ML20126B701

Summary of 820628 & 29 Meetings W/Util Re Steam Generator Recovery Program.List of Attendees & Util Presentation Encl

ML20126B701
Person / Time
Site:	Crane
Issue date:	07/14/1982
From:	Jacobs R Office of Nuclear Reactor Regulation
To:	Office of Nuclear Reactor Regulation
Shared Package
ML20126B295	List: 05000289/LER-1981-013, Forwards LER 81-013/01T-0 Re Leaking Found in Steam Generators.Event Reportable Per Tech Spec 6.9.2.A(3). Supporting Documentation Encl IA-84-897, Forwards Safety Evaluation Re Increase in once-through Steam Generator Primary to Secondary Leakage Rate,Per NUREG-1019 & Suppl 1.Rate Acceptable ML20126B293 ML20126B302 ML20126B316 ML20126B321 ML20126B337 ML20126B342 ML20126B358 ML20126B376 ML20126B390 ML20126B412 ML20126B435 ML20126B467 ML20126B475 ML20126B493 ML20126B504 ML20126B513 ML20126B520 ML20126B560 ML20126B563 ML20126B585 ML20126B592 ML20126B610 ML20126B618 ML20126B623 ML20126B635 ML20126B639 ML20126B648 ML20126B650 ML20126B656 ML20126B658 ML20126B667 ML20126B670 ML20126B684 ML20126B688 ML20126B701 ML20126B708 ML20126B716 ML20126B719 ML20126B739 ML20126B751 ML20126B758 ML20126B766 ML20126B784 ML20126B797 ML20126B806 ML20126B825 ML20126B831 ML20126B879 ... further results
References
FOIA-84-897 NUDOCS 8506140186
Download: ML20126B701 (74)

Text

,

UNITED STATES y

p, NUCLEAR REGULATORY COMMISSION 7;

.. j WASHINGTON, D. C. 20555 g...++,/

July 14, 1982 Docket No. 50-289 FACILITY: Three Mile Island, Unit' No.1 (TMI-1)

LICENSEE: GPU Nuclear Corporation (GPUN)

SUMMARY

OF MEETING WITH GPUN ON JUNE 28 and 29, 1982 CONCERNING GPUN'S STEAM GENERATOR RECOVERY PROGRAM

Background

In late November 1981, while the plant was in a cold shutdown condition, primary to secondary leakage was detected in the Once Through Steam Generators (OTSGs). GPUN has conducted an extensive program in the areas of failure analysis, tube repair techniques, inspection for the l

corrosion of other Reactor Coolant System (RCS) components, and E

Eddy Current Testing (ECT). The purpose of the June 28 and 29,1982 l

meetings was to update the NRC staff and their consultants en GPUN's current progress with these programs. The June 28th meeting was a working level meeting to discuss the results of GPUN's RCS inspection and metallurgical examination results of removed steam generator tubes.

At the June 29th meeting, GPUN briefed the staff and consultants on qualification status of the explosive expansion tube repair technique i

to be used to repair defective tubes within the Upper Tube Sheet (UTS).

Copies of GPUN's presentations and a list of attendees are enclosed.

Discussion 1.

RCS Inspection Results GPUN presented the results of their inspection of RCS components which was conducted in April and May 1982. A total of 22 different inspections and tests which involved over 1,000 selected components were conducted with no evidence of an intergranular stress corrosion

('IGSC) prnblem. Prior to conducting the inspections and tests, all RCS materials were categorized as to their susceptability to IGSC and representative materials were selected for inspection and/or testing. Various Non Destructive Examination (NDE) techniques were employed including ECT, dye penetrant testing, Padiograph testing, ultrasonic testing and video.. Additionally, three components of materials considered highly susceptible to IGSC were destructively examined using metallographic techniques.

Functional tests of incore detectors and reactor vessel vent valves were also conducted. No significant problems were found on any of the tests and inspections. The RCS inspection plan and results are docudiented in BAW 1727 dated April 16, 1982 and GPUN Technical Date Report No. 343 dated June 11, 1982.

\\

8506140186 850125 PDR FDIA DETJENS4-897 PDR 49

fb S.

s 4

-3 The primary repair criteria is to. establish as low as reasonably achievable allowable primary to secondary leakage with a seal able to sustain with adequate margins, the design basis loads.

The largest design basis axial load is achieved during a Main Steam Line Break (MSLB) where tensile loads may reach 3140 pounds.

Foster Wheeler, under direction of GPUN and B8W, will conduct the expansions. Qualification testing conducted to date indicates that an 8 inch expandian is able to withstand pullout loads greater than 4500 pounds.

It is highly possible that the expansions will be conducted in two steps; one detonation to expand the tube and the other to tightly seal the tube against the UTS. Additionally, it is presently planned that the expansions will be done one row in the OTSG at a time. Additiona.1 testing for pullout strength, effect of neighboring detonations, effect of corrosion, leak rate testing and thermal cycling testing is ongoing, but the interim results are encouraging GPUN has also planned a full scale test at' the B&W OTSG in Mount Vernon, Indiana which will be conducted in late July. Assuming no major delays, it is estimated that sufficient qualification testing will have been completed by mid August to permit commencement of repairs in the OTSG at that time. Under this schedule, GPU estimates that the OTSGs could be repaired and the plant ready for service in November 1982.

i i

Richard Jac s,

)roject Manager Operating R ac rs Branch #4 Division of censing

Enclosures:

1.

List of attendees j

2..GPU presentation l

i

-i 9

e6 -

O o

ji*

ORBd4:DL MEETING SUM 1ARY DISTRIBUTION Licensee:

GPU Nuclear Corporation s

• Copies also sent to those people on service (cc) list for subject plant Docket File NRC PDR L PDR ORBd4 Rdg TNovak JStol:

Project Manager-RJaco.bs 1

Licensing Assistant-RIngram OELD Heltemes, AEOD 4:

IE SShowe (PWR) or CThayer (BWR). IE Meeting Sunnary File-ORB #4 RFraley, ACRS-10

' Program Support Branch.

ORAB, Rm. 542 BGrimes, DEP SSchwartz, DEP

.i SRamos. EPDB FPagano, EPLB i

Meeting Participants Fm NRC:

3-HDenton PGrant I

Glainas RBosnak MGarrington SBajwa i

CMcCracken LFrank f

KWichman CSellers RConte-Region I HConrad i.

t HGray-Region I PMatthews EMurphy-RMartin i

JRajan MWilliams

}

CCheng EBrown t

CSchulten j

WCollins' PWu t

't l

LIST OF ATTENDEES - MEETING WITH GPUN JUNE 29,1982 TMI-1 STEAM GENERATOR RECOVERY PROGRAM NRC GPUN GPUN Consultants HUenton 15TiTson JPearsen, B&W TNovak DSlear*

RKosiba, B&W Glainas EWallace.

RCoe, B&W JStolz FGiacobbe*

BBarrat, FWEA RBosnak JColitz SWeems, MPR, Assistant CMcCracken*

DBedell HBehnke, B 8W**

RJacobs*

MGraham*

KWichman RNeidig RConte(Reg.1)

WWilkerson**

HGray (Reg. 1)

NKazanas**

Other Mi'iifk, PANE EMurphy a

RMartin NRC Concuritants MLewis JRajan*

JWeeks, BNL*

LConner, NRC Calendar NWilliams CDodd, ORNL JBergan, EPRI**

CChang*

CAverbaco, BNL EBrown RNewman, BNL*

CSchulten*

RBandy, BNL WCollins D. Van Rooney, BNL*

PWu*

'RDillon, PNL*

PGrant TShook. FRCA MGarrington EMucha.

FRC*

SBajwa*

ULuk, FRC*-

LFrank LLeonard, FRC*

CSellers**

CDavey, FRC*

HConrad**

PMatth ews **

t

• Also attended June 28, 1982 meeting

• • Only attended June 28, 1982 meeting 4

4 i-l 1

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TMI-1 STEAM GENERATORS GENERAL INTERGRANULAR STRESS CORROSION CRACKING FAB HISTORY MET LAB I

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OPERATING HISTORY CHEMISTRY DESIGN IMPURITIES FAILURE -

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MATERIAL FAILURE MODE, I.E., INTERGRANULAR

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O ONLY SLIGHT VARIATIONS EXISTED BETWEEN UPPER AND LOWER TUBESHEETS AND FRCti CENTER TO OUTER PERIPHERY OF A PARTICULAR TUBESHEET.

O BASED ON CCNPARISON WIm ERI WORK, ALL TUBES ARE EXPECTED TO BE lNIFORMLY SEVERELY SENSITIZED.-

O PREDICTION OF UNIFCIN SEVEPE SENSITIZATION CCRRELATES WIm RESULTS OF ACTUAL TESTS (STHt E R, MODIFIED HUCY).

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TABLE 18.

ESCA BINDING ENERGIES AND STATES OF EI.DiESTS ON SPECIMEN C FROM TUEE A71-126 l=

Depth '

j' Sputtered, Ratio S-2 sg4=

j.

A Ni Fe Cr C

S f

None 856.0 Ni(OH)2 711.0 FeOOH 577.0 Cr2 3 285.0 C 169.050 -2 0

0 4

30 856.0 Ni(OH)2 711.0 FeOOH 577.0 Cr2 3 285.0 C 169.0' SO.f2 0

1.0 162.0 S-2 I

630 852.0 Ni 710.0 FeO

' 577.0 Cr2 3 285.0 C 169.0 SO -2 2.0 0

4 162.0 S-2 1230 852.0 Ni 710.0 FeO 577.0 br2 3 169.0 SO -2 2.0 0

4 162.0 S-2 2430 852.0 Ni 710.0 FeO 577.0 Cr2 3 162.0 S-2

- > 10 -

0

[.

855.O Nio 3630 852.0 Ni 710.0 FeO 577.0 Cr2 3

> 10 0

855.0 NiO

e

'6 e

e e

e 53 II8 C.3 Alld e Co)

A6M coa u

Ce 49 u

be 6

Se 8

o se ese 8

4 2.

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le

.le il 27

• 28 29 8

I 2

3 4

5 Inches s a.

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f2 u

c a se g.

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• Mg

• 8 8

o u4 2

g 3

1 2

3 4

5 'ga gg 27 23 29 Inches A

se i.; e.,

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alw C.)

25 -,

ace O. 2e b

4 is

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'. O e

.) '

M

< to e

• 58 8

2 3

4 5

'I s il 27 26 29 Inches i

Figure 2.8.1 Concentrations of Nickel, Chromium, and Iron as a Function of Distance From the Top

/

s O

g.

....w.

~.

I:

f

0. D. OBSERVATIONS O. D. DEPOSITS DO 'NOT CC'MR THE ENTIRE TUBE SURFACE Ato ARE OF COLORS THAT MAY BE NICKEL-SULFUR COMPOUNDS.

lh INTERGi&M CRACKS HAVE BEEN FOUND ON THE 0. D. SURFACE SMALL AREAS OF ILUERGRANULAR ATTACK A FEW GRAINS DEEP HAVE BEEN FOUND ONLY IN SCATTERED LOCATIONS.

o t

e wa -

s - w ~ e-w I

+e,e

-.w.,

,-sn

-..~w.

mea,no

- e n s, o.

o

u SIUiANALYSIS a

ESULTS "4

a N b b.

GPflf b EVAU ? TION ]

[kh0N, INI C0f0lTION Tl K N0.

EAT to.-

.% C n!B-33-30 i

M2867

-0.031 8.5 AS-R9mED AFTERSERVICE SEVERELY -

I a

SENSWZED jB-33-30 M2867

.031 34.5

- CARBIDES

A-133-74 M2408

.035 6.5 NEARLY A-133-74 H2408

.035 0.1 t B-11-23 M2320

.055 7.0 CONTINUCUS 4

,i!ARCHIVETUBE M2320

.0VI.055

-MIu. ANNEALED AS-RECEIVED 13-15%

tbTSENSITIZE ii

.041.055 M.A.&~

AS-FABRICATG 9%

SEVERELY STRESS RELIEVED SENSITIZED 115(P F,18 HRS r

i B-111-62 M2560

.045.047 289 AS-rewed AFTERSERVICE SPECIMENS NOT n

YET CUT FROM lA-78-32 M2348

.029 12.5 1

TUBE i

i I

l IhTgs: 1 - AXIAL LOCATION FROM UPPER TUBESHEET FACE 1

i

a e,

FIGURE Vill-2 TUBE A 11-66 WALL THICKNESS 037 e

O O

O h

NON-ROLtFD 036

-x l

9 PERCENT WALL REDUCTION IN ROLL I

I

[

AREA = (.0363.0353) M 00) = 2.8%

p

(.0363)

O 3

v O

LENGTH OF ROLLIS ABOUT O.6 INCH 035 ROLLED PORTION OF TUBE I

O 1

2 DISTANCE FROM TOP OF TUBE SPECIMEN, INCH (ZERO DISTANCE IS ESTIMATED TO BE ABOUT 1/16 INCH BELOW TOP OF TUBESHEET) 0 m

ee

--e-w ee we m.e.,*.---*ww.we=e.

j.

3 3;

M'_

EONICAL TESTING RESLLTS

' {G)jlED S

1 B-:

TIEE N0.

A-71-126 B-33-30 A-13-8 i

HEAT lb.

M1617 M2867 M2'108 t

i AXIALLOCATION 607/16-6811/16" 331/11 til 3/ft"-

25/15-107/16" 2

{

T.S.

101,000 PSI 101,000 PSI 59,300PSl 80,000 PSI i

2 Y. S.

53,000 PSI 55,000 PSI 50,700 PSI 35,000 PSI-I ELONGATION

'33%

32 TBSILELOAD

6089La, 30T/ts.

YlELD LOAD

3306Ln, 260ts.

[0JES:

1 - TUBE CONTAINED 99" lai DEFECT IN MIDDLE OF AREA 2-BASEDON75%OFORIGINALCROSSSECTIONALAREA

EDDY CURRENT CORELATIONS - ECmD 1 & 2 (CONT.)

LCCATIONS ti-1-

~0TSC

.AB

.BE?O IEST LOCATION ItBE D

k LOCATICM 1/4 - RT (1.25-1.50) A-12-62 1.0 RT RT 13/8 1.50 A-13-63 1.7 1.25 1.25 A-62-8 1.0 1.0 1.25 1.25 RT RT A-133-74 0.6 05'1 9

1.5 1.

B-10-29 1.0 NE 1.25 B-8-25 RT,1.5 NE 1.25,'1.5 1.25

~

B-11-23 1,1.75 NE

.75,1.0 1.25 A " 93 RT RT

[0 A-88-11 RT RT 1.25:

1.25 A-112-5 RT RT 1.25 1.25 A-71-126 RT RT

,AD A-16-69 0.8 1 69

.31 RT RT TOTAL.CATEGmY 12 15 11 9

12 NOTES: NE - ibT EXMINED ND - ibT DETECTED l

a EDDY CLRRElE CORREL.ATIONS - ROUND 18 2 (CONT.)

LOCATICNS EL Ulbb..

li-EEhn$1SUAL LOCATICN IUBE D

A R

IEST 10-24 A-11-66 11,75 11.75 11.69 11.6

~

B-33-30' 23.3 lbTE 2 '

A-146-6 10

. 10.3.

10.25 10.5 TOTALCATEC 3

2 2

3 2

lbTE 2 30% DEFECT CALL IN LABORATCRY EC -ib CRACK

_CCATICNS

... EC Uldo.

1-EEFONISUAL LOCATim IUBE D

A a

TEST BEu>i(HS A-71-126 53 lbTE3 TO A-13-63 27 27 26.8 26.8 15THTSP A-133-74 31 31 32 32 R

R S

S TOTALCATEGmY~

3 3

3 4

3 tbTE 3 - f.'O CRACK.- MECHAtllCAL DAMAGE i

e i+++-

. % ww. w+ +.

4.J. g e

m. es*,. mew ego e e.. = = =

e--.

OTSG-A Tubes With Eddy-Current Defect Indications Located Below Upper Tubesheet

.A

,103

.. + u i

.m -

12

,g f5 4

100%

lNSF A* 7 s

.L 12 j,2 * ~

o I

j

( f n1 htt' 4

~

n--

1 or li v m, A

D q

g-D 1

m-

' (;4. -

O l

ri

.. ql t j, '

l 1

w =, -

Ij 34%

ti INSP

,y 0

Y'~ ~

Q 1

R/

O TOTAL Tust$ WITH

'u'"f' 8* ""'

REFECT 3 BEE 0W THE

~

S ;.,

i.

O UPPEN TUSE5 MEET 140*

~7 (L

1s '

q

?* < c K-QV

'b i

1 l

• nWest teseseewisenssure thuis ese (1) defect iedicatese. Esemi deless is tehe saa beted, ee#y.

8/7/82 4

nno.a~---

a w

~~*=***W+-

' " ~ ~

• x

I

'o -

SIMVRY - EDDY CURREhT vs. ilh1T CORFELATI0fS jl

'O IN - 0TSG EII)Y CURRENT RELIABILITY WAS LOW IN THE TUBE END AhD ROLL BANSITION i

AREA (SINCE THESE TUEES WERE REMOVED, SPECIFIC TECHNIQUES TO INSPECT THIS AREA MVEBEENDEVELOPED).

3

-i O BELOW THE ROLL TRANSITION, THE IN-FIELD EDDY CURRENT TECHNIQUES DETECT ACRIAL

~f DEFECTS WITH M RELIAEILI1Y.

a O ND UNDETECTED DEFECTS HAVE BEEN FOUND BELCW TE ROLL TRANSITION AREA DURING i

)

.T}E LABORATORY IhVESTIGATION.

O LABORATORY EDDY CURRENT TECFNIQUES TEND TO DETECT INDICATIONS WHICH ARE N REVEALED AS DEFECTS ON BENDING. THIS IS IN LARGE NEASURE EUE TO A LAC j

- 1.D. DEFECT CALIBRATION STANDARDS IN THE LABORATORY.

O l.ABORATORY EDDY. CURRENT DETECTS DFAGE FROM THE TUBE PULLING OPERATION.

i.'

i.

t{

l a

Si f

r 1

t I M

6 s

\\

n l

s, :

t J-

1.

e t

TABLE VIII-1 Tube Residual Tensile Stress l.

1-Location Axial Circumferential Wald HAZ 22,000

-22,000 Roll (center)

-10,000

-ZZ,.00(t Roll Transition 22,000 22,00G

.Relow Roll Transition 0 to 22,000(1)

@ en 22,000(1) l e

j (1) Tube stresses below the roll transitiam are pr4==r41w due to l

the tube straightening naamfacturing F-and; asyc very con-siderably depending on the loemefa= within,the tube i

,i!

nazz m t-z kximum Applied Load. Tube Streseen (pst) i Awe =r Location Center Tahe atteer Tube Circunferential Weld HAZ (1) 0 0

10,000 Roll (center)(1) 3,000 6,000-0 Roll Transition 6,000 12,000 10,000 Relow Roll Transition 6,000 12,000 10,000 8

- G.

(1) Roll joint axial load capability assumed to be at least 800 lb per B&W tests, which indicate a load capability in excess of this g

f value.

I

,j (2) These values are estimated; accurate values can be calculated if the detailed configuration of the joint can be determined.

?

[l i

'I TABLE VIII-3 i

Summary of Stresses Maximum Applied and Residual. (psi)

Axial Circumferentisi (2) i tocation Center Tube Outer Tube l

Wald HAZ 22,000 22,000

-12,000 Roll (center)

-7,000

-4,000

-22,000 Roll Transition 28,000 34.000 32,000 Below Transition 6,000 to 28,000 12,000 to 34,000 10,000 to 32,000 i

s 4

n t

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

,._..,y

__,_, -.,4

n

.?,

FIGURE Vill-1 CLADDING WELD ROLLED AREA (WITH WALL THINNING)

TUBESHEET p TUBE smmmum ET En l { TUBE ROLLTHANSIflON I

l l

l WELD HAZ l

{

i l

l i

}8 l

,g AX1AL l

l 1

)

z i

i l

\\

l 9

i w

n-i 5

l 1

,(i, r

STRESS WITHIN O

TUBE z9 I

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m I

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u POSITION (SEE ABOVE SKETCH)

TUBE /TUBESHEET ROLLED / WELDED JOINT ESTIMATED DISTRIBUTION OF TUBE RESIDUAL STRESSES

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{

Top of A11-66 i

1 i

=

r INEED ltNESTIGATI0il 0F 3RD PCGD ME SKFLES

1) CHECK SL'LFtR REMWAL EFFICIENCY BY CHBi!C/L CLEANING.

2) CECK FOt GENERAL IGA ON INSIDE SURFACE.

3) CECK FOR IGA ON OUTSIDE SURFACE.

4) ANALYZE I.D. DEPOSIT BY WET CHU41STPY METH(ES.

5) VERIFY EDDY CURRENT RESULTS BY EXTENSIVE CUTT!!G AND BENDItG.

ITEMS TO BE RESOLVED

1) PRESENCEOFIGAON0.D.OFTUBES

2) PRESENCEANDEXTENTCF0.D."oRY-ouT"DEP0' SITS.

3) FORM OF CARBON IN THE SURFACE FILMS.

4) FcRM OF NICKEL AND SULFL'R #D W.E NATURE OF THEIR ASSOCIATION IN TEE SLRFACE FILMS.

5) CORRELATION OF STMOARD DIFFERENTI L AND 4 X 1 ABSOLUTE EIDY TECHNIGUES.

O se

,a, m.

,.4

,mm.

i THIRD 10f0 LEE TED//L Tism ib.

Pasm Puu To TSP A-2W!

MAJIPLE DEFECTS 15 A-78-32 m m lueE/ GOOD AREA 15 A-111-13 VERIW EIIW CURRENT 10 A-37-29 LOW LEVEL DEFECTS 9

B-16-22 LIP CRACK, GOOD TUBE / BAD AREA 15 B-27-W G0aoTusE/BADAREA 15 B-34-19 INCOMPLETE EXIT SIGNAL 15 B-S4-27 LOW LEVEL DEFECTS 10 B-111-62 GOODRBE/bODARE 9

~-

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j.

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ASSESSIFPRIMARY #

f SCREENINGIESTS C00uNT ST!u. Y,t,,9 '."

TODUPLICATE a

[

AGGRESSIVE 6'- A]

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E"

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g,, m e VERIFYCORROSION t

%f SCENARIO WILL CRACKS # y,.t i w,w uxM e (n4 i u:

v d

1. N 4--

PROPAGATE IN ~ syd u 4 or'~/ M H*y164 l

REPAIROUAL.

PRIMARY C00UWT.u wi PARAMERICSTUDIES l

TESTitE l

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/

i S

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PARAMETERS 0 SECONDARY i

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--.--.---.--p LEADIESTS l.0tM IERM 9

OPERATION 4.----

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Hrr gy.

OPRIMARY f

i

'(

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

f TUBEEXP#lSION00ALIFICATION CORROSION TESTItti - SHORT TEBM l

' - ELa.in0 CHEMICAL CORROSION IEST TO ASSESS EFFECT OF RESIDUAL STRESS PROM EXPLDSIVE EXPANSION A. - INCONEL TUBE /INCONEL TUBESHEET SINGLE TUBE MOCKUP

- 10% NCH sowTION

- 55$ F TEMPERATURE

- RX.ARIZE' AT CRACKING POTENTIAL

- TEST UNTIL CRACKING IS OBSERVED m 5 DAYS MAXIMUM B. - INCONEL TUBE /INCONEL TUBESHEET SINGLE TUBE MOCHUP

- 1 PPM THIOSULFATE S0WTION

-1700a5500FTEMPERATURES

- TEST UNTIL CRACKING IS OBSERVED OR 5 DAYS MAXIMUM 6

l l

l L

ss PAGe10F2 LDE TEM CORf0SION TEST PROGM1

~

LEAD TEST WJECTIVE:

MICATE IFT SEQUENCE Als TYPICAL REACTOR @TRATION IN TE LABORATORY TO ASSESS EWIROMENTAL EFFECTS ON TUBE PERFOMMCE. THISTESTWILLLEAD i

ACTIPL 01SG OPERATION AIO ATTEMPT TO DUPLICATE PUWED OPERATIONAL SEQUENCES.

i i

TEST IHMTIW:

AreRaXIt%TELY 12 MONTHS i

TEST SRCIEI6:

C-RINGS ACTuALTMI11BING Fin SECTION TIBES TET PARMETERS:

CHEMISTRY -

TYPICAL PRIMARY WATER CEMISTRY WITH CONTAMINANTS AT MAXIMUM SPECIFICATION LEVELS IEMPERATtRE -

AMBIENT TO 6000 F WIm TEMPERATURE CYCUNG LOAD C-RINGS SR ESSED AT 907. Y.S.

FULL SECTION TUBES LOADED M ll @ LBS.

CYCLED DURING C00LDOWN 6/22/82

.[;

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~

./

PAGE 1 0F 2 CORROSION TEST P10 GRAM CORROSIONSCB%RIO-TEST PARAYTERS TEMPERATURE:

IFT THERmL CYCLE - 14 DAYS MATERIAL:

HT. M1671 - ACTUAL IMI ILBE

- SPECIMENS:

C-RINGS L' -

STRESSLEVEL: YIELDPOINT TESTSOLUTION: BORON

- 350 PPM LITHIlN -

.6 PPM iYDRAZINE-12 PPM CONTAMINANTS:

1) IHIOSULFATE - 1 PPM

2) SULFATE

- 30 PFM (PH "5 )

REStLTS:

NO VISIBLE CRACKS ON SIX SPECIMENS TESTED IN EACH TEST.

NO IM ON TWO SPECIMENS DESTRUCTIVELY EXAMINED IN EACH TEST.

_ _.._. J. _.

j

w' 00Rl0SIONTESTPROGRNi

- INTERIM ESULTS TESTPARMTERS TDPERATURE: 13d F' BORON:

2350 PPM LImiuM:

6 PPM ATMOSPHERE:

AIR-OPENCIRCUIT

. STRESS LEVEu YIELD Pb!NT TEsr SPECIM N

$gQ (PPM)

IlME To FAILURE 3

M2867 - IMI'

~ 200 13,5 hrs M2320 -ARCHIVE 200 14.5 ms M2320-MmELBOILER 10-24,5 ms M2320-MmEtBOILER 1

65,0 HRS M2867-TMI 1

22.0 ms M2867 - TMI O

425,0 ms - tb FAILURE r;

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APRIL NL 1982 ii.

il "EST CLER S025 "YPE EAS RESULTS TESTNO.

SPECIMEN B

ll i

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M2320 ARCHIVE 2350

.6 100 A.P.

H2 SEVERECRACKIE i i 2

M2320 ARCHIVE 2350

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H2 CRACKED f

i.i CRACKED i!

3 M2520 ARCHIVE 2350

.6 5

A.P.

H2 U.tI 4

M2320 ARCHIVE 2350

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H2 PimNG i;

I 5

M2320 ARCHIVE 2350

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l.

i 6

If#12 ARCHIVE 2350

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H2 NGCRACKS i

i 7

ACum. Time 2350

.6 10 0.C.

AIR CRACKED (68 HRS.)

8 ACnn_ TtsE 2350

.6 10 0.C.

H2 NO CRACKS (200 HRS.)

1 l

9 NDELBOILER 2350

.6 10 0.C.

AIR CRACKED (24 HRS.)

i i

10 MODEL BOILER 2350

.6 1

0.C.

AIR CRACKED (65 HRS.)

l NOTE: A.P. = AN0Dic IblARIZATION i

0.C. = OPEN CIRCulT i

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r N0 CRAC. KING. OR DEFECTS.ATT.R..IBUTABlf TO s.L,.

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'N E Nuclear TMI-1 OTSG Status and Repair Process Description June 29,1982 lI'.

Reactor Coolant System l

550-2585 i

500-2350 450-l l

-2115 400-i,,

-1880 y n

l350-li

[

-1045 i I

g 300-I' ti 2

3 I

ii

[

j

-1410 g l 250-ll

.e -

a

=

li

[

-1175,

i i

2 0 0 4 ll r

-900 i

'lli-i y

150-1

-905 100-t l

-470 50-l

-235

^

^

^

s e i ii4 i...

.i ii iiiiiiiii 1,

IAMJJASONDJFMAMJJASONDJFMAMJJASOND 1979 1980 t

6/29/82 g,

,x

_..,mge,-.=

= = - = = * * * - * * * * " * * * ' '

• SKETCH OF TYPICAL CRACK SHAPES h

l

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,<,1 y

s 6/29/82 n.

1 Three Mile Island Nuclear Generating Station Unit 1 Steam Generator A

\\

34.4 %

43.7%

2.8%

6.5 %

1.3%

0.0%

48.8%

32.3%

0.4%

9.0%

0.4%

0.2%

0.2%

0.0%

0.2%

0.2%

0.0%

0.2%

13.7%

18.5%

32.7%

48.9%

0.4%

0.8 %

1.0 %

5.7 %

47.4%

12.9%

i i

Standard Differential Eddy Current Results Percent of Tubes with Defects 6/29/82

- : Z T T ~ ~'~Z. n _

Three Mile Island Nuclear Generating Station Unit 1 Steam Generator B 3

17.2%

8.1 %

8.4%

5.3%

3.2%

7.1 %

28.9%

0.0 %

8. >%

3.7%

3.7%

0.0 %

2.1 %

0.0 %

0.8%

0.6 %

3.3%

0.4%

4.9%

0.0 %

9.0%

0.4%

0.4%

0.0 %

26.0%

0.4%

0.8%

0.2%

8.3 %

0.0 %

12.3%

0.0%

Standard Differential Eddy Current Results Percent of Tubes with Defects s/29/82 a.

e TMI OTSG Tube Defect Distribution i

I I

I I

I I

I I

h \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ \\ N Large

^

^

1390 N

l N

15 474 t

s#

Y a

.g T

l St. Gen. 'A' & 'B' totaled j

s s

E i

201 s

s v

Tubes with multiple indications are categorized into the zone farthest from the tube sheet face 6/29/82 4

14',

esa--

++em~Ne'

Intergrannular Stress Corrosion Cra cking

• Sulfur in the primary coolant as high as several ppm.

• Solution hydrogenated and heated

• Solution cooled and oxygenated

• Agressive reduced sulfur species U

Aggressive Environment w

Failure

/

h-Susceptible Tensile Material Stress a

a einconel600

• Mill annealed at ~1900*F/ stress relieved at ~1150*F

• Grain boundary chromium less than 10%

• Cracks oriented circumferentially

• Calculated residual axial stresses high in the seal weld heat affected zone and vicinity of the roll transition

• Applied axial tensile stress during cooldown and at cold shutdown 6/29/82 7.

1

1

.s c

i

!i OTSG Level j

July 1981 November 1981 i!

j; RCS PRESSURIZED RCS FILLED

-RCS

=

355

.Y

& PRESSURIZED y y LET DOWN 1,

o A

'0 i

. Ac A

d u

/

i i

/ 6 UPPER TU8E SHEET

~#

b 345 b^/

i i

i E

\\

I l

340 f

l i

,/

i 5

i

! 13TH SUPPORT PLATE l

335

\\/~

l 4

g A

i 330 RCS DEPRESSbRIZED l

=

i f-325 s

LOOPS DRAINED T$

1 a

i m

320 LOOP SEAL LEVEL {

j LOOP SEAL LEVEL t

A OSTG 1

315 -

B LOOP PUMPED DOWN i

FOR MAINTENANCEl Y BOSTG 1

1 310 I

I I

I

)

JULY AUG SEPT DCT NOV l

DDTTED LINE MEANS ESTIMATED LEVEL I

VENTING ARRANGEMENT CAUSES UP TO 27" ERROR 6/29/82 4

Heat Vs Defect Correlation Summary e Tube failures are associated with specific locations in the generator not heat relationships e The defect patterns in the two generators appear to be different and this will need to be explained by a parameter other than heat number e Heats of material exist which have high defect frequencies in bad areas and the same heats will have low defect frequencies in good areas 6/29/82

TMI-1 Steam Generator A Defective Tube Locations of Four Tube Heats

1. r. 4..............

. s....

.... 4.......

..i 4.

4...............................................................................,........

.......r................................

. n..

................................. 4..............

. s.

.................................r...........

9..r

.............a.............................................

.....r...

..r.........

w............

................... n...

. s.

s...A.

s..........

.s

4...

... 4...

..v...............................

. v.

4

..s......i.......................................................................................

.......................................................v..............

...t

...a................................................................

. s.

.v...

i 6 s.s..

....a r,

................................u.

.x.........

................s.

i.

....................................s..

1 6/29/82 6

_,.-.-,.w,-.

-e

-*--a.

= + * -

um..

4 Summary.of Failure Analysis Continued...

O Residual stress measurements in roll and roll transition region show no stress peaks but rather a uniform distribution o Chromium levels in the grain boundaries vary from 8 wt.% to 20 wt.%

o The inconel microstructure appears typical for steam generator tubing with discrete chromium carbide particles in the grain boundaries i

o Small areas of intergranular corrosion several grains deep have been observed on the ID and OD surfaces at random locations o No relationship has been established between material heats I

and defective tubing

-o Mechanical testing of uncracked tubes show that the material exceeds minimum specification requirements 1

I 6/29/82 i

b Features Covered by Scenario Time of cracking

• Mode of cracking

• Axial distribution of cracking

• Radial distribution of cracking COTSG-A) e corrosion test results l

l 6/29/82

Preliminary Corrosion Test Results I

e Corrosion tests in actual primary coolant indicate it is currently innocuous

• Reduced sulfur species can reproduce the type of cracking observed in steam generator tubes j

• l e The degree of sensitization (i.e., prior heat treatment) is a key parameter in defining the materials susceptibility to IGSCC Crack initiation appears to be the rate controlling L

parameter J

Crack growth rate is very rapid on the' order of 1 mm/ day Cracking appears to be a low temperature occurrence Cracking tendency is reduced by raising the pH L

i 6/29/82 l

I 4

Proposed TMI-1 OTSG Repair Process (Steps / Sequence)

1. Flush secondary side tube /tubesheet crevice r

2. Heat crevice to drive out moisture

3. Kinetically expand tube for ~14"

4. Cleanup de' ris o

A. Polyethylene on surfaces B. Explosive residue C. Pieces of polyethylene candle

5. Leak tests

6. Plug or' roll / flush (if required) l

7. Pre critical operational testing 6/29/82 1

x..__.______.

Repair Criteria 4

(2) Repaired tube shall sustain, with adequate margins, the design basis loads Loads Generic 177FA TMI-1 LOCA

+ 2641 lb

+ 2641 lb MSLB

+ 3140 lb

+ 3140 lb FWLB

- 620 lb

- 620 lb -

i Normal cooldown:

+ 1107 lb

+ 1107 lb

+ = tension

- = Compression 6/29/82

4 Primary System Cleanup t

Sulfur in RCS water has been reduced from 750 ppb to 100 ppb If analysis shows it is required, we plan to reduce the amount of sulfur on the surfaces of primary system components and OTSG tubes Cleanup method identification will consider:

• H O2 2 concentrations of O,10,100, and 1000 ppm opH of 7.0,8.0, and 9.0 with LiOH or NH 0H additive 4

e Normal RCS chemistry I

^

6/29/82

r FW PRESENTATION TO THE NRC y

[

FW EXPERIENCE EXPANDED OVER 5,000,000 tubes IN HEAT EXCHANGERS OVER THE LAST 20 YEARS.

HAVE PERFORMED VARIOUS FIELD REPAIR (DETNAFORMD AND DETNAPLUGTM) 0F HEAT EXCHANGERS SINCE 1%9.

USED DETNAFORM FOR THE CRBRP INTERMEDIATE HEAT EXCHANGER (17,100 EXPANSIONS)

SS304 TUBES, SECTION III,.CL 1 AND RDT STANDARDS.

REPAIRED MSR'S AT SALEM 1 AND 2 12' UNITS, EACH WITH 735 TUBES.

THESE ARE UNITS WHICH WERE ROLLED AND WELDED ORIGINALLY.

6/29/82

..m.-

,. > ~

SIGNIFICANT RESULTS CHARGE SIZING AND COMBINATION e

LENGTH REQUIRED TO ASSURE ADEQUATE PULLOUT STRENGTH.

e EFFECT OF NEIGHBORING (AFTER) HITS.

.~ EFFECT OF CORROSION ON PULLOUT.

LEAKAGE PATE DATA.

e INTERIM RECOMMENDATIONS.

6/29/82

Table 15 STATISTICAL

SUMMARY

FOR 20/14-8" EXPANSIONS 2 - HITS ALL HITS TUBE 2 - HITS ALL HITS 99/99 99/99 YIELD T>S R;S LOWER LIMIT LOWER LIMIT 57.0 5283;214 5200;276 4609 4331 53.6 53402299 5373;303 4398 4417 CORRODED 46.1 4607 407 4672;395 3325 3427 43.9 4613;208,

_46132208 3957 3957 CORRODED ALL 4977;448 50012437

. 3564 3624 TUBING b

NOTE: -1) ALL DATA FROM DEGREASED OR CORRODED TUBESHEETS.

2) 99/99 LOWER LIMITS EXTRAPOLATED TO SAME BEHAVIOR WITH 48 DATA POINTS, I.E., X - 3.15(s) s 6/29/82

.f-e..

A TUBE YIELD 4G.1 Ks!

o TUBE-YIELD 57.0 Ks!

x TUBE YIELD 60,9 Ks!

6000 -

so a

o x

E5 5000 -

g f

a 2

g 4000 -

a b

a t;; 3000 -

S si a.

2000 -

1000 -

DEGREASED BLOCK DATA 0'

0 1

2 3

4 NUMBER OF AFTER HITS EFFECT OF AFTER HITS ON PULLOUT LOAD 20/14-8" EXPANSION 6/29/82 e..-... -. _.

,4

_a e PULLOUT AFTER 12 THERMAL CYCLES 6000 0

8 f

5000 p

4000 m

Q.

S 3000 E

2000 1000 CORRODED BLOCK AND TUBES t

8 45.9 5I.6 TUBE YIELD STRESS, Kst-EFFECT OF TUBE YIELD ON PULLOUT LOAD 20/14-8" EXPANSION 6/29/82

t i

t i

Application Of Kinetic Expansion Process To TMI-1 4

s l

6/29/82

..<....__..u..,_.~u.

.s--.--

i Concept And Relation To Repair Criteria

• Basic concept of essentially leak tight mechanical joint capable of load carrying is unchanged

• Mechanical roll is held as backup to

, kinetic expansion

• Sleeving capability is retained

~

• Repair criteria presented 4/7/82 are unchanged and have been implemented by GPUN specification 6/29/82

e e

• e m.

W.

A C

m z.

\\

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g N

g x~

q

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e

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a

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\\

=

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kx x

x x

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x

--s

~

6

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/

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d

/

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)

\\

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& 'W

?

e v

il it e

il L

Considerations in Specific Application v

• Tube and tubesheet materials and geometry

• Depth of expansion l

l

• Kinetic expansion materials i

l

• Residue j

• Cleaning I

i l

l 6/29/82 I

l l

i

,.s.

Approximate

[

Expansion Length Trade-Offs Number of tubes to be 2000 plugged 1000 i

4 n

a n

n 10" 14" 18" 22" Length of expansion i

2000 Number of tubes not accessible for 1000 sleeving I

i i

10 14 18 22 Length of expansion 6

/82 Rg.ts: Sleeve Length = Expansion Length + 3" n-

I Tentative Cleaning 1

4 i

Conclusions

• Tube I.D. pre-expansion cleaning not necessary a Candle protects expanded I.D. surface Tube I.D. post expansion cleaning

- Felt plugs and/or LP Flush Sulfur removal by chemical means if required l

6/29/82

)

J

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gm,---

qw-m _,-w,ww-

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.7,.

k+

Decisions on Process Qualification Application

• Decide on kinetic expansion

- One or two expansions

- With or without vacuum

• Confirm use of ordnance cord

• Select expansion length

• Establish cleaning method 6/29/82 ^

It

=

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s.

h-y Seal Weed M

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=

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[

4 A

i D

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Kinetic Expansion Leak & Axial Load Tests Objectives

• Measure leak rate past expansion pri-sec/sec-pri

• Show no movement from expected load

• Measure' load which will cause slip

• Confirm no ligament distortion

• Determine the effect on expansions of adjacent expansions

• Correlate rate and water leak rate 6/29/82

..-.m=

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e STERE 0 PAIR e

TMI-1 TUBE #A133-74 (PIECE 2)

UPPER CRACK - 18.1" FROM TOP OF TUBE e

TUBE EXPLOSIVELY EXPANDED - 25 GRAINS /FT e

MAGNIFICATION - 63 X e

ONLY ABOUT 1/3 0F CRACK SHOWS IN PICTURES

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Test Objectives o Provide personnel familiarization walk-thru training with process o Evaluate OTSG environmental concerns.

- Pre.ssure wave

- Noise

- Ventilation i

o Evaluate cleanup requirements for OTSG Internals o Demonstrate operability of:

- Video system

- Ventilation system

- Others (test, atmosphere analyzers, radiation detectors, etc.)

l o Evaluate post kinetic expansion tube condition o ALARA 6/29/82 l

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Tube Pull / Tube Stabilization Radiation Exposure. Summary Manrem in..

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fastelletten Cap weld Cleenes Work Events 6/29/82

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Summary

• Initial testing and analysis indicates kinetic expansion is practical for application to TMI-1

• Final qualification testing and analysis to confirm process fulfills specification requirements

• Planning, training, rehearsal to implement repair process at TMI-1 6/29/82 l

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