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

From kanterella
Jump to navigation Jump to search
Created page by program invented by StriderTol
StriderTol Bot change
 
Line 16: Line 16:
{{#Wiki_filter:UNITED STATES
{{#Wiki_filter:UNITED STATES


NUCLEAR REGULATORY COMMISSION
===NUCLEAR REGULATORY COMMISSION===
OFFICE OF NUCLEAR REACTOR REGULATION


OFFICE OF NUCLEAR REACTOR REGULATION
WASHINGTON, D.C.  20555-0001


WASHINGTON, D.C. 20555-0001 June 12, 2001 NRC INFORMATION NOTICE 2001-09:               MAIN FEEDWATER SYSTEM DEGRADATION IN
===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
Line 173: Line 174:
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
Line 187: Line 188:
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
Line 201: Line 202:
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
Line 213: Line 214:
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
Line 220: Line 221:


/RA/
/RA/
                                              Ledyard B. Marsh, Chief


===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:


Office of Nuclear Reactor Regulation
===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


Technical contacts:     Ross Telson, NRR                  Krzysztof Parczewski, NRR
E-mail: dxt@nrc.gov


301-415-1175                      301-415-2705 E-mail: rdt@nrc.gov              E-mail: kip@nrc.gov
Attachments:  
1.


William D. Johnson, R-IV          David Terao, NRR
Table 1:  Summary of Related Previous Generic Communications


817-860-8148                      301-415-3317 E-mail: wdj@nrc.gov              E-mail: dxt@nrc.gov
2.


Attachments:
Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events
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 This IN requires no specific action or written response. If you have any questions about the
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


===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


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


Technical contacts:    Ross Telson, NRR                  Krzysztof Parczewski, NRR
===David Terao, NRR===
817-860-8148
301-415-3317 E-mail: wdj@nrc.gov


301-415-1175                      301-415-2705 E-mail: rdt@nrc.gov              E-mail: kip@nrc.gov
E-mail: dxt@nrc.gov


William D. Johnson, R-IV          David Terao, NRR
Attachments:
1.


817-860-8148                      301-415-3317 E-mail: wdj@nrc.gov              E-mail: dxt@nrc.gov
Table 1: Summary of Related Previous Generic Communications


Attachments:
2.
          1. Table 1: Summary of Related Previous Generic Communications


2. Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events
Table 2: Summary of Previously Identified Pipe Wall Thinning Issues and Events


3.   List of Recently Issued NRC Information Notices
3.


===List of Recently Issued NRC Information Notices===
DISTRIBUTION
DISTRIBUTION


Line 285: Line 315:
*See Previous Concurrence
*See Previous Concurrence


Accession No.: ML011490408                               Template No.:NRR-056
Accession No.: ML011490408 Template No.:NRR-056
: Publicly Available                                     9 Non-Publicly Available9 Sensitive :Non-Sensitive
 Publicly Available
 
 Non-Publicly Available Sensitive Non-Sensitive


OFFICE       REXB                  Tech Editor              C:EMCB                      C:EMEB
OFFICE


NAME          RTelson*              PKleene*                  WBateman*                  EImbro*
REXB
DATE          5/ 21 /01            5 /18 /01                  5/15 /01                    5 /29 /01 OFFICE        SC:REXB                    C:REXB


NAME          JTappert*                  LMarsh
Tech Editor


DATE           6/5 /01                   6 /11/01 OFFICIAL RECORD COPY
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. IN 89-01, Valve Body Erosion, January 4, 1989, addressed a potential generic problem
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
Line 413: Line 509:
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     Site          Details                                                              Ref.
Date


1976     Oconee 3       Pinhole leak in an extraction steam line. A surveillance program     IN 82-22 utilizing ultrasonic examination of extraction steam lines was
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     Millstone 2   Use of engineering personnel unfamiliar with plant operating         IN 93-21 conditions, plant as-built designs, or erosion/corrosion history.
IN 82-22
1981 Millstone 2 Use of engineering personnel unfamiliar with plant operating


January   Vermont       Licensee shut down the plant after identifying steam blowing         IN 82-22
conditions, plant as-built designs, or erosion/corrosion history.
1982      Yankee        from a leak in the 12-inch-diameter drain line between a
 
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   Trojan         Steam line failure resulting in plant shutdown.                     IN 82-22
IN 82-22 January
1982 February  Zion 1         Steam leak in 150 psig high-pressure exhaust steam line             IN 82-22
 
1982                    originating from an 8-inch crack on a weld joining 24-inch piping
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       While operating at 95-percent power, a 4-square-foot rupture         IN 82-22 occurred in a 24-inch-diameter long-radius elbow in a feedwater
IN 82-22 June 1982 Oconee 2 While operating at 95-percent power, a 4-square-foot rupture


heat extraction line. The reactor was manually tripped, a steam
occurred in a 24-inch-diameter long-radius elbow in a feedwater


jet destroyed a non-safety-related load center and certain non- safety-related instrumentation. Personnel were hospitalized
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 March     Dresden 3     Steam leak from the shell side of the 3C3 low-pressure               IN 99-19
IN 82-22 June 1982
1983                    feedwater heater near the extraction steam inlet nozzle. The
 
===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     Haddam Neck    Pipe rupture, approximately 1/2-by-2-1/4-inch, downstream of a        GL 89-08
IN 99-19 March
1985                    normal level control valve for a feedwater heater.


December Surry 2       Catastrophic failure of 18-inch MFW pump suction line elbow         IN 86-106
1985 Haddam Neck
1986                    when a main steam isolation valve failed closed on one of the       Bulletin 87-01 steam generators. A 2-by-4-foot section of the elbow was blown       IN 88-17 out and came to rest on an overhead cable tray. The reactive         GL 89-08 force completely severed the suction line. The free end
 
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.


Attachment 2 Date      Site        Details                                                            Ref.
IN 86-106 Bulletin 87-01 IN 88-17 GL 89-08


June 1987  Trojan      MFW degradation was discovered by the licensee in at least two      IN 87-36 areas of the straight sections of ASME Class 2 safety-related      IN 88-17 MFW piping inside containment. The thinning was discovered          GL 89-08 when the Trojan steam piping inspection program was
===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.


December  LaSalle 1    Through-wall pinhole leaks due to erosion were discovered in a      IN 88-17
IN 87-36 IN 88-17 GL 89-08 December
1987                    45-degree elbow down stream of a turbine-driven reactor


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 Surry 2     The pipe wall of an elbow installed on the suction side of a MFW   GL 89-08
IN 88-17 September
1988                    pump during a 1987 refueling outage was discovered to have
 
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   Brunswick 1 Inspection indicated areas of significant but localized erosion on IN 89-01
GL 89-08 December
1988                    the internal surfaces of several carbon steel valve bodies. The
 
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     Steam escaping from a ruptured 14-inch high-pressure steam          IN 89-53 Nuclear One  extraction line caused a spurious turbine/reactor trip from
IN 89-01 April 1989 Arkansas


Unit 2       100-percent power. This straight run of piping terminates at an
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     Surry 1     Rupture of a straight section of piping downstream of a level       IN 91-18
IN 89-53 March
1990                    control valve in the low-pressure heater drain (LPHD) system.
 
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   Loviisa 1   A flow-measuring orifice flange in the main feedwater system       IN 91-18 (foreign)    ruptured after one of five main feedwater pumps tripped, causing a check valve in the line to slam shut, creating a
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 San Onofre 2 The licensee was forced to shut down the unit after discovering     IN 91-18 a steam leak in one of the feedwater regulating valve bypass
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.


December  Millstone 3  Two 6-inch pipes in the moisture separator drain (MSD) system      IN 91-18
IN 91-18 December
1990                    ruptured when a MSD pump was stopped to facilitate


component isolation for repairs. Stopping the pump caused a
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       Site         Details                                                             Ref.
IN 91-18
 
===Attachment 2 Date===
Site
 
Details
 
Ref.
 
November
 
1991 Millstone 2 Rupture at an 8-inch elbow of a moisture separator reheater.


November  Millstone 2  Rupture at an 8-inch elbow of a moisture separator reheater.        IN 91-18
High-energy water flashed to steam, actuating portions of the
1991                    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.


1992      Millstone 3  See LER 50-309/92-07.                                                IN 93-21
IN 93-21
1992      Maine Yankee  See LER 92-007.                                                      IN 93-21
1992
1992       Salem 1      Improper determination of code minimum wall thickness                IN 93-21 acceptance criteria resulted in improper disposition of degraded


components. See Inspection Report 50-272/92-08.
===Maine Yankee===
See LER 92-007.


1992      Hope Creek    Lack of baseline thickness measurements (history) of originally      IN 93-21 designed piping was identified. See Inspection Report 50-
IN 93-21
                        354/92-11.
1992 Salem 1 Improper determination of code minimum wall thickness


1992       Millstone 1  Lack of baseline thickness measurements of replacement piping       IN 93-21 before the replacement piping was put into service. See
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       Hope Creek   Use of engineering personnel who are unfamiliar with plant
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
                        history.


1993       Diablo       Erosion/corrosion wear was discovered behind a thermal sleeve       IN 93-21 Canyon 1      in the interior of the feedwater nozzle and on the feedwater
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   Sequoyah 1   Licensee identified a 180-degree circumferential crack in a         IN 95-11
IN 93-21 November
1994                    reduced section of 14-inch condensate piping used for flow- metering. The section of piping had been modeled incorrectly in
 
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 Manual scram and emergency boration following a 6-square-           IN 97-84 foot rupture of a 12-inch diameter sweep elbow in the fourth- stage extraction steam piping. A non-safety-related electrical
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   Point Beach 1 Manual trip from 100-percent power and manual safety injection       IN 99-19 actuation when the shell side of the feedwater heater ruptured.
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     Callaway     Operators manually tripped the reactor on indication of a steam     Event
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


1999                    leak in the turbine building. An 8-inch line from the first stage    Notification
reheater drain tank to the high-pressure heater experienced a


reheater drain tank to the high-pressure heater experienced a        36015 double-ended guillotine break.
double-ended guillotine break.


Attachment 3 LIST OF RECENTLY ISSUED
Event


===Notification===
36015
______________________________________________________________________________________
OL = Operating License
CP = Construction Permit
===Attachment 3 LIST OF RECENTLY ISSUED===
NRC INFORMATION NOTICES
NRC INFORMATION NOTICES


_____________________________________________________________________________________
_____________________________________________________________________________________
Information                                         Date of
Information
 
Date of
 
Notice No.
 
Subject
 
Issuance


Notice No.              Subject                    Issuance  Issued to
Issued to


______________________________________________________________________________________
______________________________________________________________________________________
2001-08           Update on the Investigation of  06/06/01    All Medical Licensees
2001-08


Supplement 1     Patient Deaths in Panama, Following Radiation Therapy
===Supplement 1===
Update on the Investigation of


Patient Deaths in Panama,
===Following Radiation Therapy===
Overexposures
Overexposures


2001-08          Treatment Planning System        06/01/01   All medical licensees
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


Patients
06/01/01
 
===All medical licensees===
2001-07
 
===Unescorted Access Granted===
Based on Incomplete and/or


2001-07          Unescorted Access Granted        05/11/01   All holders of nuclear reactor
===Inaccurate Information===
05/11/01


Based on Incomplete and/or                  operating licenses who are
===All holders of nuclear reactor===
operating licenses who are


Inaccurate Information                      subject to Section 73.56 of Title
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


===Personnel Access Authorization===
Requirements of Nuclear Power
Requirements of Nuclear Power


Plants.
Plants.


2001-06           Centrifugal Charging Pump       05/11/01    All holders of operating licenses
2001-06
 
===Centrifugal Charging Pump===
Thrust Bearing Damage not
 
===Detected Due to Inadequate===
Assessment of Oil Analysis
 
===Results and Selection of Pump===
Surveillance Points


Thrust Bearing Damage not                    for nuclear power reactors, Detected Due to Inadequate                  except those who have
05/11/01


Assessment of Oil Analysis                  permanently ceased operations
===All holders of operating licenses===
for nuclear power reactors, except those who have


Results and Selection of Pump                and have certified that fuel has
permanently ceased operations


Surveillance Points                          been permanently removed from
and have certified that fuel has
 
been permanently removed from


the reactor
the reactor


2001-05           Through-Wall Circumferential     04/30/01    All holders of operating licenses
2001-05 Through-Wall Circumferential


Cracking of Reactor Pressure                 for pressurized water nuclear
===Cracking of Reactor Pressure===
Vessel Head Control Rod Drive


Vessel Head Control Rod Drive                power reactors except those who
===Mechanism Penetration===
Nozzles at Oconee Nuclear


Mechanism Penetration                        have ceased operations and have
===Station, Unit 3===
04/30/01


Nozzles at Oconee Nuclear                    certified that fuel has been
===All holders of operating licenses===
for pressurized water nuclear


Station, Unit 3                              permanently removed from the
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           Neglected Fire Extinguisher      04/11/01    All holders of licenses for nuclear
2001-04


Maintenance Causes Fatality                 power, research, and test
===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           Incident Reporting              04/06/01    All industrial radiography
2001-03


Requirements for Radiography                 licensees
===Incident Reporting===
Requirements for Radiography


Licensees
Licensees


______________________________________________________________________________________
04/06/01
OL = Operating License


CP = Construction Permit}}
===All industrial radiography===
licensees}}


{{Information notice-Nav}}
{{Information notice-Nav}}

Latest revision as of 01:54, 17 January 2025

Main Feedwater System Degradation in Safety-Related ASME Code Class 2 Piping Inside the Containment of a Pressurized Water Reactor
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

feedwater heaters.

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.

IN 82-22

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.

IN 89-01 April 1989 Arkansas

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.

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

selected the ruptured elbow for ultrasonic testing in its

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

Maine Yankee

See LER 92-007.

IN 93-21

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.

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.

IN 93-21

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

Overexposures

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