ML20062B598
| ML20062B598 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 07/19/1982 |
| From: | Mccracken C Office of Nuclear Reactor Regulation |
| To: | Jacobs R Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8208040633 | |
| Download: ML20062B598 (37) | |
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JUL 10 1992 50-289 liEM0RANDUM FOR: Rick Jacobs Operating Reactors Branch f4 Division of Licensing FR0ft:
Conrad McCracken, Section leader Chemical Engineering Branch Division of Engineering
SUBJECT:
DOCUMEllTS RECEIVED FRL'i GPUti, ASSOCIATED WITH TMI f;0. L S.G. REPAIRS Enclosed are two documents which I received as a result of the June 15, 1982 meeting in Parsippany.
1.
OTSG tube repair specification " preliminary" 1101-22-006 6/11/82 2.
Explosive expansion qualification requirements 61-11134292-00 6/2/82 Both of these documents are subject to change but were provided to FRC for use in their preliminary review efforit.
By copy of this meno. I am distributing these two documents our othersstaff reviewers and consultants are placing them in the PDR.
All documents provided to me by GPUN are now in the PDR.
In the future, I will distribute all documents received to the same distribution listed in this memo.
Conrad McCracken, Section Leader Chemical Engineering Dranch Division of Engineering cc:
See next page 8208040633 820719 PDR ADOCK 05000289 P
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R. Jacobs cc:
R. Vollmer w/o D. Eisenhut w/o W. Johnston w/o T. Novak w/o G. Lainas w/o J. Knihht w/o J. Stolz w/o S. Pawlicki w/o T. Sullivan w/o it. Conrad w/o W. Ilazelton C. Cheng w/o E. Hurphy w/o P. Wu S. Young R. Jacobs P. Grant J. Rajan L. Frank C. McCracken omcc>
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a gv....f All 19 $82 r0-289 MEMORANDUM FOR:
Rick Jacobs Operating Reactors Branch #4 Division of Licensing FROM:
Conrad McCracken, Section Leader Chemical Engineering Branch Division of Engineering
SUBJECT:
DOCUMENTS RECEIVED FROM GPUN, ASSOCIATED WITH TMI NO.1 S.G. REPAIRS Enclosed are two documents which I received as a result of the June 15, 1982 meeting in Parsippany.
1.
OTSG tube repair specification " preliminary" 1101-22-006 6/11/82 2.
Explosive expansion qualification requirements 61-11134292-00 6/2/82 Both of these documents are subject to change but were provided to FRC for use in their preliminary review efforts.
By copy of this memo, I am distributing these two documents to our other staff reviewers and consultants and placing them in the PDR.
All documents provided to me by GPUN are now 1n the PDR.
In the future,
! xill distribute all doctnents received to the same distribution listed in this memo.
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_., 4 onra McCracken, Section Leader Chemical Engineering Branch Division of Engineering cc:
See next page
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R. Jacobs cc:
PDR 50-289 R. Vollmer w/o D. Eisenhut w/o W. Johnston w/o T. Novak w/o G. Lainas w/o J. Knight w/o J. Stolz w/o S. Pawlicki w/o T. Sullivan w/o H. Conrad w/o W. Hazelton C. Cheng w/o E. Murphy w/o P. Wu S. Young R. Jacobs P. Grant J. Rajan L. Frank C. McCracken TMI Consultants William Seagraves, FRC w/o Dr. MacDonald, Ohio State Robert Dillion, PNL John Weeks, BNL C. Dodd. 0RNL e
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OTSG TyBC REPAIR REV
SUMMARY
OF CHANGE APPROVAL DATE t
Paragraph Change
(
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1 All Pages Changed specification number from M)
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SP-1101-22-0006 to 006 to reficct
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v 3.6.2 Add a cross reference to the electrochemical tests defined in paragraph 4. 6.2.
3.8.2 The long term design life goal is
[h 0!"h revised from 40 years to 35 years to reflect the fact that TMI-1 has already operated about 5 years.
3.10.2 Added the word qualification to
[f k 6/4/h clarify the intent.
3.10.3 Deleted the requirement to hold
$/"h' for witnessing results. Witness points will be established but it will not be necessary to holdup work.
3 j
4.3.2 Added requirement for some pullout
_fh 6[[f2 load testing at elevated f
temperatures.
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4.4.5 Changed 1.D. to 10 to correct typographical error.
4.6.1 Changed contaminants concentrations hk
(,/,/f t j
for crevice corrosion tests and added several additional samples.
l 4.6.2.1 Deleted'the hard roll-over, a
[
h'[72 i
kinetically expanded transition
.i since this is not part of reference design.
l Table 1 Corrected a typographical error in that the cycles in right hand I
column are for 40 years rather than 35 years.
I 3.9.1 Acceptable contaminant levels and
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expanded contaminant listing to dif-ferentiate between fluids used for g
q,,j final cleaning, other fluids and solid materials.
AoOCoO36 6 81
PRELIMI19"ARY 4
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Short Form Specification SP_1101-2 2-J }]ydg7
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d-1 17 NGYu#BE REPAlR GPUN U ITr7 L Approved by Date Task No.
Prepared /Date AE AE fA
'GYU$ ~D,g"h, "G'P'05@M[y[
Project Titre N/A TMI-l OTSG TUSE REPAIR 1.
BACKGROUND Failure analysis has OTSG tube leaks have been found at TMI-1. sulfur contadination cause 1.1 resulted in the conclusion that The attack is inside granular attack of the TMI-l OTSG tubes.
The majority diameter initiated and circumferential in geometry. Testing (ECT) in of the cracking has been located by EDDY Current or near the weld heat the upper end of the Inconel 600 cube at Since the failure affected zone (HAZ) and the roll transition.
to indicate that the areas of tubes free analysis results continue of ECT indications can be successfully returned to service, a re-the pair process has been selected which kinetically'expandsThe objective is existing tube against the upper tubesheet hole.
length below any defects to to expand the OTSG tube with sufficient joint.
form a new load carrying and essentially leak tight 2.
SCOPE This specification is written to define the performance require-It also includes the performance 2.1 ments for the OTSG tube repair. tube repair process qualification program.
It requirements for theall tubes which will remain in service
/
in both y
OTSG's will be kinetically expanded within the upper tubesheet by is likely that they are cracked.
the repair process regardless of whether or not The total number of tubes to be expanded is approximately 31,000.
The design life of the tube repair will be based on the qualifi-cation program.
s 1,
One objective of the qualification program is to statistically the repair process provides adequate leaktightness 1
2.2 demonstrate that confidence levels and probabilities are pro-and strength. Target vided herein for these parameters as goals to enable GPUN to achieve this objective.
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. g SP-1101-22-006 Page 2 Short Form Speci,fication 3.
OTSG TUBE REPAIR f
3.1 Steps / Sequence It should be The TMI-l OTSG repair process is as follows.
recognized that Step 2 may become a part of Step 6 pending the outcome of preliminary qualification testing.
Step Description 1
Flush the secondary side tube to upper tubesheet crevice.
Clean tube inside diameter in the area of 2
the repair.
Heat crevice to drive out moisture 3
(vaporize water).
1 Maintain crevice in the repair area at a
4 temperature at least 10*F higher than the dew point for OTSG secondary side condi-tions.
5 Kinetically expand tubes.
Cleanup debris from kinetic expansion.
6 l
7 Leak test OTSG.
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as Roll / flush (if required to repair leaking l
6 tubes).
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3.2 Codes and Standards The repair shall satisfy all applicable design parameters I
3.2.1 originally used for the TMI-l OTSG. The applicable steam generator design parameters shall be extracted from the TMI-1 Steam Generator Functional Specification CS(F)-3-33/NSS-5/0369 dated 5/15/70 and Appendices and the General Functional Specification for' R.C. System Components for TMI-l CS(F)-3-9/2NSS-5-0770 dated 7/15/70 and Appendices.
In addition, the TMI-1 OTSG Stress the Report and THI-1 FSAR shall be used to confirm that applicable design parameters have been identified.
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i SP-1101-22-006 Short Form Specification Page 3 x
3.2.2 The repaired tube is a seismic Category I component in accordance with Regulatory Guide 1.29 and a Class I com-ponent in accordance with Regulatory Guide 1.26.
The Seismic boundary for the expansion is the steam generator t
y tube up to and includidg the bottom 4" of the new ex-pansion and -he OTSG tubesheet.
s 1
s 3.2.3 ASME B 6.PV Code as follows:
Section III - " Rules for Construction of Nuclear Vessels", including Addenda thru Summer l'367, and applicable Code Cases as of June
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30", ~ 19 6 7, for Class A Vessels (or later).
a Section XI - 1974 Edition thru 1975 Winter Addenda lor s
later), Applicable sections of Article IWA 4000
" Repair Procedures".
3.2.4 10 CFR 21
- " Report on Defects and Non-Compliance".
3.2.5 10 CFR 50 -
Appendix B " Quality Assurance Criteria for Nuclear Power Plants".
3.2.6 ANSI N45.2.1 - 1980 " Cleaning of Fluid Systems and Associated Components for Nuclear Powe Plants".
3.2.7 ANSI N45.2.6 - 1978 Qualification of 'Inspectioh Examination and, Testing Personnefmfor Nuclear Power Plant".
3.3 ~0TSC/ Plant Performance j
3.3.1 The effects of both repaired and plugged. tubes on the thermal and hydraulic performance of the plant and on the structural and vibrational adequacy of the steam generator shall be evaluated and shall be within the acceptance criteria for both normal ope' rating and design basis accident conditions as specified Cs the licensing basis documents.
3.4 Ryr ; p L -, hen / Length 3,..i Tt.e tubes will be kinetically expanded from the top sur-face of the upper tubesheet to 10 + 1/4" below the top surface of the upper tubeshact. There will be a full expansion over this length with the exception of transi '
tion zones at either end.
The transition zones can'be included in this overall expansion length.
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i' SP-1101-22-006 Short Form Specification Page 4 3.4.2 The repair configuration shall accomodate future sleeve installation.
3.5 Load' conditions 3.5.1 The expansion shall be designed to the loading conditions stated herein and the documents referenced in paragraph 2.1.
The loading conditions to be considered shall in-clude: operating pressure; thermal stresses; flow indaced vibration; seismic accelerations and displacements; and faulted conditions such as loss of coolant (LOCA) and main steam line break (MSLB). The stress limits in Section III of the ASME B & PV Code shall be used for the load compinati6ns/ conditions specified.
3.5.2 The repaired tube shall sustain the maximum design basis axial tensile load of 3140 lb from the generic 177 FA MSLB accident analysis.
Since this is a thermally in-duced load, satsfying this criteria re' quires no relative movement (slippage) between the expanded area and the tubesheet at the axial strain corresponding to this load (about.0016 in/in). However, GPUN wants to avoid (if possible) taking credit for conservatisms in the TM1-1 design basis.
BAW-1588 assumes the tube responds in a purely elastic mode to arrive at the 3140 lb load and this load is retained as the design objective.
Satisfying this objective requires no slippage at 3140 lb
- load, s
3.5.3 The repaired tube tensile preload shall not be changed by more than + 30 lbf at ambient temperature. Previous test data and analysis may be utilized to satisfy this design objective.
3.5.4 Analysis will be performed to confirm that the repair 4
process does not result in tubesheet stresses or bowing that are not in compliance with the design parameters of the OTSG.
3.6 Transition Stresses 3.6.1 One design objective is to minimize tensile stress in the transition region between the expanded and unexPanded portions of the tube.
Since an abrupt transition results in higher residual stresses and larger stress concen-trations, it is required that the transition length be greater than 0.1".
A transition length between 1/8" and 1/4" has been established as a goal. The transition zone will be established by the qualification program.
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Short Form Specification Page 5 3.6 2 An additional objective of maintaining residual tensile stresses (both circumferential and axial) in the transi-l tion less than 45% of the.2% offset yield stress at room temperature has been established. Once the geometry and j
charge loading of the kinetically expanded inserts to be
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used at THI-l has been established by preliminary quali-fication testing, residual stress measurements of the l
transition region will be documented during the quali-fication program. The electro enemical ests defined in
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paragraph 4.6.2 with 10% caustic solution will also pro-vide evidence of acceptably low residual tensile stresses.
j 3.7 Leakage 3.7.1 A design objective for the kinetic expansion is to pro-duce a joint whicu will limit total primary to secondary leakage from the TMI-l OTSG's to 1 lb/ hour or less under plant operating conditions.
In order to achieve this objective, it is our goal to demonstrate the capability to produce-joints under laboratory conditions whose ag-gregate leakage would be less than.1 lb/ hour if extra-polated to all repaired tubes (approximately 31,000).
It is recognized that this is a very stringent requirement, especially considering the fact that a significant per-centage of the tubes do not have through wall defects.
However, concerns over future crack propagation in the expanded area are minimized if our goal is met.
3.7.2 The leakage design criteria is that the maximum allowable primary to secondary leakage rate for normal operation shall be as low as reasonably achievable and allow plant I
operation within the radioactive effluent limit of the TMI-1 Technical Specifications.
j 3.8 Repair Life /Cvelic Loading 1
l 3.3.1 The initial design life objective for the tube kinetic expansion is 5 years.
Sufficient cyclic testing and/or analysis will be performed during the qualification pro-gram to satisfy this objective, The key transient para-I meters which can affect the joint integrity (such as l
thermal cycling) will be tested as part of the qualifi-l cation program. The range of key transient parameters and number of cycles will be based on those used in the i
original design. The rate of change of the key para-f meters can be. greater than the rate of change which will be experienced inservice for the entire plant as long as j
the rate of change experienced by the joint being quali-l fied does not expose it to a strain which is unrepre-sentative of in service conditions.
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3 SP-1101-22-006 Page 6 Short Form Specification A design life of 35 years has been established as a l
3.8.2 goal. The qualification program will include test speci-mens for cyclic testing to a 40 year life separate from those used to qualify the repair for 5 year life.
These specimens can be tested in parallel or in series with the 5 year life specimens. These specimens will be tested using the same key parameters but with greater numbers of cycles in order to satisfy the 40 year life goal.
A summary of the transient cycles to be used from OfSG 3.8.3 Functional Specification CS(F)-3-33 is attached as Table Thermal transients with a range and rate equivalent 1to the transient cycles identified will be included in Where the identified the qualification program.
transients produce thermal transients which cause an insignificant effect on joint integrity tnan others already being tested, the qualification program may rely on analysis for repair qualification.
Thermal cyclic conditioning shall include the following 3.8.4 for the 5 year life:
30 heatup/cooldown cycles 70*-610*-70*
8 reactor trip cycles 70*-610*-70*
In order to ensure that the joint is not subject to plastic strain unrepresentative of in service conditions, the T between tube and tubesheet shall be maintained at equal to or less than 100*F during cyclic thermal testing.
In addition, the rate of temperature change of the tu5es shall not exceed 10*F/ min.
600-400*F
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One (1) Stuck open turbine bypass valve cycle is a in 10 minutes or one (1) MSLB thermal cycle if it more severe cooldown transient (B&W to determine). The T between the tube and tubesheet shall be main-maximum tained at 0*F to 30*F greater than that expected in ser-vice.
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The analysis for cyclic life will include a quantitative 3.8.5 evaluation of the dif ferential thermal growth expected between the tube and tubesheet in the repaired area. The evaluation will consider the possibility of relaxation of the contact pressure between the tube and tubesheet during thermal cycles.
If more stringent operational limits are required, they will be recommended.
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9 SP-1101-22-006 Page 7 Short Form Specification l
3.9 Cleanliness The steam generator and reactor coolant system cleanli-
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r 3.9.1 The kinetic expansion process ness shall be maintained.
expose the inside of the steam generator to the shall not j
following levels of contaminants.
For fluids to be used for final cleaning of OTSC primary l
surfaces:
1 ppm maximum sulfur 1 ppm maximum total halogens heavy metals (Pb, Cd, 0.1 ppa maximum Hg, etc.)
For other fluids (lubricating oils, flush water, etc.)
surface cleaning which will be followed by a solvent prior to operation:
100 ppm maximum sulfur 103 ppm maximum total halogens 1 ppm maximum heavy metals the levels for For solid materials (gaskets, seals, etc.)
total contaminants shall be as follows:
200 ppm maximum sulfur 200 ppm maximum halogens heavy metals 1 ppm maximum-1 Criteria for final cleaning fluids are based on accep-table levels of contaminants per ASTM Boiler & Pressure Vessel Code,Section V, Paragraph T-644 in liquid pene-
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trant materials.
The presence of trace contaminants down to 100 ppb will be documented for materials used in the kinetic expansion testing to determine leachability process. Subsequent The documentation will be pro-may be required by GPUN.
This docu-vided for GPUN approval to use the material.
mentation will be mass spectrographic analysis of samples from each lot of material, in both cases a material control program with quality controls is required to confirm that material is not introduced inside the steam generator without assurance that its constituents are known and acceptable.
Compounds such as oils, grease, coatings, cleaning fluids 3.9.2 and cleaning devices, rubber and plastics which _ contain
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- SP-1101-22-000 Short Form Specification Page 8 sulfur and chlorides and other halogens shall not be present on the final cleaned surf aces of components which are exposed to reactor coolant.
3.9.3 Materials (such as neoprene rubber) compounded from chemical compounds containing halides or sulphur are prohibited.
1.9.4 Chlorinated solvents are prohibited.
3.9.5 The use of cloth, paper or cardboard products for temporary plugging and capping purposes is pr oh io i ted.
Lint-free cloth may be used for wiping / cleaning.
3.9.6 Polyvinylchloride compounds, fluorocarbon compounds or teflon shall not be used in the R C ' system.
3.9.7 Lubricants or other materials used on components exposed to reactor coolant shall be the acceptable material for nuclear service.
3.9.8 Following completion of the repair process, the OTSG will be cleaned to Class B cleanliness in accordance with ANSI N45.2.1 -- 1980.
3.10 Quality Assurance Requirements 3.10.1 The contractor shall have a GPUNC approved quality as-
- j surance pgggram which meets the requirements of 10 CFR 50, Appendix B.
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3.10.2 Qualification work performed at Contractor's locations shall be performed in accordance with a Quality Assurance Program approved by GPUNC.
3.10.3 Contractor shall submit the qualification specification
!I and procedures for GPUNC approval and coordinate,with
!l GPUNC QA to establish witness points for the proposed qualification program.
i 3.10.4 The results of analysis, design calculation, and testing l
activities shall be documented.
a Il 3.10.5 Documents and records which provide evidence that a task I
was performed in accordance with code requirements and I
this specification shall be provided to GPUNC.
1 3.10.6 GPUNC reserves the rights of reasonable access to Con-tractor's or its subcontractor's facilities and the QA
'j activities performed at contractor or subcontractor loca-tions related to the qualification tests as specified in 5
this specification.
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o SP-1101-22-006 Short form Specification Page 9 3.10.7 All records shall be of legible quality.
3.10.8 Personnel parforming testing and inspection activities shall be qualified in accordance with ANSI N45.2.6 - 1978.
3.10.9 Submit QA program with proposal or identify the program if previously sumitted.
3.10.10 Contractor shall provide a listing of the documents to be submitted to GPUN as part of their proposal.
4.
OTSG Tube Repair Qualification Program 4.1 Intent /Ph ilo sophy 4.1.1 The overall intent of the qualification program is to perform sufficient analysis and statistically based testing to result in a high degree of confidence that the kinetic expansion process will satisfy the design ob-jective/ criteria.
4.1.2 The overall philosophy of the qualification program is to test independent affects separately whenever practicable and to rely on previous' analytical or empirical data when it can be correlated to the TMI-l repair process.
4.2 General Testing Requirements 4.2.1 An evaluation of the fabrication, operating history, TM1-1 Failure Analysis data and repair process steps / sequence will be conducted to determine key material paremeters or conditions to be simulated in the qualification program. Parameters to be simulated or bracketed include but are not necessarily limited to:
corrosion in the tubesheet crevice since the crevice surface condition can af fect joint integrity.
1
temperature conditions expected in the crevice during repair.
the tubing to be used for qualification testing will be subject to the OTSG fabrication stress relief temperatures for sufficient time to result in resi-dual stress and material properties comparable to the tubing installed in the TMI-1 OTSG.
tube strength (yield stress) and clearances, tube-sheet to tube and tube to kinetic expansion insert.
In this case it may be possible to select the most
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e SP-1101-22-006 Short Form Specification Page 10 adverse combination and test it vice bracketing the variance.
sequentially expanding adjacent tubes.
4.2.2 A 4" length of kinetically expanded tube is to be quali-fied for leak tightness, load carrying capability and any other design requirements where minimum joint length results in the most adverse condition. This length will enable us to repair tubes with defects from 0" to 6" below the upper face of the upper tubesheet using the 10" long kinetic expansion insert.
4.3 Load Testing 4.3.1 The test program objective is to document with 99%
probability at a confidence level of 99% chat the kine-tically expanded 4" long joint being tested meets the load carrying requirements. The pullout load capability for qualification purposes is to be documented subsequent to cyclic and leak rate testing. The various thermal cyclic transients required will be conducted in series prior to pullout load testing. Pullout load is defined as the first indication of relative motion between the joint and the tubesheet as indicated by a decrease in the applied load caused by tube movement.
4.3.2 The pullout load testing will include the following:
Determine pullout loads for tube joint specimens at ambient temperatures and at elevated temperatures for some of the samples.
1 Determine stress-strain curve for each group of j
pullout load specimens by using specimens from the same tube.
i j
Evaluate each pullout load test to verify that the axial strain at pullout exceeds the maximum axial d
strain for MSLB.
lt Determine pullout loads for 10 joint specimens which have not been thermally cycled. This data will be compared to tha? obtained after thermal cycling.
d.
Tubes in each test block will be expanded sequen-i tially to simulate the OTSG installation sequence.
3 4.3.3 The pullout load test profile is as follows:
Condition and heat treat material.
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i SP-1101-22-006 Short Form Specification Page 11 Kinetically expand tube.
Apply a proof axial load of 300 lbf to all joint specimens.
t Determine pullout loads / strain for 10 joint specimens Thermally cycle remaining joint specimens Bubble test joint specimens at a secondary to pri-mary 6 P of 125 psi using N.
Make a video record 2
of any bubbles noticed visually.
Leak test joint specimens (Assuming same specimens are being used for leaktightness).
Determine pullout loads for 10 joint specimens at elevated temperatures (300 - 500*F:
preferably as high as praticable).
Determine pullout loads / strain for 30 joint specimens at ambient temperature.
4.3.4 Pullout load tests will be conducted on at least 6 samples whose crevice corrosion condition is different than the crevice being tested.
The intent is to docu-ment for later. statistical consideration how critical the crevice condition is with regard to pullout load capa-bility. An uncorroded crevice, a less corroded crevice and a more corroded crevice will be tested. Key para-meters that are known (such as tubesheet and tube material, gun drilled holes) will be maintained the same i
as the qualification tes t pullout specimens.
4.4 Leakage Testing 4.4.1 The test program objective is to document with 99%
probability at a 99% confidence level that the kine-l tically expanded 4" long joint being tested will have leakage less that 3.2 x 10-6 lb/Hr-tube at operating conditions (primary temperature 604'F. primary pressure 2155 psig, and secondary pressure 925 psig). The leak rate can Se determined based on pressure decay of a know volume test system at constant ambient temperature. The l
leak rate thus determined will be corrected to that ex-i pected at operating conditions.
It is recognized that this is a more severe test than testing at elevated tem-peratues since differential thermal growth between the inconel tube and tubesheet should actually result in a more leaktight joint at high temperatures.
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SP-1101-22-006 Page 12 Short Form Specification During the leakrate testing an initial period of time will be allowed for the joints to " season" in recognition 4.4.2 tight mechanical joints of this nature of the f act that The amount of time allowed tend to self seal with time.
for " seasoning" will be determined empirically during the program by plotting pressure decay (leakrate) test Qualification record data will commence versus time.
when there -is a noticeable rate reduction (knee formed) in the leakrate versus time curve or af ter 3 days (which-The differential pressure used during ever comes first).
leakrate testing will start out high enough so that the duration will be average A P during the expected test comparable to the normal operating A P of 1275 psi.
least 30 The number of tubes tested will initially be at 4.4. 3.
with statistical analysis identifying whether or not more If additional samples are needed, samples are needed.
they can be taken from the 40 year test specimens as a The leak test duration will be that timely first source.
required to reduce the measurement error to a value which will enable us to satisfy the statistical objective.
i A ten tube sample will be leak tested following comple-tion of approximately 10% of the required thermal cycles 4.4.4 The or after 1 week of cycling,whichever comes later.
are intended to provide results from this leak testthe leakage objective will be j^
reasonable assurance that These testing results may also be used in de-j scribing status to the ACRS/NRC or third party review
- met, group.
10 samples will be leak tested with a secondary to pri-l l
4.4.5 AP of 1275 psi.
10 samples will be leak tested mary with a primary to secondary AP of 2500 psi.
4.5 Impurities The residue remaining following kinetic expansion will be An assessment of 4.5 1 identified quantitatively by Auger.this residue will deleteriously affect the whether or not OTSG tubes will be documented. A subsequent optical (SEM) evaluation of residue remaining following the cleanup process to be used in Step 6 will be documented An to confirm the adequacy of the process selected.
optical evaluation is acceptable assuming there are no trace contaminants which require more stringent cleanup i
In addi-limits based on concentration per unit area.
tion, optical evaluation or the organic polyethylenecannot be iden residue is required since it tatively as a polymer.
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Short Form Specification Page 13 4.6 Corrosion Testing 9
4.6.1 Secondary side crevice corrosion tests will be conducted to assess the corrosive ef fects of heat-up of the secon-dary side crevice in the presence of contaminants. This heatup is planned to dry the crevice prior to expansion.
4.6.1.1 Two phases of testing will be conducted using the following initial conditions:
I Specimen:
Tube /tubesheet mockup with Inconel 600 tubes and carbon steel tubesheet l
(17" thick). Duplicate specimens to be run for each test solution. Tubes to be model boiler tubes.
Temperature:
. Ambient - 350*F Heat up until crevice dries out (4 days minimum).
Solutions:
The annuluses between the tubes and tubesheet will be filled with the fol-lowing solutions:
NH2 4 (ppm)
FeS
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Tube No.
B (ppm)
SO (ppm)
C1.(ppm) 2 1
880 1
200 2
100 1
200 3
10 1
200 4
2350 880 1
200
.6 5
2350 10 1
200
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6 1
200 10 7
2350 1
200 10
.6 8
1 200 810 9
200 4.6.1.2 The test sequence for Phase I is as follows:
All tubes are to be initially hard rolled at the tubesheet face to seal the crevice at one end.
With the tubesheet upside down, the secon-dary side crevices shall be filled with the above solutions: two tubes to be filled with eech solution.
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SP-1101-22-006 Short Form Specification Page 14 g
Thermocouples shall be attached to the tubesheet and several tubes to monitor temperature profile.
Heat the tubesheet using thermal blankets to 350*F.
Heat up rate shall duplicate the anticipated heat up rate for the actual generator tubesheet heat-up prior to repair.
Hold at temperature for 4 days minimum or until all fluid has evaporated out of the crevices.
Cool down and remove one of each of the pairs of test specimens.
Conduct metallurgical investigation on samples.
Proceed to Phase 11.
4.6.1.3 Phase Il testing will be perf ormed on the re-maining tube samples in the tubesheet. The test sequence for Phase 11 is as follows:
Kinetically expand the remaining tubes using techniques developed for the repair process.
'I Place expanded tube /tubesheet sample in an autoclave.
Subject sample to secondary side steam environment cycling the temperature from i
170*F to 600*F using typical OTSG heat-up and cool-down ramps. Run through 5 cycles.
i Cool down to ambient and remove samples for metallurgical investigation.
Examine condition of all tubesheet cr ev ic es for evidence of tubesheet damage.
4.6.2 Primary and secondary side electrochemical tests will be conducted to evaluate the ef fects of roller / explosive expansion on the generator tube material susceptability to stress corrosion cracking and compare this with existing data on tubes which have been stress relieved after expanding.
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SP-1101-22-006 Page 15 Short Form Specification The electrochemical tests initial conditions 4.6.2.1 are as follows:
- Specimens:
Tube /tubesheet mock-ups using Inconel 600 archive material and Inconel 600 tubesheets in the following conditions:
Kinetically expanded only.
Kinetically expanded with hard roll within 3" of the end of expanded region but not over the kinetic expansion transi-tion.
I The tests to be conducted are as follows:
4.6.2.2 Test 1:
Temperature:
550*F Solution:
Secondary chemistry plus 10% NaOH i
Duration:
5 days maximum Potential:
Cracking potential I
Test 2:
Temperature:
170* F Solution:
B - 2350 ppm
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Li
.6 ppm S02 3 - 100 ppm j
Duration:
5 days maximum Potential:
Cracking potential l
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Test 3:
Temperature:
170*F Solution:
B - 2350 ppm Li
.6 ppm S02 3 - 10 ppm Duration:
5 days maximum Potential:
Cracking potential 170*F Test 4:
Temperature:
Solution:
B - 2350 ppm Li
.6 ppm S02 3 - 1 ppm Duration:
5 days maximum Potential:
Cracking potential
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SP-1101-22-006 Short Form Specification Page 16 Test 5:
Temperature:
170*F Solution:
B - 2350 ppm Li
.6 ppm S02 3 - 1 ppm Duration:
5 days maximum Potential:
Cracking potential Test 6:
Temperature:
130*F Solution:
B - 100 ppm Li
.6 ppm S02 3 - 1 ppm Duration:
5 days maximum Po'tential:
Cracking potential Test 7:
Temperature:
550*F Solution:
B - 100 ppm Li
.6 ppm Duration:
5 days maximum Potential:
Cracking potential 4.6.2.3 At the completion of each test, all samples are to be evaluated for evidence of cracking.
Samples not exhibiting visual cracks shall be examined by metallography/ bending techniques.
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SP-1101-22-006 Short Form Specification Page 17 TABLE 1 l
Operating Transient Cycles Transient Design Cycles l
Number Transient Description (ASME Category) 5 YEARS 40 YEARS 1A Heatup from 70*F to 8% Full Power (Normal) 30 240 IB Cooldown from 8% Full Power (Normal) 30 240 2
Power change 0 to 15% and 15 to 0% (Normal) 180 1,440 3
Power Loading 8% to 100% Power (Normal) 6,000 48,000 4
Power Unloading 100% to 8% Power (Normal) 6,000 48,000 5
10% Step Load Increase (Normal) 1,000 8,000 6
10% Step Load Decrease (Normal) 1,000 8,000 7
Step Load Reduction (100% to 8% Power) (Upset)
Resulting from turbine trip 20 Resulting from electrical load rejection 20 Total 40 320 8
Reactor Trip (Upset)
Type A 5
Type B 20 Type C 11 Trips included in transient numbers 11, 15, 16, 17 and 21 14 Total 50 400 9
Rapid Depressurization (Emergency) 5 40 10
.Cnange of Flow (Upset) 3 24 11 Rod Withdrawal Accident (Upset)
(Upset) 5 40 12 Hydrotests (Test) 3 24 13 Steady-State Power Variations (Normal) 14 Control Rod Drop (Upset) 5 40 15 Loss of Station Power (Upset) 5 40 16 Steam Line Failure (Faulted) 1 1
17A' Loss of Feedwater to One Steam Generator (Upset) 3 24 17 B Stuck Open Turbine Bypass Valve (Emergency) 1 8
18 Loss of Feedwater Heater (Upset) 5 40 19 Feed and Bleed Operations (Normal) 5,000 40,000 l
' 20 Miscellaneous A (Normal) 3,750 l
Miscellaneous B 2,500 Miscellaneous C 5x105 l
21 Loss of Coolant (Faulted) 1 1
22 Test Transients - High Pressure Injection System (Test) 5 40 Core Flooding Check Valve 30 240 23 Steam Generator Filling, Draining, Flushing and Cleaning (Normal)
Steam Generator Secondary Side Filling l
Condition 1 15 l
Condition 2 15 Steam Generator Primary Side Filling Condition 1 15 Condition 2 15 L
Flushing 5
Chemical Cleaning 3
Total 68 544 24 Hot Functional Testing' (Iest) 1 8
1
Babcock & Wilcox w
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,a.o.,. tion oevi.i.o a McD.rmott company 3315 old Forest Road P.o. Box 1260 Lynchburg, Virginia 245051200 (804) 385-2000 June 15, 1982 GPUN-82-158 fft cc:#
Mr. D. G. Slear
'Q ( 711668[
TMI-l Project Engineering Manager GPU Nuclear Je hNg 100 Interpace Parkway Parsippany, N.J.
07054
Dear Mr. Slear:
In accordance with your request during our telephone conversation on June 15th, the attached material has been forwarded to Lawrence Leonard, FRC, and to Conrad McCracken, USNRC.
ruly-yo'urs,
Very/ & ;
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TMI-l 0TSG Recovery Program Manager JFP/dsv Attachment cc: R.E. Kosiba l
R.J. Baker L.J. Stanek M.H. Fish J.R. Concklin l
ATTACHMENTS:
Drawing No. 1134900, Induced Strain Test Mockup, dated 5/21/82 Explosive Expansion Qualification Requirements for Mechanical Testing, 61-0034292-00, for Explosive Expansion Repair of TMI-l OTSG's Drawing No. 1134899 0, Rev. 2, 10 Tube Leak and Load Test Fixture
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EXPLOSIVE EXPANSION QUALIFICATI0lOLEQUIREMENTS FORMECHdNICALTESTING 61-1134292-00 FOR EXPLOSIVE EXPANSION REPAIR OF TMI-1 OTSG's.
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PREPARED BY MLv. (L f[3[#Z.
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CONTENTS 1.0 Introduction and Background 2.0 Scope and Purpose 3.0 Qualification Technical Requirements 3.1 Mechanical Tests 4.0 Documentation Requirements
- 5. 0 Quality Assurance (QA) Requirements i
6.0 Inspection and Witnessing 7.0 Disposition of Failures 8.0 Test Specimen Storage 9.0 Reference Documents W
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1.0 INTH000CT10N AND BACKGROUNO Steam Generator tune leaks were identified at Three Mile Island Unit 1 in NovemDer,1981 during pressurization for functional testing following an extended cold snutdown period.
The leaks were first identified based on increased steam generator secondary side activity when the primary side nad been pressurized to 40 psig.
Subsequent Dunble tests identified 90 leaking tubes in the A-0TSG and 44 in the B-0TSG.
A primary side fiber optic examination of selected leaking tubes nas identified circumferential cracks in the tubes witnin tne thickness of tne upper tubesheet.
Tne cnosen repair tecnnique is to install load carrying leak tignt tuce expansions witnin tne upper tuoesneet.
These expansions will be made oy an explosive forming process. A backup roll expansion is provided in tne event that the explosive expansion fails to meet the design. requirements.
2.0 PURPOSE AND SCOPE 2.1 Purpose The purpose of tnese tests is to verifj tnat tne explosive expansions meet design requirements and to CDtain documentaDie information relating to tne benavior of the repair expansion.
The purpose of tnis document is to provide tne supplier with requirements for these tests.
2.2 Scope Tnese requirements apply to tne meenanical qualification testing of tne explosive expansion process and equipment to De used in tne repair of tne TMI-1 steam generator.
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2.3 Definitions
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2.3.1 Supplier - used in tnis document, supplier is the organization performing the qualification testing or analysis.
2.3.-2 NPGD - Nuclear Power Generation Division of B&W.
2.4 Test Program Summary The testing program is swnmarized in Attacanent 1, B&W Document Numoer U2-11348800 " Testing Program".
3.0 QUALIFICATION TECHNICAL REQU1HEMENTS 3.1 Mecnanical Tests l
3.1.1 General Requirements l
3.1.1.1 Tests are to De conducted using expansion equipment i
identical to that wnicn will De used for tne actual steam generator work, except tnat aspects of tne equipment sucn as remote manipulators need not be utilized.
i 61-1134292-00 6/2/82 l
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3.1.1.2 Tube material is to be SB-163, Inconel 600, surplus OTSG tubing. Samples will be made from the following heat and lot numbers of tubing: heat no. 93452 lot no. 5060 having a minimum tested yield strength of 54,700 psi prior to stress relief and heat no. 93542 lot no. 5001 having a minimum tested yield strength of 41,500 psi prior to stress relief. Min ID of tubing will be.543" for inter face with the explosive expanders. A certificate of conformance is required for the diameter of the explosive expanders.
3.1.1.3 Tubesheet material for mockups is to be SA 508-64-CL.2.
Where single hole mockups are used the tubesheet block is to be 1.143 in 0.D. (Ref. 9.2).
3.1.1.4 Both tubing and tubesheet material for tests are to be heat treated as follows to simulate OTSG stress relief; furnace charts are to be kept:
For Inconel 600 tubes, mill annealed at'>1600 F 0
Heatup: ambient temperature to 900 F, no restrictions on rate 900 F - 1100 F,> 8 F/hr <50 F/hr Hold:
1100 F - 1150 F,18hr i lhr 0
0 Cooldown:
1100 F - 900 F,)8 F/hr (50 F/hr 900 F - ambient, no restrictions Stress relief is to be done in an inert atmosphere for tubing.
For SA 508, C12, tunesheet material, quenched and tempered:
Heatup: ambient temperature to 900 F, no restrictions on rate 900 F - 1100 F, >8 F/hr (50 F/hr Hold:
1100 F - 1150 F, 18hr 1 ihr 0
Cooldown:
1100 F - 600 F,) 8 F/hr ( 50 F/hr U
600 F to ambient temperature, no restrictions on rate 3.1.1.5 All mockup vill be fabricated on a " build to print" basis using drawings supplied by NPGD engineering. A certificate of conformance is to be provided in the Data Package.
3.1.1.6 Material test reports for all mockup components directly related to the qualification testing (i.e., not including end caps) are to be included in the Data Package to be provided with the pieces.
j 61-1134292-00 6/2/82 l
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3.1.1.7 Jigs and fixtures nave no requirements placed on them except as defined in 4.2A.
3.1.2 Leak and Axial Load Tests 3.1.2.1 Samples will simulate the corrosion of the tubesheet ID and tube 0.D. by exposure to air at 9000F for 20 - 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> as required to duplicate TMI-1 oxide thickness. The final length of time will be approved by B&W/NPGD.
3.1.2.2 Explosive expansions will be 10" long starting at the primary surface of the tubesheet mockups. Tubes will be installed in the tubesheet holes as follows:
- one piece of tubing will be inserted from the primary face. This piece of tubing will project above the primary face 3/16" + 1/64" and end 6" below the primary face. This piece oT tubing will be roll expanded at the primary end to 55 in-lb. for a depth of 1 1/4" from the tube end.
- a second piece of tubing will be inserted from the secondary face to butt against the first piece of tubing.
3.1.2.3 Tests will be done in 10 hole mockups (Ref. 9.3).
The hole diameter is to be the average tube OD +.016" +.001".
The pitch of the holes is to match that in the TMI-1 OTSG's.
A total of 6, ten 4 cle mockups will be tested. The tubing used will be heat no. 93452 lot no. 5060 for the 10 hole mockups.
10 tube sam $les are to be lettered A through F for the 1
3.1.2.4 purpose of traceability. Samples are to be subjected to various tests according to the flow chart on Attachment 1.
3.1.2.5 For the portion of this test determining the effects of adjacent expansions on a central previous expansion (blocks A & B) leak rate will be measured for the central tube in question prior to and after individually expanding all adjacent tubes.
3.1.2.6 For the portion of this test determining the effect of expanding a tube twice (block A), the leak rate will be measured for the individual tube in question prior to and after the second expansion. Results of this test may invalidate this test block from the overall leak rate data base. This decision will be made by NPGD engineering pending the results of this test.
0 3.1.2.7 Leak rates will be determined at 70 F + 15 F for a primary i
to secondary pressure differential of 1275 + 5 psi and 2500 + 10 psi depending on the specimen being tested.
Where applicable, the secondary to primary leak rate will be determined for a pressure differential of 1275 + 5 psi.
The same samples, provided leakage is present, used for the sec-pri pressure test will be subjected to a secondary to 61-1134292-00 6/2/82
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A 3.1.2.7 primary side bubble test using 125 + 10 psi N '
2 3.1.2.8 Water used for the leak testing will be demineralized.
3.1.2.9 Thermal cyclic conditioning wfll cgnsist of +38 gycles of the tgbe/tubesheet sample from 70
-+5 to 610 5 to 700 +
5 F.
Heating and cooling rates are not critTcal provideH the tube and tubesheet temperatures do not differ by more than 500F at any time. Thermocouples will be placed as a minimum on the tube ID surface and the tubesheet OD surface inthecgnterofgheexpansion. An additional thermal change from 610 F to 400 F in 10 minutes will be applied to those samples which are to be thermally cycled. No maximum temperature difference between tube and tubesheet applies to this single thermal change.
3.1.2.10 Axialloadcyclicconditionfngwiflconsistofthefollowing independent sets done at 70 + 10 F:
100 cycles 780 lbs. compression to 1110 lbs. tension 180 cycles 635 lbs. compression to 175 lbs. tension 6000 cycles 510 lbs. compression to 125 lbs. compression Cycles are to be applied at not more than 1Hz. Tolerance on all forces in cyclic conditioning is + 5 lbs.
3.1.2.11 The axial tensile load which causes the expansion to slip will be measured and recorded such that elastic (or plastic) extension of the tube will not be confused with gross movement.'
3.1.2.12 When assembled, ths mockups will be monitored for deformation of adjacent holes due to the explosive expansion. This will be done for at least 3 of the 10 hole blocks.
3.1.2.13 After assembly of the 10-tube mockups a gas leak test is to be made using the pressures that each mockup will be subjected to to determine that the seal welds of the end caps to the body are leak tight.
3.1.2.14 Test procedures are to be submitted to B&W NPGD for approval prior to use.
3.1.3 Induced Strain Test Requirements 3.1.3.1 Explosive expansions will be 10" long.
3.1.3.2 Two samples each will be made using heat no. 93452, lot no. 5060 in single hole tubesheet mockups with a.016" diametral annulus, and heat no. 93542, lot no. 5001 with a
.003" diametral annulus.
(Ref. 9.4) 61-1134292-00 6/2/82
3.1.3.3 Mockups will simulate tube to tubesheet weld location and active tube length'such that the tube end at weld location is free to move axially away from the tubesheet.
3.1.3.4 The tube is to be in tension initially,100 lbs. + 10 lbs.
Simulated gube compliance must be greater than or equal to 3.1.3.5 3.17 x 10- in/lb which is the calculated value for steam generator tubes.
(i.e., a weight could be used to produce the preload.)
3.1.3.6 Motion of the tube to tubesheet weld tube end and active tube length end of the sample caused by the expansion will be measured to.0005".
3.1.3.7 The overall tube length across the expansion will be measured to.0005" before and after the tubesheet is split following the expansion.
3.1.3.8 Test procedures are to be submitted to B&W/NPGD for approval prior to use.
3.1.4 Yield Stress Test Requirements 3.1.4.1 A stress-strain curve is to be made for each piece of tubing used to make test samples.
3.1.4.2 Each curve is to show,. as a minimum, the.2%. offset yield and should continue to ultimate tensile strength.
3.1.4.3 Test procedures are to be submitted to B&W/NPGD for approval prior to use.
4.0 DOCUMENTATION REQUIREMENTS 4.1 Qualification Plan The Supplier is to provide a Qualification Plan to B&W/NPGD. This plan shall present an overview depicting the major events, tests, analyses and i
schedules for each leading to the qualification of the subject equipment.
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By means of the plan, the Company shall be able to, as a minimum:
A.
Determine what tests or analyses are to be performed and for what purpose.
B.
Determine if and how the Vendor intends to combine the results of individual tests or analyses to arrive at combined effects.
61-1134292-00 6/2/82
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i C.
Where critical, define the sequence in which the program is to be performed.
D.
Define the acceptance criteria to oe employed.
E.
Identi fy any assumptions and provide acceptable justification.
The qualification plan shall be submitted to the Canpany for approval.
4.2 Qualification Procedures These procedures, coupled witn tne qualification plan, shall form a complete picture of the program to be conducted.
Because tne procedures become part of the qualification file, the procedures shall as a minimum:
A.
Require complete identification of all equipment to be used in in testing and/or analyses including type, make, model, manufacturer,
+
specifications, etc.
B.
Provide complete test setup description including:
1.
Mounting arrangements.
2.
Interface simulation so tnat the test configuration simulates tne required actual field installation where necessary.
3.
Connection requirements.
C.
Identi fy equipment parameters to be monitored.
D.
Identi fy tne environmental.pagapeters (including margin) to be monitored and the methods to be employed.
E.
Identify the parameters to be simulated during the test and identify the range, duration, etc. cf the test parameters and methods of moni toring.
F.
Identify the requirements that the test or analysis is intended to veri fy.
G. ' Indicate the number and identification of test specimens to be employed for each test.
H.
Identify the sequence in wnich the test is to be conducted.
I.
Identify the method of processing and disposition of failures and anomalies that may occur during testing.
J.
Provide step by step procedures for conducting the test.
These qualification procedures shall De submitted to tne Company for approval.
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4.3 Qualification Reports Qualification reports shall serve as auditable data sources to support the j
final qualification.
To serve its purpose, each qualification report l
snall as a minimum:
l l
61-1134292-00 6/2/82
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'l A.
Reference the related qualification procedure which serves as its basis.
B.
Contain all data required by the qualification procedure.
C.
Contain all analytical methods and models utilized for qualification.
D.
Contain data collected during the qualification effort.
E.
Contain the acceptance criteria.
F.
Demonstrate performance in terms of acceptance criteria.
G.
Report and analyze all anomalies to provide demonstratable proof that the anomaly does not invalidate the qualification results.
H.
Cite any precautions, restrictions, or limitations which must be taken into account by.the ultimate user of the qualified equipment in order to maintain the validity of the qualification.
I.
Contain vendor signatures and dates indicating review and approval of the report.
The qualification report shall be submitted to the Company for approval.
The Company will obtain Owner's approvals.
5.0 QUALITY ASSURANCE (QA) REQUIREMENTS
~
QA requirements are outlined in th[ Quality Requirements Matrix (QRM) 5.1 Document #48-1120199. This docunient advises the supplier of the documentation that must be forwarded to and/or approved by B&W/NPGD during the performance of the order or contract.
5.1.1 The quality assurance for the fabrication of component parts of the tube /tubesheet mockup assemblies, non-production explosive devices, l
jigs, fixture, etc. which are considered by this document to be non-safety related is
?., be perfonned in accordance with NPGD QA Spec 09-1212 as amended by Contract Technical Requirements (CTR)
Document 24-1134284-00.
Specific requirements for documentation are limited to those in the l
body of this document and on the QRM.
5.1.2 QA for the performance of qualification testing and the final assembly of tube /tubesheet mockups which is safety related is to be in accordance with NPGD QA Spec 09-1212 as amended by CTR document 24-1134283-00 except where the testing is perfonned by a B&W R&D facility (i.e., Alliance or Lynchburg Research Center) in which case QA is in accordance with NPGD QA Spec 09-1427-00, "QA Requirements for R&D".
Specific requirements for documentation are limited to those in the body of this document and on the QRM(s). ARC and/or l
LRC are to submit Quality Assurance plans for any testing they do.
Equivalent articles of 09-1427-00 may be used to respond to the l
requirements of 09-1212 as modified above.
61-1134292-00 6/2/82 1
i.
5.2 Variation in the manufacturing of components for mockups, mockup assemblies or explosive expanders from the requirements in this document are to be submitted to NPGD engineering for review and approval. The disposition of the parts is to be determined by NPGD engineering. Approved documentation is to be included in the Data Package if the prf:r'h) which varied from the requirements are allowed to be used.
psecq) 6.0 INSPECTION AND WITNESSING B&W/NPGD Engineering and Quality Assurance reserve the right to witness tests and to inspect the Supplier's test facilities.
The Supplier will give sufficient notice in advance of the performance of tests to allow B&W to exercise this option.
(i.e., notification will be made sufficiently in advance to allow arrangements to be made by B&W to have personnel on hand.)
7.0 DISPOSITION OF FAILURES B&W/NPGD Project Management is to be notified in writing of the failure of any test during qualification. Failures will be analyzed and such analyses documented. The analysis is to include:
A description of the failure, including the failure mode and e
the effect on performance.
Summary of test conditions just prior to equipment failure.
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Mode of failure.
e Cause of failure.
Recommended corrective action to prevent reoccurrence of the failure, e
Recommendations for qualification retesting.
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8.0 TEST SPECIMENS STORAGE The Supplier is to have or to develop specific written procedures for the i
maintenance and preservation of test specimens in a condition such that the specimen, or parts of specimens in the event of destructive testing, can be used for future testing if required.
Specimens are to be kept in this condition until written direction for the final disposa} of them is obtained from B&W/NPGD.
l 9.0 REFERENCE DOCUMENTS 9.1 NPGD Qual. Class. System 07-1000584 9.2 ARC LR.75:2257-01:1 9.3 B&W Dwg #11348990 9.4 B&W Dwg #1134900A 61-1134292-00 6/2/82 i
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