Text

Forwards Addl Info to 790712 Response to IE Bulletin 79-13. Discussion & Charts Encl Re Feedwater Sys Design,Fabrication History,Preservice & Inservice Insp,Feedwater Chemistry & Metallurgical Evaluation
	ML18079A996
Person / Time
Site:	Salem
Issue date:	08/24/1979
From:	Schneider F; Public Service Enterprise Group
To:	Grier B; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
References
	NUDOCS 7909290417
	Download: ML18079A996 (73)
	v • d • e

{{#Wiki_filter:" Frederick W. Sch.neider Vice President Public Service Electric and Gas Company 80 Park Place Newark, N.J. 07101 201 /430-7373 Production ' Mr. Boyce H. Grier, Director U.S. Nuclear Regulatory Commission Office of Inspection and Enforcement Region 1 631 Park Avenue King of Prussia, Pennsylvania l9406

Dear Mr. Grier:

NRC IE BULLETIN NO. 79-l3 NO. 1 UNIT SALEM GENERATING STATION August 24, l979 Pursuant to our initial response of July 12, l979 addressing items 5.a, 5.b and 5.c of the subject bulletin, the attached report addressing the balance of the bulletin items is hereby submitted for your review. The attached submi tta.l also contains information that was presented to the NRC on July l2, 1979, at Silver Springs, Maryland. If you require additional information, we will be pleased to discuss it with you. Sincerely, Attach. CC: NRC Office of Inspection and Enforcement Division of Reactor Operations Inspection Washington, D.C. Mr. L. J. Norrholm NRC, Hancocks Bridge, N.J.

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1)

Feedwater System Design A) As Built Configuration B) Design - Thermal and Seismic Analysis

2)

Fabrication History A) Materials B) - Welding History and Fabrication NDE C) Applicable Codes and Toughness Requirements

3)

Preservice and Inservice Inspection A) Preservice Inspection B) Inservice Inspection

4)

Feedwater Chemistry A) Hist6ry and Corrective Action

5)

Diagnostic Non-Destructive Examination A) Progra~:Description and Result~

6)

Metallurgical.Evaluation A) Westinghouse Evaluation B) Owners Evaluation

7)

Stress Analysis A) Westinghouse Stress Analysis B) Owners Stress Analysis

8)

Corrective Action A) Repair'Description B} Nozzle-Pitting Repairs C} Future NDE D) Instrumentation - Description '\\

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h) S~fe~y Evaluation B) ~estinghouse Owners Group

A) As Built Configuration Isometric drawings (see Attachment 1) of each steam generator feedwater pipeline from the containment wall to the steam gen-erator nozzle sho.w the des_ign,. dimensions, pipe schedules, support types, location and pipe restraints. There are no in-line valves in this section of the feedwater piping. The steam generator sparger is internal with no weld attachment to the steam generator nozzle. The sparger has J-tubes attached to the sparger header for flow distribution. There have been no reports of water hammer occurring since the unit has been in service. The feed rate is limited to increasing steam generator levels to 1.2" per minute on the wide range if steam generator levels are below the level of the feedwater sparger. B) Thermal and Seismic Analysis During Design A summary of the most significant pressure, weight,.thermal and seismic stress values, based on the original plant design, _is included in Attachment 1. (See Attachments 1-6, 1-12, 1-18, and 1-24.) The stress point numbers shown in these tables relate to points on the isometric drawings in Attachment l~ The results of the stress analyses have been confirmed inde-pendently by~Westinghouse Electric Corporation and. they do not indicate any apparent cause for failure.

t t---- (f 2 - The construction materials used for various portions of the steam generator feed system are as.follows: a) The steam generator sparger is Carbon Steel. b) The steam generator feed nozzle is ASME SA 508 Grade 2 S*teel. c) Materials for other portions of the piping.system are included in Attachment 1. (See Attachments 1-5, 1-11, 1-17, and 1-23.) The letters on the extreme left of these tabulations relate to letters marked on the isometric._ drawings which show the relative location of this material in the piping system. B) Welding History and NOE During Fabrication Welding.details a~d NOE performed during fabrication are shown in Attachment 2. The relative locations of spool numbers and weld joint designations referenced in Attachment 2 are shown on the isometric sketches included in Attachment 1. C) Applicable Codes and Toughness Requirements The code edition for fabrication of feedwater piping within. the containment is ANSI B31. 7, 1969* Edition. The design code** for piping.is ANSI B31.l.O, 1967 Edition. There were no fracture toughness requirements imposed on this piping.

I 11 12 13 14 3 - ~) PreBervice Inspection The Preservice I~spection of the feedwater piping (Nuclear Class 2) from feed~ater stop check valve to Steam Generators Nos. 11, 12, 13, and 14 were examined in accordance with the 1971 Edition, Winter 1972 Addenda of the ASME B&PV Code, Section XI. The following is the extent of PSI of the welds involved. Weld numbers are identified in Attachments 3, 4, 5, and 6. Total Circumferential Wel'ds (Both Fabricator & Field Welds) 18 19 24 16 Welds Examined 8 8 10 7 B) Inservice Inspec~ion Note Did not examine 14-BF-2111-18 (reducer to nozzle weld). Did examine 14-BF-2121-19 (re-ducer to nozzle weld). No UT from nozzle side due to nozzle configuration. Three (3) indica-tioris resolved as geometry. Did examine 14-BF-2131-24 (elbow to nozzle). No UT from downstream side due to nozzle configuration. Ten (10) indications resolved as root geometry. Exam did not include 14-BF-2141-

16.

During the second ISI (first refueling) outage, two BF circurn-ferential welds in Loop 11 were examined. They were:

~. ---. - 4 - l) l4-EF-Lll~-3 . 2) I 14-BF-2111-~ Results: 14-BF-2111-3 MT - No indications (special examination). UT - Two indications upstream of weld re-solved as geometric. No examination downstream due to pipe configuration. 14-BF-2111-4 UT - Seven indications downstream of weld resolved as geometric. No examination upstream due to pipe configuration. Corrective Action: Norte required. Four BF circumferential welds are scheduled for examination during the first ISI Interval (7-1~79 to 6-30-81)

One examination (14-BF-2111-

4) has been compl~ted for ISI.

One examination (14-BF-2111-3) has been completed as a supplemental exam for investigation of heat treatment results during constructiono Presently scheduled per ten year plan: 14-BF-2111-4 Completed se*cond Outage 1979 14-BF-2121-16 Scheduled 1982 Outage 14-BF-2131-19 Scheduled 1985 Outage 14-BF-2141-3 Scheduled 1985 Outage I I I

5 - hs a result of an NRC letter aated May 25, 1979, and* NRC Bulletin 79-13, the following Welds have been examined: llBF Loop 14-BF-2111(18) & 14-BF-2111(17) 12BF Loop 14-BF-2121(19) & 14-BF-2121(18) 13BF Loop 14-BF-2131(24) & 14-BF-2131(23) 14BF Loop 14-BF-2141(16) & 14-BF-2141(15) Preliminary Results: Confirmed indications on 14-BF-2111(18), 14-BF-2131(24), and 14-BF-2141(16). Suspect indications not resolved on 14-BF-2121(19). See Section 6 for Metallurgical Examination results.

6.::. A) Eisto~y ~~a Corr~ctive hction A review of the feedwater chemistry indicates two areas of concern that are discusseq below that will be resolved during the present refueling outage. But, at this point in time, no relation can be established between these two areas and the pipe cracking mechanism. Condenser In-Leakage Between initial operation in December, 1976 and July, 1978, only minor isolated condenser leaks were encountered. After July, 1978, condenser leaks were encountered on a daily basis. The steam generator chemistry increased beyond the normal operating levels, but were within the Westinghouse limiting specifications for steam generator chemistry. Correcti~e Action

1)

Retube Condenser AL-6X.

2)

Install full flow condensate polishing systems.

3)

Install the capability to recirculate the feedwate~ and condensate water through the condensate polishing system. Dissolved Oxygen The dissolved ox~gen levels *in the feedwater have been higher than normal since initial operation. When the unit was re-turned to service after the spring outage of 1978, the dis-

inc::-Ec.s,2C lcvi::ls ~ersisted until the unit was removed from servic~ ~or the present refueling outage. Corrective Action

1)

Full head hydrostatic test in June, 1979, with an intense survey for leaks.

2)

Instituted strong administrative controls relating to levels of actions to be taken as a result of high dis-solved oxygen levels in the condensate or high condenser air leakage.

3)

Completed several DCR's duiing the present refueling -outage tb improve the air removal capabilities of the condenser. 11 ',, i I J, i

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5)

D:.::.G:~OSTIC i;m~-DE.STRLJCTIVE E/:h!*:n;;._TIO:; YIJ A) Program Description and Results As a result of the report of a through-wall leak evidenced in the area of the st~am generator feedwater nozzle to piping connection at another utility, PSE&G examined the corresponding area of its *No. ~ Unit, No. 13 Stearn Generator. This examination by radiography (RT) revealed crack-like indications. RT was then undertaken on the feedwater nozzle to pipe fitting weld and adjacent base material on Nos. 11, 12, 13, and 14 Stearn Generators. Concurrently, an ultrasonic examination (UT) was initiated tC? supplement RT fi_ndings. Crack-like indica-tions were revealed by RT and UT in Nos. 11, 13, and 14 Stearn Generator feedwater nozzle to pipe fitting weld areas. UT indications were noted in* the corresponding area of No. 12 Steam Generator, but were not evidenced by RT in that same area. Upon receipt of IE Bulletin 79-13, dated June 25, 1979, PSE&G initiated a program to volumetrically RT examine the weldrnents and adjoining base material in the feedwater system on No. 1 Unit at Salem Generating Station. This RT examination program was in.compliance with Item 2a on Page 3 of 4 of Bulletin 79-13. RT, using a double wall technique, viewing one wall to two (2) T sensitivity has been completed as far as practicable. There were no indications of a reportable nature evidenced in this

9 - exa~ination ~~0~~am. The list, noted below, and Attach~ents ~-- 3, 4, 5, and G, feedwater piping system isom~trics, identify the welds where RT was either limited or not undertaken and the reason for the action taken. Steam Generator (Feedwater System) Weld Number Remarks No. 11 No. 12 No. 14 Nos. 11, 12, 13, and 14 12. 5, 6, 7 & 8 13 18 10 5 Aux. Feed Nozzle to feedwater piping -attachment weld. Limited RT on elbow side due~to pipe restraint. No RT due to baffle ar-rangement surrounding these welds. Limited RT on elbow side due to pipe restraint. Limited RT on elbow side due to pipe restraint. Limited RT on elbow.side due to pipe restraint. Limited RT du*e to hanger clamp. Magnetic p~rticle exami-nation only. No RT.

Note -

RT examination of a pipe diameter downstream of the No. 12 auxiliary feedwater connection could not.be accomplished since the section could not be drained. In compliance with Item 2c on Page 3 of 4 of Bulletin 79-13, PSE&G will conduct a visual examination o~ the feedwater piping system hangers and snubbers on the Nos. 11, 12, 13, and 14 Steam Generators. This examination program will be conducted upon completion of welding

r 10 - .e I r!~*\\,*-~ fit t.i~~ s i)osition. Inspec~~G~E ~ill be done ~ith a full pipe in the cold and hot condition. I I I I I

11 - h) ~estingh0use Evaluation Westinghouse examined the cracked feedwater pipe sections of Loops 1, 2, 3, and 4 of Unit No. 1, Salem Generating Station. A.completeiring section, identified as being from Loop 4, was examined at.Westinghouse R&D Center by RT, UT, Standard Metal-lography, and both Scanning and Transmission Electron Microscopy. In addition, the corrosion products on the fracture surface were

analyzed by EDAX (Energy Disperson Analysis by X-Ray).

Mechani-

cal testing (Charpy*and Tensile) and chemical analysis of the reducer material were obtained.

The ring section was examined ultrasonically from the cut face through the weldment. The deepest crack penetration was at a section change in the feedwater piping where the Schedule 100 fitting had been counter-bored to match the Schedule 60 nozzle. The deepest crack measured 0.*120 inches. A few cracks were found on the straight pipe *section. The cracks were generally straight and without side branching. The microscopic tests revealed beachmarks. Although they were extremely hard to identify as striations, preliminary assessment indicates striation spacing in the order of 1 to 3 micro-inches~ Preliminary conclusion is that the probable cause was corrosion assisted fatigue. EDAX of the as-received fracture surfaces indicated the presence of iron and aluminum. I: ii I

12 - Following are sc~e of the results obtained from the mechanical testing and ch~~ical analysis of the rinG section:

1)

The chemistry of the steel conforms to ASTM Specification Al06, Grae: c with carbon being 0.26% and Vm 0.89%.

2)

The tensile strength was 69 ksi at room temperature and 64 ksi at 440°F. The corresponding yield strengths were 38 ksi and 28 ksi. Reduced size specimens were used ih completing these mechanical tests.

3)

The ductile-brittle transition temperature was near 30°F. Typical Charpy impact values were 7 ft-lbs at -50°F, 146 ft-lbs at room temperature and 1,.62 ft-lbs at 440°F. Ring sections identified as being from Loops 1, 2, and 3 were examined by metallography. Cracks similar in nature to those found in Loop 4 were observed. Generally, the cracks were very small, the crack depth being of the order of 0.025 inches. However,.in Loop 1, a crack 0.120 inches was observed at the counterbore. This crack w~s very similar in appearance to the deepest penetration found in Loop 4. This crack was gen-erally straight and without.side *branching. As with the cracks in Loop 4., it can be *concluded that propag_ation was due to corrosi~n assisted fatigue. UR.on fi.nalization *of the Westing-house Metallurgical Evaluation, PSE&G will forward one copy to the NRC, Region I. I

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o~~ers Evaluation Mstallurgical investigations performed by WestinghoU$e at their R&D Center have confirmed the existence of circumf er-ential cracks in all four loops and~indicated them to have been caused by cyclic stresses assisted or accompanied by corrosion.

In all cases, the cracks were located in the counterbore region of the carbon steel fitting (A-234 Gr WPC or A-106 Gr C) adjacent to the feedwater nozzle circumferen-tial buttweld. Maximum.crack depths of approximately 0.120" were observed in the No. 14 and No. 11 reducers, and cracks of up to approximately.060" and.020" deep were observed in the No. 13 elbow and No. 12 reducer, respectively. All cracks examined to date have been.straight, nonbranching, perpendicular to the ID surface, filled with oxide, and probably transgranular. Fractographic studies of a cracked specimen from the No. 14 reducer show beach marks or arrest iines at low magnification. Striations could not be confirmed with a scanning electron microscope, but the geometry of the cracks and their surface appearance, e.g., short, somewhat aligned, 0 but discontinuous, suggests that*thermal fatigue is the dominant causal mechanism. Minor pitting was observed in the fitting counterbore region, but not necessarily associated with the cracking and to a lesser extent and depth than pitting observed in the A-508 Class 2 nozzles where little or no cracking has occurred. ' i'

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~... ~-*--~ f--.......... l.....i::....~:.:., A) Vendor Str~ss Analysis Re~ort The following report was prepared by Westinghouse Electric Corporation. Preliminary results from this analysis reveal no significant cause for failure. Stress analyses were performed on the feedwater line conf ig-uration in an effort to determine the mechanism causing the observed cracking. The analyses were broken into three parts:

1)

Structural analyses of the feedwater line, including the effects,of thermal, deadweight, and pressureo

2) 20 finite element fatigue analysis of the feedwater nozzle/elbow configuration.

3)

Frequency analyses of the feedwater line. The structural analysis was performed using a 3D finite element model of the feedwater line with anchors included at the steam generator (SG) and containment penetration and the vertical and horizontal thermal growth of the SG applied at the £eedwater nozzle. The WESTDYN7 computer code was used for the analysis. The geometry generally consists of the feedwater nozzle with a 16" Schedule 60 end prep, which is connected to a 16"* x 14" Schedule 80 reducer. Each 14" Schedule 80 piping run then contains a minimum of two 16" Schedule 160 long radius elbows in addition to the regular 14" Schedule 80 elbows. The pipe ** travels horizontally from a loop seal arrangement to an approx-

l 15 - i:-r1ote 40' V'2Y-:.~:::~} crop, then horizo:-itc.lly 35 fE:St to t!"-.t.:: ccr,- tainrnent p~netr~tion. Supports consist of deadweight spring hangers only. Two thermal conditions were run. The first with the SG at 550°F and the feedwater line at 470°F, representing normal operation. The second with the SG at 550°F and the feedwater line cold, representing the hot shutdown condition. The analyses results show a maximum thermal stress of approximately 13.5 ksi at the nozzle to pipe junction. The maximum deadweight and pressure stresses were.8 ksi and 11.7 ksi, respectively. These stresses are below code allowable values. The attached sketch shows the basic geometry and the stresses in the feed-water pip~ng. The second analysis performed was a detailed 20 finite element cfatigue analysis of the most severe thermal transient, which occurred during hot shutdown, in the region of the feedwater nozzle to short radius elbow junction.. The analysis used the WECAN computer code and the rules of ASME Section III, NB-3200. The model used constant strain quadralaterial elements with a minimum of 8 nodes through the wall and ran from the SG shell to JO" beyond:the nozzle to elb6w weld. The transient analyzed consisted of a ramp.change in temperature from 550°F to G0°F in.9. seconds, followed by a period of con-stant G0°F operation, ;flow velocity.38 ft/sec. This represents the injection of auxiliary feedwater* into the feedwater nozzle/

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16 - elb~~ j~nction, which has b~e~ hea~~d by the SG durins ths hot ~ sta~~by condition. When thE auxiliary feedwater is terminated, a step change in temperature is assumed from 60°F to 550°F. This represents the conservative assumption of a leaking check valve in the feedwater system, which allows water to flow from the SG to the feedwater line and assumes no mixing of auxiliary feedwater with water in the SG. The maximum peak stress range obtained from this transient was 60 ksi, which is then multiplied by a conservative factor of 1.7 to account for the detailed affect of the "notch" at the elbow counterbore. This peak stress range of 102 ksi yields an

allowable 5000 cycles using the ASME Section III S/N curves.

The design transients given in the SG E-Spec has shown ac-ceptable values of usage factors for the feedwater nozzle. Correspondingly, analysis of the nozzle to elbow junction will have an acceptable value of usage factor since the thermal transient stresses. are lower at this junction than in the nozzle. The final analysis performed was a frequency analysis of the feedwater line. The following table summarizes the line fre-quencies less than 10 Hz. These frequencies are in the same range as those found for the SG in the ~eactor coolant loop ~~ oth~r ~estinghouse plants. W testirig of other plan~s has shown that the SG vibrates in its fundamental modes due to flow in the reactor coolant loop. I q I: ~ ~ 1

FEED'*;.:-.TER 1 (j h z LINE FREQUENCIES(HZ) Loop 1

3. 3 6, 4. 6 3, 6.61, 7. 6 8, 9.99 Loop 2

2. 2, 3. 39, 4.92, 5.81, 6.96 Loop 3 2.48, 4.14, 5.19, 7.72, 8.92, 9.36 Loop 4 2.34 I 3.59,.4. 61, 7.05, 8.51, 9.42 Upon finalization of this Westinghouse Stress Analysis Report, PSE&G will forward one copy to the NRC, Region I.

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0,* u) '-~ . ~ : 18 - A) Re~~ir Descri?tion The corrective action taken to the Nos. 11, 12, 13, and 14 Stearn Generator feedwater nozzle to pipe fittings was as follows: a) The piping system in the immediate area was secured b) to prevent any translation or rotation after cutting. This was followed by a dimensioning and marking, in-eluding location and orientation, with reference to the existing steel. The preceeding was accomplished to assure proper placement of the piping after removal of the fitting and machining of weld end preparations. The respective fittings were cut _..from the piping system in a manner to preserve the RT and UT indications. The fittings once removed were retained for a metallurgical examination. c)

A visual and liquid penetrant examination of the nozzle d)

ID surface, back to the thermal.sleeve, w~s made. The areas of *shallow pitting evidenced in this examination were removed and are addressed under "Nozzle Repairs". Newly machined weld end preparations and counterbore areas on both ~he nozzLe and piping, inclbding those of the new replacement fittings, were given a visual and liquid penetrant examination. ... ---*--**-----=-----,.,..--*- -** --*-**-*-.::--*----*- -**------ -~=-- ~------*~****------- -** **-*- ------****.. -~~--**- --

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L. .-..:..~-.._.._, _____ ~.,.__ ___.. 19 - e) Fit-up of each new fitting was accomplished using the Salem Gen~rating Station Maintenance Manual. Welding of the nozzle to fitting was carried out in accordance with a welding procedure specification qualified for this repair. The fitti~g to existing pipe weld was made to previously qualified procedures. The new material is AlOS Gr 2. f) The new welds were of a consumable insert root type with two (2) layers of GTAW over the consumed ring. The remainder of the weldrnent was completed using SMAW. The filler metal used was 7018. g) ~ostweld heat treatment of the finished nozzle to fitting welds was completed as soon as possible after completion of welding. The preheat was maintained until postweld heat treatment was initiated. h) Weld r~inforcements were dressed to provided surfaces suitable for volumetric examination by RT and UT. i) RT and UT will be completed on the new butt welds prior to No. 1 Unit returning to service. j). Authorized Inspection Agency coverage for this repair program was provided. To provide assurance of integrity of the newly installed \\ pressure boundary fittings and associated weldments in the Nos. 11, 12, 13~:. and 14 Steam Generato*:r* feedwater piping systems of the No. 1 Unit, a leak test will be conducted. i' : i I .I "I I i

~--- ___....:.. ------------ - -

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20 - { l .i Th~ t~st will be perform~d at hot standby conditions of 1005 ?sis saturated +/- 15 psig prior to returning the unit to se:r-vice. The test will consist of a visual examination for leakage of the new fittings and weldments without the presence of insulation. The test and examination period will commence after the first hour at the required presstire and stabilized conditions prevail. The validity of a leak test was discussed with Mr. J. Collins, I&E NRC on August 2, 1979. A leak test was deemed sufficient, based on the following justifications: lf Technical Manual instructions received from Westinghouse limit the steam generator shell to 5 Hydrostatic Tests.

2)

An extensive and comprehensive repair NDE Program has

been performed.

3)

Other *utilities* {Kewaunee) received approval for this type of test..

4).

The leak test satisfies the intent of the repair program. B) Nozzle Pitting Repairs A visual examination of the ID surf ace of the feedwater nozzles on Nos. 11, 12, 13, and 14 Steam Generators was performed after the removal of piping system fittings to be replaced. I I j

1.. 1!,,,, Ii j ii I' 1'

~---------**--- ---------------

21 - The c~~reinati0~ reve&l~d areas of shallow pitting,. -, ""' 20-30 mils c;;;:e:::*. These areas were less extensive on the upper half of the nozzle ID surface. Removat of the pitting was accomplished by a combination of machining using a boring tool and blending using a rotating abrasive paper wheel. The nozzle ID surf ace of the four steam generators was examined by liquid penetrant after machining and blending, no reportable indications were evidenced. Verification of the nozzle minimum wall thickness was achieved by mechanical measurements. No weld repairs to the feedwater nozzles were required. C) Future NDE Requirements The new butt welds of the steam generator f eedwater nozzle to fitting and fitting to pipe in the Nos. 11, ~2, 13, and 14 Steam Generator feedwater system will be examined by RT and UT during the next refueling outage. D) Instrumentation The Nos. 13 and 14 Steam Generator feedwater ?iping inside the containment building will be instrumented prior to start-up and monitored during plant operation. The purpose of such monitoring is to obtain data to characterize the thermal re-sponse and pressure variation of the feedwater piping due to ~*----.---.-*~ *-***-*-*

- -;------~*-----~*...

-~---------'--- -----

I 22 - various operational modes of the feed~ater system. The test o~jec~ive will be achieved by monitoring the system perform-ance of the f eedwater piping at preselected locations using thermocouples and pressure transducers at selected locations inside and outside of the feedwater piping from the steam gen-erator nozzle'to the first vertical run of piping. The mea-sured parameters will be recorded during various modes of system operation and will be reduced to provide information for evaluation of the piping region adjacent to the steam generator nozzle.

i 1

i.

i .J. .. 1

~

~*

23 -

9) '

XE!~7 EVALUZ~TION A)

Safety Evaluation The replacement of the cracked portions of the feedwater lines is being accomplished using the same design with similar materials and welding procedures as were used during the construction of the plant. As such, the probability of occurrence of the conse-quences of an accident or malfunction of equipment important to safety previously evaluated in the safety analysis report, has not been increased, the possibility for an accident or malfunction of a different type than any evaluated previously in the safety analysis report has not been created and the margin of safety as defined in the basis for any technical specification has not been reduced. We, therefore, conclude that this pipe crack re-pair is not an unreviewed safety question. We do, however, recognize that the cause of these feedwater pipe cracks is not adequately understood such that a complete program of corrective measures to preclude their reoccurrence can be* taken at this time. We have joined the Westinghouse Owners Group on this subject and will remain active in the effort to identify the cause and take appropriate corrective action, based on t~e study results. Section 9B of this report describes the Westinghouse Owners Group effort. B) Westinghouse Owners Group - Problem Summary Westinghouse is actively involved in the investigation, analysis, and licensing support of the feedwater pipe cracking, which has ... ---~---~~.*-*------------*..... ---.. ----*-***--~-- *--------.*-**--* ------------***-**-.. ------*----- ****-*---*-----**-*

- -------~~-___,,__ _________.._.:;.,.._.... __

-'-~-*...;--~----

24 -~ occurred o~ s~~~ral units. As a result of t~is involvement, Kestinghouse has developed a detailed progra~ to address the Nuclear Resulatory Commission (NRC) concerns while, at the same time, allowing the plant.to return to power operation as soon as replacement parts are installed. The program objectives are summarized as follows:

1)

Perform metallurgic~l evaluation to determine mechanisms of cracking and provide field support as required (i.e., removal of pieces, repair, replacement, inspection, etc.).

2)

Perform stress analysis to determine system base line stress for normal operating condition to support plant operation.

3)

Determine plant modifications required to return to power_ and associated licensing support.

4)

Detailed evaluation (metallurgical,* stress, system oper-ation, and chemistry) into the cause of the problem and determination of design modifications to effect a perma-nent solution. The program contains three major categories and consists of six work phases, as follows: I. Plant Specific Evaluations - Phases A, B, C and D. II. Near-Term Effort ~ Phase~ E and F. III. Other Considerations I., i

-*-*--"~--:::..~;...... __

r--* --!.l....~:. ___,: __ _:

i .! l

, ~

25 - Ph&s~ A includes the metallurgical evaluation to determine the mechanisms of cracking and the field support required. Phase B entail~ the acquisition of operating data, both thermal and mechanical transients, to be used in the following phases. Phase C involves the stress analysis required to provide.a sys*tem base line and provide information to the NRC to allow plant startup. Phase D pertains to licensing support and an evaluation of the results and conclusions from Phases A, B, and C. At this point it is anticipated that the plant will be returned to operation after repair while more detailed and longer ~ange evaluations proceed. Near-Term Effort Phase E is devoted to determining the.actual cause of the problem. This phase is designed to investigate each of the following areas on a generic basis, with the expectation of eliminating certain of these items as a possible cause: System vibration/resonance Flo~ regions causing high thermal stress Operating transients (thermal and mechanical)' Chemistry Material behavior~

=--- -------*-....

~*-* - - ~----- -- - - -- -~-...... -~- 26 - P~aEe F ~ill address and define design modifications which resul~ from the preceding phases. Other Considerations This effort will address the desirability to instrument and mon-itor the feedwater lines to provide additional data in deterrninin~ the mechanism of cracking. Westinghouse would develop a complete test program, including supervision of equipment installation. i

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REFERENCE ORAWIMGS ARRGT._

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SMAW 60 ll l-SGF-45 B (ATTACH)

SMAW 60 11 Field Weld SGF-45-240 (BWI)

GTl\\W-Root: 175 Root 1150-1200 11 11 11 11 11 11 11 11 11 11 11 )TES: l-SGF-46 l-SGF-46 l-SGF-46 l-SGF-46 Field Weld l-SGF-47 Field Weld Field Weld l-SGF-48A RW l-SGF-48A RW l-SGF-48A RW SMAW-Dal. 400 Bal. A (BW) GTAW-Root: SAW and SMAW Dal. B (BW) Ditto C (BW) Ditto D (WBU) SMAW, SAW SGF-46-258 (BWI) GTAW-Root; SMAW-DCll. A (BW) GTAW-Root: SAW and SMAW Ba 1. SGF-47-268 (BWI) GTAW-Root: SMAW-na 1. SGF-48A-52B '(BWI) GTAW-Root: C (BW) . B (WBU) E ( BWI) SMAW-Bal. GTAW-Root: SAW and SMAW-Ilal

SAW GTAW-Root: SAW and SMAW Bal.

200 60 60 175 175 60 175 175 200 175 50 1100-1250 1100-1250 1100-1250 1100-1250 1100-1250 1100-1250 1100-1250 1100-1250 (l)Ref~rence NRC request for info on PWR Feedwater Lines dated 5/25/79. MT MT RT Clncl MT RT Clncl MT RT C\\ncl MT RT and MT RT and MT RT and MT RT and MT RT and MT RT nnd MT RT ilnd M'r RT ancl MT RT and MT (2) (ATTACH) =Attachment Weld: (B.W.) = Circ. Single Butt Weld No Backing Ring: (n.w.r) = Circ. Single Butt Weld with ConR. Insert: (w.n.u.) =Weld Build-Up (J)Shop Weld Filler Materials: GTAW-E70S-2: SMAW-E7018: SAW-F72-EM12K. <4 >Field Weld Filler Materials: GTAW-EB Insert MSl~ SMAW-E7010 (Except as notrd). -~====~****i* **I [

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STr'.J\\M GENgRATOn FF:lm PIPE FIELD AND -5, ioP -w*.i*~I~D '"j7J\\nRICAi'ION_J.lIS'rORY-nT -- *~*--.. -*-----------*--*--- JOINT ID. (2 ) WE~D PROCESS(ES) (°F) =.:rF.AM:::.::..:.....:::G~EN::.=..:.*-:N:.:..0:::..:-*; -t--==S=P...;::0:..::.0..;;;;L;...;;.;,N...;;.O...... -~WELD TYP E':!.1.-----1-----.:.(..:::;.J.!.,) _..l.,( 4~) ---i--=P:..::.R=EHEA T (OF) POSTIIE/\\T 11 l-SGF.. 48A F (BWI) GTAW-Root1 SAW 50 1100-1250 11 11 11 11 11 13 13 13 13 13 13 13 RW and SMAW Bal. l-SGF-48A G (BWI) GTAW Root: 50 1100-1250 RW SMJ\\W Bal. l-SGF-48A H (BWI) GTAW Root: 50 1100-1250 RW SMJ\\W Dal. l-SGF-48A K (BWI) GTAW Root; 200 1100-1250 RW SMAW Bal. l-SGF-48A J (WBU) SAW 175 1100-1250 RW Field Weld SGF-48A-27B (BWI) GTAW Root;. 175 Root 1100-1150 l-SGF-62 l-SGF-62 Field Weld l-SGF~63 l-SGF-63 Field Weld l-SGF-64 A (ATTACH) B (ATTACH) SGF-62-34B. (BWI) A (BW) B. (WBU) SGF-63-35B-A-1 (DWI) A (BW) SMAW Bal. (E8018C3 250 Bal. SMAW SMAW GTAW-Root1 SMAW-Bal. GTAW-Root:. SAW and SMAW-Bal. SMA, SAW GTAW-Root: SMAW-Bal. GTAW-Root: SAW and SMAW-Bal. 60 60 175 200 1100-1250 175 1100-1250 175 Root 1150-1200 400 Bal. 60 1100-1250 OTES: (!)Reference NRC request for info on PWR Feedwater Lines dated 5/25/79. FINISHF.D wr.Ln J.T. NPE I ---1 RT <lnd.MT _ RT and MT RT and MT RT and MT RT and P'r and MT RT and MT MT MT RT and MT RT and MT RT and MT RT and MT RT and MT (2) (ATTACH) =-Attachment Weld1 (B.W.) = Circ. Single Butt Weld No Backing Ring: (B.W.I)

== Circ. Single Butt Weld with Cons. Insert; (w.e.u.) =Weld nuild-Up <3) Shop Weld Filler Materials.: GTAW-E70S-2: SMAW-E7018: SAW-F72-*rn12K. (4 )Field Weld Filler Materials: GTAW-Ell Insert MSl1 SMl\\W-E7010 (F.xcr-pt an nnt*ril)

I

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WELD PROCESS(ES) (°F) (°F) FINISHED \\'/ELD 'EAM GEN* NO. SPOOL NO. WELD TYPE (3) (4) PREHF.AT POSTHEJ\\T J.T. NDS ..=...;;:...;,...-=::;;;~1~!~* -'--t--'-----------------t_.._ -=---~~-t----'-'...!---;_._..t----~-f-~ ~-----~

~~

13 l-SGF-64 B (BW) GTAW-Root; SAW 60 1100-1250 RT and MT and. SMAw-*aal. 13 13 13 13 13 13 13 13 l-SGF-64 Field Weld C (WBU) SAW SGF-64-368 (BWI) GTAW-Root: SMAW-Bal~ l-SGF-66RW A (WBU) SAW Field Weld SGF-65-378 (DWI) GTAW-Root; SM]'.\\W-Bal. l-SGF-66RW A ( BW) GTAW-Root: SAW and SMAW-Bal. l-SGF-66RW G (WBU) SAW SMAW, SAW 175 175 175 175 200 1100-12 50 . RT and MT RT and MT 1100-1250 RT and MT RT ancl MT 1100-1250 RT and MT 1100-1250 RT and MT RT and MT RT and MT

13. _..

1-SGF-GGRW l-SGF-66RW 1-SGF-66RW S (WBQ) W (WBU) Q (BW) SMAW, SAW GTAW.:.Root; SAW and SMAW-Bal. 175 175 175 200 1100-1250 1100-1250 1100-1250 RT and MT 13 l-SGF-66RW K (BW) 13 l-SGF-66RW T (BW) 13 l-SGF-66RW R ( BW). 13 l-SGF-66RW P (BWI) . GTAW-Root: SAW and SMAW-Bal. GTAW-Root; SMAW-Bal. GTAW-Root; SMAW-Bal. GTAW-Root: SMAW-. Bal. 200 1100-1250 RT and MT 200 1100-1250 RT and MT 200 1100-1250 RT and MT 175 1100-1250 RT and MT )TES: (1) Reference NRC req~est for info on PWR Feedwater Lines dated 5/25/79. <2> (ATI'ACH) =Attachment Weld: (B.W.) = Circ. Single Butt Weld No Backing Ring: (n.w.r) =

circ. Single Butt weld with Cons. Insert; (W.B.U.) =Weld Ruild-Up (J)Shop Weld Filler Materials: GTAW-E70S-2; SMAW-E7018: SAW-F72-EM12K.

<4 >Field Weld Filler ~aterials:.GTAW-EB Insert MSl; SMJ\\W-E7018 (Except as notrrl) * --:-k-. "m .... *-- --.. *---.. *---*--'--'*_.. _J ___..... L.. I I I I i I !'.'r I r. [' I I.t ' i t

JOINT ID (2) WELD PROCESS(ES) (3) (4) (OF) PREHEAT ~,. --~ --** --~ ---..... -. - -.' -**-.. :... ~*--*-*- *-* *----* *-....... -- -".. --- FIN IS IIE D WJ;!,D. *--.:. *-1 {OF) POSTHEJ\\T J.T. NOE __ i\\ l\\M GEN NO SPOOL NO WELD TYPE

~---------...~--~~---~t-"--'-'-

13 l-SGF-66RW D (WBU)* SAW GTAW-Root: 175 1100-1250 1100-1150 RT and MT 13 Field WeLd SGF-66-38B (BWI) 12 12 12 12 12 12 12 12 12 12 12 *' l-SGF-30 l-SGF-30 Field Weld., l-SGF-31 l-SGF-31 l-SGF-31 , l-SGF-31 Field Weld 1-SGF".'"32 l-SGF-32 A (ATTACH) B (ATTACH) SGF-30-168 (BWI) A (BW) B (BW) C (BW) D (WBU) SGF-31-17B (BWI) A (BW) B (BW) Field W~ld. SGF-32-lBB-A (BWI) SMAW-Bal. (E8018C3) SMAW SMAW GTAW-Root;. SMAW-Bal. GTAW-Root: SAW and SMAW-Bal. GTAW-Root: SAW and SMAW -Bal. GTAW-Root: SAW and SMAW-Bal. SAW GTAW-Root: SMAW-Bal. GTAW-Root; SAW and SMAW-Bal. GTAW-Root; SAW and SMAW-Bal. GTAW-Root; SMAW-Bal. 175 Root 250 Bal. 175 Root 400 Bal. 200 60 60 175 175 60

60.

175 1150-1200 1100-1250 '1100-1250 1100-1250 1100-1250 1100-1250 1100-1250

TES: (!)Reference NRC requ~st for info on PWR Feedwater Lines dated 5/25/79.

RT ancl M'l' MT MT RT and MT RT and M'r RT and MT RT and MT RT and M'r RT and MT RT and M'l' RT and MT RT and MT (2) (ATTACH) =Attachment Weld: (B.W.) = Circ. Single Butt Weld No Backing Ring: (B.W.I) ~ Circ. Single Butt Weld with Cons~ Insert; (W.B.U.) =Weld Build-Up (J)Shop'Weld Filler Materials: GTAW-E70S-2: SMAW-E7018; SAW-F72-EM12K. <4>Field Weld Filler Materials: GTAW-EB Insert MSl1 SMAW-E7018 (Except as notPd). I '._::L:: I

1 I

t t I I:I ir I i II i i I I I ! I I I I I

12 12 12 12 12 12 12 l-SGF-33A RW l-SGF-33A RW l-SGF-33A

RW l-SGF-33A RW l-SGF-33A RW l-SGF-33A RW l-SGF-33A RW JOINT ID (WELD TYPE)

SGF-33A-51B c (BW) B (WBU) E (BW) F (BWI) G (BWI) H (BW) K (BW) (2) GTAW-Root; SAW and SMJ\\W-Bal. GTAW-Root: SAW and SMAW-Bal. GTAW-Root: S_MAW-Bal. GTAW-Root: SMAW-Bal. GTAW-Root; SAW and SMAW-Bal. 200 175 so 50 50 50 200 FINISHED NF.J,D J.T. ' ~ NDE RT and M'l'. 1100-1250 RT and MT 1100-1250 RT and MT 1100-1250 RT and PT 1100,-1250 RT and PT 1100-1250 RT and PT 1100-1250 RT and PT 1100-1250 RT and PT - .\\ 1*.,, i \\_:. \\* 'i:

r.

i*, 12 l-SGF-33A RW J (WBU) SAW 175 1100-1250 RT and PT and MT 12 12 14 I .14 i l-SGF-33A RW Field Weld l-SGF,-14 l-SGF-14 AA (WBU) SMAW 60 1100-1250 SGF-33A-19B(BWI) GTAW-Root: 175 Root 1100-1150 A (ATTACH) B (ATTACH) SMAW-Bal. (E8018Cl 250 Bal. SMAW SMAW 60 60 RT a~d MT RT and MT MT MT I

>TES: * (!)Reference NRC request for info on PWR Feedwater Lines dated 5/25/79.

<2> (ATTACH)= Attachment Weld: (B.W.) =*Circ. Single Butt Weld No Backing Ring: (B.W.I) = Circ. Single Butt Weld with Cons. Insert: (W.B.U.) =Weld Build-Up (J)Shop Weld F~ller Materials: GTAW-E70S-2; SMAW-E70+~: SAW-F72-EM12K. <4>Field. Weld Filler *Materials:' GTAW-EB Insert MSl1 SMAW-E7018 (Except aR not:rd)

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. -,-.- *..,... --,I*******-**--*:*******-----~--~*--* ****-***-**.. -....... FINISHED WET.n J.T. NDF: JOINT ID (2) WELD PROCESS (ES) (°F) (°F)*

AM=-=-~G=EN~~*---N~O~__.S~P~O~O~L"-"-N~O~*---..__.W~ELD TY~P~E~---------------(3 ____ ~4_._ ____ --+.-.-.-PREHFA'--T.__i--P~O-S_T_HEJ\\_*_T

. l 14 Field Weld SGF-14-78 (DWI) GTAW-Root; 175 14 l-sGJr-15 A (BW) 14 l-SGF-15 B (WBU) SGF-15-BB(BWI) *.

.. /i4"/,1~;*. ** /_,-t

Ff~ld 'Weld 14 14 14 14 14 14 14 14 14 l-SGF-16 l-SGF-16 l-SGF-16 Field Weld A (BW)

B (BW} C (WBU) SGF-16-9B (BWI) Field Weld SGF-17-lOB(BWI) 1-SGF-lBRW A (BW) l-SGF-18RW C (WBU) l-SGF-18RW E (BWI) 1-SGF-lBRW F (BWI) SMAW-Dal. GTAW-Root: SAW and SMAW-Bal. SAW i,. ,l GTAW-Root; SMAW-Bal. GTAW-Root: SAW and SMAW-Bal~ GTAW-Root; SAW and SMAW-Bal. SMA, SAW GTAW-Root; SMAW-Bal. GTAW-Root: SMAW-Bal. GTAW-Root: SAW and SMAW-Bal. SAW GTAW-Root: SAW and SMAW-Bal. GTAW-Root: SAW and SMAW-Bal. 200 175 175 Root 250 Bal. 60 60 175 175 175 200 175 50 50 1100-1250 1100-1250 1150-1200 1100-1150 1100-1150 1100-1250 1100-1250 1100-1250 1100-1250 1100-1250 RT and M'l' RT and MT RT and M'r RT and MT. RT and MT RT and MT RT and MT RT and MT RT and MT RT and MT* RT and MT RT and MT RT and MT j :>TES1 (!)Reference NRC request for info on PWR Feedwater Lines dated 5/25/79. (2) (A'rl'ACH) *Attachment Weldf (B~W.) = Circ. Single Butt Weld No Backing Ring: (B.W.I) = Clrc~ Single Butt Weld with Cons. Insert: (W.B.U.) =Weld Build-Up (J) Shop Weld Filler Materials: GTAW-E70S-2.: SMAW-E7018; SAW-F72-D-tl2K. <4>Field Weld Filler Materiale1 GTAW-EB Insert MSl1 SMAW-E7018 (Except ae notnd).

-----*-----*-=-=--*,J__i_ -!---+-:* I' *'*-f----... --.

I r r I I I. 91 I I ~. r r f

( i JOINT ID (2) WELD PROCESS(ES) (OF) (OF) FINISIIBD WELD "' STF.AM GEN. NO. SPOOL NO~ WELD TYPE (3 4 PREHEAT POSTHEAT J. T. " ,..NOE 14 1-SGF-lBRW K (BWI) GTAW-Root: SAW 200 1100-1250 an cl RT MT and SMAW-Bal. 14 l-SGF-18RW J (WBU) SAW 175 1100-1250 RT an cl PT ond 14 l-SGF-18RW H (BWI) GTAW-Root: SAW and SMAW-Bal. 50 1100"-1250 RT and f.IT 14 l-SGF-18RW G (BWI) GTAW-Root: 50 1100-1250 RT anc1 MT SMAW-Bal. 14 1-SGF-lORW AA (WBU) SMAW 60 .1100-1250 RT and MT Field Weld SGF-18-llB(BWI) GTAW-Root; 175 Root 1100-1150 RT nncl MT SMAW-Dal. (E801BC3) 250 Bal. e NOTES: (!)Reference NRC request for info on PWR Feedwater Lines dated 5/25/79. (2) (ATTACH) =Attachment Weld7 {B.W.) = Circ. Single Butt Weld No Backing Ring: (D.W.I) = Circ. Single Butt Weld with Cons. Insert: (W.B.U.) =Weld Build-Up ~ ' (J)S~op Weld Filler Materials: GT,AW-E70S-2; SMAW-E7018; SAW-F72-EM12K. (4)Field Weld Filler Materialss GTAW-EB Insert MSl; SMJ\\W-E7018 (Except an not:Nl).

*------*+-< -*--1*---t---

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-~

II nuu.on. NO.ll artAU GENERATOR FEED 11-0f-2111 PSE8G ISO SOf-1-1 ft Fi~u re D-4 I I I Weld No. 12 Limitec'I RT on 11 . ~'('elbow s irk clt1P. I* 11 to p.L pr I* t 10 rt-,,

re s t r i"l 1 n
TllRU

~ '.IO Pl. 0 10 , I 10 f'\\.., THRU IOPL* 10 IOP'l*I IOPL*Z 1\\30~2 191 I j I i I l I. III \\

t.. b c f.J ,"j. 'l:......

nraw OIN Ne. II Weld No. 13 Limited RT 9n elbow side a;ue to pipe r*traint I

I I I. l I I J llPL.:I l llPL II f'l - I J TllllU II Pl - I II UPL IZ I I I I I I I o -*** '*--*-*--~-**:**-*~ - -*-**-**o*A*'-'"~- ~-*'*'****~- I NDE I 11 IOPl *I IOPl

2 10 STEAM GENERATOR FEED 14-DF-2121 PSE 8

G-ISO-SOF-1-18 Fi~ure D-J . ***- ---*- J __ ' -L.--- ... ~*......,,.; ..... ~** ~.... No RT on Welds No. 5,6,7 & 8 due to baffle arrangement around piping. SOUTH PCNETllATIOH AAU A30~2 195 Attachment i4 I ' I

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~** NDE /... Weld No. 18 Limited RT on.-., elbow side due 0 -.. to p'pe restrainf NOltTH P'l:NUllATIOH'l' I llP'l "..( llPi II "'I II INCAf'IUUTID FllOM WILD 9!0.4 '8 UI THI Pl:lllTU.TIOM AltU TD WILD MO. 10 Pl IN THI COllTAINMINT

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TUTll THI CONTAIN* MINT WALL THltOUOH n rr n NO. r I lJPS-1 J,,_, 4f'I 11 PL*I Jlf"U llPL*I l!IP'l-1 Ill llTEAM. l[NERATOft 'E[D 14* Bf' - 2151 PSE a 0 ISO SOF-1-1a . Figure D-Z II P'l *II THltU II P'l *II -* I ITl AM llN. II I *

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I l I t;j I._. IC..... -...J ITUM on. "'* 14 Weld No. 10 Limited RT on elbow side due pipe restraint I l'L-11 I PL-I I I I I t!!!Pl 1* 10 I to I I lM"U I l'L*I~ I I I l"L t I I PL 10 I I THAU IPL-* / I / NDE I L. f', f pl.' 1 Weld No. 5 Limited RT due to. pipe clamp ILUVI NO. I IOUTH PUETllATION A"U STEAM GENERATOR FEED 14-0F-2141 PSE 8 0 ISO SOF-1*10 Figure D-1 I

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. I A3052 IOI Attachment G . \\~ i. I* I \\ ..}}

ML18079A996

Text

Dear Mr. Grier:

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