ML20052F711

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Ringhals 3 Fretting Defects on Steam Generator Tubes
ML20052F711
Person / Time
Site: 05000000, 05000465
Issue date: 11/19/1981
From: Rosborg B
SWEDEN, GOVT. OF
To:
Shared Package
ML20049H209 List:
References
FOIA-82-167 ET-81-141, NUDOCS 8205130443
Download: ML20052F711 (27)
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Text

{{#Wiki_filter:. I [.[,; 'SiudSvik Arbetsrapport-Tec,nica ReJort Pro 3entioentif mation Project ioent.fication Daturn - Date Org enn ocn nr Heport No. 81-11-19 ET-81/141 l stel och torf attare - I tile anO author RINGHALS 3. FPITTING DEFECTS ON STEAM GENERATOR TUBES i Interim Report for the Swedish State Power Board Bo Rosborg [ ~ i Distributeon C.i 2 3 ( r

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'h l 4 & l965l$/ Godhand av - Approved by Kontont - Internal notes Rapporten dall h forhandsaviseras

SUMMARY

On October 20 a tube leakage was detected in steam generator 1 of Ringhals 3. Two tubes were ~ pulled from the steam generator 1, one of which l was the leaking tube. The visual inspection of U the reconstructed tubes revealed that the defects were confined to the tube.to-support g. plate crevice areas of the preheater region. t The defects are most probably a result of ,,..(- fretting. l l-V n e t i i i f i. i 1 l l l 8205130443 820416 !? PDR FOIA UDELL82-167 PDR e d I L

V STUDSVIK ENERGITEKNIK AB ET-81/141 2 1981-11-19 .s* 1. BACKGROUND i On October 20 a leakage from the primary circuit was detected in steam generator 1 of Ringhals 3. The plant was shut down. The steam generator design is Westinghouse Model D3 with a preheater on the cold leg of the tube bundle. Eddy current testing revealed tube defects in the preheater region of all three steam generators. The defects were confined f to the first rows of tubes next to the feedwater inlet. Up to the time of the leakage the plant has been in operation for the equivalent of 2 700 full power' hours. k (v:; 2. VISUAL INSPECTION OF PULLED TUBES On November. 4-5 two tubes with the designations R49-C55 and R49-C66 were pulled from steam gene-rator 1, the first of which contained the tube e leak. The visual examination in Ringhals after reconstruction of the pulled tubes, in'which repre-- [. sentatives from the Swedish State Power Board, Westinghouse and Studsvik took part, verified that the tube defects were confined to the preheater region of the steam generator and that tne defects (:(x+y were located to the tube-to-support plate crevice areas. The defects were of varying sizes: the maxi-mum axial height were about equal to the thickness ('*) of the support plate, the maximum circumferential width varied between 15 and 180 and the wall degradation varied from very shallow attack to in one case a through wall penetration, which caused the leakage. Some of the tube-to-support plate crevice areas showed no attack. Photographs were taken of the reconstructed tubes before they were cut into pieces of suitable length for transportation to laboratory examinations. The main part of the tube pieces were sent to Westing-house R & D Center in Pittsburgh. Two pieces of l

.STUDSVIK ENERGITEKNIK AB ET-81/141 3 1981-11,-19 tube R49-C55 were brought to Studsvik by order of the Swedish State Power Board. They were located at the support plates No 6 and 8 respectively. 3. PHOTOGRAPHS OF THE TUBE DEFECTS Photographs of the two tube pieces which were brought to Studsvik are attached. They. show that the defects are rather sharply confined to the tube-to-support plate crevice area. The defects.are 'most probably 7 ( a result of fretting. t The attached shadowgraph pictures from the area (, of maxium penetration show the amount of attack: for tube support plate No 6 less than 200 pm and for plate No 8 less than 150 um wall-degradatien. The t6be diameter is 19.05 mm and the wall thick-ness 1.09 mm. 4. FURTHER EXAMINATION A metallographical examination of the tube pieces will be performed including micro hardness testing, scanning electron microscopy, light microscopy of (rr, cross sections and relevant surface analyses. I 5. CONCLUSIONS / (, From that part of the failure analysis which is performed by Studsvik it can quite safely be concluded that l l l o the mode of failure is fretting l f In order to draw conclusions about the cause of l failure further background information is required. l Eben without a detailed knowledge about the cause of failure one may expect that the remedy is not material related. l t

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C 7,:: l ( * ' ',," RINGHALS UNIT 3 TUBE PLUGGING 1931 0 7 T c=n we i Y 2.,[N2d [ SGWRY An evaluation of recomended tube plugging in Ringhals Unit 3 steam generators and subsequent power operation has been made. A power escalation program to 100% power is recaumended for a brief period with internal instrumentation to monitor the onset of flow induced vibration. A reduced power level of 50f, is recommended during subsequent near term operation of about 1500 hours to minimize further potential tube wall degradation. A tube wall thickness of 35% of nominal value (0.043 in.) is required for structural integrity during ( accident conditions and an allowance of about 10% additional tube wall degradation is provided in arriving at the plugging level. Furthermore, 5% is added for conservatism. Thus, it is recommended that a total of 55 tubes be (3pluggedhavingeddycurrentindicationsof50%orgreater;intheeventcontinued ' wear of about 10% were to occur, the minimum tube wall thickness requirements of 351, would be maintained. _ TUBE PLUGGING CONSIDERATIONS The selection of steam generator. tubes having eddy current indications which are recommended to be plugged prior to continued operation at power, has been made based on the following considerations: The minimum tube wall thickness to provide structural integrity for a. ( postulated accident conditions is 0.015 in. or 35% of the 0.043 in. nominal wall thickness. l + l,. b. An allowance of about 10% has been identified for additional tube wall !(~ degradation so that the tube wall will not reach the minimum wall of 35%; l l approximately 5% added conservatism is built into the selection of plugging i level. As noted in Figure 1, eddy current inspection data are about 17% conservative c. 1 when compared to actual tube wall measurements in the vicinity of 50% eddy, current reading. Thus, there is ample allowance for uncertainty in eddy current inspection data.

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I ' 'STRUCR'RAL INTEGRITY 1UBE KALL LIMIT { Analysis and testing has been conducted to determine the plugging margin for Model D3 steam generator tubing. Based on the results, a minimrn tube wall thickness requirement of 0.015 in. or 35% of the nominal (0.043 in.) wall is established in accordance with the guidelines of USNRC Regulatory Guide 1.121. REDUCED p0WER OPERATION t Prior to returning to sustained elevated power operation, a power escalation i program is planned to be performed during which time installed internal and extemal instrumentation will be monitored to provide additional information that the selected reduced power level of 50% is acceptable. This power s_ , level is recommended to be adopted for approximately a 1500 hr interval, at which time an eddy current inspection of Rows 47, 48 and 49 is recommended (; to determine whether any degradation has occurred. [ Reduced power operation provides a direct means of reducing preheater ficw velocity and, thus, potential for flow-induced vibration. The peak inlet velocity in the preheater at Row 49 is estimated to be approximately 24 fps based on a computer code (THEFr) analysis. The critical velocity to initiate vibration is estimated to be 16 fps (Figure 2) for the most flow responsive tube (fully supported in preheater region). A reduction in power level to 50% should result in peak velocities which are about 12 fps and are conservatively c below the level to cause fluidelastic instability. I s l i- . I s

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i l TUEE~ PLUGGING LEVEL REC 05f M ATION , The tube plugging level based on the considerations discussed previously is as follows: Structural Integrity Requirement: 35% Remaining Wall Degradation Allowance (E10%) + Added Conservatism (5%) 15% Added Wall Total Remaining Wall 50% Plugging Criteria _(Total Allowable Degradation 49% . Therefore, tubes with 50 percent or more indication identified during the i prcspnt outage of Ringhals 3 are reconmended to be plugged, f ( TUBE SELECTION x Table 1-3 and Figures 3-11 provides a listing of tubes in steam generators 1-3 with various increments of eddy current indications. It is noted that at a plugging level greater than 49%, 25 tubes are to be plugged in S/G #1, 16 tubes in S/G #2 and 14 tubes in S/G #3. l' t- { (,. s m. 2.

g Strategic Data W Operations Analysis Division Model Date l Uma steam Generator I O~b Nov 7.A; 198 1 { site R * *J G H A L S 3 Technical Supplement No. Standard No. Type inspection Frequency Probe t f' R C 7 34 a c r'49 a c v 94 a c 739 so /o "6 49 99 59 lo *z 49 13 42*/o "5 49 bo 49 lo

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48 68 4 3 lo " 5 4967 4B lo *9 49 57 52e/o *5 49-5_Q_ 7o /o-90 48 +6 41 *lo-% 49 70 49/o-S 41 SB 52lo *5 49 SI 64%"3 9 9 76 45 lo #b 49 59 51 /o "E 49 52 69 /o *6 4a 61 4e'le *f 49 6 1 535/o *5 49 53_ 72o/o "3 ~ U 49 66 5 1*/o

  • 6 4 9 54 11o/o *4 l

49 66 52lo "4 49 55 Im lo "3 49 69 Slo /o *S 49 56 6o%-9 i;' 49 -17. 50% #5-49 62 72o/o *5 49 ao so*/o

  • E 49 L3 S e %
  • 2-48 L3 54 lo "F 49 t,6 61*/o " L

+8_hi 52e6 *5 49 79_ 679'o-

  • 5-Ae L5 81 clo
  • L l

i l( l l 1 1 ,l(v 1 v i 3 TOTA L 5 TOTAL 32 Torat 13 TOTAL 1 Reel Signature Comments: Sede Page of f i 1 -6. 1 i

Strat:gic Data 3 l W Oper tions Analysis l Divasern Sterm Genf ritor Model D:ss RincHe's 3 2 o-J cov 29,m i Unit e te s l Frequency Probe Techmcal Supplement No. Standard No. j Type inspection R C f'q g lR C ygg R C 749 R C 7 39 .so lo

  • 3 99 st 6o% *r 49 34 4; /o *si 49 52 n%-%4 9 93 o

ge/

  • q 99 38 Se */o " b 49 41 43% *lo 49 L4 48% *b49qS s

99 42 4 2 % "10 49 75 4 6% *b 494 6 Solo "9 49 44 63%*4 j c *1 67*/o *1 l 49 4~7 43% *4 4 9 So So% *E49 r l 49 53 40% *5 495 1 fl% *I 49 16_ Lo % *>o

u A1 5'l 43% *b 49 54 So /o *$o49 59 609'o */o do /o-%

49 63 41*lo *b 49 SS 50% #o 49 f, o 1 49 66 49e/o d 8 49 68 Sce/o "9 99 67 56*/o 5/o ( 99 70 4 4*/o

  • f 49 71 4 9e/o
  • g 48 65 el3elo #5 48 63 4 4 olo
  • 6 48 62 43% #5 t

18 47 93*/o # o / t t ( 1 14 TOTAL 3 tot N. e TOTA L 8 To rat l Signature Reel Comments: Sede Page _ _ of l

Strat:gic bata W W Operticns Analysis ~ Division Unit Steam Generator Model Date 3 0-3 uw 24, in ) ~ Sete RN6 pts 3 - Type inspection Frequency Probe Technical Supplement No. Standard No. t i R C ygg R C

r gg R

C y4 9 R C 7 3g 6 1o 49 50 52 /o #S 49 ~7b SS% "5 41 /o "Io 49 3/ 49'/o# 49 35 4 0 /o 8 6 4'1 39 4 56/o

  • 6 49 51 Sac /o *E 4 e, 68 55c/o--89 49 36 e

49 38 4o4o

  • b 9 9 49 45% "E 4ci 52 Sic /o #5486557/o *6 4 9 /o "E49 56 r/ */o 8 6 49 4o 40% #6 99 45 6

49 43 4 o*/o " E 4ci 4b 4 7 */o

  • 5 4es 58 So% *6 49 53 Wo /o #8 49 47 4Wo " b 99 Scf SJo/o
    • f St /o " 5-49 bo 43lo #E 49 48 48% #7 49 63 99 L4 42%- % 49 57 4ayo "g 49 bl So*/o *r b

49 '70 4 r 9'o "5 49 61 4t,lo #6 48 73 54 c/o *5 49 t9 4 o*/o " 6 99 62. As% "s i 48 So 5 + /o

  • 6 48 L 2-43e/o
  • b 99 65 49o/o-"6 48 45 r4 a/o "to j

4 o /o

  1. 549 67 9 9*/o "6 48 57 o

48 4/ 4 o*/o " 6 49 68 45/o "8 48 37 49 a/o-"6 43 L9 9 L lo-% 48 72 45 % 8 7 1 4e 7o 4so/o #5 1 48 69 46/o # 6 43 67 4 L */o #5 48 L9-95%

  • L

't_' l 9-8 61 4 9 c/o 88 4e 42. 45% 8f 48 36 49*/o " 6 ' U J7 A2 46 fo *6 l l 14 TOTAL 23 ToTAt. 11 Terat 3 To7AL-Reel Signature Comments: Side 1 Page of l l -8 1

f-f pr r ^ s OCT. 1981 RINGHALS 3 SG 1 3'='50 10'56 E RC'E'N" '1' '3'0 iO' S INNCE'NI' 8 1 ' 3' ='dNb fi 2d'P'E CE'NY 5 3 P 0 14 2 = 20 TO 29 PERCENT 4 = 40 TO 49 FERCENT 6 = OVER 60 PERCENL 13 g l2 W$ ,w a-g li &g 10 6 0 00 00 0 00 00 9 l l l l00 l l00 04035 000 00 0 200 0 00 0000 8 7 l l 01 l40 l l000 6 0 00435545555530 30 5 563000 04 00 000 5 444554545554565 434454224 3000640000 m 4 I I SI 134500040 1 00 ~ k 3 406364604 44 3 4004 0 00 0000 h 2 53 5 6 49 5 00 v. 1 0 1... 1....l... 1....l... 1....l... 1....l....l... 1....l.... 25 30 35 40 45 50 55 60 65 70 75 80 85 90 IN0! CATIONS IN COLUfWS FOR R0W 49 ~+ a-. - - - -,--. ~ wv. -.vnr.-m ,..n._ ..---,--~~g.---- ...e .-m .a ---e a ,-s

e. s pe o me -

es.gn -,. - ,mm-, y

p p e OCT. 1981 RINGHALS 3 SG 1 'O'- UNb$R 'dI'EACE'NY' 2 P 'li '50 iO' 3$I IRCE'Y' 3 3'='5'0iO'6dE55C'E'N" 5 I P N 14 2 = 20 10 29 PERCENT 4 = 40 TO 49 PERCENT 6 = DVER 60 PERCERL 13 .o 12 s W e Q-0 w 11 _a!t g 10 0 9 I I I I I I 8 7 l l l l l l 6 4 3 6 0 5 4 55 4 0 4 I I I I O I I m 3 0 ~ 9 2 ^ 1 1....l... 1... 1....l....l....l....l....l....l....l....l. ..I 25 30 35 40 45 50 55 60 65 70 75 80 85 90 INDICATIONS IN COLUMNS FOR R0W 48 t .s ,g

r . (. p [ t ~.. OCT. 1981 RINGHALS 3 SG 1 3 ' 'tjNb$Fi 2d 'P'E5CE'Nf I' II '50 I09 P5 C'ENI 3 I ' I ' = '5' ' 10' S IERCE'N" 5 0 0 3 P 14 2 = 20 10 29 PERCENT 4 = 40 TO 49 PERCENT ' 6 = DVER 60 PERCERL 13 ~. e_ 12 b'$ = a w 11 d ~ m $ 10 9 I I I l I I 8 7 l l l l l l 6 0 5 vs 9 I I I I I I 3 O 2 t-1 l ....f....I....I....l....l....l....l... 1....l....l....l....l.... 25 30 35 40 45 50 55 60 65 70 75 80 85 90 INDICATIONS IN COLUbNS FOR R0W 47 l e

[ p (. ( - .(. e OCr. 1981 RINGHALS 3 SG 2 ' ' ' I ' = 'LjNb$fi 2' d I 'EhtE'Nf ' 'I' ' ' II '50 iO' 3$ IPE5CE'N ' O P I '1' '5010'6dIERC'E'N 5 P 14 2 = 20 TO 29 PERCENT 4 = 40 TO 49 PERCENT 6 = DVER 60 PERCENL i ^ 13 ~. g12 332 3 4 W 5 n. b g 11 4 5 0 bg 10 00332 334443 432 40434453254000 3 50000 0 9 l l3200230 i l 3400 0 l l 8 0323332202002204323430022002334 332030 00 0 7 l l00200020] l 4302300l l 6 - 3020503000023334232333 433332443 4302000040 0 20 5 05 333 '303 023 4244443444233332002 443443000 02 4 0 1 036444231 13000 0I I ~ 3 0 000 0 04300020432033 22 0 4000 0 0 00 8 2 0 233303 0 0 M 1 1... 1...I....l...Ba54.Y....l....I....I....l....I. ..l. l.. .I 25 30 35 40 45 50 55 60 65 70 75 80 85 90 INDICATIONS IN COLUMNS FOR ROW 49 en amwoe-m~emw w-w '? e

i f O i .ZW w2 "uw EU LAJ C sg . s O u)O "O - O wm - Ltj q) - 18 ft O - o jQ 6 'wO M CD u ts M M -C W NM M O 2 wuJ 't -h e - CD CD N O M# O e to g N t1 O O e O OO

  • -t-O to O 6

-OO O N O LD m (_. Mr O O O a M O o - si es g o -J 'en g - Ln O 1, tn v N y z O E t O O O +- E O O N - @M i 2 O O O O_OO g OOOOO C000 O-OOOOO C000 h O W NOOO O CO 3 OOOOO OOOO O-Ln - eO

  • 6-O O

O O -hb o O O 2 l uu o O O p EC O Q. ,Q _O t. -N"' O O O O O O s-t O O O O OO .N O I Og N O 5 go O O O O cn w >- O O O - m .O O sq (- ZO ( p -DN e U - to It o I ca " O I 'ON n-g. M N Omoso m<nn i. e ,i ( 'ON) 31 bid 373308 j l i i: 1 -13 FIGURE 7 l

(m g ,~ I OCT. 1981 RIV,HALS 3 SG 2 .I'4'5010'5dEE5C'E'N" I II = '3'0 10' 39 'PIRC'E'Nt ' I 5- I 'O' = LINb Fi '2d I 'ENCE'NF P 2 = 20 10 29 PERCENT 4 = 40 TO 49 PERCENT 6 = OVER 60 PERCEHL 14 13 d 12 a W L t a as 11 d m g to 9 l-l l l l l 8 7 l l l l l l ~ 0 0 6 0 00 5 1 I I I I I er m 5 3 0 in ....I 1... 1 ..l....l. ..l. ..l.. .l.. .l ...t.. .t....l l 25 30 35 40 45 50 55 60 65 70 75 80 85 90 INDICATIONS IN COLUMNS FOR ROW 47

(_m .m ,c, DCT. 1981 RINGHA!.S 3 SG 3 s 'II '50 IO' 3$I E5C'E'I'3'='5'liO' Sd E55CE'N" 1 P N 5 O I'EhCE'NY 'O' = tjNb FI '2 P 2 = 20 TO 29 PERCENT 4 = 40 TO 49 PERCENT 6 = DVER 60 PERCENL 14 13 3 9_ 12 W 5 a m 4 4 4 g 11 !tg 10 0 404343300 3 4 4 00 2 0 044 00 0000 9 0l l0.0 3 3 0 l l 43 2l l 8 0 3 0002002024 3 3343333005202430 043320 03320000 7 0l l0023334l l2 2 2 0 0 0 01 l 6 00 233334322232344 342333544334044404323300002200 0 3 5 03 003232344434 5550230405400530 433400003500034 m 4 01 00 44 I I 4 3 0 3 2 Of I 3 0 4300 0223 33 44 00 004 0 000 h" 2 30 1....l.. 0.1.. 0.1.... 1 1.00.. 1...l.0...l... 1....I... 1. 1. 25 30 35 40 45 50 55 60 65 70 75 80 85 90 INDICATIONS IN COLUMNS FOR R0W 49 9

an.e-

( ( ....v-1 OCT. 1981 RINGHALS 3 SG 3 ' ' 'I '50 iO' 3$I 5NC'ENt' 3 P 3'='dNb fi 2dI'E CE'NI' ' ' 3 ' '5'0' 10' 60 EERC'E'N 0 P 5 g4 2 = 20 TO 29 PERCENT 4 = 40 TO 49 PERCENT 6 = DVER 60 PERCEHL 13 9_ 12 W5-A a- ? w 11 d u. g 10 22 005 0 3 240 5 9 I I200 0 01 1 0 401 I 8 000 002 0 0 20 40200 340 0 7 l l0003 0l l 0 l l 6 4400 0204 3 5 0330 34345 444420 00 4300 03 45043353 3 5 1 I ' O I i 500 I i m 4 "o 3 3 2 3000 g 2 00 5 1 ....l....l....l....l....I....l....l....l....l....l....l....l....' 25 30

35 40 45 50 55 60 65 70 75 80 85 90 INDICATIONS IN COLUMNS FOR ROW 48

.-w = = - - + w-eur - e weem

  • a-O g-s.www---

w--ese-w - p --ww'=>=eyi%,- w -e =mm wm w ee

n t... {- CCT. 1981 RINGHALSS 3 SG 3 '5'= 5'3iO'EdI IRCE'N" ' 0 P - iO iO' 3$I 5RC'E'NI I P I 'ERdE'NY ' ' ' ' ' ' ' li ' 3 ' 'tjNb Fi '2 P 0 2 = 20 TO 29 PERCENT 4 = 40 TO 49 PERCENT 6 = OVER 60 PERCEHL 14 13 1

  • e

@ 12 F A ? o-w 11 it g to 9 I I I I I I 6 7 l l l l l l 6 4 0 5 0 4 I I I I I l 3 2 1 g, I... 1....I....L... I.. 1... l. 1... 1... 1....I .l....t.... 25 30 35 40 45 50 55 i 60 65 70 75 80 85 90 INDICATIONS IN COULUMNS FOR R0W 47 g e I

f. POWER ESCALATION PROGRAM It is the objective after resumption of power to escalate the power about 50 percent for purposes of determining the instrumentation response at high main feedwater flow rates. Both internal accelerometer probes and external (acoustic) transducer probes will be carefully monitored and data analyzed to determine if possible, the orset of flow induced vibration of. tubes in the prcheater regions. If the instnmentation does indicate an enset of tube vibration, the power IcVel will be reduced immediately to well below the indicated l (. power level. L The typical program for main feed flow is given by example to be: ( 1) Startup to 50% power 3 days D,2) Power - 50 60 1 day I-3) Power = 60 75 1 day 4) Power = 75 90 ~ 1 day 5) Power = 90 95 0.5 day 6) Power = 95 100 0.5 day l-7) Reduce power to 50 53 days .i i At the end of this period, the steam generator should be eddy current inspected. t t Even if the wear mechanism should not be related to fluid clastic vibrations, e.g. common turbulences, the wear in that case is not expected to exceed the allowances included in the plugging criteria. ~ g U m.

  • a
WE8R PRQJECTION FOR PWGGED TUBES The potential for continued wear of plugged tubes with eddy current indications of 50% or greater has been considered and monitoring of this condition will be provided by internal accelerometers which are installed in Steam Generator #1 Row 49, Colume 62 and 49 tubes. The latter tube has an eddy current indication of 66% while the fonner tube has a 72; tube wall indication.

In order to verify that the wear of the tubes with major eddy current indications has not progressed, an oddy current inspection is reccznmended after 1500 hours of { operation. Consideration will be given to reexamination of previously plugged tubes. G (e. e 9 6 i t 1 l i . l t -}}

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