ML20128N156
| ML20128N156 | |
| Person / Time | |
|---|---|
| Site: | Prairie Island  |
| Issue date: | 01/31/1985 |
| From: | WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP. |
| To: | |
| Shared Package | |
| ML20128A500 | List: |
| References | |
| SG-85-02-029, SG-85-2-29, TAC-57847, TAC-57848, WCAP-10757, NUDOCS 8506030187 | |
| Download: ML20128N156 (138) | |
Text
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WAP-10757 SG-85-02-029 NORTHERN STATES POWER COMPANY PRAIRIE ISLAND NUCLEAR GENERATING PLANT LICENSE AMENDMENT REQUEST DATED MAY 17, 1985 EXHIBIT C h
PRAIRIE ISLAND UNITS 1 AND 2 STEAM SENERATOR SLEEVING REPORT (Mechanical Sleeves)
January 1985 WESTINGHOUSE PROPRIETARY CLASS 3 s
PREPARED FOR NORTHERN STATES POWER COMPANY WEST!hGHOUSE ELECTRIC CORPORATION STEAM GENERATOR TECHNOLOGY DIVISION P.O. BOX 855 PITTSBURGH, PA 15230 8506030187 850517 DR ADOCK 050 22 1751c/0223c/020685:5 1
.i PROPRIETART INFORMATION NOTICE TRANSMITTED HEREWITH ARE PROPRIETARY AND/OR NCN-PROPRIETART YERSIONS OF DOCUMENTS FURNISHE TO THE NRC IN CCiglECTION WIIH REQUESTS FOR GENERIC AND/OR PLANT SPECIFIC RE7IEW AND APPROVAL.
IN ORDER 10',CQlFORM TO ME REQUIREENTS T 10CFR2.790 W THE COMESSION'S REGULATIONS CQiCERNING THE PROTECTICN W PROPRIETART INFORMATION 30 SUBMITTED TO THE NRC, THE INFORMATION WHICH IS PROPRIETART IN THE PROPRIETART VERSIONS IS CONTAGED WITHIN BRACEET3 AND WHERE THE PROPRIETART INFORMATION HAS BEEN DELETED IN THE NON-PROPRIETART VERSIONS GILY THE BRACKETS REMAIN, THE INFORMATION THAT WAS CQiTAINED WIIHIN THE BRACEETS IN THE PROPRIETART VERSIONS HAVING BEEN DELETED. THE JUSTIFICATION FOR CLAINING THE INFORMATION 30 DESIGNATED AS PROPRIETART IS INDICATED IN BOTH VERSIONS BT MEANS OF LOWS CASE LEITERS (a) THROUGH (g) CONTAINED WITHIN PARDTHESES LOCATED AS A SUPERSCRIPT D9EDIATELT FOLLOWING THE BRACEETS MCLO5ING EACH ITEN OF INFI)RMATION BEING IDENTIFIED AS PROPRIETART OR IN 1HE MARGIN OPPOSITE SUCH INFORMATION. THESE LGin CASE LETTERS REFER TO THE TTPES & INFORMATICN WESTINGHOUSE CUSTOMARILY HG.DS IN CONFIDBCE IDENTIFIED IN SECTIONS (4)(ii)(a) through (4)(ii)(g) 0F THE AFFIDAVIT ACCOMPANTING THIS TRANSMITTAL PURSUANT TO 10CFR2.790(b)(1).
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l AF IDAVIT C:MMONWEALTWCF PEN 3* MANIA:
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.5e' fore lie, the undenignac authority, genonally appeared Robert A. Wiessmann, who, taing by me duly swam ac::rding ta law, deposes and says that he is authorized to exec:::a mis Affidavit on behalf of Westinghouse Electric,Carporation ("'destingneuse") and ca:
the avements of fact set forth fn this Affidavit are ene and c=r ac to the best of his knowledge, istmnation, and belief:
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^1 E GUHQf.,at,L Romer: A. Wtesamann. Manager Requiatory and Lagislative Affairs a
Suom to and subscribed before me this I ay d
of bM-980.
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I. am Managar cf Tegulat:ry and !.agisladve Af"ain in ce lIuclea.r -
Tecanology 31vis.ica of Westingacusa Itac:Mc Cer/craden, and as sucs, I have teen specifically delega:ad the funeden ef esv'iewing.
ce ;repriets.ry infomaden sought t: he withheld frem ';ublic dis closure in c=nnec:teri with nuclear ;cwer plant licansing er rule-i maMng g.Mngs, and am auccetzad to apply for itz witaholding I
crr banalf of the Wesdnghouse Watar React:r Divisions.
(1)
I. as maMng :Ms Af*idavit in enfemanca with he previsions of l
10CFR Secdon Z.790 of es C= mission's requ14tiens and in conjunc-tfen with the Westingacusa accTication.fbr wicheiding ac=mcanying 1
eis Affidavit.
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(I)
I have personaT Ictowledge of the crttaMa and precadures utilized by Westinghcuse Nuclear Energy systams.in designadng information
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as a trade secretJ priv11eTed se as enfidential c:mmercial or
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financial is h tton.
p (4)
Pursuant ts the. pnvisicds of paragnsk (b)(4) of !acden 24790 of
. the Ccanission's regulations, ce fol. lowing is furnished fer c:n-sideraden by the Camrission in detaraining whecer ce fitformaden scught to be withheld frca public disclosure saculd be wicheid.
(.1 )
The informati.cn scught ta he wicheid fres ;ubite dis-closure is cuned and has been he'id in enfidanca by
' M.nghouse.
(11)
The informaden is of a type as:=mmHiy held in enfi-danca by Westinghouse and not cust:maMiy disclosed ts the puh11c.
Westingneuse has a radonal basis for datamining es types cf infomaden cust:maMiy'hald in c=ndidenca by it and, in that c=nnecden, utili:ss a sys am ts datamine wnen and wnetner t: ncid car ain tyces of infor.n:..an in
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c=nfidacca.
The anclicaden of dat sys: ass and the suc-sunca of cat systas.c=nsttutar Wesdr.gneusa';ciicy anc.=revidas ce entfenal hands required.
Uncar 'est systam,. iniw..f;cn is held. in c=nfidanca if it falTs in one or aura of several types, the releasa of nicfr might resuit. in ce Tess of' an existing er patandal c=mmatttive advanugia,. p fcIlows:.
j (a)
The infomation reves.ls the disdnguisMng aspe u of a y..a (or c=mponent, st:=acture, t=ct, maced, st=.) wnere prevention of its use by any of 'Magneuse's
. c=mpetit=rs wiecut licanse fr:m Westinghouse c=nst-l tutas a w.r. tfve. ec=ncaic advanage over other c= meanies.
m (h)
I.t c=nsists cf supporting data.,. including tast dau reTative tz a. prdi: ass (or c=mmenent, st: ac=re, :=ct, I
matand, et=.), ce appifcation of dich data ' secures
- a. c=mperf ttve ec=ncaic advanuge, e.g., by opdmi=aden or improved. marketability.'
(c)
Its use by a. c=mmetiter would reduce his expenditure of resourcas or fasreve Ms c=mpetitive positica V s
2e design, manufac:ure, sMpment, installation, assur.'
anca of quality, or Ticansing a si:sfTar precuct.
(d)
It reveals c=st or prica f..fw.
tics.,, producten casac-ittes, budget level.s, or c=merdal serstasies of Wesdnghouse, its cust= men er sumaliers.
l (e)
It reveals aspec:s of past, present, or futurt Wesdngncuse er cust:=er ^;nded de'reicc:=ent : Tans anc cr'pm :f
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- r=:ercial talue := '.lastingncusa.
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It c:ntains ;atanua(e' ideas, for which ;atant pr:-
taceten may be desirsale.
(g)
It it not..ca pr:per y cf Wes.dnghaust, buimust be nes. tad.'as y 4riatary by Jkstingt::nse awniing to agreements with me owner.-
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sThere,are.'scund ;clicy reass.x behind ce Wesdngneusa systam 1
which,.'fgefuhe the following:,,
a.
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(a)
The use of s'uch information by Wesdnghcuse gives Westingacuse a emcedtive advantage over its c:mpedtcrs.
It is, therefore, withheld frca disclosure ta protact the Westin@M,e c=mpetidve position.
(b)
It is f..."w=dort which is marketable in many ways.
The extant to wk.fek such is."dr-tion is ivailable. ts "e
c=mpettt=; s dimirrishes ce Westingneuse ability 4 sail producta and seriices involvir.g me use of cae f...'m d on.
(c)
Usa by our c=mpetitar would.ut Wesdaghcuse at a cancedtive disadvantage hv... ucing his ex=enditure
'of resCurces at, our eXpens4.
I (d)
Each c:acanent of proprietary infai Jaden paw.nent ta a'particular c:r5:edti'le advanuge is gotandally as valuatie as the tatal c=meedtive advantage.
If c=mmedtars ac:;uire c:meenents of precristary infer :a-tien, any one c::r=r:nent may be ene kay ts ce andre pu::,;ie,. O.orwy decriving Wesdngncusa of a c:=ceddve advantag6.
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my. 4 (a)
Unres:Mc *' discicsure wculd jaccard:n. de pcsition of prcainenca of West nghcusa in 2e k rid.zarkez, and carecy give a market advanuge ts the (
- etiticn in these c::mttMes..
(f)
The Westinghouse capacity c: invest c:r;crata assats.
. in research and development decends ugen de sucsass
, in cataining and mainutning a. c=mpedtive advanuge.
(iii)
The infomation is being transmit ad ts the Ccantissicn in c=nfidenca and, under the provisions of 10CFR Secten 2.7g0, it is to be recaived in c:nfidenca by' the Ccmmission.
(iv)
The infomatica scugt,rt to be pretaccad is not availahle in ptdrifc scurcas tn the best of our kncwledge and belief.
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Thu r.wrietary intl tfon scught ta be withtfeld in cis suhmitui is er: drfeir is appresMataly marked Sji-57-t0(20)
- 5cuthern Caif fernia Hison Recair. Raccr * (Proprieury).
This report has beert prepared for aqd is being subert:.ad ts thia Staff at en. enouest of scothern Catifornia aisen.
The renc'rt deutis ce design of the sleeves that are :s be instn1Ted in the San Cacfra Unit i stana generat:rs.
The report. also includes the design analysis, the cast veMfica,-
tien program and descMptiens of the expanded mecnanical plug, the rcIIed plug and ce enannel head dec:numinaden precass.
This infe.
cfen is part of tnat which will' enable Wesdnghcuse ts:
(a)
Acply for patant proucticn.
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Optizi:a stasm genert :r encair tachnicues. = ex:and
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ce ser rica life of suam generst:rs.
(c)
Assist itz.cus=mers c:i couin NRC appreval.
(d)
Justtfy es de,fgir easis f=r the s2a.m gener e:r repairr and insullation methods.
Furcer, this infor.natica has subsuntial c:merdal value as fc11cws:
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(4)
Westinghouse glar.s tu sell the recair tachnicues and.
equf; ment descMhad. in part by ce infer =ation.
(b)
Westinghcuse can sail repair sorticas based usen ca l
wr fenca gained' ami da insullatien equipment and mathods devficced.
l Public discicsure of this infor=atien is likely to cause l-haJ har.n to de c=mpetitive gesition of Westinghcuse becausa (T) it would result in the less of valuable patant righer, and (2) it would enhanca ce ability of c:mcatit:rs to design, manufacture, verify and sell stasm genert :r repair tachniques for c=mmercial power esac:=rs witacut '
1 c=mmensurata expenses.
(
The develcpment of de methods and ecui;: ment described in part by to infer =ation is de result of amplying tne results of many years of experienca in an intansive Westingacuse afdcri and ce ex enditure of a c:nsicersbie sum of =cney.
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In arter for c=meetit:rs of Wes-inghcusa ts d ::lica.a..his inf r=atien, similar engineering ;:r:grs=s xuld have := be d
per er=ed and a significant man:cwer af'cre, having -::e requistta talant and excerienca, wuld have to be ex;: ended for steam generatar repair. tac::nicues.
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Further the depones sayeth not.
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WESTINGHOUSE PROPRIETARY CLASS 3 TABLE OF CONTENTS Section Title Page
1.0 INTRODUCTION
1-1 2.0 SLEEVING OBJECTIVES AND BOUNDARIES 2-1 1
2.1 Objectives 2-1 l
l 2.2 Sleeving Boundary I
2-1 I
3.0 DESIGN 3-1 3.1 Sleeve Design Documentation 3-1 3.2 Sleeve Design Description 3-1 3.3 Design Verification: Test Programs 3-6 3.3.1 -Design Verification Test Program Sunnary 3-6 3.3.2 Corrosion and Metallurgical Evaluation 3-7 3.3.3 Upper and Lower Joints 3-17 3.3.4 Test Program for the Lower Joint 3-18 3.3.4.1 Description of Lower Joint Test Specimens 3-18 3.3.4.2 Description of Verification Tests for 3-22 the Lower Joint 3.3.4.3 Leak Test Acceptance Criteria 3-23 3.3.4.4 Results of Verification Tests for Lower Joint 3-23 I
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l 1751c/0223c/020185:5 2 I
WESTINGHOUSE PROPRIETARY CLASS 3 TA8tE OF CONTENTS (Continued)
Section Title Page 3.3.5 Test Program for the Upper Hybrid Expansion Joint (HEJ) 3-25 3.3.5.1 Description of the Upper HEJ Test Specimens 3-25 3.3.5.2 Description of Verification Tests for the Upper HEJ 3-29 3.3.5.3 Results of Verification Tests for the Upper HEJ 3-29 3.3.6 Test Program for the Fixed-Fixed Mockup 3-34 3.3.6.1 Description of the Fixed-Fixed Mockup 3-34 3.3.6.2 Description of Verification Tests for 3-43 the Fixed-Fixed Mockup 3.3.6.3 Results of Verification Tests for the 3-43 Fix M ixed Mockup 3.3.7 Effects of Sleeving on Tube-to-Tubesheet Weld 3-4S 3.4 Analytical Verification 3-47 3.4.1 Introduction 3-47 3.4.2 Component Description 3-47 3.4.3 Material Properties 3-49 3.4.4 Code Criteria 3-49 3.4.5 Loading Conditions Evaluated 3-49
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3.4.6 Methods of Analysis 3-52 3.4.6.1 Model Development 3-52 3.4.6.2 Themal Analysis 3-54 3.4.6.3 Stress Analysis 3-56 3.4.7 Results of Analyses 3-58 l
3.4.7.1 Primary (Pressure) Stress 3-58 3.4.7.2 Range of Primary and Secondary Stress Intensities 3-58 3.4.7.3 Range of Total Stress Intensities 3-65 1751cl0223c/020185:5 3 t
II
WESTINGHOUSE PROPRIETARY CLASS 3 TABLE OF CONTENTS (Continued) 2-Section Title Page 3.4.8 References 3-67 3.5 Special Considerations 3-69 3.5.1 Flow Slot Hourglassing 3-69 3.5.1.1 ' Effects on Burst Strength 3-69 3.5.1.2 Efferets on Stress Corrosion Cracking Margin 3-69 3.5.1.3 Effect on Fatigue Usage 3-69 e
3.5.2 Tube Vibration Analysis 3-70 3.5.3 Sludge Height Thermal Effects 3-70 3.5.4 Allowable Sleeve Degradation 3-70 3.5.5 Effect of Tubesheet/ Support Plate Interaction 3-73
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3.5.6 Comprehensive Cyclic Testing 43-73 3.5.7 Evaluation of Operation with Flow Effects Due to Sleeving 3-74
.3.5.8 Alternate Sleeve Materials 3-77 1751c/0223c/020185:5 4 III
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WESTINGHOUSE PROPRIETARY CLASS 3 TA8LE OF CONTENTS (Continued)
Section Title P3 4'
4.0 PROCESS DESCRIPTION 4-1 4.1 Tube Preparation 4-1 r
4.1.1 Tube End Rolling (Contingency) 4-1 4.1.2 Tube Honing 4-3 4.1.2.1 C "3C Honing 4-3 4:1.2.2 Dry Honing 4-4 4.1.3 Fiberoptic Inspection (Contingency) 4-4 4.2 Sleeve Insertion and Expansion 4-4 4.3 Lower Joint Seal 4-6 i
4.4 Upper Hybrid Expansion Joint (HEJ) 4-7 4.5 Process Inspection Sampling Plan 4-7 4.6 Establishment of Sleeve Joint Main Fabrica-4-9 tion Parameters 4'.6.1 Lower Joint 4-9 4.6.2 Upper HEJ 4-9 l
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WESTINGHOUSE PROPRIETARY CLASS 3 5.0 SLEEVE / TOOLING POSITIONING TECHNIQUE 5-l' 5.1 Remotely Operated Service Arm (ROSA) 5-1
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5.2 Alternate Positioning Techniques 5-3 6.0 fee INSPECTA81LITY 6-1 4
6.1 Eddy Current Inspections 6-1 6.2 Summary 6-16 7.0 ALARA CONSIDERATIONS FOR SLEEVING OPERATIONS 7-1 7.1 ROSA Sleeving Operations 7-2 7.2 Manipulator End Effectors 7-2 7.2.1 Sleeye/ Tooling End Effectors 7-2
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7.2.2 In-Process Operations 7-3
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7.3 Control Station in Containment 47-3 7.4 Potentials for Worker Exposure 73 7.4.1 Nozzle Cover and Camera Installation / Removal 7-4 7.4.2 Platform Setup / Supervision 7-4 7.5 Radweste Generation 7-5 7.6 Airborne Releases 7-7 7.7 Personnel Exposure Estimate 7-7 8.0 INSERVICE INSPECTION PLAN FOR SLEEVED TUBES 8-1 l
1751c/0223c/020185:5 6 Y
WESTINGHOUSE PROPRIETARY CLASS 3 LIST OF TABLES Tabi Title P3 3.1-1 ASE Code and Regulatory Requirements 3-2 3.3.2-1 Su mary of Corrosion Compar.ison Data for 3-11 Thennally Treated Inconel Alloys 600 and 690 8
i 3.3.2-2 F#fect of Oxidizing Species on the SCC Suscepti-3-12 bility of Thermally Treated I-600 and I-690 C-rings in Deaerated Caustic.
3.3.3-1 Design Verification Test Program - Corrosion 3-19 3.3.4.3-1 Allowable Leak Rates For Model 51 Steam Generators 3-24 3.3.4.4-1 Test Results for the Model 44 As-rolled Lower 3-26 Joints 3.3.5.3-1 Test Results for Model 44 HEJ's Formed Out 3-35
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of Sludge 3.3.5.3-2 Test Results for Model 44 HEJ's Formed Out of 3-37 Sludge (State Axial Load Leak Test, SLB and Reverse Pressure Test) 3.3.5.3-3 Test Results for Model 44 hCJ's Formed In 3-39 Sludge (Fatigue and Reverse Pressure Tests) 3.3.5.3-4 Test Results for Model 44 HEJ's Formed in 3-41 Sludge (Axial Load Leak Test and Post-SLB Test).
3.3.5.3-5 I-690 Limited Scope Test Results 3-42 3.3.6.3-1 Test Results for Model 44 Full Length Sleeves 3 46 1751c/0223c/020185:5 7 VI
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l-WESTINGHOUSE PROPRIETARY CLASS 3 LIST OF TA8LES (Continued)
Table Title Page 3.4.4-1 Criteria for Primary Stress Intensity Evaluation 3-50 (Sleeve) 3.4.4-2 Criteria for Primary Stress Intensity Evaluation 3-51 (Tube) 3.4.C-1 Operating Conditions 3-53 l-3.4.7.1-1 Umbrella Pressure Loads for Design, Upset, Faulted, and Test Conditions 3-59 3.4.7.1-2 Results of Primary Stress Intensity Evaluations 3-60 Primary Membrane Stress Intensity
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3.4.7.1-3 Results of Primary Stress Intensity Evaluations 3-61 Primary Matrane Plus Bending Stress Int.ensity, P, + P '
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3.4.7.2-1 Pressure and Temperature Loadings for Maximum 3-62 Range of Stress Intensity and Fatigue Evaluations 3.4.7 2-2 ' Results of Maximum Range of Stress Intensity 3-64 Evaluation 3.4.7.3-1 Results of Fatigue Evaluation 3-66 3.5.4-1 Regulatory Guide 1.121 Criteria 3-71 4.0-1 Sleeve Process Sequence Sumary 4-2 7.5-1 Estimate of Radioactive Concentration in 7-6 Water per Tube Honed (Typical) 1751c/0223c/020685:5 8 VII N
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WESTINGHOUSE PROPRIETARY CLASS 3 LIST OF FIGURES i
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Figure Title Page 2.2-1 Sleeving Boundary (
3a,c.eSleeves 2-3
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3.2-1 Installed Sleeve with Hybrid Expansion 3-4 Upper Joint Configuration s
3.2-2 Sleeve Lower Joint Configuration 3-5 3.3.2-1 SCC Growth Rate for C-rings (150 percent YS and 3-13 TLT) in 10 percent NaOH 3.3.2-2 Light Photo micrographs illustrating IGA 3-14 3.3.2-3 SCC Depth for C-Rings (150 percent YS) in 3-15 8 percent Na2 SO4 3.3.2-4 Reverse U-bend Tests at 360*C (680*F).
3-16 3.3.3-1 Location and Relative Magnitude of Residual 3-20 Stresses Induced by Expansion
-3.344.1-1 Lower. Joint As-rolled Test specimen 3-21 3.3.5.1-1 Hybrid Expansion Joint (HEJ) Test Specimen 3-30 3.3.5.1-2 HEJ Specimens for the Reverse Pressure Tests 3-31 3.3.6.1-1 Fixed-Fixed Mockup - HEJ 3-44 3.4.2-1 Installed Sleeve with Upper Hybrid Expansion 3-48 Joint Configuration Main Finite Element Model Dimensions 1751c/0223c/020185:S 9 VIII L-
WESTINGHOUSE PROPRIETARY CLASS 3 LIST OF FIGURES Figure Titie Page 6.1-1 Eddy Current Signals from the ASTM 6-5 Standard, Machined on the Tube 0.0. of the Sleeve / Tube Assembly Without 6.1-2 Eddy Current Signals from the 6-6 Expansion Transition Region of the Sleeve / Tube Assembly ( Conventional Differential Coil Probe )
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6.1-3 Eddy Current Calibration Curve for ASE 6-7 SleeveStandardat(
]a,c.e with the Conventional Differential Coil Probe 6.1-4 Eddy Current Signals from the ASTM 6-8 Standard, Machined on the Sleeve 0.0.
of the Sleeve / Tube Assembly Without Expansion ( Cross Wound Coil Probe )
6.1-5 Eddy Current Signals from the ASTM 6-9 Standard, Machined on the Tube 0.0.
- of the Sleeve / Tube Assembly Without Expansion ( Cross Wound Coil Probe )
6.1-6 Eddy Current Signals from the Expansion 6-10
-Transition Region of the Sleeve / Tube Assembly ( Cross Wound Coil Probe )
6.1-7 Eddy Current Calibration Curve for ASME 6-11 Tube Standard at [
3a.c.e and a Mix Using the Cross Wound Coil Probe 1751c/0223c/020185:5 10 IX 9
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WESTINGHOUSE PROPRIETARY CLASS 3 9
6.1-8 Eddy Current Signal from a 20 Percent Deep 6-12 Hole, Half the Volume of ASTM Standard, Machined on the Sleeve 0.0. In the Expansion Transition Region of the Sleeve / Tube Assembly (Cross Wound Coil Probe) 6.1-9 Eddy Current Signal from a 40 Percent ASTM 6-13 Standard, Machined on the Tube 0.0. in
, Expansion Transition Region of the Sleeve / Tube Assembly (Cross Wound Coil Probe) 6.1-10 Eddy Current Response of Square and 6-14 Tapered Sleeve Ends Compared to the Expansion, Transitions for the Conventional Bobbin Coil Probe 6.1-11
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Eddy Current Response of the ASTM Tube 6-15 Standard at the End of the Sleeve Using the Cross Wound Coil Probe and Multifrequency Combination t
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1751c/0223c/020185:5 11 X
6
WESTINGHOUSE PROPRIETARY CLASS 3
1.0 INTRODUCTION
t SP As part of its ongoing steam generator repair develo~pment programs.
Westinghouse has developed the capability to restore degraded stem generator tubes by means of a sleeve. This technology may be applied to the steam generators of. Prairie Island Units 1 and 2 with the objective of restoring the pressure boundary of such tubes and prolonging the availability of the steam generator heat exchange system.
To date, nearly 15,000 steam generator tubes at six operating nuclear power plants world-wide have been successfully sleeved, tested, and returned to service by Westinghouse. Both mechanical-joint and brazed-joint sleeves of Inconel 600 Inconel 690, and bimetallic Inconel 625/Inconel 690 have been installed by a variety of techniques - Coordinate Transport (CT) system installation, hands-on (manual) installation, and Renotely Operated Service Arm (R0SA) robotic installation. Westinghouse sleeving programs have been successfully implemented after approval by licensing authorities in the U.S.
(NRC - Nuclear Regulatory Counission), Sweden (SKI - Swedish Nuclear Inspectorate), and Japan (MITI - Japanese Miriistry of International Trade and Industry).
The sleeving technology was originally developed to sleeve 6,929 degraded tubes (including leakers) in a plant with Westinghouse Model 27 series steam generators. Process improvements and a remote sleeving system were subsequently developed anri adapted to a Westinghouse Model 44 series steam generator with ut1112ation in full scale sleeving operations at two operating plants (2,971and3,000 sleeves). This technology has also been modified to facilitate installation of 2036 sleeves in a non-Westinghouse steam generator. Most recently, the latest Westinghouse sleeving technology was successfully applied during a demonstration at a European site in a model 51 steau generator.
1751c/0223cl020185:5 12 1-1
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WESTINGHOUSE PROPRIETARY CLASS 3 SLEEVING 'BJECTIVES AND SLEEVING SOUN0 ARIES 2.0 0
2.1 OBJECTIVES Both Prairie Island Units are Westinghouse-designed 2 loop pressurized water reactors rated at 1650 MWt each. The two units utilize a total of four vertical U-tube steam generators. The steam generators are Westinghouse Model 51 Series containing heat transfer tubes with dimensions of 0.675 inch nominal 8
00 by 0.050 inch nominal wall thickness.
The sleevi9 concept and design are based on observations to date that the tube degradation due to environmental attack has occurred near the tubesheet areas of the tube bundle. The sleeve has been designed to span the degraded region in order to maintain these tubes in service.
The sleeving program has two primary objectives:
~1.
To sleeve tubes ln the region # known or potential tube degradation.
2.
To minimize the radiation exposure to alt working personnel (ALARA) 4 2.2 SLEdVING 800NOARIES Tubes to be sleeved will be selected by radial location, tooling access (due to channel head geometric constraints), and eddy current indication elevations and size. An axial slovation tolerance of one inch will be employed to allow for any potential eddy current testing position indication inaccuracies and degradation growth. Tube location on the tubesheet face, tooling dimensions, and tooling access permitted by channelhead bowl geometry define the sleeving boundaries. Figure 2,2-1 shows an estimated radial sleeving boundary for a
(
]a,c.e sleeve as determined by a geometric radius computed from the channelhead surface-to-tubesheet primary face clearance distance minus the tooling clearance distance. (The actual "as is" bowl geometry will be slightlydifferentincertainareas.) This is the sleeving boundary for a generic Westinghouse series 51 steam generator and represents the maximum sleevingpotentialwitha(
]a.c,e sleeve. This information along 1751cIO223c/020185:5 13 2-1 L
WESTINGHOUSE PROPRIETARY CLASS 3 with addy current inspection data provides the inputs to evaluate,each, tube as a candidate for the sleeving process. Tubes within the sleeving boundary that are degraded beyond the plugging liett but not within the axial restrictions ofthe[
]*** sleeve or not withir. the radial sleeving boundary will be plugged. The actual sleevable region may be decreased based on tool length.
The actual tube plugging / sleeving any for each steam generator will be provided as part of the software deliverables at the conclusion of the sleeving effort.
The specific tubes to be sleeved in each steam generator will be determined based on the following parameters:
1.
No opposite channelhead side tube indications and no indications at an elevation not spanned by the sleeve pressure boundary which are greater than the plugging limit.,
2.
Concurrence on the eddy current analysis of the extent and location of the degradation.
l l
l l
l
' 1751cl0223cIO20185:5 14 2-2
~
I l
i SLEEVING TUBESHEET CLEARANCE RADIAN OUTLINE SERIES 50 13-DEC-83 19:41:59 SLEEVE REGION 1946 OUTSIDE REGION I442 TOTAL TUBES 3388 i
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WESTINGHOUSE PROPRIETARY CLASS 3 3.0 DESIGN 3.1 SLEEVE DESIGN DOCUMENTATION The Prairle Island steam generators were built to the 1965 edition of Section
!!! of the ASME Soiler and Pressure Vessel Code, however, the sleeves have been designed and analyzed to the 1983 edition of Section !!! of the Code through the winter 1983 addenda as well as, applicable Regulatory Guides.
The associated materials and processes also meet the requirements of the Code.
The specific documentatio9 applicable to this program are listed in Table 3.1-1.
3.2 SLEEVE DESIGN DESCRIPTION The reference design of the sleeve, as installed, is illustrated in Figure 3.2-1.
[
ja.c.e At the upper end, the sleeve configuration (see Figure 3.2-1) consists of a sectionwhichis[
Ja.c.e This joint configuration is known as a hybrid expansion joint (HEJ). [
3a.c.e 1751c/0223c/020185:5 15 3-1 1
O
I WESTINGHOUSE PROPRIETARY CLASS.3 TA8LE 3.1-1 ASE CODE AN0 REGULATORY REQUIREMENTS Itse Applicable Criteria Requirement Sleeve Design Section !!!
NS-3200. Analysis NS-3300, Wall Thick-i ness G
Operating Requirements Analysis Conditions I
Reg. Guide 1.83 S/G Tubing Inspec-tibility Reg., Guide 1.121 Plugging Margin Sleeve Material Section !!
Material Composition Section !!!
N8-2000,Identifica-tion, Tests and Examinations Code Case N-20 Mechanical Pro;;ar-l ties l
Sleeve Joint 10CFR100 Plant Total primary-Secondary Leak Rate Technical Specifications Plant Leak Rate i
l l
1751c/0223c/020185:5 16 i
3-2 i
e L_
WESTINGHOUSE PROPRIETARY CLASS 3 At the lower end, the sleeve configuration (Figure 3.2-2).,consis'ts of ~a section which is [
9
]"
The lower end of the sleeve has a preformed section to facilitate the seal formation and to reduce residual stresses in the sleeve.
The sleeve, after installation, extends above the top 'of the tubesheet and spans the degraded region of the original tube. Its length is controlled by the insertion clearance between the channel head inside surface and the primary side of the tubesheet, and the tube degradation location above the tubesheet. The remaining design parameters such as wall thickness and material are selected to enhance design margins and corrosion resistance and/or to meet ASE Soiler and Pressure Vessel Code requirements. The upper
~
joint is located-to provide a length of free sleeve above it. This length is added so that if the existing tube were to become severed just above the upper edge of the mechanical joint, the tube would be restrained by the sleeve and therefore axial motion, and subsequent leakage, would be limited. Lateral motion would also be restricted, protecting adjacent tubes from impact by the severed tube.
To minimize stress concentrations and enhance inspectability in the area of theupperexpandedregion,[
Ja,c,e,f The sleeve material, thermally treated Inconel 690 or 600, is selected to provide additional resistance to stress corrosion cracking. (See Section 3.3.2 for further details on the selection of thermally treated Inconel 600 and 690).
1751c/0223cl020185:5 17 3-3 O
ESTIN Mt0Mt!ETAftY CLAS$ 3 e
l l
I I
Figure 3.2 1 Installed Sleeve with Hybrid Expansida Upper Joint Configuration l
1751c/0223c/0201M:5 la 3-4 l
i Lf
WESTINGHOUSE PROMt!ETARY CLA55 3
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g.
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Figure 3.2-2 l
Sleeve Lower Joint configuration e
i 1751c/0223c/020185:5 19 35 i
l m
WESTINGHOUSE PR0pRIETARY Ct. ASS 3 i
3.3 DESIGN VERIFICAT!0N: TEST PROGRAMS i
i 3.3.1 OE51GN VERIFICATION TEST PROGRAM $UMAY The following sections describe the material and design verification test progrens. The purpose of these programs is to verify the ability of the sleeve concept to produce a sleeve capable of spanning a degraded region in a steam generator tube ad maintain the steam generator tubing primary-to-secondary pressure boundary under normal and accident conditions. This program includes assessment of the structural integrity and corrosion resistance of slegved tubes.
A substantial data base exists from previous test programs which verify the sleeve design and process adequacy. h ch of this testing is applicable to this sleeving program. The sleeve materials to be used, thermally treated nickel chronius iron alloy (Inconel 600 or 690), are identical to those used in prior sleeving programs., The standardized mechanical sleeve design is the same as that used in prior sleeving progrees. The fabrication of sleeve / tube jointsbythecombinationof[
ja.c.e at both ends of the sleeve was verified and applied ~on all programs. Rigorous mechanical testing programs were conducted to verify the sleeve design for various steam generator models, including the Model 44, which has the same tube dimensions as the Model 51. In addition to being dimensionally similar, analysis has demonstrated that the operating conditions of a Model 44 steam generator envelope those of a Model 51. Therefore, much of the Model 44 testing is directly applicable to the Model 51 steam generators.
The objectives of the mechanical testing programs included:
l I
Verify that the leak resistance of the upper and lower sleeve to tube joints meets the leak rate acceptance criteria.
Verify the structural strength of the sleeved tube under normal and accident conditions.
1751c/0223c/020185:5 20 3-6 f
WESTINGHOUSE PROPRIETARY CLASS 3 Verify the fatigue strength of the sleeved tube under fransient loads representing the remaining life of the reactor plant.
l Confirm capability for performance of tubes sleeved under conditions such as deep secondary side hard sludge and tube support plate denting Establish the process par meters required to achieve satisfactory installation and performance. These parameters are discussed in Section 4.6.
The acceptance criteria used to evaluate the sleeve performance are leak rates based on the plant technical specifications. Over 100 test specimens were used in the various test programs to verify the design and to establish process parsneters. Testing encompassed static at<d cyclic pressurts, temperatures, and loads. The testing also included evaluttlon of joints fabricated using Inconel 600 sleeves as well as Inconel 690 sleeves in Inconel 600 tubes. While the, bulk of the original qualification data is centered on Inconel 600 sleeves, a series of limited scope verification tests were run using Inconel 690 sleeves to demonstrate the effectiveness of the joint formation process and design with either material.
4 The sections that follow describe those portions of the corrosion (sections 3.3.2-3.3.3) andmechanical(sections 3.3.4-3.3.6) verification programs that are relevant to this sleeving program.
3.3.2 CORR 0SION AND METAlt,URGICAL EVALUATION The basic objective of the corrosion and natallurgical evaluation programs conducted was to verify that the sleeving concepts and procedures employed did not introduce any new mechanism that could result in premature tube or sleeve degradation.
Inconel Alloy 600 and Inconel Alloy fM (1-600 and I-690) are austentic nicket-base alloys. 1-600 has been extensively used, originally in the mill annealed condition, as steam generator tubing in pressurized water reactors.
1751c/0223c/020185:5 21 34
f l
i
{
WESTINGHOUSE PR0pR!ETARY CLAS$ 3 l
In recent years, attempts to enhance the !GA-SCC (Intergranular Attack-Stress Corrosion Cracking) resistace of I-800 have focused on the application of a thermal treatment in the carbide precipitation temperature range (593* to i
760*C). Microstructural modifications have concentrated on the grain boundary i
region since the $CC eorphology in !-600 is predominantly intergranular. The
- l manieme enhancement in castic ad primary water SCC performance was correlated with the presence of a see1 continuous grain-boundary carbide precipitate.
i t
Inconel Alloy 690, which contains a higher chroelue content (30 percent) than Inconel Alloy 600,has aise indicated the ability to exhibit leproved !GSCC l
resistace when thermally treated in the carbide precipitation region.
I l
The stress corrosion cracking performance of thermally treated Inconel Alloys 600 and ego in both off-chaelstry secondary side and primary side environments l
has been entensively investigated. Results have continually demonstrated the additional stress corrosion cracking resist ece of thermally-treated Inconel l
Alloys 600 and 490 compared to elli annealed Inconel Alloy 600 estarial.
Direct comparison of thereally treated Inconel Alloys 600 and 690 has further i
indicated an increased eargin of $CC resistance for themally treated Inconel l
Alloy 490. (Table 3.3.2-1).
4 l
The caustic $CC performance of siti anneated and thermally treated Inconel.,
Alloys 600 and 690 were evaluated in a 10 percent NaOH solution as a function of temperature from 20B*C to 343*C. $1nce the test data were obtained over j
various espesure intervals ranging free 2000 to 8000 hours0.0926 days <br />2.222 hours <br />0.0132 weeks <br />0.00304 months <br />, the test data were j
normalized in terms of average crack growth rate determined from destructive exeninetton of the C-ring test specimens. No attempt was made to distinguish l
between initiation and propagation rates.
I The crack growth rates presented in Figure 3.3.2-1 indicate that thema11y treated I-600 and I-690 have enhanced caustic SCC resistance compared to that of I-800 in the mill annealed condition. The performance of thermally treated
!-600 and I-690 are approxiestely equal at temperatures of 316*C and below.
At 332*C and 343'C, the additional $CC resistance of thereally treated Inconel Alloy 690 is observed. In all instances the $CC morphology was intergranular 1751c/0223c/020186:5 22 l
3-6 I
1 f
]
E l
WESTINGHOUSE PR0pRIETARY CLASS 3 in nature. The superior perfomance of thermally treated J-690 'at higner temperatures is a result of a lesser temperature dependendy.
{
Testing in 10 percent Na0H solution at 332*C was performed to index the relativeintergranularattack(IGA)resistanceofI-600andI-690. Comparison of the IGA morphology for I-600 and I-690 rings stressed to 150 precent of the f
0.2 percent yield strength is presented in Figure 3.3.2-2.
Mill annealed I-400 is characterized by branching intergeanular SCC extending from a 200u front of uniform IGA. Thema11y treated I-400 exhibited less SCC and an IGA front limited to less than a few grains deep. Thermally treated I-490 exhibited np SCC and only occasional areas of intergranular oxide penetrations, limited to less than a grain deep.
The enhancement in IGA resistance can be attributed to two factors; heat treatment and alloy composition. A characteristic of mill annealed I-400 C-rings esposed to deaerated sodium hydroxide environment is the presence of intergranular SCC along with uniform grain boundary corrosion referred to as intergranular attack (IGA). The relationship,between SCC and IGA is not well estabitshed but it does appear that IGA occurs at low or intermediate stress levels ad at electrochemical potentials where the general corrosion resistance of the grain boundary area is a controlling factor. Thermal treatment of I-600 provides additional grain boundary corrosion resistance along with additional SCC resistance. In the case of I-690, the composition provides a additional margin of resistance to IGA and the thermal treatment enhances the SCC resistance.
The addition of oxidizing species to deserated sodium hydroxide environments results in either a deleterious effect or no effect on the SCC resistance of thermally treated I-600 and I-690 depending on the specific oxidizing specie andconcentration(Table 3.3.2-2).
The addition of 10 percent copper oxide to 10 percent sodium hydroxide decreases the SCC resistance of thermally treated I-600 and I-690, and also modifies the SCC morphology with the presence of transgranular cracks. The exact mechanism responsible for these changes is not well understood, but it is believed to be related to an increase in the specimen potential, corresponding to a transpassive potential, which results in an alternate cracking regime. The specific oxidizing specie and the ratio 1751cI0223cl020185 5 23 39 E
WESTINGHOUSE PR0pR!ETARY CLASS 3 of oxidizing specie to sodium hydroxide concentration appear to p1ay.an '
important role. By lowering the copper oxide or sodium hydroxide concentration, the apparent deleterious effect on SCC resistance is elietnoted.
Mill annealed and thermally-treated I-400 and I-490 were also evaluated in a nueer of 8 percent sodius sulfato environments. The room temperature pH value, at the beginning of the test, was adjusted using sulfuric acid and essenia. Test results are presented in Figure 3.3.2-3.
As the pH is lowered, j
decreased SCC resistance for mill annealed and thermally-treated I-400 is observed, but thermally treated I-490 enterial did not crack even at a pH of l
2, the lowest tested.
The primary water SCC test data are presented in Figure 3.3.2-4 For the beginning of fuel cycle water chemistries,10 of 10 specimens of mill annealed I-400 exhibited SCC, while 1 of 10 specimens of thermally-treated I-400 had cracked. In the end of the fuel cycle water cheatstries, 7 of 10 specimens of mill anneated (-400 exhibited SCC, while 3 of 10 specimens of thermally-treated I-400 had cracked. After 13,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> of testing, no SCC has been observed in the et11 annealed or theneally-treated I-490 specimens in l
either test environment.
4 Continuing investigation of the SCC resistame of I-400 and I-490 in primary water environments has shown et11 anneated !-400 to be susceptible to cracking
{
'at high levels of strain and/or stress. Thermal treatment of I-400 in the carbide precipitation region greatly improves its SCC resistance. The performance of I-490, both stil annealed and thermally treated, demonstrates highly desirable primary water SCC resistance, presumably due to alloy comoosition.
1751c/0223c/020185:5 24 3-10
,---,w.-...--w..
^
c WESTINGHOUSE PROPRIETARY CLASS 3 Table 3.3.2-1
SUMMARY
OF CORROSION COMPARISON DATA FOR THERMALLY TR UTED INCONEL ALLOYS 600 AND 690 1.
Thermally treated Inconel 600 tubing exhibits enhanced SCC and IGA resistance in both secondary-side and primary-side environments when compared to the stil annealed condition.
2.
Thermally treated Inconel 690 tubing exhibits additional SCC resistance compared to thermal treated Inconel 600 in caustic, acid sulfate, and primary water environments.
3.
The alloy composition of.Inconel 690 along with a thermal treatment provides additional resistance to caustic induced IGA.
4 The addition of 10 percent Cu0 to a 10 percent deaerated NaOH environment reduces the SCC resistance of both thermal treated I-600 and I-690. Lower concentrations of either cu0 or Na0H had no effect, nor did additions of Fe3 4 and SiO '
0 2
5.
Inconel Alloy 690 is less susceptible to sensitizat' ion than inconel Alloy 600.
6.
Inconel Alloy 600 and 690 have comparable pitting resistance.
1751c/0223c/020185:5 25 3-11
l WESTINGHOUSE PROPRIETARY CLASS 3 Table 3.3.2-2 EFFECTOFOX10!'ZINGSPECIESONTHESCCSUSCEPTIBILITh' 0F THERMALLY TREATED I-600 AND I-690 C-RINGS IN DEAERATED CAUSTIC Temperature Exposure Environment
(*C)
Time (Hrs)_
I-400 TT I-690 TT 10 Percent NaOH +
316 4000 Increased Increased 10 Percent Cu0 Susceptibility
- Susceptibility
- 10 Percent Na0H +
332 2000 No effect No effect 1 Percent Cu0 1 Percent Na0H +
332 4000 No effect No effect 1 Percent Cuo 10 Percent Na0H +
316,
4000 No effect No effect 10 Percent Fe3 4 0
10' Percent MaOH +
316 4000 No effect No effect 10 Percent $102
- Intergranular and transgranular SCC.
1751c/0223c/020185:5 26 3-12 6-
e SCC GROWTH RATE FOR C-RINGS (150% YS AND TLT)IN 10% NaOH Average Crack Growth Rate ( gm/Hr.)
. Temperature ( F) 550 575 600 830 850 1
I I
1 I
O 1600 MA e
1600 TT su I 690 TT 10-1 w
w 10 '*
_=
10-I I
I I
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290 300
.310 320 330 340 350 Temperature ( C) 1 Piqure 3.3.2-1
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I-690 THERMAL TREATED LIGHT PHOTOMICROGRAPHS ILLUSTRATING IGA AFTER 5000 HOURS EXPOSURE OF INCONEL ALLOY 600 AND 690 C-RINGS TO 10% NaOH AT 332'C (630'F).
Figure 3.3.2-2 3-I4
i i
i SCC DEPTH FOR C-RINGS (150% YS)
IN 8% NA SO 2
4 I
Maximum Crack Depth, gm inches 1000
^
.040 80,000 ppm Na2SO4 i
332*C (630*F) l9 800 5000 Hours q'
.032 IN 600 MA
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C-rings,150% YS j'j i
600
.024 M
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l 400
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IN 690 TT k;
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10 Room Temperature, pH
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Piqure 3.3.2-3 I
REVERSE U-BEND TESTS AT 360*C (680 F) l BEGINNING OF FUEL CYCLE PRIMARY WATER Cumulative Number Cracked l
10 MAem 100 8
i 6
SO 4
t p
o TT eso MA 800 -
0 I
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END OF FUEL CYCLE PRIMARY WATER Cumulativo Number Cracked 10 100 f
8
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4 TTaoo f
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TT 000. MA eM O
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2000 4000 6000 8000 10,000 12,000 14,000 Exposure Time (Hours) l Pigure 3.3.2-4
)
WESTINGHOUSE PROPRIETARY CLASS 3 3.3.3 UPPER AND 1.0WER JOINTS All the data presented in Section 3.3.2 relative to the corrosion and stress corrosion cracking resistance of thermally treated Inconel Alloys 600 and 690 are applicable to the sleeve.
The expansion processes for both the lower and upper joints involve a combinationof[
i.
]**C
The stresses in the sleeve, based on tube to tubesheet data,' should be as shown at B and C on Figure 3.3.3-1, which are also judged acceptable, particularly in view of the corrosion resistance of the thermally treated sleeve material. Stress levels in the outer tube are also. influenced by the expansion technique. For an outer tube expansion produced solely by [
ja.c.e
~
-Confinnation that residual stresses at the tube 00 surface due to expansion were innocuous with regard to corrosion degradation was shown by accelerated controlled potential tests.
Two controlled potential tests were perfonned on HEJ's. [
7 ja c.e Electrochenically controlled test methods have been used previously to evaluate the SCC resistance of steen generator tubing.N Maximum 1751c/0223c/020185:5 27 3-17
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WESTINGHOUSE PROPRIETARY Cl. ASS 3 susceptibility to caustic SCC was observed when the electrode potent'ia'l of the Inconel Alloy 600 was held in [
ga.c.e C
3*'C tests, C-ring control specimens were cut from the unexpanded end of the tube and stressed beyond yield. These control specimens were used to verify the aggressiveness of the environment. [
83'C
These test data indicate that the residual stress levels on the 00 of the HEJ are low.
i A suonary of the results for the various verification programs is presented in Table 3.3.3-1.
3.3.4 TEST PROGRAM FOR TIE LOER JOINT 3.3.
4.1 DESCRIPTION
OF LOWER JOINT TEST SPECIMENS The tube /tubesheet mockup was manufactured so that it was representative of the tube /tubesheet joint (Figure 3.3.4.1-1) of the model 44/51 steam generators. The tube was then examined with a fiberscope, [
]"'C cleaned by swabbing, and re-examined with the fiberscope. Then the preformed sleeve (Thermally Treated Inconel 600 or Thermally Treated Inconel 690) was inserted into the tube and the lower joint l
formed.
l
[
t, ga.c.e 1751c/0223c/020685:5 28 3-18
5 STWLC:E Fi."F;;;ET.7il CUSS 3 TABLE 3.3.3 1 DESIGN VERIFICATION TEST PROGRAM - CORROSION ~
Description of Issues Test Results 1.
Corrosion and Stress Corrosion Cracking of Lower Joint e
b 2.
Corrosien and Stress Corrosion Crackirg of-
'HEJ 1681c/0216c/010985:5 23 3-19 e.
- - - ~,
,,, + - - - - -.,-
n.
WESTINGHOUSE PROPRIETARY CLASS 3 7:es.se 4
8 a
Figure 3.3.3-1 Location and Reistive Magnitude of Residual Stresses induced by Expansion s
3-20 mm.
WESTINGHOUSE PROPRIETARY CLASS 3 nos.2s f
i Figure 3.3.4.1-1 Lower Joint As-Rolled Test Specimen 6
3-21 1
s-
- -+
-mr w-r o-
WESTINGHOUSE PROPRIETARY CLASS 3 3.3.
4.2 DESCRIPTION
OF VERIFICATION TESTS FOR THE LOWER JOINT The as fabricated specimens for the Model 44 (as discussed in Section 3.3.1, Model 51 parameters and conditions are bounded by Model 44 parameters and conditions) were tested in the sequence described below. Note that the tests
~
of the Inconel 690 sleeve are similar to' those perfomed on the Ine nel 600 sleeve except that the Steam Line Break (SL8) and E0P (Extended Operation Period) tests were not considered necessary based on previous results.
1.
Initial leak test: The leak rate was determined at room temperature, 3110 psi and at 600*F, 1600 psi. These tests established the leak rate of the lower joint after it has been installed in the steam generator and prior
~
.to long-term operation.
2.
The specimens were fatigue loaded for 5000 cycles.
3.
The specimens were touperature cycled for 25 cycles.
4 The specimers were leak tested at 3110 psi room temperature and at 1600 psi 600*F. This established the leak rate after'5 years of simulated normal operation (plant heatup/cooldown cycles) produced by steps 2 and 3.
Several specimens were removed from this test sequence at this point and were subjected to the E0P Test. See Step 7, below.
5.
The specimens were leak tested while being subjected to SLB conditions.
6.
The specimens were leak tested as in Step 1 to determine the post-l accident leak rate.
7.
The E0P test was performed after Step 4 for three as-rolled specimens.
1751c/0223c/020185:5 29 3-22
WESTINGHOUSE PROPRIETARY. CLASS 3 3.3.4.3 LEAK TEST ACCEPTANCE CRITERIA Site specific or bounding analyses have been performed to determine the allowable leakage during normal operation and the limiting postulated accident condition. The leak rate criteria that have been established are based on
+
Technical Specifications and Regulatory requirenents. Table 3.3.4.3-1 shows the leak rate criteria for the Model 51 steam oenerators. These criteria can be compared to the actual leak test result; to provide verification that the mechanical sleeve exhibits no leakage or slight leakage that is well within the allowable limits. Leak rate measurenent is based on counting the number of drops'Iqaking durin'g a 10-20 minute period. Conversion to volumetric
, measurement is based on assuming 19.8 drops per milliliter.
.t 3.3.4.4 RESULTS'0F VERIFICATION TESTS FOR LOWER JOINT The test results for the Model 44 (and Model 51, since Model 44 conditions bound Model 51 condit. ions) lower joint specimens are presented in Table 3.3.4.4-1.
The specimens did not leak before or during fatigue loading.
After five years of simulated normal operation due to [
d
]C
All of the three as-rolled specimens were leak-tight during the Extended Operating Period (EOP) test.
For the Inconel 690 sleeve tests the following were noted:
Specimens MS-2 (Inconel 690 Sleeve): Initial leak rates at all pressures and at normal operating pressure following thermal cycling were [
4 Ja,b,c.e 1751c/0223c/020185:5 31 3-23 F
+-
---,e e
s-,.,
e
.e.,,.,,
e.-w..
_-.+,,--.,r-.,
-.,.., -,.,,, - - -, - - - - - - - -. - - -, - -. - - -7
WESTINGHOUSE PROPRIETARY CLASS 3 TA8LE 3.3.4.3-1 ALLOWA8LE LEAK RATES FOR TYPICAL MODEL 51 STEAM GENERATORS
~~
(NormalOperation)
Allowable Leak Allowable Lesk Condition Rate Rate per Sleeve Normal 0.35 gpa per steae 0.0002 gpa*
Operation generator' O.7 al/ min or
~
15.0 drops / min Limiting Leak Rate Leak Rate per Sleeve
- a,c.e
-Postulated Accident Condition
.(Steauline Break)
Based on 1946 sleeves per steam generator.
++ Standaro Technical Specification Limit.
- [,
3a,c.e The analysis assumes primary and secondary initial inventories of i
luct/gm and 0.luCi/gm of Dose Equivalent I-131, respectively.. In addition, as a result of the reactor trip, an iodine spike is initiated which increases the iodine appearance rate in the primary coolant to a value equal to 500 times the equilibrium appearance rate.
1751c/0223c/020685:5 32 3-24.
WESTINGHOUSE PROPRIETARY CLASS 3 Specimen MS-3 (Inconel 690 Sleeve): [
ja,b,c.e Specimen MS-7 (Inconel 690 Sleeve): '(
i ja,b,c.e 3.3.5 TEST PROGRAM FOR THE UPPER HYBRID EXPANSION JOINT (HEJ) 3.3.
5.1 DESCRIPTION
OF THE UPPER HEJ TEST SPECIMENS Two types of HEJ test. specimens were fabricated for the Model 44 testing (as dicussed in Section 3.3.1, Model 51 parameters and conditions are bounded by model 44 parameters and conditions). The first type was a short specimen as shown in Figure 3.3.5.1-1.
Some of these specimens were fitted with pots containing hard sludge to simulate the structural effects of sludge on the joint. The only type of sludge simulated in this program was hard sludge.
Soft sludge effects were bounded by the hard sludge effects and by the out-of-sludge conditions. [
4 Ja,b,c Any leakage was collected and measured as it issued from the annulus between the tube and sleeve. This type of specimen was used in the majority of the tests.
The second type of test specimen was a modification of the first type.' - It was
- utilized in the reverse pressure tests, i.e., for LOCA and secondary side hydrostatic pressure tests. As shown in Figure 3.3.5.1-2, the specimen was modified by [
1751c/0223c/020185:5 33 3-25
---n-.
4 k
og, es 0
e m
4 9
en N
ene e-6 m
e m
d um o
~
due s
T 3
e a
T S
U e
e w
n a
C
~
fut 9
eum e-p 4
Y l
E s9 G
I l
e.
4 e
b m
4 I.
Ys
=
9 b
I.-
e en I
W en i
en
(
Y M
q q
a
=
i
=
=
3-26 I
9 i
h e,-
m
..d*...y..........** e ***...t.* 3 m
o 6
I m
M 3
h 4
m.
e m
C O
U E
~~
4 e
=
I T
a w
O E
e m
e a
O I
- a r3 Ea E
E Y
8 6.
m e
5 I
-4
-+
w e.
S hh 4
b an 4
to a
9 s.
M*
-g
-t.
=
5
- ~ -. +
- e-4 e.
e e.
e 4.26 e
m.e a.e s
g g
e-
=
m.
y M
E 5
E E
5 E
- 4 e
4
=
e I
3-27
9 h..
, 3 e
e e
l I
l i
l t
=
l L
i I
t 7
.k
.5 C
3 0
e t
l U
e w
e 3
r M
en h
@ U a
e
- we em Qu i
l e
4 I
I".
e Ia l
I t
3-28 I
WESTINGHOUSE PROPREETARY CLASS 3 l
l
]C The possible reverse pressure test leak path is shown in Figure 3.3.5.1-2.
l Only specimens like Figure 3.3.5.1-1 (excluding the sludge conditions) were used in the 1690 HEJ specimen fabrication as the effects of sludge had been established in the earlier model 44 tests.
3.3.5.2 DEpCRIPTION Of - VERIFICATION TESTS FOR THE UPPER HEJ The verification test program for the HEJ was similar to that for the lower joint.
The HEJ was subjected to fatigue leading cycles and temperature cycles to simulate five years of normal operation and the leak rate was detemined before and after this simulated norell operation. For a number of the specimens, the leak rate was also determined as a function of static axial loads which were bounded by the fatigae load. It is important to note that the fatigue load used in testing was that which was caused by 4
loading / unloading. However, the inost stringent load on the sleeve / tube joint occurred at steady state operation. Hence, it was judged necessary to determine that the leak rate at static and fatigue conditions were comperable. The upper HEJ specimens were also subjected to the loadings / deflections caused by a steam line break (SLB) accident and the leak rate was detemined during and 'af ter this simulated accident. The upper HEJ was also leak tested while being subjected to two reverse pressure conditions, a LOCA and a condition which simulated a secondary hydrostatic test. An extended operation period test was also performed.
3.3.5.3 RESULTS OF VERIFICATION TESTS FOR THE UPPER HEJ The test results are presented in Tables 3.3.5.3-1 to 3.3.5.3-5.
1751c/0223c/020185:5 34 i
3-29 l
h..
3 h
a Hybrid Expansion Joint Test Soecimen (The t.eak Path, if Any Laskage Exists, is shown by the Cotted Lines)
Figure 3.3.5.1-1 3-30
3 a
s s
e d
HEJ Specimens for the Reverse Pressure Tests. The Leak Patn, if Any Exists, is Shown by the Dotted Lines Figure 3.3.5.1-2 l
3-31
WESTiltGH00SE P8t0PRIETARY CLASS 3 As can be seen from Table 3.3.5.3-I, the HEJ's fonned out-of-sludge,'i'.e., in D
air, had an average initial leak rate of approximately (
J
'C
at the normal operating condition of 600*F and 1600 psi. After five years of simulated nonnal operation due to 5000 fatigue cycles and 29 to 32 temperature cycles, the leak rate was [
]b,c.e at the normal operating
-condition. Furthermore, for the E0P test, f.e., after thirty-five years of s faulated nonnat operation due to at least 175 temperature cycles (208 were actually used) and a total of 35000 fatigue cycles, the leak rate was o
(
),b,ce Table 3.3.5.3-2 contains data for upper HEJ's formed out-of-sludge. It includes the same basic test data as Table 3.3.5.3-1, i.e., initial leak rate 1ata. However, it includes static axial load leak tests, SLS and reverse pressure tests in place of the fatigue and E0P tests includeo in Table 3.3.5.3-1.
Five of the six specimens were leaktight at normal operating conditions during the initial leak test. The leak rate during static axial sleeve loads, bounded by the. fatigue load and caused by normal operating conditions was measured for four out-of-sludge HEJs. [
4
]b,c e This leak rate was a negligible fraction of'the per-sleeve limit of [
]bc.e The results' for the post-SLB leak test, at the same temperature and pressure i
conditions, were similar to the during-SLB results, [
l
]b,c,e This leak rate was a small fraction of the post-SLB, per-sleeve limit of [
]b,c.e I
The results for the out-of-sludge HEJ reverse pressure test are shown in Table 3.3.i.3-2.
For both the simu?ated LOCA and secondary side nydrostatic L
pressure test the leak rate was zero for the two specimens tested.
The process used for forming HEJ's in sludge,'in Tables 3.3.5.3-3 and 3.3.5.3.t, nas the reference process, per Table 4.0-1 s 1751c/0223c/020685:5 35 l
3-32
WESTINGHOUSE PROPRIETARY CLASS 3 la.c.e The initial leak rate of the first group of upper HEJs formed in sludge was [
f'Catthenormaloperating condition as is shown in Table 3.3.5.3-3.
Only one specimen had a
(
] ' After exposure of the specimens to five years of simulated normal operation due to fatigue and temperature cycling, the average leak rate remained very low, [
]b,c.e at the 600*F and 1600 psi condition.
The results of the reverse pressure test for the in-sludge upper HEJs are also shown in Table 3.3.5.3-3. [
]a,b,c It was [
]a,c.e for the simulated secondary side hydrostatic pressure test.
4 Table 3.3.5.3-4 also contains data for HEJs formed in-sludge. It includes the same basic initial leak tests as Table 3.3.5.3-3.
However, it includes axial load leak test and post-SLB leak tests in place of the fatigue and reverse pressure tests included in Table 3.3.5.1-2.
All of the four specimens were leaktight during the initial. leak test, per Table 3.3.5.3-4.
Two specimens did not leak at any static axial load and two others did not leak until a compressive load of 2950 lbs was reached. However, the two leak rates at 2950 lbs were low, [
],c.e for specimens Number pTSP-23 and PTSP-33, respectively.
In general, the leak rates for static loads were approximately the same as for dynamic'(fatique) loads of the same magnitude. However, a specific set of specimens was nnt subjected to both types of loads.
1751c/0223c/020685:5 36 3-33
.._,,y,--
--,,,.,,,,.,r-
IdESTINGHOUSE PROPRIETARY CLASS 3 As shown in Table 3.3.S.3-4, the average leak rate for four in-sl0dge
- specimens during the SLB test was [
af ter the SLB test was [
ja.c.e
_ The test data generated for the Inconel 690 samples is presented in Table 3.3.S.3-5.
The following observations were noted:
j,b c were found at initial a
Specimen S-5 (Inconel 690): [
leak testing it room temperature (R.T.). At 600*F, the leak rates reduced significantly and remained below L J"' 'C during a subsequent thermal-cycling test. This specimen was formed with a tube diametral bulge that was smaller than will probably be used in the field.
i Specimens 5-8 (Inconel 690); 255-8 and 255-13 (Inconel 625), S-4, S-6, and 8-7 (Inconel 625/690 - G.740 in. Sleeve Dia.), and 8A-11 (Inconel 625/690-0.630 in. Sleeve Dia.): These seven specimens all exhibited [
]C during the initial leak testing at R.'T.. In all cases, by the end of the testing, including thermal cycling and fatigue in some cases, the leak rates had [
3 jac,e 1.3.6 TEST oROGRAM FOR THE FIXED-FIXED MOCXUP 1.3.6.1 OESCRIPTION OF THE FIXED-FIXED MOCXUP The fixed fixed full scale mockup is shown in Figure 3.3.6.1-1.
This mockup simulated the section of the stese generator from the primary face of the tubesheet to the first support plate. The bottom plate of the mockup repre-sented the bottom of the tubesheet, the middle plate simulated the top of the tubesheet and the upper plate simuisted the first support plate. The tubes werel l
'C into the bottom plate to simuiste the tube /tubesheet i
Jofit snd 89to the upper plate to simulate a dented tune condt:fon. The term
- fixed Ftxed" was derived from the fact that the tubes were fixed at these two 4
1751c/0223c/020685:5 37 '
3-34
+ -...,,,..... _,..,,, _. - _ -,
ESTINGIOUSE PROPRIETARY CLASS 3
Table 3.3.5.3-1 TEST RESULTS FOR MODEL 44 HEJ'S FOR"E0 OUT OF SLUDGE (Page.1 of 2) '
(FATIGUE PNG EXTENXD OPERATION TESTS INCL.)
s Specfme NO.
1 PTA-46 w
d, PTA-47 v.
PTA-48 4
PTA-52 l
l PTA-53 1
PTA-45 PTA-49
{
PTA-50 1
PTA-51 1
PTA-54 4
l Averages Note: Short specimens usert for this test.
ESTINGHOUSE PROPRIETARY CLASS i
Tahle 3.3.5.3-1
( Cont. )
TEST RESULTS FOR HDDEL 44 EJ'S FORMS OUT OF SLUDGE (Page 2 of 2)
(FATIGUE AND EXTENDED GPERATION TESTS INCL.)
1 l
1 Specimen No.
PTA-46 y
PTA-47 PTA-48 PTA-52 PTA-53 PTA-45 PTA-49 PTA-50 PTA-51 PTA-54 Averages :
j
'I 4
I a
Table 3. 3. 5. 3-2 fl51 M5aEIS f an enNL 44 MJ'S resse e sist er Stuard (Page I of 29 15f allt Atlat taas l(as stSt.s te ame Muten Pet 5 gag Iggi intg, gill lest Spec leen no.
PIA.5%
PIA-56 PIA.%F 7
P54.54 PIA-59
[.l Y
PIA-61 l1 sa U
- j averages:
- ?
- ?
- Spec teen i es modified le be tested ender reverse pressores.
- 3 Shart speclares used for this test.
64 (l) All test rates are la dropsAnlaute.
til leastle: * ; fampressive :.
~
E E5fillGH005E P90pRIETARV CLASS
.5 i
S
?.
R TABLE 3.3.5.3-2 (Cont.)
3 TEST MSULT5 Fee ItosEL 44 KJ's F00KB GT OF StueGE (Page 2 of 21 (STATIC AX1AL LOAS LEAK TEST,4La AND REER5E PRE 55NK. TEST INCL.IIII 4
e I
Leak Rate AfterSLS Leak Rates During Reverse Pressere Tests Average Leak Gate Accfdent Condttime Secondary leydre-Test During a Feedline (seen Temp.)
(6dgl*F) static Pressure Less of Coolant k
Specimen Break Accident, 1600 2400 1600 2400 Test,lleen Temp.
Accident I,
No.
600*F. 1600 psi psi psi psi psi 1350 psi 545*F. 1050 psi Y:
PTA-55
{
PTA-56 3
PTA-57 PIA-58 PTA-59 l
PTA-61 a
Averages:
l I
A
- Specimen was modified to be tested under reverse pressures.
Short specimens used for this test.
i (1) All feat rates are in dropsAminute.
l
s 2:
ht " N -:.!! ::::::; ::. :,:n j
.?
e 4
4 E
e 1
e.
2-
~5 t_
O a3 m
a g a
...I1 9
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- . 9"g w
- s a
_g
.c ma 4 [3 b
W I 53
~-
C 5
m 3
"I.O.
C
- 3. 2 1.
1 21 3
15
.r 2
2*5 3
1
,. ~
'. 3
]
=. t. a. n. z. a. =. x. x. *. *. =. =. m. :.
E.
d 232 EIEEEZIIIIKE II 3
A 3-39 e
, - ~.,. - - - -.,
,m,
l WESTINGHOUSE PROPRIETARY CLASS 3 TA8LE3.3.5.3-3(cont.)
TEST RESULTS FOR MODEL 44 HEJ'S FORMED IN SLUDGE (FATIGUE ANO REVERSE PRESSURE TESTS INCL.) (CONT)
Leak Rates During Reverse Pressure Tests (drops / min.)
Test Secondary Hydrostatic Loss of Coolant Specimen Pressure Test, Accident No.
Room Temp./1350 psi 545*F/1050 psi PTSP-22 PTSP-24 PTSP-25 PTSP-28 PTSP-29 PTSP-30 PTSP-31 0
0 PTSP-32 PTSP-34 a
PTSP-35 PTSP-36 PTSP-37 PTSP-38 PTSP-39 PTSP-40 0
0 Average 0
0 1751cl0223c/020185:5 38 3-40
r!!*! P :t:t is::::t :, v.::3 3
P e
f 4
I'
=
.E I g
,I
_a -
a3
.lE' W
., N I
3.
m Et
", J =j m
3.
=_
Ma 5
.3 m
c en =.
t em X_.
- t
~
t
.Y.
d.
en m -
Y $
sum 9
b I T
== b 2
S S t
-i 1 d
6 st og aun est
@'@ fle N.
M.
e g
1"
=
b k O k 3
l 3-41 0
l-
...- --. - i i
O r-o O
-W 5
m I
I W g *I 4
g 't I A
r 2
-=
W
=
Ia 3-42
,,,,..._J---
-' "2 WESTINGHOUSE PROPRIETARY CLASS 3 locations. There were thirty-two tubes in two clusters of sixteen. A sludge sinulant composed of alumina was formed around one cluster of sixteen.
Sleeves [
]a.c.e long were installed in the tubes by [
3a,c.e Each tube was perforated between the upper and lower joints to simulate tube degradation and thereby provide a primary-to-secondary leak path. End plugs were welded to the tubes to permit pressurization with water.
s No fixed fixed mockup tests were performed on the I690 samples based on the results of tlw earlier tests performed.
3.3.
6.2 DESCRIPTION
OF VERIFICATION TESTS FOR THE FIXED-FIXED MOCKUP The f'xed fixed mockup was used first to verify the full length sleeve installation parameters and tooling. It was then used to measure the leak rate of the lower joint and upper Heil. This leak rate was detennined with the sleeve Installed in a tube fixed at the tubesheet and dented at the first support plate, i.e., for the fixed-fixed condition.
~
3.3.6.3 RESULTS OF VERIFICATION TESTS FOR THE FIXED-FIXED MOCXUP Table 3.3.6.34 contains leak test results recorded for full length sleeves formed and tested in-situ, in the fixed fixed mockup, in-sludge and out-of-sludge (see Figure 3.3.5.3-3).
All of the room temperature initial leak tests produced [
3a,b,c These initial leak rate results were similar to the initial leak rate results in which the short specimens were structurally unconstrained during' forming of the upper HI.l.
Therefore, it was concluded that the results of the other several tests performed only on short specimens would be similar if the test had been performed in-situ, in the fixed / fixed mockup. During the pre-test evaluation, it was determined that the fixed / fixed mockup duplicated the most 1751c/0223c/020685:5 39 3-43
WESTINGHOUSE PROPRIETARY CLASE J,,
'nonu
(
+
,i l
.I -
P
/
Fixed Fixed Mockup - HEJ (For the HEJ In-Situ Lenk Tests, the Leak Path,if Any Exists. is Shown by the Dotted Linesi Figure 3.3.6.1-1 3-44 e
9 w
~
e v.
.n-----
.r
WESTINGHOUSE PROPRIETARY CLASS 3 stringent structural loading conditions for sleeves. Therefore', it was concluded that all of the testing with short specimens was valid. Because the
~
model 44 loads encompassed the model 51 conditions, this testing is considered applicable to model 51 units also.
- 3.3.7 EFFECTS OF SLEEVING ON TUBE-TO-TU8ESHEET WELO The^ effect of hard rolling the sleeve over 'the tube-to-tubesheet weld was examined in the sleeving of 0.750 inch 00 tubes. Although the sleeve installation roll torque used in 0.750 inch tube.s is less than a.875 inch OD tube, the radial forces transmitted to the weld would be. comparable.
Evaluation of the 0.750 inch tubes showed no tearing or other degrading effects on the weld after hard rolling. Therefore, no significant effect on the tube-to-tubesheet weld is expected for the larger 0.875 inch CD tube configuration.
d 1751c/0223c/020685:5 40 3-45
1 W I?I U 4'.'$l Pg sp*g= gy gg33 y
'e
'e e
4 9
O N-t.
w a
. a W
W
~~ ~
- =
n m.
5
--3
=
m e
I-m.-
I Eh
,0-. IE
- l i
s a=
=
5 I:s
=
3 a
3
- l L-I i
.I g
t' 3.
2Es!n-=5 3
=
3-46 e
,e-v r..,...
t, n.--,
,.-,,--n
,-w--- -. -,,. -
,--,..,,---,,nn-. -,,,,., - -, - -, - -,,- -.. - -, - -, - - -.,,,. - e v,.,-,
WESTINGHOUSE PROPRIETARY CLASS 3 3.4 ANALYTICAL VERIFICATION 3.
4.1 INTRODUCTION
' This section contains the structural evaluation of the sleeve and tube Lassembly with HEJ, sleeve material'I690 or 1600 and sleeve length [
3a,c.e in relation to the requirements of the ASME Boiler and Pressure Vessel Code,Section III, Subsection N8, 1983 Edition [ Reference 1]
a The analyses include primary stress intensity evaluations, maximum range of stress inte,nsity evaluations, and fatigue evaluations for various mechanical and thermal conditions which umbrella the loading conditions specified by the
~
Westinghouse Equipment Specification G-677164, 12/18/69, Revision 1
[ Reference 5], Westinghouse Equipment Specification Addendum No. 677030, 11/12/73, Revision 3 [ Reference 6], and Westinghouse Equipment Specification Addendum No. 952404, Revision 1,3/21/75[ Reference 7].
3.4.2 COWOMENTDESCkIPTION The general configuration of the sleeve-tube ' assembly with HEJ is presented in Figure 3.4.2-1.
f The critical portions of the sleeve-tube assembly are the two joints., the upper Hybrid Expansion Joint (HEJ) and a mechanical lower joint, and straight sect. ions of the sleeve and tube between the two joints. Past analytical experience indicates that upper joint stresses are more limiting than lower joint stresses. A detailed stress evaluation of the [
]a,c.e sleeve was turefore performed for the upper joint only. Finite element models were d)vsloped to represent the upper joint area. The tolerances used in developing the models were such that the maximum sleeve and tube outside diameters were evaluated in combination with the minimun sleeve and tube wall thicknesses. This allowed maximum stress levels to be developed in the roll transition regions.
1751c/0223c/020185:5 41 3-47
i WEIT,1RGHOUSE PACFRIETIRY C'.ALS 1
l
. l
/
Figure 3.4.2-1.
Installed Sleeve with Upper Hybrid Expansion Joint Configuration 3-48 L
WESTINGHOUSE PROPRIETARY CLASS 3 3.4.3 MATERIAL PROPERTIES The. sleeve material is Inconel 690 or Inconel 600. Both sleeve materials Inconel 690 and Inconel 600 are covered by ASME Code' Case N-20 [ Reference 8].
The tube material is $3-163 (Inconel 600).
An air gap was included between the tube and sleeve below the HEJ. Although this space could be filled with secondary fluid in the event of a d
discontinuous (or leaking) tube, assuming the physical properties of air for these elements is conservative for the thermal analysis. Primary fluid physical-pr,operties were used for the gap medium above the HEJ.
All material properties used in the analyses were as specified in the ASME Boiler and Pressure Vessel Code,Section III, Appendix 1 [ Reference 4] and
. Code Cases [ Reference 8].
3.4.4 ' CODE CRITERIA The ASME Code Stress Criteria which must be satisfied are given in Tables 3.4.4-1 and 3.4.4-2.
3.4.5 LOADING CON 0!TIONS EVALUATED The loading conditions are specified below:
1.
Design conditions a.
Primary side design conditions P = 2485 psig T = 650*F b.
Secondary side design conditions P = 1085 psig T = 600*F 1751cl0223c/020185:5 42 3-49 n.
--~~--.:-.,.-,,
m
,e
-, --e np
,.,w,,-,ne-g
-,,,-,,g m
-,,y-ym-
-YU 1-..- -
........ _3;.3 TABLE 3.4.4-1 CRITERIA FOR PRIMARY STRES$ INTEN5fTY EV 1.UATION (5LEEVE) 9 9
O 9
9 6
4 4
e 3-50
-er~e.
---n,---
~
.w----e--
,-+
v.-----
+ -
1 l
3
..e..
TABLE 3.4.4-2 l
CRITERIA roR perg:RY STRESS IMEP'SITY N'm (Tust) l i
e e
9 e
O A
e
+
0 3-51
WESTINGHOUSE PROPRIETARY CLASS 3 Maximum primary to secondary pressure different121 - 1600 psig, c.
-T = 650*F d.-
Maximum secondary to primary pressure differential - 670 psig, T = 650*F 2.
Full load' steady state conditions are:
Primary side pressure = 2235 psig Hot leg temperature = 599.1*F l
Cold leg tasperature = 535.5"F l
. Secondary side pressure = 735 psig Feedwater temperature - 427.3*F
~
Steam temperature = 510.8*F
[-
Other operating conditions are specified in Table 3.4.5-1.
3.4.6 METH005 0F AMLYSIS Using the )ECAN [ Reference 2] finite element analysis program, stress components were taken directly frtzu the analysis of finite elssent models of the tube-sleeve assembly. Separate unit pressure runs and thermal transient
~
runs were first made and then properly combined with the WECEVAL (Reference 33 l.
Program.
l.
3.4.6.1 MODEL DEVELOPMENT i
l.
A finite element model was developed for evaluating the sleeve design.
l Some significant considerations in developing the model are:
1.
Mechanical roll fixities between the sleeve and tube at the hard roll regions were achieved by using the sane nodal numbers for the sleeve and tuba interface.
2.
By varying the boundary conditions at a specified region of the model, conditions of either an intact tube or discontinuous tube were simulated.
l 1751c/0223c/020185:5 43 3-52 I
e
--a-,-c e
,<-_---,-,,,-,,.,,n+,n-,n.,,--n----,,,,,.n,.e
,_,,-,,,,.n-,..
- - -,..., - - -..n_-,,. _., - -,-- - - -,
,k Y.E".....;..:...:7.::-l.7,Y CU,0s a
TABLE 3.4.5-1 OPERATING CONDITIONS NO. OF OCCURRENCES CONDITION
-TO BE ANTICIPATED NORMAL OPERATING CONDITIONS r
Plant Heatup 200 Plant Cooldown 200 Plant
- Loading 55 Minute 18,300 Plant Unloading 5% Minute 18,300 Small Step Load Increase 2,000 Small Step Load Decrease 2,000 Large Step Load Decrease 200 Hot Star.dby Operations 18,300 Turbine Roll Test 10 Steady State Fluctuations
=
d UPSET CONDITIONS' Loss of Load 80 Loss of Power 40 Loss of Flow 80 Reactor Trip from Full Power,
400 FAULTED CONDITIONS Reactor Coolant Pipe Break 1
Steam Line Break 1
Feed Line Break-I TEST CONDITIONS Primary Side Hydrostatic Test 5
Secondary Side Hydrestatic Test 5
3-53 s-,
.,___.----..,--,-,-..,,,.-n en--...,,,-,w,,,,,..-,v.-.w-.-n---n-
..,n e-n.-
y
v WESTINGHOUSE PROPRIETARY CLASS 3 3.
The interface nodes along the upper and lower hydrauli expansion regions of the HEJ were coupled in the radial direction for-l temperature and themal stress runs. The interface nodes along the lower hydraulic expansion region were coupled in the radial direction for pressure stress runs in the case of tube discontinuous.
The element types chosen for the finite element analysis were the followingWECAN[ Reference 2] elements:
a,c.e l
l l
l
[
l l
l
\\
l-l All the element types are quadratic, having a node placed in the center of each surface in addition to nodes at each corner.
l 3.4.6.2 THERMAL ANALYSIS The purpose of the thermal analysis is to provide the temperature distribution -
needed for themal stress evaluation.
Thermal transient analyses were performed for the following events:
i Small step load increase Small step load decrease Large step load decrease Hot standby operations 1751c/0223c/020685:5 44 l
3-54 L
[-
=
WESTINGHOUSE PROPRIETARY CLASS 3 Loss of load Loss of power loss of. secondary flow Reactor trip from full power i
The plant heatup/cooldown, plant loading / unloading and steady fluctuation events were considered under thermal steady state conditions.
The finite element types chosen for the thermal analysis were STIF58 and STIF68..
In order to perform the WECAN thermal analysis, boundary conditions consisting of fluid tenperatures and heat transfer coefficients (or film coefficients) for the corresponding element surfaces are necessary. The conditions considered in the thermal analysis are based on the following assumptions:
{
The tempera,ture induced stresses are most pronounced for sleeves in the hot leg (where the temperature difference between the primary and secondary fluids is a maximum) and therefore, only the hot leg sleeves were considered. This condition bounds the thermal stresses on the cold leg.
The sleeves may be installed in any tube in the generator. Thus, to be conservatte, it is assumed that the sleeve to be evaluated is sufficiently close to the periphery of the bundle that it experiences the watee tenperature exiting the downcomer.
i Special hydraulic and thermal analysis was performed to define the primary and i
secondary side fluid temperatures and film coefficients as a function of time.
Both boiling and convective heat transfer correlations were taken into consideration.
1751c/0223c/020185:5 45 3-55
. ESTINGHOUSE PROPRIETARY CLASS 3 3.4.6.3 STRESS ANALYSIS A ECAN [ Reference 2] finite element edel was used to determine the stress levels in the tube / sleeve configuration.
Elements simlating the medium between the tub.e and the sleeve were considered as dummy elements. The element types suployed were STIF53 and STIF56.
8ased on the results demonstrating the applicability of a linear elastic analysis, thermally induced and pressure induced stresses were calculated separately and then combined to deterisine the total stress distribution using the ECEVAL computer program (Reference 3]. In addition, ECEVAL perforses the stress categorization required for an ASM Boiler and Pressure Vessel Code,Section III, stress analysis and for the complete fatigue evaluation.
The criteria in the evaluation were those specified in Subsection N8 of the ASE Boiler and Pressure Ves,sel Code (Reference 13 Pressure Stress Analysis For superposition purposes, the ECAN model was used to determine stress,
distributions induced separately by a 1000 psi primary pressure and a 1000 psi secondary pressure. The results of these " unit pressure" runs were then scaled to the actual primary side and secondary side pressures corresponding to the loading condition considered in order to determine the total pressure stress distribution.
The two edeling considerations in determining the unit pressure load stress distributions were tube intact and tube discontinuous. Therefore, the following unit ;:ressure loading conditions were evaluated to determine the maximun anticipated stress levels induced by primary and secondary pressures:
Primary pressure - tube intact Primary pressure - tube discontinuous Secondary pressure - tube intact Secondary pressure - tube discontinuous i
1751c/0223c/020185:5 46 3-56
.--..s-a,..
n
,--.,,,..nv.,-.n--
- - - - -,_--e-~~n--~------r~-
--*--v-'
^^-^
WESTINGHOUSE PROPRIETARY CLASS 3 Theendcapforcesduetotheaxialpressurestressinduce[iinthetubeaway
'from discontinuities were taken into consideration.
Thermal Stress Analysis The WECAN model was used to determine the thermal stress levels in the tube / sleeve configuration that were induced by the temperature distribution 8
calculated by the thermal analysis. The times during the thermal transient solutions which were anticipated to be limiting from a stress standpoint were evaluated.,
Combined Pressure Plus Themal Stress Evaluation As mentioned previously, total stress distributions were determined by combining the unit pressure and thermal stress results as follows:
' total *
'('I unit primary pressure
'see, I'I
- TRRI unit secondary pressure
(*} thermal At any given point or section of the model, the program WECEVAL determines the total stress distribution for a given loading conditien and categorizes that total distribution per the Subsection NB requirements..That is, the total stress of a given cross-section through the thickness is categorized into membrane,' linear bending, and non-linear components. These categorized stresses are then compared to Subsection N8 allowables.
In addition, when supplied with a complete transient history at a given location in the model, the WECEVAl. progran will calculate the total cumulative fatigue usage factor per Cbde Paragraph N8-3216.2.
.1751c/0223c/020185:5 47 1
3-57
WESTINGHOUSE PROPRIETARY CLASS 3 3.4.7 RESULTS OF ANALYSES
,c.. lyses were performed for both intact and discontinuous tubes. Fatigue and l
stress analyses of the sleeved tube assembly hate been completed in accordance with the requirements of the ASE Boiler and Fressure Vessel Code,Section III.
3.4.7.1 PRIMARY STRESS INTENSITY The umbrella loads for the primary stress intensity evaluation are given in L
Table 3.4.7.1-1.
l The results of primary stress intensity evaluation for the analysis sections
~
are suunarized in Tables 3.4.7.1-2 and 3.4.7.1-3.
All primary stress intensities for the sleeved tube assembly are well within l'
allowable ASE Code limits.
i The largest value of the ratio " Calculated Stress Intensity / Allowable Stress Intensity" of [
4 Ja,b,c i
3.4.7.2 RANGE OF PRIMARY AND SECONDARY STRESS INTENSITIES l
Table 3.4.7.2-1 contains the pressure and temperature loads for maximum range of stress intensity evaluatinns as well as for fatigue evaluations.
Ihe maximum range of stress intensity values for the sleeved asseelies are suonarized in Table 3.4.7.2-2.
l The requirements of the ASME Code, Paragraph N8-3222.2, were met directly at all locations and required no further consideration.
1751c/0223c/020185:5 48 3-58 o
3 TABLE 3.4.7.1-1 UMBRELLA PRESSURE LOADS FOR DESIGN, UP5EI. FAULTED, Ario TEST COND1TIONS e
CONDITIONS pesion Design Primary e
Design Secondary 8.sg1 Loss of Lead Loss of Power Loss of Flow Aeactor Trip from Full Power Faulted
~
Reactor Coolant Pipe Break Steam Line Break Test Primary $fde Hydrostatic Test Secondary Side Hydrostatig Test 3-59
---.v-,..,-.
~---.,-._-,,,,--.-,--,,.,,,n,--,-
TA8tC 3.4.7.1-2 RESULTS (W PRIMA.RY,, STRESS INTENSITV EVALUATi0NS l
PRIMARY MEMBRANE STRESS INTENSITY, P,
CALCULATED MAXIMJM ALLOWA8tE OF STRESS
- STRESS RATIG INTENSITY, INTENSITY, CALCULATED S.I.
tDCAT10N CONDITIONS KSI KSI hiTiWiA' tE S. i.
S T,UBE INTACT Sleeve Design Primary i
i Tule Design Secondary TUSE DISCONTINUGUS i*
- Sleeve Primary Side.
Hydrostatic Test i
Lu Tute i
G i
l l
TABLE.3.4.7.1-3 RESULTS OF PRIMARJ_STR_ESS INTENSITY EVALUATIONS, PRIMARY MEMBRANE PLUS 8ENDING STRESS. INTENSITY, P,+ P b
CALCULATED MAXIMim ALLOWABLE OF STRESS STRESS RATIO-
~~
INTENSITY, INi[NSITY, CALCUL ATED S. I.
LOCATION CONDITIONS KSI KSI AtLOWA8'LT 3.T TUBE INTACT Sleeve Design Primary Tube Loss of Power Secondary Side Hidrostatic. Test 5
TU8E DISCONTINU0US Sleeve Primary Side Hydrostatic Test loss of Power Tube O
1 l
J i
YABLE 3.4.7.2-1 1
PRESSURE AND TEIFERATURE LGADINGS FOR MAXIMIM RANGE I
~
OF STRfWIhTlil511Y AMD FATIGUE EVAL 1RT10ns 1
CASE PRES $URE. PSIG l
CON 0lil0N IIADE 11 0.
CYCLES PRIMARY-SECONDARY STRESSES THERMAL *
,i 1
Ambient i
Anblent 1
200 0
0 0
I 1
Plant loading **
Plant Heatup IPLLD 2 '-
18300 2235 1905 Steady. t = 0 set y
Plant Cooldown
}
E 2PLLD 3
,18300 2235 735 1
Plant Unloading Steady end Small Step Load Decrease 155LD 4
2000 2310 815 255LD 5
2000 2160 769 t = 30 sec i
g. 150 sec i
-Small Step Load facrease 155LI 6
2000 2213 636 t = 50 sec 255LI 7
2000 2227 687 1
t = 185 sec j
Large Step Load Decrease ILSLO 8
200 2310 1017 i
t = 60 see I
2L5LD
-9 200 2160 870 i
t = 480 sec Hot Standby Operations INSTS 10 18300
~ 2235 1005 t = 0 sec i
2HSTB 11 18300 2235 1005 t = 550 sec 4
1 l
s 1ABLE
- 3. 4. 7.2-1.(Con t) piles $URE MO TEMPERATURE LG40tIIGS FOR MAXIMM RAIIGE OF STRESS INTENSITY Allo FATIGUE EVALUATIONS CASE PltE550RE, PSIG CONDITION llAME 11 0.
CVCLES PRIMARY SECONDAltY STRESSES THEL #UlL*
Turbine Roll Test ITRT 12 10 2235 1035 0
2TRT 13 10 1875 525 0
Loss of Load ILLO 14 80 2585 1070 t = 12 sec 2LLO 15
/
80 1600 1070 t = 100 sec
[
Loss of" Power ILPW 15 40 2060 1110 t = 125 sec 3
2LPW 17 40 2485 1110 t = 2000 sec g
Loss of Flow ILFW 18 80 2210 722 t = 20 sec 2LFW 19 80 1860 930 t = 140 sec ;
Reactor Tri k
I"II # " p from 1RTR 20 400 2085 876 t = 10 sec 2RTR 21 400 1815 970 t = 70 sec Steady State ISFL
~22 10 2335 755 Steady 6
Fluctuations 2SFL 23 10 2135 715 Steady Primary Side Hydrostatic Test PRHYORO 24 5
3106 0
0 Secondary Side flydrostatic Test
.SECIIVORO 25 5
0 1356 0
- Thermal stresses are given for the specific tlwt t ---
4 TABLE 3.4.7.2-2 atsmis or MAni.nem_amGr Or statss INrtNstiv tvAtuArl0N CALCKAit0 ALLOMASLE MAllNUM MAnilNM RATIO LOAD CONDill0N RANGE OF S.I.
RANGE OF 5.I.
CALCUL ATED S.I.
LOCAi!0N
_CONBINATION KSt KSI ALLGdA8tf 5.I.~
TUSE INTACT
-?
Sleeve Ambient -
Reactor Trip Aeactor Trip -
Secondary Hydrotest
{- :
Tube Ambient -
Reactor Trip TU8E DISCONilNUGUS
[
Sleeve Primary Hydrotest -
Secondary Hydrotest Aeactor Trip -
Secondary Hydrotest b
Tube D
t WESTINGHOUSE PROPRIETARY CLASS 3 3.4.7.3 RANGE OF TOTAL STRESS INTENSITIES F
Based on the sleeve design criteria, the fatigue analysis considered a design life objective of 40 years for the sleeved tube assembites. Table 3.4.7.2-1, describes the transient conditions used in the fatigue analysis.
e Becalise of possible opening of the interface between the sleeve and the tube along the hydraulic expansion regions, the* maximum fatigue strength reduction factor of 5.0 (N8-3222.4(3)) was applied in the radial direction at the upper Hard Roll Region interface node, in the case of tube intact; and additionally
. at the lower hard roll region interface node, in the case of tube
/
discontinuous.
The resu.its of the fatigue analysis for the sleeved tube assemblies are suunarized in Table 3.4.7.3-1.
All of the cumulativs usage factors are below the allowable value of 1.0 specified in the ASIE Code.
s 1751cIO223c/020685:5 49 3-65
1 WESTINGHOUSE PROPRIETARY CLASS 3 3.
4.8 REFERENCES
1.
ASM Boiler and Pressure Vessel Code, Section Ill, Subsection N8,1983 Edition, July 1, 1983.
2.
WECAN, WAPPP and FIGURES !!, F. J. Bogden Editor, Second Edition, May 1981 Westinghouse Advanced System Technology, Pittsburgh, PA 15235.
3.
J. M. Hall, A. L. Thurman, J. 8. Truitt, " Automated ASME Stress Evaluation Progran WECEVAL, The Proceedings of the Fourth WECAN User's Collogpium, Westinghouse, October 5,1979.
4 ASME Soiler and Pressure Vessel Code, Section !!!, Appendix !.
5.
Equipment Soecification G-677164 Westinghouse, July 10, 1969 Revision 1, December 18, 1969.
6.
Equipment Specification Addendum No. 677030 Westinghouse, April 17, 1968, Revision 3, November 12, 1973.
7.
Equipment Specification Addendum No. 952404, December 21, 1973 Revision 1, March 21, 1975.
8.
ASE Soiler and Pressure Vessel Code, Code Cases, Case N-20,1983
- Edition, July 1, 1983.
9.
N. Pessall, G. P. Airey, and 8. P. Lingenfelter, "The Influence of 5
Thermal Treatment on the SCC Behavior of Inconel Alloy 600 at Controlled i
Potentials in 10 percent Caustic Soda Solutions at 315'C," Corrosion, Vol. 35, 1979.
10.
G. P. Airey, " Optimization of Metallurgical Variables to improve the Stress Corrosion Resistance of Inconel 600". Final Report under EPRI Contract No. RP621-1 March 1980.
1751cl0223cIO20185:5 50 3-67 P
t WESTINGHOUSE PROPRIETARY Ct. ASS 3 11.
G. P. Airey, A. R. Vaia, "A Caustic SCC Evaluation of Thermally Treated Inconel Alloy 600 Steam Generator Tubing," Presented at MICON 82 Symposium, Houston, Texas.
12.
G. P. Airey, A. R. Vaia, " Metallurgical and Environmental Parameters that
' Affect the High Temperature Water SCC Performance of Inconel Alloy 600 "
Presented at the EPRI Workshop, June 1981.
a 4
t s
1751c/0223c/020185:5 51 3-68 i
'\\.,
l l
r E
WESTINGHOUSE PROPRIETARY CLASS 3 3.5 SPECIAL CONSIDERATIONS 3.5.1 FLOW SLOT HOURGLASSING Along the tube-lane, the tube support plate has several long rectangular flow I
slots that have the potential to deform into an " hourglass" shape with significant denting. The effect of flow-slot hourglassing is to move the neighboring tubes laterally inward to the tube lane from their initial positions. The maximum bending would occur on the innermost row of tubes in the center of the flow slots.
e 3.5.1.1 EFFECT OF BURST STRENGTH The effect of bending stresses on the burst strength of tubing has been studied. Both the axial and circunferential crack configurations were investigated. [
ja,e,f 3.5.1.2 EFFECT ON STRESS CORROSION CRACXING (SCC) MARGIN Based on the results of an ongoing caustic corrosion test program on mill-annealed tubing, the bending stress magnitude due to flow-slot hourglassing is judged to have only a small effect, if any, on the SCC resistance margins. Two long tenn modular model boiler tests have been conducted to address the effect of bending stresses en SCC. No SCC or IGA was detected by destructive examination. It is to be noted that thermally treated Inconel 600 and Inconel 690 have additional SCC resistance compared to mill annealed Inconel 600 tubing.
3.5.1.3 EFFECT ON FATIGUE USAGE In addition to the above two considerations, one should also consider the effect of the hourglassing-induced bending stresses on the fatigue usage factor of the sleeve. This is included in the fatigue analysis by recognizing that the stress induced by this motion is a mean stress. Mean stress effects are included in the S-N fatigue curve used in the analysis, hence hourglassing induced bending stresses are included in the fatigue analysis.
1751c/0223c/020185:5 52 3-69
-_____---------3
t L5 l
I r
WESTINGHOUSE PROPRIETARY CLASS 3 ik 3.5.2 TUBE VIBRATION ANALYSIS
=
k Analytical assessments have been performed to predict nodal natural g'
frequencies and related dynamic bending stresses attributed to flow-induced h
vibration for sleeved tubes. The purpose of the assessment was to evaluate
[
the effect on the natural frequencies, amplitude of vibration, and bending
{
stress due to installation of various lengths of sleeves.
Since the level of stress is significantly below the endurance limit for the tube material and higher natural frequencies result from the use of a contribute to cyclic fatigue.
{
sleeve / tube versus,an unsleeved-tube, the sleeving modification does not E
E 3.5.3 SLUDGE HEIGHT THERMAL EFFECTS E
In general, with at least 2.0 inches of sludge, the tubesheet is isothermal at the bulk temperature of the primary fluid. The net effect of the sludge is to
{
reduce tube /tubesheet thermal effects.
L 3.5.4 ALLOWABLE SLEEVE DEGRADATION Minimum required sleeve wall thickness, t, to sustain normal and accident e
condition loads are calculated in accordance with the guidelines of Regulatory i
Guide 1.121, as outlined in Table 3.5.4-1.
In this evaluation, the surrounding
- tube is assumW to be completely degraded; that is, no design credit is taken for the residual strength of the tube.
The sleeve material may be either thermally treated Inconel 600 or thermally treatad Inconel 690. It has been shown that the properties of Inconel 600 are very similar to those of Inconel 690. In particular, the yield strength and ultimate strength are very similar.
The properties of I-600 were used in these analyses because the data base for i
I-600 is larger than the data base for I-690, thus allowing the use of a smaller tolerance factor.
E
~
17 Sic /0223c/020185:5 53
=
3-70
1
~
WESTINGHOUSE PROPRIETARY CLASS 3 Table 3.5.4-1 REGULATORY GUIDE 1.121 CRITERIA 1.
Normal Operation Determine t, mininum required sleeve wall thickness.
r a.
Yield Criterion: Sy1 39.59 ksi Loading:
Pp - 2250 psia P3 - 750 psia AP = 1500 psi AP. R Hence, tr"5 - 0.5 (P +P)=[
] inch a,c.e y
P 5
which is [ ]a,c.e percent of the nominal wall thickness, b.
Ultimate Criterion: Su 1 90.58 ksi Loading:
P - 2250 psia p
Ps = 750 psia aP = 1500 psi sP. R
=[
] inch a,c.e Hence, t r"[s - 0.5 (P +P) p 3
which is [ ]a,ce percent of the nominal wall thickness.
2.-
Accident Condition loadings a.
LOCA + SSE The ma,jor contribution of LOCA and SSE loads is the bending stresses at the top tube support plate due to a combination of the support motion, inertial loadings, and the pressure differential across the tube U-bend resulting from the rarefraction wave during LOCA. Since the sleeve is located below the first support, the LOCA + SSE bending stresses in the sleeve are quite small. The governing event for the sleeve therefore is a postulated secondary side blowdown.
1751c/0223c/020685:5 54 3-71
WESTINGHOUSE PROPRIETARY CLASS 3 Table 3.5.4-1 (cont.)
b.
'FLB + SSE The maximum primary-to-secondary pressure differential occurs during a postulated feedline break (FLS) accident. Again, because of the sleeve. location, the SSE bending stresses are small. Thus, the governing stresses for the minium wall, thickness requirseent are the pressure membrane stresses.
Criteriop: P,< smaller of 0.75, or 2.4S,i.e. 63.41 ksi Loadings:
P, = 2650 psig P, e 0 AP = 2650 AP,j5(P +P)*b 3*'
R r
Hence, tr" i
u p
s or, [ ]a,c.e perc,ent of nominal wall.
l 3.
Leak 8efore-8reak-Verification The leak-before-break evaluation for the sleeve is based on leak rate and c
burst pressure test data obtained on 7/8 inch 00 x 0.050 inch wall and 11/16 inch 00 x 0.040 inch wall cracked tubing with various amounts of; unifone thinning simulated by machining on the tube 00. The margins to burst *during a postulated SLS (Steamline Greak Accident) condition are a function of the mean radius to thickness ratio, based on a maximus j.
permissible leak rate of 0.35 gpm due to a normal operating pressure differential of 1500 psi.
Using a nean radius to thickness factor of 9.5 for the nominal sleeve, l
the current Technical Specifications allowable leak rate of 0.35 gpe, a SLB pressure differential of 2560 psi, and the nominal leak and nominal burst curves, a 25 percent margin exists between the burst crack length
~
and the leak crack length. For a sleeve thinned 54 percent through wall over a 1.0 inch axial length, a 17 percent margin to burst is
. demonstrated. Thus the leak-before break behavior is confirmed for
[
unthinned and thinned conditions.
1751c/0223c/020685:5 55 3-72
1 WESTINGHOUSE PROPRIETARY CLASS 3 3.5.5 EFFECT OF TUBESHEET/ SUPPORT PLATE INTERACTION Since the pressure is normally higher on the primary side of the tubesheet than on the secondary side, the tubesheet normally becomes concave upward.
Under this condition,.the tubes protruding from the top of the tubesheet will
. rotate from the vertical. This rotation depends on the boundary condition assumed for the edge of the tubesheet. Previous calculations of the tubesheet deflection using a finite element model of,the tubesheet whic' includes the h
effects of the adjacent channel head and the stub barrel resulted in a plot that checked with the theoretical deflection formula for circular plates with fixed edges, provided that the shear deflection is included.
Calculations sho'wed that [
3a c.e This stress was added to the cyclic stress in the fatigue evaluation. Note that this stress can be ratioed to account for different ap's that occur in different eveats. Hcttver, the seismic stress, as shown above, is not critical to the fatigue usage which was found to be low.
3.5.6 COMPREHENSIVE CYCL.IC TEST 4
The Comprehensive Cyclic Test was designed to simulate the loadings produced by. the heatup/cooldown and load / unload transients on the upper tube-to-sleeve joint. This test was initially intended to be used in conjunction with the Axial Shear Fatigue Test (a 5,000 cycle fatigue test) to evaluate the sealing integrity of the tube-to-sleeve joint after the application of cyclic loadings. They also would provide experimental confirmation of the capability of the joints to withstand fatigue loadings.
Based on analytical comparisons, the fatigue test produced fatigue that was substantially greater than that which would have been produced in the Comprehensive Cyclic Test.. Also, the fatigue test produced more fatigue than was calculated to occur due to the inservice transient conditions. Therefore, it was determined that the Comprehensive Cyclic Test was not needed in
{
addition to the fatigue test in determining the fatigue integrity of the tube-to-sleeve joint.
1751c/0223c/020185:5 56 3-73
t WESTINGHOUSE PROPRIETARY CLASS 3 3.5.7 EVALUATION OF OPERATION WITH FLOW EFFECTS DUE TO SLEEVING.
An ECCS performance analysis considering 5 percent uniform steam generator
[
tube plugging, SGTP, has been completed for the forthcoming Westinghouse fuel t
reload of the Prairie Island Units. This safety analysis assumed up to 5
. pere w t tube plugging in the ste m generators of either plant and took credit for the current 2.28 value of total core peaking factor. This study and the corresponding non-LOCA study are considered applicable for the stems generator sleeving program as regards Westinghouse-supplied fuel. The accidents evaluated include LOCA and non-LOCA transients as well as consideration of the effects on the nuclear design and thermal-hydraulic perfonnance with the existing plant reactor internals. For the accidents considered in that study, the core and system parameters either remained within their proper limits l
(i.e., peak clad temperature, DNR, RCS pressure, etc.) or the impact of the additional tube plugging was shown to be negligibly small.
1 I
(
- Inserting a sleeve into a stema generator tube results in a reduction of primary coolant f*ow. The selected sleeving program at Prairie Island involves the 36 inch long sleeve. [
~
a jace l
l
[
a,c.e l
l i
l l
l 1751c/0223c/020685:5 57 3-74 l
t
1 WESTINGHOUSE PROPRIETARY CLASS 3 Prairie-Island Unit 1 S/G 1 S/G 2, Maximum number of tubes to be sleeved 1,946 (57 percent) 1,946 (57 percent)
Equivalent Plugged Tubes 60 (1.8 percent) 60 (1.8 percent)
Existing Plugged Tubes 43 (1.3 percent) 18 (0.5 percent)
(as of October 1984) 3
' Total ranivalent Plugged Tubes 103(3.1 percent) 78 (2.3 percent) e Prairie Island Unit 2 S/G 1 S/G 2 Maximum number of tubes to be sleeved 1,946 (57 percent) 1,946 (57 percent)
Equivalent Plugged Tubes 60 (1.8 percent) 60 (1.8 percent)
, Existing Plugged Tubes 46 (1.4 percent) 95 (2.8 percent)
(as of October,1984)
Total Equivalent Plugged Tubes 106 (3.2 percent) 155 (4.6 percent)
For the steam generators in either of the Prairie Island Units, 5 percent of
- the total tubes (3388 tubes per S/G) equals 169 tubes plugged in any one steam generator. The ECCS analysis model is such that a uniform steam generator tube plugging condition is modeled. The NRC staff has required that the LOCA analysis for a plant with stese generator tube plugging models the maximum tube plugging level present in any of the plant steam generators.
For the conditions presented above for Prairie Island 1, the limiting equivalent plugged tube condition in the two steam generators is 103 tubes,.
which provides margin of 66 tubes (169 minus 103) available for additional plugging (or any equivalent combination of sleeves and plugs) before exceeding
-the basis of the LOCA analysis with 5 percent SGTP. With a smaller number 1751c/0223c/020685:5 58 3-75 n
t WESTINGHOUSE PROPRIETARY CLASS 3 of sleeves, the margin of tubes available for additional plugging.w6uld be i
larger. With only 500 sleeves per steam generator,110 tubes (169 minus 59) would be available for additional, plugging.
For Prairie Island Unit 2, the limiting equivalent plugged tube condition in
~
the two stems generators is 155 tubes, which provides margin of 14 tubes (109 minus 155) available for additional plugging (or any equivalent combination of sleeves and plugs) before exceeding the basis of the LOCA analysis with 5 percent SGTP. With only 500 sleeves per steam generator, 49 tubes (169 minus 111) would be available for additional plugging. Accordingly, no ECCS results more adverse than ethose in the existing Westinghouse fuel safety analysis are anticipated for equivalent tube plugging projected to occur at the Prairie l
Island Units with up to 1,946 sleeves per steam generator, given that the existing vessel internals remain in place.
The effect of sleeving on the non40CA transient analyses has been reviewed.
Analyses of the level of slesving and plugging discussed in this report have 3
.shown that the Reactor Coolant System flow rate will not be less than the Thermal Design Flow rate. The Thermal Design Flow rate is that which is
~ l assumed in the non40CA safety analyses and is designed to be less than the l
minimum RCS flow rate that could occur under normal or degraded conditionh.
l Since the reduced RCS flow rate is not less than the assumed flow rata l
(Thermal Design Flow), the non40CA safety analyses are not adversely impacted by this anticipated maximum amount of steam generator tube sleeving (1,946 sleeves per steen generator). The reduced RCS flow rate is within the bounds l
of the Safety Analysis Report for non40CA transient analyses and causes no safety concerns. Any smaller number of sleeves would have less of an effect.
In addition, at a result of tube plugging and sleeving, primary side fluid j
velocities in the steen generator tubes will [
]C.
The effect of l
thisvelocity[
]a,c,e on the sleeve and tube has been evaluated assuming a conservative limiting condition in which [
]a.M of the j
tubes are plugged. As a reference, normal flow velocity through a tube is approximately [
3a,c.e, for the unplugged condition. With 10 percent of the tubes plugged, the fluid velocity through an unplugged tube is
[
]ac.e ft/sec., and for a tube with a sleeve, the local fluid velocity in the sleeve region is estimated at [
]a,c,e ft/sec. This l
velocity [
]C causes no safety concerns.
l 1751c/0223c/020685:5 59 3-76
--e m
1 WESTINGHOUSE PROPRIETARY CLASS 3 i
3.5.8 ALTERNATE SLEEVE MATERIALS As was mentioned above in Section 3.4.3,.Inconel as a sleeve material is covered by the ASME Code Case N-20. The design stress intensity value 5, for'both materials I690 and 1600 covered by the Case N-20 is identical (5,-26.6ksi). Therefore, for these materials, Prisery Stress Intensity and Maximum Range of Stress Intensity allowables are similar. Only pressure
-stresses were considered when calculating Primary Stress Intensity. The maximum Primary Membrane Stress Intensity was found at the analysis.section on the straight portion of the tube. Hence, the ratio " Calculated Maximum Primary Membrane Stress Intensity / Allowable Stress Intensity" which was critical for the minimum sleeve thickness of [
]a,c.e does not depend upon the sleeve material (Inconel 690 or Inconel 600). Thermal stress, mid hence maxisnmi range of stress intensity and fatigue usage factor, could depend upon the mechanical properties of the sleeve material. The modulus of
. elasticity of Inconel 600 is higher than that of Inconel 690 by ~7 percent.
However, the coeffici,ent of thermal expansion of Inconel 690 is higher than that of Inconel 600. Past analytical experience indicates that the e-mismatch between 1690 and 1600 as sleeve material has a significant effect on thermal
- stress.. Therefore, the results of the Maximum Range of Stress Intensity and Fatigue Evaluations for the sleeve and tube assembly with I690 as.the sleeve material are conservative relative to those which would be calculated with 1600 as a sleeve material.
U 1751c/0223c/020185:5 60'
.3-77
,, -. - ~. - -.
.,-v-,...,-,.c,,
-_,n_,4
1 WESTINGHOUSE PROPRIETARY PLASS 3 l
4.0 PROCESS DESCRIPTION The sleeve installation consists of a series of steps starting with tube end preparation (if required) and progressing through sleeve insertion, hydraulic expansion at both the lower joint and upper Hybrid Expansion Joint (HEJ) regions,[
~
]a,c.e and joint inspection. The sleeving sequence and process are outlined in Table 4.0-1.
i All these steps are described in the following sections.
4.1 TUBE PREPARATION e
There are two steps involved in preparing the steam generator tubes for the sleeving operation. These consist of light rolling (as required) at the tube end and tube honing.
4.1.1 TUBE END ROLLING (CONTINGENCY)
If gaging or tube inside' diameter measurements indicate a need for tube end rolling to provide a uniform tube opening for sleeve insertion, a light
' mechanical. rolling operation will be performed. This is sufficient to prepare the mouth of the tube for sleeve insertion without adversely affec' ting the original. tube hard roll or-the tube-to-tubesheet weld. Tube end rolling will be performed only as a contingency.
Testing of similar lower joint configurations in model 27 steam generator sleeving progrens at a much higher torque showed no effect on the tube-to-tubesheet weld. Because the radial forces transmitted to the tube-to-tubesheet weld would be much lower for a larger model 51 sleeve than for the above test configuration no effect on the weld as a result of the light roll is expected.
-1751c/0223c/020685:5 61 4-1
.. a.
l WESTINGHOUSE PROPRIETARY CLASS 3
TABLE 4.0-1 SLEEVE PROCESS SEQUENCE
SUMMARY
t TU8E PREPARATION e
SLEEVE INSERTION a
LOWER JOINT FORMATION UPPER JOINT FORMATION INSPECTION, (Process Verification) 1681c/0216c/011785:5 56 4-2 w
O sa
- -, =
1 WESTINGHOUSE PROPRII!TARY CLASS 3 4.1.2 TUBE HONING The sleeving process includes boning the ID area of tubes to be sleeved to prepare the tube surface for the hybrid expansion joint and the lower' joint by J
removing loose oxide and foreign material. Honing also reduces the radioactive shine from the tube bundle,- thus contributing to reducing man-rem exposure.
Tube honing may be accomplished by either [
].a.c.e Both processes have been shown to provide tube inside diameter surfaces compatible with mechan l cal joint installation. The se'lection of the honing process used is dependent primarily_ on the installation technique utilized, the scale of the sleeving operation (small scale vs. large scale sleeving), and the customers site specific technical requirements. Evaluation has demonstrated that neither of these processes remove any significant fraction of the tube wall base material.
4.1.2.1
[
]a,c.e HONING Tube honing will be performed using a [
4 s
ja,c,e A limit switch is included in the system design that will prevent the
. insertion drive from reversing direction until the desired length of the tube has been honed.
A waste handling system may be used to collect the [
],a c,e the hone debris, and the oxide removed from the tube 10. [
M
]C
There may also be an inlet to the 1751c/0223c/020685:5 63 4-3
- - - - ~ -
--,s
--,-q
,-----,.-n,-,y
s WESTINGHOUSE PROPRIETARY CLASS 3 ja.c.e 4.1.2.2 ORY HONING The dry hone process is similar to [
]C
The dry hone process is typically nore r.
applicable to hands-on (manual) or small scale sleeving operations.
In order to remove sloose oxide debris produced by the dry honing operation,
~
the tube interior is swabbed utilizing a fluid (typically deionized water or isopropyl alcohol) soaked felt pad to an elevation slightly less than the honed length, but above the top of the installed sleeve.
4.1.3 FIBER OPTIC INSPECTION (CONTINGENCY)
As a contingency option to spot check that tube ID surfaces have been honed, a fiberscope inspection may be performed on some of the tubes to be sleeved.
Tubes to be fiberscope inspected would be selected randomly throughout the actual honing process. - This fiberscope inspection would be accomplished prior to sleeve insertion.
4.2 SLEEVE INSERTION AND EXPANSION The process of sleeving the tubes is carried out using remotely operated equipment. The following paragraphs describe the insertion of the sleeves and mandrels and the hydraulic expansion of the sleeves at both the lower joint and upper HEJ locations.
The sleeves are fabricated under controlled conditions, serialized, machined, cleaned, and inspected. They are typically placed in plastic bags, and
~
packaged in protective styrofoam trays inside wood boxes. Upon receipt at the site, the boxed sleeves are moved to a low radiation, controlled region near the steam generator. Here the sealed sleeve box is opened and the sleeve removed, inspected and installed on the expansion mandrel. Note that the U51c/0223c/020685:5 64 4-4 9
~ -- -
q WESTINGHOUSE PROPRIETARY CLASS 3 sleeve packaging specification is extremely stringent and.,1f. left unopened, the sleeve package is suitable for long term storage.
The mandrel is connected to the high pressure fluid source, e.g., Haskel Expansion Unit (HEU), via high pressure flexible stainless tubing. The
- delivery systen is manipulated to locate the guide tube attached to it near the manway. The mandrel / sleeve assembly is then inserted into the guide tube. - After the delivery system positions the sleeve upper end below the tube
~
to be restored, [
e k'
]a,c.e The deliver'y system is manipulated to locate the guide tube near the manway_for mandrel withdrawal / inspection and
~ -
loading of the next sleeve / mandrel assembly. This process is repeated until all sleeves are installed and hydraulically expanded.
In the event that a sieeve becomes jammed rter only partial insertion, contingency methods and tooling are used to remove the jammed sleeve. The tube will then be dispositioned by way of a non-conformance report after considering the appropriate input.
t 1751c/0223c/020185:5 65 4-5 vn m
w7
,.,-.,e--
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.a-y4,-y--,,-.a
,--,-m y
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.m w-----,.-
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t WESTINGHOUSE PROPRIETARY CLASS 3 4.3 LOWER JOINT SEAL At the primary face of the tubesheet, the sleeve is joined to the tube by a
[
3a,c,4 The contact forces,between the sleeve and tube due to the initial hydraulic
. expansion are sufficient to keep the sleeve from rotating during the [
~
3,ac.e The appropriate extent of hard roll expansion of the sleeve is attained by
[
]C
The hard roller torque is calibrated on a standard torque calibrator prior to initial hard
~
rolling operations and subsequently r1 calibrated at the beginning of each shift for automatic tooling. This control and calibration process is a proven technique used throughout industry in the installation of tubes in heat l
exchangers.
[
l l
l Ja,c.e This process is repeated until all installed sleeve lower ends are rolled.
I I
1751c/0223c/020185:5 66 4-6 v
1 WESTINGHOUSE PROPRIETARY CLASS 3 4.4 UPPER HYBRID EXPANSION JOINT (HEJ)
The HEJ first~ utilizes a [
']C
In the automatic mode, [
3 e
)a.c.e
~
4.5 -PROCESS INSPECTION SAMPLING PLAN In order to verify the final sleeve installation, an eddy current inspection will be performed on all sleeved tubes to verify that all sleeves received the required hydraulic and roll expansions. The basic process check on 100 percent of the sleeved tubes will be:
1.
Verify lower-hydraulic expansion average diameter 2.
Verify. lower roll and location within the lower hydraulic expansion and average diameter 3.
Verify upper hydraulic expansion' average diameter 4
Verify upper roll elevation and location within the upper hydraulic expansion and average diameter.
Tubes not satisfying the basic process check criteria will be dispositioned on an individual tube basis.
f In order to monitor the sleeving process after each operation from each lot, eddy current data on a percentage of the sleeves will be performed to obtain sleeve ID data. As confidence is gained that the sleeving process is
~
proceeding as anticipated, the lot sizes will be increased and percentages reduced. These average diameters will be evaluated versus the expected tolerances established through the design requirements, laboratory testing 1751c/0223c/020685:5 67 4-7
i WESTINGHOUSE PROPRIETARY CLASS 3 4
results, and previous experience. This evaluation will determine..whether or not the equipment / tooling is perfoming satisfactorily. If process data is detemined to be outside of expected ranges, further analysis will be performed.
~
If required, Diatest may be used in lieu of eddy current to perform sleeve installation acceptance and in-process monitoring evaluations. Undersized diameters will be corrected by an additional expansion step to produce the desired degree of expansion. Oversized diameters will be dispositioned by a specific evaluation process on an individual tube basis.
e If it is necessary to renove a sleeved tube from service as judged by an
~
evaluation of a specific sleeve / tube configuration, tooling and processes will be available to plug the sleeve or the lower portion of the sleeve will be removed and the tube will be plugged.
As mentioned previously, the. basic process dimensional verification will be completed and evaluated for 100 percent of all installed sleeves.
a 1751c/0223c/020185:5 68 4-8 e
1 WESTINGHOUSE PROPR8ETARY CLASS 3 4.6 ESTABLISHMENT OF SLEEVE.J0 INT MAIN FABRICATION FARAMETERS 4.6.1 LOWER JOINT The main parameter for fabrication of acceptable lower joints is sleeve [
].ac.e gj,,,,{
3a,c.e is determined by [
].a,c.e Accorfingly, rolling torque was varied to achieve the desired sleeve [
Ja,c.e in the original Model 44 4
program (also applicable to the mo' del 51). [
]a,c.e was achieved was used throughout the program verification testing.
4.6.2 UPPER HEJ The main parameter for fabrication of HEJ's (in-sludge and out-of-sludge) which met the leak rate acceptance criteria was [
d
]a,ce (Refer to Section 3.3.5.3 for an additional discussion of the roll expansion torque for the in-sludge case.)
In the first sleeving project performed by Westinghouse, hydraulic expansion axial length was also evaluated. [
- ].a,c.e Therefore, in later programs, the HEJ hydraulic expansion axial length [
1751cIO223c/020185:5 69 49
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,---+,,-,w~,-.n-
,w-
,,e4, p.p--,,-.w,----,w--
-v.s,,ee9r,r
-- wwe we--wrw.,.ew y9
,--r w
s WESTINGHOUSE PROPRIETARY CLASS 3 Ja,b,c.e I
r a
s 1751c/0223c/020185:5 70 4-10
I WESTINGHOUSE PROPRIETARY CLASS 3 5.0 SLEEVE /T00 LING POSITIONING TECHNIQUE 5.1 REMOTELY OPERATED SERVICE ARM (ROSA)
ROSA is a general purpose six axes all-electric computer-controlled robot used for nuclear service work. Its function, is to serve as a remotely controlled tool positioner and thereby reduce worker radiation exposure. The major ROSA system components include the mechanical arm with a servo controller and the I
supervisory computer control conso'le contained within a trailer located outside containment. The operator issues connands to the supervisory computer through the, control console and keyboard. The supervisory computer interprets these commands and calculates the desired angular positions for each axis of the mechanical arm. These desired angular positions are then sent to the servo controller. The servo controller drives 'each axis to its desired position, and sends status information back to the supervisory computer. This cycle is continuously executed at a high rate of speed, providing smooth and controlled motions,
9 One application of ROSA is its use as a "No Entry" tool positioner for primary side stese generator operations. The term "No Entry" signifies that ROSA installation / removal, tool changing, and tool operations are performed without -
any personnel passing through the plane of the manway's outer surface.
ROSA is loaded into the channel head by use of a ramp loading fixture mounted to the manway flange. The tool end of ROSA is clamped to this fixture.
Through a combination of ROSA movements and linear movements of the loading fixture, ROSA is loaded into the channel head such that. its base end and four hydraulic canlocks end up approximately 2 inches below the tubesheet. From there, a joystick controller in the control trailer is used to drive the camlocks up and into the tubes. These camlocks are then pressurized to 750 psi, generating the necessary frictional holding force to secure ROSA to the tubesheet. The tool end of ROSA is then unciamped from the. loading fixture.
With the base end of ROSA secured to the tubesheet, ROSA is programmed to reach out through the manway such that tools can be manually installed or 1751c/0223c/020185:5 71 5-1
,ym.
.,__y-y...
._,,_y,
t WESTINGHOUSE PROPRIETARY CLASS 3 removed. ROSA is then programmed to pull the tool in throug1 the..manway and up to the tubesheet..
The ROSA computer is initialized with the mounting location of the base (row and column) and with the tool being used. The operator can then enter row and column commands through a keyboard and ROSA will automatically position the tool underneath the desired tube. -The tubesheet is divided into regions which are used by the computer to generate a tool path from the present location of the tool to its destination tube. Although the computer maintains the tool's row and column position its actual row and column position is still verified every hour.
Tools'which are positioned by_ ROSA include:
~
1} Eddy Current Tool
- 2) Mechanical Plugging Tool
- 3) Lower Hardrolling Togi j
- 4) Sleeving Adapter Tool -
used for honing, swabbing, fiberscoping, sleeve Insertion, expansion, and ultrasonic testing 4
All these tools are controlled from inside containment, independently from ROSA. ROSA is progranned to move the sleeving adapter tool to a location over the manway so that there is an assembly window above the manway to change out the various* tools which it can position.
The tools typically have low light level cameras or fiberscopes mounted on i
them. These cameras or fiberscopes are used to help verify exact positioning of the tool under the desired tube, to verify that sleeves, hardrollers, UT probes, etc., are fully inserted (contacting the tube end) before initiating their operations and to assist in determining the tooling performance. The three axis joystick controller can be used to make minor position and orientation adjustments of the tool so that it is correctly aligned with the tube.
1751c/0223c/020185:5 72 5-2
!f
\\
J
^
i WESTING;0ilSE PROPRIETARY CLASS 3 5.2 ALTERNATE POSITIONING TECHNIQUES Under some conditions, positioning of sleeve / tooling with the bcse ROSA system may not be practical. In these circumstances, an alternate positioning technique may-be utilized. These alternate techniques may include alternate
- robotic or semi-remotely-operated equipment, hands-on (manual) positioning and installation, or the combination of two or more tooling subsystems into one larger tooling system.
Note that with all positioning techniques, the processes actually used to install the, sleeves (hydraulic expansion, mechanical rolling, etc.) will not be changed due to the use of an alternate sleeve / tooling positioning technique. It is the processes which the sleeves are subjected to that are critical to their successful installation; the technique used to position the sleeves and tooling is not critical so long as it does not affect the sleeve
. installation processes.
a 1751c/0223c/020185:5 73 5-3
1 J
s WESTINGHOUSE PROPRIETARY CLASS 3 6.0 NOE INSPECTABILITY The Non Destructive Examination (NDE) development effort has concentrated on i
two aspects of the sleeve system. First, a method of confirming that the joints meet critical process dimensions is required. Secondly, it must be j
shown that the tube / sleeve assembly is capable cf being evaluated througn subsequent routine in-service inspection.' In both of these efforts, the
. inspection process has relied upon eddy cur, rent-technology.
3 6.1 EC0Y CURRENT INSPECTIONS The eddy current inspection equipment, techniques, and results presented
~
herein apply to the proposed Westinghouse sleeving process for use in steam generators which have 0.875" 00 by 0.050" nominal wall. Due to the
~ imilarities between the Series 51 and Series 44 steam generator designs and s
the fact that approximately 6000 sleeves made from thermally treated Inconel 600 with mechanical joints are currently installed in Series 44 steam generators, it is expected that similar eddy current inspection results will be obtained with equipment and techniques developed for the Model 51 steam
. generators, d
Eddy ~ current inspections are routinely carried out on the steam generators in accordance with the plant's Technical Specifications. The purpose of these inspections is.to detect at an early state tube degradation that may have occurred during plant operation so that corrective action can be taken to minimize further degradation and reduce the potential for significant primary-to-secondary leakage.
The standard inspection procedure involves the use of a~ bobbin addy current probe, with two circunferentially wound coils which are displaced axially along the probe body. The coils are connected in the so-called differential mode; that is, the system responds only when there is a difference in the properties of the material surrounding the two coils. The coils are excited by using an eddy current instrunent that displays changes in the material
-surrounding the coils by measuring the electrical impedance of the coils. In the past, eddy current instrunents normally excited the coils at a single 1751cl0223c/020185:5 74 6-1
,.e.,..--.....---m.-
l WESTINGHOUSE PROPRIETARY CLASS 3 frequency. However, Westinghouse and the industry are now using.,
multi-frequency instrumentation for the inspection of steam generator tubing.
This involves simultaneous excitation of the coils with several different test j
frequencies.
The outputs of the various frequencies are combined and recorded. The combined data yield an output in which signals resulting from conditions that do not affect the integrity of the tube are reduc p. By reducing unwanted signals, improved inspectability of the tubing results (i.e., a higher signal-to-noise ratio). Regions in the steam generator such as the tube supports, the tube, sheet, and sleeve transition zones are examples of areas where esitifrequency processing has proven valuable in providing improved inspectability.-
A number of addy current probes and signal processing systems are available for the eddy current inspection of the tube / sleeve assembly. In addition to the conventional bobbin coil, probe, there are a rotating pancake coil and a cross-wound coil probe. Any of these probes may be used with either single frequency or multifrequency instrumentation.
After sleeve installation, all sleeved tubes are subjected to a series of. eddy current inspections. Some of these inspections are part of a process control procedure to verify correct sleeve installation. However, each tube / sleeve assembly also receives an eddy current inspection for baseline purposes to which all subsequent inspections will be compared.
Verification of proper sleeve installation is of critical importance in the sleeving process. An "in-process" eddy current inspection is conducted utilizing one frequency in the absolute mode with a conventional bobbin coil probe. This inspection is performed during sleeving installation to provide "in-process" verification of the existence of proper hydraulic expansion and hard roll configurations and also to allow detemination of the sleeve process dimensions both axially and radially, using the strip chart recording.
The inspection for degradation of the tube / sleeve assembly has typically been performed using conventional bobbin coil probes operated with multifrequency 1751c/0223c/020185:5 75 6-2
____.,_m.
1 WESTINGHOUSE PROPRIETARY CLASS 3 O
excitation. For the straight length regions of the tube / sleeve assembly, the inspection of the sleeve and tube is consistant with normal tubing inspections. In tube / sleeve assembly joint regions, data evaluation becomes
{
more complex. The results discussed below suggest the limits on the volume of degradation that can be detected in the vicinity of geometry changes. For the l
parent tube, these limits are on the or, der of two to three times the response of the ASME calibration standard using the conventional bobbin coil probe.
i The detection 'and quantification of degradation at the transition regions of the sleeve / tube assembly depends upon.the signal-to-noise ratio between the I
degradation, response and the transition response. As a general rule, lower frequencies tend to suppress the transition signal relative to the degradation signal at the expense of the ability to quantify. 'Similarly, the inspection of the tube through the sleeve requires the use of low frequencies to achieve detection with an associated loss in quantificaton. Thus, the search for an optimun eddy current inspection represents a trade-off between detection and quantification. With the conventional bobbin type inspection, this
- optie,ization leads to a primary inspection frequency for the sleeve on the orderof[
]a,c,e and for the tube and transition regions on the order
,0f[
]a,c e Figure 6.1-1 shows the response of the ASME tube calibration standard using a conventional bobbin coil. Figure 6.le2 shows the response of a typical expansion transition at the same frequencies as Figure 6.1-1 but at a factor of two lower sensitivity for the non-mixed channels. In Figures 6.1-1 and 6.1-2, the results of combining the 50 kHz and 150 kHz responses to eliminate the transition signals are depicted. Note that in the transition regions a signal with twice the amplitude of the standard would be detectable. However, with present instrumentation the actual noise level from the electronics limits the usefulness of this approach.
For those regions of the sleeve where the assembly has no transitions, a conventional bobbin coil inspection provides detection and quantification capability. Figure 6.1-3 shows a typical [
]a,c.e base angle versus degradation depth curve for the sleeve from which 00 sleeve penetrations can be assessed.
1751c/0223c/020185:5 76 6-3 t
s WESTINGHOUSE PROPRIETARY CLASS 3 In the regions of the parent tube above the sleeve, conventional ' obbin ' coil o
inspections will continue to be used. However, since the diameter of the sleeve is smaller than that of the tube, the fill factor of a probe inserted through the sleeve may result in a decreased detection capability for tubing degradation. Thus, it may be necessary to inspect the unsleeved portion of the tube above the sleeve by inserting a standard size probe through the U-bend from the unsleeved leg of the tube.
While there are a number of probe configurations that lend themselves to improving the inspection of the tube / sleeve assenbly in the regions of configuration tran}itions, the cross-wound coil probe has been selected as offering a significant improvement over the conventional bobbin coil probe, yet retaining the simplicity of the inspection procedure.
The overall inspection procedure involves the use of the cross-wound probe which significantly reduces the responses of the transitions, coupled with a multifrequency mixing technique for further reduction of the remaining ncise signals. This system reduces the interference from all discontinuities which have 360-degree synnetry, providing improved visibility for discrete discontinuities. As is shown in the accompanying figures, in the laboratory
. this technique can detect 00 tube wall penetrations with acceptable signal-to-noise ratios 'at the transitions when the volume of natal removed is equivalent to the ASME calibration standard.
The signif tcant raduction of response from the tube / sleeve assembly transitions due to the use of the cross-wound coil is shown by a comparison of Figures 6.1-4, 6.1-5, and 6.1-6 for the sleeve standards, tube standards and transitions, respectively. Again, this is further improved by the combination of-the various frequencies. For the cross-wound probe, two frequency.
combinations are shown; (
]a,b,c.e Figure 6.1-7 shows the phase / depth curve for the tube using-this combination. As examples of the detection capability at the transitions, Figures 6.1-3 and 6.1-9 show the responses of a 20 percent 00 penetration in the sleeve and 40 percent 00 penetration in the tube, respectively.
1751c/0223c/020185:5 77 6-4 i
i
~.. -
1 2
i e
4 Figure 6.1-1 E.C. Signals fiom the ASTM Standard. Machined on the Tuce 0.0. of the Steeve Tube Assembly Without Expansion (Conventional Differential Coil Probe) 6-5 WG
1
]
t e
e 4
Tigure 6.1-2 E.C. Signals from the Excension Transition Region of the '
Sleeve-Tuee Assembly (Conventional Differential coil Procel 6-6
\\
,s s
I
1 3
1 4
?
I
~
\\
{
l l
l l
l t
Figure 6.1-3 l
Eddy Current Calibration Curve for ASME Sleeve Suneare at
[ g a.c.e with the Conventiocal Differential Coil P cce 6-7
i 3
t s
a Figure 6.1-4 E.C. Signals from the ASTM Standard. Machined on the Sleeve 0.0. of the Sleeve-Tuce Anembly Without Expansion (Cron Wound Coil Prote) 6-8
1 3
3 e
e 1
i l
1 l
l 1
l l
l
'1 l
Figure 6.1-5 E.C. Signals from the ASTM Standard, Machined on the Tuce 0.D. of the Sleeve-Tube Assemcly Without Excansion (Cross Wound Coil Prebe) 6-9
8 3
i Figure 6.1-6 E.C. Signals from.the Excansion Transition Region of the Tube.$1eeve Assem0fy (Crom Wound Coil Proce) 6-10
r r
1 3
o O
1 e
s Figure 6.1-7
[tSCH+Maj a.c.eEddy Current Calibration Curve for ASME T and a Mix Using the Cross Wound Coal Prece 6-11 F -
a 3
t e
i i
t i
Figure 6.1-8 E.C. Signal from a 20% Devo Hole. Half the Volume of ASTM Standard, Machined on the Steeve 0.0.-in the Excension Transiten Region of the Sleeve Tuce Assemoly (Crom Wounc Coil Procol 6-12 1
1
1 J
=
)
3 e
Figure 6.1-9 E.C. Signal from a 40% ASTM Standard. Machined on the Tuce 0.0. in the Expansion Transition Region of Steeve-Tube Anembly (Cron Wound Coil Probe) 6-13
~-
3 t
e i
1 l
Figure 6.1-10 Eddy Current Re10Cnte of S4uare and Tapered Sleeve Encs Comoared to the Ex:ansion Transitions for the Conventional Scebin Coil Probe 6-14
'l 3
i 4
t e
=
of the Sleeve Using the Cross Wound C Multifrecuency Combination Figure 6.1-11 6-15 i
WESTINGHOUSE PROPRIETARY CLASS 3 The preceding discussion has centered around the inspection of the expansion transition regions of the assembly. For inspection of the region at the top end of the sleeve, the transition response using the conventional bobbin inspection is still larger than that of the expansion regions as shown in Figure 6.1-10.
Thus, the signal-to-noise rati,os for this pcet of the tube / sleeve assembly is about a factor of four less sensitive than that of the expansions. Some improvenent has been gained by tapering the wall thickness at the top and of the sleeve. This reduces the end-of-sleeve signal by a factor of approximately two. The crosswound coil, however, again significantly reduces the response of the sleeve end. Figure 6.1-11 shows the response of various ASIE tube. calibration standards placed at the end of the sleeve using the cross-wound coil and the [
]a,c.efrequency combination. Note that under these conditions, degradation at the top end of the sleeve / tube assembly can be detected.
6.2 SUP9%RY Conventional eddy current techniques have been modified to incerporate the most recent technology in the inspection of the sleeve / tube accoly. The resultant inspection of the sleeve / tube assembly involves the usu of both, a conventional bobbin coil for the straight regions of the sleeve / tube assembly and a cross-wound coil for the transition regions. It should be emphasized, that the transition regions of the assembly, where the cross-wound coil and multifrequency processing are necessary for degradation detection, comprise only a small percentage of the overal! skeve/ tube assembly. Thus the conventional inspection would constitute the bulk of the eddy current inspection. While there is a significant improvement in the inspection of portions of the assembly using the cross-wound coil, efforts continue to advance the state-of-the-art in eddy current inspection techniques. As imoroved techniques are developed and verified, they will be utilized. For the present, the cross-wound coil probe represents an inspection technique that provides additional sensitivity and support for eddy current techniques as a viable means of assessing the tube / sleeve assembly.
1751c/0223c/020185:5 78 6-16
.., _ _,, ~,.., _
i WESTINGHOUSE PROPRIETARY CLASS 3 7.0l ALARA CONSIDERATIONS FOR SLEEVING OPERATIONS.
The repair of steam generators in operating nuclear plants requires the utilization of appropriate dose reduction techniques to keep radiation
~
exposures As Low As Reasonably Achievable (ALARA). Westinghouse maintains an extensive ALARA progr a to minimize radiation exposure to personnel. This
-program includes: design and.improvemen't of remote and semi-remote tooling, including state-of-the-art robotics; decont aination of steam generators; the use of shielding to minimize radiation expo'sure; extensive personnel training 3
^
utilizing mock-ups; time trials; and strict qualification procedures. In addition, computer programs (REMS) exist which can accurately track radiation exposureachumulation.
The ALARA aspect of the tool design program is to develop specialized remote tooling to reduce the exposure that sleeving personnel receive from high radiation fields. A design objective of the remote delivery sleeving system-is to eliminate channel head entries and to complete the sleeving project with total exposures kept to. a minimum,1. e., ALARA. The manipulator arm is installed on a fixture attached to the stem generator manway after video cameras and temporary. nozzle cov'ers have been. installed. The control station
~
operator (CS0) then manually operate controls to guide the manipulator arm through the manway and attach the baseplate to the tubesheet. The installation of the am requires only one platform operator to provide visual observation and assistance with cable handling from the platform. The control 7
.statjon for the remote delivery system is located outside containment in a specially designed control station trailer.
i The control of personnel exposures can also be effected by careful planning, training, and preparation of maintenance procedures for the job. This form of adninistrative control can ensure that che minimum number of personnel will be used to perform the various tasks. A '41tional methods of minimizing evoosure t
include the use of remote TV and radio surveillance of all platform and channel head operations and the monitoring of personnel exposure to identify high exposure areas for_ timely improvement. Local shielding will be used whenever possible to. reduce the general area background radiation levels at the work stations inside containment. A combination of these techniques is expected to be used in this steam generator sleeving project.
1751c/0223c/020185:5 79 7-1
..___,__..__.--e-
-, - - " - " * ' - - - - - - ' - ~
.-=
idESTINGHOUSE PROPRIETARY CLASS 3 7.1 ROSA SLEEVING OPERATIONS The Remotely Operated Service Arm (ROSA) is a remotely-operated robotic, general purpose tool positioning systou designed for performing various maintenance tasks in the steam generator channel head and other radiologically hostile environments. The systen is operated tenotely from the control station located outside containment up to 200 feet from the channel head. The arm is designed to accept a family of and effectows that are used to implement the various processes used in steam generater tube maintenance.
7.2 MANIPULATOR ENO EFFECTORS The ROSA system is designed to assist in performing a wide variety of tasks in the channel head. This is accouplished by firstly attaching the appropriate end effector to the arm. The end effectors are designed for specific or multi-purpose use during sleeving operation. Some current applications of remote manipulators are steam generator eddy current inspection, plug weld repair, tube end repair, mechanical plug installation, and tube sleeving operations. An end effector is equipped with a standardized quick disconnect
.V-band coupling for manual attachment to the manipul'ator from the steam generator platform. The arm is extended through the aanway and the quick' l
disconnect coupling is' oriented at right angles to the axis of the manway.
l
' This allows the changing of and effectors outside direct shine of the manway radiation, minimizing radiation exposure.
7.2.1. SLEEVE / TOOLING END EFFECTORS The sequence of process steps and associated tooling required to complete a steam generator tube sleeving project results in many end effector changes.
The sleeving operations of tube end rolling (contingency), tube honing, fiberscoping (contingency), sleeve / mandrel insertion and expansion, upper hardroll, lower hard roll, process verification eddy current inspection, and baseline eddy current inspection will require a significant number of tool changes during the project. The platform operator will be required to change end e Mectors of increasing complexity from fiberscope and lower hard roller tooling to the more complex sleeve / mandrel insertion and expansion tooling 1751c/0223c/020685:5 80 7-2 k.
1 WESTINGHOUSE PROPRIETARY CLASS 3 system. The number and frequency of changes will depend on the scope ~of the sleeving project.
7.2.2 IN-PROCESS OPERATIONS The necessity of having a platform oper.ator available near the platform extends.into the in-process sleeving operations. The useful life of a hone is expected to be limited to approximately 5-5,0 tubes (depending on the honing process utilized) before the hone 'will need to be replaced. The fiberscope inspection sequence may require various lengths of fiberscopes to reach all of the tubes during the inspection. The' sleeve / mandrel insertion and expansions operations are expected to require the major part of the in-process time spent on the platform. The removal of spent expansion mandrels and the installation of the new sleeve / mandrel unit may have to be done manually from the platform. The hard rolling and eddy current operations will require much less time on the platform.
' 7.3 CONTROL STATION IN CONTAINMENT
,The process control stations for the various sleeving processes will be located in containment _ in a low radiation area near the stesn generator platforms. These wrk stations are required to operate and control the individual sleeving processes and are independent of the ROSA systems controls located outside containment. The variation in service requirements such as air,' water, electricity, radwaste generation, and proximity of controls-to-processes makes the in-containment control stations a necessity.
7.4 POTENTIALS FOR WORKER EXPOSURE The continued development of the ROSA sleeving process is expected to significantly reduce the radiation exposure to workers in comparison to previous sleeving projects. The elimination of channel head entries for the installation and removal of sleeves and sleeve tooling fixtures will keep personnel out of the high radiation fields of the steam generator channel
-heads. The majority of the sleeving operations will be done from the control stations with one or two workers stationed on or near the platform. However, 1751c/0223c/020185:5 81 7-3
WESTINGHOUSE PROPRIETARY CLASS 3 in the preparation of the steam generators'for sleeving operations, entries into the channel heads may be required.
7.4.k NCZZLE COVER AND CA E RA INSTALLATION / REMOVAL The installation of temporary nozzle covers in the reactor coolant pipe nozzles in preparation of the stesa generators for sleeving operations will require channel head entries. The covers are ins,talled to prevent the accidental dropping of any foreign objects (i.e., tools, nuts, bolts, debris, etc.) into the reactor coolant loops during sleeving operations. In the event that an accident pid occur, inspections of the loops would be required and any foreign objects or debris found would have to be retrieved. The impact on
~
schedule and radiation exposures associated with these recovery operations would far exceed the time and exposures (less than 1 minute) expended to install or remove loop nozzle covers. Consequently, it Js considered an ALARA-efficient procedure to utilize temporary nozzle covers during sleeving operations.
The use of video monitoring systems to observe ROSA operations in the channel head will also require manual installation. The installation of overview cameras to renitor sleeving operations will require a full or partial channel head entry to be installed.
The installation and removal of this equipment in the steam generators are the only scheduled requirements for channel head entry during the sleeving project.
7.4.2 PLATFORM SETUP / SUPERVISION The majority of the radiation exposures recorded for the sleeving program is expected to result primarily from personnel working on or near the steam generator platforms. The setup and checkout of equipment for the various sleeving processes, the installation / removal of ROSA, the changing of end effectors, and the operation of the sleeve / mandrel insertion and expansion system are che major sources of radiation exposure. In addition to channel head video monitoring systems, visual monitoring and supervision by one or more workers on the platform will be required for a major part of the sleeving 1751c/0223c/020185:5 82 7-4
WESTINGHOUSE PROPRIETARY CLASS 3 schedule. Experience has shown that rapid response to equipment' adjustment
._ requirements is efficiently accomplished by having a platform worker standing by in a relatively low radiation area during operations. Worker standby stations have ranged from the low radiation fields behind the biological shield to lead blanket shielding installed on the platform. Even though radiation levels on the platform are much lower than channel head levels, a substantially larger amount of time will be spent on the platforms giving rise to personnel exposures. An evaluation of radiation surveys around the steam
~
generators should indicate appropriate standby stations.
7.5 RADWAS,TE GEIERATION The surface preparation of tubes for the installation of sleeves requires that the oxide film be renoved by a honing process. A flexihone attached to a flexible rotating cable will be used to remove the oxide film on the inside surface of the steam generator tubes.- The volune of solid radwaste is expected to consist of spent hones, flexible honing cables, hone filter assemblies (optional),[
]"'C and the t
normal anti-C consumables associated with steam generator maintenance. The
, anti-C consunables are usually the customer's responsibility and will not be addressed in this report.
a Forthe[
Ja.c.e approximately thirty tubes can be honed
'before the hone is changed for process control and [
]. ace A typical estimate of the radioactive concentration'from a honed tube transported by the [
]#is given in Table 7.5-1.
The tube hones as well as the tubes [
] Consequently, radiation levels of the spent hones are normally 10-20 mr/hr based on field measurements in previous sleeving projects.
The flexible honing cable used to rotate the hone inside the tubes is also 4
flushed during the honing process. However, the construction of the stainless steel cable will cause radioactivity to build up over the course of the project. Radiation levels on segments of the cable could reach 5-10 R/Hr contact dose rates for-major sleeving jobs. It is expected that an average of 1751c/0223c/020185:5 83 7-5 e
..f...~m..,,--,
v_.. -, _,.c.,
c
--,e e.
.., m
,.__,..-..--__,m--.%r
-.,,.%,my.,w...-,,
_.,,w.re.n.,,---
WESTINGHOUSE PROPRIETARY CLASS 3 i
TA8LE 7.5-1 ESTIMATE OF RADIOACTIVE CONCENTRATION IN WATER PER TU8E HONED (TYPICAL) a,c.e Percent Inventory Activity Isotope Concentration (uct)
(sci /cc of H O) 2 e
e t
t 4
l t
ASSUMPTIONS
- 1) Tube honed 48 inches (in length)
- 2) Water flow rate of 0.6. gallons per tube honed
- 3). Essentially all radioactivity removed from tubes honed.
1751c/0223c/020185:5 84 7-6 O
l 1
WESTINGHOUSE PROPRIETARY CLASS 3 one cable per stema generator will be used during the sleeving project. The cables 'are consumables and are druened as solid radwaste.
I 7.6 AIRBORNE RELEASES The _ implementation of the proposed sleeving processes in operating nuclear plants has indicated that the potential for airborne releases is minimal. The major operations inciude [
]C and sleeve installation.
Experience has shown that these sleeving processes do not contribute to
-airborne releases, 7.7 PERSONNEL EXPOSURE ESTIMATE The total personnel exposures for steam generator sleeving operations will depend on several plant dependant and process related factors. These may
- include, but not be -limited to; the scope of work (quantity of sleeves, etc),
plant radiation levels, ingress / egress to the work stations, equipment perfonnance and overall cognizance of ALARA principles. Consequently, the projection _of personnel exposures for each specific plant must be performed at the completion of mockup training when proces's times for each operation have been recorded. The availability of plant radiation levels and worker process times in the various radiation fields will provide the necessary data to project personnel exposure for the sleeving project.
The calculation of the total MAN-REM exposure for completing a sleeving project may typically be expressed as follows:
P=Ng.O
+5
.N g
g P
' Project total exposure (MAN-REM).
Ng - Pumber of sleeves installed Og = Exposure / sleeve installed 1751c/0223c/020185:5 85 77
+
8
WESTINGHOUSE PROPRIETARY Cl. ASS 3 59 - Equipment setup / removal exposure per staan generator g = Number of steam generators to be sleeved
.N This equation and appropriate variations are used in' estimating the total personnel exposures for the sleeving project.,
e 4
a L
1751cl0223c/020185:5 86 7-8 l
1
I WESTINGHOUSE PROPRIETARY CLASS 3 8.0 INSERVICE INSPECTION PLAN FOR SLEEVED TUBES.
In addressing current NRC requirements, the need exists to perform periodic inspections of the supplemented pressure boundary. This new pressure boundary consists of the sleeve with a joint at the primary face of the tubesheet and a
~ joint at the opposite end of the sleeve.
n The inservice inspection program will consist of the following. Each sleeved tube will be eddy current inspected on completion of installation to obtain a
~'
baseline signature to which all subsequent inspections will be compared.
Periodic inspections to monitor sleeve wall conditions will be performed in accordance with the inspection section of the plant Technical Specifications.
This inspection will be performed with multi-frequency eddy current equipment.-
As part of the inspection of the sleeved tubes, there will be a series of pressure / leakage tests. These tests are intended to test the integrity of the mechanical-joint against leakage at both primary and secondary pressure loadings. The tests isill be conducted at the conclusion of the sleeving operation and will be perfomed by the owner in accordance with applicable requirements of the ASE Code and plant procedures. Periodic pressure testing of the sleeved tubes will also be perfomed in accordance with the, plant Technical Specifications.
1 i
1751c/0223c/020185:5 87 8-1 I
h