2007-047 BWR Vessel & Internals Project (BWRVIP) · 2012. 11. 29. · 2007-047 BWR Vessel &...

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rfl. 3 11ELECTRIC POWERRESEARCH INSTITUTE

2007-047 BWR Vessel & Internals Project (BWRVIP)

February 21, 2007

Document Control DeskU. S. Nuclear Regulatory Commission11555 Rockville PikeRockville, MD 20852

Attention: John Honcharik

Subject: Project No. 704 - TR-105696-R9 (BWRVIP-03) Revision 9: BWR Vessel andInternals Project, Reactor Pressure Vessel and Internals Examination Guidelines

Enclosed are five (5) CD copies of the report "TR-105696-R9 (BWRVIP-03) Revision 9: BWRVessel and Internals Project, Reactor Pressure Vessel and Internals Examination Guidelines,"EPRI Technical Report 1013394, December 2006. In accordance with NRC requirements, oneof enclosed CDs is unprotected and is labeled as such. The other four (4) CDs are protected.This report is being transmitted as a means of exchanging information with the NRC for thepurpose of supporting generic regulatory improvements related to inspections of BWR internals.

BWRVIP-03 is a living document that is updated periodically as inspection technology evolves.The "History of Changes to this Document Revision 9" section identifies the changes thatsupersede affected portions of the previous Revision 8. The enclosed CDs contain a completecopy of Revision 9 that is being published on CD only.

Please note that the enclosed report contains proprietary information. A letter requesting that thereport be withheld from public disclosure and an affidavit describing the basis for withholdingthis information are provided as Attachment 1.

Two paper copies of the non-proprietary report "TR-105696-R9 (BWRVIP-03NP) Revision 9:BWR Vessel and Internals Project, Reactor Pressure Vessel and Internals ExaminationGuidelines," EPRI Technical Report 1013394, December 2006, are also enclosed. This non-proprietary report is identical to the enclosed proprietary report except that the proprietaryinformation has been deleted and the letters "NP" appear in the BWRVIP report number.

Together ... Shaping the Future of Electricity

PALO ALTO OFFICE .,.O5R3420 Hillview Avenue, Palo Alto, CA 94304-1395 USA * 650.855.2000 * Customer Service 800.313.3774 9 www.epri.com

If you have any questions on this subject please call Chuck Wirtz (FirstEnergy, BWRVIPInspection Focus Group Chairman) at 440.280.7665.

Sincerely,

William A. EatonEntergy Operations, Inc.Chairman, BWR Vessel and Internals Project

I ELECTRIC POWERRESEARCH INSTITUTE

Attachment 1February 20, 2007

Document Control DeskOffice of Nuclear Reactor RegulationU.S. Nuclear Regulatory CommissionWashington, DC 20555-0001

Subject: Request for Withholding of the following Proprietary Document:

rIR-105696-R9 (BWRVIP-03) Revision 9: BWR Vessel and Internals Project,Reactor Pressure Vessel and Internals Examination Guidelines," EPRI TechnicalReport 1013394, December 2006

To Whom It May Concern:

This is a request under 10 C.F.R. §2.390(a)(4) that the U.S. Nuclear Regulatory Commission("!NRC') withhold from public disclosure the information identified in the enclosed Affidavitconsisting of the proprietary information owned by Electric Power Research Institute, Inc. ("EPRr)and identified above (the "Reorr). Copies of the Report and the Affidavit in support of thisrequest are enclosed.

EPRI desires to disclose, in confidence, the Report for informational purposes to assist the NRC.The Report is not to be divulged to anyone outside of the NRC or to any of its contractors, nor shallany copies be made of the Report provided herein. EPRI welcomes any discussions and/orquestions relating to the information enclosed.

If you have any questions about the legal aspects of this request for withholding, please do nothesitate to contact me at (704) 595-2173. Questions on the content of the Report should bedirected to Randy Stark of EPRI at (650) 855-2122.

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ELECTRIC POWER RESEARCH INSTITUTE, INC.

ýW"' - -,;?,D- 07

Senior Sector Business Operations Manager

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AFFIDAVIT

RE: Request for Withholding of the Following Proprietary Document:

-TR-105696-R9 (BWRVIP-03) Revision 9: BWR Vessel and Internals Project, ReactorPressure Vessel and Internals Examination Guidelines," EPRI Technical Report 1013394,December 2006

I, JOHN P. GAERTNER, being duly sworn, depose and state as follows:

I am a Senior Sector Business Operations Manager of Electric Power Research Institute,Inc. whose principal office is located at 3420 Hillview Avenue, Palo Alto, California (LEPRI") and Ihave been specifically delegated responsibility for the above-listed Report that is sought under thisAffidavit to be withheld (the "Reffot"). I am authorized to apply to the U.S. Nuclear RegulatoryCommission (QNRC") for the withholding of the Report on behalf of EPRI.

EPRI requests that the Report be withheld from the public on the following bases:

Withholding Based Upon Privileged And Confidential Trade Secrets Or Commercial OrFinancial Information:

a. The Report is owned by EPRI and has been held in confidence by EPRI.All entities accepting copies of the Report do so subject to written agreements imposing anobligation upon the recipient to maintain the confidentiality of the Report. The Report is disclosedonly to parties who agree, in writing, to preserve the confidentiality thereof.

b. EPRI considers the Report and the proprietary information containedtherein (the "Proprietary Information') to constitute trade secrets of EPRI. As such, EPRI holds theReport in confidence and disclosure thereof is strictly limited to individuals and entities who haveagreed, in writing, to maintain the confidentiality of the Report. EPRI made a substantial economicinvestment to develop the Report, and, by prohibiting public disclosure, EPRI derives an economicbenefit in the form of licensing royalties and other additional fees from the confidential nature of theReport. If the Report and the Proprietary Information were publicly available to consultants and/orother businesses providing services in the electric and/or nuclear power industry, they would beable to use the Report for their own commercial benefit and profit and without expending thesubstantial economic resources required of EPRI to develop the Report.

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Executed at 1300 W T Harris Blvd, Charlotte, North Carolina being the premises and place ofbusiness of Electric Power Research Institute, Inc.

Date ,,,• -9'0

JohP.Gaertner

Subscribed and swom before me this Aj-iday ofa 200-"7

. • Notary Public

My Commission expires .- .2.oo'

RESEARCH INSTITUTE

TR-105696-R9 (BWRVIP-03NP) Revision 9:BWR Vessel and Internals Project,Reactor Pressure Vessel and InternalsExamination Guidelines

SE WARNING:Please read the Export Control

. \ / Agreement on the back cover.ft AlTechnical Report

NON-PROPRIETARY INFORMATIONNOTICE: This report contains the non-proprietary information that is includedin the proprietary version of this report. The proprietary version of this reportcontains proprietary information that is the intellectual property of BWRVIPutility members and EPRI. Accordingly, the proprietary report is available onlyunder license from EPRI and may not be reproduced or disclosed, wholly orin part, by any Licensee to any other person or organization.I

TR-105696-R9 (BWRVIP-03NP) Revision 9:BWR Vessel and Internals ProjectReactor Pressure Vessel and InternalsExamination Guidelines

1013394NP

Final Report, December 2006

EPRI Project ManagerJ. Landrum

ELECTRIC POWER RESEARCH INSTITUTE3420 Hillview Avenue, Palo Alto, California 94304-1395 * PO Box 10412, Palo Alto, California 94303-0813 * USA

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DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS ANACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE BWR VESSEL AND INTERNALSPROJECT (BWRVIP) AND ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHERBWRVIP, EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW,NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, ORSIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESSFOR A PARTICULAR PURPOSE, OR (11) THAT SUCH USE DOES NOT INFRINGE ON ORINTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUALPROPERTY, OR (111) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'SCIRCUMSTANCE; OR

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER(INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF BWRVIP, EPRI OR ANY EPRIREPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTINGFROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS,METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT.

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Electric Power Research Institute (EPRI)

NON-PROPRIETARY INFORMATIONNOTICE: This report contains the non-propriety information that is included in

the proprietary version of this report. The proprietary version of thisreport contains proprietary information that is the intellectual propertyof BWRVIP utility members and EPRI. Accordingly, the proprietaryreport is available only under license from EPRI and may not bereproduced or disclosed, wholly or in part, by any Licensee to anyother person or organization.

NOTE

For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 ore-mail askepri @epri.com.

Electric Power Research Institute and EPRI are registered service marks of the Electric PowerResearch Institute, Inc.

Copyright © 2006 Electric Power Research Institute, Inc. All rights reserved.

CITATIONS

This report was prepared by

Electric Power Research Institute (EPRI)NDE Center1300 W.T. Harris BoulevardCharlotte, NC 28262

Principal Investigator

BWRVIP Inspection Focus Group

This report describes research sponsored by EPRI and its BWRVIP participating members.

The report is a corporate document that should be cited in the literature in the following manner:

TR-105696-R9 (BWRVIP-O3NP) Revision 9: BWR Vessel and Internals Project, ReactorPressure Vessel and Internals Examination Guidelines. EPRI, Palo Alto, CA: 2006. 1013394NP.

iii

PRODUCT DESCRIPTION

In 1990, a visual examination of the core shroud of a Swiss boiling water reactor (BWR)revealed the presence of intergranular stress corrosion cracking. Since that event, examinationsof other BWR vessel internal components have revealed an industry-wide cracking problem.In 1994, domestic BWR-owning utilities formed the Boiling Water Reactor Vessel & InternalsProject (BWRVIP), which is chartered to support a program addressing the problems of reactorinternals, internal attachments, vessel welds, and vessel nozzles. Most international BWR ownershave become members. This annual report defines inspection standards and documentedinspection techniques for BWR vessel internal components.

Results and FindingsProcedure standards have been developed for ultrasonic, visual, and eddy current inspection.Many inspection techniques have been demonstrated and documented. In support of thesedemonstrations, realistic mockups of reactor internal components have been manufactured withcontrolled flaws. BWR owners can use these documented techniques to inspect their vesselinternal components in compliance with BWRVIP guidance.

Challenges and ObjectivesIn-service inspection program managers and BWR vessel internals program managers use thisdocument to ensure that their components are inspected in compliance with BWRVIP guidance.

Applications, Value, and UseThe information contained in this report is applied by all BWR owners in the preparation for andduring refueling outages. It is updated annually.

EPRI PerspectiveThis report provides the BWR fleet with inspection options for all of the safety-related vesselinternal components, and provides a stable mechanism for documenting the capability of theevolving inspection technology. It is the sole resource for internals inspection information forBWR owners.

ApproachThe BWRVIP strives to make effective inspection techniques available by developing inspectionstandards that can ensure the structural integrity of the components and providing demonstrated,documented techniques for effectively examining the susceptible components.

v

KeywordsBWRVIPNDEInternalsInspectionUltrasoundVessel

vi

EXECUTIVE SUMMARY

This document presents findings and products of the Inspection Focus Group of the BoilingWater Reactor Vessel and Internals Project (BWRVIP). An overview of the structure of theBWRVIP is presented, with an outline of the goals and approach of the Focus Group.

The Inspection Focus Group has developed guideline documents which establish protocols forutilities and nondestructive evaluation (NDE) vendor companies to follow in order to gain accessto BWRVIP-owned mockups; to perform formal demonstrations of NDE techniques usingBWRVIP mockups; and to perform their own demonstrations of NDE techniques or inspectiontooling in a manner acceptable to the Focus Group. These documents are included in theirentirety.

The Focus Group has conducted extensive investigations and demonstrations of NDE techniquesappropriate for inspection of BWR internals. These efforts have included the design, fabrication,and inspection of a series of realistic mockups containing realistic simulations of the degradationmechanisms of concern. These investigations result in the development of evaluation factors,which are numerical values, related to the uncertainties inherent in delivering and executing anNDE technique in a BWR. These evaluation factors are combined with the actual results of aninspection to form input into a fracture-mechanics assessment of the component's serviceability.

The Focus Group's activities are ongoing. The various components of BWR vessels and internalsare being addressed in concert with other technical Committee efforts. For componentsaddressed to date, this report includes data on mockup fabrication, NDE uncertaintymeasurements and evaluation factors, and procedure standards for ultrasonic examination, eddycurrent examination, and visual examination.

This is a living document. Updates to the included data on components that have already beenaddressed, and new report sections on components that have not yet been addressed, will besupplied as they are developed. A history of changes is included within the document.

vii

HISTORY OF CHANGES TO THIS DOCUMENTREVISION 9

This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994, Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and Boiling Water Reactor Pressure Vesseland Internals Examination Guidelines (BWRVIP-03) (EPRI Report TR-105696, October 1995).The changes listed below supersede the affected paragraphs of TR-105696-R8 (BWRVIP-03)Revision 8. Boiling Water Reactor Pressure Vessel and Internals Examination Guidelines(EPRI Report 1011689, December 2005).

Affected Section(s) Description of Change

xxvii Updated the Inspection Focus Group roster.

Chapter 1

Table 4.4.2-1

4.4.42-4.4.46

5.3.2

Table 6.4.2-1

6.4.36-6.4.39

10.4.14

10.4.15-10.4.17

Updated to include NEI 03-08 Implementation Requirements.

Updated to reflect new NDE technique demonstrations.

New sections: new NDE technique demonstrations.

Added two new shroud support mockups.

Updated to reflect new NDE technique demonstrations.


Corrected errata.


ix


This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994, Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and Boiling Water Reactor Pressure Vesseland Internals Examination Guidelines (BWRVIP-03) (EPRI Report TR-105696, October 1995).The changes listed below supersede the affected Paragraphs of TR-105696-R7 (BWRVIP-03)Revision 7: Boiling Water Reactor Pressure Vessel and Internals Examination Guidelines(EPRI Report 1009910, December 2004).


xxv Updated the Inspection Focus Group roster.

2.5, Para. 4.3

2.5, Para. 6.3.2

2.6, Para. 3.1

2.6, Para. 3.3

2.6, Para. 7.3

2.6, Para. 7.5

2.6, Para. 11.0

Added guidance for visual examination training, regardingdetection and reporting of unusual crud deposits on the vesselinterior or internals.

Clarified EVT-1 guidance to require that the resolution targetsmust be seen as a dark object; detection only of the bright, glintingreflection of the lights is not adequate.

Clarified UT personnel requirements to include CP- 189 in additionto ASNT-TC- IA.

Corrected errata.

Clarified discussion of one-sided UT access. This change was alsomade in many report sections documenting individual techniquedemonstrations.

Clarified requirement for adequate recording of transducer positiondata in ultrasonic examination.

New paragraph, providing background information on UT withone-sided access.

xi

2.7, Para. 3.1

4.4.36, 5.4.21

4.4.37-4.4.41

4.7.6-4.4.7

5.4.37-5.4.39

5.6.4

10.3.5

10.4.1

10.4.11-10.4.14, 10.5.2

10.6.4

Clarified ET personnel requirements to include CP- 189 in additionto ASNT-TC- IA.

Corrected errata.

New sections: New NDE technique demonstrations.

New sections: New delivery system demonstrations.


New section: New delivery system demonstration.

Added documentation of new jet pump beam mockups.

Modified discussion of single-side access, for consistency withsimilar discussions elsewhere in the document.


New section: New delivery system demonstration.

xii


This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994 Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and Boiling Water Reactor Pressure Vesseland Internals Examination Guidelines (BWRVIP-03) (EPRI Report TR- 105696, October 1995).The changes listed below supersede the affected Paragraphs of TR-105696-R6 (BWRVIP-03)Revision 6: Boiling Water Reactor Pressure Vessel and Internals Examination Guidelines,(EPRI Report 1008061, December 2003).


xxxiii Updated the Inspection Focus Group roster.

Chapter 1

2.5, Para. 3.5

2.5, Para. 6.2

2.5, Para. 6.2.2

2.6, Para. 3.3, 4.1

2.6, Para. 5.2

4.3.1.8, 4.3.1.9

4.4.2

Replaced all references to Inspection Committee with FocusGroup.

Removed recording medium, water clarity, and lighting from listof key elements.

Changed title from Minimum Water Clarity to EnvironmentalConditions.

Added lighting conditions as an environmental condition, alongwith water clarity.

Clarified UT qualifications that are required for standby liquidcontrol welds and recognizes the recent availability of qualifiedmanual examiners.

Clarified acceptability of normal variation in transducer frequency.

New sections: Added documentation of new mockups BWRVIP-SSC-1 and BWRVIP-H6OH.

Added new Demonstration References for UT Demonstrations 33and 34.

xiii

4.4.35,4.4.36 New sections: New NDE technique demonstrations.

5.3.2

5.4.21

5.4.29-36

10.2

11.1

Changed the word six to seven in the first line of the thirdparagraph.

Corrected an erratum and clarified the description of a technique'sperformance.


Added a paragraph providing VT- I guidance for viewing jet pumpwedges.

Updated BWRVIP-27 to BWRVIP-27A where necessary.

Updated guidance for SLC examination to include all allowableinspection alternatives: volumetric every ten years, surfaceexamination every other outage, or enhanced leakage inspectionevery outage. Enhanced leakage inspection is to be performed withthe insulation removed.

11.2.3, 11.2.4

xiv


This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994 Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and the October 1995 document Boiling WaterReactor Pressure Vessel and Internals Examination Guidelines (BWRVIP-03). The changeslisted below supersede the affected paragraphs of TR-105696R5 (BWRVIP-03) Revision 5:Boiling Water Reactor Pressure Vessel and Internals Examination Guidelines, December 2002.


xix

5.4.27 - 5.4.28

5.6.3

6.4.32 - 6.4.35

All NDE techniqueand delivery systemdemonstrations

Many UT demonstrations

Updated the Inspection Focus Group roster.


New section: New NDE delivery system demonstration.


Added the publication date of each demonstration.

Where appropriate, added a note stating the need to ultrasonicallyexamine stainless steel and nickel-alloy welds from both directionsif possible. (The same note was already present in generic form inSection 2.6, the UT Standard. This action identifies more clearlywhich UT technique demonstrations it applies to.)

xv


This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994 Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and the October 1995 document Boiling WaterReactor Pressure Vessel and Internals Examination Guidelines (BWRVIP-03). The changeslisted below supersede the affected paragraphs of TR-105696R4 (BWRVIP-03) Revision 4:Boiling Water Reactor Pressure Vessel and Internals Examination Guidelines.

Affected Section(s)

xvii

2.5, Para. 8.1.2

2.6 and 2.7, Para. 2.4

2.6, Para. 3.3

2.6, Para. 7.3

4.4.2,6.4.2

4.4.33-4.4.34

4.7.5

6.3.1.4

6.4.18, 6.4.19 and 6.4.24

6.4.26-6.4.31

10.4.10

Description of Change

Updated the Inspection Focus Group roster.

Clarifies documentation of EVT-1 examination coverage torecognize access limitations. Documentation must include anestimate of the percentage of the examination area that wascovered with EVT-1 quality.

New paragraphs. References ASNT CP-189 in addition to SNT-TC- 1A for qualification and certification of examination personnel.

Clarifies qualification requirements for personnel performing UT.Provides personnel qualification requirements for examiningstandby liquid control welds, and for determining whether flawshave propagated into the pressure vessel. Deleted Paragraph3.3.3.2, which was made redundant by this change.

New paragraph. States the need to ultrasonically examine stainlesssteel and nickel-alloy welds from both directions.

Updated demonstration tables.



Added documentation of core spray tee box mockup BWRVIP-N.

Withdrew UT demonstrations for core spray hidden weld P9because of recent findings from a new, more comprehensive set ofmockups.


New section: New NDE technique demonstration.

xvii


This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994 Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and the October 1995 document Boiling WaterReactor Pressure Vessel and Internals Examination Guidelines (BWRVIP-03). The changeslisted below supersede the affected paragraphs of TR-105696R3 (BWRVIP-03) Revision 3December 2000: Boiling Water Reactor Pressure Vessel and Internals Examination Guidelines.


xvii Updated the Committee roster.

2.6, Para. 3.3

4.1,5.1, 6.1,7.1, 8.2,9.2, 10.2, 11.2, 12.2, 13.2

4.4.2,6.4.2

4.4.29-4.4.32

5.3.5

Clarifies prerequisite for UT data analysis personnel: their IGSCCqualification must be on non-overlaid components.

Clarifies that examination procedures must be appropriate to thespecific configuration of the plant. Previously "utility-specific"procedures were called for. This change of wording is intended toremove any suggestion that the procedures must be tiedadministratively to the specific utility.

Updated demonstration tables.


New section: Description of BWR/2 H8/H9 mockups.



5.4.23-5.4.26

5.6.2

6.4.21-6.4.25 New sections: New NDE technique demonstrations.

New section: New NDE technique demonstration.8.4.4

TOC, Figure 6.3.1.5-1,11.2.3 Correction of errata.

xix


This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994 Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and the October 1995 document Boiling WaterReactor Pressure Vessel and Internals Examination Guidelines (BWRVIP-03). The changeslisted below supersede the affected paragraphs of the December 1999 document Boiling WaterReactor Pressure Vessel and Internals Examination Guidelines (BWRVIP-03) Revision 2.


Updated the Committee roster.I

2.5, Para. 8.1.3

5.3.4

For EVT-1, recommends that the method of measuring flaw length(estimation or ruler) be recorded.

Updated the description of shroud support mockups.


Updates status of hidden welds.

New section: description of BWR/6 core spray mockup.

5.4.21, 5.4.22

6.2.2, 9.2, 10.2

6.3.1.5

6.4.20

10.4.9, 10.5.1

New section: New NDE technique demonstration.


Updated the status of control rod guide tube mockup.13.3

xxi


This is a living document. Updates to the included data will be added as they are developed.Minor or editorial changes may not appear in this summary listing of significant changes. Thisdocument supersedes the November 21, 1994 Inspection Committee document BWR-VIP CoreShroud NDE Uncertainty & Procedure Standard and the October 1995 document Boiling WaterReactor Pressure Vessel and Internals Examination Guidelines (B WR VIP-03). The changeslisted below supersede the affected paragraphs of the March 1999 document Boiling WaterReactor Pressure Vessel and Internals Examination Guidelines (BWRVIP-03) Revision 1.


I Updated the Committee roster.

2.6, Paragraph 3.3 Modified the personnel qualification requirements for selectedexaminations.

3.0 Correction: Changed heading numbers to correspond with rest of thedocument.

4.3.1.7 New section: Description of new mockup BWRVIP-H 1.

4.4.28 New section: New NDE technique demonstration.


6.3.1.2 Correction: Figure 6.3.1.2-4 correct image inserted.

6.4.18-19 New sections: New NDE technique demonstrations.


xxiii


This is a living document. Updates to the included data on components that had already beenaddressed, and new report sections on components that had not yet been addressed, will be addedas they are developed. Minor or editorial changes may not appear in this listing. This documentsupersedes the November 21, 1994 Inspection Committee document BWR-VIP Core Shroud NDEUncertainty & Procedure Standard and the October 1995 document Boiling Water ReactorPressure Vessel and Internals Examination Guidelines (BWRVIP-03).


I Updated the Committee roster and Acknowledgments.

2.1 - 2.4 Changes to administrative procedures, made necessary bydiscontinuation ofreferenced Inspection Committee workinggroups. Revised key elements for visual inspection.

2.5 New section: "Generic Standards for Visual Examination ofReactor Pressure Vessel Internals, Components, and AssociatedRepairs."

2.6 New section: "Generic Standards for Ultrasonic Examination ofBWR Vessel Internal Components."

2.7 New section: "Generic Standards for Eddy Current Examinationof BWR Vessel Internal Components."

3.0 New section: "Demonstration of Accuracy of Flaw LengthMeasurement by Visual Examination." This section replaces theexisting Section 3.

3.0 Correction: Changed heading numbers to correspond with rest ofthe document.

4 Added reference to generic NDE standards, Sections 2.5 - 2.7.

4.3 Added documentation of new mockups.

xxv

4.4.19 -4.4.26,4.6.5 - 4.6.6,4.7-3

4A, 4B, 4C

5

5.3

5.4.10 - 5.4.18

New sections: Documentation of NDE demonstrationsconducted since issuance of prior documents.

Deleted. Shroud-specific NDE standards deleted, references togeneric standards in Sections 2.5 - 2.7 added.

Added reference to generic NDE standards, Sections 2.5 - 2.7.

Added documentation of new mockups.

New sections: Documentation of NDE demonstrations conductedsince issuance of prior documents.

New section: Core Spray Piping and Sparger. These componentshad not been addressed in prior documents, except for Section 6A,"Standards for Visual Inspection of Core Spray Piping, Spargers,and Associated Components."

Section 6A, "Standards for Visual Inspection of Core SprayPiping, Spargers, and Associated Components," is now deleted andSection 2.5 is referenced instead. New Section 6A: "Investigationof Core Spray Internal Piping Overlay Inspection."

New section: Top Guide.

New section: Core Plate.

6

6A

7

8

9

10

11

New section: LPCI Coupling.

New section: Jet Pump Assembly.

New section: Standby Liquid Control.

New section: Vessel Attachments.

New section: Lower Plenum.

New section: Vessel Penetrations.

12

13

14

xxvi

BWRVIP INSPECTION FOCUS GROUP

Charles Wirtz, Technical Chairman

Rich CiemiewiczBunny CrockerPatrick GraedelFred HabibRick HambletonThomas JonesScott LarsonTim McClureTony OliveriGary ParkPorfirio Perez TegedorDouglas RameyRudy SchwammbergerRick SealsTed SieverKevin WhiteNorimichi Yamashita

Jeff Landrum, EPRI Task Manager

First Energy Nuclear Operating Company

Exelon CorporationEntergy Operations, Inc.BKW FMB Energie AG (KKM)PPL Susquehanna, LLCDetroit Edison CompanyNuclear Management CompanyProgress Energy, Inc.Nebraska Public Power DistrictPSEG Nuclear,LLCDuane Arnold Energy CenterIberdrola Generacion, S. A.Energy NorthwestKemkraftwerk Leibstadt AGTennessee Valley AuthorityConstellation Energy GroupSouthern Nuclear Operating CompanyTokyo Electric Power Company

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ACKNOWLEDGMENTS

The BWRVIP Inspection Focus Group acknowledges the support of General Electric, VisualInspection Technologies, Imaging and Sensing Technologies, RJ Electronics, and FramatomeTechnologies in providing personnel and equipment for demonstration of visual examinationtechniques.

The staff of the EPRI NDE Center are acknowledged for their successful completion of thisdocument:

Mark DennisJeff LandrumGreg SelbyPaul Zayicek

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CONTENTS

*1 BW RVIP OVERVIEW AND BACKGROUND ........................................................................ 1-1

1.1 BW RVIP ....................................................................................................................... 1-1

1.2 BW RVIP Inspection Focus G roup ................................................................................ 1-1

1.3 G eneral Approach to Inspection Support ..................................................................... 1-2

1.4 Im plem entation Requirem ent ....................................................................................... 1-3

2 GENERAL PROCEDURES .................................................................................................... 2-1

2.1 G uidelines for Use of BW RVIP Mockups ..........................................................................

1.0 Purpose ........................................................................................................................

2.0 Reference .....................................................................................................................

3.0 G uidelines for Usage ....................................................................................................

4.0 G uidelines for Use Prioritization ...................................................................................

2.2 Protocol for NDE Technique Demonstrations on BWRVIP Mockups ...............................

1.0 Purpose ........................................................................................................................

2.0 Responsibilities ............................................................................................................

3.0 Prerequisites ................................................................................................................

4.0 Demonstration Plan ......................................................................................................

5.0 Dem onstration Process ................................................................................................

6.0 Results Reporting and Docum entation ........................................................................

2.3 G uidelines for Determ ining NDE Technique Uncertainty ..................................................

1.0 Purpose ........................................................................................................................

2.0 References ...................................................................................................................


4.0 Demonstration Process ................................................................................................

5.0 Docum entation .............................................................................................................

2.4 G uidelines for Determ ining Inspection Tool Positioning Uncertainty ................................

1.0 Purpose ........................................................................................................................

2.0 References ...................................................................................................................

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4.0 Guidelines for Uncertainty Measurements ...................................................................

5.0 Demonstration Plan ......................................................................................................

6.0 Demonstration Process ................................................................................................

7.0 Documentation .............................................................................................................

2.5 Generic Standards for Visual Inspection of Reactor Pressure Vessel Internals,

Components, and Associated Repairs .......................................................................................

1.0 Purpose ........................................................................................................................

2.0 Scope ...........................................................................................................................

3.0 Definitions ....................................................................................................................

4.0 Personnel Training/Experience ....................................................................................

5.0 Equipment Requirements .............................................................................................

6.0 Inspection Requirements .............................................................................................

7.0 Evaluation of Indications ..............................................................................................

8.0 Documentation of Results ............................................................................................

2.6 Generic Standards for Ultrasonic Examination of BWR Vessel Internal

Components ...............................................................................................................................

1.0 Scope ...........................................................................................................................

2.0 References ...................................................................................................................

3.0 Personnel .....................................................................................................................

4.0 Technique Demonstrations ..........................................................................................

5.0 Equipment ....................................................................................................................

6.0 Calibration ....................................................................................................................

7.0 Exam ination .................................................................................................................

8.0 Recording .....................................................................................................................

9.0 Evaluation ....................................................................................................................

10.0 Reporting .....................................................................................................................

11.0 Examination of Stainless Steel and Nickel-Alloy Welds with Single-Sided Access .........................................................................................................................

2.7 Generic Standards for Eddy Current Examination of BWR Vessel Internal

Components ...............................................................................................................................

1.0 Scope ...........................................................................................................................

2.0 References ...................................................................................................................

3.0 Personnel .....................................................................................................................

4.0 Technique Demonstration ............................................................................................

5.0 Equipment ....................................................................................................................

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6.0 Calibration ....................................................................................................................

7.0 Exam ination .................................................................................................................

8.0 Recording .....................................................................................................................

9.0 Evaluation ....................................................................................................................

10.0 Reporting .....................................................................................................................

3 DEMONSTRATION OF ACCURACY OF FLAW LENGTH MEASUREMENT BY

VISUAL EXAM INATION ............................................................................................................ 3-1

3.1 Sum mary ..........................................................................................................................

3.2 Dem onstration ..................................................................................................................

3.2.1 Vendors ....................................................................................................................

3.2.2 Mockups ...................................................................................................................

3.2.3 Flaws ........................................................................................................................

3.2.4 Cameras ...................................................................................................................

3.2.5 Measurement Techniques ........................................................................................

3.3 Sizing Performance ...........................................................................................................

3.3.1 Estimation ................................................................................................................

3.3.2 M easurement by Ruler .............................................................................................

4 SHROUD ................................................................................................................................ 4-1

4.1 Sum mary ..................................................................................................................... 4-1

4.2 Inspection Considerations ........................................................................................... 4-1

*4.3 Applicable Mockups ..................................................................................................... 4-1

4.3.1 Shroud W eld M ockups ........................................................................................ 4-2

4.3.1.1 NDE Center's Original H3 Mockup ............................................................... 4-2

4.3.1.2 Utility H3 and H4 Mockups ............................................................................ 4-2

4.3.1.3 Shroud Block BW RVIP-A: Ring-to-Cylinder .................................................. 4-2

4.3.1.4 Shroud Block BW RVIP-B: Ring-to-Cylinder .................................................. 4-4

4.3.1.5 Shroud Block BW RVIP-C: Cylinder-to-Cylinder ............................................ 4-6

4.3.1.6 Shroud Mockup BWRVIP-G and H: Ring Segment Welds ........................... 4-8

4.3.1.7 Shroud Mockup BW RVIP-H1: Shroud W eld H1 ........................................ 4-11

4.3.1.8 Shroud Mockup BWRVIP-SSC1: Shroud Scallops .................................... 4-11

4.3.1.9 Shroud Mockup BWRVIP-H6OH: Overhanging Core PlateSupport Ring .............................................................................................................. 4-13

4.3.2 Special Purpose M ockups ................................................................................. 4-14

4.3.2.1 Surface Roughness .................................................................................... 4-14

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4.3.2.2 Multiple Parallel Cracks .............................................................................. 4-15

4.3.2.3 EDM Notches in W eld Toe .......................................................................... 4-16

4.4 UT Technique Demonstrations for Core Shroud W elds ............................................. 4-17

*4.4.1 General Findings for UT .................................................................................... 4-17

*4.4.1.1 Detection of Shallow Reflectors .................................................................. 4-17

*4.4.1.2 Detection of Skewed Reflectors .................................................................. 4-17

*4.4.1.3 Effect of M ultiple Parallel Defects ............................................................... 4-18

*4.4.1.4 Effect of Roughness of Scanning Surface .................................................. 4-18

4.4.2 UT Demonstration Summary ............................................................................. 4-19

4.4.3 UT Demonstration 1 .................................................................................................









4.4.12 UT Demonstration 10 ...............................................................................................
















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4.4.28 UT Dem onstration 26 ...............................................................................................

4.4.29 UT Dem onstration 27 ..............................................................................................


















4.5 VT Technique Demonstrations for Core Shroud W elds ............................................. 4-20

*4.5.1 VT General Findings ......................................................................................... 4-20

4.5.1.1 Training ....................................................................................................... 4-20

*4.5.2 VT Dem onstration 1 .......................................................................................... 4-20

4.6 ET Technique Dem onstrations for Core Shroud W elds ............................................. 4-23

4.6.1 ET General Findings ......................................................................................... 4-23

4.6.1.1 Detection of Skewed Reflectors .........................................................................

4.6.1.2 Effect of Scanning on a Rough Surface .............................................................

4.6.1.3 Scan Pattem ......................................................................................................

*4.6.2 ET Dem onstration 1 .......................................................................................... 4-26

4.6.2.1 Crack Length Measurem ent ........................................................................ 4-26

4.6.2.2 O ptim um Param eters for ET Imaging ......................................................... 4-26

*4.6.3 ET Demonstration 2 .......................................................................................... 4-29

4.6.4 ET Demonstration 3 .......................................................................................... 4-30

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4.6.4.1 Data Acquisition .................................................................................................

4.6.4.2 Data Evaluation ..................................................................................................



4.7 Delivery System Demonstrations for Core Shroud W elds ......................................... 4-36*4.7.1 Delivery System Demonstration 1 ..................................................................... 4-37

*4.7.2 Delivery System Demonstration 2 ..................................................................... 4-38

4.7.3 Delivery System Demonstration 3 ..................................................................... 4-39





4.7.7.1 Flaw Length Measurement W ithin a Single Scan .................................................

4.7.7.2 Flaw Length Measurement Using More Than One Scan ......................................

*4.8 References ................................................................................................................ 4-44

5 SHROUD SUPPORT .............................................................................................................. 5-1

5.1 Summary ..........................................................................................................................

5.2 Inspection Considerations ................................................................................................

5.2.1 Chicago Bridge & Iron/CBI Nuclear Shroud Supports ..............................................

5.2.2 Babcock & W ilcox Shroud Supports ........................................................................

5.2.3 Combustion Engineering Shroud Supports ..............................................................

5.2.3.1 Gusset Supports ................................................................................................

5.2.3.2 Cone Skirt Support .............................................................................................

5.2.3.3 Heavy Steel Baffle Plate ....................................................................................

5.2.4 Inspection Access ....................................................................................................

5.3 Applicable Mockups ..........................................................................................................

5.3.1 Shroud Support Mockup BW RVIP-D: W eld H7 .......................................................

5.3.2 Shroud Support Mockups BWRVIP-E, BWRVIP-El, and BWRVIP-E2:W eld H9 .................................................................................................................................

5.3.3 Shroud Support Mockup BW RVIP-F: W eld H8 ........................................................

5.3.4 Shroud Support Mockups BWRVIP-P, BWRVIP-Q1, BWRVIP-Q2 .........................

5.3.5 Shroud Support Mockups BWRVIP-B2SS1 and BWRVIP-B2SS2 ..........................

5.4 UT Technique Demonstrations for Core Shroud Support W elds ......................................

5.4.1 General Findings for UT ...........................................................................................

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5.4.1.1 Effect of Alloy 82/182 W eld Material ..................................................................

5.4.1.2 Effect of Mismatch in the Fit-up of W eld H7 .......................................................









5.4.10 UT Dem onstration 9 .................................................................................................






















5.4.32 UT Dem onstration 31 ..............................................................................................


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5.5 ET Technique Demonstrations for Core Shroud Support W elds ......................................

5.5.1 General Findings for ET ...........................................................................................

5.5.2 ET Demonstration 1 .................................................................................................

5.6 Delivery System Demonstrations for Core Shroud Support W elds ...................................

5.6.1 Delivery System Dem onstration 1 ............................................................................

5.6.2 Delivery System Demonstration 2 ............................................................................



6 CORE SPRAY PIPING AND SPARGER ............................................................................... 6-1

6.1 Summary ..........................................................................................................................


6.2.1 Downcomer Sleeve ..................................................................................................

6.2.2 Tee Box Assembly ...................................................................................................

6.2.3 Shroud Connection Region ......................................................................................


6.3.1 Core Spray Mockups ................................................................................................

6.3.1.1 Downcomer Sleeve Joint Mockup (BW RVIP-J) .................................................

6.3.1.2 BW R/2 Shroud Penetration Mockup (BW RVIP-K) .............................................

6.3.1.3 BW R/3-5 Shroud Penetration Mockup (BW RVIP-L) ..........................................

6.3.1.4 BWR/3-5 Core Spray Header Tee Box Mockups (BWRVIP-M and -N) .............

6.3.1.5 BWR/6 Core Spray Pipe Coupling Assembly Mockup (BWRVIP-CS6) .............

6.4 UT Technique Demonstrations for Core Spray W elds ......................................................


6.4.1.1 Detection and Sizing of Flaws Parallel to the W eld ...........................................

6.4.1.2 Detection of Flaws Transverse to the W eld .......................................................

6.4.1.3 Effect of Roughness of Scanning Surface .........................................................

6.4.2 UT Demonstration Summary ....................................................................................


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6 A INVESTIGATION OF CORE SPRAY INTERNAL PIPING OVERLAY INSPECTION..... 6A-1

6A.1 Materials ...........................................................................................................................

6A.1.1 Probes .....................................................................................................................

6A.1.2 Ultrasonic Instrument ..............................................................................................

6A.1.3 Mockups ..................................................................................................................

6A.2 Surface Condition .............................................................................................................

6A.3 Exam ination Results .........................................................................................................

6A.4 Conclusions ......................................................................................................................

6A.5 References .......................................................................................................................

7TOP GUIDE ............................................................................................................................ 7-1

7.1 Sum m ary ..........................................................................................................................


7.2.1 Aligner Pin Assemblies ............................................................................................

7.2.2 Hold-Down Assem blies ............................................................................................

7.2.3 W edges ....................................................................................................................

7.2.4 BW R/6 Hold-Down Studs .........................................................................................

7.2.5 Rim -to-Bottom Plate W eld ........................................................................................

7.2.6 G rid Beams ..............................................................................................................


7.3.1 Top Guide Grid Mockup BW RVIP-I ..........................................................................

7.4 UT Technique Demonstrations for Top Guide Com ponents .............................................


7.4.1.1 G rid Beams ........................................................................................................


8 CORE PLATE ......................................................................................................................... 8-1

8.1 Sum m ary ..........................................................................................................................


8.2.1 Rim Hold-Down Bolt Locations ................................................................................


8.4 UT Technique Demonstrations for Core Plate Rim Hold-Down Bolts ...............................

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9 LPCI CO UPLING .................................................................................................................... 9-1

9.1 Summary ..........................................................................................................................



9.4 UT Technique Demonstrations for LPCI Coupling W elds .................................................

10 JET PUM P ASSEM BLY ..................................................................................................... 10-1

10.1 Summary ..........................................................................................................................


10.3 Applicable Mockups .........................................................................................................

10.3.1 Mockup BW RVIP-U ..................................................................................................

10.3.2 Mockup BW RVIP-V ..................................................................................................

10.3.3 Mockup BW RVIP-Z3 ................................................................................................

10.3.4 Mockup BW RVIP-Z4 ................................................................................................

10.3.5 Jet Pump Beam Mockups ........................................................................................

10.4 UT Technique Demonstrations .........................................................................................















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10.5 ET Technique Demonstrations .........................................................................................



10.6 Delivery System Demonstrations .....................................................................................





11 STANDBY LIQUID CONTROL ........................................................................................... 11-1

11.1 Sum m ary ..........................................................................................................................


11.2.1 Nozzle-to-Vessel W eld .............................................................................................

11.2.2 Penetration-to-Vessel W eld .....................................................................................

11.2.3 Nozzle-to-Safe-End W eld .........................................................................................

11.2.4 Penetration-to-Safe-End Extension W eld ................................................................


11.3.1 Mockup BW RVIP-X1 ................................................................................................

11.3.2 Mockup BW RVIP-X2 ................................................................................................

11.3.3 Mockup BW RVIP-Y3 ................................................................................................

11.3.4 Mockup BW RVIP-Y4 ................................................................................................

11.3.5 Mockup BW RVIP-Y5 ............................................................................................

11.4 UT Technique Demonstrations for SLC Com ponents ................................................



11.4.3 UT Dem onstration 2 .................................................................................................

12 VESSEL ATTACHM ENTS ................................................................................................. 12-1

12.1 Sum m ary ..........................................................................................................................



12.4 UT Technique Demonstrations for Vessel Attachment W elds .........................................

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13 LOW ER PLENUM .............................................................................................................. 13-1

13.1 Sum m ary ..........................................................................................................................


13.3 Applicable M ockups .........................................................................................................

13.4 UT Technique Dem onstrations for Lower Plenum W elds ................................................

14 INSTRUM ENT PENETRATIO NS ....................................................................................... 14-1

14.1 Sum m ary ..........................................................................................................................


* This section, its subsections, and all associated figures and tables are not proprietary.

All sections that are NOT marked with an asterisk, their subsections, and associated figuresand tables, are proprietary.

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LIST OF FIGURES

Figure 4.3.1.3-1. Design of Shroud Mockup BWRVIP-A ........................................................... 4-3

Figure 4.3.1.3-2. Cross Section of Weld in Mockup BWRVIP-A ................................................ 4-4

Figure 4.3.1.4-1. Design of Shroud Mockup BWRVIP-B ........................................................... 4-5Figure 4.3.1.4-2. Cross Section of Weld in Mockup BWRVIP-B ................................................ 4-6Figure 4.3.1.5-1. Design of Shroud Mockup BWRVIP-C ........................................................... 4-7

Figure 4.3.1.5-2. Cross Section of Weld in Mockup BWRVIP-C ................................................ 4-8Figure 4.3.1.6-1. Mockup BWRVIP-G and BWRVIP-H, Representing the Ring

S egm ent W eld .................................................................................................................... 4-9Figure 4.3.1.6-2. Cross Section of Mockup BWRVIP-G and BWRVIP-H ................................. 4-10Figure 4.3.1.6-3. Shroud Ring Segment Weld ......................................................................... 4-10Figure 4.3.1.7-1. Mockup BWRVIP-H1: Shroud Weld HI ....................................................... 4-45

Figure 4.3.1.8-1. Mockup BWRVIP-SSC1 ............................................................................

2007-047 BWR Vessel & Internals Project (BWRVIP) · 2012. 11. 29. · 2007-047 BWR Vessel &...

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Transcript of 2007-047 BWR Vessel & Internals Project (BWRVIP) · 2012. 11. 29. · 2007-047 BWR Vessel &...