ML20090B478

Ruptured Tube Analysis for Ginna, Technical Evaluation Rept

ML20090B478
Person / Time
Site:	Ginna
Issue date:	05/12/1982
From:	Leonard L FRANKLIN INSTITUTE
To:	Wichman K NRC
Shared Package
ML20090B470	List: ML20090B475 ML20090B478 ML20091L704 ML20091L715
References
CON-NRC-03-81-130, CON-NRC-3-81-130, FOIA-91-106 TER-C5506-307, NUDOCS 8205170397
Download: ML20090B478 (17)

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a O I 1' I 'i 4 I TER-C5506-307 f l4 A WNTENTS J - b d. Seetion _ Title Page 1 INTRODUCIION 1 .i 1.1 Purpose of Review. 1 g i ,j 2 TECHNICAL EVALUATION 2 2.1 Meetings and Site Visits 2 i 2.2 Iccuments. 2 2.3 Technical Ef forts 3 t 2.3.1 Metallurgical 3 ,]y 2.3.2 Foreign Objects 4 5 .f-2.3.3 Impact edel ~ -{ 2.3.3.1 Theory 5 2.3.3.2 Consequr.nces of Alternative Model. 6 2.3.3.3 Ef fects of Particle Size 6 2.3.3.4 Flow Model 9 ( 2.3.3.5 Laboratory Test Models 10 l. 2.3.4 Flow-Induced Vibration. 11 I l 2.3.5 Tube Collaps a 11 4 3 CONCLUSIONS 13 3.1 Me tallugical 13 i 3.2 Flow Dynamics. 13 / 3.2.1 Theoretical Impact Model 13 ]2 3.2.2 Tampa Flod Model 14 .i 3.2.0 Plow-Induced Vibration. 14 1 3.2.4 Test Models 14 'i 3.2.5 Scenario Leading to Tube Rupture 14 S 1 4 Mw .f, M5nkhn Resea.rch Center ( iii % v > rr. j e e.s .w 1

y-TER-C5506-307 5 y?. FOaDf0RD This Technical Evaluation Report was prepared by Franklin Assearch Center under a contract with-the U.S. Nuclear Regulatory Commission (Office of Nuclear Reactor Regulation, Divinica of Operating Reactors) for technical assistance in support of IK operating reactor licensing ' actions. The I technical evaluation was conducted in accordance with criteria established by the NRC.. / i 4 4 9 5 l V $~h Kr.'. F.ank!!n Research Center 4 w o n. r -n -. ..6 ,, - -... - - - - ee a -=- = -'*** w T w

) 3 0 b TI.R-C 5 50 6-3 07 1. INTRODUCTIDH 1.1 PURPOSE OF REVIIM This Technical Evaluation Poport (TER) documents the Franklin Rascarch Center's (FRC) evaluation of work performed to determine the cause of a tube rupture in the Rochestur Gas and Electric (RGtE) Corporation's Ginna B steam generator on January 25, 1982. An independent assessment was conducted of (1) the data genet atd for RG&E ty Westinghouse Research and Development Center and by Batts 11e Columbus Leborstories and (2) the inalysis carried out for the U,84 Wuclear Regulatory Commis61on (NRC) b, 4 toob, en National Laboratory. In determining the actual cause of the tube failure, the primary concern was to ascertain whether other tubes in the generator were subject to asimii.tr f ailure on restarting the generator or whether the failure was due to circum-stances specific to this particular t.ube in this particular generator. t I b 3 1 I Ji f .i i i ii 1 9 I s ~. .... Franv);n R* search Center

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',L 4 TER-C5506-307 2. TECHNICAL EVAWATION The scope of the work included the following: 1. Attend meetings concerning the cause of the tube rupture. 2. Review documentation relevant to the tube rupture. 3. Visit Brookhaven National Laboratory to discuss work in progress and to view samples. 4. Prepare a technical evaluation report (TER) based on Tasks 1 through 3 above. 2.1 MELTINGS AND SITE VISITS The following t.eetings were atterded: 1. Rochester Gas and Electric Corporation, April 6,1982 2. Brookhaven National Laboratory, April 14, 1982 3. Westinghouse Researca and Development Center, April 27, 1982 i l 4. Nuclear Regulatory J'.osnission, Bethesda, MD, April io,1982 2.2 DOC 1HENTS The following documer.cs were reviewed 1. Examinations Perf ormed on Tube R45C52 from the B Nuclear Steam Generator ot the Hochester Gas and Electrac Ginna Plant, August 10, 1978 f 2. Notes: RG&E/NRC Meeting, February 10. 1982 3. Eteam Generator Tube Experience, NUREG-0886, February 1982 4. Sutsnary and Hotes on March 1,1982 Met Mg, RGEE/NRC, March 3, 1982 5. ARC Report on the January 25, 1982 Steam " *" ara *ar '" L a Rupture and A. E. Ginna Nuclear Power Plant, HUREG-0909, April 1982 6. Metallurgical Examination of Ginna Steam Generator Tubes, April 23, 1982 (also included in 8) ..u. FranU..S Research Center a en .% r, 4 e

zME-M + 4 f h i TER-C5506-307 g 1 7. tocumentation, Diagrams, Photographs, and Micronraphs f rom Battelle i Columbus Laboratories, Presented at a Meeting at Westinghouse R&D Center, April 27, 1982 8. Steam Generator Evaluation, Ginna Steam Generator Tube Failure incident, April 26, 1982 9. Ginna Station Steam Generator Evaluation, NRC Meeting, April 30, 1982 2.3 TEC11NICAL EFFORTS 2.3.1 Me tallur g ical The documentation prepared by Westingbruse for RG&E, in particular Document 6, was definitive in representing the damage which had bem incurred by the burst tube (R42C55) and by other tubes adjacent to it in Wedge Arsa 4. Tube rubbing and foreign object damage were clearly evident, and it is now certain

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• 1C55 had burst as a result of severe wall thinning along an approximately 4-inen length. This thinning could only have occurred as a result of rubbing against an adjacent tubes in turn, rubbing along such a long length would only have ccurred if the adjaces,t tube had been severed at the tube sheet.

A sequence of tube rubbing and severing had initiated at the peripheral tubes. Based on all the evidence, including early documentation, it is most probable that tne initial damage which led to plugging of the peripheral tubes had been foreign-object-induced. This damage consisted of nicks and/or wear. Once plugged, a tube would not be subject to f urther deterioration unless a f oreign ooject were striking or rubbing it. As demonstrated by Westinghouse tests, repeated impsets can bad to the collapse of a plugged, non-leaking I tuco. A c.ollapsed rce is then susceptiele to fatigue failure (severing) owing to botn vibration and further interaction with the foreign object. A severed tube would then rub against adjacent tudes until leaking or eddy current indications called for plugging or until a uurst occurred. There was no evidence that the chemical environment or aetallurgical deficiencies in the Inconel 600 tuning pityed any role in the bursting of the

• ube.

Fur thermor e, there was no indication of chemical attack on any of the ~3~ Ah ..a Fran&J:n Research Center I h N wa-.

h 1 'f TI:R-C550 6-307 1 J 1 mechanically deterioratef tubes. In fact, fresh fracture details were evident 1 on tubes that clearly had failed early in the sequence of events leading to i the tube rupture. It is impot tant to note that (1) a critical event in the sequence of j events leading to the tube failure was the continuing degradation and ultimate 4 severing of plugged tubes and (2) a plugged tube was no longer subject to inspection in the routine maintenance program. Accordingly, there was no way of anticipating either the type of failure that occurred or the degree of plugged tube degradation in Wedge Area 4. The failure analysis performed at Battelle and Brookhaven corroborated the Westinghouse results. None of the examined tubes exhibited deterioration due to any mechanista otaer than wear and f atigue in con 3 unction with foreign object damage. The flow model and simulated wear tests conducted by Westinghouse (Document 9) indicate that nothing in the postulated sequence of events I leading to tne f ailure is inconsistent with experimental data. i Television viewing of in-place peripheral tubes revealed some tubes with minor dings or nicks on the outer diameter (OD). On samples removed from the j i stec n generator, it was evident that such damage was minimal and should not detract from the tube's service capability. Accordingly, as long as excessivo j eddy current indications are not noted, it does not appear necessary to remove j or plug oder tubes with similar indications. ] 2.3.2 Pereign ob$ects l ) The foreign objects recovered from the generator are tabulated on pages ) t 3.5-1 and 3.5-2 of Document 8. The largest items were three pieces of 0.5-in l 1 thien carbon steel plate, one about 4 x C.3 in, one 1.5 x 3.5 in, and one l I eliptical with axes 2 and 2.4 in. The Westincb..ise calculations and tests l- ' demonstrated that the largest object would readily induce the type and extent i of damage noted on the peripheral tubes. Since the presence of such foreign objects had never been suspected, no inspections had been carried out to assure that this type of debris was not ~ d.-3 l J a Frankhn Resesren Center a %s.oa e the e n +.. -

.=.. 9 / 9 TER-C5506-307 present. If a video inspection system or an acoustic monitoring system had been in place, it now appears certain that not enly would the foreign object i have been found, but the severe deterioration of the peripheral tubes would also have been detected. t 2.3.3 Impact Model 2.3.3.1 Theory In the theory given in Document 8, an impacting mass (foreign object) is accelerated by cross flow in the space between the wrapper and the outermost l (peripheral) tubes in a wedge area. Upon impact with a tube, the impacting . ass moves together with the tube. The tube moves in its lowest resonant mode. The tube is t sgarded as "f. ed-fixed

• at the tube sheet and the first support plate. The, maximum force between the impacting masi and the tube must be sufficient to cause local plastic deformation in order to contribute to the eventual collapse of the tube. Collapse of a plugged tube will occur as a result of a sufficient number of impacts, especially if there is excess pressure outside the tube. This excess pressure, about 1,000 psi, will occur if the plugged tube has no leak.

l This model of the interaction betwoon impacting object and tube is open j to question. There is a local def ormation near the location of the impact. Tnis local deformation is entirely elastic unless the peak stress exceeds the elastic limit, whereupon some plastic deforsstion will occur. We now assume j tnat the impact is borderline, that is, not quite strong enough to cause i plastic def ormation. The elastic deformation may be modeled as a spring with a large spring constant, k. The impacting mass, m, strikes this spring, g which is mounted on the effective mass, m, of the tube. m is, in t ur n, g g attached to ground via another spring, with spring constant k. g The resonant frequency of m joined to a by k is very high cenpared g t to the resonant frequency of m joined to ground by k. Consequently, the g g l W., Frankhn Research Center % w % e w% + - - w .c --,e,-mw w ,i,s r-e w - -,--,---w--,----vi-

) A ) TER-C550 6-307 i f duration of contact between the impacting mass and t.be tube is short compared 1 to the period of the tube osod.11ation. Spring k is negligibly deflected 1 .s .) during the impact. The theoretical calculation of the peak fosce should not j be based on the taodel used in Document 8. j 2.3.3.2 - Consequences of A4ternative Model If a impacts with velocity v, its momentum and kinetic energy are, g g respectively, a v and a v /2. The peak force occurs when the distance gg g between the ends of the spring reaches its minimum. This occurs when have the same velocity. Conservation of momentum requires g and mg o that this volocity be agvg/(ag + m ). The combined kinetic energy is g 2 g + m ))2/2. Subtracting this from a v /2 we obtain the (ag+m) (a v /(a g gg energy (elastic plus plastic, if any) stored in the spring. From this) we find the fraction of the initial kinetic energy that is delivered to the spring. This fraction is a /(mg + s ). If mg is small compared to g g a, almost all the incoming kinetic energy is delivered to the spring. g 2.3.3.3 Effect of Particle Sise We consider-a reference impacting particle of mass n, and cross section l area (perpendicular to the flow) 4,. We also consider a geometrically similar particle with linear dimension a times that of the ref erence t' particle. The mass of the particle is m,s3 'and its cross section area is -A,s. The acceleration produced by the drag force is -du/dt, given by 3 a,s du/dt = cA,a o u /2 i { where u = v,-v -v,= velocity of water = constant ~ v = velocity of particle p, = density of water c. = drag coeff!cient = 1 B = c c,\\f 2m, , dh M Franklin Research Center % w n. %. m. 4. u, a.

za TF.R-C5506-307 This equation may be integrated, leading to 1 y = v" ft + where v is assumed to be = 0 for t = 0. The distance traveled in time t is fi.nd by another integration to be k=v,t-finhv,t+1 F.liminating t between these two equations, y=y-in(y+1) where Y"v w-v A plot of Btt/s versus v/V is shown in Figure 2-1. For v'small compared to 2 ,, y is small and Bx/s is approximately y /2, so that, for large a y compared to Bx, i I v 1 7"1+1 w y 1 (v<<vw) = 1+ If s is small compared to Bx, y is large and v is nearly equal, to y For large s, v is rough

• proportional to 1/[s'.

The kinetic energy of tne impacting particle (asse .1 that the travel distance, x, before impact is 3 the same f or all particles) ir 1roportional to a,s (1/f)2 That is, 2 the kinetic energy is proportional to s, For small s, the kinetic energy is proportional to s. Applying the fraction a /(m 3 g g+m) found in Section 2.3.3.2, the energy del hered to g the spring is pec,portional to _,n ~ m 1 + - *- s 3 m t g 4... Frankin Res,earch Center %vN w w-e--grwe-- wes-e re y e. ,+ 7- - - - r+wT--We'--- v v

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_ _ - -. - - - - _ -. ~ - - - -. t I r Tr.R-C5506-307 oojects were also measured and ccxnpared with the minimum static concentrated load capable of causing local plastic deformation. In addition, the nability of small foreign ocjects may have been observid. The large foreign object remained trapped in the modeled wedge area for the duration of the test run i that was shown on videotape at the April 30, 1902 meeting. It could be s een to strike the target tube several times in approximately the same spot. This supports the scenario for damage, in which a peripheral tube is ultimately flattened and torn so that it becomes separated from the tube sheet and then l wears its neighboring tubes. If observations have also been made with auf ficiently small foreign objects, with a = 0.1, say, there may be experimental support for the expection that such small objects are so highly mobile that they never strike a tube in the same place twice. But even if such experiments have not been performed, it is reasonable to conclude that if objects larger than, say, 0.25 inches in typical dimension are removed, the above scenario will not be repeated. 2.3.3.5 Laboratory Test Madels T.to laboratory test setups were shown af ter the meeting on April 27, ? 1982, the first of which is shom in Ix>cument 9. In this test, a model o inpacting mass is propelled upward against the side of a horizontally mounted tune specimen. The mounting fixture enables an external pressure to be applied to the tube. The impacting peak force is measured, the tube is moved axially or rotated about its axis between successive impacts, and the tube is backed so that it does not bend. This expwrinent appears tn be well designed to ield valid data relating (1) the peak f orce to the occurrence of permanent deformation and (2) the effect of external pressure in collapaing the tube once substantial ovality is produced. Since a statically applied force produces the same local stresses and strains as the same peak f orce applied dynamically, it would appear to be sufficient to apply tne force statically. This might have led to a simpler experiment. Furthermore. bacning the tube to prevent it from bending should make no dif ference in the final result. provided the peak applied force j .'.. Franklm Res,earch Cemer aww% w n. ,-_.,,..v_.,,.y.., __s,._m,.. ~... -

T ) i TER-C5506-307 pressure, although Document d shown that external pressure can be a significant contribution. For some of the co11 speed tubes, it may have p1syed if an essential role. Collapse (or flattening by impact alone) could have ( occurred because there was no internal pressure opposing or preventing it. I 3 However, even if internal pressure had somehow been provided, thus preventing tube collapse, severe tearing af ter many impacts by large fereign objects s /j still alght not have been prevented. ':'herefore, removal of foreign objects is } necessary, as well as suf ficient, to prevent a repetition of the tube berst incident. + I ? l i L I l I l l i gh.

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Tr.R-C 5506-307 t / 3. CONCLUSIONS 4 3.1 McTALwRGICAL 1. The tube burst f atture resulbd from rubbing-induced wall thinning. 2. Damage to the burst tube and to other tubes was caused by mechanical means, with initial major tube deterioration having been initiated by f oreign objects. 3. Theh vss no evidence that embrittlement or corrosion of the tube material contributed to the f ailure. 4. The sequence of events leading to the failure required foreign objs t induced deterioration of plugged tubes. Accordingly, an adequate inspection system to monitor the presence of foreign objects should be implemented to preclude another tube burst f ailm'e. I a } 3.2 FLOW DYNAMICS 3.2.1 Theoretical Iconet hadd \\ The use of ' fixed-pinned" tube end conditions may be more appropriate for the models used than the " fixed-fixed" conditions that were used. An o alternative model is suggested in which the tube ef fective spring constant dou not enter. Instead, the spring constant representing local tube deformation is int.luded. For impacting objects of a given shape, the peak energy stored in the spring varies rougnly as s", where s is the linear size scalet factor ind n is between 2 and 3. Because of the f airly sensitive dapendence on s, the impacting sans that causes incipient plastic deformation does not have to be determined very precisely. 9 4 9 1 e Ak E.c Frankhn Research Center wemmmm [ _ usamies-ww .1amw 6-e --,p. - - - - -sr,-~w w

- _ - -. ~ -. - _ -.. - -.. _.. _ -. - I TP:R-C550 6-307 ./. 3.2.2 Jwnpg Flow Mde'g Thas flow codel is suitable for its intended purposes. It was used to show that the largnat foreign object found can remain trapped in a wedge area long encugh to strike a peripheral plugged tube many times with snough force to cause it eventually to be flattened. It is also capable of being used with analler foreign otdects, say 0.1 times the size (linear dimension) of the largest one studied, thereby providing experimental verification that peak impacting force is much less than that needed to cause plastic deforr.ation, and coniirming that such objects are so highly mobile that they do not impact twice near the same location on a tube. 3.2.3 l f,,ow-Induced vibration The stability limit for round tubes with fixed-pianed ends is high enough 'I that it is very unlikely that.round tubes will experience excessive 4 flow-induced vibration even if local flow velocities art higher near the P'j region from which tubes have been removed. In the unlikely event that excessive flow-induced vibration were to occur, collisions between tubes would I be detected by the acoustic monitoring system to be employed in the future. 4 ( 3.2.4 Test Models The two test models shown at Westinghouse Research and Development Center on April 27, 1982 are valid for their intended purposes, although simpler experimental setups any also have served. ) i 3.2.5 Scenario Leading to Tube Rupture The scenario is reasonable and accounts for the tute rupture. In view of j the results obtained, it is reasonable to expect that removal of large foreign ] objects will prevent the recurrence of the tube burst scenario. 1 l 8 1 i 4 -u-M Frankhn Research C. enter % *w % I { ~

.I , y -l TECHNICAL EVALUATION REPORT -1a 1 ) RUPTURED TUBE ANALYSIS FOR GINNA .} ROCHESTER GAS AND ELECTRIC CORP, t R. E GINNA NUCLEAR POWER Pl. ANT t. 1 [ NRC OOCKET NO. 50-244 FRC PROJECT C5606 t i FRC AS$1GNMENT 8 / NRC CONTRACT NO. NRC 03-81 130 FRC TASKS 306, 307 ) 5 1 Preparedby Frank!!n Research Cent 6, Author: L. Leonard ,) 20th and Race Street G. P. Wachtell ,y Philadelphia, PA 19103 FRC Group Leader: L. Leonard Prepared for J' Nuclear Regulatory Commission l -) Washington, D,C. 20555 Lead NRC Engineer: K, Wichman 'A May 12, 1982 This report was p epared as an account of work sponsored by an egency of

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the United States Govemment. Neither the United $ tans Govemment nor i any agency thereof, or any of their employees, makes any warranty, on-proceed or implied, or assumas any legal liability or responsibility for any ) third party's use, or the results of such use, of any informa;1on, apparatus. 2 product or process diecioned in this report, or represents that its use by I -- such third party would not infringe privately owned rights.

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