ML20094S198

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Bge Calvert Cliffs Station Units 1 & 2 SG Tube Repair Using Leak Tight Sleeves
ML20094S198
Person / Time
Site: Calvert Cliffs  Constellation icon.png
Issue date: 09/30/1995
From:
ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY
To:
Shared Package
ML19317C161 List:
References
CEN-626-NP, CEN-626-NP-R, CEN-626-NP-R00, NUDOCS 9512060061
Download: ML20094S198 (172)
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{{#Wiki_filter:i CEN-626-NP Rev.00 COMBUSTION ENGINEERING, INC. i September,1995 Balthnore Gas and Electric Calver Cliffs Station i Units I and 2 l Steam Generator Tube Repair Udne Isak Tleht Sleeves FINAL REPORT I l I l Combustion Engineering, Inc. Nuclear Operations Windsor, Connecticut -3=

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~ LEGAL NOTICE THIS REPORT WAS PREPARED AS AN ACCOUNT OF WORK SPONSORED BY ABB COMBUSTION ENGINEERING. NEITHER ABB COMBUSTION ENGINEERING NOR ANY PERSON ACTING ONITS BEHALF: A. MAKES ANY WARRANTY OR REPRESENTATION, EXPRESS OR f IMPLIED INCLUDING THE WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, WITH RESPECT TO THE ACCURACY, COMPLETENESS, OR USEFULNESS OF THE INFORMATION CONTAINED IN THIS REPORT, OR THAT THE USE OF ANY INFORMATION, APPARATUS, METHOD, OR PROCESS DISCLOSED IN THIS REPORT MAY NOT INFRINGE PRIVATELY OWNED RIGHTS; OR B. ASSUMES ANY LIABILITIES WITH RESPECT TO THE USE OR FOR DAMAGES RESULTING FROM THE USE OF, ANY INFORMATION, APPARATUS, METHOD OR PROCESS DISCLOSED IN THIS REPORT. h l h

ABSTRACT A technique is presented for repairing degraded steam generator tubes in pressurized water reactor Nuclear Steam Supply Systems (NSSS). The technique described alleviates the need for plugging steam generator tubes which have become corroded or are otherwise considered to have lost structural capability. The technique consists of installing a thermally treated Alloy 690 sleeve which spans the section or sections of the original steam generator tube which requires repair. The sleeve is welded to the tube near each end of the sleeve for repairs at the tube support plates or welded at the upper end and hard rolled within the tube sheet for repairs to the steam generator tube at the top of the tube sheet. This report details analyses and testing performed to verify the adequacy of repair sleeves for installation in a nuclear steam generator tube. These verifications show tube sleeving to be an acceptable repair technique. 1 i 4 I 4 f r I ? [ O

TABLE OF CONTENTS Section Ihk East 1.0. INTRODUCTION 1 1.I' ' PURPOSE 1.

1.2 BACKGROUND

1-2 2.0'

SUMMARY

ANDEONCLUSION.S. 2-1 3.0 ACCEPTANCE CRITERIA 3-1 4.0. DESIGN DESCRIPTION OF STWVES AND INSTAT T ATION ^ EOUIPMENT 4-1 - 4.1 ' SLEEVE DESIGN DESCRIPTION 4-1 4.2 SLEEVE MATERIAL SELECTION 4-1 4.2.1 Field Service Performance 4-2 4.3 SLEEVE-TUBE ASSEMBLY 4-2 4.4 PLUGGING OF A DEFECTIVE SLEEVED TUBE 4-3 4.5 SLEEVE INSTALLATION EQUIPMENT 4-3 t 4.5.1 . Eemote controlled Manioulator 4-4 4.5.2 Tm! Delivery Eauipment 4-5 ^ 4.5.3 ' Inte Brushine - Cleanine Equipment 4-5 7 4.5.4 Ipte Size Rolline Equipment 4-6 4.5.5 Sleeve Expamion Equinment 4-6 i f 4.5.6 Sleeve Weldine Eauinment 4-7 ~4.5.7 - Nondestmetive Examination 4-7 i [ i .. _-. ; u -. _. _ _ _

TABLE OF CONTENTS (Continued) Section Title Eagt 4.5.8 . Post-Weld Heat Treatment Equioment 4-8 4.5.9 Sjeeve Rollina Equioment 4-8 4.6 ALARA CONSIDERATIONS 4-9

4.7 REFERENCES

TESECTION 4.0 '4-10 5.0 SLEEVE EXAMINATION PROGRAM .5-1 1 5.1 ULTRASONIC INSPECTION 5-1 5.1.1 Summary and Conclusions 5-1 5.1.2 Ultrasonic Evaluation 5-1 5.1.3 Test Equipment 5-2 5.1.4 Defect Samples 5-3 5.1.5 Detailed Results 5-3 5.2 EDDY CURRENT INSPECTION 5-5 5.2.1

Background

5-5 5.2.2 Sleeved Tube Samoles For Oualification Testine 5-6 5.2.3 New Advanced "+" Point Probe For Sleeve Insoection 5-7 5.2.4 Motorized Rotatine Axial Differential Probe 5-9 5.2.5 I-Coil Rotatine Pmbe 5-11 5.2.6 Motorized Rotatine Pancake Coil (MRPC) Probe 5-12 5.2.7 Apoendix H Oualification 5-12 i

-c-TABLE OF CONTENTS (Continued) i Section Tius East-5.2.8 Conclusions 5-12 5.3 - VISUALINSPECTION-5-13 5.3.1. Summary and Conchnions 5-13 5.3.2 '. Weld Examination'~ 5-14 l5.3.3 Test Equipment 5-14 i ,5.3.4 Defect Standards ' 5-15 6.0 ST WVE-TUBE CORROSION TEST PROGRAM 6-1 6.1

SUMMARY

AND CONCLUSIONS 6

  • 6.2 TEST DESCRIFHON AND RESULTS 6-1 6.2.1 Primary Side Tests 6-1 6.2.1.1

. Pure Water Stress Corrosion Cracking Tests 6-3 6.2.1.2 Above the Tubesheet (ATS) Weld Caosule Tests 6-3 6.2.1.3 ECS Sleeve Weld Cansule Tests 6-4 6.2.1.4 Summarv - Primary Coolant Corrosion Performance 6-5 6.2.2 secondary Side Tests 6-9 i 6.2.2.1 Modified Huev Tests 6-9 6.2.2.2 Capsule Tests 6-9 6.2.2.3 Sodium Hydroxide Fault Autoclave Tests 6-10 6.2.2.4 Summarv -Secondary Coolant Corrosion Performance - 6-11 6.3 RFF2JiNCES FOR SECTION 6.0 6-12 E

TABLE OF CONTENTS (Continued) Section Tills Eage 7.0 MECHANICAL TESTS OF SLEEVED STEAM GENERATOR 7-1 TUBES 7.1

SUMMARY

AND CONCLUSIONS 7-1 e 7.2 CONDITIONS TESTED 7 - 7.3 WELDED SLEEVE TEST PARAMETERS AND RESULTS 7-1 7.3.1 Axial Pull Tests ,7-1 7.3.2 Collapse Testine 7-2 7.3.3 Burst Testine 7-3 7.3.4 Load Cveline Tests 7-3 8.0 flTRUCTURAL ANALYSIS OF SLEEVE-TUBE ASSEMBLY 8-1 8.1

SUMMARY

AND CONCLUSIONS 8-1 8.1.1 Design Sizing 8-1 8.1.2 Detailed Analysis Summary 8-1 8.2 LOADINGS CONSIDERED 8-6 8.2.1 Unoer Tube Weld Pull-Out Load 8-6 8.2.2 lower Sleeve Rolled Section Push-Out Load 8-6 8.2.3 Weld Fatirne 8-7 8.3 EVALUATION FOR ALI OWABLE SLEEVE WALL 8-7 DEGRADATION USING 1 EGULATORY GUIDE 1.121 8.3.1 Nonnal Ooeration Safety Marrins 8-7 8.3.2 Fostulated Pine Rupture Accidents 8-8 IV 9

TABLE OF CONTENTS (Continued) 1 i Section Iitic y;ge 8.4 EFFECTS OF TUBE LOCK-UP ON SLEEVE LOADING 8-10 ) 8.4.1 Sleeved Tube. Free at Tube Sunoort Plate 8-10 8.4.2 Sleeved Tube. Iack-no at First Tube Suonort 8-15 Effect of Tube PreEt'ess Prior to Sleevine 8-16 8.4.3 r 8.4.4 Lower Sleeve Rolled Section Push-Out Due tg 8-16 Restrained Thermal Exoansion 8.5-SLEEVED TUBE VIBRATION CONSIDERATIONS 8-17 8.5.1 Effects ofIncreased Stiffness 8-17 8.5.2 Effect of Severed Tube 8-17 8.5.3 Seismic Evaluation 8-19 8.6 STRUCTURAL ANALYSIS FOR NORMAL OPERATION 8-21 8.6.1 Fatigue Evaluation of Upoer Sleeve / Tube Weld 8-21 8.6.2 Fatigue Evaluation of Lower Sleeve Rolled Section 8-22

8.7 REFERENCES

FOR SECTION 8.0 8-25 8A FATIGUE EVALUATION OF UPPER TUBE / SLEEVE WELD 8A-1 9.0 SLEEVE INSTALLATION VERIFICATION 9-1 9.1 WELD INTEGRITY 9-1 9.1.1 Cleanine Oualification 9-1 i 9.1.2-Expansion Oualification 9-1 l 9.1.3~ Weld Oualification 9-2 4 V I

) TABTR OF CONTENTS (Continued) Section ,Iitig Eagg 7 9.1.4 - Ultrasonic Testine Onnlification 9-3 l 9.1.5 Post Weld Heat Treat Onnlification 9-3 9.1.6 Summarv 9-5 9.2 ROT.Trn JOINTiNTEGRITY 9-5 9.3 COMMERCIAL SLEEVE INSTALLATION 9-5 ~

9.4 REFERENCES

FOR SECTION 9.0 9-6 10.0 EFFECT OF SLEEVING ON OPERATION 10-1 i [ P VI l

IlST OF TABLES TABT R NO. TABLE PAGE 2-1

INSTALLATIONS OF ABB-CE'S WELDED SLEEVE 3

'3-1 REPAIR SLEEVING CRITERIA 3-2 6-1 STEAM GENERATOR TUBE SLEEVE CORROSION TESTS 6-2 6-2 ABB-CENO ACCELERATED PRIMARY SIDE SCC TESTS 6-5 6-3 ENSA ACCELERATED PRIMARY SIDE SCC TESTS 6-5 6-4 - LOCAL SLEEVFJTUBE JOINT APPLIED STRESSES 6-6 6-5 AXIAL STRESSES IN TUBE AT SLEEVE JOINT 6-8 6 SECONDARY SIDE STEAM GENERATOR TUBE SLEEVE 6-10 CAPSULE TESTS 7-1 SLEEVE-TUBE ASSEMBLY MECHANICAL -11:snNG 7-5 RESULTS 8-1

SUMMARY

OF WELD ANALYSIS RESULTS 8-3 8-2

SUMMARY

OF ROLLED JOINT DESIGN, ANALYSIS AND 8-5 TEST RESULTS 8-3 20 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES 8-12 8-4 AXIAL LOADS IN SLEEVE WITH TUBE HGT LOCKED 8-13 INTO SUPPORT PLATE 8-5 AXIAL LOADS IN SLEEVE WITH TUBE LOCKED INTO 8-14 SUPPORT PLATE .8-6 UPPER SLEEVE WELD TRANSIENTS CONSIDERED,,... 8-23 8-7 LOWER SLEEVE ROLLED SECTION TRANSIENTS 8-24 CONSIDERED Vii 4 4

~ ~ P T MT OF TABLES (Continued) i TABLE NO. TABLE PAGE 8A-1A STRESS RESULTS,100% STEADY STATE AXIAL LOAD 8A-3 [ 8A-1B STRESS RESULTS,' 15% STEADY STATE AXIAL LOAD 8A-5 8A-IC STRESS RESULTS,,0% STEADY STATE AXIAL LOAD 8A-7 8A FATIGUE EVALUATION 8A-9 9-1 0.875 O.D. SLEEVED TUBE PWHT DATA ,9-7 ) 9-2 0.750 O.D. SLEEVED TUBE PWHT DATA 9-8 9-3 COMMERCIAL SLEEVING EXPERIENCE 9-9 ~9-4 ABB-CENO S/G SLEEVE OPERATING HISTORY 9-11 i 10-1 HYDRAULIC EQUIVALENCE RATIOS 10-4 g T 9 t J P Viii a

LIST OF FIGURES HGURE NO. TITLE PAfzE 4-1 EXPANSION TRANSITION ZONE SLEEVE 4-11 4-2 EGG CRATE SUPPORT SLEEVE 4-12 4-3 EXPANSION TRANSITION ZONE SLEEVE INSTALLATION 4-13 4-4 EGG CRATE SUPIORT SLEEVEINSTALLATION 4-14 4-5 MANIPULATOR AND TOOL DELIVERY SYSTEM 4-15 4-6 TOOL DELIVERY EQUIPMENT 4-16 4-7 TUBE CLEANING EQUIPMENT 4-17 4-8 SLEEVE EXPANSION EQUIPMENT 4-18 4-9 SLEEVE WELDING HEAD ASSEMBLY 4-19 4-10 SLEEVE WELDING HEAD POWER SUPPLY UNIT 4-20 4-11 ULTRASONIC TEST EQUIPMENT 4-21 4-12 VISUAL TEST EQUIPMENT 4-22 4-13 POST WELD HEAT TREAT EQUIPMENT 4-23 4-14 SLEEVE ROLLING EQUIPAENT - STRAIGHT 4-24 4-15 SLEEVE ROLLING EQUIPAENT - CURVED 4-25 4-16 EDDY CURRENT TEST EQUIPMENT 4-26 5-1 ULTRASONIC PROBE WITHIN A WELDED SLEEVED TUBE 5-16 5-2 ULTRASONIC INSTRUhENT CRT RESPONSE 5-17 5-3 REFERENCE STANDARD FOR 3/4" TUBE 5-18 ix

l l IlST OF FIGURES (Continued) -i FIGURE NO. TITLE PAGE j ? 5. SPECIMEN QUA-5: - ACCEPTABLE WELD 5-19 l 5-5. REFERENCE STANDARD 5-20 .t 5-6 SPECIMEN QUA-11: RETECTED WELD 5-21 j 5-7 SPECIMEN QUA-I'4: RETECTED WELD 5-22 5 SPECIMEN QUA-13: RETECTED WELD 5-23 5 PRESSURE BOUNDARY DESCRIFI1ON AND SAMPLE FLAW 5-24 LOCATION l 5-10 PRESSURE BOUNDARY DESCRIPTION AND SAMPLE FLAW 5-25 LOCATION 5-11 FLAW SAMPLE FOR LARGE SLEEVE TO STEAM GENERATOR 5-26 TUBE ANNULUS -{ 5 RESPONSE AT 50 kHZ - NEW ADVANCED ROTATING 5-27 'I PROBE i i .5-13 C-SCAN CONTOUR PLOT WITH A TUBE FLAW 5-28 5-14 40% ASME FLAW THROUGH AIR GAP 5-29 l 5-15 RESPONSE TO EDM NOTCHES 5-30 l 5-16 TYPICAL MOTORIZED AXIAL DIFFERENTIAL PROBE 5-31 I } t i I X I 4 I e

I i i LIST OF FIGURES (Continued) i FIGURE NO. TITLE PAGE 5-17 40% FLAW THROUGH AIR GAP 5-32 5-18 40% FLAW IN EXPANSION TRANSITION 5-33 5-19 RESPONSE TO EDM NOTCHES 5-34 5-20 40% ASME FLAW THROUGH AIR GAP - I-COIL PROBE 5-35 i 5-21 40% ASME FLAW IN EXPANSION TRANSITION, I-COIL PROBE, 5-36 5-22 RESPONSE TO EDM NOTCHES, I-COIL PROBE 5-37 6-1 PURE WATER CORROSION TEST SPECBIEN 6-13 6-2 ATS WELD CAPSULE TEST SPECBIEN 6-14 6-3 ECS WELD CAPSULE TEST SPECIMEN 6-15 6-4 CAUSTIC CORROSION AUTOCLAVE TEST SPECIMEN 6-16 8-1 WELDED SLEEVFJTUBE ASS 13fBLY 8-26 8-2 SYSTEM SCHEMATIC 8-27 8-3 MODEL OF SLEEVE AND LOWER TUBE 8-28 8-4 MODEL OF UPPER TUBE 8-29 8-5 FINITE ELEMENT MODEL OF UPPER TUBE WELD 8-30 8A-1 UPPER SLEEVE / TUBE WELD MODEL 8A-2 k

p LIST OF FIGURES (Continued) FIGURE NO. TITLE PAGE 9-1 POST HEAT TREAT-BRUSHED SECTION 9-12 9-2 0.875 O.D. LOCKED TUBE TEST 9-13 9-3 0.875 O.D. LOCKED TUBE TEST 9-14 TEMPERATURE d'ND AXIAL LOAD PROFILE 9-4 0.750 0.D. LOCKED TUBE MOCKUP 9-15 9-5 0.750 O.D. TYPICAL TEMPERATURE PROFILE 9-16 10-1 PERCENT REDUCTION IN PRIMARY SYSTEM FLOW RATE 10-2 WITH SLEEVES IN HOT LEG 10-2 PERCENT REDUCTION IN PRIMARY SYSTEM FLOW RATE 10-3 WITH PLUGGED TUBES L 4

T.TRT OF APPENDICES - APPENDIX NO. NO.OF PAGES A PROCESS AND WFID OPERATOR OUATIFICATION - A-1 A.1 SLEEVE WELDING AND SLEEVE WELDER A-1 - QUAUFICATION A.2 REFERENCES TO APPENDIX A A-1 e B F b I I xiii l

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1.0 INTRODUCTION

1 i 1.1~ PURPOSE i. j' The purpose of this report is to provide information sufficient to support a technical i i specification change allowing installation of repair sleeves in the Calvert Cliffs Units 1-l and 2 Combustion Engin-ing designed steam generators. This mport demonstrates that reactor operation.with sleeves installed in the steam generator tubes will not 1 [ increase the probability or consequence of a postulated accident condition previously L evaluated. Also it will not create the possibility of a new or different kind of accident l and will not reduce the existing margin of safety. i L . ABB' Combustion Engineering (ABB-CE) provides two types of leak tight sleeves for steam ' generator tube repair. The first type of sleeve spans the parent steam generator. tube at the top of the tube sheet. 'Ihis sleeve is welded to the tube near the upper end -of the sleeve and is hard rolled into the tube within the steam generator tube sheet. The steam generator tube with the installed sleeve meets the structural requirements of tubes which are not degraded. j-The second type of sleeve spans degraded areas of the steam generator tube at a tube b egg crate support, or in a free span section of tube. This leak tight sleeve is welded to l the steam generator tube near each end of the sleeve. The steam generator tube with the installed welded sleeve meets the structural requirements of tubes which are not degraded. y Design criteria for both types of sleeves were prepared to ensure that all design and licensing requirements are considered. Extensive analyses and testing have been l performed on the sleeve and sleeve to tubejoints to demonstrate that the design criteria are met. The effect of sleeve installation on steam generator heat remo/al capability and system flow rate are discussed in this report. Heat removal capability and system flow rate was considered for installation of one to three sleeves in a' steam generator tube. After sleeves are installed and inspected, a baseline examination is performed using eddy current (ET) techniques. The ET examination serves as baseline to detennine if there is sleeve degradation in later operating years. The ET examination and criteria [ for plugging sleeved generator tubes if there is unacceptable degradation are described i 7 in this report. 4 Plugs will be installed if sleeve installation is not successful or if 'there is unacceptable degradation of a sleeve or sleeved steam generator tube. Standard. steam generator tube plugs may be used to take a sleeved tube out of service. E j 1-1 e

i i 1.2-BACKGROUND

The operation of Pressurized Water Reactor (PWR) steam generators has m some instances, resulted in Imm1W4 corrosive attack on the inside (primary side) or outside (secondary side) of the steam generator tubing. This corrosive attack results in a _

reduction in steam generator tube wall thickness. Steam generator tubing has been ~ designed with considerable margin between the actual wall thicknes's and the wall thickness required to meet stmetural requirements. Thus it has not been necessary to take corrective action unless structural limits are being approached. j Historically, the corrective action taken where steam generator tube wall degradation has been severe has been to install plugs at the inlet and outlet of the steam generator l tube when the reduction in wall thickness reached a calculated value ieferred to as a plugging criteria. Eddy current examination has been used to measure steam generator l tubing degradation and the tube plugging criteria accounts for ET measurement uncertainty. Installation of steam generator tube plugs removes the heat transfer surface of the plugged tube from service and leads to a reduction in the primary coolant flow rate available for core cooling. Installation of welded and/or welded and hard rolled steam genera:or sleeves does not significantly affect the heat transfer removal capability of the tube being sleeved and a large number of sleeves can be installed without significantly affecting primary flow rate. I ' 1-2

2.0

SUMMARY

AND CONCLUSIONS The sleeve dimensions, materials and joints were designed to the applicable ASME Boiler and Pressure Vessel Code. An extensive analysis and test program was - undertaken to prove the adequacy of both the welded and welded-hard rolled sleeve. This program determined the effect of normal operating and postulated accident conditions on the sleeve-tube assembly, as well as the adequacy of the assembly to perform its intended function. The proposed sleeving provides for a substitution in kind for a portion of a steam generator tube.. The proposed change has no significant effect on the configuration of the plant, and the change does not affect the way in which the plant is operated. Design criteria were established prior to performing the analysis and test program which, if met, would prove that both sleeve types are an acceptable repair technique. These criteria conformed to the stress limits and margins of safety of Section III of the ASME B&PV Code. The safety factors of 3 for normal operating conditions ~and 1.5 for accident conditions were applied. Based upon the results of the analytical and test prognms described in this report the two sleeve types fulfill their intended function as leak tight structural members and meets or exceeds all the established design criteria. Evaluation of the sleeved tubes indicates no detrimental effects on the sleeve-tube assembly resulting from reactor system _ flow, coolant chemistries, or thermal and pressure conditions. Stmetural analyses of the sleeve-tube assembly, using the demonstrated margins of safety, have established its integrity under riormal and accident conditions. The structural analyses'have been performed for', sleeves which span the tube at the top of the tubesheet to a maximum length of [ ] inches, sleeves which span a tube support or free span length of tube with a. length of [' 'l inches and a combination of the sleeve types. The structural analyses performed are applicable to shorter sleeves installed at the top of the tubesheet and,the tube support plate sleeves which may be installed at the Calvert Cliffs, Units 1 or 2. The analyses for the different sleeve types and lengths is given in Section 8. Mechanical testing using ASME code stress allowables has been performed to support the analyses. Corrosion testing of typical sleeve-tube assemblies have been completed and reveal no evidence of sleeve or tube corrosion considered detrimental under anticipated service conditions. Based upon the testing and analyses performed, the proposed sleeves do not result in a significant increase in the probability of occurrence or consequence of an accident previously evaluated, create the possibility for a new or different kind of accident, or result in a significant reduction in a margin of safety. 2-1

1 1 Welding development has been performed on clean tubing, dirty tubing which has been taken from' pot boiler tests and contaminated tubing taken from a steam generator. ABB-CE in*=11M their first welded sleeves in a demonstration program at Ringhals Unit 2 in May 1984. ABB-CE's sleeving history is shown in Table 2-1. The success rate for allinstalled sleeves is 98%. Since 1985, no sleeve which has been accepted based on NDE has been removed from service due to degradation. i In conclusion, steam generator tube repair by installation of both types of sleeves is established as an acceptable method. If a steam generator tube which has been sleeved is found to require plugging to remove it from service a standard steam generator tube ' plug can be installed. Since the standard tube plug can be used, no discussion or evaluation of the tube plug is provided as part of this document. 9 d I e O 5 g 9 e 2-2 t

-1 TABLE 2-1 INSTALLATIONS OF ABB-CE'S WFIDED SLEEVE SLEEVE QUANTITY PLANT DATE INSTALLED Zion 1-1/95 162 Zion 1 11/93 61 KRSKO1 6/93 160 RTZ 14 TSP Ginna 4/93 51 Zion 2 12/92 172 Prairie Island 1 11/92 158 ASCO1 6/92 5 RTZ 49 TSP Ginna 4/92 175* 63 curved Zion 1 4/92 124 Kewaunee 3/92 16 curved Ringhals 3 7/91 46 RTZ 22 TSP Ginna 4/90 192 48 curved Zion 2 4/90 83 Prairie Lland 1 1/90 63 Zion 1 9/89 445 2-3

1 TABLE 2-1 INSTAT I ATIONS OF ABB-CE'S WFTDED SI FFVE (continued) SLEEVE QUANTITY PLANT DATE INSTAT T Rn Ginna 4/89 395 107 curved Prairie Island 1 9/88 74 Ringhals 2 5/87 571 Ginna 2/87 105 Zion 1 10/86 128 Ringhals 2 5/86 599 Ginna 2/86 36 t h Ringhals 2 5/85 59 Ringhals 2 5/84 18 l

  • Straight sleeves unless otherwise noted i

i i i 2-4 i P

i - 3.0 ACCEPTANCE CRITERIA The objectives ofine=11ing sleeves in steam generator tubes are twofold. The sleeve y must maintain structural integrity of the steam generator tube during normal operating and postulated accident conditions. Additionally, the sleeve must prevent leakage in the event of a through hole in the wall of the steam generator tube. Numerous tests e and analyses were performed to demonstrate the capability of the sleeves to perform these functions under normal operating, including Tm reduction to 596*F, and postulated accident conditions. Design and operating conditions including Tm l reduction for the Calvert Cliffs steam generators are defined as: Primary Side: 596*F (hot side)' 2250 psia (operating) 604*F (hot side) 2250 psia (operating) 650'F (design) 2500 psig (design) i Secondary Side: 525'F (100% load) 850 psia (100% load) 525'F (100% load) 850 psia (100% load) 550'F (design) 1000 psig (design) i Note 1. The temperature and pressure values represent Tm reduction. l Table 3-1 provides a summary of the criteria established for sleeving in order to demonstrate the acceptability of the sleeving techniques. Justification for each of the criterion is provided. Results indicating the minimum level with which the sleeves sur-passed the criteria are tabulated. The section of this report describing tests or analyses which verify the characteristics for a particular criterion is referenced in the table. 6 9 3-1

J a s-- -.a t TABLE 3-1 REPAIR SLEEVING CRITERIA Reference Criterion ' Justification Results Section i

1.. Sleeve is leak tight.

Leakage between primary 4.0 and secondary side is prevented when steam generator tube is is breached. 7.3 2. Sleeve-tube assembly Sleeve-tube assembly 8.0 functional integrity must meets applicable ASME be maintained for normal Code requirements. operating and accident conditions. l I 3. Pressurization of annulus Prevention of sleeve i 7.3 between sleeve and tube failure for through does not collapse sleeve hole in tube wall. at 1500 psig. 4. Pressurize sleeve to 4500 Factor of safety of three 7.3 psig without bursting. (3) for normal operating l conditions. 5. Exposure of sleeve-tube Sleeve-tube assembly 6.0 assembly to various primary required to function and secondary chemistries under coolant chemistries. without loss of functional i integrity. 6. Non-destructive examina-Periodic examination 5.0 tion of tube and sleeve of tubes and sleeves to levels of detect-required to verify ability required to show structural adequacy. structural adequacy. i 3-2

I TABLE 3-1 REPAIR SLEEVING CRITERIA f (Continued). Reference Criterion Justification Results Section F t 7. Sleeve installation does Sleeve zepair should 10.0 t not significantly affect not reduce power removal i system flow rate or heat capability of reactor or - transfer capability of steam generator below the steam generator, rated value. [ l i 4 F i 4 l 3-3 i 1 I l

4 i I t I i t 4.0 ' DESIGN DESCRIPTION OF SLEEVES AND INSTALLATION EOUIPMENT 1 i j 4.1 SLEEVE DESIGN DESCRIFTION There are two (2) types of sleeves which may be installed in various combinations A i . within a steam generator tube. These sleeves are shown in Figures 4-1 and 4-2. Each sleeve type has a nominal outside diameter of [ . ] and a naminal wall i thickness of [. - ], - The sleeve material is thermally treated Alloy 690. j i Each of the sleeve types includes a chamfer at both ends to prevent hang-up of equipment used to install ~the sleeve and to inspect the steam generator tube and. j sleeve. i The first type of sleeve, shown in Figure 4-1, spans the expansion transition zone at . the top of the tubesheet. 'shis sleeve is up to ['- ] long and includes [ k .]. A shorter h sleeve (approximately [ ]) of the same design is used to span defective areas of a steam generator tube which exist just above the tube sheet. ~ l The second type of sleeve, shown in Figure 4-2, spans a tube support. The sleeve is [ ' ] in length. The tube egg crate support sleeve is used at a tube support elevation, or on any free span section of the tube. One or two egg crate' support sleeves may be used in a tube and may be used in a tube containing a expansion l transition sleeve. r f i i 4.2 SLEEVE MATERIAL SELECTION l The thermally treated Alloy 690 tubing, from which the sleeves are fabricated, is l procured to the requirements of the ASME Boiler and Pressure Vessel Code, Section j II SB-163, Code Case N-20. Additional requirements are applied including a limit on L Carbon content of 0.015 - 0.025% and a minimum annealing temperature of 1940P i (1060*C). The thermal treatment is specified at 1300*F (704*C) to impart greater [ corrosion resistance in potential faulted secondary side environments. The enhanced I corrosion resistance is achieved in the thermal treatment by insuring the presence of j grain boundary carbides and by reducing the residual stress level in the tubing. l The principal selection criterion for the sleeve material was its resistance to stress corrosion cracking (SCC) in primary and caustic faulted secondary PWR p environments. ABB-CE's justification for selection of this material and condition is j i based on the data contained in Reference 4.7.1. 4-1 l L p t

4.2.1 Field Senice Performance Five non-post weld heat treated sleeves installed at Ringhals II in 1985 and 1986 were removed in January 1990 and extensively examined. These sleeves, which had accumulated up to 22,000 FFPH of service, showed no field service degradation. 4.3 SLEEVE-TUBE ASSEMBLY f The installed sleeve is shown in Figures 4-3 and 4 4. The sleeve shown in Figure 4-3 ~ l spans the Expansion Transition Zone (ETZ) at the top of the tubesheet. If defects exist at a egg crate tube support then a Egg Crate Support (ECS) sleeve (Figure 4-4) may be used. The ECS sleeve may be installed in combination with the ETZ sleeve. The bottom of the [ ] inch sleeve is located [ ] inches above the bottom of [ the tube end. The upper end of a [ ] inch ETZ sleeve is located [ ] inches above the tube sheet upper face. [ ] 0 m. t 4-2

\\ l t The ECS sleeve shown in Figure 4-4 is [ ] inches in length. It is appronmately i stered at a tube support plate. [ i .] 4 l i 1 i l i i i: i j When it is considend to be of benefit, a post weld heat treatment of the sleeve weld will be added to the sleeve installation process. After the sleeve has been welded into the tube, the weld joint is heated in the range of [ _ ] As described in Reference 4.7.5, this time and temperature combination is sufficient to reduce the level of residual stress in Alloy 600 without 'resulting in detrimental l [ effects such as grain growth or sensitization. This treatment is similar to that utilized j t in some operating units to heat treat the tight radius U-bends. i Qualification of the process is in accordance with the procedure described in Appendix A. ) i 4.4 - ' PLUGGING OF A DEFECTIVE SLEEVED TUBE If a sleeved tube is found to have an umepairable defect or the sleeve or sleeved tube found to have a pluggable defect, th.: tube can be taken out of service with standard steam generator tube plugs installed at both ends of the tube using approved methods. The Regulatory Guide 1.121 analysis for the sleeve is included in Section 8.3. I 4.5 SLEEVE INSTALLATION EQUIPMENT The equipment used for remote installation of sleeves in a 's' team ge'nerator is made up of the following basic systems. These systems are: i. 9 4-3 4 -4 e r

I i 1.= Remote Controlled Manipulator r 2. Tool Delivery Equipment e 3. Tube Brushing-Cleaning Equipment - 4. Tube Size Rolling Equipment l .l 5. - Sleeve Expansion Equipment 6. Sleeve Welding Equipment ] i 7. Nondestructive Examination Equipment .i i ? -8. Sleeve Rolling Equipment 9. Sleeve Heat Tmatment Equipment Dese systems, when used together, allow installation of the sleeves without entering the s: cam generator. In this way, personnel exposure to radiation is held to a l mimmum. De tooling and methods described in the following sections represent the present l technology for leak tight sleeve installation. As technological advances are made in i . sleese mstallation, the new tooling and/or processes may be utilized after they have i been laboratory-verified to provide improved cleeve installation methods. i 4.5.1 Remote Controlled Manioulator j ne remote controlled manipulator (Figure 4-5) serves as a transport vehicle for mspecton or repair equipment inside a steam generator primary head. De mamputator consists of two major components; the manipulator leg and mamputator arm. The manipulator leg is installed between the tube sheet and bottom of the pnmary head and provides axial (vertical) movement of the arm. The manipulator arm is divided into the head arm, probe arm and a swivel arm. Each arm is moved independently with encoder position controlled electric motors. The i swivel arm ' allows motion for tool alignment in both square pitch and. triangular pitch tube arrays. Computer control of the manipulator. allows the operator,to move sleeving tools from outside the manway and ' accurately position them against the tube sheet. 44 u

t 4.5.2 Tool Delivery Eauinment The purpose of the tool delivery equipment is to support and vertically position the various tools required for the sleeving operation and to provide controlled rotation to some of the tools. Two different delivery systems may be used for the tool delivery. [ t t ] e l l 4 l 6 es e k*, 4-5

9 4.5.3 Tube Brunhine-Clemnine Eauioment y 5 i, t i l t 4.5.4 Tbbe Rolline Eauinment I P i 4 4.5.5 Sleeve Exnansion Eauioment a i-P f s t I 1 J f P t ? t s 4 4-6 I s

.... - ~. O _2 l h F r i t i F t 4 4.5.6 ' have Weldina hiik,inent i i t i ) V E 6 1 .1 4.5.7 Nondestructive Examination I t 1 f l s t t r 9 - {1 a e t, i 4-7 i h d 1

il 4.5.8 Post-Weld' Heat Twatment Equinment 4.5.9 Sleeve Rolline Equipment 4-8 e am i

_._._._ _ _.. _ _ _ ~ _. _. _ _ _ _ _.. 4, j 8 '8 i i j ' 4.6 ALARA CONSIDERATIONS - I* P I - h pasm generator repair ap-tian isNa to minimi= personnel exposure during insta11stian of sleeves. The==ni=lator is installed from the manway without p entering the steam generator. It is ' operated remotely from a control station outside . the containment buihling.- The positioning accuracy of the manipulator is such that it l i .can be remotely positioned without having to install templates in ths stiam generator. i j a i The tool delivery equipment is designed so that the dovetail fitting quid:ly attaches to [ [ the manipulator. The probe pusher is designed to quickly engage the individual i l sleeving tools. h tools are simple in design and all sleeving operations are-l [ performed remotely using tools held by the manipulator. Each tool can be changed at the manway in 10-15 seconds. A tool operation is performed on several sleeves ' rather than performing each tool operation on the same sleeve before pK-ma g to l the next sleeve. This reduces the number of tool changes which are required. Spare tools are provided so that tool mpair at the manway is not mquired. If tool repair is j m-y, the toolis removed and sleeve operation continuds using a spare tool. The j (( tool may or may not be repaired during the outage butrepair is performed in an area i which does not have significant radiation. ) i i Air, water and electrical supply lines for the tooling are designed and maintained so that they do not become entangled during operation. This minimizes personnel j exposure outside the steam generator. Except for the welding power source and programmer all equipment is operated from outside the containment. Jhe welding ~ power source and programmer is stationed about a hundred feet from the steam generator in a low radiation area. In summary, the steam generator operation is designed to minimize personnel exposure and is in full compliance with ALARA standards. L Am9 W 3 i c g 4 a 4-9 x.

4.7 REFERENCES

TO SECTION 4.0 4.7.1 Allov 690 for Steam Generator Tubine Anolications, EPRI Peport NP-6997, October 1990. 4.7.2 Sedricks, A. J., Schultz, J. W., and Cordovi, M' A., "Inconel Alloy 690 - A New Corrosion Resistant Material", hpan Society of Corrosion hineerine, i 23, 2 (1979). 4.7.3 Airey, G. P., " Optimization of Metallurgical Variables to Improve the Stress Corrosion Resistance ofInconel 600", Electric Power Research Institute + Research Program RP1708-1 (1982). 4.7.4 Airey, G. P., Vaia, A. R., and Aspden, R. G., "A Stress Corrosion Cracking Evaluation ofInconel 690 for Steam Generator Tu'ving Apolications", Nuclear Technology, 51, (November, 1981) 436. 4.7.5 Hunt, E.S. and Gorman, J.A., Specifications for In-Situ Stren Relief of PWR SteaELQgnerator Tube U-bends and Roll Transition. EPRI l 1 Report NP-4364-I.D, Ehdric Power Research Institute, Palo Alto, CA, December 1985. 4.7.6 Knipowicz, J. J., Scott, D. B., and Fink, d. C.', " Corrosion I erfonnance of Alternate Steam Generator Materials and Designs Vol. 2: Posttest Duuninations of a Seawater Faulted Alternative Materials h,fodel Steam Generator," EPRI-NP-3044, July 1983. 4.7.7 G. Santarini et al, Recent Corrosion Results - Alloy 690, EURI Alloy 690 Workshop, New Orleans, LA, April.12-14,1989. i i i s e l ,s 3 4-10

e I p t l 1 l FIGURE 4-1 EXPANSION TRANSITION ZONE SLEEVE 4-11 1

a J O i E' ~ e s ma luulN FIGURE 4-2 EGG CRATE SUPPORT SLEEVE 4-12

,e i t t k i .' i .i i i z t U t .I t t R 1 f' 'l .i

~

l t i l l r e r FIGURE 4-3 i . EXPANSION TRANSITION ZONE ST.FFVE INSTALLATION _ i d i 4 13. 4 6 7 m 4 +

e L. l FIGURE 4-4 EGG CRATE SUPPORT ST FFVE INSTALLATION 4-14 .,) s

t +- } 1 . + I l 4 5 . 2 I = t 1 4, 1 I L I 4 t i.. l 6 j - 1 s e I b 1' ,3 i i r . i r + s o a i i. i i i i i i ,t 1. 4 r 1 1 a 4, f I -1 t n - 1 i 4F .A 31 Ii t ) i s t HGURE 4-5 MANIPULATOR AND TOOL DMJVERY SYSTEM t > ~ 4.15 ~ _

J FIGURE 4-6 TOOL DELIVERY EOUIPMENT d 16

i I f '5 h a 4. I 6 E I e i i l l l I FIGURE 4-7 TUBE ETRANING EOUIPMFNT A.17

3 m. k v n'. t l l~ l' t i l l. l. FIGURE 4-8 SLEEVE EXPANSION EOUIPMENT i. m ~ 4-18.

r Ii i i i I t t f i ? 1 I ~ MGURE 4-9 ' { STMVE WFT nING READ ASSEMBLX- '.s ' 4-19 -1

I l (- ) I 1 4 r I: f i i l ' FIGURE ~4-10 i ST FEVE WFTDING READ POWER SUPPLY UNIT ~ 4-20 '

-t r 4 r i ? f a e 2 .I f i 'l de 3 i r t h a C w 1 e 1 1 ] 1 I a P l I a 1 .l 8 -. s ) J l i 4-h f a, t t i f ,i - 1 v FIGURE 4-11.

ULTRASONIC TEST EOUIPMENT 4,

f FIGURE 4-12 VISUAL TEST EOUIPMENT 4-22 t

1. ggem 4

    • 4-u aw #-

ma h-n.*-J n.M s a.--ei ,M-' a . h ,A 4p. a I e c-i 4 4 i s h 9 4 4 h I T 4 5 t b 4 f i . i r h y s h i ) I ? + i l sr. h h t I k FIGURE 4-13 POST WELD HEAT TREAT EOUIPhANT 4-23 m.

%+- g 4.

1 l 1 i i I 1 s i 1 1 1 1 1 s i ? ? I f t 1 I i e I i l i 1 I I i h r i l 1 P l FIGURE 4-14 ST FFVE ROT TING EOUIPMFNT - STRAIGHT i i d.?d . ~

gap. Reliably detecting this flaw is the acceptance criteria for sleeve inspection. Three of the coils tested met this acceptance criteria. Obviously, it is desirable to find smaller j and more realistic flaws which was the motivation for using EDM notches for the j' development effort. The issue of flaw sizing was not addressed for the sleeve-in-sleeve. The' reason is that previous qualification efforts for sleeving inspection have developed the methodology for sizing and distinguishing sleeve from parent tube flaws. The pressure boundary of i the~ sleeve-in-sleeve is essentially the same as the sleeved tube with regard to flaw j . sizing. Therefore, it.was not necessary to pursue this. a The information presented here is based on the most recent qualification effort for inspecting'the sleeve-in-sleeve conflguration. As stated above, the sleeve-in-sleeve is l I representative of the welded sleeve configuration with regard to the pressure boundary. The sleeve-in-sleeve configuration is more difficult to test than the welded sleeve due to the..:ry large expansions and air gaps. Although the sleeve-in-sleeve is not welded, the weld itself is not as detrimental to eddy current sensitivity as the large expansions l and air gap. Therefore, the sleeve-in-sleeve qualification in conjunction with the i previous welded sleeve qualification effort establishes the current state-of-the-art inspection for welded sleeves. a i The "+" point coil has the best overall performance ed I; therefore currently recommended as the general purpose probe for sle,ve inspections. The I-coil is also a good general purpose probe and can be used as a back-up to the "+" point. The axial l i ~ ifferential coil (MRAD) is a special purpose probe that is recommended for use when d 'circumferential flaws are suspected. Other probes and/or techniques may be employed as technological Hvances are made. l 5 5.3 VISUAL INSPECTION F i t i 5.3.1 Summary and Conclusions i Visual examinations can be performed on the sleeve to steam generator tube welds to support UT results. The welds are examined using a diameter CCD camera system or a boroscope examination system. j i-l' The lighting is supplied as an integral part of the visual examination system. Each ] examination is recorded on video tape for optional later viewing and to provide a . permanent record of each weld's condition. l ( ~ The visual inspections are performed to ascertain the mechanical and structural 1 condition of a weld. Critical conditions which are checked include weld width and completeness and the absence of visibly noticeable indications such as cracks, pits, blow holes, burn through, etc. 5-13 1 3 I -s a w- + v. r

5.3.2 Weld Examination i A visual examination can be made of the sleeve to tube weld using a CCD camera system or a boroscope inspection system. This system utilizes a right-angle lens for weld viewing. The tool delivery system positions the VT tool at the weld and provides 360* of tool rotation. To perform the inspection, the optics system is inserted into the sleeve-tube assembly such that the lens is located at the weld. After checking for visual clarity and adjusting the lighting to reduce unwanted glare, the toolis rotated 360'. The tool may then be raised or lowered and the process repeated to ensure complete weld coverage. The entire examination is video-taped for a permanent record. Prior to the inspection, the system's adequacy is checked by observing a 1/32 inch black line on an 18% neutral gray card placed in a location similar to the area to be inspected. Additionally, to obtain an aspect for size and to check the in-tube lighting, a welded sleeve-type sample with a.020 inch diameter through hole is placed over the lens. The weld acceptance is based on the absence of cracks or other visible imperfections which would be detrimental to the integrity of the weld. Detrimental imperfections include blow holes, weld mismatch, etc. During the examination, any area which contains noticeable imperfections is examined more closely by varying the light intensity and/or the position of the lens with respect to the indication. 5.3.3 Test Equipment The test equipment necessary to visually inspect the sleeve to tube welds consists of the following: 1. A micro camera or boroscope visual examination system with an integral lighting system, lenses and a delivery and rotational tool for inspecting the upper and lower welds. 2. 18% neutral gray card with a 1/32 inch black line. 3. Welded sleeve-tube sample with a.0M inch diameter through drilled hole. 4. Video camera and recording equip'xat. 5-14

.J l 2 5.3.4 Defect Standards i Various methods are used to determine system adequacy and to aid in determming weld acceptability. 3 1. System adequacy, including lighting iritensity and camera system clarity, is verified by resolving a 1/32 inch black line on an 18% neutral guy card, t 2. Size aspect for upper weld inspections is obtained by viewing a welded sleeve-tube - j sample which has a.020 inch through drilled hole. i i 3. Sleeve-tube welds were made with both acceptable welds and intentional weld l malformities. Tliese welds were photographed and are used as aids to examiner. i; - t 1-l f i f ) 4 h 5 l f i I I I i e 3 f i 1 5-15

.. =...... k V i t d ) L h .) s .t i t t 1 0 i 1 i ? h I f I a .I i i T } -- --= MGURE 5-1 1 ULTRASONIC PROBE WITHIN n WELDED SLEEVED TUBE I o I ? f' i-5-16 i f A 6 d t ..,.m .w

..~. .a I i I -) i o k P r d I r. i. t r s F s t f I i i i I,- } t t MGURE 5-2 ULTRASONIC INSTRUhmNT CRT RESPONSE t. l i f L 5-17 i i i

+ a- ,7 . __.2. ,3, s i < r 1 i 4 t t 4 i i 4 i 1 4 E 1 HGURE 5-3 REFERENCE STANDARD FOR 3/4 inch TUBE 5-18= ' t; a ' kt,_ A

. ), e f a e 3 i = r i e f v f h t 5 P ? t, s I t 1, I i '.h ? I J I ) i i I y l 1 6 i I 1 i 1 1 - HGURE 5-4 -J i SPErTMFN OUA-5: ACrFFTABLE WFin i 1 5-19 5 a i l -'y '1 I j

A p summ 4 m FIGURE 5-5 REFERENCE STANDARD t 5-20 -w____.a

+, i s L P -t i k b i v -i k v .7 i i P i r i 6 i L v I i 1 i HGUT.E 5-6 SPECIMEN OUA-11: RETECTED WELD 5-21 ' l l; e e i l .e-l

/ f k MGURE 5-7 SPrefMTW OUA-14: RETECTED WFT n l 5-22 i 4

. - ~... ~.. _ ~... - t .1 1 2 1 I I i 4 i i = r t i 1 e i. .-( u e t 1 b ? 2 V i P f f ) 9 s a i A i ? f f I i i 1 1 i i l 8 4 - MGURE 5-8 SPECIMEN OUA-13; REECTED WELD 3 4 1 1 5-23 j d d e k ^ e ..,y s ,e

n i l i 1 MECHAN! CAL SLEEVE i CONFIGURA110N 4 ? FIGURE 5-9 PRESSURE BOUNDARY DESCRIPTION AND SAMPLE FLAW LOCATION 5-24 ~

I s ,Ii .!i1 m y m r 7 N t O IT A Y C OL 1 W A L F EL E P V E N M E O A L l S l S A D L R 0N A U 1 C G A 5 I I N F N 5 A N E H O R O 2-i 5 U l C E G 1 1 IFR ~ C SED Y R N A O TI D S N I N A U R O T B L E LO R RU PO S T S E E H R T P TA D E TACO L ERA SWA LF h

L t .I. i S U L U N N m A EBU T R O I T A RE NE G M 1A 1 u t 5 s 6 E 2-R O U T 5 GW I F H M_ IS EGR AL ROF E L P M A S WA LF clll lll1l

'![l' lll

.!ll! ll

.~ f i l 1 5 f 4 i i ) 1 I MGURE 5-12 RMPONSE AT 50 kH7. NEW ADVANan ROTATING PROBE 5-27

p i M e e MGURE 5-13 C-SCAN CONTOUR PLOT WITH A TUBE FLAW NEW ADVANCED "+" POINT ROTATING PROBE 5-28 - l l

-se~.e u _g g,_ h i 1 i .t i

l. -

1 1 ( L d a .1 ~ l HGURE 5-14 40% ASME FLAW THROUGH AIR GAP l NEW ADVANCED "+" POINT ROTATING PROBE 5-29 =

1..

J J e ,c

4 ~ l = d i e I i- ~ i l i e c FIGUiG 5-15 RESPONSE TO EDM NOTCIES NEW ADVANCED "+" POINT ROTATING PROBE 5-30 t 1 . a

p 2-A A -,,A e A es ~ >A-- COL Y MOTCR2ED DRVE UMT on e M i l e m 4 4 FIGURE 5-16 TYPICAL MOTORIZED AXIAL DIFFERENTIAL PROBE 5-31 l 4

/ j 4 4 2 i I e J t I E' 4 h HGURE 5-17 40% ASME FLAW THROUGH AIR GAP ' MOTOR 17FD ROTATING AXIAL DIFFERENTIAL PROBE 5-32 I m

7-- --m---a tu es pe,, a..ar We

  • J J

$4 - - - - - - -E eh4-4 4 n.h.n-44L M== B.4 adie MA -AJhA-M As W'. A A--4J k_ t i - h W eau o f i I i P I t I i ,8 9 m M f MGURE 5-18 P OBE. 5-33 I e 4 t I

) t 5 1 i' 1 i-t s q 1 i i-l l t i s I t l HGURE 5-19 RESPONSE TO EDM NOTCHES 1 MOTORT7Fn ROTATING N DNE, PROBE l 5-34 r

'.h ,.g',' ~ i b 3..a -.f' 3' 1 g. ' k. a. t 7 I 2 < ~, ~( : L .g. 4 ( -"' t , \\'d5 ; M { e + 7 7 I L w 1 k Od, 6 A 0 > I s e i.b I ] sh 3 I i l l l 1 f. M i r FIGURE 5-20 40% ASME FLAW THROUGH AIR GAP I-COIL PROBE - 5-35 .5 Y I g I p q ]

.p, s >) I' s e O

4. '
  • s-4 FIGURE 5-21 40% ASME FLAW IN EXPANSION TRANSITION I-COIL PROBE 5-36

,---r

  • t e

I W W e e ? i h MGURE 5-22 RESPONSE TO EDM NOTCr.Ris I-COIL PROBE 5-37 4

_ _. ~.. _.. _. _ _ _ _ I t 6.0 SLEEVE-TUBE CORROSION TEST PROGRAM C-E has coadeaA a number of bench and autoclave tests to evaluate the corrosion resistance of the welded sleevejoint. Of partict.lar interest is the effect of the n+-h==W1 expansion / weld residual stresses and the condition of the weld and weld heat affected zone. Tests have been performed on welded joints with and without a post-weld heat treatment. An outline of these tests is shown in Table 6-1. [ 3 6.1

SUMMARY

AND CONCLUSIONS 6.2 TEST DESCRIPTION AND RESULTS 6.2.1 Primary Side Tests 6-1

i TABLE 6 STEAM GENERATOR TUBE SJ.liEVE CORROSION TESTS I I E o s l h i 1 i i ? t I t L t 6-2 F r v

i 16.2.1.1-Pure Water Stress Corrosion Cracking Tests l i i i i i 1 i i I 1 i i 1 j _ 6.2.1.2 Above the Tubesheet (ATS) Weld Capsule Tests I s ~ b 1 1 l 4 i f 4 1 I I A l A J ) s, a f i i 6-3 ~ W + + c y- --v-a r-v---- r: -r e-

i f,. A- ".) i i s i 5 i i I 6.2.1.3.. ECS Sleeve Weld Capsule Tests - 1 e I I -I t i h 4 i L i 5 F I i l i i J J l I I l N l ~ l s' ) 1 w -

_ _ _ _... _ -....... _. =. i I 1 i i i TABLE 6-2 ABB-CENO ACPFTFRATED PRIMARY SIDE SCC TESTS l ~ 6 8 l ? I i i I - i i ? - 4 i 1 1 1 1 ~ TABLE 6-3 l ENSA ACCELERATED PRIMARY SIDE SCC TEST i f I i 8 1 t I i I t t ? I ~ t i i r 6-5 t i r

l a i ~ 6.2.1.4 - Summary - Primary Coolant Corrosion Performance' l 4 4 .. I i b' 1 d . t i i i + 8 i i i I r 7 a t i i e t I TABLE 6-4 i LOCAL SLEEVE / TUBE JOINT APPLIED STRESSES t t. M due mes ] s t 6-6 .~

1 4 M esumuu - I i 4 j 1 1 i 1 1 5 4 I i I I 1 1 I i f 1 4 1 2 i i m 7 M e ) I

TABLE 6-5 AXIAL STRESSES IN TUBE AT SLEEVE JOINT TUBE LOCKED AT SUPPORT l e w 6-8

t 6.2.2 Secondary Side Tests j 6.2.2.1 Modified Huey Tests l ~ i a J l. I s I t f s 1 ,i t k i i i i 6 i ) i 6.2.2.2 Capsule Tests m I I i 1 J m' 6-9 i l I

-) i i i i i i i ~ TABLE 6-6 SECONDARY RIDE STEAM GENERATOR TUBE ST FRVE CAPSUTR TESTS ENVIRONMENT EXPOSURE TIME PFRULTS i A.' 1 I I l B. [ t i i I L ^C. ? l i D. p 6.2.2 3 Sodium Hydroxide Fault Autoclave Tests ) l l 4 m, i 6-10 ~

i ~ f i I h t b t 6.2.3.4 Summary - Secondary Coolant Corrosion Performance ~ f L 1 h l I s I j e 5 6.

6.3 REFERENCES

FOR SECTION 6.0 6.3.1 Satistical Analysis of Steam Generator Tube Degradation, EPRI Report NP-7493, September 1991. 6.3.2 Summary Report, Combustion Engineering Steam Generator Tube Sleeve Residual Stress Evaluation, TR-MCC-153, November 1989. 6.3.3 I. L. W. Wilson and R. G. Aspden, " Caustic Stress Corrosion Cracking of Iron-Nickel-Chromium Alloys." Stress Conosion Cracking and Hydrogen EmbrittlementefIron Base Allovs, NACE, Houston, Texas, pp 1189-1204, 1977. 6.3.4 A. J. Sedriks, S. Floreen, and A. R. McIlree, "The Effect of Nickel Content on the Stress Corrosion Resistance of Fe-Cr-Niin an Elevated Temperature Caustic Environment". Corrosion.Vol. 32, No. 4, pp 157-158, April 1976. 6.3.5 F. W. Pement, I. L. W. Wilson and R. G. Aspden, " Stress Corrosion Cracking Studies of High Nickel Austenitic Alloys in Several High Temperature Aqueous Solutions." MaterialsPerformance. Vol.19, pp 43-49, April 1980. 6.3.6 P. Berge and J. R. Donati, " Materials Requirements for Pressurized Water Reactor Steam Generator Tubing." NucleafTechnology, Vol. 55, pp 88-104, October 1981. 6.3.7 G. P. Airey, A. R. Vaia and R. G. Aspden, "A Stress Corrosion Cracking Evaluation ofInconel 690 for Steam Generator Tubing Applications." Nuclear Technology, Vol. 55, pp 436-448, November 1981. 6.3.8 J. R. Crum and R. C. Scarberry, " Corrosion Testing ofInconel Alloy 690 for PWR Steam Generators." Journal of Materials for Energy Systems, Vol. 4, No. 3, pp 125-130, December 1982. 6-12

J L i e GusP I i I L I L l l i t o O f 9 ? i 4 l I FIGURE 6-1 PURE WATER CORROSION TEST SPECTMEN 6-13 ) k

1 t r 5 9 4 i t [ 1 ? I FIGURE 6-2 ATS WELD CAPSULE TEST SPECTMEN 6-14

4.u J.,

a - n.a j 2.4.a. .a + s #a.. 2g.,v4-9 a.e s. a 4--..u. 4 w. p. .esm_,,, +., 4 4.., ro.w s wm .,ma,.A. ' hi,%)4;- y 3:. A 1 J t ? . _ _., + s' ? M. ema 9 i f b >f' ,-l e I I = i i- < --

r,.

I .t ,.q 4 s 1 e i si s4 't l ,e i D 2 a ? i 4 e r ? t t t f 9i t t 3 t a t ' t, b 5 i I ase-- f N f i [ L i i FIGURE 6-3 ECS WELD CAPSULE TEST SPECIMEN i i p '? 6 6-15 ] 4 I .I i e ~,. -. - - m. -~-

]

?****8 e' en -3 + e eee e eg, -w eenet .e og we en eye .m e.. N l l f e - -e e - W FIGURE 6-4 CAUSTIC CORROSION AUTOCLAVE TEST SPECBfEN 6-16 i

. ~. - - - 7.0 MECHANICAL TESTS OF SLEEVED STEAM GENERATOR TUBES i 7.1

SUMMARY

AND CONCLUSIONS l Mechanical tests were performed on mockup steam generator tubes containing sleeves j to provide qualifled test data describing the basic properties of the completed i assemblies. These tests determined axialload, collapse, burst and thermal cycling l capability. - A minimum of three tests of each type were performed. i Table 7-1 summarizes the results of the mechanical testing performed on the sleeve - . tube assemblies. The demonstrated load capacity of the assemblies provides an - adequate safety factor for normal operating and postulated accident conditions. The load capability of the upper and lower sleeve joints is sufficient to withstand thermally induced stresses in the weld resulting from the temperature differential between the sleeve and the tube and pressure induced stresses resulting from normal operating and j postulated accident conditions. The burst and collapse pressures of the sleeve provide-a large safety factor over limiting pressure differential. Mechanical testing revealed j that the inelleA sleeve will withstand the cyclical loading resulting from power changes in the plant and other transients. l i 7.2 ' CONDITIONS TESTED i I The following tests were performed on the sleeve-tube assemblies at room i temperature: axial pull, load cycling, burst and collapse. Loads were applied until the point of failure, or in the case of cyclic loading,'until the number of cycles exceeded the expected number of cycles for the plant' ] 7.3 WELDED SLEEVE TEST PARAMETERS AND RESULTS i 7.3.1 Axial Pull Tests 1 e 7-1

. -....._......-. ~... ..~.... . umane 1 e b i - ,r T. 4. d. E.I 1 5-I 1 I. 4-3 7.3.2 Cn11anse Tactina e L /.- mee 4 O M 4 4 ^ 7-2 9 8 9 5 9 6

. ~. s. g ( 7.3.3'

Burst T*= tine f

f, a 2 i i = 4 f s f ?, t t t i a 1 v i o I { 7.3.'4 Lead Cveline Tests l 1 i e } 4 1 1 1 I 1 k i 1 A l 1 1 7 F l 1 7-3 m

a W.- 4 i_- 4 t e e e** a O m 0 i L t we 9 f +g, ,:s s F G e e y G 8 fE,e e 4 S - 40 e L, i I t t f I t 9 b h b 74 P I

TABLE 7-1 STWVE-TUBE ASSEMBLY MECHANICAL TESTING RR9ULTS* COMPONENT AND TEST RESkJLTS RESULTS (MAXIMUM) (MINIMUM) l t i r ~ _.1

  • A minimum of three tests of each type were performed.

t 7-5 I

4 8.0 STRUCTURAL ANALYSIS OF SLEEVE-TUBE ASSEMBLY This analysis establishes the structural adequacy of the sleeve-tube assembly. The methodology used is in accordance with the ASME Boiler and Pressure Vessel Code, Section III. The work was performed in accordance with 10CFR50 Appendix B and other - applicable U.S. Nuclear Regulatory Commission requirements. 8.1

SUMMARY

AND CONCLUSIONS Based on the analytical evaluation contained in this section and the mechanical test data contained in Section 7.0, it is concluded that both the Expansion Transition Zone (ETZ) and Egg Crate Support (ECS) sleeves decribed in this document, meet all the requirements stipulated in Section 8.0 with substantial additional margins. 8.1.1 pesien Sizine In accordance with ASME Code practice, the design requirements for tubing are covered by the specifications for the steam generator " vessel". The appropriate formula for calculating the mimmum required tube or sleeve thickness is found in Paragraph NB-3324.1, tentative pressure thickness for cylindrical shells (Reference 8.1). The following calculation uses this formula. Where t = Min required wall thickness (in). P = Maximum Design Tubesheet differential pressure (ksi)(per Reference 8.4) R = Inside Radius of sleeve (in). S. = Design Stress Intensity (S.I.)(per Reference 8.2) 8.1.2 Detailed Analysis Summary When installed and welded within specified tolerances, the ETZ sleeve and its upper weld andiower rolled joint, and the ECS sleeve and its two primarf welds possess considerable margin against pull-out for all loading which can be postulated from operating, emergency, test, and faulted conditions. The axial loads in the sleeve are a function of their location within the bundle and on the degree of tube / support lock-up. The most severe combination is determined to be{ ~ for 100% steady state power which also envelopes the current operating parameters iii 8-1

4 cReference 8.12 where the pdmary hot leg temperature is reduced. r F 1 9 ' N 1 i +, y I 4 1

0. '

Y Y 4 E. 4 b 5 ,Y I t t t f I t M e 8-2 ? . i i.

TABLE 8-1

SUMMARY

OF SLEEVE AND WFT D ANALYSIS RESULTS I I J t l The allowab!:s listed in Table 8-1 are in accordance with the ASME Code (References 8.1 and 8.2) i 4 t 8-3

- FORMULAS FOR GENERAL MEMBRANE STRESSES SUMMARWD IN TABLE 3-1 i (Note: All SI equations below are a derivation of the formula in Par. NB-3324.1 of Ref. 8.1.)

1. GENERAL PRIMARY MEMBRANE STRESS (DESIGNTUBESHEET DELTA PRF3SURE) s I

t

2. MAIN STEAM LINE BREAK
Where,
3. PRIMARY PIPE BREAK (LOCA)

S. I", PR, AP t 2 Where AP is the secondary side heatup pressure (-1.00 ksi, max. external), which is less than 6.5 ksi for instability failure to occur with this type of external pressure application. Thus, the equation for internal pressure is applicable for this AP external pressure value. um.us m> 8-4

..=...... h ) 1 i E t TABLE 8-2 a

SUMMARY

OF ROT.Trn JOINT DESIGN. ANALYSIS AND TEST RESULTS t e I 4 i 4 f 4 1~ t il 1 a 1 S 8-5

1 8.2 LOADINGS CONSIDERED 1 In this section a number of potential failure modes are enmined to determine the relative j safety margins for selected events. Failure loads are calculated based on minimum i dimensions and compared with mechanical testing results from Section 7.0. Both calculated and measured loads are compared with the maximum postulated loads. l 8.2.1 Unoer Tube Weld Pullout Load Assuming the parent tube is totally severed, the minimum ioad required to shear the upper i tube weld is calculated. The force required to pull the expanded sleeve through the l unexpanded tube is conservatively neglected. j t i i + i In the event of a main steam line break (MSLB), the secondary pressure would drop in a i short time interval. The primary pressure would rise briefly then follow the drop in j seconday pressure. It is conservatively assumed that the full pnmary pressure remains when the secondary pressure reaches zero. The maximum pullout load would be: i i Pm = Pm x wR,2 = (2250) x (.327)2 = 756 lbs. l Safety Factor SFm = 4640n56 = 6.1 [ [ i i 8.2.2 lower Sleeve Rolled Section Pushout I. mad i Assuming the parent tube is totally severed, the mmimum load required to rupture the lower rolled section is calculated. The mimmum measured test value for the pushout load is[- ]lbs., see Section 7. l t 8-6 )

4 J. i .i F Posmlating a loss of primary coolant accident (LOCA) during hot standby condition (0%. j Power), the==rinnwn available load would be: .m i j 1 1 F i j Note that the LOCA pipe break accident is not controlling for this joint. See Section 8.4. l 8.2.3 Weld Fatione ~ 1 i j Since the factors of safety are quite high for loadings due to primary stress, the failure j mechanism of greatest interest is the fatigue failure mode considering the variable axial j loading of the sleeve during normal operating transients. a f j In Section 8.6, fatigue evaluations of the upper weld, which join the sleeve to the tube will 'l be made. It is first necessary to determine the effects that tube lock-up within the tubesheet -j 2 and tube supports have on the axial loads in the sleeve during normal operation. This j subject is addressed in Section 8.4. i 4 j 8.3 EVALUATION FOR. ALLOWABL.E SLEEVE WALL DEGRADATION USING i L REGULATORY GUIDE 1.121 l NRC Regulatory Guide 1.121 (Reference 8.3) requires that a minimum acceptable tube (or sleeve) wall thickness be established to provide a basis for leaving a degraded tube in service. For partial thru-wall attack from any source, the requirements fall into two l categories, (a) normal operation safety margins, and (b) considerations related to postulated pipe rupture accidents. i 8.3.1 Normal Operation Safety Marrins .It is the general intent of these requirements to maintain the same factors of safety in evaluating degraded tubes as those which were contained in the original construction code, 4- ) ASME Boiler and Pressure Vessel Code, Section III (Reference 8.1). ,4 l For Inconel Alloy 600 and.690 tube or sleeve material the controlling safety margin is: j i i

  • Tubes with partial thru-wall cracks, wastage, or combinations of these should have a factor of safety against failure by bursting under normal operating conditions of not less than 3 I

at any tube location". ) j i From Reference 8.4, the normal operating conditions for the steam generators are: Primary Pressure Pg = 2250 psi j Secondary Pressure P. = 850 psi 8-7

t Diffematial Pressure AP = P - P. = 1400 psi g Average Pressure P, = 0.5 (Pg + PJ = 1550 psi Assuming the pamnt tube is totally severed, the sleeve is required to carry the pressure loading. The following terms are used in this evaluation. sleeve nominal inside radius R, = minimum mquired yield strength Sy,, = (per U.S. NRC Reg. Guide 1.121) actual minimum yield strength of sleeve Sye = (Sy = 35.2 ksi minimum at 650 T) i l t i t 8.3.2 Postulated Pine Ruoture Accidents b .m ee s ame. e eme= *

  • m e+ e i

8-8

A D ,4m -.e J-- w,.A ,_A n -9.-a a 4 4 a.A ,%r., -J.g a s. 6 -u+.444 m(4 hA: 4 .-A,-a-- m

e4 d

O OO g g ? h L h i 6 e ',I F 4 i f i

  • .d e

t ' t, 0 r I t r b b 1 l I l l i 1 s 1 1 I i 9 8-9

-.. =_ - _ 8.4 EFFECTS OF TUBE LOCK-UP ON SLEEVE IDADING Objective: Conservatively determine the maximum axial loads on the sleeve (tension and compression) during normal operation. ._ General Assumptions: (See Figures 8-2 through 8-4). i i i i t i i f 8.4.1 Sleeved Tube. Free at Tube Sucoort s i r I I I i ? I 8-10

A gg> d b 3 ( I l l I i 1 J t 6 l l l i I I i i i e 8-11 \\ 1 t ,. _. ~ . _.,, ~ - -, ~.---4 I

.. ~.... -.. - TABLE 8-3 E 30 INCH SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES. m% -.,s...m.-. - - ma~ w ~. _....... 4 2 8 Y. _.MTM !;OUTSIDEL1 ': lNSIDET. ^ lM ' e 4SECTION... .CORRESPONDi' liYOUNGSE W,4n W iH M 4MEAN COEFi-m..._ $ age..g,RMEE khi1NNE5$ n:--.aAE../Lz.k, N,$.y$N c[. }c R DI.US f[RA, DIUS) jf.ENG, TIC 2AREAf;. " M. Temp. 1 'e MDD..E,s, ~ g.: ULUS$ THE g. r g$j?iv.8..+.a,g.g a K;. # 3 a.. R;pu g ~1 , ;.. ~ yn&... % f(in)@.l q ..e- - > x,.,Tnj h, m , ;;. la..

A.

%<.,., c, yM 10%. ttIbli,z>vnf10'M

S.

W:..xR.i. >, e g t M

=

.u.. ,n. ~ w a ... a q.. .- y c '(in ).. e gl,j (.F)ficd %,- ;I:lb/m. @ra@!;2.n qW 2s i(in)M N(in)"

10 i

I Reference Temperatures: Primary (Hct) = 604'F Secondary = 503'F Normal Tubes = (2 T,,i + T,J/3 = 570.3*F - i NOTE: a, and E for Inconel 690 from Reference 8.2. i 2 a. for Carbon Moly Steel from Reference 8.1. i 1 I I i l i 8-12 + 1 I I .. ~

4-TABLE 8-4 AXIAL LOADS IN SLEEVE WITH TUBE NOT LOCKED INTO Tube support t @fts [Mi;:. V SiOW MN4 '> + ~ Ei51eevei:h isidevS God Wi'JKNeiM su .6# f Sleeve - Lower Tube Tube in; , dM:. 4.f ;.dLoadMd );DeflectionY 3;jlEI5nipido[+jyd 5[3 %.m*j ;!.QMfM:/Qh:j,)$$ iTh iTk ' Dellectida Deflection.

Tubesheet l

f;(7@$3^ ji ..n E6i 2, 3 ,3 ^*dj@!Rf' ? ikipF /KM ?~@(In);pl$l5(8ji ,.6;1 6 i i i , j A:4 ; CONDITIONA (*F) d('F)).i , :(In)" , J(In)1 L(In) ..(In)., ,R(ibs)M $Ti((In)Jip 1 i ? ' NOTE: Due to small variation, E and cr,,, value for normal operation,100% power, are used. i 1 8-13 t -,v,+,. --,mv. -w----.--,, .-,.-w.- ---,,r-e -..-e --,c.v- .-.,,,--.,--.m.w-.,., -w -.w+.-. -,. - < --- -, - - - - +. -. ,-.--w.. w.= -,r. - + + -

h. TADLE 8-5 AXIAL LOADS IN SLEEVE WITH TUDE LOCKED INTO Tube support I i k i 7A.... 4, . < :%W ' ;iy'&- m .c. .d.Ait.h..Q, 4.o.a'.T ; i '- .. surround, g. Upper - ~ Composite e

Composite [s JC Resultant:as-J M 4. 2 t:

1 . D ubes. ,(Tube', - 'f y; Member qd 'i! Member if ifSleeve lhedi-151eeve bad I $ M i. i M$2W' Kf $ $5 NP T c

  1. &oMi/Jh inTg wt.l;;

- r,ei (2T,+T,)/3 , benection. Denection* 8A , : toad ya 3 &-I.cid : a 4A;Denettion l'. < 5 'sa..:. l ((benecti$nj iM'-. ; Ap i-@ : 0~l.CONDITIONh EMS f% ige gjJij.hy a y,%i,'lKiG '=;a 3 y :s Q (8r.

.,,.. '--n

^ Fi c3 .e.n, o u! ::w w . := ~ ; % s ., u.p#$A : 9 MJb=.' / 5' 3: n x u. .. p0 'd 3NS-E'-ci 4.$ p .'g4 .JE 4 'M 5ff $ - NE:'. ' ' N;i3N ?f:L. :-

  • P n'-Ft

,.W.1, ; %[; ?:ti;.. p )R uPF)Ic/ lj p/::sMF"-)9;~ M. ?-(in) ' "j ' (in) ' , '-(Ibs) v>M I' i. ):' -f*-.- - L5 . i(In)iti.in intf:Un)N??3 2:5!/(Ibi) R.?.4 - M:M -.(in) ;,,- C

n.

I i i i i

  • NOTE: Due to small variation, E and cr,,, value for normal operation,100% power are used.

I r I L 8-14 -,--w.,- .-w e s*- v - -*--v...,r.,--,,# s.w-- vw,.wsw w.e w, r s. - e. m-, y, - ---.m--,-,-w--,-w-w,~r -4,,w-wr,,-www.-ni,..m-- y---

E.4.2 Sigved Tube. Lock-no at First Tube Sunoon Y~ a 4-1 e 8 8.4.3 Effect of Tube Pieansss Prior to Sleevine 8.4.4 Lower Sleeve Rolled Section Pushout Due to Restrained Thermal Exoansion ~. -.. emumme t i 1 5 / l t 8-16

3- - -m 8.5 SLEEVED TUBE VIBRATION CONSIDERATIONS The vibration behavior is :eviewed since the installation of a sleeve in a tube could affect the dynamic response characteristics of the nibe. i 8.5.1 Effects ofIncreased Stiffness Stiffness and snass have opposing influences on tube vibration. While increased stiffness tends to raise the tube natural frequency, increased mass tends to lower it. ABB/CE's vibrational testing (Reference 8.6) demonstrated among other things, that a solid rod of the same O.D. as a tube will vibrate at nearly the same frequency. However, the displacements for the stiffer rod will be significantly less. 1 In addition, if any contact is made between the tube and sleeve along their length, the increased damping will absorb more energy. The damping would have a significant i effect on amplitude of vibration. In light of this damping effect and the other above mentioned effects resulting from a sleeve inside a tube, the vibration performance of the tube / sleeve assembly is superior over the original tube. I 8.5.2 ' Effect of Severed Tube W l l i 1 8-17

l -m 4, ....o_._.. I 1 l 9 I t i 1. r i t k h a 4 l 5 t I r .i I a k i-1 I s t i 6 2 4 6 4 r j ~ i e _ f 1 n ( I b i a r a f r i ) t emmena i t i i I 4 f ? f 8-18 ~

~ - -.. ~ t i ) 8.5.3 &iemic Evahurion i e i h a t r i i b a + I 6 d I r ' i i w C 2 1 a f c !' I 4 t t a 1 i e d, t t 4 t j ( t h I .I J 4r T i i i t 4 4. h f -N q f i ? t 4 ' 19 e r w w e

i B t t a f 'It is concluded that a seismic event produces a small stress in the tube sleeve. I C i t Y t I t e ~ l 1 i ) 3 I t I s k ( l-8-20

1 8.6 STRUCTURAL ANALYSIS FOR NORMAL OPERATION 4 A static clastic analysis of the sleeved tube assembly was performed according to the. requirements stipulated in NB-3220 Section III of the ASME Code Section. His section ' i describes the methods used to analyze the upper tube weld. 8.6.I Fatirne Evaluation of Unoer Sleeve / Tube Weld a i l l l l 8-21

? The above described transient combinations, tabulated in Table 8-6, are inherently conservative. A stress concentration factor of four (4) was applied to the ILaized prunary plus secondary stresses for purposes of computing the fatigue usage factors. lhe msults of the analysis, including element stress tabulations at critical sections and-fatigue usage factors, are contained on Appendix 8A. All stresses and usage factors are ' satisfactory when compared to allowable stresses. For detailed results see Section 8.1.2, l Table 8-1 and Appendix 8A. l 8.6.2 Evaluation of Imwer Sleeve Rolled Section f i 9 i ? i f i t f l ~ 8-22 ~

TABLE 8-6 UPPER SI FFVE WFT D - TRANSIENTS CONSIDERFn I i i i 1 ) 1 h t i I l l \\ t 1 I 8-23 ~.

.,g..a-a 5 A'au 9 TABLE 8-7 LOWER SLEEVE ROLLED SECTION - TRANSIENTS CONSIDERED b s 1 8-24 ~

8.7 REFERENCES

FOR SECTION 8.0 - 8.1 ASME Boiler and P: essure Vessel Code, Section-III for Nuclear Power Plant Components,1%5 edition through Winter 1%7 addendum. 8.2 ASME Boiler and Pressure Vessel Code Case N-20, *SB-163 Nickel-Chromium-Iron Tubing (Alloys 600 and 690) at a Specified Minimum Yield of 40.0 Ksi". 8.3 U.S. NRC Regulatory Guide 1.121, " Bases for Plugging Degraded PWR Steam ~ Generator Tubes". ~ '8.4 ABB/CE Repon CENC-1161, " Analytical Report for Baltimore Gas and Electric Power Company Steam Generator", November 1971. 8.5 " Mechanical Vibrations", 4th Edition, by J.P. Hanog, McGraw-Hill Book Co.,- New York, New York, pg. 432. 8.6 " Vibration in Nuclear Heat Exchangers Due to Liquid and Two-Phase Flow," By W.J. Heilker and R.Q. Vincent, Journal of Engineering for Power, Volume 103, Pages 358-366, April 1981. 8.7 ABB/CE Nuclear Services Licensing Repon No. CEN-337-P, "V.C. Summer Steam Generator Tube Repair using Ie.ak Tight Sleeves", dated August 29,1986. i 8.8 EPRI NP-1479, "Effect of Out-of-Plane Denting Imads on the Structural Integrity of Steam Generator Internals," Contractor: Combustion Engineering, August 1980. 8.9 'Macon Wonh's (Carolina Power & Light - Shearon Hanis) fax to B. Bell on t " Required Inputs for Welded Steam Generator Sleeve Analyses", dated July 13,1995. 8.10."Model D4 Steam Generator Thermal and Hydraulic Design Data Repon for Carolina Power & Light Company - Shearon Harris Unit 1", WTD-PE-77-22 Revision 1, dated November 20,1984. 8.11, Inconel 690, Huntington Alloys, Inc., Huntington, W. Virginia. 8.12. ABB/CE Repon CR-9419-CSE95-1113, Rev. O, " Effects of Tube Plugging on BG & E Calven Cliffs Units 1 and 2 Steam Generator 'Ibennal - Hydraulic Perfonnance", July 18, 1995. i 4 3-j'- 8-25

O O e M FIGURE 8-1 WELDED SLEEVFJTUBE ASSEMBLY 8-26

n_- +a as sa a --n +u., e> a s- -a -n-.-a + .s .a + . 3 ee 8 e e a ? r h 9 I i a 9 F l \\ FIGURE 8

  • SYSTEM SCHEMATIC i

] 8-27 e .- l----.--.

i 4 e i f 4o e t i t a i 1. a' L t i 1 j-t I f i t T I i FIGURE 8-3 l t 1 STIFFNESS MODEL OF SLEEVE AND LOWER TUBE f I h a 8

  • i I

.a ,, a m 4 m. 4 na i e. 4wa F l s i f l 1 r 0 ? ? t l d I 'I I t ? 'f i - i f b t FIGURE 8-4 i l ? . SITFFNESS MODEL OF UPPER TUBE AND SURROUNDING TUBES l - E 4 8-29

l 1 t h r 5 { e i t t t 1 I r I i t s FIGURE 8-5 FINITE ELEMENT MODEL'OF UPPER TUBE WELD k 8-30 ~ 4 4 h n-W 9 s

6G APPENDIX 8A j i FATIGUE EVALUATION OF UP' ER SLEEVE / TUBE WELD P 1 i

  • e i

8A-1 1

i l 4 'i I 1 i [. L' MGURE BA-1 UPPER SLEEVE 1 TUBE WELD MODEL 8A. ' - ' - - - - - - ~ - - - -

l TABLE 8A-1A t i STRFAS RFRULTS.100% STEADY STATE AXIAL LOAD l 1 8 i ST WVE. SECTION 1 i I i i 1 s e l t I t I I i i l l ) l l l 1 8A-3

L-4*6%>.6Je4,.4h,& ~aJ e2Je @ 4 ,,,u. l t TABLE 8A-1A (Continuing) i . i + TUBE. SECTION 3 i i l ~ ! t i 6 L 1 aj h a 1 t i i ' I i J l i MM i ? I I e i I i i i i t i i i } + I i i ~ l 4-t f 2 - t 8A-4 i i

TABLE 8A-1B STRESS RESULTS.15% STEADY STATE AXIAL LOAD Si FFVE. SECTION 1 e i i i i I t 1 1 4 f 1 i i J 4 l i l BA-5

) ) ) TABLE 8A-1B '(Continuing) i i TUBE. SECTION 3 i I l i i f I i l 6 i [ I t t I t I fi -1 1 1 t I i l 'I 4 BA-6

i 1 TABLE 8A-1C 4 STRFRS RESULTS. 0% STEADY STATE AXIAL LOAD 1 ST FFVE SECTION 1 I i i i ,i 4 i e t i ? a i + 1 i l' e 4 0 i l t 8 1 I s 4 BA-7

. t ._j TABLE 8A-1C. (Continning) TUBE. SECTION 3 i l 6 i a f r i 9 ? E W F i P b [ 5 r O F f a 0 I b f i f i I 4 i i I + 4 7 8 6 b L l h a b b B t O 8A-8 i i 4

.. ;a = ~ *. TABLE 8A-2 1 FATIGUE EVALUATION . j i SECTION 1 - OUTSIDE SURFACE OF SLEEVE I i 5 e I I t -l t I l i i i i i t P l i i I l I i i 6 4-l l r i 8A-9 i t

9.0 SLEEVE INSTALLATION VERIFICATION 9.1 WELD INTEGRTTY 9.1. I' cleanine Oimhtion 9.1.2 h,ansen Oualification k i I i.. 4 r i I 9-1 1 l 1 1 s )

~ _.._._ _.- '=4-+44 -6.ee 4, 9.1.3. ' WeM Oualification i i a ? 5 t i r l 4 4 't i l . t, h t t i i 9 8 Mr M S i e k 4 \\'...

9.1.4 Ultrasonic Testing Oualification 9.1.5 Post Weld Heat Treat Oualification 9 9-3

+ a g. A __6-- L A a6,m. u m s I i t L 4 I b [ h L e h t b d L t Y S 1 i 5 1 ] 'W 94 i s t O

9.1.6 Summarv 7 3 c 9.2 - ROLLED JOINT. INTEGRITY l i i i i l 4' a ) 4 9.3. COMMERCIAL SLEEVE INSTALLATION l 4 - ABB-CE's_ commercial sleeving experience is shown in Table 9-3. The success rate for allinstalled welded sleeves is 98%. Since 1985, no sleeve which has been accepted based on U.T. and V.T. has been removed from service due to service related ) degradation,

This data is also compiled in Table 9-4 indicating the number of EFPY of exposure t

' sleeves in each of the specific plants have' experienced. The steam generators in which sleeves have been installed have experienced various tube degradation mechanisms, primarily' caustic secondary side attack and primary water stress corrosion cracking. In -l one of these units, Ringhals 2, six (6) sleeved tubes which had seen up to three (3) i EFPY were removed when the steam generators were replaced in 1989 (Reference 6.4). ~ Ev=mination of t'ese sleeved tubes indicated weld heights consistent with ultrasonic 4 9-5 c w r-, r-Y

i i I l i f ( I 9.4 : REFERENCES FOR SECTION 9.0 9.4.1 Test Report on Steam Generator Tube Cleaning for Installation of Welded l ~ Sleeves, TR-MCM-126. 9.4.2 An Investigation of the Installation of Welded Sleeves in R.E. Ginna Tubing, TR-MSD-128. I e 9.4.3 Sleeving Centrifugal Wire Brush Development and Life Test Report, TR-ESE-705. j 9.4.4 S.G. TSP /RTZ Sleeving-Tube I.D. Cleaning for 3/4 Inch O.D. X.042/.043 Wall j Tubes, 7.1-ESE-860. 9.4.5 Steam Generator Sleeving - 3/4 inch Program, Bladder Expansion Pressure, TR-l ESE-755. 9.4.6 Steam Generator Sleeving - 3/4 inch Program, Quahfication of RTZ and TSP Sleeve Expansion Tools and Bladder Life Test, TR-ESE-809. 9.4.7 Ultrasonic Examination of 3/4 inch O.D. S.G. Tube to Sleeve Upper Welds, TR-400-001. f t I I 9.4,8 Qualification of the Post Weld Heat Treatment Tool for Westinghouse "D" Series Steam Generators, 00000-ESE-830. i 9.4.9 Qualification of the Roll Transition Zone (RTZ) S1 3 Rolled Joint, 00000-ESE-826. i 9-6 l 1

t I I TABLE 9-1 i, 0.875 O.D. SLEEVED TUBE PWHT DATA s -f i 6 6 6 i I I i 3 l i r i i 1 t 1 l l l l l l 1 h I I t a 9-7 \\ l J

1 I - 4 i i I l t TABLE 9-2 l - 0.750 0.D. SLEEVED TUBE PWHT DATA ~ TUBES LOCKED AT ALL SUPPORTS - l V i 4 ~ ' i s e a i I I i i [ i i i r i I J 6 i ) T f i ) [ i L m t i I f 1 l { i f i h p 9-8 l l

e TABLE 9-4 - ABB-CENO S/G SLEEVE OPERATING HISTORY l Hot Leg Sleeve Es6 mated EFPY of Sleeve Opera #on (2) Plant Temp (F) Type (1) <1 1 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0l Total Ringhals 2 410 STAW 16 600 STAW. 571 599 59 16 1245 - Ginna 601 STAW 51 178 183 198 40P 104 36 1158 ~~ PTAW 63 29 48 107 247 Prairie leiend (4) 590 STAW 73 27 100 l STHT 117 158 62 33T Kewaunee (4) 590 PTAW 16 16 Zion 1 ' 594 STAW 61 124 445 128 756 Zion 2 (4) 594 STAW 162 170 82 414 Rmghals 3 (4) 610 RTHT 46 46 SPHT-22 22 d KRSKO (4) 619 RTHT '164 164 SPHT 16 16 Total 162 528 746 1014 0 866 262 0 577 128 0 177 0 63 4523 Cumulative Total 4523 4361 3833 3087 2073 2073 1207 945 945 368 240 240 63 63 (3) Notes: (1) Sleeve Type designa6ons and their totals are as follows: Totals STAW StandardTubesheet sleeves where the weids are in the As Welded condition 3737 PTAW Peripheral (inidacy Curved) Tubesheet sleeves where the welds are in the As Weided condition 263 STHT StandardTubesheet sleeves where the upper weld has been Post Weld Heat Treated 275 RTHT Rol Transition sleeves where the weld has been Post Weld Heat Treated 210 SPHT Support Plate sleeves where the welds have been Post Weld Heat Treated 38 (2) EFPY of opera 6on is based either on data received from the plant or calculated from the load factor i publahed in Nuclear Engneenng international for the period during which the sleeves have been in place. Operetng 6me is rounded to the neares 0.1 EFPY as of 1 July 1995 (3) 16 Sleeves which ran for a year at Ringhals 2 before T hot was reduced are included h totals for 600 F (4) Plants inspected with I-coil or Plus Point ECT probe s a 4 9-11

1 1 l l Pre Heat Treat Baseline .. a. . E 'E T. j j .- ww f ,8,9, Wuus - .D' I fee.===== Sue MB .n - se 85UstleM = M WB s .bunaiMEbup M =.M 9 99f" SfPtr y g 8534=== 90.et Tun===== le E ua uin.36 5 f.h 54 Wentge. e et MS emeess - e.===e-9,9,g, p ggpygegge + ar n ..., -,,, e 1i a,.a,* s i Z.I LW m u Emma M Ii l l Post Heat Treat - Oxidized Section ...r.

i..

O m.- I n

  • =8 WB.8Er SU.Et.========

13 9.f tes e .UU 9F5 SCG l > % SW19 0.EET g.a. - p SUS..eu FEER - WIWTt94

  • FF NB 1

y p .ff.MT T9Tfp O.NT I gg pan.- ow f5EW - SF.8EB ss... 89. uu

=

u i i t / e-- =. i e ItalesE9.R 13 pWER 94 9998 ,,,,FZ.I LU m o = n Post Heat Treat - Brushed Section t, o.e ~~ a-a ) e=rs - sw eau c.'em..===sesso.. $1 9 n as i I 1 u.rs w se sees g o - - s. l sore - m. e.= 1 .coaste.. n La g 998*. 9 0et* eerf ~ e,c, - i c eau

===* [ gyggs 39 e.., ses e u6 ea e, v e==.. en oc i 15.,LD' '*.*fR**Lt2' { 5 < -.crucT .. o.e.- e e@.si.e.Fs en OWEE $4 9990 rz.i t= m , s : ' =t w it, 1 = ;i m j F3 .3 m FIGURE 9-1 FOST HEAT TREAT - BRUSHED SECTION 9-12

t i i L i .i I i a t r 1 i i il t .i f I ? t i t t I i i r t i 1 i k HGURE 9-2 = 0.875 O.D. LOCKED TUBE TEST l 9 13

1 i i I a 1 a D t n: i o .k f w@ k I est Q 1 O = C$ N I m i i L k l k + t [ I

/ m MGURE 9-4 0.750 0.D. LOCKED TUBE MOCKUP ~9-15

I" l .1 h t - i, i I \\ ) f a i r i t i I t i t t t I i b t r c t 1 f f I e ? I -1 Eggerate Support Sleeve t ? FIGURE 9-5 0.750 0.D. TYPICAL TEMPERATURE PROFnFR f 1 [ 9-16 'I =

t t, i r t 10.0 EFFECT OF SLEEVING ON OPERATION I L .f I* - i l i f ' t.t I 1 a 'I f 7 ) 1 l. I P I ) i 4 9 e s 1 )~ 4 4 I t i ? 't 1 e 1 i 4 -- ) t I 1 h j 4 4 e 1 e r 4 4 i e (/ j o e..

y a

1 2 o a D Gd 9 10-1

.a l i e l t c -u. I -1 i ~ l i I i. 1 P i + l t i e b. i I e I '1 e i l I 1 ? e 1 i 1 n. 1 t i i 'J 3 e r 1 l i J 'l 4 l l i FIGURE 10-1 i ~ PERCENT REDUCTION IN PRIMARY SYSTEM FLOW RATE l -WITil SIEc7ES IN HOT LEG l 1 4 1 10-2

f I .!a l i i f;j I 1 k s.; i e t i i i t i I t l 2 I i t t j i i t HGURE 10-2 PERCENT REDUCTION IN PRIMARY SYSTEM FLOW RATE l WITH PLUGGED TUBES i i I s i 1 10-3 i

TM &l ' - ~ ~ ' ~ ~ ~ ~ SLEEVE TO PLUG EQUIVALENCY RATIO FOR CALVERT CLIFFS UNITS 1 and 2 l . SLEEVING EQUIVALENCY CASE CONFIGURATION RATIO SLEEVES / PLUG i ? i F I i i l i I 5 i i I I i l t t 10-4

- t' .~. . -. = APPENDIX A a PROCESS AND WFID OPERATOR OUATIFICATIONS i A.1 SLEEVE WELDING AND SLEEVE WELDER QUALIFICATION I. L Sleeve welding is qualified using an approved test procedure (Reference 1). The sleeving i test procedure is in compliance with applicable sections of the ASME Code. Sleeve j welders are qualified using test records in accordance with applicable sections of the Code. i The test procedure specifies the requirements for performing the welds, the conditions (or . changes) which require requalification, the method for examining the welded test assemblies and the requirements for qualifying the welding operators. Sleeve welding is 3 i qualified by performing six consecutive welds of each type which meet specified design i requirements. Welders are qualified by performing two consecutive successful welds of each type. A.2 REFERENCES TO APPENDIX A

1. Welded Steam Generator Tube Sleeve Semi-Automatic Gas Tungsten Arc Detailed Welding Procedure Qualification, Test Procedure 00000-MCM-050.

1 1 4 i l j 1 4 Y k e A-1 l 1 .}}

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