Text

Steam Generator Girth Weld Repair, Preliminary Rept
	ML18142A444
Person / Time
Site:	Surry
Issue date:	06/04/1985
From:	; VIRGINIA POWER (VIRGINIA ELECTRIC & POWER CO.)
To:	;
Shared Package
ML18142A443	List: ML18142A442; ML18142A444;
References
	NUDOCS 8506110425
	Download: ML18142A444 (58)
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TABLE OF CONTENTS I. Background.**.*..*. . 2 II. Repair of Welds by Grinding

3 III. Evaluation of Weld Indications Found by UT Inspection
- - . 4 IV. Stress and Fatigue Analysis of Welds in As-Left Condition..*** 5 V. Mechanism of Flaw Formation and Growth......... * * * *
7 VI. ASME B&PV Code Section XI Analysis *.......

VII. Subsequent Inspections......., Grindout Data, Weld No. 6 A, 8, and C Steam Generators, Surry Unit 2 Figure 1 Figure 2 Fig"re 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10

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I.

Background

Ultrasonic inspection (UT) of Surry Unit 2 11A11 steam generator girth weld No. 6, (Figure-1) in August 1983 revealed indications over a wide area of the circumference. These indications, which were generally restricted to the upper most region of the weld, were evaluated as resulting from weld geometry at the intersection of the transition cone with the upper cylinder. In April 1985 the Surry Unit 2 11A11 steam generator weld No. 6 was inspected from the inside surface by the magnetic particle test (MT) technique after removal of downcomer resistance plates. A. localized inspection, and subsequently a 360 degree inspection, disclosed some minor corrosion pitting and closely spaced intermittent linear indications over a large extent of the circumference. These indications were 1 imited to a narrow band at the toe of the weld crown in the contoured region between the weld and the upper cylinder as shown in Figures 2 through 4. After the finding of indications in the 11A11 generator, the 11811 and 11C11 generators were UT and MT inspected. These inspections revealed similar, though less numerous, surface indications in these generators. In addition, some indications in Weld No. 6, in the 11811 and 11C11 generators were eva 1 uated as subsurface flaws and were not associated with the surfac~ flaws. These indications appeared to be related to the initial welding of the field closure welds made in the generators dur~ng plant construction. Weld No. 6 was made by field welding from the inside surface of the generators and then back gouging or grinding and welding from the outside. Construct~on period records indicate that such repairs ... - - -*.,..,.,.. _ _, __ *--~---*..... -*-*- - --. **-'"*.. ***** --*-

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.... :. ~ ----~ :_*. ": *-~-... 1 *.! ~~*,.___~-::,--. were made to Weld No. 6 in all generators. It was concluded that some subsurface weld defects, which were either acceptable to the construction code or not detectable by construction code inspection methods, remained in the generators. The surface indications in the 11A11 steam generator girth weld were evaluated by grinding at three locations and were found during the evaluation phase to clear at a depth not exceeding 0.375 11

Since the surface related UT indications in the 11811 and 11C11 generators appeared no deeper than those found in 11A11, it was decided to repair all generators by grinding.

II. Repair of Welds by Grinding Detailed repair procedures were prepared by Virginia Power and Westinghouse for removal of the surface linear indications in the Unit 2 11A11, 11811, and 11C11 steam generators. Since the subsurface indications were relatively smaTl in the 11811 and 11 C11 steam generators, it was decided to eva 1 uate these by the ASME B&PV Code Sec ti on XI rules for fl aw acceptance. This course of action was taken to preclude the necessity of repair welding the generators as a result of the deep excavations which would be required for removing small and acceptable subsurface flaws. Surface indications were completely removed since sucli indications were open to the inside of the generators and could be increasing in depth or length due to environmental and/or operational factors. Subsurface flaws by their nature are sealed from the environment, and were considered relatively harmless if they were within the code allowable size range based on fatigue and fracture analysis.

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The repair process for the removal of surface flaws involved controlled grinding in increments not exceeding 0.125 11 depth, followed by a 360 degree MT inspection. This µrocess was follow~d, often in increments as small as 0.062 11 for the 11811 and 11C" generators, until all surface linear indications were removed. All final surfaces were given a complete 360 degree MT inspection and found free of linear indications. Defects in each weld were removed at the depths indicated in the detailed summary for each generator which is enclosed as Attachment 1. The deepest flaws were found in the 11A11 steam generator, and all flaws were cl eared by O. 500" depth. In the 11811 and 11C11 steam generators the flaws were shallow, and generally cleared by 0.3125 11

Welds which were determined to be free of surface i ndi ca ti ans were contour ground to a slope of 3 to 1, 2 to 1, or 1 to 1 (Figures 5 through 10) as allowed by the Westinghouse stress analysis.

At several locations in* the 11A11 steam generator, contour grinding resulted in the removal of metal from the remaining wall thickness of the generators after the defect had been cleared and verified cleared by MT inspection. This was realized and corrected before any significant percentage of the circumference of the generator was affected. The stress analysis of the as-ground configuration of the generator welds was found to be acceptable and is discussed in Section IV below. III. Evaluation of Weld Indications Found by UT Inspection In addition to the MT surface inspection, weld No. 6 in each steam generator was given a complete 360 degree 100~,,; volumetric UT baseline inspection. All indications in the 11A" and 11C11 steam generators found by * -....... --~:-.* **,.. ;*

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this baseline inspection were evaluated in accordance with code require-ments and found to be acceptable. Only the 11811 steam generator required an ASME B&PV Code Section XI, Appendix A fracture mechanics flaw analysis for subsurface flaws. This evaluation, which was for ten subsurface flaws, *is discussed in Section VI below. All ten of the subsurface flaws detected in the 11811 steam generator were found to be of acceptable size by the Appendix A calculations. IV. Stress and Fatigue Analysis of Welds in As-Left Condition . 'I.,':.,!, A stress analysis and a fatigue analysis of welds in the as-left condition were performed by Westinghouse. The steam generator shell has been evaluated for primary membrane stresses resulting from design, faulted and test condition loadings. The repair configurations having a !" deep as well as 1" deep circumferential groove meet the ASME B&PV Code Section III allowables for primary stresses. The reference repair configuration (t 11 deep blended to a 2:1 taper on both upper shell and cone) has been modeled by finite elements. This model was used to calculate pressure stresses and thermal stresses and to perform heat transfer analysis. Two sets of thermal hydraulic boundary conditions have been generated reflecting cold feedwater injections following a reactor trip and during hot standby operation. These two transients have been used to perform the heat transfer analyses. In order to provide peak stress conditions for fatigue evaluation, the times during, which these transients occur were identified by investigating the conditions when the shock and bending stresses are maximized. The thermal solutions at these instants of time are used for subsequent stress analysis. r *,'.~"

-~ :.... Plant operating data for Surry Units 1 and 2 has been used to obtain the projected number of occurrences associated with each transient event for a 40-year period. The stress ranges due*to pressure and temperature have been combined with an appropriate number of cycles to perform the fatigue evaluation on the referenced repair configuration. For a maximum local grind 0.85 11 deep, the stress ranges have been amplified by an analyti-cally computed stress concentration factor and a fatigue evaluation. performed. The reference repair, as we 11 as the 1 oca 1 overgri nd, have been shown to have fatigue 1 ives in excess of 20 years. The primary stress calculation utilized to determine the acceptability of the repair is shown below: Primary Stress Analysis Material SA 533, GrA, Class 1 Design Pressure= 1085 Psi Temp. 600°F Ri = 84.25 in. Shell Thickness t = 3.62 in (Nominal) Design Stress Intensity Sm= 26.7 ksi Allowable. 1.5Sm = 40.0 ksi Stress Intensity= PRm + f t 2 Nominal Case t = 3.62 in Rm= R. + t/2 = 84.25 + 1.81 = 86.06 in PRm + P = 1085X86.06 + 1085 = 26,300 psi -t-2 3.62 Ground Case 0 11 Depth) t = 3.62-0.5 = 3.12 in. R. = 84.25+.5=84.75; R = R. + T/2 = 84.75 + 1.56 = 86.31 in Stress intensity= PRmm+ f 1 1085 X 86.31 + 1085 = 30,500 psi t 2 3.12 2 Ground Case (1 11 Depth) t = 3.62 - 1.0 = 2.62 in. Ri = 84.25 + 1 = 8~~25, R _= 85.25 + 1.31 = 86.56 in. Stress intensity=__!!!+ fm-1085 x 86.56 + 1085 = 36,400 Psi t 2 2.62 2 -~***** ***:*--:*. **. *-*. - --~~.-**--.---*** --:- ),'#,".

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~::~:-*** *- Faulted Condition Maximum pressure occurs during large feedline break and is 1237 Psi. For a }11 groove PL= 30,500 x 1237 = 34,773 Psi 1085 vs. allowable 0.7S = 56,000 Psi µ For a 111 groove PL= 36,400 x i6~~ = 41,500 Psi Test Condition vs. allowable 0.7S = 56,000 psi µ No limits on PL stresses. V. Mechanism of Flaw Formation and Growth The cause for the initiation and propagation of the indications at or near the No. 6 girth weld of the Surry 2 steam generators is still under investigation. A review of the available construction records relative to the deposition of the welds as well as a review of the operational history of the units is in progress. Specific records being reviewed include, but are not limited to, the following: A. Certification of materials of construction B. Weld records C. Radiographic records D. Post weld heat treatments including heating during the post weld heat treatment of the steam generator replacement closure weld No. 11 E. Secondary side water chemistry including both pre-and post-steam generator replace~ent operations F. Operational history Preliminary results from these reviews have not suggested any one type of material degradation that can explain the initiation or propagation of..... 1....... **~" ******:-:y * *.. '....,.. *... ':""'.............. :**.. ***:=-.... \\; *_:,** ***1~... ""."'._~***:****1**::-0:.-*r-~ '","',~','1'*:***r*: *. *-*' ****.',":'""'*: '......, *:* ,, ~.

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the indications. However, one possible scenario for explaining the indications is as follows: A. The su"'face of the steel in the vicinity of the* weld pitted during the pre-replacement operations when the secondary water in the steam generator often contained relatively high oxygen concentration (often greater than 25 ppb) as well as other contaminants such as chloride (rarely as high as 300 to 400 ppm) and copper ions. B. The corrosion pits may have acted as nucleation sites for stress corrosion cracks and/or stress risers for the nucleation of corrosion-fatigue cracks. C. The cracks which may have initiated at the pits were propagated by a combination of factors including corrosion, static stress (operational and possibly residual), and fatigue. The review of the construction records to date has shown that the welds were deposited and post weld heat treated using typical procedures utilized in the industry at th2t time that satisfi-ed the requirements of the code of construction. Some of the findings from this review related to the original welding which may be of significance in understanding the cracking mechanism follow:

1.

Preheating temperatures of 180°F to 185°F for the ID side of the weld and 210°F to 220°F for the OD side of the weld were used during the deposition of No. 6 closure welds. These preheat temperatures could result in heat affected zone microstructures that are.harder than that which may have occurred if a higher preheat temperature such as 250°F had been used. *......,* -~,*-. ***;'"",* *:* -. -* *. *-.......... ".......... ****:... -**,:-. '*****'.*.... *****1:*.. --- -*~..... *. - -* *..

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2.

The weld was deposited using a sequence in which the ID side of the weld was essentially completed prior to deposition of the OD side. This welding sequence could result in higher residual stresses at the ID of the weld than might occur if a more balanced sequence had been used.

3.

The post weld heat treatment of the weld was conducted in the temperature range of 1000°F to 1100°F. Higher residual stress~s may remain in the weld area after a post weld heat treatment in this temperature range as compared to the magnitude of residual stresses that might occur with a higher temperature post weld heat treatment in the 1150°F range. This conclusion is consistent with the findings in NUREG/CR-3728, Figure 4, prepared by ORNL for NRR. Other factors have been identified that may mitigate the re-initiation of indications after the current repair efforts. First, the oxygen concentrations and the ingress of other contaminants such.as chlorides in the secondary water have been significantly reduced during operations si nee the steam generators were replaced. The oxygen concentrations prior to the replacement of steam generators was often greater than 25 ppb whereas since the replacement the oxygen concentrations in the feedwater have typically been less than 5 ppb. These lower oxygen concentrations will significantly decrease the initiation of new pits in the steel surface. Second, the weld was included in the section of each steam generator that received the post weld heat treatment given the replacement closure No. 11 welds and the feedwater nozzle welds. No record of the temperature at the No. 6 weld during this post weld heat treatment has been 1 ocated. However, heat treatment records for the, ' 'f*,'."", *

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replacement closure welds indicate that within about 2-inches on the cone side of weld No. 6 and about 18-inches on the shell side of weld No. 6 the.metal temperature was in the 1150°F to 1180°F range. These temperatures should have further reduced any residual stresses remaining from the original field weld. VI. ASME B&PV Code Section XI Analysis* The UT data for the baseline examination of the Surry Unit 2 steam generators weld No. 6 have been reviewed and evaluated in accordance with ASME Section XI, 1980 edition. A summary of the evaluation is provided below: A. Steam Generator A Weld No. 6

1.

No unacceptable indications were found per ASME Section XI IWB-3511

2.

All indications are due to geometry or are acceptable per ASME Section XI IWB-3511

3.

Geometric indications are from the ID grinding contour. B. Steam Generator B Weld No. 6

1.

Ten (10) unacceptable indications per ASME Section XI IWB-3511 were found which are considered subsurface.

2.

A fracture and fatigue evaluation has been carried out on these indications, using the recommended methodology of Section XI Appendix A. Results of the analyses have demonstrated that all of the indications are acceptable by the rules of Section XI, IWB 3600, for the remainder of the design life of the plant. The analysis 'considered all the design transients, *and is supplemented by a compilation of the transients which have already occurred, in the first 10 years of service. Detailed *,

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finite element stress analyses were performed on a model of the actual configuration, including the groove which now exists as a result of the repair by grinding of the surface flaws. Stress intensity factors were calculated using the actual stress distributions resulting from the finite element results, and fracture toughness va 1 ues were taken from the reference toughness curves of Section XI, Appendix A. C. Steam Generator C Weld No. 6

1.

No unacceptable indications per ASME Section XI IWB-3511 were found.

2.

All indications are due to geometry or are acceptable per ASME Section XI IWB-3511

3.

Geometrical indications are from the ID grinding contour VII. Subsequent Inspections A. Surface Inspections: As a result of the indications whi~h were found and removed in the 11A11, 11811, and "C" steam generator girth weld No. 6 in Surry Unit 2, Virginia Power proposes the following future inspections in addition to ASME Code Section XI, !SI inspections:

1.

At the next (October 1986) Surry Unit 2 refueling outage, after the current 1985 outage, Virginia Power will perform a MT surface inspection at four locations inside the 11A11 steam generator at Weld No. 6. The areas chosen for inspection will represent the regions of grind-out representing the highest stress concentrations. In each region at least a two foot (2') length of weld will be inspected.

2.

The above inspection will be repeated at the second refueling "~...,,.. ... _.... **.. **..,:*....,..,... *,*;: :*****~*-*~.*******.* *;******?"*~-***.. ***.~*-**"***"'*,.....,,:-* -~*-****.-**:-**,*- *.. **.--~** *..**,.* -- **-

. *'... :,*....., *-*.,.......,_.: __ :,._.~_;_-~~........ -~,.,.,..,:.........,.*.. *,.. *. -*- outage (April 1988) following the current outage. If no indications are found at this second inspection no further surface inspections will be performed. B. Subsurface Indication Inspection: As a result of the subsurface indications found in the Surry Unit 2, 11811 steam generator, the following future inspections will be performed in addition to ASME Code Section XI inspections:

1.

At the second refueling outage (April 1988) from the current outage, any regions of the 11811 steam generator Weld No. 6 which had subsurface indications acceptable only by fracture mechanics analysis to Appendix A~ of Section XI of the ASME B&PV Code, will be reinspected by the same UT technique which was used to find and size the indicat'ions. If no growth is indicated in these flaws, the inspection cycle thereafter will revert to that required by the 1980 ASME B&PV Code Section IX, addenda through winter 1980, for flaws accepted by analysis, and the Virginia Power IS! program for inspection of steam generator girth.welds. JMM/MCAVOY/002 ATTACHMENT l Grindout Data, Weld No. 6 11A11, 11 811, and 11C1' Steam Generators Surry Unit 2

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- - - , "N" 0~***,*,-;*-*r *'*-. ::** ;~**,****"*,~*,,-:,*~:.*-,:,--:-*-,,-.... _.. -;,*:-
      ,*~**,

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Figure 2: Pits and linear indications at downcomer location 3 in weld No. 6, Surry 2 11 A11 steam generator, MT inspection.

./ '!~"',,; '. ~t*:' J* .'. '.*'*"~~- '. '**~ ' Figure 3: Enlarged view of Figure 2, Surry 2 11A11 steam generator, weld No. 6.

6 09t: lJ.ddV dd L 3u\\J ;,-. .,.,.,.1.,.,.,.,.,.,.,.l. Figure 4:. Enlarged view of Figure 3 at exploratory grinding locations, Surry 2 11A11 steam generator, weld No. 6.

Figure 5: Shallow depth as-ground area in Surry 2 11A11 steam generator weld No. 6. one foot area. (Note: Dark spots on weld surface are grinding dust).

Figure 6: Approximately 3/8 11 to 1/2 11 depth as-ground area in Surry 2 11A11 steam generator weld No*. 6, section several feet in le_ngth.

Figure 7: Shallow depth as-ground area in Surry 2 11A11 steam generator weld No. 6, section several feet in length.

Figure 8: Area of locally deep excavation, Surry 2 11A11 steam generator, weld No. 6.

Figure 9: As-ground surface in Surry 2, 11811 steam generator weld No. 6; several feet of weld are shown with an area of grind out in the bottom of the weld and in the top of the weld.

'--:~... *-- '~**. .

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Figure 10: Typical shallow as-ground steam generator, weld No. are shown. surface in 6; seve ra 1 Surry 2, 11 C11 feet of weld}}

ML18142A444

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