ML20083L854
| ML20083L854 | |
| Person / Time | |
|---|---|
| Site: | Fort Saint Vrain  |
| Issue date: | 04/06/1984 |
| From: | Warembourg D PUBLIC SERVICE CO. OF COLORADO |
| To: | Jay Collins NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| References | |
| P-84104, TAC-57625, NUDOCS 8404170383 | |
| Download: ML20083L854 (102) | |
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, 16805 WCR 19 1/2, Platteville, Colorado 80651 i
April 6, 1984 Fort St. Vrain g Unit #1 5 P-84104 pg612lddV Mr. John T. Collins . Regional Administrator, Region IV U. S. Nuclear Regulatory Commission 611 Ryan Plaza Dr., Suite 1000 Arlington TX 76011
SUBJECT:
Fort St. Vrain Unit No. 1 Fuel Element Meeting
Dear Mr. Collins:
On April 4, 1984, a meeting was held in Bethesda with members of the NRR staff to discuss the two cracked fuel elements that were discovered in 1982 and the present inspection program for segment 3 fuel. We are transmitting herewith the information presented at that meeting. As a general summary we presented the following information:
- 1. HISTORICAL REVIEW, FUEL ELEMENT INSPECTION PROGRAMS An historical review of the spent fuel element inspection program at Fort St. Vrain was presented. This included a general overview of the PIE Programs for segments 1 and 2.
A typical fuel inspection video tape was shown of element 1-2693 to indicate inspection capabilities and to depict typical fuel element conditions. The video tape also contained a portion of the hot cell inspection at Fort St. Vrain of one of the cracked fuel elements (1-2415). Typical inspection results were presented. The history of the two cracked elements was presented along with the results of investigations that have been conducted to date. The conclusions from this portion of the presentation were as follows: A. All fuel elements with the exception of the two cracked elements (1-2415 and 1-0172) have been found to be in excellent condition. y - aoapg 3404170383 840406 Ne*I
6
- 8. The equipment utilized to inspect fuel elements in the FSV hot cell provides excellent inspection results and certainly provides more than adequate resolution to detect any significant fuel damage.
C. The program for investigating the two cracked elements has progressed to the point where probable cause for the cracking has been defined. No detrimental effects on fuel element integrity or fuel performance has been . identified that could result in cause for concern for public health and safety. D. Some portions of the cracked fuel element program are on going. The results of any continuing-efforts will be reported to the NRC in a timely fashion. E. All correspondence and reports were summarized and are listed in the attached viewgraphs.
- 2. CURRENT SEGMENT 3 INSPECTION PROGRAM The current segment 3 fuel- inspection. program -was discussed. The discussion included a description of- the fuel element inspection program in the- fuel handling machine and changes that were made.in- the program as ~ a result of_ experiencing problems with_ underexposed photographs.--
High quality photographs were obtained of.all six (6) i faces of all elements from Regions 18 and 33. In addition a detailed video camera inspection was made for Region 18 fuel elements utilizing the Fuel Handling Machine Cask Camera, and 7.5 power-35 mm photographs were taken.of the center of all ' faces of all Region 18 fuel elements.- Typical photographs were presented at the meeting. Tentative plans 'for1the Segment 3 PIE Program were set forth. Present plans include inspection of about .60. fuel and reflector Jelements in the Fort Saint Vrain Hot Cell.. W'e intend to examine all of the Region 18 fuel elements plus some precharacterized elements from Regions 3,.13,122 and 29. Present plans are to begin the PIE program- in late _ May.1984 with anticipated. completion _by : late
-July 1984.
._ .-, . _ . _ _ _ _ _ _ . ~ _ . _ - _ . . _ -
1 o
- 4. .
1 ! Conclusions from this portion of the presentation were as
. follows:
A. No significant fuel damage was found for those (! '- elements inspected. The. elements had stains,
- scratches, abrasions, minor gouges, all of which were typical of previous segment inspection
- results. No fuel element cracking was identified.
B. The quality of the 35 mm photographs is excellent ' and. resolution is certainly adequate to detect any +
; significant fuel damage. A complete file.of all 8 X 10 photographs,' including inspection l evaluation sheets, is, available at the site for j- NRC review. In' addition the video tapes of the '
j inspection efforts are available on site for i review. C. Based _ on power history, control rod' patterns, and the fact that Region 18 is a ring 3 region similar to Region 8 in which the -Segment 2 cracked i elements were found,' we have decided to examine j all _ Region 18 elements in the hot cell for the PIE - i program. .The PIE program will be done in the same , manner as previous PIE programs,- the results of. i
- . which have been reported to the NRC.
I
- 3. ANALYSES / TESTS FUEL ELEMENT PROGRAM- ,
j A detailed description of the probable causes for two : cracked elements from Segment 2 was presented. The , probable cause- was' defined as a high tensile stress . . experienced on the "B" face of the elements induced by
- _ .high' thermal ' gradients and shrinkage induced by neutron j' flux..
1 i The fuel : element. stress. analysis . program that was l ; developed by GA for:the large HTGR was described and -the ' _ application ,of .that' program to ' Fort -Saint Vrain fuel
~
- elements was presented.
_ .This detailed stress analysis was- also utilized to'
- investigate the probability of crack progression in. Fort-Saint Vrain fuel elements. JThe results of this analysis.
were presented. 1 e s 4
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O Loading tests of typical H-327 unirradiated fuel elements were conducted with fuel element web cracks being simulated by physically cutting the webs with a hack saw. The results of various loading combinations along with combinations of fuel element web failures (from 0 to 3) were presented. The conclusions from this portion of the program were as follows: A. High thermal stresses induced by gap flows in combination with irradiation induced stresses resulted in high tensile stresses on the inter-regional faces of the two cracked elements. The detailed stress analysis predicted the highest stress at the location of cracks. Given these causes and the possibility that these same conditions may exist in other areas of the core there is some possibility that other cracked elements might be observed in future refuelings. B. There was a discussion of H-451 graphite properties, and it was pointed out that H-451 graphite properties are better than H-327, but it would still be possible to exceed strength / strain ratios for H-451 graphite given the right conditions. This situation has been reported .to the NRC in response to questions on the use of H-451 graphite in Segment 9. C. Detailed stress analysis of the Fort Saint Vrain elements indicates that crack progression in the element is limited. As coolant hole / fuel hole webs are progressively cracked the tensile stress is reduced. The result of progressive cracking of five (5) webs from the fuel element face inward indicates that tensile stresses are reduced to acceptable values within the strength of the graphite. Cracking in one area also significantly reduces tensile stress of the other inter-regional faces of the fuel element resulting in a low probability that cracking would occur in any more than one area of a fuel element.
D. Given the possibility of fuel element cracking actual load testing was performed on elements with various combinations of cracked webs. The end result of the testing indicates that with various combinations of cracked coolant hole / fuel hole webs from 0 to 3, the strength of the fuel element is essentially unaffected. Even with cracked webs , it would take in excess of 100,000 lbs. of compressive load to fail a fuel element.
- 4. SAFETY SIGNIFICANCE, FUEL ELEMENT CRACKS The safety significance of fuel element cracking was discussed in terms of maintaining core cooling capabilities and maintaining the capability of control material insertion.
Various bounding conditions which have already been analyzed in the FSAR and other bounding conditions analyzed during the fluctuation test program were presented. It was pointed out that it would take several, non mechanistic failures of fuel elements to approach the bounding conditions. On ' a more realistic basis the scope of a seismic loading on individual fuel elements at Fort Saint Vrain based conservatively on large HTGR analysis would have no affect i on cracked fuel elements. Any loss of core cooling geometry would be very localized with minimal overall effects and certainly no effects on the health and safety of the public. There is no mechanistic failure of fuel elements of the type seen in 1-2415 or 1-0172 that could lead to failure to insert either control rods or reserve shutdown material. The conclusions from this portion of the program were as follows: A. Fuel element cracking as identified to date has had no significant effect on fuel element integrity or fuel performance. B. Fuel element cracking does. not represent any increased risks to the health and safety of the public.
9
- 5. OVERALL
SUMMARY
The overall summary of the meeting was presented as follows: A. There have been two (2) fuel elements (1-2415 and 1-0172) that have hairline cracks vertically along the "B" face. B. A program to investigate these two (2) elements to determine probable cause as well as any detrimental effects has been setforth. C. The program has progressed to the point of identi fying the probable cause, and has not identified any detrimental effects on fuel performance or fuel element integrity that could be related to the health and safety of the public. D. Some facets of the cracked fuel element program are still in progress and/or are scheduled in -the future. Results of these on going programs will be made available in a timely fashion. E. There are adequate inspection programs in place to inspect Fort St. Vrain spent fuel as it is removed from the core. F. The programs to date have resulted in the inspection and examination of a very high percentage of spent fuel elements, both in the fuel handling machine and in the PIE programs. G. A very high percentage (approximately 30%) of Segment 3 spent fuel elements have been inspected to date with no apparent problems identified. The upcoming PIE program will provide inspection of approximately 60 fuel elements in the hot cell. Photographs of all Segment 3 spent fuel elements-will be obtained in conjunction with fuel shipping. H. Inspections to date confirm the . capability of detecting any significant fuel element damage.
.c , I. In. terms of Fort St. Vrsin operation: Fuel element cracking is not progressive in nature and has not resulted in _ degrading overall fuel block strength or fuel particle integrity. Fuel performance to date has been excellent as directly evidenced by circulating activity as well as the PIE program results. Fuel element cracking as .seen to date has no implications. involving the health. and safety of the public. PSC plans to continue inspection of spent fuel elements in the fuel handling machine during all future refueling operations. The circulating activity of Fort St. Vrain is continuously monitored. Any significant fuel damage can be readily detected.
- 6. CONCLUSION The NRC ' indicated that they were satisfied with. analyses and inspections done to date in terms of-allowing Fort St.
Vrain to return to power operation. :The NRC expects to be kept informed of the results of'the PIE program inspection and would expect. timely notificationaof any s'ignificant; fuel element damage that might be discovered. . The NRC asked that consideration be given to establishing an on going fuel surveillance program,Lperhapsias'.a part of the-Technical Specifications.
'PSC indicated that they fully intended.to' maintain the.
fuel handling machine inspection efforts for .all--future refuelings, i.e.'PSC plans to obtain_35 mm photographs of-all six (6) faces of each spent' fuel element in- the fuel handling machine. In addition PSC has already committed
- to a surveillance program (see P-83348) with reference . to-inspection of H-451 graphite' elements which has been
. accepted by Amendment 40 to the Operating License.
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- 7. OTHER a
An informal update was provided on the Fort Saint Vrain PCRV tendon prestressing system. Sincerely, hVM Don W. Warembourg Manager, Nuclear Production Fort St. Vrain Nuclear 3 Generating Station DWW/dje cc: Jim Miller, NRR Phillip Wagner, Region IV Debbie Bennett, LANL i L i 4 e f f
FORT ST. VRAIN FUEL ELEMENT INFORMATIONAL MEETING APRIL 4,1984 AGENDA DESIGN FEATURES .. OVERALL REACTOR DESIGN FEATURES i FUEL PARTICLE / ELEMENT DESIGN OVERALL CORE CONFIGURATION HISTORICAL FUEL ELEMENT INSPECTION PROGRAMS GENERAL OVERVIEW PAST PIE PROGRAMS . TYPICAL FUEL INSPECTION VIDEO TAPE TYPICAL INSPECTION RESULTS i HISTORY OF CRACKED ELEMENTS INSPECTION RESULTS OF CRACKED ELEMENTS i 1 (
4 FORT ST. VRAIN FUEL ELEMENT INFORMATIONAL MEETING
. APRIL 4,1984 l AGENDA 1
~
\ CURRENT INSPECTION PROGRAMS, SEGMENT 3 INSPECTION PROGRAM CRITERIA I l TYPICAL INSPECTION RESULTS PLANS FOR SEGMENT 3 PIE PROGRAM ANALYSES / TESTS FUEL ELEMENT PROGRAM CAUSES, EXISTING CRACKED ELEMENTS CRACK PROGRESSION FUEL ELEMENT STRENGTH WITH CRACKING SAFETY SIGNIFICANCE, FUEL ELEMENT CRACKS CORE COOLING CONTROL MATERIAL INSERTION 9 L.. .
FORT ST. VRAIN FUEL ELEMENT INFORMATIONAL MEETING APRIL 4,1904
SUMMARY
THERE HAVE BEEN TWO (2) FUEL ELEMENTS (1-2415 AND 1-0172) THAT HAVE HAIRLINE CRACKS VERTICALLY ALONG THE "B" FACE. l A PROGRAM TO INVESTIGATE THESE TWO (2) ELEMENTS TO DETERMINE PROBABLE CAUSE AS WELL AS ANY DETRIMENTAL EFFECTS HAS BEEN SETFORTH.
- THE PROGRAM HAS PROGRESSED TO THE POINT OF IDENTIFYING THE PROBABLE CAUSE, AND HAS NOT IDENTIFIED ANY DETRIMENTAL EFFECTS ON FUEL PERFORMANCE OR FUEL ELEMENT INTEGRITY THAT COULD BE RELATED TO THE HEALTH AND SAFETY OF THE PUBLIC.
- SOME FACETS OF THE CRACKED FUEL ELEMENT PROGRAM ARE STILL IN PROGRESS AND/OR ARE SCHEDULED IN THE FUTURE. RESULTS OF THESE ON-GOING PROGRAMS WILL BE MADE AVAILABLE IN A TIMELY FASHION.
FORT ST. VRAIN FUEL ELEMENT INFORMATIONAL MEETING l APRIL 4,1984
SUMMARY
THERE ARE ADEQUATE INSPECTION PROGRAMS IN PLACE l TO INSPECT FORT ST. VRAIN SPENT FUEL AS , IT IS l REMOVED FROM THE CORE.
- THE PROGRAMS TO DATE HAVE RESULTED IN THE INSPECTION AND EXAMINATION OF A VERY HIGH PERCENTAGE OF SPENT FUEL ELEMENTS, BOTH IN THE FUEL HANDLING MACHINE AND IN THE PIE PROGRAMS.
- A VERY HIGH PERCENTAGE (APPROXIMATELY 30%) OF SEGMENT 3 SPENT FUEL ELEMENTS HAVE BEEN INSPECTED TO DATE WITH NO APPARENT PROBLEMS IDENTIFIED.
THE UPCOMING PIE PROGRAM WILL PROVIDE INSPECTION OF APPROXIMATLEY 60 FUEL ELEMENTS IN THE HOT CELL. PHOTOGRAPHS OF ALL SEGMENT 3 SPENT FUEL ELEMENTS WILL BE OBTAINED IN CONJUNCTION WITH FUEL SHIPPING. INSPECTIONS TO DATE CONFIRM THE CAPABILITY OF DETECTING ANY SIGNIFICANT FUEL ELEMENT DAMAGE.
FORT ST. VRAIN FUEL ELEMENT INFORMATIONAL MEETING APRIL 4,1984
SUMMARY
- IN TERMS OF FORT ST. VRAIN OPERATION:
- FUEL ELEMENT CRACKING IS NOT PROGRESSIVE IN NATURE AND HAS NOT RESULTED IN ' DEGRADING OVERALL' Fl."iL BLOCK STRENGTH OR FUEL PARTICLE INTEGRITY. FUEL PERFORMANCE TO DATE HAS BEEN EXCELLENT AS DIRECTLY EVIDENCED BY CIRCULATING ACTIVITY AS WELL AS THE PIE PROGRAM RESULTS.
- FUEL ELEMENT CRACKING AS SEEN TO DATE HAS NO .
IMPLICATIONS INVOLVING THE HEALTH AND SAFETY OF THE PUBLIC.
- PSC PLANS TO CONTINUE INSPECTION OF SPENT FUEL ELEMENTS IN THE FUEL HANDLING MACHINE DURING i
ALL. FUTURE 'R'EFUELING OPERATIONS. .
~
THE CIRCULATING ACTIVITY OF FORT ST. VRAIN IS CONTINUOUSLY MONITORED. ANY SIGNIFICANT FUEL l DAMAGd CAN .BE;RE DILY DETECTED. l l i x i i< . ' t k ry .
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SCOPE OF NON-DESTRUCTIVE POST-IRRADIATION EXAMINATIONS PERFORMED IN THE FORT ST. VRAIN HOT SERVICE FACILITY DIMENSIONAL MEASUREMENTS
- Across Flats Dimensions
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- Cracks
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- Scratches
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' A'NIssRE I TEDINS E TIONS Fig. 4-6. Top surface measurements of FSV core comoonents (sheet 1 of 2) 4-8
TOP CHAMFER
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t SEGMENT 1 AND SEGMENT 2 NON-DESTRUCTIVE POST IRRADIATION EXAMINATIONS COMPONENTS EXAMINED
- Segment 1 49 Fuel Elements 2 Reflector Elements
- Segment 2 48 Fuel Elements 6 Reflector Elements METROLOGY RESULTS
- Segment 1 Axial and Radial Fuel Element Shrinkage Little Dimensional Change in Reflector Elements
- Segment 2 Same
, VISUAL INSPECTION RESULTS
- Segment 1 All Elements in Excellent Condition
- Segment 2 All Elements in Excellent Condition Except for Two with Single Localized Cracks on Face B REFERENCES
'
- Segment 1 PSC Letter, Lee to Novak Dated 11/16/81 (P-81254)
- Segment 2 PSC Letter, Brey to Collins, Dated 6/2/83 (P-83196)
m , , - t" i r y ff 35 36 37 20 #p gy$ '"rg
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' FUEL ELEMENT 12415 REGION 8, COLUMN 5, CORE LAYER 6 (ACTIVE CO RE LAYER 3)
' Fig. 3 -3. Core location of fuel element 1-2415 3-5 l
O CHRONOLOGICAL HISTORY DECEMBER, 1981 REQUEST TO DELETE DESTRUCTIVE EXAMINATION OF A SEGMENT 2 FUEL ELEMENT (P-81322,12/11/81) APRIL, 1982 FIRST INDICATION OF A CRACK IN 1-2415 (04/26/82) CONFlRMATION AND TELECON NOTIFICATION (04/30/82) WRITTEN NOTIFICATION (P-82130, 05/04/82) . M AY, 1982 SELECTION OF CANDIDATE ELEMENTS FOR GA HOT CELL REVIEW OF PIE VIDESTAPES i I
1 h l CHRONOLOGICAL HISTORY JUNE AND JULY,1982 SHIPMENT OF FIVE FUEL ELEMENTS TO GA TECHNOLOGIES (YVB-ZGQ-005, RECEIVED 06/30/82) INSPECTION PROGRAM BEGINS (07/07/82)
! CONFIRMATION OF CRACKS IN 1-2415, 1-0172 (07/07/82)
TELECON NOTIFICATION (07/08/82) DISCUSSION IN BETHESDA (07/14/82) i AUGUST THROUGH OCTOBER,1982 CONTINUED FIVE-ELEMENT INSPECTION PROGRAM, REPORT GENERATION . 1 UPDATED STATUS (P-82394, 09/15/82) l i J ANU ARY, 1983 NRC GRANTED REQUEST TO DELETE SEGMENT 2 ELEMENT DESTRUCTIVE EXAM (G-83042, 01/24/83) SUPPLEMENTAL EXAM OF ROD FROM 1-2415 SUPPLEMENTAL EXAM OF ROD FROM FTE-2 I I l
4 CHRONOLOGICAL HISTORY FEB RU ARY, 1983 PSC COMMITMENT TO G-83042 - LANL TO PSC REQUEST FOR INFORMATION (G-83075, 02/16/83) MARCH, 1983 LANL TO PSC REQUEST FOR MEETING (G-83130, 03/22/83) f. APRIL, 1983 LANL/GA/PSC MEETING 04/07-08/83 MAY, 1983 PSC TO LANL CORRESPONDENCE (P-83176, 05/13/83) JUN E, 1983 COMPILED SUBMITTAL OF REPORTS (P-83196, 06/02/83) JU LY, 1983 l PSC TO LANL CORRESPONDENCE (P-83247, 07/14/83) l l l.. L
.= - - - -
i CHRONOLOGICAL HISTORY AUGUST, 1983 GRAPHITE SECTIONS TO LANL FROM GA TRANSMITTAL OF DATA TAPE FOR REGION 8 TO LANL FROM GA - l OCTOBER, 1983 UPDATE OF CRACKING MECHANISM (P-83348,10/27/83) NOVEMBER,1983 i (,.. , COMPLETED METALLOGRAPHIC EXAM OF 1-2415 FUEL ROD (11/08/83) pECEMBER,1983 I REVIEWS AND APPROVALS OF METALLOGRAPHIC REPORT J ANU ARY, 1984 SUBMITTAL OF METALLOGRAPHIC REPORT (P-84001, 01/03/84) l l i l I w l
I l O CHRONOLOGICAL HISTORY FEBRU A RY, 1984 NRC CONCERNS OVER SEGMENT 3 INSPECTION PROGRAM (TELECON, 02/10/84) PSC COMMITMENTS TO SEGMENT 3 lNSPECTION PROGRAM (P-84053, 02/15/84) O O
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e PROGRAM RESULTS VISUAL EXAMINATION OF 54 ELEMENTS AT FSV ELEMENT SELECTION PERTINENT RESULTS ALL SURFACES WERE VISUALLY EXAMINED, PHOTOGRAPHED, AND VIDEOTAPED. INSPECTED ELEMENTS WERE IN GOOD CONDITION. SINGLE CRACKS IN EACH OF TWO ELEMENTS WERE OBSERVED. THESE CRACKS DID NOT AFFECT ELEMENT GEOMETRY, COOLANT CHANNEL ALIGNMENT, OR HANDLING. I OBSERVED BLEMISHES WERE S(MILAR TO THOSE SEEN IN PREVIOUS EXAMINATIONS. e f i I l
O f PROGRAM RESULTS r i NON-DESTRUCTIVE EXAMINATION OF 1-2415 AT FSV DESCRIPTION OF CRACK ALCOHOL TEST WAS INCONClusivi 1 N ( I t P [ 1 a i w , , - ,, - , - ,- , --
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{' O . PROGRAM RESULTS VISUAL EXAMINATION OF FIVE FUEL ELEMENTS TO GA HOT CELL ELEMENT SELECTION PROCESS CRACK CHARACTERISTICS 1-2415 0.008" TO 0.010" AT TOP ' O.011" TO 0.012" AT BOTTOM 1-0172
's O.005" TO 0.006" AT TOP 0.002" TO 0.003" AT BOTTOM i NO OTHER CRACKS OBSERVED STACKING DEMONSTRATION CLEARANCE WAS ABOUT 0.040" to 0.050" L
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I PROGRAM RESULTS PROBABLE CAUSE OF CRACK INTER REGION GAP FLOWS + RELAYlVELY COOL SURFACE . SKEWED POWER / FLUX DISTRIBUTION + INCREASED THERMAL GRADIENT RESULT - GREATER IRRADIATION INDUCED CONTRACTION + TENSILE STRESSES W _. __ _---_--_----__--___---_-----------__________------_.__J
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PROGRAM RESULTS w l 1 METALLOGRAPHIC EXAMINATION
' FUEL ROD 13 FROM STACK 308 RESULTS -s NO ,KERNAL MIGRATION.
NO FUEL ROD / FUEL BLOCK INTERACTION MACROPOROSITY'WITHIN DESIGN % SOME sic / FISSION PRODUCT INTERACTION s NO TOTAL COATING FAILURES (., CONCLUSION s ACCEPTABLE PERFORMANCE
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TSAR UPPUE Devision 1 NOTES:
- 1. FUEL ZONE BOUNDARIES RADI AL FUEL ZONE i R ADIAL FUEL :.ONE 11
[~ 2. FUEL REGION BOUNDARIES RADIAL FUEL ZONE lli
- 3. CONTROL ROD COLUMN RADI AL FUEL ZONE IV SHADED REFLECTOR ELEMENTS N ARE NORMALLY REPLACED WITH A RADIAL FUEL ZONE V ADJACENT FUEL REGION j '
I l l SIDE REFLECTOR
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I l SEGMENT 3 FUEL ELEMENT INSPECTION PROGRAM PRIOR TO FEBRUARY 10, 1984 SCOPE
- Photograph Two Faces of One in Every Ten Fuel Elements Using the Fuel Handling Machine 35mm Camera
- Visually Examine Each Fuel Element Not Photographed Using the Fuel Handling Machine Cask Video Monitor
- Perform a Non-Destructive Post Irradiation Examination on 50 to 60 Segment 3 Fuel and Reflector Elements Similar to That Performed on Segment 1 and Segment 2 Elements BASES
- Ensures Early Detection of Significant- Structural Abnormalities
- Provides Additional Information with which to study the Fuel Element Cracking Mechanism p
SEGMENT 3 FUEL ELEMENT INSPECTION PROGRAM AFTER FEBRUARY 10, 1984 MINIMUM SCOPE
- Photograph All Faces of the Remaining Segment 3 Fuel Elements (~ 175) Using the Fuel Handling Machine 35mm Camera
- Evaluate All Photographs for Indications of Significant Structural Abnormalities Prior to Returning to Power Operation
- Using the Fuel Handling Machine Cask Video Monitor, Carefully Examine the Two Segment 3 Fuel Elements With Operational Histories Believed To Be Most Similar to Those of the Cracked Segment 2 Fuel Elements
- Perform a Non-Destructive Post Irradiation Examination on 50 to 60 Segment 3 Fuel and Reflector Elements Similar to That Performed on Segment 1 and Segment 2 Elements
.
- Keep the NRC Abreast of Findings BASES
- Ensures Early Detection of Significant Structural Abnormalities
- Provides Additional Information with which to Study the Fuel Element Cracking Mechanism
Reference:
PSC Letter, Warembourg to Collins, Dated March 6, 1984 (P-84076) 1
RESULTS OF SEGMENT 3 FUEL ELEMENT INSPECTIONS TO DATE
- First Set of ' Photos Developed Were Discovered To Be Underexposed. NRC Region IV Was Notified.
- Exposure Time Settings Were Corrected for the Last Region Refueled (Region 33)
- PSC Subsequently Committed to Retrieve and Re-Inspect Region 18 Fuel Elements Aleady in Spent Fuel Storage As Follows:
Photographs All Faces of Each Element at x 1 Power Photograph the "B" Face of Each Element at x 7.5 Power Actual Region 18 Fuel Element Inspection Consisted of: Photographing All Faces of Each Element at x 1 Power Photographing the Center of Each Face at x 7.5 Power Videotaping Examinations of Each Face
- No Significant Surface Abnormalities Have Been Detected
- All Photographs, Videotapes, and Evaluations Are Available On-Site for NRC Review
Reference:
PSC Letter, Warembourg to Collins, Dated March 6, 1984 ' (P-84076) O 3 -s
REMAINING SEGMENT 3 FUEL - I ELEMENT INSPECTIONS SEGMENT 3 POST IRRADIATION EXAMINATIONS
- Components To Be Examined All Fuel Elements from Region 18 Additional Selected Fuel and Reflector Elements from Regions 3, 13, and 22 Total of 50 Fuel Elements and 10 Reflector Elements
- Scope Dimensional Measurements Visual Inspections Gamma Activity Measurements *
- Anticipated Date of Completion - July 31, 1984 SPENT FUEL SHIPPING EXAMINATIONS
- Components To Be Examined All Fuel Elements Not Previously Examined Under the Current Inspection Program
- Scope Photograph All Faces of Each Element
- Anticipated Date of Completion - November 30, 1984 l
e i T
POST-IRRADIATION FUEL ELEMENT INSPECTION SHEET l l SERIAL NO. /-a959 ' CORE LOCATION /6.O/07 (REG. COL. LAY.) CHEMICAL TYPE //C PHOTO LISTING I I I FACE I I I I I I I I I l-I A I B l C l D l E I F ~l l E I I I I I
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- 1. Crack 4. Scratch / Scribe 7. Other 2)iscoloer4Ewo
- 2. Stain 5. Oxidation g. c/, A / Se/.
- 3. Flow Mark 6. Rub Mark /
EVALUATION
SUMMARY
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POST-IRRADIATION FUEL ELEMENT INSPECTION SHEET SERIAL NO. :-- / CORE LOCATION ' r' '
~
(REG. COL. LAY.) CHEMICAL TYPE PHOTO LISTING f l l l l FACE I I I I I I I I I I I A l B l C i O l E I F 1 I I I I I I I X 1 POWER 'il 2 '
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SURFACE FLAW TYPES
- 1. Crack 4. Scratch / Scribe 7. Other --
- 2. Stain 5. Oxidation 5. .
- 3. Flow Mark 6. Rub Mark EVALUATION
SUMMARY
l_1 l_1_I_I I I I I I I i l i l l I I I I l- 1 I I I I I I I l i l- 1 I I I I I I I I l l I I ?! i l l. I I I I i i I I I - I 1 - 1 I I I I , I I I I I I I- I l- 1 I i 'l . I I 1 .I I i I I l- I 'l I I I I I I I I I I I i 'I I i i l i I i- 1 I ~ I I I I i i ! C 8 A e :- 0 l COMMENTS-J,
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l , ma ar e = LHTGR ESIGN ANALYSIS o ONGOING LHTGR DEVELOPENT CONTRIBUTES TO UNDERSTANDING FSV FUEL ELEENT STRESS
~
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FULL CROSS-SECTION THERMAL AND STRESS ANALYSIS USING GBEAM (AXIAL) AND TWOD (RADIAL) i.
- , CAN NCH BE USED I
, o WORK ON PROBABILITY OF CRACKS EXTENDING INTO ADDITIONM; WEBS GAVE INSIGHT INTO THE FSV CRACKED ELEENT SITUATION e
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= aaw = . PROBABILITY OF WEB CRACKING o- ' THE OVERLAPPING DISTRIBUTIONS OF THE UN&RTAINTIES IN PREDICTED STRESS AND
. THE KN04N VARIATION OF GRAPHITE MATERIAL 4
. STRENGTH PROPERTIES ARE UTILIZED
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. AN#_YSIS APPROAW o :.,
STEP 1: CALWLATE PROBABILITY THAT HIGEST
, STRESSED WEB IN ENTIRE FUEL ELEENT m0SS
^
. SECTION WILL m ACK o- STEP 2: SIMJLATE THAT THAT WEB HAS mACKED, BY SETTING ITS STlFFNESS ESSENTIALLY TO ZERO
.' IN THE FINITE ELEENT 600EL o STEP 3: REANM.YZE AND OBTAIN NEW STRESS
' DISTRIBUTION 9
o- STEP 4: CALWLATE PROBABILITY.THAT NEW HIGEST l ,
- STRESSED ELEENT WILL GACK o' STEP 5: REPEAT AS MANY TIES AS NEEDED 1
4/2/84 L )
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- IESULTS OF WEB GACKING AN/QSIS u -- . :
MJ10ER . STRESS / STRENGTH PROBABILITY GACKED.- - RATIO 0F ANOTHER WEBS MACK
~
B . 0.16 . 1.0X10-3 1 . 9.17 1.0X1g-3 2 . 9.14 , 0.4X10-3 4 '
.9.13 - 0.2X1g-3 8- '.., '
O.11 0.2X10-5 16 . f ' '; 9.19 , 8.5X1g-6 t .- . . .
. 4/2/84 i
f ' 3 *
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CONQ_USIONS
- m. - . - .
. ~o- THESE RESULTS ARE NOT DIRECTLY RELEVANT TO l THE FSV SITUATION BECAUSE OF MAJOR DIFFERENCES
~
' IN THE STRESS DISTRIBUTIONS #iD MAGNITUDES
~
O THEY D0 HWEVER SHW THAT A MACK MAY RELIEVE
- STRESS IN A FUEL ELEENT WHEN THE DISTRIBUTION lS HIGILY NON-UNIFORM o :- THE ETH000 LOGY HAS BEEN APFLIED TO THE .
. SECIFICS OF THE FSV CRACKED FUEL ELEENT AND WILL BE PRESENTED SEPARATELY I ,. .
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l mauw _:= mACl(ED FUS. ELEENT AN#.YSIS l 0 1WO FUEL ELEENTS WITH HAIRLINE WACKS FOUlO DURING
'FSV FUEL ELEENT SUINEILLAN& PROGRAM I
o ALL INDICATIONS WERE THE GACKS WERE CAUSED BY HIGH STRESSES IN OTHERWISE NORMAL BLOCKS O mACI(ED FUEL ELEENT ANM.YSIS UNDERTAKEN TO . UNDERSTAND THE CAUSE OF THE GACKS j : i 4/2/84 1
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0 POWER AND FLUX DISTRIBtKIONS FROM FUEL
' ACCOUNTABILITY NUQ_ EAR DEFLETION CALQJLATIONS l 0 PadER LEVEL, FLQ4S AND TEWERATURES FROM EASUiOENTS AT FSV -
0 THESE DATA USED TO DERIVE OPERATING HISTORY 4/2/84 4 g
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. /UTS /UTS 8.42 0.78
~
! SFHSITIVITY ANALYSIS
- j. IN mEASE IN PEAK i
IN-PLANE /UTS
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== =e . : == EVM_UATION OF RESULTS (1) IN-FUNE STRESS /STRENGE RATIO ARE HIGHER THAN 'AXIM. STRESS /
l f STRENGE RATIOS b 4
~
i (2) PEAK IN-PLANE STRESS / STRENGTH RATIOS ARE CALGA.ATED AT THE - LOCATION OF T11E HAIRLINE GACK
- l
- (3) PEAK STRESS /STRENG M RATIOS ARE <1.0, ASSUMING NOMINAL, TIE-1 AVERAGED FLQ4S.
H04EVER, MESE PEAK VM.UES OCQJR DURING 4 - OPERAT10N AND ARE SENSITIVIE TO VARIATIONS FROM NOMINA. OPERATING 00NDITIONS, 1411 01 ARE CAPABLE OF INGEASING t RATIO >1.0 ,
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i . N i 4/2/84 j , k 1
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SUMMARY
RESULTS FROM PREVIOUS AN#_YSES
.ms u -2_ _i -
O PEAK STRESS / STRENGTH = 8.78 (NORMAL FLW CONDITIONS)
- o IN-FLANE STRESS > AXIAL STRESS o HIGH STRESSES LOCALIZED o PEAK STRESS / STRENGTH CALCULATED AT THE OBSERVED CRACK LOCATION o STpFRRFK SENSITIVE TO FLW/ THERMAL CONDITIONS O
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O CRACK PROGRESS 10N PATH COWATIBLE WITH OBSERVAT10N O PEAK STRESS / STRENGTH OEGEASES AFTER A FEW WEBS ARE
- WACKED i o AFTER ONE MACK OEVELOPS, STRESSES IN THE REST OF THE BLOCK REDUE IRNRTlCM.LY l
9
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FAILURE i - ELEMENT - SLAB CRACKED LOADING LOAD j NO. N0'. . WEBS ORIENTATION (KIPS) ! 1.4545 1 3 00 25.25 ' { 2 0 ,
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i i . j 4/2/84 J : !1 L - e i ,
r . 3 .
. FORT ST. VRAIN FSAR FUEL ELEENT INTEGR11Y .
,-' /
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'~/ . " STRUCTURAL < INTEGRITY OF TE FUEL ELEENTS-WlLL BE.MAINTAIED T'HR000i'iOUT .-
TE DESIGN LIFETIE'UPOER ALL ~(iPERATING , CoriDITIONS." , (PG 3.'4-7)
', , ? -; .
/
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- , / '
, T.HE ELEENTS WILL MAINTAIN SUFFICIENT INEGRITY AT TE
. ' COMPLETION OF DESIGN BURttP TO PERMIT SAFE REMOVAL FROM ' '
- /' I ^- '
THE CORE." (PG 3.2-2) r - t l .
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1 ! r . . 3 .
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== c.wr . : == SIGNIFICANCE OF FUEL ELEENT CRACKING ,
. CRACKING C0lt.D ADVERSELY AFFECT:
i . .
- 1. CORE COOLABILITY ,
l SAFETY ! 2. CONTROL MATERIAL INSERTA81LITY i 3. FUEL ELEENT REMOVABILITY INVESTENT I l . e f _ _ _ _ _ - - - . - - - -- - -e _._ m ____ _ _ _
D -
'l f@
CONSERVATIVE ASStDFTIONS p.
,MAXlR M RPF (1.83) # 8 COLLMi TILT (1.54) 1.
- 2. INSTANTANEOUS RELEASE OF COLLMi FP INVENTORY -
- (35,000,000 Cl)
- 3. TID-14844 PCRV RELEASE FRACTIONS (100% NOBLE GASES, 25% HALOGENS, 1% CONDENSIBLES)
- 4. HELilA4 PURIFICATION SYSTEM INOPERATIVE -
- 5. PCRV AT FULL PRESSURE (C00LD0144 NOT TAKEN INTO ACCOUNT) j 6. MAXlRM ALLOWABLE PCRV LEAK RATE (22 LBS/ DAY) i 4
l
o D . i f@ CONSEQUENCES 189 DAY LPZ DOSES: 9.992 REM MR.E BODY' 9.91 REM THYROID , 9.02 REM BONE DBA #1 - LOSS OF FORCED CIRCULATION 9.33 REM M R.E BODY ! 8 REM THYROID (NRC ESTIMATES)
- 5 REM BONE
~! -
v t REF: P-78146, SEPTENBER 6,1978 l (
)
4
f 3 .
- cawr .- CONTROL MATERIAL INSERTABILITY CONTROL RODS:
' INSERTION CAN BE IW EDED BY:
9.2 TO 9.5 INCH LATERAL DISPLACEENT RESERVE SHUTIXM SYSTEM (RSS): INSERTION CAN BE IWEDED BY: l 9.5 INCH LATERAL DISPLACEENT MAXlR M INTRA-REGION GAP : 9.1 INCH Y Y
< n, 9 s. , oe 1
__ _ _, M __S SAFETY SIGNIFICANCE OF CRACKING d e
- 1. CRACKING SUCH AS THAT SEEN TO DATE HAS N0 IWACT ON PUBLIC EALTH E SAFETY.
- 2. ORDERS OF MAGNITUDE MORE SEVERE CRACKING ARE REQUIRED TO IWACT PUBLIC HEALTH M SAFETY.
- 3. ANY POSSIBLE PUBLIC HEALTH E SAFETY IW ACT IS LESS THAN THAT REVilMD E ACCEPTED BY NRC FOR OTER FSV ACCIDENT SCENARIOS.
O e e 9 __- _}}