ML20097E687

Feedwater Sparger Circumferential Cracking Evaluation for Brunswick Units 1 & 2

ML20097E687
Person / Time
Site:	Brunswick
Issue date:	11/30/1991
From:	Caine T, Mehta H, Ranganath S GENERAL ELECTRIC CO.
To:
Shared Package
ML20097E661	List: ML20097E659 ML20097E687
References
GE-NE-523-112-1, GE-NE-523-112-1191, NUDOCS 9206120304
Download: ML20097E687 (25)

Text

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. 4 ENLLOSURE 2 DRUNSWICK STEAM ELECTRIC PLANT, UNIT 2 NRC DOCKET NO. 50-324 OPERATING LICENSE NO. DPR 62 NUREG-0619 FEEDWATER NOZZLE AND SPARGER EXAMINATION RESULTS FEEDWATER SPARGER CIRCUMFERENTIAL CRACKING EVALUATION FOR BRUNSWICK UNITS 1 AND 2 General Electric Report GE NE 5231121101 November S!"a o

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A P

I GE lie 523 112 1191 DRr 137 0010

!!ovember 1991 FEEDWATER SPARGER CIRCuliFERENTIAL CRACKI!4G EVALUATION FOR BRUNSWICK UNITS 1 AND 2 n

Prepared by: ,l . b4.b4' .-

TA Caine, Senior Engineer Materials Monitoring &

Structural Analysis Services Verified by: Gw%

HS Mehta, Principal Engineer Materials Monitoring &

Structural Analysis Services Reviewed by:

S Ranganath/ Manager Materials Monitoring &

Structural Analysis Services (h)

GE ilUCLEAR ENERGY

4 9

IMPORTANT NOTICE RECARDING CONTENTS OF THIS REPORT Please Read Carefully The only undertakin6 of the General' Electric Company (CE) respecting-information in this document are contained in the purchase order between Carolina Power & Light and CE, _ and nothing contained in this document -shall be construed as chan61 ng the purchase order. The use-of this information by or for any purpose other than that anyone other than Carolina Power & Light _,_

for which it is intended under such purchase order is not authorized; and with respect to any unauthorized use, CE makes no- representation or warranty, and

-"sumes no liability as to the completeness. - accuracy, or usefulness of the

b. th- contained in this document, or that its use ' may not- inf ringe ct y "j va.od rights.

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TABLE OF_C0!1 TENTS EALE 1.0 EXECUTIVE

SUMMARY

11 2.0 BACKCROUllD 21 3.0 FEED'.'ATER SPARGER AllALYSIS 3*1 3.1 Critical Flaw Site 31 3.2 Crack Crowth Analysis 32 3.3 Allowable Flaw Size 33 3,4 Loose-Parts Considerations 34 ,,s '

-- 4 1 4.0 FEEDVATER 110ZZLE CRACKING IMPACT 4.1 Methods 4 1-4.2 Assumptions 42 4.3 .Results 4 3-

5.0 CONCLUSION

S 541 5.1 Unit 2 Inspections Rasults 51 5.2 Operation, Justified 51

/6el' 6.0- REFERENCES-APPENDICES FEEDWATERLN0ZZLE BLEND RADIUS AND SPARGER: INSPECTION ' A 1 --

A  ; .

4-j

1.0 EXECUTIVE SUmiARY Carolina Power 6 Light (CP&L) requested that analysis be done to address circumferential cracking along welds at the feedwater sparger arm t o tee connections, to identify allowable conditions for operation one additional cycle. The analysis involved determination of the inaximuto allowable flaw size, consideration of loose parts issues and estiination of maximuto notelo cracking for a hypothetical sparger crack leak directly onto the nozzle.

A preliminary analysis was perfortned prior to sparger inspection (1).

The The sparger inspections for Unit 2 were subsequently performed [2].

results of the evaluation and inspections are summarized below:

e The critical flaw size for the circumferential tee weld cracking is .

14.1 inches on the outside surface.

e The crack growth in one cycle could 'be as large as 3.16 inches, due to ICSCC, so the allowable flaw size for the inspection is 10.9 inches.

• Complete separation of the sparger erm at the tee weld would not overstress the vessel bracket connection, and such a separation would be detected by the operator, so there is no loose parts concern for this particular cracking in the spargers, e = Analysis of the hypothetical case of sparger leakage on the nozzle blend radius indicates that a crack would grow no deeper than 0.85 inches due to the leakage therinal cycling. Including systern fatigue crack growth for one cycle of 0.05 inches, a crack no deeper then 0.9. inches could be developed in one cycle of. operation.

The Unit 2 inspection showed.the longest circumferential-crack to be about 2 inches long.- Comparison of inspection results from this outage and the previous outage f or one of the cracks-indicates.that no significant crack growth occurred during the last cycle.

1-1

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2.0 BACKCROUND The feedwater (lN) spargers in Units 1 and 2 at the Brunswick plants have the originally designed flow holes in the side of the sparger arrn pipes, which have demonstrated rapid therttal cycle cracking after a few cycles of operation. As a result, and in compliance with NVREG.0619, CP6L has regularly performed penetrant test (PT) inspections of the flow holes, and has found and monitored flow hole cracking. In the process of performing FT inspections during the last outage, indications were also found along the circumferential velds which connect the sparger artes to the toe. While these indications wern not measured for length, some pictures show circumferential indications at least 2 inches long on the visible side of the sparger (sco Figure 2 1).

Therefore. CF6L requested an evaluation of the structural integrity of the spargers for the next cycle of operation. The evaluation specifically addresses the circumferential cracking along the welds between the sparger arms and tee, and applies to both Units.

The evaluation consists of several asrects, as described below:

+ The critical flaw size for failure of the sparger is determined.

+ Maximum expected crack growth is predicted, based on consideration of intergranular stress corrosion cracking (IGSCC) and fatigur.

+ The likeliho.od of cortplete failure of a sparger tee veld resulting in loose parts is addressed.

+ For the worst case scenario where feedwater leaks through the circumferential crack directly onto the blend radius of the feedwater notzle. the maximum possible nor:le crack depth ir predicted.

Inspection results for Unit 2 are presented and conclusions :oncerning continued operation are made.

21

BRUNSWICK STEAM ELECTRIC PLANT

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4.0 TEEDWATER !10ZZl.E CRACK 1!!C IMPACT in the unlikely event that the sparger veld cracks opened so that feedvater was flowing directly onto the blend, radius of a TV nozzle, rapid cycling could cause crack initiation and crack growth. The nature of the damage to the nozzle is similar to two documented cracking phenoanna: TV thermal sleeve Icakage rapid cycling and flow hole rapid cycling.

Extensive testing and analysis of the thermal sloove leakage rapid cycling was conducted in the process of designing the triple thermal siceve.

Annus the analyses done was an evaluation of the expected crack growth in the-blend radius due to rapid-cycling-[4). The results showed that AK values associated with the rapid thermal. cycling drop as a crack. proceeds into the '

nozzle until the crack arrest AR threshold of 3 ksi /in (for high R ratios)_is.

reached. The depth of the arrested crack is a function of the frequency of the cycling. as shown in Figure 4 1.

Similar analysis was done for the flow hole cycling pnenomenon (5).

Again, the aK values drop as a function of distance from the flow hole , until the crack arrest aK threshold is reached. In this case, with low R ratio, the threshold is 5 ksi /in.

The frequencies and magnitudes of thermal cycles for the case of sparger leakage onto the nozzle are unknown, so any fatigue crack growth calculacion would be based on arbitrary assumptions. Instead, the maximum ixpected crack depth is determined based on the same AK attenuation and AK threshold approach used for the thermal sleeve leakage and flow hole cases. .

4.1 METHODS The method used to estimate the crack arrest depth follows = the methods used for the blend radius in (4), benchmarked by.the actual cracking sewn in the r sparger flow holes. The - flow hole cracks have .been found - to be as large-as'O.5 inches, so the benchmark of the ' AK vs,- depth calculation is that the curve.should pass through 5 ksi./in at 0.5 inch depth.

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e as shown in rigure 4 2.

The feedwater notele blend radius was modeled, The model was subjected to cycles of for finite element analysis by ANSYS.

130'T step changes between 550*F and 420*F at varying frequencies, and thermal and stress computations were performed. The ANSYS results were used with the AK relationship from (4):

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RI - 1.12 /na (Ao 4 Al *2a/w + A2*a2 where Ag through A3 are coefficients to the cubic polynomial curve fit of stress versus depth in the nozzle blend radius, obtained from ANSYS.

(,2 ASSUMPTIONS of conservatively The following assumptions were made for the purposes simplifyin6 the problem of leakage flow from-the sparger onto the-blend radius:

e Leakage flow from the cracked sparger would have similar thermal cycling characteristics to those of the sparger flow through the flow holes.

Radial thermal cycling cracks currently shown at the flow holes with a the maximum crachi.1g due to steady state length or 0.5 inches represent flow fluctuations. Further growth of these cracks is due to transient This is conservative, as events such as feedwater flow initiation.

these cracks have-already seen over ten years of transient events.

. Magnitudes of temperature fluctuations at the flow holes are greater

.than fluctuations expected from leakage onto the blend radius.

42

4.3 RESULTS Stress range and A)' profiles were developed for frequencies of 1/8 1/4 and 1/3 }{z. The 1/4 its case was found to como closest to meetita6 the The stress range profile is benchmark condition of 5 kai /in at 0.5 inches.

shown in Figure 4 3. The stress range profilo vac fit with a cubic-polynomial, and then the coef ficients were adjusted slightly until the benchmark conditions were met. The resulting AK vs. depth plot is shown in rigure 4 4. The curve extends to the high mean stress threshold of 3 ksi /in at a depth of 0.85 inches. Therefore, rapid cycling behavior which causes a crack of 0.5 inches at the flow holes is predicted to cause a crack of 0.85 inches in the blend radius.

In addition to the possible crack _ growth due to rapid cycling, system cycling crack growth could occur. In the most recent IMREG 0619 analysis for Unit 2 (6), which has the greater crack growth rate, the system cycling crack growth for 18 months of operation with a crack 0.85_ inches deep is 0.05 inches. Therefore, the maximum: expected crack depth .for sparger leakage onto the nozzle is 0.9 inches. While this is significant, it is less than the flav depth allowed in IMREG 0619 of 1.0 inch.

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5.0 CONCLUSION

S The results of this report are intended to provide justification for operation for one additional cycle given circumferential cracks less than the itaximums allowed in this report. The inspections were done for Unit 2 in October, as discussed below. Conclusions can be drawn for Unit 2, based on those inspection results. If the inspection results for Unit 1 are similar to those for Unit 2. the same conclusions apply.

5.1 UNIT 2 INSPECTION RESULT.i The Unit 2 feeuwater no::les and spargers were inspected according to the requirements of NUREC+0619.- The documented results are included in

/

Appendix A. The blend radius of each _ feedwater nozzle was liquid penetrant (LP) tested, showing no indications.

The circumferential welds were LP tested and ultrasonically tested (UT).

The LP tests show the longest crack to be 2' inches. The_UT results show that the crack lengths inside the spar 5ers are no more than the LP indications on the outside surfaces. Comparison of a crack length measured during the-last outage and during_this outage shows that-no significant crack' growth has occurred.

5.2 OPEPATION JUSTIFIED The analysis in Section 3 provides an allowable through wall crack The length of 10.9 : inches, based on 3.16 inches of ICSCC growth in one cycle.

inspection results for Unit 2 show much shorter cracks , _about 2 inches, and little if any ICSCC growth.. Therefore, operation for the next' cycle is justified.

Once crack lengths ~ and-ICSCC - growth rates are shown to be acceptable by inspection of the: Unit 1 spargers,. operation for one additional cycle will be justified.

51

s' .

6.0 REFER E! ICES (1) Letter tio. ADK.91 079, dated October 4, 1991, AD Ketcharn of CE to EA Bishop of CP6L, 'Feedwater Sparger Cirewnferential Cracking Evaluation."

[2] Letter , dated October 20, 1991, JE Cates of CP6L to AD Ketcharn of GE,

" Unit 2 Feedwater tiozzle Blend Radius and Sparger Inspection." >

Cartwright, D.J. and Rooke, D.P., C o mts e n d i u m of Stress Intensitv (3)

Factors, Her Majesty's Stationery Office, publisher, London,1976, pages 320 322.

(4) Fife et al, " Boiling ',later Reactor Feedwater 11ozzle/Sparger Interirn Pro 6 rain Report " GE Report 11EDO 21480, July 1977.

Riccardella, P.C. and Sharma, S.R., "Feedwater Sparger Hole The rinal

[5]

Stress Analysis," GE Report RSA-76-04, March 1976.

(6) Stevens, G.L., " Brunswick Unit 2 Feedwater tiozzle Fracture Mechanics Analysis," GE Report tiEDC 30633, Revision 1, May 1991 (proprietary).

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APPENDIX A-4 7

FEEDb'ATER N0ZZLE BLEND RADIUS AND SPARCER INSPECTION t

4 4

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Catchna Power a Light Company October 20, 1991 TO: A. D. Ke. n GE Site Services Manager TROH J. E. Gates llED Responsible Engineer 11oz zle Blend Radius and Sparger GUllJECT: Unit 2 Feedwater Inspection On October _12, 1991 CPt.L inspected the Unit 2 f eedwater nozzle inner blend radius in accordance with 11ureg 0619 and al!.o performed flow an LP examination of the feedwater spargers to document The the of results hole cracking and circumferential weld cracking.

the inspection are as follows:

1. 11o relevant indications were found on the nozzle inner blend radius.

crack growth continues on the flow holes but no pieces have 2.

separated.  !!ote: The pieces aid not separate during psi the plus cleaning operation using a 20,0C0 hydrolase hydrolaser unit prior to the examination. In addition to the horizontal piece between the flow holes which has been previously addressed byThe GE,largest the sizeofofwhich other has potential also loose been pieces is as shown.

previously addressed by GE.

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Page 2 of 2

3. The eight circumferential solds connecting the sparger too to the arms and the four wolds connecting the thermal sloovo to the too woro LP examined, lio relevant indications woro found Indications Woro on the thermal sloovo attachmont wolds. Some of those found on the too to arm circumferential wolds.

ran into the wolds and some woro circumforontially oriented The longest following the heat affected zone.

circumforentially oriented indication found by LP examination was 2 inches long. Following the LP examination, fivo of the eight wolds woro UT examined for the full circumference to datormino the ID longth of tho CD indications. 11o indications Dy the woro found to extend beyond the OD indications.

direction of the cracks they all acom to have originated from the flow hole cracks and are now following the heat affected zone of the wold. They are all growing 11 o downward towards the evidence of any other lower half of the sparger arm.

cracking was found in the joint. The longest crack on the right side of the 135' too did not show significant growth '

from the last LP examination.

Plonso prepare the final report for the foodwater spargers incorporating this information into the report. A copy of the inspection documentation is attached (except for the photographs of the LP indications). If you need additional information please contact me at extension 3609.

SincQaly, Hd hMJ' V*

James E. Gates, Jr 11ED Engineering JEG/Jeg cc:

. S. L. Bertz E. A. Bishop J. W. Cridor P. S. Gore

e o ,*- ,

) BRUNSWICK STEAM ELECTRIC PLANT UNIT 2 NINET}i REFUELING OUTAGE - OCTOBER, 1991 INVESSEL VISUAL INSPECTION (IVVI)

INSPECTION REPORT AND VIDEO REVIEW NUREG. 0619 INSPECTION THIS REPORT SUMMARIZES THE INVESSEL VISUAL INSPECTION AND Tile VIDEO TAPE REVIEW THAT WAS PERFORMED DURING THE NINETH REFUELING OUTAGE AT BRUNSWICK UNIT 2. THE INSPECTIONS WERE PERFORMED BY GENERAL ELECTPIC COMPANY PERSONNEL.

THE FOLLOWING IDENTIFIES THE WORKSCOPE THAT WAS PERFORMED AND 'tHE VIDEO TAPE REVIEW:

1. FEEDWATER SPARGER THE FEEDWATER SPARGERS WERE VISUALLY INSPECTED FLOW HOLES (VT-3) PRIOR TO THE LIQUID PENETRANT EXAMINATION FOR GROSS CRACKING. THE VISUAL EXAM RESULTED ag IN NO ADDITIONAL HOLES TO LP EXAMINE. A TOTAL J OF SS OF 144 HOLES WERE INSPECTED BY THE LIQUID PENETRANT METHOD. THE FLOW HOLE 4 HAVE LINEAR INDICATIONS WITl! GROWTH CONTINUOUS. SEE PHOTOS FOLLOWING THIS REPORT.

5 2. FEEDWATER NOZZLE AN LP EXAMINATION WAS ALSO PERFORMED ON THE INNER RADIUS NOZZLE INNER RADIUS'S @ 45,135,225, AND 315 DEGREES RESULTING IN NO RECORDABLE INDICATIONS.

3. FEEDWATER SPARGER THE 12 FEEDWATER TEE BOX CIRCUMFERENTIAL WELDS TEE BOX, WELDS WERE FIRST- LP EXAMINED TO DETERMINE CRACKING EXTENDING FROM THE FLOW HOLES AND TO DETERMINE j THE OD LENGTHS. AFTER A REVIEW OF THE VIDEO,

. FIVE OF THE EIGHT TEE TO SPARGER ARM CIRC WELDS WERE DETERMINED TO HAVE LINEAR CRACKING. THOSE FIVE CIRC WELDS WERE THEN ULTRASONICALLY INSPECTED TO DETERMINE ID LENGTHS. DUE TO THE ,

CONFIGURATION OF THE FLOW HOLES IN RELATION TO 9

THE CRACKING, ONLY TWO OF THE CIRC WELD CRACKS COULD BE ULTRASONICALLY " SIZED" ON THE ID.

SEE THE FOLLOWING UT DATA.

4 1

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