ML20078B646

Slide Presentation Entitled TMI-1 Once-Through Steam Generator Repair & Return to Svc

ML20078B646
Person / Time
Site:	Crane
Issue date:	04/05/1983
From:	GENERAL PUBLIC UTILITIES CORP.
To:
Shared Package
ML20077J956	List: ML20078B544 ML20078B558 ML20078B644 ML20078B646
References
FOIA-83-243 NUDOCS 8309270187
Download: ML20078B646 (51)

Text

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Muclear l

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l TMI-1 OTSG Repair

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Return to Service i

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NRC Presentation April 5,1983 Aa

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8309270187 830629 PDR FOIA DORDSHOB3-243 PDR

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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 II.

• Leak Before Break D. Croneberger 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

_.e.

.. O 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 Tl ll,,,,nW\\

. l.

_=g------

34 -FLUSH TUBES II

.H

,g TUBE PLUGGING f,/;J 75 g

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

~

~ fe' l200

~

S o

DRAIN IMMUNOL S

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4*

f, E

52 -EJECT CANDLES (FELT PLUGS) f FEB I

MAR I

APR

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=

P 44

//

5

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2ND EXPANSION jj g

35 DISG b->

.//

-0TSG A 4

i 3,rt '*

28 8:

PLAN (11/22/82)

DRAIN IMMUMOL j:

i EJECT CANDLES ACTUAL (3/28/83)

-(FELT PLUGS)

,/ f 20

/*/

4

. ;:r..-

i 12 START RCS j

EXPANSION CLEANUP e

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4 y

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l DCT NOV DEC JAN FEB MAR,'

APR MAY

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 75 W plugs

• Stabilization 235 Kinetic Expansion Pre-expansion Preparation 16 0

First Pass Expansion 168 0

• First Pass Debris Removal 132 0

a Second Pass Expansion 167 0

i

.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

5

• Bubble Test l

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

- PLUGS (Vil) o CORROSION TESTS e REMOVE TH!0 SULFATE SYSTEMS INSPECTION 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) e OPERATING PROCEDURES I

REVISED (X) e TESTING PROGRAM (APPENDIX A)

- LEAK TESTS 4

- C00LDOWN TESTS T

I o

i s

OTSG B OTSG Post-Expansion Eddy Current Absolute (8x1) Results y.

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

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5 1

a 3

I 4

OTSG A J

OTSG Post-Expansion Eddy Current Absolute (8x1) Results 3

===.

Background===

284' tubes kinetically expanded and E/C examined before and a

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 4-32 US+ 11.9 1

.5 1

18V IV e

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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OTSG Post-Expansion Eddy Current Fiberscope Examination Summary i

i VISUAL SIZE (in.)

ECT f

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

f B

3 27 Area of Pits US+10

.01 03 3

6 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 l

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Kinetic Expansion O.ualification Length

<ECT Examination Conclusions

• Many of the indications are from pits or scratches

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which are of no consequence.

l,

'e None of the indications have been identified visually as ID cracks.

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TMI-1 TUBE PLUGG!NG/ STABILIZING PLAN s

ID INDICATION <40 ANY DETECTABLE 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 l dal <2 ColLS LS -4 TO -24 BOTTOM $~ 0F HISTORICAL DEFECT AREA KINETIC EXPANSION AREA I

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1 PLUG & STABILIZE PLUG AND PLUG AND l

PLUG AND TO BOTTOM OF STABILIZE 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 PREVIOUSLY PLUGGED i

259 88 347 OR STABil.lZED STABILIZED (1983) 395 80 475 PLUGGED (1983) 231 105 336 TOTAL 885 273 1158 i

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Remain in Service

~

~ ~ ~ ~

NUMBER OF TUBES DESCRIPTION (<40% TW)

OTSG A OTSG B TOTAL 10,8x1 <2 C0lLS 3

14 17 m

~. - -,.

a_

s-TMI-1 POST REPAIR ECT INSPECTION

SUMMARY

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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 e 10 PElliPHERAL/0T3G

.540 SD*

~60

~60 WEAR 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 E

C^ '

INSERVICE (<40% TW)

• fg 66 66 he H

.540SD 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 tubes subject to MSLB and maximum cooldown loading, g

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 maximum operating cooldown.

i

• 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.

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CONSERVATISMS:

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• 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.

I 1

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 thr.u wall extent prior to propagating circumferentially to a i

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 OTSG Tube Load Capability i

360 i

D IJ o

270 4-I ASME Fatigue Curves 40 yrs, stress inten = 5

• Design Basis - 100'/ii.

• % Design Basis 5

=

5 a

u 180 I

cc 4

m C3 ECT SENSITIVITY y

0.540 D'IFF. P'R'08.

90 f

I

' DETECTED 9

+40 yrs. A kth = 4 40 yrs. A kth

• l '*~

e DETECT.ED l

l 4

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20 40 60 80 100 DEFECT THROUGHWALL - %

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OTSG Tubo Critical Crack Sizos

.00

,_.0.0.M AX ARC-LENGTH 100 F/HR C00LDOWN \\

)

\\ (w/140 F SHELL

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• TO TUBE AT) 1

\\ (1107 w-(649 LBS) 1.75

\\

\\. \\ LBS)

N)

\\.L E C T -*-

\\

\\

M k

MSLB g

1.50 LIN E, +\\.

MSLB -* 's N

(3140 lbs) \\.

(1408 lbs) s.

7

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3 1.25 g

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ECT +

g E

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g 1.00 l

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.75

's, 4

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a s.s,j

.50 i

.25

/

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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 Tube Load @ 100% Power (Lbs.)

200 (Tension) 500 (Tension) o i

TRANSIENTS:

3

.I 1 - MSLB Transient Tube Load (Lbs.)

1408 3140 (Tension)

(Tension)

Critical Crack Size (Inches) 1.28 0.52 NY s

Leakrate (GPH)

@ 100% Power Operation 14 6

i 2 - 100 F/Hr Cooldown i

(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 1107 # tension 90

~

peripheral tube load @ 100*F/Hr Cooldown

~-

gg

/

70 2

4.S 60 500 # tension

=-

<c peripheral tube load oc l

5

@ Full Power 50 j

3 E

2 W

is 40 J

-o i

30 i

1 200 # tension j

20 core tube load i

i

@ Full Power

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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 TUBE CHACK 0D ARC LENGTH (INCHES) s/

f

~'

Operater Actions es e Function of Leakrato

>l4 PLANT SHUTDOWN 1

PLANT OPERATING l

EMERGENCY PLAN ACTION LEVELS g

.s g

j<

UNUSUAL EVENT k4 ALERT g

I I

i 1

I l

I PROCEDURES l

I i

, PLANT C00LDOWN g,

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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 H0 LT' UM METHODS j4

>l l --MAKE-UP FLOW-+{

ORlN LOW RANGE HIGH RANGE i

ALARM ALARM ly,

HPI FLOW l

0FFGAS MONITOR H I

i 8

i

!< ALERT-+

l l4 UNUSUAL EVENT l

BATCH SAMPLE OFFGAS+

I i

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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 OR SHUTDOWN 0F LEAKRATE V

r LIMIT ACCESS MONITOR INSTALL SHIELDING GENERAL AREA YES AREAS IF LEVELS REACH RAD A '

\\> LIMITS /

ACTION LIMITS ES SHUTDOWN v

MONITOR ALL TAKE CORRECTIVE NO PARAM.

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 ACTION s

l ON LINE CONDENSER

.5 GPH INCREASE MONITOR CONTINUGUS TAKE BATCH SAMPLE OFF GAS IN 8 HOURS (Xe 133) i

)

1 GPM COMMENCE SHUTDOWN 0^'

SAMPLE 6 GPH (.1 GPM)

PERFORM NORMAL SHIFT (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 SURVEY EAC AIN MON TOR WHEN TRIGGERED NONE E

(GAMMA) 1 i

LEAK RATES ARE CALCULATED BASED ON RATIOS OF MEASURED SECONDARY ACTIVITIES TO RCS ACTIVITY L

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! Radiation Monitoring LOCATION METHOD FREQUENCY LIMIT ACTIDN j

P

^L D

P^

L"8" POWDEX VESSELS TWICE PER WEEK 5 MR/HR @ 10' MON TOR pOWDEX VE SE S POWDEX RECOVERY PORTABLE TWICE PER WEEK 100 MR/HR @ 10' SYSTEM VESSELS MONITOR -

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 l

ATER "

CONDENSATE

/

STORAGE TANK WATER i

RECOVERED TO TURBINE BUILDING i

~ ~ ~ ~ + -

SUMP i

h l

TURBINE l

BUILDING x

IWTS

-+

RELEASE

~

SUMP

_u uuttu-4 j

i L-____-_

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PORTABLE STORAGE TANK PRO. CESSING L---*

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.

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9 Comparison of Existing to Proposed a

Pump Trip /Subcooling Guidelines

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4-

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r 08 84

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s

1. Y jf*~ ~..

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O4p OV o

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==-----------Y PSG,TC 1

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TEMPERATURE I

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A (current requirements): - 50 subcooling

- RCP trip on HPI actuation l

B (proposed requirements): - 25 subcooling

- RCP trip on loss of subcooling D

Benefits: - RCP operation during larger breaks

- Lower tube AP 0

- 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 5

i l3 525 ac L

S 420 315 1: 25 F SC, PUMFS 0N

~

210 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

--- 50 F SCM, RCP'S ON x

lE 50 F SCM, RCP'S OFF E.

140 3

n

/,/-

120 lE

/'

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l_

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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' Natural HPl 4 _ _ _ __,

g Circulation Circulation Cool,mg L

j rf 1

Decay Heat Removal i

New Guidance:

j

- multiple tube ruptures

~

- ruptures in both steam generators I

- HPI cooling I

- Secondary water management Improved guidance:

- Minimum subcooling reduced to 25

- RCP trip criteria

- tube to shell AT

- steam generator steaming, feeding, flooding

,s'

._---___.,.T___,

- ~ _, _ _. _ _ _...

- ~ ' ~

TMI-1 Sulfur Investigation & Resolution

.s s

CORRECTIVE 4

EVIDENCE ACTIONS 1

e OTSG e 1979 PIPE CRACK PROBLEM CONTINUED eWDG RESOLUTION FOLLOW e PORV e RCS INSP.

j Ju PREVENTATIVE 4

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 Total Welds f

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 3

Pipe Segment Examined Indications 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 H0RRIZ. PIPE TO MWST 7 (7 UT)

NONE 8

r MWST DISCHARGE 17 (17 UT) 1 POSSIBl.E CRACK I

-Disposition WDG-V4 replaced 50 feet WDG pipe replaced with 304L Periodic monitoring of one weld 1

e

-Conclusion 9

Localized sulfur assisted IGSCC in HAZ l

a 0

0 L

0, 0

Evidence Relating to Sulfur Attack i

'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 g

VALVE SERVICE INDICATIONS 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 Attack 0

s RCS Component Examinations 1

AREA EXAMINED METHODS INDICATIONS COMPONENT UPPER & LOWER HEAD PT,W NONE 4

OTSG UPPER & LOWER TUBESHEET PT,W NONE l

^

N0ZZLES 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.

SIMPLIFIED s

CONTROL ROD DRIVE MECHANISM o

O m

POSITION ENO CAP INDICATOR

~

ASSEMBLY l

5 4

MOTOR TUBE TORQUE TAKER o

fD

]

MAGNET e

I jTORQUE TUBE t

ASSEMBLY 1

M SNUBBER ASSEMBLY c==

- 8 5 CD F

1 t

STATOR

, ('

STATOR WATER COOLING JACKET e

C SEGMENT ARM f

4 PlVOT PINS COMPRESSION SPRING I

ROLLER NUTS THRUST 7

BEARING

y..-.;

A BW

<l LEADSCREW THERMAL BARRIER 8

[

g ASSEMBLY REACTOR VESSEL HEAD CONTROL RODS l

l lNSPECTED COMPONENTS P.

s.

r 4

Inspections to be Performed 1

e Pressurizer Internals q

l

• Spray pipe & nozzle

• Shell I

• Ladder welds

• Heater bundle c

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 Corrective Action Summary. _.

y 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-,,

m.,.ww,m.+,w....~4

Liquid and Wipe Sampling i

Q r

.. WIPE SAMPLES s

8::::: LIQUl0 SAMPLES I

>..8.W...S.T..4 v...

8 l

,y' V

V y

> - WDL & WDG I

iBUltDIN G O*.

!:0ECAYii:i i

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!!HEATii' t:

ilS..Y.S..,T. E.M. '.:.0.:.

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RC PUMP V i

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.......;s :......

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iCHEMICAL *O:

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i.i.M.. A..l.(E...U. P..i.i

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& OTHERS

& OTHERS

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.....WA S TES..:..

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.O*

OlSPOSAL:i:

i:' SYSTEM'

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$. $. LIQUl0ii["

"".:.:.i:9:

.... GAS :

• i

.,... S,YS, T E, M,..* *.* -

.... S. Y. S. T..E..M..:..

1 b

1-.

• --7 a'

" " ' ~ ' ~ * * * '

D I

t

'E I

Sulfur

i Transport & Corrosion Mechanism 4

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 +

cracking on draindown 1

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 0

9 O

L_

~

?

Susceptible Materials & Coriditions i

e CRACKING GEN CORR OR PITTING i

D AUSTENITIC MARTENSITIC STAINLESS o

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 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,.-

v...

.-,v.,.-.-

--w

,--+ww w m-w

t e

TMI-1 e

Sulfur Investigation o

I g.

conclusions e

1. Sulfur phenomena is understood from full spectrum of studies.

c

2. Sulfur related damage has been or is being located and repaired e

as appropriate.

Q i

3. Recurrence potential is minimized by system modifications, system cleaning, and chemistry control.

i 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

e Verification of the adequacy.of the OTSG Tube i

)

Repair Program by operational leak testing and l

on-line monitoring throughout the test program L

o Determination of plant transient response i

characteristics and verification of acceptable i

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 l

COMPLETE JTSG OTSG RESTORE FILL &

RCS OTSG DRIP BUBBLE ECT RCS VENT H022

+

REPAlRS TEST TEST RCS CLEANUP SEC. PLANT READY TO SUPPORT HEATUP

• 1 ESTABLISH I

OTSG/FW HEATUP OTSG HOT ZERO COOL f AH CHEMISTRY FOR OTSG HOT TEST FUNCTIONAL POWER DOWN i

TO SUPPORT HOT TEST AND SOAK TESTING PHYSICS HEATUP i

['

'3 4

• 2 I

NATURAL POWER RETURN OTSG B>

CIRCULATION ESCALATION TO 100*/

CURRENT TESTING TESTING

~ 90 DAYS TEST

• Formal Management Review I

i 40% 75% 100%

4 G

.L O

t

~'

OTSG Tosting ORIP/ l l

l l

l l

N 8

RCS I

I 2

BUBBLE l SULFUR

' THERMAL SOAK l THERMAL SOAK.' THERMAL SOAK TEST I CLEANING i

I 8

I l

600 1

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 l

l i

8 TIME

'~li

~4 WKS l

~4 WKS I

OURATION

! WKl 8

i i

i i

SG TEST TUBE I

- HOT, PRESSURIZE 0 INTEGRAL SG LEAKAGE i

OBJECTIVE LEAKAGE l

- CORROSION ARREST l

I i

- REPAIR JOINT / TUBE STRUCTUR AL I

l

- EFW SPRAY / TUBE RESPONSE l

i MEASUREMENTi l

l4 LEAKAGE

=l 3

I 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 POWER ! POWER 8 l

l i

100 i

I I

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i ECT - 90 DAY I

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i l

l h

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i 0

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~4 WKS l

l i

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l SG TEST

- CORROSION EFW/ TUBE RESPONSE DBJECTIVE l ARREST l 1 -TUBE VIBRAT10N l - TUBE VlBRATION i-

- NATURAL CIRC l

8 I - TUBE VIBRATION TRANSITION I

l l

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I I

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MEASUREMENT 1 LEAKAGE I

• ADJ FOR STABILITY 1

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