Text

1979 Annual Operating Rept, Consisting of Info Re Production Facility Changes,Tests & Experiments,Reactor Vessel Matl Surveillance Capsules & Rept on Steam Generator Insp & Repair
	ML19296D471
Person / Time
Site:	Crystal River
Issue date:	02/28/1980
From:	; FLORIDA POWER CORP.
To:	;
Shared Package
ML19296D462	List: ML19296D461; ML19296D467; ML19296D471; ML19296D474;
References
	NUDOCS 8003040632
	Download: ML19296D471 (53)
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c menc 2 O

REPORT ON REACTOR VESSEL MATERIAL SURVEILLANCE CAPSULES 8003040 h -

STANDARD ANNUAL REPORT ON REACTOR VESSEL MATERIAL SURVEILLANCE CAPSULES AS REQUIRED BY STS 6.9.1.5(b)

Reporting Period January 1, 1979 to December 31, 1979 Caosules Currentiv Installed Holder Capsules Closure Assembly Tube Installed (l) Installed WZ T-CR3-L1 27-113-2007-60-6 3-CR3-L2 ZY T-CR3-C 27-113-2007-60-3 B-CR3-A YZ T-0CII-A 27-113-2007-60-2 3-0CI-A YX T-0CII-E 27-113-2007-60-1 3-0CIII-D XW T-CR3-E 27-113-2007-60-5 3-CR3-D WX T-0CIII-B 27-113-2007-60-4 3-CR3-F Insertions / Withdrawals During Report Period Insertions: T-CR3-L1, B-CR3-L2, T-CR3-C, 3-CR3-A, T-0CII-A, 3-OCI-A, T-0CII-E, B-0CIII-D, T-CR3-E, T-0CIII-3, 3-CR3-F Withdrawals: T-CR3-B Ownershio of Caosules Florida Power Corporation: T-CR3-L1, B-CR3-L2, T-CR3-C, B-CR3-A, T-CR3-E, T-CR3-D, T-CR3-F Duke Power Corporation: T-0CIII-A, 3-0CI-A, T-0CII-A, T-0CII-E, 3-0CIII-D, T-0CIII-B Irradiation Location See Holder Tube listing Note:

C.) T= top 3= bottom

A++nchmer>+ 3 REPORT ON PRODUCTION FACILITY CHANGES, TESTS AND EXPERIMENTS

STANDARD ANNUAL REPORT ON PRODUCTION CHANGES, TESTS AND EXPERIMENTS AS REQUIRED BY 10 CFR 30.59B Facility Changes MAR 76-11-29, completed 10/29/79 Install hour meters on Air Handling Fans 7A, 7B, 18A, 18B, 14A, 143, and 14C. These meters are needed to monitor run times so charcoal filter samples can be taken each 720 hours0.00833 days 0.2 hours 0.00119 weeks 2.7396e-4 months as required by STS. The hour meters will be fused and connected across spare contacts in the fan breakers. A failure of the meter would in no way disrupt the normal operation of the system.

MAR 77-2-11, completed 8/24/79 Add cross connect line between DHV-ll4 and DHV-116. These valves shall be locked open one turn off their closed seat. This change will prevent the overpressurization of the drop line between DHV-3 and DHV-4 which could result from fluid thermal expansion during post LOCA conditions. This MAR reduces the chances of malfunction of safety related equipment. Some flow could be lost through this line during Low Pressure Injection. However, since DHV-ll4 and DHV-ll6 are maintained only one turn off seat, the lost flow will be insig-nificant and can in no way effect core cooling.

MAR 77-3-20A, completed 4/3/79 Shaved the impellars of WDP-5A, B, and C to prevent the overpressur-ization of WDDM-1A and B and WDDM-2A and B. Installed orifices of sufficient size to prevent pump runout.

MAR 77-5-10, completed 1/19/79 Reduced time delay relays (AW-TDE, AV-TDE-3Al and AH-TDE, AE-TDE-3B1) from 5 seconds to minimum required to verify valve movement. This allows SP-332 to be performed at power. No change to actual equip-ment performance will occur.

MAR 77-6-32, completed 1/23/79 Rerouted Building Spray Pump A & B casing drains and cooling water piping in order to permit piping repair without pulling pumps.

This change effects drain and cooling water piping and does not present safety problems.

MAR 77-7-43, completed 6/11/79 SWHE-3A, 3B, 3C and 3D inspection manholes were modified by replac-ing existing corroded piping and replacing it with a stainless steel faced spool piece. The function of the heat exchanger is not changed.

MAR 77-8-4, completed 4/3/79 Seal welded bonnet on MUV-18. Seal ring replacement could not be made with plant operating. This MAR did not change the intent of the operation of the equipment.

MAR 77-8-7, completed 4/3/79 Drilled holes in CRDM Breaker Cabinets so that breakers could be reset with the cabinet doors closed. Reference Safety Committee Agenda 77-

28. This is a housekeeping / safety change only.

MAR 77-9-19, completed 10/30/79 Install a 1" drain off the 3" WD gas header and ran it to a nearby drain pot. This helped resolve a loop seal blowing problem. The WD gas system is Quality but not Safety Related system (i.e., not required for safe shutdown).

MAR 77-9-22, completed 1/19/79 Eliminated low point in 1" vent off waste neutralizer tank in order to help alleviate waste gas system problem per REI-PD-643, Part 4. This change does not affect system design.

MAR 77-9-23, completed 10/30/79 Installed clear plastic pipe for level indicatfon of three low points in the Waste Gas System. This permits visual indication of water accumulation, provided a method to drain and help alleviate problems of blown loop seals.

MAR 77-10-03, completed 8/20/79 Increased line size of RC Evaporator vent line from 1" to 2", added a two inch isolation valve and ran 2" line to 3" WD Gas header. Increase line size of Miscellaneous Waste Evaporator from 1" to 2" and run 2" line to downstream side of WDV-383. This change increases the venting capacity off the waste evaporators which should help eliminate blowing of loop seals. This is a Quality system but is not Safety Related.

MAR 77-10-5, completed 8/23/79 Rerouted 1" MUT vent line from original location to tie in downstream of check valve WDV-383. This change will prevent radioactive contam-ination of the entire WD Gas system during MUT venting and allow more efficient waste gas management to be implemented in regard to hydrogen levels and radioactive gas decay tank holdup. This is a Quality system but is not Safety Related.

MAR 77-11-7, completed 3/1/79 Replaced existing Velan Valves WDV-511, 560, 561, 562 and 564 with Nupro-SS-8CPZ-L-EP soft seat chick valves WDV-935, 936, 937, 938 and 939.

Existing hard seated valves would leak gas through, causing improper gas analyzer operation. The design of system was not affected by chang-ing valve manufacturer. This is a Quality system but not Safety Related.

MAR 77-12-2, completed 3/1/79 Modified alarm of deisel generator room fans AHF 22A, B, C and D to come in when fans fail to start instead of on every start. These alarms were meaningless and a real nuisance. This modification does not affect emergency starting of the fans.

MAR 78-1-11, completed 8/24/79 Extended drain lines from existing drain valves BSV-32, 66, 40 and 65 to elevation 98' in Auxiliary Building and added additional drain isolation valves at lower end of drain extensions. Original location of drains required operator to utilize ladder in unsafe operation to drain BS lines after building spray surveillance. This change does not affect design intent. It is for ease of operation.

MAR 78-1-2, completed 9/20/79 The RMA sample pumps had momentary contact control switches. This made it necessary to manually reset these switches if normal power was lost and emergency power was energized. Because of this, it was possible that the radiation monitors could be overlooked at a time when they were needed most. This modification entailed replac-ing these switches with a maintained contact control switch.

MAR 78-2-4, completed 4/26/79 Removed existing globe valve FSV-241 in ventilation shaft of record storage room and installed a new 1 1/4" OS & Y gate valve in record storage room. The original valve was in an inaccessible location, and the sprinklers could not be shut off in the record storage room without having to close off the entire fire service water system in the office building. The change increases the flexibility of the Fire Protection System. This particular sprinkler is not considered necessary by STS to minimize potential damage to safety related equipment.

MAR 78-10-13, completed 4/26/79 Revised the 302 flow drawings to add code references generally in accordance with the 318 isometric drawings. Deleted original design codes, added reference to isometrics where applicable. Prepared two new flow drawings FD-302-283 and FD-302-284 per 1S-318-283 and IS-318-284 and added to flow drawing index FD-302-000. Drawing changes only.

MAR 79-1-A5, completed 8/11/79 Deleted were #2 cable FSE-317 and used were #5 cable FSE-317 in its place. Wire #3 was broken and wire #5 is a spare. The Emergency Safeguards circuitry is not altered. A spare conductor is being used instead of original.

MAR 79-3-5, completed 10/29/79 Installed temporary " blind flanges" on RC pumps during outage after removal of pump seal to allow filling of fuel transfer canal. These blind flanges insured that proper water level within the RCS was maintained during refueling operations.

MAR 79-3-5C, completed 10/29/70 Addition of 2 inch spacers to existing 4 inch spacers on the tempor-ary reactor coolant pump seal covers. The original spacers were too short to use regular seal flange bolts. This revision assured gasket seals as analyzed in MAR 77-3-5.

. k .

AHnchmeu+ +

REPORT ON STEAM GENERATOR INSPECTION AND REPAIR

SCHEDULED REPAIRS OF B-0TSG DURING PERIOD FROM 4/25/79 T'4 ROUGH 6/12/79 (Extracted from Cycle One Refueling Outage Report)

2.20 3-0TSG REPAIRS A. Pre-Outsge Planning Milestones The pre-outage planning effor: for :he 3-0TSG Repairs was initiated in September 1973 with a 34W/FPC seeting to discuss repair 3oals. The results of this =eeting were that 3&W was directed to continue the development of remote repair equipment assuming that a full repair would be done at the nex: ref ueli::g ou: age. 6 addition, 3&W was asked :o develop a surveillance program. b parallel, FPC would evaluate 1:s final decision on the extent of repairs.

On January 15, 1979, W. P. Stewar: gave che following direc: ion to 3&W confirming ??C's official position on repairs :

(1) Perform a limited video inspection of selected tubes (2) Open the 120 lane tubes (3) Open/deburr 1000 random :ubes for future eddy current tes ti::g (4) bplement a surveillance program (5) Video inspect all worked tubes (6) Complace development of all remote tooling Planning for :he refueling ou: age progressed along this direccion. b parallel, remote to: .ing development had continued and a demonstration was hald on January 23, 1979 fo r F?C. This shuwed tha: :he development effor was progressing, bu: needed further work for the equipmen to be 5117 accepted for use in the OTSC. After = ore efrorts a: tooling development and refinement, another demonstra: ion was held on March 26, 1979. This resulted in a basic acceptance of the remote equipment for use, with the exception of :he sain welding uni:. Suggested improve =ents were th .. .nade on :he main welding uni: and this :co became acceptable.

S1:e preparation ef for:s began in earnest the first week of April 1979 ai:h the arrival of the tooling equipmen:

and 3&W personnel. Boile==akers were hired starting April 9,1979, in order to start a :wo week mock-up traini::g ef fo rt. In addition, set up of support f acilities (e.g. , power supplies, control centee, etc. )

was condue:ed at this cime.

All work to be done on the 3-0TSG was covered by '7 ark

equests for each major :ssk.

. The work package (Work Request, RWPs , clearances, etc.) were prepared in advance and suhaitted :o planning by late March 1979. Pr e-outag e planning, based upon inputs from 3&W and esti=ates by :he site ac:171:7 coordinacce, showed the 3-0TSG repair effort would run from April 25, 1979 to May 22, 1979, for 2.20-1

a to tal of twenty-eight (28) days (see A::a ch=ent 2.20-A). *he effort was originally planned to be off-critical pa:h. Howeve r , the last pre-outage schedule resul:ed in the 3-0TSG ef fort as critical path by a slight margin. The schedule for this effort was reduced from a thirty-seven (37) day schedule initially submitted by B&W.

3. Su==arv of Work Accomplished Attachment 2.20-3 su==arizes the as-buil: schedule for the B-0TSG repair ef fort. The following is a brief narrative of repair efforts performed du:ing the outage:

1. Equipmen: for the ef for: was staged to the R3 equip =en: hatch on 4/25/79 in preparation for R3 access.

2. The motor home control center was se: up on 4/26/79.

3. The lower primary manway removal ec=nenced on 4/28/79 and was completed on 4/29/79. The J-leg and drain hole screens were then installed. The te=porary lower manway cover installation was completed on 4/30 - 5/1/79.

4 The upper primary =anway was removed on 5/3/79. A de=ineralized water flush was conducted but had no affect on general area radiation levels (4R/hr general area).

5. The eddy current sky hook and camera for general scan was installed on 5/1/79. *he eddy current manipulator was then installed with a camera to perform free:e frame shots of the lane tubes. This was completed on 5/3/79.

6. The freepath equipmen: was mounted on the eddy current manipulator and the freepath co=menced on 5/4/79. As of 5/7/79, a total of 1,017 tubes had been checked, but only 178 would accept the 0.500" gauge. Because of the high rejection rate, freepathing was halted in favor of using the milling machine.

7. Ring girder installation coc=enced late on 5/7/79, bu: ran into delays duc to i= proper fitting of the marking template and inadequate D of the tubes being used for the holddown cam locks.

Modifications were =ade and the ring girder installation completed on 5/9/79. After corrections to proble=s with the milling =achine air connections and setup of the vacuum, spotfacing of the lane tubes commenced on 5/10/79. The first 18 tubes were 2.20-2

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spotfaced with a non-radiused :ype cutter. A radiused cutted was installed and speci cing continued through 5/11/79. A: this cime, the crossbar brace was removed :o gain = ore outar periphery access. On 5/12/79, che right angle milling head was installed and lane cube spotfacing completed.

8. Tube end opening for the eddy current sample was com=enced on 5/12/79. This effort wen: extremely slow due to lack of good =aneuverabill:7 of :he equip =ent. The cube end opening was halted on 5/15/79 in order to get on with welding the lane cubes. At :his po int , only 146 tubes were opened, but a recurs to tube end opening was planned, if :he schedule persi:, a: a la:e date. Prior to silling head re= oval, the original 13 spo: faced :ubes were respotfaced with a radiused cu::er.

9. Setup for lane tube weldi=g coc=enced on 5/16/79 with the deburring of all spo: faced :ubes. ""h e heaters were then installed and the open lane area was hes:ed :o 300-350*? and =aintained for 3 hours3.472222e-5 days 8.333333e-4 hours 4.960317e-6 weeks 1.1415e-6 months 15 minu:es. Af:er cooli=g down, the hea:ers were removed and the roll expander installed early on 5/17/79. All bu: five (5) tubes were roll expanded 2: :he upper 1/3" and these five were accepted as is.

10. The NED welder head was installed la:e on 5/17/79.

However, the. welding ef fort i==ediately ran in:o problems and delays due to such things as test block holder inadequacy, pilot assembly alig: ment, camera and cable problems, and lack of good argon cover gas. By 5/21/79, :he NED welder head was removed and replaced wi:h :he Copley, backup welder head.

Bis unit also ran in:o proble=s with argon and a control problem. These were solved by securing the ventilation to minimize cross flow and discovering a grounding problem on :he control uni:. A satisfactory test block weld was finally =ade on 5/23/79. Tube to cube heat welding commenced on 5/24/79.

11. On 5/23/79, filling of the F C for fuel shuffle was started and a gaska: leak on :he temporary lower sanway cover was discovered. Craindown and re= oval of the cover was required. Se cover was removed on 5/24/79, at which time welding was hal:ed to eliminata the possibili:7 of :he " chi =ney af fec:~

causing argon cover gas problems. A new gaska: was installed and the temporary cover replaced late on 5/24/79.

2.20-3

12. Tube to :ube sheet welding was reinitiated early on 5/25/79. Addi:icnal problems were encountered with the filler wire fusing in the wire guide tube and several o:her ite=s. Welding was again started early on 5/26/79 and all but five (5) tubes which were inaccessible, were completed on 5/27/79.

13. Setup for manual welding was then imitated and the manual welds on the five (5) inaccessible tubes completed on 5/28/79. However, there was some concern by one of the welders abou: adequa:e fusion.

~he liquid penetrant rig and ca= eras were installed on 5/29/79 to initiate the PT effort and perform a visual inspection. The visual examination was conducted on 5/29/79 and resul:ed in sixteen (16) tubes requiring repairs. Four (4) of :hese tubes had the weld deposited outside the tube and had no contac: with the tube itself (Tubes 77-14, 75-13, 75-14 and 75-15). In addition, it appeared tha-

hese four tubes were recessed below :he newly spotfaced area of the tubesheet. Weld repairs started on 5/30/79 by manual grinding and revelding.

~he decision on the four (4) tubes mentioned above was to respotface the tubesheet flush to the top of the tube and reweld. ~his was co=pleted on 5/31/79.

14. Se final visual inspection and video raping of the 92 reworked lane :ubes was conducted on 6/1/79. The PT examination was then started and completed with some delays on 6/2/79. Three (3) tubes were required to be repaired as a result of PT examination.

Based upon equipment perfo::ance and schedule considerations, it was decided to hal f urther OTSG repair work at this time.

15. The ring girder removal was s:arted on 6/2/79 and was completed on 6/3/79. All pieces were wiped down, bagged and marked, and placed by the R3 equipmen: hatch laydown area.

16. The upper tubesheet was vacuumed and cleaned on 6/3/79. Tubes for the surveillance program equipment were opened and the surveillance program initiated. The surveillance program was completed on 6/6/79 with no major problems. A final video scan of the upper tubesheet was made af ter removal of all equipment.

17. The recirculation flush system was set up on 6/5/79, and flushing was initiated on 6/6/79. However, leaks in the recirculation flush system finally forced abandoning this approach. A desineralized 2.20-4

T -*

s water flush was 1:1:iated on 6/7/79 and ran for 6 hours6.944444e-5 days 0.00167 hours 9.920635e-6 weeks 2.283e-6 months . A final QC inspection and Chem / Rad C1' leach test found the upper head acceptable.

18. he lower head of 3-0TSG was drained on 6/7/79 and the tempo rary sanway ;over re=oved on 6/8/79. *he J-leg and draim hole screens were removed and :he lower head was vacuumed. However, a few loose chips remained and in the process of tryi g :o remove them, muslin cloths were inadvertently used instead of lint-free rags. Since the muslin was only used in limited areas, it was decided cha: solvent cleaning of the lower head could not be justified due to the high radiation exposure. The 3-0TSG was

urned over to F?C mechanics for closeup on 6/3/79.

19. *he upper head was closed up on 6/9-10/79 and the lower head on 6/8-12/79. This ended that ac:ual repair ef fo rt.

20. On 6/3/79, in preparation for removal of :he repair equipment, a team en:ered :he 13 to verify appropriate markings on the pieces. At this ti=e ,

the ring girder equipment was found missing. An incensive search was ini: aced and on 6/9/79 some of the major pieces were located on a large wooden I.SA shipping crate. On 6/13/79, au:horiza: ion was given to inspect sealed waste drums and four consecutive dru=s were found to contain ring girder parts.

However, che waste drums before and af:er these four were already shipped and were not recla1=able. On 6/27/79, two more major ring girder pieces were found in the contaminated s torage trailer in incorrectly sarkad bags. All available pieces of

he ring girder equipment have been cataloged and placed in storage as of 6/28/79 (refer :o Attach =ents 2. 20-F, C, and H).

C. Schedule A comparison of A::achments 2.20-A and 3 will show that the ac:ual duration of the repair efforts was 21 days longer than the original esti=ated schedule. Some of the more significant delay 1:ess encountered are explained below:

1. Shutdown delays (e.g. , SPs on RC7-8, DEV-3 and a operation) in cura delayed 3: art of the OTSG work.

s~l.0 days)

2. Scaf folding and tent erection at :he upper and lower

anways due to coordination and sanpower experience problems. (-1.0 days) 2.20-3

3. Manway cover removal and replacement problems.

Lower manway removal was hampered by sticking nu:s and replacement by problems with the new stud tensioner. Upper manway and inspection cover replacemen also ran into days. 42.0 days) 4 Removal of C"'SG insulation also took longer than scheduled for unknown reasons. 40.5 days)

5. We temporary =anway cover installation was delayed due to problems with initial fitup and then :he leaking gasket requiring re= oval, replace =ent and reinstallation. (~1.5 days)

6. Setup of the eddy current manipulator due to equipment proble=s and some handling / installation proble=s. (~0.5 days)

7. Gauging of the 1000 random tubes due :o some equipment proble=s and the fact that =any of the pri=ary identified tubes would no: pass the 0.500" probe. "'his required addi ional ti=e spen: hunting for backup tubes. G-0.5 days)

8. Ring girder installa: ion due to various problems w1:h tube 1Ds required for holddown devices, camera f unctions , milling head operation, and vacuus o pe ra tion (.~i . 5 days ) ,

9. Spotfacing of lane tubes due to more ti=e ant;' -ipated fo r operation, especially with =illing head changeout and crossbar re= oval for access to outer periphery. (~1.0 days)

10. Tube end opening for eddy current sa=ple due to pr-ble=s noted in 9. above plus lack of hardware e e. . uverability and larger than anticipated nu=ber to be opened. (-3.0 days)

11. Welding of spotfaced tubes due to =assive welding unit problems. 48.0 days)

12. Manual repairs of reject welds due to larger nu=ber of rejects than expected. W2.0 days)

13. Penetrant testing of welds =ainly due to loss of penetran: and time to replace. 40.75 days) 14 Ricg girder removal due to excessive tangling of control cables and need to wipe down and bag these highly contaminated pieces. 6 25 days)

15. Surveillance program due :o minor setup problems and need for some retakes. 40.5 days) 2.20-6

. . . s

e . .

16. Recirculacion flush due :o the laaky recirculacion system. H .25 days)

The above to tals.~24. 25 days of delay time.

There were some 1: ems that were completed ahead of schedule and saved schedule time, such as:

1. J-leg screen installation. M .1 days)

2. Skyhook ins:allation. (~. 2 days)

3. Freeze fra=a inspection. (~1.5 days) 4 Heater installation and cubesheet heating. @0. 2 days)

5. Tube end deburring. (-0.4 days)

6. Wire brushing of welds. M .5 days) 7 Video inspection of weld reworks. (4. 2 days)

8. Upper tubesheet vacuuming. H .3 days) 9 Lower head cleaning. M .3 days)

These schedule savings :ocal coa 3.7 days. The ne:

result between delays and savings is the -21 days delay in the overall repair ef fort. T.a looking a: che delay items, the following breakdown should be noted:

- 78* to repair equipmen: proble=s

- 20% .o siscellaneous problems and setup delays 2~ to surveillance progras problems D. Personnel This repair ef fort was perfor=ed mainly by a MW crew using boilersaker craf: labor. The basic orgsnization and staffing is shown in A::ach=en 2.20-C. The :vo week sockup training session was essencial17 condue:ed on a one shif:/ day, six day / week schedule. Once actual repair efforts started, the crews were shif ted to :hree shif ts/ day, seven day / week for the duracica of the job.

Due to the high radiation levels in the OTSG, crai: labor had :o be used for sost of :he non-technical work in order to minisire exposure to the MW cachnicians. This required an ex:ensive craining program for :he boilermakers. The craining progras consisted of video tape training aides and hands-on cockup training or equipment setup and teardown. L2 addition, boilermaker wilders were trained and qualified to perfors =anual weld repairs if required. A::achment 2.20-0 provides a breakdown of :he =an rem exposure for the repair ef forts, which to taled-112.3 Res.

In general, the use of this labor force worked fairly well, and i: is recommended tha 1:s use be con inued for any future repair ef forts. One point should be noted,

hat any sanway cove: removal and replacemen: was done 2.20-7

with FPC sechanics and this should be continued since they are felt to be better qualified for these ef forts.

E. Procedures All repair procedures for this ef fort were written on-site by 36W Con.;:ruction Company and issued as field construction procedures. The procedurcs to cover the surveillance program were wri::en as a PRR to MP-104.

The source document for :hese procedures was the B&W Field Change Authorization #3062 which was converted into MAR #79-4-68.

In general, this approach worked well and for this type of effort, with B&W providing :he technical expertise, is probably the best approach. Tae only real procedural problem that arose during the repair ef fort involved the use of the muslin cloth during :he lever head cleanup.

~he repair procedures did not adequately specify how :o clean up the lower head nor wha: =aterials should and should not be used in the primary system. *his needs :o be corrected in future repair procedures. A::ach-ment 2.20-E provides an index of the procedures used for this repair eff or:.

F. Parts and Tools

~he special tooling used for the repair effor was designed by, and procured fro =, 3&W. The original design goals for :he equip =en were to perform a =ajor repair ef fort as remotely as possible. The repair equipment essentially consisted of the following 1: ems:

1. Eddy current manipulator for use in freeze frame photography and with an air cylinder and 0.500" gauge for tube end gauging.

2. Grinding machine for use in large scale tube end and/or weId renoval (not used this outage).

3. Ring girder =achine with straight-on and right angle heads for tube machining. Cu::ers are capable of both spotfacing and/or tube ID opening.

4 Welding head that mounts on ring girder machine with power supplies. Used for performing the tube to tubesheet weld.

5. 3 rushes for mounting in =1111ng machine head for tube end deburring and weld brushing.

6. Roll expander for mounting on ring girder for expanding the top 1/8' of tube end.

2.20-8

. e 9 . a

7. Heaters for drying out the crevice area.

3. Penetrant testi::g rig for applying phosphorescent dye penetrant fo r remote PT exasination of new welds.

9. Tempo rary lower sanway cover w1:h no::le aad valve to be connec:ed to a pump for a recirculacion flush of :he :ubes.

10. Surve nlance inspection equipment for use in obtaining high resolution pic:ures of the velds for the surveillance program.

Ll. Vacuu:s system

12. Control cables and special pene: ration cover fo r Fenetration 120 in order to allow use of con:rol center exterior to con:a1=ent.

With :he exception of installation, removal and repairs,

he above equipment is remotely operable from ou: side the OTSG. I: ems 3, 4, 5, 6 and 3 above are operated frca a control center -tich was housed in a vehicle located on the wes end of :he Turbine Building. Control cables

.(400') were run frcm the 3-0TSG :hrough con:21=en:

Fenetration 120 and then through the chemical cleaning penetration at :he ves: end of the Inter =edia:e Building to the control center.

As noted in See:1on C above, proble=s with the repair equipment resul:ed in ~73*. 4vi9 days) of the total repair ef fort delays. The sajor problems in this area were che welder units and the ring girder itself. The velder units' proble=s appeared to center on :he following areas:

1. Scurdiness of :he hardware / handling.

2. Electrical feedback and grounding problems.

3. Proper operacion of the indexing / centering finger and controls.

4 Control of argon cover gas.

With respect to the ring girder operation, the main problem area appears to be lack of saneuverability. Fo r angular rotation,1: is required that the front cross brace be installed in order :o provide rigidity to the rails during =ove=ent. However, wnen pe rf o rsing work in the outer peripher7 region of :he :ubeshee:, the f ron cross brace =us: be .emoved for access. Thus, any extensive cuter periphery work requires repeated, time consuming OTSG entries to install and remove :his cross brace. The mul:1:ude of control cables are also an in:erference problem. Since they. are not self-tending, 2.20-9

ring girder movement can cause them to go slack and hangup on the unit or to go :oo :1ght. Either of these can restrict movement, cause pulling apart at connectors, or cause =isalignment of cameras. In addi:1on, :he number of cables running in through the =anway are interference problems for the men =aking entries, which can result in cable pulling proble=s as described above.

~he re=aining delays caused by repair equipment proble=s can mainly be wri::eu of f to first-of-a-kind problems and were not extensive. The one exceptien is the recirculation flush system using the :emporary lower

=anway cover. Th 4elays this setup caused due to leakage problems far overshadowed any potential benefits of the system. Since the de=ineralized water flush from

he upper head proved to be efficient, both for las:

outage and as a backup for this outage, 1: is reco= mended that the recirculation flush system, including the

emporary sanway cover, not be used in the f uture.

Presently, the repair equipnent is in storage at Crystal River Unit 3. The following attachments provide the present status of the equipmen: and storage locations.

- A :ach=ent 2.20-F "A" Ring Girder Uni: Parts Status

- A::ach=ent 2.20-G "3" Ring Girder Uni: Parts Sta:us

- A::achment 2.20-E Repair Equipment Storage Locations C. Co=ments and Reec==endations Based upon the results of the repair af fort and the status of the equipment to date, the following coc=ents and reco=menda ions are offered:

1. As noted in Section F above, the repair equipment is in various storage locations. Some of the equipment must be =aintained in a controlled environment, which should be =onitored. In addition, any movement of the equipment needs to be noted for f uture retrieval. Thus, a syste= for periodic monitoring of the equipment status (location and environment) should be set up for at least the next cycle.

2. Based upon the problems encountered with the repair equipment, 1: is suggested that B&W be asked to generate a recommended list of i=provements. A

=eeting of all parties should be held to discuss the course of action on equipment improvements and for replacement of damaged or =issing pieces.

3. B&W is presently reviewing :he results of the surveillance program conducted during the outage.

The report on the surveillance program still needs to be submitted by B&W. In addi: ion a determination 2.20-10 Y

t seeds to be nade as to -hether or no: :o submi: the resul:s of :he surveillance :o :he :TRC, in wbac fa::ac, and by whom.

4 The resolution :o :he four tubes : hat were suspected of being relaxed was based upon some interi= tes:

resul:s. These :ests showed : hat :he new welds are satisfac:ory fo r :he nex: cycle of opera: ion.

However, a note extensive testing program needs to be initiated in order to pe:21: continued operation with these welds in service af:er the nex: outage.

In addi:1on, a decision as :o -tac inputs on this subjec: should be given to the NRC needs :o be made.

5. Future repair procedures need :o be core specific as to wnac =acerials should not be used in :he OTSG in order to prevent a reaccurrence of the auslin cloch incident. *his fac: needs to be fed back. :o 3&~4 for future procedure generation and needs :o be enforced during ?RC review of :he procedures.

6. A decision needs to be =ade as :o the ex:en: of repairs to be condue:ed a: the nex: ref ueling outage.

I:ess : hat need :o be considered are as follows :

- Surveillance inspec: ion program

- Additional :ube end opening for eddy current

esting

- ?.x:ent repair equipcen is :o be naistained for a possible najor repair

- Necessary repair techniques if addi:icnal work needs to be done on the four suspec: relaxed :ubes I: is suggested that a mee:1:g of interested parties needs to be held soon af tar this outage in order to discuss these copics and lay out the future repair p rog ram.

7. Misplace =ent of a large amoun: of :he ring girder equipment and even:ual loss of a number of pieces points to a need for better con:rol and staging of contaninated equipment. Procedures need to be generated in order to impose a better control system in order :o =1sisi:e future losses.

3. Celays in nanway cover re= oval and replace =en: pois:

to a need for improved procedures, equipment and/or training. This needs to be pursued for nex: ou: age.

2.20-11

4 FISPONS1 ELE RECCMMEh")ED AC'" ION ITEM DEPT /?ERSON COM?. DAU

!. Monthly Monitoring Maintenance /G. Westafer Monthly starting of Repair Equipment Chem Rad /G. Perkins 8/1/79 to next Sta tus . B&W/ W. P. E11sberry outage

2. Equipment Improve- Engineering / J. Colby 9/1/79 ment / Replac ement B&W/J. Janis Meeting.

3. Sub=ittal of B&W/J. Janis 9/1/79 Surveillance inspec: ion Report.

Determina: ion of Engineering /J. Colby 9/15/79 input to NRC. Licensing /3. Simpson

4. Establish Testing Engineering /J. Colby 9/1/79 Progran for Tube B&W/J. Janis Welds.

De:ermina:1on of En;;ineering/J. Colby 9/15/79 Input to NRC. Licensing / B. Si=pson

5. Update Future Repair B&W/J. Janis By next ref ueling Procedures to ou: age Reflect Materials Restrictions.

6. Future Repair Engineering /J. Colby 9/15/79 Program Meeting. S&W/J. Janis

7. Cant amina t ed Chem Rad /G. Perkins By next refueling Equipment Control Maintenance /G. Westafer outage Proc edure s.

8. Improve =ents in Maintenance /G. Westafer By next ref ueling Manway Cover outage Removal / Replacement.

2.20-12

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At t acliment 2.20-C - Itepair Ef fort Organization OTSG Coordinator J .1111 f onE_

Secretary

.I . S . Shetler V itleo llW , CC Support Project Hgr.

P.Al>hott R. Spruill l

NP(;D

'"I' Field QC Shift Coordinatton I. abor , C. Cox 0

I"' I'I 1 Field Supt.

I..K. Prince y3g _g g)

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~ ~ ~ ~ ~ ~ ~ ~ ~ " " * " " ' ' E"" 8 "

(1500-2400) 8 Ilollermakers

ATIACIBiEST 2. 20-D B-0TSG REPAIR MAN-REM EXPOSL"RE WORK DESCRIPTION EXPOSURE (MPIM) RWP Misc. Suppo rt 187 065 Work Outside lower Head 740 064 Install Screens in 1,ower Head 1944 066 Install Skyhook & E.C. Manipulacor 5924 067 Perforn Free:e Frane Photography 2304 067 Remove Skyhook & E.C. Manipulator

& Install P.ing Cirder 27585 285 Gage 1000 Tube Ends 4908 076 (40%)

Spotface Lane Tubes 1840 076 (15%)

Deburr Tube Ends 613 076 (05%)

Open ids of "X" Tube Ends 4908 076 (40%)

Rea: Tubesheet 966 077 (05%)

Roll Expand Tubes 1932 077 (10%)

Install Welder & Weld Tubes 39186 077, 386, 429 Ins pec t & Repair Welds (Manual) 8177 429 (25%)

PT Inspec: Welds 3990 429 (25%)

vacuum Upper Tubeshee: 407 082 Flush Upper Tubesheet & Tubes 1080 069 Clean Lower Head /Renove Screens 1707 086 Perforn Surveillance 3910 This figure was derived by computation Search Waste Drums 515 515 TOTAL

112,823

This :otal agrees with the total exposures of all B&W individuals employed in the perfornance of the OTSG repair.

ACAcaiRNT 2.20-E INDEX CF 3-0TSG RR?All PRCCROURR CRR-2 Sa allation and Removal of Skyhook and Eddy Curren:

Manipulacoe CRR-2 Inspection of Tubes to be Used for Ring Girder Holddown CRR-2 hstallacion and Renoval of :he Ring Cirder Assembly and Milling 7acuus Sys:e:2 CRR-2 Inscallacion and Removal of J-Leg Screens CRR-2 Spo: facing and Opening of Designated Tubes CRR-2 Deburring of Machined Tubes CRR-2 Hea:1 g and Expanding of Tubes :o ba Welded CRR-2 batallazion of Welding Equipmen: and Re=ote Welding and 3 rushing of Spo: faced Tubes CRR-2 Installa:1on of FT Equipment and 7' Inspection of Welded Tubes CRR-2 Installa:lon and Removal of Shieldfsg , Manual Welding of Outer Row Tubes and Reworking of Rejec:ed Tubes CRR-2 Ins:alla:1on and Ranoval of "espo rary Lswer Manway Cover and Racirculation Flush Systen PRR :o MP-104 - Surveillance Inspeccion

A 7ACHMENT 2.20-F "A" RING GIRDER UNIT PARTS STAT"S

1. "Y" Axis Ring Segment la Storage Trailer

2. "Z" Axis

3. - Axis

4. "X" Axis

5. ~I" Plus Box Frame Half

6. ~X" Minus Box Frame Half

7. Fear Brace

8. Iron: Brace

9. Rear Spring Suppor:

10. Machining Table

11. Machining Carriage

12. Theta F.ncoder

13. "R" Drive Motor

14. "X" Drive Motor

15. ~2" Drive Mo tor In Storage Trailer

16. Theta Drive Motor Missing

17. Theta Brake

18. "R" Drive Encoder

19. ";" Gear Rack

20. ";" Encoder

21. "X" Encoder

22. Hydraulic System In Storage Trailer

23. Air Motor Assembly 24 Tool Cu :ing Head

25. Angle Drive Gear Head

A?"ACletE Tr 2. 20-F ( Con t ' d)

26. Drive Shaf In Storage Trailer

27. Stiffener 3ar

~

28. Rear 'com Camera

29. Rear Tool Head Camera Missing

~

30. Fron: Tool Head Camera

31. Ligh: 3ar In Storage Trailer

32. Swivel 3recka:

33. Cabla Tray In Storage Trailer

~

34 Manway Support for Cable Tray

~

Roll T.xpander Air Manifold Roll Expander Expansion Uni: Missing Liquid Pene:ran: Tes: Uni: Partial in Storage Trailer Liquid Penetrant Tes: Uni:

Cameras (2) In Storage Trailer Corner Mount Pan & Tilt Canera Miu _ng Overhead Pan & Til: Camera In Storage Trailer

'4elding Uni:s (2 NED)

(1 Copley) In Storage Trailer & '4arehouse Freepach Equipsen: In Storage ( Aux 1]iary 3uilding)

Surveillance Equipment In Storage Trailer Motorname/ Con:rol Center In Storage a: Copley 3ackup Ring Girder In Sto rage ('4arehouse)*

Detailed Inventory on Separate Docusent

--'ACEME!C 2. 20- G "3" RING GIROER UNIT PARTS STA US PART NO. # OF PCS. DESCRIPTION STATUS 1-4 8 ea. Ring Segnents Storage at FPC Warehouse 5 1 ea. Bor Frane Half 6 1 ea. Box Frane Half 7 1 ea. Rear Brace (1) 8 1 ea. Front Brace With A Unit in Contanin-ated Storage Trailer 9 1 ea. Rear Spring Support Storage at FPC Warehouse 10 1 ea. w achine Table 11 1 ea. . chine Carriage 12 1 ea. Tneta Encoder 13 1 ea. " R" Drive Mo tor

~

14 1 ea. "X" Drive Motor

~

15 1 ea. "2" Drive Motor 16 1 ea. Theta Drive Motor 17 1 ea. ~heta Brake 18 1 ea. "R" Drive Encoder 19 1 ea. "Z" Gear Rack 20 1 ea. "Z" Encoder 21 1 ea. "X" Encoder 22 1 ea. Hydraulic Systen (1)(2) 23 1 ea. Air Motor Assenbly Stand in FPC Warehouse (Motors & Manifolds used on A Unic & are =1ssing)

(1)(2) 24 1 ea.- Tool Cutting Head With A Unit in Contanin-ated Storage Trailer (Needs Repair) 25 1 ea. Rt. Angle Drive Cutting Head Storage at FPC Warehouse a

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A "'ACEMI!C 2. 20-G (Cont'd)

? ART NO. J CF ?CS. DESCRIPTICN STATUS (1) 26 1 ea. Drive Shaf: '41:h A Uni: in Con:asin-ated Storage Trailer 27 1 ea. Stiffener 3ar Storage a: FPC Warehouse 23 1 ea. Canera 3racke:

~ ~

29 1 ea.

30 1 ea.

Cl)(2) 31 1 ea. Ligh: 3ar 3racke: with A Uni in Contanina:ed Storage Trailer (Needs Ligh:s)

{!) 32 1 ea. Swivel 3racke: '41:h A Uni: in Contamin-a ed Storage Trailer (1)(2) 33 1 ea. Cable Tray Wi:h A Uni: in Con:ssin-ated Storage Trailer (Needs Repair) 34 1 ea. Cable Tray Itinny Suppo rt No Supplied on 3 Uni:

NOTE: (1) Parts requiring replacenen: to naistain 3 Uni: as. a nack-up t:si:.

(2) Far:s requiring repairs to =ake 3 Uni: opera:1onal.

A*TACHMEN* 2.20-H REPAIR EQUIP".ENT STORACE LOCATIONS

!. IN ENVIRONMENTAL STORAGE TRAILER ITEM # DESCRIPTION TAG #

1 Air Dryer 31 2 Weld Cables 1 3 Machining Carriage for Ring Girder 16 4 Punp 13 5 Light Cords and Welding Leads 7 6 Pun; 9 7 Air Hose 15 8 Vacuun Cleaner Hose 11 9 Coarial Cables 17 10 Air Rose 23 11 Welding Leads 19 12 Cable 22 13 Hose Connecto rs 18 14 Assorted Nuts & Bolts 21 15 Canera Cables 8 16 Tenplets and Clearcom Headphones 4 17 Conductor Leads for Heaters 14 18 Stress Reliever Heater Power Supply 29 19 Stress Reliever Heater Power Supply 30 20 Air Conpressor 27 21 Barberton Welder Power Sup ..y 25 22 Copley Welder Power Supply 33 23 Assorted Extension Cords and Connections 1 24 Machining Table for Ring Girder 6

AmCEMEN! 2. 20-H (Conc'd)

InM / DESCRI? TION TAG 1 25 3ox of Temp. Manway Spacers 20 26 Tripod for Candy Cane 10 27 Manual Welding Supply 23

.23 Welder Stand 5 29 3arberton Welding Head 3 30 Copley Welding Read 2 31 31ack Light fo r PT 12 32 Junction 3cx and Cables for Welder - 22 33 Camera Hanger for Overhead Pan & Til: 32 34A Ricg Girder Par:s:

343 GIRDER PART J DESCRIPTION 1 "X" Axis Ring Seg=en:

2 *Z" Axis Ring Seg=en:

3 "W" Axis Ring Seg=en:

4 "W" Axia Ring Segmenc 5 I "Plus" Sox Frame 6 I "Minus* Sox Frame 7 Rear 3 race 3 Fron: 3 race 9 Rear Support Spring 13 "Z" Drive Mo tor 22 Hydraulic System 31 Ligh: 3a r 32 Swivel 3rackat 33 Cable Tray 34 Tray Manway Suppor Roll Expander Manifold Parts for Fr ~ Test Equipment II. STORED IN MEC9.ANICS ' TRAILER DESCRIPTION:

7acuus Sys:em fo e OTSG Work Temp. OTSG Manway Cover (Contamina:ed)

(~'he se 1:ess could not be stored in Environmental Trailer because of lack of space)

AI"ACHMEhi 2.20-H ( Co nt ' d)

III. EN7IR0hM h*IAL WAPEHOUSE EQUIPMEhi STORAGE BOX # ~ DESCRIPTION 1 Welding Console, #1, NED (Barberton) 2 We. ding Console, #2, NED (Barberton) 3 Powe r Supply, for Walder, NED (Barberton) 4 Spare Parts, "B" Ring Girder 5 Rails , ~3" Ring Girder 6 Pilot Asse=bly for #1 Weld, NED (Barberton) 7 Spare Parts, Welder, NED (Barberton)

S Circulating Tank. for 3elt Grinder 9 Electrolytic E:cher (A) 10 Bel: Sander (3) 10 Rose Assenbly 11 Welding Head, #1, NED (Barberton) 12 Not Listed -- Stored in Mock-up Area 13 Tubeshee: Grinder, Spare Parts 14 Cut Off Saw 15 Tenp. OTSG Manway Cover 16 Circulating Pu=p for Cut Of f Saw Tubeshee: Grinder Oper. Console (2 boxes)

Air Manifold for Grinder w/0ilers 2nd Filters Assorted Cable Harness for Tubesheet Grinder Cente rpost for Tubesheet Grinder Grinder Arn, #1 Grinder Arm, #2 Box (2 ea.) Trionics Digital Electronic Readout Panels (for Grinder)

ATTACH?.ENT 2. 20-E (Cont'd) 30X 1 DESCRIPTION

- Penetration Cover w/ Adjustable Passchru Por:

- 3cx Electronic Equipment

- Box Spare Parts fo r Grinder

17. El MCCI-UP AREA WIRE CACE 30X 1 ::ESCRIPT!ON 12 Ring Cirder Cables, A Cables and 7acuu:2 Roses 3 (Spool) Spare Pan and Til: Cable 4 (S pool) ND Welder Cable, Spara 5 (Spool) NED 300' Spara Weldi:g Cable

7. STORED Ci INCLIS SPCCL 1 CESCRIPTION 1 400' Ring C1 dar Asse=bly Control Cables 2 400' W1 ding Control Cables

UNSCHEDULED REPAIRS OF B-0TSG DURING PERIOD FROM 8/18/79 THROUGH 9/8/79 (Extracted f rora MPR Report to FPC dated 9/25/79)

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M P R ASSOCI ATES, INC. A JJ 4 /1 DIlCV: neM G September 25, 1979 Mr. D. A. Shook Florida Power Corporation Post Offico Box 14042 St. Petersburg, Florida 33733

Subject:

Repair of the "B" Steam Generator Tube-to-Tubesheet Welds at Crystal River Unit 3 ,

Dear Mr. Shook:

Per your request, we have prepared a summary of results of the August / September 1979 repair and inspection effort associated with correcting leaking tubes in the "B" s t e. .m generator of CR-3 (Enclosure 1). As indicated in Enclosure 1, a total of 31 tubes had to be repaired during the August /

September 1979 outage. In addition, one tube was inadvertently plugged. Cut of the total 31 defective tube wclds reworked during this outage, 29 of the defec:ive tube welds were a re-sult of repair effort on 92 tubes during the May 1979 outage.

Two other shop welded tubes had leaks and were repaired.

Based on the above results, we do not belicve we have a reliable technique for repairing the steam generator tube weld leaks if they develop. Further, we bbyio9e that one of the major problems in making reliable repair welds is that many of the techniques used during the outage were such that they could draw moisture into the weld area. Specifically, by allowing the repair area to cool off after the tubcshcet arca was pre-heated by various means, in our opinion, draws or sucks moi.qturc into the weld region. Then, when the repair wcld is made, the moisture, along with other contaminants such as boron, causes problems ir. making satis' factory wcld repairs reliably.

In addition, the inspection technig.es that were used during the early phases of the operation were not reliabic, since followup inspections kept identifying new defects or defects that had been missed from earlier tube repair efforts.

Accordingly, we believe that additional development work needs to be donc to establish reliabic weld repair procedures and improved inspection techniques for locating leaks as well as confirming that a tube has been satisfactorily repaired.

1140 CcNa tcticut Av tNu t. N. W. WASHINGTON, o. c. 2003 6 202 659 2320

a -

. s' M P R ASSoCI ATES. INC, Mr. D. A. Shook -

2- September 25, 1979 Enclosure 2 is an outline of the development effort,we believe is necessary to be ready for an effective tube repair program at CR-3. This program consists of five elements:

~

1. Development of procedures for reworking tubes that were

' field weld repaired in May 1979.

2. Development of techniques for recovery of tubes plugged during the August / September 1979 outage.

3. Repair of shop wclded tube-to-tubesheet welds that werc damaged by the BPRA failurcs in early 1979. .

4. Development of improved inspection techniques, both gen-eral inspection techniques to locate leaking tubes, and detailed inspection techniques for assuring that tubes have been satisfactorily repaired.

5. Dcyclopment of detailed secp-by-stcp procedurcs with signoff points for controlling the repair and inspection work. In this regard, we believe that lack of attention to minute details is a significant part of the trouble in making satisfactory welds under in-service conditions.

There are many detailed steps required to make satisfac-tory in-scrvice welds and to inspect them properly. It is very casy to forget or miss a cri tic.al s tcp, particu-larly in the rush to minimite personnel exposure.

Insummary,webelievethatoneoft$emajorproblemswith the welding techniques that have been develoced to date is that adequate consideration has not bec'n given to'the fact that these tubes have been in-scrvice and have been affected by contami-nants from the secondary system that are deposited in the area of the tubc/tubcsheet crevice. In some cases whero leaks have developed, the tube-to-tubesheet crevice has also been affected by borated primary coolant. Accordingly, to develop satisfac-tory techniques in repairing and inspecting such welds, the development program must use mockups that take into account in-scrvice type conditions.

. If you arc in agreement with the above, you may wich to forward Snclosurc 2 to B&W for their consideration in developing such a program. In this regard, it is recommended that FPC obtain, review, and agree to the detailed scope of BsW's repair and inspection program to ensure that the issues in Enclosure 2 are addressed. With regard to priority of effort, we belicve it should be placed on development of techniques to pinpoint leaking tubos (Item 4 above), since CR-3 may need this at an

M P R ASSCCIATES. INC.

Mr. D. A. Shook September 25, 1979 carly date. Also, this program should be focused and tailored to mcct just the specific needs o f Ca-3 (sco Enclosure 2), and not be a general all-encompassing R&D type program, or the cost will become very high.

If you have any questions or cc:rr.ents regarding this letter or its enclosurcs, please do not hesitato to contact me.

Sincerely, f'f ' f,

//2)%

,Noman M. Cole, Jr.

Enclosures cc: J. E. Colby P. Y. Baynard G. P. Boatty 9

9 S

k

Enclosure 1 to MPR Lotter dated M PR Assoc:ATES. INC. Septentbeh 25, 1979 CRYSTAL RIVER UNIT 3 OtICE-TIIROUGIf STEAM GENERATOR "B" UtlIT LANE TUBE REPAIR EFFORT DURING AUGUST AND SEPTEMBER 1979

\ /

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O e

"B" STEAM GENERATOR WELD PROBLEM

SUMMARY

SIIEET FO R C 2- 3

1. 92 lane tubes repair-welded during the May 1979 CR-3 cutage August / September 1979 outage:

2.

a. Of the 92 lane tubes repaired 29 found defective in May 1979

b. Original shop welds found leaking 2

c. Plugged one tube by error _1 .

Total repaired tubes 32 tubes

during outage

Of these 32 repaired tubes, the following should be noted:

(1) 16 tubes were repaired by removing them from service by welding " nail-plugs" in the top of the tubes and installing explosive plugs in their bottcms.

(2) Many of these 32 tubes had anywhere between one and four repairs. The total number of repairs on tubes (some tuces repaired several times) was 6i.

53 /

a e

SU:*. tARY OF ALL REPAI R At3D IllSPECTIOri CYCLLS DURIrlG AUGUST /SEPTt:MBEli 1979 OUTAGE ,

TitIRD REPAIR At3D FOU R rli I(EPAl h At3D FI FTil I<EPAI R A!;D ItJITIAL l FIRST REPAIR A'JD SECOND REPAIR A!!D ItJSPLCTIOt3 CYCLE IliSPECTIO:4 CYC1.E II:SPECTIO!1 CYCLE ItJSPECT'.O!I CYCLE ItiSPECTION IrJSPECTIO:4 CYCLE TUBE TUDE TUBE TUhE TUuE TUDE TUHE TUDE TURE AT START Of TUDE It3S PECTI O!J i(EP Allt I!J S P ECT IO!1 IriSPECTION HEPAl lt !!1SPECTION l<L P A I R I:3 S P ECT I Ot. REP A l lt AUGUST 1979 itE pal lt LJELDS i< f S U LTS OUTAGE 6JEl.DS RESULTS llELOS RESULTS 110L0S l< t:S U LTS tJELDS 1(ES U LTS 21 Leaking ' Itepair of 10 had Repair of 4 bad kepair 01 4 bad Itepai r ct All re-Itepai r o!

tubes tubes repairs tubes repairs tubes repairs tubes paired Tubes welds with bad with bad with bad with bei with bad welds welds 2 bad welds 6 new bad welds 3 new or welds satisfac-from 5/75 =12 tubes '12 tubes all repeat =7 tury outage from tdentt- welds

=19 first tied that are

~

repair bad i<epair tc .. .es cycle 2 bad original tubes shop from welded earlier tubes 3 new r e g.a i r damaged bad cycles by UPltAs tubes

=2 s identi-fied Total 12 still Total 12 still Total 12 still Total 7 still rotal 0 still Repairs bad Hepairs bad , Hepairs bed Pepairs bad Hepairs bad

=21 -12 =12 ul2 =7 f

See Table 1 See Table-2 See Table 3 'S e e Table 4 See Table 5 l l TALLY:

1. 64 weld repairs made total ,

2. 29 tubes reworked that were repaired in May 1979 l

. 3. 2 tubes had the original shop weld repair

4. I tube inadvertently plugged in error

5. 32 total tubes repaired during August / September 1979 outage (16 tubes plugged and removed from service)

e I. May 1979 Outace A. 92 lane tubes reweided

1. Inspected by LPT (water washable and viewed by TV)

(Mote: The planned nitrogen bubble test was waived for some reason.)

II. August 1979 Outage * (NAucust 18, 1979) ~

A. Initial August 1979 Inscoction The initial inspection of the "B" steam generator at the beginn'.ng of the outage to find the source of leakage indicated the following:

1. An initial inspection with " Leak-Tec" (i.e.,

a bubole leak check fluid with back pressure of 100 to 160 psi of helium) showed:

a. 19 of the 92 lane tubes repaired in May 1979 were lear.ing.

b. Two cricinal shoo welded tubes that had been " beat-up" oy tne loose opRA were found leaking.

c. Total of 21 leakina tubes (i.e., a + b).

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Plant had to shut down for reactor coolant pump seal

- problems.

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,II.B. First Rcpair Effort (21 Tabec - %Aucust 18, 19795

1. Repair consisted of local grinding out of weld defects and then, several hours later, local repair by adding filler metal to a total of 21 tubes.

2. The Leak-Tec inspection following the first repair showed the following:

a. Of the 21 tubes repaired, 9 tubes were still leaking.

b. In addition, the inspection identified 3 more lane tubes that were rewcided in May 1979 to be defective. ,

c. The net reuslt of this inspection was that a total of 12 tubes (a plus b above) now had to be repaired.

3. During the Leak-Tec inspection, the steam gen-erator instrumentation indicated that secondary side water was raised to a level of at least the top face of the upper tube. This means that secondary water could have gotten into the crevice between the tube and tubesheet, which could in turn have been a consideration.and had an impact on the second weld repair effort. The control of secondary water level (e.g., procedures and operations) was difficult.

4. The ' detailed list of s'pqcidic tubes involved in the first repair and inspection cycle is in Table 1.

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2- ,

II.C. Second acuair Effort (12 Tubes - Late August)

1. Repair consisted of local grinding out of weld defects and then, several hours later, having a welder lay dcwn a local preheat weld bead on the tubesheet surface ad]acent to local areas to be repaired. After laying down the preheat wcld bead, the welder then made a local repair of the defect area by using one fusion puddle fol-lowed by one local filler pass.

2. The Leak-Tec inspection following the second repair effort showed the following:

a. Of the 12 tubes repaired during this re-pair cycle, 10 were still leaking.,

b. In addition, this inspection identified 2 tubes that were repaired during the first repair cycle in II.B above to still be defective.

c. The net result of this inspection was that a total of 12 tubes (a plus b above) now had to be repaired.

3. During the Leak-Tec inspection phase, steam generator water level instrumentation indicated that secondary water had been raised to a level of about the top of the tubesheet. Alco, sec-ondary side water was noted to be squirting out

~

of some of the cefective tpbe/tubesheet recair welds. This secondary'0ater could have af'fected and impacted the subsequent third wcld repair effort.

4. The detailed list of specific tubes involved in the second repair and inspection cycle is in Table 2.

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s II.D. Third Repair Effort (12 Tubes - % September 1, 1979)

1. The repair consisted of: .

a. Spot facing to a total depth of 0.100' inch from the top facc of the tubcshcct.

b. Hard roll expansion of the tube for about 0.6 inch to 0.75 inch depth. The hard roll resulted in approximately 4% wall thinning of the tube,

c. An electrical blanket preheated the lane area and heated the tubes to 340*F.

d. About 2 to 7 hours8.101852e-5 days 0.00194 hours 1.157407e-5 weeks 2.6635e-6 months after completion of the preheating and subsequent cooling down, welded by two filler metal passes (i.e.,

two 360* plus passes).

2s The Leak-Tec inspection following the third repair effort showed the following:

a. Of the 12 tubes repaired during this repair cycle, 4 tubes were still leaking.

b. -In addition, the inspection identified 8 more tubes that were leaking. A breakdown of tnese d tubes is as follows:

(1) 2 tubes were repaired during the first and second re,caips (see II.A and II.3).

N (2) 6 tubes that were rewelded in May 1979.

c. The net result of this inspection was that a total of 12 tubes (a p.lus b above) now had to be repaired.

3. The steam generator's secondary water icvel con-trol and procedural technique improved so water level stayed below bottom of upper tubesheet during the inspection following the third weld

. repair.

4. The detailed list of specific tubes involved in the third repair and inspection cycle is in Tabic 3.

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-4 -

II.E. Fourth Recair Effort (12 Tubes - September 6 and 7, 1979)

1. The repair consisted of:

a. Wire brush weld area and surrounding' tube-sheet arca.

b. Light s p'o t facing so " nail-plug" has flat seating area.

c. Two fill-er passes (two 360* plus passes) wi th 0. 0 4 5 " filler wire.

d. Note: It is possible that the pressure on the secondary side of the steam generator was not completely relieved (e . g . , ' s10 psig ) .

This is not a firm fact,

e. The bottoms of the 12 tubes were explosively plugged.

2. The Leak-Tec inspection following the fourth repair effort showed the following:

a. Of the 12 tubes repaired during this repair cycle, 3 tubes were still leaking.

b. In addition, the inspection identified 3 more tubes that were leaking. A breakdown of these three tubes is as follows:

(1) 2 tubes were gep4 ired during the first through third hepair efforts (II.3, II.C, II . D) .

(2) I tube that was rewelded in May 1979.

c. Also, it was determined that a wrong tube had been plugged (i.e., Tube 67-58 had been plugged instead of 85-59). '

d. The result of this inspection was that a total of 7 tubes (a plus b plus c above)

. now had to be repaired.

3. The steam generator's secondary water level stayed below the bottom of the upper tubcsheet

, during the inspection following the fourth weld repair.

4. The detailed list of specific tubes involved in the fourth repair and inspection cycle is in Table 4. .

II.F. Fifth Repair Effort (7 Tubes - September 7 and 8, 1979)

1. The repair consisted of the following:

a. The 3 tubes that contained a " nail pA g" were wire brushed and then two more filler passes were added on top of the existing weld (i.e., two 360* plus passes); no local grinding of the defects was done.

b. In the 4 other tubes, " nail-plugs" were installed after wirc brushing and light spot facing. These " nail-plugs" were then welded with 4 filler passes ( i . e . ., 2 plus 2 passes of 360 plus). In addition, the bottoms of these four tubes were explosively plugged.

2. The Leak-Tec inspection following the fifth repair effort showed the following:

a. Of the 7 tubes repaired during this repair cycle, zero tubes were still leaking.

b. In addition, the inspection identified no new tubes that were Icaking. IIowever , this Leak-Tec inspection covers only tubes re-paired during the repair cycle and those adjacent to the ones repaired. This more limited Leak-Tec inspection was considered adequate since the Leak-Tec inspection after the fourth repair was.done much more meticu-lously (e.g., the l appficacion of Leak-Tec was more carefully handled). Also, the application of the Leak-Tec and the moni-toring for bubbles was documented on video tape, and the video tape was much more carefully reviewed (than during the earlier Leak-Tec inspections).

3. The detailed list of specific tubes involved in the fifth repair and inspection cycle is in Table 5.

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TABLE ,

Tt!IPD REPAIR AND INSPECTION CYCLE .

SATURF. OF Til I RD BEPAIR OF TUi2 WELDS DEFCCT PRIOR TT.ht "^

HISMRY TO TitIPD SPOT Bl Tin'E G I I ^

HEPA13 FACED E:4D Or LEAK-TEC DLO;4 !!CLE BLOW HGI E TO (1) ill:ATI:4G DEPTil itAND (2) AND TV l START /

TUbt FIRST SECOND START / !!1 WELD? STOP HE!tA RE S 0.100" Hol.L CLEAT 4ED !!E ATED n:Cl.taltm, 14ELDING VIStJAL l b u bb t.E S I40:4 B E R HEPAIH HEPAIP !J E'.! ! I'. WE LD STOP s340*F 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months X X X

!! 75-11 X X X 4.2% d'

" " " " X e.

2- 75-12 X + f l 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months 3 75-13 X l _ _ [ _ _ _

2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months 2 1.ours 4l 75-25 X l 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months Si 75-57 X l ___ _- - Wire - - *

? hours Two X 5' 75-63 X j brush - -

-- -~

~ -

and 7 hours8.101852e-5 days 0.00194 hours 1.157407e-5 weeks 2.6635e-6 months Filler (3)

X I Passes ___

7 77-20 X __ Dye _ _

2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months X 8: 77-25 X X l - - - --

Check - -

r . Cleaner 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months 9 ??-381 X X t 2 hours2.314815e-5 days 5.555556e-4 hours 3.306878e-6 weeks 7.61e-7 months 10j 77-40 X X l 111 77-57 X X l , y j v 7 hours8.101852e-5 days 0.00194 hours 1.157407e-5 weeks 2.6635e-6 months , o u 4340*F 7 hours8.101852e-5 days 0.00194 hours 1.157407e-5 weeks 2.6635e-6 months X X X X X X 4 . 21L ,,

12] 85-59, X i 4 -

__ O X

1l 15-18 X l X

2l 75-20 X ,

both tubes 3 75-45 X These tubes identifled as defective X have malor &(9 during inspectior) after third weld x repair f _

X blow hole $.

-4{75-55 X LYPe leaks f[1

_5' 77-34 X cr:- .

X X N 6 l 77-42 X (3)

- 7.77-49 i /. l X r3 al 77-60 Xl c0 8

crQ)

UGTES: LM

~d (1) 4.2% reduction in wall e.ickr.ess based on torque value for hard rolling operation. N'! d)

(2) Blanket type heating ar.d did not control tine between heating and welding (Note: They did not use the Cal-rod type heating h3 Qg of ccatrol time as re pested by FPC Engineer and MPR -- see FPC neno dated Sept'mber 1, 1979.)

C' w chii (3) i<eview of video tapes showed poor inspection technique had been used in the applicaticn of Leak-Tec and the vddeo recording of Leak-Tec in s pe c t ic r. ; therefore, it was not surprising that the inspection was sorrew h a t of a hit-and-miss c1cration P (e.g., sometimes a repatred tube would pass inspection when it actually still was leaking and new tubes would be adentified with leaks). Accor d i r.g ly , inspection and videoing requirements were revised ar.d upgraded for the inspection after the fourth weld repair ar.d enat inspectaon's video tape closely reviewed for satisfactory 1.cak-Tec application technique and for leaking tubes.

e = ,

TA!! L t. 4

, =

FOU RTit REPAIR AND !!:SPECTION CYCLE NATU'BE OF TYPE OF .

DEFECT PP. LOR FOURTli HEPAIR OF TUDE WELDS INSPECTION TYPE OF IIISTORY YtIFRD TO FOUHT!! WELD AFTER FOURT!! DEFECT Al'TER WlHC T V.O HiPAIR FOU RTil REPAIH REPAIH I<EPAIR I,I GitT S LO'i llOI.ES I:h0Sil SPOT tJAIL-PLUG Tlio iDDITIONAL LEAK-TEC D I O'.i liOLES AND .

START, OF TUBE FACE INSTALLED F I LLLI F I I.LE R TV START /

T(lliE FIHST SECONis ll A H D VISUAL uuhnLES IN UFLD STOP HEMAHES NUMBER H E P A l l< RLPAlf; HGLL N E*.i IN Uf t f- STOP ASEAll) (2) ( 1) P ASS t't P A S S E:S X X X X X X

!l75-12 X X f X a A a A n a 2 15-18 X _ _ _ _ _

g _ _L _

x small Jerset 3 75-20 X _ _ _ _ _ _ _ _ _ l __ '

4 75-45 X l 75-65 X _ _ _ _ _ _

l X(5) e

__6!75-63 X X { _ _

7 77-25 x l l_ __l__ __ __ ___l 1_ i tl 17-34 X l l _{ *

. X S r.a l l de f e rt 77-12 X l l Xl h 77-49 l _ _ { _

11 77-60 X j ,, y , , X Sn.a l l Jef sn X X X(4) X X X X(6) Pepaired 12 85-59 X X X wrong Lucc -

See f:O t e (6) a ,

e -

I _

____ __ 4 ( 7N e Small de: sat

' X X X 75-13 X X X . .

__1- These tubes adentifaed as defective durang inspection after fourth weld X X X Small defect 2 75-17 X l 7 X "'P**I / X X X Small cefist . _p 3 77-50 -

w 3 __-_'i I;OT_E_S.

.-.J (1) This brushing included not only the weld area, but the surrounding tubesheet area also.

G3 (2) This spot facing of existing tube welds was just enough so " nail-plug" would seat properly. ,a (3) The " nail-plugs" extended down to below the 14th support plate and the bottom end of the tubes were plugged by " explosive" C -6 C- ~~ ~jj type plugs.

99.

pp (4) Since Tube 85-59 was not a

lane tube," it was plugged by a "short-plug" rather than a " nail-plug." ,

c_fl cd (5) Tube 75-63 had two initial filler passes and approximately one .more filler pass. . 9__-v, r

2 d

' A (6) Tube 87-58 was inadvertently plugged'by mistake and, therefore, Tube 85-59 was still defective. .

r7 p

(7) During this repair cycle, actually only three repair welds were bads however, since Tute 85-59 was missed (see tJote (6)),

st still leaked, and thus nade a total of four tubes from the fourth repair cycle that needed another repair.

{

., t

T A b t.E 5

FIFTil RFPAIR AND II:SPECTIO 3 CYCLE

U ' 'A C "U I:3 iLCT :4 ItISTORY DEt C all R TO F I t'T!! L3I HE L4 E l .D AFTER FIFTil HiPAlR hHUSit LIGi!T Tt;O HEPAtR

' lit ! RD FOURTH LEAE-TEC 'IY PES OF ftEPAllt OF SPOT tJAIL-PLUG TtJO ADDITIO1AL REPAIR bl.O'.J l_lOI.F S_ DEFECT AFTIR NAIL- ST'PT/ TuuE FACE It4 STALLED FILLEft F l !.l.E R TV (5)

TUBE F l ft ST SECO:40 (!! ARD PASSES VISUAL builBl.E FIFTH HEPA:R S U ? S E !< HEPA!R PEPAIR ROLL) PLUGGED flew It1 til:t D STOP AREA (2) ( 3) PASSES X X X X X X tione X X 1 75-13 X X X X X X 2 75-17 X __._ _

X X (4) 1 75-20 - -- .

X (4) 4 77-42 _ _._ _

X X X X 5 77-50 X (4) y , ,,

6 77-60 ,, ,

X X X X X t;one X (1) X X X 7 85-5's X --

Zuro

OTES

(1) During the fourth rep 41: cycle, Tube 87-58 was mistakenly plugged instead of 85-59.

(2) This light spot facing required only one of'the four tubes4.in which " nail-plugs" had to be installed. The other three tubes had " nail-plugs" installed during Repair Cycle No.

/

(3) The "na i l- plug s" extended down to below the 14 th suppor t plate and the buttom end of the tubes were plugged by " explosive" type plugs. f:ote Since Tube 85-59 is not a " lane tube," a short plug was installed in Tube 85-59 rather than a " nail-pi;g.*

s (4) The " nail-plugs" in these three tubes had two fil'ler passes applied during I<epair cycle tio. 4 5.

(5) Leak-Tec inspection also included on inspectica of the tube ad;acent to the ones repair-welded durin9 Nepair Cycle tio.

6 W L O

5 .

ML19296D471

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Dear Mr. Shook:

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