ML20082R151

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Slide Presentation Entitled, TMI-1 Once-Through Steam Generator Repair Process Description/Qualification
ML20082R151
Person / Time
Site: Three Mile Island, 05000000
Issue date: 09/15/1982
From:
GENERAL PUBLIC UTILITIES CORP.
To:
Shared Package
ML20079Q406 List:
References
FOIA-83-479 NUDOCS 8312130066
Download: ML20082R151 (42)
v • d • e


Text

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E Nuclear TMI-1 OTSG Repair Process Description /

O.ualification September 15,1982 khf2fD 066 830914 ADATOB3-479 PDR

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'l TMI-1 Steam Generator i

l ELEVATION CROSS SECTION

i W

l PRif.1ARY SIDE n

W "2W -

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(INSIDE TUBES)

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jtri. C".'.'."

  • . I UPPER r* - r> ~

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TUBESHEET (UTS)g 7 -]- c-2[

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AUXILIARY

t. ' A w+

FEEDWATER

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i NDZZLES h,

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STEAM DUTLET%j "j M ' r i*

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MAIN FEEDWATER NDZZLES (MFW)g= _>

OTUBE l

Y i l g iw a6.

T.'""

O h, p!'

E SECONDARY SIDE

- 8* -

(EXTERNAL TD TUBES)

  • d (;g.,'

m-

.. Pt.1.1 w r=, -

Weight, operating.............. 637 tons

.m-l Height....................... 7 3 feet

)T*-

Primary flow.................. 6 9X 106 #/hr.

S team flow................... 6.1 X 106 #/hr.

SUP

=-

PLATES

  • /

Number tubes................. 15531 l

3,

- 1. -

Tube size, material............. 0.625" od,.034 wall

.o inconel 600 SECOND Manufacture date.............. 5/69 to 11/70 i

HANDHDLD i

9/15/82 I h

..-,.~-.,.-.------.-......,.._l,,$,'.11.~'

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TMI-1 Steam Generator Typical Cracks INCONEL TUBE

  1. N f, K A

TYPICAL CRACKS ROLL TRANSITION

  1. /

//

EEL TUBESHEET h

CRACK' CHARACTERISTICS: CIRCUMFERENTIAL BELOW FILET WELO I

NOT FULL ARC GENERALLY VERY TIGHT

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PRIMARY S10E INITIATED 9/15/82 1

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. _, _. _ _, ~. _ _ _ _ _ _ _ _ C,~

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TMI.1 OTSG Repair Process 1

(Steps / Sequence) p l

L.

1. Flush secondary side tube /tubesheet crevice (complete)
2. Heat crevice to drive out moisture (in process)
3. Pre-coat OTSG surfaces
4. Kinetically expand tubes for 17" or 22"
5. Cleanup debris A. Organic residue on RCS surfaces B. Explosive particulate residue C. Pieces of polyethylene candle
6. Plug tubes with defects below UTS + 8"
7. Leak tests
8. Plug or roll leaking tubes (if required)
9. RCS cleanup (if required)
10. Pre-critical operational testing a

9/15/82

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KINETIC EXPANSION PROCESS 1

1

'i DRONANCE CORD

/

Y DETONATING CAP HOLDER I

l

/

/

/ m

=

g.

j V

'@E; l

h DETONATING ELEC RICAL I

SIGNAL a

-Q 0RONANCE CORD 7

1 l

A.

800 STER 17-PRIMER CORD 0

E I

24" POLYETHYLENE INSERT Y

.a 9/15/82

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..-......-...---.. :----- :z..

Kinetic Expansion Length

,g (Repaired Tubes)

i.\\

PRIMARY FACE UTS

[

,~.;

ZONE WITH LENGTH OF DEFECTS

  • EXPANSION Aj A

17 B

22

~

3. 3 n g.5 s.

i$

' TUBES WITH MULTIPLE DEFECTS IN

~

16" THESE ZONE COMBINATIONS TO RECEIVE W'-'

22" EXPANS10NS SR AB

=. _

W 22" W/////fB VA SECONDARY FACE UTS 4

15TH TSP 9/15/82

i Kinetic Expansion Length tj {

(Plugged Tubes) i PRIMARY FACE UYS

/////////////////,1/'//

ZONE WITH LENGTH OF DEFECTS

  • EXPANSION Ai 4

u, C

22 l

D 17 7.

E 17

.f-

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&:A e5 d

!! N B

k

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  • TUBES WITH MULTIPLE DEFECTS IN M

THESE ZONE COMBINATIONS TO RECEIVE 16" 1_P_ __-'

22" EXPANSIONS AC C

EE BC

!*E CE 2__1."________

o o

22"

///////////////f,f( /7/j

  • ALL REMAINING TUBES WITH MULTIPLE l i SECONDARY FACE DEFECTS AND NON-DEFECTIVE TUBES TO

{

T UTS RECEIVE 17" EXPANSIONS E 4 15TH TSP I'

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9/15/82

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Kinetic Expansion Experience il

]

Foster Wheeler

  • Expanded over 5,000,000 tubes in heat exchangers over last 20 years F
  • CRBRP intermediate heat exchanger (17,100 expansions) o Repaired MSR's at Salem 1 and 2 (17,640 expansions)

B&W

  • Tested as manufacturing process - 3 tubes inservice at Oconee 111 with 24" expansions at both ends W
  • Used to close steam generator tube to tubesheet crevice during manufacture 9/15/82 DD

e i

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Repair Criteria (1) The maximum allowable primary-to-secondary leakage rate for normal operation shall be as low as reasonably achie'vable and allow plant operation within the radioactive effluent limits of the technical specifications.

l l;

9

  • 9 e

f 9/15/82 i

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Repair Criteria 42;) Repaired tube shall sustain, with adequate margins, the design basis loads Loads Generic 177FA TMI-1 LOCA

+ 2641lb

+ 2641 lb MSLB

+ 3140 lb

+ 3140 lb j.

FWLB

- 620 lb

- 620 lb Normal cooldown:

+ 1107 lb

+ 1107 lb

+ = tension 1

- = compression i

L l

9/15/82

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Repair Criteria i

C3D The effects of both repaired and plugged tubes on the thermal and hydraulic performance of the plant and on the structural and vibrational l

adequacy of the steam generator shall i

be evaluated and shall be within the acceptance criteria for both normal operating and design basis accident conditions as specified in the licensing basis documents.

(

9/15/82

._._________.___._----___.__,,,._-_m.,,,,_

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Third Party Review Purpose To provide a timely, independent, objective, safety evaluation of all activities defined in (the

-scope of) this charter for conformance to:

1) the NRC rules and regulations governing the i

operation of TMI-1 l

2D the adequacy of the steam generator repair program that will allow safe operation of the nuclear unit Scope o Failure analysis program o Eddy current examination program o OTSG performance evaluation e Repair criteria-e OTSG repair program 1

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9/15/82

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Third Party Review MEMBERSHIP SPECIALITY AREA 1

Stephen Brown Non Destructive Examination

-EPRI NDE Center S.A. Holland Plant Operations

-Duke Power Co.

Arturs Kalnins Stress Analysis

-Lehigh University' W.H. Layman Safety Analysis

-NSAC 1

David J. Morgan Chemistry

-Penn. Power & Light 4

E.J. Wagner

-Burns & Roe and Performance

~' Dick Weeks Materials

-Argonne National Lab

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  • Chairman k

9/15/82

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O.ualification Program Elements

i Foster Wheeler n

4.

Load carrying capability e

and leak tightness Babcock and Wilcox e New transition stresses i

e Chemical constituents of kinetic expansion device and residue l

e OTSG cleanup - use of precoat and final OTSG surface residue concentrations 9/15/82

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-i Other Program Elements Technical support considerations OTSG design basis Presence of IGSCC Site preparations Crevice dry Explosive handling Effect of process on other equipment O.uality control Manufacturing facilities During implementation at TMI-1 ALARA 9/15/82

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

- - - - - ~ ~ - - = - - - =

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s OTSG Repair Program Plan / Schedule

(

1982 1983 MAR APR MAY JUN JUL AUG SEP OCT NOV OEC JAN FEB MAR

' I, COMPLETE OTSG/RCS INSPECTIONS N COMPLETE ECT REINSPECTION N

LONG TERM TESTING i

TUBE EXPANSION i

QUALIFICATION COMPLETE Y

OTSG REPAIRS m

e CREVICE FLUSH i

e CREVICE ORY i

ePREC0AT i

eEXPANSICN i

e OTSG CLEANUP o PLUGGING e LEAK TESTING i

PLANT AVAILABLE FOR I

POST REPAIR PRE CRITICAL TESTING

  • RCS CLEANUP o NOT OPERATIONS 12/82 eECT 1

e POTENTIAL REPAIR l*

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9/15/82

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!b Key Elements of Qualification Program I. Joint qualification e Prototypical kinetic expansions e Proof test expanded joints e Thermal cycle condition joints e Axialload condition joints e Determine water leak rates e Determine joint pullout strength 9/15/82

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Key Elements of 0.ualification Program

)

Continued

11. Supporting tests e Evaluate residual stress atjoint f m,,,,,,,

transition e Determine adjacent shot effects e Determine double expansion effects e Evaluate joint integrity with different crevice corrosion e Determine joint strength with different annulus size e Determine induced strain effects n

e Evaluate tubesheet ligament -

distortion 9/15/82 l

I 10 Tubo

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l Leak and Load Test Fixture i

PRIMARY SIDE TEST EQUIPMENT j

HYORO CONNECTION p

THERMOCOUPLES 1

SEAL WELD TIMER i

HYDRO PUMP LOAD TEST DEVICE e* e h l

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SEAL WELD S

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10" EXPLOSIVES

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EXPANSION i

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HYDRO CONNECTION

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SEAL WELD TT NG 9/15/82

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j Pullout Load Design Basis 4

t 70 1

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High yield tube 56

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Low Y eld tube i

'O 3140 lbs.----

d. 42 3

E, o

2 b

-z Ia 28 2

Tube OD = 0.628" Tube thickness = 0.0385' 14 1

g m

7o O

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O O.2.

O.4 0.6 0.8 1.0 1.2 4

Strain, %

Design basis: 0.16% strain at 3140 lb. load for 0.625" OD X O.034" wall tube i

9/15/82 g,.

.m._

+ -.... - -.

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Pullout Load O.ualification Criterion

i Pull-out load of 3140 lb. with 99% probability at 99% confidence level J 1

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Preliminary Data 4

35 l0R Y_

n = t:og.

i 30 3

E e = 480 lbs.

.g 25 x = 4706 lbs.

S o

e 20

.3 x

0 3140 = 1.5 a

15 10

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P 5

5 i

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i r-O 1000 2000 3000 4000 s000 s000 Pullout load Ibs.

.j The above assumes a load-controlled behavior Actual event is thermally induced (strain-controlled)

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.4 s.2 s.s s.O s.4 Pullout strain, %

F 9/15/82

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Water Leak Rate

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Design objective: 1 lbm/hr. per plant (3.2X10-5 lbm/hr./ tube) l Qualification program objective : 3.2X10-6 lb./hr./ tube O.ualification data points for (a) 10 tube average / test block (b) Corroded blocks (c) 6" Expansion (d) 360 fully severed tube (defect)

(e) Demineralized water

  • ~ 2.4X10-6 lb./hr./ tube
  • ~ 10.5X10-6 lb./hr./ tube +- to 4" Jc-1 o
  • ~ 23.3X10-6 lb./hr./ tube (after thermal cycling, equivalent of 5 year life) +.<s A" c.. n. 4 no '

~

e ~ 30.3X10-6 lb./hr./ tube (after thermal cycling, equivalent of 5 year life) -vo 4"

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Water Leak Rate Measurement a

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Leak rate is measured using pressure decay of an enclosed water volume under pressure Pressure Temperature Effect Effect dP dT Leak Rate = PV [(K+K') dt 4 (g,_g) dt 3

Where, P = Density of water V = Water volume K = lsothermal compressibility of water K' = Structural elasticity of enclosure

' = Coeff. for enclosure volume change due to temperature Coeff. of volumetric expansion for water due to

=

temperature d

Rate of water pressure change

=

dt d

Rate of water temperature change

=

d 9/15/82

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Error Analysis for Leak Rate Physical constants 5%

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Teniperature correction

~ 20%

Other measurements

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I B&W Presentation lC

  • Qualification Program

- Kinetic expansion transition

- Control of materials

- Process residue characterized

- Immunol precoat

- Clean Up

  • Technical Support Activities -

Effect of Process

- Existing crack-indications

- Pressure vessel integrity

  • Site Preparations

- Crevice drying tests

- Maintaining crevice dry

- Mt. Vernon test

- Explosive handling

  • Quality Activities

- Off-site preparation efforts

- Site effort

(

T B&W Presentation

)

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  • Qualification Program
  • Technical Support Activities
  • Site Preparations
  • Quality Activities

9/15/82

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a

]C Qualification Program j

fj Kinetic Expansion Transition g

  • Design Objectives:

- Transition length

- Required > 0.1"

- Goai > 0.125"

  • Verification Program

- Prequal mockups 2 0.15"

- Residual stress measurements /Penn State x-ray defraction

- Mt. Vernon test - 0.3" to 0.45"

- Accelerated corrosion test in 10% NaOH -kinetic /hard roll

  • Transition produced more gradual than those with sat.

service

- Years of sat. operation with stress relieved hard roll

- Kinetic expansion transition is longer than hard roll

- > 100 unstress relieved roll transitions remain in service after 9 years /Oconee 1 4

s 9 (

9/15/82

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Qualification Program

.j Control Of Materials Specifications

- Sulfur 5 250 ppm

- Chloride and fluoride s 250 ppm

- Heavy metals s MDC*

Process materials analyzed at source Cleanness controls implemented - from source to OTSG

- Manufacturing

- Assembly

- Site handling & storage Changes made in materials to avoid introducing harmful elements

- Transfer cord for detonator cord

- Organic booster substituted

- Eliminated resin coating in detonator cord Only acceptable materials introduced into OTSG Cold leg and hot leg plugs utilized to contain debris

  • MDC - Minimum Detectable Concentration 9/15/82

,.,-.._,....,--.,-.,..-,._.-_.n_._

a.

j:c Qualification Program 1

Post Expansion Residue u

o Bulk Material

- Readily removable by hand / vacuuming o Surface Contamination

- Harmful elements controlled to acceptable levels by specifications for materials used in OTSG

- Adherent semi-transparent film with carbonaceous residue deposited on surfaces May affect heat transfer May affect sulfur removal o Desirable to reduce quantity

- Minimize net accumulation in RCS

- Prevent interference with sulfur removal

(

9/15/82

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l 1

!c Qualification Program Immunol Precoat Precoat - facilitates removal of sur! ace contamination

- Immunol - a cleaning agent

- water soluble

- acceptable chemistry

- extensive data available

- Effectiveness visually confirmed

- Mt. Vernon tests

- Mockups

- Evaluating - interaction with sulfur

- effect on H 0 process 2

2

  • Application

~

- Manual spray - dome, tubesheet & tubes

- Flood ID of tubes

- Barrier at hot / cold leg to confine precoat 9/15/82

=

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f Qualification Program I

Clean Up

)

o Bulk Material Removal

- Manual - debris in heads

- Air assist ejection of candles from tubes o Surface Contamination

- Wipe head and tubesheet

- Felt plugs blown thru tubes

- Rinse 3,

1 o Acceptance Criteria - surface swipes to meet

- B&W established standard halogen levels 1

9/15/82

=:--==::.

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Process Effect On ~

Cracks / indications o Test Results (30 gr./ft)

- 100% through wall. crack opened slightly

- No ductile growth axially

- No ductile growth circumferencially l

Conclusion:

crack did not grow o Leakage Tends to be Self Sealing l

- CR-3 operating experience

- ARC model boiler test results

~ 5 tubes defected /1 to 2 gph leakage

- After 1000 hrs operation - no leakage

- CRUD & corrosion products seal leaks

- Tubesheet corrosion insignificant by inspection 1

9/15/82 z

1 i!

Pressure Vessel Integrity j

Assessment u

o Requirements of satisfactory repair

- Maintain structural integrity

- Maintain acceptable leak rate o Structural integrity criteria - meet ASME code stress limit's

- Residual stresses in transition below acceptable past practice

- Tube preload change controlled within acceptable limits

- Process does not structurally degrade vessel o Leakage design objective - total 51 lbm/hr o Demonstration of meeting the criteria

- Repair tested for maximum faulted tube load

- Original design analyses remain valid

- Residual stresses in the transition region are minimized sfjk l

1 9/15/82

.,r..r;_nm._______.._;._____...-__.__..__.___.-________.____-

~"

I Pressure Vessel Integrity (Continued)

- Mt. Vernon test results (132 tubes)

Dynamic stress for tubesheet and shell < yield stress Change in axial tube load < 30 lbs Dynamic pressure wave is small PT examination of tube-to-tubesheet we!d shows no damage

- Test shows no measurable ligament distortion

- Analysis of crevice drying procedure indicates acceptable stresses

  • Demonstration of meeting the criteria (continued)

- Qualification leak testing conservatively performed at room temperature

  • Conclusions

- The OTSG's continue to meet the requirements of the ASME Code

(

9/15/82

Crevico Drying N(

/.

1 7

/

n's HEATERS ARE INSTALLED ON STAINLESS STEEL SPACERS ON TUBESHEET AND ENTIRE TOP SURFACE OF HEATERS IS COVERED WIT INSULATION

- THERMOCOUPLES PRINARY +

NANWAY I UPPER SURFACE [ 300*F 8 LOWER SURFACE 2 10' ABOVE TSAT (~ 125*F) 8 ' TIME REQUIRED er 4 HOURS (I PERFORMANCE CONFIRNED'BY MT. VERNON TEST 9M 5/82 5

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Maintaining Crevice Dry j{~

Forced Circulating System 1

100 CFM CESIGN m

CEHUMIDIFIER BLOWER Ng MAKEUP 3 AT ~ 1 PSIG m

I TEMP./ HUMIDITY

( "A"U INDICATOR HOLE AREEE N2. COVER GAS l

NOTES:

3

-F

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O UPPER TUBESHEET TEMP.

MEASUREMENT AT 4 TUBE 300" LOCATIONS HO 2

8 DEW POINT ON SECONDARY SIDE MAINTAINED 10*F-BELOW TUBESHEET TEMPERATURE

%)

(

9/15/82

e

/

Mt. Vernon Test Accomplishments o Verified shock to tubesheet is within acceptable limits o Allowed full dress mockup training, testing of installation tool and procedures o Provided verification of the reliability of support systems o Allowed refinement of expansion process resulting in estimated exposure savings of 200 manrem o Assessed magnitude of post expansion cleaning o Performed expansion pull test 9/15/82

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j Site Preparations ij Explosive Handling j

  • Established procedures for handling operations
  • Trained technicians, licensed explosives handler
  • Approved storage containers
  • Insert storage outside containment
  • Activities regulated / monitored by the state of Pennsylvania e Minimal quantity of inserts in containment
  • Inventory under concurrent control of plant security and FWEA licensed ~ explosives handler
  • Handling operations directly supervised by licensed handler and inspector l
  • Class C explosive

- Least hazardous explosives rating

- Requires high energy shock for detonation

- Can be shipped by commercial carrier 1

9/15/82

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T

iC j

Quality Activities Off Site-Qualification Program

  • GPUN & B&W specifications for qualification program
  • Coordinated test plan
  • FWEA QA verify test control (Monitored by B&W and GPUN)

- FWEA specs and procedures for testing

- Trained technicians

- Calibrated instruments

- Documented results

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9/15/82

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Quality Activities a

Off Site - Manufactunng

  • B&W approved FWEA specifications to subvendors
  • Chemical analysis of components l
  • Cleanliness requirements applied in process
  • In-process verification of dimensional requirements
  • In-process overchecking of components l

supplied ~by subvendors

  • FW overcheck verification of grains / foot l

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9/15/82

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Kinetic Expansion j

ALARA Estimates

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- Man-rem Exposure Estimates Crevice drying 20 Manual tube marking 10

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Pre-coating tubes

( Ao -so )

In-generator testing 10 Process expansion

-insert installation 70

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-insert removal 100

-debris removal 5

s

<c k Tubh/tubesheet/ dome cleaning

( S / - no)

Closeout inspection 2

Total 217 t

1

's (excluding precoating of tubes and cleanup) 9/15/82

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O.uality Activities i

Site Effort

(-

e Shipping and storage in approved containers e Receipt inspection for shipping damage e Comply with state of Pennsylvania explosives handling and storage requirements e in-process QC monitoring includes

- Verification of procedure compliance

- Plant condition prerequisites

- Process control to separate high and low charge density inserts

- Expansion in whole row " lots"

- Physically mark tubes to be expanded to 22"

- Random performance sampling by E/C, tube ID measurements and periodic tube expansions outside OTSG e Video overview and record of operations 1

9/15/82

I

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Summary Testing and analysis continues to indicate that kinetic expansion is practical for application to TMI-1

  • We can conclude that implementation of the kinetic expansion process will not do irreparable damage to the OTSG
  • Preliminary and final qualification testing and analysis confirms with reasonable assurance that the process fulfills specification requirements
  • Planning, training and rehearsal are essentially completed
  • Implement repair process at TMI-1 9/15/82

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