ML20151R869
| ML20151R869 | |
| Person / Time | |
|---|---|
| Site: | Three Mile Island  |
| Issue date: | 10/31/1985 |
| From: | Croneberger D, Giacobbe F, Wilson R GENERAL PUBLIC UTILITIES CORP. |
| To: | |
| Shared Package | |
| ML20151R847 | List: |
| References | |
| TDR-638, TDR-638-R01, TDR-638-R1, NUDOCS 8602060288 | |
| Download: ML20151R869 (50) | |
Text
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APPENotX S 638 I g TDR NO. REVISION NO.
BUDGET - 123125 I 30 ACTIVITY NO. PAGE OF TECHNICAL DATA REPORT t.ngineering 5 Design PROJECT: DEPARTMENT /SECTION Materials Ener2/ Failure Anal' TMI-1 GTSG REPAIRS RELEASE DATE 10/21/85 REVISION DATE DOCUMENT TITLE: Evaluation of Eddy Current Indications Detected During the loa 4 Tech. Spec. Inspection e DATE APPROV ALIS) SIGyF/ DATE CRIGINATOR SIGNpTURE ,,
@ M y, fjf /*4t M F. S. Giaco' M n/w k
/ # ## D. K. CroneberM/bbb I
/o.10 d f DATE APPROV/ L FOR EX)TERNhL DISTRIBUTION R. F. Wilson 9I\ . _ . _ %-
Does this TDRinclude recommendation (sl7 Oyes ENo if yes.TFWR/TR #
- DISTRIBUTION ABSTRACT:
In order to identify the cause of the eddy current indications detected during the TMI-l OTSG tube examination R. O. Barley beginning in November 1984, Materials Engineering / Failure Analys is perf reed an in-depth review of the eddy current D. D. Bowman results and plant operating / chemistry history since the CISG's G. R. Capodanno aere first filled af ter the kinetic expansion repairs .
J. J. Colitz Two possible causes for the eddy current indications were D. K. Croneberger evaluated: corrosion, either centinuing or newly initiated, and enhanced eddy current detectabii tty of exis ting intergranular B* D* Elam attack (IGA or intergranular stress assisted cracks (IGSAC).
N. C. Kazanas During unir layup, GPUN Layup specifications were followed.
3 me ut f Specification periods did occur; however. they were R. J. McGoey promptly corrected and were not of suf ficient magnitude to have R. F. Wilson :aused corrosion. Additional corrosion preventive conditions aere also maintained during layup.
T. G. S%h During hot operations, system chemistry conditions were naintained within specifications that industry experience and IMI-l tube testing have shown are non-corrosive.
The most likely reason f or having eddy current indications at this time was enhanced detectability of pre-existing areas or ICA/IGSAC. As a result of thermally induced strains and Tydraulic forces during hot functional testing, grains could fall out or grain boundaries could separate within pre-existing
[CA, resulting in, greater local disturbance of the eddy currents and a correspondingly higher signal to noise ratio.
Additional plant data from leak rate observations and the fiberscope examination of a sample of tubes also support the mechanical damage scenario. No leaks have been identified in the tube free span since 1983. In the region of 1984 eddy current indications, patch-like indications suggestive of ICA sere seen by the fiberscope examination.
B600060298 360204 PDR ADOCK 05000289 p PDR A00oGoJO 4-83
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nev. i Page 2 of 50 e .o .
DOCUMENT NO.
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- IN l br TDR 638 TITLE Evaluation of Eddy Current Indications Detected During the 1984 Tech. Spec. Inspection REV
SUMMARY
OF CHANGE APPROVAL DATE 1 Abstract: Changed IGA to ICA/IGSAC /Mi/W Changed larger eddy current signal to higher signal to noise ratio 1 Page 7: Changed ICA to IGSAC 1 Page 23: Deleted Para. 4 yf,/y,-
Page 23: Added under item 1: ... in the LTCT 1
LTCT (Ref. 8). This could produce W/8'
a crack like indication, etc.
1 Page 25: Revisions made to entire page 1 Page 27: Added Table 7 ID lo-8C I
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TDR 638 Rev. 1 P age 3 of 50 Table of Contents Page 5
Introductio n 6
Back ground 7
Evaluation of Eddy Current Results 7
Post-Baseline Growth Studies In-Process Testing ISI Indications June 1984 Testing 100 Tube Sanple November 1984 1984 Technical Specification Required Testing 9 Spatial Distr ibution Characterization of Indication s Degraded Tubes 12 Chemistry Specifications Corrosion Experience with Inconel 600 Corrosion Test Results Long Term Corrosion Test Short Term Test Results Bulk vs. Surf ace - E f fec ts TMI-l Chemistry Guidelines Hot Operations l Layup 17 Chemistry and Operating History Review Data Base Results of Operational / Chemistry Review
' Chloride and Sulfate Oxygen Other Operational Considerations
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a o TDR 638 Rev. 1 Page 4 of 50 page 21 In-Plant Observation s Leak Testing Fiberscope Inspection of Selected Tubes 23 Discussion
! General Detectability of Indications by Eddy Current 32 Conclusions 33 References 35 Appendix i
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TDR 638 Rev. 1 Page 5 of 50 Introduction In accordance with the requirements of Technical Specification 4.19, eddy current testing of the OTSG tubing at TMI-1 was begun in November 1984. Initial testing with the 0.540'? high gain standard dif ferential probe method revealed previously unreported indications in the unexpanded portions of the OTSG tubes between the tube sheets.
Two possible causes for the eddy current indications were identified and evaluated; first, whether corrosion of the OTSG tubes caused either new defects or growth of existing defects and second, whether straining of existing defects caused them to become more detectable by eddy current. Since the original 100% baseline inspection of the OTSG tubes in 1982, the tubes have been subjected to mechanical loading during the kinetic expansion and thermal and hydraulic loads during the two hot functional tests.
In order to attempt to determine the cause of these indications, the Materials Engineering / Failure Analysis group reviewed 1) the historical eddy current data and 2) plant operational and chemistry data -
since the OTSG's were filled af ter the kinetic expansion repair of the tubes.
Based on the results of this review, the cause of the indications is discussed. Data supporting the conclusion are also included.
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TDR 638 Rev. 1 Page 6 of 50
Background
As defined by Technical Specification 4.19, GPUN conducted eddy current examinations of both steam generators at TMI Unit 1. Performance of this examination ultimately resulted in 100% of the tubes in A-0TSG and all tubes in the outer 16 tube periphery of the B-0TSG being examined.
The B-0TSG had only a limited number of indications with an indicated through-wall extent greater than 40%. Due to the limited number of B-0TSG indications, statistically-based analysis is not feasible. All these indications, however, are located near the outer periphery of the B-0TSG.
The following generalizations about the EC indications can be drawr from the A-0TSG results:
- 1. They are primarily located in the upper tube sheet and 16th tube span area.
- 2. They are concentrated in the outer periphery, but some '
indications occur across the entire OTSG.
- 3. Approximately 78% of the indications are less than 50% through wall.'
- 4. They generally exhibit voltages in the 0.5-2 v. range.
- 5. Except for two indications, the number of 8 X 1 absolute eddy current coils producing a signal from a defect is 2 or less, indicating a small circumferential extent.
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' TDR 638 Rev. 1 Page 7 of 50 Evaluation of Eddy Current Resul6s Note: This section uses the eddy current data base as of Jan. 3,1985.
GPUN conducted a qualified full-length, eddy current examination program on all tubes from both generators during July to November 1982.
The purpose cf this program was to screen out all relevant indications and establish a 6" qualified length in the kinetically expanded zone immediately above the new transition zone which was essentially indication free. It was further established that small defects below the threshold of detection could exist. Reference 1 identifies the maximum size of these small defects which could possibly go undetected.
Prior to the expansion, a 100-tube sample of tubes in each generator was eddy current tested periodically to check for indication changes. These tests were performed on seven occasions over a 7 month period . No growth was observed.
Post-Baseline Growth Studies .
In-Process Testing During and following the kinetic expansion repair, a total of 437 tubes were inspected in both the A and B generators (Ref 2, 3).
A total of 15 tubes (3.5%) with indications were found that had not been detected by our ECT inspection program prior to the repair.
An evaluation was performed on why these indications were not identified previously (Ref. 3). It was concluded that:
- 1) The recent indications were not initiated by the kinetic expansion process nor was there any evidence of ductile propagation of existing indications.
- 2) The defects were small (threshold) type indications that had been either masked by the high background noise levels in the upper tube regions or were suf ficiently tight that the volume of lost metal was not detectable. Kinetic expansion may have altered these areas of IGA /IGSAC to make them more detectable by causing additional grain boundary separation.
Confirmation on the small size of the indications was established by the visual examination using fiber-optica. Some of the indications appeared to be small pits.
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TDR 638 Rev. 1 P age 8 o f 50 Additional confirmation was obtained that kinetic expansion would not cause ductile tearing by using test mock-ups and metallurgical examination (Re f. 2) . Small intergranular stress assisted (IGSAC) cracks were examined using eddy current techniques before and af ter kinetic expansions. Expansion caused the cracks to become non-detectable by .540" S.D. techniques. However, the cracks remained visible to the 8 X 1 absolute technique with essentially no change in signal. The se specimen tubes were
' subsequently removed from the test block and metallurgical examination did not reveal ductile tearing or generation of new indications.
ISI Indications During OTSG repairs, a subset of tubes (28 in A-0TSG, 56 in B-0TSG) was identified as having eddy current indications that did -
not require plugging. That is, the indications were less than 40%
through wall, not in the lane / lane wedge area, and below the 15th tube support plate. This group of tubes (designated as "ISI" tubes by GPUN) was fully characterized and listed for eddy current '
inspection in the future as a distinct subset.
The "ISI" tubes were re-examined in April /May 1983. No growth of the existing indications was detected.
As part of the eddy current campaign which started in October 1984, all 84 of the "ISI" tubes have been retested. No growth in the ISI subset was detected. (Growth is identified as a substantial increase in the through wall percentage, combined with an increase in voltage and/or circumferential extent.)
June 1984 Testing During June 1984, 67 tubes in B-0TSG and 3 tubes in A-0TSG were eddy current tested. This set of tubes was retested in November 1984 - no new indications were detected for the two retests performed.
100 Tube Sample November 1984 Since discovery of the additional indications in November 1984, a second 100 cube sample with indications has been re-examined at approximate two week interval s. As of December 18, 1984, no growth and no new indications have been detected for the two retests performed.
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TDR 638 Rev. 1 Page 9 of 50 1984 Technical Specification Required Testing
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In November 1984, eddy current testing required by TMI-l Technical Specification 4.19 was conducted as specified. 3% of the' tubes in each generator were initially examined. This examination included tubes randomly selected across the entire generator plus a concentrated examination in the periphery of each generator. The more extensive this was the region of examination in the periphery was p'erformed because highest previous (1981) damage .
As a result of this initial examination, OTSG A was classified as category "C-3" per technical specification and OTSG B was classified as category "C-2" . Subsequently the entire A-0TSG was inspected while the B-0TSG inspection was complete af ter the entire 16-tube periphery, approximately 6500 tubes , had been examined.
The number of indications is much higher in A-0TSG than B-0TSG. In A-0TSG, 2.0% of the tubes (299 out of approximately 14589) have indications greater than 40% through wall, while in B-0TSG, 0.5% (33 out of approximately 6576) have such indications.
4 Spatial Distribution 1
The indications with greater than 40% through wall depth are concentrated toward the outer periphery and top of A-0TSG. In the outer periphery, the percentage of tubes with greater than 40%
through wall indications is higher than the 2.0% average, while i
inside the outer support rods the percentage of indications is below 1%. 71% of the indications are located above the L5th tube support plate (TSP).
Characterization of Indications To understead the nature of the defects better, we characterized the indications reported back in the 1981-1982 time frame and compared them to the indications discovered today.
i The axial and radial locations of indications in A-0TSG are essentially the same in 1984 as in 1982, if one does not consider the 1982 indications in the kinetically expanded region in the 1984 evaluation.
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TDR 638 Rev. 1 Page LO of 50 Table 1 characterizes the 1982 and 1984 eddy current signals.
The 1984 eddy current indications exhibit a similar type of signal response as the previous test program. Details of the differences in responses are noted below:
- 1) Reported voltages are essentially the same. This indicates that the 1984 indications present a similar volume for the eddy current probe to detect as the 1982 IGSAC.
- 2) Both through wall penetration and number of coils is significantly lower in 1984. Thus, tha 1984 indications extend a shorter distance both into cnd around the OTSG tube.
Statistical analysis of the eddy current data reveals that 78% of the observed indications are less than 50% through wall and 90% are
.194" cr less in circumferential extent.
Degraded Tubes .
Per GPUN procedure, tubes with indications reported between 20 -
and 40% through wall were not required to be plugged if the tubes were not in the lane or lane wedge and the indication was below the 15th tube support plate. At the completion of the 1982 kinetic expansion repairs, a total of 15 A-0TSG tubes and 51 B-0TSG tubes were classified as " degraded" and were included in the ISI group.
As of January 4, 1985, 347 additional A-0TSG tubes and 98 additional B-0TSG tubes are classed as degradec.
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a O TDR 638 Rev. 1 Page 11 of 50 Table 1 Comparison of 1982 and 1984 Eddy Current Data a) Repot ted Voltage - % of indications reported A-0TSG B-0TSG Voltage 1982 1984 1982 ly 41 34 40 24 27 1 44 35 30 21 2 16 20 25 29 3 4 4 10 12 p3 2 1 11 11 b) Reported through wall penetration - % of indications ,
A-0TSG B-0TSG
% T.W. 1982 1984 1982 1984 4 20 4. 1 41 12 20-40 3 61 28 75 40-60 21 25 24 18 60-80 17 10 15 5
- 21 2 7 80 59 4 c) Number of coils on 8 x 1 examination - % of calls A-0TSG B-0TSG Coils 1982 1984 1982 1984 1 20 90 18 80 2 26 10 24 20 3 16 41 15 41 23 38 <1 43 41 NOTE: 1982 data includes inspection of original tube roll transition area.
The 1984 data does not include inspection from the top of tube sheet to the bottom of the kinetically expanded region. See TDR 652 for complete summary of eddy current indications (Ref. 17).
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J'. TDR 638 l Rev. 1 Page 12 of 50 Chemistry Specifications i
- Corrosion Experience with Inconel 600 j
i Three types of primary-side initiated attack have been identified
! in Inconel 600. In recirculating steam generators using mill-annealed tubes that have not been stress-relieved af ter U-bending, stress l
corrosion cracking (SCC) has initiated from the primary side in the l
- highly stressed bend areas. Also in mill-annealed tubes in recirculating l
steam generators, SCC has been found to initiate from the primary side at
' highly stressed transition areas in the lower tubesheet. Laboratory studies have shown that ~the stress relieved Inconel tubing used in OTSG's ts significantly more resistant co SCC thta the mill anneated type.
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The other primary side attack of Inconel 600 that has occurred in
' steam generators is the intergranular stress assisted cracking (IGSAC) caused by reduced sulfur species on sensitized OTSG tubing. This is the i
mechanism which caused the TMI-1 OTSG 1eakage in 1981. This mechanism l
requires sensitized tubing, low temperatures, . oxygen, and significant levels of reduced sulfur species.
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Corrosion Test Results As part of the overall program to evaluate the most recent eddy 4
current testing results, we have reviewed the results of corrosion tests performed as part of the original failure analysis and OTSG requalification programs. These data provided a - partial basis upon which we could evaluate tb1 layup and test conditions to which the steam generators had beer. subjected.
Long Term Corrosion Tect (LTCT) f The primary purpose of the long term corrosion tests was to i verify that the proposed operating chemistry specifications are satisf actory to prevent corrosive attack of the OTSG tubes. To this end, chemistry conditions for the testing were established at
! the maximum allowable values consistent with the upgraded TMI-l j
operating specification (Ref. 4). The LTCT was conducted using i
ac tual TMI-1 tubing. Temperatures, tube loads, and heatup and i cooldown rates were representative of actual plant operating conditions.
1 j In addition, as the LTCT was actually performed, specific factors which parallel actual plant layup conditions were 1
experienced. The tubes were held in a cold, aerated condition for I several days af ter the complee. ion of each operating cycle.
Aeration was done after coo ,rwn. Before heatups, or while waiting l
for other autoclaves in the est program to be ready for operation, the test-loops were operated in a cold, deaerated, circulating mode. Because eddy current examinations were done af ter each test cycle, the tubes had to be removed from the autoclaves and t
drained. Thus, drained aerated layup conditions were also included.
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- TDR 638 Rev. 1 i Page 13 of 50 l l
Table 2 summarizes LTCT operational times in each mode. All loops spent significant time under drained, cold deaerated, and aerated conditions.
Review of the dhemistry history of the LTCT's revealed that j
the conditions were comparable to the plant's experience. The LTCT specification (Ref 5) for sulfate and chlorides was 0.100 ppm +
.050 ppm. Actual analysis results (Ref. 6, 7, 8) revealed that the concentrations of these species were maintained at or slightly above the .150 ppm upper limit. The actual values measured in-these tests bound any of the contaminant " spikes" reported in the Chemistry and Operational History Review.
C-ring tube samples from archive tubing (tubing never installed in the TMI-l OTSG's, which was included as a control sample)'showed no evidence of cracking, pitting or general corrosion both before and af ter the LTCT.
Data presented from the LTCT show, that of a total of 54 "C" ring samples tested and evaluated, 46 '.ad no visible defects, 3 had '
very short circumferential cracks when strained severely, 3 had ICA patches greater than 20% but less than 40% through wall (Table 7) and 2 had IGA patches less than 20% through wall.
Five full . tube samples were examined af ter the LTCT. In addition to previously reported defects, four samples exhibited scattered, shallow cracking or IGA which were not sized metallographically and therefore a determination could not be made as to their detectability by eddy current testing.
ICA which was metallographically evaluated was consistent in size and shape with IGA that had been seen during tha failure analysis (Ref. 9). There fore , the observed IGA on these four tube's was. judged to have been present at the start of the LTCT. And as stated above, the control samples showed no ICA/IGSAC.
Results of metallographic examination of the LTCT samples (Re f. 8) confirmed that normal operations would not cause corrosion ,
of TMI-l OTSG tubing.
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TDR 638 Rev. 1 Page 14 of 50 Short Term Test Results Several sets of tests were previously run on Inconel 600 tubing to establish corrosion resistance under various conditions representative of TMI-1 service. Those results which apply to the period of this review are summarized below:
- 1) Screening work on actual TMI-l removed tubes and archive tubes (Ref. 10)' identified that at oxidizing potentials, I ppm of thiosulfate was required to cause IGSAC.
Sulfate levels as high as 10 ppm did not cause IGSAC.
- 2) Simulation of hot functional testing and cooldown (Ref.
- 11) utilizing thiosulfate contamination and actual operating temperatures and times revealed that 1 ppm of thiosulfate caused IGSAC.
These shore term tests thus confirmed that in the absence of thiosulfate contamination, no short term attack of OTSG tubes is expected.
Bulk vs. Surface Effects The above corrosion tests were performed using actual TMI-l OTSG tubing. The surface film condition was therefore representative of that in the plant. Chemistry control in both corrosion testing and acteal operation is done by the measurement and control of species of interest in the bulk fluid.
Since both surface conditions and chemistry control were identical between the laboratory tests and plant operations, the results of the corrosion tests can be directly applied to the plant environment, and, conversely, plant bulk chemistry data can be used to evaluate the propensity for corrosion.
TMI-l Chemistry Guidelines Hot Operations After sulfur was identified as the causstive agent of the 1981
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IGSAC, hot operational guidelines (Ref. 4) were reviewed to ensure that adequate corrosion protection was maintained. As a result of this review, two changes were made to provide increased margins against corrosive attack.
First, a requirement was added that primary system sulfate be maintained below 0.100 ppm. Sulfate at this level does not cause corrosive attack of Inconel 600 in primary coolant, and maintaining sulfate below this level provided assurance that intermediate sulfur species could not exist at harmful concentrations.
' Second, the lower limit on Lithium concentration was increased to 1.0 ppm, to take advantages of lithium's inhibiting ef fect on sulfur-induced IGSAC in Inconel 600 (Ref. 12).
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e TDR 638 Rev. 1 i Page 15 of 50 l
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The net result of these changes is to ensure that total sulfur species concentrations are a factor of 10 below the level at which corrosive attack might occur. At the same time, the minimum Li/S ratio will be 30 (or Li/SO4 of 10), which is a factor of 3 over the recommended (Ref.12) ratio of 10 for inhibition of IGSAC initiation.
Layup For cold layup conditions, guidelines have been established to maintain as many protective conditions as feasible. 'The individual protective conditions that are feasible for the TMI-l RCS are:
- 1) Elevated pH - during layup, pH has been elevated, using ammonia, to at least 7.2. The normal pH without ammonia is 5.6 - 6.5.
- 2) Control of contaminants - The primary water contaminants -
of concern are chlorides and sulfates. Chlorides have traditionally been limited to less than 0.100 ppm during '
operation; we have maintained this level as a general guideline during layup. The sulfate level of less than 0.100 ppm used during hot operation also applies to layup.
- 3) Control of oxygen level - When the system is filled and able to be pressurized, the oxygen level is to be maintained below 0.1 ppm. For cases where the primary system is open and oxygen cannot be excluded, air saturated conditions are specified as this is more protective than some intermediate oxygen level.
- 4) Control of OTSG 1evel - One of the contributing factors to the 1981 IGSAC incident was the existence of a water line on the primary side of the OTSG tubes. For layup of the OTSG's, wherev.er possible, no static waterline shall be allowed to exist in the OTSG tubes. Eithat the water level should be above the upper tubesheet or the OTSG primary side should be fully drained.
- 5) Inventory Turnover - Periodic replenishing of the OTSG contents wilt assure that local buildup of contaminants will not occur. Layup guidelines have included provisions for periodically turning over the water inventory on the OTSG primary side to meet this objective.
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TDR 638 I
Rev. 1 Page 16 of 50 i
TABLE 2 Summary of Operations for Long Term Corrosion Tests Operating Days Cold Circulating Drained Loop Hot Deserated Aerated Layup (Note 1) Comments 1 348 52 28 132 69 27 157 Thiosulfate loop 2 308 3 241 42 23 58 4 242 40 22 61
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- 1. Does not include drained layup between completion of operat*onal cycles and start of metallographic examination.
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I TDR 638 Rev. 1 Page 17 of 50 Chemistry and Operating History Review Data Base The chemistry and operating history data were obtained from two sources. First, the on-site Plant Analysis group reviewed operational records to identify plant conditions during this time period (Ref. 13).
Then, we retrieved the primary plant chemistry parameters of interest from the GPUN computerized chemistry. data base.
The major plant activities that occurred between May 1983 and October 1984 are listed in Table 3. Within each of these periods, we 2
identified different plant conditions of RCS level, temperatare, pressure, circulation, and pH. Then, we reviewed the chemistry data for each time period.
Chemistry data selected to be of interest with respect to corrosion were pH, oxygen, lithium, sulfate and chloride. As an additional check on the ef fectiveness of chemistry controls, we calculat..d the lithium to '
sulfur ratio for each operating period. In cases where simultaneous analyses for lithium and sulfate exist, we calculated the Li/S ratio for each data point.
The data from the operational and chemistry investigations are plotted as a function of time in Appendix A.
l Results of Operational / Chemistry Review During both hot shutdown and cold layup conditions, TMI-l has maintained conditions within chemistry guidelines for about 95% af the i
time. For short time periods, some deviations have occurred whi h are discussed. in the balance of this section.
Chloride and Sulfate There have been short time periods where chlorides and/or sulfates have exceeded specified limits. In all instances chemistry data reflect that corrective actions were appropriately Snd promptly taken to return the concentrations of these species to specified levels. Collectively, these out-of-specification periods can best be described as normal chemistry " spikes".
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TDR 638 Rev. 1 Page 18 of 50 Oxygen In preparation for both the September 1983 and May 1984 hot functional tests, it was necessary for the RCS to be taken from a layup to an operating mode. During this transition, oxygen levels were higher than desired for optimum protection, but other factors made it very unlikely that corresion occurred. First, chloride and sulfate concentrations were controlled to acceptably low levels.
Second, the lithium level was maintained such that the minimum lithium to ' sulfur ratio was 66; the recommended minimum value for protection against IGSAC is 10 (Ref. 12). Chemistry control during these periods is summarized in Tabic 4.
Other Operational Considerations During the Integrated Leak Rate Test (ILdT) in April 1984, the primary side water level was maintained at about the 12th tube support plate for 8 days. This condition was both preceded and followed by drained layup with elevated pH, aerated water. Both sulfate and chloride levels remained within specification. Therefore, no OTSG tube corrosion -
was expected.
In August 1983 and May 1984 oxygenated water was injected into deoxygenated RCS during HPI testing. Most of these tests were conducted
' prior to the high temperature portion of the hot functional tests, and the oxygen introduced would have been consumed by hydrazine and/or hydrogen added for that purpose. One test was conducted on May 26, 1984, at the end of HFT and may be postulated to have injected 5000-6000 gallons of oxygen-saturated water. During this time period, however, the lithium to sulfur ratio was greater than 30 which was more than adequate to inhibit corrosion during this test.
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TDR 638 Rev. 1 Page 19 of 50 TABLE 3 Major Plant Evolutions, 5/83 to 10/24 Duration Event
'I Fill & Bubble Test June 1983 Peroxide Clean July 1983 i
Hot Functional Test Aug - Oct 1983 l
Circulating Wet Layup Oct - Nov 1983 DR-Vi Repair Nov 1983 .
Circulating Wet Layup Nov 1983 - Jan 1984 RC-PIB Repair Feb - April 1984 Integrated Leak Rate Test April 1984 Hot Functional Test May 1984 i
Non-Circulating Wet Layup May - June 1984 Tube Plug Recolling and June - Oct 1984 Bubble Testing i
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. i TDR 63G
' Rev. 1 Page 20 of 50 TABLE 4
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i Chemistry Summary Before Hot Functional Testing
(
! Oxygen, Li, SO4 , Cl Li/S ppm ppm ppe ppa Ratio Period Days _
1 8/83 29 0.3 .82-1.96 .047 .079 .05 .156 66-123 3/84 19 .075-2.2 1.06-2.17 .02 .047 .05 .110 127-240 i
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TDR 638 Rev. 1 Page 21 of 50 In-Plant Observations Leak Testing
! Since completion of the kinetic expansion repairs, several leak tests have been performed to measure primary-to-secondary leakrates and identify individual leaking tubes. These tests are summarized in Table 5.
No pattern of tube leakage can be seen. After the cooldown tests included in hot functional testing some increase in !?akage was seen.
Further investigation showed that this leakage was th'e result of leaks through a small number of tubes. These leaks were located in the expanded region within the upper tube sheet and were repaired by mechanically rolling a portion of the expanded area.
Of greatest significance is that since 1983 no tube which is in service has had a leak in an unexpanded portion of the tube. All leaks have either been due to bypass leaks in the expanded area or leaking plugs. .
Fiberscope Inspection of Selected Tubes A fiberscope inspection was performed (Ref.14) of six A-0TSG tubes which exhibited typical eddy current indications. During the inspection features were observed on 4 out of 6 tubes at the same elevation as the eddy current indications.
The visual features were "patchlike" rounded areas having an outer ring which was darker than the general tube surface and slightly reflective components in the interior. The patches were between 0.020 and 0.060" in diameter.
The patches appeared similar to surface deposits seen during the initial tube failure analysis. These earlier deposits were found to be associated with partial through wall intergranular attack.
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TDR 638 Rev. 1 Page 22 of 50 TABLE 5 Leak Tests in OTSC's Since 5/01/83 Results Repairs Month / Year Test Type Reason For Test Test of Kinetic 2 Leaking Tubes, Plugs Installed / Rerolled May 1983 Drip l
Expansion 8 Leaking Rolled Plugs 10 Leaking Explosive Plugs i
Bubble / Drip Final Test of Small Number of Slightly Repaired welded plug June 1983 Kinetic Expansion Leaking Tubes and Plugs in A OTSG - 1 Leaking welded plug i
Establish Baseline Baseline Leak Rate None Required Sept 1983 Kr-85 Tracer Leak Rate 1 gph Measure Baseline Slight Increase in None Required May 1984 Leak Rate Leak Rate 4-5 Leaking Tubes in Plug 3 tubes June 1984 Bubble / Drip Identify Leaking Tube (s) B-0TSG w/ welded plugs 6 Rolled Plugs Missing Reroll all W plugs Replugged tubes.
Bubble / Drip Small Number of Leaking Roll 8 Tubes Oct. 1984 Test Rolled -
Repairs Tubes, one welded plug Reweld Plug Note: No leaks seen in final October 1984 Bubble Test, after tube rolling.
TDR 638 Rev. 1 Page 23 of 50 Discussion General Removal of sodium thiosulfate from the TMI-l site and tighter operational chemistry controls implemented since 1981 have made it highly .
unlikely that the conditions to cause sulfur-induced IGA /IGSAC could be recreated. The steam generator layup guidelines are specifically designed to protect the steam generators from additional corrosion and are more stringent than B&W's generic recommendations, particularly in the areas of contaminant control and the use of elevated pH during cold layup.
Industry experience on B&W PWR's also does not reveal any other primary-side initiated attack mechanisms on Inconel OTSG cubing.
TMI-L compliance with operating and layup specifications has been excellent. Transient out-of-specification conditions, which were identified during plant operation, have been infrequent and corrected promptly by the plant operators. Plant conditions have always been bounded by those which were evaluated during corrosion testing and found to be satisfactory. '
The only period of possible vulnerability to corrosion would have exisced during the time when the OTSG's were drained for the kinetic expansion repair. During this period sulfur would have remained in the oxide film on the tube surf aces as peroxide cleaning had not yet been performed. During this time, however, eddy current testing done on the 100 tube surveillance sample did not reveal any growth of existing indications or any new indications. Thus, while the oxide film may have contained sulfur during thin time, there is no evidence that corrosion continued.
Under mechanical loadings induced by kinetic expansion or cooldown, l
areas of ICA/IGSAC could become more detectable by eddy current through several mechanisms:
- 1) creation of a linear grain boundary separation within the ICA islands as was seen in the LTCT (Ref. 8). This could produce a crack-like indication, or increase the overall grain boundary volume of the ICA patch. In addition, mechanical working can also produce increased grain boundary separation of ICSAC.
- 2) disconnected grains dropping out and leaving pits.
i i
0442 L a
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TDR 638 Rev. 1 Page 24 of 50 Two additional pieces of data from Ref. 16 lend support to the mechanical scenario. F ir s t , peripheral tubes consistently see higher loads than core tubes. Therefore, in the periphery, the highest stresses would also act on this ICA/IGSAC. Second, the A-0TSG cooled down more quickly than the B unit. The peak load during the most rapid cooldown (Re f.16) was 2 00 lb. in the A-0TSG, lit higher than in B-0TSG. Figure 1 is a representation of how the A-0TSG would have had significantly more tubes carrying loads high enough to cause ICA/IGSAC to become more detectable.
A previous study (Ref.15) on crack opening displacement of archive tubes with approximately .5" lorg through-wall cracks found that loads between 1500 and 2000 lbs. would induce permanent displacements in the vicinity of the cracks. Loads less than this would induce only elastic displacements with a load of 1000 lbs. producing an elastic displacement of approximately .002". Although tubes with cracks of this size are no longer in-service with the steam generators, this study does point out that one can expect local straining in the vicinity of smaller defects, but that it would be of proportionately lesser magnitude.
During the 1983 HFT, the most rapid cooldown was calculated to have induced loads in the tubing of between '1600 and 1700 lbs. ( Re f . 16 ) . It is such loads acting on the regions of IGA /ICSAC which we believe leads to grain dropping or grain boundary separation.
Detectability of Indications by Eddy Current It should be noted that the primary defects of concern for OTSG tube integrity (i.e. tube rupture) are circumferential cracks. The production of 0.540" standard differential eddy current technique is optimized and qualified for this type of defect. However, it can also be used for detecting different defect geometries as discussed below.
The,1984 tube ID indications as detected by eddy current and as seen during the fiberscope inspection had significantly dif ferent characteristics than the IGSAC responsible for the 1981 tube leakage.
The 1981 IGSAC consisted of tight, circumferential cracks that penetrated completely through the wall. The 1984 IGA as observed by fiberscopic examination appears rounded and does not completely penetrate the tube wall.
The different geometry will have a direct effect on detectability.
The current .540" S.D. eddy current technique was optimized for the IGSAC geometry; therefore, a dif ferent geometry will have a different detectability. The balance of this section of this report will discuss changes in sensitivity due to changes in indication geometry.
0442 L
TDR 638 Rev. 1 Page 25 of 50 Figure 2 (Figure 2 from Reference 2) shows the measured sensitivity of the .540" S.D. technique in the range of short circumferentially oriented defects. The shaded region in Fig. 2 identifies the range based on eddy current indication sizing in which 90% of the 1984 indications fall. It can be seen that the eddy current calls span the 0.3 volt detectability limit. (NOTE: Circumferential length is based on the number of 8X1 coils giving a signal and not an actual defect measurement.) Thus only slight changes in indication geometry could cause a particular indication to becoms detectable assuming the defects lie close to the detectability line.
5 In Figure 3a and 3b, we have taken the eddy current data and visual observations from the fiberscope inspection (shown in Table 6) and indicated where the indications would be in relationship to the calibration curves. The tubes for fibrescope inspection were chosen to
' be representative of the types of indications being found in 1984.
- All of the below-UTS indications (Figure 3b) are close to the 0.3 v fall detectability limits; the within-UTS indications (Figure 3a) do not into the detectable range. Therefore, it is reasonaole that before mechanical loading these indications may not have been detectable. '
Mechanical loading, as discussed in the previous section, can alter IGA /IGSAC geometry.
The large increase in the number of degraded tubes in A-0TSG and B-OTSG is also consistent with the scenario of pre-existing IGA /IGSAC becoming more detectable. ICA/IGSAC of 20-40 through wall extent could be estimated to have a length of about .015 .030 inches; this is below the 300 mV sensitivity for free-span detection (Figure 2). The inability to detect these small regions of IGA /IGSAC below the level of detectability was further confirmed by evaluations which took place during the (ong Term Corrosion Test Program. This program identified four patches of IGA which also were not detected (Table 7) by oddy current examination, s
f f
9 0442L
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'IDR 638 'S
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- Page 26 of 50 .,
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' Table 6 - Oxgarison of Preliminary FAly Current Data arul Fiberscope Results
. EC Results
.540 S.D. 8X1
. "A" - OTSG Colle Visual Observatione Tube Elevation Z T.W. Volta Volta Row US+5.4 98 1.6 1.6 2 ,,
89 124 Rounded indications poselble ICA
. US+4 Antal slignment of 3 rounded indications US+5.8 USt2.4 97 2.1 0.8 2 76 119' Small dark spot when scanains w/90' head USt5.5 62 2.8 1.3 2 66 129 15+27.6 Rounded indicatione - possible ICA 15+24.5 '
59 2.3 1.1 2 61 123 15t21. 8 Small dark spot - no detail visible 15+26 28 1.7 0.5 1 15t24. 7 92 1.3 0.3 1-2 i 57 128 US-2.6 Attally oriented rounded todications' US-1.5
' i. Small single rounded' indication 60 126 15-14.2/15-6.5 20 /31 1/1.0 NDD o
TDR 638 e Rev. 1 P age 27 of 50 TABLE 7 1 GA 20% T.W. in Sampt es Removed Fraa the LTCT Not Detected by Eddy Cur ren t IGA Loca t ion With Re spec t to Top of I CA Si ze Upper Tubesheet Circum. Depth Type Sample Tut >e Sec t io n 28" .030" .010" C-r ing ( 1)
A-24 -94 25 7/16" - 30 13/16" 2 t:" .035" .009" C-ring (1)
A-24-94 19 5/16" - 25 7/16" 19 5/16" - 25 7/lb" 27" .006" .008" C-ring (2)
A- 24 -94 12.5" .020" .013" Tube (1)
A-13-63 11" - 18 15/16" Note (1): These samples were exposed to thiosul f ate contaminant during the LTCT.
(2): This sample was exposed to sulfate contaminant du ri ng the LTCT.
- ER 634 Rev. 1 PJte 28 of 50
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Figure 2 - 1984 Eddy Current Date Page 29 of 50 Ceccared to Detectaability Limits- . . . . _ _
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.' Rev. 1 Figure 3a - Within - Tubesheet Page 30 of 50 I Fiberscope Indications Compared to Detectability Limit - . . . . ..
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- Page 31 of 50 Figure 3h - Below - Tubesheet Fiberscope Indications Compared to ,
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- TDR 638 Rev. 1 4 '
Page 32 of 50 i
t Conclusions f' 1. The TMI-1 layup guidelines are adequate to prevent any i identified mechanisms for primary side initiated corrosion of
- Inconel 600 OTSG tubes.
The TMI-1 layup guidelines have been adhered to since 2.
completion of the kinetic expansion repair. Minor deviations l'
- have been corrected promptly.
- 3. Vulnerability co corrosion may have existed during the period "
~
when the OTSG's were drained for repair prior to peroxide
+
cleaning. However, eddy current data and the absence of OTSG 1eakage during thi- time period do not show evidence of corrosion of OTSG tubes.
l t
I 4. Results of both GPUN-sponsored and industry corrosion test L 1
programs confirm that corrosion would not be expected during ,
i
'TMI-I operations since May 1983.
I j 5. Results of eddy current tests since 1982 do not indicate any ,
trends of indication growth of pre-existing indications. ;
i .
J 6. Leak rate testing and OTSG bubble testing do not indicate any increases in leakage or new leaks in the tube free span.
,' i
- 7. The eddy current data and visual observations are consistent j with a mechanism where previously existing areas of ICA/ICSAC are made more detectable by mechanical loading during kinetic '
expansion and thermal and hydraulic loading during cooldown i from HTT.
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TDR 638 Rev. 1 Page 33 of 50 References
- 1. R. Barley, J. A. Janiszewski, G. E. Rhedrick and M. Torborg, "Three Mile Island - Unit 1 OTSG Tubing Eddy Current Program Qualification," CPUN Technical Data Report 423. Rev. 1, January 1984.
- 2. G. E. Rhedrick, " Task IV Report on Eddy Current Indications Found Subsequent to Kinetic Expansion of TMI-1 Steam Generator Tubes," GPUN Technical Data Report 401, Rev. O. April 1983.
- 3. T. M. Moran, " Assessment of TMI-l Plant Safety for Return to Service After Steas Generator Repair " GPUN Topical Report 008, Rev. 3, August 19, 1983.
- 4. " Primary Water Chemistry," CPUN Specification SP-1101-28-001, Rev. 3, July 11, 1984.
- 5. "Long Term Corrosion Testing," GPUN Specification '
SP-1101-22-008, Rev. 2, Oct. 29, 1983.
- 6. "Long Term Corrosion Test Program of Nuclear Steam Generator Tubing Samples from Three Mile Island Unit 1 - First Interim Report," Westinghouse Electric Corp. Report No.
0914c/0127c/010684: 5, October 1983.
- 7. "Long Term Corrosion Test Program of Nuclear Steam Generator Tubing Samples from Three Mile Island Unit 1 - Second Interin Report," Westinghouse Electric Corp., May 1984.
- 8. "Long Term Corrosion Test Program of Nuclear Steam Generator Tubing Samplos from Three Mile Island Unit 1 - Final Report,"
Westinghouse Electric Corp., unpubitshed draft.
- 9. A. K. Agrawal, W. N. Stiegelmeyer, and W. E. Berry, " Final Report on Failure Analysis of Inconel 600 Tubes From OTSG A and B of Three Mile Island Unit 1," Battelle Columbus Laboratories, June 30, 1982.
- 10. J. V. Monter and G. J. Theus, "TMI-1 OTSG Corrosion Test Program - Final Report," Babcock & Wilcox Report No.
RDD:83:5433-01-01:01, May 9, 1983.
- 11. J. C. Griess and J. H. DeVan, " Behavior of Inconel 600 in Sulfur-Contaminated Boric Acid Solutions," Oak Ridge National Laboratory Report ORNL/TM-8544, March 1983.
0442L
1 i
Task 638 Rev. 1 Page 34 of 50
- 12. R. Bandy and K. ' Kelly, " Investigation of the Sulfur and Lithium to Sulfur Ratio Threshold in Stress Corrosion Cracking ,
of Sensitized Alloy 600 in Borated Thiosulfate Solution,"
USNRC NUREC/CR-3834, July 1984.
- 13. J. R. Kaspe r, "TMI-1 Primary Plant Ststus from 5/01/83 to 11/27/84," GPUN ION PA-TMI-84-47, Nov. 27, 1984.
- 14. J. A. Janiszewskt, " Observations During Fiberscope Inspection o f A-0TSG Tubes , Dec. 19, 1984," GPUN ION MT1-1550, December 28, 1984.
- 15. J. A. Janiszewski, " Leakage and Crack Opening Displacement of OTSG Tubes," GPUN Technical Data Report 480, Rev. 1.
- 16. G. L. Lehmann, T. M. Moran, J. R. Sipp and D. G. Slear, "TMI-1 OTSG Hot Testing Results and Evaluation," GPUN Technical Data Report 488, Rev. O, Oc tober 25, 1983.
- 17. TDR 652 " Evaluation of the 1984 Required Technical '
Specification Examination for the TMI-1 OTSG." March,1985.
0442L
TDR 638 Rev. 1 Page 35 of 50 APPENDIX A TMI-l CHEMISTRY DATA MAY 1, 1983 to OCTOBER 26, 1984 Contents ,
Table A1 - Chemistry Guidelines Applied to TMI-l 5/1/83 to 10/26/84 Figure Al Al Chemistry Data for TMI-1 5/1/83 to 10/26/84 0442L
TDR 638 Rev. 1 Page 36 of 50 Table A1 CHEMISTRY GUIDELINES APPLIED TO TMI-1 5/1/83 to 10/26/84 Operating Wet Drained Hot Shutdown Peroxide Layup (Hot Functional Testing) Cleaning Mode _ Lagug OTSG Primary Level Full Drained Full Full Maximum Chloride, ppa 0.1 0.1 0.1 0.2 Maximus Sulfate, ppa 0.1 0.1 0.1 Note 2
- Maximum Oxygen, ppe 0.1 N/A 0.1 Note 2 pH greater than 7.2 4.6-8.5 4.6-9.5 8.0-8.5 Li,ppe 1.0-2.0 1.0-2.0 1.0-2.0 1. 8-2. 5 Minimum 10 N/A Li/S ratio 10 10 Notest
- 2. Sulfate and oxygen were monitored but no limit was applied.
0442L
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