st. lucie, unit 2 - in-service inspection plans, use of ... · *as submitted and approved by st....

FPL

Florida Power & Light Company, 6501 S. Ocean Drive, Jensen Beach, FL 34957

March 29, 2007

L-2007-04510 CFR 50.410 CFR 50.55a

U. S. Nuclear Regulatory CommissionAttn: Document Control DeskWashington, D.C 20555

Re: St. Lucie Unit 2Docket No. 50-3 89In-Service Inspection PlansUse of Structural Weld Overlays as an Alternative Repair TechniqueThird Ten-Year Interval Unit 2 Relief Reqiuest 10

Pursuant to the provisions of 10 CFR 50.55a(a)(3)(i), Florida Power & Light (FPL)requests approval to use structural weld overlays (SWOLs) as an alternative repairmethod. Dissimilar metal welds (DMWs) have shown a propensity for primary waterstress corrosion cracking (PWSCC) degradation. For the upcoming SL-2- 17 refuelingoutage, six (6) DMWs located on the pressurizer and hot leg piping are currentlyscheduled to have SWOLs applied. Relief is requested on the basis that the reliefrequest provides an acceptable level of quality and safety.

FPL requests approval of the relief request prior to entering Mode 4 during the fall 2007St. Lucie Unit 2 refueling outage, SL2-17, tentatively scheduled for Mid December.Please contact Ken Frehafer at 772-467-7748 if there are any questions about thissubmittal.

Very truly yours,

Site Vice PresidentSt. Lucie Plant

Attachment

GLJ/KWF

A04-7an FPL Group company

St. Lucie Unit 2 L-2007-045Third Inspection Interval AttachmentRelief Request Number 10 Page 1 of 32

Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i)

Alternative Provides Acceptable Level of Quality and Safety

USE OF WELD OVERLAYS AS AN ALTERNATIVE REPAIR TECHNIQUE

1.0 ASME Code Components Affected

Code components associated with this request are six (6) Class 1 safe end-to-nozzle dissimilar metal welds (DMWs) with Alloy 82/1 82 weld metal that arebelieved to be susceptible to Primary Water Stress Corrosion Cracking(PWSCC). Preemptive full structural weld overlays (SWOLs) are planned to beapplied to these DMWs. In addition, the SWOLs will extend across the six (6)adjacent stainless steel pipe/elbow-to-safe end similar metal welds. These weldsare scheduled to have SWOLs applied during the upcoming St. Lucie Unit 2(PSL2) SL-2-17 refueling outage.

1.1 Category and System Details:

Code Class: Class 1System Welds: Reactor Coolant SystemExamination Categories: R-A**As submitted and approved by St. Lucie Unit 2, 3rd 10-year ISI ProgramRelief Request 2

1.2 Component Descriptions:

The application of this alternative is to apply SWOLs on one (1) safe end-to-pressurizer surge nozzle weld, one (1) safe end-to-pressurizer relief nozzle weld,two (2) safe end-to-hot leg shutdown cooling outlet nozzle welds (one in each hotleg), one (1) safe end-to-hot leg B surge nozzle weld and one (1) safe end-to-hotleg A drain nozzle weld. The SWOLs will also extend outward from the nozzleacross the adjacent stainless steel pipe/elbow-to-safe end welds. The applicableweld identifications are as follows in Table 1.

St. Lucie Unit 2Third Inspection IntervalRelief Request Number 10

L-2007-045Attachment

Page 2 of 32

TABLE I

Weld Nos.

Nozzle to Safe End Safe-End to

Item Location Weld Pipe/Elbow

1 Pressurizer Surge Line Nozzle RC-514-671 RC-1 08-FW-1

2 Pressurizer Relief Line Nozzle RC-506-671 RC-101-FW-1

3 Surge Line to Hot Leg B Pipe Nozzle RC-301-771 RC-1 08-FW-3

4 Shutdown Cooling Outlet to Hot Leg 'A' Pipe RC-501-771 RC-162-FW-1

5 Shutdown Cooling Outlet to Hot Leg 'B' Pipe RC-302-771 RC-147-FW-1

6 Hot Leg 'A' Drain Nozzle RC-1 14-502-771 RC-145-FW-1.



Page 3 of 32

1 .3 Component Materials:

The specific materials are shown in Table 2:

TABLE 2

Materials

Item Location Nozzle Safe-End Pipe/Elbow Buttering

1 Pressurizer Surge P-No. 3 Group 3 Low P-No.8 Cast P-No.8 Cast F-No. 43Line Nozzle Alloy Steel SA-508 Stainless Steel Stainless Steel SA- Alloy

CL2 SA-351 CF8M. 351 CF8M. 82/182

2 Pressurizer Relief P-No. 3 Group 3 Low SA-1 82 F316 P-No. 8 SA-312 TP F-No. 43Line Nozzle Alloy Steel SA-508 304 Stainless Steel Alloy

CL2 82/1 82

3 Surge Line to Hot P-No. 1 Group 2 P-No.8 Cast P-No.8 Cast F-No. 43Leg 'B' Pipe Carbon Steel SA-105 Stainless Steel Stainless Steel SA- AlloyNozzle Grade 11 SA-351 CF8M. 351 cF8M. 82/182

4 Shutdown Cooling P-No. 1 Group 2 P-No.8 Cast P-No. 8 SA-312 TP F-No. 43Outlet to Hot Leg Carbon Steel SA-1 05 Stainless Steel 304 Stainless Steel Alloy'A' Pipe Grade 11 SA-351 CF8M. 82/1 82

5 Shutdown Cooling P-No. 1 Group 2 P-No.8 Cast P-No. 8 SA-312 TP F-No. 43Outlet to Hot Leg Carbon Steel SA-1 05 Stainless Steel 304 Stainless Steel Alloy'B' Pipe Grade 11 SA-351 CF8M. 82/1 82

6 Hot Leg 'A' Drain P-No. 1 Group 2 SA-1 82 F316 P-No. 8 SA-312 TP F-No. 43Nozzle Carbon Steel SA-105 304 Stainless Steel Alloy

Grade 11 82/182

St. Lucie Unit 2 AttachmentThird Inspection Interval Atachentof3Relief Request Number 10Paef2

2.0 Applicable Code Edition and Addenda

PSL-2 is currently in the 3rd 10-year Inservice inspection (ISI) interval. TheAmerican Society of Mechanical Engineers (ASME) Boiler and Pressure VesselCode (Code) of record for the current 10-year IS[ interval is Section XI, 1998Edition, including Addenda through 2000 (Reference 1). This is also the versionused for the Repair/Replacement Program.

3.0 Applicable Code Requirement

The applicable Code requirement for which the relief is requested is ASME CodeSection Xl, 1998 Edition including Addenda through 2000 (Reference 1),IWA-441 0(a), IWA-461 1.1 (a) and Appendix ViIl Supplement 11.

IWA-441 0(a) states in part the following:

"Welding, brazing, defect removal, and installation activities shall be performed inaccordance with IWA-4420 or IWA-4430, and the other requirements of thisSubarticle.....

IWA-461 1.1 (a) states in part the following:

"Defects shall be removed or reduced in size in accordance with this Paragraph."

Appendix ViII provides requirements for performance demonstration forultrasonic examination systems. Supplement 11 provides qualificationrequirements for full structural overlaid wrought austenitic piping welds.

4.0 Reason for Request

Dissimilar metal welds (DMWs), primarily consisting of Alloy 82/1 82 weld metalare frequently used in pressurized water reactor (PWR) construction to connectstainless steel pipe and safe ends to vessel and pipe nozzles, generallyconstructed of carbon or low alloy ferritic steel. These welds have shown apropensity for PWSCC degradation, especially in components subjected tohigher operating temperatures, such as the pressurizer. See EPRI MRP-169'Technical basis for Preemptive Weld Overlays for Alloy 82/1 82 Butt Welds inPWRs," October 2005 (Reference 2).

For the upcoming SL-2-1 7 refueling outage, six (6) DMWs located on thepressurizer and hot leg piping are currently scheduled to have SWOLs applied.Repair/replacement activities associated with SWOL repairs are required to


address the materials, welding parameters, ALARA concerns, operationalconstraints, examination techniques and procedure requirements for repairs.

ASME Code Section XI, 1998 Edition including Addenda through 2000(Reference 1), IWA-441 0(a) and IWA-461 1.1 (a) do not address all the neededrequirements for this type of repair since potential existing defects will not beremoved or reduced in size, and weld overlay of potential existing flaws in DMWswill be performed. Also comprehensive and generic NRC approved criteria arenot currently available for application of SWOL repairs to DMWs constructed ofAlloy 82/1 82 weld material for mitigation of potential PWSCC.

In addition, ASME Code Section XI, 1998 Edition including Addenda through2000 (Reference 1), Appendix VIII Supplement 11 cannot be implemented aswritten for ultrasonic examination of a structural weld overlay repair. Attachment1 includes a discussion of the Performance Demonstration Initiative (PDI)Program alternatives and their bases with respect to Appendix VI II Supplement11 requirements.

The alternative described in Section 5.0 is proposed to permit the implementationof SWOLs at PSL-2, as an alternative for the repair/replacement requirements ofthe ASME Code Section Xl, 1998 Edition, including Addenda through 2000(Reference 1), IWA-441 0(a), IWA-461 1.1 (a) and Appendix VIII, Supplement 11.

5.0 Proposed Alternative and Basis for Use

The ASME Subcommittee XI has recently approved Section XI Code CaseN-740-1, Draft dated February 2007 "Dissimilar Metal Weld Overlay for Repair ofClass 1, 2, and 3 Items," provided as Attachment 2. This Draft Code Case is theresult of the industry's experience with weld overlay repairs for flaws suspectedor confirmed to be from PWSCC and for the first time directly applies to the Alloy52M weld material that is primarily being used for these overlay repairs.

This proposal requests the use of the Code Case N-740-1 Draft February 2007(Attachment 2) for implementing the six (6) scheduled SWOLs for potentiallyPWSCC susceptible safe end-to-nozzle welds of the pressurizer and reactorcoolant hot leg piping. These SWOLs will include the six (6) adjacent stainlesssteel pipe/elbow-to-safe end welds. This request applies to each of the weldslisted in Section 1.2, which are generically depicted in Figure 1. The proposedalternative is scheduled to be performed during the SL-2-17 Fall 2007 refueloutage.

The ultrasonic and surface examinations will be performed on the temper beadportion of the SWOLs no sooner than 48 hours after completion of the thirdtemper bead layer. Currently, Code Case N-740-1 Draft February 2007,

St. Lucie Unit 2 AttachmentThird Inspection Interval Atachentof3Relief Request Number 10Pgeo3

paragraph 3(a)(2), specifies that ultrasonic and surface examination beperformed 48 hours after the completed weld has returned to ambienttemperature.

The ultrasonic examination of the completed SWOLs will be accomplished withpersonnel and procedures qualified in accordance with ASME Code Section XI,1998 Edition, including Addenda through 2000 (Reference 1) Appendix VIII,Supplement 11 (as specified in Code Case N-740-1 Draft February 2007,section 3 therein), with the alternatives used for complying with the P01Program. See Attachment 1 for the PDI Program changes to Appendix VII ISupplement 11.

5.1 Structural Weld Overlay (SWOL) Design

The SWOLs satisfy all the structural design requirements of the pipe assumingno strength contributed by the original safe end-to-nozzle welds nor thepipe/elbow-to-safe end welds, as if the welds were removed. As shown inFigure 1, the SWOLs will completely cover the existing Alloy 82/182 weld and willextend onto the ferritic nozzle and austenitic stainless steel material on each endof the weld, including the adjacent pipe/elbow-to-safe end weld. The SWOLsextend around the entire circumference of the nozzle. Alloy 52M and 52 fillermetals are compatible with all the wrought and cast base materials and the DMWand similar metal welds that will be covered by the SWOL.

The SWOLs will be designed as full structural overlays (assumed worst caseflaw) in accordance with ASME Section XI Code Case N-740-1 DraftFebruary 2007 (Attachment 2), Section 2 therein. Note that the detailssurrounding the design analysis for the SWOLs are being developed to supportthe PSL2 Fall 2007 refueling outage and our vendor has committed to supplyingthis analysis to FPL. The analysis will be available at the plant for NRC review atthe beginning of the SL-2-17 refuel outage.

5.2 Welding

The welding will be performed in accordance with Code Case N-740-1 DraftFebruary 2007 (Attachment 2) using a remote machine gas tungsten-arc welding(GTAW) process and using the ambient temperature temper bead method withERNiCrFe-7A (Alloy 52M) weld metal. Manual OTAW, using ERNiCrFe-7(Alloy 52) or Alloy 52M will be used if local repairs of weld defects are necessaryor additional weld metal is required locally to form the final SWOL contour inlocations at least 3/16 in. away from the low alloy or carbon steel nozzles.

For applicable cases where Code Case N-740-1 Draft February 2007paragraph 1 (c)(1) applies, the final SWOL ultrasonic and surface examination willbe performed after completion of welding since temper bead welding would not

St. Lucie Unit 2 L'2007-045Third Inspection Interval AttachmentRelief Request Number 10 Page 7of 32

be required. The clarifications in this paragraph are conservative with respect tothe intent of the Construction Code post weld heat treatment (PWHT) exemptionrequirements [Table NB-4622.7(b)-1] since all weld overlays are deposited on thesurfaces of the ferritic steel nozzles instead of partial or complete throughthickness welds applicable for the cases described in the Construction Code.

5.3 Examination

The ultrasonic and surface examinations will be performed on the temper beadportion of the SWOLs no sooner than 48 hours after completion of the thirdtemper bead layer. Currently, Code Case N-740-1 Draft February 2007,Paragraph 3(a)(2), specifies that ultrasonic and surface examination beperformed 48 hours after the. completed weld has returned to ambienttemperature.

The 48 hour delay is intended to provide time for delayed hydrogen crackingoccurrence. Code Case N-740-1 Draft February 2007, Appendix 1 requires themachine or automatic GTAW process to be used for temper bead weldingthereby eliminating the use of welding processes requiring flux for arc shielding.

The machine OTAW temper bead process uses a welding process that isinherently free of hydrogen. The GTAW process relies on bare weldingelectrodes and bare wire filler metal with no flux to absorb moisture. An inert gasblanket provides shielding for the weld and surrounding metal, which protects theregion during welding from the atmosphere and the moisture it may contain andtypically produces porosity free welds. In accordance with the weld procedurequalification, welding grade argon is used for the inert gas blanket. To furtherreduce the likelihood of any hydrogen effects, specific controls will be used toensure the welding electrodes, filler metal and weld region are free of all sourcesof hydrogen.

In addition, the use of the machine GTAW temper bead process provides precisecontrol of heat input, bead placement, bead size and contour. The very precisecontrol over these factors afforded by the machine GTAW process provideseffective tempering of the nozzle ferritic steel HAZ resulting in achievement oflower hardness and tempered martensite. This further reduces susceptibility tohydrogen induced cracking.

EPRI Report 1013558, Temperbead Welding Applications, 48 Hour HoldRequirements for Ambient Temperature Temperbead Welding, TechnicalUpdate, December 2006 (Reference 3) provides justification for reducing the48 hour hold time on P-No. 3 Group No. 3 ferritic steel base material to start aftercompletion of the third temper bead layer instead of the currently specified holdtime in Code Case N-740-1 Draft, February 2007. Report 1013558 addresses


microstructural issues, hydrogen sources, tensile stress and temperature, anddiffusivity and solubility of hydrogen in steels.

The base materials studied in the EPRI report are primarily P-No. 3. Thepressurizer nozzle base materials at PSL2 are P-No. 3 Group. No. 3 and the hotleg piping nozzle base materials are P-No. 1 Group No. 2. The concernsassociated with hydrogen assisted cracking are generally more significant forP-No. 3 than P-No.1 base materials due to the P-No. 3 base materials increasedhardenability. Also, post weld heat treat exemptions shown in ASME Section 111,Table NB-4622.7(b)-1 are provided for P-No. 1 Group No. 2 materials, includingtemper bead welding, whereas no post weld heat treat exemptions, other thantemper bead welding, are permitted for P-No. 3 Group No. 3 materials.

Past industry experience with the use of the machine or automatic GTAWprocess has resulted in no detection of hydrogen induced cracking after the48 hour hold NDE or subsequent in-service inspections.

There is currently an ASME XI Subcommittee action to incorporate the revisedNDE hold requirement into Code Case N-740-1 Draft February 2007. CodeCase N-638-3, "Similar and Dissimilar Metal Welding Using AmbientTemperature Machine GTAW Temper Bead Technique Section Xl Division 1,"has been revised with Main Committee and Board of Nuclear Codes and -

Standards approval to specify NDE 48 hours after completion of the third temperbead IlIayer.

All examinations will meet the requirements of the Code Case N-740-1 DraftFebruary 2007, excluding qualification of the ultrasonic examination for thecompleted SWOLs. The ultrasonic examination qualification will be inaccordance with ASME Code Section XI, 1998 Edition including Addendathrough 2000 (Reference 1), Appendix VIII1, Supplement 11 with the alternativesthat are used to comply with the PDI Program. See Attachment 1 for the PDIProgram changes to Appendix VIII Supplement 11.

The PDI Program allows closer spacing of flaws provided they don't interfere withdetection or discrimination. The specimens used to date for qualification to theTni-party (NRC/BWROG/EPRI) agreement have a flaw population density greaterthan allowed by current Code requirements. These samples have been usedsuccessfully for all previous qualifications under the Tni-party agreementprogram. To facilitate their use and provide continuity from the Tni-partyagreement program to Supplement 11, the PDI Program has merged theTni-party test specimens into their structural weld overlay program.

However, the cast stainless steel base material of the applicable safe ends andthe surge line elbow at the pressurizer surge nozzle and the surge pipe at the hotleg B surge nozzle are not currently within the scope of PDI qualified ultrasonic

St. Lucie Unit 2 L-2007-045Third Inspection Interval AttachmentRelief Request Number 10 Page 9of 32

examination procedures. Qualified representative mockups are not currentlyavailable, and examination procedures and personnel have not yet beendemonstrated for the cast material. In these cases, an Appendix Ill ultrasonicexamination will be performed, using the existing PDI qualified personnel andprocedures as shown in Attachment 1.

5.4 Conclusion

Similar NRC approved requests have been used to produce acceptable weldoverlays when applied to dissimilar metal welds with Alloy 82/1 82 weld material.The proposed alternative uses ASME Section XI Code Case N-740-1 DraftFebruary 2007 (Attachment 2) that has been developed to cover the most recentoperating experience and NRC approved criteria that are associated with similarSWOL applications. Therefore FPL considers that this Case and the PDIProgram provides an acceptable level of quality and safety, consistent withprovisions of 10 CFR 50.55a(a)(3)(i).


6.0 Precedents

Similar requests have been submitted to address the issues that are contained inthis request. These include requests from the Indiana Michigan PowerCompany's, 0. C. Cook Unit 2. NRC verbal approval was received onMarch 23, 2006, for their request, which included the application of full structuralSWOLs applied to their pressurizer dissimilar metal butt welds.

Additionally, the following requests associated with weld overlay repairs havebeen approved by the NRC: AmerGen Energy Company, Three Mile IslandNuclear Station, Unit 1, on July 21, 2004;(1) Constellation Energy's Calvert CliffsNuclear Power Plant, Unit 2, on July 20, 2k05;1(2) Millstone Unit 3, onJanuary 20, 2006;1 (3 and Indiana Michigan Power Company, Donald C. CookUnit 1, on February 10, 2006. (4

(1) NRC letter, Safety Evaluation of Request for Relief from Flaw Removal, HeatTreatment and Nondestructive Examination (NDE) Requirements for the Third 10-Year Inservice Inspection Interval, Three Mile Island Nuclear Station, Unit 1 (TMI-1),Docket No. 50-289, (TAC No. MC12O1), dated: July 21, 2004, (ADAMS AccessionNo. MLO041 670510).

(2) NRC letter, Safety Evaluation for Calvert Cliffs Nuclear Power Plant, Unit No. 2,Docket No. 550-318, Relief Request for Use Weld Overlay and AssociatedAlternative Inspection Techniques (TAO Nos. MC6219 and MC6220), dated July 20,2005, (ADAMS Accession No. ML-051930316).

(3) NRC letter, Safety Evaluation of Relief Request IR-2-39 Pertaining to the Repair andInspection of Nozzle to Safe End Weld, Weld No. 03-X-5641-E-T at Millstone PowerStation Unit No. 3 (MPS3) Docket No. 50-423, (TAO No. MC8609), dated January20, 2006, (ADAMS Accession No. ML-053260012).

(4) NRC letter, Safety Evaluation of Alternative Regarding Repair of Safe-End-To-ElbowWeld 1-RC-9-01F at the Donald C. Cook Nuclear Plant Unit 1, Docket No. 50-315,(TAO No. MC8807), dated February 10, 2006, (ADAMS Accession No.ML-060240355).


7.0 Duration of Proposed Alternative

The alternative requirements of this request will be applied for the duration of upto and including the last outage of the current 3rd 1 0-year ISI interval whichincludes inservice examination requirements of Code Case N-740-1 DraftFebruary 2007 (Attachment 2) for any applied weld overlays. The use of CodeCase N-740-1 Draft February 2007 is requested until the NRC publishes theCode Case as a future revision of Regulatory Guide 1.147. Future inserviceexaminations of weld overlays at PSL-2 beyond this inspection interval will be asrequired by the NRC in the regulations.

8.0 References.

1. ASME Code, Section Xl, 1998 Edition, including Addenda through2000

2. EPRI MRP-169 "Technical Basis for Preemptive Weld Overlays forAlloy 82/182 Butt Welds in PWRs," October 2005.

3. EPRI Report 1013558, Temperbead Welding Applications, 48 HourHold Requirements for Ambient Temperature Temperbead Welding,Technical. Update, December 2006.

9.0 Attachments

Attachment 1 "PDI Program Modifications to Appendix VIII Supplement 11"

Attachment 2 Code Case N-740-1 "Draft Dissimilar Metal Weld Overlay forRepair of Class 1, 2, and 3 Items Section XI, Division 1 "


SS Pipe8(A481 &GFSM[(PZR Surge =o10eI

SS Pipe (SA4312 TP30-4(Hot Leg Shuttdown

OColbig Outlet Nozzles'Mot L4g A Draf " Nozzei ,

88Elbow (SA-8Sl CFSM[i;

(Hot LegSure NxAw8 :


Page 12 of 32

88Sat* hid (8A4161 CFSMjPZR Surge Nozzle& PZR Relief NozzleKb~ Leg B "eNk e&H ut Leg

/Shutdown Coc~ng Outlet Nozzles

Nozzf

Low Alloy SteudIS-SCas9 2

>PZR Surge Nozzl&PZR RelW NozzleCarbnbm Ste" 4SA105 Cr11)Hot Leg B Surge Nozzle &Hot LagShutdowCooling Outlet Nozzle%~Hot Log A DmnNoale

Fig~ure 1'- TypicalWO Config~uration



Page 13 of 32

Attachment 1PDI Program Modifications to Appendix V1II Supplement 11

Appendix V1II, Supplement 11 PDI Modification1.0 SPECIMEN REQUIREMENTS1. 1 General(b) The specimen set shall consist of at least Modification: (b) The specimen set shall consist of atthree specimens having different nominal pipe least three specimens having different nominal pipediameters and overlay thicknesses. They shall diameters and overlay thicknesses. They shall includeinclude the minimum and maximum nominal the minimum and maximum nominal pipe diameters forpipe diameters for which the examination which the examination procedure is applicable. Pipeprocedure is applicable. Pipe diameters within a diameters within a range of 0.9 to 1.5 times a nominalrange of 0.9 to 1.5 times a nominal diameter diameter shall be considered equivalent. If the procedureshall be considered equivalent. If the procedure is applicable to pipe diameters of 24 inches or larger, theis applicable to pipe diameters of 24 inches or specimen set must include at least one specimen 24larger, the specimen set must include at least inches or larger but need not include the maximumone specimen 24 inches or larger but need not diameter.include the maximum diameter. The specimen The specimen set shall include specimens with overlaysset must include at least one specimen with not thicker than 0. 1 inches more than the minimumoverlay thickness within -0. 1 inches to +0.25 thickness, nor thinner than 0.25 inches of the maximuminches of the maximum nominal overlay nominal overlay thickness for which the examinationthickness for which the procedure is applicable, procedure is applicable.

Basis: To avoid confusion, the overlay thicknesstolerance contained in the last sentence was rewordedand the phrase "and the remainder shall be alternativeflaws" was added to the next to last sentence inparagraph 1. 1 (d) (1).

(d) Flaw Conditions _______________________(1) Base metal flaws. All flaws must be cracks Modification: (1) Base metal flaws. All flaws must bein or near the butt weld heat-affected zone, open in or near the butt weld heat-affected zone, open to theto the inside surface, and extending at least 75% inside surface, and extending at least 75% through thethrough the base metal wall. Flaws may extend base metal wall. Intentional overlay fabrication flaws100% through the base metal and into the shall not interfere with ultrasonic detection oroverlay material; in this case, intentional characterization of the base metal flaws. Specimensoverlay fabrication flaws shall not interfere with containing IGSCC shall be used when available. At leastultrasonic detection or characterization of the 70% of the flaws in the detection and sizing tests shall becracking. Specimens containing IGSCC shall cracks and the remainder shall be alternative flaws.be used when available. Alternative flaw mechanisms, if used, shall provide

crack-like reflective characteristics and shall be limitedby the following:(a) The use of alternative flaws shall be limited to whenthe implantation of cracks produces spurious reflectorsthat are uncharacteristic of actual flaws.(b) Flaws shall be semi elliptical with a tip width of less



Page 14 of 32

Appendix V1II, Supplement 11 PDI Modificationthan or equal to 0.002 inches.Basis: This paragraph requires that all base metal flawsbe cracks. Implanting a crack requires excavation of thebase material on at least one side of the flaw. While thismay be satisfactory for ferritic materials, it does notproduce a useable axial flaw in austenitic materialsbecause the sound beam, which normally passes onlythrough base material, must now travel through weldmaterial on at least one side, producing an unrealisticflaw response. To resolve this issue, the PDJ programrevised this paragraph to allow use of alternative flawmechanisms under controlled conditions. For example,alternative flaws shall be limited to when implantation ofcracks precludes obtaining an effective ultrasonicresponse, flaws shall be semi elliptical with a tip widthof less than or equal to 0.002 inches, and at least 70% ofthe flaws in the detection and sizing test shall be cracksand the remainder shall be alternative flaws. To avoidconfusion, the overlay thickness tolerance contained inparagraph 1. 1(b) last sentence, was reworded and thephrase "and the remainder shall be alternative flaws" wasadded to the next to last sentence. Paragraph 1. 1 (d)( 1)includes the statement that intentional overlay fabricationflaws shall not interfere with ultrasonic detection orcharacterization of the base metal flaws.

(e) Detection Specimens(1) At least 20% but less than 40% of the flawsshall be oriented within +20 degrees of the pipeaxial direction. The remainder shall be orientedcircumferentially. Flaws shall not be open toany surface to which the candidate has physicalor visual access. The rules of IWA-3300 shallbe used to determine whether closely spacedflaws should be treated as single or multipleflaws.

Modification: (1) At least 20% but less than 40% of thebase metal flaws shall be oriented within ±20 degrees ofthe pipe axial direction. The remainder shall be orientedcircumferentially. Flaws shall not be open to any surfaceto which the candidate has physical or visual access.Basis: The requirement for axially oriented overlayfabrication flaws was excluded from the PDI Program asan improbable scenario. Weld overlays are typicallyapplied using automated GTAW techniques with thefiller metal applied in a circumferential direction.Because resultant fabrication induced discontinuitieswould also be expected to have major dimensionsoriented in the circumferential direction axial overlayfabrication flaws are unrealistic. The requirement forusing IWA-3300 for proximity flaw evaluation wasexcluded, instead indications will be sized based on theirindividual merits.

(2) Specimens shall be divided into base and (2) Specimens shall be divided into base metal and



Page 15 of 32

Appendix V1II, Supplement 11 PDI Modificationoverlay grading units. Each specimen shall overlay fabrication grading units. Each specimen shallcontain one or both types of grading units. contain one or both types of grading units. Flaws shall

not interfere with ultrasonic detection or characterizationof other flaws.

(a)(l) A base grading unit shall include at least Modification: (a)(1) A base metal grading unit includes3 inches of the length of the overlaid weld. The the overlay material and the outer 25% of the originalbase grading unit includes the outer 25% of the overlaid weld. The base metal grading unit shall extendoverlaid weld and base metal on both sides. circumferentially for at least 1 inch and shall start at theThe base grading unit shall not include the inner weld centerline and be wide enough in the axial direction75% of the overlaid weld and base metal to encompass one half of the original weld crown and aoverlay material, or base metal-to-overlay minimum of 0.50 inch of the adjacent base material.interface. Basis: The phrase "and base metal on both sides," was

inadvertently included in the description of a base metalgrading unit, The PDI program intentionally excludesthis requirement because some of the qualificationsamples include flaws on both sides of the weld. Toavoid confusion several instances of the term "cracks" or"cracking" were changed to the term "flaws" because ofthe use of alternative Flaw mechanisms. Modified torequire that a base metal grading unit include at least 1in. of the length of the overlaid weld, rather than 3inches.

(a)(2) When base metal cracking penetrates into Modification: (a)(2) When base metal flaws penetratethe overlay material, the base grading unit shall into the overlay material, the base metal grading unitinclude the overlay metal within 1 inch of the shall not be used as part of any overlay fabricationcrack location. This portion of the overlay grading unit.material shall not be used as part of any overlaygrading unit.(a)(3) When a base grading unit is designed to Modification: (a)(3) Sufficient unflawed overlaid weldbe unflawed, at least 1 inch of unflawed and base metal shall exist on all sides of the grading unitoverlaid weld and base metal shall exist on to preclude interfering reflections from adjacent flaws.either side of the base grading unit. The Basis: Modified to require sufficient unflawed overlaidsegment of weld length used in one base weld and base metal to exist on all sides of the gradinggrading unit shall not be used in another base unit to preclude interfering reflections from adjacentgrading unit. Base grading units need not be flaws, rather than the 1 inch requirement.uniformly spaced around the specimen.(b)(1) An overlay grading unit shall include the Modification: (b)(1) An overlay fabrication grading unitoverlay material and the base metal-to-overlay shall include the overlay material and the base metal-to-interface of at least 6 square inches. The overlay interface for a length of at least 1 inch.overlay grading unit shall be rectangular, with Basis: Modified to require sufficient unflawed overlaidminimum dimensions of 2 inches. weld and base metal to exist on all sides of the grading

unit to preclude interfering reflections from adjacent___________________________________flaws, rather than the 1 inch requirement.

(b)(2) An overlay grading unit designed to be Modification: (b)(2) Overlay fabrication grading units



Page 16 of 32

Appendix VIII, Supplement 11 PDI Modificationunflawed shall be surrounded by unflawedoverlay material and unflawed base metal-to-overlay interface for at least 1 inch around itsentire perimeter. The specific area used in oneoverlay grading unit shall not be used in anotheroverlay grading unit. Overlay grading unitsneed not be spaced uniformly about thespecimen.

designed to be unflawed shall be separated by unflawedoverlay material and unflawed base metal-to-overlayinterface for at least I inch at both ends. Sufficientunflawed overlaid weld and base metal shall exist onboth sides of the overlay fabrication grading unit topreclude interfering reflections from adjacent flaws. Thespecific area used in one overlay fabrication grading unitshall not be used in another overlay fabrication gradingunit. Overlay fabrication grading units need not bespaced uniformly about the specimen.Basis: Paragraph 1. 1 (e)(2)(b)(2) states that overlayfabrication grading units designed to be unflawed shallbe separated by unflawed overlay material and unflawedbase metal-to-overlay interface for at least 1 in. at bothends, rather than around its entire perimeter.

(b)(3) Detection sets shall be selected fromTable VIII-S2- 1. The minimum detectionsample set is five flawed base grading units, tenunflawed base grading units, five flawedoverlay grading units, and ten unflawed overlaygrading units. For each type of grading unit, theset shall contain at least twice as many unflawedas flawed grading units.

Modification: (b)(3) Detection sets shall be selectedfrom Table VIII-S2- 1. The minimum detection sampleset is five flawed base metal grading units, ten unflawedbase metal grading units, five flawed overlay fabricationgrading units, and ten unflawed overlay fabricationgrading units. For each type of grading unit, the set shallcontain at least twice as many unflawed as flawedgrading units. For initial procedure qualification,detection sets shall include the equivalent of threepersonnel qualification sets. To qualify new values ofessential variables, at least one personnel qualificationset is required.

(f) Sizing Specimen(1) The minimum number of flaws shall be ten.At least 30% of the flaws shall be overlayfabrication flaws. At least 40% of the flawsshall be cracks open to the inside surface.

Modification: (1) The minimum number of flaws shallbe ten. At least 30% of the flaws shall be overlayfabrication flaws. At least 40% of the flaws shall beopen to the inside surface. Sizing sets shall contain adistribution of flaw dimensions to assess sizingcapabilities. For initial procedure qualification, sizingsets shall include the equivalent of three personnelqualification sets. To qualify new values of essentialvariables, at least one personnel qualification set isrequired.

(3) Base metal cracking used for length sizing Modification: (3) Base metal flaws used for lengthdemonstrations shall be oriented sizing demonstrations shall be oriented circumferentially.circumferentially. _____________________________(4) Depth sizing specimen sets shall include at Modification: (4) Depth sizing specimen sets shallleast two distinct locations where cracking in include at least two distinct locations where a base metalthe base metal extends into the overlay material flaw extends into the overlay material by at least 0. 1 inch



Page 17 of32

Appendix V111, Supplement 11 PDI Modificationby at least 0. 1 inch in the through-wall in the through-wall direction.direction.2.0 CONDUCT OF PERFORMANCE

DEMONSTRATIONThe specimen inside surface and identification Modification: The specimen inside surface andshall be concealed from the candidate. All identification shall be concealed from the candidate. Allexaminations shall be completed prior to examinations shall be completed prior to grading thegrading the results and presenting the results to results and presenting the results to the candidate.the candidate. Divulgence of particular Divulgence of particular specimen results or candidatespecimen results or candidate viewing of viewing of unmasked specimens after the performnanceunmnasked specimens after the performance demonstration is prohibited. The overlay fabricationdemonstration is prohibited. flaw test and the base metal flaw test may be performed

separately.2.1 Detection Test. Flawed and unflawed Modification: 2.1 Detection Test. Flawed and unflawedgrading units shall be randomly mixed. grading units shall be randomly mixed. Although theAlthough the boundaries of specific grading boundaries of specific grading units shall not be revealedunits shall not be revealed to the candidate, the to the candidate, the candidate shall be made aware ofcandidate shall be made aware of the type or the type or types of grading units (base metal or overlaytypes of grading units (base or overlay) that are fabrication) that are present for each specimen.present for each specimen.2.2 Length Sizing Test(d) For flaws in base grading units, the Modification: (d) For flaws in base metal grading units,candidate shall estimate the length of that part the candidate shall estimate the length of that part of theof the flaw that is in the outer 25% of the base flaw that is in the outer 25% of the base metal wallwall thickness. thickness.2.3 Depth Sizing Test. For the depth sizing test,80% of the flaws shall be sized at a specificlocation on the surface of the specimenidentified to the candidate. For the remainingflaws, the regions of each specimen containing aflaw to be sized shall be identified to thecandidate. The candidate shall determine themaximum depth of the flaw in each region.

Modification: 2.3 Depth Sizing Test.(a) The depth sizing test may be conducted separately orin conjunction with the detection test.(b) When the depth sizing test is conducted inconjunction with the detection test and the detected flawsdo not satisfy the requirements of 1. 1 (f), additionalspecimens shall be provided to the candidate. Theregions containing a flaw to be sized shall be identifiedto the candidate. The candidate shall determine themaximum depth of the flaw in each region.(c) For a separate depth sizing test, the regions of eachspecimen containing a flaw to be sized shall be identifiedto the candidate. The candidate shall determine themaximum depth of the flaw in each region.



Page 18 of 32

Appendix V1II, Supplement 11 PDI Modification3.0 ACCEPTANCE CRITERIA3.1 Detection Acceptance Criteria. Examination Modification: 3.1 Detection Acceptance Criteria.procedures, equipment, and personnel are Examination procedures are qualified for detectionqualified for detection when the results of the when:performance demonstration satisfy the (a) All flaws within the scope of the procedure areacceptance criteria of Table VIII-S2- 1 for both detected and the results of the performancedetection and false calls. The criteria shall be demonstration satisfy the acceptance criteria of Tablesatisfied separately by the demonstration results VIII-S2-l for false calls.for base grading units and for overlay grading (b) At least one successful personnel demonstration hasunits. been performned meeting the acceptance criteria defined

in (c).(c) Examination equipment and personnel are qualifiedfor detection when the results of the performancedemonstration satisfy the acceptance criteria of TableVIII-S2- 1 for both detection and false calls.(d) The criteria in (b) and (c) shall be satisfied separatelyby the demonstration results for base metal grading unitsand for overlay fabrication grading units.

3.2 Sizing Acceptance Criteria.(a) The RMS error of the flaw length Modification: (a) The RMS error of the flaw lengthmeasurements, as compared to the true flaw measurements, as compared to the true flaw lengths, islengths, is less than or equal to 0.75 inch. The less than or equal to 0.75 inch. The length of base metallength of base metal cracking is measured at the flaws is measured at the 75% through-base-metal75% through-base-metal position. position.(b) All extensions of base metal cracking into Modification: This requirement is omitted.the overlay material by at least 0. 1 inch are Basis: The requirement for reporting all extensions ofreported as being intrusions into the overlay cracking into the overlay is omitted from the PDImaterial. Program because it is redundant to the RMS calculations

performed in paragraph 3.2(c) and its presence addsconfusion and ambiguity to depth sizing as required byparagraph 3.2(c). This also makes the weld overlayprogram consistent with the Supplement 2 depth sizingcriteria.



Page 19 of32

Attachment 2

~Caze~ W740-1 ~ W~iZ~ trDissimflar iwetalel W~Overlay f o2d ________

Injit-r- Asc ana eken~ve tm tile jvnvli5ionn of lWAý4iI 6 axd TkWA-$lw 1 for eui.rdtc t'C to LT anRcc cpibailc s~.zr, in nu -TrR-c w ith thicprvso kmor hc Ccxistruction Ca&eC< Secikon XI' i 1!1 mtlhL Zi.' tdu~ee d J edt to a 1ft", of aceeptab[, S)7- eIinvt;ing iic'walli~r fii Ž'iju, I J

4~~~~~p~~~~ki~~~~~~Dletd 2fuw vty6iie~~~xt~ Fteii~~iiio

and IWA-46 Ii. &&I'ct in atnmffcni stainicsa sle r augtcnitic nickd aflly pipin._________

auic-coatic with FX13-364) by aJi' a-i rC n Lw~lddffly -AD =a L i

cthcr Editi-, , atn A>ddiuda, raCýrr to TiINC ThC Wd~d CwIVCTaysh~ 'C il~e bydciitj of wttd r~zfitbrrenwnt (l'f lialaviion 111wIIUý& ou giurfa&x i ~ePpi

or-'.'Cjexl Iotluding fer jae, arazv1fetN wlne~~y n the'FTh4flItyig rcquirarni u T -I

Pitfa 5P1.i4

-D~ ftI fee I_ __ __ _ __ __ _

I W Pfr -7 'rERi 3~ApplicýI 3f'dý ftrnwsd Uir crcincu f ceio f fthe.~_________iizn, lxm4 -ihqll bl ilkpm Izjus Urtg 4 W Pji.It FyiCV rfizqk- fVýýiog Wv eidirnp qualified in amirdamze id the Cmtuci-nnd Codeaod Oivnr'ý

the pogi weld h eat tyaml adjb4TI rerlmimLs of the Conmimeieon Code nnd ....

nh~Mdtd 1M btjtfm Mal- I& n~i

t U U I,- ',I miftui.

i~ ~~t~a ~t nd iib~quxt~ rek~ ini ai laItier.M ~d~on aS~edi, IX.



Page 20 of 32

BC06-165I 1 Deleted: BcO4-1003

')-7-07 editing and review Final - -CDeleted: 1-31-07 RPA

(b) The base material thickness shall be as defined as the maximum . __tFomatted: Bullets and Numbering

thickness of the ferritic material where the overlay is applied(2 pendix 1 may be used for ambient-temperature temper bead welding.- Fratd:Idn:Lft .3,N

bullets or numbering

(d) Prior to deposition of the weld overlay, the surface to be weld overlaid shall Deleted:

be examined by the liquid penetrant method. Indications larger than 1/16 in. (1.5 '(omte:Idn:Left: 0.5",mim) shall be removed, reduced in size, or corrected in accordance with the [pcBeo:12pNo bullets or

folowig rquiemet ~- ---- - - - ---- 1Deleted: repaired. .

(1) One or more layers of weld metal shall be applied to seal unacceptableDetd:indications in the area to be repaired with or without excavation. The 'Deleted::

thickness of these layers shall not be used in meeting weld reinforcement Inserted::

design thickness requirements. Peening the unacceptable indication prior to Formatted: Indent: Left: 0.74', No

welding is permitted. Ebulesonubrg

2L.)If.reair ofidctosietfed in 1gd) is required, the area where the - iDeleted: correctionweld overlay is to be deposited, including any local repairs or initial weld Deleted: .ooverlay layer, shall be examined by the liquid penetrant method. The area ' Deleted:cshall contain no indications greater than 1/16 in. (1.5 mmn) prior to theapplication of the structural layers of the weld overlay.

(e) Weld overlay deposits shall meet the following requirements __

Jmeaustenitic nickel alloy weld overlay shall consist of at least two weldlayers deposited from a filler material with a Cr content of at least 28% . Tefir st layer of weld metal deposited may not be credited toward the requiredthickness. Alternatively, for PWR applications, a diluted first layer may becredited toward the required thickness, provided the portion of the layer overthe austenitic base material, austenitic filler material weld and the associateddilution zone from an adjacent ferritic base material contains at least 24% Crandphe Cr content of the deposited weld. meta~l is d:etermined by chemical...analysis of the production weld or of a representative coupon taken from a_-mockup, prepared in accordance with the WPS for the production weld.Alternatively, for BWR applications, a diluted first layer may be creditedtoward the required thickness, provided the portion of the layer over theaustenitic base material, austenitic filler material weld and the associateddilution zone from an adjacent ferritic base material contains at least 20% Crand the Cr content of the deposited weld metal is determined by chemicalanalysis of the production weld or of a representative coupon taken from- a_mockup prepared in accordance with the M/PS for the production weld.

LfyThis Case is only for welding in applications predicted not to have exceeded*-thermal neutron fluence of I x 1017 (E< 0.5 eV) neutrons per c M prior to welding.(R) ,A new weld overlay shall not he installed over the top of an existing weld*-

- Deleted::

Formatte-d: Indent: Left: 0.49"% Nobullets or numbering

NDeleted: <10-The austeniliec saoinlesssteel wel d reinofrcement shalt consust ofat lent two weld layers having ats-

jdeposited delta ferrite content of at leant7E N. The first layer of weld metal with

delta ferrite content of atleast 7.5 Nahalt constitsste the first layer of the weld

nerfsrcemeat that may he creditedtoward the required thickness.Aiternutively, licst layers of at least 5 ENare acceptabl e, provided the carhoncontent of the deposited weldmetala isdetermined by chemnical ainalysis to heless than O.02q%.¶

1Formatted: Indent: Left: 0.75', No1bullets or numbering, Tabs: 0.75"Lest tabDeleted.........

Deleted:

1Deleted:

-- Formatted: Indent: Loft: 0.49", Nobullets or numbering

-- Formatted: Buliets and Numbering-. Deleted:¶

fForma tted:- Indent: Left: 0.49"overla-v that has be in service.



Page 21 of 32

13C06-1 651 D- -fDelete~d . B .C0 .4..--I..00 .3

.2-7-07 editing and review Final -.- Deleted: 1-31-07 RRA

2 Crac~k Growth and Design,~ Deleted: Consideration.

---- -- - --- ---- ----- -Formatted: Bullets and Numbering

6a .,rack G row th - ---------------------------------------------- Deleted: Flaw character izto ad

ievaluation requiremeato stshalat bbad on

The size of all flaws detected or postulated in the original weidment shall be !,h s-on la.Hwee.h

projected to the end of the$expected life of the overlay. Crackgo to - { Deleted: considerattionsej- -- ~rcerztinFormatted: Indent: Lf:07,N

both stress corrosion and fatigue,ýhafl b yoa uaQ.d-- law-carti'etzaio and b Iullets or numberingLet0.5,Nevaluation shall he based on the ultrasonic examination resul .......(1) For repair overlays, the initial flaw size for crack groxvth shall be based oniW' *'" Deleted: design

the as-found flaw------------------------ Deleted: , indluding

(2) For mitigative overlays. the initial postulated flaw size for crack growth I Deleted: crack growth,

shall be assumed consistent with the examinations performed, either pre or Deeed vlutdinte aeiasipotoverlay. The axa-lwlnt hl estat15ice 3 i)o h ý accordance with tWB-3640. If the flaw

post ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ i aalfa nthsalbseat15ice 8 mmorte nator near thebaoudoaryofltwo differentcombined width of the weld olus butterinta. whichever is areater. The mateaials, evaluation of flaw growth in

bothmrata'ial sis reqtdreCircumferential flaw length shall be assumed to be 360 dea. Deee:cadred.

(a) If an examination is perfoirmed prior to application of the overlay. Inete:00adeewhich is qualified in accordance witlLAppendix VIII Supplement I1 Deleted:

an _oýnide surface connected planar flaws are discovered, initial ,Fomte:Idn:Lf:.7

flaws (orin-inated from the inside surface of the weldment) equal to ~' Formatted: Ballets and Numbering1

10%)" of the origzinal wall thickness shall be assumed in both the axial ' Deleted:.11

and circumferential directions., Deleted: 3.0 below,(b) Ifno examination is performed prior to application of the overlay, Deleted: indicatioans

initial uiaws equal to at least iyr-,, tnrougn the onigtnal wa1 tnic.nssshall be assumned, in both the axial and circumferential directions,consistent with the overlay inservice insr~ection volume in F4,a 2."

(c) There may be circumstances in which an overlay, examination isPerformed usintt an ultrasonic examination procedure which isqualified in accordance with,&ppendix VIII. Supplement 11I for depths-gareater than the outer 25%, of the origtinal wall thickness (Fig. 2). Forsuch cases, initial flaw sizes may he assumied consistent with the depthto which the examination procedure is qualified.

- Deleted: 3.0 below

(d) Any inside surfice connected planar Tlawj[ound by the overlay .- Deleted: indication

preservice inspection of paragaraph 3.11). which exceed the depth oif' - -- Deleted:.

(a), (b) or (c) above, shall be used as the initial flaw depth indetermining~ the expected life, of the overlay.- Overlays meeting thiscondition shall be considered a repair.

(b) Structural Desicm and Sizinp, of the Overlay

The design of the weld overlay shall satisfy the following, using theassumptions and flaw characterization restrictions in 24:al. The following_design analysis shall be completed in accordance with IWA-43 11.

'I -- Formatted: Indent: Left: O7,Nbullets or numbering

3



Page 22 of 32

________________________J

(1) '11c axa ei~hn n slope offfc eld covlay s6Ha vover the eld;tntk the heat alfeed xitici -7yc-n eade s (&ofthe,,vcld. 4nd shallI proviLde tortotid rJisiri1Itiwn from the Itcm L'nto-, the, weld cwcilay and back into theftom witout ~Tttu irjpphiable ste%5 limj~ :fJB32Qr lh~t

~in ~tnfl~o An'y lfimin& Th~wfj indi; ck cIy hU bcev~nka~tM ini the nimauiyau to zrtur.! that benid redistrdbuttie.n oipe.ies& with.the aboive. Thcese rcqutiicments Will usually tV 81tisfied if theO weld o~1vtlyfull thtcemc-as 1tmvh extends nxially be-ioind tbc projc~ttd flaw by at

Iet7ii'vRi, wlwr R r thi, oulf radrlý,,, Oft, Outm ; ItdW noMIIwall th cknc", of* dth ~item

e2) Uj~-spzi7c~yaniUyzhJ nacudazýexith Isit0 -Ire if the n~vet1,w -0-All not xc~d 'zt ~g \Jeot~~ais rcconznendcd,

(3) F4:r 6:1t-irminrig ffic cc-tbincxE bfnt~h bf aiiiyoon e tws,n 7eýic ý.nkcrvv rr lnlt, I or ffairi.PlefawhC riigshl e trcatie ns

one Rlaw of teni2h equaI [ o the sum ofthe lcri~ths of the' nivddual ilawsýdria-nclTtrzead in acof~dawe with RWA-33f).

4 ,) entbifi lv y-ritmikdhw the viA'W~j ZI 113

4Slatbft I , Adq-v-ýt: Le&t4Akgmd at; 075 + Tab iftu 1,+

Itetta mmlv 1rf

wtk Uh w.udt urtmftitc

Wgiroo 'W UWif o don~ rf~aattw3

ffiuok-ptis of Lthe item ffor -icthe cr-eircwTzfcirzgfte of fi L=nit iI I Ah f H;ii k V r TI 1

tos hn e I (VQ% thu.tjugh the orilma1 w h c iiss'o the jttý for`entire p~is]k~h of 11%.eflw~ v ~ontbined flaws, ;5a ~ eplcbei rhk

Dsl~64~ Iaj~ - Lz fli~a .im

Defettdf I ------------ ------

(6) t ~ ~ ~ ~ i -,,;zra avai d 11 in ti- 0eiiz~

L 30r 4ý OMW~w.s11 TIt, iý to jh 'I" I f 1 I - _ _ _ _ _ _M__ _ _ _ _ _ _

JT fle uod f t e 1 V t dfe ldg o v .e d a v bo kn e th O n ~ r n M e ,V ~ e it.

~deposit amdyi-as requirements of1 The conibned. wall i~cnes atbe~

fc:, n.11r itd 1o.v~rl,-y yr rcznf4roetticnt f& 'a btandiMMO:11,111') Mth ~itan n 2,~I fnetm tbeee i7 6thewI

Kshal I 1-c uaitJ =id -aIA mtiect dtc toqutrinmkms oi'N -V34

~lhivT'oc;! af any vhuingý:in ;jpphvJd lojd,ý ri•iult a:f wldj ýJbIrt~k;tgwtrrn) Liitfti verksv, on Ahe-EAcnj- in theplinsýeme~ sx~lhimus & nd C kifimiinc ncvlt2~ka dhanE-- L- n -,v, ilsri ft~ibdily and

W Jitl ueto the ý d CM ra~ 41A1l e u~ Esin Laks,

Pmua: 4t fideirut 5nwJeu J, 3rd4- trtli*e: -s~rnt: S~Left

AffW a;0 ý5 TbLiti I

... ... ..... ....... ... ...

13e4

fl~bdL4tMa j

4



Page 23 of 32

BLC06-1 651 ~-IDeleted: BC04-1003.2-7-07 editing and review Final__ Deleted: 1-31-07 RRA

previously accepted by analytical evaluation shall be evaluated inaccordance with IWBM-3640, 1WC-3640,or PN-ý L s apicbl. .. Leee

Forma tted: Snap to grid3JqYapr~nati --- ---- ---- --- ---- ---- ---- --- ---- ---- --- --- - 'IFormatted: Don't snap to grid

In. lieu of all other examination requirements, the examination requirements of this Case ' 1Formatted: No bullets orshall be met. Nondestructive examination methods shall be in accordance with IWA- "\numberng -- J2200, except as specified herein. Nondestructive examination personnel shall be .\Deleted: .0

qualified in accordance with TWA-2300. Ultrasonic examination procedures and Deleted; andinspectionIpersonnel shall be qualified in accordance with Appendix VIIýjýupplernent 11. - a edIn dent: F e-- ;--

(a) Acceptance Examination Cm~et ~g k oad(1) The weld overlay shall have a surface finish of 250 micro-in. (6.3 S upie n SiP'

micrometers) RiNS or better and a flatness that is sufficient to allow for ~ 'tbeEPRIPDpIIO,,fl" i~inefladequate examination in accordance with procedures qualified per Appendix \ 'Deleted: ,section )a

VIII. The weld overlay shall be examined to verify acceptable configuration. % et .5,N

(2) The weld overlay and the adjacent base material for at least '/2 in. (13 mm~) bulj t ~orm d Inumerng:

from each side of the weld shall be examined using the liquid penetrant Formatted: utIndenumerd:

method. The weld overlay shall satisfy the surface examination acceptance Level: 3 + Numbering Style: 1, 2, 3,criteria for welds of the Construction Code or NB-5300. The adjacent base ... + Start at: 1 + Alignment: Left +

metal shall satisfy the surface examination acceptance criteria for base AlIgndedt at: 0.75"+abfr0.5material of the Construction Code or NB -2500. If ambient temperaturetemper bead welding is used, the liquid penetrant examination shall beconducted at least 48 hours after the completed overlay has returned toambient temperature.

(3) The acceptance examination volumne, A-B-C-D. in Fig. I () shall beultrasonically examined to assure adequate fusion (i.e., adequate bond) withthe base metal and to detect welding flaws, such as interbead lack of fusion,inclusions, or cracks. The interface C-D shown between the overlay and theweld includes the bond and the heat affected zone from the overlay. Ifambient temperature temper bead welding is used, the ultrasonic examinationshall be conducted at least 48 hours after the completed overlay has returnedto ambient temperatue.

Planar flaws detected in the weld overlay accentance examination shall meetthe preservice examination standards of Table TWvB-3514-2. In applying the____________acceptance standards.to planar indications within the volume, E-F-G-H- in - - ---- Deleted: , wall lhidcnesU"W shall be

Fi ~ ~~~ ~ ~ ~ ~ ----------------- the th~ickness of the weld overlyFi . Il(b), the thickness "t, " shall be used as the nomiunal wall thickness 'in .- . ....... .......... .. ........

Table iWB`1-351 4-2. For planar indications outside this examination volume.the nominal wvall thickness shall be "tj." as shown in Fig. l(c), for volumes A-R-H-D and F-B-C-G.

Deleted::Laminar flaws shall meet the following ------------------------------ Formatted: Indent: Left: 0.5", First

(Lj.Laminar flaws shall meet the acceptance standards of Table IXVB-3514-3 .~line: 0.25", No bullets or numbering

with the additional limitation that the total laminar flaw shall not exceed - Formatted: Outline numbered +

10% of the weld surface area and that no linear dimension of the laminar Level: 1 + Numbering Style: a, b, c,..+ Start at: 1 +Alignment: Left +

Aligned at: 0.75" + Tab after: V" +Indent at: 1"

5


BC06- 1651 -Deleted: BC04-1003

2)-7-07 editing and review Final_- Deleted: 1-31-07 RRA

flaw area exceeds 3.0 in. (76 ecu). or q0 f th -oia -ip -Deleted-............ ...........-................).....circumference, whichever is greater. ---------------------------- --- (Deleted: percent

(b)The reduction in coverage of the examination volume, A--C- in Fig. I(Deleted:¶

l(a) due to laminar flaws shall be less than 10%. Thepininspectable Formatted: Outline numbered +

volume is the volume in the weld overlay, underneath the laminar flaw, for Level: 1 + Numbering Style: a, b, c,which coverage cannot be achieved withang ~ ea xminatiot,--. +Start at: 1 +.Alinment: Left+

)_.Any uninspectable volume in the weld overlay shall be assumed to contain Algeat0.5+Tbatr:1+Lc Indent at 1

the largest radial planar flaw that could exist within that volume. This 1Deleted: dimensees of the

assumed flaw shall meet thelpreservice examination standards of Table Deleted: are dependet mn theIWB-3514-2. with nominal wall thickness as defined above for pl1anarDltdthflaws. Alternately, the assumed flaw shall be evaluated and meet the -=--

- --- - - 1Deleted: of the overlay.requirements of lWvB-3640, 1WC-3640, or IWD-364fl,as aLpplicable. Both ' "___________

axial and circumferential planar flaws shall be assunmed. Deleted, I

(4) Alter completion of all welding activities, affected restraints, supports, and Deleted: inservice

snubbers shall be VT-3 visually examined to verify that design tolerances are 'jDeleted: shall

met. Deleted: ,

(b) Presetvice Inspection Formatted: Outline numbered +-

(1) The examination volume in Fig, 2 shall be ultrasonically examined. The angle Level: 3 + Numbering Style: 1, 2,3,beamshal b diectd prpenicuar nd aralelto te ppin axs, tth+ Start at: 1 + Alignment: Left +

beamshal b diectd prpenicuar nd aralelto te ppin axs, ithAligned at: 0.5" + Tab after.i 0.75"scanning performed in four directions, to locate and size any cracks that might + Indent at: 0.75'have propagated into the upper 25% of the base material or into the weld Formatted: Outline numbered +

Level: 2 + Numbering Style: a, b, c,overlay.(2) The preservice examination acceptance standards of Table 1W~B-35 14-2 shall Alge at: 02"+ Ta Lefter 0.5

be met for the weld overlay. In applying the acceptance standards, wall +Indent at: 0.5'thickness, t6, shall be the thickness of the weld overlay. Cracks in the outer 'Formatted: Outline numbered +

25% of the base metal shall meet the design analysis requirements of 2.lW._ _ I ee:3+Nmern tl:123v+ Start at: I + Alignment: Left +(3) The flaw evaluation rules of IWB-3640, IWC-3640 or, RYVID-3640 shall not be Aligned at: 0.5" + Tab after. 0.75"

applied to indications identified during preservice examination which exceed ' + Indent at: 0.75"the preservice examination standards of Table 11171-3 514-1 {Deleted: .0

(c) Inservice Inspection FoRmattedM

(1) The weld overlay examination volume in Fig. 2 shall be added to the - Formatted ____

inspection plan andu.dtrasonic ally examined during_ the first or second ------- Deleted: shatl berefueling outage following application.

(2) Alterrnatively, fCor Mitigative weld overlays, s.in which examinations areperformed in accordance with 4a2Yq,)a), 34a). and 34b). and nolý2side surface Deleted: .0connected planar flaws are discovered, the overlay may he placed directly into '.Deleted: iithe popul~ation to he examined in accordanice with (c)(5) below. . D-eleted: .0

(3) The weld overlay examination volume in Fig. 2 shall be ultrasonically Detd:.examined to determine if any new or existing cracks have propagated into the Dltd eetupper 25% of the base material or into the overlay. The angle beam shall bedirected perpendicular and parallel to the piping axis, with scanningFomte iiIperformed in four directions.

'41 The inservice examination acceptance standards of Table 1WvB-3514--2 shall Detd:Atntityfrisi,-

be met for the weld overlay. jf the acceptance criteria of`Tabtle 1W13-35ý1- .-......

cannot bermeL the acceptance criteria ofl IWB-3600, IWC-3600, or IWD-360q etd:

6


J3C06-1 651,_-- IDeleted: BC04-100322-7-07 editing and review Final - - Deleted: 1-31-07 PEA

asapiablsall bermet for the -weld -overlay.- Cracks -in the outer 25% of .-- eee:the base metal shall meet the design analysis requirements of Section 2(b). - IDeleted: .0

i5'l Weld overlay examination volumes in Fig. 2 that show no indication of crackgrowth or new cracking shall be placed into a population to be examined on asample basis. Twenty-five percent of this population shall be examined once(6)If inservice examinations reveal crack growth,4 or new cracking, wýhich meet D- e - e Dlte d: me eting

the acceptance criteria ofJWVB-351.4, ]W13-3600, ]IC-3600. or TWID-3600 the- I- Delet :ed: :s :tandars, ...........

weld overlay examination volume shall be reexamined during the first or g1Deleted: Table

second refueling outage following discovery of the growth or new cracking- -ent- -s- n tome17) For weld overlay examination volumes with unacceptable indications thatithishod nbe repibed htif

4tccording to 3ikc)AJ, the weld overlay shall be removed, including the original Tirteidýin etteswdd_____they cma be eviariitecl this ietrequ irla

defective weld, and the item shall be corrected by a repair/replacement thouid al. apjy. I sget that we'd

activity in accordance with 1WA-4000. '\ ometimfn20g likefir fl~ dxeptblbe.<,N

(d) Additional Examinations. If inservice examinations reveal an unacceptable WOL ewoi na vorume.. #'indication according to 3,LcY4)) crack growth into the weld overlay desig -l D fleleted: asdesroibed inthickness, or axial crack growth beyond the specified examination volume, '"eee:.

additional weld overlay examination volumes, equal to the number scheduled for ' 'eee:2 n(

the current inspection period, shall be examined prior to return to service, Ifom~Ouln umeeadditional unacceptable indications are found in the second sample, a total of 50% Level: 2 + Numbering Style: a, b, c,of the total population of weld overlay examination volumes shall be examined + Start at: 1 + Alignment: Left +

prior to operation. If additional unacceptable indications are found, the entireAlgeatO2+Tbaer0.+Indent at: 0.5"remaining population of weld overlay examination volumes shall be examinedDetd:0prior to return to service. _____________

_4. ,QPressure.Testin Deleted:

A system leakage test shall be perfre in accordance with 1WA-5000. .Formatted: No bullets ornumbering

5.0 Documentation Formatted: No bullets orUse of this Case shall be documented on Form NIS-2. numbering ______

7



Page 26 of 32

'644 Firia O ohtudi 1 f r FTA-4

k Aft"Umft"IMM "U"Re"

4

4

II

Ii

Odutud;~

oMa&a.4i II

I

I _______r... rici

A

-4tý V ýw Twt rMqw 9

FI~ ~1~fld~k~LLm1h2rXi---------------

-(2) Th.o wald ificluzi!i IHLI 1." ýId ý-nll

----------

07V~t4 + 1,0- i~ 9, h 75'----------- ~ f~ k

I



Page 27 of 32

ILIl6 311

I -" ftw V CM, Inueia"vke EammnplicVcum .........

FigPieýwvic, ad liew~ F-ui~iin Vlmm

9


77)7cjbWrn& ýndI rni"w Fnl.w DCWW 1rd 14 -q, iwui

Am'bient Tem ruiur'e'Te twr WadWeldiny- Fk -

12A, 12B, arD 1 ZC'rnater#ia and d'1t ~oeir amwavt n tgjnn P-N~o or k~~ * 'Tn''r"04

Tr; pe~t ~nntb use-d to reiper" MZ4e EIM-la tfs* the mater~ia- '.ho bn rm~e M 4--lce Trqm Q,4%1* I Q% 11et fýqr tnd4 tnerr, r

apwirThan or a nine pflin pructk"e(b) ~Tre r~n Tji areac;p'jlvd~ void ovtr * Wood on"~b fn twdSua aC or the ________

Acfý%-6ea~ksc n a d11nw~kr4RctaI -ewid in a.r iacewwit thi~s Apvmdbcgfe fi1mid to tho"*a ;snr q""jn ~eo o~al~iik of~b a Io

"no -in fev,~ t~ ~ t~ m ~aj 'bL--e -jedor ed h a-=, ~ ~ r I~ dk pr it-~dOl eplcf YofU ree I T ba se wn rSI~G owa ot exft>I(2I ql1) f.

(e) FT i o to i-ic! e Ja reat be wewde and u te rid ~ era we afBej0rt kam i 1tvzliieu)d Cr.d,2

rjýtýe~j tnl VLfnteaim~ ft e Cofuen tAl ,h.

(Q) Peenlpg may W L"Armxprtcm the Init an AIlye a wfowi~e

Thme fianr promvvi anih fl wethrtg gperatora Oml be qiJAlflhO In tCwQf~!Kewlth ,OVe~fIX and lu rwjub~rsdnrtv .1 wrid'2.2.

(a) Th, abase materIM Tarr the kIng procedure qMMIMh~a uJWaIbe WIN@h samte P6Mumnlw, ond Gwup Wnu-mbr, is It..* n'@'"Wo t e The rmwirals shs bepashheldl Feat treated to at least dhe time and temperature ttwt vvas applied in the

(b) The rwt M= oWtclvde argIe cf fta cm"y in To tet asumt~y sag be n* grealarhnfuwirtmuwiiiipadidforthe remit,

(g) Tbe noftum kflawJo MEmperulum tfr'r mei1rlI M~e layers at thle Magi asserriby 91ta

(dI) the tes9t sasseMby Ca~ty d epthOail bel Mt east 1 lnt 45 mrn)ý t~he test asseMblythlcintelb a D at wast Wwlei dw: Mawamb ~ cytdepm,. The t"a aem~tyshallII lw' enough to pefnti roval of Me, nmeqifaed test jcIpeM*M_ The, testgggmbly drarom rO u~ndIng the eevEy ghsAbe2 Wet etwt ~atseM0

i~~le~kiA!1 aM 1&~ni ~ (1~r SOiim). Tha qi~i1Arx6I6_ ilAat ýgtoll b& VL'jFed IAa0_CoC~ance~1U1 F)Q, 1-1i

(ip} Fevt baz riae- i~ft pr~ r fi~ uls JLI ret meV Iijnpotltsrew~remneryt3of the8Gm B=aCode and: Ocwfe Reit~ilremeM.~ Ir¶3LrA

wJ6trke attall be datefrMdn by Czaloy W-i6ehifivel Lifats aft?* DetthaquaA pba bw mto i, or ii;wt iholwmst scrvic teinpatue o f heem ta berepalrel. The kxalcmndafdorentatn ofemist spcimeresshall be Gtitiarto thogerequired~t 211(2f) bcew- IM Omit be in Me. base moot,

10



Page 29 of 32

L-(~i~ri U v F Ij Lea-i

swtm p !4Meamtw, as nohe ast metal tnet 21 4e bovum -NUMtr, laNon,1, antl

coairtatian ot tests p____________beas______s

Crnehzil the thi~kryeSS Of ttt deoositcd voel me~ta Thbe COIr [or tIAZ unraLctSpeeffleng Sha be tAP11 tr~arrwer9P WD lte GpiS OT Meu varkt ao'ýC OW*We~ M dafI'ethe HAZ. The notobi of the Charpy V-notch specimen shatl be cut aptfoxihiatqlyno~mil to the m~n~ria1:sv~fa(r m *" a n~rri nero-rs tIc tr-kd asovh HZ 3%s

pgp~ci triii rcwTjr ft-ý,,Wv Jt n IftU m1w hlril tIhamo pWm it tho WSr ofa ipedirnen shall te Wiined to alla Mia roimof be ncotch to aIwalWW Par%~e tofte If morl linM.

t.)I# lthe tixw ma!*d.I is -M tho forwm Ce a plta or~ a upn. theI axi of the weld shaiibeR crlelfled pa-eiel to th pritr--aI dlrectioe Mf rdling 1ý o rge-

shall be in awooodance wh &A.70, Fq. 11, Type A, The, tes sh-a a =oim wt of MeetfulI-ize 40 mm X 10 mm s er-nio he Nolaiurl wpmin, pamoiA hsair.ksewfbederiergy.

test v~pea~ ~rs~cnand hxftmon of abi Icst e~cirerza 51nalbe feportad In thePmOce~lae QuWM tl~)n RecW____________

( Thea swrag@ lmuul exr)anslcen valie of tiw tiwek I1A C"a V-natth specrrnens pmmi1iu ~C4e~iiI I orreebrthn te w 1- lterl o w ansovaluo d the mmo NIl~ti

i*z#ecteed baie me-A Ita4peciwne'rs, Hcroevv, lfi o* vetage laliruI "'Pa Miao value

wLafr~ectfld baen mneta I jpff1nen aml ifs JpocMure Cpialimlwi et5o ael UI at"requýTiew~ts of tis ipendri, a 1t-vr of ti-x fcawi~ng $Nil be lperformo-Off Thewb dn procwr uIhall be m-zaffd- --1~2j AY,,di-t~ m eoITnperetwe F~a IJ porocedure qjiRIEaan s~phi b debet rmnrd ) MAa~d ~ truAic

In &;ewram-v wi th TrL a;V04-a Lie proynavef or N-4-3 2 dl SoCDtlo Ill, Z2QaiEdlen with 2002 AOterda, The RTq-. or bmu~t wwlce Wi-rpcatire of fthtriller:5 I Ur flwwiVIt,, khe welIn proce lum 4-l I be M- rh~ ~I I I be im~e aued by .termperature equ~ta~e 6 ft'wt o~f the Ack~ustett Temipeiatire.

2.2ovr rn~ok GýAlti Nwnnilm~d' lndi Left QA*"

-- ~fo oprtr bolte qwi~Ned in acyrarotnoe wth Ewciir X

(a) Tfi a v& "t mta & he 11 be f,' poaltIt" k uy In enstom e a &Fi meeh m G TAW p wmse.(b) 31saimlleg metal wmiids alnall be fna de usin A- No, 8 hwe Idr ntal I044 42)ý for P N o. 8

to P- No -1, 3, or 12 (A, B, wC) %w kJI ~o I s o r F -No -4 3 weld meaI {f4W-4~32? tot r -No 6 or <3ttg P-ha 1, . r 12 (tN 8, or C wijoirrt:

(0) Thi oreq lo tbe weded StIOl be- biruTCC wiUt a deposiT ct at 10;W three 40%v toZmNov&at.'*ae Vt~~t8 irl ý3mm) 6vsrlay ~IhVkfiuie MMt ViS heajt Iif!Kt 16of Een layercortmietlle to within ± 1 N of itial use~d in IN.- prcedurr~ 9ýialcetio4 tv.si The I-eet_______

im f ft firxt i~ictlay0~*hal nrl pri 4ýkLJ/li (1&±XinM) i~ _____ _____any

a uste~iIc &veriay fillet mua!lntal Lat tPA *56 of the oveftay to ensure MRa the HA2 aM __eit ru bmw me tal:. er tIcm pered S-4 i,s q rix -w r- !;~~ mha be de PQ s tc;w , a fajnprj -01 ex~yqqedr thiat VWý for 14)- i$t?-yr- thq tht V Ir fmth rqw

(dl The mayarltwjm hnterlaga tomernpmture orw lield qpoIecttre be 3-RDF I BC) 1tbr all

(e r byerp= remrde-aums ofi te te~ps dterwrnived use ofir iunlcbn

(a)~r rd *_IT Wwm

I1I

St. Lucie Unit 2 L-2007-045Third Inspection Interval AttachmentRelief Request Number 10 Page 30of 32

1h % ek~ntin ~r ia ; iceoJ ,e such ,,%en~ ae eh whe-n t~ere

01W) lAaUerrm cocuw and amnn~ i am ttw terw2 beng wmited(y) ame thme perwald part and dolay timew betw~en each pass

t4; ~U are So~ t5 eampk% tM

~Ipiute of e we" efooxwedute eftll be u~ nthe weidhig at the trtmwr(f) Rr~cur m shall to, Oen to ensure that"e wo region Is ftm of all powwu~ _________

aoreaa N Po& Te mut~e tb be.% MMOMrLd L~ _

12



Page 31 of 32

2-1.4 ~k1~

GENERAL NOTE: Rue rnetI:Chzrpy kmpmcl;tciminse nriot, '.i , 1,

13



Page 32 of 32

Tal-I Y. h f ý 'mAl-m v htj: d Addvna~ of "cttumX1

2004-B itiOn Witha"' low,Adden"

i r-o wil h thr 191S1 E& Vic 197,93M c,:-

st. lucie, unit 2 - in-service inspection plans, use of ... · *as submitted and approved by st....

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