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Summary of 791120 Meeting W/Util,Westinghouse & Wi Environ Decade Re Plant Steam Generator Tube Degradation
	ML19210E254
Person / Time
Site:	Point Beach
Issue date:	11/23/1979
From:	Trammell C; Office of Nuclear Reactor Regulation
To:	; Office of Nuclear Reactor Regulation
References
	NUDOCS 7912040167
	Download: ML19210E254 (63)
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UNITED STATES E 1, c, 'j NUCLEAR REGULATORY COMMISSION C WASHINGTON, D. C. 20555 o 'h> '!C'l G y-Docket No.: 50-266 LICENSEE: Wisconsin Electric Power Company FACILITY: Point Beach Nuclear Plant, Unit No. 1

SUBJECT:

SUMMARY

0F MEETING HELD ON NOVEMBER 20, 1979 TO DISCUSS P0 INT BEACH STEAM GENERATOR TUBE DEGRADATION On November 20, 1979, the NRC staff met with representatives of Wisconsin Electric Power Company (WE), Westinghouse Electric Corporation (W)and others as indicated in Attachment 1 to discuss steam generator tube degradation at Point Beach Unit 1. Hichlights of the meeting are summarized below. We explained that the petition to the Conmission filed by Wisconsin Environ-mental Decade e, November 14, 1979 paralleled the NRC staff's concerns in some areas. The purpose of the meeting was to explore in greater depth the safety considerations associated witi. an apparent increase in the rate of occurrence of deep crevice cracking in the steam generator tubes at Point Beach Unit 1. A similar meeting was held on this subject on November 5,1979. A copy of the summary of this meeting is attached (Attachment 2). The licensee was shown a copy of this meeting summary, and made several corrections as indi-cated in this attachment. The order in which the licensee presented the technical material is shown in. Most of the technical information presented was summarized in the form of viewgraphs which are attached, as follows: - Sumncey of chemistry history, blowdown chemistry history, tube p'ugging history, and distribution of ECT indications axially within the tube sheet zone. - Metallurgical examination of tube samples removed from Unit 1, SG "A". - Tube integrity verification summary (mechanical properties). 1468 129 7912040 k

~ ~ N712 5 GH - Suuary of revised ECCS analysis results. - QA measures for tube plugging. - SG crevice flushing procedure and results. 0 - Plot of rate constant for cr ck development of Inconel vs. temperature in caustic sol n.ons. The licensee recently completed a crevice flushing program (Attachment 9) in an attempt to remove harmful chemicals f rom the crevice zone. Both SGs have been 100% eddy-current tested in the problem zone. All tubes with ECT indications in the tube sheet zone have been plugged. An 800 psig hydro-static test (0 psig primary pressure) has been successfully conducted on both SGs. Also, a leak check 'las been conducted with primary pressure at 2335 psig and secondar pressure at about 335 psig (2000 psi pressure differential across the SG tubes. As to future operations, the licensee has requested an amendment to reduce primary coolant pressure to 2000 psia to reduce stresses on the SG tubes. Also, since all tube crevice defects have occurred only on the hot leg side, the licensee is planning to reduce hot leg temperature 40 F, from 597*F to 557 F, in order to approach previous cold leg temperature in the hot leg. This reduction in RCS temperature will result in a lower SG pressure and lower steam flow. The licensee estimates that 83% power can be achieved (turbine control valves fully open) in this mode of operation. WE will be closely monitoring SG chemistry and maintaining a low a'r in-leakage rate to the condenser. Present Tech Specs limit allowable SG leakage to 500 gallons per day (gpd). WE plans to operate at a maximum leakage of 250 gpd. In addition, WE would shut down Point Beach 1 and plug if the leakage rate increase were rapid and reached 150 gpd; also if the leakage rate rose greater than 15 gpd per day. WE will conduct another primary leak test (2000 psi differential) within 30 days after return to service and repeat 60-90 days thereafter. Any leakage detected in these tests would result in further tube plugging. WE wili conduct further eddy-current tests in one year (Tech Specs would allow up to 24 months between tests). For the longer-term, WE is considering sleeving, SG tube bundle replacement, or SG replacement as permanent corrective actions. The licensee stated that the LOCA steam binding phenomenon for broken tubes is not applicable to the current Point Beach tube problems, since the tubes are defective below the tube sheet and large leaks cannot occu-here. The rest of the SG tubes (above the tube sheet) are not experiencing problems. ~ 1468 130

. ggj g 3 7979 In conclusion, WE stated that operation of Point Beach I does not in any way pose a threat to public health and safety. The intergranular attack is confined to the tube sheet zone. Testing and analysis indicate adequate SG tube strength for normal and postulated accident conditions. The staff stated that we would need a few days to study the information prasented to reach a safety conclusion. The licensee was requested to formally ' ubmit the information presented at the meeting. The licensee was told that we will conduct our evaluation promptly and brief the Comission as to our findings prior to plant startup. Also, we will issue a Safety Evaluation Report prior to startup. / y /s ....,5 Charles M. Trammell, Project Manager Operating Reactors Branch #1 Division of Operating Reactors Attachments: 1. List of Attendees 2. 11/5/79 Meeting Summary 3. Agenda 4. Unit 1 History 5. Metallurgical Examination of Tube Samples 6. Tube Integrity Verification Summary 7. Summary of Revised ECCS Analysis Results 8. QA measures for Tube Plugging 9. SG Crevice Flushing Procedure and Results

10. P!ot of Rate Constant 1468 131

ATTACHMENT 1 LIST OF ATTENDEES POINT BEACH STEAM GENERATOR TUBE MEETING NOVEMBER 20, 1979 NRC Staff Wisconsin Electric Power D. Eisenhut S. Burstein W. Gammill G. Frieling V. P.snan C. W. Fay B. D. Liaw D. Porter C. Y. Cheng R. Newton E. Murphy N. Palmer C. Trammell C. Barth Westinghouse E. Reis W. Pasedag R. Begley R. Emch F. Pement J. Collins R. Grimm A. Schwencer D. Malinowski S. Burns G. Toth M. Moe W. Fletcher D. Basdekas C. Thompson F. Combs R. Muench B. Turovlin T. Esselman F. Almeter R. Slember G. Lainas R. Contratto P. Check J. Busch K. Parczewski W. White R. Sero Wisconsin's Environmental Decade (Petitioner) K. Falk P. Anderson Other G. Charnoff - Shaw, Pittman, Potts & Trowbridge D. Van Rooyan - BNL J. Silberg - Shaw, Pittman, Potts & Trowbridge R. Pollard - Union of Concerned Scientists B. Cowan - Eckert, Seamans, Cherin & Mellot C. Riederer - Wisconsin PSC l4bO l

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/ E WASHINGTON, D. C. 20555 4?C / A6f f.2, NOV 161979 g Docket No. 50-266 LICENSEE: Wisconsin Electric Power Company FACILITY: Point Beach Nuclear Plant, Unit No.1,

SUMMARY

OF MEETING HELD ON NOVEMBER 5,1979 WITH WISCONSIN ELECTRIC POWER COMPANY AND WESTINGHOUSE ELECTRIC CORPORATION TO DISCUSS RECENT INSPECTION OF STEAM GENERATOR TUBES AT POINT BEACH UNIT NO.1 On November 5,1979, the NRC staff met with representatives of Wisconsin Electric Power Company and Westinghouse Electric Corporation (W) to discuss the results of a recent steam generator (SG) tube inspection at Point Beach Unit No.1. In addition, W presented the results of an examination of 3 SG tubes removed from the "A" SG. A list of attendees is conta med in Attachment 1. Highlights of the meeting are summarized below. The licensee presented a brief history of steam generator operating experience for Unit 1: 1971 - Initial operation on phosphate chemistry control. Some tube cracking / wastage experienced. 1974 - Switched chemistry control to AVT. 1977 - First deep crevice cracking experienced. Three leaking tubes plus other ECT indicatic.s. Eight tubes plugged. September 1978 - More deep crevice cracking. Ten tuces plugged. March 1979 - More deep crevice cracking. Nine tubes plugged. August 1979 - Plar.t shutdown due to tube leaks. 100% ECT. Forty-five tubes plugged in B SG; 52 in A SG, all due to deep crevice cracking. ECT technique was at single frequency with some multi-frequency sampl es. 1468 133

Point Beach 1 NOV 161979 G August 29, 1979 - 1.5 gpm leak develooed. TUc tubes ~ plugged which were inadvertently not plugged following earlier 100% inspection.

r October 5,1979 - Rehuellng shutdown plus 100$ ECT testing. Three tubes removed for metallurgical examination.

Seventy-five tubes plugged in A SG (3 due to tube removal); 65 tubes plugged in B SG. ECT technique used multi-frequency testing. Total number of SG tubes plugged in Unit 1: A - 326 B - 316 or about 10% I The licensee stated that the Wisconsin PSC has ordered a public hearing to take place November 26 to discuss the economic impact of tube degrada-tion at Point Beach (the Wisconsin PSC attended this meeting). Three tubes were removed for detailed metailurgical examination - two from the " kidney" area (a good tube and a bad tube), and one from the periphery. All tubes exhibited intergranular taustkh corrosion

c. sac h s in the " deep crevice" area.

The SG tubes at Point Beach were expanded only 2-1/2" at the bottom of the tube sheet, leaving a crevice between the tube and tube sheet over the balance of the tube sheet thick-About 35 plants world-wide have this partial expansion design. ness. Other plants (San Onofre, H. B. Robinson, Ginna) have experienced deep crevice cracking, but not to the degree seen at Point Beacn. Metallurgical yu j.p T_u e 1 (R15C45). "A" SG kidney region (bad tube in bad region). Indications of,t ntergranular att::#over the full length of i crevice zone. Twenty mils general attack. Deecest crack 40 mils. (All tubes are 50 mils thick). A pH test of tube surface indicated al kalinity. Na, P K, Cl, Si, S, Ca detected. Reason for attack: Caustic s-tress corr.osion cwck-ing. A iMevq rMw Tube 2 (R20C73). Periphery region - outside kidney zone (good tube, good area). Results: similar to tube I but attack less extensive. Five mils general attack,15 mils deepest crack. Tube 3 (R22C37). Good tube frou kidney area (good tube, bad area). Similar results. 5 mils general attack, ceepes: track 25 mils. The wors tuce (No.1) showed S9% tube de;raca-icr y ECT However, tubes 2 and 3 showed no ECT indications. - Esseiman cresented a prelimirary s ru ural evalug-ion of :ne ce:# ace: tubes. See A: acnmen 2 for viewgraons cresente:. 7;:s es;rada-ion accears to be a::siera-i.g. cl-Ou;r a ci#fe er.: E:

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..i s a s s:" i # tr.5 C:~. :er 1979 inste:.icn '.ul.i -#E Usn y.Gsti"g), :ss licensee s ta i;.r.a i si E "esuits werE acrieVE: ' *. s ' -[ i #'E ue"Cy Es.' ? at 400 m: a: r5. '.-* #re:asn:y res;:nse a: C "-2. ~~3*ef 't. ..e a: ' i: al S, lao 3$o -m wy$ 1468 134 k

Meeting Summary for NOV 161979 Point Beach I number of tubes plugged this time (which is beyond previous experience) does not appear to be attributable to. the new inspection method. There are indications that defects have grown in size. The licensee did a comparison of 75 tubes between August and October. Two-thirds " " - p indic=+4nmho indicate some growth over this relati ly short operating g.; o penetration depth was about the same, but the defect size had

period,

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increased. Therefore, there is efc$gr evidence that degradation is accelerating, although the number of tubes plugged this time does include some which should have been plugged earlier,asamamtiona6casuce. Tube degradation is restricted, entirely to the deep crevice zone. c e< ro. wm The licensee stated that t'ie deep crevice tracking problem and present SG tube conditions do not present a safety concern with respect to continued operations, but that economic concerns remain, since plant availability is being affected due to shutdowns to plug and inspect tubes. The licensee is pursuing solutions up to and including SG replacement. Before resuming power operations, the licensee will flush both SGs with demineralized water in an attempt to remove chemicals believed to be trapped in the deep crevice zone. Thermal cycling between 2500F and 2000F is planned to boil out the crevice zone, and draw water back into the crevice (4-5 days of flushing). The SGs will be pressure tested at 800 psig (0 psig primary,.ressure) to inspect for leakage prior to reinstallation of the manway covers. A primary leak test will be conducted at 2335 psig (250'psig secondary side pressure) prior to resuming operation. -{, The licensee has submitted a Technical Specification change request which would lower the normal primary pressure to 2000 psia to reduce SG tube stress. The licensee is studying reductions in primary average temperature (or reduced power) since no cracking has been observed in the cold leg side of the SGs. The licensee is conducting a revised ECCS analysis assuming 18". of SG tubes plugged in anticipation of the need for further tube plugging. f W

t.. M. Trammell, project Manager Operating Reactors Branch di Division of Operating Reactors Attachments 1.

List of Attendees 2. ,iewgraphs T A68 IN

ATTACHf1ENT 1 LIST OF ATTENDEES POINT BEACH STEAM GENERATOR MEETING NOVEMBER 5,1979 NRC Staff Westinchouse E. Murphy R. Kelly J. Smith H. Von Hollen C. Trammell C. Hirst B. D. Liaw F. Pement E. Jordan E. Morgan D. Malinowski T. Esselman R. Begley W. White Wisconsin Electric Power G. Frieling C. W. Fay D. Porter Other J. Silberg, Shaw, Pittman, Potts & Trowbridge L. Smith, Wisconsin Public Service Commission } kbk3 e

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'{ 'I ' ' CC:,.:!1 I( :,'.; F.V/d n '. ! E:- f&((,,/$f/^fAAf o UNIFORM WASTAGE WITHIN OR OUTSIDE THE TUBESHEET o CRACKING OF THINNED TUBE WITHIN OR OUTSIDE THE TUBESHEET o EXAMINATIONS PERFORMED DO NOT INDICATE THAT WASTAGE OR CRACKING EXTENDS ABOVE THE TUBESHEET - THIS CONDITION IS EVALUATED FOR COMPLETE COVERAGE OF POSSIBLE CONDITIONS l c e M e M A { b@b -]""lD " l0 3 D l 1468 137

7 a LIMITIi;G CONDIT10. S FOR UtilFORM h'ASTAGE 4 OUTSIDE THE TUBESHEET gggg 747gg gy' REQUIRED CONDITION THICKNESS Sa==Ty REQUIREYENTS o DOUBLE-ENDED FAILURE DURING SB .005 INCH 0 IUBE RUPTURE DURING NORMAL OPERATION .008 INCH c TUBE RUPTURE DURING SB .013 INCH o No COLLAPSE DURING LOCA .020 INCH (6% OVALITY) HENCE, LI.".! TING CONDITIONS ARE T = 0.020 ouTsIDE THE TUEESHEET i _ W si w 0

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DUCTILITY OF REMAINING MATERIAL MUST ALLOW THE TU3E TO EXPAND TO CONTACT TUSESHEET 1468 14l

"{*f. )?gf~t /M /WAA RESULTS OF LEAD PLUG TESTS ON PULLED TUEE TES" NUMBER D!aMETRAL INCREASE 5A6

.045 INCH 5A7

.045 INCH 5B2 .030 INCH NOMINAL TUBE-TO-TUBESHEET HOLE DIAMETRAL CLEARANCE =.016 INCH EXPECTED TUEE-TO-TUBESHEET HOLE DIAMETRAL CLEARANCE ZERO THEREFORE, TUBE WILL BACK-UP AGAINST THE TUBESHEET 1468 142 em

"f5/1 SUM.'iARY FOR THE UNIFOR.'i WASTAGE C0"DIT10N ,PREL /Hina y REQUIREMENTS MINIMUM TUBE THfCKNESS OUTSIDE TUBESHEET MUST e BE GREATER THAN.020 INCH (40% OF WALL) ~ EQUIVALENT TUBE THICKNESS INSIDE TUBESHEET MUST o BE GREATER THAN.005 INCH (10% OF WALL) o THE DUCTILITY OF THE TUBE INSIDE THE TUB EHEET MUST ALLOW EXPANSION TO THE TUBESHEET WALL CONDITION OF THE TUBES EXAMINED AND TESTS PERFORMED INDICATE THAT THESE REQUIREMENTS ARE MET 1468 143 me -

uprq 1984/HiM4A.Y 7p r i m c m>.i w v; ~ - U./1dSa W i i!!!i, i U.. o LEAK RATE FOR CRACKING WITHIN THE TUEESHEET !.S GOVERNED BY ANNULAR GAP o CIRCUMFERENTIAL CRACK 0 LIMITING CASE - FULL CIRCUMFERENTIAL CRACK O LEAKAGE - 7 GPM (LOWER BOUND ESTIMATE) WILL ALLOW DETECTION DURING NO:MA'. OPERATION O EITHER 1) LEAKAGE WILL SHOW THAT THE BREAK HAS OCCURRED LEADING To oLANT SHUTDOWN OR 2) BREAK WILL BE DEEP ENOUGH IN THE TUSESHEET THAT IT CANNOT CAUSE PROBLEMS o TUBE WILL NOT PULL OUT DURING SLB BECAUSE OF TOTAL BUNDLE RESTRAINT e AX1AL CRACK 0 R I. ", l l.. T S CP L F.', t' ; U ;, .:/TE TUEE Hv

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UNIT 1 STEAM GENERATOR 3Rdo W , Av7 :sEP 7Y SG P TUBE PI,UGGING HISTORY Tubes Plugged Date of Thinning or Crevice Cumulative Outoge Elapsed Time Denting Cracking Corrosion Other Total Percent (Years) A g A g A g A g A g A B III 12/21/70 0 I <0.1 0 } 9/30/72 1.8 87 91 14 4(2) 102 95 3.1 2.9 4/6/74 3.3 1 1 103 96 3.2 2.9 2/26/75 4.2 59 98 162 194 5.0 6.0 11/16/75 4.9 6 4 168 198 5.2 6.1 10/1/76 5.8 168 198 5.2 6.1 6/24/77 6.5 1 168 199 5.2 6.1 10/4/77 6.9 10 1 2 179 201 5.5 6.2 l 2/1/78 7.1 (3) 180 201 5.5 6.2 9/20/78 7.7 1 6 4 187 205 5.7 6.3 b 3/1/79 8.2 8 1 195 206 6.0 6.3 J/5/79 8.6 52 45 247 251 7.6 7.7 I4) 8/29/79 8.8 2 3 252 251 7.7 7.7 70 64 7 4(5) 329 319 10.1 9.8 10/5/79 8.9 i Motes: (1) Plugged during manufacture. (2) Pourteen tubes in A were plugged due to gouging durino machining for clad repair. Three tubes in B were removed for analysis and one was plugged by mistake. ! }(( (3) Plugged tube was in periphery. C7' (4) An audit of tubesheet photographs indicated three tubes which were plugged but previously OC not included in inspection reports. (5) Seven tubes in A included three wibh defects less than the plugging limit, two tubes which g / 4> had no indications but which were pulled for analysis, and two tubes plugged by mistake. so Four tubes in B included three tubes with indications less than the plugging limit and one tube plugged by mistake.

e 11/13/79 ~ hQf A UNIT 2 STEAM GENERATOR TUDE PLUGGING IIISTORY Tubes Plugged Date of Thinning or Crevice Cumulative Outage Elapsed Time Denting Cracking Corrosion Other Total Percent (Years) A B A B A B A B A B A B 8/2/72 0 1 1(3) 1 1 <0.1 <0.1 II' 3 3/8/73(2) 0.6 <0.1 <0.1 10/17/74 2.2 3 4 4 5 0.1 0.1 M 8/11/75 3.0 3 4 8 0.1 0.2 2/26/76 3.6 14 4 18 12 0.6 0.4 3/4/77 4.6 2 5 20 17 0.6 0.5 3/ /78 5.6 2 22 17 0.7 0.5 L 3/ /79 6.6 1 22 18 0.7 0.6 Present 7.3 22 18 0.7 0.6 e 4 Notes: (1) 20 percent power operation. i (2) Begin increase to 100 percent power. Achieved in April 1972. (3) One tube plugged during manufacture and one tube not installed. e __ es ON ) OC LD CO

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h /.p' s,/ POINT BEACH 1, S/G A, TUBE 20-73, HL P W LABORATORY SAf1PLES CUT BELOW 2no SP g W 139-13/16 N SINGLE-WALL RADIOGRAPHY ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ' A ~ 8" RADIOGRAPHY ~ ~ ~ ~ ~ ~~~~ ~ ~ ~ ~ ~ ~ ~ ~ ' ~ ~ ~ ~ ~ ~ ./ : i f f METALL0 GRAPHY (TRANSVERSE) TOP Or TS TOP OF TS: METALL0 GRAPHY (LONGITUDINAL) RADIOGRAPHY ~ ~ ~ ~ - ~ ~ ~ - - - ~ ~ ~ - ~~~ -- 23-11/16 METALL0 GRAPHY (LONGITUDINAL + TRANSVERSE) NUMEROUS SEM/EDAX ANALYSES f Y ~ .m c 1468 160

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gI POINT BEACH 1, S/G A, TUBE 15-45, HL g LABORATORY SAMPLES m SEf1/EDAX + ELECTRON FRACT0 GRAPH h METALLOGRAPHY MECHANICAL PROPERTIES TEST SEM/EDAX METALL0 GRAPHY (TRANSVERSE + LONGITUDINAL ELECTRON BEAM _ MICR0 PROBE. HYDRAULIC PRESSURE TEST (5") MECHANICAL PROPERTIES TEST (1") c, U 20-5/8" MECHANICAL PROPERTIES TEST (1") SEM/EDAX . SEM/EDAX SEM/EDAX + METALL0 GRAPHY ~ TENSILE TEST SAMPLES ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~ ~ SEM/EDAX + METALL0 GRAPHY N SEM/EDAX -e .e. 1468~162~ L., .e

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n a ~ / f- _t CURREflTLY APPROVED P0lf;T SEACH LOCA Af!ALYSES I) PERFCRMED WITH ThE r.' 5..'. TL v APFRO',ED WE37:..1-0USE EVALUATICN MODEL (FEBRUARY 197L.
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II) AtlALYSES ACCOUNTED FOR 10 PERCENT TUBE PLUGGIf;G RESULTS: 0 (1) PCT = 2067 F (2) PEAKING FACTOR = 2.32 0 0 (3) MARGIN TO 2200 F IS 133 F -D'#'" h " ]D"Q-}\\lnla h o JU , S. w a Ju 2 1468 183 5 9 H e
RECENT CHAflGES AT POINT BEACH WHICH IMPACT LOCA ANALYSES I) INCREASED TUBE PLUGGING A) INCREASED FRCM 105 TO 18 :, B) SENSITIVITY OF APPROXIMATELY 6 F/1% T.P. C) APCT = +48 F II) REDUCED PRIMARY PRESSURE A) REDUCED FROM 2280 TO 2000 PSIA B) SENSITIVITf 0F APPROXIMATELY h/100PJIA C) APCT =,+5 F O b ^' III) REDUCED POWER A) REDUCED POWER BY 17% U U B) REDUCED COLD LEG TEMPERATURE FROM 544 F TO 510 F 0 C) SENSITIVITY: REDUCED PCT BY 290 F i 1468 184
LOCA RESULTS AT VARICUS OPERATING CONDITIONS FOR POINT BEACH PARAMETER CASE 1 CASE 2 CASE 3 CASE 4 POWER 100% 100% 100% 83% % TUBE PLUGGING 10 18 18 18 RCS PRESSURE 2280 2?80 2000 2000 TCOLD 540 544 544 510 PSEC 4F77 'l l 799 799 380 FQ 2.32 2.32 2.32 2.32 PCT 2067 2113 J f,R l 1830 ELEVATION 7.5 7.5 7.5 7.5 bhh0$0N( I468 185
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.90V ' 379 Meeting Summary for Point Beach Unit 1 DpcketJi1es GiRCR) Local PDR ORB 1 Reading H. Denton E. Case D. Eisenhut R. Tedesco G. Zech B. Grimes W. Gammill L. Shao J. Miller R. Vollmer T. J. Carter A. Schwencer D. Ziemann P. Cneck G. Lainas D. Crutchfield
8. Grimes T. Ippolito R. Reid V. Noonan
.G. Knighton D. Brinkman Project Manager OELD OI&E (3) }468 )9) C. Parrish/P. Kreutzer ACRS (16) NRC Participants NSIC TERA Licensee Short Service List Wisconsin's Environmental Decade ATTN: K'. Fal k 114 E. Mifflin St. Madison, WI f3703 C. F. Riederer Wisconsin Public Service Comm. Hill Farms State Office Building fladison, WI 83702 9}}

ML19210E254

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