ML18191A360

Letter from Wppss to NRC of Final Report on the Successful Disposition of the Fabrication Difficulties on the WNP-2 Containment Vessel

ML18191A360
Person / Time
Site:	Columbia
Issue date:	09/05/1975
From:	Strand N Washington Public Power Supply System
To:	Engelken R NRC/RGN-V
References
G02-75-253
Download: ML18191A360 (120)

Text

Washington Public Popover Supply System A JOINT OPERATiNG AGENCY P. O. Box 969 3000 Gao. WAsHtsctoN WAt Ricnt.ANo, WASHioctoN 9930k Poove (509) 946-968!

September 5, 1975 G02-75-253 DOCKET 850-397 ter. R. H. Engelken, Director Nuclear Regulatory Commission Region V 1900 N. California Blvd.

!<alnut Creek, California 94596

Subject:

WPPSS NUCLEAR PR0.1ECT NO. 2 FABRICATION DIFFICULTIES, STEEL CONTAII'lllENT VESSEL

Reference:

1. GOZ-75-178, same subject, dtd 6/23/75.

G02-75-213, same subject, dtd 7/Z8/75.

BRHP-75-2056, "Completion of Repair of Containment Vessel, NCR-213-00058, -00059, -00060", dtd 8/20/75.

BRPDN-213-F-75-128, "Containment Vessel U.T. Test Report",

dtd 7/7/75.

5. BRPD'1-213-F-75-162, "Repair of Containment Vessel, NCR-213-00058, 00059, 00060", dtd 8/20/75.

i

Dear t'lr. Engelken:

This is the final report on the successful disposition of the fabrication difficulties on the HNP-2 Containment Vessel. References 1 and 2 were interim status reports, describing the earlier actions in the repair of lamellar tears in the shell adjacent to two reinforcing ring attachments. Reference 2 men-tioned two activities yet to be performed. These were an engineering evatua-tion of a 1" x 2" indication and a final review of the" examination reports.

The engineering evaluation in reference 3 (attached) describes the basis for the conclusion that the '.ndications found by ultrasonic examination following the first pneumatic test were not caused by the pneumatic test. The meeting requested by item 2 of reference 5 took place on August 26, and satisfactory documentation has been provided.

The 1" x 2" indication wil b. because .it is the onl indication re-ma the use of Code Class o e ~ance cr o~a. This

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acceptance criteria woul~ require more engineering evaluation than had b..en provided by the contractor. By removing this irdication, there is no need for

'i the engineering evaluation, An examination and vacuum box test will be per-

t<r. R. H. Engelken September 5, 1975 Page 2 602-75-253 I

A wrap-up of the documentation is being done as described in references 4 and 5 (attached), including correction of some inconsistencies.

We have 1d a com d l dd ~

ent (reference 4) for the examination of areas wher percentage of these areas have been examined without detection of lamellar tears '(reference 3 attached). Because of personnel safet considerations, the the A ig if!

. 'ins e e areas and t e re a~r o e ' " c e accomplished for several months when scaffoldin an-structson activities, As described in reference 3, the actions taken will assure that the vessel will not be subject to lamellar tearing from containment vessel leakage tests, normal operation, or design accident loading.

A complete record of technical evaluations, meetings, repairs, examinations, and tests associated with the r'esolution'f, the, fabrication problem has been maintained and is. available for review. I

, Ver'y truly yours,

'I N. D. STRAND Assistant Director Generation & Technology NOS:JCH:lm Attachments-References 3-5 t1 cc: QJ Byrnes, Burns 8 Roe, NY

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JJ Yerderber, Burns & Roe, NY JD Wilson, Burns & Roe, Site D Roe, BPA, Richland vga t

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Burns and Roe inc 320 Fullon Avenue I Heempsfead,

~ New York 11550 < Telephone (516) 560-7070 TWX 510-222-4935 > Cabfe BURQE HEMPSTEADNY Main Oflice, ject: W.O. 2808 700 Kinderkarnacfc Road Oradeil, New Jersey 07649 Washington Public Power Sup upp 1 y System S

WPPSS Nuclear Project No. 2 Completion of Repair of Containment, Vessel NCR-213-00058,-00059,-00060 August 20, 1975 BRWP-75-2056 Washington Public Power Su pp 1 y S ystem 3000 George Washington Way Richland, Washington 99352 prNP H0.,2.

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v Attention: Mr. M. E. Witherspoon f g f ARI~'."<

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rence: 1. Letter from JJByrnes to JEW oo 1 sey, Gl 0: EGr;f BRWP-75-307, dated. 3/18/75 Gt GBH'I-

2. Letter from JJByrnes to JEWoolsey, BRWP-75-570, dated 4/30/75 Sllr f >,tfsCiff

3. Letter from JJByrnes to JEWoolsey, BRWP-75-755, dated 6/2/75 4~ Letter fr from MSchulze to RCRoot, PDMBR-CM-131-75, dated 6/5/75

5. Letter from RCRoot to MSchulze, BRPDM-213-F-75-128, dated 7/7/75

6. ~

Letter. from JFStrunk to JJVerderber, PDMBR-213-75-27, dated 7/22/75

7. Letter from RCRoot to MSchulze, BRPDM-213-F-75-155, dated 8/6/75

8. Letter from JDWilson to MSchulze, 9.

BRPDM-213-F-75-162, dated 8/1 e er from MEWitherspoon to JJByrnes,

/

WPBR-75-845, dated 7/1/75 I

'Gentlemen:

The purpose of this letter er is z.s to summarize events involved summariz in the repair of the eve ope in the con-tainment vessel where ~ ere the i e two pipe whip support girders are

'urns end Roe, Inc.

Washington Public Power Supply. System 8/20/75, Mr. M. E. Witherspoon Page attached. The details ef the lamellar tears are contained in the subject non-conformance reports.

you 'know, two cracks later identified as lamellar tears were found visually when the girder attachment welds were being cleaned preparatory to magnetic particle testing. Ultrasonic examination was used to confirm the extent of the tearing.

'I This examination revealed a number of indications of possible additional lamellar tears imbedded in the shell plates. The.

progress towards effecting acceptable repairs is described in references 1, 2 and 3.

At the time reference 3 was written, the repairs were thought to be complete. A pneumatic test had been performed successfully, and PDM was in the process of conducting the ultrasonic examination to determine if lamellar tears recurred or if unacceptable flaw growth had 'occurred. The events since that. time are described below.

The ultrasonic examination after the pneumatic test showed that the small tears surrounding the repairs made from the out-side did not grow in size. However, three previously unreported conditions were observed: a 2" long by 1" wide indication at the lower web of the upper 'pipe whip support adjacent, to a scaffold bracket, and adjacent 10" long and 14" long areas of indications at the lower web of the lower pipe whip support.

These conditions were described in reference 4. The remaining areas behind the attachment welds for the two pipe whip supports were found to be acceptable except that the areas behind scaffold brackets were not examined because they were inaccessible, and the areas repaired from the outside were not examined because they are immune to lamellar tearing being composed of weld metal through the full thickness of the shell plates.

Detailed examination of the reports documenting this examination by our site personnel uncovered a number of in-adequacies and raised a number of questions. Consequently, ref-erence 5 directed PDM to perform a UT inspection of the area behind the scaffold bracket next to the 2" by 1" indication zo confirm the size of this indication. It further directed PDM to perform a UT inspection of all other areas that were

urns on'd Roe, Inc.

Nashington Public Power Supply System 8/20/75 Mr. M. E. Witherspoon Page inaccessible for inspection because of brackets, etc. An amplified description of the "new" indications and an explanation of the use of the three UT procedures were also requested.

From further information supplied by PDM in reference 6 supplemented by phone conversations with the people involved, we learned the following additional information about the above conditions.

1. The 2" by 1" indication is behind a part. of the pipe whip support attachment weld that was not repaired. Xts location was marked in chalk by the inspector who performed the original ultrasonic survey to determine locations of dis-continuities. His chal'k marks indicate that he observed something requiring further exploration, but he did not include whatever it was in his report (Hamill Testing

'01 Laboratory Report of March 1 and 2, 1975) as a report-able indication. Since the inspector was required to record only those indications with an amplitude greater than a stated amount at the prescribed high sensivitity, we assume this indication was unreported because it was of insufficient amplitude. However, we cannot be 'sure the omission was not inadvertent..

2. The two areas of indications at the lower'eb of the lower pipe whip support were at a location where'epairs had been

. made from the inside. However, .the UT report for the original examination of these areas (Hamill Testing Laboratory Report 4002 dated March 12-16, 1975) shows no indications there. The repair resulted from "chasing" into this region a subsurface defect in the excavation of an adjacent repair.

This extension to the repair, unfortunately, was not re-corded. Thus, when the inspector performed the UT examinati'on of the original repairs, he did not examine this region because he did not know it had been repaired.

examined until after the pneumatic test.

Et was not PDM decided that the two areas of indications at the lower pipe whip support were unacceptable. The indications were removed and the areas were repaired and examined in accordance with the approved procedure. Then, the pneumatic test was

urns and Roc, Inc.

Washington Public Power Supply System 8/20/75 Mr. M. E. Witherspoon Page repeated. These areas were subjected to a soap solution test for leaks while the vessel was pressurized, and no leaks were found. The fdur attachment welds to the two pipe whip supports then were re-examined ultrasonically.

. No flaw growth was observed; no new indications were found PDM's attempt to examine the areas that were previously behind scaffolding brackets could not be fully carried out because of the impracticality of reaching certain areas after the scaffolding had been removed. Of 28 locations on the upper pipe whip support, they examined 19. Of the 28 on the lower pipe whip support, they examined only 4. Therefore, we instructed PDM to examine the remain-ing locations when the erection of the scaffolding for the installation of the insulation around the con'tainment vessel reaches a level that can be used for support. See reference 8.

In addition,'eference 8 directed PDM to remove and repair the 2" by 1" indication when they can work from the scaffold-ing. This repair is to be examined along with the remaining previously inaccessible locations, and will be subjected to the vacuum box leak test, too.

At this point. we would like to respond to the questions posed in your letter, reference 9.

Question 1 Does the pneumatic test demonstrate that lamellar tearing will not occur under service stresses'nswer 1.1 The pneumatic test, performed. at 115/o of design pressure, is a test for pressure integrity. Like hydrostatic tests, it is not intended to duplicate the service conditions of seismic, thermal transient, or postulated accident load-ing to which the vessel may be subjected. These other ser-vice loading conditions are justified by analysis.

1.2 Tabulated below are the through-'thickness stresses at the upper and lower attachment welds of the upper pipe whip support for both pneumatic test and service loading conditions (Reference B6R, Calculation No. 8.70.16. Book No. 8.70-2):

Washington public Power Supply System 8/20/75 Mr. M. E. Witherspoon Page Thx'ough-Thic'kness

~

Tensile Stresses si Loading 5 Weld 5 Conical Upper Condition Throat Shell Weld Test 554 571 Service 1738 1790 Lower Test 626 481 Weld Service 670 515 These through-thickness stress levels are quite low for both

,pneumatic test and service loading conditions. Their

,negligible magnitude may be compared to the specified 80,000 to 100,000 psi tensile strength (transverse direction, stand-ard corner test location) and to the through-thickness tensile strengths observed by Spaeder 1* on similar material:

70,000 to 80,000 psi.

For completeness a maximum of presentation, it should be noted that service tending stress level of + 41,707 psi, coin-cident with a through-thickness compressive stress of 775 psi, exists at the throat of the upper weld attachment. The resulting total stress of 42,482 psi is within the 90% yield strength value of 43,128 psi. The bending component of stress is not considered as contributing to lamellar tearing since the pure bending stress results in zero net tension.

(The value of 1738 psi is presented in the table above, since it represents a maximum through-thickness tensile stress; its corresponding bending stress 5 the weld throat is + 38,250 psi).

The through-thickness stress levels for both .pneumatic test and service loading conditions cannot be considered significant with respect to generating tears or propagating cracks.

Question 2 Can applied stresses enlarge an area of incipient tearing or initiate tearing in, an area of high residual stress?

Answer. 2 The above discussion describes the service stresses in the through-thickness direction as a tiny fraction of the

• Technical references are listed at the end of this letter-

vms ood Roc. Inc.

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Washington Public Power Supply System M'. E. Witherspoon 8/20/75 Page strength in this direction and of insuffi'cient magnitude to be a credible cause of cracking or of crack extension...The case for their being additive to residual stresses .of near fracture intensity is discussed. below.

Where cracking occurred, one may conclude with validity that the true fracture stress (or true fracture strain) was generated locally. Such areas were repaired, and are now sound.

But what of the areas that did not crack. Weren't they exposed to conditions almost,'as severe, and, since the vessel was not stress relieved, 'aren'0 those conditions present even today?'he answer is yes, they must, have been exposed to conditions conditions are not as severe today. 'n almost as severe as those that caused tearing; but no, those the intervening

,time, the plastic stresses and strains have relaxed to lower values and have been redistributed over larger volumes of metal thereby eliminating their potential for tearing.

Th'is conclusion is supported by the two attached figures 2 illustrating room temperature creep in a carbon steel and in type 3l0 stainless steel. The former steel is knosm to have low resistance to creep; the latter is known to have high resistance to creep. The carbon-manganese-silicon steel of the shell plates can be expected to resemble the carbon steel in creep resistance.

These data indicate that pea'k stresses after welding should have already experienced stain relaxation in creep well in excess to 0.0005 in/in. Most of the relaxation, occurred within hours of welding. Additional relaxation, especially for stresses in excess of the yield strength, will occur over the years. This 0.0005 value may be compared with the strain associated with the service stresses, less than 0.000l in./in.

Thus, the action of the service stresses tending to open and extend an incipient lamellar tear or to.generate a new tear is less than the amount of relaxation that has occurred

4 Washington Public Power Supply System 8/20/75 Mr. M. E. Witherspoon Page already. Those locations that may have been on the verge of cracking after welding or after repairing have relaxed more than they will ever be loaded again, and will continue to relax.

Therefore, the service stresses are incapable of developing the fracture stress even when added to existing peak residual stresses.

Question 3 WPPSS position that real flaw growth be sub-jected to engineering analysis.

Answer 3 No flaw growth was observed. The "crack front" of the numerous small cracks surrounding all the repairs made from the outside was closely monitored. They exhibited no growth after the first pneumatic test and no growth after the second penumatic test. The initial size of the 2" by 1" indication was not recorded before the first penumatic test, but its size after both pneumatic tests was recorded. No growth occurred during the second pneumatic test. The initial'izes of the two areas of indications that were removed after the first pneumatic test at the lower pipe whip support were not recorded so that no obser-vation of growth was possible.

Question 4 Evaluation of "new" indications found in the shell after the pneumatic test.

Answer 4 This concerns the 2" long by 1" wide ultrasonic.

indication at the lower web of the upper pipe whip support and the two adjacent areas of indications at the lower web of the lower pipe whip support.

4.1 As noted above, the inspector's chal'k marks on .the vessel at the 2" by 1" indication indi. cate that he observed something requiring further exploration. One reasonably may conclude that an ultrasonic indication was present at this location before the pneumatic test. Dr. W. E. Cooper, our consultant, had pointed out earlier that indications just under the reportable level and, therefore, not reported before the pneuma ic test, may grow slightly in amplitude during the test becoming reportablyThey would then show as new indications when in reality they represent only minor changes. This caution from Dr. Cooper was noted in

>vms and Roe, tnc.

Washington Public Power Supply System 8/20/75 Mr. N. E. Witherspoon Page reference 3. Later, Dr. Cooper commented on this again during the joint meeting in Waltham, Massachusetts on May 28, 1975. See Conference Notes 355, dated 5/28/75.

Referring to the experience with the reactor pressure vessel at Pilgrim Station where an ultrasonic indication

,changed in amplitude from acceptable to a conditionally acceptable level. Dr. Cooper stated that the change was attributed to a very slight opening displacement of the discontinuity.'e said this displacement had been estimated at 10-7 inch, about one atom layer.

The presence of the chalk marks from the initial examination lends credence to the conclusion that the 2" by 1" indication occurred in a similar manner.

We note further that the extreme sensitivity used in the ultrasonic examination contributes to the variability of the results. Some of the indications reported by the Hamill inspector and not repaired could not befound by the .

PDM inspector even though both were operating at the same sensitivity but at different times, for example. At this high level of sensitivity, consistent amplitude readings

're virtually impossible even for the same operator and equipment at different times. Thus, the discovery of the 2" by 1" indication after the pneumatic test may not repre-sent. a really significant change.

4;2 The known facts surrounding the two .indications found and repaired after the first pneumatic test are described above. No additional indications weze found after the second pneumatic test.

~Summa With the planned repair of the 2" by 1" indication and the anticipated examination of the remaining areas that were previously behind scaffolding brackets without further incident, the accept-I ability of the repair will have been demonstrated. The lamellar tears have been'emoved and replaced with s'ound weld metal in accordance with approved procedures. Some additional tears were produced'in the process; and they were removed and replaced with sound weld metal. These subsequent repairs have small tears

Urn@ end Roc!, Inc.

Washington Public Power Supply System 8/20/75 Mr. M. E. Witherspoon Page, around their edges. These imperfections were investigated and found to be acceptable. Close observation of them has shown they did not grow during two pneumatic tests. A small 2" by l" indication was found after the first pneumatic test. It appears to be a discontinuity that intensified'during the first pneumatic test by a process that was known to exist so that its amplitude

. after the pneumatic test was above the reportable level when examined at the. high sensitivity. While it might seem to be a new discontinuity, a more likely explanation is that it is a minor modification of a pre-existing condition. This discontinuity did not grow during the second pneumatic test. Nevertheless,

.will be repaired. Two other indications found after the first it pneumatic test were repaired, and the adequacy of this repair was verified by a second pneumatic test. The likelihood that these indications were generated during the first pneumatic test is remote because the stress in the- through-thickness direction is. only a few hundred psi; while the strength is known (from other work) to be 70,000 to 80,000 psi, and, even when added to peak residual stresses, is incapable of developing the fracture stress. A more likely explanation is that they were present. before the pneumatic test having been associated with a repair that h

was not examined ultrasonically because of a known failure of communication.

In conclusion, pending completion of the remaining work with-our further incident we consider the lamellar tears to have been repaired acceptably, and the occurrence of additional tears in the future to be impossible. We have reviewed this matter with our consultant, Dr. W. E. Cooper, and he concurs with these conclusions.

We will advise you on completion of the remaining UT measure-ments and repair of the 2" by l" indication.

Very truly yours,

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JJB/at J:

r'ames yrnes Attachment project Director JJB/HEL/JRC cc: Mr. D. J. Anderson. BPA w/1 Dr.'. E. Cooper, w/l

Lamcl 1 ar Pearlite, Compressed to Origina 40.010 Dimensions m-a After Elongation a a a a o

C W,O05 d.

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A~ a Granular Pearl i tc, Compressed a

,~ to Original Dimensions After Elonc;atio 0

~.005 32~5CO psi 0

Granular Pearlite, After W.010 Elongation 400 O~ O~~

-0.015 o~o CA XO 24i4CO psi n

W.020 200 0

-0.025 O

, 17~gKQ psi W.030 Lamellar Pearlite, After 4J Elongation 100 i 2M 300 400 W,035 Time~ hours

-0 040 FIGURE 17 TOTAL CREEP GJRYgS OF 310 STAINLESS STEEr. AT 85 Z(13)

-0,045 0 40 80 120 160 200 240 Elapsed Time at Room Temperature, min FlGURE 56 'LASTiC AFTER EFFECT OF EUTECTOxD STEEL BAR AFTER ELONGATION OR 0".!4PRESS1ON TO THE OR1GIHAL DIl!=NS101JS AFTFR 4w~ ELONGATION(22)

Room Temperature: about 10 degrees

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From Technical Re ference 2

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Burns ond Roe, inc. ATTACHMENT Technical References G. J. Spaeder, "Effect of Sulfur on Through-Thickness Properties of C-Mn Steel Plates, "Neldin Journal, June 1975, pp. 196s-200s.

2- R. E. Maringer, "Review of Dimensional Instability in Metals", DMIC Memorandum 213, June 23, 1966, Battelle Memorial Institute.

Burns md Roe,tnc.

L -'7 Nuclear Project No. 2 - 'LVPPSS rr P.Q. Boar 200 o Richlanrl, 'ivashingron 99352 rs Tele. 509-377 2301 Tele. 509-946-7621 July 7, 1975 BRPDN-213-F-75-128

Subject:

M. 0. 2808 MPPSS Huclear Projec-'o. 2 Contract Ho. 213 Containm nt Vessel U.'st Report Pittsburgh-Des Moines Steel ColP P. 0. 8ox 829 Richland, ttA 99352 Attention: Nr. H. Schulze

. Gentlemen:

Preliminary review of the PDH HDE report documenting the Ultrasonic Inspection of the upper and lower pipe wh'.p support welds. reveals certain inspection inadequac',es that musu be correct d and/or explained and documented in an inspection report, before 8urns and Roe can acc pt the vessel test results.

UT Report 40, which was accompli'shed a ter the first pneumatic test of the vessel, states; "the area inspected was the weld to the vessel wall, with the following ~exes tions:

l. Areas not accessable because of scaffold brackets, etc.

2. .Areas inspected and reported on UT Report 39.

3. 'Areas where penetration inserts are installed and fillet welds were used, rather than partial penetration welds.

Ho change was found inth size of indications previously found and reported. All new indications are reported on Pages 3 and 4 of this report."

This report generates concern in the following areas:

i"IlNP NO. 2

< ~ 1. Page 3 of UT Ho. 40 records an indication 2 inches long. It has been revealed that this indication is adjacent to a scaffold bracket and therefore, the area of the vessel wall covered by the bracket (approx. 2") was not inspected nPP and could contain a continuation of the reported indication.

ECQi LHnUS

2. Item 2 of UT Ho. 40 states that the areas inspected and reported on UT Report Ho. 39 were also excluded from UT RRr GiON inspection after the preumatic test.

RAll<OfR iii=9"rirtOl, Over Thirty.Five Years of Enginterirrg Achievement

Containment Vessel U.T. Test Report I'if t ct>>)rgb-pc c h1niiioc. %tool rninparIi PRQD The criteria for inspection after the pneumatic test stipulated that 100Ã of the upper and lower 'pipe whip support welds and repaired areas would be U.T. insp cted.

3. The stat ment in U.T. Report 40 that "all new indications're reported on pages 3 and 4 of this report" indicates that these new indications were induced as a result of the stresses imposed on .he vessel by the pneumatic test.

P.D.M. did not report the existence of new indications to Burns and Roe at the conclusion of the test.

P.D.M. is directed to take the following action and document the results in an inspection report which shall be submitted to Burns and Roe for evaluation and resolution of the vessel test results:

'. PerfomU.T. inspection (using the same procedure utilized for the original inspection) of the. vessel wall and weld area of the upper wnip support which was masked by the scaffold bracket at footage 141, where the 2" long indication was reported.

I

2. Perform U.T. inspection (using the" same U.T. procedure utilized for the o'riginal inspection) of all areas which were inaccessable for inspection because of scaffold brackets, etc., reference item (1) of U.T. 40; and of all areas reported in U.T. Report 839, reference item (2) of U.T. 40.

3. Provide documented description of the "new" indications reported in U.T. 440, and/or a documented explanation of the statement.

Review of the inspection report package indicates the use of three U.T.'rocedures, U.T. 1, U.T. 2, and U.T. 9200. Please provide justification for the use of (3) different procedures and include same in the U.T. inspection report package.

5. Page (4) of U.T. ;;40 is missing from inspection package submitted to Burns and Roe g.A.; please transmit the missing page.

Very truly yours, BURNS AND ROE, INC:

R. C. Root Acting Site Manager RCR:KF:CWF:tbr cc: ~ RD Witherspoon-MPPSS Sahlberg-HPPSS (3)

-'-'~Refer. ence P5 =;,""'-'=;.

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Gums and Roe,tnc.

t4uctear Project No 2 APPSS t. P.O. Box 200 e Richbnd. V4shtogtoo 99352 a Tele. 509-377 2301 Tele. 509-946.7621 August 20, 1975 BRPDl~-213-F-75-162

Subject:

M. 0. 2808 %rNP ND. 2 g MPPSS - Huclear Project No.

trac t, 213 2 P.t.t St.C (~ .+ l

~ 'epair Con of Containment Vessel HCR-213-00058, 00059, 8 00060 L LARlvi!Rf PS 1Rt!'P CiE p'.EQAtt l 4e4EU'>JS l Pittsburgh-Des Moines Steel Company j H;RRtrlptott  !

P. 0. Box 928 Stlj V~ttkpiR Richland, Washington 99352 Q HQ'tP~RP yt /

tl'f4Pc StPbtP Attention: Nr. H, Schulze epL"")~ltNPL

Reference:

BRPD!<-213-F-75-l 55 Gentlemen:

In-depth review of the document package you submitted on the subject HCR s has revealed some inconsistencies and insufficiencies.

Therefore, PDN is directed to take the following actions:

1. 'rovide a final ultransonic report, readable and understandable, with-out reference to previously submitted documents and correspondence, understandable to a technicality qualified person unfamiliar with the problem. The report should be complete except for the local areas yet to be examined. We feel this report can be prepared from data already recorded. It should indlude the following:

1.1 A report format similar to that used in the Hamill Testing Laboratory Report Ho. 001, 002, and 003.

1.2 Charts of the four circumferential welds involved showing the areas examined; the location of reportable but acceptable indications, if any; the location of areas not examined, the reason these areas were not examined.

1.3 Tabulations of reportable indications in each of the four cir-cumferential welds showing Size, depth, amplitude, and footage locations for all reportable indications in accordance with the approved procedures.

1.4 The charts and tabulations called for in 1.2 and 1.3 should include indications found during the July 28, 1975, examination.

In accordance with previous agreements, the individual indications surrounding the repairs made from the outside of the vessel need Over ThirtY Five Years of Engineering Achievement

tSburgh-Des tloines Steel Company August 18, 1975

~air of Containment Vessel Page 2

.'-213-00058, 00059 8, 00060 not be tabulated, but their footage locations should be shown on the charts and tables along with your report with respect to their growth. The report should state also whether the examination covered shell plate only or shell plate plus weld.-

metal.

1.5 An explanation for why each of the reportable indications is considered acceptable.

Arrange a PDl'L-BKP.-WPPSS meeting after September 10, to discuss addi-tional information needed to provide convincing answers to questions related to the indications that were observed for the first time after the first pneumatic test. At this meeting, we also want you to de-scribe how the ultrasonic indications were evaluated; that is, the basis for your determination of which indications required repair and which did not. He hope we can agree upon written statements for PON to transmit'o Burns and Roe.

3. tlhen the scaffolding for the installation of the insulation around the containment vessel reaches a level that can be used for support, remove and repair the 2" X 1" indication in the lower web of the upper pipe whip support in accordance with the approved procedure. Mhen this repair is complete, it should be examined ultrasonically when the inspection called for by the above referenced letter is performed.

The repair should be examined by the vacuum box method, too. Submit a report on these examin'ations similar to and as an addendum to the report described in l.

Yery truly yours,

. D. Wilson

.Site Manager JDt!:KF:sl

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RD gither spoon-t'PPSS Sahlberg-h'PPSS (3~)

Washington Public Power Supply System A JOINT OPERATING AGENCY P. O. BOX 966 3000 GEO. WASHINGTON WAY RICHI.ANO. WASH:NGTON QWSE PHONE (509) 946-960 I July 28, 1975 G02-75-213 Docket 50-397

/

Hr. R. H: Engelken, Director Nuclear R'egulatory Corrmission Region V 1990 North California Blvd.

Walnut Creek Plaza, Suite <202 Walnut Creek, California 94596

~

Subject:

WPPSS 'NUCLEAR PROJECT NO. 2 STEEL CONTAINflENT VESSEL FABRICATION DIFFICULTIES

Reference:

WPPSS letter G02-75-178, N. 0. Strand to R. H. Engelken, same subject, dated June 23, 1975.

Dear Nr. Engelken:

This letter is to advise you that as discussed with L. E. Vorderbrueggen of your staff on Friday, July 25, the final report on the repair of the WNP-2 lamellar tears will be delayed.

No new problems have arisen and no further physical work on the vessel is contemplated. One possible exception to this could be removal of the 1N x 2" indication. Removal of this indication will not be precluded by other construction activities until early next year. The delay is due to a longer than anticipated time to assemble the various facets of the repair program in a clear, concise manner and perform UT examination of areas that were covered by scaffold brackets. The contractor has been directed to examine these areas and is scheduled to perform this examination on July 28, 1975.

Nr. R. H. Engelken July 28, 1975 Page 2 G02-75-213 The attachment identifies activities that are to occur prior to forwarding the final report. The Architect-Engineer, Burns and Roe, Inc., has advised that based upon the examination being performed on July 28 and assuming it does not reveal any new indications, they could finalize their letter'o us on August 15. Accordingly, it is anticipated that the final report on the repair program will be forwarded to you by August 30, 1975.

Yery truly yours, I

/ /

, N. 0. STRAND Assistant Director Generation and Technology NOS:JCth:lm

'Attachment cc: JJ Byrnes, B&R-NY JJ Verderber, B&R-NY.

JD Wilson, B&R-Si te K Fox, B&R-Site

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t "r )t t" oc e orojrct No. 2 -- ',YPPSS t) P,Q. Box 200 o Hac'):~.".". ~ Vv:."n".:or)rt9352 t) Tete. 50o-377 "3rtt Tele. Ste-ctc&762t July 7, 1975 BRPE'l')-213-F-75-128

Subject:

M. 0. 2808

')iPPSS Contract Ho. 213 j

huc 1 ear Pro ec t No. 2 Containment Vessel U.T. Test Report Pittsburgh-Des Hoines Steel Ccmpany P. 0. Box 829 Richland, WA 99352 Attention: hr. H. Schulze Gentlemen:

Preliminary review o the PD) t tlDE 'report documenting the Ultrasonic Inspection of the upp r and ]ower pipe whip support welds reveals certain inspection inadequacies that must be corrected and/or explained and documented in an insp ction report) before Burns and Roe can acc pt the vessel test results.

Report 40, which was acco-tplished after tne first pneumatic test UT l.

ii>>i i 'i- ii',g Areas

~i of the vessel, states; "the area inspected was the weld to the not accessable because of scafTold brackets, etc.

'. 2.

Areas Areas welds inspected and reported on UT Report 39.

wttere penetration inserts are installed and fillet were used, rather than partial penetration welds.

No change was found in the size of indications pr 'viously found and reported. A11 new indications are reported on Pages 3 and 4 of this report."

r This report generates concern in the folio),ing areas:

IP N0.2 Page 3 of UT rio. 40 records. an indication 2 inches long. It has been revealed that this indication is adjacent to a scaf old brack t and th refore, the area of the vessel wall covered by th bract:et (approx. 2") was not inspected and could contain a continuation of the reported indication.

'JS

2. Item 2 of UT t!o. 40 states that th areas insoected and reported on UT Report tlo. 39;:ere also excluded from UT inspection ai't"r :he pn=";.static test.

Over 7hirty.Five Ye>rc 0/ Enqine'erin@'Achievement a '-. 'C

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r--.-=--,,-e.-.-:;essol UI.T. Test Ressort I '. I "' h-n " ~ I lloc'I l I ilAll> PpgO

,he criteria for inspection after the pneu'atic'-test sti ulated that 100'. of the upper and lower pipe whip s.- pport welds and repaired areas'would be U.T. inspected.

3 ~ ~ The statement in U.T. Report 40 that "all new indications are reported on pages 3 and 4 of this report" indicates that thl se new indications were induced as a result of the stresses imposed on the vessel by the pneumatic test.

P.D.t1. did not report th existence of new indications to Burns and Roe at the conclusion of the test.

P.D.H. is directed to take the following action and document the results in an insoeciion report which shall be submitted to Burns and Poe for v luation and resolution of the 'vessel test results:

I

1. PerfornU.T. insp ction (using th 'same procedure utilized for the original insp ction) of the vessel wall and weld area of the upper wnip supoort which was masked by the scaffold bracket at :go~age .41...n r th 2 long >nd~cat~on was r epo rted.

Perform U.T. ins=ection {using the same U.T. procedure utilized for tne original inspection) of all areas which were inaccessable for inspection because of scaffold brackets, etc., reference item (1) of U.T. 40; and of all al eas reported in U.T. Report r39, reference item (2) of U.T. 40.

3. Provide docum nted descr iption of the "new" indications reported in U.T. -;40, and/or a documented explanation of the statement..

4, Review of the inspection report package indicates the use of

'hree'U.T. procedures, U.T. 1, U.T. 2, and U.T. 9200. Please provide justification for the use of (3) different procedures and include sa;.,e in the U.T . inspection report package.

5. Page (4) of U.T. =40 is missing =rom inspection package sub;.litted to Sums and Roe g.A.; please transmit the missing page.

Very truly yours, BURNS ANO ROE, INC.

R. C. Root Acting Site Manager PCR:KF.C'nF:tbr cc: Q RO

'h'I i.hBpspovll-Ãr r 55 (3)

Sahlberg-RPPSS

E.

Washington Public Power Supply System' JOINT OPERATING AGENCY I al P. 0. BOX 968 3000 GEO. WASHINGTON WAY RICHLAND. WASHINGTON SQSS2 PHONC (509) 946 968 l June 23 1975 G02-75-178 DOCKET 50-397 Mr. R. H. Engelken, Director Nuclear Regulatory CoIImission V 'egion 1990 N. California Blvd.

Walnut Creek Plaza, Suite >202 Walnut Creek, California 94596

Subject:

WPPSS NUCLEAR PROJECT NO. 2 FABRICATION DIFFICULTIES, STEEL CONTAINMENT VESSEL

Reference:

G02-75-72, HWPFSS Nuclear Project No. 2 (Docket 50-397)

Fabrication Difficulties, Steel Containment Vessel",

J.J. Stein to R.H. Engelken dated March 7, 1975.

Dear Mr. Engelken:

The purpose of this letter is to forward additional information on the fabrication difficulties experienced on the reinforcing ring attachment to the WNP-2 containment vessel and to summarize the progr ess toward resolution of the difficulties.

Reference 1 reported the existence of lamellar tears in the containment vessel shell at the location of the main steam relief valve platform support ring attachment. Subsequently, the shell at, the attachment of the lower pipe whip support that is of construction similar to the main steam relief valve platform was examined ( re 1). The examination revealed the presence of eleven lamellar tears varying from 2 inches to 13' i 1 gt d ~60" m.

Repair of the lamellar tears was made from the inside of the vessel with a repair procedure that consisted of: (1) preheating the shell to 200 F and the reinforcing ring* to 300oF, (2) thermal gouging and grinding to remove the lamellar tear indication, (3) magnetic particle examination to

• The term reinforcing ring will be used henceforth for both the main steam relief valve platform support ring and the pipe whip support ring.

Mr. R. H. Engelken -June 23, 1975 Page 2 G02-75-178 assure removal of the lamellar tear, (4) building the shell plate back to the

'riginal plate surface by welding, (5) ultrasonic examin'ation to assure sound-ness of the shell plate repair and shell plate, (6) reweld>ng the reinforcing ring to the shell, maintaining a 300oF minimum interpass temperature, (7) heating to between 350oF and 400oF after completion of welding, maintaining for two hours, and then slowly cooling to ambient temperature, and (8) performing a UT examination of the repaired area to detect recurrence of lamellar tearing or the presence of other rejecgable defects.

Upon UT examination of the completed repairs, indications immediately behind (deeper in the shell plate) some of the"repair areas were found. (See Figures 2 and 3 for a more complete description of the original tears and indicat>ons

'l)ehind the repairs). These defects were also removed and repaired using the

. same repair procedure as'or the lamellar tears. The repairs were made from the outside surface of the vessel shell and >Iere extended to a depth that tied into the weld repairs made from the inside LsSee Fi ure 4 for a more complete description). This resulted in a weld deposit through the thickness of the vessel shell that distributes residual and load stresses into the shell parent plate material iri a shear mode rather than tensile mode.

Upon UT examination of the repairs made from the outside of the vessel, a different type of indication was found around the periphery of the repair welds. These indications were different than both the lamellar tears and indications behind the repair areas made from the inside., The new indications did not lay behind the weld, but began at the edge of the weld and extended a short distance into the parent material. They were located all around the per iphery of the welds as shown in Figure 5. Since these were not the same type indications as had been repaired, an eva'luation was made by Pittsburgh Des Moines and Burns 8 Roe to determine the type of defects, their cause, and their effect on the integrity of the vessel. This evaluation consisted 0'f A section of material was removed from the vessel and sent to U.S. Steel, the material supplier, for their evaluation. By metallurgical examination, these indications were determined to be of the lamellar tearing type.

Since the indications were small, were in a plane parallel to the surface of the plate, were tied together at the end by sound weld metal, and were not located in the zone of high residual through-thickness tensile stress, they were determined not to be detrimental to the serviceability of the vessel by both Pittsburgh Des Moines and Burns 8 Roe. This evaluation was concurred with by Or. 'William Cooper, of Teledyne Materials Research, whom Burns 5 Roe, the Architect-Engineer, retained as a consultant (see Attachments 1 and 2).

The defects were examined before and after the ASME Section III 115K design pressure pneumatic test and comparison of size was made to determine if growth had occurred during the pneumatic test. UT examination after the first defect "pneumatic test determined that there had been no growth of the indications

Mr. R. H. Engelken June 23, 1975 Page 3 G02-75-178 around the periphery of the repair welds, but indications were detected on the lower reinforcing ring behind an area repaired from the inside and an indication was detected on the upper reinforcing ring near a repair (see Attachment 4}. These indications were similar to those found earlier p d f 1 id,b within the area of indications. The indications on the lower reinforcing r ing were removed, repaired, the vessel pneumatically tested a second time, and again ultrasonic examined with no new indications or growth of the existing acceptable indications.

Attachment 3 shows the extent of the repairs made in the areas exhibiting i g.

Ultrasonic Examination All ultrasonic examination used to determine the extent of lamellar tears and to monitor for new or changing indications was performed to an ultrasonic procedure which has a much higher sensitivity than required by ASME Section III. The indications identified around the periphery of the repair welds made from the outside by the sensitive UT procedure are not recordable indications when examined with a UT procedure for weld material in accordance with ASME Code.

)

Prior to the first pneumatic test run (on May 30, 31 and June 1,) the only indications in the shell opposite the four reinforcing ring attachment welds were around the periphery of the weld repairs. made from the outside of the vessel.

Prior to the second pneumatic test (run on June 6, 7 and 8) the same indica-tions around the repair areas made from the outside, plus indications of the

.,'ame nature around the last repair area and the indication. on the upper ring,

'inhere present. All four bands were again UT examined after the second pneumatic test. The indications had not grown nor had new indications occurred during the second pneumatic test.

~Summa r The fabrication difficulties are being successfully resolved. Throughout the repair and evaluations, the assistance of technical experts has been retained, in that Dr. William Cooper of Teledyne Materials Research has been consultant to Burns 5 Roe, and Drs. William Love'nd Albert Kobyachi have been mechanical consultants to Washington Public Power Supply System to assist us in evaluating the actions and conclusions of Pittsburgh Des-Moines and Burns 8 Roe.

All repair, examination and test has been performed, as a minimum, in accor-dance with the requirements of ASME Section III and Appendix B of 10CFR50. They were performed not only on the basis of what actions were necessary to satisfy

~ .'he requirements of the ASME Code Section III, but were also directed toward assuring the vessel's capability to perform its intended function.

V d

Nr. R. H. Engelken June 23, 1975 Page 4 G02-7 5-178 Presently, the ultrasonic examination reports are being reviewed for complete-ness and an engineering evaluation of the indication revealed following the first pneumatic test, is being made. It is anticipated that 'a final report on the repair of the lamellad tears viill be forwarded on July 28th.

Attached for your information are the significant documents developed for the resolution of this fabrication problem. If you have any questions or desire further information, please so advise.

Yery truly yours,

'W,d' N. 0. STRAND, Assistant Director P, ~ I Generation and Technology NOS:JCH:ho'ttachments:

1. PDH Engineering Evaluation

2. Dr. Cooper's letters

3. Nap of Repair Areas

4. Ultrasonic Examination Reports

m

,WPPSS NUCLEAR PROJECT NO. 2 FABRICATION DIFFICULTIES, STEEL CONTAINMENT VESSEL STATE OF WASHINGTON )

ss COUNTY OF BENTON N. 0. STRAND, Being first duly sworn, deposes and says: That he is the Assistant Director, Generation and Technology, of the WASHINGTON PUBLIC POWER SUPPLY SYSTEM, the applicant herein; that he is authorized to submit the foregoing on behalf of said applicant; that he has read the foregoing and knows the contents thereof; and believes the same to be.

true to the best of his knowledge.'ATED ac-r..; .Z8,'975 N. '0. STRAND On this day personally appeared before me, N. 0. Strand to me known to be the individual who executed the foregoing instrument and acknowledged that he signed the same as his free act and deed for the uses and purposes therein mentioned.

GIVEN under my hand and seal this "5 day of =c ~ 1975.

Notary Public in and for the State of Washington>-~<, ~~ y~~t; Residing at

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4

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1:ov. 1 3-23,; (;, >>

flev. l" 3- >7-7-,

l!ev . G'>-@6-'>>, (;

ffea t: slloll Plat.e. ) 0 )L('0 <-'l<'c tl xc I>(.'a La)x'l I: ot)Pos) te sict(. Ql':OI>

and bot:I:o)):l)l>>l!3.:Lr }>l)LLL: <<t: loca.'o>> ol: rcp;Lir . '}'I!is I)e;L'ter shoulc! e.'Lone! aL ion!;); 5'-0 <:ir<:L>>::t'<:xe>>Li;Lily b<;yo))d oxL'tlex'ide ol':he repair )Ll'ea ~ S<'o si() L<> 3 l>i>lolv.

Place elocLric or gas 'I'.(::LL'ox. o>> Lop LL>>d l)OL I:o))) <<>>gular.plate and f;Lco plate. Ttlis heat:ox'l)043d oxLc:>>d )LL'east: 5 0 circumferontially heyo>>d oittlor 'i(t< ol'op)<ir area. See Note '3. bc Xc 1

Preheat Item (?) to 300O}: .',Ii>>., l')'elle'L L' LL>>)t (1) t.'o 200OI: itin, YOTE: The differential te)))pvratu'l'e b<:tweo)) 300'}'n .Item 2 and 200 F in Ite))) 1 can'o>>ly I'e )))ai)!LLLinod as I;ougin'nc oak:;.'s in the'eldL connect:i>>; t:llo a)l)lL)3.;Lx plate to the .shell, Xt is lee}uii od px'i)))arily in tho liLs L 1/'}" to 1/2" to prevent cl ac} pl'op)LI"a,tion,

?taint<.in prohea.t different:ial (b<:e KOTI.: in 3 above) and gouge out defoct (Go<<'e from end* to c;or! ter) in shell and annular olato as sho:;n in Figure l. Gou;.e v.eb plate Lo aL. least: the beve3.

sho;Yn in. Detail C of E52. Gou;;e to sou>>cl pare>>L'))eL'al at least G" circ<<".)i'er(;ntia3.1y beyond clef,"ocLs 3.ar;,or than 4 leeR and 2 inches circu)))ferenL'ially for clelec t.s s)); !lier th" n 4 f et.

.(5) Disc grind you eci area to clean surface.

(6') ?,!T Disc grou'nc! areq..

hIaintaining prehe t as sp cilied in Iten)'3), weld overlay on she3.1 pla,to to co))plove we'.d to tho orxt;i)!a3. p3.ate surf. ce.

itT every layor. Grind flush. See Fi '<<re 2. 0'}'"for sound:ess in parent meta3. (Phl) after fi3,line P)I cavity prior to ma!-in>>

bevel weld. She13. pla,te to).:.porat:ure ).)ay be dropped to 100 nUT.'oa I'urin dur irder )))ay bc (!ropped to 150 to 200 UT, liaintain as closely as possible an interpass of 300 at the weld. T'lax.

NOTE; 9'eld usin. strin "er beads and Joint Px.oce<}ure, 70-7lA.

Use 5/32" 9 'taz; electro(!Os for o<<t-of-posi tion v'elc!s

.. "..and 3/16"fJ i~taz..i>ox l'lLLL>>d.}lorizo)xLalfillet welds.

Use I'-69-9V for overlie;Ld repair, 5/32"p ltaz. rods.

Complete weldin;; of 'anni)l:Lr pl';lt:e "t:o 'sli(.ll }~1:ito". 'WT'- every 1/'}" a))d fin'll covex ( oo 1' "uro 2) S('e "tote in Ito:.:s 3 a>>d 7 Lbol e }'. cep L')i lte) 3, t lie p) <<lloa L'))(! intcrpass tor)nera .ur!'.

diffore)lti:Ll applios to the 1'ixst 1/-1" and 1/2" ol'old cleposiL'.

3 f. ) ox w>>ldxl,", i.'> ('0)!)plot'<)<!, iu ~))3 ..to 'llo llo.lte(t'rea and l)o (t to!}')Cr lt lix o 01 J JO '.'o'>00 i }or )l t'ca')~t ~ ho)) rJ

)

slow coo" .

KO}'}," 1: l'ox (IL'.Xocts 3.8" or less in len.th, only 18" circllm-t'oxc:n'ially boyo>>LI (:.l.tt)or sido of tt)U repair ar<".<<

n<.'<.'ds to bo !l';lL'cd.

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I'I);ly 29, 1975 ( a..r l r lt:.I.

PD.'I)13R-213-75-22 Coll t:l'a.c t 127G 1 rt )'t-'iP ~( (4t "t ti--0-)

r, (sou,Vs;":

Burns and Roe, Inc.

320 }'u1 t on Av enue Iromps to:id, NY 11550 Attentl.on: .'Irr. J. J. Verderbor, ~

Pr0J oct )'g 1)lc.el 3. ng )al1agrl'

'ubject: Conclud3.n,". Lo t L)'eld Ilepairs tel'i Su})port Ri 1) g Gentlemen:

This letter is bein. >vritten to descril)o the Lamel3ar teal'in even ls dt scl'3.bed in oui'lleeti lips of... )a) ? 7t)1 and ?St)1 ~

Dzscvssrn:i:

A periodic post-ivelcl visua.l e)(amination of the lvelds joinin" the support rin." 'irders to the vessel shell shotved Lamellar toarinA to be present:. To det:ermine the e)(ten'l Of 'those defects, a hi. hly sensitive Ultrasonic tcsti:1" techni()ue (}r'1'L-UT})-9200) v:as employe() basid on tilt) }(novI)l diSCOn ti nui t V (L'liilCll(all teal nli) 3 Th1S eÃami nil tion mapped the location of the Lamellar indications as documon r:ocl in FC}t-0005S, 00059, and OOOGO.

A v:rid repair proc Qdul'c divas developed to col'1'cct tho Lamellar tear. ll Tho first area. t:o bo repailed divas at 0 aaFiimuth I al ivcld 0f t)'IQ t:op l'vci!b 0 f,the up})el'ul)por t 1 in ~ to t:hc. Shell. The 1'0}):111vas succ s 'J,ill Sul).ieqllcnt ~

UT (to ll'rL-Ui'r-9:.O0) Shot(od Onl!,'CCOP ta.bio indiCal tionS in tht l pal11 Avoid t Conclu(lin;: that the ) cpair procedure ivor)(od su<<cessllully, 1't p lire %vere 1 n1 l'-ia t'c(l in ot:h(.1 all'I als c.xa 'al na t oil or so i l i p'll l t d all osis 1

~ I n pl l.or!r'l3 Il'i 1

1 la t:al t'l olas t 0 t t'<< '" ()lie

'r 1 ll

))'1'L-O')') ,i:.'00 1vt)re J.(Iuntr l)ihlnd t):e 1't'1).'t ll'vt!ld (t'04'art')

Xht.'lits dc or who vessel) ill t hc })siren t ma ttal'1all.

1 S 'r '<< t ar

Vcr()crbel')ay Pl).'llc'))-21:3- /G-22 5)r, J, J, 2~J, 1975 These indications v:e) e deemed unacccpLabIQ. UT examin;~'Lion oi t)>c:r.rca 2" be;ond t;he area boun()cd by the previous repairs s)rov;cd no in(licatio:!s. ftepair v;as a<<co~nplis)rcd fro!n th(. OuLsidc o].'he vessel shell. U'1'.,:ari!inaLion to; J)TL-U)'P-0200 o!'hc complQLed outside v:eld shovved indications i.n a nar1o.v band i.n t: he he:rt-af!.(;cted rove and pfrr('l!t; lrretal cone Oi( the )r t lrC pc1'lllrQL( 1 OJ. each ri out.sido repair v(:1d, UT ol'he ivcld !n(.tal itsell'.as acceptable.

Not beli.cvin 'he i.ndicati.ons to be Lamella tearing and being unable to cli!ninate the indications during thc

~veldin; procc.,s a s(.ctionr of: l:)!e vcs cl v.as re.;:oved and sent to USS Corpor~t,'on lol. e.:arni!iaLion an(t rcport (sec Attachment 1). In addition, microphot:oraphs and a report, v.'erc obtained,fI om )lan!ill '!'Qsti>>g Lab'or tory (sec At'L'achn!ent 2) .

In suu!!rrary, t)1e following is =sta LQ(t:

Orig- nal La!!;c'lar Tears v.'ere re!)aired by vveldin'.

Additional indications behind thc 1'c))aired ))'!'L-U'r'P-9200 a1'ea (thrtt thicl(ness region) we:e found by tcchni(luc ncccss11. at:ln'" 1 c})'ir fl olrl thc outside oi thc vessel.

Indications )(nown t:o be absent before t: he outside weld repai.r ap)cared in thc plate at thc boundary of the rr)pair aveld. These indications ivcrc of various lcn(.ths (up to approximately b inches), 1:ry from 1/4)'o 3,'4T !'ron! Lhc

.ou tside stll ia(:0 (rl'!d 1'vere l(l'onl 1, 8 t:0 1/'1 ).nch in Avidth.

JUST I 1'I CA T I OY, I'Ol; AC C r".P')'A YC i.:

UT scan prior to final outside svcld repair showed i band av. least 2 inc)!es o>>

iveld absent of indications.

either -ide CX the

'c)

Shell stresses in thc tlrrou;;h thic)(ness direction local to thc 1'ing (Il'c at; levels of 2) 500 psl ol'ess i3 ~ Thl'ou,".;h thlcl(ness rcpa il Kvcld res L'ores the thl ough thic)(ncs(s s t'1'Qng t:h ol,':hQ shell 1)la lc, cf, AS!r))'. Cot)Q ~

Sect;ion II I, Para)('ra))h 3)'3-;")1('30 !)Qrnri l.".r lallrllr(lr Ly])Q (')iSCOnLlnuil iQS On ))la LV Qdt S pl I ))al I

fo1'vcldlng ~

PD'IVI'-"1..-75-'-'~ hlay 29, 1975 Mr. J. J. Ver der bcr

5. The inclusion lovel i>> th'o plato seas v;ithin tho x1>>go ox(})ected for the .~xa(}(: <<>>d (}uali;y s!)Gcii'ied, a!1(1 thc base })1 ( 'L'o sa!Ii})li !;1(.'t t)lc L 1'L'rasolllc roc}ui'x o!!!cnts o I SA--135 for steel plate.s fox px'Gssux c vcss91$ .

G. Y,'hcn tho plates. are UT c.:aminc:d in accordance:

, v;ith AS.'iE U'i'roc dur', SA-578, (I'ara.ra})h YA-2532.1), the abovo (lcscribod i>>die'~'tio>>s arc:

acceptable, In ~ulllTllax ) PD:>I bolxcvos 'Lhe peri})hery i!l(lxca Lxons ar(.

not ro!eovablo and (ioc!:.s tho vessel accc.pL<<bio in accordance wi'th tho AS.'iIH Code <<,nd co>>traci. xo(}uix'('. .!cnts. ~

The su})pie!!!cnt:al "ttachments as listed belov, ivill v:}le>> co!!lpletc(1 1'e'ellt Very truly youx.s,'XTTSBUl GI}-D S MOINES STEEL CU':,I;)A'NY Q

J, I". St ru!ll(

~

Px'0 J cc'L En~i'incor JFS/ >t Attac}n!ic>>ts (I.a ter)

USS Ropox't (1) lia!!!ill Tost ('))

liollouts OJ..<<.Ch Yicb Iiopair .AreA. (3)

Swnplo Cuts by USS;lnd 11'1'L (-'1)

Pxctul'c oi 1<cpair Al'0<<. 1 18:1') Loo'cr Sup})ol'L'ii>>g (5)

I Nr. J. E. Vi'oolsey hi'})PSS ~

cc: Dr. ><'. 2, Coo})or - Telcdync hlatorials }Iosearch

1 C

~

~ BurnsI ~nd

<< 1 ~

Roo, ~ fnc.II

~

~

~I~ ~II~ ~ h ~

~ <<

32G Futton A'rr nuo i ltorrp".'.rrad. tlr.a Yo:J: l15>0 ~. Tolcphono ( ] r.GE KC~i'<<tt 1VrX 510.222 49" g CautCr SUrtQ ~

HrMf'~~TF/ DttY Ql gQ.r.I'y J l the';rt" lgt cJiClrrg r~.2

~<< <<7 ub)ecti 7,7 ~ C ~ vi~

QOr10 << 0 4'ashin'ton Public Power Su-ply Sy tcn r'<<p-0/~V TiPPSS 1I lcle '" Project P.o 2 Contr- c" >.o.."3.3 Repair o . Contains..en" Vessel W

C April 15, 1975 Pl Et Pitt"1". gh-D o hoine Steel Co."apany Hqvillc XslanQ Pitt".hurrah,. <<

i>A 15225 Attention: ';~. J. Strung Ref'erence g 1 Letter J. II. Adams t o J. J. V. deliber PDi~H3 -213-75.-19,'ates, ./'/7:i

<< '2 'ic> I ~."ov. nr$ y'e ( ~ P. ~Q. ~<<> ~auBi/7 Ql aQv3 ~"o

.J J. Vereerber, cat r':/ll/75 (attachcc.j

~ c1 Gent3.et11en: ~ H referenceQ letter (Ref'erence 1) contains

~ -. The above your 'Kin, 1 engine ring ev" lu tion oP. "he la".:ellar tearinc.

probl'one that was found in the contain.-.. nt vc.s:e3. at the vomer pip ii'hip:.upport, The Burn" <<nd';I;oe stres analy" is rcvie"7 is. cont;;inecl in the;:bove re~erencccL tee;-.,oranuur> (>>e2'ercnce "),

a co~ cf 1"hich is attachec A ntuik> r of ~selects of the la~tel3.ar still

~

tearing problev.:, however, reouire clarification.

l. p1c:ase revise t!>e trclc'. repair proceQure to c.ef ne the sensitivity to be used in the ultrasonic examination 30 "-..1v.t the examination aZ'ter the pnct -.;atic test 1)ill show i2 any f3.os growth has occurred.

2~ Please re .er to pacte,". oP. Reference 2. 4'e feel t1:c 90 arc. an."le you assu"...ccrc in your jacking frat".,e cree"ion ca 3.cui".-

tion is unre.".li tic nd shoulc". be revf.seci since the ring in sec-..::cnt".

ur~s and Rac~, Inc.

c itlogic mev bc Qif icult i'ox'ou 'o acccrtain the t:ct'-'--'1 4'hilo 1cc~ t P.:ovl.c;c-r".~i.l

)ocI iilg clPP3, lcd, l')e .fee' you .:-hou1c. c",". r.

ccilculatcd j "c':in@ load the' cor.;pa tible. ltith t..e calcu .".."..:.

shell Gt. ain.

3. Tne 'c(':nce of'he e ection of the upoox'- ra:g c'.ascribed in;.efercnce 1 i"- insuf="icic.ntly cet.~xlcCi to ho~.'t

's'Q p$.CCeO l'lCXO AS 'CRJ)1CQ c:n '.Q'd Jle gdC: 8 'n'GCC Qti' "CCl. 'Or e::vt.:p e "ou s"..ov CIl>> j itti. anQ vtcldina of the fla:>'Je ":cc: .ent

~J in "0 a x'g v 0 U~c fir t step yet,. our ".ic3d pexsonn

¹ g "I.c seg-.,ants <'ere rai"-cd..into>>o::ition before ti)ey i~ere l!c3.ceu il to ct xi..g in conforc;:inc" (; ith '.he cons tructx.on dra'.i'" il.-s. Cjne P g 1 ~P .3. l needs to )'no't i '-he jac'::s i)ere users befoxe or aeter c;:a .".eg-1Gc'Tits ('!ere 5'te3.cIQG in ~~ 8 ring L')I 6 t the Qnc

~

~ co Q~ thon 'II)D s

~thl:n the jacks l)are u=-eQ, -nQ iZ l".are th"n.one jccI= ('ao u=cc on cl O egin(en C~

I 4~ TI'e c'.etaileQ co~a,.ento esulting Gala the Burn" and Doe @tress analysis cvic~t'l". PL".T Revx, son i;un~her B, p'o-viced in Attach-cnt i~. of Boference,2, t..u't be re"olvcci i'ay Me hav your prompt attention. Co these r.atter"-.

P

+OUrs vary truly c I..

~

P PV 1

t IJ I

. John Z. V rderber P

Px'o-'ect Engine rinc~ ".nag=r E JJV/FM/JC/a Cl Attv.chr:,ent ccc )fr. Z. E. >>'oolsoy - t;tPPSS .- 3 t /3 l~w. H. Schul"e - PM! RichlanQ -. 1, w/1 P

Telecopied to J. Strung o2 PD L on 4/3.b/75 '

zm')son H H M O.R AND UM J. Sev<<rino K. Ronis BURNS and ROL, Xnc. DATE: April ll, 1975 db TO: '. J. Verderber PROl1: S. Flanzenbaum/J. Clapp SUBQZCT: N. O.. 2808 NPPS S-NP 2 Stress analysis review of Pittsburgh .

Des hioines Steel Company letter PDMBR-213-75-19, with its enclosures.

Attachment A: Detailed Comments Burns. anc'. Roe Stress Analysis Review of PD:I Re-vision Number B.

Xn the enclosures to the Subject PDN lette PDN has presented Revision Numbe B (Section XV, Subsection 5, Article 3, Pages 10 through 13B),

xihich reclines the stress intens'ty evaluation performed for the conical shell in the region

'of the upper pipe whip support ring (El. 542-'7~") i .

'as well as the. support. ring itself. Additionally, as part of Revision Number B, in Pages 288 through 296, PDhl has presented a refined analysis of the support. ring.welds.

The Burns and Roe stress analysis review of the above-'mentioned enclosures verify that tne e-vised stress intensities for the conical shell, support ring, and ~fields meet the reauirements of 4'PPSS Specification for Primary Containment Vessel-s Contract No. 213, which includes compliance with the AShK-Section XXX Code for Class hlC Components.

Although the Burns and Roe stress analysis xevi<<w will require tha't PDhl mal;e ce"tain modifi-cation to th<<ir revised stress intens'ies, and calculated weld str<<sses, these modifications are of a minor nature which will result in minor changes C:o their stress analysis calculations. Detailed comm<<nts r<< ulting from the Burns and Ro<< .. tress analysi i<<vic', i" e p'vidcd in Lh<< Att 1cil:i:Qll to thi memorandum. Th<<c co:;~icnt hould b<< trans-mitted to PDH for their resolution.

HH HO RERAN.UM April ll, 3,975 BURNS and'OE, Xnc. Sheet 2 of. 2 A separate enclosure to the Subject PDM letter includes an analysis of. the induced . train in the conical shell during fi'eld erection to close a 3-inch gap between the conical shell and'uppo t r'ng.

study of, this analysis reveals tnat the induced stra'n is highly sensit've to the assumed arc angle of sepa'at

between the shell and ring. Xf ihe 90o arc angle, assumed

'by PDM,, were halved to 45o, the induced strain would in-cxease by a factor of 5'.

PDYi should provide a more detailed description of the field erection procedure which would relapse to the ac'tual arc angle of separation between shell and ring.

Additionally, PDlI should'scertain the actual radial jacking'oad applied in order to judge sistent with the'r assumed analytical if it model and is con-evalu-ation of induced strain in the shell.

JC/SF/nc

~

Attachment

~ ~

~

'.QP 4 S. Planzenbaum/J. C lapp

~ W

~ ~

ATTAC11!!1";hV A ib Dotajlod Comments Burn and R'oo St'ross Analysis Roview of Pi).':!

Revision i~!U:aber B.

The dead load placed on Cone Ring 4'as been revised (Revision B IV.5.3. Page 12) to 1081.7 kips, and its ordor of magnitude appears reasonablo. 'Eiowover, please

. provide a break-down of this revised load.

2. The stress output from the PM-2 Program (internal pressure condition) as snown in Revision B IV.5.3. Page 13, ind'c"'os minor revisions from previously transmitted output (IV.5.3.

Page 10.).'lease justify..

3~ The revised stresses based on the BOSOR P"og"am (Rev='sion B XV.5.3. Page 13) have all been adjusted by the ratio (1.5/

1.4375) . Burns and Roe =eels tnat this ratio is only appl'cable to bending stresses and that the direct ratio of

~

be applied to the membrane stresses.

(1.5/1.4375'hould Please confirm.

Revision (IV.5.3. 12) shows the shear stress 'evaluated a'n B average shea Page stress. Inasmuch as the evaluat'on o maximum stress intensity at the outermost fiber correct'y utilize" a zero shear stress, the evaluation of maximum st'ss intensity at the neut"'al axis should cons'stently ut'lize '-he maximum shea stress (VQ/It), evaluated a" the neet al axis.

Please confirm.

~0

'5 ~ The radial load indicated for eld Point 3, Case B, Revision B 5

(IV.5..3. Page 294) is given as 692 lb./in., instead o 0he correct value of 1038 lb./in. 'Althou'h this will result in a higher level of wold stress, the corrected stress will sti'1 be below the. allowable stress for the wold.. Please confirm that the revised Case B chill then prove to be the critical loading condition for t~eld Point 3.

~ ~

y (

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<, <4r r< ~

l

>>r

\ pS>>

Nf <<<I I,R i ~,l <" 0

< 8 P< TTGQU<1 i>><, PG<Vhb rLVIN<<< IGQ<' Pl <f'NE <r <2;;<+1 <'<r)<

(-4" c ..

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Ap- il 3, l9'?5.

PDli1DR-2 l3 19 Con l.ra.ct l27r~4 Ba: ns ..nd Poe, Ill:.

320 Pxl I t on 6'. en e IIc:!lp. tead, N. Y. ll550 A.ttellt i on:  !<!r, J. 'J. VerQL<ruer l>re ect. Hn "in (::1'3.n r"  ! e.n'~. 'er Hilbj ect: ~ jc ;n~-:.>>eel "lip T,'v~lua.ti n UPPex ><< PDO>> C }kin~~ li~VL~.3.". 3'erlrS c~

Gent::0!;<en:

i'his l -t te3 cor.t';:ins t'16 inforP..t3.0'1 " .C)" Q~tP'C$ ~)V l!1e~rtin f" <1~Ld ' '1 a~i t tP 0'<"glx on<

<bh.re]1 1.2, '15.

The pipe v nip suppox t king loads ns given in the' spcc-f'r

~ 3:'lc<<'.3.0n cire c):ce~G~..gl> lar "9 cll<Ln r-'e 'x'4'c'-

40rP. to c'irrv, in nrci<'r -<.'.0 obt<'in i".>> <:Cc".=ptable de<.

cL

'P PDiI reclUcsted Yl.<,(tel'~al is <1 tile xlse 0 S.'5537 Cl"..'<s c<"<rbon-~a'lRll<g<< DPHe"<5i" ico'1

" -...<xteri". l.

<<<3'~llc)<ci+

HAG37 8 l~(~

te)llpered s'eel for use ': oressxlxe vessels. I t yield StrXeu il . f 608't'ill ';-.i a.in., an u3.'.":<list trengt!1 Of SO to i<00 ~(si ije+ lllRllltc ins rclG.'.velv ."".!i'1 ducti l='ty (-"3ir,rp<<

ill

~

. r 2")~ ~

and has -ood iield.".bi li+';. It provi(!cs t.l n l llr! a llo;:

QSB~ry 3.n tile (I8: ~.'f<< tIle slip 0 "l

sA.t3.~'t Q,ctor 'l!J,Y.")'1<'3. A.or 'v.s 1'1 Ger<"'Pi rIQent voss

= v 0: ". !:: s".Css

"~ ":.

nec:-

2'le a) 'llvsis

'16 ox tile vessel in tIl' re<i. of t le rills l'.ll'" t'10 '1P al'< 8 of the rinr,. a"'n :osed. Tne enc" osc:6 .-"11:.1y..is v,'3ll a.ppea '.n t11 SLress 1 <<port for t.'1 '= ."r(;Q..

~

t'<<

tl:Le" e 'ECt Vll . f 'a"-.il 0<.' .r>..'lt" ..VIZ . 'Ccot.'.QJ.$ .:Rile(i 3 O +Oi'I (i) r'< ) L',~ ~

2-

\

Burns and Roe, Inc. April 3, 1975.

(2) Pit v eld.

t)xe l~" vIeb plates to 'Lhe sh ll and (3) Coiaplete the splice pla te;velds. Th"'

operation h"s no~ been done yet.

The v:elding sequence .vas "s fol'lov:s:

5'feld the root p,.ss of both the upper and lower v:eb pl" tes to the sh 11.

Concux rent ly wG~." d v.'itll one i!!an Gn the top pla.te wi')i sem -< uto".i<atic ec;uip'rient men locaLed:"0o a.pax t 'v,'eld the over-while'our r head:! <an ua, 1 1>>.

(3) Co'~piete the top plate cover.v.elds. using the iARnua" ')x'ocess ~

~ ~, (4) Pre<M~<..t wa'.:

wclG v., , used dur3 ng we l (I" np <~ut t!le 11 c..v;e/i i 0 x c'< ul n to Rpi bient te)1.peratu~ e i~'L nip'it This procedure resulted ill as near:4 un<" fo~'K ~<~ te 0 f filli>><'; the v<eld gl<ooUG Qs vns practicable. A copy of the V<'elding Procedures and 3'~'eld Qualifica,tioix- used are enclosed.

In order to do a proper job nf v.elding the pi!ewhip support girder to;he shell, it divas ilecessaxy to 1nain-tain t)ie gap be ween the girder wcbs and the she"l. "t 1/16" or less. T):e shell v.as severa]. inches out o use a.t t)ie elevation of the <<irdex, a, jacking fz ave and a. jack as shown on <attached It v.as necessaxy o'ound 1 in or(.!~r to pu1 1 the shell in to fi L tlie gii'dex

~

<etch vtit)lin Lhe reouired llliliLs Tv!enty) fifty and 100 ton

~

.'hydraulic jacks were used to pull the shell into the reouired fit .vith the gixde .. The oiie )iundred ton divas used a.t only a. few spots where the ~a.~ b~tv: e<

j:!;

anc s.iell v:as sev. ral, nches. The general forci:.an o::

the job feels that 'Lhe full capaci.y of the 100 ton .".ck was>>ever used since t) e ion est i <c'.c handle iisod v:AG about >0"

3 0 Burns and }toe, Inc. April,3, 1975.

calculation pa"o 1 pl eparod by J"m Strunl'nd

~

Attached (jatcd r is 1 2 j 19 (5 In th3$ QA 1('u ation J-'!) has usQd 'Ll)Q

)j)a@i)ru)!) gap, ihroc incl>>os, bct.:oon the <<ir()er And si) 3 ll and,c..lclllatod thc na3(i)?.u.) surface strain c>> eatcd i: tho 1 shc3.1 by jackin slle3.1 and gir(ior into confo)..)icy.

~ In ma}(i.ng tl>>.s calculation ile assu:rjed that all of the strain occurred in he holi. 'i)e calculated str".in is 0.00'!5".,

-an 'ins J.pni ic:?.Bt valuo, i ~ ~

f

~

~ ~

The four v:Q3.ds betv;oon tl:e shell and the vebs of tile tivo girdo3.8 v;el o inspcctcd usua'1 I) by '.)a<<nezic Particle, And by Ult3.;)sonics. T}le vi:equal al)d UT inspect-o:.1 reveale(i extensive la:nellal t(:ars i>>1 th(. She) 1 plate at th" v;o" ('s on thc top A.nd bottom v;ebs of tho top girder.. The in-sp c'L'1 on3 1 cvci%1e(l A,:i x 1 2 dc Icct in the "i'old ol t }l to j)

'5'cb of 'Lilc bot to!?1 il'('cr ~

slap'.nc lu 8 OB UT; ave tv'olv indications 0 f lame1 la).

~

This (iefoct v,'as j u(!god to l)o a teal's ln. "Lho shell Kt tho VI'eld on ti)e bc~to)i". Kveb of L'11c botxo?i) gi (lcl.. A13. (}efc:cts v:ill be rep..ired And reinspect(.(}

ln A cc01'(ia)'Ice 1v1t h t i!Q ai.tac}) -(1 p>>'cccdul e "Hep'* il'2. ~ld Yj Pit, PLpe )li)i!3 Sllppv>>r7 to ~!dwell evlsed on .'.)arch 2'7 j 1975 ~

At the l )ceting OB Al j.l'ch 3 2t}l il Buirlbcl of qu stions Kvore asked co:)cornin;", t) c lamellar tears. I v.il" state each question and fo31orv it ivith my answer.

%Ajar\.j w~~ '

-'dl(?"""'i '

ilif6'3.X.;i

~ i? ~

tPc.i.in'f OCCQU 'SO:??OplaoeS: M'd-'~I!00'."a) Oti'.ei.

~ ~v'.<

~ Pl Zh3.s 3.S li!(e as}(in'}ly does a tensile test sj)ecimcn select

.one specific cl'0$ .. so viol) to fracture 1'athel'l')>>B ABO '"er.

Tho ans%'(1 ) of course j is th'lt i'L selects Lho v(oa)>>'Qs c cross section;lt vvhich L'0 f;lil .iie ta llic tc1 3.. ls Al e Bo!1-1 mo- I?1, genecus )?)atcrials hoy }lave varyin~~" ph) sical pro})or 1:Les 11 A,ll di.roctiol!s, i)ut tile vari. ation in tho throu<<i) thic!.Boss dil'e tion is '6'i(icl th:1B 1.B eithor, 0'f 'L'hc 0t lcl'hvo direc i Onsi Also j X ho ilvcl agc tons3. lc i".B(l yield strcnl",th 3.n ho t)'.rou "'h thicl()loss direc lion is conoid(:r:lbly lov'er than "n oi.t))er of the othe)'1vo (liroct ious ID A d(lit i ol who st1 ains 'au&cd by v.oldin" are no): uniform. Thoy vary f1 0).) place to place tondinj to incrcaso as thc length of coo)ploted ivold in-creased.

) CC al o - ~:)l> j o'.;4:)1a."j;: g;.Qs j.(jua l" 8"'1'i>: .Ih \ 'i l 'j- >> 0 i'

'l

!3urns and Poc, X))c. 'Apri3. 3, 1975, Let Iae quote froin "Cov'", rt"ry on Big! ly ¹str" ined O'Glded Connections" puclished in the AX".=C .;ngineeri)'lg Journa.3., 3rd Quarte 1973, Vol, 10, 'io. 3 page 61:

"Lame13.ar tearing is he separation in t.".0 parent or base r.ateri~l ca sed by "+!)=u-thic!'.nes~"

stra.3.ns 3.nduced by )v 7.d rt:eta.l shr=.n!:r ge ---, 'Under condit3ons of hifr!>>-Gstraint, loc-1'zcd st1-.. ns c'ue to vjeld I/keta.l shr in:iRg cB,n oe !l)Q.ny '.8$ h. gh y3.G3.d point stl ins v'boreas - L"0= ses (!"e to Bl'han Q ~

design loads are vn3.y a fr).ct"'on o yie>>d point; thus the strail)s due to noolied 10."..ds ~. G not, of prise r co.cern ."'."; can".".n. lamellar ';o" ri..p. Yo CaSeS are kncrn O.'an..l..a'CO+.. npi-:" 'in tir.tec Ol'rCPOgA'Q " ~sign <

0 'cur "voile '8--ti)vy h ~Ye no~ > 0 L o'c',)rl".

The above ouota;t3.0)! ind catcs thA Dot occul. a ter Or orop f .te;.. '" .>.'t! .. 'v riever f

10)'c'.).3:.13.,C3.Q/hs pleted Rnd 'L!le pRrt h."'s 'Gt lrned to QFbient tell! 'Gr@ture

'; ~ ' 91 t

. 'iBP Rrs 7'i '...

" 6 co".'-

~

!)Oh)'" do~ .Ic!nc3) if". RI'~3 LG"Ape)'ing-c':3gcc 'l.t)e'aL"GV"..Ql):-'1 ">

stres,es: i.').'i)e.. pl')'hen t!)e plate is aue))c!:Gd the )ri"terial the tvio sur fQcos Q,re le ft 3.3! c~ st te oi 'cnsion in t.'10 dil Gct cn transvc1 sc to .nd '::!3 "." "G1 to Lhe 1'0" 3.ing dil'ec".'3. n; tl)"

cel)L'Gl of, t!re p jl'te 3.S 3.0f t 7 n a, state of'o,'i)pl cssion 7$ !)cp the )31Q,te 's te'!n- d g" ~p 'rog-'- " y 3.1OOop higher, these stresc: 's are 3 elicvcd to a, nu ch lcv;cr 3evr 1.

After quei)ching, thc Surface stresses;"ou3.Q bc 1)GRr tile ploportioncd imit v; 3ue. After tempcril)g; t!)0 stl esse-would bc of the order o.. 15 !'si.. 'l'l)ese st=esses !vould not contribute to 1.!v." 1.">r tearing because they are par:>.llel to the face of the plate. La!:;olla,r tc.".ring Result~ fl0'l! tensile s i.resses nor)i)Q1 to the sur face of the pl:)te.

The attached repa.ir ploccdule shou" d rc -ult in a. Sound

Burns and Rce, Inc. April 5, 1975.

structure ivith nc reoccu ance of la~.ellar tearing.

VeL-y tru.!.y 'ours, PITTSBURGH-DES J:GI"..L'S S 'ZL'~< CO:HVhY

~ ~

Vi I'4 ~

/);f-, ( 4,r'"-+i.~iv JH~E: n:fb J. H. Adams, Ciif.'ef:<<". gineer.

Znc.

cc: Vi'i ilia!n Coo~~sr Teledyne J!materials Rese ) cjoy

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The ounlij'ice@ion tost ior thi p ncedu.e Specification Ila.11 I)Q pel'for)'!<!(I Lvitll L ])rehc31~ Of 2000]'.

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s]!all co>>fo)'>>: to tlio s))ecifi(:".';iot).-.

."tu) il)u 1' 1 l3 l><tl>~roti)> -".. ']'his ]))'o(.'u()ul'u <<]so <.'ovci'solds of bas('ta Lurilil a!)og. Lo C)r(>lip p Niiii!1)c) 1 ma t.e) i'als,

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l>os i.ti o!1 Tl)o vvoldin'hall bo do>>o i>>. tlie voriical, ovorl)oil(]

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'!'Iic quali I'i ca tio>> test: for this p).ocodurc specif icati.on shall l)u per fol'lii(!d t'Pith a prelioll t of 50 1".

1 Yo v,o3.di>>of a'y I'ind shall be done lvhcn the tei!ipo) atiil c OE tho I):lsc 1'ic 1::i 1 is lola'el')1'111 0 1", At tcmpe)"iturcs be t; uu>> 0 1" an i Gi)ol', tho slirfaco of all areas wit))in 3 i>>el)es of 1.)to point 1'llc) c tlie iield is to bo started sliall be prehcaie(l to:i mi.>>i.i'1lli!1 ol'O 3') as shov:)) above bofo) o vicldi>> is started,

)3;l.",(. <<!Ci'al ']'l)icl-ness - This joint is qualified for usc oil 1.:atcria3.

i liicl(licss(:s I roiil 3/iG" to 3/4",

]3acl(in,r S Li i I>s - None allov,ed for this p) occdure AS!!" Co(i('. Sect in>>

]X ]> !rag) <<pl) V-7 permits uso of bac].-i>>I; strip for qualifica" 'o).

4'c3()i>>t~ Pipe((lure - Tho @olds shall be ma(!o b'y )t)ultiplo p:is.'cs.

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(3) Preheat Item (2) to 300 I: '.I'. Px'cl)eat, Ite))) (1) to 200 )." !,Iin.

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'-'.in pa).cnt metal (P.'I) after filliP.<':il cavity plior to ):!a!(in>>

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6'M.3350 ""< (>>~")>": >" 3 ~

'6>7) l'>arch 18, 1974 TR-2OS9(a)

Hr. J. J. Byrnes hanager of Projects Burns and Roe> Inc.

320 Ful>ton Avenue Hempstead, l!Y 11550 Sub j'ect: Pro~ress R port - Lamellar Tearing =.>:perienced on the Containment Vess 1 - l PPSS !nuclear Projecl:. llo. 2.

,~4 I I

Dear >!r. Byr,

n'as:

The letter report inclu"es a gen ral' vie;> of the lamellar tearing problem and a discussion of the proposed repair procedure on the subject'essel.

This ly'iter is based upon n;y review of the l!CR and associated documents,'eetings with S> ms anJ >",oe, Ir,c. (D a R) and C".",=.;"

Pittsburgh - D s i!oines Steel> Co;,."..c'.ny (P!i>l), subs'quent telecon- with

>JPPSS and 8 5 P, personn 1 and wit!> others identif ied in the following, and a review of recert li eratu! e during the period t'arch 10 through the present..

A. Lar> liar Tearing as a General Problem>

The best available summary statem nt that;.e ha;e found with r spect to lamell(.'r tearinq is that pr ared in June 19?4 by tl = ASllE Code Task Group on Lamellar Tearing.

'"Lamellar tearing is the separation in the parent or base material caused by thru-thickness strains induced by weld metal si>rinkage.

Lamellar tearing should not be conf. ised with laminations in plate material.

"Steel may b counted upon to Jeforn iocally parallel and transverse to thc rolling direction and, if d"formed enoug!>, to br-:.iig about a i ed\stv'i "vtlcn 0> t!'o:ot cps;n suci'I a way i>iat Uli~ i ocr, 1 'i c"i stressed a. eas refuse to a.cc:t additional lo".d <<nd call upon surrnun"-

'.rg r.:ateiial to s!:are in tl:. load transfer. In the t!iru- hickocss

I ) ~ I;

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~ ~

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Hr. J. il. Byrnes l~aoag'er of projects Burns;nd Roe, Inc.

Harch lQ, 1975 Page 2 di rection, strairs in excess of the yield point may cause decohesion

'and lead to a lamellar, tear.

"A. lamellar tear occurs only in the base metal and whi1e it may originate close to the toe or root of a weld, often the tear may originate veil outsid the HAZ'and may not propagate to the surface. The cross-section of a lamellar tear is step-like, with longitudinal terraces

'hat .ar markedly longer than the transverse portions. The fracture has a fibrous appearance and this characteristic, along with th terraced pro,i le and location v!ithin tile base material away from the weld fusion line, is the best way'-of distinguishing the lamellar tear from HAZ cracks caused by. hydrogen.

cond'.tions of high restraint, localized strains due to weld

'Under metal shrinkage can be many tim s higher than yield points strains, whereas stresses due to design loa(i." are 901y a f1 ac~ ion of yield point thus the strains due to applied loads are not of primary concern in causing 1am liar te~> ing. tlo cases are known of lamellar tears being initiated by design loads.

"Investigation by the Task Group revealed lail'ellar tearing .o be a complex phenom non involving several variables. Treatmert of any singular variable without considerat'.on of other effects would be of little value. The initiation or suscepability to lamellar tearing is related to material properti. s, nonmetallic inclusion content, v!eld joint design and v!elding practice."

This Task Group, which reports to the Subgroup on Fabrication and Examination'f the Subcommittee on tluclear Po':;e , has the obje tive "to develop reco..:.'.. nda-tions to prevent lamellar tearing in restrained we1ded joints, v!i h the present: investigation limit.d to carbon and low a1loy steels." Although the .lask Group has approved so...e suggested changes for Code Subsection Vr",

.Component Suppo. ts, no high r - level action has been taken'his aspect

~ was chosen for ini tial e f1 ol ts because of t he absei;ce 0 N"~ul red. no;-

Hr. J. 0. Byrnes t~ianager'f Projec,ts lVle'il L t iieet-4>> ~'".i A .; t Burns and'Poe, Inc.

t1arch 18,'1975 Page 3 destructive examination of such supports and the extent of tearing vlhich has been experienced.

The lamellar tearing problem has become a common one in recent years, possibly because of improved examination techniques. l!ost of the pre ent research, US and foreign, is directed at identifying th basic m chanisms involved and to the developm nt of m. chanical or nond-structive test s for establishing the susceptibility to tearing of a qiven 'echniqu material. Beyond the facts that the tearing initiates at non-metallic inclusions and propagates by microvoid coalescence at temperatures of about 400'F as a result of strains caused by v.eld shrinkage, there is little ag) ment as to either the m chanism or ho:.'o measure susceptibility. Cleav ge is not involved.

Considerable a.iounts of guidance as to geometry, r.:aterial and <veld procedul"e <<re available, but are su!>"ect to.econoriic <<rgvm-Ats

~ i(hen Ao;,-

ti destructlv'xamln" on techni " 'es .".re -ppl i ed to establi sh v'hether or not tearing has occurred in sus- ptible s"ructu: es,-.here is opi'. ion +hat repair may be preferable to plevention. l~h n excessive amounts of i'epalr are required, prevention corn. s to the fore. It is clear that repair effort ts iihich simply ollon ihe original v,'ding procedures i ill only cause additional

-',cracking, so that repair procedures must reflect corrective techniques.

B. , The t'!PPSS-2 Aoo1 'ati on e Hondestructive examination. of the co.itainment vessel has indicated the presence of lamellar tearing in the shell plate bereath the iields attaching the upper pipe <;hip support ",ing. The questions to be discussed here are

~

the teel nical acceptability of. the proposed procedure for repairing those lamellar tears v:nich have been experienced and the Code acceptability o

~

the proposed repai r. Before doing this, the proposed repair procedure wi11 be discusseo.

Re air P: ocedure The p) ese;it draft of the repai> procedure in r:"I possession is Iievisio!'.

8, 3-7-75, o" RttacI;mont to 0".R DIAZ ..nd }!A3, Repair of i,'d at Pipe hip E

l ~

I Jl (~'~'Q'I f,. I L ~ ~~%'~ f, )~ ~$ f i~'am P $

Hr. J. J. Byrn.s l4PKi <<.l tel"'.I.-M L <f <~~'j <

hanag:.r of projects Burns and Roe, inc.

1)arch 1 u, 1975 Page 4 Support to Shell. In brief, this procedure involves:

a. Preheating.

b: Removal of the defect by gouging ard grindi., with tiDT check on removal.

C ~ Buttering of the shell plate to restore the ".riginal thickness and UT exa I'inatlon of ihe plate..

Perforr..arce of the attachment eld vIith in~mttent llT examination.

e. Soaking and cooling.

HT and UT at ambi nt.

g, Pneumatic test and UT.

By telecon with fir. Lunt of i<arch.l4, 19?5, I requ std that this repa'.r procedure be vodifi d to includ :

Extend";r~c the buttered region Gn tne shell".Pate to a distance

'1/2" furthel f) m t!le ('aid roo 'h<"fl '! he nl.oned !<eirht of the.

attachment i'eld to assure that the attach".;~i'i;eld vias not made to the base plate.

b. Extending the c'!e<",n out of t!. defect six inbes circumferentially'beyond the indicated ends of the cracks, ivtblthe buttering extending into this area, to assure that theattachm nt ;:eld v;as not made Co the base plate ...r the end of.:aprevious crack.

It is rp understanding that PDll and B 8 R have accepted these revisions ard that they trill be implemented.

The remaining question '.s the sequence to be folo~:.'ed in making the repair. PDH field personnel hav express d concern:ver the original concept of a sequence in the order of:

a. Remove all defect areas.

b. Repair al'. s!:.11 plates.

c. Pe< form the at tac!.:;:ent;:olds.

sC

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c(4>T). I i Hr. J. '?. ~: I'.

'rr, Byrn s jLI il(?~,j,! ~ l<, ~=e ~ii~e!

Vianagcr of projects Burns and Roe, Inc.

l'iarch 1G, 1975 Page 5 As an alternate, the fi ld forces have recommended tl;at ith s sequence be split, so that all three steps have been completed o." the b!o large cracks't the top of the ring before starting the sequence cf the bottom of the rino. Hr. Lunt {B 5P,) and I discussed this proposal on Harch 14; 1975

,and agreed that this sequence i~ould be satisfactory.

2. Te,".hnicn'I hccent="b~ilit Although some of the scient',fic aspects of lav."',.lar tearing are stil being. debated, the practical circumstances.whicl? result in lamellar tearing

~

. ~ ~

and the methods for repair are?"ell understood based on oast experience.

In the present case:

a. The presence of tearing has been identified'and the extent determined by UT, th best available tec.ini:;ue.'.

The defect remo<<al procedL(res are conven'+io!al

/

and are co!iflimed

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. - by su!" (,'ace cxa!!?'I!?at i 0!1.

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The plate repair procedures

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C. cire convent'Iona! arid are co??fll"m d by Of r('osi; im';:ortance, 'Ul'e coliseque!i" o t.l ?'epalr is a I 1G

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layer on the plate <;hich is just the "groo; - and '- butter" technique most ofter, recommended for avoidaice or repair of the phenomina.

d. Application of the attachment?!el d, particu(iarly t!ie'imensions of the v! ld, should be subject to?(?Ore atteition .han ?!l?en

~ i

, origina(ly perform d.

e. UT of the repaired area after repair and of-the entire circumfe? ence after pneumatic testing Mill confirm the abr~rce of additional lamell al

. tearing.

f. Completinq the repair on top of the bea??? pmeedinq i;it!i the bottom, in'addition to resolving tl?e practical proL1'eri? of support, v!ill provide a'hecl'-out o, the procedure.

It is our opinion that th proposed repair procedur'e is technically acceptabl

.a?ld ol'fe?'5 tlirt best ';,'ay i 0 Ii'. Alll?i e sell'ul .. delays.. T);e? e appea! l.o l ';o viable alternatives to t!;e m tliod proposed by Pot .

tsr. 0. i~. Byrnes t~ianager of. Projects Burns and Roe, Inc.

)larch 18, l975 Page 6

3. ~ii i '."Iiiii Hr .R. ii. Gibson, of'Factory liutual Research which is pert o: PD!i's Authorized Inspection Agency Factory Hutual System, in his letter to PD!l dated Feb. 11, 1975., states that "the repair does not conflict with the Code under which the,essel is being built. However, in an earlier sentence i',r. Gibson implies that the repair does not r., et the intent of the Code. The latter statement has caused some concern since none of

~

the parties involved ish to taI:e advantage of specific words and end

~ Up violating intent."

In preparation for a discussion with Hr. Gibson of his concern, I discussed th matter with:

a. Hr. L. J. ChocI;ie, a member of the Hain Coxm'.ttee and of the Subco.";;",iittee on Nuclear Power and until this month Chairman of the Subgrouip on Fabrication and Examination =.o"i~hach th.. Tasi:

Group on Lasmellar Tearing reports.

b. Hr. R. F. Peedy, Vice-Cha.Irman of the Subco.mittee on iiuclear Power and Chairman of th Subgroup on Contai,",m nt.

These gentlemen share mv opinion that the subject repair is consistent with the intent of the Code. I discussed the concern with I'r. Gibson on the afternoon of tiarch 18, 1975 and he indicated tha the phrase concerning

~

intent could probably be deleted from his letter. Ho<ever, further dis-cussions may be required.

Very truly yours, TELEDYf/E WTEPI'LS RESEARCH

+W Wd'.,

William E. Coop=r Senior Yi ce Pi esii dent 8 Technical Director NEC:raj

so:.s s=c.n vu. ro>>.o r

Vl~THAlA.M>>'SSOCa~~c; s s 5 C2l 54 (C17) 899.3350 1"IX (7lGp32' TKVo April ll, '1975 TR-2059(b) l1r. J. J. Byrnes l"anager of Pro-'.s Burns and Roe, 'nc.

320 Fulton Avenu Hempstead, HY 11550

Subject:

Progr ss Report -'amel ar Tearir g 1 Experi enced on the Conta nt.".ent Vessel-!iPPSS l4tcl ear Project l'o. 2.

Dear l1r. Byrnes:

.Our first l.etter report dated t!arch 18, 1975, described the la:-.. lla1.

tearing pro.ale-,, th= dra=t of the r pair procedure, 2nd ';he technical and Code acceptability of th. p.oposed repair. Since that date we lave been involved with respect to:

l.: The'epair accordance 1'teld procedu1"e, 1;hich has "een rc":",'-.ied, in with our rec'o,";,mendatlons 2nd 0th . K- velop-ments, and is now Revision F.

2. The question 'related to Code intent, which h=-s b en eliminat d by. the harch 20, 19?5 letter from Factory Mutual Research (R. l1. Gibson) to PK1 (J. S':un1:).

1

~

3. Review cf the Apr'il 3, 1975 letter f'.om PDN j',J H. Adams) to Burns and Ro (J. J. Verderber) providing their final

'engineering. evaluation.

the first two items a1 e self-explanatory, this 1

'ln'ce

,our cqnclusions wi tn respect to the PDl1 final engineering evaluation.

it r repol t plovldes l.. PD'1 Conclusion (po 4-5)

~

PDll concludes th.t the, repair procedure b ing used "should result in a sound structure with no r=".acciir!ence of "it is our opinion that th.letter lamellar tearing"; of triarch 19, .9?5 stated that Tl1R's p1oposed 1 oair;".rocedure is t"-chnical!y acceptable". Durinn ';.he s<!bsequenl m I ti.".:e per--..

IW pm L~ I ~ haveIQ no' i l .is.=..I bel;.,e ti1at .- 1!er nr::;~nce or -'e

~ ~ 4 ~~ ~ w ~  % W ~

g ou1 opin>."n. n -.;:.1tic"lar > with th plocedu1es p1o:".~"d by PD,'<<;i',1 re-store the containment vessel to th state in'or dud during initial c f

'I cons tl Ucti on.

Hr. J. 3. B Jrn s

'}a!la g e r 0f

~

Burns and Roe, Inc.

Pl j t 0 ec s April 11,'975 Page 2

2. AD lied Sir sses 0.'e have revie:<ed the general methods applied by PDh in the design and analysis of th siructur and the summary compu-tations provided to us by PDtl consisting of Section IV, Sub-section 5, Article 3 Pages10-13B and 288-296. Theso have been r vie:;ed under the assumption thai the 0'sign Specifi-cation has been properly interpreted by PDli, lwhich is subject to,approval by. others per ASlt= !lA-3260,and in sufficient detail to assure us that tne interpretation o, the comput'ed

~

. results is adequai .

j+ ~I Pages10-138 consider the stresses induc d in the shell

~,I1

". 'of. the containment v ssel as a result of the specified loadina

,conditions. M have supple.",: nied the computations provided to us ',vith'a telephone conversation irith PD.'< (J Strung:) on

'Hai'ch 8 1975 for th purpose of fu'rther clarification. i.'e

~

concur i;ith the PD l conclusion hai the shell stresses a'e within Code limits. It is pertinent to note that the local memb) ane stress intensity of 9.3 ksi is less than 1/3rd of the allo;able value and that the prim ly"plus"second ly sii ss intensity ls less than 2/3rds oi the al)o;!able valu .

Pao s 288-296 consider the stresses in tho support, rirg attachm. n iields. '; <;ould first note that the allo,!able primary-plus-secondary stress i ".posed by the L sign Specifi-cation is 90;l of ihe yield sir naih of tho mat rial,'or 43.1 ksi. This compares to a C""e allo::able 3Svalue of 61.5 ksi for th OBE Condition. Th refcre, there is ccnsiderab,e con-servatism in the design criterion used. Ail of the <fields meet this limit, irith the rost highly stressed i;eld, thai; for th

-'ttachm nt'f the iop plate, having a stress of 41.2 ksi.

Of t;ore importance iiitn respect to the aspect of 1am liar tearing js the "through-ihickn ss" tension applied to ihe she!1 plate bv the operating conditions. The'maxim.:;m value of this stress is 1.6 ksi, an almost negligible value.

Residual Str sses There are residual stresses in the atiac!:m nt i!elds and in

-the adjac ni p',ate as a result of. initial for..iina, jacking to assur ';: ld alignment, and w lding. 'he Code does not require considera-ion of such stresses i'hen ihe mar!.;in bet~.een one'. aiin".,

te ptSr'l*u) 0 lg(l 'I 4.l (il. 'c

% 1 > QN% 9' i> Wl Therefore, residual stresses have. not been e>plici ily ti eaied in the design or evalua io!i.

Hr. J. J: tlyrn s 4anager of Projects burns Bnd Po=, Inc.

April 3

ll, 1975 Page Despite the insignificance of such stresses,:Ie n:ust co ISA nt on the dlscUss:Gll of this Bsp ct ll Br the bottom of page ~i of the PD'1 letter. The data given by 0. J. Horger on pages 480 and 484 of the Handboo~ for Eloper'irental Stress Analysis are the mos appropriate data i; have located. Th se data indicate that Die, auenching, Gut be ore tea>pering, th residual stress iiill be about 100 I:si co-.pr ssi.e on the 'ur-

'face, 60!;si tension at the c nt r,:Iith ih through-thi"l:ness residual stress being z ro a" "h surface 'Bnd havti:o a maxirum tensile value of about 8 ksi. Tempering at 110'~Freduces tne 100 I;si to about 20 ksi co!,pressive Bt she seoul fB~c'~, Data are

.not given for o her directions'r 1ocations, but tei-poring

>till also considerably reduce..tiles vajues.

I It is our opinion that th s'e residual stresses will not be of significance to subsequent service, Bnd particularly that lamellar cracking .vill not, o'ccur after.'ovpletlon of the repaii procedure.

Yery truly yours, TEl EOYHE tQTE.".,I 'MLS PESGRCH gillian E. Cooper

'enior 3'ice Presid nt 5, Technical Director I ~

ltEC:raj

~ ~

l.

JUN5 j975 'Q3 (;l Acc h L L M*0

'vA(lHs'A t!A5~&C><VSc'ITS p2! '<

i (r17)P>P 33'P >; ic(llP)PPc 7~;3 tray 28, 1975 T-P-?059~ c-)

l'ir. J J. Byrnes htanager of'rojects Burns t Roe, Inc. =I 320 Fulton Avenue Hempstead, tlY 11550 I

Subject:

Repair of amellar Tearing Experienced on the I

Containm nt Vessel - I,"PPSS Ilucleav Project t!o.

I 2.

Dear Itr. Byrnes:

A meeting was held at TllR on htay 28, 1975 fo. the purposes of revie:;ing the resvlts OT the subject 1'epail opelc"tion, 'including a discussion o. the

'natuve and signif'.cance of certain ult:rasonic discontinuities present after completion of the planned repair. The"meeting,was attended by PPSS, Buln" '.

and Roe, PDli and TjiR personnel.

~

In addition to the oral presentation and discussion, the following documents <"ere avail able:

l. Draft Summary by PDl1.

2, Factory hutual Research (R; l1. Gibson) litter to PD!1 (J. F.. Strung), ttay 19, 1975.

3. United States S eel (B. F. 1!illiams) letter to PDt!

(A. ll. l,'iese), 11ay 15, 1975 wit.h attac!;ed evaluation bulletin.

4. Hamill Testing Laboratory Report, 004 (C. R. Vigne) to PD,'1, thy lcl, 1975, PRESEt'tT STATUS The discussion summarized the pvcsent status of the liPPSS-2 containment vessel as follows:

The planned repair has been completed witllout reinitiation of the lamellar teals which established the need for rcpaiv.

Following ccr pletion of the subsequent addit:ional repaiv discussed below, ultvclsonic exa! 1lnatinn tn Sect:ion III Pvoreduves, Part'.cul-;vly sens l ti v i t:y, di(l 11(1T. reve~ a',;,",i".,i i ca'. '. c'ns in Qxc" ss of 1

Sect.ioll III acceptance cvitev',n fov base metal ov>>eld metal.

!!,l ~, rml/> 5 hc.,":/~la~',;

I'ir. J. J: Byrnes Hanager of I'rojects Burns 5 Poe, Inc.

Hay 2D, 1975 Page 2 Following completion of the planned repair, an ultrasonic examination was performed at additional. (+ 20dB) gain, similar to that applied in establishing the material to be removed for the planned repair. This examination revealed s.all UT discontinuities in the base metal be-tween the outer surface of the vessel and the-repair weld. It was decided to remove the suspect material, worl:ing from the outer sur-face, and to weld repair tliese regions. Folio.!ino co;.;pleticn o this additional repair, th high-gain UT examination was repeated.

The result was ihat addi~".onal discontinuities were id ntified a'round the periph ry of each of these outer surface repairs in base material'hich had been examined previously and in v!hich there were no such discontinuities. These indications lie in the plane of the plate, are 1/4 T to 3/4 T from the outer surface, and extend away from the weld for a distarce generally between 1/8" and 1/4" and no

'more than 1/2". A portion of tho plate was removed and subjected to metallographic examiration by US Steel and hami 11. POll will prepare a summary report on this aspect.

If these new discontinuities are de med to be of negligible structural additional-significance, the pneumatic test !!ould be conducted and an

'igh-gain UT xa.!ination p rformed in accordance with presently established 'plans. Assuming that no.significant change in the UT results i!as experienced, the repair would be consioered to have been accomplished.

DISCUSSIO."l Item 3 of the above listing was the main topic for discussio!i at the meeting. The technical details will be documented elsewhere and are !:ot repeated he! e. As a sur:;rary of the discussion:

1. The inclusion level of the plate is not a !iolr!al, as i!idicat=.d by macioscopic and microscopic (100X) metallograoi.:; and by ul'ra-sonic trans:::issibiliiy. There are short, isola;cd non-m tallic inclusions 0!i s vc! al planes with>>no indication of g! oss seg! ega-tion and lalainar discontinuity.

2. The indications lie in the plane of the plate, and are short, and

~

aC several depths. llicroscopic examination reveals ovalization of the initially,)lanar discontinuities and cracl;ing betw en some of the closely adjacent inclusions. In that sense the cracl'ing is of a lamellar t~.",~e. The overall pattern seems to he the result of both heat and shrin!:age stress causing a broadening and connecting of'.the original inclusions with resulting amplification of the UT signal into the ro;.ortable range.

~ 1 )% I +q

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.- 't~jr. J..0. Byrnes l<anager of l'rojects BUrns 5 Po , Inc.

flay 28, 1975 Page 3

3. The presence of'hese new discontinuities at the'periphery of all repairs made from the outer surface indicates that this p:.vticul~r

~

type of discontinuity is not repairable, since further at";-.;p's at repair would just establish new discontinuities at tne new repair periphery.

4, The discontinuities are in the central region of the plate, wher>>

the bending stresses ':Ihich are of r::est significance are s".aller

~

than at the surface, and the discontir,uities are bordered oh ore

'side by <<eld rr, tal, providing shear continuity.

5. Changes in the ultrasonic pattern from the present to the time following the pneumatic test are to b expected as a result of the riatural variables of the UT. test, but are not expected to be

~

significant. Specifically,, the indi'cated size would not be expected to vary by more than about 1/4,".

. COlsCLUSIO)lS Based upon the above discussion, and assuming that subsequent documenta-tion does not result in new inforvation, it is our opinion that the new UT discont',nuities are of negligible structural significance. Therefore, <<e Oould reco-:,"end acceptance of the PDil vecovvendation to pvoceed with pr,e .-..a~ic testing and subseque)lt UT examination in acco.dance with previously establish d procedures. Assuminq success,ul completion of th se steps, we would conside:

the repair to have be n satisfactorily comp'leted.

Yery truly yours, TELEDYNE lL MATERIALS RESEARCH Sz-W llilliam E. Cooper Seniov Yice President 5 Techvical Director l]EC:raj

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2) 'IAI'ashington Pub1ic Power Supply System A JOINT OPERATING AGENCY P. 0, BOX 968 3000 GCO. WASHINGTON WAY 'RICHI.AND. WASHINGTON SSSS2 PKONC (509) 946 968!

March 7, 1975 G02-75-72 Hr. R. H. Engelken, Director Nuclear Regulatory Commission Region Y 1990 North California Blvd.

Creek Plaza, Suite 202 'alnut Walnut Creek, California 94596

Subject:

WPPSS NUCLEAR PROJECT NO. '2 (DOCKET 50-397)

FABRICATION DIFFICULTIES, STEEL CONTAINtiENT VESSEL

Dear ttr. Engelken:

The purpose of this letter is- to advance information to you regarding the nature of the fabrication difficulties being experienced in the attachment of the main steam relief valve platform support ring to the WNP-2 steel containment vessel under construction by Pittsburg-Des Moines (PDM). It is our'position that these fabrication problems are not classed as a deficiency reportable under the provisions of paragraph 50.55(e) of 10 CFR 50. The following summary of findings and progress in the. examination of this problem are presented for your review:

-'), The basic problem is the presence of what appears to be "lamellar

.'ears" in containment vessel plate adjacent to the weld attaching the large Nbox-girderH which is the support ring. (The configuration is provided as Attachment 1 to this letter).

2) These tears were detected in the course of routine inspection, recorded and reported to the appropriate Engineering and guality Assurance

, organizations for disposition in accordance with the procedures of the PDH, Burns 8 Roe and WPPSS guality Assurance Programs.

3) The extent of these "tears" can He sunJIIarized as follows:

a) Two tears on the top, 8'-78 and 7'-4H long, and one 2'ong on the bottom were detected visually in preparation for routine magnetic particle testing.

Mr. R.-H. Engelken Nuclear Regulatory Commission March 7, 1975 Page 2 602-75-72 I

3) continued:

b) There was one 6" indication on the top and approximately 21 other indications opposite the bottom weld which were detected in the course of 100/. ultrasonic testing of remaining weld zones on top and bottom. These indications range from 1/4" to 40" in length.

4) Me have directed Burns 8 Roe, the Architect-Engineer and Construction Manager, to do whatever is required to resolve this problem as expeditiously as possible. The actions to date consist of:

a) An evaluation of the characteristics of a sample of metal from the tear area by Anamet Laboratories Inc., and the U.S. Steel Research Laboratory (see Attachment 2) which have'stablished the conformance of the material to the specification; no defects in the material adjacent to the fracture, and a conclusion by the PDM Chief Melding Engineer that a "lamellar tear of a restrained joint" had occurred. Morking with this as a preliminary diagnosis, an evaluation of the evidence by the Burns and Roe metallurgist resulted in a concurrence with this opinion.

..b) A separate evaluation of fabrication techniques and any signifi-cant fabrication stresses is being conducted by PDH and Burns 5 Roe.

This evaluation has not yet been finalized.

c) PDM has prepared a repair pro'cedure in accordance with the require-ments of Section III of the ASHE Code and obtained the approval of the Authorized Inspector (Factory Mutual Engineering), Burns 8 Roe and plans to proceed with defect removal of the first of the tears.

~

....To further summarize Burns & Roe and PDM findings at the present, this

~

'ppears to be related to the combination of the heavy section of the material and the geometry involved.'his problem was considered in the design of the weld geometry by PDM, and further review of design and fabrication technique is underway to establish the cause of the tears and determine repairs and/or modifications required to complete an approved containment vessel.

Me will keep you informed of further developments.

Very truly yours, J. STEIN Managing Director JJS:MEM:cab

~

-Attachments

I

~

J

~~

\

CONTAINMENT VESSEL SHELL .

MATERIAL A 537 I

LAOlELAR TEAR AREA (APPROX. ) g~~ PIPE MHIP SUPPORT J'~g gl P ~

(TYPICAL)

ATTACHMENT l - SKETCH OF VESSEL-.SUPPORT GEOMETRY.

1

~ 44IA ~ ~ t ~ y I ~ ~e ~ I~ ~ I~ ~~ I ~

Pl%. ~t'U~~&f"f-UL".~~ 1Vi Cl) 1'ds" 6 H Ff ~L, a C Cfl'vlHA,s'JY' liI.Vll.lI I el 4+ ~ > o ~ ~ < ~ ~ H@a ~ ~ ~ ~l f~ I ~ '( ~ l ~ o' ~

' ~ ~ ~ ~ ~ l< ~ ~ ~ l 1

v J:L>>uary 28, 1973.

,Unitrd St@,tes Stccl Col.pore.tio!1 '-'00 (h fLnl. St 1'cct Eioom d:l31 E?i t tsbur."h, Pa.. 152~0

.Attention:

l

~,lr. Ron Norris ~

SubJ oct: Contract, 1'64 Vlelcl Cr LL:in;~ on Toe ol'.;" of I'illct nl:Lde to,Face Pla,tc Qe'ar llr. Norris:--- gorget Reference is laade to oui telephone conversation of January -7, 1975 I ecjLlc-.itin~ assi stfL>>ce fI om U1'1ltecl States Steel Col lull ill, Lllterpl'c;t in/ v.'liat ma) have c;Lllsecl st vel;ll cr:Lcl s in Bakln a. "il cler conTlec-tion to tile Shel 1 plate ol'lLG abovQ collt1 a.ct Ve are asl.-in'ol. your evaluation" i>> this. matter a~

a follov:-up request to us by BLLrns a>>cl ):oe's mct-Rllul gist the en+'incers O'll tllis coll cl Lct.

111cntioned to you that I had discussed this problem N'ith Dr. O. Doty a.t yollr'aboratol v llllcl he felt tllat.

hc haci Ul'lited SLatcs Steel ' sales Llpproval, he avould proceed to eva.lLLatc thc proble~l. You a'reed ancl Ulldcr. SepA.I '1 te cover 'Lve al c selldlll" DL'. Dot y a. d av'in..

sho'.vill'~ t lie vesSe 1:l.lid ~ i 1 cle, dr'!8 i '"ll L

LL11 J;I chi 0 0 f JIL8 till removed fro:a thc craclccd area. The chipped piece v,'Lls removed from the area noled in slcctch bolo';:

7 "/ g~lP ~F ~ PEAL. 8 E'MOVED gf 1

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,DL 'l >'ALL. G OWE-.. E 52

> ~ i q r,i, e'

~ ~ s w United States Steel CorporaLion

~ ~ ~ ~

~ ~

January '; 1975.

EJ ~ ~ ~ ~

~ ~1 ~

T)ie c)iippcd out pi(:c(: I~as sow~" tool ma~ I(>>'sed in re-movln~~ the section and L )le b((3.,(nc(: x.'s (I:(r)'. x n co 102 .

7'e believe the dax)( color is (:aused by Af:CAIN;;'ou"'in' lieat.. The Barns <<nd lloe i.~: tallur'ist >>ho;.e(t con "e'.n about the fx.acture and would like to 1(no':. wh(:tl ex it is a brittle or ducLil'(. fr~ctur(..

Vi'e believe this is a well oco.ni::ed p)ienomevx and 'will discuss it >

l'urther a.f Lex Dr. DoLy'~ eva,luation. )3~

copy of this letter Dr. Doty,will b not:ified to sub.nit any written report to United States Steel Corporation Technical Sex.vice prior to issue.

The material used i'n the strq(:tux e was supplied by United S Lates Steel.

I 7'-4" Area.

l~" Shell HT Y(73051, Sla,b 03Yi2 8'rea.

l T.st 1" Si.ell 117. 7 I I)656 11T 3773051 Slab 2376-'ES Sla,b 05(f 2 1y~" li'ebe HT 7lU656 Slab 237648 An early written reply will be appreciated since Burns and Roe Engineers axe delayin. approval of oux repair procedure until they receive United SLates Steel Corporation's opinion.

Sincerely, PXTTSBURG)l-DES AIOI.IES STEEL CO.'IPA'NY Pili /i LC: infb Larry Colax ossi, Chief ))'elding 'Fnineer.

e

RECORD OF. EVENTS I

1) Friday, January 3, 1975..

a) Crack originally discovered by PDM personnel during visual inspection of the pipe whip support to containment vessel sh'ell weld, prior to preparations for performing MT inspection of the pipe whip support

'eld.

2) Friday, January 3, 1975.

a) PDM gA - Les Sutton, put hold tags, Numbers 00287 and 00288, on shell adjacent to the crack area.

the'essel b) PDM Project Manager - Max Schulze, contacted Nick DeStefano -- PDM Western Division Welding Engineer, Santa Clara, for assistance in evaluating cracking problem.

3) Saturday, January 4, 1975.

a) Nick DeStefano arrived on site fr'om Santa. Clara.

'b) Removed a specimen from the cracked area for chemical analysis. The specimen included a section of the containment vessel base material and pipe whip support weld.

c) Crack area specimen sent to: Anamet Lab, Berkely, Calif., for analysis by Nick DeStefano. (For results of specimen analysis see Anamet Lab Report, Letter dated January 17, 1975, Anamet Lab No. 175.102, P.O. 9364)

4) Monday, January 6, 1975 a) Burns & Roe gA - MG Krisher, was advised by LR Sutton - PDM gA, of existence of pipe whip support crack, and that PDM was proceeding with repair using routine repair procedure.

b) PDM gA Site performed preliminary UT Scan of crack area using Site NDT technician..

c) PDM gA - LR Sutton requested assistance of NDT-UT Technician from corporate gA (Provo Shop) to UT entire crack area.

5) Tuesday, January 7, 1975 a) Burns & Roe gA - MG Krisher, advised by PDM gA - LR Sutton, that the scheduled repair was not a "routine" repair, and repairs would be stopped pending further evaluation of the crack areas.

6) Wednesday, January 8, 1975.

~ - a) PDM, NDT-UT Level I Technician, M. Cameron, arrived from Provo Shop.

Proceeded with UT inspection of crack area. (See PDM Deviation or Variation Report (DVR) on results of UT inspection. Dated January 13; 1975. (B&R File No. E52-0802)

Sheet 2 of 2 RECgr>-.

7) Friday, January 10, 1975 a) UT inspection by Provo Shop UT Technician completed.

- -(See item 6 for Report No.)

I

8) Monday, January 13, 1975 I

a) PDM gA - LR Sutton, prepared NCR on "pipe whip support crack.

Transmitted same to Burns & Roe Site gA on 1/15/75.

9) Saturday, January 18, 1975 a) Yisual inspection of )he pipe whip support crack areas was performed by H.. Lunt,'urns & Roe N.Y. (see'onference notes No. 316, dated 1/18/75) and L'.0. Rousseau, MPPSS. (See IOM, No. gA-2-75-21,. dated 1/23/75). --

b) H. Lun't, Burhs & Roe N.Y;, requested that PDM remove another specimen for fracture analysis.

10) Monday, January 20, 1975 a) PDM removed the requested specimen per H. Lunt's request. Specimen was shipped to PDM's corporate Metallurgy Department, Pittsburgh.

A section of the specimen was sent by PDM Metallurgy Dept. to US Steel

.(Manufacturers of the base material) for their evaluation. (See letter, US Steel to PDM, dated February 3, 1975, for their analysis of fracture).

~

11) Period January 21 through February 21, 1975 a) Exchange and evaluation of correspondence, test reports, and preparation of repair procedure dated 1/29/75.

12) Monday, February 24, 1975 Burns & Roe notified by POM gA, letter addendum to NRC 213-0058 of thir d crack approximately two (2) feet long, located in bottom plate of subject pipe whip support. Nature of the cracked area is the same as described for the top plate of this pipe whip support.

13) Saturday, March 1, Sunday, March 2 a) Further Ultrasonic Testing by Hamill Manufacturing Company (Report No. 001) resulting in complete map of significant indications on both top and bottom of girder.

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TCLQY vrrr ~ Jrr 1 lt r g f / 1/Q cNc:r~scns I rwnnrcr vo~s I cor~sTqrJ=tons i lrVtt r, PtTTSF Ut~HH-EDES MQINES STEEL CQ!Vfi~ANY '.I S.Z NGVILLKrSLhNO I D'TT GOUAGN, 0'i>>NNGVr VANIA'lp>>25 rr PHQr .f'lj,l,> I tO;,2

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t I.terr'?ic E!arch 3, 1975 GE IP-:?P Gf O.EGVl PDMR-213-75-13 GL GELHr'i"$

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Burns and .";oe, Xnc. $ ttf ii ~ ~~ ~

320 Ful ton Avenue ~ ~ r~ ~ ~

Ekeapstead, hevt York ll550 .. J: /~g p './X./ ~$

Attention: 'Ir. J. J. Verd erber, Proj ect =n'inee"'g. l~nager Subj ect ~ngineerinr.4L aluation of .-ipse I'r!Iil Defect, YiP~SS liuclea Proqoct i!o. 2

Reference:

1) O'-R HCr;-213-00058

2) PDU DVR - E.".2

3) U"S Corporat"on L tter to '~ . J. P.

MCCar(hy, d ted February 3, 1015 Gentlemen:

Xn response to t118 above re fere)1ces you 1 eoue'ed an en~ineering evaluation of the defects at Ghe L1nper Pipe vdhip supporl ~

'Bi~id structures of thi="type produce high strains in Vie ld I Ieta 1 and ti)e ad/ ace'Ig ~a1 ent Lr gta 1 Pl tes a e inherently r:ea!:er in t""e t:.1:ou';h thici:ness di~ ction than in tile lcn;",itudinal or t;"n ver::e di-.ections.

Xf the stra" 11s produced as the 7'el'ie 1 cools to '

nubient t .=':.. ratu cau=o stre-"es in th plat= in th"oug!1 thic'.-Iless direction beyond its ultiL!ate tensile stren-:th, the plate fail '~y laG'.c3.lar tea=in.. 'a;.all."r tear" ha~-e a distinct appearance. !Ie fractLIre vill follovs variou- pla:les of v:ea'-ness for ho= t di"-tanc s and 'sh-" o ot.'1er !Ila.". o'ea.';IIess at o'h-.r c'.c!>t.'ls from tho plato us="ce ivin>> t!Ie fracture a v:ooc. li::e appefLI.:Lnce, Ti'.o v(eld )oint at this location v.a desi ned to vainil.i".o tho po.'..ibility of la. ella@ tearin, by r~"l:in.- tho v:eld o, Partial p"notration, one idod v:old instead of. a L'ull butt v:old.

~ ~

P(TTSBUPlSH-DEB MOIRE:-S r ST@,EL COV<PP,NY PK KPi'213-75-13 LIarch 3, 107;i Hr. J. J. Vcr der bor I

The o >voids.and adjacent parent plato are c.".'cisf:.ctc"y whore they can bo devonstratod by l<D~ nethcds to bo, sound.

Those to"rs occur duri>>~ tho cool do<vn of the v'old or tho Kletal and v'Old yield enough to accG'lQc'a <.0 tho Ueld sK'in):age. 'i'hoy novor ap:.;ear "t a la.ter tir~e as happens with somo ot~ior typos of cr3chs.

This phenomenon is not nwv in tho stoel con t"uction industry. They occur frequently in bo.. girder typo brid..e Our repair procedure has included tho best novvn prec"uticns zL to minin.i"e the possib'ility of la-'ellar 'J;carin 'eo"cu'"rin in tho repaired area To. in..uro ti>at all area" o'amellar te ring have Leon rU.scoverod v'o aro 1005 "ltrasoni checl in@ the rex'i naer of the v!elds 'o t;veen the fair'or and "holi.

I believe this letter v!ill ans"..or any r~otallurgic 1 quest9.ons you nay h"'ve. T'chill you please respond A.S.;K.P.

so that ave raay field rop ir.

Very truly yours, PXTTSBU:<G.5:DZS LiiOXH"3 GTZ" L CO!<"-.ViiY J. H. Adams, Chief En@in er

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