ML20076B268
| ML20076B268 | |
| Person / Time | |
|---|---|
| Site: | Three Mile Island  |
| Issue date: | 01/04/1980 |
| From: | Giacobbe F, Rowe C, Danni Smith GENERAL PUBLIC UTILITIES CORP., METROPOLITAN EDISON CO. |
| To: | |
| Shared Package | |
| ML20076B267 | List: |
| References | |
| NUDOCS 8001210258 | |
| Download: ML20076B268 (232) | |
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4 l l l Investigation of Incargranular Stress Corrosion Cracking at i Three Mile Island - Unit 1
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Investigation of Intergranular Stress Corrosion Cracking at Three Mile Island - Unit 1 O Contributors: Report Coordinator - D. M. Smith, Sr. Materials Eng. , GPU Section 1 - C. D. Rowe, QC Specialisti Met-Ed. Section 2 - F. S. Giacobbe, Supervisor, Materials Lab. , GPU Section 3 - D. M. Smith Section 4 - A. P. Rochico, Manager, Engineering Mechanics, GPU F. S. Giacobbe i Section 5 - S. P. Sunallo, Sr. Engitteer, GPU I J. D. Abramovici, Engineer, GPU A. P. Rochine 1 Date: January 4, 1980
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TABLE OF CONTENTS
-Subject Page Abstract i Section 1: Development of UT Techniques for the Detection of IGSCC 1.1 Introduction 1-1 1.2 *n itial Stages 1-1 1.3 Procedure Improvements 1-3 1.4 Screening Procedure 1-4 1.5 EPRI Sponsored R&D Visit 1-6 1.6 Reliability and Verification Studies 1-7 k_, 1.7 Comparisons of UT Techniques 1-8 1.8 Summary and Conclusions 1-9 Tables 1-1, 1-2 1-11 Figures 1-1 1-13 Appendices 1.1 to 1.5 1-14 Section 2: Metallurgical and Corrosion Studies 2.1 Introduction . 2-1 7- .s 2.2 Corrosion Test Program 2-3 / \ 's- 2.3 Battelle N.W. Failure Analysis 2-4 2.4 Correlation of UT Data 2-4 with Metallography 2.5 Conclusions 2-5 Table 2-1 2-8 Appendices 2-1 to 2-3 2-9 Section 3: Summary of Data 3.1 Introduction 3-1 3.2 Data Analysis 3-2
O o e i l TABLE OF CONTENTS Subject Page Section 3: Summary of Data (continued) 3.2.1 Results of UT Inspection 3-2 3.2.2 Analysis of UT Screened Indications 3-3 and Leakers for Heat Number Trends 3.2.3 Analysis of UT Screened Indications 3-7 and Leakers for Shop vs. Field Weld Trend s l 3.2.4 Analysis of UT Screened Indications 3-8 for Welder Trends 3.2.5 Environmental Factors 3-9 h 1 3.3 Conclusions 3-10 Tables 3-1 to 3-8 3-12 Figures 3-1 to 3-5 3-23 Appendix 3.1 3-28 Section 4: Summary of Propesad and Final Repair Procedures 4.1 Introduction 4-1 4.2 Materials Consideration *-1 4.3 Welding Considerations 4-4 4.4 I.D. Weld Clad (Buttering) 4-5 4.5 Repairs Utilizing Strong Back Hardware 4-5 l 4.6 Cold Springing 4-7 4.7 0.D. Weld Clad Overlay 4-8 Table 4-1 4-10 Appendix 4.1 4-11
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I l l TABLE OF CONTENTS Subject Page Section 5: Discussion of Design Considerations 5.1 Introduction 5-1 5.2 Stress Analysis 5-1 5.2.1 Seismic Effects 5-2 5.2.2 Ther=al Ef fects 5-3 5.2.3 Fracture Mechanics Evaluation 5-5 of IGSCC Cracks 5.2.4 Weld Residual Stresses 5-5 (]'T w 5.3 Environmental Analysis 5-6 5.4 Recocmendations 5-16 5.4.1 Short Ters 5-16 5.4.2 Long Term 5-17
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ABSTRACT Intergranular stress corrosion cracking (IGSCC) has occurred at circum-ferential pipe welds in various borated water systems at Three Mile Island's (TMI) Unit 1 Pressurized Water Reactor (PWR). Extensive UT inspections and metallurgical studies were undertaken to define the scope of the problem and develop an understanding of the mechanism causing IGSCC in these systems. One part of this investigation has directly led to the development of a 60*/2.25 MHZ UT technique capable of detecting IGSCC in the RAZ of stainless s
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(Q steel pipe welds with the ability to overlook most geometric reflectors. A detailed evolution with justification of this technique is presented in Section 1 of this report. Metallurgical studies and data analysis were conducted to provide a fairly comprehensive understanding of IGSCC in the borated water systems at TMI-l and p ovide direction as to what remedial measures should be utilized to minimize or alleviate this problem. Highlights of these studies include:
- 1) The mechanism of failure has been identified as intergranular stress
() corrosion cracking in the weld sensitized structure in the heat-af fected-
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zone of circumferential butt welds. 2) As of this date, no specific corrodent has been identified as being responsible for cracking, however, work is continuing in this area. 3) Increased susceptibility to IGSCC has been associated with specific heats, field welds, especially repaired field welds, high carbon heats and aerated stagnant lines. The specifics of these studies and analyses are detailed in Sections 2 and 3 of this report. l l l 1
A . s . Since the basic cracking mechanism is related to sensitization, it was felt that much of the work conducted by EPRI in studying alternate solutions to the BWR pipe cracking phenomenon would be applicable. Such solutions included changing to the low carbon 304L SS or 316L SS material, weld cladding the I.D. surface at the weld joint of susceptible materials, heat sink welding, 0.D. weld overlay cladding, etc. The repair scheme to be utilized at TMI-l includes 1) the use of 304L SS for all replacement material, 2) all existing 304 SS pipe will be I.D. buttered to provide a more resistant material in the RAZ and 3) a low heat input weld procedure will be used for the circumferen-tial butt welds of the pipe. The analysis of the repair alternatives and the impact of various parameters on the design consideration of the borated water systems are presented in Sections 4 and 5 of this report. While this document represents a significant ef fort in characterizing the IGSCC in borated water systems at TMI, work is continuing in many areas to better understand this phenomenon. Such areas include the identificat'on of the cracking environment, material and structure sensitivity to IGSCC, improvement of UT, techniques in detecting IGSCC, implementation of operating and process variables to mitigate IGSCC, the development of novel repair fixes and many other l items. Therefore, it is this future work that will provide the insight required to completely define this problem and develop the remedial measures necessary to mitigate the IGSCC problem in borated water systems. 11
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Section 1: ' DEVELOPMENT OF ULTRASONIC INSPECTION TECHNIQUES FOR THE DETECTION OF INTERGRANULAR STRESS CORROSION CRACKS AT THREE MILE ISLAND UNIT 1
1.1 INTRODUCTION
On April 4, 1979 an operator noted a build-up of boric acid crystals near a weld in the Spent Fuel cooling system. This system is a low temperature, low pressure system containing aerated borated water and was constructed from eight(8) inch (203 mm) schedule 40 Type 304 aus-tenitic stainless steel. This leak prompted further investigations of this piping system. The initial investigation involved the following:
- 1) A visual walk-down of the entire system which revealed four(4)
V) ( more thru-vall leaks.
- 2) Metallographic studies of the first thru-wall leak (pipe to valve weld at SF-V-17).
- 3) An unsuccessful attempt to define the extent of cracking in several weld joints by radiography.
On the fifth of May the CPU System Materials Lab reported that a crack in the sample sent to them for study was a stress assisted intergran-ular crack similar to those reported in various Boiling Water Reactor (. (_ ) systems. By the end of May it had been determined that the development of an ultrasonic inspection technique capable of resolving incipient IGSCC was a necessary prerequisite to an extensive investigation of this problem. The following sections document the development of this UT inspection technique. 1.2 INITIAL STAGES After some initial attempts with several dif ferent transducers and coupling blocks, a 1/4" by 1/4" 5 MHz transducer mounted on a 50* 1-1 J
a . (in stainless steel) block was selected. This combination was selected for several reasons:
- 1) This frequency is more easily reflected from small discontin-uities than are lower frequencies.
- 2) The disadvantageously high attenuation factor at this frequency is partially compensated for by the very short metal path used (1/2 V path).
- 3) All nominal pipe thicknesses to be examined were thin enough to be penetrated satisfactorily with this frequency.
- 4) The relatively small angle of divergence of sound waves at this frequency allowed an examination concentrated on the area of interest.
- 5) For the typical weld geometries used, the 50* angle and a shortened coupling block provided the optimum combination for examining the heat affected zone next to the weld root (See Figure 1.1).
- 6) The 50* angle can still make use of the enhanced signal re-turned from any corner reflector that might be formed when a crack breaks the inner wall.
f In conjunction with the transducer / coupling block combination, past experience with the Sonic FTE Mark I instrument suggested that a cleaner screen presentation could be obtained by setting the instru-ment for 1 MHz operation with the transducer connected to the receive l terminal. This unusual inctrument setting has little or no effect l l on the transmitted or received frequency spectrum and has not worked 1 with any other instrument tested to date. All these elements were 1-2
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embodied in Universal Testing Laboratories (UTL) procedure UTL-UT-SP-10 Rev. 0 (Appendix 1.1). This procedure was qualified by comparison with radiographs of pipes containing crack-like indications. 1.3 PROCEDURE IMPROVEMENTS (PRASE I TECHNIQUE) During the latter part of June, five(5) weld joints with UT indica-tions were cut from the system. One was sent (a thru wall leak) to Battelle's Pacific Northwest Laboratory for examination, (see Appendix 2.2). The four(4) remaining samples were retained by Met-Ed/GPU for examination. Table 1-1 summarizes and compares the results of various (^) tests performed on these samples. (For a detailed report of these
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tests see Section 2 and Appendix 2.3.) It was during the initial comparison of Liquid Penetrant Test (PT) results with the UT indications in these samples that the need for several major procedural buprovements was warranted. Revisions 1 and 2 (Appendix 1.2) to UTL-UT-SP-10, here af ter des;gnated as the Phase I procedures, contained the following improvements.
- 1) Extensive detailing of the calibration procedure.
j-( ) 2) Extension of the calibration procedure to materials greater than .500" chick (Rev. 2 only).
- 3) Extensive detailing of the method to be used for examination.
- 4) A change in the acceptance criteria from "all indications exceedin. 25% of full screen height at a screen metal path equal to 1.4 t imes the thickness". . .to. . ." any discernable reflector violating the inner wall in the Heat Affected Zone."
1-3
I o . The most significant of these changes was the reporting criteria and because of this change all welds inspected with the Rev. O procedure were eventually re-inspected with the revised (Phase I) procedure. At this point it is important to note that the Phase I procedures were all used on a production basis and that they did not require a detailed mapping of indications, therefore there was no effort made to exclude reflections from weld geometry and other welding related anomalies. This procedural deficiency was not recognized until several indications were reported in the normally dry Building Spray piping inside the containment building. The reliability studies that were precipitated by the discovery of indications in dry piping are detailed in Section 1.6. Section 1.4 describes the ef forts which were directed toward the development of an inspection technique which did not suffer from the same inability to differentiate reflections as did the Phase I procedures. 1.4 SCREENING PROCEDURE Toward the latter part of July it became evident that the large number of reported indications were not all IGSCC. This conclusion was ed after radiographs of 10 weld joints in normally dry piping (3 in Building Spray System and 7 in Fuel transfer canal suction line) and 6 weld joints in the High Pressure Injection lines provided no confirma-l tion of IGSCC. The next obvious step was the development of a screening technique capable of discriminating against non-relevant reflectors. , Experimentation began with a technique which used two transducers l l l arranged in a " pitch-catch" configuration. This method was rejected because it was too cumbersome to use in the field. Further experimen-tation revolved around changes in transducer frequency, incident 1-4
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's angle, and calibration. The result of this effort is embodied in Revision 3 to UTL-UT-SP-10 and includes the following:
- 1) A 2.25 MHz 1/4" by 1/4" Harisonics transducer
- 2) A 60* (in stainless steel) coupling block
- 3) An evaluation criteria which required at least a 30" of full screen height screen presentation in the area of interest before the reflection was considered reportable.
Justification for this new technique is based upon the fact that welding related anomalies, such as machining marks in the counter-bore area are not detrimental to the structural integrity of the weld / pipe, therefore the screening technique need not be able to detect these reflections. This, of course, means that reflections from small discontinuities may also be missed. The selection of a 60* coupling block and a 2.25 MHz transducer was the direct consequence of this effort to eliminate the detection of geometric type reflectors. The following is a brief explanation of how this combination functions.
- 1) Increasing the incident angle to 60* causes geometric type reflectors to " disappear" as the transducer is scanned inward toward the weld, (see Figure 1.1)
- 2) The 60* angle does not make use of corner reflectors, thus a discontinuity with some depth is required before a return signal can be generated.
- 3) The greater beam spread of the 2.25 MHz transducer was necessary to prevent relevant reflections from also " disappearing" as the transducer is scanned inward (see Figure 1.1) 1-5
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- 4) The greater penetrating power of the 2.25 MHz transducer was advantageous for use over the slightly longer metal path that results from using the 60* angle.
- 5) The 2.25 MHz frequency is not as easily reflected from small discontinuities, but it is also not as sensitive to metal noise. (Note " metal noise" is defined as multiple reflec-tions frem grain boundaries which add together to give non-relevant indications.)
Revision 4 to UTL-UT-SP-10 (Appendix 1.3), which differs from Rev-ision 3 only in its method of calibration, was qualified by testing three pipe samples with known cracks. Table 1.2 summarizes this qualification and compares the results with the 50*/5.0 MIIz tech-nique. The ability of the screening procedure to discriminate against non-relevaat reflections has also been confirmed by testing seven(7) crack free weld joints. These joints all had indications using the Phase I procedure but neither Liquid Penetrant tests nor the screening procedure disclosed any cracks. 1.5 EPRI SPONSORED R&D GROUP VISIT On August 14, 1979 a research and development group for the develop-ment of an electronic method of interpreting ultrasonic indicators visited Three Mile Island. This EPRI sponsored group brought with them their prototype call confirmer for testing on several of Met-Ed's IGSCC samples. Appendix 1.4 details this visit but the follow-ing is a summary of the conclusions reached during this visit. l l-6
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- 1) The 60*/2.25 MHz transducer utilized by the screening procedure was more accurate at determining IGSCC in the samples than was the group's 45*/1.5 MHz dual mounted transducers.
- 2) Machine marks in the counterbore area were indis tinguishable from cracks for the Call Confirmer.
- 3) The Call Confirmer was sensitive to signal levels.
- 4) The Call Confirmer was incapable of using any information ob-tained while the transducer is in motion.
1.6 RELIABILITY AND VERIFICATION STUDIES r) As mentioned in Section 1.3, the discovery of indications in normally dry piping prompted a reliability study. In fact two reliability studies have been conducted, one utilizing the 50*/5 0 MHz Phase I technique and one utilizing the 60*/2.25 MHZ screening technique. The first study revealed a lack of correlation for inspections done with the Rei 0 procedure. This lack of correlation provided addition-al incentive for the reinspection of all the welds previously inspected with Rev 0. ks _/ The results of the second study were very satisfactory especially when the random nature of the human element is considered. This study used a 50% Poisson probability to show that 95.5% of the recorded results would be repeated by a single reinspection. A further examination of the study indicated that most non-repeatable results would probably involve marginal cases. However, this does not guarantee that a sig-nificant flaw will always be detected on the first inspection. 1-7 l
o . In addition to the reinspection of welds for the reliability studies, the following efforts were made to ensure the quality of the inspec-tions.
- 1) Each Level II* technician was given extensive training in these procedures.
- 2) The Level III* technician, who was also the author of most of these procedures, frequently spot checked the performance of the technicians in the field.
- 3) On four dif ferent occasions the inspection process was witnessed by a qualified independent auditor.
- 4) During the reinspections, care was taken to ensure that a tech-nician did not reinspect his own work.
- 5) The progress of the inspections was carefully followed by contin-ually updating a set of system isometric drawings.
1.7 COMPARISONS OF UT TECHNIQUES The question of why the UTL-UT-SP-10 series procedures are superior to ASME Section XI has been asked on several occasions 'oy other organi-zations. The attached sample examination data sheets (Appendix 1.5) provide the formal documentation comparing these techniques. The following is a summary of the results.
- 1) The ASME technique easily detected a 10% notch, but did not give a reportable indication for a known 25% thru wall IGSCC. The 60*/
2.25 MHz Rev 4 procedure gave a 100% full screen height response for the same crack. l
*As defined by SNT-TC-1A, " Recommended Practice for Nondestructive Testing Personnel Qualification and Certification," ASNT.
1-8
- 2) Geometric reflectors gave rejectable indications with the ASME technique but were easily distinguished or not observed with the 60*/2.25 MHz technique.
- 3) For cracks greater than 25% thru wall the ASME technique could not define the full circumferential length of the crack. The 60*/2.25 MHz technique could.
- 4) With the ASME technique, indications had to be plotted in order to classify them. The 60*/2.25 MHz technique does not require plotting to differentiate between most indications.
- 5) The ASME technique requires much more time than the UTL-UT-SP-10 procedures.
1.8
SUMMARY
AND CONCLUSIONS The techniques described in the previous sections were derived in a relatively short period of time and did not have extensive support testing. They have to date proven themselves to be superior to anything previously available, but they are by no means inf allible. The 50*/5.0 MHz technique is extremely sensitive to incipient cracks, but is hampered by geometric reflectors and can provide little or no information about the crack's axial length. The 60*/2.25 MHz technique gains its ability to overlook most geo-metric reflectors at the cost of becoming extremely sensitive to welding inclusions and lack of fusion. This technique can give some relative circumferential crack length information but no actual crack depth data can be derived from this or any other presently available nondestructive test. The examination of future ICSCC samples may 1-9
a Unprove the confidence in this relative crack depth information but the many variables involved in this type inspection make it doubt ful that actual crack penetration information will ever be available from this type of testing. A brief attempt at a theoretical explanation of these techniques is given in the previous sections but the June 1978 Electric Power Research Institute's Key Phase Report NP-761 entitled Evaluation of Ultrasonic Techniques for Detection of Stress Corrosion Cracks in Stainless Steel Piping provides some additional empirically derived support for the 60*/2.25 MHz approach used in UTL-UT-SP-10 Rev 4. Again remember that this EPRI report was not used or available during the development of this technique. The data gathered during these inspections is summarized and analyzed in the following sections. However, it should be noted that the re-suits of any given UT inspection is not positiv3 proof of the presence or absence of IGSCC. Even radiography may not be able to detect small, tight cracks. Therefore these ultrasonic testing procedures shall be considered only as a meaningful tool to be utilized for the detection of IGSCC. l 1 1-10
For More Details See Appendix 2.3 TABLE l-1 - PIPE - - SECTION INDICATION U.T. INDICATION P.T. TEST R.T. TEST HETAll.0GRAPilY SCREEN B/L AMPL .-
#1 I-l 7.6 70%FSil YES -
YES (Lack of Fusion) (SF-209) I-2 7.0 30%FSil YES - YES (Lack of Fusion) I-3 7.8 60%FSil YES - YES (Lack of Fusion)
#2 1-1 6.4 20%FSil YES -
YES Weld Root (SF-201) Irregularity I-2 6.8 10%FSil YES - YES (Weld RootIrregularity) 1-3 6.2 15%FSil YES - - I-4 6.2 25%FSil YES - YES Weld Root Irregularity) , I-5 7.0 35%FSil YES -
- Surface Roughness
- #3 1-1 6.0 40%FSil YES -
YES (ICSCC)
- j. (SF-12) 1-2 6.4 65%FSil YES -
YES (ICSCC)
'" I-2 Twin Peak 6.5 25%FSil YES -
YES (IGSCC) I-3 6.5 75%FSit & YES - YES (ICSCC) 5.6 25%FSil YES - YES (ICSCC) 5.4 100%FSil YES YES YES (ICSCC) t I-4 6.0 20%FSH YES - YES (IGSCC)
#4 I-l 5.6 15%FSil YES -
YES (IGSCC .010 deep) (SF-428)
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De finit ions : B/L - Baseline Position P.T. - Liquid Penetrant Test R.T. - Radiograplaic Test
TAllLE l-2 IDCATION APPROX. 60*/2.25 Mllz 0F HAX. CRACK AMPL. @ AHPLITUDE LENGTil 0F SAMPLE UT DEPTil MEASURED 60*/2.25 Fulz ORIGIN @ RECORDABLE 50*/5.0 Mllz ID. NO. ID. NO. (% TilRil-WALL) DEPTil LOCATION MAX. AMPI.. LEFT EDGE INDICATION HAX. AMPL. Sample 3 IND. 2 SF-12 25% 60%FSil 100%FSil + SdB .5" .875" 65%FSil Sample 3 IND. 3 SF-12 50% 100%FSil + IdB 100%FSil + 12dB .5" 3" 100%FSil SF-29 SF-35 100% 100%FSil+9 to lidB 100%FSil + lidB 6" Full Lengtli 95%FSil of Sample T C O S O O .
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l l l l l Appendices: Section 1 O I I 1-14 l l_ _ _ _ _ - _ _ _ _ _ - . - _ . . _ . - . - . _-. . - - - - . - - _ , . - - . -. - - .--. - - --
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In:IVERSAL TESTIUC LABORATO?.IES, INC. ubice:: Special Procedure for Ul:rasonic Procedure #: UTL-UT-SP 10 Exc=ina: ion of Auschnitic Welds peroval/ Concurrence: Date Issued: 6/4/79 M bpf .g Effective Date: 6/4/79 roiec:: TMI-Uni: 1 Revision #: 0 "gM Page 1 of 7 recared Ev: ealGoodenough, Lev [elIII IST OF EPTECTIVE PAGES REVISION DATE 1 0 6/4/79 2 0 6/4/79 3 0 6/4/79 ATTAC': BENT - 1 0 __ 6/4/79 2 0 6/4/79 3 O . 6/4/79 4 0 6/4/79 O 9 am n- - ~ < ---,,em,m. - , - - , - r- - - , , -. .-,.-,_,-e.,->-
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Special Procedure fciUltrasonic .. . UTL-UT-SP 10 Examination of Austenitic Welds Rev. 0 6/4/79 Page 2 of 7 I
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A.0 SCOPE 1.1 This procedure provides the requirements and method for performing examination of austenitic welds for the detection of inner granular stress corrosion cracking. 1.2 This procedure is implemented to examine the weld heat affected zones only. This procedure is designed to examine welds from 1/8" to 2" thick.
2.0 REFERENCES
2.1 ASME Section XI 1974 edition, Summar 1975 Addenda, paragraph IWA-2240. 2.2 ASMI Section XI, Appendix III for' Instrument Linearity checks if a DAC is required on a specife examination.
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3.0 PROCEDURZ QUALIFICATION 3.1 This procedure will be considered qualified by satifactory calibration checks before and after examinations and/or by comparison with radiographs from welds with known defects. 4.0 PERSONNEL QUALIFICATIONS 4.1 Personnel performing and interpreting ultrasonic examinations shall be ( qualified in ac ordance with UTL Personnel Qualification Manual which meets Sh~r-TC-1A 1975 edition. 5.0 INSTRUMENTS 5.1 Ultrasonic pulse-echo type of instrument shall be used which shall be capable of transmitting and receiving synchronized sound energy in frequen of 1-10 mhz. 5.2 50 pulse-echo probes and/or 45 transmit-receive probes may be used. j Frequency shall be 1.5 mhz. Other frequencies may be used if necessary. (i.e., 5 mhz probe - 1 ch: on machine. This combination yields the best signal response for (T304 S/S) stress corrosion examination.) 6.0 CALIBRATION 6.1 Sweep range shall be determined using IIW blocks or step wedge. 6.2 Amplitude calibration shall be determined using 5% notches and/or side drilled holes. Some thinner material may require a 10% notch to obtain an indication response. NOTE: Because screen width represents 1/2V or 1 css to remove geometrical reflectors, amplitude shall be approximately 100% FSH from the 10% notch on thickness to be examined. No DAC curve is required., (
pacial'Proegdure for Ultrasonic UIL-UT-SP 10 r.zminction cf Austenitic Welds Rsv. 0 6/4/79 Page 3 of 7
.0 CALIBRATION BLOCK 7.1 The calibration block shall be of a material acoustically si=ilar to the material being examined. Blocks in excess of 1/2" thick shall contain side drilled holes as well as notches. .0 EXAMINATION 8.1 All pipe and fittings to be examined, shall be censured with a straight beam to provide actual wall thickness, in order to properly interpret
- reflectors.
8.2 Exanine the weld perpendicular from both sides when possible with a 50 . pulse-echo or focused probe. Scan distance need only be for a distance of approxinately equal to the heat affected zone. (i.e., 1/2T.) Scan overlap should be a minimum of 10%. () RECORDING 9.1 All indications exceeding 25% of FSH located at a screen metal path equal to 1.4 times the thickness shall be considered a crack and reported. 9.2 Instru= enc calibration reports shall be =aintained on for=s. provided. (See attach =ents 1, 2, 3 & 4) Supplemental for=s and sketch,,es shall be used to clearly report the inspection.
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- - Procedure: Un,_gy_sp' Rev. 0 - 6/4/79 JOB NO. PROCEDURE NO. DATE ^acament a
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Apptndix 1.2 Ut:IVERSAL TESTIt;G LABORATORIES, Ii:C. ject: Soecial Procedure for Ultrasonic Procedurc #: UTL-UT-SP 10 Revision: 2 - Examination Accroval/ Concurrence:
, M fenitic Welds of[b
? /C) 7 Date Issued: 7/18/79 -
Effective Date: 7/18/79 - 3roject: TiII-Unit 1 Page 1 of 11 hte: 7/13/7 .
>~recared By: C ~*' 'Muh '
- ,coroved Dy:. p ,
-h, de- .IST OF EFFECTIVE PAGES REVISICN DATE -
1 2 7/18/79 2 2 7/18/79 3 2 7/18/79 4 2
.7/18/79 5 2 7/18/79 5 2 7/12/79 ATTACH Erg '
1 2 7/18/79 a 2 '2 7/13/7<3 3 2 , 7/18/79 '
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( lecia'l *Pecoedure For Ultrasonic UTL-UT-SP 10 I
- amination ;
of Austenitic Welds Rev. 2 l 7/18/79 Page 2 of 11
. 0' SCO?E 1.1 This procedure provides the requirements and method for performing examination of austenitic welds for the detection of inter granular stress corrosion cracking. - '-
1.2 This procedure is implemented to examine the weld heat affected zones only. This procedure is designed to examine welds from 1/8" to 2" thick. #. - - 1.3 See attachment #5 for weld joints.
.0 REFEREMCES ,
2.1 ASME Section XI 1974 edition, Summer 1975 Addenda, paragraph IWA-2240.
.2 ASME Section V, Article 4,1977 Edition, Summer Addenda
.0 PROCEDURE QUALIFICATION
' 3.1 ~ This procedure will be considered qualified by satisfactory calibration checks before and af ter examinations (Ref. 6.3) and/or by comparison with radiographs from welds with known defects.
.0 PERSONNEL QUALIFICATIONS .
4.1 All Level II. personnel shall be qualifiec in accordance with UTL Personnel Qualification Manual which meets SMT-TC-1A 1975 Edition. 4.2 Level I and (or) Level IT personnel shall assist in operations and obtaining data. - 3 All ~ interpretation and evaluation as well as calibration shall be performed by Level II personnel only.
.0 INSTRUP.ENTS 5.1 Ultrasonic pulse-echo type of instrument shall be used which shall be *' ,
capable of- transmitting and receiving synchronized sound energy in - frequencies .of 1-10 mhz. l t
~
5.2 Probes may consist of pulse echo and/or transmit-receive t) pes. - - - 5.3 Transducer angles shall be within the range of 450 -550 , 5.4 Transducer size shall be 1/4" to 1/2" wide for angle beam inspection. A straight beam transducer shall be 3/8" p to 3/4" 9, for determining wall thickness. - 5.5 Transducer frequencywithin the range of 2 mhz and 5 mhz may be used in conjunction with varied machine settings.
Sprcia1 Procedure for Ultrasonic . UTLcUT-Si? '10 Examination of Austenitic Welds Rev. 2 '
'7/l'8/79 -
Page 3 of 11 (' - 5.6 Cables shall not exceed 12' in length. , 5.7 Couplant shall consist of Hamikleer, Exosen #20, or equivalent to ' ensure continous coupling contact. 6.0 CALIBRATION DESCRIPTION 6.1 Sweep range shall be determined using IIU blocks or step wedge. - 1 . 6.2 Amplitude calibration shall be determined using 5% or 10% notches and/or side drilled holes. _ NOTE: Amplitude shall be approximately 100 FSH frcm the 5% or 10% - notch on applicable test standard. No DAC curve is required. 6.3 As per frequency of calibration verification. Calibration shall be verified at the beginning of each examination, not more than every 4 hours, any change in equipment, change in personnel and at the end of examination. 7.0 SYSTEM CALIBRATION (SWEEP RANGE) 7.1 Full screen width shall represent .5" depth for thicknesses of .100 to .500 to be inspected.
/ 7.1.1 Full screen width shall represent 2.5" depth for a thickness of .900 \
to 1.3" to be inspected. 7.1.2 Full screen width shall represent 1.0" depth for thicknesses over .500 to .900 to be inspected. 7.2 Position search unit for a maximum response from the corner of .2" on step wedge. Adjust left edge of this signal to line 4 on the screen with the delay control. 7 . 2.1 Position search unit for a maximum response from the corner of .4" step tha with wedge. Adjust material left edge of this .simi to line !8 cn the screen, calibration. .'2.,, 7.2.2 Repeat delay and material calibr r ' . c trol adjustments until the two signals start 'at pre ~cisely aw- ,: d 8.
-~
7.2.3 Check corner reflectors on .3 wedge and a .5 wedge. These should now . break the base line at Lines 6 and 10. 7.2.4 Each division on the sweep now is equal to .050 metal depth. 7.2.5 For wall thickness of .9 to 1.3" the corner of the IIW bldk will be - used in conjunction with.the .5 step wedge. i
! pecial'Procedpce i for U1trasonic UTL-UT-SP 10 Examination of Austenitic Welds Rev. 2 7/18/79 Page 4 of 11 7.2.6 Position search unit for maximum response from bottom corner of IIW block. Adjust left. edge of signal to line #4 on the scr en with delay control. 7.2.7 Position search unit for maximum response from the top corner of .- IIW block on full "V" path. Adjust the left edge of this signal to line #8 with the material calibration. 7.2.8 Repeat delay and material calibration control adjustments until $ , the two signals start at precisely lines 4 and 8. , 7.2.9 Each division on the sweep now is equal to 1/8" (.125) metal depth. 7.2.10 For wall thicknesses of .500 to .900 position search unit for maximum response from the corner of the .500 step wedge. Adjust lef t edge of this signal to line #5 on the screen with the delay control. 7.2.11 Position search unit for maximum response from the corner of the 1.0" block. Adjust left edge of this signal to line #10 on the screen with the material calibration. 7.2.12 Repeat delay and material calibration control adjustments until the two signals start at precisely lines 5 and 10. 7.2.13 Check corner reflectors on various other step blocks to . determine accuracy. 7.2.14 Each screen division is now equal to .100 metal depth. 7.3 System Calibration (sensitivity) 7.3.1 Sensitivity shall be obtained from the 10% or 5% notch cut on the I.D. of the applicable standard. Standards are as follows:
.100 to .300 Wall Thickness - Block SE-28-W-3C
.300 to .500 Wall Thickness - Block SF-29-W-3C M
.500 to .900 Wall Thickness - Block SF-29-W-3C *
.900 to 1.3 Wall Thickness - Block tiET-EO-019 7.3.2 Position search unit to 'obtain ma'ximum response from 100 notch on' '
the first leg of "V" path. . 7.3.3 Adjust gain control to bring signal amplitude to 100% FSH. Scanning will be performed at this level. This is to refrain from over saturation of material. 6
"Spicitl Procedure For Ultrasonic Examination of Austenitic Welds . UThrDT-SP 10
.Rev. 2 7/18/79 Page 5 of 11 I,
t. 7.4 Directions and Extent of Examination - 7.4.1 . The heat weld whereaffected zone shall be examined from both sides of the possible. Where configuration or adjacent parts of the . . _ component are such that scanning from both sides is not feasible, this fact shall be included in the report of the examination. 7.4.2 The angle beam search unit shall be aimed at right angles to the weld axis, with the search unit being oscillated approximately 20g ) , off the normal. - 7.4.3 Scan shall consist of a minimum 10% overlap at a rate of six (6) inches per sec. maximum speed. ~ 7.4.4 Scan7.4.1. See ccverage shall consist of 2T each side of weld, where applicable. 7.4.5 All scan surfaces are to be measured with a straight beam transducer to provide actual wall thickness, in order to properly evaluate reflectors. 7.4.6 All surfaces shall be free of loose scale, dirt, weld spatter or anything that would inhibit the transmission of ultrasound.
, 3.0 EVALUATION t
8.1 Any discernable reflector violating the inner w~all, in the Heat Affected Zone, will be evaluated as Stress Corro.sion Cracking. 9.0 _RECORDIliG 9.1 For each ultrasonic examination the following information shall be recorded on Attachments #1 - #4 as applicable. 9.2 Procedure - 9.3 UT equipment
;o 9.4 W Examination Personnel and Levels 9.5 Calibration Sheet identifyl .' '
T* 9.6 Weld identification and location ' 9.7 Surface of examination 9.8 Calibration block number 9.9 Record of indications (
f.~iecia'l Pfoceddrb For Ultrasonic UTL-UT-SP 10 tam,ination of,.Austenitic Welds Rev. 2 7/18/79 Page 6 of 11 9.10 Date and time of examination , 9.11 Couplant 9.12 Frequency 9.13 Surface condition 9.14 Special equipment - 1 e o e G
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.89e. . .' Procer.tre for tiltrasonic ' UTL'UT-EP LG E aliginica of Austenitic Welds
- 13evisipu 4 6/17/79 1
Page 2 ( ' 1.0 SCOPE 1.1 This procedure provides the requirc=ents an.d =ethod fo'r perforcing examination of austenitic velds for the detection.of inter granular s, tress corrosion cracking. 1.2 This procedure is implemented to' examine the weld heat affected zones only. This procedure is designed to examine welds from 1/3" to 1.25" chick. 1.2.1 See attachment #5 for veld joints. - 1.3 This procedure provides a two step screening' disposition. 1.3.1 Step one entails a highly sensitive technique, susceptible to reflectors very small in sica of nucercus- origins. 1.3.2 Steptwoentailsahighlysensitive)techniquewhichisnotassusce 1 to small reflectors (as step 01) nor.is it as vulnerable to geomet
2.0 REFERENCES
~
2.1 ASME Sectica XI, 1974 edition, Su==er 1975 Addenda, paragraph IWA-2240. 2.2 ASME Sectien'V, Article 4, 1977 Edition, Sumner Addenda ( 2.3 SNT-TC-1A, 1975 Edition. 3.0 PROCEDURE OUALIFICATION 3.1 This procedure will be considered qualified'.by satisdactory calibration checks before and af ter examinations (Ref. 6.3) and/or by cocparison with radiographs fron welds with known defects.' . 4.0 ?ERSONNEL OUALIFICATIONS 4.1 All Level II personnel shall be qualified in accordance Oith UTL Personnel Qualification Manual which meets
- S'$T-TC-1A 1975 Edition.
4.2 Level I and (or) Level II personnel shall assist in operations and obtaining j data.
- 4.3 All interpretation and evaluaticn as well as calibration shall be performed by Level 1:'. or Level III personnel only. ,
5.0 IXsTRUMENTS - t 5 5.1 Ultrasonic pulse-echo type of .i$strument shall be used which shaIl be capable of transritting and receiving synchroniced sound energy in frequencies,of 1-10 the. - f 5.2 Probes may consist of pulse echo and/or transait-receive types. ( C
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H/L7/79 Page 3 l
. .- l l
5.3 Transducur angles shall be within the range of 450 - 600 (+ 2 ). 5.3.1 Angles of 45 and 50 shall be used.for step one screening whete. applicable. .i . 5.3.2 A 60 transducer shall be used for s'tep two screening. (See 8.0 evaluation. 5.4 Transducersize shall be 1/4" to 1/2" vide Yor angle beam inspection. 'A-straight bean transducer shall be 1/4" & to 3/4" c, for deterr..ining wall thickness. , 5.5 Transducer frequency within the range of 2 mhz and 5 sh: may be used'in conjunction with varied machine ' settings. 4 O . W
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Nal.EIt.icb 'o .Nsteni5ici:~e ids- qLgJ,-SP10 Revision 4
. 8/1Uf.9 -
,e Page 4 5.6 Cables shall not exceed 12' in length. .
5.7 Couplant shall consist of Hamikleer, Excsea #20, or equivalent to ensure continous coupling contact'. 6.0 CALIBPATION DESCP.IPTIO:: ', 6.1 Sweep range shall be determined using IIW b.l.ocks or step wedge. 6.2 A:nplitude calibration shall be determined Osing 5% or 10% notches and/or side drilled holes. - NOTE: Amplitude shall be approxiinately 100", FSH from the 5% or 105 notch on applicable test standard. f!o DAC curve is required. 6.3 As per frequency of calibration .verificatio'n. ' Calibration shall be verified at the beginning of each examination, not F. ore than every 4 hours, any change in equipment, change in personnel and at the end of exami. nation. ,- 7.0 SYSTE:4 CALISPATION (SWEEP RANGE) 7.1 Full screen width shall represent .5" depth'for thicknesses of .100 to .500 to be inspected. 7.1.1' Full screen width shall represent 2.5 depth fcr a thickn'ess of .900 to 1.3" to be inspected. - 7.1.2 Full screen width shall represent 1.0" depth fcr thicknesses over .500 to .900 to be inspected. 7.2 Position search unit for a maximum response):frc the corner of .2" on step wedge. Adjust left edge of this signal to line 4 on the screen with the ceiay control. 7.2.1 Position search unit for a maximtEl response from the corner of .4" step wedge. Adjust left edge ,of this signal to -lin'e #8 on the screen with the material calibration.. - [ 7.2.2 Repeat d 2 lay and material calibration control adjustments until the two sign.11s start at precisely Lines 4 and S. 7.2.3 Check carner reflectors on ".3. wedge and'a .5 v edge. These should'now i break tha base line at Lines 6 and 10. -
~
7.2.4 Each division on the . sweep now is equal to .050 metal depf.h. 7.2.5 For wall' thickness of .9 to 1.3" the corner of the IIW block will be - - used in :enjunction with the .5 step wedge. (' l l -
F
.pecial' P,recedur : for Ultrasonic UTL-UT-SP 10 '
laminaqia,n of Austenitic Welds . Revision 4 I i 8/17/79 Page 5 - s. 7.2.5 Position search unit for maximum response from bottom corner of IIW block. Adjust left edge or signal to line #4 on the screen . with delay centrol. .
.s .
7.2.7 Position search unit for maximum response from the top corner of IIW block on full. "V" path. . Adjust the lef t edge of this signal to line !S with che material calibration.' 7.2.8 Repeat delay and material calibrat' ion control adjustments until the two signals start at precisely lines'4 and 8. 7.2.9 Each division on the sweep now is equal to 1/S" (.125) metal depth. 7.2.10 *For wall thicknesses of .500 to .900 position _ search unit for maximum response from the corner of the .500 step wedge. Adjust lef t edge,of
,_s this signal to line !5 on the screen with the delay control, l
(N-/ 7.2.11 Position search unit for maximum response from the corner of the 1.0" block. Adjust left edge,of this s,ignal to line #10 on .the screen with the material calibration. 7.2.12 Repeat delay and material calibration control adjustments until the two sigr.als start at precisely. lines 5 and 10. . 7.2.13 Check corner reflectors on various othek, step blocks to. determine accu racy. ,. 7.2.14 Each screen division is now equal to .100 metal depth. 7.3 System Calibration (sensitivity) 7- s7.3.1 Sensitivity shall be'obtained from the 105 or 53 notch cut on the I.D. q) of the applicable standard. Standards are as follows: , . .. T =
.100 to .300 Wall Thickness - Block SE-28-W 3C - -
.300 to .500 Wall Thickness '31ock SF-29-W.3C *
.500 to .900 Wall Thickness - Block SF-29-W-30 -
.900 to 1.3 Wall Thickness - Block MET-ED-C:19
. .- a ..
7.3.2 Position search unit to obtain ma'ximum response from 10% notch on' the first leg of "V" path. i 7.3.3 Adjust gain control to bring sjgnal amplitude to 1005 FSil. Scanning , will be performed at this level. This is to refrain from*cver". saturation of material.
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8 t L =
Sptcial Procedure For Ultrasonic UTL-UT*.SP f0
- Examinati-cn of A stenitic Welds Rev.,4 ,
C/17/79
}, Page 6
(. 7.4 Directions and Extent of Examination . 7.4.1 The heat affected cne shall bei examined from both sides of the weld where possible. Where configuration or adjacent parts of- the ccmponent are such that scanning frca both sides is not feasible, this fact shall be included in.the report of the examination. 7.4.2 The angle beam search unit shall be aimed. at right angles to the weld axis, with the search unit being os'cillated approximately 20 off the normal. ~ 7.4.3 Scan shall consist of a minimum 107; overlap at rate of six (6) inches per sec. maximum speed. 7.4.4 Scan coverage shall consist of 2T each siide of weld, where applicable. See 7.4.1. 7.4.5 All scan surfaces are to be measured with a straight beam transducer to orovide actual wall thickness, in order to properly evaluate refl ectors . ~ 7.4.6 All surfaces shall be free of loose scale, dirt, weld spatter or anything that would inhibit the transmission of ultrasound. ! 8.0 EVALUiTIC.' ?, .,
- 8. i' Any discernable reflector violating the irner wall, in the Heat Affected Zone, will be evaluated as Stress Corrosion Cracking.
3.1.i Evaluation (screening) will be performed using a 60 0 (i 2 ) shear wave of 2.25 the ncminal frequency. , 8.2 All information cbtained will be recorded'on Attachments #3 and !6 where applicable. 8.3 Calibration for 60 screening shall be obtai:ied'from '10% machined notch in$ A. IGA-!2
.250 - ,
B. .500 - IGA-#1
- 8.3.1 Position search unit for maximum response frcm 1,0% notch on IGA-!2.
Adjust left edge of. signal ,to. division !5 on the screen with delay Contro'.
- 3 8.3.2 Position search unit for maximum response from 10% notch on IGA-#1.
Adjust lef t edge of this sign'al to divisi~on #7 on the scr'een with the mauerial calibration.
r .
\
1 Speeli1 Pro *ce' dure for Ultrasonic ' UTL-UT-SP 10 F.sc.mioation.. ,,f Austenitic k' elds Rev. 4 S/17/79 i, Page 7 S.3.3 Repeat deliy and =aterial calibration control adjust =ents until the two signals start at precisely divisions #5 and #7. S.3.4 Position scarch unit for =axibum response from 10% acchine notch [ on either block. Adj ust gain. control uhtil signal response is 50% full screen height (FSH). , 8.3.5 Fosition search unit for maximum respon a from 10% machine notch on the opposita block used in step 8.3.4. 'Any difference > 10% of referenced level shall be brought to th'e attention of the Level III. 8.4 All indications exceeding 30% FSH in the area of concern will be recorded on Attach =ent #6. REColDINO - For each ultrasonic exacination the following information shall be recorded on
'N1 ~~-) Attachments #1 - #4 as applicable. -(500 only).-
9.2 Procedure 9.3 UT equipment 9.4 Examination Personnel and Levels . 9.5 Calibration sheet identity .
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9.6 Lbid identification and 1coation 9.7 Surface of examination
- 9.8 Calibration block number (.
v
) Record of indications 9.10 Date and time of examination ., . -
n. 9.11 Couplant . 9.12 Frequency 9.13 Surf ace co:.dition . 9.14 Special equip =ent *
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- METROPOLITAM E0! SON CO MP A N Y s.t., a c. . m. n,. .: . ,h c .,,, ., . ,,,,
Inves tigation/ Comparison Study by Electric . Power Research In:titute (EPRI) Sponsored Equipment (Ultrasonic) of Piping Samples Illustrating Intergranular Stress Corrosion Suh;,:ct TMI Muclea' Stat L... ..:a. Cracking (IGSCC). Middl etown , PA Cm September 6,1979 GQM - 3015 IMTRODUCTIC:: Cae to the neeri for additional input into the problam of accurately identifying the . indication Is) of IGSCC, a research and development program (R & DP) underway by EPRI was utilized at Three Mile Island (TMI) for the purpose of assisting in the interpretation of indications (IGSCC & Gecmetric Type Reflectors). The EPRI/ R & DP utilized personnel specializing in ultrasonics as well as specialized electronics. PERSON."EL ORGAMIIATIC:1 / GROUP C. D. Rowe tiET/E0 QC J.J. Potter MET /ED QC D. Smi th J. Godleski GPUSC Materials Eng. GPUSC QA R. Skibinski GPUSC E. P. Jernigan, Jr. QA G. A. Walton USNRC I&E R. F. Palmer USNRC I&E G. R. Stromer UTL LIII UT B&W ISI LIII it. J. Avioli, Jr. UII Y. H. Jeong Mech. Engr. UII Mech. Engr. J. Rose UII Lead Engr. PROGRAM & EVEMTS On August 14, 1979 the EPRI Group for R & D (UII) in relation to ultrasonic ev uation of IGSCC utilizing a " Call Confirmer" met with MET /ED personnel to demon-strate the development of their system. The following equipment vias set-up in the Quality ControT Department for the derauns tra tion: -
- 1. Manual Analog Cali Confir:ner A prototype buil t by Zeger-Abrams, Inc.
- 2. Ultrasonic Transducer Analyzer A prototype built by Aerotech Laboratory
- 3. Dual 1.5 MHZ Transducers (.375 x .75 by Aerotech)
Mounted on a 45' shoe
"::t i o .- . 'u;;.J: :. .
{ Investigation / Comparison Study - 2- September 6, 1979
- 4. One 1.5 MHZ Transducer mounted on a 45 shoe
- 5. Tektronix Type 422 OSCILLOSCOPE
- 6. Various CAL Blocks (IIW Block, Step Wedges & System Pipe Samples)
Basically the Call Confirmer and the Oscilloscope were connected to the output of the Transducer Analyzer and the Transducers were connected to the Analyzer's input. The first test performed was the comparison of the gains and signal to noise ratios for several transducers. The Oscilloscope screen presentations for each Transducer was photographed for later analysis, however little difference in (~] gain was noted. V The second test involved the testing of various known samples with the Call Confi.mer using the dual mounted 45o transducers. The results were incon-clusive but the following was noted:
- 1. Machine marks in the counterbore were called cracks by the " Call Confirmer".
- 2. Changing the gain settings on the Transducer Analyzer could change the call.
(A screen amplitude less than a threshold value or above a saturation value caused inconclusive calls.) The third test was a repeat of this second test except that U.T.L. 'S single 2.25 MHZ Transducer mounted on a 600 shoe was utilized. This test had much bet.ter results but was still calling machine marks in the counterbore as cracks. For cracks and root geometry the correct call was obtained 80% of the time. b The final testing involved the photographing of the Transducers PE signal and of an envelope signal generated by the Call Confirmer for several known cracks and machine marks. This data was taken in an effort to develop a method of distinguishing between cracks and machine marks. IN CO?!CLUSION:
- 1. The 60 o(mounted) Transducer utilized by U.T.L. was more accurate on IGSCC type cracks.
- 2. Machine marks are indistinguishable from cracks for the Call Confirmer.
- 3. The Call Confirmer was sensitive to signal levels.
l _, __ _ ____ ______----_-__A
. c:
I ' Investigation / Comparison Study September 6,1979
- 4. The Call Confirmer 'aas incapable of using any information obtained while the Transducer is in motion.
Respectfully , M C. D. Rowe Quality Control Specialist CDR: mig cc: J. J. Potter D. Smith J. Godleski R. Skibinski E. P. Jernigan, Jr. G. A. Walton R. F. Palmer G. R. Stromer M. J. Avioli, Jr. Y. H. Jeong J. Rose Reading File (2) Q.C. File (1) O l
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Ssecl6n'2:' METALLURGICAL AND CORROSION STUDIES
2.1 INTRODUCTION
In April 1979 during a routine visual inspection of piping in the spent fuel system a small leak was observed at a weld joint in an 8.00" diameter schedule 40, 304 SS pipe. Subsequent visual examination detected four additional leaks identified by a buildup of boric acid crystals on the pipe 0.D. surface. The location and orientation of these cracks was identified as being in the weld heat-af fected-zone (RAZ) adjacent to girth welds, running in the circumferential direc-1 tion. Several months later a leak was detected in a 10" diameter pipe in the decay heat system and another leak was observed in the spent . fuel system. In order to characterize the cracking mechanism, the decision was made to remove one of the initial failures (SF35) for laboratory investiga-at tion. The results of that investigation are contained in GPU Materials Laboratory Report, attached, as Appendix 2-1. i In essence, the failure was a result of intergranular stress corrosion cracking (IGSCC) in the sensitized structure of the weld HAZ. Cracking had initiated on the I.D. surface in the machined counterbore and then propagated in an irregular path through the wall thickness. The non-specific directionality of the crack is believed to be a result of the varying residual weld stress patterns which were estimated to be the primary stresses responsible for cracking. Additional characteristics which were observed and may have participated in the cracking phenomenon were a fine grain structure at the counterbore I.D. surface which was . a result of recrystallization of the cold worked metal by the weld 2-1
~ \ . ,
heat input. sharp transition angles in the counterbore, and variations in the degree of sensitization. The fine grain structure serves to increase the grain boundary area which increases the number of potential sites for crack initiation. Sharp transition angles act as stress risers, providing an enhanced site for crack initiation, and the degree of sensitization will affect the electrochemical reaction at the grain boundaries. The more sensitized structures either reaching a threshold for intergranular attack or assuming no discernable threshold exists, the more highly sensitized the structure (higher degree of chromium depletion) the shorter the time for crack initiation. Having identified the basic cracking mechanism as one being related to O sensitization, it was felt that much of the work conducted by EPRI in studying alternate solutions to the BWR pipe cracking phenomenon would > be applicable. Such solutions would include changing to the low car-bon 304L SS or 316L SS material, weld cladding the I.D. surface at the weld joint of susceptible materials, heat sink welding and 0.D. weld overlay cladding. These items will be discussed later in Section IV of the main report. O In regard to the environmental conditions responsible for cracking, this is an area where investigative work in still required. At this time there is no clear cut corrosive species identified. Typical water chemistry, as measured in the fuel pool itself, would contain 13,000 ppm boric acid, would be air saturated, have an average pH of 5.5 with chloride and fluoride levels of less than .1 ppm. However, there were chloride readings which were in the 12-18 ppm range. These levels, however, were not measured in other locations where cracking was ob-2-2 )
served. There does appear to be a tendency for cracking to favor stagnant lines or lines which are only circulated on occasion, but this observation is based on a limited amount of data. This would suggest, though, that concentration of contaminant may have occurred l in these stagnant areas in the past and been responsible for crack initiation. 2.2 CORROSION TEST PROGRAM A corrosion test program was established, through the help of EPRI, to identify the environmental factors necessary to produce IGSCC. The test program would include a series of Constant Extension Rate Tests ' O . i (CERT) utilizing actual pipe samples removed from the spent fuel systems. l These tests would be conducted in pure, aerated and deaerated boric acid, followed by tests with aerated 1.3% boric acid with 15 ppm chloride. Tests would be conducted at several extension rates ranging from 1.2 x 10-4 in./ min. to 4 x 10-5 in./ min. In addition, polari-zation studies will be conducted to determine if electrochemically the environment responsible for cracking can be identified. If this can be identified, the effects of varying oxygen levels and other environ-
- mental factors such as pH, chlorides and sulfates can be studied. In any event, these factors will be studied in the CERT tests.
To date, the tests shown in Table 2-1 have been conducted. The results of these tests are too preliminary to make any accurate assessment regarding the cracking phenomenon; however, they do seem to indicate that crack initiation is a critical factor in view of the fact that two tests conducted under identical conditions, one failed by IGSCC and one failed ductilely and the only difference was the ductile failure occurred in a specimen with the original I.D. surface removed. 2-3
.~ , .
2.3 BATTELLE N.W. FAILURE ANALYSIS In July 1979, a contaminated sample of a cracked spent fuel pipe (SF210) was sent to Battelle Northwest for failure analysis. Because this sample had not gone through a decontamination process it was hoped that corrosive species might be identified in internal deposits. Near the crack mouth deposits were observed. EDAX analysis of these deposits ; showed them to contain Al, Si, S, Cr, Ni, Fe and at one discrete area, chlorides. As you progressed deeper into the cracks, the deposits became less dense and chlorides were not detected. Auger spectroscopy was also performed. This was conducted on a fracture face from a crack opened in the dry nitrogen with some air. Again, as in the case of the EDAX analysis, trace chlorides were only detected at one location at the crack mouth. Sulfur and boron appeared as an overall contaminant on the fracture surface. The results of these analyses were inconclu-sive in identifying a corrosive species. The failure analysis conducted by Battelle confirmed the GPU Lab results that failure was a result of ICSCC in the sensitized structure of the weld HAZ. The preliminary Battelle report is attached as Appendix 2-2. 2.4 CORRELATION OF UT DATA WITH METALLOGRAPHY During the initial developmental stages of the ultrasonic examination to detect cracks, it was felt that correlation between UT indications and the actual defect present was required in order to qualify the UT technique. This correlation is contained in Appendix 2-3 and represents the inspection performed with the original UT procedure with a 50* angle beam transducer. The results of this investigation showed that l l 2-4 l l
l
.. 1 a consistent correlation was not being achieved between UT indications and IGSCC. Geometric reflectors other than IGSCC were being detected.
Out of the four samples investigated which contained a total of thir-l teen indications, three indication were lack of fusion, three were weld root irregularites one was I.D. surface roughness, one showed no defect and five were IGSCC. The correlation did show, however, that IGSCC tended to give screen presentations which indicated short metal path distances; i.e., screen baseline was broke at 6.4 or lower for all cracks. As a result of this comp.arison, modifications were made to the UT procedure to minimize the influence of spurious geometric signals and improve the ability to identify actual cracks.
2.5 CONCLUSION
Failure analyses conducted by Battel 3e Northwest Laboratory and GPU Materials Technology Laboratory have identified the mechanism of failure in the 304 SS borated water piping systems as intergranular stress corrosion cracking in the veld sensitized se,ructure in the heat-affected-zone of circumferential butt welds. As of the date of this report, no specific corrosive specie has been identified as being responsible for cracking; however, dilute chlorides have been identified in various stagnant lines in the building spray
- system and as such may indicate possible contamination by chlorides in other systems in the past. The role of chlorides as well as other contaminants is being studied in laboratory corrosion tests sponsored by EPRI. It is the purpose of these tests to identify the environment which can induce this mode of failure.
2-5 l
. s .
In addition to environment, the presence of weld induced sensitization also is a critical factor in the cracking phenomenon. It is in this area where the emphasis has been placed in defining solutions to the cracking problem. Low carbon, (304L) stainless steel materials known for their inherent resistance to sensitization are to be utilized when-ever possible as replacment spool pieces. In addition, weld processes using low heat input (35,000 joules /in. max.) and filler metals con-taining a minimum of 5% ferrite are being used. I.D. buttering as defined in NUREG-0313 is also being employed. The correlation between metallographic data and UT inspection data provided a much needed insight into this inspection program. As a result of this correlation, several very important items were either learned or confirmed:
- 1) All UT signals were not IGSCC because geometric reflectors could look like cracks.
- 2) Joint geometries varied greatly in shape, adding an additional interpretive problem when performing UT scans.
- 3) Screen amplitude could not be used as an indicator of crack depth.
- 4) The original UT procedure was very sensitive, finding cracks
<.010" in depth. However, it was so sensitive that rough grinding marks would give rejectable signals. Some of this sensitivity would have to be sacrificed in order to bsprove detection accuracy and reliability.
The work conducted to date has provided definite insight into the cracking phenomenon. Data collected has definitely indicated that l 2-6
I . i
- certain high carbon heats of material are more likely to have IGSCC and that stagnant conditions favor cracking. However, because so many variables are involved in such a corrosion phenomenon, it may take years before the tc.echanism is accurately defined. EPRI should be en-couraged to continue to study this problem.
i In the meantime TMI will continue to employ the best state-of-the-art techniques to mitigate this problem. i 2 4 e i 2-7
- ,-n, , . - . , . - , - - - . . . - -
TABLE 2-1 CORROSION TEST PROGRAM Extension Rate Laboratory Test Type Environment 02 Level Cl Level (In./Hin.) Results
- 1. Battelle N.W. CERT Borated Water (I) Air Saturated <.01 ppm 4x 10-5 Test discontinued at 37%
elong. ICSCC 2-3 grain deep (2).
- 2. Battelle H.W. CERT Borated Water (l) Air Saturated 15 ppm 4 x 10-5 Substantial ICSCC observed on fracture face (2).
- 3. Battelle N.W. CERT Borated Water (I) Air Saturated 15 ppm 4.x 10-5 No ICSCC (3).
- 4. Battelle CERT Pure Water Air Saturated <.01 ppu 1.2.x 10-4 No IGSCC (3).
Columbus y 5. Battelle CERT Borated Water (l) Air Saturated <.01 ppm 1.2.x 10-4 No ICSCC (3), oo Columbus
- 6. Battelle CERT Borated Water (l) Deaerated <.01 ppm 1.2.x 10-4 No ICSCC (3).
Columbus
- 7. Battelle CERT Borated Water (l) Air Saturated <.01 ppm 6.x 10-5 No ICSCC (4).
Columbus
- 8. Ohio State Polariza- Borated Water (l) Air Saturated <.01 ppm --
No active regions. tion NOTES: (1) Borated Water = pli 5.0 - 5.4, Cond. 12 umhos/cm., Boric Acid 13,000 ppm. , (2) Test specimens were made from actual pipe welds with original I.D. surface intact. ,
~
(3) Test specimens were made from actual pipe welds with original I.D. surface removed. . (4) Test specimen was made from 304 SS welded to 304L SS. - - O O .
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I i l l l 1 I i I i 1 Appendices: Section 2 i i i I f l 2-9 I l I I i
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t , . i l 1 i Appendix 2-1 GPU Materials Technology Laboratory '\ l Failure Analysis i 'l , i i i I \ ~
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GPU MATERIAL TECICIOLOGY LABOKATORY ,
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INTERGRANULAR STRESS CORROSION CRACKING OF 304 STAINLESS STEEL PIPING IN TMI #1 SPENT FUEL POOL SYSTEM SECOND REPORT O i R. L. MILLER I i F. S. GIACOBBE October 12, 1979 1 1 I
., e . . -
l Abstract Intergranular stress corrosion cracking (IGSCC) initiating on the pipe I.D. at circu:aferential butt welds is responsible for leaks in the 304 SS spent fuel pool piping. The cracks have occurred in the sensitized structure of the weld heat affected zone. To date seven through wall leakers have been observed, with an additional 35 ultrasonic indicatiorswhich are believed to be relevant. Ambient temperature borated water, possibly coupled with dilute chlorides, appears to be the environment responsible for failure. Limited data also suggests that stagnant conditions favor cracking. Repair procedures and materials which address minimizing of sensit-ization in the weld heat affected zone will be utilized. O l g i
e i In:rodue: ion Visual inspection of the borated water piping at Three Mile Island Uni: Nu=ber 1 (TMI-1) has revealed s'even coolant leaks, six in spent fuel and one in the decay heat system. Close examination of these leaks has shown them to be circu=ferential cracks in the hea:-af fected :enes of gir:h welds. The exact locations of these visible leaks in the piping are shown by sketches in Section 3. In addition, the type of weld joint used in the leaking areas is included in this appendix. The SFP is divided into two loop systems, A and B Through wall cracks, - adj acent to welds, have been confined to Systes-A, a redundan cooling loop which is normal-ly stagnant, and in piping connected to the transfer canal which is used at refueling ti=es only. System 3, a circulating loop nor: ally used for cooling the SFP, has no known cracks at this time. A pipe section containing two through wall cracks at a single weld join: " was re=oved from the transfer canal piping, decontaminated and forwarded to CPU System-Laboratory in an effort to determine the cracking mechanis=. This pipe section was assigned Laboratory Request Nu=ber 54148. The pipe sec: ion submitted for metallurgical examination was an 8" Sch. 40, Type 304 SS welded grade pip'e which was purchased to ASTM-A-358. As shown in Appendix I, the pipe see:1on was labeled SF-35 and was welded to valve number SFV-17. The type of weld joint utili:ed on the pipe / valve was a standard single "V" bevel with a counter bore on the pipe inside diameter for fit-up (alignment) purposes. A consu=able inser ring was used at the weld roo t . The pipe section was removed from the SFP by cutting through the pipe / valve weld and through the pipe wall at a 6" distance up the pipe leng:h. The pipe section's history was fif ty-four months' accumulated exposure to boric acid solutions averaging 75'F with a peak te=perature of 100*F. The fluid flow in this pipe was stagnant except during reac:or refueling periods. A :ypical water chemistry for the SFP is listed in Table I. The effluent for this analysis was withdrawn from a circulating porzion of the SF? System and may not be typical of stagnant areas. A more complete listing of the SFP chemis:ry covering the operational years is given in Appendix II. Investi:ation A. Non-destructive Testing of Pine Section The decontaminated pipe section was radiographed around its circum-ference in the yeld joint region to determine the extent of cracking. Two indications were revealed as shown in Figure 1. Each crack was approxi=ately 3" long and appeared to be in the base =etal adjacent :o the circumferential pipe / valve weld. A sketch, shown in Figure 2, was prepared from these radiographs and located the cracks with respect :o the pipe's original orien:acion in the SFP. The north-south directions, clockwise" numbering sequence, and the longitudinal pipe veld are meaningful =arkers to interested personnel at TMI as to the pipe's original position ir c.he SFP. The two views show one crack to be appro x-imately 150* around the pipe circu=ference in a clockwise direction from the other when the south direction was utilized as a O' start position. _ . _ . . . _ _ . ...-.. u . - - . ..
_. - _ ~ .
. . . Investigation (Continued)
B. Examination of Pipe Section by Scanning Electron & Oncical Microscopy
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The radiographed pipe section was cut in half lengthwise with a crack lying in each segment. Visual examination of each pipe half on the inside diameter surface showed each crack to be approximately 3" long. Also both cracks were in the counterbore adjacent to the weld and displayed a very irregular crack path. These features are shown in Figure 3. Dye penetrant examination was necessary to reveal enrough wall crack locations on the out side diameter of the pipe halves. All metallurgical specimens were cut from the same half of the pipe section. These specimens contained a weld, recessed groove and full wall thickness section. The specimen numbers and their locations in the pipe section are shown in Figure 4 Also, physical measurements of the weld joint are shown in this figure. The topography of the pipe's inside diameter in the crack region on Specimen Number 1 was examined in the Scanning Electron Microscope (SEM). (NOTE: Specimen Number 1 was examined in three distinct locations; namely, the weld root, counterbore and pipe's inside diameter surfaces.) As can be seen in Figure 5, cracks were observed running in the counterbore as well as along the edge of the weld. The crack paths were very irregular but progressed basically in the circumferential direction. Several types of particles deposited in the crack vicinity were analyzed qualitatively by the SEM Energy Dispersive X-ray Analysis attachment. The spherical particles shown in Figure 5 were primarily composed of Fe, Cr and Ni with no detectable trace of C1. Several irregular shaped, fluorescent particles (Figure 6A) were observed at the weld root. EDAX of one particle (Figure 6B) showed its composition to be primarily Fe, Cr and Ni with traces of Ca and C1. The surface of the counterbore next to.the crack is shown in Figure 7A. The surface shows machining marks plus what appear to be additional crack locations. EDAX of this region (Figure 7B) revealed the basic stainless steel constituents (Fe, Cr and Ni) plus traces of Ca and C1. Intergranular corrosion of the pipe's inside diameter surface away from the counterbore is shown in Figure 8A. This is most likely due to pickling during pipe manufacturing. EDA'C spectrum, shown in Figure 8B, displayed Type 304 SS major alloy elements plus traces of Ca and C1. Specimen number 2 was cut from the TMI-l pipe section and the crack contained therein was split open to study its features. As shown in Figure 9A, the main crack path was intergranular with little, if any, corrosion of the grain boundary facets. Secondary cracks can also be seen in this figure. I.
- EDAX spectrum (Figure 9B) for this area revealed no identifiable corrodents, only stainless steel alloy elements (Fe, Cr and N1).
Specimen number 3 was cut from the SFP pipe section and mounted in i bakelite such that pipe circumference was normal to the viewing plane. The specimen was polished and subsequently etched with the following mixture: ! six pdres glycerine, five parts HNO 3 , and three parts hcl. The three distinct parts of specimen number 3, namely, the weld root, counterbore and the pipe's full wall thickness, are shown in Figure 10 along with through-wall cracks. As can be seen, multiple cracks have initiated on the I.D., however only one !
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I . Investigation (Continued) A typical crack starting on the pipe's inside diameter and progressing through the 304 SS is shown in Figure 11. This micrograph displayed the inter-granular path of a typical crack. Another microstructural feature shown in Figure 11 was sensitization; i.e., precipitation of chromium carbides in grain boundaries in the weld heat affected zone. Other metallographic observations not shown include the existence of incipient cracks in the HAZ. C. Suscep tibility of Tvoe 304 SS to Intergranular Corrosion A specimen was cut f rom the SFP pipe section and its compositidn - analyzed chemically. The results shown in Table- II meet the 304 SS specifi-cation limits set forth by ASTM-A-358. Subsequently, certain element concent-rations were plotted on a Cihal diagram. (NOTE: This thermodynamic diagram predicts whether Type 304 SS will or will not sensitize upon heating in the 800*F to 1600*F range and thereby become susceptible to intergranular corrosion.) As shown in Figure 12, the TMI-l SFP pipe =aterial is highly susceptible, ' primarily due to its high carbon content. ' To substantiate the Cihal Diagram Prediction and the optical microscopy observ a ion that the 304 SS pipe was sensitized in the. HAZ, ASTM-A-262, Practice A* was performed on Specimen number 4. The grain boundaries in the HAZ were completely ditched (grooved) by this oxalic acid test as shown in Figures 13A and 14. Thus the SFP pipe was sensitized in the HAZ. The base metal (Figure 13B) away from the HAZ, however, showed little evidence of sensitization, indicating the material had been properly solution annealed by the pipe manufacturer.
*(Detecting Susceptibility to Intergranular Attack in Stainless Steel; 0xalic Acid Etch iast for Classification of Etch Structures of Stainless Steel)
Conclusions Metallurgical examination of the Spent Fuel Fool pipe has revealed the following: (1) An intergranular stress corrosion cracking (IGSCC) mechanism produced the leaka in the pipes. (2) The cracks were located in the weld heat affected :ene in the counterbore area. Crack propagation was from I.D. to 0.D. Grain boundaries in the HAZ were sensiti:ed as determined by ASTM-A-262, Practice A. (3) Chemical na' alysis of the pipe confir=ed its 304 SS composition. This composition was plotted on a Cihal diagram which showed this material to be highly succeptible to sensitization. All known leakers to date have been in heats of material which had carbon levels over .07%. Six were in the sa=e heat of material. (4) SEM Energy Dispersive Analysis has revealed traces of chlorine at various locations on the pipe's inside surface. These Cl traces could be a result of decontamination procedures utili:ed on the pipe's surfaces and not necessarily a result of contaminac_ ion in the borated water systems. At this time it can only be postulated that stagnant borated water possibly contaminated with dilute chloride was responsible for the intergranular corrosion. (5) Sensiti:ation of the spent fuel pipe in the counterbore was caused by welding. The degree of sensiti:ation is believed to be rate controlling with respect to crack initiation. Higher degrees of sensiti:stion would favor ) oh e ng ea c me mem po p -
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, . ., Conclusions (. Continued)
(6) Stresses responsible for cracking are believed to be primarily residual welding stresses, as the calculated applied stresses are below 15,000 psi. (7) Besides the main through wall cracks, incipient cracks were noted at several locations in the weld HAZ. (8) Cracking of the piping has been primarily confined to the stagnant "A" SFP System and the transfer canal piping. This fact may indicate a mechanism by which corrodents are concentrated in stagnant fluid areas. (9) The SFP pipa cratking mechanism is a unique phencuenoa in that IGSCC generally has not been observed below 140*F service temperature. Recommendations The metallurgical examination of the 8" Sch. 40, Type 304 SS SFP pipe section has led to the following recommendations. N- / (1) Substitute 304L SS for failed 304 SS pipe. The 304L material contains 0.03 we. % C maximum as compared to 0.08 wt. % C for 304 SS. This lower carbon content will reduce the degree of sensitization in the HAZ upon welding the pipe into the SFP. If available, the nuclear grade 304L containing
.02% C max. should be used. .
(2) Procedures such as I.D. weld clad, as defined in NUREG-0313, are to be utilized when making welds to 304 SS piping. Joint geometries whenever possible should not include a counterbore on the I.D. (3) Non-destructive examination of austenitic stainless steel weld joints in other systems in contact with borated water should be performed to determine if incipient cracks are present. Test techniques should include radiography and ultrasonics, ultrasonics being the preferred technique for finding small cracks.
) (4) If concentration of corrodents is occurring in stagnant fluids areas, periodic fluid flow should eliminate this and help prevent additional cracking in the sensiticed material. Whether existing cracks will not p ropagate, even though the corrodent has been removed, is not known at present. Those systems which cannot be periodically circulated must be flushed and drained.
(5) Since GPU Sytem Lab was unable to verify the existence of contaminants which may have been responsible for the IGSCC, arrangements have been made with Battelle Northwest Laboratory to perform a surface chemical analysis on a section of pipe which has not been decontaminated. (6) If incipient cracks at numerous weld joints are discovered by non-destructive tese methods, an in-service inspection (I.S.I.) plan could be set up in lieu of immediate pipe replacement, as catastrophic failures would not be expected, but rather a leak before break would apply. Crack growth could be monitored and replacement made at an appropriate time based on a determination of an acceptable flaw si:e for the system in question.
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(7) EPRI should be encouraged to continue the laberatory investi- 1 gations to reproduce and identify the environment and parameters necessary I to produce IGSCC of austenitic stainless steel in low temperature borie l acid solutions. l 4 o
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TABLE I
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Typical Chemistry of Spent Fuel Pool Water - as pH 5.5 Conductivity (micro-chos/cm) 12 Baron (ppm) 2000 Chlorine (ppm) .01 Flourine (ppm) <.02
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Beta-gamma (microcuries/ml) 6 x 10-2 Tritium (ppm) 4 x 10-2 Turbidity (ppm) .01 O (The known weekly water chemistry results and temperature records for the SFP's lifetime are tabulated in Appendi:: II.) an. 4 e ' l l
4 l l l J TABLE II
+M Chemical Analysis of 8" Sch. 40 -
Type 304 SS Soent Fuel Piping Element Wt. % Manganese 1.48 Phosphorus 0.023 Sulfur 0.012 . Silicon 0.56 Chromiu: 18.05 Nickel 8.72 Ba1. Iron --- Carbon. 0.073 Nitrogen 0.118 l I o esp G e
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l l l FIGURE 1. Radiographs showing cracks at two locations in SFP pipe section next to a circumferential weld (8" Sch. 40, Type 304 SS) . I
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FIGl'RE 7. SEM And EDAX near :nain crack. i, i l Crack .
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T'. B. EDAX spectrum of recessed groove surface. l l \.-____.__-___---____ -_ _ - - - - - - - - - - - - - . - - - - --- ---- -- - - - - - - - - - - - - - - - - - - ' - - - '
FIGUR$ d.' 'SEM and EDAX Spectrum of Type 304 SS Spent Fuel Pool Pipe Adjacent a to Recessed Groove. M O -
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- 4si,,~ ,
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N M!h_m A. Intergranular attack of Type 304 SS SFP Pipe. Penetration is less than one grain deep.
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4 - - B. Energy spectrum of corroded Type 304 SS material pictured above.
FIGlfRs 9. Crack Topography and Associated EDAX Spectrum. l b 5, Mag. 420X T- 1
. T 'g f .
- I.
v , 'n .,..
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A %, Y' ,: 1 N.}.-$ g\..(q l l A. Features of Through Wall Crack in Type 304 SS, SFP Pipe. 0:-].gg
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B. EDAX Spectrum for above pictured area.
1 I .. o
,. 1 FLGURE 10. Meta 11ographic Cross Section Showing Through Wall Cracks in l l 8" Sch. 40, Type 304 SS SFP Pipe. See Figure 14 for higher l l magnification photo.
I Weld Root (Consumable Insert) i lVl n: l
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, .FIQURE IJ... Typical Crack in Type 304 SS 8" Sch. 40, SFP Pipe.
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. granular Corrosion / Stress Corrosion Cracking".
~.
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% Cr = 100(%C) + 16 24 22 -
Resistant to S.C.C. , e ' b s Susceptible to S.C.C.
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Raf. _ Cordon, B. M. and Armije, V. S. , "A Comparison of Type 316, 304 & 304L Stainless for Small Diameter BWR Piping".
FIGURE 13. ASTM-A-262A; Oxalic Acid Ditching Test Results. L.:. ._ _ - .s . , _..~
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Appendix I - 1 Location of IMI-1 Spent Fuel Pool Leaks and Weld
. Joint Configurations e,
e e
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,- , . - ,, v _ _ _ .. .._e-- ...y4- 99 _ y-- 9
= +
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s .*
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Appendix II Chronological Listing of TMI-l Spent Fuel Pool Chemistries and Temperatures O GD O
- - - , . - - - ,- - - - ,e. -
~ ;. s t 3
, THI #1 SPENT FUEL POOL CilEMISTRY Year: 1979 -.
Date pil Acw' Cond. Bo ron Cl- F~ O-h 11 Turb. 1.1
< .-s , 4;. u s
,.s.p ys.. ,y, 5/5 5.32 10.62 2384 0.04 <0.02 2.96E-2 ' -
~,
4/28 5.26 11.8 2362 0.17 s 4/24 5.34 11.5 2396 i 3/6 2363 2.37E-2 1 3/3 5.35 9.1 2361 0.055 4 0.02 0.0375 0.0851 0.08 l
~
2/17 5.4 11.5 2378 0.00 0.012 4.34E-2 0.0467 0.09 2/10 5.39 11.3 2328 0.00 4.1 5.74E-2 0.00146 0.15 2/3 5.45 11.3 2397 0.05 0.026 5.71E-2 0.17 1/20 5.42 23 2384 0.0 0.037 6.19E-2 0.0529 0.1 1/6 7.0 15 2360 0.00 0.042 9.22E-2 0.0289 0.11
. / V -
sswm, j./., 4 ,j # ' n ese-co w .ch b se $ . ' s f am e O O .
II #1 SPENT FUEL POOL CllEllIST Year: 1 78 - Date
- ',I pil Cond. Baron Cl- F~ h3 - b[ 11 Turb. Li ,
12/16 5.4 13.5 2311 0.08 0.070 5.39E-2 0.0541 0.12 < 11/22 5.55 11.7 2323 0.00 < 0.1 8.16E-2 0.0577 s . 0.26 ' 11/11 5.45 14 2308 0.0 0.059 6.27E-2 0.0578 0.15 0.25 ! 11/4 5.41 13 2266 0.0 0.031 8.31E-3 0.058 9/30 5.42 13.5 2312 0.07 0.035 8.58E-2 0.0609 0.15 9/21 5.43 14 2317 0.06 5.78E-2 0.0650 0.13 9/16 5.42 13.0 2299 0.03 4.02 7.74E-2 0.0628 0.12 9/9 5.5 11.5 2273 0.0 <.02 4.7E-2 6.3E-2 0.1 . 9/2 5.56 9.1 2304 0.0 0.638 9.0E-2 6.59E-2 0.15 s 8/26 5.49 13.5 2279 0.0 0.053 67.91E-2 6.61E-2 0.10 8/19 5.58 13.5 2285 0.0 <.02 6.58E-2 6.61E-2 0.08 8/12 5.46 14.0 2269 0.0 <.02 6.38E-2 1.07E-2 0.12 8/5 5.56 15 2280 0.06 0.041 5.68E-2 6.84E-2 0.11 4 7/29 5.5 14 2270 0.05 0.043 7.25E-2 5.93E-2 0.1 7/22 5.55 9.95 2249 0.0 (.02 7.26E-2 2.73E-2 0.2 7.15 5.58 14 2239 0.035 <.02 7.1E-2 7.5E-2 0.1 7/8 5.49 12.9 2262 0.04 < 02 7.82E-2 7.59E-2 0.1 7/1 5.5 13.5 2249 0.02 <.019 7.64E-2
, 7.65E-2 0.09 6/24 5.61 10.5 2283 1.4 <.02 9.9E-2 7.81E-1 0.1 6/17 5.57 13 2280 0.0 <.02 7.55E-2 8E-2 0.09 (Continued)
t Till #1 SPENT FUEL POOL CIIDlISTRY Year: 1978 (Cont'd) -f Date pil Cond. Boron C1~ F- O-[ 11 Turb. 1.1 6/10 5.75 14.5 2238 0.0 9.36E-2 7 l
<.02 8.15E-2 .23 l 6/3 5.89 12 2238 0.0 <.02 9.35E-2 3.14E-2 .10 !.
l , 5/27 5.72 11.5 2463 0.06 <.02 1:12E-1 7.03E-2 .11 l 5/20 5.48 13.5 2269 0.08 <.019 7.67E-2 9.38E-2 0.9 5/6 5.55 10.05 2221 0.06 <0.019 5.98E-2 9.73E-2 l 0.11 l 4/29 5.49 15 2217 0.09 <.02 6.27E-2 l 9.03E-2 .01
)
4/24 5.51 13.5 2276 .09 <.02 l 4/6 2252 t i, 3/31 2189 i 3/30 2181 Na+1.23 3/30 2187 - 3/30 2179 i 3/29 2175 3/29 2181 7.41E-2 l 3/29 2181 l 3/28 2185
- l. 3/28 2181
~~
l . 3/28 2181 3/27 2193 3/26 2207 ' -
HI #1 SPENT FUEL POOL CilEMIST Year: 197 tennt d) e
- laate pil
~
Con d . Bo ron Cl- F- (3 - bf
*)
11 Turb. I.i *j
* .1 3/25 5. 36 8.4 2223 0.11 < .02 5.82E-3 2.69E-2 0.075 l i
3/21 ' 2221 0.'00 <.02 ' 3/11 5.72 8.25 2228 0 <.019 7.36E-3 2.74E-2 .07 3/4 5.37 8 9.7 2211 0 7.7E-3
<.02 2.7E-2 .26 2/25 5.90 9.2 2234 0 <.019 7.53E-3 E-2 2 .007 2/21 2218 !
2/18 5.22 9.3 2216 0 (.019 6.04E-3 2.69E-2 0.25 t 2/11 5.36
- 6. 75 2209 0.06 7.73E-3 2.62E-2
<.Q19 0.1
- 1 2/4 5.35 8.6 2215 0.04 <.02 6.96E-3 2.68E-2 0.12 1/29 0.04 1/28 .09 1/28 5.38 7.9 2217 0.075 < . 019 8.54E-3 2.68E-2 0.35 1/22 5.45 9.85 2216 0.14 0.026 7.63E-3 2.67E-2 0.56 0.21 1/14 6.69 9.1 2213 0.0025 0.035 6.19E-3 6.420E-4 0.08 -
1/7 8.4 2195 0.05 0.03 4.0 E-3 2.85E-2 0.11 S
t TMI #1 SPENT FUEL POOL CilEMISTRY 1977
, Year:
.l Date Cond.
i pil Baron Cl- F- O-Y 11 Turb. Li 5.9 e 12/31 7.80 22.08 0.04 6.6E-4 0.032 4.3E-4 0.11 12/24 5.40 7.50 2194 0.07 0.048 6.1E-3 6.35E-4 0.13 0.18 r e I, a l i f
**e .
O 9 .
i x a ' N
-.. I II #1 SPENT FUEL POOL CllEMISTCw Year: 1976 - '
.il
.j Date -
Cond. ' pil Baron Cl- F~ O-[ n 3 Turli . 1.1 10/23 5.6 13.5 2102 0.09 <.019 2.3E-3 2.6E-2 0.10 - I 1 10/16 5.52 13.5 2095 .3 <.019 2.4E-3 2.72E-2 .08 Cl-(Titrat16n) 10/9 5.71 14.7 2074 '0.08 .016 2.41E-3 2.72E-2 0.12 , 10/2 5.3 i 11 2084 0.1 024 3.5E-3 2.8E-2 0.028 9/25 5.2 15 2120 0.1 .021 2.6E-5 2.48E-2 0.1 9/18 5.70 14.5 2/10 0.05 0.020 1.85E-3 2.5E-2 0.1 9/11 5.69 15.4 2114 .08 .015 2.86E-3 2.5E-2 .15 9/4 5.75 14 2082 .06 .022 1.34E-3 2.5E-2 .125 8/28 5.69 14.5 2140 .05 .017 2.57E-2 .23 . 8/21 5.65 14 2132 .03 .015 2.01E-3 2.61E-2 .14 8/14 5.7 15.7 2122 .06 .013 2.13E-3 2.55E-2 .16 8/7 5.75 14.5 2108 0.0 .015 1.78E-3 2.6E-2 .35 7/24 5.68 18.4 2140 .07 .015 3.57E-3 2.7E-2 .075 7/17 5.71 15.5 2096 .04 .015 2.86E-3 2.86E-2 .15 7/3 5.7 17.5 2087 .08 .022 1.29E-3 2.74E-2 6/26 5.72 14.5 2069 .03 .015 2.192E-3 2.74E-2 .15 6/19 6.09 15.0 2060 .155 .012 2.28E-3 2.73E-2 .11 6/12 5.4 14,.5 2064 .09 .032 3.0E-3 2.77E-2 .14 5/22 5.60 12.5 2073 .03 .004 3.8E-3 1.29E-1 .13 4/24 5.83 16.5 2134 .07 .016 4.814E-3 3.576E-2 .04 (Continued)
t , !
, THI #1 SPENT FUEL POOL CllEMISTRY Year: 1976 (Cont'd) $.
Date pil Cond. Boron Cl- F- (3 - hf 11 Turb. Li 4/15 5.75 8.5 2132 .02 1.04E-2 4.8E-2 .14 4/13 5.38 9.2 2148 0.00 0.018 1.09E-2 1.896E-1 .15 3/30 5.26 9.0 2136 .06 0.018 7447E-3 5.30E-2 .13 3/26 5.21 ' 8.26 2113 0.015 0.015 1.31E-2 5.33E-2 .1 3/22 5.12 7.4 2106
.011 3/20 5.35 2.9 2106 0.0 0.017 1.18E-2 5.49E-2 .13 3/13 5.44 8.25 2104 .03 .013 1.064E-2 5.8E-2 .0005 3/8 4.97 6.58 2065 0.0 .015 5.17E-2 3/6 5.12 5.55 1995 .0125
, .01 1.1E-2 4.45E-2 3.4 3/5 5.04 6.25 1999 .05 .014 1.65E-2 .25 3/2 5.06 5.6 1993 .01 .017 1.08E-2 .35 1/10 4.92 6.0 2039 0.0 .038 2.89E-4 1.61E-3 1/3 4.47 1936 0.03
.012 1.13E-3 6.62E-4 i .
e e e a O
g 8' -
'il #1 SPENT FUEL POOL CllEMISTih Year: '
], .
1975 D. ate
~ .. '.
pli Cond. Boron Cl- F- O-[ 11 Turb. I.i ' t, 11/22 . 5.26 3.55 1126 0.0 0.01 3.15E-5 1.06E ' 11/15' 5.43 2.57i 847 0.00 0.02 . 2.01E-4 7.14E-5 a e e e e e I l t l
- l.
- 1 I
t'
i g -U
'1111 #1 SPENT FUEL POOL CllEMISTRY "-
^
1976 1977 Date 1978 1979 Teno. Date Te mp . Date Temp. Date Temp. Date Temp. 10/31 64 1/2 52 7/3 85 1/7 79 11/6 66 9/9 49 7/10 85 8 1/16 57 7/17 89 1/14 61 11/11 60 ' 1/23 60 7/24 91 11/19 60 1/30 66 7/31 83 1/28 68 12/5 52 /6 62 8/7 88 2/13 66 8/14 85 2/4 68 1 63 2/20 60 8/21 81 2/11 70 12/19 54 2/27 50 8/28 80 2/18 30 3/6 50 9/4 86
. 3/13 52 9/11 79 2/25 48 3/20 45 9/ 70 3/4 70 4/3 60 10/2 67 3/12 58 4/10 63 10/9 68 4/17 65 10/16 62 g
3/18 63 4/24 73 10/27 3/25 71 5/1 62 11/6 77 I 4/15 53 5/9 74 11/13 66 5/15 75 11/20 56 4/22 58
~
5/22 84 11/27 55 ' 5/29 84 12/4 60 . 6/6 78 12/11 64 6/12 73 12/18 70 ' 6/19 84 12/25 57 6/25 82 ' NOTE: The<n r o mn o . , r .. . e .- . . , . . . . . ,, . .. - . s
i Appendix 2-2 Battelle Northwest Laboratory Failure Analysis
]
~ .. -
,. n .
THREE MILE ISLAt10 110. 1 ,
; SPElli FUEL P00L PIPE CRACKIrlG AtlALYSIS
~
IrlTERIM REPORT
.: ~
t t f
- By .
s i A. B. Johnson, Jr. R. H. Jones O August 13, 1979 PACIFIC NORTHWEST LAGORATORY l ' BATTELLE MEMORIAL ItiSTITUTE . RICHLAND, WASHIriGT0tt 99352 m l 20
L. . .. . . . . - e 4, g... . .. .. .-
'a fy.
The following observations are the result of analysis performed to date on the TMI-l pipe / weld /elbcw section received on July 7, 1979. The pipe / elbow specimen received contained a weld between a. pipe (HT.334165) and elbow (HT.17616) which joined section MI48 to
".H 4JO as shown on isometric'. drawing number C-312-681-1.
The specimen is shown in Figure 1. This piping was from the spent fuel cooling wat}r piping,which contained water - ~
~
with 2200 ppm bor'on.The boric acid was added in April 1974 and the first failure was detected in March 1979. The pH varied from 4.47 t.o 7.0 from flovember 15, 1975 to May 5,1979 while the water temperature varied from 45 F to 90 F - (7.2*C - 3_2.8*C ). Prior to sectioning, visual, NDT and photographic
;(/. records were made with the following observations:
Visual: 1) Circumferential grinding on 10 near weld
- 2) Residue from dye penetrant - 00 surface
- 3) Felt pen lines - OD surface
'to 9
. 0 ly. e i m
',eT b~o w e_,. s ,
NOT: Four indications were recorded; so far, only one is identi-fied as a crack. It was at 315' to 345' (10:30 to 11:30) on the pipe side. Presumably this is the crack observed at the
) reactor.
This indication is labelled tiDT-1 while f1DT-2, 3, and a were at 60 CH (2:00) on the pipe side and 345*(11:30) on the elbow side. NOT-2 and 3 were thought to be associated with the weld while NOT-4 extended 3 inches circumferentially and was near the weld root. Phoi.ography: The attached photographs show the pipe section and the ground surfaces on the ID. Also note the oxidation in the weld root area (Figure Ib).
. Specimens were sectioned for metallography, SEN/EDX, Auger Electron Spectroscopy of a fracture surface, bulk chemical analysis and X-ray e
P.,.
N
...--..~.-;-------.
. - 6M.,
G diffraction of deposit on ID of pipe. identified in Figure 2. The location of these specimens is The following observations have been made: Me tal10qra phy
- 1) ~
9 One major crEcl ~emanstini"?F67T'Ge ID7shd propagating 40", th pipe wall was located S 0.15 inches from the weld root (Figure 3a,b). 2) Several other crack segments located between the major crack noted and the weld root (Figure 3b).
- 3) ?g(e3EanM2rdsp with only a few exceptions as noted in Figure .
4)
~
1.arge density of grain boundary precipitates in the HAZ. i Ex tiff)'o'ii'd'.thFma'jor crac,k."..,]hese precipi ta tes are presum
-~
y ~ .. ,. s
.an. a .-a
( (Figure 5). 5) Some suggestion of intergranular corrosion on the inner surface nea weld root (Figure 6).
; an unetched specimen.
This region will be examined more carefully with to be very shallow. If intergranular corrosion did occur, it appears 6) flonuniform grain size from mid-section of pipe to 10 and 00 . The grain size was much finer at mid-section than at the Also, ID and 00. there were inclusion / defects aligned with the longitudinal (pipe extrusion) direction (Figure 7). The significance of these observations to the fracture problem is not evident. SEM/EDX 1) Corrosion product buildup was evident on ground inner surface of pip near mhjor crack and on the fracture surface (Figure 8). Energy dis , persive X-ray analysis (EDX) of areas 1, 2, 3, and 4 of Figure 8C sho.ied the following elements: a) Si (sma l l a'moun t ) , Fe , Cr , fli b) c) A1, Si, S, C1 all small amounts, Cr, Fe Si, Si, both large amounts, Cr, Fe d) Al, Si, K. Cr, Fe, large amounts, tii, small amount
\
.p_......-.- - -- - _
3 2 2) Q#. The corrosion product was the densest near the crack surface of the pipe. e inn origin at The.'.Fe'.T.aT'sWe~e. ~/Idenc.w,,o,f'~dxn mwn,.n
~
~ ~ a eT .
associatedy:i des.;z.y tec t .-v ; maw-ed TiYh,.th~ t he ?{7i'nifi n[Er kD'( F i];u reThe 9aelements a rrow ) . EDX on the fracture surface of Figure 9b were: a) Fe, Cr with a little Ni . b) Fe, Cr with a little Ni c) - Al, Si, S, Cr-small amounts, Fe large '
, 3)
Deeper within the crack the fracture surface was (Figure 10). much freer of deposits The intergranular nature of the fracture is very evident
- 4) .
p The inner surface (10) of the pipe away from thea circumferenti weld l showed. features which are associated with the pickling an the longitudinal pipe weld (Figure 11). EDX elements: analysis of areas 1, 2 and 3 of Figure lla showed owing the foll
- 1) Mg, A1, Si - moderate amounts
~dggq;T,i>;pgm.aj1,p3gg@.
3,.
'~
Fe, Cr,'Th - large amounts .
- 2) A1, si - large amounts -
K - small amount Fe, Cr, Ni - large amounts
- 3) Fe, Cr, Ni only - large amounts p).
\
b Aucer Electron Scectrosecov_(AES) _ An attempt was made to fracture a specimen taken from the pi pe in the AES. This wall. s::ecimen contained a crack which had propagated rough the partially t It was hoped that by opening the crack in the AES,spheric the prior atm exposure did not contaminate the crack front. ficult to separate in the AES impact system and was exposed tHo o dry nitrogen two times prior to AES analysis. Analysis for chltrine was the primary purpose for the AES fgl d t M t 3 3-- E -E~ -e W cli.Y.~ 6.~R.m,'sr work. Et] Q ] l m eW.ff8iimWtl
~'
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= - ' . - - ^^~ ^ ' ' ^ a.ur:2.:Lu w .~"~
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~
3 W-
-4
"$ r 7.ChWi.n..e1a's m, ;p ob. s.'e.W~eM. . 6Eff91oca tio~n
... c_ 'dItYe a .. ~fr5'~t.ure.,T.
Tr .. u. t,his.was$fe?.,?~w.m~
- w .
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Mall t'ra'c'e'.d
~~ This loca tion was near the origin of the crack and therefore saw the most atmospheric exposure. TiIe"fE5I-RiiuMF353'g~EiE tha t'~c h~l or., .=. e. . .nn ~^""~'"'"~--"'.4 jne ya sgn,o[t,,prese~n i.r. t- ln'the wa ter~. ,w .m .."rtt.
environme Boron was present on all the fracture surfaces except a small region which was fractured in the Auger. Sul - " fur - wasi{W.pVEs1Mt'OralT'ths"fr'a&W5'i'.uW
.u..w.u; m u =
.w.m facessincluding w:ch the small region fractured in the AES. The boric acid is a probably source for the boron while the sulfur may have come from the atmos-phere, handling or the material.
The source of the sulfur needs further inves tiga tion. Chemical Analysis
- 1) Surf ace swices - X-ray f16uresence analysis was performed on swabs taken on interior surfaces. The? anal.:ysis- did . no't JdsteH3hT6EiWe',, but did re-
. ^ -- ~
veal a deteYtable74... 79.a e i c,ontgnt (.,02.. E m y).- Swipes from the weld root 0.13 ug/cm and pipe surfaces were the same.
.D 2) X-rav flo iresence of bulk specimen ID - (hjo,r,ide3dsi-.. .notMetectgd,**
.v~~
ion the inner surface of the pipe by bulk X-ray flouresence; however, manganese was high. The results showed 5.~6_37.tDinsnei'e7
.... ~
-a when' normalized to 19 at%
chromium in the specimen. SUM"AU O Intergranular cracks were observed amanating from the ID of tha 3-inch spent fuel pool 304 stainless steel pipe from the it1I flo.1 fuel transfer I canal. This,crac.k.ino
. . ~ was observed on the p.ipe ' side. .. on.ly a,.n.d n..o.t. the.,w . ..
i n.-
~ e,.1d
-~
or,s., elbow 3terial,] The cracks were within 0.15 inch of the weld where con-l 1 si'derable grain boundary precipitation (sensitization) occurred. The HAZ . anpeared to be severely sensitized. There was one major crack which apparently
~
, penetrated the pige, through.the penetration was on.ly'80% in the metallographic specimen examined.
There.were several smaller crack segments between the' major crack and the weld. - Octection 1imit - <2 ug/cn 2
** Detection limit - <.0039 a t %
\
t
. , u l. * -
.. . . ~ . .
~
-S-h Analysis by SEM/EDX, Auger and X-ray flouresence revealed the following:
By AES, baron and sulfur were consistent contaminants on the inner crack surfaces; chloride was minor or absent. - By SEM, A1, Si, S. K, and Cl were detectable on the ' pipe inner surface near the crack mouth; A1, Si and S were associated with corrosion products, inside the crack; away from the crack tip, the pipe ID surface had indi-cations .of Mg, Al, Si, S', C1, K and Ti; A1, Mg, and Si were more prominent; S and C1 were minor. X-ray flouresence did not detect C1, but did detect lead, which was absent - in AES -and EDX scans. iM) in summary, sulfur appears to be the most consistent contaminant. It is not yet clear whether it is present above the normal contamination level for 304 5S. C} lor.ineqagegegeQu_t ,was no$ .ayj;ogontami.nantypip[F{~jlliidIt" s absgn, Tcj"s,ujr,facWIdiihed Iby?AES"a'n~d}jieh'5fE tot (c][yRln3 discre@part@es 6ddBcron in the crack probably came from boric acid, which was transported through the crack and formed deposits on the other crack (%T surface. The interpretation of chlorine and sulfur indications is compromised some-what by the fact that both are contaminants in the dye penetrant used to inspect p V the pipe. Possible sources and consequences of the other contaminants should be con-sidered through there currently is no consistent evidence that any contributed to the cracking phenomenon. Independent analysis of carbon in the pipe and elbow sections indicated levels ab'out 0.01 wt% lower than the original pipe certification levels. RHJ/ABJ:tf . r e f ~. . TM. l l 1
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Figure 1. Photographs showing a) as received pipe / elbow specimen and b) color phctograph of weld root / pipe 10.
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Figure 11. SEMs of the Inner Surface (10) of the Pipe Away From the Circumferential Weld I l
I 1 1 l 1 l l Appendix 2-3 Correlation Between UT and Metallographic Data
1 I e se l SUtefARY OF UT/METALLOGRAPilIC DATA UT Data Meta 11ographic Data Indication Screen B/L Amplitude _ _ _ Depth Length Location Description 111 7.6 70 .010" 6-1/4" Fitting Lack of root fusion 112 7.0 30 .006" 1-1/2" Fitting Lack of root fusion 113 . 7; 60 .015" 5-7/8" Fitting Lack of root fusion a 2I1 6.4 20 .005" 1/4" Pipe Weld root irregular ity : 2I2 ! 6.8 to -- 1/4" Pipe Weld root irregularity I 213 6.2 15 i 1/4" Pipe No defect found ! 2I4 6.2 i 25 -- 1" Pipe ' Weld root irregularity 215 7. 0 35 -- 1/4" Fitting Surface roughness 3I1 6. 0 40 .043" 1" Pipe ICSCC
- 3I2 6.4 65 .062" 1-1/2" Pipe ICSCC 313 5.4 100 .110" 2-1/2" Pipe IGSCC 314 6.0 20 .047" I 1/8" Pipe IGSCC 4I1 5.6 15 .010" 3/32 " ,
Pipe ICSCC
- i O
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PIPE SECTION I (SF 209) Heat Numbers: Ht. 48985 Pipe Side: Fitting Side: Ht. 1401 ,
~
Tyne of Weld: Shop
.s
Description:
, Joint geometry on this section showed little counterbore on either the fitting or pipe side. There appears to be mismatch of the I.D. surfaces which resulted in lack of root fusion on the fitting side. This lack of fusion produced the UT indications.
Location of Indications Length Depth 1-I 1 - fitting side 6-1/4" .010" 1 I 2 - fitting side 1-1/2" .006" 1 I 3 - fitting side 5-7/ 8" .0 15" O e e G 43 _Q
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Joint geometry and resulting UT screen presentation produced by lack of root fusion defect seen in Figure 4.
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1 l
- l PIPE SECTION 2 (SF 201) l Heat Numbers Pipe Side
- Ht. 334165 j Fitting Side: Ht. 17616 i
Type of Weld: Field
Description:
This sample is characterized by sharp angular changes in the joint counterbore on the pipe side which acted as geometric reflectors. In addition, weld root irregularities existed which acted as reflectors. No cracks were found, therefcre, it must be concluded that the above account for the UT indications. Location of Indications Length 2 I 1 - pipe & fitting side 1/4" 2 I 2 - pipe side 1/4" 2 I 3 - pipe side 1/4" w 2 I 4 pipe side 1" P 2 I 5 - fitting side 1/4" l l l
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