ML031110258

E-mail from R. Tregoing to Bxb, Regarding Davis Besse Results

ML031110258
Person / Time
Site:	Davis Besse
Issue date:	10/11/2002
From:	Robert Tregoning Office of Nuclear Regulatory Research
To:	Oak Ridge
References
FOIA/PA-2003-0018
Download: ML031110258 (34)

Text

Rober.Tregoning - Davis Besse Results Page 1 From:

Robert Tregoning / e5 To:

Bxb@ornl.gov; Nanstandrk~oml.gov Date:

10111/02 11:43AM

Subject:

Davis Besse Results Guys:

compression didn't help much, so I'm sending files separately (total 6.4Mb). Let me know if you have any problems receiving these files.

Rob Rob Tregoning United States Nuclear Regulatory Commission Mail Stop T10 El0 Two White Flint North 11545 Rockville Pike Rockville, MD 20852 Voice: 301-415-6657 Fax:

301-415-5074 E-mail: rlt~nrc.gov

E deannete Torres - Fwd. Davis Besse Results Page From:

Robert Tregoning /a To:

Jeannette Torres Date:

11/27/02 8:27AM

Subject:

Fwd: Davis Besse Results

,~~ 1Jeannette Torres - Davis Besse Results Pagie I 1annette Torres - Davis Resse Results Paae From:

Robert Tregoning /

To:

Bxb@oml.gov; Nanstandrk6ornl.gov Date:

10/11/02 11:43AM

Subject:

Davis Besse Results Guys:

compression didn't help much, so I'm sending files separately (total 6.4Mb). Let me know if you have any problems receiving these files.

Rob Rob Tregoning United States Nuclear Regulatory Commission Mail Stop T10 El0 Two White Flint North 11545 Rockville Pike Rockville, MD 20852 Voice: 301-415-6657 Fax:

301-415-5074 E-mail: rlt~nrc.gov

I Jeannette Torres - D-13 Sample Phase 3 Hesuts Sept 1 9.doc Pagew t Jeannette lorres - D-B Sample Phase 3 Flesults sept 1 9.doc Pacze Phase 3 Status Report, 9/19/02 1 of 22

Reference:

Phase 3, Rev 9/11/02 Davis-Besse Reactor Head Sample Characterization Phase 3 Status Report, 9/19/02 V Every Phase 3 status report supersedes the previous one. Please read the entire document.

V From this status update (9/12102), the descriptions of the test items or steps are deleted. Please refer to the latest Phase 3 revision on the top left comer, which will always be attached in the same email message with the update.

V Test plan(s) proposed will continue to be included in the status report. However, once the proposed test plan is finalized and approved by FENOC/NRC, it will be included in the revised Phase 3 test plan.

Step I.Nozzle 2 (Work has been completed)

(a)

Completed on 8/23/02; no obvious evidence of cracking observed. Photos were taken to document nozzle condition. Based on measurement, it was estimated that 5/8" was sectioned off the bottom of the nozzle during the removal at Davis-Besse site.

(b)

Decontamination was not necessary (c)

Performed - see (a) above.

Step 2.Nozzle 3 (a)

Completed on 8/21/02; photographs were taken to document condition of the nozzle. It was determined that 4-1/2" was sectioned off the bottom of the nozzle during removal.

(b)

Completed on 8/22/02.

(c)

Completed on 8/23/02; NOTE: Prior to sectioning, a PT exam was performed on the nozzle OD in the reduced area. No indications were found.

(d)

Completed on 8/28/02, see photo below.

GJeannette Iim-'-

-rre UI

.ap -hae Heslt set ~

.do a

B Jeannette ITorres - D-B 6arnple Phase 3 Riesults, Sept9 IUdoc

' Pace'c Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 2 of 22 Figure 2(d). 2.5" long ring cut from Nozzle 3. Top face (from the 3.5" cut) and Bottom Face (from the 1" cut). The 0, 90, 180, and 270° markings are approximate.

, [Jeannette Torres - D-B Sample Phase 3 Results Sept 19.doc Paae:

_..,@.-_.......................a

_...... ~

.w_.,..-

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 3 of 22

t Jeannette Torres - D-B Samp~le Phase 3 Results Sept 1 9.doc

. Panea I Jennete Trre

-B Smol Phae 3Reslts eot1 9.oc aoe Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 4 of 22 (e)

NRC and FENOC shipment authorization and ANL contact information received on 09/03/02. Shipment was received by ANL on 09/17/02. contact:

John R. McDade, (630)252-5168, Fax (630)252-7367, jmcdade@anl.gov (f)

Completed on 8/26/02; a patch of axial crack-like indications was observed on the lower end of the nozzle OD. The largest indication extended -0.5" axially and -1/8" into the nozzle wall. These indications were located on the uphill side of the nozzle (i.e., 180' or the side facing toward nozzle #1).

00 Figure 2(f). Viewing orientation: looking at the Nozzle 3 lower end face.

Proposed sectioning plan for 1" ring from end of nozzle #3 (Dated 09/03/02).

The majority of cracks will be sectioned out of the ring (cuts #R1-3). Also, after Cuts #R1-2, the I.D. surface of the nozzle segment will be examined under SEM. Cut #R4, which is parallel to Cut #3, will be made transverse through the cracks (red line) and the two mirror surfaces will be mounted. This will permit observation of the cracks in two directions with further progressive grinding.

Further testing of Nozzle 3 is currently on-hold, until the details of further sectioning and testing plan are finalized.

U' f eannette Torres - D-B Sample Phase 3 Results Sept 1 9.doc P__age !

Phase 3 Status Report, 9/19/02 5 of 22

Reference:

Phase 3, Rev 9/11/02 Step 3.Nozzle 3 Corrosion Area (a)

The first mold of the cavity was successfully performed with FENOC and NRC personnel concurrence on June 14, 2002. Complete on 06/14/02.

(b)

The second mold of cavity (intended as a backup) was successfully performed with FENOC and NRC concurrence on June 27, 2002. Complete on 06/27/02.

(c)

A mold of the stainless cladding from the underside (RCS side) of the cavity was successfully performed with FENOC and NRC personnel concurrence on June 27, 2002. Complete on 06/27/02.

(d)

Completed on 8/23/02. NOTE: Cut #2 impinged approximately 1/166" into the side of the cavity, resulted in a small hole /2 to 3/4" dia.) on the cavity side wall. This is a deviation from the planned cutting of 0.5" min. outside cavity walls. This was caused by deflection of the band saw blade. However, this is not expected to have any significant adverse impact on the investigation.

(e)

Completed on 8/23/02; no evidence of disbond noted between the stainless steel clad and low alloy steel. One small void measuring -1/8" in length was present near the nozzle #11 J-groove weld root. See photos below, before and after removing the PT dye and developer.

Figure 3(e). Ilof stainless steel cladding and low alloy steel interlace.

Jeanniette Torres - D-13 Sample Phase 3 Results Serpt 1 9.doc

'. P'ace f Jeannette Torres B Samrle Phase 3 Results Sect 1 9.doc Paoe

0,

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 6 of 22 (f)

Microhardness (Knoop 500gram) traverse on Block B completed on 9/6102.

See plot below.

350 300 E 250

!a 200

= 150 0.0

,~100 50 Stainless Steel Cladding 4 Low alloy steel 0

0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 Inch Figure 3(f). Microhardness traverse across stainless steel cladding and into low alloy steel

• The micrographs of low alloy steels and stainless steel cladding microstructures are documented in a separate Microsoft Word file, "Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding, Rev 9/11/02." This is to limit the status report file size (make it easy on email systems and computer ram).

• deannette Torres - D-B Sample Phase 3 Results Sept 1 9.doc Page Phase 3 Status Report, 9/19/02 7 of 22

Reference:

Phase 3, Rev 9/11/02 (g)

Cut #4 completed on 8/26/02 (see photo below); NRC and FENOC shipment authorization and ANL contact information received on 09/03/02. Shipment was received by ANL on 09/17/02, contact: John R. McDade, (630)252-5168, Fax (630)252-7367, jmcdade@anl.gov.

C7.Jeaneu orres

-U-b moi i'as t-eui

.eo 1_ ~.a P-r I jeannette I orres - D-ts tSamDe Pshase 3 FResults SieDI I UMdC Pane-U

Z7:- :

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 8 of 22 (i)

Completed on 8/28102; linear crack-like indication present on ID surface; circumferential cracking present on the J-groove weld's underside surface (RSC side, the same as stainless steel cladding surface); linear voids present in J-groove weld. See the following three photos.

Figure 3(i)-i. PT results for nozzle #3 J-groove weld. Orientation: looking at stainless steel clad surface (or underside, i.e., RCS side). 0° is downhill side facing the cavity, and 1800 is uphill side. A crack-like indication measuring -1.4" long was present at

-10 degrees on the J-groove weld bore (arrow). This crack was visible on the top of the J-groove weld and was aligned with the deepest portion of the cavity.

Circumferential cracking was observed on the J-groove weld's underside surface (same as stainless steel cladding surface). These circumferential cracks are located

-3/4" radially from the penetration bore and between 00 and 450 (higher magnification photos follow). Linearly aligned voids were also present on the J-groove weld bore

-0.3" below the top surface of the J-groove weld. These voids extended from 240 degrees to 30 degrees (through 0 degrees) and measured a maximum -0.1 " wide and

-1.4" in length. These voids likely formed during original welding.

• Jeannette Torres - D-B Sample Phase 3 Results Se t 1 9.doc Page!

. ~Jeanete Trre -

-BSampliekPhase 3 Results Sep1t 1 9.doc

__Page Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 9 of 22 Figure 3(i)-2. Circumferential cracking on the J -groove weld underside or RCS side (6X). The yellow spot at the top of the photo is a grid marking for the UT thickness measurement performed at the Davis-Besse site.

Figure 3(i)-i. Detail or circumferential cracking (4UA).

r

lJeannette Torres - D-B Sample Phase 3 Results Sept 1 9.doc Phase 3 Status Report, 9/19/02 10 of 22

Reference:

Phase 3, Rev 9/11/02 Additional Stereomicroscope Inspections of Nozzle 3 J-groove Weld Area (Performed between 09/06/02 - 09/09/02).

The PT performed did reveal one axial crack indication on the J-groove weld bore surface (180°) and some circumferential crack indications on the J-groove weld un-machined undersurface (0-45O) see above. However, the surface condition of the J-groove weld, especially the upper surface and the machined bore of the J-groove weld are not conducive to PT. Hence, it was decided to use the stereo microscope (up to X50) to completely scan the J-groove weld area. This led to the following new information to the PT indication, cracking indications not revealed by the PT, and cracking in the exposed stainless steel cladding top surface.

Figure 3(i)-4. Looking at J-groove weld underface (bored surface). Crack indication corresponds to axial crack (near 00) indication in Figure 3(i)-i.

.* V T

es t-D E-arnple Phse3 es Ls~epjpd Page 1 Phase 3 Status Report, 9/19/02 11 of 22

Reference:

Phase 3, Rev 9/11/02 Figure 3(i)-a. Looking from the J-groove weld upper lace (tme J-groove beads exposed due to the removal of low alloy steel by boric acid corrosion can be seen near the 0°).

Axial crack near 1800 indications (not revealed by PT). Also see Figure 2(f) of I" ring of Nozzle 3 axial cracking near 1800. These results suggest that axial cracking near 180° on the Nozzle 3 may be only through the nozzle wall within the length covered by J-groove weld (It is also possible for axial crack to be through the nozzle wall below the J-weld).

Jeanett Tores 0- Saple has 3 esuls Spt 9.dc Pae I Jeannette Torres - D-B Sample Phase 3 Results Sept 1 9.doc

'Pane 1.

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 12 of 22 Figure.1)-o, craCK indications in the upper stainless steel clad surface in the area or maximum upward deflection (also see Figure 3(f) below for orientation). These indications were mostly about 1.25" from the J-groove weld edge and do not appear to be associated with the circumferential cracking in the J-groove weld underface in Figure 3(i)-

1.

[eanttT rs- -- D-B mq~

aas 3 Reslt Atpj 1 9MS doc a ePage 1

Phase 3 Status Report, 9/19/02 13 of 22

Reference:

Phase 3, Rev 9/11/02 Figure 3(i)-7. Top view of the corrosion cavity after Cut #5. This lower part of Block A is designated "Block A2". The crack indications on the cladding surface, by coincident, are near the red dot (0,0) pointed by the arrow. The red dot (0, 0) was previously used for establishing the Cartesian coordinates for the exposed cladding thickness measurements shown in Figure 30).

Jeannette Torres - D-B Samrle Phase 3 Results Sept 19.doc Page1; Phase 3 Status Report, 9/19/02 14 of 22

Reference:

Phase 3, Rev 9/11/02 Figure 3(i)-8. Close-up of crack montage (scale, each photo is -1" from left to right side).

• ieannefteTorres-D-B Sample Phase 3 Results Sept 19.doc

___Fge

am le Phase 3Resls Let1 9.doc;

--- f
tg.
J-,

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 15 of 22 Figure 3(i)-9. Underside (RCS side) of the corrosion cavity. All the white dots were marked at the Davis-Besse site for UT thickness measurement. The two lines on the left are believe to indicate Nozzle 11, which is just outside the this photo on the left. The red circle superimposed on the photo indicates area of maximum deflection (bulging). This maximum bulging area is shown in the next two photos under higher magnification.

'I I Jeannette I orres - u-Ls Sample Phase 3 Hesults Seot 1 9.doc

• pni if

-C

-1' I.

x Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 16 of 22 Figure 3(i)-10. Underside (RCS side) of the corrosion cavity, area around maximum deflection (bulging). No indication of cracking is found on the underside with stereo microscope scanning.

I.anntt4oes-0-B Sample Phase 3 Rsults Sept I9

Page 1

- D-apePae3ResulLs~qptdo P_

age 1, Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 17 of 22 Figure 3(i)- 1,. Close-up of underside (KCS side) of the corrosion cavity, inside the maximum deflection 6X. No indication of cracking is found on the underside with stereo microscope scanning.

(j)

Cut #5 completed on 8/27/02; Stainless clad thickness measurement completed on 9/5/02.

The Figure below shows the cladding thickness measurements superimposed on the exposed stainless steel cladding contour taken from the cavity molding*. It should be noted that some portion of the exposed cladding along its edge is inaccessible for measurement due to the undercutting close to the bottom. The #5 cut did not remove all the overhang above the exposed cladding surface.

Average thickness of all 78 readings: 0.256" Minimum measured clad thickness: 0.202" Maximum measured clad thickness: 0.314"

• Note, the area of the exposed stainless steel cladding captured by the molding of the cavity was twice measured at BWXT. On the first occasion (817/02), the image analysis was performed on a photograph of the cavity molding and yielded 17.3 sq. inch. On the second occasion (8/9/02), the image analysis was performed on a grid paper which had

IeJeannette Torres - D-B Sampne Phase 3 Results Sept 1 9.doc Page 1E Phase 3 Status Report, 9/19/02 18 of 22

Reference:

Phase 3, Rev 9/11/02 traced the outline (the outline shown in Figure 3(j)-i) of the exposed cladding area captured by the molding. By preventing inaccuracy arising form a slight cladding curvature and/or perspective distortion in the photograph, the second method is considered to be slightly more accurate. The second measurement resulted in 16.5 sq.

inch of exposed cladding area.

0208 025

--__.270.

'0244 0290266 0.244 0

+20.25

+025225 4

0 0252

,42h7

'O'

+07'067+23+02=04

'0267 0268 0.264 00°1

+0256

+0 2

+025 +0242

-I0225

+0262

+027

+0258

+239 0277

+0.261

+0272 0263

+0236 0254 0238

+

+

+0+297 402 40259 402 0239 026 5

024 90° 024.0239 40299 40028 4027 40247 40235 0238 02470261

-- _0239 40246 0297 0314 0274 0233 40234 02309

,4O029 4

0278

+025

' 0259

'0245

' I ieanette Torres B Sample Phase 3 Resuls Sept 19.doc Page~ 1!

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 Figure 3(j)-l. Exposed stainless steel cladding thickness measurement.

19 of 22 Clad Thickness 0o 029 0.28 027 026 025 024 023 022 0.21 02

-3 X

2 Figure 3(j)-2. Color representation of the exposed stainless steel cladding thickness based on Figure 3(j)-l numbers.

Je-et ore a

3 s S I Jeannette Torres - D-B Samnple Phase 3 Results Sept 1 9.doc

• Pane N(

I L

1.

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 20 of 22 Clad Profile - Top Surface 4.21 y

-2 0.09 0.06 0.03 0.0

-0.03

-0.06

-0fl9

-0.12

-3 X

2 Figure 3(j)-3, Color representation of the elevation profile of the upper exposed cladding surface.

c riels-D-BSame Phase 3 Results Sept 19.doc Page 2 Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 21 of 22 Clad Profile - Bottom Surface 42 Y

-0.14

-0.16

-0.18

-02

-022

-0.24

-026

-028

-03

-032

-034

-3 x

Figure 3(j)-4, Color representation of the elevation profile of area on the lower cladding surface corresponding to the exposed cladding on the upper side.

I Jeannette Torres - D-B SamDle Phase 3 Results Seot 1 9.doc Pne 29c

. -UM!-:

Phase 3 Status Report, 9/19/02

Reference:

Phase 3, Rev 9/11/02 22 of 22 kness measurement. The two opposing dials are mechanicallly connected to ensure their identical X-Y positioning.

- Jeannette Torres - D-B Sample Phase 3 Results Sept 1 9.doc 9

-- tt jenei~ors-DBSqpqhs eut et

.o 7:

n 9

_:
=UZI.-__1 Phase 3 Status Report, 9/19/02 23 of 22

Reference:

Phase 3, Rev 9/11/02 (k) Approved, but not performed yet.

(1) Approved, but not performed yet.

(m)Approved, but not performed yet.

Beside the above items already approved, all other testing of samples originated from Nozzle 3 Corrosion Area is currently on-hold, until the details of further sectioning and testing plan are finalized.

-kafh e prrsPa Supplement 1 Microstructures.doc

-r~age Davis-Besse Head Sample Phase 3, Status Report, Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding, Rev 9/11/02

1. Low Alloy Steel From Block B Micrographs taken on 9/9/02 Figure 1-1, Macro photo showing three distinct weld zones in carbon steel adjacent to bond line after 2% nital etch, 6X.

1 of 7

'I IF=

g Jeannette I Orres - rinase ; ouppiement 1 Mlcrosxructures.aoc Pnnrc

_IIrz:tIf

Davis-Besse Head Sample Phase 3, Status Report, Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding, Rev 9/11/02 4

, "I;I:

t i'&, i
4CM tI C

! §1 r Figure 1-3, Higher magnification detail near bond line. 475X 2% nital 2 of 7

-Jeannette Torres - Phase 3 Supplement 1 Microstructures.doc Page

,.I.

.sa.

.uSU..

pL Davis-Besse Head Sample Phase 3, Status Report, Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding, Rev 9/11/02 Figure 1-4, Typical appearance of fine-grained weld zone lOOX 2% nital r

Is'

4 Figure 1-5, Higher magnification view of fine-grained zone. 475X 2% nital 3 of 7

EL;

-a

-d t

I Jeannette Torres - Phase 3 Supplement 1 Microstructures.doc

' Pace z I Jeannette lorres - Phase 3 Supplement 1 Microstructures.doc

'Paoe Davis-Besse Head Sample Phase 3, Status Report, Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding, Rev 9/11/02 Figure 1-6, Moving toward unaffected base metal; some banding and grain coarsening apparent. lOOX 2% nital 4 of 7

.Jeannette Torres - Phase 3 Supplement 1 Microstructures.doc l-'age jja-nIi;teTarres - Phase 3 Suppl~emet 1 icrostructures.doc Pnage !

Davis-Besse Head Sample Phase 3, Status Report, Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding,- Rev 9/11/02

2. Stainless Steel Cladding (From Block B)

Micrographs taken on 9/10/02 Figure 2-1, Typical cladding near bond line I OOX. Etchant: nitric, acetic, hydrochloric, and glycerin.

Figure 2-2, Cladding near bond line 475X. Etchant: nitric, acetic, hydrochloric, and glycerin.

5 of 7 I

I Jeannette i orres - Phase 3 Supplement 1 Microstructures.doc Parie E

tJeannettei orres - Phase 3 Supplement 1 Microstructures.doc Pane F Davis-Besse Head Sample Phase 3, Status Report, Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding, Rev 9/11/02 Figure 2-3, Typical cladding near the RCS side surface,IOOX. Etchant: nitric, acetic, hydrochloric, and glycerin.

Figure 2-4, Cladding near the RCS side surface, 475X. Etchant: nitric, acetic, hydrochloric, and glycerin.

6 of 7

-Jean'nette Torres - Phasep 3 SUDDIeMent I Microstnuctures.cloc Page.

hI-rntt ore

- Pi u~eet1M~~tutrsOcrce Davis-Besse Head Sample Phase 3, Status Report, Supplement 1, Microstructure of Low Alloy Steel and Stainless Steel Cladding, Rev 9/11/02 Figure 2-5, Cladding near the RCS side surfacel OOOX. Etchant: nitric, acetic, hydrochloric, and glycerin 7 of 7

Conference Room Scheduling Meeting Date: Wed Nov 27,2002 Start Time: 02:30 PM End Time: 04:00 PM Attendees: 5 Days Needed: 1 Room: T-10C1 Requester Last Name: Cullen Requester First Name: William Requester Phone: 415-6754 Reserved Last Name: Cullen Reserved First Name: William Meeting

Title:

Teleconference on CRDM Stresses