ML20246P584
| ML20246P584 | |
| Person / Time | |
|---|---|
| Site: | Fort Saint Vrain  |
| Issue date: | 02/28/1989 |
| From: | Nichols M GENERAL ATOMICS (FORMERLY GA TECHNOLOGIES, INC./GENER |
| To: | |
| Shared Package | |
| ML20246P581 | List: |
| References | |
| GA-C19576, NUDOCS 8903280257 | |
| Download: ML20246P584 (28) | |
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i INSPECTION REPORT ON HEllUM CIRCULATOR C-2105 IN COMPLIANCE WITH TECHNICAL SPECIFICATION SR 5.2.18 l by M.K. NICHOLS i 1 i l Prepared under Purchase Order N-9291 . for the Public Service Company of Colorado i FEBRUARY 1989 l l
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l I GA-C19576 l l l I INSPECTION REPORT ON HEllUM CIRCULATOR C-2105 IN COMPLIANCE WITH TECHNICAL SPECIFICATION SR 5.2.18 1 1 l by M.K. NICHOLS
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l 1 Prepared under i Purchase Order N-9291 for the Public Service Company of Colorado l l PROJECT 2970 FEBRUARY 1989 I
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i CONTENTS 4;
.! i 1-1
- 1. -
SUMMARY
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- 2. -INTRODUCTION .................... 2-1: 1
- 3. OPERATIONAL HISTORY . . . . . . . . . . . . . . . . .
3-1 1
- 4. INSPECTION RESULTS ............-.... 4-1 4.1 General . . . . . . . . . . . . . . . . . . . 4-1 4.2' Pelton Wheel ................ 4-4 4.3 Steam Turbi ne Rotor . . . . . . . . . . . . . 9 4.4 Compressor Rotor ..............
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4-9 4.5 Miscellaneous . . . . . . . . . . . . . . . .- 4-15
- 5. CONCLUSIONS / RECOMMENDATIONS . . . . . . . . . . . .- 5-1 e
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FIGURES c.. L l
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f 1 Helium Circulator Machine Assembly 2 Pelton Wheel - Side View j 3 Pelton Wheel - End View 4 'Pelton Wheel Buckets I ( 5 Pelton Wheel Buckets 6 , Steam Turbine - Rotor Assembly j 7 Steam Turbine Rotor - Blade Detail q 8 ' Compressor. Rotor - Blade Detail 9 Compressor Rotor Assembly - Top View 10 Compressor Rotor Assembly - Side View 11 Steam Turbine Stator.- Inlet Side . i 12 Steam Turbine Stator - Discharge Side 13 Steam Turbine Stator - B1ade Detail 14 'Pelton Wheel / Turbine Tie Bolt Assembly TABLES I- FSV Circulator Operational History through June 1988 II Summary of Inspections on Helium Circulator C2105 in Compliance I with FSV Technical Specification SR 5.2.18
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- 1.
SUMMARY
Helium circulator S/N C2105 was removed from service at the Fort St. l Vrain Nuclear Power Generating Station (FSV) in July 1988 to repair the shutdown seal. This' work was performed by General Atomics (GA) in San Diego and was completed in September.1988 as reported in GA document
'GA-C19451. Circulator C2105 was returned.to FSV at that time to serve as a spare. Once it was determined that no other circulators would need replacement during the plant outage that was in progress, C2105 was returned to GA in October 1988 for inspection examinations to satisfy the requirements of FSV Technical Specification SR 5.2.18.
The compressor wheel rotor, turbine wheel, and Pelton wheel were examined for both surface and subsurface defects in accordance with the appropriate methods, procedures, and associated acceptance criteria specified for Class I components in Article NB-2500, Section III of the 1974 edition of the ASME Code. In addition, the curvic couplings were
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checked by liquid dye penetrant (PT) examination. Other accessible components were visually inspected. No unacceptable indications or
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defects were found. The Pelton wheel buckets did show some minor cavitation damage. This Pelton wheel had actually been in service on circulator C2103 and had been exchanged with that from circulator C2105 at FSV during the July 1988 outage. A new Pelton wheel from inventory was installed in C2105 with the old wheel being retained as a spare. Both the turbine and compressor blading surfaces exhibited minor pitting caused by circulation of particulate. All of the wear conditions were considered to be normal and consistent with inspection results on other circulators that have been subjected to similar operational service. At the end of February 1989 circulator C2105 had been reassembled, with the new Pelton wheel, and was being maintained in a storage status
. at GA in San Diego.
1-1
1 o ~ I
- 2. INTRODUCTION FSV helium circulator C2105 was removed from service in July 1988 to repair the shutdown seal (reference GA document GA-C19451). When C2105 )
was not required to be reinstalled, Public Service Company of Colorado (PSC) designated that the machine be disassembled to permit inspection of the compressor wheel rotor, turbine wheel, and Pelton wheel as required I by plant Technical Specification SR 5.2.18. In summary the Technical Specification states:
"Following the first complete helium circulator inspection, a previously uninspected helium circulator shall be removed and inspected at ten calendar year intervals. The helium circulator compressor wheel rotor, turbine wheel, and Pelton wheel shall be inspected for both surface and subsurface defects in accordance with the appropriate methods, procedures, and associated acceptance criteria specified for Class I components in Article NB-2500, Section III, ASME Code."
This report summarizes the inspection results on C2105 in compliance with the Technical Specification requirements. PSC invoked the 1974 edition i of the ASME Code in purchase order N-9291. All examinations satisfied the ASME Code, Section III, Division I - Subsection NB-2500, 1974 edition and the requirements for examination specified on the original manufacturing drawings. 2-1
.3. C2105 OPERATIONAL HISTORY /
Circulator C2105 was initially the spare circulator for the FSV plant. In September 1972 all circulators were rebuilt due to a cavitation problem. Upon completion'of the rebuild, Circulator C2102 was retained as the spare and Circulator C2105 was installed in the.B penetration. Except for. brief periods in 1975 and 1980-81', when Circulator C2105 was again the spare, C2105 ' remained in B penetration.until July 1988 when it was removed for shutdown seal replacement (reference GA-C19451). Through June 1988 Circulator C2105 had accumulated approximately 19,700 hours of.Pelton wheel operation and 39,700 hours of steam operation for a' total of 59,400 operational hours. :At that time only Circulator C2101, with
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63,900 total hours, had' experienced more operational time. Table I summarizes the operational hours accumulated by each circulator through June 1988. l 3-1 _ _ _ _ _ _ - - _ _ _ _ _ _ _ _ _ - - _ - _ _ _ _ - _ _ - _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ - _ _ - . _ _ - _ _ _ _ _ - - - _ _ _ - _ _ _ = _ _ _ _ - _ - - _ _ _ _ _ _ - - _ _
TABLE I-
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, FSV CIRCULATOR OPERATIONAL HISTORY THROUGH JUNE.1988 HOURS ON' HOURS ON. TOTAL CIRCULATOR' STEAM PELTON WATER HOURS-C2101 41,100 22,800 63,900 C2102 .30,600 12,400 43,000 C2103 40,000. 14,900 54,900 C2104 39,500 16,000 55,500 C2105 39,700. 19,700 59,400 a
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- 4. INSPECTION RESULTS 4.1 GENERAL l Table II summarizes the inspections that were completed on helium circulator C2105 in compliance with FSV Technical Specification SR 5.2.18.
In general, no unusual or unacceptable conditions were discovered in the inspections conducted at GA in San Diego. All of the observed wear conditions were considered to be normal and consistent with inspection results on other circulators that.had experienced similar operational service. Detailed descriptions covering each component are included in the. following sections accompanied by representative photographs. Figure 1 shows an overall view of the circulator machine assembly which includes all of the
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components that have been evaluated in this report. The inspections of all components were conducted as follows: VISUAL INSPECTIONS All components listed in Table II were visually inspected for surface defects by-both Quality Assurance and a metallurgical engineer. The compressor rotor was examined before and after radioactive material decontamination processes were used to remove surface contaminants. DYE PENETRANT EXAMINATIONS 4 The Pelton wheel, steam, turbine rotor assembly, compressor rotor disk and compressor blades, and all curvic couplings were liquid dye penetrant (PT) examined for surface defects. The examinations were done in accordance with the ASME Code, Section III for Class 1 components. e 4-1
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RADIOGRAPHIC EXAMINATIONS The Pelton wheel, steam turbine rotor assembly, the compressor rotor disk, and compressor blades were radiographically _ examined for subsurface indications. The examinations were done in accordance with the ASME Code, Section III for Class I components. 4.2 PELTON WHEEL The Pelton wheel that was examined has been in service on circulator C2103 and had been changed at FSV during the July 1988 outage. The exchange was made because'the wheel from C2103 showed more damage from minor cavitation than the wheel that had been on C2105. Performance of both circulators had been acceptable and both were passing the surveillance test to demonstrate ability to meet safe-shutdown cooling requirements. Figures 2, 3, 4, and 5 show various views of the Pelton wheel. Figure 2
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is a side view that shows the curvic coupling to the turbine rotor. Figure 3 is a view of the bottom end and Figures 4 and 5 are closeups of the buckets that clearly show the cavitation damage at the flow splitter where the nozzle flow impinges upon the tip of the buckets. Also, minor cavitation damage where the buckets join the hub can be seen on Figure 3. The minor cavitation damage was not sufficient to compromise the structural integrity of the component and no performance degradation could be detected. The Pelton wheel was liquid dye penetrant examined for surface indications and radiograph 1cally examined for subsurface indications. No unacceptable indications were found. Although the component was deemed acceptable for continued use, the decision was made to retain it only as a spare and a new Pelton wheel from inventory was installed into circulator C2105. e 4-4
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4.3 STEAM TURBINE ROTOR ASSEMBLY The steam turbine rotor was examined as an ~ assembly, i.e., the rotor blades were not removed from the disk (see Figure 6). The blade surfaces were pitted with some damage on the edges caused by the circulation of particulate within the flow stream. Figure 7 shows the condition of tne rotor biades. The irregular surface on the inside edge of the rotor disk was caused by material removal during the balancing process. The steam turbine rotor assembly was liquid dye penetrant examined for surface indications and radiographically examined for subsurface indications. No unacceptable indications were found. The component was deemed acceptable for continued use and was reinstalled on Circulator C2105. 4.4 COMPRESSOR ROTOR ASSEMBLY Following decontamination cleaning, the compressor rotor blades were removed from the rotor disk. The blades were individually tagged to
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facilitate reassembly to the as-received configuration after examination. The blade surfaces (Figure 8) showed minor pitting caused by the circulation of particulate. Figures 9 and 10 show the compressor rotor after reassembly. The compressor rotor disk and blades were separately examined for surface and subsurface defects using both PT and radiographic examination techniques respectively. No unacceptable indications were found on any of the components. The compressor rotor assembly was deemed acceptable for continued use and was reinstalled on Circulator C2105. 4-9
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g_ - s:t . s 4.5 MISCELLANEOUS' The compressor and steam turbine. stators were removed to gain access to
'the rotor components. The observed conditions of these components are summarized in Table II and shown in the referenced figures. In addition to a visual examination, the curvic couplings on the shaft and the rotor components were subjected to PT examinations. No unacceptable indications were found. The condition of other components of C2105 was_ described in GA document, GA-C19451, " Examination of Helium Circulator C2105," dated September.1988. In addition, results of plateout evaluations completed at that time are included in GA document 909658/A, "FSV Plateout Analysis for Decommissioning Study."
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Figure 14 Pelton Wheel / Turbine Tie Bolt Assembly 4-19
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- 5. CONCLUSIONS / RECOMMENDATIONS l
The compressor wheel rotor, turbine wheel and Pelton wheel from FSV helium circulator'C2105 were examined for both surface and subsurface defects in accordance with the appropriate methods, procedures, and associated L acceptance criteria specified for Class I components in Article NB-2500, Section III of the 1974 edition of the ASME Code. No defects or unacceptable indications were found. The Pelton wheel buckets showed some minor cavitation damage in the flow i_ splitter region and where the buckets join the hub, but the condition did not measurably affect the structural integrity or the performance of the component as determined by in-situ surveillance testing. The Pelton wheel was replaced with a new unit from inventory and the old part is being retained as a spare. t Components in both the compressor and steam turbine flow paths showed minor surface pitting caused by the circulation of particulate. The observed damage is considered as normal wear and does not measurably affect . aerodynamic performance. The components were reinstalled in Circulator C2105. No changes to.the Technical . Specifications or planned circulator maintenance intervals are recommended as a result of the inspections described in this report. Because of the decision by PSC to cease FSV nuclear operations on or before June 1990, no further planned inspections or maintenance on helium circulators should be required. G 5-1 q
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RO. Box 85608 e San Diego, CA e 92138-5608 (619) 455-3000}}