ML040350757

Meeting with the BWROG to Discuss Effects of Extended Power Uprates on Plant Operation

ML040350757
Person / Time
Site:	Boiling Water Reactor Owners Group
Issue date:	02/03/2004
From:	Wang A NRC/NRR/DLPM
To:
References
ML040230340, TAC MC0931
Download: ML040350757 (40)

Text

NRC FORM 658 U.S. NUCLEAR REGULATORY COMMISSION 19-19991 TRANSMITTAL OF MEETING HANDOUT MATERIALS FOR IMMEDIATE PLACEMENT IN THE PUBLIC DOMAIN This form is to be filled out (typed or hand-printed) by the person who announced the meeting (i.e., the person who issued the meeting notice). The completed form, and the attached copy of meeting handout materials, will be sent to the Document Control Desk on the same day of the meeting; under no circumstances will this be done later than the working day after the meeting.

Do not include proprietary materials.

DATE OF MEETING The attached document(s), which was/were handed out in this meeting, is/are to be placed in the public domain as soon as possible. The minutes of the meeting will be issued in the near future. Following are administrative details regarding this meeting:

Docket Number(s) 0 -

1 G

I Plant/Facility Name V3 )

X 0 (3 TAC Number(s) (if available)

YA L C q 3 1 Reference Meeting Notice r 1- 04I 0 2 3 0 34C Purpose of Meeting

-i r (copy from meeting notice)

Mee 4 i VOc79\\ 1 W e Q 6 NAME OF PERSON WHO ISSUED MEETING NOTICE TITLE A

V4 4 OFFICE DIVISION BRANCH Distribution of this form and attachments:

Docket File/Central File PUBLIC NRIC FORM 658 19 t999)

PRINTED ON RECYCLED PAPER This form was designed using InForms

June 2002 Dec 2002 April 2003 June 2003 July 2003 August 2003 Plant Quad Cities 2 Quad Cities 2 Quad Cities 2 Component Steam dryer cover plate PORVstuck open

- Dryer outer bank hood Failure

-Internal bracing High cycle fatigue: Cover plate Hz pressure pulsatiuoens drenby low Hz Root Cause aligns with vortex shedding Hz and velocities -24 Hz acoustic vibration -180Hz (exacerbated by PORV discharge)

Corrective Repair and modify

- repair/modify hood Action QC2 cover plate

- eliminate internal bracing Extent of Quad Cities 2 only Dresde 2

Condition (cover plate)

Dresden 2&3 (dryer susceptability)

Dresden 3 modifies Quad Cities 1 Licensee cover plate modifies cover plate Generic Action (Fall 2002 outage)

(Spring 2003 outage)

Monitors licensee Monitors licensee actions Issue IN 2002-26 Supp 1 NRC Action actions (extensive)

(7/21/03)

(moderate)

IssuesN(9/11/02)

Sends SIT to QC2 Meeting with Exelon/GE/BWROG (9/11/02)

~~~~~~~~~~~~~~~~~(7/25/03)

Industry.

Action GE issues SIL No. 644 (8/21/02)

Sept 2003 Oct 2003 Nov 2003 Dec 2003 Jan 2004 Plant Dresden 2 Quad Cities 1 Dresden 3

- FW sampling probe

- outer bank hood (lost part)

- FW sampling probe Component

- FW sparger (3 holes)

- ERV actuator

- cracks in dryer hood Failure

- cracks in dryer hood

- degraded MS line subcomponents FW probe HZ aligns with High cycle fatigue caused by FW probe Hz aligns with Root Cause vortex shedding Hz @

fluctuating pressure loading with vortex shedding Hz © EPU conditions acoustic component at EPU EPU conditions

- repair/modify dryer hood Corrective repair FW sparger

- eliminate bracing

- retrieves 2 FW probes Action

- ~~~~~retrieve FW probe

- ost~pad-analysis from FW sparger Action Steam dryer pieces still missing 1 probe still missing

- repair ERV actuator

- perform EPU vibration assessment Quad Cities 1 &2 Extent of Dresden 2 Dresden 2&3 Dresden 2 & 3 sampling probes Condition (FW probe)

(MS line subcomponents)

EPU impact on MS line subcomponents EPU impact on FW components for other BWRs not addressed f

other BWRs not addressed Licensee Generic Action Dresden 2 modifies

- cover plate

- dryer hood/bracing (Fall 2003 outage)

Dresden 3 (mid-cycle outage)

- modify cover plate

- modify dryer hood/bracing Quad Cities 1 conducts vibration assessment for EPU Licensee returns QC1to pre-EPU level due to EPU effect on ERVs NRC Action NRC sends letter to BWROG commenting on GE SIL Supp 1 (9/26/03)

Issues IN 2002-26 NRC meets with BWROG (11/4/03)

Supp 2 (1/9/04)

- NRC comments on SIL

- generic steam dryer issues Indusiry Action GE issues SIL No.

644 Supp 1 (9/5/03)

BWROG tasks BWRVIP to address steam dryer issues Develops survey on BWR steam dryer inspections

CONCERNS RELATED TO POTENTIAL ADVERSE FLOW EFFECTS FROM POWER UPRATES David Terao Thomas G. Scarbrough Mechanical and Civil Engineering Branch Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission February 3, 2004

DISCUSSION TOPICS Scope of failures Cause of failures Action taken (plant specific)

Further actions needed (generic)

1.

Scope of failures under power uprate conditions has expanded.

June 2002: After operating a few months at EPU conditions, Quad Cities Unit 2 experiences failure of steam dryer cover plate with pieces found in main steamline flow venturi and turbine stop valve strainer.

June 2003: Following restart from steam dryer repairs in 2002, Quad Cities Unit 2 experiences additional failures of steam dryer outer bank hood, internal braces, and tie bars.

October 2003: After 2 years of EPU operation, Dresden Unit 2 finds 4-inch fatigue cracks on inner surface of outer vertical hood panels at diagonal brace brackets of steam dryer. Dresden Unit 2 also finds three holes in FW sparger caused by broken FW sampling probe that was retrieved from sparger.

November 2003: After 9 months of EPU operation, Quad Cities Unit 1 experiences failure of steam dryer with missing pieces, main steam relief valve (including actuator, drain line, and support), and main steamline supports. During January 16 telecon, degradation of limit switch in HPCI steam supply MOV attributed to vibration.

December 2003: Following shutdown in response to Quad Cities failures, Dresden Unit 3 finds two 4-inch through-wall cracks in steam dryer hood. Dresden Unit 3 also finds two sampling probes in FW sparger that had broken loose in FW system.

December 2003: Dresden Unit 2 identifies failure of a second FW sampling probe that remains lost in FW system.

2.

Cause of failures attributed to EPU conditions; but load definition has not been firmly established.

July 2002: Licensee states that root cause of Quad Cities Unit 2 steam dryer cover plate failures in 2002 was high-cycle fatigue due to high frequency acoustic resonance (130 to 230 Hertz). Licensee attributed failure to increased loading due to EPU operation.

July 2003: Licensee states that root cause of Quad Cities Unit 2 steam dryer failure in 2003 was high-cycle fatigue due to low frequency pressure loading (0 to 50 Hertz). Licensee indicated that failure was due to operation with failed cover plate which caused accelerated fatigue in hood area, and increased loading due to PORV opening.

December 2003: Licensee's root cause evaluation of Dresden FW probe failures indicates that original probes were susceptible to failure mechanisms of Transgranular Stress Corrosion Cracking and fatigue failure resulting from flow-induced vibration, and that the more recent replacement probes are susceptible to fatigue failure from flow-induced vibration.

January 22, 2004: GE indicates during a telephone conference that a previously unevaluated fluctuating pressure load in the acoustic range is believed to be contributing to adverse vibration effects during power uprates.

TBD: NRC plans to review GE load definition and steam dryer analysis methodology in conjunction with Vermont Yankee EPU submittal.

3.

Industry actions respond to failures "after the fact," and do not resolve plant-specific susceptibility and future failures of other components.

July 2002: Licensee repaired Quad Cities Unit 2 steam dryer by installing 0.5-inch cover plate and increasing weld size to 0.5 inches.

August 2002: In SIL 644, GE recommended that BWRs with BWR/3 steam dryers with 0.25-inch cover plates consider reviewing inspection records, monitoring plant parameters, and increasing frequency of moisture content measurements, and BWRs with BWR/3 steam dryers operating or planning to operate above OLP should perform VT-1 examination of cover plates and welds at next RFO.

July 2003: Licensee repaired Quad Cities Unit 2 steam dryer by replacing 0.5-inch outer hood plates with 1-inch plates, removing internal braces, and adding gussets and stiffeners.

September 5, 2003: In Supplement 1 to SIL 644, GE recommended that all BWRs operating or planning to operate above OLTP consider reviewing inspection records, monitoring plant parameters, increasing frequency of moisture content measurements, and conducting steam dryer inspections based on their specific design to identify failures that have occurred in the steam dryer.

September 26, 2003: In a letter to BWROG, NRC provides numerous concerns regarding provisions in SIL 644, Supplement 1, such as the lack of proactive measures to avoid adverse flow effects from power uprates.

November 4, 2003: In a public meeting, BWRVIP discusses plans to develop guidelines for inspecting, monitoring, and evaluating steam dryers.

November 5, 2003: In a public meeting, BWROG discusses NRC comments on SIL 644, Supplement 1, but has not resolved those concerns. GE indicates that "subcomponents" not evaluated for potential adverse flow effects during initial power uprate reviews.

November 2003: Licensee performs repairs of steam dryer and steamline components at Quad Cities Unit 1 that are more extensive than previously performed at Quad Cities Unit 2. Licensee is unable to locate lost dryer parts, but justifies startup with lost parts evaluation.

December 2003: Dresden Unit 2 justifies restart with lost parts evaluation for missing FW sampling, probe.

January 16, 2004: Licensee states during telecon that electromatic relief valves at Quad Cities Unit 1 justified for EPU operation for only a limited time period. Licensee subsequently decides to remain at pre-EPU power levels until further modifications completed.

January 22, 2004: GE states during a telecon that previously unevaluated fluctuating pressure load can be considered generically only for the steam dryer, and that potential adverse flow effects on steam and feedwater lines and their components must be evaluated on plant-specific basis.

4.

Lack of specific industry organization coordinating response to potential adverse flow effects from power uprates.

November 5, 2003: BWROG indicates that BWRVIP tasked to develop inspection guidelines but apparently only for steam dryer. BWROG states that survey to be performed of power uprate experience at BWR plants. Not clear which industry organization intends to resolve NRC concerns with Supplement 1 to SIL 644.

January 15, 2004: During a telecon with NRC, licensee of Vermont Yankee points to its planned response to Supplement 1 to SIL 644 on steam dryers as part of initial support for NRC approval of its proposed EPU operation without clear indication of plan to resolve overall issue.

January 20, 2004: In a telephone conference with NEI, the NRC staff discusses the apparent lack of coordination among BWR owners in addressing the extent of condition and generic impact of power uprates on BWRs. During the telecon, NEI commits to contact INPO to discuss what they have found with respect to the impact of power uprates on plant performance.

January 22, 2004: In a telecon with NRC staff, GE indicates that its new fluctuating pressure loading evaluation only addresses steam dryers, and that plant-specific review is necessary for steam and feedwater flow effects.

NRC QUESTIONS Extent of condition / What else can fail?

Safety significance / What are the potential adverse impacts of failures?

Susceptibility and applicability / Which plants are vulnerable and why (e.g., all BWRs, all power uprates, all EPUs, all plants)?

Remedies / What are the options and associated advantages, disadvantages, and impacts?

Next steps / What actions should be taken by industry and NRC for current power uprates and future uprates?

Schedule / What is the urgency of the issue?

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