ML19322B870
| ML19322B870 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 12/31/1970 |
| From: | BABCOCK & WILCOX CO. |
| To: | |
| References | |
| BAW-1364, NUDOCS 7912060701 | |
| Download: ML19322B870 (29) | |
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Analysis and Resolution of Dye-Penetrant g
Indicatio .a AISI-304 Alloy Cladding of Rea ct 2- Coolant System Elbows
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I B AW - 13 64 December 1970 0
I Analysis and Resolution of Dye-Penetrant Indications in AISI-304 Alloy Cladding of Reactor Coolant System Elbows Q Duke Power Company 5 Oconee Unit 1 I l I
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BABCOCK & WILCOX Nuclear Power Generation Department Components Engineering Barberton, Ohio Babcor,k & Wilcox g
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CONTENTS Page I. IN TR O D U C TIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 II. DESCRIPTION OF ELBOW PROBLEM ........... 2 III. INVESTIGATION AND FINDINGS ............... 5 A. Investigation of Manufacturing Aspects ......... 5 B. Investigation of Oconee Unit 1 Problem and Definition of Proble m . . . . . . . . . . . . . . . . . . . . . 5 C. Manufacturing History - Barberton ........... 6 D. Investigation of Manufacturing H i s to r y - M t. Ve rno n . . . . . . . . . . . . . . . , . . . . . E E. La bo ra to ry Exa mina ti on . . . . . . . . . . . . . . . . . . . 9 IV. CONCLUSIONS OF INVESTIGATIONS ............ I1 A. Corrective Action to Oconee 1 Coo la nt Sy s te m . . . . . . . . . . . . . . . . . . . . . . . . . 11 0 B. Corrective Action to Manufacturing Processes and Quality Control Imp rov e m e nt s . . . . . . . . . . . . . . . . . . . . . . . . . . 12 V. S U M MAR Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 0
List of Tables
- 1. Initial 10% Reinspection of Elbow Clad Surface . . . . . 2 5 2 100% Reinspection of Elbow Clad Surface ........ 3
- 3. Chemical Composition of AISI 304 Cladding for Ocone e Unit 1 Elbows Typical Analyses . . . . . . . 15 B
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I. INTRODUCTION In the course of the piping 1.ystem modifications ir.cidental to the installation of a replacement coolant pump at Oconee Unit 1. Duke Power, !
the straight section of the B-67 clad piping assembly was returned to le the Mt. Vernon Works of the Babcock & Wilcox Company for rework. j In the course of this rework a routine dye penetrant examination re-vealed some indications in the cladding. The affected cladding was re-moved by machining and replaced by weldiag in Mt. Vernon.
In order to assure that the balance of the cladding in the Oconee Unit I piping system did not show a similar condition, a complete re-inspection of all of the cladding in the Oconee Unit I coolant piping sys-tem was initiated.
This report is addressed specifically to the work done with re-O lation to the cladding on the twenty-six clad elbows of the coolant pip- )
ing system; the investigation and findings of the problem with respect to manufacturing and non-destructive testing; and the corrective actions taken with respect to the Oconee Unit I coolant system elbows and man-ufacturing processes. An accompanying report, BAW-1363 addresses the work relating to cladding on the straight sections of the coolant system piping.
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II. pfGSCRIPTION OF ELBOW PROBTVM j As a result t..~ the detection of dye penetrant indications in the straight length of the B-67 coolant piping assembly returned for mod-ification to Mt. Vernon Works from the Duke Power Company Oconee
- Unit 1, it was decid l to condue; a 10% reinspection of the elbow clad-ding at the job site. This work was started on September 3,1970, under the direction of Mt. Vernon Quality Control Organization. Since additional indications were noted on the cladding during this examination ,
I a decision was made on September 14 1970, to conduct a 100% examina-tion of the clad surface of all of the elbows in the coolant piping system.
The clad surface of all of the elbows was reground to a finer fin ish to permit the detection of very small indications. Results of the penetrant examination are summarized below.
I Table 1. Initial 10'*. Reir:spection of Elbow Clad Surface I Loop Type elbow Elbow reference num be r Date Re sults_
I A- 57 B.41 45' 90*
45' 8
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PT+0K PT - RejectIAI PT - Rejec tBI 9/11/70 9/11/70
- /13*70 I B-67 90*
45*
40*
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PT - Rejec t@l PT- RejectI *I PT - Rejec t(C )
9/13/70 I*I Mic ro-f assures in the 20' elbow; refer to Figure 7 for a more detailed desc ription. refer to paragraph IV. A. 3 for repair procedure.
I SI IC I Non-relevant surface indications-cleared OK with minor regranding and re-examination.
Mic ro-fis suring in the 43' elbow and surface indications in I the 45* elbow. The 45
- elbow was PT-OK at retest on 4/14/'*0.
On 9/15/70 the 41' elbow was ground to clear the indications .a three loc ations. The depth of granding required to clear the in-dications was as f ollows:
I Location 1 - 0.057 in.
Location 2 - 0.080 in.
Location 3 - 0.07 I in.
At this point the deepest area was probe ground with a small burr grander to base metal and measured with a dial depth I indic ator to dete rmine the thickne s s of cladding rer .anning in this area. The thickness of sc,und cladding left was 0.126 in.
thic k . It was then decided to remove all of the indications by I granding since required minimum thickne s s is 0.125 in.
repair work started on September 15 1970.
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Table 2. 100f. Reinspection of Elbow Clad Surface loop Type elbow E! bow refe rence nurnbe e Re sult s Date I h g
B-45 90*
45' 13
90*
90*
18 23 16 PT - OK PT - OK PT - OK 9/15/70 9/15/70 9/16/70 i
A-33 90* 3 PT - OK 9/16/70 A-67 45* 24 PT - OK 9/16/70 i B-57 90* 25 PT - OK 9/16/70 45* 26 PT - OK 9/16/70 B-46 45* 21 PT - OK 9/18/70 90* 22 PT - OK 9/18/70 A-24-t 90* I PT - OK 9/18/70 l5 4 90* 2 PT-OK 9/18/70 B-40 90' 19 PT - RejectI *I 9/21/70 A-24-2 90* 14 PT-OK 9/22/70 5 90' 15 PT - OK 9/22/70 B-45 45* 11 PT - OK 9/22/70 B-41 45* 4 PT - OK 9/23/70 B B-46 45* 20 PT - OK 9/ ./70 I*I Rounded indications in a 4" x 9" area which exceeded acceptance standard. The elbow was PT-OK after regrinding and re-exarmnation on 9/21/70.
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- Summarizing the extent of the problem, the inspection detected several minor surf ace indications on B-40 90
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90* elbows, and B-67 45
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were non-relevant and will not be uiscussed elsewhere in this report. (
Relevant indications described above are defined as micro-fissures as discussed in section Ill of this report. See Figure 6, Reactor Coolant Loop Isometric, for elbow reference numbers and locations.
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III. INVESTIGATION AND FINDINGS l A. Investigation of Manufacturing Aspects Elbow Manufacturing - In order to provide large elbows for
, coolant piping systems, Babcock & % alcox developed a manufacturing
[ method many years ago which consists of hot-terming two elbow halves and subsequently welding these half-elbows together. This type of man-ufacturing is routine and all of the process steps involved here are well known and inderstood by B&W manufacturing personnel.
The process for manufacturing the clad elbows for the Oconee project varies from the standard manufacturing process for elbows by I the introduction of two major process changes:
3 1. These elbows are manufactured from carbon 5~
steel plate which has been explosively clad with AISI 304 plate material.
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To ensure a high quality product, the surface of the cladding is inspected by dye-penetrant examination at duPont prior to shipment to B& W. After quenching the elbow halves, the surface of the cladding is again subjected to a dye-penetrant examination at B&W with records q
being kept of the inspections. In the course of further fabrication of the elbows, portions of the cladding adjacent to weld seams are again ex-amined by dye-penetrant procedures.
,, B. Investigation of Oconee Unit 1 Problem J and Definition of Problem y
The preceding manufacturing outline indicates that the clad-ding in coolant system elbows has received two complete and several partial dye-penetrant eraminations in the course of fabrication. Despite the very careful examination during fabrication, very small indications l were found in the elbows during inspection of material that had been y
shippe<1 to Oconee. In order to quickly define and assess the magnitude l of the problem, a 100% re-inspection of the clad elbows at Oconee was I carried out. At this time it was recognized that the indications, if present, would likely be very small and difficult to detect. Since nor-mal surface preparation had not proven adequate for the detection of
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i I these small indications, the entire surface of all of the elbows at Oconee was carefully ground to provide a mor- favorable surface for the loca-q tion of indications by dye-penetrant examination. The work was done under the direction of competent B&W NDT experts. As discussed in b section HI-E of this report, the indications were defined as micro-fissures called fissures occasionally throughout this report.
The nominal cladding thickness is specified to be 1/4-in.,
] and in order to ensure that the cladding thickness in the areas that were i ground in the course of corrective work would still meet minimum clad-ding thickness requirements of 1/8-in., the entire clad surface was sub-J jected to an eddy-current testing program. A special instrument had H
g been designed and built by B&W for this type of testing and was utilized for the ark.
Only two of the 26 elbows at Oconee showed any micro-fissures in the course of dye-penetrant exammation. The other 24 elbows were completely clear and free of dye-penetrant indications except for minor surface indications in the B-40 elbow. These B-40 indications were very shallow and generally round in shape and did not appear like fissures but rather like surface impressions which could have occurred during manufacturing. This observation indicates that a general problem was not evident but rather a problem that was specific to only two of the 1 bows at Oconee. The other 24 elbows appeared to be completely free of mic ro-fis sure s.
a C. Investigation of Manu'acturing
'E "i t rv - 3^rberto" In order to determine whether the two elbows showing pene-trant indications (as discussed in B above) had experienced any different treatment in the course of their manufacture which would account for the different behavior, an additional concentrated search of the process and inspection data at Barberton was initiated. This review indicated that during the fabrication of the first elbows for the Oconee contract, some difficulties were experienced with the accidental impregnation of iron into the stainless cladding surface during the hot pressing operation.
I Shop practice at that time permitted the use of a dilute copper sulphate etchant (Strauss solution) to identify areas of iron contammation. The I
records not only indicate that dilute Strauss solution was used to identify g .e- .wri
1 I iron contamination on the clad surfac.. but there it evidence that a bottle of full-strength Strauss solution was inadvertently sent to the shop to assist in the detection of the free iron. This strong corrodent was used on the first few elbows and later recalled and replaced by less ag-I gressive material. There is reason to believe that the defective elbows noted at Oconee were treated in this manner. The composition of the copper sulphate etchant used for free iron determination is listed below:
8 g CuSO4 - 5 H2O 2
500 cc H 2O 2 to 3 cc H 2SO4 conc.
l Conventional Strauss solution has the following composition:
10 g CuSO 4 5H 2 O I 100 cc H2O 1 10 cc H 2SO4 conc.
Records also indicate that a 10% nitric acid solution was used in an ef-fort to remove contamination from the A-57 elbow. There is consider-ably less evidence that nitric acid was also used on the B-67 elbow; however, there is a probability that this was indeed the case, although no specific written reference was noted in the records.
j In the proceedings of the Second International Congress on
, Metallic Corrosion held in New York on March 11 -15, 1963, S. P.
Rideout of Savannah River reports an incident where sensitized AISI I 304 was damaged in the course of efforts to provide an ultra-clean sur-fa c e. To this end, the surface was treated with a 8-20% nitric acid so-lution to which a small amount of hydrofluoric acid had been added. It is reported that these ccmponents developed intergranular fissuring later, perhaps not dissimilar in kind but more serious in magnitude than what was fo"nd in the two elbows at Oconee.
The preceding history provides a plausible rationale which
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could readily account for the fissuring in the cladding of the isolated two elbow units at Oconee. The fact that the incident involved only two of the 36 elbows at the job site lends support to the supposition that the I unauthorized use of harsh chemicals on two of the units eventually re-sulted in the clad fissuring noted at the job site.
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It was fortunate that the problem of iron contamination of tne clad surface was solved soon after manufacturing for the Oconee Unit I contract began. The solution consisted of replacin'g carbon steel spacer
[j bars with stainless steel spacer bars during the heating cycle and de-veloping an effective technique to remove the scale with an air blast a prior to pressing the half-elbow. The use of etchants to outline iron contamination was no longer necessary, arri the use of there reagents q was discontinued in Barberton.
D. Investigation of Manufacturing History
- Mt. Vernon At the completion of fabrication of clad elbows for Oconee v
1 Unit 1, it was decided to move elbow fabricatica to B&W's Mt. Vernon, li g Indiana, plant. Barberton retained only the shape-cutting of the explo-E sively clad plate and the hot-pressing of the elbow halves. All remain-ing operations were transferred to Mt. Vernon.
It would be unreasonable to assume that transfer of the work to Mt. Vernon would totally eliminate the problern, particularly since at the time of the transfer, the problem had not been identified and some of the work saw partial fabrication in Barberton and was completed in Mt. Vernon.
A review of the fabrication histo- y of the remaining elbows now in production in Mt. Vernon indicates that over 100 of these units
- have been fabricated. Only three complete elbows and one half elbow l showed any indication of this type of clad fissuring, and in each case the extent of the affected area was considerably less than 1% of the el-bow surface. The indications discovered in Mt. Vernon are considered p similar in kind to the elbow indications at Oconee, but several orders
- of magnitude less in degree. The indications in each case were ground out with the exception e,f a few metallographic samples that were re-moved from the affected area for laboratory examination.
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,1 Mt. Vernon had also used a dilute Strauss solution to identify iron contamination; however, this practice had been discontinued. In
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the course of removing the cladding adjacent to the weld seams, remoy- i al of clad residue from air are cutting, back gouging, etc., 5% HNO 3 is reported to have been used to identify residual stainless cladding, to 4 permit its removal by grinding, r
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ip i These data, then, suggest the probability that the isolated fis-f sunng of the Mt. Vernon-fabricated elbow sections could have resu'.ted I from the inadvertent exposure of the clad enrface to harsh corrodents in
'j g a manner cimilar to the Barberton experience. Only two of the 3-1/2 j 5 elbows that showed fissuring were quenched and tempered in Mt. Verrion.
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Ty Concurrent with the corrective work at the site, B&W's Al-g liance Research Laboratory conducted a metallographic investigation of the samples received from affected areas in elbow found in Mt. Vernon F .], 3 as well as some of the eladding material provided by Barbertos.. Metal-
./ lographic. examination of the surface of the claddir.g material in the as-received condition indicates this material to be annealed AISI 304 with
- J a perfectly normal raicrostructure, as shown in Figure 1. Typi:a1 chemical analyses of the AISI 3C ' cladding used for the Oconee Unit 1 LN elbow cladding are shown in Table 3. In the course of processing the plate into an elbow in the B&W shops, the eladdic.g nr :ria' is heated B to about 2000F. T' - is followed by slow cooling. The slow cooling from elevated temperature results in almost complete precipitation o' the carbides in an intergranular manner. Figure 2 shows the structure of the explosive cladding at 90x under polarized light. Figure 2A i'lus-I5 trates the structure under normal illumination. In order to illustrate
,' that the carbide precipitation does not adversely affect the mechanical j properties of the cladding, bend specimens were prepared from the
[ excess rnaterial of one of the elbows after complete processing. The O bend specime s indicates the material to be sound and ductile, as would { be expected from this material. A typical bend specimen is shown in Figure 2B. Figure 3 depicts the micre structure from the bent portion l of the bend specimen. The cold work produced by the small amount of I f elongation involved in bending is reflected in this photomicrograph. Figure 3A illustrates the same structure under pol.rized light. Typi-j cal fissures found in specimens removed from areas that showed dye-penetrant indications are shown in Figures 4 and 5. Figure 4 is a view [ of a fissure in the unetched condition at 100x, and Figure 4A shows an b E etched view of the same fissure. Figure 5 shows another fissure in the 1 B
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5 unetched condition, and Figure SA shows the same view after etching. It is by these findings that t'se indications are defined as micro-fissures. It is interesting to note that the isolated fissures that were fourd in Mt. Vernon as well as the fissures ground out of the B-67 elbow at the Oconee site were all found to lie in a band formed between the cladding surface and a parallel plane 1/8-in, below the surface. Thus, removal of the fissures by grinding the B-67 elbow leaves an adequate thickness of cladding that was completely unaffected by the fissuring; this fact is important only in that shop and field rework is minimized. Records of the field repair of the A-57 elbow indicate that some of the fissuring extenced beyond the 1/8-in. Iaminar band down to the carbon steel base metal, requiring additional clad overlay and heat treatment. Figure 7 shows a map of the dye-penetrant indications and their extent. S g l I I I l I l I I I : Babcock & WilcoK l 1 i
m 0 1 IV. CONCLUSTONS OF INVESTMATIONS ; A. Corrective Action to Oconee I Coolant System As pointed out in section II, there were actually three elbows 1 that were not PT acceptable after the initial examication and 110% re-exa mination. They were as follows: 1 - 90* elbow in D-40 assembly. 1 - 90* elbow in B-67 assembly. 1 - 90* elbow in A-57 assembly. Repairs to each of the above listed elbows were made in the field at the Oconee Nuclear Station, as follows:
- 1. B-40 Elbow - This elbow contained only one small area h approximately 4 by 9 in. The indications were probed until PT cleared and depth reading revealed the deepest indication was 0.075 in. The area was blend-ground to a 3 to 1 taper, and re-PT cleared. No further action was required on B-40 elbow.
- 2. B-67 Elbow - This elbow required grinding of 100% of the surface to be cleared. The grinding has been completed, and the entire surface checked for cladding thickness with the eddy-current in-st rument. All areas were at least 1/8-in. thick except two small areas.
One area was a small depth probe area, and the other was a spot 1/4 by W 1/2 in. with 1/16-in. clad thickness remaining. These two areas were s within 2 in, of a field weld, and were repaired as part of the back-clad-ding process, and stress-relieved with the field weld. All heat-affected areas were PT clear after stress relief.
- 3. A-57 Elbow - This elbow also required repair on 100%
of the surface. The indications were deeper in this elbow than in the others. There were a number of scattered areas in which grinding to base metal was required in order to clear the PT. Much larger areas had remaining thickness of less than 1/8-in., as indicated by the eddy-current instrument. The total surface of A-57 elbow is presently hav-ing a layer of clad weld overlay applfed to ensure cladding greater than I 1/8-in. thick. The welding is being done in accordance with standard B&W procedures. After welding, the surface will be grour.d smooth; the entire elbow will be stress-relieved, followed by UT for bond and a 100% P T. Babcock & WilcoK l l l
The information given with regard to the A-57 elbow is
,,,, not consistert with that given to AEC Compliance during earlier dis-h cussions, in that AEC was advised that none of the PT indications that had been found were deeper than 1/8 in. The deeper indications were l determined following the discussions with AEC Compliance.
B. Corrective Action to Manufacturing Processes and Quality Control Ircorovements The occurrence of a manufacturing problem such as the one l described here usually represents financial as well as schedule losses to the manufacturer and the customer, but it also provides a lesson that can prevent similar occurrences in the future if properly heeded. The effectiveness of the lesson is best evaluated by the quality and extent of the correedve action instituted to avoid repetition of the problem. The following corrective action has been taken by Babcock 8c Wilcox: g 1. The use of harsh etchants to evaluate the presence of free U iron or stainless steel residuals has been discontinued.
- 2. B&W has instituted a program where the clad surface of l the elbow will be dye penetrant inspected after every major operation '
to assure freedom from this type of indication in the end product and assure detection and correction of the problem at the earliest possible j time in the manufacturing process.
- 3. Mt. Vernon has effected an intensive operator training program usmg the dye penetrant technique. The men see about 80 hours of classroom and practical demonstration work as part of the B&W train-ing program, and in addition are qualified dye penetrant inspectors in strict accordance with the provisions of Section III Appendix IX of the ASME Code. Qualification is in accordance with the provisions of SNT-I TCIA which is the standard upon which the ASME Code relies. This involves another 10 - 30 hours of intensive training. Actual samples of unacceptable production work such as those discussed herein are used as visual aids.
- 4. B&W initially attempted to have DuPont supply the clad plate as ELC material; however, until recently, DuPont was not in a position to supply the ELC cladding. They have now agreed to supply NM I* DK l
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5 future plate with AISI 304 ELC claddir.g. The use of the ELC cladding provides greater resistance to this particular type of fissuring. 5 5 I 9 I E l a , 1 I l 1 I I l l I I I I l Babcock & Wilcox l
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SUMMARY
B&W's actions towards the solution of this prot?em will succeed u" in completely eliminating the micro-fissures in claddMg from the cur-rent Oconee Unit I pipe elbows, as well as from those for all future jobs. The very careful training of B&W operators, togeth:r with better control of the manufacturing processes, should guarantee sound clad-ding in future components, and certainly the thorough examination and corrective work conducted at the Oconee job site provides adequate r.ssurance that the problem there has been solved. In this connection,
!t is important to recognize that the cladding of these elbows is not con-sidered part of the structure in terms of the elbow's ability to withstand operating stresses. From a design point of view, the carbon steel car-'
ries the entire load. Thc- the cladding does not contribute to the in-D tegrity of the pressure boundary but rather provides a surface protec-tion for the carbon steel. The extensive investigations, surface examinations, and field re-work as discussed throughout this report makes possible the final con-clu= ion that the reactor coolant system integrity has not been jeopardized in any way and that the reactor coolant system is 1007. sound for opera-tion with respect to the investigations and repairs reported here. Q I I I I I I Babcock & Wilcoi g .-
3 3 D B G Q Table 3. Chemical Composition of AISI-304 Cladding for Oconee Unit i Elbows Typical Analyac s (by weight) Clad heat No. C Mn P S Si Cr Ni Co 67768 0.048 1.17 0.030 0.027 0.37 18.38 9.12 0.10 67673 0.057 1.04 0.016 0.021 0.62 18.80 9.20 0.09 67758 0.057 1.10 0.028 0.021 0.64 18.27 9.09 0.10 47667 0 062 1.12 0.018 0.027 0.59 18.52 9.18 0.09 57736 0.033 1.08 0.015 0.017 0.59 18.23 9.48 0.09 37810 0.031 1.26 0.013 0.022 0.38 18.32 9.37 0.10 37783 0.058 1.10 0.021 0.029 0.49 18.61 9.05 0.09 43435 0.052 1.48 0.024 0.029 0.46 18.80 9.31 0.10 l 67735 0.053 1.12 0.017 0.011 0.52 18.02 9.17 0.10 I I I I E I -- "'"""*
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