ML20198M703
| ML20198M703 | |
| Person / Time | |
|---|---|
| Site: | Farley  |
| Issue date: | 12/29/1998 |
| From: | Jacob Zimmerman NRC (Affiliation Not Assigned) |
| To: | NRC (Affiliation Not Assigned) |
| References | |
| NUDOCS 9901050328 | |
| Download: ML20198M703 (76) | |
Text
{{#Wiki_filter:._. - - , - December 29, 1998 LICENSEE: Southern Nuclear Operating Company, Inc. FACILITY: Joseph M. Farley Nuclear Plant (FNP), Units 1 and 2
SUBJECT:
SUMMARY
OF MEETING HELD ON DECEMBER 15,1998 The U.S. Nuclear Regulatory Commission (NRC) held a meeting with Southern Nuclear Operating Company, Inc. (SNC), on December 15,1998, at NRC Headquarters in Rockville, Maryland. The purpose of the meeting was to discuss matters related to current steam generator tube inspections at Farley Nuclear Plant, Unit 1. Enclosed is a list of attendees and meeting handouts. In accordance with Section 2.790 of NRC's " Rules of Practice," Part 2, Title 10 of the Code of l Federal Reaulations, a copy of this meeting summary and its enclosure will be placed in the l NRC's Public Document Room. l ORIGINAL SIGNED BY: Jacob 1. Zimmerman, Project Manager 1 Project Directorate 11-2 1 Division of Reactor Projects - 1/11 Office of Nuclear Reactor Regulation Docket No. 50-348
Enclosures:
As stated cc w/encls: See next page _D_istribution: t See next page { 1 l ! Wo\ 9901050328 981229 PDR ADOCK 05000348 G PDR g7- ,r r" r - r- - ~n
- e. . u .
.- L To receive a copy of this document, indicate in the box: "C" = Copy without attachment / enclosure "E" = Copy with ment / enclosure "N" = No copy *See previous concurrence OFFICE PM: @ h - LA:PDil-2* D:P W J>y l l NAME JZimmermaR:cn LBerry H&r@
DATE h/29/98 12/24/98 D/t/fi8 / /98 / /98 / /97 DOCUMENT NAME: G:FARLEY\121SSG.wpd OFFICIAL RECORD COPY
s# Ut% g a UNITED STATES
.g j 4
NUCLEAR REGULATORY COMMISSION g WASHINGTON, D.C. 20eeMm01
% ,, # December 29, 1998 LICENSEE: Southern Nuclear Operating Company, Inc.
FACILITY: Joseph M. Farley Nuclear Plant (FNP), Unit 1
SUBJECT:
SUMMARY
OF MEETING HELD ON DECEMBER 15,1998 The U.S. Nuclear Regulatory Commission (NRC) held a meeting with Southern Nuclear Operating Company, Inc. (SNC), on December 15,1998, at NRC Headquarters in Rockville, Maryland. The purpose of the meeting was to discuss matters related to current steam generator tube inspections at Farley Nuclear Plant, Unit 1. Enclosed is a list of attendees and meeting handouts. In accordance with Section 2.790 of NRC's " Rules of Practice," Part 2, Title 10 of the Code of Federal Reaulations, a copy of this meeting summary and its enclosure will be placed in the
- NRC's Public Document Room.
Jacob 1.
% b imme{r an, Project Manager Project Directorate 11-2 Division of Reactor Projects - 1/ll Office of Nuclear Reactor Regulation Docket No. 50-348
Enclosures:
As stated cc w/encts: See next page I
l t Distribution for Meetina Summary dated December 29. 1998 HARD COPY Docket File PUBLIC PD ll-2 Rdg. J. Zimmerman OGC ACRS cc: Licensee & Service List (with enclosure) E-MAIL S. Collins /R. Zimmerman (SJC1/RPZ) B. Boger (BAB2) J. Zwolinski(JAZ) H. Berkow (HNB) T. Martin (e-mail to SLM3) M. Tschiltz (MDT) L. Plisco, Rll P. Skinner, Ril J. Bartley, Ril J. Blake, Ril -
,, J. Strosnider, DE l
T. Sullivan, EMCB E. Murpny, EMCB S. Coffin, EMCB P. Rush, EMCB C. Beardslee, EMCB J. Tsao, EMCB S. Long, SPSB l l; i __
l Joseph M. Farley Nuclear Plant cc: Mr. L. M. Stinson Rebecca V. Badham General Manager - SAER Supervisor Southern Nuclear Operating Company - Southern Nuclear Operating Company ; Post Office Box 470 P. O. Box 470 -- l Ashford, Alabama 36312 Ashford, Alabama 36312 i Mr. Mark Ajiuni, Licensing Manager Mr. D. N. Morey ' Southern Nuclear Operating Company Vice President - Farley Project , Post Office Box 1295 _ Southern Nuclear Operating
~ Birmingham, Alabama 35201-1295 Company, Inc.
Post Office Box 1295 Mr. M. Stanford Blanton Birmingham, Alabama 35201 Balch and Bingham Law Firm Post Office Box 306 1710 Sixth Avenue North-Birmingham, Alabama 35201 Mr. J. D. Woodard Executive Vice President ; Southern Nuclear Operating Company l Post Office Box 1295 , Birmingham, Alabama 35201 State Health Officer Alabama Department of Public Health ! 434 Monroe Street l Montgomery, Alabama 36130-1701 l 1 Chairman Houston County Commission j Post Office Box 6406 , Dothan, Alabama 36302 ! l Regional Administrator, Region 11 U.S. Nuclear Regulatory Commission Atlanta Federal Center 61 Forsyth Street, S.W., Suite 23T85 Atlanta, Georgia 30303 Resident inspector U.S. Nuclear Regulatory Commission
-7388 N. State Highway 95 Columbia, Alabama 36319
LIST OF ATTENDEES l U.S. Nuclear Reaulatory Commission Jacob Zimmerman, NRR/DRPE/PDil-2, Farley Project Manager Herb Berkove, NRR/DRPE/PDil-2, Director Jack Strosnider, NRR/DE, Acting Deputy Director Ted Sullivan, NRR/DE/EMCB, Acting Branch Chief Emmett Murphy, NRR/DE/EMCB, Acting Section Chief Phil Rush, NRR/DE/EMCB Stephanie Coffin, NRR/DE/EMCB Cheryl Beardslee, NRR/DE/EMCB John Tsao, NRR/DE/EMCB Steve Long, NRR/DSSA/SPSB Jonathan Bartley, Region 11, Farley Resident inspector Jerry Blake, Region 11 via conference call Pierce Skinner, Region 11 via conference call Southern Nuclear Ooeratina Comoanv. Inc.. et al. Dave Morey
- Mark Ajiuni Brad Moore David Pugh-Sam Casey -
Rick Mullins Bill Stock, Westinghouse Dan Malinoski, Westinghouse T. A. Pitterle, Westinghouse P Others Dave Kupperman, Argonne National Lab Dan Mayes, Duke Power Tom Harrison, McGraw Hill l .- l Enclosure 1
MEETING HANDOUTS Enclosure 2
q Farley Unit 1 Steam Generator . Status , i I =, XRC/ Southern Nuclear Operating Company Rockville, MD December 15,1998 SOUTHERN i h COMPANY Energy to Serve YourWorld" 12/14/98 1
Agenda l - Introduction Dave Morey
- Overview Brad Moore NDE Dan Malinowski
- CM/OA Tom Pitterle Conclusion Dave Morey SOUTHERN L COMPANY
'vnms 1 t...,, a. s.- r . w.,u-
t Overview i FXP 1 Background NEI 97-06 status Unplanned outage due to leakage - August 1998 Refueling outage Summary f0k5A
, m.n. , ..,, s.- r. ..u-
e y [ FXP - Unit 1 - Background l 3 loop Westinghouse PWR
- Model 51 SG's - original Started up in 1977 - Effective plugging prior to cycle 15 - 7.1%
Scheduled to replace SG next outage - Spring 2000 O PAN wum < r...,, ,. s - r.. s,w l
e e NEI 97-06 Status Committed to implement by first outage 1999 Have been performing Degradation Assessment & CM/OA since 1997 , Have been following guidance of EPRI SG Exam Guidelines Rev 5 l Plan to implement SG procedures and programs fully by Spring 1999 SOUT N
. ,_ , _7.,,
Degradation Assessment l Degradation Mode Estimate Actual Top of tubesheet ODSCC 255 263 Wextex transition ODSCC Wextex transition PWSCC Tubesheet PWSCC TSP ODSCC (2V ARC) 100 104 Freespan ODSCC 21 98 U-bend PWSCC 3 2 AVB wear Cold leg pitting Cold leg thinning 12114M8 6 5"fJAL Enerry teSever Yearbir
h g i Tubes Repaired Cycle 15 Degradation SG A SG B SG C Total TTS ODSCC 57 73 90 220 WEXTEX ODSCC 1 1 2 4 WEXTEX PWSCC 8 4 6 18 TS PWSCC 7 8 8 23 Freespan ODSCC 20 46 38 104 TSP ODSCC 42 26 36 104 U-bend PWSCC 0 1 0 1 Permeability 23 19 46 88 Sleeves- parent tube 0 1 2 3 Pitting 0 1 0 1 Sleeve ends 3 0 3 6 Total 161 180 231 572 SOUTHERN
- =""'
e I L l Unit 1 - Forced August Outage : Experienced spiking leakage in 1B SG summer 1998
- Shutdown in August 1998 - Found leaking tube R25 C51 with two indications l
l - missed indication about 8" above sleeve l
- indication at end of sleeve ,v, . . c...,, s. r... w w
4 Major Issues Missed indication in freespan . Inadequate inspection at end of sleeve High growth rate SOUTHERN ... . ,. z.,,,. ?""
Unit 1 - Refueling Outage Experienced 20 gpd leakage in 1B SG after August startup Shutdown in October for refueling Found leaking tube R43C32 l
- one indication above first TSP SOUTHERN r...,,,.f*".T'
~
.l Additional Major Issues Free span indications above top of TSP's
- Detectability
- High growth rate 1 .
SOUTHERN COMPANY ! nnas n r...na.s, r. nts
.l I
Summary . s
- NDE
- Improved freespan analysis
- + Point of sleeve end program
- Preliminary CM/OA
- Extensive UTEC & in-situ
- Two pulled tubes
- Conservative deterministic analysis - 8 months operation ,
- Limit leakage to 50 gpd SOUTHERNAAa i t
COMPANY 12fl4198 13 Emergy roSerrr Year wir
s SNC Plan of Action Complete preliminary CM/OA PORC/NORB review of CM/OA Meet technical specifications and start up with 50 gpd limit Complete final OA within 120 days Mid-cycle shutdown if necessary
~
SOUT N
---_-----------------------_-------_-2""'T~*~""
t SG 1B Limiting Flaws :
. s A R25C51 - Limiting R43C32 spiking ~ 90gpd - steady ~20 gpd :
- crack in freespan - crack above TSP
- found in 8/98 outage - found in U1R15 outage
- oval tube -
bulged tube
- no UT, in-situ, pullec. UT, in-situ, not pulled t
met SLB met SLB
- SLB LR 2.5 gpm (est) -
SLB LR 0.6gpm (est)
- not sat for 3AP - not sat for 3AP 2633 psi -
>3628 psi SOUTHERN 4 h !
COMPANY ! r.a,,ra.s - v .a,w
Farley 1 October 1998 (IR15) SG Inspectma NRC Meeting NDE Enhancements Associated with Freespan ODSCC Detection l l . l ? FARLEY 11R15 SG INSPECTION NRC MEETING December 15,1998 ROCKVILLE, MARYLAND l l l i l t t ? l NDE Pnhancernent. Amm=*M with Freespan ODSCC Detectma
. - - _ , _ .- -. . -. . .-_.-- --. ~ - . - .- - - . - - - . Farley 1 October 1998 (IR15) SG Inspection NRC Meeting Freespan ODSCC NDE issues Leakage episodes of August 1998 forced outage and the period leading up to 1R15 presented issues related to detection of Freespan OPDSCC in 3 categories:
- 1. Indications close to the upper end ofinstalled sleeves
- 2. Straight length spans above the sludge pile or between TSPs
- 3. Freespan indications outside but within ~1" of the TSP edge Measures taken to addrets these issues are discuned within.
NDE Enhancenzats Ae='M with Freespan ODSCC Detection
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Table 4.5-1. Farley 1 HI Freespan ODSCC Historical Trend Outages 1R13-1R14-August '98 -1R15
+ Point Confirmed Indications for tubes >7.5" ATS or above TSPs SG Location IR13 1R14 8/98 F.O. IRIS l Axials Tubes Axials Tubes Axials Tubes Axials Tubes l A TSP + sl.5" 0 0 1 1 13 12 l TSH, TSP + 1 1 13 4 24 12
>1.5" i
B TSP + sl.5" 0 0 1 1 0 0 17 12 l TSH, TSP + 4 4 17 17 31 13 41 25
>1.5" 1
C TSP + sl.5" 0 0 3 1 11 10 l TSH, TSP + 8 8 14 12 10l* 41
>1.5" Totals TSP + sl.5" 0 0 5 3 0 0 41 34 TSH, TSP + 13 13 44 33 31 13 166* 78
>1.5" l I
- R6C10 has 23 Axial + Point calls O
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d Farley 1 Octobe.1998-(1R15) SG Inspection NRC Meeting Conclusions The implementation of NDE enhancements for Fadey 1 SG inspection was successful in addressing the issues that contributed to the tube leakage occurrences during 1998. Detection of near-sleeve-end freespan ODSCC was assured by examination of 1" centered about the sleeve end with + Point rotating coils for all in-service tubesheet sleeves. l l Detection of freespan ODSCC as typified by the 3/97 missed indication on 25/51 was enhanced by increased emphasis on reporting small Haw-like signals for examination with + Point coils. Conservative Raw identification guidance for near TSP (within 1.5") signals enhanced detection of possible Raw signals similar to the 3/97 signal at 43/32-1H+ 0.58". The numericalincreases in indications reported for 1R15 relative to prior outages confirms the effectiveness of these measures. NDE Enhanmnents Associated with Freespan ODSCC Detection
- -. - - --s.- ---- -
~
\
P Farley Unit 1 . Condition Monitoring Assessment i Preliminary Operational Assessment ; i NRC/SNOC SG Meeting December 15,1998 l i i Presented By: l T. A. Pitterle Westinghouse NSD , i l Q.tubeint\ala\ala98\F I NRCmtr t 298 ppt- 1
Discussion Topics . Condition Monitoring Assessment for Freespan ODSCC ,
- Description of Farley freespan ODSCC mechanism
-In situ test results
- Burst Pressure Assessment for R43C32
- Preliminary destructive exam results for R25C51
-Structural Assessment
-Leakage Assessment
- Conclusions 8 Preliminary Operational Assessment for Freespan ODSCC
- Method of evaluation for interim operating period ;
- Preliminary estimate of detection threshold from pulled tube R6C28
- Growth rate estimates <
- Bounding estimate of minimum interim operating period for Cycle 16 ,
- Plan for final operational assessment
- Conclusions .
i QtubcInt\nta\mim9tPF I N R Cmtr l 291t ppt- 2
--_---___ --___ _ ___ _ - - _____ - _____________-__--______-_--_ ____ N
Farley SG Freespan ODSCC Mechanism Description .. Initiation as Multiple Microcracks
- Oriented as axial bands and local patches
- Shallow axial bands is most frequent occurrence Occasionally at Distortions in Tubing
- Large ovality (R25C51-8/98 outage leaker)
-Bulge in tube (R43C32-lR15 leaker)
- Largest growth indications at 1R15
- Expect to be low frequency event Growth Mechanism
- Microcracks coalesce with modest axial growth to form macrocracks i
- Adjacent microcracks can vary significantly in depth-overall shallow macrocracks can have a local deep microcrack.which has little influence on structural or leakage integrity Structural and Leakage Concerns Associated with a Few Macrocracks that Show Deep Indications with a Significant Length (largest found is 1.2")
t I u.a,.m.mi.mi..,mn oc m ., . 3 i
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In Situ Testing at Farley-1 in '98 . 8/98 unplanned outage
- Leaker R25C51 in SG B, no other indications exceeded criteria 1R15 Outage
-Leaker R43C32 in SG B
- Total of 20 freespan indications leak tested and 14 indications pressure tested in all 3 SGs In Situ Test Methods
-Normal method Applied if tube location permits access with mandrel '
Leak test with mandrel , Pressure test with mandrel and bladder
- Whole tube tests: Seals at ends of tube, whole tube pressurized with water Tests above sleeves, peripheral indications, U-bends Bladder seal may be moved to flaw for some peripheral locations
. Application limited due to high exposures from manual manipulation of seals Q:tubeint\alaiala98T I NRCmtr t 298 ppt- 5
~
Selection of Tubes for In Situ Testing .: l v Leaking Tubes
- Selection Criteria - EPRI guidelines with Farley specific parameters Pressure testing (Axial ODSCC)
- Crack length > 0.46": TW crack length for 3APyo
- Maximum depth > 60%: Acceptable average depth for long flaw
- Defined average depth vs length from partial depth burst correlation
. Acceptable for 3APyo at LTL properties and reduced for NDE uncertainties Leak Testing (Axial ODSCC)
- Test if 2 of 3 NDE screening parameters exceeded
- Max. + Point voltage > 1.5: Based on in situ experience for non-leakers
- Max. depth > 75%: TW less breakthrough and NDE uncertainties
- Length at depth > 75% > 0.1": TW length for leakage Q:tubcint\a!a\ala98\F I NRCmtr I 298 ppt- 6
NDE for R25C51 2 large indications with small indications between and above large ind.
+ Point ,
- Upper indication: 6.78 volts,1.22", avg./ max. depth = 89%/97%
- Lower indication: 7.25 volts,0.94", avg./ max. depth = 91%/100%
- Coil lead-in, lead-out length corrections not applied to + Point data Bobbin
- 12.7 volt indication at upper + Point flaw
- Lower indication not inspectable with bobbin Effectively not inspected from '92 to '98 due to end effects of sleeve masking flaw indication for up to about 1" from end of sleeve Masking led to implementation of+ Point inspection at ends of sleeves for SG B in 8/98 and all sleeves at IR15 Review of Prior Cycle Bobbin Data
- Upperindication: 0.96 volt missed in IR14 inspection
- Lower indication: About 0.2 volt indication in 1992 at time of sleeving i
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e In Situ Test of R25C51 . Whole Tube Test Due to Presence of Sleeve
- Pressurization test could not be performed with a bladder Test Results
- Measured leak rates increased from 0.24 gpm at 1200 psi to 1.93 gpm at 2300 psi
- Sufficient pump flow could not be maintained to increase pressure above 2300 psi and testing was terminated
- SLB leak rate = 2.5 gpm
. Leak rates adjusted to hot SLB conditions (2560 psi AP) using EPRI leak rate adjustment procedure 1 Burst Pressure Analyses
- Burst pressure calculated from + Point depth profile to be > 2800 psi Q tubeint\alaWa98iFINRCmtr1298 ppt- 10
NDE for R43C32 in SG B . Leaker at 1R15 Outage Rotating Coil
- Located about 0.67" above 1st TSP
-+ Point: 14.8 volts,0.91", avg./ max. depth = 83%/100%
- 115 coil: 18.4 volts, 0.90", avg./ max. depth = 88%/100%
. May be more accurate than + Point due to partially inclined crack network UT
-Network of about 6 cracks dominated by deep axial and network ofinclined ind.
-Indications at bulge of about 2.5 mils in tube Bobbin
- 26.8 volts at IR15
- 2.57 volts at IR14 based on review of prior data with revised bobbin analysis
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. W= . 'A 18 115 5 80HF PC
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O In Situ Test for R43C32 in SG B . Whole Tube Test Due to Peripheral Location
- Leak Test
- Leak rates of 1.1 gpm at 2500 psi and 1.27 gpm at 2600 psi
- SLB leak rate = 0.61 gpm
- Pressure Test
- Sealing bladder moved to flaw location
- Bladder ruptured at 3628 psi Video Inspection
- Performed to characterize flaw opening following pressurization
- Used to assess whether a burst occurred and to estimate burst pressure E
Q tubcint\alawa981FINRCmtrI298 ppt- }b
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I l - Assessment of Burst Capability of R43C32 . Video examination and characterization of the degradation indicates that the burst pressure was not achieved
- Flexible hinge at upper end and circumferential extent at lower end allowed opening of a flank without tearing of the tube material ,
- Bending open of a flap-like portion of the crack led to extrusion and tearing of the >
pressure tool bladder
- Maximum pressure of 3628 psi achieved .
Actual applied pressure would be slightly lower for the case of flow through the opening
-The AP across the crack flanks is less than the primary-to-secondary AP
- Magnitude of 3 AP could be ~600 psi less than 4440
- RT Pressure of 4140 psi would have been sufficient to demonstrate 3 AP Owing to flexibility at the ends of the crack, it is judged that 500 psi above the test pressure might have been achieved and could meet 3 AP
- Pressurization with the bladder does not result in a decrease in applied load with deformation of the crack o +,uu.,isrisac.i,i29s m. I7
Schematic of R43C32 Crack Opening Following Yn Situ Test Mesh type area that permitted rotation of the flap without tearing of the tip. Significant radial slope. His region is P slightly pushed Tube Axis out. , His flap is significantly deformed in the radial direction. Torn ligament His region is Formation of a hinge along I slightly pushed this zone allowed flap to push out. out and bladder to break. Overalllength is about 0.9" De circumferential extent His region is not permitted the hinge to form visibly pushed without crack extension. out. Q:tubcint\ala\ala98\F I NRCmtr I 298 ppt- }b
Summary ofIn Situ Test Results ! Pressure Tests
- 14 indications pressure tested
- 10 indications demonstrated burst margins > 3APyo
- R25C51 and R43C32 in SG B that did not reach 3APyo separately discussed -
- 2 peripheral indications with whole tube tests were leakage limited R15C68, SG C: Test reached 3873 psi (hot adjusted); predicted burst pressure of at least 5412 psi for 0.59" flaw; conclude burst pressure would exceed 3APso R10C2, SG C: Test reached 3213 psi (hot adjusted); predicted burst pressure of >4033 psi for 0.66" flaw; conclude burst pressure near 3APuo within uncertainties of prediction Leak Rate Tests
- 20 indications leak tested
- 6 indications with leakage (2 in each SG) including R25C51 and R43C32 in SG B that -
are separately discussed
- Additional indication SLB leak rates R32C17, SG A: 0.045 gpm R43C32, SG A: 0.006 gpm R10C2, SG C: 0.041 gpm R15C68, SG C: 0.013 gpm 4-Q:tubeint\ala\ala98\FINRCmtrl298 ppt- }h
a Preliminary Destructive Exam Results for R25C51 Relevant Background for Evaluation of the Indications in R25C51
- About 0.2 volt bobbin indication in 1992 (time of sleeving) at elevation just above sleeve end (elevation oflower large flaw at 8/98 outage)
- About 0.96 volt bobbin indication (missed call upon look-back) in 1R14 at elevation about 8" above sleeve (elevation of upper large flaw at 9/98 outage)
- Leaking tube leading to 8/98 unplanned outage large flaws foundjust above sleeve and about 8" above sleeve.
- SG secondary side pressurized for leak testing after 8/98 inspection :
- Tube pressurized to 2300 psi pressure differential during in situ testing at 8/98 outage
- Tube plugged at 8/98 unplanned outage (1.182 EFPY)
- Tube deplugged and pulled at 1R15 outage (1.29 EFPY)
Preliminary Destructive Exam Results for R25C51 J Post-pull NDE
-+ Point Results (lab analyst)
Voltage increase from 6.9 to 10.9 for lower flaw and 6.4 to14.6 for upper flaw Lengths 0.78 and 0.86 before and after pull for lower flaw and 1.11 and 1.13 for upper flaw . Average depth changes from 91.9% to 83.0% before and after pull and 80.7% to 86.1% for upper flaw
- Bobbin voltage increases from 15.1 to 23.1 volts for lower flaw and 12.7 to 24.7 volts for upper flaw Observations
- Tube found to have 4 to 5 mil radial ovalization which is large for a straight leg tube
- Cracks aligned along major diameter of ovalized tube
- Only upper crack visible with no apparent diameter change at flanks of crack from prior 2300 psi pressure test t
Q-tubeint\ala\ala98\F I NRCmtr l 298 ppt- 21
Preliminary Destructive Exam Results for R25C51 . Leak Test Results - Room Temperature Test in Large Leak Facility
- Lower flaw i
Leaking only drops at normal operation (0.00006 gpra hot adjusted) SLB leak rate of 0.66 gpm (iiot adjusted) Likely did not contribute significantly to in situ test SLB estimate of 2.5 gpm
- Upper flaw Room temperature leak rate of 9.95 gpm at 2170 psi AP reached leak test system capacity In situ test had 1.93 gpm leak rate at 2300 psi AP Indication clearly changed from 8/98 outage in situ test to post-pull condition Indication may have been damaged from plant heatup/cooldowns, plant operation with tube in plugged condition, secondary side pressurization with tube in plugged condition and tube removal operations
Conclusion:
post-pull test not a valid test due to apparent damage to indication following in situ test; no further evaluation planned for these leak rate measurements Burst Test Results
- Lower flaw burst at 4352 psi (hot adjusted) which essentially satisfies 3APyo = 4400 psi burst margin
- Upper flaw burst at 2633 psi which satisfies AP SLB =2560 psi but not 3APyo Influence of post in situ test flaw damage on burst pressure cannot be estimated l
Burst pressure > APsta is consistent with burst pressure predictions from + Point data o ..i n.i.wi. mu ..... i m , i . 22 1 __ ..____------I
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Farley-1 Pulled Tube R25C51 - Crack 2 (SHT +~7.5") Pre-pull NDE, Post-pull NDE and Destructive Exam Data
+ Point NDE Data ion _ _ _ _ _
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- Ligament 30 _
15 & 16 Length 1.09 1.13 1.19 (in.) l l : Avg. 84.4 86.12 87.se 20 - - l l Depth (%) 1 . . . . . l l ! Ligament 18 & 19 10 - -- l l
-8.24 in.. zero depth 0- - - L' 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 8 8.1 8.2 8.3 8.4 8.5 Axial Length (in.) !
I Q:tubeint\ala\ala98\F INRCmtr l 298 ppt- 24
Condition Monitoring Structural Assessment ;; Conclusions Conclusions Based on 8/98 Unplanned Outage and 1R15 Burst pressure for upper indication of R25C51 of SG B exceeds the SLB pressure differential but does not satisfy the 3APyo burst margin The R43C32, SG B indication has a burst pressure > 3700 psi and may not satisfy the burst margin guideline although flaw geometry indicates burst margin could be satisfied Tube R10C2, SG C expected to meet the 3AP so burst niargin although uncertainty in the assessment prevents a firm conclusion All other indications satisfy 3APyo burst margin Overall Conclusion
- Structural integrity adequate to prevent burst at SLB conditions for all SGs
-3AP yo burst margin guideline not satisfied for I or 2 indications in SG B although adequately satisfied in SGs A and C o w.i.w. n uc .im ic. 26
~
Condition Monitoring Leakage Assessment l-Conclusions
- In situ leak rates at normal operating conditions exceed plant operating leak rates prior to shutdown
- Likely associated with ligament tearing during plant cooldown and secondary side pressure tests Two indications in each SG are large enough to leak at SLB conditions SLB leak rates for each SG
- SG A: 0.051 gpm
- SG B: 3.1 gpm including R25C51 from 8/98 unplanned outage
-SG C: 0.054 gpm Overall Conclusions
- Freespan ODSCC SLB leak rate of about 3.1 gpm
- Freespan ODSCC combined with predicted 3.8 gpm for ODSCC at TSP intersections yields total SLB leak rate of about 6.9 gpm
-Total SLB leakage less that Farley-1 SG limit of 23.8 gpm for acceptable radiological consequences per 10 CFR 100 and GDC-19 I
.m ..w.w .2m n o c,. .i m . 28
Preliminary Operational Assessment Preliminary Operational Assessment
- Performed to evaluate an acceptable time to operate until final assessment completed
- Conservatively performed since only necessary to justify an interim operating period of -
about 4 months Methods for Preliminary Assessment
- Estimate detection threshold from prior Farley-1 pulled tube R6C28
- Determine bounding growth rate Confirm that R25C51 has bounding growth rate Determine R25C51 growth rate from destructive exam depth profile (currently preliminary) and detection threshold
- Apply detection threshold and bounding growth per EFPY to estimate time to 3AP yo burst margin and to throughwall Comparison of time to throughwall with times to Cycle 15 leakage provides a check on ,
detection threshold + growth Q1ubeint\ala\ala98\F1NRCmtr1298 ppt- 30
Voltage Growth Considerations ~' NRC concern that R43C32 AV was 26.8 V in 1.29 EFPY and applying that growth to a freespan indication using the ODSCC correlation would result in not meeting 3AP yo in a relatively short time after startup
- Evaluation was performed to obtain a conservative first estimate It is inappropriate to use the ODSCC correlation to predict burst of freespan indications ;
-The variance of the burst pressure with regard to crack length is much less than the variance with regard to the bobbin amplitude per the ODSCC ARC !
Geometry features of the crack likely increased the bobbin amplitude and 1 L may not have significantly increased the probability of burst
- Throughwall lengths significantly increase bobbin voltages in the absence of uncorroded ligaments The ODSCC voltage correlation is much more conservative than depth based predictions
- Example: 0.75" long throughwall crack, Paof 2900 psi expected for LTL material
- Uncertainty to lower 95%/LTL is about 500 psi for depth correlation and about 1800 psi for voltage correlation e) tui.vintiala sala9N\l'INitemie l292 git 4- 3l
Figure 12: Burst Pressure vs. Crack Length 7/8" x 0.050", Alloy 600 MA SG Tubes, of = 68.8 ksi 12.0 - 11.0 y 10.0 l o Test Data Regression Curve 90 ik o so
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Preliminary Estimate of Detection Threshold R6C2C Destructive Exam Results
- Pulled at 1R14 to assess bobbin and + Point detectability for freespan ODSCC
- 5 small indications destructively examined Compare field detection with destructive exam average and maximum depths to assess detection R6C28 reevaluated by 1R15 analysts to assess potential improvements ,
Detection of R6C28 Indications
- 1R14: Detected 2 of 5 indications destructively examined Detected average / maximum depths of 29%/49%,29W45%
Did not detect average / maximum depths of 24%/44%,16%/38%, and 22%/49%
- 1R15: Detected 3 of 5 indications Detected average / maximum depths of 29%/49%,29%/45%, and 16%/38%
Did not detect average / maximum depths of 24%/44% and 22%/49% Preliminary Estimate of Detection Thresholds
- Average depth = 25%
- Maximum depth = 45%
.---_------------------------__--_-----------------------_------__-J
~
Table 5.2-3 Summary of1997 Destructive Examination, NDE Data, and Burst Characteristics of SG B. R6C28 Farlev Unit 1 R6C28 Elevation Burst Calculated Burst Flaw Specimen (above TFS) Pressure Burst Max. Avg. Crack No. Elevation of Max. Burst Location (psig) Pressure Depth Depth Length (in.) Ligaments Depth aboveTFS Above TTS SB (contron
- N/A 11.500 11.781 N/A N/A N/A N/A N/A 14.8" above TSP 1 3A 3" to 16.5" 10.400 8.505 47.8% 29 % 2.08 4 9.38" 10.1" 3B 16.5" to 27" 10.700 9.468 45% 29% 0 64 2 21.45" 21.5" 4A 27" to 42.5" 10.400 9.214 44 % 24 % 1.15 1 39.12" 39.2" 4B 42.5" to TSPI 10.700 10.114 38% 16 % l.04 1 46.81" 46.9" 5A 1"to 10"above 10,800 9,678 49% 22 % 1.01 1 2.56" above TSPI 2.6" above TSPI TSPI
*: Sample SB was selected as a non-degraded control specimen. After burst testing, very shallow patch IGA / SCC, which did not influence the burst pressure was detected.
Crack Elevation above TFS Destructive Exam Field '97 Laboratory Number Crack Elevation Ec dy Current Call Eddy Current Call Above TTS (in.) '97 '98 '97 Bobbin RPC Bobbin Bobbin RPC 4 3-4" on burst spec. 3A 0.29 volt 0.33 volt 0.21 volt 0.30 volt 0.20 volt ; 5 8-9" on burst socc. 3A NDD 0.19 volt 0.16 volt 0.16 volt 0.13 volt 6 9-12"on burst socc. 3A 9.06 to 11.14 NDD NDD 0.27 volt 0.16 volt 0.26 volt , 6B 13-14" on burst socc. 3A 29Yd48*/. avejmax. depth 0.17 volt 0.16 volt 0.15 volt O.17 volt 0.23 volt
- 7 17-18.5"on burst socc. 3B 21.16 to 21.80 0.30 volt 0.27 volt 0.25 volt 0.30 volt 0.15 volt 8 20" on burst spec. 3B 29Yd45% avg / max depth NDD 0.15 volt NDD NDD 0.08 voit 9 23-25" on burst socc. 3B 0.35 volt 0.30 volt 0.20 volt 0.37 volt O.19 volt 10 36-37" on burst socc. 4A 38.65 to 39.80 NDD NDD NDD NDD 0.14 volt i1 38-39"on burst spec. 4A 24Yd44% avg / max depth NDD NDD NDD NDD 0.07 volt ;
12 39-40"on burst soec. 4A NDD NDD 0.19 voit NDD 0.14 volt 13 47-48" on burst spec. 4B 46.32 to 47.36 NDD 0.13 volt 0.29 volt 0.23 volt 0.15 volt i 16Yd38% ave / max deoth 14 2-4" above TSP 1 on burst spec. 2.07 to 3.08" above TSP 1 NDD NDD NDD 0.25 volt 0.19 volt SA 22Yd49% ave / max deoth , t Q tubeint\ata\ala98tFINRCmtrl298 ppt- 35 . f
Growth Rate Estimates . Bobbin Voltage Growth Trends
- Evaluated 121 bobbin voltage growth rates from Cycle 15
- Average growth of 0.83 volt which reduces to 0.29 volt when the 6 largest indications are excluded Average of 0.29 volt is comparable to that for ODSCC at TSP intersections
- Average growth for indications within 1.5" of 2.24 volt which reduces to 0.69 volt ;
when 5 largest indications are excluded Larger growth at edges of TSPs may be due to voltage increasing exponentially with depth and larger indications were not detected at 1R14 Bounding Depth Growth Rate
- EOC depths from + Point data for 6 largest indications and pulled tube destructive exam profile for R25C51
- Growth is EOC depths minus detection threshold Prior cycle bobbin volts used to estimate depths above undetected threshold associated with voltages of about < 0.5 volts - BOC depths increased by about 5% for bobbin volts near 1 volt
(<l.35 volts),10% for indications near 1.5 volt and 15% for 2.57 indication in R43C32
- Bounding growth rate of 49% per EFPY from R25C51 destructive exam data Expect final value to be reduced when final destructive exam data are obtained with reductions in depths for uncorroded ligaments Q tuheint\ala\stn98\FI NRCmtrl298 ppt. 36
Preliminary Estimate of Large Freespan Growth Rates SG Tube Elevation Bobbin Volts EOC-15 + Point Estimated Estimated BOC15m Growth EOC15 EOC14"> Length Avg. Max. Avg. Max. Avg. Max. Depth Depth Depth Depth Depth Depth A R43C32 IH-0.47 7.38 0.98 0.66 81.1 % 97 % ~30% ~50% 51.1 % 47 % R32C17 IH+0.78 11.08 1.14 0.80 79.3 % 97.0 % ~30% '~ 50% 49.3 % 47 % R8C2 2H+0.83 6.00 1.35 0.53 83.9 % 99.0 % ~30% ~50% 53.9 % 49 % B R43C32 1H+0.84 26.83 2.57 0.91 83.1 % 100 % ~40% ~60% 43.1 % 40% R25C51 Above TSH 12.7 0.97 1.09 84.4 % 99.0 % ~30% ~50% 54.4 % 49 % Sleeve (1.19)6 (87.6)6 (100 %)6 (57.6%)6 ( 50%)6 Note 3 ~0.2") 0.78 91.9 % 99.0 % ~40% ~60% 51.9 % 39 % , ( )' ( )' ( )' C R10C2 IH+1.10 13.78 1.45 0.66 87.0 % 99.0 % ~35% ~55% 52.0 % 44 % R15C68 TSH+25.9 9.21 NDD 0.59 67.7 % 95.0 % ~25% ~45% 42.7 % 50 % Maximum Growth 57.6 % 50 % Maximum Growth per EFPY' ' 49 % 45 % Notes
- 1. Estimates for NDD indications are detection thresholds estimated from pulled tube R6C28. Estimates for larger voltages are judgments on increased voltage effects. Additional detection data from pulled tubes R25C51 and RGC10 are expected to improve the BOC voltage estimates.
- 2. Estimated from growth rate reevaluations with knowledge of an indication at EOC-15
- 3. Indication too close to sleeve for bobbin detection
- 4. Estimated from 1992 inspection prior to sleeve installation in 1992. Growth to 1998 reflects many cycles of growth
- 5. Maximum growth for R25C51 reflects 1.182 EFPY (unplanned outage) while others reflect full cycle 1.29 EFPY.
Growth in maximum depth to throughwall likely occurred in < l.12 EFPY at 7/26 leakage spike.
- 6. Maximum and average depths from destructive examination ofupper and lower indications in R25C51.
Q tuhcint\mlabla93WINRCmtrl29Rppt. 38
Bounding Estimate Minimum Operating Period for Cycle 16 Method of Assessment
- Detection thresholds for maximum depth and average depth from destructive examination (R6C28 at present)
- Maximum growth rate in depth per EFPY from growth analysis of R25C51
- Project time to throughwall for leakage considerations Compare with Cycle 15 operating experience Good agreement between projected time to TW (1.02 EFPY) and actual time (1.06 EFPY for 1st 4 gpd step increase) supports adequacy of detection threshold and growth
- Assume EOC-16 crack length of 1.2" - bounds all inspection results for cracks of significant depth
- Farley-1 specific LTL properties for occurrence of freespan ODSCC Developed from Farley-1 CMTRs for 60 heats of material found to have freespan ODSCC
. Flow stress of 67.5 ksi at 650 F
- Calculate average depth (67%) for a 1.2" crack that satisfies burst pressure of 3AP yo =
4440 psi
- Calculate minimum operating period as time for average depth to grow from detection threshold of 25% to 67% - check sensitivity to uncertainties iii a.i uu.viiwiniii mi,i evneri . 3y
Bounding Estimate - Minimum Operating Period for Cycle 16 Cycle lengths important for the operational assessment are: ,
- Cycle 15 Full Cycle = 1.29 EFPY Time to Leakage Outage = 1.182 EFPY Time to August 7th 60 gpd operating leak rate spike = 1.157 EFPY Time to July 26th 29 gpd operating leak rate spike = 1.12 EFPY Time to July 3d 2 gpd operating leak rate spike = 1.06 EFPY - Cycle 16 short cycle operating length for evaluation = 1.10 EFPY Conclusions - Time to throughwall = 1.12 EFPY based on detection threshold of 45% ,
maximum depth and growth rate of 49% per EFPY
- Time to reach 3AP yo = 0.86 EFPY based on detection threshold of 25%
average depth and growth rate of 49% per EFPY
- Time to reach APsts (87% avg. depth for 1.12") = 1.26 EFPY based on detection threshold of 25% average depth and growth rate of 49% per EFPY - Extreme case for time to reach 3APyo = 0.69 EFPY based on detection threshold of 30% average depth and growth rate of 54% per EFPY !
l
Farley Unit-1 R-70A, B, C Main Steam Radiation Monitors 100 90 R-70B gain adjustment made on 7/27/98 to set inline to grab samples. 80 R-70B data prior to 7/27/98 have been re-scaled to agree with grab sample results. 70 g 60 k R-70A j 50 R-70B R-70C
.3 40 30 20 10 -- ---- - - - --- - - - - - - --
w 6/30/98 7/4/98 7/8/98 7/12/98 7/16/98 7/20/98 7/24/98 7/28/98 8/1/98 815/9 8 8/9/98 8/13/98 8/17/98 8/21/98 Date/ Time P Q tubcint\ala\ain98WINIWmtrl298 ppt. 4!
e Estimate of Time to Significant Throughwall Indication for Cycle 16 Basis Acceptable i EFPY ' Time to 29 gpd leakage spike on 7/26 1.12 To throughwall based on maximum depth growth rate of 49% per 1.12 EFPY and detection threshold of 45% max. depth (0 Time to first ~2 gpd spike on 7/3/98 1.06 To throughwall based on maximum depth growth rate of 49% per 1.02 . EFPY and detection threshold of 50% max. depth (0 Notes
- 1. Detection threshold estimated from non-detected flaws on pulled tube R6C28. Value to be updated based on destructive exam results from pullud tubes R25C51 and R6C10
F CALCULATION OF BOUNDING EOC16 AVERAGE DEPTH ADE0Ci6 = GROWTH /EFPY is
- EFPYi6 + DTADB Ci6 EOCi5 i BOCi6 ADEOCi6 ={ AD - DTADB Cis] / EFPY s}
- EFPYi6 + DTAD EOCi5 i i6 i6 ADEOCi6 = [AD /EFPY s]*EFPY -DTADB Cis*EFPY /EFPYis +DTADB Ci6 ADEOCi6 = 87.6 *0.86 /1.182 - 30
- 0.86/1.182 + 25
=
63.7 - 21.8 + 25 , i ADE Ci6 = 66.9% ' where: i6 ADE0Ci6 = Average depth at EOC i6 DTADB C16 = Detection threshold average depth at BOC i
Preliminary Estimates ; Time to Average Depth for Burst Margin of 3APuoW Estimated Average Avg. Depth Depth Comment Acceptable Detection Growth EFPY Threshold per EFPY 25 % 49 % Preliminary Estimate of Largest 0.86 ' Growth Rate and Detection 10.3 months Threshold from Pulled Tube R6C28 25 % 54 % Conservative Growth and R6C28 0.78 Detection Threshold 30 % 49 % Conservative Detection Threshold 0.76 and Preliminary Estimate of Largest Growth Rate 30% 54 % Conservative Growth and Detection 0.69 Threshold 8.3 months
- 1. Average depth of 67% for 3APuo = 4440 psi. Farley-1 specific freespan ODSCC LTL properties with a 67.5 ksi flow stress (at 650 F) applied for allowable depth since pulled tube and field experience show cracks occur in tubing with above average material properties.
Applied length of 1.2 inch corresponds to the largest indication length found (1.19" by destructive exam) at IRl5 for R25C51 and R43C32. The use of generic LTL properties for a 1.2 inch length results in an acceptable average depth of 63.5%. Q.tuhcint\aJa\ala98W I N R Cmtr l 291t ppt. O
General Approach for Final Operational Assessment Freespan ODSCC above sludge pile is only challenge to tube integrity Only about 1 to 2 indications challenge structural or leakage integrity
- Largest indications in Cycle 15 (R25C51 and R43C32) associated with extreme straight leg ovality and a bulge. Tends to indicate largest growth rates are not randomly located and should be a low probability event Evaluate short cycle length, about 1.1 EFPY vs 1. 29 EFPY, as an alternate to a mid-cycle inspection Refine detection threshold and POD based on pulled tube analyses (3 tubes)
- About 20 data points: 5 from R6C28,4 from R25C51,10 to 15 from R6C10 Implement administratively reduced Cycle 16 operating leakage limit of TBD gpd including leakage spikes
- Limit of 50 gpd being implemented for interim period until assessment completed Perform probabilistic tube integrity analyses to reduce conservatism of bounding evaluations Potentially demonstrate that the principal tube integrity challenge is that of a modest (few gpm) SLB leak rate
e General Approach for Final Operational Assessment Probabilistic analysis methods
- Growth of depth profiles (method developed for axial PWSCC) at detection threshold with growth distribution and allowance for new indications i Burst and leakage evaluated for EOC depth profiles based on burst correlation and qualified CRACKFLO leakage model with defined uncertainties
- Evaluating multi-cycle (3 cycles) probabilistic model that adjusts new indications, POD and NDE uncertainties to first two cycles to predict third cycle (Cycle 16)
- NDE uncertainties to be developed from comparisons of+ Point sizing analyses with pulled tube, ODSCC crack profiles from free span and TSP intersections Acceptance criteria for probabilistic analyses
- Calculated SLB leak rate at 95%/95% confidence, summed over freespan ODSCC and ODSCC at TSP intersections, shall 'oe less than the Farley SG allowable leak rate of 23.8 gpm Leakage limit consistent with radiological does limits of 10 CFR Part 100 and GDC-19
- Calculated tube burst probability at SLB conditions, summed over freespan and TSP ODSCC, shall be less than 3x10-2 Requirement based on NEI 97-06 allowable burst probability of 5x10-2 with an allowance of 2x10-2 for bursts from unknown causes
- APstn = 2405 psi based on assuming PORV availability can be established
_ _ _ _ _ _ _ _ _ _ _ _ = . ._ _ =___
c. Overall Conclusions ? Preliminary Operational Assessment Farley-1 can conservatively op rate a minimum of 8 months for Cycle 16 while maintaining acceptable structural and leakage integrity -
- Final operational assessment to determine acceptable cycle length As a defense in depth measure, Farley-1 will operate with a leakage limit of 50 gpd including spikes until the fmal operational assessment is completed
- Final operational assessment to establish leakage limit for acceptable cycle length ,
Q:tubcint\ala\ala98T I N RCmtr l 298 ppt- 46}}