ML20149L911
| ML20149L911 | |
| Person / Time | |
|---|---|
| Site: | Farley  |
| Issue date: | 11/06/1996 |
| From: | WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP. |
| To: | |
| Shared Package | |
| ML19353D993 | List: |
| References | |
| SG-91-11-020, SG-91-11-20, WCAP-13116, NUDOCS 9611190300 | |
| Download: ML20149L911 (26) | |
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WESTINGHOUSE PROPRIETARY CLASS 3 WCAP-13116 SG-91-11-020 STEAM GENERATOR SLEEVING INTEGRATION REPORT J. M. Farley Units I and 2 WESTINGHOUSE ELECTRIC CORPORATION NUCLEAR SERVICES DIVISION P.O. BOX 355 PITTSBURGH, PA 15230
- 1991 Westinghouse Electric Corporation All Rights Reserved l
TABLE OF CONTENTS Section Ittig Eggg i
1.0 INTRODUCTION
I 2.0 SLEEVE DESIGN 1 3.0 WELD QUALIFICATION 3 4.0 DESIGN VERIFICATION 3 4.1 CORROSION EVALUATION - SLEEVE MATERIAL 4 4.2 CORROSION EVALUATION - SLEEVE JOINTS 4 4.3 MECHANICAL TEST PROGRAM - SLEEVE JOINTS 6 4.4 RE-WELDING 7 4.5 POST WELD HEAT TREAT 7 4.6 ANALYTICAL VERIFICATION 7 4.7 EVALUATION OF FLOW EFFECTS SUBSEQUENT TO SLEEVING 9 5.0 PROCESS DESCRIPTION 9 6.0 NDE INSPECTABILITY 10 7.0 IN-SERVICE INSPECTION PLAN - SLEEVED TUBES 11 LIST OF FIGURES Fiaure li.tig Eagg 2-1 Full Length Tubesheet Laser Welded Sleeve Installed Configuration 2 APPENDICES Appendix Lower Joint Exceptional Condition Test Program 12 l
1.0 INTRODUCTION
This document has been prepared to integrate technical information presented in WCAP-11178 Rev. I and WCAP-12672 which address mechanical (HEJ) and Laser Welded (LWS) sleeves respectively. It supports the licensing of the laser welded sleeve configurations described herein for use in J. M. Farley Units 1 and 2. The 27 to 36 inch tubesheet sleeve, which includes a laser welded joint at the top and an HEJ joint at the bottom, has been analyzed, and tested for use in Westinghouse Series 51 steam generators. The analysis is based on the use of conservative, enveloping thermal boundary conditions and structural loadings, based on installation in the hot leg of the steam generator. The theoretical radial sleeving boundary and limitations of the proposed sleeve design are addressed in Section 2.0 of WCAP-12672 and WCAP-11178 Rev.1. 2.0 SLEEVE DESIGN The design basis documentation for the sleeve configuration identified in this document is the 1986 edition of the ASME Boiler and Pressure Vessel Code and additional codes and standards identified in Section 3.0 of WCAP-12672 and WCAP-11178 Rev. 1. The installed sleeve configuration is shown in Figure 2-1. At the upper end, the sleeve is hydraulically expanded to secure the proper fit-up geometry for welding. Following hydraulic expansion, an autogenous weld is made between the sleeve and tube within the expansion zone, using the laser welding process. At the lower end, the sleeve joint (Figure 2-1) may be composed of a mechanical (HEJ) joint as discussed in WCAP-11178 Rev. I or an HEJ having a laser seal weld superimposed in the area of the tubesheet cladding below the design structural required hard roll length (additional data on the lower joint hard roll design requirements and test program are contained in the Appendix). When used, the laser seal weld adds the benefit of leak tightness to the leak limiting qualities demonstrated by the HEJ. The HEJ joint assembly parameters have been established through laboratory testing to provide a leak-limiting joint, mechanical strength and resistance to stress corrosion cracking. The seal weld for the lower tubesheet sleeve joint is located in the plane of the tubesheet cladding for several reasons. The ASME Code imposes temperature exposure limits on the carbon steel tubesheet material. While the calculated 1
a,C,e ( Figure 2-1 Full Length Tubesheet Laser Welded Sleeve Installed Configuration l 2
and vasured temperatures on the tube OD surface during welding will be below the tubesheet critical temperature, placement of the weld in the clad area provides additional assurance that the tubesheet will not be exposed to unacceptable temperature excursions. The cladding, as the attachment point for the tube-to-tubesheet weld, is designed to be welded to and is compatible with the tube and sleeve material should the lower sleeve weld penetrate the sleeve and tube. Although the tubesheet cladding is compatible with the sleeve material for welding purposes, the sleeve weld maximum penetration is 85% of the combined sleeve / tube thickness and will not penetrate into the tubesheet clad material itself. The upper laser weld joint (LWJ) will be given a post weld heat treatment (PWHT) to relieve residual weld shrinkage stresses which could contribute to PWSCC in susceptible mill annealed Alloy 600 tubing. While tests of as-welded LWJs in susceptible tubes have not exhibited the degree of PWSCC experienced by roll transitions, the reference upper LWJ process includes a PWHT to enhance PWSCC resistance of the weld zone. The sleeve material, thermally treated Alloy 690, is selected for its demonstrated resistance to stress corrosion cracking. (See Section 3.3.2 of WCAP-12672 for further details on the selection of thermally treated Alloy 690). 3.0 WELD QUALIFICATION The 1986 Edition of the ASME Code does not address sleeving, nor design or testing of sleeve welds, therefore the rules of Section IX and XI, 1989 Edition,1989 Addenda of the ASME Code, including Code Case N-395 are invoked to the maximum extent possible during the weld qualification process. The qualification program and acceptance criteria discussed in Section 3 of WCAP-12672 forms the basis of the qualification program for both the upper structural and lower seal welds. 4.0 DESIGN VERIFICATION Test programs using the unit cell concept were performed to assess the corrosion resistance and structural integrity of sleeved tubes to verify their ability to maintain the primary-to-secondary pressure boundary under normal and 1 3
accident conditions. A comparison of the metallurgical and mechanical test results of lower mechanical joints with and without seal welds, shows that the addition of a seal weld does not introduce any adverse effects into the performance of the tubesheet sleeve system. Supporting data from previous test programs, in addition to the laser weld qualification program is presented in detail in Section 3.3 of WCAP-12672 and WCAP-11178 Rev.1. The testing and design verification discussed in both of these referenced documents is valid for the combined sleeve design presented in this WCAP. 4.1 CORROSION EVALUATION - SLEEVE MATERIAL Corrosion and metallurgical evaluations verify that thermally treated Alloy 690 (690 TT) is the material of choice for use in sleeving applications because of its demonstrated stress corrosion cracking resistance. Laboratory stress corrosion tests in both off-chemistry secondary side and primary side environments have shown Alloy 690 TT to have corrosion resistance superior to that of mill annealed Alloy 600 and equal to or better than that of thermally treated Alloy 600. From the extensive tests conducted with thermally treated Alloy 690, it is concluded that the material is highly resistant to stress corrosion cracking. Additional discussions of the tests conducted are provided in Section 3.3 of WCAP-12672 and WCAP-11178 Rev.1. 4.2 CORROSION EVALUATION - SLEEVE JOINTS Test programs were conducted to demonstrate that the joint formation processes do not degrade the integrity of the tube or sleeve. The testing considered the effects of the hydraulic expansion and laser weld process on the sleeve tube assembly as well as the effect of welding in tubes that have deposits on the-secondary side. Details of the testing and the results may be found in Section 3.3 of WCAP-12672 and WCAP-11178 Rev. 1. The formation process for the lower joint of the tubesheet sleeve uses a combination of hydraulic and roll expansion to bring the sleeve into contact with the tube and may include a single pass laser seal weld. The formation process for the upper joint is hydraulic expansion only, followed by laser welding. An extensive program was conducted to show that the expansion technique as well as the magnitude of expansion are acceptable for use in the installation of HEJ sleeves in steam generators. The conclusion based on these 4
tests is that hydraulic expansion of the tube and sleeve during joint formation has no significant impact on the corrosion resistance of the sleeve / tube. For stress corrosion cracking to occur several conditions are necessary; the material must be of a susceptible metallurgy, the component must be under residual tensile stress, and it must be in direct contact with the primary coolant environment. Extensive accelerated testing of free-span joints under these conditions has shown that the predominant mode of failure is through the portion of the alloy 600 tube exposed to primary water in the heat affected zone adjacent to the weld pool. Under the above test conditions, no failure has ever been observed in either the alloy 690 sleeve material or in the exposed weld pool surface on the sleeve ID. To enhance the performance of the free-span joint when exposed to the PWSCC environment, it is necessary to employ a Post Weld Stress Relief (PWHT). In contrast to the free-span upper joint (which is only hydraulically expanded prior to welding), the tubesheet lower joint is both hydraulically expanded and hard rolled into the tube with the sleeve-to-tube weld made in tho hard rolled zone. The metal-to-metal fit-up afforded by the hydraulic expansion /hard roll of the lower joint in the tubesheet effectively isolates the PWSCC prone heat effected zone in the alloy 600 tube preventing its contact with the primary coolant. Only the alloy 690 sleeve inside diameter surface and the surface of the weld pool, which have been shown to be highly resistant to stress corrosioa cracking are exposed to the primary coolant. Additionally, the test data in the Appendix to this document shows that should crack propagation across the sleeve-to-tube weld occur, the sleeve joint would retain its inherent mechanical and leak resistant properties. To demonstrate acceptability of the lower joint, corrosion testing will be performed as part of this program. Testing will employ the unit cell concept applied successfully in other Westinghouse sleeve test programs. The samples will be assembled using the approved field assembly procedure and qualified laser weld process parameters. The samples will be exposed to 750*F steam tests to permit direct comparison of the corrosion performance of the lower sleeve joint with that of the upper free-span joint and typical top-of-tube sheet roll transitions. The steam generator tubes can collect oxides or minerals on the OD, magnetite being the most prominent deposit. At tube OD temperatures observed during 5
sleeve welding or PWHT, these compounds are stable and do not thermally decompose or diffuse into the lattice cf the Alloy 600 tubing. This conclusion is based on the observation of r. variet.< of Alloy 600 samples which were h::. tea to temperatures from 1350*F to above 2000*F in the ;,resence of typical secondary side chemical species and exhibii.ea no significant diffusion, corrosion, or embrittlement of the tubing. Details of the specific conditions are addressed in Section 3.3 3 of WCAP-12672. The sleeve material, Alloy 690 TT, has been demonstrated to be highly resistant to IGSCC under steam generator service related stresses or residual stresses due to hydraulic expansion or weld pool solidification. An accelerated corro', ion test developed by Westinghouse is used to evaluate the resistance of steam generator materials and sleeve joint design to degradation in steam generator primary water environments. In this test, the corrosion performance of the slet.ve weld joints is compared with the performance of roll transitions in the same conditions. The time to cracking of the test sample is measured in the accelerated test. The response of laser welded joints to the accelerated corrosion conditions is discussed in detail in Section 3.3.3.3.2 of WCAP-12672. Since the joint degradation may be related to residual stresses, a reduction in the residual stress level will enhance the corrosion resistance of the welded joint. Enhanced corrosion resistance is obtained through the application of a post weld stress relief. These results have been verified through accelerated corrosion tests as noted above. A discussion of the tests and results which apply to the upper joint are presented in more detail in Section 3.3.3 of WCAP-12672. 4.3 MECHANICAL TEST PROGRAM - SLEEVE JOINTS Both the upper (out of tubesheet) and lower (within tubesheet) tubesheet sleeve joints have been subject to verification testing. The assembly process steps for the samples duplicate those of the approved field process for the design joints. Unlike the upper joint sample, the lower joint is assembled using a collar which represents the unit cell of the tube 6eet hole spacing in a Series 51 steam generator. The final step in the test specimen preparation consists of welding end plugs and caps to the specimens so that they can be internally pressurized and axially loaded. 6 m .
The specimens are subjected to a series of tests to evaluate joint quality as follows:
- 1. Initial leak test
- 2. Axial Fatigue Tests.
- 3. Intermediate and Post-fatigue leak tests.
- 4. Steam Line Break Tests.
- 5. Post SLB leak tests.
- 6. Axial tensile and compressive loading to failure.
The acceptance criteria for laser welded sleeve joint performance during these tests is based on leak rate, which is zero for the laser welded configuration. All of the samples successfully met the acceptance criteria defined above. Details of the tests and the results are contained in Section 3.3.4 of WCAP-12672 and WCAP-11178 Rev. 1. 4.4 RE-WELDING Under some conditions, the initial attempt at making a laser weld may be interrupted. An additional weld or re-weld outboard of the initial weld will then be employed. 4.5 POST WELD HEAT TREAT A post weld heat treatment will be used to relieve residual stresses in the upper sleeve / tube weld introduced by the welding process. The stress relief spans the weld and the adjacent heat affected zone. The stress relief process was defined empirically using representative upper joint samples to define the desired temperature distribution profile for a known stress relief temperature and time. The results were subsequently verified through accelerated corrosion testing as described above. Additional information on the stress relief process as applied to laser welded joints is contained in Section 3.4 of WCAP-12672. 4.6 ANALYTICAL VERIFICATION A structural evaluation of the full length Alloy 690 tubesheet sleeve, with a laser welded upper joint and a lower mechanical joint containing a laser seal weld, was performed in accordance with the rules of the ASME Boiler nd 7
Pressure Vessel Code, Section III, Subsection NB,1986 Edition. The loading conditions evaluated, which umbrella those specified for J. M. Farley Units I and 2 Series 51 steam generators are discussed in detail in Section 3.5 of WCAP-12672. A rigorous analytical verification of the installed sleeve configuration was conducted to assure that interactions between the tubesheet upper laser weld joint, tubesheet lower mechanical joint, and tubesheet lower laser seal weld do not result in load conditions which could be detrimental to either the sleeve system or the parent tube. The analysis considers the effects of primary stresses induced by pressure as well as secondary stresses resulting from operational thermal gradients and secondary mechanical displacements such as tubesheet rotation and their combined effect of the joint fatigue strength. Accurate modeling of the sleeving system is essential in conducting the analysis. To assure compliance of the sleeving system, the analytical model is sized to assure that maximum loading conditions will be imposed. The upper and lower joints are evaluated independently to permit adjustment of the model boundary condition to address all possible loadings. Two cases for the lower joint are evaluated; the first is an hydraulic expansion and weld (no hard roll), the :acond is the hydraulic expansion /hard roll and welded joint. (Mechanical joints have been evaluated in a similar fashion permitting a comparison of all joint arrangements.) Boundary conditions subsequently applied permit extension of the analysis to address not only an intact tube but a completely severed tube. In this manner the sleeve was subjected to a rigorous evaluation which demonstrated that all design, operation, and test conditions are satisfied. In addition to the specific ASME Section III NB-3000 design rules, the following additional conditions have been evaluated for the laser welded tubesheet sleeve and are addressed in more detail in Section 3.6 of WCAP-12672. 1 Flow Slot Hourglassing 2 Effect on Burst Strength 3 Effect on Stress Corrosion Cracking (SCC) Margin 4 Effect on Fatigue Usage Factor 5 Tube Vibration Analysis 6 Sludge Height Thermal Effects 7 Allowable Sleeve Degradation 8
8 Leak-Before-Break Verification 9 Determination of Plugging Limits Specific criteria have been established for plugging limits utilizing the recommended practices discussed in Regulatory Guide 1.121. The plugging criteria for sleeved tubes with a laser welded upper joint and a mechanical joint with a laser seal weld should be 37% as discussed in Section 3.6.4.2 of WCAP-12672. The value of the plugging limit is among other things a function of the sleeve material properties. Other reports which set the plugging limit at 31% considered the possible installation of sleeves fabricated from thermally treated Alloy 600 which has a lower yield strength than the Alloy 690 material. For those reports to blanket the strength range and possible mix of sleeves the plugging limit was established as a function of the lower strength Alloy 600 sleeve assuring conservatism in the limits. The laser welded sleeving report, WCAP-12672, and this report define the sleeve material as Alloy 690 only which allows the use of the higher strength Alloy 690 material properties in the required calculations resulting in the 37% plugging criterion. 4.7 EVALUATION OF FLOW EFFECTS SUBSEQUENT TO SLEEVING The flow effects due to the installation of laser welded sleeves are discussed in detail in Section 3.7 of WCAP-12672. The primary contributor to the flow effects of the tubesheet sleeve is the combination of the restriction of the non-expanded zone and the expansion / contraction losses at the upper and lower joints. The results as tabulated in WCAP-12672 will remain unchanged as a consequence of eliminating or re-positioning the lower laser weld to the tubesheet clad area. 5.0 PROCESS DESCRIPTION The sleeve installation consists of a series of steps starting with tube end preparation (if necessary) and progressing through tube cleaning, sleeve insertion, hydraulic expansion at the lower and upper joint, and hard rolling the lower joint. The upper joint is then laser welded, inspected by UT, post weld heat treated, and eddy current tested. The lower joint is seal welded and visually inspected. Should the lower seal weld be eliminated, it will be deleted from the process steps indicated without significant impact on the 9
total program. The discussions presented in Section 4.0 of WCAP-12672 remain applicable for the sleeving program. 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 and to establish a baseline for future eddy current examination of the sleeved tubes. The basic process check on 100 percent of the sleeved tubes will be to:
- 1. Verify presence of lower hydraulic expansion zone.
- 2. Verify lower roll joint location within the lower hydraulic expansion.
- 3. Verify presence of upper hydraulic expansion zone.
- 4. Verify the weld location of the upper laser and lower seal welds as applicable.
- 5. Check for the presence of any anomalies.
In addition to eddy current process verification and baseline testing, the upper weld joint will be evaluated by ultrasonic inspection. The ultrasonic inspection is performed only upon initial sleeve installation. It is not necessary to ultrasonically inspect the weld joints during future in-service inspections. The lower weld is subjected to visual inspection only. 6.0 NDE INSPECTABILITY The non-destructive examination (NDE) program has concentrated on methods to confirm that the laser welds meet specification dimensions and quality and that the sleeve / tube assembly may be adequately inspected during subsequent in-service inspection. To accomplish this both eddy current inspection and ultrasonic inspection techniques are used. The upper laser welded joint is inspected by ultrasonic and eddy current techniques while the lower mechanical joint is inspected by eddy current only (assuming a mechanical joint) or eddy current with a weld visual inspection (for a mechanical lower joint and seal weld) . Upon conclusion of the sleeve installation, a final eddy current inspection is performed on every installed sleeve to provide interpretable baseline data on the sleeve and tube as well as verify the correct dimensional condition of the tube joint expansion zones and weld position. Ultrasonic inspection is used to confirm weld acceptance of the upper weld 10
joint. The main goal is to verify the width of a sleeve / tube fusion zone. The UT laser weld inspection system will be used to confirm that there is a metallurgical bond between the sleeve and the tube which meets the required minimum weld width for 360 degrees while locating any through weld leak paths. 7.0 IN-SERVICE INSPECTION PLAN - SLEEVED TUBES Upon completion of installation, the supplemented pressure boundary may be subjected to eddy current inspection to obtain a baseline signature of the installed sleeve. Subsequent periodic eddy current inspections may then be performed to monitor sleeve and tube wall conditions in accordance with the inspection section of the plant Technical Specifications as discussed in section 6 of WCAP-12672. 11
Appendix Lower Joint Exceptional Condition Test Program The design configuration of the tubesheet sleeve lower mechanical joint or HEJ was developed empirically by extending classic techniques used to attach tubes to tubesheets in steam generators. Because the design was based on empirical relationships, it was difficult to apply specific design rules to optimize the joint's final configuration. However, the performance of the joint during qualification tests suggested that the base tubesheet sleeve joint design contained significant design margin due to the fabrication parameters used. The discovery in 1988 of non-conforming conditions in steam generator tube-to-tubesheet joints at another plant, prompted a detailed investigation into the performance limits typically assigned to the lower mechanical joint design configuration. The results of that investigation may be used to assess the joint performance in any Westinghouse model 44/51 steam generators. The data demonstrates that the sleeve lower joint may be reduced to as low as 0.75 inches in length and still meet all of the design performance requirements imposed on the base design. Thus it is demonstrated that the tubesheet sleeve lower joint roll region (effective roll length) meets the design requirements even if no credit is taken for the region containing the lower laser seal weld. Additional test programs were performed to verify acceptable performance of the sleeve lower mechanical joint to accommodate exceptional conditions which may exist in the steam generator tubes and anticipated conditions which may be employed during installation of sleeves. Exceptional conditions in steam generator tube characteristics and sleeving operation process parameters included;
+ shorter lengths of roller expanded lower tube joints + shorter lengths of roller expanded lower sleeve joints + lower applied torque values employed in the sleeve lower joints The specific exceptional tube conditions and changes to the sleeving process parameters tested in the first program are shown in Table 1.
( 1 12
Each process operation and sequence of operations employed in fabricating each test sample was consistent with those specified for sleeves to be installed by field procedures. In addition, the exceptional conditions and changes to the sleeving process parameters described in Table I were included in the assembly of tube and collar subassemblies. The as-fabricated specimens for this program were tested in the sequence described below.
- 1. Initial leak tests: Each specimen was checked for leak tightness prior to any verification tests. The leak tests were performed at room temperature and 2,450 psig followed by a second leak test at 600*F and 2,450 psig.
These tests established the leak rate of the lower joint after it had been installed in the steam generator and prior to long-term operation.
- 2. Thermal Soak Test: Each specimen was subject to an unpressurized thermal soak at 600*F for 1 hour minimum, and cooled to room temperature. After this test each specimen was subjected to the leak tests described above.
- 3. Thermal Cycling Test: Selected specimens from 2. above were subjected to a pressurized (1,600 psig) thermal cycling test from ambient to 600*F for a total of 25 cycles. After this test each of these specimens was subject to the leak test described in 1. above.
- 4. Fatigue Test: Specimens from 3. above were subjected to a pressurized (1,600 psig) fatigue test at 600*F for a total of 35,000 cycles. After this test each of these specimens was subjected to the leak test described in 1. above.
- 5. Compression Tests: Specimens were subjected to a destructive non-pressurized compression test. Some were tested at room temperature and others at 600*F to determine the buckling resistance of the sleeve.
- 6. Tensile . Test: Specimens were also subjected to a destructive non-pressurized tensile test at 600*F to determine the resistance of the sleeve to tensile loads.
- 7. Steam Line Break Test: Specimens were subjected to a steam line break test 13
at 650*F and 2,560 psi. After this test each specimen was subjected to the leak tests described in 1 above. As documented in Table 2, no Icakage was observed during any of the tests. The as-fabricated specimens for the second program were tested in the sequence described below.
- 1. Initial leak tests: Each specimen was tested for leak tightness prior to any verification tests. The leak tests were performed at room temperature and 3,110 psig followed by a second leak test at 600*F and 3,110 psig.
These tests established the leak rate of the lower joint after it had been installed in the steam generator and prior to long term operation.
- 2. Fatigue Test: Following the leak tests of 1. above, specimens were subjected to a pressurized (1,600 psi) fatigue tests at 600*F for a total of 20,000 cycles. After this test each specimen was again subjected to the leak tests described in 1 above.
- 3. Tensile Test: Some specimens were subjected to a destructive non-pressurized tensile test at 600*F to determine the resistance of the sleeve to tensile loads at temperature.
As documented in Table 3, no leakage was observed during any of the tests. Results from both programs indicate that the lower sleeve tube joint where installed with these exceptional steam generator tube physical conditions or changes to process parameters described, will provide:
+ adequate leak resistance + adequate structural strength under normal and accident conditions, + adequate fatigue strength under transient loads for the remaining design basis of the reactor plant.
14
1 l Table 1 EXCEPTIONAL TUBE CONDITIONS AND SLEEVING PROCESS PARAMETERS a,c.e 15
e. c, a E V E E L S D N A E B U T R O F S N O I T I D N O C L A N O I T P 2 E E CX L 8 E A H T T I W S T N I O J R E W O L R O F S T L U S E R T S E T l
lllli 11 1 , E e. c, V a E E L S D N A E B U T R O F S N O I T I D N O C L A N O I T P E C a X E E t H e T A I T W S T N I O J R E W O L R O F S T L U S E R T S E T L A N O I T I 7 D 4 D A m 1
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- 4 +
- l Enclosure 4 l
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I J. M. Farley Units 1 and 2: Elevated Tubesheet Sleeve Qualification, Westinghouse letters NSD-ST-96-388 and NSD-ST-%-391 dated November 5,1996 1 1 I i
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WESTINGHOUSE NON-PROPRIETARY CLASS 3 { Getter report NSD-ST-96-391) ' 1 J. M. FARLEY UNITS 1 & 2 [ 4 ELEVATED TUBESHEET SLEEVE QUALIFICATION i 1 i This letter report summarizes the results of the qualification testing that was performed i of the installation of 7/8 inch Elevated Tubesheet Sleeves (ETS) in Farley Units 1 and 2 steam L generators. It also addresses the lessons leamed from the Maine Yankee laser welded sleeving (LWS) campaign and how those lessons have been m irswpoieted ' to suba==at LWS camp including the planned instauntion of ETS in Fadey. , 1. ETS Lower Joint D;f4 m - Tube Undegraded in Joint Ares ! i 1 A two-step mechanical interikonce fw hardrolled lowerjoint was quahfied for use with i elevated tubesheet sleeven, heed on an installation sequence where the lowerjoint was made last, aner sleeve wel sig and stress relief heat treatment The qualification involved :
- (a) primary-to-WeS side leakage resistance testing; (b) Wa y-to-primary side :
i " onset of significant leakage" testing; and (c) sleeve pullout testing. i The roll expansion parameters included a torque of[ ]" ! and an effective axiallength of[ ]". The lowerjoint was located approximately 6 i inches below the top ofthe tubesheet 4 The primary-to-secondary side leak test results showed an average leakage of about [ ]" drops per minute (dpm) which was an order of magnitude smaller than the leakage i critenon of[ ]". 1 ! The secondary-t;-primary side leakage testing was performed to determine, conservatively, the interfacial radial contact pressure between the rolled sleeve and tube. i These contact pressures were then used to calculate the sleeve rolled joint pullout ) resistance The pullout resistance from the tests was approximatef l i f [ ]" which exceeded actual direct pullout test values of[ ]" All of these values exceed j the three delta P force requirements by a wide margin i i Direct pullout tests on sleevejoint samples fabricated using the qualified process 3 parameters showed breakway forces of[ l
]" These exceeded the three delta
- P criterion of[ )" !
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ol WESTINGHOUSE NON-PROPRIETARY CLASS 3 3 (Letter report NSD ST-96-391) j 5. i LWS Performance under locked TSP Conditions i ! \ i Accelerated doped steam corrosion testing of ETS tubes under tensile preloads derived i from the far Seid residual stress testing in support of Maine Yankee showed that the laser welded sleeves would last well beyond the planned lifetime of that plant. Those 3/4 inch i ; LWS corrosion test data are applicable to 7/8 inch LWS insta5stions with appropriate ! adjustments to address the different top-of-tubesheet to TSP spans and operating ! temperatures ne corrosion performance of the ETS underlocked TSP conditions has i been documented in Reference 2 for the'Callaway steam generator conditions ! j Comparing the times to failure of the ETS laser welded sleevejoints to that of roll j ! i transition control samples, it was detennined that the laser welded joints would last 20 i times aslong. i Additional cc,en.. ;ory accelerated doped steam corrosion testing on 7/8 inch LWS mockups have been completed in support of the Farley LWS innanatians The results provide further con 6rmation of LWS lifetime predictions made in Reference 2.
- 6. Bulging and Bowing ofETS
[ t
]" Additional far field residual stress tests conducted in j support of Farley LWS and laser welded repair of HEJ sleeves have also cc, eared that the tube bulge is insignificant and has no adverse effect on the structural and corrosion performance of thejoint or the inspectability of the sleeved tube. i
[ l
]" The maximum length of the ETS that will be used at Farley is 20 inches. There is therefore no potential for bowing of the ETS in the Farley steam generators.
1 1 - l WESTINGHOUSE NON-PROPRIETARY CLASS 3 i (Letter report NSD-ST-96-391) i 1 ! 7. Revised UT Inspection Criteria i The UT acceptance criteria that will be employed to verify weld width for the ETS is the same as that developed for use at Maine Yankee. The UT qualification program l addressed UT uncertainty and required that no welds with a width below 0.015 inch (the { structural minimum) be accepted. Tae qualification testing included debberately created ' weld samples with widths less than 0.015 inch and increasing up to 0.040 inch. Weld l i widths up to 0.020 inch were rejected by UT in all cases, A=: - ;:- the conservatism i of the acceptance criteria l l The attenuation of the UT backwan (tube OD) signal due to the praamare ofOD deposits l l could resuk in lack of backwaR reenreinas As qualdad in support of the Maine Yankee i LWS program, the lack ofbackwall remar*ian does not cause rejection of the weld. } However, backwaD signals, if present, may be used to accept welds that do not meet other aspects of the vgaaca criteria. l > l The threshold value for the sleeve / tube interface reflection is established through
- examination ofdeliberately generated narrow weld sections That value is quah6ed along with the entire acceptance criteria. FoDowing the successful qualification of the UT
?- process, the criteria is spacMad in the field procedure for use by the UT analysts. l The ec+penaca criterion far the weld width at the sleeve / tube interface is that any width less than 0.015 inch (the structural minimum) shall be rejected. Based on tests of weld . samples having widths less than 0.015 inch and increasing up to 0.040 inch, the following threshold values for UT acceptance were establinhad: 1 Criteria A and B must be met for the laser weld to be accepted. Criterion A - Accentabihty of the Weld [ 1
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WESTINGHOUSE NON-PROPRIETARY CLASS 3 ; , (Letter report NSD-ST-96-391) Criterion B - Insoectability of the Weld i 4 ! l Y ' i The samples with weld widths up to 0.020 inch were rejected by UT in all casee 'sased on 1 the above criteria. : j The information contained in this letter is an abbreviated sunwary of the quali6 cation data.
- Referenca I
- 1. NSD-JLH-6202, " Summary of Farley LWS Lower Joint Development-Task C Quahfication Testing", June 25,1996.
I 2. WCAP-145%, " Laser Welded Elevated Tubesheet Sleeves for Westinghouse Model F Steam Generators, Generic Sleeving Report, March 1996 (Note: This is the Sleeving l Report for Callaway). l I 4 . l l j
O WESTINGHOUSE NON-PROPRIETARY CLASS 3 (Letter report NSD-ST-%-391) TABLE 1. Far-field Stress as a Function of Stress Relief Temperature (Data shown are fcr 3/4 inch OD Tube-Sleeve Mockups) [ i 1" I i j O}}