COMMISSION BRIEFING SLIDES/EXHIBITS

BRIEFING ON MATERIALS DEGRADATION

ISSUES AND FUEL RELIABILITY

FEBRUARY 6, 2005
Management Of

aterials Issues

Bryce Shriver

President, PPL Generation

Chairman, Materials Executive

Oversight Group
Industry

Representatives

* Bryce L. Shriver

* James J. Sheppard, President

& Chief Executive Officer, STP

Nuclear Operating Company

* Dr. Robin L. Jones, Technology Executive - Materials, EPRI

* Alexander Marion

Senior Director, Engineering, NEI

2-'i
eeting Objectives

* Summarize the NEI sponsored

Materials Initiative

* Discuss progress since the last

meeting

u Review regulatory implications

3, ",, IF~ I
11aterials Initiative Purpose

The purpose is to support safe, reliable

and efficient operation of U.S. nuclear

power plants through the management of materials issues.

* Coordinate industry sponsored materials

research & development

* Prioritize, manage and resolve current and

future issues

* Provide accountability to assure materials

issues are resolved

4 §S
oaterials Initiative

m NEI 03-08, "Guideline for the

Management of Mlaterials

Issues" effective January 2,

2004 provides:

. Consistent management process

* Prioritization of materials issues

* Proactive, integrated approaches

* Oversight of implementation A I I

5
MEOG / MTAG

Issue Programs

r 1E I

6
1W 03-08 Guideline

* Establishes two standing

committees

* Executive Oversight

* Technical Advisory

• Establishes policy

* Defines roles, responsibilities

and expectations

* Provides for an integrated

approach

• Establishes implementation

~1%4",,, .. |, t d i,. 7
Strategic Plan

* Comprehensive, integrated view of

materials issues

* Framework for prioritizing, planning,

coordinating and directing efforts

* Defines high priority materials issues

and short & long term technical gaps

* Revision I planned first quarter 2006

* Degradation Matrix and Issue Management

Tables

~%IE:I
DEG RDATION MATRIX

A Lists all materials within scope

of the Materials Initiative

Identifies potential degradation

mechanisms for applicable

materials

* Information obtained from

materials experts, laboratory

R&D, and operating experience

Ad9
Issue Nianagement Tab les

* Addresses significance of

material degradation on

applicable materials

* Defines where materials are used

and consequences of failure

m Identifies existing programs/guidance available for

effective management

Assessment, inspection/evaluation, mitigation, repair/replacement

10
DI iverab es

* SG Management

: License Change Package - 5/05

* MRP Inspection and Evaluation

Guidelines

. Alloy 600 Management Program - 8/04

* Primary system butt welds - 7/05

* WOG

* Pressurizer heater sleeves - 4/04

* Boric Acid Corrosion Control Guidelines - 2/05

* BWR & PWR Water Chemistry - 12104

* BWR Program Implementation Guide

Rev. I - 12/05 ,1,,%, - |

11
RoH iverables

• BWR VIP

* Steam Dryers - Ongoing

• Fuel Reliability

* AOA Guideline Revision I - 6/04

* Performance Metrics -1/06

* Coordination with ASME

* MRP technical basis for Code Case - 9/03

* Degradation Matrix & Issue

Management Tables 2nd Quarter

2006

12
han es to Expect

* Pro a ctive- industry performance

relative to materials degradation

* Industry guidance from Issue

Programs will have mandatory and

needed actions

* Improved integration/coordination

among Issue Programs

* Improved communications on

materials issues and related

interactions with the NRC V%,"' E: I

13
Regulatory Process

• Implementation of mandatory and

needed actions that fall within the

scope of 10 CFR 50

* Primary system components

e General Design Criteria & Appendix B

X Subject to NRC inspection

* Performance-based approach

* Existing regulations are adequate to

assure public health and safety

14
Conclusion

Actions Taken by Industry

* Proactive, integrated and

coordinated

* Accountability to assure

plant safety and reliability

* Continuous improvement and

feedback

15
Additional Backgrounc

pI%-E: I

16
CR NYII

• AOA - axial offset anomaly

* ASME- American Society of

Mechanical Engineers

* BWR - Boiling Water Reactor

* BWR VIP - BWR Vessel & Internals

Project

* EPRI - Electric Power Research

Institute

* NEI - Nuclear Energy Institute

• MRP - Materials Reliability Program

• PWR - Pressurized Water Reactor

* SG - steam generator

• STP - South Texas Project INit's

17
aterials Issue Prograns Governed by the IitEatiy

EPRI

* BWR Vessel & Internals Program

* Materials Reliability Program

* SG Management program (SGMP)

* Fuels Reliability Program (as impacted

by materials management strategies)

* Corrosion Research

* Chemistry Control

* Non Destructive Examination (NDE)N4E: I

18
Materials Issue Programs overned by the Initiative

v NSSS Owners Group

Subcommittees

• Materials

* Chemistry

* Reactor pressure vessel

• Non Destructive Examinations

* Steam Generators

19
Naterials Executive Oversight

Group (MEOG)

* Bryce Shriver

(Chairman) - PPL

* Jim Levine (ViceChairman) - APS

* Joe Sheppard - STP

* Chris Crane-- Exelon

* Bill Eaton - Entergy

* Bill McCollum - Duke

* Mano Nazar - AEP

* Doug Gibson - DTE

Energy

• Jeff Gasser - SNOC

• Greg Wilks - Nuclear

Electric Insurance

Limited

* Joe Donahue - Progress

• Jim Klapproth - GE

* Nick Liparulo - West.

• Gary Mignogna - Framatome ANP

• Clair Goddard - INPO

• Dave Modeen - EPRI

• Alex Marion - NEI

20
aterials Technical Advisory

roup (MTAG)

* Chairman - Bill McCollum - Duke

* Vice Chairman - Bill Eaton - Entergy

BWRVIP - Robin Dyle - SNOC

* MRP - Mike Robinson - Duke

n SGMP - Forrest Hundley - SNOC

* FRP - Charles Turk - Entergy

* PWR OG - Greg Gerzen - Exelon

* EPRI NDE - Mike Turnbow - TVA

* EPRI Chem - John Wilson - Exelon

* EPRI Corrosion - Craig

Harrington - TXU

a At Large Members

* Joe Donahue -

Progress Energy

Dennis Weakland - FENOC

e Tom Jordan - STP

Les Spain - Dominion

* MTAG Support

* EPRI - Robin

Jones

* INPO -Jeff Ewin

* NEI -Jim Riley

_641 ;_~e

40, ; L

21
77* Defining Significant Nuclear

Materials Degradation

Issues and Proactive

Approaches for Resolution

Robin L. Jones

Technical Executive

EPRI

February 6, 2006

e - nVWI
I

E1`PRI's Nuciear Materials R&D

Programs

* Seven EPRI R&D programs are governed by the Materials

Initiative:

- BWR Vessel and Internals Program (BWRVIP)

- Materials Reliability Program (MRP)

- Steam Generator Management Program (SGMP)

- Fuel Reliability Program (FRP)

- Non Ubstructive Examination Program and

Performance Demonstration Initiative (NDE, PDI)

- Water Chemistry Control Program

- Primary System Corrosion Research Program

E=I (I ) 2
EPRI Worldwide Membership & Participation

U.S. & Canada

(115 GWe) Latin America

(4 GWe)

Europe & Africa

(140 GWe)

Mexico

Brazil

Argentina rest of W. Europe

France L South Africa

U.K.

Spain

Asia Romania

(70 GWe) Other

TEPCO

I

China

Eastern

Europe (37 GWe)

rest of Japan

South Korea

Taiwan

India

Pakistan

Russia

Ukraine

Blue = Full Member

Green = Program Participants

Yellow = no engagement

I~*I 2I a-(=lL

3
Licensees Participating in BWRVIP

U. S. (13 utilities, 34 units)

* Constellation Nuclear, Nine Mile Point LLC

* DTE Energy

* Energy Northwest

* Entergy

* Exelon

* FirstEnergy

* Nebraska Public Power District

* Nuclear Management Co.

* PPL Susquehanna, LLC

* Progress Energy

* PSEG Nuclear

* Southern Nuclear Company

* Tennessee Valley Authority

International (12 utilities, 44 units)

* BKW FMB Energie AG - Switzerland

* Chubu Electric Power Company - Japan

* Chugoku Electric Power Company - Japan

* Comision Federal de Electricidad - Mexico

• Forsmarks Kraftgrupp AB - Sweden

* Iberdrola Generation - Spain

* Japan Atomic Power Company - Japan

* Kernkraftwerk Leibstadt - Switzerland

* OKG Aktiebolag - Sweden

* Taiwan Power Company - Taiwan

* Tohoku Electric Power Company - Japan

* Tokyo Electric Power Company - Japan

=1 v)*I 4
The Integrated Strategic Plan

* The Plan defines a systematic approach to managing

materials degradation issues:

- Identify component vulnerabilities

- Assess condition (inspect & evaluate)

- Mitigate initiation and propagation of degradation

- Repair or replace component as required

* Implementing the Plan involves the identification and

prioritization of knowledge gaps

- Issue Management Tables (IMTs)

- Materials Degradation Matrix (MDM)

aI=2I r 5
I

IMT Format

-Section X- Issue Management Table for YYYYYYY

WIr

6 IOIra2
I Materials Degradation Matrix

Level I

Level 2

PWR

Component

Material

'Subdivision-_

Reduction in Toughness

SCC

SCC

Corrosion/Wear

C&W

Fatigue

Fat.

RiT

Aging Irradiation 1 1 7 I t 1 1,-r

+ Wstg Pit Wear FAC HC I LC/Th I Env Th Emb I VS SR I Th. I Fl

PWR

Pressurizer

(Including

Shell, Surge

and Spray

Nozzles, Heater

Sleeves and

Sheaths,

Instrument

Penetrations)

C&LAS

C&LAS

Welds

Wroubht

Ss

SS Welds &

Clad

Wrouzht

Ni Alloys

Ni-base

Welds &

Clad

Y N N Y N Y Y Y N/A N/A N/A N/A N/A

eO04 _ eO05 _s eO06 e007 eO08 __ _

Y N N Y N Y Y Y N/A N/A N/A N/A N/A

eO04 e005 eO06 e007 eO08

N N N N N Y Y N N/A N/A N/A N/A N/A

eO14 eO15

N N Y N/A N/A N/A N/A N/A

NN N_ N N /

N N N N Y Y Y N N/A N/A N/A N/A N/A

eO14 eO14 eO15

N N N N N N N/A N/A N/A N/A N/A

_ _ eO14 eO15

N

Level 3

eo30 Corrosion-assisted fatigue is a known phenomenon on secondary side (e.g., in the vicinity of girth welds in steam generator shells

and in the region of feedwater nozzles) and is not like environmental fatigue described in other areas of this DM. Environm Il

fatigue research relevant to this specific phenomenon is not ongoing within MRP Fatigue ITG, and is a potential gap.

F-_i_- Ie 71 s ~4

7 (-_F

------
IExample from BWR IMT (draft)

Se tion 3-Issue Management Table for BWR ASME Class 1 Piping and Components

Component Material | Denradation Consequences Mitiation Repair I I&E Gaps. Priority& Responsible I I Mechanism of Failure Replace Guidance Basis Proqram(s) 3.1 Reactor Coolant Recirculation

3.1.1 SS IGSCC Loss of Chemistry ASME Fatigue Resolve BWRVIP Recirculation (Typ. 304, (NUREG- Pressure Control: Section Xl: Monitoring environmentally Assessment Loop Piping and 304L,316, 0313) Retaining BWRVIP- IWA-4000 assisted fatigue Committee Fittings 316L,316NG, Boundary 130 ASME Section Xi concerns (e007) (supported by 347, 347NG) Fatigue Weld IWB-2500-1: MRP Fatigue & (e105) HWC: Overlay, Cat. B-J -Surf & ITG) &BWRVIP- IHSI, MSIP UT

Branch Band Fittings Piping Env. Fatigue 62 (BWRVIP-61) Cat. B-P - VT-2 (NUREG-

(RHR Suction and 6260, e007) BWRVIP-75: Discharge, (Inspection RWCU) Schedule Relief)

(Piping 2 NPS 4) ..

3.1.2 SS IGSCC Loss of Chemistry ASME ASME Section Xl None N/A Flow Nozzle (Typ.304, (NUREG- Pressure Control: Section Xl: IWB-2500-1: 304L,316, 0313) Retaining BWRVIP- IWA-4000 Cat. B-P - VT-2 316L, 316NG, Boundary 130

347, 347NG)

HWC:

BWRVIP62

CASS IGSCC Loss of Chemistry ASME ASME Section Xl CASS piping BWRVIP (Typ. CF3, (NUREG-0313 Pressure Control: Section XI: IWB-2500-1: embrittlement - Assessment CF3M, CF8, RZ > 0.035% Retaining BWRVIP- IWA-4000 Cat. B-P - VT-2 assessment or Committee CF8M) C or <7.5FN) Boundary 130 examination

(GALL X.M12) Thermal HWC:

Emb. BWRVIP-

(R-52) 62

CI1=1*I 2I 8
Applicable

SR

Components R&D Gap Description

AS-03 - Assess Effectiveness of HWC and NMCA at Hiah Fluences

Highly irradiated materials are susceptible to irradiation assisted stress corrosion

cracking (IASCC) in the BWR environment. Irradiation damage changes the

microstructure and mechanical properties of stainless steel in the vessel and

makes it susceptible to IASCC at high fluence levels (typically > 5x102° nlcm2 ).

Although it is reasonable to expect that IASCC should me mitigated by moderate

HWC or NMCA. there is little supporting data on irradiated materials at fluence

levels expected in BWRs to quantify this effect.

The NRC SER on the BWRVIP-14 crack growth model limits it's application to a

fluence of <5x1 020 nlCm 2 . H4 welds in some plants will exceed this limit before

end of life. In the absence of additional data, the NRC may not allow inspection

relief for highly irradiated welds which are currently not covered by B\A/RVIP-62.

Typically, core shroud inspection costs are approximately $500K per inspection

per plant. It is conservative to assume that this task will save at least one

inspection per plant. If one third of the US BWR fleet avoids one shroud inspection

each (a total of -10 avoided inspections) the cost savings would $5M. The

projected cost savings are far greater than the cost ($1 .2M) of the task.

This gap is being worked in connection with Assessment Gap AS-01 related to

assessment of the impact of high fluence on fracture toughness and crack growth

rates. Current activities are ongoing in this area. This program is structured at

present in three parts:

1. Develop test data in the Halden research reactor by participating in an

internationally sponsored program. The BWRVIP share of this program

will be less than 10% of the total cost. This task will be coordinated with

the Assessment task on development of a crack growth model for

irradiated materials.

2. A new organization called Japan Nuclear Energy Safety (JNES) has been

established to provide technical support to METI. JNES is analogous to

NRC's Division of Research. Efforts could include establishing bilateral

cooperation for information exchange and joint research. It is envisioned

that IASCC for BWR and PWR materials will be a major area of focus.

Although this is a national program in Japan, it may be possible for EPRI

and the BWRVIP to participate in the program, thereby, receiving some or

all of the results.

3. The Japanese BWR JOG has also sponsored work on IASCC and has

indicated interest in sharing this with BWRVIP.

Core Plate:

Rim Hold-down

Bolts

LPCI Coupling:

Shroud

Attachment

Ring

Shroud

Assem bly:

Shroud

Cylinders &

Welds,

Shroud Ring

Segments and

welds

Top

GuidelGrid

Assembly

Grid Assembly,

Aligner Pins,

Sockets in Top

Guide

Shroud,

Hold-down

Devices

Basis:

MDM:

BWRVI P:

eO45

BWRVI P-62, BWRVI P-14, 2006 Work Plan

Responsible Proaram(s):

B\ARVIP Assessment

P~rirtritv- HIGH-
Stages

M _ C

-4

* Develo

Qm but Pt

TS..CMac I

0n

in the Development of SCC

Units of Time (or Fraction of Life)

I-:I=Fi2 rhL ~ 10
FI*AfUra Cooperation in Proactive

Materials R&D

* Suggested approach:

- NRC reviews and comments on the knowledge gaps

and industry priorities identified in the BWR and

PWR Issue Management Tables and works with

industry to establish joint priorities

This will allow leveraging of NRC and industry funds and

will avoid the possibility of developing completely

independent (and possibly divergent) R&D programs

- The Office of Nuclear Regulatory Research and

EPRI cooperatively undertake the proactive R&D

needed, starting with the highest priority projects

11 -E 2I re Q
Rationale for Suggested Approach

• EPRI manages almost all of the U.S. nuclear

industry's proactive R&D on materials

degradation

* Most of the world's nuclear licensees participate

in the EPRI-managed materials degradation

programs that are pertinent to their plants

* A mechanism already exists for the Office of

Nuclear Regulatory Research and EPRI to

cooperate on R&D projects of mutual interest

I=Ir I 12
. Al . 6

I Existing Cooperation Mechanism

* A memorandum of understanding (MOU) between the

Office of Nuclear Regulatory Research and EPRI on

Cooperative Nuclear Safety Research was signed in

October 1997

* The MOU defines the principles of cooperation

between the parties and specific projects are defined in

separate addenda

- Management review meetings of all active projects

(and new opportunities) are held at least annually

* This mechanism has worked well and the MOU has

been extended twice since 1997

13 C-F1 v)
Iae- |* ELECTRIC POWER FMI m I RESEARCH INSTITUTE

Industry Perspective

on Fuel Performance

February 6, 2006

Joe Sheppard

Pres. & CEO,

STP Nuclear Operating

Company
Summary Of U.S. Fuel Performance

* Overall number of fuel failures has leveled

off with a slightly improving trend

* There has been no repeat of the large

number of corrosion related failures that

occurred in BWR's in 2003

2-Year Rolling Average - PWR (2000 - 2005)

100-

80-

~-70

IL.60

o5 50

40-

30

20

10

0

1os 2000 2001 2002 2003 2004 2005 2006

Year

S#_lELECTRIC POWER

O 2006 Electric Power Research Institute, inc. All rights reserved. 2 ( 1 ICI RESEARCH INSTllUTE
Summary Of U.S. Fuel Performance

(cont'd)

*Major fuel failure mechanisms: - PWR- grid to rod fretting, debris, pellet clad interaction

and unknown/uninspected

- BWR- Debris, pellet clad interaction and

unknown/uninspected

*The quality of fuel pellets, especially the presence of minor surface flaws, is

becoming a key focus areas for failures

which have occurred after power changes.

*BWR channel bowing is becoming a new focus

area because it is being observed in all vendor

designs

ELECTRIC POWER

0 2006 Electric Power Research Institute, Inc. All rights reserved. 3 fa i |Ir RESEARCH INSTITUTE
I Continuing Industry Initiatives

* Industry's Fuel Reliability Program (FRP) falls

under the Materials Initiative, NEI 03-08

* Fuel Reliability Program continues to focus on:

- Water Chemistry impacts on fuel performance

- Root cause analysis of fuel failures

- Operating experience and benchmark information are

collected in fuel reliability data base (FRED)

* Results of this analysis is then fed back to

vendors and utilities to enable corrective and

preventative actions to be undertaken

ELECTRIC POWER

0 2006 Electric Power Research Institute, Inc. All rights reserved. 4 U> I |RESEARCH INSTITUTE
Conclusions

* While not a safety issue, U.S. fuel performance continues to have adverse effects on potential radiation exposure, plant generation and economic

performance

* Goal of FRP and U.S. Industry is to operate with zero

fuel defects

* Due to the care required when handling irradiated

fuel, research and root cause results take a long time to develop

* Research and root cause results, however, are

starting to bear fruit, which should start to make a

positive impact on overall fuel performance * Cooperative effort between fuel vendors, utilities, and EPRI is dedicated to improving fuel performance, assuring safety and achieving the industry goal

e I al3 ELECTRIC POWER @ 2006 Electric Power Research Institute, Inc. All rights reserved. 5 | RESEARCH INSTITUTE
Materials Degradation Issues

and Fuel Reliability

Feb. 6, 2006

Jennifer Uhle, RES

Jack Grobe, NRR

Frank Akstulewicz, NRR

1
Proactive Management

of Materials Degradation

* Resolving degradation issues

before they become a concern by

- Preventing the degradation or

- Monitoring, mitigating and

repairing it

2
2004 Commission

Direction To NRC Staff

* Continue program to predict future

degradation and take necessary

action

* Develop research programs using

risk-informed insights

* Pursue collaborative research

programs

* Evaluate regulatory treatment

3
NRC Program to Predict

Future Degradation

* Identifying mechanisms and

susceptible components

* Evaluating in-service inspection

effectiveness

* Determining the safety

significance

* Verifying repair and mitigation

effectiveness

4
Identification of

Mechanisms

Conducted a study using several

international experts

- Identified possible degradation

mechanisms and susceptible

components

-Appraised the state of

knowledge

* Final report available June 2006

5
Collaborative Research

Program Development

* Proactive resolution requires

extensive knowledge

* Feasible through collaboration to

prevent unnecessary duplication

* Research plan

- Mechanisms

-Detection and monitoring

- Mitigation and repair

6
Status of Collaborative

Efforts

* Domestic

- Met with industry

- Meeting planned

specific areas of

* International

2005: 2 meetings

Japan)

-2006: 2 meetings

Europe)

r January 2006

to define

collaboration

held (USA,

planned (USA,

7
Summary

* NRC is working to identify and

resolve materials degradation

issues before they become safetysignificant

* NRC is using risk-informed

insights to prioritize work

* NRC is pursuing collaborative

research efforts

8
Use of Research Results

* Three related programs

- Proactive Materials Degradation Assessment

- Inservice Inspection and

Monitoring Capabilities

- Risk associated with failure

* Evaluate results to determine

need for regulatory action and

prioritize resources

to

9
Staff Requirements

Memorandum

* Industry initiative - framework for

management of materials issues

* Staff Requirements Memorandum

from Nov. 8, 2004 Commission

Meeting

- Regulatory treatment of

industry's mandatory and

needed action categories

10
Recent Regulatory Action

* Industry revised Steam Generator

Program Guidelines in 2005

* Industry implementation

mandatory

* NRC action - Steam Generator

Program Guidelines covered by

performance-based technical

specifications

11
Recent Regulatory Action

* Westinghouse Owners Group

issued report on management of

boric acid corrosion in April 2004

* Industry implementation

mandatory

* NRC action - Inspection Procedure

revised to address updated

expectation for boric acid

corrosion control following Davis-Besse

12
Recent Regulatory Action

* Material Reliability Program

issued report on butt weld primary

water stress corrosion cracking in

August 2005

* Industry implementation

mandatory

13
Recent Regulatory Action

* NRC action - Initiated action to

change requirements to include

enhanced butt weld examination

frequency

- Contacted ASME to revise Code

to reflect new examination

expectations

14
Conclusions

* Regulatory treatment of materials

issues depends on several factors

* Range of regulatory vehicles have

been used

* Some industry materials

initiatives do not need regulatory

treatment

15
Requirements And

Oversight

* Technical Specifications

* Fuel Design Reviews

* Periodic meetings with fuel

vendors

16
Current Fuel Reliability

Statistics__

Current Statistics PWR BWR

Number of plants 69 35

Number of plants with fuel defects 1 6 7

% of plants with fuel defects 23 20

Number of fuel assemblies with defects 59 1 4

Fuel assembly defect rate in 2005 3.9 0.6

(per thousand assemblies)

Fuel assembly defect rate in 2004 2.5 1.1

(per thousand assemblies)

17
BWR Failure Mechanisms

Failure Mechanisms 2003 2004 2005

DEBRIS 3 8 5

Pellet Clad Interaction-SCC 4 5 4

CRUD / CORROSION 63 3 0

GRID-TO-ROD FRETTING

FABRICATION 1 0 0

INSPECTED / UNKNOWN 8 10 5

Total Fuel Assemblies With a Fuel 79 26 14

Defect

18
PWR Failure Mechanisms

Failure Mechanisms 2003 2004 2005

DEBRIS 6 0 5

Pellet Clad Interaction-SCC 1 0 1

CRUD / CORROSION 0 0 0

GRID-TO-ROD FRETTING 37 29 31

FABRICATION 1 0 0

INSPECTED / UNKNOWN 24 9 22

Total Fuel Assemblies with a Fuel 69 38 59

Defect

19
Conclusions

* Number of failures is not of

significant safety concern

* No significant trend was observed

* Staff will continue to monitor this

area

20
Summary

e NRC will continue to monitor fuels

and materials degradation issues,

and take appropriate action

* NRC is enhancing its ability to

predict materials degradation

* There are a range of regulatory

vehicles used in addressing

materials issues

* Number of fuel failures is not of

significant safety concern

21