ML19305A609

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Affidavit Giving Essential Performance Requirements of Sensitization Tests Results Performed on TMI Specimens.Prof Qualifications & Supporting Documentation Encl
ML19305A609
Person / Time
Site: Zion  File:ZionSolutions icon.png
Issue date: 11/16/1979
From: Clarke W
GENERAL ELECTRIC CO.
To:
Shared Package
ML19262B069 List:
References
NUDOCS 7912110532
Download: ML19305A609 (64)
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Text

{{#Wiki_filter:. --_ _ _ _ _ _ _ _ UNITED STATES OF AMERICA NUCLEAR REGULATORY COMMISSION i BEFORE THE ATOMIC SAFETY AND LICENSING BOARD TJ THE MATTER OF ) ) COMMONWEALTH EDISON COMPANY ) Docket Nos. 50-295 ) 50-304 (Zion Station Units 1 and 2) ) ) Proposed Amendments to -) Increase Spent Fuel Storage ) Capacity (4 3 F.R. 30938) ) STATE OF CALIFORNIA ) ) SS. i COUNTY OF /;. ;:,

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) AFFIDAVIT OF WILLIS LLOYD CLARKE, JR. I, WILLIS LLOYD CLARKE, JR., of lawful age, being first duly sworn, upon my oath certify that the statements contained in the attached pages and accompanying exhibits are true and correct to the best of my knowledge and belief. /h//12 fd I M& p SUBSCRIBED AND SWORN TO before me this '.. day of

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1979. THIS DOCUMENT CONTAINS POOR QUALITY PAGES ,l t. t 'o t ? Notary ~Public __-----l. My commission expires [. 19 - 7912110 t

GENER AL h ELECTRIC N M EAR ENER Y ENGINEERING GENERAL ELECTRIC COMPANY,175 CURTNER AVE., SAN JOSE, CAI'FORNIA 95125 DIVISION November 12, 1979 TO WHOM IT MAY CONCERN: My name is Willis Lloyd Clarke, Jr. My background is summarized in the attached biographical sketch. The attached EPR data report sheets (Tests #169C-172C) accurately reflect the tests that I performed at the Leckenby Co., Seattle, Washington on October 25, 1979 Sincerely, Willis Lloyd larke, Jr. Principal Metallurgical Engineer i I

0 BIOGRAPHICAL SKETCH W. L. Clarke, Jr. Principal Metallurgical Engineer General Electric Company San Jose, CA Mr. Clarke received his B.S. degree in Metallurgical Engineering from the Mackey School of Mines, University of Nevada, at Reno in 1960. He has done graduate study in corrosion science at Ohio State University, and in supera11oy development and strength of materials at UCLA and Stanford, respectively. !!r. Clarke is presently involved in research study to mitigate stress corrosion cracking in nuclear reactor piping and structural components. For the past four years, he has been the Program Manager for a U.S. Nuclear Regulatory Commission contract to develop a relatively new test for detecting sensitization in stainless steels. The development of this test (EPR) has been completed, and specifications implemented for industrial usage. The EPR test is currently being used by the G.E. Wilmington manufacturing facility, numerous steel producers, national laboratories and universities, and is undergoing proceedings by ASTM for adoption as a standard practice. He has been with the General Electric Company's Nuclear Technology Department for the past eleven years, working at the Vallecitos Nuclear Center in Pleasantoi; CA. Previous experience includes six years metallurgical development for Aerojet General Nucleonics at San Ramon CA., and two years with Phillips Petroleum Company at the Idaho Nuclear Reactor Test Site. Mr. Clarke has been an ASM member since 1960, a member of the Golden Gate Chapter executive board for the past eight years, and is the current past chairman. He has also been a member of ASTM for the past four yests. He is a registered Corrosion Engineer in the State of California.

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s R;ferenced Test Proctdurcs TP. 509.0181 G.E. Spec. E50YP19 EPR DATA RECORD SHEET 0R"Sh.835rs, E dno EWA No. 8f496 Test No. /d9C PROGRAM TITLE _lfCMDJ8V kEl e[bfAGE bW SabM7th) Specimen No. 204,3[ tocation efrss? Brto - 78/> Go Material 7~88M cf 8. Heat Heat Treatment,#2f- /4)E/OED Lot No. Product Form [ roe 4(E Mr4 TegE Surface Area 6,89/9 e*+r Test Parameters initial Rest (Corrosion) Potential -350 mV versus SCE Test Temperature _ 25 C Sweep Rate 6 V/h Passivating Potential / Time,200/E mV versus SCE/ min Mounted Specimen Surface Cell / Results Integratec' Current, Q C, C,7 b~ C Maximum Anodic Current mA Flade Potential mV Grain Size k 2 ASTM No. GBA 6,d?Bd6 / cm P

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i Referenced Test Procedures TP. 509.0181 G.E. Spec. E50YP19 ~ EPR DATA RECORD SHEET 6. h er. 87dno EWA No. 6f496 Test No. /d9C PROGRAM TITLE h(A'EX/BV ME[ O#dM (( [V4h/fr/ht) Specimen No. EO4K Location cfium Deto - Thir Ex>o Material T88M cf 8. Heat Heat Treatment /If- /4/E/OED Lot No. Product Form fro #AF Sr4 TagE Surface Area g, /9/9 e*+r

  • Hst Parameters Fnitial Rest (Corrosion) Potential -360 mV versus SCE Test Temperature 25 C

Sweep Rate 6 V/h Passivating Potential / Time ECO [f-mV versus SCE/ min Mounted Specimen Surface Cell Re sults Integrated Current, Q d,Of6 C Maximum Anodic Current mA Flade Potential mV Grain Size k ASTM No. GBA 6,MBC6 / cm2 P, 3* / C/cm 2 Remarks SO/tf[ /+1/ 20At kh7'siJG : Ct/4ffs27~ from A /NG CANfG eWsGHr /xE(feWrf lD $ Whf. Determined by //)M / Mm Date /S/M/79 s-l

R:;ferenced Test Procsdurcs TP. 509.0181 G.E. Spec. E50YP19 EPR DATA RECORD SHEET 0" F No. )#N.d'Ohoo EWA No. 82996 Test No. /98 C PROGRAM TITLE ECMGr3V SE/ $70AAGE WACK SAh4DYX> Specimen No. Y0/[4 Location Nf AC NdC D/sOWF- $77& ["D Material 7,fC// [ [ Heat Heat Treatment M.f-ME/oED Lot No. Product Form [72:E4Sr-Arc /d 73 g' f Surface Area 8,877f & L c Test Parameters Initial Rest (Corrosion) Potential - 869 mV versus SCE Test Temperature ,2 f C Sweep Rate b V/h Passivating Potential / Time _ 200 2 mV versus SCE/ min Mounted Specimen Surface Cell / Results Integrated Current, Q 6, C/S~' C Maximum Anodic Current # mA Flade Potential # mV Grain Size M ASTM No.GBAd4077/4 cm 2 P /, f C/cm 2 3 Remarks Determined by ) f fhAL Date /dk&f79

1-i Referenced Test Procedures l TP. 509.017,1 l G.E. Spec. E50YP19 I I EPR DATA RECORD SHEET ~ l ORF-No.83far. d~dhoo EWA No. 82 99f Test No. /98 C PROCRAM TITLE l Elk'E4J8V Nfl $7~OAAGf $ACK [VAl/4D D Speimen No. Y0/N Location Yf//X $dC D/^OWF- $77& [A'D Material 7,fC// [ [ Heat j Heat Treatment /IT-ME/oED Lot No. Product Form [rO#4sp-8/r4' TF Surface Area d.f777M

  • c 3.t Parameters Initial Rest (Corrosion) Potential - 369 mV iersus SCE Test Temperature

,f f C Sweep Rate b V/h Passivating Potential / Time 200/Z mV versus SCE/ min Mounted Specimen Surface Cell Results Integrated Current, Q 6, C/f' C Maximum Anodic Current # mA Flade Potential # mV 2 Grain Size M ASTM No. GBAd#d97/4-cm 2 l P, /f C/cm l Remarks Determined by[ d [ [ u_ Date /d 4[79

R::ferenced Test Procedurcs TP. 509.0181 G.E. Spec. E50YP19 EPR DATA RECORD SHEET C"." No.bMM Ebisosa EwA no. B299c rest no. /7/ C PROGRAM TITLE E M CA) 8 V S f / [70 4 ASS ~ $4M [VANM/ O Specimen No. Y 0/54-Location 0fD 7E W/f$PA)tWf- $A/7El 1 Material 7', fC#.f f-Heat Heat Treatment A IT-h E / p e B Lot No. Product Form h##dedM IJF Surface Area 8,2269 & ' c Test Parameters Initial Rest (Corrosion) Potential .IAC mV versus SCE Test Temperature 25' C Sweep Rate 6 V/h Passivating Potential / Time 200 /2 mV versus SCE/ min Mounted Specimen Surface Cell Results Integrated Current, Q 6, 6/O C Maximum Anodic Current / mA Flade Potential / mV 2 Grain Size 4 ASTM No. GBAd,8M4.12 cm 2 P, f, 2 C/cm Remarks l Determined by J [!M42 Date /4 4[79

Referenced Test Procedures TP, 309.0181 G.E. Spec. E50YP19 EPR DATA RECORD SHEET 2R7%.bMM 52/Jos) EWA No. 82995 Test No. /7/ C PROGRAM TITLE ffCKd'AJ8V hf/ [47/Aff-hf.X [VdbM/ t) \\ Specimen No. Y0/S4 Location 0ff/ 7E [ff $/stJLVf

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Product Form b##r#Ntr Mac-Surface Area 8,2267 (" e Test Parameters Initial Rest (Corrosion) Potential .789 mV versus SCE Test Temperature 2f C Sweep Rate d V/h Passivating Potential / Time 2 4727 mV versus SCE/ min Mounted Specimen Surface Cell Results Integrated Current, Q 6, 6/C C Maximum Anodic Current / mA Flade Potential / _mV Grain Size 4 ASTM No. GBAd.8M4J2 cm2 P, 2, 2. ' C/cm2 Remarks l Determined byMb / [M4 Date /4/24M9 i

Referenced Test Prccedures TP. 509.0181 G.E. Spec. E50YP19 EPR DATA RECORD SHEET BRF-No. b.er. Mh04) EWA No. 8 f 993~ Test No. /72 G PROGRAM TITLE [(/t'C4)By' kr/ 7D&fGE~ fdCE EVA?hMMA) / Specimen No. $dE fh7fkfEWyLocation hfAJCL fAO hElOM[^>7~ Material 7'368 C.f Heat Heat Treatment Aff- /dE/OED _ Lot No. Product Form MAffE 8A 7F Surface Area O 4878 Sm

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Test Parameters Initial Rest (Corrosion) Potential -8 74-mV versus SCE Test Temperature ff C Sweep Rate d V/h Passivating Potential / Time ESO 2-mV versus SCE/ min Mounted Specimen Surface Cell Results Integrated Current, Q d, @ 7 C Maximum Anodic Current / mA Flade Potential / mV 2 Grain Size 4 ASTM No. GBA48095/9 cm 2 P, d, 7[ C/cm Remarks Determined by h j [Ib Date /014!79

a o Referenced Test Procedures TP. 509.0181 G.E. Spec. E50YP19 EPR DATA RECORD SHEET W o.[Arar.[Ohod EWA No. 8f995^ Test No. /72 C PROGRAM TITLE [{MCD8y' 5f/ 7DfAM fACid SVAhMMU / g rimen No. $AE fh7fkfEhLocation $fx)[L fAO k E/OmMr Material T 3 6 8.ff Heat Heat Treatment ///- ME/OED Lot No. Product Form [Affc-8A r Surface Area d. 4878 M

  • f Test Parameters initial Rest (Corrosion) Potential -874 my versus SCE Test Temperature ff C

Sweep Rate d V/h Passivating Potential / Time __ ESO /2-mV versus SCE/ min Mounted Specimen Surface Cell [ Results Integrated Current, Q d, tCD 7 C Maximum Anodic Current / mA Flade Potential / mV 2 Grain Size 4-ASTM No. GBA4869ff9 cm 2 P, d, 7[ C/cm Remarks Determined by

  • [IM Date /4,#4[79

I. INTRODUCTION AND PROCEDURES Cracking was detected in the Type-304 stainless steel heat exchanger piping used in the fuel pool of the Three-Mile Island Unit 1 power station. The cracks were located predominantly in the weld heat-affected zones (HAZ) of piping used to circulate 2200 to 2300 ppm boron as boric acid. The piping was installed in 1974, and sections were removed in mid-1979 for evaluation. The work reported here was co. ducted at the request of the Materials Department of the Corrosion Research and Engineering Operation, Battelle Pacific Northwest Laboratory (BNL). The BNL investigation is being performed under a DcE contract concerned with Long-Term Storage of Spent Fuel and Spent Fuel Equipment. 1 A small segment (4 times 6 in.) of the heat exchanger piping (Figure 1) was received to evaluate the extent of sensitization in the cracked weldsent (Heat 334165), and for comparison with the noneracked material on the other side of the weld (unknown heat). The sensitization evaluation was performed using the EPR technique in 0.5 !! H S0 = 0.01 !! KSCN at 30 C and 6 V/h scan 2 4 rate. The details of this technique are described in ASTM STP 656, "Cocparative Methods for Measuring Degree of Sensit'.zation in Stainless Steel," (a copy is enclosed with this report)._ For conventional laboratory EPR testing, samples were removed from the base metal and the inside diameter of the weld HAZ of both weldment heats (see Figure 1 for sample identification). Also, a sample was removed from the teld HAZ outside diameter of the cracked heat for weld profiling using the at quential grinding and measurement technique (Figure 2). This sample permits profiling through the weld HAZ, and provides information useful for in-situ nondestructive EPR measurements which may be requested at some later date. Finally, in-situ outside diameter measurements were obtained on the pipe segment using a recently developed field cell and portable polarization system. II. RESULTS AND DISCUSSION The results of the EPR measurements obtained on the heat exchanger pipe weldcent are given in Table 1. The base metal of the cracked material (Heat 334165) taken as being greater than 0.250 in. away from the weld did not reveal any evidence of sensitization (Pa = 710-3 C/c=2). For comparison, P values a greater than 2.0 C/cm2 for Type-304 stainless steel reflect significant degrees 1

of sensitization. The weld HAZ on the inside diameter of piping generally 2 2 range between 4 and 20 C/cm ; structures with values greater than 20 C/cm are considered severely sensitized. The significance of these quantified values should be evaluated in conjunction with the resultant microstructures. Those microstructures where the sensitized grain boundaries are continuous (ditched) are more prone to intergranular stress corrosion cracking (and intergranular corrosion or both) than those which are discontinuous (dual). This statement also applies to sensitized microstructure 1 where the carbides precipitate along the grain boundaries as discrete particles, rather than carbide networks which appear as sheet-like arrays. 2 TABLE 1. RESULTS OF EPR MEASUREMENTS (C/cm ) FOR TYPE-304 STAINLESS STEEL FUEL POOL. HEAT EXCHANGER PIPING FROM THREE-MILE ISLAND UNIT 1 0 (0.5M H SO4 + 0.01M KSCN at 30 C and 6 V/h) 2 Sample Distance from Weld Fusion Line (mils) Sample Heat Location FL 50 100 150 200 250 2 10-3 869 334165 Base Metal 867 334165 HAZ (i.d.) 22.8 2 10-3 868 334165 HAZ (o.d.) 14.5 21.4 12.1 3.4 1.7 148C 334165 HAZ (o.d.)' 13.1 870a Unknown Base Metal 10-3 870b Unknown HAZ (i.d.) 0.8 149C Unknown RAZ (o.d.)* 1.4 8 In-situ using field cell The =icrostructure af ter EPR testing the Heat 334165 base metal sample (Sample 869) is shown in Figure 3a. It is apparent the grain boundaries are free of sensi-tization which is substantiated by the step structure (annealed) shown in Figure 3b for the same sample electrolytically etched with oxalic acid. In contrast, the inside diameter weld RAZ (Sample 867) of Heat 334165 revealed 2 severe sensitization (Pa = 22.8 C/cm ), and the grain boundary networks are mostly continuous (Figure 4). This sample was also re-evaluated in the through-wall direction where a banded microstructure was noted (Figure 5). The grain size varied from about ASTM 1 near the pipe surfaces, to ASTM 5 in the middle 2

of the wall. The EPR values (P ) are always normalized to account for grain a size differences; however, many samples contained both the large-and small-grained microstructures within the measurement area. In the latter case, the grain size was averaged to ASTM 3 before the final P computation was a made. The normalized, large-grain regions produce higher P values and generally a stress corrosion crack more readily than the smaller grained regions where the carbides are precipitated over a greater surface area. The results of profiling through the outside diameter weld HAZ of Heat 334165 reveal a maximum degree of sensitization about 50 mils from the weld fusion line. This distance is consistent with other heats of Type-304 stainless steel welded piping where the maximum degrees of sensitization usually occur between 50 and 100 mils from the fusion line. The HAZ extends to about 0.250 in. away from the fusion line which is also consistent with most of the steels 2 studied. It is of interest, however, that the P value of 21.4 C/cm measured a on the outside diameter is nearly the same as the 22.8 C/cm2 obtained on the inside. The welding practices generally used on stainless steel piping produce P values 2 to 10 times higher on the inside diameter compared to a the outside. The microstructures developed by EPR testing are shown in Figures 6 through 10 for the 50 to 200 mil sequential measurements, respectively. In Figures 6 and 7, both the large-and small-grained microstructures are shown (the grain boundary continuities are apparent). At 150 mils away fro = the fusion line the connected boundaries are absent, although the EPR indicates a minor degree of sensitization. The base metal of the unknown heat similarly did not reveal any sensitization (Pa = I 10-3 C/cm ). Even 2 more impcrtant, the inside diameter HAZ did not reveal significant sensi-2 tization, (Pa = 0.8 C/cm ), as clearly illustrated by the microstructures shown in Figure 10. The oxalic acid etch does indicate a few sensitized boundaries, but the EPR reveals individual discrete carbide particles rather than continuot i grain boundary networks. The miniaturized field cell was used to obtain EPR measurements on the outside diameter of the weld HAZ using 'the techniques developed for in-situ field application. The outside dia=eter HAZ of Heat 334165 revealed a P 2 value of 13.1 C/cm, which is considered a a severely sensitized value considering that the area measured was 0.250 times 0.250 in., so that an averaging effect of high and low values results. 2 The unknown heat revealed a relatively low value (Pa = 1.4 C/cm ), which l is exemplified by the microstructures shown in Figure 11. Only a few carbices 3

e decorate the grain boundaries of the unknown heat, while the sensitized grain boundaries in Heat *334165 are continuous. The first grinding and polishing eperation performed on the outside diameter of Heat 334165 revealed a shallow intergranular crack which emanated from the weld deposit (Figure 12). This crack, which extended about 45 mils into the base metal, was very shallow, since it was not present upon subsequent grinding to a depth of about 25 mils toward the inside. If additional investigation of nonwelded segments of Heat 334165 are performed, an approximation of the homogeneous heat treatment necessary to produce various levels of sensitization in Type-304 stainless steel is shown in Figure 13 2 value of 22 C/cm, for example, could be obtained by heating the steel AP a at 13500F for about 10 min, or at 1150 F for about 40 min. However, these times and temperatures are approxichte because considerable heat-to-Peac variability occurs in response to both welding and heat treatment for Type-304 stainless steel. II7.. CONCLUSIONS Based on the results of this evaluation, the following general conclusions can be made: 1. The heat exchanger pipe (Heat 334165) which revealed cracking after boric acid exposure was severely sensitized in both the inside and outside weld HAZ. 2. The base meta'l of the cracked piping did not reveal any significant sensitization. 3 A shallow crack (no greater than 25 mils deep) was detected which emanated from the weld on the outside of the cracked pipe, and extended about 45 mils through the HAZ. 4

4 The other side of the weldment evaluated was fabricated from an unknown i heat of Type-304 stainless steel. This heat did not reveal any significant levels of sensitization in the base metal, or in either HAZ locations (inside diameter er outside diameter). 3 1 5. The nondestructive in-situ EPR measurement technique was successful in identifying the high level of sensitization in the cracked pipe weld HAZ, and the low level of sensitization in the unknown pipe. I l i 1 5 i i l l I e 5

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