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: ML17256A838
References
NUDOCS 8204260126
Download: ML17256A838 (40)

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GINNA STATION B-STEAM GENERATOR NRC MEETING MARCH 23, 1982 AGENDA o INTRODUCTION o INSPECTION AND EXAMINATION RESULTS 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 MAINTAINING RADIATION 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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.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 METALLURGICAL EXAMINATION 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 WEA% ON PLUGGED TUBES 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 OVAL ITY 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

'AX IAL 'L'OADS 0 STRUCTURAL EVALUATION TUBE-TO-SHELL MISMATCH TUBE-TO-TUBE MISMATCH MI SAL 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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Structurally Degraded (19 tubes)

Video Indication (1 tube)

~Eddy Current Signal (5 tubes)

Q Preventatively Plugged (3 tube's)

I I GINNA STATION B-STEAM GENERATOR NO. 6 WEDGE AREA COLUMN 92 91 90 89 88 87 86

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Video OD Indication'(5 tubes)

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GINNA STATION B-STEAM GENERATOR RC40C70 AREA COLUMN 77 76 75 74 '3 72 71 70 69 68 67 66 65 0 41 0 0 40

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0 Q 0 0 0 0 0 0 G 0 0 0 0 34 ROW S tructurally Degraded (no tubes)

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Current Signal (4 tubes) 3/19/82

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GINNA STATION B-STEAM GENERATOR CATEGORIZATION OF DEFECTS NO. 6 R40C70 NO. 4 NO. 2 CATEGORY WEDGE AREA AREA WEDGE AREA WEDGE AREA l

1. Structurally R8C92 R42C55M R43C59 R44C55M Degraded R11C91 R43C53. R43C60 R44C56 R12C91 R43C54M R43C61 R44C57 R14C90 R43C55M R44C52 R44C58 R15C90 R43C56M R44C53M R45C53 R43C57 R44C54 R45C54 R43C58

2. Video R9C91 R38C71 R45C51 OD Indication R10C91 R38C72 R13C90 R39C68 R16C89 R39C69 R17C89 R39C70

3. Eddy Current R15C89 R35C75 R45C46 R12C2 Signal R40C67 R45C47M R28C12 R40C68 R45C48 R30C15 R41C66 R45C49 R31C15 R45C50 R32C15 R32C16 R33C15

4. Preventatively R41C55 Plugged R42C54 R42C56 TOTALS 28 M Metallurgical Samples NRC Meeting March 23, 1982 R45C52 pulled April, 1978.

GINNA STATION s I B-STEAM GENERATOR NO. 2 WEDGE AREA Column 17 16 15 14 13 12 <<

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'I 0 30 0 0 0 0 0 '0 0 '29 0 0 0 0 0 ~ 0 28 0 0 0 0 0 0 0 27 ROW Structurally Degraded (nc tubes)

Video OD Indication (no tubes)

Eddy Current Signal .(6 tubes)

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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 VIBRATION AMPLITUDES, MILS CROSS SECTION OF DISTORTED ZONE VORTEX SHEDDING TURBULENCE CYLINDER (NOMINAL) 0.77 0.81 10% OVALITY 0.79 0.83 KIDNEY 0. 79 0.83 FLAT 2.13 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 )

INPUT CROSS-FLOW VELOCITES: 6.0 ft/sec. hot leg 5.4 ft/sec. cold leg AVERAGE VELOCITY IN MAX. GAP VELOCITY IN CASE TUBE REMOVAL REGION FIRST TUBE ROM DOWNSTREAM NOMINAL 5. 30 19.40 10 TUBES REMOVED 3. 69 13.50 40 TUBES REMOVED 3. 86 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)

I Q. ENVELOPING TRANSIENT - PLANT LOADING/UNLOADING, 14,500 CYCLE!

0 ASSOCIATED LOADS

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TEMPERATURE VARIATIONS, PRIM'ARY T:

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

SECONDARY T ST': 547F (HOT STANDBY) TO 518F (100% POWER) o EXTERNAL PRESSURE RANGE: 795-1020 PSI .

o AXIAL TUBE LOAD RANGES o TUBE-TO-SHELL THERMAL MISMATCH + 780 lbs.

ASSUMPTION.- TUBE IN CONTINUOUS THERMAL E(UILIBRIUM WITH SECONDARY FLUID; STUB-BARREL WITH INFINITE THERMAL INERTIA o 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

~ 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 MAXIMUM STRESS INTENSITY RANGE

= 56.25 KSI SALT (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)

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

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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 MAXIMUM hp

- 1020 PSI RE(UIRED WALL DEGRADATION IS 80'X,"IF UNIFORM, AND

> 90K IF LOCAL TUBE COLLAPSE RESULTS FROM PLASTIC INSTABILITY AND REPRESENTS AN INSTANTANEOUS FAILURE MODE. OF ALL THE IQADING CONDITIONS FOR RGE TUBING, THE MAXIMUM ap (- 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 TSP THK = 0.75 INCH

'TUBE SEVERED JUST 51.88 INCH BELOW THE FIRST PLATE 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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.+~. START B S/G MODI CATIONS March 19, 1982

) .z-~ NUS MOCK-UP 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