Text

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 of crack,the tangential aim a complementary technique technique calledisradial not suitable aim is usedforto:determining

1) verify (depth 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. .

, r This relationship 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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y = Time of arrival of echo from the corner of the keyhole; propagation path length - dy .

V3 = Velocity of shear waves in steel.

y = Angle of incidence of ultrasonic rays on radial through the keyhole

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, FIG. 3' Relationship of Keyhole Echoes as Function of

-!: - Transducer Location.

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FOmme peo. PGED 8044 UNIT I LP _ O CUSTOMER VN M0 M A A) Al A DISC TEST NO. TAT / 3 0 6 BB-@f / DATE f ,b f /

sO p9 - A - 3593 6glAL Ag RADIAL AIM WEDGE IDENTIFICATION FL S5 c te

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['liIl END % GOVERNOR O GENERATOR

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FACE O INLET % OUTLET j ' gg.ggg'~

Instrument Settings:

s LIEN N 465 8 *b VOLTS /Div hNNh lh UPPER SCALE b LOWER SCALE 3 p SEC/DIV.

p SEC/Div

' ustP il SENSITIVITY 4Cd b4 DB

.u A ,

R S LUTl N 1 h3 D G. SWITCH OFF SUPPRESSION OFF PULSE ENERGY t 2h FREQUENCY SELECTOR % OR 2TO8 gawr T T 1 sci '

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b Tect = D'/4 WEDGE IDENTIFIC TION b- ( Old _

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[ FACE: O INLET TOUTLET

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' i HEE lEmlmusiasfar , 5 UPPER SCALE 90 p SEC/DIV 5

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'OWER SCALE p SeC/Div.

r E 'I E al sys:Tr ap r hTil5 Nit t!i t

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UNIT ! LP O D'SC TEST NO TA) f306 Be S 8 0 DATE I//3!I/

S O. O 3- A - 3593 hGENTIALQ RADIAL AIM WEDGE IDENTIFICATION i:t 53 C to H VALUES M~3h

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,i 6 5 votTS/Div UPPER SCALE 50 p SEC/DIV.

t '; LOWER SCALE i p SEC/DIV.

l j

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, j' * , FACE- O INLET D OUTLET

?.] g. .33. dwgg Instrument Settings: \

l 465 B e_$ VOLTS /Div UPPER SCALE bO p SEC/DIV. [

LOVfER SCALE 5 pSEC/Dtv. :

8 E 11 MM UStP 11 SENSITIVITY 4 O# DB I

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7 Circle One Below:

1 h3

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RESOLUTION 0 G S)vlTCH OFF

[ PULSE ENERGY 1 2h SUPPRESSION OFF

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1 b0A fd hk b lNDICATION LOCATION ..

L Teel - 3'/4 F FOR RADIAL AIM ONLY p/SEC X IN = IN j INCLUDE RADIAL AIM CALI'oRATION PHOTO ON ATTACHED SHEET INSPECTORS I a w m. . AM RV CE D V S N es#atumre ///g/'/ V '

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.INblCATION RdPbRTING SHEET ronu no.rono sou l-CUSTOMER VEPeo m AA/Mg S tp _a DISC TEST NO. ~ 7A) 13 o 6 BB /18/ DATE I 12/P/

SO.r03-A V93 6ANGENTIAL Ai @ RADIAL AIM

[ WEDGE IDEN ICATION 5 5 -53cre

~

l H VALUES

.' C i_{ l j. ,'I,k[ ; - '

BALANCE HOLE LOCATION - M

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d4 END (GOVERNOR O GENERATOR 7 FACE. O INLET YOUTLET o ..; , ,

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j .j - - - -

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, j4; , _ss 4e t 5 VOLTS /Di[

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j ,, ~ [ iN - , j ~ i, ,

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. USIP 11 SENSITIVITY O b D-j5f:; ^,

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RESOLUTION 1h3 D G SWITCH OFF

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INDICATION LOCATION HEM b C A /0 9 5 t.

WEDGE IDENTIFICATIONG W -53 (CW H VALUES 2~

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@YE -,g FACE: O INLET $ OUTLET

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l w- QS,, g;Gu_'fifQ '"#'~'"'"' ''"9*

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l RESOLUTION 1 h3 D G SWITCH OFF PULSE ENERGY 1 2 $: SUPPRESSION OFi[i FREQUENCY SELECTCR gjh) OR 2 TO[

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5 INDICATION LpCATION I ,

b Tb cl 1. 9 .

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, , ,_ FACE: O INLET jfOUTLET m~ **ee m w w - - ,

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MUEUEE 485 B

=> b VOLTS /DIV. !

UPPER SCAL 5 OO p SEC/DIV.

k LOWER SCALE O p SEC/DIV. .

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NE JM RESOLUTION 1h3 D G. SWITCH OFF mw PULSE ENERGY 1 2$ SUPPRESSION OFF FREQUENCY SELECTOR IND 7 +l I .5 TO 2.5 OR h bTect ' 09hc l INDICATION LOCATION _ NVM I i S. 3 dx. x . o c a -M l

WEDGE IDENTIFICATION H VALUES O BALANCE HOLE LOCATION ~M l DISC s l

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END V GOVERNOR O GENERATOR 7 y giggj;g uwm g r^Ce: a l~'a <Ouun

. Instrument Settings:

0 " -" ~ ~~

4658 .5 votTS/Div.

UPPER SCALE _ OO p SEC/Div.

LOWER SCALE b p 'SEC/DIV.

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USIP 11 SENSITIVITY iO 4 M DB ,

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p.. Circle One Below:

l RESOLUTION 1h3 D G. SWITCH OFF PULSE ENERGY 1 2@ SUPPRESSION OFF

&na 4 i FREQUENCY SELECTOR

.5TO2.5 OR h ,

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sr-i = o% t INDICATIOtJ LOCATION MYMY FOR RADIAL Alld ONLY

p/SEC X . 063 IN.= 3b? iN.

INCLUDE RADIAL AIM CALIBRATION PHOTO ON ATTACHED SHEET INSPECTOR

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UNIT ! LP DISC TEST NO. N l 3 O I" BB NI I !I 3 Iff'I DATE S.O. M'A-3M3 . TANGENTIAL AIM WE DGE IDENTIFICATION f~l 4 I H VALUES 4" BALANCE HOLE LOCATION 3

' DISC , I I

END- kGOVERNOR O GENERATOR

, FACE: OINLET M OUTLET Inst.umcnt Sctrings: '

U E D D'A IU dos B

-Q VOLT,S/DIV I ji 'E,( ,' lE' UPPER SCALE - 20 p SEC/DIV.

LOWER SCALE p SEC/DiV.

b I L UStP 11 SENSITIVITY d O

N i IB M i

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Corcle One Below:

DB RESOLUTION 1@3 D.G. SWITCH OFF PULSE ENERGY 1 26 SUPPR ESS!ON OFF k-IND -+1 FREQUENCY SELECTOR b ml a '%

.5 TO 2.5 OR h INDICATION LOCATION BIO A I 5.7o &c.><.o63 d '6Go D

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WEDGE IDENTIFICATION FL 4I H VALUES S z.

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DISC a END.

l

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3:y instrument settings:

ab l

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VOLTS /DIV.

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LOWER SCALE O p SEC/DIV.

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CUSTOMER U R P/' o 10. 4 A1A16 UNIT I LP O DISC TEST NO.
M M59 es .3 81 DATE I,/ I El S.O. M3 ' A - MN hGENTIAL Awl RADIAL AIM l WEDGE IDENTIFICATION h bb ON f HVALUES ~3 BALANCE HOLE LOCATtON I DISC s I l
. l END eO GOVERNOR R GENE R ATOR pr F*CE. O lNLET XOUTLET Instrument Settings:
hh . ba, um ndMl=b= 465 B *b VOLTS /D '
UPPER SCALE 50 p SEC/Div. )
LOWER SCALE 5 p SEC/DIV.
UStP 11 SENSITIVITY 4 bi f
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Circle One Below:
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\ VW @ TM- , M 'M 41 INDICATION LOCATION Yd Y l l
b Ted = 31/4
_ WE DGE IDENTIFICATION FL 53 &ta H VALUES Od BALANCE HOLE LOCATION f END D GOVERNOR 7 GENER ATOR f
1 . - -- '
.,'c-FACE O INLET SIOUTLET 7a _
g Instrument Settings-485 B i$ yot7sfc UPPER SCALE M p SEC/Dtv l LOWER SCALE b p SEC/DIV l .Y ' ggyggsgegg USIP 11 SENSITIVITY 4 b i O] t gg g9
- mm 6 annese.seamme u m 4 Circle One Below:
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~
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b Trel' 3W .
FOP R ADIAL AIM ONLY p/SEC X IN = lt.
INCLUDE RADIAL AIM CALIBRATION PHOTO ON ATTACHED SHEET
/'A POWER GE' ERATION N INSPECTOR /' #m- .
SERVICE DIVISION se6atunge ///J/h .on't
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. 2. A lfu m I ih CUSTOMER V N O /3 hl N10d A UNIT LP __ O DISC TEST NO. TM i 6 59 BB A K ) DATE if labI S.O D A- O - 3N3 RADIAL AIM
. . WEDGE IDENTIFICATION 5 9 5T-53 Cu '
H VALUES BALANCE HOLE LOCATION I DISC s I ll* END O GOVERNOR Di(GENERATOR I g[g p. , FACE. O INLET Jl8' OUTLET I l b c M s helsu a M M 4e e e5 v0LTS/Dit l
UPPER SCALE 50 p SEC/DIV.
j ,
-b LOWER SCALE b p SEC/DIV.
USIP 11 SENSITIVITY OiM Di :-
Corcle One Below:
9 RESOLUTION 1h3 D G SWITCH OFF
,{v.32jl PULSE ENERGY 1 2 h ; SUPPRESSION OFl .-
I*'# d~~ FREQUENCY SELECTOR W OR 2 TO I.i
, y@V O Y %)D. -
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.bTee)'4 INDICATION LOCATION N MM Y Sca r0 W 5 WECGE IDENTIFICATION 59 sT-53 CC4; j -
, H VALUES 8~Y
" BALANCE HOLE LOCATION !
I
! DISC s I l END. O GOVERNOR gGENERATOR
= -
FACE: OINLET gOUTLET
) .
Instrument Settungs:
y , .a.y gg 4650 c5 votTS/Div g_
UPPER SCALE D p SEC/Div.
LOWER SCALE b p SEC/DIV.
USIP ll SENSITIVITY 4O# DE
_L Circle One Below:
RESOLUTION 1h3 D.G. SWITCH OFF ,
PULSE ENERGY 1 2 h . SUPPRESSION OFG FREQUENCY SELECTOR OR 2 TO t?! '
( ~
tYi .- - - - -- -
sont #5 b YU W INDICATION LOCATION bTee p/SEC X iM IN.=
IN FOR RADIAL AIM ONLY INCLUDE AADIAL AtM CALIBRATION PHOTO ON ATTACHED SHEET INSPECTOR W +*h b
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CUSTOMER \/Eg -
I tp q unit DISC TEST MO. D IbN BB Db DATE I! "')II S.O. O 3- A - 3M3 TANGENTIAL AIM AtM WE DGE IDENTIFICATION b* -
l' H VALUES S DALANCE HOLE LOCATION ' I DISC e I ! END.
8 '
O GOVERNOR kGENEHATOR FACE: O INLET NOUTLET WI9SM Instrument Settings: e >
465 8 ,
a 5 votT.S/Div.
UPPER SCALE OO p SEC/DIV.
LOWER SCALE O p SEC/DIV.
E USIP 11 SENSITIVITY DB Circle One Below:
RESOLUTION 1 63 CLG SWITCH OFF PULSE ENERCY 1 2h: SUPPRESSION OFF
' FREQUENCY SELECTOR * .5 TO 2.5 OR
[ Te e t :. Qg '
INDICATION LOCATION NMSY sa k .On GhocD WEDGE IDENTIFICATION H VALUES BALANCE HOLE LOCATION " '
DISC
END. O GOVERNOR O GENERATOR FACE: OINLET O OUTLET ,
Instrument Settings: l 465 B _ VOLTS /DIV.
ATTACH UPPER SCALE p SEC/DIV.
PHOTOGRAPH LOWER SCALE p SEC/DIV.
USIP li SENSITIVITY DU Circle One Below:
RESOLUTION 1 2 3 : D.G. SWITCH OFF . ~
PULSE ENERGY 1 2 3 - SUPPRESSION OFF FREOUfNCY SELECTOR .5 TO 2.5 OR 2 TO 8 INDICATION LOCATION FOR RADIAL AtM ONLY p/SEC X IN.= IN.
INCLUDE RADIAL AIM CALIBRATION PHOTO ON ATTACHED SHEET, l
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POWER GENEHAllON iNSeEC10RS .. s. O 2 ,....1-// w ,q A -!1- o t.?3 seavice o.v's'or- i l .
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TANGENTIAL AIM RECORDING SHEET-INLET # # ~ '~ "~
FCSLM NO. PC50 8043 CUSTOMER i. e CO P_
uNir i oo Em oisc 1 STATION OrN A NNh
l te ROTOR TEST NO. N/ F6 6 _ s o. 23886 93 LOCATION IN 1 EM -
DAl.ANCE GENERATOR GOVERNOR R y p, H HOLE 300 SCAN 360 SCAN LOCATION REMARAS CW CCW CW CCW 8Ohd hjyAJQP, L 9s 73 51 0-/ -
01< ole ex O/c /2t/- J M, 6 Y = 130 r:JDicM NOA.6
~
1 ' 7d 57 k-/% -
I ! i /37 -a7/
l 66 SR /A ~
i
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. SV SS~ Y&3h -
I b I A 9 - Mf-.
\/ 50 57.5'h-Y -- U U b '
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INSPECTOR
N ML ^
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TANGENTIAL AIM RECORDING SHEET- OUTLET r==,no.easo,on '
,j CUSTOMER-. 8 PO O /
STATION - WOP b UNIT LP- b BB 2 M /_
E \
LOCATION 1 N5 \ b-ROTOR TEST NO. TA)/5Db S.O. 23 A 3593 DISC - M END: STGOVERNOR 8 GENERATOR BAL.ANCE KEYWAYS 300 SCAN R tp (I6 H HOLE -_-
LOCATION CW CCW CW aEMARKS fxg5' Qo 4/ 7 CCW
] gQ Qg 6 .6K I
6K o/< ole op- $b-lRS auw 90 </ 7 .os~ t c4 '
15 -/60 wr 6?. 57.S~ 1 % .2 %
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TANGENTIAL AIM RECORDING SHEET-INLET D*f]D *]D 2 .1N Inl.:=
J a b Ju o Ju 3'
h ' .
, FORM NO. PGSO 8043 CUSTOMER 6 bO UNIT \ LP 2 BB 2Ol DISC 2 STATION O ANE ROTOR TEST NO. #IOh S O. 2M359 3 LOCATION N/ &d! I -
2 BALANCE GENERATOR GOVERNOR n y p, H HOLE seosCAN 360 SCAN REMARKS LOCATION CW CCW CW CCW 30 MM kM6(*
39 %7 49 ' O- I ^
~
Ok nA: 6K ok //h -2'/9 l
O k = JJ o 1~ubic>t v e n s
,s c h- Ib '
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4 0
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1 TANGENTIAL AIM RECORDING SHEET- OUTLET U h
FOIM NO. PCSD t042 CUSTOMER (b b UNIT / LP O BGM I STATION A ) o (P h AIll)N b/ ROTOR TEST NO. N /5Ob_S.O.-8 M AE93 LOCATION M iLJIfd d l!4. f DISC 3 END: E GOVERNOR EI GENERATOR -
BALANCE KEYWAYS 3GO SCAN R tp h6 H HOLE 1-LOCATION CW I CCW CW CCW g g ggj 21 15 90 47 b .625' l OK op o/c ox 90- 172 mx So 41 /,25b/.01 /)2 = 1/o & lvc # Cro m 7S- / s7 Fort bd SC 1%db i .
//fo - 3 II Eur 59 53 .2 - 3 kY l 1 isa- 3</9 5,4 50 ss- 3-Y @ V \/ h 51 M/ _@5-
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Mw L MS ABOL's
/ 1 1
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k h d \/ N/ h I ; i
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fi?h Po*a ce~ca"'oa
TANGENTIAL AIM RECORDING SHEET-INI.ET r@M No. Poso sees CUSTOMER e GO UNIT / LP -- 2 _BBM/ DISC 3 STATION MOI O NWA / ROTOR TEST NO. /SE SO.2-M 3 6 S LOCATION N/ 8IE! E-BALANCE GENERATOR GOVERNOR R v p, s note aco scan aco scan neuanxS LOCATION
CW CCW CW CCW bQdI[\j kMM@C S, G 92 49 O-I -
ox.
ok Ok oie 1:14-3Sb OK = 1)e k lucs n uin W Lif fr-lif -
I i 127 -245
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INSPECTORS " "
. e . . . . . hnvi r ni
TANGENTIAL AIM RECORDING SHEET- OUTLET s -
FOZM NO.PCSD 1042 CUSTOMER N h>O UNIT [ LP BB STATION __O_S NMMN M[ ROTOR TEST NO. I Ob S.O. O 3M 3 M8 LOCATION M i M II M14b N. DISC END: fd GOVERNOR YGENERATOR
l DALANCE KEYWAYS 360 SCAN
"
p6 a nott -
g LocAToN CW CCW j CW CCW gg pgg e'B as Go 49 o nc ~'S I OK ok OK OK fn - 113 nM* A/o hacx1Pous 3525 'lo 42 .mT-/.09 '
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ML19341B498

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