ML20062H936
| ML20062H936 | |
| Person / Time | |
|---|---|
| Site: | San Onofre  |
| Issue date: | 10/04/1990 |
| From: | Martin J, Mostafa M, Phoenix W SOUTHERN CALIFORNIA EDISON CO. |
| To: | |
| Shared Package | |
| ML13302B374 | List: |
| References | |
| NUDOCS 9012070160 | |
| Download: ML20062H936 (294) | |
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FEEDRING FAILURE-ROOT CAUSE: REPORT.~ ; (
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SAN ONOFRE NUCLEAR GENERATING' STATIONS UNITS,'2 AND 3' 1 e a F
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. October.,4 , 1990.' ;
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Root Cause Evaluation Team.- l c a
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- JL H. Martin W. C.c.Ph 3 1x
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-i Approved byt t
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9012070160 901129 PDR T/.. ' k P ADOCK 05000361 C . ' l PDC ,
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1 ( t l TABLE OF CONTENTS' l Title Page Executive Summary. l-Root Cause Evaluation of'FeedriNg Steam Generator-i Units 2 and 3 Failure Description J Evidence Collection-j t Failure Modes Failure Scenario .. . Root Causes comparison Between Units 2 and 3' Corrective Actions Appendices Appendix A: Feedring. Failure Mode Analysis for Unit 3 Appendix B: Feedring Failure Mode Analysis.for-Unit.2- ! Appendix C: Inspection of U-Bolts,. Units 2 & 3 f Appendix D: 3-D Flow Model of Distribution Box Assembly 1 t Appendix E:-Estimation of General-and Localized Erosion in Distribution Box' Assembly l Appandix F: Estimation of the Number of Thermal Cycles i Due to batch Feeding with Auxiliary ' ' Feedwater During Initial Plant'Startups Appendix G: Estimation of-the Number ofcThermal Cycles Due to Trips Appendix H: Temperature Profiles Within the Feedwater Ring During Auxiliary Feedwater Batch-Feeding- . t Appendix I: Stress Analysis a l Appendix J: 10CFR21 Evaluation.
Reference:
- 1
- 1. CE Failure Analysis.of' Damaged U-Bolts,, Unit.2
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i. EXECUTIVE
SUMMARY
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SUMMARY
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(. l In May - 1990, during the SONGS, Unit' 3 refueling . outage, .: a < few
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i pieces of carbon steel metal-were foundoin the secondaryjside..of-h Steam ~ Generator. 3E089.' A detailed' visu'alf . inspection . Lwas -- j l subsequently conducted of both Unit 3 steam generator : secondary - l internals. The general configurations; of the.~distributlop ibox,
. . 1 pups, and feedring are illustrated (in Figures l' throught- 4'. ? The!
- i inspection revealed that the botton-portions.of,three-ofLthe.four pups (Schedule 40 pups approximately 9" longl connecting tthe-i Schedule 120 feedring and the center'distiribution box).were missing; !
and the other was cracked. The 3" vents were also inissing from'the distribution box. , , The Unit 2 steam-generators were subsequently inspected 0in. July < ; 1990. The vents were also missing. LDnlike Unit'3, the pups!were: , , cracked at the toe of the outer veld:andsthere was one broken U-i bolt. s l t A root cause investigation was < initiated to identify the L root; '! I lauses of the feedring and the-distribution box vent failures.. L The process and-results, including flow a'nd. stress analysis, are documented in.this. report. 3 (1)- i l j.
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Root'causa Results- i j A) The root cause - failure" of ' the!- feedring Lwas due- to: inadequate design of the:feedring and'feedring' supports-
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in two aspocts. : First, jthe design 'did! notj takeiintoa l consideration the in-service thermalestresses that may- d result from normal operating- conditions? CE stress-calculation SS-305,1981' did not: consider' cyclicithermal!" ]q ) bending;nor thermal stripireg from AFW: feeding condition.. - This design deticiencyJresults?inifeedringhandOfeedring-support damage. The design- deficiency resultsL.in q through-wall cracking : at . the _ welded connection ~ f at- the !
- distribution: box, : excessive -. natialithinning and finally -
sparger debris being generated.- 4 m
.. q The root cause failure ofLthe'.ventLand! distribution box-B) i was' due to inadequate design. . The . design 4 .- didicnot, consider the localized erosion / corrosion rate:in the ve'nt .
andinthe.distribukionbox.- As t-result of this design- y deficiency, excessive metal loss ; wais' found < inside the.- distributilon boxes, and the vent'siseparated . f rom' L the - distribution box due to severe erosion.
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Corrective ' Actions Taken/Reca=martied 3 A) The -corrective a c t i o n s t a k e r. : t o resolve the feedring- .n failure consisted of: (2)j , 3 l
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(1) Replacing the Schedule 40, pups withJSchedule 120 pups, thereby: eliminating .the- presenc3- of a- .l relatively low: sectional modules ' segment that acted? as a stress riser, j! l (2) Providing a~better; weld configuration'with the use'. , of ~ ' a weld-0-let to join ~ the feedring' to i box,
. . l significantly reducingj the stress concentration factor at the- joint. >
- 1 (3) Modifying the feedring: supports by using a stronger -
bolting : material (lowg alloy. steel" withyafyield -, s . strength: of 80 kai) instead.of the original bolts-(yield strength of'36 ksi). i In . addition, the . support plates Jere imodified by introducing slotted holes' instead of Lround ones. - - This: will reduce.the overall stresses; atithe welded joints., B) The corrective actions takers to resolve;th'eLvent fe llure - consisted of:
- 1) Removing the vent 'from thel design, based-on,the fact that the ,venst. < c not required to t satisfy :any -
steam generator. design. requirements. q
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- 2) Wald-build-up of all eroded areas withinL- Lthe ,
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repairs:were applied'to bothfUnits--2' and 3.
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C. The recommended-future corrective, action to monitorLthe arosion/ corrosion rate consists-of A annitoring program.will' be implemented to observe metal! thinning..of 'the distributioni box; Land ithe3: replaced' Schaduled 120: pups Vapproximatel'y ' evhryi; five [ years of J operation.- If the wall'thickn$ss is 'less;than* allowable-y for the feedring fdesign basis'. Ii.'e,,inoicallapse- with: [! vacuum inside the ' feedring and . full'. steam: ' generator-. pressure outside)~, repair ~or; replace'as, appropriate, y N
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l 1,_ i i j- '-: s 72fEIRB la SIDE VIEW OF SONGS, UNITS 2 AND-3, STEAM GENERATORS , -l l V .l 81eam Dome-
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.J FIGURE 4::- TOP VIEW OF THE FEEDWATER DISTRIBUTION PIPING Feedwater-
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L i i. ROOT CAUSE EVAIDATION: OF: FEEDRING J ; STEAM GEIERATOR, UNITS ~2 LAND 3 .
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.1 A. FEEDKING AND SUPPORT FAILURE l
L. I. Failure Descrintion for-Feedrina afni ES uenort Failura
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l ' The following!is based on! inspections ofJthe Unit'2iand'.
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Unit.3 steam generators:. l , !
.1) UNIT 3 FEEDRINGS:AND SUPPORTS: l l- a. .The Unit 3 steam generator' pups ware d'amaged;; i l .
significant.. amounts of the' bottom. portions.of three-oflthe four pups were missing. lThe; missing. pieces were;foundlin'thelsteam s generators,:as'detailediin Appendix A.. 4 l o, I b. '"he other Lintact- (without pipe l wall tearing off from the~.botton) pdp on Steam Generator. 3EO88, had outside: surface" cracks 1inithe' Heat-Affacted Zone;(HAZ)lLat.the-toeLof;the: weld that joins'the. distribution'boxLtofthe pup. The cracks-were located between1 .4 Land"5 j o' clock, on the wrapper.. side of:the. pup. li
- c. Maximun : localized erosion was observed on the' '
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pups at'11 o' clock;';andEin'one' case, it. y i
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produced a through-wall' penetration.' The intact pup was;not significantly" eroded.- d .- Many of the U-bolts were stretched and: , deformed, indicating-they.had:been subjectedJ to high tensile and. bending;1oads'.
- 2. UNIT 2 FEEDRINGS AND SUPPORTS .
.a. All the Unit 2. pups-were intact.
D. All'the pups had cracked around:the-perimeter. TheLcracks.wereLcoincident'withi the toe;of the-weld (see. Appendix;B). Both legs of.one of.th'e:two U-bolts,'at the c. end of the feedring:in 2E088,'had; fractured. ..
- d. All the pups.-were somewhat thinned in much' the same way asithe intact. Unit'3' pup-(see
'Appendik B)'. -
. e.- Many of.the U-bolts'were stretched and deformed,- indicating that they't b had been; subjected to highctensiletand bendingLloads-(see' Appendix C)..
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II.* Evidence collected'for Feedrinas-and Sunnerts j [ i The following additional facts relevant to the rootf j cause analysis'of the feedring_-and vent: damage were- i collected duriag;.the investigation: A.
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- 1. None of the failures: described:have been; reported; . ,
7 st other CE steam generators. lCE stated that? .;
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f_ on13ertCliffshadfaxperienced41ocalized. thinning. i l sin the distribution box, and .CE 'also stated. that-L'a7 d zeuunt' inspection of..Lothisiana Power and Light! (Wheastford-3) L feedwater nozzles: did !nott-identify _
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q . - . 1 any_ amamely,'such as : vent ; pipe [ erosion orl missing C , gameti=== - of , the': feedring;;.a 4 y . 2- 1manimmin differences between the"SONGST feedring- -
. .. . m W and'other/ plants lare: 1(1)nthe short section -
j af tho' schedule.40 pipes (the pup)).between;th'e7 Stdtneale 120' feedring ?and distribution ' box;Tand)
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((2) eum to the.. seismic concerns.lat ~ SONGS,6each
.' l W anchor point has'two U-bolts-instead'of +
one < U L 7 The rate of metal thinning -in the intact pupsjwas - 1l 1 a lau% alientJ 10oto :20_ mils.perl year at'the worst '
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. eroded / corroded' areas.- (The intact pups did not.
have through-wall' cracks.) .
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- 4. There was only;one uncracked pupL(located at'thel left hand side of-2E089) in all'the stease generators. iBoth legs of-one of,the U-bolts at l the far end of the feedrang were fractured,.
nuggesting-that!the restrainingLforces(of both-;U-~ i bolts encourages cracking. There.is,a history of U-bolt failure at this location.- 'In?1'984,s one. leg - d of each of the two U-bolts was i ound f br$ ken., The-
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feedring had moved upward approximately 1b 1/4":and l inward tauard the shroudDapproximately?l/2"q(cold- . .; 1 distances). The= failures'w'ere eval'uated by(CE. y The d estion stated.that during.replacementiofL the'feedring int 1982, it had b'een"nacessarycto~ jack and heat the feedring:to . bring it ito .the proper location.: CE concluded:that:theqfailure vos the=.reunit of high prestresses:c6mbinedlwith strammes dee:to periodic'injactions:ofIcold ; fonemater. .The ~ solution: was to allowLthe 'sedringL l to r====im incits as-found location, wedga snd s "shia ; itgla place, and install new;U-boltsc(see' Referemen 1).. I 4 OF.21- , Ci [ g _ Y$
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. This history suggests _that construction = techniques:
during the 1982-replacement of.theLfeedrIng may. ! have contributed to theJfailure'ofitheipups. q 5.- Chemical analysis of fendring materialiindicated_ conformance'to ASME SA106 carbon:steellspecifi- ,
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cations. Fracture analysis determined' fatigue to
-i the fracture mode of failure.
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- 6. Metal surrounding the holes in the three failed pups in Unit 3 wereivery thin. .. Appendix 5 A details:
i* - the shapes 'cf. these holes.- tsome of the mis'sirigt metal pieces wereiretrieved-from the: steam' l generators and were:foundito be severely; y
- eroded / corroded. j y
a Flow. analysis also shownsthat evenlaismalli
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7. j. through-wallDerack at the; junction of>the J pup:and- d distribution box will1changelflow-patterns 1and increase flow velocity at the. crack'toJcausetrapid erosion. (
- 8. The feedrings ,we're ' subjected - to: thousarids(of thermal cycles during. low poweri. operation wheni . 1 cold (70*F) auxiliary feedwaterfwas intermittently' introduced-into the. hot-(545'F') distrib'ution box .
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. - -- 1 and piping inia process called " batch, feeding". q The number ~of thermal cycles and reactor trips,- 4 i
which also would have-introduced-cold feedwater, was approximately the same'for bothLUnits (ses- j i Appendices F-& G). . 1 1
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- 9. At the start of each batchffeedingl cycle, if the: ,
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>. .- . . a flow rate to-each-steam. generator is less thani_400; gpm (as it normally was), there wills.be a sharply;
- i stratified flow with the much. denser < cold incoming- 'P
. water displaci.ng the hot" water insidot the feedringc until the cold water reaches the end of the fendring. There will'be a. marked temperature change at the interface between thatcold'and hot.
water that1will persist atsthe pupcfor- , M
.i approximately thirty seconds. Thermal; analysis" y
shows that.for a wide. range of auxiliary'feedwater a
.a flow rates, the interface would be r'ela'tivelyj j constant =at approximately 4'and-8(o8 clock (see-Appendix H).
. 1
- 10. In-addition:to stresses due to thelihterface 1 itself,~ stress: analysis: suggests that severe stresses tillLbe imposedtatithe. toe of:theLweld as a
" I the 'relatively: thin : pup contracts relEtive to the t
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- 11. Stress analysis showsL thatithe' feedring will band. i downward due to.the stratified flow,Eand'also j;
contract and bend inward due to overall cooling.- j I
- 12. Stress analysis also ~calculatesflarge : stresses due to through-wall temperatureigradients. Thei '
gradient should be largeriatEthe wrapperiside of:
.the pup as the coldE feedsatersimpacts the p;tp"and-increases the rilm heat _tr:nsfer'coefficiens.~
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- 13. Stress analysis'-shows that stressasi are:1far !
greater if the'feedring cannotomoveLat?its: anchor points. < l
- 14. Every pup'that did notmhave through-well cracks?'
did not suffer. severe.netal loss.
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III. Failure' Modes' for- Feedrina andLSunnert Failure. u h Based on the observed: damager the facts? described ~
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above, and the flow and. stress calculations: described in the Appendices, therfollowing;are fallureLmodesefor.' the components:' , l
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- 1. Feedring Pups
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The failure mode is through-wall fatigue cracking leading to rapid localized erosion / corrosion of
-the cracked area.
O Cracks first: initiated at the toe'of.the weld-that l} joins the box to-th's pup at'approximately14 .
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o' clock (the wrapper side) .- The cracks then. propagated through the wall and changed the flow pattern within the pup to produce:very high local. i
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flow = velocities as: water flowed'through the cracks. The pup, wall: then locally; eroded until the-r~. aining metal:was so.: thin that it; ruptured I and pieces-were torn away.by feedwater exiting:the' g-feedring. i
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It should bs emphasized-that although the pups i l were slightly eroded prior: to the through-wall? I cracks, it was tueJ1ocal'high flow' vel'ocities : following through-wall' cracking that then' rapidly C thinnt/ the pup and produced the:as-found; 1 condition. 1 K I '. 8-OF 21
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- 2. U-Bolts '
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The-failure mode was' deformation or-fractureidue'
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'i-to high. tensile oribending.'stressest (overload):: and ;. I the thermal expansion;and contraction:of;the: 4 feedring.. .
t, IV. Failure Scenario-for Feedrina-Danaaa {. Based on the failure modes andt factai described,Jthe
.following is the most>1ikely failure scenario that: i produced the:.f3naltfailure of the:UnitL3 4 feedrings:, O
- 1. CE designed:the entire feedring'with Schedule l40 pup. !
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- 2. U-bolts in the leftLhand'end:offthe staanL generator'2E089 1feedring'were found brokennin-1984.- The U-bolts weretreplaced andtwedges[were added for- sc;. port to - allow the ring toc remain--
outside'its originally-designed position. '~ 3., After plant shr.tdown and during plant: startup,L a- . thermal cycle is imposed on'.the;feedring;every time cold auxiliary.feedwater or cold 1 main 9 OFc21-4
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'I faedwater is injected'into the steam' generators.
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.I Most auxiliary-'feedwater cycles:alsofinclude a.
brief period'of significantjthermal:stratifi- , cation. The cycling'was greatly.reducedJin:1986- , after the auxiliary foedwater system sasLaodified' t i; i so it could be usedLat a continuous' low-flow rate . rather than batch. feeding. , 6
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I. . , . . . Stratification produces radial and horizontal.
- 4. ,
bending of th's feedring, fItLal'so produces , m through-wall. stresses. The bending! stresses, l together with residual stresses?from' welding.and< ,
. assembly, result 1in crack initiation on theLouter.
surface of the puptat-the. toe.of the; weld?that 9(
.. .. .i joins the pup to'dihtribution box. Tha highest.
1 stresses are below!the can'terline.of the~ pipe-at-4i n and-8 o? clock, as illustrated-in AppendixiI.. The pups'with more rigid U-bolts'.would have , experienced higher-wtressesJand are; believed to have cracked first. n
- 5. The' developed cracks then propagated!through the pup' wall via corrosion' fatigue:as a; result'ofL
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thermal cyclic stresses. I
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- 6. 'High-velocity.'feedwater flowed'through1the? cracks '
and further eroded the~ crack.;;It!also changed:
.- t flow patterns that '*roded/ corroded the ladjacentt . 'i metal and metal 2ownstream of,thefcracks. '
' i L a s .
l-The'-pipe'. continued <to-thin'until it was torn off J j !- 7. s . . . .-.. - z. , o ! byLfeedwater and' recirculating; flow (andylodgedEinL
- l. e ,
.4 the steam. generator internals'.c g,. .
T f
~
l- 8. At the same time,.the' vents eboded duo'.to high" ' a internal flow'velocitiesi thinned,Tandzwe e2 torn. I away. They1too lodged inhthelintiernals.' , y ( a
- 9. An inspection of Unit-3 found thinLmetal pieces. I t-fromtheventsand; pups.intheslower. portions [of' the; steam generators.-
s t The most likelysfailurelscenario:sf f themUnitH2L J 3 feedring cracking. problem.ise similar totwhatsis- 1 ; described above: for? Unit ' 3 f fesdringsE LHowever, : o a 1 h because'of differencesiin.the rigiditytof;UnitF2 2 feedring~ supports-andLUnit.3.feedring: supports = ' (described in the' Comparison ~Between UnitL2'and; Unit.3 section),?theLUnit2 failurejscenario! stops 1, z at step 6. : The-cracks observed /in Uniti2LpupsTare' [ shallow and: are distributed around;.thefperimetier.; ; of the. pups weld.
~
,11'or:21 2 ,
7
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V. . Root Causes-of Feedrina and Sunnert-Failure. I l .
- 1) INADEQUATE DESIGN'OF THE FEEDRING i
1 f The root causeJofLthis failure-isc-the inadequate-
~
j i ~ L design.of the feedring to' accommodate. thermal-cycles during-low power' operation.- , i The ' feedring and. its restraints: ware. not; designed? I to accommodate thermal cyclic stresses,during'AFWi . injection operation. 'The designjan'alysis by CE'of' > the feedring (
Reference:
2)?does.not; consider l . ! cyclic stresses which'are'highsenough under stratified conditions'tol produce cracking.- ] Moreover, the Schedule 40 pup; tietween- the Schedule: 4 120 feedring1and theith'ick' distribution box, acts a as'a " strain riser". 1The' poor'designLoftthe? joint; R o l configuration gives rise-to highishress. concentration factors. cAlso, therenis evidence lof; residual)stressr' in the pipe ,- -
- which' indicates ,
that the welds were not stress relieved. lit - ;j should be noted that batch feeding the0 AFW:is = a-a,
. permissible' mode of operation, perlthe over-all I v plant = design. ,
q. L!
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12 OF'21 -
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- ________. ,__~.._ _ _ _ _
s b i i e
- 2. INADEQUATE DESIGN OF THE FEEDRING< RESTRAINTS .
l The original CE design consisted of two U-bolts [ and slots that allowed the center portion _of the feedring limited motion toward'the center of=.the ! steam generator (radial motion).: _ The ends of the h feedrings were rigidly fixed with two sets of U- ; bolts. The design is intolerant'of misalignments that prevent the feedring. from freely expanding: and contracting. -There'are.indicati'ons that the, difference between the intact _and damaged; pups is
~
largely due to the differences in freedom of l eion. i VI. Corrective Actions for Feedrina and'Suenort Failuraf l l The following corrective actions'are based on the' root l causes:-
- 1. . Modify tte supports.by introducing ;st'ronger bolts-
'(ASME SA193-B7M grade),EandJenlarge~ e size of '
the slotted holes in_the mid span.of.theisparger: 1 at 90' and 270'. Routine periodical' inspection; j for any damage in the; supports will1befperformed.. j i ll 13-OF 21 } i i t
+tw c- y v e . . . .U.-- ,- ,- -m , -
l l' l l l \
- 2. Replace the Schedule 40-pups with~ Schedule 120 pups to match section modiolus and reduce stress at the distribution-box-to-ou? weld. (The new:
j design, implemented on both Units, accomplishes' :; this.) l I 3. Improve the distribution-box-to-pup weld : I configuration to reduce stress concentration;at L l the HAZ by introducing a " weld-0-let" forging - between the box and sparger. (The new' design, implemented on bothl Units, accomplishes this.)- l
- 4. A monsring program will.be implemented to ol' serve metal thinning of the distribution box'and L the Schedule 120' pups-will be replaced-- L approximately every five years of: operation. If ,
the wall thickness:isLlessLthan' allowable for that feedring design basis: (i.e.,'no coll' apse _witho vacuuaLinside tho'feedring.and full' steam - 1 generator l pressure outside),t repair or replacefas-appropriate. l
- 5. Limit batch' feeding. The modified auxiliary: i feedwatercsystem, which was; implemented'in 1986' ,
provides'for. continuous feeding-o'f the steam- _ j 14 OF 21; I
---L. ..n, ,- .. <w , w
. generator. Thus, thermal' stresses-will be-=
minimized, l i
- 6. The construction techniques used to repair the feedring incorporate-stress relieving:at-the new ,
joints. This minimizes residual' stresses and- ' t' increases' design margin.- i B. VENT AND DISTRIBUTION BOX FAILURE
-(
I. Failure Descrietion for Vent! & Distribution Box Failure
- 1. UNIT 3 VENT AND DISTRIBUTION BOX'
,i
- a. The 3" vents on the distributioniboxes were '
severely eroded. . The tee section of the-vents were missing.:The as-found. condition of the steam Generator 3EO89 ventiis.shown in Appendix;A. The missing.' parts:were found in > the steam generstors.
- 2. UNIT 2 VENT AND DISTRIBUTION BOX:-
.i
- a. The distribution box ar.d vent'were damaged in much'the:same way as Unit 3. ,
15 OF 21' d
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. _ . _ . _ _ . . _ . _ _ _ . . - _ ~ _ _ . _ . _ . . _ . . _ __ _ _ - - . . _ _ __ _ _ _ _ _. ..._ _ . . ___.____ __ _
h II. Evidence Collected for Vent & Distribution Box Damage
- 1. Analysis of feedwater flow within the distribution ;
boxes, vents, and feedrings shows that the:shapel and location of the components.will produce flowi i velocities high enough-to cause rapid erosion of I the vent and slow erosien in the pups and' distribution boxes-(see Appendices D E.E)..,
- 2. Flow analysis calculated localizediflow! velocity?
r l in excess'of 70 ft/sec at-thel 11 o' clock position ~. of the feedrino. .This; supports'the"observationL i that the erosion /(corrosionTastalliossirate'is the highest at the top of the feedring, and asthrough-- wall' hole was observed. r l ! III. Failure Modes for Vent'and Distribution Box. i
- 1. VENT PIPES The failure mode'of the vent pipe is localized j
. erosion of.the pipe wall as e result of flow velocities at high. power' levels.iThe'high' .
velocitiesL(as high as 70-ft/sec at. full: power). , are due to the shape and location-ofuthe vent.- l 16 OF 21 1
-i.
.l _ __ _ _l ___.__ _ ______ + . . . . _ , . _ , , , , , . . , _ ,, . _ , , , ,. , _ . , . . . . . . . . ~ ,~,,. ,, ,.
1
- j l
- 2. DISTRIBUTION BOX ,
The distribution boxes have not failed, but their-( walls have thinned due.to_ erosion / corrosion. IV. Failure Scanario for Vent Danmaa~ r i As discussed in Appendix D,'tha local 1 velocity.'in the-distribution box vent is high enough to result in the observed metal thinning damage.. The most likely i l failure scenario for this damage is described'in tho' i following: ;
- 1. CE designed the: distribution box originally, without the vent, before.startup of Units.2 and13.
q
- 2. .During the early'part of the Unit 2.startup, a ~
test of the_ auxiliary feedwater system in March 1981 caused a partial vacuum withinuthe:feedrings-in Steam Generator 2E088.. This' caused them.to , o collapse due to inadequateiflow;arealof the - feedring's J-tubes'andithe relativelyl thin . Schedule.40 feedring walls..
- 3. In 1982,'CE replaced the. collapsed feedringLpiping.
except for a 9" pipe on.both sidesf.the o 17'OF 21- i s h . ;l
I i I
>q
. distribution-box (pups)>with schedule-120 pup. CE also installed vents in the. distribution box ~and i
replaced the- J-tubes: with larger 'diameterf elbows. l t 4.. In 1982, CE installed vents in the distribution ~ box that are intended to. vent off steam- i accumulated at the top of?the distribution boxes-to prevent steam collapse induced waterhammer. l
- 5. During normal operation,-the feedwater flow inTthe distribution box'. vent results in excessive erosion / corrosion.
l ( , It should be noted that;CE,has:recently changed' its1 technical position on1tha t necessity-oftthe. distribution. box vent-for waterhammer prevention.: CE now believes that the vent is?not needed toL prevent steam condensation induced:waterhammer because ofolarge J-tubes installed,after;the 1982 feedring collapsing event. -4 i
-(
Y. Root cause for Vent'and-Distribution Box-Failure' i i
- 1. INADEQUATE DESIGN OF THE DISTRIBUTION' BOX AND VENT
~FOR HIGH POWER OPERATION- l 18 OF'21
- ____,._,.;_.-.m.i - . . - . . , .
a-
\
1 Normal high power. operation necessarilyIinvolves i high velocity water that erodes / corrodes andLthins - i metal ~ pipe walls. The' local flow velocities in-the vent were so high that'it could have eroded ! after four to five years of operation.- CE'did not. perform a design analysis to identify this failure .;
-l mode.
VI. Corrective Action for vant and Distribution Bow' Failure.
- 1. Repair local thinni'ng.of.the distribut' ion. box:by-weld buildup'and remove any: local surface ,
discontinuities (such as-the and plate nut)'inside the distribution box.
. 1 COMPARISON BETWEEN UNITS 2 aun 3 The major differences between Units 2 and 3 are listed:below:- -
l i
- 1. Crack ~ Development In Unit 2, cracks were found.to develop;around;the perimeter of the pups weld. Bauever, in Unit 3,rcracks swere.found to: l
~
develop preferentially et 4 andis o' clock: positions.
-1 q L
19-OF 211 b
, gr . _ ,_ . ,,
i l 1
- 2. Crack Propagation Rate .
t In Unit 2, cracks propagated to'a depth of.0.040" to 0.020".- In Unit 3, cracks propagateit through-wall in three pups. : i i l Based on the operational history of: Units 2 and 3,J one1wouldl expect-similar degrees of degradation,'since:both Units have
~
the same design and experiencedLalmost similar number of thermal cycles. -However, this is not-the case.- This difference in degrauation extent'can be explained in1 terms ~ j of the magnitude of-thermal cyclic stresses 1 exerted'on,th's feedring. According to the CE repair report dated 1984,~Rhfarence 1, i the.end supports were modified:in Unit.2 only.1 The l modification included slotting'the round holes to'within 1-3/16" i 1/16". , I This anlargement was noticed during repair ofjUnit 2 and confirmed by Mr. O'Connor of1SCE. -This modification would allow the Ur.it 2 feedrings-to-move freely, thereby' reducing j. the magnitude of the thermal-stresses.- This in turntwould-change the state of' stress in Unit 1 if' compared to Unit'3.. As a: result, crack initiation: sites and crack propagation; rate would. vary accordingly. 20 OF~21 _ _ _ _ _ _ , ._ _ .. . _ . . ..~ _ . _ _ _ , . . .- _
. . -.=.. .. . . . - . . - - . . - . . .- . . -.-- . . _ - _ _ .
I t 4 The other' degradations that were observed in'the~feedring, which were not a function ou thermal stresses,"were found to. , i be almost identical-in both Units'2'and 3.' For example, the ~ . vent degradation, localized'orosion of pipe and distribution. q box were found to be in the same damaged condition.in' Units- , t 2 and 3. l, 10CFR21 EVALUATION The feedring, vent, and distribution box damage is determined l not to be reportable under 10CFR21 because the' damage does not constitute a sienificant safety hazard to public health and; safety. See Appendix J -for details. ] i l E!
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.4 APPEh'0IX A-
.FEEDRING FAILURE MODE ANALYSIS ,
i
'FOR' UNIT:3 I
7 i I 1' i
,l 7
4
"l APPENDIX A i
i l FEEDRING FAILURE MODE ANALYSIS, UNIT 3 l l Purpose-L l This appendix consists of two parts: the Fracture Analysis and.the' ! Metallurgical Analysis. The objectives of the tracture Analysist-section were to determine fracture origins and crack propagation-f direction in - order to reconstruct- the sequence - of rupture and- .f degradation of the pipe. , The objectives of the Metallurgical Analysis section were to l 1 determine the integrity of the . weld, crack propagation path, piping material, and microstructure verification., ! Sketch A.1 shows a schematic . drawing- of the- feedring box, illustrating the arbitrarily chosen -clock position and the convention used to identify the:feedring segments. . The convention' i
. maintained will be maintainedf~in. all' discuss' ions tabout : the t feedrings on both Units. The pups are called "left" or "right"'
based on ~ looking at the distribution ' box c fromJinsideE the~ steam. generator. The pup's clock positions Jare -always at . 3 . o ' clock (toward the inside- of the steam _ generator) ,12 o' clock -(at the top: of the pup), 6 o' clock (at the bottom of the pup), and 9 o' clock (toward the.outside wall of the. steam generator)'. A-1
The steam generators will be identified as.they.are in the plant,. I l as 3E088 6r 3E089. FRACTURE ANALYSIS-L 4 Procedure The Fracture Analysis consisted of visual- - examination,= w'all. l l thickness measurements at and' near metal discontinuities, ; and Scanning Electron Microscopy (SEM) .of ' fracture surfaces. The analysis was conducted' on pieces that had been. removed from the'. . steam generators. J f Visual examination was performed using:a binocular microscope at magnifications up to 40X, while wall thicknees measurements-were. . i
-1 performed using a point-micrometer. The.SEM used'in the; analysis was an ISI Super III Model.
Results'
.i y
~E088 Right Pup.' '
4 Visual examination of the damaged feedrings inside; steam generator.- E088 indicated excessive material loss- especially. at r the bottom - s'ide of the ring.in the vicinity of.the box._ y s A-2
+ ,
.i li'
-I
?igures A.1, A.2, and A.3 show the feedring pup 2EO88R and illustrate' the excessive material loss observed betiveen 3 o' clock l and 9 o' clock positions, in addition to the tearing rupture at 9 o' clock.
l Visual examination also revealed wall thinni.'g at . the ruptured ; l surfaces. Sketch A.2 shows the wall thickness: as measured at approximately 1/8 inch distance from the edge of tho ruptured wall. The sketch illustrates minimal wall thickness observed at point 6 (O.014") and point 18 (O.012"), which correspolids ' to' 4 and 8- ! I o' clock positions, respectively. At 6 o' clock pon.ition, the thickness was found to range from 0.036" to 0.089".: i The apparent pipe degradation. in T i g u r e s ' A'. 1 through A.3 may 4 l suggest complete material loss as a result ofi erosion / corrosion. l However, the wall tiiickness _ profile suggested otherwise.; This= initiated an effort to piece together-the-debris.foundEin E088. > This effort was performed by Dr. Waldo of SCE. The result, shown in Sketch A 3, illustrates excessive localized = material loss at. approximately 4 and 7 o' clock. Matching contour lines, wall-thicknesses and microstructural data such as ' roll directior , were - , used in piecing the debris together. The arrows in the sketch depict the crack- propagation! diruction that was determined with the use of tho' binocular microscope. 'The A-3
detailed wall thickness profile of each' debris (88A, 88C, 88D, 88E, -l and 88F) is on file. The surface of debris 88A was examJned in the SEM and the results are shown in Figures A.4 and A.5, which represent the conc ave side and the convex side of the debris, respectively. Both figures were taken at the same magnification -(10X) . As' illustrated, each-surface shows evidence of scalloping and an absence of: pitting, which in turn suggest wall thinning, as a result of' erosion only. In addition, the scallops size on the concave side (I.D. of pipe) is much smaller than that of the convex side (o.D. of pipe) . Th'is soggests the presence of water flow on each side of debris, high velocity on I.D. and a low velocity on O.D. surface.- Water flowed for a period of time in the. developed crack. . This observation is also illustrated in Figure A.5a which represents a micro-section of i the same SA debris (difforent scallop' size). All of the above mentioned observations suggest localized cracking,- followed by excessive localized erosion rates at. approximately 4 . o' clock and 7 o' clock locations. 3E088 Left Pup visual examination.and wall thickness measurements of 3E088 left
~
pop indicated a similar type of material.-loss and pipe degradation , to those observed on the 3E088 right pup. Figures A.6 through A.'10 A-4
+.g .,.,..,..y--g y-4,,---- # y.--,. e,.._ ,,,y. ,<-w - , . ,
l i i l 1 show the appearance of the removed pup, and the localised material-loss betwo'en 4 and 8 o' clock positions. Figure A.8 shows again, a similar pattern of excessive material loss duo' to erosion at 4
-1 o' clock and 7 o' clock positions.
Sketch A.4 shows the wall thickness profile of the removed pup at ,
-I the ruptured and eroded surfaces, and illustrate maximum' wall thinning at 4 o' clock and 7 o' clock positions (0.011"). The wall .
i thickness at 6 o' clock was found to range - between 0.083" and I C.104*. l In the process of piecing together the debris foundLin 3E088, the piece that was identified as 88F was foundL to fit a portion of the cavity (material loss), as shown in Sketch A~.1. The arrows in the 1 I sketch depict the crack prope9ation direction as determined by visual amamination unde,c binocular microscope; The sketch illustrates the excessive localized material loss due to erosion at the 4 o' clock and 7 o' clock positions.- As' mentioned earlier, this was very similar to that of the 3E088 right pup. 3E089 Left Pup Visual awamination of the 3E089 left pup (after removal' from-the ! steam generator) indicated a localized material loss associated with max 4=nm wall thinning.at 4 and 8 o' clock, and.a rectangular shaped hole with thinned edges at.the 11 o' clock position. The A-5 f i
...r,.- .--v-y . . ,,a- +-*-g- + - - + - - = - d s-
- y t -
i 3E088 - left pup was also observed to be thinned down.to 0.099" in the vicinity of ll.o' clock (see Figure A.7a). q I. l Figures A.11, A.12, and A.13 show the degraded pup after removal from the steam generator. Sketch A.7 shows- 'a schematic ! representation of the . 3E089_ left pup and; the wall thickness- ; measurements at the different clock positions.' Maximum wall l thinning (0.017" and 0.012") was observed at 4 .and 8 o' clock, respectively. Sketch : A.8 shows the overall appearance: of. the degraded section of the pipe with maximum wall-thinningsat-4 and-8 o' clock positions._ . The thickness at ' 6 ' o' clock was' O.134". The-arrow in the figure depicts tihe crack propagation direction. The detailed thickness measurement of the debris 89A~ (as shown in l l sketch A.8), as well as closeup pho'tographs, are-on file.- In summary, visual examination and wall thickness measurements of-E089 left pup indicated:locali:.ed' wall thinning _ at approximatelyL4 l l and 8 o' clock position, similar to those' observed on E088 left and-E088 right pups, which. in turn suggest> a- similar degrading mechanism. 3E089-Right Pup Visual examination' of- the 3E089 right pup'did.not indicate any significant wall thinning or the material loss as was observed on e the other Unit -3 pups. However, dye penetrant inspection indicated. I
'A-6 1
l' i the presence of a crack at 8 o' clock and in the vicinity of the l . weld. 1 1 1 Figures A.14, A.15, and A.16 show different closeup views of a ring l t of the pup's metal, including the~ weld. The crack, approximately ' ) 3" long, is illustrated by red colored dye.- The crack was cut open , for SEM examination, and the fracture mode was documented. It is > important to mention ' that while cutting ' the ring to expose the . fracture surface, the ring sprung open after the first cut': and - l separated a distance of approximately 0.4" (1ca), . a s - s h o w n -- i n - Figures A.17 and A.18. The springing - open .indicatesf residual-stresses. Springing open was also observed while sectioning'the 3E088 right and left pups. ( Visual av==i== tion, after the crack was, cut open, showed that'the l crack was shallow, with - a nominal depth 'of - 0. 04" . and . a . maximum crack depth of 0.068 Figure A.19 shows an SEN fractograph of.the crack observal on-the ring. at the s o' clock position.' The crack has.: the ; 2. allowing characteristics: i I
- 1. There are asaltiple fatigue crack origins, which is ' indicative of high stress concentration'. This is illustrated in the-prenanew of several hackle' marks - at the crack initiation.
1 surface. , A-7 h
= - * - - . - . . - - , . . - , .. 9- ,v_....,,- , .;.,,. ...,.e,- , . ,
9 ,. , ,,
= ,
d l~ k
- 2. 'the fracture surface was oxidized to 'different ~ levels i depending on the, crack depth, which indicat es that the crack' i
existed and progressed- for a period of .timeF(see: Figures A'.42 l l
)
and A.43). J l 3. The presence of secondary cracking associated':with weld' defects such as porosity-~(see figures A.20 and A.21). ! t l 4. The crack initiated at the outside surface of'theipipe, t i l i L l . . Figure A.22 shows an SEM fractograph of the overload zone that was - 1 l {mhaned during the opening' of. the crack. 'The-figure. illustrates. disple rupture which'is indicative of the ductile' properties of tho' , I astal in the heat affected zone. L l In summary, the SEM examination revealed the crack to be.- a: fatigue' ;
~
cracAt that initiated at the 0.D. surface of the' pipe at the toe of ' i the unld that joins the -distribution box .to the= Schedule 40 ' pup. Sketch 30. A.9 shows a schematic representation Hof the ring,~ illustrating the wall' thickness measurement. The : nominal thickness - of tho' ring was found to be 0.48", .i.e.,-the pipe did.'notrerode. . The initial thickness of the pipe would be in the range of'0.406" [ d, i o. ass =.
=!
)
A ,
Discussion Based on the visual and SEM examination and the thickness measurements of the four feedring pups and debris removed from SG EOR 8 and E089, the' following possible failure scenarios were considered: i ! Scenario 1: Erosion Before Cracking f l Under normal operating conditions, the pups ' are postulated ~ to erode / corrode uniformly to the point.that the pipe would rupture i and produce further . excessive material' loss due to' erosion / corrosion. This scenario is unacceptable since it does not explain the excessive localized material loss at two specific locations, 4 and 3 o'cicck. It does not explain the absence'of any erosion-in-i the EOS9 right pup, nor dcas it exple.in the presence of the crack, especially when the crack - location coincides with the- 8 o' clock position. l Scasario 2: Crack Initiation'Due to Weld Defects 1 I Thls mammario suggests the presence of weld defects that initiated a cmt through which the' water rushed out at a high . velocity and caused severe erosion. This scenario is also unacceptable.for the-following r=amann: first, all welds were penetrant inspected ~and no indicaticas were found; second, it' appears to be too much of a - A-9. e
-~-*w +,w.,- ,s we-r-- w..-,,-w= se ,g=-y e- ~ w w a-e,
i i I. "
~
- j. coincidence that defects would ' be . concentrated: soi that allt four .
l weids developed cracks at spe'cific locations such as 4 and; 8 ! l o' clesck. l Scenario 3: Single' Crack Initiation- ,
'I l
A single crack is proposed to be initiated at either 4 or 8 o' clock - q positions due to thermal. stress, bending stress, or other . sorts f stresses (residual, etc.), then excessive erosion takes placei and erodes the bottom of the -pipe all, the way ' to. the otheri extreme. This somnario is also unacceptable because the pipe.has a-minimum- l s wall thir h === profile at 4.and 8 o' clock, and a' higher-nominal'
~
value at 6 o' clock. h l Scenario-4: Initiation of Two Cracks Followed by: Erosion-The most probable scenario would be" an initiation! ofi two cracks possibly at the same tisse or. within a short . period 'of - time. ' This creates a higbar ' flow -- rate that in- - turn increases; the. metal - thinning. rate, aleeg with introduction ofl flow . induced fluttering '
~
of the partially thiw surfaces. 'Under the' flow forces, tho' , l l l , eroded sagsset any break away, as ' observedini E088 L and ' E089. SGs. l This scenario is supported by the fact that.. although . the ' intact:
.i E089R pup did. not erode / corrode, it had a fatigue crack which~
developed at the 8 o' clock position. , . .1 l A-10 I
.1
~l
.. _ . 2 ....1... .i.._._,__.
4 5 I Vent E088 visual examination of the vent indicated localized severe material loss, as illustrated in Figures A.23~and A.24. The appearance of the inside diameter surface 'is illustrated in Figures A.25 and A.26. It shows evidence of water flow cutting marks, indicative of' r l- exceptionally high flow rate. ' l ( l Wall thickness measurements indicated excessive wall' thinning.at the inside radius of the elbow and adjacent to the T-shaped section q of the vent. This is illustrated in sketch A'10. . A colaputer model
.. 1 I
l- of flow in the distribution box .and in particular at the vent area was required to explain the excessive localized wall thinning. The results of the flow model calculation . indicated localized water 1 velocities in excess of 80 ft/sec at the eroded location in1 the elbow and explains the localized erosion that took place. l Vent.E089 l Visual examination of the vent indicated similar localized material j loss (see Figures A.27 - and A.28) . The~ appearance of the:inside -j diameter surface of the vent again indicated. water -cut - marks- , a similar to those observed on vent.E088, which indicates aL high; flow velocity. A-11 f
- 4 t
.~.
L ; L Metallurgical Examination-1 Procedure f l 4
,t The metallurgical examination of . the distribution box assembly ,
consisted of preparing metallurgical microsections-of'the debris for microstructural identification, and microsectioning the cracked i ! welded joint. This was performed'to determine the weld quality and. the relative location of the- crack with respect 4 to the different' ; weld zones. Also, micro-hardness asasurements were conducted in the base metal-and in the HAE of the cracked wcid. For the purpose of material identification, ta quantitative chemical I - analysis was. performed on the debris found. Results E088 Debris g d The debris found in, steam _ generator E088 weral labeled ' 88A, 88C, 1 88D, and 885. The source of'the debris is shown in Sketch A.3. - Debris 88B was consumed during the metallurgical analysis performed by CE. - 1 A 3 1 t t Y i
- ,- , .~. . _ , , , . . . ~ _ , - . . . , - . ,e .,- .. , . . - y#.4
s Ttte chemical composition. of the debris found in E088 'is listed in ' Table A.1,- which indicates that the material used was- in' conformance witr specified SA106 Grade 8 specification. Figures A.31, A.32, A.33, and A.34, show the typical microstructure , asA, 88c 88D and 88E, respectively. -The of the. debris microstructure is ferritic/ perlitic with fine grain size. > The hardness'of the debris SSD was found to be,in the range 74-80 HRB. \ \ E088 Vent The typical adszustructure of the vent is shown in Figures A.35 and - i A.36. Ttas aderestructure is ferritic/ perlitic'in: structure'with .l evidence of grain flew = typical of a forged structure. E088 Imft Pup 1 Sketch No. L12 shaus the relative location - of the prepared-microsectiam anname the weld and at an, area- containing. tho' crack. This crack appseem to be aL final ~ tearing .crackirather1thEn' an initial crack
.4 A-13 s
,va , ,,,,-w-,.,m -
,. --ve,,,, v , -w,-- ,,-,f,,, ,,.e,wns.-, , .k
I I l Figure A.37 shows a microphotograph of, the prepared microsection'in the as-etched condition. The crack appears to coincide-with~the
~
i HAZ. This is illustrated in more detail in Figures'A.38 and A.39. The micro-hardness measured at the weld, HAZ,-and base. metal', is , listed in Table A.2. It indicates a minimal hardness 'of '99- HRBi in the HAZ and 94 HRB at the base metal. The weld has a hardness of l 96 HRB. These hardness values do not reflect anyL evidence " of ; hardening. of .'ects. -No evidence of any major weld defects were detected. E089 Right' Pup In order to determine exactly the relative location of'the crack i that was found on the right pup at the 8- o' clock . position, . a . microsection was prepared in a direction transverse;to.the weld. A macrophotograph of the prepared cross-section .is shown in. Figure: A.40. The figure illustrates - tho' coincidence; of the crack d initiation with the toe of the weld-.and~ propagation through:the: HAZ. Figures A. 41, - A.42 and A.43 show high ' magnification microphotographs illustrating the veld microstructure and-the: crack-l \ path. The microhardness traverse the veld.and-in the different HAZ. a is listed in' Table A.3. As. can be seen 'in .this - table, the range 'of . i hardness is similar to that observed,previously_on the weld joint of E088 left pup at the 9 o' clock position. A-14 f k
~ , ...- . .......- , . . .-:. . . :. . .
Discussion 1 4 Based on the metallurgical and chemical analysis, the' following was concluded:
- 1. The feedring pipe material and the vent natorial conform to-
-l ASME SA106. e
- 2. No significant microstructural defects, such as . inclusion stringers, were observed when the microstructure was examined in the as-polished condition.
- 3. No significant weld. defects were observed in the examined microsections, especially at the cracked location on'the E089 t
right pup.
- 4. The crack at 8 o' clock on E089 pup weld wasifound'to initiate at the toe of the weld.- The toe of the weld' normally .
l 4 l represents an area of high residual tensile stresses. As' I mentioned' earlier-in this text, evidence of overall residual' > l stresses ~was observed during the cutting of the pipe. , VENT PIPE FAILURE MODE DETERMINATION Based on' three-dimensional flow ~ field and . pressure field calculation, as documented in Appendix D, the local velocity in the A-15 , f ________i__
, ..~,,.; -- -..v+ -- E
- - - _ ~ _ . - . - - _ . - . . - - _ - - . . - . - _ _ _ , . - - - _ . .._ ._---. .
.i, l
Vent pipe ;can be as high as 80 .ft/sec. At this1 velocity, the . >, localizes erosion / corrosion rate: is. calculated -(as e extrapolated:' from Appendix B calculations) to - be about 60 mils per year.- . i Knowing chat Unit 3 has about four full-power years since startup,. ! the total erosion / corrosion rate is as high as. 2201 mils. The-erosion /corrosihn ustal loss correlation has an uncertainty of 1 250%, the actual astal loss for the vent pipes could be as high as t 1 600 mils. i Based on tihe fahame picture shown in Figures- A.~2.1 and A.2.2, the-metal loss ikn t!be lummt pipe is most severe in two areas. One1is- l the area heerne Who 21mur separation zone at. the , inner side'.of ' the 1 U I band. Ihm N jis at:-the area just-- downstream of the outer side of the hundL. h tus high metal loss I.ones are areas where flow. field enlieninndrunn shame tho' highest velocities. .
- . i 1 Many unteur f5kas
- umre observed on' the!inside lof 'the vent pipe. -
l These mutuar ametNus aus a result of high velocity wateri ero'sion j
.i (ma< ha=Emmm)) gnummons These water sarks suggast that erosion.is a.
strong *w=*mHh*ug fbustaur, and the--failure mode of the vent' pipe. , is era =EnvW===nah
.l A-16
, .t
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . . _ _ _ _ _ _ . _ _ _ _ , . _ . . . _ . . _ _ . . _ , . . . ~ . - , _ . . , , . . . , . , , , . _ , . - . ~ , , ,
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l l l Table L.2 j MICROHARDNESS MEASUREMENTS
-KNOOP ' HARDNESS )
SAMPLE POSITION MICROHARDNESS CONVERTED 1 I.D. (IN) (KHN)- FROM '. (KHN) E088 Left Pup Weld 2'20 ' 94 Rb' 234- 97 Rb HAZ 258 21 Rc 235 97-~Rb' .l 230 96:Rb-246" - 99 Rb, 231 - 96 Rb' >} 248 99fRbi Base Metal 220 94'Rb.
~
220L 194 Rb , .]
- \
1 (
' Table A.3 l 1 MICROMARDNESS MEASUREMENTS >
KNOOP HARDNESS SAMPLE POSITION MICROHARDNESS' CONVERTED ., I.D. (IN) L(KHN) ,FROM1 (KHN) 4 89 Right Pup Weld' '261 <- -22 Rb= 235, '97 Rb-- ll HAZ 213 92?Rb. l 218 93 Rb , ..' l- 189' 87:Rb--
'189
'87;Rb q l . 173 83 Rb: .
175 84 Rb d l i Base Metal 161 79 Rb' ;
.'60 79'Rb l
.:I 6
i i
.q
.+. _ . . . - _ - . . . . . . __1___.___ m _ _ . . . __ . . _ _ _ _ _ _ - _ _ . _ _ _ _ _ _ . ..___.___~i - - _
f . 'l i j ) 1 l Sketch A.1 l is I r,9 ,
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- l l
l l j , e--- 0 _ ,__ h Siti view of the distribution box assembly-illustrating the arbitrarily chosen clock positions. The arrow depicts the water- 1 flow direction. i j-li i s
. - + , ,. .. r . . - . - - . . -- , ~ . . . - . -- -
L J ; 12 @ .ogg 1
@ .162 i 11 og .
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- - . . , ahr i ~~
F. Possible fatigue !.1
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^'%i,tamiM%Kov L, 4 o' Clock new -
- . 7 O, Clock 5 O' Clock 6 O' Clock
[ l I Feed ring side EO88 Right Pup l l l . l ! Sketch A.3
~!
i _ _. . . _ , _ . - . . . , . . _ _
t ;
'i I
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Pup 40 Schedule U10 077" 1 J~ c s34% @ .060" @ .182" , e [ Ring 120 Schedule @ .121" i
- 9 8 7- 6 5 4 3 t
i 4 t
! Sketch A.4 1 _
- f- m. ,,.v ,[- --y---~y ,
- c. * # y- .,
,w- - - -
L J 1 i .i ~ t !! - 6:00 7:00 ; 4 ! 5:00 --- m-e - - - W: ~"" men
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@ .061" @ .041" @ .072" :
- ' @ .089" @ .022" @ .085 " 1
@ .083" @ .011" 14 .052"
@ .104" 10 .095" @ .043 " j l
EO88 Left Pup 4 Sketch A.5 ;
. _ . _1.1 - - , ,:
= . _ - _ . _----- - _ _ - - - - -
u l t ._/ : Distribution Box Side 1 j~ . , . ,r =.c:,. m
. ims.+
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- 6 O' clock r t f i
Feed Ring Side i i 2 Sketch A.6 I
. - - + - .c, , . c e- . .r ..r - + , ~ , - - , . - - - . . -- . .- . . . . . - - ... ,
L J ' i ,
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+
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- y,m e;.:. g ;, M..
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.: : = <ir :
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.57MinPRM@ 1/8 From Edge Edge mq4g+rw mg$Wegg,a?2x.,pTnMimig;a
.w;w. m. rq 3 n ACQ
. =Mrf -e #,.isi7Ei1 = s igt f #;i:E3p;C T- a--cgifif -Q j"#7M s ?ni % u . ;:g p y;f d s2::'*T-i?!snJPixa .VUUn - .
! . ..r:#Fs%ste - :
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^
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-pr:
w- . e A r;;: m y 9 08 .023,, @.0s7,, .oio. t
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- 17' wis
- w.- '
1 m.:" 7 '4" w s'M W @ .069,, @ .037 .004 ;
@ .115,, @.022,, .004 4.
8 @ .134,, @.034,, .oos. l eup 4o @ .129,, @.061,, .008 ' scheouie l l
@ .080,, @ .121,, .006 l
^
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- Ring 120 m H g~
m b:4
@ 018" EO89 Left Pup
=
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l l l Sketch A.7
k L C J i Distribution box side
, ' G;h . ~_
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' = gdisN Ybi Wg%-
. = ,0:N 1.
~
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.= = ::#:wr.
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a m=:.~ = m . x ~~'/Iu %;n' :N:3~I J f hi.'I.i}j-? ~a+iy . o awewm!6 Eld.: 4 O' Clock i c mW
*" 7 O' Clock 5 O' Clock- -
'6 O' Clock -
I Feed ring side EO88'Left Pup l i
't Sketch A.8 I
l
- - ,, , ~ ~ , . ,, _ _ _,_ , .~- _ _, _ , _ _ _ _ _ _
I L - _) j i i 12 ' i 11 1 1 .503" 2.455" i 10 2 3 .455" 4 .470" -l - 5 .437" 6 .480" 3 7 501" ! 9 , 'eossa. ia i 9 .510"- mew n=*aess 10 .511 " A
- L- \ -
4 11 .493" " O - A 12 .476" - \ 5 7~ 6 i l
- EO89 Right Pup i
i, j Sketch A.9 I
l -
.-- }
l. _ /- - I mm +,,__ - ,g ea g"
,r.2ttTa ++ i
- ^ av. ,
g . wyf%~kh m tg_ (+:4 nn
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y y,
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ye-d i I stL. 34[jl; 4 ., ! =
, D:$7a #Ed g* ,.
Cuts l@hnN N ,f69
@ .046" @ .238" @ .099 " @ .074"
@ .050" @ .265" @ .082"- @ .066" l @ .038" @ .241" @ .107" @ .069"
@ .066" @ .031" @ .045 " @ .249" li @ .094" @ .076" @ .066 " @ .247" i Sketch A.10 i 1
6 i . Aggi au--ytwa:w.43f:r "&. af . . _, , [ qq av =curps w..-%m.:]w:r53 a v h;fmfcg- de p;(. ._,s%;J ueQ -: -- =. -n % n=q s= . i Mg cP:95 4w.O t
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=
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@ .069 @ .028 @ .063
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@ .072 @ .033 @ .051 ;
.049 Vent EO89 I @ .078 @
1 i Sketch A.11 4 - - --
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i 7:00 9:00 - si r* - _ . _a_ 8a 6A':;'h:gri&495,/j? - e ; %-g_ g wun eniAkW.
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gp y .. a s: ,
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1 .122" 6 .061 "' 2 .122" 7 .016" 3 .101" 8 .018" 4 .087" 9 .018" 5 .079" 10 .055" 11 .075" EO88 Left Pup Sketcli A.12 w .- ._ = .- . - - - =- - - -- - . = - -
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TIGURE A.3 l 1 r 1 e o FIGURE A.4
1 a e l MAG. FIGURE 10X A,3 1 l l l i.. . -: :. . .
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FIGURE A.7
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I N, VISUAL: EXAMINATION'RESULTS 2E088 Right~ Pup l' -) Figures B.1-through B.4.show cracks as revealed by'the penetrant-
, inspection and marked in red'in the 2E088 right pup. -The-cracks a
were around the perimeter, as Lshown- in Sketch B.1,1 between.1 and 3 ! o' clock and 4 and 7 o' clock positions. Small crack ~ indications , were also observed'between the:9 and 10 o' clock;positior,. Visual ~ examination'of the inside- diameter surface of :the pup; indicated uniform wall thinning. Wall ~ thickness measurements are tabulated. in Sketch B.1. ' Wall thinning on the .6-9-12 o' clock. side Lis greater t than on the other side. This is in agreement:with the. flow model . calculation (Appendix D) . - 3 t 4 2EO88 Left Pup j i Figures B.5 through B.8 show segments of the 2E088 left pup. ' The , dye penetrant inspection. revealed : isolated cracks < almost.all around: the perimeter, as illustratedzin Sketch B.2. -The wall; thickness , measurements- of: the: 2E088' left pup- measured in the . vicinity Lof the . ' weld (tabulated' in Sketch -B.2) , -indicated i a' thickness: profile ! similar to that observed on 2E088 right pup. Morewallithknningt g
! was observed at.the-6-9-12 .o' clock side.
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'l 2E089 Right Pup Figures B.9 through B.12 show the crack. indications as. revealed by penetrant-inspection of the 2E089 right pup. Sketch B.3 shows the crack locations and> wall thickness measurements.- Again,; a thickness profile similar to that of 2E088 was found.
4 2E089 Left Pup l
- Figures B.13 through B.16 lshow the crack - locations in, red as --
revealed- by the. penetrant inspection of E089 ileft pup. ' Sketch B-4 illustrates the cracking which was found at.most.of thefweld'that' ; joins the pup to the distribution box. Sketch.B-4 also shows the-wall thickness-measurements of the sparger in the vicinity of:the i weld. .Again, more wall thinning was' observed at <the 6-9-12 o' clock . 4 side. l Fractography.Results l l An SEM was_ performed on one of the. cracks;' the crackIin the 2E089L j pup at 2:30 clock position.- The crack is illustrated"in Figures B.17 and B.18,: at two difforent magnifications. ...The O.D.Jdenotes the outside diameter of the pipe. The crack was found'.to extende to about .12" . The macro features of the crack are typical of fatigue cracking . with ~ high stress - concentration condition.- ThisL sis ; manifested by the presence of several hackle marks. . The arrows'in Figure B.17 point to the crack origins. The: fracture surface was covered'with high temperature (500*F range) oxidation,--as shown inL ' Figure B.19.- The crack was. opened in the laboratory, and Figure j B-3 4 .en- ~ , - . - , - m . a , , e e w v e- ,,
1 l l l B.20 shows the disple' rupture typical-of an overload fracture of- 'l ductile material. 4 Metallurgical Examination - t Purpose t
.. q The purpose of the metallurgical-examination was to-determine the integrity of.the weld that-joins theifeedring.toLthe-distribution' s
box, and to determine the crack initiation side 'and "the L crack ~l propagation path. .. l Procedure The dye penetrant inspection revealed cracking 'at different' , locations around the perimeter of the four.. pups. Since ~ the 1 cracking was different from those of Unit 3, t several' aicrosections' q
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in each weld, at four different locations, were..made to verify the 1 cracking pattern.- Metallurgical Results 2E088 Right Pup: Figures B.21 through B.24 show macrophotographs of the cut sections at.1:30, 5:00, 6:30,.-and 10:30 clock' positions, respectively. - As . illustrated in these figures, the indications that were revealed by. penetrant inspection were true cracks.o These cracks initiated ati the toe of the weld and propagated into the HAZ. -Figure.B.25 shows' the metallurgical' microsection prepared at the 1:30' clock position. - ' l j B-4 j _______ _ _ _ _ _ __._ . ._ _____ _ . a_ __ _ _ _ _ _ . . . -
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.l The' figure illustrates crack initiation at the toe'of:theLweld and:
at the ' weld pass- interface. . Figure B.26; shows ' the. typical . microstructure of the pup Schedule' 40 pipe. material,' . which: is '[ p parlitic/forritic microstructure. Lt 1 2E088 Left Pup s Figures B.27- through B.30 show macrophotographs of the cut sections-N prepared at 4:00, 7:30, 10:30, and 12:30 clock, respectively. Again, the-indications that were revealed by. penetrant inspections-represent true cracking. . Localized porosity was observed 1at=the s 12:30 clock . cut section, as illustrated in ~ Figure B.30. Th'is'
~
localized defect was not associated with crack initiation. ' Figure Figure 8.31 shows a typical microstructure of ~ the 12:30 clock. ] B.32 shows the typical microstructure of the pupLSchedule.40 pipe. l material. l i 2E089 Right Pup 3 Figures B.33 through B.36 show macrophotographs of the cut sections - l
- 1. at 1:00, 4:00, 7:30, and.- 10:30 clock positions. These' :
I macrophotographs--again illustrate the. presence of pairs of cracks: p that initiate at the toe of the weld ~and propagate into the1HAZ. j Figure B.37 shows an optical-macrophotograph of the crack at'th'e .
.. 1 10:30-clock position. The crack initiated at the toe of the weld- ;
y
-a'nd propagated in the heat-affected zone andDinto the base metal'., !
FigureL B.38 shows the typical- microstructure of the Schedule- 40. pup. This microstructure is different from the other pups intthat: it has a finer grain structure and appears.to have.been from.a,
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1 WATT' THICKNESS . clock Clock-- .! Position- Thickness ' Position. Thickness j ' 1 .393"- 17-
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- i Clock , Clock Position Thickness Position: Thickness 1 -.357"- 7 .380" 2 .354"- :.273" ;;
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i I APPENDIX C INSPECTION OF U-BOLTS INITS 2 AND 3-Y
l APPENDIX C i INSPECTION OF U-BOLTS, UNITS 2 & 3 Purpose i The objective of the dimensional analysis of the U-bolts removed from the steam generators in both Units, was to determine the degree of j i degradation in the bolt. The bolts were checked for evidence of any bending or stretching. This appendix also includes a calculation that shows the U-bolts were stretched and bent during.~ service, not during , installation. STEAM GENERATOR, UNIT 3 INSPECTION RESULTS l Visual and dimensional inspection of the U-bolts removed from the staan . generators 3E088 and 3E089 indicated evidence'of bending in the shank - area and stretching in the threaded portion.- The inspection results
~
are listed in the Dimension Inspection Laboratories (DIL) report which is included in this appendix. (See Table C.1.-) The degree of stretching was found to vary from no stretching to 0.022" , per inch of thread length.
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i l l l l i l 1 l I Not all U-bolts were tested because they had been damaged during removal. To avoid damaging the feedring piping, some of these bolts had to be cut in their mid-section and some had to be cut it. the thread , I section. The reduction in the cross =;oction in the shank area was in some cases i associated with rubbing and surf ace polish. This is illustrated in the ! DIL report, Table C.2. Two of the U-bolts that were not severed in their mid-section were checked for overall dimension, one of which indicated bowing outward. l This is illustrated in the DIL report, Te.ble C.3. l l STEAM GENERATOR, UNIT 2 IN3PECTION RESULTS similar dimensional analysis was performed on the U-bolts removed from Unit 2. All of the U-bolts were tested. The results are illustrated , in Tables C.4 - C.7. Table C.4 lists the thread pitch measurements which illustrates bolt stretching. Table C.5 lists bolt diameter measurements, per Sketch C.4. The table also shows the overall dimensions of the bolts.
.C-2
I l Table C.6 lists the bolt diaseter at the shank area right above the threads, per sketch C.5. Table C.7 lists the angles of bending in the bolts in the threaded area, per sketch C.5. ; The bolts were found to have been stretched less than those in Unit 3. The maximus 14tretch was 0.011". Some bolts may exhibit compacting. rather than stretching in the tables. This was caused during the removal and dismantling of the bolts. Those bolts show evidence of l hammering at the threaded and. i The bolts were somewhat bent, although the angles of bending were not as high as in Unit 3. The Unit 2 U-bolts were not stretched and bent as severely as the Unit 3 U-bolts. The difference is attributed to slotting the holes at the Unit 2 and supports during U-bolt repair in~1984. . Calculation of Stresses During Installation and In Service The calculations in this section rule out the possibility of stretching - the U-bolts during installation. Stretching due to the thermal stresses while the U-bolts were in service.- , C-3 t P
. - - - . . . - - . . - . _ . . . - - _ - . . . - -.- _ . _ - - . - _ . . - -w __ _______
I l I Tthe bolting' material (per SCE Drawing 234-607) was made of carbon steel ; bars, SA306 GR.60, with a yield strength of 30,000 psi and tensile strength of 60,000 to 72,000 psi. According to the CE Site , representative, the U-bolts were preloaded to 100 ft/lb of torque. l l l The calculated tensile stress exerted on the bolting material, as a result of the proloading, using the empirical formula Tao.2 FD*. It l was found to be 18,108 psi, which is below the yielding' point of the bolt material. Therefore, the resultant stretching in the bolts was a remmit of in-service condition. The stretchking, bending, and side wear - of the examined U-bolts, are indimtive of relative feedring movements with respect to its initial maamting position within the U-bolts. The movements are a result of thernm1 espansion and contraction associated with cold auxiliary femenstar feedring. l
- T is Tergne (1b/in)
F la Ferce tensica (1b) D is B4m==ter of bolt (in).
Reference:
c-1 leechanical Engineering Design, by J.E. Shigley c-4
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9 DIMENSIONAL INSPECTION l
! LABORATORIES >
' REFORT: S001 >
CUSTOMER: SOUTHERN CALIFORNIA EDISON DATE: 7-30-9c ' PART NO.: 50LTS 1-QF t- *
' FAGE l Table C.1 _
.......*.*.e. ..*.** a D I A .- .
l l SERIAL . 3.0 3.5' 4.0
- 1. 5 ,, 2.0 2.5 j 4 Ya0 0.5 1.0 '
*****.**...***.***********.***********.*************.**********.e.e**s >
l . 1 .7512 .7467 . 7505 1.7521
.7499 7509 .7513 7507 .7517 . .7518 -
2 .7485 . . 3 .7505 .7496 . 7512
./524 . 7524-4 .7501 .7498 . 7486 .7509 . 7515 E
5 .7512 .7504 . 7497 .7516 . 7517 .7522 l l 6 .7474 .7472 . 7524 .7539 . 7525 t 7 .7534 .7524 . 7560 .7561 . 7573 .7572. ,
-e S .7460 .7180 . 7501 .7509 . 7532 1 9 .7487 . 7"A t . 7510 to .75$0 .7503 . 7517 .7520 . 7518 .7513-
.11 .7533 .7145- . 7522 .7493 . 7544 .7577-'.7558 -
.7555 ,7526 12 .7509 .7511 . 7531 '7535
. . 7540 .7539 . 7536. ,
13 .7531 .7538 . 7527 .7514 . .7537 .7542 . 7542. .7540 s t 1 C :
- - - v - -re , e , -e v- a w -- ww -- n-,--- ~ - ~ . w w
g ,
- j. I i
,m i * ,
FSORT : 2001 ' DIENS!ONAL DATE: 7-30-90 INSPECT!ON ~ FAGE: 2 OF 2 LABORnTORIES (BOLT 5) l Tible C.2 l DEVIATION 1S THE AMOUNT OUT OF TOLERANCE l ...........****.......****..*****.....*.*********....+............ SERIAL DAMAGED # OF F1TCH X*XX' THREADS TEETH MEASURE- TOTAL. BLEND W/OX1DE BETWEEN MENT DEV!ATIOts MEASREMNT .i
. . . . . ... . . * * ** * * * * * *
- e e e e e e e e e e *
- e * * * * * * * * * * * * * *
- u e * * * * * * * *
- 0*10' FLATTENED 5 .5053 .'0053 j 1
.023 ITEP 2 0*30' FLATTENED 8 .8061 .0061
.005 DEEP i
3 1'10' FLATTEED 10 1.0221 .0221
.013 DEEP 4 0*30' FLATTEED 10 1.0079 .0079
.010 DEEP 5 1*30' FLATTEED- 9 .9149 .0149
.009 DEEP 6 0*40' FLATTENED 12 1.2010 .0010 4
.005 DEEP 7 0*40' FLATTEED 10 1.0000 .0000
.000 DEEP.
8 1*40' FLATTEED 13 1.3061 .0061
.0E0 DEEP -
l 9 0*30' NO 9 .9061 .0061 i 10 0'20' FLATTENED- 14 1.4097- .0097 ;
.008 DEEP 11 5*0' FLATTEE D TOO-
.005 DEEP DAMAGED 12 0* 20 '. FLATTENED' 11- 1.1006 .0006-
.005 DEEP i -
L./ ~ 13 180' FLATTENED 17 1'.7039= .0039'
.010 DEEP C-6 g . ;
, . . . . . . . . _ . , - - - . , . - _ . ._ - , . . - . _ . . .a ,, . -.. .-,.!
ll . 'l t i 1 . ll DIMENSIONAL i 'g INSPECTION lg LABORATORIES i I REPORT: 2001-l CUSTOMER: SOUTHERN CALIFORNIA' EDISON 7-30-90 DATE: DESCRIPTION: U/EG.T5 PAGE 1.0F 1 1 T.able C.2 (continued)
******************************DIA. DIA. DIA. DIA. DIA. DIA.
} SERIAL DIA. 6 7 2 3- "
.4 5 3 # 1
- ******************++e*************************************n***********
- t
.7502 .7501 .7497 .7465 .7479 .7456 .7485 14 & 15 :
.753. .7536 .7535 .7506 .7484 .7509 .7533 16 & 17 l
l . I i Table C.3 ' .. t SERIAL DIA. DIA. DI A. - DI A. . WIDTH- WIDTH RADIUS ' 8 9 10 11 #12 #13 #14 t 14 & 15 .7490 .7500 .7499 .7507 13.8231 13.6443 6.3375 *
.7493 .7526 .7527 .7528 13.4988 13.5038 6.4660-16 & 17 l 6
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j DIPENSIONAL i INSPECTION ! LABORATOR!ER l l l CUSTOMER: SOUTHERN CALIFORN!A EDISON REPORT: 2057 !
- DESCRIPTION: U/SQLT CATE: 8-20-90 l
- PAGE 1 0F 4 i 4
; e e e e e e ** e e e e e e e e e e e e e e e e *
- e e e** * * * * * * * * ** ** * * * * * * * * * *
- o * * * * . . . . e e .... .
D!A. D!A. D!A. D!A. D!A. NO. 4 5 6 7 . 8
***eeeeeeee***eseeeeeeeeeeeeeee********eeeeeeeeeeeeee***a*****ee****eeeee a
50 08/185* .7544 .7555 .7540 .7564 .7535 SG 98/1788 .7561 .7548 .7563 .7559 .7539 SS XX 2698 .7509 .7508 .7405 .7508 7493 l SG 88/91* .7497 .7490 .7489 .7407 .74RM SG 88/898 .7540 .7539 .7550 .7530 7539 S3 89/2698 .7531 .7538 .7S10 .7503 .7528 SS 09/G98 .7508 7503 .7493 .7439 7504 SS 89/91' .7519 .7516 .7490 .7487 7492 S3 88/1708 .7585 .7584 .7567 7566 .7575 SS 89/190* .7525 .7515 .7523 155 .7536 , S3 99/1848 .7534 .7545 .7520 .7540 .75C9 SS 89/172' .7538 .7508 .7518 .7517 .7532 S3 88/1908 .7564 .7539 .7533 .7539 .7540 ! SS 39/271* .7593 .7509 .7594 .7580 .7591 SG 89/1708 .7535 .7537 .7551 .7536 .7530
+SEE DETAIL "Aa FOR DIAMETERS #1, 2, 3, 9, 10
- 11
'C-11
o o r s - o e W C2 0 . 1 m a e n - P'83 4
-E l O!PENSIONkL REPORT:' 205'-
l- INSPECTION DATE: 8-to-9C' LABORATORIES PAGE 2 0F 3 l [ eeeeeeeeeeeeeeeeee**********************************eeme**ee************* STRAIGHT E.O.P. SECT!0N , WIDTH WIDTH RADIUS . NO. it 13 14 REMARKS
.........******eme ****eee********************************** ************ !
SG 88/188* 13.6478 13.5735 J6.3733-SG 88/172' 13.4988- 13.6469-6.3603 SG XX E69' 13.7385 13.6024. 6.4811 BG 88/91* 13.5551 13.5476 6.4110, SG 88/89' 13.5968 13.6420 -6.4001 SG R9/R698 13.4946 13.5639 .6.4001 i SG 89/89* 13.6011 13.6888 6.3858 SG 89/91* 13.6280 13.6 ate 6.4214 , i 50 89/170' 13.5443 13.4593~ _'6.3810 SG 88/190* - 13.6368- 13.5060 6.4048 SG 89/188' 13.5978 13 5338- 6.4R00 ; S3 89/1788 -13.5416 .33.5594 6.3718-
'i b6 88/190' 13.5897 .33.6801 6.4053 WARPED .928-SG 89/271*- 13.5E73 13.6020 6.4378 l SG 89/1708 13.7584 33.6076 6.'4071'
( C-12 c i L; h .' E
, , , .- . .c j ..
~ ~ " ^ ~
' ' ' ' ~ ~
. 6 6 FJ WWN CC TE N OT ' ~ - ~ ~ ~ ' ~ ~ " ~
l D! MENS!ONAL INSPECT!ON LA80RATORIES I CUSTOMER: SOUTHERN CAL 1FORN!A ED! SON. REPORT:> 2057 -l l= DESCRIPT!ON: U/SQLT' DATE: 8-20-90 l
- PAGE 3 OF 8: !
l , DETAIL "A" ' - LEFT l' '. t DIA. . NO . - Y=0 0.5 1. 0 , 1.5' t.0- 2.5 3.0' SG 88/188* .7535 .7541 . 7553 .7548 . .7538 .7538 7537 SG 88/172* .7548 .7540 .7555 .7560 .7556 .7555 .75561 SG xx 2698 .7330 .7010 . 7518- .7530 .7538 .7526' .7508
.7525 SG 88/91* .7478 .7485 . 7488- .7474 - .7485- CUT .7483 SG 88/898 .7518- .7528 . 7551- -.7575 .7590 .7588 .7576- '
SG 89/2698 . 7501 .7505 . 7514 . 7515 .7514 .7539- .7524 , SG 89/898 .7499 .7503 . 7506 .7580' .7509 .7526 .7530 i l l- SG 89/91* . 7516 .7508 . 7514; .7513- - .7516 .7521- .7534 . l t
- SG 88/170* . 7581' .7584 . 7587 .7583 -.7597 .7560 .7591 SG 89/190* . 7543 .7546 . 7551 .7531 .7530 .7519 .7545 SG 89/1988 . 7559 . 7561 . . 7584 .7574 .7568 .7574 .7560 i
SG 89/17E* . 7537 .7533 . 7534 .7587- .7528 .7526 .7525 ! SG 88/190* . 7541- .7544 . 7555- .7562 .7559 .7569 .7565 SG.89/271* . 7507 .7510- . 7508 .7491 CUT. .7517 .7511 > SG 89/170* . 7557 .7531 . 7587 .7540 .7548- .7553. .7548 l C-13 t ' - ' . t r- , w ~ r ,----we we ,+ w , . , . -a m v - - e ,
___y- _ , , . , ,,_ ._ _ s ,< . J DIMENSIONAL ~ REPORT: 2C$7 INSPECT 16N 1 DATE: 8-20-90' LABOMATORIES PAGE 4 0F S i DETAIL "A" LEFT t e e ee e **
- ee eeee e ee e e e ee e e e ee e e e ee ee e e ee e * ** e ** * * * * * * * * * * * * * * * * * ** e e e e e e e ,
DAMAGED THREADS '
~
X*IX' (WITH OX!DE) NO. 3.5 4.0 SEND ?- REMARKS
* * * * * * * * * *
- ee e e e e e e s e e t e e e e e e e e e e e e e e * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
- e * * -
_SG 88/1888 .7545 .7580 0837' FLATTENED .012 - DEEP- 9 SG 88/1728 .7540' .7564 080" NOTCHED UP TO'
.000 l 98 IX 849' CUT .7539 UP TO HEAVY DAMAGE 'PART lS "$"- ..
- 5*16' .025 DEEP. SHAPED. POSSIBLE CRACK IN SHAFT :!
S8 88/91* .7489 .7409 1825' FLATTENED .010 DEEP
$8 88/89* .7580 .7585. 084' NO l-SS 89/869* .7531 .7541' 0*B' NO '
SS 89/89* .7511 .7506 0813' NO SS'89/91* CUT --- C'15' FLATTENED,.0094 END HAMMERED DEEP SS 88/170* .7595 .7587 0'59' ' HEAVY DAMAGE
.05$ DEEP l SS 99/190* .7545 .7550 089' NOTCHEDJ.081, CUT! SEGMENT NO OXIDE NOT MEASURED-
- SS 89/188*- .7551 .7558 0848' NO END HAMMERED:
88 89/17E* .7525 .7524- 084' NOTCHED .005' j DEEP. 1 53 88/190* .7595 .7599 NOT.- FLATTENED'& BROKEN INSP. NOTCHED . 010-DEEP ll SG 89/8'71 * - .7514 . 7495 0*R' NOTCHED'.004-DEEP' SS 89/270*.7549 .7555 NOT NO HAMMERED ON INSP. THD'S C-14 a
---gg3 4- 36 3y o. . -
t O. i-l DIMENS!ONAL INSPECT!8N LABORATORIES-L ! CUSTOMER SOUTHERN CAL!FORN!A' EDISON REPORT: 2057 .-, , DESCRIPTION: U/SQLT DATE: 9-20-90 ' L PAGE'5'OF S , DETAIL'"A" THREAD P!TCH MEASUREMENTS.- LEFT t 1
***************e********************************* a********************* j NO. OF ~
TEETH .- SEYWEEN -- 10TAL NO. MEASURMENT- MEASUREMENT DEVIAT10N
*************ee**********************************************************
SS 88/188* 17 1'.7046- .0044' SS OS/172* 17 1.7085 .0025 SS XX E698 10 1.3117 .0117 SS 98/91* 13 1.'8089 .0099
$$ 39/898 E0 R.0004 .0004 SS 99/E698 17 1.7043- .0043 SS 39/89* 18 1.3034 .0034' SS 39/91* 19 1.3993 .0007-
- SS 80/170* 10 1.3089 .0029 4 SS 99/190* 9 .9053 .0053 r SG 89/1888 44 4.3903- .0092 SS 89/17E*- 16
~
1.6089 -.0029 SS 80/190* 16 1.6108 .0102 .s SS E9/271* 10 .9993 .0002 SS 09/170* NOT INSPECTED NOT INSPECTED NOT INSPECTED , I C-15 6 . i I,
. - . . - - . . , - - . . .,,--,n v., .-,L4
[ ocv-
~ ~~ ~
o-oo c E n o a o o' ~ [~ ~ ~ ~ ~ ~ ' WM L l i c D! MENS 10NAL INSPECT!ON LA90RATOR!ES 1 CVSTOMER: SOUTE RN CAL!FORN!A ED! SON . REPORY:l. i?O57 . DESCRIPTION: U/ DOLT , DATES.8-20-90 PAGE 4 0F e j
~
DETA!L,"A" - RIGHT 1
*eaeeeeeeeeeee**eeeeeeeee**eee***************************ee..............
O!A. NO. Y.0 0.5- 1.0 1'.5 3.0' a.5J 3.0
* *
- e * * * * * * *
- e e e e e e e e e ee e e e e * * * * * * * * * * * * * * * * * *
- e n e e * * * * * * * * * * * * * * * . . . . . . . . . 4 SG 88/1888 .7531 .%1 .7548 . 7547 CUT- .7550 .7547 SG 88/17E* .7549 .7554 .7555- .7555 . 7567 .7553 .7564 SG XX 8698 .7496 .75E1 .7543 . 7530 . 7548 .7545 CUT SG 88/93* .7464 .74&9 .7479' 7488 . 7471 CUT' .7499 SG 88 / 99 * ' .75BE .7536 . 7576 . 7573 .7579 . 7584 .7570 ;
SG 89/269* .7511- .7517 .7514 . 7584 . 75R0' .7580 '.7514 l- SG 99/998- .7476- .7431 .7501 . 7519, .7528 .7516- .7581-1 SG 89/9t* .7476 .7480 .7465- . 7485 . 7498 . 74 9'/ CUT SG 33/170* .7489 .7468 .7509 . 7506 CUT- .7566 .7572 SG 39/190* .7534 .7519- .7589 . 7535- . 7547- .7547 .7545:
. SS 99/198* .7533 .7533 .7544 . 7514 .7584 .7513- .7512 1
SG 89/17E* .7519 .7535 .7525 . 7541- . 7533- .7540' .7546 SS-88/190* .7556 .7581 .7556 . 7586 .7500 .7574. .7582 SG 89/271* .752E .7538 .7587 . 7559 . 7556- : CUT .7497 SG 99/170* . 7555 .7529 :.7525 . 7547- .7546 .7534 .7531 i C-16 b ja
< --,-.~,m- - -s-,. --o e-,e a , , w- w, - w e r - we r e e - s - w-, -
---e-., e se p r E y-ts,v,w.
'~ ~ ' ~ ' - - ~ ~ " ~
.ecT- . *--~ --- -.* w * == %
^~ ~ ' ^ ~ ~ ~~ ~ ~~~ - - ]
l i l l l DIMENSIONAL REPORT -301!7 ~! l INSPECTION DATEt 4-20-80
- LA80RATORIES PAGE 7;OF S DETAIL "A" - RIGHT_
...ee...****..***.*****.ee...********.t**.a*****..* ..................... '
DAMAGED THREADS- ; X'XX' (WITH OX2 DEL 1 NO. 3.5 4.0 BEND- ~t REMARKS .
...................*....****..*..............****** ..................... )
SS 88/188' .7550 .7553 1'40 ' - FLATTENED .018 - l- DEEP S3 88/1788 .7554' .75583 0'th' .NO - SG XX'269' .7589: .7549 C'27 ' ' FLATTENED .025- r DEEP l
.SG 88/91' .7495 .7496' 0 ' 8 3 '- NOTCHED .005 DEEP SG 89/898 .7584 .7564 0'6' NQ 1
SG 89/R698- .75E4- .7522- C'9' FLATTENED .005 C DEEP SG 89/898 .7503 .7507 0845'- - FLATTENED ~.005 DEEP 7 SG 89/9i* .7513 .7511 0'9' FLATTENED,.005- .END; HAMMERED j DEEP: SG 88/170' .7569 .7559 0'2' NOTCHED- 015'
' DEEP i
SG 89/190' .7543 .7549 . C ' 3 ', - FLATTENED .018. CUT SEGMENT NO-QX!DE NOT ME ASURED - , SG 99/188' .7504- .7506 0'14' FLATTENED 009- END HAMMERED DEEP
-.SG h5/172* .7534 .7542" NOT. :NO l INSP.
SG 88/190* .7570 .7575 4'10' . NOTCHED'.0131
. DEEP.
4 SS 09/271' i.7518 .7498' C'E' ' NOTCHED .008'
' DEEP-SS 89/170* .7536 .7532 NOT NO HAMMERED ON INSP. THD'S
.i
'C-17. i
, ' g g .g. . g 08'.WCD 10887' '
. ' +)i.
DItWNSIOrdRL INSPECT!Gd i LABORATINtIES CUSTOMER: SOUT14150 CALIFORNI A EDISON REPORT: 2057 DESCRIPTION: U /SS.T DATES,8-40-90 i PAGE's M e DETAIL "A" TWIWAD, PITCH MEASUREMENTS - R!GMT
**eveeeee**e o * ******ee* * *** * * * * * * * * * * * * * * * * * * * * * * * * * * * *
- e s e * * * * * * . . .
ND. DF - TEETH M %EEN TQTAL= NO. PEMEL8DIENT -MEASUREMENT. DEV1AT!ON e e e e e e.* * *eeeeeeeeeeeeeeeeeeeeee e * * * * * * * * * * * * * * * * * * * * * * * *
- e e e e * * *
- e e e * *
- c c SS 38/1888 19' l.9090 .0090 SS 88/172* R&> :-5999 ' . cool SS EX 869* 13 1.2074' .0074 SG 99/91* 17 l 3.7038 :.0038:
SS 98/098 ~ n7 ' '1.7089 .00&B .; SS 89/P69* ' tB 1.8022. .0022 i SG'09/898
~
RE 1.8001' . 0oo - SS 99/91* 18 1.7991- . .0009 SS 89/170* 24+ .t.4044
. 0044.
SS 89/190* SE 2.4999 .0001. SS 89/188*. En- 5.0977 ..oo33 ;
'SG;89/1728 NOT INSPECTE!1 .NOT: INSPECTED NOT INSPECTED'.
i
.SG 88/1906 tt 3 ~.1034 ' .0034 SS 89/271* 9' .9046- .0056' l SS 89/1708 NGT' INSPECTE!!- 'NOT. INSPECTED NOT~!NSPECTED-
' ~
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J i APPENDIX'D 0 FIDW MODEL'0F THE DISTRIBUTION BOX ASSEMBLY , a
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-j APPENDIX D1
- 3-D FI4W MODEL' 0F DISTRIBUTION .
BOX ASSEMBLY j
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' Purpose. j I
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The objectives of this appendix.: were-- to determine the, flow- g a j
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distributions, patterns, . rates, and'~ pressures 1.within ; the: steam'. i generatur distribution box, vent, andLfwedringC The 4Mwas of computer modeling the. flow'in;the steam generator E distriwi== box. were to develop a better understandingg of the
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flow, and to ' calculate the general' . flow rates in the vent', fendring, and distribution box. The'3-D finite elementiflow model' was maan by Spectron Research Labs:in CostaTMesa,l California, :using the "F2 strum
- program. The calculations and assumptions-considered i
in the cada calculations are listed .in the Spectron report attached at the and of 'this appendix. - A calculation of the pressure within the fasering -was included' in this. section ' because it dealt wib) - fice. p Results .J l 1; The M;4 tram' 7 esults explain the observed" material . loss. ] l lL 1..> . .
- Under messa) operatirg conditions, i the ' flow. velocityLin the; vent.'s.
-elbau rrEus, .cen be as high' as: 70 ft/sec aslshown in Figure D;8.- -
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6 1 This was foundL to exist at two locations. Actual : localized -1 l material ~1oss was observed at these. locations, as shown in Figure A-30. l 1 The average velocity of water exiting the vent was-calculated-to be- ; in excess of 50 ft/sec. This explains ~the extensive material loss-observed on the_ vent (see Fig D.6). . b The velocity profile in ,the feedring at' the pup / box interface is
~
_It showsia nominal velocity -is F 45.
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illustrated in Figure D.9. ; ft/sec in the 6-9-12 o' clock half section;of. pipe and is 25 ft/sec in the other half (6-3-12). This: flow distribution is primarily a function design of the box assembly. l I At approximately the 11' o' clock position,' a localized:high velocity, j i g zone was cheerved where ' the flow. rate may reach as :high1as 70 - ft/sec (Figure D.9). At this particular. ' location in Unit '3, - localized, erenica was also observed and' produced a' through-wall penetrations ~ (Figures A.7(a) and A.11) . By inta- ? -- M a point crack in the - ~ 2-D_ model,- the -vortex _ (recirculatien zone) size was found'to increase from~1.5D (pipe diameters} to 2D (Figure D.11). 'In. addition, a locali' zed velocity-increase was- observed .at the crack location (Figure D.15)'.
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1 1 1 The stre&m - flow ' lines, illustrated. by the l model, L.sr.ggest that I. design changes of the distribution - system-1 ; may reduce the-L '
' recirculation zones arut prwide a more uniform floe without local' i
areas'of high velocity. t
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l 1 f l ! :l l D-3 1 l l
q l 9 San onofre Feedwater Inlet l -3
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Flow Field calculations Abstract: 'l The flow field in a vented tee fitting has been quantified'using a finite ! i element technique. Two-dimensional and three-dimensional representations ! vere both evaluated. A crack at the distribution. box outlet was . included in the two-dimensional nodel to quantify the effects of the crack on .the flow field. Pressure field and streamlines.: vere also calculated'. This
' flow field data suggests possible improvements in the distribution box:to reduce stagnated areas; and thus,' wear on.the fitting.
i Approach: A finite element method -was chosen to provide ' . detailed flow field !- information in complicated, three-dimensional geometry of the vented. tee. Tne finite element code used is P/Flotran1which. is part of . tho' Patran suite of software. It uses a streamline upwind. method to iterate to a solution. Typically, fifty to one .hundred ' iterations are required to reach convergence. Patran is a product of PDh. Engineering, Inc.~of Costa Mesa. It'. includes provisions for building the basic geometry of the modeliin a graphic interactive ' fashion. ' Patran will then pave the geometry with finite s L elements with ' minimum guidance from the operator. . .The most advanced i-features of'Patran-are utilized to check the model forTvoids. If even the smallest void exists in the model, . the results.- will .be E totally - l p-4 Am .-
l l When voids ~are detected they must be. manually repaired. As i invalid.
~
this model- has 12,000' elements, this repair. becomes tantamount to surgery.- Most numerical solutions require boundary conditions.and P/Flotran is'no different. The boundary conditions for this model consist of one inlet and two outlets-(three outlets when the crack is considered) in the shape l- of a tee. The tee. inlet boundary is a flat, turbulent velocity profile . l of specified magnitude. The vent; outlet boundary ~ is to ' the - steam generator pressure. Tine steam generator pres'sure is~taken as-0 psi and all pressures are given relative to'this. The' tee outlet boundary is to a pressure field 10 psi. hiWr .than the = steam generator. This 10 psi l level is due to pressure losses in thei manifold.' downstream of - the tee fitting. A special haamdary is the symmetry plane down the , axis of th.e tee body. This symmetry plane allows the model ~ size (and .thus, processing time) to be cut in half -by' modeling .? half the tea and specifying symmetry along.the edge. Finite Element Model: , There are two finite element models of = the feedwater. inlet: a two-dimensional model. in which the 4.35" z-axis offset ' of the vent- is ignored, and a three-dinammismal model which - simulates the full. flow field ~. The two-dimensional.model has several advantages. It.has one-sixth the number of finite' elements as the three-dimensional model;.so
, computational and post-pi-- ---- ing time is greatly reduced. The results of the two-dimensional model confirm the validity of the two-dimensional D-5 +
. . . . . . . . . . - . . . . . . , - - - - - . - - ~ . ..L-.m.:.....-, ,
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i l . assumption and this model was used to simulate a crack at'the outlet. l The mesh on t'he two-4imensional model' was adapted to provide the greatest , resolution in the recirculation zone-in the body.and at the simulated _ ; Crack. The three-dimensional model is a very detailed accounting of flow in the tee body and outlet, as well as the flow in the vent. The vent: elbow is t modeled, but the vent toe is not. The effect of the vent tee on flow in L the body does not justify the resources necessary to model it. If the flow at the vent tee is required, the model could be modified to include the vent-tee. The finite element mesh was . adapted with two goals in j mind: reduce the total number of . elements, and' concentrate elements in areas of interest (i.e., stagnation point, high gradients, etc.). There c are 12,000 elements in the model with the highest element densities.at , the vent and body-inlet intersection. Results: , Tttree quantities are reported in this analysis: velocity, pressure, and streamlines. Note that streamlines are only available on two-dimensional models with the current version of P/Flotran. This is not as limiting as it might seem, because the streamlines are readily; inferred on.three-dimensional models from the _ velocity vector plots. Vectors on - these , plots are both scaled and color-coded to their magnitudes. l The majority of.the flow in the body travels at'360-420 in/sec. The flow ! accelerates to 650 in/sec as it rounds the corner from the body to the l D-6 _._ _ ~ _ _ . - - . . _ . , . . . . - . _ . ._._. -- _ . . , . . - . . - . - ,
f outlet. This area also generates a recirculation region which persists for 20" down the outlet. The flow in the non-recirculating region correspondincjly accelerates to 420-480 in/sec. The flow stagnates as it moves toward the end of the body where velocities reach 60 in/see or less. The flow accelerates radically aseit enters the vent. Velocity here reaches 900 in/sec. The pressure field values range from 16.7 psi above the steam generator pressure to 12.1 psi below it. The highest pressures. occur at the end of the body where the flow " dead ends" into the wall which holds the vent. This pressure quickly falls to -12.1 psi in the vent elbow. Mis extreme gradient causes the high vent velocities; described above. Me pressure at the outlet entrance falls to O (generator pressure) where the fluid rounds the corner. Comparison of the two dimensional streamline plots reveals the effects of a crack on the flow field. The crack is located where the outlet meets the body and on the side of the outlet nearest the vent.- The crack slows a portion of the outlet flow by 40-60 in/sec. The most pronounced effect of the crack is tc double the length of the recirculation zone in the outlet. This causes the average velocity in the outlet to increase.from 450 to 520 in/sec. D-7 i I
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Conclusions:
Velocity and pressure fields were calculated for the vented tee feedwater inlet. These velocity fields were well-behaved ' except for stagnated areas at the end of the body and high ' velocities (900 in/sec) in the- - vent. A two-dimensional model showed that n 0.050" crack at~ the outlet = l body interface caused the outlet recirculation ' region .- to double in 1 l length. Also, the average outlet velocity increased by 70 in/sec due to the reduced flow' area available. These calculations suggest two possible , improvements to the feedwater inlet fitting.- The first and most marked. 1 .. _ _
^ is to move the body and-plate back to the outlet wall. This. !
would. remove the stagnated cocket . at the end- of the body. A further 1 i ,---- .
-t would shape the end-plate to slit the flow to ' direct. it towards the outlets. The second improvement would move the.vant to the top'of the bodw i h of the end plate. This would remove.the vent frcen the direct line af flav and reduce vent velocities'significantly, l
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