ML20082E371

Forwards Matl Presented at 831115 Meeting Re Procedures Used for Ultrasonic Exams,Qualification of Personnel,Crack Growth Analyses & Details of Weld Overlay Repairs Performed Per IE Bulletin 83-02 Insp

ML20082E371
Person / Time
Site:	Browns Ferry
Issue date:	11/17/1983
From:	Mills L TENNESSEE VALLEY AUTHORITY
To:	Harold Denton Office of Nuclear Reactor Regulation
Shared Package
ML20082E377	List: ML20082E371 ML20082E469
References
REF-SSINS-6820 IEB-83-02, IEB-83-2, NUDOCS 8311280177
Download: ML20082E371 (70)

Text

, -

• TENNESSEE VALLEY AUTHORITY CH ATTANOOG A. TENNECSEE 37401 400 Chestnut Street Tower II November 17, 1983 Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, D.C. 20555

Dear Mr. Denton:

In the Matter of the ) Docket No. 50-259 Tennessee Valley Authority )

On November 15, 1983 we met with your staff to discuss the results of the pipe crack repair program for Browns Ferry Nuclear Plant unit 1. Included were discussions of the procedure used for the ultrasonic examinations, qualification of personnel, crack growth analyses, and details of the weld overlay repairs performed. No problems or outstanding unresolved items were identified by your staff in that meeting.

It was stated by the NRC staff that the material presented in the November 15 meeting should be formally submitted on the Browns Ferry unit 1 docket. As agreed, we are submitting as an enclosure the material presented in the meeting. The conclusions of your staff were that the information presented to the NRC staff in the meeting and in previous submittals demonstrates the adequacy of inspections, evaluations, and repairs performed.

Very truly yours, TENNESSEE VALLEY AUTHORITY L. M. Mills, Manager Nuclear Licensing Subscribe _a d sworn to before ,

me this / l da of [M y'ptd/t!1983

( l}( . I Notary Public My Commission Expires yh d 0pI7/

Enclosure cc (Enclosure):

U.S. Nuclear Regulatory Commission Region II ATTN: James P. O'Reilly, Regional Administrator 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30303 A Mr. R. J. Clark Browns Ferry Project Manager g g U.S. Nuclear Regulatory Commission '

7920 Norfolk Avenue k Bethesda, Maryland 20814 8311280177 831117 PDR O

ADOCK 05000259 PDR An Laval Onportunity tmployer

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Browns Ferry Nuclear Plant Unit 1 i

Final Presentation of Inspection and Repair Activities Associated with IEB 83-02 f

November 15, 1983 s

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BROWNS FERRY NUCLEAR PLANT UNIT 1 FINAL PRESENTATION NOVEMBER 15, 1983 AGENDA I. Inspection Summary II. Flawed Pipe Analysis - Overview III. Description of Inspection IV. Result of Review of Radiographs V. Results of Overlays VI. Qualification of Sweepolet Overlay

VII. Result of RWCU Repair VIII. Results of C1. 2 Core Spray Indications IX. Results of Baseline of Overlays X. Verification of Piping Systems Due to Overlays 4

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I. INSPECTION

SUMMARY

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INSPECTION

SUMMARY

- UNIT 1 IEB 83-02 INSPECTION BFNP UNIT 1 A. WELDS EXAMINED

1. RECIRCULATION RISERS -

40 SWEEP 0LETS -

8 LARGE DIAMETER -

43 SMALL DIAMETER -

12

2. RESIDUAL HEAT REMOVAL SUPPLY (20") -

8

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RETURN (24") -

27 SMALL DIAMETER -

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3. REACTOR WATER CLEANUP -

14

4. CORE SPRAY -

34

5. HEAD SPRAY -

27 S. CONTROL ROD DRIVE -

2 TOTAL -

216 B. WELDS HAVING INDICATIONS OF CRACKING

1. RECIRCULATION -

33

2. RESIDUAL HEAT REMOVAL -

14

3. REACTOR WATER CLEANUP -

3

4. CORE SPRAY -

4 TOTAL - -

51

C. WELDS REPAIRED -

42

! D. WELDS REPLACED -

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TABLE 1 KR-1-24 28" Pipe / Elbow Elbow Side of Weld 92:30 approx. 2" long Approx. 10% thru wall 8 4:30 approx. 2" long Approx. 17% thru wall e 11:00 approx. 3" long Approx. 25% thru wall 8 12:35 approx. 4" long Approx R% thru wall Pipe Side of Weld 4

@ 4:30 approx. 3" long Approx. 9% thru wall KR-1-45 28" Pipe /Elbcw 4

Indications 3600 intermittent both sides of the weld Approx. 23% thru wall KR-1-47 28" Pipe / Elbow Elbow Side of Weld 9 5:00 to 8:00 approx. 21" long Approx. 23% thru wall Pipe Side of Weld

@ 5:00 to 8:00 approx. 21" long j Approx. 20% thru wall KR-1-48 28" Pipe / Elbow Indications 3600 intermittent both sides of the weld Approx. 28% thru wall KR-1-52 28" Pipe / Elbow Elbow Side of Weld Indications 3600 intermittent Approx. 27% thru wall GR-1-27 28" Pipe / Pump Discharge Side Pipe Side of Weld e 6:30 approx.1" long Approx. 36% thru wall max.

e 8:30 approx. 1" long "

@ 10:00 to 11:00 approx. 7" long "

@ 12:00 to 2:00 approx. 14" long "

@ 4:45 approx. 1" long a GR-1-56 28" Pipe / Valve Elbow Side of Weld 6 12:30 to 3:00 approx. 17-1/2" long Approx. 29% thru wall GR-1-57 28" Pipe / Valve Pipe Side of Weld Indications 3600 intermittent Approx. 32% thru wall l GR-1-61 28" Pipe / Pipe '

Upstream Side of Weld 8 5:30 approx. 5" long Approx. 28% thru wall -

@ 8:00 approx.12" long Approx. 23% thru wall Downstream Side of Weld 0 7:30 to 11:00 approx. 25" long Approx. 30% thru wall

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4 GR-1-64 28" Elbow / Pump Intake Side Elbow Side of Weld Indications 3600 intermittent Approx. 335 thru wall GR-1-54 28" Pipe / Elbow Indications 3600 intermittent both sides of the weld Approx. 45% thru wall

, GR-1-58 28" Elbow / Pump Intake Side Pipe Side of Weld Indications 3600 intermittent Approx. 45% thru wall GR-1-1 28" Pipe / Pump Discharge Side Pipe Side of Weld

@ 2:00 to 5:00 approx. 21" long Approx. 6% thru wall

@ 6:30 to 8:00 approx. 10-1/2" long Approx. 85 thru wall

@ 10:00 approx. 1" long Approx. 10% thru wall GR-1-2 28" Pipe / Valve Pipe Side of Weld Indication 3600 intermittent Approx. 15% thru wall GR-1-3 28" Pipe / Valve Pipe Side of Weld Indications 3600 intermittent Approx. 33% thru wall KR-1-2 28" Pipe / Elbow Pipe Side of Weld

@ 11:30 to 12:30 approx. 7" long Approx. 6% thru wall

@ 2:00 to 8:00 approx. 42" long Approx. 15% thru wall Elbow Side of Weld

@ 2:30 to 3:30 approx. 7" long Approx. 8% thru wall KR-1-3 28" Pipe / Tee Pipe Side of Weld Indication 3600 intermittent Approx. 43% thru wall GR-1-60 28" Pipe / Elbow Pipe Side of Weld

@ 4:00 approx. 3" long Approx. 29% thru wall Elbow Side of Weld

@ 11:30 to 1:30 approx. 14" long Approx. 18% thru wall

@ 10:00 approx. 3" long Approx. 36% thru wall KR-1-25 28 Pipe / Tee Pipe Side of Weld

@ 8:00 to 3:00 approx. 49" long Approx. 14% thru wall KR-1-15 22" End Cap Pipe Side of Weld

@ 5:00 to 7:00 approx. 12" long Approx. 14% thru wall ,

Cap Side of Weld Indications 3600 intermittent Approx. 27% thru wall

KR-1-12 22" Pipe / Cross Pipe Side of Weld 9 7:00 approx. 3" long Approx. 26% thru wall KR-1-34 22" Pipe / Cross Pipe Side of Weld 9 6:00 approx. 4" long Approx. 85 thru wall 9 3:00 approx. 6" long Approx. 6% thru wall KR-1-37 22" End Cap Cap Side of Weld 8 11:30 to 3:00 approx.19" long Approx. 355 thru wall

@ 7:00 to 8:30 approx. 9" long Approx. 35% thru wall KR-1-14 Sweepolet Weld Saddle Side of Weld 8 5:30 approx. 2" long Approx. 10% thru wall

@ 6:20 approx. 2" long Approx. 10% thru wall Header Side of Weld

@ 11:20 approx. 9" long Approx. 19% thru wall KR-1-20 Sweepolet Weld Header Side of Weld

@ 2:00 approx. 1" long Approx. 29% thru wall KR-1-36 Sweepolet Weld Saddle Side of Weld 8 12:00 to 3:00 approx. 18" long Approx. 25% thru wall 8 8:00 to 9:00 approx. 6" long Approx. 25% thru wall KR-1-42 Sweepolet Weld Header Side of Weld 8 4:00 approx. 1" long Approx. 38% thru wall 8 10:00 approx. 1" long Approx. 20% thru wall KR-1-16 12" Pipe / Elbow Pipe Side of Weld Indications 3600 intermittent Approx. 35% thru wall KR-1-18 12" Pipe / Elbow Pipe Side of Weld Indications 360o intermittent Approx. 35% thru wall KR-1-21 12" Pipe / Elbow Pipe Side of Weld Indications 3600 intermittent Approx. 35% thru wall KR-1-22 12" Pipe / Elbow Pipe Side of Weld Indications 3600 intermittent Approx. 35% thru wall GR-1-41 12" Pipe / Tee Pipe Side of Weld

@ 11:00 to 1:00 approx. 6" long Approx. 12% thru wall

@ 9:00 approx. 3" long Approx. 8% thru wall

_. . _ _ - _ ,, _ r , , _ _ - _ _ _ _ , - - . _ _ . - - , , . , , . , - .

GR-1-46 12" Pipe / Elbow Pipe Side of Weld Indications 3600 intermittent Approx. 20% thru wall DSRHR 1-4 24" Pipe / Elbow Elbow Side of Weld

@ 11:00 to 2:00 approx.18" long Approx. 30% thru wall

@ 8:30 approx. 1" long Less than 10% thru wall DSRHR 1-4A 24" Elbow / Elbow Upstream Side of Weld Indication 3600 intermittent Approx. 44% thru wall DRHR-1-4 24" Pipe / Elbow Pipe Side of Weld

@ 7:00 approx. 1" long Less than 10% thru wall

@ 9:00 approx. 1" long Less than 10% thru wall 9 10:30 approx. 1" long Less than 10% thru wall DSRHR-1-5 24" Pipe / Elbow Elbow Side of Weld

@ 2:00 approx. 7" long 31% thru wall

@ 8:00 to 12:00 approx. 25" long 31% thru wall }

DSRHR-1-8B 24" Pipe / Elbow Pipe Side of Weld

@ 12:00 to 3:00 approx. 20" long Approx. 41% thru wall Elbow Side of Weld

@ 1:00 to 3:00 approx. 14" long Approx. 31% thru wall DRHR-1-8 24" Pipe / Valve Pipe Side of Weld

@ 11:00 approx. 5" long Approx. 25% thru wall DSRHR-1-9 20" Pipe / Elbow Elbow Side of Weld 0 7:00 to 11:00 approx. 28" long Approx. 29% thru wall DSR HR-1-10 20" Pipe / Elbow Pipe Side of Weld

@ 12:00 approx. 3" long Approx. 30% thru wall

@ 10:30 approx. 3" long Approx. 12% thru wall Elbow Side of Weld

@ 12:00 approx. 6" long Approx. 23% thr1 wall DSR HR-1-11 20" Pipe / Elbow Elbow Side of Weld

@ 6:00 to 9:00 approx. 19" long Approx. 24% thru wall DRHR-1-15 24" Pipe / Valve Pipe Side of Weld

@ 6:00 approx. 8" long Approx. 30% thru wall DRHR-1-17 24" Pipe / Valve Pipe Side of Weld Indications 3600 intermittent Approx. 31% thru wall

.. - . _ _ . . . _ , . - . . - - .-, ~, . _ _ , . _

o .

DRHR-1-18 24" Pipe / Tee Pipe Side of Weld

@ 12:00 to 3:00 approx. 20" long Approx. 16% thru wall

@ 7:00 approx. 4" long Approx. 20% thru wall DRHR-1-20 20" Elbow / Valve Elbow Side of Weld Indications 3600 intermittent Approx. 43% thru wall DRHR-1-5 24" Elbow / Valve Elbow Side of Weld Indications 3600 intermittent Approx. 36% thru wall DCS-1-7 12" Pipe / Valve

• Pipe Side of Weld Indications 3600 intermittent Approx. 41% thru wall DCS-1-8 12" Pipe / Valve  ;

Pipe Side of Weld I

@ 12:30 to 3:30 approx. 9" long Approx. 30% thru wall

@ 9:30 to 10:30 approx. 3" long Approx. 30% thru wall DCS-1-2 12" Valve / Elbow (Class 2)

Elbow Side of Weld Indications 3600 intermittent Approx. 35% thru wall CS-1-69 12" valve / Elbow (Class 2)

Elbow Side of Weld 0 12:00 to 1:00 approx. 3" long Approx. 27% thru wall

@ 6:00 to 9:00 approx. 9" long Approx. 27% thru wall DSRWC-1-2 6" Pipe / Elbow Elbow Side of Weld

@ 12:00 to 1:00 approx. 3" long Approx. 50% thru wall

.DSRWC-1-3 6" Pipe / Elbow Elbow Side of Weld

@ 2:30 approx. 2" long Approx. 85% thru wall

@ 9:00 approx. 2" long Approx. 85% thru wall

@ 12:00 approx. 2" long Approx. 85% thru wall 4

i e

- . , - - -v. - . - - . ,. -, ., w,-

9 4 e O i

i t

9

/

=

s 1

0 a

W.

11. FLAWED PIPE ANALYSIS - OVERVIEW i t

t

, s' k

h m *

(

i 0 e a e A

FLAWED

.s ,

PIPE ANALYSIS s

t CRACK EN DES GROWTH CURVES ---) ^^

CRACK GROWTH '

BUTT WELD --"--g ANALYSIS 4

RESIDUAL STRESS INPUT

%k ASME SECTION XI EVALUATION i IW B-3640 s

k s qr

RE-EV AlbATION FOR SHRWKAGE OF ADJACENT OVERLAYS

~

1 s

i

\

{ *

s. t

'? .

ri - ~ r '

CRACK GROWTH ANALYSIS METHOD DRIVE _ -- COMPUTER PROGRAM (FORTRAN SUBROUTINE DEVEL UTILIZED TO COMPUTE STRESS INTENSITY VALUES, K MAIN CALLING PROGRAM WRITTEN IO:

\

e INCLUDE CRACK GROWTH CURVE DATA ACCEPT ALL INPUT (1.E., SUSTAINED STRESSES, RESIDUAL STRESSES, Ah INITIAL CRACK SIZE) ,

-- CALL DRIVE IN SMALL TIME INCREMENTS TO CALCULATE NEW K VAL THE CURRENT CRACK SIZES I

-- CALCULATE CRACK GROWTH AND RESULTING CRACK SIZES UTILIZING THE CALCULATED K VALUES h

$ e

• • m

(

, - - , - . - . , - - . - , , , , - , , , , - . , - - - - - --,....n.. . , , . . . - . - . - - - . ---.,-.-.._..,,----,,--n -..- ,.

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O G

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= / A Sf8eltfilf3 At ll60*F.2h 0 2 co n

{ ,,-. .

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@ svaNr CLAnst fif4tO

@ $0Lowose-CECRO to,g -

@ tf ASAOut - Mtf Acme nt.

SF ARCH LAS

,", @ PArta - AACO%est seat lag 4AIF M 343 8 SteelefellO SY vetLOeseQ. LTS AT 931*8. 24 m. 8 ap== O 8 8# % "I ' " 3

/ 2 90't - I t t t i e is ao ao ao se 88 80 STRtSS 18ef f eest?v. E theJ66 EPRI N P- 2t72 Figure H-1.

$wannary of Constant Load Crack Growth Data (Curves are evaluation curves.) Data collected in 0.2 ppe 20 and a ppus 0 ''

2 Different levels of sensitization enantned.

H-64 s

t

,,-,---,e--- , , -.- - - - , --- - -

o . . -

. 3 Loc 4 Tion M 55 (KsI) 3o _

o (en) + so. o 0.20 t 0.0 0.25t -7.0 0.301 -10.0 0.40 t -13.0 20 --

0 50% ~lI.O l.oo t (ov) + s. I 3+10-v E

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s o.2t o.4t 0.Gt o.8t OD i

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l AXIAL RE. SIDUAL ST'RE.SS PIPE DI AMETER O F 2 0 T O 2 S "

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- -. . . . _ ... . . - . . .- - . . - - - =- - - . - _ - . . . - - . _ - . . . - .-

4 1

STRESS DATA INPUT FOR CRACK GROWTH ANALYSIS l

, SUSTAINED SYSTEM STRESSES  :

--DEAD WEIGHT

--THERMAL EXPANSION I

--INTERNAL PRESSURE i

> i

STRESS DATA USED IN IWB-3640 EVALUATION i PRIMARY STRESSES r

--DEAD WEIGHT i

--SEISMIC

--lNTERNAL PRESSURE

i

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1 i

r L

i'

's -'%e- r.mm ry-_v. t*,-s w e 4 . w _s,n-,w-.ym,3,e,,,--m3.re.,y-+m._,3 r w ,mm v w _ c. ,m.--. -,,m, .-3.w,_-,-.,_,c.-.,m ,m+,w-re, we..- ,%--

ASME SECTION XI TADLE IWD-3641-1 ALLOWABLE END-OF.lNSPECTION PERIOD SIZE FOR CIRCUMFERENTIAL FLAWS NORMAL CONDITIONS (1) Ratio of Length to Circumference Pm+Pb 0.1 0.2 9.3 0.4 0.5 or more Ratio of Flaw Depth to Thickness (2) 1.5 (3) (3) (3) (3) (3) 1.4 0.30 0.20 (3) (3) (3) 1.3 0.48 0.38 0.28 0.18 0.18 1.2 0.66 0.56 0.46 0.36 0.28 1.1 0.73 0.63 0.53 0.43 0.33 1.0 0.75 0.70 0.60 0.50 0.40 0.9 0.70 0.75 0.66 0.56 0.46 0.8 0.73 0.75 0.72 0.62 0.52 0.7 0.75 0.75 0.75 0.68 0.58 0.6 0.75 0.75 0.75 0.73 0.63 (1) Pm = Primary Membrane Stress Pb = Primary Bending Stress Sm = ASME Code Design Stress at Temperature (2) Crack Depth = a for a Surface Flaw 2a for a Subsurface Flaw p) IWB-3514-3 Standards Govern o

~*

,y

Flawed Pipe Analysis of Larae Diameter Piping Welds

• Flaw Size Greater than 105 I ,

' Allowed End-of 2 Allowed Initial 2 Margin for2 Initial Crack Steady Statel Evaluation Period Crack Size for s Ueld No. Size (1) Stress (ksi) Error in Flaw Flaw Siza (5) 18 mo. Cycle (5) Sizing GR-1-2 155 - 3600 7 941 63 49.2 228 KR-1 2 155 - 3600 8.266 63 48.0 220 KR-1-24 255 - 3 in. 8.167 753 70.23 1813 i

KR-1-25 145 - 3600 9.263 63 43.5 211 KR-1-47 235 - 21 in. 8.081 753 62.23 1703 1

Includes weld shrinkage stress

2. Based on 3600 intermittent riaw i 3 Based on flaw with defined end points 4

i Flaw Size less than 10%

,i d Allowed End-of- Allowed Initial Margin for Initial Crack 1 Steady State 2 Evaluation Period Crack Size fer j . Weld No. Size (1) Stress (ksi) Error in Fir-Flaw Size (1) 18 mo. Cycle (1) Sizing (1)

KR-1-12 6 13.186 63 26.1 335 i KR-1-34 8 10.847 63 37.4 367 GR-1-1 8 8.078 63 48.7 54P DRHR-1 4 10 8.063 63 49.4 4

39

, 1. , Assumed to be 3600 intermittent

2. Includes weld shrinkage stress i

j JHF:FSB '

i 10/12/83 i

) FeeSc m' g

1 1

1 i

i 111. '

DESCRIPTION OF ULTRASONIC INSPECTIGNS f

l I

BROLiNS FERRY - UNIT 1 h

ULTRASONIC PROCEDLRE - N-UT-25 0UALIFIED 'N /CCORDMCE WITH IE e REQUIRES CALIBRATION FROM 5% NOTCHES O CORRECTION FOR ATTBiUATION DIFFERENCES (TRMSFER TECHt1100E) 8 EXMINATION OF ltEREASED SENSITIVITY MIMINlli 60s ABOVE CALIBRATim 8 RECORD MD EVA'UATE ALL REl.EVANT REFLECTORS, REGARDLESS OF AMPLITUDE, ORIGifMTING IN THE HAZ OR BASE E TAL 8 EXANNING THE WELD FROM EIGHT DIRECTIONS, 2 PERPENDICUl#, 2 PARALLEL. 4 OBL10VE e SCMtilNG SRED REDUCED TO 4 INCHES PER SECOND e PERFORM 1/2 N0DE EXAMINATION ON ALL lELDS, 450 MD 600 AS REQUIRED i

.f I

- . , - _ _ , . . , _ . . . . _ , . . _ __ .....m__,_..___,,,,,.m .

_,_..,..m.,mm.,.m. _ . _ . _. . , , . - . . .. - . _ . .,_ .-. .-__ ,,,_,__.,. , _ , . . ,,, , _ . . , . .. , , , . -_

h .

4

• CALIBRATION 5

80% FSH l

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l l

i I

I i .;

e

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1/2 NODE 1 NODE l-1/2 NODE

\

5% NOTCH O

n . ,--

TRANSFER TECHNIQUE Xdb 80% FSH CALIBRATION BLOCK g Xdb + db REQUIRED FOR 80% FSH ll

'l I

l l lIl Xdb I

I d + CALIBRATION = REFERENCE SENSITIVITY I

l PIPE TO BE EXAMINED l <

l l

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PIPE DIAMETER GREATER TMAN 22" AND SAFE ENDS If d i FIFE DIAMETER 22" AND LESS N

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a-2 u~1 - w - -

45* @

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EXAMINATION 9

1-1/2 NODE 1/2 NODE i h W

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e e s e WIDE WglD CR e s 600 W ,

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' e 4

EVALUATIONPROCESS S SIGN 4. CHARACTERISTICS

' i 4 THIO (ESS EASTEtelTS #0 0.D. PROFILitG e GOSS SECTIONAL DATA PLOTTitG, MULTIPLE #GLES 4 REVIEW T CONSTRUCTION RADIOGRAPHS 8 REEXRilNATION BY LEVEL 111 GENERALLY USItG DIFFERENT ELES S BASED ON REEXMINATION RESULTS. PROPER EVALUATION MAY R

1. 1. D. PROFILING WITH 00 TRMSDUCER

2. CHEE IN EXMINAT10tl FREQUENCY

3. CHEE Ill EXMINAT10tl ANGLE fl. CHNGE IN TRMSDUCER S12E

5. RE-REVIEW 0F RADIOGRAPHS

6. RE-RADIOGRAPH l 3 COMPMISON WITH OPPOSliE HND WEIR 91TS i

t COMPMISON WITH OTHER MEAS OF THE SNE WELD 0 COMPMISON WITH SIMILM WELDS AT OTHER PLMTS 9 EVALUATION OF GE0MEIRlC INDICATIONS WITH THE POSSIBILITY OF T EXISTENCE 8 LOOK FOR UNIF0 MITY! I.E.,IFCOUNTERBORE/ROOTETC. ME UNIFORM ALONG ENTIRE WELD - THE UT SIGNAL SHOULD BE UNIFORM AL0tG ENTIREWELD 8 REVIEW 0F PREVIOUS UT DATA

1 INDICATIONS WERE EVALUAED AS IGSCC IF:

1. CROSS SECTIONAL PIOTS USitG FINITE SOUND PATH ISSUREWNTS 2

IWICATE REFLECTOR IN TE HAZ j

2. FINITE SOUND PATH EASlREENTS ARE LESS THAN OR EQUAL TO TE DISTANCEREQUIREDTOItifERSECTTHEI.D. SURFACE 4

4 4

J N I' 4  :

i N N s

. 60 'x i 45

' 's N

s s y  %

i i- TYPICAL

,7 .c,- ,.--n- ,..,--g , , . - -

, , , , ,,,n-.. .nm, - _ , . . - - - , - . ..-.--,-.--_-,---,-,,.----,-..--.n., -

~

$1 ZING i -

MAXIMUM AMPLIRJDE NOISE LEVEL t

60' SINCLE ELEMENT

~

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s .s ,

N 4

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A 4

W l

e .

EXAMINAT10t1 PERSONNEL 4 EVEL lil's - WA PERS0tlNEL - QUALIFIED PER lE 83-02, PARCH 1983

\ -

0 LEVEL ll's - WA PERS0tNEL - QUAllFIED PER lE 83-02, PARCH 1983 8 EVEL l's - CONTRACTOR PERSONNEL - MitllMUM LEVEL I CERTIFICAT10fl IN ACCORDANCE WITH ASNT REC 0ft B-IDED PRACTICE t10. SNT-TC-1A,1975 EDIT 10t1 PLUS - 32 HOURS TRAINltE C0lRSE AT IVA's POWER OPERATION TRAINitG CBlTER TITLE (F C0lRSE:

ULTRASONIC SC#NitG FOR DETECTION OF IGSCC IN ACCORDANCE WITH PROCEDLRE N-ilT-25 C0lRSE OUTLINE

1. INTRODUCTION

2. INSPECTION ENFORCBET EULLETIN 83-02

3. IGSCC - CHARACTERISTICS MD CAUSES

4. PROCEDlRE - ti-UT-25

5. EQUIPMENT

6. IRORATORY EXERCISE - ON PIPE SEGEtD!T CONTAltiltG IGSCC PLUS SEVERAL PIPE SEGEtBIT WITH IGSCC LIKE FlA S (IC>-20 H0lRS)

7. EXANNATIONS - SPECIFIC MD PPACTICAL t0TE: 4-DAY C0lRSE MAXIMlil 8 PERSONS PER CLASS

e. .

e .

9 IV. REVIEW 0F RADIOGRAPHS 1

~

-- - ~ - , , - , ,-. ,

I REVIEW 0F RADIOGRAPHS

1. AVAILABLE RADIOGRAPHS WERE EXAhlNED FOR A. ID GRINDING B. OsVIOUS COUNTER BORE II. A CORRELATION APPEARS TO ExtST BETWEEN GRINDING AND/0R COUNTER

BORE TO CRACKING - ESPECIALLY GRINDING I

A. THIRTY- D AD10 GRAPHS OF WELDS CONTAINING INDICATIONS WERE EXAMINED, TWENTY SIX OF THESE HAD ID GRINDING OR Osv10uS COUNTERBORES B. TWENTY-0NE OF ABOVE WELDS HAD ID GRINDING i

i l

i T

+

Radiograph Sunnary .

~

Weld Description Defect ID Grinding Counterbore Coassents' ~

. GR-1-11 12" Pipe to SE No No 1

GR-1-14 No No R2 GR-1-21 No No GR-1-24 No No R1 GR-1-37 No No GR-1-40 No No GR-1-43 No No -

GR-1-47 No No R1 GR-1-50 No No GR-1-17 KR-1-16 12" Pipe to ELL 35% No No KR-1-17 No No KR-1-18 35% Yes No R1 KR-1-21 35% No Yes (Possible)1/4"

, KR-1-22 35% No Yes 1/4" Kr-1-38 No Yes (Possible)1/4" i KR-1-39 No No R1 l KR-1-40 No No i Kr-1-43 No Possible 1/2" j KR-1-44 No Yes 1/2" t GR-1-10 12" Riser to ELL No No

GR-1-13 No No R2 (Root)

GR-1-16 No No R4 (Root)

GR-1-20 No No GR-1-23 No No GR-1-36 Yes Partial No R1 GR-1-39 No No R1 GR-1-42 No No

GR-1-46 No No R2 GR-1-49 20% Some No R2 Root Pas

, GR-1-9 12" Riser to SW-0-Let No No R3 GR-1-12 No No R1 GR-1-19 No No R2 GR-1-22 Yes No R2 (ID)

GR-1-35 No No GR-1-38 No- No R3 -

GR-1-45 No No R1

, GR-1-48 No No GR-1-15 12" Riser to Reducer No No RS l GR- 1-41 12% No No R1 KR-1-14 SW-0-Let to Manif. 19% Yes No R1 i

Weld D*scription Defect _ ID Grinding Counterboro Commento ,

KR-1-13 , Yes No - -

KR-1-19 Yes No Some Repair:

KR-1-20 29% Yes No Some Repairr KR-1-35 Yes No KR-1-36 25% Yes No R1 KR-1-41 Yes No Fill Scar Il KR-1 42 38% Yes No Some Repair; KR-1-11 28" Reducer to Cross No No R2 KR-1-33 No No R1 l KR-1-15 22" "anif to End 27% Yes No R3

KR-1-37 35% Yes No R2

)

KR-1-12 22" Manir to Cross 26% Yes (Partial) No R1 GR-1-18 No No R1 GR-1-44 No No

KR-1-34 8% Yes Partial No R1 i GR-1-8 28" Cross to Tee No Yes 1/2" R3 5

GR-1-34 No No KR-1-3 28" Tee to Pipe 43% Yes No R1 KR-1-25 14% No Yes 1/4" KR-1-2 28" Pipe to Ell 15%

KR-1-24 25% No Yes 1/4" GR-1-3 28" EL to Valve 33% No No i GR-1-29 Yes No R3 GR-1-2 28" Valve to Pipe 15%

', GR-1-28 Mabye No R1 I

GR-1-1 28" Pipe to Pump 10% Yes No R1 GR-1-27 37% Phbye No GR-1-58 28" Pump to Ell 34% No Yes 1/4" Faint j GR-1-64 31% Yes No R2 1 KR-1-48 28" Ell to Pipe 30% Yes Partial No R2

} KR-1-52 27% No No R1 j GR-1-57 28" Pipe to Valve 33% Yes No R2 GR-1-63 No No R2 OD Grind GR-1-56 28" Valve to Ell 28% Mabye No GR-1-62 Yes No R2 KR-1-47 28" Ell to Pipe 20% Yes No R4 KR-1-51 Yes No R1 KR-1-46 28" Tee to Pipe i I GR-1-55 28" Pipe to Tee No No R8 .

GR-1-61 28" Pipe to Pipe 30% No No GR-1-54 I

) 28" Pipe to Ell 45% No No R1 Large i

s

, Wald Description Defect ID Grinding Countsrbora Comments -

3 GR-1-60 36% No No R3, Por,,

Lof, Slag KR-1-45 28" Ell to Pipe 23% Yes No KR-1-50 No Yes (Possible) 1/2" GR-1-53 28" Pipe to SE Yes No GR-1-59 No No GR-1-25 22" Manir to Valve Partial No R2 GR-1-51 No No 1

GR-1-26 22" Valve to Pipe No No

, GR-1-52 Partial No

'.; DRHR-1-3 No Possible 1/2" R1 l

j DRHR-1-5 365 Yes No  !

4 DRHR-1-6 Yes No R2 DRHR-1-8 25% Yes No I i DRHR-1-9 Yes Yes R2 '

DRHR-1-11 No No R1 1 DRHR-1-12 No No I i

DRHR-1-16 No No i

i l I 4

l I

" l

[

i I

j _ _ _ _

}

1

! r

V. RESULTS OF OVERLAYS - NUTECH i

l l

l 1

l l

i

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04 4 -

1. 5 WELD OVERLAY REPAIR 8 DESIGN METHODOLOGY t DESIGNS 9 RESIDUAL STRESS 8 CRACK GROWTH

)

FLAW EVALUATION METHODOLOGY

. Select Highest Applied Stress at a Crack Location in Size of Piping Being Evaluated

= Use ASME Section XI Tables or Source Equations to Determine End of Inspection interval" Allowable" Flaw Size

. Establish Flaw Size at Beginning of Cycle by Doubling Maxirnum UT Depth

• Determine Crack Growth Using Conservative Crack Growth Curve to identify " Calculated" End of Cycle Flaw Size

• Compare " Calculated" to " Allowable" Crack Depth at End of Cycle to Determine the Need for Repair N P R E 83.59-01 4

5 FRACTURE MECHANICS ANALYSIS APPROACH FOR ACCEPTABLE CRACK DEPTH DETERMINATION

!^

• Net Section Collapse Approach for Allowable End of-

' ., s Cycle Crack Size ,

- Axlal and Circumferential Crack Depth vertus Length

- Conservative with Respect to More Exact Tearing I Modulus Approach

- Proposed Section Xi Article IWB-3640

• Crack Propagation Analysis to Determine Beginning of-Cycle Flaw Which Would Grow to Above Allowable

- DA / DN and DA / DT Data

-l

- Stress Intensity Factor

- Crack Depth versus Time j d

• Typical Result - Evaluation of Recent IGSCC Indications .

• Residual Stress Considerations </

e soum.u nuteC1 >

Y

r 3 WELD OVERLAY AS A REPAIR DESIGN OF OVERLAY REPAIR

• Determine Residual Stress Pattern of Weld Geometry with Overlay

- Residual Stress Pattern Calculated at Small Weld Overlay increments (" WELDS" Analysis)

• Calculate Crack Growth with Overlay in Place

- Crack Depth at Beginning of Cycle Equal to Twice the Maximum UT Depth

- Crack at Ful! Depth for Entire UT Determined Length

- Two Growth Laws Used a K

10-

7 = 4.116 x da = 1.2 x 10-8 e '"

• l l

I l

N PR E83.59-02

1 l

r 3 PROPOSED TABLE IWB 3641-1 ALLOWABLE END OF INSPECTION PERIOD SIZE FOR CIRCUMFERENTIAL FLAWS )

NORMAL CONDITIONS .

Ratio of Length to Circumference (1)

Pm+Pb 0.1 0.2 0.3 0.4 0.5 or more

• Ratic of Flaw Depth to Thickness (2) 1 1.5 (3) (3) (3) (3) (3) ,

I l 1.4 0.30 0.20 (3) (3) (3) 1.3 0.48 0.38 0.28 0.18 0.18 1.2 0.66 0.56 0.46 0.36 0.26

I 1.1 0.73 0.63 0.53 0.43 0.33 1.0 0.75 0.70 0.60 0.50 0.40 0.9 0.75 0.75 0.66 0.56 0.46 0.8 0.75 0.75 0.72 0.62 0.52 1

l 0.7 0.75 0.75 0.75 0.68 0.58 0.6 0.75 0.75 0.75 0.73 0.63 (1) Pm = Prirnary Membrane Stress Pb= Primary Sending Stress l

Sm = ASME Code Design Stress at Temperature (2) Crack Depth = a for a Surface Flaw l 2a for a Subsurface Flaw (3) IWS-3514 3 Standards Govern c

' . u.:y, nuteC1 >

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3 P

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5 4

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V O

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I 3 l i

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M D E 3 T I L 0 P 9 P 5 A 3 T 8 E

N 1 E Pf T N A

P r

. i ,

OVERLAY DESIGNS Unoverlaid Steady

Pipe Crack

• Overlay Ove rlay State Wr No. Diameter Depth Thickness Length Stress Category

> KR-1-37 22in. 35% .200in. 4. Sin. '6,099 psi 1 KR-1-15 22 27 .200 4.5 6,099 1 FR-1-3 28 43 .35 7.0 10,583 2

, GR-1-58. 28 45 .35 7.0- 8,520 2 GR-1-54 28 45 .35 7.0 9,339 2 GR-1-3 28 35 .25 7.0 8,087 3 GR-1-60 28 36 .25 7.0 8,472 3 GR-1-27 28 36 .25 7.0 7,460 3 GR-1-57 28 32 .200 4.5 7,971 3' GR-1-64 28 33 .200 4.5 7,426 3'

.KR-1-45 28 23 .200 4.5 9,490 3' KR-1-48 28 28 .200 4.5 8,461 3' 4 GR-1-52 28 27 .200 4.5 7,299 3' GR-1-56 28 29 .200 4.5 7,862 3' GR-1-61 28 30 .200 4.5 8,103 3' KR-1-18 12 35 .125 2.5 8,327 4 KR-1-21 12 35 .125 2.5 10,505 4

-KR-1-22 12 35 .125 2.5 7,894 4 KR-1-16 12 35 .125 2.5 8,700 '4 GR-1-46 12 20 .125 2.5 10,106 4 GR-1-41 12 12 .200 4.5 19,114 5 l

D-RHR-1-17 24 31 .200 4.5 10,287 6 D-RHR-1-18 24 20 .200 4.5 10,669 6 D-RHR-1-15 24 30 .200 4.5 7,571 6 DS-RHR-1-9 20 29 .200 4.5 16,115 6 DS-RHR-1-8B 24 41 .200 4.5 9,234 6 DS-RHR-1-11 20 24 .200 4.5 16,908 6 DS-RHR-1-10 20 30. .200 4.5 16,518 6 DS-RHR-1-5 24 31 .200 4.5 8,362 6

'DS-RHR-1-4 24 30 .200 4.5 9,128 6 D-RHR-1-20 20 43 .200 4.5 15,571 6 D-RHR-1-8 24 25 .200 4.5 11,051 6 D-RHR-1-5 24 36 .25 7.0 7,972 7 DS-RHRl-4A 24 44 .25 7.0 9,275 7 The measured UT depth was multiplied by 2.0. The tabulated depth 1 is in percent of unrepaired pipe thickness.

OVERLAY CATEGORI2ATION Minimum ' Minimum Initial Design As-Built Applied CraygI Pipe Pipe Overlay Overlay Overlay Category Stress Size Diameter Thickness Thickness Thickness Length

1. 6,099 psi 70% 22" 1.03 .2" .25" 4,5" 2 8,411(5) 90 28.51 1.322 .35 .39 7.0 3 - 8,145(5) 72 28.15 1.138 .25 .24 I4) 7.0 3' 9,258(5) 66 28.15 .. 1.138 .20 .22 4.5 4 15,110 70 12.75 .709 .125 .16 2.5 5 19,114(2) 24 12.75 .579 .20 .26 4. 5' 6 16,908 I3) 86 20. 1.031 .20 .25 4.5 7 13,617 88 20. 1.031 .25 .28. 7.0

~

III The measured U.T. depth was multiplied by 2.0 for use in the crack growth analysis. The tabulated crack sizes are in percent of unrepaired pipe thickness.

(2) Crack growth evaluation performed using 14,207 psi 19,114

=

.579___

.579 + .200 (3) Crack growth evaluation performed using 14,161 psi = 16,908 1.031 1.031 + .200 (4) As welded thickness was greater than 0.25" so residual stress prediction applies. Required structural thickness is 0.16".

(5) These. values exceed S T , where S and T overlay are given on the previous page.

T+TO

' I 60 -

40 -

20 - APPLIED k

s E

cc o 0 . . i i U 20 40 60 80 100 CRACK DEPTH N (% OF OVERLAID THICKNESS) a Z

$ 2 Q

g . RESIDUAL ti CTVA83.0141 Figure 1 STRESS INTENS TY FACTOR FOR CATEGORY 1

- - - - - , - - , -e .-a., _ , -- ,,,,,,,-.---,,,,-,,-------,--,---,,,n, -- , e---ae.-n. ---,,..n--.,,,-r,- - - - - ,-,,-m

'# g ,

g 4

@ O 100-

- 80 -

8 75 ALLOWABLE DEPTH Z

M N

z O 59 NO CRACK GROWTH AS K IS NEGATIVE g,

5 m

W O

u.

O at 40 -

I w

j O

! g O

4 m

o 20 -

0 , , , ,  ;

O 20 40 60 80 100 TIME (MONTHS)

CTVA83.0102 Figure 2 CRACK GROWTH FOR CATEGORY 1

ee *O e ,

e

• 40 -

APPLIED b .

b 3 20 -

3 O

u.

0- . . , ,

C 20 40 60 80 100

.n

$ CRACK DEPTH y

(% OF OVERLAID THICKNESS) g g RESIDUAL 4 _;

CTVA83.0143 Figure 3 STRESS INTENSITY FACTOR FOR CATEGORY 2

100 .

i g 80 -

w z 72 ALLOWABLE DEPTH 5

E 71 NO CRACK GROWTH AS K IS APPROXIMATELY 0.0 W

9 5 a-a:

W 0

u.

O z 40 -

=

0 M

U -

4 a:

20 -

0 , , , ,

0 20 40 60 80 100 TIME (MONTHS)

CTVA83.0104 Figure 4 CRACK GROWTH FOR CATEGORY 2

. _ . ., _ . . . ~ -, . - . . _ _ _ _ - . . . _ _ _ _ _ . . - _ _ _ . ... . _ . _ _ _ _ . . . _ . _ . . . _ . . _ _ _ _ , . . - . . _ . _ _ . . . _ _ _ _ _ . - _

60 -

40 -

APPLIED FOR CATEGORY 3' 1- 20 - APPLIED FOR 2 CATEGORY 3 2

1. .)

E I o , , , ,

20 40 60 80 100 h

m CRACK DEPTH g (% OF OVERLAID THICKNESS)

M uJ p r RESIDUAL m

-60 CTVA83.0145 1

Figure 5 STRESS INTENSITY FACTOR FOR CATEGORIES 3 AND 3'

100 80 -

h 74 ALLOWABLE DEPTH z -----------------

U E

P-59 NO CRACK GROWTH AS K IS NEGATIVE FOR CATEGORY 3 60 -

m y 56 NO CRACK GROWTH AS K IS NEGATIVE FOR CATEGORY 3' O

55 40 -

{

t E ~

5 u 3_

0 , , , ,

0 20 40 60 80 100 TIME (MONTHS)

CTVA83.01G Figure 6 CRACK GROWTH FOR CATEGORIES 3 AND 3'

e 60 -

- I 40 -

APPLIED 5

4 20 -

m O

u.

O i i e i

$ 20 40 60 80 100 s

g CRACK DEPTH z (% OF OVERLAID THICKNESS) ,

g RESIDUAL CTVA83,01-07 Figure 7 STRESS INTENSITY FACTOR FOR CATEGORY 4

. . ... - - .... -. .. - - - - .. . . - _ . . . . . _ . - - - . . _ . - ~ _ -

- & ,m ,

h h 4 4

,100-80 -

AL ______________

h, _75_ _LOWABLE DEPTH 5

E F-9 NO CRACK GROWTH AS K IS APPROXIMATELY 0.0 5

• 5 0

L O

8 2 40 -

E u

O

(

5 20 -

0 , , , 3 0 20 40 60 80 100 TIME (MONTHS)

CTV A83.01M Figure 8 CRACK GROWTH FOR CATEGORY 4

, o, .

80 -

60 -

40-5 APPLIED

.5 4

5 5 20 -

ti .

2 C

E z

^

5 0 . . , .

E- 20 40 60 80 100 m CRACK DEPTH

% (% OF OVERLAID THICKNESS) en RESIDUAL CTVA83.0103 Figure 9 STRESS INTENSITY FACTOR FOR CATEGORY 5

. . . . - _ . . . . . _ . . . . . - . ~ . . . - ..

l 100 80 -

w z

M 9

z o 62 ALLOWABLE DEPTH

$ 60 -

e W

0 u.

O z #- 0.11 K da.

dt - 1.2 X 104 e g

w w  %

I K<0 = -

U m

" 20 -

- =

dt 4.116 X 10'I K 0 , , , ,

0 20 40 60 80 100 TIME (MONTHS)

CTVA83.01 10 Figure 10 CRACK GROWTH FOR CATEGORY 5 4

-,4-- , . . , - ~ . , - , --,m, , . . _ _ . . , , _ ,,,m_,_,_..-..,.,.,,p-m, .,-- r-_,., y -,,_,,-e,% 7- .--.m-,.,,,, ,y,,,s

80 -

60 -

i 40 -

2 5

3 APPLIED

~

20 ~

o /s: .

i I

b E

• O . . . .

z- 80 100 20 40 60

$ CRACK DEPTH

$ (% OF OVERLAID THICKNESS)

_20 -

RESIDUAL CTV A83.01 11 Figure 11 STRESS INTENSITY FACTOR FOR CATEGORY 6

q e a w $

100 ALLOWABLE OEPTH g 80 -

E x

l!! _.3 __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - -

U 5 72 NO CRACK GROWTH AS K IS APPROXIMATELY ZERO w

o 5 60 -

<e

. W 0

u.

O

= 40 -

m C

M U

4 c::

O 20 -

0 6 1 4 4 0 20 40 60 80 100 TIME (MONTHS)

CTVAa101.t g Figure 12 CRACK GROWTH FOR CATEGORY 6

80 -

L 60 -

40 - APFt. LED o 20 - ,

b C

a u,_J o . . . .

E 20 40 60 so 100 h CRACK DEPTH g (% OF OVERLAID THICKNESS)

=

RESIDUAL CTVA83.01 13 Figure 13 STRESS INTENSITY FACTOR FOR CATEGORY 7

h 9 6 100

- 80 -

N 75 ALLOWABLE DEPTH E

5 E 71 NO CRACK GROWTH AS K IS APPROXIMATELY 0.0 c

$ 80 -

5 0

a O

[ 40 -

A b

Q M

O E

" 20 -

0 6 i i 1 0 20 40 60 80 100 f

TIME (MONTHS)

CTVA83.01 14 Figure 14 CRACK GROWTH FOR CATEGORY 7

I VI. QUALIFICATION OF SWEE0PLET OVERLAY

~ . .

- - , . ., , ,. ,-- , --,, , -,--v.,,w,.,n_,,, ,,,-,,,,,m-v,+-. g,,,,,,,,.,,- ,,,7,, ,,._nn,,,,,v,ay,,-. 7,_.wyn .,,,,v,,y,,,-,,_.., , . . _ .

SWEE0PLET QUALIFICATION & REPAIR

1. SIZE OVERLAY ANALYTICALLY A. OBTAIN LIMERICK SWEEP 0LET-TO-MANIFOLD ASSEMBLY B. ANALYZE DIMENSIONALLY C. MEASURE BFNP ASSEMBLY TO CONFIRM MATCH D.

DETERMINE RESIDUAL STRESS STATE OF llMERICK ASSEMBLY ANALYTICALLY E. SIZE OVERLAY FROM ABOVE INFORMATION F. INITI AL DETERMINATION 4" WIDE X .25" THICK II. PERFORM OVERLAY WELDING ON llMERICK ASSEMBLY A. DESIGN & BUILD WELDING FIXTURE B. INSTALL TMERM0 COUPLES, PUNCH MARKS (FOR SHRINKAGE MEASUREMENTS)

END CAPS, WELDING EQUIPMENT ON MOCKUP C. PERFORM OVERLAY WELDING ON MOCKUP 111. ANALYZE MOCKUP i

i A. OBTAIN INPUTS

1. SHRINKAGE

2. THERMAL HISTORY DURING OVERLAY WELDING

3. SURFACE RESIDUAL STRESS

4. THROUGHNALL RESIDUAL STRESS B.

REITERATE ANALYSIS TO CONFIRM OVERLAY SIZE IV. PERFORM REPAIR OVERLAY BFNP U-l l

~

L

WELD NO. _ CRACK DESCRIPTION XR-1-14 (12") INDICATIONS AT 5:30 (APPROXIMATELY 2", 10% THRUWALL);

6:30 (APPROXIMATELY 2", 10% THRUWALL); AND 11:20 (APPROXIMATELY 9", 19% THRUWALL)

KR-1-36 (12") TWO INDICATIONS SWEEP 0LET SIDE TOTAL LENGTH 24", 20%

THRUWALL KR-1-20 (12") HEADER SIDE, 1", 29% THRUWALL KR-1-42 (12") INDICATIONS AT 4:00 ( APPROXIMATELY 1", 38% THRUWALL);

AND 10:00 (APPROXIMATELY 1", 20% THRUWALL) m e > - ,,m - -- ---,, . -- ,- - - , . - , , , , , - -

---

w-e--.. - , - . . , , - . e .--,--,----~..e, -~ . - - - , - - - - - < -

13 e

e '

1 y Q..' . )

s G R) i Sammar As a/uoa

_ _ _ _ , , , , _ _ - . - - + * ' - ' " ' " - ~ ' ' " * ' ' ' "