JAFP-87-0737, Responds to NRC IE Bulletin 87-001, Thinning of Pipe Walls in Nuclear Power Plants. Description of Efforts to Develop Piping Insp Program to Detect Erosion/Corrosion of Susceptible Sys,Sketches & Typical Data Sheet Encl
| ML20196G626 | |
| Person / Time | |
|---|---|
| Site: | FitzPatrick  |
| Issue date: | 09/18/1987 |
| From: | Radford Converse POWER AUTHORITY OF THE STATE OF NEW YORK (NEW YORK |
| To: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| References | |
| IEB-87-001, IEB-87-1, JAFP-87-0737, JAFP-87-737, NUDOCS 8803090282 | |
| Download: ML20196G626 (15) | |
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- > NewYorkPbwer 4# Authority September 18, 1987 JAFP 87-0737 Regional Administrator U.S.
Nuclear Regulatory Commission 631 Park Avenue King of Prussia, Pennsylvania 19406
Subject:
James A.
FitzPatrick Nuclear Power Plant Docket No. 50-333 Response to NRC IE Bulletin 87-01 Thinnino of Pine Walls in Nuclear Power Plants
Reference:
- 1. NRC IE Bulletin 87-01. dated July 9 1987
Dear Sir:
IE Bulletin 87-01 described the catastrophic failure of a feedwater line in a nuclear power plant which resulted from erosion / corrosion of the piping.
The bulletin requested that the Authority provide information concerning the program for monitoring pipe wall thickness in high-energy single-phase and two-phase carbon steel piping systems. to this letter describes efforts to develop a piping inspection program to detect erosion / corrosion of susceptibl6 systems.
It also provides a chronological summary of the inspections conducted to date.
Attachments 2 through 4 are sketches which show the locations of typical inspection points and a typical data sheet.
Very tru y yours.
/
88030002g2 gynogg PDR ADOCK 05600333 Radford J.
Converse O
DCD Resident Manager State of New York County of Westchester (l
me this l%% nd Sworn to before Subscribed a ay o f Sapf.19 87.
t 42 w n S. M w Notary Public l
BONNIE S. BOSTIAN 84857051 Notary Neu State et hen Yort CsettoCoun*v Wy Commsica bpres Joe 30. HIS L-
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5 Attachment cc: Office of the Resident Inspector l
U.
S. Nuclear Regulatory Commission P. O.
Box 136 Lycoming, NY 13093 f
U.S. Nuclear Regulatory Commission Document Control Desk Washington, D.
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20555
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L ATTACHMENT 1 TO JAFP 87-0737 EROSION / CORROSION INSPECTION PLANS
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NEW YORK POWER AUTHORITY JAMES A.FITZPATRICK 'TUCLEAR POWER PIANT DOCKET NO. 50-333 DRP-59 i
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EROSION / CORROSION INSPECTION PROGRAM FOR THE JAMES A FITZPATRICE_ NUCLEAR POWER PLANT INTRODUCTION:
The secondary piping systems at the FitzPatrick plant were designed and fabricated in accordance with ANSI B31.1.0, the 1967 Edition through 1969 Addenda.
Most of the pipe material is type A106 carbon steel.
Due to industry concerns, an informal erosion / corrosion inspection program has been in place since September 1984.
At that time steam extraction piping was inspected as a result of INPO SOER 82-11, "Erosion of Steam Piping and Resultant Failure".
During the October 1986 maintenance outage at the FitzPatrick plant, inspections were again performed on extraction steam lines.
During the recently completed Reload 7/
Cycle 8 refueling outage (4/30/87), inspections to detect wall thinning were perforried on the extraction steam piping, feedwater heater drains, and also on the feedwater and condensate piping systems.
The feedwater and condensate systems were included in the scope of work as a result of NRC Information Notice 86-106 and INPO SOER 87-3. Inspection results are discussed later in this report.
Systen inspection points were based on previous industry experience and on the following parameters as described in EPRI report NP-3944:
Piping geometry based on a review of piping isometric o
drawings e
Temperature e
Pressure e
Moisture content for two phase systems i
e Flow velocities Water Chemistry (pH and oxygen levels) i e
Most inspections were performed using automated UT methods.
In addition, manual UT detection methods were used in areas that had restricted access and on the inside curved surfaces of piping elbowa.
All inspections were performed by qualified 1
personnel.
e
DISCUSSION:
The Authority is currently developing a formal inspection program.
An Authority engineer has been assigned to attend industry seminars, collect and review industry data and interview vendors providing inspection program development services.
Erosion / Corrosion Inspection drawings are being developed for the following systems e
Feedwater Heater Vents and Drains e
Condensate e
These inspection drawings will combine information from isometrics, heat balance drawings, etc. to facilitate the inspections.
The Main Steam System and the Reactor Water cleanup System will also be evaluated to determine the effects of Hydrogen Water Chemistry.
Hydrogen Water Chemistry implementation is presently planned for the 1st quarter of 1988.
Upon completion of the preliminary draft of the inspection drawings, the system heat balance will be reviewed to establish inspection points.
Water chemistry data will also be reviewed for its impact on the inspection program.
Since Reference 1 requires chromium content information, piping spool piece Certified Material Test Reports will be reviewed.
However, since chromium content was not required in the ladle analysis at the time of fabrication (circa 1970), this information may not be available.
EPRI reports NP-3944, EPRI Project No. EPRI-25 (SIR-87-010, Draft) and the EPRI Final Report on Single Phase Erosion / Corrosion have been reviewed for guidance and applicability with respect to areas of inspection and program development and are used in the inspection program.
The Authority has also purchased the EPRI CHEC program which is currently under evaluation for screening inspection points.
The Erosion / Corrosion program will be formalized and implemented via a plant procedure.
The finalized program is scheduled to be completed by early 1988.
The frequency of inspections will depend on corrosion rates detected during subsequent inspections.
Repair decisions will be governed by the predicted end of life of the component, i.e.,
when it reaches the mininum wall thickness required by the design Code.
The safety factor used in the calculations is based on the piping application.
It results in a required wall thickness at least as conservative as if the corrosion factor specified in ANSI B31.1 were used.
Any component predicted to reach mini =um wall thickness before the next scheduled outage will be repaired or replaced.
If possible, an improved material will be used.
f INSPECTION RESULTS TO DATE:
September 1984 Maintenance Outage:
l The work during this outage included the inspection of extraction steam (two phase) lines from the main turbine to the feedvater heaters.
Inspections were performed using an automated UT system (P-scan) with verification by manual examination.
Manual UT examination was also performed in places where access was restricted.
Fifteen (15) scan plans were developed for inspection on pipes ranging in size from 14" to 36".
Areas to be inspected were based on fluid velocity, moisture content, temperature, and piping geometry.
A typical scan plan consists of several components on the piping segment.
An example of a scan plan is shown in Attachment 2.
No wall thinning was detected below nominal wall thickness.
It is also noteworthy that the majority of the thicknesses were approximately 5 to 10% above nominal wall thickness which provides an additional safety margin for wear.
4 1
October 1986 Maintenance Outages i
The work during this outage consisted of inspection of extraction steam lines.
A typical inspection scan plan from the l
1986 outage is shown in Attachment 3.
The drawing shows that eight different scans were completed in this one area.
A total of 16 inspection scans were completed during the outage.
Sample data is also shown in Attachment 3.
l During the inspection, two scans detected wall thinning.
Both i
instances were evaluated as erosion / corrosion.
The results were l
also verified by manual UT nethods.
The following is a description of the two areas in which wall thinning was detected.
l 1.
2nd Point Extraction Steam Manifold j
Material Type Carbon Steel A155, Gr. C55, C1. 1 Operating Pressure-S psig at T= 227 F l
Wall thinning was detected by Auto P scan and verified by i
manual UT.
l Maximum readings in the area of thinning are in the range of i
0.772 to.0826 inches.
The pipe (tee configuration) is l
considered to have a nominal wall thickness of 0.750 inches, i
Minimum thickness found was 0.512 inches, and the wall thinning l
was confined to localized areas.
Minimum wall calculations j
(using ANSI B31.1 code equations) were performed to show that the thickness was acceptable.
EPRI NP-3944 was used as guidance for calculating and of life.
The end of life at which the pipe would reach code minimum wall thickness, was calculated to be an additional 14 years of operation.
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2.
2nd Point Extraction Steam Manifold End Cap Material Type Carbon Steel A155, Gr. C55, C1. 1 Operating Pressure-5 psig at T= 227 F Wall thinning was detected by manual UT and verified by another inspector.
Maximum readings were approximately 0.420 to 0.470.
Nominal pipe thickness is 0.375 inches.
Minimum thickness of 0.2 inches was detected over an area of 2.5" x 3".
This area was repaired by weld build-up to restore the original wall thickness (0.375").
The weld repair, including the area adjacent to the weld build-up, was inspected during the refueling outage (2/87),
and nc additional wall thinning was detected in this area.
f Winter Refueling Outage (1/16/87 to 5/1/87)
Twenty eight piping scan plans were developed for inspection during the refueling outage for erosion / corrosion.
Piping scans were performed on the extraction steam piping, feedwater heater drain lines, and condensate /feedwater piping.
A typical scan plan for a piping segment is shown in Attachment 4 and consisted of several areas which were inspected by automated (P-scan) and manual UT methods on different piping components.
Wall thinning was noted in the following three areas 1.
Feedwater Heater Drain line from 3B to 2B-4 areas on line Material Type-A106 Gr. B Carbon Steel /18" pipe size Operating Pressure-45 psig at T= 227 F Pipe thickness based on UT data shows that the wall thickness is 0.55 inches for elbows and 0.375 for pipe.
Nominal thickness required from the piping specification is 0.375.
Minimum thickness found was 0.315 inches on one elbow area.
Based on initial thickness of 0.55 inches, the estimated life remaining is approximately 9 years based on EPRI NP-3944 calculations to reach the code minimum wall thickness.
2.
Condensate line from 2B to 3B feedwater heater Material Type-A106 Gr. B Carbon Steel /20" pipe size Operating Pressure-720 psig at T= 217 F Pipe nominal thickness based on a review of UT data sheets shows that the thickness is 1.031 inches.
Lowest minimum thickness measured was 0.9 inches.
Using EPRI Np-3944 calculations, estimated life remaining is 21 years of operation to reach code minimum wall thickness.
3.
Feedwater Heater Drain line from 5B to 4B-2 areas on line Material Type-A106 Gr. B Carbon Steel /12" pipe size Operating Pressure-162 psig at T= 332 F l
Based on a review of UT data the nominal pipe thickness is 0.5 inches.
Lowest measured minimum thickness is 0.339 inches. Based on the use of EPRI NP-3944 calculations, the estimated life remaining is 9 years of operation to reach code minimum wall thickness.
COMPONENT REPIACEMENT:
The following are components which have been replaced due to erosion / corrosion problems:
1.
MPCI Steam Supply Drain Line Replacement-Plant Modification F1-84-017 Due to erosion from flashing of steam / condensate fluid the drain line was replaced.
Original material was ASTM A106 Gr. B pipe.
The replacement material was Chrome-Moly ASTM A335-P5 material.
In addition, the pipe was redesigned to eliminate as many 90 degree elbows as practical to simplify the piping arrangement and reduce the number of flow direction changes.
2.
Replacement of Manifold and Piping Drains from Turbine to the Condenser-Plant Modification F1-85-018 An 8" manifold, eight 1 1/2" and four 1" Reactor Feedwater Pump Turbine drain lines were replaced and modified to avoid erosion / corrosion of the lines.
The pipe and manifold were replaced with Chrome-Moly ASTM A335 P5 pipe.
The pipe supports were also redesigned in this work effort.
3.
RCIC Steam Line Drain Replacement similar to Item 1, the drain line was re-designed and the material (originally ASTM A 106 Gr. B) has been replaced with stainless steel 304L material to avoid erosion / corrosion problems in the future.
NOTE: All_enuineerina calculations have been nrovided to the RRC I&E Resident InsDector at the FitzPatrick site for reviev.
i ATTACHMENT 2 TO JAFP 87-0737 INSPECTION SCAN PLAN _(1984)
NEW YORK POWER AUTHORITY JAMEG A.FITZPATRICK NUCLEAR POWER PLANT DOCKET NO. 50-333 DRP-59
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