ML20086C055

Final Rept of Ultrasonic Exam of Steam Generator Cladding Cracking

ML20086C055
Person / Time
Site:	Salem
Issue date:	06/30/1976
From:	Public Service Enterprise Group
To:
Shared Package
ML20086C053	List: ML20086C049 ML20086C055 ML20086C074 ML20086C084
References
NUDOCS 8311220544
Download: ML20086C055 (11)

Text

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REPORT OF ULTRASONIC EXAMINATION.

STEAM GENERATOR CLADDING CRACKING .

NO. 1 UNIT '

SALEM NUCLEAR GENERATING STATION ,

INTRODUCTION U

- Anultrasonicexaminationmeasuringtheextentofcladdink cracks in the No. 14 steam generator.on Unit No. 1, Salem Nuclear Generating Station, has been completed. This .

inspection together with our letter of May 28, 1976 discussing liquid penetrant and'metallographic evaluation completea the investigation of steam ge'nerator cladding cracking on No. 1 Unit.

RESULTS The ultrasonic inspection has lead to the determination that cladding cracks can be detected from the O.D. surface and that -

those examined do not penetrate into base metal .

B A CKGROUI!D Liquid penetrant inspection of the steam generator channel heads on Unit No. 1 revealed the presence of cladding cracks.

These cracks were most hecvily concentrated in a 2' x 4' area in the upper half of the cold leg side of the No. 14 steam. .

generator. The ASME Boiler and Pressure Vessel Code accepts -

surface indications.in cladding providing such indications are

. confined to the cladding itself (Code Case No. 1738). .

Exploratory grinding of four'are'as within the 2' x 4' zone was conducted to det~ ermine the extent of the surface dye penetrant .

indications. Grinding was initiated to a depth of 1/8" below -

the top surface of the cladding, at which time a dye penetrant re-examination was performed. Of four* areas excavated and dye penetrant inspected, three revealed crackinI still present.

Excavation was then halted.to avoid possible exposure of base metal. .

. To determine whether the cracks progres'ed-through s the cladding into base metal an ultrasonic examination was initiated. A -

cladding crack 4" in length, located at a~ distance of 5" from the interface between the Inconel back' cladding and the channel. head cladding in No. 14 steam generator was sele'eted for examination. (Photograph No. 1) This defect'was judged to be representative of the defects in the upper head and

' throuChout the balance of the steam generators. This defect was also selected for examination in view of its location in the highest stressed area of the channel head and its ease of inspectability using existing UT-methods. -

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i . U'I,TRAdONIC TEST METI:OD

• Ultrasonic test procedures and equipment were developed by Westinghouse in collaboration with Automation Industries ( A. I. ).

at Danbury, Connecticut. The procedures and equipment were then supplied by Westinghouse to Public Service for examination of the No.14 S.G. These procedures and equipment were applied l

.successfully at the Indian Point No. 3 Nuclear Generating

. Station. Results of the Indian Point program are described in ,

i a supplement to Westinghouse Report No. TD-MET-75-080.

It was decided that UT surveillance would be limited to a single

] patch on'the cold leg side of No. 14 steam generator. The hot

leg si'de of No. 14 steam generator, and both legs of the remaining

! steam generators did not reveal any evidence of the extensive, l concentrated cracking present in the cold leg side of No. 14.

All steam generators kill also be monitored ty periodic visual examination. 4 s

A calibration block was prepared by A.I. Nuclear Engineering Services Division for Westinghouse.from a section of the same scrap channel head used for the U.T. standard at Consolidated

' Edison's Indian Point No. 3 Nuclear. Generating Station. . T,he block,approximately 12" x 13-1/2", was sectioned'from the upper

• I edge of the SA-216 Grade WCC channel head after cladding with '

j the same submerged are process ~used on production heads. .

Although the steam generators at Indian Point No. 3 are series No. 44 and Salem No 1 has series No. 51, the channel head j

configuration is essentially the same. The 309'S.S. cladding -

was ground smooth and four notches, 3/4"*long by .125", .250",

375" and .450" deep respectively were cut perpendicular to

.-- the clad surface by the electro discharge machining process.

l A scanning fixture was fabricated to provide guided straight l

line manual scanning at fixed intervals and mounted to the calibration block O.D. (unclad) surface.

On June 8, 1976 the calibration procedurs was demonstrated to PSE&G representatives by Westinghouse at Danbury, Connecticut with a.model UM-775 Reflectroscope, a 1 MHz l-1/8" diameter 480 search unit, and an x-Y recorder. The recorder was attached to the Reflectoscope and the scanning fixture so that the

, recording pen was moved in the x direction by amplitude response I from Reflectoscope and Y direction by vertical movement cf the search unit. Calibration was done essentially to Westinghouse

~

I Procedure NPT-61. The calibration block was traversed in 5" long scans at 1/4" intervals until maximum response was obtained from the four reference notches. Then the four appropriate 5" scans were recorded, using the top corner reflection as the end point of each scan. The test was considered satisfactory in that the notches were detectable and provided a reasonably '

linear response up to the 375" notch.

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. On June 9, 1976 Westinghouse and A.I. personnel measured the 1

cladding thickness at Salem on No. 14 steam generator ultra-sonically. On June 10, 1976 a base line examination was i

performed on the selected patch using the same equipment and procedures described above. Locator holes approximately 3/16" diameter x 3/16" deep for the scanning fixture were developed by drilling through the mounting feet of the fixture into the channel head after the fixture had been attached to the channel head magnetically. Prior to drilling of the locator holes, proper location of the fixture was established by through-transmission technique using a receiv'ing crystal on

, the I.D. of the channel head to determine the point of exit or

reflection of the sound beam from a transmitting crystal on

the 0.D.(co-ordinates 58 H-5v). After mounting the fixture, j

i 24 five-inch vertical scans were made at 3/4" intervals

• using the Inconel 182 back cladding to 309 S.S. channel head l clad interface reflection as the end point of the upper travel.

Dual traces were made of each scan on the X-Y recorder. Several reflections of approximately 20 to 25% of screen height were recorded indicating that the cracking 5" from the tube sheet was detectable but not significantly deeper than 1/8". All scanning was done from the cyclindrical portion of the channel head 0.D. with the 48 1-1 / 8" diameter, 1 MH z shear wave search unit focused upwards towards the channel head-to-tube sheet veld. No surface preparation was required other than wire brushing to remove loose rust and dirt. USP grade glycerine was uccd as the couplant as in the on-site calibration and Danbury demonstration. -

~

. Copies of NPT-61 and traces made during calibration and scanning are attached.

- CONCLUSIONS The data shows that the 4" long cladding. crack determined previously by dye penetrant inspection was detectable by ultra-sonic examination from the O.D. of the channel head. More importantly, the depth of the crack was indicated to be no greater than 1/8" below the cladding surface and therefore still within the boundary of the stainless steel cladding.

PROPOSED SURVEILLANCE PROGRAM .

The ultrasonic inspection will serve as the base line preservice surveillance excmination for the cracked cladding. Public Service will continue to monitor the above cracking on a schedule consistent with the first three re-fuelin6 outages.

The inspection will consist of monitoring the same area (defined by the existing locator points) discussed in the pecceding discussion with the same U.T. procedure.

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In addition, a supplementary surface examination technique is under investigation. .

After the first three refueling outages, the program will be re-

evaluated from the standpoint of crack propagation to determine

! if the examination frequency can be reduced or eliminated.

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.j e PURP0".E:

Ultrasonic surveillance procedure for periodically determining the extent, G. Hughcs. 'and possibic growth of clad cracking in designated areas of stcam generator channoi br.ad s . The procedure includes the means to measura clad thickness oc a baseline

- process and the fixturing necessary to duplicate the test program periodienlly.

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• GUALTPICATIOM OF PDISOMMEJL Personnel performing the examination under this pro-

_) cetiure shall be qualified in accordance with ASNT-TC-1A, Supplement "C", Level II

~l or III. .

OPERATIONS: . **

. . . .. . .:.u - ...

Part I: Clad !!casurement: ,

1. Measure clad thickness in the approximate center of designated areas using the procedure detailed 'in Automation Industries' Re; fort #TR-71-24A.

2.

Record clad thichness determined in each area.

3. Clean and check clad surfaces in examination areas.

Equipment: ,

a) U11771 instrument " Automation" (nuct fit through 18 inch manuay).

, b) 10S db. pulser / receiver Son 1815 r.odification. .

c) Scarch unit fixture 57A6878 57A3615 SIZ transmitter search unit 57A2796 SIL receiver cearch unit

.d) Reference standard S/N 1 e) Clycerine for couplant . - '

I Calibration: .

a) Ensure that display selector cuitch on inside of 105 db. pulser / receiver is set.at Position "D". ,

b) Turn on instrument and allou proper varm up.

c) Connect cables from transmitter and receiver sea'rch units in fixture 57A687S t'o their respective jachs on the 10S db. pulcer/ receiver.

d) Adjust the instrument controls to the following preliminary settings:

UM 771 ,

IOS db

% -1) Sweep Delay gD Push button 5-50 1) Reference - max. (cv)

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Slide control 1/3 towards max.  !

Vernier - max. (cev)

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2) Sweep, Range 2) Sens. db control - 30

,I b,. ,' Push button - 1 -

3) Video Filter - 3

?.,1 Slide control - calibrate 4) Reject - set to reduce 30%

{,s' '.J Material Vernier - mid range FSD signal to 5% FSD

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. 3) Vertical,- adjust to locate 5) Test - Through

.\ baseline at 0 vertical position

.N . 4) Altn. - m.u. (cev) 6) Lov 7.

' 5) Rate - cax. (cv) 7) Puloc tune - max. (cc9)

6) llorizontal - adjust to center 8) Pulse length - max. (cu) baseline on scope cereen

7) !! ode - out 9) Freq.-2.25 }f!!,

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Peg'c 2 of 3 C. Calycn (continued)

Calibration: C. Hughes -

c) Position transigate switch to "Off".(glycerine / water fmix) c to reference blo f) Apply couplant Chcngcd -

creen Position front surface signal near Icft side of Refice j

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and mark location on screen with grease pencil. sensitivity db control as required u Hanipulate fixture and adjust Position front surface signal h) j signal is obtained from reference hole A. Vernicr.. Mark location _

at mark obtained in (g) ab'ove, using sucep delayh grease pencil. ctive

' of hole "A". signal on Reflectoscope screen witstep (h) for refere i) Repeat d 0.35" respec- _

locations on the Reficctoscope screen.0.20", 0.25", 0.30" an -

D represent cladding thickness of . .

tively. t 4 Part II. Surveillance Procedure . .

-t Equipment: .

e) 1Di 775 Reflectoscope (Automation) .

b) SN Ucid Pulser / Receiver _j incident angle c) Alarm and recording module (TransiEate)

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Westinghouse Immersion / contact scarch fixture 201-1/8" dia

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d) '

e) 1.0 Mit f i

f) Scannidg fixture (kTD) y by 1/S",

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! g) X-Y Recorder - !!osely Autograph Model #2D-2AClad chann ..f' h) 'M i) 1/4",

Couplant:

3/8'.' and 3/16" deep Elox notches - 2 parts glyceririe,1 part wate j I

pint ' i Calibration:' .

h a) Reject off W t l

b)

Set response from the 3/S" deep Elox notch to 90% of full screen heig

{ (FSil) note and record response from the 1/4" and 1/8" deep i lnotches -

' should be approximately 50% 15% (FSH) and 36% 15% (FSH) respect ve y. - i ,

f (Note response from 3/16" deep notch). .

l - .

Procedure:

l I follows:

1. . Set "fcct" on scarch unit fixture as 0.040-0.045 inch thick a) Place assembled " empty" scarch unit fixture on ' .

shin on flat surface.

'b) Adjust feet to touch flat surface.

2. . Till fixture with water and pressurize so that approximately 75-SO%  !

ficxibic bladder width touches flat surface on which fuur "fec

• 1-resting. ~

3.

Mount scanning fixturc including scarch unit on reference block so that sound beam is projected perpendicular to nctches. '(FSl!).

4. Set response fron 3/S deep notch to 90% of full screen height Note rccpouce from 1/4" and 1/0" deep notches. -

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WC511agh3U30 [10WiC CCip0131ign opp NPT-61 IJmpa Dhision Ihtricar INef ty Sysicms Q ,

Patie 2 of 3 .

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Icst; 1 317-t1 1RfCLEAR POWER Cn?!PO!UMTS n .. Page 3 of 3

,, . METI!OD OF 9/29/75 # F/JL k' AVE ULTRASONIC CLADDI: G Q'EILLA* CE

• C.Calycn Procedure: (continned)

C.lfughes 5. Set recording gate " start" at peak point of 1/8" notch indication ninus 1" of test netal distance. Set recording gate "END" at peak point of 1/8" accch indication plus 3/4" of test metal distance.

Channed 6. Set recording threshold at 10% of screen height belou peak responsa fres 1/S" deep notch.

7.

Connect data potentio=cter of scanner (5 inch scan icngth) tif cerrdinate of X-Y recorder. Connect amplitude response co'X coordinate of X-! reccrder.

l 8. Record calibration by scanning across reference block at appropricte-l (approx.1/4") incrc=ents to record maximum responses and locaticas fro:

1 reference notches. Set pen manually to duplicate scan spacings.

l 9. Place scanner on sc1ceted arca of channel head. Sct scarch unit c: left hand g- edge of area to be scanned. Move scarch unit to top of scan (5") :nd rot :r to bottom of scan length. Move search unit 3/4" to right, move pc on recorder 3/4" and repeat 5" scan. Repeat process at 3/4" incre= cuts until 12" wide (circum (crential direction' on. channel head) has been traversed.

10. Maintain records for cceparison with periodic in-service recordings nade in the same manner as described. '

11. Clean and identify creas. '

12. Follow the above procedure on channel head by placing the search unit fixture "fect" in drilled holcs for c ch position. -

13. Record UT results for each area scanned on channel head.

14. i Maintain records for comparison with periodic in-service recordings =ade in the same manner as described. '

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