ML20117M441
| ML20117M441 | |
| Person / Time | |
|---|---|
| Site: | Palisades  |
| Issue date: | 12/10/1976 |
| From: | Scherer A ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY |
| To: | |
| Shared Package | |
| ML20117M404 | List: |
| References | |
| FOIA-84-762 CEN-42(P), NUDOCS 8505170070 | |
| Download: ML20117M441 (115) | |
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COMBUSTIOil E?tG:liEER:i:G, INC. Reoort tio.: C Eti-42(P) December 10, 1976 Palisades Steam Generator Tuoe Recair Sleevinc Comoustion Engineering, Inc. Nuclear Power Systems Windsor, Connecticut 8505170070 041022 PDR FDIA KERDILEB4-762 PDR l i
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*- t LEGAL NOTICE This recort was prepared by Combustion Engineering, Inc. as an account of work. sponsored jointly by Consumers Power Company (CPC) and Combustion Engineering, Inc. pursuant to CPC Purchase
' Order No. 77657-Q. Neitner CPC, _recresentatives of CPC, nor
)
Combustion Engineering, Inc., nor any person acting on behalf of 4 ' " either: - s s) Makes any warranty or representation, express or implied in-cluding the warranties of fitness for a particular purpose or merchantabili ty, with respect to the accuracy, complete-ness, or usefulness of the information contained in this re-port, or that the use of any information, apparatus, metnod, or process disclosed in this report may not infringe privately owned rights; or b) Assumes any liabilities with respect to the use of, or for damages resulting from the use o#, any information, - apparatus, method or process disclosed in tnis report.
1 oo oo .
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is 1 _p CR:TERIA FOR OROPRIE*ARY lNFORMATION t
-Informaticn Montainbd in this report whicn is delimited by means of sur-
' rounding crackets is proprietary to Comoustion Engineering, Inc. Code numbers 1-6 have ,been placed in the vicinity of such brackets to classify this proprietary information. The following list identifies the classi-fication criteria associated with these code nuccers.
Chde 4 4 The information reveals privileged cost or price informa-t1
- j. tion, commercial strategies, production capabilities, or budget levels of Comoustion Engineering, Inc., its cus-tomers or suppliers.
-2 The information reveals data or material concerning Com-
, bustion Engineering or customer funded research or develop-U 4' ment plans or programs of substantial present or potential competitive advantage to Combustion Engineering, Inc.
3 The use of the information by a competitor would substan-
-tially decrease his expenditures, in time of resources, in designing, producing or marketing a similar product.
4 The information consists of test data or other similar data concerning a process, method or comoonent, the acolication of wnich results in a substantial comoetitive advantage .to Combustion Engineering, Inc. 5 The information reveals special aspects of a process, method, comoonent or the like, the exclusive use of which results in a suostantial competitive advantage to Combustion Engineering, i Inc. [$ 6 The information contains ideas for which patent protection ,' e( . is likely to be sought. a h). -
-oo 'o e ABSTRACT A technique is presented for repairing degraded steam generator tubes in pressurized water reactor Nuclear Steam Supply Systems (fSSS;.
The technique described alleviates the need for removing steam generator tubes from service due to loss of structural capabili-ti es . In this manner, the design generating capacity of the or-iginal NSSS need not be reduced. This _ work was performed under contract with Consumers Power Company for use in the Palisades
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Plant steam generators.
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TACLE GF CONTE.'!TS
.Secticn T_i t l e Pace 1.0 INTRODUCT:0N 1-1
1.1 REFERENCES
FOR SECTION 1.G l-2 2.0
SUMMARY
AND CONCLUSIONS 2-1 3.0 ACCEPTANCE CRITERIA 3-1
3.1 REFERENCES
FOR SECTION 3.0 3-1
4.0 DESCRIPTION
OF TUBE / SLEEVE ASSEMBLY a-1
4.1 REFERENCES
FOR SECTION 4.0 4-3 5.0 NONDESTRUCTIVE EXAMINATION OF TUBE / SLEEVE ASSEMBLY 5-1 5.1
SUMMARY
AND CONCLUSIONS 5-1 5.2 TEST EQUIPMENT 5-3 5.3 CALIBRATION STANDARDS 5-4 5.4 RESULTS 5-5 5.4.1 EXPANDED REGION OF TUBE / SLEEVE ASSEMBLY 5-5 5.4.2 UNEXPANDED REGION OF TUBE / SLEEVE ASSD1BLY 5-9 6.0 TUBE / SLEEVE CORROSION RESISTANCE 6-1 6.1
SUMMARY
AND CONCLUSIONS 6-1 6.2 TEST FACILITY 6-1 6.3 TEST CONDITIONS 6-3 6.4 RESULTS 6-4 7.0 STRUCTURAL ANALYSIS OF TUBE / SLEEVE ASSEMBLY 7-1 7.1
SUMMARY
AND CONCLUSIONS 7-1 7.2 TUBE SLEEVE ASSEMBLY QUALIFICATION ANALYSIS 7-3 7.2.1 RADIAL GAP IN EXPANSION JOINT 7- 3 7.2.2 AMOUNT OF TUSE SEPARATION 7-5 7.2.3 MAX
- MUM EQUIVALENT STATIC LOAD ON SLEEVE 7-6 p,
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oo o* TABLE OF COllTE.*lTS (Con ti nued) Section Title 0 2qe
- 7. 3 FAILURE MODE DETERMI:lATI0ft 7-15 7.3.1 STRESS IN TUBE SLEEVE 7-15 7.3.2 STRAIN ENERGY AllALYSIS 7-15 7.4 ALLOWABLE SLEEVE DEGRADATION 7-22 7.4.1 NRC STAFF (KNIGHT'S) CRITERIA 7-22 7.4.2 COMBINED LOCA & SSE ANALYSIS 7-24
- 7. 4. 3
SUMMARY
OF ALLOWABLE SLEEVE DEGRADATION 7-27
- 7. 5 SLEEVED TUBE VIBRATION ANALYSIS 7-28 7.5.1 VIBRATION RESPONSE TEST 7-28 7.5.2 SHELLSIDE FLOW VIBRATION TEST 7-29 7.5. 3 TUBE VIBRATI0ti DESIGN CRITERIA 7-30 7.5.4 AXIAL FLOW REGI0fi 7- 31
7.6 REFERENCES
FOR SECTION 7.0 - 3: 8.0 MECHANICAL TESTS OF TUBE / SLEEVE ASSEMBLY 3-1 8.1
SUMMARY
Afl0 CONCLUSIONS 3-1 8.2 CONDITIONS TESTED 3-1 8.3 RESULTS 84 1
8.4 REFERENCES
FOR SECTION 8.0 8-6
os o' ; I LI:7 0F TABLES Table Ti tle Pace 2-1 "a.<im m Alloweble Coerating Limits for Sleeved alisades 2-3 Steam Generators 3-1 Repair Sleeving Cri teria 3-2 6-1 Initial Palisades Secondary Chemistry 6-5 6-2 Second Generation Palisades Secondary Chemistry 6-6 6-3 1976 Palisades Secondary Chemistry 6-7 6-4 Palisades Secondary Chemistry with Condensate Polisners 6-8 6-5 Palisades Primary Chemistry 6-3 8-1 58-163 Ultimate jJrength 3-7 8-2 Diameters of Separated Samples 5-8 3-3 Criteria for Minimum Acceptable Wall Thickness S-9 LIST OF FIGURES Ficure Title Pace 1-1 Steam Generator Tube Sleeve 1-3 4-1 Tube, Sleeve and Hydraulic Forming Tool J-4 5-1 Phase Angle Versus Deptn of Defect Curves 5-11 5-2 Phase Angle Versus Depth of Defect Curves 5-12 5-3 Phase Angle Versus Depth of Degradation Curves 5-13 5-4 Axial Wound Probe Coil Concept 5-14 5-5 Defect Locations in Calibration Standards 5-15 5-6 Calibration Standard Defect Information 5-16 5-7 Calibration Standard Defect Information 5-18 5-3 Signals from Clean Bulge 5-20 5-9 Signals from Outer Surface Defects 5-21
** o' LIST OF FIGLRE5 (Continued)
F i :ure Title illi 3ignals # rom Tute Inner Surface 5-22 5-10 Expanded Region Signals 5-23 5-11 Unexpanced Region Signals 5-22 5-12 Unexpanded Regicn Signals 5-25 5-13 Unexpanded Region Signals 5-25 5-14 Unexpanded Region Signals 5-27 5-15 Unexpanded Region Signals 5-28 5-16 Unexpanded Region Signals 5-29 5-17 6-10 6-1 Test Soiler Schematic 6-11 6-2 Test Boiler U-Bend Tube Typical Tube Material Microstructure Af ter Preliminary 6-12 6-3 Corrosion Test Typical Sleeve Material Microstructure After Preliminary 6-13 6-4 Carrosion Test 7-33 7-14 Ootical Comoarator Plot for Profile Tube - Sleeve As-sembly Excansion Joint Tube Sleeve Response History 7-34 7-15 7-35 7-16 Stress Strain Curves Tensile Test to Full Separation 7 36 7-17 Palisades Support Arrangement 7-37 7-13 7-38 7-19 Flow Model , Vibration Heat Transfer and Thermal Hydraulic Test 7-39 7-20 Tube / Sleeve 5!ction Under Reversing Lead S-10 S-1 Uniaxial Tensile separati:n S-11 l 3-2 l f
1.0 INTR:'CUCTION in acccccance wi tn Regulatory Gui e 1.32 'Re'erence i-1,, Pressgrizec ..ater Peactor T.J : stean generators are :eria.2ically non-cestructivelj exarined sstng e:tj :.crent tecnniques. As a resoit c' trese erart nations, ;ces l may te fc cd tnat have ; s aicec ! etal los: cr aal! tric. ness recuc.icn. Present tecnnical specification recairerents are to s!;g taces ansn :ne nall :nickness reduction reac .es certain levels. :n order to maintain t;ce integrity, even during postulated accident conditions sucn as a cesign ba-sis eartnquake, a main steam line break or a loss of coolant accident, tabes can become cancicates for plugging long before their mecnanical integrity ' is lost. 5 i The installation of a structural sleeve to span the reduced wall thickness j region would allow the tubes to be fully used until the wall is penetrated i i and leakace exceeds existing limits. Sleeving of such tubes would mini- } mize the number of tubes that would require plugging and maintain the maxi- .- mum neat transfer surface area and primary coolant ficw area in the steam - genera tor. Sleeving would therefore permit plant operation at maximum cap- l acity under original design limitations without any loss of tubing mech- l < anical strength. 5 The steam generator sleeving concept consists of installing, insice tne ! I steam generator tube, a slighly smaller diameter sleeve with a nominal
.032 incn wall to span tne degraded area of the parent steam generator tube. -
This system is senematically shown in Figure 1-1. Both ends of the inserted : sleeve are hydraulically swaged into an interference fit with the parent tube. This hydraulic swaging is done away from the degraded portion of tne parent tube in an area wnere no tube support structures exist, ensuring no effect on either the .
. degraded area or the function of support structures. The rationale for in-stalling the sleeves in this manner is tnat the criteria for plugging a steam generator tube is based upon ensuring that the structural strength of the tube is adequate to prevent rupture dating postulated accident conditions.
By installing a sleeve to span the degraded area, the structural integrity of the tube is reestablished. Even in the event of full penetration of tne steam generator tube, the sleeve will provide tne required structural link 1-1 .
m ooi oo-and a hign restriction to leakage between tne primary and secondary systems, The 0.032 thus ensuring that adouble ended break of the tube cannot occur. inch wall of the sleeve is appreciably greater than tne pa en: wall thick-ness.cf 0.043 inches with 64 percent degradation, whicn has een deternined acceptable under the accident loads potentially produced by a loss of cool-ant accident (LOCA) ir. combination with a safe shutdown earthquake (SSE). Sleeving of steam generator tubes has previ_ously been undertaken by var-ious organizations and several approaches to the problem have been developed. The primary objective of all of' these previous approaches has been to insure leak tightness af ter the repair. The approach taken here is that the hieeve
.is to reestablish the structural integrity of the tube and that the need for As the sleeve pro-absolute leak tightness is of secondary consideration.
-vides a structural link between two ends of even a severed tube, it prevents release of all but minute quantities of primary coolant to the secondary side.
While the information and data in this report pertain to the Consumers Power Company Palisades plant steam generators, the sleeving process is applicable to all PWR generators. To qualify the sleeve for other applications, spe-cific sizing and environmental conditions must be addressed and would re-quire reanalysis to insure applicability.
1.1 REFERENCES
FOR SECTION 1.0 1-1 Inservice Insoection of Pressurized Water Reactor Steam Generator Tubes, USNRC Regulatory Guide 1.33, Revision 1, July 1975 1-2
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oo oe 2.0 Sct' MARY 20 C0:iCLUSIO:iS Cevelocment of the steam generator tube sleeve enccmoasses mechanical, cnemical, metallurgical and analytical considerations. These processes demonstrate that the steam generator tube sleeve assembly described here-in is structurally adequate to withstand normal, transient and accident conditions which occur or are postulated to occur in the Palisades steam generators. Fluid flow, coolant chemistry, thermal, and pressure condi-tions to date have experimentally s hown n o detrimental effect upon the integrity of the sleeve to tube joint and the resulting assembly strength. Structural analyses of the tube / sleeve assembly have established its in-tegrity under design basis earthquake, main steam line break, loss of cool-ant accident, combinations of these and both primary and secondary flow in-duced vibrations. Based upon these experimental and analytical results, the sleeve is acceptable as a repair device to span a degraded area of a steam generator tube as it will provide a positive and reliable structural link between sound portions of the tube. Sleeve joints will only be formed in tube areas where degradation is not detected. The sleeve is capable of providing adequate structural reinforce-ment in spanning circumferential or other tube wall defect regions up to 100 percent in depth. Once the tube degradation becomes a through wall hole, primary to secondary coolant leakage becomes a limiting condition per the plant operating technical specification. After a tube has been sleeved, it shall be plugged per Table 2-1 criteria. Region I, shown in the table, is the initially degraded area of the tube. The sleeve prevents the tube from separating even for a through wall tube defect of complete circumference. The sleeve may be degraded up to 34 percent in this region with a 100 per-cent wasted tube and still have strength enough to. prevent a double ended break even under postulated accident conditions. In Region II, the inboard portions of the tube / sleeve expansion joint, some tube wall is necessary to ensure the tube to sleeve link. A 64 percent degraded tube is being veri-fied a de qua t e for ensuring this link. A maximum sleeve wall degrad-
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0cl -6' ation of. 34 cerr.ent was snown acceptable tc maintain tute to sleew ;; int integrity witn tne maximum permissible degraded tube. In *ne outtoard cor-tions _of the tuce/ sleeve joint and in tne tuce only sections (Region III), the present Palisades plugging criteria for tube wall degracaticn is usec since no joint strength results from tube material in this region. Fourteen eignt-inen sleeves of otnerwise identical design were insts fled Lin the Palisades C steam generator during tne March 1976 outage. These sleeves have performed without any detected interruption to norrnal plant opera tions . These sleeved tubes will be inspected by eddy current test and.Other techniques at the next outage. It is expected that corrosion and other testing will properly anticipate the results of these examinations, k c l - l L 2-2
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~Tablo 2-1 Maximum Allowable Operation Limits for Sleeved Palisades Steam Generators v l 1 i l I I I i
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x x x x ' x x x x ' x- x g' , ,. I I I Itegmn i1I l Itegion iI l Region 1 [ Region !I g Region Iii Region 1 Tube: 100% degradation acceptable Sleeve: <34% degradation Region !! Tube: <65% degradation Sleeve: <34% degradation Region 111 Tube: Per current Palisades technical specification Sleeve: 100% degradation acceptable. 2-3
co .o* 3.0 ACCEPTA; ICE CRITERIA Tne price oojective of the repair sleeve.is to reestaolish tne stractarai integri ty of- the steam generator tuce so tnat a d o u b 1 e ended break cannot occur. iumerous tests and analyses' were performed:to demon-strate tne capability of the sleeve to aerform this- function under normal-operating and postulated service conditions. Design operating conditions for the Palisades steam generators are defined as: Primary Side: 600U F, 2100 psia (current) 6000 F, 2500 psia (under consideration) 0 Secondary Side: 486 F, 600 psia (maximum .P condition) 5140 F, 770 psia (100". power) 518 F, 800 psia -(under consideration) 70 F,1300 psia (hydrostatic test)
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Table 3-1 provides a summary of the criteria employed in demonstrating that the sleeve is an adequate method for repairing degraded steam generator
-tubes. Justification for each of the criterion is provided. The section of this ieport describing test or analyses which verify tube / sleeve char-acteristics for a particular criterion is referenced in the table.
3.1 REFERENCES
FOR SECTION 3.0 3-1 Testimony of James Knight before the Atomic Safety and Licensing
-Board in the matter of Northern States Power Company, Docket Nos. 50-282 and 50-306 3-1
oc- n' Taole 3-1 Reoair Sleevina Criteria . Cri te rion Jus ti fica tion Reference
- 1. Tensile separation of Greater than 3/8 inch separ- Section 3.0 tube and slemve by 1/4 ation allows contact between inch to require great- adjacent steam generator tubes.
er than 1000 lb force. For a maximum P of 2500 osi an axial load of 330 It force resul ts .
- 2. Rapid tube / sleeve ID Prevention of double ended Section 8.0 pressurization to 2500 tube break under MSLB condi-psi without total tube / tions required 2500 psi is sleeve separation. maximum anticipated primary pressure.
- 3. Collapse of tube / sleeve Prevention of tube / sleeve Section 8.0
. assembly at greater collapse under LOCA condi-than 1300 psi external tions required,1300 psi is pressure. maximum anticipated secondary pressure.
- 4. Pressurization of tube / Factor of safety greater than Section 8.0 sleeve ID to 5100 psi three required between anti-without tube / sleeve cipated maximum operating P burst. and that necessary for burst, 1700 psi is maximum normal op-erating P.
- 5. Tube / sleeve joint integrity Section 8.0 Thermalandprgssure cycling to 600 F/2200 required for startup/ shat-osi primary with 514 F downs.
saturation secondary for 100 cycles with-out loss of tube / sleeve functional integrity
- 6. Primbary coolant flow at Tube / sleeve joint integrity re- Section 8.0 600 F/2200 psi, 25 gpm quired for primary flow condi-for 1000 nours without tions.
loss of tube / sleeve functional integrity
- 7. Exposure of tube / sleeve Tube / sleeve assembly required Section 6.0 assr21y to Palisades pri- to function under Palisades mary and secondary chem- chemistries.
istries without loss of functional integri ty, crevice corrosion or ag-gravation of tube corro-sion. 3-2
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Table 3-1
- Recair'51eeving Cri teria (Continued)
Cri terion Jus ti fica tion Reference
- 8. . Tube / sleeve assembly - Tube / sleeve integri ty re- Section 7.0 functional integrity quired under postulated
;aust be maintained dur- accident conditions.
ing LOCA & SSE, MSLB &
.SSE, Reference :3-1 cri-teria and primary and secondary flow induced vibra tions.
- 9. Nondestructive examina- Periodic examination of Section 5.0 tion of tube and sleeve tubes and sleeves required to verify structural ade-quacy 3-3
oo o 14.0 DESCR:PTION OF TUBE / SLEEVE ASSENSLY Ine pnysical layout of a tuae/ sleeve assemoly is shown in Figure 1-1 and tr.e Reference 4-1 anc 4-2 drawings. The acproacn snown utilizes a sleeve of slign:ly smaller outside diameter than :ne steam generator tace insice
-diameter so nat it can be inserted into tne parent tube.. Af ter the sleeve nas been positioned to span the questionable area of tne parent tace, both ends of the sleeve are locally expanded until intimate contact with the parent tube is acnieved. Then, by means of injecting a fixed volume of water, both tne tube and sleeve are further expanded approximately [ 2, 3 inches] diametrically so that a swaged joint is formed. The tube will then maintain its mechanical integrity even in the event of the complete removal of the parent tuce in the area spanned by the sleeve. The sleeve wall thick-ness is slightly less than the parent tube wall but of greater cross section than the minimum required for the parent tube. The sound sleeve is thus cap-able'of fulfilling the structural design requirements of the steam generator tube. The mechanical attachment of the sleeve to the parent steam generator tube allows for easy inspection to prove that the interference joint has been successfully made. No cleaning or other surface preparation of the parent tube is required. In fact, the[ lcondition of the parent 2, 3 tube has been shown to improve the structural characteristics of the as-semoly and provides an effective barrier to corrosion.
The sleeve is a seamless annealed tube of Inconel 600 (ASTM-SB-163), with 2, 3 a[ ] coati ng. The Inconel 600 is the same as the steam gen-erator tube material thus preventing tnermal stress ratcheting which would be possible with dissimilar materials. Further, Inconel 600, haswe11 defined and previously accepted performance characteristics in a steam generator.
] coating provides greater separation resistance between tube and 2, 3 The(
sleeve. Annealing of the sleeve tubing removes cold work effects and les-sens ' tha tendency of the sleeve to spring back af ter having been expanded to fonn the tube / sleeve joint. The sleeve inside diameter is( l inches to provide 2, 3 a narrow clearance fit for the U-cuo seals of the forming tool. 4-1 y- -
l oo ao
~he sleeve e il -hickness of .332 incnes is acecuate on :ne basis cf : m-
- arison wi:r, 6.;sotable :: ear ;ecerator ::.:e aalis anc allowaoie cegraca-
-en. Tests and analyses nave snown :nis t: :e true structurally. I sleeve lengtn of 12 incnes was selectec to :revide maximum cefect scanning capatili ties consistent wi tn :inimum ins talla tion clearances. A 12-incn lengtn provides a margin of ; 21/2 incnes in locating a sleeve to scan two defects an anticipated maximum of four incnes apart. The lead-in of
.1/4 inch on tne sleeve minimizes crevice corrosion and fretting difficul-ties, but pemits taking full advantage of the strength of the expansion joint. The one inch long expanded mechanical interference joint provides adequate strength margins for the tube / sleeve assembly, yet does not com-promise the span length of the sleeve. A diametrical defomation of[ 2, 3
]provides an adequate structural fit without failing the tube or sleeve material or unnecessarily restricting secondary coolant flow.
The mechanical interference joint is fomed by hydraulic means. The hydraulic fluid used is demineralized water thus eliminating one s o u rc e o f corro-sion producing elements to the sleeve or steam generator tube. The tool used to form these joints is shown in Figure 4-1. The tool expands the sleeve and tube by injecting hydraulic fluid into the region to be fomed until a suffi-cient volume has been injected to expand the tube and sleeve the required amount. The fluid is maintained in the region to be expanded by two U-cup urethane seals. The hydraulic process was developed for its simplicity, speed and ease in adapting to a remote sleeve installation. The tube / sleeve joint forming process is a three step process. Initially a [ ] pressure is applied to the system for hydrostatic leak detection. 2, 3 After confirming that there is no leakage, pressure is s epped up to approx-imately[ ] to seat the sleeve against tne tube. If there have been 2, 3 no leaks up to this point, a carefully controlled amount of hydraulic fluid is forced into the feming tool resulting in the tube and sleeve being ex-panded into a joint. The joint shown in Reference ?-l is formed at[ 2, 3
], Because of the injection of a fixed amount of hydraulic flJic.
overexpansion of the tube and sleeve is precluded. The sleeve is care #ully cleaned in the manufacturing process, and tne cleanness is maintained to ore-vent the introduction of corrosive elements. 4-2
04 g# l.1 REFERENCES FOR SECTIOil 4.0 4-1 sleeve *as tallation, CE Orawing rio. 0-19173-501-004-01 4-2 Long & s'ncet Sleeves , CE Drawing tio. C -19173-501-007-02 4- 3 - - - . . _ _ _ _ _ . _ . . _ _ _ _ _ _ _ . m. .
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00 b* 5.0 '40t4 DESTRUCTIVE EXAMIMTIO!! 0F TUSE/ SLEEVE ASSE?'8LY Ine tuce/ sleeve assembly is a cri :ary pressure boundary and as sucn, it ust te ceriodically verified that serious weakening of tnis assemb!y is not oc:urring. The ability to monitor the condition of the installed sleeve and the parent tube for this potential weakening is essential to the viability of the sleeving concept. 5.1 SUMfMRY AtiD C0?iCLUSIOt45 Initial inspections of the expanded portions of the steam generator tube / sleeve assembly with the standard .540 inch diameter eddy current probe pro-duced signals which saturated the test equipment and made evaluation of de-fects impossible. Techniques have been develooed for eddy current testing both the expanded and unexpanded regions of sleeved steam generator tubes. These techniques, used in combination with considerations of crimary to sec-ondary leak rates, will provide conservative criteria for determining tube and/or sleeve wall degradation. The techniques developed are in conformance wi th the guidance supplied in Reference 1-1. For either the exoanded or unexpanded region of the assembly, it is possible to detect significant amounts of degradation penetrating from the tube outer surface, to differentiate between this condition and any other combination of degradation which might exist, and to estimate the depth of penetration from the Lissajous pattern phase angle. This can be done uniquely on the basis of one examination (see the phase angle ranges of 110 to 1600 ,110 U to 160 , and 210 to 310 in Figures 5-1, 5-2 and 5-3, respectively). Util-izing the techniques developed in this program, 3/16 inch diameter (in con-fomance with industry ECT standards) tube wall degradation proceeding from the outer surface was detected wnen the cenetration reached about 40". of tubeell. Degradation which has nearly penetrated the tube wall, or has fully pene-trated the tub? wall either with or without ninor sleeve outside surface degradation; and degradation of the tube inner surface with no sleeve de-gradation are both readily detectable in either the expanded or unexpanded 5-1
os s* region of tne tute/sieeve assemly. Inese two classes of cegracation cannot, hcwever, te distinguisned from eacn otner daring are examina: ion on :ne basis of tne cefect signai phase angie. (3ee One :: nase angle ran-ges of 700 to 1100, 500 to 1100, ana 1600 to 2l00 cn Figures 5-1, 5-2 a nc
- 5. 3, respecti /ely). The above degradation situations can generally te separatcu on the basis of phase angle results from a previous examination i wnich snows the defect. In certain situations, consideration of pricary t 2
to secondary side leak rate may be useful in making the suDject discrimina-tion. With the program eddy current test tecnniques, 3/16 inch diameter tube wall degradation proceeding from the inner surface can be detected with confidence when the penetration reaches about 35 percent of tube wall. It is not possible to estimate the depth of degradation proceeding from the tube inner surface on the basis of the defect signal phase angle. [ Degradation which has fully breached the tube wall and penetrated some dis-l tance into the sleeve, and degradation which has penetrated into the sleeve wall from its outer surface without tube involvement can be detected in either [ the exoanded or unexpanded region of the tube / sleeve assembly. Discrimina-i tion between these two classes of degradation can be accomplished in the same [ manner described for the two classes of degradation in the previous paragraon 0 U U [ (see the phase angle ranges of 0 to 70 , 350 to 50 , and 40 to 160 on Fig-ures 5-1, 5-2 and 5-3, respectively). Once discrimination between these two [ i classes of degradation is made, an estimate of the death of cenetration can be ! made from the defect phase angle for either category of degradation. A 3/16 inch diameter sleeve degradation proceeding from the sleeve outer surface can f be confidently detected wnen the penetration reaches about 30 percent of the [ sleeve wall. (See Figure 5 17 d). Samples are being made to investigate the j minimum detectable level of sleeve degradation. .1 Inspection of the expanded region of the tube / sleeve assenD1y and the adja-cent area at the end of the sleeve i s performed with an axially wound differential cof i probe (See Figure 5-4). This probe must be rotated 3600 with a fixed axial position, then moved an appropriate axial increment and again rotated 3600 This procedure is repeated until the recuired coverage is ccmoleted. For operation at a single frequency, 200 KH: gives the bes t ' overall results for the tube / sleeve assembly. The phase angle versus deDth 1 5-2
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- of defect curve for this test applied to the suoject region is presented in Figure 5-1 A shortccming of this probe design is its relative insen-sitivity to axisyninetric defects (such as wastage of the same death 3600 around either the tube or sleeve at a given axial position). This is ana-logous to the insensitivity of the circumferential1y wound probe to long axial defects with gradual changes-in depth.
[. , For the tube / sleeve assembly region between the expansion joints, inspec-tion may be performed as indicated i.. the previous paragraph, or the ex-amination may be made with the standard .540 inch flex probe operated at 400 KHz. The coverage of the flex probe is limited to areas removed at least 3/8 inch from the edge of the expanded region. The phase angle versus depth of defect curve for the flex probe test at 400 KHz is presented in - Figure 5-3. The same type curve for the axially wound probe operating at 200 KHz in this region is presented in Figure 5-2. The final choice be-tween these test options will consider both the required examination time for the entire tube / sleeve assembly and the inspection advantages associ-ated with each approach. More specific results and conclusions from this test program are presented in Section 5.4 5.2 TEST EQUIPMENT The test equipment utilized in this program included a number of exper,-
' mental probes as well as the following test hardware:
- 1. The~ Eddy Current Testor (EM 3300)
This is the signal conditioning unit which allows the selection of necessary test parameters (frequencies), excites the test orobe, and wnose output contains the eddy current information which may be re-corded and/or displayed on a self-contained oscilloscope. The current-ly reconsnended settings on this unit are as follows: 5-3 m
g- go-J
- a. : From .5 to 5 volts / division on vertical and narizontal cnannels.
b. Sensitivity (emit gain) of approximately 50 for the flex crote and 70 for the axial probe tests. c. Frequencies of 200 KHz for the axial probe and 400 KHz for the flex probe inspections.
- 2. The Da ta -Reduction.. System '
This consists of a vector analyzer (electronic protractor) which is used in conjunction with the memory storage oscilloscope to measure the phase angles from the' signals of the artificial imperfections in both the sleeve and the tube. These phase angle readings are used to establish a phase angle versus depth curve for predicting deaths of imperfections without actual physical measurement. 5.3 .CALIERATION STANDARDS 1 In order to evaluate the capability. of eddy current test techniques, tube / sleeve assemblies were fabricated which contained a significant variety of
. degradation deaths and locations. Figure 5-5 illustrates the range of .lo-cations in the assembly for the artificially introduced defects.
For defects on the tube and sleeve outer surface fully in the unexpanded region (defect . locations 15 and 16 of Figure 5-5), the range of deaths studied varied from just over 20 percent to 100 percent of wall for both the sleeve and tube. Defect location 17 on the tube inner surface was studied for two depths. This area of the tube and sleeve represents the 10-
. cation. of original- degradation. Inspection in this region of the tabe al-
' lows a record, to be kept of wall thickness changes. Full degradation of ' the tube wall will require special attention to any sleeve degradation te-cause of strength considerations (Table 2-1). Defect locations 3 through 14 of Figure 5-5 are located in, or close1: adjacent to the critical tube / sleeve assembly exoansion joint. It is e 5-4
- 00. O*
i in :nis region that the tube /slee',e axial strength is devel;oec. A W.s - led.;e ]f 3nj degr3 cation in either the tuce and/or the sleeve in tnis ared is imoortant in deterining the continued structural adequacy of tre recair sleeve and tate. Defect depths studied in tne subject locations vary from 3 bout 20 cercent to 100 percent of the component walls. For defects on the tube outer surface near the end of the sleeve (defect locations 1 and 2 of Figure 5-5) degradation is introduced to allow a de-termination of how the eddy current test capabilities are influenced by the sleeve termination. Defects studied in these locations are approximately 40 percent of the tube wall. Essentially all tube and sleeve degradation areas were introduced with an electric discharge machine (ECM). In three areas on the tuce outer sur-face, wastage was simulated with a controlled acid attack. In two areas of the tube and two areas of the sleeve, intergrar.ular attack (IGA) was induced at a location which was to correspond to the middle of the bulge af ter expansi . Figures 5-6 and 5-7 present detailed information on those calibration tube defects primarily utilized in the program to this point. The capability to perform meaningful eddy current examination of defects at locations I through 17 is sufficient to demonstrate the ability to evaluate all probable significant areas of degradation in the tube / sleeve assembly. l In certain circumstances, consideration of primary to secondary leak rates l
; will assist in such an evaluation. Initial results from the eddy current evaluation of the defects at the subject locations are cresented in Sec-i tion 5.4. (Final results including a characterization of the statistical i
variation in phase angle as it relates to defect depth will be presented later.) 5.4 RESULTS 5.4.1 EXPANDED. REGION OF TUBE / SLEEVE ASSEMBLY In and closely adjacent to the expanded area of the tube / sleeve assembly l (defect locations 3 through 14 on Figure 5-5) phase angle versus defect
' depth relationships were studied for various probe concepts and various
[ test frecuencies. The result of these studies indicated that an axial 5-5 j
oc oo l l l l wound differential coil probe rotated at a series of fixec longitucical cositions in tne excansion provided the most suc:ess of any of tne can-didate probes (See Figure 5 4). Use of this proce configuration in :ne stated manner improved the signal to noise ratio such that significant defects could be detected and have their signals interpreted. In tnis discussion, noise is the signal from a cefect free bulge wnile signal refers to the response from a defect in the bulge. Figure 5-8 shows the typical noise signal for various positions in the expanded area tested with the axial would probe. In general, these signals are a very flat pattern of from 1 to 5 volt amplitudes. The signals obtained wnile the axial probe is centered at the outboard end of the expanded region are not as clean as would be desirable. This is thought to result from the fact that in this position, a portion of the probe coil extends beyond the end of the sleeve, and the end of the sleeve may not lie in one plane after the expansion operation. In some cases, the signals for a 3600 probe rotation at this position resemble a defect signal (see the lower right hand illustration on Figure 5-8). Of course, defect signals are traced much more rapidly if they have limited circumferential extent. By proper frequency selection, these noise signals can be placed at a phase angle separated from most defect signals of interest. As a matter of background information, the signal from a clean exoansion tested with a standard
.540 inch diameter flex probe typically has a signal voltage of about 70 volts. This total signal cannot be displayed on present equipment; how-ever, since it saturates when ir.put signals reacn about 15 volts.
The cotimal frequency for testing the expanded region of both the sleeve and tube with the axial wound probe is a ppro xim ate 1y 200 Kliz. At this frecuency, good detection capability is possible in both the sleeve and the tu.ie. In addition, phase angle results for any given depth of de-fect are re0sonably close to the values for the same cefect depths in the unexpanded region. This could reduce the importance of knowing the cre-cise longitudinal position of the probe in the assemcly if the decision is made to test the entire length of the tube / sleeve assembly witn the axial wound probe. 5-6
-co 'oo-F Figure 5-1 cresents a clot of pnase angle versus defect dectn 'or t.he axial wound ;:roce ocerating at 200 KH: on the cefects at locations 1
- nrougn la (See Figures 5-5, 5-6 and 5-7). Figure 5-) present signals for defects of various deaths penetrating from tne tube outer surface.
Figure 5-10 presents signals for defects initiating at the tube inner surface and penetrating part of the way tnrough the wall, with no sleeve degradation. Figure 5-11 presents signals for defects which completely j penetrate the tube wall and all or part of the sleeve wall as well as sig-nals for defects which start at the sleeve outer surface and penetrate part of that component wall with no degradation of the parent tube. For the test results depicted on Figure 5-1, calibration. is accomplished by setting the phase angle of the signal from a .080 inch diameter tube through wall hole at 900,- With this setting the locus of the noise sig-nal from the clean bulge lies essentially on the horizontal plane (phase angle of 0). This setting is arbitrary; however, the interval between these two' signals will remain the same at this test freouency regardless of where the phase angle for the calibration hole is set. It should be noted that probe motion phase angle' cannot be measured consistently with the axial wound probe. An evaluation of Figure 5-1 indicates that there are three distinct re-gions of the curves. Region I contains phase angles from approximately
, 1100 to 1600 These phase angles represent degradati'on in the tube only,-
I penetrating from the outer surface. The range of depths represented by these pnase angles are from almost complete penetration of the tube down to degradation near the limits of detectability . 11umerically this is from about 90 percent of the tube wall (55?; of combined wall) to 40 per- [ cent of the tube wall (257. of combined wall). flote that in Region 1 the phase angles are unique and allow the analyst to identify the compo-nent being degraded and make an estimate of the depth of degradation on the basis of a single examination. 0 Region 2 contains phase angles from about 70 to 110 . This phase angle range may represent two basic classes of degradation. The first is de-gradation penetrating from the tube outer surface and going almost ccm-I pletely through the tube wall, or corpletely penetrating the tube wall 0"I
'go - co.
F b ) !4 and involving a cortion of tr.e sleeve. The second class of degracation involves penetration of tne tuce from its inner surface. As an exacole, the pnase angles for complete at:netration of the tube wall from tne outer surface and a 40 percent of ttbe wall degradation penetrating from the tube inner surface are essentially the same (around 90 U to 1000 ). *t is neces-sary to use the results from a previous examination wnich snows the defec: to distinguish between these two classes of degradation. Once this is
' done, an estimate of the depth of degradation penetrating from the outer surface can be made on the basis of the phase angle. Presently it is not possible to make this estimate for degradation penetrating outward from the tube inner surface.
Region 3 contains pnase angles from 0 to about 70 . This phase angle range may represent two basic classes of degradation. The first is de-gradation which nas completely penetrated the outer tube and a part or all of tne sleeve. The second class includes degradation penetrating from
- the sleeve outer surface part or all the way through the sleeve with no 0
tube degradation. As an example a phase angle of 50 could represent either complete penetration of the tube wall and approximately 80 percent ,, penetration of he sleeve or about 30 percent penetration of the sleeve wall from the voter surf ace with no tube degradation. Again, it is neces-sary to use tt e results from a previous examination which shows the defect to distinguish between tnese classes of degradation. Limited selective leak testing might also allow this distinction to be made. Once the clas-ses of degradation are separated, estimates of the penetration depth can be made from the phase angle for either category of degradation. The previously described situations relative to distinguishing between de-gradation in various locations, and the ability to esticate their depth exist for all test frequencies evaluated (from 100 KHz to 600 Khz). One other point of interest should be noted on figure 5-1. The data for outer surface tube degradation at the end of the sleeve, and just beyond the sleeve termination, do not fit the curve for defects "inside" the tube / sleeve assembly. This is considered to result from the fact that 5-S
~
' testing defect locations 1 and 2 are essentially testing the. tube without the sleeve, and different characteristics are to be expected. Future work will have to define appropriate curves for this region by implanting a range of defect depths for testing (presently only
' ~
40 percent nominal depths of degradation are available).
- A shortcoming associated with the test using the axial wound probe rotated in -the tube is the relative insensitivity to axisymetrical defects.
5.4.2 UNEXPAUDED REGION OF TUBE / SLEEVE ASSEMBLY For this region of the assembly, inspection may be perfonned with the axial wound probe at 200 KHz operating with circumferential motion. This would be the same type of inspection used in the expanded region. Figures 5-12, 5-13 and 5-14 present signals for defects in the unexpanded region An equally valid option of, the tube / sleeve assembly tested in this manner. is to do the inspection with a standard .540 inch flex prote coerating at
~
#0 TJiz. .,This option would only be valid for regions of the tube / sleeve assemb_ly removed at least 3/8 of an inch from the edge of the exoansion.
-- +
Figures 5-15, 5-16 and 5-17 present signals for defects in various areas e,L 4 of.the unexpanded region produced .by tests with the .540 inch diameter fl ex, p robe . The choice between these two techniques will be made af ter an
\'
evaluation of the inspection speed obtainable with the axially wound probe and the relative ab'ility of the two probes to examine defects in the vicin-
~
.ity of dents.
Figure S-2 presents a plot of phase angle versus defect depth for the axial All wound probe operating at 200,,KHz or degradation in the subject region. the results and conclusions for thl's situation are virtually unchanged fran those presented in Section 5.4.1, except that the phase angles for Regions The similarity between Figures 5-1 and 5-2 y ahd,3 are slightly different.
.; pQdicate that resdits' for tne axial probe are not strongly influenced by
[ the particular axial cosition of the probe along the tube / sleeve assembly i
'during tne tes't, except tha *j the influence of axial position is strong at
, the end of the sleeve.
- u. ..
? u
.ca no a> ,
\
If the cecisionlis t ade to examine the unexpanded area of tne tabe/ sleeve assemcly wi tn a standa d .50 inch dianeter flex ; rote, then the :: nase an-gle versus centn of defect carve presented on Figure 5-3 is accropriate for a 400 KHz test. From an emination o' Figure 5-3, it is covious tnat the conclusions relative to distinguishing between degradation in various areas and the capability to estimate degradation d'epth from Section 5.4.1 are alsc, applicable for this test. The calibration for tne tests whicn de-fine Figure 5-3 is accomplisned by setting the phase. angle of a signal from a .100 inch diameter nole through the tube and sleeve at approximately 400 . With this initial setting the probe motion line has a phase angle of about 10 . Definition of the phase angle for the probe motion line is more un-reliable in a sleeved tube than in a standard steam generator tube because there is little actual motion cf the probe in the sleeve. Because of this, it is not used in the calibration approach. 3 In sev'eral areas i t has been noted that certain oairs of degradation condi-tions give essentially the same phase angle (tube through wall hole and tuce e inner surface degradation without sleeve degradation or tube through wall
; inole plus some sleeve outer surface degradation and sleeve outer surface
[oegradation with no tube degradation). It is considered that these situa- , tions result from the degradation at the tube / sleeve interfacs shadowing the material behind it so that the presence or absence of that material has little influence on the interface degradation signal. 5-10
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oc oc i Figure 5-4 aX l a L L Y l'10 V N D D I F F I R E N T l al C O I L
. ECT PROBE NOTE COIL OR IdNTAT10N IS PARALLIL TO TUBE-SLEI'/E AX15 DURING SECTION OF TUBE IN INDICnTED TRAVEL EXPANSION AREA SECTION OF SLEEVE -
IN EXPANSION AREA i l n ! y {
/ 'll . ........
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l DIRECTION 0F C0ll TRAVEL l v l 5-14 l J - _ , , , , _ _
co .. Figure 5-5 DEFECT LOC ATIONS IN CALIBR ATION S AMPLES _1l8'i 6 13 UBE $
\ SLEEVE 3 A-
-B-3/8" -AT LEAST 1"-
- 1. DEFECT LOCATION No.1 HAS THE EDGE OF THE DEFECT 1/8" FROM THE END OF THE SLEEVE
- 2. DEFECT LOCATION 9 and 12,10 AND 13, AND 11 AND 14 ARE SPACED 3/8" FROM DEFECT CENTERLINE TO DEFECT CENTERLINE, RESPECTIVELY
- 3. DEFECT LOCATIONS 15,16 AND 17 ARE OFTEN CONTAINED IN SECTION OF TUBE / SLEEVE ASSEMBLIES WITHOUT AN EXPANSION JOINT. THIS ALLOWS THESE DEFECTS TO BE MOVED WITH RESPECT TO EACH OTHER SO THAT SITUATIONS VARYING FROM ALIGNMENT TO COMPLETE SEPARATION MAY BE INVESTIGATED 5-15 l
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_Colibration Standard Defect Information _ Defect Information - .. .-....,..... . -- Dimensions -
~
Sonip' le'- A B- Position Actual % of 1 of Isun ber inches Cross. Component-flumber Depth Section -Total Component Wall Wall Type 46 li 1/4 16 .014" Consnents
.18 7 "+ . Sleeve 44 17 47 1+
EDM 1/4 2 .019" .187"+ Tube 39 23 EDM 48 1+ 1/4 Rounded End 9 .049" .25" + Tube 100 '60 11 .015" .187"4 Sleeve 00M 47 19 EDM 49 1+ 1/4 6- 7-8 .081" .25" + Tube / Sleeve 100/100 100 7 .015" .187"+. Tube EDM 47 28 E0H 50 1+ 1/4 4 .019" .187"> Tube 39 10 .019" .187"+ 23 LDM Tube 39 - Rounded End 13 .019" .187"4 23 EDM _ .-- - -- ---- Tube 39 _-. - 23 EDM Tube tiot 15-16 .081" E Applicable .098"4 Tube / Sleeve 16 .025" 100/100 100
.095"4 Sleeve 78 EDM Sleeve 16 .022" 31
.095"4 Sleeve 68 EDM
^ 16 .023" .050"+ 27 10H 16 Sleeve 71 28
.015" .095"+ Sleeve EDM 16 .009"- 46 18
.095"+ Sleeve 28 EDM 16 .010"' 11 16
.187"+ Sleeve 32 EDM
.032" . 09 B"+ 13 tom IS-16 Sleeve 100 40
.071" '095"+/
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( NOTl!S:
- 1. Ai 1 defeet -: en.i t , recorded w i th 1.\1 3300 sens i t i vi t . .it ~1, and tertica1 and l'ori:.mtal 4ettines at I volt / division, unles< indicated.
- 2. S ignals are :>ro.!uced from the axial wound probe operat in ; at 2 : kil: . .
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4l';N.\l.S !!o Et 111PI I'N R SURI'.\CE DEFECTS - NO S!.EE\T DEI;R.\D, TION t i i ! l , l l L b ! # . it W - ,. ,_ , [, . ' '7 , f i , W p,N 3 1 z - + M l t
. c, s t s -
60 Tube Wall ( I . D. ) 221 Tube Wall (I.D.) Ot Sleeve Wall Ot Sleeve Wall l 285 Combined Wall 131 Combined Wall l (a) (b) i l l 6 r i NOTES: I
- 1. All defect signals recorded with D13300 sensitivity at 50, and vertical l and hori: ental settings at I volt / division, unless indicated.
- 2. Sit:n...s are produced from the .540" flex probe operating at 400 Kil:.
L C 5-28
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.. S l f!ht l, di e ' t ' L ! llc ed F. W Ihe 3 III I[eX p TMC C T II i ll II 5-29
= m
os :so 5.0 TUSE SLEE7E C*RROS!CN RES: STANCE
.':ilicirc rt arj arc secoccacy aater : e-istr'et reo eserta:i.e o' tysica:
ccci:1ons in tre Palisaces staa gerera;;rs, t.:e/ sleeve :: recs::n eval.atter tests were ;ee# -9ed. T;:eisliese as ": les tested tec'..;ec Or a!, aastec
;ates arc si viated intergraea:ar at:a;< :: ;re stea. gecera:or :.:e. Te ocjecti.e of inis orogra was 0 :er0rst-ite *a: ; .e siesvirg se::ess coes not aggravate tne :cerosion of s:eam generator t.tes, car ca.se : :e/ sleeve
- revice-::rrosion.
-5.1 SL4HARY AND CONCLUS!CNS Corrosion tests of sleeved steam generator tubes are in progress to confirm trat installation of a sleeve coes not lead to corrosion croolems. The test conditions incluce a variety of normal and faulted seconcary sice enemistry
~ conditions and naninal primary sice concitions. These tests are co cucted in
; pot boilers wnich provide the cacability of deternining susceptibility to corrosion in sthe presence of heat transfer and two-pnase secondary side condi tions. Results of the planned tube and sleeve examinations will be included-in a recort af ter these tests are canpleted; however, no detrimental effects
~
of sleeving have been noted to date during the :cncoct of :nese tests. Beoirming in 1975, several sleeves were installed in 'a pot bailar like the ones used for tne corrosion tests. This boiler operated for several nuncred nours under transient and steacy-state conditions 1witn normal volatile secondary chemistry and primary cnenistry concitions. Visuai and metallogra:nic examinations'following this test snowed no tendency for One sleeve insta'lation to prm70te corrosive attack frcm eitner tne primary or secondary sice. The results of these examinations are detailed below. 6.2 TEST FACILITY
. Co'rrosion evaluation . tests are conducted in :ne Combustion Engineering Nuclear Laboratory, utilizing a high temperature, high pressure facility capable of supplying primary coolant at 600oF, 2200 psig. Soilers simulating steam generators in an NSSS, c o n t a i n the secondary enemistry being investigated.
Sleeves are installed in the straight cortion of short U-bend sections of steam generator tubes and primary chemistry similar to that at Palisades is passed- through. the tube / sleeve asserely. Sy means 6-1 1.
. 2a
Hoo ao r of neat transfer tneougn tne tu:es, secc.:dary coolant is rai seo - frcn accroxi-ately. 2000 ~ to N F at satura-ion pressare. Secondary Ores;ure ard *.eco-erature .are maintained by allowing the steam to flow througn a concenser and returning' tne condensate to the boiler at a point beneatn :ne water line. The tubes are keot covered witn a minimum of six inches of seconcacy water at all times. Samples of the secondary chemistry are taken :nree times week-ly with chemical additions as necessary. Cue to the small volume essentially closed loop system and the steady state nature of tne test, little fluctua-t- tion in chemistry conditions is evidenced.
?
Primary chemistry is sampled weekly. Again little necessity for chemical ad-ditions is found due to the' sealed nature of the test icop. Figure 6-1 pre-p sents a schematic of the steam generator simulation test system. A flow rate of-2 to 4 gpm per four tube test boiler is maintained for primary coolant. The tubes in the boilers are as configured in' Figure 6-2. Each boiler
;f houses four U-bend steam generator tubes with two sleeves installed per tube, one in eacn leg. The sleeves installed are eight inches in length, L but othenvise identical to that pictured in figure 1-1. One virgin tuce and three partially laboratory degraded tubes are studied under each chenistry. These samples represent the range of defects anticipated for sleeving.lhesamples are present in each of the four chemistry tests. One tube defect is a 70 per-
- cent of' wall circumferential phosphate wastage midway between the two expan-sion joints. This-simulates a tube which would r eq u i r e plugging by b ' current tecnnical Secifications. A second tube with 90 percent elliptical wast-age at center scan i's studied. The final tuce defect is a 13 oercent of wall intergranular attack (IGA) located in the expanded joint region. The IGA is introduced prior to tube / sleeve expansion processes. This defect is representative of expanding a sleeve in an area where a tube defect is not detected oy non-destructive eddy current examination. Eacn of tne de-fects is encouraged to propagate by means of an umbrella concentrating device affixed lto the tube just above the defect. These concentrators, J.
coupled with the severe pnospnate chemistry, provide a simulation of the
" ' Palisades corrosion. characteristics in a much shorter time (typically one month) than is expected or nas been found in the Palisades generators.
. 6-2
T I I i i t U l ll g o.; in. u .DITIONS If m: ja As mentionec, tre tube / sleeve samples are er csed to seseral seconcary and a single primary water cremistry. Tne secondary cremistries are { representative of cast, present and proposed Palisades steam ;enerator I conoi ti ons . A crimary system cnemistry is used whicn is reoresentative
); of that in all PWR steam generator primary coolant systems.
I i {. The first secondary chemistry sequence explored is descrited in Table ( 6-1. A one month period of pnosphate chemistry of the intense nature j described is believed adequate to simulate early steam generator condi-i tions, particularly with the umore113 concentrators on the tubes. These f conditions provide corrosion propagation and deoosits eoual to those at j Palisades in one month. The test samples are subjected to a transition f to volatile for a four month operating period. Over this length of time, i any corrosion tendencies are excected to become evident. Finally, the h tube / sleeve samples experience a wet layup cnemistry to simulate i Palisades down pericas wnen the secondary side was lef t filled. L i The second generation Palisades chemistry described in Table 6-2 acds con-
. censer in leakage to tne secuence to represent tnat onase of plant coera-I tion. Concentration and pH 1evels are in accord witn Calisades tecnnical l specifica tion levels. Attemots are made to match actual clant concitions wnere infomation is availaole. These first two enemistries utili:e Lake Michigan water in phosonate and volatile chemistries, respectively.
h l- The third test (Table 6-3) simulates the volatile seconcary cnemistry con-l trol witn cooling tower water. Pnosonate chemistries are run to introcuce i corresive deposi t: on the test samples. A pre- and post-volatile wet layup again simulates filled steam generator down periods. An investigation of corrosive effects of one possible future Palisades chemistry on the tuce/ sleeve assemoly is being race. :ntroduction of sodium representative of levels excected from a condensate cemineraliza-
, tion system (COS) is being made during tne transition to . volatile (Table i
6-4). f 6-3
n _ -._ . - - - . . - . _ - - - - - _ . - - - _ _ - - . _ . . . . - -
- 00. os ine. primary system chemistry empicyed in all tests u tnat snown in
[ Taole 6-5. I l 6.4 -RESULTS t, b i The tests of various tube / sleeve assemolies under four cifferent secondary l j chemistries were designed to show the effect of the sleeving operation on j l tube corrosion and to determine whether tuce to sleeve crevice corrosion i might occur. Preliminary results of a virgin tube tested for over 700 hours under volatile type chemistry conditions indicated no cor-osion in -{
- the tube as a result of the sleeve installation further pos t --st met- l allographic sectioning showed no evidence of . . ice corrosion nor stress corrosion cracking. The expanded regions of t- >
- ere ,urrounced with .l the umbrella ' style concentrators to accelerate c. rosion effects. No signs .1 '
of localized or other corrosion were found af ter examination. This evidence indicates tne acceptability of the expansion joint employed fecm a corrosion , resistance standpoint. Final acceptability will be verified by corrosion ; tests still in progress. l
- }
Longitudinal and transverse sections of tne tube and sleeve were examined t
-microscopically for signs of corrosion. Examinations focused on tne ex- {
pansion areas. Figures 6-3 and 6 4 present typical microstructure from the f tube and sleeve in the expansion area after 700 nours of tes .. "o evidence {
'of pitting 'or cracking is seen.
Axial' looseness testing of the assembly after this test showed no cnange from the pretest values of one to three mils movement with 25 pounds force t q V applied. ' Leakage rates of 1-10 cc/ minute were determined for post test-samples of the tube / sleeve assembly by drilling a leak hole at midspan in the tube. This is comparable to the rate determined for samples wnich have I 3 not been corrosion tested. ! u l-H - s2 ! i _ - _m . _ -. . . . . . _ . . _ . . . . . . . . .. . . . . . . 6
l i .. ** ' i Tacle 6-1 ni ti al :ali saces Seconcary Chemistry Chemistry Daration 00: Chemistry Control 1 .'-ic n tn pH (J 25 C) 9.0-10.2 Phosphate 30-60 ppm Sul fi te 10-30 ppm Addi tions of Lake Michigan To the extent necessary condenser cooling water to maintain a pH of 9.8-10.2 Transition to Volatile 4 Months 0 pH (3 25 C) 3.2-9.2 Hydrazine addi tion for oxygen control Morpnaline for pH con-trol -
'det Layup 1 Month '
pH (9 25 C) 9.8-10.2 Hydrazine 150-250 ppm Ammonia <10 pon Inert Gas Overoressure L 6-5
Table 6-2 i secena Generation calisaces secondary Cnemistry Cnemis try :uratior Wet Layuo 1 Month pH () 25 C) 9.3-10.2 Hydrazine 150-250 opa Amoni a <10 ppm Inert Gas Overpressure P04 Chemistry Control l Month pH (3 25 C) 9.5-10.0 Phosphate 30-60 ppm Sul fi te 5-10 ppm Transition to Volatile 1 Month pH (0 250C) 8.2-9.2 Hydrazine addition for pH and oxygen control Volatile clus Condenser In-Leakace 3 .' ion ths pH (0 25 C) 8.2-9.2 Hydrazine addition for oxygen control Additions of Lake Michigan water to maintain conguc-tivity (Specific 3 25 C approx. 15 amhos/cm Morphaline for pH control I i.
, 3-6 i
.- Q O. ' b ' :-
l
\
l l l Table 6-3 , Third Generation Palisades Secondary Ch imistry Duration PH4 Chemistry Control 1 Month pH (@ 25 C) 9.5-10.0 Phospha te 30-60 ppm Sulfite 5-10 ppm Wet Layup 1 Month pH (@ 25 C) 9.8-10.2 Hydrazine 150-250 ppm
- Amonia <10 ppm
. Inert Gas Overpressure Transition to Volatile 3 Months
-pH (@ 25UC' 8.2-9.2 Hydrazine addition for
~
-oxygen control
-florphaline for pH control Additions of Palisades To the extent neces-cooli.'g tower water sary to gintain pH of o.2-8.o
~
. Wet Layup 1 Month
. pH (@ 25 C) 9.8-10.2 Hydrazine 150-250 ppm smani a <10 pp.n
-Inert Gas Overpressure 6-7
,-- . . , . _ _ - - . - . ., , ,- - - . _ - . . - s.
%['
,o S t-hIN s s- 's *v
< s
% 5 Table 6 4 2^
-}'{31isaces Seconcary Chemistry witn Concensate Polisners Chemistry Duration p04 Chemistry Control 1 Montn pH -(@ 25 C) 9.5-10.0 Phosohate 30-60 pom Sul fi te 5-10
<> Transition to -Volatile w/ Sodium Concentration from CDS 4 Months s -pH (9 25 C) 8.2-9.2 Feed and vent of CDS ef-fluent to concentrate sodium in the bulk water ' to approximately 400 ppb . Hydrazine addition for oxygen control Morphaline for. pH control Wet Layuo 1 Month pH (@ 25 C) 9.8-10.2 Hydrazine 150-250 ppm Ammonia <10 ppm Inert Gas Overpressure 6-8
^,n . <-
j Table 6-5 Palisades primary Chemistry Controlled Variable Limits
~
pH (9 25 C) 4.5-10.2 Hydrazine - 1.5 x (0 2), max. 20 pom Amonia <0. 5 ppm Oxygen <0.100 ppm
, Chloride : <0.15 ppm Fluoride <0.10 ppm
' Boron 500-4400 ppm Li thium 0.2-1.0 ppm s
6-9
oo ..
, 1 i
n l VENT i V
%)
Y
' CONDENSER INSULATED "
I i i I a
.I I
I I I l l BOILER I I I I I I I
] r------
, ,s i
I / \ l u <- - .- ,- > LEVEL ' CHEMICAL l CONTROLLER ADD lTIONS - A i FILL j l 1 1 9 9 I I , l l
- SAMPLE E I '
PR IMARY_ IN y
' PR IMARY_
OUT
~
y Figure 6-1 TEST BOILER SCHEMATIC b-10
9 b o 8 l' '\ p f-gg: .
~
\ t
- j -
es o' Figure 6-3 Typical Tube Material Microstructure Af ter Preliminary Corrosion Test ~
.s .
r
\ /
's s .
' f,/f s,
+.,
/ ..
, , t
. .- - t
* ,r - '
~ . .> \;
. c~c l.l. ,/ , i,\ g.
\
k . . _. , - i. fi N w
\
/^ /
n
/ , .
9 Mg ,
, -3 e . :. .
, s 5 C I
*I .\. / ' . ,\ , .--
...s.
l l Typical microstructure of the I'1conel 600 tube in the expan-sion area. The edge (black area) is that edge of the tube l to tube sleeve mating surface in the crevice area. No signs of corrosion are evident. 200X. Etched l 6-12 I 4l
ea e s Fi<nre 6 4
^pical T/ Sleeve Ma terial *'icros tructure
~
U. _t_e._r_ P re l i r i na ry Co rWs io n Te s t
)
)
I I l r M
./
a e l . . i i I l Typical microstructure of the tube sleeving in the expansie:i/
- crevice area. The black edge is the sleeve to tube mating sur-l ,
face. No signs of corrosion were evident. 200X. Etched b-13 t I i l l _. . _ . - . . . _ _. . 1
00 OD 7.0 STRUC T AL W L(5:S OF D1BE-SLEEVE ASSEMBLY It is t7e intention of :nis analysis to establisn :ne structura' integri*y of the tube-sleeve assemoly for cost.'ated wcrst case accident corditicr.s.
'he accident condi icns considered are main steam line break and loss of coolant.
7.1 Surnary and Conclusions A qualification analysis is cerformed to insure the structural integrity of the tube-sleeve assembly during a main steam line break accident. There exists a radial gao in the expansion joint of the sleeved tube. This re-suits in an axial gao which allows the parent tube to separate a finite amount before the sleeve comes in contact with both ends of the carent tube. The geometry of the exoansion joint is determined from an optical comoarator plot of a typical exoansion joint. The rate at which the sleeve engages the carent tube is extracted from axial oull test results. This amount of tube separation is then incorporated into a simolified dynamic analysis of the tube-sleeve assembly. From this dynamic analy-sis, a maximum, equivalent static, axial load on the sleeve is deternined. This maximum axial load on the sleeve is compared with the exoerimentally determined load recuired to pull apart a severed tube-sleeve assemoly, and a factor nf safety of 2.4 for sleeve disengagement is calculated.
- lext, the mode of faf ure for sleeve disengagement is analytically de-termined and compared to experimental test results. A strain energy analysis is used to determine the force recuired to pull the sleeve out of the parent tube. This force was determined to be 4522 lb. which agrees closely with the experimentally determined failure load of 3795 lb. The stress in the sleeve due to a static axial load indicates that the mode of failure for the tube-sleeve assembly will be a neck down of the sleeve if sufficient force and freedom for the tube to separate axially were available. This agrees with the experimental test results.
Next, the effect of a tube-sleeve assembly with 100" degraded tube on orevious analytical assessments of oostulated loadings is looked at. 7-1 1
CD c8
'ce '.RC Sta Cet teria gises a ,axi am sleeve wali cegracation of 53.. Tre
_ CA - ISE a::icent 1:aci g is tre l'~it eg :r4 teria arc irc4:a:es :na: tre d de t ur sleeve weil cegracation ;er-ittec sacule ce 34.. A v bration response test will be conducted :n c4; and 100: ;egradec sleevec i
- aces in orcer to obtain a qualitative assessrent of tne presence o' sleeved taces from the standcoint of dynamic tube response. Inf ormation with regard to tne natural frequency and darping of the sleeved tuces will also .e ob ta ined . These measured natural frequencies will be canpared with the frecuencies of virgin tubes in order to assess the effect of the presence of sleeves. The predominant vibratory forcing function in the seconcary
- fluid bundle entrance region is fluid elastic coupling. For Palisades steam generator virgin tubes, no vibration problem due to fluid elastic vibration is anticipated. Unless there is a large divergence in oynamic response or natural frequency between virgin tubes and sleeved tubes, no vibration problems are expected for sleeved tuces.
Pressures considered in this analysis are those originally specified for coerating conditions. Higher primary and secondary pressures corresponding to the " stretch rating" will be considered at a later time. A ornamic analysis of Main Steam Line Break plus Safe Shutoown Earthauake siil be performed and the results provided at a later time. e 7-2 L 2
ee se 7.2 TUBE-SLEEVE ASSEMBLY Ol'ALIFICATICM ANALYSIS Assuming an instantaneous circumferential failure of a sleeved tube Oue 3 to main steam line break, the behavior of the 'leeved tube is cnaracterized. The amount of tube separation before the sleeve comes in contact with both ends of the parent tube is conservatively determined. The rate at which the sleeve engages the tube is extracted from axial cull test re-sults. A dynamic analysis of the sleeved tube assembly is performed and a maxi-mum, equivalent static, axial load on the sleeve is determined. The maximum axial load is compared with the load required to oull apart
' a severed tube-sleeve assembly, which has been deterinined by a pull test.
r The comparison of the failure load with the maximum applied load (from dynamic analysis) represents a factor of safety for sleeve disengagement. 7.2.1 Radial Gao in Exoansion Joint The unpressurized radial gap in the expansion joint is calculated using an inelastic analysis with a plane strain assumption. 3 clane strain model is used to aporoximate the hydraulic exoansion of the sleeve into the tube. A thin section of tube-sleeve assembly
. at the center of the expansion joint is modeled.
- , W =-
sf I \ l Expansinn Joint sf l, N tjr n Qt I v - -- [x Plane Strain Section NI [s N j N 1 , - N l l sv-FIGURE 7-1
' a.o : ao lc..
f The pressurized radial gap between the sleeve and tt.be is determined from theoretical radial deflection ecuations and the uncressurized racial gao. Plane Strain Model
.37E " y l '
I l .327 " 3 M* l p Sleeve 10 !
' 1l 2 3 4l5 6 7 8 9 l11 i 1213 14 !15 16 17 '18 p
.7R1a y
. 313 " ,
. FIGURE 7-2 The above dimensions are dimensions before any hydraulic pressure is applied to sleeve.
An inelastic analysis of the plane strain section is cerformed using the "ANSYS" Computer Program (Reference 7.3). The sleeve and tube are modeled with the isoparametric element STIF42 using the axisymmetric option. Eight elements were used to model the sleeve and tube wall thickness so as. to orovide better representatiun of the inelastic pro-pagation. The initial radial gao between the sleeve and tube is modeled with the interface element STIF12. olane strain is assumed as the sleeve is expanded into the tube. After the sleeve has been hydraulically exoanded into the tube and the
, pressure removed, an uncressurized radial gao exists.
t . From inelastic analysis: GAP uncressuri:ed = .00004 in. l Pressurized Radial Gap
'The pressurized radial gap is determined by adding the radial deflec-tion of the tube under cressure to the uncressuri:ed radial gap.
I T. .- - - _ _ - - -
1 FI3L'R~ 7-3
~ ~ ~.,_.
R I A 4 4 i ! i l
+P:~ le P.-* i
*P2-l V V I V l
b f ! 2;
, Tube
~
Sleeved % 10 = (h-f) P = Presserized Radial Gao b = Expanded inside radius of tube = [ ] 2, 3 t = Tube wall thickness = .048 in
, R=[ } 2, 3 E = Elastic modulus of Inconel = 29.4 x 10e psi, 6000F v = Poisson's Ratio = .3 P = Pressure = P: -P 2 = 2150 osi - 770 psi = 1380 psi s
GAP
, oressurized = .' p = .0001041 in G# radial = .00004 in + .0001041 in = .0001441 in 7.2.2 Amount of Tube Secaration flow determine the maximum amount of tube separation before the sleeve comes in contact with both ends of the parent tube.
Figure 7-14 is an cotical comparator plot for the expansion joint of a tube-sleeve assembly, from which the geometry of the exoansion joint is determined. C 7-5
e' I FIGUoE 7 J
- k. Exoansion Joint I
I
,<, .100" >!
e M* ^ 9,' .0001441"
.001"
_ pee ve - A
.J .001" i _ Zr -
f I X 4--- tan 9 = = .01 Let X = axial gap of which there are two between the sleeve and tube tan i = .01 = .0001441 X X = .01441 in Let d = maximum amount of tube separation d = 2X = 2(.01441 in) = .02882 in For conservatism, multiply d by 1.5: d = 1.5 (.02882 in) = .043 in
.'. The tube separates a maximum distance of .043 inches before the sleeve engages the parent tube.
7.2.3 Maximum Ecuivalent Static Lead on Sleeve The maximum axial load on the sleeve is detemined from a simplified dynamic analysis of a severed tube-sleeve assembly. The tube-sleeve assembly is modeled as a spring-mass system using the "ANSYS" computer program (Reference 7.3). The lower part of the severed tube and the tube sleeve are modeled as springs using the spring element STIF 14 The mass of the sleeve and the mass of both
, ends of the severed tube are modeled using the general mass element STIF21.
; 7-6
so ,e The distance tnat the uccer cart cf the tube travels before the sleeve comes in contact wit.1 both ends of the carent tube is redelec aitn 3 gic condi ti on. This consists of a gaa and a stiffness associated witn the closed gap. This stiffness is taken to be the rate at which the sleeve comes in contact with both ends of the tube. In order to simolify the dynamic analysis, the force on the scriro-mass model is applied in compression rather than tension. This results in a ccm-pressive force in the sleeve whereas .it should be a tensile force, but the magnitude is correct. Soring-Mass Model of Sleeved Ruoturad Tube _
*F(t)
V
@ Mass of Raotured Tube, Upoer Part
%gf -o or fX Engagement 7
l
'2 Mass of Sleeve 4 K Sleeve i
$ 1/2 Mass of Ruoturrd Tube Lower Part i
Ruptured Tube, Lcwer Part m Tubesheet si//v/// FIGURE 7-5 . l
'F(t) is the blow-off force due to a main steam line break accident.
77
e* ,* Using the preceeding si?clifiec Oynanic analysis, caracetric stacies of various t'.be rows and different de ect locaticns irdicate ta.at Tube P.ow 1 at its uccerr.ast sa oort olate reoresents tre oorst case condition for a sleeved tuce. This conclusion is also substantiated by examining the 3nalytical salution to the Simolified single degree of freedom problem. The above described location is 216 incnes above the face of the tubesheet. Now assume that a tube in Tube Row 1 is sleeved at this defect loca-tion and sustains an instantaneous circumferential failure at this location during an MSLB accident. A reduced linear transient analy-sis is performed using the spring-mass model. F(t) is the bicw-off 1 load on the severed tube. This force is conservatively assumed to be I applied instantar.eously to the severed tube. A force-time history is given below. l i FIGURE 7-6 A 722 2
!?
C'
=
.00002 1.0
. Time (sec)
Blow-off Load for Main Steam Line Break F(t) = Blow-off Load = PAj7 P = P: -Pt Where P = Drimary Pressure = 2150 psi 7-3 L .. _ _ . . _ . . _ _ _ _ _ _ _ _
~
m Moc} . cA ' .A : i o
.P = Secondary: Pressure = 0 :si t
i D = 2150 si -0 csi = 2150 :si
.F(t) = 2150 psi x .336 in; = 722 lb
( Mass of Severed Tube, Lower Part Ruoture
- h. Point l
.; FIGURE 7-/
N , 1 1 y y,,,,,,,, Tubesheet M{ = Mass of severed tube, lower part M
- t. * (AP'T
- U iT i.t CAofoL) 9 07 = Density of tube material = .205 lb/in2 og = Density of water in tube = .026 lb/in2
~
o gg = Density of water: displaced by Icwer part of tube = .014 lb/ ins n AT = Area of tube material = .106 in AiT = Inside area of . tube = .336 in:
'Ag7 = Outside area of tube = .442 in k,.( : C = Virtual mass coefficient = 1.0 Lg = Length of tube lower part = 216 in 1 ;- - g = 386 in/sec r
?
.M l ~-
= .026 lb-sec2 /in I
7-9
L- .. L. : 00- 0 0~ ( c
'e ass of Severed 'Ae. ';ccer Dart G .-
e. 0
'/
! FIGU9E 7-8 L -Ruotre Point l Succort Plate a:
f ,L u- = Length of tube, upper part Lu = 18 in + j 2 in = 21.9 in Mu = Mass of severed tube, uoper cart 4
- Lu u TT+A iT 4 + CAofouI g
..; O cu = Density of water displaced by upper part of tube = .008 lb/in' r Mu = .0025 lb-sec2 /in Mass of Sleeve M3 = i' ass of sleeve i
M3 = (A c33+A j3 0$ + CAoS# o) 3 3 = Density of sleeve material = .305 lb/in' 3 9 = Density of water in sleeve = .026 lb/in' O g = Density of water displaced by sleeve = .026 lb/in' A3 = ' Area of sleevesaterial = .059 in# Ajg = Inside area of sleeve = .238 in:
'Ag3 = Outside area.of sleeve = .308 in 2 i C = Virtual mass coefficient = 1.0 j; Lg = Length of sleeve = 12.0 in f..
6. 7-10 t-n-
g = 336 in/sec v 3
= .@ ic-sec; . i n Tube-Sleeve Asserolv Parameters 15 = Inside radius of sleeve = .281 in
-- R g3 = Outside' radius of sleeve = .313 in t3.= _ Sleeve- wall thickness = .032 in
.L3 = Length of sleeve = 12.0 in A3 = Area of sleeve material -= .059 in:
-RiT = Inside' radius of tube = .327 in Roi = Outside radius of tube = .375 in
.t
! = Tube wall thickness = .048 in LT= Length of tube from face of tubesheet to defect = 216.0 in AT = Area of tube material = .106 in E = Elastic modulus = 29.4 X 10' psi, 6000F K3 = Sleeve stiffness KT = Lower part of severed tube stiffness A3 E-X 3=L 3 * '
A,. E KT*l = 14423 lb/in T . Rate of Sleeve Engagement
.Now the rate at which the sleeve comes in contact with both ends of the parent tube will be determined using Figure 8-2. Figure 8-2 gives a load-displacement history for a tube-sleeve assembly as determined from a tensile pull test.
7-11
; oo- ;n o
' ensile Pull Tes t -
F 1 A ! 1 1 1' G- V f., 3 . engagement X = Rate of sleeve engagement
.f' sleeve K3 =-51eeve stiffness as tested K T= u e S W ness as tested 9 tube r
if/f/o FIGURE 7-9 From Figure 8-2: X=(= lD=8a00lb/in n (A conservatively stiff spring coefficient for the tube-sleeve assembly is chosen.)
.A g E
'K S=g = 144550.lb/in A7 E K
T' L L.T- = 173133 lb/in A3 = Area of sleeve material = .059 in: L3 = Length of sleeve used ,in tensile test = 12.0 in E = Elas tic modulus = 29.a X 10 lb/in A7 = Area = of tube material = .106 in'
~
L = Length of tube used in tensile test = 18.0 in 7 J P
\
7-12
% , pq;; 'ne 1
'g- ,1 1. 1
<g K,.
.< 3 p
z.p.g. e .S s af-- '= .0001064 - KE = 9400 lb/in Coefficient of Viscous Damoing C = Coefficient of viscous damping C=2Mq.; M = Total mass of spring-mass . system
-; Viscous-damping factor = 1",= .01'(Ref. 7.6' w,,
= Natural frequency of spring-mass system
=' = 775 rad /sec K = 8400:lb/in g ,.026 lb-sec + .001 ID'S'C = .014 ib-sec 2 in in in-C = 2 (.014 ID-5'C )(.01)(775s "> )
C = 22 lb-sec
-in
'daximum Equivalent Static t. cad on Sleeve -
The results of the dynamic analysis of the spring-mass system are shown in Figure 7-15. The ceak . force in the sleeve is taken to recre-sent the maximum ecuivalent static icad on ene sleeve. *
. , - Fp
,,g = 1560 lb = F g ),,y, 7-13
- a. v
c-
-pp go e This maximum axial load will now be ccmcared with the Icac recuired
- to cull apart a severed tube-sleeve assembly, anc a factar of safete for sleeve disengagement will be determined. This failure lead was detemined from unpressurized . experimental tensile Ouli tests.
.Fp ,il re 3795 lb '
Factor of Safety = F F
'"' '* 9$
- 2'#
sleeve
'This '.or of safety shows that there is a large margin of safety for sleeve disengagement.
3. 6 e 7-!a
-r
00 oc-7.3 FtIU;c.E MODE CE'E M:':M:O'l In this section, a ccmparisen is made between' the ca:culated acces c#
'ailure of the tube-sleeve expansion icint and excerimental test re-sal ts . Samole severed tute-sleeve assemolies anicn have been exceri-rentally pulled apart are studied to determine the mcce of failure.
Figure 7-17 shows a tune-sleeve assemoly tnat has been culled aDdrt.
~his specimen indicates that the sleeve yielded and the tube did not.
The specimen also indicates that the sleeve necks cown when the assembly is pulled apart. This neck-down at the tube-sleeve exoansion joint reduces the normal force between the sleeve and tube, thus lower-ing the. friction force and allowing the sleeve to be culled out of the tube.
- low a mode of failure is analytically determined.
- 7. 3.1 Stress in Tube Sleeve The stress in the sleeve-is detemined assuming an instantaneous circumferential failure of the narent tube during a MSL3 accident.
The' stress is calculated for the static case using the maximum equivalent static load on the sleeve as detennined in Section 7.2.3. F 4 i
! N' /
g k ,,d N r A-j l + P --*- i +Pc h .i f
. .N .
\
'h.
FiriURE 7-10 l I-I3 L
+_ - G o. o [D F:= 1 sleeve = 5 0 lbs -(Section 7.2.3) R gg = Outside encius o#; sleeve = .313 in 943.= *nside 'esdius of sleeve = .201 f r
- t,a = Sleeve. wall thickr.ess ' = .032 in
' Ag ;=- Area of sleeve material _ = - (Rgg' -R gg ) = .059 in#
P = Pi . - P: = 2150 'osi - 0 = 2150 osi
- x-
=1=
A 25.4 ksi s r'= a'
= 19.9 ksi S
Where R =-{Rog + Rgg) / 2 = .295 in
-P a
- r. * ' Y. = - 1.1 k s i S . I . ,,, = 2 x -3 r = 26.4 ksi + 1.1 ksi S . I .,,, = 2 7 . 5 k s i < *:33 ja, = 0.7 cu ltimate = 56.0 ksi
'lo te:
S. I.,,x = 27. 5. ksi < : yield = 27.9 ksi
. From Aapendix F of Ref. 7.1.
7.3.2. Strain Energy Analysis Assume that an instantaneous circumferential failure has occurred in a sleeved tube. The force reouired to pull the-sleeve out of the carent tube is determined. r , 7-16 Q --6. . &. .
., ,e y.
l f F A 4 F is the force recuired
~
to pull the sleeve a dis-l i tance of d = .9" . l Note: 4 (1) The effect of P is ignored in order to
! conform with the h axial pull tests.
+- P -*- d = .9 I' Y (2) d is the distance l
over which the sleeve and tube are in con-1 - q~ tact. l i
}
i I i FIGURE 7-i! i 1 7 17
>v 5 g = 3utside racius of tube = .375 in O
R9 . = Inside racius of tube = .327 in F.j7 = ExDanded outside radius of tube = [ ] 2, 3 Rj7=Expandedinsideradiusoftube={ l 2, 3 t7 = Tube wall thickness = .048 in Rg3 = Qutside radius of sleeve = .313 in R93 = lnside radius of sleeve = .231 in Ryg = Expanded outside radius of sleeve = [ ] 2, 3 Rjg = Expanded inside radius of sleeve = [ ] 2, 3 03 = Sleeve wall thickness = .032 in Hooo Stress P'R' O sleeve * ~ t 3
'~
*~ I P'R' 0 *
- P' = 7.1 P' tube t., . 8 Where P' is contact pressure between the sleeve and tube.
=
tube - 2/3 O sleeve' r y ,je = 31.5 ksi at 600F (see Figure 7-16). g sleeve may attain a maximum value of 37.3 ksi before
.. O the tube yields.
'. The sleeve will deform clastically and not the tube.
- Note: This assumes that the sleeve and tube have the same yield strength.
?.*o
a :: gs-y 1 [: f- The oork doce in deforming tne sleeve is ecual to the charge in > [ strain energy of tne sleeve material. l i W = ;U i
, Where W = work i
IU = change in strain energy a l l c2 I I
- .u = v /ci dc !
Where: Y = Volume of deformed material V=? (R 2 -Rj ) (.9) = .053 in' ( I i
-g- .
...._ ... l l
Il Il l--..,.-
... . 1 111 .4 ,. . i
.< 11J. . ..1MJ p. s:: 7:::.. M . .. .a . . + K. -:n . . . . . .... .
I i l ((, .b- '" ' (( ! I a .L >' 4dj I.,, 1 l, l l R
; R.1 '7 . oS l t !
FIGURE 7-12 i t l S II ' c= = g
= .038 = 3.85
'oS oS ,.
t
; Assume that the material exists in a virgin state: ci = 0. This !
t is conservative since it yields a lower strain energy. [ l ' 1 ! Assume that c2 =-t2 = .019 = 1.91 - l (In being pulled thru the tube, the sleeve experiences 3.8= j strain only at the peak of the expansion joint.) [ 1.95 ! From Figure 7-16: / oc = A = 644 osi l 0 t t l i + 7-19 l
, p
i i
- L
.. = (.053 in ') (64a lb/ic .i = Il in-Ib a
. , The energy required to deform the sleeve is _U = 24 in 'bs.
Two types of work are done by culling the sleeve a distance d - posi-tive work by the force F and negative friction work. W = total work done on sleeve = WF~Wf Wp = work done by force on sleeve = F.d e 0.9 F l Wf = friction work = DN.d c = 31500 psi = P'RiT yield s I
- p. , #?xt s , 31500 x .032 = 3082 psi R .327 iT N = lcrmal force between sleeve and tube N = 2-P'iT x d x P = 5700 lb u = Coefficient of friction between sleeve and tute l u = .8 (from exoerimental pull test results)
Wf = pNd = .8 x 5700 x .9 = 4104 in-lb i W=Wp-W7 = 10 , W = 0.9 F a10a in-1b = 3a in-lb 0.9 F = 4070 in-lb F = 4522 lb Where F is force requirec to defonn the sleeve and move it the distance d.
-rom Section 7.2.3, the maximum applied load on the sleeve duriag a main steam line break is 1560 lbs.
- .-. l.:L -.
- 2. : ,ja ;
I h !
\;
i l
.l l
Comcaring tne force required to ::ull the sleeve cut of the tuce and i the maximum 3Colied load on the sleeve gives a factor of sarety *cr-sleeve disengagement. Factor of safety = = 2.9 Again this factor of safety indicates a large margin of safety. In i O fact, sufficient room is not available within the tube bundle for I
. the tube to separate axially even if sufficient force was avaflable. l This adds to the already large margin of safety against sleeve dis-engagement.
. ll
-In summary, the mode of failure for the tube-sleeve assembly will l I
be a neck-down of the sleeve if sufficient force and freedom for I the tube to separate axially were available, which agrees with the ; k experimental test results, f l I i l 5 l l l I i I 7-21 n-m--- .. I
_ _ _ . _ _ _ _ - _ _ _ _ . _ _ _ _ _ _ . _ . . _ _ _ _ _ _ . _ - . . . . _ _ _ _ . . _ . _ _ . _ _.m_,
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i 7.4 3LLCMAELE SLEI'.'E DEGRACAT:G'. , Ih This analysis is intended to determire the effect of a ta:e-sieeve assembly wi th 100': degraded tube on orevicus analytical assesscents of I costulated loadings and safety margins (Deference 7.2). Healthy Sleeve: Ros = .313 in Ris = .281 in I t = .032 in k l I = .0026 in- ' Z = .0084 in' , i -i i 7.4.1 NRC Staff Criteria (Reference 7.21 Determination of ininimum required thickness tg . - l
- i. Normal Operation Tubes with defects will not be stressed beyond tne elastic !
range of the tube naterial. ' Sy < 27.9 ksi. 600 F [ IP Ris . tg = Sy - 0.5 (Pt + P: ) i Pt - = 2150 psi { P: =.770 psi f, 2P = 1380 psi t 1.38 (.231) R
- 27.9 - 3.5 (2.92) tR = .015 i Allowable degradation of Sleeve
, ,.032 .015
.032 X 100
= 53
)
l e* .* l i ii ';crea' ?cera tion The factor of safety 3 gainst failure by burstir.g is rot less tnan three at any tute location where defects have been :e tec tec . 3.: < S = 80.0 isi, 600F u
, 31 3 Ris
'R ~ Su - 0. 5 ( P . + P )
P. = 2150 psi
= 770 psi D:
IP = 1380 psi 3(1.38)(.281) ta = 80.0 - 0.5 ( 2.92) tg = .015
" Allowable degradation of sleeve
,, .032 .015 X 100
.032
" = 53 iii. Main Steam Line Break Defects that could lead to ruoture during a main steam line break accident condition would not be acceptable.
- < .7 Su = 56.0 ksi, 600 F AP R 93 t
R = . 7 Su - 0.5 (Pi
- 3: )
P t = 2150 asi P: = 0 3 = 2150 asi
, , 2.15 (.231)
'R 56.0 - 0.5 (2.15) 7-23 i . _.. -.
oo #
; I i
tg = .011 Allowable degradation of sleeve
, .032 .011 X 100
.032
= 65 Of the three criteria, the first and second one are the most restrictive. For these criteria, the allowable sleeve wall degradation is 535 7.4.2 Combined LOCA + SSE Analvsis The LOCA + SSE analysis considers stresses produced by various hydrau-lic pnenomena associated with raDid flow through the tubes, the dynamic responses due to the imouisive load occurring at the pi::e break ooening, safe shutdown earthquake induced accelerations, and differential cres-sure. Stresses resulting from these loadings are combined elastica 11y in a conservative manner and evaluated against an allowable for faulted conditions, determined from Accendix F, Section III of the ASME Code.
The elastic analysis is intended to crovide justification for establish-ing the a11cwable sleeve wall degradation. At some later time, a plastic analysis will be cerfor ed to orovide additicnal evicence in j support of the conclusions drawn from the elastic results. A static j plastic analysis will be performed on a degraced sleeve using the At:SYS computer program. Experimental work will be cerformed to demon-U strate the conservatism and accuracy of the A';SYS camouter arogram. From Reference 2: q (i) Tube Row 110 exhibits the most severe r"craent due to the lateral LOCA + SSE Icading. (ii) 7he value of *n is morent is 402.5 in-lb. (iii) P, = 0 Po = 770 esi 7-2: 0
.[
0 0- ge p-- Concined Stress Intensity 6 L C'GtJRE 7-13 l_ i-
! 7
[ _- e f
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4
- l. M TABLE 7-1
= .032 in ts
; Healthy Sleeve lis = .281 in i Z = .0084 in 3 Stress (ksi)
, ! i
; t Loading Tyce of Stress ! A 3 i
y . LOCA + SSE ! +47.9 -47.9
! :z = + I .
! , , (Pi - Po)Ris 3.4 '
+ 3.2
~z 2ts i I
, Pressure :, = (Pi - Po)Ris
- 6.3 l' + 6.3 ts or=-Po - 0.9 - 0.3 Stress Intensity = (47.9 + 3.4 + 0.8)
Point A = 52.1 ksi < allowable = 80.6 ksi Stress Intensity = (-47.9 + 3.4 - 6.3) Point B = 51.3 ksi < allowable = 80.6 ksi N t i 7-25
m 1
- e.6 .i a*
W:- -, si if Now solve f<;r tne required siseve wall tntekness of a :egraced f sleeve :) an' iterative solution. TABLE 7-'2 ,
's
.Cegradeo Sleeve. Ris = .231 'n '
Z l Loading - Tyoe of Stress 5*ress (ksi) ' S LOCA + SSE :z = +, ? + 4025
. . .4025 c
, z z U .
q . (Pi - Po)Ris ! +.108 i + 1C8 2ts t t Pressure -:
. (Pi - Po)Ri + 216-
. ! + 216 ts t C f
cr * -Po- -0.8 -0.8 Stress' Intensity = 4025 . 108 + 0.8l <-80.6 ksi Point A _~l C j 9
.4025 x Ros + .108 + 0.8 : < 80.6 ksi l3(ros
.281') (R .231) cs -
Ros
- 302 74.3 ksi + 5.1 ksi = 79.4 ksi < 79.8 ksi ts = .302 in .281 in = .021 in 7-26
6o - fs." t
.j Allowable degradaticn Of s:eeve.
.. .032 .321
.)32
- = 34 7.4.3 Summary of Allowable Sleeve Degradation (i) NRC Staff's Criteria
" Allowable sleeve degradation = 53 (ii) LOCA + SSE
" Allowable sleeve degradation = 34 Based on these results, the maximum sleeve wall degradation oermitted should be 344.
J 7-27
W Ic 0 4a N 7.5 SLEEVED TUEE VIEPAT: Oft AUL*S:S 7.5.1 7+:enten Pescanse Tes:
; test'wili ce carcac:ec anien ~0cels a c!.ste :# sever :s:es w 4 0-
~ 3alisades : late arc *eggc-ste ' L:e s.c:cets.
D e verti:a: s: air: tute region fecn tre L:e snee: to ne nignest "eggcrate" sa:: ort wii' te represen:ed. Several tubes will :e sleeved in a probable sleeving location. Circumferential defects of 64'; and 100', degraca:icn will :e sieulated in the sleevec tubes. The tests will be :encuctec witn shell-side water at room temperature. Using secondary sice aater at room temperature (o = 62.4 lb/f t ) is conservative since tne ocerating secondary coolant is less cense (c = 49.3 lb/ft maximum) and thereby decreases the virtual mass. Primary coolant is omitted from tne test but a compensating density correction will be made to tne test data. At tne completion of these tests, an examination of the tute/ sleeve joints will be made to ensure that vibration has not caused wear of metal surfaces or loosening of tne joints. A :echanical snaker will input a lateral acceleration of 1 G into One base plate, which is connected to the tubesneet, sweeping fr:n 20 H to 200 Hg . g The 1 G case plate acceleration is a more severe forcing func: ion : nan tnat anticipatec in service. The selection of 1 G is predicated on control of test equipment and accuracy in :ne interpre-tation of resconse data. Tube responses will be measurec at several locations in eacn tube span as well as at succort locatiens fer four of the seven tubes in the cluster (see Figure 7-18). Even numeered support olates are used in ene test bundle to provide :ne longest span from the tubesheet to tne lowest tuce succor: plate. I: is conservative to c'odel tubes wnich cass :nrougn alternate :ute su:por plates since longer spans croduce lower natural frecuencies. Da ta from these tests wculd assess the effect of tne cresence of the tube sleeve from the stardpoint of dynanic tube response. In Udition information with regard to natural frecuency and camping would :e obtained. For virgin tubes One fordanental natural frequencies are as follows (Reference 7.10): 7-23 t
a e- .) At t9e t;besreet (Fi.sec-51 cie; s= .j :. n
= f * '"/ ..,{ ;
. # ere - L = 12.0 ic. ,
0.00655 i# E = 29.4 ( 100 osi
= 36.9 e, ~5'C 47 = .00,'7 in.
Between Drilled Suoport clates anc "Eggerates" (Simple-;ircle) 9 37 e' f = n h g{i i Where L = 28.0 in (Tjpical)
= 33.5 H z A comparisen of the ceasured sleeved tube natural frequercies witn t
the frecuencies of virgin tubes will provide a qualitative assessnent of the presence of the sleeved tuces. 7.5.2 Shellside Flow Vibration Test A test wnien 90cels the bundle. entrance regior of secondary fluid (at the tubesneet) nas been conoleted and is generic to all CE steam generators. The test was run at rocm temperature witn a maximun flow rate of 450') GPM. Tube rotion was recorded with internally ncunted strain gages and accelerometers. In addition cressure deco, velocity profiles and water terceratures were recorced. Several tubes in tne paray were monitored simultaneously to determine t e relationship of one tube's movement witn regard to another. All cata was viewed in . a real time mode as well as being recorded on tace. This test enabled a cuantitative acoraisal of ta:e vibration in water cross flow (see Figure 7-19). Since tne tuce external geometry is only sligntly affected by the presence of a sleeve, tnis test data is valid for predicting forcing functions on a sleeved tube.
~.:9
r
) ,. e4 7.5.3 7.:e';i:ratica Oest;* ~r ite-ia Tes 'r; an: ' acirgs in :.e'eeer:e 7.3, iaci: ate tre :rece- an:
v 4: 5:: y #:e:'ag 'an::1 c a. ir tre se::r:a*y '!.t: :.r:'e ec- an:e e;t:-
.as 'ta:: elas;' : e:iirg. ::.i: elasti: ::a:!ieg Oc:.es 49er sa##':ien: #I:w se!a:ity exts:s :: :a: :ne :; e ir a ::icn 'an':9 tee:S
- :ne estaclismnen; Of a feec:acx ecnanism. Inis :a.ses ever increasing am:litu e of vibration antil ei:ner a talance is reacnec between fluic energy a screec an: erergy cissi:ated neougn cam:4rg y :.ae tace or ic: acting ensues. Tre :ertinent relationsnt; is as folicws:
Y V c m * /"- c; critical =Leuf n eo
'inere:
< - Experimental Constant = [ j 2 LF - Length Factor - 16/48 = 0.33 f n- Tube Span Natural Frecuency = 36.9 H d - Tube Outside Diameter - 0.75 in = .0625 f t m, - Tuce Virtual Mass = 0.745 lb/f t 5, - L:garithmic Decremen = 0.157 (s o = 2rt)
- - Camping Ratio = 2.5
- - Fluic Density = 49.3 lb/ft3 For Dalisaces tne secondary fluic buncle entrance velocity in :ne tube gap was calculatec to be 11.0 feet /second at 100% power,
- 7 30 l
4 k..
- M. :
Y 17.6 3EFEPE*lCES FOR SEC'!O*: 7 7.! S.'dE Boiler and Dressure lessel Coce, Secticn * *! f:r *..ciear
. 7essels.
7.2 Letter from David A. Sixel, Consumers Power Cemcany, to the Director of fluclear Reactor Regulation, Ooerating Reactor Branen *10. 1. U.S. L
'luclear Regulatory Commission, dated February 12, 1976, Concerniag Occket 50-255 License DPR-20, Palisades Diant, Steam Generator I be Plugging Criteria ." Analysis to Detemine Allowable Tube Wall De- t gradation for Palisades Steam Generator," January 29, 1976, and Revision 1, March 15, 1976. Revie. ion 2. March 20,1976.
i ' 7.3 - AftSYS. . Engineering Analysis System, User's w arual, Jchn A. Swanson. 1971. , 7.4 CE :C-1120 (Palisades Steam Generator Final Recort). 7.5 Engineering Scecification for a Steam Generator Assembly, Scec. *:o. 70P-002- (Palisades ) . l 7.6 Regulatory Guide 1.61, Camping Values for Seismic Cesign of 'suclear Power Plants. 7.7 " Hydrodynamic Inertia Coefficients for a Tube Surrounded by Rigid Tubes," .woretti and Lowery, June 23, 1975, ASME Publication 75-PVD 27. t 7.3 Testimony of James Knight before the Atomic Safety and Licensing [ Soard in the Matter of 'forthern States Pcwer Comeany (Darf rie :sland !
!!uclear Generating Plant, Units 1 and 2). Occket 'los. 50-232, 50-306, 7.9 "Fluidelastic Vibration of Tube Arrays Excited by Cross Flow," H. J.
Connors, Jr., Westieghouse Research and Cevelocment Center. 7.10 t'echanical Vibrations (Fourth Edition), by J. P. Den Fartog; w egraw-Hill Book Comoany. *lew York, 'l. Y. , 7 30 ; i n- , . -,-..,,-,--.,-,nn-,_,.,.-.,._-,n ,,. _.__ ., ,.,... _,,. . ~ . ,.,,- ,y~.. - -. _ n,, -- -.-..
V. 4 9 3) "[. '#*/seC. 4 4
~e s:ia; *es,.':s dacicate :na: ta:e m:ve'en: anc sa:secuert s *ess a*e a: ?:w 'ese's .e:ti :ne "resaci: :f insta:i:j *s *ea:Pe:. ~ * * : e '.
<y ., co .i:*ati r :* :le~s ara antict:atec #:* vie::a :.:es.
Similarly, unless tnere is large civergence in dynamt: res: case Or natura frecuency De: ween virgin tubes and sleevec tubes, no vibraticn
- rocleas are antici:ated for sleevec tubes. Tne slaevec ta e parameters measured in :ne " Vibration Resconse Test" will be evaluatec f:r critical velocity.
fl 7.5.4 Axial Flow Region lL The 1-1/2 MWt steam generator m'odel duolicates flow incuced vibration in the axial flow region. The model is a minature steam generator with 21 active U-bend tubes, naving an average lengtn Of a:oreximately 25.5 feet. Control features enaole tne parameteric operation of tne model in all ranges of steam cuality, mass flow rate and steam oressure which are experienced in CE steam generators. Vibration cata was { taken with high temperature strain gages mounted 90* apart circumfer. I entially at a given elevation. From tne raw output data, the resultant vibration amplitude as a ' unction of frequency was plottec and evaluated. Final data recuction is in progress but preliminary results are now available. Results from tne 1-1/2 MWt Steam Generator Model Test (see Figure 7-20) indicate a low level of tune vibration in tnis region. The maximum amplitudes measured did not exceec 0.005 inenes. Thus no vibratory problems are anticipated in :nis region wnicn extenas tne 1 erg:n of the vertically straignt tubes. Based on :ne dynamic resconse cata obtained from the " Vibration Response Test" for sleeved tuees, an evaluation of tne maximum ex:ected amplitude of vibration will be mace 'or sleeved tunes in ene axial flow region.
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o Y 3.0 MECHANICAL TESTS OF T'E/SLEDE ASS ELY
- 'ecnanical tes ting of the t ::e/ileeve asse.Dif .vas ::erfor e: to orovite a characteri:ation of its perfor~ance ancer a range of ror al anc postaiated ac:ident steam generator operating conditions.
d.1
SUMMARY
ATiD CONCLUSIONS The looseness, leakage and reaction to thermal / pressure cyling properties of the tube / sleeve assembly were characterized. The capability of tne as-semoly to withstand postulated conditions of loss of coolant and nain steam line break were demonstrated. Preliminary tests indicate potential axial movement of the sleeve in the unpressurized tube of 0.001 to 0.003 incnes end to end, wi th application of a 25 pound load. Leakage rates of 1 to 10 cc/ minute were evident in early internal pressure tests. The preliminary tnermal cycling tests indicate no cnange in joint cnaracteristics (leakage or looseness) resulting from that environment. Uniaxial tensile testing of a sleeved steam generator tube wi th a t h r o u g h w a 11 c i r cur 'erenti al defec t , indicated that more than three times the axial load resulting from the internal pressure effective during a main steam line break is recuired to separate the tube from the sleeve. Pressuri:ation of a sleeve sarple inside diameter resulted in material yielding at greater than 185 percent of the normal operating pressure differential (Criteria 1, Table 3-3) and burst at greater than four times the normal Palisades reactor coerating onissure differential (Criteria 2, Table 3 3). While all of these results are preliminary in nature (results of final testing will be reported later), all Indications are that the repair sleeve is an acceptable technique for reestablisning the structural integrity of a degraded steam generator tube. 3.2 CON 0!TIONS TESTED Vechanical tests are of both a charactari:ing and a cualification nature. [nitially parameters of tube / sleeve mec h a nic al and leak ti gn nes s are measured at econ temcerature and pressure. Thi s inforv tion pro-vides a standard against whicn tubes tested ander accident conditi:ns :an 31
- O be compared. Additionally, the axial strength of the tuce/sieeve joint in resisting seoaration is determined. These three parar.eters , tnen ,
cnaracteri:e tne tuce/ sleeve joint. Tace / sleeve samoles are excosed to loss of coolant accicent (L'CA), main steam line Dreak (MSLB), repeated startup/snutcown and primary ficw in-duced vibration condi tions. The irtent of these tests is to demonstrice the integri .j of the tube / sleeve joint under simulated normal coeration and accident envi ren" ants. Post test examinations are made to demonstrate tnat the characteristics of the joint do not va ry si gni ficantly and the p
- mary pressure boundary is not violated.
Looseness testing is conducted in a fixture wnich applies + 25 pouncs axial force to a sleeve which has been installedinto a steam generator tube sample. The tests are performed at room temperature and pressure. Terp-erature effects c a n b e i g n o r e d since sleeve and tube materials are identical. Pressure was not included in the screening test for ease in handling. Motion is approximately linear up to a force of 25 counds. At 25 pounds, a large increase in force is required for additional sleeve no-tion. Leakage testing, for screening purposes, is conducted at 1550 and 2500 psig internal,1550 psig external and a repeat of tne 1550 psig internal. The two internal pressures are representative of effective maximum normal acer-ating and accident pressures. The external pressure is in excess of the maximum anticipated pressure of 1300 psi for a secondary hycrostatic test and is used to provide for ease in testing. The internal pressure test is re-peated at one condition to verify that pressure cycling of the assertly does not alter leakage rates. All tests are done at room temperature due to tute/ sleeve material identi ty. Uniaxial tensile separation tests are performed at room temper 3ture and 6000 F for unoressurized tuce/sleevu assecolies. ine assemolies a re mounted in a test fixture and pulled to separation. Recordings of load versus separa. tion are made. The test is perfor ed to demonstratc that under coerating conditions, a taoe degraded 100 percent ctreeferentially at its center will J .'
- A 1
not slip on tne sleeve far enougn to ::ermit tortact <ith tne adjacent tu::e
.e + ;n is more tnan :nrw eigrt? s of an incn away. ac ::lica .icn c' the axiv ao sicle internal pressure of 2500 :::ig resalts in an axiai icac 3 # 520 :ounds.
Sinulation of a MSLS is perfomec cy internally oressuri:1rg a tuce/
- sleeve. The test demonstrates that the assemolj will not fail at tne maximum anticioated pressure and tnat a safety margin of mre tnan a factorcf tnree exists against burst at the normal operating pressure differential.
The maximtri internal pressure of 3125 psig was used. This corresponds to 2500 psi at 600 F when ratioing 58-163 yield stengtns (See Table I-2.2, Re ference 8-1) . Burst testing is also conducted to demons :ra te no failure oe-l lov 5610 psig. This corresponds to three times a cifferential pressure of 0 i 1370 psi at room temperature (70 F), wnich is eouivalent to 1700 psi at 600 F ahen ratioing ul timate strengths of 58-163 (See Table 8-1). Test-ing is conducted on a variety of tube center wastage levels including 100 percent. i LOCA simulation testing is conducted by externally pressurt:ing a tube / , sleeve asserely. A collapse pressure in excess of 1200 psig at 700 F is sougnt as this represents the maximum anticipated secondary nydrostatic leak test and is greater than tne maximum secondary ressure of 1000 psi elim- l l ing a LOCA. Tests are conducted on assemblies with four incnes of the l l s team generator tube missing f rcm the center of the tube / sleeve asseroly. . This prevents the tube from adding to sleeve collapse strengtn. j l i Thermal and pressure cycling tests are conducted to demonstrate that plant l I starteo and snutdown cycling does not significantly affect tuce/ sleeve joint i cna ra c te ris tics . An assembly is cycled from cold (2000 F), low pressare, , 0 startup conditions to normal operating conditions (600 F/2200 psig) and back y l J total of 100 times. !
'k 3-3 i
, i 1
l
, i i
f.
.. s lF w
l I [ Tuce sleeve asserolies are ex::osed to a crimary ficw of 25 gpr at 6000F/ [ a C0 p<ig for 1000 nours. This test is cerformeo to investigate the like-j lihood of fretting at the tube / steeve joint region as a result of primary [ ficw inouced vibrations. A test period of 1000 hours is adequate for the f investigation of fretting. 5
~
8.3 RESULTS The results presented in this section are the initial ones or incomplete due to the fact that many of the tests were performed for development rea- [ sons. They are presented for information and will be supplemented with [ controlled condition tests, later. All tests discussed, herein, will be I repea ted. The results found substantiate the capabilities of the sleeve as an acceptable repair structure for a degraded steam generator tube. While these results are preliminary, the trends shown and the magnitude of the results presented are expected to be repeated in final tube /sieeve as . sembly testing. Testing for axial looseness has shown a zero to .003 inch axial motion unoer a reversing load of approximately 25 pounds for all of the 11 tube / sleeve as-sembly samples tested to date. Free floating looseness, as such, has not been found. The 25 pound applied load greatly exceeds service conditions. Figure 8-1 presents looseness test information for two representative sam-pie assemblies. In addition to providing a characteri:ation of tube / sleeve joint properties, the tight nature of the joint indicates that sleeve free-play is minimal. This is beneficial in preventing any tube to sleeve wear or fretting problems. Leskage rates across the tube / sleeve joint were characterized. For internal pressures of 1000 to 2500 psig, leakage ratos of 1 to 10 cubic centimeters per minute (cc/ min.) of ambient temperature water were found with most sam-l pies at about I cc/ min. For external pressures of 500 to 1550 psig, leak-Jge rates of 0 to 20 cc/ min, were found. Af ter the external pressure leak-age tests, a second internal pressure test at 1000 to 1550 psig was ccnducted. 34
muss y ] g
- Leakage rates of 1 to 10 cc/mi,n. again resulted. Additional tests are being performed to characterize the nature of the scatter in leak rates.
-The data indicate rates well below the steam generator acceptable operating rate of 1136 cc/ min. -(.3 gallons / min.). Thus, in addition to its strengtn characteristics, the sleeve provides a significant barrier to leakage.
Uniaxial tensile separation testing of sleeved tube assemblies has shown full separation loads in excess of 3700 pounds force. Separation of tube ends by 1/4 inch required a minimum of 1350 pounds force which is in ex-cess of the 1000 pound level established in Section 3.0 criteria. All tests were performed on sleeved tube assemblies with a 100 percent ciretaferential defect at. the tube mid-span. This indicates that even under worst degradation conditions, the maximum anticipated pressure loads will not result in an axial force sufficient to elongate a sleeved steam generator tube far enough to contact its nearest neighbor, which is 3/8 inches away. The mode of tube / sleeve failure in the separation tests was either the sleeve necking down plastica 11y then sliding through the undeformed tube; or the sleeve necking down and the tute expanding slightly as the two were pulled apart. Figure 8-2 shows the applied load versus axial tube separa-tion. Table 8-2 presents diametrical measurements of separated tube / sleeve assemblies. This information provides the basis for establishing the poten-tial assembly failure mode. A single sleeve has been internally pressuri:ed to failure in an MSLB sim-ulation. This too provides preliminary infomation on sleeve burst pressure margin in satisfaction of Reference 3-1 criteria. The tube indicated yield-ing, by visual observation, at approximately 4000 psig internal. This ex-ceeds the Reference 31 criteria (the first in Table 8-3) of 3125 psi;. ! Burst of this samcle occurred at 3:50 psig. Since these tests were conducted 4t 700F, a burst pressure in excess of 5610 psig shows a safety margin of l I greater than three for the Reference 3-1 second criteria of Table 3-3. Preliminary tneral cycling tests '1 ave been completed with more detailed teceratures tnd cressure cycling tests scheduled. *he retier d s hssed
o b l in Secticn 6.; .vas ;sec for 7:6 rours of steady state a:eration and 42 startuc/snutac.,n cycies. A typical Palisades pricarj cnems try was main-tained at 6CCU F, 2:00 asig. Volatile secondary cnemistry cond;tions were neld at 535 F and saturation pressure. Post test leakage tests at 1550 an: 2500 psig internal,1550 psig external, and a second internal test at 1550 asig revealed leak rates in the same 1-10 cc/ min, range snown in Dase-line tests. (All leak tests were conducted using a leak hole drilled at tne tube mi d-s pan . ) This indicates tnat thermal cycling has little or no effect on tube / sleeve leak rates across the joint.
8.4 REFERENCES
FOR SECTION 3.0 81 ASME Boiler & Pressure Vessel Code, Section III, Nuclear Power Plant Comoonen ts , 1974 3-6
. _k Table 3-1 I
)
$8-163 Ultimate Strenctn Based on 881 tube samples:
Mill reports lists minimum ultimate tensile strengen (Su) as 37.5 ksi at room temperature. An ultimate tensile strength (Su ) of 80.0 ksi at an operating tem-perature of 600 F is found based upon the curves from Nuclear Sys-tems Materials Handbook, TID-26666, Hanford Engineering Development Labora tory , 1975 t t l\ l t
.5 - 7
Table U-2
)
l Diameters of Separated Sauiples 4 4 1 lube
- \ /
sjeeve g Tube i _ _ _ _ _ . - - _ _ .- . _ _ _ _ . _ _. . _ . _ _ f l l l l l l A C E G ! K i I l l Sepa ra tion Di arie ter lotal fiuminal fiomina l (Inches) J Load dt Separation Sleeve Tube
- Assembly 1/4 Inch Load OD OD G E fio . _(Ibs.) (lbs.)
l (inches) (inches) A C E hxl _ l_ byfl I 1350 4293 .628 .746
- .5932 .5943 .5955 .6490 .7457 .//60 2 1800 4512 .628
- .746 .5826 .5856 .6156 .6493 .7478 .7/b6 I 3 --
4387 .628 .746 .6005 .5987 i .5992 .6501 .7463 ./71/ 1 4 -- 3795 .b28 .747 .6131 .6131 .6148 .6526 .7495 ./604 i flu t e: Assemblies 1 and 3 separated due to plastic sleeve sieckdown. l Asseid> lies 2 and 4 separated due to plastic sleeve sieckdown drid minor tube expal.sion, i 8-8 l l l
J Iable 3-3 Criteria for Mini: um Acceotacle Wall Thickress (Reference 3-1)
- 1) Tubes witn detected defects will rot be stressed during the full range of normal reactor operation beyond the elastic range of tube material.
- 2) The factor of safety against failure by bursting under norcal operating conditions is not less than three at any tube loca-tion where defects have been detected.
- 3) Crack-type defects that could lead to tuce rupture either dur-ing normal operation or under postulated accident conditions will not be accectable, i
l 1 J .2 L
. J Figure 3-1 TUBE / SLEEVE MOTION UNDER REVERSING LO AD
+40 , , +40 , ,
+20 -
+20 E
E 2 0
; 0 )
s h e
~
~
_ -20 -20 I I
-40 -40 DISPLACEMENT DISPLACEMENT (1 INCH = .0010 INCHES) (1 INCH = .0010 INCHES)
ASSEMBLY A ASSEMBLY B M 9M
. f,-: 31 2700 ' 8 ' ' '
2650 2400 _ 24 0 2100 - 1800 - 1800
~
1500 -
$ 1350 E
2 1200 - a e 900 - 600 - - 300 - - 0 i i i i i 0 1/4 0 1/4 0 1/4 DEFLECTION, INCHES Figure 3-2 UNI AX I AL TENS ILE SEP AR ATION 9.11 k-
AFFIDAVIT PURSUANT TO 10 CFR 2.790 Combustien Engineerir:g, Inc. ) State of Connecticut ) County of Hartford ) SS.: I, A. E. Scherer, depose and say that I am the Manager, Licensing of Combustion Engineering, Inc. , duly authorized to make this af fidavit, and have reviewed or caused to have reviewed the information which is identified as proprietary in the enclosure document referenced below; that the identified information includes trade secret and commercial or financial information belonging to Combustion Engineering, Inc. , which we believe to be privileged ! or confidential; that the identified information has been maintained as privileged or confidential by Combustion Engineering, Inc. and cannot be obtained from public sources without the expenditure of significant amounts of time and effort and is information the release of which would be likely to cause substantial harm to the competitive position of Combustion Engineering, Inc.; and that this information is of a type customarily held in confidenc.e
- l. or transmitted in confidence by Combustion Engineering, Inc.
l
Enclosure:
Palisades Steam Cenerator Tube Repair Sleeving; CEN-42(P)P, December 10, 1976. Sworn to before me this ! 10th day of December,1976 A. E. Scifbrer Manager, Licensing \ / .. W. ~ I Notary Public r p,r ' * . 8
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