Information Notice 2001-09, Main Feedwater System Degradation in Safety-Related ASME Code Class 2 Piping Inside the Containment of a Pressurized Water Reactor: Difference between revisions
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{{#Wiki_filter:UNITED STATES | {{#Wiki_filter:UNITED STATES | ||
NUCLEAR REGULATORY COMMISSION | ===NUCLEAR REGULATORY COMMISSION=== | ||
OFFICE OF NUCLEAR REACTOR REGULATION | |||
WASHINGTON, D.C. 20555-0001 | |||
===June 12, 2001=== | |||
NRC INFORMATION NOTICE 2001-09: | |||
===MAIN FEEDWATER SYSTEM DEGRADATION IN=== | |||
SAFETY-RELATED ASME CODE CLASS 2 PIPING | SAFETY-RELATED ASME CODE CLASS 2 PIPING | ||
INSIDE THE CONTAINMENT OF A PRESSURIZED | ===INSIDE THE CONTAINMENT OF A PRESSURIZED=== | ||
WATER REACTOR | WATER REACTOR | ||
| Line 48: | Line 50: | ||
It is expected that recipients will review the information for applicability to their facilities and | It is expected that recipients will review the information for applicability to their facilities and | ||
consider actions, as appropriate. However, suggestions contained in this IN are not NRC | consider actions, as appropriate. However, suggestions contained in this IN are not NRC | ||
requirements; therefore, no specific actions or written response is required. | requirements; therefore, no specific actions or written response is required. | ||
| Line 57: | Line 59: | ||
scheduled inspections to assess the effects of erosion/corrosion on steel piping exposed to | scheduled inspections to assess the effects of erosion/corrosion on steel piping exposed to | ||
flowing water (single-phase fluids) and water-steam mixtures (two-phase fluids). These effects | flowing water (single-phase fluids) and water-steam mixtures (two-phase fluids). These effects | ||
are commonly referred to as flow-accelerated corrosion (FAC). Inspections identified several | are commonly referred to as flow-accelerated corrosion (FAC). Inspections identified several | ||
instances of localized MFW system piping wall thinning to below the minimum thickness | instances of localized MFW system piping wall thinning to below the minimum thickness | ||
| Line 66: | Line 68: | ||
to below the minimum thickness specified by American National Standards Institute (ANSI) | to below the minimum thickness specified by American National Standards Institute (ANSI) | ||
B31.1, Power Piping, for non-safety-related portions of the MFW system. The wall | B31.1, Power Piping, for non-safety-related portions of the MFW system. The wall | ||
thicknesses in the degraded areas had not been previously measured. | thicknesses in the degraded areas had not been previously measured. | ||
| Line 72: | Line 74: | ||
The licensee had expanded and upgraded its FAC program following an August 11, 1999, event in which an 8-inch moisture separator reheater drain line experienced a double-ended | The licensee had expanded and upgraded its FAC program following an August 11, 1999, event in which an 8-inch moisture separator reheater drain line experienced a double-ended | ||
guillotine break causing operators to manually trip the reactor. The upgraded and expanded | guillotine break causing operators to manually trip the reactor. The upgraded and expanded | ||
FAC program, utilizing CHECWORKS' Rev. F software, predicted wall thinning in the MFW | FAC program, utilizing CHECWORKS' Rev. F software, predicted wall thinning in the MFW | ||
system. However, without wall thickness trending data, the software was not able to accurately | system. However, without wall thickness trending data, the software was not able to accurately | ||
predict the extent of degradation. After performing an inspection during the current outage, the | predict the extent of degradation. After performing an inspection during the current outage, the | ||
licensee found the MFW degradation to be more extensive than anticipated. | licensee found the MFW degradation to be more extensive than anticipated. | ||
| Line 85: | Line 87: | ||
were expanded to include portions of the condensate system, auxiliary feedwater (AFW) | were expanded to include portions of the condensate system, auxiliary feedwater (AFW) | ||
system, feedwater heaters, and other areas. Additional degradation was found in piping for the | system, feedwater heaters, and other areas. Additional degradation was found in piping for the | ||
feedwater heaters. | feedwater heaters. | ||
| Line 91: | Line 93: | ||
Several instances of MFW system wall thinning were identified in risk-important sections of | Several instances of MFW system wall thinning were identified in risk-important sections of | ||
14-inch ASME Code Class 2 safety-related piping components inside the containment. The | 14-inch ASME Code Class 2 safety-related piping components inside the containment. The | ||
licensee identified six 90-degree elbows, two 45-degree elbows, one 14-to-16-inch expander, and a 6-foot section of piping that had degraded to less than the ASME minimum design | licensee identified six 90-degree elbows, two 45-degree elbows, one 14-to-16-inch expander, and a 6-foot section of piping that had degraded to less than the ASME minimum design | ||
| Line 97: | Line 99: | ||
allowable wall thickness (below allowance) or that the licensee projected would degrade below | allowable wall thickness (below allowance) or that the licensee projected would degrade below | ||
allowance during the following cycle. The as-found wall thicknesses for components degraded | allowance during the following cycle. The as-found wall thicknesses for components degraded | ||
below allowance ranged from 75 to 96 percent of the minimum allowable thickness required by | below allowance ranged from 75 to 96 percent of the minimum allowable thickness required by | ||
the code. These components were identified in common MFW/auxiliary feedwater (AFW) flow | the code. These components were identified in common MFW/auxiliary feedwater (AFW) flow | ||
paths to three of the units four steam generators (SGs). All safety-related components in the | paths to three of the units four steam generators (SGs). All safety-related components in the | ||
containment that were below allowance (or that the licensee predicted would degrade below | containment that were below allowance (or that the licensee predicted would degrade below | ||
allowance during the following cycle) were replaced. Some degraded non-safety-related | allowance during the following cycle) were replaced. Some degraded non-safety-related | ||
components outside the containment were repaired rather than replaced. | components outside the containment were repaired rather than replaced. | ||
Background | ===Background=== | ||
Since 1982, the NRC has issued numerous generic communications addressing various issues | Since 1982, the NRC has issued numerous generic communications addressing various issues | ||
and events related to pipe wall thinning. Several of those communications are particularly | and events related to pipe wall thinning. Several of those communications are particularly | ||
relevant to the recently identified MFW wall-thinning at Callaway Plant. They are summarized | relevant to the recently identified MFW wall-thinning at Callaway Plant. They are summarized | ||
below and annotated in Table 1, "Summary of Related Previous Generic Communications. | below and annotated in Table 1, "Summary of Related Previous Generic Communications. | ||
| Line 127: | Line 128: | ||
1987 discovery of MFW degradation at the Trojan Nuclear Plant similar to that observed at | 1987 discovery of MFW degradation at the Trojan Nuclear Plant similar to that observed at | ||
Callaway Plant. The thinning was discovered when Trojans steam piping inspection program | Callaway Plant. The thinning was discovered when Trojans steam piping inspection program | ||
was expanded to include single-phase piping. It was attributed to high fluid flow velocities and | was expanded to include single-phase piping. It was attributed to high fluid flow velocities and | ||
other operating factors. | other operating factors. | ||
| Line 137: | Line 138: | ||
Power Plants, April 22, 1988, summarized licensee responses to and NRC observations on | Power Plants, April 22, 1988, summarized licensee responses to and NRC observations on | ||
the thinning of nuclear power plant pipe walls. The IN noted that all licensees reported having | the thinning of nuclear power plant pipe walls. The IN noted that all licensees reported having | ||
established programs for inspecting pipe wall thinning for two-phase, high-energy carbon steel | established programs for inspecting pipe wall thinning for two-phase, high-energy carbon steel | ||
piping systems. Inspection locations were generally reported to have been selected in | piping systems. Inspection locations were generally reported to have been selected in | ||
accordance the 1985 guidelines in Electric Power Research Institute (EPRI) Document | accordance the 1985 guidelines in Electric Power Research Institute (EPRI) Document | ||
| Line 147: | Line 148: | ||
NP-3944, Erosion/Corrosion in Nuclear Plant Steam Piping: Causes and Inspection Program | NP-3944, Erosion/Corrosion in Nuclear Plant Steam Piping: Causes and Inspection Program | ||
Guidelines. However, because implementation of these guidelines was not required, the | Guidelines. However, because implementation of these guidelines was not required, the | ||
scope of the programs varied significantly from plant to plant. | scope of the programs varied significantly from plant to plant. | ||
| Line 157: | Line 158: | ||
that procedures or administrative controls were in place to maintain the structural integrity of all | that procedures or administrative controls were in place to maintain the structural integrity of all | ||
carbon steel systems carrying high-energy fluids. EPRI released the pipe wall thinning | carbon steel systems carrying high-energy fluids. EPRI released the pipe wall thinning | ||
predictive computer code CHEC' in June 1987, CHECMATE' in April 1989, and | predictive computer code CHEC' in June 1987, CHECMATE' in April 1989, and | ||
CHECWORKS' in August 1994, to assist licensees in selecting for testing those areas of the piping systems with the highest probabilities of wall thinning. The Massachusetts Institute of | CHECWORKS' in August 1994, to assist licensees in selecting for testing those areas of the piping systems with the highest probabilities of wall thinning. The Massachusetts Institute of | ||
Technology method described in NUREG/CR-5007, Prediction and Mitigation of Erosion- Corrosive Wear in Secondary Piping Systems of Nuclear Power Plants, September 1987, also | Technology method described in NUREG/CR-5007, Prediction and Mitigation of Erosion- Corrosive Wear in Secondary Piping Systems of Nuclear Power Plants, September 1987, also | ||
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observations on the industrys design and implementation of erosion/corrosion programs in | observations on the industrys design and implementation of erosion/corrosion programs in | ||
response to Generic Letter 89-08. Among other observations, the IN identified instances of | response to Generic Letter 89-08. Among other observations, the IN identified instances of | ||
erosion/corrosion in safety-related portions of MFW and main steam systems and described the | erosion/corrosion in safety-related portions of MFW and main steam systems and described the | ||
problems licensees were having in implementing effective FAC programs. In November 1993, EPRI released document NSALC-202L, Recommendations for an Effective Flow-Accelerated | problems licensees were having in implementing effective FAC programs. In November 1993, EPRI released document NSALC-202L, Recommendations for an Effective Flow-Accelerated | ||
Corrosion Program. Rev. 2 of the document was released in April 1999. | Corrosion Program. Rev. 2 of the document was released in April 1999. | ||
Discussion | Discussion | ||
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catastrophic failure, the extent of the degradation at the time of discovery is of concern to the | catastrophic failure, the extent of the degradation at the time of discovery is of concern to the | ||
NRC, given the maturity of the industrys FAC programs. Of particular concern is the | NRC, given the maturity of the industrys FAC programs. Of particular concern is the | ||
degradation in risk-important non-isolable sections of single-phase ASME Code Class 2 piping | degradation in risk-important non-isolable sections of single-phase ASME Code Class 2 piping | ||
inside the containment. These factors can impact the safety significance of pipe wall thinning. | inside the containment. These factors can impact the safety significance of pipe wall thinning. | ||
MFW systems, like other power conversion systems, are important to the safe operation of | MFW systems, like other power conversion systems, are important to the safe operation of | ||
nuclear power plants. Past failures of feedwater and other high-energy system components | nuclear power plants. Past failures of feedwater and other high-energy system components | ||
have resulted in complex challenges to operating staff when the released high-energy steam | have resulted in complex challenges to operating staff when the released high-energy steam | ||
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and water interacted with other systems, such as electrical distribution, fire protection, and | and water interacted with other systems, such as electrical distribution, fire protection, and | ||
security systems. Personnel injuries and fatalities have also occurred. The failure to maintain | security systems. Personnel injuries and fatalities have also occurred. The failure to maintain | ||
high energy piping and components within allowable thickness values can (1) increase the | high energy piping and components within allowable thickness values can (1) increase the | ||
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for safe shutdown and accident mitigation; and/or (3) impact the integrity of fission product | for safe shutdown and accident mitigation; and/or (3) impact the integrity of fission product | ||
barriers. This IN requires no specific action or written response. If you have any questions about the | barriers. This IN requires no specific action or written response. If you have any questions about the | ||
information in this notice, please contact one of the technical contacts listed below or the | information in this notice, please contact one of the technical contacts listed below or the | ||
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/RA/ | /RA/ | ||
===Ledyard B. Marsh, Chief=== | |||
Events Assessment, Generic Communications | Events Assessment, Generic Communications | ||
and Non-Power Reactors Branch | and Non-Power Reactors Branch | ||
Division of Regulatory Improvement Programs | ===Division of Regulatory Improvement Programs=== | ||
Office of Nuclear Reactor Regulation | |||
Technical contacts: | |||
===Ross Telson, NRR=== | |||
Krzysztof Parczewski, NRR | |||
301-415-1175 | |||
301-415-2705 E-mail: rdt@nrc.gov | |||
E-mail: kip@nrc.gov | |||
William D. Johnson, R-IV | |||
===David Terao, NRR=== | |||
817-860-8148 | |||
301-415-3317 E-mail: wdj@nrc.gov | |||
E-mail: dxt@nrc.gov | |||
Attachments: | |||
1. | |||
Table 1: Summary of Related Previous Generic Communications | |||
2. | |||
Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events | |||
3. | |||
List of Recently Issued NRC Information Notices This IN requires no specific action or written response. If you have any questions about the | |||
information in this notice, please contact one of the technical contacts listed below or the | information in this notice, please contact one of the technical contacts listed below or the | ||
| Line 250: | Line 266: | ||
/RA/ | /RA/ | ||
===Ledyard B. Marsh, Chief=== | |||
Events Assessment, Generic Communications | Events Assessment, Generic Communications | ||
and Non-Power Reactors Branch | and Non-Power Reactors Branch | ||
Division of Regulatory Improvement Programs | ===Division of Regulatory Improvement Programs=== | ||
Office of Nuclear Reactor Regulation | |||
Technical contacts: | |||
===Ross Telson, NRR=== | |||
Krzysztof Parczewski, NRR | |||
301-415-1175 | |||
301-415-2705 E-mail: rdt@nrc.gov | |||
E-mail: kip@nrc.gov | |||
William D. Johnson, R-IV | |||
===David Terao, NRR=== | |||
817-860-8148 | |||
301-415-3317 E-mail: wdj@nrc.gov | |||
E-mail: dxt@nrc.gov | |||
Attachments: | |||
1. | |||
Table 1: Summary of Related Previous Generic Communications | |||
2. | |||
Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events | |||
3. | 3. | ||
===List of Recently Issued NRC Information Notices=== | |||
DISTRIBUTION | DISTRIBUTION | ||
| Line 285: | Line 315: | ||
*See Previous Concurrence | *See Previous Concurrence | ||
Accession No.: ML011490408 | Accession No.: ML011490408 Template No.:NRR-056 | ||
Publicly Available | |||
Non-Publicly Available Sensitive Non-Sensitive | |||
OFFICE | OFFICE | ||
REXB | |||
Tech Editor | |||
DATE | C:EMCB | ||
C:EMEB | |||
NAME | |||
RTelson* | |||
PKleene* | |||
WBateman* | |||
EImbro* | |||
DATE | |||
5/ 21 /01 | |||
5 /18 /01 | |||
5/15 /01 | |||
5 /29 /01 OFFICE | |||
SC:REXB | |||
C:REXB | |||
NAME | |||
JTappert* | |||
LMarsh | |||
DATE | |||
6/5 /01 | |||
6 /11/01 | |||
===OFFICIAL RECORD COPY=== | |||
Attachment 1 Table 1: Summary of Related Previous Generic Communications | Attachment 1 Table 1: Summary of Related Previous Generic Communications | ||
| Line 303: | Line 365: | ||
particularly relevant are underlined. | particularly relevant are underlined. | ||
1. IN 82-22, Failures in Turbine Exhaust Lines, July 9, 1982, addressed the rupture of a | 1. | ||
IN 82-22, Failures in Turbine Exhaust Lines, July 9, 1982, addressed the rupture of a | |||
24-inch-diameter long-radius elbow in a feedwater heat extraction line at Oconee Unit 2 and four similar failures identified by the Institute of Nuclear Power Operations (INPO). | 24-inch-diameter long-radius elbow in a feedwater heat extraction line at Oconee Unit 2 and four similar failures identified by the Institute of Nuclear Power Operations (INPO). | ||
2. IN 86-106, Feedwater Line Break, December 16, 1986, addressed a potentially generic | 2. | ||
IN 86-106, Feedwater Line Break, December 16, 1986, addressed a potentially generic | |||
problem with feedwater pipe thinning and other problems related to the catastrophic | problem with feedwater pipe thinning and other problems related to the catastrophic | ||
| Line 313: | Line 379: | ||
failure of an 18-inch-diameter MFW pump suction line at Surry Unit 2. | failure of an 18-inch-diameter MFW pump suction line at Surry Unit 2. | ||
3. IN 86-106, Supplement 1, Feedwater Line Break, February 13, 1987, discussed the | 3. | ||
IN 86-106, Supplement 1, Feedwater Line Break, February 13, 1987, discussed the | |||
licensees failure analysis, the parameters that could have potentially contributed to pipe | licensees failure analysis, the parameters that could have potentially contributed to pipe | ||
| Line 323: | Line 391: | ||
ANSI B31.1 for other piping systems. | ANSI B31.1 for other piping systems. | ||
4. IN 86-106, Supplement 2, Feedwater Line Break, October 21, 1988, addressed the | 4. | ||
IN 86-106, Supplement 2, Feedwater Line Break, October 21, 1988, addressed the | |||
discovery that an elbow installed on the suction side of a MFW pump during a 1987 Surry | discovery that an elbow installed on the suction side of a MFW pump during a 1987 Surry | ||
| Line 329: | Line 399: | ||
Unit 2 refueling outage had thinned more rapidly than expected, giving up 20 percent of its | Unit 2 refueling outage had thinned more rapidly than expected, giving up 20 percent of its | ||
0.500-inch wall thickness in 1.2 years. Wall thinning was also observed in safety-related | 0.500-inch wall thickness in 1.2 years. Wall thinning was also observed in safety-related | ||
MFW piping and in other non-safety-related condensate piping. | MFW piping and in other non-safety-related condensate piping. | ||
5. IN 86-106, Supplement 3, Feedwater Line Break, November 10, 1988, further addressed | 5. | ||
IN 86-106, Supplement 3, Feedwater Line Break, November 10, 1988, further addressed | |||
the faster-than-expected wall thinning at Surry Unit 2, noting the disparity between the | the faster-than-expected wall thinning at Surry Unit 2, noting the disparity between the | ||
| Line 339: | Line 411: | ||
previously estimated 20-30 mils/year thinning rate and maximum observed rate of | previously estimated 20-30 mils/year thinning rate and maximum observed rate of | ||
90 mils/year. The IN also noted that accelerated wall thinning may have coincided with a | 90 mils/year. The IN also noted that accelerated wall thinning may have coincided with a | ||
reduction in feedwater dissolved-oxygen concentration. | reduction in feedwater dissolved-oxygen concentration. | ||
6. NRC Bulletin 87-01, Thinning of Pipe Walls in Nuclear Power Plants, July 9, 1987, requested licensees to inform the NRC about their programs for monitoring the thickness | 6. | ||
NRC Bulletin 87-01, Thinning of Pipe Walls in Nuclear Power Plants, July 9, 1987, requested licensees to inform the NRC about their programs for monitoring the thickness | |||
of pipe walls of carbon steel piping in both safety-related and non-safety-related high- energy fluid (single-phase and two-phase) systems. | of pipe walls of carbon steel piping in both safety-related and non-safety-related high- energy fluid (single-phase and two-phase) systems. | ||
7. IN 87-36, Significant Unexpected Erosion of Feedwater Lines, August 4, 1987, addressed potentially generic unexpected erosion which resulted in pipe wall thinning in | 7. | ||
IN 87-36, Significant Unexpected Erosion of Feedwater Lines, August 4, 1987, addressed potentially generic unexpected erosion which resulted in pipe wall thinning in | |||
both safety-related and non-safety-related portions of feedwater lines (both inside and | both safety-related and non-safety-related portions of feedwater lines (both inside and | ||
outside the containment) at Trojan Nuclear Plant. The thinning was discovered when | outside the containment) at Trojan Nuclear Plant. The thinning was discovered when | ||
Trojans steam piping inspection program was expanded to include single-phase piping | Trojans steam piping inspection program was expanded to include single-phase piping | ||
| Line 357: | Line 433: | ||
and was attributed to high fluid flow velocities and other operating factors. | and was attributed to high fluid flow velocities and other operating factors. | ||
8. IN 88-17, Summary of Responses to NRC Bulletin 87-01, Thinning of Pipe Walls in | 8. | ||
IN 88-17, Summary of Responses to NRC Bulletin 87-01, Thinning of Pipe Walls in | |||
Nuclear Power Plants, April 22, 1988, reported the results of responses to NRC Bulletin | Nuclear Power Plants, April 22, 1988, reported the results of responses to NRC Bulletin | ||
| Line 363: | Line 441: | ||
87-01 and described a recent event at LaSalle County Station Unit 1. | 87-01 and described a recent event at LaSalle County Station Unit 1. | ||
Attachment 1 9. | Attachment 1 9. | ||
IN 89-01, Valve Body Erosion, January 4, 1989, addressed a potential generic problem | |||
with erosion in carbon steel valve bodies in safety-related systems. | with erosion in carbon steel valve bodies in safety-related systems. | ||
10. Generic Letter 89-08, Erosion/Corrosion-Induced Pipe Wall Thinning, May 2, 1989, requested licensees to implement long-term erosion/corrosion monitoring programs to | 10. | ||
Generic Letter 89-08, Erosion/Corrosion-Induced Pipe Wall Thinning, May 2, 1989, requested licensees to implement long-term erosion/corrosion monitoring programs to | |||
obtain assurance that procedures or administrative controls were in place to maintain the | obtain assurance that procedures or administrative controls were in place to maintain the | ||
| Line 373: | Line 455: | ||
structural integrity of all carbon steel systems carrying high-energy fluids. | structural integrity of all carbon steel systems carrying high-energy fluids. | ||
11. IN 89-53, Rupture of Extraction Steam Line on High Pressure Turbine, June 13, 1989, addressed a potential generic problem with erosion in carbon steel piping in secondary | 11. | ||
IN 89-53, Rupture of Extraction Steam Line on High Pressure Turbine, June 13, 1989, addressed a potential generic problem with erosion in carbon steel piping in secondary | |||
plant systems. | plant systems. | ||
12. IN 91-18, High Energy Pipe Failures Caused by Wall Thinning, March 12, 1991, addressed continuing erosion/corrosion of high-energy piping systems and apparently | 12. | ||
IN 91-18, High Energy Pipe Failures Caused by Wall Thinning, March 12, 1991, addressed continuing erosion/corrosion of high-energy piping systems and apparently | |||
inadequate monitoring programs. | inadequate monitoring programs. | ||
13. IN 92-35, Higher Than Predicted Erosion/Corrosion in Unisolable Reactor Coolant | 13. | ||
IN 92-35, Higher Than Predicted Erosion/Corrosion in Unisolable Reactor Coolant | |||
Pressure Boundary Piping Inside Containment at a Boiling Water Reactor, May 6, 1992, addressed an unexpectedly high rate of erosion/corrosion in certain main feedwater piping | Pressure Boundary Piping Inside Containment at a Boiling Water Reactor, May 6, 1992, addressed an unexpectedly high rate of erosion/corrosion in certain main feedwater piping | ||
inside the containment at the Susquehanna Unit 1 boiling water reactor (BWR). The | inside the containment at the Susquehanna Unit 1 boiling water reactor (BWR). The | ||
condition was noted to be of particular concern since it was in a section of piping that | condition was noted to be of particular concern since it was in a section of piping that | ||
| Line 391: | Line 479: | ||
could not be isolated from the reactor vessel. | could not be isolated from the reactor vessel. | ||
14. IN 93-21, Summary of NRC Staff Observations Compiled During Engineering Audits or | 14. | ||
IN 93-21, Summary of NRC Staff Observations Compiled During Engineering Audits or | |||
Inspections of Licensee Erosion/Corrosion Programs, March 25, 1993, addressed NRC | Inspections of Licensee Erosion/Corrosion Programs, March 25, 1993, addressed NRC | ||
| Line 399: | Line 489: | ||
in response to Generic Letter 89-08. | in response to Generic Letter 89-08. | ||
15. IN 95-11, Failure of Condensate Piping Because of Erosion/Corrosion at a Flow- Straightening Device, February 24, 1995, addressed possible piping failures caused by | 15. | ||
IN 95-11, Failure of Condensate Piping Because of Erosion/Corrosion at a Flow- Straightening Device, February 24, 1995, addressed possible piping failures caused by | |||
flow disturbances that were not accounted for in erosion/corrosion programs. | flow disturbances that were not accounted for in erosion/corrosion programs. | ||
16. IN 97-84, Rupture in Extraction Steam Piping as a Result of Flow-Accelerated Corrosion, December 11, 1997, addressed potential generic problems related to the occurrence and | 16. | ||
IN 97-84, Rupture in Extraction Steam Piping as a Result of Flow-Accelerated Corrosion, December 11, 1997, addressed potential generic problems related to the occurrence and | |||
prediction of flow-accelerated corrosion (FAC) in extraction steam lines. | prediction of flow-accelerated corrosion (FAC) in extraction steam lines. | ||
17. IN 99-19, Rupture of the Shell Side of a Feedwater Heater at the Point Beach Nuclear | 17. | ||
IN 99-19, Rupture of the Shell Side of a Feedwater Heater at the Point Beach Nuclear | |||
Plant, June 23, 1999, addressed the rupture of the shell side of a feedwater heater at the | Plant, June 23, 1999, addressed the rupture of the shell side of a feedwater heater at the | ||
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Point Beach Nuclear Plant Unit 1. | Point Beach Nuclear Plant Unit 1. | ||
Attachment 2 Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events | Attachment 2 Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events | ||
Date | Date | ||
1976 | Site | ||
Details | |||
Ref. | |||
1976 Oconee 3 Pinhole leak in an extraction steam line. A surveillance program | |||
utilizing ultrasonic examination of extraction steam lines was | |||
initiated and, in 1980, identified two degraded elbows identical | initiated and, in 1980, identified two degraded elbows identical | ||
to the Unit 2 elbow that subsequently failed in 1982. The | to the Unit 2 elbow that subsequently failed in 1982. The | ||
elbows were replaced. | elbows were replaced. | ||
1981 | IN 82-22 | ||
1981 Millstone 2 Use of engineering personnel unfamiliar with plant operating | |||
January | conditions, plant as-built designs, or erosion/corrosion history. | ||
IN 93-21 January | |||
1982 Vermont | |||
Yankee | |||
Licensee shut down the plant after identifying steam blowing | |||
from a leak in the 12-inch-diameter drain line between a | |||
moisture separator and heater drain tank. | moisture separator and heater drain tank. | ||
January | IN 82-22 January | ||
1982 | |||
1982 Trojan | |||
Steam line failure resulting in plant shutdown. | |||
IN 82-22 February | |||
1982 Zion 1 Steam leak in 150 psig high-pressure exhaust steam line | |||
originating from an 8-inch crack on a weld joining 24-inch piping | |||
with the 37.5-inch high-pressure steam exhaust piping leading | with the 37.5-inch high-pressure steam exhaust piping leading | ||
to the moisture separator reheater. The event resulted in plant | to the moisture separator reheater. The event resulted in plant | ||
shutdown. | shutdown. | ||
June 1982 Oconee 2 | IN 82-22 June 1982 Oconee 2 While operating at 95-percent power, a 4-square-foot rupture | ||
occurred in a 24-inch-diameter long-radius elbow in a feedwater | |||
heat extraction line. The reactor was manually tripped, a steam | |||
overnight with steam burns. An ultrasonic inspection had | jet destroyed a non-safety-related load center and certain non- safety-related instrumentation. Personnel were hospitalized | ||
overnight with steam burns. An ultrasonic inspection had | |||
identified substantial erosion of the elbow In March 1982, but | identified substantial erosion of the elbow In March 1982, but | ||
| Line 454: | Line 578: | ||
the erosion failed to meet the licensees criteria for rejection. | the erosion failed to meet the licensees criteria for rejection. | ||
June 1982 Browns Ferry 1 Steam line failure resulting in plant shutdown. | IN 82-22 June 1982 | ||
===Browns Ferry 1=== | |||
Steam line failure resulting in plant shutdown. | |||
IN 82-22 March | |||
1983 Dresden 3 Steam leak from the shell side of the 3C3 low-pressure | |||
feedwater heater near the extraction steam inlet nozzle. The | |||
leak was attributed to erosion by deflected extraction steam. | leak was attributed to erosion by deflected extraction steam. | ||
| Line 463: | Line 595: | ||
inspection program. | inspection program. | ||
March | IN 99-19 March | ||
December | 1985 Haddam Neck | ||
Pipe rupture, approximately 1/2-by-2-1/4-inch, downstream of a | |||
normal level control valve for a feedwater heater. | |||
GL 89-08 December | |||
1986 Surry 2 Catastrophic failure of 18-inch MFW pump suction line elbow | |||
when a main steam isolation valve failed closed on one of the | |||
steam generators. A 2-by-4-foot section of the elbow was blown | |||
out and came to rest on an overhead cable tray. The reactive | |||
force completely severed the suction line. The free end | |||
whipped and came to rest against the discharge line for another | whipped and came to rest against the discharge line for another | ||
pump. The failure of the piping, which was carrying single- phase fluid, was caused by erosion/corrosion of the carbon steel | pump. The failure of the piping, which was carrying single- phase fluid, was caused by erosion/corrosion of the carbon steel | ||
pipe wall. The unit had been operating at full power. An | pipe wall. The unit had been operating at full power. An | ||
automatic plant trip occurred and four workers suffered fatal | automatic plant trip occurred and four workers suffered fatal | ||
injuries. Released steam caused the fire suppression system to | injuries. Released steam caused the fire suppression system to | ||
actuate, releasing halon and carbon dioxide into emergency | actuate, releasing halon and carbon dioxide into emergency | ||
switchgear. The NRC dispatched an augmented inspection | switchgear. The NRC dispatched an augmented inspection | ||
team to the site. | team to the site. | ||
IN 86-106 Bulletin 87-01 IN 88-17 GL 89-08 | |||
===Attachment 2 Date=== | |||
Site | |||
expanded to include single-phase piping. The thinning was | Details | ||
Ref. | |||
June 1987 Trojan | |||
MFW degradation was discovered by the licensee in at least two | |||
areas of the straight sections of ASME Class 2 safety-related | |||
MFW piping inside containment. The thinning was discovered | |||
when the Trojan steam piping inspection program was | |||
expanded to include single-phase piping. The thinning was | |||
attributed to high fluid flow velocities and other operating | attributed to high fluid flow velocities and other operating | ||
| Line 495: | Line 656: | ||
factors. | factors. | ||
IN 87-36 IN 88-17 GL 89-08 December | |||
feedwater pump minimum-flow control valve. Subsequent | 1987 LaSalle 1 Through-wall pinhole leaks due to erosion were discovered in a | ||
45-degree elbow down stream of a turbine-driven reactor | |||
feedwater pump minimum-flow control valve. Subsequent | |||
inspections identified additional areas of wall thinning. | inspections identified additional areas of wall thinning. | ||
September | IN 88-17 September | ||
1988 Surry 2 The pipe wall of an elbow installed on the suction side of a MFW | |||
pump during a 1987 refueling outage was discovered to have | |||
thinned more rapidly than expected, losing 20 percent of its | thinned more rapidly than expected, losing 20 percent of its | ||
0.500-inch wall thickness in 1.2 years. Wall thinning was also | 0.500-inch wall thickness in 1.2 years. Wall thinning was also | ||
observed in safety-related MFW piping and in other non-safety- related condensate piping. | observed in safety-related MFW piping and in other non-safety- related condensate piping. | ||
December | GL 89-08 December | ||
1988 Brunswick 1 Inspection indicated areas of significant but localized erosion on | |||
the internal surfaces of several carbon steel valve bodies. The | |||
affected safety-related valves were the 24-inch residual heat | affected safety-related valves were the 24-inch residual heat | ||
| Line 520: | Line 690: | ||
injection and 16-inch suppression pool isolation valves. | injection and 16-inch suppression pool isolation valves. | ||
April 1989 Arkansas | IN 89-01 April 1989 Arkansas | ||
Unit 2 | Nuclear One | ||
Unit 2 Steam escaping from a ruptured 14-inch high-pressure steam | |||
extraction line caused a spurious turbine/reactor trip from | |||
100-percent power. This straight run of piping terminates at an | |||
elbow that was replaced during the previous outage because of | elbow that was replaced during the previous outage because of | ||
erosion-induced wall thinning. The pipe and those of similar | erosion-induced wall thinning. The pipe and those of similar | ||
geometries had not been included in the licensees surveillance | geometries had not been included in the licensees surveillance | ||
| Line 534: | Line 710: | ||
the elbow replacement. | the elbow replacement. | ||
March | IN 89-53 March | ||
1990 | |||
Surry 1 Rupture of a straight section of piping downstream of a level | |||
control valve in the low-pressure heater drain (LPHD) system. | |||
The LPHD system was included in the licensees FAC program | The LPHD system was included in the licensees FAC program | ||
| Line 543: | Line 723: | ||
affected section of piping. | affected section of piping. | ||
May 1990 | IN 91-18 May 1990 | ||
Loviisa 1 (foreign) | |||
A flow-measuring orifice flange in the main feedwater system | |||
pressure spike. Subsequent inspections determined that 9 of | ruptured after one of five main feedwater pumps tripped, causing a check valve in the line to slam shut, creating a | ||
pressure spike. Subsequent inspections determined that 9 of | |||
10 flanges had thinned to below minimum wall requirements. | 10 flanges had thinned to below minimum wall requirements. | ||
July 1990 | IN 91-18 July 1990 | ||
===San Onofre 2=== | |||
The licensee was forced to shut down the unit after discovering | |||
a steam leak in one of the feedwater regulating valve bypass | |||
lines. | lines. | ||
IN 91-18 December | |||
1990 | |||
Millstone 3 Two 6-inch pipes in the moisture separator drain (MSD) system | |||
pressure transient. The high-energy water flashed to steam and | ruptured when a MSD pump was stopped to facilitate | ||
component isolation for repairs. Stopping the pump caused a | |||
pressure transient. The high-energy water flashed to steam and | |||
actuated portions of the turbine building fire protection deluge | actuated portions of the turbine building fire protection deluge | ||
system. Two 480-volt motor control centers and one non-vital | system. Two 480-volt motor control centers and one non-vital | ||
120-volt inverter were rendered inoperable by the flooding, resulting in the loss of the plant process computer and the | 120-volt inverter were rendered inoperable by the flooding, resulting in the loss of the plant process computer and the | ||
| Line 568: | Line 761: | ||
isolation of the instrument air to the containment building. | isolation of the instrument air to the containment building. | ||
Attachment 2 Date | IN 91-18 | ||
===Attachment 2 Date=== | |||
Site | |||
Details | |||
Ref. | |||
November | |||
1991 Millstone 2 Rupture at an 8-inch elbow of a moisture separator reheater. | |||
High-energy water flashed to steam, actuating portions of the | |||
turbine fire protection deluge system. The license had not | turbine fire protection deluge system. The license had not | ||
selected the ruptured elbow for ultrasonic testing in its | selected the ruptured elbow for ultrasonic testing in its | ||
erosion/corrosion monitoring program. See LER 50-336/91-12. | erosion/corrosion monitoring program. See LER 50-336/91-12. | ||
IN 91-18 | |||
1992 Millstone 3 See LER 50-309/92-07. | |||
IN 93-21 | |||
1992 | |||
1992 | |||
===Maine Yankee=== | |||
See LER 92-007. | |||
IN 93-21 | |||
1992 Salem 1 Improper determination of code minimum wall thickness | |||
1992 | acceptance criteria resulted in improper disposition of degraded | ||
components. See Inspection Report 50-272/92-08. | |||
IN 93-21 | |||
1992 Hope Creek | |||
Lack of baseline thickness measurements (history) of originally | |||
designed piping was identified. See Inspection Report 50- | |||
354/92-11. | |||
IN 93-21 | |||
1992 Millstone 1 Lack of baseline thickness measurements of replacement piping | |||
before the replacement piping was put into service. See | |||
Inspection Report 50-245/92-80. | Inspection Report 50-245/92-80. | ||
1992 | IN 93-21 | ||
1992 Hope Creek | |||
Use of engineering personnel who are unfamiliar with plant | |||
operating conditions, plant as-built designs, or erosion/corrosion | operating conditions, plant as-built designs, or erosion/corrosion | ||
1993 | history. | ||
----- ----- | |||
1993 Diablo | |||
Canyon 1 Erosion/corrosion wear was discovered behind a thermal sleeve | |||
in the interior of the feedwater nozzle and on the feedwater | |||
nozzle itself. | nozzle itself. | ||
November | IN 93-21 November | ||
1994 Sequoyah 1 Licensee identified a 180-degree circumferential crack in a | |||
reduced section of 14-inch condensate piping used for flow- metering. The section of piping had been modeled incorrectly in | |||
CHECMATE' without any diameter or thickness changes and | CHECMATE' without any diameter or thickness changes and | ||
| Line 608: | Line 841: | ||
had not been visually inspected. | had not been visually inspected. | ||
April 1997 Fort Calhoun | IN 95-11 April 1997 | ||
===Fort Calhoun=== | |||
Manual scram and emergency boration following a 6-square- foot rupture of a 12-inch diameter sweep elbow in the fourth- stage extraction steam piping. A non-safety-related electrical | |||
load center, several cable trays and pipe hangers were | load center, several cable trays and pipe hangers were | ||
damaged. In addition, asbestos-containing insulation was | damaged. In addition, asbestos-containing insulation was | ||
blown throughout the turbine building and portions of the fire | blown throughout the turbine building and portions of the fire | ||
| Line 618: | Line 854: | ||
protection system were actuated. | protection system were actuated. | ||
May 1999 | IN 97-84 May 1999 | ||
===Point Beach 1=== | |||
Manual trip from 100-percent power and manual safety injection | |||
actuation when the shell side of the feedwater heater ruptured. | |||
The fish-mouth rupture was approximately 27-inches long and | The fish-mouth rupture was approximately 27-inches long and | ||
0.75-inch at its widest point. Feedwater heater leaks were also | 0.75-inch at its widest point. Feedwater heater leaks were also | ||
identified at Pilgrim Station and the Susquehanna units. None | identified at Pilgrim Station and the Susquehanna units. None | ||
of the feedwater heaters had been included in a periodic | of the feedwater heaters had been included in a periodic | ||
| Line 630: | Line 871: | ||
inspection program. | inspection program. | ||
August | IN 99-19 August | ||
1999 Callaway | |||
Operators manually tripped the reactor on indication of a steam | |||
leak in the turbine building. An 8-inch line from the first stage | |||
reheater drain tank to the high-pressure heater experienced a | |||
double-ended guillotine break. | |||
Event | |||
===Notification=== | |||
36015 | |||
______________________________________________________________________________________ | |||
OL = Operating License | |||
CP = Construction Permit | |||
===Attachment 3 LIST OF RECENTLY ISSUED=== | |||
NRC INFORMATION NOTICES | NRC INFORMATION NOTICES | ||
_____________________________________________________________________________________ | _____________________________________________________________________________________ | ||
Information | Information | ||
Date of | |||
Notice No. | |||
Subject | |||
Issuance | |||
Issued to | |||
______________________________________________________________________________________ | ______________________________________________________________________________________ | ||
2001-08 | 2001-08 | ||
Supplement 1 | ===Supplement 1=== | ||
Update on the Investigation of | |||
Patient Deaths in Panama, | |||
===Following Radiation Therapy=== | |||
Overexposures | Overexposures | ||
06/06/01 | |||
===All Medical Licensees=== | |||
2001-08 | |||
===Treatment Planning System=== | |||
Errors Result in Deaths of | Errors Result in Deaths of | ||
Overseas Radiation Therapy | ===Overseas Radiation Therapy=== | ||
Patients | |||
06/01/01 | |||
===All medical licensees=== | |||
2001-07 | |||
===Unescorted Access Granted=== | |||
Based on Incomplete and/or | |||
===Inaccurate Information=== | |||
05/11/01 | |||
===All holders of nuclear reactor=== | |||
operating licenses who are | |||
subject to Section 73.56 of Title | |||
10, of the Code of Federal | 10, of the Code of Federal | ||
Regulations (10 CFR 73.56), | Regulations (10 CFR 73.56), | ||
===Personnel Access Authorization=== | |||
Requirements of Nuclear Power | Requirements of Nuclear Power | ||
Plants. | Plants. | ||
2001-06 | 2001-06 | ||
===Centrifugal Charging Pump=== | |||
Thrust Bearing Damage not | |||
===Detected Due to Inadequate=== | |||
Assessment of Oil Analysis | |||
===Results and Selection of Pump=== | |||
Surveillance Points | |||
05/11/01 | |||
===All holders of operating licenses=== | |||
for nuclear power reactors, except those who have | |||
permanently ceased operations | |||
and have certified that fuel has | |||
been permanently removed from | |||
the reactor | the reactor | ||
2001-05 | 2001-05 Through-Wall Circumferential | ||
Cracking of Reactor Pressure | ===Cracking of Reactor Pressure=== | ||
Vessel Head Control Rod Drive | |||
===Mechanism Penetration=== | |||
Nozzles at Oconee Nuclear | |||
===Station, Unit 3=== | |||
04/30/01 | |||
===All holders of operating licenses=== | |||
for pressurized water nuclear | |||
power reactors except those who | |||
have ceased operations and have | |||
certified that fuel has been | |||
permanently removed from the | |||
reactor vessel | reactor vessel | ||
2001-04 | 2001-04 | ||
Maintenance Causes Fatality | ===Neglected Fire Extinguisher=== | ||
Maintenance Causes Fatality | |||
04/11/01 | |||
===All holders of licenses for nuclear=== | |||
power, research, and test | |||
reactors and fuel cycle facilities | reactors and fuel cycle facilities | ||
2001-03 | 2001-03 | ||
Requirements for Radiography | ===Incident Reporting=== | ||
Requirements for Radiography | |||
Licensees | Licensees | ||
04/06/01 | |||
===All industrial radiography=== | |||
licensees}} | |||
{{Information notice-Nav}} | {{Information notice-Nav}} | ||
Latest revision as of 01:54, 17 January 2025
| ML011490408 | |
| Person / Time | |
|---|---|
| Issue date: | 06/12/2001 |
| From: | Marsh L Operational Experience and Non-Power Reactors Branch |
| To: | |
| Telson, R - NRR/DRIP/REXB - 415-1175 | |
| References | |
| IN-01-009 | |
| Download: ML011490408 (18) | |
UNITED STATES
NUCLEAR REGULATORY COMMISSION
OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, D.C. 20555-0001
June 12, 2001
NRC INFORMATION NOTICE 2001-09:
MAIN FEEDWATER SYSTEM DEGRADATION IN
SAFETY-RELATED ASME CODE CLASS 2 PIPING
INSIDE THE CONTAINMENT OF A PRESSURIZED
WATER REACTOR
Addressees
All holders of operating licenses for pressurized water nuclear power reactors except those who
have ceased operations and have certified that fuel has been permanently removed from the
reactor vessel.
Purpose
The U.S. Nuclear Regulatory Commission (NRC) is issuing this information notice (IN) to alert
addressees to the discovery of main feedwater (MFW) system wall thinning to below allowable
limits in turbine building components and in risk-important, safety-related portions of American
Society of Mechanical Engineers (ASME) Code Class 2 piping inside the reactor containment
building (containment) at the Callaway Plant.
It is expected that recipients will review the information for applicability to their facilities and
consider actions, as appropriate. However, suggestions contained in this IN are not NRC
requirements; therefore, no specific actions or written response is required.
Description of Circumstances
During a refueling outage that began on April 7, 2001, the Callaway Plant licensee conducted
scheduled inspections to assess the effects of erosion/corrosion on steel piping exposed to
flowing water (single-phase fluids) and water-steam mixtures (two-phase fluids). These effects
are commonly referred to as flow-accelerated corrosion (FAC). Inspections identified several
instances of localized MFW system piping wall thinning to below the minimum thickness
required by ASME Boiler and Pressure Vessel Code,Section III, for safety-related piping, and
to below the minimum thickness specified by American National Standards Institute (ANSI)
B31.1, Power Piping, for non-safety-related portions of the MFW system. The wall
thicknesses in the degraded areas had not been previously measured.
The licensee had expanded and upgraded its FAC program following an August 11, 1999, event in which an 8-inch moisture separator reheater drain line experienced a double-ended
guillotine break causing operators to manually trip the reactor. The upgraded and expanded
FAC program, utilizing CHECWORKS' Rev. F software, predicted wall thinning in the MFW
system. However, without wall thickness trending data, the software was not able to accurately
predict the extent of degradation. After performing an inspection during the current outage, the
licensee found the MFW degradation to be more extensive than anticipated.
Based on the licensees initial findings and on additional industry information, FAC inspections
were expanded to include portions of the condensate system, auxiliary feedwater (AFW)
system, feedwater heaters, and other areas. Additional degradation was found in piping for the
Several instances of MFW system wall thinning were identified in risk-important sections of
14-inch ASME Code Class 2 safety-related piping components inside the containment. The
licensee identified six 90-degree elbows, two 45-degree elbows, one 14-to-16-inch expander, and a 6-foot section of piping that had degraded to less than the ASME minimum design
allowable wall thickness (below allowance) or that the licensee projected would degrade below
allowance during the following cycle. The as-found wall thicknesses for components degraded
below allowance ranged from 75 to 96 percent of the minimum allowable thickness required by
the code. These components were identified in common MFW/auxiliary feedwater (AFW) flow
paths to three of the units four steam generators (SGs). All safety-related components in the
containment that were below allowance (or that the licensee predicted would degrade below
allowance during the following cycle) were replaced. Some degraded non-safety-related
components outside the containment were repaired rather than replaced.
Background
Since 1982, the NRC has issued numerous generic communications addressing various issues
and events related to pipe wall thinning. Several of those communications are particularly
relevant to the recently identified MFW wall-thinning at Callaway Plant. They are summarized
below and annotated in Table 1, "Summary of Related Previous Generic Communications.
Table 2 is a brief chronology of previously identified pipe wall thinning issues and events.
IN 87-36, Significant Unexpected Erosion of Feedwater Lines, August 4, 1987, addressed the
1987 discovery of MFW degradation at the Trojan Nuclear Plant similar to that observed at
Callaway Plant. The thinning was discovered when Trojans steam piping inspection program
was expanded to include single-phase piping. It was attributed to high fluid flow velocities and
other operating factors.
IN 88-17, Summary of Responses to NRC Bulletin 87-01, Thinning of Pipe Walls in Nuclear
Power Plants, April 22, 1988, summarized licensee responses to and NRC observations on
the thinning of nuclear power plant pipe walls. The IN noted that all licensees reported having
established programs for inspecting pipe wall thinning for two-phase, high-energy carbon steel
piping systems. Inspection locations were generally reported to have been selected in
accordance the 1985 guidelines in Electric Power Research Institute (EPRI) Document
NP-3944, Erosion/Corrosion in Nuclear Plant Steam Piping: Causes and Inspection Program
Guidelines. However, because implementation of these guidelines was not required, the
scope of the programs varied significantly from plant to plant.
Generic Letter 89-08, Erosion/Corrosion-Induced Pipe Wall Thinning, May 2, 1989, requested
licensees to implement long-term erosion/corrosion monitoring programs to provide assurance
that procedures or administrative controls were in place to maintain the structural integrity of all
carbon steel systems carrying high-energy fluids. EPRI released the pipe wall thinning
predictive computer code CHEC' in June 1987, CHECMATE' in April 1989, and
CHECWORKS' in August 1994, to assist licensees in selecting for testing those areas of the piping systems with the highest probabilities of wall thinning. The Massachusetts Institute of
Technology method described in NUREG/CR-5007, Prediction and Mitigation of Erosion- Corrosive Wear in Secondary Piping Systems of Nuclear Power Plants, September 1987, also
ranked systems and components according to their erosion/corrosion susceptibility.
IN 93-21, Summary of NRC Staff Observations Compiled During Engineering Audits or
Inspections of Licensee Erosion/Corrosion Programs, March 25, 1993, addressed NRC
observations on the industrys design and implementation of erosion/corrosion programs in
response to Generic Letter 89-08. Among other observations, the IN identified instances of
erosion/corrosion in safety-related portions of MFW and main steam systems and described the
problems licensees were having in implementing effective FAC programs. In November 1993, EPRI released document NSALC-202L, Recommendations for an Effective Flow-Accelerated
Corrosion Program. Rev. 2 of the document was released in April 1999.
Discussion
Although the MFW degradation was identified and addressed by the licensee before
catastrophic failure, the extent of the degradation at the time of discovery is of concern to the
NRC, given the maturity of the industrys FAC programs. Of particular concern is the
degradation in risk-important non-isolable sections of single-phase ASME Code Class 2 piping
inside the containment. These factors can impact the safety significance of pipe wall thinning.
MFW systems, like other power conversion systems, are important to the safe operation of
nuclear power plants. Past failures of feedwater and other high-energy system components
have resulted in complex challenges to operating staff when the released high-energy steam
and water interacted with other systems, such as electrical distribution, fire protection, and
security systems. Personnel injuries and fatalities have also occurred. The failure to maintain
high energy piping and components within allowable thickness values can (1) increase the
initiating event frequency for transients with loss of the power conversion system, main steam
line breaks, and other initiating events due to system interactions with high-energy steam and
water; (2) adversely affect the operability, availability, reliability, or function of systems required
for safe shutdown and accident mitigation; and/or (3) impact the integrity of fission product
barriers. This IN requires no specific action or written response. If you have any questions about the
information in this notice, please contact one of the technical contacts listed below or the
appropriate Office of Nuclear Reactor Regulation (NRR) project manager.
/RA/
Ledyard B. Marsh, Chief
Events Assessment, Generic Communications
and Non-Power Reactors Branch
Division of Regulatory Improvement Programs
Office of Nuclear Reactor Regulation
Technical contacts:
Ross Telson, NRR
Krzysztof Parczewski, NRR
301-415-1175
301-415-2705 E-mail: rdt@nrc.gov
E-mail: kip@nrc.gov
William D. Johnson, R-IV
David Terao, NRR
817-860-8148
301-415-3317 E-mail: wdj@nrc.gov
E-mail: dxt@nrc.gov
Attachments:
1.
Table 1: Summary of Related Previous Generic Communications
2.
Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events
3.
List of Recently Issued NRC Information Notices This IN requires no specific action or written response. If you have any questions about the
information in this notice, please contact one of the technical contacts listed below or the
appropriate Office of Nuclear Reactor Regulation (NRR) project manager.
/RA/
Ledyard B. Marsh, Chief
Events Assessment, Generic Communications
and Non-Power Reactors Branch
Division of Regulatory Improvement Programs
Office of Nuclear Reactor Regulation
Technical contacts:
Ross Telson, NRR
Krzysztof Parczewski, NRR
301-415-1175
301-415-2705 E-mail: rdt@nrc.gov
E-mail: kip@nrc.gov
William D. Johnson, R-IV
David Terao, NRR
817-860-8148
301-415-3317 E-mail: wdj@nrc.gov
E-mail: dxt@nrc.gov
Attachments:
1.
Table 1: Summary of Related Previous Generic Communications
2.
Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events
3.
List of Recently Issued NRC Information Notices
DISTRIBUTION
Public
REXB R/F
IN File
- See Previous Concurrence
Accession No.: ML011490408 Template No.:NRR-056
Publicly Available
Non-Publicly Available Sensitive Non-Sensitive
OFFICE
REXB
Tech Editor
C:EMCB
C:EMEB
NAME
RTelson*
PKleene*
WBateman*
EImbro*
DATE
5/ 21 /01
5 /18 /01
5/15 /01
5 /29 /01 OFFICE
SC:REXB
C:REXB
NAME
JTappert*
LMarsh
DATE
6/5 /01
6 /11/01
OFFICIAL RECORD COPY
Attachment 1 Table 1: Summary of Related Previous Generic Communications
The titles of generic communications referenced in the text of this IN or considered
particularly relevant are underlined.
1.
IN 82-22, Failures in Turbine Exhaust Lines, July 9, 1982, addressed the rupture of a
24-inch-diameter long-radius elbow in a feedwater heat extraction line at Oconee Unit 2 and four similar failures identified by the Institute of Nuclear Power Operations (INPO).
2.
IN 86-106, Feedwater Line Break, December 16, 1986, addressed a potentially generic
problem with feedwater pipe thinning and other problems related to the catastrophic
failure of an 18-inch-diameter MFW pump suction line at Surry Unit 2.
3.
IN 86-106, Supplement 1, Feedwater Line Break, February 13, 1987, discussed the
licensees failure analysis, the parameters that could have potentially contributed to pipe
break, the predictive measures used to detect erosion/corrosion, and the inservice
inspection requirements of ASME Code for Code Class 1 and 2 piping systems and of
ANSI B31.1 for other piping systems.
4.
IN 86-106, Supplement 2, Feedwater Line Break, October 21, 1988, addressed the
discovery that an elbow installed on the suction side of a MFW pump during a 1987 Surry
Unit 2 refueling outage had thinned more rapidly than expected, giving up 20 percent of its
0.500-inch wall thickness in 1.2 years. Wall thinning was also observed in safety-related
MFW piping and in other non-safety-related condensate piping.
5.
IN 86-106, Supplement 3, Feedwater Line Break, November 10, 1988, further addressed
the faster-than-expected wall thinning at Surry Unit 2, noting the disparity between the
previously estimated 20-30 mils/year thinning rate and maximum observed rate of
90 mils/year. The IN also noted that accelerated wall thinning may have coincided with a
reduction in feedwater dissolved-oxygen concentration.
6.
NRC Bulletin 87-01, Thinning of Pipe Walls in Nuclear Power Plants, July 9, 1987, requested licensees to inform the NRC about their programs for monitoring the thickness
of pipe walls of carbon steel piping in both safety-related and non-safety-related high- energy fluid (single-phase and two-phase) systems.
7.
IN 87-36, Significant Unexpected Erosion of Feedwater Lines, August 4, 1987, addressed potentially generic unexpected erosion which resulted in pipe wall thinning in
both safety-related and non-safety-related portions of feedwater lines (both inside and
outside the containment) at Trojan Nuclear Plant. The thinning was discovered when
Trojans steam piping inspection program was expanded to include single-phase piping
and was attributed to high fluid flow velocities and other operating factors.
8.
IN 88-17, Summary of Responses to NRC Bulletin 87-01, Thinning of Pipe Walls in
Nuclear Power Plants, April 22, 1988, reported the results of responses to NRC Bulletin
87-01 and described a recent event at LaSalle County Station Unit 1.
Attachment 1 9.
IN 89-01, Valve Body Erosion, January 4, 1989, addressed a potential generic problem
with erosion in carbon steel valve bodies in safety-related systems.
10.
Generic Letter 89-08, Erosion/Corrosion-Induced Pipe Wall Thinning, May 2, 1989, requested licensees to implement long-term erosion/corrosion monitoring programs to
obtain assurance that procedures or administrative controls were in place to maintain the
structural integrity of all carbon steel systems carrying high-energy fluids.
11.
IN 89-53, Rupture of Extraction Steam Line on High Pressure Turbine, June 13, 1989, addressed a potential generic problem with erosion in carbon steel piping in secondary
plant systems.
12.
IN 91-18, High Energy Pipe Failures Caused by Wall Thinning, March 12, 1991, addressed continuing erosion/corrosion of high-energy piping systems and apparently
inadequate monitoring programs.
13.
IN 92-35, Higher Than Predicted Erosion/Corrosion in Unisolable Reactor Coolant
Pressure Boundary Piping Inside Containment at a Boiling Water Reactor, May 6, 1992, addressed an unexpectedly high rate of erosion/corrosion in certain main feedwater piping
inside the containment at the Susquehanna Unit 1 boiling water reactor (BWR). The
condition was noted to be of particular concern since it was in a section of piping that
could not be isolated from the reactor vessel.
14.
IN 93-21, Summary of NRC Staff Observations Compiled During Engineering Audits or
Inspections of Licensee Erosion/Corrosion Programs, March 25, 1993, addressed NRC
observations on the industrys design and implementation of erosion/corrosion programs
in response to Generic Letter 89-08.
15.
IN 95-11, Failure of Condensate Piping Because of Erosion/Corrosion at a Flow- Straightening Device, February 24, 1995, addressed possible piping failures caused by
flow disturbances that were not accounted for in erosion/corrosion programs.
16.
IN 97-84, Rupture in Extraction Steam Piping as a Result of Flow-Accelerated Corrosion, December 11, 1997, addressed potential generic problems related to the occurrence and
prediction of flow-accelerated corrosion (FAC) in extraction steam lines.
17.
IN 99-19, Rupture of the Shell Side of a Feedwater Heater at the Point Beach Nuclear
Plant, June 23, 1999, addressed the rupture of the shell side of a feedwater heater at the
Point Beach Nuclear Plant Unit 1.
Attachment 2 Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events
Date
Site
Details
Ref.
1976 Oconee 3 Pinhole leak in an extraction steam line. A surveillance program
utilizing ultrasonic examination of extraction steam lines was
initiated and, in 1980, identified two degraded elbows identical
to the Unit 2 elbow that subsequently failed in 1982. The
elbows were replaced.
1981 Millstone 2 Use of engineering personnel unfamiliar with plant operating
conditions, plant as-built designs, or erosion/corrosion history.
IN 93-21 January
1982 Vermont
Yankee
Licensee shut down the plant after identifying steam blowing
from a leak in the 12-inch-diameter drain line between a
moisture separator and heater drain tank.
IN 82-22 January
1982 Trojan
Steam line failure resulting in plant shutdown.
IN 82-22 February
1982 Zion 1 Steam leak in 150 psig high-pressure exhaust steam line
originating from an 8-inch crack on a weld joining 24-inch piping
with the 37.5-inch high-pressure steam exhaust piping leading
to the moisture separator reheater. The event resulted in plant
shutdown.
IN 82-22 June 1982 Oconee 2 While operating at 95-percent power, a 4-square-foot rupture
occurred in a 24-inch-diameter long-radius elbow in a feedwater
heat extraction line. The reactor was manually tripped, a steam
jet destroyed a non-safety-related load center and certain non- safety-related instrumentation. Personnel were hospitalized
overnight with steam burns. An ultrasonic inspection had
identified substantial erosion of the elbow In March 1982, but
the erosion failed to meet the licensees criteria for rejection.
IN 82-22 June 1982
Browns Ferry 1
Steam line failure resulting in plant shutdown.
IN 82-22 March
1983 Dresden 3 Steam leak from the shell side of the 3C3 low-pressure
feedwater heater near the extraction steam inlet nozzle. The
leak was attributed to erosion by deflected extraction steam.
The feedwater heaters had not been included in a periodic
inspection program.
IN 99-19 March
1985 Haddam Neck
Pipe rupture, approximately 1/2-by-2-1/4-inch, downstream of a
normal level control valve for a feedwater heater.
GL 89-08 December
1986 Surry 2 Catastrophic failure of 18-inch MFW pump suction line elbow
when a main steam isolation valve failed closed on one of the
steam generators. A 2-by-4-foot section of the elbow was blown
out and came to rest on an overhead cable tray. The reactive
force completely severed the suction line. The free end
whipped and came to rest against the discharge line for another
pump. The failure of the piping, which was carrying single- phase fluid, was caused by erosion/corrosion of the carbon steel
pipe wall. The unit had been operating at full power. An
automatic plant trip occurred and four workers suffered fatal
injuries. Released steam caused the fire suppression system to
actuate, releasing halon and carbon dioxide into emergency
switchgear. The NRC dispatched an augmented inspection
team to the site.
IN 86-106 Bulletin 87-01 IN 88-17 GL 89-08
Attachment 2 Date
Site
Details
Ref.
June 1987 Trojan
MFW degradation was discovered by the licensee in at least two
areas of the straight sections of ASME Class 2 safety-related
MFW piping inside containment. The thinning was discovered
when the Trojan steam piping inspection program was
expanded to include single-phase piping. The thinning was
attributed to high fluid flow velocities and other operating
factors.
IN 87-36 IN 88-17 GL 89-08 December
1987 LaSalle 1 Through-wall pinhole leaks due to erosion were discovered in a
45-degree elbow down stream of a turbine-driven reactor
feedwater pump minimum-flow control valve. Subsequent
inspections identified additional areas of wall thinning.
IN 88-17 September
1988 Surry 2 The pipe wall of an elbow installed on the suction side of a MFW
pump during a 1987 refueling outage was discovered to have
thinned more rapidly than expected, losing 20 percent of its
0.500-inch wall thickness in 1.2 years. Wall thinning was also
observed in safety-related MFW piping and in other non-safety- related condensate piping.
GL 89-08 December
1988 Brunswick 1 Inspection indicated areas of significant but localized erosion on
the internal surfaces of several carbon steel valve bodies. The
affected safety-related valves were the 24-inch residual heat
removal/low pressure core injection (RHR/LPCI) system
injection and 16-inch suppression pool isolation valves.
Nuclear One
Unit 2 Steam escaping from a ruptured 14-inch high-pressure steam
extraction line caused a spurious turbine/reactor trip from
100-percent power. This straight run of piping terminates at an
elbow that was replaced during the previous outage because of
erosion-induced wall thinning. The pipe and those of similar
geometries had not been included in the licensees surveillance
samples, and the degraded condition was not detected during
the elbow replacement.
IN 89-53 March
1990
Surry 1 Rupture of a straight section of piping downstream of a level
control valve in the low-pressure heater drain (LPHD) system.
The LPHD system was included in the licensees FAC program
at the time, but the program did not provide an inspection for the
affected section of piping.
IN 91-18 May 1990
Loviisa 1 (foreign)
A flow-measuring orifice flange in the main feedwater system
ruptured after one of five main feedwater pumps tripped, causing a check valve in the line to slam shut, creating a
pressure spike. Subsequent inspections determined that 9 of
10 flanges had thinned to below minimum wall requirements.
IN 91-18 July 1990
San Onofre 2
The licensee was forced to shut down the unit after discovering
a steam leak in one of the feedwater regulating valve bypass
lines.
IN 91-18 December
1990
Millstone 3 Two 6-inch pipes in the moisture separator drain (MSD) system
ruptured when a MSD pump was stopped to facilitate
component isolation for repairs. Stopping the pump caused a
pressure transient. The high-energy water flashed to steam and
actuated portions of the turbine building fire protection deluge
system. Two 480-volt motor control centers and one non-vital
120-volt inverter were rendered inoperable by the flooding, resulting in the loss of the plant process computer and the
isolation of the instrument air to the containment building.
Attachment 2 Date
Site
Details
Ref.
November
1991 Millstone 2 Rupture at an 8-inch elbow of a moisture separator reheater.
High-energy water flashed to steam, actuating portions of the
turbine fire protection deluge system. The license had not
selected the ruptured elbow for ultrasonic testing in its
erosion/corrosion monitoring program. See LER 50-336/91-12.
1992 Millstone 3 See LER 50-309/92-07.
1992
Maine Yankee
See LER 92-007.
1992 Salem 1 Improper determination of code minimum wall thickness
acceptance criteria resulted in improper disposition of degraded
components. See Inspection Report 50-272/92-08.
1992 Hope Creek
Lack of baseline thickness measurements (history) of originally
designed piping was identified. See Inspection Report 50-
354/92-11.
1992 Millstone 1 Lack of baseline thickness measurements of replacement piping
before the replacement piping was put into service. See
Inspection Report 50-245/92-80.
1992 Hope Creek
Use of engineering personnel who are unfamiliar with plant
operating conditions, plant as-built designs, or erosion/corrosion
history.
-----
1993 Diablo
Canyon 1 Erosion/corrosion wear was discovered behind a thermal sleeve
in the interior of the feedwater nozzle and on the feedwater
nozzle itself.
IN 93-21 November
1994 Sequoyah 1 Licensee identified a 180-degree circumferential crack in a
reduced section of 14-inch condensate piping used for flow- metering. The section of piping had been modeled incorrectly in
CHECMATE' without any diameter or thickness changes and
had not been visually inspected.
IN 95-11 April 1997
Fort Calhoun
Manual scram and emergency boration following a 6-square- foot rupture of a 12-inch diameter sweep elbow in the fourth- stage extraction steam piping. A non-safety-related electrical
load center, several cable trays and pipe hangers were
damaged. In addition, asbestos-containing insulation was
blown throughout the turbine building and portions of the fire
protection system were actuated.
IN 97-84 May 1999
Point Beach 1
Manual trip from 100-percent power and manual safety injection
actuation when the shell side of the feedwater heater ruptured.
The fish-mouth rupture was approximately 27-inches long and
0.75-inch at its widest point. Feedwater heater leaks were also
identified at Pilgrim Station and the Susquehanna units. None
of the feedwater heaters had been included in a periodic
inspection program.
IN 99-19 August
1999 Callaway
Operators manually tripped the reactor on indication of a steam
leak in the turbine building. An 8-inch line from the first stage
reheater drain tank to the high-pressure heater experienced a
double-ended guillotine break.
Event
Notification
36015
______________________________________________________________________________________
OL = Operating License
CP = Construction Permit
Attachment 3 LIST OF RECENTLY ISSUED
NRC INFORMATION NOTICES
_____________________________________________________________________________________
Information
Date of
Notice No.
Subject
Issuance
Issued to
______________________________________________________________________________________
2001-08
Supplement 1
Update on the Investigation of
Patient Deaths in Panama,
Following Radiation Therapy
06/06/01
All Medical Licensees
2001-08
Treatment Planning System
Errors Result in Deaths of
Overseas Radiation Therapy
Patients
06/01/01
All medical licensees
2001-07
Unescorted Access Granted
Based on Incomplete and/or
Inaccurate Information
05/11/01
All holders of nuclear reactor
operating licenses who are
subject to Section 73.56 of Title
10, of the Code of Federal
Regulations (10 CFR 73.56),
Personnel Access Authorization
Requirements of Nuclear Power
Plants.
2001-06
Centrifugal Charging Pump
Thrust Bearing Damage not
Detected Due to Inadequate
Assessment of Oil Analysis
Results and Selection of Pump
Surveillance Points
05/11/01
All holders of operating licenses
for nuclear power reactors, except those who have
permanently ceased operations
and have certified that fuel has
been permanently removed from
the reactor
2001-05 Through-Wall Circumferential
Cracking of Reactor Pressure
Vessel Head Control Rod Drive
Mechanism Penetration
Nozzles at Oconee Nuclear
Station, Unit 3
04/30/01
All holders of operating licenses
for pressurized water nuclear
power reactors except those who
have ceased operations and have
certified that fuel has been
permanently removed from the
reactor vessel
2001-04
Neglected Fire Extinguisher
Maintenance Causes Fatality
04/11/01
All holders of licenses for nuclear
power, research, and test
reactors and fuel cycle facilities
2001-03
Incident Reporting
Requirements for Radiography
Licensees
04/06/01
All industrial radiography
licensees