ML20078B646
| ML20078B646 | |
| Person / Time | |
|---|---|
| Site: | Three Mile Island  |
| Issue date: | 04/05/1983 |
| From: | GENERAL PUBLIC UTILITIES CORP. |
| To: | |
| Shared Package | |
| ML20077J956 | List: |
| References | |
| FOIA-83-243 NUDOCS 8309270187 | |
| Download: ML20078B646 (51) | |
Text
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l TMI-1 OTSG Repair
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NRC Presentation :
April 5,1983 1
1
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Aa 8309270187 830629 PDR FOIA DORDSHOB3-243 PDR
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1 NRC Presentation 4/5/83 Agenda r )
- 1.
- Introduction /Pepair Status _
.D. Slear
- Overview of SER Logic
- Plugging / Stabilization Plans
- Qualification Zone 8x1 ECT Indications
- ECT Future Plans ,
D. Croneberger II.
- Leak Before Break 111.
- Operational Guidelines G. Broughton
'l IV.
- Support Systems Sulfur investigations M. Sanford -
e Snifur Transport Mechanism
- Corrective and Preventive Actions <
V-; *Startup Program J. Carroll
, m
_ _ ___- _ , , - - o
_ _ ,, _, _.e. .. O
~~
l OTSG REPAIR PROGRESS GRAPHICAL SUMM ARY
' \ COMMENCE LEAR l TESTING .
100 -
FREE PATH / FINAL CLEAN TUBES (FELT PLOGS) i-~~~~~~~~~ ,-
92 PLUG TUBES . l.
l Tl ll,,,,nW\
_=g------
34 -FLUSH TUBES II
.H
,g - - - -- ,
75 - TUBE PLUGGING g
f,/;J 1000 3 */ son -
COMMENCE '
x 68 END MILL TUBES !
- l
- FREE g j soo -
PATHING o e i i P ~
,,f l 400 OTSG A+ OTSGB l
~
l200 S
~ fe' ,.
o DRAIN IMMUNOL f, S I i 4* '
E 52 -EJECT CANDLES (FELT PLUGS) f
'f FEB I MAR I APR
? i!
y =
ll P 44 -
//
5 ' '?
] 2ND EXPANSION jj g 35 -
DISG b-> .//
4
-0TSG A i
3,rt '*
28 8: PLAN (11/22/82)
- DRAIN IMMUMOL j:
i EJECT CANDLES ,* '! -
ACTUAL (3/28/83) 20 -(FELT PLUGS) ,/ f 4 /*/
. ;:r..-
i 12 , ,!
j . START RCS
! EXPANSION CLEANUP e
\ 4 -
~
- y
.'i .-
g I l l l l l MAR ,' ' '
0 3
Exposures from OTSG Program 3
' 's
- 3 Actual to Date Additional Projected RCS Inspection 12 0 Eddy Current Testing 35 10 Pre-Repair Testing 5 0 e t -
Tube Sample Pulling Plugging and 120 0 Stabilization 0 .
Plugging and Stabilization
- W plugs - 75
.
- Stabilization -
235 Kinetic Expansion
- Pre-expansion Preparation 16 0
- First Pass Expansion 168 0
- First Pass Debris Removal 132 0 i a Second Pass Expansion 167 0
.i
- Second Pass Debris Removal 75 0 1 End Milling 125 0 i
- Clean up l
- Flush -
30
- Soak and Clean - 30
- Individual Tube Cleaning -
10-40*
i Testing .<..
- Drip Test - 5 l
- Bubble Test - 5
- Final Inspection and Turnover -
5-10*
Totals 855 405-440
- ltems for which planning is not complete.
0 l b
PLANT RETURN TO SERVICE SAFETY EVALUATION OVERVIEW PLANT SAFE TO OPERATE
~l FAILURE MEASURES TAK5N RCS & SUPPORTING STEAM NO ADVERSE MECHANISM TO PREVENT SAFETY GENERATORS ENVIRON.
UNDERSTOOD RECURRENCE SYS. UNDAMAGED OPERABLE IMPACT o METALLURICAL TESTS e DX1DlZE AND/0R e RCS INSPECTION (ll.E)
- REPAIRS QUALIFIED e APPENDIXl (H.8) REMOVE SULFUR (IV.C) - EXPANSION (V & VI) CALCULATIONS (XI.B) e SUPPORTING o CORROSION TESTS e REMOVE TH!0 SULFATE SYSTEMS INSPECTION - PLUGS (Vil) e ALARA CONSIDERATIONS (ll.C & lil) (IV.A) (ll.E) e PLANT PERFORMANCE (XI.C) j e PREVENT FUTURE ANALYZED (Vill)
CONTAMINATiuN (IV 4) e UNREPAIRED SECTIONS OPERABLE e IMPROVE CHEMISTRY CONTROLS (IV.8) - CT DETECTABWTY ADEQU ATE (IX.B) '
-CRACK PROPAGATION ANALYSIS (IX.C)
-FLAW GROWTH PROGRAM (IX.A)
- CORROSION TESTS (lX.A)
I e OPERATING PROCEDURES REVISED (X) e TESTING PROGRAM (APPENDIX A) 4
- LEAK TESTS
- C00LDOWN TESTS ,
T I
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1 i
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OTSG B OTSG Post-Expansion Eddy Current y.
Absolute (8x1) Results l
Backgroun'd
, 151/ tubes kinetically expanded and E/C examined. Nine (9) _
tubes were reported by 8x1 as having indications not seen by
.540 S.D.
Results ABSOLUTE NOISE LEVEL S.D.
Row / Tube Location , Coil Volts Distortion 400 Basa Mix .
4-19 US+11 1 .5 1. 2V .UV :
4-30 US+ 12.9 2 2 2 3-27 US + 9.4 3 8 2 2V .6V 3-25 U S + 10.7 1 1 1 2V .6V 4 3-24 US + 12.6 2 2 2 2V .6V )
1 3-21 US+10 1 1 1 2V .3V 2-21 US+ 13.1 1 1 1 2V .6V
-l 2-22 US+ 13.2 4 1 (MULTIPLE) 2 f.8V .5V l t *2-25 US+07 1 1 1 1.5V .5V
'New Kinetic Transition l .
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D l
l E _ . _ . _ __ _ _ _ _
5 1 a
3 I 4 OTSG A J
OTSG Post-Expansion Eddy Current 3
Absolute (8x1) Results
Background
a 284' tubes kinetically expanded and E/C examined before and ,
after expansion. Six (6) tubes were reported by 8x1 as having indications not seen by .540 S.D.
Results - Absolute - - Level of Noise S.D. -
, Row / Tube Location Coil Volts Distortion 400 Base Mix
, , AFTER EXPANSION 2-12 Not expanded .8V .4V
' 6-43 US+4 1 1 1 .8V .2V i 7-54 US+1 TO 1 1 (.v0LTIPLE) 1 .6 V .3V US +13.7 1 4-4 U S+ 9.1 1 <1 1 2V IV e
4-32 US+ 11.9 1 .5 1 18V IV 2-7 US+ 6.3 1 .5 1 1.2V .4V g BEFORE EXPANSION i '2-12 US-3 TO 1 <1 (MULTIPLE) 1 US+7 3 <.5 1
- 6-43 US+4 1 <1 1
- 7-E4 US-8 TO 1 <1 (MULTIPLE) 1 US+13
'8x1 Repgrted 3 tubes as having indications before expansion 3
o n
x
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l OTSG Post-Expansion Eddy Current i Fiberscope Examination Summary i
f VISUAL SIZE (in.) ECT i OTSG R0W TUBE INDICATION LOCATION CIRC AXIAL COILS VOLTS i
B 3 24 Liria of Pits US+13 .01 .02 2 2 i B 2 22 Area of Pits US+13 .01 . 06 4 2 i
B 3 27 Area of Pits US+10 .01 03 3 6 f .
i
- B 2 25 Scratch US+7 >.05 -
1 1 l
A 4 32 No visible US + 11.9 -
1 <1 ;
indications
( A 2 7 Na visible US+ 6.3 - -
1 <1 indications -
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l Kinetic Expansion O.ualification Length
- <ECT Examination Conclusions .
- Many of the indications are from pits or scratches which are of no consequence.
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'e None of the indications have been identified visually as ID cracks.
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TMI-1 TUBE PLUGG!NG/ STABILIZING PLAN s
ANY DETECTABLE ID INDICATION <40 DEFECT 240% TW PERCENT TW AND INDICATION 8x1 >2 COILS I
E E I E E .
E E E E 15TH SP TG LS-4 IN ANY TUBE SPAN 15TH SP TO 1.5-4 IN 15TH SP TO LS-4 LANE / WEDGE- 1 ETH SP TO LS-4 US + 4 TO +8 AND NOTISOLATED BY LANE / WEDGE 15TH SP TO US + 4 8x1 >2 C0lLS HISTORICAL OEFECT LS -4 TO -24 BOTTOM $~ 0F HISTORICAL DEFECT AREA l dal <2 ColLS KINETIC EXPANSION AREA I l l i I _
f.
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PLUG & STABILIZE PLUG AND PLUG AND PLUG AND STABILIZE l TO BOTTOM OF STABILIZE TO PLUG ONLY PLUG ONLY STABILIZE TO 14TH SP ROUGH SPAN OF BOTTOM OF 14TH SP BOTTOM CF 14TH SP 1
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9
. Tube Plugging Summary 0
Plugged NUMBER OF TUBES DESCRIPTION OTSG A OTSG B TOTAL i
PREVIOUSLY PLUGGED 259 88 347 OR STABil.lZED STABILIZED (1983) 395 80 475 PLUGGED (1983) 231 105 336
, TOTAL 885 273 1158
, i e l
Remain in Service ,
~ ~ ~ ~ ~
- NUMBER OF TUBES DESCRIPTION (<40% TW)
. 10,8x1 <2 C0lLS 3 14 17 m
~ . - - , . -- -
- a_ _- - . . _ _ _ - _ . _ _ . _ s- ,
l TMI-1 POST REPAIR ECT INSPECTION
SUMMARY
s
(
\ TOTAL NUMBER OF TUBES DESCRIPTION SCOPE PROBE BASELINE DATA 90 DAYS DEVELOPMENT e 15 TUBES WITH PR8iVIOUS KINETIC EXPANSION INDICATIONS 8x1 15 15 (6" QUAL. LENGTH) e 3% BASELINE /0TSG 8x1 930 930 WEAR e 10 PElliPHERAL/0T3G .540 SD* ~60 ~60 e 10 WITH DEFECTIN (INSERVICE TUBES 15TH 10TH GR 1ST ADJACENT TO UNSTABILIZED SPAN /0TSG .540 SD* ~120 ~120 PLUGGED TUBES) e 5 WITH .540 SD >3V .540 SD* ~60 ~60 LMid C^ '
INSERVICE (<40% TW)
- fg E ,
H .540SD 66 66 he
! HIGH PLUGGING DENSITY e 50 FULL LENGTH /0TSG .540SD 100 100 l
Ntb STANDARD INSPECTl0N e 3% FULL LENGTH /0TSG .540 SD COMPLETED IN 1982 930
[
l _ . . .
. TDTAL ~1350 ~2300 s
- LABDRATORY QUALIFICATION USING WEAR SPECIMEN CDliiPLETED
. OTSG Tube Leak Indication Before Tube Break Introduction PURPOSE:
i i _
Provide the results of critical thru-wall crack sizes in OTSG g
tubes subject to MSLB and maximum cooldown loading, establish the leakrate for critical crack sizes and to -
demonstrate that OTSG leakage provides indication of tube cracks before tubes are subject to failure during cooldown transients.
i .
OUTLINE:
1
,
- Provide critical thru-wall de-fect sizes for MSLB and i maximum operating cooldown.
- Provide results of crack growth due to mechanical effects.
- Provide single tube leakrate versus thru-wall defect sizes based on tube tensile load.
[
- Provide the leakrate from critical thru-wall defects.
! Establish an operational leakrate limit.
5 L
l .
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/
O l CONSERVATISMS: .
?
l i ,
- MSLB tube loads based on guillotine break with double
[ ended flow through 36" M.S. lines (TMI-1 has 24" @ M.S.
nozzles and can't have double ended flow). Cooldown less ,
severe.
- All leakage is assumed from only one tube.
- The single leaking tube is assumed to be in a location
. which will produce the smallest leakrate.
1 I
l OPERATIONAL LEAKRATE 1
- Measured leakage following post-repair testing establishes base line.
- Post-repair testing assures leakage from any single tube is cmall compared to leak rate predicted from leak-before-break analysis.
- Guidelines for operationalleak rate are a function of 6 GPH
] increase from baseline leakage.
I .
1 4 .
CONCLUSION:
Defects will propagate radially and result in leakage due to i thr.u wall extent prior to propagating circumferentially to a critical size.
A leak rate change of no more than 6 GPH assures that a normal plant cooldown can be accomplished and that a more i, rapid cooldown due to a MSLB can be accomodated without a tube rupture.
0 s
t 1 +
O o l l OTSG Tube Load Capability .
i 360 ;
i D
IJ o .-
270 -- - - - - - -.
ASME Fatigue Curves 4- I 40 yrs, stress inten = 5
- Design Basis - 100'/ii.
' * % Design Basis 5
= .
5 a '
u 180 I cc 4
, m --
C3 y ECT SENSITIVITY
, 0.540 D'IFF. P'R'08.
90 - -- - -- -
f I
9
' DETECTED +40 yrs. A kth = 4 40 yrs. A kth
- l '*~ .'
e DETECT.ED - ---
l l 4 G 20 40 60 80 100 l
DEFECT THROUGHWALL - %
l 1 >
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l . _ - . _ . _ _ _ - - . - _ . . - . _ _ . _ _ _ - . . . _ . _ . . . . , . . . . . . . . . . . . , . . . . . . .
OTSG Tubo Critical Crack Sizos -
.00 -
,_.0.0.M AX ARC-LENGTH 100 F/HR C00LDOWN \
) -
' \ (w/140 F SHELL '
\
-
- TO TUBE AT) -
\ \
1.75 - -
1
\ (1107 w-(649 LBS)
\ \. \ LBS) N)
E C T -*- -
\ .L
\ \ M 1.50 -
MSLB LIN E , +\.
g kN MSLB -* 's s.
(3140 lbs) \. (1408 lbs) 7 g \
s E #.
\
] 3 1.25 -
g <
l0 z -
g ECT + .
E \
g 1.00 - -
l 5 \.
E N.
(I c \
[ ] .75 -
's, 4 %
i O 'N s.
4 a
.50 -
s,j i
.25 -
/
.c l l l 1 O 20 40 60 80 100 DEFECT DEPTH IN % WALL THICKNESS NOTE: 1) PERIPHERAL TUBES
- 2) CORE TUBES -
L
?
TMI-1 OTSG Tubes
, Critical Crack Sizes and Operating Leakra te s.
, TUBE LOCATION: CORE PERIPHElQ o Tube Load @ 100% Power (Lbs.) 200 (Tension) 500 (Tension) i 3
TRANSIENTS: ,
.I
, 1 - MSLB Transient Tube Load (Lbs.) 1408 3140 (Tension) (Tension)
Critical Crack Size (Inches) 1.28 0.52 s
NY Leakrate (GPH) .
- @ 100% Power Operation 14 6 i
i 2 - 100 F/Hr Cooldown (140 F Shell to Tube AT)
Transient Tube Load (Lbs.) 649 1107 (Tension) (Tension)
Critical Crack Size (Inches) ,
1.72 1.48 s.
Leakrate (GPH)
@ 100% Power Operation 22 72 t
OTSG Leak Rate as a Function of Crack Length & Tube Tensile Load 100 90 - 1107 # tension
~ -
peripheral tube i l
load @ 100*F/Hr
~-
gg _ ,
Cooldown ,
/
70 -
24.
S 60 -
= 500 # tension
<c _
oc peripheral tube load l 5 @ Full Power -
50 - -
j 3 E -
- 2 W
J is 40 -
o i
! 30 -
i 1 200 # tension j 20 -
< . core tube load i
i -
@ Full Power -
] . -
i 10 -
1 i
. > i I I i l I 0- 0;1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 l
TUBE CHACK 0D ARC LENGTH (INCHES) s/
____f *__
' ~'
Operater Actions es e Function of Leakrato ,
1 PLANT OPERATING PLANT SHUTDOWN >
>l4 .
l
. g EMERGENCY PLAN ACTION LEVELS
.s g j< UNUSUAL EVENT k4g ALERT >.
I I i 1 I l
I '
PROCEDURES l I i
, PLANT C00LDOWN >!
, g, i I I i '
4-OPERATION WITH TUBE LEAKS->i TUBE RUPTURE >
.1 1 50 2 . . . m PRIMARY TO SECONDARY LEAK RATE (GPM)
, : : I : : I :. ,
.001 .01 .1 1 10 100 1000 p MAKE-UP TANK LEVEL
. RATE 0F CHANGE s
MONITORING j4 H0 LT' UM METHODS ORlN >l l --MAKE-UP FLOW-+{
! LOW RANGE HIGH RANGE i ALARM ALARM ly,,, HPI FLOW >
l 0FFGAS MONITOR H , .
! I i 8
i l l4 UNUSUAL EVENT !< ALERT-+
! l BATCH SAMPLE OFFGAS+
I i
r
5 .
i Steady State Monitoring Guidelines I '
)
OPERATE AT STEADY STATE POWER v
MONITOR LEAKRATE CTION ^
YES ACT0 LEVELS REDUCE POWER RATE OF CHANGE EXCEEDED ,
-] 0F LEAKRATE V OR SHUTDOWN r
MONITOR LIMIT ACCESS INSTALL SHIELDING GENERAL AREA AREAS YES '
IF LEVELS REACH RAD A ' \> LIMITS /
ES ACTION LIMITS SHUTDOWN v
MONITOR ALL TAKE CORRECTIVE PARAM. NO SECONDARY > ? ACTION PER CHEMISTRY IN SPEC CHEM. PROC.
YES . -
y .._
/\
TRENDS TAKE ACTION INCREASING < YES TO PREVENT
,,.. TOWARDS/ EXCEEDING SPEC LIMITS V
- =
)
! Leakage Detection 1
i
- LOCATION METH'0D FREQUENCY .
LIMIT s ACTION l
ON LINE -
CONDENSER MONITOR CONTINUGUS
.5 GPH INCREASE TAKE BATCH SAMPLE OFF GAS IN 8 HOURS
, (Xe 133) ,
i
) 1 GPM COMMENCE SHUTDOWN SAMPLE 0^' " " -
PERFORM NORMAL
- SHIFT 6 GPH (.1 GPM)
(Xe 133 Xe 135 ABOVE BASELINE SHUTDOWN WHEN TRIGGERED TOTAL GAS) ' ,
i i
REACTOR PRIMARY COOLANT LEAK RATE EACH SHIFT .33 GPM INCREASE TAKE BATCH SAMPLE SYSTEM CALCULATION l
S EA NONE SURVEY EAC AIN MON TOR WHEN TRIGGERED E
(GAMMA) 1 i
LEAK RATES ARE CALCULATED BASED ON RATIOS OF MEASURED SECONDARY ACTIVITIES TO RCS ACTIVITY L o
c . .
w- . .- ..: __ -___. _r_ ___ ___ _- e -e- e ._ ~ - . --
! Radiation Monitoring '
.; LOCATION METHOD FREQUENCY LIMIT ACTIDN j .
POWDEX VESSELS P ^L TWICE PER WEEK 5 MR/HR @ 10' D P^ L"8" MON TOR pOWDEX VE SE S
! POWDEX RECOVERY PORTABLE TWICE PER WEEK SYSTEM VESSELS MONITOR -
100 MR/HR @ 10' NORMAL SHUTDOWN -
INCREASE TWICE PER WEEK .5 MR/HR PORTABLE FREQUENCY TO DAILY TURBINE BUILDING .0R DAILY DNITOR PERFDRM i WHEN TRIGGERED 5 MR/HR
- NORMAL SHUTDOWN l
- TURBINE BUILDING SWIPE WEEKLY 1000 DPM/100 cm2 By DECONTAMINATE DRAINS 100 DPM/100 cm2 a DRAIN i
SECONDARY SYSTEM PORTABLE WHEN DPERATING SECONDARY ACTIVITY OBSERVE HP VENTS AND DRAINS MONITOR VENTS AND DRAINS > MDA PRECAUTIONS 0
Throo Milo Island Unit 1 --
Turbino Building Liquid and Solid Wasto Managemont '
During Operations with OTSG Leakage i
POWDEX ---* IWFS .-> RELEASE l
SUMP ut. . myy s .
\
! - - - - - + HIC / LINER
> PROCESSING -~
SYSTEM j ----+ SOLIDIFICATION DECANT ATER "
l CONDENSATE i
WATER RECOVERED
/ STORAGE TANK TO TURBINE BUILDING i ~~~~+- SUMP i
h .
l TURBINE l
~
BUILDING x ., IWTS -+ RELEASE SUMP
_u uuttu-4
', j i L-____-_ ,
I l.
' l l PORTABLE STORAGE L---* TANK -> PRO. CESSING j DEMINERAllZERS I
4
o.
," Guidelines for Operation During i
Power or Temperature Changes l
, Objective:
I Reduce tube end loading to reduce j leakage from existing cracks and to -
p.revent crack propagation 1
l Limits:
The following limits will maintain tube end loading less than 550 lb.
1
- cooldown limit 1.67 F/ min 1
- tube to shell AT 70 F i
l Shutdown if leakage exceeds .1 gpm (6 gph) above i baseline.
t t
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9 a Comparison of Existing to Proposed Pump Trip /Subcooling Guidelines
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&a
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- 08 84 4
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- .. , O4p OV
> NA
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e ==-----------Y PSG,TC 1
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- TEMPERATURE I
I I
]' A (current requirements): - 50 subcooling l
- RCP trip on HPI actuation B (proposed requirements): - 25 subcooling
- RCP trip on loss of subcooling D
Benefits: - RCP operation during larger breaks 0 - Lower tube AP
- Reduced 'sak rate 1
!D O
'O
- a. .
i ,
B'reak Flow for Single Ruptured Tube 1050 i i i i il 945 - -
. I 11 111 840 - -
, E 735. - -
- n. <
N 630 - -
i 5 l3 525 - -
ac L
S 420 - -
, 315 - -
' ~
210 -
1: 25 F SC, PUMFS 0N -
I II: 50 F SC, PUMPS ON i 105 -
III: 50 F SC, PUMPS OFF -
{ 0 I O 10 20 30
't FLOW LBM/SEC I
- w.
)
O e
)
_ . . . ._ .. . _ , . , _ s. -
.mnua. a-mw .- - ,
I, FIGURE 3 i ! ,
Effect of RC Pump Operation 4 on Integrated System Leakage for Single Ruptured Tube ,
180 , , , , , , ._..,-._ , , ,
i n **,,...-
= 160 -
25 F SCM, RCP'S ON x --- 50 F SCM, RCP'S ON *... **,... .
lE 50 F SCM, RCP'S OFF -
E.
3 140 -
n /,/-
lE 120 - .
o x /'
- u. /.*. # /
g /p#p
~
100 - -
< /,/ '
u /
1 w
a 80 -
/
/
/./ /
/
uJ e--
4
/ p/s i 1
/ l l
n gg -
/,/**/.# f / -
3 / /
/ ,.// /
~ .
40 -
7
/
10
.f*
1 I I I I I i 1 l_ l I g _ f-l .-
30 40 60 80 100 iii)
TIME IN MIN -
w . .
S.
. 'q -
lc Tube Rupture Guidelines Primary to -
s Secondary Leakage
> 50 gpm 1
[
h .
Manual Automatic i Shutdown Shutdown t 1 y ? ?
! Cooldown l
i
- . E 1 r I
Forced' 4 _ _ _ __ , Natural g HPl Circulation Circulation ,
Cool,mg L j 1 ,
rf Decay
, Heat Removal i New Guidance:
j - multiple tube ruptures
~
- ruptures in both steam generators I
I - HPI cooling -
- Secondary water management Improved guidance:
- Minimum subcooling reduced to 25 l
, - RCP trip criteria l
- tube to shell AT
- steam generator steaming, feeding, flooding
,s'
-~'~
._---___.,.T___, . - - _ _ _ _ _ _ _ _ _ , . - ~ _ , _ _ . _ _ _ . . .
TMI-1 Sulfur Investigation & Resolution
.s s 4 CORRECTIVE EVIDENCE ACTIONS 1
! e OTSG e 1979 PIPE CRACK PROBLEM CONTINUED eWDG % RESOLUTION "-* FOLLOW e PORV j e RCS INSP.
Ju 4 PREVENTATIVE 4 ACTIONS I
I '
I
- I I
L_, _
MECHANISM DETERMINATION JL SAMPLING PROGRAM ,
1
Evidence Relating to Sulfur Attack t ,
- 1979 Pipe Cracking
-Through wall cracks in Spent Fuel Pool Cooling Pipe at weld HAZ
-Extensive NDE program undertaken f
Total Welds system Welds Inspected SPENT FUEL 566 566 8
DECAY HEAT 408 408 BUILulNG SPRAY 241 241 MAKE-UP 1051 697 CORE FLOOD 31 31 REACTOR COOLANT SURGE 11 11 REACTOR COOLANT SPRAY 28 28
't
-Disposition
] Periodic monitoring of 20 indications Remaining joints removed - replaced with 304L
's
' ~
-Conclusion IGSCC of some HAZ's in stagnant, borated, oxygenated sistems 0
~ * ,
i l
4
S.
r Evidence Relating to Sulfur ,
Attack . !
s 7
e Waste Disposal Gas Piping - 1982
-Through wall crack on Aux Bldg side of WDG-V4
-WDG piping examined between RCDT and MWST Welds
- Pipe Segment Examined Indications <
3 i -
RCDT to WDG-V3 3 (U.T.) NONE 8 WDG-V3 to WDG-V4 11 (2 UT,11 RT) 4 WITH PITTING NO CRACKING WDG-V4 to H0RRIZ. PIPE 7 (7 UT,4 RT) 4 CRACKS 8
H0RRIZ. PIPE TO MWST 7 (7 UT) NONE r MWST DISCHARGE 17 (17 UT) 1 POSSIBl.E CRACK I .
-Disposition WDG-V4 replaced 50 feet WDG pipe replaced with 304L 1 Periodic monitoring of one weld e
9
-Conclusion Localized sulfur assisted IGSCC in HAZ l
a 0
0 L _
0, l
1 0
Evidence Relating to Sulfur i ,
Attack
't
- PORV j
-PORV 1 (in service 4/76 - 4/81)
- No unusual corrosion observed during 1979 refurbishniont
- l General and pitting corrosion of Martensitic and inconel X-750 parts observed during 1982 refurbishment ,
I
-PORV 2 (in service 4/81 - 2/83)
,{ General and pitting corrosion of Martensitic and inconel X-750 parts observed during 1983 examination
' Pure crystalline sulfur and sulfur compounds found on PORV body & parts
-Block Valve No unusual corrosion observed (no Martensitic or X-750 parts)
't High sulfur deposits present
] -Disposition Clean, inspect, and re-install block valve
] Clean & inspect PORV body; replace internal parts
-Conclusion "1) Damage mechanism existed after 1979 and prior te 1981 HFT as well as during 1981 HFT l'
- 2) Martensitic and Inconel X-750 parts are susceptible to corrosion l 3) Non-sensitized austenitic parts are not susceptible to corrosion i
i i
9 9
_,.,--,-w. r . ,. ..-,r.,m,-._.._.. , , m. _ , _ _ g.
e Evidence Relating to Sulfur Attack
's Pressurizer Area Valve Examinations
.. VALVE SERVICE INDICATIONS g
S DEPOSITS RC-V1 PRESSURIZER SPRAY 3 i NO CORROSION <
i RC-V17 PRESSURIZER VENT MINOR PITTING e
RC-RV1A SAFETY VALVE NONE RC-RV1B SAFETY VALVE MINOR PITTING WDG-V1 RCDT RELIEF MINOR PITTING
- f i
l Disposition; All corrosion indications are minor and do not
_ affect valve integrity or function.
l
Conclusion:
- 1) Safety valves were protected by loop seal.
- 2) Valves not in close proximity to pressurizer are not significantly attacked.
i l
0
Evidence Relating to Sulfur 0
Attack s
" RCS Component Examinations 1
AREA EXAMINED METHODS INDICATIONS COMPONENT UPPER & LOWER HEAD PT,W NONE -
OTSG 4 UPPER & LOWER TUBESHEET PT,W NONE l
N0ZZLES
^ " "' I g /- PRESSURIZER SPRAY & SURGE RT,UT NONE <
l -
LEADSCREW V, W NONE F CRDM MOTOR TUBE UT NONE END FITTING PT, M. W NONE RV N0ZZLE EC NONE u -
INNER 0-RING M,PT,W NONE PLENUM LIFT LUG BOLTS UT NONE RV & PLENUM ASSEMBLY V NONE
{
i PLENUM PLENUM CYLINDER BOLTS UT NONE INCORE DETECTORS & SHEATH F, PT, W NONE
( VENT VALVE TC N0ZZLE EC NONE i
TOP DF CORE & CONTROL COMP V NONE FUEL ASSEMBLY & CONTROL COMP V NONE RV RNS RETAINER PT,M NONE INTERNALS CORE SUPPORT SHIELD TO BARREL BOLT UT NONE
] LOWER HEAD & BOLTING RING V NONE a BAFFLE PLATE REGION V NONE VENT VALVES & CORE SUPPORT SHIELD V, F NONE
? KEY: UT ULTRASONIC PT DYE PENETRANT V VISUAL OR VICEO W WIPE SAMPLE F FUNCTIONAL
)
RT RADIOGRAPH M METALL0 GRAPHIC
Conclusion:
i No general RCS component corrosion had occurred.
b i
L _ _ . . _ . . _ . _ . . _ . . . _ _ - . . . . _ . _ _ . _ _ _ . , . _ . . . _ . _ _ _ _ - ._ . .._m . . . . _
o.
s SIMPLIFIED o
CONTROL ROD DRIVE MECHANISM m
O POSITION -
- ~
INDICATOR -
ASSEMBLY -
l 5
4 MOTOR TUBE o TORQUE TAKER > :
] fD -
MAGNET -
e -
I -
jTORQUE TUBE >-
t ASSEMBLY $
1
, M c== $ < SNUBBER ASSEMBLY F
- 8 5 CD 1
t : STATOR STATOR WATER > , ('
COOLING JACKET :
e -
- C
, SEGMENT ARM 4 PlVOT PINS f COMPRESSION SPRING I
, ROLLER NUTS THRUST _
7 BEARING y. .- .; - .
A BW
< , <l LEADSCREW THERMAL BARRIER 8 [ :
ASSEMBLY g ,
REACTOR
< VESSEL HEAD
< CONTROL
, RODS l
lNSPECTED l l COMPONENTS P. . _ - - - . - . . _ - --
- s. .
r
. 1 4
Inspections to be Performed 1
e Pressurizer Internals q l
- Spray pipe & nozzle
- Shell -..-
I
- Ladder welds c
- Heater bundle j ,
.i RCS Piping-
- Hot leg vent '
1
- Pressurizer vent i
ij Auxiliary Systems
- Make-up tank relief valve
] & nozzle .
- /. .
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i .
y Corrective Action Summary. _.
1 e j i OTSG il l Kinetic Expansion .
l Plugging PORV Clean & refurbish
- 1 WDG l Replace 50 feet of pipe Replace WDG - V4 n
f l
- D o
o
,_., , _ - . , - ... , _. . . , m.,.ww,m.+,w....~4
. 1
. I Liquid and Wipe Sampling i .
Q r
. . WIPE SAMPLES s
I
> :.:-.8.W.
..::::. .:.S.T.. 8::::: LIQUl0 SAMPLES 4
., v... -
8
- l ,
y' V
V y > - WDL & WDG I ;iBUltDIN G O* . .
- !:0ECAYii:i :
i i ".i!! SPRAY::::..*9+~* !!HEATii' t:
ilS.
.. .Y.S. .,T. E.M. '.:.0.:.
ii 5.Y. .S.T.E. .li.d. ii T
s a PZR i
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s 4:d CFT : :-
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RC PUMP V
. "O
. . . . . ..;s :.....
t :0: NUCLEAR l* :iCHEMICAL *O:
- $ :::Nf::::::::::: -
1,iAD01 TION :::::
- .:. .:.S.YSTI. M. .O 0
'i:S
^ :::YS T.ii.M.:+.:.*+
.i u u A
i.i.M. . A. .l.(E. . .U. P. .i.i Xj&. '
FROM-RCS FROM RCS xYU$iIlCNNdN:;i
& OTHERS & OTHERS : SYSTEM
^ - - -
^.: -
I v v v y .......-
- . . . ....... :!O E M i :. N.,.,.,.:.,
0;.
. . . W A s f E ... .*.* * *.I
. .. ... .WA S TES. .: .. ...
- .O* :::W AT E R........<
- OlSPOSAL:i: > .
.:.2: DISPOSAL:$':' '
- i:' SYSTEM'
- .$. . GAS ..... : :$.
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"" .:.:.i:9: *i
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... .. . S. Y. S. T..E.
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, . . _ . . - . - - .-- . - , , . . - _ - - _ . . 1-. . . - *--7 -- a' " ' " " ' ~ ' ~ * * * '
D I
t
'E I
' Sulfur
- i 4 Transport & Corrosion Mechanism l .
, OTSG Tube Cracking (review) .
I e ID initiated stress assisted IGA e Temperature + oxydation potential + sulfur +
'l potentially aggressive form
- Sulfur concentration mechanism + oxygen +
1 cracking on draindown I
PORV Pitting and General Corrosion & WDG Cracking
- Gaseous sulfur compounds are transported from liquid j phase
- Condensation areas result in potentially corrosive local concentrations
]
- Corrosion occurred at low temperatures l
0 9
O
~
.,; L_,
?
Susceptible Materials & Coriditions i
e CRACKING GEN CORR OR PITTING o i D AUSTENITIC MARTENSITIC STAINLESS MATERIAL STAINLESS OR HIGH OR INCONEL X-750 )
NICKEL ALLOY j
, i .
- 1) EXPOSURE TO GASEDUS FORM WITH A CONDENSING 1) EXPOSURE TO GASEOUS CONDITIONS SURFACE. FORM WITH A CONDENSING SURFACE
- 2) EXPOSURE TO A CONCEN-TRATION MECHANISM i
I
- l Conditions NOT Associated with Attack -
i
- Non-sensitized materials
- Flooded & flowing piping .
e Piping drained well after shutdown t
l 1
/~
_-..__.~.______l.___...C____._._.-.
4 l
r 6 .
L i, L- Preventative Actions R
b A Eliminate Sulfur Source p
- Sodium thiosulfate tank eliminated f * ,Monitor chemical additions i
l h Clean Residual Sulfur b .
- Hydrolaze pressurizer l
- Peroxide clean: Reactor Coolant System Decay Heat System l Make-up and Purification System 9
3 Prevent Recontamination
{
- Sample storage tanks to assure quality
- Monitor building spray and fuel pool cooling
)
( Propide Continued Monitoring l
- Daily RCS sulfur samples 4
- - - - - - - - , .- .-,v.,.-.- --w ,--+ww w m-w
t .,
e e TMI-1 Sulfur Investigation o
- g. I conclusions e
- 1. Sulfur phenomena is understood from full spectrum of studies.
c e 2. Sulfur related damage has been or is being located and repaired as appropriate.
Q i 3. Recurrence potential is minimized by system modifications, i system cleaning, and chemistry control.
L 3 4. Chemis try monitoring will provide rapid detection in the i unlikely event of recurrence.
i 1 .r.
m s
L ,
-. __. - . , - - -,, - .-------.-..-...--......,-,.-.....~..,,--.~.-...-.u, -
- , , , , ,_,..w .,
re.-
TMI-1 Restart Test Program !
Purpose
- To provide a deliberate, methodical well
, planned verification of proper modification 1 installation and performance in accordance with 3
design 1
i e Verification of the adequacy.of the OTSG Tube <
) Repair Program by operational leak testing and l on-line monitoring throughout the test program L
i o Determination of plant transient response i
characteristics and verification of acceptable integrated plant operation with modified
] systems / components I o Verification of acceptable system readiness and plant operation with new and modified plant operating, surveillance, emergency, abnormal
,' and maintenance procedures o Performance of sufficient modified system / plant steady state and transient
, operations to provide operator training and L familiarization with modified system / plant l- response throughout a range that he is likely to experience during the design life of the plant l
- l
TMI-1 Rostart --
Test Program -
including OTSG Repair
- ECT -
+
, SEC. PLANT READY TO -
SUPPORT ,
HEATUP .
- 1 ESTABLISH HEATUP OTSG HOT ZERO I
OTSG/FW COOL FOR OTSG HOT TEST POWER f AH CHEMISTRY ..
HOT TEST AND SOAK DOWN FUNCTIONAL TESTING PHYSICS i TO SUPPORT
- HEATUP i
['
'3 4
, *2 I NATURAL POWER RETURN OTSG CIRCULATION ESCALATION TO 100*/
B> _ -
CURRENT TESTING TESTING
~ 90 DAYS TEST
- Formal Management Review I i 40% 75% 100%
4 G
.L__________ _ _ _ _ _ _ _ . _ _ _ . . _ _ . _ _ _ _ O
~'
OTSG Tosting t
l ORIP/ l l l N2 8 RCS I I
l l BUBBLE l SULFUR ' THERMAL SOAK l THERMAL SOAK .'I THERMAL SOAK TEST I CLEANING i 8
' I 600 -
1 l i ,
I i 1 . I I I ' I I I 500 - 2150 psig 400 -
-60 /hr 300 -
-90 /hr 200 -
+ TO HFT 100 300 psig I
i -
i l l 8 TIME '~li ~4 WKS I l ~4 WKS OURATION ! WKl 8 i i i i
SG TEST TUBE I
- HOT, PRESSURIZE 0 INTEGRAL SG LEAKAGE i OBJECTIVE LEAKAGE l - CORROSION ARREST I i ' l .
- REPAIR JOINT / TUBE STRUCTUR AL I l ! !, - EFW SPRAY / TUBE RESPONSE l i ,
MEASUREMENTi 3
l l4 LEAKAGE
=li I I l l l t .
' ~
OTSG Testing _.
during HFT & Pewor Escalation . - -
l i STO l' ! I HFT & 0 ' LOW ! 40% POWER OWELL I 75% POWER OWELL 3 FULL POWER l
POWER ! POWER i 8 ! $
l 100 -
i I
I
, i u I i I
i ECT - 90 DAY i
75 -
1 i
- l l h ! !
ii: 50 -
1 l
E
- a 25 - -
i i
0 i i FEED
, i i TURBINE -
i TRIP l l TRIP
, I TEST DURATION i ~2 WKS l-1 WK, ~4 WKS l ~4 WKS l l i i l
l
- CORROSION SG TEST DBJECTIVE l ARREST l l1 -TUBE
- CORROSION VIBRAT10N ARRESTi-i CORROSION l - TUBE VlBRATION
- CORROSION EFW/ TUBE RESPONSE ARREST AR
- NATURAL CIRC l 8 I - TUBE VIBRATION TRANSITION I l
- i i l
i l l l l 3 I I
i i
MEASUREMENT 1 : LEAKAGE
- I 1
- ADJ FOR STABILITY i
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