ML19341B498

Low Pressure Disc Ultrasonic Insp Rept

ML19341B498
Person / Time
Site:	North Anna
Issue date:	01/16/1981
From:	Virginia Power (Virginia Electric & Power Co)
To:
Shared Package
ML19341B497	List: ML19341B496 ML19341B498
References
NUDOCS 8102020371
Download: ML19341B498 (41)

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VIRGINIA ELECTRIC POWER COMPANY NORTH ANNA UNIT #1 LOW PRESSURE DISC ULTRASONIC INSPECTION REPORT 1/16/81 8'o o 037

LOW PRESSURE DISC ULTRASONIC INSPECTION REPORT INTRODUCTION This report covers the ultrasonic inspection of the Virginia Electric Power Co, North Anna #1 unit. This unit is of a shrunk on dise design with each disc keyed to the shaft at the disc bore area.

The disc keyways are located such that standard NDT techniques cannot be used.

The U.T. inspection was perfomed to detect possible cracking in the disc keyway area. The need for this inspection is a result of recent industry experience where stress corrosion cracking h~as occurred in machines of shrunk on disc design.

Cracking in this disc bore area, if allowed to propagate, could eventually lead to a disc burst.

DISCUSSION Ultrasonic inspection techniques have been developed for detecting keyway cracks without the need for unshrinking discs.

Two techniques are used; one for detecting crack indications and the other for verifying crack indications and measuring their depths.

The initial technique used is the tangential aim, where an ultrasonic transducer is mounted on a plexiglass block that sits on the disc hub.

'The plexiglass block is contoured so that it is in complete contact with the disc hub.

The ultrasonic waves are directed tangentially towards the keyway so that any cracks above the keyway area will be perpendicular to the sound beam and reflect the sound.

A careful analysis of the time difference between the echoes from the keyway and the crack allows

-discrimination of false indications.

This time differential procedure is accomplished by circumferentially scanning (see Figure 1).

Since the disc profile is composed of a series of compound radii a mathematical model was developed for transducer positioning and alignment.

The model was computerized to allow calculation of: (1) all needed infonnation for positioning and aiming the transducer for detection anywhere on the disc bore, (2) metal path length, elapsed time to keyway echoes, and time between keyway echo and crack echo, (3) time between keyway echo and suspected spurious indications, (4) various angles with interrelated ultrasonic central ray direction to disc and transducer axis.

Also because of the disc profile and the need for good sonic coupling between the disc metal and the plexiglass blocks (called compound angle wedges) a large number of blocks are required (see Figure 2).

Ifacrackindicationispickedupsonically,tilelocationisdetermined by the transducer location and its relationship to keyhole echoes and indication echoes (see Figure 3 and 4).

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Since the tangential aim technique is not suitable for determining (dept of crack, a complementary technique called radial aim is used to:

1) verify cracking detected by the tangential aim technique, and (2) to estimate the depth of crack.

In this method, the ultrasonic waves are directed perpendicular to the keyway.

The radial aim method works because a crack undergoes branching and spreading while it grows. Thus, the branching part of the crack includes components which reflects ultrasound back to the transducer.

Depth of the crack is estimated by measuring the time between the keyway echo and the flaw echo, and then coverting to round trip distance by multiplying by shear wave propagation velecity (126,000 in./sec).

ANALYSIS After ultrasonic inspection has indicated a possible disc crack, an analysis is made to determine what the indicated crack size is in relationship to the critical crack size as determined by fracture mechanics.

This relationship r

is used to determine Westinghouse recommendations regarding continued operation with a disc crack indication.

EQUIPMENT Electronic Instruments A)

KrautkramerUSIPll-UltrasonicEquipment(forrecommendedtest settings see Appendix A).

B) Tektronix Model 465B or Model 465 Portable Oscilloscope.

(Model 465B is preferred).

(For recommended test settings see Appendix B).

Transducers Transducers ranging in diameter from 1/4 inch to 1-1/8 inch and in frequency from 2-1/4 MHZ to 10 MHZ as detailed in the specific tables for each of the BB discs. Other frequencies may be used to further evaluate indications.

Wedoes Numerous plexiglass wedges varying in entrance angle, rotational a'ngle, radius of curvature, physical size and rotational direction are provided, as required for each of the BB discs, as detailed in the specific tables.

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Tran'sducer Hanipulators Transducer manipulators are used whenever hand scanning cannot be conducted.

A) Wedge Extensions B) Transducer Manipulators (j{R&DDrawingNo.12222J20)

C) Charlotte Fhnipulator Camera Tektronix C-5A Oscilloscope Camera, or equivalent.

Couplant Ultragel II. Westinghouse M-54410LF.

Calibration Standards A) 3/4 inch x 8 inches long cylindrical rod.

B) Plexiglass Block Conversion Factors.

Ultrasonic measurements of distance are presented as time interval measurements on the 465B oscilloscope.

Thus, time measurements in s/ division on the oscilloscope must be multiplied by 0.113 in/ sec for she r wave travel to convert them to linear measurements in inches.

INSPECTION RESULTS North Anna - LP-1 and LP-2 No. 1 LP -

No indications were reported on this rotor.

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. No. 2 LP - The discs on this rotor were free of indications with the following exception:

The No.1 disc, governor end, outlet side,. displayed a tangential aim indication in the disc keyway at balance hole No. 28.

This indication was confirmed with the use of the radial aim technique, the depth.is estimated to be.360" deep.

The No. 1 disc, generator end, outlet side, displayed a tangential aim indication in the disc keyway at balance hole No. 1.

This indication was confirmed with the use of the radial aim technique, the depth is estimated to be.200" deep.

RECOMMENDATIONS No reportable indications were found on any of discs on LP #1.

On LP #2, the No. I disc governor end.360" keyway crack and generator end

.200" keyway crack indications were evaluated. Based on our engineering judgement, the rotors are suitable for satisfactory operation, but disc #1, LP #2 must be reinspected in six months.

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Input Parameters :*eeded to Cales:Inte Direction Angles 86 and $ for Compci:nd-Angic Wedge.

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propagation path length = d '2 Ty = Time of arrival of echo from the corner of the keyhole; propagation path length - d.

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