ML20235F449
| ML20235F449 | |
| Person / Time | |
|---|---|
| Site: | Oyster Creek |
| Issue date: | 09/21/1987 |
| From: | Fiedler P GENERAL PUBLIC UTILITIES CORP. |
| To: | Russell W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| References | |
| IEB-87-001, IEB-87-1, NUDOCS 8709290127 | |
| Download: ML20235F449 (13) | |
Text
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GPU Nuclear Corporation 5 Nuclear m'e=r388 Forked River, New Jersey 08731-0388 609 971-4000 Writer's Direct Dial Number:
September 21, 1987 Mr. William T. Russell, Administrator Region I U.S. Nuclear Regulatory Commission 631 Park Avenue King of Prussia, PA 19406
Dear Mr. Russell:
Subject:
Oyster Creek Nuclear Generating Station Docket No. 50-219 Response to IE Bulletin 87-01 " Thinning of Pipe Walls" On July 9,1987, the USNRC issued IE Bulletin 87-01 identifying several nuclear power plants which had experienced difficulties related to pipe wall thinning.
The bulletin further specified information to be supplied by nuclear licensees.
This letter is being written to meet that requirement.
Attachment I provides the specific information required by this bulletin relating to the Oyster Creek Nuclear Generating Station.
If any further information is required, please contact Mr. John Rogers at (609)971-4893.
Very truly yours, p c:
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f At I; 8709290127 870921 I
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8 P
riedier
)> g PDR ADDCK 05000219 P
PDR Vice President and Director p
Oyster Creek h
t4 PBF/JR/dmd (0346A) cc; Document Control Desk (original)
Sworn to and Subscribed U.S. Nuclear Regulatory Commission before me this A/3Fday Washington, DC 20555 ofM.ndou 1987.
/
/
Mr. Alexander W. Dromerick, Project Manager
/_
U.S. Nuclear Regulatory Commission
//7 -
d Division of Reactor Projects I/II Notary Public Of'NJ 7920 Norfolk Avenue, Phillips Bldg.
Bethesda, MD 20014 DIANA M. DeBLASIO My Commission Expiree ggEY NOTARY PUBUC 0F NE Mail Stop No. 316 NRC Resident Inspector Oyster Creek Nuclear Generating Station j
I g/
GPU Nuclear Corporation is a subsidiary of the General Pubhc Utihties Corporation
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I Response to IE Bulletin 87-01 Attachment I j
1 The following information specific to the Oyster Creek Nuclear Generating l
Station is submitted as required by IEB 87-01.
Actions Requested:
f Within 60 days from the receipt of this bulletin, licensees are requested to provide the following information concerning their programs for monitoring the wall thickness of pipes in condensate, feedwater, steam, and connected high-energy piping systems, including all safety-related and non-safety-related piping systems fabricated of carbon steel:
1.
Identify the codes or standards to which the piping was designed and fabricated.
Response
OCNGS piping was designed and fabricated in accordance witt. Burns and Roe Inc. Specification SP-2299-60 for the Reactor Building and Lurns and Roe Inc. Specification SP-2299-48 for the Turbine Building.
SP-2299-60 (Reactor Building) required piping connected from the pressure vessel, up to and including the first isolation valve, to comply with ASME Sections I and IX,1965 edition, with supplements, addenda, and applicable code cases in force at the time of the contract with Burns and Roe Inc.
SP-2299-48 (Turbine Building) required fabrication in accordance with ASA B31.1, 1955 edition, Sections 1 and 6 with appendices, c
2.
Describe the scope and extent of your programs for ensuring that pipe wall thickness are not reduced below the minimum allowable thickness.
Including in the description the criteria that you have established for:
a.
se'e:: ting points at which to take thickness measurements b.
determining how frequently to take thickness measurements c.
selecting the methods used to take thickness measurements d.
making replacement / repair decisions 1
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Response
The following systems have been identified and are presently within the scope of the OCNGS Pipe Wall Thinning Program:
Turbine Drains Main Steam (outside Containment)
Reheat Steam Extraction Steam Condensate Feedwater FW Heater Drains Aux Boiler Steam Heating Steam Shutdown Cooling a.
Component selection for thickness measurements is based on the following criteria:
1.
Process Fluid:
temperature above 195*F, pH and oxygen content (all systems included-no exclusions made), and moisture content (2% and above) 2.
Pipe Material (carbon steel, lack of alloying metals Cr, Mo, Cu) 3.
Geometry (each system is evaluated for arrangement of components-configurations conducive to flow disturbances) 4.
Fluid Velocity (all systems included-prioritization of inspection selections with nigher velocities) 5.
Additional inspection prioritization criteria:
System Category (e.g. required for :;hutdown; prevention of challenges to safety systems)
Component Locations (e.g. related to safety equipment; personnel hazard)
Operating Frequency Design Margin (based on ratio between nominal and minimum design pipe wall thickness)
NOTE: Minimum design pipe wall thickness based on ANSI B31.1 formula for internal pressure (hoop stress), where A=0.
See Table 1 b.
Thickness measurement frequency:
1.
New inspections scheduled during refueling outages.
2.
Reinspection scheduled during refueling outages, or at earliest windows of opportunity if required by engineering evaluation of remaining Safe Operations Life.
Refer to Table 1.
c.
Thickness measurement technique:
Thickness will be measured utilizing ultra-sonic (UT) non-destructive examinations.
j-d.
Repair / replacement decisions:
The decision to repair and/or replace identified piping will be made on the evaluation criteria specified in Table 1.
3.
For liquid-phase systems, state specifically whether the following factors have been considered in establishing your criteria for selecting points at which to monitor piping thickness (Item 2a):
a.
piping material (e.g., chromium content) b.
piping configuration (e.g., fittings les:; inan 10 pipe diameters apart) c.
pH of water in the system (e.g., pH less than 10) d.
system temperature (e.g., between 190 and 500*F) e.
fluid bulk velocity (e.g., greater than 10 ft/s) f.
oxygen content in the system (e.g., oxygen content less than 50 ppb) i
Response
The factors included in the OCNGS evaluation include:
a.
Piping Material (carbon steel, lack of allo)%g metals Cr, Mo, Cu) b.
Piping Configuration (each system is evaluated for arrangement of components-configurations conducive to flow disturbances) c.
pH Value (all systems included) d.
Temperature (195-440*F) e.
Bulk Velocity (all systems included-prioritization of inspection selections with higher velocities) f.
Oxygen Content (all systems included)
NOTE: pH and oxygen factors have not been used to prioritize inspection points. Future use of the 'CHEC" E/C computer program, currently under evaluation, may take pH and Oxygen contents into account.
4.
Chronologically list and summarize the results of all inspections that have been performed, which were specifically conducted for the purpose of identifying pipe wall thinning, whether or not pipe wall thinning was discovered, and any other inspections where pipe wall thinning was discovered even though that was not the purpose of that inspection, a.
Briefly describe the inspection program and indicate whether it was specifically intended to measure wall thickness or whether wall thickness measurements were an incident determination.
b.
Describe what piping was examined and how (e.g., describe the inspection instrument (s), test method, reference thickness, locations examined, and means for locating measurement point (s) in subsequent inspections).
c.
Report thickness measurement results and note those that were identified as unacceptable and why.
d.
Describe actions already taken or planned for piping that has been found to have a nonconforming wall thickness.
If you have performed a failure analysis, include the results of that analysis.
Indicate whether the actions involve repair or replacement, including any change of materials.
Response
a.
Development of Oyster Creek's Wall Thinning Program June 1978, at high power operations, a small crack developed in a feedwater discharge pipe imediately downstream of "C" Reactor Feed Pump. The failure occurred at the small end of a 14"x8" reducer.
The plant was reduced in power, metal plates were welded to the reducer and power increased.
Oct..1978, during a maintenance outage, U.T. readings were taken at the discharge of all three feedwater pumps. The readings revealed that wall-thinning had occurred at all locations and subsequently the three fittings were replaced. A visual examination and evaluation by the General Physics Corporation stated that the damage occurred as a result of the following:
1.
The system being maintained in a partially drained condition during maintenance outages; 2.
The formation of scale (above normal) due to the water / air interface in the reducer; 3.
The removal of this scale due to high velocities at the 8" section of the reducer; and 4.
Erosion amplification from cavitation in the damaged area as local fluid velocities rose from small eddies formed in the damaged regions.
During 0ct.1978 wall reduction was also discovered in the six inch pipe downstream of a reheater drain tank flow control valve.
Wall thinning was the result of wet steam traveling at a high velocity. A 6"xS" reducer located downstream of a low flow control valve was ultrasonically tested in Oct.1978 and indications of mild wall thinning was discovered.
Nov.1982, INP0 issued a Significant Operating Experience Report (SOER 82-11) " Erosion of Steam Piping and Resulting Failures." In the report it was noted that erosion and subsequent failure of steam piping, at four nuclear power plants have led to personnel injury and lost plant production.
In response to INP0's concerns and General Physics recommendations five locations on Main Steam and Extraction Steam piping sections were identified for wall thickness measurement at Oyster L. reek (March 1983).
In April 1983, Plant Materiel Department worked with the Technical Functions and Nuclear Assurance Divisions to identify additional areas of concern. Most noticeably, pipe sections subjected to the:
- 1. high steam moisture content; 5% moisture
- 2. high steam velocity; 150 ft/sec
- 3. unusual pipe geometry; elbows and T's
l l-1 Based on the above, the following list was developed.
1.
Main and Extraction Steam - piping carrying H.P. and L.P. exhaust l
and extraction steam to the Moisture Separators and Feedwater Heaters.
2.
Feedwater and Condensate - smaller 4 and 8 inch diameter piping.
3.
Heater Drain & Vent and Relief - piping susceptible to fluid flashing.
4.
Isolation Condenser - vent line from isolation condensers to 24" main steam line.
May 1983, the list was expanded to include piping from the following systems:
- 1. Circulating Water
- 4. NRW Service
- 5. Heating System
- 3. Emergency Service Water
- 6. Domestic Water The above list was prioritized and a 10R refueling outage (1983-1984) workscope was developed.
This included:
6 inspections of Main Steam & Extraction Steam Piping 28 inspections of Feedwater System Piping 6 inspections of Circ Water Condenser Backwash Piping All inspections were satisfactory except for the 14" X 16" increasing elbows upstream of all three H.P. Feedwater Heaters.
Thin spots were recorded near a longitudinal weld and were repaired using a weld overlay.
For the llR outage, Plant Materiel developed an extensive wall thinning scope which included the following pipe locations:
2 inspections of High Pressure Turbine Exhaust to Moisture Separators 17 inspections of Moisture Separator Drains and Reheater Drains 8 inspections of Feedwater System i
9 inspections of Main Steam System in the DW j
9 inspections of Extraction Steam System 1
6 inspections of SCRAM Discharge System 1
Most of the above U.T. inspections were deferred due to tasks of higher management priority.
Five Main Steam Drain Lines were U.1. inspected.
One of the lines (2" from the Main Steam leads to condenser 1-A) developed a thru wall leak during cycle 10 and was replaced during llR.
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l Additional ultrasonic inspections have been completed outside of the Plant Materiel Wall Thinning Program, including the following systems:
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Shutdown Cooling Service Water Screenwash HVAC Steam Scram Discharge Containment Spray Closed Cooling Water Emergency Cooling Water Circ Water Off Gas H O Removal 2
The review and disposition of these inspections were completed by various departments.
Inspection results are presently being reviewed as part of the Wall Thinning Program for scheduling future thickness measurements.
The OC Pipe Wall Thinning Inspection Program presently involves a number of groups. The groups along with their responsibilities are listed below:
- 1. Technical Functions Mechanical Systems a) Identify high-energy systems with potentially susceptible piping, b) Identify specific piping locations for inspections and set priorities.
- 2. Technical Functions Mechanical Components a) Determine where individual wall thickness measurements should be taken.
b) Establish pipe section inspection methods.
j c) Establish inspection frequencies.
d) Establish replacement criteric.
- 3. Oyster Creek Plant Materiel a) Schedule and initiate work needed to support the inspections, b) Review all inspection data.
I c) Determine if any corrective actions are needed.
d) Maintain and update scope of inspection program based on a review of inspection data.
- 4. Maintenance & Construction a) Provide craft to prepare pipe surface for inspection and performing correction action.
- 5. Quality Assurance NDE a) Perform the U.T. inspection.
I General Physics recommended in their report that a comprehensive program designed to predict and prevent pipe failure be initiated, l
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~7-ll j-Cycle 11 and Post Surry. Inspections The following. inspections have been performed during 1987 using some of the information gained from the Surry accident:
1.
7 inspections on the'Feedwater systeo, Loth upstream and downstream of the Reactor Feedwater Pumps.
- 2.. 1 inspection on a 2" Main Steam Drain Line from the 30" header.
3.
5 inspections on various fittings of the Heater Drain System which included locations between Drain Tanks and Flash Tanks 1-1 and 1-2.
4.
Emergency Service Water elbows and tees on the Containment Spray Heat Exchangers.
All inspections were satisfactory except for the following:
1.
A Feedwater elbow downstream of reactor feed pump 1-C readings were less than manuf acturing tolerance (12.5% minus nominal). The l
minimum wall thickness allowed by the. application of this l
manufacturer's tolerance is.082 inches.
The as-found minimum was
.0730 inches. Materiel Non-Conformance Report 87-075 was dispositioned use-as-is because a conservative erosion rate predicted a safe operating life of five years.
In addition, the i
elbow will be reinspected during 12R.
2.
A thru wall leak and thin areas were identified on a 6", 45 degree elbow upstream of a FCV on the line from the 1-3 Drain Tank (Moisture Separator Drains) to the 1-2 Flash Tank.
A clamp was placed on the elbow to stop the leak and the component is scheduled to be replaced during a shutdown.
3.
A thru wall leak and thin areas were identified on the Emergency Service Water System. An outlet tee from a Containment Spray heat Exchanger was repaired and other components (elbows and tees) were I
placed on a monitoring schedule, b.
Examinations Thickness measurements were performed previously to determine pipe condition with minimal consideration made to provide for locating measurement points during future inspections. While test methods did vary in past inspections, most of the wall thickness measurements were taken by drawing a grid 2" or 4" on a component and ultrasonically scanning each grid to determine: (1) the thinnest point on the grid and (2) a representative reading for the grid.
Once a lowspot was located a D-Meter was used to determine the minimum thickness in the grid.
These two readings were recorded on a data sheet showing the grid layout chosen for each component.
During future inspections on components with previously recorded data, a decision will be made on a case by case basis to determine if the original grid can be reproduced from the data sheet layout.
E.
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c, d.
Inspection Results and Actions Taken Table 2 is a computer listing of the OCNGS Wall Thinning inspections. The table is sorted by system and the date the inspection was performed and contains the following:
1.
NDE#: Nondestructive Examination Data Sheet #'s.
The data sheet contains the ultrasonic measurements and a drawing indicating where the readings were taken.
2.
Date: Date inspection was performed.
3.
System #: 3 digit number corresponding to a unique plant system.
4.
Component: Component (s) type inspected, e.g. elbow, tee.
5.
Size: Size of Pipeline.
6.
Sched: Piping Schedule as listed in Burns & Roe Piping Specification S2299-48.
7.
Nom: Nominal Thickness for the schedule.
8.
==
Description:==
Location description.
9.
Inspection: Type of inspection, e.g. full, partial.
- 10. Min: Minimum wall thickness list on the NDE data sheet.
11 RPTBL: Reportable thickness = Nomital thickness - 12.5%
manufacturing tolerance.
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- 12. Comments: Satisfactory, Reportable or Unsatisfactory.
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Notes for Table 2 1.
Drain line replaced during 11R Refueling Outage.
I 2.
The 14" X 16" 90 deg elbows on all three feedwater strings had thin areas around a longitudinal weld. All were repaired with a weld overlay during the 10R Refueling Outage.
3.
Presently has a temporary repair, clamp around a thru wall leak.
Piping will be replaced at next outage of sufficient duration.
4.
Material Non-Conformance report 87-075 was dispositioned use as is because a conservative erosion rate was calculated and a safe operating life of 5 years was projected.
This component will be scheduled for a 12R Refueling Outage ultrasonic inspection.
5.
Under consideration for a 12R Refueling Outage inspection.
.____m____m_-
6.
Material Non-Conformance Report 87-096 was dispositioned use as is and re-inspect after three months.
7.
Material Non-Conformance report 87-100 was dispositioned use as is and re-inspect prior to cycle 12 startup presently scheduled for early 1989.
5.
Describe any plans either for revising the present or for developing new or additional programs for monitoring pipe wall thickness.
Response
Present plans for revising the pipe wall thinning program are being developed to shift the program from one that determines only the condition of the pipe to one that predicts the future service 14 fe of the i
pipe.
This will be done by implementing the following:
1.
A program that assures all reportable readings (nominal thickness -
12.5%) are formally dispositioned and include both long and short i
term action items.
(e.g. Use-As-Is disposition for the short term, l
however, schedule for repair replacement next outage).
The disposition will include standard erosion rate calculations and safe i
operating life determination.
2.
A method to assure that all inspections on a component are tracked and recorded will be achieved by developing Wall Thinning Drawings of a system which shows the components and their unique identifier.
(This has been initiated on the Feedwater system where numbers identifying components on a drawing corresponded to numbers in a computer data base containing design data and inspection history.)
3.
Development of a standardized methodology for drawing an inspection 1
grid which assures repeatability.
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b
TABLE 1 COMPONENT EVALUATION CRITERIA BASED ON REMAINING SAFE OPERATING LIFE (SOL) l I
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I ACCEPTANCE CATEGORY l
CRITERIA (1) l COMMENTS (3) l I
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l A l IMMEDIATE REPLACEMENT l O CYCLES (2)
I ADDITIONAL EVALUAfl0N BY l
I l OF COMPONENT l
l TECH FUNCTION OPTIONAL l
l 1
1 I
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-1 I
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4 IBl ENGINEERING l
LESS THAN ONE CYCLE l
EVALUATION REQUIRED FOR l
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l EVALUATION l
l COMPONENT REASSIGNMENT l
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INTO CATEGORY A OR C l
l 1
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lCl P0TENTIAL NEXT l
LESS THAN TWO CYCLES l
RED ALERT STATUS (R/A) l l
l OUTAGE REPLACEMENT l
l
- NEXT OUTAGE INSPECTION l
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- CONTINGENCY REPLACEMENT l
l 1-1 I
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l D l NEXT OUTAGE l LESS THAN THREE CYCLES l YELLOW ALERT STATUS (Y/A) l l
l INSPECTION SUGGESTED i
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- 2nd OUTAGE INSP. REQ'D l
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- CONTINGENCY REPLACEMENT l
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PREPARATION FOLLOWING l
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l 1st OUTAGE l
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l E l COMPONENT RE-l MORE THAN THREE CYCLES I COMPONENT REASSIGNMENT I
I l SCHEDULING FOR LATER l
l INTO CATEGORY D REQUIRED l
l l INSPECTIONS I
l WHEN S0L (5 YRS l
1 I
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I NOTES:
(1) ENGINEERING EVALUATION OF REMAINING YEARS BEFORE PIPE WALL WILL REACH MINIMUM THICKNESS.
(2) MINIMUM WALL THICKNESS ALREADY REACHED.
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