ML20095F501
| ML20095F501 | |
| Person / Time | |
|---|---|
| Site: | Oyster Creek |
| Issue date: | 08/04/1984 |
| From: | Abramovici J, Covill D, Elam B GENERAL PUBLIC UTILITIES CORP. |
| To: | |
| Shared Package | |
| ML20095F481 | List: |
| References | |
| 580, 580-R, 580-R00, NUDOCS 8408270290 | |
| Download: ML20095F501 (86) | |
Text
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- . . w 580 O J g TDR NO. REVISICN NO.
BUDGET 107 ACTIVITY NO. 323357 PAGE 1 OF TECHNICAL DATA REPORT PROJECT: E&D Oyster Creek DEPARTMENT /SECTION Nuclear Generating S tation RELEASE DATE E' N'N REVISION DATE DOCUMENT TITLE: Isolation Condenser System Piping Cracked Welds - Repair and Failure Analysis ORIGINATOR SIGNATURE DATE APPROVAL (S) SIGNATURE DATE F. .fi J.D.Abramovici)/A/hdM7 [Mf I B.D. Elam 8 23[k.,.,o #6 4 y D.W. Covill 7-3 FY R.T. DeMuth [ $d[gf-APPROVAL FOR EXTERN 3L DISTylBUTION DATE D.K. Croneberged - 8d-dd Does this TDRinclude recommendation (si?%Yes ONo if yes,TFWR/TR # )
o DISTRIBUTION ABSTRACT:
S ta tement of Problem M. Laggart Edity-seven welds containing crack-like indications D. Holland were discovered in the Isolation Condenser system J. Chardos piping outside containment. Determine the cause of J. Sullivan the indications and repair the welds in a manner which D. Grace will permit the system to be returned to service.
R. Keaten F. Giacobbe Stnmary of Key Results G. VonNieda 1. Bree welds were removed and destructively eval-G. Capodanno uated, he failure mechanism was concluded to be G. Taylor indicative of intergranular stress corrosion cracking.
J . Abram ovici (IGSCC).
D. Covill B. Elam 2. Nine of the affected welds are being replaced; the
- n. saiah remaining eighteen are being repaired with weld D. Croneberger overlay. ,
Conclusions
- 1. Be Isolation Condenser system may be returned to service af ter successful ccupletion of the repair effort. De repair methods used will not adversely affect the system's operabili ty and will not reduce safety margins.
Actions To Be Taken
- 1. Evaluate the use of the system piping as-repaired for more than one fuel cycle.
- 2. Perform augnented inspections, during the next scheduled outage, of stainless steel piping welds ,
in systems susceptible to IGSCC.
8408270290 840822 PDR ADOCK 05000219 p PDR Il
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1 TDR 580.
Rev. O Page 2 TABLE OF CONIENIS fage 1.0 ~ INTRODUCTION 3 2.0 METHODS 2.1 Introduc ti on .7 2.2 Inspections 7 2.3 Metallurgical Evaluations 8
'2.4 Repairs 10 2.5 Overall Systen Evaluation 15 3.0 RESULIS 3.1 Introduc ti on 19 3.2 Inspections 19 3.3 Metallurgical Evaluations 20 3.4 Repairs 22 3.5 Overall System Evaluation 22
4.0 CONCLUSION
S 22 5.0 ACTIONS TO BE TAKEN 23
6.0 REFERENCES
25 7.0 TABLES 26 8.0 FIGURES 29 9.0 APPENDICES 35
. TOTAL EFFECTIVE PAGES 107
TDR 580 Rev. O Page 3 l' l.0 INTRODUCTION 1.1 . This report describes CPUN's actions taken to return the Isolation Condenser systen to service after the discovery of a leak in the
-Return Line piping outside containment.
1.2 Background
During a hydrostatic test of the "A" Condenser, water was seen dripping from the Return Line. The insulation was renoved fran the pipe in the area of the leak. The origin of the leak was fram the pipe near weld NE-2-12. This pipe is 8-inch dianeter, Schedule
- 80. All the piping in the Isolation Condenser system is made fran Type 316 austentic stainless steel.
1.3 Inspections All piping welds in the Isolation Condenser system outside contain-ment were inspected by ultrasonic testing (UT) techniques that have been shown to be capable of detecting intergranular stress corro-4 sion cracking (IGSCC) and have been qualified to IE Bulletin 82-03.
Fif teen welds in the Isolation Condenser systen inside containment f
and ten welds in the Reactor Water Cleanup system outside contain-ment were ultrasonically inspected.
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TDR 580 Rev. O Page 4
- 1.4 Inspection Results There were 27 welds containing crack-like indications in the heat-affected zones in the Isolation Condenser system outside con-
< tai nnent . A summary is shown below:
"A" Condenser Supply Line - 8 welds Return Line - 6 welds "B" Condenser Supply Line - 9 welds Return Line - 4 welds J
More detailed listings of these welds are provided in Tables I and II.
No crack-like indications were detected in welds in the Isolation Condenser system inside containment or in the Reactor Water Cleanup system outside containment.
1.5 Metallurgical Evaluations Three of the af fected welds, including the leaker, were renoved from the Supply (NE-1-15, NE-1-61) and Return Lines (NE-2-12) and
TDR 580 Rev. O Page 5 were sent to General Electric's Turbine Technology Laboratory and Brookhaven National Laboratory for metallurgical evaluation. The results of the evaluations revealed that the cracking was a result of intergranular stress corrosion.
1.6 Repairs As a result of the inspections performed, it was decided to repair the welds containing crack-like indications by either replacement or weld overlay with the intent of returning the system to service without jeopardizing safety. Eighteen welds are being repaired using the weld overlay method, and the remaining nine welds will be renoved and replaced with new piping material.-
1.7 Overall System Evaluation The perfornance and availability of the Isolation Condenser system
- is not altered by this repair process. Since the piping used for replacement and the welding techniques are superior to those originally used, and since the weld overlay repair restores the structural integrity of the pressure boundary, the overall system availability and reliability has actually been enhanced.
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TDR 580-Rev. O Page 6 1.8 Conclusions a) The cracking was a result of intergranular stress corrosion, b) The repair methods used to correct the Isolation Condenser piping indications due to IGSCC are adequate to support system perfonnance in a safe manner for at least one additional fuel cycle.
1.9 Actions to be Taken a) Evaluate the adequacy of the repaired piping for service beyond one fuel cycle.
b) Perfonn augnented inspections, during the next scheduled outage, of stainless steel piping welds in systems susceptible to IGSCC.
c) Plant operating procedures will be reviewed and revised as necessary to preclude the potential for water hammer in the stean lines and to minimize the thernal cycle loading on Iso-lation Condenser system.
e TDR 580 Rev. O Page 7 2.0 METHODS 2.1 Introduction This section describes the methods used to perform 1) inspection of welds, 2) metallurgical evaluations, 3) repairs of cracked welds, and 4) overall evaluation of the repaired system.
2.2 Inspec ti ons 2.2.1 Sampling 2.2.1.1 Isolation Condenser System Af ter the leak was detected, ultrasonic inspections were perfonned on 100% (124) of the butt welds outside containnent and 32% (15 of
- 47) of the butt welds inside containnent. The nunber of welds it spected inside containment is consistent with the sanpling re-quirements of the ASME Code and the NRC.
2.2.1.2 Other Systems Ten welds in the Reactor Water Cleanup system piping outside con-tainment were inspected. Six welds were located in the inlet line; i
- TDR 580 Rev. 0-Page 8' four were located in the return line. This system was inspected since it is environmentally similar (temperature, pressure) to the Isolation Condenser System.
2.2.2 Inspection Methods The welds were inspected using ultrasonic techniques (Reference 1) shown to be capable of detecting IGSCC in austentic stainless steel and qualified to IE Bulletin 82-03.
Radiogrpahy was also used to evaluate indications detected by ultrasonics.
2.2.3 A report of the inspection methods is provided in Reference 2.
2.3 Metallurgical Evaluations 2.3.1 Introduction GPUN renoved three spool pieces containing crack-like indications fran Isolation Condenser system piping for shipnent to laboratories for metallurical evaluation.
One piece contained welds NE-2-12 (the leaker) and NE-2-13 from the "A" Return Line. Another contained weld NE-1-15 fran the "A" I
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TDR 580 Rev. O Page 9
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Supply Line. The last piece contained weld NE-1-61 from the "B" Supply Line. The locations of these sanples in the syst a are ,
shown in Figures 2, 3, and 4 Weld NE-2-12 (the leaker) contained one through-wall crack and one crack-like indication (Figure 1).
Welds NE-1-61 and NE-2-12 were identified to be field welds; NE-1-15 and NE-2-13' were identified to be shop welds.
General Electric's (GE) Turbine Technology Laboratory, GPUN's con-tractor, evaluated NE-1-15, NE-2-13, and the bottom half of NE-2-12.
Brookhaven National Laboratory (BNL), the NRC's' contractor, evaluated NE-1-61 and the top half of NE-2-12, 2.3.2 GE Evaluation Samples from NE-1-15 and NE-2-12 were examined using Scanning Electron Microscopy (SEM) and metallography.
NE-2-13 was liquid penetrant inspected on the inside surface.
Chemical analysis was performed on one sanple, each, resoved from wrought material adjacent to NE-1-15 and NE-2-12.
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l TDR 580 .j Rev. 0 Page 10 Details of the GE evaluation can be found in Appendix A.
2.3.3 BNL Evaluation Later 2.4 Repairs 2.4.1 In troduc ti on Based on the metallurgical evaluation and the nondestructive test-ing performed on the Isolation Condenser system piping, it was decided to repair all the welds containing crack-like indications with the intent of returning the system to service for at least one f uel cycle without sacrificing safety. The entire piping system outside the drywell will be evaluated before and during next refueling outage to detennine the adequacy of the repair beyond one cycle.
There were a total of 27 welds containing crack-like indications, 17 in the Supply lines and 10 in the Return lines, all of which will be repaired by either replacement or weld overlay. Based on the samples renoved and weld locations,18 welds will be repaired using the weld overlay process and the remaining 9 welds will be physically renoved and replaced by new piping or fittings, as necessary.
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IDR 580 Rev. O Page 11 Of the eighteen welds to be overlaid, six are pipe-to pipe and twelve are pipe-to elbow butt welds.
2.4.2 Replacement Replacement piping and fittings were ordered to lower than nonnally allowable carbon content for the original material used. The original piping was bought in accordance with Burns and Roe Speci-fication 2299-S60 and was ASIM A 312 or 376 Grade 316. Piping replacement was purchased to ASME SA-312 Type 316 seamless with carbon content not to exceed 0.05%. Fittings were also purchased to ASME standards ( ASME SA-403 Type 316) with 0.05% max. carbon.
Additionally,12" pipe was purchased to ASME SA-358 Type 316 (nuclear grade stainless steel with 0.02% maximum carbon content) .
The welding process used for the repair defines low heat input welding which, together with the lower than previously specified carbon content, minimizes the possibility or 133CC. Addi ti onally ,
the malding procedures included the "?q ' r. nts of the NRC Regula-tory Guides 1.31 and 1.44, s.
The original piping design code appears to be Section 1 of ASME per i B&R specification 2299-S60, whereas the replacement piping IJ to be in accordance with ASME Section III Subsection NC(Class 2) which is considered superior to original code.
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TDR 580 Rev. O Page 12 2.4.3 Weld Overlay 2.4.3.1 Introduction The weld overlay is a repair method by which filler metal canpat-ible with the matching pipe is deposited on the pipe outside diameter to restore the piping structural integrity.
2.4.3.2 Design The weld overlay is an NRC accepted piping repair
The design was conducted by General Electric under contract from GPUN and the design / stress analysis is documented in Appendix B.
The weld overlay designs for repair of the Isolation Condenser system piping were determined based on maintaining the ASME Code required factor of safety against net section collapse of the over-laid welds. The minimtm required weld overlay thicknesses were obtained cssuming the flaws to be fully circunferential and to extend through the original pipe wall. The applied primary loads used in the thickness calculations were enveloped to provide
- Inspection of BWR Stainless Steel Piping (Generic letter 84-11) dated April 19,1984
, TDR 580 Rev. O Page 13 further conservatism and generality in the designs. The minimom thicknesses do not include the first weld layer, which must pass liquid penetrant exanination, or possibly the second layer if the first has a measured ferrite number of less than 8FN. The overlay widths were sized to optimize the anount of welding time and material necessary to provide the required structural reinforcement of the flawed weld regions.
The criterion used in design of the weld overlays for the Isolation Condenser system piping was to provide full structural reinforce-ment of the cracked region. In evaluation of the overlay designs, it was conservatively assumed that the flaws are fully circum-ferential and extend through the susceptible material of the original pipe wall. With this assumption, no credit was taken for the beneficial compressive residual stresses induced by the heat sink weld overlay process that would oppose crack extension through the thickness. The postulated through wall cracks also provide assurance that the overlay design is independent of the crack size as determined by the ultrasonic testing. IGSCC propagation into the weld overlay material beyond the first layer is considered to be unlikely since the weld material (low carbon, high ferrite) beyond the first layer is resistant to IGSCC.
Detail design analysis, assumptions and results are docunented in Appendix B.
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' TDR 580 ,
Rev. O !
Page 14 2.4.3.3 Application The weld overlay process is implemented via Reference 3 at Oyster Creek. To minimize weld shrinkage resulting from the overlay
-process and, therefore, reduce stress, cooling water is flowed through the pipe. An actual field mock up test verification was set up to insure that cooling water flow rates obtainable in the field were sufficient to insure adequacy of the weld overlay process and resultant shrinkage.
All weld overlays are to be applied in accordance with a procedure qualified in accordance with ASME Code Sections IX and XI. The effective overlay thickness is to be deposited af ter the first overlay layer having a ferrite number of 8FN, or higher, as deter-mined with an instrument meeting the requirements of AWS A4.2 (Reference 4). The overlay dimensions and shrinkage are to be determined with before and af ter dimensional measurements. Liquid penetrant examination is to be performed on the pipe surface, be-fore velding, and the first and last layers of the overlay. Radi o-graphy will be performed on the finished weld overlays to verify their integrity.
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T TDR 580 Rev. O Page 15 2.5 - Overall System Evaluation 2.5.1 System Perfornance The repair process does not affect, in any way, the operation of the Isolation Condenser system, since the piping is replaced with similar material and pipe schedule and the overlay is applied to the piping outside diameter. The muount of shrinkage expected due to the overlay process is considered insignificant in affecting the flow through the piping in an accident mitigation function. Valve operability (containment isolation) and condenser perfonnance are not af fected by this modification.
2.5.2 Stress Analysis 2.5.2.1 Overall Discussion The original system stress analysis was performed by the architect engineer (Burns & Roe) and included the then defined seismic load-ing in addition to the nonnal deadweight and thernal loads. It is apparent from the design drawings that cold spring was used to improve the stress characteristics of the system, yet the calcula-tions did not take credit for them, nor were they found when the sample spool pieces were removed.
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- TDR 580 l Rev. C l Page 16 j i
Subsequently, EDS Nuclear performed another stress evaluation of the Isolation Condenser system piping and found it to _be adequate (Reference 5).
As a result of the indications found, the repair process, the above mentioned cold spring question, and the revised (higher) seismic loads as a result of the Systematic Evaluation Program (SEP) for Oyster Creek (Reference 5), GPUN's consultant, MPR, performed a new analysis on the entire Isolation Condenser system outside the dry-well (Reference 6).
The analysis was based on deadweight, design pressure (1250 psig),
thennal loads (70*F to 550*F), anchor displacenents due to drywell penetration movement, and seismic loads based on the SEP criteria (Reference 7) using Reg. Guide 1.61 damping values for OBE and SSE.
The load combination used was based on ASME Section III, NC-3650 equations 8, 9 and 10 respectively, and the resulting stresses still meet ANSI B31.1 code allowable stress.
W'a terhammer loads were specifically not included for two distinct reasons:
- 1) No evidence of waterhammer was evident f rom the operational data at Oyster Creek, and
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- TDR 580 Rev. O Page 17
- 2) Procedural guidance is provided to the operators to maintain shell side emergency condenser water level within a given band, such that the probability of waterhanmer is minimized.
The results of the analysis concluded that the Isolation Condenser system piping is adequate "as is" without any modifications and without need of any cold springs and, therefore, will be rein-stalled without adding cold spring (for replacement piping).
2.5.2.1 Cycle Fatigue An analysis (Reference 8) was performed prior to the destructive testing of the metallurgical sasple to try to determine the cause of the leakage in the NE-2-12 joint. Cycle fatigue was considered as one of the possible causes. However, the analysis concluded that the Isolation Condensers were used 33 times ( A) and 36 times (B). The exact nunber of cycles used each time the condenser was put into service is not known since it would require a large anount of time to evaluate the strip charts from plant initial operation to present, but even if 100 cycles per use is conservatively assuned the total number of cycles is still less than the 7000 cycles identified by ANSI B31.1 as not being considered significant in the stress analysis (i.e. stress range reduction factor = 1.0 per ANSI B31.1 Table 102.3.2(c)) . Therefore, cycle fatigue is not considered a contributor to the leakage.
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TDR 580 Rev. O Page 18 2.5.2.2 Cold Spring As discussed above, the original design drawings show various degree of' cold spring being applied to the Isolation Condenser system piping for both Supply and Return lines outside the drywell; however the AE analysis did not consider it in their analysis. A re analysis without cold spring performed by MPR concluded ' that cold spring is not required, and the replacement piping will be installed without any cold spring. It appears that cold spring was not a contributor to the piping cracks. No credit was taken for the beneficial canpressive residual stresses induced by the heat sink weld overlay process that would oppose crack extension through the thickness.
2.5.2.3 Shrinkage S tress Due to Weld Overlay Application Application of a weld overlay produces an axial contraction of the pipe which is a function of the pipe size and the overlay thickness and width. This shrinkage imposes stresses on the entire piping system. The anount of shrinkage was estimated by GE based on typi-cal shrinkages observed in similar weld overlay applications per-f ormed by GE. The 8-and 10-inch pipe overlays were assumed to shrink 1/4 inch, and the 12- and 16-inch pipe overlays were assumed to shrink 3/8 inch. The shrinkage effect was simulated by forcing thennal contractions at the weld overlay locations equivalent to
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- TDR 580 Rev. O ;
Page 19 the assumed 1/4 and 3/8-inch overlay shrinkage. The shrinkage stresses obtained were low due to the overall flexibility of the piping system; the piping is supported mainly through hangers and snubbers. The actual weld overlay shrinkages will be measured and compared to the assumed values. Variations will be re evaluated to determine the significance of the deviation from the assumed shrinkages (from Appendix B).
2.5.2.4 Weight Effects of Weld Overlays The ef fects of the weld overlay weight on the stress analysis, including seisnic, is considered insignificant since the weight added is of the same magnitude or less than, the pipe fabrication weight tolerance and is very localized over a narrow area.
3.0 RESULTS J.1 in t rod uc ti on This section provides the results of the various efforts described in Section 2.
3.2 Inspections e--- . ,,- - - ,+ - ,
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- TDR 580 Rev. O Page 20 3.2.1 Isolation Condenser System Outside containment, ultrasonic inspection revealed that 27 (22%)
welds contained crack-like indications. Of these,19 were con-finned by additional ultrasonic examination and/or radiography.
Ihe renaining eight (8) were classified as " suspect", because they could not be either confirmed as cracks or classified as geometric reflectors.
Tables I ("A" Condenser) and II ("B" Condenser) list the defective welds and other pertinent infonnation.
Figures 2, 3, 4, and 5 show the locations of the defective welds.
Inside containment, none of the welds inspected contained crack-like indications.
3.2.2 Other Systems None of the welds inspected in the Reactor Water Cleanup system contained crack-like indications.
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3.2.3 A report of the inspection results is provided in Reference 2.
3.3 Metallurgical Evaluations l
. TDR 580 Rev. O Page 21 3.3.1 General Electric Fractography of the crack surface of welds NE-2-12 (the leaker) and NE-1-15 revealed an intergranular surface on both.
Metallography of NE-2-12 and NE-1-15 revealed that both had cracks that were intergranular and adjacent to the weld bead. And, in NE-2-12, metallography revealed a second crack in the base material between the weld bead and the leaking crack. All the cracks were located within the heat affected zone of the weld.
Liquid penetrant exanination on the ID surface of NE-2-13, a
" suspect" weld, revealed no indication in the region of the ultra-sonic indication.
Chemical analysis of wrought material adjacent to NE-2-12 and NE-1-15 verified the material as being Type 316 stainless steel.
Details of the results, including photographs, are provided in Appendix A.
3.3.2 BNL 1
Later 1
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. - TDR 580 Rev. O Page 22 3.4 Repairs The repair process used, replacement or weld overlay, is considered adequate for safe operation of the Isolation Condenser system at Oyster Creek for at least one fuel cycle without any loss in factors of safety.
The nondestructive examinations performed on the existing and re-paired pipe together with the repair process assures safe plant opera ti on.
3.5 Overall System Evaluation The repair process did not and will not affect system performance and availability. As a matter of fact, the repair process together with the additional NDE and piping support verification, provide additional assurance of system reliability and availability.
4.0 CONCLUSION
S 4.1 Repair Effort The repair effort, replacement and weld overlay, is a satisfactory method to return the Isolation Condenser system to service in a 2
l safe and reliable way.
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TDR 580 Rev. O Page 23
'4.2 Metallurgical Evaluation 4.2.1 The cracking was circunferentially oriented intergranular stress corrosion in the weld heat affected zone.
4.2.2 No firm conclusions regarding the eight " suspect" welds could be reached. For conservatism, we treated these welds as being cracked welds and repaired each one.
4.3 overall System Evaluation The overall Isolation Condenser system perfornance and . availability are not being lessened by the repair process but, in fact, are enhanced since the probability of system unavailability due to ICSCC-induced leakage has been reduced.
5.0 ACTIONS 10 BE TAKEN
- 1) Evaluate the piping in the Isolation Condenser system outside the drywell before and during the next refueling outage for adequacy for service beyond one fuel cycle.
- . . TDR 580 Rev. O Page 24
- 2) Perform augmented inspections, during the next scheduled out-age, of stainless steel piping welds in piping systems susceptible to IGSCC.*
- 3) Plant personnel shall be instructed to minimize the use of energency condensers to energency use only and not for normal plant cooldown such that the cyclic loading is minimized.
- 4) Verify plant procedures to ensure that the probability of waterhammer is minimized by controlling the water level in the energency condensers.
- A response to Generic Letter 84-11 addressing these examinations is in preparation.
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TDR 580 1 Rev. O I Page 25
6.0 REFERENCES
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- 1) GPUN Procedure MTIS-008 Rev. 4: " Ultrasonic Examination of Piping Welds 0.2" - 6.0" in Ihickness."
- 2) GPUN Report No. 6153-ISI-84-001: "0yster Creek Isolation Condenser System Auguented Exanination Program" (to be issued).
- 3) GE Process Specification P50YP225 Rev.1: Thin Weld Overylay for Austenitic S tainless Steel Piping Welds; with ECN NH18401.
- 4) AWS A4.2-1974: " Standard Procedures for Calibrating Magnetic Instrunents to Measure the Delta Ferrite Content of Austentic S tainless S teel Weld Metal."
- 5) Oyster Creek Isolation Condenser System Piping Stress Report, prepared by EDS Nuclear, Novenber 1979, EDS Report No.
02-0370-1021
- 6) MPR 830: " Analysis of Emergency Condenser Piping Outside Contaimnent", dated July 1984
- 7) NUREG/CR-1981 " Seismic Review of the Oyster Creek Nuclear Power Plant as Part of the Systanatic Evaluation Program",
dated April 1981
- 8) MSS-84-166 "0yster Creek Emergency Condenser Leakage Investi-gation", dated April 17, 1984
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. .. TDR 580 Rev. O Page 26 7.0 TABLES I. "A" Condenser Piping Welds with Crack-like Indications II. "B" Condenser Piping Welds with Crack-like Indications e s J
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- TDR 580 Rev. 0 l Page 27 Table I l "A" Condenser Piping Welds with Crack-like Indications Supply (S) or Pipe Weld Camp onent Repair Weld Number Return (R) Line Diameter (In) Type (1) Type (2) Method (3) 16 S P-P O NE-1-2(*) S NE-1-11 S 12 F P-E O NE-1-13 S 12 S P-P O 12 S P-E R NE-1-15 S 12 S P-P O NE-1-20(*) S 12 S P-P O NE-1-25 S NE-1-29 S 12 S P-P O NE-1-32 S 12 S P-E O 8 S P-E O NE-2-4(*) R NE-2-8 R 8 F P-E O NE-2-12 R 8 F P-E R 8 S P-E R NE-2-13(*) R NE-2-17(*) R 8 S P-E O NE-?-28 R 8 F P-E O
- "Suspec t" (see 3.2.1)
Notes:
- 1) S = Shop, F = Field
- 2) P = Pipe, E = Elbow
- 3) 0 = Overlay, R = Replace
.- . TDR 580 Rev. O Page 28 1
Table II
. "B" Condenser Piping Welds with Crack-like Indications Weld Supply (S) or Pipe Weld Canponen t Repair Ntaber Return (R) Line Diameter (In) Type (1) Type (2) Method (3)
NE-1-37 S 16 S P-R R NE-1-38 S 16 S P-P R NE-1-39A S 16 (4) P-P R 1
NE-1-40 S 16 S P-E R NE-1-41 S 16 S P-E R NE-1-46 S 12 S P-E O NE-1-51 S 12 F P-E O i NE-1-54A S 12 (4) P-P O NE-1-61 S 12 F P-E R NE-2-80(*) R 8 S P-E O NE-2-91( * ) R 8 S P-E O NE-2-98 R 8 S P-E O l NE-2-103(*) R 10 S P-P O
- " Suspect" (see 3.2.1) i Notest
- 1) S = Shop, F = Field
- 2) P = Pipe, E = Elbow, R = Reducer
- 3) 0 = Overlay, R = Replace i 4) Weld type is unknown. Weld records cannot be located. Most likely, these two welds are field welds.
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. ' TDR 580 Rev. O Page 29 8.0 FIGURES 1 -
Defects in Weld NE-2-12 2 -
' A' Supply Line, Defective Welds 3 -
' A' Return Line, Defective Welds 4 -
'B' Supply Line, Defective Welds 5 -
' B' Return Line, Defective Welds
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TDR 580 Rev. O Page 30 INDICATION 200 1.65" LONG f
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Page 34
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1 IDR 580 Rev. O Page 35 9.0 APPENDICES A -
GE Metallurgical Evaluation Report B - GE Weld Overlay Design Report i
l
App";nd5x A l P;ga 1 cf 44 I I
- 'IDR 580 P.M.T. 'IRANSMITIAL Rev. O NhCLEAR ENERGY EUSINESS OPERATIONS GEN ER AL h ELECTRIC 10. 178-84-015 Page 37 IRF W. l PLNfr MAERIALS 'ITOINIDGY FAILURE ANALYSIS OF OYSER OtEEK ISCLATION QEDENSER PIPDG DATE: June 25. 1984 PREPARED BY: d2 Mb D.E. Deilwichef Plant Materials Tedsnology APPROVED BY: _ M G.M. Gorflon, Manager Plant Materials 'INM:hnology LEGAL NOTICE
"% c,1.y undertakings of General Electric Ccnpany (GE) respecting infotration in this document are contained in the agreenent betteen GPU Nuclear Corporation (GPUN) and GE for failure analysis (Purchase Order No.FC-013224) and nothing contained in this document shall be construed as changing the agreement. The use of this information for any purpose other than that for which it is intended, is not authorized; and with respect to any unauthorized use GE nukes no representation or warranty, (express or inplied) with respect to the completeness, accuracy, or usefulness of the inforration contained in this document, or that the use of such information may not infringe privately owned rights, nor does GE asstre any responsibility .for liability or damage of any kind which may result frcrn the use of any of the inforration contained in this document.
DED008.LL i
j Appendix A P ga 2 cf 44 TDR 580 f
.. Rev. O j Page 38 '
u.
INTRODUCTICN During a recent hydro test performed on the Oyster Creek isolation condenser piping return line (A loop), a leak was noticed near an isolated The insulati m elbow on the condensate piping, downstream of the condenser.
The weld was examined was removed to reveal a crack near weld NE-2-12. An ultrasonically, which pinpointed the existence of two through-wall cracks.
inspection of both A and B loop isolation condenser piping (steam and condensate side) has been performed. A total of 27 welds have been found with crack indications, all outside the drywell isolation valves. 'No sections of piping were sont to the General Electric Turbine Technology Laboratory to One piece of pipe was an 8" diameter determine the nature of the defects.
Schedule 80 elbow frcra the A loop which contained the through-wall crack (weld NE-2-12). The second section of pipe was a 12" diameter Schedule 80 spool piece frcra the supply line (B loop) containing weld NE-1-15.
The attached report, " Investigation of Pipe Cracks Found in Oyster Creek l
Piping" (Memo Peport CI-1108), describes the results of the radiographic and metallographic inspection of the two pieces of AISI 316 stainless steel pipe frcra Oyster Creek.
PESULTS A total of three cracks were found, all beginning at the inside pipe wall The material and prcpagating intergranularly in a heat affected zone.
camposition was found to be within the AISI 316 stainless steel ccrposition range, with a carbon content high enough to prcrote a sensitization zone after The defects are welding (A loop section - 0.046'tC, B loop section - 0.060%C) .
typical of intergranular stress corrosion cracks.
- Appzndix A _s Pega 3 of 44 Rev. O Pcge 39 ,
Memo Report Cl-1108 Chemistry and ElectricalInsulation Subsection Turbine Technology Laboratory Schenectady, New York ,
e INVESTIGATION OF PIPE CRACES FOUND IN OYSTER CREEK PIPING
- by -
c.c.GOULD June 20,1984 Abstract: The results of radiographic and metallographic inspection of two pieces of AISI 316 stainless steel pipe are presented. Three different cracks were found, all beginning at the inside pipe wall and propagating intergranularly.
l h
i
Appsndix A Peg 2 4 of 44 2DR 580 Rev. O Page 40 Memo Report CI-1108 INVESTIGATION OF PIPE CRACES FOUND IN OYSTER CREEK PIPING
_ by _
c.C.couto INTRODUCTION Two separate pieces of pipe were sent from Oyster Creek to the Turbine Technology Laboratory for investigation into the nature of defects that were uncovered by NDT while the piping was in place.
One piece of pipe was an 8" Schedule 80 elbow contained in the isolation condenser system "A" return line, while the second, received at a later date, was a 12" diameter Schedule 80 spool piece from the isolation condenser "B" supply line containing weld NE-1-15.
The results of the investigation will be presented in two parts, one pertaining to each piece of pipe.
PART I: INVESTIGATION OF THE LEAKING INDICATION IN THE 8" SCHEDULE 80 PIPE, NE-2-12 FROM ISOLATION CONDENSER "A" RETURN LINE The 8" Schedule 80 pipe elbow was received at 1:00 a.m. May 19,1984. The level of radiation was 70 mR/ hour at contact on the interior surface and less than 2 mR/ hour at three feet.
The sample, as received, is shown in Figure 1. The first operation was to cut the weld, NE-2-12, out as indicated in Figure 1.
This smaller, ring-like specimen was radiographed around the full circumference of the weld, and a defect was found " intermittent 3600". Prints taken from these radiographs are included as Appendix 1.
' The ring specimen was split axially with half being forwarded to Carl Czajkowski at Brookhaven National Laboratory in Upton, New York. ,
The remaining half of the specimen containing the leaking indication 201 in NE-2-12 was ,
sectioned as shown in Figure 3. Figure 4 is a photograph of the pipe section, with Figure 5 l
showing the leak from the outside. l l
Chemical analysis by X ray fluorescence was done in the piece marked "1" in Figure 3, '
and subsequently, chips were removed for a carbon determination from the same piece.
Scanning electron microscopy was performed on the piece marked "2" in Figure 3. The long piece was sawed out and placed in a vise and broken open (by hand) and the fracture surface cleaned by ultrasonic agitation in a detergent water solution.
The part of the leaking crack adjacent the scanning electron microscope specimen was labeled "3" and removed with both sides of the crack intact, mounted in epoxy resin, and l
! prepared metallographically. While being inspected, the weld bead was identified and
! photographed, and later, at a higher magnification, the crack was photographed. A second l
l
- App:ndix A Pega 5 cf 44 ER 580
~
R2v. O Page 41 crack, nearer the weld bead, was found during this microscopic inspection and photographed.
A red dye penetrant inspection was performed on weld NE-2-13 on the inside pipe surface.
RESULTS The results of the chemical analysis done on piece "1" of Figure 3 are shown in Table 1.
The carbon content, 0.046 percent, is sufficiently high to allow sensitization in the heat affected zone of the weld.
The scanning electron micrographs taken from the "2" location in Figure 3 (Indication 201, leaker) appear in Figure 6. The result of a complete scan of the fracture surface showed only an intergranular surface with some variation in the amount of oxide on the fracture surface. As mentioned in the Frocedure section, a ten minute exposure to ultrasonic
~~ agitation while immersed in a water / detergent solution was employed to reduce the
~ fracture surface oxide and improve the clarity of the SEM pictures.
The Metallography carried out on Indication 201 " leaker" is shown in Figures 7 through 9.
location of this specimen is shown as "3" in Figure 3.
Figure 7 shows the weld bead at 8X and the location of the leaking crack adjacent to the weld bead. In addition, there is a second crack visible very close to the weld bead. This second crack extends only slightly past the midwall thickness of the pipe, penetrating about 60 percent of the wall thickness.
Figures 8 through 10 show the leaking crack at the inside wall, midwall, and at the outside of the pipe.
Figures 11 and 12 show the second, non penetrating crack at its origin on the inside wall and at the midwalllocation.
All cracks are judged to be intergranular along the austenite grain boundaries. Neither of the cracks in the 8" pipe are observed propagating into the weld bead. A Magnagage reading on this weld showed a ferrite number between 3 and 4.
A red dye penetrant inspection was performed on the I.D. of weld NE-2-13. Figures 13 and 14 show the 8" pipe looking at NE-2-13 toward NE-2-12. Note the axial weld bead for orientation in Figure 13 and the linear indication approximately 2300 from the axial weld. Figure 14 shows a close-up of the red dye indication found in weld NE-2-13.
In service, the axial weld is at 5 o' clock looking from NE-2-13 toward NE-2-12.
CONCLUSIONS
- 1. The fracture path of the leak and a second crack found just adjacent the weld bead are unambiguously intergranular.
I
- 2. The material composition is within the composition range of AISI 316 stainless steel, and the carbon content is high enough to allow heat affected zone sensitization. )
l l
1
- - -- - _ ._______ _ _ , _ _ . , " " 1 -c p, y _. . , _
- App 2ndix A Paga 6 of 44
- TDR 580 Rev. O Page 42 ;
- 3. The cracking is most probably intergranular stress corrosion cracking of the weld heat affected zone.
PART D INVESTIGATION OF THE 12" SCHEDULE 80 PIPE SPOOL FROM ISOCONDENSER "B" SUPPLY LINE The 8" long section of 12" diameter pipe was received May 20,1984, at approximately 9:00 p.m. The level of radiation measured was about 110 mR/ hour at contact on the inside surface and 6 mR/ hour at three feet. The sample as received is shown in Figure 15. A slice of the 12" pipe wall was cut from the spool piece as shown in the sketch in Figure 16.
Radiography was done on the circumferential weld, and prints of the radiographs and their location are shown in Appendix II.
Figure 17 shows the piece removed from the 12" spool piece and the location of the pieces used for each of the subsequent examinations.
~
Chemical analysis was performed on piece "4" by X-ray fluorescence, and the results are shown in Table II.
Scanning electron microscopy was performed on piece "3" in Figure 17, and in this case, a f heavy coating of oxide necessitated the use of ultrasonic agitation for two ten minute periods in a 5 percent H2SO4 solution containing catechol.
The piece marked "5" in Figure 17 was mounted in epoxy resin and ground, polished, and etched with Kalling's etchant prior to being photographed. The weld bead was photographed at 8X while the crack was done at 50X. The location of the 50X pictures is given on the 8X picture.
A Magnagage was used to measure the ferrite content of the circumferential weld on the 12" diameter pipe.
RESULTS
- S.- :-.:lts of the chemical analysis by X ray fluorescence appear in Table II. The location of the chemical analysis specimen is shown in Figure 17 as piece "4". ,
4 The results of the scanning electron microscope fractography are shown in Figures 18 and 19. The fractographs shown in Figure 18 are taken near the inside wall of the pipe near the crack origin and have a thicker coating of oxide on them than those in Figure 19, taken at midwalllocation near the growing end of the crack, or crack tip.
Figure 20 is a montage of microphotographs showing the weld bead, the crack, and the location of the photomicrographs that make up Figures 21 through 23. The crack has penetrated about 54 percent of the pipe wall.
Notice the surface weld beads on the right outside surface in Figure 20. These beads make the weld appear larger than it is, in fact, from the outside pipe surface and undoubtedly led to NDT conclusion of a midbead or centerline defect when, in fact, the crack is located in wrought material.
i w , - . - - - . , - - - . . - . - . - , , - . . , - -
App 2ndix A Pega 7 of 44
, . TDR 580 Rev. O
~
Page 43 F!gures 21 through 23 show the crack at the inside wall (origin), midwall at the Y of the weld bead, and at the growing branching end past midwall.
It can be seen that the crack grows into the weld bead and arrests on several occasions, albeit not very far. M:gnagage readings gave a ferrite number between 12 and 13 for this weld.
CONCLUSIONS
- 1. The cracking is wholly intergranular initiating at the inside pipe wall in the heat affected zone.
- 2. The composition of the steel falls within the specified range of AISI 316 with the carbon content 0.060 percent, high enough to allow sensitization in the weld heat affected zone.
- 3. The most probable cause for the cracking in intergranular stress corrosion cracking in the weld heat affected zone.
~
O I
- 1679/CG/7 l
~ . _ _ _ .
Appindix A
. . Pega 8 of 44 IDR 580 Rev. O Page 44 l
Table I T
CHEMICAL ANALYSIS OF WROUGHT MATERIAL l
DONE ON 8" DIAMETER SCHEDULE 80 PIPE FROM OYSTER CREEK *
)
i l
Weight Percent Cr Ni Mo C 17.0 11.1 2.20 0.046
~
- Location of the chemical analysis sample defined as "1" in Figure 3. j l
l O
6 0
m---,--- --m --- +- . . , - - - - . -m, - --.. . ---- - - -,.-
- Appandix A
- Pcgs 9 of 44 TDR 580 Rev. 0 Page 45 Table II CHEMICAL ANALYSIS OF WROUGHT M ATERIAL DONE ON 12" DIAMETER PIPE FROM ISOCONDENSER B*
Weight Percent Ni Mo C Cr 16.9 13.1 2.26 0.060
- Location of specimen defined in Figure 17 as part "4".
O I
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- Appandix A Paga 10 of 44 'IDR 580 Rev. O Page 46 Sawed this section out for analysis v
, NE-2-12 ,
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NE 2-12A F
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e Figure 1: 8" Dia. schedule 80 pipe received from Oyster Creek ,
m Appendix A
- Pege 11 of 44 IDR 580 Rev. O Page 47 Indication 200
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/ N, Brookhaven CUT TurbineTechnology g / Laboratory g /
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I Indication 201
" Leaker" Indication 200 N i/ N
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\ Brookhaven NE-2-12 CUT NE 2-12A
~
I Turbine Technology
/ Laboratory l
x / p x /
I Indication 201 Figure 2: Axial cut to divide NE-2-12(and NE-2-12A) between Brookhaven National Laboratories and Turbine Technology Laboratory
i
, 1 Appendix A Psgs 12 of 44 7DR 580 Rev. O Page 48 l
i (2) l (3)
/ Indication 201 i
l NE-212 (Leaker) j
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(1) Chemical Analysis Sample (2) Sem Fractographic Sample .
(3) Metallographic Sample Figure 3: The half of the pipe kept for analysis at Turbine Technology Laboratory. The other half to Brookhaven National Laboratory.
Appzndix A Page 13 of 44 IDR 580 Rev. O Page 49
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Appendix A
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! 2.2X Neg. No. 4-1461 l
l - - _ ._
Appendix A ER 580
- Page 15 of 44 Rev. O Page 51 c
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Appandix A Page 16 of 44
'IDR 580 Rev. O Page 52 i
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Crack origin inside wall. 50X Neg. No. 4-1481F-1 Kallings
Appendix A Page 18 of 44 TDR 560 Rev. O Page 54 i
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Midwall location. 50X Neg. No. 4-1481F-2 Kallings
Appendix A Page 19 of 44 TDR 580 Rev. O Page 55
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Beg. No. 4-1481F-3 Kallings
App'.ndix A Pegs 20 of 44 TDR 580
- Rsv. O Page 56 l
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Crack origin inside pipe diameter close to notch.
50X Neg. No. 4-1481F-6 Kallings
- App 2nc1x a Pcg3 21 of 44 'IDR 580
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Midwall location " Growing End,. 50X Neg. No. 4-1481F-5 Kallings
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. Appandix A
- Pega 23 of 44 TDR 580 Rev. O Page 59 1
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Appandix A Pagt 24 of 44
'IDR 580
, . Rsv. O Page 60 t
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Appandix A
- Pega 25 of 44 1DR 580 Rev. O Page 61 1
L\ i l , i I l 1 I I I I y I I A I l dI I I I NE 1 15'g l I I I I I I I l , I l A N i Primary piece used for investigation i l l FIGURE 16: Sketch of 12 inch diameter spool piece showing i NE-1-15 and axial l' weld in addition to the piece removed for examination. l l
Appandix A Page 26 of 44 TDR 580 Rev. O Page 62 1 l 1 l 1 I l I I 1 I I I g ; (5) l I I I i 1
' ' Crack I (3) 1
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WeId h I (4) I L__- A----------- Figure 17: Piece removed from 12 inch spool piece and the location of fractographic specimen (3); metallographic specimen (5); chemical analysis specimen (4).
Appandix A 'IDR 580
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Appendix A
- Page 28 of 44 TDR 580 Rev. O Page 64 h f' I .
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- Appsndix A Pena 29 cf 44
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. Appsndix A
- Pega 30 of 44 .IDR 580 Rev. O Page 66
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f t i l Figure 22 - Twelve inch diameter pipe crack at mid wall. Note the l l change in direction. l ) Neg. No. 4-1480-5 50X Kallings
App;ndix A
, , P.cg2 32 #f "0 TDR'580 Rev. 0 Page 68
. >.. .. n. . .;r., . .
. / . . . , . . .,
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. - 1 Figure 23 - Twelve inch diameter pipe crack at the "growir.g" end.
Neg. No. 4-1480F-6 Kallings
Appsndix A Page 33 Of 3 R 580
- Rev. 0 Page 69 I
l m g NE-2-12
=- " Leak l
C A g NE-2-12A B i l r Location of the radiographs on NE 2-12 in the 8 inch pipe. APPENDIX h i
Appendix B TDR 580 Page 6 of 26 Rev. O Page 87 Assuming that the indications are fully circumferential, the method described in Reference 2 can be used. There, a relationship between the applied loads, the flow stress, and the critical crack depth to thickness ratio is defined by Equations (1) and (2). n (1 t a E) p= (1) 2-f 2a (2) P b
= --
(2-f) sin S w he re of = material flow st re s s, Py = primary membrane stress, Pb " primary bending stress, a = crack depth, t = total thickne ss (pipe wall + weld overlay thickness), and S = angle that defines location of neutral axis. These equations cannot be solved directly for the allowable flaw depth to thickne ss ratio, so an iterative approach must be used. In the iteration scheme, a weld overlay thickness is assumed and the primary stresses are adjusted to the new total thickness. The allowable Pb corresponding to the new thickne ss and the adjusted primary membrane stress is calculated from P +P Equations (1) and (2). ) Facter of Safety is then The allowable ( 'Sa P
+P compared to the actual adjusted 3
. If the allowable is less than the a
actual, then the assumed weld overlay thickness is insufficient to provide full structural reinforcement and the procedure is repeated using a larger weld overlay thickne ss. The iteration is perf onsed until the minimum required j weld overlay thickness is determined. A f actor of safety of 3.0 is used in accordance with the ASME Code, Section II, Paragraph IVB-3640. 4
a .o Appendix B Page 7 of 26 TDR 580 Rev. O Page 88 3.2 Anelled Stresses at the Veld Overlav Locations . The deadweight and seismic stressoa at the weld overlay locations were obtained from the Oyster Creek Isolation Condenser System piping stress r e po r t , Reference 3. The welds and the corresponding node numbers and stresses from this report are sammarized in Table 2. The seismic stresses listed in this table are the greater of the two reported in Reference 3, corresponding to seismic analyses perf ormed in two orthogonal horizontal directions. A revtew of the deadweight and seismic stresses listed in Table 2 reveals considerable variation in each at the dif ferent weld locations. To obtain conservatism and generality in the weld overlay designs for the four different pipe sizes, the deadweight and seismic stresses were each enveloped based on the maximum stresses shown in Table 2. Thus, the enveloping deadweight stress is 3.3 ksi and the enveloping seismic stress is 5.1 ksi. The pressure used in calculating the primary membrane stress was 1090 psi. This is the technical specification limit for the opening of electro-mechanical relief valves. In the IWB-3640 Tables [1], the implied f actors of safety for normal / upset conditions are twice that f or the emergency /f aulted conditions (i. e. , 2.8 versus 1.4). Therefore, the emergency /f anited condition primary loads are controlling only when they are more than twice the corresponding normal / upset condition loads. Since this was not the case for the subject isolation condenser line, the normal / upset condition loads stated in this subsection l were used in the overlay design, i 3.3 Weld Overlav Thickness Results The iterative calculations described in Section 3.2 were performed for the four pipe sizes using the enveloping stresses. The flow stress ag was taken a s 3 S,. The results are provided in Tables 3 through 6. The thicknesses generated by this calculation are the minimum necessary for the overlay to maintain the required 3.0 factor of safety. They do not account for the various geometries specific to each weld, but serve only as the basis for the recommended design thickne sses.
- Appandix B Page 8 of 26 TDR 580 Rev. O Page 89 3.4 Weld Overlaw Widths
' Unlike the thickness requirements for veld overlay designs, which are based on satisfying the saf ety margins of the ASME Code, there are no guidelines for determination of the weld overlay widths. General Electric has perfonned finite element studies which compared the stresses obtained in pipes with dif ferent weld overlay widths. Results showed that there is no significant dif ference between the stresses obtained for widths in excess of one attenuation length, Rt, and it was concluded that the additional material of the wider overlay contributes little to the overall structural reinforcement of the weld. Therefore, minimum weld overlay widths of Rt are used here as the basis f or the reconsended overlay designs. This reduction in width l greatly reduces the time required for application of the weld overlays. The minimum widths are included in Tables 3 through 6 also for each pipe size. 3.5 Weld Overlav Desians The minimum weld overlay thickne sses and widths provided in Tables 3 through 6 were used as the basis for the individual weld overlay geometries. The 3 specific overlay designs were siso based on consideration of such factors as the relative thicknesses of the butt welding members, the weld crown geometry, the extent of the original heat affected zone, and the proximity to other pipe fittings such as elbows and attached piping. The slopes of the overlay ends were set to three-to-one (width-to-thickness) to reduce stress concentration i effects. A further consideration was weld metal-base metal dilution in the first weld overlay layer. The overlay-base metal mixing could result in a lessening of the weld material's resistance to IGSCC close to the fusion line. Thus an effective design thickness for overlay deposited af ter the first weld layer was specified in accordance with Reference 4. Of the eighteen welds to be overlayed, six are pipe-to pipe and twelve are pipe-to-elbow but t welds. A schematic of the overlay design geometries for 4 the pipe-to pipe welds and a summary of the overlay dimensions f or each 6 _,_.._._._._....i
Appsndix B Pags 9 of 26 2DR 580 Rev. 0
--!' --- --- 8'ad !- Figure 5.
Similarly, for the pipe-to-elbow Figure 6 sammarises the weld specific overlay design dimensions.
~
welds, ._ D
-7
Appsndix B ) Page 10 of 26 TDR 580 Rev. O Page 91
- 4. WELD OVERLAY SERINEAGE STRESS ANALYSIS Application of a weld overlay produces an axial contraction of the pipe which is a function of the pipe size and the overlay thickness and width. This shrinkage imposes stresses on the entire piping system. The amount of shrinkage was estimated for the purpose of this analysis based on typical shrinkages observed in similar veld overlay applications. The 8- and 10-inch and the 12- and 16-inch pipe pipe overlays were assumed to shrink 1/4 inch, overlays were assumed to shrink 3/8 inch. A finite element analysis of the Loop B supply end return piping was performed to determine the magnitudes of the stresses due to these assumed shrinkages. This analysis was perf ormed using the PISYS finite element code (Reference 5). The models are provided in Figures 7 and 8. The shrinkage effect was simulated by forcing thermal contractions at the weld overlay locations equivalent to the assumed 1/4- and 3/8-inch overlay shrinkages. A summary of the maximum shrinkage stresses obtained in the Loop B supply and return lines is provided in Table 7.
I The shrinkage stresses obtained in Loop B are low due to the overall flexibility of the piping system: the piping is supported mainly through hangers and snubbers. The Loop A supply and return lines are very similar in configuration and support to Loop B and thus the stresses due to overlay shrinkage in these lines would be of the same low magnitude as calculated for the Loop B line s. The actual weld overlay shrinkages will be measured and compared to the assumed values. Variations will be reevaluated to determine the significance I of the deviation from the assumed shrinkages. l
)
l i l l
)
8
App 2ndix B Page 11 of 26 IDR 580 Rev. O Page 92
- 5. REFERFNCES
- 1. ASME Boiler and Pressure Vessel Code. Section II.1980 Edition. Winter 1983 Addenda.
- 2. Ranganath, S. and Mehta. H. S. , ' Engineering Methods for the Assessment of Ductile Fracture Margin in Nuclear Power Plant Piping, ' Elastic-Plastic Erecture: Second Symoostum. Volume II-Fracture Resistance Curves and Ennineerina Acelications. ASTN STP-803. 1983, pp. 309-330.
- 3. Dester Creek Isolation Condenser System Pinina Stress Report, prepared by EDS Nuclear. November 1979, EDS Report No. 02-0370-1021.
- 4. Letter from William J. Dircks, NRC to the Commissioners, NRC, ' Staff Requirements f or Reinspection of BWR Piping and Repair of Cracked Piping, '
November 7,1983, SECY-83-267C.
- 5. PISYS05. GE Pinina System Analysis Comenter Pronram. NEDE-24077, January 1981.
G e l I 9
4 !I l l'
=
NE-1-13 v p , NE-1-20 i l NE-1-11
~ ~
i' 3 4 TO ISOLATION l CONDENSER NE 01-A l N
- NE-1-32 d gg i '
#" , n 4 o M NE-1-29 NE-1-25 % cs o 6 w
TO ISOLATION CONDE NSER NE Ot-A 1 r PENETRATION i X-3 A FLOOR REDUCER f i i 1 NE-1-2 "2 l Oyster Creek isolation Condenser Piping Loop A Supply Line j3~ ~ !!! I coE Figure 1
6 { ' o h:d$t y*ug D: g k ~* a y*. o r; g I O O L F R
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e U D 7 1 i n E R 2 L Ii E N n tp
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! NE-1-84A (
NE-1-48 9 4 L r 4 b z I ISOLATION on u 4 m 3f i CONDE NSER 9t 3 L NE 01-8 g c~ es [ l M t r i o ! d m tis i N m 1 U i PENETRATION X-3B FLOOR REDUCER E ISOLATION CONDENSER OS.y i Oyster Creek isolation Condenser Piping Loop B Supply Line li'$ c o cn figure 3 i
' t
>a$
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- O% Ne ,d" .? ,%
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- App 2ndix B Pcg216 of 26 2DR 580 Rev, O Page 97 TABLE 1 Welds at which Indications were Identified in the Oyster Creek Isolation Condenser System Piping Nominal Veld ID Pinine Line Pine Size (laches)
NE-1-2 Loop A Supply 16 Schednie 80
12 NE-1-11
12 NE-1-13 NE-1-20 12
12 NE-1-25
12 NE-1-29 NE-1-32 12 NE-2-4 Loop A. Return 8
8 NE-2-8
8 NE-2-17
8 NE-2-28 NE-1-46 Loop B, Supply 12
12 NE-1-51
12 NE-1-54 A NE-2-80 Loop B, Return 8
8 NE-2-91 NE-2-98 8
10 NE-2-103 l
I 9 14
App 2ndix B
. Pcg2 17 of 26 IDR 580 l Rev. O Page 98 i TABLE 2 Summary of Deadweight and Seismic Stresses at Veld Overlay Locations Oyster Creek Isolation Condenser Piping Finite Element Dea dweight Sei smic Weld ID Node #* (ksi) (ksi)
NE-1-2 9 .211 .3 90 NE-1-11 46 .903 1.174 NE-1-13 52 1.205 1.346 NE-1-20 64 3.249 .594 NE-1-25 19 .604 .549 NE-1-29 28 .270 1.210 NE-1-32 33 .510 2.055 NE-2-4 40 1.114 .530 NE-2-8 33 2.293 .691 NE-2-17 18 2.330 1.871 NE-2-28 54 .846 5.021 NE-1-46 43 2.423 .629 NE-1-51 51 1.386 .406 NE-1-54 A 55 1.571 .316 NE-2-80 32 .218 .823 NE-2-91 48 .326 2.241 NE-2-98 36 1.660 2.126 NE-2-103 6 .198 .411
' Node numbers correspond to the piping finite element models from Reference 3 e
15
. App ndix B Pega 18 cf 26 7DR 580 Rev. O Page 99 Table 3 -
Minimum Weld Overlay Dimensions for Eight-Inch Isolation Condenser Piping
$$$$$$$$$$$$$$$$$$$t$$$$$$$$8888$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
- WELD ID: B INCH *
$ FIFE THICKNESS = 0.50 INCH *
- FIFE DIAMETER = 8.6 INCH *
- FRIMARY LOADS (STRESS): *
- PRESSURE = 4.70 KSI *
- DEAD WEIGHT = 3.30 KSI *
$ SEISMIC = 5.10 KSI *
- FB (KSI) EBiEB EBiEB *
$ __I__ FM -------------- SM 3SM *
- WOT T4WOT (KSI) ACTUAL CALC (ACTUAL) (CALC)
- g ...__...._____..............___........................___. g
- 0.225 0.690 3.411 5.793 24.304 0.526 0.528 *
- FRIMARY STRESS RATICS (ADJUSTED): *
- FM/SM = 0.195 *
* (FMfFB)/SM = 0.526
- 8 MINIMUM REQUIRED WELD DVERLAY THICKNESS = 0.225 INCH *
- MINIMUM REQUIRED WELD OVERLAY WIDTH = 1.5 INCH *
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$5$$$$$$$$$$$$$$$$$$$$$$$$$$$t*
16 l
- App:ndix B Page 19 of 26 IDR 580 Rev. O Page 100 Table 4 Minimum Weld Overlay Dimensions for Ten-Inch Isolation Condenser Piping
*$$$$$$$$$$$$$$$$$$8$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$ts WELD ID: 10 INCH
- FIFE THICKNESS = 0.59 INCH *
- FIFE DIAMETER = 10.8 INCH
- FRIMARY LOADS (STRESS):
= 4.94 KSI *
- FRESSURE
- DEAD WEIGHT = 3 30 KSI *
- SEISMIC = 5 10 KSI *
- FB (KSI) E51EB EniEB *
$ ..I.. FM -------------- SM 3SM *
- WOT TfWOT (KSI) ACTUAL CALC (ACTUAL) (CALC) *
........................................................... g g
- 0.275 0.6S3 3.548 5.739 24.656 0.531 0.537
- 5
- PRIMARY STRESS RATICS (ADJUSTED): *
- FM/SM = 0.203 *
* (FMfFB)/SM = 0.531 *
- MINIMUM REQUIRED WELD OVERLAY THICKNESS = 0.275 INCH *
- MINIMUM REQUIRED WELD OVERLAY WIDTH = 18 INCH *
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$588$$$$585 17
r App 2ndix B
, . Paga 20 of 26 TDR 580 Rev. O Page 101 Table 5 Minimum Weld Overlay Dimensions for Twelve-Inch Isolation Condenser Piping
$388884t*****tt4848888888888888888888888888888t***$388888888888888888
- WELD ID: 12 INCH *
- PIPE THICKNESS
- 0.69 INCH *
- PIPE DIAMETER = 12.8 INCH *
- PRIMARY LOADS (STRESS): *
- PRESSURE = 5.06 KSI *
- DEAD WEIGHT = 3.30 KSI *
- SEISMIC = 5.10 KSI *
- PB (KSI) EHiEB EdiEB *
* ..I.. PM --------------
SM 3SM *
- WOT TfW3T (KSI) ACTUAL CALC (ACTUAL) (CALC)
- g ........................................................... g
- 0.320 0.682 3.623 5.731 24.615 0.535 0.53C *
- PRIMARY STRESS RATIOS (ADJUSTED): *
- PM/SM = 0.207 *
* (PMiPB)/SM = 0.535 *
- MINIMUM REQUIRED WELD OVERLAY THICKNESS = 0.320 INCH *
- MINIMUM REQUIRED WELD OVERLAY WIDTH = 2.1 INCH *
*S$$$$$$$$$$$$$$$$$888tst8tttttt$$$888$$$888$$$$$$$$$$$$$$$$$$$$$$$$$
1 _ . , . _ .18 _. _ _ _ _ _ _ _ _ _ _ _ __ __
AP psndix B Pcg2 21 of 26 IDR 580 Rev. O Page 102 Table 6 Minimum Weld Overlay Dimensions for Sixteen-Inch Isolation Condenser Piping
$$$$$8*tt**tt*** stat **tt$$$$$$$$$$$$$$$388888***$$$$$$$$$$$$$$$$$$$$$ *
- WELD ID: 16 INCH
- PIPE THICKNESS = 0.84 INCH FIFE DIAMETER = 16.0 INCH
- PRIMARY LOADS (STRESS):
- FRESSURE = 5.18 KSI DEAD WEIGHT = 3.30 KSI
- SEISMIC = 5.10 KSI FB (KSI) EHiEB EHiEB *
-------------- SM 3SM
- __I_. PM TfWOT (KSI) ACTUAL CALC (ACTUAL) (CALC)
$ WOT g .... ................................ _...._............... :
- 0 540 *
- 0.395 0.681 3.698 5.718 24.629 0.538
- PRIMARY STRESS RATIOS (ADJUSTED):
$ FM/SM = 0.211 (FMfFB)/SM = 0.538 *
$ MINIMUM REQUIRED WELD OVERLAY THICKNESS = 0.395 INCH
= 2.6 INCH *
- MINIMUM REQUIRED WELD OVERLAY WIDTH
*$$$$$$$$$*$$5$$$$$$$**$$$$$$$$$$$$$$$$$$$$$$$$$$48888$$$$$$$$$$$$$$$
}
r i 19
Appsndix B TDR 580
- Page 22 of 26 Rev. O Page 103 C 'W" MIN O WELD h *W " g O C CROWN WIDTH
= = *W " +
g MIN MIN - FIRST 3 If LAYER y/ - llN//////////////f/ \ _ x BUTT WE LD ELBOW PIPE j OVE LAY THICKNESS d so - 9 WELD PIPE-It)-PIPE Pipe Size Wall Weld No. Loop (inches) Thickness Tg, Wg W NE-1-2 A 16 .843 .40 .75 3.3 NE-1-13 A 12 .687 .35 .60 3.0 NE-1-25 A 12 .687 .35 .60 3.0 NE-1-29 A 12 .687 .35 .60 3.0 NE-1-54 A B 12 .687 .35 .60 3.0 NE-2-103 B 10 .593 .30 .50 2.5 Figure 5 Design Dimensions for the Pipe-to-Pipe Weld Overlays Oyster Creek Isolation Condenser Piping 20
Appandix B TDR 580
- Pcg2 23 of 26 Rev. O Page 104 C *W' MIN C
*Wg" MIN CO C C OWN O CC **1** MIN WIDTH
= FIRST
"' II 3 LAYER
(([ g 1 I I od SUTT ll i i ELBOW WELD "T" MIN 1 PIPE sd ( WELD PIPE-It)-EIJ10W Pipe Size Ts11 W Weld No. Loop (inches) Thickne s s T,g, W1 12 .687 .35 .60 3.0 NE-1-11 A 12 .687 .35 .60 3.0 NE-1-20 A 12 .687 .35 .60 3.0 NE-1-32 A 8 .500 .25 .50 2.1 NE-2-4 A
.50 2.5 NE-2-8 A 8 .500 .25 8 .500 .25 .50 2.2 NE-2-17 A 8 .500 .25 .50 2.3 hI-2-28 A 12 .687 .35 .60 3.0 i NE-1-46 B
.60 3.0 NE-1-51 B 12 .687 .35 8 .500 .25 .50 2.7 NE-2-80 B 2.4 8 .500 .25 .50 NE-2-91 B 2.3 8 .500 .25 .50 NE-2-98 B 8
Fisure 6 Desisa Dinensions f or the Pipe-to-Elbow Weld Overlays Oyster Creek Isolstion Condenser Pipins 21
g?> . y$ w, e, y* g* go g". o _
@5 3 Wi "l i t
s s H i ( e s m s X s Y t n - i e - s m s e i l y s es E y n l e a g n a A
, k
, n s i s r e h r 6 S t 2 S Z e
@ g a
' k n
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- M o 2 L
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i n
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, s n
. e d
n n o 4 C n o i A t a l
, o s
I 5 6
., l% 1
,l '
e 1 5 6 _ s - i N" - S 5 5 g
hY Mh ts NE-2-80 h, yi 3si l psi i agi , Z X @ Shrinkage Elements sei, gg 2%
'/ $ 0: 5 o
as t$ , ** W NE-2-103 s i NE-2-8 ,, sti i 3*
$ne
** #9
# sa les =8 *'f NE-2-98 n .:
4,i, a *l ,, as ,9 m, , e 4st'l c Figure 8 55& g ,< M Isolation Condenser Piping Ptodel for Shrinkage Stress Analysis-- gag* Toop B Return 8 _______D
. App 2ndix B i Pega 26 of 26 TDR 580 !
Rev. O l Page 107 l Table 7 Neximum Shrinkage Stresses I Isolation Condenser Piping--Loop B Finite Pipe Element Section Nominal Location Line Node # Noment Modulus Stress (esi) Weld NE-1-40 Supply 10N 29,219 144.5 202
' Y' Re du c er Supply 13 29,153 74.5 391 Penetration I-5A Return 1 67,712 45.6 1,487 Weld NE-2-98 Return 38 54,514 45.6 1,197 A
l < i t h 24
Appandix A Pcga 34 of 44 IDR 580 Rev. O Page 70 .i r+.'T. t '5Lr' C... q.
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Appendix A
. Page 35 of 44 I
, TDR 580 Rev. 0 l Page 71 l 1
1 1 7>9 ',
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Page 81 Appendix B GE Weld Overlay Design Report
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TDR 580
- ' Appandix B Rsv. O Page 1 of 26 DRF #137-0010 Page 82 MAR 84-17 Rev. 1 MAWO3. DA WELD OVERLAY DESIGNS AND SHRINKAGE S'IltESS EVALUATION FOR THE INDICATIONS IN THE OYSTER CREEK ISOLATION CONDENSER SYSTEM PIPING t
j July 1984 Prepared By: M. A. White. Engine er Mechanics Analysis Reviewed By: H. S. Mehta, Principal Engineer Mechanics Analysis Approved By: - S. Ranganath." Manaser Mechanics Analysis
f Appsndix B
,
- Pega 2 of 26 TDR 580 Rev. 0 Page 83 ;
' WNIENTS h
1
- 1. INTRODUCTION 2
- 2.
SUMMARY
AND RESULTs 3
- 3. WELD OVERLAY DESIGNS 3
3.1 Methodology for Determining the Minimum Required Teld Overlsy Thicknesses 5 3.2 Applied Stresses at the Weld Overisy Locations 5 3.3 Weld Overlsy Thickness Results 6 3.4 Weld Overlsy Vidths 6 3.5 Weld Overlsy Designs 8
- 4. WELD OVERLAY SHRINKAGE STRESS ANALYSIS 9
- 5. REFERENCES 10 TABLES AND ILLUSTRATIONS
AppIndix B "~ I j Pcg2 3 of 26 TDR 580 ; Rev. 0 l Page 84
- 2. INT?OPUCTION Geners! Public Utilities (GPU) Nuclear performed an ultrasonic testing (UT) inspection of the Oyster Creek Isolation Condenser System piping in May 1984, for detection of Intergranular Stress Corrosion Cracking (IGSCC). The piping consists of two loops. A and B, each being made up of a supply line and a return line. Reportable indications were found at welds in each of the four l ine s, totaling twenty-seven. All of the indications were circumferential in orientation.
GPU Nuclear has decided to weld overlay repair eighteen of these welds and replace the remaining nine welds. The four pipe lines and the overlay locations are shown in Figures 1 through 4. Table 1 sammarizes all of the welds and the respective pipe lines and pipe diameters. All but two of the indications were found in the 12-inch supply lines and the 8-inch return l ine s. The other two were at welds in a 10-inch return line and a 16-inch supply line. The overlays are to be designed to assure that the full structural margin intended by IWB-3640, Section II [1], is maintained. This report provides recgnmendations for the design of the weld overlays to meet the Code safety margins and specific geometric considerations at each weld. The effects of axial shrinkage of the piping from application of the overlays is also eramined in terms of the additional stresses imposed on the piping system. i 1 1
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- 2.
SUMMARY
AND RESULT 5 The weld overlay designs for repair of the Isolation Condenser System piping were determined based on maintaining the ASNE Code required factor of saf ety against net section yielding of the overlaid welds. The minimum required overlay thicknesses were obtained assuming the flaws to be fully circumferential and to extend through the original pipe wall. The applied primary loads used in the thickness calculations were enveloped to provide further conservatism and generality in the designs. The miniana thicknesses recommended here do not include the first weld layer. The overlay widths were sized to optimize the anonut of welding time and material necessary to provide the required structural reinforcement of the flawed weld regions. The stresses imposed on the Loop B supply and return lines from axial shrinkage of the overlays were calenlated based on typical shrinkages. These stresses were found to be very low due to the overall flexibility of the piping. Loop A shrinkage stresses are expected to be of the same low ma gnitude. l l I l
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App 2ndix B TDR 580 Pcg2 5 of 26 Rav. O Page 86 I
- 3. WELD DVERLAY DESIGN ANALYSIS 1
I The criterion used in design of the weld overlays for the Isolation Condenser System piping is to provide full structural reinforcement of the cracked In evaluation of the overlay region maintaining the ASME Code saf ety margins. designs, it is conservatively assumed that the flaws are fully circumferential I and will extend through the susceptible material of the original pipe wall. With this assumption, no credit is taken for the beneficial compressive residual stresses induced by the heat sink weld overlay process that would The postulated through-wall oppose crack extension through the thickness. cracks also provide assurance that the overlay design is ladependent of the IGSCC crack growth into crack size as determined by the ultrasonic testing. the weld overlay material beyond the first layer is not expected since the weld material away from the fusion line is not susceptible. 3.1 Methodoloav for Determinina the Minimum Reanired Weld Overlav Thickness The minimum weld overlay thickne ss ne ce s sary to achieve full structural reinforcement of the cracked section is that thickness'which provides the appropriate f actor of safety against net section collapse of the uncracked metal. For a fully circumferential crack, the depth at which not section stress, the overall collapse, occurs is a fantion of the pipe material flow wall thickne ss including the weld overlay, and the primary membrane and bending stresses applied. The primary membrane stress is produced by pressure, and the primary bending stress is the sum of the dead weight and seismic bending stresses. Paragraph IWB-3640 of Appendix 1 to Section II, Reference 1, contains tables of the allowable circumferential flaw depth to pipe thickness ratios (a/t) for various applied primary stress ratios: (P, + P b) / S,. The Isolation Condenser System piping welds are subjected to primary loads where the (P, + P b) / Sm (assuming ratios are less than 0.6 af ter the weld overlay thickness adjustment The tables a design stress intensity S, of 17.5 ksi for 316 stainless steel)., Instead, the of Reference 1 do not apply for these low stress ratios. allowable flaw depth to thickness ratio must be calculated from the actual applied loads. 3 m}}