ML20091L704
| ML20091L704 | |
| Person / Time | |
|---|---|
| Site: | North Anna  |
| Issue date: | 10/19/1987 |
| From: | Ballinger R MASSACHUSETTS INSTITUTE OF TECHNOLOGY, CAMBRIDGE |
| To: | |
| Shared Package | |
| ML20090B470 | List: |
| References | |
| FOIA-91-106 NUDOCS 9201280184 | |
| Download: ML20091L704 (22) | |
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l I f NORTH ANNA #1 STEAM GENERATOR ROW 9 COLUMN 51 TUBE FAILURE ANALYSIS by Professor R.G. Ballinger Departments of Nuclear Engineering and Materials Science and Engineering Massachusetts Institute of Technology October 19,1987 Final Report gggt2pg}g4910621 WILLIAM 91-lo6 PDR
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IN1110DlC110N i- l Un July 15 1987 a leak occurs ed in the "C" Steam Generator of the Nor th ;
AnnaUnitInuc}earpowerplant. The source of the leak was determined to be the rupture of the tube in the flow 9 Column $1 position. 1he author was retained as a consultant by the Nilt Staff to help in the evaluation of the failure and to provide input with respect to the vendor utility (Virginia Electric l'ower Compny) analysis of the(Westinghouse) andfailure solution to the problem.
The author attended three meetings bet.eeen the NitC ttaf f, VEPCU, and Vestinghouse personnel and received all VEPCU and Vestinghouse reports related to the incident. Table 1 lists meeting dates and locations. Table 2 lists the reports that were received and reviewed.
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l Alfil10!!'S (jUAllTICA110NS 1he author's rescine is attached as Ap iendix 1. Theauthorholdsajoint j appointment in the Depar tinents of Nuclear .;:ngineering and n!aterials Science and 1:ngineering at the !!assachusetts Institute of Technology as Associate l'rof essor. 1he author has conducted extensive research in the areas of corrosion fatigue and stress corrosion cracking of nickel base alloys, in particular, alloy 600, in hi The fatigue crack growth data from the author'gh ternperature aqueous systems.s laboratory represe available in the literature.
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QUESTIONS TO DE ADDIUiSSED:
The following questions wctr addrened as part of the analysis:
(1) What was the mode of failure?
(2) Was the vendor / utility analysis of the failure adequate?
(3) Are the pro msals for avoiding future failures likely to be successful in their goa' 57 (4) Are there any additional areas of concem that have not been addressed in the vendor / utility analysis 7 Failure Mode Based on analysis of fracture surfaces it is proposed that failure was by crack initiation and preparation by fatigue in the aqueous emironment of the secondary side of the steam ger.erstor. The necessary cyclic stress was provided by flow induced vibration.
Initiation was facilitated by the presence of a high mean tensile stress associated with denting of the R9C$1 tube in the upper support plate. Abnormally large vibrational '
amplitudes were the result of: (1) the absence of antivibration bars and,(2) the presence of a fluid clastic instability.
After examination of micrographs of fracture surfaces, the author concurs with the cor: ntion that failure was caused by fatigue. The presence of clearly identitiable fatigue striations as well as other features associated with : atigue failures, leaves no doubt.
With respect to the source and magnitude of the attemating stresses, futther discussion will be presented in a subsequent section.
Vendor Utility Analysis The vendor / utility analysis of the tube failure consisted of a number of major tasks.
Among these were the following:
(1) Irlentification of the cause of failure (2) Analysis of the failure scenario -
l (3) Identifiction of mitigation measures.
The identification of cause of failure was discussed in the previous section. The failure scenario consisted of two distinct phases: (1) initiation and (2) propagation. A major conclusion of the analysis indicates that the fhilure process was dominated by the initiation phase. Available crack propagation data indicates that once initiation has occurTed, through wall penetration can occur m as little as a few hours with tube failure occurring in as little as 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />. Based on this analysis any mitigation scheme must be aimed at extending the time l- .to initiation. Proposed mitigation measures will reduce the amplitude of tube vibrations and, hence, will extend the time to initiation.
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l De vendor's analysis is based on the observed failure made of corrosion fatigue.
The assumption is then made that the fhilure initiated in a rrgion of high tensile surss just above the seventh support plate. The high tensile stress (approaching yield) is calculated c.s a result of the high (exceedmg vield) compressive stress generated in the suppon plate region due to tube denting, which was observed for this tube.
Using the observed time to failuir and an estimate of the initial AK (st' ess intensity factor range) from striation spacing measurements a stress amplitude for the iritiation phase was estimated. A reduced stress amplitude is calculated assuming a large effett of mean stress on fatigue strrngth.
Subsequent to initiation, crack growth rates are estimated based on striation Qacing and literature data. From these rates, crack opening angles and, hence, leak rates are calculated as a function of time. Vibrat;onal stresses are calov]ated to res Jt from fluid / elastic sources.
In general, the above analysis is consistent with in service and fracture surf. ace observations. The type of calculatioris necessary for the analysis and the assumptions made with respect to the mean stress effect on initiation and fluid / clastic calculat:ons normally would result in a large uncertainty in any calculated results. However, the field observations, especially fracture features su:h as striation spacings and morphology, tend to pin down the initial AK and subsequent crack growth rates which provide a bench mark for the analysis. Fracture features near tk crack origin have been observed, by the author, in laboratory specimens for the exact conditions of servic: in North Anna 1 and are consistent with an initial AK of approximately 4KSIV in.
The high mean stress, assumed to exist as a result of tube denting in the support plate region,is calculated to rrach approximate y11 ding levels in the region of crack initiation. As an independent estimate of what stress levels would be :onsistent with the presence of a small thumbnail crack and a reasonable estimate of the maximum stress intensity factor of 4KS1 V in which is assumed based on fractographic evidence the far field strese were calculated using a model for K developed by Parks and Chen (1).
Parks and Chen have recently completed K calculations for a thin wall tube with a thumbnail crack initiating from the exterior which, at lear,t for very small crack depths, reasonably represents our conditions. Figure I shows a schematic of the tube and Figure 2 shows the crack geomeny. Figure 3 shows the K solution as a function of crack parameten foi various crack depths. The solutions for K do not include effects of bending so the solution is only applicable for very shallow crack depths where the axial stress gradient is small. Figure 4 shows the solution for Kmt; (4/Ot/2) - 1) as a function of depth. If we extrapolste back to a depth of 0.0025"(alt - 0.05) a far field stress of 57 KSI is calculated if one assumes an initial Kmax of 4KS1 V in. This stress is consistent with the contention that yield conditions existed in the surface region prior to initiation. .
This calculation si consistent with the vendori assumption of a mean stress approximating yield at crack initiation.
The estimated stress amplitude at initiation of from $10KSI was arrived at by independent estimates of minimum and maximum values that are consistent w: h observation. Striation spacings in the region just before slar.t fracture began indicated an .
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e appmximate AK of $0 KS! V in. In order for this to be the xase a back extrapolated stress amplitude at initiation of 10 KS1 maximum was caleuinted. If the stress amplitude was higher an unphysical stress history during crack propagation would result. In aarticular, the stress intensity factor range would have to decrease as the crack propagatec. for constant amplitude loading an impossibility.
The lower limit for the stress amplitude range was arrived at by back extrapolation from a just through wall crack. At the point of wall penetration a AK effective of 9.3 KSI in is calculated based on striation spacing observations with a correction for the effcct of mean stress. Back extrapolation of th s to initiation, using a single edge notch model results in a far field stress amplitude of 6.3 KSt. This is reduced to 4 KS! to account for uneenainties in the use of the single edge notch mndel, the assumed R ratio (Pmin/Pmax) of 0.5, and the fact that one is using long crack data to judge behavior of small cracks.
%e above calculation and estimates are consistent with the author's calculations above and AK vah'es which are consistent with fn.ctography. A high mean stress most likely existed with a superimposed 4-10 KS! (most likely closer to 4 KSI) stress amplitude at initiation. This resulted in an approximate AK, during inidal stages of crack growth, of approximately 4KSI V in.
Based on initial stress intensity factor ranges above, the vendor's calculation of penetration times and failure times are consistent. Table 3 shows the author's estimates of the madmum and minimum tirres to failure for a range of AK values. These times bracket the vendor's more rigorous calculations.
In conclusion, based on the assumptions made, the vendor's analysis is adequate.
However, the possible effect of Intergranular Attack (IGA)in the region of the failure has not been considered as a factor. The factor will not affect the overall conclusions with respect to failure mode or solution but will be discussed further later.
(1) Parks, D.M., Chen, ILS.," Stress Intensity Factors for Surface Flawed Plates and Shells: The Line Spring Model," Unpublished MIT Report. I l
Mitiration TnimiqucJ.
With the assumption that tube vibration was the sourre of the fatigue stresses, the 1 solution consisting of generator modifications to reduce the stirst amplitude by reducing i vibration is an adequate solution and will result in an extension of the tirne to crack initiation. Since the proce6s is initiation dominated, this should extend the tube life significantly. '
Additional CommentvAreas of Concem The effect of mean stress on cyclic life was assumed to be represented adequately by the relationship proposed by Smith et al.(2) Smith at, al. propose a relationship of the form c a.omax-C ,
where c ais the cyclie stress amplitude and omas is the maximum stress during a cycle.
'Ihis formulation results ir a severe mean stress effect more so than those proposed by others such as Goodman l Sa/St + Sm/Su = 1), Gerber (Sa/Sf MSm/Su)2 = 1), Soderberg (Sa/St 4 Sm/Sy u 11, or Morrow [Sa/Sf + Sm/Of = 11 where i Sa = P.lternating stress amplitude Sf a fatigue limit Sm - mean stress Su = ultimate tensile stress Sy = tensile yield stress oy = true fracture stress (3). While the Smith et. al. relationship provides for a reasonable reconciliation of the field observations and the analytical calculauons, data reponed by Jacko et. al. (4) for alloy 600 tubing in AVT water indicate that the mean stress effect is mmimal in nomirwl AVT environments and is adequately represented by a Goodman functional form foi faulted AVT chemistry conditions. If this data is a reasonable representation of in4ervice conditions one would expect a less severe mean i; tress effect. It must be pointed out, however, that the mean stress effect data reponed by Jacko et. al. is quite limited and co.'ers a range of mean stresses significantly less than those calculated to exist in the situation of interest.
If we were to assume ,. :ss severe mean stress effect and, at the same time, assume that the cyclic stress amplitude at initiation was between 410 KSI then, for this to be the case, another mechanism or mechanisms would have had to contribute to in'tiation. Two yssibilities would be IG A and degraded local chemistiy. In the author's opinion, the most
..ikely cause of a reduction in fatigue strength would have been the presence of10A.
IGA was observed in the region of failure. IfIGA is present, there is no reason to believe that the presence of IGA cracks will not affect the fatigue strength of the material. The effect of surface fmish on fatigue life is well knowrt if IGA does play a role then this
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a additional sctor will warrant close observation of other generators that, while they may not have such a high degree of denting or vibration, rnay still have IG A. As IGA progresses in these generators, an increase in probability of fatigue crack initi;. tion from the IG A cracks will occur. The presence of IGA williesult in initiation at a lower level Stress and hence AK. For this set of conditions a lower mean suess and'or smaller vibrutional surst may be trquired. Unfonunately, no data exists that would show more clearly the effect of IGA on crack initiation. For this reason and the above discussion, the author recommends that other generators be closely monitored in the future to see if such an effect may exist.
(2) Smith, K.N., Watson, P., and Topper, T.ll.,"A Strrss Strain Function for the Fatigue of Metals", Journal of Metris, JMLSA, Vol. 5, No. 4 Dec.1970, pp. 767 778.
(3) Fuchs,11.0., Stephens, Ra., Metal Fatigue in Engineering, Wiley & Sons,1980.
(4) Jacko, R.J., et. al.," Fatigue Performance of Ni Cr Fe Alloy 600 Under Typical PWR Steam Generator Conditions", El'R1 Report NP 2957, March 1983.
lable 1 t!ectings Attended 1
09/02/87 blecting at Vestinghouse - l'lttsburgh, l'A 09/10/87 Aleeting at NRC + liethesda, k!D '
09/21/87 llecting at NRC - llethesda, n!D :
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lable 2 llepolts lieceived 1.
" North held Anna 1 Steam Generator lube llupture," Trif. Conrad. USNI!C staf f. p N 07/20-07/23/87,11.
- 2. " North Anna Unit 1 July 15, 1987 Steam Generator lube Itupture 1; vent Presentat ion," Virginia Elect ric l'ovel Compftny, July 29, 1987, llevision O.
- 3. Vestinghouse slide presentation material for 09/02/87 meeting in Pittsburgh, PA.
- 4. Vestinghouse slide presentation aaterial for 09/10/87 meeting in liethesda, MD.
- 5. Yl;PCU Flide presentation material for 09/10/87 meet ing in liethesda, kD.
- 6. SlD 7.2.4- 7126. "horth Anna 1 S/G lube !!uptut e and I!cn;edial Attions Technical Evaluat ion," Vestinghouse Electric Cor poration, butlear I;nergy Systems, 09/13/87.
- 7. SlD 7.2.4 1270 Addendum, O'J/21/87.
S. "Nort h Anna Unit 1 July 15.19S7 Steam Generator lube llupture Lvent
!!cport ," llevision 1, beptember 15, 1987.
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'lable 3 AK AE penetration growth t penetration t growth (Esl/fii) (Ksl/fii) (hrs) (hrs) 4 4 42 833 7 15 0.2 4.2 7 20 0.2 1.3 da/dn=3.17X10'II AK 4 frecuency = 40 llz total circumfetcatial growth 0.90"(1/2807of circumfcrence)
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- AITENDIX 1 1
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October 00, 1987
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Profesnor llonald George llallinger l l
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65 Ilurnham lload l Andover, lh 01810 (617) 475-W20 Title Associate Professor, Department of Nuclear Engineering and Materials Science and Engineering, Massachusetts Institute of Technology Ljucation !!ASSAcil0SETTS INSTITUTE OF TECllN01,0GY Sc.D. degree in Nuclear Materials Engineering titled
" Corrosion fatigue of Nickel liaso Alloys for Nuclear Applications," February 1982.
S.M. degree in Materials Science, February,1978.
September 1977. '
S.M. degree in Nuclear Engineering,hanical llehavior of Thesis title: "The Anisotro Zircaloy- 2. " (llothdegrees)pichec V0flCESTEli POLYTECllNIC INSTITUTE S.II. degree in Mechanical Engineering, with high distinction, l'ebruary,1975. Emphasis in Materials Science.
Organization and President, MIT Student Section, American Nuclear Society Society, 1977 78.
Memberships Vice -President, MIT Student Section, American Nuclear society, 1970- Tt Member, Tau lieta Pi Associnte Member Sig Member,PiTauSipama11 Member, American Auc1 car Society Member, American Society for Metals Member, National Association of Corrosion Engineers Member, The Electrochemical Society Member, American Society for Testing and Materials Awards and Prizes 1973 S
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MetallurgyandMaterialsSciencePrize,ivcaIn.ionsored hv the lloston Section of the AIME and g tonor of P'rofessor Morris Cohen. ,
1971 72 Cit 0 EnginecH ug Science Achievement Award, Vorcester Polytechnic Institute..
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. Prof. R.C. Itallinger Awards and Prizes 1975 George Eastman Award for Outstanding Graduate Class of 1975, Vorcester Polytechnic Institute 1985 illT ANS Outstanding Professor Award 1985 kilt Graduate Student Council Teaching Award Research Interest Mechanical behavior of structural materials with emphasis on corrosion fatigue and stress corrosion cracking behavior in high temperature aqueous environments. Applications of state of-the art experirental and analytical techniques to data acquisition and analysis, liigh temperature aqueous electrochemical analytical and measurement techniques.
Application of advanced statistical techniques for materials optimization.
Fuel cycle analysis with respect to materials selection and performance. A ? plication of advanced deterministic and statistical teciniques to the analysis of nuclear fuel performance.
Material performance at low temperatures for superconducting and structural applications.
Professional Associate Professor, Department of Nuclear Engineering Experience and i!ateriale Science and Engineering, MIT.
1987 present.
Assistant Professor, Department of Nuclear Engineering and Materials Science and Engineering, MIT. 19S2 1987.
Member, International Cyclic Crack Grouth Review Group.
Member, Int :rnational Cooperative Vorking Group on Irradiation Assisted Stress Corrosion Cracking.
Entropy Ltd., South Grcat Road Lincoln. MA.
ConsultantonNuclearfuelPerlormanceModeling.
1978- present .
Chairman, SPEAR ruel Rod Reliability Code Vorkshop, Lincoln, MA, September 25 k 26, 19SD.
Military Service U.S, Naval Euclear Power Program: Most Advanced rating, D- 6. Served as Enginecting Vatch Supervisor on an operating nuclear submarine. Three years as instructor and Leading Petty Officer, M-Division at the SIC Naval Reactor Prototype.
Background Born and raised in Vest Hartford, Connecticut.
References Turnished upon request.
JOUILNAL PUllLICATIONS !
l R. G. Dallingar and R. M. N. Pelloux, "The Anisotropic n!cchnanical Behavior of Zircaloy2."ThirdInternationalConferenceonn!cchanicalBehaviorofWaterials, Cambridge LL August 1979, Vol. 2, pp 0S5 095.
R. G. Dallinger, V. G. Dobson, R. R. Diederman Zircaloy-4 in an Unlimited Stena Environment," 3."Nuc.0xidation Reaction n!aterials, 02, 2, 3, Kinetics of November 1970.
V. G. Dobson, 0xidation in Steam under Transient 0xidizing Conditions," , 1977. ASIM, STP 00 G. S. Vas, D. II. Tischner, P. L. hll, R. !!. Latanision, R. C. Dallinger and R. M.
N. Pelloux, " Effects of Deat Treaw ent on Segregation and Precipitttion of Trace Elements in inconel 600 " presented by Environmental Fracture Session 1, fall Meeting of TMS AIME, Llifwaukee, September 1970.
R. G. Dallinger and R. M. N. Pelloux, "The Effect of Anisotropy on the Mechanical Behavior of Zircaloy 2," .I Nucl. !!aterials, 97, No. 3, April 1981.
R. G. Dallinger CencralDescript(on,"Researc)hProjectscontributor a 971 1 971 2, 700 ,3R. Christensen Interim Report, (ed.), " SPEA Electric Power Research Institute, Palo Alto, CA, March 1980.
R. G. Dallinger, R. Christensen,"R. Ellbert, S. Oldberg E. Rumble and C. S. Vas,
" Clad Failure Modeling Progress, Fifth International Conference on Zirconium in the Nuclear Industry, August 1980.
R. G. Dallinger, R. M. latanision, V. C. Moshier, and R. M. N. Pelloux, "The Role of Uncertainty in the Measurement of Crack Length by Compliance Techniques."
International Conference on Subcritical Crack Grath, Freiberg (V. Cer.), May 13 15, 1981, pp 201 2S5.
R. G. Dallinger et al., "rission Cas Release and Fuel Reliability at Extended Durnup", Top 2cd Meeting on LVR Extended Burnup, fuel Performance and Utilization, Villiamsbulg, VA, April 4 8,1982, pp 4-35.
C. K. Sheeks, V. C. Moshier, R. C. Dallinger, R. M. Latanision and R. M. Pelloux,
" Fatigue Crach Crowth of Alloys X 750 and 600 in Simulated PVR and DVR Environment," International Symposium on Environmental Degradation of Materials in Nuclear Power Systems, Myrtle Dench, S.C., August 22 25, 1983.
R. C. Dallinger, v. C. Moshier, K. N. Siebein, R. M Latanision, "A Study of the Thermal Aging Dehavior in Alloy 600 Tubing," 9th International Congress on Metallic Corrosion, Toronto, Canada, June 3 7, 1984, pp 205 273 l
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4 C. K. Shecks, R. G. Itallinger,11.11. Latanision, " Fatigue Crack Growth Inconel Alloy x 750 in Simulated PVR and llVR Environments," 9th Internstional wngress on h!ctallie Corrosion, Toronto, Canada, June 3 7,1984, pp 310- 310.
R. C. Ballinger, G. E. Lucas, R. n!. Pelloux, "The Effect of Plastic Strain a the Evolution of Cr stallographic Texture in Zircaloy-2, " Journal of Nuclear n!aterials,126 19S4),pp5309.
R. C. Ballinger " Corrosion Patigue lesting in Aqueous Environment at liigh TerperaturesandPressures," Invited Article for h!TS Closed Loop 11agazine, IITS Systems Corporation, llinneapolis, Nh!.
R. G. Itallinger, J. V. Prybylowski, C. K. Elliott, "Effect of Processing llistory and Chemistry on the Structure of Nickel linse Superalloys," Second International Symposium on Environmental De Vater Reactors, alonterey, CA, gradation Sept. of klaterials in Nuclear Power Systems -
9- 12,19S5.
"1he Influence of h!icrostructure on J. V. Prybylowski, Environmentally R. Cracking Assisted G. Itallinger,f o Alloy 718", Corrosion,43,No.2(1987),pp 111 117.
C. K. Elliott, R. G. Dallinger, J. V. Prybylowski, " Corrosion fatigue llehavior of Alloy X 785 in liigh Temperature Aqueous Systems", in press.
"lhe Role of llicrostructure K.
in Enviromentally Ilosoya, R. Dallinger, J. Prybylowski, Assisted Cracking l.S.AIlwang,lloys," Corrosion, in press.
of Nickel-liase
!!. D. Iloenig, " Low Coefficient of R.
Expansion G. Ballinger, StructuralM. !!. llorra, hiaterials J. L n!artin,for Conductor A,plications,"
Development Ninth Annual Cryogenic Structurai llaterials Vorkshop, Reno, NY, )ctober 6 8, 1986.
J. V. Prybylowski, R. G. Ilallinger, "An Overview of Advanced lli h Strength Nickel Dase Alloys for LVR Applications," EPRI Vorkshop on Advanced 111 h Strength
!!aterials for LVR Internal Applications, Clearwater Beach FL, )! rch 12-13, 1980.
I Books R. G. Dallinger, The Anisot ronic Hechrnien1 Behavior _nLJJrenlon2, Carland Publishing P.o., Inc., New York, 1979.
IPUftUlES/ SEMINARS CIVEN Environmentally Assisted Fatigue Cracking of 6'ickel-Base Alloys for Nuclear Applications, MIT Industrial Laision Program Symposium on Corrosion, Decenter 2, 1982.
Fatigue in Nickel Base Alloys - Seminar given at Framatome, Paris, France, March 28, 1983.
Corrosion Fatigue in Alloy X-750, Seminar given at Cruesot Loire Laboratories, Firminy-france,3/29/S3.
Thermal Behavior of Nuclear Fuel Rods, Thermal-Hydraulic Design and Safety for Light Vater Reactors, Center far Advanced Engineering Study, MIT, May 1b-kl,1983.
Advanced Fuel Design and Performance, Short Course given at Vestinghouse Electric Corporation, Water Reactor Division;, July 11, 1983.
l_ Pattern Recognition Techniques for Alloy Development, Seminar given at TRV Inc.,
Caldwell Laboratorias, Uclid, Ohio, July 12. 1983.
L " Fracture in Nickel-Base Alloys in Naclear Power System Environments", Seminar given at Vorcester Polyicchnic Institute, March 29, 1985. .
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l Professor Ronald George Dallinger Professor Ballinger is an Associate Professor at the Massachusetts Institute of Technology with a joint appointment in the Departments of Nuclear Engineering and Materials Science and Engancering. Professor Ballinger's areas of s ccialization are as follo"s: (1 Nuclear Fuel (including clad) ding) Performance and Analysis; (3)EnvironmentalEffectso Advanec f2 Techniques for Experimental Design and Analysis and the Development of Advanced Materials for Cryogenic Structural Applicatio(4)ns. Professor Ballinger is the author of sever..1 papers in the above areas and is a member of the Internat.ional CyLile Crack Growth Reviev Group which is charged with the development of a; understanding o' the behavior of reactor pressure vessel steele with regard to fatigue, stress corrosion cracking and coirosion fatigue.
Professor Ballinger is also a member of the International Cooperative Vorkin,;
Group on Irradiation Assisted Stress Coriosion Cracking which is charged with the development of an understanding of this phenomena.
' ro , _ 'nr Dallinger is active in nuclear fuel c Eni; .s' icated fuel performance analysis codes.Professor ycle analysis andteaches Dallinger is co-author of entre. courses dealing with materials selection and performance in the nuclear
,c i cf Ic. Professor Dallinger is a member of several professional societies and us cm ulted extensively in the above areas and is an expert in failure ar.nlysis celstuc to these areas.
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