ML17317B288
| ML17317B288 | |
| Person / Time | |
|---|---|
| Site: | Cook |
| Issue date: | 06/15/1979 |
| From: | Hunter R AMERICAN ELECTRIC POWER CO., INC. |
| To: | Jordan E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| References | |
| AEP:NRC:00221, AEP:NRC:221, NUDOCS 7906260421 | |
| Download: ML17317B288 (38) | |
Text
REGULATORYKIFORI~tlATION D ISTR IBUTI ON S Y
'M (R IDS)
ACCESSION NBR:7906260021 OOC ~ DATE: 79/06/15 NOTARIZED NO FACIL:50-'315 Donald C ~
Cook Nucl'ear Power Pl ant r Unf t 1 r Indi ana 8
50-316 Donald C ~
Cook Nuclear Po~er Pl antr Unf t 2r Indiana 8
AUTH INANE AUTHOR AFFILIATION HUNTERzR ~ ST American Electric Power Co,g Ines RECIP ~ NAVE RECIPIENT AFFILIATION JOROA"lgE ~
Division of Reactor Operations Inspections
SUBJECT:
Responds to NRC 790611 r eauest for info r e teedwater 1 fne cracks'orwar ds 10CFR50
~ 59 evaluation 8 special procedure quiae for feedwater line data collections akes commitment for periodic reptsgtesting R surveillance programs+
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AMERICAN ELECTRIC POWER Servi ce Corporati on 2 Broadway, Nnn York, X Y. l000a (2l2J 422.4800 IIMNN Mt,'QT RI)
II'une 15, 1979 AEP:NRC:00221 Donald C.
Cook Nuclear Plant Units l. and 2
Docket Nos.
50-315 and 50-316 License Nos.
E. Jordan Office of Inspection and Enforcement U.
S. Nuclear Regulatory Commission Washington, D.
C.
20555
Dear. Nr. Jordan:
On June ll, 1979 we met with the Commission to discuss the matter of the cracks found in the feedwater line elbows of the Donald C.
Cook Nuclear Plant.
Our letters of Nay 26, 1979'nd June 7, 1979 (AEP:NRC:
00216) reported the circumstances surrounding this problem and the corrective actions taken..
At the conclusion of the June ll meeting, you requested that we submit this additional information for your review:
l.
A 10 CFR 50.59 evaluation.
This is attached.'.
The feedwater line data collection procedure including acceptance criteria.
Attached is Special Procedure Guide for feedwater line data collection.
3.
A commitment to provide periodic reports on the results of our ongoing investigation.
'e will"provide you.with a monthly periodic report of our data col,lection, program and. our other evaluations beginning one month from the time of Unit 2 criticality.,
4.
The basel'ine non-destructive examination'data.
Ve will do an ultrasonic examination of the nozzle-to-elbow.'eld, areas which, with the associated radiographs, will serve as the. basel'ine. for future. inspections.
This:
will'e-available. at. the plant for your inspection.
V 906260
i f
Mr. E. Jordan AEP:NRC:00221 5.
A commitment that we will perform surveillance of the nozzle-to-feedwater elbow weld at the next refueling outage for Unit 2.
Me agree with this commitment.
6.
A copy of the metallurgical evaluations and stress analyses.
This will be provided to you as soon as available.
Your staff also recommended that we radiograph the weld at the other anchor point at the containment wall.
Me radiographed two of the feedwater pipe-to-penetration welds and found no indications.
Very truly yours, RSH/emc Attachment unter Senior Vice President - Construction American Electric Power Service Corporation cc:
R.
C. Callen G. Charnoff R.
W. Jurgensen D. V. Shaller - Bridgman J.
G. Davis - NRC J.
E. Dolan
\\
l
DONALD C.
COOK NUCLEAR PLANT Safety Evaluation of the Modified Feedwater Elbow Design and Installation of the Data Collection Instrumentation Subsection 59 of 10 CFR Part 50 requires that each design change and/or test program be reviewed to determine whether or not the proposed change or test involves an unreviewed safety question.
The safety review of the elbow design modifications and the instrumentation installation are discussed below.
The results of our review of the modifications/data collection instru-mentation installation verify the acceptability of the Donald C.
Cook Plant for continued safe operation in that they do not represent a potential safety hazard.
The design change/data collection program, as described in our AEP:NRC:00216 submittal, will have no adverse effect on the health and safety of the general public.
The new 16 inch feedwater elbows are made from the same materials as the original elbows, that is, A234NPB carbon steel.
The feedwater elbow design has been improved by eliminating the sharp discontinuities inside the elbow caused by counterboring the original Schedule 80 elbow to match the Schedule 60 steam generator nozzle.
In addition, the new elbow has been built up to a Schedule 80 thickness near the elbow to nozzle weld.
These modifications reduce the stresses in the area adjacent to the elbow to nozzle weld and as such will not increase either the probability or the consequences of a design basis event.
The modified elbow design will not lead to the malfunction of any equipment important to safety nor will it create the possibility for an accident of a different type than any evaluated in the safety analysis.
The modified elbow design does not result in the reduction of the margin to any safety analysis limit.
Two feedwater lines in Unit No.
2 will be instrumented
.as part of our data collection/evaluation program.
The objective of this program is to gather, and subsequently
- evaluate, information on steady state and transient conditions during normal operation from cold shutdown to 100K power.
Evaluation of the data collected can aid in determining the cause of cracking in the feedwater elbows and verify the adequacy of the new elbow design.
Any changes in power level made for the data collection program will be within the applicable Technical Specification limits.
The appropriate cable separ ation criteria and containment penetration provisions are met for the instrument cables used for this program.
A review of-the. Post Accident. Combustible Gas Control Analysis for Unit No. 2,. FSAR Section 14.3.6, indicates that the aluminum content of the data collection instrumentation, when added to the existing aluminum inventory inside containment, does not result in an aluminum inventory in excess of the. analysis assumption.
DONALD C.
COOK NUCLEAR PLANT SPECIAL PROCEDURE GUIDE FOR FEED>1ATEH LINE DATA COLLECTION
- l. ~~rm Information regarding displacement,
- pressure, temperature and strain will be 'collected during the performance of the sequence of events as outlined in section 8.
The purpose of this program is to determine the amplitude and frequency of cyclic stresses on the feedwater lines.
The feedwater lines to steam generators 2-1 and 2-3 are to be instrumented as outlined in section 3.2.
The same locations on both lines are chosen to be instrumented in order to assure duplication of information.
The results of this test will be applicable to both units.
2.
EmmZBm 2.1 Personnel Categories 2.1.1 Test Coordinator - will be an I &: M Power D.C. Cook Plant Performance Engineer 2.1.2 Test Consultant
- will be a Brewer Engineering Laboratory person and/or AEPSC person.
3 3.1 List of Test Instrumentation 3.1.1 Linear Accelerometers Statham Instruments-Inc.
3.1.1.1 Model A5-10-350 Range
+ 10 g
Natural frequency 250 cps Damping
.7 -.1 of critical Direction of Sensitivity - perpendicular to base Non-lineirity Ee Hysteresis lpga of full scale 3.1.1.2 Model A6-15-350 Range - ling
+
Natural freauency 150 cps
+
Damping
.7 -.1 of critical Direction of Sensitivity - perpendicular to long axis of accelerometer Non-linearity 4 Hysteresis
- 1 f~ of full scale 3.1.2 Weldable Strain Gages BLH Electronics SR-4 gages 3.1.2.1 FNW Type 3.1.2.2 FNWFB Type 3.1.3 Thermocouple Compensators Omega Engineering, Enc.
Type MCJ Sensitivity - 1.8"F (- 1"C)
B..ttery Type - Silver Oxide Q.1.4 T hermocouples Chromel/Alumel Wire (Type K) 3.1.5 Pressure A Differential Pressure Transducers
3.1.5.1, Differential Pressure Transducers BLH Electronics Type HMD
'HF Range
+ 100 psid 0 to 1000 psig Line
$000 psig 5000 psig Nonlinearity 0.25$ of Rr,ted Output Hepeatability O.lgo of Rated Output Hysteresis 0.15$ of Hated Output 3.1.5.2 Pressure Transducers CEC 4-317 4 4.-317-0001 Range 0 to 4000 psig; Line 5000 psig 3.1.6 Direct Current Differenti 1 Transformers Trans-Teck Model 354-000
+
Range - 1 inch 3.2 Location of Instruments For orientation and location of test instruments see attached sketches.
2-Temp-07 (1 thru 12) 4.0 Prereauisites 4.1 Test Xnstrumentation is located per Section 3.2 and installed per existing state of the art techniques described by procedure 02-Temp-07.4.1.
4..2 Test instrumentation is calibrated per attached state of the art techniques(see 02-Temp-07.4.2) 4.3 The following system instrumentation shall be installed and checked as operational.
(For manufacturer and model see section 3.0):
4.,3.1 Twenty three, thermocouples on each of feedwater loops
- 1. and 3 at. positions shown on drawing 2-Temp-07 sheets 7 and 8..
4-3.2'ne, or. if possible,,two thermocouples attached to pipe radiograph plug on each of feedwater line elbows
as shown on drawing 2-Temp-07 sheet 12.
4.3..3 Twelve temperature compensated FNMFB type weldable strain gages on feedvater line elbow and nozzle for each loop as shown in drawing 2-Temp-07 sheets
< and 6.
Two type FNM strain gages, assembled in a bridge to compensate for temperature, may be substituted for a single type FNNFB strain gage.
4.3.4 Three type FN(l strain gages, one on one of the snubber rods at each snubber location at feedvater loop 1.
4.3.5 Thirteen accelerometers per loop on both loop 'nd 3 at the following locations and orientation (refer to drawing 2-Temp-(f7 sheet 4).
4.3.5.1 Nine accelerometers, one in each of the x, y Zc z axis at the steam generator elbow, the lower vertical elbow and the wide flange of the snubber on the horizontal pipe run.
Two accelero-
- meters, one each on the y Ec z axis at the lover horizontal elbow and tvo accelerometers, one each on the x 8c y axis midway between the two restraints on the vertical riser.
4.3.6 Ten Direct Current Differential Transformers (DCDT)~
tvo each, to measure pipe movement in the direction perpen-dicular to the pipe, at. the four piping rupture restraints arid the crane wall sleeve on both line 2-1 and 2-3.,
4..3.,7 Pressure Transducers at the following test connections FPI 210,. FPI 230, FFI 210 and FFI 230 to measure any pressure surges in both auxiliary and main feedwater lines, and one
<<t pros"ure t:ip on hnth loop 1 an.t 3:is shown in drawing 2-Temp-07 sheet 11.
4.3.8 Differential Pressure Transducers.
at the following locations FFI-210, FFI-230 and FFC-230 or 231 as shown in drawing 2-Temp-07 sheet 10.
4.4 Oscillographs and magnetic tape decks are in place and operational.
>t.5 Test Instrumentation is protected as shown by sketch No. 02-Temp-07.4.5.1 and installation procedure No. 02-Temp-07.4.5.2 4..6 Feedwater line has been'einsulated under direct supervision of Brewer Engineering Labs personnel.
4.7 Verification has been performed on sequence of connection of the test instrumentation to their proper reco rding channel.
4.8 Power circuits labeled Trans.21CHC, ABC 21-CMC-7,MCC2EZC-CG and MCC-2-CT-CS have been tagged to SOB to prevent de-energizing.
4.9 All testing personnel have been thoroughly briefed on per-formance of the test, and acknowledge that instructions are understood.
See signoff sheet 4.10 SOE has notified test consultant that the Unit is ready to return to service.
4'll Communications to the recording equipment area has been established with the control-room.
4.12 Time Code generator is to be synchronized with control room clock.
4..13 Test coordinator is stationed in the control room throughout the test'eriod with suitable communication with the recording equipment area.,
4.14 Verify by sample that temperature compensator electronics are modified to accept silver oxide battery source.
~t.15 DCDT's <<re reset sometime following step 8.P but before step 8.6
4-.16 The cold portion of the main feedwater system interference walk-down test as specified by AHPSC Piping ana Valves Section letter to U.V. Shaller dated b/ll/79 has been completed.
4.17 Feedwater piping should be filled with water prior to step 8.1.
5.0 Precautions 5.1 SOL or unit forman shall notify test coordinator a minumum of 3 minutes prior to start of all transients
~
Test coordinator will immediately notify recording personnel.
If plant evolutions are such that immediate operator response is necessary for an observed plant condition, no notification to test coordinator is necessary prior to the operator response.
The test coordinator should endeavor to obtain as much data as possible from an unannounced transient which corresponds to one of the below listed events.
6.0 Acceotance Criteria 6.1 The data collection as outlined in section 7 >vill be considered acceptable if sufficient data is collected during the times specified in section 8.
Instrumentation readings from any one of loops 1 or 3 or any combination, will be con idered sufficient with the approval of the test consultant.
6.2 Analyze the strain gage data to determine the magnitude and frequency of cyclic stresses due to pipe motion ana temper-ature changes.
Resulting cyclic str'esses must. be within the design allowable per ASM',Section III Division I Figure I-91 (S/N) curves.
7.0 Data Collection 7.1 Record data during periods as specified in section 8 on both oscillograph an'd magnetic tape recorders.
7.2 Test i'nstrumentation re~dings as recorded by either oscillo-graph (strip chart) or magnetic tape will be considered acceptable.
7.3 Data collected during steps 8.4-and 8.5 need not be recorded in any specific sequence.
7.4 Strain gage readings on snubbers need only be obtained at test consultants request.
I 7'.g DCDT readings will be recorded on data sheets or, strip charts.
7.6 Tape Recorder Log Sheets are to be used to record sequence.
of events and each tape as >>ell as each reel permanently ident ified-.
7.7 RCS temperature for hot and cold legs shall be recorded from station instrumentation at each test sequence.
7.8 During performance of steps 8.6 and the following steps record main feedwater pump turbine speed using station instruments.
8.0 Sequence of Events Data collection will take place during the following events in accordance with Acceptance Criteria specified in section 6.
8.1 Feedwater Line Displacement Test.
8.1.1 Displace feedwater pipe to some value slightly greatly th.~n 1/4 inch perpendicular to horizontal run, in the horizontal direction, at lower horizontal elbow on either feedwater line 1 or 3 and record strain gage and accelerometer readings for 30 seconds.
8.1.2 Suddenly release the pipe and continue recording until stable conditions have been reached according to the juagment of the test consultant.
8.2 Record strain gage, accelerometer and DCDT readings for 1 minute prior to startup of each reactor coolant pump and continue recording after pump has started until readings have stabilized as determined by the test consultant.
8.3 Thermocouple, strain gage, accelerometer, pressure transducer and DUDT readings will be recorded for a period of 3 minutes during heat-up when the Reactor Coolant Temperatures are at the following values:
8.3.1 200"F-25"F 8.3.2 300'- 25" F 83.-3 400F-25F
8 3.4 500"F - 25" F 8.3.5'ot Standby Conditions 8.4 In the event that steam generator 1 or 3 is fed with auxiliary feedwater during heat-up, the test consultant
- may, it his own judgement, record thermocouple, strain gage, pressure and accelerometer readings 1 minute prior to auxiliary feedpump start up and continue to record until stable conditions are reached according judgement of test consultant.
8.5 When the unit is at hot standby, record pressure transducer, thermocouple, strain gage, DCDT and accelerometer readings during at least two events of startup of auxiliary feedpumps to either steam generator 1 or 3 and, continue to record until at.least five minutes after stop of flow.
8.6 When unit is at hot stand-by, and when steam generator 3 is expected. to receive a fairly constant rate of auxiliary feedwater flow for an extended period, pressure transducer, thermocouple, strain
- gage, D(;DT and accelerometer readings will be recorded for a period of three minutes at least twice.
8.$
Hi, Aux &/ f'low check.." Let SG No.
1 or 3 level decrease to Low alarm point.
Immediately start AFN pump on associated steam generators~
and rapidly open associated FMO valve until. AFW..flow of 150 gpm is reached.
when SG leve9.
returns to: normal level, close associated FMO valv 0'ecure running AF>l pump if necessary.
Start data recording, ec~uipment just before reaching low level alarm point and record data for 3 minutes after FMO associated valve i" clo.ed <<g:iin.
8.8 Pressure transducer, thermocouple, DCDT, strain gage and accelerometer readings will also be recorded under the following conditions:
8.8.1 One minute prior to startup of first main feedwater pump continuing until both steam generator 1 and 3
8.8.2 8.8.3 8.8.4 are on main feedwater and the flow has stabilized according to judgment of test consultant.
During power ascens ion, every 10/~ - 2I of power level up until startup of second,feedwater pump, for at least three minutes ~t each level.
From one minute prior to startup of the second feedwater pump until stable conditions are met after pump start, according to judgement of test consultant.
During continuation of power ascension every 10/~ -
2I~o power level until full power, for at least three minutes.
8.8.5 From one minute prior to turbine valve seguence test for main stop valves until stable conditions are met according to judgement of test consultant.
8.8.6 For three minutes every hour at full load or during any one hour period that the system is maintained at steady state.
Full load will be considered as any load anywhere above 3200 MWth 8".9 Trip reactor according to plant procedures.
Record pressure transducer, thermooouple, D('DT, strain gage and accelerometer readings one minute prior to reactor. trip and continue until readings have stabilized according to judgement of test consultant
G.loThe test consultant may decide, at his own di cretion, to record instrumentation readings at any time during the test period.
IP GENERATOR tiOZZLE ARP ELBOM STRAIN GAGE ANO THERHOCOUPL'E INSTALLATION PROCEDURE aa-T'Cm P-a7.+.
2.
3.
5.
6.
Layout the strain gage and. thermocouple locations in accordance with the AEP sketches.
Mark the locations centerlines using a magic marker.
Smooth and polish the surface at each. Iocation using an 80-100 grit'isc.
grinder with a rubber backing disc..
An area approximately 4 inches in diameter is'equired for each strain gage.
An area. approximately I'nch in diameter.is required, for the thermocouples..
Layout the.. locations again and mark the centerlines with a penci1.
Clean the metal surface: using a tissue wet with an industrial cleaner..
(Solvent)
Set up the-resistance spot welder for an energy level of 10-12 Matt seconds.
Test the welder by making one spot at the corner o'f a test sample provided with the strain gages.
Remove the test sample by pulling with pliers.,
A clean hoIe approximately
.020 inches in dia-meter should be observed in the test. sample.
0 Position the strain gage: over the centerlines and align the strain gage.
Tack the strain gage to. the surface using. one spot weld at one end of.
the. strain. gage=.
Check.the gage alignment and adjust if necessary.
Continue the spot welding until completed, in accordance with the.
manufacturers'ecommendations.
9.
10.
Align and spot weld ceramic terminals at each end of the strain gages.
Connect'he nichrome foil strain gage leads to the terminals and check the strain gage for continuity and leakage.
Complete the Mheatstone bridge circuit wiring and again check continuity and leakage.
Attach the cable leads.to the terminals and make the. final continuity and leakage check.,
Thermocouple Installation Following Step 5:
12.
Strip the-thermocouple leads for a length of 3; inch and spread the leads apart from each other.
13.
Using the flat face of a small ball peen hammer.flatte'n the leads to a
thickness of approximately
.015 inches.
14.
15.
Position the two thermocouples leads each side of the Iocation and at I/16'nch spacing and spot weld, the leads. to the surface using several spots.
Check the thermocoupIe operation using a potentiometer.
02"THHP"O'P.4'. 2 CALIBRATION PBOCEDUEP ectrical Shunt Calibration for strain ~a~es:
lL'croinch/inch =
Hx 10
~G.P.
B.P.
H~~ ~sh)
H'.P.:
B.P.:
Bsh:
gage resistance gage factor Bridge factor Shunt resisto A resistor is used to shunt one arm of the wheatstone br'dge to simul te the si;rain.
The value is calculated by using the above stated formula.
Typical values for ti e shunt re i tors are
- 121K, 2'-:3K, 499K etc.
Nben one arm of ti e stra'n gage bridge is shunted, a step functior is observed on the osci"lo~raph By measurin"-. the deflection calibration value in. ter:~s cf r icro"nches/
inch pcr inch of deflection is determined. strain is converted in to stress by usin. appropriate modulus of elasticity.
U.C.D.T. Calibration Using holding jig equipped with micrometer-Mjust; DCDT in the fixture so that Digital Volt:ieter (DVii) reads 0 volts ~
II 1love micrometer
+-1" in steps of 0.25 and note down the DVif read-ing.
Use linear regression to determine the calibration value in incnes per volt.
Pressure Cells Calibration:
All pressure cells will be calibrated in the laboratory using dead weight pressure tester.
Only electrical. calibration will be performed prior to testing.
Procedure will be the same as that of strain gage calibration.
Accelerometer Calibration:
Accelerometers will be calibrated by placing the accelerometer such that its sensitive axis is vertical.
ifote down the reading.
Turn the accelerometer upside down and note down the reading.
Determine the ca1ibration in terms of microinches/inch per "g".
Electrical calibration will be performed prior to testing same as that of strain gages.
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02"TEMP-0'7.4'. 2 INSTALLATION PROCEDURE FOH PROTECTIVE COVERS After completion of the strain gage installation Zc cable hook up~
clean the surrounding area of the size of a protective cover ~rich an approved cleaner.
Place the cover over installation so that the cables from strain gages come out thru the side hole and then cement it do~rn :rith a high temperature epoxy cement.
Tack veld small strips of shim stock (0.003") to the cover and.
pipe (use same spot ~>elder as for gages).
Band. the covers on to the pipe during epoxy cure if necessary.
A.E.P.S.C.
- M.EJl.
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