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September 7,1982 Docket No. 50-289 MEMORANDUM FOR: John Stolz, Chief, Operating Reactors Branch #4, DL FROM:
Richard Jacobs, Project Manager, Operating Reactors Branch #4, DL
SUBJECT:
FORTHCOMING MEETING WITH GPUN CONCERNING REPAIR OF TMI-1 OTSGs Date & Time:
Wednesday, September 15, 1982 9:30am-3:00pm Location:
Phillips Building, P-422 Bethesda, MD
Purpose:
To discuss GPUN's explosive expansion repair technique which will be used in the THI-1 OTSGs.
Requested Farticipants: NRC-DEisenhut, Glainas, WJohnston, RBosnak, JStolz, CMcCracken, TIppolito, RJacobs, JRajan FYoung, Region I;NM6iyr-Regio @-
GPUN-RWilson, et. al.
ERCConsultants-FRCLLeonard,et.al.
, fa s, o Richard Jacobs[Pr ject Manager Operating Reacto Branch #4 Division cf Li nsing cc: See next page r< 3, $&A g//4" 3N},
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September 7,1982 4
Docket No. 50-289 l
MEMORANDUM FOR: John Stolz, Chief, Operating Reactors Branch #a, DL FROM:
Richard Jacobs, Project Manager, Operating Reactors Branch #4, DL
SUBJECT:
FORTHCOMING MEETING WITH GPUN CONCERNING REPAIR OF TMI-l OTSGs Date & Time:
Wednesday, Septenber 15, 1982 9:30am-3:00pm Location:
Phillips Building, P-422 Bethesda, MD
Purpose:
To discuss GPUN's explosive expansion repair technique which will be used in the THI-l OTSGs.
Requested
Participants:
NRC-DEisenhut, Glainas, WJohnston, RBosnak, JStolz.
NcCracken TIppo,1jto, RJacobs, JRajan FYoung, Region I; o w,, C ; 7- ' '
GPUN-RWilson, et. al.
NRC Consultants-FRC LLeonard, et. al.
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Richard Jacobs/P ject Manager Operating Reacto Branch #4 Division of Li nsing cc: See next page g
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E ETING NOTICE DISTRIBUTION OPERATING REACTORS, DIVISION OF LICENSING Docket File Regional Administrator I NRC PDR U. 5. N. R. C., Region L'PDR TERA NSIC ORB #4 Rdg JStolz Project Manager-RJacobs GLainas JHeltames, AEOD DELD IE-3 OSD-3 SShowe IE (PWR) or CThayer, IE (BWR)
Licensing Assistant Receptionist, Bethesda.
ACRS-10 Program Support Branch PTKuo (seismic reviews only)
R!1att:on ORA 8, Rm. 542 Meeting Notice File BKGrimes, DEP
$$chwartz, DEP FPagano, EPLB SRamos EPDB MJantour NRC
Participants:
DEisenhut WJohnston RBosnak CMcCracken TIppolito JRajan FYoung, Region !
quray, Megion D
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p e m.w a McD.rmott company 3315 old For ! M d September 13, 1982 P.o. m isso GPUN-82-260 7 d ** " "
.. Mr. D. G. "Slear
-THI-1 Project Engineering, Manager GPU Muclear i
.100 Interpace' Parkway '
Parsippary. N.J.
07054 Attention:
- 8. Elas Subject GPUN(TMI-1)
-M..
.. Master Services Contracta Ef.fective 'Date February 4.1981
.Referenc'e 1tos: 8310:581-7105'. 'GPUNIC 290082 Task 3 - OTSG Tube Expansion Repair Program Information Required to Support Precoat SER Deer Mr. 51sar:
The following questions were transmitted to B&W in a letter from R. C. Suff to R. Baker and J. Corcklin dated September 7,1982.
Responses art provided as follows'
?
Question 1:
Immunol - Manufacturer; comercial industrial or nuclear grade; physical and chemical composition; procurement lead times, costs etc.
_ Answer: Manu,facturer:
Harry Miller Corporation Philadelphia, Pennsylvania Grade:
The B&W Purchase Order will specify that the manufacturer sd,
provide Imunol X 236 and it will invoke a requirement for r"
certification that it meets the contamination levels of the EPUM specification or to provide the results of chemical analyses on the lot supplied for use.
Physical and Chemical Composition:
Liquid - nonionic surfactant Coconut diethanolamide and nonylphenol - 15 ethylene oxide P'rocurement lead tirse approximately ten days for intermediate quantities. Cost approximately $5.00 per gallon.
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September 13, 1982 Question 2: B&W certification that Imunol will satisfy limits of GPUN SPEC 1101-22-006-R4 (chemical constituents).
Answer: Certification'to meet GPUN specification 1101-22 006-R4 will be prtivided via certification from the supplier, chemical
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analysis from the supplies or chemical analysis from 84W. A minimue of one week following receipt of sample is required for 88W to perform chemical analysis.
Duestion 3: B&W confimation/ certification that Innunol maaining in the
-,RCS will;.have:no. deleterious,effect on performance / safe operation of' the primary system.
Answer: saw will provide a letter to GPUN documenting that Immunol X 236 is acceptable.for use on RC5 components and that residue maaining after removal by felt plugs or wiping and water flush will not have a deleterious effect on performance and/or operation of the primary system.
For the specific case of TMI-1 however, additional work is underway to test for reactions with combinations of sulfur and kinetic expansion residue..
Question 4:
B&W technical description and sketches providing the method of precoating and cleaning /rnoval, anticipated doses for precoating and cleaning / removal, anc A' ARA assessment.
Ar.swer: Application / Removal:
The application method of Immunol will consist of a three part system:
i (a) Spray to coat the heads and tubesheets.
(b) RecirEulating system to apply Instunol frcut the upper tubasheet down through the tubes, and (c) A pipe ring in the lower head fed with air to bubble innunol up through the tubes.
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- Babcock s WDcom. September II. 1g82 The removat method.wf11 be to use Ph controlled domine'ralized water to wash down the coated surfaces.
Inaccessible areas will be isolated.
Felt plugs will be used as part of the,
removal of expansion residue and will be blown through the tubes.
Inaccessible areas:which will be plugged include:
(a)
Hot legs, cold legs, and (b) Tubes with explosive plugs in the upper tubasheet Radiation exposure estimates will be provided when the deteils v
of the tooling have been identified.-
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Ouestion 5:
Ispect of' introducing Issunol to the secondary system (small enount of leakage through cracked tubes). Also a discussion
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of the effect of leakage into the crevice p.rior to expansion.
Answer:
The introduction of Innunol into the secondary system in small quantities is not considered a contaminant problem for two reasons.
First, the secondary system is equipped with cohdensate pol-ishers, which are capable of removing contaminents from the secondary system prior to plant startuo.
Secondly, at operating temperature, Iseunol'will volatilize'in the secondary system, and subsequently be removed.
i For the specific case of TM!-1, the secondary side nitrogen pressure should be maintained higher than the primary side pressuru during the time period up to the completion of expansion.
Inaunol in the crevice prior to expansion might prevent forming a good joint.
1 should you have any questions or comments regarding this information please contact me at (804) 385 2611 in Lynchburg.
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- yours, L.4 J. Stanek Engineering Product Manager
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Lett::r No.. 0317-34-82
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O-m INTRA LABORATORY CORRESPONuENCE ~
OAK RIDGE NATIONAL LASORATORY August 17, 1982 To:
- 1. W. McClung From:
C. V. Dodd C. V. OM
Subject:
Travel to Harrisburg, Pennsylvania, August 8-9, 1982 On Monday, August 8, I est with General Public Utilities (GPU) and IRC personnel to discuss the eddy-current inspection of the Three-Mile Island Unit 1 steam generators. A partial list of attendees is attached.
Nick Ma'anas of GPU 3 ave a presentation of the development and s
qualification program for the eddy-current inspection of the steam l
generators. A set of inside diameter calibration standards with circumferential notch lengths of 0.060, 0.100, and 0.187 in., notch depths of 20, 40, 60, and 80%, and widths of typically 0.004 to 0.005 in. were constructed.
In addition, an asial notch standard with 0.060 in. long notches was constructed.
These standards were used to test circumferential differential probes of
' O.510 and 0.540 in., and an eight-coil array with 0.187 in. outside diameter pancake coils.
Various gain and other conditions were run. The best combination for the differential coil system was the 0.540 in.
outside diameter probe with a permanent angnet saturating core and a gain setting of 60. The permanent magnet should not have increased the signal any but only reduce the noise a small amount.
I examined a probe and its figid did not seen strong enough to saturate any ferroessnetism associated with Inconel (about 0.3 T is usually needed). Nowever, it did seem to be more carefully made than the regular 0.540 in. probe. An additions 1 mix of the 200 and 400 kHa mixed signal with an 800 kMa signal reduced the noise due to probe chatter and pilgering.
The 811 absolute probe showed more signal to the small defects at a gain of 53, but a fairly large lif t-off signal was also present. The 8X1 probe array is being revised to increase the probe body from 0.520 to 0.540 in, which should reduce the lif.t-off,probles.
' A correlation of the ' defects seen by the pancake coils with the defects seen with the 0.540 in. outside diameter differential probe showed that of 3233 defects detected by the pancake coil, 3216 were also detected by the difforential. probe. This maber was improved to 3229 by using the, min. to reduce the inside disaster noise. This shows an excellent astch and also showed that the 0.540 in. differential probe, operated under these conditions, can reliably detect the same type of circumferential crack.
In order to directly apply the results obtained from the electrodischarge machined standards, an " effective antal crack width" for these intergranular stress-corrosior ' cracks met be determined.
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. August 17. 1932 on Monday aftornoon, John Janiszewski of GFt1 gave a presentation of the results of the metallography of the cracks.
Some cracks appeared to.have regions of bulk intergranular attack associated with them, and some appeared to be very narrow with very little branching and axial component.
However,'the crack would only need a few branches to offactively disrupt the flow of eddy currents.
John Janissevski will generate an " effective axial component" by reviewing the results of the previous antallography and furnish it to us.
This number,will show how applicable the calibration results from electrodischarge machined notches is for the circumferential cracks, and furnish an independent verification of the ability to detect the defects
_ with a different probe. he results of a dimensional analysis experiment using large scale models at ORNL will be used to correct the sensitivity at one length to the sensitivity at another.
It was stated that the region near the crack was depleted in chrone, but no estimate was ande of the bulk electrical and angnetic properties of the region. A total of 19 ft of " good" tubing has been examined by antallography, with an additional 6 ft to be examined. No defects were detected by-this test that were missed by the eddy-current test.
Some of the defects detected by the eddy currents were not found by the estallographic emanination, probably due to the way the samples were cut. some of the eddy-current signals turned out to be due to annufacturing, handling, and assembly artifacts, and would not be detrimental to the service of the tube.
On hesday I visited the data reduction site at the Most Inn "near the plant.
I reviewed the results of the scan on tube A71-126. his tube was pulled and a section sent to ORNL for examination. A through-wall defect wa's detected using a high-frequency (5 Nia) scan with a small (0.020 in.
mean radius) probe from the outside. S e defect was then etched and showed a 0.005 to 0.010-in.-wide affected region on the outer surface.
It is not known if this entire region appears as a low conductivity region or not. The defect was record,ed as,80% through-well by ConAm, and a blind remeasurement of the defect from tape showed 842. The angnitude of the signal was 1/2 V at a gain of 34, and an 0.510 in. outside diameter differential probe was used.
I also looked at runs using' the d.540 in. outside diameter differential probe with a sain of'60. he practical noise level to est a reasonable measurement of the defect depth appears to be around 0.5 V, although in many cases smaller defects can be measured.
Based on the 0.005 in. wide standards, this falls in the range of a 0.060 in. long defect, 40%
through-wall.
Depth usasurements on smaller defects will probably be very insecurate.
A 100% inspection of the full length of all the tubes is being performed i
using the 0.540 in. probe with a sein of 60. The number of indications is about three times as many as were observed with the 0.510 in. dif ferential j
probe. Tube 310-48 shewed 16 inside diameter defects, all about,1 Y in l
amplitude, between 30 and 60% of the wall.
he lowest defect was near the third support plate. he high sensitivity of this nov inspection is'sise j
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, P.sgo Thrao Aughst 17, 1982 picking up a mober of outside hiameter signals from the annufacturing process, which are not detrimental to the service and can be ignored. The-tubes that exhibit the inside diameter signals should be rescanned with the 8X1 pancake coil array, and the tubes with defects greater than the plugging limit plugged. The tubes with defects below the plugging limit can be reexamined at later intervals to monitor growth of this type of defect.
There appears to be a drifC and a quality assurance problem with the probes. This probles doesn't affect the accuracy of the test, but results in frequent probe changes. The inclusion of several of these types of defects in an in-line standard (for future tests) should be considered.
.The instrument gain in the field is set to give a repeatable voltage amplitude from a drilled hole flaw, rather than an absolute maber.
The pancake coil array is operated at a single frequency and unch more
' susceptible to different types of noise than the differential probe. This array also requires m ch more equipment than the differential probe.
Zetec is working on a more compact system, but no estimate of the availability of this instrumentation was given.
. The results that I saw on Honday and Tuesday answered all the previous questions that Emmett Earphy had submitted in his letter of April 12, 1982,.encept the one on safety evaluation.
Some attempt should be made to determine how large a defect would have to be before it would present a safety problem. I feel that the defects that can now be reliably detected are sich smaller than those that would present a hasard, but have no information to back this up.
The study, done by the utility, their contractors, and the EPRI NDE Center to determine their sensitivity limits, was outstanding.
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J. C. Criess F. J. Homan N. Masanas, GPU A. L. Lotts C. McCracken, NRC J. Ikascara, NRC F. Patriarca C. M. Slaughter J. H. Smith F. Es, NRC C. V. Dodd/ File 4
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