ML20092N726

Testimony of DE Lee,Dk Croneberger & DG Slear on Issue 5 (Contention 1.b) Re Repair Process for Tube Ruptures. Certificate of Svc & Prof Qualifications Encl.Related Correspondence

ML20092N726
Person / Time
Site:	Crane
Issue date:	06/29/1984
From:	Croneberger D, 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 8407030485
Download: ML20092N726 (18)

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UNITED STATES'OF AMERICA pg NUCLEAR REGULATORY COMMISSION 4{ y w:..

NO 77 Before The' Atomic Safety And Licensing BESrd" In the~ Matter of

)

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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 DOUGLAS E.

LEE, DON K. CRONEBERGER AND DAVID G.

SLEAR ON ISSUE 5 (CONTENTION 1.b)

To Mr. Lee:

Q1.

Please. state your name and address, and describe your involvement with the TMI-1 steam generator tube repair.

A2.

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 of the Engineering Department.

This section contained the Mechanical Design Unit that was responsible to design, 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.

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.To Mr.'Croneberger:

I

Q2.

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

A2.

My name is Don K. Croneberger.

I.am employed by GPU Nuclear-Corporation,.100 Interpace Parkway, Parsippany, New-Jersey 07054. :As the-Director of Engineering and. Design, I provided technical management oversignt of the failure analysis 1

and repair activities,.with special emphasis.on evaluation of the-steam generator's mechanical design'and the impact of any

indwelling defects on the response of the components.

My de-partment also provided engineering support.in the areas of Ma-terials/ Engineering / Failure Analysis, Chemical Engineering,.

Mechanical Engineering and Engineering Mechanics.

~

A statement of my professional qualifications is attached.

To Mr. Slears.

Q 3.-

Please state your name and address, and describe your

. involvement with:the TMI-l steam generator tube repair program.

1A3.

My name-is David G.

Slear.

I am employed by GPU Nu-clear' Corporation, 100 Interpace Parkway, Parsippany, New

' Jersey _07054.

..I am the 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-dent of Technical Functions.

My responsibilities included all activities associated with the evaluation and repair of the

-steam' generators.

A; statement of my professional qualifications is attached. L

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To'AllLWit'nesses:

?Q4. LWhat is the; purpose of your testimony?

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7 7A4. 'The purpose of this testimony is to address the issue related to Contention'l.b.as enumerated at page 32 of the

-Board's Memorandum and Order (Rulings on Motions for Summary 3 Disposition,; dated June 1, 1984), in which the Licensing Board

' stated:

....[T]he central-issue is whether the re-pair process has' increased the probability F'

of [ simultaneous tube ruptures involving

,both'TMI-l steam generators).

.QS~.

-Has the. repair process increased the' probability of

. simultaneous tube ruptures involving both steam. generators?

"AS.

No.

The repair process has not increased'the likeli-Ihoodiofitube rupture, and therefore'has not increased the prob-

~

' ability'of'simultanecus tube ruptures involving both steam gen -

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r JIn. developing the repair joint to be used'in the TMI-l ionce-through steam. generator (OTSG) repair program, the primary a

objective ~~was-to' establish'a: system that would not increase the likelihood of tube rupture.

This. objective was met by estab-ilishingithatLtheLrepair joint is"not more susceptible-to tube Lrupture than the original' joint would have been, and1that the repair process has.not. adversely affected the tube in a manner

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that*wouldLincrease'.the. likelihood of tube rupture,

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a The. design basis transients specified for the original' de-

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-sign tube-to-tube sheet joint were specified as. applicable to s

.the-repaired steam generator tube-to-tubesheet joint.

These '

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transients.in temperature and pressure-produce a postulated main steam line break load of 3140 pounds tension.

This is the maximum-design' basis loading of the tube-to-tubesheet joint.

All other normal operating or postulated accident loadings are enveloped by this loading.

The repaired joint'was carefully designed and qualified to carry loads resulting from normal and faulted conditions.

The work performed in the steam generators during the repair pro-

cess was conducted in such a manner that the design and q2ali-fication work was applicable to the actual kinetic expansion repair.

That is, the minimum six-inch length of defect free expansion exists'for all. tubes returned to service.

Moreover, additional margin exists in the steam generators since'most tubes have more than this minimum defect free expansion quali-fication length.

If, nevertheless, one were to postulate " failure" of the kinetic expansion joint, the " failure" would be by slippage L.

under applied axial load, rather than by tube rupture.

This allows the repair joint to remain leak resistant even if loads are' applied which " fail".the joint.

Furthermore, slippage is limited because slipping relieves the applied load..This indi-cates that " failure" of the expanded portion of the tube-to-

.tubesheet joint would not result in a tube rupture.

Thus, the likelihood of tube rupture due to the failure of the tube-to-tubesheet joint is no greater than for the original joint.

1 The kinetic expansion repair produces a new transition zone between the expanded and non-expanded portions of the tube.

.A similar transition zone existed previously at the originaliroll: expansion.

However, the transition for the ki-i netic expansion was carefully developed to be more gradual than that of the original. shop roll expansion.

The residual stresses in the kinetic expansion transition may be slightly higher than those in roll expansions which have experienced the fabrication stress relief heat treatment.

Nonetheless, residu-al stresses and the amount of cold working in the kinetic ex-pansion are both less.than in non-stress-relieved roll expan-sion transitions for which there is a considerable body of satisfactory operating experience in nuclear power plants.

The residual stresces within the transition zone are not a concern from a static or fatigue stress standpoint, but could affect the susceptibility of the material to intergranular stress-assisted cracking (IGSAC).

The resistance of the kinet-

.ic expansion transition zone to IGSAC is demonstrated by op-erating experience of OTSGs containing non-stress-relieved roll expansions,-and by Licensee's accelerated and long-term corro-sion testing.

To date, there have been no failures, by cracking in the transition zone, of tubes with non-stress-relieved roll expan-

,sions in B&W OTSGs in service.

Short-term (accelerated) corro-sion testing, which was performed as part of the TMI-1 qualifi-cation program, showed no evidence of cracking in either.

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4 kinetic orEnon-stress-relieved roll expansion transitions dur-fing the' simulated life of the repair when exposed to a caustic

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' ;(10% NaOH at constant potential) environment.

Thus,sthe' likelihood of tube rupture of the new transition c

-due to either loading or IGSAC is no greater than that for I

, tubes' currently operating in other OTscs.

The' potential effects of the kinetic expansion process on

.the. balance of the. tube'were also carefully evaluated.

The.

only effect warrcnting further analysis was'the change in tube Lproload. LThe kinetic expansion' repair process produces less t

thanla 30-pound decrease in tube preload for normal steam gen-

erator tubes.. A small percentage of the tubes in the steam generators may have lost all preload due-to the IGSAC com-

pletely ' severing the tube in or near the original roll expan-sion'at the; top of the tube.

This allowed the tube to slip down slightly and relieve the existing preload in the tube.

In some cases, vibrations from nearby kinetic expansions may have contributed.totthe slipping process.

-The increase in the com-pressivef oad due to loss of any or all'of the tube preload l

Jwhen.added to the. maximum compressive load (which occurs during

.a normal heat-up transient of 100'F/hr) is less than the com-

-pressive load required to cause contact between adjacent tubes.

Accordingly, there is no increased potential for tube ruptures due to increased wear.

Furthermore, the loss of the tube preload does not increase the likelihood of fatigue failure be-

.cause preload, being a constant load, is not a factor in the ;

= fatigue load range and does not reduce nktural frequency to a

level which would be of concern.

Total loss of tube preload reduces the tube. natural frequency by approximately 15% which

.i.s less than the variation in natural frequency within some individual steam generators.

Another plant with'similar steam generators operates with tube natural frequencies 15% lower than those expected for TMI-1.

Thus, the kinetic expansion repair process does nothing to the balance of the tube to increase the likelihood of tube rup-tures.

Therefore, for the reasons indicated above, the repair process has not increased the' likelihood of tube ruptures, and hence of simultaneous tube ruptures.

~7-

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-PROFESSIONAL QUALIFICATIONS DOUGLAS E. LEE EXPERIENCE v

Babcock & Wilcox company

(Current Assignmentl Manager, Engineering Department -

-Responsible for eng:.neering activities involving system design, performance analysis, component design and structural / stress analysis in support of asw~ 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 technology, develop new products and services and to automate engineering-functions.

Work is managed to be in accordance with customer, regulatory ~and quality assurance requirements.

Managed the efforts-of 250 professionals organized into three sections and ten units.

(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 Jintegrity and for reactor plant materials and chemistry.

Defined and implemented research programs to maintain and 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 professionals in four working units.

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

to provide : competitive, quality-engineered nuclear power plant-and system; level engineering design and analysis' including reliability and risk evaluations. ' Responsibilities included

~

system design requirements and functional design, performance i

and safety analyses,' preparation of appropriate SAR materials, defining and implementing computer code development programs,

-resolving operational. problems and developing operator I

guidelines to safely manage the plant during anticipated Ltransients.

Work was managed to be in accordance with contractual and quality assurance requirements.

Managed the

' efforts of approximately 110 professionals in six working units.

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J1980) Manager, Equipment Engineering Section - Responsible to I

develop, specify,. standardize, license and provide competitive, l

reliable, quality-engineered equipment and equipment related l

services for plant protection,-control, monitoring and display, 7

i for. reactor coolanc system and auxiliary system operation, and 1

for fuel storage activities which comply with contractual I

obligations, satisfy customer needs, meet plant and system performance requirements and meet applicable quality assurance i

requirements.

Managed the efforts of approximately 50 f

i professionals in three working technical units.

l (1978 - 1980) Manager, Fluid Systems Unit - Unit responsible for NSSS auxiliary system design, hardware specification and i

procurement.

Specific systems are makeup, chemical addition, decay heat, emergency safeguard cooling and waste processing.

l Bardware responsibilities include valves, heat exchangers, tanks, domineralizers and filters.

Work was managed in accordance with technical, contractual and quality assurance l

4 requirements.

Directly managed the efforts of 15-20 l

~ professionals.

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I (1978) Associate Project Manager - Responsible for portions of i

the NSSS being supplied to the Power Authority of the State of New York for the Greene County Nuclear Power Plant.

Plant l

design and licensing reached the stage of meeting the requirements for a construction permit.

-(1977 - 1978) Site Coordinator - Temporarily assigned to TMI-2 to organize and coordinate-site efforts to install accelerometers and strain gages in the primary side of a steam generator fer the purpose of measuring tube vibration.

Work-included supervision of craft personnel, planning and

. coordination with customer, site personnel and.Bsw design.

engineering'to complete the installation prior to reactor start-up.

r (1975 - 1977) Associate Proiect Manager, NSSS supplied to Power i

' Authority of the State of New York.

Responsibilities included

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ensuring-that the accessory equipment portion of the B&W scope i

of supply is technically acceptable, delivered on time and l

delivered within the contract budget.

Contract in the detailed i

design phase-requiring frequent, detailed interface with the l

Architect Engineer as well as project direction of engineers in l

- matrix' organization assigned to the contract.

l (1974 - 1975) Generic Project Manager - Responsibilities I

included identifying items with potential risk impact (cost increases) to backlog NSSS contracts and driving these problems i

to a least impact solution, managing selected programs designed j

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.to minimize. cost impacts to backlog contracts, and performing

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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 system design and equipment procurement for reactor support i

fluid systems such.as makeup and decay heat.

Work included l

preparing system descriptions, PSAR material, equipment

-specifications and-obtaining quotations for the Toledo Units 2 i

and.3-(NSS-25 & 26) project as well as providing-support for the Toledo Unit 1-(NSS-14) project.. Achieved the functional l

flevel of Task Engineer in this assignment.

l Division of Naval Reactors, USAEC (1968 - 1973) Engineer in the Refueling Branch - Responsible

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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-development of refueling systems, for planning and following refueling work and for. design and procurement of specialized refueling 1

equipment.

Work with. equipment. ranged from approving initial 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.

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EDUCATION

. University of Virginia, Charlottesville, Virginia f

B.S. degree in Engineering, graduated with distinction in June, l

1968.

Majored in aerospace engineering.

Dean's List,-elected i

to Tau Beta Pi Honorary-engineering fraternity.

Naval Reserve

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Officer's Training Corps scholarship program.

Midshipman Battalion Commander.

Awarded the Commanding Officer's Sword as

-the outstanding midshipman.

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f Lynchburg College, Lynchburg, Virginia Master of Business Administration in May, 1980.

Subject area l

was Management Control.

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MILITARY SERVICE i

Commissioned Ensign, USN in June, 1968 upon graduation from-college.

Assigned duty with the Division of Naval Reactors,

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USAEC, Washington, D.C.

' Earned a certificate from the Bettis j

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'k Reactor Engineering School, Pittsburgh, Pennsy van a in June, l

i 1969.

Promoted to grade of Lieutenant in June, 1971.

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PROFESSIONAL QUALIFICATIONS

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DonIK.lCroneberger;

' Director -LEngineering & Design GPU. Nuclear Corporation-GPU-Experiences Technical responsibility for the: Mechanical, Electrical, Civil / Structural, Chemical,.Radwaste and Materials Engineering support;for-allinuclear generating stations for the GPU Systems.

p 1978 to 1980 was. Manager - Design and later Manager -

c Engineering & Design with GPU Service Corporation.

Directed

. design engineering. activities for all nuclear and fossil power c'

generating _ facilities and modifications assigned to GPUSC.

Other Experiences.

Prior work. experience included a number of positions at Gilbert / Commonwealth,during the period 1963 to 1978.

The last

? position-was Manager Structural Engineering.

It included

,technicaleresponsibility-for structural engineering mechanics fortoll nuclear and fossil _ generating facilities.

Some of the

.other positions included Project Manager for. balance of-plant Estudies for_a liquid metal fast breeder reactor demonstration

plant.

Other positions as Project Structural Engineer included 1

responsibility for technical supervision of_ structural

. engineering and' engineering mechanics for a number of domestic

_ nuclear. power plants.

Earlier experience with the U.S. Navy included engineering and construction of radio taloscope and ancillary experience.

Industry. affiliations have included the.EPRI Steam

~ Generator Owners Group, ASME Section 3 Division 2 (former Chairman) and other industry nuclear standards activities including Nuclear Structures and Plant Design Against Missiles.

-Education and training includes a B.S. degree in Civil Engineering from Pennsylvania State University, 1959.

Other technical' training includes courses at U.C.L.A., M.I.T. and the University.of Michigan.

I'have been involved in the Steam Generator tube failure issue ~from the beginning.

I provided technical management

oversight of failure analysis and repair activities.

Special emphasis was placed'on understanding the mechanical design of the Steam Generators and applying that understanding to the repair program and the understanding of the impact of the repair on the response of the components.

My department provided engineering support in the areas of Materials Engineering / Failure Analysis, Chemical Engineering and Chemistry, Mechanical Engineering and Engineering Mechanics.

o a

PROFESSIONAL QUALIFICATIONS DAVID G. SLEAR

~ WORK EXPERIENCE Company:

GPU Nuclear Corporation

~~

Title:

TMI-1 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 the various modes ~and components of modification available for implementation at TMI-Unit 1.

' Dates:

1983 - Present Company:

GPU Nuclear Corporation Title OTSG Reptir Project Manager Responsibilities:

Management (in conjunction with individual task managers) of all aspects of the OTSG Recovery program at TMI-l including failure anclysis, eddy current testing, corrosion testing, RCS examination, RCS sulfar cleanups, and plant performance analysis.

This pos,4. tion involved direct' management of the 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 of the overall project, and required a broad overview and analysis of the OTSG Recovery program.

In his capacity as OTSG Repair Project Manager, Mr. 31 ear was also called

s David G.LSlear.

i Professional Qualifications.

Page Two upon to deliver numerous presentations concerning project details before the NRC, ACRS, TPR, and the GPU Nuclear Corp.

management.

- Dates December 1981 - November 1983 4

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 Responsibilities:

This position entailed: the review of design specifications and technical details of products going into TMI-2, including the

. steam generators, pressurizer, main

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. David G. Slear9 Professional'Q'u'tilifications

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condensors, co'oling towers, reactor vessel, and internals; technical consultation and analysis of problems;~and review of the contradtor's design work on new domponents going'into a plant. '

UNIT::D STATES ' NAVY NUCLEAR SUBNARINE FORCE OFFICER

Title:

~

Engineer Officer Responsibilities:-

Thisipos'ition 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 1for: all mechanical components of_the primary _and secondary s'ystems of the power plant includ:s ng _the steam generator, j

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 of non-nuclear life support systems, and as a~ Communications Division Officer..

Dates:

1968.- 1972 Mr. Slear also attended the Nuclear Power Submarine School i

from-1966 - 1968, during which time he obtained one year of nuclear l

~

power plant. training (6 s months classroom, 6 months actual plant training)1in 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 Dates:

1974

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$I UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION Before the Atomic Safety and Licensing Board In the' Matter of

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)

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, 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)

)

m CERTIFICATE OF SERVICE I hereby certify that copies of

'(1)

Licensee's_ Testimony of Richard F. Wilson, David G. Slear and Don K. Croneberger on

-Issue'1.a (Contention 1.a) ;-

(2). Licensee's Testimony of Richard F. Wilson,

~ David G.

Slear and F. Scott Giacobbe on Issue 1.b (Contention 1.a) ;

'(3). Licensee's Testimony of Richard F. Wilson, David G. Slear and T. Gary Broughton on Issue 1.c - (Contention _1.a) ;

(4)

Licensee's Testimony of. Don K. Croneberger and F. Scott Giacobbe on Issue 1.d

.(Contention 1.a) ;

(5)

Licensee's Testimony of Douglas E. Lee, Don K. Croneberger and David G. Slear on Issue 2 (Contention 1.a) ;

(6)

Licensee's Testimony of Douglas E. Lee, F. Scott Giacobbe and David G. Slear on Issue 3 (Contention l.a) ;

(7) ~ Licensee's Testimony of Dr. David H. Pai on Issue 4 (Contention 1.a) ; : and

'(8)

Licensee's Testimony of Douglas E. Lee, Don K. Croneberger and David G. Slear on Issue 5 (Contention 1.b) were served upon those persons on the attached Service List, by

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- deposit;in-th'e United States mail, postage prepaid this 29th

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l UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION I

Before'the Atomic Safety and Licensing Board j

t

'In tho' Matter of

)

I

)

METROPOLITAN EDISON COMPANY, ET AL. )

Docket No. 50-289-OLA l

)

ASLSP 83-491-04-OLA l

(Three Mile Island Nuclear

)

(Steam Generator Repair) l Station, Unit No. 1)

)

l I

l SERVICE LIST Sheldon'J. Wolfe Atomic Safety and Licensing Administrative Judge Board Panel Chairman, Atomic Safety and U.S. Nuclear Regulatory Commission!

Licensing Board Washington, D.C.

20555 i

i U.S. Nuclear Regulatory-Commission Docketing and Service Section (3) !

Washington, D.C.

20555 office of the Secretary j

U.S. Nuclear Regulatory Commission!

Dr. David L. Hatrick Washington, D.C.

20555 i

Administrative Judge Atomic Safety and Licensing Board Joanne Doroshow, Esq.

I i

Professor of Nuclear Engineering Louise Bradford University of Arizona Three Mile Island Alert, inc.

l Tucson, Arizona 85271 315 Peffer Street Harrisburg, Pennsylvania 17102 Dr. James C. Lamb, III l

Administrative Judge.

. Atomic Safety and Licensing Board 313 Woodhaven Road l

Chapel Hill, North Carolina 27514 l

Richard J. Rawson, Esq.

Mary E. Wagner, Esq.

j office of Executive Legal Director U.S. Nuclear Regulatory Commission I

Washington, D.C.

20555 Atomic Safety and Licensing Appeal t

Board Panel j

U.S. Nuclear Regulatcry Commission Washington, D.C.

20555 i

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