Text

L5-04GA440 (0), SO23-617-1-M1415, Rev. 0, San Onofre, Units 2 & 3 - Replacement Steam Generators Divider Plate Weld Joint Separation Root Cause Evaluation Report. Page 146 Through 484
	ML092600516
Person / Time
Site:	San Onofre
Issue date:	09/10/2009
From:	; Mitsubishi Heavy Industries, Ltd
To:	; Office of Nuclear Reactor Regulation
References
	L5-04GA440 (0), SO23-617-1-M1415, Rev 0
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Document No.LS-04GA440

__________________________ AFLAttachment-A J.... Attachment-A II. Second Investigation II. Second Investigation

1. Purpose Purpose The purpose of this report is to provide provide results of additional additional investigation investigation of II type mockups mockups and boat samples collected from the U38 U3B and U3A RSGs.

2. Background

8ackground discovered on the divider Cracks were discovered divider plate-to-channel plate-to-channel head weld, during the inspections inspections of tube-to-tube tube-to-tube sheet welds in secondarysecondary side hydrostatic test of .Unit Unit 3B RSG. The cracks were 38 RSG.

caused by the separation separation of the divider divider plate and channel head. The same separation separation was also confirmed confirmed in in Unit 3A RSG.

RSG. The II type mockups were made for a part of root cause analysis.

Investigation Methodology

3. Investigation Methodology 2 boat samples were additionally collected collected from Unit 3A RSG at the location location as shown in in Figure A.44. The detail of the each sample sample was shown in Table A.5.

II type mockups and boat samples already taken were also used for additional investigation. investigation.

Table A5 Table A.5 Locations and purpose Locations and purpose of boat boat samples samples Sample Sample No. Location Purpose Purpose Sample F buttering LAS under 152 buttering To investigate the situation of the separation (sample E) between 152 buttering and LAS in in U3A U3A.

Sample G Area of typical 152 152 To investigate the situation of the HAZ (heat buttering without affected zone) of LAS and fusion boundary separation in in UT between 152 buttering and LAS in in U3A.

As for the boat samples already taken (sample A, 8B and C), grain size measurement samples alr~ady measurement was was performed.

The investigation investigation methodology methodology matrix of sample F and G was summarizedsummarized in in Table A.6 A6 As for the II type mockups, grain size measurement measurement and hardness test was also performed.

Grain size in in heat affected affected zone (HAZ) of low alloyallox steel (LAS) was measured steel (LAS) measured with comparison method: some photographs method: photographs of micro structure of the cross section were comparedcompared to figures of G0551:2005 JIS G0551 :2005 standard standard grain size number.

number.

2 Grain Grain size number G is described by equation number of grains per 11mm equation 1 using m: number mm 2 in cross cross section. The grain grain size D 0 is obtained obtained by equation 2.

m = 88 xx22 G (eq. 1)

(eq.1)

D = l/ým = 1/ý8 .2G (eq. 2)

D=1/rm =1/~8x2G (eq. 2)

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~ Attachment-A Attachment-A Table A.6 Investigation Methodology of sample Investigation Methodology sample F and G Item Item Method Purpose Purpose Sample Sample Visual examination Confirm that the sample conditions conditions appearance appearance (contains expected materials)

Separation Visual examination examination at low Evaluate the macro-structure macro-structure of the the surface magnification magnification separation surface separation surface Macro-structure Macro-structure Visual examination examination of the Evaluate the macro-structure macro-structure of the the cross-section at low materials constituting constituting the sample sample magnification after magnification after etching Micro-structure Micro-structure Visual examination examination of the micro-structure of near the Evaluate the micro-structure the cross-section at high cross-section fusion boundary magnification after etching magnification after Examine Examine the existence micro-cracking in existence of micro-cracking LAS LAS Measure the grain size of HAZ Measure HAl Hardness Hardness Measure Vickers hardness Evaluate Evaluate the hardness distribution distribution near thethe fusion boundary and HAl HAZ

4. Results of investigation investigation 4.1 Boat 80at samples A, 8 B and C Table A.7 shows the result of the grain size measurement measurement in HAZ. The photographs in HAl. photographs used for grain size measurement measurement were were shown in in Figures A.45.

The HAl HAZ of 152 buttering tends to reveal larger grains (mean grain size was about 0.1mm) 0.1 mm) compared compared with HAl HAZ of stainless stainless steel clad (mean grain size was 0.02mm 0.02mm to 0.01mm). ItIt was was nd considered that the HAlHAZ of stainless steel clad was refined by heat input of 22nd layer welding.

4.2 Sample F Figure A.46 shows appearance appearance of boat sample FF collected from U3A. The sample contains contains low alloy steel part after sampling of 152 buttering part (sample E).

Figure A.47 shows appearance appearance of fracture fracture surface of the sample. A rough surface was was observed on the fracture surface as observed in sample sample F. ItIt is supposed that the rough surface surface corresponds to welding bead shape buttering.

shape of 152 buttering.

Figures A.48 show macro-structures macro-structures and micro-structures micro-structures of cross section section of sample F. F. The The separation occurs separation occurs along along the fusion boundary between 152 boundary between 152 weld metal metal. In metal and LAS base metal. In higher magnification pictures, the crack paths seem to be similar to the boat samples collected higher magnification from U3B; crack path in fromU3B; in LAS or crack path in in the weld metal locate adjacent adjacent to the fusion boundary. Any micro-cracking micro-cracking inin HAZ HAl was not observed in in the cross section.

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J~ Attachment-A Attachment-A Table A.8-1 shows the results of grain size measurement measurement of HAl 152 buttering HAZ of 152 buttering in sample F.

distributionof The grain size distribution* HAZ of 152 buttering of HAl buttering was almost almost similar to that of boat samples samples collected from U3B. ThereThere were both coarse grained region and small grained coarse grained grained region in HAl HAZ of 152 buttering.

152 buttering.

Figure A.49 shows result of Vickers hardnesshardness measurement measurement of cross section of sample F.

There is no abnormality abnormality in hardness of LAS base base metal and heat affected zone of LAS.

4.3 Sample G Figure A.50 shows appearance appearance of boat sample G G collected from 152 buttering area without without separation separation in U3A. The sample contains low alloy steel and 152 buttering. Any surface cracks cracks were not observed.

Figures Figures A.51 A.51 show macro-structures and micro-structures show macro-structures micro-structures of cross section of sample G. G. Any separations were not observed. The micro structure of sample G was similar to that of sample sample F and and those of boat samples samples collected collected from U3B. Any micro-cracking micro-cracking or defect defect werewere not observed in HAl.

HAZ.

Table A.9-1 shows the results of grain size measurement measurement of HAl HAZ of 152 152 buttering in sample G.

The grain size distribution distribution of HAl HAZ of 152 buttering was almost similar to those of other boat samples. There There were were both both coarse coarse grained grained region and small grained grained region in HAl HAZ of 152152 buttering. Mean grain size of the HAZ was approximately HAl of 152 buttering was approximately 0.1 mm.

Figure A.A.52 52 shows result of Vickers hardness measurement of cross section hprdness measurement section of sample sample G. The The 152 buttering revealed high hardness (HV440 to 480) in colored zone adjacent colored -zone adjacent to the fusion boundary boundary as observed observed in boat samples samples collected from U3B.

4.4 I type mockups mockups Table A.10-1 A.1 0-1 shows the result of the grain size measurement measurement in HAlHAZ ofof, Il type mockups. The The photographs used for grain size measurement photographs measurement were shown in Figures A.53.

Any difference difference in grain grain size was not observed between machining and grinding grinding after 152 after 152 buttering in I type mockups as shown in Figure A. 53(1). The effect of gouging on grain size buttering size was observed before 152 buttering as shown in Figure Figure A. 53(2).

The grain size of HAlHAZ of 152152 buttering in II type mockups mockups tend to be smaller than that of boat samples. It was considered considered thatthat the grain input of 22nd grain refining with heat input nd layer of 152 buttering buttering occurred occurred in II type mockups mockups compared to boat samples, since the distance between fusion line line nd and 22nd layer layer of 152 buttering buttering of I type mockups was smaller than that of boat samples.

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.J...Attach~ent-A Attachment-A Figures A.54 show result of additional additional Vickers Vickers hardness measurement measurement of cross section section of I type mockups. Any significant differences were not confirmed in Vickers hardness distribution distribution and width of HAl HAZ of 152 buttering between between machining machining and grinding after after 152 buttering. The The widths of HAlHAZ of ESW were varied by hardness measurement measurement location.

5. Summaries of the investigation investigation investigation were as follows summaries of the investigation The summaries follows 5.1 Boat samples already taken taken

1) The HAlHAZ of 152 152 buttering buttering tends to reveal larger grains grains (mean grain size was approximately approximately 0.1mm) 0.1 mm) compared with HAl HAZ of stainless steel clad (mean grain size was 0.02mm 0.02mm to 0.01mm).

5.2 Sample F F

1) Sample F F revealed revealed similar rough fracture fracture surface as observed in U3B.

separation occurs in LAS or in weld metal adjacent

2) The separation adjacent to fusion boundary.

Micro-cracking in HAl

3) Micro-cracking HAZ was not observed in the cross cross section.

4) The grain size distribution distribution of HAZ HAl of 152 buttering buttering was almost similar to those of boat samples collected from U3B. There were both coarse grained grained region and small grained HAZ of 152 buttering.

region in HAl 5.3 Sample Sample G G

1) Any surface cracks cracks were were not observed.

micro-cracking or defect

2) Any micro-cracking defect were were not observed in HAl HAZ in cross section.

3) There There were both coarse grained grained region and small grained region in HAl HAZ of 152 buttering.

Mean grain size of the HAZ buttering was approximately HAl of 152 buttering approximately 0.10.1mm.

mm.

4) The 152

4) The buttering revealed 152 buttering revealed high hardness hardness (HV440 (HV440 to 480) in colored zone adjacent to the the fusion boundary boundary as observed observed in boat samples collected collected from U3B.

U3B.

5.4 I type mockups mockups

1) Any difference in grain size was not observed observed between between machining machining and grinding after 152 after 152 buttering buttering in I type mockups mockups

2) The grain size of HAl HAZ of 152 buttering buttering in I type mockups tend to be smaller than those of boat samples. ItIt was considered considered that the difference of distance between fusion line and and nd 2 nd layer of 152 2 152 buttering buttering affected affected to grain size distribution of HAl.

HAZ.

3)

3) Any Any significant differences were not observed in Vickers significant differences hardness distribution and width Vickers hardness width of HAZ of 152 buttering between HAl between machining and grinding after 152 152 buttering.

buttering. The widths of HAZ of ESW were varied by hardness HAl measurement location.

hardness measurement location.

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AAW Attachment-A

~ Attachment-A Cold Cold side

1. ý /

A,B ii AB A.B The separated butter I d ad had already been removed in this area .

.,~ 9 (/ I, A.BSap A,B U The separated butter / clad had already been removed In this area.

,0. / \

.': { /~'

.S *l ',(.', ' \ '.;3)

, Sa\ l

\, ' - ; - - - - -

'-./

\ \

\

t /i~

A.44(1)

Figure A.44(1) The collecting location location and schematic schematic illustration illu stration of boat boat samples.

(collecting (collecting location of boat sample samples) s)

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~ Attachment-A (20) **Fusion Fusion boundary (70) between LAS and between LAS and buttering 152 buttering (8)

/i\

(8) ,~

"'--1-- .

~

~.~ ~ .

LAS LAS c __~

(107)

Divider plate Divider plate (20)

(20) I

'-r 152 buttering LAS LAS c:___~

Figure A.44(2) The collecting location location and schematic schematic illustration illustration of boat samples.

(schematic (schematic illustration illustration of boat samples)

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JAWI Attachment-A Table A.7 A. 7 The results of grain size measurement measurement in A. B in HAZ of boat samples A, and C Band Grain size number/

number/

Weld metal Welding Welding process process Mean, grain size Mean*

Grain size measured measured 4/

4/ 3/

3/ 5/

5/

152 SMAW 0.09mm 0.088mm 0.088mm 0.125mm 0.063mm 6/

6/ 9.5/

9.5/ 9/

9/

ESW 0.024mm 0.044mm 0.013mm 0.013mm 0.016mm Stainless steel 10.5/

10.5/ 12/

12/

SMAW SMAW 0.008mm O.OO8mm

( 0.009mm 0.006mm

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~ Attachment-A Details are shown in in next page page JA Attachment-A Sample A, HAZ by 152 buttering A, HAl buttering (SMAW)

(SMAW)

Grain size number:

number: 4, 0.088mm 4, Grain size: O.088mm Sample B,S, HAZ HAl byby 152 152 buttering buttering (SMAW)

(SMAW) Sample B, HAl by 152 S, HAZ 152 buttering buttering (SMAW)

(SMAW)

Grain size size number:

number: 3,3, Grain Grain size:

size: 0.125mm O.125mm Grain size number:

Grain number: 5,5, Grain Grain size:

size: 0.063mm O.063mm Figure Figu re A.45(1)

A.45(1) Microstructure Microstructure of of the the cross cross section section of LAS channel channel head head in in boat boat samples A andan d B(152 B( 152 buttering) buttering)

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Doc ument No.L-5-04GA440 o.L5-0-lGA440 (0)

AkAttach Attachment-A (0) ment-A 2Du Sample Sample A, A, HAZ HAl by Stainless steel (SMAW)

Grain Grain size size number:

number: 10.5, Grain size:

10.5, Grain size: 0.009mm 7(

4-4 Sample C, HAZ by Stainless steel (ESW)

Grain size number:

number: 9.5, size: 0.01 9.5, Grain size: 3mm 0.013mm

~

I 1\

I 'ý' I .

20 trn

\

Sample C, HAl HAZ by StaStainless Sample C,C, HAl HAZ by Sta Stainless inless steel (ESW)

Sample in less steel (ESW) number: 6, 6. Grain size:

size: 0.044mm Grain size number:

Grain number: 9,9, Grain Grain size:

size: 0.0193 0.0193mm mm Grain size number:

Figure A.45(2)

A.45(2) Microstructure of tthe cross se he cross section ct ion of LAS LAS channel head head in boat ssamples a mple s A aand nd CC

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AW1 Attachment-A

~ Attachment-A Divider plate Divider plate **

4- - - -

Top Top A

A B D D D

q 9

¢:::J LAS channel LAS channel head Bottom Bottom U C

Fracture surface Fracture surface (direction (direction A)A) 234 234 Electron discharge Electron discharge machined machined surface surface (direction B) B)

Electron discharge machined surface (direction C) C) 89 4-1, 2 ...1 ..,4 5. 6 7 Electron discharge machined surface (direction D )

D)

Figure A.46 Appearance of Appearance of sample F collected collected from U3A U3A

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~Attachment-A A.k Attachment-A Fracture surface of sample F 1

1mm lmm Figure Figure A.47 A.4 7 Appearance Appearance of of fracture fracture surface surface of sample sample FF

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)"l Attachment-A Attachment-A (0)

Fusion boundary The location location for detail observation Detail observation of location location A observation of location B Detail observation

j. r-Flla r E u j r' i irgtu .L nlargea A.48(1)

Figure A.48(1) Macro structure and micro structure of cross section of sample Macro structure sample F

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)Ak Attachment-A boundary Fusion boundary Detail observation observation of location C The location for detail observation I Enlarged Enlarged Figure A.48(2)

A.48(2) Macro structure structure and micro structure structure of cross section of sample F MITSUBISHI HEAVY MlTSUBISHI HEAVY INDUSTRIES, LTD.

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Ak Attachment-A J.,.,Attachment-A Table A.8-1 A,8-1 The results of grain size measurement measurement in in HAZ of sample F Welding Welding Grain size number number//

Weld metal Mean grain grair:l size size process Grain size measured 10.5/

10,5/ 5/

5/ 3.5/

3,5/

152 152 SMAW 0.009mm O,009mm 0.063mm O,063mm 0.105mm O,105mm 0.059mm O,059mm (Location A)A) (Location B) (Location (Location C)

C)

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At (0)

Attachment-A Fusio Fusionn boundary Hardness measurement measurement location 600 600 .. _ - _ . . .

LAS LAS_

r--.

l.(")

500 HAZ HAZ II

~i c:i

c 400 /

I 6.

vi I Vl CO Q) I c I\... I 300 -ts

".r:.

~

.... I C\l I I

~

Vl Q) 200 200 I LJ. - -1\

u I I

> Il 100 L. . .. . I I

I

.1 0

0o 2 4 66 88 Distance from fusion line (mm) (mm)

Figure A.49 Vicker s hardness of cross section Vickers sect i on of samp sampleIe F

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)k

~ Attachment-A Top Divider plate Divider A

B q

Boto 152D D

¢:::l 1 52 buttering 152 buttering Bottom Bottom LAS LAS U cC Surface of 152 buttering Surface buttering (direction A )

A)

Electron discharge machined surface (direction discharge machined (d irection B)

B)

Electron discharge Electron discharge machined surface surface (direction C) C)

Electron Discharge Machined Machined Surface (Direction D)

Surface(Direction D)

Figure Figure A.50 Appearance of boat sample G Appearance

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)*Attachment-A Attachment-A (0)

Cross section 1 The location for detail observation observation 55mm oamt Detail observation observation of location A Detail observation Detail observation of of location location BB Enlarged Enlarged Enlarged Lniargea Co Iored zone ,

FiurAr s e a20pmro Figure A. 51(l) Macro structure and micro structure of cross section I of sample G Figure A. 51( 1) Macro structure and micro structure of cross section 1 of sample G Page 162 of 484 S023-617-1-M1415, Rev. Rev . 0

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Ak Attachment-A Attachment-A The location location for for detail observation observation 5mm Smm Detail Detail observation observation of of location location C servation of location D Enlarged Enlarged

- ~

Enlarged Enlarged S t j Colored zone

' ~ "'"

I,.

, . S. '. r .~

Figure A.

Figure A. 51 51(2)

(2) structure and micro structure of Macro structure of cross section 2 ofof sample G G Page 163 163 of 484 S023-617-1-M1415, Rev S023-617-1-M1415, Rev.. 0

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Attachment-A Attachment-A T The location location for for detail observation observation 5mm 5mm Detail Detail observation observation of location location E Enlarged Enlarged Colored zone 51(3)

Figure A. 51 (3) structure and micro Macro structure micro structure structure of cross section section 2 of sample G G Page 164 164 of 484 S023-617-1-M1415, Rev. 0 S023-617-1-M1415,

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~Attachment-A Iý Attachment-A Cross section 3 The The location location for detail detail observation observation 5mm Smm Detail observation observation of of location location F Detail Detail observation observation of of location location G

+ Enlarged ý Enlarged Enlarged 1C, -A-OIL 4W KV-11.4ý-, 20pm ýý7 -- -ff , t I A. 51(4)

Figure A. Macro structure and micro structure of cross cross section 3 of samplesample G G Page 165 Page 165 of 484 S023-617-1-M1415,. Rev. 0 S023-617-1-M1415

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. Attachment-A (0)

Table A.9-1 Table A.9-1 grain size The results of grain size measurement measurement in in HAZ HAZ ofof sample sample GG Welding number/

Grain size numberl Weld metal Weld size Mean grain size process Grain size measured 3.5/

3.51 3/

31 0.105mm 0.105mm 0.125mm 0.125mm --

(Location A) (Location B)

(Location B) 10.5/

10.51 4.5/

4.51 2.5/

2.51 152 SMAW 0.009mm 0.074mm 0.148mm 0.096mm

0.096mm (Location C) (Location D)

(Location D) (Location E) 2.5/

2.51 5/

51 0.148mm 0.063mm -

(Location F) (Location G)G)

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~ Attachment-A Attachment-A The location location for hardness hardness test (cross sect sectionion 2) 5mm 5mm 600 600 152 buttering butte r ing *-----*

oil

LAS LAS

,-- 500

..-.- ,A Load: 500g Ln !:-:. Load: 500g 0

- Load: 2g I 400 II)

II)

Q) cC

-o

'"C

~

300

.u

<Il

...c U)

II)

~

Q) 200 S200

...:x:

Q

>100 100 0

--88 -6

-6 -4

-4 --22 0 22 4 6 8 Distancee from Distanc fusion bou from fusion nda ry (mm) boundary (mm) y 1

T Enlarged Transition zone Transition zone 600 * "229 229 152 buttering butt ering 4-oil I *o- LAS LAS 212

- 212 Colored CO I or ed Ilzone

.zone 222 a222 2

221 221 N

c'J 500 . ' . 224 C

0 a

a ;t

258

226 0c::i A Load:

!:-:. Load : 500g t ~248* 219 IJ: 400 .

Looad: 2g L 2g 231 . .. 248 A

2~~

"

23164 264 III III a,

.~

Load: 7 2

.. 264 .. 154

265 265 _,

0 300

" 24~ 258

~ ~t~.f +t ~~

-o .. -276

-E

-z

.<:: Co lor ed zone

2

247' ?53 ..242 476 472

"' 236" 238 . ~ 449 449 46J 251 III

....a' 200 ~ . \

~,

OJ

-"0 -I, 454 443 " 255 ~ 232 *

>" 100 100 .. 264 295 "AI

~ 242 .. 268 u0

'J k 239

252

273

-0.2

-0.2 -0.1

-0.1 o0 0.1 0.1 0.2 0.2

176 ,

Distance Di from stance fr om fu fusion sion boundary (mm (mm)) " 221 '" 297

" 262

253 I ,o..m I

284

255. 280 Figure A.52 A,52 Vickers hardness of cross section Vickers hardness section of sam sample ple G

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~Attachment-A AFL Attachment-A Table A.10-1 A.1O-1 The results of grain size measurement in size measurement in HAZ of I type mockups mockups Process of clad clad Grain size number/

number /

Welding process Mean grain size size removing removing Grain size measured Grain size measured SMAW 10.5/

10.5/ 10.5/

10.5/ 0.009amm Gouging and grinding Gouging and grinding (152 buttering) 0.009mm 0.009mm 0.009mm (152 buttering) 0.009mm 0.009mm SMAW 10.5/

10.5/

Machining Machining (152 buttering) 0.009mm --0.009rmm 0.009mm (152 buttering) 0.009mm Gouging 14/

14/ 0.003rmm

- - -- 0.003mm (without ESW clad) 0.003mm 13/

13/

Gouging and grinding - - 0.004mm 0.004mm *1 0.004mm *1 10/

10/

Machining Machining - - 0.011 mm O.Ollmm 0.011 O.Ollmmmm *2

1 Grain

1 Grain size of HAZ of gouging gouging

2 Grain

2 Grain size of of LAS base base metal machined machined

")

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Document No.L5-04GA440 o.L5-04GA440 (0) (0) ilk Attachment-A A,Attachment-A

-4 20um .f<4 7 TP.2-2, ESW ++ Gouging + grinding + 152 buttering buttering (SMAW)

Grain number: 10.5, Grain size number: 10.5, Grain size size:: 0.009mm TP2-2, ESW + Gouging TP.2-2, Gouging + grinding grinding + 152 buttering (SMAW)

Grain size number: 10.5, Grain number: 10.5, Grain size:size: 0.009mm

'.7 0

)7777 7~..77*

7; Aj~

~

7777{~ 7~, ~ 7 777 ~ 4~{~ ~ 7 77~ 777 777,77 *7Ž~ ~

~777 20u TP.3-1, TP.3-1 , ESW + Machining Machining + + 152 buttering (SMAW) 152 buttering (SMAW)

Grain Grain size number:

number: 10.5, 10.5, Grain Grain size size: 0.009mm 0.009mm Figure Figure A.

A. 53(1) 53( 1) Microstructure Microstru cture of of the the cross cro ss section section of of LAS LAS in in I type model model (after 152 152 buttering) buttering)

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Document A

Document No.L5-04GA440 NO.LS -04GA440 (0)

A kI Attachment-A (0)

Attachment-A TP.2-1, TP.2-1 , ESW ESW + Gouging + grinding grinding Grain size number:

number: 13,13, Grain Grain size:

size: 0.004mm 0.004mm TP.4-2, gouging TP.4-2, As gouging Grain Grain size number:

number: 14,14, Grain size:

size: 0.003mm 0.003mm TP.3-1,, As machini TP.3-1 machining ng Grain size number:

Grain number: 10, Grain size: 0011mm size: 0.011mm Figure A.

A. 53 53(2)

(2) Microstructure of th Microstructure thee cross cross section of LAS LAS in in I type mode modell (before 152 buttering) buttering)

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~ink Attachment-A Attachment-A clad of ESW clad HAZ of Line A Line A HAZ of HAl HAl of 152 buttering buttering

300 300 250 1~~buttering

b 152 ....

152 I/\

-* LAS LAS LLJ... -r Ln 250 I buttering oo t I

):

I'2n0200 02 I U,

VJ I VJ I Q) c 150 .-- 1 B -c

-c II .. . Ij ro

..c I ~I I

... _ v

..,I I I I VJ S100 100 r_

II jI I I

I Q)

~

I I Une C .25 50 .- HAZ. of 152 HAl 1521I HAl HAZ of of ESW I -

I . 1 ..

I > 50 I b~ttering blittering II clad I

I I

1 I ' I 0

-5 location -5 00 55 10 10 15 15 measurement location Hardness measurement Hardness Distance from fusion boundary ((mm)

Distance mm )

Line B 3 0 0 . Line 300

..152 B - . . -. LASt . I.

I 152 +-i7 LAS I I I p250

-,:n 250 I buttering buttering _

o oI I

):

I> 200 . . .

VJ bI t I I VJ Q) 0 -

~

C-ro

..c

~

Q) 150 -150 100 1H2 0

II H~l of of 152:

!I 5

HAz of HAl I

I ofl Esw ESW 1

1 1 u

50 ~----- I----r l - - - --T-S50 buttering buttering II clad clad I 1 3 00 o I----~~~~I--~~,~I~~~~~~~~------~

-T

-5 0 5 10 15

-5 o 5 10 15 Distance from fusion boundary (mam)

Distance from fusion boundary ( mm )

Line Line C C

300 300 152 . LAS I I 152 ~ LAS; ;

,.--..S250 I -buttering.. . .!.I . . ...I I

~--;:r;:t:l---~-

II) 250 ci I.

~

I 200 200 10 J . II~

VJ I VJ Q) I I I c 150 I I I

-c I I I ro

..c 0-- A15 of. 15 I1'--v-----1I E I"-y----J VJ 100 -----

150rin b~I I

I I

I IIla I I

II Q) I I I

~

Fu HAZ HAl of of 152 152 II HAZ HAl ofiofl ESW ESW M::; 5 50 0SH It- . -- ..... bbjttering 1 -

Iclad I . ............

-- I1- - -~

-50 b~ttering 0 I clad 5 I 01 0 I II I

_ I 1_ - ~L __

0

-5 0 5 10 15

-5 0 5 10 15 Distance from fusion boundary (mam)

Dis ta nce from fusion boundary ( mm )

Figure A. 54(1) Vickers hardness of cross section of I type mockup 2-2 Figure A. 54(1) Vickers hardne ss of cross section of I type mockup 2-2 MITSUBISHI HEAVY INDUSTRIES, LTD.

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A k Attachment-A HAZ of ESW clad Line D 300 1b52 HAZ of 152 buttering buttering A*+-LAS 250 t -

G 200 II

-t 150 I

_0 E 100 50 buttering I clad I 0

-5 0 5 10 15 Hardness measurement location Distance from fusion boundary (mm)

Line E 300 152 - LAS i buttering ----

2501 6 . ... I I 200 I II (I)

U) a C 150 I

- I L

U) a 100 0 HpAZ of 152, HAZ of ESW 50 buttering I clad I I I 0

0 5 10 15 Distance from fusion boundary (mm)

Line F 300 300

~::t::"i"~l'. ~S;.;;::

152 LA I AI I

n 250 250 ! !

0 5~

I ui rJ) 200 I ~~=--

I I 1 I

Q) c: 150150

!/%

I I

ofII 15ýHZf I 1

I1 1

S

".s::.ro

-C l... II I1 1'--y------1'---y---'1 1I V,

rJ) 1 1 1 l...

Q) 100 100 II1 I - I rII

-"() HAZ 1 of 152i 1 HAZ ofi 1 ESW

> HAZ of .1521 HAZ oflf* ESW

. .. 1--- _ --+

LI. . . _- _

50 b~ittering Iclad I b~ttering /I : clad I S I I 0 --

-5

-5 0o 5 10 15 Distance from fusion boundary boundary (mm)

Figure Figure A.

A. 54(2) 54(2) Vickerss hardness Vicker hardness of cross cros s section section of I type mockup 3-2 3-2

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~A Attachment-B Attachment-B J-I-Type Type Tensile Test Tensile Test MITSUBISHI HEAVY

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ilk Attachment-B Attachment-B

1. Purpose The main purpose of this test is to confirm confirm whether the small mockup tensile test (I(I type type model) can reproduce fracture at fusion boundary reproduce the fracture boundary of weld which occurred in Unit 3. The The secondary purpose is to examine the difference difference between gpuging gouging and machining machining on the the fracture at fusion boundary.

boundary.

Outline of test

2. Outline The mockups mockups (I (I type model) were fabricated, simulating the fractured weld betweenbetween LAS LAS and alloy alloy 152. Two types of methods to remove remove stainless steel cladding were employed.

~as gouging which was applied for Unit One was Unit 3 and the other was machining machining which whibh waswas applied for Unit 2.

Smooth and notched tensile specimens specimens were machined machined from these mockups mockups and tensile tensile tests at room temperature temperature in air and fracture surface observations were conducted.

conducted.

3. Test method Mockup (I 3.1 Mockup (I type model) model)

The fabrication flow chart of mockup (I(I type model) is shown in Fig. B.1. manufacturing B.1. The manufacturing procedure for the actual SG was reproduced procedure reproduced including heat treatment and inspection.

inspection. To examine metallurgical metallurgical feature of mockup mockup at intermediate intermediate stage of fabrication, fabrication, test sample sample was machined from the mockup machined ,from mockup and metallurgical examination examination was conducted. To confirm the gouging gouging effect, gouging was appliedapplied to the surface surface of mockup mockup without without stainless steel cladding and metallurgical metallurgical examination examination of it was conducted.

configuration of mockups The configuration mockups is shown shown in Fig. B.2.

3.2 Tensile specimen Three types of tensile specimens specimens were tested. One was typicaltypical smooth specimen and the the specimen~ which radius of notch root was 2mm and 4mm (See Fig.

other two were notched specimens B.3).

1.3). The notched specimens specimens were applied to examine the effects of constraint constraint on fracture fracture because there is three-dimensional mode because three-dimensional constraint constraint around fracture fracture location in the actual SG.

The specimens specimens were machined machined from mockups to make the longitudinal direction direction of specimens same as the height direction direction of mockups. The fusion boundary boundary of weld was set at the center of smooth smooth specimen specimen or the root of notched notched specimen.

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Attachment-B 3.3 Tensile test Tensile tests were were conducted conducted in room temperature temperature air with 1 10tonf(98kN)universal atonf (98kN) universal test machine. The test procedure according to JIS Z 2241 procedure was according (98).

2241(98).

4. Test results 4.1 Tensile test The results of all tensile tests are shownshown in Table B.1 and Photographs Photographs of specimen and fracture surface surface were shown shown in Fig. B.4 BA and B.S.

B.5.

As shown in Fig.BA, smooth specimens Fig.B.4, all smooth specimens were broken at 152 buttering or welding portions portions and did not fracture at the boundary boundary between LAS and 152 buttering. buttering. As shown in Fig.B.5, notched specimens all notched specimens were broken at the notch but all fractured fractured surfaces shows ductile ductile feature and brittle fracture surfacesurface which was observed observed in the actual SG was not reproduced.

No difference difference between gouging machining on the tensile strength gouging and machining strength was observed.

4.2 Metallurgical Metallurgical examination examination The results of metallurgical examination (macro metallurgical examination (macro structure, micro structure, hardness hardness measurement and surface measurement etching) on mockups surface etching) mockups are summarized summarized in Attachment Attachment C.

The following results were obtained.

(1) Metallurgical structure observed Metallurgical observed near the fusion boundary of the mockup mockup to which gouging gouging was applied was similar to that observed near the fusion boundary boundary of Unit 3, but were found to have aa smaller grain size than the as-built (boat/strip) samples. It is considered that this was because because grain refining occurred occurred in the I-Type samples samples under application of the second layer the heat input during application layer of the butter, because the the distance between the butter/base distance butter/base metal fusion boundary boundary and the second layer of the butter was smaller on the I-Type I-Type samples samples than on the actual actual RSGs.

(2) Hardness Hardness near near the fusion boundary of the mockup to which gouging was applied was was measured in Unit lower than that measured Unit 3, but itit is estimated estimated that this difference can be due due scattering.

to scattering.

(3)

(3) It is estimated that there is no difference difference of metallurgical metallurgical structure and hardness hardness near the fusion boundary between between the mockup gouged gouged and the one machined.

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Attachment-B Attachment-B

5. Summary

5. Summary The small mockup tensile test (I(I type model) did not reproduce the fracture at fusion The boundary of weld which occurred in Unit 3.

Metallurgical feature near Metallurgical near the fusion boundary boundary ofof the the fabricated mockup was similar to that observed near the fusion boundary of Unit Unit 3.

3.

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Attachment-B Attachment-B A,B A,B Fig. B.1 Fig. B.1 Flow Flow chart chart of manufacturing IItype of manufacturing type mockup mockup MITSUBISHI HEAVY

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Attachment-B 6~~

A,B A,B Fig. B.2 Appearance mockup Appearance of I type mockup

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~ Attachment-B Attachment-B A,B A,B Fig.B.3 Tensile test specimen MITSUBISHI HEAVY

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~. Attachment-B Attachment-B3 Table B.1 Result Table Result of of Tension Test A,B A,B Spec Specimen Specimen Test.No Test. No Type Type 0*-2-1

(%)-2-1

(%)-2-2 (2)-2-2 R2 R2 notched notched (2)-2-3

(%)-2-3 Effect of gouging ()-2-4

(%)-2-4 (Simulating U3) (Z-2-5

(%)-2-5 R4 notched notched (Z)-2-6

(%)-2-6

~-2-11 (c-2-11 Smooth

~-2-12

()-2-12 (3)-2-1

@-2-1 (2)-2-2

@-2-2 R2 notched notched (1)-2-3

@-2-3 Effect of

(-2-4

@-2-4 machining machining (a)-2-5

@-2-5 R4 notched R4 notched (Simulating U2)

(Simulating U2)

(1-2-6

@-2-6

@-2-11 So-2-11 Smooth Smooth I/

A,B

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~ Attachment-B

-Attachment-B Specimen Specimen Spec Spec Test.No Test.No Appearance Appearance Type Type

@-2-11 Effect Effect of of JIS 4 gouging gouging 2 7 07i-2-1

'2ý-2-12

@-2-12 Q)-2-11 1,-2-11 Effect of JIS 4 machining machining

@-2-12

'3-2-12 Fig.B.4 Fig smooth specimen after

.SA Photograph of smooth after test (Sample @-2)

C1-2)

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Attachment-B Attachment-B A,B A,B Fig.B.5-1 Fig. B. 5-1 Photograph of fracture surface (0)-2) surface (Sample (6)-2)

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~ . Attachment-B Attachment-B A,B A,B Fig.B.5-2 Fig.B.5-2 Photograph Photograph of of fracture fracture surface surface (Sample 2-2)

(Sample ~-2)

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AOL Attachment-B Attachment-B A,B A,B Fig.B.5-3 Photograph of fracture surface (Sample @-2)

Photograph (3_-2)

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(0) 4 Attachment-B

.A. Attachment-B A,B A,B Fig.B.5-4 Fig. B.5-4 Photograph Photograph of of fracture fracture surface surface (Sample (Sample (3)-2)

@-2)

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_______________________ .J.... AW Attachment-C Attachment-C Attachment-C

-Type Metallurgical I-Type Metallurgical Examination Examination MITSUBISHI HEAVY INDUSTRIES,

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_________________________ ~ ,~Attachment-C Attachment-C

1. Sample J)-1 (1)-1 (1) Purpose (1) Purpose metallurgical structure and hardness To examine the metallurgical hardness in in heat affected zone of low alloy steel after electroslag welding.

welding .

Fabrication process process electroslag Gouging + Machining Tensile test welding grinding Machining welding Machining

('2:D-1 (2)-2 (g)-1 @.2 Effect Effect of Macro-structure Macro-structure Macro-structure Macro-structure gouging Micro-structure Micro-structure - Micro-structure Micro-structure (Simulating U3) Hardness Hardness Hardness Hardness Surface etching etching Tensile test (j)..1

@:D1 @--1.

1, @-24-2 Effect of Macro-structure Maro-structure Macro-structure Macro-structure removal of HAZ removal of HAZ Mirotture Micro-structure Micro-structure Micro-structure by gouging Hardness Hardness Hardness Hardness 30-1 (1-2

@-1 @-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure machining machining - Micro-structure Micro-structu re Micro-structure Micro-structure (Simulating U2)

(Simulating Hardness Hardness Hardness Hardness Surface etching Surface Tensile test (2)Results Macro-structure observation:

Macro-structure observation : The maximum maximum depth of heat affected affected zone zone by electroslag electroslag welding is(

is( A*B A,B ))as as shown shown in Fig Fig.C.1.

.C.1 .

Micro-structure Micro-structure observation:

observation: The colored zone with width width oft of ( .\ B A. )) is observed observed inin fusion boundary between stainless steel clad and LAS as shown in boundary between in Fig Fig.C.2.

.C.2.

Hardness Hardness measurement:

measurement: The hardness hardness of stainless stain less steel clad is about HV(0.5)(.AJ4tas HV(O.5) (A,B) as shown shown in in Fig.C.3.

Fig .C.3. The hardness of heat affected affected LAS is HV(OHV(0.5)(

.5)( A,B A,B ]and hardness land hardness of colored zone along fusion line is highhigh and HV(0.002)(

HV(O.002)( A.B A.B ).).

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________________________ J... Ak Attachment-C Attachment-C A,B A,B

/

Fig.C.1 Fig.C.1 Macro-structure observation Macro-structure observation

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)'L Attachment-C

~ Attachment-C A,B A,B Fig.C.2 Micro-structure Micro-structure observation

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A Document No.L5-04GA440 Document

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C NO.LS-04GA440 (0)

(0)

Attachment-C AB A.B Fig. C.3 Result of Vickers hardness measurement measurement MITSUBISHI HEAVY

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_________________________ A ~k Attachment-C Attachment-C

2. Sample (2)-1

2. Sample Z2-1 (1) Purpose Purpose examine the metallurgical To examine metallurgical structure and hardnesshardness of low alloy steel after removing removing electroslag welding by gouging electroslag welding gouging and grinding the surface surface process Fabrication process electroslag electroslag Gouging Gouging + Tensile test Machining welding welding grinding grinding Machining

@-1 -2 Effect Effect of Macro-structure Macro-structure Macro-structure Macro-structure gouging gouging Micro-structure Micro-structure - M icro-structu re Micro-structure (Simulating U3) Hardness Hardness Hardness Surface etching Tensile test CD-1 T-1 @- 1, *-2

-1. @-2 Effect Effect of Macro-structure Macro-structure Macro-structure Macro-structure ro gofgHAZ removal of HAZ by gouging Micro-structure Micro-structure Hardness Micro-structure Micro-structure Hardness by gouging Hardness Hardness

@-1 @-2 Effect Effect of Macro-structure Macro-structure Macro-structure Macro-structure machining machining - Micro-structure Micro-structure Micro-structure Micro-structure (Simulating U2) Hardness Hardness Hardness Surface etching etching Tensile test (2) Results Macro-structure observation Macro-structure observation: The partial heat affected zones by gouging are observed as shown shown in Fig.C.4 Fig.C.4..

Surface etching:

etching : Some circular circular heat affected zones by gouging are observed observed as shown Fig.C.5.

in Fig .C.S.

Micro-structure observation: The partial heat affected Micro-structure observation affected zones by gouging gouging are observed as as shown in Fig.C.6.

FigC .6 The size of one is( is (A,SA.11 Jof width,, (( A,S

)of width X.B Jof)of depth and that of thethe other is( A,B otheris( A,S ]of width,((

)ofwidth, A.11 A,B Jof Jofdepth.

depth.

Hardness measurement:

measurement: The hardness hardness of heat affected affected zones zones by gouging gouging is about HV(0.5)(A,B~as HV(O.S)( A,SJ as shown in Fig.C.7. hardness of LAS at the location Fig .C.7. The hardness location 4mm from heat affected zone by gouging gouging is HV(O HV(0.5)\.BI1.

.S)("\,S). The cause hardening in heat affected zones cause of hardening zones by gouging is estimated by the effect of gouging gouging and the effecteffect of cold working by by grinding.. (Detail grinding (Detail estimations estimations are described later in sec. of @-1) 9-1 .)

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________________________ J.... )A Attachment-C Attachment-C A,B A,B

-I Fig.C.4 Fig.CA Macro-structure observation Macro-structure observation r

A,1B A,B Fig.C.5 Fig.C.S Surface observation observation after etching etching MITSUBISHI HEAVY INDUSTRIES, LTD. - - - - - - - - - - -

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Attachment-C Attachment-C A,B A,B Fig.C.6(1)

Fig.C.6(1) Micro-structure observation Micro-structure observation

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...i.

,+/- Attachment-C Attachment-C A,B A,B Fig.C.6(2)

Fig.C6(2) Micro-structure observation Micro-structure observation

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Ak Attachment-C

.J... Attachment-C A,B Fig. C.7 Result of Vickers Vickers hardness measurement hardness measurement MITSUBISHI HEAVY INDUSTRIES, LTD. - - - - - - - - - - -

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.LS-04GA440 (0) (0 )

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C pO Attachment-C 3.

3. Sample (3-1@-1 (1) Purpose To examine examine the metallurgical metallurgical structure removing structure and hardness of low alloy steel after removing electroslag welding electroslag welding by machining machining Fabrication process process electroslag electroslag Gouging Gouging + Tensile test Machining welding grinding Machining C2-1

-1 02(-2

-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure gouging M icro-structu re Micro-structure - Micro-structure Micro-structure (Simulating U3)

(Simulating Hardness Hardness Hardness Hardness Surface etching etchinQ Tensile test Effect of T*-1 (1)-1 @-1, *-2 (4-1, @-2 Eectvl of Effect of Macro-structure Macro-structure Macro-structure Macro-structure ro gofgHAZ removal of HAZ Micro-structure Micro-structure Micro-structure Micro-structure by gouging Hardness Hardness Hardness Hardness

@-1 @-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure machining - Micro-structure Micro-structure Micro-structure Micro-structure (Simulating (Simulating U2) U2) Hardness Hardness Hardness Hardness Surface etching Tensile test (2)Results (2)Results Macro-structure observation:

Macro-structure observation : Heat Heat affected zone by machining or stainless clad is not observed observed as shownshown in in Fig Fig.C.8.

.C.B.

etching:: Heat Surface etching Heat affected zone by machining or stainless stainless clad is not observed as as shown in in Fig.C.9.

Fig .C.9.

Micro-structure observation Micro-structure observation:: Heat affected zone by machining machining or stainless stain less clad is not observed as shown in in Fig FigC,10.

.C.1O.

Hardness measurement:

Hardness measurement: The hardness of LAS near the machined surface is about HV(O . 5 ~ A,B))while HV(0.5XAB while at the location 2mm from the surface is HV(O.5)(A.B HV(0.5)(AB)as ] as shown in Fig.C.11.

Fig .C.11 . The hardening near the mach machined ined surface is assumed to be produced produced by electroslag welding.. The hardened electroslag welding hardened zone HV(0.002JA,B)is zone of about HV(O .002{AB]is observed observed very nearnear machined the mach ined surface and this hardening hardening is assumed assumed to be produced produced by electroslag electroslag welding and machining.

machining .

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________________________ J... At Attachment-C Attachment-C A,B A,B

_1 Fig.C.8 Fig.C.B Macro-structure observation Macro-structure observation

\

A,B A,B J2 Fig.C.9 Fig.C.9 Surface observation etching observation after etching

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; . . . Attachment-C Attachment-C m

A,B A,B Fig.C.10 Fig.C.10 Micro-structure observation Micro-structure observatior

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_ _ _ _ _ _ _ _ _ _ _ _....,-_ _ _ _ _ _ _ _ _ _ ~ Attachment-C A Attachment-C A,B A.B Fig. C.11 Result Result of Vickers hardness measurement hardness measurement MITSUBISHI HEAVY

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Document No.LS-04GA440 No.L5-04GA440 (0) (0)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C A k Attachment-C 4.

4. Sample *-1 @-1 (1) Purpose Purpose examine the metallurgical To examine metallurgical structure and hardness hardness of low alloy steel just after gouging gouging Fabrication process Fabrication process electroslag electroslag Gouging + Machining Tensile test Machining welding grinding grinding C2-1 Z-2

~-1 ~-2 Effect Effect of Macro-structure Macro-structure Macro-structure Macro-structure gouging Micro-structure M icro-structu re - Micro-structure Micro-structure (Simulating U3) Hardness Hardness Hardness Hardness Surface etching Tensile test CD-1 T-1 @-1, (1-1, @-24-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure by gouging removal of HAZ Micro-structure Micro-structure Micro-structure Mjero-structure by gouging Hardness Hardness Hardness Hardness

@-1 @-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure machining machining - Micro-structure M icro-structu re Micro-structure Micro-structure (Simulating U2)

(Simulating Hardness Hardness Hardness Surface etching Tensile Tensi le test Results (2) Results Macro-structure observation Macro-structure observation: The maximum maximum ( \,f3

.B )thick

) thick heat affected zones by heat affected gouging are observed observed as shown in Fig.C.12.

Fig .C.12.

Micro-structure observation:

Micro-structure observation : The heat affected zones by gouging gouging and black deposit near near surface surface are observed as shown in Fig.C.13.Fig.C.13. The deposit deposit isis estimated to be a layerlayer of carbon which is main main composition composition of arc weldwelding electrode.

ing electrode.

Hardness measurement: The hardness of heat Hardness measurement: heat affected zones by gouging is about HV(0.5)(:\.B]as HV(05)(A,Bl as shown in in Fig.C.14.

Fig.C.14. The hardness hardness with light light load of 0.002g is alsoalso same same value. This value . Th is hardness of LAS is lower than HV(0.5)(A[i)in HV(05)(A,B)in heat affected zone zone inin Fig Fig.C.7.

.C.?

The cause of hardening hardening in heat affected affected zones zones by gouging Fig.C.7 is estimated by the goug ing in Fig.C.l the effect effect of gouging and the effect effect of cold working by grinding grinding..

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C

)k Attachment-C A.B Fig.C.12 Macro-structure observation Macro-structure

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________________________ A Jý Attachment-C Attachmerit-C A,B Fig.0.C13 Fig.C.13 Micro-structure observation Micro-structure

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C AO. Attachment-C A,B A,B Ig. U.14 f-ig.

I- C. 14 i(esult Kesult or OTVICKers nard ness measurement VIcKers naraness measurement

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C )O Attachment-C

5. Sample @-2

5. Sample @-2 (1) Purpose Purpose To examine examine the metallurgical structure and hardness hardness of low alloy steel after gouging gouging and final stress relief heat treatment (595+/-300C S treatment (59S+/-30°C 5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months )

Fabrication process process electroslag electroslag Gouging +

Gouging Machining Tensile test Machining welding grinding grinding C2-1 20-2

~-1 ~-2 Effect Effect of Macro-structure Macro-structure Macro-structure Macro-structure gouging Micro-structure Micro-structure - Micro-structure Micro-structure (Simulating U3) Hardness Hardness Hardness Hardness Surface etching etching Tensile test (1)-1 @-1, (T-1 @-2 14)-2 EffectofofHAZ Effect removal Macro-structure Macro-structure Macro-structure Macro-structure by gouging removal of HAl Micro-structure Micro-structure Hardness Micro-structure Micro-structure Hardness by gouging Hardness Hardness C1-1

@-1 (1)-2

@-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure machining machining - Micro-structure Micro-structure Micro-structure Micro-structure (Simulating U2) Hardness Hardness Hardness Hardness Surface Surface etching Tensile test (2)Results Macro-structure observation Macro-structure observation: : The maximum(

maximum ( A.13 A.S )) thick affected zones by heat affected gouging are observed observed as shown shown in in Fig.C.1 Fig.C15. 5.

Micro-structure observation Micro-structure observation:: The heat affected affected zones by gouging and black deposit near surface are observed as shown in Fig.C.16.

in Fig .C.1 6 .

Hardness Hardness measurement:

measurement: The hardnesshardness of heat affected affected zones by gouging is about about HV(0.5)(A.B]as HV(OS)(A.BJas shown shown in in Fig.C.17.

Fig .C.1 7. The hardness with light load of 0.002g is also same same value. Compared with Fig value. Compared Fig.C.14

.C.1 4 and FigFig.C.17,

.C.17, the hardness hardness in in heat heat affected zones zones by gouging decreased about 50 gouging is decreased SO by final stress relief heat treatment.

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- Attachment-C

.J.... Attachment-C 7-A,B A,B J

Fig.C.A Fig.C.155 Macro-structure observation Macro-structure HEAVY INDUSTRIES,

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At

~ Attachment-C Attachment-C A,B A,B Fig.C.16 Fig.C.16 Micro-structure observation Micro-structure

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C

)* Attachment-C A,B A,B Fig. C.17 Result of Vickers hardness hardness measurement measurement MITSUBISHI HEAVY

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).

~ Attachment-C Attachment-C

6. Sample ~-2

6. 2-2 (1) Purpose Purpose metallurgical structure and hardness To examine the metallurgical hardness near fusion boundary boundary between between 152 152 mockup test specimen buttering and LAS of mockup specimen Fabrication process process electroslag Gouging Gouging + Tensile test Tensile Machining welding grinding Machining 02-1

~-1

(-

-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure gouging gouging Micro-structure Micro-structure - Micro-structure Micro-structure (Simulating (Simulating U3)U3) Hardness Hardness Hardness Hardness Surface etching etching m~nsile test)

(Tensile test}

Effect of (1)-1 T-1 @-1, C)-2 (A)-1, @-2 Effect of Eectvl of Macro-structure Macro-structure Macro-structure Macro-structure ro gofgHAZ removal of HAZ Micro-structure Micro-structure Micro-structure Micro-structure by gouging by gouging Hardness Hardness Hardness Hardness

@-1 @-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure machining - Micro-structure Micro-structure Micro-structure Micro-structure (Simulating U2)U2) Hardness Hardness Hardness Hardness Surface etching (Tensile test)

(2) Results Results Macro-structure observation:: The (A,S Macro-structure observation (A.B) ) depth depth heat affected zones zones by 152152 buttering in LAS is observed observed as shown in in Fig.C Fig.C.18.

.18. The clear trace affected zone trace of heat affected zone by gouging gouging can not be confirmed.

confirmed.

Micro-structure observation:

Micro-structure observed near fusion boundary as shown observation The white zone is observed in Fig in Fig.C.19.

.C.19.

Hardness measurement:

measurement The hardness hardness of 152 buttering is about about HV(0.5)(A HV(0.5)(A,BiBjas

)as shown shown in in Fig.C.20(1).

Fig .C.20(1) . The hardness hardness of LAS near fusion boundary is about HV (0.5) (A,B] and that (0.5) (A.s)and at the location 2mm from the fusion boundary is HV(0.5)(A,B).

HV(0.5)(,jB).

The hardness hardness of 152 buttering very boundary is from HV(0.002)(

very near fusion boundary HV(0.002)( A,S NB }

The hardness hardness of LAS very near fusion boundaryboundary is from HV(0 HV(0.002)(

.002)( A,S A.B ), but the the hardness of colored zone hardness zone very near near fusion bo boundary HV(0.002)(

un dary is from HV(0.002){ A.11 A.S ) in in Fig.C.20 Fig .C.20 (2).

(2) There is large scattering of hardness very near fusion near fus boundary.

ion boundary.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C

)"L Attachment-C

/

A.B AB

-y Fig.C.18 Macro-structure Macro-structure observation observation

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)k

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . ~ Attachment-C Attachment-C A,B A,B Fig.C.19 Micro-structure Micro-structure observation observation

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C Jot Attachment-C A,1B A,B C.20(1) Result Fig. C.20(1) Result of Vickers hardness hardness measurement measurement

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ AkI ~ Attachment-C Attachment-C A,B A,B Fig. 0.20(2)

C.20(2) Result of Vickers hardness measurement measurement HEAVY INDUSTRIES,

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~~~Attachment-C ) Attachment-C

7. Sample (1-2@-2 (1) Purpose To examine examine the metallurgical metallurgical structure hardness near structure and hardness boundary between 152 near fusion boundary 152 buttering and LAS of mockup test specimen process Fabrication process electroslag electroslag Gouging + Machining Tensile Tensile test Machining welding grinding 2_)1 0)-2

~-1 ~-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure gouging gouging Micro-structure Micro-structure - Micro-structure Micro-structure (Simulating (Simulating U3) Hardness Hardness Hardness Surface etching (Tensile test) 2

) of Effect of . T-1 CD-1 @-L

(-1, @-2

@-2 Effect Macro-structure Macro-structure Macro-structure Macro-structure ro gofgHAZ removal of HAZ by gouging Micro-structure Hardness re Micro-structu Micro-structure Hardness Micro-structure by gouging Hardness Hardness

@-1 @-2 Effect of Macro-structure Macro-structure Macro-structure Macro-structure machining - Micro-structure Micro-structure Micro-structure Micro-structure (Simulating U2)U2) Hardness Hardness Hardness Hardness Surface etching (Tensile test)

)

(2) Results Results Macro-structure observation:

Macro-structure observation: The heat heat affected affected zones by 152 buttering in in LAS is observed as shown in in Fig.C.21.

Fig.C.21.

Micro-structure observation:

Micro-structure observation: The white zone is observed observed near fusion boundary boundary as shown in in Fig.C.22.

Hardness measurement: The hardness Hardness measurement: hardness of 152 buttering buttering is about HV(0.5)(A,Bjas HV(0.5)(A,B) as shown in in Fig.C.23. The hardness hardness of LAS near fusion boundaryboundary is about HV (0.5) (A,B) and that at boundary is HV(O.5)~\'B).

the location 3mm from the fusion boundary HV(0.5)A, B).

The hardness hardness of 152 buttering very near fusion boundaryboundary is from HV(0.002)( AB A,B j.).

The hardness of LAS very near fusion boundary boundary is from HV(O.002)(

HV(0.002)( AB A,B 1. There is large scattering of hardness verynear very near fusion boundary.

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Attachment-C

_ _-;--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-C r

A,B A,B Fig.C.21 Macro-structure Macro-structure observation MITSUBISHI HEAVY INDUSTRIES,

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Attachment-C Attachment-C A.B A,B Fig.C.22 Micro-structure observation Micro-structure MITSUBISHI HEAVY

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________________________ ~ w' Attachment-C Attachment-C A,B A,B Fig. C.23 Result of Vickers measurement Vickers hardness measurement

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,~

Attachment-C Attachment-C

8. High hardness hardness in the heat affected affected zone Hardness Hardness tests were conducted conducted using mockup. Conclusion Conclusion is as follows.

1.

1. Hardened Hardened depths of mockups mockups are the same between between the grooves prepared by machining and gouging gouging to remove ESW stainless steel clad.

2. Hardened Hardened depth observed in boat samples is similar to the mockups that have ESW stainless stainless steel clad and the removal of it is as explained in item 1 above.

3.

3. Mockup Mockup that does not have ESW stainless steel clad and buttered buttered zones to gouged surface does not have hardened area like mockups in item 1 above.

4. Hardened Hardened depth by gouging is the same as the depth of heat affected zone observed macro"structure, which varies from ((

observed by macro-structure, A,B ).].

MITSUBISHI HEAVY

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__________________________ ~ Art Attachment-C Attachment-C Manufacturing process simulated mockup (1) Manufacturing mockup Mockup is prepared with full of manufacturing manufacturing process process simulation.

simulation. That is, Stainless steel cladding Stainless cladding by ESW process process PWHT Remove clad by machining machining (simulate u2) or gouging/grinding (simulate u3) 152 buttering by SMAW process Alloy 152 Joint weld weld of divider plate According According to these mockups, hardened hardened depth (Hv>200) and peak value are almost the same

.~

A,B A,B RCE report; C-26 I type mockup RCE report; C-31 I tYJ2e mockuJ2 J f ..

A,B A,B RCE report; E-16 E-16 RCE report; report; E-20 Scale model mockup mockuJ2

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At. . . Attachment-C

Attachment-C Reference; Hardness Reference; Hardness of heat affected zone of the boat samples samples 152 buttering

\ SS cl clad ad LAS LAS surement line Measurement Mea I ine of hardness The position of hardness test test 500 600 600 II LAS LAS 400 LAS lAS I1 152 -butteri butter inng. E! 500 500

+

. I 400 400 300 300 . . ...

J" l-.-..

300 300 ,

c~

200 200

> 100 100 f * ..... -

I 5

zoo 200 ~--- ~

100 100 I

I o0 0

-5 0 5 10o0 15 15 -z

-2 0 2 4 6 8 10 12 14 Disýt-- from Distance from .i-..s (mn,o crack (mm)

Distance from from fusion boundary (mm)

(mm)

Boat samplesa mple A Boat sample B RCE report A-32 A-32 RCE reportreport A-50 SS cclad SS I ad 1 LAS LAS r Position of hardness test test 600 500 500 LAS SS cclad lad

5

~

6 I

J: 400 -

"c 300

~

x" 200 . ."'" ~

~f"~

> " 100 100 0

--15 15 -10

-10 -5

-5 0 5 10 10 Distance from Distance fusion bounday from fUSIon mm) boundary (mm Boat sample Boat samp le C RCE repo report rt A-64 A-6 4

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~ Attachment-C Attachment-C (2) Mockup Mockup without without ESW Mockup is prepared without ESW stainless steel clad and without finishing after gouging. That is, Remove low alloy steel steel by gouging and no grinding or buffing buffing is applied applied to finish gouged surface.

Alloy 152 buttering buttering by SMAW SlVlAW process on as gouged gouged surface.

Joint weld of divider divider plate According According to this mockup, hardness hardness is similar to that of base material material and is much lower than that of HAZ in test (1) above.

A,B No ESW clad => removed by gouging RCE report; D-10

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______________________ ; A . . . Attachment-D Attachment-D Attachment-D Additional J- I-Type Type Test Test MITSUBISHI HEAVY

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1. Purpose Purpose The purpose purpose of this test is to obtain metallurgical metallurgical feature and tensile strength of fusion boundary of the weld which was welded on the gouged surface without boundary without grinding.

2. Outline of test The mockup (I(I type model) model) was fabricated fabricated where 152152 butter was welded on LAS LAS after gouging without grinding.

examination of the mockup Metallurgical examination Metallurgical mockup was conducted and smooth and notched tensile tensile specimens were specimens were machined machined from it. Then, tensile tests and fracture fracture surface surface observation observation were were conducted at room temperature.

conducted

3. Test method 3.1 Mockup Mockup (I(I type model) fabrication flow chart The fabrication chart of mockup mockup (I was D.1. Alloy 152 clad was (I type model) is shown in Fig. 0.1.

welded on the gouged surface without grinding and the mockup was fabricated.

electrode might remain when 152 carbon included in arc electrode For the reason that carbon was 152 butter was gouging without grinding, the hardening welded on LAS after gouging near fusion boundary hardening near boundary could could temperature cracking could increase, FSR occur and the susceptibility of low temperature occur FSR was done done 48 48 post-heating to provide enough time for cold cracking hours after post-heating cracking to appear.

appear.

mockups is shown in Fig.

The configuration of mockups D.2.

Fig. 0.2.

3.2 Tensile 3.2 specimen Tensile specimen Two types of tensile specimens were were tested. One was typical smooth smooth specimen and the the other was notched notched specimen which radius of notch notch root was 4mm. The specimens were were machined longitudinal direction mockups to make the longitudinal machined from mockups specimens parallel to the direction of specimens the mockups. The fusion boundary of weld was set at the center of smooth height direction of mockups.

height specimen or the root of notched specimen.

specimen specimen.

3.3 Tensile Tensile test Tensile Tensile tests were were conducted at room temperature 10tonf(~8kN)universal condition with 10tonf(98kN)universal temperature condition procedure was according to JIS Z 2241 test machine. The test procedure 2241(98).

(98).

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4. Test results 4.1 Tensile test The results of all tensile tests are shown in table 0.1 D.1 and Photographs Photographs of specimen specimen and fracture surface were shown in Fig. 0.4 D.5.

D.4 and 0.5.

As shown in FigD.4, smooth specimens Fig.D.4, smooth specimens were were broken at LAS base metal and fracture at boundary between between LAS and 152 152 buttering did not not occur. As shown shown in Fig.D.5, notched notched specimens were broken at notch but all fracture surfaces showed ductile ductile feature and brittle brittle fracture surface which fracture observed in the actual SG was not observed.

which was observed observed.

The tensile strength equivalent to that of mockup strength was equivalent mockup with grinding after gouging.

The difference fracture location, 152 buttering difference of fracture buttering in the specimen specimen of mockup grinding mockup with grinding gouging and LAS in the specimen of mockup without grinding after after gouging after gouging, waswas observed. The reason for this difference assumed that there difference is assumed there was small difference difference of hardness hardness (strength) betweenbetween LAS and 152 152 buttering difference of strength buttering and the small difference differences in fracture caused the differences fracture location.

4.2 Metallurgical Metallurgical examination examination examination (macro structure, micro structure, The results of metallurgical examination hardness structure, hardness measurement and surface etching) on mockups are shown measurement shown in Fig. D.6, 0.6, D.7 0.7 and D.8.

0.8.

(1) Indication Indication of the presence presence of remaining remaining carbon carbon that was included in arc electrode electrode and it affects to the metallurgical structure was not observed and the metallurgical structure near near fusion boundary boundary was almost same as that of the mockup with almost the same grinding after after gouging.

(2) Hardness near Hardness near the fusion boundary boundary was equivalent equivalent to that of the mockup mockup withwith gouging although high hardness region was observed.

grinding after gouging

5. Summary Welding 152 butter on LAS after after gouging without without grinding did did not affect the metallurgical not affect metallurgical feature andand tensile strength strength of fusion boundary.

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A"k Attachment-D Attachment-.D A,B Fig. D.l manufacturing I type mockup D.1 Flow chart of manufacturing

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachmen t-D *Lt Attach ment-D D.1 Table 0 .1 Result of Tension Test ofTension Test AS A.B Specimen Spec TestNo Test.No Appearance Appearance Type Type (74-2-4

@-2-4 Effect Effect of of JIS 4 gouging 4,-2-5

@-2-5 , 8 40 3 4 5 i 3 4 S Fig.D.4 FigO .4 Photograph (Sample Ph otograph of smooth specimen after test (Samp C,-2) le @-2)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ A*L ~ Attachment-D Attachment-D A,B A,B Fig.D.5 Photograph of fracture surface FigD.5 surface (Sample @-2)

(-2)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-D AIF.LAttachment-D f

A.13 A.B Fig.D.6 FigD.6 Macro-structure observation Macro-structure

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-DAt LAttachment-D A,B Fig. D.7 0.7 Micro-structure Micro-structure observati(

observation

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________________________ ~ Attachment-D A,B A,B

-I Fig. D.8(1) Result of Vickers hardness measurement Fig. 0.8(1) Result of Vickers hardness measurement MITSUBISHI HEAVY INDUSTRIES, LTD.

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A,B A,B Fig. D.8(2) 0.8(2) Result of Vickers hardness hardness measurement measurement

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Attachment-E Attachment-E Attachment-E T-Type T-Type Test Test MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E )O Attachment-E Attachment-E Scale model test report

1. Purpose Purpose Purposes of the scale model test are shown below.

scale model (1) To confirm whether (1) fracture stress of the scale model test is almost equal to the whether the fracture the stress due to hydrostatic hydrostatic test.

differences between gouging and machining (2) To confirm whether the differences machining affects fracture affects fracture (location where (location fracture load) of the welding joint between divider where fracture occurs, fracture plate divider plate and channel head.

2. Outline of the scale scale model test simulates the welding joint between Two test pieces, which simulates divider plate and channel head, between divider manufactured. Gouging process was applied to one of the test pieces (TYPE-A) to were manufactured.

simulate unit 3, machining process was applied to the other test piece (TYPE-B) to simulate simulate simulate Tension load due to hydrostatic test was applied to the test pieces unit 2. Tension pieces until the test pieces pieces were fractured.

measured during the test. After the tests, the location of fracture was The applied load was measured was confirmed confirmed and metallurgical metallurgical examination (macro-structure, micro-structure examination (macro-structure, micro-structure and hardness hardness measurement) was performed.

3. Scale model test specimen 3.1 Limited condition for design of the test specimen have to be considered for design of the test specimen, are shown Limited conditions, which have below.

(1) Load capacity of test machine machine Maximum load capacity of the available machine is 5500 kN (=1237 Ibf).

available test machine lbf). Therefore, Therefore, thethe maximum load of each test has to be smaller than 5500 kN ((== 1237 lbf).

1237 Ibf).

(2) Maximum section of the divider plate Maximum stress at the cross section plate If fracture does not occur at the fusion boundary between Alloy 152 buttering If buttering and channel head (low alloy steel), fracture will occur at the divider plate because the ultimate stress of the divider plate is lower and itit has to sustain higher stresses.

maximum load divider plate caused by the maximum Therefore, stress at the divider load of the test machine machine set to be equal equal to the ultimate stress stress of the divider plate.

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_________________________ A. Document No.L5-04GA440 At Attachment-E Attachment-E (3) Thickness of the divider divider plate plate The thickness of the divider plate of the scale model test specimen is ( A,B I) which is the the thickness of the actual actual divider divider plate.

(4) Material Material of the divider plate plate Alloy 690 plate whose thickness thickness was ( A,B )] was not available, low alloy steelsteel plate was was used as the divider plate used plate instead instead of alloy 690 plate. Since the purpose purpose of this test is to to evaluate fracture at the fusion boundary between alloy 152 buttering and low alloy steel and evaluate the divider divider plate is just jig to transmit the load, it is considered that to use the divider plate of low alloy steel does not affect affect the fracture fracture load load at the fusion boundary between between alloy 152 152 buttering and low alloy steel.

buttering Validity of using the low alloy steel plate is also confirmed in comparison comparison of stress stress distributions calculated by FE analysis. This FE analysis result is described distributions described in section section 3.3.

3.2 Design Design of the scale scale model model test specimen A,B A,B

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E AAW Attachment-E K A,B A,B 3.3 Stress 3.3 Stress distribution distribution ofof the scale scale model model test specimen specimen In order In order to confirm thethe stress stress distribution distribution of of the the test specimen near near the boundary between between alloy 152 alloy 152 buttering and low buttering and low alloy steel steel is almost equal equal to that of the the Unit analyses are Unit 3, FE analyses are performed and the performed the stress stress distribution distribution of the test specimen specimen is is compared with that of unit 3.

compared with stress distributions. From comparison of both stress FigureE.3 shows the comparison From FigureE.3, because the the stress distribution stress distribution of the the test specimen almost equal specimen is almost seen that equal to that of unit 3, it can be seen test specimen the test specimen cancan simulate the stress distribution that resembles the stress distribution distribution of unit 3.

3.4 Manufacturing process of the test specimen Manufacturing process specimen FigureE.4 shows flow of manufacturing process of the test of the manufacturing test specimen.

Two test specimens manufactured to perform fracture test.

specimens were manufactured One is the test specimen which simulates unit3 unit3 and itit is called "TYPE-A", the other is the the specimen which simulates unit2 and itit is called "TYPE-B".

test specimen The only difference difference between TYPE-A TYPE-A and TYPE-B is removal method method of stainless steel cladding on low alloy steel. The removal method cladding method of stainless steel cladding of TYPE-ATYPE-A is gouging and grinding, while for TYPE-B is machining.

gouging machining.

4. Test method 4.1 Test machine machine Photo and sketch of the test machine machine which set the test specimenspecimen and jig are shown in in FigureE.5.

Tension load is applies to two pins which are shown in FigureE.5 FigureE.5 until the test specimen is broken.

4.2 Measurement Measurement (1) Load(Strain)

FigureE.6, strains are measured using four strain gauges on the section of the As shown in FigureE.6, divider plate. Load which is applied to the test specimen is is calculated using the measured strains.

strains.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ). Attachment-E

~ Attachment-E (2) Fracture location(point) fractured test piece, fracture From the video image and fractured fracture location (point) is evaluated.

(3) Metallurgical (3) Metallurgical examination examination (macro-structure, (macro-structure, micro-structure micro-structure and hardness measurement)

Metallurgical examination Metallurgical examination (macro-structure, micro-structure and hardness micro-structure and hardness measurement) measurement) are performed near near the fusion boundary between between alloy 152 buttering buttering and low alloy steel.

5. Test result result TYPE-A (simulated (1) TYPE-A (simulated unit3)

a. Location Location (point) where where fracture occurred Photo of TYPE-A after test is shown shown in FigureE.7.

From FigureE.7, location (point) where occurred is the divider where fracture occurred divider plate simulated by alloy 152 buttering.

b. Maximum Maximum load load FigureE.8 shows relationship between between load and time. From FigureE.8, FigureE.8, the maximum load is

(( A,B A,B ].

).

c.

c. Metallurgical examination (macro-structure, micro-structure Metallurgical examination micro-structure and hardness hardness measurement)

Figures E.g E.9 to 11 show show the results of macro-structure macro-structure observation, micro-structure micro-structure observation and hardness measurement.

Metallurgical structure observed near the fusion boundary Metallurgical boundary of TYPE-A was similar to that observed near near the fusion boundary of Unit 3.

From metallurgical metallurgical structure observed near the fusion boundary structure observed boundary of TYPE-A, crack crack did not occur at the fusion boundary.

Hardness Hardness near near fusion boundary was (( A,B 3

}

TYPE-8 (simulated unit2)

(2) TYPE-B

a. Location Location (point) where where fracture occurred occurred Photo of TYPE-A TYPE-A after after test is shown in FigureE.12.

FigureE.12.

From FigureE.12, fracture fracture location (point) is the divider plate simulated by alloy 152 152 buttering.

b. Maximum load FigureE.13 shows shows relationship relationship between load and time. From FigureE.13, the maximum load

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E ). Attachment-E is((

is A,B A,B J.).

Metallurgical examination (macro-structure, micro-structure

c. Metallurgical micro-structure and hardness measurement)

Figures Figures E.14 to 16 show show the results of macro-structure macro-structure observation, micro-structure micro-structure observation and hardness observation hardness measurement.

Metallurgical structure observed Metallurgical structure near the fusion boundary of TYPE-B was similar to that observed near observed near near the fusion boundary boundary of Unit 3.

From metallurgical structure observed observed near the fusion boundary boundary of TYPE-B crack crack did not occur at the fusion boundary.

Hardness near fusion boundary was ((

Hardness A,B A,B }

6. Summary

-Two test pieces which simulated simulated the welding joint between divider divider plate and channel head were made and tension load due to hydrostatic hydrostatic test was applied to the test piece piece until the test piece piece is fractured.

-Gouging process was applied applied to one test piece (TYPE-A) to simulate unit 33 while while machining process process was applied to the other test piece (TYPE-B) to simulate unit 2.

-Both

-Both test specimens fractured fractured at the divider plate simulated by alloy 152 buttering and 152 buttering did not fracture at the boundary boundary between the alloy 152152 buttering buttering and low alloy steel of channel head.

-- Metallurgical Metallurgical structure observed observed near the fusion boundary boundary of TYPE-A was similar to that observed near observed near the fusion boundary boundary of Unit 3.

3.

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________________________ ~ ' Attachrnent-E Attachment-E A,B A,B FigureE.1 Sketch Sketch of configurations configurations of the scale model test specimen specimen

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E )l Attachment-E A,B A.B FigureE.2 Sketch and photo of the jig and the test specimen FigureE.2

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________________________ J.... )k Attachment-E Attachment-E A,B A,B distributions of vertical direction(X-direction)

FigureE.3 Comparison of stress distributions direction(X-direction)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ A& ~ Attachment-E Attachment-E A,B FigureE.4 Flow of the manufacturing FigureEA manufacturing process process of the test specimen

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E )* Attachment-E A.B A,B of the test machine which set the and sketch of FigureE.5 Photo and and jig the test specimen and jig

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E Attachment-E At A,B FigureE.6 Strain gauge gauge to measure measure load MITSUBISHI HEAVY INDUSTRIES,

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________________________ ~ At. Attachment-E Attachment-E A,B A,B FigureE.8 Relationship between FigureE.8 between load and time time MITSUBISHI HEAVY

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No.L5-04GA440 (0)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-EinL Attachment-E A,B Fig.E.10 Fig.E.10 Micro-structure Micro-structure observation (type-A)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E *). Attachment-E A.B A,B J

Fig. E. 11 Result of hardness measurement Fig.E. measurement (type-A)

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)'L Attachment-E Attachment-E (0)

A,B A,B FigureE.13 Relationship between load and time FigureE.13 Relationship time

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ )'*Attachment-E ~ Attachment-E A,B A,B Fig. E. 15 Fig.E.15 Micro-structure observation Micro-structure observation (Type-B)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-E Ak Attachment-E A,B A,B Fig.E.16 Result Fig.E.16 Result of hardness measurement measurement (Type-B)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ AL ~ Attachment-F Attachment-F Attachment-F Attachment-F Fracture Toughness Test Fracture Test MITSUBISHI HEAVY INDUSTRIES,

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ )'L ~ Attachment-F Attachment-F

1. Purpose

1. Purpose The purpose of fracture toughness test is to reproduce reproduce the fracture along fusion boundary boundary of weld occurred in in Unit 3 RSGs, to obtain the necessary necessary data for fracture evaluation and to confirm the effects effects of the differences differences between gouging and machining on fracture along the the fusion boundary.

2. Outline Outline of test The mockup mockup which simulated simulated the fractured fractured weld between LAS and 152 alloy was fabricated.

Two types of methods to remove stainless stainless steel cladding were employed. One was gouging which was applied to Unit 3 3 RSGs and the other was machining machining which was applied to Unit 2 RSGs.

Fracture toughness toughness specimens were machined machined from these mockups mockups and fracture toughness toughness tests and fracture surface obseNations observations were were conducted at room temperature. Parts of the the tests were conducted conducted after hydrogen hydrogen charge charge to examine the effect effect of hydrogen on the the fracture along along fusion boundary.

3. Test method Mockup 3.1 Mockup The fabrication flow chart of mockup mockup is shown in in Fig. F.l.

F.1. The manufacturing manufacturing procedure for for the actual actual SG was reproduced including heat treatment and inspection.

reproduced including 3.2 Fracture toughness test specimen The location and direction direction of specimens specimens and the configuration configuration of specimen were shown in in Fig.F.1 and F.2 respectively. The specimen specimen was machined to make the direction direction of crack propagation parallel (S-L) and perpendicular propagation perpendicular (S-T) to welding direction. The slit of specimen was set at fusion boundary boundary of weld. The configuration configuration of specimen specimen was referred to ASTM E1820, but the side groove was not introduced introduced for both side of the specimen.

The specimens without fatigue pre-crack, those with about (A,B ( A,B ]) fatigue pre-crack pre-crack and those with pre-crack pre-crack which was introduced after hydrogen hydrogen charge to introduce pre-crack along fusion boundary were tested.

3.3 Fracture Fracture toughness test The condition of fracture toughness test is shown in in Table F.1.

F. 1. Parts of tests were were conducted right after hydrogen charge.

Fracture toughness tests were conducted conducted inin room temperature temperature air with 1Otonf10tonf (98 k N) universal test machine. The test procedure procedure was according to ASTM ASTM El 820.

E1820.

Fracture toughness Fracture toughness was evaluated according according to ASTM E1820. The following values which

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F ). Attachment-F are averages averages of LAS and 152 weld metal metal were used for fracture toughness toughness evaluation.

evaluation.

Young modulus:

modulus: 200300MPa 200300MPa Yield stress: 481 MPa MPa Tensile stress: 620MPa Tensile 620MPa Poisson ratio: 0.38 0.38

4. Test results results 4.1 Fracture Fracture toughness test Photographs of specimen are are shown shown in Fig. FA, F4, F.5 and appendix-2, results of SEM observation on some fracture surfacesurface are shown in Fig.F.6.

displacement curves during tests are shown in appendix Load and load-line displacement appendix 1.

(1) Specimens with hydrogen pre-charge pre-charge The fracture surface of both gouging (G-1) (G-1) and machining machining (M-1) (M-1) is uneven and macroscopically brittle surface which shows the aspect macroscopically aspect of fusion boundary crack crack observed observed in Unit F.4.

Unit 3 as shown in Fig. FA.

Flat fracture fracture surface surface with grain boundary boundary like like feature, quasi-cleavage quasi-cleavage fracture surfacesurface and ductile fracture fracture surface surface were observed observed in Fig. F.6 which were observed in Unit were observed Unit 3.

(2) Specimens with fatigue pre-crack (2) pre-crack Ductile fracture occurred occurred in 152 152 buttering buttering and fracture fracture along along fusion boundary did not occur.

(3) Specimens Specimens without pre-crack pre-crack and hydrogen hydrogen pre-charge pre-charge Ductile fracture fracture occurred in 152 buttering and fracture along fusion boundary did not occur. occur.

(4) Specimens Specimens with hydrogen hydrogen crack The fractured fractured surface of both gouging gouging (G-6) and machining machining (M-6) whichwhich propagates propagates due to the tensile load applied after after hydrogen hydrogen charge charge is uneven and macroscopically macroscopically brittle surface surface as shown in Fig. F.5. The fractured fractured surface of those which propagated due due to the tensile tensile load undergone ductile fracture load applied after heat treatment undergone fracture in 152 buttering fractures buttering and fractures along the fusion boundary boundary did not occurred.

occurred. The The fracture fracture surfaced surfaced which propagates propagates before treatment was colored with light brown heat treatment heat ( A,BB. ).

brown by the heat at (A,B (5) Fracture toughness (5) Fracture toughness From the above boundary did not occur and fracture above test results, fracture along fusion boundary toughness toughness cannot cannot be obtained under hydrogen hydrogen free condition.

J-R curve J-R obtained in tests after curve obtained after hydrogen pre-charge (G-1, (G-1, G-6, M-1,M-1, M-6)

M-6) is shown in Fig.F.7. There Fig.F.? are no large differences There ,are differences of the J-R J-R curve between gouging and machining.

Although the exact fracture toughness toughness according according to ASTM E1820 cannot be obtained, the obtained, the

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. Attachment-F Attachment-F (0) toughness of (

fracture toughness A,B 3was

) estimated as the cross point of J-R estimated J-R curve andand 0.2mm O.2mm off set line. This value corresponds stress stress intensity factor K of ( A,B 3} by below below equation.

K="j K=4 (E* J/ (1 (E

J/ ( 1 -v"2)

-v2) 4.2 Metallurgical examination of mockup Metallurgical examination mockup The results of macro-structure observation, micro-structure macro-structure observation, micro-structure observation, and hardnesshardness measurement of mockup measurement mockup G and M are shown in appendix-3.

The results of macro-structure macro-structure observation, observation, micro-structure micro-structure observation, observation, and hardness hardness measurement of specimen measurement specimen G-1 after test are shown in appendix-4.

The below results are obtained.

(1) The metallurgical metallurgical structure structure observed near the fusion boundary boundary of mockup mockup G (gouging) was similar to that observed observed near the fusion boundary boundary of Unit 3, but the color of grain grain boundary boundary near the fusion boundaryboundary of specimen specimen G-1 was different different from the other location. The reason reason of this difference difference may be related to the effect effect of hydrogen hydrogen charge.

(2) There are no largelarge differences differences of metallurgical structure structure near the fusion boundary between the mockup mockup G G (gouging) and M M (machining).

(3) The hardness (3) hardness near fusion boundary mockup G, specimen boundary of mockup specimen G-1 and mockup M was was

( A,B A,B I

), ( ( AB A,B ) and(

) and ( fA,B A,B I, respectively, but higher hardness

), respectively, but higher hardness beyond( A,B beyond( A,B )was observed observed at the other point. Therefore, it is supposed supposed there is not not large difference of hardness among mockups and specimens.

among the mockups

5. Summary (1) Fracture Fracture along fusion boundary boundary occurred occurred after hydrogen charge but fracture toughness toughness did not occur under hydrogen hydrogen free condition.

condition.

(2) There are no large differences differences of fracture resistance of fusion boundary (J-R curve) fracture resistance between the mockup mockup G G (gouging) and M (machining).

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_________________________ ~ A& Attachment-F Attachment-F A,B Fig. F.l F.1 Flow chart of manufacturing manufacturing I type mockup mockup MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F )k Attachment-F A,B A,B Fig.F.3 11T Fig.F.3 Compact Tension T Compact Tension Specimen Specimen MITSUBISHI HEAVY

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Attachment-F Attachment-F Test matrix Table F.1 Test matrix Pre Pre H H22 Orientation Fracture Test No.

Fracture No.

Orientation Pre-crack Pre-crack Charge Charge of crack Machining Gouging "1 of crack Machining Gouging

1 No Yes S-L 8-L M-1 G-1 Fatigue Fatigue No S-L 8-L M-2 M-2 G-2 G-2 No crack crack S-T 8-T M-3 M-3 G-3 G-3 S-L 8-L M-4 M-4 G-4 G-4 No No No S-T 8-T M-5 M-5 G-5 G-5 Hydrogen No *3 S-L M-6 G-6 No *3 8-L M-6 G-6 crack *2

2 SA,B

1: charge condition before H22 charge

1: Pre H before fracture fracture test A,B

2: Hydrogen

2: crack is Hydrogen crack is introduced introduced at at the the same same condition of M-1 condition of M-1 and and G-1 tests.

G-1 tests.

3: Heat

3: Heat treatment treatment to remove hydrogen to remove hydrogen fromfrom the the specimen is conducted after hydrogen specimen is conducted after hydrogen pre-cracking pre-cracking at 400°C 400'C for 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months .

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l Document Document NO.LS-04GA440 (0)

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A Attachment-F Attachment-F A,B A,B Fig.F.4-1 Photograph Fig.F.4-1 Photograph of of fracture fracture surface surface (M-1)

(M-1)

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Attachment-F Attachment-F A.B A,B Fig.F.4-2 Photograph Fig.FA-2 Photograph of of fracture fracture surface (G-1)

(G-1)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F )* Attachment-F A,B A,B Fig.F.5-1 Photograph Fig.F.5-1 Photograph ofof fracture fracture surface surface (M-6)

(M-6)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F )k Attachment-F A,1B A,B Fig.F.5-2 Photograph Fig.F.5-2 fracture surface (G-6)

Photograph of fracture MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ )'kAttachment-F; . . Attachment-F A,B A,B Fig.F.6-1 Fig.F.6-1 SEM M-1 SEM observation of fracture surface of M-1 HEAVY INDUSTRIES, MITSUBISHI HEAVY

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________________________ ~ ik Attachment-F Attachment-F A,B A.B Fig.F.6-2 Fig.F.6-2 SEM observation SEM observation ofof fracture fracture surface of M-1 surface of M-1 HEAVY INDUSTRIES, MITSUBISHI HEAVY MITSUBISHI INDUSTRIES, LTD. LTD.

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Attachment-F Attachment-F A,B A,B Fig.F.6-3 observation of SEM observation SEM of fracture fracture surface of G-l surface of G-I HEAVY INDUSTRIES, MITSUBISHI HEAVY MITSUBISHI INDUSTRIES, LTD.

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________________________ ~ 'L Attachment-F Attachment-F A,B A.B Fig.F.6-4 SEM observation ofof fracture surface of G-1 INDUSTRIES, LTD.

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_ _ _ _ _ _ _ _ _ _ _....,-_ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F Attachment-F A,1B AB

_'l Fig.F.7 J-R curve of specimens specimens after after hydrogen pre-charge hydrogen pre-charge Page Page 267 of 484 484 S023-617-1-M1415, Rev. 0 MITSUBISHI HEAVY MITSUBISHI INDUSTRIES, LTD.

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Attachment-F Appendix-1 Load-Load Appendix-1 Load-Load line displacement displacement curve during during test A,B Fig.F.8 Load-Load Fig.F.B Load-Load line displacement displacement curve curve

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F JA Attachment-F A,B A,B Fig.F.9 Load-Load Fig.F.9 Load-Load line line displacement displacement curve MITSUBISHI HEAVY

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)k Attachment-F (0)

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Attachment-F A,B A,B Fig.F.10 Load-Load Fig.F.10 Load-Load line line displacement displacement curve curve HEAVY INDUSTRIES.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _~-------- ),'iAttachment-F ~ Attachment-F A.B A,B Fig.F.11 Load-Load Fig.F.11 Load-Load line line displacement curve curve MITSUBISHI HEAVY

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I Att~achment-F Attachment-F A,B Fig. F. 12 Load-Load Fig.F.12 Load-Load line line displacement displacement curve curve MITSUBISHI HEAVY

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Attachment-F Attachment-F A,B Fig.F. 13 Load-Load Fig.F.13 Load-Load line displacement displacement curve (After remove hydrogen)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F AO. Attachment-F J

A,B A,B Fig.F.14 Load-Load Fig.F.14 Load-Load line line displacement displacement curve curve (hydrogen (hydrogen crack test) test)

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_______________________ ~ I Attachment-F Attachment-F Appendix-2 Photograph Photograph of fracture surface surface A,B A,B Fig.F.15-1 Fig.F.15-1 Photograph (M-2)

Photograph of fracture surface (M -2)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ AFk ~ Attachment-F Attachment-F A,B A,B Fig.F.15-2 Photograph Fig.F.15-2 Photograph of of fracture fracture surface (G-2) surface (G-2)

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AL Attachment-F (0)

Attachment-F A,B A,B Fig. F. 15-3 Photograph Fig.F.15-3 fracture surface Photograph of fracture surface (M-3)

(M-3)

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Attachment-F Attachment-F A.B A,B Fig.F.15-4 Photograph of fracture fracture surface (G-3)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ )' ~ Attachment-F A,B Fig.F.16-1 Fig.F.16-1 Photograph Photograph of fracture surface (M-4)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F AU Attachment-F A,B A,B Fig.F.16-2 Fig.F.16-2 Photograph of Photograph of fracture surface surface (G-4)

(G-4)

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Attachment-F Attachment-F A,B A.B Fig. F.16-3 Photograph Photograph of fracture fracture surface surface (M-5)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Ak ~ Attachment-F Attachment-F A,B A,B Fig.F.16-4 Photograph Fig.F.16-4 Photograph of of fracture fracture surface surface (G-5)

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Attachment-F Attachment-F Appendix-3 Appendix-3 Metallurgical examination Metallurgical examination of mockups mockups A,B

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.F.17 Fig .F.17 Macro-structure Macro-structure observation

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; . . . Attachment-FAttachment-F A,B A,B Fig. F.18 F. 18 Micro-structure observation Micro-structure observation MITSUBISHI HEAVY INDUSTRIES,

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_ _ _ _ _ _ _ _ _ _ _'--_ _ _ _ _ _ _ _ _ _ _ A' ~ Attachment-F Attachment-F A,B A,B Fig. F.19-1 Fig. F.19-1 Result Result of of Vickers Vickers hardness hardness measurement measurement MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-F )'.11 Attachment-F A,B F. 19-2 Result of Vickers hardness measurement Fig. F.19-2 measurement MITSUBISHI HEAVY

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________________________ ~ ~Attachment-F Attachment-F A,B Fig .F.20

.F.20 Macro-structure observation Macro-structure MITSUBISHI MITSUBISHI HEAVY INDUSTRIES, INDUSTRIES, LTD.

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Attachment-F Attachment-F A&~

A,B A,B Fig. F.21 Micro-structure observation Micro-structure observation

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ AAW ~ Attachment-F Attachment-F A,B A,B Fig. F.22-1 F.22-1 Result Result of Vickers Vickers hardness measurement measurement MITSUBISHI HEAVY

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Attachment-I" A,B Fig. F.22-2 Result of Vickers hardness hardness measurement measurement MITSUBISHI HEAVY

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________________________ ~ At Attachment-F Attachment-F Appendix-4 Metallurgical examination of tested specimen Metallurgical examination specimen A,B A,B Fig. F.23 Macro-structure observation Macro-structure

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--.;._ _ _ _ _ ~ Attachment-F )i Attachment-F

/I, A,B F.24-1 Fig. F.24-1 Micro-structure observation Micro-structure observation MITSUBISHI HEAVY

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Attachment-F A.B A,B Fig. F.24-2 F.24-2 Micro-structure Micro-structure observation MITSUBISHI HEAVY INDUSTRIES, MITSUBISHI INDUSTRIES, LTD.

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AAW Attachment-F Attachment-F A,B A,B Fig. F.25-1 Result of Vickers hardness hardness measurement measurement MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Aw.'LAttachment-F ~ Attachment-F A,B A,B Fig. F.25-2 F.25-2 Result of of Vickers hardness measurement measurement MITSUBISHI HEAVY

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_ _ _ _ _ _,....-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ AAW ~ Attachment-O Attachment-G Attachment-G Buttering Buttering Mock Up TestTest MITSUBISHI HEAVY

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___________________________ ~ At Attachment-G Attachment-G

1. Purpose Purpose The purpose purpose of this report is to provide the investigation investigation results of test coupons which are are welded by using coated electrode electrode with moisture absorption absorption for hydrogen hydrogen cracking.

cracking.

2. Test coupon Schematic illustrations of the test coupons are shown in Schematic in Figure Figure G.I.

G.1. The stainless steel clad clad by ESW was removed by gouging and grinding grinding (TC H-G) or machining (TC H-M). 152 152 buttering buttering was performed SMAW using coated electrode with moisture absorption.

performed by SMAW Moisture absorption absorption. Moisture condition and welding condition is shown in in Table G.1.

G.1.

3. Investigation Investigation Methodology Methodology The investigation investigation methodology methodology matrix of test coupon was summarized summarized in Table G.2

4. Results of investigation investigation Table G.3 shows the result of ultrasonic inspection of test coupons. Any significant indications indications were not inspected in in both coupons.

Figures Figures G.2 show macro-structure macro-structure of cross section of test coupons. Any significant significant cracks or defects defects were not observed .in in both test coupons.

Figure G.3 shows micro-structure micro-structure of cross section of test coupons. Any significant significant difference difference between the coupons was not observed observed in in microstructure.

microstructure. There is no abnormality abnormality in in microstructure of 152 buttering and LAS base metal.

Figure G.4 shows the results of Vickers hardness test. Any significantsignificant difference between between thethe coupons was not confirmed in in hardness distribution.

distribution. There There is no abnormality abnormality inin hardness hardness of 152 152 buttering buttering and LAS base metal.

5. Summaries of the investigation investigation

1) Hydrogen

1) Hydrogen cracking was not observed in in ultrasonic ultrasonic inspection test and macrostructure macrostructure observation observation inin this test (T-5).

differences in

2) Any significant differences microstructure and hardness were not confirmed in microstructure confirmed between the the test coupons.

3) There is no abnormality in in microstructure microstructure and hardness hardness in in test coupons.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-G )1 Attachment-G A,B A,8 Figure G.1 G.1 Schematic illustration of test coupons.

Schematic MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ a4'L ~ Attachment-G Attachment-G Table G.1 Moisture absorption condition and welding condition A,B A, B 71 Table G.2 Investigation Methodology Investigation Methodology of test coupon Item Method Method Purpose Purpose Ultrasonic Ultrasonic Ultrasonic Ultrasonic inspection inspection from Inspect Inspect the crack occurrence occurrence inspection surface surface Macro-structure Macro-structu re Visual examination of the Evaluate the macro-structure macro-structure of the the cross-section at low cross-section materials and crack occurrence crack occurrence magnification after etching magnification Micro-structure Micro-structure Visual examination examination of the Evaluate the micro-structure Evaluate micro-structure of near the the cross-section at high fusion boundary magnification after magnification etching after etching Hardness Hardness Measure Vickers hardness hardness Evaluate the hardness Evaluate hardness distribution near the the fusion boundary and HAZ HAZ

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-G )* Attachment-G Table G.3 The results of ultrasonic inspection inspection test Removal Removal process process for Results of ultrasonic Results ultrasonic inspection T est coupon Test coupon No No stainless stainless steel clad clad After buttering After 48Hr later H-G Gouging and grinding Gouging grinding No indication No indication H-M H-M Machining No indication indication indication No indication MITSUBISHI HEAVY

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__________________________ ~ jI Attachment-G Attachment-G K

A,B A,S

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Figure G.2(1)

G.2(n Macro-structure Macro-structure of cross sect section i on of test coupon (Goug (Goug iing ng and grinding) gr i nd i ng)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-G AL Attachment-G A,B Figure G.2(2)

Figure G.2(2) Macro-structure of Macro-structure of cross sect section (Machining) i on of test coupon (Mach i n i ng)

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Attachment-G f

A,B A,B Figure G.3 Micro-structure of cross sect Micro-structure section coupons i on of test coupons MITSUBISHI HEAVY

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Attachment-G A,B Figure

Figure G.4 Vickers hardness of cross section of test coupons G.4Vickers coupons MITSUBISHI HEAVY

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J. Attachment-H Attachment-H Tensile Restraint Cracking Cracking Test Test

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-H Document

)No.LS-04GA440 (0)

Attachment-H

1. Purpose investigation results of tensile restraint cracking The purpose of this report is to provide the (investigation cracking (TRC) test.

2. Testing procedure procedure appearance of TRC testing machine. The load was applied Figure H.1 shows appearance applied and held by oil cylinder. Figure H.2 shows shape of TRC test piece. Tensile load was applied on test hydraulic cylinder.

piece immediately Moisture absorption condition of electrode and welding immediately after welding. Moisture loading condition were shown in Table H.2. Gouging condition and loading Gouging condition condition was shown in in Table H.3.

Methodology Investigation Methodology

3. Investigation methodology matrix of test pieces after testing was summarized The investigation methodology summarized in in Table Table H.1 H.1 Table H.1 Investigation Methodology Investigation Methodology Item Method Method Purpose Purpose Fracture Fracture surface surface examination at low Visual examination Evaluate macro-structure of the Evaluate the macro-structure the magnification magnification fracture surface fracture surface Separation Separation SEM (Scanning Electron Electron Evaluate the micro-structure Evaluate the micro-structure of the surface Microscope) examination at high fracture surface fracture surface magnification magnification Micro-structure Micro-structure microscopic observation Optical microscopic Evaluate the micro-structure Evaluate micro-structure near the the of the cross-section cross-section at high fracture surface surface etching magnification after etching magnification

4. Results of testing Figure H.3 shows results of TRC test. In normal groove type, with decreasing load, rupture In normal time became longer. Rupture did not occur below certain load.

addition and gouging of groove surface seemed that the carbon addition ItIt seemed surface accelerates accelerates the rupture rupture occurrence. ItIt was assumed that the hardening hardening in in transition zone, which was caused by carbon addition and remained carbon by gouging as shown in in Attachment Attachment J "Carbon ResidueResidue Boundary Hardness", affects the rupture behavior.

Influence on Fusion Boundary Influence Figure H.4 shows SEM pictures surface of TRC test piece. The fracture surface pictures of fracture surface surface relatively flat fracture morphology similar to the separation revealed relatively revealed separation observed in in boat samples samples collected from Unit 3 collected 3 RSG as shown in in Attachment Attachment A "Unit 3 3 As-Built Sample Investigation".

fracture surface The fracture quasi-cleavage fracture surface surface revealed quasi-cleavage surface as observed observed inin boat samples.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ At ~ Attachment-H Attachment-H Figure H.5 shows micro-structure micro-structure of cross section of test piece ruptured. ItIt was observed that the rupture had been occurred occurred adjacent adjacent to fusion boundary between between 152 weld metal and LAS LAS base metal as observed in in boat samples samples collected collected from Unit 33 RSG. ItIt was supposed that thethe separation which occurred separation occurred inin Unit 3 was reproduced reproduced by TRC test.

5. Summaries of the investigation investigation

1) It was presumed that the separation separation occurred in Unit 3 RSG was reproduced occurred in reproduced by TRC test. test.

2) ItIt seems that the carbon addition and gouging of groove surface affect affect the possibility for occurrence occurrence of separation.

separation.

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Attachment-H Attachment-H 7-A,B A,B H.1 Figure H.l Appearance of Appearance of TRC testing machine.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--'-_ _ ~Attachment-H ) Attachment-H A,B A,B Figure H.2 Figure Shape of Shape of TRC test test piece .

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.,....-_ _ _ _ _ _ _ ~ Attachment-H ), Attachment-H Table H.2 Moisture absorption condition and welding condition absorption condition condition A,B -B.

r N i

i i

+ -

A,B A,B H.33 Table H Gouging condition of TRC test piece (Gouging type)

Gouging

/,---------------------------------,---~----------------,.~

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_________________________ ~ &I Attachment-H Attachment-H A.B A,B Figure H.3 Results of TRC test test

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A,B Figure H.4 HA Fracture Fracture surface surface of TRC test piece ruptured ruptured (Normal groove groove type, applied stress:425MPa) applied stress:425MPa)

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A,B A,B Figure H.5 Microstructure of cross section of TRC test piece ruptured Figure H.5 (Normal groove type, Microstructure of cross section applied of TRe test piece ruptured stress:425MPa)

(Normal groove type, applied stress:425MPa)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-I Ak Attachment-[

Attachment-I Attachment-I Measurement Measurement of Residual Hydrogen Hydrogen

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Attachment-I Measurement of Residual Measurement Hydrogen Concentration Residual Hydrogen Concentration II.Purpose

.Purpose The purpose purpose of this report is to confirm the influence influence on residual residual hydrogen by the heat-treatment heat-treatment conditions of the mockups by simulating simulating alloy 152 buttering buttering of Unit-2A, 2B and 3A13B 3A/3B RSGs, and to measure the residual hydrogen at welded part (alloy 152 buttering and stainless steel clad) clad) by by using the samples obtained obtained from Unit-3A RSG.

2.Conclusion 2.Conclusion

- Concentration Concentration ofof trapped hydrogen was confirmed confirmed to be about (A,B ( A,B ]) in the mockups. This result result equivalent of the established value.

is the equivalent

- As for the influence influence on residual hydrogen by the post-heat, post-heat, no significant difference in the the mockups mockups was observed, though the heat treatment treatment conditions such as temperature temperature for Unit-2 and and 3 were were different. \

- Hydrogen remained in alloy 152 buttering and stainless steel steel cladding cladding at Unit-3A RSG. RSG The hydrogen concentration concentration was approximately approximately 3 ppm in alloy 152 152 buttering buttering and stainless steel (SMAW), and approximately 2 ppm in stainless cladding (SMAW), (ESW).

stainless steel cladding (ESW).

3. Methods and Procedures Procedures (I) Mockups (I) Mockups The following is the specifications specifications for the mockups used in the experiment.

experiment.

A,B A.B (2)Conditions for Measurement Measurement The conditions for the test piecespieces of residual hydrogen concentration measurement hydrogen concentration measurement are presented on Table 1.1. Figure Table I. L 1 (a)

Figure 1.1 (a) shows the initial shape of the test pieces. For For post heating, the test pieces were were cut into the shape shown in Figure 1.1 1. 1 (b). Figure Figure 1.2 selected parts of the test pieces shows the selected pieces (from Unit"3AUnit-3A RSG) for hydrogen hydrogen concentration measurement. The mockups and the samples were cut into the shape concentration shape of a HEAVY INDUSTRIES, MITSUBISHI HEAVY INDUSTRIES, LTD.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-I A cube, approximately ( A,B ]) for hydrogen concentration cube of approximately( concentration measurement.

measurement. As for simulated heat treatment time timeline line which is recorded recorded for reference, reference, it is shown shown in Figure 1.3.

1.3.

Table 1.1 The conditions of Test pieces No. of No. of Case Condition Condition Measurement Measurement AI AI pre-heated and not post-heated post-heated (Basis of PPl,P2 1,P2 & P3)

P3) 3 P1 PI simulate Unit-2A RSG 3 P2 add post-heat to AA lI simulate simulate Unit-2B RSG 3 P3 simulate Unit-3A/3B simulate Unit-3A/3B RSGs 3 R1 RI Sample (Unit-3A (Unit-3A RSG) Alloy 152 buttering 3 R2 Sample (Unit-3A (Unit-3A RSG)

RSG) Stainless Stainless steel cladding/SMAW cladding/SMAW 3 R3 Sample (Unit-3A (Unit-3A RSG)

RSG) Stainless Stainless steel c1adding/ESW cladding/ESW 3 A,B Figure 1.1 Figure 1.1 Shape Shape of test pieces for measurement measurement of hydrogen hydrogen concentration concentration

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_ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachmen )'~ Attachment-I t-I RI - I RI-I RI-2 RI-2 Alloy 152 buttering buttering Stainless steel Stainless steel cladding

__--~--~. . . . . .. r I R2-2 R2-1 R2-3 R3-2 RI-3 I R3-1l R3-3 1.2 Figure 1.2 Locations of samples obtained from Unit-3A Unit-3A RSG RSG MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-I Attachment-I

,Ak A,B A,B Figure 1.3 1.3 Heat-treatment Heat-treatment condition condition of mockups mockups MITSUBISHI HEAVY INDUSTRIES,

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-I p' Attachment-I (3) Measurement Measurement Methodology released from the specimen when it is chromatograph, the amount of hydrogen released By using a gas chromatograph, heated until the melting point was measured.

Appendix-I shows the data of released hydrogen at each temperature For reference, Appendix-I temperature when Alloy 152 weld metal was heated up gradually in the previous test.

(4) Results of Measurement (4) Measurement Table Table 1.2 Results of Measurement Measurement Condition Hydrogen Concentration (ppm)

Hydrogen Concentration Case Sample Sample Sample Sample Average Average

/"

1 2 3 Pre-heat and not Post-heat A-1 A-I A,B (Basis of P1,P2 &

(Basis ofPl,P2 P3)

& P3)

Simulate P-1 P-I Unit-2A RSG With Simulate Simulate P-2 With Post-heat Post-heat Unit-2B RSG Unit-2B RSG Simulate Simulate P-3 P-3 Unit-3A/3B RSGs

'- 1../

Sample Sample (Unit-3A RSG)

R- 1 R-I 3.6 3.6 3.4 3.4 3.3 3.3 3.4 3.4 Alloy 152 buttering Sample Sample (Unit-3A RSG)

R-2 R-2 3.3 3.3 3.3 3.3 3.6 3.6 3.4 3.4 Stainless Stainless steel cladding/SMAW Sample (Unit-3A RSG)

Sample (Unit-3A RSG)

R-3 1.8 1.8 1.9 1.8 1.8 1.8 1.8 Stainless steel cladding/ESW Stainless steel cladding/ESW

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-I Attachment-I inkl

~ 10 --------------------------~

!5. 9 lie Sample 1

.3 c: 8 o Sample 2

~

e" 7 6 o Sample 3

Avera~e

c

'0 5 g 4 A,B

'.p -, - -

~ 3

ii 2 g

(.J 1

o Rl R2 T nIl R3 Alloy 152 Sta inless steel cladding buttering Samples Figure 1.4 Resul ts of Measurement Results Measurement MITSUBISHI MITSUBISHI HEAVY HEAVY INDUSTRIES, INDUSTRIES, LTD.

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Attachment-I Attachment-l Appendix-i Appendix-l r

A.B Figure 1.5 Results Results of Thermal Thermal Desorption Spectrometry of hydrogen Desorption Spectrometry hydrogen gas

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________________________ ~ J. Attachment-J Attachment-J Attachment-J Attachment-J Carbon Residue Influence Influence on Fusion Boundary Hardness MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ). ~ Attachment-J Attachment-J

1. Purpose Purpose purpose of this report is to provide The purpose provide the investigation investigation results of remained remained carbon by gouging.

2. Test coupon Two test coupons coupons were prepared prepared for the investigation.

investigation. Schematic Schematic illustrations of the test coupons were Figure J.1.

were shown in Figure J.1. Gouging was performed coupon A to produce performed on test coupon produce residual carbon on the surface. Then, welding residual welding was performed over the residual residual carbon.

Gouging Gouging condition and welding condition were shown in Table J.2.

condition were In the test coupon B, welding was performed on the thin groove with mashed carbon electrode electrode of gouging. Welding Welding condition of test coupon coupon BB was shown in Table J.3.

3. Investigation Methodology Investigation Methodology The investigation methodology matrix of test coupon was summarized investigation methodology summarized in Table J.1 Table J.1 J.1 Investigation Investigation Methodology Methodology of test coupon A and B Item Method Purpose Purpose Macro-structure Macro-structure Visual examination examination of the Evaluate the macro-structure Evaluate macro-structure of thethe cross-section at low magnification cross-section magnification materials materials after etching after etching Micro-structure Micro-structure Optical observation of Optical microscopic observation Evaluate the micro-structure micro-structure near the cross-section cross-section at high the fusion boundary magnification after magnification after etching Hardness Hardness Measure Vickers hardness Measure hardness Evaluate the hardness distribution Evaluate distribution near near the fusion boundary

4. Results of investigation investigation 4.1 Test coupon coupon A (welding afterafter gouging)

Figure appearance of test coupon. The remaining carbon on the surface Figure J.2-1 shows the appearance surface in the gouged gouged condition condition was observed observed (remained (remained carbon was indicated indicated by arrow in Figure J.2-1).

J.2-1).

macro-structure of cross Figure J.2-2 shows the macro-structure cross section of test coupon.

coupon. Some defects defects were were observed near the fusion boundary in cross section of test coupon.

Figure J.2-3 shows the micro-structure micro-structure of cross cross section of test coupon.

coupon. The remaining carbon, surrounded by weld metal, resulted by the defects which was surrounded defects was observed.

observed. The light etched zone and deep deep etched etched zone were observed in the transition zone adjacent adjacent to the carbon carbon in thethe defect. It is assumed that carburization carburization which was caused by the remaining carbon affects the affects the optical microstructure microstructure in transition zone.

\

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Document No.LS-04GA440 I Attachment-J (0)

Attachment-J Figure J.2-4 J.2-4 shows results of Vickers hardness hardness test. High hardnesshardness was measured measured in in transition zone adjacent to the carbon around the defect. ItIt is assumed that carburization carburization caused by the remaining affects the hardness in remaining carbon affects in transition zone.

T Figure J.2-5 shows the micro-structure micro-structure of the cross section of the test piece shown in in Figure Figure J.2-3 after additional additional polishing to remove the defect. The light etched etched zone which corresponds corresponds to the transition zone was still observed observed at the position position where defect had been located.

where the defect located.

Figure J.2-6 shows the results of Vickers hardness hardness test in in the cross section shown in Figure in Figure J.2-5. High High hardness value was obtained in in transition transition zone. ItIt was assumed that carburization carburization which was caused by removed removed carbon affects affects the hardness in in transition zone.

4.2 Test coupon B (welding on the mashed mashed carbon electrode)

Figures J.3-1 show macro-structure macro-structure and micro-structure micro-structure of cross section of test coupon. Any significant significant defects or carbon remained were not observedobserved in in the cross section of test coupon.

The abnormal abnormal micro structure structure was also not observed. Light colored zone adjacent to the fusion zone adjacent boundary was observed.

observed.

Figure reference of hardness Figure J.3-2 shows reference hardness distribution in in transition zone inin samples samples with or without without carbon added. It It is assumed that carbon addition affects affects the hardening hardening of transition zone.

5. Summaries Summaries of the investigation investigation

1) Welding on gouged surface with remaining remaining carbon leads leads to carburization in transition zone.

carburization in

2) Adding carbon results in high hardness hardness in in transition transition zone.

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A*iL Attachment-J A,B A,B Figure J.1 Figure J.l Schematic illustration Schematic illustration of test coupons.

HEAVY INDUSTRIES,

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_ _ _ _ _ _ _ _ _ _ _ _ _"--_ _ _ _ _ _ _ _ _ _ _ ~ )'.LAttachment-J Attachment-J Table J.2 Gouging condition and welding condition of test coupon coupon AA A,B A,B i

4 .4 A,B A,B Table J.3 Welding condition of test coupon B

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At Attachment-J Attachment-J A.B A,1B Figure J.2-1 Appearance Appearance of test coupon A MITSUBISHI HEAVY INDUSTRIES,

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'L Attachment-J Attachment-l A,B A,B Figure J.2-2 Figure J.2-2 Macro-structure of Macro-structure of cross sect sections of test ions of coupon A test coupon A MITSUBISHI HEAVY

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_________________________ ~ )L Attachment-J A,B Figure J.2-3 Figure Micro-structure Micro-structure of cross sect section i on of test coupon (Location coupon A (Locat i on E)

E)

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A,B A,B Figure J.2-4 Figure J.2-4 The results of The of Vickers Vickers hardness hardness test of cross test of cross sect sect iion on (Locat (Locatii on on E)

E)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-J A Attachment-J A,B A,B Figure J.2-5 Figure J.2-5 of cross Micro-structure of Micro-structure cross sect section of test i on of test coupon coupon A A after additional after add polishing i tiona I po Ii sh i ng

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~ Attachment-1 Attachment-J A,B A,B Figure Figure J.2-6 The results of Vickers section Vickers hardness test of cross sect i on of test coupon A after after additional pol ishing polishing

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jAttachment-J Attachment-l A,B A,B J.3-1 Figure J.3-1 Macro-structure and micro Macro-structure micro structure structure of of cross section of of test coupon coupon MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-J Ak Attachment-J f

A,B

-I

. Figure J.3-2 Reference Reference of hardness hardness ddistribution transition i str i but ion in trans i t i on zone in samples samp I es with or without carbon addition MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ kttachment-K ,A Attachment-K Attachment-K Attachment-K Zeheat Cracking Reheat Cracking Investigation Investigation

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J.Attachment-K kttachment-K

1. Purpose The purpose of this investigation investigation is to determine determine whether whether heat input during gouging could initiate initiate reheat reheat cracking.

cracking.

2. Outline of investigation investigation The mockup which simulated the weld between LAS and 152 152 alloy was fabricated. Two types of welding methods were employed.

employed. One was SMAW SMAW which which was applied to the center center of channel head head bottom bottom and the other is ESW ESW which was applied to the other area of channel channel head. After that, the the gouging gouging was applied to remove the clad. After gouging, alloyalloy 152 joint weld was performed on the the mockup.

mockup.

The test specimens were machined machined from the mockup mockup and metaliographic metallographic investigation investigation and tensile tensile test were performed performed on them.

investigation methodology Detail investigation methodology is discussed in Section Section 3.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ;"'Attachment-K A.Attachment-K

3. Investigation Investigation Methodology Methodology Figure K.1 shows schematic illustration of test coupon and specimens schematic illustration specimens for metallographic metallographic investigation investigation and tensile test. The detail conditions conditions of specimens were shown in Table K.1 and K.2.

Table Table K.1 Detail condition condition of metallographic investigation 0 specimens for metallographic investigation ANBB K.22 Table K specimens for tensile test Detail condition of specimens AB A,B

/~

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~Attachment-K A.Attachment-K The investigation investigation methodology summarized in methodology was summarized in Table K.3.

Table T K.33 a bl e K IInvestigation nveslga Meth a doogy f f Ion Methodology I Item Method Purpose Purpose Macro-structure Macro-structure Visual examination examination of the Evaluate the macro-structure Evaluate macro-structure of the the cross-section cross-section at low materials materials magnification after etchinq maqnification etching Micro-structure Micro-structure Visual examination examination of the Evaluate the micro-structure Evaluate micro-structure around around the the cross-section cross-section at high fusion boundary magnification after etching Examine the existence Examine existence of micro-cracking micro-cracking in low alloy alloy steel (LAS)

(LAS)

Measure Measure the grain qrain size of HAZ HAZ Hardness Measurement for Vickers Measurement Evaluate Evaluate the hardness distribution of heat hardness distribution hardness affected affected zone (HAZ) zone (HAl)

Tensile Test Tensile Tensile Test on the Round Evaluate Evaluate whether the reheat cracking cracking Bar Specimen initiation initiation occurs on the welding boundary area area Grain Grain size in HAZ HAZ of LAS was measured measured with comparison method: some comparison method: some photographs of micro structure of the cross cross section were were compared fi~ures of JIS G0551 compared to figures G0551:2005 standard grain size

2005 standard size number.

2 Grain Grain size number G is described by equation 1 using m: number of grains per 1mm size number 1mm in cross cross section. The grain size size 0D is obtained by equation 2.

m = 8 x 2G (eq. 1)

(eq. 1)

D =l/-m =1/~8x2G 0=1/£ = 1! 8 . 2 G (eq.2)

(eq.2)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J.,..Attachment-K A Attachment-K

4. Investigation Results Results 4.1 Results of metallographic investigation metallographic investigation Figure K.2 shows macro macro structure of cross section of test coupon. HAl HAZ of ESW was observed observed in specimens specimens that stainless steel clad was welded by ESW. Neither cracks nor defects defects were observed in macro structure structure observation.

Figures K.3 shows micro micro structure of cross section of test coupons. Neither Neither micro-cracking micro-cracking nor defects were observed in HAl HAZ in cross section. There is no abnormality in microstructure microstructure of 152 152 buttering and LAS base metal.

buttering Table K.4 shows the results of the grain size measurement measurement in HAl.

HAZ. NoNo significant difference difference was was confirmed confirmed in grain size distribution in specimens specimens whose whose clad were were welded by ESW or SMAW. The The grain grain size in those specimens specimens was consistent with the results in boat samples and mock-ups mock-ups already reported.

Figure Figure K.4 shows results of Vickers hardness test. No significant difference between specimens was difference between was confirmed confirmed in hardness distribution. There is no abnormality abnormality in hardness hardness of 152152 buttering buttering and LASLAS base metal.

4.2 Results of tensile tests tests Figure K.5 shows the test specimens after tensile test. The tensile test samples fractured within the the base metal. These These tests did not produce produce reheat cracking cracking and the sample fracture surfacesurface characteristics did not duplicate those present characteristics present in the samples collected collected from the Unit-3 Unit-3 RSG.s.

RSGs.

5. Summaries of the investigation investigation

1) No micro-cracking micro-cracking or defect were observed HAZ in cross section.

observed in HAl

2) Any significant significant difference was not confirmed confirmed in grain size distribution in specimens specimens whose whose clad clad were welded by ESW or SMAW.

3) There is no abnormality abnormality in hardness buttering and LAS base hardness of 152 buttering base metal.

4) No No cracking were observed on the fusion boundary between LAS and alloy 152 152 in the tensile test specimens.

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___________________________ J... A.Attachment-K Attachment-K A,B A,B Figure K.1 Schematic illustration of test coupon.

Schematic illustration coupon.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~Attachment-K A'.Attachment-K A,B A,B Figure K.2 Macro structure of cross section of test coupons coupons MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ kttachment-K A.Attachment-K A,B A,B K.3(1)

Figure K.3(1) structure of cross section Micro structure Micro section of Jest coupon (clad test coupon ESVV)

(clad was welded by ESW)

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___________________________ ) Attachment-K

~ Attachment-K A,B A,B Figure K.3(2) Micro structure structure of cross section section of test coupon (clad was welded welded by ESV)

ESW)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ kttachment-K &Attachment-K A,B A,B Figure K.3(3)

Figure K.3(3) Micro structure Micro structure of cross section of of test test coupon coupon (clad (clad was welded by SMAW)

SMAW)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ;"'Attachment-K t.Attachment-K A,B A.B Figure Figure K.3(4) Micro structure of cross section of test coupon (clad was welded welded by SMAW)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ;"'Attachment-K ,i Attachment-K Table Table K.4 The results of grain size measurement measurement in HAZ of test coupon r}

A,B Z-*,

13

+

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .A kttachment-K Attachment-K A,B A,B Figure K.4 Vickers hardness of cross section of test coupons Figure KA coupons MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; . .Ajttachment-K Attachment-K Cladding Cladding process process Test.No Test.No Appearance Appearance 152 LAS ET1 ESW ESW ET2 ET2 152 , LAS ST1 SMAW SMAW ST2 Unit:mm Unitmm K.5 Figure K.5 Photograph of specimen specimen after tensile test MITSUBISHI HEAVY

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__________________________ ~Attachment-L

)'.! Attachment-L Attachment-L Attachment-L Alloy 152 Butter Residual Residual Stresses Stresses Analysis

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_____________________________ J.... tAttachment-L Attachment-L Residual stress evaluation Residual evaluation of the channel head after Alloy 152 buttering was performed Purpose

1. Purpose The purpose of this evaluation evaluation is to demonstrate the qualitative differences differences of residual residual stress due due to the differences of buttering buttering configuration between Unit2 and Unit3Unit3 after after 152 buttering was performed on the channel channel heads.

2. Outline Outline of analysis analysis After stainless stainless steel cladding cladding was performed on the low alloy steel with the same thickness thickness as thethe channel head flat bottom region, the cladding cladding near near the center of the plate is removed. After that, alloy buttering is performed 152 buttering performed on the area where the stainless stainless steel cladding cladding was removed.

Figure L.1 shows the sequence sequence of manufacturing manufacturing process from stainless steel cladding cladding process process to alloy 152 buttering process. In the analysis, three manufacturing manufacturing processes in Figure L.1 are simulated and stress distributions of Unit3 and Unit2 are compared simulated compared to evaluate the qualitative qualitative difference of the residual stress due to the difference difference difference of buttering configuration.

configuration.

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___________________________ A ) Attachment-L Attachment-L A,B A,B Figure L.1 Manufacture Manufacture process process TSUBISHI

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_____________________________ J.... At Attachment-L Attachment-L

3. Analysis model Figure L.2 shows the dimensions Figure stainless steel cladding and alloy dimensions of the stainless alloy 152 buttering of Unit2A, Unit2B, Unit3A and Unit3B. Since the dimension Unit2B, dimension of Unit3A is almost equal equal to that of Unit3B, the the used for analyses of Unit3A and model is used same analysis model and Unit3B and it is written Figure L.2 as written in Figure as "Unit3AB".

As shown shown in Figure L.2, the difference difference between Unit2A and Unit2B Unit2B is the length of the flat bottom of (L 1). Unit2B is more similar to Unit3AB compared alloy152 buttering (L1).

alloy152 Unit2A in regards of L1.

compared to Unit2A L 1.

Since the purpose of this evaluation demonstrate the qualitative evaluation is to demonstrate qualitative differences differences of residual stress due to the differences due differences of buttering configuration between Unit2 and configuration between and Unit3, Unit2B which is more more similar to Unit3AB is selected for comparison comparison with Unit3AB. Therefore, Therefore, two kinds of analyses, which are CASE-3AB and CASE2B,CASE2B, are performed.

performed.

As shown in Figure L.3, L.3, the analysis three-dimensional model with unit thickness. In Figure analysis model is three-dimensional L.4, three kinds of material LA, properties are shown. The material material properties properties used in the analyses are material properties shown from Figure L.5 through Figure Figure L.7. The material of the channel head head in actual actual plant is low low alloy steel, but carbon steel is used in the analysis analysis because because carbon carbon steel can be selectedselected in

( AB A,B J) and and its its property is similar property is similar to low alloy to low alloy steel.

steel. Four different phases, Four different which are are "ferrite", "bainite", "martensite" and "austenite", are set in the material property of carbon material property steel because carbon steel and low alloy steel have have phase transformation.

transformation.

boundary condition is shown in Figure L.8. Figure The boundary Figure L.9 ~ndand Figure L.10LAO show welding welding passes used in this analysis. Figure L.11 and Figure L.12 show welding sequences sequences used in this analysis.

Heat input of welding FigureL.13. From the macro photograph of cross section of welding passes is shown in FigureL.i13. of I type mockup specimen, melted length mockup specimen, length due to welding is set to( to( AB].

A,B).

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___________________________ .J..... AF4' Attachment-L Attachment-L AB AB Figure L.2 Dimension of stainless steel cladding alloy152 cladding and alloy 152 buttering buttering MITSUBISHI

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; .+4I . .Attachment-L Attachment-L A,B A.B Figure Figure L.4 Material properties LA Material properties

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___________________________ A. AI*LAttachment-L Attachment-L A,B A.B Figure* L.S L.5 Material Material properties properties of channel channel head rbon steel: SCM420(2OMoCr4_022C))

(Carbon SCM420(20MoCr4_022C))

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_________________________~_ J.... AAttachment-L Attachment-L A,B A,B L.8 Boundary Figure L.B Figure condition Boundary condition MITSUBISHI

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___________________________ A. A*k Attachment-L Attachmenl-L A,B A,B LAO0 Welding passes Figure L.1 passes of alloy152 buttering buttering

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______________________________ )~Attachment-L Attachment-L A,B A,B passes of Figure L.12 Welding passes of alloy152 alloyl52 buttering buttering

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___________________________ J.... , Attachment-L Attachment-L A,B A,B Figure L.13 Heat input of welding passes passes MITSUBISHI HEAVY

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_____________________________ A )' Attachment-L Attachment-L

4. Analysis result Figure L.14 shows shows the residual stress distribution distribution after after the 3rd process. The 3rd processprocess refers to the process where alloy 152 buttering buttering is performed on the area where the stainless steel cladding cladding was removed.

removed. From Figure L.14, the stress at each each direction direction of Unit3AB and and Unit2B Unit2B shows the the almost same tendency.

For the residual stress after the 3rd process, stress at the x direction is higher because because of the the restraint of X-direction X-direction at both both sides of the area area where alloy152 alloy152 buttering buttering was performed.

Since the occurrence occurrence of defect at the boundary boundary between between alloy152 alloy152 buttering and low alloy steel steel depends depends on the stress at the boundary, normal stresses stresses at the boundary boundary between alloy152 buttering between alloyl52 and low alloy steel of Unit3AB Unit3AB and Unit2B are evaluated evaluated as shown in Figure L.15. From Figure L.15, for stress on where distance from the center of alloy152 buttering buttering is(

is( A,B ),), stress of Unit3AB Unit3AB is higher than that of Unit2B because higher because of the difference difference of the shape of the boundary between between alloy152 alloy1S2 buttering and low alloy steel.

buttering As shown in Figure L.15, the angle between between the boundary of alloy152 buttering and low alloy steel alloy152 buttering and X-direction X-direction is defined as "TH1"."TH1'". Since Since the angle angle of Unit3AB is larger larger than that of Unit2B Unit2B as as shown in Figure L.2, the direction of the normal normal stress at the boundary of Unit3AB is closer to the the X-direction than that of Unit2B.

Unit2B. Therefore, for stress on where the distance from the center of alloy152 alloy152 buttering is( A,B ],

is (A,B ], it is considered considered that the normal normal stress at the boundary of Unit3AB is higher than that of Unit2B.

higher

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ AAW Attachment-L A,Attachment-L A,B A,B Figure Figure L.14 Stress contour after 3rd process proc(

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ,J....Attachment-L JAL Attachment-L A,B A,B Figure L.1S boundary between Normal stress distribution to the boundary L.15 Normal Alloy1S2 buttering between Alloy152 buttering and carbon steel(channel steel(channel head)

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)k Attachment-M Attachment-M Attachment-M Attachment-M 2D Analysis to Evaluate Evaluate the Effect of the Divider Plate OffsetOffset

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AO. Attachment-M FE Analysis Analysis The FE model is shown in Figure M.I. Load and boundary Figure M.I. boundary condition are shown Figure M.2.

Each material is shown in Figure M.3 and the material properties properties (S-S curve) used in the the analyses are shown in Table Table M.1.

M.I.

The deformation and the stress contours due to elastic analysis are shown in Figure MA-\

M.4-1 through Figure M.4-4.

MA-4.

The deformation deformation and the stress/strain stress/strain contours due to elastic-plastic elastic-plastic analysis analysis are shown shown in Figure Figure M.5-1 through Figure M.5-7.

M.5-7.

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Attachment-M Attachment-M A,B A,S Figure M.l M.1 Analysis Model

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________________________ ~ AW Attachment-M Attachment-M A,S A,B Figure Figure M.3 Material

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________________________ A )'L Attachment-M Attachment-M Table M.

M.lI Material Material Properties Properties A,B A.B

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-M A,B A,B Figure M.4-1 Displacement (Elastic Analysis)

Figure M.4-l Displacement (Elastic Analysis)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-M )I Attachment-M A,B A,S (1/3) Stress Contour [Mises]

Figure M.4-2 (1/3) [Mises] (Elastic (Elastic Analysis)

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AOý Attachment-M

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(3/3) Stress Stress Contour <Part-2> [Mises] (Elastic Analysis)

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_ _ ~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ ik Attachment-M A.B A,B

"\

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Figure M.4-3 (1/3) [cX] (Elastic (1/3) Stress Contour [aX] (Elastic Analysis)

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_________________________ ~ ). Attachment-M Attachment-M A,B A,S (3/3) Stress Contour Figure M.4-3 (3/3) Contour <Part-2> [5X] (Elastic

<Part-2> [oX] (Elastic Analysis)

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A ' Attachment-M A,B A,B M.4-4 (1/3)

Figure MA-4 (1/3) Stress Contour [aY]

[crY] (Elastic (Elastic Analysis)

Analysis)

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(3/3) Stress Contour <Part-2> laY]

[TY] (Elastic Analysis)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-M Attachment-M A,B A,S Figure M.5-1 M.S-I Displacement (Elastic-Plastic Analysis)

Displacement (Elastic-Plastic

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_________________________ )O J... Attachment-M Attachment-M A,B A,S Figure M.S-2 M.5-2 (1/3)

(1/3) Stress Contour [Mises] (Elastic-Plastic (Elastic-Plastic Analysis)

Analysis)

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_________________________ ~ At Attachment-M Attachment-M A.B A,B Figure Figure M.5-2 M.S-2 (3/3)

(3/3) Stress Stress Contour Contour <Part-2>

<Part-2> [Mises]

[Mises] (Elastic-Plastic (Elastic-Plastic Analysis)

Analysis)

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________________________ ~ )L Attachment-M Attachment-M A,B A.B Figure M.5-3 (1/3) [oX] (Elastic-Plastic (1/3) Stress Contour [aX] (Elastic-Plastic Analysis)

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Attachment-M Attachment-M .

A,B A,B Figure M.5-3 (3/3)

(3/3) Stress Contour <Part-2> [aX]

[GX] (Elastic-Plastic (Elastic-Plastic Analysis)

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________________________ J... Document AFi Attachment-M Attachment-M A,B A.B Figure M.5-4 (1/3)

Figure M.S-4 [aY] (Elastic-Plastic (113) Stress Contour [crY] (Elastic-Plastic Analysis)

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_________________________ J... Attachment-M Attachment-M A,B A,S (3/3) Stress Contour <Part-2> [GY]

Figure M.5-4 (3/3) [crY] (Elastic-Plastic (Elastic-Plastic Analysis)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-M Ak Attachment-M A,B A,S Figure M.S-S M.5-5 (1/3)

(1/3) Strain Contour [equivalent plastic plastic strain] (Elastic-Plastic (Elastic-Plastic Analysis)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-M A*L Attachment-M A,B A.S Figure Figure M.5-5 M.S-S (3/3) Strain Contour <Part-2> [equivalent

[equivalent plastic plastic strain] (Elastic-Plastic (Elastic-Plastic Analysis)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-M )111 Attachment-M A,B A,S Figure N/1.5-6 M.S-6 (1/3)

(1/3) Strain Contour strain :X]

Contour [plastic strain: (Elastic-Plastic Analysis) c:X] (Elastic-Plastic MITSUBISHI HEAVY

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_________________________ A. At Attachment-M Attachment-M A,B A,S Figure Figure M.5-6 (3/3)

(3/3) Strain Contour Contour <Part-2> [plastic strain :X]

[plastic strain: (Elastic-Plastic Analysis)

EX] (Elastic-Plastic

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Ak Attachment-M Attachment-M A,B A,B (1/3) Strain Contour [plastic Figure M.5-7 (1/3) strain F:Y]

[plastic strain: (Elastic-Plastic Analysis) t:Y] (Elastic-Plastic Analysis)

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A'k Attachment-M Attachment-M A,B A,B Figure M.5-7 M.S-7 (3/3)

(3/3) Strain Contour <Part-2> [plastic strain *Y]

[plastic strain: (Elastic-Plastic Analysis) tY] (Elastic-Plastic

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______________________ ; Ak. . . Attachment-N Attachment-N Attachment-N 3D Analysis to Evaluate the Channel Head-to-Tubesheet Head-to-Tubesheet Weld Weld Shrinkage MITSUBISHI HEAVY INDUSTRIES, LTD.

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_________________________ J... Document A'. Attachment-N Attachment-N Analysis FE Analysis Load condition N. I in the Tubesheet-to-Channel condition is shown in Figure N.l Tubesheet-to-Channel Head welding.

(~T=(

(ATh( A,B A,S )

))

The materials and the material material properties properties are the same same as the ones in "Design "Design Report of of the Tubesheet Region" (L5-04GA40 Tubesheet Region" (L5-04GA401). I).

The deformation deformation and the stress/strain stress/strain contours are shown shown in Figure N.2 and Figure N.3.

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Figure N.2 Contour of Strain [Tubesheet Weld]

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(1/3) Contour of Mises Stress [Tubesheet ofMises [Tubesheet Weld]

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Figure (2/3) Contour Contour of of Mises Mises Stress Stress [Tubesheet

[Tubesheet Weld]

Weld]

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ; . . . Attachment-N A k Attachment-N A,B A,S Figure N.3 Figure N.3 (3/3)

(3/3) Contour Contour ofMises of Mises Stress Stress [Tubesheet

[Tubesheet Weld]

Weld]

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-O , Attachment-0 Attachment-O Attachment-O 3D Analysis Analysis to Evaluate the Channel Head-to-Tubesheet Head-to-Tubesheet Weld PWHT PWHT

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Document No.LS-04GA440

_________________________ ~ Art Attachment-O Attachment-O FE Analysis Analysis The FE model is shown in Figure 0.1. '.Design

0. 1. This model is the same as the one in HDesign Report Tubesheet Region" Report of the Tubesheet (L5-04GA40 1).

Region" (L5-04GA40 I).

Load and boundary temperatures are based on boundary conditions are shown in FigureO.2. Nodal temperatures "Thermal Analysis under PWHT" "Thermal PWHT" (L5-04GA414).

(L5-04GA414).

The material properties used in the analyses shown in Table 0.1.

analyses are shown 0. 1.

temperature contours for PWHT are shown in Figure The temperature 0.3-1. The stress contours Figure 0.3-1. contours are shown in Figure 0.3-2 through Figure 0.3-4.

L5-04GA401 and Comparison of temperature distribution (End of Heat up Process) of LS-04GA401 0.3-5.

LS-04GA414 is shown in Figure 0.3-S.

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0.11 Analysis Model MITSUBISHI HEAVY INDUSTRIES,

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~_ ~ Attachment-O Attachment-O A,B A,S 0.3-1 Temperature Figure 0.3-1 Temperature Distribution Distribution MITSUBISHI HEAVY

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- .,;",________________________.j."., Attachment-O Attachment-O A,B A,B Stress Contour Figure 0.3-2 Stress Contour [Mises]

[Mises] (End of of Heat up Process)

Process)

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[Mises] (End of Heat Heat up up Process)

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Figure 0.3-4 Stress [Mises] (End (End of of Heat Heat up Process)

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Attachment-P Attachment-P Attachment-P Attachment-P 3D Analysis Including the Actual Condition Condition of 3B RSG RSG

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Attachment-P FE Analysis Analysis The FE model is shown in Figure P. 1. Load and boundary P.I. boundary condition are shown Figure Figure P.2.

The materials are shown in Figure Figure P.3. material properties used in the analyses are P.3. The material shown shown in Table P.l.

P. 1.

Table P.l P.A Material Material Properties Properties AB A,B deformation and the stress contours are shown in Figure PA The deformation P.4 through Figure P.8.

The Stress distribution distribution are shown in Figure P.9.

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Attachment-P Attachment-P A,B A,B I',-

Figure P.4 Displacement PA Displacement MITSUBISHI HEAVY INDUSTRIES,

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-P J Attachment-P A,B A,B

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Figure P.5 (1/2)

(1/2) Stress Stress Contour [Mises]

[Mises]

A,B A,B

<Part- I>

Figure P.5 (2/2) Stress Contour <Part-J > [Mises]

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-P SAttachment-P A,B A,B K

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Figure P.6 (1/2) r A,B A,B (2/2) Stress Contour <Part-I> [GX]

Figure P.6 (212) [aX] (Elastic Analysis)

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_________________________ JJ.... Attachment-P Attachment-P A,B A.B (1/2) Stress Figure P.7 (1/2) [crY]

Stress Contour [cyY]

A,B A.B

-I Figure P.7 (2/2) Stress Figure Stress Contour <Part-l

<Part-I> [IY]

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-P Attachment-P

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Contour <Part-I>

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Document Document No.L5-04GA440 No.LS-04GA440 (0)

__________________________ ~Attachmenl-Q

)'.kAttachment-Q Attachment-Q Hydrogen Diffusion Diffusion Analysis

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J....Attachment- ' Attachment-Q Q Analysis Hydrogen Diffusion Analysis I.Purpose I.Purpose The purpose of this report is to provide the analysis results of hydrogen diffusion behavior in alloy 152 152 buttering buttering and low-alloy steel (LAS)

(LAS) cladding.

2.Conclusion 2.Conclusion (1) As a result of hydrogen diffusion analysis with models simulating the heat treatment treatment conditions of Unit-2B Unit-28 and Unit-3A, Unit-3A, the significant significant difference difference of residual hydrogen concentration between hydrogen concentration between alloy 152 and LAS afterafter heat treatment confirmed although the heat treatment conditions treatment was not confirmed (temperature and time) are different.

conditions (temperature (2) In both cases cases (simulating Unit-2B Unit-28 and Unit-3A), the hydrogen diffusion diffusion coefficient coefticient within the range ofof heat treatment for LAS is 100 times smaller or more in comparison comparison with alloy 152.

152. Therefore, the progression of hydrogen concentration concentration from alloy 152 to LAS can be observed near the boundary boundary of alloy 152 and LAS but but there was no significant difference in the concentration concentration of hydrogen in alloy 152 after heat treatment.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ,A ,Attachment-QQ J...Attachment-

3. Method of Procedures Procedures (I) Analysis (I) Analysis models and Analysis conditions conditions To simulate hydrogen behavior behavior through-thickness through-thickness direction, direction, the analysis models are assumed as the the configuration configuration shown in Figure Q.I. Q.I. Table Q.I Q.I shows the heat treatment conditions for hydrogen hydrogen diffusion diffusion analysis based on actual actual welding welding record. The graphs of the number number of laminated laminated layers of the models by time time are presented presented on Figure Q.2 and Figure Q.3.Q.3.

Initial hydrogen diffusion in LAS and in alloy 152 is (A,B [ A,B ]and [ A,.B

) and (A,!,!. )each.

)each. The hydrogen hydrogen diffusion coefficients coefficients in metal are presented Apendix-1.

presented on Apendix-I.

A,B A,B Q. I Model for hydrogen Figure Q.I analysis hydrogen diffusion analysis Table Q.l Q.I Heat treatment conditions conditions A,B AB k, B

__I __ ____ __ ____ ____

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Attachment-Q

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A,B A,B Heat-treatment and Welding Figure Q.3 Heat-treatment Welding condition condition of Case-2 (U3A-RSG)

(U3A-RSG)

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______________________________ A. A.Attachment-Q Atlachment-Q

4. Results of Measurement Measurement For both Case-I Case-I and Case-2, a steep slope of hydrogen concentration concentration is observed observed and verified at the boundary of alloy 152 and LAS (this (this happens happens because the hydrogen coefficient of alloy 152 and LAS within the hydrogen diffusion coefficient range of heat treatment treatment differs 100 times or more),

more), but no significant significant difference difference was found between between case-1 case-I and case-2 in the following points.

- The depth where hydrogen concentration begins to decrease hydrogen concentration decrease is is less than(

than( A,B ]from

)from the boundary boundary of alloy 152 and LAS.

- Hydrogen Hydrogen diffusion value are(

are( A,B )(in case-I),

)(in case-I), and(

and( A,B ](in case-2)

)(in case-2) at the boundary of alloy 152 152 and LAS.

A,B Q.4 Hydrogen Figure QA Hydrogen Concentration Concentration -in.in Alloy 152 buttering buttering

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Ak ~Attachment-Q Attachment-Q A,B A,B Figure Q.S Q.5 Hydrogen Concentration Concentration in Low alloy steel (The under side isis the expansion expansion of the the upper side.)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ AAltaChment- Q

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1.0 1.0 FAULTTREE FAULT TREEANALYSIS INVESTIGATIONPLAN ANALYSIS&&INVESTIGATION PLAN used to produce the channel The FaultTree The Fault Analysis and TreeAnalysis Investigation Plan and Investigation shown ininTable Plan shown R.1 isisan Table R.1 analysis ofofthe ananalysis processsteps the process steps used to produce the channel for each process and leads to identification of specific investigations that are assembly.This headassembly.

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CO, zZ 0

c en

-I A.B A,B

--I

0 mm en ti 9

I--

-4" CI

>C C

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Document No,L5-04GA440 NoL5-04GA440 (0) (0)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~Attachment-R A*Attachment-R 2.2 Channel Head Cladding Channel Head Cladding Process Process The cladding was applied on the channel channel head bowl by the Electro-Slag Electro-Slag Welding process process (ESW) except except at the center center where where the Shielded Shielded Metal Arc Welding process (SMAW) was was used, used. One of the root causes causes that could degrade degrade weld quality is "migration of detrimental materials into the base metal, which could lead to degradation of the base metal material properties". Another cause could be improper welding (i.e, properties", (i.e. exceeding exceeding the heat input input limit).

limit),

Actions taken to address address this family of causes include include review of the welding records for Units 22 and 3 to confirm that the correct correct material material was used and the welding processes welding processes were performed properly.

performed properly, Table R.5 through 8 lists the welding materials materials used on the Unit 2 & & 3 channel heads, heads.

Welding Welding conditions such as current, voltage, speed, preheat /I interpass interpass temperature temperature were all found to be within the instructed range. The values instructed range, values for Units 2 and 3 are the the same same with minor differences. According According to the welding welding record, the cladding materials materials and processes were applied correctly and it can be concluded that the bond between specification and the base metal contains no cladding and channel head are per specification no detrimental inclusions inclusions or degraded cladding..

degraded cladding.

MITSUB MITSUBISHI I S H I HEAVY INDUSTRIES, LTD.

HEAVY INDUSTRIES, LTD.

Page 433 of 484 484 S023-617-1-M1415, S023-617-1-M1415, Rev, Rev. 0

A,B A,S Table R.5 Table R.5 Weld condition of channel Weld condition cladding (SONGS-2A) channel head cladding (SONGS-2A)

(a m

Cn m

o o

(")

c CD 3(1)

I ~

I C-

> ~--

___________ L__________________ I _____ I ____________ L ____________ ___________ ________ ________ ___________

Page 434 of 484 S023-617-1-M1415, Rev. 0

A,B A,B Table R.5 Table R5 Weld condition Weld channel head ofchannel condition of cladding (SONGS-2A) head cladding (SONGS-2A)

~

4. 4. 4.

3:

~

en C,,

CC wID en C,,

I:E IJ:

mm

~

Z o

Cc en Cd,

-4 J

-t a;!

mm en C',

j-

-t p!=l II

_____ + I -t t t t I-

_____ 4 + 1 t t 4 0

- C 2

C H U.

2 -u-'---

C

3 ~

~

484 Page 435 of 484 S023-617-1-M1415, Rev.

S023-617-1-M1415, Rev. 00

A,B A,B Table R.6 Table R6 Weld condition Weld channel head of channel condition of cladding (SONGS-2B) head cladding (SONGS -28)

~

____ ______ II ___ __

Cl)

C C')

m m

z Cn

-4 m

C 0

2 0

I C-tJ~

2 -~----~

C Page 436 of 484 S023-617-1-M1415, S023-617-1-M1415, Rev.Rev. 00

A,B A,B Table R.6 Table R.6 condition of Weld condition Weld channel head of channel cladding (SONGS-23) head cladding (SONGS-2B)

C, C

CI

-I Table R.7 Table R.7 condition of Weld condition Weld channel head of channel weld (SONGS-3A) clad weld head clad (SONGS-3A) m o

o(")

c:

3 ro

> a Page 437 of 484 484 S023-617-1-M1415, S023-617-1-M1415, Rev. Rev. 00

A, B Table R.7 Table R.7 condition of Weld condition Weld channel head of channel clad weld head clad weld (SONGS-3A)

(SONGS-3A) A,B

/~

C/)

C/

m 0

____ +/- ________ I _________ I ________ I I _______ _________ I ________

C C',

m C

0 2

0

___________________1______ 1________I___t_____________II____________ I_____________

__I_____ _________ __I________

-I 4 4 4 I- 4 2 -'~---~

____________ ___________________ I I ____________ I ______________ +/-____________ C _________ L L ______________ +/-____________

1 0

"-- 7 -

Page 438 of 484 484 S023-617-1-M1415, Rev.

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A,B A,B Table R.7 Table R.7 Weld condition Weld channel head of channel condition of weld (SONGS-3A) clad weld head clad (SONGS-3A)

~ ~

I rn m

Table R.8 Table R.8 Weld condition Weld head clad channel head condition of channel weld (SONGS-3B) clad weld (SONGS-38)

C

--I m

0o 0o

()

t:

3

10. <1l

~z

l o

r Y,

v,

~ b -l'-

2EO o

()

=r );-

3 -l'-~

~;;o

~ ~

<1l

l

N8~

Page 439 of 484 484 S023-617-1-M1415, Rev.

S023-617-1-M1415, Rev. 00

A,B A,B Table Table R.8 R.B Weld condition of Weld condition channel head of channel clad weld head clad weld (SONGS-3B)

(SONGS-38)

s::

=i Ci) en C

ID fjj

I:

mm

~

Z o

c Cn en

-tI

0 miii en 5-

~

r,

!='

t I -I--

+ +/- +/- I I >

+

I- -I I t -4 4.

440 of 484 Page 440 484 S023-617-1-M1415, S023-617-1-M1415, Rev.

Rev. 00

2.3 Clad 2.3 Removal Process Clad Removal Process 2.3.1 Unit-2 and 2.3.1 Unit-2 Fabrication and and 33 Fabrication Process Comparison and Process Comparison Table R.9 Table R.9 Fabrication Process Fabrication for Unit-2 Comparisons for Process Comparisons & 33 RSGs Unit-2 & RSGs

s::

=l cen c

tIl Cii C

I:

m

>>

A, B

~

Cn CO) A,B Z

0 c

t--

en

-i

!! CnC m

en

!:j 9

zz CnC C l 4 Page 441 of Page 441 of 484 484 S023-617-1-M1415, Rev. 00 S023-617-1-M1415, Rev.

(R-20)

________________________ AA.

No.L5-04GA440 (0)

Document No.LS-04GA440 (0)

Attachment-R Attachment-R 2.3.2 Clad Removal 2.3.2 Removal Process Prior to Buttering Buttering Machining was used for SONGS-2 SONGS-2 and arc-air-gouging arc-air-gouging was used for SONGS-3. Detail is as follows.

SONGS-2 A,B A,S

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MITSUBISHI HEAVY INDUSTRIES, Page 442 of 484 SO23-617-1-M1415 , Rev. 0 S023-617-1-M1415,

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~_ _ _ _ ~ ,b Attachment-R Attachment-R SONGS-3 SONGS-3 A,B A,S MITSUBISHI HEAVY INDUSTRIES,

- - - - - - - - - - - MITSUBISHI INDUSTRIES, LTD. - - - - - - - - - - -

Page 443 of 484 Page S023-617-1-M1415, Rev, S023-617-1-M141S, Rev. 0

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Document Document No.L5-04GA440 (0)

No.LS-04GA440 (0)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~Attachment-R 4A Attachment-R A,8 A.B MITSUBISHI HEAVY INDUSTRIES,

- - - - - - - - - - - MITSUBISHI INDUSTRIES, LTD.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ttachment-R &LAttachment-R 2.4 Buttering Buttering at Divider Plate Location Location Welding record record was reviewed reviewed in order to confirm that correct material material was used and application was performed properly, check ifif the base metal contains any detrimental application inclusions, verify ifif alloy 152 152 butter application application could degrade degrade the base metal II Pre-heat and post-bake post-bake record for SONGS-2A for SONGS-2A I r

A,B

-I Pre-heat and Pre-heat post-bake record and post-bake for SONGS-2B record for SONGS-2B I A,B A,B

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ J.:ttachment-R A IAttachment-R Pre-heat and post-bake record for SONGS-3A Pre-heat

/-

A,S A,B

-'I, Pre-heat and post-bake record for SONGS-38 SONGS-3B 7f.

A,B A,S J

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LTD.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ttachment-R 41 Attachment-R A,B A,B Table R.11 Weld condition of channel channel head butter weld (SONGS-2A) i

- - - - - - - - - . . . . . . . ; . . - MITSUBISHI MITSUBISHI HEAVY INDUSTRIES, INDUSTRIES, LTD.

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________________________ ~ 4 Attachment-R Attachment-R A,B A,S d'Itlon

Table R.12 R.12 Weld con condition h 0 f channel of cannel hhead ea d butter weld ((SONGS-2B) 50 NG5 -28)

~

___________________________ ]

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No.LS-04GA440 (0)

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)l

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .J....Attachment-R Attachment-R A,B A,S Table R.13 Weld condition condition of channel head butter weld (SONGS-3A)

(SONGS-3A)

I r I c,

-1 MITSUBISHI HEAVY

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Document No.LS-04GA440

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ttachment-R A Attachment-R A,B A,S C ~

Table R.14 head butter weld (SONGS-38) condition of channel head R.14 Weld condition (SONGS-3B) i

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HEAVY INDUSTRIES, lTD.

Page 450 of 484 S023-617-1-M1415, Rev. 0

mechanical property of Welding Materials Table R.15 Chemical Composition and mechanical Materials s::

=i en C.)

c

[Il C:

en

~

M

r:

m m

)-

~

Z z

0 A,B A,S Cl C

en

-I 22 m

en r-

-I

~

XC-

,7 p. .

Page 451 of 484 484 S023-617-1-M1415, Rev. 0

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Document Document No.L5-04GA440 No.LS-04GA440 (0)

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_~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~Attachment-R 4 Attachment-R A,B A,S Figure R.1 Design Drawing R.1 Design Drawing Requirement Requirement HEAVY INDUSTRIES, MITSUBISHI HEAVY

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LTD. - - - - - - - - - -

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Document No.L5-04GA440 No.LS-04GA440 (0) (0)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .J.,.Attachment-R At, Attachment-R prepared for SONGS-2/3 The welding materials prepared SONGS-2/3 project project were used correctly correctly and welding welding performed properly.

was performed properly.

Welding condition such as welding current, welding voltage, welding speed and pre-heat/interpass/post-bake temperature pre-heatlinterpass/post-,bake temperature were within the instructed condition range.

They are almost the same. There There are few difference difference between SONGS-2 SONGS-2 and SONGS-3SONGS-3 except number except number of layer and bead per layer.

In In the case of SONGS-2, alloy 152 152 was buttered [(A,BAB .)) which is higher higher than ambient ambient stainless stainless steel clad surface surface and then ground flush. In In the case of SONGS-3, alloy 152 152

[ A,B was buttered (A,B Jto be the ,nominal

]to nominal buttering thickness, which resulted I AB resulted (A,B J less less than SONGS-2. In In SONGS-3B, 55thth layer was buttered locally locally to satisfy the buttering buttering

) buttered thickness of SONGS-3 would be about [( A,B ]Jless than thickness. As a result, buttered that of SONGS-2 including the amount of grinding.

grinding.

Number of bead per layer would relate to the buttered groove width, width. (Drawing (Drawing requirements are shown in Fig.R.1) requirements Fig.R.1) SONGS-2A has wider groove groove width so that number of bead bead is more than that of SONGS-2B.

SONGS-2B. Groove bottom width of SONGS-2B SONGS-2B and and SONGS-3 are the same. But required corner radius is larger in required corner SONGS-2B. Actual in SONGS-2B.

number number of weld bead reflects the requirement. As a result, although the drawing drawing requirements requirements . are satisfied, groove surface width would be be SONGS-2A>SONGS-2B>SONGS-3. This difference SONGS-2A>SONGS-2B>SONGS-3. difference may may affects to the residual stress stress difference between SONGS-2 and SONGS~3, difference SONGS-3, but there is no difference difference in the quality of welded metal.

According to the welding record, there is no potential that the base metal contains contains any detrimental detrimental inclusions and clad welding degraded the base metal.

inclusions andclad metal.

MITSUBISHI HEAVY

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ttachment-R )I Attachment-R 2.5 Welding Channel Head Welding of Divider Plate to Channel Head The processes sequences used for welding processes and sequences welding the divider divider plate to the channel head buttered surface were generally buttered generally the same for all four RSGs.

Fabrication record was reviewed if alignment accuracy if alignment accuracy or bracing can increase stress inin this weld.

A,B A,S

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Document Document No.LS-04GA440 (0)

No.L5-04GA440 (0) 4'. Attachment-R

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .J....Attachment-R A,B A,S MITSUBISHI HEAVY

- - - - - - - - MITSUBISHI HEAVY INDUSTRIES, LTD. - - - - - - - - - -

INDUSTRIES, LTD.

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Document No.LS-04GA440 Document No.L5-04GA440 (0) (0)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~Attachment-R A Attachment-R Bracings were applied in order to keep the flatness flatness of divider plate. As shown in the the drawings drawings and picture above, bracings bracings were placed in the radial directions directions at the lip of shrinkage or deformation Bracings were not applied to prevent shrinkage channel head. Bracings deformation of weld in in the direction of tubesheet to channel head bottom, which which is the concerned concerned direction of the separation.

Another counter measure, welding divider divider plate to channel head alternatively from hot head alternatively leg side and cold leg side, was applied applied so that the weld deformation deformation would be almost equal to both side of the weld.

As aa result, flatness of divider plate was good in in SONGS-2A SONGS-2A andand the number of bracings bracings was reduced SONGS-3A and 3B. Flatness of divider plate was not measured reduced to two in SONGS-3A measured during fabrication but measured after the occurrence occurrence of this issue.

Applied bracing has least least relation to the divider plate separation separation issue and did not increase or reduce stress in the weld.

Divider plate was welded to channel channel head and tubesheet tubesheet by GTAW and SMAWSMAW process.

In order to minimize weld shrinkage In shrinkage and distortion, welding was applied in accordance in accordance with a strict instruction.

instruction. The same instruction instruction was applied to the four RSGs of SONGS-2A SONGS-2A to SONGS-3B.

A,B A,S

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-RA k Attachment-R A,B A,S MITSUBISHI HEAVY MITSUBISHI HEAVY INDUSTRIES, INDUSTRIES, LLTD.

TD.---------

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Document No.L5-04GA440 (0)

Document No.LS-04GA440 (0)

..0,------------------ J.....

)"D Attachment-R Attachment-R A,B A,B MITSUBISHI HEAVY INDUSTRIES, MITSUBISHI INDUSTRIES, L LTD.

TD.----------

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________________________ ~Attachment-R

~ Attachment-R A,B A.B MITSUBISHI HEAVY MITSUBISHI HEAVY INDUSTRIES, INDUSTRIES, LLTD.

TD.----------

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Document Document No.L5-04GA440 No.LS-04GA440 (0)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ At ; . . Attachment-R Attachment-R A,B A.B MITSUBISHI HEAVY MITSUBISHI HEAVY INDUSTRIES, LLTD.-

TD . - - - - - - - - - -

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Document No.L5-04GA440 NO.L5-04GA440 (0)(0)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Art ~ Attachment-R Attachment-R Table R.16 Weld layer/pass layer/pass sequence sequence of divider divider plate to channel head weld channel head weld A.B A,B c ( SO NGS-2A)

(SONGS-2A)

~

4. - 4.

+ 4* I.

4. 4.

I 4* 4.

i - 4-

4. 1 4.

+ 4* 4

________ 4. 4. 4-

+ + ________ I 4. 4.

I I I I MITSUBISHI HEAVY INDUSTRIES, LLTD.

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ At ~ Attachment-R Table R.17 Weld layer/pass sequence sequence of divider divider plate to channel head weldweld A.B A,B (SONGS-2B)

(SONGS-2 B)

~

________ 4 I-

+ 4 4 +

______ 4- 4 4

______ ______ + + 4 I1

__ __ I

__ I__ __

1_ 1_ _ _

______ ______ ______ + +

______ ______I- +

-x MITSUBISHI HEAVY MITSUBISHI HEAVY INDUSTRIES, L LTD.

TD.----------

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~ Attachment-R ,* Attachment-R Table R.18 Weld layer/pass sequence sequence of divider divider plate to channel channel head weld weld A,B A,S (SONGS -3A)

(SONGS-3A)

.~

I

__ _ __ I-

+ 4 4 + 4 +

+ 4 4 ________ -I 4 + +

+ i i 4 4 4

+ 4 4 ________ 4 4 4 t1 4- 4 4 4

__ _ 4

__ 4

__ 3 1__ __

_____________ _____________ I _____________ I _____________

I _____________

MITSUBISHI HEAVY MlTSUBISHI HEAVY INDUSTRIES, INDUSTRIES, LTD.-

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_________________---'______ A. Document Document No.LS-04GA440

)"*I (0)

No.L5-04GA440 (0)

Attachment-R Attachment-R R.19 Weld layer/pass Table R.19 layer/pass sequence sequence of divider divider plate to channel channel head weld weld A,B A,S (SONGS-38)

(SONGS-3B)

\

________ + +

________ 4 + +

-4 .4 4 4

.4

___________________ .4 .4

______ + .4 .4

______ .4- .4- .4-MITSUBISHI HEAVY INDUSTRIES, MITSUBISHI LTD.-

INDUSTRIES, L TD.----------

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Document NO.LS-04GA440 (0)

_________________________ ~ A Attachment-R k Attachment-R 2.6 Welding Welding of Divider Plate to Tubesheet Tubesheet The processes processes and sequences sequences used for welding the divider plate to the tubesheet clad surface were were generally generally the same with the welding to channel head and for all four RSGs.

2.7 Welding Welding of Channel Channel Head to the Tubesheet Tubesheet The processes and sequences sequences used for welding the channel head to the tubesheet tubesheet were generally generally the same for all four RSGs.

2.8 Heat Treatments Treatments The processes andand sequences sequences used for heat heat treating the channel head to the tubesheet tubesheet welds were were generally generally the same for all four RSGs.

PWHT PWHT was applied applied in accordance accordance with the approved approved procedure procedure "Post Weld Heat Heat Treatment Procedure" SB-SO-HT-1001 S8-S0-HT-1001 for SONGS-2A128/3A138 SONGS-2A/2B/3A/3B channel heads.

Every Every heat treatment designated in FPS (Fabrication Process Sheet) was followed treatment steps designated correctly and verified.

verified.

PWHT PWHT record was confirmed confirmed, that the heat heat treatment time and temperature are satisfactory to the procedure procedure and Code requirement.

Difference Difference in the accumulated accumulated holding time for each channel head head is not large. They are inin the order of 2A>3A>28>38 2A>3A>2B>3B (">" (">" means means longer longer holding time).

MITSUBISHI HEAVY MITSUBISHI INDUSTRIES, LTD.

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Page 465 of 484 S023-617-1-M1415, Rev. 0

A,B A,B History of R.20 History Table R.20 Table PWHTof of PWHT Channel Head ofChannel Head 3:

=l en c:

[Xl 1i5 mh~ -

r:

m

~

z0 "

c:

en

-I 2:l C/)

m

-1 en 29 t:j _

~

C C

2

3 C

LA

>5 9

3

~

Page of 484 466 of Page 466 484 S023-617-1-M1415, Rev. 00 S023-617-1-M1415, Rev.

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Document No.L5-04GA440 No.LS-04GA440 (0) (0)

~ Attachment-R Attachment-R 3 Review Review of Inspection Inspection Record

3. 1 Alloy 152 butter butter and Divider Plate weld Records Records Inspections/checks by QC for the Alloy 152 butter under Inspections/checks under Divider Plate (WF-V116-1)

(WF-V116-1) and Divider Divider Plate welds (WA-V1 16-1) are listed below tables.

(WA-V116-1)

As for PT, UT and VT, inspection inspection results were all accepted accepted and there were no recordable UT indications. As for the other QC check, all results were accepted.

Furthermore, the same procedures Furthermore, procedures and instructions were used for each inspection inspection and check, and the same methodmethod and acceptance acceptance criteria were applied applied among all RSGs. (Note that verification of removal by etching for Unit-2 were not performed.)

In conclusion, no particular difference In difference between between Unit-2 and Unit-3 were identified in in the review of inspection record.

inspection Table R.21 History History of Inspection and QC check check for Divider Divider Plate welds (WF-V116-1)

(WF-V116-1)

A,B A,S Table R.22 History History of Inspection and QC check check for Divider Divider Plate welds (WA-V116-1)

(WA-V116-1)

A,B A,S 3.2 Stainless Stainless Steel Clad Records Records Inspections for the SS clad (WO-V105-1, (WO-V105-1, 2) are listed below.

PT result of WO-V1 WO-V105-1 05-1 on 2A RSG was unacceptable.

unacceptable. All locations locations of unacceptable indications unacceptable indications were out of the divider divider plate attached attached area, and their indications were appropriately appropriately repair-welded repair-welded in accordance in accordance with UGNR-SON2-RSG-071.

UGNR-SON2-RSG-071. The PT results for the other RSGs were accepted. accepted.

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LAttachment-R Attachment-R UT result of WO-V105-1 WO-V1 05-1 on 3A RSG was unacceptable.

unacceptable. Unacceptable Unacceptable indications and acceptable acceptable but recordable indications were detected. All locations locations of indications were were out of the divider plate plate attached attached area, and unacceptable unacceptable indications indications were appropriately repair-welded in appropriately repair-welded in accordance accordance with UGNR-SON3-RSG-031. The UT results for the other RSGs were UGNR-SON3-RSG-031. were accepted.

accepted.

UT result of WO-V1 05-2 on 3A RSG was acceptable, but one recordable indication was identified.

This indication was so small that we in accordance w'e did not perform repair in accordance with the procedure.

procedure.

VT results were all accepted.

accepted.

Table R.23 History History of Inspection Inspection for stainless steel clad (WO-V1 (WO-V1 05-1, 05-1, 2)

[I A,B A,S 2

J

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3. 3 Hydrostatic Test records records The following table shows all Hydrostatic Hydrostatic Tests have have been performed performed for all RSGs. All records records were verified that the test pressure pressure were within the proper proper limits required by the hydrostatic test procedure, and unusual pressure drop/raise drop/raise was not identified. All hydrostatic tests were properly performed for Unit-2 Unit-2 and Unit-3 RSGs.

TableR.24 Hydrostatic Records Hydrostatic Test Records A,B A,S

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.,....-_ _ _ _ ~ Attachment-SAttachment-S Attachment-S Additional Investigation ofof Boat Samples M[TSUBISHI HEAVY INDUSTRIES,

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1. Purpose Purpose The purpose purpose of this report report is to provide results of additional investigation of boat samples collected collected from the U3B U3B RSG.

2. Background

Background Cracks were discovered discovered on the divider plate-to-channel plate-to-channel head weld during the inspection of the the tube-to-tube sheet weld after the secondary tube-to-tube hydrostatic test on Unit 3B RSG. The cracks were secondary side hydrostatic were caused caused by the separation separation of the divider plate plate and the channel head.

head.

3. Investigation Investigation Methodology Boat samples A, B and C Band C which had been collected collected from U3B U3B RSG were used used for additional investigation.

investigation. Collecting Collecting locations of boat samples are shown shown in Figure S.1.

S.1.

The investigation investigation methodology methodology matrix is summarized in Table S.1. S.1.

Table S.1 Investigation Methodology Methodology 0off boat samples samples Item Method Method Purpose Purpose Separation Separation SEM (Scanning (Scanning Electron Evaluate Evaluate the micro-structure the micro-structure of the surface Microscope)

Microscope) examination examination separation surface separation surface at high magnification magnification (x1500, x2500, x5000)

Chemical EPMA (Electron (Electron Probe Evaluate chemical composition of the chemical composition the analysis Micro Analyzer) analysis material near the separation and and separation surface surface

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4. Results Results of investigation investigation Figures S.2 S.2 shows the SEM pictures pictures of the fracture surface of sample A, B Band and C C at high magnification.

magnification.

ItIt was observed that the separation between between low alloy steel and 152 buttering reveals indented 152 buttering surface which was like martensitic lath structure surface structure at high magnification, relatively flat fracture magnification, though relatively fracture surface was observed at low magnification (Figure S.2(1), S.2(2) and S.2(3)). At high magnification, surface magnification, the separation separation between between low alloyalloy steel and 152 buttering appeared appeared with similar similar fracture surface surface morphology to hydrogen-induced morphology hydrogen-induced transgranular cracking in its feature feature as shown in Figure S.2(5)(a) for reference.

Fracture surface of the separation Fracture separation between between lowlow alloy steel and stainless stainless steel clad reveals reveals relatively relatively smooth surface surface at highhigh magnification magnification (Figure S.2(4). It is assumed assumed that the separation separation between low low alloy steel and stainless steel clad appeared with similar similar fracture fracture surface morphology morphology to hydrogen-induced intergranular cracking in its feature hydrogen-induced intergranular feature at high magnification as shown in Figure S.2(5)(b) for reference.

reference.

Figures S.3 shows the results results of EPMA line analysis across fusion boundary in the cross section of sample sample B. Component variations was observed observed in 152 152 buttering adjacent adjacent to the separation.

Figures Figures S.4 SA shows the results-of results'of compositional compositional mapping by EPMA in the fracture surface surface of sample sample B and C.

Band C. ItIt was observed observed that there was a certain level of compositional distribution of Fe, Cr and C compositional distribution at the fracture fracture surface.

5. Summary

1) At high magnification, magnification, the fracture fracture surface of separation between between low alloy buttering alloy steel and 152 buttering appeared to be like martensitic lath structure.

2) At high magnification, the fracture surface of separation high magnification, separation between between low alloy steel and and stainless steel clad reveals relatively relatively smooth surface.

3) Component variations were observed in 152 buttering buttering adjacent to the separation.

separation.

4) ItIt was observed that there there was a a certain level of compositional compositional distribution of Fe, Cr and C C at the the fracture surface.

surface.

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Attac~hment-S Attach men t-S Cold SideSide I 400 j(

E E

1'0 U")

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M Hot Side F Hot Side Figure SS.11 The collectin collectingg locations locations of boat samples.

samples.

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Nko.1,5-O-GA440 (0)

Document No.L5-0-lGA4-10 Au~hmen~S (01 152 buttering 152 buttering Stainless steel clad LAS LAS Location of the SEM observation Enlarged / Enlarged ý Figure S.2(

S.2(1)

1) SEM pictu pictures res of the fracture fracture surface surface of the boat sample sample (Sample A,A, TP A-1, A-1 , location C) location C)

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)O Attachment-S

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ Au~hm~~S 152 buttering buttering Discharge Electron Discharge Stainless steel Machined Surface Machined Surface clad clad Location of the SEM observation observation Detail observation of Location C Enlarged Enlarged / Enlarged Figure S.2(2) SEM pictures of the fracture fracture surface of the boat sample sample (Sample A, TP A-2, A-2 , location location A)

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-========================.......--.J... Ul Attaehmenl-S Location of the SEM Location SEM observation observation Enlarged , Enlarged / Enlarged S.2(3)

Figure S.2(3) sample SEM pictures of the fracture surface of the boat sample buttering),, location C)

(Sample B (152 buttering)

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Attachment-S Forced fracture surface surface Cutting Cutting Location of the SEM observation observation Detail observation of Location A Enlarged Enlarged/ Enlarged ,

Figure S.2(4) SEM pictures pictures of the fracture surface surface (Sample C, C, TP C-1, C-1 , location location A)

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_____________________________ ~ AO A ttachment-S Attach me nl-S Tlý (a) Fracture Fracture surface of hydrogen-induced cracking in 1 hydrogen-induced cracking 1%Cr-0,5%Mo steel

%Cr-0 .5%Mo steel Fracture surface of hydrogen-induced (b) Fracture 2%Cr-4%Mo steel hydrogen-induced cracking in 2%Cr-4%Mo Figure S.2(5)

Figure S2(5) SEM pictures of the fracture surface of hydrogen-induced cracking for reference of hydrogen-induced reference

("Fractography"

(" Fractography" ed ited by The Society of Materials edited Science Japan Materials Science (2000), p.

Japan,, (2000), p.129-130.)

129-130 .)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Art ~ Attachment-S Atlachmenl-S p

tp

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0 a ':) .

o~

6 ° II Q

1101J1li\.

oprk Location of the EPMA Location EPMA observ observation ation Ch2 MI Ll F Fe 6080 40130 0L-~J-_L_L~-J_~~J__L_L~~~~~J__L_L~ __~~~~~

mm 0.08 8.02 0. 134 0. 06 13.08 0.10 0 . t2 Ch5 PETJ Cr 40 08 Ch4 LDE2H C

800 l\1J~~I\.~""""O\W"t1M'ooI\~...~,'fJfVi-.iJ~~*..y~~\\OI\

c 8~~~~~~~~~~~~~~~~~~

0.130 8 . 02 0.04 mm 0.06 8.08 0. 10 8.12

'*Resin Resin waswas removed removed from from the the specimen specimen afterafter polishing polishing for for the the analysis analysis S.3(1)

Figure S.3(1)

Figure EPMA lineline analysis across fusion boundary boundary (sample B. B, 152 152 buttering buttering side)

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F)OCumnent No.LS-04GA440 Document Attachmenl-S (0)

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0 Document No.L5-04GA440 (S-Ill (0)

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" G " J ,. 0.

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Location of the EPMA observation 152 buttering 152 buttering Cl-t3 M1 Ch3 Ml PETH 20 r-,--,--,..-,..-,---...,.---,--,--,---.--.--.---,----,---,-,---,---,-r-,--,--,..-.,---,

200 PET H I IF F F F I F F F FI F FI I 1 F Ho Hlo 100 1013 13 mm mm 0.00 13.1313 0.02 13.132 0.04 8.134 0.136 0.06 B.BB 0.08 0.10 13.18 0.12

0. 12 Ch2 Cl-t2 2138 LIF LIF 200 C

Coo too 11313 Co 0 F I I III IF FI lIIFI IIII I I_.I .

8 mm mm 0.00

0. 013 0.02 0.04 0.06 0.08 0.10 0.

13.1122 Cl-t3

h3

.IFH 21313 200 LIFH I II I I I I I I III I I I I I I I I I r,

TI IBB 100l L

Ti 0.00 rmm 0.02 0. 04 0.08 0.08 0.10 0. 12

Resin was removed from the specimen specimen after polishingpolishing for the ana ly sis analysis S.3(2)

Figure S3(2) analysis across fusion boundary (sample B, EPMA line analysis B, 152 buttering side side))

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.J... Altachmcn t- S Location of the Location the EPMA EPMA observation observation Low alloyalloy steel Ch2 B2 LIF.

LlF I I I l t tI~l ~l l LFe Fe Fe 6000 6131313 4131313 I

4000-2080 213130 - r

(

I Fe ,

mm mm 0.00 0.02 13 . 132 0.134 0.04 0.06 13.136 13.138 0.08 130.10

. 113 ChS ehS 6000 6131313,-.-. - , - - . - , - ,- , - . - ,- , -. - . - , - , -- , - ,- ,- . - , - - , - . - . - , -,

PETJJ PET 6088 I I I I I I I I I I I I I I I I I I I I I I I Cr Cr 401313 4000-2000 2131313 Cr Cr 13 1 I I L- I I I I mm mm 0.130 0.00 0.02 13.02 0.04 13.04 13.136 0.06 0.08 8.138 0.10 0.10 Ch4 Ch'!

LDE2H LOE2H I I I I CC 300 8013 C

C mm .00 0.02 0.06 0.03

Resin was removed

'Resin removed from the specimen after poli polishing shing for the analysis analysis Figure S.3(3 Figure S.3(3)) EPMA line EPMA line analysis analysis across fusion boundary boundary (sample S, B, Low alloy steel side)

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_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ )~ Attachment-S Attachment-S Location of the EPMA observation Low alloy steel Ch3 B2 PETH 200

-to 100 Mo 0

J , I , I I I I I mm 0. 00 0.02 0.04 0.06 0.08 0. 10 0. 12 Ch2 Jb'l!4 ......

LIF Co

'ýUlj I 1 1 I I I I I I I I I I I I I I I 100 Co I I I F I I I I MM 0.02 0.04 0.06 0.08 0. t0 0. 12

h3 LIFH Ti 1, L mm 0.00 0.02 0.04 a.06 0.06 0. 10 0. 12

Resin was removed from the specimen after polishing for the analysis Figure S.3(4)

S.3(4) EPMA line analysis EPMA boundary (sample B, Low alloy steel side fusion boundary analysis across fusion side))

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J Attachment-S Attachment-S i i Location of the Composition mapping Composition mapping Figure S.4(1 S.4(1)) Compositional mapping by EPMA EPMA on the fracture surface (Sample (Sample B, B, 152 152 buttering side) side)

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)A Attachment-S Attachment-S Forced fracture Forced surface

_____Ctigsurface Cutting Location Location of the Composition Composition mapping SL: Secondary Secondary electron image CP:

CP : Composition image Composition image Figure S.4(2)

S.4(2) Compositional Compositional mapping mapping by EPMA on the fracture surface fractu re surface C, TP C-1, (Sample C, C-1, stainless stainless steel stee l clad side)

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2. Background

2. Background

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