ML20112C267

Notice of Issuance of Amend 103 to License DPR-50

ML20112C267
Person / Time
Site:	Crane
Issue date:	12/21/1984
From:	Stolz J Office of Nuclear Reactor Regulation
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ML20112C223	List: ML20112C219 ML20112C257 ML20112C267
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NUDOCS 8501110112
Download: ML20112C267 (4)

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7590-01 U. S. NUCLEAR REGULATORY COPtilSSION METROPOLITAN 2DISON COMPANY JERSEY CENTRAL POWER AND LIGHT COMPANY PENNSYLVANIA ELECTRIC COMPANY GPU NUCLEAR CORPORATION DOCKET NO. 50-289 NOTICE OF ISSUANCE OF AMENDMENT TO FACILITY OPERATING LICENSE The U. S. Nuclear Regulatory Comission (Comission) has, pursuant to the Initial Decision of the Atomic Safety and Licensing Board dated October 31, 1984, issued Amendment No.103 to Facility Operating License No. DPR-50, issued to Metropolitan Edison Company, Jersey Central Power and Light Company, Pennsylvania Electric Company, GPU Nuclear Corporation (the licensees), which revised the license and the Technical Specifications (TSs) for operation of the Three Mile Island Nuclear Station, Unit No. 1, (the facility) located in Dauphin County, Pennsylvania. The amendment is effective as of the date of its issuance.

This amendment permits the return to operation of the repaired steam generators. On Auaust 25, 1983, the Comission issued Amendment No. 86 (48 FR 39709) which addressed a portion of the licensees' application of May 9, 1983. That amendment revised the TSs to recognize and approve the steam generator tube kinetic expansion repair technique as an alternative to plugging of defective tubes, only for purposes of steam generator hot functional testing using pump heat (non-nuclear), and permitted such hk o oo O

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7590-01 testing. Similarly, Amendment No. 91, issued on April 9,1984, further modified TS 4.19 to cover the total period of pre-critical (non-nuclear) hot functional testing of the plant.

This amendment completes the Comission's action on the May 9 application by further modifying the TSs to remove restrictions as to the period of effectiveness of the acceptability of the kinetic expansion repair process as an alternative to plugging defective tubes in the steam generators, thus permitting them to return to operation. Pursuant to the Licensing Board's Initial Decision of October 31, 1984, the TSs are further modified to add requirements regarding the condenser offgas radiation monitor, and conditions have been added to the license to require primary-to-secondary leakage restrictions, power ascension test program results availability, extended inservice inspection, evaluation of operational leakage, and reporting corrosion lead tests.

The application for the amendment complies with the standards and requirements'of the Atomic Energy Act of 1954, as amended (the Act), and the Comission's rules and regulations. The Comission has made appropriate findings as required by the Act and the Commission's rules and regulations in 10 CFR Chapter I, which are set forth in the license amendment.

Notice of Consideration of Issuance of Amendment and Proposed No Signifi-cant Hazards Consideration Determination and Opportunity for Hearing in con-nection with this action was published in the FEDERAL REGISTER on May 31, 1983 (48 FR 24231), and corrected June 14, 1983 (48 FR 27328).

In response to this notice, requests for hearing were filed by TMIA on May 19, 1983, as amended on June 23, 1983, and by Lee, Molholt, and Aamodt on June 30, 1983, as amended on July 13, 1983. Coments were made by six other persons and the Commonwealth of Pennsylvania.

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u 7590-01 On August 25, 1983, the Commission issued a Safety Evaluation,(NUREG-1019) related to this action and reopened the coment period to receive further public coments on the proposed no significant hazards consideration published on May 31. A " Notice of Additional Opportunity for Coment" was published in the FEDERAL REGISTER on August 31, 1983 (48 FR 39541). Addi-tional coments were filed by the Comonwealth of Pennsylvania.

A hearing was held on July 16-18, 1984, and the Atomic Safety and Licensing Board issued its Initial Decision on October 31, 1984, The Comission has prepared an Environmental Assessment and Finding of No Significant Impact which was published in the FEDERAL REGISTER on December 21, 1984, 49 FP,49740.

For further details with respect to the action see (1) the application for amendment dated May 9,1983,(2) Amendment No.103 to Facility Operating License No. DPR-50, (3) the aforementioned Initial Decision dated October 31, 1984, (4) the Licensing Board's Memorandum and Order (Rulings on Motions for Sumary Disposition) dated June 1,1984, and (5) the Comission's related Safety Evaluation (NUREG-1019), Supplement No. I to NUREG-1019, and the Commission's December 21, 1984 letter to GPU Nuclear Corporation. All of these items are available for public inspection at the Comission's Public Document Room, 1717 H 5treet, N. W., Washington, D. C., and at the Government Publications Section, State Library of Pennsylvania, Education Building, Commonwealth and Walnut Streets, Harrisburg, Pennsylvania 17126.

,.ss 7590-01 4

A copy of items (2), (3), (4) and (5) may be obtained upon request addressed to the U. S. Nuclear Regulatory Commission Washington, D. C.

20555, Attention: Director, Division of Licensing.

Dated at Bethesda, Maryland this 21st day of December 19G4.

FOR THE NUCLEAR REGULATORY COMMISSION i

Jo n F. Stolz, Chief 0

rating Reactors Branch #4 vision of Licensing T

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TECHNIC'AL EVALUATION REPORT Attachment i EVALUATION OF TMI-1 STEAM GENERATOR TUBE /TUBESHEET REPAIR REVIEW AND EVALUATION OF PROCEDURES DEVELOPED FOR ONSITE REPAIR-0F TMI-1 STEAM GENERATOR T11BES BY EXPLOSIVE EXPf.NSION mC PROJsCTcimos PRCAsslGNMsNT 10 l

NRC COKmACT NO. NRC4341 130 PRCTAsKs 311, 312, 313 l

Preparedby Frank 8n Research Center 20th and Race Streets Philadelphia,PA 19103 FRC Group Lander: T. Shook L. Leonard Aruperedfor Nuclear Reguistory Commission Land NRC Engineer: J. Rajan Washington, D.C. 20585 July 8, 1983 This report wee prepared as an account of work sponsored try an agency oe the United States Government. Neither the United States Govemment nor any eGency thereof, or any of the6r employees. rnekee any warrer:ty, expressed or implied, or assumes any legal liatuilty or

,oepen.imty ror any adtd party e us.. or th. roeuh. oe h

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resus, product or procese disclosed in thee report, or represents that its use by such third l

party would not infringe prtvoesty owned rights.

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TECHNICAL EVALUATION REPORT EVALUATION OF TMI-1 STEAM GENERATOR TUBE /fUBESHEET REPAIR REVIEW AM3 EVALUATION OF PROCEDURES DEVELOPED FOR ONSITE REPATR OF TMI-1 STEAM GENERATOR TUBES BY EXN.0SIVE EXPANSION mCPnoJacTc1 sos enc mumw 10

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NRC CONTP.ACT MC. NRC441130 MCTASKS 311. 312, 313 Preparedby Franidin Research Center 20th armd Race Streets Philadelphia, PA 19103 MC Group Lander: T. Shook L. Leonard Prepared &

Nucieer Reguistory Comrnumion Land NRC Engineer. J. Rajan Washington, D.C. 20555 July 8, 1983 This report was prepared as an account of work eponsored by an agency of me United States Government. Neither me United States Government nor any agency thereof, or any of meer empicyees, makes any warranty, expressed or impiled, or assumes any legal liability or responalbility for any mird party's use, or the reeutts of such use, of any information, appa-retus, product or procesa disclosed in this report, or represents that its use by such mord party would not infringe petvately owned rights.

Prepared by*

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TER-C5506-311/312/313 CONTEh"rS Section Title Pace 1

1 INTRODUCTION 3

2 Z2E 4

3 EVALIRTION CRITERIA.

4 TECINICAL, EVALUATION 5

4.1 Licensee's Depair Qualification Program 5

4.1.1 Description of the Licensee's Depair frecess 5

4.1.2 Historical Background of Repair Process.

6 4.1.3 Analytical and Experimental Background 7

of Repair Process 4.1.4 Adequacy of the Seal Between the Primary and Secondary Sides of the Tubesheet 9

4.1.5 Effects of the Kinetic Expansion Process on the Tubestaet Dimensional Integrity.

10 4.1.6 Effe.s of the Kinetic Expansion Process on the Design Adequacy of the Welded Connections in the Tubesheet/Shell section.

12 4.1.7 Adequacy of Residue ammoval.

12 4.1.8 Effects of the Einetic Expansion Process on Tube Pretensioning 13 4.1.9 Adequacy of Tube Pullout Strength 14 4.1.10 stress concentration in the Tube Transition Length of Expansion.

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TFJN:5506-311/312/313 CCHTENTS (Cont.)

Section h

Page 4.2 I.icensee's Evaluation Prograss of Stress and Perfarmance of Tube /Tubesheet Assembly.

16 4.2.1 Stress and Performance of the Espended Tubes Subjected to various Imed conditions 16 4.2.1.1 mar==1 operating Pressure.

16 4.2.1.2 Thermal Transient.

17 4.2.1.3 Flow = Induced vibration.

17 4.2.1.4 Seismic Accelerations and Displacements la 4.2.1.5 Isso-of-coolant Accident 18 4.2.1.6 Main Steam I.ine Break.

la 4.2.2 Tubenheet I.igament Strength.

18 4.2.2.1 Change in I.igament Width After Repair.

19 4.2.2.2 Warping of Tubeekeet 19 4.2.3 Effect of the Change of Tube Pretension Isad 19 4.2.3.1 Frequency of Vibration of Espanded Tubes 19 4.2.3.2 Fatigue Life of Expanded Tubes.

20' 4.2.3.3 Buckling of Expanded Tubes.

20 20 4'. 3 Independent Test Prograa 4.3.1 Test Specimens.

20 4.3.2 Test Procedures 20 4.3.3 I4aktightness Tests.

23 4.3.4 Tube Interference Fit and Tubesheet Residual Stress 24 4.3.5 Tube Pullout 29 4.4 onsite Monitoring of popair Process 31

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TFJH:5506-313/312/313 CONTENTS (Cont. )

Section Title Page 35 5

OPEN ITEMS.

36 6

COBCLUSIONS.

38 7

REFERENCES.

APPERDIX A DOCUMENTS RECEIVED APPENDIX B MEETINGS ATTENDED APPENDIX C STATEMENT OF CONSUI. TANT APPENDIX D TEST PROCEDUEES

' APPENDIX E TEST D M APPENDIX P PECTOGRAPES OF TEST ASSEMBLIES l

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TEM 5506-311/312/313 10ED00BD This Technical Evaluation Report was prepared by Franklin Research Center under a contract with the U.S. Nuclear Regulatory Ccenission (Office of Nuclear Beactor Regulation, Division of Operating Reactors) for technical assistance in support of MEC operating reactor licensing actions. The technical evaluation was conducted in accordance with criteria established by the NBC.

Contributors to the technical content of this report were L. Leonard, T. Shook, V. Luk, C. Davey, D. DeCleene, and R. Brooks of Franklin Research l

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TER-C5506-311/312/313 1.

INTacocCTIcu In November 1381, steam generator tube leaks were discovered at Tktee Mile Island Unit 1 (TMI-1) during pressurization for functional testing following an extended cold shutdown period. Se conclusion resceted by the j

Licensee, GPU Nuclear, after the performed failure analysis was that sulfur con h aination caused intergraaular attack and cracking in the upper ends of the Inconel 600 tubes in the regions of the weld heat-affected zones and the 2-in roll seals. Because scat tube cracks were in the upper 2 in of the 24-in-thick tubesheet, the Licensee proposed establishmaat of a new load-bearing and leaktight seal below the defects as the optinua manner in which

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the generators could be restored to service. The Licensee fure.her proposed l

that the new seal be formed by kinetic (explosive) expansion of the individual tubes and that an expanded length of 6 in be qualified as meeting the load-carrying and leaktightness objectives.

To verify the adequacy of the proposed repairs and to d==anatrate that the kinetic expansion would not compeceise the structural integrity of the generator, GPU Nuclear, in association with Babcock and Wilcox (B&W) and Foster Wheeler Energy Application (Foster itseeler), conducted c series of tests and analyses.

As a further check on the proposed repair process, Franklin Research center (FEC), under contract to the NEC, conducted an independent testing program and reviewed the Licensee's data and analyses regarding the repair's effects on the generator.

Expansions were carried out on acck-ups that simulated the actual materials and surface conditions in the once-through steam generators (0:sGs);

leak testaand pullout tests and dimensional measurements were performed on the expanded samples, both in the a-5 = W condition and after they had been subjected to load and thermal cycling that sinutated 5 years of typical service. In addition, full-scale expensions were performed on a ccaparable B&W steam generator to evaluate the stresses imposed by the repair process and their effects on the CrrSG structure.

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i ten-C5506-311/312/313 The results of the various testing and analyses programs indicated that GPU maclear should implement the repair process, and the procedure was carried out. At the time of publ.ishing this report, FIC had not received documentation of the oraluation of the repairs by eddy current, dimensional, and hot functional testing.

Included in the present report are (1) a discussion of the Licensee's testing and analyses, (2) a presentation and discussion of FEC's tests and analyses, and (3) FEC's c-inaions concerning the espected adequacy of the repair pr~ ance and its influence upon the structural integrity of the generators.

The appendices present documents received, meetings at*= Mad, test procedures, test data, and the statement of a consultant with considerable experience and expertise in the field of explosive expansion techniques who was retained by FRC for this project. Photographs of the test assemblies are also included.

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TER-C5506-312/312/313 2.

SCQFE The scope of the evaluation was as follows:

1.

Review the Licensee's development and testing programs and conduct independent testing to evaluate whether the Licensee-developed kinetic expansion repair procedure is capable of producing a tube /tubesheet seal with less than a specified leak rate and greater than a specified pullout strength.

2.

Carry out independent analytical and experimental work to determine whether the kinetic expansion repair procedur.e has any adverse effects on the orsG's structural integrity.

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EVALUATION CRITERIA The Licensee specified that the repair process must satisfy all applicable design parameters originally used for the TMI-l OrSG aed must comply with the requirements stated in the following documents:

GPU mw=1ame THI-l OTSG Tube Repair Pr=14=4amey Specification No.

1101-22-006, Rev. 4, including codes and standards listed in Paragraph 3.2. [1]

naherw+ and Wilcos (B&W) Company's Explosive Expansion Qualification Requirements for Mechanical Testing (61-1134292-00) for Explosive Expansion Repair of Or$Gs [2].

Specifically, the kinetic expansion repair process was to result in a tube-to-tubenheet seal with a leak rate less than 3.2 x 10 ' lb/h per tube

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and a pullout strength greater than 3140 lb.

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TEIMICAL EVALUATION 4.1 LICENSEE'S REFAIR QUALIFICATION PROGRAM 4.1.1 Description of the Licensee's Receir Process Based upon a developmental test program, GPU Nuclear, in asacciation with B&W and Foster Mbeeler,' developed a tube repair method using an explosive (kinetic) technique [3] to expand a sufficient length of undamaged tube below the defects to form a new tube /tubesheet seal. Although specific details of the expansion process are considered proprietary by GPU Nuclear, it can be j explosive expansion was deemed optimum to effect a new seal without inducing distortion in the tubesheet. In this procedure, a detonating cord charge is inserted in a polyethylene tube or " candle".which, in turn, is placed in the tube to be =wp= M. The explosive force from the charge drives the candle against the tube, forcing it against the tubeabeet.

The total length of the expansion joint and the portion of that length to be qualified for specific leak rate and pullout strength goals were selected primarily on the basis of the locations of the tube defects and the maximum number of tubes that would be repairable by a standardized procedure.

o Accordingly, all repairable OrSG tubes were expanded over 17 in. Those tubes with defects more than 11 but less than 16 in below the top surface of the tubesheet were expanded over a 22-in length in all cases. The lower 6 in of the expansion is the qualified seal.

The tube /tubesheet seal is a mechanical interference rather than a metallurgical weld between the tube and the tubesheet and is influenced by such variables as the size and nature of the explosive charge, the mechanical characteristics of the tube and tubesheet materials, the spacing between the components, and the nature of the components' surfaces.

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TEA C5506-311/312/313 4.1.2 Historical Background of Repair Process 4

12ie use of explosive energy to form metals is not a new technique its applications and successes predata the serospace age [4], and the.procesa for emplosively expanding rings has been discussed in some detail (5]. In forming a specific shape, the explosive drives the workpiece metal into a forming die. In order to distribute the pressure uniforsly over the workpiece and to eliminate local hot spots and fragments from the detonated amplosive, a trans-mitting inter== diary== din =, usually water, is placed between the workpiece and die. In addition, the space between the workpiece and die is usually evacuated.

In the repair process for the 13E1-1 OTSGs, the M*aaheet served as the die, a tube was the workpiece, and the transmitting medium between the explo-sive charge and the tube was a polyethylene tube or " candle." This applica-tion of explosive expansions to seal a tube into a tubesheet is not a new process, and a few examples should suffice to demonstrate the effectiveness of this technique. In 1947', a leaking heat==*mager was successfully repaired I

by explosive expansion. Operating pressures of 1500 pai and poor surface finishes in the tubesheet holes and variation in their bore size did not adversely affect.the integrity of repaired joints (6].

A number of feedwater heaters have been explosively expanded in their original fabrication in a manner st=41ae to that proposed for the 13tI repair i

[7). As of August 1970, Poster Wheeler had built 200 feedwater heaters using exp,losive expansion, with up to 3000 expansion joints per heater..

Leaking heat exchangers have been explosively repaired while under 1500 pai steam pressure (8]. For example, the Yimpact section of Yorkshire Imperial Metals used explosive expansions to seal against leakage under pressures up to 170 atmospheres in a waste-heat exchanger which had rolled and welded tube /tubesheet jo,ints (9]. Subsequently, all joints were expanded as an additional safeguard against leakage.

Explosive expansion of carbon steel, brass, and Monel tubes into carbon staal tubesheets has been achieved in retubing operatiens on feedwater heaters (10). Hydrostatic, vibration, and thermal cycling tests have been applied to

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TE3H:5506-311/312/313 verify the integrity of explosively expanded joints. For example, Monel (SB 163) tubes expanded into a carbon steel tubesheet achieved pressure seals to

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12,000 psi after 100 thermal cycles and 500 h of vibration cycles.

In the Conner's Creek plant of Detroit Edison Company, in-place repairs were ande to replace existing tubes,with 304 stainless steel tubes 'against SA 179 carbon steel tubesheets (10). In this case, concentric grooves were cut into the tubesheet to provide good seals and to increase pullout strength.

4.1.3 Analytical and Erperimental Background of Receir Proctsa The magnitude of the explosive charge required to achieve a tube /tubesheet seal to meet the requirements indicated in section 3 of this report were determined in an experimental development and testing program conducted by Foster M2eeler in conjunction with B&W and the Licensee [11,12,13,14].

Using the method in maference 5, F3C e=Tani=ted an approximate pressure intensity necessary for tube expansion and found fair agreement with the appropriate explosive charges determined in the Licensee's experimental program. Because information on the dynamic stress-stress behavior and work hardening of the tube material, Inconel 600, was not available, the relative intensity of the

" expansions was determined solely by experimental testing. --

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It was demonstrated experimentally by both the Licensee and FRC that this procedure produced an adequate tube pullout resistance [15]. In addition, leakage data derived as a result of the experiments conducted for the Licensee and at FEC showed that, although some leaks may be expected immediately after expansion, the leak rate tends to decrease with time at the operating pressure of the OrsGs.

Although, the repair process (described earlier) of kinetically expanding tubes onto tubesheets is not new, this is the first application of this method to repair a nuclear steam generator tube in what is, in metallurgical terms, a g h-3.h Frankhn Re.s,e. arch C.orner a w wn.

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l TIA-C5506-311/312/313 sensitized condition, i.e., grain h adary precipitation of carbides had resulted from the strese-relieving heat treatment applied to the generators I

following their original fabrication, which involved mechanical tube rolling and seal welding of the tubes on the outside surface of the tubesheet.

Forming a new seal length below the old one and thus eliminating the upper cracked region of tubing from consideration is also a novel application.

Finally, the tube /tubesheet crevices were in an oxidised or corroded state stemming from both service operation and idle downtime exposure.

Based upon the history of successful applications of the explosive expansion of, tubes into a tubeeheet, both in fabricating new heat exchangers i

l and in repairing in-service ones, there did not appear to be any serious questions concerning the t=chnia =1 feasibility of the expansion p.:ocess.

1 Rather, efforts were concentrated on assuring that the procedure would be adequate to meet the tube /tubeeheet qualification specifications (sectica 3) for strength (pullout) and leaktightness, while at the same time not adversely affecting the structural integrity or fatigue resistance of the generators as a d ole.

Accordingly, to evalusta the adequacy of the repair process, the Licensee and FRC conducted comprehensive qualification testing programs using amm11 scale models [12. 13]. In addition, the effect of the kinetic erpansion process on the structural integrity and the performance of the tube /tubenheet i

assembly and its supporting system was assessed (3,15].

Conditions representative of those in the OTSGs were reproduced in test samples. Se Inconel 500 tube samples were from the same production heats as those used in the OTSGs and were of two different strength levels. The tubesheet steel met the same specification - SA508 C12 - as the tubesheets in the OTSGs. All materials were heat treated to simulate the stress relief treatment to which the generators were subjected and to oxidise or corrode the tube /tubesheet joint surfaces to a condition similar to the actual ones-in the OTSGs.

Single tube /tubesheet expansion samples (Figure 1.1 in Appendix D) were used for initial evaluations and for developing procedural specifications.

Tubes were then expanded into 10-tube acck-up assemblies on which leak and g'J.h Frankhn Re.s,ea.rc.h. c.e.rner

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TER-C550(-311/312/313 pullout tests could be carried out (Figure 1.0 in Appendix D). The presence of cracks in the OTSG tubing was taken into account in the mock-ups with a simulated 360* crack. Two separate tube lengths were placed in each tubesheet hole. A 2-in stub length was initially rolled into the tubesheet test block and then it and a longer test section, which included the 6 in to be qualified as the new joint, were explosively expanded.

S e assemblies, which permitted an evaluation of the effects of after hits on individual tube /tubesheet seals, were subjected to leakage tests under representative pressure differentials between the inner and outer diameters (ID and OD) of tubes. In addition, the assemblies underwent thermal and axial load cycles to simulate 5 years of operating service, including start-ups, shutdowns, power changes, and accident conditions such as loss of cooling (LOCA), main steam line break (MSLB), and feedwater line break (FMLB).

Tests have also been run on an out-of-service saw steam generator at s4t.

't Vernon, Indiana, to investigate the effect of the kinetic expansion process on equipment similar to the THI-l CTSGs.

4.1.4 Adequacy of the Seal Between the Pr4==7 and Secondary Sides of the i

Tubesheet As stated in Section 3, the desigr. objective for the kinetic expansion was to produce a seal to limit the total primary-to-secondary leakage from the TNI-l CTSGs to 1 lb/h per plant under plant operating conditions, or 32 x 10 lb/h per tube (there are 31,062 tubes per plant). Se technical specification limit for the ' plant is 1.0 gal / min (500 lb/h) total leakage for both generators.

The water leak tests were conducted by the Licensee in accordance with Reference 11 and the logic chart in Figure 2-16 of Reference 15.

Seven expanded assemblies, consisting of the 10-tube corroded blocks with 360* fully severed tubes as described previously, were subjected to a series of leak tests using domineralized water at 70*F + 15'F.

The tests evaluated the effects of the expansions and of thermal and axial load cycling equivalent to 5 years of plant operation (section 2.4.2 of Reference 15) on the leakage rate.

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TFJH:5506-313/312/313 Se test spec 4=ana were subjected to a pressu::e of 1275 psi on the primary side to simulate nocmal operating conditions (Para. 4.4.2 of Reference

1) and 1275 psi on the secondary side to simulate the LOCA condition (Para.

5.3.1 of Deference 16). A water leak test was performed on a block subjected to 2500 psi to simulate the worst accident, the usLa ::oedition (Para. 5.3.1 of Deference 16).

Se leak test results indicated a 994 statistical confManca level that the water leakuge rate for 99% of the r

. -- ted tubes was less than 132.4 s 10 lb/h per tube (3],* which exceeds the qualification goal of 32 x 10 14/h per tube. S e tubes subjected to thermal cycling yielded leak rates

-4 varying from 1.18 x 10 to 187.4 z 10 lb/h per tube. S e leak rate results for tubes after room-temperature axial load cycling were 30 x 10 14/h per tube after 90 hours0.00104 days <br />0.025 hours <br />1.488095e-4 weeks <br />3.4245e-5 months <br /> of curing [171 One test block was tested at temperatures ranging between 10*F and 400*F, and the leak rate results showed insignificant variations.

According to Reference 3, during the repair process at TMI,15 new addy current test indications were detected in the 6-in qualification zone out of approziantely 435 initial espansions in both steam generators. S e Licensee determined that these new indications most likely were not from new defects caused by the expansion process, but rather from defects which were below the threehold of detectability of the eddy current testing technique employed prior to expansion. Based on fiberscope examination, these defects appeared to be pits and scratches of a size that would nor % fluence the reliability of the joints.

4.1.5 Effects of the Itinetic Expansion Process on the Tubesheet Dimensional Integrity Se objective of the kinetic expension process was to explosively expand tubes into the tubesheet without altering the ligament and the pitch distance of the tubesheet. It was therefore essential to maintain, after the kinetic

• The statistical confidence level of 999 for 994 of the tubes, referred to as

$9/99, is also used in the tube pullout evaluation in Section 4.1.9.

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expansion process, the dimensional integrity of the tubesheet, which has a direct bearing on the tubenheet ligament strength. Using; charges determined 1

i in the test program, the Licensee found a minimal effect on the diameter of adjacent tubesheet holes in the 10-tube test blocks due to the expansion process.

c Full-scale tube "xpansion testing in a similar staam generator at Mt.

e Vernon using strain gages and profilometry also showed no degradation of the tubesheet ligaments [3].

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tensile stress of 95,000 psi was recorded' during.

the expansion process. In spite of the fact that the static yield stress of the tubesheet was 67,000 to 70,000 psi, no residual strains were noted following the expansion., the Licensee concluded that the dynamic yield strength of the steel, which can be up to twice the static yield, was not exceeded and thus no deformation would occur in the TMI-l CPfSGs.

Bowever, since only a limited number of tubes were awpandad at Mt.

i Vernon, it is not clear that this is a valid conclusion. Furthermore, tnere will be tubes distributed throughout the THI-l OTSG tubesheet which will require 22-in reexpansions, and this additional, nonuniformly distributed g

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deformation could induce scan tubesheet warpage. Accordingly, it is recommended that measurements be made on the tubenheets at TMI following the repair process to establish the degree of warpage, if any.

At the time of this final report preparation, FEC had received no information as to whether tubesheet warpage had been evaldated by the Licensee.

A number of welds at the top of the upper tubeabeet at TMI were cracked during the expansion process. The mechanism responsible for this cracking and its effect on the tubenheet ligaments in the immediate vicinity of the damaged welds have not been identified and evaluated. At the time this report was written, FEC was informed that the cracks on the outside face of the tubesheet were e,round away to eliminate any stessa risers. Since the actual qualified tube /tubenheet seal is in the last 6 in of the 17-in expansion, these welds no longer serve any leak-prevention or load-bearing purpose; thus, grinding of the welds shculd not present any problems.

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1 TFJN:5506-311/312/313 4.1.6 Effects of the Kinetic manion Process on the Desi.cn Adecuacy of the welded connections in the Tubesheet/shell section-Se kinetic expansion process may affect the structural integrity of welded connections in the vicinity of the tubesheet, tspecia My iA the tubeeheet/ shen junction. To determine the nature of this effect, the Licensee used strais geges and an accelerometer to seasure loads imposed at two locations on an out-of-service steen generator at Mt. Vernon (18,19].

One location was the junction between the inlet header and the tubesheet, and the other was at the shell weld location underneath the tubesheet. S e strain gege measurements were taken at the two ends of a diametral row of 132 tubes J awpandad at the same time. On the basis of these data, the peak stresses and stess intensity were calculated for fatigue evaluation. An accumulative usage factor

• of 0.12 was *=1-utated on the basis of the conservative assumption that every expansion, inelnnMag thcee in faraway rows, win produce the same stresses at these locations. S e low usage factor led the Licensee to conclude that the welded connections in the tubenheet/ shen section wecid not be affected by the expansion process and that it is acceptable to use simulta-neously a==u4=u= number of 137 charges, a combination of 132 charges in the longest row plus up to five misfires from the previous row.

4.1.7 Adequacy of Residue Removal S e kinetic expansion process produces sulfur reaidue and polyethylene cartridge debris which must be removed. There were concerns over the inherent sulfur rgsidue derived from the explosive asterial used in the repair process (pentaecythritoltetranitrate), even though ti's sulfur content as sulfates does not norum11y exceed 0.54 as sulfuric acid (20]. S is concern was partially alleviated by the Licensee's specification that any material, i.e, candles or explosives, to be introduced into the OrSGs contain r.o more than 250 pga sulfur and 250 pga total chlorides and fluorides. Also, the polyethylene cartridge captures a latge portion of the reaction products from the detonation. The

• rne usage factor is defined as the percentage of the useful life consumed

~

through cyclic loading.

• j f'J.'.u Franken.n.seare.n C.enier Re r

TEA-C5506-311/312/313 surface contamination problem was further mitigated by precoating the exposed which is a water-soluble surfaces of the steam generator with cleaning agent with no critical contaminants and for which there are extensive application data (15). The Licensee successfully demonstrated the application of

, in test mock-ups and Mt. Vernon tests (15].

A remaining concern is the polyethylene cartridge perforation. During preliminary and qualification testing, " blow-throughs" occurred in cart' ridges

+

Testing and analyses were conducted by the Licensee to examine the

[211 expanded tubes that have experienced blow-through. Me*=1'agesphic analyses were, performed on test specimens to assess the condition of the tube ID at blow-through locations which might experience higher local stresses than any l

other portions of awpandad tubes.

The' Licensee has not addressed this issue in Topical Report 008 [3], and FEC has not been informed of any action concerning this aspect of the expansion process evaluation.

4.1.8 Effects of the Kinetic 'wamamion Process on Tube Pretensioning

~

All tubes of the steam generators were pretensioned at the fabrication stage so that they would not be in compression when cold. According to Para.

3.5.3 of amference 1, the repaired tube tensile preload shall not be changed by more than + 30 lb at ambient temperature. This design objective of l

amintaining the tube preload tension is necessary in order not to change the vibrational. characteristics of the tubes.

The change in the pretension in the tubes due to the kinetic expansion j

process is a direct function of the change in the length of the tubes caused by the repair process. The Licensee conducted induced strain tests on test blocks to take length measurements of tubes before and after the From the viewpoint of material behavior, i

' The not change in length of

'may therefore be insignificant, leading to the general tubes after belief that the change in tube pretensioning due to the repair process will also be minimal. The Licensee's test results confirmed this belief. Induced s

'.: - 4N Frankhn Re.se. arc.h C. enter

/

'.. ac==maern.

m.

TER-C5506-311/312/313 strain measurements taken before and after the expansion process showed maximum longitudinal strain va uns,

which is less than the design

~

limit of 30 lb.

4.1.9 Adequacy of Tube Pullout Strength me Man at the interface of the tube and tubesheet produced by tha kinetic expansion process is purely mechanical, and the holding strength is the frictional force derived from the contact surface pressure between tube and tubeabeet. It is therefore important to maintain tight contact in order to sustain the desired holding strength at the bonding surface.

According to Para. 3.5.2 of Beference 1, the repaired tube is expected to sustain the anzimum design basis axial tensile load of 3140 lb from the 177-FA MsI,a accident analysis (see Tacle 5-7 of Beference 16). Satisfying this qualification objective requires that no slippage will occur at a 3140-lb load. The Licensee conducted tube pullout strength tests in accordance with Foster leiseler Test PrWee No. 5054-QT-9 [111 The effects of thermal cycling, asial loading, and the number of after-shots on the tube pullout strength were evaluated. Seven 10-tube test blocks were subjected to pullout tests at an ambient temperature of 70*F + 5*F, and one test block was maintained at an elevated temperature of 330*F during testing.

Several factors interact to influence the elevated temperature 'ullout p

s trength. Mose factors include the relative coefficients of thermal expan-i sion of the tubesheet and tubes, the degree of relaxation of the circumferen-l tial residual stresses contributing to the tube-tubesheet seal, and the.

lowering of the yield strength of both the materials. The latter factor is important since overcoming the friction between the two surfaces involves yielding of surface irregularities on the interacting, unbonded components.

'Sie differences in the coefficients of expansion lead to a tighter joint at elevated temperatures, while stress relaxation and a lowered yield strength would degrade pullout capacity both a,t the elevated temperature and subse-quently at lower temperatures. The short-term effect of 610*F temperature l

%=Franun Reseeren Center E;: 2.h l

4On ameW Thep - -

---

n-

TEB-C5506-311/312/313 exposure was demnnstrated by the Licensee's pullout results af ter 30 cycles of 70*F to 610*F to 70*F.

A slight decrease in pullout at room temperature was

noted, Accordingly, it is unlikely that a more prolonged 600'F exposure would critically degrade the room tenIperature pullout strength.

The Licensee's pullout tests at 330*F on one 10-tube block which had been thermally cycled as described above gave, and a 99/99 statistical confidence of pullout As pointed out by the Licensee, this,

. in mean pullout load at elevated' temperature is stat'istically significant, and'it is attributed to the reduction in yield strength of the material at elevated temperature." No testing was done at the 650*F design temperature. Bowever, when the 330*F data were extrapolated to the 650*F design temperature, a mean slip load of was obtained, and, assuming that the standard deviation would be the same at 650*F as at the 330*F test temperature, it was concluded that the 3140-lb goal would be " easily met".

Although it is not clear that the extrap-l olation is valid, the 3140-lb pullout load goal is so conservative [17] that there appears to be no cause for concern that tube slippage will occur at 650*F under an MSLB.

Additional crsnfidence concerning the adequacy of the repair procedure was gained after the tube pullout test conducted at Mt. Vernon showed a load-carrying capability 4.1.10 Stress Concentration in the Tube Transition Length of Expansion A requirement imposed on the repair process was that the magnitude of the residual stresses at the-transition region between the expanded and unexpanded portions of the tubes on the downstream side of the expansion be minimized in order to reduce the possibility of stress-corrosion cracking. Since an abrupt transition results in higher residual stresses and larger stress concentra-tions, the goal was to limit the transition length to between 1/8 and 1/4 in

• See footnote on page 9.

g.n-h 3.h Frenaden Research Center A Quese af The Pseuse numan

.., _ _ -. - ~ -, _ _ -,. _., _..

l 1

TEA-C5506-311/312/313 (Para 3.6.1 of Beierence 1). It was further required that the residual i

tensile stresses (both circumferential and axial) in the transition region should be less than 45% of the 0.2% offset yield stress at room temperature (Para. 3.6.2 of Beference 1). Stress====4 nations were conducted *at Penn-sylvania State University using special E-ray diffraction and strain gage techniques to find post-kinetic espansion tube stresses in the transition area at the bottom of the espansion and at a second point n2ar the middle of the

~

expansien. The Licensee stated that the requirements were met [3]; however, the detailed test results were not made available to FEC at the time of this writing.

4.2 LICENSEE'S ETALDATIQFS PRCERAK OF STRESS AMD PERFORIGu1CE OF TUBE /TUnemrywT ASSEMBLY 4.2.1 Stress and Performance of the Expanded Tubes Subiected to Various Load Conditions An evaluation was ande of the stresses on and the performance of the awpandad tubes when subjected to the following load conditions:

a.

normal operating pressure b.

thermal transient

~

c.

flow-induced vibration d.

seismic accelerations and displacements e.

lose-of-coolant accident f.

main steam line break.

4.2.1.1 Normal Operating Pressure The normal operating differential pressure is 1275 psi (Para. 4.4.2 of Reference 1).

Seven 10-tube blocks were subjected to a series of water leak tests specified in Poster meeler Document No. 5054-QP-1, Rev.1, Para. 5.4

[11] and Test Procedure No. 5054-QT-4, Rev. 0 [11). The operating pressure was supplied on the primary side of the tube for six of the test blocks; the seventh block was pressurized on the secondary side (discussion of this is found in Section 4.2.1.5).

Desdits of the leak rate tests performed by GPU t

Nuclear have demonstrated that the seal between the primary and secondary

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.# m e.

1

., - - - - - -,, -, -,, -, ~., ~,,, - _. - - _ _ - - - - - - - - ~, - - - - - - -

1 TEA-C5506-311/312/313 sides of the tubesheet is functio--11y effective with leak rates well below the technical specification limit but slightly higher than the repair design objective of a maximum water leakage rate of 1.0 lb/h per plant.

4.2.1.2 S eraal Transient Beforence 22 (the specification for the Licensee's thermal cycling program) states that transient No.1 (heatug/cooldown) goes from 70*F to 557*F and back to 70*F, and that there are 240 full design cycles to simulate 40 years of service. Also, there are 64 design cycles related to thermal transient lwW for reactor trips. To simlate 5 years of servic'e, the test procedure required thermal cycle conditioning of seven 10-tube test blocks from 70*F to 610*F and back to 70*F 38 times (30 heatup/cooldowns and 8 reactor trips). [1]. S e effects of these cycles on leak rates and pullout strengths are discussed in Secti,ma 4.1.4 to 4.1.3.

4.2.1.3 Flow-Induced Vibration A tube vibration test was conducted during the design stage in the IS60s using a typical OTSG Inconel tube with 0.625-in outer diameter, a length cf 52 f t 1.375 in, and a wall thickness of 0.035 in [23]. S e test specimen, which rep;esented the exposed portion of tube, was fixed at the ends to simulate the effect of the tubesheet and was supported between the ends by supports similar to those in the full-sized unit. S e test results demonstrated satisfactory i

performance of tubes during vibration. Since the expanded portion of the tube inside the tubesheet was not included in tne vibration test, the kinetic repair process did not affect the established test results.

According to Reference 3, the Licensee evaluated the effect of a high cycle flow-induced vibration bending load plus a thermally induced steady axial load on tubes. A maximum axial tension of 500 lb can be exerted on tubes due to the shell-to-tube temperature difference during steady state operation.-

The flow-induced vibration loading combined with a cooldown of 100*y/h can generate a maximum tube tension of 1107 lb.

Se Licensee's study showed that if there were any undetectable defects (i.e., defects with less than 40%

Y~A 3.h Fren6 din Research Center A(been af The Feuen umanse

TER-C5506-311/312/313 throughwall cracks) in tubes, they would remain, stable and would not propagate under these loads.

4.2.1.4 Seismic Accelerations and Displacements According to Para. 3.2.2 of Beference 1, the repaired tube is a Seismic Category 1 component in accordance with Begulatory Guide 1.29 and a Class 1 component in accordance with megalatory Guide 1.26.

Se seismic boundary (the portion of the tube /tubesheet configuration which should be seismically qualified) for the expansion esteeds down to the end of the qualified 6-in length. Sia change in the structural configuration of the expanded tubes is minor and will probably not produce any significant effect on the performance of tubes subjected to seismic di=p1 - t and accelerations. Bowever, the Licensee has not addressed this issue in the Topical Report 008 [3].

4.2.1.5 Ioss-of-Coolant Accident The lose-of-coolant accident (LOCA) is simulated by the pressure loading test described in Section 4.2.1.1.

The test pressure of 1275 psi from the

= Mary side of the tubes is conservative in view of the value of 925 psi given in Reference 16 (pp. 5-6).

4.2.1.6 Main steam Line Break A main steam line break (MSLB) subjects the tube to a tension of 3140 lb

[16), the highest tension of any design condition. In order to sinnlate this condition, a pressure of 2500 psi was applied on the primary side (Para. 5.3.1 of Reference 16) in the water leak tests discussed in section 4.1.4 of this -

report.

4.2.2 Tubesheet Licament Strenoth An evaluation was made of tabesheet ligament strength due tot a.

change in ligament width af ter repair b.

warping of the tubesheet.

dA Uh Frankhn Research Center A h of the Psumen auenas e

L i

TFJt-C5506-311/312/313 4.2.2.1 Change in Ligament Width After Repair According to Reference 3, the test results from test' blocks and the Mt.

i Vernon steam generator showed minimal changes in tubesheet ligament width due to the expansion process'.

4.2.2.2 Warping of Tubenheet mere is concern as to whether the process will cause the tubesheet to warp due to nonuniform espansion of the holes through the thickness. It has been postulated by the Licensee that the unit A tubesheet might have alr'eady been warped, based on the high concentration of defective tubes in the peripheral area of the tubesheet.

J This problem should be addressed by the Licensee (Para. 3.5.4 of Reference 1).

i 4.2.3 Effect of the Chance of Tube Pretension Imad An evaluation was made of the effect of the change of tube pretension load on:

a.

frequency of vibration of a'rpaad=4 tubes b.

fatigue life of expanded tubes c.

buckling'of expanded tubes.

l.

4.2.3.1 Frequency of Vibration of Expanded Tubes Se amount of pretension to which a tube is subjected affects the natural frequency of the tube, i.e., the higher the pretension, the higher the frequency. If the pretension is altered due to the direct effect of the repair process on the tube or the indirect effect on the tube due to warping of the tubesheet, the natural frequency will change. Various analyses (231 l

have shown that the change in frequency due to change 'in tension will be less than 6.5 Hz for a 200-lb difference in tension. M e Licensee's test results showed a maximum reduction of.

in tube pretension due to the expansion process. Sus, the repair process has a minimal effect on the frequency of vibration of the tubes.

e

_1,_

3.h Freniden Research Cereer j

a n==== as tne raman summe.

TFJWC5506-311/312/313 4.2.3.2 Fatigue Life of Exp ided Tubes Since the tube pretensi i change is small, there is no reason to expect that the fatigue calculation, based on transient loads presented in Reference 16, Para. 6.2.3, would signi Lcantly alter the fatigue life of awpanaad tunes.

4.2.3.3 Buckling of irwpaada Tubes In ther absence of prete: sica, the largest negative load (compression) of

-775 lb in the tube occurs d -ing transient No.1 (Reference 15, Table 5-41 Since the pretension is 1000 lb, a san 11 perturbation in pretension should not put a tube in danger of buck. ing, which will occur at about -700 lb [23].

4.3 IEDEPENDENT TEST PROGRAI 4.3.1 Test specimens All tubes and tubesheet samples tested were supplied by 1Lahr=rw* & Wilcox, along with data daaracterizi: 3 the materials. All semples were heat treated to simulate strength levels id surface conditions in the orSGs. Drawings of the test assemblies, which we ce either single-tube or 10-tube sock-ups, are shown in Appendix D.

The test specimens consisted of two 10-tube /tubesheet acck-ups, six single tube /tubesheet mock-urs, and insert assemblies which provided the means of detonation for the expans an process.

One of the 10-tube asse 311es was shipped directly to FBC for expansion and subsequent tests. Se s :ond.was expanded by Foster Meeler Corp. and then shipped to FRC for simi tr testing. Rose two (identical) units are depicted in Figure 1 of Appe lix D.

Se single-tube assemblies and the plastic insert primacord ass elles are seen in Figures 1.1 and 1.2a, respectively, of Appendix D.

4.3.2 Test Procedures n e tests which compris i the independent test program are listed below.

A detailed description of th test procedures is given in Appendix D.

Some 1-4 -

'J W Frankhn Re.neerch. C.orner a w evmrua

1 l

o l

TER-C5506-311/312/313 test data appear in the text of the report; the remainder of the data appear as Appendix E.

The tests were patterned af ter those conducted by the Licensee (11],

thereby providing an independent evaluation of the explosive expansion Unless otherwise specified, the tests listed below were performed on process.

one or both of the 10-tube test assemblies. The tests were as fonows:

receiving and inspection / measurements and marking o

high yield and low yield tubes identified and marked o

rou expansion and explosive expansion of one 10-tube assembly (The o

other was expanded by Foster Wieeler Corp. and delivered to FN: for further testing.)

explosive expansion of three single-tube assemblies o

o bubble tests o axial load cycling o punout strength tests leak tests (secondary-to-primary, and primary-to-secondary) o o residual stress measurement o microgragdiy.

Dimensional measurements were made at various junctures in the test program.

i certain elements of th'e test program were deleted, including thermal j

cycling of au test assemblies. The rationale for deletion of thermal cycling f

is as fonows:

During service transitions, the ma'sinua temperature difference that can exist between the tubes and the tubenheet at the joint must be very small j

compared to the temperature difference between the tube in the main body of the generator and in the massive tube.dieet. Since the latter tempera-J ture differences are responsible for the axial stresses that are included i

in the axial cyclic tests, and since cycling of boop arui radial stresses win have a negligible influence on tube punout shength in comparision with that of axial cycling, tubes were not cyclican y " conditioned" to simulate thermal graditats betwen the tube and the tubesheet.

4a-M 21-3.W Frankhn Res,e. arch. Center a o, e n..

_ _ _ _ _ -. _ _, _ _ _ - - - _ _... _ ~ _ _. _ _ _ _ ~, -. - - - _..

TER-C5506-311/312/313 A number of tests on the single-tube assemblies were deleted due to budget and schedule considerations. M e original intent of these test samples was that they would serve only as "pcactice" pieces prior to the, tests on the larger 10-tube assemblies. Se testa daich were deleted are so noted ir AW4w D.

Two of ther singletube assemblies were instrtmented with strain gages in an attempt to measure instantaneous strain during the expansion process.

These tests were n--nful primarily due to the inability of the strain gages and external wiring to remain mechanically intact during the expansion process.

The requirements that a specific miniana joint strength and a maximum allowable leak rate be maintained for a minimum of 5 years of service operation defined the test parameters. Se loading that the tube /tubesheet joint will experience in service over a period of 5 years owing to temperature transitions, including start-ups and shutdowns, was simulated by axial cycling. Following a " conditioning" with the appropriate number of cycles at each service stress range, the tubes were tested for leakage under pressure conditions representative of normal operations and of loss of pressure on either the primary or secondary side. Next, the load required to pull tubes out of the tubesheet was determined.

+

=

a Thermal conditioning was performed in Foster Wheeler Corporation's qualification test program. Dae of these tests were witnessed, and tne pullout and leakage data were reviewed (see Section 4.1.7) for tubes so conditioned. Thus, this aspect of simulated service life was more than adequately covered.

s No conditioning with simultaneous thermal stress and representative load variations was or will be carried out in any of the various evaluation programs.

Such testing should not be required since pullout and leakage results af ter axial conditioning indicate the tube seal is acceptable.

For some specified tubes, the residual stresses induced in the tuberheet were determined by strain gaging sections of the tubesheet and then machining out the expanded tube.

%' h Frankhn Research Center h

22-

/.

A h of The huuman m

TFJH:5506-311/312/313 4.3.3 Leaktightness Tests Two 10-tube blocks were initially subjected to a low' pressure (125 psi) primary-to-secondary bubble test (Nil) (Appendix D) to assure that no gross leakage was present prior to any of the load cycling tests. As shown in the test results (Appendiz E), a few bubbles did amanate from most, tubes, but there was no evidence of a total lack of a tube /tubesheet seal.

,Pollowing the axial load cycling to siaiulate 5 years of service condi-tions, in which no tube exhibited any sign of slippage, the test blocks were j

subjected to both primary-tc>-ahary and secondary-to-primary leakage tests as detailed in the test plan (317 and M18). The leakage rates after 72 h are summarized below:

Pressure Average Leak Rate Tube Assembly (psie)

Pressure Direction per Tube (lb/h) l

' F-1 1275 Secondary to Primary 6.37 x 10

-5

-5 F-1 1275 Primary to "

• 7 2.49 x 10

~$

F-1 2500 Primary to Secondary 2.94 x 1D

_" = 7 to Primary 1.07 x 10 '

~

F-2 1275

~$

F-2 1275 Primary to Secondary 1.28 x 10

-5 F-2 1275 Primary to Secondary 1.90 x 10 The qualification leakage goal set by GPU Nuclear was 3.2 x 10' lb/h per tube based on a total leakage of 1 IVh from both OFSGs, whereas the technical specifications limit is 1.0 gal / min (500.22 lb/h) total leakage for both generators. For comparison, the Licensee's tests ranged from 1.18 x 10 to 187.4 x 10 lb/h per cube. From the data above, it is clear that the leakage rate from block F-1 was about twice that of block F-2.

The latter block met the acceptance level goal, whereas the former slightly exceeded this goal for one test condition but was well below the technical specification limit of 500 lb/h. Accordingly, it must be concluded that these tests indicate the kinetic expansion does lead to an adequate leaktight seal between the tube and tubesheet.

Y'!.' u Frankhn Research Center

-A J AEbummeetThe Pemummesmae

TER-C5506-311/312/313 4.3.4 Tube Interference Fit and Tubesheet Residual Stress Sete were several approaches to evaluating the degree of the interference fit between a tube and the tubesheet. In the 10-tube assembly (2-2) expanded at FEC, the ID and OD of ead tube and the ID of the tubesheet hole were asasured prior to espansion and the ID of each tube was measured following each espansion. The tubes in F-2 wererin two sections:

the first 2 in were separata lengths to simulate a full circumferential crack at the 2-in location. S ese ' stub

• ends, which initially had been roll-espanded, were esposed to the kinetic espansion process with the 6-in test region. In the data in Table 1, the D, measurementa at the 1-in location reflect the use of different tubing for these stubs, whid were not part of the qualification tests.

After the first expansion, the D asasurements were essentially the 3

same for all sections of the tubes including the stub ends. The first expansion clearly induced an interference as indicated by the fact that the diametral change due to the first expansion was greater than the tube hole clearance. Se diametral change due to the second expansion was at least one order of magnitude smaller than the change from the first espansion. 21s difference indicates that the second expansion contributed only slightly to the interference fit and that excessive deformation of the tubesheet was not a concern.

The test data for the. single-tube blocks 3A and 3D contrast with those for the 10-tube block in several aspects. Not only is the first step diametral change in the single tube less than that for the first step in the tube in the 10-tube assembly, but the total accumulated diametral change af ter the second expansion, whis caused about 1/4 to 1/5 of the total tube expansion, was also less than that for the 10-tube first step. Furthermore, this total diametral change was less than the original tube /tubesheet clearance, indicating a relatively poor tube /tubesheet joint. Se basis for this phencaenon appears to be the fact that the simulated tubesheet tube in the single-tube mock-up increased in outside. diameter af ter etch expansion, and thus, did not effectively restrict the explosive energy to expanding the gn,'mits T.h Frankka Research=Cereer ae-memen a===.

ens.

TEIK5506-311/312/313 Table 1.

Tube and Tubesheet Dimensional Data Demonstrating Effects of Two Expansions Block F-2 Inside diameter of tube At 1-in location Tube' Do D1' D2 D -D1 D -Do 1

2 1

0.5615 0.5653 0.5655 0.0038 0.0002 2

0.5615 0.5652 0.5657 0.0037 0.0005 3

0.5619 0.5657 0.5659 0.0038 0.0002 4

0.5625 0.5652 0.5655 0.0027 0.0003 5

0.5625 0.5649 0.5645 0.0024 0.0016 6

0.5621 0.5662 0.5667 0.0041 0.0005 7

0.5621 0.5661 0.5665 0.0040 0.0004 8

0.5625 0.5678 0.5640 0.0053 0.0002 9

0.5615 0.5673 0.5640 0.0058 0.0007 10 0.5629 0.5664 0.5681 0.0039 0.0013 4

At 2 1/8-in location j

1 0.5500 0.5653 0.5660 0.0153 0.0007 2

0.5500 0.5649 0.5653 0.0149 0.0004 3

0.5508 0.5640 0.5666 0.0152 0.0006 4

0.5500 0.5649 0.5657 0.0149 0.0008 5

0.5503 0.5645 0.5655 0.0142 0.0010 6

0.5500 0.5653 0.5657 0.0153 0.0004 7

0.5498 0.5657 0.5660 0.0159 0.0003 8

0.5510 0.5662 0.5662 0.0152 0.0000 9

0.5502 0.5652 0.5655 0.0150 0.0003 10 0.5495 0.5650 0.5657 0.0155 0.0007 At 3 1/4-in location I

1 0.5502 0.5648 0.5653 0.0146 0.0005 l

2 0.5495 0.5665 0.5670 0.0170 0.0005 3

0.5510 0.5660 0.5658 0.0150

-0.0002 4

0.5502 0.5660 0.5661 0.0158 0.0001 5

0.5510 0.5663 0.5667 0.0153 0.0004 6

0.5504 0.5648 0.5651 0.0144 0.0003 7

0.5500 0.5659 0.5661 0.0159 0.0002 8

0.5512 0.5655 0.5655 0.0143 0.0000 9

0.5504 0.5653 0.5658 0.0149 0.0005 10 0.5498 0.5652 0.5655 0.0154 0.0003 Do = inside diameter of tube before expansion.

Di = inside diameter of tube after first expansion.

D2 = inside diameter of tube after second expansion.

D -Do = diametral change due to first expansion.

1 D -D1 = diametsal change due to second expansion.

2 Note: All dimet.sions are inches and measured from the face of the block.

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.... _ _ _... _. ~ _... _ _ -...... _. > - -.., _ _ _..

e TE36-C5506-311/312/313 Table 1 (cont.)

Block F-2 Clearance (-=lant =ted f :s data on first page of Table 1) e at 21/s-in location hm - (D -Do)-(%s-%)

Tube

%s or

".--4 1

1 0,6403

.6284 0.0119 0.0034 2

0.6400

• .6285 0.0115 0.0034 3

0.6395

. 6284 0.0111 0.0041 4

0.6400 1.6287 0.0113 0.0036 5

0.4390 a.4281 0.0109 0.0033 6

0.6390 3.62S9 0.0101 0.0052 7

0.6395 1.6284 0.0111 0.0048 8

0.6400 1.6284 0.0116 0.0036 9

0.6395 1.6283 0.0122 0.0038 10 0.6390 1.6284 0.0106 0.0049 At 3 1/4-in location 1

0.6403

).6284 0.0119 0.0027 2

0.6400 3.6287 0.0113 0.0057 3

0.6395 3.6281 0.0114 0.0036 4

0.6400 3.6285 0.0115 0.0043 5

0.6390 0.6282 0.0108 0.0045 6

0.6390 0.6286 0.0104 0.0040 o

7 0.6395 0.6281 0.0114 0.0045 8

0.6400 1.6283 0.0117 0.0026 9

0.6395 3.6280 0.0115 0.0034 10 0.6390 1.6283 0.0107 0.0047 Dg = diameter of tu sheet hole before expansion.

outside diamet : of tube before expansion.

D

=

T T " "1**#*"#**

D

-D Dgyg = interference.

Isote: All dimensions a e in inches.

g'J.' u Frank 4n Research.une

.h J Cent a o==== m the room

TEA-C5506-311/312/313 Table 1 (Cont.)

Test specimen 3A At 1-in location D -D1 D -Do 4

D1 D1 2

1 Tube inside diameter 0.5495 0.5590 0.5610 0.0095 0.0020 Block outside diameter 1.1420 1.1425 1.1440 0.0005 0.0015 clearance = 0.0112 At 2 3/8-in location Tube inside diameter 0.5498 0.5580 0.5598 0.0082 0.0018 Block outside diameter 1.1415 1.1440 1.1450 0.0025 0.0010 clearance = 0.0111 At 3 1/4-in location Tube inside diameter 0.5496 0.5540 0.5602 0.00s4 0.0022 Block outside diameter 1.1425 1.1440 1.1445 0.0015 0.0005 clearance = 0.0110 Note: All dimensions are in inches.

(" h Frenen Research. C.e.rner

-h.

a w arn.a

_j

ten-C5506-311/312/313 Talsle 1 (Cont.)

Test specimen 3D At 1-in location D -D1 D -Do Do El D2 2

1 Tube inside diameter 0.5494 0.5545 0.5610 0.0091 0.0025 31ock outside diameter 1.1435 1.1455 1.1455 0.0020 0.0000 clearance = 0.0111 At 2 1/8-in location Tube inside diameter 0.5520 0.5542 0.5594 0.0062 0.0016 alock outside diameter 1.1435 1.1440 1.1450 0.0005 0.0010

.learance = 0.0132 Tube inside diameter 0.5494 0.5583 0.5610 0.0087 0.0027 alock catside diameter 1.1428 1.1448 1.1450 0.0020 0.0002 clearance = 0.0120 Note: All dimensions are in inches.

.h g'J.'Ju Frenen Reneeren Ceneer A h W the Pw amase

i_

TER-C5506-311/312/313 tube. Ora che other hand, the larger mass of the 10-tube tubesheet appears to have forced the deformation of the tube.

In an attempt to monitor the strain incurred at the CD of tne single-tube tubesheet, strain gages were mounted on the ODs of test blocks which were then subjected to expansion (Tasks M3 and N4). Unfortunately, the shock waves detached the gage's or the wire leads: thus, no meaningful data were obtained from these tests.

Strain gages were successfully used in measuring the tubesheet ligament springbac,k which occurred when expanded tubes were machined out of' 10-tube block F-1 (Task N21). Based on these tests and the data in Table 2, the following observations were made:

1.

In generali some amount of strain relaxation in the tubesheet ligaments occurred in the immediate vicinity of a tube that was partially machined and removed. S is phenomenon was more pronounced for tubes with low yield strength, i.e.,

in ligament 7-10.

j 2.

De stress state of the tubenheet ligaments away from a tube subjected to machining appeared unaffected by the tube removal process.

3.

Se accuracy of measuring a small amount of strain relaxation in the l

tubesheet ligaments did not appear to have been affected by the machining process. M ere were no noticeable rises in the ligament temperature in the area dere nachining and strain gage data reading took place.

4. ' De===11 measured amounts of strain relaxation in the tubesheet ligaments indicate that the kinetic expansioa did not induce excessive plastic deformation in the tubesheet nor did it alter the dimensional integrity.

4.3.5 Tube Pullout The data for tube pullout tests on acck-ups F I and F-2 are summari:ed in Table 3.

As discussed prev.ously, sir. of the tubes in assembly F-1 were left intact in the 'tubesheet" so that residual strain measurements could be conducted on the ligaments between tubes on cross sections of the assembly.

The qualification pullout load goal of 3140 lb was based on the worst case, Y-M 1 3.3. Frankhn Research.C. enter ac wwa

l TFJH:5506-311/312/313 i

i Table 2.

Besidual Strain Measurements on 10-Tube Block, F-1 i

Strain Levels in Micro Strains (uin/in) l h

M M

ti M

i:Z, M

7-10 Cut Depth (in)

I j

Before clamping 0

0' O

O O

O O

<*1 W

-1 0

0 0

+2

-1

+2 Mter ube 1

-40

-24

-1 0

+3

-2

+3 1/4 u-s

(

Nactiining out

-56

-35

+1

-1

+3

-2

+3 1/2 m-s

-44

-27

+2 0

+3

+2

+4 3/4 E-W l

l Mter Tube 4

-54

-27

-1

-1

+4

-3

+6 1/25-s l

-54

-26

-4

-1

+5

-3

+7 1/2 E-W

-54

-26 I*I 3/4 E-W

-54

-27

-3

-2 3/4 N-S

-34

-30

-12

+7

-4

+11 3/4 N-S Mtar Tube 5 II

-51

-34

-30

-44

+7

-5

+11 3/4 E-W Mter Tube 6

-51

-38

-19

-12

-2 3/4 EWNS Mter Tube 7

-50

-40

-35

-46

-16

-115 3/4 NSEW Mter Tube 10

-50

-41

-35

-36

+15

~223 3/4 NSEW Unclamp d

-50 442

-36

-36

+17

-226 Notes B> 5 and E-w are arbitrary north-south and east-west locations at which the tube was z.illed away to the tubesheet to the depth indicated.

~

• See Figure 1.2.h.

j a.

- indicates readir4 did not change.

I b.

Gage disconnected, reading doubtful. No further readings possible.

i g'J.h FreNen Reneerch Center

-M A 8 human W The Pamums emanse

TE*i-C5506-311/312/313 MsLB-induced thermal length changes of the tube and tubesheet/shell assembly.

Since an sicngation strain of 0.0016 in/in in each tube would nullify the thermal length change diffsrences (15], the stress on each tube is strain limited. Accordingly, in the qualification tests, if there was no slippage or reduction in load prior to 0.0016 in/in elastic plus plastic strain, the joint would clearly be adequate for generator service. Bowever, the load to cause this strain could be less than 3140 lb, and in keeping with the or'iginal qualification goals, the tests on block F-1 were conti,u=A until the maximum load that could be sustained by the joint was achieved.

As shown in Table 3 for test block'F-1, the total elongation at maximum load of each tube relative to the bottes surface of the tubesheet was well above 0.016 in, the elongation corre-~~*iM to 0.0016 in/in strain in a 10-in-long tube. The elongations on the high yield (ET) tubing were about half those for the low yield (LT) tubing, consistant with the larger amount of plastic deformation in the latter. These results clearly indicate-the ability of the joint to satisfy the pullout strength goals.

For block F-2, the total tube movement (elastic and plastic deformation plus any slippage) was monitored and loads were determined for yielding (when the load versus time curve under constant loading rate deviated from linearity). As can be seen in Table 3, as expected, the load on each low yield tube at yielding was close to or below the 3140-lb goal. At elongation of 0.030 in (0.003 in/in strain) and 0.060 in (0.006 in/in strain), the maximum load had not yet been reached in any tubes, bet the el.angstions were so much larger th44 could be expected on actual steam generator tubes that tests were not centinued to actual pullout.

4.4 ONSITZ MONITOICNG OF REPAIR PROCESS Repair processes performed on the TMI-1 A and B steam generators were sonitored by means of a series of teleghone conversations with the resident NBC inspector, Mr. Skip Young, and by visiting the site to confirm that repairs were proceeding in a generally satisfactory manner.

h

%*1'.'.'u Frankkn Res,earch Cemer b-

_31 A h W The em

l l

l ten-C5506-311/312/313 l

l l

Table 3.

Summary of Tube Pullout Testing A.

alock r-1 Tube 51ongation M

S_tr_ength Max. Load (1b) at Naz. Load (in) 2 IT 4100 0.051 3

LT 4000 0.105 8

EY 4050 0.041 9

LT 3800 o.092 B.

Riock F-2 Load (1b) at Tube Strenoth Yield Load (1b) 0.030 in 0.060 in 1

ET 3800 3900 41.0 2

NY 3500 3740 3900 3

LY 3200 3275 3500 4

EY 3750 3800 4000 5

NY 3700 3820 4000 6

LY 3034 3275 3450 7

LY 2900 3090 3275 8

ET 3750 4060 9

LY 3170 3430 3675 10 LY 3150 3300 3500 l

l l

l

[3.h Freren Reseerdi Center

,m b A h of The Psamma tuense

~ _ _ _,...

TE3H:5506-311/312/313 It was determined that there were some early problems with ignition of the ordnance cord. This cord communicates detonation from a single point, an electric blasting cap, located outside the steam generator, to each part of located within plastic tubes (candles) in the tubes of the generators. Itsere detonation failed to occur, in the bundle did not receive enough energy to initiate them reliably the problem was solved by using Another factor contributing to the early difficulties was what was thought to be a " bad batch" Subsequent batches performed reliably and this,

'resulted in a very high percentage of successful detonations.

At the time of the first site visit, diametral measurements were being made at 1-in spacings along the longitudinal axis of the tube. Althouga there was some difficulty in the interpretation of the results, it was determined that the expansions were within previously defined diametral limits. No adverse reports have been received following the initial problems.

Eddy current testing for crack detection was begun immediately after the first expansions were made. First examinations showed indications of defects that had not been detected earlier. As discussed in Section 4.1.4, the Licensee concluded that these indications were primarily pits and scratches which were detected by oddy current testing equipment more sensitive than that used previously and that these defects would act influence the reliability of the joints.

Cleanup after expansions was difficult. The plastic candles adhered tenaciously to the tube wall and blasting air from the bottom of the generator was ineffective. Pressure from the underside of the candle was increased to 700 poi to make the process more efficient.

s r,as::.,

3 h FranWin Re.se. arch. C. enter a a e n a.

a

j TER-C5506-311/312/313 It appears that the repair procedures were conducted according to the qualification program set forth by GPU leuclear and its contractors. In the case of the early detonation failures, the number of repeated hits on tubes that had already been==paadad could increase chances of leakage, but planned bubble leak tests etwald indicate such leakage. It would be well to pay particular attention to the regions of the generators where these repeated hits occurred.

e 1

s I

T

%'f.';u Frankhn Res,urch Ce.nter b,

34 a w e n.

l TFJt-C5506-311/312/313 5.

OPEN ITEMS As indicated previously, at the time of issuance of this report, several open items remain to be addressed by the Licensee. While some or all of these may have been dealt with, no information on them has been received.' Thus, these topics are listed belows a.

an evaluation of warpage distortion, if any, of the tubesheets of the TMI-1 OfSGs i

b.

a consideration of the number and severity of candle " blow-throughs,"

the possible effects of these blow-throughs on the cleanup of tubes, and the residual stresses and streseconcentrating effects associated j

with these blow-throughs c.

an evaluation of the validity of extrapo?ating 330*r pullout load test data to 650*F d.

the conclusions concerning the X-ray measurements of the residual stresses in kinetically==paadad tubes (work done at Pennsylvania state University).

It is not espected that any of the above items will be critical to the generator's return to service. However, an accurate appraisal of the expected long-term life of the generator requires that they be fully taken into account.

I 1

i I

l l

l l

l t

i T'I.% frankkn Res,earch Ceneer

..,-3:i.:s

• A Chaume. et The emma summer

-v-<

~.

_~.

TFJN:5506-311/312/313 6.

CceCLDAICMS j

i 4

I assed on the evaluation of the Licensee's qualification program and the results of the independent test program, the fouoving conclusions have been reached:

1 1.

Se kinetic (emplosive) espansion * " = 5 e is an effective means for l

repairing the cracked. tubes in the THI-l once-through steam generators (OTSEs). By forming a new tube /tubeeheet seal joint below the cracks in the tubes, the cracked regions are essentially removed from the system.

2.

expension procedure accomplishes a tight seal without excessive deformation of the tuboeheet..-

3.

In order to maximize the number of tubes that can be salvaged, all tubes were expanded for 17 in. Se lower 6 in of this was the length qualified in the Licensee's test programs and evaluated in FRC's independent test program. It is espected that tubes with defects up to 11 in below the upper face of the tubesheet can be repaired in this manner and that tubes with defecta between 11 and 16 in below the upper face of the tubeeheet will be repaired by reespanding a 22-in length.

4.

It is anticipated that after the tubes have been expanded, a seasoning win be required to reduce leakage to acceptable levels. Both the Licensee's and FRC's test programs have shown that the probable leak rate is well below the Technical Specification of 0.016 lb/h per tube, and approaches the qualification goal of 3.2 x 10-5 lb/h per tube.

5.

In general, the results of testing and analysis have been favorable in terms of having met the Licensee's qualification requirements.

Thus, to the extent that the test assemblies represent a reasonable simulation of the TMI-l OTSG, the repair process implemented at TMI-l should meet its objectives.

A list of open cr unresolved items -(to F3C) is presented in Section 5.

It is not espected that any of these items wi U be critical to the generator's return to service. Bowever, an accurate appraisal of the expected long-term life of the qenerator requires that they be fuu y taken into account.

[-M -y' ' h Fra.nkh.n Renee.rch C.e.rwar J.

aa. enep

TER-C5506-311/312/313 It should also be emphasized that there are scan fundamental differences between the test assemblies and the actual generator which could affect the success of the repair process. These differences are as follows:

a.

length of expansion b.

number of tubes simultaneously expanded c.

tube length (different 4W=ce to expansion) d.

geometry of tubesheet e.

variation in tube-to-tubesheet crevice conditions.

It is not anticipated that these differences will have a major adverse impact on the effectiveness of the repair process. In this regard, the hot functional testo in the start-up program should critically evaluate the state of the generators.

g' 'h Frankkn Research Center

-b J.

a W W The Pw m i......

'I 1

TER-CS506-311/312/313 i

7.

EEFEM E IS 1.

GPU Muclear TMI-1 OrSG Tube Repair Preliminary Specifi::stion No. 1101-22-006, Rev. 4 2.

Babcock & Wilcox 36W Explosive Espension Qualification Boquirements for Mechanical Testing (61-113423-00) for Explosive Espansion Repair of or3Gs June 2, 1941 t

3.

GPU m taar Topical Report No. 008, Bew. 2, ' Assessment of THI-1 Plant safety for Beturn to Sersice After Steen Generator Bepair*

March 29, 1983 4.

L. Sernow and I. Lieberman j

'Esplosive Mstal Fabrication, A Technical mennw=4e Tradeoff" sahavior and Utilization of Explosives in Engineering Design,12th Annual Symposium, AS E, March 2-3, 1971 5.

A. A. Ezra PrinciDies and Practice of ENDlosive Metal Working 4

Industrial Newspapers Limited, London,1973, pp.112-116 6.

R. A. Mottraz and R. V. Andrew

" Tube Espansion and Waldiry by Explosives" Engineer, Septamber 29, 1947 7.

" Explosive Breakthrough in Tube Expansion" Welding Design and Fabrication, August 1970 i

8.

R. A. Mottram

• Explosive Tube to Tube Plate Expansion" Proceedings of Meeting of Eign Pressure Technical Association l

March 14,1969 9.

Pipes and Pipelines International June 1978, p. 32 10.

F. J. I4cke, R. V. Collins, J. W. Schroeder, and D. E. Sidell l

• Esplosive Forming Speeds In-place Retubing of Feedwater Beaters' Power, September 1978, p. 84

11. Foster Wheeler Development Corporation TMI-1 Steam Generators Espair Qualification Program for Einetic Tube

• lxpansions 4

9 9

g'.3-1 :

J.h Frankhn Rene.e.rc.h C.orner a w w n. e.

TER-C5506-311/312/313 Document No. 5054-QP-1, Rev. 1 Test Procedure No. 5054-QT-1, Rev.1, Kinetic Expansion General Requirements Test Procedure No. 5054-QT-2, Rev. 1, Tube Tensile Tests Test Procedure No. 5054-QT-3, Rev. 2, Kinetic Expansion of Tubes in Tube Blocks Test Procedure No. 5054-QT-4, Rev. O, Kinatic Expansion Proof Load Test Test Procedure No. 5054-QT-5, Rev.1, Kinetic Expansion Seraal Cycle Conditioning Test Procedure No. 5054-QT-4, Rev. O, Kinetic Expansion Hydrostatic Leak Testin9 Test Procedure No. 5054-QT-9, Rev.1, Einetic Expansion Tube Pullout Tests Test Procedure No. 5054-QT-la, Rev. O, Kinetic Expansion Induced Strain Testa 18 1

12.

Babcock & Wilcox 10 Tube Leak and Load Test Fixture B&W Drawing No. 1134899 D-05 13. Babcock & Wilcox Test Blocks for Induced Strain, Residual Stress, and Annulus Effects

~

B&W Drawing No. 1134900 A-02 May 21,1982 14.

Babcock & Wilcox Corroded Crevice Mock-up Assembly B&W Drawing No. 1134950 D-01 15. GPU Huclear GPUN '2DR-007, BAW-1760, *TMI-l Once 2 rough steam Generator Repair Kinetic Expansion Technical Report" November 1982 16.

Babcock & Wilcox B&W-10146 Generic Topical Report

" Determination of Miniana Required Tube Hall Thickness for 177-FA Once-Brough Steam Generator" October 1980 17.

Three Mile Island Unit 1 - once Through Steam Generator Repair Kinetic Expansion Tecnnical Report PROPRIETARY November 1,198( - Draf t g.h 2.h Frankka Research Career A Eb= men at The Pemma suanse

TEA-C5506-311/312/313 is, sa w a Wilcom MW Drawing so. 131102 E, Bew. u 19.

nabcock & Wilcos M W Drawing No. 131112 E, mov. 12 20.

R. Meyer, Dolosiva Verlag Chemic, Weinheim, New York 1977 21.

C. Davey, L. Leonard, T. Book, and I. Marshall FEC Trip Report - Mount Vernon MW Plant Franklin Essearch Center August 15, 1942 22.

n= W & Wilcos B&W Punctional Specification No. C3(F)-3-33 March 6, 1969 23.

Babcock & Wilcos MW-10002, Topical Report

'Once-Through Steam Generatog Research and Development Report" August 1969, Para. 3.2 e

%u-h 3..

Frankka Res,ea.rch C. enter a w e n..

APPENDIX A occourms maczzw.o e

e e

"h

. 0. Franklin Research Center A DMsion of The Franklin Insetute The Senpenen Fransen Partruey. h. Pa. 19103 (213) us.1000

TER-C5506-311/312/313 APPENDIX A DOCIDENTS MCEIVED FOR C5506, ASSIGMENT 10 1.

M. J. Graham Letter to T. A. Shook, FRC.

Subject:

Tratsmittal df TMI-l OTSG Specs GPU Nuclear, 02-Jul-82 E&L: 4434 2.

D. D. Mokris Equipment Specification for Once Through Steam Generator Babcock & Wilcox, 08-May-70 CS-3-33 3.

R. E. Bam General Functional Specification for Reactor Coolant System components Babcock & Wilcox,15-Jul-70 CS (F) 3-92/NSS-5 4.

R. E. Bam Functional Syncification for Steam Generators Babcock & Wilcox, 15 4 y-70 i

CS (F)-3-33/NSS-5 i

5.

J. W. Merchent Functional Specification for Steam Generators Babcock & Wilcox, 01-Mar-49 CS(F)-3-33 6.

Steam Generator Operation With Less Than Four Reactor Coolant Pumps Babcock & Wilcox, 06-Mar-49 CS (F)-3-33, App.1 7.

C. E. McCracken Memo to R. Jacobs.-

Subject:

Reports Received from GPUN During the June 22,1982 Meeting with GPUN USNRC, 25-Jun-82 8.

TMI-1 Steam Generator Status - ACRS Subccanittee GPU Nuclear, 07-Jun-82 9.

N. C. Kazanas Technical Data Report: TMI-l GTSG Recovery GPU Nuclear, 14-Jun-82 TDR No. 343 i

A-1 0

l'rankan Reneerth Center A Damen af he Pamuse summse

.. _. _ _..~.. _. _,, _, _,,, - -. -... - -. - _ _, _ _.,.. -,,, -.

1 TER-C5506-311/312/313 10.

J. D. Jones, R. L. Jones, and J. S. Olssowski Technical Data moport: TMI-1 OTSG Failure Analysir Report l

DRAPT ONLY - NOT FOR RELEASE GPU Nuclear TDR No. 341 11.

SFwification OTSG Tube aspairs PRELIMINAE!

GPU Nuclear,11=Jun-42 1101-22-006 12.

N. C. Eazanas and G. E. M adrick TMI-1 Steam Generator Recovery Prograar Task 7: Primary Systes Review, Reactor ("elmat System Inspections and Requalification.

Appendix C Examination Results GPU Nuclear, 00-

-42 13.

3. Jacoba Summary of Neeting with GPUN on June 28 and 29,1982 Concerning GPUN's Steam Generator Recovery Progrant Three Mile Island, Unit No. 1 i

1 USNE, 14-Jul-42 14.

R. J. Baker Letter to D. G. Slear, GPU Nuclear.

Subject:

Transmittal of B & W Informal Review of Franklin Procedures h w & Nilcos, 23-Aug-42 GPUN-42-224 15.

T. J. Morgan QA Data Package 12" Single Bole Tubesheet Mckup Induced Strain Test / Annulus Effect Test Babcock & Wilcox, 25-Aug-42 23-1135711-00 16.

T. J. Morgan QA Data Package 10-Sole Tubesheet Mockup with Low and High Strength Short and I.and Tube Pieces Babcock & Wilcock,13-Aug-42 23-1135713-00 17. TMI-l Steam Generators Repair Qualification Program for Kinetic Tube Expansion: Qualification Plan j

Foster meeler Development Corp., 09-Aug-82 5054-QP-1, Rev. 1 4

18.

TMI-1 Steam Generators Repair Qualification Program for Einetic Tube Expansion:

Kinetic Expansion General Requirements Poster Wheeler Development Corp., 09-Aug-42 5054-7f-1, Rev. 1 A-2 FranWin Reneerch Center A Chuan W 7tm Psumen m

TER-C550 6-311/312/313 19.

TMI-1 Steam Generators Repair Qualification Program for Kinetic Tube Expansions Tube Tensile Tests Foster Wheeler Development Corp., 09-Aug-82 5054-QT-2, nov. 1 20.

TMI-l Steam Generators Repair Qualification Program for Kinetic Tube Expansion:

Kinetic Expansion of Tubes in Tube Blocks Foster Wheeler Development Corp., 09-Aug-82 5054-QT-3, Rev. 2 21.

TMI-l Steam Generators aspair Qualification Program for Kinetic Tube Expansion:

Kinetic Expansion Procf Imad Test Foster Wheeler Development Corp.,16-Jul-82 5054-QT-4 22.

TMI-1 Steam Generators Repair Qualification Program for Kinetic ' lube Expansion: Kinetic Expansion Thermal Cycle Conditioning Poster inneeler Development Corp.,17-Aug-82 5054-QT-5, Rev. 1 23.

THI-l Steam Generators Repair Qualification Program for Kinetic Tube Expansion: Kinetic Expansion Rydrostatic Leak Testing Fostar leseeler Development Corp.,17-Aug-82 5054-QT-6 24.

TMI-1 steam Generators Repair Qualification Program for Kinetic Tube Expansion:

Kinetic Expansion of Tubes Into Tube Blocks for Franklin Institute Evaluation Foster itseeler Development Corp.,12-Aug-82 5054-QT-8 25.

Evaluation of Tube Samples from TMI-l Babcock & Wilcox, 00-

-82 77-1135317 26.

J. F. Pearson Letter to D. G. Slear, GPU Nuclear. Subjects Overall Expansion Length for Tube Depair at TMI-l Babcock & Wilcox, 09-Jul-82 GPUN-82-177, Proprietary 27.

Once-Through Steam Generator Research and Development Report Babcock & Wilcox, 00-Aug-69 BAW-10002, Proprietary

)

28.

Or.ce-Through Steam Generator Research and Development Report j

Supplement 1 Babcock & Wilcox, 00-Jun-70 BAW-10002, Supp.1, Proprietary i

i l

A-3 1

N b Frankun Research Center A Deusen af The Pamuse muumme i

I e

I

_m.,

TER-C550 6-311/312/313

.9.

Determination of Minimum Bequired Tube Mall Thickness for 177-FA once-Through Stead Generators Babcock & Wilcox, 00-Oct-40 BAW-10146 30.

C. McCracken Memo to v. Benaroya. Subjects Status Update for TMI No. 1 Steam Generator Repairs USERC, 10-Sep-41 31.

C. v. Dadd Memo to R. W. McClug. Subjects Travel to Barrisburg, PA, August 8-9, 1982 to Discuss the Eddy-Current Inspection of Three Mile Island Unit 1 Steam Gesierators Oak Ridge untional Laboratory,17-Aug-42 32.

D. D. Mar

• maid Letter to v. Benaroya, Mac.

Subject:

Review of Bsw Document No.

77-1135317, " Evaluation of Tune Samples from TMI-l 30-Aug-82 33.

TMI-l Steam Generators Repair Qualification Program for Einetic Tube Expansion:

Kinetic Expansion Tube Pullout Tests Poster Wheeler Development Corp., 03-sep-03 5054-QT-9 34.

TMI-l Steam Generators Preliminary Tests for Einetic Tube Expansion:

Residual Stress Measurement of Test Blockn at Pennsylvania State University Foster Wheeler Development Corp., 03-6ep-82 i

5054-PT-2, Rev. 1 0

35.

Specification: TMI-l OTSG Tube aspair GPU Nuclear, 10-Aug-82 SP 1101-22-006, Rev.

36-R. Marshall Letter to T. A. Shook, FEC.

Subject:

Transmittal of Comments Regarding Kinetic Expansion Demonstration of August 5,1982 Enasco Services Inc., 24-Sep-82 37.

TMI-l Steam Generators Preliminary Tests for Kinetic Tube Expansion:

Residual Stress Measurement of Test Blocks at Pennsylvania State University, Foster Wheeler Development Corp.,16-Sep-82 5054-PT-2, Rev. 2 38.

J. H. Taylor Af fidavit Concerning the Designation of Proprietary Material Babcock & Wilco:c, 22-Sep-C2 A

A-4 llbhb nkin Research Center A

senaf The Pseuse suunse

l m

TER-C5506-311/312/313 39.

TMI-l Steam Generators Repair Qualification Program for Kinetic Tube Expansion: Kinetic Exper.sion Tube Pullout Tests Foster meeler Development Corp., 22-Sep-82 5054-QT-9, Rev. 1 40.

TMI-l Steam Generators Repair Qualification Program for Kinetic Tube Expansion: Kinetic Expansion Induced Strain Test Foster Wheeler Development Corp.,17-Sep-82 5054-QT-10 41.

1MI-l Steam Generators mepair Qualification Program for Einetic Tube Expansion: Einetic Expansion Corroded Crevice Effects Test Poster meeler Development Corp., 24-Sep-82 5054-QT-ll 42.

TMI-l Steam Generators Aspair Qualification Program for Einetic Tube Expansion: Kinetic Expansion of Westingbouse Blocks Poster itseeler Development Corp., 24-Sep-82 i

5054-QT-12 l

43.

B. D. Hukill Letter to J. F. Stolz, MRC.

Subject:

Transmittal of TMI-l l

OTSG Repair Drawings, mos. 131102E, Bev.12 and 1311122, l

Rev.12 (Attached) l GPU Huclear Corp., 25-Oct-82 l

5211-82-252, Proprietary l

44.

E. J. Magner 9t al.

Interim Report of Third Party Review of Three Mile Island, l

Unit 1, Steam Generator sepair 27-Sept-82 45.

D. L. Baty Examination of TMI-l Anactor Vessel O-Ring and CBDM Closure Insert - Final Deport Babcock & Wilcox, 03-Jun-82 RDD:83:5490/5494 46.

W. A. McInteer and G. M. Bain TMI-l Recovery - RMS Astainer Examination l

Babcock & Wilcox, 20-May42 RDD:83:5489:01 47.

A. K. Agrawal, W. M. Stiegelmeyer, and W. E. Berry Final Report on Failure Analysis of Inconel 600 Tubes from OTSG A and B of Three Mile Island Unit 1 Battelle Columbus Laboratory, 30-Jun-82 rankEn Research Center A shimme of The Pummen muunse

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48. T. J. Morgan QA Data Package 10-Bole Tubenheet Mockup with Low and High Strength Short and Long Tube Pieces Babcock & Wilcox, 29-Jul-82 23-1132760-00

49. C. McCracken Memo to V. Benaraya.

Subject:

TMI-l orSG Status Update-USNBC, 14-Nov-82

50. C. V. Dodd Memo to R. M. McClung.

Subject:

Travel to Bethesda, Md.,

October 18-13, 1982, for Meeting on Repair of Three Mile Island Unit 1 Steam Generator Oak Ridge National Laboratory, 27-Oct-82 1027-46-82

51. D. D. w daa=1d Letter to V. Benaraya, MK.

Subject:

Review of GPU Nuclear Submissions on Tsu-l or$Gs to NEC, October 18-19,1982, and of Battelle Columbus Final Report on Inconel 600 Tubes 23-Oct-82

52. T. M. Moran Assessment of TMI-l Plant Safecy for Return to Service Af ter Steam Generator Espair GPU Nuclear, 07-Dec-82 Topical Report 008, Rev.1

53. J. P. Moore et al.

Three Mile Island Unit 1 Once-Through steam Generator Repair l

i Kinetic Expansion Technical Report Babcocx & Wilcox, 00-Nov-82 GPU36-TDR-007, Proprietary

$4. P. E. Troy Letter to T. Shook, FEC. Subjects TMI-l Kinetic Expansion Repair Program Procedures Approvals Babcock & Wilcox, 07-Sep-82

55. TMI-l OrSG Repair Process Description / Qualification GPU Nuclear,15-Sep-82

56. P. E. Troy Letter to T. Shook, FIC.

Subject:

TMI-l Kinetic Expansion Repair Prograag Residual Stress Measurements Procedure i

Babcock & Wilcox, 22-Sep-82 l

4 A-6 UNU Franklin Research Center A Dammme af The Passen summas

57. TMI-l Steam Generator hepair Safety Daluation GPU Nuclear, 30-Sep-82 SE 120012-006, Proprietary

58. v. Benaroya Memo to J. Stolz. Subjects Evaluation of TMI-l Plant Safety Subsequent to Recovery from OTSG Corrosion Problems USNBC, 28-Jan-83

59. J. F. Stolz Letter to H. De Bukill, GPU Nuclear.

Subject:

Assessment of TMI-l Plant Safety for Return to Service After Steam Generator Repair.

Request for Additional Information.

USNBC, 07-Feb-83'

60. C. McCraken Memo to L. Frank, S. Kirslis, J. Rajan, D. Sellers, P. Wu.

Subject:

Preparation of TMI-l SER for Bestart Subsequent to the OrSG Repairs USNEC, 08-Mar-83 e

s rankan Research Center A Onuman W The Fm aummes s

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1 APPENDIX B MEETINGS AT*END3D shr

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. Franklin Research Center A Division of The Franklin Institute The Bonpamn Frannhn Perweey. PMe Pt 19103(21S) 448 1000

TER-C5506-311/312/313 APPENDIX B - Meetings Attended Date Site Purpose June 11, 1982 Bethesda, MD Finalize scope of work on Assignment 10 June 22 Livingston, E N presentation of tschnical details of explosive process June 28, 29 Bethesda,DC GPUM presentation of background details of OTSG failure analysis July 21 Livingston, E Qualification program schedule August 5 Mt. Vernon, IN Multiple tube expansion demonstrations meeting with consultant August 12,13 Livingston, E Witness espansion of 10-tube block assembly August 20 Lynchburg, VA Discuss details of FIC RI August 26 Livingston, E Witness Licensee tests September 10 Philadelphia, PA N/BW witness of 10-tube block expansion September 15 Bethesda, MD GPUN presentation on repair process October 18 Bethesda, MD Finalise Licensee plans October 28

' Barrisburg, PA Witness production tube expansion i

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5-1 ranidin Research Center A Desumasiaf The Presumme m

APPENDIX C STATD0Df1' OF CONSULTANT l

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Dear Mr Shook:

C'.'H ER:

Attached for your review are my comuments regarding the Kinetic Expansion Demonstration at Mt Vernon, Indiana on August 5, 1982.

Should you have any questions concerning the information contained in te attachment, please feel free to contact me at the above referenced address.

Very t ly yours,

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ATTAQ9dErr TRIP REPORT KINETIC EXPANSI N DEMONSTRATION NT VERNON, INDIANA AUGUST 5, 1982 The kinetic expansion demonstration performed by Foster Wheeler and B 6 W in the B & W Mt Vernon plant.

As we are all aware, the kinetic, technique for expansion of tubes in steam generators is a very acceptable one that has been used by suppliers for the last twenty (20) years. There is no question that this technique is a very acceptable one for Three Mile Island steam generator, however, I cannot over stress the importance of using 2he right variables in this program.

Some of the more 'important considerations are:

1) The air gap between the candle and the tube prior to the expansion. Large air gaps will tend to fragment the candle.

It was noted in this demonstration that a large number of candles were fragmented which adds to the time required in high radiation levels for clean up.

2)

It is important to have knowledge to the hardness factor range of the tubes in a unit since this is directly related to the required force for proper expansion:

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3) To minimize the amount of canile rupture there have been some techniques used in the past that may be considered, such as:

bringing the candle temperature down by refrigeration into the 40-45 degree range prior to installation. Again, the main concern being the amount 6f time it would take for the cleaning of the unit.

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ATTA09ENT j

PAGE i It has been tHe writer's experience using this expansion technique that, upon the performance of a hydro on completion of the program, there will be numerous slight tube weepage. This weepage will disappear when the unit is subjected to a hot flow of water thr,ough the secondary side f

which will develop an iron oxide in the annulus between the tube and the

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tube sheet. Much research in this area has been done by the industry l

and this reaction has been verified.

Because of the high radiation levels in the units and the potential airborne contamination that will develop during this program, I cannot oier stress the importance of the development in techniques to shorten the exposure time in the placement, removal and cleanup.

4 Robert Marshall 1

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AFFDIDIX D TEST PROCEDUERS l

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sh.1 Franklin Research Center A DMsion of The Franklin Institute The W Frereen Portruey, PNs., Pe 191Q3 (215) us.1000

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-l TASK N1 - MCEIVING, INSPECTION, AND MARKING OF SPECIENS 1.1 GENERAL All materials (tubes and tube blocks) received will be subjected to the following procedure

-Inspect for conformance of configuration of the 10-tube blocks in accordance with M W Dug. 1134899D, mev. 4 (Figure 1.0) and of the one-tube blocks in accordance with MW Dwg. 1134900A (Figure 1.1).

-Visually inspect and confirm oxide coatings on tube holes and the tubes, and note presence of any contamirants and rust. Do not disturb oxide coatings escept to measure tube dimensions outside of test region.

-Visuan y inspect for identification per MW certificates to verify traceability and for damage, including evidence that moisture protection had not been maintained during shipment.

-Recora inspection acceptance or discrepancy on test log sheet.

-Review certificates, test reports, etc. received for each item received as fonows and as applicable (a) Stress Relieve Treatment (b) Oxide Coatings Parameters 4

(c) Material Test Reports (d) Dimensional Data moport j

(e) Certificates of Conformance

-Verify markings of acceptable items for maintaining traceability to l

MW markings, heat numbers etc.

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-Test blocks shan be stored to prevent oxide coatings deterioration by placing in an oven or in a plastic bag with MW-suppliec desiccant. Prevent contact of desiccant with cuide surface.

-Items win be allowed to come to ambient temperature prior to test.

1.2 M

ASE. 55-163 Inconel 600 tubes (0.625-in CD x 0.034-in miniana l

thickness), af ter stress relieving and with surface conditioning simulating oxidation conditions at TMI-1 steam generator upper

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l TASE N1 - MING, INSPECTION, AND MMLKING OF SPECIMNS tubesheet crevice, will be supplied by Babcock & Wilcos. It is essential that this aside condition at tube CD in the region to be awpandad remain undisturbed during au pre-expansion steps. Tubes may be either high. yield or low yield span immas.

Each tube shan be identified as to whether it is a high yield or low yield specimen. Tubes shall be marked with "P for high yield and 'L' for low yield. Tube yield stroogth data obtainee from tube tensile tests (Procedure No. 5054 92-2) win be recorded on data sheets when available.

1.3 10-TU5E TEFF BLQCE8 Strese-relieved Aam Sh-508 CL. 2 test blocks (12 in thick) with 10 gun-drilled holes per block will be used. Details of the assembly are seen on Figure 1.0.

Se holes win be drined to a triangular pitch of 0.875 in.

The nominal hole diameter will be 0.644 in.

The hole surface win be conditioned to simulate oxidation conditions at TMI-1 steam generator upper tubesheet crevice. It is essential that this oxide condition remain undisturbed during all pre-espansion steps. Se block CD win be sized to hate a standard Schedule 160 pipe cap for sealing during leah testing.

Two test blocks with the above description wiu be supplied by 34W and protected from asisture during shipment. One test block will be supplied completely assembled with tubes expanded. The other test block will be supplied with tube (part 7) rolled in place with remainder of assembly by FEC.

o Care must be taken while handling the blocks to prevent cisturbing the cuide conditioning in.the block holes in the region to be expanded.

1.4 CNE-TUEE BLOCES Stress-relieved ASME SA-508.CL. 2 test blocks (12 in thick) with a gun-drined hole will be used. See Figure 1.1 for schematic. The bole surface will be conditioned to simulate oxidation concitions at TMI-1 steam generator upper tubesheet crevice. It is essential that this oxi,de condition in the holes in the regions to be D-4 renidn Research Cent

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i TASE M1 - RECEIVING, INSFECTION, AND HARKING OF SPECIJENS e

expanded remain undisturbed during all espansion steps. Six test blocks with the above description will be supplied by B&N and protected from moisture during shipment.

1.5 PG.yETETLENE INSEETS Monsity polyethlene pentrothene uh 301, polyethylene resia, amit index 1.2, mensity 0.917 inserts will be procuried from the Thielex Plastic Corporation. Sey will have a configuration shown in Figure 1.2a.

Dimensions for inserts will be inspected to the requirements of Figure 1.2a.

1.6 CETOMATION Cosip Detonation antarial for the. kinetic expansion will be,

purchased from the Ensign Bickford 4

Company.

Grain size certifications will be filed in the data log sheet. The cord will be analyzed for graina/ft every 50 ft and recorded in tae data log book. Detonation cord will be stored in an isolated magazine area.

1.7 Six (6) test specimens No. 3 shall be supplied. They shall be marked 3A, 33, 3C, 3D, 3E, and 3F.

Se Licensee shall supply g,

tube bloca shall be marked by etching on the outside surface at no more than 1 in from end of tube bloca. Marked end shall be considered the secondary and of the tube block. The tubes aball be marked by etching on the outside surface at no more than 1 in from end of tube. Marked and shall be the socordary and of the tube.

j Tubes 3A, 33, and 3C are to be high yield tubes. Tubes 3D, 3E, and 3F are to be low yield tubes.

i 1.8 Keep the test specimens 3C and 3F unassembled in case additional tests,need to be perforneo.

1.9 Take the assembled tube /tubesheet and, with reference to Dwg.

1134899D, Dev. 4 (Figure 1.0), mark "Fl* on test specimen parts No.

2, No. 3, No. 5 and No. 6: subsequently, unscrew part No. 3 and ansk the tubes at the primary side from 1 to 10 as show in Figure e

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1.2b.

Mark the primary side with "P" located above tube 2 as,shown in Figure 1.2b.

For reference, row 1 consists of tubes 1,'2, and 3, row 2 consists of tubes 4, 5, 6, and 7, and row 3 consists of tubes 8, 9, and 10.

1.10 Unscrew part No. 5, and mark the secondary side with "5" located above tube 2, and mark the tubes at the seco@y side from 1 to 10 corresponding to the numbers at the primary side as shown in Figure 1.2c.

i 1.11 Take the unassembled tube /tubesheet components and, with reference i

to Dwg.1134899D, Rev. 4 (Figure 1.0), mark "F2" on the parts No.

2, No. 3, No. 5, and No. 6.

1.12 Identify the location.of tube hole 2 on the primary side, reference end with tubes rolled in place, and location of high yield and low yield tubes, part No. 7, and mark the primary side of part No. 2 with "P" located above tube hole 2 as shown in Figure 1.2b.

Mark all holes at the primary side from 1 to 10 as abown in Figure 1.2b.

1.13 Mark the secondary side with "s* located above tube hole 2 and mark the tube hole at the secondary side from 1 to 10 corresponding to the numbers at the primary side as shown in Figure 1.2c.

1.14 select' the high yield and low yield tube specimens (part No. 8) for proper assembly in accordance with the tube specifications shown in Figures 1.2b and 1.2c.

Mark the tubes, from 1 to 10 for proper assembly with tube holes of part No. 2.

The tubes shall be marked I

by etching on the outside surface at no more than 1/2 in from end of tube. Marked end shall be considered secondary side of tube.

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i TASE N2 - MASURFJWITS OF TEST COMPONENTS 2.1 P-ior to expansion, test specimens must be stored in an oven oc in a plastic bag with Baw-supplied desiccant to prevent oxide coatings deterioration. Prevent contact of desiccant with oxide surface.

2.2 Take the assembled test specimen "F-l* and measure the inside diameter of each tube at 1, 2-1/8, and 3-1/4 in from the primary 4

l face of the tube block. Record data.

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2.3 Before assembly of eacia single tube block (see Figure 1.1) and corre W iaa tube, measure the length of the tube and tube block and measure the outside and inside diameters at 1 in, 2-1/8 in, and 3-2/4 in from the primary (unmarked) and of both tube and tube block. Care must be taken,to avoid disturbing the oxide conditioning in the tube block hole and on the tube outside diameter in the region to be==p= W. Take dimensions at 90* to strain gage location (reference paragraph 3.2) after strain gages are installed.

2.4 Before explosive expansion of test specimen 'F-2,* asasure the inside diameters of each rolled tube or tube hole at 1 in, 2-1/8 in, and 3-1/4 in from the primary face of the 10-tube block. Measure the outside diameter and inside diameter at 1/8 and 1-1/2 in from the expansion (unmarked) and of each tube. Care must be taken to avoid disturbing the oxide conditioning in the tube block hole and on the tube outside diameter in the region to be expanded.

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TASK N3 - INSTALIATION OF STEIN GAGES FOR SINGLE TURE BLOCKS 3.1 Prior to expansion, test specimens must be stored in an oven or plastic bag with M W-supplied desiccant to prevent oxide coatings deterioration. Prevent contact of desiccant with oxide surf aces.

3.2 Take single tubesheet specimens marked 3A and 3D and, before

' expansion, install two element rosette 90* planar strain gages along two axial lines,180* apart, on the outside surface of each tubesheet. Three strain gages are to be located on each axial line at 1 in, 3-V4 in, and 5-1/2 in from the primary end of the tubesheet. Axial lines shall be referenced A and 3 and readings shall be labeled 1A, 3-1/4A, 5-1/2A, la, 3-1/43, and 5-1/23. All strain gages shall be secoed and connected to a magnetic recorder for recording of strain during explosive expansion.

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TASK N4 - EXPLOSIVE EEPANSION OF SINGLE TUBE MOCIUPS Install tube section for specimen 3C into corresponding single tube block so that the primary tube end is. flush with the primary face of the block.

Maintain the tube and block temperature during these and subsequent operations between 60*F and 100*F.

Insert detonation cord lengths into each plastic so that the tapered and is flush with,the detonating cord. Heat-fuse cord with its plastic on this end.,.

At the expansion site, __, _ _

into the test hole frca the primary face for first step of expansion. Tape the end of the cord-plastic assen Ay and the tail cord together. Then tape the detonating cap to the end of the " tai 1* cord. Plastic insert shall rest on the tube end.

Remove spent items and clean the test specimen of deposit lef t by explosion.

Install tube sections for specimen 3F into corresponding single tube block so that the primary tube end is flush with tne primary face of the bicck.

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TASK M4 - EXPLOSIVF. EXPANSICH OF SINGLE TURE MOCKUPS Expand tube /tubeshee't 3F in accordance with paragraphh 4.2 through 4.10.

Install tube section for specimen 3A into corresponding single tube block so that the primary tube end is flush with the primary face of the block.

Maintain the tube and block temperature during these and subsequent operations between 60*F and 100*F.

1 Insert detonating cord lengths into each plastic so that the tapered end is flush with the detonating cord. Heat-fuse cord with its plastic on this end.

At the expansion site, connect tape recorder for recording of strain readings during explosion expansion (reference paragraph 3.2 of task N3).

i Remove spent items and measure and record the outside diameter and the length of the tube block and the inside diameter and length of the tube. Cutside and inside diameters shall be taken at the three strain gage sections, 90* to strain gage locations, referenced at 1 in, 2-1/8 in, and 3-1/4 in from primary face of test block.

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manove the strain gages and clean the test specimen of adhesive used for strain gages, debris, and deposits left by explosions.

Install tube sections for specimen 3D into corresponding single tube block so that the primary tube end is flush with the primary face of the block and explosively espand specimen 3D using the same f

procedure as for specimen 3A given in paragraphs 4.14 through 4.23.

Remove the strain gages and clean the test specimen 3D of adhesive used for strain gages, debris, and deposits lef t by explosions.

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.i TASK MS - BURRLE TEST FOR SINGLE TUEF/TURESEF.ET 5.1 For the test specimens 3A, 3C, 3D, and 3F, perform a secondary-to-primary-side bubble test, using 125 + 1p psi nitrogen. The test shall be made at 70*F + 15*F.

bottle with pressure regulator, shutoff valve, and 5.2 Connect N2 precision pressure gage.(range o to 200 psi) at the extended tube end (secondary side).

5.3 Immerse the entire test setup in a container filled with distilled water.

5.4 Apply 125-poi pressure using N2 bottle and pressure regulator at the secondary side of the tubesheet, and check for leakage in the test setup.

i 5.5 If there is no leakage between the above parts and the pressure at the secondary side is steady and equal to 125 poi, start the bubble l

test close the shutoff valve and start the clock at the same timer record the pressure versus time until the pressura falls to 10 pai.

NorE Any leakage at gage, valve, or tubenheet connection is unacceptable since it will give a falso reading.

I 5.6 Note sise, location, and rate of air bubbles if any.

5.7 Terminate test after 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />.

(Test deleted) i s

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TASE N6 - PULLOUT AND ARIAL LOAD TEST FOR SINGLE TUBE /TURESHEET i

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6.1 memove excess length of tube (tubesheet assembly 3C) by cutting at l

approximately 2 in from==enadary face of tubesheet.

I 6.2 weld tube plug in==aaadary end of tube.

6.3 Measure extension of tube from ther maaandary face. Measure from j

tubesheet face to plug face.

i 6.4 Place tube /tubeekeet assembly into Instron testing machine using fiatures as aboun in Figure 6.0a.

f 6.5 Using Instron machine, perform the following asial load cycling test at ambient temperature of 70'F g 10*F:

3 a.

100 cycles 760 lb compression to 1110 lb tension b.

180 cycles 635 lb compression to 175 lb tension c.

6040 cycles 510 in coupeession to 125 lb compeession j

The specified cycles should be applied at not more than 1 Er 3

frequency. The tolerance on all cycling forces should be 1 5 lb.

The tube subjected to the cyclic loads should be aligned with the center line of the actuator applying the load. Record all loading.

6.6 Remove tube /tubesheet and axial load fixtures from testing machine.

6.*

Measure extension of tube from secondary face.. Measure from l

tubesheet face to plug face.

6.8 Piece tube /tubesheet into testing machine for pullout (pushout) test using fixtures as shown in Figure 6.0.

6.9 Place grit into each tube to a level within 1/4 in of the secondary tubesheet face and install pushrod on top of grit.

6.10 Apply load gradually, approximately 10 lb/sec. Record load and tube movement relative to tubesheet at both primary and secondary faces. Visually monitor tube behavior. Continue test until relative movement at primary end is at least 0.030 in.

Accurnef of relative displacement seasurement should be 1 0.0001 in.

6.11 Remove tube /tubesheet and pullout fixture from test nachine.

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e TASE N6 - PULLOUT AND AXIAL LCAD TEST FOR SINGLE TURE/TURESEEET 6.12 Measure extension of tube from secondary face. Measure from tubesheet face to plug face.

6.13 Repeat procedure of paragrapha 6.1 through 6.12 for tube /tubenheet assembly 3F.

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i TASK M7 - MICROGRAPHY 7.1 Cut the tube /tubesheet assemblies 3A and 3D at 1 in, 3-1/4 in, and 5-2/2 in from the primary face of the tubesheet (reference Figure 7.0).

Care abould be taken to avoid excessive roughing of the surface or inducing of strain in the tube or tubesheet during saw cutting.

7.2 Prepare the primary face (reference surface in Figure 7.0 marked 1P) of the 1 in to 3-1/4 in block and both faces of the 3-1/4 in to 5-2/2 in block (reference surfaces in Figure 7.0 marked 3-1/4P and 5-1/2S) for micrography by polishing these surfaces.

7.3 Perform micrography of the polished faces, references IP, 3-1/4P, and 5-1/2S.

7.4 Etch faces IP, 3-1/4P, and 5-1/2S and perfosa micrography of these polished and etched faces.

(Test Deleted) i

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TASK N8 - RESIDt2AL STRESSES 8.1 Af ter micrography is completed, install three (3) double strain gages on each of the polished and etched faces (reference surfaces in Figure 7.0 marked 17, 3-1/47, and 5-1/23). Strain gages are to I

be mounted as cloce as possible to the inside diameter of the tubenheet at 120* intervals about tubesheet centerline.

8.2 zero all strain gages and 5=t- ;mtly machine inside tubes so that they can be m11= red and removed. Remove inside tubes and record strain gage readings.

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TASK N9 - ROLL EXPANSION OF SPECIMEN 2 9.1 Install the 10 tubes (part No. 7 in Dwg.1134899D, any. 4, Figure 1.0) from the primary side, one by one, matching the numbers of the tube with the numbers of the holes. The tube should project 3/16 +

1/64 in above the primary side of the tubesheet. Each tube shall be roll espanded at the primary and to 55 in-lb for a depth of 1-1/4 in from the tube end.

9.2 After roll expansion, measure inside diameters of rolled tubes per paragraph 2.4.

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TASE N10 - EIPIASIVE EXPANSICH OF SPECIMEN ~"F-2" 10.1 Install the 10 tubes (part No. 8, Dwg.1134899D, Rev. 4, F,igure 1.0) from the secondary side, matching the numbers on the tubes with the numbers of the holes in the tubesheet and butting unmarked (primary) and of each tube (part No. 8) against rolled tube (part No. 7). All 10 tubes are to be in place during explosive expansion of any one tube. Secure in place without staking.

10.2 Maintain the tubes and block temperature during these and subsequent operations between 60*F and 100*F.

10.5 Cut detonation cord lengths for each tube expansion equal to the longth of expansion ~ ~

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10.6 Insert detonating cord lengths into each plastic so that the tapered end is flush with the detonating cord. Heat-fuse cord s

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TASK N10 - ZXPLOSIVE EXPANSION OF SPECIMEN "F-2" with its plastic on this end.

10.7 If applicable, propr.re detonating cord " tails" to facilitate simultaneous expansion of more than one tube and to keep detonating " cap" debris away from test face.

10.8 At the expansion s'ite, insert proper S-in-long ' plastic insert primacord assembly from the primary face of the test block into the proper tube. Reference proper tube and priancord assembly from expansion sequence given in paragraph 10.4 above. Reference preper primacord assembly from paragraph 10.6.

Tape the end of each cord-plastic assembly and the tail cord together. Then tape the detonating cap to the end of the " tail" cord. Plastic insert shall rest on the tube end. Cover unshot holes with rubber plugs to protect from debris.

10.9 Perform detonation, remove spent items, and record expansion on test log sheet. If misfire occurs, take corrective action to expand tube. Do not proceed to subsequent sequence until tube has been expanded.

10.13 After completion of expansion of all tubes'

~ aeasure and record the inside diameter of each tube hole at 1, 2-l'/8, and 3-1/4 in from the primary face of the 10-tube block.

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D-23 01,) Franklin Research Cemer A Desume.af The Psammase summer

t TASE NM - BUBBLE TEST FOR SPECIJESS F-1 and F-2 n.1 For test specimens F-1 and F-2, perform a secondary-to-primary-side bubble test using 125 + 10 poi nitrogen. The test shan be made at 70*F + 15'F in distined water and at a maximum depth of 15 in.

u.2 weld tube plugs, part No. 9, in awary and of tube (reference Figure 1.0, B&W Drawing 11348990, Bev. 4).

Welded plugs must be air-tight. Check air-tight; welds by immersion of block in distilled water.

11.3 Assemble welded and cap, reference part (5) and (6), on s"=ry end of part (2) against a gasket to obtain a leak-free connection between tubesheet and and cap.

M.4 Connect N2 bottle with pressure regulator, shutoff valve, and precision pressure gage (range 0 to 200 psi) at the provided coupling in part (6) (see Figure 11.0 for test setup).

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u.5 Immerse the entire test setup in a container fined with distilled water.

11.6 Apply 125 psi pressure using N2 bottle and pressure regulator.

Check to insure that there is no leakage between parts (2) and (5), parts (5) and (6), or in any connection of tne 32 source.

11.7 Start the bubble test by setting pressure at 125 poi and then closing the shutoff valve. Record pressure versus time after closing of shutoff! valve. Record by reading pressure gage at 5-pai or 1/2-hour intervals, whichever occurs first, for a minimum of 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />. Record water temperature at same intervals.

11.8 Check tube /tubesheet assembly for gr.s bubbles. Note the size, location, and frequency of any bubbles. Make a video record of bubbles.

11.9 For test specimens F-1 and F-2, perform a primary-to-secondary-side bubole test using 125 + 10 psi nitrogen. The test shall be made at 70*F + 15'F in distilled water and at a maximum depth of 15 in.

H.10 Assemble end cap, referen*ce part (3), on primary end of part (2) against a gasket in order to retain a primary side pressure.

11.11 Immerse the entire test setup in a container filled with distilled water.

D-24 A!,0 Frankun Research C. enter a cm w n r

TASK N11 - BUBBLE TEST FOR SPECIMENS F-1 and F-2 11.12 Apply 125 psi 110 psi pcessure using N2 bottle and pressute regulator. Check to insure that excessive leakage does not cccur at the gasket and that pressure can be maintained for a minimum test period of 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />.

11.5 With pressure maintained at 125 psi i 10 pai, start the test ty checking the secondary end of the tubesheet for gas bubbles at the tube /tubesheet interfaces and at the weldsent of each tube plug.

Note and record the time, size, and location of any bubbles that are released from the specimen during 0 to 5 min, 30 to 35 min, 60 to 65 min, and 115 to 120 min of test period.

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TASK N12 - TBFJup.L CYCLING l

12.1 Install three thermocouples:

two on the ID of tubes No. 9 and No.

10, 6 in from the primary side, and one on the CD of the tubesheet, also 6 in from the primary side (thermocouple range 50*F to 700*F).

12.2 Using thermal blankets or an electric oven with a temperature control,. perform the following thermal cycling:

a.

30 heatup/cooldown cycles from 70*F (+0/-25'F) to 610*F

(+25/-0 *F) to 70*F (+0-25'F) b.

8 reactor trip cycles from 70*F (+0/-25'F) to 610*F (+25/-0*F) to 70*F (+0/-25*F) c.

1 stuck-open turbine bypass valve cycle from 610*F (+25/-0*F) to 400*F (+0/-25'F) in 10 minutes.

During thermal cycling (a) and (b), the temperature difference between tube and tubesheet shall not exceed 100*F, and the rate of temperature change of the tubes shall not exceed 10*F/ minute. The maximum temperature difference between the tube and tubenheet during thermal cycle (c) shall not exceed 30*F.

(Test Deleted)

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TASE N13-BUBBLE TEST ~ POST TIERMAL CTCLE 13.1 After thermal cycling, perform a primary-te==eandary-side bubble test in accordance with paragraphs 11.S through 11.13.

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TASE N14 - ARIAL LOAD CYCLING 14.1 Calibrate Instron nachine.and recording system using FAC known weights.

14.2 Measure extension of each tube from secondary face to plug face and record data.

14.3 Install tube /tubesheet assembly marked F-1 into Instron machine using fixtures and arrangesenats as shown in Figure 6.0.

14.4 Correct axial load (+ 2 lb) and readout for dead weight of adaptors or fixtures, if any. Check to insure that the tube being subjected to cyclic loads is aligned with the centerline of the actuator applying the loads and that mounting is not susceptible to buckling or side loading.

14.5 Using the Instron aschine, apply the following axial load cycling at ambient temperature of 70*F + 10*F for each tube separately, starting with tube (1) 100 cycles 780 lb compression to 1110 lb tension a.

b.

180 cycles 635 lb compression to 175 lb tension c.

6040 cycles 510 lb compression to 125 lb compression.

The specified cycles should be applied at not more than 1 Es frequency. The tolerance on all cycling forces is + 5 lb.

14.6 Perform axial load cycling for all tubes,1 through 10, in that order., secord load limits of each cycle.

14.7 Measure exteasion of each tube from secondary face to plug face and record data.

l 14.8 Perform axial load cycling for tube /tubesheet marked F-2 using the procedure in paragraphs 14.2 through 14.7.

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TASK N15 - BesaLE TEST - POST AXIAL LCAD 1

15.1 After axial load cycling is completed, perform a primary-td-

= h ary-side bubble test in accordance with paragraphs 11.9 through 11.13.

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4 TASK N16 - MARDtENEarf5 - POST AXIAI, m 16.1 After completion of axial load cycling, make the same measurements as in paragraph 2.2 and record them.

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TASE N17-LEAE RATE TEST i

17.1 Perform leek rate test wita a =hary-to-primary AP of 1275 psi

(+ 25 poi) at room temperature of 70'F 115'F.

17.1 Using an 32 bottle with pressure regulator and the test setup as shown in Figure 17.0, charge the accumulator to 200 psi (+30 psi) by opening shutoff valve (4). Close valve (4) after accumulator l,

has been charged.

1 17.3 Connect the handpump at shutoff valve (3). Make sure that shutoff valves (3) and (5) are open and charge the accumulator and the Wry side of the test specimen with distilled water at 1275 +

25 psi. Use air vent plug to elimiv te air at the==caadary side of the test specimen. Men the air is eliminated and the pressure reaches 1275 + 25 poi, close shutoff valves (3) and (5) and dimenanar t the handpump.

f 17.4 Connect the handpump at shutoff valve (1). Make sure that shutoff i

valves (1) and (5) are open and shutoff valve (2) is closed.

Charge the primary side of the test specimen with distilled water.

Use air vent plug to eliminate air at the primary side of the test specimen. Men the air is eliminated and the pressure reaches 20 poi (+ 10/- O psi), close shutoff valves (1) and (5) and disconnect the handpump.

17.5 Adjust N2 pressure regulator and open valve (4) to maintain accumulator pressure at 1275 psi

(+ 25 psi). open shutoff valve (2) very slowly. Do not collect the water at valve (2) for the i

i first 5 minutes. After 5 minutes, begin collection of the water.

Record pressure and the collected leakage every 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> for a miniaua period of 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />.

i 17.6 Maintain pressure and collection of leakage (seasoning) either for a period of 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> or until the amount of leakage in any 2-hour period is the same as the amount callected in the previous 2-hour period, or.the change between the amounts collected in the last two periods is less than 10% of the change between the amounts collected in the two previous periods.

17.7 The leak rate test shall be initiated as soon as ' seasoning" is completed by maintaining the pressure at the secondary side at 1275 poi (+ 25 psi) and recording the accumulated leakage. Record the accumulation of leakage water every hour up to and including the amount accumulated in an 8-hour period.

(GPU specifications are 116 cu um maminum in an 8-hour period.)

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s TASK N18 - LEAE RATE TEST Perform leak rate tests with a primary-to-sW= y AP of k275 13.1 psi (+ 25 psi) and with a primary-to-maeaadary AP of 2500 psi (1 25 psi). Maintain room temperature at 70*F t 15'F.

13.2, Using an N2 bottle with press.ure regulator and the test setup as shown in Figure 17.0, but with the block reversed, charge the assumulator to 600 psi (130 psi) by opening shutoff valve (4).

Close valve (4) after accumulator has been charged.

18.3 Connect the handpump at shutoff valve (3). Make sure that shutoff valves (3) and (5) are open and charge the accumulator and the primary side of the test specimen with distilled water at 1275 psi

+ 25 psi. Use air vent plug to eliminate air at the primary side of the test specimen. Men the air is =14=i==ted and the pressure reaches 1275 psi + 25 poi, close shutoff valves (3) and (5) and di=aaanect the handpump.

14.4 Connect the handpump at shutoff valve (1). Make sure that shutoff valves (1) and (5) are open and shutoff valve (2) is closed.

, Charge the s"-

y side,of the test specimen with distilled water. Use air vent plug to eliminate air at the secondary side of the test specimen. Men the air is eliminated and the pressure i

reaches 20 psi (+ 10/- O psi), closs shutoff valves (1) and (5) and disconnect the ha t 7 18.5 Adjust N2 pressure regulator and open valv'e (4) to maintain m

accumulator pressure at 1275 psi (+ 25 psi). Open shutoff valve (2) very slowly. Do not conect the water at valve (2) for the first 5 minutes. Af ter 5 minutes, begin collection of the water.

Record pressure and the collected leakage every 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> for a sinimum period of 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />.

18.6 Maintain pressure and collection of leakage (seasoning) either for a period of 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> or until the amount of leakage in any 2-hour period is the same as the amount collected in the previous 2-hour period, or the change between the amounts col),ected in the last two periods is less than 10% of the change between the amounts collected in the two previous periods.

18.7 The leak rate test shall be initiated as soon as " seasoning

• is completed by maintaining the pressure at the primary side at 1275 psi

(+ 25 psi) and recording the accumulated leakage. Record the accumulation of leakage water every hour up to and including the amount accumulated in an 8-hour period.

(GPU specifications are l

116 cu sa maximum in an 8-hour period.)

D-34 O

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TASK N18 - LEAR RATE TEST 18.8 Adjust N2 pressu:e regulator and open valve (4) to maintain acen=ulator pressure at 2500 psi (125 psi). Do not collect,the water at valve (2) for the first 5 minutes. After 5 minutes, begin conection of the water. ancord pressures and the co n ected leakage every 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> for a minimum period of 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />.

18.9 unintain pressure and conection of leakage (seasoning) either for a period of 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> or until the amount of leakage in any 2-hour period is the same as t,he amount conectM in the previous 2-hour i

period, or the change between the amount:s conected in the last two periods is less than 10% of the change between the amounts co nected in the two previous periods.

18.10 The leak rate test shall be initiated as soon as " seasoning" is completed by maintaining the pressure at the primary side at 2500 psi (125 poi) and recording the accumulated leakage. mecord the accumulation of leakage water every hour up to and including the amount accumulated in an 8-hour period.

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n TASE N19 - PULLOUT LOAD TEST 19.1 Calibrate Instron machine and recording system using FEC known weights. Correct asial load (12 lb) and readout for weight of adaptors or fixtures, if any.

19.2 Install tube /tubesheet assembly marked F-1 into Instron machine with tube marked (2) posi*iw for punhout. Use fixtures and arrangement as aboun in Figure 14.0.

19.3 Place grit into the tube marked (2) to a level within 1/4 in of the aw=ry tubesheet face and install pushrod on top of grit.

19.4 Apply load gradually, approximately 10 IVsec. Bocord load and relative displacement between = h ary face of tubesheet and

====aadary tube end. Visually monitor tube behavior. Continue test until relative di==1 = --- =t at====aadary and is at least 0.060 in.

Accuracy of relative displacement measurement abould be 1 0.0003 in.

19.5 Remove tube /tubesheet assembly.

19.6 Repeat procedure of paragraphs 19.2 through 19.5 for tubes marked (3), (8), and (9) in that order. Take care not to loed or disturb tubes marked (1), (4 ), (5 ), (6), (7), or (10) of tube /tubesneet assembly marked F-1.

19.7 Install tube /tubesheet assembly marked F-2 and repeat procedure of paragraphs 19.2 through 19.5 for tubes 1 through 10, in that order.

D-36 Frenidin Research Center A Dean af The Presses emmemp

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TASK N20 - MICROGRAPHY 20.1 Cut the tube /tubesheet assembly marked P-1 at 2-1/4 in, 4-7/8 in, and 7-1/2 in from the primary face of the tubesheet (referende Figure 20.0).

Care should be taken to avoid escessive roughing of the surface or inducing of strain at the cut face of the tube sheet or tube.

t 20.2 Prepare the primary face of the 2-1/4 in to 4-7/8 in block (reference surface marked 2-1/4P in Figure 20.0) and both faces of the 4-7/8 in to 7-1/2 in block (reference surfaces marked 4-7/8P and 7-1/2E in Figure *20.0) for micrography by' polishing these surfaces.

20.3 At the polished surfaces (references 2-1/4P, 4-7/SP, and 7-1/25) perform micrography around tubes 4, 5, 6, and 7.

20.4 Etch faces 2-1/4P, 4-7/8P, and 7-1/28 and perform micrography of these polished and etched surfaces around tubes 4, 5, 6, and 7.

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TASK N21 - MASURDENT OF RESIDUAL STRESSES 21.1 For the test specimen marked F-1, perform measurement of residual stresses in the tubesheet ligaments shown in Figure 21.0a.

21.2 Af ter micrography is completed, install double strain gages on each of the seven ligaments shown in Figures 21.0a and 21.0b.

Repeat this pattern at each of the polished and etched faces (references 2-3/4P, 4-7/8P, and 7-1/28 in Figure 20.0) for a total of 21 strain gages. Strain gages are to be mounted equidistant from each tube hole.

21.3 zero all strain gages and subsequently machine inside tubes so that the tubes can be collapsed and removed. Remove tubes and record strain gage readings.

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APPENDIX E TEST DATA i

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• DATA SHEET - RECEIVINE, INSPECTION, AND MARKING Task N1 1.

As received in shipping box, the plastic bag containing the 10 hole tubesheet block was torn on both ends by the tubesheet threads. The bag has 6 holes approximately 1/2" long 3 holes approximately 1" long and 1 hole appreximately 2" long.

In addition, there are four splits previously taped sheet. Marking on the bag is as follows:

10 Hole Tubesheet Mockup Corrosion Conditioned Per TP-526 i

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5045-SP2-76D857-1-2 7-22-87 Also received, six tubes approximately 24" long and sealed in plastic bag. Also received, additional tubesheet block with tubes in place.

As received, tubesheet block with tubes in place was sealed in double plastie bag.

2.

Torn plastic bag containing tubesheet block placed inside additional bag and resealed for later inspection.

3.

Tubesheet blocks removed from bags, marked and resealed.

O 4.

Six single tube blocks received in sealed individual bags.

Six tubes l

received in sealed bag marked low yield.

5.

Ten (10) tube /tubesheet block removed from plastic bags for inspection.

Desiccant in intermal vented bag has mostly blue color indicating it is still active. Some crystals are white. Small amount (about teaspoon) of dessicant is loose in bag with tubesheet.

Inspection of holes under high intensity lighting indicates slight reddish oxide near end of holes (approximately 1/4" and very insignificant).

Inside diameter of holes looked clean and free of loose reddish oxide. Unit was resealed with fresh desiccant. (9/9/82) l l

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Task N2 Project 5506-10-312 Data are in Table 1 of the report.

Task N3 Project 5506-10-312 1.

Installation of strain gages was completed on specimen 3A.

expansion was accomplished on September 30,1982.

• Impact of explosive expansion caused strain gages to separate from specimen and caused separation of the lead wires to the strain gages. No useful data obtained.

2.

Strain gage mounting procedures and lead wire arrangement were modified and two gages were installed expansion was accomplished with modified strain gage iristallation in order to evaluate strain gage mounting and wiring procedure. Procedure appeared satisfactory. Gages and lead wires appeared to have remained in place However, no valid data were obtained.

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I Task N9 Project 5506-10-312 Data are in Table 1 of the report.

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Deus A Devenson d The Franhen insumme vm DATA SHEET - TASK N11 - BUBBLE TEST FOR SPECIMEN F1 1.

Secondary $:o primary bubble test on tube /tubesheet marked F-1, started at 11:15 on August 30, 1982.

Pressure set at 125 psi. Water temperature 73*F. Sanil leak at gasket between parts 2 and 5.

Test teminated and gasket resealed. Bubble test restarted at 0930 on August 31, 1982.

Pressure decay verse time as follows:

Time

,PSIG

'fF, 0930-8/31/82 125 73 1030 125 73 1130 124.8 73 1230 124.0 73.8 1330 123.8 73.8 122.4 73.8 1442 1530 122.0 73.8 1630 121.8 74.0-

~

I 1705 121.0 74 0830-9/1/82 109.0 75 0952 108.0 75 107.8 75 1037 l

1130 107 75 1250 106 75 1330 105.8 75 1430 105 75 1530 104 75 1549 104 75 Test Taminated at 1549 s

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o.m 3 % m.g DATA SHEET - TASK N11 - BUBBLE TEST FOR SPECIMEN F1 (CONT.)

Secondary to primary bubble test on tube /tubesheet marked F-1 started at 0930 on 8/31/82. No leak at gasket. Pressure steady and no apparent leaks or bubbles. Very small bubble stream observed between tube and tubesheet at tubes M and #8 at 1130. Also at 1130 bubbles of various size are discovered inside top of all tubes. Unable to detemine whether bubbles result from air entrapped in tube before starting test, or whether air is escaping past tube plug, or whether air is collecting from air originallydissolved in water.

Small probe is used to move bubbles at upper inside surface of tubes. Small bubble stream continues at tubes #4 and #8 after removal of bubbles at inside of tubes. Videotape of bubbles at tubes M and #8 taken at 1145 hours0.0133 days <br />0.318 hours <br />0.00189 weeks <br />4.356725e-4 months <br />.

No additional le' ks discovered at 1406 but bubbles inside tubes have refomed, a

source unknown. At 1454 hours0.0168 days <br />0.404 hours <br />0.0024 weeks <br />5.53247e-4 months <br /> lesh between tube and tubesheet at #4 continue with bubbles being slightly larger and of much lower frequency (18 to 35 sec interval). At 1705 leak still visible at tubes #4 and #8. At 0830 on 9/1/82, all tubes have large bubbles entrapped inside tubes, small bubbles escaping at tube #4 at 10 to 15.second interval and can no longer detect bubbles at. tube #8.

At 1200 houn, can no longer detect bubbles at tube #8, bubbles at tube M escaping at 10 to 15 second intenals. At 1430 hours0.0166 days <br />0.397 hours <br />0.00236 weeks <br />5.44115e-4 months <br />, cannot detect bubbles escaping at tube #8, bubbles at tube M escaping at

, 60 to 90 second intervals.

Lcrge bubbles continue to refons slowly inside each tube, approximately at butdng of tubes. Test teminated. Still in-possible to detemine whether bubbles feming inside tube result from leakage past tube or past tube plug or possibly slow migration of oringally entrapped ai r.

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DATA SHEET - TASK Mll - BUBBLE TEST FOR SPECIMEN F1 (CONT.)

1.

Primary to secondary bubble test started on tube /tubesheet marked F-1 at 906 hours0.0105 days <br />0.252 hours <br />0.0015 weeks <br />3.44733e-4 months <br /> on October 4,1982. Pressure set and maint.ained at 125 psi + 10 psi. Average frequency of bubbles at tube and tubasheet l

interface noted as follows:

. Tube #1 2 minute 39 second interval

1. 2 58 second interval

1. 3 very slow M

2 minute 37. seconds

1. 5 1 minute 53 seconds

1. 6 very slow 1

.i

1. 7 no bubbles observed

1. 8 4 minutes 58 seconds

1. 9 1 minute 30 seconds

1. 10 3 minutes 25 seconds No bubbles observed at tube plugs.

Bubble size is estimated at 1/16 to 1/8" diameter.

2.

At 1000 hours0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> on October 4,1982, average frequence of bubbles noted as follows:

Tube #1,

1 minute 36 seconds j

1. 2 5 minutes 56 seconds

1. 3 4 minutes 25 seconds

1. 4 2 minutes 9 seconds

1. 5

' 2 minutes 55 seconds

1. 6 1 minute 52 seconds

1. 7 no bubbles observed j

1. 8 one bubble observed

1. 9 5 minutes 38 seconds

1. 10 11 minutes 25 seconds No bubbles at tube plug.

l l

3.

At 1055 hour0.0122 days <br />0.293 hours <br />0.00174 weeks <br />4.014275e-4 months <br /> on October 4,1982, average frequency of bubbles at tube l

and tubesheet interface ncted as follows:

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DATA SHEET - TASK N11 - SU88LE TEST FOR SPECIMEN FI'-(CONT.)

Tube #1 5 minutes 4 seconds

1. 2.

2 minutes 28 seconds

1. 3 no bubbles observed

1. 4 2 minutes 11 seconds i

1. 5 2 minutas 15 seconds M

one bubble observed

1. 7 no bubbles observed

1. 8 one bubble observed

1. 9 3 minutes 23 seconds

1. 10 5 minutes 38 seconds No bubbles observed at tube plug.

Subble size is approximately 1/8" diamatar.

Test terminated at 1106 hours0.0128 days <br />0.307 hours <br />0.00183 weeks <br />4.20833e-4 months <br />.

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DATA SHEET - N11 - BUBBLE TEST FOR SPECIMEN' F2 1.

Secondary to primary test on tube /tubesheet marked F-2, reference paragraphs 11.1 to 11.8, deleted because test does not identify source of the leak.

2.

Primary to secondary bubble test started on tube /tubesheet marked F-2 at 1355 hours0.0157 days <br />0.376 hours <br />0.00224 weeks <br />5.155775e-4 months <br /> on October 4,1982.

Pressure set and maintained at 125 PSI + 10 PSI. Average frequency of bubbles at tube and tubesheet 6terface noted as follows:

Tube #1 no bubbles observed

1. 2 no bubbles observed

1. 3 55 seconds

1. 4 no bubbles observed f5 no bubbles observed

1. 6 37 seconds

1. 7-no bubbles observed

1. 8 41 seconds

1. 9 13 seconds

1. 10 20 seconds No bubbles observed at tube plugs.

Bubble size estimated at 1/16" to 1/8" diameter.

3.

After 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br />, the average frequency of bubbles was noted as follows:

Tube il no bubbles observed

1. 2 no bubbles obsened

1. 3 one bubble obsened

1. 4 no bubbles observed f5 30 seconds

1. 6 15 seconds

1. 7 one bubble" observed

1. 8 25 seconds

1. 9 13 seconds

1. 10 18 seconds renu casnom

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4.

At 1555 houn on October 4.1982, average frequency 6f bubbles noted as follows:

Tube #1 no bubbles observed i

1. E no bubbles observed M

one bubble observed M

no bubbies observed M

1 minute 5 seconds M

10 seconds

1. 7 1 minute 1 second M

37 seconds M

13 seconds

1. 10 20 seconds No bubbles noted at tube plugs.

Bubble size estimated at approximately 1/8".

Test terminated at 1559 hours0.018 days <br />0.433 hours <br />0.00258 weeks <br />5.931995e-4 months <br />.

Task N14 1

Project 5506-10-312 Full chart recordings of all axial load cyclings are on file at FRC.

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DATA SHEET TASK N15 Project 5506-10-312 1.

Primary to secondary bubble test started on tube /tubesheet marked F-1 after axial load test at 0945 hours0.0109 days <br />0.263 hours <br />0.00156 weeks <br />3.595725e-4 months <br /> on October 8,1982. Pressure set and maintained at 125 psi + 10 psi. The number of bubbles at the tube and tubesheet interface observed in a 5-minute observation period of 0945 hours0.0109 days <br />0.263 hours <br />0.00156 weeks <br />3.595725e-4 months <br /> to 0950 hours0.011 days <br />0.264 hours <br />0.00157 weeks <br />3.61475e-4 months <br /> is as follows:

Tube Number of Bubbles

1. 1 4

1. 2 2

1. 3 4

1. 4 4

1. 5 3

1. 6 0

1. 7 1

1. 8 1

1. 9 2

1. 10 1

No bubbles observed at tube plugs.

Bubble size is estimated at 3/16 to 1/8" diameter.

2.

In a 5-minute interval from 1500 hours0.0174 days <br />0.417 hours <br />0.00248 weeks <br />5.7075e-4 months <br /> to 1055 hours0.0122 days <br />0.293 hours <br />0.00174 weeks <br />4.014275e-4 months <br /> on October 8,1982, the number of bubbles observed at the tube and tubesheet interface is as follows:

Tube Number of Bubbles

1. 1 2

1. 2 2

1. 3 4

1. 4 3

f5 2

i

1. 6 0

l

1. 7 2

1. 8 1

1. 9 1

1. 10 0

3.

In a 5-minute interval from 1150 hours0.0133 days <br />0.319 hours <br />0.0019 weeks <br />4.37575e-4 months <br /> to 1155 hours0.0134 days <br />0.321 hours <br />0.00191 weeks <br />4.394775e-4 months <br /> on October 8,1982, the number of bubbles observed at the tube and tubesheet interface is l

as follows:

Tube Number of Bubbles I

fl 3

l ft 2

1. 3 4

1. 4 2

l

1. 5 2

1. 6 0

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I!dti Nw6er of Bubbles

1. 7 0

2

1. 9 1

1. 10 0

No bubbles observed at tube plug.

Bubble size is approximately 1/8" to 3/16" diameter.

Test terminated at 1155 hours0.0134 days <br />0.321 hours <br />0.00191 weeks <br />4.394775e-4 months <br />.

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e DATA SHEET, TASK N15 Project 5506-10-312 1.

Primary to secondary bubble test started on tube /tubesheet marked F-2 after axial load test at 1300 hours0.015 days <br />0.361 hours <br />0.00215 weeks <br />4.9465e-4 months <br /> on Octcher 19, 1982.

Pressure set and maintained at 125 psi + 10 psi. The number of bubbles at tube and tubesheet interface observed in a 5-minute observation period of 1300 hours0.015 days <br />0.361 hours <br />0.00215 weeks <br />4.9465e-4 months <br /> to 1305 hours0.0151 days <br />0.363 hours <br />0.00216 weeks <br />4.965525e-4 months <br /> is as follows:

Tule Numinr of Bubbles

1. 1 4

1. 2 13

1. 3 4

1. 4 7

1. 5 19 '

1. 6 7

1. 7 2

1. 8 1

1. 9 2

1

1. 10 1

No bubbles observed at tube plugs.

Bubble size is estimated at 3/16 to 1/8" diameter.

1 2.

In a 5-minute interval from 1330 hours0.0154 days <br />0.369 hours <br />0.0022 weeks <br />5.06065e-4 months <br /> to 1335 hours0.0155 days <br />0.371 hours <br />0.00221 weeks <br />5.079675e-4 months <br /> on October 19, 1982, the number of bubbles observed at the tube and tubesheet inter-face is as follows:

i Tube Number of Subbles

1. 1 5

.f2 12 l

1. 3 4

1. 4 3

1. 5 24

1. 6 11 4

1. 7

1. 8 6

1. 9 4

1

1. 10 1

3.

In a 5-minute interval from 1400 hours0.0162 days <br />0.389 hours <br />0.00231 weeks <br />5.327e-4 months <br /> to 1405 hours0.0163 days <br />0.39 hours <br />0.00232 weeks <br />5.346025e-4 months <br /> on October 19, 1982, the number o bubbles observed at the tube and tubesheet inter-face is as follows:

Tube Number of Bubbles

1. 1 3

1. 2 9

1. 3 6

64 1

1. 5 18

1. 6 13 E-13 i

_.,, - - ~. _ _.

3.

(Cont'd)

Tube Number of Bubbles 07 0

N 6

1. 9 1

1. 10 1

4.

In a 5-minute interval from 1500 hours0.0174 days <br />0.417 hours <br />0.00248 weeks <br />5.7075e-4 months <br /> to 1505 hours0.0174 days <br />0.418 hours <br />0.00249 weeks <br />5.726525e-4 months <br /> on October 19, 1982, the number of bubbles observed at the tube and tubesheet inter-face is as follows:

Tube Number of Bubbles i

1. 1 6

1. 2 13

1. 3 5

1. 4 0

1. 5 28

1. 6 13

1. 7 1

1. 8 8

1. 9 1

1. 10 3

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2 4

9 0

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Task N17. Secondary to Pridary Side Leak Rate Test. Specimen F-1 Test started at 10:15 en October 9.1982.

Liquid collected in graduated flask.

i Date Time Pressure, h Liquid Collected Oct. 9 1015,

1275 75' O

Oct. 9 1020 1275 0

0 (Small droplet on inside of Oct. 9 1220 1275 tube but not measurnable) i 0 (Small droplets on inside of Oct. 9 1420 1275 tube but not measureable)

Note (1)

Oct. 9 1530 1275

(

Note 1)

Unable tc measure water leakage since water droplets adhere to inside I

of tube and are not collected in graduated flask. A one-quarter inch (6.35 un) I.D. tube was mounted vertically against a 1/64" graduated machinist scale. Distilled water was added to primary side to bring water level up to the base of machinists scale. Secondary side pre-ssure was maintained at 1275 psi.

Readings were taken as follows:

Date Time Pressure Water Height

.T,gg, i

Oct. 9 1535 1275 psig 42/64 78'F Oct. 9 1735 1275 1-5/64 78'F Oct. 9 1935 1275 1-33/64 77.5'F Oct. 11 0845 1275 11-3/8 72*F Note: Water was drained from tube, through valve (1), to reset water level at

(

bottom of scale. Readings taken as follows:

Qg,13, Time erassure Water Heicht Temo.

" t. 11 0900 1275 32/64 72*F Oct. 11 1107 1275 1-16/64 75' Oct. 11 1300 1275 1-60/64 77 Oct. 11 1500 1275 2-44/64 77 Oct. 11 1700 1275 3-28/64 78 Oct. 12 0845 1275 8-48/64 76*F num ca.m:.e i

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5506-10-312 E-16

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Note:

After 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> of seasoning,10/9/82 to 10/12/82, water was drained thru valve (1) to reset water level at bottom of scale and initiate eight (8) hour test. Readings taken as follows:

gggg, Time Pressure jgter Heicht

Igh, Oct.12 1015 1275 32/64 76*F Oct.12 1115 1275 55/64 77 Oct. 12 1215 1275 1-15/64 77 Oct. 12 1315 1275 1-36/64 77 Oct. 12 1415 1275 1-60/64 77 Oct. 12 1515 1275 2-20/64 77 Oct. 12 1615 1275 2-42/64 78 Oct. 12 1715 1275 3-1/64 78 Oct. 12 1815 1275 3-24/64 78 Test was terminated at 1815 after 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> of collection. Total water collected in 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> was 3-24/64 - 32/64 = 2 56/64 = 2.875 in.

= 73.025 m Volume = (73.025 m) ({} (6.35)2 = 2312.64 cu. m.

or 289 cu. m/hr.

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W 5506-10-312 nklin Research Center

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$D& DOC Task N17. Secondary to Primary Side Leak Rate Test Specimen F-2 Test started at 1700 hours0.0197 days <br />0.472 hours <br />0.00281 weeks <br />6.4685e-4 months <br /> on 10/22/82.

Date Time Pressure Water Height Temp.

Oct. 22 1700 1275 1-56/64 79'F Oct. 23 NO READINGS Oct. 24 NO READINGS i

Oct. 25 0850 1275 7-24/64 73.5'F Note: Reset water height to 1 inch at 0850 hours0.00984 days <br />0.236 hours <br />0.00141 weeks <br />3.23425e-4 months <br />.

Oct. 25 1000 1275 1-6/64 75.5

.Oct. 25 1115 1275 1-12/64 76 Oct. 25 1214 1275 1-17/64 76 Oct. 25 1300 1275 1-21/64 76.5 Oct. 25 1400 1275 1-29/64 77 Oct. 25 1504 1275 1-35/64 77 Oct. 25 1610 1275 1-42/64 77 Oct. 25 1710 1275 1-48/64 77 Note: 72 houn of seasoning coepleted. Eight hour ts.st as follows.

i Oct. 25 1730 1275 1-49/64 77'F Oct. 25 1830 1275 1-53/64 77.4 Oct. 25 1930 1275 1-58/64 77.5 I

Oct. 25 2030 1275 1-62/64 77.5 Oct. 25 2130 1275 2-1/64 77.6 Oct. 25 2230 1275 2-5/64 77.5 l

Oct. 25 2330 1275 2-10/64 77.6 l

Oct. 26 0030 1275 2-14/64 77.6 Oct. 26 0130 1275 2-16/64 77.5 Test terminated at 0130 hours0.0015 days <br />0.0361 hours <br />2.149471e-4 weeks <br />4.9465e-5 months <br /> after 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> of collection. Total water collected in 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> was I

2-16/64 49/64 = 31/64 =.484 inch i

l

= 12.3 m Volume = (12.3 m) ({} (6.35)2 = 389.6 cu. m or 48.7 cu. m/hr.

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Task N18, Primary to Secondary Side Leak Rate Test, Specimen F-1 Test stated at 9:30 on 10/13/82.

gg33, Time Pressure Water Height

Tgg, Oct. 13 930 1275 77'F Oct. 13 935 1275 48/64 77 Oct. 13 1135 1275 3-57/64 78 Oct. 13 1335 1275.

6-12/64 78 Oct. 13 1535 1275 7-40/64 77 Note: Reset at 1535 to 48/64 water height.

Oct. 13 1735 1275 1-62/64 78 Oct. 14 835 1275 6-14/64 76 Note: Roset at 835 to.24/64 water height.

Oct. 14 935 1275 40/64 77 Oct.14 1135 1275 1-4/64 77 Oct. 14 1335 1275 1-32/64 77 Oct. 14 1535 1275 1-56/64 77 Oct. 14 1717 1275 2-12/64 77 Oct. 15 835 1275 4-24/64 75 Oct. 15 935 1275 4-32/64 76 Oct. 15 1135 1275 4-50/64 77 Oct. 15 1335 -

1275 5-12/64 77 Oct. 15 1535 1275 5-32/64 78 Oct. 15 1715 1275 5-51/64 78 Note:

Reset at 1715 to 32/64 water height.

Oct.16 920 1275 2-20/64 Note:

72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> of seasoning coupleted. Eight hour test as follows:

Oct. 16 930 1275 2-20/64 83*F Oct. 16 1030 1275 2-29/64 78.5 Oct. 16 1130 1275 2-40/64 78' Oct. 16 1230 1300 2-48/64 78 mau cece

s%)0l} Franklin Research Center 5506-10-312

• E-19

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Task 18. Specimen F-1 (. cont'd)

Data Time Pressure Water Height Temp.

Oct. 16 1330 1275 2-58/64 78.5 Oct. 16 1430 1275 3-4/64 79 Oct. 16 1530 1275 3-12/64 79 Oct. 16 1630 1275 3-20/64 79 Oct. 16 1730 1275 3-28/64 79 Test was terminated at 1730 after 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> of collection'. Total water co lected in 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> was 3-28/64 - 2 20/64 = 1 8/64 = 1.125 inch

= 28.575 su Vo1 Lane = (28.575 m) ({} (6.35)2 = 904.9 cu. mm or 113 cu. nn/hr I

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6-10-312

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Task M18 Primary to Secondary Side Leak Rate Test Specimen F-1

~

Test started at 1830 hours0.0212 days <br />0.508 hours <br />0.00303 weeks <br />6.96315e-4 months <br /> on 10/16/82 2:3g, Time Pressu m Water Height h

Oct.16 1830 2500 32/64 79*

Oct. 16 1835 2500 32/64 79 Oct. 17 NO READINGS Oct. 18 0830 2500 5-60/64 72 Note: Set water height to 32/64 at 830 hours0.00961 days <br />0.231 hours <br />0.00137 weeks <br />3.15815e-4 months <br />.

Oct. 18 1030 2500 56/64 76 Oct. 18 1230 2500 1-16/64 77 Oct. 18 1430 2500 1-40/64 75 Oct. 18 1630 2500 1-63/64 75.5 Oct. 18 1715 2500 2-4/64 76 Oct. 19 0830 2500 3-54/64 73 Oct. 19 1030 2500 4-8/64 78 Note: Reset water height to 32/64 at 1030 hours0.0119 days <br />0.286 hours <br />0.0017 weeks <br />3.91915e-4 months <br />.

Oct. 19 1230 2500 53/64 77 Oct. 19 1530 2500 1-20/64 76.5 Note: Reset water height to 1 inch at 1630 hours0.0189 days <br />0.453 hours <br />0.0027 weeks <br />6.20215e-4 months <br />.

Oct. 19 1630 2500 1

76.5 Oct. 19 1730 2500 1-10/64 76 l

Note: 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> of seasoning complete. Eight hour test as follows:

l Oct. 19 1830 2500 1-20/64 77'F Oct. 19 1930 2500 1-31/64 77.6 4

i Oct. 19 2030 2500 1-40/64 78 Oct. 19 1130 2510 1-50/64 78.4 l

Oct. 19 2230 2510 1-60/64 78.5 l

Oct. 19 2330 2525 2-8/64 78.8.

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Task N18, Specimen F-1 (Cont'a)

Date Time Pressure Water Height Temp.

Oct. 20 0030 2525 2-18/64 79 Oct. 20 0130 2538 2-29/64 79 Oct. 20 0230 2550 2-41/64 79 Test was terwinated at 0230 hours0.00266 days <br />0.0639 hours <br />3.80291e-4 weeks <br />8.7515e-5 months <br /> after 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> of collection. Total water collected in 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> was 2-41/64 20/64 = 1-21/64 = 1.328 inch

= 33.73 un Volume = (33.73' un) ({} (6.35)2 = 1068 cu. un or 133.5 cu. an/hr.

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vm Task N18, Primry to Secondary Leak Rate Test Specimen F-2 Test started at 1030 hours0.0119 days <br />0.286 hours <br />0.0017 weeks <br />3.91915e-4 months <br /> on 10/26/82.

g,gg, Time Pressurg Water Heicht Teig_,_

Oct. 26 1030 1275 1-56/64 77.5'F Oct. 26 1158 1275 6-V64 78 Oct. 26 1230 1275 7-28/64 78 Note: Reset water height at 1-2/64, at 1230 hours0.0142 days <br />0.342 hours <br />0.00203 weeks <br />4.68015e-4 months <br />.

Oct. 26 1302 1275 2-8/64 78 Oct. 26 1430 1275 5

79 Oct. 26 1630 1275 8-24/64 79

~

Note: Reset water height at 1 inch at 1645 hours0.019 days <br />0.457 hours <br />0.00272 weeks <br />6.259225e-4 months <br />.

Oct. 27 0830 1275 12 76'F Note: Roset water height at 16/64 at 0840 hours0.00972 days <br />0.233 hours <br />0.00139 weeks <br />3.1962e-4 months <br />.

Oct. 27 1030 1275 57/64 78'F Oct. 27 1230 1275 1-32/64 77.5 Oct. 27 1430.

1275 2-3/64 77.5 Oct. 27 1632 1275 2-28/64 78 Note: Reset water height at 8/64 at 1634 hours0.0189 days <br />0.454 hours <br />0.0027 weeks <br />6.21737e-4 months <br />.

~

Oct. 28 0843 1275 2-16/64 76*F Oct. 28 1050 1275 2-32/64 77 Oct. 28 1307 1275 2-48/64 78 Oct. 28 1430 1275 2-54/64 78 Oct. 28 1620 1275 3

78 Note: Roset water height at 32/64 at 1621 houn.

Oct. 29 0843 1275 1-3/64 74*F Note: 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> of seasoning completed.

Eight hour test as follows:

Oct. 29 1030 1275 1-10/64 76.5 1

Oct. 29 1130 1275 1-12/64 76.5 Oct. 29 1230 1275 1-18/64 77 Oct. 29 1330 1275 1-24/64 77 mau apac.m

1, 5506-10-312 E-23 L

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Ti,lo Task 18. Specimen F-2 (Cont'd)

Date Time Pressum Water Heicht Temo.

Oct. 29 1430 1275 1-30/64 77 Oct. 29 1530 1275 1-34/64 77 Oct. 29 1630 1275 1-38/64 77 Oct. 29 1730 1275 1-42/64 78 Oct. 29 1830 1275 1-47/64,

78 Test terminated at 1830 hours0.0212 days <br />0.508 hours <br />0.00303 weeks <br />6.96315e-4 months <br /> after 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> of collection.

Total water collected in 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> was as follows.

1-47/64 10/64 = 37/64 =.578 inch

= 14.68 m Volume = (14.68 m) ({} (6.35)2 = 465 cu. m or 58.1 cu. m/hr.

Test startad at 1000 hours0.0116 days <br />0.278 hours <br />0.00165 weeks <br />3.805e-4 months <br /> on 11/1/82.

p,a_13, Time Pressure Water Height h

Nov. 1 1000 2500 32/64 78'F Nov. 1 1200 2500 47/64 78 Nov.1 1400 2500 1

79 l

Nov. 1 1600 2500 1-16/64 79 Nov. 2 1600 2500 2-42/64 80 Nov. 3 1426 2500 3-27/64 79 Nov. 4 0900 2500 3-46/64 76.5'F Note: Reset water height to 1 inch at 0904 hour0.0105 days <br />0.251 hours <br />0.00149 weeks <br />3.43972e-4 months <br />.

Note: 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> of seasoning' completed.

Eight hour test as follows.

Nov. 4 1000 2500 1-2/64 77'F Nov. 4 1100 2500 1-9/64 78 Nov. 4 1200 2500 1-18'64 79 Nov. 4 1300 2500 1-25/64 79 Nov. 4 1400 2500 1-34/54 79 Nov. 4 1500 2500 1-40/64 79.5 P0Abe SMIC41

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rm Task fl18. Specimen F-2 (Cont'd) g Time h

Water Height h

Nov. 4 1600 2500 1-48/64 79.5 Nov. 4 1700 2500 1-53/64 80 Nov. 4 1800 2500 1-57/64 80 Test tensinated at 1800 hours0.0208 days <br />0.5 hours <br />0.00298 weeks <br />6.849e-4 months <br /> after 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> of collection. Total water collected in 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> was as follows:

1-57/64 2/64 = 55/64 =.859 inch 21.83 as

=

Volume =(21.83mm)G)(6.35)2=691cu.nu or 86.4 cu. mm/hr.

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To Task N19

' Pullout Load Test - Specimen F-2 Tube #1 1

Tube Displacement Load 0

0 0

265

.0005" 1225

.001 1460

.0015 1700

.0025 1945

.003 2250

.0035 2500

.004 2650

.0045 2800

.005 3000

.0055 3200

.006 3375

.0065 3500 I

.007 3800 Yield

.030 3900

.060 4120 Tube #2 0

0

.0 40

.0035 210

.004 250

.005 310 l

.006 400

.008 500

.009 625

.010 835

.0105 1100

.011 1330 l

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• E-26 5506-10-312 i.

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LMA*lfl%T Task N19 - Pullout Load Test - Specimen F-2 (Cont'd)

Tube #2 (Cont'd)

Tube Displacement Mgd

.0115 1700

.012 1875

.0125 2050

.013 2200

.0135 2350

.014 2500

.0145 2660

.015 2800

.0155 2950

.016 3050

.016 3190

.017 3300

.0175 3380

.018 3480

.019 3500 Yield

.030 3740

.045 3870

.060 3900 Tube #3 0

0 25

.0

.001 460

.0015 540

.002 800

.0025 1090

.003 1250

.0035 1400

.004 1700

.0045 2000

.006 2100

.0065 2220 posmi m

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Task N19 - Pullout Load Test - Specimen F (Cont'd)

Tube #3 (Cont'd)

Tube Displacement Qad

.007 2300

.008 2490

.009 2600

.010 2700

.011 2800 I

.012 3100

.015 3200 Yield

.030 3275

.045 3380

.060 3500 Tube #4 0

0

.0 40

.0005 600

.001 1260

.0015 1300

.002 1600

.0025 1670

.003 1857

.0035 2000

.004 2100

.0045 2200

.005 2300

.0055 2400

.006 2500

.0065 2630

.007 2750

.0075 2830

.008 2900

.009 3070 PonW CS MIC41

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Task N19 - Pullout Load Test - Specimen F-2 (. Cont'd)

Tube #4 (Cont'd)

Tube Displacement M

i

.010 3300

.01T 3550

.0T2 3700

.013 3750 Yield

.030 3800

.060 4000 Tube #5 0

0

.0 185

.0005 800

.001 1100

.0015 1300

.002 1500

.0025 1600

.003 1750

.0035 1900 i

.004-2000

.0045 2180

.005 2300

.0055 2430

.006 2500

.0065 2620

.007 2700

.0075 2800

.008 2900

.009 3100

.010 3300 l

.011 3500

.012 3600 i

.014 3668 i

.015 3700 Yield

/

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LWrLWdW Title Task N19 - Pullout Load Test - Specimen F-2 (. Cont'd)

Lube #5 (Cont'd)

Tube Displacement M

.030 3820

.045 3870

.060 4000 Tube #6 0

0

.0 115

.0005 240

.001 300

.0015 380

.002 480

.0025 610

.003 730

.0035 850

.004 950

.0045 1090

.005 1200

.0055 1350 j

.006 1440

.0065 1550

.007 1700

.0075 1825 l

.008 1930

.0085 2000

.009 2100

.010 2350

.011 2570 f

.012 2750

.013 2875

.014 2975

.015 3034 Yield

.030 3275 peau esce

_.,.-,_.__-_,_-,,,.-_._-_,___y.

,_.___,-,m m

...,.,m.__.

,__.,.-,-.m_.

4 5506-10-312 E-30 ll.0j Franklin Research Center av o,.

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Task fl19 - Pullout Load Test - Specimen F-2 (Cont'd)

Tube #6 (Cont'd)

T@e Displacement

kogd, g

.045 3360

.060 3450 Tube #7 0

0 0

158

.001 570

.0015 780

.002 1050

.0025 1700

.0045 1900

.005 2000

.006 2500

.0065 2364

.007 2400

.0075 2500

.008 2570

.0085 2630

.009 2690

.010 2760

.011 2800

.012 2900 Yield

.015 2956

.030 3090

.045 3172

.060 3275 O

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Task M19 - Pullout Load Test - SP*cimen F-2 (Cont'd)

Tube #8 Tube Displacement Load 0

0 0

150 0 Reset 800

.0005 927

~

.001 1150

.0015-1300

.002 1530

.0025 1650 4

.003 1740

.0035 1800

.004 1970

.0045 2100

.005 2200

.0055 2400

.006 2475

.007 2600

.008 2800

.0085 3000

.009 3150

.010 3340

.011 3560

.012 3680

.013 3750 Yield

.015 3800

.045 3900

.060 4060 Tube #9 0

0 s

0 150

.0005 1075

.0015 1600

- om es.enom

,__._.-._______.____.___...__.._._____.-____._..,_---_.,__....__._,,...-._.__a_,_._..-_.

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Task N19 - Pullout Load Test - Specimen F-2 (. cont'd)

Tube #9 (Cont'd)

Tube Displacement (9,ad,

.002 1774

.004 2000

.0045 2500

.005 2235

.0055 2400

.006 2550

.0065 2650

.007 2800

.0075 2875

.008 3000

.0085 3074

. 009 31 50

.0095 3200

.010 3270 l

.011 3170 Yield

.030 3430

.045 3540

.060 3675 Tube #10 0

0 0

170

.0005 530

.001 650

.001 1000

.002 1300

.0025 1575

.003 1760

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Time Task N19 - Pullout Load Test. Specimen F-2 (Cont'd)

Tube #10 (Cont'd)

Tube Displacement Load

.0035 1900

.004 2080

.0045 2200

.005 2400

.0055 2500

.006 2675

.0065 2775

.007 2900

.008 2974

.009 3000

.010 3083

.012 3150 Yield

.015 3220

.030 3300

.045 3385

.060 3500 5

i i

. ~.

q@000 Franidin Research Center 5506-10-312 E-34 m.,

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LDd*M=T LC & JS & DOC Task N19 - Pullout Load Test - Specimen F-1 Tube Reference

• Tube Reference

• Tube Maximta Tube No.

at Start at Finish Disolacement load 2

1.724 1.775

.051 4100 lb 3

1.750 1.875

.105 4000 lb 8

1.700 1. 7 41

.041 4050 lb 9

1.755 1.847

.092 3800 lb

• Mote, tube reference is dimension from tube plug face to Instron mounting plate for tubesheet.

Task N21 Project 5506-10-312 Data are in Table 2 of the report.

4 W

e APPENDIX F rnomanras er asr uszet.zzs I

mI&

.00. Franklin Research Center A DMsion of The Franklin Institute h w reemen rem =r.m h isios msius.iooo

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