ML19341A333
| ML19341A333 | |
| Person / Time | |
|---|---|
| Site: | Cooper  |
| Issue date: | 10/31/1980 |
| From: | Czajkowski C BROOKHAVEN NATIONAL LABORATORY |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| CON-FIN-A-3106 BNL-NUREG-28724, TAC-12589, NUDOCS 8101220637 | |
| Download: ML19341A333 (37) | |
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BNL-NUREG-28724 INFORMAL REPORT LIMITED DISTRIBUTION e EXAMINATION OF A CRACKED TURBINE DISC FROM COUPER NUCLEAR POWER STATION BY C. J. Czajkowski October 1980 Corrosion Science Group Department of Nuclear Energy Brookhaven National Laboratory Upton, New York 11973 NOTICE: This document contains preliminary information and was prepared primarily for interim use. Since it may be subject to revision or cor-rection and does not represent a final report, it should not be cited as reference without the expressed consent of the author. l l 4
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1 L TABLE OF CONTENTS Page L i s t o f F i gu res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 111 Abstract........................................................ 1 Section 1.0 Introduction...................................... 2 Section 2.0 Visual Inspection / Optical Photography............. 3' Section 3.0 SEM/EDS........................................... 4 Section 4.0 Discussion........................................ 6 Section 5.0 Conclusions....................................... 8 Section 6.0 Recommendations................................... 9 Section 7.0 Acknow1edgements.................................. 9 Re fe re n c e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 e i _ _ _
LIST OF FIGURES Page Figure 1. F ro n t v i ew o f tu rb i n e d i s c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1
- 2. Three-quarter view of disc...................................... 12
- 3. Schema tic o f d i s c dimens i ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- 4. K eyway c ra c k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 .
- 5. Liquid Penetrant Examination of Keyway (front view) ...... .. .. .. . 15
- 6. Liquid Penetrant Examinati on of Keyway (top view). .. .. .. .. .. .. .. 16
- 7. Fra c tu re fa c e o f ma i n c ra ck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- 8. Cros s secti on of crack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- 9. Fractu re face o f crac k f ront. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- 10. Schemati c of crack face wi th di me ns ions . . . . . . . . . . . . . . . . . . . . . . . . . 20
- 11. Schematic o f opposing fracture face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- 12. Intergranula r area of fracture face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- 13. Fractograph of transgranular section of fracture face... .. .. .. .. 22 14 a) SEM photo of particles near initiation site b) EDS scan of particles for constituents present. ...... .. .. .. .. 22
- 15. a) SEf1 photo of circular pa rticles b) EDS analysi s of pa rticl es. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 23
- 16. a) Fractograph of imbedded particles b) EDS scan of pa rticl e 's chemi s try. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- 17. a) Fractograph of particles b) Chemical analysi s of pa rticl es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- 18. a) SEM photo of crystalline particle b) EDS scan of particle..............er .s;...................... 24 .
- 19. a) SEM photo of partially opened crack b) Con stituents i n c rack area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 .
- 20. F ra c tog ra p h o f c rac k c h i p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5
- 21. a) SEM photo of granular particles in " chip" l b) Chemical analysi s of parti cl es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 i
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LIST OF FIGURES - Cont'd Page Figure 22. a)Fractographofparticulate b) EDS scan of pa rticul ates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
, 23. a) SEM photo of particles in area of partially thru crack b) EDS scan o f pa rti cl e s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- 24. a) Fractograph of particles on fracture face b) EDS analysi s for chemical consti tuents. . . . . . . . . . . . . . . . . . . . . . 27
- 25. a SEM phota of graphite-like substance b EDS scan of substance....................................... 28
- 26. EDS scan of l ubrican t "A" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- 27. EDS s can of l ub ri cant "B " . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- 28. EDS scan of l ubrican t "C" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- 29. EDS s can of l ubri cant "D" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- 30. Log of Crack Growth Rate vs 1/ Temperature in 3 CrMo turbine disc steel..................................................... 30 i
O I i l 191 _
l l l ABSTRACT An investigation was performed on a cracked low pressure turbine disc from a boiling water reactor. The fracture face was observed to have both inter-granular and transgranular cracking present. MoS2 was observed on the hub inside surface and various MoS2 lubricants were investigated for possible con-
. tributary effects. The crack growth rate of the disc was estimated from the measured crack size to be consistent with published British results, assuming crack initiation occurred during initial startup of the turbine. Crack depen-dency on prior cold work, MoS2 application and temperature are discussed.
I J 1 4 0
1.0 INTRODUCTION
The possibility of inservice failures of steam turbines, especially at nuclear power stations, has become the object of increasing concern in the past few years. This concern arises out of not only the non-profits derived by plant shutdowns which can amount to hundreds of thousands of dollars a day, but also of the possibility of significant damage to safety systems in the event of a - catastrophic-type failure. The most notable instance of this type of failure occurred in 1969 at the British Hinckl ey Point Huclear Power Station. The principal cause of the failure was determined to be intergranular stress corrosion cracking of a low pressure disc in the areas of the keyways, attributed to a concentration of HaOH in the keyways combined with a low fracture toughness of the steel caused by temper embrittling during manufacture. As a result of this incident, investigations were initiated to determine if any U.S. turbines had similar flaws. Weeks [1], in a review of stress corrosion cracking in various nuclear turbines e.g. Rancho Seco, Arkansas Nuclear -1, Hinckley Point -A, and Shippingport determined that caustic was present in all instances and that sufficient evidence was available to conclude stress corro-sion cracking as the primary mode of cracking. (Weeks considered that any por-tion of the fracture face which exhibited an intergranular surface evidenced the fact that the environment played a part in the propagation of the fracture by either stress corrosion cracking or corrosion fatigue.) Since stress corrosion cracks are normally brittle in nature and occur at stresses substantially less than those required to cause a failure in a benign environment, the type of failures which result can be quite cataclysmic in nature e.g. Hinckley Point -A. However, the growth rate of these stress corrosion cracks is relatively small (10-8 to 10-9 mm sec-1), and their presence can usually be detected before catastrophic failure occurs. The United States Nuclear Regulatory Commission - (U.S. HRC) has been conducting ongoing investigations into these phenomena for some tine. Pursuant to investigations by the HRC, a section of turbine disc from the Nebraska Public Power's Cooper Nuclear Station was sent to Brookhaven National Laboratory for examination.
The following information regarding the units operating characteristics and material history were obtained from discussions with representatives of both Nebraska Public Power and the U.S. Nuclear Regulatory Commission: a) The disc was manufactured of ASTM A471 steel, Class unknown. b) The disc was the #1 disc (generator end) and contained two cracks. c) The Station is a General Electric Boiling Water Reactor and the turbine manufactured by Westinghouse Corporation. d) The low pressure turbine did not have a prior reheating of the steam. e) The Station went into commercial operation July 1,1974. f) The disc received 41,913 hours of operation (on time). g) The keyway temperature during operation was approx. 350*F. h) Prior to shipment to BNL the disc had undergone both ultrasonic testing and liquid penetrant examination and had been cleaned with acetone before crating for shipment. 2.0 VISUAL INSPECTION /0PTICAL PHOTOGRAPHY The disc section weighed approximately 110 pounds and its dimensions were recorded (fig. 3). Initial examination de.'rted a crack in the keyway traversing its length measuring approximately 5 inches long (fig. 4). There was a second crack which seemed to initiate at the toe of the keyway and ran almost
. parallel to the main crack.
Further examination of the section disclosed some evidence of pitting in the keyway. There was also a coating of a greyish graphite-like substance covering the hub / keyway surfaces of the disc. (This is discussed in the SEM/EDAX section). I i l 2 l
In order to further characterize the extent and direction of cracking, a liquid penetrant examination was performed (figs 5 and 6). It can be seen from figure 6, that the crack extends into the hub surface from the tip of the keyway ' and a second crack branches into the keyway also seeming to initiate at the keyway tip. The depth of the crack was estimated to be approximately 2" deep as measured on the outer surface (fig. 5). A section was cut from the turbine disc approximately 4" deep and 1/4" from the edge of the crack on the hub surface to facilitate opening the fracture face. After sectioning, a large notch was machined (approximately 2") under the crack whose apex was approximately positioned below the crack tip. The section was then immersed in liquid nitrogen for almost one hour and summarily opened by applying force on the notch in a compression tester. The resulting fracture face is shown in figure 7. The remainder of the turbine disc was then liquid penetrant tested again to determine if the entire crack had been removed. This examination showed that some of the cracks still remained (fig. 8). The disc was then cut approximately one inch further along the crack direction and the above steps repeated. The resulting fracture face is shown in fig. 9. The fracture faces were then reassembled and measurements taken to show the crack dimensions (figs. 10 and 11). The crack's length measured 13.45 cm (approximately 5.3") at its longest dimension and 5.564 cm (approximately 2.1") at its greatest depth. The crack was characterized by a black adherent film covering the fracture face and appeared to be mixed intergranular and transgranular in nature as viewed thru a stereo microscope. Visual examination disclosed no arrest lines j or beach marks which would indicate that once the crack initiated, it progressed with no apparent cyclic frequency. 3.0 SEM/EDS Various chips of the fracture face were broken off for SEM/EDS examination. These were taken near the crack tip in hopes of determining if any corrodent species were present and to pick areas where the prior liquid penetrant examinations had not contaminated the fracture face. 1 S _ _ _ _ _
The cracking appeared to be of a miyed mode, both intergranular and transgranular in nature with the intergranular appearance more predominant in the chips taken from areas closer to the keyway. (Probable area of initiation) figs. 12 and 13. Various particulates were investigated by EDS on the varying chips, (figs.14 thru 18) all particulates showed peaks of C1 and evidence of both Si and K in varying degrees from traces to peaks; one scan showed a trace of S and V with an abnormally high Mn peak with the C1 and K present. These particu-lates were widely dispersed among the chips. On one of the chips, a partially opened crack was scanned (fig.19). The scan portrayed peaks of Na, Mg, Si, Mo, C1, K and Ca with a trace of Ti in addition to the Cr, Fe and Ni. A smaller partially thru crack on the disc was then opened up and examined in the area of the crack tip (fig. 20). Various types of particles were scanned of the four depicted, (figs. 21 thru 24) three of the particles showed C1 peaks with Si, S and Al varying by particle. One type of particle (fig. 24) showed only peaks of Al and Ti. An EDS scan of the graphite-like substance found on the hub surface of the disc was also perfomed (fig. 24), the scan showed peaks of S and Mo with a background peak of Fe (possibly from tool used to remove substance froa the disc surface). This is indicative that MoS2 was used as a lubricant. Since the detrimental effects of sulfur on high strength turbine materials is well documented, a further investigation into the MoS2 lubricant material was conducted. Four commercial brands of MoS2 were sprayed on graphite blocks and then scanned (EDS) to determine the actual material deposited (figs. 25 thru 28). - The results varied greatly from only Mo/S being deposited (fig. 25) to various metallic Mg, K, Ca, Si deposition with the MoS2 (fig. 26). One brand deposited Ti and Sb with the MoS2 (fig. 27) while the fourth brand (fig. 28) deposited only S and C1 with no discernable Mo after two different sprays. The l second spray did deposit a trace of Al, however, not shown on scan. 1 l l 5 I
4.0 DISCUSSION Since the deposition of contaminating species in c turbine environment is of concern in the stress corrosion cracking of discs, it is important to understand the possible methods of transport. - Very dilute solutions normally added to the turbine can be concentrated by . either of two methods. The first being solutions added to the turbine prior to operation will concentrate during the evaporative stage of startup as the tur-bine temperature begins to rise. Since each solution is a delicate equilibrium relationship between the variables of concentration, partial pressure and tem-perature; as the solution is heated (water is evaporated) the concentration process will continue until a new more concentrated equilibrium balance is established. This is particularly important in crevices (e.g. keyways) where
" steam ,, ashing" will not remove the contaminants. The second case occurs with contaminants already present in a " cold turbine." As the turbine is heated, condensation will cause these contaminants to deposit on turbine surfaces. The condensate can then be concentrated by the evaporation process. Jonas [2] has identified over 50 compounds of various types (oxides, silicates, sul f ates, phosphates, carbonates, etc.) in a review made of deposits in steam turbines.
Some of these compounds specifically Nacl, Na0H and sulfides have been known to cause corrosion of turbine materials [1,3]. It has also been observed [4] that there is a steam transport method of carrying over strong electrolytes (e.g. NaC1) from water into the steam phase, which potentially could concentrate and initiate corrosion. l The environmental sensitivity of turbine disc steels have been substan-tiated by the stress corrosion cracking of low and medium strength low alloy . steels in high purity wet steam [5,6]. This study also suggested a close relationship between certain non-metallic surface inclusions (specifically , sulfides) and stress corrosion cracking. 6
Turbine disc steels also exhibit a sensitivity to prior cold working in their relative resistance to stress corrosion cracking. It was observed [7] that the susceptibility to stress corrosion cracking was increased by prior cold work at a maximum of 15% cold reduction and decreased with continued cold work-ing up to 70% reduction. A limited amount of cold working in a disc steel would be normal in the process of shrink fitting the discs. Although the majority of stress corrosion cracks are almost entirely inter-granular in appearance, transgranular cracking has also been observed. A mixed mode of both intergranular and transgranular cracking was observed by Lyle et al. [3] on a cracked turbine disc (plant C). The intergranular attack was only evident at initiation sites with the remainder of the fracture face predominant-ly transgranular. The major contaminants visible on the fracture face were ob-served to be sodium, lead and sulfur; with high concentrations of both sulfur and lead found in sub-cracks. Sulfur (in the form of sulfide) contamination has been attributed to the formation of H2 S in the steam phase, with additions of sodium sulfite as an oxygen scavenging agent [8]. The effects of sulfide has been proven [11,12] in a variety of instances to cause stress corrosion cracking of disc alloys and other high strength steels. Sulfur's role in the fonn of nelybdenum disulfide (a lubricant in disc installation) may also be detrimental to disc steels in a turbine environment. Thornton, et al. [6] . observed that the addition of aclybdenum disulfide paste to the surface of disc steels (in a steam environment) did not affect the crack growth rate but had the effect of reducing crack initiation time by a factor of 3. The molybdenum disulfide also had the effect of producing a mixed inter / transgrarular mode of cracking and in reducing the amount of crack branchi'ng observed.
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Figure 30 is a plot of the temperature dependence of the crack growth rate in condensing steam, pure water and power station steam. In addition, a data point for the Cooper turbine disc is plotted. Points 1, 2 and 3 were taken from 1 7
the references at an initial K of 45 MNm-3/2 in order to take advantage of the relative insensitivity of the crack propagation rate in the range of 20 to 70 MNm-3/2. It should be noted, that the data point for the Cooper station is a minimum . value based upon actual measurements of the crack and assumes that the crack initiated at the turbine's initial operation. The plot does somewhat substan- . tbte the work of Thornton [6] in that the MoS2 had little effect on the crack growth rate. This plot is considered to be a representation of minimum values in crack growth rate as crack initiation time is assumed to be at time zero.
5.0 CONCLUSION
S The crack appears as a stress corrosion crack both intergranular and transgranular in nature. The EDS scans of the fracture face showed a wide dispersion of Si and C1 in particulates. The absence of beach marks or arrest lines denote that the cracking phenomena was continuous and not cyclical in nature. There was some branching of the crack from the keyway outward indicating that the toe of the keyway was the initiation site of cracking. The deposition of a film of MoS2 on both the hub section and in the keyway (film approximately 1/32" thick in areas) coupled with the fact that all of the PWR turbines which cracked had MoS2 present (telecon. W. Hazelton, U.S. NRC) gives credence to the following conclusion - that either the MoS2 or the medium of lubricant application (propellant, etc.) could have been the corrodent species necessary to initiate cracking. This is substantiated by the various EDS scans of four commercial brands of MoS2 which deposited a wide variance of elements which could be detrimental to the disc material. Although the current industry investigations of salt deposition by steam transfer may have been a , contributing factor in crack propagation (Na, K, Ca, Mg found in some scanning) it is more logical that the seemingly higher concentration of sulfur which would be found in MoS2 coupled with the potential additives possibly induced by the l transfer medium would be sufficient to initiate cracking in this instance. l 8
6.0 RECOMMENDATIONS l It is recommended, therefore, that an effort be made to ascertain which brand or brands of commercial grade MoS2 were used in the installation of the
^
cracked turbine discs and that the use of other lubricants be substituted in the installation sequence rather than MoS2-
)
It is also suggested that the effects of molybdenum disulfide on high strength disc material in a turbine environment be examined further. 7.0 ACKNOWLEDGEMENTS The author would like to thank C. Schnepf for his help with the sample preparations; D. Eriksen for his schematics of the fracture face; R. Sabatini for the SEM work and Dr. J.R. Weeks for his helpful discussions and support. i . l l l 9
l REFERENCES
- 1. Weeks, J.R., BNL-NUREG 22689-R, Brookhaven National Labcratory, June 1978.
- 2. Jonas, 0., paper presented at International Water Conference, Pittsburgh, .
Pa. , November 1973.
- 3. Lyle, F.F. , Jr. , Burde, A.J. , Burghard, H.C. , Jr. , Leverant, G.R. ,
- Corrosion 1980, Paper No. 233.
- 4. Styrikhovich, M. A. , Martynova, 0.I., Belova, Z.S. , Teploenergetika,1965
]2_(9)86-89.
- 5. Parker, J.G., British Corrosion Journal, Vol .13, No. 2,1978.
- 6. Thornton, D. V., liould, P.B. , Patrick, E.C. , Conference on Grain Boundaries, 1976, D13 (London: The Institution of Metallurgists).
- 7. Daig, P. , Browne, R.J. , Flewitt, P.E.J., British Corrosion Journal,1977, Vol. 12, No. 2.
- 8. McCord, T.G. , Bussert, B.W., Curran, R.M., Gould, G.C. , Materials Performance, Februa ry,1976.
- 9. Ford, F.F. , General Electric Report No. 79CRD119, fiay 1979.
- 10. ficIntyre, P., Central Electricity Research Laboratory, unpublished.
- 11. Opoku, J. , Clark, W.G. , Jr. , Corrosion, Vol . 36, No. 5, May 1980.
- 12. Wilde, B.E., Doyle, M.J., Corrosion, Vol. 35, No. 6, June 1979.
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DISTRIBUTION: NRC Materials Engineering Branch, ONRR c/o S.S. Pawlicki
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Materials Engineering Branch, ONRR c/o C.D. Sellers (10) BNL W.Y. Kato, Deputy Chairman Corrosion Science Group Files (50)
- Lawrence Livermore Laboratories A. Goldberg 3 (5)
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