ML20070E196
| ML20070E196 | |
| Person / Time | |
|---|---|
| Site: | Peach Bottom  |
| Issue date: | 08/31/1982 |
| From: | Bertossa D, Fitzsimmons M, Zschaler W GENERAL ELECTRIC CO. |
| To: | |
| Shared Package | |
| ML20067D329 | List: |
| References | |
| EPRI-NP-2527-LD, GL-81-04, GL-81-4, NUDOCS 8212170101 | |
| Download: ML20070E196 (197) | |
Text
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Induction Heating Stress Improvement, implementation
, gl Planning, and Field Procedure ""*#e"$'SS Development l'o"o"!s"M Keywords:
Induction Heating Stress Corrosion Stainless Steel BWR Piping Field Procedures Welds Prepared by General Electric Company San Jose, California i
1 ELECTRIC POWER RESEARCH INSTITUTE l
Induction Heating Stress improvement, Implementation Planning, and Field Procedure Development NP-2527 LD Research Project T113-1 Fir'al Report, August 1982 Prepared by GENERAL ELECTRIC COMPANY Nuclear Engineering Division 175 Curtner Avenue San Jose, California 95125 Principal Investigators D. C. Bertossa M. D. Fitzsimmons W. A. Zschaler Prepared for BWR Owners Group and Electric Power Research institute 3412 Hillview Avenue Palo Alto, California 94304 EPRI Project Manager A. J. Giannuzzi Nuclear Power Division
i EPRI PERSPECTIVE PROJECT DESCRIPTION i This report describes the results of a laboratory test program performed under BWR Owners Group Project RPT113-1 and designed to demonstrate the feasibility of applying the induction heating stress improvement (IHSI) process to actual BWR recirculation piping. The IHSI process was success-fully applied to BWR recirculation systems in Japan as part of an earlier study conducted by Ishikawajima Harima Heavy Industries Co., Ltd., and others and has been documented and reported in EPRI Research Report NP-81-4-LD. The results presented in this report describe the efforts performed in this project to evaluate and qualify the IHSI process as an intergranular stress corrosion cracking (ICSCC) countermeasure and to qualify a domestic supplier, General Electric Company, to implement the
- process.
PROJECT OBJECTIVES The objectives of this task of the ongoing IHSI laboratory research project were (1) to determine and verify the applicability of the IHSI process on an actual BWR recirculation system mock-up, (2) to qualify a domestic vendor, and (3) to produce generic procedures for the process application.
The demonstration of IGSCC resistance improvement as a result of applying this process is continuing in other tasks under RPT113-1.
PROJECT RESULTS The results of this task study demonstrated that the IHSI process can indeed be performed on nearly all welded joints in the recirculation piping system of a BWR. The only joints that present potential obstacles to suc-cessful application of the process are the discharge to manifold cross and the discharge to residual heat removal tee. The complexity of the config-urations of these joints suggests tnat sophisticated IHSI coil designs will be required to successfully hest-treat these joints. One significant 111 1
refinement to the process specification resulting from this task was the minimum water velocity requirement for 5-G joints. The original specifica-tion required a minimum water flow of 0.5 m/sec (1.6 feet /sec) through the inside of the pipe during IHSI application, whereas the laboratory tests performed in this program indicate that a flow of 1.2 m/sec (4 feet /sec) is necessary to produce the required temperature gradient at the top of the pipe. General Electric has incorporated this change in current specifica-tions.
The companion IGSCC demonstration tasks in RPT113-1 have indicated that IHSI can be a very effective countermeasure to ICSCC in BWR stainless steel piping systems. The results described in this task report demonstrate that the process is feasible and can be applied ef fectively to BWR recirculation-system piping. The results of this study will be of interest to utilities seeking to apply this process to their BWRs and to all engineers consider-ing the use of residual-stress countermeasures to reduce stress corrosion cracking in piping systems.
i Anthony J. Giannuzzi, Project Manager Nuclear Power Division t
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ABSTRACT Typical boiling water reactor recirculation piping welds and laboratory test i specimen welds were induction heat treated to improve the residual stress 4 distribution for the purpose of inhibiting intergranular stress corrosion
! cracking. The tests employed equipment selected for field application to treat 4,12,16, 22, 26 and 30 inch pipe welds in straight pipe and various pipe fittings in horizontal and vertical orientations. The results include recommendations for equipment specifications, heat treatment procedure and quality control, and personnel training and qualification.
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i ACKNOWLEDGMENTS This test was perfomed and completed by R. Menze and G. Nuckols of GE Installation and Service Engineering with the support of J. k"natley of Test Facilities Operation.
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CONTENTS Section Page 1 INTRODUCTION 1-1 1.1 General 1-1 1.2 IHSI Program Objective 1-1 2 TASK 4 PROGRAM 2-1 2.1 Site Survey 2-1 2.2 Specification and Procurement of Equipment 2-1 2.3 Piping Mockup Fabrication 2-1 2.4 Coil Specification 2-1 2.5 Test Facility Design and Erection 2-1 2.6 Equipment Installation 2-2 2.7 operator Training 2-2 2.8 IHSI Treatment 2-2 3 TEST DESCRIPTION 3-1 3.1 Test Facil*cy 3-1 3.2 Induction Heating Equipment 3-4 3.3 Induction Coils 3-11 3.4 IHSI Data Acquisition System (DAS) 3-11 3.5 Test Specimens 3-19 3.6 Test Plan and Procedure 3-23 4 TEST RESULTS 4-1 1 4.1 Piping Surveys 4-1 4.2 Equipment Installation 4-7 4.3 Coil and Cable Installation 4-11 4.4 Temperature Monitoring and Control 4-13 4.5 IHSI Treatment Procedure 4-15 l
4.6 Acceptance and Calibration Tests 4-19 4.7 Coil Installation 4-27 4.8 Pipe Cooling Requirements 4-34 i
4.9 Temperature and Time Limits 4-40 l 4.10 Program Specimen and Transition Joint Welds 4-43 ix
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1 CONTENTS (Continued)
Section Paga 5 CONCLUSIONS AND ACCOMPLIS!!MENTS 5-1 6 NOMENCLATURE 6-1 7 REFERENCES 7-1 APPENDIX A INDUCTION llEATING EQUIPMENT PURCHASE SPECIFICATION A-1 APPENDIX B SPECIFICATI0i! mR INDUCTION HEATING COILS B-1 APPENDIX C IHSI DATA ACQUISITION SYSTEM C-1 APPENDIX D TEST PLAN AND PROCEDURE D-1 APPENDIX E TRAINING AND CERTIFICATION PROGRAM OUTLINE E-1 APPENDIX F IllSI GENERIC PROCESS PROCEDURE F-1 f
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l i i i ILLUSTRATIONS
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Figure , . - Pg
$ . O 3-1 ' Test Facility ArrangeAent -- 3-2 3-2 ' Schematic Diagram of Test racility 3-3 s.
3-3 Cooling Water Pump, Tank,l a.3d Piping 3-5 s y 3-4 Cable Tray Centaining Air-Cooled Cables and,' Equipment.-g Cooling Water komes j 3-5 2, ', \.
3-5 Test Area With Mockup ani Simulated Biological Shield 3-6 t l <
3-6 Horizontal'T st S'and t With 26-inch Pipe, Coil and Cable 3-6 3-7 3-7 Induction Heating Unit Configuration 3-8 Power Supply [and Step Up Transformer \ 3-8 3-9 Control Console .., N ' 3-9 3-10 Step Down Transformer, Cable Guards Removed 3-10 o
V 3-11 Work Station s 3-10
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3-12 Closed Cooling Water Supply j i 3-12 3-13 Cable and Hose Reals,'Short Cabic i ,
4 3-12 3-14 26-inch AKO Induction Coil and Shipping Container 3-13 3-15 4-inch AKO Coil an$ Shipping container 3-14 3-16 30-1nch Straight JHI Induction Coil 3-15 1 .
3-17 12-inch Sweer,olet Tec Induction Coil 3-15 3-18 22-inchV$1veEnd,12-inchSweepoletTee,and 12-inch Elbow IHI Induction Coils Mounted on Recirculation Piping Mockup 3-16 3-19, , Data Acquisition System' Block Diagram 3-17 3-20 '( mputer and Plotter 3-18 3-2L Strain Cage Amplifier and Multiplexer 3-18
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3- 2 s Mock Up Test Welda 3-20 4' 3-23 Recirculation Piping Mockup and Shield Wall 3-21 xi
I l ILLUSTRATIONS (Continued) j Figure Page 3-24 Thermocouple Locations - 26 in. Pipe 3-22 4
3-25 Four-inch Calibration Specimen 3-24 3-26 4-inch Vertical Test Stand (on Right, Coil Installed) 3-25 3-27 12-inch Sweepolet Toe Setup 3-26 4-1 BWR/5 Recirculation System Arrangement 4-3
, 4-2 Typical BWR/4 Recirculation System Arrangement 4-4 4-3 BWR/4 Plant Drywell Access 4-5 4-4 Electrical Service Elementary Diagram 4-9
- 4-5 Work Station Transformer (Top) and Capacitor (Bottom)
Connections 4-10 4-6 Acceptance Tests With 26 Inch Pipe and Coil - 50% to 60% Power Achieved Desired Results (Temperature at Coil Centerline)
(6x105 J/Sec (600 kW) Capability at 100% Power) 4-18 4-7 Heat Treatment Chart - 26 inch Pipe 4-20 4-8 Through-Wall Temperature Profiles 26-inch Pipe 4-21 4-9 Axial Temperature Profile - 26 inch Pipe 4-23 a
4-10 Heat Treatment Chart - 4 inch Pipe 4-24
- 4-11 Through-Wall Temperature Profile - 4 inch Pipe 4-25 4-12 Axial Temperature Profile - 4 inch Pipe 4-26 4-13 Heat Treatment Chart E4-03D (First Treatment of Welded Pipe Specimen E4-03D With Weld Crown Not Machined Flush) 4-28 1 4-14 Heat Treatment Chart - E4-03D (Second Treatment of Welded Pipe Specimen E-03D With Weld Crown Machined Flush) 4-29 4-15 Weld W5a Sweepolet Wall Profiles 4-31 4-16 Ueld W5A Sweepolet Profile 4-32 l
4-17 Sweepolet Wall Profile (Weld Crown Removed From Right Side) 4-33 4-18 Heat Treatment Chart W7-2, 0.5 m/sec (1.64 ft/sec) Flow 4-35 xit 1
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ILLUSTRATIONS (Continued)
Figure Page 4-19 Heat Treatment Chart W7-8, No Flow 4-36 4-20 Heat Treatment Chart, C26-03, 0.5 m/sec (1.64 f t/sec) Flow 4-38 4-21 Heat Treatment Chart C26, No Flow 4-39 4-22 Heat Treatment Chart W3A9, 1.2 m/sec (4 f t/sec) Flow 4-41 4-23 Heat Treatment Chart, W3A-11, Low Flow 4-42 4-24 Coil Installation on Weld W1, 22 in. Pipe to Valve Mock-Up 4-48 4-25 Idle Temperature Distribution Chart - Weld Joint W1 4-49 4-26 INSI Process Control Chart - Wl-1 Aborted 4-50 4-27 IHSI Process Control Chart - W1-1 4-51 4-28 Heat Treatment Chart, W1-1 4-52 4-29 Coil Installation W2, 12-inch Pipe to Reducer 4-54 4-30 Heat Treatment and Chart, W2- 4-55 4-31 Coil Installation on W3C,12-inch Elbow 4-56 4-32 IHSI Process Control Chart, W3b-1 4-57 4-33 IHSI Heat Treatment Chart, W3B-1 4-58 4-34 IHSI Process Control Chart, W3C-1 4-59 4-35 Heat Treatment Chart, W3C-1 4-60 4-36 Coil Installation on W5a, 12-inch Pipe to Sweepolet 4-62 4-37 Peak Temperatures During Weld W5b Treate.ent 4-64 4-38 IHSI Process Control Chart, WSB 4-65 4-39 Heat Treatment Chart - W5B 4-66 4-40 Strain Gage Locations on Weld W5b 4-68 4-41 Microstrain Record During IHSI Treatment 4-69 4-42 W1 Coil Installation on W6b 4-71 xiii
ILLUSTRATIONS (Continued)
Figure Page 4-43 IIeat Treatment Chart, 22-inch Pipe to 30-inch Cross 4-72 4-44 !! cat Treatment Chart, W7, 30-inch Tee to 30-inch Cross 4-73 4-45 W1 Coil Installed on W9, 22-inch Pipe to Cap 4-74 l 4-46 Idle Temperature Distribution, W9, Second Trace 4-75 4-47 IllSI Process Control Chart, W9 Aborted 4-77 4-48 IIcat Treatment Chart, W9 4-78 I
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t d
EXECUTIVE
SUMMARY
Induction Heating Stress Improvement (IHSI) treatments have been performed under simulated field application conditions. The results demonstrate the successful use of developed equipment and procedures to treat welds in actual reactor piping components up to 76 cm (30 in.) in diameter. This work was conducted in accordance with Task 4 of EPRI/GE/BWROG Contract RP 1394-1.
The objective of the joint EPRI/GE/BWROG IHSI Program is to establish the neces-sary data base and procedures for domestic application of the IHSI process to BWR piping. The IHSI process improves resistance to intergranular stress corros-ton cracking (IGSCC) by producing compressive residual stresses at weld heat af fected zones in Type 304 stainless steel piping systems. Compressive stresses at the inside wall surface (and subsurface) are produced by induction heating the outer surface of pipe while simultaneously cooling the inner surface with i water. Application of the process is directed principally at those Type 304 i stainless steel piping systems now in BWR plants, either newly installed or
! operating, where other improvement methods are not practical. The technique can be applied without pipe removal.
l The total IHSI Program is divided inte four major tasks.
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- 1. Optimization of the ind- 3 process para-meters of pipe size, powe1; 7re and time to obtain the most desirable .. A stress conditions in stainless steel pipes. The experimental work of l this task has been successfully completed and produced the daca and test specimens required for the remaining tasks.
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- 2. Quantitative measurement of the improvement in resistance to IGSCC produced by IHSI treatment through comparative evaluations of environmental pipe tests, residual stress measurements, mechanical property tests and microstructural investigations of treated and untreated pipe welds. The experimental work of this task is continuing.
- 3. Evaluation of the effects of the IHSI treatment on piping containing preexisting IGSCC and other defects, by both an analytical modeling and environmental pipe test of specimens containing defects. The experimental work of this task is continuing.
- 4. Development of field procedures and planning for the application of IHSI treatment of BWR piping. This task is the subject of this report.
Site surveys of the reactor coolant recirculation system piping were performed to evaluate the restrictions of personnel and equipment access to candidate welds. The site surveys were performed at two domestic plants. The surveyors identified the need for special coil designs to treat welds between piping and fittings or components of differing wall thickness and non-symmetrical contours.
Constraints on equipment size, weight and placement within the plant were identified. From these surveys it was concluded that there are no access restrictions which would prevent successful IHSI treatment of recirculation piping welds.
The recommended equipment configurations, together with the IHSI process parameters derived from the optimization studies were used to specify the induction heating equipment procured for development test at GE-San Jose facilities. The induction heating equipment was, for the most part, com-mercial equipment modified to accommodate long, flexible, interconnecting cables. It consisted of a 6x105 J/sec (600 Kw), 3000 Hz power supply, trans-formers, work station (to tune the induction circuit) and a closed cooling water supply system.
A mockup of reactor recirculation piping was fabricated from surplus recirculation system components. It contained representative pipe weld sizes, fittings and orientations. A steel-faced biological shield wall mockup simulated pipe to wall clearances and nearby netallic structures. '
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Induction heating coils were procured to treat pipe welds to elbows, tees, reducers and simulated valve bodies for 12, 22 and 30 inch pipe. In addition, coils and fixtures for straight pipe specimens of 4 and 26 inch size were procured for the purpose of verifying results of previous testing and preparation of specimens for other program tasks.
The induction heating equipment, piping mockup and supporting test equipment were installed in a test facility which simulated anticipated site working conditions. The power supply and equipment cooling water supply were located approximately 37 m (120 ft) from the piping mockup and shared electric power with another test facility. The piping t ickup, other pipe specimen fixtures, work station, transformer and specimen, cooling water piping, and controls were all contained within a small test area. Temperature monitoring instrumentation was located in yet another room, necessitating telephone communication between the operators during an IHSI treatment.
See Figure 1.
The initial series of tests, using calibration specimens of Task 1, confirmed that the equipment purchased for field use produced the same temperature distributions as were obtained with the equipment used to establish the IHSI process parameters. In particular, it was concluded that single and multiturn induction coils of similar overall dimensions functioned equally well. See Figures 2 and 3.
Tests performed at recommended and reduced cooling water flow rates confirmed the adequacy of 0.5 m/sec (1.65 ft/sec) minimum cooling water flow in vertical and horizontal pipe runs. However, subsequent tests of horizontal piping with trapped air pockets showed that higher water velocities 1.2 m/sec (3.94 ft/sec) were required to provide adequate cooling in this unrepresentative circumstance. The results of these investigations are included in the IHSI Field Application Process Control Parameters summarized in Table 1.
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- 3. POWER SUPPLY
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- 7. TEST PIPING MOCKUP (0) (6 0)
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- 9. TEST PIPE COOLING SYSTEM PUMP 55,900 J/sec (75 hp)
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- 11. PROCESS EQUIPMENT COOLING SYSTEM
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- 13. STARTER 55,900 J/sec (75 hp) PUMP
- 14. EMERGENCY STOP AND LOCKOUT 15 DATA ACOUISITION SYSTEM
- 16. VERTICAL PIPE TEST STAND Figure 1. Test Facility Arrangement 4
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Table 1 IHSI FIELD APPLICATION PROCESS CONTRDL PARAMETERS
- 1. Pipe Outer Surface Temperature 500 ! 75*C (932 135 F)
Within Treatment Zone (Notes 1, 2)
- 2. Minimum Throughwall Temperature 275 C (495 F)
Difference (AT)
- 3. Minimum Width of Zone Heated to 1.5 /Rt AT Minimum (R = Radius and t = thickness)
- 4. Minimum Distance from Weld 15 mm (0.6 inch) or t/2 Center to Boundary of AT Minimum (whichever is larger)
- 5. Minimum Heating Time 0.7 t2/a seconds (Note 3) (a = thermal diffusivity,.
t = wall thickness)
- 6. Frequency 3 to 4 kHz
- 7. Induction Coil Length 3 /Rt Minimum (R = pipe radius, t = wall thickness)
- 8. Minimum Water Velocity 0.5 m/sec (1.64 ft/sec)
(in vertical or horizontal flooded pipe)
- 9. Minimum Water Velocity 1.2 m/sec (4 f t/sec)
(in pipe with air pockets)
NOTES: 1. Minimum surface temperature will normally occur at the minimum pipe wall thickness and/or maximum coil to pipe surface clearance.
- 2. Maximum surface temperature will normally occur at the maximum pipe or fitting wall thickness and/or the minimum coil to pipe surface clearance.
- 3. Derived from Fourier Number = 0.7.
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Thermocouple attachment techniques were developed during the course of IHSI treatment of straight pipe test specimens for other program tasks. The best overall performance was obtained with 24 gage Chromel-Alumel thermocouples spot welded to the pipe. !
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IHS1 Field treatment procedures were developed in the course of IHSI treatment of the recirculation piping mockup welds. Seven different types, sizes and orientation of welds were treated using five induction coils. The welds were between straight pipe and various transition fittings such as elbows, tees, caps and reducers ranging from 12 to 30 inch nominal pipe size. See Figure 4, 5 and 6.
A pretreatment temperature distribution measurement procedure was developed to assist in positioning the coils on weld joints of non-uniform wall thickneas and contour. This measurement is made to a surface temperature of about 200"C (392*F), well below the treatment temperature of 500"C (932*F). Success-ful IHSI treatments were achieved using manual. control procedures in which the operators monitored two temperatures and adjusted the power level to achieve specified temperature within the specified times. A typical treatment record is shown on Figure 7.
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l TASK 4 CONCLUSION Field surveys concluded that site access is available to treat candidate recirculation piping welds. Induction heating equipment was designed,
- procured and operated to successfully treat representative recirculation
- piping weld joints under simulated field conditions. Equipment specifi-cations, process parameters, treatment procedures and personnel qualification requirements required for field application of the IHSI process have been prepared.
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l Section 1 INTRODUCTION i
1.1 GENERAL I This report summarizes the results of tests performed to simulate field con-ditions of usage of Induction Heating Stress Improvement (IHSI) equipment and I procedures. The work was performed under EPRI contract RP1394-1, Task 4:
l Implementation Planning and Field Procedure Development.
1 The major accomplishments of Task 4 are:
- a. The survey of two reactor plant piping installations to evaluate the IHSI equipment requirements,
- b. The procurement of commercially available induction heating equipment and the o.aonstration of its suitability for IHSI usage.
i
- c. The successful IHSI treatment of pipe welds to elbows, reducers,
- tees and other transition fittings as well as in straight pipe.
,' Both horizontal and vertical welds were treated with various
- coil placement, cooling flow rates and power levels. The welds were in size from 4 to 30 Inch stainless steel pipe.
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- d. The development of generic IHSI process procedures, Appendix F, i equipment purchase specifications, Appendices A and B and per-l sonnel qualification requirements, Appendix G.
l 1.2 IHSI PROGRAM OBJECTIVE i
The objective of the joint EPRI/GE IHSI Program is to establish the necessary 1
-data base and procedures for domestic application of the IHSI process to BWR piping. -The method involves improving resistance to intergranular stress cor-rosion cracking (IGSCC) by producing compressive residual stresses at sus-l ceptible weld heat affected zones in Type-304 stainless steel piping systems.
1 Compressive stresses at the inside wall surface (and subsurface) are produced l-1
by induction heating the outer surface of a pipe weldment while simultaneously cooling the inner surface with water. Application of the process is directed principally at those Type-304 stainless steel piping systems now in BWR plants, either newly installed or operating, where other improvement methods are not practical. The technique can be applied without pipe removal.
The IHSI process has previously been qualified and applied to BWR piping in Japan. Experimental work performed for qualification in Japan is published and has been used as a reference to minimize the work performed in this domestic evaluation and qualification program.
The scope of this program was divided into four principal tasks designed to 1
demonstrate and quantitatively measure the degree of IGSCC immunity achieved through experimental, analytical and implementation activities. The subject of this report is Task 4. The task descriptions are as follows:
1.2.1 Task 1, Process Optimization The purpose of this task was to optimize induction heating parameters to pro-duce the most desirable residual stress conditions in pipe weldments. Induc-tion heating tests were conducted on 4- through 26-inch Schedule 80 pipe samples, instrumented with a number of surface and throughwall thermocouples to develop pipe temperature distributions for various induction heating and pipe water cooling conditions.
The experimental work of Task 1 was successfully completed and produced the preliminary optimum IHSI process parameters of Table 1-1 which were developed for pipe sizes ranging from 4 inch Schedule 80 to 26 inch Schedule 80.
1.2.2 Task 2, Quantitative Measurement of 'morovement The objective of this task is to demonstrate the improvement in resistance to ICSCC produced by IHSI treatment. Activities include environmental pipe tests, residual stress measurements, mechanical property tests, and micro-structural investigations.
1-2
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L 1
i i Table 1-1
! PRELIMINARY IHSI PROCESS CONTROL PARAMETERS l
j
- 1. Pipe Outer Surface Temperature 500 1 50*C (932 2 90*F) l 2. tunimum Throughwall Temperature 300*C (540*F)
Difference (AT)
- 3. Minimum Width of Zone Heated-to 1.5 /Rt aT Minimum (R= Radius and t= thickness) 2
- 4. Minimum Distance from Weld Center 15 mm (0.6 inch) or t/2 j to Boundary of AT Minimum (whichever'is larger) i 5. Minimum Heating Time to Minimum 0.7 t 2/ a seconds Temperature (a = thermal dif fusivity, I t = wall thickness)
- 6. Frequency 3 to 4 kHz 4
) 7. Induction Coil Length 3 /Rt Minimum
! (R = pipe radius, t = wall _ thickness)
- 8. Minimum Water Velocity 0.5 m/sec (1.64 ft/sec) i 3
1.2.3 Task 3, Evaluation of IHSI Application to Operating Plant Piping Possible defects in existing piping that are below the detection limits of j conventional in-service inspection (ISI) techniques are studied in this task to evaluate the effect of IHSI on crack growth. This task included throughwall analytical modeling residual stress measurements and environmental pipe testing using pipes with pre-existing IGSCC and other defects.
1.2.4 Task 4, Field Procedure Development and Implementation Planning l
Potential field application problems, details of performing IHSI in limited plant access conditions, and field requirements for equipment were evaluated in this task. Activities include surveys of BWR plants, recirculation system mockup tests and preparation of general field procedures for IHSI application.
l 1-3
i As the program progressed, additional tests were performed to establish an improved statistical base for pipe testing factors of improvement and to provide information more directly related to piping in service. These included tests on large pipe sizes and piping mockups and evaluation of service stress effects.
l l
l l
l l-4
1 l
Section 2 TASK 4 PROGRAM The scope and outline of Task 4 program are as follows.
2.1 SITE SUI;VEY A BWR/4 and 1WR/S reactor plant were surveyed for restrictions of personnel and equipment access to IHSI candidate welds in the recirculation piping.
The survey results were input to the equipment purchase specifications and the design of the recirculation piping mockup.
2.2 SPECIFICATION AND PROCUREMENT OF EQUIPMENT
. IHSI equipment was procured to specification requirements developed by Task 1 of RPl??4-1. The procurement specification is included in Appendix A.
2.3 PIPING MOCKUP FABRICATION Reactor recirculation piping components were procured and fabricated into a mockup chich simulates the configuration of a portion of a field installation, together with a simulated obstruction or impediment.
2.4 COIL SPECIFICATION Coils will be specified and procured to treat the various piping components.
Straight butt weld coils were purchased as part of the IHSI equipment. The field weld treatment coils were purchased using specification parameters developed from measurements and surveys of the piping mockup.
4 2.5 TEST FACILITY DESIGN AND ERECTION A test facility was designed which provides an enclosed test area, electrical supply and service water connections for the IH5I equipment, cooling water circulation through the piping mockup and pipe specimens and a tempercture data acquisition system.
2-1
2.6 EQUIPMENT INSTALLATION The IHSI equipment was installed in accordance with the manufacturer's instructions and evaluated with respect to field application requirements. l l
2.7 OPERATOR TRAINING Test operators operate the IHSI equipment, install thermocouples and coils and perform the IHSI treatment. The experience gained will be used to develop operator training and certification requirements.
2.8 IIISI TREATMENT Instrumentation and coils were installed and welds IHSI treated using the general procedures and parameters provided. These procedures were evaluated and modified as required to achieve successful treatments. Out-of-specification conditions will also be applied to evaluate the limits of operation.
2-2
1 i
l
'T l
Section 3 i
TEST DESCRIPTION i
3.1 TEST FACILITY The test facility was located at the General Electric Curtner Avenue Site in San Jose, California. It shared electrical and other services with the other nearby facilities. The support equipment consisted of test fixtures to hold the test specimens, cooling water tank, water circulating pump, piping electri-cal controls, instrumentation and Data Acquisition System (DAS). The induc-tion heating equipment consists of a static inverter power supply, control console, transformers, work stations, induction coils, closed cooling water supply and interconnecting cables and hoses.
The general arrangement is shown on Figure 3-1. The static inverter and closed cooling water supply are located near available electrical. power sources. The test fixtures and induction heating work stations are located
- about 37 meters (120 feet) from the static inverter power supply, similar to field arrangement. The tank, pump, test fixtures and piping form a closed' 4 loop in which demineralized water is circulated through the test specimens.
The flow rate is measured by an orifice meter and controlled by a manual j throttle valve. The heat input is rejected to the atmosphere from the opea tank surface. The induction heating transformers and work stations are located near the test fixtures. A nearby jib crane is available to assist in placing the induction heating coils and cables on the test specimens. ,
The instrumentation consists primarily of temperature measuring and recording equipment. The cooling loop flowmeters and induction heating equipment adjustments and meter readings are recorded manually since they are essentially invariant during a heat treatment run. A schematic diagram of the facility water piping and electrical circuits and instrumentation is shown on Figure 3-2.
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15 9. TEST PIPE COOLING SYSTEM PUMP. 75 hp FEET
- 10. TEST PIPE COOLING SYSTEM RESERVOIR (m)
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- 13. STARTER,75 hp PUMP
- 14. EMERGENCY STOP AND LOCKOUT 15 DATA ACQUISITION SYSTEM
- 16. VERTICAL PIPE TEST STAND Figure 3-1. Test Facility Arrangement
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t 1 460V 3 PHASE, 60 Hr.1200 amp Figure 3-2. Schematic Diagram of Test Facility e
Views cf various portions of the test facility are shown on Figures 3 through 3-6.
3.2 INDUCTION HEATING EQUIPMENT The induction heating equipment consists of five cabinets and interconnecting 4
hoses'and electrical power and control. cables. The configuration of these components is shown on Figure _3-7. The purchase specification for this I
equipment is included in Appendix A.
} The power supply is a 6x10 5 J/sec (600 ' Kilowatt) static inverter which. converts 480 volt, 3 phase, 60 hertz input power to 800 volts, single phase, 3000-4000 Fertz, induction heating power. This unit, Figure 3-8, also contains the power _
supply controller, safety interlock and. fault and limit annunciators. The controls and some of the annunciators are duplicated in the control console,
, Figure 3-9, which also contains the work piece temperature controller.
4 A step-up transformer attached to the power supply increanes the output
- voltage by a ratio of 4 to 1 to permit a corresponding reluction in current 1
, and cable si'e. The 91.5 m (300 foot) long air cooled cable conducts the elec-trical power to the step-down transformer, Figure 3-10, which reduces the voltage to 800 volts required for input to the work station.
! The work station, Figure 3-11, contains a multiple tap transformer and a bank of capacitors required to tune the induction heating load to the power supply frequency. The transformer can be connected to function as an isola-l tion stepdown transformer or as an auto transformer to provide a wide range of voltages. The capacitors can be connected :hi series and parallel combi-
- nations to provide a wide range of capacitance. All interconnections with1u i
the cabinet are made with water cooled bolted bus vars.
l A 15.2 m (50 foot) long water cooled cable connects the work station to the induction heating ct ils. Two cables were evaluated: a) a 4 conductor 2000 MCM cable supplied with the induction heating unit; and, b) a 4 conductor 216 MCM cable purchased separately.
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The closed cooling water supply, Figure 3-12, recirculates demineralized water through the power supply, step-down transformer, work station, water cooled cables and induction heating coils to remove heat from these components. ,
It contains a 1.49x104 J/sec (20 horsepower) circulating pump, 908 L (240 gallon) reservoir, and a heat exchanger, together with temperature and electrical con-trols. Interconnection between the components is made with hoses fitted with quick disconnect couplings.
Both hoses and cablce are coiled on motor operated reels, Figure 3-13, for storage and transport.
3.3 INDUCTION COILS The coils purchased for this test are supplied by two manufacturers. They differ primarily in mechanical design. The coil purchased with the power supply is an assembly of cast and brazed copper shape, fastened to an insu-lating support structure. The mating contact surfaces of the split halves were fitted with alignment pins and uith silver inserts, and are clamped together by toggle clamps. The coil is centered with screw adjusted inetal blocks which bear on the pipe surface. The construction is massive and strong. These coil are designed for straight pipe only. See Figures 3-6, 3-14 and 3-15.
The coil, purchased to treat a piping mockup weld, is an assembly of copper tubing formed as two halves and brazed to copper contact pads. The tubing turns are fastened to longitudinal insulating supports which contain center-ing screws near the outer ends. The coil halves are aligned and clamped together by stainless steel nuts and washers. The centering screw tips are
! rounded where they bear upon the pipe surface. The construction is light-l weight. These coils are designed for elbows, reducers, sweepolets and straight pipe joints. See Figures 3-16, 3-17 and 3-18.
l 3.4 IHSI DATA ACQUISITION SYSTEM (DAS) l l The DAS is a NEFF 620S system consisting of a NEFF Series 400 multiplexer and llewlett-Packard 9825S desk top computer, Figures 3-20 and 3-21.
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mA Figure 3-21. Strain Gage Amplifier and Multiplexer i
3-18
-Additional accessory components are a Hewlett-Pa'kard c 7225A plotter, Hewlett-Packard 98035A real time clock, NEFF isothermal thermocouple input terminal and necessary interconnecting cables. The inputs to the system are the millivolt electrical output of Type K (chromel-alumel) thermocouples attached to the work piece. The output is c time history of work piece temperature in degrees centigrade.
The equipment is interconnected as shown in the block diagram, Figure 3-19.
The thermocouples are connected to the system by 20 gage twisted and shielded Type K extension wire. Up to thirty thermocouple outputs can be F recorded with the system. The details of operation of the DAS are included
, in Appendix.C.
3.5 TEST SPECIMENS e The reactor recirculation system piping mockup, Figures-3-22 and 3-23, is the primary structure used to develop the IHSI field application procedures. It was fabricated of surplus recirculation system piping components provided by EPRI. It contains *epresentative pipe weld sizes, fittings and orientations.
A steelfaced biological shield wall mockup is used in conjunction with the
! central riser to simulate the-pipe to wall clearances and nearby metallic structures. The recirculation piping mockup also contains thermocouples on the inner wall weld centerline and a flow baffle within the 30 inch pipe to-pernit attainment of minimum cooling flow velocities at the available system j pump capacity. The remaining test specimens fall into two categories; culi-1 i bration specimens and test specimens.
l The calibration specimens consist of 4 inch and 26 inch pipes with extensive thermocouple instrumentation. The 26 inch calibration pipe, Figure 3-24, and the 4 inch calibration pipe are identical to those used in Task 1 to develop the IHSI treatment parameters. The purpose of these calibration I specimens is to confirm that the equipment and coils can develop the same temperature distributions which were observed in Task 1 optimization tests.
The test specimens treated for Tasks 2 and 3 are 4 inch, 12 inch and 16 inch
, straight pipe of various lengths and numbers of welds, a 22 inch simulated .
l 3-19 i
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FOR STRAIN GAGE TESTS N.
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Figure 3-22, Mock Up Test Welds 3-20
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Figure 3-23. Recirculation Piping Mockup and Shield Wall 3-21
i e45 cm (17.8 in.) - >-. e7.9 cm (3.12 in.) )
l
--*- +7.9 cm (3.12 in.) PIPE - 26 in. NPS, SCHEDULE 80 TC 12 + 7.9 cm (3.12 in.) MATERIAL: TYPE 304 3 STAINLESS
-->- +7.9 cm STEEL, (3.12 in.) ASTM A358 TC 13 p TC 10 TC 14 TC 9
___mmmmsmmmm_____
TC4 TC4 TC 1 TC-5 TC-2 TC-6 FLOW DIR ECTION T m,
/
TC 3
---~__ _ _ _ - - - - _.
4 "G" ? TC-11
-4 122 cm (48 in.) >
4.8 mm (0.19 in.) 4 PLACES 16.8 mm (0.66 in.) DEEP 25.2 mm (0.90 in.) DEEP 8.4 mm (0.33 in.) DEEP
- 1.57 mm (0.062 in.) DI A TYP TC-12 , ,
1 /
j 2.34 mm (0.092 in.)
A T C-5
- TC4 TCJ -
Figure 3-24. Thermocouple Locations - 26 in. Pipe 3-22
my,- _ .
valve end and a strain gage instrumented tee. These specimens were treated'
' in the 4 inch vertical test stand, Figure 3-26, or the horizontal test stand.
' Figure 3-6, or connected into the system piping, Figure 3-27.
3.6 TEST PLAN AND PROCEDURE Field procedure development testing starts with the installation of the IHSI induction heating power supply and coils under simulated site conditions.
The inie.ial IHSI treatments are performed on' test specimens previously treated in Task 1 in order to calibrate the equipment and confirm the reproducibility of the process. These calibration tests also serve to train the equipment operators and shake down the equipment prior to treating the recirculation piping welds.
The treatment of the recirculation piping welds is performed in accordance with the procedures developed from the equipment manufacturer's instructions and to process parameters developed by Task 1. Multiple treatments of each
! weld joint type are made to develop and refine the procedures to the joint
- where a single successful treatment can be made. Thereafter, the remaining weld joints will be given single treatments and reserved as archive specimens or used for Tasks 2 or 3.
The acceptable limits of IHSI process parameters are established by treating welds at extremes of cooling flow rates, power 1cvels and induction coil
! placement. The data obtained from these tests is used to modify tha Task 1 l
straight pipe IHSI process parameters and procedures to produce parameters and procedures applicable to field welded pipe and fittings.
l The details of the test plan and procedure are included in Appendix D.
F i
i l
3-23
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j DOWNS EAM TC-1 TC4 - N 4 WATER # h WATER FLOW g n
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i 76.8 mm
+
(3.015 in.) 97.97 mm BAFFLE (3.857 in.)
I
' 2.39 mm (0.094 h.) DEEP p
4.42 mm (0.174 in.) DEEP TC-2 & WATER FLOW II 6.15 mm (0.238 in.) D EEP 1\\\\\\ \\ \ \ \ N) V*
i STAINLESS STEEL) TC-5 TC-6 COIL CENTERLINE TC1 SECTION A-A -
Figure 3-25. Four-inch Calibration Specimen i
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Figure 3-26 4-inch Vertical Test Stand (on Right, Coil Installed) 3-25
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Figure 3-27. 12-inch Sweepolet Tee Setup 3-26
4 a
Section 4 TEST RESULTS 4.1 PIPING SURVEYS Site piping surveys were completed at two domestic plants representative of the BWR/4 and 3WR/5. The findings were applied to purchase documents for the
{ procurement of induction heating equipment. Surplus Type-304 stainless steel recirculation system piping components used for the piping mockup were also surveyed to provide dimensienal information for the procurement of the induction heating coils and the fabrication of the mockup.
4.1.1 BWR-5 Plant Survey The accessibility within the drywell for proposed IllSI equipment was studied at a typical BWR/5 plant on November 2, 1978. In this typical BWR/5, Mark II plant, there are no access situations which would prevent successful applica-l tion of IllSI treatment of recirculation piping field welds. There are some considerations which must be taken into account in the planning and qualifica-tion of the process.
For BWR/S plants with Mark II containments, the best location for the power supply and the closed-loop water cooling unit is immediately outside the equipment hatch airlock at ground level. These two items could be mounted in or on a trailer having highway wheels. From there, ficxible cables and hoses would lead into the drywell to the transformer and heat station. The hose / cable assembly would have to be at least 36m (120 ft) long.
The work station can be placed within 3m (10 f t) of welds to be treated, llowever, this will involve moving the work station from place to place within the drywell to accomplish the treatment of the various welds. All welds in lower portions of the recirculation pump intake and discharge i
4-1 I
i
piping can be reached with the unit standing on the ground level decking.
The welds joining the recirculation risers to the ring headers are below l l
the third level of deck grating and may require special hookups between the work station and the heating coils. A three ton capacity trolley hoist above the third level will facilitate placement of the work station could be used to suspend it at an elevation closer to that of the welds to be treated. There is a radial distance of approximately 3m (10 ft) from the recirculation inlet safe end-to-pipe welds to the centerline of the trolley, which may complicate connections between the transformer and the heating coil. The use of a 15 m (50 ft) cable to connect the work station to the induction coil is recommended in order to minimize the relocation of the work station.
Of the 22 or 23 field welds in each recirculation loop at this BWR/5 Station, 8 involve joints between pipe and heavier wall pump or valve body castings.
The latter may require special coil designs to treat effectively the non-a uniform material masses. Almost all of the remaining welds are at tees, safe ends, orother areas where there are diameter differences near the weld
. locations. These differences may affect coil design or operation. See Figure 4-1 for typical examples of the above situations.
4.1.2 BWR/4 Plant ' Survey '
A tour of the drywell at a typical BWR/4 with Mark I containment, has shown that accessibility is much more restricted than in plants of newer design.
While the quantity and types of equipment located in the space between the biological shield and the inner containment wall are more or less identical with newer plants, the containment itself is considerably smaller and of a shape which limits floor areas working space. See Figures 4-2 and 4-3.
The elevations of the gratings with respect to the field welds to be treated will create problems. Structural arrangements within the containment may vary from plant to plant. For example, in one plant the recirculation system ring header and all of its field welds to the vertical risers, lie some i
a 4-2 i
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- FIELD WELDS Figure 4-2. Typical BWR/4 Plant Recirculation System Arrangement I
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0 180 PERSONNEL AIRLOCK Figure 4-3. BWR/4 Plant Drywell Access 4-5 t
L 0.6 to 1m (2 to 3_ft) below the grating. In this location there are many obstructions in the form of structural steel which support the grating itself and support other_ equipment. This steel is quite massive and of ten is fairly close, within 0.6m (2 ft) or so to the welds requiring IHSI.
Similarly, the field welds to the recirculation pumps, and at the large valves on either side of the pumps, are below the main level grating. This means that all IHSI work on those welds will have to be conducted through openings in the grating. In the BWR/5 Mark II plant previously studied, these welds were at a much more convenient level and were above the corre-sponding grating structure. At a BWR/5 Mark-1 plant, the next lower _ working platform is so constricted in width'and diameter that it will be very diffi-cult to use as a place to set the work station equipment. Two large equipment ,
doors provide entrance into the containment, 3.66m (12 ft) diameter each, located at azimuths 135* and 315*. These will easily pass the work station, 1 but the two large recirculation pumps are also located precisely on these azimuths. This may cause handling problems once the equipment enters the
, containment. Only the door at the 135* is_ conveniently accessible to outer doors in the reactor building. The inner and outer doors in the personnel airlock at azimuth 180* are 1.2m (4 ft) wide by 1.98m (6.5 ft) high, and could serve as an entryway for equipment or power cables.
At one BWR/4 plant, the openings ~in the biological shield are circular and are somewhat more constrictive to work in than are the square or rectangular openings found at many other plants. The coil design for treating the recir-culation nozzle safe end-to-pipe welds will have to consider and accommodate the size and shape of the biological shield openings.
j i
Except for large steel restraint structures located immediately above the
, reducers, the crosses between the 28 inch discharge risers, the ring header arms, and the 28 inch to 12 inch upper reducers'are more open and accessibic than at a BWR/S plant. The residual heat removal system connections below those crosses are also very accessible.
i i
I 4-6 L - __ ._ -._. _ - _ _ _. . ,
( IHSI of recirculation system welds in-a BWR/4-type plant is not impossible, but will require careful attention to the design and fabrication of induction heating coils and require flexible interconnecting cables.
i 4.1.3 Mockup Piping Survey The weld end preparation dimensions of the partially fabricated recirculation
. piping components were measured while they were in storage. The results of these measurements were used to specify the five induction-heating coils 11 used to treat the piping mockup welds and to design the recirculation piping mockup. Because the coils were purchased before the mockup was
- welded and the exact weld contours could be established, the undistorted
, weld joint configurations were used to design the coils. The piping con-figurations are included in Appendix B.
i 4.2 EQUIPMENT INSTALLATION The IHSI induction heating equipment was delivered to the test site in an-air ride moving van, as recommended by the manufacturer to avoid shipping damage to the electrical components. All cabinets and containers arrived in good condition. The equipment was moved by forklift to the test area l and placed in position with a crane.
4 l
4.2.1 Mechanical Installation The installation and assembly of the induction heating equipment was accomplished in accordance with the manufacturer's instructions. See Paragraphs 3.1 and 3.2 for a description of the arrangement.
r The cabinets and containers, with the exception of two items were easily moved into position using norest material handling equipment and rigging-techniques. The two items which presented difficulties were the power supply cabinet and the water cooled cable reel. Both had high and off-center
! mass centers of gravity which made them awkward to balance while being I
transported.
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Match markings on the bolted cable guards, interconnecting cable terminations l
and cooling water hose couplings'made the equipment assembly and inter-- l connections quite simple and free of error. No special: tools were required.
l Recommendations: . Equipment installation would be facilitated by marking-the weight and location of. center of gravity on each piece of equipment, providing lifting points closer to the center of gravity of the cable reels, and relocating heavy components -at the bottom of the cabinet.
4.2.2 Electrical Installation
)
The electrical design problems encountered in the installation of the IHSI equipment are similar to those which might be encountered in a reactor where no spare electrical circuits are available. The IHSI test facility obtained the required 1200-ampere, 480-volt, 3-phase power. for the static -
inverter by sharing a substation circuit breaker with an existing 2.61x105 J/sec (350 HP) circulating pump. A separate 2x500 MCM 3-phase feeder _was run.
in two 3 inch conduits from the substation to the IHSI power supply. Because of higher current requirements, a separate smaller circuit breaker was installed locally to protect the pump motor. The combined currents for-the pump motor and inverter exceeded the substation capacity. Therefore, electrical interlocks and procedural lock-outs were provided to prevent simultaneous operation. Similarly, the power required for the closed cooling water system and pipe cooling pump was obtained from circuit breakers in an existing motor control center. The details of the installation are 1
shown on Figure 4-4. The 90 m (300 ft) long air cooled power lead between the inverter step-up transformer and the work area step-down transformer was routed in a covered cable tray. In order to minimize the cable inductance, excess cable was turned back on itself in a wide- section of tray rather than coiled.
The water cooled power cable was simply laid on 15 cm (6 in.) high wooden blocks and held at least 8 cm (3 in.) away from metal surfaces to avoid inducing excessive heat generation in adjacent structures. All high current carrying connections in the circuit were coated with electrical joint compound in order to reduce the contact resistance and increase thermal conductivity.
4-8
4 l
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, Figure 4-4. ~ Electrical Service Elementary Diagram I
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Figure 4-5. Work Station Transformer (Top) and Capacitor (Bottom)
Connections l
l' i
m 4-10
Recommendation: The large water cooled cable which connects the step-down transformer to the work station should be replaced with a smaller, lighter cable similar to that used as an output cable to the induction coil. See Section 4.3 for details.
4.3 COIL AND CABLE INSTALLATION Induction coils were installed by halves, bolted or clamped together, and centered and supported on the pipe by centering screws or pads. Coils on vertical piping required auxiliary supports. Of the various techniques used to support and position vertical coils, the most effective was the com-bination of rope tied to a support structure and turnbuckles for elevation adj us tment , see Figure 3-16. Those coils which were fitted with lifting eyes were more easily supported and positioned than those which were hung by centering screws. The only precaution taken with the rope and turnbuckle installation technique was to keep the rope out of contact with the induction coils or heated pipe to avoid burning the rope.
The assembly of the coils designed for recirculation pipe joints, was easily accomplished. The coil halves were easily manipulated into alignment and bolted together using a conductive ccmpound on the coil mating surfaces.
Centering was easily accomplished using the adjusting screws, except for the elbow coil, in which one set of screws did not bear perpendicularly on the curved portion of the elbow. This caused the screws to bend and the coil to shift. -
The cooling water connections to the coils were easily made with the quick disconnect couplings, provided the manifolds were depressurized. The male and female coupling halves coincided with the inlet-outlet connections of the coil turns to prevent false connections. Two instances of coupling malfunctions were encountered. In both, the internal check valve failed to open, blocking flow to a portion of the coil. The resultant overheating discolored the af fected coppercoils and scorched the coil insulating supports, but did not prevent the completion of the treatment. The dis-coloration is evident in Figures 3-16 and 3-17.
i 4-11 i
The 2000 MCM cable was difficult to connect to the induction coils because of its weight and stiffness. Although the cable construction included clamps to maintain conductor alignment, the individual conductors slipped and rotated sufficiently during cable movement to misalign the lugs.
Individual conductors were easier to lift and twist into alignment when making connections to the coils than cable. The smaller conductors, although having greater electrical losses, were adequate with the pcwer supply and the coils used.
Recommendations: The following design features are recommended for incorporation in the coils and cables.
- 1. The weight and volume of the coil and support structure should be minimal to facilitate coil placement in confined spaces.
Copper tubing coils proved to have adequate strength to support ,
their own weight and reasonable handling forces.
- 2. Coil assemblies should be provided with hooks, eyes or lugs for lifting and positioning, located in a plane parallel to the coil axis containing the center of gravity of each coil half. These lif ting points should be located so they do not interfere with the operation of the coil centering devices.
- 3. Coil centering screws or mechanisms should be located so as to be perpendicular to the pipe and of sufficient strength to withstand gravitational and reasonable clamping forces. It is preferred that these devices bear on straight portions of the pipe, and be provided with swivel pad tips.
- 4. The insulating coil support structure should be nonflammable and able to withstand elevated temperatures.
- 5. The use of bolted assembly joints has proved to be satisfactory; however, nuts, washers and screws should be retained by the joint in order to avoid handling loose parts. The wrenching surfaces should be accessible by an air wrench to facilitate assembly.
- 6. The cooling circuits should be provided with flow monitors to indicate adequate flev.
4-12
l l
4.4 TEMPERATURE MONITORING AND CONTROL 4.4.) Temperature Monitoring The induction heating equipment was supplied with an automatic temperature controller. The infrared temperature sensor proved to be difficult to focus on the surface of the pipe between the coil turns, could only observe the temperature of a single spot, and did not have a sufficient range to monitor the heating of the pipe from ambient to the maximum treatment temperature.
A replacement controller was ordered, but it did not arrive in time to be evaluated. Therefore, the equipment was operated under manual control, using thermocouples as temperature sensors. The temperature monitoring was accomplished through the display and the plotter output of the data acquisition system.
4.4.2 Thermocouple Installation All tests were run using resistance spot welded Type K, Chromel-Alumel thermocouples. The best performance was achieved with 24 gage asbestos and glass braid insulated thermocouple wire. The wire stripped 3mm (1/8 in.) and resistance spot welded directly to the pipe surface using 30 to 55 J (watt-seconds) energy. The thermocouples were fixed to the pipe wall and protected by bands of 0.12mm (0.005 in.) stainless steel foil spot welded to the pipe.
Although acceptable welds could be achieved with as-stripped round wire, slight flattening of the wire assisted in maintaining the welding electrode position.
Two configurations were used: 1) with the exposed thermocouple wires parallel to the thermocouple cable axis; and, 2) perpendicular to the cabic axis. No differences in sensitivity or response were observed between these arrangements. The thermocouples and shielded cable required careful routing and grounding to minimize electrical noise pickup.
4-13
ASME Code Case N252 was used as a guide to the installation and removal of the thermocouple junctions. The spot veld nugget between the thermocouple and wire and pipe wall was small, and easily removed down to sound metal with hand tools.
Other less successful thermocouple installations were tested:
- 1. Twenty gage asbestos and glass braid thermocouple wire makes acceptable junctions, but is rather stiff and difficult to handle and terminate. The stiff wire tends to put larger stresses on the junction weld when flexed.
- 2. Stainless steel sheathed thermocouples were used for the Task 1 test specimens and were especially useful for mid-wall and measurements since the junction could be precisely placed in the hole. It was observed that thermocouples mounted on the pipe surface indicated slightly lower temperatures -
probably due to conduction and convective heat losses from the sheath, than adjacent spot welded thermocouples. The small gage thermocouple wires were difficult to terminate and were easily broken.
- 3. Attempts to cement foil thermocouples to the pipe were unsuccessful. The thin foil was extremely difficult to handle and weld to extension wires. The high temperature ceramic cement used to attach these thermocouples is difficult to apply and tends to flake off during heating.
- 4. ' Attempts to cement wire junction thermocouples to the pipe surface were also unsuccessful. Twenty-four gage thermo-couple wire required large masses of cement to hold in position and the differential expansion between the pipe, wire and cement during heating caused the cement to break allowing the junction to lose contact with the surface.
- 5. The use of spring loaded or otherwise clamped contact thermocouples was considered. The configuration of the available induction coils did not easily accommodate the necessary mounting hardware at or near the desired points of measurement. Also, pipe surface irregularities present difficulties in achieving good thermal contact. Considering these difficulties, and test schedule constraints, contact thermocouples were not evaluated.
4-14
4.5 IHSI TREAIMENT PROCEDURE The IHSI treatment procedure evolved during the performance of many treatment cycles. Not every treatment was performed exactly as outlined here, using all of the DAS programs, since several were written and rewritten to satisfy needs as they were identified. See Appendix C for an explanation of the DAS programs.
! 4.5.1 Preconditions 1 a. The weld to be treated is identified and exposed for treatment by removal of obstructing insulation and interfering structures.
- b. Thermocouples are mounted and connected to the data acquisition j system.
- c. The coil selected for the weld is installed and connected to the power cable.
I
- d. The cooling water hoses are connected to the coil and cable.
4.5.2 E_quipment S_tartup i
- a. Turn on the electrical power to the closed cooling water supply, the power supply and the control and instrumentation.
f b. -Turn on the closed cooling water supply and check for proper flow and pressure at each unit and for leaks at each connection.
4.5.3 Pipe Cooling Water
- a. Verify that the pipe cooling water is circulating at a flow rate sufficient to develop the specified velicoty at the weld to be treated.
l Discussion: It is essential that.the pipe segment containing
! the weld to be treated is completely free-of air and does
> not accumulate steam during treatment in order to maintain adequate cooling on the inside of the pipe. Establishing a i minimum system flow rate through well designed piping is sufficient to sweep air and steam away from the treatment
]
area. See Section 4.8 for additional discussion.
i
- 4-15 l
_ .__ _-- , . . . . . - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ - . - _ _ _ _ ._ _ _ .. _ .. ~
- b. Turn on the data acquisition system and verify the thermocouples are reading consistently by usitig the " EXAM" program to record the temperatures.
Discussion: All thermocouples read pipe ambient temperature l within a degree centigrade unless open circuited or connected l in reverse polarity.
4.5.4- Coil Circuit Tuning
- a. Adjust the power supply to minimum output power and while using the program " DISP" to display the temperature of a selected thermocouple and monitoring it so that the temperature does not exceed 250*C (482*F), turn the power on. Chack that the fre-quency is within operating range and that the supply operates at low power.
- b. If the supply does not run, check the indicator panel using the manufacturer's operating instructions to check the power circuit or make the necessary system adjustments to run the load. Caution: Turn off the power supply breaker and wait two minutes to allow voltage to decay before entering a cabinet or the coil area.
- c. While monitoring and limiting the pipe temperature to 250*C (482*F) maximum, momeatarily raise the power to the level required.
Observe and note the limiting condition, if any, and the power level achieved. Zune the load circuit as required to achieve the pcwer level required for treatment.
4.5.5 Coil ?osition and Thermocouple Check
- a. Increase the power level, while monitoring the pipe temperature, to maintain stable temperature 200 to 250*C (392 to 482*F) . Use the program " IDLE" to measure and record the temperature of each thermocouple over a 60-second interval and calculate the mean temperature during the interval,
- b. Turn of f the power. Review the temperature recording for noisy or erratic measurements. Correct faulty thermocouples as required. Review the temperature distribution for circum-ferential uniformity and axial distribution. Check that the temperature difference between the high and low reading thermocouples is within the recommended range for the weld to be treated.
4-16
e
- c. If not within the recommended range, adjust the coil position with respect to the weld to improve the temperature distribution.
Decrease the clearance to increase temperature, increase the clearance to reduce temperature. Caution: Turn off the power supply breaker before entering the coil area.
- d. Repeat a. through c. as required to achieve the desired temperature distribution.
Discussion: A coil position and thermocouple check is essential to assure an error-free treatment. Attempts to rely on dimen-sional clearance measurements have not been successful because of the irregularities of the pipe, weld, and coil. Shifting coil position, and in some cases, removing excessive weld crown, has been effective in reducing the surface temperature spread sufficiently to achieve IHSI heat treatment temperature tolerance. Empirical temperature range limits at low power have been used for particular joints and coils to predict satis-factory treatments at high power. An example of an " IDLE" temperature distribution chart is shown on Figure 4-6.
4.5.6 IHSI Treatment
- a. Select the highest and lowest reading pipe wall thermocouples to monitor during treatment and display the temperatures. Run the data acquisition program "IHSI" and enter the required data.
- b. Select the appropriate treatment power level for the induction coil and weld joint to be treated.
- c. Set the specified maximum and minimum temperature limits which assure the development of a minimum through wall temperature difference without exceeding maximum pipe material temperature limits.
- d. Set the specified minimum and maximum treatment time limits which will develop the required temperature gradients.
- e. Turn on the power supply and monitor the temperature rise.
Turn off the power supply when both the temperatures are between the maximum and minimum limits af ter the minimum time.
If the maximum temperature limit is approached before the minimum time, decrease the power slightly. If the minimum temperature is not achieved af ter the minimum time, increase the power slightly. If the minimum temperature is not reached at the maximum time specified, turn the power of f.
4-17
t 600 -1112
!', TC12 MAXIMUM J
_9a __ _ _
80% 70% 60%
im
_ _ _ - 50% POWE R
~
j 500 - - - - 932 i
40% POWER S
400 - MINIMUM - 752 i
I o$ _
_- 30% POWER E -
h 300 - -
572 oI t
I e f : a
! - 2 <
00
$ - 20% POWER C
_ - - g 2
200 - - #24 w 10% POWER 1
100 - -
212 60% POWER FOURIER NUMBER = 0.7 70% POWER FOR HEATf NG TIME TO TEMPERATURE "
O R 0- ! ! ! ! I l
~17.8 0 100 200 300 400 500 600 700 HEAT TREATMENT TIME (sec)
Figure 4-6. Acceptance Tests With 26 Inch Pipe and Coil - 50% to 60% Power Achieved Desired Results (Temperature at Coil Centerline) (6.0x105 J/sec (600 kW) Capability at 100% Power)
- f. If the treatment is not successful, because the maximum temperature limit is reached before the minimum temperature is achieved, at minimum time limit, reposition the coil per
4.5.5. Discussion
The above procedure is based on a manual control strategy which relies on knowledge of the coil-pipe character-istics to select power level which will result in a satisfactory treatment. Another strategy is to control the power level to constrain the temperatures between predetermined limits as the
! weld heats. An example of manual control in this mode is shown in Figure 4-7 and 4-8.
The highest and lowest temperatures during the IHSI heating are not always predicted from IDLE steady state heating if the pipe or fitting wall thickness is not constant.
Recommendation: The DAS and control system used for field treatment should be capable of monitoring and displaying either all surface temperatures or selecting and displaying the highest and lowest limiting temperatures during treatment.
4.5.7 Coil and Thermocouple Removal Caution: Disconnect the power supply breaker before disconnecting the cable from the coil.
- a. Disconnect the water cooling hoses from the coil.
- b. Remove the coil,
- c. Remove the thermocouples.
- d. Remove the thermocouple spot veld nuggets, and liquid penetrant inspect the weld area for cracks per ASME Code Case N-252. Remove additional material as required to achieve a sound surface, and reinspect.
4.6 ACCEPTANCE AND CALIBRATION TESTS The first trial operation was performed on 26 inch calibration pipe fully instrumented for temperature profile calibration (pipe C-26). A second calibration was performed on 4_ inch pipe to demonstrate the full range of the equipment.
l 4-19
C26-02 MAX POWER TASK 4 TASK 1 500 -
932 TC 11 (180 )
TC 12 (0 ) AN TC11,TC12 400 -
% - 752 OUTER SURF ACE o'-
c 3 3300 TASK 1 TASK 4 -
572 E
$ RUN No. 2602 C2642 POWER 5 5 d 5.7x10 J/sec (570 kW) 4.0x10 J/sec (400 kW) 3 tb $ WATER FLOW RATE 0.36 m/s (1.18 fthec) 0.5 m/s (1.64 ft/sec) 200 -
FREQUENCY 3 kHz 3.5 kHz -
424 100 - TC 3 (180*)
INNER SURFACE TCO2 --
212
_ __gg TC 2 (O')
TCO3 4 --
0 -17.8 O 30 60 90 120 150 180 210 HEAT TREATMENT TIME (sec)
Figure 4-7. Heat Treatment Chart - 26 inch Pipe
l l
TASK 1 TASK 4 l RUN No. 2602 C2642 180 see POWER 5.7x105 J/sec 4.0x10 5jj,,,
(570 kW) (400 kW)
WATER 0.36 m/s 0.5 m/s 150 sec F LOW R ATE (1.18 ft/sec) (1.64 ft/sec)
FREQUENCY 3 kHz 3.5 kHz
,% INDUCTOR 356mm 394mm WIDTH (14 in.) (15.5 in.)
130 sec PIPE SIZE 26 in. SCH 80 26 in. SCH 80 x N
%9 sec 90 sec %g 400 -
\ - 752 N
l s N F_
s U N \ E E
\ \ E S 300 50 sec \ 89 sec 995'c 572 $=
< N \ -
' \ $
5 N \ \ #
- N \ N s s
% N 66 \
's N \ \sec \
200 - 30sec g 46 sec
\ -
424 N
\ \ g %
20 sec %
TAS IN \ \
TASK 4 \
33 sec g 100 -
\ k- 212
\ \
N
\
c wc
- 3 -
1
' 17.8
[ } ] l 7e .d.
0 3/4 o d. 1/4 1/2
+l0.09 in.
! FRACTION OF WALL THICKNESS Figure 4-8. Through-Wall Temperature Profiles 26-inch Pipe 4-21
. . -- . - _ _ . _. ,. . - ~ .
Calibration pipes C-4 and C-26 did not contain a girth weld, but were extensively instrumented with thermocouples axially, circumferentially and through wall beneath the coil. .See Figures 3-24 and 3-25 for details.
Operation at 100% power, 6.0x105.J/sec, (600 KW) on the 26 inch pipe completed i the acceptance tests on the machine. The vendor previously performed accept-ance tests on 4 inch pipe at his shop. Several minor modifications were .,
required to the work station and a number of items had to be corrected to achieve proper operation. A series of ten runs was made on 26 inch pipe from
, 10% to 100% power, 0.6 to 6.0x105 J/sec (60 to 600 KW) in 10% increments to test stability of the equipment and to determine minimum, optimum and maximum power settings for this size pipe. Temperature' traces from these runs are
- - shown in Figure 4-6.
i a
Referring to these traces, it can be seen that a minimum power setting of approximately 43% is required to achieve the lowest temperature of-450*C (842*F); a maximum power setting of 65% resulted in the temperature reaching the highest temperature of 500*C (932*F) in the minimum time of 183 seconds (Fourier Number = 0.7) . The optimum power setting is therefore approximately 53%. At this power the mean temperature of 500*C (932*F) is achieved in a time that results in a Fourier Number greater than 0.7, but the maximum tem-j perature of 575"C (1067'F) will not be exceeded if the power remains on beyond this time.
This pipe is the same pipe that was used in previous Task 1, for which the
~
temperature profiles of run 2602 were reported in the Second Semi-Annual Progress Report. Comparisons between the data of Task 4 run C26-02 and Task 1 run 2602 are shown on the time-temperature curve of Figure 4-7, the
~
through wall temperature profile of Figure 4-8 and the axial surface tempera-ture profile of Figure 4-9. Similar comparisons between Task 4 run C4-14 and l
Task 1 run. number 3 are shown on Figures 4-10, 4-11 and 4-12. Since these profiles are consistent, there appears to be no difference between the single
, turn coil used in Task 1 and the multiturn coil used in Task 4.
f 4-22
.- . - - - - , . _ . _ _ _ - _ - - _ _ _ _ _ _ , _ ~ . _ . _
DISTANCE FROM COIL CENTER (mm) 158 79.2 0 79.? 158 600 1112 I I I l
I i 500 - p- i - 932
- \ TASK 4
\
! TASK 1 N L 400 - -
752 A
TASK 1 TASK 4 o g
RUN No. 2602 C26-2 w
~
0.36 m/s (1.18 f t/sec) 0.5 m/s (1.64 f t/sec) u WATER FLOW RATE
$ FREQUENCY 3 kHz 3.5 kHz 3
- F INDUCTOR WIDTH 356 mm (14 in.) 394 mm (15.5 in.)
o.d. TEMPERATURE (00) A E i.d. TEMPER ATUR E (00) A O 200 - - 424 t
i I
100 - -
212 1
~ --
0 -17.8 6.24 3.12 0 3.12 6.24 DOWNSTR E AM UPSTR E AM DISTANCE FROM COIL CENTER (in.)
Figure 4-9. Axial Temperature Profile - 26 inch Pipe 4-23
(M 1112 o.d. TEMPERATURE - TC 9 e
500 -
/ -
932
/[ o.d. TEMPER ATUR E - TC 10 TASK 1\
//
/
400 -
I, TASK 4 752 1,
e
?
j;l TASK 1 TASK 4 e
E 3 300 - -
572 3 y RUN No. 3 (SINGLE TURN C4A.18 y w INDUCTOR) MULTITURN w 4 4 POWER 1.9x10 J/sec (192 kW) 2.4x10 J/sec (240 kW)
- WAT ER FLOW RATE O.93 m/sec (3.05 ft/sec) 0.5 m/sec (1.64 f t/sec) o.d. MAXIMUM O (POINT 9/10)
TEMPERATURE f i.d. MAXIMUM O (POINT 2/3) 200 - TEMPERATUR E -
424 f TC10 j TC09 i
TC 2 AND I TCO2 TC 3 100 I C 0- '
O=& -CP O- O- <> O O. 4 -
212 h TCO3 6.d. TEMPER ATUR E TCO3 0
I I I I I I " ! -17.8 0 10 20 30 40 50 60 70 80 HE ATING TIME (sec)
Figure 4-10. Heat Treatment Chart - 4 inch Pipe 1
4-24
600 1112 TASK 1 TASK 4
( RUN No. 3 4 4 i POWER 1.9m10 J/sec (192 kW) 2.4x10 J/sec (240 kW)
WATER FLOW RATE 0.93 m/sec (3.05 f t/serl 0.5 m/sec (1.64 ft/sec) 6.d. AND o.d. TEMPERATURES TAKEN ARE VALUES AT C* AND 1800 AZIMUTHS .
500 40 sec T- -
932 TASK 4 N
20 see
% N N
C 400 -
g % TASK 1 -
752 l h 44 s 31 y U 10 sec -
-- N 20 sec o E
y 300
% 572 y 5
T -
i
\ !
uJ
\
N N
4 5 sec N % %
200 - -
424
\ I l
\ 6 sec \
N N__ -% %
100 -
212
__ _ _ _ J 'L - --
i I ! ! ! -17.8 0-o.d. 1/4 1/2 3/4 l
j FR ACTION OF WALL THICKNESS l
18.5mm (0.330 in.ll l
l Figure 4-11. Through-Wall Temperature Profile - 4 inch Pipe
! 4-25 l
600 1112 0 180" OUTER SURFACF 500 -
932 N
~
/
400 - TASK 1 -
752 TASK 4
/ \
l \ r e/300 -
\
572 i
4 5 5 9 b RUN No.
^ '
N POWEP ^
4 4 WATER FLOW RATE 1.9 x10 Mu 092 kW) 2.4x10 J/sw (240 kW) 0.93 m/sec (3.05 f t/sec) 0.5 m/sec (1.64 ft/sec)
_ Q o.d. TEMPERATURE - 424 0 i.d. TEMPERATURE 100 -
>- -% - 212
, INNER SURFACE O I I I I -17.8 3 2 1 0 1 2 3 DOWNSTREAM UPSTREAM D8 STANCE FROM COIL CENTER (in.)
Figure 4-12. Axial Temperature Profile - 4 inch Pipe 4-26
4.7 COIL INSTALLATION 4.7.1 Coil Alignment The 26 inch calibration pipe was treated with the coil mounted excentric and skewed with respect to the pipe. The nominal radial clearance between the concentric induction coil a:::1 the pipe was 19mm (0.75 in.) With dia-metrically opposed spaces of 14mm (0.56 in.) and 24mm (0.94 in.), the temperature at the narrowect space was 52*C (94*F) higher than the widest space as this temperature approached 550*C (1022*F). With spaces of 9.5mm (0.375 in.) and 28.5mm (1.125 in.) the difference was 70*C (126*F) .
A similar setup was then made on the 4 inch calibration pipe C-4, and optimum power was established at approximately 43 percent, 2.6x105 J/sec (260KW). Eccentric mounting of the coil gave a temperature difference of 53*C (95'F) with spaces of 6mm (0.25 in.) and 18mm (0.75 in.).
These results demonstrate both the need to maintain a uniform clearance between the induction coil and the pipe wall and the possibility of centering a coil by monitoring surface temperature during induction heating and readjusting coil position to equalize temperatures. This latter technique was extensively used when treating transition pipe jointre.
4.7.2 Pipe Contour The first welded specimen to be treated was E4-03D, a 4 inch pipe with the weld crown temperature raised to slightly over 500*C (932*F) (Figure 4-13).
The temperatures of adjacent locations on the pipe only reached 420*C (788'F) and did not give a desired rounded axial temperature profile. Extrapolations of the temperature curves indicated that the temperatures might not be within the desired range if the treatments were repeated for a longer time. The I temperature of the pipe wall adjacent to the weld is less than other pipe wall and weld c Jwn temperatures. This location may be shielded by the weld crown. In an attempt to nmke these readings more uniform, the weld crown was machined flush on the first specimen (E4-03D) and a second run made as shown on Figure 4-14. The range of temperatures between weld and pipe was reduced to approximately 50*C (90*F).
4-27 i
600 1112 HIGH JL SPECIFIED 500 - TREATMENT - 932 g
RANGE ACTUAL TREATMENT RANGE 1r Y r LOW 400 - - 752 0
i $ 4 in. SCH 83 PIPE 304 SS $
3 40% POWER 3 y 300 -
p 8.56mm (0.337 in.) WALL THICKNESS
- 572 y 5 5 e B 9
= k e e
200 - - 424 TYP 12.7mm (1/2 in.)
100 $l ,'f) l -
212 lc 1.5 M >l R = PIPE RADIUS MINIMUM T = WALL THICKNESS O
' ' -17.8 0 10 20 30 40 50 60 HE AT TRE ATMENT TIME (sec)
Figure 4-13. Heat Treatment Chart E4-03D (First Treatment of Welded Pipe Specimen E4-03D With Weld Crown Not Machined Flush)
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I I I I T I
I I I I WELD 3 l I I g i i SWEEPO LET o iso
- 90 270 Figure 4-15. Weld W5a Sweepolet Wall Profiles 4-30
- . - - - - - . . - . _ . - - - - - . . - - . - - , . . _ _ . _ - - _ - . _ - . . .~ . _ . . . - - . - . .
l Operating experience to this point brought out the fact that the highest.
and lowest reading thermocouples could not be accurately predicted before operation. A procedure was then adopted whereby the pipe surface was heated to a low temperature at low power of sufficient duration to reach equilibrium conditions. From these data it was possible to select the proper thermo-couples to monitor during the actual treatment. This procedure was satisfactorily applied during all subsequent treatments.
The difficulties with equalizing induction heating temperatures became more difficult when treating the pipe to transition joints. The 12 inch pipe to elbow and 12 inch pipe to sweepolet veld joints were particularly difficult to heat uniformly because of pipe surface irregularities, variations in pipe wall thickness and coil centering problems.
Weld W5, the riser to sweepolet tee is an example of how both out of roundness of welded pipe and thermal distortion produced by the welding process com-bine to produce irregular coil to pipe clearances and wall thicknesses. The I
rolled and welded 12 inch pipe was out of round, especially at the longi-tudinal seam weld. Counterboring the inside of the pipe to mate with the fitting resulted in a nonuniform wall thickness which was thinnest near the longitudinal seam. Thermal distortion of the pipe during welding results in a diameter reduction of the pipe wall adjacent to the circumferential weld, increasing the relative clearance between the coil and the pipe wall.
Both welds W5a and W5b exhibited low temperatures near the junction of the longitudinal pipe seam weld and the circumferential weld. Typical pipe surface contours are shown on Figures 4-15, 4-16 and 4-17.
Recommendation: Piping surveys should measure out of round and wall thickness in the heat treatment zone to provide the data required to more i precisely match the coil and pipe contours and identify the location of extreme temperatures.
I I
4-31
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I 4-32 l
l
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Figure 4-17. Sweepolet Wall Profile (Weld Crown Removed From itight Side) l 4-33 1
4.8 PIPE COOLING REQUIRDfENTS The IHSI process requires the pipe wall to be cooled in order to develop residual compressive stresses on the inside surface.
This cooling is provided by water contained within the pipe for which the nominal specification velocity is 0.5m/sec (1.64 ft/sec). The cooling water requirements are evaluated by measuring the temperature distributions in calibration and recirculation mockup test pipes containing both outside and inside surface thermocouples at various flow conditions and pipe orientations.
Three configurations were evaluated; vertical straight, horizontal straight and horizontal elbow weld joints.
4.8.1. Vertical Pipe The vertical pipe configuration was evaluated using wald W7, the 30 inch tee-to-cross weld. The temperature chart of run W7-2, Figure 4-18, per-formed at 70% power and 0.6 m/sec (2 ft/sec) water velocity, shows the outside wall temperatures, TCO2 and TC04 to be 500*C (932*F) and the insidc wall temperature, TWO3, to have increased from 30*C to 50*C (86 to 122*F) at 600 seconds. The temperature chart of run W7-8, Figure 4-19, performed at 68%
power and zero velocity, shows the outside wall temperature to be 510"C (950*F) and the inside wall temperature to have increased from 40*C to 95*C (104 to 203*F) at 600 seconds. Since the inside wall temperature at 1000 seconds cor-responds closely to the saturation temperature,102*C (216*F) at the estimated pressure heat of 1 meter of water, it appears that natural convection boiling head transfer provided adequate cooling of vertical surfaces to limit the inside temperature to saturation temperature at IHSI treatment power levels.
4.8.2 Horizontal Pipe, Vented and Submerged The horizontal pipe configuration was evaluated using the 26 inch straight pipe in the horizontal test fixture. This fixture differed from usual piping installation practice in that it was not constructed to be as self-venting as properly pitched pipe. The 6 inch pipe outlet was concentric with the 26 inch pipe. Therefore the fixture was provided with a small high-point vent to remove the trapped air.
4-34
4 0
C Co w ea2$
T 3 8 2 H 2, 7 2 W 2 O 2 4 2 O 1
1 G 3 O 5 C 7 2 1 W 1 I
9 7 5 4 2 -
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1 1 The temperature chart of run C26-03, Figure 4-20, performed with a 0.5m/sec [.
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(1.64 f t/sec) water velocity, shows outside wall temperatures at '230/secon5s c i to be 460*C (860*F) while top inside wall temperatures aid not exceed 100"C ,_
(212*F), saturation temperature. The temperature chart of rUn'"zero, velocity," '
Figure 4-21, shows the wall temperatere rising to 510*C and 480*C (950 and 896 F)y at 230 seconds af ter starting from 25*C (77"E) . During this interval the~ tem- ,
+
perature at the bottom of the pipe did noi; exceed 90*C (19d*F). The temperature +
at the top of the pipe experienced temperatures postulated to have been caused by the following events. Starting with.a flooded pfpe, the pipe heated the water which rose by natural convection to the > top of the pipe, until at 90 sec-
- i onds, boiling started and continued'untit the surface was blanketed by steam at 180 seconds. Thereafterthetemperaturet$creasedrapidlyuntiltheinput ~/'
power was turned off and more slowly thercafter as additional heat was 2 absorbed from the pipe wall until tic [ inner and outer walls cooldd.to a '
7 uniform temperature. The sudden temperature decrease of 440 seconds is/ /
+ ,
probably due to the escape of a quantity of steam and the subsequent inrush of cool water from the outlet pipe which cmdensed the remaining steam and created sufficient turbulence to wet the uppe; Jinjide surface for a short
- s s
time, causing a momentary drop to saturation tem'perature.
s t h These results demonstrate the need for water flow in horizontal pipe runs [
to prevent the formation of a stesm void on the upper surfaces and the
~
consequent increase in temperature aiove saturation temperatures. 4 '?
1
.. d 4.8.3 Horizontal Pipe, Not Vented ot Submerged Y This horizontal pipe was a 12 inch pig e which discharged into a chice*2t ic i t /- 4 6 inch pipe. Although it is a high point in the piping, the 12 inch lpi;ic was % I f
not fitted with a vent. Because of this configuration it always trapped an -; ,
air pocket at the start of a test. This test condition simulated the field condition of an incorrectly pitched pipe shortly after having been drained p and refilled and prior to high flow operation which would flush the ' air from s
the pipe.
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The temperature chart for run W3A9, Figure 4-22, performed with a water velocity of 1.2 m/sec (4 ft/sec), shows an acceptable inside pipe w ll temperature.
The temperature chart for run W3A-ll, Figure 4-23, in which the initial velocity was 0.8 m/sec (2.6 f t/sec), increased to 1.2 m/sec (4 ft/sec),
shows a rapid increase of top inside wall temperature, with only a slight leveling of temperature at saturation temperature at 20 seconds, until the induction heat was turned off. The temperature dropped rapidly at 175 seconds when the flow rate was increased to 1.2 m/sec (4 ft/sec). The postulated internal condition is that a pocket of air is present at the start of the run which is mixed with super-heated steam as the water boiled at the edges of the air pocket. The steam and air are swept away from the top of the pipe when the flow velocity is increased.
4.8.4 Recommendations A minimum water flow velocity of 0.5 m/sec (1.64 ft/sec) provides adequate cooling for welds in a horizontal pipe run without air pockets. Horizontal piping should be surveyed for pitch and high point venting prior to treatment to verify that it cannot trap an air pocket. Increasing the water flow velocity to 1.2 m/sec (4 ft/sec) in incorrectly pitched pipe is sufficient to displace an air pocket with a depth of 25% of the pipe inside diameter and provide adequate cooling.
4.9 TEMPERATURE AND TIME LIMITS
~
The preliminary IHSI process control parcmeters of Table 1-1 were used to perform the IHSI heat treatments and evaluate the results of the treatment procedures. These parameters were chosen on the basis of experimental and analytical data derived from Task 1 work on straight pipe.
As the testing progressed, the limiting parameters were established to be: the pipe outer surface temperature of 450 to 550*C (842 to 1022*F) within the mini-mum width of zone heated to the minimum through wall temperature difference of 300*C (540*F). (The minimum heating time could be achieved by induction heating 4-40
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power adjustment.) Difficulties arose from the nonuniform wall thickness and irregular contour of welded pipe and transition fittings. Typically, the weld crown or other raised portion of the fitting reached or exceeded 550*C (1022*F) maximum before the pipe wall adjacent to the weld reached the 450*C (842*F) minimum temperature.
The 550*C (1022*F) maximum temperature had been chosen to prevent outer pipe wall sensitization of Type 304 stainless steel base metal to intergranular stress corrosion cracking by the IHSI process. A sensitization evaluation of welded pipe IHSI heat treated to excessive temperatures for excessive times reported no clear increase in sensitization for 5 minute IHGI treatments to 600*C (1112*F) . A maximum temperature limit of 575'C (1067*F) was therefore established for the evaluation of the results of Task 4.
The 450*C (842*F) minimum temperature was selected to provide a 300*C (540*F) throughwall temperature difference with an estimated maximum inside wall tem-perature of 150*C (302*F) which might occur at the lowest point in the piping under conditions of boiling heat transfer resulting from marginal cooling flow. Since it is unlikely that all adverse conditions will be experienced simultaneously during IHSI treatment, the 150*C (302*F) estimate is conserva- g tive. Other developers of the IHSI process reported a minimum throughwall temperature _ difference of 220*C (396*F) as an acceptable limit for IHSI treat-ments performed by them.6 This low temperature difference is also supported by analytical modeling and strain gage data reported in Section 4.10 which show that a difference of as little as 200*C (360*F) to be effective in reducing residual tensile stress on the pipe inside diameter. These observations sup -
port reduction in the minimum acceptable throughwall temperature difference from 300*C to 275*C (572 to 527*F). The resultant minimum temperature limit then becomes 425"C (765'F) . The process control parameters for field applica-tion of the IHSI process are shown on Table 4-1.
4.10 PROGRAM SPECIMEN AND TRANSITION JOINT WELDS The summary of test weld treatments is shown on Table 4-2. This table includes the specimens treated for further testing and examination by 4-43
Table 4-1 IHSI FIELD APPLICATION PROCESS CONTROL PARAMETERS y
1.- Pipe Outer Surface Temperature 500 75'c (932 135'F)
Within Treatment Zone (Notes 1, 2)
- 2. Minimum Throughwall Temperature 275'C (495'F)
Difference (AT)
- 3. Minimum Width of Zone Heated to 1.5 V10I AT Minimum (R= Radius and t = thickness)
- 4. Minimum Distance from Weld 15 mm (0.6 inch) or t/2 (whichever Center to Boundary of AT is larger)
Minimum
- 5. Minimum Heating Time 0.7 t 2/a seconds (Note 3) (a = thermal diffusivity, t = wall thickness)
- 6. Frequency 3 to 4 kHz
- 7. Induction Coil Length 3 VIE Minimum (R =. pipe radius, t = wall thickness)'
- 8. Minimum Water Velocity 0.5 m/sec (1.64 ft/sec)
(in vertical or horizontal flooded pipe)
- 9. Minimum Water Velocity 1.2 m/sec (4 ft/sec)
(pipe with air pockets)
NOTES: 1. Minimum surface temperature will normally occur at the minimum pipe wall thickness and/or maximum coil to pipe surface clearance.
- 2. Maximum surface temperature will normally occur at the maximum pipe or fitting wall thickness and/or the minimum coil to pipe surface clearance.
- 3. Derived from Fourier Number = 0.7.
4-44
Table 4-2
- TEST JOINTS r
Description Number of
- Identity * (all Type 304 S/S) Position Comments Treatments W1 22 in. Mockup, Header Horizontal Contract requirement: 1 to Valve size, configuration and residual stress measurement **
W2 12 in. Mockup, Riser Vertical Contract requirement: 7 to Reducer position, size and -
configuration W3a 12 in. Mockup, Elbow Horizontal Contract requirement: 5 to Pipe position, size and-configuration 4
W3b 12 in. Mockup, Elbow Horizoatal Archive 1 to Pipe W3c 12 in. Mockup, Elbow VerticrJ Contract requirement: 1 to Pipe position W5a 12 in. Mockup, kiser Vertical Parameter deter- 6 to Sweepolet mination; Contract requirement:
configuration W6a 22 in. Mockup, Cross Horizontal Trial with W1 coil 2 to Header W6b 22 in. Mockup, Cross Horizontal Not treated; no O to Header suitable coil on hand W7 30 in. Mockup, Cross Vertical contract requirement: 7 to Tee size and configuration i
W8 12 in. Mockup, Tee Horizontal Not treated; no O to Discharge suitable coil on j hand W9 22 in. Mockup, Cap Horizontal Trial with W1 coil. 1 to Header Archive l
See Figure 3-22 for location.
. To be given single treatement for residual stress evaluations.
l l
I 4-45 i
t _ ---.--. _
Table 4-2 (continued)
TEST JOINTS Description Number of
_ Identity * (all Type 304 S/S) Position Comments Treatments W10a 4 in. Test Specimens Vertical Metallurgical + UT 1/ weld tests E403-B, (8 welds)
E403-C, E403-D, E403-E, E405-C,-
8045-2, 8045-1, E349-D W10b 4 in. Test Specimens Vertical Pipe test laboratory 16 RS01-2, RS-12, E408, RS-13 and RSP03-1 W11a 12 in. Test Specimen Horizontal Archive 1 C4 4 in. Straight Pipe Vertical Calibrate unit and 11 temperature profile C26 26 in. Straight Pipe Horizontal Calibrate unit an.1 11 temperature profile W5b 12 in. Mockup Specimen Vertical New scope (strain 1 Riser to Header gage tests)**
C16 16 in. Straight Pipe Horizontal Calibration tests 5 with 16 in. coil (New Scope)-
RS-16-4 16 in. Multiweld Horizontal- Full size pipe .est 1/ weld Specimen for specimen (New Scope) (4 welds)
PTL testing RS-10 4 in. Multiweld Vertical For statistical 1/ weld Specimen basis information by (7 welds)
PTL testing (New Scope)
RS-12 4 in. Multiweld Vertical For statistical 1 weld Specimen basis information by (7 welds)
PTL testing (New Scope)
RS-12 4 in. Multiweld Vertical For evaluation of 1/ weld Specimen for welds not ground on (7 welds)
PTL Testing the root side (New Scope)
See Figure 3-22 for location.
To be given a single treatment for residual stress evaluations.
4-46
I Tasks 2 and 3 of the program, recirculation piping mockup welds in traasition joints and calibration treatments in straight pipe. The latter are identi-
! fled as C4, C26 and C16.
- j. All IHSI treatments were performed with the intent of achieving 'the pre-liminary process parameters of Table 1-1. The success of recirculation
[ piping weld treatments was evaluated ~using the field application process
~
parameters of Table 4-1.
4.10.1 Straight Pipe Joints These program test specimen joints are butt welds in stainless steel straight pipe. The welds are in 4, 12, and 16 inch Schedule 80 pipe with 4 inch size predominating. The 4 inch pipe was treated in a vertical orientation using the 4 inch induction coil. The 12 inch pipe was treated in the horizontal orientation using the 12 inch coil for the reducer joint.
The 16 inch pipe was treated in the horizonts' orientation using a continuous l coil (not split). All specimens received a treatment conforming with the j preliminary IHSI treatment parameters of Table 1-1, except for some 4 inch j specimens exposed to higher temperatures and longer times for metallurgical i evaluation of extremes of acceptable treatments.
f While the straight' pipe joints did not pose any serious difficulties in IHSI treatment, the repetitive treatments provided an opportunity to refine thermocouple attachment and removal and coil placement techniques.
[ 4.10.2 22 Inch Pipe to Valve Mockup - W1 i
l This is a horizontal pipe welded to a simulated valve body. Only one treatment was given, because this joint was scheduled for residual stress
, evaluation. The preliminary coil and system calibration was performed on f weld W6, for which the W1 coil was not designed. The coil installation is shown on Figure 4-24. The coil was centered in two IDLE trials, Figure 4-25.
f During treatment, see Figures 4-26, 4-27 and 4-28, the power supply
- momentarily limited the output power at 145 seconds. The operator manually i
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reduced the power from 73% to a lower value, but over controlled at 160 seconds. The power was raised to 70% at 180 seconds to complete the-
-treatment.
t 4.10.3 12 Inch Riser to Reducer - W2 This is a vertical pipe welded to a 12x30~ inch reducer. .It was IHSI treated
< with the W2 coil specifically designed for this joint. The coil installation
! is shown on Figure 4-29. Since the pipe joint.and coil are axisymmetric, the coil was relatively easy to position concentric with the pipe. No IDLE t
checks were being made when this joint was treated and the coil .was not repositioned to eq1stize temperature.
i The treatment chart, Figure 4-30, shows the reducer surface to heat less j rapidly, but reach higher temperatures (dotted line) than the pipe wall (solid line). The weld centerline temperatures were relatively higher than-the pipe wall, but not excessively so.
i J
4.10.4 12 Inch Pipe to Elbow - W3 Both horizontal and vertical pipes welded to a 90* elbow were trea'ted.
l These joints were treated with a coil specifically designed for this I configuration. A typical coil installation is shown on Figure 4-31. The horizontal pipe to elbow weld in the center riser was treated 14 times to calibrate the coil, determine water flow requirements and develop coil-positioning techniques. This coil was particularly difficult to-position because one set of Jack screws was not well placed on the coil structure.
The jack screws were relocated, with much better results. The temperature records of single treatments of the. horizontal pipe to elbow weld and vertical pipe to elbow weld are shown in Figures 4-32 through 4-14. The
! horizontal weld was treated af ter four coil adjustments and the vertical-af ter nine coil adjustments. Both results represent successful field' treatment simulations, i
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- 4.10.5 Sweepolet Tee to 12" Riser Pipe - W5 This . weld joins the 12 inch rolled and welded riser pipe to a sweepolet forging which is welded into the 22 inch recirculation pipe header. The .
induction coil was specifically designed for this joint using the component dimensions prior to welding.
Two joints were treated, W5a and W5b. The one in the recirculation piping
, mockup, W5a, was used to calibrate the coil and develop coil position techniques. See Figure 4-36 foe a typical installation. This joint was treated approximately 46 times. The temperature distributions resulting from the manufacturer's recommended coil position with respect to the weld were not satisfactory. Many treatments were made with the coil raised and ,
excentric by various amounts in attempts to equalize the temperature i
distribution. The pipe wall temperature nearest the intersection of the longitudinal pipe seam weld and the circumferential butt weld, at 0*, was invariably lowest of all the temperatures in the pipe heat treatment zone,-
while the sweepolet surface at 90* was generally highest. During the
't interval when the coil vendor was responding to our request for assistance, I two other install. tion modifications were investigated; one in which a steel plate was interposed between the coil and the base of the sweepolet for the i
i purpose of altering the magnetic field, and one in which'the coil was turned 90 degrees to the manufacturer's recommended orientation. Both techniques improved the temperature distribution. These results are
- reported at length in the Fourth Semi-Annual Progress Report, June 1980-j December 1980.
I The tee which was fabricated for strain measurements, W5b, exhibited a pattern of temperature distributions during IDLE runs similar to that
! experienced with the mockup tee. With the coil installed in accordance 4 with the manufacturer's recommendations and even when raised and shifted excentrically, tha .nge of temperatures exceeded the limits which would result in a satisfactory heat treatment. Since the weld joint also had a i large weld crown, it was ground down to achieve a lower contour. Although
- the temperature distributions improved somewhat, it was not until the coil i
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i throughwall temperature difference was about 360"C (648'F).
The strain gage data obtained during the IDLE runs and IHSI treatment are i summarized on Table 4-3. The location of the strain gages on the inside of
! the weld joint are shown on Figure 4-40. Strain gages SGL1 through SGL4 are i
, one half inch long strain gages which abutt the weld and extend longitudinally 4 ,
} along the pipe wall and are-spaced at 90 degrees. SGC5 is a one half inch long gage which abutts the weld and extends circumferentially along the pipe wall. SGL7 is a one inch long gage mounted longitudinally on the sweepolet.
and SGR6.is a one half inch long gage held against, but not welded to, the pipe wall as a zero strain. reference. The microstrain measurements following the first IDLE run with surface temperatures.of 120 to 240*C (248 to 464*F) .
show the development of' relative compressive (negative) strains which persisted 1
1 (except for SGL3) eduring subsequent IDLES and weld crown removal. The post 3
IDLE strain measurements confirm an increase in relative compressive strain due to throughwall temperature differences of about 200*C (360*F). The rela-tive compressive strains-increased by a factor of 2.4 or more following the IHSI 1 .
treatment. Inasmuch as the pipe wall stress at the time of. gage installation I was not known, no quantitative estimate of compressive stress following 4
treatment can be made.
i The surface temperature and microstrain recordings during IHSI treatment are J
shown on Figures 4-39 and 4-41. A comparison of the temperatures and micro-strains shows a correlation between the different rate of increase of' temperature and microstrain in the thick nozzle section and the thinner pipe wall.
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POWER INPUT: 3.3x10 ;/s.c (330 kw)
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> Gage Identification SGL1 SGL2 SGL3 SCL4 SCC 5 SCR6 SGL7 Before Treatment 0 0 -5 0 0 -5 0
- After First IDLE -195 -455 -135 -325 -130 -15 -40 1
- i. After Seventh IDLE -275 -475 -5 -325 -90 55 -5'5 After 7th IDLE -335 -515 -20 -305 -85 35 -75 Following Weld
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4.10.6 22 Inch Pipe to 30 Inch Cross - W6 This weld joint connects the 22 inch horizontal header pipe to a 310 inch cross. The coil vendor declined to provide a coil for this joint. Therefore, the cgil designed for the 22 inch pipe to valve body, W1, was used to evaluate the difficulties in IHSI treating weld W6 and to calibrate the coil for a single treatment of weld Wl, see Figure 4-42.
The IHSI treatment temperature record which most closely achieved the specification requirements is shown on Figure 4-43.
4.10.7 30 Inch Tee to 30 Inch Cross - W7 This weld is in the vertical run of the recirculation piping and, although connecting two pipe fittings, is essentially a butt weld in a straight piece of pipe. A satisfactory treatment was achieved in the second trial after increasing the power from 65% to 70%, see Figure 4-44.
a 4.10.8 12 Inch Pipe to 30 Inch Tee - W8 This weld joint connects a horizontal 12 inch pipe to the vertical 30 inch tee. No coil was purchased to treat this joint. The coil for weld W5, the 12 inch pipe to sweepolet joint, was to have been used to make a single treatment of this weld. However, the difficulties encountered in achieving a satisfactory treatment with W5 resulted in the elimination of weld W8 from the program.
! 4.10.9 22 Inch Pipe to Pipe Cap - W9 This weld joint connects a pipe cap to the end of the 22 inch recirculation piping header. The induction coil for the valve end weld, Wl, was used to give this joint a single IHSI treatment see Figure 4-45.
The coil was centered and temperatures equalized in the second IDLE run, 5
Figure 4-46. An IHSI treatment was attempted at 3.6x10 J/sec (360 KW) power, but was aborted at 250'C (482*F) because the temperatures were not within the 4-70
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l ? Section 5 e CONCLUSIONS AND ACCOMPLISHMENTS The original and supplementary Task 4 requirements of Contract RP1394 ; have been completed. Field surveys show that site access is available to perform the process. Equipment was designed, procured, calibrated and tested on full size mockups simulating field conditions. Representative
; weld joints were successfully treated in horizontal and vertical orientations,
~ in pipe sizes ranging from 4 inch Schedule 80 to 30 inch Schedule 80, and in straight pipe, tees, elbows, reducers, caps and simulated valve connections. The performance of each piece of equipment has been evaluated. Design improvements have been incorporated and others recommended to improve per-formance, safety and utility. The need for careful matching of the induction coil to the weld joint contour has been determined. IHSI treatment procedures and process controls have been developed which, using manual control alone, result in successful IHSI treatment in the first I trial. Changes to the optimum IHSI process control parameters have been recommended that clarify the definition of these parameters in terms of field appli-cation and that include expanded acceptance limits, within which beneficial-compressive stresses are produced without ICSCC sensitization. l ! Test samples examined by metallographic and other sensitization evaluation , methods indicate process standards are conservative. Test specimens have been prepared for residual stress evaluations and full size environmental tests to support thermal profile conclusions that compressive stresses are
- produced at inner surface weld heat affected zones of nonsymmetrical weld 1 joints.
1 r 5-1 l
General procedures for controlling the process, monitoring temperatures, qualification of procedures and personnel and equtpment specifications have been prepared for application of IHSI treatment to piping in the field. i 5-2 g . - , . _ .,.g
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l Section 6 , NOMENCLATURE i DAS - Data Acquisition System EPRI - Electric Power Research Institute HAZ - Heat Affected Zone 1HSI - Induction Heating Stress Improvement 6 ' RSI - Residual Stress Improvement ] ICSCC - Intergranular Stress Corrosion Cracking MCM - Million Circular Mils 4 1 1 l l' I 6-1 i i
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- Section 7 I
! REFERENCES ,
- 1. EPRI Program Contract Agreement and Schedule RP 1394-1 and T113-1, R2.
t b 2. D. C. Bertossa, et.al, " Techniques to Mitigate BWR Pipe Cracking in 1 Existing Plants (Induction Heating Stress Improvement) First Semi-Annual Progress Report, EPRI Contract RP1394-1 November 1978-April 1979,"
.; Ceneral Electric Company, (NEDC 25146) j 3. D. C. Bertossa, et al ---- "Second Semi-Annual Progress Report, EPRI
.i Contract RP1394-1 May 1979-October 1979," Ceneral Electric Company, (NEDC 25146-1)
- 4. D. C. Bertossa, et al - - "Third Semi-Annual Progress Report,
, November 1979-May 1980," General Electric Company, May.1980 (NEDC 25146-2) { 5. D. C. Bertossa, et' al --- " Fourth Semi-Annual Progress Report, EPRI - Contract T113-1 R1, June 1980-December 1980, General Electric Company, (NEDC-25146-3)
- 6. " Test Results on IHSI Treated Large Diameter Pipe," IHI Presentation, EPRI Pipe Crack Remedy Seminar, January 1980, Palo Alto, California-
.I h I 2 7 I l S i 7-1 i
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Appendix A INDUCTION HEATING EQUIPMENT PURCHASE SPECIFICATION
- 1. SCOPE 1.1 PURPOSE This specification defines the generic requirements for the induction heating equipment used for stress improvement treatment on welded stainless steel pipes to produce compressive residual stresses on the pipe's inside surfaces.
- 2. APPLICABLE DOCUMENTS 2.1 CODES AND STANDARDS.
The following codes and standards (latest or specified issue) form a part of this specification to the extent specified herein. 2.1.1 Code of Federal Regulations
- a. Federal Communications Commission Rules - 47 CFR 18
- 3. DESCRIPTION 3.1 GENERAL This induction heating equipment is used to heat 4 inch to 30 inch Schedule 80 stainless steel pipe for the purpose of producing compressive residual stresses on the pipe's inside surfaces.
3.2 COMPONENT DESCRIPTION The induction heating equipment consists of: -
- n. A solid-state power supply to convert three-phase AC power into medium frequency single phase power suitable for induction heating applications.
A-1
- b. A closed loop water cooling system to provide deionized cooling water to various elements of the induction heating system.
- c. Transmission cables to transmit the induction heating power from the power supply to the work station.
- d. Work station components consisting of transformer and capacitor assemblies necessary to convert the high voltage, low current output of the power supply into low voltage, high current power for induction heating.
- c. Induction heating coils of various sizes suitable for providing induction heat to various stainless steel pipes up to 30 inches.
- 4. REQUIREMENTS 4.1 SYSTEM 4.1.1 System capacity.
The induction heating system shall be capable of heating a 30 inch Schedule 80 pipe to an outer surface temperature of 600*C (1112*F) in a maximum time of 360 seconds, while the pipe's inner surface temperature is being maintained at 100*C (212*F) by flowing cooling water through the pipe. 4.1.2 System Protection
- a. Interlocks - The system shall be protected by interlocks'so that operating personnel and the equipment will be protected against injury or damage which may be caused by any of the following:
(1) Low cooling water flow (2) High cooling water temperature (3) Removal of load 1 (4) Short circuiting of load (5) High cabinet temperature (6) High/ low input voltage (7) Opening of any access door The status of each interlock shall be displayed to the operator. A-2
i i
- b. Grounding - The equipment shall have suitable grounding provisions to provide protection against injury or damage in the event of short circuits or line voltage transients.
- c. Circuit Protection - The input and output of the power supply shall be protected by suitably sized enclosed circuit breakers or fuses. Circuit breakers are the preferred means of protection.
4.1.3 Control
- a. Manual Mode - The equipment shall be capable of being manually adjusted to provide a specified power output ranging f rom 6.0 to 60x104 J/sec (60 to 600 KW).
- b. Remote Control - The system shall be capable of being manually shut down at the local work station up to 107m (350 feet) from i the power supply.
- c. Automatic Shutdown - The system shall have provisions for auto-
-! matic shutdown whenever a preselected work piece temperature or a preselected heating time have been exceeded,
- d. Operator's Console - An operator's console shall be provided which will include all standard control functions required to operate the heating cycle. The console may be integrated with the power supply.
4.1.4 Instrumentation. The system shall include the following meters or gauges:
- a. Percent power available at the power supply output.
- b. Load resonant frequency or output power. factor.
- c. Cooling water outlet temperature (local indication at each cabinet).
- d. Closed water recirculation system operating pressure (local at each cabinet).
+
- e. Closed water recirculation system water flow (local at each cabinet).
I
- f. Digital readout of work piece surface temperature.
1 } A-3
4.1.5 The following functions shall be capable of being monitored either by meter or indicator light when safe limits are exceeded:
- a. High/ low input voltage.
- b. High cabinet temperature.
4.1.6 Recorder Signals. The following instrumentation signals shall be provided at the operator's console for remote recording.
- a. Power supply output power
- b. Load resonant frequency or output power factor 4.2 MECHANICAL i
4.2.1 Power Supply The power supply shall conform to the following mechanical requirements:
- a. Housing. Metal cabinet, NEMA-12, or the equivalent.
- b. Access. Doors of sufficient size to allow easy access to all components which may require service or repair.
- c. Dimensions. 4.1m (160 inches) maximum length by 0.9m (36 inches) maximum width by 2.3m (90 inches) maximum height.
- d. Weight. 4.5x10 3Kg (10,000 pounds) maximum.
- e. Lifting Provisions. Lifting eyes in top of cabinet and skids under bottom of cabinet.
- f. Cooling. Water-cooled from closed cycle cooling water system such that no equipment or personnel hazard exists when the equipment reaches thermal equilibrium when operating at full power.
4.2.2 Work Station The work station shall conform to the following mechanical requirements:
- a. Housing. Metal cabinet, NEMA-12, or the equivalent.
- b. Access. Doors of sufficient size to allow easy access to all components which may require service or repair.
A-4
- c. Dimensions. The intent is for the work station cabinets and coil connecting cables to be as small and compact as possible while still supplying the required heat to the work piece.
(1) Step-down transformer cabinet - 0.9m (36 inches) long by 0.9m (36 inches) wide by 0.9m (36 inches) high. (2) Auto transformer and capacitor cabinet - 1.5m (60 inches) long by 0.9m (36 inches) wide by 1.8m (72 inches) high. (3) Isolation transformer and capacitor cabinet - 0.9m (36 inches) long by 0.9m (36 inches) wide by 1.8m (72 inches) high.
- d. Weight. Any one cabinet - 680 Kg (1500 pounds) maximum.
- e. Lifting Provisions. Lifting eyes in top cabinet and skids under bottom of cabinet.
- f. Cooling. Water-cooled from closed cycle cooling water system such that no equipment or personnel hazard exists when the '
equipment reaches thermal equilibrium when operating at full
- power.
- g. Interconnections. Interconnecting cables and hoses to be ten feet long.
4.2.3 Closed Water Recirculation System The closed water recirculation system shall conform to the following mechanical requirements:
- a. Mounting. All components shall be mounted on an open steel frame.
This will be located adjacent to the power supply.
- b. Access. Each component shall be mounted for easy access for required servicing or repair,
- c. Dimensions. 2.1m (84 inches) maximum length by 1.5m (60 inches) maximum width by 1.2m (48 inches) maximum height.
- d. Weight. 680 Kg (1,500 pounds) maximum, dry,
- e. Lifting Provisions. Lifting eyes and under frame skid.
- f. Site Water Input. Vendor shall state flow required at 25"C (77'F) maximum inlet temperature,
- g. Closed Cooling. Sufficient flow and water temperature to provide water output necessary cooling to the power supply and work sta-tion when operating at maximum power.
A-5
4.2.4 Cable Assemblies The transmissio , cable assembly and the induction cable assemblies shall be lightweight and flexible. The induction cable may be assembled from indi-vidual conductors at the work-sites.. The transmission cable shall be packaged on a cable reel. 4.2.5 Cooling Water Lines Long cooling water lines shall be packaged on appropriate reels similar to those described above for the transmission cables. 4.2.6 Miscellaneous Items Other items such as heating coils, coil cables and short water lines shall be packaged in reusable containers. The containers shall be designed to provide adequate protection for the components when they are_being trans-ported or stored. The containers shall have skids or lifting eyes as appropriate for ease in handling. The container shall have an easily identi-fiable location for each component which it is designed to hold. 4.3 ELECTRICAL 4.3.1 Power Supply The power supply shall conform to the following electrical requirements.
- a. Input Power. 460 VAC i10%, three-phase, 60 Hz 750 KVA maximum, four-wire.
- b. Output Power. 600 KW minimum at 2700 to 4400 Hz, continuous, single phase,
- c. Output Voltage. Between 600 to 3000 volts,
- d. Power Regulation. 2 percent for all conditions of input voltage fluctuations of 10%.
- c. Power Factor. Greater than 0.90.
- f. Input Power. Input power protection shall be provided as follows; three-phase four-wire, air circuit breaker of 1200 amps rating with low voltage release and single phase protection.
A-6
l
- g. Radio Frequency.~ The power supply shall meet the requirements-of
- Subpart. D of 47CFR18 for Industrial Heating Equipment. .In addi-tion, the Seller shall furnish test data which define the radiated field strengths at distances of one, two, five and ten feet froe the power supply, transmission cable, work station and heat coil while the equipment is operating at the power level specified in
- Paragraph 4.1.1. Measurements shall be made at the equipment operating frequency and at all harmonics up to the tenth.
4.3.2 Work Station i i The work station shall conform to the following electrical requirements:
- a. Input. 600 KW maximum at 2700 to 4400 Hz, single phase at between 600 and 3000 volts.
- b. Output. Up to 5.4x10 5 J/sec (540 KW). Output voltage to be determined by Seller as appropriate for single or multiturn coils.
. c. Power Factor. Creater than 0.80. 4 4.3.3 Closed Water Recirculation System ! The closed water recirculation system shall conform to the following electri-cal requirements:
- a. Input Power. 460 volt 10 percent, three-phase, four-wire, 60 Hz, 10 KVA maximum.
- b. Pump Motor. Three-phase drip-proof design.
l c. Instrumentation. The work station shall accommodate either single [ turn or multi-turn coils as appropriate. i 4.3.4 Transmission cable f The transmission cables between the power supply and the work station shall conform to the following electrical requirements: , n. Type. Coaxial or stranded copper. 1 b. Length. 91.5m (300 feet) . j c. Cooling. Air cooled.
- d. Temperature Rise. Maximum cable temperature rise of 55*C (99'F) when operating at maximum power.
4
- A-7 I
! , , - - = - - _ . . . - . _ _ _ _ , , ._ __ _ . - _ . _ . . _ . . _ _ _ .
- e. Connectors. Appropriate connectors to mate with the power supply and work station will be securely attached to the cable ends.
4.4 LOCATION AND ENVIRONMENT The induction heating equipment shall meet the following environmental conditions: Power Station Work Station
- a. Temperature: 4.4 to 40*C 21 to 49*C (40 to 104*F) (70 to 120*F)
- b. Relative Hunidity: 10 to 90% 10 to 90%
12.1x10-4 MPa 2.1x10-4 MPa
- c. Pressure: ( 'O.03 psig). (i0.03 psig) maximum maximum
- 5. INSPECTION AN'. TESTING 5.1 ENCLOSURE TESTS AND INSPECTIONS 5.1.1 Mechanical Inspection All components shall be inspected to see that they are correctly located in the enclosure in accordance with the applicable drawing and that they are properly mounted, labeled and secured. All wiring shall be inspected for proper insulation and to see that it is routed, bundled and cabled in a neat manner. Crimped connections shall be checked to see that they are secure and that the insulation is proper. Plugs and connectors shall.be checked for loose pins and sections and proper cable clamping.
5.1.2 Performance Test The performance test shall consist of a series of measurements of the electri-4 cal characteristics of the equipment to ensure that performance is in accordance with the design requirements. Additional tests shall be included to verify that the equipment complies with the power transfer, dissipating , limitations, heating, control, electrical interference and equipment cooling , requirements of this specification. A-8 __ . _ __ _. ~.- ,-
Appendix B SPECIFICATION FOR INDUCTION HEATING COILS
- 1. SCOPE Seller shall design and furnish 6 induction heating coils to apply the induction heating stress improvement process to piping configurations marked and dimensioned on the attached sheets as follows:
#1 Cross to Tee
#2 Reducer to Riser Spool
#3 Elbow to Pipe (Riser)
#4 Cross to Header
#5 Header to Sweepolet
#6 Straight Pipe (16 inch)
- 2. REQUIREMENTS
- a. Coils shall be capable of establishing a delta-T of 100 50*C (540 90*F) at least 2t on each side of weld centerline with 1 metet/
second (0.30 ft/sec) of 90*C (194*F) water flow through inside of pipe and maximum 500 50*C (932 90*F) heat zone centerline,
- b. Coils shall be designed to connect to power supply and cable assemblies as provided by buyer. Detail connection require-ments will be furnished later.
- c. Colls to be delivered within 8 weeks of receipt of a purchase order.
B-1
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. _ _ ~ . _ __ . _ _ _ _ _ _ . .
+ 17.8mm 10.5 g (0.70 in. 20.02) 324.9mm DI A *1.0 (PIPE)
(12.79 in. DI A/10.04) (PIPE)
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SECTION A-A SECTION 0-8 i 0 25.4 50.8 76.2 102 127 763.8mm . __ _ (0) (1) (2) (3) (4) (5) lini fi..il i I I l l (30.07 n.) mm (enches) a j 124n. NOMIN AL TEE BR ANCH 3r TO BE TREATED WITH COIL FOR WELD 2 OR COIL FOR WELD 5 Figure B-6. Weld 5 for IllSI Test a 1 i
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Appendix C IHSI DATA ACQUISITION SYSTEM The IHSI Data Acquisition System (DAS) is a NEFF 620S system consisting of a NEFF Series 400 multiplexer and Hewlett-Packard 9825S desk top computer. Additional accessory components are a Hewlett-Packard 7225A plotter, Hewlett-Packard 98035A real time clock, NEFF isothermal thernocouple input terminal and necessary interconnecting cables. The inputs to the system are the millivolt electrical output of Type K (chromel-alumel) thermocouples attached to the work piece. The output is a time history of work piece temperature in degrees centigrade. The thermocouples are connected to the system by 20 gage twisted and shielded Type K extension wire. Up to thirty thermocouple outputs can be recorded with the system. The thermocouple millivolt output is conducted to the system input terminals by thermocouple lead wires. The input terminals are mounted on an isothermal block whoac temperature is measured. This reference junction temperature, together with up to 15 thermocouple signals, are input to each of two 16 channel multiplexer boards. The multiplexer, under control of the computer, connects each signal, in sequence, to the amplifier and analog to digital converter. Af ter conversion and transmission of the digital value into the computer's memory, the multiplexer is instructed to select the next channel. This sequence is repeated until all active channels are recorded, completing the scan. The start of each scan is controlled by the clock. When all scans for a test run are completed, the millivolt digital values are converted to engineering units and stored in the magnetic tape cassette. Each cassette also contains the DAS operating-programs and data recovery programs. Up to two channels of data are also presented to the operator on the computer LED display and the plotter. The operating programs are all contained on track zero (trk 0) of the data cassette. Data are recorded on track one (trk 1). The programs are named and ordered as follows: C-1
FILE O PROGRAM REQUEST MONITOR
- 1 PLOT 2 EDIT
- 3 EXAM
- j 4 DISP 5 INIT*
6 TCHK* 7 Binary file of thermocouple conversion factors 8 TIME
- 9 IHSI 10 DATA 11 IDLE 12 TLIM 13 not used 14 not used 15 Binary file of file management parameters.
16 et. seq., Binary file of channel tag I.D. (acronym) and engineering unit conversion factors for each channel The programs marked with an asterisk are unmodified NEFF programs which are explained in the NEFF 620S programming manual. A brief description of these programs follows: PROGRAM REQUEST MONITOR: Prompts the operator to select an operating pro-gram and run the selected program. It is assessed by turning the power on with the cassette in place. EDIT: Is used to input the channel tag I.D. (4 character acronym) and engineering conversion factors into the analog point specification file. EXAM: Scans each channel, converts to engineering units and points out the value of each active channel. , IHIT: Configures the system for the hardware supplied. This program is not used unless the system size is altered. C-2
TCHK: Scans thermocouple channels for open circuits. TIME: Is used to reset the time of day in the real time clock. Each of the above programs is described by the NEFF System 620S Programming Manual (Version 3). The remaining programs have been written using the NEFF data acquisition pro-grams as a base to incorporate special features required by the IHSI test. The list of variables has been expanded to include those required for these added features such as on-line plotting, automatic recording start, on-line display, etc. The description of these special programs follows. TLIM: Plots selected temperature boundaries from time zero to the maximum and minimum temperature limit line ends. ISHI (modified CSCM): After obtaining the scan identifications, high temperature channel tag, low temperature channel tag, data acquisition auto-start value from the operator, the program loads the analog paint specifica-tion files and organizes the scan file. After obtaining the pipe wall thick-ness, the program draws and labels the on-line plot axes and marks the required data file size. After the operater responds to the question " start?", the program under control of the real time clock, scans all channels and con-verts the data to engineering units. The high and low temperature values are displayed during each scan. No data are retained until after the high temperature exceeds the auto-start value. Thereafter, until the present number of scans is completed, the data are stored and the two preselected temperatures are plotted following each scan. Following the completion of the run, the scan identification, together with the data, is stored on the cassette. Thereafter, control is returned to the Program Request Monitor. PLOT: This program recovers the scan identification of all test data files and prints them, together with the file location on the paper tape. Following the operator's selection of the data file to be plotted, the computer loads C-3
the selected data into memory, prints the channel tags and draws and labels the plot. Following the selection of each channel to be plotted, the plotter plots the stored values for that channel. IDLE: After obtaining the scan identification from the operator, this program draws and labels the axes for a low temperature plot. Following the l request for an on-line channel tag end the operator response to a start I request, the computer will scan all channels at one second intervals for one minute. The temperature of the selected channel will be plotted during the-test run. Following the completion of the test run, the computer.will list the average temperature of each channel and plot the data for each channel. This program does not store data on the cassette. DATA: This program recovers the scan identification of all test data files and prints them, together with the file location on the paper tape. Follow-ing the operator's selection of the data file to be printed, the computer loads the selected file into memory and prints the channel tags. Following the operator's selection of each channel to be listed, the computer prints the data list. DISP: This program lists the channel tags for each analog point specifica-tion file. Following the operator's selection of a channel tag, it will scan the channel and display the channel value in engineering units for approxi-mately thirty seconds. C-4
t l l } Appendix D TEST PLAN AND PROCEDURE 9
l CONTENTS
.Page No.
- 1. TEST PLAN D-2 1.1 Test Objectives D-2 T-1.2 Test Items D-3 1.3 ~ Test Facility Description D-4 1.4- Instrumentation Requirements D-5 1.5 Test Matrix D-5 1.6 Acceptance Criteria D-5 1.7 Safety D-7 1.8 Report Requirements
- 2. QUALITY ASSURANCE PLAN D-7 2.1 Test Item Identification D-7
; 2.2 Test Item Inspection D-8 2.3 Test Facility Inspection D-8 2.4 Test Facility Environmental D-8 Requirements 4 2.5 Calibration Requirements D-8 2.6 Documentation D-9 2.7 Certification of Personnel D-10 i 3. TEST PROCEDURE D-10
- 3.1 Specimen Water Loop Operation D-10 3.2 Data Acquisition System D-11 3.3 Log Book D-11 3.4 IHSI Equipment Installation D-11 3.5 IHSI Equipment Operation D-12 s 3.6 Operator Qualification D-14 1
i i D-1 i
-- . _ . , _ . . _ - , . , . ._ ~ - .~. ,. , . , . , , - , . .
- 1. TES7 PLAN 1.1 Test Objectives -
The objectives of this program are to demonstrate the ability.of induction heating equipment to produce specified temperature gradients in water cooled ; pipe for the purpose of mitigating the occurrence of intergranular stress corrosion and to develop field application procedures for the heat treatment of typical boiling water reactor recirculation piping welds. Specific objectives to be achieved are: 1.1.1 To evaluate the manufacturer's installation and operating procedures in the course of installing, operating and removing the induction heating equipment, and to revise or supplement these_ procedures as required for safe, effective and efficient use. 1.1.2- To evaluate the temperature gradients produced in 4 inch, and 26 inch i pipe specimens treated in accordance with the recommendations of Table 1.1.2 and to select maximum, minimum and optimum equipment power settings and treatment times which will produce acceptable temperature gradients. 1.1.3 To evaluate induction heating coil configurations, equipment power settings and treatment times for the induction heat treatment of representative recirculation piping configurations, orientations and sizes, and to select the maximum, minimum and optimum equipment operating parameters for each case. 1.1.4 To evaluate the ef fect of air pockets at horizontal joints and to develop techniques for the detection and elimination of significant air accumulations. 1.1.5 To develop instrumentation and recording procedures which will provide a permanent heat treatment record. 4 D-2
Table 1.1.2 PRELIMINARY IHSI PROCESS CONTROL PARAMETERS
- 1. Pipe Outer Surface Temperature 500 50*C (932 90*F)
- 2. Minimum Throughwall Temperature 300*C (540*F)
Difference (AT)
- 3. Minimum Width of Zone Heated to 1.5 /Rt (R = Radius AT Minimum and t= thickness)
- 4. Minimum Distance from Weld Center 15 mm (0.6 inch) or t/2 to Boundary of AT Minimum whichever is larger)
- 5. Minimum Heating Time 0.7 t /2 a seconds (a = thermal diffusivity, t = wall thickness)
- 6. Frequency 3 to 4 kHz
- 7. Induction Coil Length 3 /Et Minimum (R = pipe radius, t = wall thickness)
- 8. Minimum Water Velocity 0.5 m/sec (1.64 ft/sec) 1.1.6 To develop training and qualification procedures and equipment checkout and calibration procedures which will assure a controlled induction heat treatment.
1.1.7 To prepare induction heat treated pipe' specimens for further evaluation by others to confirm the effectiveness of the equipment and procedures. 1.2 TEST ITEMS 1.2.1 The following items shall be tested:
- a. 4 inch test specimens
- b. 12 inch pipe sample
- c. 26 inch pipe sample
- d. Recirculation loop piping D-3
- e. Induction heating equipment
- f. Pipe with transition 1.2.2 All the test items shall be returned to the Requestor.
l 1.2.3 The types and quantities of test specimens are shown on Table 1.5 and i Figure 1.5. 1.3 TEST FACILITY DESCRIPTION 1.3.1 The test facility is located near the Atlas Loop in Building B on the Curtner Avenue Site in San Jose, California. It is a temporary instal-lation which shares electrical and other services with the other nearby facilities. It consists of test fixtures containing the test specimens, cooling water tank, circulating pump, piping, electrical controls and instrumentation. The induction heating equipment consists of a static inverter power supply, transformers, work stations, induction coils, closed cooling water supply and interconnecting cables and hoses. The static inverter and closed cooling water supply are located near their water and electrical power sources. The electrical power is obtained from Atlas Loop Substation lA. Electrical current capacity limitations prevent simultaneous operation of the induction heating equipment and the Atlas Loop 2.61x105 J/sec (350 HP) circulating punp. The test fixtures, cooling water loop and induction heating work sta-tions are located about 36.6m (120 feet) south of the static inverter, similar to a field arrangement. The tank, pump, test fixtures and piping form a closed loop in which clean (demineralized water filled) water is circulated through the test specimens. The rate of flow is measured by an orifice meter and controlled by a manual throttle valve. The heat input is rejected to the atmosphere from the tank surfacc. The induction heating transformers and work stations are located near the test fixtures. A bridge crane and nearby jib crane are available to assist in placing the induction heating coils and cables on the test specimens. D-4
The instrumentation consists primarily of temperature measuring and recording equipment. The cooling loop flow meters and induction heating equipment adjustments and meter readings are recorded manually since they are invariant during a heat treatment run. 1.3.2 The test facility shall be dismantled following the test and the parts and equipment returned to the owners. 1.4 INSTRUMENTATION REQUIREMENTS 1.4.1 The test facility instrumentation is shown on the P&ID. 1.4.2 The test specimen thermocouples are chromel-alumel, Type K. Their locations are shown on Figure 1.4.2. 1.4.3 The induction heating equipment temperature monitor and electrical power meters are shown on the vendor drawings. 1.4.4 The data acquisition system consists of a Hewlett-Packard 9825S Desk Top Computer and NEFF Instrument Corp. Series 400 Digital Multiplexer System with 30 data channels. 1.5 TEST MATRIX The tests to be performed are summarized on the test matrix, Table 1.5. They may be performed in any sequence, although specimens C4 and C26 should be tested at the beginning of the program to calibrate the system. 1.6 ACCEPTANCE CRITERIA 1.6.1 The recommended maximum power, minimum power and optimum heat treatment process parameters shall develop a pipe outside surface temperature of 500* cts 0*C (932 90*F) and a throughwall temperature difference of 300*C 50*C (540 90*F) (inner wall temperature of approximately 125*C (257'F)). The surface temperature requirements apply for a distance of S=0.375/Rt, where t is the pipe wall thickness on either side of the weld centerline in straight pipe. The throughwall temperature gradient at the weld centerline at the end of the heat treatment D-5
+S ? q S 7 4S 3 C S+
S = 0.375 8 TC-1 TC-2 TC4 TC4 TC4 w , . . Jk [ TC4 h TC-7 TC4 TC4 90' AND 270 AZIMUTH OUTSIDE SURFACE FLOW TC-13
, d U . -
TC 10
\ TC-11 TC-12 Figure 1.4.2
- 1. Control and safety temperature sensing elements are to measure the temperature of the outside of the pipe at the midpoint of the coil length regardless of the weld location with respect to the coil.
- 2. In cases where the pipe is welded to a part which has an abrupt char.ge in wall thickness the spacing distance 's' is to be the same as for straight pipe.
- 3. If thermocouples cannot be conveniently attached to the inside wall of the pipe or part, they may be installed in holes which have been radially drilled to within 0.51 0.13 mm (0.20 0.005 inch) of the inside surface.
- 4. Spacing does not apply to previously instrumented specimens.
D-6
cycle shall increase monotonically from a minimum at-the outer wall to a. maximum at'the inner wall; that is,.it shall have a "parab'olic" shape. 1.6.2 The minimum-power shall achieve the desired temperatures in a treatment
. time of t=200L .5' seconds, 110%, where L is the pipe wall thickness in
! 1 inches. 1.6.3 The maximum power shall achieve the desired-temperatures in a treatment time of t=105L2 seconds, 10%, where L is the pipe wall thickness in j inches. 1.6.4 The-optimum power shall be selected to achieve the-desired temperatures. i within the maximum and minimum times defined in 1.6.2 and 1.6.3 with - due consideration for tolerable variations in coil placement, coil excentricity, pipe wall. thickness, temperature measurements and other i process parameters. 1.7 SAFETY Test Facility Standard Safety Operation Procedures shall be observed. Any violation or potentially hazardous situation shall be reported to the Test: Facility Supervisor and/or responsible managers and be reported in the test facility log book and in the Incident Report. Specific caution warnings are included in various subsections of this Test Plan and Procedure. 2.0 QUALITY ASSURANCE PLAN A ^ 2.1 TEST ITEM IDENTIFICATION All test items shall be provided by the Requestor, who will retain all certi - fications and quality control inspection records pertaining to these items. Each test item will be identified by the applicable fabrication drawing or specification number together with a heat number, serial number or other i designation required to identify unique characteristics of the item. This identification will be entered in the test log book. A Certification of Test Components shall be prepared by the Requestor and submitted with the test items. i t D-7 1
. - . . . , ,_ , - .- . _,..---m - . , _. ,, , . , , _ . . . . . , _ _ - . - . . , _ -.
2.2 TEST ITEM INSPECTION No inspection of test items identified by fabrication drawing number, specifi-cation number or serial number.i.s required unless it.is modified subsequent to receipt for testing, or if as-built measurements are required by_the test procedure. Such supplementary _ inspections shall be made by qualified personnel using calibrated equipment and the results entered into the test records. No post test inspections are required. 2.3 TEST FACILITY INSPECTION The adequacy of the test facility, exclusive of the equipment under test, to function over the full range of required operating conditions shall be demon-strated by an acceptance test. The Test Facility configuration and acceptance performance shall be verified by the Responsible Test Engineer and the Requestor and entered in the test log book. 2.4 TEST FACILITY ENVIRONMENTAL REQUIREMENTS 2.4.1 The closed cooling water system shall be filled with demineralized or
' soft' water. No further treatment or inspection is required.
2.4.2 The test loop cooling water system shall be filled with demineralized or " City water". No further treatment or inspection is required. 2.4.3 The closed cooling water system shall be cooled with " City water". 2.4.4 The electrical equipment shall be protected from the weather and water, except for interconnecting cables wnich may be run outdoors. 2.5 CALIBRATION REQUIREMENTS 2.5.1 Instruments provided as part of the equipment to be tested and which are used for process control need not be recalibrated. D-8
2.5.2 Data acquisition systems equipment shall be calibrated-to traceable
. National Bureau of Standards (N.B.S.) standards to the greater of 3*C'
. (5.4*F) or il% for ' temperature and 15% for all other parameters by quali-fied personnel prior to start of testing.- Vendor's certification is acceptable evidence of calibration. A test-case data collection will be performed during calibration to verify that the digital output-conforms with the calibration analog input to acceptable accuracy. A copy of the computer program will be included in the design record file.
i 2.5.3 Thermocouple material output shall be verified for conformance to N.B.S. standards by comparison with a calibrated thermometer at room tempera-ture and certified by an entry in the Test Instrument Record and Control Sheet. No additional calibration is required of individual thermocouples. 2.5.4 Orifice meter dimensions shall be measured by qualified inspectors using calibrated equipment. 2.5.5 Instrument identification and calibration data shall be entered in tha Test Instrument Record and Control Sheet. 2.6 DOCUMENTATION i 2.6.1 The control copy of the test procedure shall be maintained at the test facility. I 2.6.2 Test data accumulated by a data acquisition system shall be reduced to. 4 hard copy form and identified by test as soon as practicable following the test. All data, observations, test configurations and a diary of activities shall be entered in a bound log book which shall be main-tained at the test facility. Entries shall be signed and dated by Level 1 or higher test personnel. 1 2.6.3 All test documents and records shall be identified by test procedure and design record file numbers and transferred to the Requestor follow-ing the test for recording and retention. D-9
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2.7 CERT'iFICATION OF PERSONNEL Test personnel shall be certified by to be qualified to perform their duties. In addition, the Responsible Test Engineer or Test Area Supervisor shall certify those test personnel qualified to operate the test equipment by an l entry in the log book. 3.0 TEST PROCEDURE 3.1 SPECIMEN WATER LOOP OPERATION The specimen wate- loop supplies the cooling uater to the interior of the pipe specimen during the IHSI heat treatment. It is always put into operation prior to heating the pipe. 3.1.1 Prior to operating the specimen water loop, visually verify that the:
- a. pipe specimen is securely connected to the loop,
- b. tank is filled to within 0.6m (2 ft) of the top,
- c. pump suction valve HV-1-21 is open; and,
- d. flow control valve HV-1-22 and all other loop valves are closed.
3.1.2 Start the pump and slowly open the flow control valve until the desired flow rate (about 1/2 meter /second (1.64 f t/sec) specimen flow velocity) is indicated on the flow meter FI-1-32. If the 4 inch test section is used, set the pump flow at not less than 1890 t/ min (500 GPM), and adj us t the flow control valve HV-1-24 to obtain the desired flow rate as indicated by flow indicator FE-1-35.
-CAUTION-DO NOT OPERATE THE PUMP AT LESS THAN 1890 1/ min (500 GPM) FOR EXTENDED PERIODS TO AVOID OVERHEATING AND UNBALANCED IMPELLER FORCES.
3.1.3 Open and close high point vent valves to remove trapped air from the system and ensure uniform cooling of the specimen. 3.1.4 To shut the loop down, close the flow control valve and turn off the pump. D-10
3.2 DATA ACQUISITION SYSTEM Refer to the equipment manuals for specific operating procedures. l l 3.2.1 Prior to data collection from a newly installed test specimen, the thermocouples and data acquisition system shall be calibrated at isothermal ambient temperature by comparison with a calibrated thermo-meter. The other data channels, if any, shall also be checked at this
- time.
3.2.2 Binary data shall be identified by test run and shall be traceable to a specific specimen treatment. Binary data shall be reduced to graphic or print form as soon as practicable following collection. t 3.3 LOG BOOK 3.3.1 A bound log book, together with the control copy of this procedure, shall be maintained at the test facility. This log book shall contain entries by test technicians and engineers including, but not limited to:
- a. a diary of test activities commencing with the facility shakedown test and/or IHSI equipment installation,
- b. Instrumentation identification and calibration,
- c. installation procedure details and critical observations,
- d. sketches and/or photographs of test setups,
- e. identification of test specimens, test run, process parameters, and results for each test run; and,
- f. estimates of elapsed time for installation, operation, and removal of equipment.
3.3.2 All entries shall be signed and dated by Level 1 or higher test personnel. 4 1 3.4 IHSI EQUIPMENT INSTALLATION The IHSI equipment shall be installed in accordance with the manufacturer's instructions supplied with the equipment. D-11
s 3.4.1 ~ The time, effort and equipment required shall be recorded in the log l book together with critical comments. The installed configuration shall be recorded by sketches or photographs and verified by the-Requestor and the Test Engineer for'conformance with the Manufacturer's instructions. l 3.5 IHSI EQUIPMENT OPERATION ! 3.5.1 The IHSI equipment shall be operated in accordance with the manufac-turer's operating instructions supplied with the equipment. I i -WARNING-IF THE INTERLOCKS ARE DISABLED AND THE MAIN POWER SUPPLY CIRCUIT + BREAKER IS ON WITH THE DOOR OPEN, LETHAL VOLTAGES ARE EXPOSED. THERE IS ALWAYS 460VAC PRESENT BEHIND THE CONTROL CIRCUIT POWER
- SUPPLY BREAKER AND ON THE LINE SIDE OF THE MAIN POWER SUPPLY CIRCUIT BREAKER CARE SHOULD BE EXERCISED AT ALL TIMES WHEN THE DOOR IS OPEN. POWER SHOULD BE REMOVED BY OPENING THE FEED BREAKER 1A5 EXTERNAL TO SUPPLY BEFORE WORKING WITHIN THE POWER
- SUPPLY CABINET.
WORK STATION CABINETS AND CONNECTING CABLES OPERATE AT LETHAL VOLTAGES AND POWERS. POWER SHOULD BE REMOVED BY OPENING THE POWER SUPPLY MAIN BREAKER FIRST. AND THEN LOCKING THE EMERGENCY STOP PRIOR TO WORKING WITHIN-THE WORK STATION OR HANDLING COILS' OR CABLES. 3.5.2 The sequence of operations required to heat treat a specimen is as follows:
- a. Verify that feeder breaker lAS and motor control center breakers H1 (feeder breaker 1C4) and L1 (feeder breaker lA3) are open and locked out prior to setting up the equipment.
- b. Mount the coil on the pipe specimen with the coil positioned over the weld and concentric to the pipe. Record the actual position i to the nearest millimeter.
- c. Mount the temperature detector so that it measures the maximum
! weld surface temperature. Connect additional thermocouples.Das - required.
- d. Connect the water cooled output cable to the coil and couple all cooling water hoses.
3
- e. Check out the instrumentation and data acquisition system.
1 ? D-12
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- f. Close the motor control center ' breakers H1 and L1.
- g. Start the closed cooling water pump, check the cooling water connectiona for leaks.
- h. Start the cooling water loop, set the flow rate and check for leaks.
- i. Clear all protective interlocks and set the power adjustment to zero.
-WARNING-LETHAL VOLTAGES ARE EXPOSED WITHIN POWER SUPPLY AND WORK
, STATION CABINETS AND AT COIL AND INTERCONNECTING CABLE CONNECTIONS. CABINET DOORS SHOULD BE CLOSED AND COILS AND CONNECTIONS CHECKED FOR PROPER' ASSEMBLY AND THE TEST AREA VACATED PRIOR TO CLOSING FEEDER AND MAIN BREAKERS.
- j. Close the feeder breaker lA5 and the main power supply breaker.
-WARNING-OPEN THE POWER SUPPLY MAIN BREAKER AND LOCK THE EMERGENCY STOP PRIOR TO WORKING WITHIN THE WORK STATION CABINETS OR HANDLING COILS OR CABLES.
- k. Turn the power supply output on and verify that the load resonant frequency is 3000 Hz 300 Hz. .If not, turn off the power supply, open the power supply main breaker, lock the emergency stop, and adjust the work station capacitance and transformer tap as required to obtain the desired frequency. Repeat the procedure starting at h.
- 1. Adjust the treatment time limit to r! e time specified by the test data sheet, l.
- m. Adjust the power level to the % power specified on the test data sheet.
- n. Adjust the temperature limit to 200*C (392 F).
-CAUTION-THE INDUCTION HEATING COILS AND CABLES OPERATE AT HIGH POWER LEVELS TO HEAT THE WORK PIECE WHICH MAY ALSO HEAT ADJACENT METAL STRUCTURES. EXERCISE CAUTION FOLLOWING HIGH POWER OPERATION TO AVOID TOUCHING HOT SURFACES.
D-13
s
- o. Turn' the power supply output on. Monitor the rate of temperature-rise and temperature distribution. If as specified, continue. If-not, adjust the power level, coil position, or work station voltage.
as' required. Repeat the procedure at the preceding step appropriate to the action taken.
- p. Adjust the temperature limit to 575*C (1067*F), . turn the power supply '
output on and heat the- pipe for the specified time and temperature. (For repeated treatments, return to K.) 4
- q. Turn off the power supply output, open the main breaker, lock the emergency stop, turn off the closed cooling water supply pump, turn off the specimen cooling loop pump.
i
- r. Remove the cables, hoses and coil after test sequence is completed.
3.5.3 The time, effort and equipment required to perform each step of a heat. i treatment cycle shall be recorded in the log book together with critical comments. 3.6 OPERATOR QUALIFICATION IHSI operators shall be qualified to operate the equipment by pcsetical i demonstration of their knowledge, judgment, and skills in a safe manner while observed by a certified operator and the area supervisor during at least five error-free heat treatments. Certification of qualification shall be entered in the log book. 4 I 4 I j ] i D-14 I
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0, Appendix E TRAINING AND CERTIFICATION PROGRAM OUTLINE
- 1. INTRODUCTION Background of IGSCC - GE's approach to mitigate and how ISHI fits this program.
- 2. PROCESS DESCRIPTION Overall view of the process, what it accomplished and how it is
, controlled.
- 3. EQUIPMENT DESCRIPTION An introduction into the basic equipment used and how they are controlled.
- 4. EQUIPMENT DEMONSTRATION AND DETAIL Detailed explanations at each piece of equipment describing all parameters monitored, alarms and major components. 'This is followed by a performance run to show how each of the pieces performs during a satisfactory _
performance.
- 5. EQUIPMEiT PREOPERATIONAL CHECKOUT A review of each piece of equipment with checklists to show the exact condition the equipment should be in prior to performing a treatment.
- 6. EQUIPMENT FAMILIARIZATION Personnel will be able to examine equipment in their own way and all will be able to operate the equipment (each person to become familiar with the equipment and gain a feel for its operation).
- 7. CAPACITANCE AND FREQUENCY MATCHING Explanation as to why the frequency selected is important. The effect of improper frequency; capacitance and inductance of a balanced circuit.
What happens if not balanced. I E-1
- 8. COIL PLACEMENT The inductor coil will be discussed in relation to how it performs its job. The concepts and limitations on installation will be discussed.
This will include details of installation on different types of welds and why the installation is done using certain methods.
- 9. THERM 0COUPL PLACEMENT l
l A discuss on about installipg thermocouples on piping, why the location I and what;must be done on removing the thermocouples. is as sho
- 10. THERMOCOUPLE - -
TION AND REMOVAL PERFORMANCE Must be performed and signed by demonstrating proper installation technique and removal including NDE techniques used.
- 11. PRACTICE PERFORMANCE ON TREATMENT Each will perform a complete performance to include pre-op checks start-ing and treatment run. At least one error-free performance is required from everyone.
- 12. DATA ACQUISITION An explanation of all parameters monitored. How is it monitored, displayed and used for documentation. How is the computer programmed and used.
- 13. EQUIPMENT TROUBLESHOOTING An explanation of the normal problems that have occurred to date. A look at all parameters and how they can tell you where the problem is.
A review of all information provided by the vendors concerning equip-ment problems.
- 14. EQUIPMENT OPERATION Changing capacitor configurations and how this is shown on indications.
- 15. PRACTICE OPERATION Coil installation teenaiques will be practiced.
- 16. PROCESS FIELD PERFORMANCE A description of how the field performance will be done in relation to inside and outside containments.
- 17. SETTING EQUIPMENT UP ON SITE An explanation of how equipment will arrive at the site and the equipment checkout that must be performed. This will include setups on the dummy pipe.
E-2
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! 18. SHIPPING AND HANDLING How will equipment be prepared for shipment off Iite. / 1
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i 19. DIFFERENT JOINT CONFIGURATIONS l An explanation of what type of configurations we expect to eacounter and action plan on how to set up each. ('
- 20. FINAL PERFORMANCE REVIEW
. /
At least one error-free performance in the presence of the Program Manager who records final certification. - ). f
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i. Appendix F r IllSI GENERIC PROCESS PROCEDURE h' t i i 'j I T
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l 1 CONTENTS 1.0 PURPOSE F-2 l 2.0 APPLICABLE DOCUMENTS F-2 . 2.1 Supporting Documents t 2.2 Codes and Standards F-2 3.0 CENERAL F-2 i 3.1 Process Description and General Requirements F-2 3.2 Equipment Description and Functions F-3 )' ] 3.3 Process Requirements F-6 4.0 PREPARATIONS F-6 4.1 Site Preparation F-6 F-7 4 4.2 Equipment Preparation i 4.3 Personnel Preparation F-7 1 5.0 INSTALLATION F-8 I 5.1 Cables and Hoses F-8 5.2 Power Supply and Equipment Cooling Water System F-9 5.3 Work Station and Step-Down Transformer .F-9 ; 5.4 Instruments F-10 5.5 Thermocouples F-10 5.6 Coil Installation F-13 6.0 OPERATION F-13 6.1 Initial Equipment Checkout and Operation F-13 6.2 Pre-Treatment Checkout F-14 6.3 IDLE F-15 j 6.4 Preparation for Weld Treatment F-15 [ 6.5 Power Application F-16 6.6 Coil Removal F-16 7.0 EQUIPMENT RDIOVAL F-16
- 7.1 Decontamination F-16 i
7.2 Removal Preparation F-17 7.3 Dismantling F-17 l 8.0 QUALITY CONTROL- F-18 l i 8.1 Records F-18 8.2 Approvals F-19 Attachment A Process Parameter Requirements F .!0 Attachment B Sample Weld Treatment Preparation Instructions F-22 l [ p_1 ,
- - _ - .-,.- ,~ _- - _ - _ . - . _ , . . . , - .. - ,_ , -
~_ - . . . - . . - _- .-. _ _ _ __ - . _ .
1.0' PURPOSE I 7 1.1.This procedure describes in general terms, the equipment, personnel, practices and safety considerations necessary to apply the Induction Heating l Stress Improvement (IHSI) Process to butt welded piping assemblies.
! 1.2 USE
! To guide the planning of IHSI application for specific plants and to fulfill CE/EPRI 1394-1 contract requirements. 3 2.0 APPLICABLE DOCUMENTS r 2.1 CODES AND STANDARDS l The following codes and standards, latest or specified issue, form a part of the procedure to the extent specified. I { 2.1.1 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code
- a. Section III, Division 1, Subsection NB Nuclear Power Plant Components
- b. Section XI, Division J , Rules for In-Service Inspectipn of Nuclear Power Plants }
- c. ASME Code Case N252, Low Energy Capacitance Discharge Welding Method for Temporary or Permanent Attachments to Components and Supports.
3.0 GENERAL i 4 . 3.1 PROCESS DESCRIPTION AND GENERAL REQUIREMENTS I r 3.1.1 Description The IHSI process rapidly heats the outside of a pipe to approximately 500*C (932*F) by electromagnetic induction while the inside of the pipe is cooled by flowing water at ambient temperature. This thermal gradient causes plastic 1 deformation of the inside and outside surface regions which result in p re manent residual compressive stresses on the inside surface of the pipe. When the
, 1
. F-2 i
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process is applied to a butt weld region in a piping system, the compressive stresses mitigate the possibilities of intergranular stress corrosion cracking , in' the heat affected zones adjacent to the weld. Process times range from approximately 20 seconds for 4 inch Schedule 80 pipe to 11 minutes for 762mm (30 inch) 0.D. x 63.5mm (2.5 inch) wall pipes. Required power input to the coil varies from approximately 3.0 to 4.2x10 5 J/sec (300 KW to 420 KW) depend-ing on pipe size. 3.1.2 Ceneral Requirements The IHSI process shall treat a given weld configuration to produce parameters within the range listed in Attachment A in both the circumferential and axial directions. 3.2 EQUIPMENT DESCRIPTION AND FUNCTIONS i 3.2.1 General Description The equipment for the process converts 460V, 3 phase, 60 cycle power to single phase 3 to 4 KHz power at variable voltage up to 800V. The power supply output voltage is transformed to approximately 3000V for transmission to the work area through air cooled cables which can be up to 150 meters (492 ft) long. At the work site the voltage is transformed to approximately 800V for input to the work station. The work station contains a capacitor bank and multiple tap i transformer which are connected as required to create a resonant circuit with 4 any given coil and pipe configuration. Fifteen meters (50 ft) of water cooled cables connect the work station to the coil. These cables are flexible and of l suf ficiently low weight to permit manual manipulation to various weld loca-tionc. A closed loop cooling water system is used to cool the power supply, the work station, the step-up and step-down transformers, the connecting cables and the coil. The coils are split into halves longitudinally to permit installation on the piping system. Connections between the two halves can be bolted or clamped and one side may be hinged. Cooling hose connections to the coil are made with quick connect *self sealing fittings. F-3 i
W;ien installed at a reactor site the power supply, controls and the cooling water system are located at a convenient location on the outside of the drywell. The work station (s) is (are) positioned in the drywell at a location (s) which permits connection to as many welds as possible with the water cooled cables, while presenting a minimum impediment to other drywell activities. Also located near the work site is a Lock-Out Switch and Emergency Stop Button which are used to prevent starting the machine while installation work is in progresa and to manually stop the machine in the event of any emergency situation. 3.2.2 System controls System controls consist of the fallowing:
- a. Primary circuit breakers at the point of power tie.
- b. Manually operated circuit breakers or fused disconnects at the power supply (converter) and cooling water system.
- c. On-off push buttons at the power supply and the cooling water system.
- d. Output power adjustment knob.
- e. Timer to limit duration of heat cycle.
- f. Automatic proportional temperature control (optional).
3.2.3 Inst rumentation The following instruments are required for monitoring-the process and the equipment operation.
- a. Temperature vs time plotter and/or recorder to monitor designated control points on pipe,
- b. Cathode ray tube (CRT) to monitor all temperatures and other select parameters at all times.
- c. Output power meter.
- d. Frequency meter.
- e. Power status lights (on/off).
- f. Equipment cooling water flowmeters and indicators.
- g. Equipment cooling water pressure gages.
F-4
- h. Data acquisition system to record all pertinent data. This equip-j ment may include or be redundant . to items a. and b. above.
l l i. Pipe cooling water flowmeters in reactor control room. 3.2.4 Safety Features A variety of devices are provided which protect personnel, the system pipe and the equipment from electrical and heating hazards.
- a. Circuit breakers and/or fuzed disconnects protect against overloads
- or short circuits.
- b. The lock-out and emergency stop switches at the work site prevent
, machine starting when installation work is in progress and provides a means of instantaneous stopping in the event of any ' abnormal condition.
- c. Interlock switches on all equipment enclosure doors and covers preclude equipment operation if they are open or not in place..
- d. A maximum temperature instrument and switch stops the equipment if
, maximum permissible temperature is reached on the pipe being treated.
- e. An automatic timer limite the duration of the heating portion of the ,
i cycle.
- f. Flow, temperature and pressure activated switches installed in the i equipment cooling system preclude machine operation if an out-of-tolerance specification condition exists.
I g. Monitoring devices and circuits within the power supply preclude operation or give warning if faults exist at the power supply or at the load. 3.2.5 Equipment Checkout Test Pipe Stand 4 In order to verify the integrity of the machine assembly after initial setup at a site or af ter any significant change or repair, a dummy pipe and coil ! combination is included as part of the equipment. Pipe size should be between 20 and 24 inches to be representative of an average size pipe and to enable the equipment to be operated at a high power output. Cooling of the pipe can be achieved by hose connections to a water source and drain or by open
. pot boiling to the atmosphere. It is estimated that approximately 11 Kg (25 lb) of water will be evaporated in a 5 minute period of testing with a 22 inch Schedule 80 pipe.
F-5
3.3 PROCESS REQUIREMENTS 3.3.1 Temperature, Time and Zone Dimension The process is required to heat the specified zone within the time, temperature and axial distance specified by governing documents. The required values are given in Attachment A. 3.3.2 Water Flow To obtain the optimum temperature differential between the inner and outer surfaces of the pipe, water contact on the inner surf ace is essential Requirements are listed in Attachment A. 3.3.3 Monitoring Pipe external surface temperature monitoring is essential to verify the adequacy of the treatment. Internal monitoring by thermocouples or similar device is not practical in existing piping systems but qualified water flow rate measurements assure proper inner wall cooling. Externally, thermocouples shall be placed to monitor circumferential temperature uniformity and axial temperature profiles over the specified heated length. 4.0 PREPARATIONS 4.1 SITE PREPARATION 4.1.1 Piping Preparation All piping to be treated must be prepared as recommended in the site survey which is completed prior to the IHSI process and in accordance with the QA requirements in effect for the piping system. . Pipe insulation, obstructions and interferences must be removed and hoist and hanger anchors must be installed. The pipe is to be cleaned or conditioned where necessary. 4.1.2 Access and Equipment Locations Proposed equipment locations and access to these locations must be cleared and - opened. F-6
.. . ..- . =. . . . . . _ -_ _. . - - - = _ . - -
4.1.3 Service Requirements Service connections must be provided in appropriate areas for electricity, water, compressed air, etc., as required. 4.2 EQUIPMENT PREPARATION 4.2.1 Equipment Inspection and Inventory
; Upon arrival at the site, all IHSI equipment is to be inspected for shipping i ,
i damage and a complete inventory of components and parts shall be made, j- 4.2.2 cleaning of components Flush all equipment cooling pipe, tubing and hoses with demineralized water to remove all traces of ethylene glycol which was added to prevent freezing i during shipping and storage. This step is to be performed only when no further 1 exposure to freezing conditions is likely to occur. 1 4.2.3 connections All electrical connections rade with threaded hardware shall be inspected for proper tightness. T 4.2.4 calibrations An instrument check and calibration is to be performed after the components are in place and all physical installation work is complete. i 4.3 PERSONNEL PREPARATION 4.3.1 Supervisory Qualifications All supervisory personnel must have previous experience working with the equipment in use and the process. This experience shall be acquired through 4 a formal training program. i 1 1 i F-7
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4.3.2 Operator Qualifications Each operator shall receive instrue. tion on the control and manipulation of the equipment involved. Each operator shall operate the equipment on the mockup pipe prior to treating plant welds. 4.3.3 Personnel Training All other personnel must attend a lecture explaining the process and the equipment. All safety aspects shall be thoroughly covered to assure the safest possible operation. 5.0 INSTALLATION Note: Installation of the components in the drywell is to be performed af ter completion of initial equipment checkout as described in Section 6.0 of this procedure. 5.1 CABLES AND HOSES If the cables and hoses are contained on reels and it is not planned to leave the recis in the immediate area, the cablee and hoses should be roughly placed and the reels removed before other major pieces of equipment are brought into place. 5.1.1 The cables and hoses should be routed and suspended so as to present a minimum impediment to other activities in the area. 5.1.2 In any area where the cables or hoses are exposed to any damaging hazard such as personnel or equipment traffic, or heat from welding processes, adequate protection is to be provided. 5.1.3 Whenever individual cables are used for any alternating current transmission, regardless of frequency, they are to be bound together in pairs of multiple pairs so that the electromagnetic fields cancel each other. Binding is to be done at intervals of 760mm (30 in.) or less using a durable, non-metallic material. F-8 i
5.1.4 In any instance where cables cannot be paired such as at the coil terminations, no extraneous metallic object except the coil and the pipe is to be permitted within 150mm (6 in.) proximity to the cable. l 5.1.5 The cables are not to be looped (coiled) and an individual cable or pair shall not be crossed back over itself. "S" turn switchbacks shall be used to take up excess length. 5.2 POWER SUPPLY AND EQUIPMENT COOLING WATER SYSTEM These components are contained in self standing cabinets. They are to be placed as close as possible to the drywell access in a position and location which will allcw operating personnel free access to controls and instruments while at the same time presenting minimum interference to other activities in , the immediate area. Other location factors which must be considered are the routing of input and output cables, the cooling water hoses and instrument connections to the recording system. 5.2.1 After all electrical connections are complete, all threaded hardware used to make the connections is to be checked for proper tightness. 5.2.2 Install covers and protective devices as provided for personnel and machine protection. 5.2.3 Ground all cabinets and enclosures as required. 5.3 WORK STATION AND STEP-DOWN TRANSFORMER 5.3.1 Locating Equipment in the Drywell The work station and step-down transformer are contained in free standing cabinets which have integral suspension attachment devices; i.e., the cabinets may be placed on a supporting structure such as a catwalk or suspended from above with chain or cables. These components are installed in the drywell in a position which satisfies the following requirements,
- n. The units are to present a minimum impediment to all activities in the area.
F-9
r
- b. The work station must be- accessible to' operating personnel for -
adjustment of transformer and capacitor combinations.
- c. Connection between coil and work station with a 15.2m (50 f t). long water cooled cable must be possible for a maximum number of welds by moving the cable and coil cooling hoses only. This requirement holds whether single or multiple work stations are used.
I 5.3.2 Connections
- a. Connect all cables and hoses as required and check all connections for proper tightness.
b' . Connect grounding straps or cables to the step-down transformer and work station cabinets,
- c. Install covers and protective devices.
5.4 INSTRUMENTS 5.4.1 Instruments which are permanently mounted in the power supply or other-equipment require no installation. 5.4.2 Data Acquisition System The primary external instrumentation required for the assembly is a data acquisition system or suitable recorders for temperatures. These units can be placed on a table or bench located in close proximity to the power supply and control console. The bench or table should be of sufficient size to also provide a writing surface for making entries in log books and on data sheets.
- 5.4.3 Flow and Other Miscellaneous Gages These instruments will be installed and calibrated as the components are assembled.
! 5.5 THERMOCOUPLES i l 5.5.1 Types and Attachment Techniques Type K or Chromel-Alumel thermocouples are used for all~ pipe temperature measurements. Wires approximately 0.79mm (1/32 in.) in diameter with braided glass insulation are individually spot welded to the pipe wall to form the F-10
junction in accordance with ASME Section XI allowable practice and governing system requirements. The length of these wires must be sufficient to locate the connection to the thermocouple extension wire twelve inches or more beyond the end of the coil in either direction. 5.5.2 connectors Connection between thermocouple and extension wires is made with polarized plugs and jacks specifically made for this purpose. Lead wires can be a multiple cable with polyvinyl insulation and aluminized mylar shield. 5.5.3 Routing The lead wire cables are routed to the monitoring and recording systems by a route which minimizes exposure to physical damage and abuse. Exposure to extraneous electromagnetic fields which might induce noise into the system must also be avoided. 5.5.4 checking Proper installation and connection of the thermocouples is initially checked by reading the output signal on the cathode ray tube (CRT) display. All correctly installed couples will give the same steady ambient readings. 5.5.5 Location of Thermocouples Location of thermocouples will be as prescribed for a particular weld on the data sheet which will give all pertinent information required for the treatment of that weld. See Appendix B. Different pipe / fitting / valve / coil configurations may require individual consideration and thermocouples will be attached at points which satisfactorily monitor the pipe heat affected zones and the maximum temperatures generated by the coil. On an ideal straight pipe configuration, the axial treatment zone length defined by 1.5 /Rt will be divided into four equal lengths which are 0.375 /Rt long. Five thermocouples will be positioned at the ends of these divisions as shown on Figure F5-1 on i at least one azimuth with additional couples installed on the pipe heat affected zones on the remaining azimuths spaced at 90*. f 4 F-ll
4 3.05 > h 1.5 5 + COIL % g 0375 8
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Figure F5-1. Thermocouple Locations F-12
5.6 COIL INSTALLATION i 5.6.1 Initial Placement Af ter the thermocouples have been installed and checked, the coil is installed in accordance with the special instructions provided for the particular weld being treated as specified in Attachment B. These instructions specify method of support, positions with respect to the weld, cable connection orientation, cooling water hose connections and protective blanket installation. 1 5.6.2 Flow and Leak Inspections Af ter all connections are complete, the cooling water system is turned on and flow through all parallel cooling paths is checked by observing the in-line flow indicators. At this same time the assembly is inspected for leaks. 6.0 OPERATION 6.1 INITIAL EQUIPMENT CHECK 0UT AND OPERATION 6.1.1 After the power supply, the equipment cooling system, the control console and the recording system are in place and properly connected to electrical power and cooling water sources, a step-down transformer and work station are to be connected to a coil which is installed on the Checkout Test Pipe Stand. An initial operational checkout is to be performed according to the following procedure. 6.1.1.1 Actuation Sequence,
- a. Fill Checkout Test Pipe Stand with water from either the sanitary water supply or demineralized water if it is available.
- b. Unlock circuit breakers and cabinet doors as necessary and close all circuit breakers.
- c. Open cooling water system valves and turn the cooling system pump on.
- d. Check in-line flow indicators in coil hoses for flow in all parallel branches.
F-13
- e. Clear all fault lights as prescribed in power supply manual,
- f. Complete pre-operation checkout procedure as prescribed in power supply manaal.
,g. Prepare data processing and recording systems for operation.
6.1.1.2 Power Application.
- a. Set power output control knob to 100% position.
- b. Turn power on and monitor all temperatures on CRT.
- c. When highest temperature reaches the maximum value as specified in Attachment A, turn power off.
- d. Open all circuit breakers and turn lock out switch to off.
6.1.1.3 Dismantling,
- a. Disconnect cables, hoses and thermocouples from coil, work station and step-down transformer for subsequent installation on reactor piping system.
6.2 PRE-TREATMENT CHECKCUT 6.2.1 Activation Sequence , a. Before operation, all electrical and water connections which were made up for the first time shall be checked for proper fit and tightness.
- b. Verify reactor recirculation water flow through pipe if induction heating equipment is installed on reactor system by contact with reactor control operator,
- c. Set power control to lowest setting and high temperature trip point at 250*C (482*F) .
- d. Unlock circuit breakers and cabinet doors as necessary and close all circuit breakers.
- e. Open cooling water system valves and turn cooling water system valves and twin cooling vater system pump "on."
- f. Check in-line flow indicators in ccil hoses for flow in all parallel paths.
4 F-14
- g. Turn lock-out switch at work site to " operate" position.
1 i
- h. Clear all fault lights as prescribed in power supply manual.
- i. Complete pre-operation checkout procedure as directed in the power supply operating manual.
- j. Prepare data processing system for operation.
6.3 IDLE 6.3.1 Initial Low Temperature Thermal Range and Profile Test
- a. Set pcuer level control at approximately 6x100J/sec (60 KW) output.
- b. Turn power on and leave on until temperatures are stable at equilibrium conditions. No temperature is to exceed 250*C (482*F).
- c. Turn power off and inspect temperature traces for proper functioning of thermocouples and for range of temperatures from minimum to maximum.
6.3.2 Adjustments for Electrical Positioning
- a. If the range of temperatures is greater than the permissible range as specified for that particular weld the radial positioning of the coil with respect to the pipe must be adjusted. Temperatures are increased by moving the coil turns closer to the pipe wall.
- b. Repeat 6.2.1 and 6.2.2.a until a satisfactory range of IDLE temperatures is attained.
- c. Select the highest and the lowest reading thermocouples within the 1.5 /Rt axial distance span for monitoring during the treatment cycle and set up the recording system to display these two temperatures as a minimum.
6.4 PREPARATION FOR WELD TREATMENT
- a. Close all breakers, set lock-out switch on " operate", set power output control at specified setting for weld being treated and prepare recording system for operation.
- b. Verify that equipment cooling water system is on and functioning '
properly.
- c. Verify that reactor cooling water is being circulated in the pipe being treated.
- d. Reset the high temperature trip to 575*C (1067 F) .
F-15 l
6.5 POWER APPLICATION
- a. Turn power on and continuously monitor the high and low temperatures as a minimum. Adjustments to the power output may be made.during the cycle to bring the temperatures within the prescribed temperature range and also satisfy the elapsed tiac period requirement as speci-fled in Attachment A.
- b. Turn power off when the following conditions are met:
- 1. The lowest outside pipe surface temperature reaches the minimum value of the treatment range in a time period that is equal to or greater than the minimum time specified in Attachment A.
- c. Open all circuit breakers and turn lock-out switch at work site to off.
- d. Turn the recorder off af ter temperatures return to near-ambient values. The cooling part of the temperature trace is important in that it verifies proper cooling on the inside of the pipe.
- e. Verify from recorded temperature data that the treatment met specified parameters before removing coil or disconnecting cables.
6.6 COIL REMOVAL
- a. Disconnect cooling hoses and cables from coil and move ends to next work location.
- b. Remove coil.
- c. Remove thermocouples and holding tabs. Condition the surface as specified by Paragraph 2.2.1.b and the governing QA requirements for the system.
- d. Leave weld joint exposed for post treatment examination.
7.0 EQUIPMENT REMOVAL 7.1 DECONTAMINATION All induction heating components which may have been exposed to possible contamination with radioactive substances are to be moved to proper controlled areas where decontamination is to be performed and final disposition determined. F-16
7.2 REMOVAL PREPARATION If there is any possibility of the equipment being exposed to freezing i conditions before the next usage, the cooling system must be protected by flushing with a glycol water mix. This procedure is to be performed af ter all operation is complete but before the various components are disconnected from the closed loop cooling system. The cooling system pump must not be discon-4 nected from the electrical power source until this procedure is performed.
- a. Drain the cooling system sump to a level that barely covers the pump suction port in the sump.
- b. Add ethylene glycol to the remaining water in the sump.
- c. Open all valves in the system and circulate the coolant throughout the system for ten minutes or longer.
- d. Turn off the pump and open all circuit breakers.
7.3 DISMANTLING 7.3.1 Disconnect all electrical leads at both the source and at the equipment components. 7.3.2 Remove electrical conduits, raceways or trays as appropriate and ccnnecting wires and move to scrap or salvage area. a 7.3.3 Remove closed cooling water system hose connections starting at the lowest point and drain various components as disconnecting process progresses. 7.3.4 The power supply, control console and cooling water-system are to be moved to any convenient location for placing in shipping containers, then crated and moved to the shipping area. 7.3.5 If hoses have been in a radioactive area, decontamination may be i necessary af ter which final disposition is to be determined. Hoses are then to be moved to either a convenient location for loading on the shipping and i storage reels or to a disposal area. F-17
- 4. ,
7.3.6 Hose and cable reels are to be moved to a convenient location for loading these two pieces of equipment and the reel drive connected to a 440 volt, 3-phase weld supply outlet.: The near end of the hoses are to be attached to the reels and loaded onto the reels by pressing the proper control buttons on the face of the reel electrical control enclosure. The drive is to be " bumped" first to assure proper direction of rotation. In order to prevent high tensile loads on the cables and hoses due to friction drag against various structures, successive loops are to be " walked" through starting from the far end. These loops are to be taken up at the reel by repeated starts and' stops of the reel. 7.3.7 Disconnect reels from the electrical power source, secure the ends of the hoses and cables to the reels'and move the reels to the shipping area. 7.3.8 All of the induction heating coils are to be examined for possible 4 contamination, decontaminated if necessary and moved to a location where the cooling water remaining in the turns is to be blown out by the use of service - l' compressed air. i i 7.3.9 Place each coil in the permanent shipping and storage container and move to shipping or storage area as appropriate. 8.0 QUALITY CONTROL 4 8.1 RECORDS i 8.1.1 The following permanent records shall be made on each weld treated:
- a. A data sheet which shows
- 1. Treatment number
- 2. Weld identification
- 3. Date and time of treatment
- 4. Name of responsible operator
- 5. Power setting F-18
__ -. _ _ . , . . - ._. - - _ ._._,__ _ _ . . _ _ . _ _ . __ . . - . _ . ~ _ _ _ - .
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- 6. Frequency =
- 7. Type and model number of coil used
- 8. Location of all thermocouples monitored.
I
- b. Temperature vs time plots of all thermocouple readings during treatment. Each trace shall be clearly identified.
8.1.2 A file containing copies of operating personnel certifications or a list of approved operators shall be kept and shall be available for inspection at all times. 8.1.3 A file of current certified instrument celibrations records shall be kept for all primary data measuring instruments and shall be available for inspection at all times. 8.1.4 All secondary instruments such as equipment cooling water flow devices, pressure gages and temperature indicators shall bear tags attesting to current calibration. 8.2 APPROVALS 8.2.1 Each original data sheet is to contain appropriate signature _ blocks for approval signatures by QA personnel and process supervisor which verify that the treatment data did or did not comply with process specifications. I I 8.2.2 Each original data sheet is to contain a signature block for signa-tures which verify that all primary instruments were under current calibration at the time of the treatment. F-19
V T Attachment A a Process Parameter Requirements
?
Al '- Pipe Cooling Water Flow
- a. Horizontal Tnd vertical (flooded) 0.5 m/sec.
(1.64 ft/sec.) 1 b. Horizontal with air pockets 1.2 m/sec. (4 ft/sec.) A2 - Time and Temperature
- a. Temperature range at outside surface: 500 75'C (932 135'F)
- b. Minimum time to reach outside surface temperature range: 0.7 t2a*
- c. Maximum temperature at inside surface: 150*C (302*F)
A3 - Heated Area Location and Boundary
- a. Minimum axial distance heated to required range. 1.5 /Rt*
(See Fig. A-1)
- b. Minimum axial distance from weld center to temperature range boundary: Greater of:
t/2 or 15 um (0.6 in.) A4 - Miscellaneous
- a. Frequency: 3 to 4 KHz-
- b. Minimum induction coil length: 3 /Rt*
*t = pipe wall thickness j a = thermal diffusivity R = mean pipe radius f
F-20 I L
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S Figure FB-1. Sample Weld Treatment Preparation Instructions F-22
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