ML20205K335
| ML20205K335 | |
| Person / Time | |
|---|---|
| Issue date: | 04/06/1999 |
| From: | Stewart Magruder NRC (Affiliation Not Assigned) |
| To: | Carpenter C NRC (Affiliation Not Assigned) |
| References | |
| PROJECT-689 NUDOCS 9904130112 | |
| Download: ML20205K335 (29) | |
Text
i April 6, 1999 i
MEMORANDUM TO: Cynthia A. Carpenter, Chief Generic Issues and Environmental Proj0 cts Branch Division of Regulatory improvement P,'ograms Office of Nuclear Reactor Regulatica FROM:
Stewart L. Magruder, Project Manager " Original Signed By" Generic issues and Environmental Projects Branch Division of Regulatory improvement Programs Office of Nuclear Reactor Regulation
SUBJECT:
SUMMARY
OF FEBRUARY 9,1999, MEETING WITH THE MATERIALS RELIABILITY PROJECT AD HOC ISSUES TASK GROUP Members of the Materials Reliability Project Ad Hoc Issues Task Group met with Nuclear Regulatory Commission (NRC) staff on February 9,1999, at the NRC offices in Rockville, MD. Meeting attendees are identified in Attachment 1. A summary of the meeting is provided in Attachment 2. Attachments 3 and 4 contain the slides presented during the meeting.
Project No. 689 Attachments: As stated cc w/att: See next page DISTRIBUTION: See attached page Document Name: g:\\SLM1\\msum0209.wpd i
N l
OFFICE PM:RGEB (A)SC:PGEB NAME SMagruder:a% TBergmanM 9N DATE 4/ G /99 4/ h/99
'7947 9904130112 990406 PDR REVOP ERONUMRC PDR o
Nuclear Energy Institute Project No. 689 cc:
Mr. Ralph Beedle Ms. Lynnette Hendricks, Director Senior Vice President Plant Support and Chief Nuclear Officer Nuclear Energy Institute Nuclear Energy institute Suite 400 Suite 400 1776 i Street, NW 1776 l Street, NW Washington, DC 20006-3708 Washington, DC 20006-3708
- Mr. Alex Marion, Director Mr. Charles B. Brinkman, Director Programs Washington Operations Nuclear Energy Institute ABB-Combustion Engineering, Inc.
Suite 400 12300 Twinbrook Parkway, Suite 350 1776 i Street, NW.
Rockville, Maryland' 20852 Washington, DC 20006-3708 Mr. David Modeen, Director j
Engineering Nuclear Energy institute Suite 400 1776 i Street, NW Washington, DC 20006-3708 Mr. Anthony Pietrangelo, Director Licensing Nuclear Energy Institute Suite 400 j
1776 l Street, NW 1
Washington, DC 20006-3708 Mr. Nicholas J. Liparuto, Manager Nuclear Safety and Regulatory Activities Nuclear and Advanced Technology Division Westinghouse Electric Corporation P.O. Box 355 l
Pittsburgl, Pennsylvania 15230 l
Mr Jini Davis, Director Operations Nuclear Energy institute Suite 400 l
1776 l Street, NW l
Washington, DC 20006-3708 l
NRC/MRP Meeting LIST OF ATTENDEES February 9,1999 NAME ORGANIZATION Dick Wessman NRC/NRR Keith Wichman NRC/NRR Matthew Mitchell NRC/NRR Ted Sullivan NRC/NRR Mark Hartzman NRC/NRR Eric Debec N9C/NRR Jim Shapaker NRC/NRR Jack Strosnider NRC/NRR Kamal Manoly NRC/NRR David Modeen NEl Kurt Cozens NEl Millan Straka NUS-LIS Tom Mulford EPRI Ernest Throckmorton Virginia Power J. Michael Davis Duke Energy
F l
MINUTES OF THE MEETING BETWEEN NRC DIVISION OF ENGINEERING AND NUCLEAR ENERGY INSTITUTE PERSONNEL FEBRUARY 9,1999 1~
ROCKVILLE, MD On February 9,1999, Division of Engineering staff members rnet with an Ad Hoc issues Task Group (AHITG) of the Materials Reliability Project (MRP), an industry group associated with the Nuclear Energy Institute.
The objective of the meeting was:
l a) to share the results of a recent industry survey performed by the AHITG regarding inspection of unisolable portions of High Pressure Safety injection (HPSI) piping attached to the RCL, and susceptible to thermal cycling fatigue cracking (addressed in NRC Bulletin 88-08) b)-
to solicit NRC feedback on these issues, for possible further discussion with an MRP group, the issue integration Group.
NRC Presentation (see Attachment 3) i The staff presented a summary of the issues regarding potential cracking of HPSI piping from I
the NRC perspective. The presentation addressed the following:
- The Oconee 2 High Pressure injection / Normal Make Up line through wall crack event, and its risk significance.
Recent experience of cracking in foreign plants and lessons learned.
Recommended measures in NRC Bulletin 88-08 to prevent cracking due to thermal stratification cycling.
e'
. Perceived dMciencies in ASME Section XI inspection requirements for Class 1 small bore piping.
NEl Presentation (see Attachment %)
The AHITG conducted a survey of licensees to determ;ne the measures adopted in their plants to prevent potential cracking in HPl lines.
i
_11 licensees, with a total number of 32 PWR units, were interviewed This represents about half of the total number of PWR units in the US.
All units have addressed the requirements of NRCB 88-08 to varying degrees.
e ATTACHMENT 2
-l
E t,
1 28 of 32 units conducted volumetric examinations of welds in piping connected to the e
RCS beyond the requirements of lWB 2500.
21 of 32 units examined welds in piping less than 4" NPS 15 of 32 units found evidence of thermal fatigue cracking as a result of the e
examinations. However, only 9 of 32 units used enhanced UT techniques (those developed to detect IGSCC).
18 of 32 units maintain a program for assessing the potential of thermal fatigue cracking e-in unisolable piping connected to the RCS.
7 of 11 utilities considered additional research useful but not necessary e
t3ased on its survey, and discussions with the licensees, the AHITG concluded that:
e Thermal cycling failure mechanism in the HPl lines is not well understood.
Domestic failures appear to be related to the failure of specific system components (i.e.
e leaky valves), and not to a generic design issue.
The industry would benefit from improved knowledge on:
e The thermal cycling mechanism Monitoring Non destructive examination techniques for the HPSI piping. The staff agreed with these conclusions.
The AHITG also stated that the ASME Code is moving toward including thermal fatigue as a criterion f;r selection of welds for inspection on any line.
The AHITG proposed to request that the MRP issues Integration Group recommend to the MRP's Senior Executives that funding '.s allocated to establish a standing ITG, and to support additional research related to these topics. The staff concurred with this proposal,
4 SAFETY INJECTION PIPE CRACKING MATERIALS RELIABILITY PROJECT SURVEY RESULTS PRESENTED TO THE NRC STAFF ON FEBRUARY 9,1999 ATTACHMENT 4 1
4 MEETING OBJECTIVES o Present results of the PWR MRP Ad Hoc ITG survey results o Solicit NRC feedback on issue for discussion with MRP issue Integration Group (llG)
I 2
n p -.
1 I.
I SURVEY PARTICIPANTS Licensees o
PWR Units -- 32 I
.3
p l
t l
Survey Questions Yes -- 28 A) As a result of thermal fatigue concems, does/has the plant
/
conducted volumetric examinations of welds in piping
/
connecting to the RCS boundary beyond t' e requirements of IWB 25007-N No - 4 1
- 1) If yes; Yes - 21 l Does/Did the examinations include any pipino less lNo - 6 l
than 4 inch NPS?
Unkn - 1 l Yes - 9 l Were/Are enhanced UT examinations techniques lNo -- 5 l
used?
Unkn - 121 Yes - 17 l
- 2) Has the plant ever performed any purely base metal examinations because of thermal fatiaue concems?
No - 13 l
- 3) Has the plant ever found evidence of thermal fatigue Yes,15 l Primarilyrelated to cracking as a result of the examinations? If yes, please No - 13 l generic activity.
describe.
<10 welds -- 1 l
j
- 4) Does the plant have a small number of welds ( < 10 ),
a moderate number of welds ( 10 to 30 ), or a large l10 - 30 welds - ii l 1
number of welds (> 30 )in unisolable piping less than 4
> 30 welds - 19 l inch NPS connecting to the RCS?
Unkn - 1 l
4
fi~
t i
Yes - 18 l B) Does the plant maintain a program for assessing the potential of thermal fatigue cracking to develop within unisolable piping lNo - 7 l
connecting to the RCS?
Unkn - 5 l
- 1) If yes; lMonitorina (temperature or pressure or both)?
l 3-IValve condition assessment?
l
[
IOther, please describe? '
l
- 2) Does the plant monitor industry events related to thermal
- Yes j i
fatigue cracking and assess the events for applicability?
- 3) If no to B1 and/or B2 above. please identify the basis; lN/A l
analytical assessments. etc.?
4 6
4 5
i
r-4 C) Describe the actions the plant took in response to IB 88-08 or other industry events related to thermal fatigue cracking?
See insert 1
- 1) If any of these actions were discontinued please 4
describe why.
The temporary T/Cs were removed cr monitoring was otherwise discontinued based on the judgment that the monitoring period envelopes the susceptible behavior.
None of the actions were of a I
continuous nature. This was a one time assessment.
UT only performed once; thermal j
monitoring has not detected a problem.
6
f t
INSERT 1 Detailed Responses to Survev Question 3 Started enhanced UT's on all HPl and safe end welds. Augmented RT's were planned and have been done on HPl nozzles to e
' ensure thermal sleeve to safe end gap is not growing and to ensure adjacent base meta lis still acceptable.
The phenomenon described in 1B88-08 was not applicable. No action or inspections were conducted.
e All unisolable piping was reviewed to determine its susceptibikty to thermal stratification. It was concluded that the HPI line the only lines that were susceptible. The activities performed in 1982 were deemed adequate to prevent cracking in the HP These 1982 activities were: The thermal sleeve in the normal make up line was replaced and the remaining three were re-rolled.
(Subsequent events have lead to replacing these three sleeves ) HPl check valves were moved so that they are further fro RCS. Strain gages and thermocouples were instaUed and data gathered from a start up in 1982. No deleterious readings wer found. Periodic RT is being priormed due ensure that the thermal sleeves have t'ot moved from the intended location.
)
These units came on the line posMB 88-08; however, the plant instituted an ongoing thermal stratification monitoring program.
o Data is sent to Westinghouse for analysis. No significant problems to cate. [ltis believed (but not confirmed) that extra inspections were performed, however, this is a moot point because the plant would have been new at the time).
The Emergency HPllines were identified as being susceptible to the phenomena described in the t "etin. Welds on these knes e
were examined using UT. These lines were instrumented in one un t using temporary extemally mounted thermocouples to search for phencmena as desenbed in the bulletin. Such phenomena were not observed, but thermal cycling associated with check valve leakage as well as cross flow associated with Reactor Coolant Pump cycling was observed. At that time, there was no base ASME fatigue analysis for inclusion of these events since the branch lines were analyzed only to B31.1 These events have subsequently addressed in the recently completed ASME Class 1 aaalysis upgrade for these lines. NRC has requested a updated Bulletin 88-08 response to include discussion of experience related to the Normal HPl weld leak in 1997.
The 1 % inch Charging Pump Safety injection lines were identified as being susceptible to the phenomena described in the bulletin. Accessible welds on these lines were er.amined using PT for socket welds and UT for butt welds. These lines were instrumented using temporary extemally mounted thermocouples to search for phenomena as described in the bulletin. Su phenomena were not observed, but thermal cycling associated with check valve leakage as well as cross flow associ Reactor Coolant Pump cycling was observed. Observed events have been addressed in the ASME Class 1 analyses for thes j
lines.
The 1 % inch Charging Pump Safety injection lines were identMed as being susceptible to the phenomena described in th e
i bulletin. Welds on these lines were examined using PT for socket welds and UT for butt welds. Further actions were avoided use of the USNRC screening criteria allowing exemption based on the distance from the Reactor Coolant loop to the first v Future p!ans are to instrument similar to that done for our other units.
'The plant performs temperature monitoring of non-isolable lines that are considered susceptible to thermal fatig e
those lines showing sign 9 ant thermal stratification! cycling, Westinghouse evaluates the data for susceptibility to therm cracking and recommends corrective actions. Augmented UT examinations are performed, as deemed necessary.
CE Owners Group activities concluded that the safety injection, shutdown cooling, pressurizer safety and relief, PORV main spray! aux spray piping may be susceptible to stratification of either the type described in 88-08 or second
- the piping between the first and second isolation valves off the RCS). Layout considerations (proximity of the to the RCS or lack of horizontal piping run) eliminated the primary stratification concems as described in 88-08. Global mome from secondary stratification are being incorporated into design. Pressurizer piping in proximity to the pressurizer is replaced cur ently becauee of thermal fatigue concems, stemming mainly from review of past operations and real thermal transients were not considered by the original design. These include multiple sprays during each cooldown, re of the upper portions of the piping when aux spray is terminated, inadvertent use of aux sprays at full power stratification in the header horizontal piping when RCPs are initially tumed on.
7
o Detailed Responses to Survey Question 3 (Continued)
Structural Integnty Associated performed a detailed review for I&E Bulletin 88-08 and concluded that with safety injection isolation o
valve leak testing in place, none of the piping required immediate action. Minor susceptibility to in-leakage was identified for the out of service charging line in loop 'D' and the aux spray line. The recommended inspection locations were forwarded to the Risk Informed ISI group. It is believed that these locations did not screen in. Inspections for the Feedwater nozzle are being planned j
to assess cracking due to thermal fatigue.
1 In the 1992-1993 time frame the CE owner's group started a study to resolve the issues for all of the CE units on a generic basis.
o The CEOG report was issued in 1995. Dir Hartman was the most interested party at NRR. The licensee took the generic CE report and customized it for their plant (s) by gathenng empirical data on the one line that was identified as a possible source of high pressure cold water leaking past shut isolation valves into the RCS. This one line is the Auxiliary spray line. Empirical data was collected for two fuel cycles and came from 120 thermocouples, flowmeters, and strain gages. The data was extrapolated for all possible leakage rates past the isolation valves. The conclusion was that high cycle therma! fatigue was not possible. (The low cycle bending moments due to stratification is being added to the piping stress analysis.) The USNRC has issued the licensee an SER closing this issue. The licensee is still working on the final report but considers the issue closed. No further monitoring or evaluations are planned.
Aware that inspections were performed on selected piping and material locations.
o Reviewed the lines which could be susceptible to the licensee event. Performed a UT examination of areas most likely to see e
therma! fatigue if it existed installed thermal monitonng on the lines.
The plant has an ongoing thermal stratification monitoring program where data is taken at least once per 6 months. Data will be o
sent to Westinghouse for analysis if!when the measured temperature differential exceeds a specified value. Augmented UT inspections were performed on Unit i suscept;ble welds in response to Bulletin 88-01, but not on Unit 2 because it had not started operation.
The Auxiliary Spray System piping and Charging to High Pressure Safety infection bypass lines were identified as being susceptible to the phenomena describe in the bulletin Thirty-one welds considered most likely to be affected by thermal cycling were identified. Thirty of these welds (one weld was obstructed by a pipe cl amp) were subjected to nondestructive tests (NDE).
Ultrasonic testing (UT) performed on the selected welds during Refuel 3 showed no indications of cracking. The results of the ultrasonic tests were evaluated to determine the frequency at which these welds should be examined in the future. The engineering evaluation concluded that no further examinaticns were required. However, we will conservatively UT the same thirty welds once each ten yearinterval.
8 l
r 1
D) Does the plant have a group or an individual considered an l
' expert" or highly competent in the theory of thermal fatigue
- Yes-32, Sometimes uses blSSS cracking? If yes:
vendor
- 1) is the group or person familiar with the existence and content of EPRI Technical Report TR-103581 All aware of EPRI report, but using (Thermal Stratification, Cycling, and Striping (TASCS),
it to various dearees
)
March 1994) and is it used in evaluating the potential for thermal fatigue cracking?
- 2) Does this group or person feel the analytical tools are Yes, but simplified screening adequate to assure the plant is protected against ap roach based on an improved unisolable leaks in the piping connecting to the RCS? If mechanistic definition would be not, what is missirg?
useful.
9 i
E) Does the plant feel the development of an industry " tool box" to provide both analytical and inspection / monitoring assistance in the management of thermal fatigue cracking:
- 1) is needed and should be developed, or lYes - 14 (4 utihties) l
.2) Would be useful be not really necessary, or lYes - 9 (5 utilities) l
- 3) is a waste of time and money?
lYes - 9 (3 utilities) l 10
r i
Summary of Survey Results A
3 ants aerormec at east one o"t1e "o owing in o
res 3onse to B _88-08:
Ana ysis Vlonitoring Insaection Vost 3 ants lave ins 3ectec Jipes wit 1 diameters ess o
i tlan L incles and base meta for t1erma "atigue crac<ing Vost 3 ants Jer"orm activities for t1erma 'atigue in areas o
of concern Vosty t1erma monitoring A
3 ants monitor inc ustry events "or 11erma "atigue o
issues - sus 3ectec Owner Event Re3 ort 3rocess usec A
31 ants lave access to <no'uledgeaale 3ersonnel o
Industry sunort 'or additiona researclis not strong 0
11
t DRAFT AD HOC ITG CONCLUSIONS Fai ure meclanism not we uncerstooc o
Numerous root causes Vode s may 3e a]e to 3recict Jotentia "or crac<ing, l
Jut una] e to 3recict w1en and where crac<ing wi occur Domestic "ai ure a] pears to 3e fant s]ecific o
Event c riven - not generic design issue
=
nc ustry wou c 3enefit 4 rom improvec <now edge on o
r iure mechanism a
Vonitoring teclnicues N DE tec1nic ues 12
Ad Hoc ITG Actions o
Ac Foc l G wi ma<e recommendation to Vateria s Re la 3i ity 3ro,'ect issues Integration Grou a on 2/' 8/99 3ro30 sing ceve o] ment o"tec1nica 3 asis re] ort wit 1 anro riate sunorting researcl 3
l' recommencation acce3tec:
o
- orma y estabis1l G
=
TG wi define cetails and sclec u e o" aro.'ect See< VR3 "unding Accitiona interactions wit 1 t1e \\ RC sta=, as anroariate i
13
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