ML17256A838

Slide Presentation from 820323 Meeting Re Steam Generator Repair Activities at Facility

ML17256A838
Person / Time
Site:	Ginna
Issue date:	03/23/1982
From:	WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP.
To:
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ML17256A836	List: ML17256A835 ML17256A838
References
NUDOCS 8204260126
Download: ML17256A838 (40)

Text

GINNA STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 AGENDA o

INTRODUCTION o

INSPECTION AND EXAMINATIONRESULTS o

DAMAGE MECHANISM EVALUATION o

RECOVE RY PROGRAM o

TECHNICAL BASIS FOR REPAIRS o

PLANT SCHEDULE o

CONCLUSION'

GINNA STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 OBJECTIVES o

DETERMINE FULL EXTENT OF DEFECTS AND LOOSE PARTS o

DETERMINE FAILURE MECHANISM(8) o RESTORE STEAM GENERATOR TO A CONDITION WHICH IS SAFE TO OPERATE MAINTAININGRADIATION EXPOSURES AS LOW AS REASONABLY ACHIEVABLE o

OBTAIN NRC CONCURRENCE FOR RETURN TO POWER

GINNA STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 PURPOSE OF MEETING o

TO REVIEW RESULTS OF INSPECTIONS TO DATE o

TO OBTAIN CONCURRENCE WITH STEAM GENERATOR PROGRAM CONCEPTS o

TO'OBTAIN APPROVAL FOR REMOVAL OF STEAM GENERATOR

. TUBE SECTIONS

GINNA STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 NSARB C REVIEWS o

concurrence with program concepts NSARB - 2/26 NRC

- 3/1 o

approval of removal of metallurgical samples NSARB - 2/26 NRC 3/1 o

approval of repair program NSARB 3/16 NRC 3/23 o

approval of return to power NSARB mid April NRC late April

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.c'INNASTATION

.B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 INSPECTION UPDATE NO. 4 WEDGE AREA o

R45C54

-missing and severed at first support plate o

R44C54

-severed at top of tubesheet o

R44C55

-severed at top of tubesheet

-partially severed at first support plate o

R43C55

-severed at top of tubesheet, o

R44C56

-missing and severed at first support plate o

R44C57 I

-missing and severed at first support plate

GINNA=STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 METALLURGICALEXAMINATION o

site photography o

Westinghouse R&D laboratories o

model for wear orientation comparisons o

photography at.'90'ncrements o

radiography at 45'ncrements o

transverse cross sections of column 55 tubes

-R42C55 - 2.5" and 4" from upper end

-R43C55 - 2.5" and 4" from upper end

-R44C55 -'.5",'".and 8" from upper end

-SEM and standard photomicrographs

GXNNA STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 LABORATORY EXAMINATION REMOVED TUBING WEAR SURFACES 0 PRXMARXLY RUBBING WEAR CIRCUMFERENTIAL DXRECTXON 0

NO EVIDENCE OF CORROSION XNVOLVEMENT 0 EVXDENCE OF SURFACE COLD WORKING 0 FATIGUE STRIATION ON FRACTURE SURFACE 0 TENSILE OVERLOAD BURST TUBE FAILURE,SURFACE

R.

E.. GINNA S/G 8 -

POSTULATED TUBE RUPTURE MECHANISM.

FOREIGN OBJECT IN HIGH FLUID VELOCITY FIELD LATERAL IMPACT/WEAR ON PLUGGED TUBES TUBE COLLAPSE FATIGUE TEAR TUBE SHREDDING/

FRAGMENTATION TUBE SEVERANCE, TUBE WHIP IMPACT/WEAR ON PLUGGED TUBES WEA%

ON ACTIVE TUBE TUBE RUPTURE

MECHANISM EVALUATION PROGRAM I

INVESTIGATION OF. VARIOUS INFLUENCES MECHANICAL LATERAL LOADS GROSS FLUID LOADS AXIAL LOADS LOCAL FLUID LOADS 4

HISTORICAL.INFORMATION REVIEW 0

INITIAL PERIMETER TUBE 'INVESTIGATION

4 LABORATORY EXAMINATIOH OF REMOVED TUBE SECTIONS 4

MODEL TESTING 0

LABORATORY COLLAPSE AND FATIGUE TESTING 4

FIEL'D TESTING AND EXAMINATIOH

LATERALLOADS 0

EXTERNAL PRESSURE 0

TUBE OVALITY 0

VARYING LEVELS OF CONCENTRATED LOADS 0

VARYING LEVELS.OF TUBE MALL THICKNESS I

AXIAL LOAD AFFECT

GROSS FLUID LOADS 1

FLUID ELASTIC INTERACTION ANALYSIS FLOM VELOCITIES TUBE CROSS SECTION FLUID ELASTIC STABILITY VORTEX SHEDDING CROSS FLOW 0

EFFECT OF TUBE.REMOVAL ON FLUID FLOM FIELD

'AXIAL 'L'OADS 0

STRUCTURAL EVALUATION TUBE-TO-SHELL MISMATCH TUBE-TO-TUBE MISMATCH MISAL I GNMENT

, TUBESHEET-SUPPORT PLATE MISMATCH TUBESHEET ROTATION STRESS CONCENTRATION 0

U-BEND WITH REMOVED SECTION

GINNA STATION B-STEAM GENERATOR NRC MEETXNG MARCH 23, l982 LABORATORY EXAMINATXON REMOVED TUBING 0 WEAR SURFACES 0 PRIMARXLY RUBBING WEAR CIRCUMFERENTXAL DIRECTION 0

NO EVXDENCE OF CORROSXON INVOLVEMENT 0 EVIDENCE OF SURFACE COLD WORKING FATIGUE STRIATION ON FRACTURE SURFACE 0 TENSILE OVERLOAD BURST TUBE FAILURE SURFACE

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LABORATORY TESTING 0

COLLAPSE TESTING EXTERNAL PRESSURE LATERAL LOADS AXIAL LOAD FATIGUE TESTING AMPLITUDES GEOMETRY BOUNDARY CONDITION AXIAL LOAD

GINNA STATION B-STEAM GENERATOR NRC MEETING, MARCH 23, 1982 CORRECTIVE ACTIONS eddy current examination o

video inspections o

- obtain metallurgical samples o

remove structurally degraded tube sections o

restore preventatively plugged tubes to service o

remove foreign objects and tubing fragments o

eddy current examine tubes. adjacent to repairs o

secondary side video inspection following repairs o

primary and secondary hydrostatic tests o

metal impact monitoring system

GINNA STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 REPAIR OPTIONS o

EDM cutting process o

mechanical cutters o

'hydraulic tube removal system o

loose parts retrieval equipment o

remove from tubesheet end o

additional shell penetrations o

proven repair techniques

GINNA STATION B-STEAM GENERATOR NO.

4 WEDGE AREA COLUMN "62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46

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0 41 40 ROW Pulled April 1978 (1 tube)

Structurally Degraded (19 tubes)

Video Indication (1 tube)

~Eddy Current Signal (5 tubes)

Q Preventatively Plugged (3 tube's)

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GINNA STATION B-STEAM GENERATOR NO.

6 WEDGE AREA COLUMN 92 91 90 89 88 87 86

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ROW Structurally Degraded (5 tubes)

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Video OD Indication'(5 tubes)

Eddy Current Signal (1 tube) 3/19/82

GINNA STATION B-STEAM GENERATOR RC40C70 AREA COLUMN 77 76 75 74 '3 72 71 70 69 68 67 66 65 0

41 0

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0 34 ROW Structurally Degraded (no tubes)

Video OD Indication-(5 tubes)

~~ Eddy Current Signal (4 tubes) 3/19/82

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GINNA STATION B-STEAM GENERATOR CATEGORIZATION OF DEFECTS CATEGORY l

1.

Structurally Degraded 2.

Video OD Indication 3.

Eddy Current Signal NO.

6 WEDGE AREA R8C92 R11C91 R12C91 R14C90 R15C90 R9C91 R10C91 R13C90 R16C89 R17C89 R15C89 R40C70 AREA R38C71 R38C72 R39C68 R39C69 R39C70 R35C75 R40C67 R40C68 R41C66 R42C55M R43C53.

R43C54M R43C55M R43C56M R43C57 R43C58 NO.

4 WEDGE AREA R43C59 R43C60 R43C61 R44C52 R44C53M R44C54 R45C51 R45C46 R45C47M R45C48 R45C49 R45C50 R44C55M R44C56 R44C57 R44C58 R45C53 R45C54 NO.

2 WEDGE AREA R12C2 R28C12 R30C15 R31C15 R32C15 R32C16 R33C15 4.

Preventatively Plugged R41C55 R42C54 R42C56 TOTALS 28 M

Metallurgical Samples R45C52 pulled April, 1978.

NRC Meeting March 23, 1982

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GINNA STATION B-STEAM GENERATOR NO.

2 WEDGE AREA Column 17 16 15 14 13 12

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'29 28 27 ROW Structurally Degraded (nc tubes)

Video OD Indication (no tubes)

Eddy Current Signal.(6 tubes)

R12 C2 notshown Stay Bar 3/19/82

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ORIGINAL IN IT I AL, DATC NUMIICR REVISION DRAWN

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RCSP, CNG, CNG MANG'R ROCHESTER GAS 81 ELECTRIC CORP.

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RGE B POST TUBE REPAIR EVALUAT+

CONDITIONS:

- TUBE REMOVAL SURFACE IRREGULARI'TY WITHOUT COLLAPSE

- SEVERED TUBES AT FIRST TSP HYDRAULICS CONSIDERATIONS:

- TUBE FATIGUE DUE TO FLUID INTERACTIONS

- FLUID-ELASTIC STABILITY

- VORTEX SHEDDING

- TURBULENCE

- LOCAL FLUID EFFECTS - EDDYS, CRACK STABILITY FLOH VELOCITY AND EQUALITY CHANGES STRUCTURAL CONSIDERATIONS:

- FATIGUE MARGIN UNDER OPERATING TRANSIENTS COLLAPSE INTEGRITY

- STABILITY QF TUBES SEVERED BELOW'SP

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SUMMARY

OF VORTEX SHEDDING AND TURBULENCE ANALYSES

- FIXED-FIXED BOUNDARIES

- CROSS-FLOW VELOCITY, 10.0 FPS

- DAMPING RATIO, 0.01 CROSS SECTION OF DISTORTED ZONE VORTEX SHEDDING TURBULENCE VIBRATION AMPLITUDES, MILS CYLINDER (NOMINAL) 10% OVALITY KIDNEY FLAT 0.77 0.79

0. 79 2.13 0.81 0.83 0.83 1.53 VIBRATION AMPLITUDE DUE TO VORTEX SHEDDING AND CROSS-FLOW TURBULENCE ARE RELATIVELY UNAFFECTED BY SMALL DISTORTIONS'ND SURFACE IRREGULARITY

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EFFECT OF HOT LEG TUBE REMOVAL ON CROSS-FLOW VELOCITY

( 2-D MATHEMATICAL STUDY

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INPUT CROSS-FLOW VELOCITES:

6.0 ft/sec.

hot leg 5.4 ft/sec.

cold leg CASE AVERAGE VELOCITY IN TUBE REMOVAL REGION MAX.

GAP VELOCITY IN FIRST TUBE ROM DOWNSTREAM NOMINAL 10 TUBES REMOVED 40 TUBES REMOVED

5. 30

3. 69

3. 86 19.40 13.50 14.14 TUBE REMOVAL DOES 'NOT,'ADVERSELY AFFECT FLOW VELOCITIES

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FATIGUE EVALUATION OF SURFACE DAMAGED PLUGGED TUBE (ASSUME FULL AXIAL RESTRAINT AT FIRST TSP)

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ENVELOPING TRANSIENT -

PLANT LOADING/UNLOADING, 14,500 CYCLE!

0 ASSOCIATED LOADS TEMPERATURE VARIATIONS, PRIM'ARY T:

547F (HOT STANDBY) TO 602F (1.00$

POWER)

HOT SECONDARY T

547F (HOT STANDBY) TO 518F (100%

POWER)

ST' o

EXTERNAL PRESSURE RANGE:

795-1020 PSI o

AXIAL TUBE LOAD RANGES o

TUBE-TO-SHELL THERMAL MISMATCH

+ 780 lbs.

ASSUMPTION.-

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PLUGGED-TO-ACTIVE TUBE THERMAL MISMATCH: 0 TO + 1200 L

ASSUMPTION -

SINGLE PLUGGED TUBE WITHI'N A CLUSTER OF ACTIVE TUBES 6

AXIAL BENDING LOADS

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AS-BUILT MISALIGNMENT, 0.25 INCH o

TS-TO-TSP THERMAL GROWTH MISMATCH, 0-05 INCH o 'S ROTATION DUE TO PRIM-TO-SEC Ap, 0.08 INCH

O FATIGUE USAGE CALCULATIONS MAXIMUMSTRESS INTENSITY RANGE SALT = 56.25 KSI (ADJUSTED TO E. ~ 26 x 10 KSI FOR ASME FATIGUE CURVE)

ASSUMED STRESS CONCENTRATION FACTOR FOR SURFACE DAMAGE = 4.0'(MAX. PER ASME)

NUMBER OF CYCLES n = 59,000 (THIS NUMBER RE-PRESENTS ALL TRANSIENTS LUMPED CONSERVATIVELY)

MIHIMUMACTUAL USABLE::CYCI,ES PER ASME CODE H = 135,000 CALCULATED USAGE = n7N = 0.4303

~u8E G~oM&rRy WRAPPER FIRST; TUSE'V&'OR 7 PLRrE Dura PER)P~EA'l P~usszu ruach o 87'S 0$. A o a5o

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COLLAPSE INTEGRITY EYALUAT NS BASED ON EXTENSIVE LABORATORY TESTING COLLAPSE PRESSURE FOR NOMINAL TUBING 5000 PSI COLLAPSE STRENGTH IS RELATIVELY UNAFFECTED BY SHORT (a < TUBE DIAMETER), THROUGH-MALL TIGHT CRACKS FOR TUBE COLLAPSE, DUE TO THE MAXIMUMhp - 1020 PSI RE(UIRED WALL DEGRADATION IS 80'X,"IF UNIFORM, AND

> 90K IF LOCAL TUBE COLLAPSE RESULTS FROM PLASTIC INSTABILITYAND REPRESENTS AN INSTANTANEOUS FAILURE MODE.

OF ALL THE IQADING CONDITIONS FOR RGE TUBING, THE MAXIMUMap (- 1020 PSI)

OCCURS DURING NORMAL OPERATZON WHICH, THEREFORE, REPRESENTS A PROOF TEST.

STABILITY OF TUBES SEVERED BELOW TSP BROKEN HOT LEG OF TUBE GUIDED BY UPPER PLATES

'TUBE SEVERED JUST BELOW THE FIRST PLATE TSP THK = 0.75 INCH 51.88 INCH TS 4

MAXIMUM TUBE BUNDLE STRETCH

= 0.,12 IN.

DURING FLB, bp = 2560 psi 4

Prior-to-sec therma1 growth mismatch FOR PULL OUT* THRU 0.75 INCH THI'CK PLATE, RE(UIRED ~T

= 1900 EXPECTED >T

<100F DURING OPERATION (400F DUIRNG A LOCA 4

.TUBE PULL-OUT DUE TO TUBE SWING OR ROTATION AT U-BEND NOT POSSIBLE SINCE BROKEN LEG OF THE TUBE IS GUIDED THRU UPPER PLATES REQUIRES PRIMARY SIDE DOWN TRANSIENT IF TUBES ARE AXIALLY RESTRAINED AT THE PLATE,.SECONDARY SIDE DOWN TRANSIENT, IF FREE

4 POST-REPAIR TUBE EVALUATION

SUMMARY

-FLUID-ELASTIC STABILITY, VORTEX.SHEDDING AND TURBULENCE RESPONCES OF A TUBE ARE PRACTICALLY UNAFFECTED BY SMALL DISTORTIONS AND SURFACE IRREGULARITIES.

-LOCAL FLUID FORCES ARE NEGLIGIBLY SMALL TO CAUSE CRACK PROPAGATION.

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-REMOVAL OF TUBES HAS NO ADVERSE IMPACT ON TUBE STABILITY DUE TO FLUID INTERACTIONS.

-FOR SURFACE DAMAGED TUBES, ACCEPTABLE FATIGUE MARGIN EXISTS FOR SUBSEQUENT OPERATIONS

-PLANT':OPERATION BEING A PROOF COLLAPSE TEST, STRUCTURALLY STABLE TUBES ARE EXPECTED TO REMAIN STABLE DURING SUBSEQUENT OPERATIONS.

'-TUBES SEVERED AT THE FIRST "TSP ARE GEOMETRICALLY STABLE AND CANNOT PULL OUT OF THE PLATE DUE TO OPERATING AND FAULTED TRANSIENTS.

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.z-~ NUS MOCK-UP MODI CATIONS March 19, 1982 TEST March 22, 1982 NRC MEETNQ'- March 23, 1982 REMOVAL OR DAMAGED TUBES IN P4 AND f6 WEDGE AREAS March 31, 1982 MECHANICAL PLUG REMOVAL April 2, 1982 COMPLETE WORK IN LOWER SECTION OR "B" STEAM GENERATOR April 5, 1982 COMPLETE "B" S/G MODIRICATIONS April 11, 1982 RCP WORK COMPLETE April 12, 1982 MATER 'LANCE "B" S/G April 12, 1982 FINAL TV INSPECTION April 13, 1982 SECONDARY HYDRO "B" S/G April 10, 1982 CONTAINIKNT AIR TEST (ILRT) April 15, 1982 FINAL S/G REPORT April 16, 1982 CREVICE CLEANING April 20, 1982 NRC MEETING Late April