ML031110247

E-mail from W. Cullen to Koc, Regarding Industry Cooperation Phone Call

ML031110247
Person / Time
Site:	Davis Besse
Issue date:	10/30/2002
From:	Cullen W Office of Nuclear Regulatory Research
To:	Nuclear Energy Institute
References
FOIA/PA-2003-0018
Download: ML031110247 (9)

Text

I HooDert I regoning - Industry cooperation phone call Page From: William Cullen / r C3 To: koc~nei.org Date: 10/30/02 11:07AM

Subject:

Industry cooperation phone call Good morning, Kurt.

Here is what I have put together as prep for our Nov. 5/1:00 pm phone call. It turns out that Mike Mayfield will participate from Germany.

The numbers are either 1-800-638-8081 or 301-231-5539, and the passcode is 5006# (we always remind people to punch up the "#" key). At this moment, I've reserved ten lines, and we/NRC will need four of them. If industry will clearly need more than five, let me know, and I'll arrange that.

These pages contain a tabulated list of possible areas of cooperation. Christine King and John Hickling have received a preliminary version of this, and I have doctored it only slightly since. The last page consists of two slides that I presented at the NSRC meeting on Monday afternoon, outlining the programs that (a) we have going at ANL, and (b) are about to initiate at ORNL.

Please call if/when you or your colleagues have any questions, additions, or modifications. As you said, we want to name names and assign dates to as many initiatives as we can during this phone call.

As much as I can, I've tried to put our cards face up on the table so that you can see where we need to go.

Brian Sheron has not minced words in his presentations, nor in his letter to Alex last week about his feelings on the industry's need to focus harder on Alloy 690 testing (or inspection frequency alternatives),

boric acid corrosion processes, continued inspection processes for existing heads, and the transfer of those processes to replacement heads. With these incentives, I think we ought to be able to find plenty of areas in which to work together.

I've not included several materials-related items that are already a part of EPRI/MRP/NEI and NRC/RES cooperation - things that are discussed during the infrequent phone calls held between our Office or Research management and EPRI management (typically Ashok Thadani & Ted Marston plus supporting staffs). As far as I know there is a loosely forming plan to schedule such a phone call fairly soon. Perhaps, since Ted is at the NSRC meeting this week, he and Ashok will set a date - I don't know.

However, such things as the two questionnaires - on thermal fatigue and component aging - that I forwarded to Alex about a month ago, should be dealt with in the NEI-EPRI/NRC context, and not in this phone call, since they do not spring directly from CRDM or Davis-Besse issues.

Regards, Bill William H. Cullen, Jr., Sr. Materials Engineer Materials Engineering Branch Office of Nuclear Regulatory Research (for mailing, abbreviate as NRES/DET/MEB")

US Nuclear Regulatory Commission Mail Stop: T-10 El0 Washington, DC 20555 Ph: 301 - 415 - 6754 FAX: 301 - 415 - 5151 whc~nrc.gov CC: Allen Hiser; Carol Moyer; Deborah Jackson; Keith Wichman; Michael Marshall; Michael Mayfield; Michael Switzer, Nilesh Chokshi; Robert Tregoning; Stephanie Coffin; Terence Chan; Wallace Norris

t Robert Tregoning - Possible cooperation with EPRI-MRP.doc I 1- 11 .. , _1-11 1-111- I - -_ _ _.-page, Page Robert Tregoning Possible cooperation with EPRI-MRP.doc Topical Areas for Possible, Cooperative Research Between NRC and Industry Related to Davis-Besse Incident Where RES/DET/MEB stands, and where industry stands on CRDM inspection-relevant research Item Topic What RES/DET/MEB Is doing, or plans to do What EPRViMRP Is doing, or plans 1 Crack Growth Rate ANL testing Alloy 600 & 182, will include Alloy 690 Westinghouse is testing Alloy 600, 690, 182/82 &

Neural network proposal awarded 152/52. No growth in 690, yet 2 Bonc Acid Program in place at ANL, Exps begun Re-visiting SwRI program, getting a final report, Corrosion Corrosion Rates, aqueous & molten H3 BO3 Dominion Engrg continues on literature search, D-Flowing & near - static B timeline and plausibility studies Range of temps & concentrations EPRI has proposal for new research (new vendor)

Galvanic (Em) measurements Possible mockup of leaking CRDM 3 PRM & PRA Wilkowski on probabilistic leak rates Whatever SIA and DEI (or others??) are doing Shack on prob. approach to inspection intervals Stress analysis seems to be very important 4 D-B Head Testing Alloy 600 and 182 removed from head Tensile, hardness, surface microphotography Degradation MEB letter report collecting/correlating bonr acid (SEM), metallography, on clad and low-alloy steel properties and corrosion (LAS), all done by FENOC Where we might go with industry cooperation in those four areas Item Topic Areas of potential coordination/cooperation 1 Crack Growth Rate Agree that we need more emphasis on 690/152/52, get matenals, get programs underway 2 Bonc Acid Corrosion Coordinate SOW's for forthcoming programs 3 PRM & PRA Companson of results, calibration of databases (everyone using the same starting points?, data?).

Otherwise should be NRC work that is independent of industry's calculations. Stress analysis, residual stress determination in mockups, old heads, B&W-Canada test welds, FEA, etc.

4 D-B Head Degradation Relatively short term programs aimed at better definition of the root cause, ORNL safety assessment Iprogram needs BWXT/Framatome/FENOC input from BWXT testing & exams I have begun to try to think ahead to the availability of the Oconee heads when they are replaced. There is a high likelihood that there will be several CRDM housings with cracks, if not a few leakers going into the RFO dunng which they will be replaced. These heads represent a test bed parexcellence. We could conceptualize some terrific inspection programs, materials testing programs, fractography surface film analysis, metallography, residual stress analysis, etc, with the matenals from these heads. They would need to be deconned, and will be slightly activated, but I think those hurdles would not prevent substantial testing from being done It would seem prudent to use non-activated head elements (e 9, Midland, Jamesport, other mockups) as developmental testbeds before incurring personal dose through work on the Oconee heads.

I Rlobert Tregoning - Possible cooperation with EPRl-MRP.doc Page 2 Topical Areas for Possible, Cooperative Research Between NRC and Industry Related to Davis-Besse Incident Content of New, Flawed Cladding Failure Cntenon Research Program

• Analytical Calculations

• Thermal- and process-induced strains in the cladding

• Actual cavity dimensions, flawed cladding, biaxial stress

• Flaw geometries: 5%, 25% & 50% thru thickness, 318",1 "& 2" length

• Actual flaw geometry- once determined

• Calc. crack driving forces, net section collapse with blunted flaws

• Experimental Program

• Parallels analytical program, includes materials properties tests

• Burst tests on simple, circular or elliptical cavity geometries

• Flat, clad plates, 6O0OF, with flaws, strain monitoring

• Actual cavity dimensions and clad test sections

I Robert Tregoning - Possible cooperation with EPRI-MRP.doc  :'

• P~age 3 Robert Tregoning - Possible cooperation with EPRI-MRP.doc Page 3 Topical Areas for Possible, Cooperative Research Between NRC and Industry Related to Davis-Besse Incident Content of New Boric Acid Corrosion Research Program

• Crack Growth Rates of Alloys 600 & 182 from Davis-Besse Head

• 2. Computational Model, Based on Probabilistic Assessment of:

• Probability of Detection & Accuracy of Sizing

• Crack Growth Rate Variations

• Stress Intensity Factor Gradients (Residual Stress, Interferences)

• Critical Crack Sizes, Including Factor of Safety

• Electrochemical Potential and Polarization Measurements of Low-Alloy Steel, Alloys 600 & 182 in Concentrated Boric Acid Solutions

• Mockup to Simulate Cavity Growth in Davis-Besse

• Simulate Initial, Intermediate and Final Stages of Cavity Development

• Examine Nozzle #2 cavity from Davis-Besse Head

Jeannette Torres - Fwd: Industry cooperation phone call Page From: Robert Tregoning To: Jeannette Torres Date: 11/27/02 8:18AM

Subject:

Fwd: Industry cooperation phone call

Jeannette Torres - Industry cooperation phone call Page From: William Cullen To: koc nei.org Date: 10/30/02 11:07AM

Subject:

Industry cooperation phone call Good morning, Kurt.

Here is what I have put together as prep for our Nov. 5/1:00 pm phone call. It turns out that Mike Mayfield will participate from Germany.

The numbers are either 1-800-638-8081 or 301-231-5539, and the passcode is 5006# (we always remind people to punch up the "#" key). At this moment, I've reserved ten lines, and we/NRC will need four of them. If industry will clearly need more than five, let me know, and I'll arrange that.

These pages contain a tabulated list of possible areas of cooperation. Christine King and John Hickling have received a preliminary version of this, and I have doctored it only slightly since. The last page consists of two slides that I presented at the NSRC meeting on Monday afternoon, outlining the programs that (a) we have going at ANL, and (b) are about to initiate at ORNL.

Please call if/when you or your colleagues have any questions, additions, or modifications. As you said, we want to name names and assign dates to as many initiatives as we can during this phone call.

As much as I can, I've tried to put our cards face up on the table so that you can see where we need to go.

Brian Sheron has not minced words in his presentations, nor in his letter to Alex last week about his feelings on the industry's need to focus harder on Alloy 690 testing (or inspection frequency alternatives),

boric acid corrosion processes, continued inspection processes for existing heads, and the transfer of those processes to replacement heads. With these incentives, I think we ought to be able to find plenty of areas in which to work together.

I've not included several materials-related items that are already a part of EPRI/MRP/NEI and NRC/RES cooperation - things that are discussed during the infrequent phone calls held between our Office or Research management and EPRI management (typically Ashok Thadani & Ted Marston plus supporting staffs). As far as I know there is a loosely forming plan to schedule such a phone call fairly soon. Perhaps, since Ted is at the NSRC meeting this week, he and Ashok will set a date - I don't know.

However, such things as the two questionnaires - on thermal fatigue and component aging - that I forwarded to Alex about a month ago, should be dealt with in the NEI-EPRI/NRC context, and not in this phone call, since they do not spring directly from CRDM or Davis-Besse issues.

Regards, Bill William H. Cullen, Jr., Sr. Materials Engineer Materials Engineering Branch Office of Nuclear Regulatory Research (for mailing, abbreviate as "RES/DET/MEB")

US Nuclear Regulatory Commission Mail Stop: T-10 El0 Washington, DC 20555 Ph: 301 - 415 - 6754 FAX: 301 - 415 - 5151 whc@ nrc.gov CC: Allen Hiser; Carol Moyer, Deborah Jackson; Keith Wichman; Michael Marshall; Michael Mayfield; Michael Switzer; Nilesh Chokshi; Robert Tregoning; Stephanie Coffin; Terence Chan; Wallace Norris

I Jeannette Torres - Possible cooperation with EPRI-MRP.doc Page Topical Areas for Possible, Cooperative Research Between NRC and Industry Related to Davis-Besse Incident Where RESIDET/MEB stands, and where industry stands on CRDM inspection-relevant research Item Topic What RESIDET/MEB is doing, or plans to do What EPRIVMRP is doing, or plans 1 Crack Growth Rate ANL testing Alloy 600 & 182, will include Alloy 690 Westinghouse is testing Alloy 600, 690, 182/82 &

Neural network proposal awarded 152/52 No growth in 690, yet.

2 Boric Acid Program in place at ANL, Exps begun Re-visiting SwRl program, getting a final report, Corrosion Corrosion Rates, aqueous & molten H3BO3 Dominion Engrg continues on literature search, D-Flowing & near - static B timeline and plausibility studies Range of temps & concentrations EPRI has proposal for new research (new vendor)

Galvanic (Ep) measurements Possible mockup of leaking CRDM 3 PRM & PRA Witkowski on probabilistic leak rates Whatever SIA and DEI (or others??) are doing Shack on prob. approach to Inspection intervals Stress analysis seems to be very important 4 D-B Head Testing Alloy 600 and 182 removed from head Tensile, hardness, surface microphotography Degradation MEB letter report collecting/correlating bonc acid (SEM), metallography, on clad and low-alloy steel properties and corrosion (LAS), all done by FENOC Where we might go with industry cooperation in those four areas Item Topic Areas of potential coordination/cooperation 1 Crack Growth Rate Agree that we need more emphasis on 690/152/52, get matenals, get programs underway 2 Bonc Acid Corrosion Coordinate SOW=s for forthcoming programs 3 PRM & PRA Companson of results, calibration of databases (everyone using the same starting points?, data?).

Otherwise should be NRC work that is independent of industry=s calculations. Stress analysis, residual stress determination in mockups, old heads, B&W-Canada test welds, FEA, etc.

4 D-B Head Degradation Relatively short term programs aimed at better definition of the root cause, ORNL safety assessment

. I program needs BWXT/Framatome/FENOC input from BWXT testing & exams I have begun to try to think ahead to the availability of the Oconee heads when they are replaced There is a high likelihood that there will be several CRDM housings with cracks, if not a few leakers going into the RFO dunng which they wil be replaced These heads represent a test bed parexcellence We could conceptualize some temfic inspection programs, materials testing programs, fractography surface film analysis, metallography, residual stress analysis, etc., with the matenals from these heads. They would need to be deconned, and will be slightly activated, but I think those hurdles would not prevent substantial testing from being done It would seem prudent to use non-activated head elements (e g, Midland, Jamesport, other mockups) as developmental testbeds before incurring personal dose through work on the Oconee heads.

I Jeannette Torres - Possible cooperation with EPRI-MRP.doc Page 2 Topical Areas for Possible, Cooperative Research Between NRC and Industry Related to Davis-Besse Incident Content of New, Flawed Cladding Failure Criterion Research Program

• Analytical Calculations

• Thermal- and process-induced strains in the cladding

• Actual cavity dimensions, flawed cladding, biaxial stress

• Flaw geometries: 5%, 25% & 50% thru thickness, 3/8", 1" & 2" length

• Actual flaw geometry- once determined

• Calc. crack driving forces, net section collapse with blunted flaws

• Experimental Program

• Parallels analytical program, includes materials properties tests

• Burst tests on simple, circular or elliptical cavity geometries

• Flat, clad plates, 600'F, with flaws, strain monitoring

• Actual cavity dimensions and clad test sections Content of New Boric Acid Corrosion Research Program

• Crack Growth Rates of Alloys 600 & 182 from Davis-Besse Head

• 2. Computational Model, Based on Probabilistic Assessment of:

• Probability of Detection & Accuracy of Sizing

• Crack Growth Rate Variations

• Stress Intensity Factor Gradients (Residual Stress, Interferences)

• Critical Crack Sizes, Including Factor of Safety

• Electrochemical Potential and Polarization Measurements of Low-Alloy Steel, Alloys 600 & 182 in Concentrated Boric Acid Solutions

• Mockup to Simulate Cavity Growth in Davis-Besse

• Simulate Initial, Intermediate and Final Stages of Cavity Development

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I Jeannene l orres - Possible cooperation with EPRI-MRP.doc . ,_,Page e '

Topical Areas for Possible, Cooperative Research Between NRC and Industry Related to Davis-Besse Incident Content of New Boric Acid Corrosion Research Program

• Crack Growth Rates of Alloys 600 & 182 from Davis-Besse Head

• 2. Computational Model, Based on Probabilistic Assessment of:

• Probability of Detection & Accuracy of Sizing

• Crack Growth Rate Variations

• Stress Intensity Factor Gradients (Residual Stress, Interferences)

• Critical Crack Sizes, Including Factor of Safety

• Electrochemical Potential and Polarization Measurements of Low-Alloy Steel, Alloys 600 & 182 in Concentrated Boric Acid Solutions

• Mockup to Simulate Cavity Growth in Davis-Besse

• Simulate Initial, Intermediate and Final Stages of Cavity Development

• Examine Nozzle #2 cavity from Davis-Besse Head