Text

Reactor Vessel Nozzle Insp.
	ML19296C820
Person / Time
Site:	Sequoyah
Issue date:	02/26/1980
From:	; TENNESSEE VALLEY AUTHORITY
To:	;
Shared Package
ML19296C819	List: ML19296C818; ML19296C820;
References
	NUDOCS 8002280570
	Download: ML19296C820 (48)
	v • d • e

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E! CLOSURE SEQUOYAH NUCLEAR PLANT UNIT 1 REACTOR VESSEL N0ZZLE I':SPECTION FEBRUARY 26, 1980 i s k1

DESCRIPTIO' OF ULTRASCNIC TESTING TECHNIOUE The enacinations were conducted from the clad no::lc bore surfaces using 700 lcngitudinal wave, dual element, transmit-receive search units manu-factured by Krautkramer/ RID /3AM. The time base of the instrument was calibrated on :=n diaceter side-drilled holes at depths of 3=m, 7:=, and ll=m. Test sensitivity was established on the flat bottom of a 2:= dia-

=cter hole drilled just below the clad / base ectal interface in a represen-tative calibration block. i After the test system was calibrated, instrument sensitivity was increased by 6db for scanning. Scanning was conducted en the clad no::le bore sur-faces in both circumferential directicas. When an indication was detected, instrument sensitivity was returned to the primary reference level and the *

=aximus amplitude obtained. If the amplituda was equal to or greater than 50% of primary reference, the indicatien was recorded per the criteria de-fined in the procedure. -

The calibraticn sensitivity of this exaninaticn technique is at least 5 times that required by cenventional ASMI Section XI exacinatien methods (3/32 side drilled hole). This fact was demonstrated by making a direct cocparison between the instrument gain recuired to set the amplitude of the 2== diameter flat bottom reference reflector to 80% of full screen height versus that required to obtain the same signal a=plitude from a side drilled hole of the same diameter. An increase of 14-16db was noted, which is approximately 6 times more sensitive.

Areas where reportable indications were detected with the 70 search unit were evaluated with a K3I, Ga==a Series, 5.0MHz, 00, transmit-receive search unit. Calibration for this examination was established ,

on the flat bottom of a 2=m diameter flat bottom hole drilled to the clad / base =etal interface in a representative calibration block. Any indication detected by the 700 longitudinal wave inspection and also detectable by the 00 straight beam inspection was considered acceptable by the criteria defined in the test procedure. A copy of the detailed test procedure is attached as Appendix A.

The nozzle bore examinations were conducted by qualified ultrasonic test operators from Sonic Systems International, Houston, Texas under the direct supervision of Westinghouse personnel. Personnel and equip =ent certification records are on file.

INSPECTION RESULTS The inspection results from all eight nozzles are summarized below:

LOOP 1 INLET 3 reportable indications LOOP 1 OUTLET 5 reportable indications LOOP 2 INLET 21 reportable indications LOOP 2 OUTLET 1 reportable indication LOOP 3 INLET 2 reportable indications LOOP 3 OUTLET indications of reheat phenomena LOOP 4 INLET 5 reportable indications LOOP 4 OUTLET 1 reportable indication

Raw data sheets and ultrasenic reflector plots are included as Appendix D.

Eaca reflector in the loop 2 and loop - cutlet nc::les had :rr2sp~ndin; straight beam indications and are therefore considered acceptable by ths criteria cutlined in the test procedure. The remaining reflectors vere subject to further inspection, namely ASSIE Section XI acceptance criteria.

E'/ALUATION Reflector lengths were measured using a 12db drop method. The inherent conservatism of this technique was demcastrated by the fact that the 2mm diameter flat bottom hole in the calibratica block resulted in an ultra-sonically measured length of 7.5mm.

Current NDE technology does not permit a direct measurement of the through wall dimension of the underclad cracks. However, a number of these cracks have been examined destructively and from these data a reliable estimate of the thrcugh wall dimension can be made. Boat samples from three dif-ferent nozzles containing underclad cracks were examined metallographi-cally. The results from all three were in excellent agreement. In every case the cracks were confined to the heat affected zone (RAZ) of the second weld deposited clad layer and had a maximum through wall dimen-sion of 0.150 inches. This is consistent with the depth of the HAZ and the metallurgical analysis of the cause of the cracking (cold cracks).

The dimensions of the HAZ are such that one would expect the cracks to have an aspect ratio (length to height) of about 6 to 1. The metallo-graphic examination showed aspect ratios of about 4 to 1. An examina-tion by others via progressive grinding of many cracks confirmed a cor-relation between the length and height of the underclad cracks.

Since the exact nature of the reflectors is unknown, all indications were conservatively assumed to be planar surface defects with thru-wall dimen-sions equal to 1/8 inch or 1/3 of the measured length, whichever is larger, for ASME Section XI evaluation purposes. The conservatism of this assump-tion has been substantiated by a/1 ratios determined by metallographic examination of typical reheat and underclad type cracks as discussed in the previous paragraph.

The outlet nozzle thickness is 11.315 inches, and the inlet nozzle thick- ,

ness is 13.425 inches. These figures I inTableIWB-3512.1, note 2,wheret=ygg7gegpfgdbythemethodoutlined

, , and dimensions from nozzle fabrication drawings.

In the case of all inlet nozzles, except loop 1, the longest indication recorded was 0.625 inches. In this case the thru-wall dimension of the indication is assumed to be 0.208 inches. The allowable a/t value is 3.5%, while the actual a/t value for this case is 1.5%.

Indications in the loop 1 outlet nozzle in the vicinity of the safe end weld were evaluated to the 1977 Edition of ASME XI, Table IWB-3514-2. The maximum thru-wall dimension was estimated to be 0.125 inches, based on 1/3 the length of indication number 4 (.375 inches). Considering an aspect l ratio of 0.33 the allowable a/t value is 9.5%. Considering the thickness of the nozzle is 2.33 inches in this area the actual a/t value is 5.25%.

4 4

In the case of outlet nozzles 1 and 3 the longest indication recorded was 0.375 inches. In this case the thru-wall dimension of the indication is assumed to be 0.125 inches. The allowable a/t value is 3.5%, while the actual a/t value for this case is 1.1%.

INSERVICE INSPECTION The inservice inspection program will be conducted in accordance bith the technical specification requirements for the Sequoyah Nuclear Plant. The need for and feasibility of conductiong augmented inservice inspection of the reactor vessel no :les will be evaluated at the next inservice inspection interval. The state of the technology for remote irmersicn e::anination and the calculational efforts to date will be determining facters in the evaluation of the need for augmented inservice inspection.

4 APPE'3IX A ULTRASONIC TEST PROCCDURZ

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< ULTRASONIC 7EST FRCCECUF.E FCR CETECTICM OF SUS-CLACCING CRACKS IN REACTOR VESSEL NCI LE ECRES ,

e 1.0 SCOPE 1.1 This document describes the ultrasonic testing technique and evaluation criteria to establish the existence of cracks beneath cladding on reactor vessel no::le bores.

e 2.0 EOUIPMENT .

2.1 Puls"e-echo ultrasonic equipment shall be used. The instrument shall be equipped with c3 calibrated gain or attenuation controls.

2.2 A dual-element, t.ansmit-receive, 2.0 MH:, 70 longitudinal wave search unit shall be used for the primary examination.

This search unit shall be of the type Krautkramer-RTD-BAM SE-70-L2-lS0-F18, or equivalent. ,

2.3 A dual-element, transmit-receive, 2.0 - 5.0 MHz, miniature O' longitudinal wave search unit shall be used to aid in e evaluation of reflectors. This search unit shall be of the type Krautkramer SEB-4-KF-8, or equivalent.

2.4 Glycerine or an equivalent shall be used in sufficient cuantity to maintain continuous coupling of the search unit to the part being examined.

2.5 A reference block shall be provided for calibration of the ultrasonic test system. The block shall be clad using a process and material representative of that used on the production part. The contour of the bicck shall be representative of t..e ID of the no::le bore. The block shall contain 2mm diameter side drilled holes at locations

, specified in Figure 1.

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.3.0 SURFACE FINISH. CLA0 THICKNESS. AND PREPARATION i 3.1 All examinations will be conducted from the clad surface of the no::le bore. The clad surface shall be free frca dirt, weld spatter, or any other foreign material that might interfere with free movement or contact of the search unit.

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The clad surface finish of the reference bicck shall be no better than that of the part being tested.

3.3 The defects of concern are located in the heat-affected-zene of the no::ie material, just belcw the clad / base metal interface.

To aid in evaluaticn of reflecters it it imcortant to have as much information as ;ossible concerning the ncminal clad thickness.

3.4 Divide scanning theand nc::le bore reccc inginto fcur ecual sections to aid in of reflectcrs.

Measure the circumference of the no::le bcre at the vessel and piping ends to establish the lccations of the 0*, 90 ,180*, and 270 axes. Mark these

- axes alcng the entire lengtn of tne no::le bcre with an approved, semi-permanent marking pen.

4.0 SWEEP RA*;GE CALIERATICN 4.1 Establish a linear sweep presentation for the 70* examination system by adjusting the instrument delay and range controls to set the maximum responses frcm the side drilled holes whose axes are perpendicular to the clad bead direction such that each screen division represents 2mm of depth.

See Figure 1, reference holes "A", "B", and "C".

4.2 '

Establish a linear sweep presentation for the 0* T-R examination system by adjusting the instrument delay and range controls to set the maximum responses frca the side drilled holes whose axes are perpendicular to the clad direction such that each screen division represents 2.Tm of depth.

See Figure 1, reference holes "A", "B", and "C".

5.0 TEST SENSITIVITY 5.1

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Establish the test sensitivity for the 70* examination system by adjusting the instrument gain controls to obtain an 805 of full screen height indication from the flat bottcm of the

. 2mm diameter hole drilled just below the clad / base metal interface and parallel to the clad bead direction. This is

,. ,,. the primary reference level.

See Figure 1, reference hole "0".

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5.2 Establish the test sensitivity for the 0* transmit-receive examination system by adjusting the instrument gain controls to obtain an 80", of full screen height indication frcm the flat bottcm of the 2m ciameter hole drillec thrcugh carben steel to the clad / base metal interface. This is the primary

. reference level.

See Figure 1, reference hole "E".

6.0 SCA ;MI!;G - 70* EXAMI"ATIC!!

, 6.1 Scanning with the 70' search unit shall be performed frem the clad surface in both circumferential directicns, i.e., parallel to the welding direction. The entire nozzle bore shall be examined in this fashion.

6.2 The scanning speed shall not exceed 6 inches per second.

6.3 Each scan shall overlap the previous scan by at least 25%

of the search unit width to assure complete examination coverage.

'6.4 Scanning shall be performed using a minimum gain setting of two times the primary reference level (+ 6 dB). All indications shall be evaluated at the primary reference level.

7.0 RECORDING OF REFLECTORS - 70* EXAMINATION 7.1 Indications ecual to or greater than 505 of the primary reference level defined in paragraph 5.1 shall be recorded and their locations marked on the no::le bore for further evaluation with the O' transmit-receive examination system.

72 The specific sequence for data recording is provided i,elow.

7.2.1 Record the maximum amplitude of the reflector, a) in percent of the primary reference level when reflector amplitude is less than the primary reference level, or b) by number of d3 required to reduce the maximum amplitude to the primary reference level when the reflector amplituda is

/ greater than the primary reference level; i.e., "100% + 6" when reflector maximum amplitude is 200" of reference.

7.2.2 Record the search unit location where the maximum amplitude is observed. Axial location shall be measured from the safe end, circumferential location shall be measured from the nearest longitudinal axis of the bore; O , 90*,

180* or 270a.

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7.2.3 Record the scanning direction, clockwise or counter-clockwise as viewed from the large diameter end of the nozzle (vessel side).

/ e - 7.2.4 Record the depth of the reflector at the location of maximum amplitude as read frcm the instrument sweep.

7.2.5 Record the length of the reflector as determined by the "12 dB drop" method. Move the search unit to the left of the point of maximum amplitude until the -

reflector amplitude drops to 255 of maximum. Mark this point. Then move the search unit to the right of the point of maximum amolitude until the reflector again drops to 255 of maximum. The distance between these two points is the reflector length. .

7,2.6 Mark the reflector location on the nozzle bore surface with an approved, semi-permanent marking pen.

. 7.2.7 Rotate the search unit 180 and scan the area of interest to establish whether the reflector can be detected when scanning in the opposite circumferential direction. Record any indication, regardless of amplitude, per paragraphs 7.2.1 through 7.2.5.

8.0 EVALUATION OF REFLECTORS WITH THE 0* TRANSMIT-RECEIVE

. EXAMINATION SYSTEM 8.1 Only areas where indications are detected with the 70* search unit shall be scanned with the 0* transmit-receive examination system. Any indication detected with the O transmit-receive search unit, regardless of amplitude, shall be recorded.

8.1.1 Record the maximum emplitude of the reflector, a) in percent of the primary reference level when reflector amolitude is less than the primary reference level, or b) by number of

. dB required to reduce the maximum amplitude to the prima y reference level when the reflector amplitude is greater than the primary reference level; i.e., "1000 + 6" when reflector maximum amplitude is 2005 of reference.

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,/ 8.2.1 Record the depth of the reflector at the location of maximum amplitude as read from the instrument sweep.

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f 9.0 REFLECTCR CHAR.:CTERIZATIC.'! .

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. 9.1 Reflectcrs which meet the folic.ving criteria are considered Indicative or inclusicns, porosity, or lack of bcnding betwaan

.the cladding and base material. Theyare,therefore,censic5 rad

, innocuous. -

, 9.l.1 Any indicaticn detected by the 70 examination, regardless of amolitude, at a death with in the weld-deposited, stainless steel cladding.

9.1.2 Any indication de e:ted by the 70' examination,

, regardless of amplitude, also detected by the O transgit-receive examination at a corres'ponding location and at a depth within + 2 m of that predicted by the 70' test. -

9.2 Reflectors who exhibit characteristics other than those described above are cons: cered susocct and will be subject to evaluation on an indivicual basis.

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g- 12/21/79 ULTRASC!IC TEST PROCEDURE FOP. DETECTIO:1 0F SUS-CLADDI::G CRACKS I:1 REACTOR VESSEL N0ZZLE SCRES 1.0 SCOPE 1.1 This document provides supplementary calibration requirements g- and additional scanning requirements for outlet no::les.

e- 5.0 TEST. -SEriSITI','ITY .

Add the following paragraph .

5.3 " Calibration shall be checked at four hour intervals during the examination. If, during any calibration check it is determined that the primary reference amplituce has decreased by 20 of its amplitude, all data sheets since the last calibration check

- shall be marked void, a new calibration sheet made, and the

\ voided examination areas reexamined.

If the primary reference amplitude has increased by 20'; of its amplitude, all recorded indications since the last valid calibration check shall be reevaluated with the corrected calibration arrd their values shall ce changed on the data sheets".

t 6.0 SCA? MING - 70* EXAMIrlATIO (

6.1 Add the following sentence "The end face of all outlet nozzle projections shall be scanned in two circumferential and two radial directions".

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.sppendix C Fracture Mechanics Analysis Introduction Indications observed during the recent inspection of the outlet nozzle regions of the Sequoyah Unit I reactor vessel are either the commonly observed " reheat cracking," which was addressed in considerable detail in 1971-1972, or underclad cracking which will be covered later in this section. Such cracks are small and located beneath the vessel cladding, and therefore not exposed to the reactor water environment.
The reheat cracks occur in vessels which are strip-clad, and result from the post weld head treatment process. This issue was addressed in three n'estinghouse reports sent to the SRC in 1971 (references 1-3). In these reports a metallurgical investigation of the indicatiens was reported, as well as a fracture assessment. A summary of that work will be provided here, along with an assessment of the applicability of the conclusions reached in light of the include a general assessment of flaws in the outlet nozzles found to be of a larger size than the aforementioned "rcheat cracks" or of different origin. Ribeat Cracks These cracks are restricted to the coarse-grained region directly beneath weld bead overlaps, which has been found to be less than .125 inches in depth. The r.ajority of reheat cracks are less than this size, but for conservatisa this is the size crack which was analyzed. A fatigue crack growth analysis was carried out for such a flow located in several differnet regions of the reactor vessel, including the head regions, the beltline, and outlet nozzle /shell weld areas. Results showed that the maximum growth of such flaws would occur in the nozzle shell region, and would be only about 0.004 inches, during an entire 40 year operating lif e, and therefore this type of crack would not penetrate the cladding during the vessel lifetime. The assumptions made in this fatigue crack growth analysis are listed below, and add some considerable conservatism to the analysis:
a. The flaws (intergranular separations) are continuous and are on the inside surface. The assumption that the flaws are continuous rather than the maximum observed 0.4 inches in length adds conservatism to the analysis and simplifies the calculational methods,

b. As a most detrimental orientation, the flaws are directed normally to the maximum stress at each location investigated.

c. The stress distribution due to thermal transients are linear through the wall. This conservatism also facilitates the-stress intensity calculations and eliminates the need to consider several time steps for each transient. .

d. The maximum flaw depth is equal to the maximun depth of grain coarsened region at the overlap area, i. e., 125 mils as opposed to actual observed flaws of 100 mills depth maximum.
I C-2 The fatigue crack grcwth properties used were verified by growth rate tests of actual affected material, uhich showed no difference in behavior frca unaffected material. Each of the assumptiens above could be refined based on later technology, (for example a finite length rather than cen-tinuous flaw could be considered) but in each case the result would be to make the crack growth results smaller. The specific area where the indications presently of interest are located was not considered in the analyses of references 1-3, but the crack growth in any region of the vessel for such cracks will certainly be very small. This has been shown for a number of different cases of buried flaws, for example reference 4. The expression used for stress intensity factor K for this region was that , for a centinuous surface flaw, which could be as much as a factor of two-three conservative. Since this value of K is raised to a power of 3-4 in the crack growth analysis, considerabic conservatism results. Furthe rmore , investigation of both the chemical and mechanical properties of the materials exhibiting this cracking behavior showed them to be simi-lar to those of the unaffected material. Therefore it is concluded that the structural integrity of the vessel has not been impaired, and it is therefore suitable for service. CONSIDERATION OF LARGER CRACKS The above assessment shows that re-heat cracks of 1/8 inch maximum depth will act impair the structural integrity of the reactor vessel. In this section the behavior of other postulated flaws 1/8 inch and 1/4 inch maximum depth in the outlet nozzles will be evaluated. It is assumed that the flaws are all semi-ellipses of major axes 3/4 inch and 1-1/2 inches, respectively. INLET vs OUTLET N0ZZLES Calculation of the growth of flaws in the outlet nozzle by fatigue shows that the majority of crack growth results from the load follow transient. Typically, this transient generates 250%(usually--75%) of the total growth. The same transient accounts for 5% of total growth in the inlet nozzle. The difference is due to the temperature change in the inlet nozzle being 2F versus 65 F in the outlet nozzle thus yielding a much lower thermal stress for the inlet nozzle. Accordingly, only the outlet nozzle will be addressed here. Attention will be focused on the corner region since the most limiting conditions are generally observed there. Unless otherwise noted the total number of specified design transients (load-follow) will be used. FATIGUE CRACK GROWTH Detailed fatigue crack growth calculations of postulated flaws in outlet nozzles have been performed on other vessels. It is judged that these results are applicable to TVA since the thicker nozzles considered would have higher thermal stresses (17.3 inches vs 14.8 inches thick in the to:ner).
C-3
~~,- CR0kTH TilRU ClltD \ .~~
For an assumed clad thickness of 1/4 inch, initial flaws of 1/8 inch or 1/4 inch depth will not penetrate the clad during the 40 year design life-time. This result is based on the assumption of no residual stress in the clad. This assumption is considered valid and perhaps even con-servative since even with the assumption of an initial residual stress of 50 kai, " shakedown" during the componenc hydro is expected to eliminate the residual tensile stress in the clad and leave the clad in ccepressicn. CROWH IN BASF METAL A very conservative estimate of the growth of flaws in the base metal may be obtained by ignoring the clad and arbitrarily increasing the depth of the initial flaws to 3/8 and 1/2 inches. The maximum penetration into the base metal is then calculated to be < .25 and < .29 inch for base metal cracks initially 1/8 and 1/4 inch deep, respectively. ' These results did not include the structural affect of the clad on growth of cracks in base metal. The affect of the clad is to reduce the growth slightly since the calculated maximum tensile component of the cyclic stresses of most of the transients evaluated is reduced. FATIGUE CRACK GR0biH - SU' DIARY The above indicates that postulated flaws initially 1/8 inch and 1/4 inch deep if present in the outlet nozzle corner: 1, will not penetrate the clad during design life, and
~~2. will not grow significantly into the base metal.~~
Finc.1 base metal crack depth is estimated as < .25 and < .29 inches for initial 1/8 inch and 1/4 inch flaws. These estimates are considered conservative since experience indicates that the load follow transients rarely if, at ever, occur at a rate of 5%/ minute and a very small number of transients extend frca 15 to 100% power. For example, a review of records for a base load plant suggests a maximum expected rate of change of < 3%/ minute and a number of 15 to 100% transients of about 300, as opposed to 18,300 specified and used in the above calculations. Critical Flaw Sizes Normal Operation Experimental data derived from vessel tests (ref. 5) indicates that the critical flaw size in the nozzle corner region (vessel V-5) is of the order of the wall thickness. A more conservative approach can be obtained by considering calculated critical flaw sizes. Calculations made in 1975 (ref. 6) assuming finite (3-D) flaws yield a critical flaw size in the nozzle corner region of 4.0 inches in depth.
C-4 - llence experimental data and calculations indicate that the critical flaw size is greater than 10 times the naximum expected flaw size which is < .3 inches. Accident Canditions A highly conservative calculation nade of the critical flaw size in the nozzle corner following a large loss of coolan: accident is given in ref. 7. The results were for a continuous (2-D) flaw and the critical depth was >2 inches. More recent calculations using 3-D methods yield critical flaw depths of
~~> 3.0 inches for loss-of-coolant and large-steamline break accident's.~~
The minimum critical flaw size for the TVA nozzle under accident conditions is estimated to be significantly greater than twice the conservative estimated end-of-life size of < .3 inches. Conclusion Since the maximum expected growth of initial flaws (1/8" and 1/4" deep) is conservatively estimated to result in final flaw sizes ( 3 inches deep, which is more than 10 times less than the critical flaw size for normal operation and more than 2 times less than critical flaw size for accident conditions, ASME Section XI evaluation criteria are satisfied and integrity is assured. O
1 . .r REFERENCES
1. Ma ge r , T . R., et al, " Reactor Vessel Weld Cladding--Base Metal Interaction," Westinghouse Report WCAP 7673-L, April 1971.

2. Mager, T. R., et al. " Reactor Vessel Weld Cladding--Base Metal Interaction," Westinghouse Report WCAP 7673-L, Addendum 1, August 1971.

3. Mager, T. R. , et al, " Reactor Vessel Weld Cladding--Base Metal Interaction," WCAP 7733, July 1973.

4. Marstone, T. U., editor, "Section XI, Flaw Evaluation Procedure:
~~Background and Applications," EPRI SP 719-SR, January 1977.~~
5. ORNL/NUREG-7, " Test of Six-Inch Thick Pressure Vessels Series 4: Interaction Test Vessel V-5 and V-9 with Inside Nozzle Corner Cracks," August 1977.

6. Marshall Report, "An Assessment of the Integrity of PWR Pressure Vessels," United Kingdom Atomic Energy Authority, October 1976.

7. Buchalet, C. B., " Fracture Mechanics Evaluation of the Integrity of an Inlet Nozzle of a Pressurized Water Reactor Vessel Following Postulated Loss of Coolant," ASTM, STP 560, August 1973.
~~e}}~~

ML19296C820

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