L-2004-233, Westinghouse WCAP-15918-NP, Revision 2, Steam Generator Tube Repair for Combustion Engineering and Westinghouse Designed Plants with 3/4 Inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves.

Westinghouse WCAP-15918-NP, Revision 2, Steam Generator Tube Repair for Combustion Engineering and Westinghouse Designed Plants with 3/4 Inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves.

ML050120454
Person / Time
Site:	Saint Lucie
Issue date:	07/31/2004
From:	Bell B, Gahwiller W, Kurdziel E, Maurer R, Stepnick D Westinghouse
To:	Office of Nuclear Reactor Regulation
References
L-2004-233 WCAP-15918-NP, Rev 2
Download: ML050120454 (160)

Text

St. Lucie Unit 2 Docket No. 50-389 L-2004-233 Enclosure 2 Enclosure 2 Nonproprietary version Westinghouse WCAP-15918-NP, Revision 2 Steam GeneratorTube RepairForCombustion Engineeringand Westinghouse Designed Plants With 314-inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves, dated July 2004, (160 Pages)

Enclosure I Contains 2.390 Proprietary Information

Westinghouse Proprietary Class 3 WCAP-15918-NP July 2004 Revision 02 Steam Generator Tube Repair for Combustion Engineering and Westinghouse Designed Plants with 3/4 Inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves O Westinghouse

WESTINGHOUSE ELECTRIC COMPANY LLC LEGAL NOTICE This report was prepared as an account of work sponsored by Westinghouse Electric Company LLC (Westinghouse). Neither Westinghouse Electric Company LLC, nor any person acting on their behalf:

A. Makes any warranty of representation, express or implied, including the warranties of fitness for a particular purpose or merchantability with respect to the accuracy, completeness of usefulness of the information contained in this report, or that the use of any information, apparatus, method or process disclosed in this report may not infringe privately owned rights; or B. Assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this report.

WESTINGHOUSE ELECTRIC COMPANY LLC WCAP-15918-NP, Rev. 02 Steam Generator Tube Repair For Combustion Engineering and Westinghouse Designed Plants With 3/4 Inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves JULY 2004 Prepared by: Wayne R. Gahwiller Edward P. Kurdziel Bruce A. Bell Richard S. Maurer Approved by: David G. Stepnick

©2004 Westinghouse Electric Company LLC 2000 Day Hill Road, P.O. Box 500 Windsor, Connecticut 06095-0500

WESTINGHOUSE ELECTRIC COMPANY LLC COPYRIGHT NOTICE This report has been prepared by Westinghouse Electric Company LLC and bears a Westinghouse Electric Company copyright notice. Information in this report is the property of and contains copyright material owned by Westinghouse Electric Company LLC and /or its subcontractors and suppliers. It is transmitted to you in confidence and trust, and you agree to treat this document and the material contained therein in strict accordance with the terms and conditions of the agreement under which it was provided to you.

You are permitted to make the number of copies of the information contained in this report that are necessary for your internal use in connection with your implementation of the report results for your plant(s) in your normal conduct of business. Should implementation of this report involve a third party, you are permitted to make the number of copies of the information contained in this report that are necessary for the third party's use in supporting your implementation at your plant(s) in your normal conduct of business if you have received the prior, written consent of Westinghouse Electric Company LLC to transmit this information to a third party or parties. All copies made by you must include the copyright notice in all instances and the proprietary notice if the original was identified as proprietary.

The NRC is permitted to make the number of copies beyond those necessary for its internal use that are necessary in order to have one copy available for public viewing in the appropriate docket files in the NRC public document room in Washington, DC if the number of copies submitted is insufficient for this purpose, subject to the applicable federal regulations regarding restrictions on public disclosure to the extent such information has been identified as proprietary. Copies made by the NRC must include the copyright notice in all instances and the proprietary notice if the original was identified as proprietary.

WESTINGHOUSE ELECTRIC COMPANY LLC ABSTRACT A technique is presented for repairing degraded steam generator tubes in pressurized water reactor Nuclear Steam Supply Systems (NSSS). The technique described alleviates the need for plugging steam generator tubes which require repair. The technique consists of installing an Alloy 800 sleeve which spans the defective section of the original steam generator tube.

The upper end of the sleeve is expanded into the steam generator tube and the lower end is mechanically rolled into the tubesheet for repair of a defect in the expansion transition zone at the top of the tubesheet. For a defect at a tube support or in a free span section of the tube, the sleeve is expanded into the steam generator tube at both ends.

This report details analyses and testing performed to verify the adequacy of Alloy 800 sleeves for installation in a nuclear steam generator tube. These verifications show sleeving to be an acceptable repair technique.

i WCAP-159 18-NP, Rev.

WCAP-15918-NP, Rev. 02 02 i

WESTINGHOUSE ELECTRIC COMPANY LLC RECORD OF REVISIONS l Rev. Date Revision Description 00 November Original Issue 2002 l 01 January Revised extensively 2004 pp. iv-xiii Revised to reflect page changes

p. 2-2 Added explanation of sleeve performance p .2-3 Added information to experience table

p. 4-3 Clarified criteria for plugging defective sleeve

p. 4-5 Clarified tube conditioning verification

p. 4-6 Added reasons for sleeve re-expansion

p. 4-7 Added reasons for re-rolling 02 July p. 5-1 Added pre-installation inspection explanation 2004 p. 5-2 Added word "periodic" to clarify Clarified ECT criteria, analysis training and guidelines

p. 5-3 Modified definition of pressure boundary

p. 5-4 Clarified description of ECT qualification samples

p. 5-5 Figure 5-1 redrawn to clarify

p. 5-6 Figure 5-2 redrawn to clarify

p. 6-2 Clarified discussion of sleeve/tube crevice corrosion

p. 8-32,35 Added firther discussion of installation stresses

p. 9-2 Clarified tube conditioning verification

p. 9-3 Clarified reasons for sleeve re-expansion

p. 9.4 Clarified reasons for re-rolling operation p.10-1 Modified description of sleeve/plug ratio methodology All Removed "repair" from sleeve nomenclature for consistency with Sections other documents ii WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE OF CONTENTS Section Title Page

1.0 INTRODUCTION

1-1 1.1 PURPOSE 1-1

1.2 BACKGROUND

1-2 2.0

SUMMARY

AND CONCLUSIONS 2-1 3.0 ACCEPTANCE CRITERIA 3-1 4.0 DESIGN DESCRIPTION OF REPAIR SLEEVES AND INSTALLATION EQUIPMENT 4-1 4.1 SLEEVE DESIGN DESCRIPTION 4-1 4.2 SLEEVE MATERIAL SELECTION 4-1 4.3 SLEEVE-TUBE ASSEMBLY 4-2 4.4 PLUGGING OF A DEFECTIVE SLEEVED TUBE 4- 3 4.5 SLEEVE INSTALLATION EQUIPMENT 4-3 4.5.1 Remote Controlled Manipulator 4-3 4.5.2 Tool Delivenr Equipment 4-4 4.5.3 Tube Conditioning Equipment 4-5 4.5.4 Sleeve Positioning/Expansion Equipment 4-5 4.5.5 Sleeve Rolling Equipment 4- 6 4.5.6 Nondestructive Examination 4- 7 4.6 ALARA CONSIDERATIONS 4- 7

4.7 REFERENCES

TO SECTION 4.0 4-8 iii Rev. 02 WCAP-15918-NP, Rev. 02 iii

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE OF CONTENTS (Continued)

Section Title Page 5.0 SLEEVE EXAMINATION PROGRAM 5-1

5.1 BACKGROUND

5-1 5.2 SLEEVE/TUBE SAMPLES 5- 4

5.3 REFERENCES

TO SECTION 5.0 5-4 6.0 ALLOY 800 SLEEVE CORROSION PERFORMANCE 6-1 6.1

SUMMARY

AND CONCLUSIONS 6-1 6.2 LABORATORY DATA AND OPERATING EXPERIENCE 6-1 6.2.1 Primary Side Performance 6- 1 6.2.2 Secondary Side Performance 6- 3 6.2.3 Overall Performance and Experience 6- 3 6.3 SLEEVE/TUBE ASSEMBLY CORROSION TESTS 6-4 6.3.1 European-Based Corrosion Tests 6- 4 6.3.2 Welded Sleeve Corrosion Tests 6-5 6.3.3 Confirmatoly Alloy 800 Tests 6- 5 6.3.4 Discussion 6- 6

6.4 REFERENCES

FOR SECTION 6.0 6-9 7.0 MECHANICAL TESTS OF SLEEVED 7-1 STEAM GENERATOR TUBES 7.1

SUMMARY

AND CONCLUSIONS 7-1 7.2 MECHANICAL TESTS 7-1 7.2.1 Axial Load and Pressure Tests 7- 3 iv WCAP-1 5918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE OF CONTENTS (Continued)

Section Title Page 7.2.2 Collapse Testing 7-4 7.2.3 Thermal and Load Cycling Tests 7- 5 7.3 LEAKAGE ASSESSMENT 7- 8 7.3.1 Leak Rate Tests 7- 8 7.3.2 Leak Test Evaluation 7-11 7.3.3 Leak Test Results Under Abnormal Installation Conditions 7-12 7.4 INSTALLATION STRESSES 7-13 7.5 EFFECTS OF CHANGES IN TUBE AND SLEEVE DIMENSIONS 7-14

7.6 REFERENCES

FOR SECTION 7.0 7-15 8.0 STRUCTURAL ANALYSIS OF SLEEVE-TUBE ASSEMBLY 8-1 8.1

SUMMARY

AND CONCLUSIONS 8-1 8.1.1 Design Sizing 8-1 8.1.2 Detailed Analysis Summary 8-2 8.2 EVALUATION FOR ALLOWABLE SLEEVE WALL DEGRADATION USING REGULATORY GUIDE 1.121 8-8 8.2.1 Normal Operation Safety Margins 8-8 8.2.2 Postulated Pipe Rupture Accidents 8-11 8.3 EFFECTS OF TUBE LOCK-UP OR UNLOCKED SITUATION ON SLEEVE AXIAL LOADING 8-12 8.3.1 Sleeved Tube in CE Plants. Unlocked at First Tube Support 8-13 8.3.2 Sleeved Tube in Westinghouse ID" & "E" Plants.

Unlocked at First Tube Support 8-14 WCAP-15918-NP, Rev. 02 v

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE OF CONTENTS (Continued)

Section Title Page 8.3.3 Sleeved Tube in CE Plants. Locked at First Tube Support 8-14 8.3.4 Sleeved Tube in Westinghouse "D" & "E" Plants.

Locked at First Tube Support 8-15 8.3.5 Effect of Tube Prestress Prior to Sleeving 8-27 8.3.6 Lower Sleeve Rolled Section Pushout Due to Restrained Thennal Expansion 8-27 8.4 SLEEVED TUBE VIBRATION CONSIDERATIONS 8-28 8.4.1 Effects of Increased Stiffness 8-28 8.4.2 Effect of Severed Tube 8-28 8.4.3 Seismic Evaluation 8-30 8.5 EVALUATION OF SLEEVE TO TUBE EXPANSION SECTION 8-31 8.5.1 Analysis of Sleeve Material 8-35 8.6 EFFECTS OF SEVERED, UNLOCKED TUBE ON SLEEVE AXIALLOADING 8-53

8.7 REFERENCES

FOR SECTION 8.0 8-53 9.0 SLEEVE INSTALLATION VERIFICATION 9-1 9.1

SUMMARY

AND CONCLUSIONS 9-1 9.2 SLEEVE-TUBE INSTALLATION SEQUENCE 9-1 9.2.1 Transition Zone Sleeve 9-1 9.2.2 Tube Support Sleeve 9-1 9.3 EXPANSION JOINT INTEGRITY 9-1 9.3.1 Tube Conditioning Oualification 9-1 WCAP-15918-NP, Rev. 02 vi As WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE OF CONTENTS (Continued)

Section Title Page 9.3.2 Expansion Qualification 9-2 9.3.3 Summary 9-3 9.4 ROLLED JOINT INTEGIRITY 9-3

9.5 REFERENCES

FOR SEBCTION 9.0 9-4 10.0 EFFECT OF SLEEVINC i ON OPERATION 10- 1

10.1 REFERENCES

FOR SEBCTION 10.0 10-2 vii WCAP-1 WCAP-15918-NP, Rev. 02 5918-NP, Rev. 02 vii

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF TABLES Table No. Table Page 3-1 SLEEVING CRITERIA 3-2 7-1 SLEEVE-TUBE ASSEMBLY MECHANICAL TESTING 7-17 RESULTS 7-2 TUBESHEET SLEEVE-TUBE ASSEMBLY 7-18 LEAK TESTING RESULTS 7-3 TUBE SUPPORT SLEEVE-TUBE ASSEMBLY 7-19 LEAK TESTING RESULTS 7-4 EFFECTS OF DIFFERENT SLEEVE AND TUBE DIMENSIONS TZ SLEEVES 7-20 7-5 EFFECTS OF DIFFERENT SLEEVE AND TUBE DIMENSIONS TS SLEEVES 7-20 7-6 LEAKAGE BEFORE AND AFTER CYCLIC LOAD TEST 7-21 8-1

SUMMARY

OF SLEEVE DESIGN AND ASME CODE ANALYSIS FOR TZ AND TS SLEEVES 8-5 8-2A 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR CE PLANTS WITH 0.048" TUBE WALL AND EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-16 8-2B 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR CE PLANTS WITH 0.042" TUBE WALL AND EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-17 8-2C 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D3 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-18 8-2D 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D4 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-19 8-2E 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D2 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-20 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF TABLES (continued)

Table No. Title Page 8-2F 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D5 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-21 8-2G 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE E2 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-22 8-3A AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED IN TUBE SUPPORT FOR CE PLANTS WITH 0.048" TUBE WALL 8-23 8-3B AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED IN TUBE SUPPORT FOR CE PLANTS WITH 0.042" TUBE WALL 8-23 8-3C AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED IN TUBE SUPPORT FOR WESTINGHOUSE D3 PLANTS 8-24 8-3D AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED IN TUBE SUPPORT FOR WESTINGHOUSE D4 PLANTS 8-24 8-3E AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED IN TUBE SUPPORT FOR WESTINGHOUSE D2 PLANTS 8-25 8-3F AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED IN TUBE SUPPORT FOR WESTINGHOUSE D5 PLANTS 8-25 8-3G AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED IN TUBE SUPPORT FOR WESTINGHOUSE E2 PLANTS 8-26 84A TUBE SLEEVE EXPANSION SECTION -TRANSIENTS CONSIDERED FOR A CE PLANT 8-33 84B TUBE SLEEVE EXPANSION SECTION - TRANSIENTS CONSIDERED FOR A WESTINGHOUSE "D" OR "E' PLANT 8-34 8-5A STRESSES IN SLEEVE FOR CE PLANTS WITH 0.048" TUBE WALL 8-37 8-5B STRESSES IN SLEEVE FOR CE PLANTS WITH 0.042" TUBE WALL 8-37 8-5C STRESSES IN SLEEVE FOR WESTINGHOUSE D3 PLANTS 8-38 ix WCAP-15918-NP, Rev. 02 Rev. 02 ix

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF TABLES (continued)

Table No. Title Page 8-5D STRESSES IN SLEEVE FOR WESTINGHOUSE D4 PLANTS 8-38 8-5E STRESSES IN SLEEVE FOR WESTINGHOUSE D2 PLANTS 8-39 8-SF STRESSES IN SLEEVE FOR WESTINGHOUSE D5 PLANTS 8-39 l 8-5G STRESSES IN SLEEVE FOR WESTINGHOUSE E2 PLANTS 840 8-6A PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.048" TUBE WALL 842 8-6B PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.042" TUBE WALL 842 8-6C PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D3 PLANTS 843 8-6D PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D4 PLANTS 843 8-6E PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D2 PLANTS 844 8-6F PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D5 PLANTS 8-44 8-6G PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE E2 PLANTS 8-45 8-7A PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.048" TUBE WALL 847 8-7B PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.042" TUBE WALL 847 x WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF TABLES (continued)

Table No. Title Pa e 8-7C PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D3 PLANTS 8481 8-7D PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D4 PLANTS 8481 8-7E PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D2 PLANTS 8491 8-7F PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D5 PLANTS 8491 8-7G PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE E2 PLANTS 8-501 8-8A ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Svxr PEAK STRESS RANGE FOR CE PLANTS WITH 0.048" TUBE WALL 8-501 8-8B ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR CE PLANTS WITH 0.042" TUBE WALL 8-51 8-8C ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D3 PLANTS 8-511 8-8D ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D4 PLANTS 8-511 8-8E ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D2 PLANTS 8-521 8-8F ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D5 PLANTS 8-521 8-8G ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE E2 PLANTS 8-521 10-1 TYPICAL SLEEVE TO PLUG EQUIVALENCY RATIO 10-21 WCAP-15918-NP, Rev. 02 Xi

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF FIGURES Figure No. Title Page 4-1 LEAK LIMITING TZ SLEEVE 4-9 4-2 LEAK LIMITING TS SLEEVE 4-10 4-3 LEAK LIMITING TZ SLEEVE INSTALLATION 4-11 4-4 LEAK LIMITING TS SLEEVE INSTALLATION 4-12 4-5 TUBE CONDITIONING TOOL 4-13 4-6 SLEEVE EXPANSION TOOL 4-14 4-7 SLEEVE ROLLING TOOL 4-15 5-1 TZ SLEEVE PRESSURE BOUNDARY DESCRIPTION 5-5 5-2 TS SLEEVE PRESSURE BOUNDARY DESCRIPTION 5- 6 6-1 SLEEVE CORROSION SPECIMEN 6-11 7-1 AXIAL LOAD/CYCLIC LOAD-TZ TEST ASSEMBLY 7-22 7-2 AXIAL LOAD TEST SET-UP 7-23 7-3 CYCLIC LOAD TEST ASSEMBLY-INTACT TUBE 7-24 7-4 CYCLIC LOAD TEST ASSEMBLY-SEVERED TUBE 7-25 7-5 TS LEAK TEST ASSEMBLY 7-26 7-6 LOCKED TUBE TEST FIXTURE 7-27 7-7 AVERAGE LEAK RATE PROJECTIONS FOR DIFFERENT AP'S 7-28 7-8 95 % CONFIDENCE ON MEAN PROJECTIONS OF LEAK RATE 7-29 8-1 MECHANICAL SLEEVE/TUBE ASSEMBLY 8-55 8-2 SYSTEM SCHEMATIC FOR "WORST" CASE CE PLANT WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-56 xii WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF FIGURES (Continued)

Figure No. Title Page 8-3 SYSTEM SCHEMATIC FOR WESTINGHOUSE "D" & "E" PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-57 l 8-4 MODEL OF SLEEVE. LOWER TUBE, AND TUBE IN TUBESHEET:

UNLOCKED AT TUBE SUPPORT 8-58 8-5 MODEL OF COMPOSITE MEMBER. UPPER TUBE. SURROUNDING TUBES, AND TUBESHEET: LOCKED AT TUBE SUPPORT 8-59 l WCAP-15918-NP, Rev. 02 xiii

WESTINGHOUSE ELECTRIC COMPANY LLC

1.0 INTRODUCTION

1.1 PURPOSE The purpose of this generic report is to document the acceptability of an Alloy 800 sleeve in a hot or cold leg steam generator tube of Combustion Engineering and Westinghouse designed steam generators with 0.750 inch OD Alloy 600 tubes. The report includes sufficient information to support a technical specification change allowing installation of these sleeves. The sleeves are designed to be installed in steam generator tubes spanning the defective section. This report demonstrates that reactor operation with sleeves installed in the steam generator tubes will not increase the probability or consequence of a postulated accident condition previously evaluated.

Also it will not create the possibility of a new or different kind of accident and will not reduce the existing margin of safety.

Westinghouse provides two types of leak limiting Alloy 800 sleeves. The first type of sleeve spans the transition zone (TZ) of the parent steam generator tube at the top of the tubesheet. This sleeve is hydraulically expanded into the steam generator tube at the upper end and is hard rolled into the tube within the steam generator tubesheet. The second type of sleeve spans degraded areas of the steam generator tube at a !ube support (TS) elevation or in a free span section. The sleeve used for both of these locations is called a TS sleeve. This TS sleeve is hydraulically expanded into the steam generator tube near each end of the sleeve.

The steam generator tube with the installed sleeve meets the structural requirements of tubes which are not degraded. Even in the event of the severance of the steam generator tube, the sleeve will provide the required structural support and acceptable leakage between the primary and secondary systems for normal operating and accident conditions. Design criteria for the sleeve were prepared to ensure that all design and licensing requirements are considered. Extensive analyses and testing have been performed on the sleeve and sleeve to tube joints to demonstrate that these design criteria are met. The effect of sleeve installation on steam generator heat removal capability and system flow rate are also discussed in this report.

After sleeves are installed, a baseline examination is performed using eddy current (ET) techniques. The ET examination is used to verify certain installation process steps, as well as to provide a baseline to determine if there is sleeve degradation or degradation of the pressure boundary portion of the steam generator tube spanned by the sleeve in later operating years. The ET examination and criteria for plugging sleeved generator tubes if there is degradation are described in this report.

Plugs will be installed if for any unforeseen circumstance that a sleeve installation is not successful or if there is degradation in the pressure boundary section of the sleeves or sleeved steam generator tubes. Standard, site approved, mechanical or welded plugs Page 1-1 WCAP-15918-NP, Rev.Rev. 02 02 Page 1-1

WESTINGHOUSE ELECTRIC COMPANY LLC installed at each end of a steam generator tube may be used to take a sleeved tube out of service.

1.2 BACKGROUND

The operation of Pressurized Water Reactor (PWR) steam generators has, in some instances, resulted in localized corrosive attack on the inside (primary side) or outside (secondary side) of the steam generator tubing. Historically, the corrective action taken for severe steam generator tube wall degradation has been to install plugs at the inlet and outlet of the steam generator tube when the degradation reached a value referred to as a plugging criterion. Eddy current examination has been used to measure steam generator tubing degradation with the tube plugging criterion accounting for ET measurement uncertainties and degradation growth rate.

Installation of steam generator tube or sleeve plugs removes the plugged tube from service, eliminating the heat transfer surface associated with that tube. In addition, plug installation leads to reduction in the primary coolant flow available for core cooling. The repair technique described in this report for installation of sleeves allows the steam generator tube to remain in service, with minimal affect on heat transfer surface and coolant flow. The sleeves are installed at the local area of tube wall degradation and impose only a minor restriction to primary coolant flow. Thus, while providing structural integrity to the weakening effect of tube wall degradation, the effects on heat transfer and primary coolant flow are minimized.

WCAP-15918-NP, Rev. 02 Page 1-2 1-2 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC 2.0

SUMMARY

AND CONCLUSIONS This report has been prepared and reviewed in accordance with 10 CFR 50, Appendix B.

The Alloy 800 repair sleeve is similar to many other sleeves, except new features are provided to improve the design as follows:

• No welding, brazing, or heat treatment is required, thereby greatly reducing the complexity of the installation process.

• The strain within the tube is low, thereby reducing the likelihood of future corrosion cracking. Specifically, the target tube diametrical expansion is between [

1', cwhich is significantly lower than other mechanical sleeve designs.

To utilize its attractive features, the Alloy 800 repair sleeve is a leak limiting design.

Specifically, a small leakage, well within all requirements, will be permitted.

The Alloy 800 repair sleeves were designed to the applicable ASME Boiler and Pressure Vessel Code. An extensive analysis and test program was undertaken to prove the adequacy of both the upper and lower mechanically expanded joints. This program determined the effect of normal operating and postulated accident conditions on the repair sleeve-tube assembly, as well as the adequacy of the assembly to perform its intended function. The mechanical testing verified that the sleeve meets the cyclic load requirements of the original plant design. In addition, to fully confirm the adequacy of these repairs for U.S. plants, primary and secondary side caustic corrosion tests have been completed and the results evaluated relative to previous testing performed in support of both the Alloy 800 sleeve and the TIG welded sleeve.

The proposed repair has no significant effect on the configuration of the plant, and the change does not affect the way in which the plant is operated. The sleeve was designed to meet criteria that would prove the sleeve is an acceptable repair technique. These criteria conformed to the stress limits and margins of safety in Section III of the ASME B&PV Code. Based upon the results of the analytical and test programs described in this report the Alloy 800 repair sleeve fulfills the intended function as a leak limiting structural member and meets or exceeds all the established design criteria. Installation of the sleeves will conform to ASME B&PV Code Section XI, IWA-4420.

Evaluation of the sleeved tubes indicates no detrimental effects on the repair sleeve-tube assembly resulting from reactor system flow, coolant chemistries, or thermal and pressure conditions. Structural analyses of the repair sleeve-tube assembly, using the demonstrated margins of safety, establish its integrity under normal and accident conditions. The structural analyses have been performed for both TZ and TS sleeves.

The TZ sleeves have a length of up to [ ja c inches which spans the degraded tube section at the top of the tubesheet and generally places the expansions above the sludge 0

WCAP159 8-N, Re. Pag 2-WCAP-15918-NP, Rev. 02 Page 2-1

WESTINGHOUSE ELECTRIC COMPANY LLC pile. The TS sleeves have a length of up to [ ] c inches for a sleeve spanning a tube support section of the tube or a tube free span. The analyses also address the sleeve to plug equivalency with respect to system thermal and hydraulic effects for installation of one TZ sleeve or one tube support sleeve. Acceptable sleeve locations covered in this report are from the top of the tubesheet up to and including the u-bend/square bend region in both the hot and cold legs. The analyses were performed for Combustion Engineering and Westinghouse designed plants with 3/4 inch, Alloy 600 steam generator tubes. A TZ sleeve with a length of [ Ia, cinches would result in an approximately [ ]. c inch span between the top-of-tubesheet and the lowermost part of the sleeve/tube joint above the tubesheet.

Mechanical testing has been performed to support the analyses prepared using ASME code stress allowables. Corrosion testing of typical sleeve-tube assemblies have been completed and reveal no evidence of sleeve or tube corrosion considered detrimental under anticipated service conditions.

In addition to the analysis and test program discussed in this report, a significant number of sleeves have been in operation for a number of years with no service induced degradation. Additionally, no detectable leakage has been associated with a tube with an Alloy 800 leak limiting sleeve. The accompanying table provides the operational experience of the design described herein as well as two earlier variations of this same type sleeve. No degradation of the installed sleeve or steam generator tube in the area of the expansions has been identified. A portion of these sleeves were installed with a [ 1a, c diametrical expansion, well above the [ Ia, c target expansion of the sleeve described in this report. Based upon the testing and analyses performed, the sleeves do not result in a significant increase in the probability of occurrence or consequence of an accident previously evaluated, create the possibility for a new or different kind of accident, or result in a significant reduction in a margin of safety.

In conclusion, the Alloy 800 mechanical sleeve is established as an acceptable repair method.

Page 2-2 WCAP-15918-NP, Rev. 02 WCAP-15918-NP, Rev. 02 Page 2-2

WESTINGHOUSE ELECTRIC COMPANY LLC ALLOY 800 SLEEVE INSTALLATIONS AND OPERATIONAL EXPERIENCE Ouantity of Cycle (Year)

Plant S/G Model T Hot Joint Tube Joint Design Sleeves Installed EFPY Comments (OF) Expansion a,c Angra W-D3 620 79 10 (04/01) 0.5 Operational 179 11 (07/02) - P-RSG* 2006 351 12 (10/03) <1 Calvert Cliffs I CE-67 595 68 14 (04/00) 1.8 RSG** 02/02 Calvert Cliffs 2 CE-67 595 365 13 (04/01) -1.0 P-RSG 2003 Comanche Peak I W-D4 559 10 (04/04) <I Operational Kori I W-51 607 1205 14 (03/96) 1.4 RSG 07/98 Krsko W-D4 613 135 14 (05/98) 1.7 110 15 (05/99) 0.9 RSG 06/00 Ringhals 4 W-D3 610 76 17 (09/01) -2.5 Operational 91 18 (09/02) -0.9 Operational Tihange 2 FRAM-51M 617 10 13 (08/97) 3.6 RSG 06/01 Tihange 3 ACE-E 617 20 9 (08/95) 2.4 104 10 (11/96) 1.4 RSG 08/98 Ulchin I FRAM5IB 613 986 9 (02/99) -4.0 Operational 702 10 (07/00) -3 Operational Ulchin 2 FRAM51B 613 1234 9 (02/00) -3.2 Operational 527 10 (09/02) - 1.2 ..

Watts Bar I W-D3 148 5 (10/03) <I Operational Yonggwang 4 CE-KSNP 621 35 5 (06/01) -2.5 Operational 151 6 (10/02) - 1.2 ..

Yonggw 3 CE-KSNP 621 - _ _ 136 7 (06/03) 60% throughwall. For the purpose of this sleeve inspection qualification, this value was reduced to >50% throughwall for the parent tube and >45% for the sleeve in order to provide an operational margin between the detection limit and the structural limit for defect growth. For sleeves with minimum wall thickness, the structurally limiting flaw depth per Regulatory Guide 1.121, calculated using a conservative crack configuration model (Section 8.2), is 48%, and for the tube the limit is greater than 60%. A sufficient number of flaw samples has been used to demonstrate that the statistical requirements for probability of detection are met.

Based upon Westinghouse's experience with the installation of Alloy 800 and TIG welded sleeves and the fact that Westinghouse has not established an ECT sizing error, it has been Westinghouse's recommendation and the plant owner's decision to plug a tube upon the detection of a defect in the pressure boundary portion of the sleeve.

Page 5-2 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC

- ALC The method used for sleeving inspections has been to establish detection capability with an operational margin relative to structurally limiting flaws and to plug flaws upon detection. Accordingly, no attempt was made to size flaws or to leave detected flaws in service at this time. By this approach, the sizing accuracy does not need to be quantified. If future developments provide a qualified flaw sizing technique, an updated Appendix H qualification report will be submitted.

The pressure boundary for a TZ sleeve-tube assembly is considered to be: a) the entire sleeve except for the portion above the [ ]"a c hydraulic expansions, b) the steam generator tube above the hydraulic expansions and below the rolled joint and c) the steam generator tube behind the hydraulic expansion joint and rolled joint regions. The pressure boundary for a TS sleeve-tube assembly is considered to be: a) the sleeve from the lower of the [ ]3 c expansions in the lower joint to and including the upper of the

[ Ia,Cexpansions for the upper joint, b) the steam generator tube above the upper expansion joint and below the lower expansion joint and c) the steam generator tube behind the hydraulic expansion joint region.

Consequently, there are four distinct regions of the pressure boundary, as shown in Figures 5-1 and 5-2, that have been addressed in the Appendix H qualification report:

1) The sleeve-tube assembly at the mechanical joint region (either expansion or roll expansion transition). I

2) The sleeve between and including the upper joints and lower joints (either expansion or rolled depending on sleeve type).

Page 5-3 WCAP-159 WCAP-15918-NP, Rev. 02 18-NP, Rev. 02 Page 5-3

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC

3) The pressure boundary region of the steam generator tube behind sleeve.

4) The unsleeved region of the steam generator tube.

Although the presence of the parent tube is required to complete the tube to sleeve hardroll joint, any postulated degradation of the tube behind the nickel band is judged not to adversely affect the ability of the joint to perform its intended design function, based on observations of parent tube degradation in Westinghouse Model D or Combustion Engineering steam generators. It is considered that the tube in this region is not required to meet tube pressure boundary inspection criteria and therefore no flaws were generated at this location during the qualification program.

The tooling and methods described in this section represent the present technology for leak limiting sleeve inspection. As technological advances are made in NDE methods for sleeve inspection, the new equipment and/or processes may be utilized after they have been qualified to provide improved sleeve inspection.

5.2 SLEEVE/TUBE SAMPLES Samples with the sleeve-tube configuration were made for the qualification testing effort. The qualification test program was performed in accordance with 10 CFR 50, Appendix B. Each of the samples was a configuration that represents the material, dimensions and geometries of the as-installed sleeves. Qualification was performed on the probable flaw orientation as required by Appendix H. Samples were fabricated with axially and/or circumferentially oriented notches in both components representing flaws at each of the transitions and hydraulic expansion zones. Corrosion testing of sleeve/tube samples as well as industry experience to date indicate that in the event cracking did occur it would be oriented in these directions. In addition, sleeve and tube flaws in the pressure boundary away from the expansion regions were included in the sample set. Tooling representative of the field equipment was used to assemble the samples.

In addition to the samples with EDM notches, a limited number of samples with corrosion cracking in the parent tube were also included in the overall program. These tube samples included sixteen (16) sleeve/tube assemblies containing laboratory grown IGSCC in the parent tube behind the sleeve, as well as a pulled tube from an operating steam generator in Europe

5.3 REFERENCES

TO SECTION 5.0 5.3.1 EPRI Steam Generator Examination Guidelines Appendix H Qualification for Eddy Current Plus-Point Probe Examination of ABB CE I-800 Mechanical Sleeves, ABB CENO Report No. 97-TR-FSW-019P, Rev. 00.

WCAP-15918-NP, Rev. 02 5-4 Page 5-4 WCAP-1591 8-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC

a. c FIGURE 5-1 TZ SLEEVE PRESSURE BOUNDARY DESCRIPTION Page 5-5 WCAP-1 WCAP-15918-NP, Rev. 02 5918-NP, Rev. 02 Page 5-5

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC D.c FIGURE 5-2 TS SLEEVE PRESSURE BOUNDARY DESCRIPTION WCAP-1 5918-NP, Rev. 02 5-6 Page 5-6 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC 6.0 ALLOY 800 SLEEVE CORROSION PERFORMANCE The corrosion assessment of the Alloy 800 sleeve is based on the following experiences and test programs:

• The long term service performance of Alloy 800 steam generator tubes and rolled tube plugs in operating steam generators

• Laboratory corrosion tests on full scale mock-ups of the Alloy 800 sleeve/Alloy 600 tube configuration

• Westinghouse's welded sleeve corrosion program

• Correlation of operating experience with these tests Alloy 800 has been successfully used as a steam generator tube and plug material in a number of units located primarily in western European countries. Some of these units have operated with hot leg temperatures as high as 618'F. This data, in addition to evaluations by Westinghouse and others have indicated that Alloy 800 is a viable sleeve material for domestic steam generator applications. As is the case with many steam generator tube repair methods, the principal issue is whether the repair itself will create conditions that will lead to future failures of the susceptible Alloy 600 tubing.

The Alloy 800 mechanical sleeve installation is specifically designed to address this issue by imparting the minimum amount of residual stress in the parent tube consistent with a very low leak rate. In so doing, the potential for future tube failures is minimized.

6.1

SUMMARY

AND CONCLUSIONS The Alloy 800 sleeve provides corrosion resistance under anticipated design and fault primary and secondary environments without increasing the potential for future corrosion induced failures of the pressure boundary section of the original tube. This conclusion is based on laboratory data and operating experience for both Alloy 800 and Alloy 600 steam generator tubing and is verified by corrosion tests conducted by Westinghouse.

6.2 LABORATORY DATA AND OPERATING EXPERIENCE 6.2.1 Primary Side Performance The principal concern with a sleeve joint on the primary side is the potential for primary water stress corrosion cracking (PWSCC) as a result of the stresses imparted to the tube due to the sleeve installation. PWSCC of the Alloy 800 sleeve is not a principal concern because of excellent performance of Alloy 800 steam generator tubes during extensive operating experience as well as past test results. The corrosion resistance of the sleeve/tube joint will be governed by three elements: (1) the chemical and metallurgical conditions of the sleeve and tube material, (2) the water chemistry within the sleeve/tube crevice, and (3) the stresses (residual from sleeve installation WCAP-15918-NP, Rev. 02 Page 6-1

WESTINGHOUSE ELECTRIC COMPANY LLC plus operating) and strains associated with the sleeve/tube mechanical joint. The mechanical joint will not affect the chemical composition of either the tube or sleeve and will result in only a mildly cold worked condition in either material. Some oxygen will initially be present within the sleeve/tube crevice, however, any tendency to trap oxygen will be reduced with this design because ofjoint leakage at lower temperatures.

Based on this, oxygen-rich crevice conditions are not considered to last long enough after startup to be of concern. Experience with Alloy 800 tubes in European steam generators, as well as testing described herein, indicates Alloy 800 exhibits excellent corrosion resistance under both primary and secondary nominal and fault environments.

Further, examination of in-service sleeved tubes with similar crevices, although of the welded Alloy 690 design, have not shown any corrosion attack associated with crevice deposits. Thus, the long term corrosion resistance of the sleeve/tube joint will depend primarily on the local stress and strain level which will be determined by the plastic deformation in the region of the joint.

Alloy 800 has seen considerable usage under PWR conditions without experiencing primary or secondary side stress corrosion cracking. As described in Reference 6.4.1, this experience is based on over two hundred thousand tubes in service for up to nineteen years with only minimal tube failures. This resistance is due to the alloy's chemical composition and heat treatment. In particular, the excellent performance of Alloy 800 in previously installed sleeves (see Section 9.0), hydraulically expanded tube to tubesheet joints and rolled blind steam generator tube plugs (similar to the Alloy 690 plugs employed by Westinghouse) have provided significant primary side experience at strain levels equal to or greater than those experienced during installation of this sleeve.

For this reason the Alloy 800 sleeve is not considered to be the limiting component of the assembly.

An initial assessment of the Alloy 800 sleeve corrosion performance can be made by comparing the level of plastic deformation in the sleeve joint with that typically present at the top of the tubesheet in the steam generators. Whereas the strain in the tube due to sleeve installation is up to [ ] C tube expansions in the tubesheet are up to 1.5%

strain over a comparable [ c length. As such, it can be expected that the sleeve joint would have a longer life than the original tube to tubesheet expansion zone.

In some plants, such as ANO-2 and Calvert Cliffs 2, the tubing has not demonstrated significant PWSCC at the mechanically expanded tubesheet transition zone. For example, examinations of tubes removed from ANO-2 (total of 10 tubes) confirmed that the mode of degradation of the Alloy 600 tubes has been O.D. initiated intergranular stress corrosion cracking (IGSCC) and/or intergranular attack (IGA)

(References 6.4.2, 6.4.3, and 6.4.4). Only where severe plastic deformation has occurred, as in the case of kinetically expanded sleeves at ANO-2, has any PWSCC been indicated. In these cases, it can be argued that since the sleeve imparts less strain into the tube than the tube has experienced at the tubesheet, the sleeve joint would be expected to have a life greater than that of the original tube. Even in cases where PWSCC has been experienced, the resulting sleeve joint life would be expected to be WCAP-159 18-NP, Rev. 02 6-2 Page 6-2 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC no less than the original tube life. This conclusion would be applicable to either Westinghouse or Combustion Engineering designed steam generators.

6.2.2 Secondary Side Performance In addition to the experience and laboratory data described in Reference 6.4.1, Westinghouse has evaluated Alloy 800 under model boiler conditions. In only one out of three boilers, run with as much as 30 ppm chloride in the secondary side bulk water, was any corrosion, in the form of modest pitting and shallow intergranular attack observed (Ref. 6.4.5). Additionally, a fourth model run with sulfate fault secondary chemistry found some wastage but no stress corrosion cracking (Ref. 6.4.6). Based on this data, the Alloy 800 sleeve is considered to be sufficiently resistant to potential fault chemistries to maintain its integrity in the event through wall penetrations are produced in the parent tube.

As stated in Section 6.2.1, for some plants the mode of degradation of the Alloy 600 tubes has been O.D. initiated intergranular stress corrosion cracking (IGSCC) and/or intergranular attack (IGA). This has been the case for circumferentially oriented degradation in the tubesheet expansion transitions and for axially oriented degradation at tube support locations. The destructive examinations of over 20 removed tubes from ANO-2 and Calvert Cliffs 2 have revealed only one tube with primary side initiated stress corrosion cracking (PWSCC). The general lack of PWSCC to date at these plants indicates that the probability of having PWSCC is low and that the potential degradation of concern is O.D. initiated IGA or IGSCC.

In order to minimize the possibility of tube corrosion attack at the upper mechanical joints, the length and positioning of the sleeve have been designed such that the mechanical joints are located above the sludge pile and above and below the tube support elevation. Under these circumstances the potential for fault species to concentrate and cause stress corrosion failures is minimized. Nevertheless, as in the case of primary side performance, the strains and applied stresses associated with these joints are less than those experienced by the tube to tubesheet expansion joint and as such would be expected to provide lifetimes at least as great as this section of the tube.

6.2.3 Overall Performance and Experience The sleeve/tube corrosion performance, including the mechanical joint area, is expected to be acceptable based on the following:

• Plus point inspections after more than one fuel cycle at KORI 2 and Tihange 3 indicated no degradation of the sleeve or tube hydraulic expansion area. Some of these sleeve installations involved tube expansions resulting in higher strains (up to 2.5%) than the current design.

• At ANO-2, many RPC eddy current examinations at the expansion transition at the top of the tubesheet have been performed over many fuel cycles. No WCAP-15918-NP, Rev. 02 Page 6-3

WESTINGHOUSE ELECTRIC COMPANY LLC substantial degradation has been found provided the tube location was not within the sludge pile. Since the Alloy 800 tube sleeve joint will be above the sludge pile and since tube strain for the joint will be on the order of 10% of that of an expansion transition, satisfactory tube service is expected with this design.

Although temperatures are lower, the U-bend region of the tubes at ANO-2 and Calvert Cliffs 1 and 2 provides another base of comparison which indicates good expected tube performance with the Alloy 800 sleeve design. Here, tube strain levels about 1 00 times that for the subject tube repair have been in service for many fuel cycles with satisfactory corrosion performance.

6.3 SLEEVE/TUBE ASSEMBLY CORROSION TESTS 6.3.1 European-Based Corrosion Tests Since late 1995, Westinghouse Reaktor has prepared sleeve/tube test assemblies for corrosion tests performed by Laborelec Laboratories in preparation for Alloy 800 sleeve installation at Tihange 2 and 3. Two sets of tests were performed. The first set, using archive tubing from Tihange 3, was performed for a pre-established time in order to verify a minimum sleeved tube life. The second set, using SCC susceptible tubing, was conducted until such time as all the sleeved tubes had cracked.

The sleeved specimens were prepared with tube diametrical expansions of up to I sib, In addition, reference roll transition assemblies, prepared from the same tubing, were expanded to the original generators' design configuration (approximately 2.5% with 4% wall reduction).

All assemblies were pressurized to a differential pressure of 1300 psi at 6600 F with deaerated 10% sodium hydroxide as the I.D. test environment.

The goal of the Tihange 3 Alloy 800 sleeving program was to keep the steam generators in service for three cycles until replacement units were available. Inasmuch as the roll transitions had begun to crack after one cycle of operation, the goal of the corrosion program was for the time to failure of the sleeved assemblies to be at least three times as long as that for the reference roll transition specimens.

The four reference roll transition specimens failed after [

]b. Based on this value, the goal of the sleeved specimens was a time to failure of greater than [ ]b. The three sleeved assemblies maintained pressure throughout the test and the test was stopped after [

1 b of operation. No cracks were observed in the parent tube expansion transitions of these specimens.

WCAP-15918-NP, Rev. 02 Page 6-4 64 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC In the case of Tihange 2, a more long term goal was desired thus requiring an assessment of the total lifetime of the sleeved tube. Two roll expansion reference samples exhibited through wall cracking in [

]b. Nine sleeved samples were also tested and exhibited lifetimes of [

]b representing an increased life of [

fb times that of the roll transition.

6.3.2 Welded Sleeve Corrosion Tests Westinghouse conducted a similar corrosion test in support of welded sleeve installation in Westinghouse "D" Series steam generators. The purpose of the test was to determine the approximate life of the sleeve/tube joint in the as-welded and the post weld heat treated conditions. The sleeved tube specimens were prepared using EPRI-supplied PWSCC susceptible Alloy 600 tubing. All eight samples were expanded to a tube diametrical expansion of [ Ib and welded using standard welding parameters. Four samples were then post weld heat treated. Additionally, a series of c-rings were prepared for stress determination. The assemblies were pressurized to a differential pressure of 2250 psi at 6600F with deaerated 10% sodium hydroxide.

The as-welded specimens failed at an average time of [ ]b, while the PWHT specimens failed at an average time of [ ].b All cracks occurred in the [

].b Experience has shown that the roll transition region in "D" Series tubes begins to crack after two cycles of operation. Using this data, as well as relationships developed for time to failure for pure water stress corrosion cracking of Alloy 600, it was determined that the as-welded joint life was 6.3.3 Confirmatory Alloy 800 Tests In order to verify the assessments described earlier, accelerated corrosion tests were conducted with full length sleeved tube assemblies (Figure 6-1). This set of tests was performed with the goal of verifying the viability of the installed Alloy 800 sleeve in a caustic environment, as well as confirming the joint performance under aggressive conditions. These assemblies were fabricated with tube expansions ranging from the nominal value of [ ]b to the maximum value of [ ]b, duplicating the anticipated range of expansions for sleeve installation.

This configuration was used to test both primary and secondary side response in accelerated environments. In the primary side case, the sleeve/tube assembly was pressurized on the I.D. to a differential pressure of approximately 1600 psi with deaerated 10% sodium hydroxide at 6607F.

For the secondary side tests, the O.D. environment consists of deaerated 10% sodium hydroxide at 660'F. In this case, the samples are immersed in an autoclave and Page 6-5 WCAP-1591 WCAP- I5918-NP, Rev. 02 8-NP, Rev. 02 Page 6-5

WESTINGHOUSE ELECTRIC COMPANY LLC pressurized, with deionized water, to a differential pressure of 1600 psi. C-ring samples stressed to various levels were also included in the secondary side test capsules.

It is considered that these samples represent the worst case scenario for tubes that are either locked or that are free to move at the tube supports. This conclusion is based on the stresses measured in the installation stress assessment described in Section 7.4 and the operating stresses described in Section 8. In the case of the corrosion samples, the higher pressure stresses resulting from the higher test temperature and the capped tube end, produce a higher applied axial tensile stress in that section than would be experienced by the in-service sleeved tube.

The assemblies were monitored on a continual basis in order to determine whether or not the assemblies maintained pressure. Loss of pressure would indicate a through wall crack in the parent tube or a test fixture problem and would require the test to be interrupted for inspection. The autoclaves containing the test assemblies were removed from service at various junctures in order to visually inspect the assemblies.

The primary side tests, which had average tube expansions of [ ]b, were exposed for over [ ]b with no leakage as defined by loss of pressure. Two of the three assemblies developed [

bb The secondary side tests, which had average tube expansions of [

were exposed for over [ ]b, with two assemblies being exposed for [

fb, respectively. One of the assemblies developed a [

]b during the test, while the other three maintained pressure until shutdown.

The Alloy 800 sleeves showed no signs of cracking in both the primary and secondary side tests.

6.3.4 Discussion The corrosion tests performed on various Alloy 800 sleeve and tube configurations, in conjunction with operating experience, indicate that the Alloy 800 sleeve is a viable repair methodology for use in steam generators with degraded Alloy 600 tubing.

The results of the welded sleeve corrosion tests performed by Westinghouse indicate that weld joints in the as-welded condition will have a service life, as a minimum, of

[ ]b times the time to failure of the roll transition regions of the parent tube.

Removal of an as-welded sleeved tube from Prairie Island after [ Ia,C of service revealed no evidence of weld joint degradation. This field data tends to confirm the test results of the program if only on a preliminary basis. This data is applicable to the Alloy 800 program for the following reasons. The corrosion tests were performed in a similar manner for both programs. The expansions placed in the Page 6-6 WCAP- 1591 8-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC tube for the two types of sleeves are similar, with the expansions of a larger diameter imparted on the welded sleeved tube. Even with this larger diameter expansion, the

[

]8. C. To reiterate, this would be the equivalent of 2.5 times the time to failure of the parent steam generator tubes.

The final set of confirmatory tests performed by Westinghouse support the previous data generated, as well as the field experience. The samples accumulated [ ib times the exposure time of the Westinghouse Reaktor samples and [ jb times the exposure time of the as-welded samples while maintaining pressure and not exhibiting any leakage. The Alloy 800 exhibited no degradation, confirming both field experience and previous corrosion tests performed on the alloy during its development phase for nuclear applications.

The results of corrosion tests performed for Westinghouse Reaktor indicate that the installation of Alloy 800 sleeves in SCC tubing will result in a repair with a service life many times the original roll transition life.

The actual lifetime of sleeved tubes in a particular plant will depend specifically on the tube condition, the failure mechanism and tube joint designs of that plant. As such, a method which compares the ratio of failure times during the corrosion testing to that for the life of the original tube is the most appropriate method for determining the potential sleeved tube life.

In order to evaluate the life of sleeved tubes, the Arrhenius relationship established for stress corrosion cracking can be applied. Using this relationship, comparisons can be made between the ratio of failure times for the roll transition baseline and the sleeved tube, in the test environment and under primary coolant conditions.

Inasmuch as the NaOH tests were conducted under isothermal conditions for both the roll transition and the sleeve mechanical joint, the temperature component of this relationship is unity. As such, the determining factor with respect to life is the total stress associated with the joints. Where tests conditions were controlled to apply the same differential pressure at temperature as is generally experienced in the steam generator (9 Mpa / 1300 psi ), no correction to operating conditions is required. Sleeve life can therefore be determined from the following relationship and the appropriate value for n:

tsleeve _ r sleeve 1 troiltrans I arolltrans )

Page 6-7 Rev. 02 WCAP-15918-NP, Rev. 02 Page 6-7

WESTINGHOUSE ELECTRIC COMPANY LLC Where:

tsileeve = Time to failure of the sleeved tube trolitrans - Time to failure of the original tube at the roll transition aileeve = Stress in the sleeved tube aroiftrans= Stress in the tube at the roll transition n = Empirically determined exponent The value of n, for caustic stress corrosion cracking has been given as 2.4 to 4 and as 4.0 to 4.2 for primary water stress corrosion cracking (PWSCC). (References 6.4.10 and 6.4.12)

Using the minimum times to failure in the caustic test:

tkleave OTlceve A .

] a, b,c troitrans _

=Uo.lrans A mean stress ratio can then be calculated as:

a, bc

[ _.

Using this ratio with the exponent for PWSCC the stress component of the sleeve life can be determined by:

] a,b,c

[.

A further adjustment to the roll transition life would then be made to compensate for any temperature difference between the original and sleeved tube. Due to the insulating effect provided by the sleeve, calculations have determined that the tube temperature may be as much as 5 tolO 0C lower in the region of the sleeve joint as it was at the original roll transition.

WCAP-15918-NP, Rev. 02 Page 6-8 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC Using the temperature dependent function of the Arrhenius relationship, tslkeve (_e Q RT,,

trothtrans e Q RTS Jlsa Applying a value of Q equal to 50 Kcal/mole, a factor of 2 would be applied to the roll transition life for every 100 C of temperature differential (Reference 6.4.10)

Therefore, for example in a plant which had experienced roll transition cracking after two (2) years and in which the temperature differential was calculated to be 10'C; the life of the sleeved tube would be estimated as:

[ J a,b,c Further margin may be applied to this calculation by considering the average time to cracking. The ratio for the average time to cracking is approximately 70 percent greater than that for the minimum times. This would result in additional margin of 2.5 times that estimated.

An assessment of the corrosion testing performed results in the conclusion that Alloy 600 tubes repaired with the Alloy 800 sleeve can be expected to have a life considerably longer than that of the original tube.

6.4 REFERENCES

FOR SECTION 6.0 6.4.1 "Corrosion Resistance of SG Tubing Material Incoloy 800 mod and Inconel 690 TT',

Werkstoffe und Korrosion, p 490, Vol. 43, 1991, Kilian, R., et al.

6.4.2 "Examination of Steam Generator Tubes Removed from Arkansas Nuclear One, Unit No. 2," TR-MCC-210, ABB Combustion Engineering, August 1992.

6.4.3 "Examination of Steam Generator Tubes Removed from Arkansas Nuclear One, Unit No. 2," TR-MCC-225, ABB Combustion Engineering, October 1992.

6.4.4 "Examination of Steam Generator Tubes Removed from Arkansas Nuclear One, Unit No. 2," TR-MCC-258, ABB Combustion Engineering, February 1993.

6.4.5 "Corrosion Performance on Alternate Steam Generator Materials and Designs, Vol. 2, Post Test Examination of a Seawater Faulted Alternative Materials Model Steam Generator," Combustion Engineering, EPRI-NP-3044, Vol. 2, July 1983, Krupowicz, J.

J., et al.

Page 6-9 WCAP-15918-NP, Rev. 02 Rev. 02 Page 6-9

WESTINGHOUSE ELECTRIC COMPANY LLC 6.4.6 "Corrosion Performance on Alternate Steam Generator Materials and Designs, Vol. 3, Post Test Examination of a Freshwater Faulted Alternative Materials Model Steam Generator," Combustion Engineering, EPRI-NP-3044, Vol. 3, July 1983, Krupowicz, J.

J., et al.

6.4.7 "Summary Report - Combustion Engineering Steam Generator Tube Sleeve Residual Stress Evaluation," TR-MCC-153, ABB Combustion Engineering, November 1989.

6.4.8 "Tihange 3 S.G.'s Sleeving Campaign 1995 - ABB Weldless Sleeves Corrosion Tests,"

Report No. C01 -200-95-031 /R/LZN, Laborelec Laboratories, October 10, 1995.

6.4.9 "Corrosion Tests Of Steam Generator Tubes With Alloy 800 Mechanical Sleeves,"

Report No. 98-FSW-021, ABB Combustion Engineering, October 1998.

6.4.10 "Statistical Analysis of Steam Generator Tube Degradation," Staehle, R. W., et al, EPRI NP-7493, 1991.

6.4.11 "Tihange 2 S.G.'s Sleeving Campaign 1997 - ABB Pluss Sleeves Corrosion Tests,"

Report No. MATER-97-200-0047/R-Lz, Laborelec Laboratories, May 1997.

6.4.12 1987 EPRI Workshop on Secondary Side Intergranular Corrosion Mechanisms:

Proceedings, NP-5971, 1988.

Page 6-10WCP158NPRe.0 6-1 0 WCAP-1 5918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC b

FIGURE 6-1 SLEEVE CORROSION SPECIMEN WCAP-15918-NP, Rev. 02 Page 6-1 1

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WESTINGHOUSE ELECTRIC COMPANY LLC 7.0 MECHANICAL TESTS OF SLEEVED STEAM GENERATOR TUBES 7.1

SUMMARY

AND CONCLUSIONS Mechanical tests were performed on mockup steam generator tubes containing repair sleeves to provide qualified test data describing the basic properties of the completed assemblies. These tests determined axial load, collapse, burst, leak rates and thermal cycling capability.

Table 7-1 summarizes the results of the mechanical testing performed on the repair sleeve/tube assemblies. The demonstrated load capacity of the assemblies provides an adequate safety factor for normal operating and postulated accident conditions. The load capability of the upper and lower sleeve joints is sufficient to withstand thermally induced stresses and displacements resulting from the temperature differential between the repair sleeve and the steam generator tube and pressure induced stresses resulting from normal operating and postulated accident conditions. The burst and collapse pressures of the repair sleeve provide margin over limiting pressure differential.

Mechanical testing revealed that the installed repair sleeve will withstand the cyclical loading resulting from power changes in the plant and other transients.

Table 7-2 summarizes the results of the leak testing performed for the tubesheet sleeves at various test and operating conditions. Table 7-3 summarizes the leak test results for the tube support sleeves under the same test conditions. The overall results of these leak tests are that leak rates are sufficiently small so as to allow a large number of sleeves to be installed, without exceeding typical plant allowable leak rates for either accident or normal operating conditions. As described in Section 7.4, tests were performed to determine the residual stresses in a steam generator tube resulting from installation of a repair sleeve, where the steam generator tube is locked at the first tube support. These stresses are well within yield stress and are expected to be acceptable based on corrosion tests in Section 6.

To confirm the sleeve assembly capability to withstand thermal and mechanical cyclic loads without degrading the strength or leak resistance of the expansion joint, thermal and load cycling tests which considered the operating thermal gradient and maximum expansion loads were performed. It was found that the leak rate was reduced after operating condition cycles and no degradation in strength was indicated.

7.2 MECHANICAL TESTS The following mechanical tests were performed on the sleeve/tube assemblies:

leakage, axial load, load cycling, burst and collapse. Loads were applied per the design requirements, or in the case of cyclic loading, until the number of cycles exceeded the expected number of cycles for the original design life of the plant. Clean, unoxidized repair sleeve and steam generator tube samples were used for all tests. [

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WESTINGHOUSE ELECTRIC COMPANY LLC Ca,c a,c Also, based on our experience, any oxide remaining on the inside of the tube after conditioning is expected to have no effect on the structural capability or leak resistance of the mechanical joint between the sleeve and tube. Therefore mechanical testing with properly conditioned unoxidized tubes is sufficient to qualify the sleeve design. This would not necessarily be true if a welded joint were used.

The steam generator tubes used for construction of the test assemblies all had a room temperature yield strength of 49 ksi. The results of the tests performed on these assemblies are contained in Tables 7-1 through 7-3. A finite element stress analysis described in Reference 7.6.7 was performed to determine the effect of different tube yield strengths and different sleeve to tube radial gaps. The analysis considered tube room temperature yield strengths from 35 ksi to 60 ksi. The contact stress at the expansions after sleeve installation was shown to be greater when the tube yield stress was higher. Depending on the gap size, the contact stress for the cases with the highest tube yield stress ranged from 8.7 to 14.8 ksi compression, and for the lowest tube yield stress the contact stress ranged from 6.3 to 7.8 ksi compression. In all cases the contact stress increased significantly, (7.7 ksi on the average) at operating conditions. [

]a, C J.' c Sufficient load capability margin is demonstrated in the tests to cover such an extreme case. From this study it is judged that the tube yield stress variation anticipated to be encountered in steam generators is not a dominant parameter in the sleeve to tube leakage resistance and joint strength, provided that the extent of the tube expansion is in the range of the values tested.

A series of leak and thermal cycle tests were performed to verify this analytical prediction. Test samples were assembled with tubing having a room temperature yield strength of 38-39 ksi. The results of this program are contained in Reference 7.6.9. All samples met minimum joint strength requirements, and experienced leak rates similar WCAP-159 18-NP, Rev. 02 Page 7-2 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC to those found using nominal strength tubing.

With respect to the tube joint at severe accident conditions of high pressure (2500 psi) and temperature (1200-15000 F), pressure tends to loosen the joint and temperature tends to tighten it. As the temperature increases toward 1500'F, both the sleeve and tube will yield at steam line break pressures. Because the sleeve material is specified to have a low yield stress (30 ksi minimum, carefully controlled maximum), the sleeve will yield at a lower temperature (or pressure) than the tube, thereby tending to tighten the joint.

At 1500'F the ultimate stress of the sleeve material is comparable to that of the tube, therefore the integrity of the sleeve repair is commensurate with the integrity of the inservice steam generator tubes. Because of this, sleeving should have no impact on the risk.

7.2.1 Axial Load and Pressure Tests F b Page 7-3 WCAP-15918-NP, Rev. Rev. 02 02 Page 7-3

WESTINGHOUSE ELECTRIC COMPANY LLC significantly above the MSLB/FLB pressure of 2560 psi) corresponding to an axial load of 1369 pounds of force. One specimen was loaded to 5075 psi ( an axial load of 1705 lbs) to demonstrate the sleeve acceptability for higher differential pressures which would result from secondary side pressures lower than 900 psi, e.g. 790 psi. The displacement (maximum of six specimens) of the upper to lower section of the steam generator tube at the axial load of 1369 pounds was .035 inches, and the displacement due to the 1705 lbs was 0.102 inches, see Table 7-1. The maximum load on a severed and locked tube according to Section 8.1.2 is 1296 lbs which is less than the loads tested. The displacements determined in these tests are much less than the 0.25 inch motion which would be required before a severed tube could contact another tube in the U-bend area. These tests show that the displacements are of no concern even for major overload pressures.

7.2.2 Collapse Testing F b WCAP-l 5918-NP, Rev. 02 Page 7-4 WCAP-1 5918-NPI, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC tube joint and the leak rate for the TS sleeve is higher than that of the TZ sleeve, this test is applicable to the TS repair sleeve.

Since collapse testing of the sleeve is not dependent on the steam generator tube wall thickness, these test results are applicable to sleeves in .042 to .048 inch nominal wall.

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7.3 LEAKAGE ASSESSMENT 7.3.1 Leak Rate Tests b

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7.3.3 Leak Test Results Under Abnormal Installation Conditions b

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7.6 REFERENCES

FOR SECTION 7.0 7.6.1 3/4" US NSSS Sleeving Summary of Test Results Report no. GBRA 039-927, Rev. B.

7.6.2 Design Verification and Qualification Report Sleeving of El Steam Generator Tubing (3/4" SG) by Weldless Sleeves, Report no. GBRA 033 43 1.

7.6.3 Fatigue Testing of I800 Sleeved Tube Samples at Operating Temperature; Report no.

MISC-PENG-TR-096, Rev. 00.

7.6.4 Steam Generator Tube Leak Rate Testing of A800 Sleeve Samples, Test Report no.

00000-NOME-TR-0049, Rev. 00.

7.6.5 Test Report for the Locked Tube Support Mock-up Strain Testing for Installation of WCAP-15918-NP, Rev. 02 Page 7-15

WESTINGHOUSE ELECTRIC COMPANY LLC A800 Sleeves, Report no. 00000-NOME-TR-0051, Rev. 00.

7.6.6 Test Report on Thermal and Load Cycling Tests on Alloy 800 Sleeves, Report No.

MISC-PENG-TR-100, Rev. 00.

7.6.7 Calculation Report: Sleeving of ANO2 Steam Generator Tubing ( 3/4") by PLUSS Sleeves with 6 x 8 mm Zero-Expansions, Report GBRA 040194.

7.5.9 7.6.8 Telefax # Ru-wg r1214-ce, from ABB Reaktor to ABB CENO, June 11, 1997, and subsequent telefax from ABB Reaktor to ABB CENO on June 19, 1997.

7.6.9 Test Report On The Alloy 800 Mechanical Sleeve - Additional Qualification Testing Using Low Yield Strength Tubing, Report No. 98-TR-FSW-005.

7.6.10 "Alloy 800 Sleeve Leak Test Summary", Report No. 99-TR-FSW-0044.

7.6.11 "Alloy 800 Sleeve Installation and Operational Stress Test and Analysis Summary",

Report No. 99-TR-FSW-045.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 7-1 REPAIR SLEEVE-TUBE ASSEMBLY MECHANICAL TESTING RESULTS COMPONENT IES r RESULTS Room Temperature Tests:

Cyclic Loading (Wear Test) I Upper Joints Intact Tube Cyclic Loading (Axial Capability)

Upper Joints Severed Tube Operating Temnerature Tests:

Axial Capability Severed Tube Sleeve Assembly Burst Pressure Sleeve Assembly Collapse Pressure Cyclic Loading ( Axial Capability)

Thermal and Load Cycling Tests Sleeve Assembly Collapse Pressure Cyclic Loading (Axial Capability)Capability)

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 7-2 TUBESHEET REPAIR SLEEVE-TUBE ASSEMBLY LEAK TESTING RESULTS PRIMARY SECONDARY PRIMARY AVERAGE 95% UPPER MAXIMUM MINIMUM PRESSURE PRESSURE TEMPERATURE LEAK RATE MEAN LEAK RATE LEAK RATE (psi) (psi) OF) (GAL./HR) (GAL/HR) (GAL./HR) (GAL./HR)

I Ib The upper (one sided ) 95% confidence limit on the mean is calculated as follows:

XI, X2, ...XN are the leakage data for each of the N tests.

XM is the arithmetic average, or the sum of the data values / N tests.

S. the standard deviation of the sample, is the square root of the sum of the (XM-Xi) squared divided by the square root of N-1.

XM(95) is XM + t(95) times S divided by the square root of N. t(95) is the 95% value from Student's "t"'istribution with N-1 degrees of freedom. In this case, since N is 6, t(95) is >.O4 WCAP-15918-NP, Rev. 02 7-18 Page 7-18 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 7-3 TUBE SUPPORT REPAIR SLEEVE-TUBE ASSEMBLY LEAK TESTING RESULTS PRIMARY SECONDARY PRIMARY AVERAGE 95% UPPER MAXIMUM MNIMUM PRESSURE PRESSURE TEMPERATURE LEAK RATE MEAN LEAK RATE LEAK RATE (psi) a \

(psi) \ \

(O) (GAL./HR) (GALJHR) (GAL.IHR) (GAL./HR)

I i b The upper (one sided) 95% confidence limit on the mean is calculated as follows:

XI, X2 , ...XN are the leakage data for each of the N tests.

XM is the arithmetic average, or the sum of the data values / N tests.

S, the standard deviation of the sample, is the square root of the sum of the (XM-X 2) squared divided by the square root of N-1.

XM(95) is XM + t(95) times S divided by the square root of N. t(95) is the 95% value from IStudent'ks "t" distribution with N-1 degrees of freedom. In this case, since N is 6, t(95) is 2.02.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 7-4 EFFECTS OF DIFFERENT SLEEVE AND TUBE DIMENSIONS TZ SLEEVES Sleeve Type Tube thickness Tube yield Leakage at 510 (Inches) strength (Ksi) psi and room temperature

_ __(g_ al/hr.)

Series I Tests TZ .042 47 ___ b TZ .042 47 ___

TZ .042 47 ___

TZ .042 47 ___

Series 2 Tests _ _

TZ .042 38 _

TZ .042 47 ___

TZ .04 57 _

TZ .048 35 ___

TZ .048 49 ___

TZ .048 55 ___ __

TABLE 7-5 EFFECTS OF DIFFERENT SLEEVE AND TUBE DIMENSIONS TS SLEEVES Sleeve Type Tube thickness Tube yield Leakage at 510 psi and (Inches) strength (Ksi) room temperature

_- (gal/hr.) _

TS .042 38 1 b TS .042 47 TS .042 47 =_=

TS .042 57 _

TS .042 57 s __I Page 7-20 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 7-6 LEAKAGE BEFORE AND AFTER CYCLIC LOAD TESTS Sleeve Tube Tube yield Leakage at 510 psi and room Number of Type thickness strength tempe ture Load (Inches) (Ksi) Before Test After Test Cycles (gal/hour) (gal/hour)

TZ 0.042 57 __ _ 1000 TZ 0.048 49 2000 TZ 0.048 55 j b 1000 Page 7-21 WCAP-15918-NP, Rev. 02 Rev. 02 Page 7-21

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FIGURE 7-1 AXIAL LOAD/CYCLIC LOAD-TZ TEST ASSEMBLY WCAP-15918-NP, Rev. 02 Page 7-22 WCAP-15918-NP, Rev. 02

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FIGURE 7-2 AXIAL LOAD TEST SET-UP WCAP-15918-NP, Rev. 02 Page 7-23

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FIGURE 7-3 CYCLIC LOAD TEST ASSEMBLY-INTACT TUBE Page 7-24 WCAP-15918-NP, Rev. 02

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FIGURE 7-4 CYCLIC LOAD TEST ASSEMBLY-SEVERED TUBE Page 7-25 WCAP-15918-NP, Rev. 02 Rev. 02 Page 7-25

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FIGURE 7-5 TS LEAK TEST ASSEMBLY Page 7-26 WCAP-15918-NP, Rev. 02

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FIGURE 7-6 LOCKED TUBE TEST FIXTURE Page 7-27 Rev. 02 WCAP-15918-NP, Rev. 02 Page 7-27

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FIGURE 7-7 AVERAGE LEAK RATE PROJECTIONS FOR DIFFERENT AP'S WCAP-1 5918-NP, Rev. 02 Page 7-28 WCAP-1 5918-NP, Rev. 02

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FIGURE 7-8 95%/n CONFIDENCE ON MEAN PROJECTIONS OF LEAK RATE Page 7-29 Rev. 02 WCAP-15918-NP, Rev. 02 Page 7-29

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WESTINGHOUSE ELECTRIC COMPANY LLC 8.0 STRUCTURAL ANALYSIS OF SLEEVE-TUBE ASSEMBLY This analysis establishes the structural adequacy of the sleeve-tube assembly. The methodology used is in accordance with the ASME Boiler and Pressure Vessel Code,Section III. The work was performed in accordance with 10CFR50 Appendix B and other applicable U.S. Nuclear Regulatory Commission requirements.

8.1

SUMMARY

AND CONCLUSIONS Based on the analytical evaluation contained in this section and the mechanical test data contained in Section 7.0, it is concluded that both the Transition Zone (TZ) and Tube Support (TS) sleeves described in this document, meet all pertinent requirements with substantial additional margins. In performing the analytical evaluation on the tube sleeves, the operating and design conditions for all of the Combustion Engineering and Westinghouse "D" and "E" Series operatina plants with 3/4 inch Inconel 600 tubes are considered (Reference 8.2), as well as the SONGS operating conditions in Reference 8.12. The results of this analytical evaluation are summarized in Table 8-1.

8.1.1 Design Sizing In accordance with ASME Code practice, the design requirements for tubing are covered by the specifications for the steam generator "vessel". The appropriate formula for calculating the minimum required tube or sleeve thickness is found in Paragraph NB-3324.1, tentative pressure thickness for cylindrical shells (Reference 8.1). The following calculation uses this formula for the tube sleeve material which is Alloy 800 material (SB-163, UNS N08800) with a specified minimum yield of 30.0 ksi and a design stress intensity of 20.0 ksi.

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WESTINGHOUSE ELECTRIC COMPANY LLC Where t = Minimum required wall thickness, in.

P = Design Primary Pressure, ksi (maximum value for intact tube situation)

R = Inside Radius of sleeve, in. (maximum value for tam in Reference 8.18).

Sm = Design Stress Intensity, S.I. @ 650TF maximum design (per Reference 8.1) 8.1.2 Detailed Analysis Summarv In determining the axial loads acting on the TZ sleeve at 25.0 inches (Figure 8-1 and Reference 8.9) there are several combinations of tube and tube support conditions which are considered. The two extreme cases for the tube condition are:

1.) the tube is intact.

2.) the tube is totally severed at the defective location.

The two extreme cases for the tube support condition are:

1.) the tube is free to move past the supports.

2.) the tube is locked in the first support and is prevented from axial motion.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-1

SUMMARY

OF SLEEVE DESIGN AND ASME CODE ANALYSIS FOR TZ AND TS SLEEVES lCATEGORY RESJTS-.>i:: l Axial Load [ Ic lb. for intact tube unlocked in the supports during [ ] lb. for severed tube unlocked in the supports 100 % Steady State Operation [ I c lb. (max.) for intact tube locked in the supports lI [ ] c lb. for severed tube locked in the supports Tentative Sizing trqd = 0.0362 in. (per ASME Code) < tit = 0.040 in.

% Allowable Degradation 48% (per NRC Regulatory Guide 1.121, Ref. 8.3)

Limit for both CE and Westinghouse "D" & "E" Plants

.<A gr,. - '., a bE u jtes.n8 , t t (,;.m per~ASME.CodeSksi);

General Primary Membrane Stress Intensity Sm = 20.0 Stress for Sleeve Material Primary Local Membrane Plus Primary Bending Stress Stress Intensity [ 1.5 Sm = 30.0 for Sleeve Material Primary Plus Secondary Stress Stress Intensity = [ IC 3 S. = 60.0 for Sleeve Material Fatigue of Sleeve Material U =[ U = 1.0 Main Steam Line Break Stress Intensity =[ 0.7 Su = 52.5 (CE Plants)

Feedwater Line Break Stress Intensity = ]C 0.7 Su = 52.5 (Westinghouse "D" & "E" Plants)

Primary Pipe Break (LOCA) Stress Intensity =[ ] l 0.7 Su = 52.5 Page 8-5 WCAP-159 18-NP, Rev.

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WESTINGHOUSE ELECTRIC COMPANY LLC GENERAL MEMBRANE STRESSES SUMMARIZED

1. GENERAL PRIMARY MEMBRANE STRESS (P.)

(per Par. NB-3221.1 of Ref. 8.1 w/ Design Primary Pressure of 2.5 ksi and Ri =[ ]in., maximum inner radius for tmin =[ ]in. per Reference 8.18) 1 C L I

2. PRIMARY LOCAL MEMBRANE PLUS BENDING STRESS INTENSITY (PL + PB)

(per Par. NB-3221.3 of Ref. 8.1 w/Design Primary Pressure of 2.5 ksi, Solc (seismic stress) of 5.2 ksi, and Ri of [ ]in., maximum inner radius for tmin =[ ]in. per Reference 8.18)

C L. -J

3. PRIMARY PLUS SECONDARY STRESS INTENSITY (per Paragraph NB-3222.2 of Ref 8.1 w/ Spec. Service Pressure for Intact Tube Situation on Sleeve's Inside Surface C

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WESTINGHOUSE ELECTRIC COMPANY LLC GENERAL MEMBRANE STRESSES SUMMARIZED (continued)

4. MAIN STEAM LINE BREAK FOR CE PLANTS C

5. FEEDWATER LINE BREAK FOR WESTINGHOUSE "D" & "E" PLANTS C

6. PRIMARY PIPE BREAK (LOCA) (assumes a severed tube)

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WESTINGHOUSE ELECTRIC COMPANY LLC 8.2 EVALUATION FOR ALLOWABLE SLEEVE WALL DEGRADATION USING REGULATORY GUIDE 1.121 NRC Regulatory Guide 1.121 (Reference 8.3) requires that a minimum acceptable tube (or sleeve) wall thickness be established to provide a basis for leaving a degraded tube in service. For partial thru-wall attack from any source, the requirements fall into two categories, (a) normal operation safety margins, and (b) considerations related to limiting postulated accidents.

8.2.1 Normnal Operation Safety Margins It is the general intent of these requirements to maintain the same factors of safety in evaluating degraded tubes as those which were contained in the original construction code, ASME Boiler and Pressure Vessel Code,Section III (Reference 8.1).

For Inconel Alloy 600 tube or Alloy 800 sleeve material the controlling safety margins from NRC Regulatory Guide 1.121 (Reference 8.3) for partial thru-wall attack are:

I. "Tubes with detected part thru-wall cracks should not be stressed during the full range of normal reactor operation beyond the elastic range of the tube material".

2. "Tubes with part thru-wall cracks, wastage, or combinations of these should have a factor of safety against failure by bursting under normal operating conditions of not less than 3 at any tube location".

From References 8.2 and 8.15, the normal operating conditions for the "worst" case envelopment of steam generators from the CE and Westinghouse "D" & "E" plants are:

CE Plants West. "D" & "E" Plants Primary Pressure Ppr = 2250 psi 2250 psi Secondary Pressure P5 = 790 psi (Ref. 8.15) 877 psi Differential Pressure AP = Pp - P.,< = 1460 psi 1373 psi Average Pressure Pavg = 0.5 (Pprj + P) = 1520 psi 1564 psi Assuming the parent tube is totally severed, the sleeve is required to carry the pressure loading. The following terms are used in this evaluation.

Ri, = sleeve nominal inside radius, i.e. 1cin. per Reference 8.18 Synn =min. required yield strength (per U.S. NRC Reg. Guide 1.121, Ref. 8.3)

Symfi = minimum yield strength of sleeve (Sy = 23.7 ksi min. at 650 0F, Ref. 8.1)

Based on the information provided in Reference 8.1, the Alloy 800 tube sleeve material (SB-163, UNS N08800) has an ultimate strength of 75.0 ksi at 650 'F. The required thickness is shown below using a derivation of the formula in Paragraph NB-3324.1 of Reference 8.1 with 3 times ? P as mentioned in Regulatory Guide 1.121 (Reference 8.3) and Su in place of Sm per controlling safety margin 2 above.

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WESTINGHOUSE ELECTRIC COMPANY LLC 8.2.2 Postulated Pipe Rupture Accidents NRC Regulatory Guide 1.121 requires the following:

"The margin of safety against tube failure under postulated accidents, such as a LOCA, steam line break, or feedwater line break concurrent with the safe shutdown earthquake (SSE), should be consistent with the margin of safety determined by the stress limits specified in NB-3225 of Section Imof the ASME Boiler and Pressure Vessel Code".

The above referenced ASME code paragraph deals with "faulted conditions", where for an elastic analysis of Alloy 800 sleeves, a general membrane stress of 0.7 S, = 0.7(75.0) =

52.5 ksi is allowed. In conjunction with the NRC Regulatory Guide 1.121, the following accidents are postulated:

(a) For a downcomer feedring steam generator, a feedwater line break (FWLB) accident would have very little effect on steam generator internals. The feedwater line break (FWLB) accident causes a significant pressure differential between the inside of the steam generator and the containment atmosphere. However, the many discharge elbows in the feedwater ring and the ring itself result in large pressure losses for the flow exiting the break. Thus, the flow at the break is limited and the associated forces acting on the steam generator internals (i.e. tubes and tube supports) is not significant when compared to other accident loads. For an economizer steam generator, a feedwater line break (FWLB) accident causes large tube bending stresses near the feedwater nozzle but would have very little effect on the tube spans just above the tubesheet. For a Westinghouse economizer steam generator, a feedwater line break (FWLB) accident produces a maximum differential pressure loading of 2.85 ksi (page 8-7) on the sleeve. A small axial stress could be induced in a sleeved tube if it were locked into the first tube support plate. However, this stress would be negligible compared to the dominant hoop stress due to differential pressure (b) A LOCA accident causes large tube bending stresses in the upper tube bundle but produces only negligible compressive stresses in the region of interest. Thus, the axial loading, etc. in this evaluation applies to sleeves in the lower end of the tube bundle from the fourth support plate down to the tubesheet.

The required thicknesses for a main steam line break (MSLB) or feedwater line break (FWLB) accident are shown below using the derivation of the formula in Paragraph NB-3324.1 of Reference 8.1 with .7 S in place of Sm.

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8.3 EFFECTS OF TUBE LOCK-UP OR UNLOCKED SITUATION ON SLEEVE AXIAL LOADING Objective: Conservatively determine the maximum axial loads on the sleeve (tension and compression) during normal operation for both intact and severed tube situations.

General Assumptions: (See Figures 8-2 through 8-5).

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WESTINGHOUSE ELECTRIC COMPANY LLC 8.3.1 Sleeved Tube in CE Plants. Unlocked at First Tube Support From the diagram in Figure 8-4, the following equations are derived with the basic "mechanics of materials" equations in Reference 8.16.

The deflection of an axially loaded member in compression or tension, A, is defined from Equation 14.6 in Reference 8.16 or: A = F/K with K = AEAL where:

F Force on the respective body, lb.

K = Spring constant for the respective body, lbJin.

A = Cross-sectional area of the respective body, in2 .

E = Modulus of Elasticity of the respective body, psi L = Length of the respective body, in.

The deflection or deformation of an axially loaded member due to temperature differences, 5, is defined from Equation 14.9 of Reference 8.16 or: 5 = L a (T - 70) where:

a = Coefficient of Thermal Expansion of the respective body, in./inJ "F T = Temperature of the respective body, TF 10 8-13 WCAP-1 5918 -NP, WCAP-15918 Rev.02

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8.3.2 Sleeved Tube in Westinghouse "D" & "E" Plant. Unlocked at First Tube Support c

8.3.3 Sleeved Tube in CE Plants, Locked at First Tube Support c

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8.3.4 Sleeved Tube in Westinghouse "D" & 'E" Plants. Locked at First Tube Support L I c

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Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2A 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR CE PLANTS WITH 0.048" TUBE WALL AND EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT

.OUTSIDE INSIDE EFFECrIVE SECTION .'CORRESPOND. YOUNG'S MEAN COEF.

COMPONENTa RADIUS RADIUS LENGTH AREA Temp. 'MODULUS STIFFNESS THERM. EXP.

R. RI *L. A. To E KA1

. ((in) (m) (m) (in2) (CF) lb/in 2 x 106 Ib/inx 1 In/In 0 Fx 10 (1) Sleeve (2) Lower Tube (3) Tube in Tubesheet (4) Upper Tube (5) Surrounding Tubes IC Reference Temperatures: Primary (Hot) =6 10 F (sleeve I.D. temperature)

Secondary= 5060 F (tube O.D. temperature)

Normal Tubes = (2 Tpri + Tsec)/3 = 576TF NOTE: 'Nominal Dimensions for sleeve from Reference 8.18.

2 a,, and E for Inconel 600 and 800 from Reference 8.1.

3 Nominal Dimensions for tubes from Reference 8.4.

4am for Carbon Moly Steel from Reference 8.1.

Page 8-16 WCAP-15918-NP, Rev. Rev. 02 02 Page 8-16

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2B 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR CE PLANTS WITH 0.042" TUBE WALL AND EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT OUTSIDE INSIDE EFFECTIVE SECTION CORRESPOND. YOUNG'S MEAN COEF.

RADIUS RADIUS LENGTH AREA Temp. MODULUS STIFFNESS - THERM. EXP.

COMPONENT R. R L A T- E K = AE/L 2

in)(in). (

__-_*_*_ (in)(in) ). - *(in (lF)b/in x 10; In/InxF x 1046 (1) Sleeve _ _

(2) Lower Tube (3) Tube in Tubesheet (4) Upper Tube _ _ _ _ _ _ _ _ _ _ _ _ _ _

(5) Surrounding IC Tubes Reference Temperatures: Primary (Hot) =61 1F (sleeve I.D. temperature)

Secondary = 5060F (tube O.D. temperature)

Normal Tubes = (2 Tr, + Tc)/3 = 5760F NOTE: XNominal Dimensions for sleeve from Reference 8.18.

2 a. and E for Inconel 600 and 800 from Reference 8.1.

3 Nominal Dimensions for tubes from Reference 8.8.

4am for Carbon Moly Steel from Reference 8.1.

WCAP-15918-NP, Rev. 02 Page 8-17

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2C 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D3 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT

. OUTSIDE INSIDE EFFECTIVE SECTION. 'CORRESPOND. YOUNGrS MEANCOEF.

C RADIUS RADIUS LENGTH AREA Temp. MODULUS STIFFNESS THERM. EXP.

,I L -A'. E K - AE/L O.

l ,, (mn)

_ . ,(im) . (3in)'. (in2)' (OF) bl Ib/in X10 3 lblinxI In/In OF x O4 (I) Sleeve lI (2) Lower Tube (3) Tube in Tubesheet (4) Upper Tube (5) Surrounding Tubes Reference Temperatures: Primary (Hot) = 620 V (sleeve I.D. temperature)

Secondary= 526.5 0F (tube O.D. temperature)

Normal Tubes = (2 Tpr, + Ts¢¢)/3 = 588.8 0F NOTE: lNominal Dimensions for sleeve from Reference 8.18.

2 .. and E for Inconel 600 and 800 from Reference 8.1.

3 Nominal Dimensions for tubes from Reference 8.9.

4a,,, for Carbon Moly Steel from Reference 8.1.

WC A P 1 5 9 1 - N P Re v 0 2P a ge 8-1 WCAP-15918-NP, Rev. 02 Page 8-1 8

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2D 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D4 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT OUTSIDE INSIDE EFFECTIVE SECTION' CORRESPOND. YOUNG'S: MEAN COEF.

COMPONENT CMRADIUS NETRL.A,- RADIUS KLEGM ARE. T. STIFFNESS THERM. EXP.

(in)' lrM 2EXIo. K-AE/L I/xl in/in a.

oF x io-( m) . '(in) '(in) _ __ -b_ __ m_x i_6_x1 0 _ X (1) Sleeve _

(2) Lower Tube (3) Tube in Tubesheet (4) Upper Tube (5) Surrounding Tubes Reference Temperatures: Primary (Hot) = 620 0F (sleeve I.D. temperature)

Secondary = 526.5 0F (tube O.D. temperature)

Normal Tubes = (2 Tp, + T,,,)/3 = 588.8 0F NOTE: 'Nominal Dimensions for sleeve from Reference 8.18.

2 ,, and E for Inconel 600 and 800 from Reference 8.1.

3 Nominal Dimensions for tubes from Reference 8.9.

4o6 for Carbon Moly Steel from Reference 8.1.

Page 8-19 WCAP-159 18-NP, Rev.

WCAP-15918-NP, Rev. 02 02 Page 8-19

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2E 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D2 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT l OUTSIDE INSIDE *EFFECrIVE SECTION CORRESPOND. YOUNG'S MEAN COEF.

RADIUS. RADIUS LENGTH AREA Temp. MODULUS STIFFNESS THERM. EXP.

COMPONENT 0 4 LA.T - E K=AE/L a (in). ( ((in) in) (in2) (")lblintx 103 ibm Inin"Fx 10l (1) Sleeve _

(2) Lower Tube (3) Tube in Tubesheet_

(4) Upper Tube l (5) Surrounding Tubes ll Reference Temperatures: Primary (Hot) = 620 "F (sleeve L.D. temperature)

Secondary = 526.5 "F (tube O.D. temperature)

Normal Tubes = (2 Tpd + TSEC)/3 = 588.8 OF NOTE: 1Nominal Dimensions for sleeve from Reference 8.18.

2 am and E for Inconel 600 and 800 from Reference 8.1.

3 Nominal Dimensions for tubes from Reference 8.9.

4am for Carbon Moly Steel from Reference 8.1.

Page 8-20 WCAP-1 5918-NP, Rev.

WCAP-15918-NP, Rev. 02 02 Page 8-20

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2F 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE D5 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT OUTSIDE INSIDE EFFECTIVE. SECTION CORRESPOND. YOUNG'S MEAN COEF.

RADIUS RR RADIUS LENGTH L. AREA A Temp.

T. MODULUS E STIFNESS K-=AE/L THERM.a EXP.

(in) (in) (in) ( ). (CF) ibrm2x 106 lb/in x io1 InI&InFxX1 (1)Sleeve _ _

(2) Lower Tube (3) Tube in Tubesheet (4) Upper Tube (5) Surrounding lC Tubes l Reference Temperatures: Primary (Hot) = 620 0F (sleeve I.D. temperature)

Secondary = 526.5 0F (tube O.D. temperature)

Normal Tubes = (2 Tpi + T,,,)/3 = 588.8 0F NOTE: lNominal Dimensions for sleeve from Reference 8.18.

2 ca, and E for Inconel 600 and 800 from Reference 8.1.

3 Nominal Dimensions for tubes from Reference 8.9.

4am for Carbon Moly Steel from Reference 8.1.

W CAP1591 -NP Rev 02Page 8-2 WCAP-15918-NP, Rev. 02 Page 8-21

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2G 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE E2 PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT

. OUTSIDE INSIDE EFFECTIVE SECTION CORRESPOND. YOUNG'S MEAN COEF.

C RADIUS RADIUS LENGTH AREA ' Temp. MODULUS S=FNESS THERM. EXP.

COMPONENT R ~EKELa 2)x1 6 3 lb/inxlO10 .Inl OF x 104

__:_-(in) (in) (lb)tn (1)Sleeve (2) Lower Tube (3) Tube in Tubesheet (4) Upper Tube (5) Surrounding T u b es _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _j Reference Temperatures: Primary (Hot) = 620 OF (sleeve I.D. temperature)

Secondary = 526.5 'F (tube O.D. temperature)

Normal Tubes = (2 Tpd + Ts¢,)/3 = 588.8 0F NOTE: lNominal Dimensions for sleeve from Reference 8.18.

2 an and E for Inconel 600 and 800 from Reference 8.1.

3 Nominal Dimensions for tubes from Reference 8.9.

4an, for Carbon Moly Steel from Reference 8.1.

W C PP Rev 1_102P ge 8 2 WCAP-15918-NP, Rev. 02 Page 8-22

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-3A AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR CE PLANTS WITH 0.048" TUBE WALL Sleeve Load Sleeve Load F, TRANSIENT PO PTpf Tpn Fs*for Locked CONDITION for Unlocked Condition (ksi) (ksi) (CF) (OF) Condition Fmax (ibs)

Fmin (ibs)

1. 100% Power [

2. 15%S.S.

3. 0%S.S.

4. Reactor Trip

5. Secondary Leak Test TABLE 8-3B AXIAL THERMAL LOADS IN SLEEVE WITH TU3BE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR CE PLANTS WITH 0.042" TUBE WALL Sleeve Load Sleeve Load F1 CONDINTIO COND ION Ppri Pse TO~ T= F1*

for Unlocked for Locked, Condition (ksi) (ksi) (OF) ('F) Condition Fmax (Ibs)

Fmin Obs)

1. 100%Power [

2. 15%S.S.

3. 0%S.S.

4. Reactor Trip

5. Secondary Leak Test Page 8-23 WCAP-15918-NP, Rev. Rev. 02 02 Page 8-23

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-3C AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE D3 PLANTS Sleeve Load Sleeve Load F, TRANSIENT PIO 5 c Ps Tprl TC Fi* for Locked CONITONfor Unlocked Condition (ksi) (ksi) (°F) (°F) Condition Fmax (Ibs)

Fmin (lbs)

1. 100% Power

2. 15% S.S.

3. 0%S.S.

4. Reactor Trip

5. Feedwater Cycling

._ .. _ . IC TABLE 8-3D AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE D4 PLANTS Sleeve Load Sleeve Load F, RANSIENT Ppi P Tp, TS F* for Locked CONITONfor Unlocked Condition (ksi) (ksi) (F) (F) Condition Fmax (lbs)

Fmin Obs)

1. 100% Power

2. 15% S.S.

3. 0%S.S.

4. Reactor Trip

5. Feedwater Cycling WCAP-1 5918-NP, Rev. 02 Page 8-24 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-3E AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE D2 PLANTS Sleeve Load Sleeve Load F1 TRANSIENT Ppn PWC Tpn TS F* for Locked CONDITION for Unlocked Condition (ksi) (ksi) (0 F) (F) Condition Fmax (Ibs)

Frnin (lbs)

1. 100%Power

2. 15%S.S.

3. 0%S.S.

4. Reactor Trip

5. Feedwater Cycling

._ .. ... IC TABLE 8-3F AXAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE D5 PLANTS Sleeve Load Sleeve Load F1 TRANSIENT Ppri Psec TpO Tc Fi* for Locked COND1TION for Unlocked Condition (ksi) (csi) (OF) (OF) Condition Fmax (Ibs)

Fmin (Ibs)

1. 100% Power -

2. 15% S.S.

3. 0%S.S.

4. Reactor Trip

5. Feedwater Cycling Page 8-25 WCAP-15918-NP, Rev. 02 WCAP-159 18-NP, Rev. 02 Page 8-25

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-3G AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE E2 PLANTS Sleeve Load Sleeve Load F, CANSiIONT CONITONfor Pxri P= Tpfi TM F1*

Unlocked for Locked Condition (ksi) (ksi) (() OF) Condition Fmax (lbs)

Fmin Obs)

1. 100% Power

2. 15%S.S.

3. 0% S.S.

4. Reactor Trip

5. Feedwater Cycling

.. _ ___ __ _ _ _ __ _ _ _ _ _.________ .________ ___ _ _ _ _ _ _ _ _ _ _ _ ]'

WCAP- 15918-NP, Rev. 02 Page 8-26 WCAP- 15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC 8.3.5 Effect of Tube Prestress Prior to Sleeving C

8.3.6 Lower Sleeve Rolled Section Pushout Due to Restrained Thernal Expansion C

CE Plant with 0.048" tube thickness _

CE Plant with 0.042" tube thickness Westinghouse D3 Plant Westinghouse D4 Plant _

Westinghouse D2 Plant Westinghouse D5 Plant Westinghouse E2 Plant _ ._- _- _

WCAP-15918-NP, Rev. 02 Page 8-27

WESTINGHOUSE ELECTRIC COMPANY LLC 8.4 SLEEVED TUBE VIBRATION CONSIDERATIONS The vibration behavior of a sleeved tube is evaluated as follows:

8.4.1 Effects of Increased Stiffness

_C 8.4.2 Effect of Severed Tube Page 8-28 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC F -1c WCAP-15918-NP, Rev. 02 Page 8-29

WESTINGHOUSE ELECTRIC COMPANY LLC 8.4.3 Seismic Evaluation The natural frequency of a sleeved tube for the span between the tubesheet and the first 1

tube support for the "worst" case situation is: C WCAP-1 5918-NP, Rev. 02 Page 8-30 Page WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC C

8.5 EVALUATION OF SLEEVE TO TUBE EXPANSION SECTION The normal operating, design seismic, and transient conditions on the steam generator tube sleeves are used in accordance with ASME Code Section m evaluation, considering both temperature and pressure loads.

The transient conditions defined in References 8.8 and 8.23 represent the worst case situation for a CE plant steam generator. Table 8-4A shows the grouping of these transients with the logic as follows:

• The 500 cycles between ambient (room temperature) and 0% steady state represent the 500 heatup and cooldown conditions.

• The 17,000 cycles between 15% steady state and full power are the sum of the 15,000 loading and unloading conditions and 2000 step load events.

• The 480 cycles between full power and reactor trip are a combination of 400 trip, 40 loss of flow, and 40 loss of load cycles.

• The 200 cycles for secondary leak testing.

The transient conditions defined in Reference 8.19 represent the worst case situation for a Westinghouse 'D" or "E" plant steam generator. Table 84B shows the grouping of these transients with the logic as follows:

• The 280 cycles between ambient (room temperature) and 0% steady state represent the 200 normal heatup and cooldown conditions and 80 loop out of service conditions.

• The 18,300 cycles between 15% steady state and full power are the sum of the 18,300 loading and unloading conditions.

Page 8-31 WCAP-l 5918-NP, Rev.

WCAP-15918-NP, 02 Rev. 02 Page 8-3 1

WESTINGHOUSE ELECTRIC COMPANY LLC

• The 500 cycles of loading/unloading represent loading and unloading between 0%

and 15% power.

• The 400 cycles of reactor trip represent 400 upset conditions.

• The 2000 cycles of feedwater cycling represent excursions from 0% steady state.

Hydro tests are isothermal and produce negligibly small sleeve loads regarding fatigue.

Further details on the results of the load cycling tests are presented in Section 7.

A bounding analysis which envelopes the sleeve and the tube at the expansion zone is performed in which Primary plus Secondary and Peak stresses are evaluated. The axial and radial stresses in the sleeve due to thermal expansion differentials are conservatively calculated assuming total restraint of the sleeve/tube joint. The peak stress calculations conservatively ignore fluid film resistances and use total bulk fluid temperature differences to calculate a thermal skin stress. The actual linear temperature gradient across the sleeve wall is small and produces an insignificant secondary stress.

The stress calculations assume a straight sleeve and tube with nominal dimensions. The residual strains introduced during the sleeving procedure are small, thus there is very little distortion as noted in Reference 8.4. Any non-conservatism introduced by not applying a stress intensification factor at expansion zones is covered by the other conservatisms in the modeling and loading assumptions. The major conservatisms in this analysis, relate to the treatment of the thermal conditions and the assumption that the sleeve to tube attachment points are rigid. The use of a thermal gradient across the tube-sleeve assembly wall will result in a significant reduction in the temperature differential between the sleeve and tube.

Stresses introduced during the installation of the sleeves will "shake down" during the first few operational cycles as noted in Reference 8.4 and are neglected in the ASME evaluations as the ASME Code does not address mechanical joints. A rolled or mechanical joint does not concentrate stresses the way a welded joint does because the two bodies are not directly bonded together. It is only interfacial pressure and friction that is used to maintain the integrity of the joint. Several cyclic tests were performed to evaluate the effect of these types of loadings on the integrity of the joint as described in Section 7.2.3. In general, the integrity of the joint was either unaffected or improved following the tests. Hence, cyclic loadings will not degrade joint integrity.

During the initial plant heatup following Alloy 800 sleeve installation, the sleeve will expand more than the parent tube. As the sleeve lengthens, it will be restrained by the upper and lower joints and the tube will be in compression. At some point during the initial heatup, the sleeve will move (with respect to the tube) and the compressive stresses will be reduced. During subsequent plant heatups there will be no relative movement between the sleeve and tube and compressive stresses on the tube will be lower than occurred during the initial heatup. A more detailed explanation of this process is contained in Section 7.2 of the report.

WCAP-l 5918-NP, Rev. 02 Page 8-32 Page W CAP-15918-NEP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 84A TUBE SLEEVE EXPANSION SECTION - TRANSIENTS CONSIDERED FOR A CE PLANT RESTRAINED TRANSIENTS END POINTS CYCLES.  : THERMAL P1 . PI -P EXPANSION (psi) (psi) (psi)

AXIAL LOAD (Ibs)

(1) Heatup/Cooldown Ambient 0% S.S. 500 (2) Loading/Unloading 15% S.S.

(15%-100%) 100% S.S. 17000 l (3) Reactor Trip 100% S.S.

and Upset 0% S.S. 480 (4) Secondary Leak Test Test Condition l Ambient 200 10 CONDITIONS:

(a) Worst Case: Tube is locked-in to first tube support.

(b) Tube is Intact: Tube/sleeve restrained thermal expansion.

(c) Axial loads are from Table 8-3A.

(d) Sleeve is 25.0 inches long.

(e) Transient Cycles are defined in References 8.8 and 8.23.

8-33 WCAP- 1591 8-NP, Rev.02 WCAP-15918-NP, 8-33

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-4B TUBE SLEEVE EXPANSION SECTION - TRANSIENTS CONSIDERED FOR A WESTINGHOUSE "D" OR "E" PLANT RESTRAINED TRANSIENTS END POINTS CYCLES THERMAL 1 ps)

EXPANSION (psi) (psi)

AXIAL LOAD (lbs) -

(1) Heatup/Cooldown Ambient 0% S.S. 280 (2) Loading/Unloading 15% S.S.

(15% - 100%) 100% S.S. 18300 (3) Loading/Unloading 0% S.S.

(0%- 15%) 15% S.S. 500 (4) ReactorTrip 100% S.S.

and Upset 0% S.S. 400 (5) Feedwater Cycling 0% S.S.

FW Cycling 2000 CONDITIONS:

(a) Worst Case: Tube is locked-in to first tube support.

(b) Tube is Intact: Tube/sleeve restrained thermal expansion.

(c) Axial loads are from Table 8-3C.

(d) Sleeve is 25.0 inches long.

(e) Transient Cycles are defined in Reference 8.19.

(f) For Reactor Trip & Upset, PI is assumed to be a maximum of 2250 psi.

Page 8-34 WCAP-1 Rev. 02 WCAP-1 5918-NP, Rev. 02 Page 8-34

Westinghouse Proprietaxy Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC The stresses on the sleeves that occur during the installation process are not neglected in the ASME Code analysis. The stresses are treated separately. A detailed description of the installation stresses is contained in Section 7.4. As described therein, residual stresses were maintained below the yield stress of the material and were evaluated as part of the material evaluation in Section 6.0.

As described previously, axial stresses on the tube (tension) and sleeve (compression) are reduced during the initial plant heatup when the sleeve is displaced. This displacement does not occur during subsequent heatups and cooldowns and the stress on the components is less than during the first cycle. Further, axial loads on the sleeve are calculated assuming no displacement of the sleeve relative to the tube. Hence, the axial loads calculated in the report are conservative relative to those that would occur in a steam generator. Other stresses calculated in the report for normal and faulted conditions are dependent on the primary to secondary pressure differential and are unaffected by installation stresses.

8.5.1 Analysis of Sleeve Material

-Ic Page 8-35 WCAP-15918-NP, Rev.02 WCAP-l 591 8-NP, Rev.02 Page 8-35

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC

-__ C WCAP-1 5918-NP, Rev. 02 Page 8-36 8-36 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-5A STRESSES IN SLEEVE FOR CE PLANTS WITH 0.048" TUBE WALL Stress Hoop Stress due Thermal Radial Thermal TRANSENT due to to Sleeve/Tube Differential Skin Stress CONDITIONAxial Load Differential Stress, crTamal a dd s -a Temperature, ce (ksi)(ksi)

(ksi) (ksi)

1. Ambient 1 .

2. 0% S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip

6. Secondary Leak Test .C TABLE 8-5B STRESSES IN SLEEVE FOR CE PLANTS WITH 0.042" TUBE WALL Stress Hoop Stress due Thermal Radial Thermal CO OENT due to to Sleeve/Tube Differential Skin Stress CONDTION Axial Load Differential Stress, codr .

cTemperature, ae (ksi)si)

LSi) (ksi)

1. Ambient [

2. 0% S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip .

6. Secondary Leak Test Page 8-37 WCAP-159 18-NP, Rev.02 WCAP-15918-NP, Rev.02 Page 8-37

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-5C STRESSES IN SLEEVE FOR WESTINGHOUSE D3 PLANTS

. R=SEWStress Hoop Stress due Thermal Radial Thermal CO M N due to to Sleeve/Tube Differential Skin Stress CONDITIONal Load Differential Stress, cacrslh Gax i aTemperature, ae (ksi) N isi)

(ksi) (ksi)

1. Ambient[

2. 0%S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip_

6. Feedwater Cycling C TABLE 8-5D STRESSES IN SLEEVE FOR WESTINGHOUSE D4 PLANTS Stress Hoop Stress due Thermal Radial Thermal TRANSIEN due to to Sleeve/Tube Differential Skin Stress CONDITIONAxial Load Differential Stress, ,r&2; hi Temperature, cr (ksi)

(ksi) (ksi)

1. Ambient [

2. 0% S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedwater Cycling . 1 Page 8-38 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-SE STRESSES IN SLEEVE FOR WESTINGHOUSE D2 PLANTS Stress Hoop Stress due Thermal Radial Thermal TRANSIENT due to to Sleeve/Tube Differential Skin Stress CONDTON Axial Load Differential Stress, o,,, a" caxw Temperature, 06 (ksi) (ksi)

_ (ksi) (ksi)

1. Ambient [

2. 0%S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedwater Cycling ._ _ ]

TABLE 8-SF STRESSES IN SLEEVE FOR WESTINGHOUSE D5 PLANTS Stress Hoop Stress due Thermal Radial Thermal CONSIENT due to to Sleeve/Tube Differential Skin Stress CONDTON Axial Load Differential Stress, a& CT"

FxW Temperature, 06 (ksi) si)

(ksi) (ksi)

1. Ambient [

2. 0% S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedwater Cycling _ C WCAP-15918-NP, Rev.02 Page 8-39

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-5G STRESSES IN SLEEVE FOR WESTINGHOUSE E2 PLANTS T . Stress Hoop Stress due Thermal Radial Thermal TRANSENT due to to Sleeve/Tube Differential Skin Stress CONDITIONAial Load Differential Stress, c&,rnki, Temperature, a0 (ksi) ki)

(ksi) (ksi)

1. Ambient[

2. 0% S.S.

3. 15% S.S.

4. 100%S.S.

5. Reactor Trip

6. Feedwater Cycling . . ]

WCAP-15918-NP, Rev. 02 Page 8-40 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC c

Page 8-41 1591 8-NP, Rev.02 WCAP 15918-NP, Rev.02 Page 8-41

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-6A PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.048" TUBE WALL Total Total Total TRONSITINT Axial Hoop RadialSxSosx CONDIINT Stresses Stresses Stresses Sxr Sr SOx CX total Go total crx total (ksi) ksi) (ksi)

(ksi) (ksi) (ksi)

1. Ambient [

2. 0%S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip _ _ _ _

6. Secondary Leak Test Sxr range= c ksi < 3.0 Sm =60 ksi S0r range=[ c si S0x range=[ ]c ksi TABLE 8-6B PRIMARY AND SECONDARY STRESSES AND STRESS lNTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.042" TUBE WALL TR.ANSIEN Total Total Total CODMNAxial Hoop RadialSrSeso CONDiON Stresses Stresses Stresses Sxr S~r SOx ax tota ae total ax tota (ksi) OMs) (ksi)

_ (ksi) (ksi) (ksi)

1. Ambient [

2. 0% S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip _ _ _

6. Secondary Leak Test Sxr range =1 lcksi<3.0 m= 60ksi SOr range =[

SOx range =[

WCAP 15918-NP, Rev.02 8-42 Page 842 WCAP 15918-NP, Rev.02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-6C PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WVFqTNQCr-OT Tq'F- D3 PLANTS RNSIINT Total Total Total CNIINAxial Hoop Radial Sxr SE~r sox CONDITION Stresses Stresses Stresses GX total 00 tow laX total (ksi) (ksi) (ksi)

(ksi) (ksi) (ksi)

1. Ambient [ ._.

2. 0% S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip .

6. Feedwater Cycling _ _ C Sxr range [ ] ksi < 3.0 Sm =60 ksi SOr range=[ ]c ksi SOx range=[ ]c ksi TABLE 8-6D PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D4 PLANTS Total Total Total CONDTN CNIINAxial Stresses Hoop Stresses Radial Stresses Sxr SOrso S~x Cx total C total aX total (ksi) (ksi) (ksi)

(ksi) (ksi) (ksi)

1. Anibient [

2. 0% S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedwater Cycling ]

Sxr range =[ ] Cksi <3.0 Sm= 60 ksi SOrrange =[ ]cksi SOx range =[ Cksi WCAP 15918-NP, Rev.02 Page 8-43

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-6E PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D2 PLANTS SENT Total Total Total TRNSIENT Axial Hoop Radial Sxr SorS(

CONDIONStresses Stresses Stresses aX total CF total C1X total (ksi) (ksi) (ksi)

Nisi) (ksi) (ksi)

1. Ambient

2. 0% S.S.

3. 15% S.S.

4. 100%S.S.

5. Reactor Trip

6. Feedwater Cycling _ . ]

Sxr range ksi < 3.0 Sm=60 ksi SOr range =S[ ] i S0x range=[ c ksi TABLE 8-6F PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D5 PLANTS Total Total Total TRONSONT Axial HOOP Radial Sxr ser sex CONDITION Stresses Stresses Stresses cCO tota l ax total (ksi) csi) (ksi) l (ksi) (ksi) (ksi)

1. Ambient [ _ _

2. 0%S.S.

3. 15% S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedater Cycling .__ . ]'

Sxr range =1 I Cksi <3.0 Sm =60 ksi SOr range =[ ]I ccsksi S~x range =[

8-44 WCAP-1591 8-NP, Rev.02 Page 8-44 WCAP-15918-NP, Rev.02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-6G PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE E2 PLANTS TASETTotal Total Total TCOMSINT Axial Hoop Radial xSr so CONDITION Stresses Stresses Stresses Sxr Sr Sx Ox total Go total aX total (ksi) (ksi) (ksi)

_si) (ksi) (ksi)

1. Ambient [

2. 0%S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedwater Cycling IC Sxr range=[ ] cksi < 3.0 Sm = 60 ksi SOrrange =[ ] c ksi SOx range =[ ] c ksi Page 8-45 WCAP-15918-NP, Rev.02

Class 2 Proprietaty Westinghouse Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC

6. Fatigue Evaluation F Ic WCAP-15918-NP, Rev. 02 Page 8-46 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-7A PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.048" TUBE WALL TRANSENT Spxr SpOr SpOx Number CONDITION of Cycles l(ksi) (ksi) (ksi) ______

1. Ambient [

2. 0% S.S.

3. 15%S.S.

4. 100% S.S. .

5. Reactor Trip _

6. Secondary Leak Test ]

TABLE 8-7B PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR CE PLANTS WITH 0.042" TUBE WALL STRANSIENTpxrSpOr SpOx Number CONDITION of Cycles l(ksi) (ksi) (ksi) _____

1. Ambient [

2. 0% S.S.

3. 15%S.S.

4. 100%S.S. l l

5. Reactor Trip

6. Secondary Leak Test 3 I__

WCAP-159 18-NP, Rev.02 Page 8-47 WCAP-15918-NP, Rev.02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-7C PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D3 PLANTS TRANS ENTSpxr SpOr SpOx Number CONDMTION of Cycles (ksi) (ksi) (ksi) _____

1. Ambient

2. 0% S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip I I __

6. Feedwater Cycling I ]

TABLE 8-7D PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D4 PLANTS TRANSIENT Spxr Sper SpOx Number CO NDITION of Cycles l(ksi) (si) (icsi) 1.Anbient[

2. 0% S.S.

3. 15%S.S.

4. 100%S.S.

5. Reactor Trip I I I

6. Feedwater Cycling I I _I IC WCAP-159 18-NP, Rev. 02 Page 8-48 848 WCAP- I5918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-7E PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D2 PLANTS TRANSIENT Spxr Sper SpOx Number CONDITION of Cycles (Icsi) (ksi) (ksi) _____

1. Ambient [

2. 0%S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedwater Cycling I]II__

TABLE 8-7F PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE D5 PLANTS TRANSENT Spxr SpOr SpOx Number CONDITION of Cycles (ksi) (ksi) (ksi) _____

1. Ambient [ ._. -

2. 0%S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip I I _

6. Feedwater Cycling I]II IC Page 8-49 WCAP-15918-NP, Rev.02 WCAP-1 591 8-NP, Rev.02 Page 8-49

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-7G PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE E2 PLANTS TRANSIENT Spxr SpOr SpOx Number CONDITON ofCyclesl (ksi) (ksi) (ksi)l

1. Ambient [

2. 0% S.S.

3. 15%S.S.

4. 100% S.S.

5. Reactor Trip

6. Feedwater Cycling I._

For the Spxr peak stress range, the accumulated fatigue damage is calculated as follows in Tables 8-8A thru 8-8G:

TABLE 8-8A ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR CE PLANTS WITTH 0.048" TBRE WALL Max. Stress Intensity Min. Stress Intensity l 2 Transient SI Transient SI Sa Sa*(') N (2) n U-ksi ksi ksi ksi n/N Ambient I I 100% S.S.[

Secondary Leak Test I I ' 100% S.S. .

0% S.S. [ I-L 100% S.S.

15% S.S. C100%S.S. ] c (1) - Per Reference 8.1,Section III, Paragraph NB-3222.4 (e) (4), the definition for Sa* is:

Sa* = Ecuv / Eacwal (Sa) = 1.0755 Sa Where: Ecutv, = 28.3 x 106 psi; Reference 1,Section III, Figure I-9-2 Eactuat = 26.313 x 106 psi; Reference 1 for the sleeve material (2) - Reference 8.1,Section III, Figure I-9-2 Therefore, EU =L 1c < Allowable = 1.0 Pae85 CP1518NRv0 Page 8-50 WCAP-15918-NP, Rev.02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-8B ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR CE PLANTS WITH 0.042" TUBE WALL Max. Stress Intensity Min. Stress Intensity l Transient SI Transient SI Sa Sa*(') N (2) n U=

ksi ksi ksi ksi n/N Ambient [ ]c 100% S.S. [ _

Secondary Leak Test Jj ] 100% S.S.

0% S.S. C 100% S.S.

15% S.S. r C 100% S.S. IC Therefore, ZU =1 -I < Allowable = 1.0 TABLE 8-8C ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D3 PLANTS Max. Stress Intensity Min. Stress Intensity l Transient SI Transient SI Sa Sa*(') N (2) n U=

ksi ksi ksi ksi n/N Feedwater Cycling [ C 100% S.S.

Ambient IC I 100% S.S. c Therefore, flY =U 1< Allowable = 1.0 TABLE 8-8D ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D4 PLANTS Max. Stress Intensity lMin. Stress Intensity l Transient SI Transient SI Sa Sa*(1) N (2) n U=

Feedwater Cycling Ambient r

I ksi I] 100% S.S.

100% S.S. I ksi ksi I ksi nN Therefore, ZU =1 c < Allowable = 1.0 Page 8-51 WCAP 15918-NP, Rev.

WCAP Rev. 02 02 Page 8-51

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-8E ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D2 PLANTS Max. Stress Intensity Min. Stress Intensity Transient SI Transient SI Sa Sa*(') N (2) n U=

ksi ksi ksi ksi n/N Feedwater Cycling [ ] 100% S.S. r Ambient [ ]C 100% S.S. ___ IC Therefore, M LU IC < Allowable = 1.0 TABLE 8-8F ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE D5 PLANTS Max. Stress Intensity Min. Stress Intensity ___ _

Transient SI Transient SI Sa Sa*(') N n U ksi ksi ksi ksi nN Feedwater Cycling I C 100% S.S. [

Ambient I I 100% S.S. IC Therefore, ZU =1 C < Allowable = 1.0 TABLE 8-8G ACCIJMTILATED FATIGUE IN SLEEVE MATERIAL FOR Snxr PEAK STRESS RANGE FOR WESTINGHOUSE E2 PLANTS Therefore, U= j IC< Allowable = 1.0 WCAP-1 5918-NP, Rev. 02 Page 8-52 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC 8.6 EFFECTS OF SEVERED, UNLOCKED TUBE ON SLEEVE AXIAL LOADING

8.7 REFERENCES

FOR SECTION 8.0 8.1 ASME Boiler and Pressure Vessel Code, Sections II and m for Nuclear Power Plant Components, 1995 Edition, No Addenda.

8.2 ABB CENP Letter Report No. CSE-96-116, "Tube Sleeve History Data for 3/4 inch Steam Generator Tubes", May 07, 1996.

8.3 U.S. NRC Regulatory Guide 1.121, "Bases for Plugging Degraded PWR Steam Generator Tubes".

8.4 ABB Reakior GmbH Calculation Report No. GBRA 040 194, "Sleeving of ANO2 Steam Generator Tubing (3/4') by PLUSS Sleeves with 6 x 8 rnum Zero Expansions", June 10, 1997.

8.5 "Mechanical Vibrations", 4th Edition, by J.P. Hartog, McGraw-Hill Book Co., New York, New York, pg. 432.

8.6 "Vibration in Nuclear Heat Exchangers Due to Liquid and Two-Phase Flow," By W.J.

Heilker and R.Q. Vincent, Journal of Engineering for Power, Volume 103, Pages 358-366, April 1981 (REF-96-015).

8.7 EPRI NP-1479, "Effect of Out-of-Plane Denting Loads on the Structural Integrity of Steam Generator Internals," Contractor. Combustion Engineering, August 1980.

8.8 ABB CENP License Report CEN-613-P, Rev. 01, "Arizona Public Service Co. Palo Verde Steam Generator Tube Repair Using Leak Tight Sleeves", January 1995.

8.9 ABB CENP Drawing No. E-SGNS-222-700, Rev. 02, "1-800 Transition Zone Sleeve Installation".

8.10 ABB CENP Drawing No. E-SGNS-222-701, Rev. 02, "I-800 Tube Support Sleeve Installation".

8.11 ABB CENP Report No. TR-ESE-178, Rev. 1, "Palisades Steam Generator Tube/Sleeve Vibration Tests", October 05, 1977 (REF-96-003).

WCAP-15918-NP, Rev.02 Page 8-53

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC 8.12 ABB CENP Report No. A-SONGS-9416-1168, Rev. 0 (Attachment D), "Thermal-Hydraulic Analysis of the Southern California Edison San Onofre Nuclear Generating Station Unit 3 Steam Generator with Degraded Eggcrates", June 04, 1997.

8.13 ABB Reaktor GmbH Test Report No. GBRA 039927, Rev. A, "3/4" US NSSS Sleeving Summary of Test Results".

8.14 ABB CENP Drawing No. E-SGNS-222-702, Rev. 02, "1-800 Tube Support Sleeve for CE, W "D" & W "E" Series S/G Tubes".

8.15 ABB CENP Memo No. W097136.DS, "Re-analysis of Alloy 800 Sleeve Due to a Change in Secondary Side Pressure", August 20, 1997.

8.16 "Mechanical Engineering Reference Manual", Ninth Edition, by Michael R. Lindeberg, P.E., 1994, pages 14-3 thru 14-4.

8.17 ABB CENP Report No. ABBCE-9416-1174, Rev. 00, "Evaluation of an Alloy 800 Tube Sleeve for Application in 3/4 inch Steam Generator Tubes", October 1997.

8.18 ABB CENP Drawing No. E-SGNS-222-703, Rev. 02, "I-800 Transition Zone Sleeve for CE, W "D" & W "E" Series S/G Tubes".

8.19 ABB CENP License Report No. CEN-624-P, Rev. 00, "Carolina Power & Light Shearon Harris Steam Generator Tube Repair Using Leak Tight Sleeves", July 1995.

8.20 NRC Generic Letter 95-05: "Voltage - Based Repair Criteria for Westinghouse Steam Generator Tubes Affected by Outside Diameter Stress Corrosion Cracking", Page 3 of Attachment 1, as applied to the Westinghouse plants.

8.21 Inconel Alloy 600 Information from Inco Alloys International, Inc. Product Information Booklet, Huntington, W. Va., 1986 (REF-00-036).

8.22 "Model D4 Steam Generator Thermal and Hydraulic Design Data Report for Carolina Power & Light Company - Shearon Harris Unit 1", WTD-PE-77-22 Revision 1, dated November20,1984.

8.23 ABB CENP Report No. CENC-1272, "Analytical Report for Southern California Edison San Onofre Unit 2 Steam Generator", September 1976.

8.24 "Formulas for Stress and Strain", 5h Edition, by R. J. Roark and W. C. Young, McGraw-Hill Book Co., New York, New York 1975.

8.25 Steam GeneratorDegradation Specific Management Flaw Handbook, EPRI, Palo Alto, CA: 2001. 1001191 8.26 Westinghouse Design Spedification 13172-31-2, Revision 6, Project Specification for Steam GeneratorAssemblies for FloridaPower & Light Co. St. Lucie Plant Unit 2 1978-890MwExtension, June 1982.

WCAP-159 18-NP, Rev. 02 8-54 Page 8-54 WCAP- 15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC a1 c FIGURE 8-1 MECHANICAL SLEEVEfFUBE ASSEMBLY WCAP-15918-NP, Rev.02 Page 8-55

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC c

FIGURE 8-2 SYSTEM SCHEMATIC FOR "WORST" CASE CE PLANT WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT WCAP-l 5918-NP, Rev. 02 8-56 Page 8-56 WCAP'-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC

- c FIGURE 8-3 SYSTEM SCHEMATIC FOR WESTINGHOUSE "D" & "E" PLANTS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT Page 8-57 WCAP-1 591 8-NP, Rev.02 WCAP-15918-NP, Rev.02 Page 8-57

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC c

FIGURE 84 MODEL OF SLEEVE. LOWER TUBE. AND TUBE IN TUBESHEET:

UNLOCKED AT TUBE SUPPORT WCAP-159 18-NP, Rev. 02 Page 8-58 WCAP-15918-NP, Rev. 02

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC c

FIGURE 8-5 MODEL OF COMPOSITE MEMBER, UPPER TUBE. SURROUNDING TUBES. AND TUBESHEET: LOCKED AT TUBE SUPPORT Page 8-59 WCAP-15918-NP, Rev.02 Rev.02 Page 8-59

Westinghouse Proprietary Class 2 WESTINGHOUSE ELECTRIC COMPANY LLC ThIS PAGE INTENTIONALLY LEFT BLANK WCAP-15918-NP, Rev. 02 Page 8-60 WCAP-1 5918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC 9.0 SLEEVE INSTALLATION VERIFICATION 9.1

SUMMARY

AND CONCLUSIONS The Westinghouse Alloy 800 repair sleeve installation process and sequence has been tested to ensure that the installation of a sleeve conforms to the design criteria described in Section 3. During this testing, actual steam generator conditions, such as the influence of tubes locked at tube supports, have been considered in assessing the acceptability of the various processes and the sequence in which they are performed. In addition, sleeve installation meets the requirements of ASME B&PV Code Section XI, IWA-4420.

9.2 SLEEVE-TUBE INSTALLATION SEQUENCE 9.2.1 Transition Zone Sleeve The TZ sleeve with the rolled lower joint is described in Section 4.3 and Figure 4-3.

Installation is accomplished using the processes described in Section 4.5 in the following sequence:

(1) Tube I.D. Conditioning (2) Sleeve Installation and Expansion (3) Sleeve Lower End Torque Roll (4) Sleeve and Tube ET Examination 9.2.2 Tube Support Sleeve The TS sleeve is described in Section 4.3 and Figure 4-4. Installation is accomplished using the processes described in Section 4.5 in the following sequence:

(1) Tube I.D. Conditioning (2) Sleeve Installation and Expansion of Upper Joint (3) Expansion of Lower Joint (4) Sleeve and Tube ET Examination 9.3 EXPANSION JOINT INTEGRITY Westinghouse has conducted a comprehensive test program, an Eddy Current Appendix H qualification and an analysis development program, as well as a corrosion test program to ensure expansion joint integrity. Tube I.D. conditioning tests and sleeve/tube expansion tests have been completed as part of the process verification.

9.3.1 Tube Conditioning Oualification Steam generator tube conditioning is one of the preconditions for the leak limiting capability of the sleeve-tube expansion joint. In contrast to a welded sleeve, the surface WCAP-15918-NP, Rev. 02 Page 9-1

WESTINGHOUSE ELECTRIC COMPANY LLC preparation, not the oxide layer on the tube I.D., is the governing parameter for qualification of a conditioning process. The tube I.D. conditioning is performed to accomplish the following; surface preparation, elimination of loose particles (i.e., boron crystals) and the mitigation of axial marks.

A series of tests have been completed to determine the optimum conditioning head design, the optimal work cycle and the life of the consumable elements of the system.

Clean tubing, air oxidized tubing and primary side autoclaved tubing were used in the program. Results of the tests performed have shown that flexible hones, centrifugal brushes, abrasive cloth with a centrifugal brush carrier and a stainless steel buffing tool are all effective to achieve the desired I.D. surface conditionl. Because there is essentially no removal of tube material, the acceptability of the process is insensitive to the strength of the tubing. The test program is outlined in References 9.5.1, 9.5.2, 9.5.6 and 9.5.7.

As stated in Section 4.5.3, an evaluation of field experience involving video examination of conditioned tubes indicated that process control, in the form of in-process instructions and quality assurance surveillance, is sufficient to ensure acceptable conditioning of the tube ID. This experience involved over 600 conditioned tubes in eight steam generators at four different plants during five different outages. No scratches, loose particles, or other detrimental conditions were identified during these inspections.

9.3.2 Expansion Qualification An important design and installation issue for the Alloy 800 sleeve is the hydraulic expansion. There are three variables associated with the expansion: the number of expansions, the axial length of each expansion, and the diametrical extent. A finite element stress analysis was performed to study the effects of expansion length and diametrical extent. The study addressed expansion lengths from [

fb Maximum installation stresses and the effective strain on the inside surface of the tube and the O.D. diametrical expansion as a function of sleeve expansion pressure for [

]b expansion lengths were all considered.

The finite element stress analysis showed that the axial and hoop stresses increase rapidly with expansion pressure, with the hoop stress greater than the axial stress except for the higher expansion pressures. The radial stress, which is the stress between the sleeve and the steam generator tube, tends to be relatively constant as a function of expansion pressure. The radial stress is relatively more sensitive to expansion length than the other stress components, with a peak value at an expansion length of about [

1" for all diametrical expansions.

The selection of design parameters is intended to provide the best leak resistance and the best corrosion resistance. The best leak resistance should be associated with the greatest radial stress between the sleeve and the steam generator tube. This indicates that the Page 9-2 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC expansion length of [ c is the optimal length to resist leakage. The C

short expansion length also permits a greater number of expansions, which will also contribute to leak resistance. The number of expansions has been chosen to be [ 1a,c Leak testing was conducted for different diametrical expansions ranging from [

]b, as described in Section 7.3.1. The test results did not identify any significant improvement in the leak rate of sleeves installed with [ ]b as compared to those with smaller diametrical expansions. The diametrical expansion is therefore targeted to be in the [ Iac range for improved corrosion resistance. The minimum of the range, I ja c, is established as acceptable by the load and leakage tests of Section 7. The upper limit on the strain, [ a"c, is established by the results of the corrosion tests of Section 6 and the installation tolerances achievable.

Based on the above analytical study, an extensive test program was performed to qualify the expansion design. This program, as described in Section 7, considered structural and leakage limits of the design.

References 9.5.3 and 9.5.5 contain information related to one of the expansion system qualifications. This expansion system monitors the stroke of the intensifier and corresponding pressure to the expansion tool. With this system, the diametrical expansion is controlled to [ c for steam generator tubing within the range of anticipated yield strengths.

As discussed in Section 4.5.4, re-expansion of the joint can be performed should the initial expansion not reach the required minimum pressure. Failure to reach the minimum pressure would result in failing to achieve the expansion size associated with the structural integrity established in the test matrix. The re-expansion is intended to increase expansion size by increasing the applied pressure. There would be a necessary increase in cold working due to this operation, but no more than had the proper pressure been reached during the initial pressurization. Limits on the number of re-expansions are specified in the process procedures.

9.3.3 Summgar In summary, Westinghouse has conducted a comprehensive development and verification program to ensure the integrity of the expansion joint.

9.4 ROLLED JOINT INTEGRITY The rolled joint at the lower end of the Alloy 800 sleeve was developed to duplicate the rolled joint of the Alloy 800 mechanical plugs used by Westinghouse in Europe and Korea. These rolled joints have been demonstrated by testing and operating experience to be leak tight and capable of withstanding operating conditions. The Alloy 800 mechanical plugs have operated many years with no degradation of the rolled joint in the roll transition area. Westinghouse has drawn on this successful experience in designing the lower rolled joint of the Alloy 800 sleeve.

Page 9-3 WCAP-159 WCAP-15918-NP, Rev. 02 18-NP, Rev. 02 Page 9-3

WESTINGHOUSE ELECTRIC COMPANY LLC A development program was conducted to ensure the rolled joint of the TZ sleeve was leak tight and capable of withstanding the design loads. The sleeves were rolled into mock-ups consisting of steam generator tubes which had been rolled into blocks simulating the tubesheet. The sleeves were then tested to confirm the rolled joint was leak tight both before and after cyclic load testing. Tests of the rolled joint were also conducted where process parameters such as torque, tube diameter and roll location relative to the [ Ia,c were varied. A test matrix was used to verify the sleeve installation with sleeve rolling process parameter tolerances. The test program confirmed that the rolled joint integrity is acceptable within the allowable rolling process tolerances.

As discussed in Section 4.5.5, re-rolling of the joint can be performed should the initial rolls not reach the required minimum torque value. Failure to reach the minimum torque value would result in failing to achieve the wall thinning associated with the structural integrity established in the test matrix. The re-roll operation is intended to increase the wall thinning value by increasing the torque applied. There would be a necessary increase in cold working due to this operation, but no more than had the proper torque value (and wall thinning) been reached on the initial rolling operation. Limits on the number of rolling operations are specified in the process procedures.

References 9.5.4, 9.5.8, 9.5.9, and 9.5.10 contain information concerning the qualification of the rolled joint.

9.5 REFERENCES

FOR SECTION 9.0 9.5.1 GBRA 031 980, "Tihange 3 Steam Generator Sleeving, Surface Treatment of Steam Generator Tubes For Weldless Sleeving".

9.5.2 Memo From E. P. Kurdziel To D. Proctor, "Alloy 800 Tube Conditioning and Surface Roughness Measurements," October 22, 1998.

9.5.3 Report No. GBRA 039-930, "3/4" US NSSS Sleeving, Volume-Controlled Hydraulic Expansion of Sleeve".

9.5.4 Report No. GBRA 039-933, "3/4" US NSSS Sleeving, Torque-Controlled Hard Rolling of Sleeve".

9.5.5 Report No. 00000-NOME-TR-0097, "Test Report Qualification of Expansions of Alloy 800 Sleeves in .75 inch O.D. x .042/.043 inch Wall Steam Generator Tubes".

9.5.6 Report No. 00000-OSW-034, 'Test Program for Particle Removal Prior to Sleeve Installation".

WCAP-15918-NP, Rev. 02 9-4 Page 9-4 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC 9.5.7 Report No. 00-TR-FSW-008, "Test Report to Determine Tube Surface Roughness After Tube Conditioning Using the Burnishing Tool".

9.5.8 Report No. 00000-NOME-TR-0091, "Test Report for the Qualification of the Alloy 800 Sleeve Rolling Operation for Combustion Engineering 0.75 inch OD x .048 inch Wall Steam Generator Tubes".

9.5.9 Report No. 00000-NOME-TR-0100, "Test Report for the Qualification of the Alloy 800 Sleeve Rolling Operation for Combustion Engineering 0.75 inch OD x .042 inch Wall Steam Generator Tubes".

9.5.10 Report No. 00000-NOME-TR-0101, "Test Report for the Qualification of the Alloy 800 Sleeve Rolling Operation for Westinghouse D2, D3, D4, D5 and E 0.75 Inch OD x .043 inch Steam Generator Tubes".

Page 9-5 WCAP-159 WCAP-1 5918-NP, Rev. 02 18-NP, Rev. 02 Page 9-5

WESTINGHOUSE ELECTRIC COMPANY LLC THIS PAGE INTENTIONALLY LEFT BLANK WCAP-159 18-NP, Rev. 02 Page 9-6 9-6 WCAP-15918-NP, Rev. 02

WESTINGHOUSE ELECTRIC COMPANY LLC 10.0 EFFECT OF SLEEVING ON OPERATION Multiple plant specific analyses have been performed to determine the effects of installation of varying lengths and combinations of TZ and TS sleeves. Sleeve lengths and various combinations of installed sleeves were used to evaluate the effect of sleeving on the hydraulic characteristics and heat transfer capability of steam generators. Using the head and flow characteristics of the pumps, in conjunction with the primary system hydraulic resistances, system flow rates have been calculated as a function of the number of sleeved tubes and the types of sleeves installed. Similarly, curves are generated from calculations that show the percent reduction in system flowrate as a function of newly plugged tubes (per steam generator). These curves are derived from plant specific information based on the following steam generator conditions:

• Number Of Open Tubes Per Steam Generator

• Number Of Tubes Sleeved

• Primary System Flowrate

• Primary Coolant Temperature This information has been used to generate tables, such as Table 10-1, that provide hydraulic equivalency of plugs and installed sleeves, or the sleeve/plug ratio. Table 10-1 is provided as an approximation only and is based on assumed operating parameters and sleeve types for steam generators with 3/4" O.D. tubes. It must be assumed that some variations in the sleeve/plug ratio will occur from plant to plant based on operating parameters and steam generator conditions.

The overall resistance to heat transfer between the primary and secondary side of the steam generator consists of primary side film resistance, the resistance to heat transfer through the tube wall, and the secondary side film resistance. Since the primary side film resistance is only a fraction of the total resistance and the change in flow rate is so small, the effect of this flow rate change on heat transfer is negligible.

When the sleeve is installed in the steam generator tube there is an annulus between the sleeve and tube except in the sleeve-tube expansion regions. Hence, there is effectively little primary to secondary heat transfer in the region where the sleeve is installed. The loss in heat transfer area associated with sleeving is small when compared to the overall length of the steam generator tube.

In sumnmary, installation of sleeves does not substantially affect the primary system flow rate or the heat transfer capability of the steam generators.

WCAP-15918-NP, Rev.02 Page 10-1

WESTINGHOUSE ELECTRIC COMPANY LLC

10.1 REFERENCES

FOR SECTION 10.0 10.1.1 ABB-CE Calculation, "Effects of SG Tube Sleeving and Plugging on Primary Flow Rate in ANO2, A-PENG-CALC-020, Revision 01, October 31, 1997.

TABLE 10-1 TYPICAL SLEEVE TO PLUG EQUIVALENCY RATIO CASE CONFIGURATION RATIO (Sleeve/Plug)*

1 TZ (1) [ ]b 2 TZ (1) and TS (1) [ ]b 3 TZ (1) and TS (2) [ b 4 TS(1) [ b 5 TS (2) [ ]b

• This ratio should be considered approximate due to plant to plant variation WCAP-15918-NP, Rev.02 Page 10-2