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{{#Wiki_filter:. (([' " o,, I UNITED STATES NUCLEAR REEULATCRY COMMISSION o E WASHINGTON, D. C. 20555 k*..../ January 12, 1984 Docket No. 50-289 MEMORANDUM T0: Wayne Houston, Assistant Director f.or Reactor Safety, DSI Hugh Thompson, Director, Division of Human Factors Safety FROM: John F. Stolz, Chief, Operatino Reactors Branch No. 4, DL
SUBJECT:
TMI-1 STEAM GENERATOR REPAIR HEARING Further tc my neno of Decenber 13, 1963 on this subject, I an enclosire e copy of the ASLE Menorandum and Order of January 9, 1984 ruling on motions for reconsideration of some admitted TMIA cententions. Contention Ib and Id have not been changed (see discussion in the Order), but contentions Ic and 2c have been modified significantly. For vour information, I an also enclosing all interrooations and resonnses Sydiable tr ra a. Please note that irte roaations or. the s+a" have r.ct ve* been served but are expected momentarily. A two-week turnaround will be recuired. My December 13 memo identified two contentions in which your organizations should be involved. Subseouent discussions with RSB indicated that AEB shculd also be involved in contentions Ib andor Ic. Please review all contentions and notify Harley Silver as to which portions of each contention you feel should be handled by your organizations. I will assume that the working-level contacts will remain as they have been; i.e., RSB-Ted Marsh, PSRB-Jerry Mazetis, and AEB-Ted Quay. x M9/A3qxp9s M G as
F r n.,. s t .2-DE has received all the above.information separately.. The TACS number to be used for the TMI-1 Steam Generator Hearings is 53295. I s Jo i F. Sto z, Chief 0 ating Reactors Branch No. 4 ision of Licensing
Enclosures:
As stated cc w/ enclosures: 'T. Marsh G. Mazetis .T. Quay ec w/o enclosures: R. Vollmer .C..McCracken d
N} \\ i,.' y[,. ;f+.s# O p. ( + / -s my y uni s tu MATES 7, j NUCLEAR REGULATORY COMMISSION = = 'a = ~ = 2. 2a**5 .y ... ~. October 5,1982 Docket No. 50-289 MEMORANDUM FOR: John F. Stolz, Chief. Operating Reactors Branch #4 Division of Licensing I FROM: Richard H. Jacobs, Pmject Manager, Operating React Branch #4 rs SUBJECT-FORTHCOMING MEETING WITH GPU NUC OF TMI-1 STEAM GENERATOR (SG) RECOV Date & Time: Nonday & Tuesday, 9:30 a.m.-3:00 p.m6. ' Location: P-ll8
Purpose:
Phillip's Bldg., Bethesda, Maryland To discuss results of GPU Nuclear's SG repair qualification pro Requested
Participants:
current testing program, gram, eddyRCS cleanin 'HRC-DEisenhut, Glainas, WJohnston, JStolz, Tippolito, CMcCracken.BJacobs, PWu, LFrank, FYoung-Reg. I, M. i PGrant, EBmwn, JRajan l, flRTConsultants-3 TRC ISFook et. 'al., PNL-RDillon BNL-JWeeks et. al. ORNL-C0 odd Ohio State-DMacDona,ld, GPU-DSlear et. al. l M OperatingRichard H. J cobs, Project Manager actors Branch #4 Division of Licensing cc: See next page l i y y so/bt
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Middletown, Pennsylvania 17057 717 948-8000 TELEX 842-386 October 5, 1982 Mr. Charles Nork Chief, Explosives Safety Section Bureau of Mining and' Reclamation Pa. Dept. of Environmental Resources P.O. Box 2063 Harrisburg, PA 17120
Dear Mr. Nork:
RE: BLAST PLAN FOR REPAlRS ON UNIT 1 ONCE THROUGH STEAM GENERATORS AT THREE MILE ISLAND NUCLEAR STATION The oriEinal of the site Blast Plan 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 ctampad proprietary, contains infonnation developed by Foster Wheeler and Babcock & Wilcox in an extensive testing and qualification program for repair of tubes in B&W nuclear plant steam generators. B6W hac determined that the development, application, and use of this infortation results in a competitive advantage to them. Items 1 & 2 on Page 1 of the Bisst Plan must, thereforc', be kept confidential by PaDER. Item 8, Page 2, of the Blast Plan states that the blast area will be 2. inside the Unit 1 steam generators in tubes located in a two-foot g3; This is true with the exception of misfires which thick tubesheet. ' V#E8TT' '* !Y!I* will be detonated in the blast box. Also, periodically one explosive 6 y 4..J./b./ en expansion will be detonated in a free expansion tube in the blast box to provide assurance that storage and handling of explosive ///,g.c; e4 nrss expansion assemblies on site has not compromised their integrity. ggg g, All magazines will be appropriately licensed following inspection by OMMN 3. Oh' /8 2. a representative of the Explosives Safety section of PaDER. 9
= (".Y.- L c %g Mr.^ Charles.Nork. October 5,.1982 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. CPU Nuclear Corp. P.O. Box 480' Middletown, PA 17057 A copy of the approved Blast Plan should be sent to: ~ .m Mr. D. G. Slear. TMI-1~ Project Engineering Manager GPU Nuclear Corp.. 100 Interpace Parkway Parsippany, NJ 07054 ~ EBy concurring with the Blast Plan 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) 948-8553. Sincerely. 7 n, . Colit Plant Engineering Director, TMI-1 JJC/dsk. Enclosure 7 cc: ' R. O. Barley, Lead Mechanical Engineer, TMI-l .F. R. Fai,st, B&W Resident Engineer, TMI-l l D. Hallman, B&W S. Levin, Manager, M&C Production, TMI-1 C. F. Nash, Foster Wheeler D. G. Slear, Manager, TMI Engineering Projects f I'
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. T.- 1*t ' *. Revision 1 September 16, 1982. BLAST PLAN-This blast plan is written for the Once-Through Steam Generator Kinetic Expansion Program at Three Mile Island Unit I.
Purpose:
The purpose of this blast plan is to document the flow and controls' of high explosives and caps.
Enclosure:
1. Explosive Flow Diagram General: 1. Th'e explosive assemblies used for this job will consist of a polyethylene ~ cartridge 22 or 17 inches long loaded.with detonating cord at 20 or 14 grains _ per foot. A booster which is attached to 25 feet of. ordnance cord - will be inserted into the top end of the polyethylene cartridge.. The assemblies will herein be referred to as a 20 grain or 14 grain candle.
- 2. sThe candles will be assembled by Foster Wheeler in Mountain Top, Pennsylvania.
-The candles will be tied and bagged in groups of 17. Weight / Group of 17 Groups of 17/50 lb '17 in. candles /20 grain /ft. .0729 lb. 685 17 in. candles /14 grain /ft. .0533 lb. 857 22 in, candles /20 grain /ft. .0932 lb. 536 22 in. candles /14 grain /ft. .0725 lb. 689 3. Detonations will be accomplished through the use of instantaneous electric - blasting caps. One blasting cap will be used for up to 132 candle assemblies. 4. General Public Utilities Nuclear (GPUN) is the recipient of this service. Babcock and Wilcox (B&W) is the prime contractor (and purchaser) and Foster Wheeler Energy Applications is a sub-contractor (and supplier). An inventory of ab'ut a 3-day supply of candles and caps will be maintained 5. o in the security controlled storage areas but in no_ case will this exceed 50 pounds of explosives and 1000 caps. 6. The work area will be under site security force control 24 hours per day, seven (7) days'per week, with detonations occurring around the clock with the exception of production problems. L 7. Pennsylvania licensed blasters will accomplish all blasting operations. f% N ff. E FO. II f.M '9 fl W U ht* .il L f;. r 1,,- CE{d,ij(.r'i}qflTn W-O J U L L e... L r 51-1137710-00
- vw-.--n--w--e.,_-,..m
o lg ; *. ' 8.' The blasii area'will be inside the' Unit I 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 7 h-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.. -9. Access to the security controlled storage areas will be controlled by designated Security Department personnel and/or the Foster Wheeler candle controller. 10. Daily use boxes shall be, set up inside the reactor building. Not more than one (1) day's supply of candles or caps will be placed in.this location. At no. time will this exceed 2500 candles (15 pounds or 25 caps). Pro'cedure: 'l. Candles and caps will be received by the candle controller and inspected for obvious deficiencies then placed.in the security controlled storage areas. The candle controller will be responsible for inventory records for receipts at.Three Mile Island t.ad at the security controlled storage areas. Site security will accompany all transfers of explosives outside the reactor building'.
- 2.. Explosive handlers will be responsible for replenishing the day boxes at the start of each shift. They will hand-carry candles and caps from the security controlled storage areas to the day boxes. The shift licensed blaster will be responsible for inventory records for the day boxes.
3. During their work shift, the explosive handlers will remove candles from the day box and deliver them to the candle loader. -4. The candle loaoer will remove the candles from the bag and load them in candle holders. The loaded holder will then be placed in a candle holder t rack capable of holding about 10 loaded candle holde'rs. The candle loader i will keep sufficient loaded candle holders in the rack to load the next blast -sequence. Up to 10 loaded candle holders may remain in this rock during -[ i. detonation of one blast sequence inside the steam generator. The rack will ~ be equipped with a cover that will be closed during detonations. L As the tent man and jumper become ready for loaded holders to be inserted i into the steam generator tubes, the candle loader will hand them into the tent to the tent man. 5. The tent man and jumper will place the candles into the tubes as directed by the procedure and sequence controllers, then hand the bitter ends of the ordnance cord through a slit in the far side of the tent to the licensed blaster. The temporary manway cover will then be installed and the tent man and jumper will exit the main tent to the designated safe area in the tent annex. L e h L i 51-1137710-00
^ ^ .' 4... 9.
- 6. -The licensed blaster will ensure that the' blast initiation area is checked
'for stray electrical currents using a blaster's multimeter. f currents are detected which exceed 50 mil 11 amperes, the source will be sought and eliminated before initiation. During testing, the blaster will verify that the firing circuit line is disconnected from the -blasting machine and properly shunted. After DER regulatory safety checks, the blaster will bundle the bitter-ends of the ordnance cord and insert them into the special detonation device and place the assembly into the detonator suppression chamber and attach the, detonator leads to the firing circuit lines. After ensuring that only authorized personnel remain on the pla^ form level and they are located in designated safe areas, the blaster will go to the "D" -ring control area and check continuity using a blaster's multimeter, connect the blasting machine and fire the circuit. Blasting machine is approximately
- 25. feet from detonator suppression chamber.
7. After detonations, the firing line shall be disconnected from the blasting machine, the control station will view the blast area visually or with the remotely operated TV camera installed in the steam generator to verify that all candles detonated. After the ventilation exhaust system has removed the blast fumes, the sequence in accordance with Steps 4 through 7 will be repeated. -If a misfire is detected during the inspection, visually, or with the TV camera, a w'aiting-period of not less than 15 minutes must ce observed before the mis-fired candle (s) may be removed under the direction of the licensed blaster for storage in a secure area until disposed of. WRITTEN BY R.L.Pruif nd H.4. Fish a/ tom, REVIEWED B b O [] _mm REVIEWEDBY(B&W) 34t/4+t_, i REVIEWEDBY(FW) 8 #'/)L. REVIEWEDBY(GPUN) b.-w 5h h.[M[ APPROVED BY (PENN) A /- SF' Chief, Explosives Safety Dept. of Environnental Resources l 51-1137710-00
,t .a 9 PLATFORM INSIDE THIS RING 13 ABOUT 30 FT LOWER THAN THE CONTROL AREA OTSG BfTTER-END OF ORDINANCE CORDS J U M P E P* WILL BE BROUGHT LOADED RACKS OF AS OUT OF NERE AND MUCN AS 170 CANDLES CONNECTED TO A (TOTAL) WILL BE LASTING CAP HERE MISFIRE hI STING e - BOX CAP \\ f MN g j S BLASTER "D" RING l EXPLOSIVE MANDLER CONTROL AREA IS l SAME ELEVATION DAY BOX AS T0P 0F "0" RING DETONATORS l DAY B0 l CANDLES TME TENT MAN AND JUMPER r WILL STAY HERE DURING l DENOTATION PROCEDURE CONTROLLER I REACTOR BUILDING pg p A 4 SECURITY CONT-ROLLED EXPLO$tVE DETONATOR STORAGE CANDLE. ENCLOSURE I STORAGE EXPLOSIVE FLOW DIAGRAM MAGAZlHE 51-1137710,
..e>- ( " EVALUATION" Three Mile Island Nuclear Station
- 5. [ i 0-r 4 i r < s e i u Safety / Environmental Impact Evaluation M O-
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- 1. Doc. tD _
YMD ~ Number of Dtle [ 2. Safety Evaluation Does this procedure: yes O no V increase the probability of occurrence or the consequences of an accident or
- (a) malftstiction of equipmentimportant to safety?.
yes O no P create the possibdi;y for an accident or malfunction of a different type than any ^
- (b) evaluated previously in the saf ety analysis report?..
'*(c) reduce,the mistgin of safety as defined in the basis for any technical yes O no 7 specification? - Details of Evaluation (Explain why answers to above questions are "no" Attach add A SE-lacc/D.-ooR Nym See GPt/N SAFSTY SVALumfoN required.) .EAffAc,"r EVAlvATioN 6F WSE of SAlcE,7 y ygggggw74 L, S-Ixi oysc, REPA/R 6PERATio^' IMMhAhr$ )(c23 cf / M Date_ t Evaluation 8 n y NRC pnor to
- 1f any of these quest ons are answered"YES" the change must be reviewed and approved implementation.
IGwithnmentalimpact Evaluation 3. yes O no O . Does this piccoddre: 7 possibly involve a rgnificant environmentalimpact f Evaluation" (a) (if 3(a) is "yes'.. answer questions (b) and (c) and fill in "Datails o below.lf no. state why by filing in the " Details of Evaluation" below.) yes O no O have a sigriit?, ant adverse ef fect on the environment ?.. l e iewed yes O no O
- (b)
- (c) ' eewolve a sigmficant environmental matter or question not previous y r v and evaluated by the N R.C..
Details of Evaluation (Attach additional pages if required) w ~s ~ /o!o d -- Date w / / Evaluation 8 Q^ d by the NRC pnor to
- 1f any of these questions are answered"YES" the change must be reviewed and appr implementation.
C. Approval (s) (Per A 1001 A) ICf2/ UA$ A U/ 1st care Segnaturg)%=="1 glMG. h-12db v ^^a a qqg
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. ),7 v 4 - IMMUNOL BUBBLER OPERATING INSTRUCTIONS r120: LIMITATIWS~AND PRECAUTIONS L1'.1.' Nuclear Safety.N/A 11.2f Environmental Safety - N/A 1.3. Personnel Safety-1.3.1> ;Use extreme caution when connecting / disconnecting Service Air Supply. 1.4 Equipment Protection - N/A 2.D-iPREREQUISITES .2.1 Immunol level between and inches visible in level tubing..(Plant Engineering.to provide level banM after filling initially). 2.2 Service-Air System available. Cleanliness of Air Supply verified as aieceptable at frequency specified by Plant Engineering. _j .2.3 Communications established between upper head and 281' Elev. of the D-rings. 2.4 Cold. leg plugs installed with inflation pressure maintaining at approx-imately 20 pais. = . h@ 13 3,, to 9,, g.S t' 2.5 The 'OTSG's must be under a positive pressure of ','z" "";" w".g. (verified by manometer indication) prior to each bubbling operation. 13.0. PROCEDURE' (REFER TO SKETG #1). ' NOTE:. Asterisk (*) indicates to record value on attached Log Sheet (Attachment .1). f
- 3.1- -Verify.0TSG to be bubbled is under positive pressure by reading and record-
- ing OTSG Secondary Side pressure. This pressure must be maintained between
.$n. y s ** - .". _d ""i" w. g. pressure. This pressure is obtained from manometers located'in the Intermediate Building. See Attachment #1 for manome.ter n l'st 6 Th es band,A&MC?lcW ' locations.'IffRES$4RE Is . p sf pAEnanE R & duce g' Int 5 t dG Ax. B Id.. rc netaan P'* ' ' "" ' "$ " sg.d i s ts w 4 /sr Pts " 1 E"'" ' ' TV. .t'a, ' ? " 'I M G 6 N
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- 3.2 Record Immunol~ Level from Indicator (Sketch #1).
Open IS-V26A/B, 27A/B and 28A/B as required. 3.3 Verify' hose connected from Service Air Supply Valve (SA-V140 for A OTSG/SA-V147 -for B OTSG)' to' Immunol Bubbler Rig upstream of IS-V-1A/B. (See. Sketch #2). (NOTE::.This connection also supplies compressed air for cold leg plug 4 air. regulators. Pressure must be maintained on these plugs for the duration of Immunol being in the lower-head). .
- 3.4
~0 pen _ Valve IS-V1A/B and record pressure at IS-PI-1A/B. L3.5 Adjust IS-V2A/B to obtain 10 psig at IS-PI-2A/B.
- 3. 6.
Inform upper head that Immunol Bubbling about to commence.
- 3.7J Open IS-V3A/B and record time.
3.8~ Readjust IS-V2A/B to maintain 10 psig at -IS-PI-2A/B. '* 3.9 After pressures have stabilized record pressures at IS-PI-1A/B and IS-PI-2A/B. 3.10 Discoatinue air supply by closing valve IS-V3A/B when all tubes saturated with immunol as determined by visual observation of upper-head and tube sheet (via video monitor) as directed by Procedure Controller.
- 3.11 Record Immunol Level from level visible in level indicator and record time. Add Immunol as required by STP# 1-82-0061 (Immunol fill / Drain /
Sampling).
- 3.12 Repeat Steps 6 through 10 for repeated bubble cycles as required.
NOTE: Repeat for-a total of 3 times initially and af ter extended idle - periods as directed by the Shif t Engineer. 2.0 W*
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p ~ ( O Three Mile Island Nuclear Station Special Temporary Procedure Note. !nstructions anc guidennes m AP1001 A
- 10. 37P No C-!!I-!! !
must be followed wnen completing inis form.
- 11. Implementation Date SS SF Signature 1.
Title - ^-, M"E -,J #>* fib, 'r"Y ^ 2. Purpose kn wm +. 3. Attach procedure to this form written according to the following" format. Note: If ESAS, EFW. RPS and/or RMS Systems are affected by this STP - insure procedural requirements are satisfied see AP1001 A section 3.6 for details. A. Limitations and Precautions
- 1. Nuclear Saf aty
- 2. Environmentai Safety
- 3. Personnel Safety
- 4. Equipment Protection B. Prerequisites C. Procedure 4.
Duration of STP Shall be no longer tnan 90 days from the implementation data of the STP or ta) or (b) below - wnicnever occurs first. (a) STP will be cancelled by incorporation into existing or new permanent procedure submitted by C tb) STP is not valid af ter Nd A 'C C# (fig in circume'tances wn.cn g' result m STP twing cancealeal 5. Is tne procedure "important to Safety"7 if "yes. complete Safety Evaluation. (Side 2 of tnis Form) Yes gNo C 6. Does tne procedure af fect Environmental Protection ? If "yes". complete Environmental Evaluation. (Side 2 of tnis Form). YesC Nog Review Signatures 7. Generated by M- - m~ 4MMA 8. Reviewed by 8 1 [g74) - Signature Q 03:e
- 9. Approvals (per AP1001 A)
- 2. Note. If ine answers to questions 15 and or 5 l
were "yes" thert approvals must be per
- 1. Note. If tne answers to cuestions =5 and 6 l
AP1001A were "no" tnen tne SS may approve tne g j fp 7 f STP I (pnG) MAfl49t 10/21/8A 5.jna:.re 3 e, l S'g"UwrM./ /0-z/42 SS 5 ;na:wre Da:e g 04:+ l STP is Cance;:ac Shift Supervisor Shift Foreman L* 4g 8-82 ACCGt 133A
_= l Y; Es Nuclear .a TMI-1 OTSG Repair Process Update ~ and Return to Service Overview i October 18/19,1982
a. j NRC OTSG Update 10/18/82
- 1. Oualification Program Update D. Slear
- 11. Final Eddy Current Test Results N.Kazanas 111. Return to Service Safety Evaluation Overview P. W a ls h...._.
~ IV. Interpretation of ECT Results D. Slear 10/19/82 IV. Plant Performance Analysis with Plugging N. Trikorous VI. Sulfur Removal Test Program , Status W. Greenaway 9 Vll. Corrosion Test Program S. Giacobbe Vill. Steam Generator Post Repair Test Program P. Walsh 9 9 e 9 '****e-t em menenemme ee m e geaum me_+ e e e see e ei es> 5 e e .O he * *
- e. emman emema em o
e e a k .-um
p.: - PULLOUT LOAD QUALIFICATION & PREQUALIFICATION DATA PULL OUT LOAD OF 3140 L5.WITH 58% PROBASILITY AT SS% CONFIDENCE LEVEL 35 W REQUAL ~ n = 109 (PREQUAL) N = 39 (GUAL) @ guAL 28 - ~ g ]PREQUAL E 28 ag = 244 LBS g Tg = 4737 LSS ,,PR = 4ssis8 ,,ggg , II ~, g 1pg =4788LSS 13 - g h 5 r-f-r i... n..
== un
== PULLOUT LSAO LBS. / PULLOUT STRAIN QUALIFICATION DATA e $x'? e-
- s., 1
., =,, Fg =.838%
- q. <
T = 5.88 % Q i is E E 2 3 s E 4 8% 2 2 n 1 F'l i O 1 3 3 4-5 6 7 E PULLOUT STRAIN % 10/18/82 6 L;
3 j. O s l I i en P 4 ~4 1 g agm eet E3 O W D 2g* ' ~, _, a l M mA 2 >n ) I g I s., ~. ' k ' ~ tJ ~ n p 5(4I/7 L** I e $O $ ~$ l- % r+ .~ 7 = f j 4( '.I s s y S Oj S \\ r+ ll M i. 7, 5 N \\ \\ \\ \\ \\ 4fg,,,,"<a ' i. '.'} \\ '$$l!lgr N ,d _,o b ) e n 8 P se - - - - - - - ^ ^ ^ ^
7, <, ~., m o. ~ LEAK RATE DATA QUALIFICATION PROGRAM 1D TUBE TEST BLOCKS a 80 800 [**.. p Lock 0 see n .I = l.0 = ses ; l asLOCK s ses ;; BLOCK E 4 48 BLOCK D ~ SP1 MI#"I _ A BLOCK 29 200 BLOCK A ABLOCK SP1 Igg _A, BLOCK A i f 0 0 28 44 88 Og 108 120 TIME (N0uns) 80 808 780 \\ BLOCKD g' jHOT TEST N g 500 g w-BLOCK 0 E 40 488 5 '300 h BLOCK A 2nd SHOT A j 20 SP1 (AFTER STAN0 LNG 200 11 DAYS) A (OCK A 2nd SHOT B 100 4 SP1 (AFTER STANDING 11 DAYS) f e f f f I f f f f f 0 0 20 40 60 In 100 120 TIME (HOURS) 10/18/82 new - - - ~<- 8 ^ - __,_.m...
m Comparison of Rockwell Hardness ~ Rockw 311 "C" Effective Range 70-20 70 60 - Tube Region Tested Unexpanded Transition Expanded 50 - 40 - Rockwell "B" Effective Range 100-0 30 - 105 ID ID Roll Roll OD-20 - 97 CD OD7 B tIU-- o p/ip Klnetic 89 CD ID New Tube 'O 81 73 e 65 tusu 9 0-10/18/82 j
e e_ \\= P. 6 8, e f O e O t O e ( h o .Q i lll3 9 .,s O e S. \\ /M e E g + a i M bO Q-I 4 er g E
- C g
g c. I ~ x: Q C 85 D \\f O ? s O t e e s / 6 ' g. S
y. Roller' Expan'ded Tuba Transition Zone op - f t e h 4e 1 Kinetically Expanded Tube " Transition Zone og 1 1D j ...( l /- p r j-Transition e [ y. _ e.. m__ -h
v - _ _, _ Roller Expanded Tuba Away From Transition Area \\ iQ hh Kinetically Expanded Tube Away From TFansition Area I-E em l e <g>. <g> 1 e I e e e l /% l1 1 ./ Expanded \\. N.. ___
~ ~ IMMUNOL APPLICATION e t
- D 0,t (0
i I lMMU'NOL SUPPLY ~ V _ -__w p=_ A lMMUNOL A i 3 s ,g S -+ L AIR PRESSURE 7 N led[., f")' $c ) BUBBLER SYSTEM 2d <Ps y, g e/ V S-sd k e/ s
- d *' e '
Nh{$l$j @g oN',j p% qu. ,, ~ Og ( p' sd I S' es e e S e-9
- D ese egh 4see e
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y w=r- ~.
SUMMARY
OTSG ECT PROGRAM TASK l 4 l V STANDARO DIPP. G S AMM ECT 1P V V h DEVELOP DEVELOP 10. CALIBRATION CAUWN STANDARO .510 STANDARO if 1P 1F DEVgggp - INEPECT DEVELOP OPERATING EXPANDED OPERATING PanAasETg m AREAS PARAAAETERB e 1P V ORA. ORA. CONCLUSIONS ASSOLUTE CONCLUBIONS PROAATHESE 4X1 PROM THESE PARAA4ETERg PARAA8ETERS, y P ASORT l INSPEC. l TIONS y OPTIMlZE OUAL TECHNIQU EVALUATE m m SulTAaluTY 37 POR TEST PROGRAM AND ENGINEERING y CRITERIA q EXAMINE EXAMINE ADVANTAGES & ADVANTAGES & OlSADVANTAGES 'P DISADVANTAGES RECOMMENOATION O l g e se o e- .,-..,_,,,_.3 _,_,,.,,m.,. ,,,,,_.ow.,,~. 77_,__y.,. ..ws.--
n /.,r-- Pigure V.2 OTSG TUBING DEFECT MOCKUPS SAMPLE #1 (4) NOTCHES LENGTH 0.080". NOTCH DEPTM
- I.D.C ntumrinand NORNES (nA0lEl
- =';';.a====,.%
8.% ( 8 + l a l ( s
- s-mia w,i.
l 92 isens. =*2 min
- g,...,, 1 SAMPLE #2 (4) NOTCHES LENGTH 0.100" i.e.CincumpenenTIAL NOTCH n0Tc4 osPTM-(#A88All PER;tN.T,THRoue# WALL 'e%
2 40% '80% 80% ,mm i.. .I J l { D L L i i g 43 min d a k'181N*' ' ;i. min 4_L 4 s min < SAMPLE #3
- (4) NOTCHES LENGTH 0.137
,,, g,,gg,,,,,,g,,g, NOTCHstPTM-(RA01All PentsNTTNn00sNWALL rn0m 1.0. 20% 40% 80% 80 % l l l l ( e i 8 8 e e e i 92 ming I e32 ulna
- s min d 9 s mid <
SAMPLE #4 (4) NOTCHES LENGTH 0.080" i.o Lons:TuntuAL poTCM NOTCH otPTM + (AXIAll f PERCINT THROUSNWALL 20% 40% 10 % 80% rnom 1.5. I e 1 ( i e e = 6 6 4 42 mM I g 2" M N 4
- s ulN 8
~ 4 5 Ml" I ~ * ~ ~ ' ~~ 5
I FILL FACTOR COMPAR8 SON
- l Standard lll I I I AI I I A I I I '7 I I IS I I I i I I I '3 I I I 's ' I I 's I I I 's s
A a1 .1 a .1 a Differential .137. l
- - :g - - g-i 1.510,35 + RA 400 KHZ 84% FlLL FACTOR
~ i 2.540,35 + RA 400 KHZ 94% FILL FACTOR ' DETECTABLE i l l UNDETECTABLE I 1 .034 .06: .10 t --.14 17 .20 .24 .27 .31 .34 3 g,.100.,.j - 2 E o S l O S o fi E .Os0. 2 1 .os .11 .17 .23 .2s__ .34 .3s .45 .51 .57 a I a l Increasing Aspect Ratios a/L Note: Response 0.150 Volts Min. Sensitivity Lab constion .t ,j
- (Probe Dia.)?
i (Tube ID12 1111111 I I'l l i l l lll11ll 1111lll ll1llll Through Wall 20% 40% s0% 30% 100%
a t, ( GAIN COMP # RISON FOR DETECTION PROBABILITY Standard llll ll I I I , _ M.l l l M.,..l l E l ! l 07l l lM l l l.33 l l l-l31 l l l l l lM-l l l28 l l Differential ,M
- j g7*
100 Mv/piv. 2 3 4 s 1. .540,50+RA 400KHZ 2. .540,45+RA 400KHZ 3. .540,40+RA 400KHZ 2 1 8, $ O 4. .540,35+RA 400KHZ 5. .510,35+RA. 400KHZ O *$
- o a
e O*,* 5 g O a E E 3 3 j 034 .9is 10 .14
- 17. -
.20 .24 .27 .31 .34 ,j QQ, g o E lE z 5 o w au ~ o fo .060. .06 --.11 ,.7 - 1 .23 .28 -- .34 .3 .9..
- 45, 51 7
3 s N h N 1 N N N Note: Response 0.300 Volts Min. Sensitivity Field Conditions IlIllll l'l l I l.I l ll1IIll lllllll l llllll Through Wall 20% 40% 60% 80% ~ 100 %
.a 9 h OPTIM8 ZING FREQUESICY M8X Standard lllllll 12 l l l l l l lllllll lllll]l lllllll l Differential .1 s7. 540.45 + RA 1. 80 MIX IONI.Y) 1400 - 2005 s00 KHz
- 2. ~ 400 KHz t
t I ~ _.e34 .ess .i e, .34 ._s 7 .re .24 .27 .3 .34 1 + ? a 1 5 E i 3 .0s0. .es _.i t _.i7 .pt_ .2s _ .34 .3s .4s _ _ .51 ..57 NN NNN N Ng N s,s i s. N, a RESPONSE 0.300 Vol.TS. usN. SENSITIVITY IIl1IIl lllllll lllllll l1lllll llllll1 ) Through wan 20% 40% s0% s0% 100 % il 4 i ,,J_..
a I AMP!.lTUDE RESPONSE l STANDARD DIFFERENTIAL VS Sul ASSOLUTE' SIMULATED DEFECTS 0.005" WSOE i 1 I ABS Sul (2 RUNS OF 4x1) 53 GAIN 5 SD.540 SO GAIN i 'e 4 h i- _2 / 4e e 6 m 3 il 3 t = a E
- I 2
4 4 i + 99 I .e48' 1 .stl' ji ~ Noise Level l r******* I 10 20 30 40 50 60 70 SO )
- g I
% Thru wem l l 1
c
- )
- j J
ESLET O(Dar71MIQs f S1mspue DIFTEIGNTIAL i MGET. IC OIART FIIL FAC10R CAIN FMUENLY, SA1takTIGE SENSITIVIW Ol'rIMIZED PARAE1 ENS .540 PI0BE 60 - 65 400 Nf3 BASE Pelt 9HNr MG-100 W/DIV mT ArvixEn BDEFITS INCIEASE3 ID MIX IUR SPHTTn PENE-INCIFASED ANAINSP'S SENSITIVIW TSP ABILIW SIQ4AIS ABILIW EUR UtlER-PRE 5RTIOi FRN S.C.R. IEDUOD P10EE SMMHlR EE-ID MIX 10 E-OIATIER EECIS [E-DUCE NOISE (@ISE) 1ECTED (40% i 1HRJ WML 200"l l NN O.060" CIR-400j CLMEIENCE) 800 MIX INCIEASED ELIABILIW IN IEPFATED IESlLTS g-ABSOEDIE ODIL MAGETIC OIART OPTIMIZED ODVERAGE GAIN FIEQlENCY SNIURATION SENSITIVIW PAIW4 IERS 8 (DIIS 4'O - 53 38') - 420 NDP ADhPFABIE 100 W/b1V FOR PENENENT 990ET BDEFI1S INCIEASED lilGI E-MINIMIIED IES-INCIEASE ANMXST 10 36a* SIU4SE SIG-04ANCE ADO CIEES ABILITY EUR IN!ER-CNERME NAL 1RIJC BEmEEN PIETATION FIOM S.C.R. (DIIS lEIL ABOE NOISE
r Recognized Characteristics S.D. Absolute Advantages Disadvantages Advantages Disadvantages 'e Durability e Poor in expanded e Expanded areas e Podr durability areas e Reliable mercentage o Dverly sensitive e High response e Coil to call thru-wal to some surface signals variation for calls anomal!ss response amplitude e 380* Coverage e Low voltage e Not overly e Unreliable response sensitive to percentage surface thru-wall calls e Maintenance e Signal distoratiun e Maintenance of and analysis of minimal data analysis data well (probe design) established e t 6 9 9 \\ 8 1 l
f \\ Recommendation for Production t Examination - 1, S,D. 540 hi-gain most suitable for full production testing. A). Why?
- 1. Excellent durability
- 2. Reliable percentage thru-wall calls
- 3. Maintenance and analysis of data well understood
- 4. Expanded area of tubes was not a factor B) Recognized limitations can be resolved by second method UI 5-
- 1. Ovebsensitivity to surface anomalies can be resolved J,' 96 by a solute
/[,'".
- 2. Low amplitude signals can be interrogated by s.bsolute 3
4 II,' Absolute as a dispositioning instrument. A) Why notfor production?
- 1. Poor durability (0 to 100 tube coverage)
- 2. Unreliable percentage thru-wall calls B) Why as a supporttechnique?
- 1. Excellent supportto S.D. limitations
- a. Surface anomalies
- b. Low amplitude
- 2. Signal distortion is minimal 8
s 5 9 e 9 e
a ( e a o ~ t FLOW CIIART ON GPUN ECT PROGRAM, FOR DISPOSITIONING OTSG TUBES 540 SD 100% TUBES i ) ACCEPTABLE HI GAIN > FOR FULL LENGTH A 7 (RETURN TUBES WITII SURFACE AHOMALIES) l y INDICATIONS TO ] ( 8x1 BE EVALUATED f ABSOLUTE 1 I l V TUBES FOR ENGINEERING DISPOSITION ENGINEERING ) DISPOSITION ) )404 - TAKE OUT 'F SERVICE O AT-401 T.W. 9 y O ~ (40%-IN-SERVICE,SUPPLEMENTARYISIPROGRAM
y; r.cgre..-- m._ ' ^ EDDY CURRENT METALLOGRAPHY
SUMMARY
= CAACMS PULL 3 .540S.D. j IN l E/C.510 S.D. GEN.A4s SELECTION Y V TaCHNIQUE Tc o'ITERMmE QUALIFICATION _ PU TUSEE EvAtuATE . PA LURE CAmosoATE 1P 1I EXAMINE .510 SAMPLES CANDIDATES WITH.See M ~ 1P 1r i PULL 1 & 2 THRESHOLD LOOK POR. EVALUATION 10 INITIATED CIRCUMFERRENTIAL 1005 TH ALL UPPER AREA . DEVELOP LAS INDUCED CRACKS .I i V V LOOK M EVALUATE PARTIAL THRU DRAW. WALL AND @ RELATION CONCLIMION r LOWER gel ~ D G 6 O l t
.r. m g~- p .s ,+ N 2 2 i ~ ~ e n. L.i o.- S.D. BELOW ROLL TRANSITION R.-6 y ~ METALLURGICAL' CORRELATION. ( So#.iS6 g/s. ./. NO. INDICATION CONFIRMED TUBES IN REPORTED INDICATIONS ~ GEN. SAMPLE BY E/C BY E/C MISCALLS OVERCALLS A. 12-23 23 8 0 i B j 5-5 0 0. !15 28 28 0 JC NO. It{DICATIONS - CONFIRMED REPORTED BY E/C 28 INDICATION BY METALLOGRAPHY 28 OVERCALL -0 l MISCALLS 0 28 3 e8 i 15 TUSE SAMPLE 100% AGREEMENT S.D. a e a l 3 i 9 y
s'd .. y ] ABSOLUTE METALLURGICAL CORRELATION 1 0 Below.25"'Fross Top of Tube, 'NO. INDICATIONS CONFI.RMED TUBES IN REPORTED BY INDICATIONS BY MISCALL OVERCALLS GEN... SAMPLE E/C METALLOGRAPHY BY E/C BY'E/C A 16 25I 22* 2 3 B 2 2 2 0 0 ~ 18 27 - 24 2 3 I l 1 NO~ INDICATIONS CONFIRMED l REPORTED BY E/C '27 INDICATIONS BY METALLOGRAPHY 24 OVERCALLS -3 MISCALLS +2 24 26 18 TUBN SAMPLE (INCLUDING ROLL TRANSITION) ~ 92% AGREEMENT ABSOLUTE i 18 TUBE SAMPLE (EXCLUDING ROLL TRANSITION) 1004 AGREEMENT 1 j
- - Work performed with 4x1 3
8,
c%.;, .m >_.a s_: m c o es a m.o 4 o.2 =e a >.o. s *o . s o. e e_Ejje a3 Ea e mEs a l Multiple Crack Region Single Crack Region o N O, -mg O W }_ 'd - a . = ~...,'.m.q.;w..m>p.w w r., m o-:4;.M:.. :.,,,. J.w.,.w'.3.w.7,5.4. fap; Ow n. v W > a.z;.. - n. m,. Q sE ~ .....:.&. c,..-.. -w .,., p.9.w a .,a.s g e.pp% m,gh
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- 4. :
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- w
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- P
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- E W
u..rr. e.. ..s.....h. 80+ + u 0; 7 o 01 g b i-t 7 g y =Q%lM.%W.* - guf,1 * * .I.'.=,':, ).2..,, ;..... ug =g ?,..,4 =..f+i.: x f,3 & v..,.t M y.- g s $2 cf e $'.. c,.v,,. f:(~g. s..;f.r ;..- . ; e. : ., x e '. o O QW . :ig o e, .. = l g
- ==< %
_g g wc o f,+.. e. ..O M. ' '. '. ' '. " '... .. y,,i <.,, :.. '... W j - w.c ::: s,.-.: g:- ~y. 4o w S. T T g* -3 ur e-4 3 efj .n . _:p e_.g. ; *... m.,...b. F 0 .V. ., i .*1 eL C pM O .C.,',-. ,,--,.' e..C O :i 1' QQ p... .s..,.'M. i.' ei a .o .*t.. f, 0.'.. ', ". ' C'.'. ) : ' '. ;... - "i S.- go) O 4w
- a g
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- ~
y,,. Q N gr _= p-ow o, 2 o _r r-o o az .m p o r* m o cc o e q> w# a m m. n. .. o. 2 c, w o o o o o o W o T to N to e N e n n uotsJoAuoo ispueJapunoato e e. .e uE e E =a. l
- 13 e
1% O ..e f o2 i 1 1 i 1
y mn~ n 1...,. LAB INDUCED CRACKS ~
- o 8 SAMPLES TESTED o HIGH GAIN SD TECHNIQUE
- REPORTED-INDICATIONS 7*
- 5 SAMPLES WERE WITH 540 HIGH-GAIN
- CONFIRMED BY METALLOGRAPHY 5 o.. ABSOLUTE TECHNIQUE - REPORTED INDICATIONS 5 ~ - CONFIRMED BY METALLOGRAPHY 5 o USING GPUN RECOMMENDED ECT PROGRAM 8 SAMPLES TESTED g - NO. DISPOSITIONED AS ACCEPTABLE 4 METALLOGRAPHY CONFIRMATION 1004 (includes two samples with,(40% - thru wall) .NO. DISPOSITIONED REJECT 4 .METALLOGRAPHY CONFIRMATION 100t 1 ~
As LOWEST DEFECT j if f BY ELEVATION 50-- jjf! i PLUG _ e '> \\ m 4 LEGEND 'M] Eh REPAllR EaGENERATOR B ~ N 7 amGENERATOR A 9 300-ec l n, l / g',j y I y w N bl d f, 0-b I $d (d4 us I. [ E g 200-f? l pf i$ u. 3,( l I o j / I 1[ ^ (lD. i,[ g 150-11
- s
= I g dy l = 4 hf,! y; fi] f' 100-f. r; ?.. 'i IN h ?- I 50- ~f.' .[ M l-T ls E M -- 05NO JalER S._. 0 I e%p:R:g$$h&&&$4ANAVd'A4$# pk ELEVAT10N RANGE k O
~. PL ANT RETURN TO SERVICE' SAFETY EVALUATION '0VERVIEW l ~ PLANT SAFE I TO OPERATE FAILURE. MEASURES RCS AND STEAM' NO ADVERSE MECilANISM TAKEN TO SUPPORTING. GENERATORS ENVIRON. UNDERSTOOD PREVENT SAFETY SYS, OPERABLE IMPACT-8. . RECURRENCE IINDAMAGFD .4dTALLURGICAL OXIDIZE AND/0R - RCS INSPECTION -REPAIR QUALIFICATION - APPENDIX l TESTS REMOVE SULFUR EXPANSION PLUGS CALCULATIONS l- - SUPPORTING - CORROSION REMOVE THl0 SULFATE SYSTEMS. - UNREPAIRED TUBE ~ INSPECTION SECTIONS OPERABLE TESTS - PREVENT FUTURE CONTAMINATION - TESTING PROGRAM' IMPROVE CHEMISTRY ~ CONTROLS a e
3 -.-.~. _ -- FAILURE' MECHANISM ADEOUATELY UNDERSTOOD METALLURGICAL TEST.RESULTS - STRESS ASSISTED _ INTERGRANULAR CORROSION - INITIATED FROM TUBE INSIDE SURFACE - SULFUR PRESENT-ON FRACTURE SURFACES - SENSITIZED TUB 1NG MATERIAL CORROSION TEST RESULTS - THIOSULFATE CAN PRODUCE SIMILAR CRACKING - AN-OXIDIZING POTENTIAL IS REQUIRED - TUBING MATERIAL PROPERTIES HAVE STRONG EFFECT ON CRACKING SUSCEPTIBILITY - - CRACK GROWTH RATES ARE' RAPID b-4 a 8 6 e 9 4 0 + 6 e a o
w ~ PREVENT ~ RECURRENCE PROGRAM UNDER DEVELOPMENT TO OXIDIZE AND/OR REMOVE SULFUR . THIOSULFATE REMOVED FROM PLANT PREVENT INTRODUCTION OF CONTAMINANTS INCREASE SAMPLING FREQUENCY ON SOME ANALYSIS NEW SPEC 1FICATIONS ON: LITHlUM CHLORIDES. SULFATE SODIUM PH CONDUCTIVITY SILICA CALCIUM MAGNESIUM W 6 9 T 1 hu. . w m- -n-.?v---,-~_,e
7 9.-. c \\..', i 1 RCS INSPECTION
- - LARGE NUMBER OF COMPONENTS INSPECTED WIDE RANGE OF MATERIALS REPRESENTED WET, DRY AND INTERFACE AREAS INSPECTED UT, PT, ECT, VISUAL AND DESTRUCTIVE EXAMINATIONS USED NO EVIDENCE OF ANY lNTERGRANULAR CRACKING SUPPORTING SYSTEMS INSPECTION SYSTEMS INSPECTED IN 1982 AS PART OF THREE YEAR SUPPLEMENTARY ISI PROGRAM WHICH WAS INITIATED DUE TO
~ IGSCC IN SPENT FUEL SYSTEM IN 1979 - SPENT FUEL - DECAY HEAT BULDING SPRAY-Q4 Got-<._ udt yML 6:uld bv % W)CSLA O A % _ So Wu." w & ft~-$ d, Y OrJWv0h t VISUAL AND UT METHODS USED NO DISCREPANCIES NOTED IN THESE SYSTEMS OTHER SYSTEM INSPECTIONS IN PROGRESS G e e e q e e g,
STEAM GENERATOR REPAIR - - KINETIC EXPANSION' - JOINT MEETS DESIGN BASIS PLUGGED TUBES - THREE TYPES OF PLUGS -WELDED. TAPERED PLUG WITH STABILIZER EXPLOSIVE' PLUG ROLLED PLUG .ALL TYPES PREVIOUSLY QUALIFIED AT OTHER UNITS ROLLED PLUG-0UAL. PROGRAM FOR TMI-1 COMPLETED IN FEBURARY 1982 INTERACTION BETWEEN WELDED AND EXPLOSIVE. PLUGS AND EXPANSION ANALYZED - NO IMPACT t -lNTERACTION BETWEEN ROLLED PLUG AND EXPANSION - TEST PROGRAM IN PROGRESS OPERATION WITH PLUGGED TUBES ANALYZED - NO IMPACT ON OPERATIONAL OR SAFETY LIMITS 6 b e e 4 e
.g s' UNREPAiRED TUBE SECTIONS ARE OPERABLE ~ .;. e aj r..+ +..v. - DAMAGE MECHANISM ARRESTED - CORROSION TESTS - SHORT AND LONG TERM - FLAW GROWTH PROGRAM -IceWs.-yk. % M g (CF ~74 w - - 44 g - DEFECTS THAT COULD PROPAGATE BY MECHANICAL LOADS ARE - DETECTABLE AND REMOVED FROM SERVICE - ECT CAllBRATION PROGRAM - CALCULATIONS OF THRESHOLD FOR PROPAGATION UNDETECTABLE DEFECTS ARE ACCEPTABLE - SMALL CRACKS ~WILL NOT PROPAGATE MECHANICALLY - LOCAL IGA IS ACCEPTABLE A SMALL NUMBER OF " MISSED" DETECTABLE DEFECTS IS ACCEPTABLE - SMALL PROBABiL1TY WITH 100% INSPECT 10N - WILL LEAK DETECTABLY BEFORE FAILURE b TEST PROGRAM - LE K TESTS - COOLDOWN TRANSIENT TESTS " SOAK" TIME'TO DETECT LEAKS AND ANY CRACKS THAT PROPAGATE. e e e a w
7,.,
- .V.
ENVIRONMENTAL IMPACT
- ASSUMPTIONS
- 6 GPH LEAKRATE (50 TIMES REPAIR LEAKRATE GOAL) .03% FAILED FUEL -
- 1E (MAXIMUM EXPERIENCE AT TMI-1)
- BASED ON EXISTING PROCESSING CAPABILITY
- RESULTS
- MAXIMUM HYPOTHETICAL OFF-SITE DOSES: APP. I Ll'MIT. SOURCE CALCULATED DOSE FOR TMI 1 IODINE & PART1CULATES 1.5 MREM /YR 15 MREM /YR NOBLE GASES ~ GAWiA 4.2 MRAD /YR 10 MRAD /YR BETA 3.4 MRAD /YR 20 MRAD /YR LIQUID EFFLUENT WHOLE BODY 3 x 10'4 -MREM /YR 3 MREM /YR - LIVER 5 x 10'4 MREM /YR 10 MREM /YR e .h
- e S
9 N. ....~w.. -.---.m.-
7 n l STEAM GENERATOR , POST REPAIR TEST PROGRAM -LEAK TESTS - COLD: DRIP TEST SECONDARY SIDE FLOODED AT 150 PSIG PRIMARY SIDE DRY d N ' l ' . -h #./.'-e BUBBLE TEST 2 SECONDARY SIDE PRESSURIZED WITH NITROGEN AT 150 -PSIG PRIMARY FLOODED ABOVE UTS - HOT: .0PERATIONAL LEAK TEST (1500 PSI DELTA P) PRIMARY 2285 PSIG - SECONDARY 785 PSIG PRECRITICAL OPERATIONAL TESTS - HEATUP - SOAK TO MONITOR LE5KAGE - C00LDOWN AT 70-100*F/HR FOR 1-2 HRS. (500-1100 LB. TENSION) - HEATUP - SOAK TO' MONITOR LEAKAGE - ACCELERATED C00LDOWN AT A RATE AND'FOR A PERIOD TO OBTAIN -- 110% OF NORMAL C00LDOWN LOADS HEAT UP SOAK TO MONITOR LEAKAGE - C00LDOWN AT 70-100*F/HR"TO COLD SHUTDOWN CONDITIONS (1100 LB. TENSION)
v p t + I I STEAM GENERATOR POST REPAIR TESTING SEQUENCE ^' LOWER UPPER I ECT TUBESIIEET TUBESIEET E f 8 8 )" E [ "'S 2 COMPLETE DRIP TEST BUBBLE TEST CLEANUP lF ICAN300 HEATUP FOR NORMAL HEATUP TUBING STRESS -{b-- COOLDOWN LEAK TEST AND TEST h 3 SG TESTING TRANSIENT THERMAL SO* (THERMAL TRANSIENT) l-I ..L I J \\. j f,... 4 J,s .t n e -i 4 COMPLETE fI l POWER- -h> IHERMAL COOLDOWN HFT ESCALATION SOAK TESTING $0' rd [, I / g.. th",1 ~ I OPERATION OPERATION 'd g COh IINUOUS 90 CALENDAH DAYS SHUTDOWN CONTINUED f- 'I NA lbN lE ECT OPERATION F E RIL NOTE: DOUDLE LINE BOXES INDICATE NORMAL
- PLANT TESilNG
~ OR OPEfuiIONS ,.., i'. /. )., a. s. .4. h
g_ _ - 7 I e Flow induced Vibration Analysis Overview i Objective Calculate the threshold between stable and and unsta-ble crack growth based only on mechanical loading in a PWR environment Compare this th'reshold to the ECT detectability and demonstrate that ECT has located cracks which would be unstable (ie: fail by fatigue crack propagation within 40 years) Basis Precritical hot functional tesfing will confirm tiiat a rapid-ly progressing corrosion process will not cause tube leaks once critical Prior to criticality we require assurance that FIV will not cause rapid failure of OTSG tubes O 9 D e v-t---- e-- ,--,,..,-.mm._ m -m ,-,.m., ..m,,,m%_r, n,y.., ,,.,,-,ry,w._,.,,__ ,,r,.-,y,,,.----.
y-n FLOW INDUCED VlBRATidN A) FRACTURE MECHANICS MODEL OTSG TUBE w7 h T 1r I A 2a 1r h n k m GEOMETRY e PART THROUGH-WALL CIRCUMFERENTIAL FLAWS IN TUBES e ASPECT RATIO VARIED T .2.4.6.8 T 1 24 8 10/18/82 e G - -.. - ~.. _
3 / FL,0W INDUCED VlBRATION B) FRACTURE MECHANI'CS MODEL LDADING 'l a Myly hk f ~ ( jM FIV
- 1) P AXIAL LOAO 1
v pj i
- 2) BENDING STRESS DUE TO FLOW INDOCED VIBRATION'(Mply)
- 3) INTERNAL PRESSURE ACTING ON PAR. TING FACES OF CHACK
- 4) SOLUTION OF STRESS INTENSITY PROBLEM BY PROF. F. ERDOGAN, LEHIGH UNIV., BETHLEHEM, PA.
) 10/18/82 w y e-- _y ,, _ ~
l l 2 I 4 Flow Induced Vibration C) AxialTube Load Reflects
- 1. Stretch of steam generator due to' pressure in heads on primary side 2.. Elastic deformation of tubesheet at center-line
_(opposing stretch)
- 3. Tube longindinal stress from internal pressure (poisson's effect)
' 4. Residual axial load from fabricaiion 4
- 5. Shell-to-tube temperature difference, including higher than design basis superheat i
e used + 500 lbf axial tensile load
- TMI-2 instrumentation showed
~ ~ 0 to +500 lbf at > 40% power 10/18/82 i e i i -.. _..... _..._... y - _
r=. _.+ _ - 1 TMI-1 SUPERHEAT-DESIGN BASIS VS ACTUAL 100% 8%
- 15%
DESIGN BASIS ACTUAL VALUE RC 0UTLETTEMP 510 (807.5) 800 INCREASED SUPERHEAT STEAM TEMP. 590 580 l AVG. RC. TEMP. i (582) 570 O RC INLET TEMP. 550 540 TSAT / 530 I I f I l 0 5 10 15 20 25 30 l l TIME, MINUTES l 10/18/82 e _o-eww-,-me. w-i+-,-,-*-
- * * - - - - =. - -
,----v --w-, v
r
-~ -
FLOW INDUCED VIBRATION - D) FIV 11ENDING STRESS - TMI-2 INSTRUMENTATl0N \\- A \\ \\ \\ UPPER TUBE 3HEET \\ "'L=0 \\ \\ / N \\~ STRAIN GAGE MAXIMUM STRAIN-g ACCELEROMETER $8fC E E MMAX / aMID-SPAN DISPLACEMENT O;l / l l 15TH S.P. d / Y I /f N' o L a / L-l 4v g i s N A l \\ l 14TP S.P. i N \\ \\ g ~ \\ w \\ \\ i l \\ l 10Th S.P. A \\ b \\ O\\ DISPLACEMENT MEASURED i' ACCREROMmR AT ACCREROMmR .56 MMax f l /b. / s s -o\\ 6 l / l STH S.P. 6 \\ r j p
- DEFECT CCNEIDERED TO BE.AT L=0 - LOCATION OF MAXIMUM BENDING STRESS
- TMI-2 FIV RESULTS FROM EPRI NP-1878 4-10/18/85 i
l .TMI-2 FIV INSTRUMENTATION LOCATION W a o o o A-3 e o,A3 TANGENTIAL a a y Z X ooo ooo ao 6 o o o I I RADIAL Tuse Tust se S A - ACCELERATION ~ ~ ~ ' SG - STRAIN GAGE O - SLEEEED TUBE A - AOCELER0 METER LOCATED BETWEEN - 9 AND 10 SUPPORT PLAT'E e INSTRUMENTATION BOTH ON TURE LANE AND IN QUADRANT WITH MAIN STEAM OUTLET 4 e LANETUBES EXHIBITED HIGHEST FIV RESPONSE e HIGHEST RESPONSEVALUES USED IN GPUN'S ANALYSIS k 1O/18/82
I TMI-2 FIV INSTRUMENTATION RES'ULTS - STEADY ' STATE TANGENTIAL DISPLACEMENT j,j - \\ / 1.a ~~ j 97% POWER 3 O.8 es g 0.7 g 75'% POWER . 0.5 - a ga 0.4 ee E,0.3 - O.2 ( 40% POWER O.1, O ~ OTSG-15 30 f f g n 3 A 80 a n a 45 50 40 35 30 23 2119 4 1 LANE TUBE LOCATION,glNCHES (ARROWS SHOW ACTUAL TUBE LOCATIONS) e' STEADY STATE DEFLECTION Folk FRACTURE MECHANICS ANALYSIS = MILS. e ONE CAN SAY WITH A CONFIDENCE LEVE.L OF 98% THAT FOR A GAUS,SIAN DISTRIBUTION THE_ MAXIMUM AMPLITUDE WILL NOT EXCEED THREE TIMES THE RMS. 6 m 4 10/18/82 e 4 4 e-*- , = - - - - -, ,-v-- ,.__v.,e-w,--._m.,,,..,.,m--e__ _.__._,.e-m
~ 1 t TMI-2 FIV Instrumentation Results - Transients 75% POWER, 3 RC PUMP 90% POWER, 97% POWER, PEAK HALF-AMPLITUDE PUMP A1 UNBAL OTSG REACTOR / ~ TURBINE ~ ~ ~ DISPLACEMENTS, MILS TRIP OPERATION (a) TURBINE TRIP TUBE 77001 (LANE) 3.7 3.0 3.8 3.4 77050 (LANE) 1.5 1.8 114.9 I 5.4 40113 (BUNDLE) 2.4 2.4 3.3 9.1 12068 (10TH SPAN) 0.8 1.0-0.8 1.7 o e
- O 10/18/82 ww w -
c w me gr yweme.. w i.w
- 4. enw 'et we*
h 2 - r v a e-- - e-v --=---e--n .---w v s
i i TMI-2 FIV INSTRUMENTATION BENDING STRESS TRANSFER FUNCTION VS ESTIMATED AXIAL LOAD d 280 200 240 CMI gg.St#U 220i - g200-
- =
E 1801 a $ 160 .140 3 120- - 5 5 1001 80 77030R 80 . - 77030T
- 77035R 40
- ---- - - 7 7 0 3 5T 2 01 - O' I I I I I I I I -300 -200 -100 0_. 100 200 300 400 500 TUBE AXIAL LOAD (16 ) 9 e RELATION TO 08TAIN BENDING STRESS AT TUBESHEET (L=0) BASED ON TU8E DEFLECTION IN ORDER TO OBTAIN BENDING MOMENT e O 10/18/82 s + ---r ___._..___,.,__._.,._m._ ,,,m.. .,,,,.. _m__
Flow Induced Vibration ~ E) OTSG Tube Fracture Mechanics Evaluation '
- Loads Axial tension, Fax = 500 lbf Bending Moment = 23.73 in - Ib (FIV) @ 75 Hz
~ ~ Pressure acting on parting faces Ap=12451b/in2
- Propagation threshold, AKTh The threshold AK implies a stress intensity factor range below which an initiated crack will not propagate O
10/18/82 u-
n_,m-FLOW INDUCED VIBRATI'ON F) LOA 0 CYCLE APPLIED e FOR FAX =500 lb, ALTERNATING LOA 0 IS FlV ONLY e 40"iEARS OF LOA 0 CYCLING - 1107 b 500 2.365x108 CYCLES /YR / 100*F/HR HEAT UP. C00LOOWN. / TO STEADY STATE %8 CYCLES /YR TIME e m e* me 10/18/82 e 9 9 d '.T.'-.%-
.i,, GENERIC THRESHOLD STRESS INTENSITY .+ .? i DATA UPPER BOUND 1 8a AK SASED ON LINEAR EXTRAPOLATION OE UPPER BOUND ./ / l l/ ' KNEE' REGION I I l AK BASED ON DATA I r LOG AK
- NURE5/CR 1319 DTD JAN.1980
- SCHEMATIC REPRESENTATION OF THE LINEAR EXTRAPOLATION OF THE UPPER
. BOUND LINE TO APPROXIMATE THE THRESHOLD AK 9 O 10/18/82 e
n/ 9 inconel 600 Threshold Stress Intensity (MIT Corrosion Laboratory Data) 10-3'- e FREQUENCY = 5 Hz e R (PMIN/PMAX) = 0.05 e 554*F PURE WATER
- 77 F AIR 10-4 l
l 2 I E. lE \\ i ~ l l .f.l - i. 10-5 EBY ff 4 i! LINEAR EXTRAPOLATION M f J - 5 (KNEE REGION) // x B E 10-8 / / I 58 u u 4; m u i ! l l !I 10-7 ll M e 808*F, TMI-1 PWR CHEMISTRY g e Hz AND R SIMILAR TO OTSG TUBE LOADING i! Ig-8 + 1' 2 3 5 10' 100 THRESHOLD STRESS INTENSITY AKth (M PaM 10/18/82
bI y Stress Intensity Calculation G) Execution of Stress Intensity Solution e The L.E.F.M. computational code, "BIGIF", developed for EPRI, was used to integrate over a ^ range of stress intensities following a modified ' PARIS' equation: dN.4 x 10-10AK3.5 7 a I-e The modification was that of applying a test for (AK)Th Different R values were used when calculating crack propagation due to high or low cycle loading to-4 capture the effect of mean stress i ) 4 .i 4 l 4 4 10/18/82
- a-~*-
- M w-M ;.
-w- . =+ -.--e- --e
== -.-_,y-,um----ms----s=--
p g-~= ECT DETECTABILITY VS. ' FLOW INDUCED VIBRATION 1 .500 FIV (2) ai WlV (1) i \\ Y.400 \\ UNSTABLE STABLE \\ AREA AREA \\ E uMSTA8tE g
- 3,,
g AREA. s - 7 STABLE !.200 AaEA ( - s M ECT- { DETECTED\\_ .100 - j ~ NOT DETECT 5D - I l t i t 0 20 40 80 , 80 100 % THRouGHWALL (l/h) V ~. ~:: I 2a A h FIV (1): AXg = 2;2.MPaVm - ECT: DEFECT-4 MIL WIDE NOTCH PROBE - DIFFERENTIAL DEFLECTION = 14 MILS .540 IN DIA. FIV (2): AKg = 1.1 MPaVm GAIN - 40 + RA DEFLECTION = 3 MILS - SENSITIVITY - 300 MV IN LAB EQUIVALENT l TO FIELD es 10/18/82 4 y -e -E Mf*=_ -*N-erp tsyg trete was= etg s wa g w e-F T f Pwem es-M =r e e hwe * **M W we W"*N " ' " * ~ ' " " -
~% Flow induced Vibration Conclusion
- The.540 inch diameter high gain standard differential probe used at TMI-1 has detected those defects which would propagate unstably from only the mechanical loads anticipated over a 40 year service life
- Once the threshold stress intensity is exceeded and crack ' growth commjences the crack progresses through wallin about 60 hours I
i mID I O = + -.u
_m Leak Before Break Analysis Overview ~ Objective ~ Calculate leakage rate from circumferential cracks to establish leakage as a function of crack geometry Compare calculated leakage to the detectability limits for leakage, to conclude that leaking tubes can be detected and taken out of service prior to the crack becoming unstable due to plastic tearing or ligament necking during the cooldown following leak detection Basis Ensure that tubes can be taken out of service before they are degraded to the point that a double ended rup-ture will occur during cooldown I \\
s j l
- ht PRI-SEC LEAK RATE VS. DETECTABILITY i
30 ' ASSUMED CRACK GEOMETRY 20 - P i-24 - Ap = 2200-900 psi 1 n 1 22 - l 20 - P = +1100 # 3 10 - ' g; JCRACK' 4 OPENING 10 - 'y l a 1 STRETCH m h 14 - l 12 - 'I 4 10 - J l P 0-g XX g, 8-( V-*-lh -*- pi,,,,,,_,_ l 4-2- Pg = +100 #w LIMIT OF / :'Ml""" ' {ux\\\\\\\\ \\%\\\\\\\\\\\\\\\\N G 1 P 2 0U SiE T DETECTA0lLITY 0.10 0.14 0.10 0.22 0.' 0 0.'30 0.34 0.30 ; L.42 0.40 0.00 .02 .00 2 3 j l.D. ARC LENGTH -2a (INCHES) i .0 30' 00* 00* O 12h CRACK 10/18/82 a
l S. mali ECT ID Indications Objective To leave in service a limited number.of small cracks to provide inspectability for crack growth rate studies ECT Results Cracks identified with < 40% through wall Identified cracks are acceptable: - e Cracks will not propogate by FIV e Cracks are too small to initiate ductile tearing - E -- T 9" o e Small number (~76) t6p ~ Conclusion ECT identified cracks < 40% 'through wall will not be plugged l-e e e 10/18/82 1.., ..__e.,_., ,,_--.--..-._..,_.____,m__.
Steam Generator Tube Plugging Plan
- Tubes with defects in high cross flow areas will be plugged and stablilized
- Tubes requiring plugging, but with no defects in high cross flow areas will be plugged but not stabilized
- Plugging plans
~ Area of Crack Location Number Stabilization Stabilized: UTE+ 4'415th TSP 551 UTS + 24"-*14th TSP 1te -. Being evaluated: LTS-*1st TSP 6t LTS*1 st TSP - C'.. s. 9 Not Stabilized: UTS + 4+ UTS + 8 246t ~ ~ ~ ~ ~ ~ ~ n TSP +1 st TSP 3431 ..d 15t Total Plugged Tubes 1146t 6 O G 10/18/82 W O
3 - _.,,#3 _- - l t' ~ DESIGN 8 ASIS ANALYSIS CONSIDERATIONS -OF TM I - 1 SG TUBE PLUGGING PLANT PERFDRMANCE PARAMETERS - REACTOR COOLANT SYSTEM FLOW RATE -REACTORC0dLANTPUMPFLOWCOASTDOWNRATE LOCA ANALYSIS CONSIDERATIONS - SMALL BREAK LOCA - LARGE BREAK LOCA FSAR TRANSI'ENTS e e 9 8 G O e O a e e e S
~ C[ 7. mmy, m. RGS FLOW RATE MINIMUM ~ CALCULATED RCS FLOW RATE AT-TMI-1 = 109.5% - OF-DESIGN ~ FLOW-MAXIMUM ERROR ON CALCULATION = 1.5% MINIMUM AVAILABLE' FLOW RATE = 108%' DESIGN FLOW REQUIRED IN TMI-1-TRANSIENT ANALYSIS = 106.5% DESIGN
- FLOW MARGIN.= 1.5%
FLOW REDUCTION'FROM 1500 PLUGGED TU.BES = 0.8% Y e e h O w 4 e 4 1
7 h 4 e -e e TOTAL RC FLOWRATE VERSUS TOTAL-NUMBER OF TUBES PLUGGED 1.5 D M m - M 6 M e 1.0 E= E e B 3 ' So u s"s 55 .n.-
==
- O g
5 =. us" o.s M M e m 6 6 e I I I 0 O 500 1000 1500 2000
- , TUBES PLUGGED O
k
q w,. ~ . J. RC PUMP kLOW COASTDOWN RATE ANALYSISPERFORMEDWITHB'&W" PUMP"C0bE ~ * - HYBRID DIGITAL AND' ANALOG CODE CASES ANALYZED - - CASE 1: 1 PUMP TRIP WITH ZERO PLUGGED TUBES - CASE 2: CASE 1 WITH 1500 PLUGGED TUBES - CASE.3: TRIP ALL RC PUMPS WITH ZERO PLUGGED TUBES CASE 4: CASE.3 WITH 1500 PLUGGED TUBES RESULTS 1500 PLUGGED TUBES HAS NEGLIGIBLE-EFFECT ON SINGLE PUMP TRIP AND TRIP OF ALL RC PUMPS G e t 9 e G 0 e e 8
g. ._n. i ~ /.. FLOW COASTDOWN FOR ONE' PUMP TRIP CORE FLOW (%)- CORE FLOW (%) TIME (SECONDS) (ZERO PLUGGED TOBES) (1500 PLUGGED TUBES), 0 99.73 99.74 1-98.87 98.92 2 97.42 97.55 3' 95.61 95.75 5 91.88 91.94 7 87.88 87.93 9 84.63 84.87 i 9 O 3 e o S O
y -.~ _. { - FLOhCbaSTDOWNFOR FOUR PUMP TRIP CORE FLOW (%) CORE FLOW (%) TIME (SECONDS) (ZERO PLUGGED TUBES) (1500 PLUGGED TUBES) 0 '99.92 99.83 1 98.24 97.82 2 94.0 93.24 3 87.67 86.74 .5.5 71.8 71.09 7.5 62.4 61.6 9.5 54.6 54.34 G h D 9 e 4 h o S S e S 4 i h_ 4. ,e c e< m.- + ' - - - + - - " - - - - - + - - - -
m.___-- y SMALL BREAK LOCA CONCERNS A. STEAM GENERATOR HEAT REMOVAL IN BOILER . CONDENSER MODE B. - EMERGENCY FEEDWATER SPRAY HEAT REMOVAL ~ C. EFFECTS OF-REDUCED RCS LIQUID INVENTORY ON CORE UNC0VERY TIME 9 I E o a O O 0 9 e 6 0 e e a w = ^ ~ h
~ t STEAM GENERATOR HEAT-REMOVAL IN BOILER-CONCEN9ER MODE GENERIC LOCA ANALYSIS POWER LEVEL-WAS 2772 MWT 1500 PLUGGED TUBES APPROXIMATELY-EQUAL TO 5% SG AREA REDUCTION HEAT REMOVAL CAPABILITY OF SG WILL BE. DEGRADED BY APPROXIMATELY 5% HEAT REMOVAL CAPABILITY REDUCTION - CAN BE OFFSET BY POWER REDUCTION - 5% POWER-REDUCTION FROM ~ GENERIC VALUE REQUIRED MAXlMUM ALLOWABLE GENERIC POWER LEVEL OF 2633 MWT TMI-1 LICENSED POWER LEVEL OF 2535 MWT PROVIDES ADDITIONAL 4% MARGIN GENERIC SMALL BREAK LOCA ANALYSIS IS APPLICABLE TO TMI-1 WITH PLUGGED TUBES ....z.
7% s SMALL BREAK LOCA EMERGENCY FEE 0 WATER HEAT REMOVAL ~ SMALL BREAK LARGE ENOUGH TO'DEPRESSURIZE SYSTEM (WORST CASE SB LOCA) - PRIMARY AND SECONDARY TEMPERATURES EQUAL AT ABOUT 300 SECONDS (SG HEAT REMOVAL CEASES) - CORE UNC0VERY BEGINS-AT 1350 SECONDS - PEAK CLADCING TEMPERATURE OCCURS BETWEEN 1600 AND 1700 SECONDS - CORE RECOVERED AT ABOUT 1750 SECONDS - EFFECT OF SG COOLING ON THIS ACCIDENT IS NEGLIGlBLE (SG ACTS AS HEAT SOURCE FOR MOST OF.THE TIME DURING THIS EVENT) - EFFECTS OF REDUCED EFW HEAT REMOVAL ARE NEGLIGIBLE SMALL BREAK WHICH REQUIRES SG HEAT REMOVAL TO DEPRESSURIZE SY' TEM S -THESEBREAKSIZESDONdTRESULTINCOREUNC0VERY - REDUCED SG COOLING WILL RESULT IN ADDED PRIMARY SYSTEM INVENTORY BOIL OFF INVENTORY REMAINING IS SUFFICIENT TO PREVENT CORE UNC0VERY PEAK CLADDING TEMPERATURE REMAINS AT SYSTEM SATURATION TEMPERATURE (500 - 650*F). d o REDUCED EFW COOLING NOT EXPECTED TO RESULT,,. M' gP,.t :,f IN CORE UNC0VERY y 0 .L& v y'$p@ (W $i f gy
y n. ~~- SMALL BREAK LOCA RCS LIOUID INVENTORY FOR WORST CASE'SB LOCA -ANALYSIS PERFORMED AT 2772 MWT-CORE UNC0VERY OCCURED AT APPROXIMATELY 1350 SEC WITH 1500 PLUGGED TUBES: .1. CORE UNC0VERY WILL OCCUR APPROXIMATELY 3 SECONDS EARLIER 2. . PEAK CLADDING TEMPERATURE WILL INCREASE BY ABOUT 10*F 3. PEAK CLADDING TEMPERATURE WILL REMAIN AT APPROXIMATELY 1100*F CONCLUSION GENERIC SMALL BREAK LOCA ANALYShS APPLICABLE FOR TMI-1 WITH PLUGGED TUBES e F 9 0 9 9 a S
w w g A h LARGE'sREAK'LOCA CONCERN ~ -ALTERATION OF LOOP AND CORE ~ FLOW PATTERNS DURING EARLY PHASE 0F~LB LOCA EVALUATION-FLOW REDUCTION OF 0.8% FROM 1500 y* - ~ -PLUGGED TUBES 'W' .:..; r &(y\\ ')
- FLOW RATE USED IN GENERIC LOCA ANALYSIS WAS 137.9 x 100 LBS/HR
?(\\. r TMI-1 DESIGN BASIS FLOW RATE IS 106.5% OF 3 CYCLE 1DESIGNFLOWOR13g.8x106LBS/HR. Y(f REDUCED' FLOW = 138.7'x-10 LBS/HR. TMI-1 REDUCED FLOW RATE GREATER THAN LOCA ANALYSIS VALUE B & W SENSITIVITY STUDIES HAVE SHOWN THAT HIGHER INITIAL RCS FLOW RESULTS IN LOWER PEAK CLADDING TEMPERATURES ~ ' CONCLUSION GENERIC LARGE BREAK LOCA ANALYSES ARE APPLICABLE TO TMI-1 WITH PLUGGED TUBES. O
3 ~ t FSAR TRANSIENTS TRANSIENT EFFECT 1. UNCOMPENSATED OPERATING REACTIVITY CHANGES REACTIVITY AND RADIATION RELEASE TYPE 0F EVENTS 2. STARTUP ACCIDENT /CRA ARE UNAFFECTED BY ' WITHDRAWAL AT POWER TUBE PLUGGING 3. MODERkTOR DILUTION-4. CQLD WATER ACCIDENT 5. STUCK / DROPPED ROD 6. FUEL HANDLING-7. ROD EJECTION ~ 8. MAXIMUM HYPOTHETICAL 9. WASTE GAS TANK RUPTURE e 9 6 ~ t e 9 O e e I 9 g _we,-,m, _.2---
w n-y_ ~ j f, . FSAR TRANSIENTS (CONT'D) TRANSIENT EFFECT 10. LOSS OF COOLANT FLOW UNAFFECTED SINCE FLOW COASTDOWN RATE UNCHANGED FROM ZERO PLUGGING CASE. FSAR ANALYSIS ALSO BASED ON MINIMUM-RC FLOW. 11. LOSS OF ELECTRIC POWER - FSAR RESPONSE UNCHANGED. 12. STEAMLINE FAILURE FSAR ASSUMPTION'0F SG g-INVENTORY WAS VERY 3, CONSERVATIVE (55,000LBM)N."'2' e FSAR BOUNDING. ,f v-.f W 9 13.- SG-TUBE RUPTURE-FSAR ANALYSIS WILL BE UNCHANGED. 14. LOSS OF FW/FEEDLINE NO EFFECT OF TUBE PLUGGING BREAK ON PEAK PRESSURE IS EXPECTED. LONG TERM DH REMOVAL CAPABILITY WILL NOT BE EFFECTED. CONCLUSION: PLUGGING OF 1500 TUBES WILL HAVE NO IMPACT ON FSAR ANALYSES. FSAR REMAINS BOUNDING. 4 i e B O e a g'^ eseame= hs n;--=--
RCSblaanu:0 Purpose - Eliminate Possibility of Future Attack o Convert sulfur.to innocuou's form i:SO4: 1 as quickly as possible under protective Ialkaline:I conditions e Remove as much as the SO4 from th.e system as possible . Options ~e Steam generators only
- Entire primary system o Core in~ or out Use known, safe technology e
6 10/18/82 c
Extent of Sulfur Contamiriation ~ ( gm SO4/ft2) _4 4 Fuel Rod i: Clean ' 533 AldT uhm G'id 418 r RN.S Retainer 530-700 RNS Spring 144 Tubes - upper SG plenum 970-3600 Tubes -Iower SG plenum 770-930 Tubes - during fabrication < 250 i: Method sensitivity - 250: 1 10/18/82 4 m.-,__. .;,______.,m._._....
l BMI Ni S Tests Ni S 17 ppm SO4- .C.r =_. 5 X 10-3cm) H22 200 ppm, O ppm 0 ~ Temp ' 25 C,33 C Cever gas air, argon. pH 4.5, 8, 9 e l a e 0 10/18/82 w , mma
--v ~ SO4 = FORMATION RATE. MEASUREMENTS FOR REACTION BETWEEN ~ NIS AND H 022 IN AQUEOUS MEDIA AT pH8. RUN N0.7 _________,y,,, CONCENTRACTION 1s-RUN N0.'1 l RELATIVE REACTION t ",u," SriNNaNa rEme m TUNE. 3 NATE 'C !t to-1 .1 2s j s 1/2 2s 3 7 1 33 Eg i RUN NO. 7 (sLANK). so 44 - g s-RUN NO.1 (SLANK) RUN NO. 5 (SLANK) A!$= g g i i i i O 58 100 158 200 258 REACTION TIME, MOURS O 3 0 \\ 10/18/82 e e-e v t -+-w--r e -,www,w-, +,- .,-e-,-e .------w-m-w
- mwe
ev e,---s
e----m%--
1: c .c Y '34 ? F SO4 = FORMATION RATE MEASUREMENTS FOR REACTION BETWEEN NIS AND H 022 IN AQUEOUS MEDIA AT ROOM TEMPERATURE, pH8, AND RELATIVE STlRRING RATE OF ONE. maximum so. CONCENT m loN RUN No. Is ts_ ] RUll NO.1 - i RUN N0.12 3 I E CWEE H 8 CONCENTRACTION 22 g I le. ~ 1 INITIALLY 200 PPM A8R g h. 13 INITIALLY 200 PPM AA005 15 fAAINTAINED AT 25 PPM AIR E e' ", s-RUH NO.15 (BLAllt) RUN N0.1 (BLANK) - AUN NO.13 (BLANK) ,__u 0 , 5'O ide 1$8 2$0 2$3 REACTION TIME HOURS QV V y W k q v ( 4 O e O 10/18/82 W
H022 CONCENTRATION MEASUREMENTS FOR THE REACTION BETWEEN NiS AND H 022 IN AQUEOUS MEDIA AT ROOM TEMPERATURE, pH 8, AND RELATIVE STIRRING RATE OF ONE see - k { 2ee - .s Y! numm0.is 2 E ~ los - o C E N82 2 TARGET LEVEL (H 8, ADDED AT VERTICAL DASM MARKS) 22 RUN NO.15
- i i
i 4 0 50 100 150 200 250 REACTION TIME. HOURS e e 10/18/82 )
.= Conclusions from NiS Reaction Rate Measurements t i
- 1. With H 02 2
- Decreasing stirring rate increased SO4 formation rate e increasing temperature increased SO4 formation rate SO4 formation rate the same at pH 8 and pH 9 but..
initially about 4 times slower at pH 4.5 No difference in SO4 formation rate between air and argon i II. Without H202
- SO4 formation rate decreased with decrease in stirring rate e increasing temperature increased SO4 formation rate
- SO4 formation rate decreased with decreasing pH-
- SO4 formation rate approximately zero in argon.
- Initial and final conversion r.ates made slower than with H202 10/18/82 g
...,_9 m ap e, e, .,,_*p-e _
7 i J-E Consultants GPUN Workshop - RCS Cleanup BatteIIe-Columbus Aug ust 9-10,198'2. Name Company Jack H. Hicks Bablock & Wilcox Company Yale Solomon Westinghouse Electric Corp. Fred Pement Westinghouse Electric Corp. Mary Miller Battelle-Columbus . Arun K. Agrawal Battelle-Columbus Henry Leidheiser Lehigh University v 1 Warren E. Berry Battelle-Columbus Merl J. Bell NWT Corporation R.H. Barnes Battelle-Columbus, Paul Cohen Consultant (EPRI) Joan Lathouse Battelle-Columbus Afaf Wensky Battelle-Columbus 10/18/82
== a f 5& y.'y n PHASE 11 l Friority Descriptiost pil H02 2 (PPs)' 8 (ppm) S Form Temperature t I 1 ,/ Zero Run-1 8 (Nil ) 200 (unstablised) 2300 N1S (17 ppm) Room Temperature 3 f ,-/ Zero Run-2 8 (Nil ) 200 (unstablized) 2300 NIS + I-600 Room. Temperature 3 Zero Run-3 8 (NH ) 200 (unstablised) 2300 Tetrathionate (20 ppm) Room Temperature @p^ [ZeroRun-4 8 (NH )3_ 200 (unstablized) 2300 Nis + I-600 130*F 3 p 2 Tubes Run-1 8 (Nil ) 20 (maintained) 2300 Tubes (3"-7") 130*F 3 t Tubes Run-2 8 (Nil ) 20 (maint ined) 2300 Tubes (3"-7") 130*F 3 Tubes Run-3 10 (L10H) 20 (maintained) O Tubes (3"-7") 130*F f Tubes Run-4 10 (LiOH) 20 (maintained) 0 Tubes (3"-7") 130*F 3 Tubles Run-5 8 (Nil ) 02 (cover gas) 2300 Tubes (3"-7") 130*F 3 deleted Tubes Run-6 8 (Hil ) 02 (cover gas) 2300 Tub s (3"-7") 130*F t ,4 3 Tubes Run-7 10 (L10ll) 03 (cover gas) 0 Tubes (3"-7") 130*F4p F Tubes Run-8 10 (LiOH) 02 (cover gas) 0 Tubes (3"-7") 130*F > I 4 Corrosion Run-1 8 (Nil ) 20 (maintained) 2300 U-tubes, C-rings, 130*F 3 Corrosion Run-2 8 (Nil ) 20-(maintained) 2300 and tetrathionate 130*F 3 Corrosion Run-3 10 (Lioll) 20 (maintained) 0 (20 ppm) 130*F j Corrosion Run-4 10 (Lioll) 20 (maintained) 0 130*F t 5 Corrosion Run-5 8 (Nil ) 02 (cover gas) 2300 1 U-tubes, C-rings, 130*F 3 deleted Corrosion Run-6 8 (NH ) 02 (c ver gas). 2300 and tetrathionate 130*F 3 Corrosion Run-7 10 (LiOH) 02 (cover gas) 0 (20 ppm) 130*F i Corrosion Run-8 10 (L10ll). 0.(cover gas) 0 130*F 3 I6 ") Immuno 1 Run-1 8 (Nil 3) 20 (maintained) 2300 3-1, 3 -2, 3-3 130*F Immunol Run-2 8 (Nil ) 20 (maintained) 2300 3-4, 3-5, 3-6 130*F 3 Immunol Run-3 8 (Nil ) 20 (maintained)- 2300 3-7, 3-8, 3-9 130*F 3 Immunol Run-4 8 (NH ) 20 (maintained) 2300 4-1, 4-2, 4-3 130*F 3 -m.m.m. (a) = All samples (12 pieces) should be rinsed with DI H2O(pH9k0.withNil0H). Use 100 m1 from a squirt bottle 4 for cach piece and as much as possible treat them identically., T i I! r
m Corrosion Tests Conditions - like cleaning except 02 cover Specimens - 304SS 1:Sens.;l U-bends,1-600 U-bends iTMI. Heat Treat:1, C-rings from TMI tubing l NaS added as corrodant at same rate as . released in first test Test length twice time of SO4 release ~140 hrs 4 e 1 4 6 I 10/1s/s2 y.- :p.=--.--_-- _- ;_ ,-- - _- ;.. _. = :- =--:===---
1 1 i I
- 1 l '
+ l]I itBE CLEANIIIG EXPERifENTS j, a;. !Ii N0 Concentration.- Reactten Zg Type of Test ' Sample nel som* Teaserature, of Cover Gas o Sulfur Cleaning Inconel Tubes pil 8 (H B0 /lel 0st)
- 20. maintained 130 Air 3 3 4 pHle(L10H)
- 20. maintained 130 Air o
o Corrosion Inconel C. Rings pil 8 (N 50 /198 'lH) -
- 20. maintained 130 0
3 3 4 2 and U-Be d pH10(Ll0H)
- 20. maintained.
130 O g l o Sulfur Cleaning of Immunol Treated Inconel pH 8 (H 80 /NH W) M. maintaW IN Air ].! 3 3 4 Issunal treated Tubes tubes 4 feet from i: espanded region pH10(L10H)
- 20. maintained 130 Air
]i-o Sulfur Cleaning of Transition region of pH 8 (H 80 /lel 0H)
- 20. maintained 130 Air espanded Issuunol treated Immunol treated 3 3 4
- ?]I tubes Inconel tube s
d Trans.tlon region of pil 8 (H M / W UH)
- 20. maintained 130 Air 3 3 4
j untreated expanded il inconel Tube 1 1 Isaunol Treated Inconel pH S (N 30 /lgt 0H)
- 20. maintained 130 Air
~ 3 3 4 tube 20 inches from expanded region '] ; ty-Untreated inconel Tube pH8(HB0/lel0H)
- 20. maintained 130 Air 3 3 4 20 f.iches.from espanded j
region ., l
- Unstabilized H 0 22 9
0 S 1 h 0 e .I I 0
h i -t ~ 1.0-f ll .1 - 50 Concentration e 4 e Equivalent to Sulfur - In Tubes 1 e J e T g, 0.5-2 o b E ~ 8 l I 0 t i 0 50 100 150 200 { . Reaction Time. Hours 1 PRODUCTION OF SO DURING CLEANING OF Sul.FijR CONTAMINATED INCONEL-600 TUBE SAMPLES WITH H 0 4 MAINTAINEDAT20 ppm (TubeA78-32-2) 22' i 4 j -{ y ~.
~ .l _.- l _, l I L -. _. L _. I - I i.
- i..
i,i f r,_-. .I-i- a-4 e L. Addition of sl 0 2 2 I 1 ( l i H0 Target Level 20 + - - - - - - - - - - - - - - - - - - - - - -* - - - - - 2 2 l. ~ j l i e e i 10 - e e 1 4 e e is 0-0 50 100 150 200 ii Reaction Time. Hours i 11 0 HEASUREMENTS HADE DURING CLEANING OF SULFUR CONTAMINATt6 INCONEL-600 TUBE SAMPLES WITH H 0 22 22 i: HAINIAINED AT 20 ppm (Tube A 78-32-2). i k i I
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,,.,,,,c ~,. i y 22L469 LT= 200 SECS 1000X GENER'AL SCAN. --e 5000 N I C R q ij 4000 u-
- i.
h Element Weight Percent ~ AL 0.9 SI 2.2 gggg ]~-~ ~~-- ~ ' 5. 2 a, I-- TI 0.7 2 --) CR 27.8 i O ~ FE 5.9 1: U 2000 .h NI 57.4 3 e j' 8 y kE y d' 1000. g AI T NL I p 1 E j I 6.-A g U. L r= -. q g -7 e. i s.ses s.saa 18.ses 15.see 28.eas E4ERGY(kev) ENERGY DISPERSIVE X-RAY SPECTRUM FOR SULF JR CONTAMINANT AREA (AREA C) IN CROSS SECTION OF AS-3 RECEIVED INCONEL-600. TUBE. a
LT= 1000 SECS TEST TUBE 1 N ] ll s 1 t i
- 3 Element Weight Percent 20K an.
o.s a i. SI 0.9 q h C Cs oO (( R-1 o.2
- j y)
CR 19.3 M, b c-Z FE 12.1 W D c o NI 66.4 lll u d' 10K F E
- il N'
il C I ' NAS CT F S . ILI R I 1 E ljI [ ~. w. Ju l J. u. g i 0.800 5.800 18.900 15.999 20.900 di .i ENERGY (kev) AT pil8. ENERGY DISPLRSIVE X-RAY SPECTHUM FOR ID SUR/ ACE INCONEL-600 TUBE SAMPLE AFTER CLEANING ~ f
- .g LT=
1000 SECS . N EXEC (2-V) DATA LABEL i '~ I l* l 20.K Element Weight Percent AL 0.9 , \\.. st 1.s P 0.3 "q C' TI 0.4 R U) CR 19.0 I i-FE 12.4 z NI 65.4 a O l U i 10K j F' E ~ C -N j I N P CT F I R I E wJ Jy i 3 g, 8.800 i 5.000 19.000 15.000 20.800 i ENERGY (kev) ENERGY DISPERSIVE X-RAY SPECTRUM FOR ID SURFACES INCONEL-600 TUBE SAMP H 0 AT pil 10. p7
.j 1000 SECS n.
- 3 X SECTION: AREA 2 4
LT= [ I ji l;: I C 40K R Element. Weight Percent Al. 0.5 SI 0.9 1 P 0.2 30K TI 0.3 CR 23.7 l I M FE 14.2 n I-- NI 60.3 .3 l Z. i. o F u 20K g j' 1 j I C N ~' It 10K R I j h P T i ' N Myu f ~~ N J L i g 8.800 5.800 10.800 15.800 20.800-r ENERGY (kev) l ENERGY DISPERSIVE X-RAY SPECTRUM FOR SULFUR CONTAMINAIED AREA (AREA 2) IN CROSS SECTION OF INCONEL 600 TU6E SAMPLE AFTER CLEANING WITH H 0 AT.pH8 l p2
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LT= 300 SECS RUNL#3-X SECT 10N-2A: .N-I 10K Element Weight Percent i C At 0.8. ~ R sr-0.4 CR .22.8 FE-8.7 ), U) NI 67.3 I l--- ~ ZD o '5000 t._) t t p E N' C I R N AS F I E I LI q .) g i B.800 S.800 18.000 1S.600 20.800 ENERGY (kev) ENERGY DISPERSIVE X-RAY SPECTRUM FOR AREA 2, POINT A IN CROSS SECTION Of IHl10N01. C0ATED lilC0ilEl.- 600 TUDE SAMPl.E FROH ABOUT flVE FEEL FF0H EXPANSION ZONE AFTER REMOVAL Of Sulfur BY 1130., Cl.EAllitir. AT n11 10.
=~ 4 Preliminary Conclusions from TMI Tubing Cleaning & Corrosion Tests
- 1. The process works about as anticipated-
- 2. Cleaning time appears to be <100 hrs
- 3. No indication of corrosion has been seen
- 4. Presence of Immunol does not appear to be detrimental to the process O
4 e ) e 10/18/82 8 i .,,.w , ~ _ _
=. 2._:- Work in Progress
- 1. Loop tests
- 2. Preparation of plant procedure
- 3. Completion of radwaste considerations
- 4. Confirmation of IX performance 1
- 5. Method development on reduced sulfur on swipes 5
9 e \\ ~ o G e l 10/18/82 1 L ...[ -.(([ 2-.) .,._S. Id'* [. m ..d. ' 7 ~ -.I-*_1_._,_m._,.._ i*""*^ * * * ', * " '. - -... - - -.. -,. - -, -, -
= CORROSION TEST PROGRAM OTSG RECOVERY TU8E STATUS FAILURE MECHANISM ENVIRONMENTAL REPAIR v v ASSESS IF PRIMARY COOLANT STILL SCREENING TESTS AGGRESSIVE TO OUPLICATE CRACKING MODE y. 9ERIFY C'ORROSION SCENARIO WILL CRACKS -. PROPAGATE IN A PRIMARY COOLANT v REPAIR QUAL. TESTING PARAMETRIC STUDIES W S B LI T 'I 02 (T EVALUATE CRACK ARREST TECHNIQUES V SHORT TERM i m TESTING e PRIMARY ESTABLISH OPERATING
- SECONDARY PARAMETERS V
i LONG TER' M 4 m V V ^ LEAD TESTS - PLANT OPERATION LONG TERM ) TESTING e PRIMARY \\ ,' ~ Lc.. st+~" i. ' *uI O \\ {i" - s S.g, :. s
- n.M e'.
- m s.
.'g 4 'f s' p g
- ~
10/18/82 w.,...---
==.. =-- Long Term Corrosion Test Program Objective: Duplicate HFT sequence and typical reactor operation in the laboratory to assess environmental effects on tube - performance. This test will lead actual OTSG operation i i . and attempt to duplicate planned operational sequences Test Duration: Approximately 1 h months ~ ~ Test Specimens: Lead Test f Full section tubes Actual TMI tubing C-rings Actual TMI tubing and archive tubing (heat M2320) i Repair O.ualification~ 4 Single tube /tubesheet mockups using actual TMl tubing Test Parameters: r Chemistry Typical primary water chemistry with contaminents at maximum specification levels Temperature-Ambient to 600 F with temperature cycling Load C-rings s~ tressed at 90% Y.S. ~ Vull section tubes, loaded 500-1100 lbs ,-. _ - ~/s e e j Pressure Actual primary and secondary operating pressures 10/18/82 9 .....-,-&..m, ,.i.e-,,,. ~ I l'['*
9....--= .'}i 3 g;- k'h ~ )f.$ TEST LOOP SCHEM ATIC - f ,e t SAMPLE AXIAL MApE LOADING g TANK PRESSURE a i T CIRCULATION PUMP- ) A 8 m l ~ f"* t u / j ~ ~ AXIAL .$AMPLES. C RIN6S' ' AS SHOWN = LEAD TEST (FOR REPAIR TEST, 1-- WITHOUT CAN OF C RINGS) CATCH TANK. 10/18/82 v"" ~ " ,_..[__'- .?' ~~ ,_,5,., , $.',,N IN,, ?l, TA I- < ~~ - ~ ~, 'N ""e' ~~~$ ^~ ~
n. SAMPLE LOADING FIXTURE Q's \\ LOADING BELLOWS f UPPER ACADING PLATES It i 1 l A EFFLUENT FROM SAMPLE 3 l M ~ SAMPLE LOADING FIXTURE 8 ACTUAL OTSG TUBE SAMPLE v f $$iNG R + INFLOENT LINE PLATE 7 e INSPECTION CAP L l' 10/18/82 e --.---.-_;_=,.-- =. = = - ....=. -.... -.
T__ ' ~ ~ ' ~ ~ _. Summary of Specimens-Long Term Corrosion Testing Lead Test Solution 1 Solution 2 (thiosulfate) (sulfate) Full Tube Sections w/o indications as-removed 1 1 Immunol treated 1 Immunoland H 02 1 ~ 2 treated w/ fndications as-removed 1 1 Immunol treated 1 Immunol and H202 1 . treated ID stressed C-rings actual TMI-1 tubing 15 15 archive tubing 4 4 Repair Test all actual tube sections without defects as expanded - 4 loaded,2 unioaded Immunol. treated, expanded, H202 cleaned - 2 loaded,1 unloaded-10/18/82 r-w-- e wem .m-- - -,, -=e ,-----..~---m' ^'~I
m y g ~ u SOLUTION 00tISTR(- 1 s JADTEST f.ADIEST w.UTIONl' A UTION 2 .REPAIRIEST 1-Bm0N, PPH AS B 2350-100 2350-100 1200-100 Li,PPHASll Oh'.5 0.h.5 {2.S 0. CHLORIDE, PPH AS 6. .05 .15 .05 .15 .05 .]'; Fl.umiDe, PPM AS f .05 .15 .05 .15 .05 - ilS THIOSULFATE,,PPMAS% .05 .15 I SULFATE,PPMASS0r; .05..15 .05 . I'. j HYDRAZINE, PPH (IMbil) .2-10 2 - 10 2 - 10 l 02 PPB ( 10 (10 ( 10 l 112 cc/m 15-110 15 10 '15 110 I% TO BE DEFlili11 i ~ i i i e
~ [ 33 ; i. 0 0) ~ j H a il O n 1 - Precondition e No samples in place
- Establish 550-600 F in autoclave
- Flush with demineralized water until conductivity
-is acceptable
- Run test solution until:
Outlet SO4 is > 90% of inlet concentration ~ _.jp w.c u. % s.: 4. & Insert Specimens 3 - Operate' System o Run simulated cycles - HFT and operational e Specimen load - 500 lb during heatup and hold,1100 lb during cooldown 1 10/18/82 l tm& "****'~~_T~'X'~?~,'~.
, : iT 1
--~~,-[? '~~' ; A - ^ ' ~ " ' ~~
J t 'i . LEAD TESTS ]
- n m._.
.s t ] s ,c. l- - TEMPERATURE g -( - - - - - - LOAD j' ,,j - l, e ll i a .3 lift CY6LE 83 OPERATIleG CYCLES it c ,g II g1 O II ' gg- ,e l' si S si ' l, ,i il = sn e 6=- c n m 3->-,8' g
I E
U-g- r-- i 500' i.8 g l I _3 1' E 4.'O l ADD 1-c- I NEW - 2 WEEKS I E I SOLUTlON I F -I 7 DAYS ~ i I j l i - AMBIENT I i t i ,i 2N I l 3 AMBIENT 8 I [s ag}g7;,p. D4 t 8 150'- g
- 30 DA'_.' *
.l 50* 2' WEEKS l%., I WEEK % lw-- I 8 l l l . 1. I i I,.,. L _! l. l. 1.l I I. I i . i _L o y... 0 2 4 6 8 10 24 26 28 30 32 34 36 51 58 1,.1 90 l 24 DAYS. 66 DAYS y 11 RUN) ISIX RUNS = 396 DAYS) t L
d J REPAIR TESTS t s g I l l 8 1061 8 l .f i i. p-
- i f
8 4 ,s g it i TEMPERATURE 8i N 11 E0 la Il Ig - --- LOAD g Il i-3 p 3 gi - g y Il-I' 9 3I al I g gg g t s .4 n i is e i s CIA 8 g li ,g g a3 'c , 8-t l 't I' l l 8 l I g g L 8 3 g l l 0 8.E I ______.J. -____.'_____..l i___._.'___ __ _ _ __ a e _ _ _ _ __ _ I $XAMIN__E c I. in I SPECIMENS O Q-AND EDDY. .p'. ) h 2 WEEKS 4 WEEKS 4 WEEKS 4 WEEKS CURRENT Il i !j TEST I w h I l l ~ j I 2t0 l 1 WEEK l d I i I p l / l r l' c' e i .~ ' r - 13(P g i 1 AMBIENT ,.l..._ l I i l l l-l TEMPERATURE 'I g l 1 8 9 23 24 54 61 91 121 124
- i DAYS I
l .f Repeat 2 to 3 Times ~
p
- 3 I
8 c LONG TERM CORROSION TEST SCHEDULE, l y LEAD TEST ist 2nd 3rd 4th Eth sah HFT Operational Operational Operatismal Operational Operational Operational Evalmate Data Cycle ycle Cycle Cycle - Cycle Cycle - Cycle P I I -l 1 'I I I I I laterim Interim lateria. Final Repesa Report Repari Report 14-17 menil. - 30 day 90 day 8 meaths Data Data i e R,EPAIR TEST 1st 2nd. 3rd Cycle Cycle Cycle Evalmate Data l I l_ l 1 l I I I laterim laterim laterim Final Repeen l Report Report Report 14-17 me. ui. 60 days 4 months 8 months 1 ) I I l' l-1 I I I I I .I Oct Dec Jan Mar May Jaly Sept New Jan Mar May .l..s v 1982 1983 1984 j' 1nd a u/u2 m
g i ^ s l ) Specimen Evaluation 1 - Full Tube Specimens
- Eddy current prior to operation with 0 540" std.
differential probe e Eddy current after each testing cycle e Metallurgically evaluate at end of program 2 - C-Rings e After each cycle, visually inspect all specimens e At end of each cycle, remove one C-ring and metallurgically evaluate e Metallurgically evaluate all specimens at end of program i 4 3 0 e 10/18/82 f 3,v,yp.he~' - -- T ~ -- _,__.,,7,_^;- _;;,:_ __ ; ;: ; - ~-- 7- - _.f; 7:=;7 7-- '7-
- =,7 r---
r;,,,.. -~.m :
7- ,a ^~ ^ ~ ~ ~ ~ b.f. ~ N, Au \\' '[ 'o,, UNITED STATES ! \\* NUCLEAR REGULATORY COMMISSION a h., WASHINGTON, D. C. 20$$5 \\...../ OCT 2 0 1982 Docket No. 50-289 FACILITY: THREE MILE ISLAND, UNIT NO.1 (TMI-1) LICENSEE: GPU NUCLEAR CORPORATION (GPUN) i
SUBJECT:
SUMMARY
OF MEETING WITH GPUN ON SEPTEMBER 15, 1982 CONCERNING ? GPUN'S STEAM GENERATOR (SG) REPAIR PROCESS . 7
Background
As part of their program to recover the SGs from intergranular stress corrosion cracking of the tubes, GPUN has proposed a repair program . involving an explosive expansion technique.to recover tubes with defects within the upper tubesheet (UTS). The purpose of the 1 September 15, 1982 meeting was to provide a final briefing to the staff prior to start of the actual repair and to resolve any remaining staff or staff consultant concerns regarding the repair itself. A copy of GPUN's presentation is enclosed. A list of attendees is also enclosed. Discussion GPUN's proposed repair process consists of kinetically or explosively expanding tubes within the UTS. All 31,000 tubes will be expanded for 17 inches or 22 inches within the 24 inch UTS. In order to establish a qualified seal, there must be a six inch area free of defects. Hence, a 17 inch expansion will recover tubes with defects only within the top 11 inches and a 22 inch expansion will recover tubes with defects g only within the top 17 inches of the tube. The process involves use of low level explosives including prima cord, booster, ordance transfer cord ~ and blasting caps. The prima cord and booster are inserted into a poly-ethylene " candle" and detonated by a blasting cap outside the OTSG via h the ordance transfer cord. GPUN will be ready to commence the expan-sions in mid October 1982. Related actions involve secondary side flush, crevice drying, expansions, debris cleanup, plugging tubes unable to be recovered and testing. GPUN expects to complete these operations by 9 December 1982. The staff issued a Safety Evaluation limited to the steam generator repairs on October 13, 1982. No staff members or staff con-sultants raised concerns that would postpone or prevent GPUN from j_ commencing the repairs. A meeting has been scheduled October 18 and 19, 4 1982 (previously October 13 and 14) to discuss remaining aspects of k i JM T/ ~ m ()_ ^\\ ,e S.._ 6i
= p:,' TMI-l. -GPUN's steam generator recovery program. E ? >Y 04, S E g Richard H. Jacobs', Project Manager y Operating Reactors Branch #4 Division of Licensing f
Enclosures:
l. List of Attendees 2. GPUN's Presentation E cc w/ enclosures: g See next page k e i f m F b: ' ~ E I
i
- 5. :
i..- ORBf4:DL~ MEETING SUM 4ARY DISTRIB TION Licensee:- GPU Nuclear Corporation A o' pies also sent to those people ~on service (cc) list for subject plant (s). C L Do'cket File NRC PDR L PDR ORBf4 Rdg Glainas JStolz Project Manager-RJacobs Licensing Assistant-RIngram 'OELD' Heltemes, AEOD IE 'SShowe (PWR) ' Meeting Sumary File-ORBf4 RFraley, ACRS-10 Program Support Branch: ORAB, Rm. 542 BGrimes,. DEP - SSchwartz, DEP' .SRamos, EPDB FPagano, EPLB Meeting Participants Fm. NRC: C. McCracken J. Rajpn E. Brown e '6 R. Major F.-: Young, TMI Site L. Frank H. Gray, Reg. I H. ' Bramer. e =
Enclosura 1 ~ LIST OF ATTENDEES NRC GPUN G. Lainas P. Clark J. Stolz D. Slear C McCracken E. Wallace R. Jacobs J. Colitz J. Rajan R. Neidig E. Brown J. Fidler R. Major M. J. Graham F. Ydung, TMI Site S. Giacobbe L. Frank H. Gray, Reg. I GPUN Consultants H. Brammer B. Barratt, F.W. D. Pai, F.W. NRC Consultants J. Pearson, B&W L. Leonard, FRC R. Kosiba, B&W T. Shook, FRC S. Weems, MPR Assoc. V. Luk, VRC J. Concklin, B&W C. Davey, FRC Other S. Maingi, Pa. BRP L. Connor, NRC Calendar A. Manik, PANE
Nuclear i TMi-1 OTSG Repair Process Description / . Qualification e September 15,1982 W-www m -e -pesee-y w e== e e-=- hem
= TMI-1 Steam Generator l i ELEVATION CROSS SECTION W PRIMA'RY SIDE . sr.rg.:. (INSIDE TUBES) m p t:r."e ". 9 :"* " ' '.~ *~- ~, UPPER -L'- TUBESHEET (UTS) ~ N3St-h.~MN-AUXILIARY ,.-m 74E47G +.g 5 FEEDWATER e. g,,,g _, i ypptaggg N0ZZLES a im - Z -^ 1 - (AFW) ps3gD. J.% X 4'; g 1 ;gw4-5 Fr M M.L;q 3 aa j l' !1..:#a; d.YINg((sh k ~ ~ l 3 _a,.!J =.* w m, Pf wm STEAM'00TLET N j / D'm - %w + - - 'g LANE MAIN FEEDWATER j yQ nillr N0ZZLIS (IWFW)g iom A oTUBE [ g aiu..w. T y l 4,.pf O 4i U SECOND ARY SIDE h l,',h d,.' (EXTERNAL TO TUBES) il D," ' .ns~ - Weight, operating.............. 637 tons ,m-
- g,,
Height....................... 7 3 feet , 'T"" * - Primary flow.................. 6 9X 106 #/hr. Steam flow................... 6.1 X 106 #/hr. SUP me - PLATES \\ Number tubes................. 15531 h,,, Tube size, material............. 0.625" od,.034 wall .o i LOWER inconel 600 SECONDARY
- i.
g Manufacture date.............. 5/69 to 11/70 HANDHOLD 9/15/82 I =- =. = = = = = = = = = = = - - - - - - - -
= =. TMI-1 Steam Generator Typical Cracks. INCONEL TUBE i g x, p9<e TYPICAL CRACKS ROLL TRANSITION / . -l b I / 6 ^ / STEEL TULESHEET CRACK CHARACTERISTICS: CIRCUMFERENTIAL BELOW FILET WELD NOT FULL ARC GENERAL.LY VERY TIGHT PP.lMARY SIDE INITIATED ---w =w ...h,.
TMI-1 OTSG Repair Process (Steps / Sequence) 1, Flush secondary side tube /tubesheet crevice . (complete)
- 2. Heat crevice to drive out moisture (in process)
- 3. Pre-coat OTSG surfaces
- 4. Kinetically expand tubes for 17" or 22"
- 5. Cleanup debris A. Organic residue on RCS surfaces B. Explosive particulate residue C. Pieces of polyethylene candle l
- 6. Plug tubes with defects below UTS + 8"
- 7. Leak tests
- 8. Plug or roll leaking tubes (if required)
. 9. RCS cleanup (if required)
- 10. Pre-critical operational testing 9/15/82 l
l [ - ~. _ _ _ _
u - =. - - - - 4-B KINETIC EXPANSION PROCESS ORDNANCE CORD DETONATING CAP HOLDER r I / ) / n c ecc y '@%%pe-e e ,. c ' (' A tt mum I " 7( e ~' ' OETONATING ELECTRICAL CAP SIGNAL .j ll 4 ORONANCE CORD E i 3 BOOSTER 97 ER CORD 24." POLYETHYLENE INSERT ~ V u y 9/15/82 g
=..-- . Kinetic Expansion' Length (Repaired Tubes). PRIMARY FACE UTS VfMf/Mffi #4 K M .A w wm 1; a:: om au:. ys M ZONE WITH LENGTH OF M ME DEFECTS
- EXPANSION A
Wh,y st! qN %b 5 A 17 $?5 Qilj B 22 fi?$f 58 6 a% M$
- p w[M, m
14 1 1.".- 3 w .]?fhl ,a y; ~ w: a B E$ i$ $7
- TUBES WITH MULTIPLE DEFECTS IN 1_ _6_"_.
- .T M
THESE ZONE COMBINATIONS TO RECEIVE 1_7_ _" - 22" EXPANSIONS SE AB m <= Ma,5" = W 22"_ _ _ _ _ _. !/ M / M M f M VA SECONDARY FACE UTS L 15TH TSP 4 9/15/82 ,e.a m-s-.4r*
- m%'
~ ~ -
+. i e Kinetic Expansion Length (Plugged Tubes) PRIMARY FACE UTS VfffffffA #A Q R.m v %e ZONE WITH LENGTH OF is@ DEFECTS
- EXPANSION A(
M*'I## y s': ?T? C. 22 W, -/ wN 0 17
- 9 JOk E
17 Mc ps t? n S5b; W i 1 , _ _1 ". _.m %q Mir a w eo s< El M;3f ' i !t jgi
- TUBES' WITH MULTIPLE DEFECTS IN 16" "T
THESE ZONE COMBINATIONS TO RECEIVE 1_P_...~ 22" EXPANSIONS ~ S$ AC C 5" BC 2__1"________==.5 CE = , 2_ _2. "_ _ _ _ _ _ - - fffff///g,,( f/j
- ALL REMAINING TUBES W TI H MULTIPLE -
SECONDARY FACE DEFECTS AND NON-DEFECTIVE TUBES TO - UTS t RECEIVE 17" EXPANSIONS E' { 15TH TSP 9/15/82 B 4 -uu.+mo.*#-a.,-e.-w..w .2...~m.#_ _m _,.4.------.2 .--._w--
Kinetic Expansion Experience Foster Wheeler ~* Expanded over 5,000,000 tubes in h over last 20 years angers
- CRBRP intermediate heat exchanger (171 expansions) e Repaired MSR's at Salem 1 and 2 (17 640 expansions)
B&W
- Tested as manufacturing process - 3 tubes at Oconee ill with 24" cxpansions at both ends nservice W
\\
- Used in field to close tube to tubeshe steam generators revice on CE -
- Used to close steam generator tube to tu crevice during manufacture e
l 9/15/82
.= -+ s i Repair Criteria (1) The maximum allowable primary-to- ~ secondary leakage rate for normal operation shall be as low as reasonably achievable and allow plant operation within the radioactive effluent limits of the technical specifications. O 9 9 9 9/15/82 p l J
____.x..___._- ~. - s Repair Criteria (2) Repaired tube shall sustain, with adequate margins, the design basis loads Loads Generic 177FA TMI-1 LOCA + 2641lb + 2641 lb MSLB + 3140 lb + 3140 lb FWLB - 620 lb - 620 lb Normal cooldown: + 1107 lb + 1107 lb i- + = tension ~ - = compression r O = $ 9/15/82 ~ ~ ~ ~ ~~ ~ ~ - ' ~ ~ ~ ~ ~ ' ' ~ r
'f e e' Repair Crite.ria (3) The effects of both repaired and plugged tubes on the thermal and hydraulic performance of the plant and on the. structural and vibrational . adequacy of the steam generator shall be evaluated and shall be within the acceptance criteria for both normal operating and design basis accident conditions as specified in the licensing basis documents. e 9/15/82 I
Third Party Review Purpose To provide a timely, independent, objective, safety evaluation of all activities defined in (the scope of) this charter for conformance to: 1? the NRC rules and regulations governing the operation of TMI-1 2? the adequacy of the steam generator repair program that will allow safe operation of the nuclear unit l Scope
- Failure analysis program i
- Eddy current examination program
- OTSG performance evaluation
- Repair criteria e OTSG repair program 9/15/82
-= --~
- o 0.ualification Program Elements Foster Wheeler i
Load carrying. capability e and leak tightness Babcock and Wilcox e New transition stresses
- Chemical constituents of kinetic expansion device and residue OTSG cleanup - use of precoat.and final OTSG e
surface residue concentrations t 9 9/15/82 9 + +*-- g, y
== Other Program Elements Technical support considerations 1 ~ OTSG design basis Presence of IGSCC Site preparations Crevice dry Explosive handling Effect of process on other equipment O.uality control Manufacturing facilities During implementation at TMI-1 ALARA 9. ~, - -,.. :~ ~:. I~.: ~T - ~~ ~ ~ ^ ~ L'
-=--- r s ' e* Third Party Review MEMBERSHIP SPECIALITY AREA Stephen Brown Non Destructive Examination -EPRI NDE Center-S.A. Holland Plant Operations -Duke Power Co., Arturs Kalnins Stress Analysis -Lehigh ' University' W.H. Layman Safety Analysis -NSAC David J. Morgan Cheinistry -Penn. Power & Light E.J. Wagner
- Steam Generator Design
-Burns & Roe and Performance Dick Weeks Materials .-Argonne National Lab
- Chairman 9/15/82 o
-<a*e +i-,,-,*===w -,-em. 4-g we e,. - -. -a m --m.w-. .-.,-w-+--.-
OTSG Repair Program Plan / Schedule 1982 1983 MAR APR MAY JUN JUL AUG SEP OCT NOV OEC JAN FEB MAR COMPLETE OTSG/RCS INSPECTIONS N ECT REINSPECTION COMPLETE LONG TERM TESTING N TUBE EXPANSION g L QUALIFICATION i i 0TSG REPAIRS COMPLETE Y m e CREVICE FLUSH IEEEEEEEEEEEEMEMBE, e CREV!CE ORY i i e EXPANSION j e PREC0AT i e OTSG CLEANUP e PLUGGING i e LEAK TESTING i PLANT AVAILABLE FOR i POST REPAIR I PRE CRITICAL TESTING e RCS CLEANUP - e HOT OPERATIONS - 12/82 eECT e POTENTIAL REPAIR l O 9/15/82 5-m- ... #ep h e64m en.emi me.a --vgc .m. --e.m
= o Key Elements of 0.ualification Program I. Joint 'ualification
- Prototypical kinetic expansions
- Proof test expanded joints
- Thermal cycle condition joints
- Axialload condition joints l
- Determine water leak rates
~
- Determine joint pullout strength O
r I 9/15/82 l
Key Elements of O.ualification Program Continued II. Supporting tests Evaluate residual stress at joint L transition Determine adjacent shot effects ~
- - Determine double expansion effects Evaluate joint integrity with different crevice corrosion Determine joint strength with different annulus size i
Determine induced strain effects Evaluate tubesheet ligament distortion 4 9/15/82 n-v--- +, e- ,e, .n.,, ,-.e ,,-._,_,,.,.,-,_,,.,_,.y.,, .,,nm--,,.,,,,,,._-,
~10 Tubo Leak and Load Test Fixture PRIMARY SIDE TEST EQUIPMENT HYDRO CONNECTION sa PRESSURE GAUGE r THERM 0 COUPLES J SEAL WELD TIMER [ HYDRO PUMP (, LOAD TEST DEVICE ~ Oj-/";g \\ l 1" MECHANICAL ROLL ,',/p/ { Q '' "" %*4 i
- p _f Q3 g'
p:fA ! N \\N-';xN / '/! \\ \\], / / i \\ , :f f i- >\\N / / i' \\ i ,' fl h u / L \\ / 10" EXPLOSlVEs / - y/ q \\ / EXPANSION . N; i s , / b Q' {/g / k N
- ~N i
,4 I Z
- \\ SEAL WELD
\\ \\ $a! \\ \\ I N'\\ ~
- yl'u'iOk4
.1, 1 s x! N \\- N1 a. g' N f SEAL WELO i CONDARY SIDE HYORO CONNECTION LOAD TEST SEAL WELD FITTING l e 9/15/82 j I;. d z_ _ _ _. _
1_ 9 k Pullout Load Design Basis 70' 5 / High Yield tube 56 ./ 4 1 Low yield tube 42 3140 lbs.7 3 ,g o I O x l 5 i v) m g 28 a 2 Tube OD = 0.628" Tube thickness = 0.0385' '14 g 1 e t ";o 0-I I I I I O I O 0.2 0.4 0.6 0.6 1.0 1.2 Strain, % Design basis: 0.16% strain at 3140 lb. load for 0.625" OD X 0.034" wall tube 9/15/82 r u -- -
e ~ Pullout Load 0.ualification Criterion Pull-out load of 3140 lb. with 99% probability at 99% confidence level Preliminary Cata 35 /69 n =W E o = 480 lbs. .9 ' 25 Y = 4706 lbs. lii> e 20 5 Y C 3140 = 1.5 e 15 N 30 ,a ~ o 5 n i i I I I I I 9 0 1000 2000 3000 4000 5000 6000 Pullout load Ibs. The above assumes a load-controlled behavior Actual ' vent is thermally induced (strain-controlled) T== 6.0% a i g .16 = 37.5 .16% i i j7, 2 i i i i i i .i 0 .2 .4 5. 5.6 6.0 6.4 Pullout strain, % 9/15/82
2 Water Leak Rate Design objective: 1 lbm/hr. per plant (3.2X10-5 lbm/hr./ tube) 0.ualification program objective : 3.2X10-6 lb./hr./ tube O.ualification data points for (a).10 tube average / test block .(b) Corroded blocks L (c) 6" Expansion l (d) 360* fully severed tube (defect) l -(e) Demineralized water p e \\ _, + - , s. - ru ,e o ~ 2.4X10-6 lb./hr./ tube e ~ 10.5X10-6 lb./hr./ tube j, < g. # e ~ 23.3X10-6 lb./hr./ tube (after thermal cycling, equivalent of 5 year life) .l ',' [,- e ~ 30.3X10-6 lb./hr./ tube (after thermal cycling,1 8 J...s.' l equivalent of 5 year life) 4 9/15/82 l' ~ ,...,w --..-a- _---,--,-~,._,emw-
= Water Leak Rate Measurement Leak rate is measured using pressure decay of an enclosed water volume under pressure Pressure Temperature Effect Effect dP BT Leak Rate = PV [(K+K') _dt _ 4 ( g,_ g ) d t g
- Where, P = Density of water V = Water volume K = lsothermal compressibility of water K' = Structural elasticity of enclosure
' = Coeff. for enclosure volume change due to temperature = Coeff. of volumetric expansion for water due to temperature dP = Rate of water pressure change - d d = Rate of water temperature change P t 9/15/82 "?' ~ _, -~
- T ~.
_?,-._., ' *'~*r ~ ~ ~ %e
Error Analysis for Leak Rate i I Physical constants 5% ~ Teniperature correction 20% ~ Other measurements 3% ~ l l l l l t e 4 9/15/82
1g 4 i B&W Presentation t Qualification Program ~ . Kin tic expansion transition e t - Control of materials [ - Process residue characterized li - Immunol precoat - Clean Up f ~ Technical Support Activities - Effect of Process i - Existing crack-indications ( - Pressure vessel integrity it Site Preparations i - Crevice drying tests [ - Maintaining crevice dry 5 - Mt. Vernon test - Explosive handling [ Quality Activities u i: - Off-site preparationsefforts - Site effort j
- ALARA h
l .m,
- 1. _ _ _ _.-.
o
-mL-- ..o. B&W Presentation i e L
- Qualification Program
- Technical $upport Activities 3
J 4 Site Preparstions 1
- Quality Activities
- ALARA Update j
2 -5 5 i: k 9/15/82 ? b =
= Qualification Program Kinetic Expansion Transition o Design Objectives: - Transition length - Required > 0.1" - Goal > 0.125" o Verification Program - Prequal mockups 2 0.15" - Residual stress measurements /Penn State x-ray defraction - Mt. Vernon test - 0.3" to 0.45" - Accelerated corrosion test in 10% NaOH -kinetic /hard roll o Transition produced more gradual than those with' sat. service - Years of sat. operation with stress relieved hard roll - Kinetic expansion transition is longer than hard roll - > 100 unstress relieved roll transitions remain in service after 9 years /Oconee i o 9/15/82 .,,,,_,o -M: -b
4 Qualification Program Control Of Materials o Specifications - Sulfur 5 250 ppm - Chloride and fluoride s 250 ppm H.eavy metals s MDC* o Process materials analyzed at source o Cleanness controls implemented - from source to OTSG - Manufacturing - Assembly - Site handling & storage o Changes made in materials to avoid introducing harmful elements - Transfer cord for detonator cord - Organic booster substituted i - Eliminated resin coating in detonator cord o Only acceptable materials introduced into OTSG o Cold leg and hot leg plugs utilized to contain debris
- MDC - Minimum Detectable Concentration 2
9/15/82 ________________________,,,_,,._.__._.,.,_.___,_,..,,,,__.,.,.,,,,-._,,.,7
T f. Qualification Program Post Expansion Residue o Bulk Material - Readily removable by hand / vacuuming o Surface Contamination - Harmful elements controlled to acceptable levels by specifications for materials used in OTSG - Adherent semi-transparent film with carbonaceous residue deposited on surfaces May affect heat transfer May affect sulfur removal o Desirable to reduce quantity - Minimize net accumulation in RCS - Prevent interference with sulfur removal 9/15/82 cr -~-
=_ ~. Qualification Program Immunol Precoat Precoat - facilitates removal of surface contamination - 1mmunol - a cleaning agent - water soluble - acceptable chemistry - extensive data available - Effectiveness visually confirmed - Mt. Vernon tests - Mockups - Evaluating - interaction with sulfur - effect on H 0 process 2 2 i o Application - Manual spray - dome, tubesheet & tubes - Flood ID of tubes - Barrier at hot / cold leg to confine precoat i 9/15/82 ~
L e Qualification Program Clean Up o Bulk Material Removal - Manual - debris in heads Air assist ejection of candles from tubes ^ o Surface' Contamination - Wipe head and tubesheet - Felt plugs blown thru tubes - Rinse o Acceptan.ce Criteria - su~rface swipes to meet - B&W established standard halogen ~ ' levels ~ 9/15/82 . 2 :
'==-1==2--
:-=
~~-
I Process Effect On~ Cracks / indications o Test Results (30 gr./ft) - 100% through wall crack opened slightly - No ductile growth axially - No ductile growth circumferencially
Conclusion:
crack did not grow o Leakage Tends to be Self Sealing - CR-3 operating experienge - ARC model bbiler test results ~ 5 tubes defected /1 to 2 gph leakage. - After 1000 hrs operation - no leakage - CRUD & corrosion products seal leaks - Tubesheet corrosion insignificant by inspection 9/15/82
.. = = s Pressure Vessel. integrity Assessment o Requirements of satisfactory repair - Maintain structural integrity - Maintain acceptable leak rate o Structural integrity criteria - meet ASME code stress limits - Residual stresses in transition below acceptable past practice - Tube preload change controlled within acceptable limits - Process does not structurally degrade vessel o Leakage design objective - total 511bm/hr o Demonstratiori of meeting the criteria - Repair tested for maximum faulted tube load i .- Original design analyses remain valid - Residual stresses in the transition region are minimized i ) 9/15/82 =
.= = '?. t Pressure Vessel Integrity (Continued) - Mt. Vernon test results (132 tubes) Dynamic stress for tubesheet and sheit < yield stress Change in axial tube load < 30 lbs Dynamic pressure wave is small PT examination of tube-to-tubesheet weld shows no damage - Test shows no measurable ligament distortion - Analysis of crevice drying procedure indicates acceptable i stresses o Demonstration of meeting the criteria (continiued) - Qualification leak testing conservatively performed at room temperature o Conclusions - The OTSG's continue to meet the requirements of the ASME Code 9/15/82 1
Crevice Drying -/ -(/ < - / / 1M,iaf HEATERS ARE INSTALLED ON STAINLESS POWER LEADS STEEL SPACERS ON TUBESHEET AND EN TOP SURFACE OF HEATERS IS COVERE TC - THERMOCOUPLES 'RIMARY + !ANWAY h I UPPERSURfACE{.300'F 8 LOWERSURFACE210'ABOVETSAT (~ 125'F) 8 TINE REQUIRED := 4 HOURS 8 PERFORMANCE CONFIRMED BY MT. VERNON TEST 9/15/82 4
a ~ Maintaining Crevice Dry Forced Circulating System 100 CFM DESIGN 5 DEHUMIDIFIER BLOWER N2 MAKEUP AT ~ l PSIG TEhP./ HUMIDITY INDICATOR H D HOLE AFW N0Z2LE N2. COVER GAS NOTES: 4 -F e UPPER TUBESHEET TEMP. MEASUREMENT AT 4 TUBE LOCATIONS 300" HO 2 e OEW POINT ON SECONDARY SIDE MAINTAINED 10*F BELOW TUBESHEET I TEhPERATURE O 9/15/82
r = -- o. ( Mt. Vernon Test Accomplishments o Verified shock to tubesheet is within acceptable limits t o Allowed full dress mockup training, testing of t installation tool and procedures o Provided verification of the reliability of support systems o Allowed refinement of expansion process resulting in estimated exposure savings of 200 manrem o Assessed magnitude of post expansion cleaning o Performed expansion pull test e 9/15/82 J
e 4 Site Preparations ~ Explosive' Handling
- Established procedures for handling operations
- Trained technicians, lice nsed explosives handler
- Approved storage containers
- Insert storage outside containment
- Activities regulated / monitored by the state of Pennsylvania
- Minimal quantity of inserts in containment
- Inventory under concurrent control of plant security and FWEA licensed explosives handler
- Handling operations directly supervised by licensed handler and inspector
- Class C explosive
- Least hazardous explosives rating - Requires high energy shock for detonation - Can be shipped by commercial carrier e e 9/15/82
e Quality Activities i ) Off Sits-Qualification Program
- GPUN & B&W specifications for i
qualification program o' Coordinated test plan
- FWEA QA verify test control (Monitored by B&W and GPUN)
- FWEA specs and procedures for testing - Trained technicians - Calibrated instruments - Documented results j i 9/15/82 y
= ,\\ ?* l Quality Activities Off Site - Manufacturing 1
- B&W approved FWEA specifications to subvendors
- Chemical analysis of components
- Cleanliness requirements applied in i
process
- In-process verification of. dimensional 1
requirements L l
- In-process overchecking of components l
4. supplied by subvendors i
- FW overcheck verification of grains / foot l
9/15/82
r. ':. Kinetic Expansion ALARA Estimates Man-rem Exposure Estirnates Crevice drying 20 Manual tube marking 10 Pre-coating tubes in-generator testing 10 Process expansion -insert installation 70 -insert removal 100 -debris removal 5 Tube /tubesheet/ dome cleaning Closeout inspection 2 Total 217 Kexcluding precoating of tubes and cleanup) 1 e 9/15/82 sy - y
=
1 0.uality Activities Site Effort
- Shipping and storage in approved containers
- Receipt inspection for shipping damage e Comply with state of Pennsylvania sxplosives handling and storage requirements
- In-process O.C monitoring includes
- Verification of procedure compliance - Plant condition prerequisites - Process control to separate high and low charge density inserts - Expansion in whole row " lots" - Physically mark tubes to be expanded to 22" - Random performance sampling by E/C, tube ID measurements and periodic tube expansions outside OTSG l e Video overview and record of operations t 9/15/82 t
- e. e-- + <e
.r,, Summary e Testing and analysis continues to indicate that kinetic expansion is practical for application to TMI-1
- We can conclude that implementation of the 1
kinetic expansion process will not do irrsparable damage to the OTSG e Preliminary and final qualification testing and ' analysis confirms with reasonable assurance that the process fulfills specification requirements
- Planning, training and rehearsal are essentially 1
completed
- implement repair process at TMI-1 i
9/15/82 _--.--...,n
Oi Ncws Roleaso Taimi.'ti."' k 61NucIear Post Office Box 480 PA 17057 @t {"47 Public Information Services l For Further Inforrnation *
Contact:
John Fidler or. Doug Bedell For Release: Imediately Date: October 28, 1982
- 147-82N STEAM GENERATOR REPAIRS BEING READIED AT TMI-1 Middletown, PA -- Repair operations for the Three Mile Island Unit 1 steam generators are shifting from testing laboratories to 'the plant.itself.
Final prepara-tions and qualification testing for the repairs are underway at Three Mile Island. The repair process itself could begin within a week. In a briefing this morning, officials of theI pU Nuclear Corporation explained G technical features of the repair process. The repairs will follow months of off-site evaluation and development of the repair process, known as kinetic expansion, and are expected to be completed about The Unit 1 reactor, shut down for more than three and a half the end of the year. years, is expected to be ready to resume operation early next year. .The repairs are necessary because of cracking that occurred on the inside of Leaks many of the 31,000 tubes in the two steam generators while Unit 1 was shut down. in more than 100 tubes were discovered a year ago during testing under low pressure. Immediately, GPU Nuclear began an extensive investigation into the cause of the crack-Besides investigating ing, enlisting assistance from throughout the nuclear industry. the cause of the cracking, GpU Nuclear also began a search for the best repair method The tubes are five-eighth; of an inch in diameter and are made 'for the damaged tubes. of inconel,,an alloy of nickel, chromium and iron. After looking into several alternatives, which 1,ncluded plugging and taking tubes out of service; plugging some damaged tubes and placing sleeves in others; replacing all the tubes; and replacing the steam generators, GPU Nuclear settled on expanding the tubes against the upper tubesfieet, a two-foot thick disc of stee,1 that anchors'the tops of the tubes in the generators. 69 ^ ~
r , October 28, 1982 y
- 147-82N The expansion is accomplished with a controlled explosive charge inside the
~ tube. The tube is resealed against the tubesheet below the point of cracking. GPU' Nuclear selected this repair method because most of the defects in the tubes are located in the top few inches of the 56-foot long tubes. By expanding the tubes-for a distance of at least six inches below the lowest defect, the tubes will be repaired for safe operation. Those tubes with defects too far down in the tubes to, permit this repair will be plugged and taken out of service. Of the more than 31,000 tubes in the' generators, GPU Nuclear estimates that approximately 1,100 tubes will be plugged. The project is being carried out with the assistance of Babcock and Wilcox, supplier of the nuclear steam supply system in Unit 1, and Foster Wheeler, a sub-contractor to B&W. The cost of the project is expected to be about $25 million. To repair the tubes, Foster Wheeler and B&W have trained GPU Nuclear personnel to place the explosive charges, long plastic " candles," in the tubes in groups of 17 using a special holder. Candles in groups of 132 -- corresponding to the longest The rows of tubes -- will be detonated by a Pennsylvania-Iicensed technician. explosive components of the repair materials will be stored at TMI in compliance. with state regulations. Virtually all of the 31,000 tubes will be expanded for efficient performance of the work. The expansion work is expected to take about two months, and will be followed by the plugging operation. The qualification process. at Foster Wheeler consisted of a series of tests on tube samples t' hat were expanded using this process at FW's research facility at hivingston, New Jersey. Such tests as thermal cycling, leak tests, pullout load tests and stress tests were all performed repeatedly to insure that the process would work at TMI-1. ( [ -more-
(o '.v ' October 28,1982
- 147-82N Foster Wheeler has'used this process to expand more than five million tubes in heat exchangers since 1966. Tiie process has been used in other nuclear applica-tions, namely, at Salem Units 1 and 2 and the Clinch River Breeder Reactor Project.'
The TMI-1 repairs will be the largest application of this process at a nuclear plant. The Unit 1 application of the kinetic expansion process has been, reviewed by the staff, of' the U.S. Nuclear Regulatory Commission. Research concluded that the cracking in the steam generator tubes was caused by stress-assisted intergranular attack, most probably initiated by the formation of an aggressive species of sulfur in the Unit 1 reactor coolant system. The primary system carries water heated by the reactor to the 15,500 tubes in each steam genera-tor, where the reactor's heat is transferred to a. separate secondary source of water,- whjch flashes to steam to drive the turbine-generator to make electricity. To insure that the same kind of problem had not occurred in the reactor, GPU f Nuclear performed more than 1,000 individual inspections of materials and components of the Unit 1 reactor last spring. Radiation exposure to the workers performing the kinetic expansion program will be kept as low as possible. Federal regulations say that a worker may not receivemorethanthreerems(3,000 millirems)inacalendarquarter. GPU Nuclear estimates that the approximately 200 company workers doing the kinetic expansion work will receive'well under the. federal limits. 0 8 W - - -}}