ML20070H518
| ML20070H518 | |
| Person / Time | |
|---|---|
| Site: | Three Mile Island  |
| Issue date: | 06/03/1982 |
| From: | Baty D BABCOCK & WILCOX CO. |
| To: | |
| Shared Package | |
| ML20070H501 | List: |
| References | |
| RDD:83:5490-549, RDD:83:5490-5491:02, RDD:83:5490-5491:2, NUDOCS 8212270047 | |
| Download: ML20070H518 (74) | |
Text
{{#Wiki_filter:- - - - - _ _ _ _ . - . - - - - - - _ LftC 130 R:sserch ord D:v:Ispent Divisisn I Babcock &Wilcox a McDermott company LYNCHBURG RESEARCH CENTER LYNCHBURG, VIRGINIA IO R. S. PIASC1K, FUEL ENGINEERING, NPGD From D. L. BATY, NUCLEAR MATERIALS TECHNOLOGY I'.RC { _ Cust. File No. GPU or Ref. RDD:83:5490/5491:02 Subj. EXAMINATION OF TMI-l REACTOR VESSEL O-RING Date JUNE 3, 1982 AND CRDM CLOSURE INSERT - FINAL REPORT { m. .. .. ... . s ...
SUMMARY
This report outlines the results of the metallurgical examinations performed on IMI-l reactor vessel 0-ring sections (ailver plated alloy 718) and a CRDM closure insert (type 304 stainless steel). These components were Ntentially exposed to sulphur [ contaminated primary coolant. This examination war to determine wher'her any inter-granular attack had occurred in these components as a result of this potential expo-sure. The examination of both components consisted of visual examination, nondestructive evaluation, surface examination by stereo light microscopy, scanning electron micro-scopy (SEM), Kevex energy dispersive x-ray spectroscopy, metallography, and bend t es t in g. The results have shown that neither component suffered any intergranular attack although the presence of sulphur was detected. The 0-ring contained some shallow cracks prior to bending, and some sections fractured as a result of bending. How-ever, fracture surface examination revealed all cracking to be transgranular ductile rupture. The CRDM closure insert did not contain any cracks prior to or as a result of bend testing. ( DISTRIBUTION (COMPANY-LIMITED) This information is freely available to all Company personnel. Written approval by the sponsoring unit's R&D coordinator is required only when release outside the Company is requested. [ DISTRIBUTION NPGD LRC ARC Andrews, JB Bain, GM Machin. WS Ayres, PS Baker, RJ Beauregard, RJ Mayer, JT Bhada, RK Behnke, HW Clevinger, GS McInteer WA CIS (Library)(3) Garner, CL Davis, HH Parham, BJ Domian, HA
- Library (2) Dietrich, MR Rigdon, MA McNary, TA Matheson, JE Downs, VD Wehrmeister AE Monter, JV Moore, KE Engelder TC Sarver, LW Olszewski, JS File (2) Theus, GJ
{ Pearson, JF Hamilton, WT Pryor, CW Hayner, GO Roy, DH Inman, SC ( Smith, JL Stanek, LJ Library (2) Lynch, ED
' 8212270047 821027 PDR ADOCK 05000289 (3 P PDR
I s I I I B&W makes no warranty or representation, expressed or implied:
. with respect to the accuracy, completeness, or itsefulness of the information contained in this report
. that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately owned rights.
B&W assumes no liability with respect to the use of, or for damages resulting from the use of:
. any information, apparatus, method, or process disclosed in this report
, experimental apparatus furnished with this report.
I I I
[ BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 1 I-L ACKNOWLEDGMENTS The following LRC personnel contributed to the completion of this investigation: Mr. V. D. Downs, Nuclear Materials Technology Section [ Mrs. S. M. Haghi, Nuclear Materials Technology Section Mr. W. T. Hamilton, Nuclear Materials Technology' Section { Mr. J. F. Kramer, Nuclear Materials Technology Section Mr. D. E. Kimmel. Irradiated Materials Technology Section Mr. W. S. Machin. Irradiated Materials Technology Section Mr. B. J. Parham, Irradiated Materials Technology Section Mr. J. C. Dillard, Project Services E [ [ E r L . L F~ L
BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 2
- 1. INTRODUCTION This report contains a summary of the results obtained from the metallurgical examination. of the Three Mile Island Unit-1 (TMI-1) reactor vessel 0-ring and a control rod drive mechanism (CRDM) closure insert. These components were g
examined to determine if the metal had undergone any intergranular attack as E a result of sulphur contamination in the primary coolant. The entire exami-nation was performed at the Lynchburg Research Center (LRC) of the Babcock & Wilcox Company. 1.1 Component Description 1.1.1 0-Ring The reactor vessel 0-ring examined was the inner of two 0-rings. Four (4) approximately 12-inch long sections were shipped to the LRC. These sections were identified as follows: Sample #1: contained circumferential weld; from X to Y quadrant. Sample #2: contained a circumferential weld. Sample #3: taken from Z to W quadrant. Sample #4: taken from'end of W to X quadrant. As seen from above, two specimens contained a circumferential weld.
% inner 0-ring is fabricated from alloy 718 tubing which is typically solu-tion annealed at 1950 2 25'F for 30 minutes maximum and precipitation hardened at 13501 25*F for 3-6 hours, air cooled. The outer surface of this ring has been plated with silver. The tube outer diameter prior to plating is 0.500", +0.006", -0.000" with a nominal wall thickness of 0.050". The silver plate has a thickness of 0.004" to 0.006". The mean diameter of the inner 0-ring is 169.750" REF. Figure 1 illustrates the 0-ring geometry.
1.1.2 CRDM Closure Insert A single closure insert was sent for examination. This component forms a high elevation primary boundary in the upper part of the control rod drive mechanism. I
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l ( BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 3 As such, the lower portion of this component comes into contact with the pri-( mary coolant. The component is machined and assembled from type 304 stainless steel in the annealed condition. Figure 2 is a schematic illustration of the CRDM closure insert geometry. { L r F [ [ [ f L E l (
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- 2. EXAMINATION PLAN Based upon the request for examination by GPU and discussions with NPGD, a work scope was proposed in Reference 1. This workscope was agreed upon with some modifications as identified in Reference 2. The tasks performed on each component and a brief description of the procedures is given below.
2.1 0-Ring The examination of the 0-ring consisted of the following tasks. 2.1.1 Receipt Inspection I The four 0-ring specimens were visually examined and photographed at low magnification to document any unusual appearance. 0-ring tube outer dia-meter measurements were taken at 0* and 90' with dial calipers to document the ellipticity of the 0-ring tube's cross section. 2.1.2 Nondestructive Examination The 0-ring specimens were examined using two eddy current techniques. An annular differential encircling coil was used with a 400 kHz and 900 kHz mix to suppress the effects of wobble. The other technique used a radial absolute pencil probe with the same frequency mix to suppress the effects of lift-off. This examination was used to identify surface defects both I on the OD and ID of the 0-ring tube. 2.1.3 Radiography Radiographs at three orientations were performed on the four 0-ring sections using a Norelco 150 KV industrial x-ray unit. The following operating para-meters were used: 140 KV, 12 MA, 48" source to film distance, 3/4" to 3-3/8" collimator at source. Type M film was used with 45 second exposure time. 2.1.4 Surface Examination Stereo light microscopy and scanning electron microscopy (SEM) were used to examine the ID and OD surfaces for evidence of any surface cracking and unusual = I I
{ BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 7 [ deposits. Kevex energy dispersive x-ray spectroscopy was utilized to examine these surfaces for the qualitative composition of deposits. Samples 1, 2, and 4 received complete ID and OD examinations. Sample 3 was held in reserve and was not sectioned for ID examination; however, the OD was examined by light microscopy. The sectioning diagrams for samples 1, 2, and 4 are shown in , Appendix 1. All cutting was performed dry on a band saw. 2.1.5 Metallography_ Based upon the examinations above, locations for metallographic examination were selected from samples 1, 2, and 4. Sample #3 was not destructively ( examined. Sectioning was performed with either a diamond saw, band saw, or hack saw. No water or cutting lubricant was used during sectioning. Appen-dix 2 contains the sectioning diagrams for specimens to be examined metallo-graphically and to undergo bend tests. Samples were mounted in "Epimet" for excellent edge retention and processed with normal metallographic specimen preparation procedures. All specimens were examined initially in the unctched condition on an Olympus metallurgical microscope. Photographs were taken to document both typical and unusual conditions. Examination of all specimens was performed at magnifications from 50X to 1000X in bright field illumina-tion. A total of ten (10) metallographic sections were prepared and exam-ined; four (4) were axial sections, six (6) were transverse sections. Tvo (2) transverse sections and one (1) axial section were examined after bending. ( 2.1.6 Bend Testing Based upon the nondestructive examinations, both axial and circumferential bend test specimens were selected. Figure 3 illustrates the specimen geo-metry and the geometry of the bend test. The axial bend specimens were approximately 2-1/2" long x 1/4" wide (circum-ference). These specimens were bent over a 1/2" diameter steci rod using a bench vise. Tests were performed which put either the ID or OD in tension.
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[ . BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 9 [ The circumferential bends were performed on %3/8" long half cross section or "C" specimens. Again tests were performed to put either the ID or OD in ten-sion. The OD tension tests were performed by flattening the "C" section with a pair of vise grips. The ID tension specimens were pressed into a flat strip with a bench vise. A total of six (6) axial bends were performed, three (3), in ID tension. Nine (9) transverse bend specimens were performed; five (5) in OD tension, four (4) in ID tension. Appendix 2 contains the sectioning diagrams illustrating the location of the bend test specimens. 2.2 CRDM Closure Insert 2.2.1 Receipt Inspection The CRDM closure insert was visually examined and photographed at low magni-ficatica to document unusual or suspicious features. 2.2.2 Nondestructive Examination Eddy current examination'was performed on the outer surface exposed to the primary coolant. A radial absolute pencil probe was used to scan the entire surface. A frequency mix of 200 kHz and 900 kHz was used to reduce the re-sponse to lift-off. 2.2.3 Surface Examination Low magnification stereo light microscopy and low to high magnification scan-ning electron microscopy was performed on surfaces suspected of containing I defects based on the previous examinations. Kevex energy dispersive x-ray spectroscopy was performed to obtain qualitative analysis of deposits on surfaces in contact with primary coolant. s 2.2.4 Meta 11ography Two (2) metallographic sections were prepared. These sections were taken from two different surfaces in contact with primary coolant. Appendix 3 illustrates the location of these metallographic specimens. Both were mounted in "Epimet" to preserve the specimen edges. The samples were ? I l .
I BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 10 prepared using standard metallographic techniques and examined in the unctched condition. The examination was performed on an Olympus metallurgical microscope at magnifications ranging from 50X to 1000X in bright field. Subsequently, one specimen was prepared and examined in accordance with Practice A of ASTM A-262, Detecting Susceptibility to Intergranular Attack in Stainless Steels. 2.2.5 Bend Testing A total of eight bend specimens were prepared from two different surfaces ex-posed to primary coolant. Appendix 3 illustrates the location of the bend specimens. The specimens were machined strios removed from the insert so that the tensile surface had been exposed to the primary coolant. Specimen dimensions were either 718" or 1-1/8" long x 1/4" wide x 1/16" thick. The specimens were bent over a 1/4" diameter steel bar using a bench vise. Fig-ure 4 illustrates the specimen and test geometry. Due to the curvature of the surfaces being tested the specimens did not have a flat surface in the tensile bend side. The surfaces were either slightly convex in the width g direction with a radius of 1-1/4" or concave in the width direction with a E radius of 7/8". During all handling and sectioning the specimens from both components were I kept from any liquid contamination and handled with latex gloves and poly-ethylene bags. The 0-ring specimens had already been marked on the OD sur-face with a black ink marker. I I l I I l I
BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 11 OD Surface Bend Specimen ID Surface Bend Specimen A 1/4" 1/4" [ ' 7/8" R 7/8" 41-1/8" N ID Surface r (
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I BABCOCK & WILCOX RDD:83:5490 /5491:02 PAGE 12
- 3. RESULTS 3.1 0-Ring Examination 3.1.1 Receipt Inspection All four (4) 0-ring sections had a light silver appearance except for bronze colored stains associated with the seating flats on the top, bottom, and outer diameter of the 0-ring. Figure 5 shows the 0-ring samples in the as-received condition. The inside diameter of the 0-ring was free of these stains. Associated with the bronze stain were grayish-black stains covering a much smaller area and located at the interface of the smeared flat seat and undisturbed surface as shown in Figure 6. These bronze and grayish-black stains were usually elongated in the tube axis direction. At high magnification these stains could be seen to be cracked and flaking off in certain areas. Figure 7 illustrates one such region.
Visual examination of these stained areas with the Nikon stereo light microscope indicated that some axially aligned cracks may be present in these stained areas particularly near the interface between the flat g seating and the smooth surface. One of these areas is shown in Figure 8. E Dimensions taken at the major and minor axis of the now approximately elliptical cross section showed dimensions ranging from 0.501" to 0.504" at the major axis to 0.424" to 0.431" on the minor axis. Table 1 lists this dimensional data. 3.1.2 Eddy Current Examination No defect indications were found on the ID or OD of any of the four samples. I I I E
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[ BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 15 [ - f ( 8 ( '
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BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 17 Table 1. 0-Ring Tube OD Dimensional Data
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I 1 Due to the elliptical cross section, two diameter measurement readings were taken. The 0* reading was on the major axis; the 90* reading was on the minor axis. I 2 The identified end is the end from which the " Semple #" label is started. This crimped material on this end was cut off and distance is measured from this cut. I I
I BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 18 3.1.3 Radiographic Examination No indication of cracking was found in any of the four (4) samples. Some broad circumferential bands were observed on all four samples; however, the location of these bands varied between orientations on the same sample and the band was missing altogether in some orientations. This is believed to be an artifact and had no bearing on tube integrity. Subsequent examinations in these areas revealed nothing which would correlate with these marks. A porosity-like structure was seen on all four sections at specific locations and orientations. No pattern tppeared to be present and this pattern was not related to the welds. R Roughness in the silver plate layer may account for this effect or it is an W artifact. 3.1.4 Surface Examination Results Samples 1, 2, and 4 were each sectioned axially yielding two 12" half sections. Each half section was cut into three (3) approximately 3-inch sections yielding six (6) specimens per sample or 18 specimens in all. Appendix 1 contains sec-tioning diagrams. The results of visual, low magnification light microscopy, SEM, and Kevex indicated that some shallow cracking was present on both the ID g and OD of some specimens, but not all specimens, and that sulphur was present 5 on the OD of the 0-ring and possibly on the 1D in some locations. Table 2 summarizes the specimens which were examined on the SEM and which contained cracking. Figure 9 shows an example of the shallow cracking observed on spe-cimen 1B1 at the outer diameter seating flat. This area is put in tensile bending during loading. The presence of S was detected in this location. Figure 10 illustrates cracking in the surface stain areas, and S was found in this area. An example of the ID surface cracking found is shown in Figure 11. This cracking was found on specimen 2B5. The presence of S could not be clearly detected due to the presence of niobium L lines which overlap the sulphur K lines. The ID cracking was contained in regions under the top t...d bottom seating flat of the 0-ring. This is an area which is also put in tension g by bending during loading. W 1 l I l I
[ BABCOCK & WILCOX RDD:83:5490/5491:02 PACE 19 Table 2. Susmary of 0-Ring Specimens Examined for Surface Cracking Prior to Bending and Sulphur Contamination {
" E "# #" "E Specimen Surface (s)
[ Identification E' m amined ID OD ID OD 1B1 ID, OD Yes Yes No Yes 1B2 ID, OD Could Yes No No not tell [ 1B3 ID, OD Could Yes No Yes not tell 1B4 ID Could No not tell 1B5 ID Could No not tell IB6 ID, OD No No Yes, very No shallow 2B1 ID, OD No No Yes No 2B2 ID, OD No No Yes No 2B3 ID, OD No No Yes, small No amounts 2B4 ID, OD No No No Possibly 2B5* ID Could Yes Yes not-tell 2B6* OD No No No No 4B1 OD No Yes No No 4B2* OD No Yes No No No No { 4B3 OD j 4B4 ID No No
*The surface listed for examination received the main attention; however, the other surface was also examined for specific areas of interest.
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BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 29 3.1.6 Bend Testing Of the 16 bend specimens tested and examined, ten (10) contained evidence of-cracking on either the ID or OD. Table 4 summarizes these results. For each ( type of bend test (i.e., transverse-ID tension, transverse-0D tension, axial ID tension, or axial OD tension), there was at least one specimen which had , no cracking or only shallow surface cracking. Cracking ranged from shallow ( surface cracking to through-wall fracture. In all cases, however, the frac-ture features contained cusps and voids, or shear parabolas, all indicative of a ductile rupture mechanism. There were no indications of any intergranu-lar cracking. This was true near the surface in tension, where such cracks might act as initiation sites for further propagation by ductile means, as well as deeper into the fracture where active crack propagation was occurring. ( Figures 16-39 show examples of the severest cracking for each type of bend i test. 3.2 CRDM Closure Insert Examination I 3.2.1 Receipt Inspection Visual examination indicated the presence of a grayish-black film on the in-side surface which had been in contact with primary coolant. The outer sur-faces which were also in contact with primary coolant did not contain this film. In general, the part appeared in very good condition except for the film. Small amounts of a white crystal were observed in the vent hole and these are believed to be boric acid crystals. Figure 20 illustrates the locations of these films. 3.2.2 Nondestructive Examination Results from the eddy current pencil probe examination of the outer surfaces in contact with the primary coolant showed no indication of cracking. Eddy current examination on the inside surfaces was delayed and eventually not performed due to the need to confirm whether intergranular attack was occur-ring by examination on the SEM and subsequent metallography. F k r L _. _____-___a
I BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 30 Table 4. Summary of Bend Test Specimens and Results Transverse Axial Cracking and _ Specimen Identification ID OD ID OD Ductile Complete 1B2-2 (weld) X Yes 1B2-3 (weld) X Yes-ductile 1B2-5 X No 1BS-1 X No IB5-2 (weld) X Yes-ductile 2B2-2 (weld) X Yes-ductile 2B2-3 (weld) X Yes-surface only 2B5-1 (adjacent to HAZ) X No 2B5-3 X Yes-ductile 2B5-4 (weid) X Yes-shallow surface only I 4B5-1 X No 4BS-3 X No 4B5-5 X Yes-ductile 1B3-2 X Yes-shallow surface ductile 1B3-3 X Yes-ductile I Appendix 2 and Figure 3 contain specimen location, size and test configuration. 1 I I
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BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 36 3.2.3 Surface Examination Examination of the inside surface film with stereo light microscopy revealed a pattern which resembled intergranular attack as shown in Figure 21. The closure insert was sectioned dry using a band saw and milling machine to gain access to this surface for examination on the SEM. SEM examination revealed that the suspected intergranular attack was basically a film which had formed on the surface in a pattern resembling a grain boundary network. Examples of this film as viewed on the SEM are shown in Figure 22. This network was clearly raised and could be readily smeared. Kevex energy dispersive x-ray spectroscopy revealed a large amount of Si to be present in the film with possibly some S and C1 also present. 3.2.4 Metallographic Examination Two (2) metallographic sections were prepared to examine the inside and out-side surfaces. Appendix 3 shows the location of these sections. No evidence ( of intergranular attack or cracking of any kind was found in and away from areas containing the surface film. Figure 23 illustrates the typical micro-structure observed. One section was further examined for susceptibility to intergranular attack and was found to have an acceptable microstructure. - 3.2.5 Bend Testing ( Eight (8) bend specimens were prepared from both inside and outside surfaces at 90' intervals around the insert. Table 5 lists these bend test specimens. ( Appendix 3 shows the location of these specimens. All bends were made with-out any obvious cracking. Further examination of the maximum tensile strain areas on the SEM showed no signs of cracking. Figure 24 illustrates the sur-face of specimen CRDM-2 which is typical of the others examined. ( [ r
BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 37 l l Table 5. Summary of CRDM Bend { Test Specimen Results I Specimen Tension Results f CRDM-1 OD No Cracking ID CRDM-2 OD I ID " CRDM-3 OD ID I CRDM-4 OD ID I Appendix 3 and Figure 4 contain test I specimen location, size and bend test configuration. I I I I I I lI
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I [ BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 42
- 4. CONCLUSIONS
[ Although the presence of S was detected on both the reactor vessel 0-ring and CRDM closure insert, no intergranular attack was found. Cracking which was found on the 0-ring surfaces before and after bending was ductile rupture and not intergranular. The closure insert contained no evidence of cracking before or after bend testing. [ [ [ [ [ l l t E [ m E [.
I l BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 43
- 5. REFERENCES 1
D. L. Baty to L. J. Stanek, " Proposed Work Scopes for Reactor Vessel 0-Ring and CRDM Closure Insert Examinations," March 31, 1982. 2 D. L. Baty to L. J. Stanek, " Additions to Work Scope of TMI-l Reactor Vessel 0-Ring and CRDM Closure Insert Examinations," April 20, 1982. I I I I I I I l I I I I I I . _ _ _ _ _ _ _ . _ _ __ _ _ , , . . _ _ , . - ._.,,.,,y__, , _ , , , , . - , , _ _
I' ' BABCOCK & WILCOX RDD:83:5490/5491:02 _ PAGE 44 I' I' I I I I ( APPENDIX 1 0-Ring Tube Sectioning Diagrams I I I I I I l I Note: Appendix 2 contains further sectioning of specimens identifi;d in this appendix. I I
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I BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 48 I I I I APPENDIX 2 Sectioning Diagrams for 0-Ring Metallographic and Bend Test Specimens I I I Note: The specimens whose sectioning diagrams are in this appendix were removed from the 0-ring samples as shown in Appendix 1. I
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a i BABCOCK & WILCOX RDD:83:5490/5491:02 PAGE 54 i i l l l 1 t I i l I-APPENDIX 3 i j Sectioning Diagram for CRDM Closure Insert I I I I I
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