ML20092N725

Testimony of Dh Pai on Issue 4 (Contention 1.a) Re Use of Kinetic Expansions to Seal HX Tubes.Prof Qualifications Encl.Related Correspondence

ML20092N725
Person / Time
Site:	Crane
Issue date:	06/29/1984
From:	Pai 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 8407030482
Download: ML20092N725 (14)

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. UNITED' STATES OF. AMERICA

' N e-NUCLEAR REGULATORY COMMISSION

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1 ', :Before The Atomic Sath y And Licensing Board g-m s

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Docket No.'SO-289-OLA

- METROPOLITAN". EDISON COMPANY, ET AL'!

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ASLBP 83-491-04-OLA m

[(Three Milh 'I;slanci'Nuclea[

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(Steam Generator Repair)

Station,1 Unit.No.

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- LICENSEE' S TESk'IMONY -OF. Tid. DAVID H.

PAI ON ISSd5-4'(CONTENTION 1.a) s Q1..Pleasefstate,your nam'e'and address, and describe your involvement?with-the TMI-1 steam generator tt.Le repair program.

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My name is Dr. David H. Pai.

'I am employed by E'oster

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Wheeler Developm.ent ' Corporation, 12 Peach Tree Hill Road, Liv-i c ;

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I ingston,.New Jersey 07039.

As Senior Vice President'of-the En-s gineering'and Services division of Foster Wheeler Energy Appli-NN cations, Inc.-

the-business unit responsible for nuclear energy related activities at Foster, Wheeler,.I had overall responsi-

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bility for thed inetic expansion proces's, qualification and

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on-site applicition of the kinetic' expansion pre.

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'in'the TMI-l. steam. generator repai~r p,rc:gry is statement ~ of'my profession,al qualifi. atio.. is attached.

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B407030482 840629

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'PDR ADOCK 05000289 s

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-What is the purpose of.your testimo.ny?

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,My testimony is intended to address Issue 4 of Con-

[tention 1. alas enumerated at page 23 of the Board's Memorandum

andLOrder (Rulings on-Motions for-Summary Disposition, dated JJune 1, 1984), in.which the Licensing Board stated:

4.

- Recalling Licensee's statement in 1 6-8 thatLthe use of kinetic expansions to seal heat

exchanger tubes within tubesheets has a broad base of successful experience, information is

_ requested about whether tube integrity during

- subsequent' operation depends on whether the pro-

' cess.is a repair,-or a manufacturing process using:new materials.

Q3'. ~ Doesithe integrity of tubes sealed with the kinetic expansion repair process depend on whether the process is a re-pair, or aLmanufacturing process-using new materials?

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No.

The seal is effective for kinetic expansions,

. hether performed as.a field repair or as'part of the original w

fabricatidn.

The industry, and Foster Wheeler in particular, 1

.have considerable experience with this process in b'oth situa-

<tions.

The kinetic expansion process used for the TMI-l OTSG re-pair was developed by Foster Wheeler over 20 years ago.

Foster

~ Wheeler is aware.of the employment of_similar processes in the L

. manufacture of steam generators by Combustion Engineering,.and hin~ selective field applications-by-Westinghouse and Babcock &

Wilcox.

The Foster Wheeler process utilizes a controlled amount of explosive, generally a primacord containing the ex-1 plosive PETN-(pentaerythritoltetranitrate) to impart the neces-sary energy to expand tubes.

A plastic insert encapsulating Q

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Ethe primacord is used to. transmit this energy and attenuate the

shock waves. 'The.use of this plastic material also enhances Tourzability'to accommodate dimensional tolerance between the

< tube and the tube hole.

For a power station (nuclear or fossil), there are differ-ent kinds of heat-exchangers (e.g.,

feedwater heaters, moisture separator reheaters, etc.), most of which.are of the shell-and

tube '. type.

The TMI-I once-through steam generators (OTSG) is but one: type of shell'and tube' heat exchanger and it shares all the-relevant common characteristics with other. heat exchangers, s

e.g.,Esmall diameter,= thin-walled tubes. attached to tubesheets and containment ofLthe tube bundle in a shell which forms the

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component pressure boundary. -Heat transfer takes place between

th'e'shell' side'and tube side fluids through the tubewalls, gen-erally at'certain pressure and. temperature differentials be-

-tween.the two. fluids, depending.on the functional 1 requirements cHE the system.-

-Initially,.the kinetic expansion process was used to sup-port 1our shop fabrication.

We'have. expanded _some 5,000,000

' tubes to date.

In' fact, since 1967, we have. adopted ~the kinet-Sn ic: expansion process as the primary means of the tube expansion for high pressure feedwater heaters.

z Since the mid-seventies, the kinetic expansion process also has'been applied'-routinely to field repairs.

The various repair methods include:

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Expansion'of tubes below the tube-to-tube-sheet weld region to effect a new joint

'similar to what was done on the TMI-1 c

.OTSGs.

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Expansionof new tubes into an existing tubesheet as.part of a tube bundle replace-

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. ment.

3): : Expansion of sleeves into existing heat ex-changer; tubes to prevent erosion-corrosion

-~of the tubeside inlet regions.

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Tube plugging using the Detnaplug* pro-

-cess.

This process kinetically expands a serrated plug into the inside diameter to t

form a mechanical seal.

LAlliof..the above. methods of repair utilize the kinetic forming pr'inciple.

A partial. listing of the various Foster

. Wheeler field repair jobs is attached (Table 1).

The tubing sizes,tas.well as most of the tubing and tubesheet materials, are similar.to those in the OTSGs.

In addition, the operating

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. temperatures and pressures.of repaired' equipment bracket the

.OTSG conditions. ' Table 2 is a partial. listing of field sleeving programs, mostly for high pressure feedwater heaters.

The sleeves are made of austenitic material.- These high pres-F

'sure feedwater. heaters operate in the range of 3,000 to 5,000 psi.

Table-3 is a partial listing of-facilities where we have applied our Detnaplug* process to heat exchangers of various kinds.

'Again, the tubing sizes are similar to those in the

'OTSG and the1 pressures involved range from about 1,000 to over 5,000. psi.

When the TMI-l OTSG tubing problem surfaced, it was readi-ly apparent that our experience base in kinetic expansion 6

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ebrackets the' material'and geometry parameters of TMI-1 units Iand-the process would be uniquely suited to solve the problem.

The integrity of kinetically expanded joints depends pri-

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i marily on key material:and geometric parameters in the kinetic-expansion. process, irrespective of whether the process is ap-plied to new equipment during fabrication or to the repair of

-existing equipment.

These key parameters are:

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.The tube-to-tubesheet material properties (yield strength, ductility) should be l

checked to assure that their relative val-I ues are'in a range consistent with Foster Wheeler's experience, i.e.,

the; tube mate-

rial yield strength should be less-than that of the tubesheet material to assure proper tube-to-tubesheet interference and

'the. tube material should be sufficiently ductile to accommodate the kinetic expan-

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sion-strains without tube damage.

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The annular. gap between the tube and the tubesheet should be free of condensates since the incompressibility of any signifi-cant. amount of liquid substance may hinder the kinetic expansion process.

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In~kinetically expanding tubes in standard heat exchanger iequipment, for new construction sr-repair, Foster. Wheeler fol-lowsLthe above guidelines in a routine manner.

The excellent

-service record for these units confirms the long-term reliability of the process.

To date, we have enjoyed overwhelming success in that the only_' feedback we have received from the utilities and chemical process plants where we have applied these methods'has-been favorable.

No organization has come back to us with any complaints on.the reliability of the process.. '

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-In some. situations, such as the TMI-1-tube repair program, more' stringent and exacting requirements are imposed.

In the TMI-liOTSG, the tube and tubesheet geometries and materials were within the range of geometries and materials we dealt with

' in the past.. However, because of the very high reliability

- goals specified,.the following steps were taken to ensure that the kinetically expanded tubes and tube joints satisfy the de-

' sign requirement in as-built and in service conditions:

1).

A qualification program was performed using tubes obtained from the manufacturer's (Babcock & Wilcox) archives.

The yield strengths of the tubes used in the program covered the entire range of tube. yield strengths in the TMI-1 Steam Generators.

The test tubesheets-in the qualification program were fabricated from tubesheet ma-terial for which the material properties, fabrication methods and heat treatment were identical to-those used for the TMI-1 OTSG.

2)

.The original TMI-1 construction included a transition between the roller expanded and unexpanded portions of the tubes about 1-1/4 inch below the upper tubesheet.

The ends' of the kinetic expar.sion inserts used in the repair were optimized such that the new kinetic expansion. transition below is more gradual in-order to minimize residual c

stresses.

3)

Tube samples removed from TMI-1 steam gen-erators showed that'only a very thin oxide layer.was present on the tube outer surface and tubesheet hole.

The tubes and tubesheets used in the qualification pro-gram duplicated this oxide film.

To assure that no moisture existed between the tube and tubesheet, the on-site repair procedure provided for drying of the crevice and in-troduction of a dry nitrogen blanket to as-sure a continued moisture-free crevice..

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.s The repair.of the TMI-l OTSG tubes was accomplished.with smore than:the usual care.

Stringent. nuclear quality assurance procedures were-followed, both with respect to the qualifica-

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7 tion program, as well as the procurement and use of-the explo-isive inserts on-site.

Important issues, such as pull-out load Jand-qualification program-leak rate measurement accuracy and

reliability,

chemical composition of. insert material and the c

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.traceabi11ty'of all components. going into the making of the in-

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sertfassembly,.were fully dc:umented.

The excellent results of the: pull-out and leak rate-tests conducted after simulated ser-vice conditions, further verified the soundness of the process application.

The extrapolation of.this data to actual service gives us high confidence-in the operating reliability of the crepaired tubes.

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q-TABLE.1

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Y PARTIAL LISTING OF TUBE BUNDLE

-REPAIRS USING DETNAFORM5 r

-Number of Tube Tube Tube Tube Sheet

.Date Customer Ends Size-Material ~

Material T1967 PSE&G 2,200-3/4" 304 SS Carbon Steel-1976' -Detroit Edison 542 5/8" 304 SS Carbon Steel 1977 Montana ~ Power 2,380 3/4" 70/30 CuNi Carbon Steel 1977- ; Montana Power 3,644 5/8" 70/30 CuNi Carbon Steel

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1979; PSE&G 8,832 3/4" 90/10 CuNi Carbon Steel 1980"-

TVA 2,124 5/8" 304 SS Carbon Steel 1980 TVA-2,124 5/8" 304 SS Carbon Steel

19811 TVA

'1,892 5/8" 304 SS Carbon Steel

1981 TVA 1,598 5/8" 304 SS Carbon-Steel p

_1981 Detroit Edison 2,280-3/4" 304 SS Carbon Steel 1981 TVA 4,248 5/8" 304 SS Carbon Steel 1981 TVA-1,600 5/8."

304 SS Carbon Steel 1981-TVA-3,200 5/8" 304 GS Carbon Steel

.1982 Dairylan'd 2,510-5/8" Carbon Steel Carbon Steel 1982-TVA 12,344 5/8" 304 SS Carbon Steel 1984' TVA 3,086 5/8" 304 SS Carbon Steel

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TABLE 2 FIELD INSTALLATION EXPERIENCE STAINLESS STEEL SLEEVES No. of ClientI

' Station Sleeves Detroit. Edison Company Connors Creek P.P.

1,064 Detroit Edison Company Connors Creek P.P.

635 Pennsylvania ~ Electric. Company Keystone Station 10,740

Pennsylvania Electric Company Conemaugh Station 7,482 Detroit. Edison ~ Company Monroe Power Pland 1,100

.DetroitJEdison' Company Monroe Power Plant 1,100

Detroit Edison Company-Monroe Power Plant 1,100

, Detroit. Edison Company Monroe Power' Plant 1,100 gr Detroit Edison. Company.

Monroe Power Plant 1,100 Houston Lighting & Power Company P.H.. Robinson Station 3,000

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Cedar Bayou Station 3,800 1 Houston' Lighting &-Power Company.

Lower Colorado River Authority-Thomas C.

Ferguson Plant-1,050

' Foster Wheeler' Limited Saskatchewan Power Corp.

440 Houston : Lighting & Power Company

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Parish Station 2,963 Nova Scotia Power Corporation Point Tupper ?lant 400 c

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DETNAPLUG. USERS. LIST Y

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' Customer Station

-GeorgiaIPower, Company Plant Harlee Branch

-Cleveland Electric Illuminating Co.

-Avon Lake Station Public: Service Co.-.of.New p

Merrimack Station Hampshire Oklahoma'Cas & Electric Company Muskogee Station ct Kansas City Power & Light Co.

Itan Station Pacific: Power & Light Co.

Centralia Station i-

, Boston Edison Company New Station 400 a-t.

Jer LLower Colorado River Authority Fayette Power Project

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-Cincinnati ~ Gas & Electric Co.

East Bend Station Central-Louisiana Electric Co.

Rodemacher Station

.Pittsburgh Plate Glass Industries Lake Charles, LA f-Mississippi' Power & Light Co.

Baxter Wilson SES

.GECB England Tilbury Plant i

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PROFESSIONAL QUALIFICATIONS DR. DAVID H. PAI Senior Vice President, Foster Wheeler Development Corporation

. Education Bl. S. in C.E.

Virginia Military Institute - 1958 M.S. in C.E.

-Lehigh University - 1960 LSc.D.

New York University - 1965 Experience 1984 -

Senior Vice President responsible for the R&D and Contract Operations Divisions and for the Core Research Group.

1980 - 1984 Vice President and Director of Engineering, FW Energy Applications, Inc.

Responsible for.all proposal,1 project,'and development engineering.

Major programs included:

design and analysis'of components and systems for. Liquid-Metal Fast Breeder Reactor.(LMFBR) and Light Water Reactor plants and design and development of advanced

-energy systems, including solar steam generators, ocean thermal-energy conversion, and coal gasifi-cation.

1973'- 1980 Chief Engineer, Nuclear and Special. Products Department, Equipment Division.

Responsible for thermal, structural, mechanical design, and. mater-ials aspects of engineering of Nuclear and Special Products.

'1968 - 1973-Senior Research Associate and Assistant Head, Solid Mechanics Department, Research Division.

Structural

' consultant advising commercial divisions on thermal shock, thermal stress, creep, and fatigue.

Specific s

cc assignments included lead responsibility in struc-tural analysis and development for the Fast Flux Text Facility (FFTF) Intermediate Heat Exchanger (IHX); LMFBR Low-Capacity IHX Conceptual Design Studies supporting FFTP development;-and LMFBR IHX Research and Development, Program Definition Phase.

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.9-Page Two Also consultant to Equipment Division on structural problems involved in the design of a sodium-heated steam generator for a breeder reactor program.

1965 --1967 Research Associate and Head, Analysis Section, Solid Mechanics Department.

Responsible for supervising a number of engineers and technicians in carrying out basic studies in thermal stresses, creep, plasticity, stress concentration, low-cycle fatigue, and high-pressure forming.

Also advised other departments in the Corporation on structural mechanics problems.

1964-- 1965 Senior Engineer,.Research Division.

Performed basic studies in creep, creep rupture, and plasti-city, including analyses of various structural components.

- 1960 - 1964 Development Engineer, Research Division.

Performed analytical and experimental stress analysis of steam-generating equipment, including pressure vessels, naval nuclear steam generators, and other power and_ chemical plant equipment.

Experimental methods included strain gages, brittle coating, and photo-stress techniques.

Analytical tools in-cluded the use of digital computers.

Also performed experiments on low-cycle fatigue on full-size vessels.

1958 - 1960 Lehigh University.

Research and Teaching Assistant, Fritz Laboratory, Department of Civil Engineering.

Tested structural components for industry-supported projects., Taught fresnman engineering.

Other Author or coauthor of 25 papers.

Holds four patents.

Member, ASME, American Society of Civil Engineering, and Fritz Engine-ering and Research Society, Chairman (1970-1973), Design and Analysis Committee and Member (1973-1978), Executive Committee of Pressure Vessels and Piping Division of ASME.

Member, Executive Committee of Chinese Institute of Engineers Vice President (1972-1973).

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't PROFESSIONAL

SUMMARY

Dr. Pai joined Foster Wheeler's Research Division in 1960 as leader of the Methods Development Group supporting the Cor-poration's entry into the advanced nuclear reactor component market.

In 1973 he was appointed Chief Engineer of Foster Wheeler's Nuclear Department which later became FW Energy Applications, Inc.

He held increasingly important.pesitions in that organization and was re-sponsible.for the engineering of the major components designed and fabricated by Foster Wheeler for the U.S. Liquid Metal Fast Breeder Reactor.and High Temperature Gas-Cooled Reactor Programs.

More recently, he headed the successful effort in applying the Foster Wheeler Detnaform TM process to the repair of steam generator tubes at the Three Mile Island Unit #1.

A 1958 graduate of Virginia Military Institute, Dr. Pai re-ceived an M.S. degree from Lehigh University in 1960 and his Doctorate in 1965 from New York University.

He is active in the American Society of Mechanical Engineers, having served as Chairman of the ASME Pressure Vessels and Piping Division.

He was elected a Fellow of the ASME in 1980 and has served as~a Vice President (Materials & Structures) of the ASME.

Dr. Pai is a member of the Engineering Technology Advisory Committee to the Board of-Trustees of the New Jersey Institute of Technology, as well as a member of the University of Chicago /Argonne National Laboratory Review Committee on Experimental Breeder Reactor II.

He also serves as a consultant to the U.S. Department of Energy c.

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., on the Steering Committee for the Liquid Metal Fast Breeder Reactor Structural Design Technology Program at the Oak Ridge National Laboratory.

He is a member of the American Society of

- Civil Engineers and the Chinese Institute of Engineers.

He has written over 30 technical articles, edited two books, and holds

.several domestic patents.

Foster Wheeler Corporation is an international engineering, manufacturing and construction organization with 26 subsidiaries operating worldwide.

Its major U.

S. operating subsidiary, Foster Wheeler Energy Corporation, designs, fabricates and constructs steam generating equipment, process plants and fired heaters-for electric utilities, shipbuilders, petroleum refiners and chemical

. producers.

Foster Wheeler Development Corporation provides research services for both the parent organization and outside clients.

The corporations are headquartered in Livingston, N. J.

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