ML18093B283

Responds to NRC Bulletin 88-009, Thimble Tube Thinning in Westinghouse Reactors. Instead of Continuing to Inspect Wearing Thimble Tubes,Util Proactively Replaced & Modified Thimble Tubes So Potential for Wear Significantly Reduced

ML18093B283
Person / Time
Site:	Salem
Issue date:	11/02/1988
From:	Labruna S Public Service Enterprise Group
To:	NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM)
References
IEB-88-009, IEB-88-9, NLR-N88161, NUDOCS 8811080146
Download: ML18093B283 (27)

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' . 'i tt' Put:llc Se1vice Elect11c and Gas Ccmpar.)

5!<1le)' LaBrur.~ P.;bLc Se~vice E~e::~ic a:.: Gas Cornpa:.y P.O. Box 236. Hancocks Bridge. NJ 0803E. 609-339-4&0C; November 2, 1988 NLR-N88161.

United States Nuclear Regulatory Commission Document Control Desk Washington, DC 20555 Gentlemen: ,.

RESPONSE TO NRC BULLETIN 88-09 SALEM GENERATING STATION UNIT NOS. 1 AND 2 DOCKET NOS. 50-272 AND 50-311 Public Service Electric and Gas Company (PSE&G) has received the subject NRC bulletin regarding thimble tube thinning in Westinghouse designed reactors. The information requested by this bulletin is provided in the enclosure to this letter.

Since Salem Station has established an inspection program as described Jn the bulletin, this response is being submitted within 90 days of receipt of Bulletin 88-09.

Should you have any questions with regard to this transmittal, please do not hesitate to contact us.

Sincerely,

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Enclosure

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8811080146 881102 .

~DR ADOCK 05000272

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ENCLOSURE RESPONSE TO BULLETIN 88-09 Bulletin.88-09, entitled "Thimble Tube Thinning in Westinghouse Reactors," requires licensees to submit a written response that (a) confirms that an inspection program consistent with that described in Part 1 of the bulletin has been established and (b) confirms that inspections of the thimble tubes have been performed and that corrective actions were taken. Our response to these two items follows. Also included is the status of this inspection program in light of our recently installed improved thimble design.

INSPECTION PRO.GRAM Part 1 of Bulletin 88-09 requires that an inspection program be established to monitor thimble tube performance. This program should include the following:

- the establishment, with technical justification, of an appropriate thimble tube wear acceptance criteria.

- the establishment, with technical justification, of an appropriate inspection frequency.

- the establishment of an inspection methodology that is capable of adequately detecting wear of the thimble tubes.

PSE&G has conducted an inspection program since October 1982.

Salem Unit 1 began commercial operation in June 1977. During the third operating cycle in 1981, three thimble tube leaks developed. These leaks were isolated by closing the manual isolation valve for each line located in the seal table room.

The cause of these leaks has since been determined to be flow induced vibrations between the core support plate and fuel assembly nozzles. During the third refueling outage, (January 1982) all thimble tubes were replaced in kind. During each subsequent refueling outage the thimble tubes have been eddy current tested to ensure that the thimbles were not degraded to an unacceptable degree. The results of the Salem Unit 1 inspecti"on program are summarized below.

Salem Unit 1 Inspection Program Refueling outage Results 4th Refueling outage Few wear indications observed.

(October 1982) 5th Refueling Outage More wear indications observed.

(July 1984) Three thimble tubes isolated.

Refueling outage Results 6th Refueling Outage Many wear indications. Ten (April 1986) thimble tubes isolated.

7th Refueling outage All thimble tubes removed and (December 1987) replaced with an improved design.

During each outage, the eddy current test results were evaluated.

Acceptance criteria were established which either justified the use of the thimbles for another operating cycle or required that they be iso~ated. Appropriate action was taken based on this criteria. In December 1987, the thimble tubes were removed and replaced with an improved tube design that should greatly reduce flow induced wear.

Salem Unit 2 began commercial operation in October 1981. An identical inspection program was established in 1983 with the following results.

Salem Unit 2 Inspection Program Refueling Outage Results 1st Refueling Outage Some wear indications found.

(May 1983) 2nd Refueling Outage Some wear indications. Three (February 1985) thimble tubes isolated.

3rd Refueling Outage Many wear indications. Three (October 1986) thimble tubes isolated. The remaining thimble tubes were shortened to provide new wear surfaces.

4th Refueling Outage All thimble tubes removed and (September 1988) replaced with an improved design.

As in Salem Unit 1, during each refueling outage eddy current tests were conducted and the results evaluated. Acceptance criteria were established and corrective actions, in the form of thimble tube isolation or shortening of tubes, were taken. An improved design was installed during the current Unit 2 refueling outage to greatly reduce flow induced wear.

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IMPROVED THIMBLE PESIGN The periodic in.spections required by the Bulletin ensure that thimble tubes are isolated or replaced if they become unacceptably degraded. These in~pections only monitor wear; they do not prevent it. PSE&G has improved the design of the thimble tubes and implemented modifications to the Salem units to greatly reduce flow induced vibrational thimble tube wear in the lower core plate region. These modifications were included in the design changes PSE&G implemented to meet the requirements of NUREG-0737, Item II.F.2 (Inadequate Core Cooling Instrumentation).

In letters dated April 4, June 19, August 13 and September 17, 1984, PSE&G committed to upgrade the core exit thermocouples (CETs) to meet the NUREG-0737 requirements. The NRC documented this in their safety evaluation dated October 24, 1984. The CETs are stationary thermocouples located within the core. The thermocouple columns are mounted on the reactor vessel head.

They indicate the temperature of the reactor coolant exiting the core. The movable incore detector flux thimbles are mounted on the bottom of the reactor vessel. These tubes provide a path for the movable incore detectors. The detectors map the neutron flux by moving through the thimble tubes within the core. These two instrumentation systems were integrally combined as described below.

The top mounted thermocouple column penetrations on the Reactor Vessel Head were cut and capped. The thermocoupie columns were removed from the upper internals. The original thimble tubes entering through the bottom of the reactor vessel were cut and removed. Replacement thimble tube. assemblies with built in thermocouples were installed. These flux thimble thermocouple (FTTC) assemblies consist of an outer pressure boundary tube and an inner tube to act as a guide path for the movable in core flux detectors. Thermocouple and spacer cables are installed in the annulus between the two tubes. The tubes are fabricated from high strength Inconnel 600 material. In addition, the area of wear indication on these tubes was chrome plated. Also, wear inserts were installed in the lower core support plate region.

PSE&G implemented these improvements on Salem Units 1 and 2 during their seventh and fourth refueling outages, respectively.

These improvements provide the following benefits in terms of wear reduction. The outer tube provides increased strength since it

~ is made of Inconnel 600 material as opposed to previously used stainless steel. Also, the outer tubes are chrome plated in the

- area which previously showed wear for increased wear resistance.

The addition of wear inserts reduces wear by limiting the forcing function and amplitude of vibrational motion the FTTCs can experience. This will limit the contact forces on the outer

< I tube. T~e reduced*forces will in turn reduce wear of the FTTC outer tube. Also, the wear inserts significantly increase the wear area so that the contact forces are distributed over a larger area of the FTTC outer tubes. This will reduce concentrated wear of the tubes in the fuel assembly nozzle areas.

PSE&G contracted the services of Combustion Engineering to conduct Salem specific tests to model the wear phenomenon and design the wear inserts. These tests, conducted in July 1987, identified the primary causes of the excitations that resulted in the wear of the flux thimbles. They were also used to optimize the design of the wear inserts to minimize the causes of the flux thimble vibrations. The test results further established the following benefits from the improved design. The addition of wear inserts decreases the wear rate by a factor of at least four by limiting the amplitude of the tube vibrations. The increase in wear area that the inserts afford decrease the wear rate by at least a factor of two. And finally, the chrome plating of the tube in the fuel nozzle area reduces the wear rate by at least a factor of five. These reductions are multiplicative, and result in a possible reduction in the wear rate by a factor of forty.

However, to be conservative, Combustion Engineering concluded that the overall wear rate will be reduced by at least a factor of twenty. It is anticipated that with the improved wear resistance of the flux thimbles due to replacement material and chrome plating, and the installation of wear inserts to reduce forcing functions and vibrational amplitudes, the wear phenomena will be below the threshold value so that it shouldn't be a concern.

It should further be noted that the inner tube in the FTTC assembly provides an additional pressure barrier that was not previously present.. Also, in the unlikely event of a leak through both tubes of the FTTC assemblies, the leak detection system and manual isolation valves will continue to provide assurance that the leaking FTTC assembly will be quickly identified and isolated.

Instead of continuing to inspect wearing thimble tubes, PSE&G has proactively replaced and modified the thimble tubes so that the potential for* significant wear is greatly reduced. However, since the modified thimble tube design uses two concentric tubes with cables wound around the inner tube, eddy current testing conducted from within the inner tube will not yield meaningful results. As such, PSE&G cannot continue its current inspection program utilizing eddy current testing. At present, no alternative viable inservice inspection techniques exist that will adequately detect wear. Therefore, since PSE&G cannot inspect the current thimble tube design (the FTTC assemblies),

and since a conservt. ive interpretation of the test results show that the wear rate is reduced by at least a factor of twenty, it

is PSE&G~s position that no further inspections are necessary at this time. PSE&G will reevaluate the need for future thimble inspection. This reevaluation will be based on advancements made in inservice inspection techniques and the operating performance of the FTTC assemblies. Within four months after restart from the Salem Unit 2 seventh refueling outage, PSE&G will supplement this Bulletin response with our reevaluation for both Salem units. This approach is justified by the Salem specific test*

results that predict a very significant reduction in the wear rate and the recent replacement of the flux thimbles with FTTC assemblies.

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Audit Agenda

I NRC. AUDIT OF SALEM 1 &2 ON BULLETIN 88-09 AGENDA I. Review thimble wear problems occured in Salem 1 &2 A. Thimble inspection program and findings since 1982.

B. Root cause of high rate wear (The rate is higher than other reactors of similar design.)

C. Subsequent interim actions.

II. Review inproved thimble design A. Verification of design margins B. Periodic inspection program (1) The inspection method (2) The program (3) .The acceptance criteria C. Assessment of actual performance D. Capability to isolate possible leakage III. Document review IV. Hardware inspection i . .-

Attachment 3 Photographs of Thimble Tube Failures

oo SAMPLE-A (O.SX) oo SAMPLE- 8 (O.SX)

FIGURE 2-1. OUTSIDE DIAMETER SURFACE APPEARANCE OF THE AS-RECEIVED THIMBLE TUBE SAMPLES A AND B.

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FIGURE 2-3. CLOSE-UP VIEW OF THE OUTSIDE DIAMETER SURFACE APPEARANCE OF THE DEFECT REGION IN THE AS-RECEIVED THIMBLE TUBE 18'.

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FIGURE 2-10. LIGHT OPTICAL METALLOGRAPH ON AN AXIAL SECTION OF THE TUBE 'B' AT THE DEFECT REGION.

Attachment 4 Eddy current Testing Inspection Results

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SALEM UNIT 1 INCORE THIMBLE EDDY CURRENT INSPECTION COMPARISON TABLE

% WALL LOSS INDICATION OCT. 8.2 JULY 84 APRIL 86 THIMBLE i I.D. O.D. I.D. O.D. I.D. O.D.

1 0 0 0 0 30 2 0 0 0 0 30 4 0 0 10 0 40-50 5 0 0 0 15 50-60 8 0 10-20 30 25 30-40 9 0 0 0 25 50 12 0 0 20 0 20-30 13 0 0 10 0 20 14 0 0 0 0 50-60 15 45 0 45 15 20 16 0 0 0 0 30 17 0 40 0 65 80-90 18 0 0 0 15 40-50 19 0 0 0 0 30-40 20 0 0 10 0 50-60 21 0 0 0 0 60-70 22 0 0 0 0 20 23 0 0 0 0 60-70 24 0 0 30 0 20 26 0 0 20 0 0 27 0 0 10 35 20 28 0 30-35 0 25 40-50 31 0 0 0 0 30-40 32 0 0 0 0 20 33 0 0 0 0 50-60 34 0 0 30 0 0 38 0 0 20 0 0 39 0 0 10 0 50-60 40 0 0 0 0 20 43 0 0 10 0 0 46 BLOCKED BLOCKED 10 0 20 47 0 0 10 0 20 48 0 0 10 0 0 49 0 0 0 0 20 51 0 0 0 0 20 53 0 0 10 50 40-50 54 0 0 0 50 80 56 0 0 10 0 0 57 0 0 20 0 0 58 40-45 0 45 0 50-60

- = <20% INDICATION 1982, 1984 EXAMINATIONS CONDUCTED BY CRAMER & LINDELL ENG. INC.

1986 EXAMINATION CONDUCTED BY MAPLEWOOD LABS.

ALL THIMBLE LOCATIONS NOT LISTED HAVE NO INDICATIONS OR INDICATIONS

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