ML20098E119
| ML20098E119 | |
| Person / Time | |
|---|---|
| Site: | Oyster Creek |
| Issue date: | 09/17/1984 |
| From: | Abramovici J, Covill D GENERAL PUBLIC UTILITIES CORP. |
| To: | |
| Shared Package | |
| ML20098E114 | List: |
| References | |
| TDR-580, TDR-580-R01, TDR-580-R1, NUDOCS 8409280191 | |
| Download: ML20098E119 (110) | |
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TOR NO. 380 REVISION NO. 1 Bur'GeT TECHNICAL DATA REPORT 323357 1 ACTIVITY NO. PAGE OF 110 ;
IICOJECT:
oyster Creek CE?ARTMENT/SECTION E&D Nuclear Geneta hng S tation --
RELEASE DATE O'C-N REVISION DATE 9-) I-b
'OOCUMENT TITLE) Isolation Condenser System Piping Cre: ked k' elds - Rc; air and Failure Analys's ORIGINATOR SIGNATURE DATE APPROVAL (S) CGNATURE II . .1 m DATE J.D.AbrameviciI[A/hMtr k [-]/N B.D. Elam M fdmm #/3 A~
n.'. Cavi11 1 W R.T. Deny .nf '
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[ APPROVAL FOR EXTERN 4L DISTylBUTIONDATE D.K. Croneberge'[ M e 84-dd Doos this TDR include recommendatients)?%Ye.- C No if yes.TFWR/TR # A~ b[f 4 IN7 o DISTRIBUTION ABSTAACT:
S ta temen t of Pruolem t' . Laggart Twenty-se'ren welds containing crack-like indica tions D. *dolland were discovered in the Isolation Condenser system J. Chardos piping outside containment. De te rmine the cause of J. Sullivan the indications and repair the welds in a manner which
, D. Crace will .pe rsi t the systes to be returned to service.
j R. Gaten l 7. Giacobbe Stnsary of Key Results G. VonNieda 1. Ihree welds were removed and destructively eval-C. Capcdanno uated. The failure mechanis:s was concluded to be '
G. Taylor indicative of intergranular stress corrosion cracking.
J. N>rn ovici (IGSCC).
C . Covill f 5
- E 13': 2. Nine of the af fected welds were replaced; the R. D&tuth remaining eighteen were repaired with weld D. Croneberger overlay.
Conclusions
! 1. The Isolation Condenser system may be returned to l service. The repair methods used will not adverse-ly af fect the system's operability and will not reduce safety margins.
I Ac tions To 3e Taken
- 1. Ivtiuata f.1 1 use of the sys:= pipi . v-repcired ice scry :a.in one fuel cycle, f 2. Pa rfon a :. nom 2l nuee t :qs di ri ng the next sche:iu ted au tage, of stainicss steel piping welds ,
i l l in synems surcap ti ble to ICSCC.
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l 8409280191 840921 1 PDR ADOCK 05000219 i g PDR ll
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. Page la of'110 DOCUMENT NO.
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TDR 580 TITLE Isolat. ion condenser system cracked welds-repair and failure analysis REV
SUMMARY
OF CHANGE APPROVAL DATE 1 1. The tense was changed from present and future M past on the following pages:
1-3 places 15-2 places 5-2 places 17-1 place 11-4 places 14-4 places 18-1 place 19-2 places 88d.t B.D. Elam 9/q/r'/
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R. . DeMuth k 8f
- 2. Page 10, Para. 2. 3. 3 and pacie 22 , para .
3.3.2-Revised to include current 9 ll 84 information provided by Brookhaven. .K. Crone rger Also, identified that BNL report will be sent directly to NRC.
- 3. Page 15, para. 2.4.3.3-Revised last -. .,
sentence to reflect actual sequence of inspections. -
- 4. Page 19, para. 2.5.2.3-Added results of evaluation ot actual weld overlay shrinkage effects.
- 5. Pages84-110, Appendix B-Final GE report on weld overlay de.3ign.
- 6. Page 91, Appendix B-Added " J 2 places. Editorial correction.
I
- 7. Page 92, Appendix B-Added 3.6 to provide information requested by NRC.
l 8. Page 93, Appendix B-Added results of evaluation-of actual weld overlay -
shrinkage.
- 9. Page 10.7, Appendix B-Added Table 7 summarizing information requested by NRC.
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1 TDR 580
. Rev. 1 )
Page 2 i
TABLE OF CONTENTS Page
1.0 INTRODUCTION
3 2.0 METHODS 2.1:' Introduction 7 2.2 Inspections 7 2.3 Metallurgical Evaluations 8 2.4 Repairs 10 2.5 Overall System Evaluation 15 3.0 RESULTS 3.1 Introduction 20 3.2 Inspections 20 3.3 Metallurgical Evaluations 21 3.4 Repairs 22 3.5 Overall Syst em Evaluation 23
4.0 CONCLUSION
S 23 5.0 ACTIONS TO BE TAKEN 24
6.0 REFERENCES
26 7.0 TABLES 28 8.0 FIGURES 31 9.0 APPENDICES 37 TOTAL EFFECTIVE PAGES 110
. TDR 580 Rev. 1
. Page 3
1.0 INTRODUCTION
1.1 This report describes GPUN's actions taken to return the Isolation Condenser system to service after the discovery of a leak in the Return Line piping outside containment.
1.2 Background
During a hydrost -ic test of the "A" Condenser, water was seen
. dripping from the Return Line. The insulation was removed from the 4
pipe in the area of the leak. The origin of the leak was from the pipe near weld NE-2-12. This pipe is 8-inch disseter, Schedule
- 80. All the piping in the Isolation Condenser system is made from Type 316 austenitic 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-sion cracking (IGSCC) and have been qualified to IE Bulletin 82-03.
Fif teen welds in the Isolation Condenser system inside containment and ten welds in the Reactor Water Cleanup system outside contain-ment were ultrasonically inspected.
, TDR 580 Rev. 1 Page 4 1.4 Inspection Results There were 27 welds containing crack-like indications in the .
heat-nffected zones in the Isolation Condenser system outside con-tainment. 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 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 removed from the Supply (NE-1-15, NE-1-61) and Return Lines (NE-2-12) and
TDR 580 Rev. 1 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 were repaired using the weld overlay method, and the remaining nine welds were removed and replaced with new piping material.
1.7 overall System Evaluation ,
The performance 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. 1 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 performance in a safe ma.ner for at least one additional fuel cycle.
4 1.9 Actions to be Taken.
a) Evaluate the adequacy of the repaired piping for service beyond one fuel cycle.
b) Perform augmented inspections, during the next scheduled outage, of stainless steel piping welds in systems susceptible to IGSCC.
I c) Plant operating procedures will be reviewed and revised as
, necessary to. preclude the potential for water hammer in the l steam lines and to minimize the theresi cycle loading on Iso-lation Condenser system.
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TDR 580 Rev. 1 Page 7 2.0 MTHODS 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 Inspections 2.2.1 Samplina 2.2.1.1 Isolation Condenser System Af ter the leak was detected, ultrasonic inspections were performed on 1001 (124) of the butt welds outside containment and 32% (15 of
- 47) of the butt welds'inside containment. The number of welds inspected inside containment is consistent with the sampling re-quirements of the ASE 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; a
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TDR 580 Rev. 1 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 austenitic stainless steel and qualified to IE Bulletin 82-03.
Radiography 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 removed three spool pieces containing crack-like indications from Isolation Condenser system piping for shipment to laboratories for metallurgical 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 from the "A"
s; TDR 500 Rev. 1 Page 9 Supply Line. The last piece contained weld NE-1-61 from the "B" Supply Line. The locations of these samples in the system 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-2-15, and the bottom half of NE-2-12.
Brookhaven National Laboratory (BNL), the NRC's contractor, evalu-ated' NE-1-61 and the "p half of NE-2-12.
2.3.2 GE Evaluation Samples from NE-1-15 and NE-2-12 were examined usinE Scanning Electron Microscopy (SEM) and metallography.
NE-2-13 was liquid penetrant inspected on the inside surface.
Chemical analysis was performed on one sample, each, removed fros l wrought asterial adjacent to NE-1-15 and NE-2-12.
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TDR 580 Rey, 1 Page 10 Details of the GE uvaluation can be found in Appendix A.
2.3.3 BNL Evaluation 4 BNL is performing fractographic and metallographic evaluations of 1
samples from NE-1-61, the top half of NE-2-12, and the bottom half of NE-2-12 (the leaker, forwarded from GE). Sensitization tests of the base material per ASTM A262 and EDS scans of the fracture faces i for contaminants are also being performed.
A formal report detailing BNL's evaluation methods will be released directly to the NRC.
2.4 Repairs 2.4.1 Introduction Based on the metallurgical evaluation and the nondestructive test-ing performed on the Isolation Condenser system piping, it was decided to repair all the wells containing crack-like indications with the intent of returning the system to service for at least one fuel cycle without sacrificing safety. The entire piping system outside the drywell will be evaluated before and during next refueling outage to determine the adequacy of the repair beyond one cycle.
TDR 580
- Rev. 1 Page 11 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 were repaired by either replacement or weld overlay. Based on the l samples removed and weld locations,18 welds were repaired using l the weld overlay process and the remaining 9 welds were physically l removed and re placed by new piping or fittings, as necessary.
Of the eighteen welds that were 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 normally 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 ASTM 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 standa rds (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 defined low heat input l welding which, together with the lower than previously specified t-
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.. TDR 580 Rev. 1 Page 12 carbon content, minimizes the possibility of IGSCC. Additionally, the welding procedures included the requirements of the NRC Reguia-tory Guides 1.31 and 1.44.
The original piping design code appears to be Section I of ASME per 4
B&R specification 2299-S60, whereas the replacement piping is to be in accordance with ASME Section III Subsection NC(Class 2) which is considered superior to original code.
2.4.3 Weld Overlay 2.4.3.1 Introduction The veld overlay is a repair method by which filler metal compat-ible with-the macching 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
- method and is designed in accordance with ASME Section XI paragraph IWB-3640.
The design was conducted by General Electric under contract from GPUN and the design / stress analysis is documented in Appendix B.
O Inspection of BWR Stainless Steel Piping (Generic letter 84-11) dated
- April 19, 1984
TDR 580 Rev. 1 Page 13 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 minimum required weld overlay thicknesses were obtained assuming the flaws to be fully circumferential and to extend through ths original pipe wall. The applied primary loads used in the thickness calculations were enveloped to provide further conservatism and generality in the designs. The minimum thicknesses do not include the first veld layer, which must pass liquid penetrant examination, 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 amount of welding time and material neces sary to provide the required structural reinforcement of-tha 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 evalua tion 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
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TDR 580 Rev. 1
. Page 14 assurance that the overlay design is independent of the crack size as determined by the ultrasonic testing. ICSCC propagation into
-the weld overlay asterial 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 documented in Appendix B.
4 2.4.3.3 Application The weld averlay process was 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,were applied in accordance with a procedure l qualified in accordance with ASME Code Sections IX and XI. The effective overlay thickness was deposited af ter the first overlay l layer having a ferrite number of 8FN, or higher, as determined with an instrument meeting the requirements of AWS A4.2 (Reference 4).
The overlay dimensions and shrinkage were determined with l
TDR 580 Rev. 1
, Page 15 before-and-after dimensional measurements. Liquid penetrant examination was performed on the pipe surf ace, before welding, the first layer with a ferrite number of SFN or higher, and the last layer of the overlay. Radiography was performed on the finished weld overlays to verify their integrity.
2.5 Overall System Evaluation 2.5.1 System Performance 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 amount 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 performance are not affected by this modification.
2.5.2 Stress Analysis 2.5.2.1 overall Discussion t
The original system stress analysis was performed by the architect engineer (Burns & Roe) and included the then defined seismic I
l
. l TDR 580 Rev. 1 '
Page 16 loading in addition to the normal deadweight and thermal 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 wtAn the sample spcol pieces were removed.
i Subsequently, EDS Nuclear performed another stress evaluation of the Isolar. ion Condenser system piping and found it to be adequate (Reference 5).
As a result of the indications found, the repair process, the h' bove 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),
thermal loads (70*F to 550*F), anchor displacements 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.
TDR 580 Rev. 1 Page 17 Waterhammer 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
- 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 waterhammer is minimized.
, The results of the analysis concluded that the Isolation Condenser system piping is adequate "as is" without any modifications and without need o f any cold springs and, therefore, was reinstalled without adding cold spring (for replacement piping).
2.5.2.2 Cycle Fatigue An analysis (Reference 8) was performed prior to the destructive testing of the metallurgical sample 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. Howeve r, the analysis concluded that the Isolation Condensers were used 33 times (A) and 36 times (B). The exac t number of cycles used each time the condenser was i
put into service is not known since it would require a large amount
- of time to evaluate the strip charts f rom plant initial operation l
l l
f TDR 580 Rev. 1 Page 18 ,
to present, but even if 100 cycles per use is conservatively assumed the total number of cycles is still less than the 7000 cycles identified by ANSI B31.1 as not being considered significant 4
in the stress analysis (i.e. stress ra nge reduction factor = 1.0 per ANSI B31.1 Table 102.3.2(c)). The refore, cycle f atigue is not considered a contributor to the leakage.
- 2. 5.2.3 Cold Spring As discussed a bove, 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 dqrwell; however the AE analysis did not consider it in their analysis. A re-analysis without cold spring performed by !fPR concluded that cold spring is not required, and the replacement piping was l installed without any cold spring. It appears that cold spring was not a contributor to the piping cracks. No credit was taken f or the beneficial compressive residual st resses induced by the heat sink weld overlay process that would oppose crack extension through the thickness. ,
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2.5.2.4 Shrinkage Stre se Due to Weld overlay Appilcation Application of a weld overlay produces an axial contraction of the pipe which is a function of the pipe size and the overlay thickness t
4
TDR 580 Rev. 1 Page 19 and width. This shrinxage imposes stresses on the entire piping system. The amount of shrinkage was estimated by CE based on typi-cal shrinkages observed in similar weld overlay applications per-formed by CE. The shrinkage ef fect was simulated by forcing thermal contractions at the weld overlay locations equivalent to the assumed 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 were measured and compared to the l assumed values. Variations were re-evaluated to determine the l significance o f the deviation f rom the assumed shrinkages. It was concluded that the actual shrinkage had no adverse effect on the system piping.
2.5.2.5 Weight Ef fects of tield Overlays The effects of the weld overlay weight on the stress analysis, including seismic, 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.
TDR 580
, Rev. 1 Page 20 3.0 RESULTS 3.1 Introduction This section provides the results of the various efforts described in Section 2.
- 3.2 Inspections 3.2.1 Isolation condenser System l Outside containment, ultrasonic inspection revealed that 27 (22%)
L welds contained crack-like indications. Of these, 19 were con-1 firmed by additional ultrasonic examination and/or radiography.
The remaining eight (8) were classified as " suspect", because they
~
could not be either confirmed as cracks or classified as geometric f~ reflectors.
Tables I ("A" Condenser) and II ("B" Condenser) list the defective welds and other pertinent information.
Figures 2, 3, 4, and 5 show the locations of the defective welds.
Inside containment, none of the welds inspected contained crack-like indications.
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- TDR 580 Rev. 1 Page 21 ea
.3.2.2 Other Systems None of the welds inspected in the Reactor Water Cleanup system contained crack-like indications.
3.2.3 A report of the inspection results is provided in Reference 2.
3.3. Metallurgical Evaluations 3.3.1 General Electric Fraccography of the crack surf ace of welds NE-2-12 (the leaker) and d
NE-1-15 revealed an intergranular surface on both.
Metallography of NE-2-12 and NE-1-15 revasled 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.
Y Liquid penetrant examination on the ID surface of NE-2-13, a
" suspect" weld, revealed no indication in the region of the ultra-sonic indication.
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.. TDR 580
. Rev. 1 page 22 t
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 BNL has not yet completed their evaluations. However, BNL reported that EDS scans of the fracture face of the leaker (bottom half of NE-2-12) revealed no contaminants considered to be contributory to IG3CC.
BNL's results will be provided in a formal report released directly to the NRC.
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.
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,, TDR 580
. Rev. 1 Page 23 The' nondestructive examinations performed on the existing and re-paired pipe together with the repair process assures safe plant operation.
3.5 .0verall 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 Effore The repair effort, replacement and weld overlay, is a satisfactory method to return the Isolation Condenser system to service in a safe and reliable way.
4.2 Metallurgical Evaluation 4.2.1 The cracking was circumferentially oriented intergranular stress corrosion in the weld heat-affected zone.
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.. TDR 580
+ Rev.-1 Page 24 4.2.2 No firs conclusions regarding the eight " suspect" welds could be reached.- For conservatism, we treated these welds as being cracked 4
welds and repaired each one.
4.3 Overall System Evaluation The overall Isolation Condenser system performance and availability are'not being lessened by the repair process but, in fact, are enhanced since the probability of system unavailability due to IGSCC-induced leakage has been reduced.
5.0 ACTIONS TO BE TAKEN s
- 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.
- 2) Perform augmented inspections, during the next scheduled out-t age, of stainless steel piping welds in piping systems susceptible to IGSCC.*
- A response to Generic Letter 84-11 addressing these examinations is in preparation.
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., TDR 580
. Rev. 1
. .. Page 25-
- 3) Plant personnel shall be instructed to minimize the use of emergency condensers to emergency 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 femergency condensers.
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6.0 REFERENCES
- 1) .GPUN Procedure MTIS-008 Rev. 4: " Ultrasonic Examination of Piping Welds 0.2" - 6.0" in Thickness "
- 2) GPUN Report No. 6153-ISI-84-001: "0yster Creek Isolation Condenser System Augmented Examination Program" (to be issued).
- 3) GE Process Specification P50YP225 Rev. 1: Thin Weld Overylay for Austenitic Stainless Steel Piping Welds; with ECN NH18401.
- 4) AWS A4.2-1974: " Standard Procedures for Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austentic Stainless Steel Weld Metal." '
- 5) Oyster Creek Isolation Condenser System Piping Stress Report, prepared by EDS Nuclear, November 1979. EDS Report No.
02-0370-1021 l
i
- 6) MPR 830: " Analysis of Emergency Condenser Piping Outside Containment", dated July 1984.
- 7) NUREG/CR-1981 " Seismic Review of the Oyster Creek Nuclear Power Plant as Part of the Systematic Evaluation Program",
dated April 1981
]
,, TDR 580
, Rev. 1 Page 27
- 8) MSS-84-166 "0yster Creek Emergency Condenser Leakage Investi-gation", dated April 17, 1984
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!. ,,. TDR 580-y Rev. 1-Page 28
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7.0 TABLES s t I. "A" Cond'enser Piping Welds with Crack-like Indications
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II. - "B" Condenser Piping Welds with Crack-like Indications l
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TDR 580 Rev. 1 Page 29 Table I "A" Condenser Piping Welds with Crack-like Indications Weld Supply (S) or Pipe Wald Component Repair Number Return (R) Line Diameter (In) Type (1) Type (2) Method (3)
NE-1-2(*) S 16 S P-P O NE-1-11 -S 12 F P-E O NE-1-13 S 12 S P-P O NE-1-15 S 12 S P-E R NE-1-20( * ) S 12 S P-P O NE-1-25 S 12 S P-P O NE-1-29 S 12 S P-P O NE-1-32 S 12 S P-E O NE-2-4(*) R 8 S, P-E O NE-2-8 R 8 F P-E O NE-2-12 R 8 F P-E R NE-2-13(*) R 8 S P-E R NE-2-17( *) R 8 S P-E O NE-2-28 R 8 F P-E O 4
- " Suspect" (see 3.2.1) ?
Notes:
- 1) .S = Shop, F = Field
.2) P =. Pipe, E = Elbow
- 3) 0 = Overlay, R = Replace
- w a-e TDR 580
- . Rev. 1 Page 30 Table II "B" Condenser Piping Welds with Cr&ck-like Indications Weld Supply (S) or Pipe Weld Component Repair Number Return (R) Line Dismeter (In1 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 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 2 12 F P-E O 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 NE-2-103(*) R 10 S P-P O
'O " Suspect" (see 3.2.1) l l
Nctes:
- 1) S =-Shop, F = Field
- 2) P = Pipe, E = Elbow, R = Reducer
- 3) 0 = Overlay, R = Replace
- 4) Weld type is unknown. Weld records cannot be located. Most likely, these two welds are field welds.
TDR 580 Rev. 1 Page 31 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
- , . - . , . - - . - , , -- , , , , ~ ,--~r, e, - - . ~ . . - - - - ,-.- - - - - -
TDR 580 Rev. 1 Page 32 INDICATION 200 1.65" LONG
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WELD NE-2-12A WELD NE-2-12 INDICATION 201 FIGURE 1- Defects in Weld NE-2-12 Rev. 0
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TDR 580 Rev. 1 Page 37 9.0 APPENDICES A -
GE Metallurgical Evaluation Report 3 -
GE Weld Overlay Design Report
TDR 580 Rev. _
Page 38 Appendix A GE Metallurgical Evaluation Report
Appsndix A Page 1 of 44 TDR 580
. inucuan eNunov GEN ER AL 6 ELECTRIC P.M.T. 'IRANSMITTAL Rev. 1 BUSINESS OPEnATIONS M). 178-84-015 Page 39 DRP NO.
PUNP MMERIALS 'IECHMXIXTI FAILURE ANALEIS OF O'lS'IER GEEK ISGATION CDNDEESER PIPDG DEE: _ June 25, 1984 PREPARED BY: 82 db D.E. DeIlwichd' Plant Materials Technology APPROVED BY: -
G.M. Gordon, Manager Plant Material 3 'I4chnclogy LEGAL NorICE The only undertakings of General Electric Ccrepany (GE) respecting infomation in this document are contained in the agreement between GPU Nuclear Corporation (GPUN) and GE for failure analysis (Purchase Order No.PC-013224) and nothing contained in this documnt shall be construed as changing the agreement. The use of this infomation for any purpose other than that for which it is intended, is not authorized; and with respect to any unauthorized use GE makes no representation or warranty, (express or inplied) with respect to the ccepleteness, accuracy, or usefulness of the infomation contained in this document, or that the use of such infomation may not infringe privately owned rights, nor does GE assume any responsibility for liability or damage of any kind which may result frcan the use of any of the information contained in this document.
IED008.LL l
Appandix A Paga 2 of 44
. Rev. 1 Page 40 IhTRCOUCTICN _
During a recent hydro test performed on . the Oyster Creek isolation condenser piping return line (A loop) , a leak was noticed near an isolated elbow on the condensate piping, downstream of the condenser. The insulation was removed to reveal a crack near weld NE-2-12. The weld was examined ultrasonically, which pinpointed the existence of two through-wall cracks. An 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. Two sections of piping were sent to the General Electric Turbine Technology Laboratory to determine the nature of the defects. One piece of pipe was an 8" diameter Schedule 80 elbow frcm the A loop which contained the *dirough-wall crack (weld NE-2-12). The second section of pipe was a 12" diameter Schedule 80 spool piece frcn the supply line (B loop) containing weld NE-1-15.
The attached report, " investigation of Pipe Cracks Found in Oyster Creek Piping" (Memo Peport CI-1108), describes the results of the radiographic and metallographic inspection of the two pieces of AISI 316 stainless steel pipe from Oyster Creek.
RESULTS A total of three cracks were found, all beginning at the inside pipe wall and propagating intergranularly in a heat affected zone. The material cceposition was found to be within the AISI 316 stainless steel ccuposition range, with a carbon content high enough to prcnote a sensitization zone after welding (A loop section - 0.046%C, B loop section - 0.060%C) . The defects are typical of intergranular stress corrosion cracks.
Appendix A
.. Page 3 of 44
. R 580 Rev. 1 Page 41 l
Memo Report Cl-1108 Chemistry and Electrical Insulation Subsection Turbine Technology Laboratory Schenectady, New York ,
e INVESTIGATION OF PIPE CRACES FOUND IN OY!rrER C2EEE PIPIN'.
- by -
G.C.couLD 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.
Appendix A
. Page 4 of 44
. TDR 580 Rev. 1 Memo Report CI-1108
~
Page 42 INVESTIGATION OF PIPE CRACKS FOUND IN OYSTER CREEE PIPING
- by -
G.C. GOutD 1
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 conder ser 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.
PARTI: 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 4
radiation was 70 mR/ hour at contact o t the ir.+erior 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 speciman 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 I.
- 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 showing the leak from the outside.
Chemical analysis by X ray fluorescence was done in the piece marked "1" in Figure 3, j and subsequently, enips were removed for a carbon determination from the same piece.
I 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 ultrasonle agitation in a detergent water solution.
i The part of the leaking crack adjacent the scanning electron microscope specimen was l labeled "3" and removed with both sides of the crack intact, mounted in epoxy resin, and i prepared metallographically. While being inspected, the weld bead was identified and photographed, and later, at a higher magnification, the crack was photographed. A second
Appendix A Page 5 of 44
. TDR 580:
Rev. 1 Page 43, 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.
RESUJM The results of the chemical analysis done on piece "1" of Figure 3 are shown in Table I.
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, lenker) 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 Procedure 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.
Metallography carried out on indication 201 " leaker" is shown in Figures 7 through 9. The location of this specimen is shown as "3" in Figure 3.
F!gure 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 Figura 13 and the linear indication approximately 2300 from the axial weld. Figure 14 shows n' close up of the red dye indication found in weld NE-2-13.
In service, the axial weld is at 5 o'cleck 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.
- 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.
Appendix'A Page 6 of 44
. TDR 580
- Rev. 1
~
Page 44
- 3. The cracking is most probably intergranular stress corrosion cracking of the weld heat affected zone.
PART II: 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 peints 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.
4
~
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 heavy coating of oxide necessitated the use of ultrasonic agitation for two ten minute periods in a 5 percent H2 SO4 solution containing catechol.
4 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 '
i photographed at 8X while the crack was done at 50X. The location of the 50X pictures is given on the 8X picture.
i A Magnagage was used to measure the ferrite content of the circumferential weld on the 12" diameter pipe.
RESULTS
- The results 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". ,
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 midwall location 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 l
l Appendix A Page 7 of 44 f
-TDR 580l
- Rev. 1 ,
Page 45i Figures 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. Magnagage readings gave a ferrite number between 12 and 13 for this weld.
f0NCLUSf0NS
- 1. The c.acking is wholly intergranular initiating at the inside pipe wall in the heat affected zone.
- 2. The composition of the steel falls within the spec 8fhd 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 . veld heat affected zone. ,
- 1679/CG/7
Appendix A Page 8 of 44 TDR 580
. Rev. 1 Page 46 Table I CHEMICAL ANALYSIS OF WROUGHT MATERIAL DONE ON 8" DIAMETER SCHEDULE 80 PIPE FROM OYSTER CREEK
- Weight Percent Cr Ni Mo C 17.0 11.1 2.20 0.046
>r .
- Location of the chemical analysis sample defined as "1" in Figure 3.
l E
l f
I
l p ge f 44 TDR 580
,. Rev. 1
. Page 47 Table II CHEMICAL ANALYSIS OF WROUGHT MATERIAL DONE ON 12" DIAMETER PIPE FROM ISOCONDENSER B*
Weight Percent Cr Ni Mo C 16.9 13 1 2.26 0.060 4
r
- Location of specimen defined in Figure 17 as pe.rt "4".
e e
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. Appendix A Page 10 of 44 TDR 580 Rev. 1 Page 48 Sawed this section out for analysis
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Appendir A c , Page 11 of 44 TDR 580 Rev. 1 Indication 200
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- Indication 200
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' / Turbme Technology I Laboratory A /
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i Indication 201 l Figure 2: Axial cut to divide NE-2-12 (and NE-2-12A) between Brookhaven National Laboratories and Turbine Technology Laboratory
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Appendix A Page 12 of 44 TDR 580 Rev. l Page 50 N #
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(3) Metallographic Sample Figure 3: The half of the pipe kept for analysis at Turbine Technology Laboratory. The other half to Brookhaven National Laboratory.
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Appendix A Page 13 of 44
. TDR 580 Rev. 1 Page 51
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. Appendix A Page 14 of 44 TDR 580
, i Rev. 1 Page 52
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. Appendix A Page 15 of 44 TDR 580
. Rev. 1 Page 53
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. Appendix A Page 17 of 44 TDR 580 Rev. 1 Page 55 s.
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i4 Appendix A Page 19 of 44
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Rev. 1 l Page 57 4 i i i i utside '; fall i o *I - . . . . _ ~
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App:ndix A Pag 2 21 of 44
*- ,. TDR 580 Rev. 1 Page 59 s .
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1 Appendix A Page 22 of 44 , 1 1
. TDR 580 1 1
Rev. 1 Page 60 TOP 1 l l
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Appendin A Page 23 of 44
.. TDR 580 Rev. 1 i Page 61 i
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Appendix A Page 24 of 44 TDR 580
' Rev. 1 Paqe 62
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Appendix A Page 25 of 44
TDR 580 Rev. 1 Pace 63 1
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I l 2 A I g ski l I I I NE 115l I I I I I 1 I I I 4 I A ! N Primary piece used for investigation FIGURE 16: Sketch of12 inch diameter spool piece showing iNE-1-15 and axial weld in addition to the piece removed for exam nation.
' Appendix A
. Page 26 of 44
*. TDR 580 Rev. 1 Page 64 l
l 1 1 I I I I I g l (5) 1 I I I I I Crack Weld / ... .. .. . . . . . . . . . . . . _ _ _ _ _ . [
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1 Appendix A Page 27 of 44 TDR 580 ) Rev. 1
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- Je g . :J o . 4-1480F1-3 8X Kallings
Appendix A Page 30 of 44 Rev. 1 Page 68 i ># J Q }. ' . . . .
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Neg. No. 4-1480F-4 50X Kallings
, Appendix A Page 31 of 44 TDR 580 Rev. 1 Page 69 j' '; . [$. (( *MN
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Appandix A Paga 32 of 44 ' TDR 580 Rev. 1 Page 70
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l El Appendix A Page 33 of 66 TDR 580 Rev. 1 Page 71 l p NE-212 , i I Teak t A C p NE-2-12A w i I i I A P P E N D IX I: Location of the radiographs on NE 212 in the 8 inch pipe. i f .I t 1
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l l s J 4 J 5 APPENDIXII: Location of the radiograph on NE 1 15 weld on the 12 inch pipe.
Appendix A Page 37 of 44 TDR 580 Rev. 1 Page 75
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*. Page 1 of 27 Rev. 1 - Pace 84 DEF #137-0010 MAR 84-17 Rev. 3 MAWO3. DA TELD OVERLAY DESIGNS AND SERINEAGE STRESS EVALUATION FOR THE INDICATIONS IN THE OYSTER CREEK ISOLATION CONDENSER SYSTEM PIPING August 1984 Prepared By: YM M. A. White. Engine er Mechanics Analysis l
l l Reviewed By: ! H. S. Mehta. Principal Engineer Mechanics Analysis l l Approved By: ~~ (T l S. Ranganatt, Manager Mechanies Analysis i
-m--.- - . _ _ . .,__ _, - _ . - -- - . - . _ , . , , , . _ , - . . . . . . . . . - - _ . . . - . - . . . _ , - - _ _ -
l Appendix B TDR 580
. Page e of 27 Rev. 1 . . Pace 85 CONTENTS .
f!811
- 1. INIRODUCTION 1 1
- 2. SUlGIARY AND RESULTS 2 j
- 3. WilLD OVERLAY DESIGNS 3 3.1 Methodology for Determining the Mininnue Required Weld 3 Overlay Thicknesses 3.2 Applied Stresses at the Weld Overlay Locations 5 3.3 Weld Overlay Thickne ss Results 5 l 3.4 Weld Overlay Widths 6 3.5 Weld Overlay Designs 6 3.6 Safety Factors Evaluation 7 4.- WELD OVERLAY SERINEAGE STRESS ANALYSIS 8
- 5. REFERENCES 9 TABLES AND ILLUSTRATIONS 10
,1 4
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. Appendix B 580 Pace 3 of 27 Rev. 1 Page 86 l
- 1. INTRODUCTION General Public Utilities (GPU) Nuclear performed an nitrasonic 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 too 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 line s, totaling twenty-seven. All of the indications were cirensferential in orientation.
l GPU Nuclear has decided to weld overlay repair eighteen of thess welds and replace the remaining nine welds. The four pipe lines and the overlsy locations are shown in Figures 1 through 4. Table 1 sammaritas all of the welds and the respective pipe line s and pipe diameters. All but too of the indications were found in the 12-inch supply 11aes and the 8-inch return line 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 l structural margin intended by ITB-3640, Section II [1], is maintained. This report provides recommendations 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 examined in terms of the additional stresses imposed on the piping system. i 1
. Appendix B TDR 580 ;
Page 4 of 27 Rev. 1 l Page 87 l
~
- 2. SUl01ARY AND RESULTS
- The weld overlay designs for repair of the Isolation Condenser System piping were determined Sased on maintaining the ASlE Code required factor of safety against r;n section yielding of the overlaid welds. The miniana required esclay thicknesses were obtained assuming the flaws to be in11y circumferential and to extend through the original pipe wall. The applied !
I primary loads used in the thicka6as calculations were enveloped to provide further conservatism and generality in the designs. The minimum thicknesses reconnended here do not include the first weld layer. The overlay widths were sized to optimize the smount of welding time and material necessary to provide , the required structural reinforcement of the fiswed weld regions. The stresses imposed on the Loop B supply and return line# from axial shrinkage of the overlays were calculated 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 srpested to be of the same low an gnitsde. , t 2
Appendix B TDR 580 Pace 5 of 27 Rev. 1 Page 88
- 3. WELD OVERLAY DESIGN ANALYSIS The criterion used in design of the weld overlays for the Isolation Condenser System pining is to provide full structural reinforcement of the cracked segion maintaining the ASME Code safety margins. In evaluation cf the everlay designs, it is conseevatively assumed that the flaws are fully circumferential and will extend th ush the susceptible material of the original pipe wall.
With this assumptic no credit is taken for the beneficini compressive residual stresses induced by the heat sink weld overlay process that would oppose crack extension through the thichaess. The postulated through-wall . cracks also provide assurance that the overlay design is independent of the crack size as determined by the nitrasonic testing. IGSCC crack growth into the weld overlay material beyond the first layer is not expected since the weld material away from the fusion line is noc susceptible. 3.1 Nothodolory for Determinina the Miniana Reantred Weld Overlav Thickness The minimum weld overlay thickness necessary to achieve in11 structural reinforcement of the cracked section is that thickness which provides the appropriate fr.etor of safety against not section collapse of the uncracked metal. For a in11y circumferential crack, the depth at which not section collapse, occurs is a fantion of the pipe material flow stress, the overall wall thickness 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 sua of the dead weight and seismic bending stresses. Paragraph ITB-3640 of Appendiz I to Section II, Reference ., contains tables of the allowable circumferential flaw depth to pipe thickness ratios (a/t) for various applied primary stress ratios: (P,+ Pb )/8m. The Isolation Condenser System piping welds are subjected to primary loads where the (P. + Pb)/S m i ratios are less than 0.6 after the weld overisy thickness adjustment (assuming a design stress intensity q, of 17.5 kei for 316 stainless steel). The tables i of Reference 1 do not apply for these low stress ratios. Instead, the l allowable flew depth to thickness ratio aust be es1culated from the actual applied loads. I i l
Appendix B TDR 580 Page 6 of 27 Rev. 1
** Page 89 Assuming that the indications are fully circumferential, the method described in Reference 2 can be used. De re, a relationship between the applied loads, the flow stress, and the critical crack depth to thickness ratio is defined by Equations (1) and (2).
P S n (1 t J) a
- p= (1) 2I .
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=
(2-f) sin p (2)
- l
. whe re og = material flow stress, I P, = primary membrane strest, Pb = primary bending stress, a = crack depth, t = total thickness (pipe wall + veld overlay thickness), and 5 = angle that defines location of neutral axis. 4 nose equations cannot be solved directly for the allowable fisw 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. He allowable Pb corresponding to the new thickness and the adjusted primary membrane stress is esiculated from P +P Equations (1) and (2). no allowable ( 'g ) i Factor of Safety is then a P, + Ph . compared to the actual adjusted g . If the allowable is leu 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 veld overlay thickne ss. De iteration is performed until the minimum required weld overlay thieksess is detonnised. A factor of safety of 3.0 is used in accordance with the ASam Code, Section II, Paragraph ITB-3640 4
Appendix B TDR 580
- Page 7 of 27 Rev. 1 Page 90 3.2 Ann 11ed Stresses at the Weld Overlav Locations ,
The deadweight and seismic stresses at the weld overlay locations were obtained from the Oyster Creek Isolation Condenser System piping stress report, 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 perfonsed in two orthogonal horizontal directions. l l A review of the deadweight and seismic stresses listed in Table 2 reveals considerable variation in each at the different weld locations. To obtain conservatism and generality in the weld overlay designs for the four dif ferent pipe sizes, the deadweight and seismic stresses were each enveloped based on the maximum stresses shown in Table 2. Thus, the enveloping deseveight stress is 3.3 kai and the enveloping seismic stress is 5.1 kei. The pressure used in i calculating the primary membrane stress was 1090 psi. This is the technical specification limit for the opening of electro-mechanical relief valves. l In the IWB-3640 Tables [1], the implied facters of safety for normal / upset conditiens are twice that f or the emergency /fanited conditions (i.e., 2.8 versus 1.4). Therefore, the emergency /fanited condition primary loads are , controlling only when 'they are more than twice the corresponding normal / upset condition loads. Since this was not the ca:se for the subject isolation condenser line, the normal /apset condition loads stated in this subsection were used in the overlay design. 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 og was taken a s 3 S,. The results are provided in Tables 3 through 6. The thicknesses generated by this celestation are the minimum necessary for the overlay to maintain the required 3.0 factor of safety. They do not accosat for the varioso geametries speelfic to each weld, but serve only as the basis for the recommended design. thiekne s sess - - ' S
Appendix B TDR E30 Page 8 of 27 Rev. 1 Page 91 3.4 Weld Overlaw Widths Unlike the thickness requirements for weld overlay designs, which are based on satisf-ing the saf ety margins of the ASME Code, there are no guidelines for determination of the weld overlay widths. General Electric has performed finite element studies which compared the stresses obtained in pipes with different veld overlay widths. Results showed that there is no significant difference between the stresses obtained for widths in excess of one attenuation length, (R$ and it was concluded that the additional material of the wider overlay contributes little to the overall' structural reinforcement of the weld. Therefore, einimum weld overlay widths of i[Rt are used here as the basis for the recommended overlay designs. This reduction in width 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 Overlaw Desians The minimum weld overlay thicknesses and widths provided in Tables 3 through 6 [ were used as the basis for the individual weld overlay geometries. The l specific overlay designs were also 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 , effects. l l A further consideration was weld setsi-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 veld layer was specified in accordance with Reference 4. Of the eighteen welds to be overlayed, six are pipe-to-pipe and twelve are pipe-ter-elbow butt welds, A schematie of the overlay design geometries for the pipe-to-pipe welds and a summary of the overley dimensions for each 6
. Appendix B Page 9 of 27 TDR 580
Rev. 1 1
- Page 92 l specific weld are pro' vide,d in Figure 5. Simil ar1r, for the pipe-to-elbow welds, Figure 6 summarizes the wold specific overlay design dimensions.
3.6 Safety Factors Evaluation To demonstrate the conservatism built into the overlay design thickness calesistions and to perform supplementary evaluations using thermal, expansion stresses, a safety factor calculation for each weld overlay was performed and I the results are shown in Table 7. The dead weight and seismic (OBE) stresses in Table 7 are the same as those in Table 2. The applied (P, + P b) stres se s shown in the next column are the sum of the pressure, dead weight, and seismic stresses. The next column shows the calculated limit (P, + Pb ) of the overlays using Equations 1 and 2. This calculation was based on the recommended design thicknesses of overlays given in Figures 5 and 6. The safety factors, i. e. , limit (P, + P b) over applied (P, + P b), were then calen1sted. It is seen that the f actors of safety are in excess of 4.1. In order to assess the impact of inclusion of thermal expansion stresses on the safety factors, a supplementary evaluation was perf ormed and the resnits i are shown in the last two columns of Table 7. The operating condition thermal expansion stresses at each weld are shown first. Note that these stress ma gnitude s, as are the others, do not include the stress intensification factors. This is consistent with the use of not section collapse theory in the overlay design. From an examination of the last column in Table 7, it is seen that even with the inclusion of thermal expansion stresses the safety i I factors are no less than 3.4. It is emphasized that this is only a supplemental calculation and does not imply that the thermal expansion stresses need be included in the overlay design. Moreover, available data on the TIG weldments of the type used in the weld overlays indicate that their I toughness approaches that of wrought austenitic material for which the l secondary stresses are of no concern. l l t ( 7
, Appendix B TDR 580 l Page 10 of 27 Rev. 1
" l Page 93
' l
- 4. VI!LD OVERLAY SERINEAGE SIRESS 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 amonat of shrinkage was estimated for the purpose of this analysis based on typical ! shrinkages observed in similar weld overlay applications. The 8- and 10-inch pipe overlays were assaned to shrink 1/4 inch, and the 17- and 16-inch pipe overlays were assumed to shrink 3/8 inch. A finite elesmat analysis of the Loop B supply and return piping was performed to determine the magnitudes of the stresses due to these assumed shrinkages. This analysis was performed 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 overisy locations equivalent to the assumed 1/4- and 3/8-inch overlay shrinkages. A summary of the maximan shrinkage stresses obtained in the Loop B supply and return lines is provided in Table 8. The shrinkage stresses obtained in Loop 4 are low due to the ovmli flexibility of the piping system: the piping is acpported main 1r thwagh
- hangers and snubbers. The Loop A supply and return lanes are very similar in configuration and support to Loop B and thus the stresses due to overlay i shrinkage in these lines would be of the same low magnitude as calculated for the Loop B lines.
The actual shrinkage data from the fis1d were unavailable at the time the shrinkage stress analysis was conducted. A review of the actual shrinkage data indicates that the maximum axial shrinkages are as follows: 8-inch pipe overisys, 0.465 inch; 10-inch pipe overlays, 0.33 inch; 12-inch pipe overlays, 0.36 inch; and 16-inch pipe overlays, 0.234 inch. Taking the worst deviation cese frce the aesu ed valuee, the 8-inch pipe averlay shrinkase is 1.86 tinea the value assumed in the stress analysis. The maximum shrinkage stress shown in Table 8 is 1487 psi. By conservatively multiplying this stress by 1.8, a maximan shrinkage stress of 2765pa'is obtained. This stress is well within the allowable value, which is equal to the material yield stress. Thus, the calculated weld overlay shrinkage stresses in the isolation condenser line are acceptable. , , 8 t
- Appendix B TDR 580 Page 11 of 27 Rev. 1 Page 94
~
$. REFERENCES
- 1. AE_ME Boiler and Pressure Vessel Code. Section II. 1980 Edition. Winter 1983 Addenda.
- 2. Ranganath, 5. and Nehta H. S. , ' Engineering Methods for the Assessment of Ductile Fracture Nargin in Nuclear Power Plant Piping,' Elastic-Plastic Fracture: Second Synoosium. Volume II-Fracture Resistance Carves and Enmineerina Anelications. ASTN STI'803. 1983, pp. 309-330.
- 3. Oester Creek Isolation Condenser System Pinian Stress Resort. 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 for Reinspection of BWR Piping and Repair of Cracked Piping,'
November 7,1983 SECY-83-267C.
- 5. PISYS05. GE Pinina System Analysis Comenter Promram. NEDE-24077 January 1981.
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o h 02 l N i - - < l FLOOR 1 NE-2-98 l i j d'4 i l REDUCER 1 a O :n a 1 l Oyster Creek isolation Condenser. Piping Loop B Return Line $.0 E u, l Figure 4 gg ] 1
Appendix B Page 16 of 27 TDR 580 Ren 1 0 Pace 99 TABLE 1 -- Walde at which Indications were Identified in the Oyster Creek Isolation Condenser System Piping Nominal Veld ID Pinina Line Pine Size (inches) NE-1-2 Loop A, Supply 16 Schedule 80 NE-1-11 12 NE-1-13 12 NE-1-20 12 NE-1-25 12 NE-1-29 12 NE-1-32 *' 12 NE-2-4 Loop A. Return 8 NE-2-8 8 NE-2-17 8 NE-2-28 8 NE-1-46 Loop B, Supply 12 NE-1-51 12 NE-1-54 A 12 NE-2-80 Loop B, Return 8 NE-2-91 8 NE-2-98 8 NE-2-103 10 4 14
Appendix B Page 17 of 27 TDR 580 Rev. 1 Page 100
)
TABLE 2 -- Simsmary of Deadweight and Seisaf e Stresses at Veld Worlay Locations Oyster Creek Isolation Condenser Piping Finite Element Deadweight Seienic Teld 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 1.3 86 .406 NE-1-54 A 55 1.571 .316 l NE-2-80 32 .'218 .823 K1-2-91 48 .326 2.241 i NE-2-98 36 1.660 2.126 l NE-1-103 6 .198 .411 l
- Node numbers correspond to the piping finite vienent models from Reference 3 9
#Geud 15
Appendix B TDR 580 Page 18 of 27 Rev. 1 Page 101 Table 3
- Minimum Weld Overlay Dimensions for Eight-Inch Isolation Condenser Piping
********************************************************************3
- WELD ID: 8 INCH *
- PIPE THICKNESS = 0.50 INCH *
- PIPE DIAMETER = 8.6 INCH *
- PRIMARY LOADS (STRESS): *
- PRESSURE = 4.70 KSI
- DEAD WEIGHT = 3.30 KSI *
- SEISMIC = 5.10 KSI *
- PB (KSI) EMIES EMIES *
- __I__ PM --------------
SM 3SM *
- WOT TfWOT (KSI) ACTUAL CALC (ACTUAL) (CALC)
- g ___________________________________________________________ g
- 0.225 0.690 3.411 5.793 24.304 0.526 0.523 *
- PRIMARY STRESS RATICS (ADJUSTED): *
- PM/SM = 0.195 :
* (PMfPB)/SM = 0.526 *
- MINIMUM REQUIRED WELD DVERLAY THICKNESS = 0.225 INCH *
- MINIMUM REQUIRED WELD DVERLAY WIDTH = I.5 INCH *
- sts ::::::::::::****::::::::::::::::::::::::::::::::::::
l 16
. ~. _- _ . _ _ . _ , _ _ . _ . _ _ _ . _ . _ _ _ . - . _ _ _ . _ _ _ _ _ . -
l Appendix B TDR 580 Page 19 of 27 Rev. 1
. Page 1FJ Table 4 Minimum Wald Overlay Dimensions for Ten-Inch Isolation Condenser Piping
$$$$$$$$$$$$$$$$$$$$t88$$$$$3888$$$$$$385888888835$$$$$$$$$$58$$$stst t *
$ WELD ID: 10 INCH ". t t t t t t PIPE THICKNESS = 0.59 INCH $
$ PIPE DIAMETER = 10.8 INCH t S $
$ PRIMARY LOADS (STRESS): 5 .
3 PRESSURE' = 4.94 KSI *
$ DEAD WEIGHT = 3.30 KSI t 3 SEISMIC = 5.10 KSI $
- t t PB (KSI) E51ER E5128 5 t __I__ PM - - - - - - - - - - - -
SM 3SM t t WOT T+WOT (KSI) ACTUAL CALC (ACTUAL) (CALC) $ g __________________________.________________________________ g 8 3
$ 0.275 0.683 3.548 5.739 24.656 0.531 0.537 5 3 5 5 5 5 5 t PRIMARY STRESS RATIOS (ADJUSTED): $
$ PM/SM = 0.203 3 5 (PMfPB)/SM = 0.531 *
$ MINIMUM REQUIRED WELD DVERLAY THICKNESS = 0.275 INCH $
$ MINIMUM REQUIRED WELD OVERLAY WIDTH = 1.8 INCH $
$$$$$$$$588$$$$$$$$$3888$$$$$$$$$$$$38$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$
17
TDR 580 Appendix B Page 20 of 27 Rev. 1 4 Page 103 Table 5 Minimum Weld Overlay Dimensions for Twelve-Inch Isolation Condenser Piping
$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$C5555 3 5
$ 1
$ WELD ID: 12 INCH $
$ PIPE THICKNESS = 0.69 INCH $
$ PIPE DIAMETER = 12.8 INCH t 8 5
$ PRIMARY LOADS (STRESS): 3
$ PRESSURE = 5 06 KS! $
$ DEAD WEIGHT = 3.30 KSI *
$ SEISMIC = 5 10 KSI $
. $ t t t t t 3 PB (KSI) 2H123 2H128 5 5 __I__ PM --------------
SM 3SM $
$ WOT T+WOT (KSI) ACTUAL CALC (ACTUAL) (CALC)
- g ___________________________________________________________ g 8 $
$ 0.320 0.682 3.423 5.731 24.615 0.535 0.538 *
$ t t 3
$ PRIMARY STP!SS RATIOS (ADJUSTED): 3
$ PM/SM = 0.207 5
$ (PMfPB)/SM = 0.535 3
- 3 $
l t t 5 MINIMUM REQUIRED WELD DVERLAY THICKNESS = 0.320 INCH $
$ MINIMUM REQUIRED WELD OVERLAY WIDTH = 21 INCH t 8 8 8 8
$$$$$$$$$$$$$t$$$$$$$$$$$$$$$$$$$$$$t88888$$$$$$$$$$$$$$$$$$$$$$$$$$$
l i r { I l l 18
Appendix B TDR 580 Page 21 of 27 Rev. 1 Page 104 Table 6 _ Minimum Weld Overlay Dimensions for Sixteen-Inch Isolation Condenser Piping
$$$53$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$$558$$$$$$$$$$$$$$$$$$$$$$$$3838
- WELD ID 16 INCH *
$ PIPE THICKNESS = 0.84 INCH *
- PIPE DIAMETER = 16.0 INCH t t *
- PRIMARY LOADS (STRESS)! * ,
3 PRESSURE = 5.18 KSI *
- DEAD WEIGHT = 3.30 KSI *
- SEISMIC = 5.10 KSI $
t t
- PB (KSI) EHiEB EH12B $
- __I._ PM - - - - - - - - - - - - -
SM 3SM $
$ WOT T+WOT (KSI) ACTUAL CALC (ACTUAL) (CALC)
- g _________...__________..._______________.-_..-_____-_.-_-
- t 0.395 0.681 3 698 5.718 24.629 0.538 0.540 $
- PRIMARY STRESS RATIOS (ADJUSTED)!
- t PM/SM = 0.211 *
$ (PMfPB)/SM = 0.538
- 3 5
- 3
$ MINIMUM REQUIRED WELD DVERLAY THICKNESS = 0.395 INCH *
- MINIMUM REQUIRED WELD DVERLAY WIDTH = 2.6 INCH
- 8 8
*$$$$$$$$$$$$$$$$$***$$t8$$$$$$*$$$$$$588$$$$$$$$$$555$$$$$$$$$$$$$$5 a
a
- t '
19
. - _ - ___ _ _ . - . _ . . - _ . _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ . . _ _ . _ _ . . ~ . _ . . . . . _ . _ - _ _ _ _ . - . . _ - _ . - _ . .
Appendix B TDR 580 Page 22 of 27 Rev. 1 Page 105 e C N" MIN O WELD hM " j O C CROWN r c N "+ g MIN WlOTH 3 MIN = FIRST I LAYER k / - NAYNN/EN/N/f/ K x
\I BUTT WELD Il l ELsOW PIPE
' [y"E M'
' Y THICKNESS
/ -
w - il is - 9, WELD PIPE-70-PIPE Pipe Size Vall. Weld No. Loop (inches) Thickness T,g, Tg T 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 Dinsasions for the Pipe-to-Pipe Veld Overlays Oyster Creuk Isolation Condenser Piping 20 I
/
'+
TDR 580 Appendix B Rev. 1 Page 23 of 27 Page 106 C *W" MIN 5
**1" MIN C1 C C WN i C5 *Wg " MIN 2
WIDTH
' = FIRST 3 LAYER
~
HMH/H NK' U suTT
~ 2 ,
N 'd o ELBOW WELD jL
=T" MIN l, PIPE
,E
, io -
( WELD PIPE-10-ELBOW l Pipe size Wall Wold No.. Loop (inches) Thickne s s T,g, W1 W NE-1-11 A 12 .687 .35 .60 3.0 NE-1-20 A 12 .687 .35 .60 3.0 NE-1-32 A 12 .687 .35 .60 3.0 NE-2-4 A 8 .500 .25 .50 2.1 NE-2-8 A 8 .500 .25 .50 2.5 NE-2-17 A 8 .500 .25 .50 2.2 NE-2-28 A 8 .500 .25 .50 2.3 NE-1-46 B 12 .687 .35 .60 3.0 NE-1-51 E 12 .687 .35 .60 3.0 15-2-80 3 8 .500 .25 .50 2.7 [_ NE-2-91 3 2 .500 .25 .50 2.4
; NE-2-98 3 8 .500 .25 .50 2.3 y
Figsre 6 Desi8s Disensions for the Pipe-to-Elbow Weld Overlays Oyster Creek Isolation Condenser Pipias 21
Tcblo 7 ,, SAPETY FACIORS FOR OYSTER CREEK ISG ATION 00NDENSEE WELD DVEELAYS Safety
- Nominal Limit Safety Factor Thermal Factor w/
Pipe Size Deadve18ht Seismic (P,+Pb ) Load Based on Expaaston Thornal Wald ID Pleine Line (inches) (ksi) (ksi) (ksi) (ksi) Primary Stress (ksi) Exnassion
~
35-1-2 Loop A. Supply 16 .211 .390 5.78 41.5 7.2 0.5 6.6 15-1-11 *' 12 .903 1.174 7.14 43.2 6.1 3.9 3.9 35-1-13 12 1.205 1.346 7.61 43.2 5.7 2.6 4.2 35-1-20 12 3.249 .594 8.90 43.2 4.8 3.4 3.5 95-1-25 " 12 .604 .549 6.21 43.2 6.9 2.7 4.8 35-1-29 12 .270 1.210 6.54 43.2 6.6 3.7 4.2 95-1-32 " .510 43.2 5.7 2.4 4.3 12 2.055 7.62 35-2-4 Loop A. Return 8 1.114 .53 0 6.34 42.8 6.7 0.1 6.6 g 35-2-8 *' 8 2.293 .691 7.68 42.8 5.6 0.2 5.4 m *o b 35-2-17 8 2.330 1.871 8.90 42.8 4.8 0.1 4.7 *@ 05-2-28 H .846 5.021 10.57 42.8 4.1 0.2 4.0 y$ x O 95-1-46 Loop B. Supply 12 2.423 .629 8'11 43.'2 5.3 4.7 3.'4 mm 95-1-51 ** 12 1.3 86 .406 6.85 43.2 6.3 2.4 4.7 35-1-54A 12 1.571 .316 6.95 43.2 6.2 5.4 3.5 U 35-2-80 Loop B. Return 8 .218 .823 5.74 42.3 7.4 0.8 6.5 95-2-91 8 .326 2.241 7.27 42.8 5.9 0.4 5.6 35-2-98 8 1.660 2.126 8.49 42.8 S.0 0.4 4.8 35-2-103 10 .198 .411 5.55 43.4 7.8 0.4 7.3 I
*Thnce safety factors are calculated for information purposes only, ney do not imply that thermal ezpassion stresses be oossiderod in weld overlay design.
Note: The P, values are 4.70 kai (8-inch pipe) 4.94 kai (10-inch pipe) . 5.06 kai (12-inch pipe) 5.38 het (16-inch pipe)
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Appendix B TDR 580
, Page 27 of 27 Rev. 1 Pace 110 Table 8 -
l Maximum Shrinkage Stresses l Isolation Condenser Piping--Loop B l. Fisite Pipe Elseent Section Nomiral Location Line Node # Moment Modulus Stress (nsi)
. Weld NE-1-40 Supply 10N 29,219 144.5 202
'Y'-Reducer Supply 13 29,153 74.5 391 Penetration I-5A Retsr3 1 67.712 45.6 1,487 Weld NE-2-98 Return 38 54,514 4L6 1,197 25 J}}