ML20128N270
| ML20128N270 | |
| Person / Time | |
|---|---|
| Site: | Prairie Island  |
| Issue date: | 01/15/1985 |
| From: | ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY |
| To: | |
| Shared Package | |
| ML20128A500 | List: |
| References | |
| CEN-294-NP, TAC-57847, TAC-57848, NUDOCS 8506030219 | |
| Download: ML20128N270 (63) | |
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i 1432(8402)/js-1 '
1 CEN-294-NP
.,- NORTHERN STATES P0i4ER COMPANY PRAIRIE ISLAND NUCLEAR GENERATING PLANT LICENSE AMENDMENT REQUEST DATED MAY 17, 1985 EXHIBIT E , ,
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COMBUSTION ENGINEE$ING, INC.
January 15, 1985 Prairie Is1.and *
, Steam Generator Tube Reoair Using Leak Tight Sleeves i
FINAL REPORT Ccmbustion Engineering, Inc.
Nuclear Pcwer Systems Windsor, Connecticut
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8506030219 850527 PDR P
ADOCK 05000282 PDR .
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3 LIGAL,NCTICS ,
THl3 REPORT'WAS PREPARED AS AN ACCCUNT CP WORK 3PCNSCRED ,
BY CCIMUSTION ENGINEERING, INC. NEITHER CCMBUSTICN ENGINEERING
_, NCR ANY PERSON ACTING CN 173 BEHALP: ,
i' A. MAXIS ANY WARRANTY OR REPRESENTATICN, EXPRESS CR IlWLIED INCLUDING THE WARRANTIES CF PITNESS PCR A PARTICULAR PURPOSE OR MERCHANTAIIUTY, WITH RESPECT TO THE ACCURACY, i CCMPLETENESS. CR USIPULNESS OF THE INPCRMATICN CCNTAINED IN THIS REPORT, OR THAT THE USE OF ANY INFORMATICN, APPARATUS METHCC, CR PRCC333 CISCLCSID IN THl3 REPCRT MAY NOT INFRINGE PRIVATELY 4
CWNED RIGHT3;OR E. ASSUME 3 ANY UAIluTIES WITH RESPECT TO THE USE CP, CM PCh CAMAGE3 RESULTING PRCM THE USE OF, ANY INPCRMATICN, APPARATM, METHCC CR PROCIES Cler" *e IN TNis REPORT.'
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ABSTRACT - . .
A' technique is presented for repairing degraded steam generator tubes in pressurized water reactor Nuclear Steam Sucaly Systems (NSSS). .The technioue described alleviates the need for plugging steam generator tubes Jhien have -
become corroded or are otherwise considered to have lost structural capability. The technique consists of installing a thermally treated Inconel 690 sleeve which spans the section of original steam generator tube which
,. requires recair, and welding the sleeve to the tube near each end cf the sleeve.
4 . *
' This report details analyses and testing performed to verify the adecuacy of .
repair sleeves for installation in a nuclear steam generator tube. These verific,ations show tube sleeving to be an acceatable repair technique.
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A 1432(8402)/js-3 TABLE OF CONTENTS -
Section Title Pace
1.0 INTRODUCTION
1-1 1.1 PURPOSE -
1-1 i
1.2 SACXGROUND 1-1 2.0
SUMMARY
AND CONCLUSIONS 2-1
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4 3.0 ACCEPTANCE CRITERIA 3-1 4.0 OESIGN DESCRIPTION OF SLEEVES, PLUGS ANO. INSTALLATION .
EQUIPMENT 4-1 4.1 SLEEVE DESIGN DESCRIPTION 4-1 4.2 SLEEVE MATERIAL SELECTION 4-1 4.2.1 General Corrosion and Corrosion Product Release Rates 4-1 4.2.2 Stress Corrosion ~Crackine Resistance 4-2 4.2.3 Cocedinated Phoschate Chemistry 4-2
- 4. 2. 5 Faulted Phoschate Chemistrv Control 4-3 4.,3 SLEEVE-7USE ASSEMBLY 4-3 4.4 PLUG DESIGN DESCRIPTION 44 4.5 ,W ELDED PhuG ASSEMBLY .
4-4
, 4.6 SLEEVE INSTALLATION EQUIPMENT 4-5 4.6.1 Remote Controlled Maniculater 4-5 4.6.2 Maniculator Elevator 4-6 1
~4..6 3 Tube Brushine - Cleanine Ecut; ment '
4-6 4.6.4 Tube Size Rolline Ecutement 4-6 4.6.5 Sleeve Installation Ecuiement 4-6 4.6.6 Sleeve Exoansion Ecutement 4-7 4.6.' Sleeve Weldine Ecui: ment 4-7 ;
4.6.3 Nondestructive Examination 4-8
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'1432(E402)/js 4 TABLEOFCONTE0TS(Continued)
Section Title Page 4.7 PLUG INSTALLATION EQUIPMENT 4-8 4.7.1 Remote Controlled Elevator 4-8 4.7.2 Sleeve Size Rollino Ecuioment 4-8
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'4.7.3 Plue Installation Eauioment 4-9 4.7.4 Plue' Welding Ecuioment _.4-9 ..
. . . . 4.7.5 Nondestructive Ecutoment .
. 4-9 ... . . .
4.8 ALARA CONSIDERATIONS 4-9 ..
4.9 REFERENCES
TO SEETION 4.0 4-10 5.0 SLEEVE EXAMINATION PROGRAM 5 5.1 ULTRASONIC INSPECTION 5-1 5.1.1 Sumary and ConcTusions
- 5-1 5.1.2, Ultrasonics Evaluation 5-1 5.1.3 Test Eouioment . 53 2 .
5.1.4 Defect Samoles 5-3 5.1.5 Detailed Results . 5-3 5.2 'ED0Y CURRENT INSPECTION 5-5
,' 5.2.1 Sumary and Conclusions 5-5 5.2.2 N1ti-Frecuency Eddy Ctirrent Ecuioment Recuirements 5-5 5.2.3 Defect Samoles i
, 5-5 5.2.4 Results and Conclusions 5-4 5.3 VISUAL INSPECTION 5-7 5.3.1 Sumary and conclusion 5-7 5.3.2 Lewer Weld Evaluation 5-7 5.3.3 Uccer Weld Examination 5-8 o ,
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Section Title Page 5.3.4 Test Ecuioment 5-9
- 5.3.5 Defect Standards -
59 6.0 SLEEVE-TUBE CORROSION TEST PROGRAM
- 6-1 6.1
SUMMARY
AND CONCLUSIONS 6-1
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6.2 TEST DESCRIPTION AND RESULTS -
6-1 6.2.1 Modified Huey Tests ,
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. 6.2.2 Caosule Tests 6-3 6.2.3 Pure Water Stress Corrosion Tests 6-4 6.2.4 Sodium Hydroxide Fault Autoclave Tests 6-5
6.3 REFERENCES
FOR SECTION 6.0 6-6 7.0 MECHANICAL TESTS OF SLEEVED AND PLUGGED STEAM 6tNERAiOR Td8E5 7-1 7.1
- SUMARY AND CONCLUSIONS 7-1 7.2 CONDITIONS TESTED -
/-1 7.3 WELDED SLEEVE TEST PARAMETERS AND RESULTS 7-1 7.3.1 Axial Pull Tests ,
7-1
,- 7.3.2 Load Cycling Tests 7-2
'7.3.3 Co11aose Testing 7-2 7.3.4 Burst Testing 7-3 7.4 WELDED PLUG TEST PARAMETERS A,ND RESUL75 7a 7.4.1 Weld Intecrity 7-4
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7.4.2 Axial Lead Cacability 7-4 8.0 STRUCTURAL ANALYSIS OF SLEE'/E-TUBE ASSEMBLY 8-1 x 8.1 SUFMARY AND CONCLUSIONS 8-1 8.1.1 Cesign Sizine 1 -
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1432(8402)/js-6 TABLE OF CONTENTS (Continued) * .
Secten Title Pace 8.1.2 Detailed Analysis Sunnarv 8-1 -
8.2 LOADINGS CONSIDERED 8-5 8.2.1 Uccer Tube Weld Pull-Out Lead 8-5 8.2.2' Lower Stub Weld Push-Out Load' 8-5
.8.2.3 Weld Fatieue -
8-6 8.3 REGULATORYGUIDE1.121EVALUATIONFORAL}.0WABLE 8-6 - '
SLEEVE WALL DEGRACATION 8.3.1 Normal Ooeration Safety Marcins .
8-7-- -~
8.3.2 'PostulatedPioekuetureAccidents 8-a -
8.4 EFFECTS OF TUBE LOCX-UP ON SLEEVE LOADING 8 8.4.1 Sleeved Tube in Central Bundle Recion 8-9 Free at Tuow 5uccort Plates 8.4.2 Sleeved Tube Near Bundle Perioherv 8-14 Free at Tune Succort Plates 3.4.3 Sleeved Tube in Central Bundle Recion -
Locx-uo at towest succort Piate 8-15 8.4.4 Sleeved Tube Near Bundle Perichery. Lock 8-15A at Lowest succort Plate ,
8.4.5 Effect of Tube Prestress Prior to Sleevino 8-16 8.4.5 Lower Stub Weld Pushout Cue to Restrained 8-16 Thermai Excansion ,
8.5 SLEEVEDTUBEVISRATIONCONSID(RATIONS 8-16 8.5.1 Effects of increased Stiffnes's 8-16 8.5.2 Effect of Severed Tube 8-17 8.6 STRUCTURAL ANALYSIS FOR NORt9L OPERATION 3-18 -
8.6.1 Faticue Evaluation of Uccer Sleeve-Tube Weld 8 19 8.6.2 Faticue Evaluation of Lower Stub Weld 8-21
8.8 REFERENCES
FOR SECTION 8.0 8-25 i
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9 TABLE OF CONTENTS (Continued) *
- Section Title Pace 8A FATIGUE EVALUATION OF UPPER TUBE / SLEEVE WELD SA-1 88 FATIGUE EVALUATION OF LOWER STUB WELD 88-1 8C FATIGUE EVALUATION OF TUBE SLEEVE PLUG WELD SC-1 9.0 SLEEVE INSTALLATION Po.0 CESS VERIFICATION 9-1 9.1 WELD INTEGRITY 9-1 9.2 SLEEVE INSTALLATION IN RINGHALS 2 . 9-2 .
10.0 EFFECT OF SLEEVING ON OPERATION 10-1
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s 1432(8402)/js-8 LIS7 0F TABLES -
TABLE NO. TABLE PAGE 3-1 REPAIR SLEEVING CRITERIA 3-2 3-2 WELDED PLUG CRITERIA 3-4 6 STEAM GENERATOR TUSC SLEEVE CORROSION TEST 6-2 6-2 STEAM GENERATOR TUBE SLEEVE CAPS LE TESTS 6-4 7-1 SLEEVE-TUBE ASSEMBLY MECHANICAL TESTING RESULTS 7-5 8-1 ANALY!IS RESULTS
SUMMARY
TAB'.E , 8-3 .
8-2A AXIAL MEMBER PHYSICAL PROPERTIES 8-10 8-2S AXIAL MEM8ER PHYSICAL PROPERTIES 8-11 8-3 AXIAL LCADS IN SLEEVE WITH TUBE NOT-LOCXED 8-12 INTO SUPPORT PLATE 84 AXIAL LOAOS'!N SLEEVE WITH TUBE LOCXED INTO 8-13 SUPPORT PLATE -
8-5 UPPER SLEEVE WELO-TRANSIENTS CONSIDERED 8-20
. 8-6 LOWER STUB WELD-TRANSIENTS CONSIDERED 3-22
$-7 SLEEVED ~ TUBE PLUG WELO-TRANSIENTS CONSIDERED 9-24 9
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1432(8402)/js-9 LIST OF FIGURES -
FIGURE NO. TITLE PAGE 4-1 STEAM GENERATOR TUBE SLEEVE 4-11 4-2 SLEEVE INSTALLATION 4-12 4-3 STEAM GENERATOR TUBE
- PLUG 4-13
'4-4 PLUG INSTALLATION 4-14
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4-5 MANIPULATOR ELEVATOR 4-15 4-6 TU8E BRUSHING AND CLEANING TOOL , 4-16 .
4-7 TUBE ROLLING TOOL 4-17 4-8 SLEEVE INSTALLATION TOOL 4-18 4-9 HYDRAUL.*C EXPANSION TOOL 4-19 4-10 ELASTOMER EXPAhSION TOOL 4-20 4-11 SLEEVE WELOING HEAD ASSEMBLY -
4-21 4-12 SLEEVE WELDING HEAD POWER UNIT 4-22 4-13 PLUG WELDING TOOL 4-23 4-14 PLUG WELDING TOOL POWER UNIT 4-24 5-1 UT TRACE SHOWING ACCEPTABLE WELO 5-10
. 5-2 UT TRACE SHOWING WELD WITH LACX OF FUSION 5-10
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CALIBRATION FLAT SOTTCM ORILLiu HOLES 5-11 5-4 FLAT 90TTOM CRILLED HOLE STANCARDS 5-12 5-5 CALIBRATION MILLED NOTCHF.,5 STANDARD 5-13 5-6 MILLED SLOT STANDAR0 5-14 5-7 ACCEPTABLE .. ELD 5-15 5-8 WELO WITH LACX OF FUSION 5-15
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1432(8402)/js-10
,- l LIST OF FIGURES (Continued)
. FIGURE NO. TITLE PAGE 5-10 DUAL CROS!WOUNO PROBE ED0Y CURRENT FIELD 5-18 5-11 E00Y CURRENT TEST FLAWS-SLEF/E AND TU8E FLAW 5 19 5-12 TU8EINSPECTIONCURRkNTTESTSIGNALS-SLEEVEEND 5-20
) '
WITHOUT AND WITH A TUBE FLAW
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5-13 TUBE INSPECTION CURRENT TEST. SIGNALS-EXPANSION AND 5-21 WELD WITHOUT AND WITH A TU8E FLAW 5-14 SLEEVE INSPECTION'ED0Y CURRENT TEST' SIGNALS- 5-22
- SLEEVE FLAWS, EXPANSION AND WELO
. 5 SLEEVE INSPECTION ED0Y CURRENT TEST SIGNALS- 5 -
SLEEVE FLAW $ AT EXPANSION TRANSITION 6-1 CAUSTIC STRESS CORROSION AUTOCLAVE TEST SPECIMEN 5-7 8-1A WELDED SLEEVE / TUBE ASS B8LY IN CUTRAL BUNOLE REGION 8-25
. 8-18 WELDED SLEEVE /TU8E ASS D8LY NEAR BUNCLE PERIPHERY 8-27 8-2 LOWER JOINT ROLL OVER 8-28 8-3A SYSTEM SCH DATIC IN C DTRAL SUNOLE REGION . 8%29 .
8-38 SYSTEM' SCHEMATIC NEAR SU:10LE PERIPHERY 8-30 8-4 M00(1. OF SLEEVE AND LCWER TU8E . 8-31 8-5 MODEL OF UPPER WELD -
8-32
,' 8-6 FINITE EL DENT MODEL OF UPPER TUBE WELD 8-33 8-7 FINITE ELEMENT MODEL OF LOWER STUB WELD 8-34 8-8 FINITE ELEMENT MODEL OF SLEEVE 0' TUBE PLUG WELD 8-35 8-9 .TU8ESHEET PERFORATED PLATE LIGAMENT STRESSES 8-36 PA-1 UPPER SLEEVE / TUBE WELO ANALYSIS (1) 8A-2
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LISTOFFIGURES(Continued) -
FIGURE NO. TITLE PAGE 8A-2 UPPER SLEEVE / TUBE WELD' ANALYSIS (2) SA-3 SA-3 N00E AND ELEMENT IDENTIFICATION AND SECTIONS SA-4 0F INTEREST 8A-4 N00AL AND ELEMENT STRESS,ES AT SECTIONS OF 8A-5 i
INTEREST-8A-5 STRESS RESULTS SECTION 1 THROUGH WELO 8A-6 8A-6 ' STRESS RESULTS SECTIONS 2 AND 3 , 8A-7 .
88-1 SLEEVE /TU8E STUB WELD (HOT STAN08Y) 88-3 88-2 SLEEVE / TUBE,STU8 WELD (FULL POWER) 88-4 88-3 SLEEVE / TUBE STUS WELD (REAC OR TRIP) 88-5 88-4 SLEEVE / TUBE STUS WELD (SEC LEAK TEST) 88-6 88-5 LOWER TUBE / SLEEVE WELO ANALYSIS 88-7 8C-1 SLEEVED TU8E PLUG WELD (FULL POWER) 8C-2 8C-2 SLEEVED TUBE PLUG WELO (SEC. LEAX TEST) 8C-3 _
SC-3 SLEEVED TUBE PLUG ANALYSIS SC-4 9-1 RINGHALS 2 - DEMONSTPATION - TYPICAL GOOD WELO 94
. 9-2
- RINGHALS 2 - DEMONSTRATION.- WELD WITH LACX OF 9-5 i
' FUSION ACROSS THE WELO
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i LIST OF APPENDICES i
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APPEN0!X NO. -
NO. OF PAGES A PROCESS AND WELO OPERATOR OUALIFICATION ,
A.1 SLEEVE WELDING AND SLEDE WELDER 1
-! QUALIFICATION A.2 REFERENCEStoAPPEN0!XA 1 6
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-1432(8402)/js-13,
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- 1.0 -INTRODUCTION-1.1. PURPOSE The purpose of this report is to p. ovide information sufficient to support a technical specificati.on change allowing
~ installation of. steam generator repair sleeves in the Prairie Island plants. Although a large scale sleeving operation in the
.' Prairie Island steam generators is not anticipated, support for 1 reactor operation with up to two thousand sleeved tubes _in each-steam generator is provided. This report demonstrates that .
reactor operation with sleeves installed in the steam generator tubes will not increasa the probability or consequence of an
- accident previously evaluated. Also it will not create the Possibility et a new or different kind of accident and will not-- ---*
reduce the existing margin of safety.
Combustion Engtnkering (C-E) provides a leak tight sleeve which is welded to the steam generator tube near each end of the sleeve. The sleeve spans the. degraded area of the parent steam generator in the tube sheet region. The steam generator tube with the welded sleeve installed meets.the structural requirements of tubes which are not degraded. Design criteria for welded sleeves were prepared to ensu6* that all design and ifcensing requirements are considered.-
Extentive analyses and testing have been performed to demonstrate
, that the design criteria are met.
The effect of sleeve installation on steam generator heat removal .
. capability ,and system flow rate are discussed in this recort. Heat removal capability and system flow rate are considered for installa-tion of up to two thousand sleeves in each steam generator.
.After sleeves are installed and i'nspected, a basel'ine examination is perfomed using eddy current (ET) techniques. The ET examination
' . serves as baseline to determine if there is sleeve degradation in
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, latea operating years. The ET examination and criteria for plugging sleeved generator tubes if there is unacceptable degradation are describedsin this report.
Plugs will be installed if slehve in'stallation is not sue:essful or if nere is unacceptable degescation of sleeves or sleeved steam -
generator tubes. Analyses and testing are described whien comen-strate that the welded plug design which is provided by C-E is leak tight and will meet structural requirements during normal and postulated accident conditions. .
1.2 BACXGRCUND The operation of Pressuri:ed Water Reactor (PWR) steam generstars i has in some instances, resulted in localized corrosive attack on the
, inside (primary side) or outside (secondary side) of the steam i
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.1432(8402)/js-14 generator tubing. This corrosive attack results in a reduction in steam generator tube wall thickness. Steam generator tubing has been designed with censiderable margin between the actual wall thickness and the wall thickness recuired to meet strJctural g requirements. Thus it has not been necessary to take corrective action unless structural limits are being acoroached.
Historically, the corrective action taken where steam cenerator tuce
. wall degradation has been severe has been to install plugs at the inlet and outlet of the steam generator tube when the reduction in .
wall thickness reached a calculated value referred to as a plugging criteria. Eddy current (ET) examination has been used to measure steam generator tubing degradation and the tube plugging criteria accounts for ET measurement uncertainty.
Installation of steam generator tube plugs removes the heat transfer surface of the plugged tube fecm service and leads to a reduction in the primary coolant ficw rate available for core ecoling. Installa-tion of welded steam generator sleeves does not significantly affect the heat transfer removal capability of the tube being sleeved and a + '
large number of sleeves can be installed witacut significantly affecting primary flow rate. .
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2.0 SUMM RY AND CONCLUSIONS
- The sleeve design, materials, and joints were designed to the I applicable ASME Soiler and Pressure 'lessel Code. An extensive ,
analysis and test program was undertaken to prove the adequacy of '
the welded sleeve. This program determined the effect of normal
' operating and postulated accident conditions on the sleeve-tube assembly, as well as the adequacy of the assembly to perform.its intended function. Design criteria were established prior to
.g performing the ' analysis and test pregnam which, if met, would prove
.that the welded sleeve is an acceptable. repair technique. Based .
upon the results of the analytical and test program described in * '
this report the welded sleeve ful' fills its intended function .as _a i
leak tight structural member and meets or exceeds all tha established design criteria. . -
- i
' No detrimental effects on the sleeve-tube assembly are predicted to result from reactor system flow, coolant chemistries, or.thennal ~and -
pressure conditions. . Structural analyses of the sleeve-tube assembly have established its integrity under normal and accident conditions. The structural analyses have been performed on thirty-six inch long sleeves but twenty-four inch long sleeves will
. also be installed.in Prairie Island. Discussion of why the analyses of thirty-six inch long sleeves are conservative for shorter sleeves is given in Section 8.1.
Mechanical testing has been performed to support the analyses and ASME code stress allowables have been used. Corrosion testing of typical sleeve-tube assemblies have been completed and reveal.no- ,
- evidence of sleeve or tube corrosion considered detrimental under anticipated' service conditions, r
Welding development has been performed on clean tubing and dirty [
tubing which has been taken from pot boiler tests 'and simulate
' operation in a steam generator.* C-E successfully installed eighteen *
,. welded sleeves in a sleeve installation demonstration in Ringhals-2 (
- steam generators in May, 1984 The sleeve installation :
demonstration and a demonstration showing that welded sleeves can be successfully inspected asing visual examination or ultrasonic testing (UT) techniques are described in this report. ;
i Velded alugs nave been develeced for sleeved steam generster tuces in the event that sleeve installation is not successful. No cetri-mental effects resulted frem subjecting plug-sleeve-tube assemo11es to pressurt conditions or mechanical tests. Structural analyses of the installed plugs have demonstrated their integrity under the l' normal operating conditions or accident conditiens.
- In conclusien, steam generator tube repair by installation of welded sleeves is established as an acceptable method. Recair of sleeved steam generator tubes using welded slugs is also establisned as an acceptable method, e ',.
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i 1432(8402)/js-17.
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3.0- ' ACCEPTANCE CRITERIA
- The objectives of installing sleeves in steam generator tubes are twofold. The sleeve must maintain structural integrity of the steam egenerator tube during normal, and postulated accident conditions. *
' Additionally, the sleeve must prevent leakage in the event of a through hole in the wall of the steam generator-tube. Numerous tests and analyses.were performed to demonstrate the capability of the sleeves to perform these functions under normal cperating and i
postulated service conditions. Design and operating conditions for
'the. Prairie Island steam generators are defined as:
Primary Side: 590*F(hotside)2235psig(ooerating)
.. -650*F (design) 2485 psit design)
Secondary Side: 547*F 735 psig operating) ,
600*F (design) , 1085 psig design)
Table 3-1 provides a summary of the criteria established for .
sleeving in ordeg to demonstrate the acceptability of the sleeving techniques. Justification for each of the criterion is provided.
Results indicating the minimum level with which the sleeves sur-
! passed the criteria are tabulated. The section of this recort describing tests or analyses which verify the characteristics for a particular criterion is referenced in the table.
Plugs are installed in the sleeved steam generator tubes when the tubes cannot be successfully repaired with sleeves. The objective
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of the plugging is to prevent leakage between the primary and 1 -
secondary sides of the steam generator during normal and postulated accident conditions.
Table 3-2 provides a summary of the criteria for welded plugs. The format in Table 3-2 is the same as Table 3-1.
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1432(8402)/js-22.
4.0 DESIGN DESCRIPTI" ' 0F SLEEVES,- PLUGS AND INS 6LLATION EOUI? MENT
- length and has a acminal outs e diameter of[ . Sleeve wall-thicknessis{ The sleeve material is thermally treated Inconel 690. ,
g As shown' in Figure 4-1 the sleeve is chamfered at the upper end to prevent hang-up with equipment which 11 used to install or inspect the sleeve (or steam generator tube). [
- The outside diameter of the sleeve was selected to provide,a gener-ous clurance between the sleeve and steam generator tube-so that the sleeve slides freely through the tube 'during .
instalfation. There were two considerations in selecting the sleeve thickness: first, the sleeve has sufficient thickness so that the steam generator tube with the sleeve bridging the corroded section of the tube meets the structural requirements of the undamaged steam generator tube (without benefit from the tube). Second,' there is a large margin in thickness over what is required structurally to allow for sleeve eddy current measurement uncertainty. The inside diameter of the sleeve is large enough se that the flow rate and heat transfer capability of the steam generator tube are not signif-icantly affected by sleeve installation. *
' Boiler and Pressure Vessel Code Case N-20. In addition a themal
, treatment of 740*C is also specified in order to imoart greater corrosion resistance and lower the residual stress level in the tube.
The primary selection criterion for the sleeve material was its corrosion resistarice in primary and fault secondary PV3 environ-ments. Specific resistance to pure water and caustic stress corro-sion cracting were considered.
C-E's justification for selection of this material is based on the following . infomation:
4.2.1 General Corrosion and Cor-osion #-edue: Release ca tes Information published by INCO (Reference 1) indicates that the corrosion product release rate of Alloy 690 is superior to Alloy 6CO in both high temperature anatoniated and borated waters. The o ',
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'1432(8402)/js-23 corrosionrateofAlloy600issignificantlyhigher,especiallyin -
borated waters, with the concurrent formation of thicker oxides.
The latter is a potential concern during thermal transients which could initiate crud bursts. .
4.2.2 Stress Corrosion Crackine-Resistance Al'loy 600 in a variety of themal treatments exhibits known
' susceptibility to-intergranular stress corrosion cracking (IGSCC) in
.' high temperature pure water-splutions. . Deaerated boric acid at high temperature is relatively undisassociated and thus the
'C Recent. investigations (Referencehave *2 resistance-susceptibility shown that pure water IGSCCof Alloy)600 to IG
, _. resistance of Alloy 600 can be improved via controlled thermal-mechanical processing. . .
Laboratory testing on Alloy 690..(References 1 and 3) tubing show it A -
to be~ femune to high temperature deaerated pure H.,0 IGSCC in a -
variety of thermal-mechanical conditions. Apparently resistance to stress corrosion cracking (SCC) in- Alloy 690 is the result of a
, compositional improvement rather than a specific microstructure thus making'it more attractive for a welded sleeve design.
Tests in pure water environments with oxygen present at elevated temperatures resulted in IGSCC of 304 stainless steel, Allov SCO, and Alloy 800 within a stressed crevice region (Reference 1). Alloy 690 in a variety of metallurgical conditions exhibited complete inmunity to SCC in this test program with exposure times of 48 weeks. For comparison, the fomer materials exhibited evidence of LIGSCC corrosion after two weeks exposure. *
- 4.2.3 Coordinated Phosohate Chemistry An extensive laboratory test program utili:ing high temoerature pot
, 'and model boiler facilities was. performed by C-E in the early 1970's. The results of these heat transfer tests indicated that phosphate chemicals concentrated in areas of steam blanketing and v produced thinning of the Alloy 600 heat transfer tubing. This phenomena was observed.over a wide range of sodium to phosphate ratios with and without feedtrain corrosion product additions. The consisted of a green nickel-rich corrosion product incontaining, phosphate comoound all cases, lesser amounts of iron and chromium.
In this program Alloy 800 and 204 stainless steel tubing were also te.ted and determined to be more resistant to chosphate wastage. A general correlation between corrosion rate and the nickel content of the transfer tube alloy was observed.
Although the corrosion resistance of Alloy 690 in coordinated phosphate solutions has not been extensively tasted at C-E, based on the observed correlation between corrosion rate and nickel concentrations, its perfomance should be better tnan Alloy 600.
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4.2.4' Faulted Phosahate Chemistry Control .
.If condenser leakage cccurs it is possible to alter the sodium to-phosphate ratio .cf the _ coordinated phosphate solution such that caustic conditions result in the boiler water. Under these: -
conditions, caustic Linduced SCC may occur. While none of-the
-presently used heat transfer tubi.ng alloys are totally resistant to this form of corrosion attack, mill annealed Alloy 690 shows equivalent ~ resistance to. mill annealed Alloy 600 in concentrated W solutions (Reference 3). Thermally treated Alloy 690 exhibited.
notable improvement in this $ tress corrosien test as compared with
^' ? mil _1-annealed Alloy 690 and a slight improvement as compared with' -'
thermally treated Alloy 600.
- Similarly, acid forming _ impurities spec,ies introduced as the result .
of condenser leakage may concentrate in low flew regions to i aggressive levels. Chlorides have been shown-to'readily-produce SCC
' of austenitic stainless ~ steels and iron base allows, e.g. Alloy-800 :--
underthesecon(itions.: Immunity to chloride: induced SCC was-a primary-criteria for the switch to nickel-base-(Alloy 600) tubing for.. nuclear steam generating ' units. . Laboratory tests indicate that Alloy 690 also exhibits-immunity to chloride induced SCC probably due to its intermediate nickel concentrations (Reference 1).
Recent information obtained via cooperative test programs with the Electric-Power. Research Institute has identified acid sulfur species
- as aggressive' impurities leading to accelerated corrosion of Alloy 600 steam' generator tubing. The modes of attack observed with
'different sulfur. species and concentrations consist of wastage, intergranular attack (IGA)'and IGSCC. The latter' produced primary
.to secondary. leakage of Alloy 600 tubing-representative of all commercial heat treatments, i.e. mill annealed, sensitized,
- thennally treated. The environment consisted of volatile chemistry
. control . faulted with. acidified (H SO 4 fresh water impur.ities.
Alloy l690(millannealed)tubinglxpos)edtothisenvironmentfne-longer test-periods did not exhibit through-wall.IGSCC.
4.3l SLEEVE-TUBE ASSEMBLY
'The installed sleeve is shown in Figure 4-2. Since the sleeve is 36 inches ~long,.the upper end ofithe sleeve is about 15 inches above
~t he:too of-the ,t,ubesheet and abcut 31 inches below the first tube
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The weld and welding operators have.been qualified for making upper and lower welds and the weld qualification documents are given in Appendix A. Sin ~ce the upper weld is repaired by making a second weld.which is' centered two inches below the first weld and is made .
using the same welding parameters, a qualification document for repair is not required.
- 4.4* PLUG DESIGN DESCRIPTION
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'4.5. WELDED. PLUG ASSEMBLY
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~ The weld and weld operator cualificatton document for installing
' plugs in sleeved steam generator tubes is given in Aapendix A.
' 4.6 SLEEVE INSTALLATION EQUIPMENT The equipment used for remote installation of sleeves in a steam -
generator is made up of the following basic systems. These systems are:
- 1. Remote Controlled Manipulator
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- 8. Nondestructive Examination Equipment .
'These systems, when used together, allow installation of the sleeves
, without entering the steam generater. In this way, personne1
- exposure to radiation is held to a minimum.
.i 4.6.1 ~ Remote Controlled .vaniculater The remote controlled manipulaitor seh es as a transcort vehicle for inscection or recair eoui;: merit inside 'a steam generator crimary head.
The manipulator consists of two major ccmconents; the maniculater
. leg and manipulator arm. The manipulator leg is installed between the tube sheet and bottcm of the primary head and provides axial
- movement of the arm. The manipulater am is divided into the head arm, probe arm and a swivel arm. Each arm is moved indecendently with electric mot 0rs with enc der position con.rol. The swivel arm
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. allows motion for tool alignment in both squa're pitch and triangular' ~
pitch tube arrays. Comcuter centrol of the manipulater allows the operator to move sleeving tcols frcm outside the manway and accurataly position them against. the tube sheet. *
- 4. 6. 2 . Maniculator Elevator r N g . .
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, 4.6.4 Tube Size Rolling Ecuiement #
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4.6.5 Sleeve Installation Ecufoment e s L .
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4.6.6 Sleeve Exeansion Eauiement-
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4.6.7 Sleeve Weldino Ecuiement 5
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4.6.8 . Nondestructive Examination -
' Three types 'of-nondestructive examination equipment are used during the sleeving process. They are as follows: eddy current testfrg
. (ET) equipment, ultrasoni,c testing (UT) equipment and visual equipment.
i '
A dual ~ cross wound probe and ' bobbin probe usino the multifrequency
' eddy _ current method will be used to do a base.line inspec:fon of the '
installed sleeve for future reference. The ET fixture with conduit is used on the manipulator arm to position the probe. Eddy current-
- testing using a bobbin probe may also be used to determine the -
inside diameter of the tube to be sleeved and the sleeve expansion siza.
Ultrasonic testing using an immersion technique with demineralized water as a couplant is used to inspect the upper tube to sleeve weld. . A one-quarter inch diameter focusing transducer is positioned in the weld area by the elevator and is rctated with an electric motor to scan the weld. The pulse echo tester has the ability to interface with an on line data reduction computer to produce a display /hardcopy during radial and axial scanning.
. Visual inspection of the uccer and lcweritube to sleeve weld is
. accomplished with the use of a borescope mounted on the manipulator arm. .
4.7~ PLUG INSTALLATION EQUIPMENT The equipment used for remote installation of plugs in a sleeve steam generator tube is made up of the following systems:
_, 1. Remote Centrolled Manipulator r >
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- 5. Nondestructive Examination Ecuipment /
'4. 7.'1 ~ Remote Control Maniculator.
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!!ee Section 4.6.1 for a description of t.he Remote Control Manipulator.
4.7.2- Sleeve Size Rollina Ecuicmen:
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4.7.3- Plue Installation Ecuiement r \
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4.7.4 . Pluo Weldine Ecuioment
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4.7.5 Nondestnictive Examination .
Visual inspection of the plug weld is accomplished with the use of a boroscope mounted on the manipulator ann.
4.8 ALARA CONSIDERATIONS ,
' The steam generator repair operation is designed to minimize personnel exposure during installation of sleeves or plugs. -The manipulator is installed from the manway without entering the steam generator. It is cDera,ted remotely from a control station outside the containment building. The positioning accuracy of the manipulator is such that it cap be remotely positioned without having to install.temolates ip the steam generator.
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Air,' water and electrical sucoly lines for the toolfrig are designed and maintained so that they do not become entangled during operation. This minimizes personnel excesure cutside the steam-generator. Except for the" welding power source and programer all O equipment is operated from outside theicontainment. The power
-source and programer is stationed about a hundred feet from the steam generator in a low radiation area. -
In summary, the steam generator operation is designed to minimize personnel exposure and is in full compliance with ALARA standards. -
4.9 REFERENCES
TO SECTION 4.0 (1) .Sedricks, As J., Schult:, J. W., and Cordovi, M. A., "Inconel Alloy 690 - A New Corrosion Resistant Matarial", Jacan Society of Corrosion Encineerina, 28,, 8 2 (1979),
(2) Airey, G. P.., " Optimization of Metallurgical Variables to Improve the Stress Corrosion Resistance of Inconel 600",
Electric Power Research Institute Resesrch Program RP1708-1 (1982).
(3) Airey, G. P., Vaia, A. R., and Aspden,'R. G.. "A Stress Corro-sion Cracking Evaluation of Inconel 690 for Steam Generator
, TubingApplications",NuclearTechnoloov,jj,,'(November,1981) 436.
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5.0 ~ ^ $lEEVE EXAMINATION PROG.1AM 3- . .
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5.1' ULTRASONIC INSPECTION .
5.'1.1 Summarv and Conclusions An ultrasonic examination is used to confirm fusion of the sleeve to
, the tube'after welding g*his ttrt consists of introducing a sound l wave with a frequency of[ _;into the welded region. -This sound.
1.
wave is rotated 360 gegreer arcund the tube, the fixture is tnen
., raisec approximatelyL _ inches and scanned again. A minimum of three scans are performed and if one or more of these scans show fusion for the whole 360 degrees, the weld is considered ac eptable.
=The beam that is used is capable of , easily detecting a{ inch
^ diameter flat bottomed hole. ' ' ',
5.1.2 Ultrasenic Evaluation Ultrasonic techniques-are emoloyed to confirm tne presence of sleeve-tube weld fusion. The evaluations'were_made of Inconel 690 .
jinchoutside alloysleeveswithnominaljimensionso(heInconel500alicysteam diameter,'andminimu( Jinch wall. 4 generatortubesare0.875inchcutsi}dediameterX0.050inenwa11.
Weldpositionissacroximately(, inches frem the too of the
. sleeve.
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- Ultrasonic contained waterenergy column at( in the vicinity of theAfter weld.lis'emittedfromat passing into the sleeve at its entry point, the sound continues to travel 5-1 ,
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'u'ntil it arrives at a. separation in material'or to the opoesite side-
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1 of the material. The transducer is designed so that when traveling through the total thickness of sleeve, weld and tube, the energy is
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, approximately(focused at- thq sleeve.ou}+er diameter wall, with a
- f When sound enters the sleeve some of the sound energy is reflected ,
at the sleeve I.D. and the reflection is referred to as the interface signal. The trknsmitted sound passes through a weld with 1 - proper fusion and is sometime; but not always reflected back to the J' transmitter frem the tube backwall; i.e., the tube 0.0. Should no fusion exist at'a given point, the sound energy will be reflected at -
the sleeve backwall, i.e. the sleeve-0.0. A weld area is considered
. to have proper fusion where an interface signal exists withcut the 1; presence of sleeve backwall . reflection. . A gcod weld is shown in .
. Figure 5-1 where the tube backwall signal is also present. No >
J . fusion is shown in Figure 5-2 where the display in the cathode ray *
- tube (CRT) shows the interface signal followed by a sleeve backwall
.m signal. Sometimes when there is lack of fusion the interface signal w
- is followeft ,by multiple sleeve backwall signals.
~
~ The weld examination begins when the transduce'r is inserted into the sleeve / tube assembly to a position such that the transducer is
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aligned with the* weld. The transducer is then rotated 360 degrees
.at this elevation and the degree 'of fusion is detemined by
' observing the ultrasonic instrument's CRT, or by other readouts.
, Additional scans at other elevations can be perfomed to evaluate the complete weld area.
, . In this manner, the weld . integrity c be assr ed and lack of i
fusion, with an area equivalent to a l diameter flat bottom hole or a slot with a width of can" reliably be detected.
In actual test specimens, a la of fus on ' had been reliably detected as shown in Figure 9-2. ' ' -
5.1.3 - Test Ecufement '
t Test equipment for welded sleeve inspection consists of the following comconents: .
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1432(8402)/js-35 5.1.4 Defect Samoles Qualification of the ultrasonic inspection system was made through a variety of pedigree defect samples, as well as welds with good fusion across the entire area. Weld samples are typical of conditions to be present in the steam generator. The calibration samples are described as follows: s 3 . .
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5.1.5 '
De+. ailed Results .
, The ccmouter output for each calibration samole is included in this
- report. The information contained on each chart ccnststs of'the following:
- 1. Rotation (degrues). This is the angular position of the transducer measured in degrees.' The :ero degree coint for the transducer is aroitrsrily selecte'd, locked into placa and is consistent for all follcwing scans. This enables circumferential 1ccation of any lack of fusien area indicatec on the print out.
- 2. Elevation (inches or centimeters). The elevation or vertical '
position of the transducer within the sleeve is given in both inches and centimeters. This information enables accroximation nf the weld height and location of any lack of 'usion areas.
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- 1432(8402)/js-36,
- 3. Scan limits. The uccer and lower scan Iimits for the weld are '
shown by the unprinted section of the scan limit figure.
4 Data on the too of each chart relates to infomation concerning the inspected tube, steam generator and time, as well as weld signal amplitude threshold values for recording. There are two sleeve-tube areas that can be monitored by electrcnic gating
. circuits. One gate measures the level of the signal from the tube outer surface and the other gate monitors the sleeve-tube y interface. A tube outer. surface ' signal above the threshold value and/or no sleeve signal above the threshold value can indicate fusion. ,
Gate 1, the tube backwall monitor, is positioned so that its leading edge aligns with the leading edge of the tube backwall -
signal.
Gate 2, the sleeve backwall monitor, is positioned so its leeding edge fo11cws the interface signal and teminates before the tube backwall signal.
The cceputer software allows versatility with regard to monitoring the weld integrity by selection of the gates to be used, as well as the setting of the threshold limits. The nomal inspection is perfomed by c.onitoring only the sleeve-tube signal (Gate 2) withcut regard to the tube backwall signals (Gate 1).
In reviewing the computer readouts for the two calibration samples used, the following analysis is offered:
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It can be seen that each of the artificial flaws used for these qualification examinations can be detected, while the good 'usion areas of the weld presented no indicated areas of lack of fusion. ~
5.2 ED0Y CURRENT I!!SPECT!0ft The objective of this examination is to establish baseline dat3 en
, the primary pressure boundary of the sleeve-tube assembly. The 5..t ,
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1432(8402)/js-37 examination was develoced to detect 40 percent ASME sized flaws in .
the parent tube and/or sleeve in any region of the sleeve-tuce assembly with a single pass of an eddy current coil.
Sumary and conclusions 5.2.1 -
An eddy current test has been qual.ified for the inscection of installed welded sleeves to detect flaws in the pressure boundary.
Eddy currents circulating in the sleeve and steam generator tube are i
interrupted by the presence of flaws i,n the material with a resultant change in test coil' impedance. This impedance change is orocessed and displayed on the test instrument to indicate the -
presence of a flaw. -
The pressure boundary is considered to be the sleeve uc to and ,
including the upoer weld joint and the steam generator tube above the weld. Consequently, there are three distinct regions relative
. to the inspection methods: 1) The sleeve belcw the weld, 2) the steam weld) generator and 3) thepube steambehind generatorthe top tube section aboveofthethesleeve.
sleeve (above the Using speciali:ed prebes and multifrequency eddy current techniques, it has been demonstrated that a
]isdetect le anywhere in the sleeve or tube, including the weld region. [,
j The test results are recorded on magnetic tape and strip chart recordings. Other than the probes, the inspection equipment is the same as used for a conventional eddy current test of steam generator tubing. Additiona1 laboratory testing of accelerated corrosion samoles has shewn that this method can detect IGSCC in the parent tube.
5.2.2 Multi-Frecuency Eddy current Ecutement Recuirements The equipment required to perfor n this examination include the
' folicwing:
s e e 5.2.3 %efectSamo1es A variety of simulated de#ect samoles were faericatec to represent different possible flaw locations in the sleeve or steam generator tube. The basis f the qualification was to demonstrate e detectability of a 5-5 L.
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at any location in the pressure boundary. Several
- sampleswere]recuiredtosimulatethepotentialsignalinterfere from the sleeve end, sleeve bulge and weld. The sample matrix included: -
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A s 5.2.4 Results and Conclusions - -
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- [ 3 multi-frequency eddy
, . current techniques are emolayed to further enhanes the signal to noise ratio. A total of four separate test frequencies and wo-
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1432(8402)/js-39, mixing channels are emoloyed simultanecusly'. Sy c moining the
- signals from two frequencies, the residual noise signals frem the bulge, etc., can be virtua',,1v eliminated. For this carticular application, a comoination -
jis used to inspect the sleeve. In Figures 5-11 through 5-15, the eddy current test signals for various qualification samoles are shown, both the single and multi-frecuency.results are shcwn, however, in general,the( jwillbeusedasthebasisof g analysis. . i The icw frequency required to examine the steam generator tube '
thrcugn the sleeve and the total ' wall thickness of the sleeve-tube assembly result in insufficient phase shift of the defect signals frcm the steam generator tube defect calibration standard to allow .
evaluation of steam generator tube wall degradation indications by relating signal phase angle to the death of penetration.
Consequently, detection is possible, but accurate sizing generally is not possible.
Sleeve wall degradation indicationi can be evaluated for depth of .. .
penetration and origin by plotting the phase angle of data to graphs rq1ating signal phase angle to death or penetration. '
The smallest sleeve wall di. gradation demonsttated to be detectable with this examination technique was a s qq1el, frcm the 0.0. of the sleeve.
5.3 VISUAL INSPECTION
- 5.3.1 Sumary and' conclusions Visual examinations are performed on the upper and Icwer sleeve to tube welds to determine their integrity and ac:ept'ance. The welds
'are examined using a fiber optic or boroscope examination system.
, The lighting is supplied either as an integral part of the visual examination system or as a sucplemental system. Each examination is recorded on video tape for optional later viewing and to provide a pemanent record of each weld's condition.
The inspections are cerfomed to asciertain the mechanical and structursi condition of eacn weld. Cr'itical conditions wnicn are checked include weld width and c:moleteness anc tne absence of visibly noticeable indications such as cracks, pits, b1cw holes, burn thrcugh, etc.
5.3.2 Lower Weld Evaluation
- The lower weld of the sleeve-tube assemoly is ins:ected using a boresc:ce examination system. The boroscoce is :asitionec uncer tre lower weld and the lignting is adjusted to obtain the optimal viewing conditions. Rotating the boroscope around the weld and tilting it wnen necessary, provides complete coverage of the 5-7
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I 1432(8402)/js-40, examination area. A videotape recording is made of the entire examinations.
Prior to the inscection, the system's accurtcy is ascartained by observing a 1/32" black line on an 135 neutral gray card placed on the surface to be examined or a location similar to the inscection area. Proper use of this system provices image resolution on the order of 0.001 inch. , .
g Weld acceptance is bt. sed on the absence of any cracks or other visible imperfections which would be detrimental to the integrity of the weld. During the examination, an area containing a noticable
- indication is inspected more closely. This is done by varying the light intensity, distance from the lens to the indication, and/or the angle used during the viewing, e -
5.3.3 Uccer Weld Examination A visual examination is made of the uceer sleeve to tube weld using a boroscope inspection system. This system utilizes a right-angle lens and a tool which can deliver the lens up to the weld as well as to provide 360* rotational capabilities.
To perfonn the inspection, the actics system is inserted into the sleeve / tube assembly such that the lens is located at the uoper weld. After checking for visual clarity and adjusting the lignting
- to reduce unwanted glaro, the lens is rotated 360'. The lens may then be raised or lowered and the process repeated to ensure ccmplete weld coverage. The entire examination is, video-taped for a ,
pennanent record.
Prior to t.he inspection, the system's adecuacy is checked by observing a 1/32" black line on an 18 neutral gray card placed in a location'similar to the area to be inspected. Additionally, to
'obtain an aspect for si:e and to check the in-tube lighting, a welded sleeve-type samole with a .020" diameter througn hole is
' placed over the lens.
The weld acceptance is based on the absence of cracks or other visible imperfections which would be detrimental to the integrity of the weld. Cetrimental imoerfections' include blow holes, burn thrcugn, weld mismatcn, etc. Curing t'ne examination, any area wnich contains noticable imoerfectiors is examinec ?. ore closely oy varying the light intensity and/or the ;ositten of the lens with res:ect to the indication.
5.3.4 Test Ecuicment
- The test equiement necessary to visually inscect the uccer and Icwer sleeve to tube welds c:nsists of the fo11cwing:
5-3
1432(8402)/js-41
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.1. Soroscope visual examination system with* an inte ral Ifghting -
- system, lenses.and a delivery and rotational too for inspecting the upper and lower welds. 3 2.- .18". neutral gray card witn a 1/32" black line. '
-3.
~
Welded sleeve-tube samole with a .020. inch diameter through drilled hole. ,
4 . Video camera and recording ecuicment.
5.3.5 Defect Standards ~*
. Variousmethodsareusedtodete[ninesystemadecuacyandtoaidin determining weld acceptability. ,
- 1. System adequacy, including light ng intensity and camera system clarity, is verified by resolving a 1/32" black line on an-18.
neutral. gray card.
- 2. ' Size aspect for upoer weld inscections is obtained by_ viewing a welded sleeve-tube sample which has a .020 inch thecugh drilled hole.
- 3.. 5.leeve-tube uocer. and Icwer welds were made with both acceptable welds and intentional weld malformities. These welds were photographed and are used as aids to examiner.- '
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, SLEEVE IMSPEC'"ICM EOGY CURRE?!T TEST SIGNAt.S - SLEE'/E .:LA'JS AT
' ., EXPANSION TRANSITICN k-1 L':"u ftae :_ . '6 .:
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6.0 SLEEVE-TUEE CORRCSION TEST F:.CGRAM
'C-E has conducted a number of bench and autcclave tests to avaluate the corrosien resistance of the welded sleeve joint. Of particular interest is the effect of tne mechanical expansion / weld residual stresses and the conditicn of the weld and weld heat affected Icne.
Varicus tests have or are presently being conducted under
-accelerated conditions to, assess the sleeve-tube jcint cerformance under potential nominal and fault environmental ecnditions. An
-. )
outline of these tests is shcwn in Table 6-1. [
,j e .
6.1
SUMMARY
AND CONCLUSIONS
( e -
. J 6.2. TEST DESCRIPTION AND RESULTS 6.2.1, Modified Huev Tests 0
l!
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- 26. 3. ~ .
REFERENCES FORlSECTION 6.0 : ,
- 1. I. Li W.. Wilson and R. G. Asoden, " Caustic Stress Corres'ics
' ~
- Cracking of : Iran-Nickel-Chrom ~ium Alloys." Stress Corrosion Crackinc and Hydrecett Embrittlement of Iron Base Allovs, NACE, Houston, Texas,.pp 1189-1204, 1977.
. A .
~ .
2.: L A'. .
J. Sedriks, S.1Floreen, and A.~ R. McIlree, "The Effect of .
. Nickel Content en Lthe Stress.. Corrosion Resistance of Fe-Cr-Ni
- in an Elevated Temperature Caustic Environment". Cerrosiin_,
- *=
Vol . 32,' No. 4,L pp 157-158, April ~ 1976.
- 3.- F. W. Pement,:I L. W. Wilson and R. G. Aspden,' " Stress Corrosion Cracking Studies of High Nickel Austentic-Alloys in-L Several High Temperature Aquecus Solutions." Materials
.n Performance! Vol. ;19, pp 43-49, April 1980. -
~
A. P. Berge and J.-R.~0onati, " Materials Requirements for
. Pressurized Water Reactor. Steam Generator Tubing." Nuclear
~
4echnoloov,.Vol. 55, pp 88-104, October 1981.
~
5.
- -G. P.~Airey, A..R.,Vaia and R. G. Asaden,' "A Stress Corrosion' Cracking Evaluation of Incenel 690;for Steam Generator Tubing
., JApplicaticns." --Nuclear Technolecy, Vol. 55, po 436 448,'
- m. .- m November 1981.;
~
, 6.- !J. R. Crum and R. C. Scarberry, "Corrosicn. Testing of:Inconel
~
Alloy ,690~ for PWR . Steam Generators." Jcurnal of Materials for Enercy Systems,:Vol. 4,-No. 3 pp 125-130, Cecemcer 1982.
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7.0' ~
MECHANICAL TESTS OF SLEE7ED AND PLUGGED STEAN GENERATOR T1J2E5.
7.1
SUMMARY
AtID CCNCLUSICMS Mechanical tests were performed on mockup steam generator tubes containing sleeves and plugs to provide qualified test data describ-
-ing the basic aroperties of the ccmoleted assemblies. [
3 3
g . .
f
.]
The welded plugs'have sufficient load capacity to perform their.
function during normal and postulated accident conditions. The axial:-load required to loosen the plug from the sleeve-tube assemoly is-approximately- fcur times greater than the design load.
. 7. 2 ~ CONDITIONS TESTED
( .
3-
, -C 3 .
7.3 ' WELDED SLEEVE TEST PARAMETERS AND RESU,LTS 7.3.1 Axial Full Tests-
. J.
7-1
+
-.h
g .. __. .__. .
o .
8.0 STRUCTURAL WLYSIS CF ILEI'iE tJSE SSSME!.Y It is the zur;cse cf this analysis :: establish :he structural adecuacy cf the sleeve-tuce assim:1y. The matheccicqy usac is in ace:rcance wita :ne ASME 3ciler and Pressure 7essel Ccde, Sectica
- II. The werk was performed in a manner in ace:rdance with 10C.~R50 Ap;endix 3.
Also, it is c nstruc:ad such that all U.S. Regulat:ry recuirements ars =ct. -
-1 8.1
- SUFFARY AMO CONCLUSICMS Based en the analytical evaluatien'::ntained in this secticn and :te
, achnical tes; data contained in Section 7.0, it is c ncludac na:
the welded tute. sleeve, described in this.cccu=ent, meets all ne -
recuire=ents stipula:ad in Sectica 5.0 with substantial adci:icnal margins.
8.1.1 Desien Sizine ,
In ac:Ordanca with ASME C de cractice, the design recuirsments for tu ing is covered by -he scecification for -Me steam genera: Or
" vessel". The accropriate formula for calculating :he minimum re:uired tube er sleeve -hickness is fcund in Faragra n NS-3224.1,
. :entative pressure':hickness for cylincrical shelis. The felicw-ing calculatica uses this formula.
"q
- '4here-5m-v..: P : = Min re:uired waii :hicx (in.)
. t- " P = Desien Tutetheet dif[eren:ial ressure ~
~
t= (ksi)
R = Inside Racius (in) 5* = Oesien Stress Intensity (S.I.)
- (per Ref. 8.2) a
- =
_,. . J '
s ',
3.1.2 Detailec Analvsis Summarv When :recerly installed anc weiced wi nin s:ecified :lerancas, ne '
sle.e,ve and its ,:wo :rimary we.ics :cssess ::nsicers:te targin agains Ou t s -cut Or al . . C ncaivaCle -.
6cacing un' *. Can :e OCs:uia:Ec.
~
J..
2*
a .
r
w- _
t
. .. _3 . .
_.L_._.----. --- - .
b
/
Ce:encing en :te degree *f tube /suc;cr: Icck-uc, axial icacs in the sleeve do not extascf 3 When c nsidering the favoracle resul:s fr:m :te cyclic Tcadine :as:sf
_Jfatigue ;rceiems are act antiaipa::c. '
In_ Secticn 3.2, a c::carisen is :ade be: ween calculated failure =cces and tas; data discussed in Secticn' 7.0 of this recert. The agree =ent between calculatac and tag data was gecd. Safety fact:rs were de-tar rined for h of safety of[ yccrnecical pipa break accicants, and a :ini=um fac :r
]wasdetar=ined.
safety wasi jbased The ner:a1 ocerations fact:r of icading. Eusn} cur a: :en the full ;cwer restrainec thermal ex:ansica -
he icwer sleeve /tuce stu: Jcin: is :te critical c:nsideration (see Sectica 3.4.5) .
The axial sleeve icad: calcula:ad in Sectica 3.3 'are used as
~
bouncary c:nditicns and One basis for assu=cticns usec in :ne Section 3.5 and S.7 fatigue evaluations.
An NRC Regulater/ Guide 1.121 evaluatien was :erferred in Secticn 8.3 :: derarmine a sleeved tube ;1uccine limit. A~ lalicwacie degraca:icn lici: was ce:armined. f5is ts ;cssible[:eEause :ne Reg.
Guida s ecifically uses ner al c:erating ;arameters, sucn as coerating
..;ressure. prus:ure,-rather : nan tucesheet design differential differential C nsideration: cf suscaptibility t: flew- incucac vibraticn was dis-cussed in -!ecticn 3.5. Based cn C-E ex:erienta and tas; data, it was datar than a:ined nor=al that a sleeved tune is no ucre suscactible :: tibratica
- he. "
- ~
Fatigue of 5'c-n the uccer and icwer jcin:s was c:nsidered in Sectic 3.5. The gac=etry was snewn :: meet all AEME Ccde alicwa:ie stress intansities inciucing iccal =rimary anc range of ;rimary :ius sec:n:-
ary stress.
A tabulaticn of the resul:s is presentec in Tacle 3+1.
7he maximus Iccai primary stress'intansity was f
' lesye at the icwer- weld jcint, as c:::ared wi'a :ne Jksi acr:ss :ne liicwacle of jksi .
The maxime: range of =rimary ;1us sac:ndary stress was
{ ; ksi acr:ss the sleeve a: ;ne icwer jcin:, near ne weld, as cc=:ared with the alicweble of) ]ksi. The maximum faticue usat fac: r was[0.19 a :he sa:e 1:ca:1cn. This ai due in :arE :: ]cen:sistantly ::nserva:'iv,e assum:gn
- tens race in :ne usage faci:r was calcula:1cn. s Sleeve and 24 inch evaluatten near buncle_ was :erf:rmec periphery. fer 35 inen siseves in the centrai tube bu The :nermai mista::n :e:ueen :na sleeve anc cis:ance :uce wnica
- ecween :ne :::affects axiai icacs Occurs :ver a sner: .
of :ne tu:e snee: anc : e'u::er weld. T* e rela:ive severity of :ne axiai. icacs wn :n ire :eveic:sc are a functicn of ::at Ois:anca civicec :y :ne :verati :is:anca -
be: Ween :ne 2::er anc icwer seits.
e b-e mm.-
~-
E ,
3 9-A sleeved-tube plug was suecassfully evalua:ed in Sectica 3.7 in
' case it shcule ever be.needed (see Tacle 2-1 and Ac;endix 3C).
- ,. c.Mu
. , , &, d, uJ C.3-. --.ke.
be awC , .4e ,J, In this secticn a.nu=ber of pctantial failure Icdes are examined 0 determine ne relative safety margins for selectac events. Failure leads are calculated based on minimum dimensicns and cc=:ared with
' mechanical _ tasting resui:2 fr m Secticn 7.0. Both calculatad and
)
measured icads are c:= ared with :ne m7ximum pcszu11:sd Tcacs.
'8.2.1 Uccer Tube-Weld ulicut Lead -
- Assuming the parent tube is ::: ally savered, the minimum lead recuired : shear'-he u::er tu:e weld is calculatac. The fcrea required :: ;ull the ex;anded sleeve thrc'ugn the unex;andec u:e is .
c:nservatively neglec ad.
t r
t In the event of _ a main staam line break (MSL3) ac:f den: -he sec:ncary pressure wculd dr:0 curing a shcr: :ime Lnzerval. The crimary :fessure would rise briefly :nen felicw the dre in
'sec:ndary cressure. It will be conservativel fuli
', :rimary prassure remains wnen :ne sac:ncary :yressure assumec :na reacnes :er0.
'Postulatin a main steam-line break (MSL3) accident,-:he maximum available cad wculd be:
3.2.2. L:wer 5 u: Wele :usccut L:ac Assuming :ne caren- tube is :: ally severec, :ne mindrum Icac recuirec : ~ructure One 1:wer stu naic is :aicula:ac. :: 's in:aresting :c nc:a ::a: #:r :nis gecce:ry, tasec :n :ne es-resul s, :ne wel: :1c nc 'ai! in :ure snear.
f 3-5
S Q
'.-d.'
.'7 t
M~' , , ,_ -
'w r ,
- ' 1
< r 3,. # - - , .p --
, 3-- --
i 3
wl. . __ .. - , . . - - . .-
%f -N '
'n 4 s -
y 1
% 1
- y. _
~ '
.u
~ Tne weld 110 seemed to " roll. cver'. as is iliustratah'in Figsre 3;2. -
such -hat de weld failed primarily in :encien.
,
cir:tmference . ,
a .
s ,
.7
~ '
!Frca References .3.1' and '8.2, -the minimum tensi.le -strength is 30.0.
' ' . ksi.- ~ Tnersfere. a predictad "pushcut" Icad en :Me sleeve might be calculated:
- ss . . .<.
[b:
7, "h * ' '
iPostulatingia Icss of primary c:alant ac:1 den: -(LOCA) durinc het istandbyj cenditions .(0 power), the maximum available Icac wculd be:
~ ~
t
..'h' 4.
8.2.3J
.J Weld-Faticue Since the factors _of safety;are quite hign for Icadings dde ::'
- - primary stress,- 2e, mecnanism of grea:est interes: is de ' fatigue ,
gm ,
sfailure scde due to variaole axial leading of One .sieeve during,
~c, ncrmal operation. -
In Section 3.i. fatigue evaluatiens of ':cth the uc:er and,icwer -
' welds ,' which join the sleeve.:a ' the tube will be mace. 4t is firs-r necessary to cetermine the effects, wnich :::e lect-uc witnin :.se r , ' L; -
- tubesheet* and ube succor: plates have en tne axial-leacs in :ne a
~
... '-_3 , T Meeve during ner::al cceration. 'This subject .is.-accr'essed in.
_ .. .Section'3..t. -
,1-, ,"
E': 3.3; REGU1.ATORY GUI::E :12121 E'/AL'.!ATICN FOR 'ALLCWASLE SLEE'/E WALL
'.OEGRACA..7!ON '
m . R.G. ' l.'121 -(Reference '3.2) recaires ca: a .'inimum ic:e::2:;e :::e - :
? v (or sleeve) wall :nicxness :eiestamiisn'ec ::' :revice s : asis 7:e
' removing a tu:e from servica. Fcr :artiat :nru--aiiLa: acx #r:: arv
~ - source,;:ne recuirements fali.. in:6 wo :2 egeries , (a) Scr a! _
~< ' oceratten safety targins, and (b)- censiceraticns reia:sc :
Ocs:Ula:ec :: ice rJ: ure' accidents,
- g. ,
1:
e ,* , Q m
. ,a
~.
- a.
I
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.A
,='se n, 4'
d in h^, ,
~~
e
- f, -
.7-- , , ,
4 %
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s 3
) ._ .__ _, , .
8.3. I' Ner al Ocera:1cn Saf=tv .va r-i ns It is the g
.act:rs or, eneral intan; Of taese recuirecen;s :: Taintain :he same sa ety .in evaluating cegraced :U:es as those inien we*r. .
c:ntained .in the original c:nstructicn ::ce, ASME 3ciler anc
. Pressure Yessel Cede,Section III (Reference 8.1).
. Fcr Incenal Alicy 500 and 590 tube or sleeve material :ne c:ntrailing safety margin is:
) . .
- Tubes with par thr wall cracks, wastage, ce cc=binations ~
shculd have a fac:cr of.safaty agains: failure :y cursting unce ~-f [-5e='=
~
ncr :al o ra:ing canditions of not ;ess than 3 at any :uce Iccation 0
W e I i
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- 44 cwde f / j s-ca . -
.w 3.3? f .EMERCEI FGR SECEON S.0 -
P 13.1 ASME Eciler and Pres:ure Yessel Ccde, Sec:icn ::* for Nuclear
' Fcwer 91an: Cam:cnents.
A 8.2:LASME Soiler and ?ressure Vessel Cace Casc N-20, "S5-153'
- ; Nickel-Chromium-Ircn Tubing '(Aliqys .500 and 690) at e. 5
- ecifiec
- Minimus Yield. Streng
- S cf '10.0 K3I.
~ U .
8.I 10.5. NRC'Requia:Or/ Guide'1.121, 'Sases fer Plugging.Cecraded ~
PWRt Stean Generat:r Tubes". .
. RFQ frem Swedish Stata ?cwer Scard, SIVI-L3n/Gn4331, dated Y January 4, IS84J ts ~C-E Pcwer Systems, far Ringnals 2 Staam -
Genera::r Cemenst aticn Sieeving.
3.5 Lettar, E. L. = 'dat:1 (NSF) to R. 3. Grinstrand (CE), dated July 20.
~ .'
'1984,e" Prairie Island Gecmetric anc Crera:ing Parametars"._
3"p ' SSF3 Scecification fcr Reciacaman: Staam Geners::r'fer Rf nchair
' 7. Nuclear ?cuer Flant, datac January 1934 ~
3 8.7 -Intarnational Nickal C:. Ecckler "Ine:nel 650"'
8.3 Nuclear Sys ams Matarf ais Hancheck, Volume 1 "Cesign Cata",
s Par 1, Greu;z
. 4,. Section 5 - Inc:nel Alicy 600.
11 8.9: "'libration in Nuclear Hear Exchanc
- Two-Fhase Flcwi', By:*4 J. Heilker'ers- Cue and R. :c Licuid
- 0. Vincant, anc Jcurnal~cf
..~ .bgineering-.fer .-
?cwer, Volume 103, Pages 255-3E5, Acril 1931. . '
s ,
'3.10 "ANS75, L &gineering Analysis 'Systam, User's Manual, by Jenn A.
^Swanscn.
' '^, , , : 8'.11 EFRI NP-1479,J" Effec cf Cut-of-Flane Centing !.:ad: cn :ne Structural intagri y o';$taam Genera::r,in:arnals, C:nzrsc r:
C-E,-August 1950.
1 :,;
18.12 "?rimary/Sec ndary Scundary Cecccnents Stancy State:!:ress Evaluaticn", Frscared y 'Raymenc- Paul 'decler, '4esting Elactric
' Cere. , Acril 19e:. i
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~1d2[8402)/js-572 3
q '10.0) EFFECT OF ELEEVING GN OPERATION An analysis was cerfomed to determine tne effect of installing
- welded sleeves in the steam generators. It was assumed that two.
- thousand sleeves would be installed in each steam generator. Since
~it is not kncwn hcw many 36" long and how many 24" long' sleeves will be installed; it was conservatively assumed that all sleeves were 36" long. - Using the puma enaracteristic curve and the system
' resistanca
.~ curve, the flow rata change, was determined far-increased 4
iflow resistance associated with ;nstalling the sleeves. The change in total:.ficw rate was only[ '
and should not have a significan: .
.effect on reacter operation. ~
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1432(8402)/js-55 n . '
~ APPENDIX A TO REPORT NO -
PROCESS AND WELD CPERATOR OUALIFICATIONS
- FdR TUBE SLEEVE AND PLUGGING SLEE'IED TUBES O
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- Id32(C402)/js-59, B e H
APPENDIX A A.1_ SLEEVE WELDING AND SLEE'/E WELCER CJALIFICATICM Sleeve welding is cualified using an 3poroved test precedure (Reference 1).
plug _ welding in cleeved tubes is qualified using an approved test precedure 3 (Reference 2). The sleeving test precedure is in ccmpliance with acplicable sections of the ASME Ccde even thcugh it does not directly apply to sleeves, and the plugging proradure is in compliance with Section XI of the latest '
edition of the ASME Ccde. Sleeve and plug welders are cualified using test records in accordance with applicable sections of the Code.
The test precedures -specify the requirements for performing the welds, the canditions (or changes) which require requalification, the method fcr examining the welded test assemblie.s and the requirements for qualifying the~ ~~'----' -----
welding operators. Sleeve *and plug welding are cualified by performing six consecutive welds of each type which meet specified design requirements.
Welders are cualified by performing two consecutive successful weids of each type.
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1432(8402)/js-60 2 .
- .o A'. 2 REFERENCES TO APPENDIX A
- 1. Welded Steam Generator Tube Sleeve Semi-Autcmatic Gas Tungsten '
Arc De'tached Welding Procedure Qualification,.
Test Procedure -00000-NCM-0EO, Rev. 00, April 14,1984
- 2. Engineering Requirements for Plugging Sleeve Tubes in
-yi Westingncuse Series da and 51 Steam Generators,
.NCE Engineering Procedure EP-6275G-104 Rev. O, Acril 19, 1984 1
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