ML20024E163
| ML20024E163 | |
| Person / Time | |
|---|---|
| Site: | Pilgrim |
| Issue date: | 12/31/1982 |
| From: | Cipolla R, Hayward J, Aaron Sanders APTECH ENGINEERING SERVICES |
| To: | |
| Shared Package | |
| ML20024E158 | List: |
| References | |
| AES-81-10-83, AES-81-10-83-R01, AES-81-10-83-R1, NUDOCS 8308090330 | |
| Download: ML20024E163 (76) | |
Text
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AES-81-10-83 (Rev. 1)
Job No. AES 8102243 APTECH onginaaring services,Inc e~ol~ . Rim o Co SuL1A T.
1 1
l 795 SAN ANTONIO ROAD . PALO ALTO CALIFORNIA 94303 (415)858 2863 FINAL REPORT STRUCTURAL EVALUATION OF THE PILGRIM STATION CORE SPRAY SPARGER BASED UPON RESULTS FROM THE OCTOBER 1981 REMOTE VISUAL INSPECTION Prepared by John A. Hayward
- Russell C. Cipolla A. Joseph Sanders Apte:h Engineering Services, Inc.
795 San Antonio Road Palo Alto, California 94303 Prepared for Boston Edison Company Pilgrim Station Rocky Hill Road Plymouth, Massachusetts 02360 Mr. Joseph W. Nicholson Mr. Frank N. Famulari December 1982
- Mr. J. Hayward is now with Design Reliability Assoc., Mountain View, CA 94040.
Services in Mechanical and Metallurgical Engineering. Welding, Corrosion, Fracture Mechanics, Stress Analysis 8309090330 830804 PDR ADOCK 05000293 G PDR
- AES-81-10-83 (Rev. 1)
Job No. AES 8102243 SO9lOS$flOQ /$fU!CS/,!OC ENGINEERING CONSULTANTS 795 SAN ANTONIO ROAD . PALO ALTO = CALIFORNIA 94303 (415) 858 = 2863 FINAL REPORT STRUCTURAL EVALUATION OF THE PILGRIM STATION CORE SPRAY SPARGER BASED UPON RESULTS FROM THE OCTOBER 1981 REMOTE VISUAL INSPECTION Prepared by John A. Hayward
- Russell C. Cipolla A. Joseph Sanders Aptech Engineering Services, Inc.
795 San Antonio Road Palo Alto, California 94303 Prepared for Boston Edison Company Pilgrim Station Rocky Hill Road Plymouth, Massachusetts 02360 Mr. Joseph W. Nicholson Mr. Frank N. Famulari December 1982 OMr. J. Hayward is now with Design Reliability Assoc., Mountain View, CA 94040.
Services in Mechanical and Metallurgical Engineering, Welding, Corrosion, Fracture Mechanics, Stress Analysis
QUALITY ASSURANCE VERIFICATION RECORD SHEET TITLE: Structural Evaluation of the Pilgrim Station Core Spray Sparger Based Upon Results Fror, the October 1931 Remote Visual Inspection.
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Originated by (ly%1 .:/.':j 2 ;
Russell C. Cipclla O
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A. Joseph nders(l /
Approved anc Verified b.
Sec'frey R. Egar.
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Quali ty Assurance An reval bpTE !2._ __ h(1'_C_1__ __ _ '_1.. ~
Je#frey D. E're'n 1
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TABLE OF CONTENTS Section Contents Page INTRODUCTION 1 1
2 BACKGROUND 2 3 SPARGER EVALUATION TECHNIQUES 5 Inspection Plan 5 Reference Indications 5 Sparger Indication Calibration 6 Summary of Structural Integrity and Fracture Mechanics 7 Analysis General Overview 7 Regions Away From Welds 9 Regions Near Welds 9 Back-Side of Sparger 15 4
SUMMARY
AND CONCLUSIONS 19 REFERENCES 23 APPENDIX A - Comparison of Photographs From 1980 and 24 1981 Inspections APPENDIX B - SWRI Inspection Evaluation Report 49
l I
ILLUSTRATIONS Page Figure Title Core Spray Sparger - Elevation View. 3 2-1 Effect of Stress Level and Material Crack Growth Rate 10 3-1 on Flaw Length vs. Time For Front-Side Indication Away From Weld Region.
3-2 Residual Stresses Due to Rolling. 11 Predicted Crack Growth For Indications on Front-Side of 12 3-3 Sparger Pipe Away From Welds for 18 Months of Operation.
Effect of Stress Level and Material Crack Growth Rate 13 3-4 on Flaw Length vs. Time For Indication Near a Weld.
Predicted Crack Growth for Indications Near Welds Over 16 +
3-5 '
18 Months of Operation.
Sketch Showing Location of Cracks in the Sparger Pipe 20 4-1 Adjacent to the "B" Junction Box.
Computer Enhancement of Reference Calibration of 0.001 26 A-1 Inch Wire on Sparger Pipe.
1981 Original of Nozzle 40 on B (3450) Sparger Adjacent 27 A-2 to Junction Box. Horizontal Camera Viewing Angle.
1981 Computer Enhancement of Video Tape Frame Shown On 27 A-3 Figure A-2. Suspect Linear Indications at Weld HAZ.
1981 Computer Enhancement of Nozzle 408. Approximately 28 A-4 450 Camera Viewing Angle.
A-5 1981 Computer Enhancement of Nozzle 40B. Camera Viewing 28 Angle Is Nearly Vertical.
1981 Original of Nozzle 41 on B (3450) Sparger Adjacent 29 A-6 to Junction Box.
1981 Computer Enhancement of Video Tape Shown on 29 A-7 Figure A-2.
1981 Computer Enhancement of Nozzle 41B. Approximately 30 A-8 450 Camera Viewing Angle.
1981 Computer Enhancement of Nozzle 41B. Camera Viewing 30 A-S Angle Is Nearly Vertical.
1980 Original of B Sparger Junction Box - 900 Side. 31 A-10 1980 Computer Enhancement of Video Tape Frame Shown In 31 i A-11 Figure A-10.
1980 Original of Same Area Shown on Figure A-10. 32 A-12
s (ILLUSTRATIONS - Continued)
Figure Title Page A-13 1981 Enhancement of Lower Quadrant of B Sparger Junction 32 Box.
A-14 1981 Original of Sparger Junction Box - 900 Side. 33 A-15 1981 Computer Enhancement of Area Shown on Figure A-14 33 Shows Mechanical Mark Indication.
A-16 1980 Computer Enhancement of Upper Quadrant of B Sparger 34 Junction Box.
A-17 A981 Original of the Same Area Shown On Figure A-16. 34 A-18 Computer Enhancement of Local Area of Figure A-16. 35 A-19 Computer Enhancement and Expansion (4x) of Figure A-18. 35 A-20 1980 Computer Enhancement of Nozzle 25 on B Sparger. 36 A-21 1981 Original of Nozzle 25B Af+er Cleaning. 37 A-22 Computer Enhancement of the Same Area Shown on 37 Figure A-21.
A-23 1981 Original of Sparger D (1650) Junction Box Area. 38 A-24 1981 Computer Enhancement of Area Shown on Figure A-23. 38 A-2E 1981 Computer Enhancement. Closeup View of Area Shown 39 on Figure A-24.
A-26 1981 Computer Enhancement of Lower Quadrant of Sparger A 40 (150) Junction Box Area.
A-27 1981 Original of Sparger A (150) Junction Box Area. 41 A-28 1981 Computer Enhancement of Same Area Shown on 41 Figure A-27.
A-29 1980 Computer Enhancement of Indication on 1700 Side of 42 the A Sparger Junction Box.
A-30 1980 Enhancement and Expansion (4x) of the Area Shown on 42 Figure A-29.
A-31 1981 Original of Indication on 2700 Side of the A 43 Sparger Junction Box.
A-32 - 1981 Computer Enhancement of Same Area Shown on 43 Figure A-31.
A-33 1981 Additional Computer Enhancement and 0.001 Inch 44 Calibration Wire.
A-34 1981 Computer Enhancement and Expansion (4x) of the Same 44 Area Shown on Figure A-32.
A-35 1980 Original of Indications on the 2700 Side of C (1950) 45 Sparger Junction Box.
L (ILLUSTRATIONS - Continued) .
Figure Title Page A-36 Computer Enhancement of Area Shown on Figure A-35. 45 A-37 1981 Original After Cleaning. Same Area Shown on 46 Figure A-36.
A-38 1981 Computer Enhancement of Same Area Shown on 46 Figure A-37.
A-39 1981 Original of Lower Quadrant of A Sparger Junction 47 Box.
A-40 1981 Computer Enhancement of Same Area Shown on 47 Figure A-39.
A-41 1981 Computer Enhancement and Expansion (4x) of the 48 Indication Shown on Figure A-39.
A-42 1981 Computer Enhancement and Expansion (4x) of the 48 A Sparger Junction Box At the 3 0' Clock Position.
TABLES Table Title Page 3-1 Summary of Analysis Assumptions 8 3-2 Pilgrim Core Spray Sparger Evaluation 14 3-3 Summary of Crack Growth Predictions For Back-Side Flaw 17 3-4 Computed Remaining Time For a Visible Back-Side Flaw 18 Indication
SYNOPSIS The significance of surface indications located in the core spray sparger of r
the Pilgrim Nuclear Power Station was assessed. This report presents the results from the video inspections performed in January 1980 and October 1981, and a summary of the structural evaluation findings undertaken by Aptech Engineering Services, Inc., and documented in a separate report.
The video inspection results from the two inspection periods were compared.
. Based upon this information, it was concluded that no significant changes in the observed indications were apparent over that time period. Crack growth predictions summarized in Section 3.4 indicate a conservative crack growth of 0.2 inch in these regions during the time span between inspection periods.
Structural integrity calculations indicate that the observed indications are smaller than the critical flaw sizes determined from a limit load analysis.
The estimate of crack growth over the next 18-month fuel cycle is less than 1 inch for all regions, and the resulting final indication lengths will be less than the critical size.
It was, therefore, concluded that based upon interpretations of the video inspection information and the findings of the integrity evaluations contained herein, the surface indications are within the established structural integrity criteria of Boston Edison Company and clamping it is not required for the next 18-month fuel cycle.
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Section 1 INTRODUCTION -
This report provides a summary of findings and conclusions from an underwater television camera inspection of the Pilgrim core spray sparger essembly conducted in October 1981. Visual examination included sparger pipes, junction box weld regions, nozzles, and attachment welds of all nozzles.
Present inspection results were compared to areas previously identified as ,
containing possible linear indications based upon a similar visual inspection 1 performed in January 1980. Comparisons of the results from two inspections were made by examination of photographs taken after computer enhancement of selected frames from video tapes of each inspection.
Principal subcontractors to Boston Edison Company (BECO) and Pilgrim Station who were involved in the spargar inspection and evaluation, are listed below with designated responsibilities:
e Mr. Robert Shimkus, Level 3 NDE Technical Consultant from Southwest Research Institute, San Antonio, TX, who was responsible for directing the inspection and interpreting inspection results from video tapes and computer enhanced video tape f rames. Mr. Shimkus provided Level 3 NDE interpretation of the 1980 sparger inspection video tapes.
e CTS Consulting Personnel Services, Inc., Baldinsville, NY, was -
responsible for operation of camera rig and recording video tape ~
records.
e Aptech Engineering Services, Inc., Palo Alto, CA, was responsible for -
structural integrity evaluation, fracture mechanics analyses and -
fluid mechanics evaluations. AES established calibration reference :
indications from 1980 video tapes.
e Aptech Imaging, Inc., Palo Alto, CA, was responsible for on-site computer enhancement of areas identified as being suspect. AII had previously provided computer enhanced photographs of suspect areas from the 1980 video tapes.
The 1981 sparger inspection results were recorded on 3/4 in. video tapes. The inspection file consists of ten video tape cartridges plus one additional 2 cartridge containing computer enhanced f rames.
l 2
Section 2 BACKGROUND One lof the scheduled tasks during the Reload 4 refueling and maintenance outage in January 1980 at the Pilgrim Nuclear Power Station was the performance of a visual inspection of the Core Spray Spargers using underwater television cameras. This inspection was conducted as part of the 10 year Inservice Inspection Program at Pilgrim Station, and also as recommended by General Electric in Service Information Letter (SIL) 289 (1). Figure 2-1 shows the configuration and details of the core spray spargers.
During the inspection of the core spray spargers, linear indications were observed on the upper and lower sparger headers in the area adjacent to the junction boxes in the heat affected zone (HAZ) of the weld and remote from the HAZ. The discovery of these indications was reported to the Nuclear Regulatory Commission (NRC) on February 1, 1980 (2), followed by a meeting involving NRC staff, BEC0 representatives and GE personnel on February 29,1980 (3) and March 13,1980 (4). Those meetings culminated with the submittal of a GE report (5) which documented the technical justification to support a proposed start-up plan and the technical basis used to establish continued structural integrity of the core sprey spargers for all normal, transient and accident conditions. The report included discussion of the methods and assumptions used in the Loss-of-Coolant Accident (LOCA) analysis to determine the MAPLHGRs, assuming no credit for core spray heat transfer, and a discussion of the possible consequences-of a potential loose piece from a broken sparger.
In January 1981, Aptech Engineering Services Inc. (AES) was requested to perform an independent structural integrity and fracture mechanics evaluation based upon. the assumption of linear crack indications established from video tapes from the 1980 inspection. The quality of the 1980 video tapes was-generally poor and difficult to interpret due to video noise, camera motion and difficulty in focusing. Aptech Imaging, Inc., an affiliate of AES, provided image enhancement using digital computer techniques to improve the quality and contrast of video tape franes of areas of concern. These combined efforts in l
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) 4 conjunction with additional information about actual sparger material properties and fabrication residual stresses, resulted in a significantly improved understanding of the problem and enabled refined structural integrity analyses and predictions of crack propagation rates.
Results and conclusions of the APTECH work formed the basis for BEC0 to revise ISI maintenance contingency plans for the October 1981 outage. In July 1981, a meeting was held with the NRC staff (6), attended by GE, BEC0, TES, and APTECH personnel, to present the results of recent analytical studies and to propose sparger maintenance contingency options. At the request of NRC, BEC0 submitted an action plan (7), including. acceptance criteria for maintenance options, schedule estimates and ALARA estimates.
The core spray spargers were inspected during a five day period, ending October 9, 1981. On-site computer image enhancement was performed during and immediately after the inspection in order to enable prompt level 3 NDE review and interpretation.
At the request of the NRC staff, a review meeting was held on October 14, 1981 (8) . The meeting was attended by BECO and APTECH personnel. Prelimina ry results and conclusions were presented and computer enhanced video tapes of areas of previous concern were reviewed.
Following the video tape presentation, BECO informed the staff that findings based upon interpretation of the 1981 sparger inspection had indicated that the sparger is fully operational and no maintenance action is required. NRC staff requested documentation of the work performed to support stated conclusions. This report provides a summary of supporting information.
1 h
5 Section 3 SPARGER EVALUATION TECHNIQUES 3.1 Inspection Plan Visual inspection of the core spray sparger assembly was performed using two television rigs. The rotating-fixed rig consisted of a horizontal rotating boom with a pivot point fixed at the center of the reactor vessel. Two TV cameras were fixed, one above the other, at the end of the boom close to the ;
sparger. Lights were also attached at the end of the boom. This rig was used for horizontal and 45 vertical angle scanning of nozzles, nozzle welds, and
-top and bottom areas of the sparger pipe and junction boxes. These cameras were stationary. A hand operated TV camera rig was used for close-up inspection and for inspecting areas which required viewing from different angles.
The camera rig was operated by CTS personnel located on the fuel loading floor in the reactor building. Video recording monitors, equipment and telecomunications were located at the inspection control area one floor below.
APTECH Imaging personnel, computer and imaging hardware were located in the same area. Imaging equipment was connected by a cable branch connector which enabled monitoring and processing video signals directly from the TV cameras.
Simultaneously, CTS personnel monitored and recorded video tapes of the inspection. Mr. Shinkus directed the inspection and reviewed results on video monitors located in the inspection control area.
3.2 R fLference Indications Specific areas for 1981 examination had been selected based upon SWRI Level 3 NDE interpretation of video tapes from the 1980 sparger inspection, and subsequent APTECH review and computer enhancement of suspect areas from inspection tapes. Photographs of those areas and a video tape constructed from computer enhanced video tape frames provided a basis for assessing crack growth.
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6 During.the 1981 sparger inspection, video tape frames from these areas and ether' areas of interest were " grabbed" by computer processing equipment and
, stored on magnetic tape for computer image enhancement. As the inspection proceeded, computer enhanced pictures were taken from computer storage and displayed on a CRT screen for review by Mr. Shimkus to assist with interpretation of suspect indications. Computer image enhancement was used to
' provide more video information for the following reasons:
e? To demonstrate visual resolution of at least 0.001 inch based upon 1 mil wire e To determine if original indications were cracks, mechanical marks, or shadows e To assess the details oh newly discovered indications
'e s To determine if the character of an indication had changed
- . e To measure and quantify the amount of crack propagation in the weld
( .
HAZ and areas remote from the welds
" Af ter completion of the sparger inspections, APTECH Imaging personnel enhanced all' areas of concern 'ident1'fied by Mr. Shimkus. Final enhancements.were x - , recorded on video tape ifckease of access for comparison to original nspe.ction tapes and for records management purposes. A sumary comparison of
, pi.otdgraphs of enhanced video tape frarnes from the 1980 and 1981 inspection is
,y"\ i'ncluded in Appendix A of this report.
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.; 3.3 Sparger Indication Calibration ,
- As discussed in (7), reference enhanced video tape frames provided a baselitie Yor establishing crack growth rates when compared to similar images from the 1981 inspection. Obviously, it was not possible to reproduce exactly the same camera angle, location, etc. , during the 1981 inspection. For this reason, a calibration procedure was developed, based upon identification of distinctive lan'dmarks in each 1980 photo. Distance between landmarks was measured.and ,
compared to the measured length of an indication. Identical procedures were ,
applied'to 1981 inspection results, except the measurements were taken directly from the CRT screen. This ratio scheme obviates the need for mathematical corrections otherwise necessary te ' count for variables such as camera angle, camera distance from the sparger, etc., and permitted a
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7 reasonably accurate method for determining the present crack growth over the time period between inspections. The length of an indication was determined based upon the same scaling technique by a ratio of indication length or landmark length to pipe diameter.
3.4 Summary of Structural Integrity and Fracture Mechanics Analysis 3.4.1 General Overview Fracture mechanics analyses have been performed by Aptech Engineering Services, Inc. (9). A bounding analysis approach was used to obtain conservative estimates of crack arrest length and rates of crack propagation.
Parametric studies were performed assuming different values of sparger service stress in conjunction with residual stress fields based upon theoretical and empirical residual stress data. Crack growth rate data were taken from available IGSCC data for Type 304 stainless steel. Upper bound crack growth rates were developed from test data for furnace sensitized Type 304 in 8 ppm oxygenated water environnent at 550*F. A second crack growth law was taken from an approximate average of all as-welded Type 304 data. These values were used in a "best estimate" evaluation of sparger weld regions and sparger pipe areas remote from the weld heat affected zone for comparison with worst case crack growth predictions.
Two separate fracture mechanics models were developed for sparger evaluation.
' The first model characterized the region in the weld heat affected zone with with residual stress assumptions based upon pipe weld experimental data. The second model represented the pipe region away from the weld region where residual stresses are present due to cold work during the rolling operation to form the pipe to the required radius of curvature. The sparger assembly was not heat treated after rolling nor after welding.
Linear elastic fracture mechaincs (LEFM) concepts were used to evaluate indications in the core spray sparger pipe. In the evaluation, the indications were assumed to be crack-like and LEFM models were developed to predict crack extension and final cret e lengths associated with crack arrest. A summary of the analysis assumptions is given in Table 3-1.
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8 TABLE 3-1 SUtt1ARY OF ANALYSIS ASSUMPTIONS
- 1. Linear elastic fracture mechanics is : applicable'for predicting ~~
subcritical grack growth.
- 2. Flaw growth cracking mechanism is IGSCC 3i Flaw model assumes center-cracked flat. plate geometry under
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- 4. - _ Crack growth predictions are.primarily based cui upper bound l
da/dt gehavior (i.e. furnace sensitized Type 304 in 8 ppm 02 at 550 F).
'5. Crack arrest is . assumed when crack' driving force, i.e. maximum
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- 6. Maximum stress level limited to yield strength at 550 F
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3.4.2 - Regions Away From Welds The effect of: stress level and material crack growth rate on the calculated flaw length are shown in Figure 3-1. These results are applicable to flaw
-indications located on the front side of the sparger pipe away from any weld-joints. In the analysis of crack growth, two material conditions were assumed:
- 1) Worst case condition where data from tests performed on furnace sensitized material in 8 ppm 02 water at 550 F
- 2) - A best estimate condition where the average crack growth data were used typical of the as-welded condition, in the same environment Based on these computations, crack arrest is expected.for an applied stress level, in addition to the residual stresses due to pipe fabrication, of 10 ksi' or less. The residual stress distribution used in this analysis is the theoretical distribution based-on. beam theory as shown in Figure 3-2.
- Experimental results from strain gage analysis performed by Teledyne on similar curved pipe segments formed on the same equipment used to fabricate the actual sparger pipe, are also shown in Figure 3-2.
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The' predicted crack growth for an 18-month plant operation period based upon observed reference indications is shown in Figure 3-3. In this period, the plant availability is conservatively assumed to be 100%. Figure 3-3 gives the-maximum crack growth for a flaw located on the intrados (front-side) of the I
sparger away from any welds. Worst case da/dt behavior was assumed in the calcul'ation of final flaw length. Hence, Figure 3-3.can be used-to estimate !
conservatively the expected crack growth (final flaw length) for 18 months of plant operation for the observed flaw indication and applied service stress level. As an example, Table 3-2 illustrates the determination of crack growth
- l. for a 3-inch flaw over two 18-month periods.
3.4.3 ~ Regions Near Welds
. c l . A similar analysis was performed on a flaw postulated to exist near a sparger pipe weld connection. The residual stress distribution was assumed to have a sinusoidal shape along;the pipe circumference having a peak stress of yield strength level and a period equal to the pipe circumference. This stress distribution is consistent with measured. surface stresses performed on 4-inch circumferential welds as discussed in (9_). The results for this analysis are
.given in Figure 3-4.
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Figure 3 Effect of Stress Level and Material Crack Growth Rate on Flaw Length vs. Time For Front-Side
, Indication Away From Weld Region.
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14 TABLE 3-2 PILGRIM CORE SPRAY SPARGER EVALUATION PREDICTED CRACK LENGTHS, (2af)*
SPARGER REGION SEPTEMBER 1981 MARCH 1983 Away from weld 3.2 inches 3.4 inches Weld HAZ** 3.8 inches 4.7 inches
-NOTE: Crack arrest in regions away from welds is predicted to occur at a length of about four inches. In the region under the influence of weld residual stresses the length at which arrest is calculated to occur is approximately ten inches.
- Based upon a 5 ksi service stress plus residual stress and an initial crack-like indication length of three inches observed in January 1980.
- These predictions based on best estimate (as-welded) crack growth data tested in water with 8 ppm 02 at 5500F. Furnace sensitized data (upper bound) gives growth to ~10 inches by March 1983.
e
15 The predicted crack growth for an 18-month period' based upon observed reference indications is shown in Figure 3-5. Like Figure 3-3, the 18-month period of cperation assumes the plant is 100% available which is conservative. In
, Figure 3-5, the predicted. growth for a flaw on the intrados (front-side) of the sparger in a weld-related region is given for two material behavior assumptions:
- 1) An upper bound or worst case material crack growth rate behavior
- 2) A best-estimate behavior based upon average crack growth rate data These curves can be used to estimate the expected crack extension for 18 months of operation for an observed flaw indication. As an example, Table 3-2 also illustrates-the predicted crack. growth for a 3-inch flaw indication in a weld region of a sparger pipe.
3.4.4 Back-Side of Sparger For flaws initiating and growing on the back-side of the sparger pipe, Table 3-3 gives a sumary of the predicted time for cracking assuming upper bound crack growth rate behavior. If the measured tensile stresses on back-side (see Figure 3-2) are an indication of a local surface stress effect, then the theoretical stress distribution w,ould be more representative for long flaws. This model predicts arrest in crack growth at ~210 after the crack becomes visible. However, a conservative assessment of the tensile stresses "as measured" on-the back-side does not predict crack arrest. It should be noted that the limited test data shown in Figure-3-2 show considerable data scatter, particularly on the back-side of the pipe, Because " hand jacking" was used for. final pipe curvature adjustments, it is believed that non-uniform and highly localized stresses may exist in the sparger pipe. Table 3-4 gives the remaining time for cracking beyond 180 at which point the back-side crack just becomes visible from the front side. Although crack arrest is not predicted if the "as'-measured" tensile stress values are conservatively assumed to be global in nature, the results in Table 3-4 indicate significant plant operation time is required to grow the crack beyond 180'.
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17 TABLE 3-3
SUMMARY
OF CRACK GROWTH PREDICTIONS FOR BACK-SIDE FLAW TIME (MONTHS)
CRACK GROWTH- AS-MEASURED
- THEORETICAL 2a o r0NLY r
+ 5 ksi o rONLY o + 5 ksi r
~1.0 0 to 1800 1484 160
-1800 to 3600 1928 37.1 Arrests Arrests at 2040 at 2260 OSee Figure 3-2 for assumed stress distribution 00 Theoretical distribution'gives negative stress on back-side so cracking will not initiate. If measured tensile stresses are local as expected, the distribuiton shown in Figure 3-2 will also result in limited crack growth.
FLAW HODEL Front Back side
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18 TABLE 3-4 COMPUTED REMAINING TIME FOR A VISIBLE BACK-SIDE FLAW INDICATION REMAININGTIME(MONTHS)
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- THEORETICAL CRACK ANGLE RESIDUAL RESIDUAL RESIDUAL RESIDUAL
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- See Figure 3-2 for stress distribution FLAW P10 DEL _
i Back Front side side 3
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19 Section 4
SUMMARY
AND CONCLUSIONS A photographic comparison of video' tape frames of identical areas from 1980 and 1981 inspections is.provided in Appendix A of this report. These photographs represent a summary of numerous areas inspected (i.e., 224 nozzles, approximately 115 feet of sparger pipe, and 4 junction boxes). A discussion of examination results and conclusions is contained in the preliminary report (10) prepared by Mr. Robert Shimkus of SWRI. A copy of that report is provided in Appendix B. Conclusions taken from Mr. Shimkes's report are as follows:
e Six of the indications from the 1980 examination have been resolved as not significant. Two were determined to be heavy grinding marks, one was determined to be a mechanical mark, and two of the indicat!ons could not be found.
e One area, "B" header to pipe weld and the area to nozzle 25B was determined to have undergone no change since the 1980 examination.
Cracks appear in the upper quadrant. This area has stabilized with regard to crack propagation and further area degradation is not anticipated.
Cracks identified as being present in the sparger pipe adjacent to the B junction box are shown on Figures A-10 to A-19 in Appendix A. This area is shown sketched on Figure 4-1 to assist the reader with locating crack orientation with respect to the. pipe and junction box.
The principal crack can be seen on Figure A-16 in the upper quadrant of the pipe. The crack travels through a dark wire brush mark (away from weld HAZ) and travels downward, curving towards the weld HAZ and then veers in a dog leg fashion away from the HAZ. Scaling calibration calculations indicate this crack is about 1 inch long and 0.002 inch wide, from the bottom of the brush mark'to the crack tip. The length of the dog leg portion is approximately 0.3 inch. A very faint line suggests possible branching at the dog leg.
Figure A-19 shows a 1981 enhancement of the same area after cleaning. A branch crack, approximately 0.9 inches long, eminates from the dog leg joint, travels into the HAZ, along the toe of the weld and veers out of the HAZ in a path approximately parallel to the dog leg portion of the principal crack. Note on
20 Reference Brush Mark from 1980 Nozzle # 25 5 in. junction box Spray Nozzle Fillet Weld Walded end plate ~
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, 31 in. Sparger
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1980 Principal Reference Crack Fishhook Mechanical Mark Figure 4 Sketch Showing Location of Cracks in the Sparger Pipe Adjacent to the "B" Junction Box (See Figures A-16 and A-19 in Appendix A).
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21 Figure A-16 (from the 1980 inspection) an indication below the dog leg and
. parallel to the dog leg. Subsequent review of the 1980 inspection video tapes revealed that indication to be the same branch indication shown in Figure A-19.
The quality of video tape records -did not permit further enhancement of that specific area. Visual inspection indicates that the character of the branch crack has not changed.
Crack growth. predictions summarized in Section 3.4 indicate a conservative crack growth of 0.2 inch over the time period since the 1980 inspection. This prediction was -based upon maximum growth of an existing 3-inch crack away from the weld. As seen on the photos, the ends of the crack tend to grow away from the weld HAZ where a predicted crack growth of 0.2 inch would be applicable.
At the crack tip locations, the peak residual weld stresses would be significantly reduced from that used in the weld region analysis and the away from weld analysis was used. Video tape resolution did not permit complete crack growth calibration accuracy within the predicted limit; however, calibration of the dog leg portion of the crack showed no significant growth since the 1980 inspection.
Based upon available video tape information, it is concluded by APTECH personnel that no significant changes are apparent. Moreover, the crack propagation rates would be expected to be lower due to the fact that the cracks are now propagating in an area where pipe fabrication residual stresses are dominant. There remains a question of detail resolution of the branch crack; however, that question is somewhat academic since the 1981 inspection results j show the indication is propagating away from the weld.
It was not possible to obtain close-up pictures of the top of the pipe due to
~
interference from protruding nozzle ends. However, a close inspection of the pipe midsection and-lower quadrant revealed no relevant indications.
Mr. Shimkus prepared his inspection report on site immediately after reviewing i inspection tapes and computer enhanced tape frames of areas of concern.
Subsequently, APTECH reviewed the 1981 video tapes and " fine-tuned" computer enhancement of suspect areas for photographic documentation contained in Appendix A of this report. In the course of this effort, several additional suspect indications were found and enhanced for further evaluation.
22 Photographs of those areas were forwarded to BECO and SWRI for review and iterpretation. Mr. Shinkus concluded that one indication was relevant. He identified a fine crack indication located in the lower quadrant of the sparger pipe near the toe of the weld at the "A" sparger junction box. This indication is shown in Figures A-39 to A-33. The crack appears from a mechanical mark or arc strike at approximately the 5 o' clock position as shown in Figure A-42.
Calibration techniques indicate a crack length of approximately 1.75 inches and an estimated width of approximately 0.002 inch.
Unfortunately, computer image processing from 1980 inspection tapes of this region was not possible; therefore, reference calibration information is not available. However, insignificant crack growth determined from 1981 inspection and calibration of cracks away from the weld HAZ suggests that the use of average weld crack growth data provides a conservative prediction for sparger crack growth. Therefore, our best estimate of crack growth is less than 1 inch over the next 18-month fuel cycle.
It is concluded, based upon interpretations and structural integrity evaluations contained herein, that the linear crack indications in the upper quadrant near the B junction box and in the lower quadrant of the A junction box fall are within established structural integrity criteria (7), and clamping is not required.
Early during the inspection, crack growth calibration calculations were performed for reference indications away from the weld HAZ (see Figures A-29 and A-31). Those calculations showed no significant differences in indication length. Subsequently, after computer enhancement, those areas were determined to be non-relevant indications as reported in Appendix B.
4 a u- - - g-m e gy - -
23 REFERENCES
- 1. Inspection of Core Spray Spargers, General Electric Service Information Letter (SIL) No. 289, Dated January 1979.
- 2. Licensing Event Report (LER) No. 80-004/023-0, Dated February 1,1980.
- 3. Boston Edison Company meeting with the NRC, Bethesda, MD, Februa ry 29, 1980.
- 4. Boston Edison Company meeting with the NRC, Bethesda, MD, March 13, 1980.
- 5. Supplement 1 Reload Licensing Submittal for. Pilgrim Nuclear Power Station Unit 2 Reload 4, NEDO-24224-1, Supplement 1, Dated March 1980.
- 6. Boston Edison Company meeting with the NRC, Bethesda, MD, July 30, 1981.
- 7. Boston Edison Company letter to NRC, Dated September 9,1981.
- 8. Boston Edison Company meeting with the NRC, Bethesda, MD,
. October 14, 1981.
- 9. A Fracture Mechanics Evaluation of Core Spray Sparger Indications, R. C. Cipolla, W. P. McNaughton, and J. A. Hayward, APTECH Report FR8102243, December 1982.
- 10. Preliminary Report of 1981 Remote Visual Examination of the Pilgrim Nuclear Reactor Core Spray Piping and Spargers, R. P. Shimkus, SWRI, October 9, 1981.
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24 Appendix A COMPARISON OF PHOTOGRAPHS FROM 1980 AND 1981 INSPECTIONS 4
25 Appendix A COMPARISON OF PHOTOGRAPHS FROM 1980 AND 1981 INSPECTIONS
-This section contains photographs that provide a summary comparison of important sparger reference areas which were inspected in 1980 and 1981.
Figure A-1 demonstrates optical resolution to 0.001 inches as indicated by the 0.001 inch wire on the sparger pipe. Figures A-2 to A-34 show comparisons of 1980 and 1981 original and computer enhanced video tape frames.
These photographs were prepared to coincide with the text and sketches included in the SWRI inspection interpretation report in Appendix B.
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Reference:
Par. 3.1.1 and Figure 1 in Appendix B.
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ment Shows Mechanical Marks Shows Wide Mechanical Marks 1 from Weld Grinding. From Weld Grinding.
Reference:
Par. 3.1.1 and Figure 1 in Appendix B.
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Enhancement Shows Mechanical Shows Wide Mechanical Marks Marks From Weld Grinding. From Weld Grinding.
Reference:
Par. 3.1.2 and Figure 2 in Appendix B.
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Junction Box. Indication Appears From Brush Mark, Heads Towards Weld HAZ, and Veers Away From HAZ.
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Par. 3.1.4 and Figure 4 in Appendix B.
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Junction Box Area.
Reference:
Par. 3.2.1 and Figure 5 in Appendix B.
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1 49 Appendix B SWRI INSPECTION EVALUATION REPORT e
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50 MM/6fco A/15 MEMORANDUM TO: Frank Famulari Boston Edison Company Pilgrim Station DATE: October 9,1981 FRON: R. P. Shinkus S.W.R.I.
SUBJECT:
Preliminary Report of 1981 Remote Visual Examination of the Pilgrim Nuclear Reactor Core Spray Piping and Spargers 1.0 SCOPE Perform a remote visual examination of the subject reactor component.
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The examination is to meet ASME Section XI, Item Bl.1 and category B-N-1.
In addition, the examination is to address the NRC Bulletin 80-13 requirement for a visual resolution of a 1 mil. wire placed in the examination area.
2.0 EXAMINATION .
The examination was performed in accordance with the Southwest Research Institute (SWRI) Examination Plan prepared for project 17-6676 (81-BEC-PPS-1-1-0) approved by Boston Edison Company (BECo) . The resulting data was evaluated by the writer, a Level III visual examiner, qualified by experience i
i and written examination.- Re-examination and surface cleaning was accoep-lished as considered necessary for indication resolution.
l 3.0 EXAMINATION RESULTF 3.1 Resolution of 1980 examination indications on lower sparger.
3.1.1 "B" sparger, nozzle 40B - 1980 examination showed HAZ linea}r indications, see figure 1. The 1981 examination resolved these as resulting from grinding to remove weld undercut, see tape 10. The 1980 examination equipment did not permit view of the indications from the nearly vertical position. The resulting oblique lighting cast a sharp narrow shadow (linear indication). .
51 3.1.2 "B" sparger, nozzle 41B, see figure 2. Same as 3.1.1.
3.1.3 3450 Header-to-sparger pipe weld and area out to nozzle 25 on the "B" system. The 1980 examination showed many linear indications, see figure 3. The 1981 examination exhibits the same characteristics as in 1980, see tape 8 count 330-413 and tapes 9 and 10. There is no continuous crack like indication extending from over the top of the sparger piping to underneath the same pipe. A fine line appears on the header-to-sparger weld, but because the weld is thicker than the sparger pipe wall it would not normally be considered significant (a crack).
-46 3.1.4 1,65o Header, "D" Sparger, to pipe weld. Thc linear indication found during the 1980, see figure 4, examination is no longer visible.
The 1980 indicator is believed to have been a shadow.
3.2 Upper Sparger 3.2.1 150 Header, "A" Sparger, Header to pipe weld linear indication observed during the 1980 examination, see figure 5, is no longer visible. It appears to have resulted from some residual weld undercut not completely removed by grinding.
3.2.2 The transverse indication pipe 8" - 12" towards 2700 from the "A" sparger header observed during the 1980 examination, see figure 6, has been resolved as not significant, aee tape 8, count 413-453.
This indication has been shown to have no depth when viewed close
, up normal to the pipe.
3.2.3 1950 Header, "C" Sparger, " to 1" from header to sparger weld on the
- pipe. The 1980 examination, see figure 7, showed a linear indication, extending vertically downward from an are strike. No linear indication could be found during the 1981 examination. The area was wire brushed and re-examined, see tape 10. No linear indication could be resolved.
J ;.
52
4.0 CONCLUSION
Six of the indications from the 1980 examination have been resolved as not significant. Two'were determined to be heavy grinding, one was determined to be a mechanical mark, and two of the indications could not be relocated (found).
One area, "B" header to pipe weld and the area to nozzle 25B was determined to have undergone no change since the 1980 examination. Cracks appear in the upper quadrant. This area has stabilized with regard to crack propagation and further area degradation is not anticipated.
l R. P. Shimkus Technical Consultant Southwest Research Institute I
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59 Index Tape #11 EXCERPTS FROM 1980 & 1981 TAPES Tape Footage _ Description 0-20 Leader 20-32 1800 side C Junct. Box Upper Portion 32-61 1800 side C Junct. Box Upper Portion after cleaning 1981 view . 61-67 1 Mil Wire 1800 side C. Junction Box 1981 View
'67-76 00 Side B Junct. Box 1980 View 76-83 00 Side B Junct. Box 1981 View 83-91 00 Side B Junct. Box 1981 View Computer enhanced.
91-100 00 Side B Junct. Box after cleaning 1981 View. 100-112 Computer Enhanced View of Heat Affected Zone (HAZ) between Nozzle 25B and B Junct. Box, 1981 Vis 112-120 Expanded View (Comp. enhanced) of HAZ between B Junct. Box and Nozzle 25B, 1981 View. 120-127 HAZ Nozzle 25B, Computer enhanced, 1981 View. 127-138 HAZ Nozzle 40B, 1981 View 138-145 HA2 Nozzle 40B, 1981 View 145-153 HAZ Nozzle 41B, 1981 View 153-159 HAZ Nozzle 40B,1981 View enhanced l 159-167 HA2 Nozzle 40B, 1981 View enhanced 167-175 HAZ Nozzle 41B,1981 View enhanced IIS-185 2700 side D Junct. Box 1980 View 185-195 270 Side D Junct. Box 1981 enhanced 195-203 Area of Interest above Nozzle 32A,1981 203-206 Area of Interest above Nozzle 32A, 1981 206-218 Enhanced View of Area above Nozzle 32A, 1981 218-225 Cal. Standard adjacent to Nozzle 32A 225-240 2700 Side of A Junction Box 1981 240-245 Cal. St'd. Check at A Junct. Box, 2700 Side m.- --
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