ML081550279

WCAP-16845-NP, Revision 0, Browns Ferry Nuclear Plant Unit 2, Evaluation of Dissimilar Metal Weld Indication at Weld RCRD-2-52.

ML081550279
Person / Time
Site:	Browns Ferry
Issue date:	02/29/2008
From:	Conermann J, Junker W, Ottinger B, Rao G Westinghouse
To:	Office of Nuclear Reactor Regulation
References
WCAP-16845-NP, Rev 0
Download: ML081550279 (82)

Text

ENCLOSURE I TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)

UNIT 2 EVALUATION OF DISSIMILAR METAL WELD INDICATION AT WELD RCRD-2-52 (SEE ATTACHED)

Westinghouse Non-Proprietary Class 3 WCAP-16845-NP .February-20( 38 Revision 0 Metallurgical Investigation of Recorded Indications at the Check Valve to Pipe Dissimilar Metal Weld at Browns Ferry Unit 2 Nuclear Generating Station Westinghouse

WESTINGHOUSE NON-PROPRIETARY CLASS 3 WCAP-16845-NP Revision 0 Original Publication Proprietary Class 2: August 2007 Reclassified as Non-Proprietary Class 3: February 2008 Metallurgical Investigation of Recorded Indications at the Check Valve to Pipe Dissimilar Metal Weld at Browns Ferry Unit 2 Nuclear Generating Station Gutti Rao Joyce Conermann Warren Junker Brian Ottinger Materials Center of Excellence February 2008 Reviewer: Lance Harbison*

MCOE Approved: Michael A. Burke*, Manager Materials Center of Excellence

• Electronically approved records are authenticated in the electronic document management system.

Westinghouse Electric Company LLC P.O. Box 355 Pittsburgh, PA 15230-0355

© 2007,2008 Westinghouse Electric Company LLC All Rights Reserved WCAP-16845-NP.doc-021108

iv ACKNOWLEDGEMENTS The authors wish to acknowledge Stephen C. Willard of TVA for helpful discussions and for the prompt support in providing TVA records for review. The support provided by Robert Rees of Westinghouse Electric Company in conducting the SEM work is appreciated.

February 2008 WCAP-16845-NP WCAP-16845-NP February 2008 Revision 0

V TABLE OF CONTENTS LIST O F TA BLES ........................................................................................................................ ............ vi-LIST OF FIGU R ES ..................................................................................................................................... vii 1 IN TR OD U C TIO N ............................................................................................................................ 1 2 EXAMINATIONS AND TESTS ......................................................................................................

2.1 SURFACE EXAMINATIONS ........... .................. .................... 1 2.2 NDE EXAMINATIONS ..................................................................................................... 2 2.3 SECTIONING PLAN ................................. I................................................................. 2 2.4 METALLOGRAPHIC EXAMINATIONS ................................................................... 2 2.5 FRACTOGRAPHIC EXAMINATIONS ....................................................................... 2 2.6 CHEMISTRY ASSESSMENTS ................................................. 2 2.7 MICRO HARDNESS MEASUREMENTS ................................................................... 3 2.8 REVIEW OF TVA'S WELDING AND UT INSPECTION PROCEDURES ................ 3 2.9 MECHANISTIC AND ROOT CAUSE CONSIDERATIONS ....................................... 3 3 RESULTS AND DISCUSSION ................................................................................................ 3 4

SUMMARY

AND CONCLUSIONS ........................................................................................... 5 ATTACHMENT A NDE EXAMINATIONS .................................................................................... 42 ATTACHMENT B MATERIAL PROCUREMENT, WELD FABRICATION AND INSPECTION RECO RDS......................................................................................................... 47 WCAP-16845-NP .February 2008 Revision 0

vi LIST OF TABLES Table 1 Chemistry Analysis Results of Carbon Steel Pipe, Stainless Steel Valve and the W eld Filler M aterials ......................................................................................... 7 Table 2 Vickers Hardness Traces Across Weld- Low Alloy Steel Interface, Piece A3B ............. 8 February 2008 WCAP-16845-NP February 2008 Revision 0

vii LIST OF FIGURES Figure 1 Schematic Representation of the Geometry of As-received Sample Showing the Location of Suspected Field Indication .................... ........................................................... 9 Figure 2 Side Views Showing the OD Surface Condition of the As-received Sample ..................... 10 Figure 3 Side Views Showing the OD Surface Condition of the As-received Sample - Punch Marks at O'Clock Location of Value Body can be Seen .......................................................... 11 Figure 4 Appearance of the ID Surface Condition of the Weld in the As-received Sample ............. 12 Figure 5 ID Surface Condition of the Weld in the As-received Sample - The Caliper Points to the Region Corresponding to 4 to 6 o'clock Location where Suspected UT Indication was Reported by Site Personnel ............................................................................................... 13 Figure 6 ID Surface Appearance of the Weld at the Carbon Steel Interface - Note the Presence of Pitting in the Carbon Steel at the Weld Heat Affected Zone ........................................... 14 Figure 7 Image of the Inside Surface of the90°-120° Segment .......................... 15 Figure 8 Digitized Radiograph of the Section of Pipe-Valve Weld Assembly Corresponding to the Indications Found in the Field Ultrasonic Examination - Note the radiograph was taken with the id of the assembly against the film. The arrows show the locations of the radiographic indications ....................................................................................................... 16 Figure 9 Enhancement of the X-ray Radiographs in the Vicinity of the weld - Upper image is from the image in Figure 8 while the lower is for a radiograph taken with the II of the component away from the film. The arrows show the location of the radiographic indications .............................................................................................................................. 17 Figure 10 Fluorescent Dye Penetrant Examination Results of the ID Surface of the Pipe to Valve W eld Sample ............................................................................................................................ 18 Figure 11 Schematic Representation of Pipe to Valve Weld Sample Illustrating the Orientation of Initial Axial Cuts and Sample Identifications (Looking from the Value Body into the Pipe). 19 Figure 12 Schematic Representation of Sectioning Procedure Employed in Securing Test Samples for Various Examinations and Tests ...................................................................... 20 Figure 13 Appearance of 2700 Axial Cut Face Revealing the Presence of 80% Through Wall Crack (B2A Segm ent) ............................................................................................. 21 Figure 14 Metallography Results in the As-polished Condition of Axial Section at 2700 Orientation Showing the Deepest Crack at the Carbon Steel Interface ................................................ 22 Figure 15 Metallography Results in the As-polished Condition of 270' Section Illustrating the Morphology of Crack in the Weld Metal (Specimen B2A) ....................... 23 Figure 16 Metallography Results in the As-polished Condition of Axial Section at 270' Illustrating the Cracking Morphology in the Weld Metal (Specimen B 1A) .......................................... 24 Figure 17 Morphology of Crack at 2700 Orientation (Specimen B2A Polished and Etched Condition) ....................................... ........................ ........... .......... ............ 25 WCAP-16845-NP February 2008 Revision 0

viii LIST OF FIGURES (cont.)

Figure 18 Morphology of Crack at 2700 Orientation (Specimen B2A Polished and Etched C ondition) .................................................................................................................... 26 Figure 19 Morphology of Crack at 2700 Orientation (Specimen B2A Polished and Etched C ondition) .................................................................................................................... 27 Figure 20 Morphology of the Crack-tip of the Deepest Crack seen at 2700 (Specimen B2A Polished and Etched Condition) .............................................................. 28 Figure 21 A3B Mount Showing the Section at 180°Orientation - Showing in the a) As-polished and b) Polished and Etched Conditions ........................................................................... 29 Figure 22 Metallography Results of an Axial Section through the Indication at the 1800 Orientation Shown in the "As-Polished" Condition (Piece A3B) ........................... 30 Figure 23 Metallography Results Shown in the 'Polished and Etched' Condition of the Crack at 1800 Orientation ................................................................................................................... 31 Figure 24 Morphology of Crack in the Carbon Steel Side, on 90' Section (Specimen A2A Polished and Etched Condition) .............................................................. 32 Figure 25 Metallography Results Illustrating the Typical Microstructures of the Carbon Steel and W eld Metal in Sample A3B ......................................................................................... 33 Figure 26 Sectioning Procedure Illustrating the Opening of the Crack at 2700 o'clock Orientation ....... 34 Figure 27 Lower Magnification SEM Fractograph of Freshly Opened Crack at 2700 Orientation -

Showing the Carbon Steel Face with Islands of Weld Metal .............................................. 35 Figure 28 Scanning Electron Fractograph of the Freshly Opened Crack at 2700 Location -

Delaminated Carbon Steel Interface and Islands of Weld Metal can be Seen .................... 36 Figure 29 SEM Fractographof 2700 Crack Illustrating the Appearance of Carbon Steel Surface and Weld Metal Islands at the Interface ............................................................................. 37 Figure 30 SEM Fractograph of 2700 Crack Showing Weld Metal and Iron Oxide Regions on the Fracture Face ........................................................................................................................... 38 Figure 31 EDS Spectrums Illustrating the Weld Metal and Iron Oxide Regions on the Fracture Face .......................................................................... I................................................ 39 Figure 32 EDS Spectrums Illustrating the a) Weld Metal and b) Iron Oxide Regions on the Fracture Face ........................ ................................................................................................

I 40 Figure 33 Piece A3B, Weld Mount Prepared for Microhardness Measurements ................ 41 WCAP-16845-NP February 2008 Revision 0

1 INTRODUCTION This document summarizes the evaluations and the results of a metallurgical investigation of the recorded ultrasonic (UT) indications at the check valve to pipe dissimilar metal weld joint (No. RCRD-2-52) at Browns Ferry Unit 2 nuclear generating station. The indications were recorded during the 2007 spring outage inspection while conducting a manual UT of the weld (Reference 1). The inspection was being performed as part of the implementation process of TVA's Risk Informed ISI Program. The affected weld joint consisted of a 4 inch diameter schedule 80 ASME SA 333 GR 6 carbon steel pipe joined to ASME SA 182 GR F316 austenitic stainless steel valve body, joined by ER 309 stainless steel filler metal.

An approximately 4.5 inch long ring section consisting of 2.5 inches of carbon steel pipe joined to a 1.5 inches of stainless steel valve body by a 0.5 inches of crown weld was shipped to Westinghouse hot cell facilities for investigation. A view of the as-received pipe weld sample is illustrated in Figure 1(a).

The piping was reportedly procured initially as schedule 160 and was counter bored at the weld joint to an approximate schedule 80 wall thickness. It was also reported that the recorded indication was positioned the between 3 and 4 o'clock (900 and 1200) locations from the punch marked Top Dead Center (TDC),

looking into the valve from the pipe end. The location of the punch mark and the suspected location of the field indication are illustrated in Figure l(b).

The Westinghouse investigation included the following major tasks:

• Surface Examinations

• NDE Examinations 0 Sectioning Plan

• Metallographic Examinations

• Fractographic Examinations

• Chemistry Assessments

• Hardness Measurements

• Review of pipe welding and UT inspection procedures

• Mechanistic and Root Cause Considerations The overall purpose of the investigation is to establish the cause and mechanism of occurrence of indications/cracking in the pipe weld and further to develop information that would be helpful in mitigating the potential for similar occurrence at Browns Ferry.

2 EXAMINATIONS AND TESTS The following describes the examinations and tests conducted on the 4.5 inch long pipe section containing the pipe to valve weld received from TVA.

2.1 SURFACE EXAMINATIONS The as-received surface condition of the ring sample containing the weld was examined visually and by light optical microscopy for evidence of cracking, surface attack, deposits, corrosion or any other surface distress. The examinations were conducted both on the outside diameter (OD) and inside diameter (ID)

WCAP-16845-NP February 2008 Revision 0

2 surfaces. The results of the surface examinations were documented by photographic recordings. The results are illustrated in Figures 2 through 6. The results are discussed in Section 3.

2.2 NDE EXAMINATIONS Non destructive examinations (NDE) were conducted on the as-received weld sample to confirm the field reported indication as well as to identify the presence any additional indications. Initial NDE efforts were focused on identifying the reported indication by light optical microscopy and dye penetrant tests. When the effort failed to confirm the field findings, Westinghouse embarked on a detailed NDE examination procedure on the entire weld sample by employing light optical microscopy (LOM), Radiographic testing (RT), and fluorescent dye penetrant testing (PT) examination techniques. A detailed description of the NDE procedures and results is summarized in the Attachment 'A' of the report. The results of the NDE examinations are illustrated in Figures 7 through 10. Westinghouse also reviewed the site UT examination procedures. A discussion of the procedures and the results is included in the appendix.

2.3 SECTIONING PLAN Based on the results of the NDE examinations and the suspected locations of the indications, a sectioning plan was developed for destructive examination of the weld sample. The sectioning plan provided test samples employed in various examinations and tests conducted under the scope of the current investigation. The sectioning plan is illustrated in Figures 11 and 12.

2.4 METALLOGRAPHIC EXAMINATIONS Metallographic Examinations were conducted by light optical microscopy on axial sections transverse to the pipe weld. The sections were positioned to go through major weld indications recorded during the laboratory NDE examination. The metallographic examinations were conducted both in the 'as-polished' and in the 'polished and etched' conditions, to establish depth and distribution of cracking, crack initiation sites, crack propagation directions, the base metal and weld microstructures, the cracking morphology and its relation to thelocal microstructure. The results of the metallographic examinations are illustrated in Figures 13 through 25. The results are discussed in Section 3.

2.5 FRACTOGRAPHIC EXAMINATIONS Fractographic'examinations were conducted on freshly opened cracks in the laboratory by employing light optical and scanning electron microscopy (SEM) techniques. The purpose of the fractographic examinations is to establish the crack initiation sites, propagation directions and the general fracture morphology. The results of the fractographic examination are illustrated in Figures 26 through 30.

2.6 CHEMISTRY ASSESSMENTS Wet chemistry analysis of the weld and base materials was conducted to examine if they conformed to the specification requirements. The results of the wet chemistry analysis of the carbon steel pipe, stainless steel valve body, and the weld filler materials are summarized in Table 1.

WCAP-16845-NP February 2008 Revision 0

3 Semni quantitative chemistry assessment of the fracture surface compositions was conducted by energy dispersive spectroscopy (EDS) to identify the constituents and further to aid in the mechanistic assessment of the fracture process. Typical results of the EDS analysis of the fracture constituents is illustrated in Figures 31 and 32.

2.7 MICRO HARDNESS MEASUREMENTS Micro hardness measurements were conducted on a polished section of the weld to establish the strength levels of the base and weld materials and further to examine the proper-ties of the transition or mixing zone where major cracking was observed. The results of the micro hardness measurements are illustrated in Figure 33 and in Table 2.

2.8 REVIEW OF TVA'S WELDING AND UT INSPECTION PROCEDURES As part of the investigation, Westinghouse reviewed TVA's material procurement, weld fabrication and weld inspection records that were made available. The results of the review were utilized in developing the investigation tasks and in the interpretation of the investigation results. The records are included in Attachment B.

2.9 MECHANISTIC AND ROOT CAUSE CONSIDERATIONS Based on the overall results of the investigation, the mechanism and cause of cracking in the pipe weld was established and the contributors to the crack initiation and crack progression were identified.

3 RESULTS AND DISCUSSION The results of the surface examination of the pipe weld sample in the as-received condition are illustrated in Figures 1 through 6. Figure 1(a) shows the appearance of the as-received sample with punch marks made in the field for referencing the field indication. Figure 1(b) is a schematic representation of the sample showing the location of the field indication, looking from the pipe into the valve body.

The outside diameter (OD) surface appearance of the pipe weld sample in the as-received condition is illustrated in Figures 2 and 3. The surface appeared smooth with no evidence of cracking, corrosion or any mechanical distress. The punch marks seen on the OD surface on the valve side corresponds to the 12 o'clock location or top dead center. (The valve and pipe were oriented horizontally.) Figures 4 through 6 illustrate the inside diameter surface appearance of the pipe to valve weld. The caliper pointers show the position of the suspected UT indication recorded at the site. Several important observations can be made from the ID surface examination results: the weld root pass appeared irregular and of non uniform thickness; the circumferential machining marks in the counter bore region of the carbon steel pipe appeared to be deep and significant; and the carbon steel counter bore region adjacent to the weld showed evidence of significant pitting (Figure 6). Another important observation from Figure 6 is the presence of a circumferential crack in the carbon steel adjacent to the weld interface. These observations suggested potential deviations from the normally expected conditions associated with the welding process.

WCAP-1 6845-NP February 2008 Revision 0

4 TVA's in-service inspection reported that an indication was recorded between 900 and 1200 (3 o'clock and 4 o'clock) orientations in the weld at the ID, looking from the pipe side in to the valve. Detailed surface examinations by light optical microscopy and dye penetrant tests failed to confirm the reported ID surface indication at the 90 to 120 degree location. The Westinghouse NDE examination procedures were then extended on to the entire weld sample by employing fluorescent dye penetrant (PT), Radiographic (RT) and Ultrasonic (UT) examination techniques. A brief summary of the NDE procedures and the results is summarized in the Attachment 'A' of the report. The RT examination results of the 90 to 120 degree segment are illustrated in Figures 7 through 10. Although PT examination failed to reveal any indications, volumetric examinations by UT and RT confirned the presence of at least two indications at the suspected field indication location. The fluorescent dye penetrant examination results of the remaining ID surface are illustrated in Figure 10. PT indications. were recorded at several isolated regions around the circumference.

Based on the results of the NDE evaluations, a detailed sectioning plan.was developed to facilitate test samples employed in the various examinations and tests. The sectioning plan is summarized in Figures 11 and 12.

The results of the metallographic examinations are illustrated in Figures 13 through 25. The metallographic examinations were focused on axial sections of the pipe weld, taken through three most significant indications, namely the deepest indication at 2700 orientation, and two other indications at 900 and 1800 orientations, respectively. Figure 13 illustrates the appearance of the as-cut face at 270°corresponding to the field indication. The presence of an approximately 80% through wall crack initiated from the ED surface can be seen here. Figure 14 illustrates the as-polished condition of the 270 section showing that the crack followed carbon steel to weld interface. Figures 15 and 16 illustrate the higher magnification micrographs of the crack in the as-polished condition. The metallography results of the cracking morphology in the 'polished and etched' condition are illustrated in Figures 17 through 20. Detailed examination of the cracking morphology illustrated here showed that the crack primarily initiated at the geometric discontinuity at the weld interface on the ID and progressed primarily through the dilution or the mixing zone in the weld metal at the interface. The crack was covered with heavy oxide deposits at the crack mouth and all the way up to the crack tip region. Intergranular attack and oxide penetration was also seen in the weld metal along the crack progression. The metallography results of the indications at 90' and 1800 orientations are illustrated in Figures 21 through 24. The results showed that both of these indications are associated with crack penetration into the carbon steel material at the weld interface. They were both associated with initiation at the geometric discontinuity at the weld interface on the ID and progression along the interface butin the carbon steel matrix. Again, heavy oxide deposits were seen in the crack and at the crack mouth region in both cases. As was indicated in Figure 22, the oxide deposit was heavy enough to completely bridge the crack mouth region. This could have potentially prevented the PT technique from detecting the indication on the ID surface. Typical microstructures of carbon steel and weld metal can be seen in Figure 25.

The results of the scanning electron fractography of the cracks freshly opened in the laboratory are illustrated in Figures 26 through 30. Figure 26 illustrates the crack opening procedure employed in the laboratory in opening the deepest crack at 2700. A low magnification fractograph of the freshly opened crack showing the laboratory fractured and field fractured regions is shown in Figure 27. The fracture surface shows the weld interface with islands of weld metal. Higher magnification SEM fractographs in WCAP-16845-NP February 2008 Revision 0

5 Figures in Figures 28 and 29 illustrate the morphology of interdendritic attack in the weld metal islands.

Figure 30 illustrates the formation of iron oxide crystal deposits in the crack.

The fracture constituents and oxide deposits were identified by semi quantitative EDS spectroscopy.

Figures 31 and 32 illustrate the typical results of EDS spectroscopy results of the fracture constituents. A comparison of oxygen and chromium peaks differentiates the iron oxide deposits from weld metal islands.

Wet chemistry analysis of samples from the carbon steel pipe, the stainless steel valve body and the 309 weld deposit materials was conducted to examine their conformance to the specification requirements. The results are summarized in Table 1. The chemistry analysis results suggested that the materials generally met the specifications with the exception of the Nitrogen content in the weld metal.

Micro hardness traverse measurements were made across the weld interface on the polished samples to assess in strength levels of base and weld materials, and to gain more understanding of the transition or mixing zone where the major crack was detected at 2700 orientation. The results are summarized in Figures 33 and in Table 2. These results suggestedthe occurrence of a thin hardened zone at the interface in the weld metal potentially due to dilution, inadequate pre heat and cleaning effects associated with the welding. These conditions are likely to contribute to the observed cracking.

A review of the materials procurement, weld fabrication and weld inspection records of the subject weld from TVA was conducted to examine any potential deviations and to identify contributing factors to the cracking. The records are included in Attachment-B of the report. The review suggested no abnormalities in the procurement and weld inspection during fabrication. The review also indicated that no cracking was detected during weld fabrication.

4

SUMMARY

AND CONCLUSIONS The OD surface examination of the as-received pipe weld sample showed a clean surface with no evidence of cracking, deposits, or other mechanical distress marks. This suggested that the cracking did not initiate on the OD and that there was no through wall leak from the I). The inside diameter surface examinations however clearly identified deviation from normally expected conditions from the weld process. The examinations showed evidence of irregular weld beads, deep machining grooves and pitting in the counter bore and the presence of a circumferentially oriented crack in the carbon steel immediately adjacent to the weld interface in the heat affected zone. The procurement and fabrication records and the weld profile geometry suggested that significant machining at the counter bore was needed to prepare the joint for welding and that the ligament thickness was reduced significantly at the weld, favorable to stress enhancement. These observations suggested a potential for the presence of higher residual stresses from restraint or fit up and from stress concentration effects at the weld joint.

The metallographic examinations suggested that cracking was initiated on the ID surface at the weld interface where an unusually sharp geometric discontinuity due to excessive root bead penetration was present. The initiation of isolated cracks at multiple locations around the circumference suggested that residual stress conditions associated with the weld may have played a role in the cracking. The metallographic examinations revealed that the crack progression occurred both in the carbon steel as well as in the Type 309 stainless steel weld metal dilution zone immediately adjacent to the interface where resistance to oxidation is minimized due to the chromium depletion and/or other dilution affects in the mixing zone. The presence of heavy oxide deposits at the crack mouth as well as within the cracks, all WCAP-16845-NP February 2008 Revision 0

6 the way up to the crack tip regions, revealed by the metallographic examinations suggested that corrosion played a significant role in the cracking process. The observations also point out that the oxygenated conditions of the piping system played a role in the cracking process. Microhardness measurements supported the existence of hardened zone in the diluted weld metal region which is likely to support higher residual stresses.

Based on the overall results of the investigation it is concluded that the, observed cracking in the TVA check valve to pipe weld joint occurred by pitting and general corrosion in the carbon steel and intergranular stress corrosion cracking (IGSCC) in the diluted weld metal at the weld interface. The presence of geometric discontinuity and residual stresses from pipe restraint conditions most likely contributed to the crack initiation. Oxygenated conditions and aqueous environment in the presence of weld residual stresses most likely contributed to the crack progression.

February 2008 WCAP-16845-NP WCAP-16845-*NP February 2008 Revision 0

7 Table 1 Chemistry Analysis Results of Carbon Steel Pipe, Stainless Steel Valve and the Weld Filler Materials Heat No. Element (wt. %)

C Mn P S Si Ni A1A2 0.19 1.13 0.014 0.021 0.18 0.032 ASME SA333 Grade 0.30 0.29- 0.025 0.025 0.10 --

6 Requirements max. 1.06 max max min Heat No. Element (wt. %)

C Mn P S Si Ni Cr Mo N AIA 0.060 1.83 0.081 0.009 0.75 13.74 17.53 2.19 0.12 ASME SA182 Gr. 0.08 2.00 0.045 0.030 1.00 10.0- 16.0- 2.0- 0.10 F316 Requirements max max max max max 14.0 18.0 3.0 max Heat No. Element (wt. %)

C Cr Cu Mn Mo Ni P S Si A1A3 0.050 23.40 0.097 1.91 0.21 12.50 0.014 0.006 0.45 ASME SFA5.9 0.12 23.0- 0.75 1.0-2.5 0.75 12.0- 0.03 0.03 0.30-ER309 Requirements max 25.0 max max 14.0 max max 0.65 WCAP-16845-NP February 2008 Revision 0

8 Table 2 Vickers Hardness Traces Across Weld- Low Alloy Steel Interface, Piece A3B Trace A Location on Specimen Hardness Values TraceA (readings made 0.006" apart) (Vickers, 500g) 1 weld 191 2 weld 179 3 weld 204 4 transition 170 5 low alloy steel 176 6 low alloy steel 158 7 low alloy steel 138 Trace B 1 weld 164 2 weld 162 3 weld 158 4 weld 166 5 transition 304 6 low alloy steel 186 7 low alloy steel 164 8 low alloy 'steel 144 9 low alloy steel 139 Trace C 1 weld 193 2 weld 164 3 weld 181 4 weld 160 5 transition 238 6 low alloy steel 141 7 low alloy steel 144 8 low alloy steel 139 9 low alloy steel 144 WCAP-16845-NP February 2008 Revision 0

9 fype 316 Stainless Steel Valve Body Weld Carbon -

Steel Pipe Punch Marks (a) As-received Sample Punch marks (O'clock locatiol Stainless steel

). valve body

\"

Suspected field indication Carbon steel pipe region positioned between 3 o'clock and 4 o'clock (900-1200) locations (b) View looking from pipe into valve Figure 1 Schematic Representation of the Geometr y of As-received Sample Showing the Location of Suspected Field Indication WCAP-16845-NP February 2008 Revision 0

10 Figure 2 Side Views Showing the OD Surface Condition of the As-received Sample WCAP-16845-NP February 2008 Revision 0

11 Figure 3 Side Views Showing the OD Surface Condition of the As-received Sample - Punch Marks at O'Clock Location of Value Body can be Seen WCAP-16845-NP February 2008 Revision 0

12 Figure 4 Appearance of the ID Surface Condition of the Weld in the As-received Sample WCAP-16845-NP February 2008 Revision 0

13 Figure 5 ID Surface Condition of the Weld in the As-received Sample - The Caliper Points to the Region Corresponding to 4 to 6 o'clock Location where Suspected UT Indication was Reported by Site Personnel WCAP-16845-NP February 2008 Revision 0

14 Figure 6 ID Surface Appearance of the Weld at the Carbon Steel Interface - Note the Presence of Pitting in the Carbon Steel at the Weld Heat Affected Zone and Cracking at the Weld Interface February.2008 WCAP-1 6845-NP WCAP-16845-NP February 2008 Revision 0

15 Figure 7 Image of the Inside Surface of the9 0 °-120° Segment February 2008 WCAP-16845-NP February 2008 Revision 0

16 Figure 8 Digitized Radiograph of the Section of Pipe-Valve Weld Assembly Corresponding to the Indications Found in the Field Ultrasonic Examination - Note the radiograph was taken with the id of the assembly against the film. The arrows show the locations of the radiographic indications.

WCAP-16845-NP February 2008 Revision 0

17 Figure 9 Enhancement of the X-ray Radiographs in the Vicinity of the weld - Upper image is from the image in Figure 8 while the lower is for a radiograph taken with the II of the component away from the film. The arrows show the location of the radiographic indications.

WCAP-16845-NP February 2008 Revision 0

18 Figure 10 Fluorescent Dye Penetrant Examination Results of the ID Surface of the Pipe to Valve Weld Sample February 2008 WCAP-16845-NP Febvary 2008 Revision 0

19 Carbon Steel y- Weld Area Stainless Steel 90 0 00 Punch Mark Chemistry Specimens 2930 SEM Exam.

Pieces, Metallographic "

Specimen Crack Broken Open 2540 Crack Broken Open Metallographic

• Specimen Figure 11 Schematic Representation of Pipe to Valve Weld Sample Illustrating the Orientation of Initial Axial Cuts and Sample Identifications (Looking from the Value Body into the Pipe)

WCAP-16845-NP February 2008 Revision 0

20 StainlessSteel 1340 900 Face Face 1340 Face 230' Mount Face and polish this face Segment A2A (Metallographic Specimen)

Segment A2 Segment A3 3450 _ 2930 2930 Face Face F:ace AlA2 Segment B1 (Broken Open) A1A3 AlA BI B2 Segment B1/B2 Segment AIA Figure 12 Schematic Representation of Sectioning Procedure Employed in Securing Test Samples for Various Examinations and Tests WCAP-16845-NP February 2008 Revision 0

21 (a)

(b)

Figure 13 Appearance of 2700 Axial Cut Face Revealing the Presence of 80% Through Wall Crack (B2A Segment)

WCAP-16845-NP February 2008

.Revision 0

22 Figure 14 Metallography Results in the As-polished Condition of Axial Section at 270' Orientation Showing the Deepest Crack at the Carbon Steel Interface WCAP-16845-NP February 2008 Revision 0

23 MetallographyPiee B2A Figure 15 Metallography Results in the As-polished Condition of 2700 Section Illustrating the Morphology of Crack in the Weld Metal (Specimen B2A)

February 2008 WCALP-16845-NP WCAP-16845-NP February 2008 Revision 0

24 Figure 16 Metallography Results in the As-polished Condition of Axial Section at 270' Illustrating the Cracking Morphology in the Weld Metal (Specimen BiA)

February 2008 WCAP-1 6845-NP WCAP-16845-NP February 2008 Revision 0

25 Metallography Piece. B2A.(Nitch Etch)

Figure 17 Morphology of Crack at 2700 Orientation (Specimen B2A Polished and Etched Condition)

WCAP-16845-NP February 2008 Revision 0

26 Figure 18 Morphology of Crack at 2700 Orientation (Specimen B2A Polished and Etched Condition)

WCAP-16845-NP February 2008 Revision 0

27 Figure 19 Morphology of Crack at 270' Orientation (Specimen B2A Polished and Etched Condition)

February 2008 WCAP-16845-NP WCAP-16845-NP February 2008 Revision 0

28 Figure 20 Morphology of the Crack-tip of the Deepest Crack seen at 2700 (Specimen B2A Polished and Etched Condition)

February 2008 WCAP-16845-NP February 2008 Revision 0

29 (a) As-Polished Condition (b) Polished and Etched Condition Figure 21 A3B Mount Showing the Section at 180 °Orientation - Showing in the a) As-polished and b) Polished and Etched Conditions WCAP-16845-NP February 2008 Revision 0

30 Metallography Piece A3B (a)

(b)

Figure 22 Metallography Results of an Axial Section through the Indication at the 1800 Orientation Shown in the "As-Polished" Condition (Piece A3B)

WCAP-16945-NP February 2008 Revision 0

31 (a)

(b)

Figure 23 Metallography Results Shown in the 'Polished and Etched' Condition of the Crack at 1800 Orientation WCAP-16845-NP February 2008 Revision 0

32 Metallography Piece 2A2 (Glycerergia)

Figure 24 Morphology of Crack in the Carbon Steel Side, on 900 Section (Specimen A2A Polished and Etched Condition)

WCAP-16845-NP February 2008 Revision 0

33 Figure 25 Metallography Results Illustrating the Typical Microstructures of the Carbon Steel and Weld Metal.in Sample A3B WCAP-16845-NP February 2008 Revision 0

34 Figure 26 Sectioning Procedure Illustrating the Opening of the Crack at 270' o'clock Orientation WCAP-16845-NP February 2008 Revision 0

35 Field -

Fracture (a) (b)

Figure 27 Lower Magnification SEM Fractograph of Freshly Opened Crack at 2700 Orientation - Showing the Carbon Steel Face with Islands of Weld Metal WCAP-16845-NP February 2008 Revision 0

36 (a) (b)

Figure 28 Scanning Electron Fractograph of the Freshly Opened Crack at 2700 Location - Delaminated Carbon Steel Interface and Islands of Weld Metal can be Seen WCAP-16845-NP February 2008 Revision 0

37 (a) (b)

Figure 29 SEM Fractograph of 2700 Crack Illustrating the Appearance of Carbon Steel Surface and Weld Metal Islands at the Interface February 2008 WCAP-16845-NP February 2008 Revision 0

38 Figure 30 SEM Fractograph of 2700 Crack Showing Weld Metal and Iron Oxide Regions on the Fracture Face February 2008 WCAP-1 6845-NP WCAP-16845-NP February 2008 Revision 0

39 5150-

-0 '

4480-330-

22404 1120.-

i~i'&i~ ::l4 rw

. A) B.righ Weld

\J(

e.t.a. Pat 1'\~&

9.:.. key:

2060-

. . . . 7 V

i:!i ii*i!!

b) O .. i ....

Ik~

78 9 W.

(A) Bright Weld Metal Patch (b)Oxide Particle Figure 31 EDS Spectrums Illustrating the Weld Metal and Iron Oxide Regions on the Fracture Face February 2008 WCAP-16845-NP February 2008 Revision 0

40 4400i

1640-U14 l*q*!- ::' . . : :u ' - ' .:u i:"

i 'i : :2 34 S heY (a) Weld Metal (b) Oxide Area Figure 32 EDS Spectrums Illustrating the a) Weld Metal and b) Iron Oxide Regions on the Fracture Face WCAP-16845-NP February 2008 Revision 0

41 Figure 33 Piece A3B, Weld Mount Prepared for Microhardness Measurements WCAP-16845-NP February 2008 Revision 0

42 ATTACHMENT A NDE EXAMINATIONS As part of the failure investigation for the Browns Ferry pipe to valve weld, non-destructive examinations were conducted to locate the indication that had been identified during the field inspections. The information provided initially was that there was a possible crack on the inside of the component in the weld toward the pipe at between 3 and 4 o'clock as viewed from the pipe side of the component where 12:00 o'clock was coincident with punch mark on the remaining portion of the valve. The inspections that were conducted were performed strictly to confirm the location of the field indication so that the destructive examination could identify the underlying discontinuity. None of the inspections conducted during the investigation sought to identify the presence of additional discontinuities.

The fist inspection conducted was a dye penetrant examination using red dye. Dye was applied to the ID of the assembly and allowed to dwell. The excess was removed and developer applied. No indications were identified. The component was cleaned in an ultrasonic cleaned for more than an hour and the test repeated. Again nothing was identified. Since the indications that had made the weld suspect arose from an ultrasonic examination an ultrasonic inspection was conducted. In the interim the field inspection report became available that placed the indication at between 3.0 and 4.1 inches from the punch marks in the clockwise direction as viewed from the pipe side of the assembly. Further the indication had been identified using high angle (60 and 70 degree shear and longitudinal wave inspections). Rather than duplicate the field inspection a simpler approach was taken. The ends of the assembly were milled smooth to allow an ultrasonic transducer to be mounted on the ends of the component. A simple manual inspection from the end faces using 2.25 MHz longitudinal wave transducer was conducted. Indications were identified in the area of interest from both the pipe and valve side of the component. The response from the pipe side of the component suggested that the discontinuity was associated with at least two axial locations separated by perhaps 1/10 of an inch located within the weld on the pipe side of the weld center. The indication was stronger from the valve side with its maximum being a single response at the location thought to be the greatest extent through wall as found in the field examination. The laboratory ultrasonic examination confirmed the location of the indication and was qualitatively similar to the field results.

Having identified the location of the indication no further characterization of the indication was conducted and the destructive examination of the assembly commenced. A section was cut from the assembly between 2.8 and 4.3 inches clockwise from the punch marks as observed from the pipe side of the assemble. This section of the assembly contained the field indication confirmed by the laboratory ultrasonic examination. Figure 1 shows an image of the inside surface of the removed section. To assist in locating the discontinuity responsible for the ultrasonic indication, X-ray radiographs were taken of the section with it placed on the film with either the ID of the assembly toward or away from the film. The radiograph shown in Figure.2 is an overall view of the section. The counter bore on the pipe and the location of the weld are noted in the figure. Arrows highlight the location of the indication which occurs in various axial locations and is discontinuous in nature. The indication is generally toward the pipe side of the weld which is consistent with the location provided by the ultrasonic examination. Figure 3 shows enhanced image of the region showing the indication. The upper image is an enhancement of the indication in Figure 2 and the lower is the.enhancement of the radiograph taken with the ID of the section WCAP-16845-NP February 2008 Revision 0

43 away from the film. Theindication in the latter was more diffuse than that of Figure 2. The images are consistent with a linear separation within the weld.

After the radiographic examination a visual inspection of the ID surface of the section identified the presence of a crack like feature on the surface where the x-ray indications were located. Why these had not been found by the dye penetrant examination is possibly due to the presence of a small ligament present on the inside surface that was breached when the section was cut from the component or crud present in the crack. The resolution of this dilemma awaits final destructive characterization.

A further investigation was conducted on the remaining portion of the assembly. The assembly was cut into two sections to facilitate handling and the surfaces were cleaned. A florescent dye penetrant examination was then conducted. Numerous small indications were identified in a location consistent with the discontinuity found in the removed section. Figure 4 shows the results of the dye penetrant examination.

Figure A l Image of the Inside Surface of the Removed Section - The Pipe Portion of the Assembly is Toward the Left WCAP-16845-NP February 2008 Revision 0

44 Figure A2 Digitized Radiograph of the Section of Pipe-Valve Weld Assembly Corresponding to the Indications Found in the Field Ultrasonic Examination - Note the radiograph was taken with the ID of the assembly against the film. The arrows show the locations of theradiographic indications.

WCAP-16845-NP February 2008 Revision 0

45 Figure A3 Enhancement of the X-ray Radiographs in the Vicinity of the Weld - Upper image is from the image in Figure 1 while the lower is for a radiograph taken with the II of the component away from the film. The arrows show the location of the radiographic indications.

WCAP-16845-NP February 2008 Revision 0

46 Figure A4 Florescent Dye Penetrant Results for the Remaining Portion of the Assembly - Both images are taken from-the pipe end of the assembly. The indications in the counter bore region are believed associated with the original welding. The obvious indication in the counter bore in the upper image is at approximately the 180 degree orientation. The left surface in the upper image corresponds to approximately 4.3 inches from the 0 degree reference while the right surface of the lower image corresponds to approximately 2.7 inches from the 0 degree reference so that the right side of the upper image corresponds to the left side of the lower image.

WCAP-16845-NP February 2008 Revision 0

47 ATTACHMENT B MATERIAL PROCUREMENT, WELD FABRICATION AND INSPECTION RECORDS WCAP-16845-NP February 2008 Revision 0

48 TENNESSEE VALLEY EXAMINATION

SUMMARY

AUTHORITY AND REPORT NUMBER:

RESOLUTION DATA SHEET 0 -74 PROJECT: Fr 'tUNIT: ,. CYCLE: COMPONENT ID: O -5 2-EXAMINATION METHOD SYSTEM: teISI DWG. NO.1 -. _-T2 --- C)

MT [] PT [] UT M 'CODE

... ... CLASS: CATEGORY: *-A-PROCEDURE: J-.REV: TC: 1 I CONFIG.: VAtAE TO PI G EXAMINE R: EXAMINER: EXAMINER: EXAMINER:

LEVEL: HJL-LEVELL,9 This report contains the data associated with the manual ultrasonic examination of RCRD-2-52 to meet the requirements of ASME Section XI, category R-A, item number RI. 16D, and BWRVIP-75.

This exam was performed using equipment, procedures and personnel qualified in accordance with ASME Section XI, Appendix VIII as amended by 10CFR50.55a final rule.

The component configuration is a 4" diameter, Sch 80 carbon steel pipe, welded to a forged stainless steel valve.

Both refracted longitudinal (RL.)and shear wave search units were used ,s defined in pmcedure PDI-UT- 10. The ultrasonic examination is limited due to the taper configuration of the dissimilar metal weld.

During the examination, a planar indication was detected that was oriented in the circumferential direction with a recorded length or 1.10 inches. The indication was detected using a 600 shear wave and a 60' RL wave search units. The indication was sub sequentially confirmed using a 700 shear wave and a 70' RL wave search units.

Due the inherent component geometrv. it is niot possible to obtain depth measurements of this indication usinz P6I uitrasonic qualified techniques. However, a best effort through wall sizing technique was applied and indicated as Cstimated remaining ligament of 0.20" in depth.

ASME Section XI Coverage:

Circumferentialscan coverage was I00%. Axial scan coverage was 74%

Combined ASMIE Section XI Code coverage was 87%

&.7 RESLyT9,NN:>IIEYTWED BY: ANTI:

I/iI _ _ _ _ _ _ _

14i ,ý/ , DATE:

LEVEL: -Y7 DATE: -3/3/07 LEVEL: 7Z ýATE: 4 V-510-7 PG. / OFI WCAP-16845-NP February 2008 Revision 0

49 ISI report no. R-017 NOI no. U2C14-017 Component I.D. RCRD-2-52 Additional resolution details:

Weld configuration:

4" Carbon Steel, sch. 80 pipe to a forged stainless steel check valve. The joint configuration exhibits a dissimilar metal weldwith a pipe wall thickness at the weld joint of .36" connected to a SS check valve body. The weld crown is tapered fromtthe pipe to the valve at an angle of 18'. This configuration limits the ability to scan across the weld crown in the axial direction.

Exanminatiou teclhique:

The examination was perfonned in accordance with ASME Section XM, Appendix VIII qualified techniques for examination of dissimilar metal welds. The procedure utilized

• was TVA/ISO NDE Procedure N-UT-82 that implements the PDI Generic procedure PDI-UT-10.

Indication discrimination:

The joint configuration limited the ultrasonic examination angles to 60 and 70 degrees.

The weld taper and width prevented the use of a 45' inspection angle.

The indication presented signal characteristics indicative of a planer reflector located in the weld. The reflector continued to return energy until the transducer contacted the weld taper. The higher examination angle returned more reflected energy than the lower examination angle. The reflector maintained echo dynamic motion during the axial raster scan and during skewing of the search unit.

The PDI dissimilar metal examin-ation does not contain qualified through wall sizing techniques. However, a best effort through wall, sizing technique was applied and indicated an estimated remaining ligament of 0.20" in depth.

Conclusion:

The weld configuration does not allow for all of the indication discrimination tools detfned in the PDI generic procedure. The discrimination tools utilized indicate the presence of a planer flaw located in the weld metal. The available data indicates the presence of a planer reflector that would not meet the ASMffE Section XI, Table IWB-3514-2, for allowable planer flaws.

4 3e I WCAP-16845-NP February 2008 Revision 0

C") W W TVA PROJECT:. '4 SYSTEM:_ ______ REPORT NO.:

ON Go Office of Nuclear Power Unit: -WELD NO.: Fe-RD-Z-5O 90oT ý I

0

• u, t

~1

- ,~A t~i~ A'is'l A~j~

• ~41 7 ~ ~ cPLf /~44O~h ~wk$vI6L~tv

b. I ,

,=.Il

, , 1., , , , , , , ,

0G C BY- LEV TVA 19669 (ONP-6-88) 0

00/ .. -- ' ... . ... .. .: - - .

00 (A ý..,5 Z

- L ___________ ---- ~-~----.-~~--.----..--

f-I ~ ~

.~4t(

0 I

n I u n Ll a iI n P u Tn q M.n 3t 1 0 1 T:, u p TP 4 P a a x t q Ll T n u P vp 6 P. 0 u 7 -1 is ýl A M 0

IN) 000

000C C'4 IV-c

'ýC) fe/

00.

~ 4,;

• Mr

53

.W1 ...

• i:4!

.=

. o === ======...

..: ? ..:..: ..........

i.............

-.....;:.i:!i.

WCAP-16845-NP February 2008 Revision 0

54 LOO .. ... ~% IN 4o 4'.gh- PM UbZ '

Dy_

WCAP- 6845NP FbruaMI200 WCAP-16845-NP February 2008

. Revision 0

55 PwMm o -

I~~~~~~~ L_7~~I W.$ L.

'J 1qJ~ 1: 1!tRipg oldo~N~I Ds$italFp ~ lt in~ctic~R~p9ts j Rad~at~ Th~u

- .2 I

F ~w RaU lu plate eh 3 H* .... 21 . ,*

Req. Sei Size 110 S"'gl

'14lb I .....

"I $etUp"C~

CL I

"I I . . ... -~ .j -. .. ... . . ...

16 Febru2ry 2008 WCAP-16845-NP February 2008

• Revi si~on 0

56

..war X.LA~

W-': trx UE~~A~~S 1 WW VodD zeflO..'3 Vark Plan o eZiSpoeg~

lsIre am~$U.

& SzeW NO~W-~

V.V.

l~t February 2008 WCAP-16845-NP February 2008 Revision 0

57 TENESEE VALLEY AUThORITY DeOR Weld procedur.e 14.:* 0fB--1 T ONv.: 3 new, 2-ý28-75 BawiV Joint type's uich mny'ýv be- used vithn this rrooedn are, depiCte.d L-1 TYPICAL WELD JOINT DESIGN Wr~dtric £or.r.:~ c.n:

10-14 volts 6o-13oq

.1-3/4 min riH-2 s;.n Ga.s1 M ER309

1116'1 or 3/32tz mion 11101 CarT. Siz A-rgcn Ox.; Sl. 10W~f iemm 15-25eh 1,5-25L25a

"£ , 321" O Argon Arg=n a./a" max Pi 3 FkT Ratme 1/a" it q bs_

80 F min, 30Fmax F,"R, V'3 ORf S u.i U- . ' s" *S. M",* .~lA0t WCAP-16845-NP February 2008 Revision 0

58 Ternnessee -Valley Authority WELDING PROCEDURE QUALIFICATION RECORD December 10, 1970 W.P, .Ft.No. (;T 8-0-1 Welding Process Gas *z*getenw Arc MAnn.ssl IIgllk I*UI Semi-Automatic MtI. Type and Spec. BA-312 Type 304 To BA-333 Gr 1 P.No. 1 Tu P-No. 8 Thickness (and Die. If Pipe) 3/8" x 6" dis. Thickness Range Qualified l_.11 ,.3L...3 WELDING MATERIALS . WELDIlNG PROCEDURE Filler Metal F-No...L. 7 A-No. 7 Position Qualified: :Leal pipe .

Electrode F-No. :_ _ A-No. Qualifying For: VO 'IT Spec. or Anlyis SA-371 ~~e~ Single or Multiple Pass: b tiple

. One

• Number of Arcs:

Preheat Temp. 600 F min.

Flux: Interpass Temp. 4500 F max.

Other Additives: Weldi-nL grade Argon Post Weld Heat Treatment: Noe Torch flow rate 30 cfh Plrge flao rate 5-7 cfb FOR INFORMATION ONLY Trade Name Filler Mils: Hoba61t Bead Electrode or ' Arc Travel 5:-2s.c No. Filler. Size Amperes Volts i Inc. s.I .-

Tpe Current: ]OSTP

.-Jinl Configuration: Si,, le V. open butt ~75-05~ 12-.

41 LE9131 2-35M-0 -22 ALL WELD MEIAL AND/OU THANSVERSt JUlINl HREUUD U SLLIIUN ItF'*Lt I1t;1Z Type Dimensions Area Ultimate Ultimate Character A*.G Specimen Width I Thickness Sq. In. Load Lbs. Streas-Psi Location of Fai;:,-

Transverse .753n .3z = 237 1 79,750 tile - Pipe 0-6.( n v ,..  : .21 l.0 J g....

GUIDED BEND TESTS NON DESTRUCTIVE EXAMINATIDON Type Specimen No. Results Examination Method Location Resilis Root Q-7.2 2GRI Acceptable Magnetic Particle Root Q-7.2 2GR2 Acceptable Liquid Penetrant Face Q-7.2 2GF1 Acceptable Ultrasonic Face Q-7.2 2M'tb Radiographic CHARPY V NOTCH IMPACT TESTS Location Temp. Ft/Lb Value Avg. of 3 Lateral Expansion %Shear HAZ 200' 2.'". 8 60 .o055". .047". .o8o0 _65. 54. 96 WELD JOINT DESIGN Dept. Conducting Test -11M .

Welder .H. C. Ca=penter Symbol Test TestinNo.:

No.,, Bend Tests -))EMI Tesile & Bmpae Test - F P _ ,

We certify that the statements in this record are correct, ano that the test welds were prepared, welded and tesea i-.

accordance with requirements of the ASME Code.

February 2008 WCAP-16845-NP WCAP- 16845-NP February 2008 Revision 0

59 Taaneusee Valley Authority WELDING PROCEDURE QUALIFICATION RECORD December 10, 1970 W.P.Q. R. No. G"18-0-.

Gas Tlmgsten Arc Ma.lual Semi-Automatic Automatic v* Tr= z-- Spear SA-31. Type 304 Ti SA-333 Gr 1 P-No. 1 To P-No. 8 6

-.;1 .j Dia. if Pipe) 3LB" x 6" dia. Thickness Range Qualified _/1 Thru 3/4" W'ELDING MATERIALS WELDING PROCEDURE

*5:* -

=:.- 7 A-No. 7 j5 G)

Position Qualified: Horizontal Fixmd *ipe Ez:':r. F-%0o. A-No. Qualifying For: F. V. OR SA -. sis: .. SA-371-TI ER3o9 Single or Multiple Pass: fttiple Number of Arcs: One Preheat Temp 600 F Mmn.

AUA. Interpass Temp. 5Oo M

ijvrs

: We1din* s tad e Argon Post Weld Heat Treatment: None Torch flow rate 30 dfh Purge flow rate 5-7 cfh FOR INFORMATION ONLY Arc Travej Speed

_.zle 'Jer~e Filter '.4tis: ,.-..Bead iElectrode or Amcrs Hobar No. Filler Size A Volts (InLhes/Min.)

1 13[2 0-7 12 -

7. SP DeCrr: 3 A/2" 95"100 12

- 2'..rtin:

-t Single V, OPen butt 1_2 1Z_/?2" 90-31-'0 R*.3132" M12.0-.0 12 ALL WELD METAL AND/OR TRANSVERSE JO!NT REDUCED SECTION TENSILE TESTS

.,;!a Dime sions Area Ultimate Ultimata Character And Specimen Width Thickness Sq. In. Load Lbs. Stress-Psi "Location of Failure Trans' erse -763- ..29Y 1500 D70ctile - Pipe

-7,90 Ductile.- Pipe GUIDED BEND TESTS NON DESTRUCTIVE EXAMINATION T.:e Specimen, No. Results Exaimination Method Location Results Root r-7.2 5MM; Acceptable Magnetic Particle Root 0_-7.2 5CI2 , Aaeeptale Liquid Penetrant lace Q-7.2 501 Acee~able ,Ultrasonic Face Q-7.2 5ZRk Aeet ble Radiographic CHARPY V NOTCH IMPACT TESTS t,:21u-Temp. Ft/Lb Value Avg. of 3 Lateral Expansion

".* -200 F I 1C, 92, 13.1 1 W* .CT9" .0 7" . o -60" % 69,Shear 100O WELD JOINT DESIGN Dept. Conducting Test . BM WMlder H. C. Ceamenter Symbol _B5 Test No.:

. -- Testing Lab Bend tests - PT Teni-Le LTimnaet Tests - PTL We certify that the statements in this record are correct, and L , - _J that the test welds were prepared, welded and tested in accordance with reQuirements of the ASME Code.

Februar.y 2008 WCAP-1 6845-NP WCAP-16845-NP February 2008 Revision 0

60 FORMf 6- PROCUREMENT DATA SHEET PEG PKG NO, CMML27E QA RECORD PAGE 1 OF 3.

RJMS/EDMS R27 070412 333 REV NO: 0)

NO:

SUPERSEDED RIMS NO: N/A QA LEVEL: 3

'TECHNICAL EVALUATION PKG NO: 01006521-BFNMI PDS EXPIRATION DATE:"

TEGHNICAL EVALUATION RIMS NO: R27 0704 12 3'31 N/A TI.C NO: CMMI27E COMMMODITY N/A SOLE SOURCE: ((1-YES I1ll A CODE:

L ANO MAILING IASTý N/A" IQA'PROGRAM: IMPOSED: [EJ] YES 10, NO PROPOSED SUPPLIER WESTINGHOUSE ITEM INTENDED END USE:

SERVICE FOR PIPE CrUOUT ITEM D)ESCRWflON:

SERVICE. CONTRACT, Q LEVEL: QA 3, APPLICATION: OFF SITE SUPPORT VENDOR TO PERFORNM METALLURGICAL EVALUATION OF WELD RCRD-2-52 4," DIAMETER SCHEDULE 80, A-333, GR 1_7 CARBON STEEL PIPE TO A-182 FORGED STAINLESS STEEL CUTOUT TO DFTERMINE THE CAUSE OF WELD FLAW INDICATION (I.E. IGSCC OR SERVICE INDUCED ETC.)

M ,,NfL.*-AMI RE:R/VEND'oR: .... PART N(O:

WESTINGHOUSE ELEC CORP NOT SPECIFIED EXTERNAL NOTES & ATTAC-MENTS:

I. Vendor shall provide complete MetaUllurgical report of the cutoul sa*ple provided by TVA

2. TVA Technical contact for this service is Mr. Travis Shuis ai 256-729-2040.

T2050-Except Prior Executi S 1054-TVA right of acccss QA PROGRAM & VENDOR SUBMITTALS/DOCUMENTATION:

N/A INTERNAL NOTES & ATTACHMENTS:

/*C - COMMENTf-/

I..Purchasing: Please contract lhe Teclmical Engineer (Mi', Travis Shulhs E., 2040) for this service for AIy additional inlbonation required.

Receiving: Please contact Travis Shults for nimerial culout and handle thl material per SNM Since it ha, radioactive contamination.

N 105- No Bid Rev Non-ASL N1097-No Stock Level AssL, ADDITIONAL INTFORMATION:

N/A PRE-I*AEI) BY: DATE:

P'EG i.ý40NXINA: NIAJMUDAK. ARU.'.N 04- 11-07 l(,:4 REM W-EL'D BY: DAT'E:

INDEPIONI)NT REVii:WER: SOUTH.JULIAN "04,12-0,709:47

.,APPROVED BY: DATE:

WCAP-16845-NP February 2008 Revision 0

61 FORM PROC-U REMENT DATA SHEET P EG PKG NO. CMMJ2 7E QA RECORD p AGE 2 OF 3 I PR(X'( RFMENT LNCI~TERRY, WILIAM R 1 04-12-1.71 3:U I I I I

DIS'RI'Il.TON:

10] NUCLEAR PROCUREMNENT 10]

[01] MATERI-].

~.x & PRC1-CUREMENT I.0J NUCLEAR STORES February 2008 WCAP-16845-NP February 2008 Revision 0

.62 FORM 7 - RECEIPT VERIFICATION/INSPECTION PEG PKG NO. CMM127E REQUII

[RM ENTS PAGE 3 OF 3 ThC NOIDESCRIPTION CMMI27E -OA LEVEL: 3 PHYSICAL DAMAGE MATERIAL ID' -

\rEN/MFG REC/SUBM PROTECTIVE COV.

COATING .

PRES/DES/ GAS CLEANLINESS PHYICHEM PROP _

SIZE/SHAPE LUBRICANT8S RESIST. TEST/ELECTRICAL INSUL DIMENSIONS WORKMANSHIP __

SPEC. INSPECT',

S. HAN/STORAGE SOURCE SURVEILLANCE/INSPEC SHELF LIFfE TRACEABILITY_

TAGGING/POST INSPEC HARDNESS TESTING TVA APPR OF DOC WELD PREP NOTES:

None.

WCAP-16845-NP February /ouIs Revision 0

ENCLOSURE 2 TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)

UNIT 2 INSERVICE INSPECTION WELD ISOMETRIC DRAWING, 2-ISI-272-C, SHEET 1, FOR WELD RCRD-2-52 (SEE ATTACHED)

NOMINAl. I IVLT EYTENL.,L- *WT-Ar/JIILb NOMINAL CRD-2-O05 REGION OF THERMAL fATIGUE RCIC-2-004 EAM)

, NAY ION PEN NUREC-O61b

-HRMAL "TE`4

• I ,.f -17 (UPSTREAM OF VALVE

-;tL. ow

.2-FZV-69-630) NOTE:

.,.TNSDRANG, SUPERSEDES.CHM720757C 0 AND CHM-2072-C (ALL SHEETS)

"N 0. .. RWCU-2-003-G'002 RCRDS-2-OJ-TEE--' MATERIAL SPECZFICA TIODS

.:-DRWC-2-079 RCRDS-2-02

',RCRDS-2wOJ STAINLESS STEEL

-DRWC-2 -07A ý RCRD-2-4,1 FITTINGS THEtRAL rEE ---

• 6" SA403 WPJ16NG SCh. 80 5S PIPXNG 6" SAJ76 TPJI6NG SCH. 80 SS 6: AJ'6L;G TPJOF SCH. UJ !;S 6" A312OR TP304 SCH. 80 SS CARBON 7STEEL1 fDSRWC-2-06 4" SCHN 80 A-J35, GR7 (SEAMLESS) CS CARBON STEEL 6" X 0.562- NOM WALL SCH. 120 CS "STAINLESS STEEL 8".X 0.583" NOW WALL SCH. 100 r.

/ *DSRWC-2-05 ( OL) R14 061025 105 -,-_ VALVE tZ-69-630 SAJSl CGPsU SS CR07 CA" 4" X 0.674" NOV WALL SS RX-2.OQICOOASME CC-I (EDUIVALENT) 2-£*-"TTJ,7RE*9 I

. TEL)

TRCI-ZC--O01-r "RW-OAO84.O -0 2 5 "DSRWC-2-04 (OL)

TRcrc-2-001A. AOw6JJ jI

."DSRWC-2-03 (OL)

TRE!E-2-04-00 AZWG fIISW PSRWC`.-2-=2, Rco'se' 8r X - -.TES .R OX91 10' 8 R14RCRD-2-j32-06125"104 5 (t, L-69 *00 (R -AD-2-'

R1410 060.13 DSRWC-2-OJ0 L ,-SOCKOL TR I-2O JO A .. c wn

~ ~

.-- ~ ~ ~ ~ ~ *0100PO

~ ll 2t0014'I05 CC00 U fPt AI -00~ LIMEWmE m00 0

• C I$.

MNSESSLE VALLEYAITHMITT?

ASROWNS FERRY NUCLEAR PLA77F (2 UNIT 2 REACTOR #A4TERCLEANUP RI ANDCR0 WELDI0ENTIF] A TION pq5<pI3An ,*uy KAL+/-E...APNIM All.

ALLA/DA/fl HISTORY HISTORY RLSEARD4ED RESEARDtED AT ROOC ATRO000 ___________________ ccD - -i CAD MAINTAINED DRAWIII CD

ENCLOSURE 3 TENNESSEE VALLEY AUTHORITY BROWNS FERRY NUCLEAR PLANT (BFN)

UNIT 2 NOTIFICATION OF INDICATION (NOI)-U2C14-017 (SEE ATTACHED)

NOTIFICATION OF INDICATION FORM PART I - FINDINGS NOI No 4.ZCqY-17Plant/Unit ISI Dwg./Sh. No. c;2X2 o.2 7,;-C jo. ZW

?ot3 I

Examination Report No. ________ Component ID *7&::.,D -,Z z5" Description of IndicAtion (SketqhtPhg/pgraphif Required for Cnrification) d2~d~ ,-inA~.V iA~i~T~ 9 Signature of Examiner/Certifical ion Level: /Date:

Signature of ISO Coordinator (Field Supervisor):. ,Date*:V Signature of ISI Program Owner: /Date.

PART I1- DISPOSITION SP-,Q++/-aa Corrective Action Program or Administrative Control document number (PER, - I el A Wu) if applicable:

ASME XI Subsection IWE C] Yes UNo If Yes, complete the supplemental information Parts II and III of Page 2 of this form in addition to Parts II, Ill, and IV, of Page 1. If No, completion of Parts II and I1 of Page 2 of this form is not required and attachment of Page 2 with Page 1 is not required.

Disposition Prepared/Recorded By: ^'1 Org. o.-M1 Date: 09-10-2007 PART Ill - *DDITIONAy..EXAM I NATIONS J\)

Additional Sample Required [IW(X)-24301: M0 Yes ((ro Page 2 of 2 additional # es toS.'

41, samples attached?

(Attach list of items in additional sample, if yes.)

Ye1, Sl Progrim Owher t Successive Examination Required: El Yes &'No  ; _

. Vor CSl Program SwIer /D6"te PART IV - VERIFICATION OF CLOSURE Reexamination Report number, if Applicable: "JIA Date:

Signature of ISO Coordinator: Date:

/I Finding resulted from performance of the General Ses

/No If Yes, concurrence of the Registered visual Examination ]Yes O Professional Engineer (RPE) or Individual Responsible for performance is required (NWA otherwise):

N/A RPE/Responsible Engineer Date Comments:

Verification of Complete Corrective Action R by isposition (. cdin age 2, il applicable) j -

Signature of ISI or CISI Program Date: lk Owner: //

TVA 40580 [ 10-20031 Page 1 of 2 SPP-9.1-2 [10-03-20031

NOTIFICATION OF INDICATION FORM ATTACHMENT NOl No. U2C14-017 Plant/Unit BFN Unit 2 Examination Report No. R-074 Component ID RCRD-2-52 Part II- Disposition This NOI documents a planar indication that was observed during manual ultrasonic examination of dissimilar metal weld RCRD-2-52 (4-inch Carbon Steel, Schedule 80 pipe to stainless steel check valve 2-CKV-085-0576) during the Unit 2 Cycle 14 Refueling Outage. This examination was performed in accordance with ASME Section XI, Appendix VIII qualified techniques for examination of dissimilar metal welds (Report Number R-074). The procedure utilized was TVNISO NDE Procedure N-UT-82 that implements the PDI Generic Procedure PDI-UT-10. The indication presented signal characteristics indicative of a planar reflector located in the weld. The available data indicated that the planar reflector would not meet the ASME Section XI, Table IWB-3514-2, criteria for allowable planar flaws.

The planar indication was removed when check valve 2-CKV-085-0576 was cut out and replaced under Work Order Number 07-713160-000. The indication was removed in such a manner to allow subsequent metallurgical evaluation. Westinghouse, LLC has been contracted to determine the cause of the planar indication, and is expected to have preliminary results of their evaluation by June 2007.

Prepared By: e-YA&,e .2 l Org. SM -. h Date_____________

NOI U2C14-017 List of Items in Additional Sample

_ _Weld ED ISI Exam Report Nunber Exam Results RCRD-2-33 manual UT R-116 No Recordable Indications RCRD-2-50 manual UT R-118 No Recordable Indications DRHR-2-11 manual UT R-119 No Recordable Indications DRHR-2-03 manual UT R-121 No Recordable Indications

NOTIFICATION OF INDICATION FORM SUBSECTION IWE Complete this page in addition to Page I for findings affecting Class MC/Subsection IWE_

NOI No. __, __-__________ Plant/Unit 4F/v/z Examination Repor No. Oomponent ID CX ,0 ____

PART II - DISPOSITION (Supplemental Information)

Evaluation of inaccessible areas as required by 10CFR50.55a(b)(2)(ix)(A)

(Include (1) A description of the type and estimated extent of degradation, and the conditions that led to the degradation; (2) An evaluation of each area, and the result of the evaluation; and (3) A description of necessary corrective actions) (additional separate continuation sheets may be attached, as necessaryj.

Corrective Action Program or Administrative Control document number (PER, WO) it applicable:

Disposition Prepared By: Org. Date PART III - ADDITIONAL EXAMINATIONS (Supplemental Information)

Additional examinations required per 10CFR50,55a(b)(2)(ix)(D) [I Yes [I No If Yes, provide (1) A description of each flaw or area, including the extent of degradation, and the conditions that led to the degradation; (2) The acceptability of each flaw or area, and the need for additional examinations to verity that similar degradation does not exist in similar components; (3) A description of the necessary corrective actions; and (4) The number and type of additional examinations to ensure detection of similar degradation in similar components [additional separate continuation sheets may be attached, as necessary].

Specified By: Org. Date:

TVA 40580 [10-20031 Page 2 of 2 SPP-9.11-2 [10-03-20031

TENNESSEE VALLEY EXAMINATION

SUMMARY

AUTHORITY AND REPORT NUMBER:

RESOLUTION DATA SHEET j C74-PROJECT: F.: "¶ NIT: 7- CYCLE: j I COMPONENT ID: i/,7-.--62.-

EXAMINATION METHOD SYSTEM: pi,.X 6"* ISI DWG. NO. Z -I..:-C27Z-C-CJ MT PT UT j VT Li CODE CLASS: CATEGORY: Z -A PROCEDURE: 4!."J[-bi* REV: TC: All,/ CONFIG.: VA .\JE TO ?1,pC EXAMINER: EXAMINER: EXAMINER:

LEVEL: . LEVEL: LEVEL: LEVEL:

• ~ ~ ~ . \ ý1-5. \K'~~i This report contains the data associated with the manual ultrasonic examination of RCRD-2-52 to meet tEi requirements of ASME Section Xl, catlegory R-A, itemn number RI. 16D, and BWRVIP-75.

This exam was performed using equipmrent, procedures and personnel qualified in accordance with ASNE Section XI, Appendix VIII as amended by 10CFR50.55a final rule.

The component configuration is a 4" diameter, Sch 80 carlon steel pipe, welded to a forged stainless steel valve.

Both refracted longitudinal (RL) and shear wave search units were used as defined in procedure PDI-UT- 10. The ultrasonic examination is limited due to the taper configuration of the dissimilar metal weld.

During the examination, a planar indication was detected that was oriented in the circunmerential direction with a recorded length of 1.10 inches. The indication was detected using a 60' shear wave and a 60" RL wave search units. The indication was sub sequentially confirmed using a 70" shear wave and a 70'" RL wave search units.

Due the inherent comoonent geometrvy it is not i)ossihle to obtain deth mea'surements of this indication using PDI ultrasonic Cualified techniCques. However, a best effort through wall sizing technique was applied and indicated as estimated remaining ligament of 0.20" in depth.

ASME Section XI Coverage:

Circumferential scan coverage was 100%. Axial scan coverage was 74%

Combined ASME Section XI Code coverage was 87%

I<,. .' ,'.t ,.zc, 1-/1

/c/lKee/ A I-alle"/L1 RE REVIWVEI) BY: ANII:

DATE:

LEVEL:_Y__ DATE: -313102 LEVEL: 2IDATE: 3/3/1c7 IPG.

I PG. /

i OF OF L!I~YEL:1J DATE 3/3/02

ISI report no. R-017 NOT no. U2C14-017 Component I.D. RCRD-2-52 Additional resolution details:

Weld confiuration:

4" Carbon Steel, sch. 80 pipe to a forged stainless steel check valve. The joint configuration exhibits a dissimilar metal weld with a pipe wall thickness at the weld joint of .36" connected to a SS check valve body. The weld crown is tapered from the pipe to the valve at an angle of 18'. This configuration limits the ability to scan across the weld crown in the axial direction.

Examination technique:

The exaniination was pertormed in accordance with ASME Section XI, Appendix VIII qualified techniques for examination of dissimilar metal welds. The procedure utilized was TVA/ISO NDE Procedure N-UT-82 that implements the PDI Generic procedure PDI-UT- 10.

Indication discrimination:

The joint configuration limited the ultrasonic examination angles to 60 and 70 degrees.

The weld taper and width prevented the use of a 450 inspection angle.

The indication presented signal characteristics indicative of a planer reflector located in the weld. The reflector continued to return energy until the transducer contacted the weld taper. The higher examination angle returned more reflected energy than tile lower examination angle. The reflector maintained echo dynamic motion during the axial raster scan and during skewing of the search unit.

The PDI dissimilar metal examination does not contain qualified through wall sizing techniques. However, a best effort through wall sizing technique was applied and indicated an estimated remaining ligament of 0.20" in depth.

Conclusio in:

The weld configuration does not allow for all of tile indication discrimination tools defined in the PDI generic procedure. The discrimination tools utilized indicate tile presence of a planer flaw located hi the weld metal. The available data indicates the presence of a planer reflector that would not meet the ASME Section XI, Table IWB-35 14-2, for allowable planer flaws.

-7~

TVA PROJECT: - SYSTEM:_ _____ REPORT NO.:

Office of Nuclear Power Unit: WELD NO.: ___,_______/\__/_

S/_S VALNIJ I 3,&Z5 "

• 'P~o-,Z0 A-r -.

/v,/ /e

/A41 dqj....... ~ 6 . ..

" AT:7 PAGE BY:_____________ LEVEL:________ OF DAE 1517 AG____OF__

TVA 19669 (ON P.6-88)

ACTUAL WORK PERFORMED (Continuation Sheet)

F UNID: BFV-2-CKV -085-0576 WO NOt 07-713160-000 DESCRIBE ACTUAL WORK PERPORMED (00nt)l

-6 ,Ci VMnL , At J -' rIM Aff"2 o ,,- , + h t- ' t_e,,n. . .

Ie-1o

"/*,* .t~~~a,,,*l .** - a-'*.

-- 3,7 0o,.Ik 11}/, f,. . '.'t I I

)

Al~OP O Afel-Y 50.4 3! 50,r-' 3ePr.12-0100hv P,~'

R17 ioej I , jL4- r AI g I 4- S94P t-J6%Lg.To rckI ( dj C" 'j ~+ Q -e eJ I-'

r A f 0L~ vcoI j 414 . , ca.%A-i SecdkJ.c S4&.r4ej werI,'. ms, oA 1*4 t.% A TV  %/-.Ivt- wuj~itý 4o l!o& lpin , j4 ~h'tapper mmd C,1uC ftvdc -slft - '

4wedAa/m Sd e--iz O&Z AA br-m A4G/c

/2~g~ ALJ ~, ,rr~r~ itjprJa 012D

ACTUAL WORK PERMORIED (Continuation Sheet)

F UNIDs BFN-2-CKV -085-0576 Wo No? 07-713160-000 DESCRIBE ACTUAL WORK PERFORMED (cont):

2/0.jlr7 771% ,,.I-A 0-,,L g A.Ji L 4-,

'-.. &.e4il CU Alte- t (datjeds- w- 4 j2.

I* r Ah,4U. 4

- iF ý -

A ..),A ,..,,o

( A lv,.,v--*

-f- I - - -~

, ' V I i~ziP/~~

I ~ AA ýA..AA 1f w I

2, f -- 'I ifzQtQ.J ',nd~caMW\ WQ*z VfUxwa -RomY mlve, 2-z-5-osi(D Qv-cr lmAZ w

ozi