ML032090144

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Handouts for Meeting with South Texas Project Nuclear Operating Company, South Texas Project, Unit 1, Bottom Mounted Instrumentation Penetration Leakage Issue
ML032090144
Person / Time
Site: South Texas STP Nuclear Operating Company icon.png
Issue date: 07/17/2003
From:
South Texas
To:
Office of Nuclear Reactor Regulation
Thadani M, NRR/DLPM, 415-1476
References
TAC MB8435
Download: ML032090144 (27)


Text

Bottom Mounted Instrument Penetration Condition Resolution

/17/03 1

STP Participants Tom Jordan VP, Engineering & Tech Services Mark McBurnett Manager, Quality & Licensing Steve Thomas Manager, Plant Design Tim Bowman Unit 1 Operations Manager Michael Lashley Test Engineering Supervisor Bill Humble NSSS Supervisor Wayne Harrison Licensing Engineer Ulhas Patil Design Engineer

/17/03 2

INTRODUCTORY REMARKS Mark McBurnett Manager, Quality & Licensing

/17/03 3

Agenda Introductory Remarks Mark McBurnett Summary Tom Jordan Root Cause Process and Monitoring / Inspection Plan Steve Thomas Return to Service Tim Bowman

/17/03 4

Desired Meeting Outcome NRC has sufficient information to complete their assessment

/17/03 5

SUMMARY

Tom Jordan Vice President, Engineering & Technical Services

/17/03 6

Evidence of Very Small Leakage Found in Routine Inspection

/17/03 7

BMI Guide Tube Penetration

/17/03 8

Extensive NDE Campaign Conducted

/17/03 9

Eddy Current J-Groove Probe

/17/03 10

eveloped Technology to Identify Wastage

/17/03 11

Comprehensive Examination Performed Using Industry Experts

  • Enhanced visual exam of J-groove weld surface
  • Volumetrically interrogate vessel base metal for wastage
  • Profilometry
  • Metallurgical analyses of removed nozzle remnants
  • Boat sample analyses

/17/03 12

Examination Results

  • Penetration #1

- Three axial indications, one leak path

  • Penetration #46

- Two axial indications, one leak path

/17/03 13

Permanent Half-Nozzle Repair Mechanical plug used during repairs (not shown)

Existing BMI nozzle Original structural weld Alloy 52 weld pad Alloy 52 J-Groove weld Alloy 690 replacement nozzle Original BMI NiCrFe socket weld Thimble Guide Tube

/17/03 14

Repair of Both Nozzles Complete

/17/03 15

Remaining Activities Boat sample analysis Sep 21 Nozzle remnants analysis Sep 21 LER supplement Oct 12

/17/03 16

Condition Limited to the Two Identified Nozzles

  • Routine inspection identified very low leakage

- Axial cracks in tubes

- No wastage

  • Substantial safety margin existed
  • Repairs are complete
  • Monitoring / inspection plan developed

/17/03 17

ROOT CAUSE PROCESS and MONITORING / INSPECTION PLAN Steve Thomas Manager, Plant Design

/17/03 18

/17/03 19 Comprehensive NDE Narrows Consequences

  • No circumferential cracks
  • No cracks above or below J-groove weld
  • No wastage

- UT examination

- Visual examination

- No iron in residue

- Very small deposits and leak rates

Conclusion:

Leakage is the only expected and observed consequence

/17/03 20

Two Possible Causes STP Unit 1 BMI Flaw Consequences Leak Investigation July 8, 2003 Results Axial Crack in Nozzle and/or Weld Crack Propagation PWSCC Low-Cycle Fatigue Nozzle and/or Weld Nozzle or Weld Crack Initiation Fabrication Flaw PWSCC Over-Stress Nozzle and/or Weld Nozzle and/or Weld

/17/03 21

Facts Inconsistent with PWSCC

  • No cracks identified except in #1 and #46
  • Cracks relatively old (3-5 yrs), about same age
  • Cracks not ID initiated

/17/03 22

What Might be Expected Assuming PWSCC The industry has inspected 543 upper head CRDM nozzles and found 114 TW or partial TW defects.

Therefore, if PWSCC were the cause and STP inspected 58 nozzles, we would expect to find 12 nozzles with TW or partial TW defects.

/17/03 23

Facts Suggesting Fabrication Flaws

  • Cracks not at highest residual stress locations
  • Penetrations #1 and #46 are different in terms of residual stress
  • Some cracks do not appear to be in contact with primary water

/17/03 24

Crack Propagation Scenario Tube wall J-groove Weld Crack Crack contacts grows at Crackinitiates to primary propagates the point to of tube/weld due water. leakage Growth interface thermalinto duecontinues annulus.

high by fatigue.

to fatigue or residual PWSCC.

stresses and

/17/03 thermal fatigue. 25

Boat Sample Objectives Nozzle 1

  • Capture portion of leaking crack including part of nozzle wall, part of weld, and site of observed helium leakage Nozzle 46
  • Capture portion of crack shown by UT not to connect with the surface

/17/03 26

Mock-up Penetration #46 Boat Sample

/17/03 27

Monitoring / Inspection Plan Confirms Effective Corrective Action

  • Continue bare metal visual inspections under boric acid control program
  • Perform periodic UT of vessel base material around repaired penetrations
  • Perform volumetric examination of Unit 2 penetrations at next refueling outage with core barrel removal

/17/03 28

Condition Limited to the Two Identified Nozzles

  • Routine inspection identified very low leakage

- Axial cracks in tubes

- No wastage

  • Substantial safety margin existed
  • Repairs are complete
  • Monitoring / inspection plan developed

/17/03 29

RETURN to SERVICE Tim Bowman Unit 1 Operations Manager

/17/03 30

Unit 1 is Ready to Return to Service

  • Extent of condition known
  • Probable causes identified
  • Engineering work complete
  • Condition corrected
  • Confidence in repair
  • Plant staff prepared

/17/03 31