Application of Master Curve fracture toughness for reactor pressure vessel integrity assessment in the USA

The Master Curve fracture toughness approach has been used in the USA for better defining the transition temperature fracture toughness of irradiated reactor pressure vessel (RPV) steels for end-of-life (EOL) and EOL extension (EOLE) time periods. The first application was for the Kewaunee plant in which the life-limiting material was a circumferential weld metal. Fracture toughness testing of this weld metal corresponding to EOL and beyond EOLE was used to reassess the PTS screening value, RT PTS, and to develop new operating pressure–temperature curves. The NRC has approved this application using a shift-based methodology and higher safety margins than those proposed by the utility and its contractors. Beaver Valley Unit 1, a First Energy nuclear plant, has performed similar fracture toughness testing, but none of the testing has been conducted at EOL or EOLE at this time. Therefore, extrapolation of the life-limiting plate data to higher fluences is necessary, and the projections will be checked in the next decade by Master Curve fracture toughness testing of all of the Beaver Valley Unit 1 beltline materials (three plates and three welds) at fluences near or greater than EOLE. A supplemental surveillance capsule has been installed in the sister plant, Beaver Valley Unit 2, which has the capability of achieving a higher lead factor while operating under essentially the same environment. The Beaver Valley Unit 1 evaluation has been submitted to the NRC. This paper reviews the shift-based approach taken for the Beaver Valley Unit 1 RPV and presents the use of the RT T 0 methodology (which evolved out of the Master Curve testing and endorsed through two ASME Code Cases). The applied margin accounts for uncertainties in the various material parameters. Discussion of a direct measurement of RT T 0 approach, as originally submitted for the Kewaunee case, is also presented.