ML20199C562
| ML20199C562 | |
| Person / Time | |
|---|---|
| Site: | Zion File:ZionSolutions icon.png |
| Issue date: | 06/03/1986 |
| From: | ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY |
| To: | |
| Shared Package | |
| ML19292F437 | List: |
| References | |
| CEN-331-NP, CEN-331-NP-R01, CEN-331-NP-R1, NUDOCS 8606180191 | |
| Download: ML20199C562 (150) | |
Text
n 425b(82W6)/mes-1 CEN-331-NP REV 1 NP COMBUSTION ENGINEERING, INC.
June 3, 1986 ZION Units 1 & 2 Steam Generator Tube Repair Using Leak Tight Sleeves FINAL REPORT Combustion Engineering, Inc.
Nuclear Power Systems Windsor, Connecticut BbObi s a l.
PDR P
P t
THIS PAGE LEFT INTENTIONALLY BLANK
425(82W6)/ mis-2 ABSTRACT A technique is presented for repairing degraded steam generator tubes in pressurized water reactor Nuclear Steam Supply Systems (NSSS). The technique described alleviates the need for plugging steam generator tubes which have become corroded or are otherwise considered to have lost structural capability. The technique consists of installing a thermally treated Inconel 690 sleeve which spans the section of original steam generator tube which requires repair, and welding the sleeve to the tube near each end of the sleeve.
This report details analyses and testing performed to verify the adequacy of repair sleeves for installation in a nuclear steam generator tube. These verifications show tube sleeving. to be an acceptable repair technique.
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425(82W6)/cis-3 TABLE OF CONTENTS Section Title Page
1.0 INTRODUCTION
1-1 1.1 PURPOSE 1-1
1.2 BACKGROUND
1-1 2.0
SUMMARY
AND CONCLUSIONS 2-1 3.0 ACCEPTANCE CRITERIA 3-1 4.0 DESIGN DESCRIPTION OF SLEEVES, PLUGS AND INSTALLATION EQUIPMENT 4-1 4.1 SLEEVE DESIGN DESCRIPTION 4-1 4.2 SLEEVE MATERIAL SELECTION 4-1 4.2.1 General Corrosion and Corrosion Product Release Rates 4-1 4.2.2 Stress Corrosion Cracking Resistance 4-2 4.2.3 Coordinated Phoschate Chemistry 4-2 4.2.4 Faulted Phosphate Chemistry Control 4-3 4.3 SLEEVE-TUBE ASSEMBLY 4-3 4.4 PLUG DESIGN DESCRIPTION 4-4 4.5 WELDED PLUG ASSEMBLY 4-4 4.6 SLEEVE INSTALLATION EQUIPMENT 4-5 4.6.1 Remote Controlled Manipulator 4-5 4.6.2 Manipulator Elevator 4-5 4.6.3 Tube Brushing - Cleaning Equipment 4-6 4.6.4 Tube Size Rolling Eauipment 4-6 4.6.5 Sleeve Installation Eauipment 4-6 .
4.6.6 Sleeve Expansion Equipment 4-6 4.6.7 Sleeve Welding Equipment 4-7 4.6.8 Nondestructive Examination 4-7
425(82W6)/ mis-4 TABLE OF CONTENTS (Continued)
Section Title Page 4.7 PLUG INSTALLATION EQUIPMENT 4-8 4.7.1 Remote Controlled Elevator 4-8 4.7.2 Sleeve Size Rolling Equipment 4-8 4.7.3 Plug Installation Equipment 4-8 4.7.4 Plug Welding Equipment 4-8 4.7.5 Nondestructive Equipment 4-9 4.8 ALARA CONSIDERATIONS 4-9
4.9 REFERENCES
TO SECTION 4.0 4-9 5.0 SLEEVE EXAMINATION PROGRAM 5-1 5.1 ULTRASONIC INSPECTION 5-1 5.1.1 Summary and Conclusions 5-1 5.1.2 Ultrasonics Evaluation 5-1 5.1.3 Test Equipment
- 5-2 5.1.4 Defect Samples 5-3 5.1.5 Detailed Results 5-3 5.2 EDDY CURRENT INSPECTION 5-4 5.2.1 Summary and Conclusions 5-5 5.2.2 Multi-Frecuency Eddy Current Equipment Requirements 5-5 5.2.3 Defect Samples 5-5 5.2.4 Results and Conclusions 5-6 J
5.3 VISUAL INSPECTION 5-7 5.3.1 Summary and Conclusion 5-7 5.3.2 Lower Weld Evaluation 5-7 4
5.3.3 Upper Weld Examination 5-8
425(82W6)/ mis-5 TABLE OF CONTENTS (Continued)
Section Title Page 5.3.4 Test Equipment 5-8 5.3.5 Defect Standards 5-9 6.0 SLEEVE-TUBE CORROSION TEST PROGRAM 6-1 6.1
SUMMARY
AND CONCLUSIONS 6-1 6.2 TEST DESCRIPTION AND RESULTS 6-1 6.2.1 Modified Huey Tests 6-1 6.2.2 Capsule Tests 6-3 6.2.3 Pure Water Stress Corrosion Cracking Tests 6-3 6.2.4 Sodium Hydroxide Fault Autoclave Tests 6-4
6.3 REFERENCES
FOR SECTION 6.0 6-5 7.0 MECHANICAL TESTS OF SLEEVED AND PLUGGED STEAM GENERATOR TUBES 7-1 7.1
SUMMARY
AND CONCLUSIONS 7-1 1 7.2 CONDITIONS TESTED 7-1 7.3 WELDED SLEEVE TEST PARAMETERS AND RESULTS 7-1 7.3.1 Axial Pull Tests 7-1
<.3.2 Load Cycling Tests 7-2 7.3.3 Collapse Testing 7-3 ,
7.3.4 Burst Testing 7-3 l
7.4 WELDED PLUG TEST PARAMETERS AND RESULTS 7-4 7.4.1 Weld Integrity 7-4 7.4.2 Axial Load Capability 7-4 l 8.0 STRUCTURAL ANALYSIS OF SLEEVE-TUBE ASSEMBLY 8-1 l
8.1
SUMMARY
AND CONCLUSIONS 8-1 8.1.1 Design Sizing 8-1 l
425(82W6)/ mis-6 TABLE OF CONTENTS (Continued)
Section Title Page 8.1.2 Detailed Analysis Summary 8-1 8.2 LOADINGS CONSIDERED 8-5 8.2.1 Upper Tube Weld Pull-Out Load 8-5 8.2.2 Lower Stub Weld Push-Out Load 8-5 8.2.3 Weld Fatigue 8-6 8.3 REGULATORY GUIDE 1.121 EVALUATION FOR ALLOWABLE 8-6 SL.EEVE WALL DEGRADATION 8.3.1 Normal Operation Safety Margins 8-7
! 8.3.2 Postulated Pipe Rupture Accidents 8-8 8.4 EFFECTS OF TU8E LOCK-UP ON SLEEVE LOADING 8-9 8.4.1 Sleeved Tube in Central Bundle Region 8-9 Free at Tube Support Plates 8.4.2 Sleeved Tube Near Bundle Periphery 8-14 Free at Tube Support Plates .
8.4.3 Sleeved Tube in Central Bundle Region Lock-up at Lowest Support Plate 8-15 8.4.4 Sleeved Tube Near Bundle Periphery, Lock 8-16 at Lowest Support Plate 8.4.5 Effect of Tube Prestress Prior to Sleeving 8-16 8.4.6 Lower Stub Weld Pushout Due to Restrained 8-17 Thermal Expansion 8.5 SLEEVED TUBE VIBRATION CONSIDERATIONS 8-17 8.5.1 Effects of Increased Stiffness 8-17 8.5.2 Effect of Severed Tube 8-17 8.6 STRUCTURAL ANALYSIS FOR NORMAL OPERATION 8-19 l
8.6.1 Fatigue Evaluation of Upoer Sleeve-Tube Weld 8-19 8.6.2 Fatious Evaluation of Lower Stub Weld 8-20
i 425(82W6)/Q1s-7 TABLE OF CONTENTS (Continued)
Section Title Page 8.7 SLEEVE / TUBE PLUG WELD FATIGUE EVALUATION 8-22
8.8 REFERENCES
FOR SECTION 8.0 8-26 8A FATIGUE EVALUATION OF UPPER TUBE / SLEEVE WELD 8A-1 88 FATIGUE EVALUATION OF LOWER STUB WELD 88-1 8C FATIGUE EVALUATION OF TUBE SLEEVE PLUG WELD 8C-1 9.0 SLEEVE INSTALLATION PROCESS VERIFICATION 9-1 9.1 WELD INTEGRITY 9-1 9.2 SLEEVE INSTALLATION IN RINGHALS 2 9-2 10.0 EFFECT OF SLEEVING ON OPERATION -
10-1
425(82W6)/ mis-8 i LIST OF TABLES TABLE NO. TABLE PAGE 3-1 REPAIR SLEEVING CRITERIA 3-2 3-2 WELDED PLUG CRITERIA 3-4 6-1 STEAM GENERATOR TUBE SLEEVE CORROSION TEST 6-2 6-2 STEAM GENERATOR TUBE SLEEVE CAPSULE TESTS 6-4 7-1 SLEEVE-TUBE ASSEMBLY MECHANICAL TESTING RESULTS 7-5 8-1 ANALYSIS RESULTS
SUMMARY
TABLE 8-3 8-2A AXIAL MEMBER PHYSICAL PROP 0RTIES - 36 INCH 8-10A CENTRAL BUNDLE REGION 8-28 AXIAL MEMBER PHYSICAL PROPERTIES - 36 INCH 8-10B NEAR BUNDLE PERIPHERY 8-2C AXIAL MEMBER PHYSICAL PROPERTIES - 27 INCH 8-11A CENTRAL BUNDLE REGION 8-2D AXIAL MEMBER PHYSICAL PROPERTIES - 27 INCH 8-11B NEAR BUNDLE PERIPHERY 8-3A AXIAL LOADS IN SLEEVE WITH TUBE NOT LOCKED 8-12A INTO SUPPORT PLATE - 36 INCH 8-38 AXIAL LOADS IN SLEEVE WITH TUBE NOT LOCKED 8-12B INTO SUPPORT PLATE - 27 INCH 8-4A AXIAL LOADS IN SLEEVE WITH TUBE LOCKED INTO 8-13A SUPPORT PLATE - 36 INCH 8-4B AXIAL LOADS IN SLEEVE WITH TUBE LOCKED INTO 8-138 SUPPORT PLATE - 27 INCH 8-5 UPPER SLEEVE WELD-TRANSIENTS CONSIDERED 8-21 8-6 LOWER STUB WELD-TRANSIENTS CONSIDERED 8-23 8-7 SLEEVED TUBE PLUG WELD-TRANSIENTS CONSIDERED 8-25 s
425(82W6)/als-9 LIST OF FIGURES FIGURE NO. TITLE PAGE 4-1 STEAM GENERATOR TUBE SLEEVE 4-11 4-2 SLEEVE INSTALLATION 4-12 4-3 STEAM GENERATOR TUBE PLUG 4-13 4-4 PLUG INSTALLATION 4-14 4-5 MANIPULATOR POSITIONING ELEVATOR AND 4-15 UPPER WELD HEAD 4-6 MANIPULATOR ELEVATOR 4-16 4-7 TUBE BRUSHING - CLEANING TOOL 4-17 4-8 TUBE SIZE ROLLING TOOL 4-18 4-9 SLEEVE INSTALLATION TOOL 4-19 4-10 SLEEVE EXPANSION EQUIPMENT 4-20 4-11 UPPER WELDING HEAD ASSEMBLY 4-21
, 4-12 LOWER WELDING HEAD ASSEMBLY 4-22 4-13 SLEEVE WELDING HEAD POWER SUPPLY UNIT 4-23 4-14 EDDY CURRENT TEST EQUIPMENT 4-24 4-15 ULTRASONIC TEST EQUIPMENT 4-25 4-16 VISUAL TEST EQUIPMENT 4-26 4-17 PLUG WELDING HEAD ASSEMBLY 4-27 4-18 PLUG WELDING HEAD POWER SUPPLY UNIT 4-28 l
5-1 FOCUSED TRANSDUCER FOR SLEEVE WELD INSPECTION 5-10 5-2 ULTRASONIC INSTRUMENT DISPLAY FOR SLEEVE 5-11 WELD INSPECTION 5-3 CALIBRATION MILLED NOTCHES STANDARD 5-12 5-4 PRODUCTION WELD ACCEPTABLE 5-13 5-5 MILLED NOTCH STANDARD - NOTCHES 5-14 5-6 PRODUCTION WELD - REJECTABLE 5-15 l
425(82W6)/als-10 LIST OF FIGURES (Continued)
FIGURE NO. TITLE PAGE 5-7 PRODUCTION WELD - ACCEPTABLE 5-16 5-8 PRODUCTION WELD - REJECTABLE 5-17 5-9 DUAL CROSSWOUND PROBE EDDY CURRENT FIELD 5-18 5-10 EDDY CURRENT TEST SIGNALS-SLEEVE AND TUBE FLAW 5-19 5-11 TUBE INSPECTION CURRENT TEST SIGNALS-SLEEVE END 5-20 WITHOUT AND WITH A TUBE FLAW 5-12 TUBE INSPECTION EDDY CURRENT TEST SIGNALS-EXPANSION 5-21 AND WELD WITHOUT AND WITH A TUBE FLAW 5-13 SLEEVE INSPECTION EDDY CURRENT TEST SIGNALS- 5-22 SLEEVE FLAWS, EXPANSION AND WELD 5-14 SLEEVE INSPECTION EDDY CURRENT TEST SIGNALS- 5-23 SLEEVE FLAWS AT EXPANSION TRANSITION 6-1 PURE WATER CORROSION TEST SPECIMENT 6-6 6-2 CAUSTIC CORROSION AUTOCLAVE TEST SPECIMEN 6-7 8-1A WELDED SLEEVE / TUBE ASSEMBLY IN CENTRAL BUNDLE REGION 8-27 8-1B WELDED SLEEVE / TUBE ASSEMBLY NEAR BUNDLE PERIPHERY 8-28 8-2 LOWER JOINT ROLL OVER 8-29 8-3A SYSTEM SCHEMATIC IN CENTRAL BUNDLE REGION AND 8-30 NEAR PERIPHERY 8-38 SYSTEM SCHEMATIC NEAR BUNDLE PERIPHERY AND 8-31 CENTRAL BUNDLE REGION
- 8-4 MODEL OF SLEEVE AND LOWER TUBE 8-32 8-5 MODEL OF UPPER WELD 8-33 8-6 FINITE ELEMENT MODEL OF UPPER TUBE WELD 8-34 8-7 FINITE ELEMENT MODEL OF LOWER STUB WELD 8-35 8-8 FINITE ELEMENT MODEL OF SLEEVED TUBE PLUG WELD 8-36 8-9 TUBESHEET PERFORATED PLATE LIGAMENT STRESSES 8-37 8A-1 UPPER SLEEVE / TUBE WELD ANALYSIS (1) 8A-2
425(82W6)/als-11 LIST OF FIGURES (Continued)
FIGURE NO. TITLE PAGE 8A-2 UPPER SLEEVE / TUBE WELD ANALYSIS (2) 8A-3 8A-3 NODE AND ELEMENT IDENTIFICATION AND SECTIONS 8A-4 0F INTEREST 8A-4 NODAL AND ELEMENT STRESSES AT SECTIONS OF 8A-5 INTEREST 8A-5 STRESS RESULTS SECTION 1 THROUGH WELD 8A-6 8A-6 STRESS RESULTS SECTIONS 2 AND 3 8A-7 8B-1 SLEEVE-TUBE WELD (FULL POWER) 88-3 88-2 SLEEVE-TUBE WELD (FULL POWER AND THERMAL LOAD) 88-4 88-3 SLEEVE-TUBE WELD (REACTOR TRIP AND THERMAL LOAD) 88-5 88-4 SLEEVE-TUBE WELD (SEC. HYDROTEST) 88-6 88-4A SLEEVE-TUBE WELD (PRIM. HYDROTEST) 88-6A 88-5 LOWER TUBE / SLEEVE WELD ANALYSIS 88-7 88-5A LOWER TUBE / SLEEVE WELD ANALYSIS 88-7A 8C-1 PLUG-SLEEVE-TUBE WELD (FULL POWER) 8C-2 8C-2 PLUG-SLEEVE-TUBE WELD (SEC. HYDROTEST) 8C-3 8C-2A PLUG-SLEEVE-TURE WELD (PRIM. HYDROTEST) 8C-3A 8C-3 SLEEVED TUBE PLUG ANALYSIS 8C-4 8C-4 SLEEVED TUBE PLUG ANALYSIS 8C-5
425(82W6)/ mis-12 LIST OF APPENDICES APPENDIX NO. NO. OF PAGES A PROCESS AND WELD OPERATOR QUALIFICATION A-1 A.1 SLEEVE WELDING AND SLEEVE WELDER A-2 QUALIFICATION A.2 REFERENCES TO APPENDIX A A-2
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4 425b(82W6)/ mas-10
1.0 INTRODUCTION
1.1 PURPOSE The purpose of this report is to provide information sufficient to support a technical specification change allowing installation of steam generator repair sleeves in Zion Units 1.and 2. This report demonstrates that reactor operation with sleeves installed in the steam generator tubes will not increase the probability or conse-quence of a postulated accident condition previously evaluated.
Also it will not create the possibility of a new or different kind of accident and will not reduce the existing margin of safety.
Combustion Engineering (C-E) provides a leak tight sleeve which is welded to the steam generator tube near each end of the sleeve. The sleeve spans the degraded area of the parent steam generator tube in the tube sheet region. The steam generator tube with the. welded sleeve installed meets the structural requirements of tubes which are not degraded. Design criteria for welded sleeves were prepared to ensure that all design and licensing requirements are considered.
Extensive analyses and testing have been performed to demonstrate i that the design criteria are met.
The effect of sleeve installation on steam generator heat removal capability and system flow rate are discussed in this report. Heat removal capability and system flow rate are considered for instal-lation of up to two thousand sleeves in each steam generator.
Aftersieevesareinstalledandinspected,abaselineexaminationis performed using eddy current (ET) techniques. The ET examination serves as baseline to determine if there is sleeve degradation in later operating years. The ET examination and criteria for plugging sleeved generator tubes if there is unacceptable degradation are described in this report.
Plugs will be installed if sleeve installation is not successful or if there is unacceptable degradation of sleeves or sleeved steam generator tubes. Analyses and testing are described which demon-strate that the welded plug design which is provided by C-E is leak tight and will meet structural requirements during normal operating and postulated accident conditions.
1.2 BACKGROUND
The operation of Pressurized Water Reactor (PWR) steam generators has in some instances, resulted in localized corrosive attack on the inside (primary side) or outside (secondary side) of the steam
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1-1
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425(82W6)/ mis-14
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generator tubing. This corrosive attack results in a reduction in steam generator tube wall thickness. Steam generator tubing has )
been designed with considerable margin between the actual wall l thickness and the wall thickness required to meet structural '
requirements. Thus it has not been necessary to take corrective action unless structural limits are being approached.
Historically, the corrective action taken where steam generator tube wall degradation has been severe has been to install plugs at the inlet and outlet of the steam generator tube when the reduction in wall thickness reached a calculated value referred to as a plugging criteria. Eddy current (ET) examination has been used to measure steam generator tubing degradation and the tube plugging criteria accounts for ET measurement uncertainty.
Installation of steam generator tube plugs removes the heat transfer surface of the plugged tube from service and leads to a reduction in the primary coolant flow rate available for core cooling. Installa-tion of welded steam generator sleeves does not significantly affect the heat transfer removal capability of the tube being sleeved and a large number of sleeves can be installed without significantly affecting primary flow rate.
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425b(82W6)/ mas-2 2.0
SUMMARY
AND CONCLUSIONS The sleeve dimensions, materials, and joints were designed to the applicable ASME Boiler and Pressure Vessel Code. An extensive analysis and test program was undertaken to prove the adequacy of
' the welded sleeve. This program determined the effect of normal
, operating and postulated accident conditions on the sleeve-tube assembly, as well as the adequacy of the assembly to perfonn its intended function. Design criteria were established prior to perfoming the analysis and test program which, if met, would prove that the welded sleeve is an acceptable repair technique. Based upon the results of the analytical and test programs described in this report the welded sleeve fulfills its intended function as a leak tight structural member and meets or exceeds all the established design criteria.
Evaluation of the sleeved tubes indicates no detrimental effects on the sleeve-tube assembly resulting from reactor system flow, coolant chemistries, or thermal and pressure conditions. Structural analyses of the sleeve-tube assembly have established its integrity
- under normal and accident conditions. The structural analyses have beenperformedon[- ] inch long sleeves, but shorter length sleeves [ ] ma be installed at Zion. Discussion of why the analyses of [ inch long sleeves are conservative for shorter sleeves s given in Section 8.1.
i Mechanical testing using ASME code stress allowables has been
- performed to support the analyses. Corrosion testing of typical sleeve-tube assemblies have been completed and reveal no evidence of j sleeve or tube corrosion considered detrimental under anticipated service conditions.
Welding development has been performed on clean tubing, dirty tubing which has been taken from pot boiler tests, and " hot" or contaminated tubing taken from a steam generator. C-E has installed eighteen welded sleeves in a demonstration in a Ringhals Unit 2 steam generator in May 1984. C-E has also installed 59 sleeves in a Ringhals Unit 2 steam generator in May 1985 and 36 sleeves in Ginna steam generators in February 1986. These sleeve installations and a demonstration showing that welded sleeves can be successfully inspected using visual examination or ultrasonic testing are described in this report.
Welded plugs have been developed for sleeved steam generator tubes in the event that a sleeve installation is not successful. No detrimental effects resulted from subjecting plug-sleeve-tube assemblies to pressure conditions or mechanical tests. Structural analyses of the installed plugs have demonstrated their integrity under normal operating and accident conditions.
In conclusion, steam generator tube repair by installation of welded sleeves is established as an acceptable method. Repair of sleeved steam generator tubes using welded plugs is also established as an acceptable method.
2-1
425b(82W6)/ mas-3 3.0 ACCEPTANCE CRITERIA The objectives of installing sleeves in steam generator tubes are twofold. The sleeve must maintain structural integrity of the steam generator tube during normal operating and postulated accident conditions. Additionally, the sleeve must prevent leakage in the event of a through hole in the wall of the steam generator tube.
Numerous tests and analyses were performed to demonstrate the capability of the sleeves to perform these functions under normal operating and postulated accident conditions. Design and operating conditions for the Zion Units 1 and 2 steam generators are defined as:
Primary Side: 594*F (hot side) 2235 psig operating) 650*F(design) 2485 psig design)
Secondary Side: 506*F (100% load) 705 psig operating -
100% load) 600*F (design) 1085 psig (design)
Table 3-1 provides a summary of the criteria established for sleeving in order to demonstrate the acceptability of the sleeving techniques. Justification for each of the criterion is provided.
Results indicating the minimum level with which the sleeves sur-passed the criteria are tabulated. The section of this report describing tests or analyses which verify the characteristics for a particular criterion is referenced in the table.
Plugs are installed in the sleeved steam generator tubes when the tubes cannot be successfully repaired with sleeves. The objective of the plugging is to prevent leakage between the primary and secondary sides of the steam generator during normal and postulated accident conditions.
Table 3-2 provides a summary of the criteria for welded plugs. The format in Table 3-2 is the same as Table 3-1.
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425(82W6)/ mis-17 TABLE 3-1 PEPAIR SLEEVING CRITERIA Reference Criterion Justification Results Section
- 1. Sleeve is leak tight. Leakage between 4.0 primaryand secondary side is prevented when steam generator tube
. is breached.
- 2. Sleeve-tube assembly Sleeve-tube assembly 8.0 functional integrity must meets applicable ASME be maintained for normal Code requirements.
operating and accident '
conditions.
- 3. Axial load cycle 200 pounds Duplicates thermal 7.3 to 1700 pounds for 1000 cycle loading from a cycles, 200 pounds to 2550 normal operating and pounds for 1000 cycles transient conditions, without weld failure.
- 4. Pressurization of annulus Prevention of sleeve 7.3 between sleeve and tube failure for through does not collapse sleeve hole in tube wall.
at 1500 psig.
- 5. Pressurize welded sleeve Factor of safety of 8.3 to 4500 psig without three (3) for normal burs ting. operating conditions.
- 6. Exposure of sleeve-tube Sleeve-tube assembly 6.0 assembly to various required to function primary and secondary under coolant chemistries without loss chemistries, of functional integrity.
- 7. Non-destructive examina- Periodic examination 5.0 tion of tube and sleeve of tubes and sleeves to levels of detect- required to verify ability required to show structural adequacy, structural adequacy.
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425(82W6)/ mis-18 TABLE 3-1 REPAIR SLEEVING CRITERIA Reference Criterion Justification Results Section
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- 8. Welded sleeve installation Sleeve repair should l 10.0 does not significantly not reduce power affect system flow rate removal capability of :
or heat transfer capabil- reactor or steam i ity of the steam generator below rated generator. value. g 1
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425(82W6)/ mis-19 TABLE 3-2 WELDED PLUG CRITERIA Reference Criterion Justification Results Section
- 1. Plug is leak tight. Leakage between 7.4 primary and secondary side is prevented when steam generator tube is breached.
- 2. Axial load of 1791 pounds Factor of safety of 7.4 applied on plug welded to three (3) on load sleeve-tube assembly, corresponding to pressure differential across plug at normal operating conditions.
- 3. Plug-sleeve-tube assembly Plug-sleeve-tube 8.0 functional integrity must assembly meets ASME be maintained for normal Code requirements, operation and accident "- -
conditions.
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425b(82W6)/ mas-4 4.0 DESIGN DESCRIPTION OF SLEEVES, PLUGS AND INSTALLATION EQUIPMENT 4.1 SLEEVE DESIGN DESCRIPTION The sleeve is shown in Figure 4-1.
length, has a nominal outside diameter The of sleeve
]to[ d a.] in is up, an
]. fhe sleeve material is nominal thermally treated wall thickness Inconel of[690.
As shown in Figure 4-1 the sleeve is chamfered at the upper end to prevent hang-up with equipment which is used to install or inspect thesleeve(orsteamgeneratortube).[
J ,
The outside diameter of the sleeve was selected to provide a gener-ous clearance between so that the sleevethe sleeve slides freelyand steam through thegenerator tube tube [during insta1]ation.T There were two considerations in selecting the sleeve thickness: first, the sleeve has sufficient thickness so that the steam generator tube with the sleeve bridging the degraded section of the tube meets the structural requirements of the undamaged steam generator tube (without benefit from the tube). Second, there is a large margin in thickness over what is required structurally to allow for sleeve eddy current measurement uncertainty. The inside diameter of the sleeve is large enough so that the flow rate and heat transfer capability of the steam generator tube are not signif-icantly affected by sleeve installation.
4.2 SLEEVE MATERIAL SELECTION The tubing from which the sleeves are fabricated is procured to the requirements of ASME Boiler and Pressure Vessel Code Case N-20. In addition, a thermal treatment is also specified in order to impart greater corrosion resistance and lower the residual stress level in the tube.
The primary selection criterion for the sleeve material was its corrosion resistance in primary and fault secondary PWR environ-ments. Specific resistance to pure water and caustic stress corro-l sion cracking were considered.
C-E's justification for selection of this material is based on the following information:
4.2.1 General Corrosion and Corrosion Product Release Rates Information published in Reference 1 indicates that the corrosion product release rate of Alloy 690 is superior to Alloy 600 in both l high temperature ammoniated and borated waters. The corrosion rate 4-1
425(82W6)/Q1s-21 of Alloy 600 is significantly higher, especially in borated waters, with the concurrent fomation of thicker oxides. The latter is a potential concern during themal transients which could initiate crud bursts.
4.2.2 Stress Corrosion Cracking Resistance Alloy 600 in a variety of themal treatments exhibits known susceptibility to intergranular stress corrosion cracking (IGSCC) in high temperature pure water solutions. Deaerated boric acid at high temperature is relatively undisassociated and thus the resistance-susceptibility of Alloy 600 to IGSCC is comparable. Recent investigations (Reference 2) have shown that pure water IGSCC resistance of Alloy 600 can be improved via controlled thermal-mechanical processing.
Laboratory testing on Alloy 690 (References 1 and 3) tubing show it to be immune to high temperature deaerated pure H 0 IGSCC in a 2 variety of thermal-mechanical conditions. Appare itly, resistance to stress corrosion cracking (SCC) in Alloy 690 is the result of a compositional improvement rather than a specific microstructure thus making it more attractive for a welded sleeve design.
Tests in pure water environments with oxygen present at elevated temperatures resulted in IGSCC of 304 stainless steel, Alloy 600, and Alloy 800 within a stressed crevice region (Reference 1). Alloy 690 in a variety of metallurgical conditions exhibited complete 4 immunity to SCC in this test program with exposure times of 48 weeks. For comparison, the former materials exhibited evidence of
> IGSCC corrosion after two weeks exposure.
4.2.3 Coordinated Phosphate Chemistry
- An extensive laboratory test program utilizing high temperature pot
- and model boiler facilities was performed by C-E in the early 1970's. The results of these heat transfer tests indicated that
' phosphate chemicals concentrated in areas of steam blanketing and i
produced thinning of the Alloy 600 heat transfer tubing. This
- phenomena was observed over a wide range of sodium to phosphate ratios with and without feedtrain corrosion product additions. The corrosion product in all cases consisted of a green nickel-rich l phosphate compound containing lesser amounts of iron and chromium.
In this program Alloy 800 and 304 stainless steel tubing were also tested and determined to be more resistant to phosphate wastage. A general correlation between corrosion rate and the nickel content of the transfer tube alloy was observed.
l The corrosion resistance of Alloy 690 in coordinated phosphate l
solutions has not been extensively tested at C-E. Based on the observed correlatj,on between corrosion rate and nickel concentrationM'ts performance should be better than Alloy 600.
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425(82W6)/rsis-22 4.2.4 Faulted Phosphate Chemistry Control If condenser leakage occurs it is possible to alter the sodium to phosphate ratio of the coordinated phosphate solution such that caustic conditions result in the boiler water. Under these conditions, caustic induced SCC may occur. While none of the presently used heat transfer tubing alloys are totally resistant to this form of corrosion attack, mill annealed Alloy 690 shows equivalent resistance to mill annealed Alloy 600 in concentrated solutions (Reference 3). Thermally treated Alloy 690 exhibited notable improvement in this stress corrosion test as compared with mill annealed Alloy 690 and a slight improvement as compared with thermally treated Alloy 600.
Similarly, acid forming impurities species introduced as the result of condenser leakage may concentrate in low flow regions to aggressive levels. Chlorides have been shown to readily produce SCC of austenitic stainless steels and iron base Alloys, e.g. Alloy 800 under these conditions. Immunity to chloride induced SCC was a primary criteria for the switch to nickel-base (Alloy 600) tubing for nuclear steam generating units. Laboratory tests indicate that Alloy 690 also exhibits immunity to chloride induced SCC probably due to its intermediate nickel concentrations (Reference 1).
Recent information obtained via cooperative test programs with the Electric Power Research Institute has identified acid sulfur species as aggressive impurities leading to accelerated corrosion of Alloy 600 steam generator tubing. The modes of attack observed with different sulfur species and concentrations consist of wastage, intergranular attack (IGA) and IGSCC. The latter produced primary to secondary leakage of Alloy 600 tubing representative of all comercial heat treatments, i.e. mill annealed, sensitized, thermally treated. The environment consisted of volatile chemistry control faulted with acidified (H 7503 ) fresh water impurities.
Alloy 690 (mill annealed) tubing Exp6 sed to this environment for longer test periods did not exhibit through-wall IGSCC.
- 4.3 SLEEVE-TUBE ASSEMBLY l
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425(82W6)/ mis-23 The weld, repair weld and welding operators have been qualified for making upper and icwer welds and the weld qualification documents are given in Appendix A.
4.4 PLUG DESIGN DESCRIPTION 4.5 WELDED PLUG ASSEMBLY 44
425(82W6)/ mis-24 for installing in Appendix A.
The weld and weld operator qualification document plugs in sleeved steam generator tubes is given 4.6 SLEEVE INSTALLATION EQUIPMENT in a steam These systems The equipment used for remote installation of sleeves generator is made up of the following basic systems.
are:
1.
Remote Controlled Manipulator
- 2. Manipulator Elevator Tube Brushing-Cleaning Equipment
' 3.
- 4. Tube Size Rolling Equipment 5.
Sleeve Installation Equipment
Nondestructive Examination Equipment f the sleeves
- 8. i These systems, when used together, allow installat on oIn th without entering the steam generator. exposure to r Remote Controlled Manipulator a transport 4.6.1 The remote controlled manipulator (Figure 4-5) serves asin vehicle for inspection or repair equipment primary head. nipulator The manipulator consists The manipulator of twoleg major components; is installed d and provides between axial the m leg and manipulator arm.the tube sheet and bottom of the prima Each arm is moved The (vertical) the head ann, movement probe armof the andarm. a swivel arm. l t ic motors.
independently with encoder position controlled e ec rh squar swivel arm allows motion for tool alignment ide thein botComputer manway triangular pitch tube arrays.
allows the operator to move sleeving tools
-9 Manipulator Elevator 4.6.2 1"
6 4-5
425b(82W6)/ mas-5 4.6.3 Tube Brushing-Cleaning Equipment 4.6.4 Tube Size Rolling Equipment 4.6.5 Sleeve Installation Equipment l
4.6.6 Sleeve Expansion Equipment O
l 4-6
425(82W6)/ mis-26 1
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4.6.7 Sleeve Welding Equipment 1
4.6.8 Nondestructive Examination Three types of nondestructive examination equipment are used during 4
-the sleeving process. They are as follows: eddy current test (ET) equipent (Figure 4-14), ultrasonic test (UT) equipment (Figure 4-15) and visual test (VT) equipment (Figure 4-16).
A dual cross wound probe and bobbin probe using the multifrequency eddy current method will be used to perform a base line examination l of the installed sleeve for future reference. The ET fixture with conduit is used on the manipulator arm to position the probe.
! Ultrasonic testing using an immersion technique with demineralized
! water as a couplant is used to inspect the upper tube to sleeve weld. A one-quarter inch diameter focusing transducer is positioned in the weld area by the elevator and is rotated with an electric motor to scan the weld. The pulse echo tester has the ability to interface with an on line data reduction computer to produce a display /hardcopy during radial and axial scanning.
Visual inspection of the upper and lower tube to sleeve weld is accomplished with the use of a boroscope mounted on the manipulator arm.
4-7
425(82W6)/ mis-27 4.7 PLUG INSTALLATION EQUIPMENT The equipment used for remote installation of plugs in a sleeve steam generator tube is made up of the following systems:
- 1. Remote Controlled Manipulator
- 2. Sleeve Size Rolling Equipment
- 3. Plug Installation Equipment
- 4. Plug Welding Equipment
- 5. Nondestructive Examination Equipment 4.7.1 Remote Control Manipulator See Section 4.6.1 for a description of the Remote Control Manipulator.
4.7.2 - Sleeve Size Rolling Equipment 4.7.3 Plug Installation Equipment 4.7.4 Plug Welding Equipment
-J 4-8
425(82W6)/als-28 4.7.5 Nondestructive Examination Visual inspection of the plug weld is accomplished with the use of a boroscope mounted on the manipulator arm.
4.8 ALARA CONSIDERATIONS The steam generator repair operation is designed to minimize personnel exposure during installation of sleeves or plugs. The
. manipulator is installed from the manway without entering the steam generator. It is operated remotely from a control station outside the containment building. The positioning accuracy of the manipulator is such that it can be remotely positioned without having to install templates in the steam generator.
Air, water and electrical supply lines for the tooling are designed and maintained so that they do not become entangled during operation. This minimizes personnel exposure outside the steam generator. Except for the welding power source and programmer all equipment is operated from outside the containment. The power source and programmer is stationed about a hundred feet from the steam generator in a low radiation area.
In summary, the steam generator operation is designed to minimize personnel exposure and is in full compliance with ALARA standards.
4.9 REFERENCES
TO SECTION 4.0 (1) Sedricks, A. J., Schultz, J. W., and Cordovi, M. A., "Inconel Alloy 690 - A New Corrosion Resistant Material", Japan Society-of Corrosion Engineering, 28, 2 (1979).
(2) Airey, G. P., " Optimization of Metallurgical Variables to Improve the Stress Corrosion Resistance of Inconel 600",
Electric Power Research Institute Research Program RP1708-1 (1982).
l 4-9 l
b
425(82W6)/ols-29 (3) Airey, G. P., Vaia, A. R., and Aspden, R. G. , "A Stress Corro-sion Cracking Evaluation of Inconel 690 for Steam Generator Tubing Applications", Nuclear Technology, 55_, (November,1981) 436.
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425(82W6)/cis-48 5.0 SLEEVE EXAMINATION PROGRAM 5.1 ULTRASONIC INSPECTION 5.1.1 Suninary and Conclusions An ultrasonic examination is used to confirm fusion of the sleeve to the tube after welding. This test consists of introducing sound energy with a frequency of[ ] into the welded region. A rotation device enables a 360 degree scan around the tube, whereaftertheultrasonictransducerisraisedapproximate1yC Jand the weld scanned again. A minimum of three scans are performed and if continuous fusion is shown for 360 degrees, the weld is considered acceptable. [
.3 5.1.2 Ultrasonic Evaluation Ultrasonic techniques are employed to confirm the presence of sleeve-tube weld fusion. The evaluations were made of Inconel 690 alloy sleeves with nominal dimensions ofC 3outside diameter, and minimum [ ] wall. The Inconel 600 alloy steam
, generator tubes are 0.875 inch outside diameter X 0.050 inch wall.
Weldpositionisapproximately(, 3 from the top of the sleeve.
5-1
425b(82W6)/ mas-6 Ultrasonic energy of [ .] is emitted from a transducer through a contained water column in the vicinity of the weld. After passing into the sleeve at its entry point, the sound continues to travel until it arrives at i separation in material or to the opposite side of the material. The transducer is designed so that its energy is focusedatthesleeveouterdiameterwall,[ l J. l When sound enters a weld with proper fusion, a reflection of sound )
energy may be obtained from the tube outer wall. Should no fusion exist at a given point, the sound energy will travel only as far as the sleeve outer wall. In the former case, weld fusion will be displayed on the CRT by first an interface signal where sound enters the sleeve, followed by a second signal from the tube outer surface (back wall reflection). Depending upon weld geometry, the tube backwall reflection amplitude may sometimes vary.
Where lack of fusion exists, the sound will only travel to the first reflector, which is the sleeve 0.D. The display on the cathode ray tube (CRT) will still show the interface signal, followed now by a more closely spaced reflection or reflections, which denotes the thickness of the sleeve (Figure 5-2).
A weld area is considered to have proper fusion where there is an absence of the sleeve back wall reflection (s).
The weld examination begins when the transducer is inserted into the tube-sleeve assembly to a position such that the transducer is aligned with the lower edge of the weld. The transducer is then rotated 360 degrees at this elevation and the degree of fusion is '
determined by observing the ultrasonic instrument's CRT, or by other readouts. Additional scans at higher elevations can be performed to evaluate the complete weld area.
In this manner, the weld integrity can be assured and lack of fusion, with an area equivalent to a slot with a width of [
),canreliablybedetected. In actual tests, a lack of fusion
.012 inches wide had been reliably detected.
5.1.3 Test Equipment Test equipment for welded sleeve inspection consists of the following components:
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425(82W6)/als-50 3.
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5.1.4 Defect Samples Qualification of the ultrasonic inspection system was made through use of calibration standards, and twelve production welds made in a mock-up.
The calibration samples were three in number, and identical with respecttomilledslotdimensions(Figure 5-3).[;
)Thesesampleswereinspectedpriortomachining tne notches into them, to insure usage of acceptable welds. The system was calibrated according to procedure, and calibration standards evaluated in the computer control mode.
The twelve -(12) production welds in mockup were then evaluated in the same manner. Of the twelve, two welds were found to have lack of fusion. Inspection results from four (4) of these welds are included and analyzed in this report.
5.1.5 Detailed Results The computer output for the calibration sample and four (4) production welds (A-1, A-2, A-4, A-6) are included in this report.
The information contained on each chart consists of the following:
a) Rotation (degrees). This is the angular position of the transducer measured in degrees. The zero degree point for the transducer is preset, locked into place and is consistent for all following scans. This enables circumferential location of any lack of fusion area indicated on the printout.
b) Elevation (inches). The elevation or vertical position of the transducer within the sleeve is given in inches. This information enables approximation of the weld height and location of any lack of fusion areas.
9 5-3
425(82W6)/ mis-51 c) Scan limits. The upper and lower scan limits for the weld are shown by the elevations indicated at the 360 degrees position.
d) Data on the top of each chart relates to information concerning the inspected tube, steam generator and time, as well as weld signal amplitude threshold values for recording. The classification of the weld is given at the bottom of the charts.
- In reviewing the computer readouts for the calibration standard and production welds used, we offer the following analysis:
1) t 2) 3)
4) 5)
5.2 EDDY CURRENT INSPECTION The objective of this examination is to establish baseline data on the primary pressure boundary of the sleeve-tube assembly. The 5-4
425(82W6)/ mis-52 I
examination was developed to detect 40 percent ASME sized flaws in the parent tube and/or sleeve in any region of the sleeve-tube assembly with a single pass of an eddy current coil.
5.2.1 Sununary and Conclusions An eddy current test has been qualified for the inspection of installed welded sleeves to detect flaws in the pressure boundary.
Eddy currents circulating in the sleeve and steam generator tube are interrupted by the presence of flaws in the material with a resultant change in test coil impedance. This impedance change is processed and displayed on the test instrument to indicate the presence of a flaw.
The pressure boundary is considered to be the sleeve up to and including the upper weld joint and the steam generator tube above the weld. Consequently, there are three distinct regions relative to the inspection methods: 1) The sleeve below the weld, 2) the steam generator tube behind the top section of the sleeve (above the weld) and 3) the steam generator tube above the sleeve.
Using specialized probes and mul,tifrequency eddy current techniques, '
it has been demonstrated that al lisdetectableanywhereinthesleeveortube, includingtheweldregion.f.
.] The test results are recorded on magnetic tape and strip chart recordings. Other than the probes, the inspection equipment is the same as used for a conventional eddy current test of steam generator tubing. Additional laboratory testing of accelerated corrosion samples has shown that this method can detect defects in the parent tube.
5.2.2 Multi-Frequency Eddy Current Equipment Requirements The equipment required to perform this examination include the following:
1.
2.
3.
. 4.
. 5.2.3 Defect Samples A variety of simulated defect samples were fabricated to represent different possible flaw locations in the sleeve or steam generator tube. The basis for the cualification was to demonstrate detectabilityofa{
5-5
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425(82W6)/ mis-53
}at any location in the pressure boundary. Several samples were required to simulate the potential signal interference from the sleeve end, sleeve bulge and weld. The sample matrix included:
5.2.4 Results and Conclusions D
S 6
6 5-6
425(82W6)/als-54 multi-frequency eddy
[ current techniques are employed to further e]nhance the signal to noise ratio. A total of four separate test frequencies and two mixing channels are employed simultaneously. By combining the signals from two frequencies, the residual noise signals from the bulge, etc., can be virtually eliminated. For this particular application, a combination of C, Jis used to inspect the sleeve. In Figures 5-10 tnrough 5-14, the eddy
. current test signals for various qualification samples are shown.
Both the sinole and multi-frequency results are shown, however, in general,the( 1results will be used as the basis of analysis.
The low frequency required to examine the tube through the sleeve and the total wall thickness of the sleeve-tube assembly result in insufficient phase shift of the defect signals from the defect calibration standard to allow evaluation of tube wall degradation indications by relating signal phase angle to the depth of penetration. Consequently, detection is possible, but accurate sizing generally is not possible.
Sleeve wall degradation indications can be evaluated for depth of penetration and origin by plotting the phase angle of[ ]
data to graphs relating signal phase angle to depth of penetration.
The smallest sleeve wall degradation demonstrated to be detectable with this examination technique was a single [
, ]from the 0.0. of the sleeve.
5.3 VISUAL INSPECTION 5.3.1 Summary and conclusions i Visual examinations can be performed on the upper welds to support
- U.T. results and are performed on the lower welds to determine their integrity and acceptance. The welds are examined using a boroscope examination system. The lighting is supplied as an integral part of i the visual examination system. Each examination is recorded on i video tape for optional later viewing and to provide a permanent record of each weld's condition.
The inspections are performed to ascertain the mechanical and structural condition of each weld. Critical conditions which are checked include weld width and completeness and the absence of visibly noticeable indications such as cracks, pits, blow holes, burn through, etc.
. 5.3.2 Lower Weld Evaluation The lower weld of the sleeve-tube assembly is inspected using a boroscope examination system. The boroscope is positioned under the 5-7
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425b(82W6)/ mas-7 l lower weld and the lighting is adjusted to obtain the optimal viewing conditinns. Rotating the boroscope around the weld and i tilting it when necessary, provides conplete coverage of the examination area. A videotape recording is made of the entire examination.
Prior to the inspection, the system's accuracy is ascertained by observing a 1/32" black line on an 18% neutral gray card placed on the surface to be examined or a location similar to the inspection area. Proper use of this system provides image resolution on the 1 order of 0.001 inch. ,
Weld acceptance is based on the absence of any cracks or other visible imperfections which would be detrimental to the integrity of the weld. During the examination, an area containing a noticable indication is inspected more closely. This is done by varying ther 4 light intensity,' distance from the lens to the indication, and/or the angle used during the viewing.
5.3.3 Upper Weld Examination A visual examination can be made of the upper sleeve to tube weld.
using a boroscope inspection system. This system utilizes a right-angle lens and a tool which can deliver the lens up to the weld as well as to provide 360' rotational capabilities.
To perform the inspection, the oc'.scs system is inserted into the sleeve-tube assembly such that the lens is located at the upper weld. After checking for visual clarity and adjusting the lighting to reduce unwanted glare, the lens is rotated 360'. The , lens may then be raised or lowered and the process repeated to ensure complete weld coverage. The entire examination is video-taped for a permanent record.
Prior to the inspection, the system's accuracy is checked by observing a 1/32" black line on an 18% neutral gray card placed in a location similar to the area to be inspected. Additionally, to obtain an aspect for size and to check the in-tube lighting, a welded sleeve-type sample with a .020" diameter through hole is placed over the lens.
The weld acceptance is based on the absence of cracks or other ,
visible imperfections which would be s *rimental to the integrity of the weld. Detrimental imperfections i,clude blow holes, weld mismatch, etc. During the examination, any area which contains-noticable imperfections is examined more closely by varying t'1e.
light intensity and/or the position of tr.e lens with respect to the indication.
5-8 -
425(82W6)/cis-56 5.3.4 Test Equipment The test equipment necessary to visually inspect the upper and lower sleeve to tube welds consists of the following:
- 1. Boroscope visual examination system with an integral lighting system, lenses and a delivery and rotational tool for inspecting the upper and lower welds.
. 2. 18% neutral gray card with a 1/32" black line.
- 3. Welded sleeve-tube sample with a .020 inch diameter through
. drilled hole.
- 4. Video camera and recording equipment.
5.3.5 Defect Standards Various methods are used to determine system adequacy and to aid in determining weld acceptability.
- 1. System adequacy, including lighting intensity and camera system clarity, is verified by resolving a 1/32" black line on an 18%
neutral gray card.
- 2. Size aspect for upper weld inspections is obtained by viewing a welded sleeve-tube sample which has a .020 inch through drilled hole.
- 3. Sleeve-tube upper and lower welds were made with both acceptable welds and intentional weld malformities. These welds were photographed and are used as aids to examiner, 5-9
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nsLDED 5.Er4 LA.TmtSOMIC DGPECTION REPORT reeaY FIBAUARY 18 1985 7:51:45 PM o
This weld has been evaluatec as ACCE. TABLE.
By
. UT level FIGURE 5-4 Production weld (A-2)-Acceptable e
e 5-13
czeustrow > eenmue wi.am suave ts.nusourc tweenow ammrr
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By UT lev.el FIGURE .5-5 Milled Notch STANDARD-NOTCHES
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a casusrtow : a*nmettu 14LDED St.Ir4 f.A.71tR90NIC INOPECTION REPORT eoeny monumiv to tses nasar m l i
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This weld has been evaluated as REJECTABLE.
B y-UI levei FIGURE 5-6 Productionweld(A-1).Rejectagle due to lack of fusion in the 0 area.
4 5-15
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ccMeusf!ON shoIHEIRIHu WELDED SLEEVE ULTitABONIC INSPEC* ION EIEPGtT
, PCDENRY PE3mueRY le 1985 7:14:44 Pvt a
Ihis weld has been evaluated as ACCEPTABLE.
By UT 1e.rel FIGURE 5-7 Production weld (A 4.)-acceptable.
Passed hydrostatic test at 800 P.S.I.
for four minutes.
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5-16
CDFOU$770M 7.r4GiteERING idELDED SLEEW LA.TIPftfCMIC (HgPTCTION REParr MEMuBY N M I Lt?es 6453:49 PM m
This weld has been evaluatec as REJECTABLE.
By UI level 2
FIGURE 5-8
. i Production weld (A-6) Rejectabig due to lack of fusion in the 200 area. Failed hydrostatic test at 800 P.S.I. after one minute.
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- n .
l 50/150 KHz Mix 400/800 KHz Mix l
SLEEVE INSPECTION ED0Y CURRENT TEST SIGNALS - SLEEVE FLAWS AT 4 EXPANSION TRANSITION FIGURE 5-14 5-23 i
425(82W6)/ mis-57 6.0 SLEEVE-TUBE CORROSION TEST PROGRAM 4
C-E has conducted a number of bench and autoclave tests to evaluate the corrosion resistance of the welded sleeve joint. Of particular interest is the effect of the mechanical expansion / weld residual stresses and the condition of the weld and weld heat affected zone.
Various tests have or are presently being conducted under accelerated conditions to assess the sleeve-tube joint performance under nominal and potential fault environmental conditions. An
, outline of these tests is shown in Table 6-1. C
'.]
6.1 SumARY AND CONCLUSIONS m mi 6.2 TEST DESCRIPTION AND RESULTS
~ ~
6.2.1 i
o e
m i
6-1
425(82W6)/ mis-58 TABLE 6-1 STEAM GENERATOR TUBE SLEEVE CORROSION TESTS TEST MATERIAL ENVIRONMENT l
(1) Mill Annealed l
l . (2) Themally Ireced 1
i
(
6-2 l
425(82W6)/ mis-59 6.2.2 Capsule Tests 6.2.3 Pure Water Stress Corrosion Cracking Tests e
9 i
M 6-3
1 I
425b(82W6)/ mas-8
)
TABLE 6-2 STEAM GENERATOR TUBE SLEEVE CAPSULE TESTS ENVIRONMENT 3 EXPOSURE TIME RESU!TS A.
B.
C.
D.
6.2.4 Sodium Hydroxide Fault Autoclave Tests
-4 . - =
6-4
425(82W6)/ols-61 l
l f
6.3 REFERENCES
FOR SECTION 6.0
- 1. I. L. W. Wilson and R. G. Aspden, " Caustic Stress Corrosion Cracking of Iron-Nickel-Chromium Alloys." Stress Corrosion Cracking and Hydrogen Embrittlement of Iron Base Alloys, NACE, Houston, Texas, pp 1189-1204, 1977.
- 2. A. J. Sedriks, S. Floreen, and A. R. McIlree, "The Effect of Nickel Content on the Stress Corrosion Resistance of Fe-Cr-Ni in an Elevated Temperature Caustic Environment". Corrosion, Vol . 32, No. 4, pp 157-158, .\pril 1976.
- 3. F. W. Pement I. L. W. Wilson and R. G. Aspden, " Stress Cerrosion Cracking Studies of High Nickel Austentic Alloys in Several High Temperature Agueous Solutions." Materials Performance, Vol. 19, pp 43-49, April 1980.
- 4. P. Berge and J. R. Donati, " Materials Requirements for Pressurized Water Reactor Steam Generator Tubing." Nuclear Technology, Vol. 55, pp 88-104, October 1981.
- 5. G. P. Airey, A. R. Vaia and R. G. Aspden, "A Stress Corrosion Cracking Evaluation of Inconel 690 for Steam Generator Tubing Applications." Nuclear Technology, Vol. 55, pp 436-448, November 1981.
- 6. J. R. Crum and R. C. Scarberry, " Corrosion Testing of Inconel
,Ailoy 690 for PWR Steam Generators." Journal of Materials for Energy Systems, Vol. 4, No. 3, pp 125-130, December 1982.
6-5
e 4
W l
I 9
O t
=
6-6
e D
ecumui M
~
6 -7
425(82W6)/ mis-62 7.0 MECHANICAL TESTS OF SLEEVED AND PLUGGED STEAM GENERATOR TUBES 7.1
SUMMARY
AND CONCLUSIONS Mechanical tests were performed on mockup steam generator tubes containing sleeves and plugs to provide qualified testJata describ-ing the basic properties of the completed assemblies. L 3
The welded plugs have sufficient load capacity to perform their function during normal operating and postulated accident conditions.
The axial load required to loosen the plug from the sleeve-tube l
assembly is approximately four times greater than the design load.
7.2 CONDITIONS TESTED l
i l
i -
7.3 WELDED SLEEVE TEST PARAMETERS AND RESULTS -
7.3.1 Axial Pull Tests M'
7-1 l
.-yw m - -,a -- --- , --.
- w. w- , , - - ,----- - -- _- - -_ _ -- _
425(82W6)/als-63 i
2 E
t t
5 a
J i
7.3.2 Load Cycling Tests n
1 1
- r i
f I'
e--a.
t 7-2
425(82W6)/als-64 7.3.3 Collapse Testing
~
l l 7.3.4 Burst Testing i _
7-3 L
l 425(82W6)/ mis-65 l 7.4 WELDED PLUG TEST PARAMETERS AND RESULTS 7.4.1 Weld Integrity 7.4.2 Axial L'oad Capability _
e
- a. /
7-4
425(82W6)/ mis-66 TABLE 7-1 SLEEVE-TUBE ASSEMBLY MECHANICAL TESTING RESULTS*
COMPONENT AND TEST RESULT (MAXIMUM) RESULT (MINIMUM) 9 O
I .
l l
7-5
425a(83T14)/ mis-1 8.0 STRUCTURAL ANALYSIS OF SLEEVE-TUBE ASSEMBLY It is the purpose of this analysis to establish the structural adequacy of the sleeve-tube assembly. The methodology used is in accordance with the ASME Boiler and Pressure Vessel Code,Section III. The work was performed in a manner in accordance with 10CFR50 Appendix B. Also, it is constructed such that U. S. Regulatory requirements are met.
8.1
SUMMARY
AND CONCLUSIONS Based on the analytical evaluation contained in this section and the technical test data contained in Section 7.0, it is concluded that the welded tube sleeve, described in this document, meets all the requirements stipulated in Section 8.0 with substantial additional margins.
8.1.1 Desian Sizinc In accordance with ASME Code practice, the design requirements for tubing is covered by the specification for the steam generator
" vessel". The appropriate formula for calculating the minimum required tube or sleeve thickness is found in Paragraph NB-3224.1, tentative pressure thickness for cylindrical shells. The following calculation uses this formula.
PR t = 3 m-0.5 P .
't Where t = Minrequiredwaiithick(in.)
P = Design Tubesheet differential pressure (ksi)
R = Inside Radius (in)
S, = Design Stress Intensity (S.I.) (per Ref. 8.2) 8.1.2 Detailed Analysis Summary When properly installed and welded within specified tolerances, the sleeve and its two primary welds possess considerable margin against pull-out for all loading which can be postulated from operating, emergency, test, and faulted conditions.
8-1
425b(82W6)/ mas-9 Depending on the degree of tube support lock-up, axial loads in the sleeve do not exceed [- ] When considering the favorable results from the cyclic loading tests ['
], fatigue is not a problem.
In Section 8.2, a comparison is made between calculated failure modes and test data discussed in Section 7.0 of this report. The agreement between calculated and test data was good. Safety factors were determined for hypothetical pipe break accidents, and a minimum factor of safety of [ The nomal operations factor of safety was [ ))wasdetermined.
based on the full power restrained thermal expansion loading. Pushout at the lower sleeve / tube stub joint is the critical consideration (see Section 8.4.6).
The axial sleeve loads calculated in Section 8.4 are used as boundary conditions and the basis for assumptions used in the Section 8.6 and 8.7 fatigue evaluations.
An NRC Regulatory Guide 1.121 evaluation was performed in Section 8.3 to determine a sleeved tube plugging limit. A[ ] allowable degradation limit.was detennined. This is possible because the Reg.
Guide specifically uses normal operating parameters,.such as operating differential pressure, rather than tubesheet design differential pressure.
f.
Considerations of susceptibility to flow induced vibration was discussed.in Section 8.5. Based on C-E experience and test data, it was determined that a sleeved tube is no more susceptible to
- vibration than a normal tube.
I Fatigue of both the upper and lower joints was considered in Section
, 8.6. The geometry was shown to meet all ASME Code allowable stress intensities including local primary and range of primary plus secondary stress. The geometry considered was a " worst case"
- , situation where part of the tube extending below the primary side of the tubesheet was modified (removed) by machining (see Sheets 8-27 l
t and 8-28). A tabulation of the results is presented in Table 8-1.
The maximum local primary stress intensity was [ ] ksi across the alug at the lower weld joint, as compared with the allowable of
- ] ksi. The maximum range of primary plus secondary stress was
[ ] ksi across the sleeve at the lower joint, near the plug weld, as compared with the allowable of 80 ksi. The maximum fatigue. usage factor was [ ] at the same location. This high usage factor was due in part to consistently conservative assumptions made in the calculation.
Sleeve evaluation was performed for [ ] sleeves (I) in the central tube bundle and near the bundle periphery. The thermal mismatch between the sleeve and tube which affects axial loads NOTES:
! Both[ sleeves in the central bundle and periphery regions were considered with]the ][ sleeve yielding the maximum axial load (See Tables 8-2A through 8-4B).
8-2
425b(82W6)/ mas-11 ANALYSIS RESULTS
SUMMARY
TABLE TABLE 8-1 Allowable (1) Analysis Results Stress Category Litrit (ksi) location (ksi)
Primary Stress (P,) S,= 26.6 Primary Local Stress (Pg ) 1.5 S, = 40.0 Range of Stress (Q) 3 S, = 80.0 Fatigue (F) U = 1.0 Main Steam Line Break 0.7 Su = 63.0 I2)
Primary Local Stress (PL) 1.5 S,= 40.0 Range of Stress (Q) 3 5, = 80.0
, Fatigue (F) U = 1.0 Primary Pipe Break (LOCA) 0.7 Su = 63.0 Primary Local Stress (Pg ) 1.5 S, = 40.0 Range of Stress (Q) 3 S, = 80.0 Fatigue (F) U = 1.0 d'
NOTES:
(1) The allowables listed in Table 8-1 are in accordance with the ASME Code.
(2) [
3 8-3
- c. ._
425b(82W6)/ mas-12.
FORMULAS FOR GENERAL MEMBRANE STRESSES SinNARIZE0 IN TABLE 8-1_
- 1. GENERAL PRIMARY tf?/3RANE STRESS (FOR PRIMARY DESIGN P'tESSURE)* _
j L _
- 2. -MAIN STEAM LINE BREAK l
- 3. PRIMARY PIPE BREAK (LOCA)
'k .
~
L ,
- NOTE: Design Tubesheet Differential Pressure. (Reference 8.5) 4-8-4
425a(83T14)/ mis-5 occurs over a short distance between the top of the tube sheet and the upper weld. The relative severity of the axial loads which are developed are a function of that distance divided by the overall distance between the upper and lower welds.
A sleeved tube plug was successfully evaluated in Section 8.7 in case it should ever be needed (see Table 8-1 and Appendix 8C).
8.2 LOADINGS CONSIDERED In this section a number of potential failure modes are examined to determine the relative safety margins for selected events. Failure loads are calculated based on minimum dimensions and compared with mechanical testing results from Section 7.0. Both calculated and measured loads are compared with the maximum postulated loads.
8.2.1 Upper Tube Weld pullout Load Assuming the parent tube is totally severed, the minimum load required to shear the upper tube weld is calculated. The force required to pull the expanded sleeve through the unexpanded tube is conservatively neglected.
Shear area = weld throat circumference . -
In the event of a main steam line break (MSLB) accident the secondary pressure would drop during a short time interval. The primary pressure would rise briefly then follow the drop in secondary pressure. It will be conservatively assumed that full primary pressure remains when the secondary pressure reaches zero.
Postulating a main steam line break (MSLB) accident, the maximum available load would be: --.
8.2.2 Lower Stub Weld Pushout Load Assuming the parent tube is totally severed, the minimum load reouired to rupture the lower stub weld is qa1culate'd. It is 8-5
425a(83T14)/ mis-6 interesting to note that for this geometry, based on the test results, the weld did not fail in pure shear.
The weld lip seemed to " roll over" as is illustrated in Figure 8.2 such that the weld failed primarily in tension.
Weld area = weld throat circumference __
~~
From References 8.1 and 8.2, the minimum tensile strength is 80.0 ksi. Therefore, a predicted "pushout" load on the sleeve might be calculated: -
__J Postulating a loss of primary coolant accident (LOCA) during hot standby conditions (0% power), the maximum available load would be:
8.2.3 " Weld Fatigue Since the factors of safety are quite high for loadings due to primary stress, the mechanism of greatest interest is the fatigue failure mode due to variable axial loading of the sleeve during normal operation.
In Section 8.6, fatigue evaluations of both the upper and lower welds, which join the sleeve to the tube will be made. It is first necessary to determine the effects, which tube lock-up within the tubesheet and tube support plates have on the axial loads in the sleeve during normal operation. This subject is addressed in Section 8.4.
8.3 REGULATORY GUIDE 1.121 EVALUATION FOR ALLOWABLE SLEEVE WALL DEGRADATION R.G. 1.121 (Reference 8.3) requires that a minimum acceptable tube (or sleeve) wall thickness be established to provide a basis for removing a tube from service. For partial thru-wa11 attack from any source, the requirements fall into two categories, (a) normal operation safety margins, and (b) considerations related to postulated pipe rupture accidents.
8-6
425a(83T14)/ mis-7 8.3.1 Normal Operation Safety Margins It is the general intent of these requirements to maintain the same factors of safety in evaluating degraded tubes as those which were contained in the original construction code, ASME Boiler and Pressure Vessel Code,Section III (Reference 8.1).
For Inconel Alloy 600 and 690 tube or sleeve material the controlling safety margin is:
" Tubes with part thru-wall cracks, wastage, or combinations of these should have a factor of safety against failure by bursting under normal operating conditions of not less than 3 at any tube location".
From Reference 8.5, the 100% power conditions for the Zion Units 1 & 2 steam generators are:
Primary Pressure Ppri = 2235 psig Secondary Pressure P = 705 psig sec Differential Pressure AP = Ppri - P sec = 1530 psi Average Pressure P,yg = 0.5 (Ppri + Psec) = 1470 psi Assuming the parent tube is totally severed, the sleeve is required to carry the pressure loading. The following terms are used in this evaluation.
R is
= sleeve inside radius (see Tables 8-2A and 8-28)
Sy = minimum required yield strength (per US NRC Reg.
r.m.
Guide 1.121)
Sym in = actual minimum yield strength of sleeve (Sy a 40.0 ksi minimum at 650*F)
I 8-7
425a(83T14)/als-8
)
l i
8.3.2 Postulated Pipe Rupture Accidents R.G. 1.121 requires the following:
"The margin of safety against tube failure under postulated accidents, such as a LOCA, steam line break, or feedwater line break concurrent with the SSE, should be consistent with the margin of safety determined by the stress limits specified in NB-3225 of Section III of the ASME Boiler and Pressure Vessel Code."
C
]
Due to the following: _
}
4 9
M 8-8 p., --w-- e e- . - , , , , -,n,,_-, ,---
--_.e ,, w- -,, w,-,.-., - -
425a(83T14)/als-9 8.4 EFFECTS OF TUBE LOCK-UP ON SLEEVE LOADING Objective: Conservatively determine the maximum axial loads on the sleeve (tension and compression) during nonnal operation.
General Assumptions: (See Figures 8-3 through 8-5). _
e t
8.4.1 Sleeved Tube in Central Bundle Region Free at Tube Support Plate (1) -
l l
l
[
l e-v
,, , _ _ _ _ . _ . -- ~___._____..-___---._.-...y- - -
425a(83T14)/cls-10 .
t TABLE 8-2A - [ ] SLEEVE
- AXIAL MEMBER PHYSICAL PROPERTIES At Reference IN CENTRAL BUNDLE REGION Normal Oper. Temps.
Outside Inside Section Correspond. Youngs Mean Coef.
Radius Radius Length Area Temperature Modulus Stiffness Therm. Exp.
Rg L A - E K=AE/L am R,
0 3 (In) (In) (In) (In ) -
lb/in X10 lb/inX10 g,jg,.7 (1) Sleeve (2) Lower Tube (3) Tube in Tubesheet T
h (4) Upper Tube (5) Surrounding Tubes Reference Temperatures: Primary (Hot) = T prj = 594*F (Use for E and am)
Secondary =T sec = 506*F (in central bundle region - sat. temp.) ,
'I Normal Tubes = sec = 565*F 3
Notes: (1) a ,and E for Inconel 690 from Huntington Alloys Bulletin.
(2) a , for Carbon Moly Steel.
l
425a(83T14)/.ls-17 TABLE 8-4B - [ ] SLEEVE AXIAL LOADS IN SLEEVE WITH TUBE LOCKED INTO SUPPORT PLATE Sleeve Net Load T 2T,+T s Elongation - __ _ _
pri T,,, t=
3 0
5 0
4 0
Forced F
6 A##
6 6 6 66+A6 A44 j 3 6 FdKj jj F2=F 6 -F j
Condition (*F) (*F) (*F) (In) (in) (in) (Lbs) (In) (In) (Lbs) (Lbs)
CENTRAL TUBE BUNDLE _ ,
- a. Normal Oper.
100% Power
- b. Reactor Irlp*
(50 sec.)
- c. Hot Standby
- EAR BUNDLE PERIPHERY
- d. Normal Oper.
ca 100% Power C
c'
- e. Reactor Trip *
(50 sec)
- f. Hot Standby *
~
- NOTE: Due to small variation, E and a m value for normal operation, 100% power are used.
i
._ s_.- . _ . . . _ _ . ,__ ,,,_._
425a(83T14)/;1s-18 9
8.4.2 Sleeved Tube Near Bundle Periphery. Free at Tube Support Plates (1)
S 6
M 8-14 hemMMS*Me eme_mm.,..
- ' wgM"-
7 425a(83T14)/als-19 8.4.3 Sleeved Tube in Central Bundle Region. Lock-up Lowest Support Piate 0
9 e
NOTES:
8-15 l
t - - _ . . .
4253(83T14)/;1s-20 Consider the same conditions as for Section.8.4.2.
8.4.4 Sleeved Tube Near Bundle Periphery,' Lock-up at Lowest Support Plate (
8.4.5 Effect of Tube Prestress Prior to Sleevinq _
NOTES:
8-16
425a(83T14)/als-21 Therefore, the prestressed state of a locked-in tube to be sleeved is not of significant concern, so long as it does not hamper the sleeve installation process.
- .8.4.6 Lower Stub Weld Pushout Due to Restrained Thermal Expansion 8.5 SLEEVED TUBE VIBRATION CONSIDERATIONS Since the installation of a sleeve in a tube could effect the dynamic response characteristics of the tube, it would seem prudent to review vibratory predictions.
8.5.1 Effects of Increased Stiffness ,
t 8.5.2 Effect of Severed Tube l
C :
I - -
8-17
425a(83714)/als-22 Y
4 0
1 4
4 W
i 1
I I m e
~~*
i 1
8-18
_ . . - - _ . . _ .- - _ . . _ . - _ .__ _ .- . . . . . . _ _ _ _ _ ~ , . - - _ _ _ _ . . . ._ _
425a(83T14)/cis-23 3
8.6 STRUCTURAL ANALYSIS FOR NORMAL OPERATION A static elastic analysis of the sleeved tube assembly was perfonned according to the requirements stipulated in NB-3220 Section III of
, the ASME Code Section 1983 Edition. This section describes the analytical methods used to analyze the upper tube weld and lower stub weld. Section 8.7 describes the analytical method for the tube sleeve plug weld.
8.6.1 Fatique Evaluation of Upper Sleeve / Tube Weld l
l
.i l
8-19
425b(82W6)/ mas-13 8.6.2 Fatigue Evaluation of Lower Stub Weld e
'W gm ,
6 8-20 4-- - . . - . . . ... . ._.. . ._ ..
42Gb(82W6)/ mas-14 TA8LE 8-5 UPPER SLEEVE WELD-TRANSIENTS CONSIDERED RESTRAINED THERMAL EXPAN.
CYCLES AXIAL LOAD T
ori T,,e CONDITION (LBS.) (*F) (*F)
(1) AM8 TENT -.
(2) NOT STBY ._.
(3) FULL POWER (4) REACTOR TRIP -
(LOSS OF FLOW 50SEC.) ,
ASSUMPTIONS -
(1)
(2)
- (3)
(4)
(5) _
l 8-21
425b(82W6)/ mas-15 p
e 9
5 9
d 8.7 SLEEVE /TU8E PLUG WELD EVALUATION O
e M
8-22
- N"
425b(82W6)/ mas-16 TABLE 8-6 LOWER STU8 WELD-TRANSIENTS CONSIDERED RESTRAINED THERM EXPAN P P
CONDITION CYCLES AXIAL LOAD 1 2 P
~
l' (1) AMBIENT __ __
(2) HOT STBY ,,
(3) FULL POWER (4) REACTOR TRIP (LOSS OF FLOW-50 Sec.)-
(5) SECONDARY LEAK TEST ASSUMPTIONS: .
' ~
(1)
(2)
(3)
(4)
(5)
(6)
- i .,
.
- NOTE: AP = Ppp9 - P su To be used for detemination of tubesheet flexure.
8-23 N # W - 2 6m e a
-^=_%,, -#
425b(82W)/ mas-17 p
O e
e O
- d e
9 8-24
r -
425b(82W6)/ mas-18 TA8LE 8-7 SLEEVED TU8E PLUG WELD-TRANSIENTS CONSIDERED P P CONDITION CYCLES ori sec AP*
~ ~
. (1) AMBIENT (3) FULL POWER (5) SECONDARY LEAKTEST ASSUMPTIONS: .,
(1)
(2)
(3)
(4)
(5)
(5)
(6)
~ -
- NOTE: AP = Ppri - P,,, To be used for determination of tubesheet flexure.
O 8-25
425b(82W6)/ mas-19
8.8 REFERENCES
FOR SECTION 8.0 8.1 ASME Boiler and Pressure Vessel Code,Section III for Nuclear Power Plant Components.
8.2 ASME Boiler and Pressure Vessel Code Case N-20, "SB-163 Nickel-Chromium-Iron Tubing (Alloys 600 and 690) at a Specified Minimum Yield Strength of 40.0 KSI". ,
. 8.3 U.S. NRC Regulatory Guide 1.121. " Bases for Plugging Degraded PWR Steam Generator Tubes".
- 8.4 RFQ from Swedish State Power Board, BIV1-LBn/Gn-6331, dated January 4,1984, to C-E Power Systems, for Ringhals 2 Steam Generator Demonstration Sleeving.
8.5 Correspondence Letter No. ASV-86-07, D. R. Tolliver (CE-Chatt.) to P. W. Richardson (CE-Windsor), dated April 18, 1986, " Zion Units 1 &
2 Plant Geometric and Operating Parameters".
8.6 SSPS Specification for Replacement Steam Generator for Ringhals 2 Nuclear Power Plant, dated January 1984.
8.7 International Nickel Co. Booklet, "Inconel 690".
8.8 Nuclear Systems Materials [ Handbook, Volume I " Design Data". Part I, Group 4, Section 3 - Inconel Alloy 600.
8.9 Vibration in Nuclear Heat Exchangers Due to Liquid and Two-Phase Flow", By W. J. Heilker and R. Q. Vincent, Journal of Engineering for Power, Volume 103, Pages 358-366 April 1981.
8.10 "ANSYS", Engineering Analysis System, User's Manual, by John A. Swanson.
8.11 EPRI NP-1479, "Effect of Out-of-Plane Denting Loads on the Structural Integrity of Steam Generator Internals", Contractor:
! C-E, August 1980.
8.12 " Primary / Secondary Boundary Components Steady State Stress Evaluation", Prepared by Raymond Paul Wedler, Westinghouse Electric Corp., April 1965.
i i .
8-26
e .
/
N FIGUP.E 0-1A WELDED SLEEVE /TU8E ASSEMBLY IN CENTRAL BUNDLE REGION 8-27 m ae , ,
e mesoamem M*****
W ^ 'We -w.
u-gn 9
4
/
D i
l e
/-
'\
FIGURE 8 18 WELDED SLEEVE / TUBE ASSEMBLY NEAR BUNDLE PERIPHERY 8 .
~ e - m. .
- dummemme M w- e.- m
, _ _ _ r._ r _ . _ ___ _
. . . . . + ...m_ _
6 eaum , ,, y.
- e 9
0 5
6 e
P L
e 4
- e 4
i e
l s s O
9 h
a e
S
- a e
O L
l FIGURE 8-2 LOWER JOINT ROLL OVER .
8-29 - g.
c
f 1-s >
i e
i t
4 .
FIGURE 8-3A SYSTEff SCllEttATIC N IN CENTRAL BUNDLE SECTION AND NEAR PERIPHERY REGION 3 30
- ~ -- - .. ,
-y.
\
/
A h
d s
I 4
l I
r
> +
I i I
FIGURE 8-38
\_ SY37EM SCHEi1ATIC NEAR BUNDLE PERIPHERY AND CENTRAL ,
BUNDLE REGION i
t 8~3I- s G
- - - ~. - -- -- .- _-
1 s
/
t 1 -
i I
\
.v 4
\ i FIGURE 8-4 l
- MODEL OF SLEEVE AND LOWER TUBE 8-32 ok-t _ _C L _ . . _ . - - .._
c :. -
I
~
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V
.i I
1
?.- -
i
(~
t I
J i-i
. 1
\ 4 FIGURE 8-5 MODEL UPPER WELD 6
4 8-33 G
OK G
-e=-,,r ..w.w---- m-w- e --,, , m-. , , -, - n --.--_----r-_.w.,__e, , - , , , w-wy , y9e.,,w ,y---,7 ,y,97--, -.-
r,---e,--.y,-w-y,,,9 .-. m
,.-yy--
N
/
I i
l i
^
~
.N FIGURE 8-6 FINITE ELEftENT t00EL OF UPPER TUBE WELD l '
o.t .
. 8-34 ,
l
r- : .
p N i . . j .
I f% V y l 4, CXXXXX (Mer.do
. l V ; . .u /W-nd"g) s
.:c.- .
- ' ^
lET.O Aree MedalTed fn I 'i l -
Finita ETement Analysis .
- ... ( ,
1 l
I g. .
l SLEEVE TUBE-SHEET 1
11
'l CONTACT : y s
l AREA CLAD l
I
_. I
~
I ~/ \A y l
- =p_ __ 3'
T TUBE L
CENTER LINE FIGURE 8-7
. FINITE ELEMENT MODEL OF LOWER STUB WELD 0
8-35
,- ----_-,v, ------,v. m
(
- r e
O
% 4 t ..... e SEE d N:
I i-M e
~
TusE-SHEET w
r I .
e wasulwmust UO (g
i o
PLUG ENTER LINE TWE-TO-TWESHEET (REDUCED) WELD 1 TUBE FIGURE 8-8 FINITE ELEENT MODEL OF 8-36 SLEEVED TWE PLUG WELD
~
g
$ e
_ _ - - ' ' _ - -- ~ ~~
425a(83T14)/als-31 Y
e 9
d APPENDIX 8A FATIGUE EVALUATION OF UPPER TUBE / SLEEVE WELD 4
6 l
r D
_ --- ,e,e--s I 'l - - - - - - - - - - - - -
PRIMARY 4ECONDARY BOUNDARY COMPONENTS STEADY STATE STRESS EVALUATION.
8Y RAYMONO PAULWEDLER, APRIL 1965
_ m e
i i
i t
t i
1 8-37
i l
l I
ll
's_ :
UPPER SLEEVE / TUBE WELD Analysis l _ FULL POWER 1
l l
FIGURE 8A-1 l
m l
l 1
l l
1 l 4 1
i .
E k
I I l-
} {t_
UPPER SLEEVE / TUBE WELD ANALYSIS FULL POWER l
FIGURE 8A-2 8A-3
I
- l i
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FTGURE 8A-3 8A-4
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STRESS RESULTS - SEC? d 2-AttD 3 FIGURE 8A-6 8A-7.
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425a(83T14)/als-32 O 1 e
O APPENDIX 88 FATIGUE EVALUATION OF LOWER STUB WELD l
F 88-1 j __
s - a-m m
- Nw * -w .m -
m me me m p.
425 (83T14)/als-33 DERIVATION OF EXPANSION / CONTRACTION ON LOWER TUBE-SLEEVE WELD DUE TO TUBESHEET FLEXURE STRESSES O
O e
O e
88-2 N* * ' * * *"-
6 s._ _,
Y W
FIGURE 8B 88-3
4 AXIAL LOAD DUE TO RESTRAINED THERMAL EXPANSION y I i
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COPPRESSIVE
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, 0 IJ FLEXURE OF
- TU8ESHEET
,SLE . LD (FULL P0ldER & THERtPL LOAD) 9 FIGURE ~88-2 88-4
,,__ e- ^
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r-AXIAL LOAD DUE TO RESTRAINED THERMAL EXPANSION
- A
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COMPRESSIVE FLEXURE OF
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,SLFpy -E% ELD (REACTOR TRIP & THERt1AL LOAD)
FIGURE'88-3 88-5 d W4m 6
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APPENDIX 8C FATIGUE EVALUATION OF TUBE SLEEVE PLUG WELD e
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425(82W6)/als-67 9.0 SLEEVE INSTALLATION VERIFICATION 9.1 WELD INTEGRITY O
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7 425(82W6)/als-68 4
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- m 9.2 SLEEVE INSTALLATION DEMONSTRATION AT RINGHALS 2 -"
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425(82W6)/als-70' 10.0 EFFECT OF SLEEVING ON OPERATION An analysis was performed to determine the effect of installing welded sleeves in the steam generators. For analysis purposes, it was assumed that two thousand sleeves would be installed in each steam generator. A conservative length of 36 inches was used in evaluating the effects of the sleeves on the heat transfer capability of the steam generators. Using the pump characteristic curve and the system resistance curve, the flow rate change was determined for increased flow resistance associated with; nstalling the sleeves. The change in total flow rate was only and should not have a significant effect on reactor operation. "
o IW O
10-1
425(82W6)/cis-71 APPENDIX A PROCESS AND WELD OPERATOR QUALIFICATIONS FOR TUBE SLEEVE AND PLUGGING SLEEVED TUBES h
9 9
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425(82W6)/ols-72 APPENDIX A
- A.1 SLEEVE WELDING AND SLEEVE WELDER QUALIFICATION Sleeve welding and plug welding in sleeved tubes are qualified using approved test procedures (References 1 and 2). The sleeving test procedure is in compliance with applicable sections of the ASME Code even though it does not directly apply to sleeves, and the plugging procedure is in compliance with Section XI of the latest edition of the ASME Code. Sleeve and plug welders are qualified using test records in accordance with applicable sections of the Code.
e The test procedures specify the requirements for performing the welds, the conditions (or changes) which require requalification, the method for examining the welded test assemblies and the requirements for qualifying the welding operators. Sleeve and plug welding are qualified by performing six consecutive welds of each type which meet specified design requirements. Welders are qualified by performing two consecutive successful welds of each type. -
A.2 REFERENCES TO APPENDIX A
- 1. Welded Steam Generator Tube Sleeve Semi-Automatic Gas Tungsten Arc Detailed Welding Procedure Qualification, Test Procedure 00000-MCM-050.
- 2. Engineering Requirements for Plugging Sleeve Tubes in.
Westinghouse Series 44 and 51 Steam Generators, NCE Engineering
. Procedure EP-6275G-104.
1 s
A-2 t
425a(83Tl'4)/ci s'-ll TABLE 8-2B - [ ] SLEEVE I
AXIAL HEMBER PHYSICAi PROPEPTIES At Reference
~
NEAR BUNDLE P Rfi>HERY Nonnal Oper. Temps.
SectTon Correspond. Youngs Mean Coef.
Outside Inside Stiffness Therm. Exp.
Radius Length Area Temperature Modulus Radius A E K=AE/L am Rg R, L -
6 3 lb/in X10 lb/inX10 g,jg,.7 I (In) (In) (In) (In ) -
~
l (1) Sleeve (2) Lower Tube
, (3) Tube in Tubesheet o
tu (4) Upper Tube l
(5) Surrounding Tubes _
Reference Temperatures: Primary (Hot) = T = 594*F Pri (Use for E and am)
Secondary =T sec = 489*F (near bundle periphery - 17*F (Assumed) subcooled downconer temperature)
=
sec = 559 F Normal Tubes 3 Notes: (1) a ,and E for Inconel 690 from Huntington Alloys Bulletin.
, I (2) a , for Carbon Holy Steel.
425a(83T14)/als-12 ,
l i. -
\s
\\ TABLE 8-2C - [ ] SLEEVE
\ '
At Reference )
\ s' Outside AXIAL MEMBER PHYSICAL PROPERTIES IN CENTRAL BUNDLE REGION Inside Section Correspond. Youngs Normal Oper. Temps.
Mean Coef.
s s
Radius Length Area Temperature Modulus Stiffness Therm. Exp.
Radius-A E K=AE/L am R, Rg L -
2 2 6 3 (In) (In) (In ) -
Ib/in X10 lb/inX10 In/In*F (In)
(1) Sleeve i (2) Lower Tube (3) Tube in Tubesheet I l
{ (4) Upper Tube (5) Surrounding Tubes Reference Temperatures: Primary (Hot) = T = 594*F Pr1 (Use for E and am)
Secondary =T sec = 506*F (in central bundle region - sat. temp.)
l I
' 2T
! Normal Tubes = M+ 3 T * = 565 F Notes: (1) a ,and E for Inconel 690 from Huntington Alloys Bulletin.
l (2) a , for Carbon Moly Steel.
I I i
425a(83T14)/als-13 TABLE 8-2D - [ ] SLEEVE AXIAL MEMBER PHYSICAL PROPERTIES At Reference NEAR BUNDLE PERIPHERY Nomal Oper. Temps.
Outside Inside Section Correspond. Youngs Mean Coef.
Radius Radius Length Area Temperature Modulus Stiffness Them. Exp.
R g R, L A - E K=AE/L am 2 6 3 (In) (In) (In) (In2) -
lb/in X10 lb/inX10 In/In*F
- T (1) Sleeve (2) Lower Tube (3) Tube in Tubesheet m
h (4) Upper Tube m
(5) Surrounding Tubes
.\
Reference Temperatures: Primary (Hot) = T = 594 F Pr1 (Use for E and am)
Secondary =T = 467 F (near bundle periphery - 39 F sec subcooled downcomer temperature)
Normal Tubes = 2TP#I + T sec = 552 F 3
Notes: (1) a ,and E for Inconel 690 from Huntington Alloys Bulletin.
(2) a , for Carbon Moly Steel.
425a(83T14)/als-14 TABLE 8-3A - [ ] SLEEVE AXIAL LOADS IN SLEEVE WITH TUBE NOT LOCKED INTO SUPPORT PLATE Sleeve Net Load Elongation T
pri T
sec 6
7 6
2 6
3 6
Forced Fy A1 = Fy/Ky (67+Ag ) = 6 6 Condition ( F) ( F) (In) (In) (In) (In) (lbs) (In) (In)
IN CENTRAL TUBE BUNDLE
~
, ~Y
- a. Normal Operation 100% Power
- b. Reactor Trip (50 sec.)*
- c. Hot Standby
- m NEAR BUNDLE PERIPHERY
% d. Normal Operation 100% Power
- e. ReactorTrip(50sec.)*
- f. Hot Standby *
- NOTE: Due to small variation, E and a, value for normal operation,100% power are used.
425a(83T14)/als-15 TABLE 8-3B - [ .] SLEEg AXIAL LOADS IN SLEEVE WITH TUBE NOT LOCKED INTO SUPPORT PLATE Sleeve Net Load Elongation T
pri T
sec 6
7 6
2 6
3 6
Forced F
1 A
y = Fy /K y (67+A7 ) = 6 6 Condition ( F) (*F) (In) (In) (In) (In) (1bs) (In) (In) i IN CENTRAL TUBE BUNDLE
- a. Normal Operation 100% Power
- b. Reactor Trip (50 sec.)*
- c. Hot Standby
- m NEAR BUNDLE PERIPHERY
$ d. Nonnal Operation 100% Power
- e. Reactor Trip (50 sec.)*
- f. Hot Standby *
- NOTE: Due to small variation, E and a, value for normal operation,100% power are used.
i
425a(83T14)/alS-16 TABLE 8-4A - [ ] SLEEVE AXIAL LOADS IN SLEEVE WITH TUBE LOCKED INTO SUPPORT PLATE Sleeve Net Load Elongation - - - - -
T F2 6 -F T
pri T,,, t= 2Tl+T* 5 6 04 0 Forced F
6 A s6
- /K 6 66+A6 A44 j j 6 I 14 1"1 j Condition ('F) (*F) ('F) (In) (In) (In) (Lbs) (In) (In) (Lbs) (Lbs)
CENTRAL TUBE BUPOLE - ,
- a. Normal Oper.
100% Power
- b. Reactor Trip *
(50 sec.)
- c. Hot Standby
- NEAR BUDOLE PERIPHERY
- d. Normal Oper.
100% Power en I* e. Reactor Trip
- y (50 sec)
- f. Hot Standby *
- NOTE: Due to Small variation, E and amvalue for nomal operation,100% power are uSed.
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