ML19257D784
| ML19257D784 | |
| Person / Time | |
|---|---|
| Site: | Point Beach  |
| Issue date: | 01/25/1980 |
| From: | WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP. |
| To: | |
| Shared Package | |
| ML19257D783 | List: |
| References | |
| NUDOCS 8002060438 | |
| Download: ML19257D784 (22) | |
Text
{{#Wiki_filter:. ATTACHMENT A WISCONSIN ELECTRIC POWER POINT BEACH #1 LOW PRESSURE DISC ULTRASONIC INSPECTION REPORT 1/25/80 1W, D 1929 326 800206043 S .
LOW PRESSURE DISC ULTRASONIC INSPECTION REPORT INTRODUCTION This report covers the ultrasonic inspection of the Wisconsin Electric Power, Point Beach No. 1 unit. This unit is of a shrunk on disc design with each disc keyed to the shaft at the disc bore area. The disc keyways are located such that standard NDT techniques cannot be used. The U.T. inspection was performed to detect possible cracking in the disc keyway area. The need for this inspection is a result of recent industry experience where stress corrosion cracking has occurred in machines of shrunk on disc design. Cracking in this disc bore area, if allowed to propagate, could eventually lead to a disc burst. DISCUSSION Ultrasonic inspection techniques have been developed for detecting keyway cracks without the need for unshrinking discs. Two techniques are used; one for detecting crack indications and the other for verifying crack indications and measuring their depths. The initial technique used is the tangential aim, where an ultrasonic transducer is mounted on a plexiglass block that sits on the disc hub. The plexiglass block is contoured so that it is in complete contact with the disc hub. The ultrasonic waves are directed tangentially towards the keyway so that any cracks above the keyway area will be perpendicular to the sound beam and reflect the sound. A careful analysis of the time difference between the echoes from the keyway and the crack allows discrimination of false indications. This time differential procedure is accomplished by circumferentially scanning (see Figure 1). Since the disc profile is composed of a series of compound radii a mathematical model was developed for transducer positioning and alignment. The model was computerized to allow calculation of:(1) all needed infonnation for positioning and aiming the transducer for detection anywhere on the disc bore, (2) metal path length, elapsed time to keyway echoes, and time between keyway echo and crack echo, (3) time between keyway echo and ~ suspected spurious indications, (4) various angles with interrelated ultrasonic central ray direction to disc and transducer axis. Also because of the disc profile and the need for good sonic coupling between the disc metal and the plexiglass blocks (called compound angle wedges) a large number of blocks are required (see Figure 2). If a crack indication is picked up sonically, the location is determined by the transducer location and its relationship to keyhole echoes and indication echoes (see Figure 3 and 4). g29 327
Since the tangential aim technique is not suitable for determining depth of crack, a complementary technique called radial aim is used to: (1) verify cracking detected by the tangential aim technique, and (2) to estimate the depth of crack. In this method, the ultrasonic waves are directed perpendicular to the keyway. The radial aim method works because a crack undergoes branching and spreading while it grows. Thus, the branching part of the crack includes components which reflects ultrasound bar.k to the transducer. Depth of the crack is estimated by measuring the time between the keyway echo and the flaw echo, and then coverting to round trip distance by multiplying by shear wave propagation velocity (126,000 in./sec). ANALYSIS After ultrasonic inspection had indicated a possible disc crack, an analysis is made to determine what the indicated crack size is in relationship to the critical crack size as determined by fracture mechanics. This relationship is used to detemine Westinghouse recommendations regarding continued operation with a disc crack indication. EQUIPMEtlT Elect'ronic Instruments A) Krautkramer USIP 11-Ultrasonic Equipment (for recomended test settings see Appendix A). B) Tektronix tiodel 465B or tiodel 465 Portable Oscilloscope. (Model 465B is preferred). (For recommended test settings see Appendix B). Transducers Transducers ranging in diameter from 1/4 inch to 1-1/8 inch and in frequency from 2-1/4 MHZ to 10 !!HZ as detailed in the specific tables for each of the BB discs. Other frequencies may be used to further , evaluate indications. Wedoes Numerous plexiglass wedges varying in entrance angle, rotational angle, radius of curvature, physical size and rotational direction are provided, as required for each of the BB discs, as detailed in the specific tables. 1929 328
Transducer Manipulators Transducer manipulators are used whenever hand scanning cannot be conducted. A) Wedge Extensions B) Transducer Manipulators (WR&DDrawingNo.12222J20) C) Charlotte Manipulator Camera
,Tektronix C-5A Oscilloscope Camera, or equivalent.
Couplant Ultragel II. Westinghouse M-54410LF. Calibration Standards A) 3/4 inch x 8 inches long cylindrical rod. B) Plexiglass Block Conversion Factors , Ultrasonic measurements of distance are presented as time interval measurements on the 465B oscilloscope. Thus, time measurements in us/ division on the oscilloscope must be multiplied by 0.113 in/usec for shear wave travel to convert them to linear measurements in inches. INSPECTION RESULTS Point Beach - LP-1 and LP-2 LP-1 Disc-2 Governor End Good tangential aim indications were found in both the clockwise and counterclockwise directions at keyway number 2 (Ref. Balance Hole-17). Good tracking characteristics make it appear that the discontinuity is located at the apex. Using the radial aim technique signals were found from es far away as 3.6 to 4.0 seconds from the top of the , keyway echo. These at's converted to 0.227 and 0.252 inches in depth, 0 respect [vely. Best radial aim indications came from Sg = 35 weige, 86 = 40 wedge, with the 86 being the better of the two. 1929 329
LP-1 Disc-3 Governor End Tangential aim indications in both clockwise and counterclockwise directions were seen at the keyway. (Ref. Balance Hole-28). We were not able to confim these indications using the radial aim technique. The "b" location was estimated to be about 2 inches from the hub face. The "h" location was also approximately 2 inches. Additional investigation obtained with other wedges suggested that some discontinuity extends into the region of b = .75 to 1.75 inches. Also some discontinuity in the region of b - 2.25 to 3.25 inches, at3 was shorter when aiming counterclockwise than cigckwise, thus suggesting that the major indication is off the apex 5 0 to 10 The inspection of the discs included the keyways and a 360 scan of the outlet edge of the bore. No other reportable indications were found on any of the remaining discs. RECOMMENDATIONS The following recommendation and opinion supercedes the letter by J. S. Bonk of 11/30/79. Indications were noted in two of t!:e 20 discs inspected. Disc #2 in the governor end of LP-1 has an indication in one of the three keyways .250 inches in depth. Disc #3 displayed a tangential aim indication in one of the three keyways. This indication could not be confirmed with the use of the radial aim technique, therefore no depth could be estimated. Based upon our experience to date in the verification process, it is reasonable to assume that the indication is below the normal detectable depth. The present crack growth rate data upon which the estimated life is based includes all Westinghouse experience and 3% Ni, Cr, Mo, V alloy discs from the British experience. Based upon the upper bound of this combined Westinghouse and British experience, the depth of the indication and the physical disc properties, it is our opinion that the estimated remaining life of disc #2 is 24 months. To account for uncertainties in the predictive process, the theoretical propagation time was divided by 3. It is recommended that a reinspection of disc #2 and disc #3 be made within the next 12 months of operation or during the next refueling outage whichever occurs first. Q
3~2 %g Transducer Circumferential Scan I I g Y r~ ) > 9 Flaw - u I N Edge of keyhole Side of keyhole Transducer Transmit Position _ pulse g _ e - s f f At, = t,-t0 l E n l l at) = t3-t0 2-3 t) FIG. 1 Sequence of Appearance of Echoes, During Circumferential Scanning, from Keyhole with Off-Apex Flaw. ~ gC) 335
e a l
*I Whert E20 Transducer 3 CCW aim f , g
_ Transduce r & i y CW aim 7 -* b
- Disc G
~
+ sn.
R2 (f 0.2 cm)
-o Flaw on
/
N - a t _' ^ keyhole h4
/ \
l \ \ Y 06 Normal to surface v k- .
% Compound-curved Angle-beam wedge 0;Y*
6 S ij R 2 > R4 , $1 N', #~) Ni h)
/ /
\l J
r FIG. 2. Input Parameters :: ceded to Calculat.e Direction Angles 86 and $ for Compcund-Angic l? edge. k
}
n N
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c . k:
.R 2 d ,d o1 3 Transducer Y }
9
. V,
- - f N
/
d d d 0 2 t _
/ / / _
o h - ) I t - b f
- / (
iL bs h - axial distance from hub face to a reflec * *- Rg = in. (9.6 cm) tor near the apex of b = transducer the keyhole axial distance from hub face TO = Time of arrival of reference echo at side of the keyhole at b; propagation path length - d ' O T3 = Time of arrival of echo from a refle-cor near the apex of the keyhole at h; propagation path length = d
- 2 T1 = Time of arrival of echo from the corner of the keyhole; propagation path length = dy .
V3 = Velocity of shear wav-s in steel. y = Angle of incidence of ultrasonic rays on radial through the keyhole . 2 ([do+Rg (1-sin y)]2 + b ) 1/2 -d o AT1 = Ty-TO % .3 V 3 y " f(A) ([dC+Rg (1-cos y)]2 + (h-b) } 1/2 -d
# =T4 3 3 0 .5 V S FIG. 3 Relationship of Keyhole Echoes as Function of '
Transducer Location. I
ca.,-a- P y' Ultrasonic rays [ 6 *7 i =3 tirse to echo fro = flaw
~
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t0 = time to echo frcm side '(
, f of heyvaj (Reference /
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di on - ,of keyvay N
- I I
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= Refraction angle h in vedge I
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Plane of hub face -
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y b ->. Tangent to Ultrasonic transducer . surface at
~
mounted on vedge P I"E Of s M entry of M y / * ' central ray y - p l V Normalat point of to surfa e
/' i / entry of central
/ /
I
- ray j/ Disc ,
Disc
/
, '/ L
/ Sha f_t I Keyway #
Radial through , * , \ arget t point j[ g of keyway N Radial through (flav) g point of entry of * - J d~ central ray on disc FIG. '4- Transducer Position ( A ,b) and Alignment Paraneters (36 '#)
)h to Examine Keyway Target ( c, h) .
LP 1 DISC-2 GOV. KEYWAY 3 (Bal Hole 17)
~
TANGENTIAL AIM
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LP-1 DISC-2 GOV. KEYWAY #B.H.-17 1 RADIAL AIM 0 h = 2.5" B6 = 40 Shear Wave 20 usec/div rg, [th' j. ; , l' 2 usec/div, gs . s
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POINT BEACH LP-1 DISC-3 GOV. END KEYWAY #B.H.-28 0 TANGENTIAL AIM: 86 = 51 Y = 700 CCW 13 Pan. 2 1/4 MH z CW 13 1" Dia. Sens.: +40 db + 24 db 50usec/div. Susec/div. b = 1 1/2 - 2 l i l Cetd 13 CCLJI] M
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'OINT P BEACH LP-1 DISC-3 GOV, END KEYWAY #B.H.-28 TANGENTIAL AIM: $ = 66 2-1/4 MH7 X 1" dia. KB U P-11 0
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1929 345
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e F ATTACHMENT B t L POINT BEACH NUCLEAR PLANT, UNIT 1 TURBINE ROTOR DISC FRACTURE ANALYSIS 497 MWe 132% OVERSPEED i LP-1 DISC #2 GOVERNOR END t Klc (FRACTURE TOUGHNESS) = 171 KSI/IN. atu (INDICATION DEPTH) = 0.250 IN. aut + 0.060 (UT UNCERTAINTY FACTOR) = 0.310 IN. , a cr (EFFECTIVE CRITICAL CRACK DEPTH) = 1.213 IN. f ac r - a tu = 0. 9 03 7'4 TK (KEYWAY Tc:MPERATURE) = 274*F da/dt (CRACK GROWTH RATE) = 1.7 x 10-5 IN./HR. ESTIMATED TIME TO REACH CRITICAL CRACK SIZE = 73 MONTHS ADDITIONAL SAFETY FACTOR = 3 1, WESTINGHOUSE ESTIMATED LIFE = 24.3 MdNTHS WISCONSIN ELECTRIC INSPECTION INTERVAL = 12 MONTHS
,f 3929 346 p
6
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ATTACHMENT C POINT BEACH NUCLEAR PLANT, UNIT 1 BORE CRITICAL CRACK SIZE EVALUATION Operating Hr. Disc #2 Disc #3 Highest Through 12/80 a_ ac r_ a -a,qr \a/a cr 72,500 2.28 3.9 2.28 4.5 0.58 a = Estimated crack depth from bore using growth rate at Zion-1 [ inches]
. 1.22 in.
= Operating hrs. x 38,858 hrs.
a cr = Critical crack depth for bore [ inches] i i aI 1929 347
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