographic exainnaon (FT) od Steam Generator Charlie v Wet Nozzle to Sale End and Sale End to Pipe welds QS1 item numbers

a | 805070 .005 and 9051 30.010 respedrveA eons ich (l.00 x .1251 ineor dicatonwas deteced atti RTnumber 0.The RT rrlocated on teappecuimate heel ofi be elbow The lowcornasitindicationwes chiamctedzed tbe consistentih o slag type dcationwith esmail troughwel dimension

bThe labication Mim was viewed in the analog and digital bfoers for comparisons. The fobication radiographs did olx record the idication. The detection ofthe hdicetion in 2004 and not durdng tab ication i contributed lo te piane of b e lowein rotion o te kw n change inthe plane of radiation from the owce

A paralxR FT eposure wa perfomed to dete.rine hoe dept aoft e slag indication. The dept wes determined a be I.01 from be OD udaca. A srmpleplot based on the two source locations during the parallax exposure in relation to the image shit and location from the weld edge supports the 1.01 depthcaiculation and plots the indicabon to be located wi the SS material at or near the interlace of tie Safe End material and the Duk oield weld.

'The parallax exposure and calculations were veritied by Level I Radiographer J.L Smith.

tiLTucderRT Upvl

.Bodlyoftmessege -

In addition to the radiography shots made to characterize the flaw, both the originalconstruction film and the 2EOC13 film (non-parallax shots) wNere digitized. The originalconstruction film was digitized to determine if the indication could be seen from initialfabrication welding. Digitization of the film can greatly enhance the visibleinterpretation of the film in some cases. Next, the 2EOC13 film was digitized andreviewed to determine if the linear indication was actually separated into multiple flaws.In both of these cases, there was no conclusive evidence from the digitization process thatchanged the film interpretation or flaw characteristics.

Based on the conclusions provided from the radiography review above, a best estimatecharacterization of the flaw has been provided. The flaw is located 1.01" from theoutside surface of the piping in the stainless steel weld material. The flaw is orientedcircumferentially with a length of 1.0". The flaw is most likely the result of a slaginclusion during fabrication. It has very little contrast that indicates a limited depth. It islocated at the interface between the stainless steel buttering and the Duke stainless steelfield weld.

Catawba Nuclear Station, Unit 2 Orig: WOC 10/12104Evaluation of 2EOC13 IS1 Flaw in SG2C to Hot Leg Weld Check: JFW 10/13/04CNC-2206.01-00-0006, Rev. 0 Page A_

The flaw location from the OD surface of 1.01" was considered from three positionsrelative to the flaw depth (top, center & bottom). The three positions were considered fortwo different aspect ratios. All six cases were found to be acceptable. Based on themethod used to determine location, the center position is the most appropriate and is usedin the documented flaw calculation below.

For the initial evaluation, the flaw depth will be assumed as l/2 of the length and evaluatedas an embedded flaw. From the flaw handbook, several parameters are necessary todetermine the acceptability of the indication. These are provided below. The appropriatefigure for the purposes of evaluation from reference [7] for a circumferential embeddedflaw in the stainless steel material is Figure A-3.7.

a = half flaw depth (in)= 0.25 in.l = length of flaw (in)= 1.0 in.

t wall thickness (in)= 3.25 in.

Note: The wall thickness is based on profiling of weld using UT probe.Value of 3.25" is conservative and represents the lowest readingthroughout the weld region of interest. See page a for the LIT profilereadings at the location of interest.

6 = distance to flaw centerline= 1.01 in.

6/t = 1.01/3.25= 0.311

a / t = 0.25 /3.25= 0.077

The 6/ t and a /t parameters may be plotted on Figure A-3.7 to determine theacceptability of the flaw. This point (A) is shown on the attached sketch.

In addition to the above evaluation, the flaw depth was increased to 1" yielding an aspectratio of 1:1. In this case, the parameters change as noted below:

a = half flaw depth (in)= 0.50 in.

I = length of flaw (in)= 1.0in.

t = wall thickness (in)= 3.25 in.

6 = distance to flaw centerline

Catawba Nuclear Station, Unit 2 Orig: WOC 10/12/04Evaluation of 2EOC13 ISI Flaw in SG2C to Hot Leg Weld Check: JFW 10/13/04CNC-2206.01-00-0006, Rev. 0 Page S.

= 1.01 in.6lt - 1.01 /3.25

= 0.311alt = 0.50/3.25

= 0.154

Again, the 6 I t and a I t parameters have been plotted on Figure A-3.7 as point (B) todetermine the acceptability of the flaw.

Results

In both cases evaluated above, it is clearly evident that the flaw is within the bounds ofthe acceptability provided by Figure A-3.7 of reference [7]. As a result, the pipingcontaining this flaw is acceptable for continued service for the design life of the plant.The figure in reference [7] indicates 10, 20 and 30 year acceptance lines. These lines arerelated to the design number of occurrences of transients used in the fatigue crack growthcalculation. As such, this indication is acceptable for life of plant provided a proratedvalue (30/40 = 75%) of the design number of occurrences are not exceeded betweennow and end of plant life. This limit on fatigue cycle counts will be tracked under ourfatigue management program.

Conclusion

The flaw discovered during 2EOC13 is acceptable without repair for the life of plant.Acceptance by the performance of analytical evaluation as allowed by ASME XI, IWB-3132.4 has been validated. Additional examinations have been performed during2EOC13 to satisfy IWB-2430. Successive examinations for the SG2C hot leg weldnumber 2NC-13-2 will be necessary in the subsequent three ISI periods as required byIWB-2420.


Orig: WOC 10/12/04Check: JFW 10/13/04

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Reference Drawings:1) CNM-2201.01-00082) CNM-1201.01-0076

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Problem Investigation ProcessCatawba Nuclear Station

PIP erialNo: Action Category:^ a 'LER-No: : . - OtherReport: .. :..... ;IC-04-05421 3

Problem Identification

Discovered Time/Date: 10:33 10/111/2004 Occurred Time/Date: 10/07/2004

Unit(s) Affected:Unit Mode %Power Unit Status Remarks2 NOMODE

System(s) Affected:NC Reactor Coolant

Affected Equipment

(No Equipment Affected)

Location or Problem:Bldg: RX Column line: Elev:

Location Remarks:S/0 'C

Method Used to Discover Problem:RT (ISI) of S/G'C' Inlet/outlet nozzle weld

1 tief Problem Description:Inear indication of I inch found in S/G 'C' on Hot leg during RT(radiography)

Detail Problem Description:Linear indication of I inch found in S/G 'C' hot leg nozzle weld duirng RT.Linear indication of I inch exceeds the acceptance standards of NDE-12, ASME Code Sections III and XI.(Procedure NDE 12 Rev. I1. Appendix A, ASME Code Xl IWB-3514, ASME Code Section 111 NB-5320).Slag indication of I inch in length located at RT film interval number 0. The indication was not visible on the construction radiographs. A changein the source position in relation to the plane of the flaw was determined to be the basis for the flaw detection in 2004 and not during the fabricationRT. This is a reportable indication.

Originated By: JFB8158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/1112004

Other Units/Components/Systems/Areas Affected(YNU): U

Industry Plants Affected(Y.NU): U

Immediate Corrective Actions:Engineering to perform Fracture Mechanics Analysis.

Originated By: JFB8158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/1 112004

Immediate Corrective Action Documents I Work Orders:

Problem Identified By:Problem Entered By:

Indiv TeamJFB8158 JLW3805JFB8158 JLW3805

GroupIWSIWS

Date10/111200410/1112004

ScreeningAction Category: 3 Root Cause performed? No

10/1112004 11:33 Page 1 PIP No: C-04.05421

101120 Ino1.-33 Page I PP PNo: C-04-05421

Problem Investigalion ProcessCatawba Nuclear Station

K 3EP No:

Other Report Nos:

Event Codes:F8 Testing

Screening Remarks:

Originated By: MLS9465: STANDRIDGE. MICKEY L Team: PAM7334 Group: SRG Date: 10/1 1/2004

Assignments:Responsible Groups(s) for Problem Evaluation:Responsible Group for Present Operability:Responsible Group for Report Support Info:Responsible Group for Reportability:Responsible Group for Overall PIP Approval:

MCEN/AN/AN/A[WS

Mechanical/Civil Eng

INSPEC. & WELD. SERV.

Si attreene By d, ni M S 946nPA733 SRO 10111roup2004 i.;. A9Daiet|Screened By: MLS9465 PAM7334 SRG 10/11/20041

Present Operability

)esponsible Group: Status:

Sys/Comp Operable? (Y.N,CET):

Required Mode:

Comments:

No Current Signatures For This Section

Reportability

Responsible Group: Status:

Problem Reportablc(Y.N,E):

Reportable Per:

Comments:


Investigation Report:

Iesponsible Group:

Jvestigator:

Act Date:

Group:

Due Date:

10/11I2004 11:33 Page 2 PIP No: C-04.05421

PIP No: C-04-0.5421onmoo704 11..33 Page 2


D')ate Due to VP or Sta. Mgr:\,atc Rcgulatory or Agency Rpt Duc:

bate Investigation Report Approved:

NRC Cause Codes:

Report Support Info:

Responsible Group: Status:


Problem Evaluation

Problem Evaluation From: Resp. Group: MCE Status: ReadyForAccept OEDB Checked: No

OEDB Comments:

Remarks Comments:

Assigned To: MCE 10/1 l/2004Due Date: I 1/10/2004 _ _ _-

Corrective Actions

CA Seq. No: 1* pW-irWWO'}., a44 ., a~CCusCo -"

I ROC Open IWS FB A2 YYY

Proposed Corrective Action:Notify the NRC of the Reportable indication.

Originated By: JFB8158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/1 1/2004No Current Signatures For This Section

General:Outage: Mode:

Other Tracking ProcessesType Number Text

Actual Corrective Action:priority: N Actual CAC: Status: Due Date:

1I11t12004 HZ.-3. Page 3 PIP No: C-04-05421


'rSignature Type mdiv - . Ta :Group' Date' i.AssignedTo: RGC 10/1112004

CA Seq. No: 2|Resp Group -Stats O..'nrig Gfroup Event .Code& p. Prop CAC ?..CaUse CIRGC --- f L IWS F8 A2 YYY

Proposed Corrective Action:Provide Fracture Mechanics Analysis data to the NRC for their review prior to unit re-start.

Originated By: JFB8 158: BUMGARNER, JAMES F Team: JLW3805 Group: IWS Date: 10/11/2004No Current Signatures For This Section

General:Outage: Mode:

Other Tracking ProcessesType Number Text

Actual Corrective Action:Priority: N Actual CAC: Status: Due Date:

\EssigneTo: RGC 10/111/2004

Final and Overall PIP Approval

Responsible Group: IWS Status: Screened

0 "idSl,i'te Type"~_ 'al't-il-.ws, > .W ,; T ia"O p ,;iH.> 7e .;,e

| Assigned To: IWS 10/111/2004

Any Supplemental Concurrence Signatures Above Do Not Affect PIP Closure.

Closure Document Type Closure Document No

Attachments

Generic Applicability

Responsible Group: Status:GO PIP No:

Assessment Remarks:No Current Signatures For This Section

-Pailure Prevention InvestigationNo FPI Records for this PIP.

101f11200411:33 Page 4 PIP No: C-04-05421

Problem Invesligalion ProcessCatawba Nuclear Station

KJRetnarksNo Remarks for this PIP.

Maintenance RuleNo Maintenance Rule Records for this PIP.

End of the Document for PIP No:The status of this PIP is:The duration of this PIP was:

C-4-542 1Screened0 days

10/ll/2004 11.33 Page 5 PIP No: C-04-05421

I QA-516 A I Revision 4

Indication Evaluation Report

STATIONCatawba

UNIT _2

ISI PLAN ITEM NUMBERB05.070.005rf! 130 .010 I

ISI PLAN ID NUMBER2SGC4lNLET-SE

,qmrin-0qNDE METHOD NDE PROCEDURE USED INDICATION SERIAL NUMBERRadiography NDE 12 REV. 11 S/N I (located at RT# 0)

DESCRIPTION OF ITEM CONTAINING INDICATION DATE INSPECTED EVALUATION NEEDED BY DATESteam Gen Inlet Nozzle to Safe End Weld 1010712004 1011112004Steam Gen Nozzle Safe End to Pine weld

COMMENTS: Slag Indication 1.00" In length located at RT film interval number "O". TheIndication was not visible on the construction radiographs. A change in source position inrelation to the plane of the flaw was determined to the basis for the flaw detection in 2004 and notduring the fabrication RT.

A

ORIGINATED BY: T.L Tucker DATE: 1011112004

ACCEPTANCE STANDARD USED: Procedure NDE 12 Rev 11 Appendix A, ASME Code Sect. XlIWB-3514, ASME Code Sect. III NB-5320.

CALCULATIONS/COMMENTS: Unear indication length of 1.00" exceeds the acceptance standardsof NDE 12, ASME Codes Sect. III and Sect. Xl.

EVALUATION STATUS = Reportable

B

Evaluated By(NDE LEVEL Ill): T.L Tucker DATE: 10/11/2004

PIP SERIAL No: E - 0 c- 5721C

ISI COORDINATOR: DATE:

ADDITIONAL INSPECTIONS El NOT REQUIRED

El REQUIRED: ISI PLAN ADDENDA S/N:

D SURVEILLANCEINSPECTIONS 0 NOTREQUIREDO REQUIRED: ISI PLAN ADDENDA SIN:

ISI PLAN MANAGER |DATE

DISPOSITION El ACCEPTABLE IN ACCORDANCE WITH IWB-3600 (FMA)

El REPAIRED

El REPLACEDE COMMENTS:

DISPOSITIONED BY (ISI Plan Manager)_ DATE