ML023240512

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Part 2 of 2, FPL Energy, Seabrook Station, Root Cause Analysis for CR 02-08166 Evaluation of D Steam Generator Tube Cracking
ML023240512
Person / Time
Site: Seabrook NextEra Energy icon.png
Issue date: 11/08/2002
From: Ballinger R, Esselman T, Gold R, Legally H, Lieder R, Mcbrine W, Mcgee T, Mckrell T, White R
Altran Corp, Florida Power & Light Energy Seabrook, Massachusetts Institute of Technology (MIT), Westinghouse
To:
Document Control Desk, Office of Nuclear Reactor Regulation
References
CR 02-08166, NYN-02118 02807-TR-001, Rev 0, SG-SGDA-02-37, Rev 1
Download: ML023240512 (78)
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Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix A APPENDIX A Calculation of Solution Concentration for Modified Huey Test B- 51

I Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix A Calculation Sheet arlN ia.Caw-

-.t c a Na- _ _ _ _ TP-M -4By'-v42

_ _ kz Date,Y;/ýQ _ _ _ _ _ _

J- e z I' 111,1 3 .4 6

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A ;VO Z B- 52

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B APPENDIX B Bulk Chemical Analysis of Tube Materials Analytical Results B- 53

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B 14.44 V508 835 6262 MASS MATERIALS It001 07/03/02 A Subsidlwry of THE MMR GROUP, INC Massachusctts Matciials Reselaich, Inc.

P 0. BOX 810 . 1500 CENTURY ORIVE - WEST BOYLSTON, MA 01583 - TEL. 50 6354262 - FAX 508-35-D9025 Altran Corporation OATE: July 3, 2002 451 D Street Boston, MA 02210 PO. NO-* Mlla65 MMR NO.. 0262-26 ATTEN'ION. Tom McKreli1 MMR ID#:

PAGE#: 1 of 1 SAMPLEI IDENTIFICATION:

Inconel 600, Sample #02807-IA CFFEMISTRY (Subcontracted to CT Metallurgical)

Element Compositi2o V%)

Carbon .043 Manganese .20 Phosphorus <.010 suz far <. 001 Silicon .44 Chromium 15.30

ton 7.99 it anliun 25 Alumr-"num .14 Cobalt < 01 Copper 5.21 Nichcel 75.82 According to the above test results, this sample conforms to the chemical requirements of UNS NOSSOD, Inoo. 600.

The above test2ng was conducted in accordance with vN0R's Quality Control Manual, Revision 15A, Dated August 31, 2000 and your purchase order requirements.

This material is controlled under the United States Nuclear Regulatory Comemission Ruies and Regulations, Title 10, Chapter 1, Code of Federal Regulatione-Energy, Part #21.

MASSACHUSETTS MATERIALS RESEARCH, INC.

Rachel Gabriel Chemist Cheml:a3 a1"Iye PserformedbyIrdcbvey Coujpled Flasma/r pt el Emn-ssbioln Specrometer Carton, surlu, irtogen,hydrogen and ceygenp./tormedoyy LeeS Corro*sin,. MeOlanical " menhlurgeil testing Worrrned per MWIPnoedures The resu repoed zoo%,e lest app)y ojy to th~e sarnl:e~s) provded* t C=cur wIvbe e.ecteo free 0 &de',ge We beleve Sthascy. lest to beielable arN conrect. Inaecuracies or error&. Ihey

  • n0 ese.1 Ma Mal;a~ueaeettsMet~rnafs RlesemecSIn=.be IR~le t any I~ecal Coros teguaaror other cnMa~es Figure B- 1. Test Report for Seabrook Service Sample R5C62 B- 54

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B 07103102 14,14 '0508 035 6262 MASS )NATERIALS 1z002 A Subsmd~ary d"MMR THE GnOUP. INC Massaclhusetts F0 Matusials Rcsearch, Inc.

BOX 810 - 1SO0CENTURY DRIVE* WEST BOYLSTON. MA01503 *TEL 50-835-262

  • FAX 508-3S-9025 Altran Corporatior. DATE: July 3, 2002 451 D Street BOston, MA 02210 P. NO-, M11855 MMR N0- 0262-26 ATTENTION, Ton McKrell MUR 11# 2 PAGE V 1 of 1 SAMPLE 9DENTfj9ATLON Inconel 600, Sample #C2837-2A CHEMISTRY (Subcontracted to CT Meta1lurgical)

Element Colyosition (S)

Carbon .047 Manganese .20 Phosphorus <.010 Sulfur <.001 Silicon .44 Chromium 14.87 Iron 8.22 Titanium .22 Aluminum .12 Ccbalt .06 Copper .19 Nickel 75.62 According to the above test results, this sample conforms to the chemical requirements of UNS N06600. Inco. 600.

The above testing was conducted in accordance with ?07"'s Quality Control Manual, Revision 15A, Dated August 31, 200D and your 7urchase order reqairements.

Thus material is controlled under the United states Nuclear Regulatory Commnission Rules and Regulations, Title 10. Chapter 1, Code of Federal Regulations-Energy, Part #21.

M"CHUSETTS MATERIALS RESEARCH, INC.

Rachel Gabrie.

Chenist Coucled Pllmnoplcat E ,"eSlosoo ronotor Carbon surur. flroges.h hy*rogeaL Chamey anIalyam po'onol by ind.,de*y v.ndory* en rirton"eYd by .*oe Combu ston. Me met alur ,gca el a ndt lneu Ien ngp arfo rme dper MM 9Proceajrc "Ireresult reported aboe apply only e the lest samph(s) Dbrooded ad correct lnaccura , or errs Pity' occur, will be orre *edfree of CU-Se pzl='2 We beheve the Booe ltot to be rbae in ft. everrs1ial rjassactNJse Matenals Researn'.. Ine be I*o*e toa any $recal consequee*lor Mar dar0g9es Figure B- 2. ,Test Report for Seabrook Service Sample R9C63 B- 55

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B CMI !0002

.0_8/02 ON 13"39 FAX 1 860 528 1516 I

CMI A Subsdiary of THE MMR GROUP, INC ConnEcticut- Metallurgical, Inc. Fax 860-528-1516 100 PRESTIGE PARK - EAST HARTFORD. COWN. 06100 - 860-289-7481

  • LABORATORY REPORT Massachusetts Materials Research, Ic July 8, 2002 1500 Century Drive Cust. 4 West Boylston. MA 01583 CMI # 64350 Atm: Tom Baxter Page I of I Received: 2 Test Pieces Identified. Ref Quote #WD06288-2, PO #M1 1874 Material: Into. 600. Sample Nos. 02907-5A, 02807-7A Puxpose: Verification Tested to UNS N06600. in accordance vith Purchase Order Requirements:

Dispositon. In Spec

£bhmimtx SA 7A C.rnmp,./

Carbon 026 038 Manganese .16 19 Phosphorus <.010 <.010 Sulfur < 001 <001 Silicon 34 21 Chromium 1520 1472 Iron 9.56 7.22 Titanium .16 26 Alumnum 13 15 Cobalt <01 <01 Copper 37 .01 Nickel 74.05 7714 600)

Both these samples do conform to t he chemical requirements of UNS N06600, (Inco Note. Chemical analysis performed by IC? Method ZMETALLURGICAL, INC.

~S'e or ZM 0 Re1i8stes1ed.Th. reofmt shiO tboieodwuwveopt ** i We b.J..*

The zbovwresuft rWets o.1 y*tVje if they oc=-. weillI- cornered frie of G"SJ Xa theab*vo ato

  • bereliabloan dLM11 InmcawoJes or offor.

for my qp.i consflMtial w ol*her damages.

In no ev.ent shoo.Co.nectmt UMeoIgwcl. Ine,be l6W&e Figure B- 3. Test Report for Seabrook Archive Sample TY9402 9993 B9579B (designated as 5A above) and Heat 96845 Sample (designated as 7A above)

B- 56

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B A Subsidary of THE MMR GROUP, INC.

Massachusetts Matcvials Rcscarch,,1nc.

P 0 BOX 810 - 1500 CENTURY DRIVE *WEST BOYLSTON, MA 01583 *TEL. 508-835-6262 - FAX 508-835-9025 DATE: August 27, 2002 Altran Corporation 8C Fargo Street P.O. NO: M11970 Boston, MA 02210 MMRNO-: 0278-18 ATTENTION Tom McKrell MMR IDN. 1 PAGE #: 1 of 1 SAMPLEIDENTICA 02807-12 CIHEMISTRY Element Composition (%)

Carbon .043 Sulfur .002 The above testing was conducted in accordance with MMR's Quality Control Manual, Revision 15A, Dated August 31, 2000 and your purchase order requirements.

This material is controlled under the United States Nuclear Regulatory Commission Rules and Regulations, Title 10, Chapter 1, Code of Federal Regulations-Energy, Part #21.

MASSACHUSETTS MATERIALS RESEARCH, INC.

Chief Corporate Chemist Chemical analysis perlormed by Indictvely Coupled Plasmai'Optcal Emission Spectrometer Cattion sulfur nitrogen. hydrogen I and oxygen performed by Leco Combustion Mecharical and metaillurgscal testing pedormed per MMRProcedures t

The results reported above app y o*ly to the test sample(s) provided We believe the above test to be reliable and coned Inacouracies or errors d Itey occur willbe corrected free 01 charte In no event shall Massactluseis Materials FiesearCh Inc be liable for any special. consequeintal or other damages This repot sthat nrotbe reproduced except in full without written approval ol WIR Figure B- 4. Test Report for Seabrook Archive Heat 1456 Sample B- 57

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B A Subsidiety of THE MMR GROUP. INC Massachusetts Materials Rescarlch, Inc.

P0. BOX 810 - 1500 CENTURY DRIVE

  • WEST BOYLSTON, MA 01583
  • TEL. 508-836-6252
  • FAX 508-835-9025 Altran Corporation DATEZAugust 27, 2002 80 Fargo Street Boston, MA 02210 PO NO: M11970 MMRNO: 0278-18 ATTENTION: Tom McKrell MMR IDE: 2 PAGEI: 1 of 1 SAMPLE IDENTIRZCATION:

02807-13 CHEMI STRY Element Composition (W)

Carbon .022 Sulfur <.001 The above testing was conducted an accordance with MMR's Quality Control Manual, Revision 15A, Dated August 31, 2000 and your purchase order requirements.

This material is controlled under the United States Nuclear Regulatory Commission Rules and Regulations, Title 10, Chapter 1, Code of Federal Regulations-Energy, Part #221.

"MASSACHUS¶WMATERIALSYSEARCH, INC.

Vernon K. Loutu Chief Corporate Chemist Chemical analysis performed by Inductively Coupled Plassma'Optical Emission Spectrometer Carbon sulftw. nitrogen olydrogen and oxygen performed by Leco Co*nbustion Mechanical and meatllugrcal testing performed per MMR Procedures The results roported above apply only to the lest samples) provided We believe the above restto be reliable and corect Inaccuracies or errors,,l they Ocow willbe corrected free of charge In no eventshal Massachusetts Materials Research. Inc be liable for any spesial consequential or other damages This report shall not be reproduced except m fUin athout writen approval of MMR Figure B- 5. Test Report for Seabrook Archive Heat 1457 Sample B- 58

- j

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B A Subsidrary of THE MMR GROUP, INC Massachusetts Maicrials Rcscar.cl, Inc.

PO BOX 810

  • 1500 CENTURY DRIVE
  • WEST BOYLSTON, MA 01583 - TEL 508435-6262 - FAX 508-835-9025 Altran Corporation DATE August 27, 2002 80 Fargo Street Boston, MA 02210 PO NO. M11970 MMRNO.: 0278-18 ATTENTION Tom McKrell MMR IDS 3 PAGE # i of 1 SAMPLE IENT1FICATIMJ 02807-14 CHEMISTRY Element Comoosition (%)

Carbon .036 Sulfur <.001 The above testing was conducted in accordance with MMR's Quality Control Manual, Revision 15A, Dated August 31, 2000 and your purchase order requirements.

This material is controlled under the United States Nuclear Regulatory Commission Rules and Regulations, Title 10, Chapter 1, Code of Federal Regulations-Energy, Part #21.

MASSACHUSETTS . ThRIALS RESEARCH, INC Chief Corporate Chemist Chemical analysis performed by Inductvely CopAled Plasmaeoptical Enmssion Spectrometer Carbon suifur, nmrogen hydrogen and oxygen performed by Leco CombustiOn Mechanical and metal!urgical testing performed per MMR Procedures The results reported above apply only to the lest sample(s) provided We berreve the above test to be reieable and correct Inaccuracies orerrors it they occt, milbe cormecled tree of charge In no event shall Massachusetts M~atenats Research Inc be liable for any special, consequential or other damages This report shall not be reproduced except in tLI with"r written approval of MMFt Figure B- 6. Test Report for Seabrook Archive Heat 1374 Sample B1- 59

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix B I Wfr.ý.t ;,ALS II.4 I

"*47S

].v' I 31

70 Figure E- B. CMTR for Heat 1638, Received from Al McIlree of EPRI B- 60

Altran Corporation STechnical Report 02807-TR-001 Revision 0 Appendix C APPENDIX C Two-Step Etch Results I I B- 61

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C Figure C- 1. As Received Sample R5C62-Carbide Etch Figure C- 2. As Received Sample R5C62-Grain Boundary Etch B - 62

'S Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C Figure C- 3. Laboratory Thermally Treated Sample R5C62'- Carbide Etch Figure C- 4. -Laboratory Thermally Treated- Sample R5C62 - Grain Boundary Etch B- 63

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C

-J Figure C- 5. As Received Sample R9C63-Carbide Etch Figure C- 6. As Received Sample R9C63-Grain Boundary Etch B - 64

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C Figure C- 7. Laboratory Thermally Treated Sample R9C63-Carbide'Etch' Figure C-, 8. Laboratory ThermallyTreated Sample R9C63-Grain Boundary Etch B1- 65

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C t'* -

1

  • 4

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-i Kt '- 7 Figure C- 9. As Received High Temperature Mill Annealed Sample Heat 96485-Carbide Etch Figure C- 10. As Received High Temperature Mill Annealed Sample Heat 96485-Grain Boundary Etch B- 66

Altran Corporation Technical Repot 02807-TR-001 Revision 0

-Appendix C Figure C- 11. , Laboratory Solution Treated High Temperature Mill Annealed Sample Heat 96485-Carbide Etch 4

st t

'44' 4' 4 4- 4 'V

  • 44 4' '4
  • 4 a 4J

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A 4 4 <:p; 4 4 I ij SOjtrn '7""'4 *4 4 Figure C- 12. -- Laboratory Solution-, Treated High Temperature Mill Annealed Sample Heat 96485 7 Grain Boundary Etch;1 .- -H . - ,,

B- 67

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C Figure C- 13. Laboratory Thermally Treated High Temperature Mill Annealed Sample Heat 96485-Carbide Etch r-7 Figure C- 14. Laboratory Thermally Treated High Temperature Mill Annealed Sample Heat 96485-Grain Boundary Etch B- 68

Altran Corporation Technical Rep6'602807-TR-001 Revision 0 Appendix C Figure -C- 15. 'As Received Seabrook Archive Sample TY9402 9993 B9579B-Carbide Etch Figure C- 16. As Received Seabrook -Archive Sample TY9402 9993 B9579B-Grain Boundary Etch B- 69

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C Figure C- 17. Heat 1374 Seabrook Archive, Longitudinal Section-Carbide Etch Figure C- 18. Heat 1374 Seabrook Archive, Longitudinal Section-Grain Boundary Etch B - 70

TehiclAltran Corporation Technical Repo't'02807-TR-001 Revision 0 Appendix C I-~

~# +

Figure C- 19. Heat 1374 Seabrook Archive, Transverse Sebtion 1-Carbide Etch Figure C- 20. Heat 1374 Seabrook Archive, Transverse Section _1-Grain Boundary Etch B- 71

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C Figure C- 21. Heat 1374 Seabrook Archive, Transverse Section 2-Carbide Etch Figure C- 22. Heat 1374 Sdeabrook Archive, Transverse Section 2-Grain Boundary Etch B - 72

__j

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C C-aim Figure C- 23. 'Heat 1456 Seabrook Archive, Longitudinal' Section-Carbide Etch Figure C- 24. .Heat :1456, Seabrook Archive, Longitudinal Section-Grain Boundary Etch B - 73

Altran Corporation Technical Report 02807-TR-001 Revision 0 A pendix C N -7W

~~7 7 Figure C- 25. Heat 1456 Seabrook Archive, Transverse Section-Carbide Etch Figure C- 26. Heat 1456 Seabrook Archive, Transverse Section-Grain Boundary Etch B - 74

Altran Corporation Technical RepoWO28O7-TR-O91 Revision 0 AAA Appendix C A

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. AAA,.

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ft<t A A A.A. .  % 1AA *

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+/-'.. j/" AAA ft Figure C 27 Heat 1457 Seabrook Archive Longitudinal Section Carbide Etch Figure C- 28. Heat 1457 Seabrook 'Archive, Longitudinal Section-Grain Boundary Etch B- 75

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix C Figure C- 29. Heat 1457 Seabrook Archive, Transverse Section-Carbide Etch Figure C- 30. Heat 1457 Seabrook Archive, Transverse Section-Grain Boundary Etch B - 76

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix D APPENDIX D Residual Stress'Analysis Prepared by: Thomas Service, Ph.D., P.E.

Checked by: Jose Magalhaes, Ph.D.

B- 77

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix D RESIDUAL STRESS ANALYSIS Bending Stress-Diameter Change Relationship A relationship was given in Reference 17 but no derivation of the relationship was provided and using the relationship on the experimental data from the Seabrook tubes resulted in unrealistic residual stresses. Therefore, the following is a derivation for the deflection of a split ring subject to a point load that can be used to estimate the resulting stress state, Reference 18.

Consider a thin split ring shown in Figure C-i with mean radius, R, thickness, h, and width b subject to a vertical load P at the slit opening. This load results in a bending moment, M, at any location B and is given by the expression:

M = PR(cos(cL)-cos(e)) (1) d B where ot and 0 are as shown in Figure 1. For a A small slit (x= 0 and the maximum moment occurs P_ at 0 = 1800 and the corresponding bending stress C( cy at that location is given by:

P6 P R (1+ cos(a))

D bh 2 12PR (2) bh 2 Ring Figure D-1. Split Through the use of Castigliano's theorem and the principle of virtual work the displacement, Y, at the slit opening can be shown to be (Reference 18):

S3tR 2 (T 37rl2PR 3 Eh Ebh 3 (3) where E is the elastic modulus. Similarly, it can be shown that the displacement at the ring diameter, d, is given by Yd:

B- 78

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix D d (7t+4)R 2' 6(7c+4)PR 3 2Eh Ebh 3 (4)

Therefore, given Eq. (4) the maximum bending stress 1800 from the split is given by:

2YdEh

((TI + 4) R25 where Yd is the diameter displacement after the split is made. Finally, from Eq.

(1) the bending stress at 900 from the split is 1/1/2 that at 1800 from the split giving:

YdEh (7 4) R(6)

Assuming an elastic modulus, E, for Inconel 600 to be 31.1.x10 6 psi Eq. (6) can be simplified to:

4 .3 5 5 x106Ydh R2 (7)

This approximates the stress at the location of the applied strain gauges on the split steam generator tubes. The stresses act in the hoop direction and vary with the bending moment around the ring.

Finite Element Analysis Technique A more realistic assumption of the stress state in a split ring with residual stresses would be to assume a bending moment applied to the split end rather than a vertical applied load. Finite-Element Analysis (FEA)'models were created for both size tubes. The models consisted of 1/2 /symmetry 2-dimension models.

Linear elastic material properties were assumed. A bending moment (a one pound load applied to the ID in the negative vertical direction and to the OD in the positive vertical direction) was applied to the free end of the tube and symmetry displacement conditions were applied to the other end. This results in a outward radial displacement corresponding to an increase in diameter. A moment in the opposite direction will result in a corresponding decrease in diameter. This also results in a uniform bending stress through the wall thickness of the tube.

Assuming linear elastic behavior the outward radial displacement can be scaled up B- 79

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix D to equal the measured increase in diameter and the resulting stresses can be scaled in proportion.

Figure C-2 shows the FEA element model and the input files are attached. The nomenclature in the figure refers to the geometry parameters used in the model -j generation. Figures C-3 and C-4 show the radial displacement plot and the hoop stress plot for the 11/16" diameter tube model.

I AN TH OD SPLIT TUBE 11/16" DIA Figure D-2. FEA Element Model B- 80

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix D L ANSYS 5.6 SEP 11 2002 16:25:34 NODAL SOLUTION STEP-1 SUB -I TIME-i UY (AVG)

PSYS-1 PowerGraphics EFACET-1 AVRES-Mat DMX -. 984E-04 SMN --. 355E-06 SMY -. 844E-04 1'

F

-. 355E-06

.906E-05

.185E-04

.279E-04

.373E-04

.467E-04

.561E-04

.656E-04

.750E-04

.844E-04 SPLIT TUBE 11/16" DIA Figure D-3. Radial Displacement Plot for 11/16" Diameter Tube.

ANSYS 5.6 SEP 11 2002 16:26:43 NODAL SOLUTION STEP-I SUB -1 TIME-i SY (AVG)

RSYS-I PowerGraphics EFACET-1 AVRES-Mat DMX -. 957E-04 SM -- 143.833 SMX -156.575

-143

-11D.454833

-77.076

  • -43.697

_10.318 23.06 56.439 F-189.817 I*12i.196 C-X 156.575 SPLIT TUBE 11/16" DIA Figure D-4. Hoop Stress Contour Plot for 11/16" Diameter Tube.

The results of these analyses show that for a unit bending moment applied to the free end of the slit tube there is a radial displacement of 0.844x10 4 inches with an OD hoop stress of 144 psi for the 11/16" diameter tube and a radial displacement B- 81

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix D of 0.876x10-' inches with a corresponding OD hoop stress of 115 psi for the 7/8" diameter tube. These results can be used to scale the displacement and resulting OD hoop stresses to the observed diameter changes through the relationships:

S= 1.706x10 6 Yd forll/16" (8)

T = 1.313x10 6 Yd for 7 / 8" The following are the FEA input files used for the 11/16" diameter and 7/8" diameter analyses.

11/1 6" Diameter Tube

/BATCH

/COM,ANSYS RELEASE 5.7

/PREP7

/TITLE, SPLIT TUBE 11/16" DIA ET,1,PLANE42 !PLANE42 MPEX,1,31.1E6 !INCONEL 600 MP,NUXY,1,.327 OD=11/16 I DEFINE DIMENSIONS (INCHES)

TH=0.04 K,1,0,0 'DEFINE KEYPOINTS I

CIRCLE,1,OD/2,,,180 DEFINE LINES CIRCLE,1,(od/2)-TH,,,180 LSTR,2,5 LSTR,3,6 LSTR,4,7

!DEFINE AREAS AL,1,6,3,5 AL,2,7,4,6

'MESH AREAS MSHKEY,1 ESIZE,0.01 AMESH,1,2

/SOLU ANTYPE,STATIC  ! STATIC ANALYSIS DL,7,,SYMM DK,7,,,,0,UX FK,2,FY,1 FK,5,FY,-1 SOLVE !SOLVE FINISH

/POST1 SET,LAST PLDISP,1 ESEL,U,,,1 ESEL,U.,,2 ESEL,U,,,55 B- 82

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix D ESELU,,,56 ESEL,U,,,109 ESEL,U,,,1 10 ESEL,U,,,163 ESEL,U,,,164 RSYS,1 PLNSOL,S,Y,0,1 ALLSEL PLNSOL,U,Y,0,1 FINISH SAVE

/EXIT 7/8" Diameter Tube

/BATCH ICOM,ANSYS RELEASE 5.7 IPREP7

/TITLE, SPLIT TUBE 7/8" DIA ET,1 ,PLANE42 1PLANE42 MP,EX,1,31.1E6 !INCONEL 600 MP,NUXY,1,.327 OD=7/8  ! DEFINE DIMENSIONS (INCHES)

TH=0.05 K,1,0,0 DEFINE KEYPOINTS CIRCLE,1 ,OD12,,,180 DEFINE LINES CIRCLE,1,(od/2)-TH,,,180 LSTR,2,5 LSTR,3,6 LSTR,4,7 I !DEFINE AREAS AL,1,6,3,5 AL,2,7,4,6

!MESH AREAS MSHKEY,1 ESIZE,0.01 AMESH,1,2 ISOLU ANTYPE,STATIC 1STATIC ANALYSIS DL,7,,SYMM DK,7,,,,0,UX FK,2,FY,1 FK,5,FY,-1 SOLVE  ! SOLVE FINISH

/POST1 SET,LAST PLDISP,1 RSYS,1 PLNSOL,S,Y,0,1 ALLSEL PLNSOL,U,Y,0,1 FINISH SAVE B- 83

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E APPENDIX E XPS Analysis of Deposit Collected from Cracked Tube Sample B- 84

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Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E A.dkmt I~m.hslwAnuCrT.U)1 t&l t1fl~l3SStt *191W Wwr~, *WWI 7 IWO&

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Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E Momin wwwt A &M 1+1"1 3.. ~ ~ ~18W.~~Mk~~ "XVX OJVu t . i P b,. Ws'w* .. . ....

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B- 86

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Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E MUM IA"'V mU ~~~~~

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,Figure E- 3. Spectrumn at Position B- 87

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E A.*u~I C.AA)=Id~d~tTAUb "da~w L MAN8

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B- 89

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Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E i, lm-an.ait o

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Figure E- 7. Spectrum for Position 4 Prior to Sputtering B- 91

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E A.OeUtM I Xneaw" Nmt ,%e aum ul3

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I r r r r Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E Figure E- 9. Spectrum at Position 4 After Sputtering 30 Sec.

B- 93

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix E The examination of samples using XPS was performed under contract by Analytical Answers and was witnessed by Altran's Ockert Van Der Schiff. These results are considered to be non safety related, because the vendor was not included on Altran's approved vendor list for Nuclear Grade Services. However, the instrument was calibrated and Analytical Answers maintains a documented calibration program. Since the results of this report do not directly qualify a design basis but rather offer insight to probable root cause, the use of this examination is appropriate.

B- 95

Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix F APPENDIX F GC/MS And EDS Analysis of Tectyl 506G Preservative B- 96

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Operator [BSBI]jh Acquired 2 Aug 102 2.22 pm using AcqMetbOd cOATXN5.1 Instrument 5971 - In Saw.ple Vamp, Techtyl S06G grease Misc Info  : 50-320 l/mln.

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Altran Corporation Technical Report 02807-TR-001 Revision 0 Appendix G APPENDIX G References 1-8 and 15 B -106

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,1

SG-SGDA-02-37,Rev 1 Appendix C Appendix C Summary of EC Signature of Degraded Tubes I

I 'C C- I

SG-SGDA-02-37,Rev 1 Appendix C Summary of EC Signature of Degraded Tubes

1. The low frequency (150 kHz-absolute) EC channel is sensitive to structures adjacent to the tubes, OD flaws and deposits, and to the conductivity of the tube material.
2. The conductivity of the tube material changes when the material is strained, e.g., for bending the u-bends; thus, it can be used to identify relative material condition. This technique was previously utilized to discriminate between thermally treated and non-thermally treated tubing at San Onofre in 1985.
3. The capability of the bobbin to detect a the difference between a strained and stress relieved section can be demonstrated by examining the normal trace for a tube that was thermally treated prior to bending the u-bend compared to a similar trace for a tube that was mill annealed, straightened and polished prior to bending the u-bend (see following figure). For the thermally treated tube (a), the tube is initially stress-free prior to bending the u-bends, and the bending process strains the u-bend region only. The EC signal is clearly offset in the U-bend region. For the Mill Annealed tube, the entire tube is initially strained due to the bending and polishing processes. Bending the u-bend strains the U-bend region, but not in an additive manner.

The EC trace for the mill annealed tube (b) does not exhibit the offset in the U-bend region that the thermally treated tube exhibits since the entire length of the tube is strained. The key point is that the EC signal can discriminate between relative levels of strain along the length of a tube.

4. The EC signal (c) for a small radius (< row 11) thermally treated and stress relieved U-bend is essentially flat without exhibiting the u-bend offset. The manufacturing process renders the entire tube essentially stress free. A thermally treated tube is bent into a U-bend, and then the u-bend only is stress relieved after bending. Consequently, the straight legs remain stress free, and the u-bend is made stress free by the stress relief process. Since there is no significant difference in the material condition between the straight legs and the u-bend, the EC signal remains essentially flat from end to end. The beginning and end of the stress relief heated zone is identified by the two bumps at about the 1/3 distance points along the trace.
5. The Seabrook pulled tubes were shown by testing to exhibit significant residual stress along essentially the entire length of the pulled tube section (about 200 inches from the top of the tubesheet).

C- 2 iI

SG-SGDA-02-37,Rev I Appendix C If it is assumed that a tube with elevated residual stress is bent init0 a u-bend and then'stress relieved as noted aboVe, on*l the u-bend Would be in an essentially stress-'free state. Thus, the condition of this low row tube'would be opposite of the normal state of a longer row tube, for which the stress state of the material is higher in the u-bend Therefore, it would be expected that the EC signal, which discriminates between relative states of the materiAl, should exhibit the opposite effect of the nornni long row tube. The EC trace for such a short-row if-bend (d) conifirms this ihypothesis. Compare figure (d) with figure (a).

6. All 15 of the degraded Seabrook tubes exhibit the signal characteristic of figure (d). In addition,-4 other tibes in SG-D Withouit degradation also exhibit this characteristic. None of the tubes in any of the other three SGs exhibit this characteristic. None of the tubes in eight other SGs in two other Model F plants exhibit this characteristic.

C- 3

SG-SGDA-02-37,Rev 1 I

(a) (b) (c) (d)

(a) Normal 150 kHz Eddy Current strip chart for a Row >10 thermally treated tube (b) Normal 150 kHz Eddy Current strip chart for a Row >10 mill annealed tube (c) Normal 150 kHz Eddy Current strip chart for a Row <10 thermally treated tube (d) Seabrook degraded tube, 150 kHz Eddy Current strip chart for a Row <10 thermally treated tube C- 4

SG-SGDA-02-37,Rev 1 Appendix D Appendix D Root Cause Hypotheses THIS PAGE INTENTIONALLY BLANK

(&Westinghouse Westinghouse Electric Company Nuclear Services Waltz Mill Service Center P.O. BOX 158 Madison, Pennsylvania 15663 USA FPL Energy - Seabrook Sation Direct tel: 724-722-5082 P.O. Box 300 Direct fax: 724-722-5889 Seabrook, NH 03874 e-mail: lagallhoO~westinghouse corn Your ref:

Attention: Mr. Robert White Our ref: LTR-SGDA-02-361 Date November 6,2002

Subject:

Errata for SG-SGDA-02-37, Revision 1; "Seabrook Tube Cracking Root Cause Evaluation Report" The following is an errata summary for the subject report.

I. On page 22, under Hardness Testing, the reference to tube R5C63 should be R5C62 in two places.

2. On page 23, second paragraph, the reference to R5C63 should be R5C62.
3. On page 23, second paragraph, the sentence "Destructive examination showed a 0.2-inch long by 50% TWD crack on one ... " should read "Destructive examination showed a 0.139-inch long by 35.6% TWD crack on one
4. On page 40, Table 4.1, the reference to heat no, "NX1460" should be "NX0146".

H.O. Lagally EDRE/SGD&A Electronically Approved in Documentum A BNFL Group company

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