Application of Joint Boring Technique in Solving RCL Wall Thickness Problem

Abstract

Nuclear Power Project RCL (reactor coolant loop) is one of the most critical nuclear safety class 1 equipment in PWR nuclear power plant. Filled with borated water, the RCL is a closed loop and serves as pressure boundary incorporating the reactor pressure vessel, steam generator and reactor coolant pump. Since in-service inspection is required for welds of the RCL, the two sides of the welds shall be bored to meet UT (Ultrasonic Testing) inspection requirements. The design standard states that “if the weld is subject to service inspection, the length of the counterbore shall be 2Tmin (Tmin = minimum of wall thickness) for pipe and Tmin for components and fittings. Therefore, the minimal wall thickness of the boring area inside the RCL shall also meet design requirements. Examination of the RCLs delivered to the nuclear power project sites showed that the wall thickness of some parts of the RCL exceed tolerance in varying degrees (the wall thickness is too thin). The RCL borings need to be analyzed to mitigate the negative impact of insufficient wall thickness, maintain RCL wall thickness to the largest extent and meet design requirements. Under the condition of the jobsite data are idealized, this study analyzes the boring plans for the cold leg of loop B at the reactor vessel side for this nuclear power plant Unit 1 NI (Nuclear Island) and discusses the three methods of boring, namely, general boring, taper boring and eccentric boring. It finds that a combination of taper boring and eccentric boring is the optimal plan. This joint boring technique can help achieve the minimal boring wall thickness, reduce the grinding quantity and maintain the required wall thickness, thus resolving the out-of-tolerance issue. In addition, it meets the design requirements, the wall thickness and in-service inspection requirements. Supervision agency approved the application of the joint boring technique to the RCL for the projects. The RCL installation has proved to be a success.