ML040300702

to WCAP-15919-NP, Steam Generator Tube Repair for Westinghouse Designed Plants with 7/8 Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves.

ML040300702
Person / Time
Site:	Beaver Valley
Issue date:	08/31/2003
From:	Gahwiller W, Kurdziel E, Stepnick D Westinghouse
To:	Office of Nuclear Reactor Regulation
References
FOIA/PA-2005-0108 WCAP-15919-NP, Rev. 0
Download: ML040300702 (136)

Text

Westinghouse Non-Proprietary Class 3 WCAP-15919-NP August 2003 Revision 00 Steam Generator Tube Repair for Westinghouse Designed Plants with 7/8 Inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves

• Westinghouse

Westinghouse Non-Proprietary Class 3 WESTINGHOUSE ELECTRIC COMPANY LLC LEGAL NOTICE This report was prepared as an account of work performed by the Westinghouse Electric Company LLC (Westinghouse). Neither Westinghouse Electric Company LLC, nor any person acting on their behalf:

A. Makes any warranty or representation, express or implied, including the warranties of fitness for a particular purpose or merchantability with respect to the accuracy, completeness or 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.

C)2003 Westinghouse Electric Company LLC 2000 Day Hill Road, P.O. Box 500 Windsor, Connecticut 06095-0500

Westinghouse Non-Proprietary Class 3 WESTINGHOUSE ELECTRIC COMPANY LLC WCAP-15919-NP, Rev. 00 Steam Generator Tube Repair For Westinghouse Designed Plants With 718 Inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves AUGUST 2003 Prepared by: Wayne R.Gahwiller Edward P.Kurdziel Approved by. David G.Stepnick

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 described repair technique alleviates the need for plugging steam generator tubes that require repair. The technique consists of installing an Alloy 800 sleeve that spans the defective section of the original steam generator tube. The upper end of the sleeve is hydraulically 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 or roll transition zone. For a defect at a tube support or in a free span section of the tube, the sleeve is hydraulically 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.

WCAP-15919-NP, Rev. 00 i

WESTINGHOUSE ELECTRIC COMPANY LLC THIS PAGE INTENTIONALLY LEFT BLANK WCAP-159 19-NP, Rev. 00 ii ii WCAP-15919-NP, Rev. 00

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 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 Delivery Equipment 4-4 4.5.3 Tube Conditioning Equipment 4-4 4.5.4 Sleeve Positioning/Expansion Equipment 4-5 4.5.5 Sleeve Rolling Equipment 4-6 4.5.6 Nondestructive Examination 4-6 4.6 ALARA CONSIDERATIONS 4-7

4.7 REFERENCES

TO SECTION 4.0 4-7 WCAP-15919-NP, Rev. 00 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 Confirmatory 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 STEAM GENERATOR TUBES 7-1 7.1

SUMMARY

AND CONCLUSIONS 7-1 7.2 MECHANICAL TESTS 7-1 7.2.1 Axial Load and Pressure Tests 7-3 WCAP-15919-NP, Rev. 00 iv iv WCAP-15919-NP, Rev. 00

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 LEAK TEST OF SLEEVES FOR 0.875 INCH DIAMETER TUBES 7-14

7.6 REFERENCES

FOR SECTION 7.0 7-16 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 8-10 8.3 EFFECTS OF TUBE LOCK-UP OR UNLOCKED SITUATION ON SLEEVE AXIAL LOADING 8-11 8.3.1 Sleeved Tube in Westinghouse Plants, Unlocked at First Tube Support 8-12 8.3.2 Sleeved Tube in Westinghouse Plants, Locked at First Tube Support 8-13 8.3.3 Effect of Tube Prestress Prior to Sleeving 8-19 V

WCAP-15919-NP, Rev. 00 WCAP-159 19-NP, Rev. 00 v

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE OF CONTENTS (Continued)

Section Title Page 8.3.4 Lower Sleeve Rolled Section Pushout Due to Restrained Thermal Expansion 8-19 8.4 SLEEVED TUBE VIBRATION CONSIDERATIONS 8-19 8.4.1 Effects of Increased Stiffness 8-19 8.4.2 Effect of Severed Tube 8-20 8.4.3 Seismic Evaluation 8-21 8.5 EVALUATION OF SLEEVE TO TUBE EXPANSION SECTION 8-23 8.5.1 Analysis of Sleeve Material 8-27 8.6 EFFECTS OF SEVERED, UNLOCKED TUBE ON SLEEVE AXIAL 8-36 LOADING

8.7 REFERENCES

FOR SECTION 8.0 8-36 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 Qualification 9-1 9.3.2 Expansion Qualification 9-2 9.3.3 Summarv 9-3 9.4 ROLLED JOINT INTEGRITY 9-3

9.5 REFERENCES

FOR SECTION 9.0 9-4 vi WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE OF CONTENTS (Continued)

Section Title Page 10.0 EFFECT OF SLEEVING ON OPERATION 10-1

10.1 REFERENCES

FOR SECTION 10.0 10-1 vii WCAP-15919-NP, Rev. 00 WCAP-159 19-NP, Rev. 00 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 RESULTS 7-17 7-2 TUBESHEET SLEEVE-TUBE ASSEMBLY LEAK TESTING RESULTS 7-18 7-3 TUBE SUPPORT SLEEVE-TUBE ASSEMBLY LEAK TESTING 7-19 RESULTS 7-4 EFFECTS OF DIFFERENT SLEEVE AND TUBE DIMENSIONS TZ 7-20 SLEEVES 7-5 EFFECTS OF DIFFERENT SLEEVE AND TUBE DIMENSIONS TS 7-21 SLEEVES 7-6 LEAKAGE BEFORE AND AFTER CYCLIC LOAD TESTS 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 WESTINGHOUSE "44" STEAM GENERATORS WITH EFFECTIVELENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-15 8-15 8-2B 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE "44F' STEAM GENERATORS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-16 8-2C 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE "51" STEAM GENERATORS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT 8-17 8-3A AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE "44" STEAM GENERATORS 8-18 8-3B AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE "44F" STEAM GENERATORS 8-18 viii WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF TABLES (Continued)

Table No. Table Page 8-3C AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND 8-18 LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE "51 " STEAM GENERATORS 8-4 TUBE SLEEVE EXPANSION SECTION - TRANSIENTS CONSIDERED 8-25 FOR A WESTINGHOUSE "44", "44F', OR "51" STEAM GENERATOR 8-5A STRESSES IN SLEEVE FOR WESTINGHOUSE "44" STEAM GENERATOR 8-29 8-5B STRESSES IN SLEEVE FOR WESTINGHOUSE "44F" STEAM GENERATOR 8-29 8-5C STRESSES IN SLEEVE FOR WESTINGHOUSE "51 " STEAM GENERATOR 8-29 8-6A PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES 8-31 ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE "44" STEAM GENERATORS 8-6B PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES 8-31 ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE "44F' STEAM GENERATORS 8-6C PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES 8-32 ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE "51 " STEAM GENERATORS 8-7A PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH 8-34 LOCKED AND INTACT TUBE FOR WESTINGHOUSE "44" STEAM GENERATORS 8-7B PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH 8-34 LOCKED AND INTACT TUBE FOR WESTINGHOUSE "44F" STEAM GENERATORS 8-7C PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH 8-34 LOCKED AND INTACT TUBE FOR WESTINGHOUSE "51" STEAM GENERATORS 8-8A ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK 8-35 STRESS RANGE FOR WESTINGHOUSE "44" STEAM GENERATORS WCAP-15919-NP, Rev. 00 ix

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF TABLES (Continued)

Table No. Table Page 8-8B ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK 8-35 STRESS RANGE FOR WESTINGHOUSE "44F" STEAM GENERATORS 8-8C ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK 8-36 STRESS RANGE FOR WESTINGHOUSE "51" STEAM GENERATORS 10-1 TYPICAL SLEEVE TO PLUG EQUIVALENCY RATIO 10-2 x WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF FIGURES Fieure No. Title Page 4-1 LEAK LIMITING TZ SLEEVE 4-8 4-2 LEAK LIMITING TS SLEEVE 4-9 4-3 LEAK LIMITING TZ SLEEVE INSTALLATION 4-10 4-4 LEAK LIMITING TS SLEEVE INSTALLATION 4-11 4-5 TUBE CONDITIONING TOOL 4-12 4-6 SLEEVE EXPANSION TOOL 4-13 4-7 SLEEVE ROLLING TOOL 4-14 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 OF DIFFERENT AP'S 7-28 7-8 95% CONFIDENCE ON MEAN PROJECTIONS OF LEAK RATE 7-29 8-1 MECHANICAL SLEEVEfTUBE ASSEMBLY 8-39 8-2 SYSTEM SCHEMATIC FOR WESTINGHOUSE "44". "44F', & 8-40 "51 "STEAM GENERATORS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT xi WCAP-15919-NP, Rev. 00 WCAP-159 19-NP, Rev. 00 xi

WESTINGHOUSE ELECTRIC COMPANY LLC LIST OF FIGURES (Continued)

Figure No. Title Pae 8-3 MODEL OF SLEEVE, LOWER TUBE. AND TUBE IN TUBESHEET 841 UNLOCKED AT TUBE SUPPORT 84 MODEL OF COMPOSITE MEMBER, UPPER TUBE, SURROUNDING 842 TUBES. AND TUBESHEET: LOCKED AT TUBE SUPPORT xii WCAP-15919-NP, Rev. 00

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 Westinghouse designed steam generators with 0.875 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 for installation in steam generator tubes, and span the defective section of the tube. 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 tube support (TS) elevation or in a free span section. The sleeve used for both of these locations is called a TS sleeve. This TS repair 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 that 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 repair joints to demonstrate that these design criteria are met. The effects 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 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-15919-NP, Rev. 00 WCAP-159 19-NP, Rev. 00 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 criteria accounting for ET measurement uncertainties and degradation growth rate.

Installation of steam generator tube 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 effect 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.

Page 1-2 WCAP-15919-NP, Rev. 00

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 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 [

]a, c which 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 sleeves were designed to the applicable sections of the 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 that 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 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 sleeve-tube assembly resulting from reactor system flow, coolant chemistries, or thermal and pressure conditions. Structural analysis of the sleeve-tube assembly, using the demonstrated margins of safety, establishes its integrity under normal and accident conditions. The structural analysis has been performed for both TZ and TS sleeves.

The TZ sleeves have a length of up to [ ]8 c inches, which spans the degraded tube section at the top of the tubesheet and generally places the expansions above the sludge pile. The TS sleeves have a length of up to [ ]i C inches for a sleeve spanning a tube WCAP-15919-NP, Rev. 00 Page 2-1

WESTINGHOUSE ELECTRIC COMPANY LLC 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 and/or up to two tube support sleeves. Acceptable sleeve locations covered in this report are from the top of the tubesheet up to the u-bend region in both the hot and cold legs. The analysis was performed for Westinghouse designed plants with 7/8 inch, Alloy 600 steam generator tubes. A TZ sleeve with a length of [ ]3a c inches would result in approximately a [ ]' 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 analysis prepared using ASME code stress allowable values. Corrosion testing of typical sleeve-tube assemblies has been completed and revealed no evidence of sleeve or tube corrosion considered detrimental under anticipated service conditions.

In addition to the analysis and test programs discussed in this report, a significant number of sleeves have been in operation for a number of years with no service-induced degradation or significant leakage. 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 [ ]ja c diametrical expansion, well above the [ Ia.c target expansion of the sleeve described in this report. The sleeve installations are listed below. Based upon the testing and analysis 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.

WCAP-15919-NP, Rev. 00 Page 2-2 Page WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC ALLOY 800 SLEEVE INSTALLATIONS AND OPERATIONAL EXPERIENCE S/G Model T Hot Joint Tube Joint Design Ouantity of Cvcle Plant (° Expansion Sleeves (Year) EFPY Comments

_____ ____ ____ ___In stalle d Angra W-D3 620 _c _ _c79 10 (04/01) 0.5 Operational 179 11 (07/02) - P-RSG* 2006 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 Kori 1 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) -1.5 Operational

______ ______ __ _ __91 18 (09/01) -0.9 Operational Tihange 2 FRAM-51M 617 _ 10 13 (08/97) 3.6 RSG 06/01 Tihange 3 ACE-E 617 l 20 9 (08/95) 2.4

_________ __________ _____ 104 10 (11/96) 1.4 RSG 08/98 Ulchin 1 FRAM51B 613 986 9 (02/99) -3.0 Operational

___________ _____ 702 10 (07/00) -1.8 Operational Ulchin 2 FRAM51B 613 _ 1234 9 (02/00) -2.2 Operational TOTAL _ _ 5364

• RSG-P: Replacement Steam Generator Planned for Year Shown ** RSG: Replaced Steam Generator in Year Shown WCAP-15919-NP, Rev. 00 Page 2-3

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WESTINGHOUSE ELECTRIC COMPANY LLC 3.0 ACCEPTANCE CRITERIA The objective of installing sleeves in steam generator tubes is twofold. The sleeve must maintain structural integrity of the steam generator tube during normal operating and postulated accident conditions and the repair sleeve must limit the primary to secondary leakage in the event of a through wall defect in the section of the steam generator tube spanned by the sleeve. Numerous tests and analyses were performed to demonstrate the capability of the sleeves to perform these functions under normal operating and postulated accident conditions. In doing so, the conditions for all of the Westinghouse operating plants with -7/8 inch Inconel 600 tubes were considered.

Although the absolute values may differ from those at any specific plant, the evaluations are a function of the differential pressures and temperatures which are bounded by the conservative design basis values below.

Westinghouse Models '44', '44F', '51', and '51M' Primary Side: 594 'F (operating) 2250 psia (operating) 650 'F (design) 2500 psia (design)

Secondary Side: 467.57F (operating) 700 psia (operating) 550 'F (design) 1130 psia (design)

Accident Conditions: Primary to Secondary 2650 psi (FWLB)

AP Secondary to Primary 1130 psi (LOCA)

AP Table 3-1 provides a summary of the criteria established for sleeving in order to demonstrate the acceptability of the Alloy 800 sleeving techniques. Justification for each of the criterion is provided. Results indicating the minimum level with which the sleeves surpassed the criteria are tabulated. The sections of this report that describe the tests or analyses which verify the characteristics for a particular criterion are referenced in the table.

Page 3-1 WCAP-159 WCAP-15919-NP, Rev. 00 19-NP, Rev. 00 Page 3-1

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 3-1 SLEEVING CRITERIA Criterion Approach Results Reference Section

1. Repair sleeve-tube assembly Sleeve-tube assembly meets 8.0 structural integrity must be applicable ASME Code maintained for normal operating requirements, including fatigue. a, c and accident condition per SAR.

2. Sleeve/tube joint load capability Factor of safety of 3 for normal 7.0 3 times normal Ap (4590 psi) operating conditions and 1.4 for and 1.4 times steam line break accident. b Ap (3584 psi) even for a severed tube.

3. Sleeve/tube joint load/ No degradation of leak limiting [ 7.0 deflection capability sufficient or structural load capability for b for thermal expansion effects worst case thermal expansion with non- severed or severed cycles.

tube even if tube locked within tube supports.

4. Pressurization of annulus Prevention of sleeve failure [ 7.0 between sleeve and tube does based on tests. b not collapse sleeve during LOCA (1130 psi)

5. Exposure of sleeve-tube Demonstrate by corrosion [ 6.0 assembly to various primary testing and experience that and secondary chemistries sleeve-tube assembly corrosion without loss of functional resistance is adequate a, c integrity.

WCAP-159 19-NP, Rev. 00 Page 3-2 WCAP- I 5919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 3-1 (Continued)

SLEEVING CRITERIA Criterion Approach Results Reference Section

6. Non-destructive exam of tube Periodic exams of tubes and [ 5.0 and sleeve pressure boundry sleeves are required to verify with levels of detectability structural adequacy. Plug sufficient to show structural sleeved tube for any real adequacy. degradation, irrespective of indicated penetration. b

7. Sleeve installation to Allowable leakage established [ 7.0 satisfactorily limit leakage in by user per technical any direction and under normal specification and other and accident conditions. requirements (site boundary dose). Number of installed sleeves limited as needed %ith suitable margin assuming all sleeved tubes have through wall leakage paths.

8. Sleeve installation effect on Allowable reduction in reactor 10.0 system flow rate or heat transfer coolant flow rate limited by user capability of the steam per technical specifications.

generator is acceptable. Number of installed sleeves limited as needed. Steam pressure reduction due to reduced heat transfer to be b limited by user based on commercial considerations.

Page 3-3 WCAP-159 19-NP, Rev.

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WESTINGHOUSE ELECTRIC COMPANY LLC 4.0 DESIGN DESCRIPTION OF SLEEVES AND INSTALLATION EOUIPMENT 4.1 SLEEVE DESIGN DESCRIPTION The sleeve for defects at the top of the tubesheet, called a transition zone (TZ) sleeve, is shown in Figure 4-1. The sleeve for defects at tube support plates or egg crates, called a tube support (TS) sleeve, is shown in Figure 4-2. These Alloy 800 sleeves have a nominal outside diameter of [ Ia,c and a minimum wall thickness of [

] c. Each sleeve type includes a chamfer at both ends to provide a lead in for equipment used to install the sleeve and to facilitate the inspection of the parent tube and sleeve. The TZ sleeve is [ c long while the TS sleeve is [

]I c long. [

Ia c The TZ sleeve includes nickel band and a thermally sprayed nickel alloy band at the lower end. The nickel band improves sealing of the sleeve when it is rolled into the tube and the thermally sprayed nickel alloy band, which results in a rough surface, enhances the strength of the rolled mechanical joint. Based on the flow loss analysis detailed in Section 10, either sleeve type may be used in a steam generator tube. The flow loss analyses addressed up to two tube support sleeves in a steam generator tube and the combination of up to two TS sleeves and one TZ sleeve in the same tube.

4.2 SLEEVE MATERIAL SELECTION The Alloy 800 tubing, from which the sleeves are fabricated, is procured to the requirements of the ASME B&PV Code Section II, Part B, SB-I 63, NiFeCr Alloy UNS N08800, and Section III, Subsection NB-2000. Additional requirements, as stated in the material specification (Reference 4.7.1), are applied including a limit on [

ia-¢. Other elements, [ ] ' are also more tightly controlled

'within the ASME specification limits. The final annealing temperature is specified as

[

]8 . The yield strength is specified to be between [ Ja ¢at 68 0F.

The selection criteria for the sleeve material were its [

Ikc and its excellent corrosion resistance in both primary side and faulted secondary PWR environments (Reference 4.7.2). Westinghouse's justification for selection of this material and condition is based on the data discussed in Section 6.

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WCAP-15919-NP, Rev. 00 00 Page 4-1

WESTINGHOUSE ELECTRIC COMPANY LLC The following typical high temperature data has been used to assess the response of the sleeve/tube assembly under severe accident conditions.

Alloy 600 Alloy 800 Temperature Yield Ultimate Yield Ultimate (OF) Strngth Strength Strength Strength (ks (ksi) (ksi)(ksi)

R.T. Min 35 80 30 75 1200 25.6 54.4 20.7 45.2 1500 12.8 23.4 10.7 21.3 4.3 SLEEVE-TUBE ASSEMBLY The installed sleeve is shown in Figure 4-3 for a transition zone repair and in Figure 4-4 for a repair at a tube support. The [ Ia,c inch long sleeve spans the defective region of the steam generator tube at the top of the tubesheet in the Transition Zone (TZ). [

] a,c The sleeve installed at a Tube Support (TS) elevation or in a free span section of the steam generator tube is [ ]8acinches long. [

] a. c A plant specific document specifies the allowable locations of tube ECT indications in order to perform a successful sleeve installation. This criterion is utilized to determine whether a tube is an acceptable sleeving candidate. Indications outside of the acceptable locations would not be sleeved.

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WESTINGHOUSE ELECTRIC COMPANY LLC A sleeve installed in a steam generator tube, which does not meet the minimum requirements, details of which are discussed in Section 9.0, may be re-rolled, for the rolled joint, or re-expanded for the hydraulic expansion.

4.4 PLUGGING OF A DEFECTIVE SLEEVED TUBE In the unlikely event that a sleeved steam generator tube is found to have an unacceptable defect in the pressure boundary portion of the tube or sleeve, the steam generator tube can be taken out of service by installing standard, site approved mechanical or welded plugs at both ends of the tube.

4.5 SLEEVE INSTALLATION EQUIPMENT The equipment used for remote installation of sleeves in a steam generator is made up of the following basic systems. These systems are:

1. Remote Controlled Manipulator

2. Tool Delivery Equipment

3. Tube Conditioning Equipment

4. Sleeve Expansion Equipment

5. Sleeve Rolling Equipment

6. Nondestructive Examination Equipment These systems, when used together, allow installation of the sleeves without entering the steam generator, hence reducing personnel exposure to radiation.

The tooling and methods described in the following sections represent the present technology for leak limiting sleeve installation. As technological advances are made in sleeve installation to improve the installation rate and/or decrease the personnel exposure, the new tooling and/or processes may be utilized after they have been laboratory-verified to provide improved sleeve installation methods.

4.5.1 Remote Controlled Manipulator The remote controlled manipulator serves as a transport vehicle for inspection or repair equipment inside a steam generator primary head. These sleeves can be delivered off of a multitude of different manipulators, including the Genesis, ROSA and Roger manipulator systems.

The Genesis and Roger systems utilize a leg installed between the tubesheet and the bottom of the primary head, while the ROSA system utilizes a tubesheet mounted base WCAP-15919-NP, Rev. 00 Page 4-3

WESTINGHOUSE ELECTRIC COMPANY LLC plate. Each system has an arm configuration with a varying number of joints. These joints provide the degrees of freedom required for delivery of the tooling to the steam generator tube. Each arm is moved independently with position controlled electric motors. The arm allows motion for tool alignment in both square pitch and triangular pitch tube arrays. Computer control of the manipulator allows the operator to move and position sleeving tools accurately below the steam generator tube to be sleeved.

4.5.2 Tool Delivery Equipment The purpose of the tool delivery equipment is to support and vertically position the various tools required for the sleeving operations. The tool delivery system consists of two major components; a probe pusher located outside the steam generator and a guide conduit extending from the probe pusher to the adapter on the robotic arm.

The probe pusher is a Zetec 10-D or similarly configured drive wheel system. The probe pusher is located outside the steam generator, adjacent to the manway. The guide conduit extends from the probe pusher to the adapter block located on the manipulator.

The adapter block includes a fitting for mounting on the manipulator. Two pins extending above the adapter block are used to align the guide conduit relative to adjacent tube locations.

A remotely actuated sleeve loader may be used in conjunction wvith the probe pusher delivery system. The sleeve loader consists of a magazine mounted on an actuator which positions a single sleeve for insertion into the steam generator.

Alternate Sleeve Delivery Equipment As an alternate to the probe pusher delivery system, a tool driver mounted directly on the robotic arm can deliver the sleeves.

The tool driver is attached to the end of the manipulator arm by a fitting and lock mechanism. The tool driver includes two sets of gripper wheels that work in conjunction with one another to insert or withdraw the tool.. The drive grippers are powered by electric motors to insert and remove the various sleeving tools and the sleeve into the steam generator tube. Vertical positioning of the tool is accomplished by using hardstops and/or visual references that are verified by using a small camera located on the tool driver.

4.5.3 Tube Conditioning Equipment Prior to sleeve installation, the steam generator tube I.D. is mechanically conditioned with a high speed buffing tool. This operation is performed using a tool similar to that shown in Figure 4-5. An air motor rotates the tool head as it is inserted into the bottom of the tube. The buffing tool removes raised material and some of the oxide, and prepares the sealing surface of the tube in the areas of the hydraulic expansions for the Page 4-4 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC sleeve. Based upon current testing and evaluation, this process step may be eliminated in the future when a sufficient confidence level is developed.

4.5.4 Sleeve Positioning/Expansion Equipment The sleeve expansion equipment is used to provide the required structural fit-up of the sleeve at the upper end, for a TZ, and at both the upper and lower joints for a TS location. The expansion of the sleeve is performed with a tool that makes [

c simultaneously. The expansion tool is then repositioned for the Ca-remaining [ ]ao in an expansion joint.

The minimum distance between expansion joints for a [ ]c c inch TS sleeve which must span a tube defect based on Figure 4-4 is [ ]. c inches. This will adequately cover a maximum tube defect axial length of [ ]3 c inches, considering the sleeve elevation tolerance of [ Ia C inches. This span will also adequately cover the uncertainty in the elevation of the tube support plate or eggcrate support.

The sleeve is located on the sleeve expansion tool by a sleeve hardstop approximately the same O.D. as the sleeve. The expansion tool functions to guide the sleeve into the tube and install the sleeve to the selected elevation within the steam generator tube.

For both the TZ and TS sleeves a tool hardstop on the sleeve expansion tool, which contacts the tube end is provided for proper sleeve vertical positioning within the steam generator tube. Once the sleeve is at the proper elevation within the steam generator tube, it is hydraulically expanded.

The expansion tool, shown in Figure 4-6, consists of a mandrel and a bladder. The bladder contains the water that is used as the pressurization fluid. The expansion tool simultaneously performs [ Ia C per expanded joint. The expansion tool is then repositioned within the sleeve [

V. ' For a sleeve at a TZ elevation, the expansion tool is [repositioned once].a c For a sleeve at a TS elevation, the expansion tool is [ ].a

' The sleeve is located on the expansion tool prior to insertion in the steam generator tube. A low pressure hold is applied to the bladder to secure the sleeve on the expansion tool without distortion of the sleeve. When the sleeve is in position within the tube, the hydraulic expansion tool is pressurized, expanding the bladder directly against the inside diameter of the sleeve causing expansion of the sleeve.

F axc WCAP-15919-NP, Rev. 00 Page 4-5

WESTINGHOUSE ELECTRIC COMPANY LLC 1c 4.5.5 Sleeve Rolling Equipment The sleeve rolling equipment is used to expand the lower end of the TZ sleeve into contact with the steam generator tube within the tubesheet, forming a strong leak tight joint. The rolling tool is positioned within the steam generator tube by the manipulator.

The rolling equipment consists of the air motor, the sleeve expander, torque readout, computer control and a torque calibration unit. The sleeve expander includes a shoulder which supports the bottom edge of the sleeve during the sleeve rolling process. The approximately [

a,c on the lower end of the TZ sleeve. The sleeve is expanded to a torque [WDS1]which has been demonstrated by testing to provide a leak tight joint. A record of the rolling tool torque is taken by the computer for further evaluation of the rolling process for individual sleeves. A rolled joint that fails to meet the minimum torque criteria may be re-rolled.

This is discussed further in Section 9.0.

The roll expander used to hard roll the sleeve within the tubesheet has an effective length of approximately [ ].a c The shoulder on the roll expander stops against the bottom of the sleeve during the rolling process. The sleeve is then rolled two times to a torque that results in a [ Ia c sleeve wall reduction. This wall thinning is sufficient for leak/load requirements as well as providing adequate resistance for future corrosion cracking. The sleeve roller design and the rolling process are essentially a duplicate of those used for Westinghouse's welded sleeve and mechanical plug installations. This process does not include hydrostatic expansion of the sleeve before roll expansion.

4.5.6 Nondestructive Examination As described in Section 5, the "+" point rotating probe will be used to perform an initial eddy current test (ET) acceptance and baseline inspection of 100% of the installed sleeves. Other eddy current coils and/or methods will be considered for any Page 4-6 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC complementary inspection capability they may provide. The ET fixture, with conduit, is used on the manipulator arm to position the probe.

4.6 ALARA CONSIDERATIONS The steam generator repair operation is designed to minimize personnel exposure during installation of sleeves. The manipulator is installed from the manway without entering the steam generator. It is operated remotely from a control station outside the containment building. The positioning accuracy of the manipulator is such that it can be remotely positioned without having to install templates in the steam generator.

The sleeve delivery system allows the sleeve to be positioned on the expansion tool outside the steam generator and away from the manway. The expansion tool and sleeve are then delivered into the steam generator remotely through the guide conduit, further reducing the number of operations performed in the manway. The conduit adapter is designed so that the fitting quickly attaches to the manipulator.

The tools are simple in design and the majority of the sleeving operations are performed remotely. Spare tools are provided so that tool repair at the manway is not required. If tool repair is necessary, the tool is removed and the sleeving operation continues using a spare tool. The tool may or may not be repaired during the outage but repair is performed in an area which does not result in significant radiation exposure.

Air, water and electrical supply lines for the tooling are designed and maintained so that they do not become entangled during operation. This minimizes personnel exposure outside the steam generator. All equipment is operated from outside containment.

Installation of the Alloy 800 sleeve is also expected to reduce personnel exposure over that required to plug a steam generator tube. The operations required to install an Alloy 800 sleeve are similar to those required to install a plug in a steam generator tube. The Alloy 800 sleeving operations, however, are performed in one channel head, saving the exposure associated with the plugging operations in the second plenum.

In summary, the steam generator operation is designed to minimize personnel exposure and is in full compliance with ALARA standards.

4.7 REFERENCES

TO SECTION 4.0 4.7.1 Purchasing Specification for Alloy 800 Tubing, Specification No. 00000-OSW-020, Latest Revision.

4.7.2 Corrosion Resistance of SG Tubing Material, Incoloy 800 mod. and Inconel 690 TT, by R. Kilian, N. Wieling, and L. Stieding, from Werkstoffe und Korrosion 42, pp. 490-496 (1991).

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.c FIGURE 4-1 LEAK LIMITING TZ SLEEVE Page 4-8 WCAP-15919-NP, Rev. 00

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a. c FIGURE 4-2 LEAK LIMITING TS SLEEVE Page 4-9 Rev. 00 WCAP-15919-NP, Rev. 00 Page 4-9

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a. c FIGURE 4-3 LEAK LIMITING TZ SLEIEVE INSTALLATION WCAP-159 19-NP, Rev. 00 4-100 Page 4-1 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC a c FIGURE 4-4 LEAK LIMITING TS SLEEVE INSTALLATION Page 4-11 WCAP-15919-NP, WCAP- Rev. 00 I 5919-NP, Rev. 00 Page 4-1 1

WESTINGHOUSE ELECTRIC COMPANY LLC FIGURE 4-5 TUBE CONDITIONING TOOL Page 4-12 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC FIGURE 4-6 SLEEVE EXPANSION TOOL Page 4-13 Rev. 00 WCAP-15919-NP, Rev. 00 Page 4-13

WESTINGHOUSE ELECTRIC COMPANY LLC FIGURE 4-7 SLEEVE ROLLING TOOL Page 4-14 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC 5.0 SLEEVE EXAMINATION PROGRAM

5.1 BACKGROUND

In addition, there will be an inspection process for the dual purposes of process verification for individual steps as well as confirmation of the pressure boundary integrity. Eddy current inspection methods will be used for this purpose.

For process verification, the following inspection will be performed for all sleeves at all locations until sufficient confidence is developed to do otherwise.

a.c In-service inspection of the sleeved tubes will be done as part of the periodic inspection program of the steam generator tubing using eddy current testing techniques. The eddy current test method is a technique whereby electrical currents are induced Page 5-1 WCAP-159 19-NP, Rev.OO WCAP-15919-NP, Rev.00 Page 5-1

WESTINGHOUSE ELECTRIC COMPANY LLC electromagnetically from the test coil into the sleeves and parent tube material. The electrical currents are interrupted or impeded by the presence of flaws in the material, which results in a change in the test coil impedance. This impedance change is processed and displayed on the test instrument to indicate the presence of a flaw.

During the installation, all sleeves will be examined. A sampling program consistent with inspection requirements will be used for subsequent examinations. The ISI inspection will be performed using the "+' point coil rotating probe. Other coils and/or methods will be considered for any complementary inspection capability they may provide. The inspection method qualified has been used in operating steam generators in three foreign plants for both the initial installation acceptance and the subsequent in-service inspection. Over 2500 sleeves have been installed and inspected at this writing.

The objective of the installation examination is to establish ISI baseline data and initial installation acceptance data on the primary pressure boundary of the sleeve-steam generator tube assembly. The eddy current inspection method used has a documented qualification, Reference 5.3.1, in accordance with Appendix H of the EPRI PWR Steam Generator Examination Guidelines, Revision 5 dated September 1997. The essential variables specified in the Appendix H portion are documented and will be used in the field procedures. Also, an analysis procedure for interpreting data has been written and used for field inspections. All data analysts will be subjected to a performance demonstration qualification test prior to performing any data analysis.

EPRI Appendix H guidelines specify that adequate flaw detection capability be demonstrated for flaws > 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 45%, 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 TIG welded sleeves, it has been the plant owner's decision to plug a tube upon the detection of a defect in the pressure boundary portion of the sleeve.

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WESTINGHOUSE ELECTRIC COMPANY LLC

a. c 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 [ ja, Chydraulic 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 region and rolled joints. The pressure boundary for a TS sleeve-tube assembly is considered to be: a) the sleeve from the lower of the [ ]. c expansions in the lower joint to and including the upper of the

[ ]Ia c expansions 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 rolled).

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

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

4) The unsleeved region of the steam generator tube.

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.

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WESTINGHOUSE ELECTRIC COMPANY LLC 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. Samples were fabricated with axially and/or circumferentially oriented notches representing flaws at each of the transitions and expansion zones. 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 samples with corrosion cracking in the parent tube were also included in the qualification data. These tube samples included laboratory grown IGSCC 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 AB3B CE 1-800 Mechanical Sleeves, ABB CENO Report No. 97-TR-FSW-0 19P, Latest Revision.

e.0 Pae54WA-51-P Page 5-4 WCAP-15919-NP, Rev. 00

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a. c FIGURE 5-1 TZ SLEEVE PRESSURE BOUNDARY DESCRIPTION WCP1519N, e.OPg WCAP-15919-NP, Rev.00 Page 5-5

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a. c FIGURE 5-2 TS SLEEVE PRESSURE BOUNDARY DESCRIPTION WCAP-15919-NP, Rev. 00 5-6 Page 5-6 WCAP-15919-NP, Rev. 00

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-15919-NP, Rev. 00 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. 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 [ a, 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 no less than the original tube life. This conclusion would be applicable to either Westinghouse or Combustion Engineering designed steam generators.

Page 6-2 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC 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 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 Page 6-3 WCAP-159 19-NP, Rev.

WCAP-15919-NP, 00 Rev. 00 Page 6-3

WESTINGHOUSE ELECTRIC COMPANY LLC 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 I and 2 provides another base of comparison which indicates good expected tube performance with the Alloy 800 sleeve design. Here, tube strain levels about 100 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

[ ].b 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 [

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

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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 [

]b 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 [ ]b 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 6600 F 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 [weld heat affected zone, not in the expansion transition zone]." 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 [

b 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 6601F.

For the secondary side tests, the O.D. environment consists of deaerated 10% sodium hydroxide at 6600 F. In this case, the samples are immersed in an autoclave and Page 6-5 WCAP-159 WCAP-15919-NP, Rev. 00 19-NP, Rev. 00 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 [ lb, were exposed for over [ ]b with no leakage as defined by loss of pressure. Two of the three assemblies developed [

I.b The secondary side tests, which had average tube expansions of [ 1b, were exposed for over [ ]b, with two assemblies being exposed for [

lb, respectively. One of the assemblies developed a [

fb 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

[ fib 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-15919-NP, Rev. 00

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

[

]la 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 [ 1b times the exposure time of the Westinghouse Reaktor samples and [ lb 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:

f -~~n tslreew CUsleve troll/nzm Cilltams )

WCAP-15919-NP, Rev. 00 Page 6-7

WESTINGHOUSE ELECTRIC COMPANY LLC Where:

Isleere = Time to failure of the sleeved tube t

rou/rans Time to failure of the original tube at the roll transition Osleee = Stress in the sleeved tube Crollhrans= 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:

tsieeve troifrrans (Ileeve GFoiltrams)

=a L ] b, c A mean stress ratio can then be calculated as:

a,b, c

[ ]

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

[ I a,bc 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 tolO0 C lower in the region of the sleeve joint as it was at the original roll transition.

Page 6-8 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC Using the temperature dependent function of the Arrhenius relationship, Isleew eQ / RT(,_e trntorm eQ IRTN Applying a value of Q equal to 50 Kcal/mole, a factor of 2 would be applied to the roll transition life for every 10C 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 100 C; the life of the sleeved tube would be estimated as:

ab,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 Tr',

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.

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 WCAP-15919-NP, Rev. 00 Page 6-9

WESTINGHOUSE ELECTRIC COMPANY LLC 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. CO1 -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.

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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 both 3/4 inch and 7/8 inch mockup steam generator tubes containing sleeves, to provide qualified test data describing the basic properties of the completed assemblies. The majority of these tests were performed on assemblies using 3/4 inch diameter tubes to determine axial load, collapse, burst, leak rates and thermal cycling capability. Confirmatory tests, described in Section 7.5, were conducted on assemblies using 7/8 inch diameter tubes. The results of these tests verify that the leak rates established for the 3/4 inch sleeve, described in Section 7.3.1, may be applied to sleeved 7/8 inch tubes.

Table 7-1 summarizes the results of the mechanical testing performed on the 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 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 sleeve provide margin over limiting pressure differential. Mechanical testing revealed that the installed 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 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. In some cases the leakage was reduced, and in other cases it increased somewhat. In all cases the leakage remained small and within the range of measurement variability and with no degradation in strength.

7.2 MECHANICAL TESTS The following mechanical tests were performed on the 3/4 inch sleeve/tube assemblies:

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WESTINGHOUSE ELECTRIC COMPANY LLC leakage, axial load, load cycling, burst and collapse. Leakage, axial load and load cycling tests were performed on assemblies using 7/8 inch tubes. Loads were applied per the design requirements for the respective tube size, 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 sleeve and steam generator tube samples were used for all tests. [

a, 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 3/4 inch 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 perfonned 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. [

[ c V' 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.

WCAP-159 19-NP, Rev. 00 Page Page 7-2 WCAP-15919-NP, Rev. 00

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

With respect to the tube joint at severe accident conditions of high pressure (2500 psi) and temperature (1200-1500'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 15007F 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

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7.2.2 Collapse Testing h

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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 .050 inch nominal wall.

7.2.3 Thermal and Load Cvcling Tests F -lb Page 7-5 WCAP-159 WCAP-15919-NP, Rev. 00 19-NP, Rev. 00 Page 7-5

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7.3 LEAKAGE ASSESSMENT 7.3.1 Leak Rate Tests r- -1 b WCAP-15919-NP, Rev. 00 Page 7-8 WCAP-15919-NP, Rev. 00

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b 7.3.2 Leak Test Evaluation b

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• h 7.3.3 Leak Test Results Under Abnormnal Installation Conditions F 1b WCAP-15919-NP, Rev. 00 Page 7-12 WCAP-15919-NP, Rev. 00

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7.4 INSTALLATION STRESSES b

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7.5 LEAK TESTS OF SLEEVES FOR 7/8 INCH DIAMETER TUBES F Ib Page 7-14 WCAP-15919-NP, Rev. 00

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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 033 431.

7.6.3 Fatigue Testing of 1800 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 A800 Sleeves, Report no. 00000-NOME-TR-005 1, 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.

7.6.8 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.

7.6.12 "Steam Generator Tube Repair for Combustion Engineering and Westinghouse Designed Plants with 3/4 Inch Inconel 600 Tubes Using Leak Limiting Alloy 800 Sleeves", WCAP-15918-P, November 2002.

7.6.13 " Leak Rate Testing of Alloy 800 Sleeves Installed in 7/8" Diameter Alloy 600 Steam Generator Tubes", MRS-DFD-1362-SGSLV, March 2003.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 7-1 SLEEVE-TUBE ASSEMBLY MECHANICAL TESTING RESULTS COMPONENT TEST TEST QTY RESULTS Room Temperature Tests:

b Cyclic Loading (Wear Test)

Upper Joints Intact Tube Cyclic Loading (Axial Capability) Upper Joints Severed Tube Onerating Temperature 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 SLEEVE-TUBE ASSEMBLY LEAK TESTING RESULTS PRIMARY SECONDARY PRIMARY AVERAGE 95% UPPER MAXIMUM MINIMUM PRESSURE PRESSURE TEMPERATURE LEAK RATE MEAN LEAK RATE LEAK (psi) (psi) (OF) (GAL./HR) (GAL.IIR) (GAL./I IR) RATE (GAL.AIR) 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-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" distribution with N-I degrees of freedom. In this case, since N is 6, t(95) is 2.02.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 7-3 TUBE SUPPORT SLEEVE-TUBE ASSEMBLY LEAK TESTING RESULTS PRIMARY SECONDARY PRIMARY AVERAGE 95% UPPER MAXIMUM MINIUM PRESSURE PRESSURE TEMPERATURE LEAK RATE MEAN LEAK RATE LEAK RATE (psi) (psi) (OF) (GAL.AIR) (GAL.JR) (GAL./R) (GAL./R) -

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

X 1 , X 2 , ...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-i.

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" 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 (gal/hr.)

TZ TZ J

Series I Tests (3/4" Diameter T ubes)

.042

.042 47 47 r_ __

b TZ .042 47 TZ .042 47 Series 2 Tests (3/4" Diameter T ubes)

TZ .042 38 l _ _

TZ .042 47 _

TZ .042 57 TZ .048 35 TZ .048 49 TZ .048 55 Series 3 Tests (7/8" Diameter Tubes TZ .050 39 ______

TZ .050 39 TZ .050 39 TZ .050 44 TZ .050 44 _

TZ .050 44 TZ .050 56 TZ .050 56 TZ .050 56 TZ .050 56 _ _

Page 7-20 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC 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.)

Series 1 TESTS 3/4" Diameter Tubes TS .042 38 TS .042 47 TS .042 47 TS .042 57 TS .042 57 Series 2 Tests (7/8" Diameter Tubes TS 0.050 44 =_=

TS 0.050 44 TS 0.050 44 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 temperature Load (Inches) (Ksi) Before Test After Test Cycles (gal/hour) (gal/hour) 3/4" Diameter Tubes _ _ _

TZ 0.042 57 _ 1000 TZ 0.048 49 _ 2000 TZ 0.048 55 _ 1000 7/8" Diameter Tubes TZ l 0.050 39 l l 1000 TZ 0.050 44 _ 1000 TZ 0.050 56 l 1000 TZ 0.050 56 _ 1000 WCAP-15919-NP, Rev. 00 Page 7-21

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FIGURE 7-3 CYCLIC LOAD TEST ASSEMNBLY-INTACT TUBE WCAP-15919-NP, Rev. 00 Page 7-24 WCAP- I 5919-NP, Rev. 00

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FIGURE 7-4 CYCLIC LOAD TEST ASSEMBLY-SEVERED TUBE WCAP-15919-NP, Rev. 00 Page 7-25

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FIGURE 7-5 TS LEAK TEST ASSEMBLY WCAP-159 19-NP, Rev. 00 Page 7-26 WCAP-15919-NP, Rev. 00

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FIGURE 7-6 LOCKED TUBE TEST FIXTURE Rev.

00 19-NP, WCAP-159 Page 7-27~~~~~~~~~~~~~

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FIGURE 7-7 AVERAGE LEAK RATE PROJECTIONS FOR DIFFERENT AP'S WCAP-15919-NP, Rev. 00 Page 7-28 WCAP-15919-NP, Rev. 00

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FIGURE 7-8 95% CONFIDENCE ON MEAN PROJECTIONS OF LEAK RATE Page 7-29 WCAP-15919-NP, Rev. 00 WCAP-159 19-NP, Rev. 00 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 m. 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 Westinghouse "44", "44F', 51 and "5 iM" Steam Generator operating plants with 7/8 inch Inconel 600 tubes are considered (References 8.2 and 8.4)., Inasmuch as the tube dimensions and geometry in the area of interest are the same, future reference to model "51," steam generators also includes model "51M". 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.

2 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 tmin in Reference 8.18).

Sm = Design Stress Intensity, S.I. ( 650TF maximum design (per Reference 8.1)

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WESTINGHOUSE ELECTRIC COMPANY LLC 8.1.2 Detailed Analysis Summary 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.

r l~~~~~~~~~

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-1

SUMMARY

OF SLEEVE DESIGN AND ASME CODE ANALYSIS FOR TZ AND TS SLEEVES i -CATEGORY 3 l 3 5ESLTS.

Axial Load [ ]C lb. for intact tube unlocked in the supports during []c lb. for severed tube unlocked in the supports 100% Steady State Operation [ ]c lb. for intact tube locked in the supports

[ ]c lb. for severed tube locked in the supports Tentative Sizing trq'd = 0.0435 in. (per ASME Code) < tnffi = 0.048 in.

% Allowable Degradation Limit 45% (per NRC Regulatory Guide 1.121, Ref 8.3) for Westinghouse "44", "44F1, & "51" Steam Generators CATEGORY ANALYSI RESULTSALLOWABLE-I-

,iil ii Itti id.h I tHe'., C! X . ~rA9ME Cde' General Primary Membrane Stress Intensity = [ ]c Sm = 20.0 Stress for Sleeve Material Primary Local Membrane Plus Primary Bending Stress Stress Intensity = [ ]c 1.5 Sm = 30.0 for Sleeve Material Primary Plus Secondary Stress Stress Intensity = [ ]c 3 Sm = 60.0 for Sleeve Material Fatigue of Sleeve Material U= Ic U = 1.0 Main Steam Line Break Stress Intensity = [ ]c 0.7 Su = 52.5 Feedwater Line Break Stress Intensity = [ ]c 0.7 Su = 52.5 Primary Pipe Break (LOCA) Stress Intensity = [ ]c 0.7 Su = 52.5 Page 8-5 WCAP-159 WCAP-1 5919-NP, Rev. 00 19-NP, Rev. 00 Page 8-5

WESTINGHOUSE ELECTRIC COMPANY LLC GENERAL MEMBRANE STRESSES SUMMARIZED

1. GENERAL PRIMARY MEMBRANE STRESS (Pm)

(per Par. NB-3221.1 of Ref. 8.1 zv/ Design Primary Pressure of 2.5 ksi and Ri = [ ]f in., maximum inner radius for tmin =[ ]f in. per Reference 8.18) 3 C 4

2. PRIMARY LOCAL MEMBRANE PLUS BENDING STRESS INTENSITY (PL + P3)

(per Par. NB-3221.3 of Ref. 8.1 w/Design Primary Pressure of 2.5 ksi, SOBE (seismic stress) of 4.3 ksi, and Ri of [ ]c in., maximum inner radius for tmin = [ ]c in. per Reference 8.18)

C

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

C WCAP-15919-NP, Rev. 00 Page 8-6 8-6 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC GENERAL MEMBRANE STRESSES SUMMARIZED (continued)

4. MAIN STEAM LINE BREAK 5FI1 c

5. FEEDWATER LINE BREAK 6F c

6. PRIMARY PIPE BREAK (LOCA) (assumes a severed tube) 7 c Page 8-7 WCAP-1 591 9-NP, Rev.OO WCAP-15919-NPRev.00 Page 8-7

WESTINGHOUSE ELECTRIC COMPANY LLC 8.2 EVALUATION FOR ALLOWABLE SLEIEVE 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 Normal Operation Safety Majrins 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:

1. "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 Reference 8.24 the normal operating conditions for the "worst" case envelopment of steam generators from the Westinghouse "44", "44F", & "51 " Steam Generators are:

Primary Pressure Ppi = 2250 psia Secondary Pressure Pe= 699.5 psia Differential Pressure AP = POr; - Psm:= 1550.5 psi Average Pressure Pa, g= 0.5 (Ppri + Psec) = 1474.5 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. [ ]f in. per Reference 8.18 Syl, = min. required yield strength (per U.S. NRC Reg. Guide 1.121, Ref. 8.3)

Sy,i = minimum yield strength of sleeve (Sy = 23.7 ksi min. at 650 TF, 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 AP 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 III of 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 Su = 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, concurrent with the safe shutdown earthquake (SSE), 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 a Westinghouse "44", "441F' and "51" 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 "44", "44F" and "51" steam generator, a feedwater line break (FWLB) accident produces a maximum differential pressure loading of 2.65 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.

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WESTINGHOUSE ELECTRIC COMPANY LLC (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.

C 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.

C 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.

C Page 8-11 WCAP-15919-NP, Rev. 00 WCAP-159 19-NP, Rev. 00 Page 8-1 1

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8.3.1 Sleeved Tube in Westinghouse Plants. Unlocked at First Tube Support C

From the diagram in Figure 8-3, 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 = AE/L where:

F= Force on the respective body, lb.

K Spring constant for the respective body, lb./in.

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.

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8.3.2 Sleeved Tube in Westinghouse Plants. Locked at First Tube Support c

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2A 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE "44" STEAM GENERATORS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT OUTSIDE,"r INSH)E4 'Z ScO '~CORRE-SPOND.`,~ ~MEAN ;YUN'S CO3F.-'

RADIUS> IRAnDIUS zK~ EGH~ RA< <e MODULUS ""STIFFNESS KHR.EP

,COMPONENT E,,

m1 my l1 lX io n 100 A:: - 1a l1~in (1) Sleeve _ ______ c (2) Lower Tube (3) Tube in Tubesheet (4) Upper Tub e _ _ _ _ _ _ _ _ _ _

(5) Surrounding Tubes Reference Temperatures: Primary (Hot) 5940F (sleeve I.D. temperature)

Secondary = 4670F (tube O.D. temperature)

Nonnal Tubes = (2 Toj + Tsec)/3 = 551.70 F NOTE: lNominal 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 8.4.

4am for Carbon Moly Steel from Reference 8.1.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2B 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE "44F" STEAM GENERATORS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT

' tOUTSIDE,-, '..'INSIDE' LsEFFECTVE- SECTION4.CORRESPOND. .. ,YOUNGS.is. .MEAN COEF.

C. vIPONENT *W? RADIUS,, LENGTH. AREA, j - TeDIUIwI[ MODULUSUS STIFFNESS THERM- EX

-_ (in) (n ' e X(jn) XB y~~~*Qn)

, Ag$ I . b '(. n x (1) Sleeve _ _ ___

(2) Lower Tube (3) Tube in Tubesheet (4) Upper T u b e_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _

(5) Surrounding Tubes _

Reference Temperatures: Primary (Hot) = 594TF (sleeve I.D. temperature)

Secondary = 467°F (tube O.D. temperature)

Normal Tubes = (2 Tpn + Tsec)/3 = 551.7°F NOTE: 1 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.

4a, for Carbon Moly Steel from Reference 8.1.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-2C 25.0 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES FOR WESTINGHOUSE "51" STEAM GENERATORS WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT D

OUTSIDE IN.SIDE. .4EFFECTIVE.", SECTION ORRESP . OU MEAN OE RAD>V>.+t<>X 7 LENGTH .

RADI >.XIUSfiva.<.v. . . ~emMODULUS STIFFNESS TH RM EXP.

COMPONENT ~

1 ~~~~~~~R ~ ~ >A ~ ~ ~ K`-AE/Lt

_________________ (in) (in) ,(in) (in,) -l'\iCFb/in:, 06 lbrinix i03 In/In F I (1) Sleeve __ _ c (2) Lower Tube (3) Tube in Tubesheet (4) Upper Tube (5) Surrounding Tubes _

Reference Temperatures: Primary (Hot) 594TF (sleeve I.D. temperature)

Secondary = 467TF (tube O.D. temperature)

Normal Tubes = (2 Tpr1 + T,)/3 = 551.70 F 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.

4

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

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-3A AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE "44" STEAM GENERATORS TABLE 8-3B AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE "44F' STEAM GENERATORS TABLE 8-3C AXIAL THERMAL LOADS IN SLEEVE WITH TUBE UNLOCKED AND LOCKED INTO TUBE SUPPORT FOR WESTINGHOUSE "51" STEAM GENERATORS Page 8-18 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC 8.3.3 Effect of Tube Prestress Prior to Sleeving C

8.3.4 Lower Sleeve Rolled Section Pushout Due to Restrained Thermal Expansion C

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ T . PmIpresssi , 'tl 'a'dt'*

s on ob AS,t 9Co Westinghouse "44" Steam Generator [ ]

Westinghouse "44F' Steam Generator [ ]

Westinghouse "51" Steam Generator [ ]C 8.4 SLEEVED TUBE VIBRATION CONSIDERATIONS The vibration behavior of a sleeved tube is evaluated as follows:

8.4.1 Effects of Increased Stiffiess C

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I c 8.4.2 Effect of Severed Tube I-c Rev. 00 Page 8-20WCAP-15919-NP, Page 8-20 WCAP-15919-NP, Rev. 00

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WESTINGHOUSE ELECTRIC COMPANY LLC Since this analysis dose not take credit for the additional support provided by the tubesheet, this conclusion applies to both the TS and TZ sleeve.

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 III evaluation, considering both temperature and pressure loads.

The transient conditions defined in Reference 8.8 (and later refined in Reference 8.21) represent the worst case situation for a Westinghouse "44", "44F"', or "51" steam generator.

Table 8-4 shows the grouping of these transients, which are detailed below:

1. Heatups and Cooldowns - 250 cycles between ambient (room temperature) and 0%

steady state.

2. Loading and Unloading- 18,300 cycles between 0% steady state and 100% steady state.

3. Step Load Events of 10% Full Power - 2500 cycles between 0% steady state and 100%

steady state.

4. Large Step Load Decrease - 250 cycles between 0% steady state and 100% steady state.

5. Temperature Coast-downs - 50 cycles between 0% steady state and 100% steady state.

6. Reactor Trip - 500 cycles between 100% steady state to loss of flow.

7. Loss of Flow - 100 cycles between 100% steady state to loss of flow.

8. Loss of Load - 100 cycles between 100% steady state to loss of flow.

9. Loss of Power - 50 cycles between 100% steady state to loss of flow.

10. Inadvertent Spray- 10 cycles between 100% steady state to loss of flow.

11. Design Earthquake Events - 20 cycles between 100% steady state to loss of flow.

12. Primary Side Leak Tests - 60 cycles between ambient (room temperature) and 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.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-4 TUBE SLEEVE EXPANSION SECTION - TRANSIENTS CONSIDERED FOR A WESTINGHOUSE "44". "44F", OR "51" STEAM GENERATOR X~bTRANSIENTS, t<gEND POINTSo CYCLES (1) Heatup/Cooldown Ambient 0% S.S. 310*

(2) Full Power 0% S.S.

100% S.S. 21,100**

(3) Reactor Trip 100% S.S.

and Upset Loss of Flow 780*** =______

CONDlTIONS:

(a) Worst Case: Tube is locked-at the first tube support.

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

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

(d) Sleeve is [ ]4 c inches long.

(e) Transient cycles are from the previous table, grouped as follows:

• - Sum of Transients 1 and 12 or 250 + 60 = 310 cycles

• • - Sum of Transients 2 through 5 or 18,300 + 2500 + 250 + 50 = 21,100 cycles

- Sum of Transients 6 through 11 or 500 + 100 + 100 + 50+ 10 + 20 =780 cycles Page 8-25 Rev. 00 WCAP-15919-NP, Rev. 00 Page 8-25

WESTINGHOUSE ELECTRIC COMPANY LLC 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.

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 of the WCAP. 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.

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-5A STRESSES IN SLEEVE FOR WESTINGHOUSE "44" STEAM GENERATOR I -Strisix i HXStre. dueThn :A 1Radial .Thedn

1. Ambient _ __ _ __ _ _ _ _ c__

2. 0% _ .  :.I. _

3. 100%S.S. I ____ _______

4. Reactor Trip

5. End of Reactor Trip L TABLE 8-5B STRESSES IN SLEEVE FOR WESTINGHOUSE "44F' STEAM GENERATOR

<Stress HoopS~~sdt 'lThnaRadial,' hrna

-TR.ANSIENT~ 8 1ueo iSleiiiiirulbi<

6 ~'Diff rnIa Skin Stums C',ONDIToN-ly rw '

. 4"en, etiea

1. Ambient

2. 0%S.S.

3. 100% S.S.

4. Reactor Trip ___ .__ _

5. End of Reactor Trip = . =

TABLE 8-5C STRESSES IN SLEEVE FOR WESTINGHOUSE "5 1" STEAM GENERATOR Page 8-29 WCAP-159 WCAP-1 5919-NP, Rev. 00 19-NP, Rev. 00 Page 8-29

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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 WESTINGHOUSE "44" STEAM GENERATOR I

Sxr range = [ ]Cksi < 3.0 Sm = 60 ksi SOr range = [ ]c ksi SOx range = [ ]cksi TABLE 8-6B PRIMARY AND SECONDARY STRESSES AND STRESS INTENSITIES ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE "44F" STEAM GENERATOR Sxr range = [ ]cksi < 3.0 Sm = 60 ksi SOr range = [ Icksi SOx range = [ ]C ksi Page 8-31 Rev. 00 WCAP-15919-NP, Rev. 00 Page 8-3 1

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 WESTINGHOUSE "51" STEAM GENERATOR TRASIENT- Aia;oo ada, Sx Sc S

Stresse&~~~~~~~~~~ ,.Stresgesi,,-

2

'tresses-K

1. Ambient c

2. 0% S.S. . . _

3. 100% S.S. _

4. Reactor Trip _ _

5. End of Reactor Trip _L_ . _ _

Sxr range = [ I' ksi < 3.0 Sm = 60 ksi SOr range = [ ]c ksi SOx range= [ ]c ksi e.0 Pae83_CP191-P Page 8-32 WCAP-15919-NP, Rev. 00

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WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-7A PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE "44" STEAM GENERATOR

~' 'IANSINT~ 1/2 Spx

' Spj Sp~ NxU~

CONDITION ,i (ksi). (ksi) ( (ksi) of

1. Ambient

2. 0% S.S.

3. 100% S.S.

4. Reactor Trip _ _

5. End of Reactor Trip _ _ _

TABLE 8-7B PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTINGHOUSE "44F' STEAM GENERATOR

-~iCONDITION, ~(kX (s) (s)~~<fCyce~

q

1. Ambient _

2. 0% S.S.

3. 100% S.S.

4. Reactor Trip _ _

5. End of Reactor Trip _ ___

TABLE 8-7C PEAK STRESS INTENSITY ON INSIDE SURFACE OF SLEEVE WITH LOCKED AND INTACT TUBE FOR WESTlNGHOUSE "51" STEAM GENERATOR

^~CD T e *pi S :S

1. Ambient r

2. 0% S.S.

3. 100% S.S.

4. Reactor Trip _ _

5. End of Reactor Trip WCAP-15919-NP, Rev. 00 Page 8-34 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC L ]C TABLE 8-8A ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE "44" STEAM GENERATOR no &< ' Max. Stress Intensityns- - > je Min. Stress IntensityW+-

'Transient iSL Transent'ka'Ma'-

", S "" Sant S q N nS -Ur End of Reactor Trip [ ]c 100% S.S. _ _ _

Ambient [] 100% S.S.

0% S.S. [ ]C 100% S.S. _ _

0% S.S. [ ] Reactor Trip _ _ _

(1) - Per Reference 8.1, Section m, Paragraph NB-3222.4 (e) (4), the definition for Sa* is:

Sa* = Ecte / Ewal (Sa) = 1.0755 Sa Where: Ec,,,, = 28.3 x 106 psi; Reference 1, Section m, Figure 1-9-2 E~ct" = 26.313 x 106 psi; Reference 1 for the sleeve material (2) - Reference 8.1, Section m, Figure I-9-2 Therefore, ZU [r l < Allowable = 1.0 TABLE 8-8B ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE "44F' STEAM GENERATOR Max.R Stress t <>8 '9 Intensit~ Mm . Stress Intensity _ _ __

TaientS Transie t k-si l3 - s~ -;A ks~' A ksi: - -N End of Reactor Trip y~] 100% S.S. [ __ _ _ _ _ __ _ _ _

Ambient [ 100% S.S.

0% S.S. [ ]c 100% S.S. _

0% S.S. ( ]c Reactor Trip Therefore, MU = r 1c < Allowable = 1.0 Page 8-35 WCAP-159 WCAP-15919-NP, Rev. 00 19-NP, Rev. 00 Page 8-35

WESTINGHOUSE ELECTRIC COMPANY LLC TABLE 8-8C ACCUMULATED FATIGUE IN SLEEVE MATERIAL FOR Spxr PEAK STRESS RANGE FOR WESTINGHOUSE "51" STEAM GENERATOR 4

-~$ Max. Stresi Intenlsity thi+¢ Miii. Stress Intensity! X______ ____ ____

TransTient  ; SL6 -Transient i :St " a- S i 3 2 I End of Reactor Trip [ ]c 100% S.. __

Ambient []C 100%.5. __ .

0% S.S. [ ]C 100% S.S. _ _

0% S.S. [ IC Reactor Trip _ _ _

Therefore, ZU = f 1c < Allowable = 1.0 8.6 EFFECTS OF SEVERED, UNLOCKED TUBE ON SLEEVE AXIAL LOADING C

8.7 REFERENCES

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

8.2 Westinghouse Letter Report No. CSE-96-115, "Tube Sleeve History Data for 7/8 inch Steam Generator Tubes", May 03, 1996.

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

8.4 Westinghouse Report No. NSD-RMW-90-070, SG-90-02-026, "Steam Generator Information Report", Revision 6, February 1990.

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).

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WESTINGHOUSE ELECTRIC COMPANY LLC 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 Westinghouse Report No. A-DBLCN-9449-1204, Rev. 0, "Evaluation of an Inconel 690 Tube Sleeve for Application in Pacific Gas & Electric - Diablo Canyon Steam Generator Tubes", August 1998.

8.9 Westinghouse Drawing No. E-SGNS-222-704, Rev. 01, "1-800 Transition Zone Sleeve Installation for W "44" & "51" S/G Tubes".

8.10 Westinghouse Drawing No. E-SGNS-222-705, Rev. 01, "1-800 Tube Support Plate Sleeve Installation for W "44" & "51" Series S/G Tubes".

8.11 Westinghouse Report No. TR-ESE-1 78, Rev. 1, "Palisades Steam Generator Tube/Sleeve Vibration Tests", October 05, 1977 (REF-96-003).

8.12 Westinghouse Letter Report No. SAE-LIS-98-587, "Diablo Canyon Unit 1 and2 (PGE/PEG) Maximum Anticipated LOCA Secondary to Primary Pressure Differential for Structural Analyses", by J. A. Barsic, December 07, 1998.

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

8.14 Westinghouse Drawing No. E-SGNS-222-707, Rev. 02, "1-800 Tube Support Plate Sleeve for W "44" & "51" Series S/G Tubes".

8.15 Westinghouse Reaktor GmbH Calculation Report No. GBRA 040 194, "Sleeving of ANO2 Steam Generator Tubing (3/4") by PLUSS Sleeves with 6 x 8 mm Zero Expansions", June 10, 1997.

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

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

8.18 Westinghouse Drawing No. E-SGNS-222-706, Rev. 02, "1-800 Transition Zone Sleeve for W "44" & "51" Series S/G Tubes".

8.19 Westinghouse E-mail from J. S. Taylor to D. G. Stepnick on "Design Inputs for 7/8" A-800 Generic Sleeve Analysis / Licensing Report", May 29, 2001.

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.

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WESTINGHOUSE ELECTRIC COMPANY LLC 8.21 Westinghouse Letter Report No. CSE-01-062, "Revision to the Transient Cycles for the 7/8" A-800 Generic Sleeve Qualification Program, June 20, 2001.

8.22 Westinghouse Report No.WCAP-14707, Revisions. 0 and 1, "Model 51 Steam Generator Limited Tube Support Plate Displacement Analysis for Dented or Packed Tube to Tube Support Plate Crevices", August 1996 and April 1997.

8.23 EPRI 1001191, "Steam Generator Degradation Specific Management Flaw Handbook",

Palo Alto, CA, 2001.

8.24 Westinghouse Calculation Note CN-SGDA-01-70, "Thermal Hydraulic Performance Evaluation of Beaver Valley Units I and 2 Steam Generators at 9.4% Power Uprating",

by M. H. Hu, August 2001.

WCAP-15919-NP, Rev. 00 Page 8-38 WCAP-15919-NP, Rev. 00

WESTINGHOUSE ELECTRIC COMPANY LLC c

FIGURE 8-1 MECHANICAL SLEEVE/TUBE ASSEMBLY Page 8-39 WCAP-15919-NP, Rev. 00 Rev. 00 Page 8-39

WESTINGHOUSE ELECTRIC COMPANY LLC FIGURE 8-2 SYSTEM SCHEMATIC FOR WESTINGHOUSE "44", "44F". & "51" S. G.

WITH EFFECTIVE LENGTH BETWEEN LOWER JOINT AND LAST UPPER JOINT Page 840 WCAP-15919-NP, Rev. 00 WCAP-159 19-NP, Rev. 00 Page 840

WESTINGHOUSE ELECTRIC COMPANY LLC C

FIGURE 8-3 MODEL OF SLEEVE, LOWER TUBE. AND TUBE IN TUBESHEET:

UNLOCKED AT TUBE SUPPORT WCAP-1 5919-NP, Rev.00 Page 8-41

WESTINGHOUSE ELECTRIC COMPANY LLC FIGURE 84 MODEL OF COMPOSITE MEMBER, UPPER TUBE. SURROUNDING TUBES. AND TUBESHEET; LOCKED AT TUBE SUPPORT WCAP-15919-NP, Rev. 00 Page 8-42 842 WCAP-15919-NP, Rev. 00

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 Qualification 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-15919-NP, Rev. 00 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 condition[wdsl]. 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.

A video examination of conditioned tubes in numerous steam generators has shown that this is an acceptable method relative to the removal of loose particles and the mitigation of axial marks.

9.3.2 Expansion Oualification 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 [

] b 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 [

lb 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 [

] c 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 expansion length of [ Ia c is the optimal length to resist leakage. The short expansion length also permits a greater number of expansions, which will also WCAP-15919-NP, Rev. 00 Page 9-2 WCAP-15919-NP, Rev. 00

S WESTINGHOUSE ELECTRIC COMPANY LLC contribute to leak resistance. The number of expansions has been chosen to be ( ]a 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 [ IatC range for improved corrosion resistance. The minimum of the range,

[ ]. c, is established as acceptable by the load and leakage tests of Section 7. The upper limit on the strain, [ Ia 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 [ a, Cfor steam generator tubing within the range of anticipated yield strengths.

9.3.3 Summary 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.

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 [ a,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.

Page 9-3 WCAP-159 WCAP-15919-NP, Rev. 00 19-NP, Rev. 00 Page 9-3

WESTINGHOUSE ELECTRIC COMPANY LLC 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".

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-009 1, "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".

9-4WCP191NPRe.0 Page 9-4 WCAP-15919-NP, Rev. 00

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 7/8" 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 minimal when compared to the overall length of the tube.

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

10.1 REFERENCES

FOR SECTION 10 10.1.2 "Calculation of Alloy 800 Sleeve Hydraulic Resistance in Westinghouse 7/8 Inch Model Steam Generators," NSD-ENG-CALC-3 10, August 2003.

Page 10-1 WCAP-159 WCAP-15919-NP, Rev. 00 19-NP, Rev. 00 Page 10-1

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

I TZ (1) b 2 TZ(1)andTS(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-15919-NP, Rev. 00 Page 10-2 WCAP-15919-NP, Rev. 00