ML20126B825
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Installation Procedure
Title:
A25K-51512-IP7 ASSDiBLY OF' STADILIZER JUMP PACKS
. LIST'0F EFFECTIVE PAGES PAGE REV. EFFECTIVE DATE EXHIBIT PAGE REV. EFFECTIVE DATE 1:0 0 03/12/83 7.1 1.0 0 03/12/83 2.0 0 03/12/83 7.2 1.0 0 03/12/83 3.0 0 03/12/83 -
7.3 1.0 0 03/12/83 4.0 0 03/12/03 5.0 0 03/12/83 6.0 0 03/12/83 7.0
- 0 03/12/83 8.0 0 03/12/83 .
9.0 0 03/12/83 WA-ADL # 23~7 Page / Sheet /#M gg 4 A2 d- nm SIC &TtRf TITLE / DIVISION / DEPARTMENT DATE.
3rteinator 838n Job Planner 3/////.3
- enturrenr1 3 /[bh/8/f r-rbh Technical Support 3//e/[D MJ f] O]. 4 (-) Responsible Technical Reviewer Y/'/[FO
,}{)f& Plant Revteu Grouc ///h/g3
'f k).a).W} 9 Rad Con '
3fI1/83 i TNMJPd (~IM.) 3')& S3 y ,,[ -
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- Pts Manaaer 3 -t v -P3 eO W/ourd_ O&M Director or N/A 3./f-t'3 L
?Y fh f YA'^l? M-ModfDps QC Manager or N/A 3 /t~$3 8506140224 850125 Revision DE 897 PDR 1.0 Mo. OM
-i :- Rev. O
/eO ' $NTAopucyroW pMP $cerf"
- l. l ffE Pk/AroCE of ?W/S 7AoCEPUK6 /5 7D fetow 7%C-ASSEstdLY of setsc7arv srnssttarx scuswrs ourstre /wr 07S6 urret WEN 9PS. TH/S WILL /1/M//!/ a 6 7NC 77/1C S7D/7 /NCIPa* 7?tE* $75G Horp ANP .tepecc Mpt477W cyPose*4*. .71 seso sesows cHnk6ss 18 r/eSewr&Y esss71stE> .iu/r? 7setsys Asserfstcp lW AccoerAxc5 sorysv G70A/ Srec. SP-//d/- /2-b30, *Asv. 7 w FC /fep/f/Ep 70 BC /N co/174/dWCE N/ 7?/ 4+7 tat MEWStoNS of 7WAY S7ec/f/cgr7sA/.
20 Revexexces 2./ A7/020, Cc.snxiixes5 Rea urA:enex7s
- 2. 2. G70A/ .S' rec. SP-//of-/2-630, ~Jkv. 8 9 s5 2.3 G70Af Srec. SP- //0/- /2- 039, Rev. 4
- 2. Y Bhd OfarA77NS docapace o3-/02Yosy-oY
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- 3. O ' Tesrmwsissuries 3'. / ///C 'Pemernor is respexsistc rox sie nicer.s or ms woxx. l l
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- 4. 0 - 73rcxcavis/7es . .
- 4. / A wonx Ascs sesto ar esinsusxsp rysr wuc evnsic woxxcxs re ns v M/W rNE REGWRE> $4ss 8 ewxWUNESS of rWe s7nsivecx nssenser PMcKErS.
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sneu gr poconskiva ex 14ssansLY 7&ot l Ventricsr7ed Tsin Skrer(d Fooks /M Jos Cxpen.
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i' Rev. O S.O .Txsr4annow Tetwisswswrs (o. / Pre-assembly jump packs' are of 11 different styles based on the length of the segments used. The length of the segments, and thus the style of the jump pack is determined utilizing a computer calculated dome height which takes into account installation clearance needed for THI-1 OTSGs.
The styles and their makeup are as follows:
Table 1 Design i stalled Style Make up length 16 y~,) 5#
A 12 ea 9-3/4" segments 109" I ea. end rod 1 ea. cap P/N 660 .
8 8 ea. 14-1/16" segnents 111-1/2" I ea end rod 1 ea. cap P/N 660 C 6 ea. 18-7/16" segments 112" 1 ea. end rod 1 cap P/N 660 D 4 ea. 28-1/4" segments 118" I ea. end rod 1 ea. cap P/N 6o0 E 3 ea. 9-3/4" segments 115-5/8" 3 ea. 28-7/16" segments 1 ea. end rod 1 ea. cap P/N 660 F 12 es. 9-3/4 seg:nents 109" I ea. end rod 1 ea. cap P/N660 G 12 ea. 9-3/4" segments 109 1 ea. end rod 1 ea, cap P/N 1104483-003
- (FCA 3921 only) i 35ea. 3-34" es a t:; 25 7/S - E -
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-- ... Taerso %(t3 .g
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-J Z .. 3-34" wp.in 295-7/o= I ;
II[ I b, bD 000
%,f K As A except cap (P/N 660) is replaced by cap 1 l
(P/N1104483-003) *g a -
L As A except cap (P/N 660) is replaced by cap @[
n es (P/N1104483-005) g & .< '
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Y. O
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SfyIe Makecap Desia .rvs%//ed LexM M I u ..e rufA IV D " t?'
- m. M&Gs (p.te.nY I
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Awlable shshyI* i ER (ENr fhs si S Resite cTk d 67 dome cleannes. .
WA-ADL # 23~7 Page / Sheet [MM W A # _B.5g -fF.1.&
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- - REV. 0 6.2" Pre-crimping shall be accomplished only on jump-pack styles E, F, G, and J as follows: % ,
Style Pre-crimped segments Total E 1 - nose'+ 28-7/16" 4 pre-crimps / pack
. 2 3/4" + 28-7/16" l
1 3/4" +' cap F. 1 - nose + 9-3/4" 7 pre-crimps / pack
- 5 - 9/34" + 9-3/4" 1 3/4" + cap
! G 1 - nose + 9-3/4
- 6 pre' crimps
- / pack i 5 3/4" + 9-3/4 (Do NOT crimp cap)
I cap + 9-3/4 *
, J 1 - nose .
18 pre-crimps / pack 17 3/4" + 9-3/4" .
i 1 3/4" + cap
- ~
NOTE: All assembly / crimping tools shall be qualified in accordance with #rrempsyr Z 2. .
- 6. 3 Additionally, each cap will have screwed into the " head" end, a tube
" flag marker" provided by GPUN. This flag marker will serve as a
' final row-tube verification marker, as well as serving as a readily i visible marker for subsequent welding of the cap to the tubesheet.
This will support ALARA concepts.
~~--
b (p.Y " Jump pack" containers, sized and compartmented to accommodate each style, based on selected segment lengths, Are itraussay. ,
I if M . ;
- N l-q 6.5 Each flag marker shall be narro on one side with the following .
l information: , fJ .i
- 1. OTSG, either A or 8 .
d '
<~p
- 2. Row (e.g.,R32) Example: (AR32-T56) dE .
3 Tube (e.g.,T56) i
'N$kl m a seed
- 6. 6 All stabilizer parts (including weld cap), shall/h inspected prior to use in accordance with Rar. 2. 3 / 2. 4/.
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$. 7. 3 llfdsoAf TMg" OVrAA44 AsfAWB&fD LUN67W AND RECadP 7N/S MENSMtCMENY OM kr7McHMENT ? l.
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- 6. kl.L swp. Kop (Moschsgett ar /psrA LLED w/7g MovNDED EWP E'XPOSEP. .
- b. kl.L SaGngN75 $Unt/. pf /W374LLGV W/7W MAL &~
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4.7. 2 A serAAATE ArrneNnowr l- l SWAtt se conPterEn /s4 c4c4 s7ns/s/ecit 7xr- Assans4 Y, Axp Q. C.
VfA/7MJ77dd $M464. 36 //1Pt>SGP fAq. cACH 7AE-As5c/fRLY ANP Jun7 7ACX ASGr/tBL Y.
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l 7./ 6TSG Srsouture nr.or/Pxe.sssansa Swerr (SR/1PLU) 7.2 Assenser % s. Mrsiriennw Dom Sxcer (S4/17AM) 7.3 Ixsrxucnex Syrer een Gussiriennas er Assenos y Cxmrox / Howex Taozs O
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V.'A- ADL # 23-7 f e /2,, f
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. I s l V/A- ADL # - 23'7 PagcIShtet 10 of S PACKET STYLE OTSG lg. , 4 gggg/,7 l OW/WBE . _ , _ , , _ _ _ , .
ATTACHMENT 7.1 OTSG STABILIZER FITUP/ PRE-ASSEMBLY DATE -
SEGMENT NUMBER HEAT OR SEGMENT ID NUMBER LENGTH 1 _
2 ,,
4 .,5 5
6
,g#
7 ,-
9 ,
'S 10 -
11 ,5 12 ,
13 g gE 14 CAP EFFECTIVE LENGTH _
STABILIZER ASSEMBLED LENGTH PRE-ASSEMBLY YES NO (LESSCAP)
OVERALL EFFECTIVE LENGTH TUBE MARKER INSTALLED CR1MPER NUMBER
/DATE CRIMPED STRAIGHTNESS CHECK PERFORMED YES NO PACKET ASSEMBLED TT'
, QC VERIFIED BY NOTE: Pre-assembly crigs perfoned on styles E F, G, and J only.
. M*. O - AW A E MM Cn rovAIMrd i d.)bc ' Xh tvtt clear on '
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ASSEMBLY TOOL VERIFICATION DATA SHEET ATTACHMENT 7.2 Page of
- NOTE: Qualification of tooling shall be performed as specified in Attachment 7.3 of Installation Procedure A25K-51512-IP7
. WA-ADL # 23-7 I Page / Sheet // # /1 WA # A2.YX-C)f/ 2 TOOL NUMBER DATE TIME SAT. UNSAT. $dNbFF COPMENTS M
W
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O sh .
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Crimper Qualification
) place tested Vice grip holder in the middle of ATTACHMENT 7.3 .
the stabilizer part of the crisp tool qualification device.
(2) Insert the mdified Bolt into the other end.
(3) Crimp the joint with a special vice grip crimping tool previously adjusted.
(4) Using a torque wrench on the bolt specified in Step (2), measure the torque required to cause the joint to rotate. This, must be greater than 8 ft/lbs.
(5) If crimp slips at less than 8 ft/lbs, adjust the Vice grip crimping tool accordingly and repeat Step (4).
(6) Upon satisfactory crimp test, lock (weld) the crimping tool adjustment screw and lock nut.
Holder Qualification (1) Clamp a special vice grip holder onto the modified bolt of crisp tool qualification device.
(2) Apply a torque to the bolt head using a torque wrench until the modifled bolt held with the special vice grip holder slips, or until a ,
maximum of 20 ft/lbs is reached. .
(3) If 20 ft/1bs is rwached without slippage, adjust -
the special vice grip holders to ensure slippage occurs at less than 20 ft/1bs, but greater than 10 f t/lbs. !
(4) Upon satisfactory testing, securely tighten the
'A-/E # 2 3 ~7 adjustment screw lock nut. Page ISnoct - /2 # M -
(5) Repeat Steps (1) through (4) for additional fA #
special vice grip holders, as required.
TMI UNIT NO. 1 M&C TRANSMITTAL A'/A JON No. 8d/4/ ;
71:nt Maint. (If Applicable)
Charg3 No. (If Applicable) f M. A. No. A2S*/- J~/C'/2. B.A. No. /2.00/2.
J.O. No. A2 5~$- V/S*/2 E.D. No. M/A
//[ [4AP, Auth:rization For Production Work To Be Accomplished By: (Installation Organization) f "
/c.gsT Approved By: 3 ugE'/
Assigned To: Area Supervisor
, Job Supervisor .
Th13 Transmittal Provides:
I O 2niti 1 Jod Order issue
% Change To Existing Job Order (Supp. i
$)
O wA-^Dt update (in of f f 3 IWL Item For Closeout: Released Ey: M6C P&S Manager O other:
DISTRIBUTION:
Cop s To: $t)G UKAS NCfar. Nec. ON7. 3l/f//3
' Da'te (Name)
(Dept)
Copy To: (check), If Applicable M&C Admin. D.H. Campbell............(d M&C Tech. Support N.R. Ho11erbush. . . . . ([)
L.M. Zubey...........( i
- MOD /0FS QC R.F.Tenti......'........b(d M&C Production Flant Maintenance D.M. Shovlin........( )" Startup T.M. Hawkins................( )
- M&C Work Load & Control D . S . Lowry . . . . ( d Plant Engineering J.J. Colitz.....N ( I M&C Scheduling P. A. L1pinsky. . . . . . . .( d M&C Planning & Sched. J.T.Taulkner...(d M&C Planning G.J. Treffer . . . . . . .k( d M&C Estimating & Cost K.W. Feather....(d M&C Planner 6. M. Mato Nd M&C Tech. Support C.D. Brumbach.....( )
~P LA*'4Ah' AA W-( 4 F %vNs - UXC 4CVM _( W
.( )
()
- = w/ Tie-In Doc. only *** = N dA/ d I o - w/all attachments
l awu1Mah AC"C1hG B&WGdi - Bh61u3 1 #CIGE111 A114a11Ch she,kI&as l bAeto trugram Suggart Branch, ik ese Begion 1 I Notification /Sumject Desccattiem ei Iteas or &weats J/J Sh4 faz [ Completion or tune statA1Azation and plugg4ag is espected aurage taas
, once Zhros3h stema meet. Isles stasilized dad plugges weres thong takes tant scuta act Genetatot to1SGJ tune he tepaald uslag the Aimet.ic as sansion 4.rocess. kzeparaticas are Atang Segrad4trom Update made to pertora a Asak test. om aeth utse.*s. A dIf& test v411 shock the C*
- tagataess ct the meu sech4arcal seals tormed m) a,Laetas ess emas 4ca, zcilgd 4 plugs and stah11Asad tu&es gehAch have diso mega gluggedJ.. Jag test wall 7A
- me gerictaed by 1111Ang the secondat} sAde og the G1sGPs mata metaz j
l o(coveting ver pressure all oftothe tune the surf acemade.
secondary are4J and She g61 tubegang a 130 amadAe as paAg essessedmatscgem as j the lower he4e et the 01SG on the primary side {me4ctor Coplaat .SAda datij l side) tot asy leasage. Af ter tas drAs test, a 11aal f reeg gath caese gj i tubes estrig eddy current troses milA be conoscaed derAeg AA A4A 19h3.
l l Susseguest glanned evolutions are hCS (All/ seat, c1SG aussAe test and
! NCS cleanup. the progress on the u1SG is om schedalg to su1Apst het f unctica41 testaag et hoth CisG *s A.; June 1, 1,5mJ.
i j J/ 29 sal paone A s e ill or radioactive resia and mater occezzed aapat 10 p.a. on J/ 2h m&&m l
4 sLght glass trote darkag ressa traastet eyeKataoas. the Lesso age matgr
- sete contined to the area surrounding the syest redan metering t 4 (14s4de 1 tme ammillary huAlding) and the riper drains. he gaseous Agleases cccusige.
} An operator was aligat13 contasiaated when he eatered the ared to ,4am44tagate.
j - The scutce cz the resia ses the mascellaneous maste Aon gacAaagar, w&4ch ;
) grocesses floor drains and other low level maates. Ime AAce.asee mas .AsoA4tga i tae atiected area gresia eaa tioor measures up to 0.2 h/Ah and 4s mahang h
} to decostanimate.
i ,
J/3d Em1 f aa Amost 8:30 a.m. on 3/29, welding on the outside ci tae torus shell causge 4 herculate step cit yad AasAde the torus to caermeat and saaleas. S he '
l smoldering hercalate uns removea at the plaat $ Ate Aragade eithAm 1G managgs
{ and no actasation of the fare su ayression system uma regu144d. 3, i !
j dC641mG 63domi - sag 1Ca 1 Eh1Gd111 A11AhKAGm Aaku2AAA 3-30-83 b
.I
{
Cct1L1ca tkoa/S uk]ect Gescrkgt.1oa at iteam er keeata D J/29 4.tcensee phone Plammed peacetal demonstration hs the *CoalitAca for nuclear kgega
]
to RA Postponemeat" om AyzAl a, 19dJ at. the Sales arte.
L-. - .- _ . -
. .. -. - - _ . - _ A
~~
w GENERAL PUBLIC UTILITIES OT5G REPAIRS DATE 3/21/83 DATE .
ITEM DESCRIPTION RESPONSIBILITY REQUIRED Round Robin Samples-NWT Lab J. Colitz .
. Spent Fuel
. BWST
. Decay Heat - Monthly Samples End of Month
. Ship Next Monthly Samples 3/31
- 2. Restoration Secondary Side A. Temp. Chem. System
- 3. Ops OTSG Status
. A and B OTSG Full Wet Layup 2/7
. Receive Backing Plates for "A" Upper Manway 4/1
- 4. Post Expansion .
. Felt Plug Blowing Device-Store at Reactor Bldg amt t , s tr5
. Final Freepath - Blow Plugs from Top TBD
. 84W Equipment 3/27
. B&W Proposal
. Mt. Vernon Test 3/23
. Technique for Marking Plugs
- 5. Immunel Flush System
. Revised Spec for Flushing T. Functions TBD
- 6. Tube Plug Stabilization
. M&C Procedure Requirements
/W IP4 Rev. O Remove W Roll Plugs IPS Rev. 9 Tapered Plug Removal (4 en4j G. Kull G. Kull TBD TBS att IP7 Rev. 8 Jump Pack Assen61y' G. Kull 3/18 IP8 Rev. 0 Exp. Plugging, Lower Hd. G. Kull 3/18
. Receive Eddy Current Templates- 3/18
. Explosive Plugs en-site 3/21 v ,,./ ,n, na ~ n.s ,_,.
b "5 ,,.,,,
g 4 p g E - /
- h a Wu/ Ag
s ,' ,, -2.'
OTSG REPAIRS DATE 3/21 /83
'. DATE ITEM DESCRIPTION RESPONSIBILITY REQUIRED
- 7. Miscellaneous Items to Resolve
. Hydrogen P,eroxide Tube Soak
- 8. Waiting Documentation MNCR Responsibility 215-82 Plug Exploded at Wrong Area of Tube- B&W 345-82 2 Tubes Plugged Incorrectly 354-82 Documentation for Immunol-1st Batch Eng 426-82 -Wire Brush B6-1 049-83 Immunol at Cold Legs 041-83 Tube Ends Eng.
459-83 Stabilizers in Wrong Tubes ,
~Dnig %d5
- 9. Tube Endmilling
- 10. Rad Con Exposure Data (Based on SRDs) as' of 3/15
. Total OTSG Exposure since 1st Blast - 692.4 Man Rem C O.I,
. Total OTSG Exposure since Nov 1981 - 868.6 Man Rem 873,3 hS p scuedM M
- 11. Bubble andGrip TestV Final Detailed Spec T. Reichter 3/25
& .N Y
- 12. Cleaning of the Cold Legs Issue Purchase Requistion for Vendor M/re haa b Peo
- 13. Anticipated Jumps ,
Date Description Responsibility 3/21 A - Upper - 1 % Levin / Catalytic A - Lower -
3/21 B - Upper -
B - Lower -
0 0
k
e intor-@ffico Momsrandum i 1
l' arch 21,1983 Da:e Suopct Request for copies of kP j %# Nuclear Documentation -
Locaten W NS To C. W. Smyth Licensing Department Trailer 68 -
Unit I On 3-21-83 , S. Young requested copies of the following:
(date) (name) l'.NCR's # 0215-82 0345-82 0041-83 Attached you will find copies of the above documentation, please forward.
T.F. Grat/am QC Receiving & Programs Supervisor
. TFG/dal ,
cc:
QC File -
CARIRS ,
(b J . . . , p.
g'. . , 4 .
,. MNCR TRANSMITTAL' FORM 7
gt. . . Natiegsr s Date: G. - 2 8 - 8 ::L ,
3 1 . d b l e Y 2_ (Action Addressee)
@gi;ct: MNCR No.:- O 9 IC-6VA. File No.:
y The attached MNCR has been evaluated by QC and found potentially reportable. Please review the MNCR and take action you consider necessary to inform Regulatory Agencies.
Upper Management and GRC/PORC Committee Chairman. You are requested to furnish written'
-acknowledgement'of the receipt of this notification. Please provide copy of completed
' evaluation report to QC Manager for placement in MNCR file.
The attached MNCR is forwarded for evaluation and disposition. Please arrange for the completion of Section 3 of the MNCR, taking care to identify and notify the individuals /
organizations responsible for implementing material disposition and other corrective action and providing a date by which corrective action should be completed. Return the MNCR, with.Section 3 co=pleted. to the QC Manager. You are requested to furnish written acknowledgement of the receipt.of this transmittal. '
f -
For Tour Information.
The attached MNCR and supporting documents are forvarded for your retention as QA Record and are to be retained for the life of Unit I/II. You are requested to furnish written
-acknowledgement of the receipt of this transmittal.
Examination of our records indicates that this MNCR disposition is incomplete, please j' MU provide'an estimated completion date to the QC Manager.
h.
The attached MNCR is forvarded for resolution of the identified vender nonconformances Other/ Additional:
)ccipt-Acknowledgement Required: l l Yes } V lNo f rsecipt acknowledgement from addressee is required, sign the following statement and return
$s: fcrm to the QC Manager.
Fro =:
p rce2ipt .of xaca 3,*,
> h2raby acknowledged.
[gurds '
- Date:
): ( .) Operations Manager U-I/II (M Technical Functions 'p-1)II
( ) Maintenance Director U-I/II ( ) QA Department - Parsippany
(~-) Director-Site Operations U-I/II ( ) Manager-Ad=in. & Services U-I/II i
(.) Supervisor-Licensing, ( ) PORC TMI U-I/II
( )_ Director Material Manager ( ) GRC TMI U-I/II
. ( 4 Manager-Maint. & Constr. @ II, ( ) Nuclear Safety Assessment Director Manager-QA Mod / Ops ( ) Other:
b . . . . .
(d( Plant Engineering hII
- y. .
7
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. f Pao
- 1 ef 2
- .e
~
MATERIAL NON CONFORMANCE REPORT (MNCR) Part A - Initiation
- 1. DESCRIPTION OF NONCONFORMANCE (Completed by initiator)
. a.
^
Unit:TM T-1 lnitiator : Muo b l. . t. m c. w t% e /C p s C, A ( . u r u '=r oo
=:
== Name section ostemme
~~~ Material,' Part, Component, ete: !! c T f <'. 'R,.e /u- . n .,r,- c. / o ,_. _ , ,_
Location: L c . , . c re Ho *b 14 C T*C f-Manufacturer: Leeer < c w,t ev N/
Name Coce
- b. Purchase Requisition No: ,W Line Nos. /t<A Specification No.: /* / '
System: h erc4 (e~r System Tag No.: /..e
! Drawing No.:fm c.. fe.o Heat Code No.: M Other: 4s -
- c. Requirement (s): .
>>~.'.,.
s3 .J v 1.ss-risv - tu A rL.n l 2 - 17A '
, f,, -- ,e ./., . . . . . r',)
,,ud.wna 'a:t,. -h r..t.a L.,af
- d. LConditions: .
rL ,, ~ r l. s , J.. , L b,.Af L A.,- /~'s m/-e. c / & L. JA. , / 'h.
. /2 LL J :n
- sL.-,2 w : rk n J. c. 1- t E J
. . . , , , C (L J . > --J , e . lu r. J < 'd f h /' 2r- & /rJ J M 1, v
,a, AL . A / -P s.2 <~_J.A a --Z J, A,
r
. J < /<, JfD. 'L/ -
.< o
,y
! .V m- ,
- e. Possible Causes: .
fe,b J,/J, L nAue i.M Me ,r. ) L , 2,/ ,,J J E Ma .--a 9
HAND CARRY TO QC MANAGER (OR SHIFT SUPERVISOR ON WEEKEND /BACKSHIFTS)
- 2. Evaluation by QA/QC Yes No Yes No V Hold Tags issued V important to Safety: ' -
Potential 10 CFR 50: # I Potential 10 CFR 21:
Hold Tag o _ _
- Potential 10 CFR 71:
- Evaluated t. i t h QC EatT2, /96 Potential L.E.R.:
Potential 10 CFR.2),71: C,! C
" / NepeMtle M.pg Detemme Q.C. Menager's Concurrence: D Cl .4.~1 If evaluated to be potentially rep 6rtable notify t.' nit Operations Director and send copy of MNCR to Super-
' . visor Licensing. /
Date/TMI U. nit Manager Notified: N/M
. Licensing Supervisor Notified: Yes O No e/ Time MNCR No. CfL/f-@
I. '~~ Sem CA e121 Rev. I AOOOC314 (Q -
g:- .
R*.r *,
~~
4
- Pace 4 U. A MNCR No.: CB/f-ML '
MATERIAL NON CONFORMANCE REPORT (MNCR) Part B Evaluati*n. Disposition and Close Out
- 3. M-ACTION a.
nXGAr,bkA.**GlA'ANPARTY EVALUATION flC Ap &. (Tfu% .MnZk')MA AND dvh=DISPOSITION:E Wn
~'
== V V'
= .Eru 0 andkf1 Em:bh th-84
(,#
'/ Cf
- b. Disposition O Scrap C Obtain Document O Repair
- O Use As Is*
Rework @
- Requires Engineering A preval and Evaluation Evaluated by:9.@ Ozzet$5n 6-9 3-f c1
'l&JAN me/organizatichtbete' '70.ee 4 . E m .
~
- 4. ENGINEERING EVALUATION AND DISPOSITl6N
- a. Disposition Concurrence: Yes R No* O If no, recommendation is: Scrap O Obtain Document O Repair O Use As is O Rework O b.* Technical Justi ication:r~ 8 M M 1.1-r>c-n M d s irn d m b ' % I Yr c N Y T h & D t'r H 8 C W W h & '; C i*e k .
A 012As9an /M. uin & ErM tb albM . shf M-M red % x 2 Tit.o m >1A.2'.//P '65 % 1 m ; fcetW
%x.
YY $
Tt ajs eRC 2Aifi2xEL GAiwX.>&m YSb'$b$fAoinYcr)W2.m2.ds' r]
Technical Corrective Action (As Applicable) S f t' sp((j9ehgg d.
Check, as appropriate,if corrective action requires change to:
Specification O As Built Drawing C Design O Procedure O Tech. Spec. O Document No,
- FSAR O Manual O Evaluated by MM (, d -a 2.
e.
Name/@a&zation/@ lite Conditional Release issued
- 5. DISPOSITION CONCURRENCE:
- Reject Tag No.
f f .,~m lL, ef cru(q -QW&N (QC. 4-23-82 QC Manager /Date j
Pn Cew ws- u $ -) % 4 o '
Cf 6'. QC a.
VERIFICATION AND Cl.OSE OUTVerification of satisfactory completion of P Verification Method:
9 U
E
= .
S at. I Unset. ' Not Aeolic.
Complete Following Details As Appropriate:
EE Inspections:
inspectiersReport No.:
$ Test Report No.:
Tests:
5 Other Work / Shipping Order No.:
3 Date Tags Removed by: -
E_ Name/ Title 4.
E Verified by: Name/ Title / oste q=_. :
Ar 7. FINAL PACKAGE REVIEW:
r=
Reviewed by:_ ,
oc Managertoate Date Computer input Card Completed:
El a00002't
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.d OOI \D (Action Address;e'4 cc:t ENCR No.: OM6 -83 rile No.:
EE .. .
s# The attached MNCR has'been evaluated by QO and found pctentially repertable. Please reviev the MNCE and take action you consider necessary to info = Regulatory Agencies.
Upper Managenent and GRC/PORC Comittee Chai=an. You are requested to furnish v-it:en ceknowledge=ent of the receipt of this notification. Please provide copy of co=pleted cvaluation report to QC Manager for place =ent in MNCR file.
e attached HNCR is forwarded for evaluation and disposition. Please arra=ge for the y[ce=pletion of Section 3 of the MNCR, taking care to identify and notify the indiv organisations responsible for i=plementing =aterial disposition and c:her corrective action and providing a date by which corrective action sheuld be completed. Return the MNCR, s-ith Section 3 co=pleted, to the QC Manager. You are requested to furnish vritten acknowledgement of the receipt of this trans=1ttal.
For Tour Infomation.
The attached KNCR and supporting docu=ents are forvarded for your re:ention as QA Record and are to be retained for the life of Unit I/II. You are requested to fu=ish written acknowledgenent of the receipt of this transt.ittal.
Exa=ination of our records indicates that this MNCR disposition is ince=plete, please provide'an esti=ated completion date to the QC Manager.
The attached MNCR is forwarded for resolution of the identified vender nonconfc=ances ,
. Other/ Additional:
/ .
cript Acknowledge =ent Required: I V l Tes l I No
- ccipt acknowledge =ent fro = addressee is required, sign the folleving statement and return is fcrn to the QC Manager. ,
Tro=:
e roccipt.of .
MNCR No.: MM - M h rchy acknowledged.
gnad:
Date:
/
- ( ) Operations Manager U-1/II ( Lg Iechnical Functions J- II
( _) Maintenance Director U-I/II ( ) QA Depart =ent - Pars.ppany
( ) Director-Site Operations U-I/II ( ) Manager-Ad=in, & Services U-I/II
( ) Supe:Tisor-Licensing ( ) PORC TMI U-1/II
( ) Director Material Manager ( ) GRC TMI U-1/II v.anager-Maint. & Co:istr. U-I/II ( ) Nuclear Safety Assessment Di:ector
(( [) Manager-QA Mod / Ops ( # 0:her: G . \-ho\ \(=>f hum g, ) Plan: Engineering U-I/II O MMSOM
. i 15.
,s .
Usee 't nf 2 .
. MATE',;1 AL NON. CONF 07;M ANCE REDORT (MNCR) Par
- A - Initiation !
.=
DESCRTFTION OF NONCONFORMANCE (Complettd by initiator) s' .1.
- a. . Unit: "I' initiant : 7)n e;i b t L. ^ m /: e 675 CA 9. ,v :; /
Name Section Date/Teme Material. Part Component. ete: c er c- -
- 2 ,- o . _, / fw-/c e Lecation: r.r e. 1 'T , _ . .
E Manuf ac urer: "R r LO Name coa.
- b. Purchase Requisition No: A; f. Line Nos. /J A Specification No.: SP ocr-#:.c;o System: 1, e r , .h.- &4J System Tag Nc.? o .o Drawing No.: A/ 4 Heat Code No.: /vA Other: /s 4
- c. Recuirement(s): -11 , - . '
tr ~riu. 6 ., u 9 r ~A J> i_6,' ,h. , , . . s > - i r .- r - o , - n <; - , : 1.
> ! ' , ., _. ) ' ., .
- L .. Tt r eu -a.irGJ * /._ ,- .,_ -H ? +, l: f - - r,) c't e.l+ re- J -t
- s & Bru 6 1.! f, -) '
of Wr J--W .
e . <
r ..
- d. Conditions:
i
~r" J.-u i~9 ed //u - / C6 n<.a .LA) c- 1.< L~) 1, u s /s . ' i.
1P nu/ //~* - /05 . t-n i a# , > xx 11' s t s ., . J ' , _ ' ' ' .12,/ , /. . . . +
di ~-1,. /h_ ~/~J- ~ 12
-f .L n', .'.'.',/ J , 1 i . . ~.. I '.f -) _.
1' s . . .J. 't
/ ~, .t E 1.3 J , ,1 ~ t .1m i-9 n.. J /s'* - se 6 4 , / u' - rf e
. ,/2, . , , , . _ , , . . + ,r , u , + u.) .' L . ,-1, + s-.*,,i . ' eL _ , t,.
- {>
- w. / s e, 2.x
.i .i .
I 2 L
f.T. .
- D ' e.. Possible Causes:
de ,_) , /U
.PJvidt una e'. w us.fn su n }n o '
, n.,
+1, J eh 'n.la ,, n Arv jn &f. e r- r- J . ..,'.
i,.,.,,..
A -s> .! dl, .
- /> . M
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' / _ ,. )i. ..
s .
HAND CARRY TO QC MANAGER (OR SHIFT SUPERVISOR ON WEEKEND /SACKSHIFTS)
- 2. Evaluation by QA/QC Yes No Yes l No j ,
Important to Safety: # Hold Tags issued I #l l #
l Potential 10 CFR SO:
j Potential 10 CFR 21:
I# Hold Tag No ,
Evaluatec b M -. cpC F.Jo f2 /c30
-. .. Pcter.:ial 10 CFR 71: '
f /Namennee Deiemme Pctential LE.R.:
Potential 10 CFR 73.71: sm' C- - -
-
- Q.C. Manager's Concurrence: M iTiM If evaluated to be potentially reppable notity U/ut Operations Director and send copy of MNCR to Super.
visor Licensing. I Date/TMI Unit Manager Notified: ,
Licensing Supervisor Notified: Yes O No te/ Time MNCR Negqd y h h $h.I h $
..= .
t:=::.
- .= ,
w t
M .DW ,
.6 . m
I teniusuon. msmo.u.w..... w .. vm I
3'.,1 ACTION PARTY EVALUATION AND DISPOSITION: *
. -a E.valuatirn of cause:
y ,
a::: :.,.
,.-m:
- b. Disposition Rework C Repair
- C Use As is* C Scrap C Obtain Document C
'Recuires Engineering Approval and Evaluation
~ *
. . - Evaluated by:
hemo/0egoniastsonrDate l
. i A. ENGINEERING EVALUATION AND DISPOSITION
- a,- Disposition Concurrence: Yes C -
No* C if no, recommends; ion is:
Rework C - Repair C Use As is Scrap C Obtain Document C .
- b. Technical Justification:
- c. Re-inspectiori/ Retest Rec;uirements (As Applicabiel ,
- d. Technical Corrective Action (As Applicable)
Cneck, as apprdpriate. If corrective action recuires change to:
i Design O Procecure C Specification C As Evilt Drawing C ,
t FSAR C Manual i och. Spec. C Document Nc. _i hi5M
- e. Evaluated by -
NemerorgenastenIDete ~~~ l
~
- 5. DISPOSITION CONCURRENCE: Conditional Release issued
. Reject Tag No.
QC Meneper/Dete i ,
- 6. OC'VER!FICATION AND CLOSE OUT . t
- s. - Verification of satisf actory completion of material disposition and technical corrective action. i Verification Method:
1
. .- 1 Complete Following Details As Appropriate: 5eC unaat. Not Ac3iic.
Inspection Report No.:
Inspections: l i
Test Report No.: Tests: 8 Work / Shipping Order No.: Other Date Tags Removed by: '
Nemo/Tni.
~
Ve'rlfied by:
home/Tetiercate
.n .
tsar
- 7. FINAL PACKAGE REVIEW:
- =5; Reviewed by: l c : . . ,e.,2.,e ,
Date Comcuter input Card Completed: ,
1
..ee. m
_.==,_a 3.== =. s ==esm==w====- ,._: 1 =
- .:..: :::u;...; ;.
- b. b R h5
~ '
(Actics Addrdssco) hij0ct W CR No.: oO Q l- B 3 File No.:
he attached WCR has been evaluated by Q and fcund potentially rep:rtable. ? lease reviev the W CK and :ake action ye censider necessa-e te infer: Regu*atery Agencies,
- Upper Management and GRC/PORC Co=1::ee Chair =an. Ycu are requested :c furnish wri::e:
l acknowledgement of'the receipt of this notification. ? lease previde copy of comple:ed evaluation report to the QC Manager for placement in MSCE file. .
The at: ached MNCR is f'orwarded for evaluatien and disposition. Please arrange for the completion of see: ion 3 of the MNCR, taking care to identify and notify the individual organizations responsible for implementing material disposition and c: hor corrective action and providing a date by which corrective action should be completed. Ratc:r. th MNCR,' with Section 3 completed, to the QC Manager. You are requested te furnish writt a:knowledgement of the receipt of this trans=ittal.
Ter your information.
The attached MNCR,and supporting documents are forwarded for your retention as a QA.
Record and are to be retained fer the life of Unit 1/II. You are requested te furnish written acknowledgement of the receipt of this transmittal.
Examination of our receords indicates that this MSCR disposition is incomplete, please provide an estimated completion da:e :o the QC Manager. -
The attached MNCR is forwarded for resolu: ion of the identified vender nonconfermances i .
^
Other/Additionati ftA* s4NKbdd $nfe/ d p d gn bl$1;;b6///0W k/ $ N W $ S .y f u d u keA$C Abu/s t* & M W ,
Receipt /Acknowledgement required: Y, Ies No ,
If receipt acknowledgement from addressee is required, sign the following statement a-return this form to the QC Manager.
From:
Ihe receipt of MSCR No.: oc W g_4 is hereby acknowledged.
!$igned:
- Date: ,
.( ) Operations Manager U-1/II ( ) Iechnical Fun::icns U-1/II
( ) Maintenance Director U-1/II (( ))Manager-Adr.in.
QA Department-Parsippany
& Services U-1/I!
( * .) Director-Si:e Operations U-I/II
-(. ). Supervisor-Licensing ( ) PORC TMI U-I/II
( ) Director Material Management () GRC TMI U-I/II
( ) Manager-Maintenance & Constr. U-I/II ( )
d , Nuclear Safety Assessment Director
-( 4 Manager-QA Mod / Ops SiteQAIngneeringManager (A ?lan: Infineer U-I/II * (( 4 Other: / , [A/S f* 3dd ,7ep!
()
()
)E e 8 f- m
QC'.Manaser ,
Da:e: 2. n .t$ 3
. ,.8L.KA4 -N .CUMCTt osa .s (Ac: ism Add:cssso)
Itett W CR No.: -
dO4 I - O file No.:
he attached WCR has been ava$uated by QC and found potentially reportable. 71 ease review the WCR and take action you consider necessary to i= form Regulatory Agencies, Upper Management and CRC /PORC Con =ittaa Chairs.an. You are requested to furr.ish written acknowledgement of the receipt of this notification. ? lease provida copy of co=ple:ed evaluation report to QC Manager for placement in WCR file. ,
The attached MNCR is forwarded f$r avsluation and disposition. Please arrange for the
~/ completion of Section 3 of the MNCR', taking care to identify and notify the individuals organisations responsible for implementing sa:arial disposition and other corrective action and providing a date by which corrective action should be complated. Return the MNCR, with Section 3 completed, to the QC Manager. You are requested to fursish writte acknowledgement of the receipt of this trans ittal. -
For Tour Information. -
The attached MNCR and supporting documents are forwarded for your retention as QA Reco:
and are to be retained for the life of Unit I/II. You are requested to furnish writter acknowledgement of the receipt of this transmittal.
Examination of our records indicates that this MNCR disposition is in:o= plate, please provide an estimated completion agte to the QC Manager.
The attached MNCR is forwarded for resolution of the identified ,vando: nonconfe:mances e
Othar/ Additional a1pt Acknowledgement Required: I /l Yes 1 IXo cecipt acknowledgement from addressee is required, sign the folles-ing statement and return a fcru to the QC Manager.
- From:
W CR No.: 0041-83 ya owledged.
- r.d - Dates ;
. /. _
( ()
( f) Operations ManagerQl,:ZTII Iechnical Functions (L-7/II
( ) Maintenance Director U-1/II ( ) QA Department - Parsippany
( ) Directot-gite Operations D-1/II ( ) Manager-Ad=in. & Services'U-I/II -
( ) Supervisor-1,1eensing ( ) PORC TMI U-I/II Director Matairial Manager ( ) CRC ':XI U-1/II
( /))
(if Managar-Maint. & Constr. - II Nutinar Safety Assessment titector
( Managar-QA Med/ Ops - (( d) other:n .l.4mMerba A ;
( ) 71antEngineeringhII C~ rod Wn it"+ ( Amt O rs=Q t
1
,.,, i E . - . - - . . . . .. , , , _ ,
. . . . ~
Psee i e8 2 MATERfAL NON+CONFORMANCE REPORT iMNCm Part A - feitiatien
- 1. DESCRIPTION C NONCONFORMANCE ICom::leted by initiatori
- a. Unit: Initiator :8. 05e A4_b -
GC. f 23 83/o93c Name Se:tc6 oate Time Material. Par.. Component. ete: OTOG- A
- S C Eco ro sa.noc oe ro ss/]
Location: Farac'rtDA. 5cos UAcer 7ogc. sutsts Manufacturer: 0.8 AU A.p/A Name Cooe
- b. Purchase Re isition No: M/d- Line Nos. 4Y4- Specification No.: //OI-/2-o49 System: Tot Coot.da r - /PiM AA M System Tag No.: A>/4-Drawing No.: A//A- Heat Code No.: ^1/A- Other: _ A 255. V /512
- c. Recuirement(sl:
. [kg flCI t 2. . O 4 9 S fo i * \/C/sf.tcArroM rHAT ALL Locsg.-ro8g FA)DS
,Re corr o sa -r'o -res /" o c ee su er ^ . "'
Conditions:
Qd. raShtod o F- Ee b 191e u_ r MC. coa.15: Src o o 4 A ScA M o * '7W E
-rvSt 3 4 s g.r s ( 4 # e-) . Gca ene t c. 4 bin s 1 Acts. rHAT-IVTDBC EM Ds ACLe[ fort oc. Loose phers d Jesstb Eb&ss th-"TT)O6 KU D5 rL3M C Ad/Vf0d LO 04 d,Mb fn ft.1.IAl0- D a t.As N *T n t% A.,
Cunr 'i o
2ln f1F T I1 ssit 2 d- KwrJrtoM S -r6 THg A 80 0 C. JC/Al D N (,$ G)R,d.K, Dt3CedLAsb _ 7~46M ls.our CdDL t rmcb J A C M ) W d c t n~ b .
A lo rir s itPd.e GMC.E. A % Eb CttTtaiA %I6 m (TYCb SW RAui- 6.ne.
WorC.* %*r as -r-HE O Puu na up o t- SC THAI- A t- t. gas s- 99 ej, os n.is rusts (der ** A 8 Si coerch -ro rst Au osN6s 4 eo or '. .rr #5 Ats6 ru E eAoroO a* <e e- rN a r- (I L r. n e Aeroe Aoc.c' e<. mu.ca rusc4 4 9.9 */o op -rut ryee f As65 (so"H e 4 b) Heat 6sta etItt tt> ro we surunr.
- e. Possible Causes:
VACt Arocus- or) 'rtJ 6C KMb dir& Hrs.
triedxtNG- Ceaorrteus.
HAND CARRY TO OC MANAGER (OR SHIFT SUPERVISOR ON WEEKEND /BACKSHIFTS)
- 2. Evaluation by QA/OC
. Yes No Yes Nu Imoortant to Safety: # Hold Tags issued i/ 6 Potential 10 CFR 50:
' 4-dca.o Coeur ro sc inu es we c. Fi.uss.l
' Hold Tag Nos.tgjalEM 'STP ss issu s.h j Pctent:al 10 CFR 21: '
Potential 10 CFR 71:
Evaluated by f1///71or.l.2 t's / art 20183/04.' ' .
Fotential L.E.R.: - / ' ' Weineistie coi6 T.me Potential 10 CFR 73.71: ( l /9
- C.C. Manager's Cencurrence: W/ M d'23*f3 If eva!uated to be potentially reprtable notitly Unit Operations Director and send copy of MNCR to Super.
visor Licensing.
Oate!TMI Unit Manager Notified: ,,,,,.
M/4
'. cens.n; $60ervisor Notified: Yes ' Ne[Dete Time M/4- MNCR No 0041 83
.i
- l 4.- ca a i o a.. -
ao:::st4 f4+
(, .
Osci 2 of Y MATERIAL NON>CONFORMANCE REPORT (MNCRI Part B MNCR No.: OO41-fb3 Evolustian. Discenition and Close Out
- 3. ACTION PARTY EVALUATION AND DISPOSITIONr* *
- a. Evaluation of cause:
- b. Disposition Rework C Repair
- C Use As is* C Scrap C Obtain Document C
- Requires Engineering Approval and Evaluation Evaluated by:
Name/Organiast ofVoete 4 ENGINEERING EVALUATION AND O!SPOSITION
- a. Disposillon Concurrence: Yes C No* C If no, recommendation is:
Rework C Repair C Use As is : Scrap C Cctain Docursent C
- b. Technical Justification:
- c. Re inspection / Retest Recuirements (As Applicable)
- d. Technical Corrective Action (As Applicable)
Check, as appropriate, if corrective action requires change to:
Design C Procedure C Specification C As Built Drawing C Tech. Spec. O FSAR C Manual C Document No.
- e. Evaluated by Nemo/organisatiefVDete
- 5. DISPOSITION CONCURRENCE: Conditional Release issued Reject Tag No.
[, CC Menseettoste
- 6. OC VERIFICATION AND CLOSE OUT a.. Verification of satisfactory completion of material disposition and technical corrective action.
Verification Method:
Complete Following Osteils As Appropriate: gT- un,,,, ; ye. ;;;ng, Inspection Report No.: Inspections:
Test Report No.: Tests:
Work / Shipping Order No.: Other Date Tags Removed by:
. . Name Tries Verified by: '
Nameistiercete
', 7. *lNAL PACKAGE REVIEW:
s.- .
1' - Reviewec by:
- cc menever.oete u., , ,
Cate Compute' input Care Compietec:
I MrdI
/f1 A)C/t C0 41 6 3
(.-
L VISUAL INSPECTION OF ENDMILLED TUBES QC to inspect tube ends to verify:
! 1. No loose pieces or' jagged edges where pieces are e.issing.
- 2. Tube ends are removed down to or close to the seal weld. .
The conditions noted above vill be verified as indicated by:
- 1. A relatively smooth finish on the top of the tube / seal weld.
- 2. Ninimal extenston of the tube above the seal weld.
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REQUIREMEllTS FOR CUTT 3ks UPPER OT56 TUBE IMDS
- N #M*E As9novAL DATs 3 Changed.page 2 of 6 paragraph 4 and page 3 of 6 Q.O*" *dkE3 paragraph 1 to delete refereoce to rasping tool g .1/g/f7 and add reference to B&W single cutter tool.
Also expended words is include operation of tools ,
Z _ vag,y 1 Page 3 cf 6 paragraph 4 added:
- Tor tubes to be '
- plugged, the seal meld may be milled to .030".
g/&[/ : a./085 pa&- Yak 2 Added paragraph ta page 6 on Disposition of M% NS/N MNQt0043-83. Also added References 12 and 13 to page 7.
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Nuclear Safety 5nvironmentaf Impact Evaluation Summary Sheet e.aw.nr 41a Tits, E*1et>ut./A4 m bC. d0 mo6 UPA 073 le Dd5.d.E.#
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1.W Done W. ehenes reedre fe***n 8f the afste'm/semponent emmenynam h1he Sedefy Anakois Asperg) WEC
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W Does we ehenge eher precadares from shoes desarbed h the Sedesy Armares Aspert?
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woA W Are taste er empenmenes conducted wheih == act descresad h the Safety Anmysm Aspert?
YE3C Nose ti m,y of the sneerers to 1 W. M. at W are VES a esenaud evabenen emot he seteshed.
N 2.W Hue the prohahaty of essvivonos or v. coneeousnee of an eeshant or matfunet,en of apoment ytsC W to safety 7 4 evesessed a the Safety Ana,yes Mapert been Insteemed?
nom W Has the poemeatty per en seesser or reattunedert e( e aeWerent type n any eveamend yesO pretteue4in she Safety Ano#se Aspert been e,ested?
' er NoR b) Hus the merge of safety se defired in the hones fe(eny Testmsai Speartkonaan boon sedueed? ytsO y .. -
NOC Near. N any of the snowers to 2 W. W, or W are WS. tr$ shange must to approved by the AWC.
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7,o, Rr0013tD(NTS FOR CUTTING UPPER 01% TL2E I.OS Safety Iwwaten PURPOSE Cut off all tube ends that extend beyond seal welc. T.%se : te ,
ends have experienced corrosive attact and shoulc be e:cyoc to prevent them frou becoraing loose parts in the pricary systar.
during operation.
SYSTEM AFFCCTED All tubes in upper tube sheet of the TMI.1 OT5S's except the ones which have alrendy been plugged. ,
EFFECTS ON SAFEh Lince all tubes except the previously plugged ones have been kinetically expended in the upper tubesheet (UTS) to either 17' or 22* below the primary surface of the UTS, a new leak.
tight and load carrying joint is provided at least 11" below the tube to tubesheet weld joint to serve as a new pressure boundary. Qualification results revealed tnat the load carrying capability of the kinetically es.panded joint is adequate to meet the load requirements based on the main steem line break, which is the most stringent axial tensile load imposed on the steam generator tubes. The seal ield at the upper end of tube will no longer be subject to axial tube loads.
An operator using a hand held air tutor with piloted tube end facer will be used to cut off all the tube ends. The stall torque of the air motor used to drive the single tube end cutter is approximately 100 ftf. However, based on tool design practice, it was concluded t a wrs ca torque with a pis gria ha le.n ho'd so bximately Th's eq 20 ftd of to a person resisting a repetit$ve force of 60f at the handle. In order to '
reach the stall tordue of 100 fti, a person would have to hold onto a force of 300s. Therefore, it was :oncluded that the anz.iean torque will be 30 ftf. Evaluatter. of 30 ftf torque (Ref.1 shows that shear stress 14, 338 psi is less th*.n the yield s)trenath of the material. 35.000 osi.
. N 1 W. tg er ts) is Yts, h Tespeoussa essenmerus beloor.
- Yes See TR4 Does the o6ames s=owee en upshta ed the FSAA7 O K Dess the enange rogues a Teennent Spee ficadon setwenent? D. K Cees me enange sogne a Ov aty casadeceuon Lat ameamment 7 C K ogner C D NMC anorwsd has been otenssi 8N% VtJ/J'.1 fAL Wfh ?f$sd 3 s-.-~ o.- == w 1
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, The stalla'ir ector of terque used25 by f"tf.B&W for t:.;be ar.d stabilization has a :sxiar..
However, this tool is positica,$ c,n sn, tube sheet with haresteps and from troerience in using this same tool in the past, the *.cc1 canrot be stalled. i.e., the persen operating the tool w.ald decrease the pressure on the cutter a1%
ing the actor to dwell on the tube and seal weld being cut. It is espected that the running torque of this tool will not crcted 30 f-0.wrator training will preclude the potential of stalling (Ref, g).
In addition, the fillet wid and the minina of 10* kinetic expen-sion between the tube top and top of 6" qualified kinetic expansiot length will transfer the torsion load to the tubesheet so the new joint will not be stressed by the tube end renoval process.
The designainimus seal weld vertical leg height is .051*.
However, previous tube and nachining for plugging has down that the minimue dimension for most welds is .080" or more,
, so .070* has been set as the noodnal height above the tutre-sheet to unich the tubes will be machined. In addition,
. Reference 7 requires periodic tube end examinations during and milling to confirm that " protruding tube ends are being removed slightly down into the weld". Any tubes which are not nachined to the top of the seal held will be remachined to a lower height within the .070* 019" tolerance establisbed.
AccordingtoB&W'sanalysis(FCA04-3922), for a kinetically espanded ti6e, minimus vertical wid dimension of .030' is required to provide' adequate fillet meld area for subsequent plugging. For subsp to be plugged, the seal weld may be milled to .030 . Since the tube and with the seal weld is nominally allowed to be cut off to 0.D70* +.010 above the tubesheet
.019 cladding, there will be more than enough margin to assure that the remaining seal weld will have adequate dimension for future plugging. The removal of the upper tube ends will not 1spect the tube preload and stresses.
toose Parts Effects
- 1. Loose parts from the unchining process will very from fines to approxiantaly 1/32' x 1/16' x 1/2".
. Larger pieces breaking off the tube and may be as large as 9/64",x 5/8' x 1/32".
Loose parts as a result of the tube end machining will
. be removed by the following:
A. Vacuusing during and after machining operation.
- 8. Flushing of CTSE per approved flushing step.
C. Final felt slug bicwing down through all tubes remaining in service per approved procedurt.
D. Final inspection and cleaning in the cold legs.
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- 2. .
. Potential loose parts behind the seal weld curing operation.
Meta 11ograpMe exaeination of tube samples removed from the steam of the tube ends extends tnically into the portion of tub beMnd the seal weld. ;
cracking is described below.The geometric characterization of tnis ,
It is not intended to remove '
this portion of the tube end because of the h er potential for generation of loose parts from this region (campared to the region above the seal weld). .
based on the following logic The ,19stification for this is (1) The tube end eachining operation and subsequent flusMng i operation will impose loading on potentially loose pieces' heMnd the seal meld. These operaths will tand to remove the pieces with Mghest potentia' to fall out. i (2) The loading on portions beMnd the seal aid, during normal operation, will consist of fluid dynamic forces. Analpis described below demonstrates that this loading is very unlikely to dislodge loose pieces.
(3) The " potential offacts of loose parts in the RC5" analysis described below demonstrates that any pieces that any on released due to uncertanties in the fluid dynamic / stress analysis (described in (2)) represent an acceptable risk. i For tfur tube top above,fhe seal weld, GPW analyzed effects (Ref.5) of main flow and turbulent pressure pulsations on a
- tube siiver 1/8* high by 1/4" long (1005 through wall on both i sides and 70s, through wall on the horizontal portion), it was found i that the s11vec is stable throughout the plant life assaning no '
further degradation of tube tMcAness. !
For the tube end beMod the seal weld, fine 1SASC cracks have been found near the heat affected zone and down in the inside surface of tube appmximately 3/8" from the top tube end. Loading from the turbulent pressure pulsations on this part of the tube (Ref. 5 appendir 1) during normal operation is calculated to be less than the tube end loading of the sticking out portion by a factor of about 6, because the sliver behind the seal weld will not be esposed to the main flow. Although ISA has been noted in the seal wld HAZ area,the metallurgical analysis typically shows that at leent 505 of the tube area in each polished specimen is .
not affected by the IEA (Ref. 8). Since the nacunt of ductile asterial required to amintain stability Ci.e.. not have tube pieces coming loose due to flow loading) ts small, the ntaber of pieces released into the RC5 from tMs tube location over the life of the
, plant is small, and released in a randos aanner.
- 3. Potential Effects of loose Pieces in the ACS I
Technical evaluations of the potential effects of loose pieces in '
- the RC3 fitut the UT5E tube ends are given in Referencas 2.3 and 4.
Refe mece 4 addetsses effects on fuel and core components (fuel
- assemblies, control alements, incore instrumentation, internals vant valves) and Reference 3 addresses effects on mechanical components
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j Paga 5 01 7 in the rest of the primary system (centrol rod drive. E pwups, valves).
Based on the analyses described in Section 2 (above) the population of ,
loose pieces will be small and randomly releaseo from the damaged tube j walls during operation. Safety risks are considered as those damage effects :
that have the potential of. by themselves placing the plant in an unsafe I configuration. These include wear of E pump seals, wear and jaming of control rod drives and code safety valves, and jauning or restricted sove- I ment of control rods and intamals vent valves. l Variations in coolant flow in the core are not large enough to create f significantly preferential flow paths for the pieces. Distribution to f fuel and core cogonents will. therefore, also be randos. Given these senditions,
.the technical evaluations conclude that safety risks created by tube and pieces have a low probability of occurrence.
Operational risks. (such as jamming of AP54A's or incore instrumentation strings and usar of valves have a low to mediwa probability of occurrence, again assuming the listited) population of loose pieces described in Sec l tion 1. Cartain operations) risks, such as fuel assembly flow blockage (
and breach of fuel rod cladding due to user. are safety-related but do not :
directly esapremise any safety systems and are controllable and detectable by other means. (e.g.. Technical specifications and radiation annitors). 1 l
Matarial e-*^111tr
& t Lubricants used in the internal [of the aschining tools will not same into contact with any surface of the primary systas. On ancMning ;
that ashaust .into 075G, only 1rcarine will be used tools far 1"=4 cation wh is an appr'oved liquid per "sG ' AP.lo20. No pfD.
(air driven)ich l hibited material will be introduced into the staan generators during l the tube end machining operation. l L
jyrveillance proeren t An OTSS tube end surveillance program will be put into affect during and after nachining. This program will consist of three parts: l (1) In-process surveillance of a sagling of tube ends (by photographing) l j
during the,end milling process. l f (t) Fellowing completion of tube and milling and stems generstar flusning a sampling of phossgraphs of tube end will be taken. .
This sospling will provide informatiam on at least 3% of the .
l total tubes.
- " (3) The item (2) will be typeeted after 90 full power days of plant !
operation.
lf any missin l
surveillance.g tube end en engineering pieceswill evaluation arebe detected during conducted prior to the itam j>
i allowing consencement of plant operation. The item (3) surveillanca will identify any incremental loose parts after 90 days and will be ,
evaluated prior to further plant operatism.
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3 SE 120012-007 page 6 of 7
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Cceeleafm (1) The tube and machining does not constitute a chamse to the licanains basis for the Orsc's and it will n.st impair the eafe shut down function of the unit.
(2) The tube and machining does not increase the probability of occurrence of so accident pre-viewly evaluated in the FSAR. and the possibility of occurranse of an umamalyzed accident has not been ir,trodscad.
.(3) Bemoval of apper take ende vf11 not impact t.he performance of the steam generator.
(4) After the several steps of tube end willfag.
tube f1whing and 0755 clamaring as planned. the only loeoe places that may be generated vill be as a raentt of f. low tadeced vibratism fatigue.
Analysis of these forcing feastions have shown the probabiltty of loose pieces is suffielently low so as not a be a safety problem.
(5) The small emadat and random distributies of debris provide's reseenable aneurance of the law probability of the occurrence of safety risks as determined in the evaluettons of saferences 3 and 4. -
Tweluartoe of actual Tube Bad Condittee Af ter Cmletion of Machimina operettem ,
Tnapection won performed by Site Q. A. and reported by totC1 0041-83 (Raf. 12). This Mpca has been dispositioned by Technical Functions Tagineering and copy of the Engin-sering disposition to 15CR 0041-83 la attached as Ref-esence 13.
The disposition democatrataa that the conclusion of this $1 fu inchanged and the CrtSC miy he returwod to rectvice.
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(3) Effect of 0750 Primary Side Loc.se Piece MC-1530 dated 11/22/12 (4) 0T50 Tube End leses Ptecas Potential Effects en Core P- ' :wts XT3057 dated 2/4/83 (5) CPUN Calculations fl1011-532D-A43 (6) CI'UN SP1101-12-049 - taquiremmets for cuttlig Upper OTSC Bada (7) R&W FCA 620-0005-04-3920-00 (8) Incariat yrt Examination of 'DC-! Third Polling Sequence OTsc Tubea EDD:43 5064-03 02 . j (9)* 'DE-I fastallattan PNcedure " Single Tube End M1111r.g A & R CTSC'a" i Procedura No. A251-51512-IF1-RD 1.
(10) 34W FCA 620-0003-04-3922 (11) 34W Letter TMI-81-115 dated Dec. 8, 1981
" Approval to use toeshte safe 620 nydraulic, Neolube and Clycerine in the OT!4f' (12) HNCR 0041-83 dated 2/23/83 (13) Engineering Disposition to WCR 0041-83 dated 2/23/83 n..e
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. Attachment to MNCR0041-83 February 23, 1933 INGINT.ERING DISPC.SITION OF TUBE END MILI,1NG - CTFSG
. .;. M In order to r.ake an engineering disposition of this MNCR0041-83 and to satisfy Safety tvaluation SE 120012-007 Ref. 1, on the ans11 nue.ber of tube ends that have been reported with tube or a quadrant of tubo projecting above the sen1 wcld after machining, the writer viewed close-up photos of tube enda representing approx-e imately 1.000 tube ends (7% of total).
It was noted that approx-imately 200 milled tube ends were approxi.mately 1/15 of an inch or less (mostly less) above the anal weld. In some cases, the small tube and projected all the way around tube end and in etbar cases, only a quadrant of the tube was visible.
All the tube and viewed in the photos appeared to be sound. A definition of a " sound tube end" is described belows No pieces missing from the 2. D. of the tube or freet the seal weld. This includess a) The milled tube end that projected into
, the seal weld b) The milled tube that is just flush with the seal weld y l . c) The milled tube e"nde that were slightly (less than 1/15 of an inch) above the seal weld '
' L 2.
,N'o sealvisible weld. cracks were noted in the tube end and/or Thu writers personal interview with many of the boiler-makers doing the milling operatic.n resulted in ccznents as fol. lows:
(awplative) tube blev apart until 2 milled down to sound metal."
" Tube cut very easily and clipa worn flying all arcund antil I hit good metal.' ,
'I know when I reached seal weld by the feel.*
'There were no pieces missing from the tube when I finished milling."
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" Tubes looked very uniform and concentric."
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- IzeS2MEERIM3 DISPOSITION OF TURE END M2L2.2MG - DT5G d 4 "
'The tubes looked like denuts cut in half.*
"Some of the tube ands bad axial cracks before I allied them. It was not apparent after ,
milling.'
'The tube endo cane off in saml1 clips and .
then became soil aros."
The boi.lermakern upon being advised that there were ses11 quadrants of tube ends not milled off completely,
- were very surprised. '?he general cpinion of all those who participated in the milling operation was that the tool machined the tube ends to ' sound status", i.e.,
no cracks or pieces missing.
Further confirmation that the 'A' OFSC & 'B' OTSC Generator tube ends have been milled to a
- sound condition' is the fast that the running tor y by the two bladed milling outter pro-duced an average stress in the tube end of 14.3Rs2-cK32 = 7.1 SSI 2
(Ref., 2) whisk is sevee timmer.the estimated stress a typical projecting piece will esperience during the operating sondition (1xs1 - not. 3), due to postdiated fluid dynasio loads
- s assed m the above,. it is corieluded that although visual inspection after the ad.lling operation the indicated that not 100% of the tube ends have been removed f'aush with the top of the seal weld, the final condition is acceptable for operation of the steam gen-erators. This sonolusion is based ost The eutting operation, due to its nature and the technique used by the operators, has removed tube end material that had the potential ta become loose parts in operation, i.e.,
tube material in in poor condition.
In oases where a short ridge of tube end material reaalas above the sea) weld, it is engineering's opinion that it is sound material for the same reasons, and will not be sub-
$eeted to finid momentan forces causing sig=ificant stresses in operation. , ,
Referesee I = SE 120012-007 Rev.1, Safety Evaluation Requirements
- for attting apper OrSG Tube Ende.
Reference 1 - GPUs TM2-2 0750 Tube End calculations 1101-5310-014 Reference 3 - GPUR calculations 1101X-5320-A43 S
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- eviev the 53 and take acties yeu censider na:assary to 1:fc;: 7.egula ::y Agtse.ies.
"' r;per Ma:agaman: ast CRC /PORC Cen=1::ee Chat;=an. You are requestet it furnish vri::e ackmovledgeman: of tha retaipt of this sc:ifica:ic:. ? lease p;cvide me;y of ::= pie ed evaluation report to Q Manager for pla:ase:: in W 3 file.
- ne a:tached W3 is fo:varded fo':'avaluatic: and dispositto:. 71stse a :a:se fo: the
/ co=pletion of Section 3 ef the 23, taki:g ca:e :s idassify a d notify the 1:iividual c ga:iza:iens : espe =sible for i=ple=a::iss =.a:arial dispositic: and c har cc : active at:ios and provid1=g a date by which co::e :ive action should be ec=;1a:ad. La:ur. th WC7., with gec: ion 3 co=pisted, to the Q: Eanager. Tou ara retuasted to fur ish v:itt achmovledgement of tha receipt of this ::a:ssistal. -
yor Tou Information. -
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ne attached W3 and suppo::t:g do:u=e::s a:a in:va:ded fc: yo!.:: :::an:1:n as QA Le:
and a:e to ba retained 'c: the life of U.it :/:1. You a:a :sguanted :e fu: ish v:1:::
acknavladgesent of the recaipt of this ::a:::itta.1.
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na attached 22 is forwarded for :esolution of the identified , vends: no:ce:f t =a=:a 0:ha /Addf.:fonals alpt Acknowledganent Required: I /l Tas 1 INo roccipt acksovledgn= ant fres addresses is : equi et, sig: the follevi:s : ate:a=: and :stu:
s f: s to'the QC Manager.
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/ doda/dacknowledged. dI h.M M t ,* Dsta 3 -/ 1 - V.5
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Operations Manage:WRII
( ()) Maintenasta Vi; acto: U-I/II Technica.1 yune:1 cts (.y/II
( ( ) QA Depart =ent - PA:sippany
( ) Directer-tite Operations U-I/II ( ) Manager-Admin. & Services'U.1/:,1 .
( ) Sups:viso:-1.icensing ( ) 7:10 iY.I U-1/II Diresto Ma:arial Ma age- ( ) CA: ':M. c.:/I:
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TM1 UNIT No. 1 M&C TRANSMITTAL Joy yo, fg/4 /
Flant Maint. N/A (If Applicable)
Charge No. (If Applicable)
W.A. No. AlfI- f/f/2. B.A. No. /200/.2 3.0. No. A1.CX- Y/C/2. s.D. No. N/4 Authorisation For Production Work To Be Accomplished By:
// ![ [403P, (Installation Organisation)
/!/CffL Approved By: Eugr/
Assigned Tot Area Supervisor
, Job Supervisor This Transmittal Provides:
O Initi 1 Job Order 1..ue '
E Change To Existing Job Order (Supp. #
7) 0 WA-^DL Update (As of / / )
O Iwt Ite. ror Closeout, Released By: M&C F65 Manager O Otheri DISTRIBUTION:
T opEetos $U6 l!WMAS NfC ?Aop, W [on, 3bt/t3 (Dept) ' Dats (Name)
Cgry To (check), If Applicable M&C Admin. D.M. Campbell............(d M&C Tech. Support N.R.Ho11erbush.....([)
L.M. Eubey...........( g MOD /0P5 QC R.F.Fanti...........N.T(d M&C Production Startup T.M. Hawkins................( )
Plant Maintenance D.M. Shov11n........( )
M&C Work Load & Control D.S.Lowry....(d Plant In51neering J.J. Colits. M ( d M&C Scheduling F . A. L1pinsky . . . . . . . .( d M&C Flanning & Sched. J.T. Faulkner...(d MAC Estimating & Cost K.W. Feather....(d M&C Flanning C.J. Treffer ..MM d F _( d M&C Tech. Support C.D. 3ruebach.....( )
. M&C Flanner 8 Me v4,6 ATC $%3H'L( 4 ]. LANsM M (4 fe YouWs
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- M OM o o w/all attachments
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Te1 Mac Job ord.r suppi.m.ni rorm Job Order No. A25K-V1512 Supplement No.
JON #80161 Description of change or supplementary information:
The purpose of this Supplement is to issue to the field Installation Procedure A25K-51512-IP8. Rev. O which deals with the explosive plugging of tubes in both the 'A' & 'B' OTSG's. Also being issued are the Checklists for Tube Identification.
Cleaning and Plugging which spells out the specific firing groups in the 'B' OTSC only. Additional " Checklists" will be issued later detailing the firing groups for the 'A' OTSC.
The attached sheets supersede the corresponding sheets currently in the Job order. The superseded sheets are to be marked " Superseded By Supplement # 7 ". Transfer any existing signatures from the superseded sheets to the replacement sheets. Attach the superseded sheets to this Supplement Form and insert at the very end of the Job Order package for records retention.
WA-ADL # 2 Z ' /~ 7 n , ,, , , , , ,,, p ,,,,. .
Page ISheet l Of 3 WA # f2W~ EM2 lY^^^#~ P&S Menepee
Nuclear rui.1 m a e Job order Form ease 2 of 4 A25K-V1512 S7 Sheet 4 of JON #80161 General instructions, Notes, Limitations, Etc.
REFERENCE DOCUMENTS Document Description / Number WA-ADL No.
A25K-51512-IP7, Rev. 0 23-7*
A25K-51512-IP8, Rev. 0 23-8*
Checklist for Tube I.D., Cleaning & Plugging (16 Pgs) 61-15* 07 1E-224-WM-001, Rev. 3 OTSG 'A' Weld Map 31 1
-1E-224-WM-002, Rev. 3 OTSG 'B' Weld map 31-2*
Tube /Tubesheet Plugging Weld Record 'A' OTSG 32-1 Tube /Tubesheet Plugging Weld Record 'B' OTSG 32-2*
Tube /Tubesheet Plugging Weld Record, Explosive Plugs. 'A' OTSG 32-3 Tube /Tubesheet Plugging Weld Record, Explosive Plugs, 'B' OTSG 32-4*
Welding Engineering Checklist 35-1*
A.N.I. Review Notification 36-1*
WPS #04322, Rev. 1
- 36-2*
WPS #04323, Rev. 1 36-3*
WPS #04324, Rev. 0 36-4*
l l
WA-ADL # 22-/- 7 Page / Sheet 2 87 3
- ATTAcuED wA , gy5g.g7g72
4 Nuclear Tui.i u a e sob order Form e.g. a of 4 Sheetf2 of J.O. Number A25K-V1512 S7 JON #80161 NOTE: Sequential performance of the work steps listed below is not mandatory unless otherwise noted.
- 10. Job OrderWork Plan ll**k M M s a$a
- 37. Verify that the prerequisites of "IP2" Prod. N/A -
(23-2) are satisfied prior to starting Supv.
. work in the 'B' OTSG.
- 38. Remove old stabilizers as specified in M&C N/A "IP2" from the 'B' OTSG. Prod.-
- 39. Verify that the prerequisites of "IP3" Prod. N/A (23-3) are satisfied prior to starting Supv.
work in the 'A' OTSG.
- 40. Remove remnant of partially inser,ted plug M&C .N/A from row / tube A-143-61 as stated in "IP3". Prod.
- 41. Provide support on an as required basis M&C N/A for the assembly of stabilizer jump packs Prod.
in accordance with "IP7" (23-7).
- 42. Verify that the prerequisites of "IP8" Prod. N/A (23-8) are satisfied prior to starting Supv.
work in the 'A' OTSG.
- 43. Verify that the prerequisites of."IP8" Prod. N/A (23-8) are satisfied prior to starting Supv.
work in the 'B' OTSG.
/s7
- 44. Provide support on an as needed basis to M&C N/,A complete the required explosive plugging Prod.
in the 'A' 0TSG.
- 45. Provide support on an as tieeded basis to M&C M/.A complete the required explosive plugging Prod. -
in the 'B' OTSG.
WA-ADL # 2 2-/- 7 Page / Sheet 3 or 3 WA # A2rK-5/512 .
- Acco122oC
THI-1 Maintenance and Installation
[ r p,j l j g g g Construction Department ,
Procedure No.
Installation Procedure
Title:
A25K-51512-IP8 Page 1 of 29 INSTALLATION OF EXPLOSIVE PLUGS ;
LIST 0F EFFECTIVE PAGES 1
PAGE REV. EFFECTIVE DATE EXHIBIT PAGE REV. EFFECTIVE DATE j l'. 0 0 03/21/83 7.1 1.0 ~ 0 '03/21/83 2.0 0 03/21/83 2.0 0 03/21/83 3.0 0 03/21/83 3.0 0 03/21/83 4.0 0 03/21/83 4.0 0 03/21/83 5.0 0 03/21/83 5.0 0 03/21/83 6.0 0 03/21/83 6.0 0 03/21/83 7.0 0 03/21/83 7.2 1.0 0 03/21/83 8.0 0 03/21/83 2.0 0 03/21/83 9.0 0- 03/21/83 3.0 0 03/21/83 4.0 0 03/21/83 5.0 0 03/.21/83
. 6.0 0 03/21/83 7.3 1.0 0 03/21/83 7.4 1.0 0 03/21/83 2.0- 0 03/21/83 3.0 0 03/21/83 4.0 0 03/21/83 5.0 0 03/21/83 6.0 0 03/21/83 7.0 0 03/21/83 WA-ADL # 23-8 Page / Sheet 'I#N WA # #2W-r/SA .
SIGNATIIRE TI n.E/ DIVISION /DEPARIMENT DATE 3rfeinator M Job Planner 3/22,//J
- oncurrenk jNbhdr.e Technical Support [1Sl2.) 3.'22/,23 UkQ m Responsible Technical Reviewer 3 Z.E!d3 Mfdh A4A Q.tsou Plant Review Group Wb, I[21fS3 1 )).Y).fk_ Y<.p Rad con 3/22/P3 f $
= /
A, - .
f i k GJN b - _ -
P&S Manaaer 3lst2.lf3 et A # k IA,d . O&M Director or N/A 3-22_g3 i
- Si ZM ',_ MzvteeRNB Mod / Ops QC Manager or N/A 3 42.-83 1.0 Revisions g ___
R2v. 0 l
1.0 INTRODUCTION
AND SCOPE j l
1.1 This procedure shall govern the technique for identifying and plugging once-through-steam-generator tubes which require explosive tube plug welding. ,
2.0 REFERENCES
2.1 AP 1020, Cleanliness Requirements 2.2 AP 1030, Control of Access to Primary System Openings
" 2. 3 Radiation Protection Plan 2.4 GPUN Specification SP-1101-12-030, Rev. 9 .
2.5 GPUN Specification SP-1101-12-039 Rev. 6 1
~
WA-ADL # 23-8 '
Page iSheet I *f I ?
2.
WA # 425#- f/f/2 1
i n
Ksv. 0 3.0 RESPONSIBILITIES 3.1 M&C Department is responsible for all aspects of this work.
3.2 Plant Engineering will provide assistance as required.
4.0 PREREQUISITES .
4.1 OTSG Primary side drained and manway removed. ,_
4.2 Tubes to be explosively plugged have been identified.
'4.3 Specific training on explosive plugging must be accomplished prior to plugging into tubes.
4.4 ALARA and RWP requirements have been satisfied.
4.5 Safety Department " Confined Space Entry Requirements" are met.
4.6 Additional LTS template holders installed.
4.7 Welders shall be qualified under current applicable welding procedures.
4.8 Secondary side water level shall be drained to a minimum 12" below the secondary face of the upper tubesheet.
4.9 Work Platforms shall be installed in the lower head.
WA-ADL # 23-8 3.0 Page / Sheet 3 8F 2E wA g A2SX-&~/S~/2 c
i-Rav. 0
'5.0 SPECIAL/ SAFETY PRECAUTIONS 5.1 All personnel performing the actual work described in this procedure should be thoroughly familiar with the procedures, the handling and operation of all special tools and materials, and all applicable safety precautions. Documented evidence of this training will be.
available for review.
5.1.1 Detailed handling, placement, operation and manner of use cf all special tools and material shall be as per the dir-ection of the B&W Supervisor.
5.2 Assure that lower head cold leg covers or plugs are installed prior to any work commencing in the OTSG concerning tube plugging.
5.3 Prior to any plugging activity the following conditions shall exist.
5.3.1 All tubes to be plugged shall be identified on an Engineering drawing firing group. Plant Engineering will review these drawings to verify firing groups.
5.3.2 Attachment 7.3 is completed by the B&WCC Representative in charge of explosive tube plug welding prior to commencement of the tube plugging activity. The firing sequence within each group is to be determined by the B&W Supervisor.
5.4 Attachment 7.3 will be completed during the tube plugging activity.
5.5 An enclosure shall be provided around the opening to the steam gen-erator to ensure that any contaminated air is contained. This area shall be free from oil, scale, chips, wire, grease, chemicals and other foreign materials which may be detrimental.to the primary' system.
WA-ADL #
23-8 4.0 Page / Sheet Y ## -
WA # A2W~#
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'Rsv. ' O 5.6 -During work performed in accordance with this procedure, proper control'of'all tools, equipment, materials and supplies shall be maintained to prevent their loss and/or inadvertent introduction into a system.
.5.7 An exhaust fan shall be connected to the hand hole located in the top and bottom steam' generator head to remove airborne con-tamination prior to and after detonation.
-5.8 Each plug installed shall be detonated individually. This method provides the ability to identify misfires if they should occur.
5.9 No one shall be permitted to' handle the. explosive tube plug mat-erials unless authorized by the welding operator.
5.10 Other personnel may clean the tubes and install the plugs only after proper instruction.
5.11 The explosive plug is classified as " Detonating Fuses, Class "C",
and shall be shipped, handled and stored accordingly.
15.12' The detonators used for this process are the Exploding Bridge Wire (EBW) type, which require a minimum of 600V'to detonate. The de-tonators are classified as Class "C" explosives.
5.13 A single asterisk (*) by a step indicates step ' completion signature /
initials is required on Attachment 7.3.
5"o WA-ADL # Ud Page / Sheet [ of U WA # 42M f/fR
'.. Rsv. 0 5.14 Any time the primary pressure boundary is breached, the requirements of AP 1030, Control of Access to Primary Openings, must be observed.
5.15 Any item entering the OTSG, must meet the cleanliness requirements of Ref. 2.5.
5.16 Exercise extreme care to prevent dropping tools or parts inside the OTSG or piping since such an accident will result in lengthy retrieval operations. Use of nylon lanyards or equivalent means of positive capture is required.
- 5.17 Internal surfaces of the 0TSG must be protected from foreign materials,
~
debris, dropped tools, etc.
5.18 Observe all applicable limits and precautions of the Radiation Pro-tection Plan.
5.19 For entry into the OTSG heads for inspection, equipment installation, maintenance, or equipment removal particular attention must be paid to observing the RWP requirements such as Radiation Controls super-vision and extremity dosimetry.
5.20 If a misfire occurs, Plant Engineering is to be. notified as soon as possible. Misfires are to be noted.in the comments section of Attach-
. ment 7.3.
WA-ADL # 23'E 6.0' Page / Sheet 4 #F 2E WA # A25Y- MII -
(
)
i l Rev. 0 6.0 INSTALLATION REQUIREMENTS se -
NOTE: Attachment 7.3 is tojused during entire plugging procedure. It will be considered the procedure compliance documentation.
1gr 6.1 Clean the ID of all tubes identified in the preceeding sequences using a sthinless steel rotary wire brush and drill motor provided by B&W. Clean the tube ID's to a 12" to 15" depth.
NOTE: The ID surface shall be free of moisture prior to install-ing the plugs per the welding technicians recommendations.
NOTE: The cleaned area of the tube may be swabbed to remove N
excessive' dustud rhothh#d. . S/2h
^
gir 6.2 Prepare the explosive plug.
6.2.1 Assemble the detonation train (detonator, firing cable, etc.) and verify electrical continuity prior to installing the plugs. .
6.2.2 Securely tape all leg wires, holding devices and connections not designed to be self holding prior to plug installation.
6.2.3 Perform check for stray electricai currents using a blaster's multimeter prior to plug insertion. Document the accomplish-ment of this check on Attachment 7.3.
6.3 Install one (1) explosive plug (serial Number) in Attachment 7.3 in
. each of the five (5) tubes in the firing group (See Attachment 7.3).
NOTE: Insert the plug (s) into the tube (s), front (nose) first, and position midway into the tubesheet.
7.0 WA-ADL # 23 Page / Sheet 7 ## O WA # 42M- UM ,
]
Rsv. 0 W 6.4 After the last man exists the OTSG head, the qualified detonator f his representative shall verify visually through the manway that all plugs and wires appear to be in place, and were not dis-turbed by traffic into/out of the OTSG.
NOTE: . Plug / Stabilizer insertion will be completed in upper head prior to explosive plugging in the lower head. (Not re-quired when tapered plugs are to be installed in uts.)
6.4.1 Perform check for stray electrical currents using a blaster's multimeter prior to electrical hook-up of plugs. Document the accomplishment of this' check on Attachment 7.3.
W 6.5 Install temorary manway cover and explode each explosive tube plug in the preplanned sequence as stated on Attachment 7.3.
NOTE 1: If a misfire occurs or a plug fails to fire, stop procedure at the end of this firing sequence and notify the on site OTSG coordinator for resolution prior to continuing the procedure. The B&W Construction Company representative is trained in steps involved in andlin wis e%
9'l# # g a misfired plug. l NOTE 2: Explosive tube plug --1:21..; shall be conducted in accor-dance with B&W Construction Company Procedure 9-EP-01
" Procedure for Once-Through-Steam-Generator Explosive Tube f l
Plug Welding", except as modified herein.
6.6 Repeat Steps 6.2 thru 6.5 until all tubes requiring plugging in the i l
l lower tubesheet are plugged. l 6.7 PLUG VERIFICATION 4 6.7.1. Each tube shall be probed-by pushing a rod or EC probe against the detonated plug to verify plug location.
8.0 WA-ADL # UJ
- Page / Sheet I#N WA # #2f6 NE
Rsv. 0 7.0 ATTACHMENTS 7.1 Steam Generator Explosive Handling-Procedure 7.2 GPUN Letter to Mr. Charles Nork (01/26/83) RE: Blast Plan for Repairs on Unit 1 OTSG's at THI-1 7.3 Checklist for Tube identification, cleaning and plugging (Sample)'
7.4 List of tubes to be explosively plugged.
D WA-ADL # 23-8 9'U E ## 2f Page / Sheet WA # A2 SY- f/C/2.
.* .= ,
kT7~.
STEAM GENERATOR EXPLOSIVE HANDLING PROCEDURE
- 7. /
1.0 PURPOSE To provide for the secure and safe storage, handling, and site transportation of the_ explosive material utilized for the explosive plugging of the TMI-1 OTSG Tubes. ,
2.0 APPLICABILITY / SCOPE The procedure defined herein shall be applicable in' Unit 1. .The scope covers all GPUN personnel and their contractors.
3.0 DEFINITIONS
' 3.1 Magazine - A building or structure used exclusively for the long-tenn storage of explosives.
3.2 Day Box - A structure used exclusively for the storage of a limited quantity of explosives (nonna11y one shift's supply).
3.3 Explosives - For the . purpose of this procedure explosives wi1'1 be.
B&W MK3 explosive plug assemblies and detonator caps. .
3.4 Licensed Blaster / Welder _- Any perton duly licensed by the State of Pennsylvania as qualified to detonate explosives in blasting operations.
i He shall also be a qualified explosive plug welder.
3.5 Explosive Handler - That person directly responsible to the Licensed Blaster / Welder for the safe transportation of explosives and maintenance of Day Box inventories.
3.6 Explosive Plug Controller - That person directly responsible for the
. Magazine inventory.
WA-ADL # 23-8 i Page / Sheet /d 87 2 9 1 10 WA # A2SW-5~/S/~ 2 I
1 4.0 LIMITATIONS AND PRECAUTIONS 4.1 Prior to receipt of explosives on site all necessary licenses and pemits must be available. These include:
4.1.1 Magazine Licenses 4.1.2 Seller Pemit 4.1.3 Purchaser Pemit 4.1.4 Approved Blast Plan 4.2 Separate licensed Magazines for explosive plug assemblies and the detonating caps shall be staged within the Turbine Building at the location specified in Attachment 1.
4.2.1 No flammable material shall be stored within five feet i of the Magazines.
4.2.2 The Magazines shall be clearly labeled " Explosives".
4.2.3 No artificial light shall be used in Magazines except portable electric dry cell battery lamps.
4.3 Blasting operations.will only be perfomed by the Licensed Blaster / Welder.
.4.4 Explosives must always be stored and transported in non-sparking containers. ;
i 1
~
4.5 Explosive plugs and detonator caps shall be stored separately until just prior to use when they will be assembled into one unit (explosive plug assembly) and.thereafter stored in the Explosive Magazine. l 4.6 When opening explosive shipping crates only non-sparking tools shall be i
utilized.
WA-ADL # 23 d Page / Sheet OFU 2.0 WA # 42M'U M a.-
Arr. 7./
l
' ~
4.7 Smoking is prohibited when handling explosives.
4.8 Handling of explosives outside of the Buildings will be discontinued during electrica1 stoms.
5.0' PROCEDURE 5.1 Receipt of Material 5.1.1 Upon arrival of a shipment of explosives at the North Gate.
Security _ shall be notified and shall accompany the carrier directly to the Magazines.
5.1.2 Prior to offloading the carrier, the Explosive Plug Controller.
QC and Warehouse Receiving personnel shall be notified.
5.1.3 The Explosive Plug Controller shall supervise the storage of the explosives within the Magazines and shall update the Magazine Inventory List. He shall also inspect for obvious deficiencies.
5.1.4 QC and Warehouse Receiving personnel shall complete their necessary receiving foms.
5.1.4.1 It will not be necessary to do an individual explosive plug count. A count of shipping containers is required.
5.1.5 The Magazines shall be locked and keys maintained by the Explosive Plug Controller and Security.
5.1.6 The carrier is then released.
5.2 Transporting Explosive Material from Magazines to Day Boxes 5.2.1 At the beginning of every shift, or as necessary to replenish Day Bo'x supplies, the Explosive Handler, the Explosive Plug Controller, and a Security Guard shall open the Magazines.
WA-ADL # U '8 Page / Sheet M *F O 3.0 WA # 42f#-MM
.i - -
7, 5.2.2 The Explosive Plug Controller will transfer the required quantity of explosives from the Magazine to the custody of the Explosive Handler, update the Magazine inventory, and lock the Magazine.
5.2.3 The Explosive Handler will supervise the transportation of the explosives to the Day Boxes located within the Reactor.
Building.,
5.2'.4 The route for moving the explosives from the Magazine to the Day Box will be previously approved by Plant Engineering.
5.2.5 Security will accompany the movement of explosives from the Magazine to the Reactor Building hatch.
. 5.2.6 The Explosive Handler will store the explosives within the Day Box and update the Day Box inventory accordingly.
-5.2.7 ~The Day Box shall then be locked and the key maintained by the Explosive Handler or Licensed Blaster / Welder.
5.3 Moving. Explosives from Day Boxes to the OTSG Tent 5.3.1.During their work shift, the Explosive Handlers will remove the plug assemblies.. . from the respective Day Boxes for (
use during the explosive plugging process.
5.3.2 Upon removal of explosi,ves from the Day Box, the Day Box shall be locked and the Day Box inventory updated. , ,
, 5.3.3 The Explosive Handler will supervise the transport of the Explosive Plug assemblies to the respective OTSG.
WA-ADL # 23
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Page / Sheet O#2
. WA # A2M MM 4.0 K.
- 7. /
Arr.
l 5.4 Explosive Plug Assembly Installation Within the OTSG l 5.4.1 Explosive Plug assemblies,will be handled within the OTSG's and their respective tents by the Explosive Plug Loader and Tentman in accordance with Reference 7.1.
5.4.2 The Explosive Plug Loader and Tentman will receive prior training in performing their functions and will be certified as being adequately qualified.
5.5 Disposal of Misfires 5.5.1 During the explosive plugging process, some misfires may occur.
5.5.1.1 Misfired explosive plug assemblies shall be removed from the OTSG by the Explosive Plug Loader and given over to the custody of the Explosive Handler.
5.5.1.2 All misfired explosives are to be placed in a storage container (Dud Box) within Containment and the inventory of the Dud Box shall be maintained by the Explosive Handler.
5.5.1.3 At the conclusion of each shift or on a schedule dictated by the Licensed Blaster / Welder, misfires shall be removed from the Dud Box, transported to the 3,
Blast Box and detonated. / U ddff D0d NM IAVNff 5.5.1.4 The Dud Box shall be locked with keys maintained by the Explosive Handler or Licensed Blaster / Welder.
5.6 Return Shipment of Explosives
~
Upon the completion of explosive plug operations, all unused j 5.6.1 explosives shall be returned to the vendor. 2.7- 8 l WA-ADL #
Page iSheet 5 of 27 5.0 WA # A2 SX-C/f/2_
Arr. 7. /
5.6.2 The Explosive Plug Controller and Licensed Blaster / Welder shall be responsible for meeting all required packaging and shipping regulations as dictated by the State of Pennsylvania.
6.0 RECORDS 6.1 The following records shall be completed and maintained. . -Q 6.1.1CAackl:St for TDke led.byQW 3 3 C=t ":nrd Chut; (required Ref. 7.1)% PlvgE3
~
6.1.2 Magazine Inventories 6.1.3 Day Box Inventories .
6.1.4 Dud Box Inventory
7.0 REFERENCES
7.1 Explosive Plugging Procedure 7.2 THI-1 Explosive Plugging Blast Plan 7.3 TMI-1 OTSG Repair Safety Evaluation l
l
. I 6.0 WA-ADL # 23-8 l Page / Sheet /[ # 29 WA # A25Y- 5/f/2. ]
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P OPU Nuclear UCIMr. P.O. Box 480 Route 441 South Middletown. Pennsylvania 17057 717 948 8000 TELEX 842-386 January 26, 1983 Mr. Charles Nork 77~. 7.
Chief. Explosives Safety Section Bureau of Mining and Reclamation r [G. ! l 1
PA Dept. of Environmental Resources l P.O. Box 2063 1 Harrisburg,-PA 17120
Dear Mr. Nork:
l l
RE: BLAST PLAN FOR REPAIRS ON UNIT 1 ,
. ONCE THROUGH STEAM GENERATORS AT THREE MILE ISLAND NUCLEAR STATION I
The site Blast Plan for explosive plugging of the steam generators is enclosed for your review and approval. Although it is unnecessary to revise the Blast Plan there are several matters which need to be clarified and discussed. ,
They are as follows: ;
)
- 1. The first page of the Blast Plan, which has been stamped proprietary, ,
contains information developed by Babcock & Wilcox in an extensive :
testing and qualification program for repair of tubes,in B&W nuclear plant steam generators. B&W has, determined that the development, application, and use of this information results in a competitive advantage to them. Items 1 and 3 on Page 1 of the Blast Plan must, therefore, be kept confidential by PaDER.
'2. Item 9, Page 1, of the Blast Plan states that the blast area will be inside the Unit 1 steam generators in tubes located in a two-foot thick tubesheet. This is true with the exception of misfires which )
]
will be detonated in the blast box.
- 3. All magazines have been appropriately licensed following inspection by a representative of the Explosives Safety section of PaDER.
l Upon completion of your review please indicate your approval by signing the Blast Plan on Page 3 and return the original to:
Mr.*J. J. Colitz WA-ADL # -
J3-[
GPU Nuclear Corporation P.O. Box 480 Page / Sheet W
Middletown, PA 17057 ggg g/gf2.
1 1
. I J
Mr. Charles Nork January 26, 1983 A copy of the approved Blast Plan should be sent to:
Mr. D. G. Slear THI-l Project Engineering Manager GPU Nuclear Corporation 100 Interpace Parkway Parsippany, NJ 07054 By concurring with the Blast Plan for the explosive plugging it is understood that we meet with the intent of Pennsylvania's regulation regarding the storage, handling, and use of explosives as applicable to this program.
Your prompt response to this letter will be appreciated. Should you have any questions concerning the Blast Plan or related issues, please contact me at (717) 948-8533.
Sincerely, e*
. J. Col z Plant Engineering Director, TMI-1 JJC:cm Enclosure R. O. Barley, Lead Mechanical Engineer, TMI-l )
cc:
F. R. Faist, B&W Resident Engineer,'TMI-l 6* ]
l Hallman, B&W D.
S. Levin, Manager, M&C Production, TMI-l [G , . 2 D. G. Slear, Manager, TMI Engineering Projects 9
WA-ADL # 23-/
PageISheet _ l7 av 29 WA # A2SY~C/3~f2 G
'[ I, . [ ,
1/13/83
$77o ,bA BLAST PLAN g3 This Blast Plan is written for the Once Through Steam Generator Explosive Tube Plugging Program at Three Mile Island, Unit 1.
PURPOSE: The purpose of this Blast Plan is to document the handling and transportation of explosive tube plugs and initiators.
GENERAL:
- 1. - The explosive assemblies for this job consist of an inconel cylinder '"~'~]
approximately 34 inches long. This cylinder is loaded with 1.9 grams of " - - #-""
nitroguanadine as a main charge and .2 grams of P.E.T.N. as a booster "*' ~ ~ ~ ~ ' l charga. This assembly makes up one (1). explosive. plug. * " " "
2.. The explosive plugs will be assembled by Babcock & Wilcox Construction Company (B&W C.C.) in Apollo, Pennsylvania, and transported to TMI in accordance with federal and state regulations.
- 3. The total quantity of plugs to be used at TMI is expected to be approxima,tely 600 plugs. The total weight of-explosives in the 600 plugs is less than.'.'_,~..T.'.2 ' ~,i 3 Pounds. t...'t......... .. .
- 4. Detonations will be accomplished through the use of Exploding Bridge Wire Initiators (EBW). One (1) initiator will be used to detonate each explosive plug.
-5. General Public Utilities Nuclear (GPUN) is the recipient of this service.
Babcox & Wilcox (B&W) is the prime contractor and supplier of this process.
~
- 6. The total inventory of explosive plugs and initiators will be maintained in security controlled storage areas and in no case will this exceed 50 pounds of explosives and 1000 initiators. ,,,
- 7. The work area will be under Site Security Force control 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> per day, seven days per week, with detonations occurring around the clock with the exception of' production problems.
- 8. Pennsylvania licensed blasters will accomplish all blasting operations.
- 9. The blast area will be inside the Unit 1 Steam Generators in tubes located in a two-foot thick tubesheet. The open end of the tubes will be contained by the dome of the steam generator which is about 7h inch thick carbon steel.
This dome has a 5" handhole which will be connected to a ventilation exhaust system and a 16" manway which will have a temporary metal cover attached
. prior to each detonation.
- 10. Access.to the security controlled storage areas will be controlled by designated Security. Department personnel and/or the B&W explosive plug controller.
WA-ADL # 2N
- Page / Sheet MMN 1.0 WA # A2M- IM2.
E bA ?g, Y 6 kf7e
- 11. Daily use boxes shall be set up inside the Reactor Building. Not more than one (1) day's supply of explosive plug assemblies will be placed in this location. At no time will ~this exceed 50 explosive plug assemblies.
PROCEDURE:
- 1. Explosive plugs and initiators will be received by the explosive controller and inspected for obvious deficiencies then placed in the security controlled storage areas. The explosive plug controller will be responsible for inventory records for receipts at Three Mile Island and at the security controller storage areas. Site Security will accompany all transfers of explosives outside the
~ Reactor Building.
- 2. Licensed blasters will complete the pre-assembly of explosive plugs and initiators, to form an explosive plug assembly, in an authorized area outside of the Reactor Building. Explosive. plug assemblies will be bagged in groups of five (5) and then stored in a licensed magazine.
- 3. Explosive handlers will be responsible for replenishing the' day boxes at the start of each shift. They will hand-carry explosive plug assemblies from the security controller storage areas to the day boxes. The shift licew ed blaster will be responsible for inventory records for the day boxes.
- 4. During their work shift, the explosive handlers will remove explosive plug assemblies from the day box and deliver them to the explosive weld engineer.
- 5. T'ie licensed blaster will ensure that the blast initiation area .is checked for stray electrical currents using a blaster's multimeter.. If currents are detected which exceed 50 milliamperes, the source will be sought and eliminated before explosive plugs are loaded into the steam generator tubes.
- 6. As the tentman and jumper become ready for explosive plug assemblies to be inserted into the steam generator tubes, the explosive weld engineer will hand them into the tent to the tentman.
- 7. The tentman and jumper will place the explosive plug assemblies into the tubes as directed. by the procedure controller, then hand the bitter ends of the firing circuit leads through a slit in the far side of the tent to the licensed blaster.
The temporary manway cover will then be installed and the tentman and jumper will
, exit the main tent to the designated safe area in the tent annex.
- 8. Prior to initiation,- the licensed blaster will repeat the checks for stray electrical currents using a blaster's multimeter. Again if currents greater than 50 milliamperes are detected,'the source will be identified and eliminated.
During testing, the blaster will verify that the firing circuit line is discon- e nected from the capacitor bank and properly shunted.
- 9. Aft'er DER regulatory safety checks are completed and the licensed blaster ensures that all personnel remaining in the area of the steam generator are located in
!' . designated safe areas, he will make final firing line continuity checks using a blaster's multimeter, connect the capacitor bank and fire the circuit.
- 10. Step 9 will be repeated until each individual explosive plug assembly in the
~
group of five (5) has been successfully fired.
WA-ADL # 2M Page / Sheet O A'~ 28 2.0 WA # 42M S75H.
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- 11. After detonations, the firing line shall be disconnected from the capacitor bank, the explosive weld engineer or his designated representative will view the blast area visually to verify that all explosive plug assemblies detonated.
After the ventilation exhaust system has removed the blast fumes, the sequence in accordance with step 5_ through step 11,will be repeated.
If a misfire is de'tected during the inspection, a waiting period of not less than 15 minutes must be observed before the misfired explosive plug assemblies may be removed under the direction of the licensed blaster for storage in a secure area until disposed of.
~
Written by [S[
Reviewed by Reviewed by (B&WCC) M k M F L'l e h s t-n.s3 Reviewed by (B&W UPGD) M A/
h O F // h
. Reviewed by (GPUN) O. O <1 d Approved by (PENN) 8 4, d Chief, Explosives Safety Dept.
of Environmental Resources 3.0 WA-ADL # U-E Page / Sheet 20 of 2 9 WA # #2M-EM2 e
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