ML18347A531

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Transmitting Report, Tube Burst and Leakage Test (Palisades), CENC-1256, Which Describes Testing Program & Analysis
ML18347A531
Person / Time
Site: Palisades Entergy icon.png
Issue date: 03/01/1976
From: Bixel D
Consumers Power Co
To:
Office of Nuclear Reactor Regulation
References
CENC-1256
Download: ML18347A531 (70)
v • d • e


Text

{{#Wiki_filter:* File cy,, consumers Power company General Offices: 212 West Michigan Avenue, Jackson, Michigan 49201

  • Area Code 517 788-0550 March l, l9'i6 Director of Nuclear Reactor Regulation US Nuclear Regulatory Commission Washington, DC 20555
  • DOCKET 50-255, LICENCE DPR-20 PALISADES PLANT -

TUBE BURST AND LEAKAGE TEST REPORT Our letter of January 30, 1976 proposed Technical Specifications changes re-lating to steam generator tube plugging criteria.for the Palisades Plant. In that letter, we indicated that the Nuclear Steam Supply System Vendor was con-ducting a testing program and analysis relative to acceptable steam generator tube leakage. On February 26, 1976 we presented the results of the" testi.ng program and analysis to members of yolir staff. This letter transmits the re-port, "Tube Burst and Leakage Test (Palisades)", CENC-1256, which describes the testing program and* analysis. As discussed in the February 26, 1976 meeting, we have concluded that our January 30, 1976 Technical Specifications request with respect to allowable primary to secondary leakage should be amended. We expect to submit this amendment by March 15, 1976. David A. Bixel Assistant Nuclear Licensi.ng Administrator CC: JGKepper, USNRC ):::;

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60-s2-¢ ~ecrJ dlf( ~...-/-7~ TUBE BURST AND LEAKAGE TEST (PALISADES) CENC-1256 J. K. Hayes Lab Supervisor February 1976 Components Engineering Test Laboratory Chattanooga, Tennessee CETL-2-76(Rl)

DISTRIBUTION SHEET Mr. P. Anderson Mr. J. c. Campbell Mr. T. Halvorsen Mr. w. Heilker Mr

  • F. Hill (5)

Mr. D. Sher Corporate Library - Windsor Components Engineering Test Lab (9)

ABSTRACT This report documents the leak rate and burst tests performed on virgin, wasted, and wasted (with EDM cracks) tube speciments. All tube specimens were acquired from one steam generator tube of Inconel 600 material having a yield strength of 40,000 psi, a tensile strength of 91,000 psi and an elongation of 49% in two inches. The tube was nominally.750" O.D. X.048" average wall thickness. A total of 27 tube specimens were prepared for test purposes. Selected tubes were machined to simulate uniform wastage (nominal 64% of tube wall removed) as shown on C-E Dwg. D-62676-003 which is located in this section of the report. Approximately 1/2 of the tube specimens were prepared with cracks. The cracks were 1/4" in length machined parallel to the axis of the tubes. The cracks were machined using an Electric Discharge Machine (EDM). A 1/4" X.005" silver solder electrode was used. Since the electrode is always discharging as it progresses through the metal this provides a larger crack opening at the top than at the bottom. In some instances a variation in crack width also occurred. The crack width ranged from.007" to a maximum of.014" at the bottom of the crack. All crack measurements are documented in this report. A brief discussion of the results of the various tests is provided below: Burst Tests - Both simulated wasted and virgin tubes were ruptured under water pressure at room temperature conditions. Two of the wasted tubes were subjected to bending load such as to produce a maximum stress in the outer fiber equal to 35 ksi. The burst test results are provided in Table 1 of this section of the report. Based on this data (2 tube samples of each type) it may be concluded that the average burst pressure is reduced approximately as follows compared to the virgin specimen for the various conditions: Spec. Config. No. 1 2 3 4 Description 1/2" wasted all around (.017" MWT) 5/16" wasted all around with bending load (.017" MWT) 5/16" wasted all around (.017" MWT) 1/2" long dished wastage, one side (.017" MWT) Ratio of Specimen Burst Pressure To Virgin Tube Burst Pressure 65% 68% 69% 63%

Based on the preceding, each condition produces approximately the same drop in burst pressure with the 1/2" long wasted condition being slightly more severe. In inspecting the bursted test specimens the following types of failures were noted: Spec. Config. No. 1 2,3 4 6 (Virgin Tube) Type of Failure Bulged in wasted region. Crack occurred transverse to tube axis for approximately 1/3 of circumference. Tube failed by complete circumferential seperation at wastage region. Bulging and rupture of tube in local region of wastage. Bulging of entire tube occurred. O.D. of tube increased from.75" to. .9". At failure tube split parallel to axis of tube. Leak Tests - Both virgin and wasted tubes with EDM cracks (essentially 1/4" long) were leak tested with pressurized water under room temperature conditions. As noted earlier the width of the cracks in the various specimens varied to some extent at the bottom of the crack. Two to three specimens of each configuration were leak tested. Plots of the leak rate (GPM) versus pressure (psig) are contained in this report for each specimen. Two dif fer~nt piping arrangements were used with an MTS servo controlled system and an oil to water intensifier. The maximum pumping rate with one arrangement was approximately 4 to 5 gpm and with the revised piping arrangement 14 gpm. This test phase was terminated when the maximum pressure was attained that could be achieved by the. hydraulic system. A summary data sheet showing the specimen number, crack width, leak rate at two pressures, maximum differential pressure imposed on the tube,.and final appearance of specimen is shown in Table 2 of this section of the report. Figure 1 contained in this section of the report provides a plot of average flow rate versus pressure for each test configuration. In reviewing this plot the following conclusions may be reached: (A) At 1200 psig pressure differential the leak rate did not exceed 3 gpm for all test configurations. (B) From the plots it may be concluded that local bulging of the tubes, resulting in greater increase in crack width opening, is starting to occur where the plots start deviating from a straight line.

However, it should be noted that this is not indicative of inuninent tube failure as is apparent in the subsequent section

  • Maximum Differential Pressure Test - Since the capacity of the hydraulic system could.not exceed approximately 14 gpm it was considered desirable to utilize a system which could impose a higher differential pressure on the specimens ::.ontaining EDM cracks.

The piping arrangment shown on C-E Dwg. C-62676-004 was subsequently assembled. With this arrangement it was possible to pressurize both the I.D. and 0.D. of the tube to the same pressure and then quickly vent the external pressure such as to achieve a high differential pressure. Sufficient volume existed on the primary side of the tube to allow flow through the crack for a very short interval. It was decided to pressurize the specimens to a* value not exceeding 5000 psig prior to the secondary side venting operation. Differential pressures of approximately 4600 to 4800 psig were subsequently measured using a differential pressure cell and a strip chart recorder. Measurements were made of the maximum crack opening at the end of the test and photographs were made. This test data is summarized in Table 2 in this section of the report and the photographs are included in the appendix. In reviewing the information contained in Table 2 the following conclusions may be reached regarding the condition of the cracked tubes after being subjected to a pressure differential of 4600 to 4800 psig: (A) Some bulging of the tubes occurred in the wasted region in the vicinity of the cracks * (B) The *cracks increased in width at the center but generally did not increase in length. When the crack did increase in length it did not exceed 1/16 inch at each end of crack. The crack openings varied as follows: Config. No. 1 2 3 4 1/2" long wasted all around 5/16" long wasted all around 5/16" long wasted all around 1/2" long dished wasted one side of tube Maximum Crack Width Opening .050" to.* 085" (Max. pressure 4700 psig)

  • 025" to
  • 02 7" *

(Bending load & pressure, maximum pressure of 4000 psig) .044" to.059" (Max. pressure of 4800 psig) .032" (Max. pressure of 4900 psig)

e 9 (C) Based on (A) and (B) it may be concluded that with this type wastage and size cracks catastrophic failure of the tubes will not occur at pressure differentials up to 4800 psig under the conditions tested. The crack width openings will only increase to some extent resulting in increased flow rates. Prepared by:

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/ / J. K. Hayes Task Investigator (Lab Supervisor) Components Engineering Test Laboratory Accepted by: 4/:7#!/. F. P. Hill, Jr. Manager Analytical Engineering Department Approved by: T ~~r al~~tf.-~J-, / 9 \\~ ~ T. Halvorsen Manager Engineering Services

A I 7 e !I 2 A c

  • 031 1 t.001* REMOl/A.L O'F '11""1.:*

(.011' W.TliRl>.I.. U:FT) TE.ST COt..IF'IG\\J~A.TION 1-10. I s 'SIPE.C.IMElr.\\S WITH. C.AAC.1<. '!. 9PE.cu.,,a.1s \\IJITHOUT C.RAGK 1 .03.1. s:.oo\\* RE.MOVA\\. o~..VALL* (.,o\\i* M.. T.. t:U'- ~~") TEST CONF'IGURA.TI0"1 "10. '!. 3 "bPEC.IM~..iCJ. WITH C.R.... C.toe. S <g.PS.C.lh1EN.S. VrllTMOUT t.P.AC.W. TEST CON!=IG.URll.TI0'-1 N0.5 S ~P£C.\\"'*N~ B c .'f!510.D... 04rf 111<:0NS1..TUH°" D D I! I G H )* 1 ---+*:+-------~=~-------~~---~~=-\\_~~=~]* *?::::~~- i.. ftl' .o~,* '!.001* RKMO'IAL OF' WAU.. * (..o)l1' M>.T""""'- l..El'T~ TE'E>T CONl"IGURll.TION NO.t 3,;pf:C.IMEo.15 'tllnl C.R.. C.I( S SP£C.l.,ENS W'1\\.\\0UT CRACK 1*11.Al:I. os1'~.0011 REMO~..... OF~ (.011' ~~...._ LS") TF.ST CONF'IGURl>.TION NO. 4 ~ "PU.IME>I'!> WIT>! CRACK 'I. SPE<.!ME.llS WITMOllT CR.l\\l'K TEST COt.IF'IGURll.TION NO." 'I. QP£C.\\M£WS. I F G COlllSUSTION INQlht:IClllll'ltO-PllC. W*l'lDSC*. CCN.._ &OOOl8-10*1*1-.oo.. c11- "HO 90.....,,,,. ""' ""*O***""-

  • -....,_ OP O****-* -.......
    • 1... 11*c1......,......... >D*o*""'

ft at*IJ.... *Y *°......:ooot'.. 1 ............. 0-626 76-003-0 I H 7 II

Specimen No. 1-1 3-1

  • 1-2
  • 2-2 4-3 C\\-1 3-4 4-4 1-6 2-6 Comments:

Table 1 Tube Burst Tests (Palisades) Tube Size - .750"0.D. X.048"W.T., Material - Inconel 600 Configuration Brief Description Burst Pressure No. of Specimen 1/2" long wastage 1 all around 7400 1/2" long wastage 1 all around 7450 5/16" long wastage 2 all around

  • 7700 5/16" long wastage 2

all around

  • 79nn 5/16" long wastage 3

all around 7800 5/16" long wastage ".l ~1, ~..-~.. ~ri ~nnn 1/2" long dished I 4 one side 7nnn wastal!e 1/2" long dished I l 4 wastal!e ono !':inP f 7i;n*n 6 I Virl!in Tuhe 11_qoo 6 Virl!in Tube i 11

  • mo f

i ~

  • Bending load applied such as to eroduce bending stress eg,ual to 35 ksi.~~

See C-E Drawing C-62676-006 for test apearatus.

e.

Table 2. Summary Sheet for Specimens With EDM Cracks Spec ~***----*- Description Crack Width Leak Rate Max. Final No. Config. of Wastage at.Bottom Pressure GPM Pressure Description Differential of Specimen (PSIG) 1/2" long wastage 4 1 all around .007" 1400 1.8 2400 3.3 4700 Crack ooened to.085 11 at the center. 1/2" long wastage l ' 5 1 all around

  • 008" 1400 2.6 to*~

2400 5.0 +370n

  • Crack onened to.050" I

.010" at the center. I I 1/2" long w13.stage I I 6 1 all around y

  • 008" 1400 "1.8 t

i i to 3560 7.2 4700 Crack opened to.072" j I l .009" at the center. i 1 I ! ... I I ~/16" long wastage i .3

  • 2 all around i

.007" 1400 2.0 t* I I to 2400 3.0 i t i .012 11 I .027" l ~ 4000 6.6 4000 I Crack opened to I I t J at the center. i I i i

  • I l

I I 5/16" long wastage t 3. i 4 l *2 all around

~

.012n 1400 f

  • .2 l

t f 2400 f 4. 5 to I I I a. 3 I

  • 013" 3950 3950 Crack opened to.025"

. I i I at the center

  • I

) I I .mm.en ts:

  • These SEecimens tested with bending load such as to Eroduce maximum stress
  • equal to yield stress at outer fiber.

+ Solenoid yalye failed. This was last specimen tested.

. e Table 2. Summary Sheet for Specimens With EDM Cracks -.~l?.~~c:_** ___ Description Crack Width. Leak Rate Max

  • Final No. Config.

of Wastage at Bottom Pressure GPM Pressure Description Differential of Specimen (PSIG) 5/16 11 long was ta*ge 1 3 all. around .010" 1400 3.1 to 2400 4.8 4800 Crack onened t:o

  • Ol.r.l.r."

.01111 at t-h.o l'e>nf-pl". I 5/16 11 long wastage ' I 2 3 all around i .011" 1t.nn t... n 1 * *-- to ?t.nn " " t...Rnn ('.,...,,.t,. ~~~~~.:! t-n n <:,/,II

  • 014"

<>f-f"hP rpnf-.or I I I 5/16 11 long wastage i i 3 3 all around .008" 1400

2. 1 I

i to 2260 4.1 +t...1nn r.r<>rlr nn.onP*n t-n O'lQ" I I f at:. t:he> l'C>nf-Al". I .009" I j I I I 5/16 11 long wastage .~ 1 4 all around .007 11 1400 2;0 I i to 2400

2. 91 I

I I I l .008"

  • 1 l
4. 2 I
  • 1 I

3500 !l2QQ I Ci:ac.k opened to 032 11 I I I l I i ~ at t-hp_ rpnt-pr I i I I I I I I I i 5/16 11 long wastage , 2. 2 t I i I 2 4 all around ~ .008" 1400 I I '.. t 2400 3.0 I I is. 0 I 3450 4qnn r.r:il'k nnPnPrl f"n 01? 11 . I I

If" f"ht::. l'Pnf°Pl" I

differential pressure device.

Table 2. Summary Sheet for Specimens With EDM Cracks Spec Description Crack Width Leak Rate Max. Final

        • H*--*-

No. Config. of Wastage at Bottom Pressure GPM Pressure Description Differential of Specimen (PSIG) 1 5 Virgin .007" 1400 2.7 to 3500 4.8 35nn .009" I 2 I 5 Virgin* .008" 1400 2.15 3500 I i t to 3500 3.7 I .009-" I I I 3 I 5 I i . 00711 I it..nn

i. n'l,

I i I ~~QQ ; . I l Vpry slight bulging in I to .3, 5 5100 I .( I .* 009" vicinitv of crar-lc. Nn I i aonarPT'\\1: C".h<>nQ"p in I I l I I l crack dimPn !::: *inn!::: I i ! I I l f, l I I l I

  • I I

I I I I I I I . I I I I I I I ' I i . I I I i I I. I I

1 ._,.. ---,. -*-c--' / l.. -*- I 400 800 2800 3200 3600 4000 Pressure - Psig Figure 1.

  • Average Flow Rate Vs. Pressure (Te~t Configura~ions 1 through 5)

8 7 6 4 3 2 1 B c D E lt&VIAD F\\.. ooR \\..E.VEL. F MITROGEN 'i!;O"fiL.E G ~ITROC.E~ RJ:.C:iUL.P..TOR TO MT$. SER.'40 C.Ot-ITR.O\\. S'f'<:.TEM ---~-------------- -------""-'-----------------------------------...J.._-L--- A 'lol..... TER \\..'C.VEI.. C.O~iR.OL. 'llA.L.VE B t 50\\..El>IOl'O 'l,_1..VE. TO f>RESt;,URE TRll.wS.CUC.ER. '~ 1 Sc.H l~O PIPE TE.ST PIT . Pl?ING:. ~BRP..~~t:N\\t..\\-SI TC) SIMUL~IE ST~A.M -~"°E:i\\1\\;.B,~'tc5R. M~\\\\-1 C:,TE.~M Llt-lE Fj!t.\\LURE (C.OLD CO\\-lOITIC\\-lS Ol'JL'i FOR TEST) c D I E TO PRESSURE T'R.11.~SOUC.ER. 4'-1 -- ~._ 1*~ 1' IE.E: (.?.,000 -#) Pl 'llASTED Tl.l~'E.':> 'l<lill C.Rll.C.KS lll.~~~ 1..EM ,-o;;;c:,T<:.) ..,,. P~L~S/l..\\DES TE.ST PROC:.AAM 8CAU -...I DAT"K a.....,. *., H.. \\JA.RWELL CMt:c*&o** T*ACl:DeY COMP. CODS THI* D*A..,"0 1e T"C ~.-TY °' COM*UST10N !:NQIN'rll'"l,..c; INC. WINDSO... COHN. ANO I*..oT TO *11: *l:P'9"00UCl:D 04' U91:D TO PUllOfl8M ANT IMPOIUll a TION POiit MAKINO M D*AWIN08 Otl....... lltATU8 IUCl:ll"'T WM&*t: '1ltOVIDSD POtl

  • T AG*t:IUtl""' wrn4.... ID CClff'AllT DllAWI- -*C-62676-004-0 G

H 8 7 5 4 2

CONTENTS. ABSTRACT 1.0 PURPOSE 2.0 OBJECTIVES

3.0 DESCRIPTION

OF TEST SPECIMENS 4.0 DISCUSSION OF TEST RESULTS (A) Burst Test Data (B) Leak Rate Test Data (C) Maximum Pressure Differential Test Data

5.0 DESCRIPTION

OF TEST FACILITY (A) Burst and Leak Rate Test Equipment (B) Maximum Pressure Differential Test

6.0 CONCLUSION

S APPENDICES Appendix A - Drawings of Test Specimens and Test Apparatus Appendix B - Tables of "As Built" Dimension of Specimens, Cracks a~d Test Data Appendix C - Plots of Test Data ~ppendix D - Photographs of Specimens Appendix E - Mill Test Report for Tubing Appendix F - Engineering Request for Test Program

1.0 PURPOSE The general problem is that of tube degradation and the allowable pressures for particular degradations. The type degradations to be investigated are: (A) Uniform wastage - Nominal tube size.750" O.D. X.048" wall* thickness. Wastage shall be such as to reduce wall thickness to.017 inches. (B) Longitudinal through wall cracks superposed upon the wastage

  • 1-1

2.0 OBJECTIVES The objectives of the tests are as follows: (A) Determine burst pressures at room temperature for tubes with no deg.radation and with simulated wastage degradation alone. (B) Determine leak rates vs. pressure for tubes wit~ no wastage degradation and. tµrough-the-wall cracks; and for tubes with wastage and cracks. (C) With tubes containing simulated wastage and cracks impose maximum differential pressure feasible (approximately 5,000 psi) and identify physical changes in the tube at the crack location. 2-1

3.0 DESCRIPTION OF T~ SPECIMENS All tubular test specimens. were cut from one steam generator tube to ensure there would be no variation in material properties. The mill test report for this tubing is contained in Appendix E. The fabrication drawing used for preparing the test specimens is provided in Appendix A. Six seperate specimen configurations are identified with the desired simulated wastage shown for each specimen. The quantity of specimens with and without EDM cracks are also shown. Throughout the test report the specimens are identified by two numbers. The first number is the specimen number in a particular test configuration. The second number identifies the test configuration. The test plan for the specimens is provided in Table lA of Appendix B. The "as built" dimensions of the specimens are shown in Table 3 located in Appendix B. The machined dimensions of the EDM (Electric Discharge Machine) cracks are also provided in Table 4 in Appendix B. The cracks were machined with an Electric Discharge Machine (EDM) using a.005" silver solder electrode. Since.the electrode is always discharging as it progresses through the metal this provides a larger crack opening at this top than at the bottom. In some instances a variation in crack width also occurred. The crack width ranged from.007" to a maximum of.014" at the bottom of the crack as shown in Table 4

  • 3-1
  • e 4.0 DISCUSSION OF TEST RESULTS Burst Tests - Both simulated wasted and virgin tubes were,ruptured under water pressure at room temperature conditions.

Two of the wasted tubes were subjected to bending load such as to produce a maximum stress in the outer fiber equal to 35 ksi. The burst test results are provided in Table 1 of Appendix B. Based on this data (average of* two specimens) it niay be concluded that the average burst pressure is reduced approximately as follows compared to the virgin specimen for the various conditions: Ratio of Specimen Burst Pressure Spec. Config. No. 1 2 3 4 Description To Virgin* Tube Burst Pressure 1/2" wasted all 65% around (. 017" MWT) 5/16" wasted all 68% around with bending load. (. 017" MWT) 5/16" wasted all around (. 017" MWT) 1/2" long dished

  • wa~tage, one side

(. 017" MWT) 69%. 63% Based on the preceding, each condition produces approximately the same drop in burst pressure with the 1/2" long wasted condition being slightly more severe. In inspecting the bursted test specimens the following types of failures were noted: Spec. Config. No. 1 2,3 4 6 (Virgin Spec.) Type of Failure Bulged in wasted region. Crack occurred transverse to tube axis for approximately 1/2 of circumference. Tube failed by complete seperation at wastage region. Bulging and rupture of tube in local region of wastage. Bulging of entire tube occurred. 0.D. of tube increased from.75" to .9" *. At failure tube split parallel to axis of tube.

Photographs of the following specimens after the burst test are contained in Appendix D: Photo Spec. No. No. DescriEtion 1,2 1-1 1/2" wasted all around 3 3-1 5/16" wasted all around 18

  • 1-2 5/16" wasted all around 20 4-3 5/16" wasted all around 31,32 3-4 1/2" dished wastage, one side 33,34 4-4 1/2" dished wastage, one side 40,41 1-6 Virgin tube 42,43 2-6 Virgin tube
  • "Burst Test with bending Leak Rate Tests - Both virgin and wasted tubes with EDM cracks (essentially 1/4" long) were leak tested with pressurized water under room temperature conditions.

As noted earlier the width of the cracks in the various specimens varied to some extent at the bottom of the crack. See Table 4 in AppendixB for d'etail dimensions. Two to three specimens of each configuration were leak teste.d. Plots of the leak rate (GPM) versus pressure (psig) are contained in this report for each specimen. These plots are identified as Figures 1 through 6 and are contained in Appendix C. Figure 1 is a plot of the average flow rate versus pressure. Tabular data of all leak rate tests is shown in Table 5 in Appendix B. The leak rate data for the 1/2" long wasted (all around) tubes is shown in Figure 2. It appears that crack widening is starting to occur at 2400 psig since one of the curves starts to deviate from a straight line. In Figure 3 it can be readily seen that the bending load (crack on neutral axis) did slightly increase the leak rate for the 5/16" wasted (all around) specimens. A good comparison between crack on the neutral axis and compressive side was*not feasible.since the crack width varied between the two specimens. Crack widening of the tubing apparently occurred at: around 3200 psig. In Figure 4 the leak rates for the 5/16" wasted (all around) tubes vary. _as would be expected in that the specimen with the largest crack width had the largest leak rate. Apparently, crack widening of this tubing started occurring around 2000 psig

  • 4-2

In Figure 5 crack widening of the 1/4" long dished (one side only) samples started to occur at around 2800 psig. In Figure 6 it is apparent that no appreciable 'changes in the crack width occurred in the virgin tubes up to a pressure of 3600 psig. Two different piping arrangements were used with an MTS servo controlled system and an oil to water intensifier. The maximum pumping rate with the first arrangemen_t was approximately 4 to 5 gpm and with the revised piping arrangement 14 gpm. This test phase was terminated when the maximum pressure was attained* that could be achieved by the hydraulic system. A summary data. sheet showing the specimen number, crack width, leak rate at two pressure, maximum differential pressure imposed on the tube, and final appearance of specimen is shown in Table 2 in Appendix B. Figure 1 contained in Appendix C provides a plot of average flow rate versus pressure for each test configuration. In reviewing this plot the following conclusions may be reached: (A) At 1200 psig pressure differential the leak rate did not exceed 3 gpm for all test configurations. (B) From the plots it may be concluded that' local crack widening resulting in greater increase in crack opening, is starting to occur where the plots start deviating from a straight line.

However, it should be noted that this is not indicative of imminent tube failure as is apparent in the subsequent section.

Maximum Differential Pressure Test - Since the capacity of the hydraulic; system could not exceed approximately 14 gpm it was considered desirable to utilize a system which could impose a higher differential pressure on the specimens containing EDM cracks. The test arrangement discussed in Section 5.0 was utilized. With this arrangement it was possible to pressurize both the I.D. and O.D. of the tube to the same pressure and then quickly vent the external pressure such as to achieve a high differential pressure. Sufficient volume existed on the primary side of the tube to allow flow through the crack for a very short interval. It was decided to pressurize the specimens to a value not exceeding 5000 psig prior to the secondary side venting op~ration. Differential pressures of approximately 4600 to 4800 psig were subsequently measured using a differential pressure cell and a strip chart recorder. Measurements were made of the maximum crack opening at the end of the test and photographs were made. This test data is summarized in Table 2 of Appendix B. Photographs of the test specimens are included in Appendix D. 4-3

In reviewing the information contained in Table 2 the following conclusions may be reached regarding the condition of the cracked tubes after being subjected to a pressure differential of 3700 to 4900 psig: (A) Some local puckering of the tubes occurred in the wasted region in the vicinity of the cracks in range of 3700 to 4900 psig for 1/2" long wasted (all around) tubes. (B) Local puckering was barely visible for the 5/16" long wasted tubes up to 4000 psig. More identifiable puckering was evident after pressurization from 4000 to 5000 psig. However, this puckering was less than for the 1/2" long wasted (all around) tubes. (C) The cracks increased in width at the center but generally did not increase in length. When the crack did increase in length it did not exceed 1/16 inch at each end of crack. The crack openings varied as follows: Config. No. 1 2 3 4 l/~' long wasted all around 5/16" long wasted all around 5/16" long wasted all around 1/2" long dished

  • wasted one side of tube Maximum Crack Width Opening

.050" t().085" (Max. pressure 4700 psig) .025" to.027" (Bending load & pressure, maximum pressure of 4000 psig) .044" to ~054" (Max. pressure of 4800 psig) .032" (Max. pressure of 4900 psig) (D) Based on (A), (B), and (C) above it may be concluded that with this type wastage and size cracks catastrophic failure of the tubes will not occur at pressure differentials up to 4800 psig under the conditions tested. The crack opening (width) will only increase to some extent resulting in increased flow rates

  • 4-4

'.. ~....

5.0 DESCRIPTION

OF Tl FACILITY (A) Burst and Leak Rate Test Equipment 1 Equipment for burst and leak rate test consisted of an MTS closed loop hydraulic servo control system with a hydraulic power supply of 35 gpm at 3000 psi as shown on C-E Dwg. C-62676-005 shown in Appendix A. A pressure transducer near the test specimen links the MTS system controls to the desired pressure at the test specimen. An oil to water intensifier is used to provide water at elevated pressures for testing of the specimens. The intensifier was used in two different arrangements, one provided higher pressures, required for burst testing, the other arrangement provided a greater flow rate (but lower maximum pressure) used for testing of specimens requiring the higher flow rates. The intensifier was filled with city water for each test. Water flow was limited to approximately 3 gpm for the high pressure arrangement and approximately 14 gpm for the high flow rate arrangement. For the leak rate tests a pipe to tube adapter and an outer pipe over the tube was used to contain and collect the water as shown on C-E Dwg. C-62676-005. After the desired pressure was achieved for each leak rate test the water was collected for a specific time interval (stop watch used) and then the water weighed and the flow rate calculated, tabulated in Table 5 in Appendix B and plotted. For the leak rate tests in which bending was employ'ed the test arrangement shown on C-E Dwg. *c-62676-006 was utilized. A copy of the drawing is 'contained in Appendix A. The leaking water was .I trapped in a plastic tee with o-ring seals in the vicinity of the crack. The water leaking out of the branch of the tee was then coll.ected and weighed as discussed previously. Prior. to the leak rate test each wasted specimen was loaded t9 produce a maximum bending stress at the outer fiber of the wasted section of 35 ksi. All burst tests were performed with the specimens in the test pit as shown on C-E Dwgs. C-62676-005 and c~62676-006. The wasted specimens were loaded in the same manner in the test pit for the burst tests. (B) Maximum Pressure Differential Test As noted earlier the hydraulic system had limited capacity. It was therefore decided that to achieve the desired high pressure differential that the piping system shown on C-E Dwg. C-62676-004 should be assembled. With the arrangement it was possible to fill the primary and secondary side of the tubing with water and maintain an air reservoir of approximately the same volume over the water on the primary side. To achieve the desired pressure the 2" pipe_ was first pressurized with nitrogen to 2500.. psig and then the MTS 5-1

  • system used~ raise the pressure to 5000 ps. A differential pressure transducer was piped to connections 1 and 2 shown on C-E Dwg. C-62676-004.A Heise gag~ was used to monitor the total pressure.

A strip chart recorder was also used to record the differential pressure reading versus time. When the desired test pressure was reached (generally 5000 psig) the strip chart recorder was activated at 125 mm/minute and the solenoid valve energized. This very quickly vented the secondary pressure resulting in a pressure differential of 4600 to 4800 psig (per strip chart). The pressure differential then dropped in a few seconds as the reserve water flowed through the leak. This system worked very satisfactorily

  • 5-2
6. 0 CON CL US IONS The burst pressure of tubes with no through wall cracks and with 64%

through wall wastage (remaining wall thickness =.017") is approximately 63% to 69% of that for a virgin tube, the smallest burst press4re measured at room temperature being 7000 psi. This would correspond to a burst pressure of approximately 6150 psi at 600°F.. This represents a margin against bursting of 6150/1380 = 4.46 for the specified operating conditions. The reinforcing influence of the unwasted portions of. the tube accounts for the difference from the 4140 psi calculated burst pressure for the 64% wasted tube. The tubes with 1/4 inch long machined through wall cracks at the 64% wasted locations exhibited leak rates between 2 and 3.5 gallons per minute at 1380 psi, with the leak rates increasing to between 3 and 5.5 gallons per minute at 2500 psi. The "bulge" pressure of these tubes was determined to be in the range 4600 psi to 4800 psi at which time the cracks had not propagated in the longitudinal direction but had widened considerably. This indicates that the tubes with through wall cracks will leak considerably beyond the leak detection levels at 1380 psi differential pressure, and that the leak rates at 2500 psi differential pressure will increase to only approximately twice those at 1380 psi. The margin to the bulge pressure is up to approximately 4700 psi. At 609°F the bulge pressure could be expected to be approximately 4100 psi. Thus the leakage rates above the leak detection levels at operating pressures with a bulge pressure of more than 4000 psi indicate the leaks through cracks to be detected during operation with a margin against bulging and gross leakage up to in excess of 4000 psi. 6-1

APPENDIX A Drawings of Test Specimens And Test Apparatus

8 e !I 4 3 2 A B c \\0. t~' i------*--*-----*----- -<f---- ------------ - *-. ED"\\ C.R"-C.K (M1~ Wlt>TI\\) .03\\1'!:.001* RE:MO'.Jt...\\. 6~'-N,..U.. (.011" ~TE.RU~\\.. LEFT) TE.ST COt-.IFIG\\JRATICN \\.JO. I ~ SPECIME~ \\IJIT'°' CRA..C.~ 3 !SPE.CIME."-1.S \\IJIT~OU'T C.RACI<. ~,, 10_-~"~--- ----------*----- TE.ST C.ONFIGURATION N.O.:. 3 ~PEC.1M-.W.S Wl1'"H C.R.A.C.K 3, SP&C.\\ME.N5 WIT~OUT C.RA.C'f(. -*-1 i .75*0.D. 1'.04 1 u~c.oNEL TUS'E. -+["'::-=::-:~-::::=-=-~*::::.::=-=-:-= -=-=-=~;~;T~-~*~-=--=-=* -.=-~* =*=~=~-.* ---* -~3t-*l.J~~M~~i%~: EOM CAAC.K,,,r\\ L,* lMl>l Wlt>T>l)./.:_j 4 A TE.ST C.OlJFIG\\JRl>.TIOt.! N0.5 5 SP£.C.IMEN~ B \\ c D D E r------ ----.. ---* f- --+-- ~:*r I

  • -1 F

G H ,~11 '!.*' .. *----------- - ------ >v--- --.. --~=~ ~ --~-__ -___ : =-~_E'~*~---~] t -7;:~~£t ~~ EOM CRN:,.1( (Mii-i WIDTM) l,---.03\\" ~.00\\ 1 REMO\\/AL. OF WA.LL. (,ori' MA,T~Rl"-L \\..EFT) ~.... _ }"E.ST C.ONFIGURt>.TION NO. 2. 3 SPEC.IME.t..IS WlTH C.R~CJ( 3 SPECIMEN.S WIT\\.\\OUT CRA.C.K I s"*l' f--*--.. I 4 -~1 REF TF-ST C.ONFIG\\JRl>.TION NO. 4

2. Sl'IEC.\\ME,~ 'HITl-t CRACK

'2.. SPEC\\ME.~S W1THOU1" CRA.CK. lo" tl'

  • -------~----*-.

r -E-~-=*--~---=-* ~~* --=*:~=--=-~-~~~' __ ____ _ ____ =-,...-=:J-_-_->-1&-"~1=s'~o.~o.=*~*="4~s~'- =-=-=-=..d 1\\J.C.0\\JE.l.. TUBE E TEST C.ONFIGURl>.TIDN !JO. i;. 'Z. ~PEC.\\MEt-l5t F G -(P"L"S"IDES TE.ST PROGRMA) ~. D... - .... M.\\IAA.Nl.L..\\. TltAo;Ulrt ,.,.ISD*AWINOISTM*~ COMaUSTION llNOINSUllNQ, INC. -.cc...

  • - IS.aT 'JO *& *CNOD\\IC&O O*

USG TO N*-...... *owo-*no. POOOMA*-o.O**-S-U9A

    • 1usuc1P1'-1111"°"1om*011 SYAOSS1Urt:lf1'*1YMSAID-A*Y

........ "°"D-626 76-003-0 I H B 7 5 4 3 2

A e 7 6 !5 4 3 2 A B HVIHD F"LOOR LE.VEL 'Z.d SC\\.\\ 11;.0 PtPE. W""-IER L'E.\\/E.L C.O\\o.lTROL. \\/~1...VE. B c D E F G i..l1*n~o<aei..1 Ri:.C.llLP..TOR H TO MIC:. SEl~..JO C.ONTR.OL S~<:.'iE.M i' SOLENOlt> 'IAL'IE. TO PRESSURE: TR.ta."'1St>IJC.E.R :f-z. !. t SC.I-\\ 1'-0 PIPE. TE.ST PIT P\\~ING A..RRt>-.~~EME\\..lT TO SIMULA.TE STEA.M G.Et>.lER.A.TDR MA.\\\\..! STE.Mk Lll-JE l='~\\L\\JR.E (C.OLD. COND\\TIO\\..lS Ot-!L'( \\='OR. TEST) c D E F 1" 14 SC.\\.\\ llDO PIPE TO PRE.C:.SURE T'R.P.\\..ISOUC.ER. " Pl \\'JASTED T\\.lSE'=> l,\\J\\Ti-\\ C.RP..C.KS (.1>.l=iER. LE..._¥. 'TE-ST"') POR P~LA.SA.IDES TE.ST PROGRM.A SCALI: DATE .. !)

  • DRAWNOY 11. V"'Ri.IELL CH*CK*DOY TIIACED*Y C-15 CCM... CODI:
  • ~vm THl8 DRAWING IS THI: ~ElfTY OP' COM*USTION ENGINEERING, INC.

WINDSOR. CONN. ANO 18 NOT TO a11: ltEP'ttOOUCl:D. Olt UDIEO TO l'UltNISH ANY INP'OIUllATION l'OR MAKING Of' DRAWINGS OR A,,,,.A. ltATU8 llXCl:PT WHltRI: "'°Y1DKD ll'OR ay AORl:l:MSNT WITH MID COlll"ANT. DilAWINCI -*C-6267 04-0 G H 8 7 5 4 2

8 7 6 !5 4 3 2 A I~ 'SC.I-I 4o PIPE. c E\\£~TA.IC:. COMTltOL Llt.lE '!IS. GAii H't'DR.1'ULIC POv.IE.11. 'SU~" VlllC.li.l A~t> ~C:;TE\\:I . TUBE SPECIMENS WI~ E.t>~ CR~C.K. ARR/),\\l.IGE.ME.t--IT ~OR LE~\\<. TESTS A B c D ~E.R>JO CONTROL ~VES D E 0\\\\.. \\0 W~TER INTEWSll='tER .1 /TO PRESSURE /V TRMlSDUCER. "\\~C:.IW Nolt> Sl~ULATED G WM.TED TUl!iES (NO E.t>M CRl>.C.l<S) Tl:.~T PIT H ARRA."1GEME\\-1T FOR B\\J~ST TESTS E F TEST P~O~Rfl..M DltA-llT "-\\111<11.NELI.. nu.cm.., DA1S

  • 5*'7(.

CM*c:KDllY 11tl9 DRAWINCI 18 THIE ~llT'Y OP' COMSUSTION IENGINDlllNG. INC. WINDSOR. CONN. AND.. NOT TO a ~ucm. Oft ~ TD PU....... ANY INPOMllATION POii -...mMCI OI' DRAWINGa O" AWA. llATUll UcmP'T WMD& P'ltOVIDED l'Ofl 9Y MRSDllaNT WrT'M MID COMPANY. DllAWIMI --C-626J6-005~ 0 G H 8 7 6 5 4 2

8 7 6 4 3 2 A B RRVIAD TO M°"' ~'iOf:IAULIC. CONTR.eL S'(STEM c D E F"LOO~ LE"E.L "t-t-- r-----------------------------,----------*-**-l --****a WA.... TED TUBE ~-~"----- SPE.C.1N!ENS (~O !:.OM CRl>.CKS) l'..J (,,' (TO PRESSURE TRAIJS. OIJC.ER r:: ,. LL" 2

  • w'
.~

w-a* f'p,* 351000 PSI (Mf>::I..) iEST PIT L_ _______ -:~~~'-----*-------*- ARRAl\\IGEME.~T FOB, BIJRST TE.ST TO PRESSIJRr;, 'TRA'-ISOUCER.. i I . I~ ~ DETlo..IL l ~ lE-~) WASTED TUSE SPE.C.lt.1E"1 WIT\\-\\ EOM CRACK. ~l

  • 7S.4 J

'\\il 0'6 * ?>5 1000 PSI ( Ml-'i.,_; WASTED Afl.EA) A.RRt>.~C:>E.\\11\\E.~T FOR-LE.AK TE.STS A 8 D ~ -~ E F ?LA'S.TIC:. TEE: ,G OCAU: - DATI: 2

  • S-"'I(,.

DRAWN ** 1-1. \\JA~WEl-L CHIECl<IED ** TltACaDllY COMP. CODIE APPROVED THle DRAWING HI TMI: P~ElllTY OP COMBUSTION ENGINEERING. INC, WINDSOR. CONN. AND 18 NOT TO all: ltl:.. ltODUCl:D, OR U81ED TO PURNl8H ANY INPORMATION ,.OR MAKING OP' DRAWINGa Olt APPA. ltATUa OCll:" WMI:.. ~KO POtt

  • 'I' Mlltl:l:llSNT WITM MID CGIPANT.

DllAWI- --C-6267 06-0 G H 8 7 5

  • 4 2

_j

APPENDIX B Tables of "As Built" Dimension of Specimens, Crack, and Test Data /

e TABLE lA TEST PLAN FOR SPECIMENS Diff. Spec. Test Crack Leak Press. Burst No. Config. Description Req'd* Test Test Test 1-1 1 1/2" long wasted No No No Yes 2-1 1 all around Reserve 3-1 1 (10" long) No No No Yes 4-1 1 Yes Yes Yes No 5-1 1 Yes Yes Yes No 6-1 1 Reserve 1-2 2 5/16" long wasted No No No

  • Yes 2-2 2

all around No No No

  • Yes 3-2
  • 2 (18" long)

Yes Yes No No 4-2 2 Yes Yes No No 5-2 2 Reserve 6-2 2 Reserve 1-3 3 5/16" long wasted Yes Yes Yes No 2-3 3 all around Yes Yes Yes No 3-3 3 (10" long) Yes Yes Yes No 4-3 3 No No No Yes 5-3 3 No No No Yes 6-3 3 Reserve 1-4 4 l/i" dished Yes Yes Yes No 2-4 4 one side, only Yes Yes Yes No 3-4 4 (10" long) No No No Yes 4-4 4 No No No Yes 1-5 5 Virgin Yes Yes No No 2-5 5 Tube* Yes Yes No No 3-5 5 Yes Yes Yes No 1-6 6 Virgin No No No Yes 2-6 6 Tube No No No Yes 27 specimens (TOTAL) 1.

  • I I

I I Table 1 Tube Burst Tests (Palisades) Tube Size - .750"0.D. X.048"W.T., Material - Inconel 600 Specimen Configuration Brief Description Burst Pressure No. No. of Specimen 1/2" long wastage 1-1 1 all around 7400 1/2" long wastage 3-1 1 all around 7450 5/16 11 long _wastage

  • 1-2 2

all around

  • 77nn 5/16" long wastage
  • 2-2 2

. ~11 around

  • 7Qnn 5/16" long wastage 4-3 3

all around 7800 5/16 11 long wastage r t>-1.

1.

<>11 "'~~**~~. ~ s:innn 1/2 11 long dished ~ 3-4 4 wastal?e one. side I 1nnn i 1/2" long dished 1 4-4 4 wasta1?e onf> s;rlo t 1c;nn j. 1-6 6 Vir1?in Tube 11 qnn .i 2-6 6 Vir1?in Tube 11 -100 Comments: *Bending load applied such as to produce bending stress equal to 35 ksi.._ See C-E Drawing C-62676-006 for test apparatus.

Spec -**-*I..... -.. -;--**

o. ! Config.

4 1 I l Table 2. Suriunary Sheet for Specimens With EDM Cracks Description. of Wastage 1/2" long wastage all around Crack Width Leak Rate Max.

... ---i at Bottom Pressure GPM

.007" 1400 1.8 Pressure Differential (PSIG) I Final Description of Specimen I ---~-;-l-~~T'~----------+-------+__:;2_4~0-0~~3~.3:<...-!---"4~7~0~0 __ ~C~r~a~c~k~o~ne~n~ed=-t~o"-'.~0~8~5_ 11_ I at the center. I 5 1

  • 008" 1400

. _____ '..__ __ _._! ____.---------*+ ~"--~t~o~~---+--~2~4~0~0-~'~5~*~0_._l_~+~*1~7~*n""'-n-~~*~C~r~a~c~k~o~ue~n~e~d:........=t~o'-'-.~0~5~C_';_ 6 1 l I .010" I l/~' long wa~tage all around .008 1400 at the center. 1.8

  • ----------;----------...,~---t-o--~,

1-3_5_6_0-+,.... 7-.2---4-7_0_0 __.,_l_c_r_a_c_k_o_pe_n_e_d_t_o_._0_7_2_ 11_1 . ----.. *---------!-----------..i;.--_...;;;,__ __ ..,.._~...;;..;;-~~;_..;.--;..;....;;;..;;,_ __

....
~=,;_..;'-"-'=o.;;;;...--=--:;..._;'-'-'~-

. A'-: ___ ..... ~----0_0_9_"_-+-----.i-i--+--------;ll_a"""t_t_h_e_c_e_n_t_e_r_. _____ 1 ~ i J i I -*-~-*-~--,--~~-----------4------.\\.----.;--.11--------~------------- 3 1<2 1 5116 ~1i 0 ~;o:~~tage ~

  • 007

i400 L. 0 J ______i;_.). ---t

) ----1 1

~ to 1

  • 2.400 I 3. 0 f

,.. -----*~--------------------..,._---+---+--------,,'------------- i ~ .012 4000 I 6.6 J 4000 I Crack opened to.021 11

i.

} 1 ll 1, to I 2400 , 4. 5 _____...._ __ ___. ____________ -'i------+----..;_--t-------+----------,------ 6 l i 3950 ~ 8.3 i 3950 . 013" Crack opened to.025 11 at the center. Comments:~-*-=T=h=e~s=e-=s~p_e_c=i=m_e_n_s___..t_e_s_t_e.d......,,.w=i_t_h;_,;b_e_n_d_i_n~g._....l_o_a_d;..,,.;;;;s_u_c_h;....;;:;a_s ___ t_o_.p_r_o_d_u_c_e ___ m~a~x-i=m=u=m"--"s~t~r~e-s_s ___ _ equal to yield stress at outer fiber. + Solenoid yalve failed. This was last specimen tested.

  • .. :.,*1.:..
  • e e

Table 2. Summary Sheet for SEecimens With EDM Cracks Spec Description Crack Width Leak Rate Max. Final iii-0*:* 1 c~nfig-~ of Wastage at Bottom Pressure GPM b Pressure Description I if ferential of Specimen i I PSIG) 5/16" long wastage 1 3 all around . 010" 1400 3.1 to 2400 4.8 4800 Crack II ~- . 011 11 at 5/16" long wastage 2 3 all around .01 II to II

  • 014"

. l I I 5/16 11 '1 1 I long wastage r, l 2. 3 3 all around I .008" 1 1400 ~ j l I l to 2260 14.1 ! +4100 I Crack opened to.059" .I I ~ I l I I I i .009" l at the center. ~ I ii r . I I ~ s ~ I 5/16" long wastage l f 1 4 all around .007" ~ 1400 2;0 i I I l f, to 2400

12. 9

(

4. 5 i

\\ I . 008" I 3500 4900 } Crack opened to 0 32 11 I I i

1.

l ~ I at the center. 5/16" long wastage ~ ~ 2 4 all around ~

  • 008" 1400 I 2. 2 ~

~ I l i 2400 l 3.0 I I I 1 I 3450 r 5. o l 4900

Crack opened to 032"

-I ~ L f I at the center. j i I I Comments: + Shims 12laced in crack to increase pressure. Tube not test~d in ma:21:imum differential Eressure device.

e e Table 2. SummarI Sheet for S2ecimens With EDM Cracks .Spec Description Crack Width Leak Rate Max. Final -C:onfig. of Wastage at Bottom Pressure GPM Pressure Description Differential of Specimen (PSIG) 1 5 Virgin

  • 007" 1400 2.7 to 3500 4.8

~c;nn .009" I 2 I 5 Virgin* t i .008" 1400 12.15 3500 I to 3500

13. 7

.009" I I I I I f 11,nn 3 5 I _ nn11i h nc;, I f t-o ' t,.1.nn. t~ c; I c;1nn 'lT-- ~1 -{ nl...+- hn1 o-;,,o- ;,, rel I i I lvic~nitv-of c.ra,.k. Nn I I .009" I J I I. annaren t c.han era in I J I t I I *crack dima,,sinnC>. I l f I I I I j I f I I I I I i . I I i i I I I i .I f i i I i I I ' l i I t I I I l j l

  • I I

I I i i J t I Comments:

Specimen No. e e Table 3. "As Machined" Dimensions of Specimen* Configuration No. Length of Wasta e Nom. Tube O.D. Tube Wall Thickness (Nom.) i ! Wasted Area Min. O.D. Wasted Ai Min. Wall Thickness Comments: *All measurements are in inches. All SRecimens were ~hecked after

e e Table 4. "As Machined" Dimensions of Cracks Crack Opening (inches) .; ecimen Configuration Length Top Bottom No. No. of Crack Left Center Right Left Center Right 4-1 1 - 2 l)Q .009 .009 .009 .007 .007 .007 5-1 1 .244 .012 .013 .013 .009* .008 .010 6-1 1 .250 .012 .012 .012 .OOQ .ooq . noR t I l 3-2 2 .232 .013

  • 020 m c; 007 01?

n1 n j 4-2 2 .255 .014 .014 .019 .012

  • 01 ~

I

  • 01 ~

I f I 1-3 3 .253 _ nlli. _n1 ~ 01 ".t ni1 n11 n1 n l .j i 2-3 3 .265 .015 .015 .015 .014 .014 .013 ' I l I .008 3-3 3 .260 .013 .011 ~ .009 .009 .009 I t i I l i 1-4 4 .240 J .010 .010 .012 .008 .007 .007 r I t i r i 2-4 4 r .251 .015 l .013 .013 I .008 .008 .008 I ~ i l f i ~ I i I f I l 5 .274 .019 r .012 .013 .009 .007 t .007 1-5 l i l i 2-5 5 .253

  • 016

.015 * .015 .009 .008 l .008 l I f i j I 3-5 5 .250 .015 .015 ~ .015 .007 .008 .009 I t i i I I l j i I J t l I i I f ' '::-~*, -...._. - -. '.,-*, :f ::.. i-

I Specimen Brief Description No. of Specimen 1/2 11 long wasted 4-1 all around 1/2 11 long ~asted 5-1 all around Comments: ** Last ape.cjmen could not be achieved. Table 5 Tube Burst and Leakage Tests (Palisades) Leak Rate Crack Pressure GPM Opening (p.,.f,..\\ - 500 .43 1000 1.3 1500 1.8 1800 1.9 2000 2.7 2400 3.4 2600 4.2 ~ 2800 5.4 i 2900 I I I 7.2 l I 4700 I -- i **.085 11 I I ~ i \\i " ~ l c;nn 1.5 f 1000 2.2 ~ ~ I l f 15QQ 2.7 ~ i 1800 I 3.2 f I I t ~ 2nnn 3.6 f I 2200 I 3.9 I I I ( f 2400 4.6 ~ 'J l f I 2600 5.8 i 2Rno 7.5 f J

  • J

~

  • 3700

~ **.050" Sheet No. 1 ~... ' Bulge Tube Pressure Failure Pressure I I I I I I l r i I I I I l I tested Sclencid ~al:lz:e mal functfoned Higher Eressure / I

    • Measured at center of crack.

e e Sheet No. 2 Table 5 Tube Burst and Leakage Tests (Palisades~ Specimen Brief Description Leak Rate Crack Bulge Tube No. of Specimen Pressure GPM Opening Pressure Failure ('Ped ~) Pressure 1/2" long wastage 6-1 all around 200 0.5 400 0.8 I 600 1.1 \\ 800 1.3 1000 1.5 l 1200

1. 7 f

1400 1.8 t j 1600* 2.0 { I I ( 2.2 1800 f ' f i i 2000 2.3 I 2200 I 2.6 t 0 I '~ I 2400 2.7 ~ ~ I l J 2600 f 3.0 ~ I f i! j 2800 3.3 ~ ~ I 3000 I 4.0 I t I I ~ I ~ 3200 ~' 4.9 f , I. I 1 t I 3400 I 6.0 r 'I. j I t i 3560 7.2 ~ I i I I 3900 l --- i t *.044" i 4700 --- -t *.072" I. Comments:.* Measured at center of crack. This test performed in apparatus shown -..* on C-E Dwg. C-62676-004.

Specimen No. 3-2 Brief Description of Specimen Table 5 Tube Burst and Leakage Tests (Palisades) Leak Rate Crack Pressure GPM Opening ('Ped o) 5/16" long wastage all around t...no 0_1 - Sheet No. 3 Bulge Tube Pressure Failure Pressure Slnn

1. n 1\\Tn 1 ~..,,:i 1-1?nn 1 ?

Rnn 1 h I 1?nn 1.9 ' 1400 2.0 i I i 1 1600 2.2

  • ~

f 1900 2.4 l 2.6 ' 2100 i l f I j f

  • 2300 2.7 I

I i 2500 ! 3.0 f I I I ~ I i 2700 3.1 fi ~ ~ I l I* j ~ 2900 \\ 3.3 ~No visual g~owth of cradk i I 4 i I I 3.8 I

  • ~

3300 K I t f f I I I. 3500 G 4.0 I t I* f 3800 5.8 s ~ 1 f I 4000. I 6.6 J *.027" I l r, i I f I ? 5/16" long*wastage, I I t 4-2 all around:-- l Rnn 2.5

f.

f J I

i f

~ 1 ?nn I 2.9 ~ t f I I j I I 1 1600 3.$ I Comments:

  • Measured at center of crack.

Specimen No. 1-J -e-2-J Comments: Brief Description of Specimen 5/16" long all ~n11nrl T.7<>Q.f-<>ao 5/16" long all around wastaao Table 5 Tube Burst and Leakage Tests (Palisades) Leak Rate Crack Pressure GPM Opening ('Pt:i.-i 0' 2000 4.2 ?,400 u '\\ 12nn 'l n 3600 7.2 3950 I 8.3 j

  • .025

~ I i 700 2.1 1200 2.8 I. ~ + 1600 I 3.3 I I i 2000 ~ 3.6 f I t 2400 4.8 t I i '~ I ~ 4800 ~

    • .044 I

I i i i I ~ 1 ?00 ( 3.6 K I 4.4 ' 1,;on ?nnn t 4.9 ~ ~ J. ?t..nn f 5.5 I I t t 2ROO i ~ I ~ In trv in!! { to or~ssurize to ~ I y flow rate reauired was !?rea j hvdra1i ic.' svsteJ caoabilitv ~ Measured at center of crack. Bulge Pressure 1800 osig er than I I f I I t t t Sheet No. 4 Tube Failure Pressure Measured at center of crack. Test a aratus shown on C-E Dw. C-62676-004 used for this test. I

Specimen Brief Description No. of Specimen 5/16" long all 3-3 around wasta12:e ) l:'.:-4 Table 5 Tube Burst and Leakage Tests (Palisades) Leak Rate Crack Pressure GPM Opening f'Pc:d o) 4800

  • .054" 1 ?40

].q 1600 2 ?'i ~ 2000 2.4 ' 2450 4.1 I 2260 4.1 I ~

    • 4100 i

-14400 I l 800 ' 1.1

t. *'

I I ~ 1200 1.8 ~ " § I t 1650 I 2.3 ~ f, I 2000 2.5 ~ ~ I 2400 2.9 i 2800 3.3 I I 3000 I 3.4 3200 3.9 i i i I +r3500 4.5 ~ 4900 ( +++.032" .i Sheet No. 5 Bulge Tube Pressure Failure Pressure \\ I J f I Comments:__.__*~~M~e~a~s~u~r~e=m~e~n~t'-.!::a~tc.......:::c~e~n~t~e~r_o~f;..__os~p~e~c~i~rn~e"n".__.,S~p~e~c~i~m~e~n_._t~e~s~te~d.._1~*nu-..a~p~p~a~r~a~t~11~s._.,s~h~a~w~n-a~n.._,c~-~E..._. _Tu.7~. C-62676-004 used for this test. I 010" installed in crack in attempt to increase pTQSSUrQ (Shims) +.030" installed in crack in attempt to increase pressure (Shims) +r No visual enlargement of crack. +++ Measurement' at center of crack. Specimen tested in apparatus on C-E Dwg. C-62676-004. I

Specimen No. 2-4 2-5 Brief of

  • Table 5 Tube Burst and Leakage (Palisades)

Description Leak Rate Specimen Pressure GPM ('Ped<>\\ 1175 2.1 HOO 2.u ?000 ?.7 \\ 2uoo 1 n I 2800 I 1 " 1?00 u 1 I *3450 J 5.0 4900 I I 1200 I 2.4 I l J 1600 2.9 I i 2000 3.6 i l 2300 t 5.3 ~ I ' J 2400 3.7 ~ ~ I I 2800 4.0 y I ... i 3200 1 4.3 I 3400 4.3 I 3500 4.8 ~ I I 1200 f 2.0 ' l 1600

2.3 Comments

No visual enlargement of crack. e Sheet No. Tests Crack Bulge Tube Opening Pressure Failure Pressure I.

l. !
j.

I / i I **.032" i ~ l.. ~ f .r.

  • ~

i

1 g

f I ~ j ~ t i: i t 0 I i I ~ I J ~' I ~ ~ t r I s I I ~ j I .~ Measurement at center of crack. Specimen tested in apparatus shown on C-E Dwg. C-62676-004. ,... ~.*.... '; *'*' ~;*;__'.'_** 6 I I I I I

Specimen Brief Description No. of Specimen 3-5 I Table 5 Tube Burst and Leakage Tests (Palisades) Leak Rate Crack Pressure GPM Opening ('P.,,-ta) 2000 2.6 2400 2.9 2800 3.2 3200 3.5

  • 3500 3.7

~ I 1200 1.5 I I 1600 i 1.8 f f I 2000 2.0 I I 2400 2.3, f 2800 2.5 ~ f, I i

j
1 3200 l

2.6 i I 1 3600 f 2.9 I l ( ~ I t f 4000 I 3.1

1 I.

i ~ 4400 3.5 l 'l ~ ~ ,14 I ~

  • ~'<5100 t

f Only slight ~ ~ i j I Jin general I J Crack does ii J ~* I ~increased I l I ¥. f ~ 1 .~ Comments:.

  • No enlargement of crack visually detectable.

S ecimen tested in device shown on C-E Dwg. C-62676-004. Sheet No. 7 Bulge Tube Pressure Failure Pressure f ' I I I I I j J I I r bulging not~d vicinity of brack. i ' not appear t9 have I n width. l f I I

APPENDIX C Plots of Test Data ... ;... /*.*****"-'-"*****"---*.,-------------

1 ,-,. *-~LI lL l- :.., I '*t --~ J ~

-~

~-. l * : I. 400 800 1200 Pressure - Psig Figure 1. Average Flow Rate Vs. Pressure (Test Configurations 1 through 5)

20 Crack Dimensions .,. 1 ___, __._. --* ---.,.~+-,-i-+-;-+--+---T-1--+~;......;..-+-f_,..-+-1 Spec. Width of No. Bottom 4-1

  • 007" 5-1

.008" to 6-1

  • 008" to

. ti .4~4 R.E:F"' ,_ ~1-1'/~~(::\\t:), t R\\... f'! 15 ~ p.. t.!} Qj 10 .µ ct! ~* I **--;---i '7~*-:-* -,***r-*~.. *~~..-...-.-~-.--r ~-;--1-1--'--. -r--:-,--, _-.~~.-~.-....:.... 1 **.*

  • 1-** i.

.... '-'-"-~-=-=-. +-+-;f--1-..,.....j

ii 0

.-l ~ 5 0 0 Pressure Psig Figure 2. Flow Rate Versus Pressure, Test Configuration No. 1

8 . ;-=-1-i=. - - - -y ~*-* l'- J'--1--*---- -}'-- L - --::::..~!- - - _-d Pressure Psig Figure 3. Flow Rate Versus Pressure, Test Configuration No. 2

5 4 Length Width of 1/4 .010 11 to 1/4 11 .013" to 1/4 11 .008" to 1000 1200 1400 1600 1800 2000 2200 2400 Pressure Psig Figure 4. Flow Rate Versus Pressure, Test Configuration No. 3

6 'fj I f' -~ ~ i, -f ~>; L -t;-; ; ! ~. -~.*.~.I.:!.. ~ j.1.*.i..-11*.--p:*-;n,:-1:1tt-r .. : :~- l. ~.. I ~

  • I. -!'*-*~.... *-+-l-. * -i *- * ****r-1"--t-* t-

~-* I

; r
r' J....
  • _*..... :

_.jL __

  • -~--:._:_ti_. :-:--:- '. 1-L.'

-~-*.: - -; *t -~.;-~ - , ~- h-,.. -~*-*._ *---~**-~, ~ ~.. ~ . !.. : ;... ~- -~ !.. -.. ~ l-.. **+* -,_. ~.,. -i l-.--*--l--* 11 -\\. :.1 *. : :

~: i : I 1 : ;.;: ~-; FiH.E:'.

j' .4~4 RE~ H-1 11 RAt>. I fl RC~ j * ~., 5 "t** I i i . I :.* : ... * *--l, :--~ ;- 1 *.. '.

  • -t**

l J 1* ~* j i i + .l -! i

    • -* _j

, I ;. ;. 4; -~---+-------'- __..._... I 3 2 I

      • -- -t I

j -------**-*... I I l j i ;.. l -.J-

I.

I I . i l I l i : ; ~

: I 1 *-~-* *** :.J __

l~~~~*n:*~---~:-tf~~~~~i~,--~rt~~~~~~~~~~s=p=e=c~i~m=e=n=N=oH.~1~-=4~~~+tt~~ 1 4 i ~

. G * ;-;

1 -- - r**- *

        • -:_~:~: ~-~*_'.-1 1

-:< *: :.j ~S~e~,ime~JNo~*~-~-4 1

  • -* ~

---~-*-*.._..,... I

  • .. i----~... :.... -i-~-~~~-~-~

i ~ r I 1 *.. -. : l Pressure Psig Figure 5. Flow Rate Versus Pressure, Test Configuration No. 4

Q) .u ~ 5 4 3 2 1 _,r_. _,.z_ L ~-- > \\ " C E.Dr./\\ 4 CR/:\\C.\\( RE.'r-

  • -i. ~

~.;... -~

  • I.
        • -'- ;_ ~-1--:... -

I =+t~-*~~:~--~=f~~:--~~~~:-~*-: <: l.: . ---r---- -~ ___ L~-- ---.~..:-.. *t * -* ! I .. ~ ~--~ -. ** ~ *.. ; :.. *. ' ~

; ~. !.

~ -*7-... ~!*-~ :... ~ ~ - -....... -*--* p ~* -~--~:--:~L.i.:~:~:.... ---*--~--*-r**- i-*-_, 0 Pressure Psig Figure 6. Flow Rate Versus Pressure, Test Configuration No. 5

APPENDIX D Photographs ol Specimens

e List of Photographs Photo Spec. Description of Phase of No. No.* Test Shown 1,2 1-1 After Burst Test 3 3...;..1 After Burst Test 6,7 4-1 After Leak Test 8,9 5-1 After Leak Test 16,17 6-1 After Maximum Differential Pressure 18 1-2 After Burst Test (with bending) 19 3-2 After Leak Test (with bending) 20 4-3 After Burst Test 21,22 1-3 After Leak Test 23,24 2-3 After Leak Test 25,26 1-3 After Maximum Differential Pressure 27,28 2-3 After Maximum Differential Pressure 29,30 3-3 After Maximum Differential Pressure 31,32 3-4 1After BuIJst Test 33,34 4-4 After Burst. Test 35,36 1-4 After Maximum Differential Pressure 37,38 2-4 After Maximum Differential Pressure 39 1-5 After Maximum Differential Pressure 40,41 1-6 After Burst T0,st 42,43 2-6 After Burst Test

Photo 1 Test Configuration 1 After Burst Test Specimen 1-1 Photo 3 Specimen 3-1 Photo 2

Photo 6 Photo 8 Photo 16 e e Test Configuration 1 (Cont.) After Leak Test Specimen 4-1 Specimen 5-1 Test Configuration 1 '(Cont.) After Maximum Differen*tial Pressure L I Photo 7 Photo 9 Photo 17 Specimen 6-1

Photo 18 Specimen 1-2 (After Burst Test) 0 i: '"" ** ~ .. *.;ff¥""' 0 t,.~'l\\ ~ ,,~<<','Ji.$*"*;<,"' **** 'JI;~.~

,i!;"'~"

"+'!;;~."" I I Photo 19 Specimen 3-2 (After Leak Test)

Photo 21 Photo 23 Test Configuration 3 After Burst Test Photo 20 Specimen 4-3 Specimen '1-3 Specimen 2-3 Photo 22 Photo 24

Test Configuration 3 (Cont.) After Maximum Differential Pressure

  • '\\

'" ~ r r f ,~ ';{('. t.* 0 ~ J. ~"." *

      • i:.*"

I Photo 25 Specimen 1-3

  • '11:"' *

~ * ~ }"" - ~ ~

.:. ~,,,. "llil Y.'"'1' 0 "'.

Photo 27 Specimen 2-3 Photo 29 Specimen 3-3 Photo 26 Photo 28 Photo 30

Photo 31 Photo 33 Test Configuration 4 After Burst Test Specimen 3-4 Specimen 4-4 Photo 32 Photo 34

Photo 35 Photo 37 Test Configuration 4 (Cont.) After Maximum Differential Pressure Specimen 1-4 Specimen 2-4 Photo 36 Photo 38

Photo 40 Photo 42 e Test Configuration 5 e After Maximum Differential.Pressure Photo 39 Specimen 1-5 Test Configurati-0n 6 After Burst Test Specimen 1-6 Specimen 2-6 Photo 41 Photo 43

APPENDIX E Mill Test R~port for Tubing

CYCLOPS CORPORATION Sawhill Tubular Division Sharon, Pa. Southern California Edison San Onofre III 11r"1mer CERTIFICATE CF TESTS Date 11/5/75 Unit No. 2 Combustion Engineering, Inc. Sawhill S.O. 60002 ~~~~~~~~~~~~~~~~~~~- ity Ch at tan o o g a, Tennessee Size .750" O.D. x.048" Ave. Wall .o. 44-80079

  • Material Seamless Ni-Cr-Fe Allov Tubing

~~~~~~-'-.;..___~~~~~~~~~~~~

mtract 72270 ASME SB-163-71 As Modified By C.E.

Purchase Spec P43B2(h) And P.O. ob No. A-98098 Specification 44-80079 And Supplements M.O. lot Heat 0000-92 L-16-M NX6824 at Number NX6824 c Mn p l.adle Analysis .03

  • 34

.009 llcil low Check .40 .009 '1. .ysis s .003 .004 .750" O.D. Tube Check Analyses For Carbon .03 CHEMICAL ANALYSIS Si Cr Ni Cu Ti. Fe Al Co .16 15.35 74.13 .30 .28 9.18 .17 .05 .15 15.60 73.63

  • 33

.34 9.00 .16 .05 MECHAi.~ICAL PROPERTIES B Mg .005 .002 .010 M.O. Lot Yield Strength Tensile Strength Elongation in 2" Rockwell B *

  • 0000-92 L-16-M 40,000 psi 91,000 psi 49%

75-75 -~* Long. Tran. Long. Tran. Microstructure * (Photo~icr~ Long. Tran. graphs Lot I.G.A. Grain Size

  • Submitted) 0000-92 L-16-M

.001 max ** 001 max. 5-6 5-6 Complete Complete M.O. Lot Surf ace Roughness

  • Information Only QM0-92 L-16-M 26 - 42 M 11 tt.~bes Fere flare tested on es.ch ancl in accordance with STI*-163.

11 tubes were eddy current tested in accordance with Sawhill Procedure STP-21B, July 1, 1974. 11 tubes were ultrasonic tested in two. circumferential directions in accordance with Sawhill Procedure STP-22D, July 1, 1974. 11 tubes were ultrasonically tested for wall thickness in accordance wi*th Sawhill Procedure STP-24A, ~uly 1, 1974. ny reconditioning was performed, when necessary, in accordance with Sawhill Procedure STP-23B, July 1, 1974. 11 tubes were bent in accordance with Sawhill Bending Procedure, October 10, 1974. 11 tubes were hydrostatically tested in the bent condition at 3150 psi for 10 seconds minimum. 11 tubes were tested for alloy identity. Refer to lot number, mill order and heat number on attached packing list. he ~hove material has been inspected f o knowledge and belief. w~r~d subscribed to before me

h.

5th day of November, 1975 -~-el).£,_ftc,~ :. c_j_ ffi!El TRANICK, Noury Pu~lic . Whea!lan~. Mercer Cour:ty. P~nnsylvania and conforms to the applicable specifications to the best CYCLOPS CORPORATION Sawhill Tubular Division Cir,t1,4___j, Cf',~-- 3 Authorized Signature

APPENDIX F Engineering Request for Test Program

~POWER <~SYSTEMS

  • Interoffice Correspondence

/* Mr. J. K. Hayes *

  • Tube Burst and Leakage Test***

(Palisades)* Anaiytical ~ngineering cc: Mr. P. Anderson Mr. W. Heilker AMG-76-015 January 29, 1976 This is to fulfill the requirements of Section 3.5.1 of the Design Quality Assuranc~ Procedures for establishing test require-ments for a test or development program. 3.5.1.5 (1) Description of Design Problem - (2) The general problem is that of tube degradation and the. allowable pressures for particular degradations. The type degradations to be investigated a~:

a.

Uniform "Wastage" - Remaining wall thickness =.017" b *. Longitudinal through wall cracks superposed upon the wastage. Detailed Objectives of Test - The objectives.of the tests are:

a.

Determine burst pressures at room temperature for tubes with no degradation, with wastage degradation alone, and with wastage and crack degradation at the same location.

b.
  • Determine leak rates vs. pressure for tubes with no wastage degradation and through wall cracks; and for tubes with wastage and cracks degradation.

(3) Description of Proposed Test Models - There are six ( 6)_ styles or type's. of specimeqs (see attached drawing) *

. i Mr~ J. K~ Hayes January 29, 1976 AM.G7 76-015.

a.
  • ( ;;

6*specimens Wastage simulation all around f'or a length of 1/2" -.the _minimµm wall thickness-being .017 11

  • 3 specimens to_* be: with 1/1+" longitudinal

. cracks at the locati.on o-f w.astage - 3 speci.mens without cracks.

b.

6 sp~cimens - Same as Type a except that th~ wastage length is 5/16 11 in~tead of. 1/2" * . c.. 4 specimens - Local s:i,:rp.ulated. :wastage (machiriec;I fJ,.at-*. dished on one side only) for* 1/2 11 length - minimum wall thickness.017". 2 specimens with simulated wastage and 1/4" longitudinal through wall crack - 2 specimens with simula.tec;l wastage only~-

d.

3 spe.cimens with no simulated wastage. an,d 1/4" longitudinal c_racks.

e.

2 specimens with no wastage and no cracks - virgin tubes. All. specimens* for Types* a*; b; c, d and e approximately 10 11 long..

f.

6 specimens like Type b except the tube length approxi-mately 18 11 * (The.se are to be loaded in bending_ and internal pressure.) _(4) Acceptance Criteria - Accurately determine and report required data listed in Items. ( 5)" through (9) be*lpw. * * (5) Discussion of Tests to be Performed -

a.

All specimens for Types. a through e ~hall be :J.oaded* with internal pressure (pressurized water) ()nly.

1.

Determine bursting.pressure fqr those ~pecimens without cracks ( fpr Types a "'through e) ~ \\

2.. Determine ieakage rate *for those specimens with cracks. (for specimens a through !::)...

The. leakage rates should be determined as a f'unction of pressure - 1200 psi, 1600 psi, 2000 psi, 2400 psi, 2800 psi *... as high as can be determined. The

Mr. J. K. Hayes *

  • January 29, 1976 AMG-76-0.l,.S (6)
b.

}. ~~ 'i.. failure mode will probably be local bulging with a widening of the crack and subsequent greatly increa~ed leakage. The failure mode is to be qualitatively determined.. by observation and a final burst pressure is to be* determined. Specimens of Type f These are to be loaded with internal pressure plus bending (4 point bending). The bending should be of such magnitude to cause a bending stress of approxi-mately Sy (yield stress) in.the tube. 'Ihe loads will be larger for the unwasted tubes than for the wasted tubes since the moment of inertia of the wasted tube is smaller.. The specimens without cracks are to.be burst with internal pressure while the bending stress is present. The leakage rate of the specimens with cracks shall be determined as a function of pressure while the hending str~ss is present. One specimen should have the crack on the compression side, one on the tensile side and one on the neutral axis. Instrumentation and Readout Equipment - That necessary to document pressures and leak rates. (7) Test Data - A Specimens should be identified as to material, mi~ test prope~ties, type degradation (wastage and. cracks).

a.

Pressure vs leak rates should be obtained for the cracked specimens to as high pressure as reasonably feasible, then .obtain burst pressure~ Plots of pressure vs leak rates should be made. The specimen should be identified on the plot sheet.

b.

Burst pressure should be obtained for uncracked specimens. (8) Qualification Standards (Not applicable.)

Mr. (9) e J. January 29, 1976 AMG-76-015 Test Report - A test report should be produced.* The results should be close to* the beginning of the report.

a.

Specimens should be completely described (.the size and type.of degradation, physical properties_, s*ize of crack, etc.). Photographs of specimens if possible.

b.

Plots of leak rate and burst pressure for the cracked specimens should be given.

c.

Burst pressures for uncracked specimens should be* given.

d.

A comparison of the following should be made: . 1. Burst pre'ssure of virgin.tube (uncracked) (unwasted). 2 *. Burst pressure of 1/2" long flat wasted tube (uncracked). 3~

  • Burst pressure of 5/16" long all around ~Tasted tube *

(uncracked).

4.

Burst pressure of l/~" long all around wasted tube (uncracked).

5.

Burst pressure. of 5/16" long all ara.ind wasted tube (uncracked). with bending stress present.

6.

Burst pressure of unwasted tube with cracks with leak rates at varying pressures given. 7* Burst 'pressure of 1/2" long flat wasted tube with cracks with leak rates at varying pressures given.

  • a.

Burst pressure.of 5/16" long all around wasted tube ~ith cracks with leak rates given at varying pres-sures.

9.

Burs.t pressure of 1/2" long all around wasted tube with cracks with leak rates given at varying pres-sures.

10.

Burst pressure of. 5/16" long all around with.cracks with bending stress present rates at varying pressures given. wasted tube with leak \\

Mr. J.

  • January 29, 1976 AMG-76-015 A table is the preferred way to give these data.

An example of the table is shown on attached sheet. FH/lh Atta~h

  • f;/;JJ F. Hill}}
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