ML051950197

6/27/05, Catawba, Meeting Summary Handouts, Attachment 2, Polyethylene Piping Use for Safety Related Buried Service Water Pipe

ML051950197
Person / Time
Site:	Catawba
Issue date:	06/27/2005
From:	Office of Nuclear Reactor Regulation
To:
Peters S, NRR/DLPM, 415-1842
References
Download: ML051950197 (48)

Text

I M Catawba Nuclear Station Polyethylene Piping Use for Safety Related Buried Service Water Piping ATTACHMENT 2

Agenda

• Meeting Purpose and Expectations

• Polyethylene Piping Use by Catawba

• Polyethylene Materials

• Joining Polyethylene

• Seismic Analysis

• NDE Technique Evaluation

• Relief Request

• Overall Strategy for Service Water System

• Questions (questions encouraged during presentation)

Meeting Purpose

• Nuclear service water systems have been designed using codes that specify only metallic materials.

• Polyethylene (HDPE) material has demonstrated superior corrosion and fouling resistance in non safety related cooling water system service.

Meeting Purpose

• Provide information on use of Polyethylene Piping in non safety related service water system at Catawba Nuclear Station

• Provide information on development of relief request for replacement of safety related piping with high density polyethylene (HDPE) in buried service water applications

Meeting Expectations Information presented in the 6-27-05 meeting is expected to be useful for future review of Duke Relief Request.

• NRC comments and questions during the 6-27-05 meeting will be used to focus efforts to develop and prepare the Duke Relief Request.

Catawba Nuclear Station Polyethylene Pipe Use

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Catawba Nuclear Station

• Located 19 miles southwest of Charlotte, NC on the shores of Lake Wylie

• Two Unit 1208 MW Westinghouse PWR

• Main condenser cooling provided by closed loop cooling tower system

• Commercial operation in 1985 & 1986 respectively

Water Systems

• Nuclear Service Water System coo ling to nuclear safety related components. Piping material: SAl 55, Class 1, KC 70 & SAl 06 CS plain carbon steels

• Low Pressure Service Water System secondary cooling and cooling tower makeup. Piping material: A1 06 CS & AP15L carbon steel

• Both systems combined total approximately 45,000-50,000 feet of piping

LEGEND

• RC CONDENSER CIRCULATING WATER RL CONVENTIONAL LOW PRESSURE SERVICE WATER LAs y tIE

• RN NUCLEAR SERVICE WATER AND STANDBY NUCLEAR SERVICE WATER

• RY EXTERIOR FIRE PROTECTION SERVICE WATER 4

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Service Water Problems

• Potential loss of adequate cooling due to flow restrictions

• Concern for Foreign Material Exclusion (FME) from the corrosion products, sedimentation, biological growth, and clams fouling components within the system

• Localized through wall pitting

Problems Addressed by System Monitoring

• UT corrosion rate monitoring to address structural integrity issues

• Systems Engineers trend flows, temperatures, equipment performance, and set maintenance equipment PM frequencies

Problems Addressed by System Cleaning

• In 2000, CNS cleaned and inspected over 8,000 feet of Nuclear Service Water System piping.

• The primary methods used for this operation were "Pigging" and Hydrolazing (High Pressure Wash) with Turbo Vacuum Trucks to remove the debris.

• Chemical treatment was added to the safety related service water system after the cleaning to help control the biological growth. Currently monitoring actual results of treatment

Polyethylene

• 1985 CNS began experimenting with Polyethylene piping materials as a replacement for Polybutylene

• Further testing of the Polyethylene piping began in 1991 -1992

• The test proved conclusively that Polyethylene was very compatible with the system design parameters and water chemistry

Polyethylene Piping Replacement

• After six years of actual in service application, there was no corrosion or biological material buildup on the inside of the pipe walls

• In 1998, the existing A-1 06 carbon steel supply and return piping to the Unit 2 generator hydrogen coolers was replaced with 500-600 feet of 6" & 8" HDPE, SDR-1 1, polyethylene piping

• Inspection results and performance of this piping since installation have been flawless (No degradation and no measurable fouling)

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Conclu SiUons - Non Safety Related Service Water Piping Experience HDPE Piping has not exhibited any corrosion or degradation or significant fouling in over 10 years of service at Catawba Nuclear Station.

HDPE USE by British Energy

• Coordinated efforts with British Energy Sizewell B Plant to use HDPE Piping

• Monthly teleconference meetings

• PE Training organized in September/2004

• HDPE Piping installed by Sizewell B in Spring 2005 in the ASME Section III Class 3 emergency service water system.

HDPE USE by British Energy

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HDPE USE by British Energy Polyethylene Piping Materials ASTM Material Specifications Used:

• ASTM D-3350 Standard Specification for PE Plastic Pipe & Fittings Material

• ASTM D-3035 Standard Specification for PE Plastic Pipe based on controlled outside diameter

• ASTM D-2837 Standard Method for Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Material or Pressure Design Basis for Thermoplastic Pipe Products

HDPE Butt Fusion

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HDPE Butt Fusion Joints made by trained and qualified operators in accordance with a qualified procedures Essential parameters by data logger as a permanent record

HDPE Butt Fusion 2 H Minimum 1/2 H Maximum 2-1/2 H Maximum

_ , H Uniform Bead Size & Shape Bead Rolled to Pipe Surface PE Pipe (Cross Section View)

McElroy Joint Report

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, Project Seismic Analysis Jack Spanner EPRI NDE Center June 27, 2005 USNRC Offices-White Flint

Objectives This project will provide a seismic analysis methodology for the technical justification to accompany the relief request and a Code Case to allow utilities to repair or replace safety related piping with polyethylene Contract deliverables.

• Task 1-Develop a general methodology for buried HDPE pipe

• Task 2-Analyze a buried system at Catawba NPP

- Piping to diesel heat exchanger

• Task 3-Prepare Code case for Section III/XI

Status

• Seismic analysis scheduled for completion by August 1, 2005

• Obtained HDPE and seismic performance data from Gas Technology Institute

• Catawba staff will also provide information necessary for seismic analysis-soil type, ground accelerations, drawings, etc.

• Contractor provided analysis for buried HDPE pipe at a DOE facility

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- I Polyethylene Replacement Pipe x-A Project NDE Technique Evaluation Jack Spanner EPRI NDE Center June 27, 2005 USNRC Offices-White Flint

Objectives of EPRI PE Pipe Project This project will develop a technical justification to accompany a Code Case to allow utilities to repair or replace safety related piping that has degraded, usually due to corrosion. It was decided to also evaluate NDE techniques for qualifying joining procedures.

• Task 1- Evaluate NDE techniques for HDPE joints.

• Task 2-Develop and publish a technical report that provides the technical justification for the Code case and Relief Request

• Task 3-Submit a Code case to the Code for implementation.

- Buried pipe Code case first

- Above ground Code case later

NDE Techniques to Evaluate

• Visual Inspection of joint and bead

• Microwave Inspection-Evisive

• Ultrasonic Phased Array

• Ultrasonic Time of Flight Diffraction (TOFD) 9 Radiography

Microwave Inspection at Waveguide Catawba NPP Evisive Manual Scanner

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Microwave Inspection of EF Coupling Joint RG&E Mockup Evisive Microwave NDT File Saturday, May 1,2004 13:55:33 Right Circular Cylinder - Sample Rate (Hz): 240

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Time of Flight Diffraction (TOFD) UT Technique-Cold fusion in butt joint

• Stage 3 - correlation UT-TOFD vs.

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• Lab test spools

. Field welds Field Sample &

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• Results

• Strong positive correlation of NDE indications to actual flaws FLUOR.

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Status

• Evaluating NDE techniques

• RG&E, Duke and EPRI mockups

• Microwave system interfaced with UT pipe scanner and used at Catawba and on mockups

• Ultrasonic time of flight demonstrations in progress

• Tried phosphor plate RT techniques-not successful

- NE Gas Assoc. had better success

• Collaborating with others like British Energy (Sizewell), NorthEast Gas Assoc., RG&E, etc.

Relief Request - Scope

• Catawba Nuclear Service Water System -

Buried Piping (ASME Section Ill Class 3)

• Buried Supply Piping to the heat exchangers that reject heat for the main emergency diesel generators

• Existing 10 inch Carbon Steel NPS Piping to be replaced with HDPE

• Approximately 1700 feet of piping for Catawba Units 1 and 2

Relief Request - Development

• EPRI Project for code case development began in 2004.

• Code case concept introduced at ASME Section Xl Committee in February, 2004.

• Code case and relief request work compliment one another.

• Duke Power made decision to pursue relief request since piping replacement will be required before code case is approved.

• Target date to submit relief request is2Fall, 20052

Relief Request - Development

• Relief Request will address:

Design Installation Inspection Testing Procurement

Service Water Piping Refurbishment Plan NSW Plan (2006-2010)

• Replace portions of auxiliary building piping

• Install NSW pump house header crossover

• Install NSW auxiliary building header crossover

• Replace EDG cooling supply headers

• Remove selective cooling loads from NSW

• Move isolation valves to reduce lake water exposure

• Submit LAR for single header operation 12

Contacts:

Larry Rudy, Regulatory Compliance, lirudy@duke-energy.com, 803-831-3084 Steve Lefler Engineering, sslefler@duke-energy.com, 704 382 0138 Ernie McElroy, Engineering, ewmcelro~duke-enerqv.com, 803 831 4174 Dave Ward, Engineering, dIward@duke-enerqy.com' 803 831 4190 Mel Arey Engineering, miareyl @duke-energy.com, 704 382 8619 Joel Reeves CNS Service Water Project, jereeves@duke-energy.com, 803 831 3835 Terry Edwards CNS Service Water Project, tledward@duke-energy.com 803 831 4153 Jack Spanner (EPRI), ispanner@epri.com, 704 547 6065