ML20092N719
| ML20092N719 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 06/29/1984 |
| From: | Giacobbe F, Slear D, Wilson R GENERAL PUBLIC UTILITIES CORP. |
| To: | |
| Shared Package | |
| ML20092N717 | List: |
| References | |
| 83-491-04-OLA, 83-491-4-OLA, OLA, NUDOCS 8407030474 | |
| Download: ML20092N719 (17) | |
Text
,
%-4 RELATED CORi!2SPONDENCE i
DOCKETED N
June 29, 1984 UNITED STATES OF ER A
NUCLEAR REGULATORY COMMISSION e m.
Before the' Atomic Safety and Licensing Board
-In the Matter of
)
)
METROPOLITAN EDISON COMPANY, ET~AL.
)
Docket No. 50-289-OLA
)
ASLBP 83-491-04-OLA
,(Three Mile Island' Nuclear
)
(Steam Generator Repair)
- Station, Unit No. 1)
)
LICENSEE'S TESTIMONY OF RICHARD F. WILSON, DAVID G.
SLEAR AND F.
SCOTT GIACOBBE-ON ISSUE 1.b (CONTENTION 1.a)
To Mr. Wilson:
.Q1.
~Please-state'your name and address, and describe your involvement with-the TMI-1 steam generator tube repair program.
~A1.
_My name is Richard F. Wilson'.
I.am employed by GPU
" Nuclear Corporation, 100.Interpace' Parkway, Parsippany, New-Jersey 07054.
As Vice President of TechnicalLFunctions, I was responsible for the overall project and technical management of
.the.TMI-1 steam. generator tube repair program.
Aistatement.of my professional qualifications is attached.
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'To Mr. Slear:
l Q2. 'Please state your name and address, and describe your I
involvement with.the TMI-1 steam generator tube repair program.
1 IA2. 'Myrname is David G.
Slear.
I am employed by GPU Nu-i
~
- clear ~ Corporation,.100 Interpace Parkway, Parsippany, New l Jersey _07054.
As the Manager of' Engineering Projects for 5
TMI-1,.I-wasLthe overall task manager-for the TMI-1 steam gen-erator tube repair program. reporting-directly to the Vice Pres-i
'ident of Technical Functions.
My responsibilities included all activities associated-with-the evaluation and repair of the j
A: statement of my professional. qualifications is attached.
To Mr. Giacobbe:
-Q3.
Please state your name and address, and describe your
[
involvement with the TMI-1 steam generator. tube repair program.
A3.
My nameHis F.
Scott Giacobbe.
'I am' employed by GPU
. Nuclear Corporation, P.O. Box 1018, Reading, Pennsylvania 19603.
As Manager of Materials Engineering / Failure Analysis I have been involved'in the planning and management of the fail-
[
ure analysis activities, corrosion testing programs, materials
[
evaluation and tube ~ sampling and removal programs associated f
with the. steam generator tube repair program.
I A-statement of my professional qualifications is attached.
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To-nll witnnccan:
Q4.
What is the purpose-of your testimony?
A4.
The purpose of this testimony is to address Issue 1.b of Contention 1.a as enumerated at page 23 of the Board's Memo-frandum and Order (Rulings on Motions for Summary Disposition, dated June 1, 1984), in which the Licensing Board stated:
1.
- The rationale underlying certain pro-posed license conditions should be addressed, with' attention.to:
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b.
Method of determining frequency ef ECT tests.
QS..How was the frequency of eddy current testing follow-ing restart of Unit 1-determined?
AS.
Industry experience has shown eddy current testing
~
~(ECT) is the preferred method for non-destructive examination ofcsteam' generator' tubes to ascertain damage.
The technique t
'has the ability to detect-different types of tube damage states,_such as different kinds and sizes of cracks, inside and outside surface defects, and tube erosion and wear.
It is used to provide knowledge'of the' generator state well before tubes
' degrade to the point of through-wall leakage or an unsafe con-dition develops within the generator.
Characterization of the I
asignal gives insight as to the type of damage and substantially assists-the investigator in understanding the damage mechanism.
JuiECTfis a technique-for_ inspecting tubing remaining in ser-t vice as part of_the primary pressure boundary, the role of eddy current inspection ~for the TMI-1 steam generators is the same i
as for; generators at any other operating plant.
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The= existing'once-through steam generator (OTSG) Technical
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Specification' requirements for ECT at TMI-1 implement NRC's I
- Regulatory Guide-1.83, Rev. 1.
The requirements are the same p
-as those for other nuclear plants in that they require at least 3% of-_the total number of. tubes in the steam generators to-be examined at each-inspection (certain criteria on tube selection Lare: included).
'The' Technical Specification testing frequency is specified to be not more than 24 months after the previous it
~ inspection with' provisions that the interval could be extended to,a maximum of_once per 40 months, contingent on prior inspec-
. tion'results.
Further conditions are imposed on the inspection
-frequency if there are primary to secondary tube leaks, degra-dation.is in excess of_ Technical Specification limits, and/or a loss of coolant accident or'a main steam line or feedwater-line break has occurred. LIf, in the-course of inspecting the steam generators, more than 5%;of the total tubes inspected are'found-to be degraded (imperfections equal to or_ greater than 20%'
,through-wall) or any of the tubes' inspected are defective
~
(g'reater than 40% through-wall), then.the sample size of the
^
-inspection is increased.
Licensee has adopted supplements to the TMI eddy current
. test 1 program which-the'NRC has~ incorporated into proposed
. license conditions.
These supple.ments will act as a precau-tionary: confirmation of Licensee's conclusion that crack initiation or propagation is not anticipated by chemical or me-chanical means following return of the steam generators to
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What has been proposed is that either 90 days after reaching full power or 120 calendar days after achieving 50%
power (whichever occurs first), the plant would be shut down for eddy current inspection of the generators.
In addition, ECT would be done at the subsequent shutdown refueling.
The plant currently is loaded with fuel which would permit full power operation for a little less than one year.
In establishing the above recommended change in eddy cur-rent test frequency, we considered the conditions of the gener-ator, the type of repairs performed within the generator, the damage mechanism leading to the repairs, and our expectation that if any new damage were to occur, it would be at a slow rate.
In addition, there are considerations other than those relating to the steam generators, i.e.,
the overall question of plant accessibility, other operational sequences being con-ducted, and prudent operating practices, which dictate that the opening of steam generators, with its attendant exposure to ox-ygen, should be minimized.
With regard to TMI-1 specifically, there is considerable detailed information available on the state of the generator, and-its-recent repair.
We have in place a special ECT differ-ential probe characterization of all tubes remaining in service (approximately 29,000 tubes) and special absolute probe ECT data on over 800 tubes.
We have a clear understanding of the type of damage which occurred in the generator and the reasons therefor.
We have an extensive qualification program on the
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repair which has tested kinetically expanded joints out to five years of load cycling and 15 years of thermal cycling.
We have a general industry understanding of experience with explosively expanded tubes in tubesheets for other applications.
In addi-tion, we are performing lead corrosion tests to provide advanced confirmatory corrosion and crack behavior data.
This information has been used to draw a number of conclu-sions on the predicted behavior of the tubes remaining in ser-vice:
1.
The initial intergranular stress-assisted cracking (IGSAC) of the steam generator tubes occurred with reduced sul-fur species and with the plant cooling down or cold.
- Steps, have since been taken to reduce levels of sulfur through chemi-cal. cleaning, stringent controls on primary system water chem-istry (less than 100 ppb sulfur) and elimination of potential sulfur contamination sources.
Tests have shown that the fail-ure mechanism is inoperative in the absence of sufficiently high levels of reduced sulfur species, and that IGSAC will not reinitiate under the TMI-1 operating conditions.
Thus, there is reasonable assurance that the rapid IGSAC which caused the original damage will not affect the steam generators in the fu-ture.
2.
There currently exists hot operational experience on the repaired steam generator of about 40 days with no indica-tion of leakage.in excess of Licensee's new, stringent adminis-trative limits on primary-to-secondary leak rate.
This.
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- available1 test data. supports the conclusion that unforeseen rapid orfgross changes ~are not taking place.,
-3.
12ue long term corrosion lead tests support the con-i clusion.that under the conditions attendant to operation, rapid t
. chemical' attack is not predicted.
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'4.
The possibility of steam flow-induced mechanical vi-t 4'
bration. propagation of small' cracks was examined analytically
'and;found to be non-significant.
5.
No mechanism has'been' identified relating to other mechanical crack' propagation scenarios while operating at full i
power.
Crack propagation due to-thermal cycling has been shown
.to be small and to occur principally during the act of cooling g
Udown.- Thus, mechanical crack propagation is not expected to change-tube condition during operation.
Since~the ECT progran is designed to characterize change, there'is a.need to allow reasonable operating time on the gen-1 r'
erators to allow any unforeseen mechanism to cause change.
It
'is= clearly a matter of judgment as to the. period of time.re-
. quired, but several factors considered by Licensee support the~
90 days /next. refueling; intervals' proposed:
'1.
'EddyJcurrent examination should take place after-chemical equilibrium is obtained within the system.
An extend-ed; period 'of time nay :be necessary for this to occur, given-the time associated. with ' gradual. dissolution of tlus residual sulfur in.the oxide' films.and its removal from.the reactor coolant l system (RCS)..The full benefits of eddy current-testing can, t
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.again, only'be obta'ined'after operation at some period of time
..to allow-the system to approach chemical equilibrium.
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Mechanical propagation due to flow induced vibration at" steady? state operation, if.any, will only occur at full or
.near-full st'eam flow conditions. To confirm these analytic con-clusions the generator must-be operated at full steam flow.
1Duas, _ a period of time of OTSG operation at power' is required if: eddy ~ current examination is to be most meaningful.
s 3.-
The-plant extended startup and power escalation pro-
- gr,amLis' designed-to~ maximize operator training, plant re-familiarization,-and allow non-0TSG related performance testing along the way.
ihis same extended power escalation program al-lows significant time to be accumulated on the generators at
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. reduced power. ~The period of time at reduced power is also a imeansoof accumulating ~ generator experience when the consequenc-es of any hypothetical crack propagation are reduced.
~
c4.
Detailed technical assessments of the repair within ithe tubesheet do not' reveal mechanisms which could lead to cat-astrophic-failure.
The~above facts.and experience suggest a minimal period of
-several months of, initial operation is necessary to ensure that sufficient data can be obtained during the inspections to trend
. conditions within the steam generators. ' Licensee's proposed augmented eddy current test program is a judgment based on the available facts.regarding generator condition and potential
. failure mechanisms, and includes consideration of general
industry experience. -Because special probes and. techniques Iwere developed for TMI-1, the condition of the TMI-1 steam gen-erators,is probably known with greater precision than for com-parable' steam generators at other plants.
The proposed supple-mental. steam generator ECT program for the inspections during the operating cycle after restart will continue to utilize these special probes and techniques.
It is a program which can reasonably be carried out without undue, unnecessary risk to
- the plant and-will provide the requisite degree of insight on changes,.if any, in the generator.
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PROFESSIONAL QUALIFICATIONS.
Richard!F. Wilson ViceLPresident, Technical Functions
~
GPU Nuclear: Corporation-GPU Experiences l Technical responsibility for the Engineering, Design,
' Licensing and. Technical Support of all nuclear generating stations.for the GPU System.
The. position manages.the technical resources of GPU Nuclear including day-to-day support for plant operations.
Previously was Acting Director for TMI-2 from September, 1979, to about March, 1980, and before that was Director of the Engineering and-Quality Assurance Departments within the GPU Service' Corporation.
Between 1975 and 1977, was Manager of Quality Assurance for the GPU Service Corporation with responsibilities for design and construction Quality Assurance.
~Other Experience:
Prior work experience included two years (1973-1975) as Manager of Manufacturing Engineering for Offshore Power Systems, Jacksonville, Florida.
Responsibilities included activities associated with. manufacturing planning, tooling,
. industrial engineering, manufacturing engineering, and technical support to the-planned manufacturing facility.. Prior
~
to joining Offshore Power Systems, held a. number of positions at the Atomic International Division of Rockwell International, 1954 to 1973.
Some of these positions included Engineering Supervisor, Department Manager, Chief Project Engineer, Program Manager, and Chief Program Engineer on a wide variety of Atomic International programs.
The last position was Program Manager for the Atomic International work on the fast breeder program.
. Performed and supervised work in almost every facet of reactor engineering, physics, facility design, safety, reactor operations, etc.
-Committee affiliations have included the EEI QA Task Force, the AIF Committee on Power Plant Design, Construction
- and Operation, B&W Plant Owners and BWR Owners Groups, EPRI Nuclear Divisional Committee, etc.
Outside the utility industry has served on a number.of company and company / government advisory groups as related to specific programs.
Education and training includes a B.S. degree in Mechanical Engineering, University of California at Berkeley, 1951; an M.S. degree in Mechanical Engineering, University of Michigan, 1953; and one year attendance at the former Oak s
Ridge School of Reactor Technology in 1954.
Has attended a large number of management and other courses, including the University of Michigan Public Utility Executive Program.
i t
PROFESSIONAL QUALIFICATIONS i
DAVID G. SLEAR I
i WORK EXPERIENCE L
i Company:
GPU Nuclear Corporation L
Title:
TMI-1. Manager Engineering Projects Responsibilities :
Management of TMI-1 modification, which i
entails:
Management of the $25 million j
. annual budget. allocated for plant modifi-cation; prioritization of the various l
phases of plant modification; oversight j
of the technical adequacy of plant modifi-cation and of the components involved in plant modification; consultation regarding problem resolution with respect to matters concerning plant modification; and direct supervision of 16 GPU employees.
This l
n position demands constant attention to long term and daily plant modification i
concerns and an extremely firm grasp of i
both the technical aspects of TMI-Unit.1 l
and of the various modes and components of modification available for implementation l
at TMI-Unit 1.
Dates:
1983 - Present j
[.
Company:
GPU Nuclear Corporation Titles.
OTSG Repair Project Manager l
l Responsibilities:
Management (in conjunction with individual task managers) of all aspects of the OTSG Recovery program at TMI-l including failure j
analysis, eddy current testing, corrosion testing, RCS examination, RCS sulfer cleanups, and plant performance analysis.
This position involved direct management of the OTSG repair process and personal involvement 1
in the decisien making process with respect to the repair program.
This position also entailed the definition and implementation of the o^terall project, and required a broad j
overview and analysis of the OTSG Recovery program.
In his capacity as OTSG Repair Project Manager, Mr. Slear was also called
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i avid G.-Slear-D Professional Qualifications Page Two upon-to-deliver numerous presentations concerning project details before the NRC, ACRS,.. TPR, and the GPU Nuclear Corp.
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management.
Dates:
December 1981'- Novenber 1983 1
Company:-
GPU Service Corporation
Title:
TMI-l Manager Engineering Projects Responsibilities:
Similar to those listed for Mr. Slear's present position including management of a $20 million budget and of project engineer-ing for modifications.
Dates:-
1979 - 1981
, company:
GPU Service Corporation
Title:
Preliminary Engineering Manager Responsibilities:
. This position entailed: the analysis and preliminary design of 400 Megawatt combustion turbines and of a 600 Megawatt coal fired power plant; extensive analysis of the reliability and availability of the components to be installed in the prospec-tive power plant; and the establishment of a baseline criteria document for the designated plants including the technical documentation and presentation of the plant design for-management review.
Dates:
1978 - 1979 Company:
GPU Service Corporation
Title:
Component Engineer Responsibiliticis :
This position entailed: the review of design specifications and technical details of products going into TMI-2, including the steam generators, pressurizer, main e
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Professional Qualifications
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Page Three condensors, cooling towers, reactor vessel, and internals; -technical consultation and analysis of problems; and review of the l
. contractor's design work on new components going into a plant.
UNITED STATES NAVY NUCLEAR SUBMARINE - FORCE OFFICER i
Title:
Engineer Officer j
-Responsibilities :
This position entailed: essentially primary responsibility and control of the l
onboard nuclear power plant; control of all
(
engineering sections, command of 4 divisions; and supervision of approximately~55 crewmen.
= Dates:'
1972 - 1974
Title:
' Machinery Division Officer Responsibilities:
As Machinery Division Officer, Mr. Slear was responsible.for:.all mechanical components of-the_ primary and secondary systems.of the power plant including the steam generator, reactor, and drive controls; chemistry control of the primary.and secondary systems; and the. supervision of 15 crewmen.. Mr. Slear also served as an Auxiliary Division Officer.
in charge 1of non-nuclear life support systems, i
amd as a Communications Division Officer.
Dates:
1968 - 1972 l
i Mr' Slear also attended the' Nuclear Power Submarine School i
from 1966 - 1968, during which' time he obtained one year of nuclear power plant. training -(6 months-classroom, 6 months actual plant L
-training) in addition to ' the submarine qualification program.
i EDUCATION o
l College University of Oklahoma Degree:
B.S. Mechanical Engineering Dabes:
1961 - 1966 I
e College:.Stevens Institute of Technology
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Degree:
.M.S. Mechanical Engineering l
Dates:
-1974
.1978 l
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m STATEMENT OF QUALIFICATIONS AND EXPERIENCE l
I F.
SCOTT GIACOBBE j
v i
I, F. Scott Giacobbe,.am employed by General Public l
i Utilities Nuclear Corporation as Manager, Materials Engineer-t
'ing/ Failure Analysis.
.I-have been in this position since July of-1982.
i Myxeducation includes a Bachelor's Degree in Mechanical Engineering from Villanova University in 1970 and a Master's Degree 'in Materials Engineering from Drexel University in 1975.
My. work experience has provided me many years of direct involvement in the materials evaluation and failure analysis of-l r
power plant components; early in my career it also provided a very intense involvement in heat exchanger tubing evaluations.
(
i In 1970,.I. began my employment with Westinghouse Electric l
Corporation in their Heat Transfer Division as : Materials En-gineer..
In this position I worked on the materials selection, i
corrosion evaluations and failure analysis of heat exchanger j
components'such as feedwater heaters, condensors, radioactive c
waste evaporators and other secondary side heat exchangers.
In i'
l particular, I was responsible for assuring that tubing utilized l
in the Westinghouse heat exchangers was properly specified and L
i manufactured.
This function provided me with in-depth knowl-I edge of heat exchanger tubing fabrication practices, corrosion I
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resistant properties and failure mechanisms.
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i In 1977 I left Westinghouse to join General Public I
-Utilities as a Senior Engineer in their metallurgical laborato-ry.
This position afforded me the opportunity to expand my areas of' expertise to include materials selection, corrosion i
evaluation and failure, analysis of other components of both nu-r clear and fossil power plants, and to gain a broader u$ der-t standing of power plant operation.
i In 1978 I was promoted to supervisor of the metallurgical l
-laboratory.
This was a first line supervising position which j
i gave me the responsibility for the. daily operation of the labo-i ratory and supervision of the technicians and engineers re-l r
porting to me.
This position also carried with it a large technical _ responsibility which kept me heavily involved in the day-to-day materials engineering problems.
My career took on a slight change in direction in 1980 when the company reorganized and formed the Nuclear-Corpora-tion.
At that time I became Materials and Welding Manager in the Nuclear Assurance Division.
With this position I assen-tially had the same functions a's before, vith the added respon-sibility for welding at the nuclear power stations.
While in
-this position.I was responsible for the technical and metallur-gical aspects of the development of the Nuclear Corporation welding program.
During this time I was still supervising all failure analysis activities, including the TMI spent fuel pool pipe cracking incident..
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i In July.1982, another reorganization took place.
At this I
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time my section merged with the materials engineering section
'in the Technical Functions Division and I took over management of:that newly formed section.
In this position I now had func-F tional responsibility for the materials configuration control f
i-of-both GPU nuclear power plants as well as welding engineering
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and failure analysis.
In addition, my section still provided 1
1
. failure analysis services to the fossil companies.
r
'I have-been involved in the steam generator tube failure
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-issue'from the beginning.
I participated directly in the ini-tial decision-making regarding the tube sampling and removal operations and was present to perform the initial visual evalu-1
-ations of the removed tubing.
I personally planned and oversaw
-the failure analysis activities performed by the outside la-boratories.
I also' developed the corrosion testing programs f
which'GPUN implemented to gain insight and understanding into i
the failure mechanism and responsible corredants.
It was also
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my' responsibility to coordinate the input from all our techni--
i cal consultants as well as plant experience and formulate the
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t l-current failure scenario.
During the steam generator repair, my section al.so provid-l 1
ed materials evaluation and consultation on all aspects of the t
repair. including explosive expansion, flushing, peroxide cleaning, and so forth.
My section also developed and imple-
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t mented the long term corrosion testing program and is l
evaluating the results as the testing progresses.
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J Lastly, during the, course -of _the steam generator repairs, I'was responsible for making all presentations to the NRC on L
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.s corrosion testing..and' failure analysis activities.
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i over the years I have kept fully abreast with the state-(
of-the-art in corrosi'on technology through my attendance and i
_ 'b,
, participation in" technical seminars and conferences, and 1
s through attending training sessibns.
I am a member of the j
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Edison.Electri'c Institute Materials, Piping, Welding and Corro-sion Task Force,,a group of i'ndustry representatives who meet N..
I to. share and develop solutions to corrosion problems in the a +
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L field of materials ' a'nd welding in the power industry.
In addi-l s
x tion, I am ai member of the American' Society for Metals.
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FT S. Giacobbe, "Examin'ation, Evaluation and Repair of Stress Corrosion Cracking in a PWR Borated Water Piping l
System", NACE~ Corrosion 81.
2.
F. S. Giacobbe, J.D.., Jones, R. L. Long, D. G.
- Slear, "Re-l pairs of TMI-l OTSC Tube Failu'res" Plant / Operations Prog-
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ress AICHE, Ju).y 1983', Vol.' 2, No.: 3.
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