ML17298A646

Summary of 831012 Meeting W/Util & C-E in Bethesda,Md Re Results of Anomalies Discovered During Hot Functional Testing at Unit 1

ML17298A646
Person / Time
Site:	Palo Verde
Issue date:	10/31/1983
From:	Licitra E Office of Nuclear Reactor Regulation
To:	Office of Nuclear Reactor Regulation
References
NUDOCS 8311160285
Download: ML17298A646 (86)

Text

OCT 3z )g83 Docket Nos.:

50-528, 50-529 and 50-530 APPLICANT:

Arizona Public Service Company FACILITY:

SUBJECT:

Palo Verde, Units I, 2 and 3

SUMMARY

OF MEETING CONCERNING RESULTS OF HOT FUNCTIONAL TESTING FOR PALO VERDE UNIT I A meeting was held on October 12, 1983 in Bethesda, Maryland with representative of the applicant and Combustion Engineering (CE).

The purpose of the meeting was to provide the staff with an updated status report on the evaluation of the anomalies that were discovered at Palo Verde Unit 1 following hot functional testing.

(A previous status report was presented at a meeting held on August 17, 1983.)

Attendees for the meeting are listed in Enclosure l.

Enclosures 2 -

5 include the viewgraphs used during the meeting.

The meeting is summarized as follows.

~Summa r CE updated the status of the efforts to resolve the anomalies discovered during and after hot functional testing of Palo Verde Unit 1.

These include loose thermal

sleeves, broken thermowells, loose and broken parts to the reactor coolant

pumps, and cracked CEA shrouds.

The source of the problem for the loose thermal sleeves'(Enclosure

2) is attributed to flow and mechanically induced vibrations.

CE has reevalated the need for thermal sleeves in the safety injection lines and has determined that without sleeves, and with removal of the grooves in the lines, the usage factor only increases from 0.32 to 0.34.

Therefore, the four sleeves to the safety injection lines will be removed.

The remaining two thermal

sleeves, one in the pressurizer surge line and one in the charging line, will remain since no problems were encountered with these and their design ar rangement is the same as for other CE plants where the sleeves have functioned without problem.

Failure of the thermowells (Enclosure

3) was attributed to high cycle fatigue due to flow induced vibration.

To correct for this effect, the design of the thermowells will be modified to stiffen them, as shown in the viewgraphs.

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All thermowells will be replaced with the modified design, 12 in the cold legs and 18 in the hot legs.

The original and modified designs will be tested at both the CE Windsor facility and the CE Newington facility.

With regard to the RCS pumps (Enclosure 4), tests on a half scale model at the KSB facility in West Germany have been completed.

Results show that increasing the gap size (difference between the diameters of the diffuser and impeller divided by impeller diameter) from 2.3X to 6.0% reduced the radial hydraulic forces by a factor of 3.3.

Metallurgical tests performed on the broken impeller vanes indicate that the cracking mode is fatigue failure and initiated in a high stress region associated with thin areas of the vanes.

The vane material was found to be in accordance with specified requirements.

Based on the above tests and other evaluations, the RCS pumps will be modified, as shown in the viewgraphs, to increase the gap size, cut back on the impeller leading edge, increase the length and number of bolts as well as an increase in bolt torque, increase the number of diffuser support

segments, and other changes.

With these

changes, design flow for the pumps will be maintained.

Testing at the CE Newington facility using a full scale prototype, with the baseline and modified designs, is scheduled to start shortly.

The status of the evaluations for the cracked CEA shrouds was also discussed (Enclosure 5).

Initially seven cracked shrouds were identified.

Further inspection revealed four additional cracked shrouds and some web cracks.

Failures are attributed to high cycle fatique possibly due to mechanical excitation, acoustic induced vibration and/or hot functional test conditions.

Tests are currently underway at the CE Windsor facility to get a better under-standing of the cause of the failures.

At the conclusion of the meeting, the staff requested that the applicant determine the time frame for submittal of the reports covering the above anomalies and to provide by letter the target dates for their submittal.

The applicant agreed to do so.

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Enclosures:

1.

Meeting Attendees 2.

Viewgraphs on Thermal Sleeves 3.

Viewgraphs on Thermowells 4.

Viewgraphs on RCS Pumps 5.

Viewgraphs on CEA Shrouds cc:

See nex page DL:LB83fQ Dl, 3

EALicitra/y GW ighton 10/pi /83 10/)y /83 E. A. Licitra, Project Manager Licensing Branch No. 3, DL

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Palo Verde Mr. E.

E.

Van Brunt, Jr.

Vice President - Nuclear Projects Arizona Public Service Company P. 0.

Box 21666 Phoenix, Arizona 85036 Arthur C. Gehr, Esq.

Snell 5 Wilmer 3100 Valley Center

Phoenix, Arizona 85073 Mr. Charles S. Pierson Assistant Attorney General 200 State Capitol 1700 West Washington Phoenix, Arizona 85007 Charles R. Kocher, Esq. Assistant Counsel James A. Boeletto, Esq.

Southern California Edison Company P. 0.

Box 800

Rosemead, California 91770 Ms. Margaret Walker Deputy Director of Energy Programs

'conomic Planning and Development Office 1700 West Washington

Phoenix, Arizona 85007 Mr. Rand L. Greenfield Assistant Attorney General Bataan Memorial Building Santa Fe, New Mexico 87503 Resident Inspector Palo Verde/NPS U.S. Nuclear Regulatory Commission P. 0.

Box 21324 Phoenix, Arizona 85001 Ms. Patricia Lee Hourihan 6413 S. 26th Street Phoenix, Arizona 85040 Regional Administrator - Region V

U. S. Nuclear Regulatory Commission 1450 Maria Lane Suite 210 Walnut Creek, California 94596 Kenneth Berlin, Esq.

Winston 5 Strawn Suite 500 2550 M Street, NW Washington, DC 20037 Ms. Lynne Bernabei Government Accountability Project of the Institute for Policy Studies 1901 gue Street, NW Washington, DC 20009

1 I

Enclosure 1

Meetin Attendees cto er NRC APS T. Noyak M. Licitra G.

W. Knighton S.

Hou B. Bosnak L. Dewey D. Terao C.

D. Sellers G. Bagchi S. Black G.

C. Meyer H. L. Brammer R. J. Kiessel Nucleonics Meek J.

Branscome Combustion En ineerin C. Tuguson C. Ferguson G. A. Davis A. E. Scherer l<. D. Mawhinney D. B. Amerine C. B. Brinkman B. guinn E.

E.

Van Brunt, Jr.

G.

C. Andognini A. Gehr Westin house J.

Galembush General Electric J.

W. Pendlebury GAP Lynne Bernabei LADMP H. Dziegiel

0 Enclosure 2

THERMAL SLEEVES 10/12/85 CI F,

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THERMAL SLEEVES INVESTIGATIONS e METALLURGICAL NO ABNORNLITIES e DIMENSIONAL IN ACCORDANCE HITH DESIGN o MANUFACTURING RECORDS REVIEM CONFORMED TO REQUIREMENTS SLEEVES HERE PROPERLY POSITIONED AND INSTALLED 10/12/85 Cs F,

THERMAL"SLEEVES CONCLUSIONS o FAILURE 1<AS VIBRATION INITIATED CAUSING LINER TO

LOOSEN, TWIST AND DISLODGE FROM THE NOZZLE

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SOURCE OF VIBRATION HAS FLOM AND M CHANICALLY INDUCED

~ A POSSIBLE CONTRIBUTING FACTOR HAS THE DESIGN REDUCTION IN THE QPLANSION GROOVE DE, TH FROZE 0,125 INCH TO 0.100

INCH, 10/12/85 Ce Fs

THERNL SLEEVES CORRECTIVE ACTIONS o

RENOVE THE RENAINING SAFETY INJECTION SLEEVES o

RENOVE AND BLEND IN THE EXPLANSION GROOVE TO THE ADJACENT HALL CONTOUR o

LEAVE THE SURGE AND CHARGING NOZZLE SLEEVES IN PLACE

- THESE NOZZLES ARE PERPENDICULAR TO THE RC PIPE; THEREFORE, THERE IS NO TORSIONAL FLOW CONPONENT THE TRANSIENTS AND THE NUNBER OF CYCLES ON THE CHARGING NOZZLE REQUIRES THE LINER TO NINTAIN THE USAGE FACTOR BELOM 1 0 THE'XPLANSION GROOVES ARE 0,125 INCH DEEP AS IN OUR OTHER PLANTS HHERE HE HAVE NOT EXPERIENCED ANY FAILURES 10/12/83 Cs Fe

THElWL SLEEVES USAGE FACTOR CONPARISON e NXINUM USAGE FACTOR IN AREA PROTECTED BY THE LINER',09 o

USAGE FACTOR AT SAFE END ABOVE THE LINER AREA 0,32 o

USAGE FACTOR WITH SLEEVE REl10VED AND THE EXPLANSION GROOVE REt!OVED o ACTUAL LOSS OF USAGE FACTOR (0,30 0.32) 0.02 10/12/83

Enclosure 3

RESISTANCE TEMPERATURE DETECTORS (RtD)

THERNOHELLS (TW) 10/12/83 Co Fe

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FAILURE NODE

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THE THERNOL<ELLS EXPERIENCED HIGH CYCL'E'IBRATION o VIBRATION YNS IN A PLANE PERPENDICULAR TO THE FLOM DIRECTION o FAILURE 'AS INITIATED BY FATIGUE o FINAL FAILURE BY FLOM LOADING (PRI.'DRILY) OR INPACT FRON REACTOR COOLANT PUNP DEBRIS o EXTENSIVE NEAR OBSERVED IS A RESULT OF INCONEL TO INCONEL COUPLE o THE VIBRATION MHICH LED TO THE FAILURE '<AS DUE TO VORTEX SHEDDING 10/12/83 Ce fe

THERNOl<ELL CORRECTIVE ACTIONS LARGER OUTSIDE DIAMETER STRENGTHEN THERMONELL AND INCREASE ITS NATURAL FREQUENCY TAPERED NOZZLE/THERMOHgLL SUPPORT (PRELOADED IN POSITION)

ELIMINATE GAPp INCREASE NATURAL FREQUENCY AND VALIDATE STRUCTURAL MODEL ASSUMPTION BY FIXING BOUNDARY CONDITIONS REDUCE INSERTION INTO FLOH STREAM INCREASE NATURAL FREQUENCY AND REDUCE FLOW LOADING CHROME PLATE CONTACT, iAREA REDUCE GALLING 10/12/85 Cs F,

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CE NEMINGTON RC PUP)P FULL FLOM TEST FACILITY 10/12/85 Cs Fo

RTD/THERE/0!BELLS TEST PROGRA>

o CE WINDSOR YORTEX SHEDDING TESTS IN TF-2 ORIGINAL DESIGN THEfNONELL TAPERED DESIGN SHAKE TABLE TESTS TO DETERMINE THE NATURAL FREQUENCY AND DAMPING OF EACH DESIGN o

CE NEHINGTON DETERl'lINE STRUCTURAL RESPONSE FREQUENCIES USING ACCELERONETERS DETERMINE YORTEX SHEDDING FREQUENCY

- MEASURE YELOCITIES AT THE RTD/TM USING A MODIFIED TH MITH P ITOT INSTRUFlENTATION 10/12/85 Ce F,

Enclosure 4

RC PUMPS 10/12/83 Ci Fs

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RADIAL BEARINGS

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ORIGINAL DESIGN.

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ORIGINAL DESIGN, GAP 2 3 PERCENT, THIS TEST USED FOR BASELINE.

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CUT BACK TO PROVIDE A 6 PERCENT GAP.

RESOLED.

SLIGHT HEAD LOSS AT DESIGN AND LESS AT RUNOUT CONDITIONS.

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~2LKlLER 2IEEU'ZR BACKFILED TO RECOVER HEAD LOSSES DUE TO INCREASED GAP, ONISSION OF SUCTION PIPE RINGS AND CUTTING BACK OF THE LEADING EDGE OF INPELLER VANES-CUTBACK TO PROVIDE A 6 PERCENT GAP RECOVERY OF THE HEAD LOSS WAS ACCOi'1PLISHED BY THE BACKFILING OF THE IMPELLER.

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I SLIGHTLY UNDERFILED, VANES NACHINED TO PROVIDE SIX PERCENT GAP.

ORIGINAL DESIGN REQUIRED TOO NCH BACKS.LING TO REGAIN LOST HEAD.

DECIDED TO CUT BACK THE"DIFFUSER NOT THE VANES OF THE INPELLER TO OBTAIN 6 PERCENT GAP.

DISCHARGE AND SUCTION PRESSURE PULSATIONS WERE RECORDED USING PRESSURE TRANSDUCERS.

INPELLER AND DIFFUSER VANE LOADINGS MERE NEASURED USING STRAIN GAUGES.

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CLEARANCE BETWEEN INPELLER AND DIFFUSER MAS INCREASED FRON 2.3X To 6,0X BY CUTTING BACK QIFFUSER VANES WITHOUT RESULTING IN SIGNIFICANT HYDRAULIC INPACT.

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HEAD LOSSES DUE TO INCREASED GAP, RENOVAL OF SUCTION PIPE RINGS 8 CUTTING BACK THE LEADING EDGES OF INPELLER MERE RECOVERED BY BACKFILING THE IMPELLER.

e RADIAL HYDRAULIC FORCES ON THE DIFFUSER MERE REDUCED BY A FACTOR OF 3

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PERCENT,

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THE NEASURED STRESS LEVELS ON THE IMPELLER AND DIFFUSER VANES MERE OF ACCEPTABLE LEVELS,

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TOTAL HEAD LOSS AT THE DESIGN POINT MAS 2,3%

WITHOUT BACKFILING.

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REACTOR COOLANT PUMP IMPELLER METALLURGICAL RESULTS PALO VERDE FAILURES -

PUMP 1B:=

NO 5 VANE BROKEN PUMP 2A:

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R 6 VANES BROKEN IMPELLER MATERIAL IN ACCORDANCE HITH ASME SA-087 CL, CA6NN NICROSTRUCTURE ACCEPTABLE TEMPERED MARTENSITE CRACKING MODE IS FATIGUE CRACKS INITIATED IN flIGHEST STRFDS REGIOl'I AND ASSOCIATED WITH THIN AREAS OR STRESS RISER CASTING IMPERFECTION PRESENT ON ONLY ONE OF TMO FRACTURE SURFACES NO EVIDENCE OF CORROSION 10/12/83

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REACTOR COOLANT PUMP DIFFUSER BOLTS METALLURGICAL RESULTS MATERIAL IN ACCORDANCE WITH ASTM A-193 GRADE B6 FRACTURE MORPHOLOGY TRANSGRANULAR FATIGUE MOST LIKELY FAILURE MODE NO EVIDENCE OF CORROSION OR HYDROGEN EMBRITTLEMENT CF 10/19/AW

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e CUT BACK IMPELLERS AT LEADING EDGE WHERE NECESSARY TO MEET A MINIMUM THICKNESS REQUIREMENT, e

MODIFY VANE TO SHROUD RADII TO ASSURE THAT AN ACCEPTABLE MINIMUM RADIUS IS MAINTAINED, o

REMOVE ANY STRESS RISER IMPERFECTIONS FROM THE VANE LEADING EDGES.

e BACKFILE IMPELLERS AS REQUIRED TO RECOVER DESIGN POINT HEAD LOSSES RESULTING FROM THE MODIFICATIONS.

e CUTBACK THE DIFFUSER VANES TO PRODUCE A 6,0 PERCENT GAP BETWEEN IMPELLER AND DIFFUSER, CF 10/12/8S

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CUT BACK VANES TO PRODUCE A 6X GAP, o

INCREASE NUMBER OF BOLTS FROM 16 TO 29.

BOLTS MILL BE LONGER BY 35 MM, e

INCREASE NUMBER OF DIFFUSER SUPPORT SEGMENTS FROM 0 TO 14.

ALSO INCREASE HARDNESS OF SEGMENT RINGS MATERIAL t!ILL BE ASTM-A087 CA6NM, e

INCREASE TORQUE ON BOLTS TO APPROXIMATELY 260 FT-LBS FROM 130 FT-LBS, THIS INCREASES CLAMPING FORCE BY A FACTOR OF 3, o

HEDGES MILL BE USFD FOR INSTAltATIONAL PURPOSES TO ASSURE CONTACT ON ALL LOADING SURFACES,

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BOLTED JOINT CLAMPING FORCE IS INCREASED BY A FACTOR OF 3 ~

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e DELETE TAPERED FIT BETMEEN DIFFUSER AND SUCTION PIPE TO ASSURE POSITIVE BOLTING SURFACE, a

INCREASE BOLTS FRON 16 TO 24 A;"<D INCREASE TORQUE FRON 110 FT-LBS TO 155 FT-LBS, o

USE 4 TAPERED PINS TO ABSORB SHEAR LOAD AND ASSIST IN FIELD ASSEMBLY, o

ADD RING TO CONTAIN TAPERED PINS.

RING MILL ALSO INCREASE STIFFNESS OF JOINTS, o

DELETE PISTON RINGS AT BOTTON END OF PIPE.

e BOLTED JOINT CLAMPING FORCE IS INCREASED BY A FACTOR OF 2 CF 10/12/85

e CUT BACK LEADING EDGES OF VANES MHERE REQUIRED TO NEET THE THICKNESS CRITERIA, o

BACKFILE THE TRAILING (DISCHARGE)

EDGE OF VANES-7rlM TO RECOVER THE DESIGN POINT HEAD LOST DUE TO THE INCREASED

GAP, INPELLER CUTBACK AND DELETION OF SUCTION PIPE

GAP, CF 1A/1'//RW.

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DIFFUSER BOLTS (29)

SEGNENT RINGS (10)

DIFFUSER VANES (11)

CUTBACK SUCTION PIPE BOLTS (2Q)

DIFFUSER SUCTION PIPE lit 10/12/85 CF

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REACTOR COOLANT PUMP TEST AT CE-NEW INGTON o

INSTRUMENT TEST LOOP WITH ACCELEROMETERS ON DIFFUSERS HAL'VES TO MONITOR VIBRATION OF DI FFUSERS RELATIVE TO CASINGS WITH DISPLACEMENT PROBE AT BOTTOM OF SUCTION PIPE TO MONITOR MOVEMENT OF SUCTION PIPE RELATIVE TO CASING WITH STRAIN GAUGES ON SELECTED DIFFUSER BOLTS WITH THERMOCOUPLES NEXT TO THE DIFFUSER BOLTED JOINT AND AT THE DI FFUSER BOLTS TO IDENTIFY POSSIBLE REASONS FOR CHANGES IN PRELOAD o

RUN BASELINE TEST OF ORIGINAL DESIGN AT CONDITIONS THAT MIGHT AFFECT THE JOINTS e MODIFY THE PUMP TO INCORPORATE CHANGES AND COMPARE WITH BASELINE 10/12/83 CaFs

Enclosrue 5

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'OWER SUPPORT STRUCTURE FLOtrtt SKIRT INSTR UNCTION NOZZLE.

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36 35 37 45 52 QSO 46 53 39 97 58 Q42 59 S1 52; 35 WIt SHROUD ASSEHBLY NOE INSPECTION BOTTOM TOP CRACK LOCATION 4i 42 43 40 0

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- shr aud tube - web weld cracks

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SUMMARY

UGS ACTIVITIES I,

FIND CAUSE AND CONFIRM FIX ADEQUACY A,

TESTING 1.

MODEL TESTS ON SHROUD ASSEMBLY 2,

ACOUSTIC EXCITATION IN SINGLE TUBE 3,

MECHANICAL EXCITATION OF SINGLE TUBE REACTOR DEMONSTRATION TEST B,

ANALYSIS 1,

SINGLE TUBE FINITE ELEMENT MODEL 2,

UGS ASSEMBLY, SIMPLIFIED, LUMPED MASS MODEL 3,

UGS ASSEMBLY, FINITE ELEMENT MOOEL UGS FLOM VELOCITIES C,

METALLURGY 1,

CRACK INSPECTION AND EVALUATION 10/12/83 Cs Fi

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l CEA SHROUD ASSENBLY DESCRIPTION OF FAlLURE e

HI6H CYCLE FATI6UE OF CEA SHRQUD TUBES.,

NESS, AND CONNECTIN6 NELDS AT TOP

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10/12/83 CF CEA GUIDE TUBE CRACK ttECHANISN HIGH CYCLE FATIGUE CRACKS POSSIBLY DUE TO:

1, NECHANICAL EXCITATION 2,

LOCAL FLOW/ACOUSTIC INDUCED VIBRATION 3,

VIBRATION DUE TO HOT FUNCTIONAL TEST CONDITIONS

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10/12/83 CF CEA SHROUD PACKAGE TEST PROGRAMS o

MODAL TESTING OF THE FOUR AND TMELVE FINGER GUIDES IN BOTH AIR AND HATER o

RESIDUALSTRESS TEST-o FLOM VIBRATION TEST o

SINGLE CEA':.TUBE SHAKER TEST o

ACOUSTIC / HYDRAULIC TEST

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0 0 0 0 0 0 0 0 0 0 0 0 0 0 IC) m XI isa>sr

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f RESULTS FRON UPPER PLENUM CROSS FLON MODEL ELEVATION PRE COBE POST CORE LONER PLANE TUBE CAVITY 14 FT/SEC UP 2 FT/SEC UP 62 FT/SEC DOHN '8 FT/SEC UP To 45 FT/SEC DO'i'IN UPPER PLANE TUBE CAVITY 1 FT/SEC UP To 2 FT/SEC DOWN 0,7 FT/SEC NAX UP

~,5 FT/SEC 0,6 FT/SEC MAX UP 10/12/83 CI Fs

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SHROUB TUBES MUI;TIP4E QIGTIhCT PQAKS {9495 HR)

TYPICAL.PEAKS AT ~ 1R; 1CO] RN]4$ HZ INWATii.1u, lu,103,251 tC

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VIORATIONCOUP I.INQOF COMKNIINT IS VERY RVlbhNT

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UGS

SHROUD, SINGLE TUBE MECHANICAL EXCITATION TESTS OBJECTIVES:

o TO IDENTIFY THE CRITICAL RESONANCE FREQUENCIES OF AN UGS TUBE o

TO DETERMINE THE STRAIN DISTRIBUTION AT THE REGIONS OF OBSERVED TUBE FAILURES e

TO SIMULATE THE FAILURE MECHANISM OBSERVED IN THE PLANT

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TO DEMONSTRATE THE MARGIN OF IMPROVEMENT WHICH CAN BE EXPECTED WITH THE CORRECTIVE ACTION 10/12/83 Cs Fe

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UGS SfPJXS, SINGLE TUBE HYDRAULIC EXCITATION TESTS OBJECYIVES:

e IINVESTIGATE MHETHER GR NUT FLCM INDUCED PRESSURE BJJCTUATIM'RE AQIuiSTItCA'LQ APPLIFIED ND THUS COULD EXCITE CEA SHRQLii9 PUBE SHELL. NODES o

NEASURE FLUCMTIiKPRESSURE PJS STRAIN IN REGIOHS OF--THE CEA-SH~ WHERE FAittLUHE HAS OBSERVED, o KKRNIKTHE KCURIKKE QiR NGKCCURRENCE OF CRiIYIiGRL FLN PHEHGHBR NHKiCB PiIGHT LEAD TO UN-acoa.wxz ~ t4uczs vnu@rroxs.

10/12/85 Ce Fs

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MEETING

SUMMARY

Ot'T 3 1 1983 LDocument,-Control:(50=528/529/530)M NRC PDR L'DR NSIG..

TERA LB'eading:

J'. Lee-G. Knightori '-

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Manager, EALicitra Attorney'ELD L. Jordan-Regional Administrator, Region J. N.'ayTor PARTICIPANTS'RC TNovak 11Licitra GMKnighton;=

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