Experience of LBB Application to Korean Nuclear Power Plants

August 15, 2001 YounWon Park Korea Institute of Nuclear Safety

Contents
! Status of LBB Application in Korea ! Experience in LBB Application ! Recent Leak event at Wolsung Unit 2

Status of LBB Application in Korea

Status Reactor Type Units Wolsong 1 CANDU (4) Wolsong 2,3,4 Kori 1 Kori 2 Operation (16) WH type RX (8) Kori 3,4 YGN 1,2 UCN 1,2#
(# Framatome Rx)

COL Date 1978

LBB Application

X 1999 1978 1983 1986 1987 1988 1996 1999 (2002) (2005) O (Applied design stage) X

YGN 3,4 KSR* (4) UCN 3,4 YGN 5,6 Construction (4) KSR* (4) UCN 5,6

* KSR : Korean Standard Reactor (1000MW, based on CE Type Reactor)

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Summary of LBB piping in KSR

RCS SA508 Cl.1a Carbon Steel 36, 49 2.5, 3, 3.875 SAW, SMAW J-T (FEM) 260% Prz S/L SA312 TP347 SS 12 1.312 GTAW J-T (FEM) 2% Thermal Stratification Low Margin SIS (ECCS) SA312 TP316 SS 10, 14, 16 1.2, 1.4 GTAW J-T, Limit Load 12% SCS (RHR) SA312 TP316 SS 16 1.6 GTAW J-T, Limit Load 56% MS SA160 Gr.C Carbon S 26 1.125 GTAW J-T (FEM) 0.4% DSA LDS Low Margin 4

Pipe Material

Pipe OD(in) Pipe Tk(in) Welding Type Crack Stability Method Crack Stability Margin

Special Issue

DSA

Thermal Fatigue Thermal Fatigue

Potential Issues for LBB Application

! Operating Plants
" Lack of plant specific data
Load: Piping Design data ! Material: Tensile & Fracture Material Properties
!

" " " " "

Thermal Stratification Load (Pressurizer Surge Line) Thermal Fatigue in S/L, ECCS, and RHR Lines Aging of Cast Stainless Steel (CF8M, CF8A..) Treatment of Radioactive Waste material: PWR removal Modification of Leak Detection System or Demonstration of Leak Detection Capability

! New plants
" Dynamic fracture Toughness for Carbon Steel Piping due to Seismic loads " Additional Leak detection system for Secondary sysems(MS, FW) " Aging and degradation of materials
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Impacts of LBB Application

! Safety Concerns
" Resolution of Unresolved Safety Issue(USI) A-2: Asymmetric Blowdown Load " Removal of Pipe Whip Restraint(PWR) " Increase of Safety Margin in Probabilistic Safety Analysis (PSA)

! Industrial Concerns
" Construction Cost Saving (~ 30M$/unit)
!

Reduction of design loads

" Decrease of Radiation Exposure to onsite workers " Decrease of Overhaul duration (~ 1 or 2 days) " Snubber reduction

Experiences in LBB Application

1. 2. 3. 4. 5. 6. 7. 8. Screening Criteria Leak Detection System Leak Rate Calculation Material Properties Loading Condition Crack Stability Evaluation Method ISI Program Snubber reduction Program

Experiences in LBB Application

! Screening Criteria
" Regulatory Position: It should be verified that the possibility of piping rupture due to water hammer, creep, erosion, corrosion, and fatigue(thermal and mechanical) is extremely low. Operational experiences and/or quantitative analysis may be used to verify it. " Actions Taken
! ! ! ! !

Thermal Stratification load is included as a design load. Thermal fatigue analysis was done on thermal cycling: No crack growth. Water hammer is included as a design load for MSL. Design modification is done to minimize valve leak off in SCS. Enhanced UT qualified by performance demonstration is performed for ECCS and RHR lines.

Experiences in LBB Application

! Leak Detection
" Regulatory Positions
! ! ! !

3 separated leak detection systems(LDS) are required. LDS capability(1 gpm within 1 hour) should be demonstrated during pre-operational test. Additional LDS is required for the secondary pipings (MS, FW) LBB because the radiation level is very low. Re-evaluation of current LDS is required for old NPPs.

" There is no special issue for KSRs LDS but some difficulties exist in old NPPs for demonstrating LDS capability.

! Leak Rate Calculation

" PICEP code was used for the calculation of leakage size crack but due to the uncertainties in leak rate calculation further research is needed.
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Experiences in LBB Application

! Material Properties
" Regulatory Position
!

For Korean Standard Reactors

# # #

Material properties should be determined using archive material. J-R curve should be available for base metal, weldment, and safe end. Dynamic strain aging should be accounted for. Material database could be used. Thermal aging of cast stainless steel should be considered.

For Old NPPs

# #

" Dynamic Fracture Toughness Test

! !

Test temperature: Operating temp.(288oC) and Room temp. Loading rate: LR = 4 x nf(#1) x Di
# #

Nf(#1): first mode natural frequency of piping system Di: load line displacement at crack initiation (Static test)

RCS: LR=2000 mm/min, MSL: LR=840mm/min.

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Experiences in LBB Application

Dynamic fracture Toughness

J-R Curve of RCS base metal

J-R Curve of RCS weldment

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Experiences in LBB Application

! Loading Conditions
" Loading condition used in LBB analysis
! !

Leak crack calculation: NOP load = DW + Pr. + Thermal load Crack stability Calculation: LBB Load = NOP + SPL + SSE
#

Special Load (SPL)

$ $

Surge line : thermal stratification load Main steam line : water(Steam) hammer load

The worst combination of material properties and stress should be used in crack stability analysis.

" The thermal stress based on heat-up design condition (T=300oF, P=2250 psi) exceeds ASME III allowable. The temperatures at hest-up were measured at Kori #4 in 1997 and determined to be T=105oF & P=357 psi).
!

Thermal load was reduced but CUF increased from 0.13 to 0.81.
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Experiences in LBB Application

! ISI Program
" ISI is performed in accordance with ASME Sec. XI 1989 ed. " Enhanced UT should be used for the inspection of following components regardless of LBB application:
! !

Piping subjected to thermal stratification and/or thermal fatigue Upper shell-to-transition cone girth weld of S/G

" Enhance UT is required for LBB application in the cast stainless steel piping for the inspection. % Enhance UT means: - qualified UT by performance demonstration for S/S - automatic UT for S/G transition cone

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Experiences in LBB Application

! Snubber Reduction Program
" Status
! ! !

Kori unit 2 : 2298 snubbers WH type reactor : ~ 500-600 snubbers/reactor KSR : 130 snubbers KSR (YGN 3, 4 & UCN 3, 4) Wolsung 2, 3, 4(CANDU) ~ 130 ~ 130 (from 300)

" Snubber reduction program from design stage

! !

" Snubber reduction program in operating plants

! !

Kori unit 1 & 2: 91 and 34 snubbers eliminated respectively. Other reactors are underway for snubber reduction.

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W2 Leak Event-LBB Experience

! Wolsung 2, CANDU type reactor in service from 1997, experienced a primary water leak March 3, 2001. ! Detection
" 14:00 March 3, 2001 3H activity increased from normal 1.5 to 4.4 DAC in A-side of Feeder Cabinet (F/C-A) " 24:00 March 4, 2001 3H activity increased to 79.4 DAC in F/C-A " 14:50 March 5, 2001 Reporting actions to be taken to regulatory body: plant shutdown in case of maintaining 300 DAC or reaching to 500 DAC " 12:00 March 7, 2001 Plant shutdown
12:30 Release the information of plant shutdown on the Internet ! 16:00 Press release by MOST (according to Information Release Guide) ! 16:10~16:30 1st inspection (hot survey) to identify leak location ! 17:20~17:50 2nd inspection (cold survey) to identify leak location
!

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W2 Leak Event- Leak Detection

3H

Activity in Reactor Building

0.10
R201 R501 R107 R108 F/C-A F/C-C W2(2001)

Population Exposure Dose

Limit is 1 mSv/yr from Notice of MOST 2001-2 W2(2001)

500

Population Exposure Dose (Sv)

3/6 02 3/6 18 3/7 14 --

400

0.08

H Activity (DAC)

300

0.06

200

0.04

100

0.02

0 3/4 06 3/5 10

0.00 3/3 3/4 3/5 3/6 3/7

Time (Day Hour)

Date

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W2 Leak Event- D2O Leak Rate

! D2O and 3H Leak Rate
800
Return (Coolant) Return (Moderator) Exhaust Total Leak W2(2001)

200
Noble Gas (Ci-MeV) 3 H (Ci) W2(2001)

Daily Gas Leak Rate through Stack

Daily Leak Rate (kg-D2O)

600

Limit is 0.45 kg/sec (38880 kg/day) for Unidentified Leak from Tech. Spec.

150

DRL( H) is 1.095E7 Ci/yr, Limit is 1%DRL (300 Ci/day) from Tech. Spec.

400

100

200

50

0 0 3/2 3/3 3/4 3/5 3/6 3/7 3/2 3/3 3/4 3/5 3/6 3/7 3/8

Date

Date

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W2 Leak Event- Inspection

! Inspection of various system piping and equipment ;
" Crack of the weld #W018, joining line 3335-4D-19 and the weldolet in Line 33312-20D-13 Heavy water leak Increase in tritium level in the A Side Feeder Cabinet

! Crack length = through-wall : ~16 mm ! PHT purification line

" Weldolet : SA105 " Return line elbow : 4 SCH80, B.W., SA234 WPB, Cl.1 " Return line pipe : 4 SCH80, SMLS, SA106 Gr.B, Cl.1

! Construction defect
" Weldolet-to-pipe mismatch: weldolet dia. Greater than pipe by 4.8mm " Defect in weld
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W2 Leak Event- Inspection

! PHT Purification Return Line

Leak location

19

W2 Leak Event- Weld Defect

Crack(16mm)

Cracked area of weld

Weld after repair

20

W2 Leak Event- Crack Shape(by NDE)

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W2 Leak Event- Repair and Test

! Replacement of the weld joint with a new weld and the pipe elbow in accordance with the ASME Section III, NB ! NDEs of the new weld joints
" MT, RT : after welding " MT, RT : 48 hours after welding for possible delayed cracking " UT : after leak test

! In-service leak check by visual examination of weld joints at the PHT system operating pressure (9.628 MPag) by ASME Code Case N-416-1 ! In-service inspection of similar welding points

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Lessons Learned from W2

! Criteria defined in the Technical Specification need to be flexibly applied to the operation. The inspector as well as operator must take a big credit not to the value itself but to the trend of it or rate of rise. ! Leak detection system must be well-maintained and proper actions should be taken in time for the possible abnormal increase of leak to prevent unstable pipe rupture. ! Leak-before-break is a good fracture mechanics concepts applicable to the design if the detection system is adequately installed, maintained, analyzed and evaluated. Coming events cast their shadows before !
!"#$
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