ML20092N724

Testimony of DE Lee,Fs Giacobbe & DG Slear on Issue 3 (Contention 1.a) Re Hardness Tests on Repaired Tubes.Prof Qualifications Encl.Related Correspondence

ML20092N724
Person / Time
Site:	Crane
Issue date:	06/29/1984
From:	Giacobbe F, Lee D, Slear D GENERAL PUBLIC UTILITIES CORP.
To:
Shared Package
ML20092N717	List: ML20092N716 ML20092N719 ML20092N721 ML20092N722 ML20092N723 ML20092N724 ML20092N725 ML20092N726
References
83-491-04-OLA, 83-491-4-OLA, OLA, NUDOCS 8407030481
Download: ML20092N724 (15)

Text

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R E U' M D C :.n. s s a u g UNITED STATES OF AMERICA ogg NUCLEAR REGULATORY COMMISSION us En

• k Before the Atomic Safety and Licensing Board Ed -j

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.In the. Matter of

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~5 METROPOLITAN EDISON COMPANY, ET AL.)

Docket No. 50-289-OLA

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ASLBP 83-491-04-OLA

'(Three. Mile Island Nuclear

)

(Steam Generator Repair)

Station, Unit No. 1)

)

LICENSEE'S TESTIMONY OF DOUGLAS E.

LEE, F.

SCOTT GIACOBBE AND

. DAVID G.

SLEAR ON ISSUE 3'(CONTENTION 1.a)

To Mr. Lee:

Q1.

Please state-your name and address, and describe your

-involvement with the TMI-1 steam generator tube repair.

A1.

My name is Douglas E.

Lee.

I am employed by Babcock

& Wilcox,.an operating unit of McDermott, Inc.,

P.O.

Box 1260, Lynchburg, Virginia 24505.

I managed the Mechanical Engineer-ing Section lif the Engineering Department.

This section contained the Mechanical Design Unit that was assigned to de-sign, qualify and implement the kinetic expansion joint in-stalled as part of the TMI-1 steam generator tube repair pro-

. gram.

A statement of my professional qualifications is attached.

l 8407030481 840629 PDR ADOCK 05000289 T

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~To Mr.' Giacobbe:

HQ2.

Please state your name and address, and describe your involvement with the TMI-l steam generator tube repair program.

A2.

My name.is 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 p

have.been involved in the' planning and management of the fail-ure analysis activities, corrosion test programs, materials evaluation and tube sampling and removal programs associated

- with the steam generator tube repair program.

A statement of my professional qualification 3 is attached.

=To Mr. Slear:

. Q3.

Please state your name and address, and describe your involvement with the.TMI-l steam generator tube repair program.

A3.

My'name is David G.

Slear.

I am employed by GPU Nu-F<

clear' Corporation, 100 Interpace Parkway, Parsippany, New Jersey 07054.

'I amLthe Manager of Engineering Projects for TMI-1.

As such, I was the overall task manager for the TMI-l OTSG Tube Repair Program reporting directly to the Vice Presi-denttof. Technical Functions.

My responsibilities included all activites associated with the evaluation and. repair of the steam generators.

Azstateme.it of my professional-qualifications is' attached.

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'O To All Witnesses:

Q4.

What.is the purpose of your testimony?

A4. "The purpose-of-this testimony is to address Issue 3

of. Contention 1.a as enumerated at page 23 of the Board's Memo-r'andum and Order (Rulings on Motions for Summary Disposition, dated June 1, 1984) in which the Licensing Board stated:

3.

The reasons for not including hardness tests on repaired tubes in the post repair testing program should be addressed.

QS.

Did the post-repair testing program include testing the repair joints for hardness?

c.i5.

No.

Hardness testing of the repair joints would be both unnecessary and impractical.

Hardness is a material prop-erty which measures a material's resistance to deformation.

When_ tubes are expanded (through " cold working"), the hardness of-the material increases due to the deformation.

This can re-

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sult in high residual tensile stress, which can be indicative of increased susceptibility to intergranular stress assisted cracking (IGSAC).

The' kinetic expansion process used at TMI-1 resulted in cold working of the expanded portions of the tube, which in-creaseu the hardness of the material.

The roll expansion pro-cess used in the original tube-to-tubesheet joints also pro-duced cold working and thereby increased the material's hardness.

?-

Hardness testing was used during the qualification pro-grams to determine how the kinetic expansion process compares to_the non-stress-relieved roll expansions in terms of cold working.

These tests showed the kinetically expanded joints to be less-hard, and therefore to have less cold working of the inside diameter surface, than non-stress-relieved rolled joints.

Less cold working results in lower residual tensile stresses.

This suggests that the kinetically expanded joint will be less susceptible to intergranular stress assisted

. cracking (which is associated with residual tensile stress) than are non-stress-relieved rolled joints.

Such rolled joints have operated'successfully in many steam generators in nuclear power plants.

Hardness was not considered a parameter indicative of the adequacy of the kinetic expansion joint.

The joint was quali-fied for a range of material tensile strengths bracketing those of the TMI-l steam generator tubes and a range of possible tubesheet annulus geometries and conditions.

Joint adequacy was established by qualification tests and internal tube diame-ter measurements.

Post-repair testing in the steam generator included measurements to verify that the expansion process was in accordance with the qualification program.-

This provided a much more direct and informative means of assessing the adequa-cyfof the joint than would any measurement of hardness.

More-over, as a practical matter, hardness testing is-done with rel-atively~1arge equipment. and cannot be performed on the repaired tubes within the steam generator.

_4_

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En PROFESSIONAL QUALIFICATIONS t

t DOUGLAS E. LEE EXPERIENCE-Sabcock s Wilcox Company.

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-(Current Assign' ment) Manager, Engi neering Department -

"[

Responsible for engineering activities involving system design, performance analysis, component design and structural / stress

analysis inLsupport of'B&W supplied engineering services and engineered. service products.

Responsibilities.also include engineering' efforts to complete nuclear steam supply system backlog contracts in the above areas.

Responsible to define

-and, implement.research programs to maintain and. advance base ctechnology,. develop new products and services and to automate i

engineering-functions. ' Work is. managed to be in.accordance with1 customer, regulatory :and quality assurance requirements.

ManagedLthe. efforts of 250 professionals organized into-three l

sections.and ten' units.

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(1982 - 1983)~ Manager, Mechanical Engineering Section -

-Reponsible for reactor component and reactor accessory

[

. equipment mechanical. design, specification, acquisition

. hardware and related engineering services.

Also responsible

[

.~for-component' performance such as. steam generator tube l

' integrity and for reactor plant materials and chemistry.

Defined and implemented research programs to maintainLand strengthen materials and chemistry technology.

Work is managed

.to-be.in accordance with contractural, internal and quality assurance requirements.

Managing the efforts of about 90 l

professionals in four working units.-

l (1980 - 1982) Manager, Plant Engineering Section - Responsible

to provide competitive, quality-engineered nuclear power plant 3

and: system level engineering design and analysis including l'

reliability and-risk evaluations.

Responsibilities included l

' system design requirements and functional design, performance i

p'

.and. safety analyses, preparation of appropriate SAR materials,-

l defining.and implementing. computer code development programs, resolving operational problems and. developing operator j

P guidelines to safely manage the plant during anticipated transients.

Work was managed to be in accordance with 3

. contractual and quality assurance requirements. -Managed;the l

H. efforts of:approximately 110 professionals in six working

[

units.

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(1980) Manager, Equipment Engineering Section - Responsible to

[

. develop, specify, standardize, license and provide competitive, reliable, quality-engineered equipment and equipment related

. services for plant protection, control, monitoring and display, for reactor coolant system and auxiliary system operation, and t

for fuel storage activities which comply with contractual obligations, satisfy customer needs, meet plant and system

. performance' requirements and meet. applicable quality assurance requirements.' Managed the efforts of approximately 50 l

[

professionals in three working technical units.

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l (1978 - 1980) Manager, Fluid Systems Unit - Unit responsible

[

for NSSS auxiliary system design, hardware specification and e

procurement.- Specific systems are makeup, chemical addition, l

-decay heat, emergency safeguard cooling and waste processing.

Hardware' responsibilities include valves, heat exchangers, l

tanks, domineralizers and filters.

Work was managed in accordance with technical, contractual and quality assurance requirements. -Directly managed the efforts of 15-20 professionals.

(1978) Associate Project Manager - Responsible for portions of

'the NSSS being supplied to the Power Authority of the State of i

New: York for the Greene County Nuclear Power Plant.

Plant

[

' design and licensing reached the stage of meeting the Jrequirements for a-construction permit.

(1977 - 1978) Site Coordinator - Temporarily assigned to TMI-2 Lto organize and coordinate site efforts to install

. accelerometers and_ strain gages in the primary side of a steam 1

-generator for the purpose-of measuring tube vibration.

Work-t included supervision'of craft personnel ~, planning and l

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coordination with customer, site personnel and B&W design L

engineering to complete the installation prior to reactor j

j start-up.'

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'(1975 - 1977) Associate Project Manager, NSSS supplied to Power i

Authority of the State of New York.

Responsibilities included t

ensuring 1that the accessory equipment portion of the B&W scope of supply is technically acceptable, delivered on time and delivered:within1the contract budget.

Contract in the detailed

[

L design-phase requiring frequent, detailed interface with the i

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-Architect Engineer as well as project direction of engineers in j

matrix organization assigned to the contract.

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(1974 - 1975) Geraric Project Manager - Responsibilities inciudad-identifying items with-potential risk impact (cost increases) to backlog NSSS contracts and driving these problems r

'to a least. impact solution,. managing selected programs designed l

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to minimize costfimpacts to backlog contracts, an'd performing

. assigned Project Management Department projects.

Key feature of assignment was to work across-NSSS contracts to identify and minimise contract risk.

~

(1973 -~1974) Auxiliary Systems Engineer - Responsible for the isystem design and. equipment procurement for reactor support fluid systems such as makeup'and decay heat.

Work included preparingisystem descriptions, P9AR material, equipment-specifications and obtaining q.;eations for the Toledo Units 2 and 3 (NSS-25 &f26) project as well as providing support for the Toledo Unit _1_(NSS-14) project.. Achieved _the functional level.of Task Engineer in this assignment.

Division of Naval Reactors, USAEC k1968-1973) Engineer in the-Refueling Branch - Responsible

.for supervising prime contractor organizations in the refueling and maintenance of U.S. Navy and.AEC nuclear reactors.

This

, work-includes. technical responsibility for the develcpment of refueling systems, for: planning and following refueling _ work and'for design and procurement.of specialized refueling

_ Work with equipment-ranged from approving initial

equipment.

equipment design concepts and specifications'through use of the equipment'by field. organizations such as shipyards.

Have

' extensive experience in planning,_ design, procurement and use of special purpose: weld cutting and welding machines.

EDUCATION University of Virginia, Charlottesville, Virginia B.S. degree in Engineering, graduated with distinction in June, 1968.

Majored in aerospace engineering.

Dean's List, elected

~

to Tau Beta Pi. Honorary engineering fraternity.

Naval Reserve Officer's Training Corps scholarship program.

Midshipman Battalion Commander.

Awarded the Commanding Officer's Sword as

-the outstanding _ midshipman.

Lynchburg College, Lynchburg, Virginia LMaster of' Business Administration in May, 1980.

Subject area was Management Control.

MILITARY SERVICE

-Commissioned'Ension, USN in June, 1968 upon graduation from

= college.

Assignet. duty with the Division of Naval Reactors, USAEC, Washington, D.C.

Earned a certificate from the Bettis

r s

~ Reactor Engineering School, Pittsburgh, Pennsylvania in June,

- 1969.. Promoted to grade of Lieutenant in June, 1971.

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' STATEMENT.OF QUALIFICATIONS AND EXPERIENCE l

F. SCOTT GIACOBBE

{

i I, F. Scott'Giacobbe, am employed by General Public l

Utilities Nuclear Corporation as Manager, Materials Enginear-j ing/ Failure Analysis.

I have been in this position since July of 1982.

I My education-includes a Bachelor's Degree in Mechanical fl Engineering from Villanova University in 1970 and a Master's r

Degree in Materials Engineering from Drexel University in 1975.

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9 My work experience has provided me many years of direct j

involvement in the materials evaluation and failure analysis of-

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power plant components; early in my career it also provided a j

t very intense involvement in, heat exchanger tubing evaluations.

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In 1970, I began my_ employment with Westinghouse Electric f

Corporation in their Heat Transfer Division as a Materials En-

[

gineer.

In this position I worked on the materials selection, j

corrosion evaluations and failure analysis of heat exchanger i

components such as feedwater heaters, condensors, radioactive j

waste evaporators and other. secondary side heat exchangers.

In i

i particular, I was responsible for-assuring that tubing utilized j

in the Westinghouse heat exchangers was properly specified and manufactured.

This function provided me with in-depth knowl-

{

edge of heat exchanger tubing fabrication practices, corrosion resistant properties and failure mechanisms.

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In 1977 I left Westinghouse to join General Public Utilities as a-Senior Engineer in their metallurgical laborato-ry.

This position afforded me the opportunity to expand my I

areas of expertise to include materials selection, corrosion cvaluation-and failure analysis of other components of both nu-clear and fossil power pl'nts, and to gain a broader under-a standing of power plant. operation.

In 1978 I was promoted to supervisor of the metallurgical i

laboratory.

This was a first line supervising position which l

i gave me the responsibility for the daily operation of the labo-i ratory and supervision of the technicians and engineers re-porting to me.-

This position also carried with it a large l

technical responsibility which kept me heavily involved in the j

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-l tion.

At that time I became Materials and Welding Manager in j

l!

the Nuclear Assurance Division.

With this position I essen-tially had the same functions as before, with 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 l

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welding program.

During this time I.was still supervising all i

failure analysis activities, including the TMI spent fuel pool I

pipe cracking incident.

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t; i._____._...._._._______.._.__._....

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"O In July 1982, another reorganization took place.

At this i

time my section merged with the materials engineering section l

in the Technical Functions Division and I took over management of!that newly formed section.

In this position I now had func-tional responsibility for the materials configuration control j

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~of both GPU nuclear power plants as well as welding engineering l._SE'

'and failure analysis.

In addition, my section still provided i

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failure analysis services to the fossil companies.

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I have been involved in the' steam generator tube failure L

. issue from the beginning.

I participated directly in the ini-tial decision-making regarding the tube sampling and removal i

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operations and was present to perform the initial visual evalu-ations of the removed tubing.

I personally planned and oversaw l

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the failure analysis activities performed by the outside la-boratories.

I also developed the corrosion testing programs 1

which GPUN implemented to gain insight and understanding into r

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'the failure mechanism.and responsible corredants.

It was also l

my responsibility to coordinate the input from all our techni-i cal consultants as.well as plant experience and formulate the l

current failure scenario.

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During the steam generator repair, my section also provid-l i

ed materials evaluation and consultation on all aspects of the j

repair including explosive expansion, flushing, peroxide cleaning, and so forth.

My section also developed and imple-f mented the long term corrosion testing program and is evaluating the results as the testing progresses.

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o Lastly, during the course of the steam generator repairs,

'I was responsible for making all presentations to the NRC on l

corrosion testing and failure analysis activities.

l Over the years I have kept fully abreast with the state-of-the-art in corrosion technology through my attendance and l

- participation in technical seminars and conferences, and through attending training sessions.

I am a member of the Edison Electric Institute Materials, Piping, Welding and Corro-l sion Task Force, a group of industry representatives who meet

' to share and develop solutions to corrosion problems in the 1

field of materials and welding in the power industry.

In addi-tion, I am a member of the American Society for Metals.

Publications 1.

F. S.'Giacobbe, " Examination, Evaluation and Repair of Stress Corrosion Cracking in a PWR Borated Water Piping System", NACE Corrosion 81.

2.

F.

S. Giacobbe, J.D._ Jones, R. L.

Long, D.

G.

Slear, "Re-pairs of TMI-1 OTSG Tube Failures" Plant / operations Prog-ress AICHE, July 1983, Vol. 2, No. 3.

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PROFESSIONAL QUALIFICATIONS DAVID G. SLEAR

~ WORK ' EXPERIENCE Company:

GPU Nuclear Corporation

~~

- Title : ~

TMI-l Manager Engineering Projects Responsibilities:'

Management of TMI-l modification, which entails:

Management of the $25 million annual budget allocated for plant ' modifi-cation; prioritization of the various phases of plant modification; oversight 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 position demands constant attention to

~

long term and-daily plant modification' concerns and an extremely firm grasp of both the: technical aspects of TMI-Unit 1 and-of t6e various. modes and components. of modification available for implementation

-at TMI-Unit 1.

Dates:

1983 - Present Company:

GPU Nuclear Corporation

Title:

OTSG Repair Project Manager Responsibilities:

Management (in conjunction with individual task managers) of all aspects of the OTSG l

.-Recovery program at TMI-l including failure analysis, eddy current. testing, corrosion

. testing, RCS examination, RCS sulfer cleanups, and plant performance analysis.

This position involved direct management of the G

OTSG repair process and personal involvement in the decision making process with respect

-to the repair program.

This position also

-entailed the definition and implementation l

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of the overall project, and required a broad l

overview and analysis of the -OTSG Recovery b

- program.

In his capacity as OTSG Repair

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Project Manager, Mr. Slear was also called l

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't David G.*Slear:

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1 Professional' Qualifications 3

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upon-to deliver numerous presentations con,cerning project details before the NRC,

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~ ; ACRS, TPR,,and the GPU Nuclear Corp.

j management.

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December <l981 - November 1983 l

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, Company:'

GPU Service Corporation u

Title ~

.TMI-l Manager Engineering Projacts j

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.lResposisibilities :

Similar: to those listed for Mr. Slear's

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present position including management.of

-a $20 million budget and of project engineer-ing for modification's.

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• Dates:

21979 - 1981

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' Company:.

I,, ' cGPU Service Corporation.

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Preliminary Engineering Manager j

Title:

Responsibilitie's hhis positio'n' entailed: e;the analysis and t

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preliminary design of.;400 Megawatt l

- combustion, turbines and'_of a 600 Megawatt 7.. '

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coal fired poweF plant; extensive _ analysis l

,~

of the reliability and availability of the vi components to be ins ~talled in'the prospec-(

4f' tive power plant; and the establishment of i

4,5 a baseline' criteria document.for the. designated plants including the technical' documentation l

and presentation of'the plant design for management review.,

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-Dates:

1978 - 1979 t

Company:

GPU' Service, Corporation j

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Title:

' Component Engineer j

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Responsibilitio,s : -

This position-entailed: the review of design i

specifications _and technical. details of t

products going'into TMI-2, including the I

steam generators, pressurizer, main i

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LDavid G) Slear.-

Professional Qualifications Page '.Three -

condensors, cooling towers, reactor vessel, and internals; _ technical consultation and analysis of problems; and review of the contractor's design work on new components going into a plant.

UNITED STATES NAVY -NUCLEAR SUBMAr(INE FORCE OFFICER

Title:

Engineer Officer Responsibilities :

This1 position entailed: essentially primary responsibility and control of the 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 superv'ision of 15 crewmen. _ Mr. Slear also served as an Auxiliary Division Officer in charge of non-nuclear life suppor.t systems, and as a Communications Division Officer.

Dates:-

1968 - 1972 Mr. Slear also attended the Nuclear Power Submarine School from 1966 - 1968, during which time he obtained one year of nuclear power plant training (6 months classroom, 6 months actual plant 4

training) in addition to the submarine qualification program.

EDUCATION College:

University of Oklahoma Degree:

B.S. Mechanical Engineering Dates :

1961 - 1966 College Stevens Institute of Technology Degree :

M.S. Mechanical Engineering 4

Dates:

1974

.1978 t