catawba nuclear stationmeeting purpose *provide information on use of polyethylene piping in non...
TRANSCRIPT
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I M
Catawba Nuclear Station
Polyethylene Piping Use forSafety Related Buried
Water PipingService
ATTACHMENT 2
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Agenda
* Meeting Purpose and Expectations* Polyethylene Piping Use by Catawba* Polyethylene Materials* Joining Polyethylene* Seismic Analysis* NDE Technique Evaluation* Relief Request* Overall Strategy for Service Water System* Questions (questions encouraged during
presentation)
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Meeting Purpose
*Nuclear service water systems havebeen designed using codes thatspecify only metallic materials.
*Polyethylene (HDPE) material hasdemonstrated superior corrosion andfouling resistance in non safety relatedcooling water system service.
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Meeting Purpose*Provide information on use ofPolyethylene Piping in non safetyrelated service water system atCatawba Nuclear Station
*Provide information on developmentof relief request for replacement ofsafety related piping with high densitypolyethylene (HDPE) in buried servicewater applications
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Meeting Expectations
Information presented in the 6-27-05meeting is expected to be useful forfuture review of Duke Relief Request.
*NRC comments and questions duringthe 6-27-05 meeting will be used tofocus efforts to develop and preparethe Duke Relief Request.
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Catawba Nuclear StationPolyethylene Pipe Use
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Catawba Nuclear Station
* Located 19 miles southwest of Charlotte, NCon the shores of Lake Wylie
* Two Unit 1208 MW Westinghouse PWR
* Main condenser cooling provided by closedloop cooling tower system
* Commercial operation in 1985 &1986respectively
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Water Systems
* Nuclear Service Water System coonuclear safety related components.material: SAl 55, Class 1, KC 70 &plain carbon steels
ling toPiping
SAl 06 CS
* Low Pressure Service Water Systemsecondary cooling and cooling towermakeup. Piping material: A1 06 CS & AP15Lcarbon steel
* Both systems combined total approximately45,000-50,000 feet of piping
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LEGEND
LA s y tIE
* RC CONDENSER CIRCULATING WATER
RL CONVENTIONAL LOW PRESSURESERVICE WATER
* RN NUCLEAR SERVICE WATER ANDSTANDBY NUCLEAR SERVICE WATER
* RY EXTERIOR FIRE PROTECTIONSERVICE WATER
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CATAWBA NUCLEAR STATIONSERVICE WATER PROJECT
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Service Water Problems
* Potential loss of adequate cooling due toflow restrictions
* Concern for Foreign Material Exclusion(FME) from the corrosion products,sedimentation, biological growth, andclams fouling components within thesystem
* Localized through wall pitting
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Problems Addressedby System Monitoring
* UT corrosion rate monitoring to addressstructural integrity issues
* Systems Engineers trend flows,temperatures, equipment performance,and set maintenance equipment PMfrequencies
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Problems Addressedby System Cleaning
* In 2000, CNS cleaned and inspected over 8,000feet of Nuclear Service Water System piping.
* The primary methods used for this operationwere "Pigging" and Hydrolazing (High PressureWash) with Turbo Vacuum Trucks to remove thedebris.
* Chemical treatment was added to the safetyrelated service water system after the cleaningto help control the biological growth. Currentlymonitoring actual results of treatment
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Polyethylene
* 1985 CNS began experimenting withPolyethylene piping materials as a replacementfor Polybutylene
* Further testing of the Polyethylene piping beganin 1991 -1 992
* The test proved conclusively that Polyethylenewas very compatible with the system designparameters and water chemistry
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Polyethylene Piping Replacement
* After six years of actual in service application,there was no corrosion or biological materialbuildup on the inside of the pipe walls
* In 1998, the existing A-1 06 carbon steel supplyand return piping to the Unit 2 generatorhydrogen coolers was replaced with 500-600feet of 6" & 8" HDPE, SDR-1 1, polyethylenepiping
* Inspection results and performance of this pipingsince installation have been flawless (Nodegradation and no measurable fouling)
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Conclu USions - Non Safety RelatedService Water Piping Experience
HDPE Piping has not exhibited anycorrosion or degradation or significantfouling in over 1 0 years of service atCatawba Nuclear Station.
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HDPE USE by British Energy
* Coordinated efforts with British EnergySizewell B Plant to use HDPE Piping
* Monthly teleconference meetings* PE Training organized in September/2004* HDPE Piping installed by Sizewell B in
Spring 2005 in the ASME Section III Class3 emergency service water system.
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HDPE USE by British Energy__cKFsWTTTZ
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HDPE USE by British Energy
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Polyethylene Piping Materials
ASTM Material Specifications Used:* ASTM D-3350 Standard Specification for PE
Plastic Pipe & Fittings Material* ASTM D-3035 Standard Specification for PE
Plastic Pipe based on controlled outsidediameter
* ASTM D-2837 Standard Method for ObtainingHydrostatic Design Basis for ThermoplasticPipe Material or Pressure Design Basis forThermoplastic Pipe Products
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HDPE Butt Fusion
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HDPE Butt Fusion
Joints made by trained and qualifiedoperators in accordance with a qualifiedprocedures
Essential parameters by data logger as apermanent record
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HDPE Butt Fusion
2 H Minimum1/2 H Maximum
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Bead Rolled to Pipe Surface
PE Pipe (Cross Section View)
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McElroy Joint Report
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f Polyethylene Replacement Pipe, Project
Seismic Analysis
Jack SpannerEPRI NDE CenterJune 27, 2005USNRC Offices-White Flint
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Objectives
This project will provide a seismic analysismethodology for the technical justification toaccompany the relief request and a Code Case toallow utilities to repair or replace safety relatedpiping with polyethylene
Contract deliverables.*Task 1-Develop a general methodology for buried
HDPE pipe*Task 2-Analyze a buried system at Catawba NPP
- Piping to diesel heat exchanger*Task 3-Prepare Code case for Section III/XI
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Status
*Seismic analysis scheduled for completion byAugust 1, 2005
*Obtained HDPE and seismic performance datafrom Gas Technology Institute
*Catawba staff will also provide informationnecessary for seismic analysis-soil type, groundaccelerations, drawings, etc.
*Contractor provided analysis for buried HDPEpipe at a DOE facility
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NDE Technique Evaluation
Jack SpannerEPRI NDE CenterJune 27, 2005USNRC Offices-White Flint
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Objectives of EPRI PE Pipe Project
This project will develop a technical justification toaccompany a Code Case to allow utilities to repair orreplace safety related piping that has degraded, usuallydue to corrosion. It was decided to also evaluate NDEtechniques for qualifying joining procedures.
* Task 1 - Evaluate NDE techniques for HDPE joints.* Task 2-Develop and publish a technical report that
provides the technical justification for the Code case andRelief Request
* Task 3-Submit a Code case to the Code forimplementation.- Buried pipe Code case first- Above ground Code case later
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NDE Techniques to Evaluate
*Visual Inspection of joint and bead* Microwave Inspection-Evisive*Ultrasonic Phased Array* Ultrasonic Time of Flight Diffraction (TOFD)9 Radiography
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Microwave Inspection atCatawba NPP
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Microwave Inspection of EF Coupling JointRG&E Mockup
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Phased Array UT of EFCoupling Joint
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Time of Flight Diffraction (TOFD) UTTechnique-Cold fusion in butt joint
* Stage 3 - correlation UT-TOFD vs.destructive examination* Lab test spools. Field welds
Field Sample &Scan"
* Results* Strong positive
correlation ofNDE indicationsto actual flaws
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Status
*Evaluating NDE techniques* RG&E, Duke and EPRI mockups* Microwave system interfaced with UT pipe scanner
and used at Catawba and on mockups* Ultrasonic time of flight demonstrations in progress* Tried phosphor plate RT techniques-not successful
- NE Gas Assoc. had better success
*Collaborating with others like British Energy(Sizewell), NorthEast Gas Assoc., RG&E,etc.
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Relief Request - Scope
* Catawba Nuclear Service Water System -Buried Piping (ASME Section Ill
* Buried Supply Piping to the heatClass 3)
exchangers that reject heat for the mainemergency diesel generators
* Existing 10 inch Carbon Steel NPS Pipingto be replaced with HDPE
* Approximately 1700 feet of piping forCatawba Units 1 and 2
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Relief Request - Development
* EPRI Project for code case development beganin 2004.
* Code case concept introduced at ASME SectionXl Committee in February, 2004.
* Code case and relief request work complimentone another.
* Duke Power made decision to pursue reliefrequest since piping replacement will berequired before code case is approved.
* Target date to submit relief request is2Fall, 20052
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Relief Request - Development
* Relief Request will address:DesignInstallationI nspectionTestingProcurement
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Service Water PipingRefurbishment Plan
NSW Plan (2006-2010)
* Replace portions of auxiliary building piping* Install NSW pump house header crossover* Install NSW auxiliary building header crossover* Replace EDG cooling supply headers* Remove selective cooling loads from NSW* Move isolation valves to reduce lake water
exposure* Submit LAR for single header operation
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Contacts:
Larry Rudy, Regulatory Compliance, [email protected], 803-831-3084Steve Lefler Engineering, [email protected], 704 382 0138Ernie McElroy, Engineering, ewmcelro~duke-enerqv.com, 803 831 4174Dave Ward, Engineering, [email protected]' 803 831 4190Mel Arey Engineering, miareyl @duke-energy.com, 704 382 8619Joel Reeves CNS Service Water Project, [email protected], 803 831 3835Terry Edwards CNS Service Water Project, [email protected] 803 831 4153Jack Spanner (EPRI), [email protected], 704 547 6065