ML20002E011

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Suppls RO on 710617:cracks Found in 3-inch Stainless Steel Tee Removed from Cleanup Sys.Southwest Inst Rept on Metallographic Exam Encl.Caused by low-cycle Fatigue Due to Transient Thermal Stresses.Ultrasonic Exam Planned
ML20002E011
Person / Time
Site: Big Rock Point File:Consumers Energy icon.png
Issue date: 08/04/1971
From: Haueter R
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To: Morris P, Skovholt D
US ATOMIC ENERGY COMMISSION (AEC)
References
NUDOCS 8101260077
Download: ML20002E011 (11)


Text

{{#Wiki_filter:" < ~.... + to I f[gOM h 5 % sen,i [ Np'any Consumers tfl[ \\ Di$# ~ w. 517788-0550 [ General Offices: 212 West M,chigan Avenue, Jackson, Michigan 49201. Area Code g ~G August h, 1971 h Dr. Peter A. Morris, Director Re: Docket 50-155 Division of Reactor Licensing DPR 6 (ZEK) United States Atomic Energy Commission Regulatory File Cy. Washington, DC 20545

Dear Dr. Morris:

Attention: Mr. D. J. Skovholt By letter dated June 17, 1971, we reported a cracking condition in a three-inch stainless steel tee removed from the Big Rock Point Nuclear Plant clean-up system. This letter is written to follow up the June 17 letter. A metallographic examination of this three-inch tee was performed by Southwest Research Int'.;a+e and their report of this examination is attached. The Southwest Research Institute report concludes that the cracks were primarily the result of low-cycle fatigue caused by the transient thermal stresses which occur when cold water is injected into the tee. They suggest that the presence of corrndon products in the cracks indicates that a corrosion mechanism may have also been involved in the failure. Discussions with Southwest Research In-stitt,;e personnel yielded that the primary cause of the failures is thermal stresses and the corrosion mechanism was only a minor assisting mechanism. They conclude that the results of this examination are consistent with the evaluation performed by General Electric Company on a similar tee which failed in the same service in May 1066. These conclusions confirm the conclusion of the June 17, 1971 letter. It is anticipated that the newly installed tee will not ex-perience this thermal fatigue cracking because the severe thermal mixing conditions were corrected by plant modification in September 1966. How-ever, Consumers Power Company will ul+rasonically inspect the newly insta] led tee using techniques described in the Southwest Research Inst'.tute report at the next refueling outage and at two-year intervals thereafter until the tee has been installed for five years. This in-spection will reveal any cracking that may develop in the newly in-stalled tee, i The attached report reveals tnat, the metallographic examina-tion uncovered sensitization in the failed tee. The manufacturing [ records of the newly installed tee were checked to insure that it did I i 3562. f/b/a4007)

8 4 Dr. Petar A. Morrio 2 August 4, 1971 not undergo heat treatment which would cause heavy sensitization. The material certification for the tee specified ASTM-A-403 which does not include heat treatment that would cause heavy sensitization. Yours very truly, 1 s.ac'c '< ' i a. r g,, v t. RBS/dmb Robert L. Haueter Electric Production Superintendent - CC: EHGreer Nuclear Div of Comp 1 USAEC

SOUTHWEST RESEARCH INSTITUTE POST OFFICE DnAWER 28510 SAN ANTONIO. TEXA S 78228 June 21,1971 Regulatcry File Cy. asses,d,4,rrafet S '7 1] Mr. D. M. Noble Nuclear Fuels Engineer Consumers Power Company 212 West Michigan Avenue Jackson, Michigan 49201

Subject:

Southwest Research Institute Project 07-2951-35 Purchase Order No. 58502 " Investigation of Cracking in 3-inch Type 304 Stainless Steel Piping Tee" FINAL REPORT

Dear Mr. Noble:

The ultrasonic and metallographic examinations of cracking in a 3-inch Type 304 stainless steel tee removed from the Big Rock Point piping system has been completed. This letter constitutes our report on these examinations. The surface of the tee was badly pitted as a result of the pickling-decontami-nation operation. Five cracks emanating outward from the inside surface of the tee approximately one inch from the piping-to-tee weld were readily apparent on visual examination as shown in Figure 1. These cracks were arbitrarily labeled Nos. I through 5. An ultrasonic examination of the tee was performed using both 45* and 70* angle probes. The probe size was approximately 8 x 9 mm and a frequency of 4 MHz was employed. The sound beam was directed from the OD fillet surface circumferential1y into the cracked area. The curved surface of the fillet presented some difficulty in maintaining adequate contact between the probe and tee, but the difficulty was partially overcome by use of a thick paste couplant. All the cracks were readily detectable with the 45' probe. The echo indication received from Crack No. 2 is shown in Figure 2 The results obtained in this laboratory inspection indicate that similar cracks would be readily detectable in the field with this ultrasonic technique. For field inspection, the use of sub-miniature, 4 or 5 MHz, 45' probes is rec-ommended to eliminate the surface-curvature difficulty encountered in this preliminary inspection. h.;23 g 4........... ...................... ~.. ~........... ~.

t Mr. D. M. Nobla Consumers Power Company June 21,1971 --2-- The metallographic examination was directed toward establishing the nature of the cracking and the nature of the weld root defect indications which origi-nally led to removal of the tee. A ring section was cut from the tee and broken open to permit examination of the fracture surfaces of Crack No. 2. The mating fracture surfaces are shown in Figure 3. The surfaces were covered with a tightly adherent black deposit, except for a narrow band of bright metal near the intersection with the inside surface. The black deposit is probably magnetite, the iron oxide formed at high temperatures, although a definite determination was not made. The bright metal presumably resulted from removal of oxide from the crack at the inside surface of the tee during the pickling-decontamination operation. The fracture surfaces are relatively flat and coarse textured. The crack is approximately 0.28-inch deep at the j deepest point. 1 Cross sections through Cracks Nos. 3, 4, and 5 are shown in Figure 4. The l crack paths are largely transgranular and the cracks are relatively straight with only a slight amount of branching present. The cracks appear to have 1 initiated from pits at the inside surface, but it is not possible to tell whether i these pits occurred during service or were induced by the pickling-decontam-ination operation. Corrosion product is visible at various points along the crack paths, particularly at the crack tips (Figure 5). The inside surface of the tee appears to have been severely cold worked in spots, as indicated by the. Mip-lines at the upper left in Figure 4c. An uneven etching response, or " banding", was obtained at the ID surface. Such banding results from localized segregation of alloying elements or impurities. The grain boundaries of the alloy are readily apparent in Figures 4 and 5, indicating-that the alloy has been subjected to a sensitizing heat treatment. A sample of the alloy was given a Streicher etch

  • to determine the degree of sensitization.

The microstructure after this treatment is shown in Figure 6. Carbide pre-cipitation at the grain boundaries is essentially continuous. Oar experience is that Type 304 stainless steel sensitized to this degree will fail standard i ASTM intergranular corrosion tests and, more importantly, is subject to intergranular stress corrosion cracking in boiling water reactor environments if stresses approaching the yield strength and a moderate amount of oxygen (8 to 10 ppm) or other oxidizer are present. Electrolytic etch in 10% oxalic acid solution for 90 seconds at a current 2 density of l' amp /cm 1

C. / \\ Mr. D. M. Noble Consumers Power Company June 21,1971 --3-- The general appearance of the fracture surfaces of Crack No. 2 and the morphology of the crack paths of Cracks Nos. 3, 4, and 5 indicate that the cracks are the result of low-cycle fatigue. The source of the cyclic loading necessary for fatigue is probably transient thermal stresses which occur when cold water is injected into the tee. The presence of corrosion products in the cracks indicates that a corrosion mechanism may also have been involved in the failure. A failure which occurred at this location in 1966 was attributed to thermal fatigue (GE CR-5401, Jan. 1967). The results of this investigation are consistent with those of that evaluation, although sensitization had occurred only near welds in the first tee and no corrosion products were noted. A metallographic section through the piping-to-tee weld, taken at the location shown in Figure la was also examined. A fatigue crack propagating from the weld root was observed in this section, Figure 7. As shown in Figure 8, this crack is transgranular without appreciable branching and contains a corrosion product at the tip. Also this section revealed that a portion of the root pass had either fallen out or been corroded away. In summary, this limited investigation has shown that ultrasonic inspection techniques properly applied are capable of detecting cracks in both welds and base metal of 3-inch tees in the Big Rock Point piping system. Cracks in the weld and base metal are attributed to corrosion assisted fatigue, probably resulting from thermal stresses induced during injection of cold water into the hot line. Future failures for the same reason are likely unless the connection is redesigned to account for thermal stressing. The tee material also exhibits an appreciabic degree of sensitization. Type 304 stainless steel in the sensitized condition is susceptible to stresc corrosion cracking in boil-ing water reactor environments. We strongly recommend that the employment of stainless steel components in this condition be avoided. Very truly yours, f ,e ( HCD/j H. C. Bur hard, r. Attachments Project Manager Prepared by: Fred F. Lyle, Jr.

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