ML20107E161
| ML20107E161 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 06/30/1984 |
| From: | Hall J, Dawn Powell ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY |
| To: | |
| Shared Package | |
| ML20107E145 | List: |
| References | |
| NUDOCS 8502250400 | |
| Download: ML20107E161 (52) | |
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Materials and Chemistry w=2 #8k O
(3$%?FAs COMBUSTION ENGINEERING INC
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DESTRUCTIVE EXAMINATION OF TUBE L29R84 FROM THE B STEAM GENERATOR AT FORT CALHOUN JUNE 1984 D. E. POWELL J. F. HALL -
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Reviewed by: '-
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F. Hall
! Approved by:
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COMBUSTION ENGINEERING, INC.
NUCLEAR POWER SYSTEMS 1000 FR0SPECT HILL ROAD WINDSOR, CONNECTICUT 06095
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Section 1.0
SUMMARY
Combustion Engineering, Inc. has completed a detailed destructive examination of a failed steam generator tube (L29R84) removed from the Ft. Calhoun Station.
Tube failure occurred during plant heat-up following a refueling outage and resulted in a leak exceeding 100 gpm. The analysis indicated that the cause of failure was intergranular stress corrosion cracking which propagated essentially throughwall prior to the final ductile rupture.
The examination of the stress
_ corrosion cracks and deposits removed from the tube failed to identify a Tausative species for the failure.
The tube was confirmed to be typical of mill annealed NiCrFe Alloy 600 tubing used in C-E supplied steam, generators.
Bastd on the infonnation available, it was concluded that the failure was most likely the result of caustic stress corrosion cracking with the caustic environment resulting from the concentration in steam blanketed areas of condenser cooling water in-leakage. ,
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Section
2.0 INTRODUCTION
A large leak (;*100 gpm) developed in the B steam generator at Ft. Calhoun Station during plant heat-up following a refueling outage in 1984. Subsequent non-destructive inspection indicated a large throughwall defect in tube L29R84 in the area of the first (hot leg) vertical support strap on the horizontal run.
The location of the f ailure in the horizontal run and the location of the tube in the second peripheral row of tube made removal of the failed section
,possible.
Accordingly, Combustion Engineering removed by cutting with a TIG Torch that part of tube L29R84 extending from near the hot-leg 90 to the bend center vertical support. To gain access to tube L29R84, C-E removed an equivalent section of tube L29R86, a first peripheral row tube. After a brief on-site visual examination, the removed sections of both tubes were shipped to
~ C-E's laboratory facilities for detailed non-destructive examinations. The examinations included the following tasks: ~
- 1. Laboratory eddy current testing (ECT) _
2.
Visual examination and documentation of the as-received tube segs.ents l 3. Dimensional measurements
- 4. Light microscoopy examinations
- 5. Scanning electron microscopy exartinations
- 6. Quantitative and quali'tative chemical analyses of tube materials and deposits. -
This report documents the results of the laboratory examinations of segments of
' tube L29R84.
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Section 3.0 VISUAL EXAMINATIONS C-E received two sections, identified as 238 and 23C, from the horizontal run of tube L29R84.
0 Tube section 238 was the length of tube extending from near the hot leg 90 bend to the inboard side of the first vertical tube support, and contained the throughwall defect.
Tube section '23C was the section of the same tube extending from inboard of the first vertical support to outboard of the middle vertical support.
Figure 1 illustrates the relative position of the tube sections in the steam generator.
Figure 2 a-h documents the as-received condition of section 238. Not shown in this series of photomacrographs is the' bend induced during the removal process and the severe scarring of the hot leg end caused by the tools used to remove
, section 233.
Section 238 was deformed and securely locked into the first vertical support by build-up of corrosion products .in the tube ,to-support crevice and significant effort was required to free it after TIG cutting was completed. ,
A major crack, approximately 1-1/4 inch long, was present at the six o' clock position of section 238 between the two scallop bar locations. Other areas of
' smaller cracks were present at either end of the major cracks. In one of these areas (Figure 2d), the crack's were oriented at an angle of 45 relative to the' axis of the tube. Deposits at the scallop bar locations, which made' location of th2 scallop bar positions possible, are shown in Figure 2d. Deposits, cspecially in areas near the major crack, were very thin and generally were orange to brown in color.
At the scallop bar locations, there were some white d: posits also present in addition to the orange-brown deposits.
Outside of the area of the vertical support, the tube section was covered with a black, or copper-brown colored loosely adherent deposit . overlying a white deposit.' In some' areas, these deposits had flaked off ' exposing bare and non-corroded material underneath.
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Tube 'section 23C was also covered uith a dual layer of black or coppgr-brown
. colored deposits overlying a layer of whitish deposits (Figure 21). There were no obvious areas of corrosion visible in section 23C nor were there any areas of deformation except for the deformed ends resulting from the cutting operation.
In addition to photomacrographs, C-E also used video tape to document the as-received condition of tube sections 238 and 23C from tube L29R84.
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Section 4.0 LABORATORY EDDY CURRENT TESTING Af ter receipt tube sections 238 and 23C were re-examined by ECT. For this examination, a bobbin probe and MIZ 12 ECT equipment calibrated using an inline calibration standard with mix frequencies of 400 and 100 kHz was used.
The defomation of tube section 238 precluded the use of any other probes or techn.iques for examination of this tube section.
ECT testing with the bobbin probe clearly showed a 100 percent through*all Nignal at the location of the major crack.
One end of the defect signal was not clearly resolved because of probe interference at the torch cut area of the tube section.
Approximately 1/4 inch from the hot leg end of the major defect, a second 00
- initiated indication was present. The location of this signal corresponded to the location of the second area of cracking. A mechanical kink in section 238, induced during tube removal, distorted tl}e signals from this smaller defect, j rendering depth estimates impossible.
l Significant dent signals were present at the general location of the defects in
, section 238. These signals could not be quantified due to bending of the tube during removal from the steam generator. Several small dings were seen along l the remaining portion of the tube section.
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These were not observed within the steam generator and, consequently, were probably caused during tube removal from the steam generator.
.No defect signals were present in tube section 23C.
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Section 5.0 DIMENSIONAL MEASUREMENTS Figure 3 gives results of dimensional measurements from the defect region.
These measurements were taken before descaling, and as such thickness of residual deposits. include the The data indicate that the tube was ovalized with the major axis (6-12 o' clock) being elongated by 0.046-0.122 inch while the minor axis (3-9 o' clock) was compressed by 0.045-0.070 inch diametrically.
Figure 4 illustrates qualitatively the degree of ovalization present in the area of the major defect in section 238.
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Section 6.0 MATERIALS CHARACTERIZATION.
6.1 SECTIONING 4
C-E sectioned tube sections 238 and 23C in accordance with Figure 5 to provide j ;
samples for both materials characterization and defect characterization. The
- I objective of the materials characterization testing was to determine if tube L29R84 was typical of mill annealed Alloy 600 tubings i
I.2 MICROSTRUCTURE CHARACTERIZATION Transverse sections of tube sections 238 and 23C were metallographically prepared ' for evaluation using a dual electrolytic etch procedure. In this procedure, an Alloy 600 sample is etched with nital to reveal grain boundaries, and with orthophosphoric acid to reveal carbide distribution and location. This
' procedure is used because the more connonly used electrolytic oxalic acid etch may give misleading infor1 nation on carbide presenc'e and distribution. ,
i Figure 6 shows typical photomicrographs of the microstructure of tube L29R84 after the nital etch and the orthophosphoric etch.
. The microstructure of tube L29R84 consisted of medium size grains with some grain boundary carbides and j
2 very few intragranular carbiides. - The microstructure of tube L29R84 was nominal and a typical example of mill annealed Alloy 600 tubing.
6.3 MODIFIED HUEY TEST On3 piece from each of 238 and 23C was cut and tested using the modified Huey procedure to evaluate the degre~e of sensitization of tube L29R84. In this test, specimens were exposed to boiling 25% nitric ~ acid for 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />. Af ter the exposure, the _ pieces were cleaned and weight loss determined. Mill annealed caterial typically exhibits weight losses of 0.5% or less, while sensitized material exhibits weight losses in excess of 5.05.
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.The weight losses for pieces 239 and 23C were 0.103% and 0.128%, respectively.
- Th'is* result, coupled with the dual etch microstructure results, confinns that tube L29R84 was in the mill annealed condition.
I 6.4 CHEMICAL ANALYSIS
' Two pieces of tube L29R84, one each from sections 238 and 23C, were obtained for bulk chemical analysis to verify that there were no anomolies in the chemical I
composition of the tube.
Both sections were chemically decontaminated using a nitric-hydrofluoric acid solution prior to chemical analysis. .
Results of the chemical analysis are given in Table I along with the specified composition from ASME S8-163 (the applicable commercial tubing specification).
_The data show that the chemical composition of tube L29R84 was typical of Alloy
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600 steam generator tubing. '
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Section 7.0 DEFECT CHARACTERIZATION Figure 5 shows how sections 238 and 23C were further sectioned to provide samples of the defects for characterization.
1 7.1 ANALY$15 0F MAJOR CRACK One end of the large throughwall crack was mounted, polished and examined to
_ determine crack morphology.
Figure 7 includes typical photomicrographs of 7 racks at the end of the major fracture. The intergranular nature of the cracks is evident in these photomicrographs. In the as-polished sections, there were no indications of intergranular attack (IGA) on the tube surface between thg stress corrosion cracks. This was subsequently confirmed by etching the i
specimen with glyceregia, or an etchant which is particularly sensitive to IGA in nickel base alloys. Discrete intergranular stress corrosion cracks were present.
One f ace of the fracture surface was chemically descaled to remove all surface deposits using the standard two step APAC procedure. Subsequently, the specimen c s examined by scanning electron microscope (SEM) to detennine the relative amounts of IGSCC and ductile failure area. Figure 8 is a low magnification optical photograph of the desI:altd crack surfaces.
Figure 9 is a low power scanning electron micrograph showing a relatively flat crack surface with a central ductile tear ridge running from the 0.0. to the I.0. surf ace of the tube. There were also other areas of ductile failure along the I.D. of the tube.
Figure 10 shows a section of the crack surface from 0.0. to I.D. In this area, the failure appeared to be complete intergranular with evidence of secondary cracking resulting from branching of the main crack as it progresses through the caterial. The absence of any ductile failure area suggests that in this area a 7-1
'small throughwall defect (and low level primary to secondary leakage) existed
. prior to th2 final rupture that resulted in large scale leakage.
Figure 11 is a montage of two photomicrographs showing the crack surface from 0.D. (on the left) to the I.D. of the tube. Here, also IGSCC appeared to have progressed completely through the tube wall prior to final failure.
Figures 12-14 show that, although IGSCC covered most of the crack surface, there were small areas of ductile failure, as expected.
Figure 12 shows a tear ridge extending from the 0 D. to the I.D.
surface. Figure 13 is a higher magnification scanning electron micrograph more clearly showing the transition from IGSCC to ductile failure near the I.D. surface.
Figure 14 is a high magnification scanning electron micrograph that shows more Niearly the intergranular nature of the crack cracking. and the presence of secondary Figure 16 also shows throughwall IGSCC in yet another area of the crack surface.
The SEM examination of the crack surface clearly showed that IGSCC was the prevalent failure mode. In relative terms, IGSCC covered approximately 95 percent .of the crack surface with the remaining area being a ductile failure formed during the final fracture of the tub.e.,-
7.2 ANALGIS OF SMALLER CRACKS A transverse metallographic section passing through the area containing the smaller cracks oriented at'. 450 to the tube axis was also prepared.
This section was cut, ground and polished, without the application of any water, to prevent the elution of chemical species from the partial throughwall cracks. It cas anticipated that contaminant species could be trapped in the tight intergranular cracks or in deposits in the crack. This metallographic section tas examined by both light microscopy and scanning electron microscopy in the l as-polished condition.
i Typical photomicrographs of cracks in this area are shown in Figure 17.Several discrete cracks, with no indications of IGA were present in this section. The 4
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intergranular nature of the cracks is readily apparent in th2se
. photomicrographs.
Th4re were no obvious deposits present in most of the cracked area. There was, however, significant amounts of metallographic mounting material present in the larger cracks.
This same section was examined with an SEM supplemented with energy dispe spectrometry to identify chemical species present.
Numerous EDS analyses of crack tip regions were completed without positive identification of contaminant species.
Typicalare regions scanning shown in electron micrographs and EDS analysis results of crack ti Figures 18-23. Elements identified by .EDS analysis included Ni, Cr and Fe from the tube base metal; Si, probably from the grin Ng,AlandTi.op; rations; and minor indications in one or more loctions of C X-ray mapping of selected areas showed no major concentrations in the cracks of any of these elements.
Thus, the EDS results provided no strong conclusions about possible aggressive species that may have promoted the IGSCC.
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Section 8.0 SCALE ANALYSIS 8.1 pH MEASUREMENTS There were only minor deposits present on tube L29R84 after it was removed from the steam generator.
The flushing action of the leak may have removed deposits that had accumulated during operation.
Measurement nf the pH of the deposits oa the tube were attempted with drops of deionited water and litmus paoer. Th"
_ litmus paper was capable of detecting pH's in.,the range of 9-12, with different Tolcrs at each .5 pH unit.
The paper registered no reading (below 9) when wstted by defonized water.
Some of the deposits were subsequently removed from the tube surface and crushed to form a slurry.
When the pH of the slurry was checked, no change in color of the litmus paper was registered. This suggests the pH was below 9.0.
Finally, drops of water were placed at several locations along section 238. In general the pH paper did not register any color change at these locations.
However, one spot along section 238 did have a color change, suggesting a pH of 10.0.
8.2 ANALYSIS OF SCRAPINGS '
Scraping of the deposits from tube L29R84 were removed from the thin deposits in the scallop bar region
- and from the free ' length of tubing between vertical support straps. Deposit scrapings were dissolved in deionized water to f acilitate analyses by ton chromatography and atomic absorption techniques. Ion chromatography detected 1793 ppm of 504 and 833 ppm of NO in these deposits 3
(error in measurement is ,+ 50%, due to the small sample size). Atomic absorption techniques did not detect metal cations such as potassium, sodium, calcium, or magnessium.
6 8-1
Outside the scallop bar vertical strap region, the dark flakes of deposi anhlyzed for these same elements, and 147 ppm S0 found. 4 and 78 ppm NO were 3
The concentration of potassium, sodium, calcium, and magnesium b21ow the 50 ppm detectability level for these relatively abundant scale deposits.
Scrapings were taken from the whitish colored deposits of the inner . They scale were collected from the various holes of the exterior scale position away from the vertical strip-scallop bar region. When analyzed, 3256 ppm sulfate and 1500 ppm nitrate were observed.
was again estimated at + 50%.
The error for this measurement No alkaline metals were detected. The above scale analysis for this tube L29R84 are sumarized in Table II.
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Section 9.0 DISCUSSION OD initiated IGSCC has been identified as the cause of the steam generator tube failure at Ft. Calhoun. The elements required for IGSCC include (a) a susceptible material conditions, (b) a significant tensile stress, and (c) an aggressive environment. All elements must be present for IGSCC to occur.
Stress corrosion cracking (SCC) of Alloy 600 will occur under the appropriate fondition in all metallurgical conditions, including the " mill annealed" condition.
Material used in the steam generator tubes at Ft. Calhoun is typical of high temperature mill annealed Alloy 600.
This material is resistant to IGSCC in some but not all environments.
Normal operating stresses in straight lengths of steam generator tubes are relatively low. Additional stresses may be imposed through support-tube interactions.
At Ft. Calhoun, there was evide,nce that the failed tube was t constrained by the vertical support strips,to the extent that deformation of the tube occurred, probably the result of indigenous corrosion product growth on the vertical support. This lateral deformation provided additional stress at the point where f ailure occurred.
Three different environments %re known to be capable of producing IGSCC in Alloy 600.
These environments are (a) caustic (caustic stress corrosion cracking),
(b) relatively pure water (Coriou stress corrosion cracking), and (c) sulfur containing environments. Of these environments, C-E considers that a caustic environment was the most likely cause of the observed failure.
A caustic environment may have occurred in steam blanketed areas at Ft. Calhoun as a result of periodic low level condenser in-leakage. When concentrated, the cooling water (Missouri River) tends to become alkaline, thereby producing a
! caustic condition. Deposits in the steam blanketed area, which may have contained alkaline species such as Na, K, etc., may have redissolved during the t
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plant, shutdown prior to the f ailure.
This could explain the absence of theso
. el'ements in the small cracks adjacent to the failure. Although some deformation of the tube occurred during service, the total deformation was relatively small (less than one percent).
Caustic SCC has been produced in the laboratory in Alloy 600 at strain levels as low as 0.5% (elastic plus plastic). Also, caustic SCC has occurred in relatively short times at temperatures of 600 F or less, which approximates the tube wall temperature at Ft. Calhoun.
These observations, coupled with the f act that the failures occurred in a steam
- blanketed area where caustic species could concentrate, leads C-E to conclude that the failure was probably the result of caustic stress corrosion cracking.
Pure water stress corrosion cracking (Coriou cracking) is considered as a significantly less probable mechanism for the tube f ailure. Coriou cracking has been identified as the failure mechanism in numerous steam generator tube Nailures in both domestic and foreign PWRs.
No chemical contaminant (s) have been associated with this type of SCC.
Field and laboratory failures attributed to this particular mechanism generally occur in either highly defomed tubes (strains greater than 14%) or in tubes with distinct mechanical and/or microstructural characteristics (high strength and intragranular carbides).
Most, although not all, of the Coriou type failures have been I.D. initiated.
Although the failure tube at Ft. Calhoun, was defemed, the total strain was relatively low (less than one percent). Furthermore, the tubing used at Ft.
Calhoun was relatively low strength and the microstructure appeared relatively resistant to Coriou cracking, i.e.,
intergranular carbides with few intragranular carbides.
Similar tubing has been severely defomed as a result of support plate and/or %ggcrate denting in other C-E supplied steam generators. Non-destructive and post-service destructive examinations of removed tubes have confirmed the absence of Coriou type cracking in these steam generators.
Furthermore, Coriou cracking is strongly temperature dependent and thus tends to occur when temperature is the highest; i.e., on the tube I.D.
The Ft. Calhoun failure was 0.0. initiated.
Based on these observations, Coriou cracking is not considered to be the cause of the Ft. Calhoun tube failure.
IGSCC induced by a sulfur containing compound is the least likely of the three 9-2
postulated failure mechanisms.
There was no apparent source of S bearing comp'ounds at Ft. Calhoun, other than the condense'r cooling water. Furthermore, the condenser cooling water becomes alkaline when concentrated, not acidic The various forms of S .
induced corrosion (IGSCC, wastage, intergranular attack, pitting) all occur at acidic values of pH. In addition, analysis of the intergranular cracks in the failed tube did not produce evidence of the presen of S, although some S compounds (ex. NiS) that form in high temperature aq environments are insoluble.
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Section
10.0 CONCLUSION
S The detailed examination of section of tube L29R84 from the Ft. Chlhoun "B" steam generator resulted in the following conclusions / findings:
1.
The cause of the failure of tube L29R84 was intergranular stress corrosion cracking which propagated essentially throughwall during the preceeding fuel cycle.
During plant heat-up at the start of the next cycle, the remaining uncracked portion of the tube failed as a result of a ductile overload.
2.
The major crack was located on the bottom of the tube between the scallop bars in the first (hot leg) vertical support strap.
3.
The tube had been ovalized as a result of corrosion-product build-up in the tube-to-support crevice.
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The most likely mechanism of failure was caustic stress corrosion cracking with the caustic environment being developed by the concentration of in-leakage of the condenser cooling water.
5.
Tube L29R84 was typical of mill annealed Alloy 600 tubing used in C-E
- supplied steam generators. The chemical composition, microstructure and degree of sensitization were all nominal for mill annealed Alloy 600.
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Table I CHEMICAL COMPOS ~ TION OF TU8E L29R84 Ni Cr Fe Mn Cu Si C S Co 72.0 14.00- 6.00- 1.0 0.5 0.5 0.15 0.015 (min) 17.00 10.00 (max)58-163 (max) (max) (max) (max) 76.08 14.50 8.16 0.248 0.325 0.190 0.025 0.001 0.035 238
. 76.04 14.44 8.26 0.245 0.324 0.195 0.024 0.001 0.035 23C t
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Table II SCALE ANALYSIS FROM TUBE L29R84 (In ppm, based on original dry . weight of scale)
SCALE SCRAPINGS NO, S. 0,4 K, Na, Ca, Mg Scallop Bar Region - 1793* 833* 1050 Dark Exterior Scale 147 78 Outside Scallop Bar Area 50 Whitish Deposits Within 3256* 1500* 2500
- Holes of Dark Exterior Scale CValues.are + 50%
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Table 1 ELEMENTAL ANALYSIS Ni Cr Fe Mn Cu Si C S Co 72.0 14.00- 6.00- 1.0 0.5 0.5 0.15 0.015 58-163 (min) 17.00 10.00 (max) (max)
(max) (max) (max) 76.08 14.50 8.16 0.248 0.325 0.190 0.025 0.001 0.035 238 76.04 14.44 8.26 0.245 0.324 0.195 0.024 0.001 0.035 23C 4 ..-
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L .pyy
,. ;;.q . e . .@;
. eW ..c,.4?
,f;;l. ' M,, g
.q. &y r. .ya .
,q%
.'e . - +$ :, .. "' % g f . "; _ %-* .* '. %g l { ; ( , ,_ .v.g[ e,l -i ey }
fL, i,? .
(b) Close-up View of One End of the Major Crack (Neg. #68015, 8X)
Figure 2. Photomacrographs Documenting the As-Receivea Concition of Tube L29R84.
1 f
1 i
I REEED: f
- l i
(c) Bottom Scallop Bar Location in Section 238 (Neg. #68010,-1.5X) s.... - ,, . . 3s, e , ; . .. ., + -
... s .
h# . .s -
O.- ' " ' "
s
.~.,.:..;.. .
i
,.,,7 ;'. e
'. gp.. *
. .i."-. -
.t.-
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'd
- * 7.'+.,
. .:
- E^ ' ' ..W' ; L' .' ; . ; e
' a$w. '7 3p;yp:);.;5:l...Y..;.T
.av. i.::,; . .;;, ,.. ,lg.
%: ~. :? : : .,w.
. .. 3.). A ; c. 'l sz..y;;.. +
1,.Y.. [. :
>: d., ; g.,( #4 . ['. . Q .~._n :_ p _ ; .. :,y .fgnp:y : - :l;. ) y~* -'.; :y.s , : . . /. p p %
y . -' ,- -
- ,. t. y e ~ ' s- ~ ..
~'M a . '
'4 : -
c ; -;. e :
-l*-Q t .i.; ,. . , ; , ,' .4 q
. ,_' ,,4
,; j.
.'. .'; . d,., ;. '.Q.4 . ,,. AFR.-
4,.s .. ,},;
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~c wy;%n
,, u. wg.
- 4y,
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7.
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%; h/ f.: . [ fn p,: . e ',?. *
. ._ W
- -s..s.c. Q f[?. .. u. :w. y z; y;_ .;;3..s b :.; .9 s J,y .y:
( .-
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.+ .,
- se o4
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.g 7
% f.%! {,4:.. b. l% ' .I. 3 l f. ' ';5 'g( . ~ )3
- 7.2
- n. . . . . u.,
$ &g_ hyg. ,q. . w..; 1 ._ 3. q.v h. b a
,- . _ . ,i . , ,,. E,
- s. : .. , .-. 1 .e..
- e. .. .. .:. l ", . ' : ' N l . ? ' ?, ?* ."u..% ' .
i'. G % a (d)
Area (Neg. of #68011, Smaller SX) Cracks Oriented 450 to Tube Axis Figure 2.
Photomacrographs Documenting the As-Received Condition of Tube 1.29R84 (continued).
i
- - - . . - --.--5---
- y. . .
g . n ' g ,.:(:. L .::9*q, .: . 7. . , . ..?_::_ (_;.
.c ;
V. ..3.:.,;r': .,f;J, * - d.~: P 's,.... ,,%; < . 4.r...4 .. ,%.. .;.-
6 y.. .
'. 3.; .;pr sk%v4 c
., g; y3 4 v . .. . .%. . ,=
..a t. .
.. c . ~. vy ... .,,- s a c
, ' . . :,) p ,..: n s .. .
.*t. r -
- e~ s.
3 .,_ , " +:y . . .s g*{,, y . '
e u . ': *.
4
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..;p
... >, . .. ..,;c..: .. .. .. : +p. ;4 .
.- r.,.
. .::og i . .. .
i g.g ,
- .
- .. ; . a; 3. . , . . . x:.... . . ..;:., g;i., r m7 -
.. . . . f..
\. ;,v..R ., . m . .~ . . . .. ; :,n_ : . ._. . ;. {. 4: * ,y .
cc..:. .,v .. ;f'. . g. ,
,;;; e , y ...&m,. < . .... +
.:_ ..,.\. *.. c*
.; .j;:., -...
- y. y.c; c.,
.., c. . ,..$- e; . . ; . . .. . J.:.
'q
.* : . . .. , . .,....:, f,
,, C'
! ~
- [4. . _,..- , ..>; ,.,,,f((5(ii.
g
- 7. M.#Qdk(c. e
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- h.
o c. .hx.'k~. -
1.e Yhd . . m[. .: s
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I
@p.p.r l -
,- v -..c .'. .
- .b.y.yT +:,$..'.. ,..- g f,::: . 'c. :4 $g.f.mgi .& . .i j: : .:s,l q?... -
i .
t .
. . . ., y :. g ; . . . , .,_
4
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l Q{_. .fm:.6 : ?.,i.u':;2:l if:$h...,...=?.._ . .gij(.; $
i
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(: h %M3R:
g.g . *g g2 ..;. - 7.M. ?j..g . . ..;g' m
~
.e % 4 y'.P F;
?
- i (e) Close-Up View of the Area of Smaller Cracks j (Neg. #68106, 20X) !
t l i .
l
- . r
?
l ,
i N 4 t
t t -
- r. 2
- e. s
. l 1
l
' (f) Top Scallop Bar Location of Section 238 '
(Neg. #68012, 2X)
Figure 2. Photomacrographs Documenting the As-Received Condition of ,
i l Tube L29R84 (continued).
I e
I .
r- .
k 4
l l
\
\
\
f . .
1
.. a
, , .,a ! *
- r. !
1 (g) Area of Deposits o.1 Section 238 (Neg. #68013, 2X)
.g. .
5' . J pt,'4 . : j !
. .% i
~
..3
.g. <
=
t (h) View of the Fracture Surface of the Major Crack (Neg. #68008, 20X) l 1
Figure 2. Photomacrographs Documenting the As-Received Condition of l s
Tube t.29R84 (continued).
l
1 1
i <
s i
\
i j I
i i
l
\
l
! l l
i t
- I iu...
- 'j;~gW*,,.g 3f5, st 55
' " 4~, -- n~mst
'-* ' ' se '
' i 9' .
) :e s@:v:e.se*
5;y,.r.gr g 92-
.,jl~.?h,.
l
--T ' ._ - x 2, l
(1) Area of Deposits on Section 238 (Neg. #68013, 2X) ;
i i
i r
h l
I l
1 l
I 1
nting the As-Received Condition of f Tub 9R8! o tinued).
t
-~n-----. , , - - . , - - - - - - , - - - - . ..-----.----.-m - - - - - . - , . - - - - - , , . - - - -
,- / 4 d Q _ . . -
g
,7 54 o ,g7,y i
.757c SLD2 Joao ,785o .7att
( 4 V.T E W 4
\1L U Uf .
t .4120 t l
4 i v vf--
N 71/ UN
,7597 n y "#6W
( n g I
1 *6867 1 1lls .
l l
Figure 3.
Dimensional Measurements of Section 238.
} .
1 .
j . .
i I
i
! ~
l l '
~ ,,
\
Es..
i
-+ ;
l e
i ,
f J
T 6
c Figure 4. Cross-Section View of Tube Section 238 Near the Major Crack Showing Extent of Service Induced Ovalization. '
(Neg. #68026, 3X)
s .e
\ ' '
R.o E. SEM , '
I
\
W
\
\
\
g g
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k l l g ,
s' o.le,c!. ..I !
3
-* tv84 s .. i NcJ./ I l '
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i 6s 1 na.c.) 0l
{ N.J "*'1 nu TmL '16 %wJ M. or kk'*
sa
+es s.J *C
- n. A-n.
er m car
- )
i
~ r 1 F l i I'T , i l , j i
i
' f GF4 F l ' '
( I
. V .' '
l l 6 it Cha .at P. s e e 13 a t (
1 l .
D l GM.
M6skbr ut. C,.J T., A Ct H a < *; LA
,e-,
6t
/ 1 !
\ \ i " ",r \ Q ' 8 It ;
Q/
@ 4 m<. cm.-.c / '
QN J
\ Pise t 23C l
l l
Figure 5.
l Sectioning Diagram Showing the Location of Samples Removed l
for Various Analyses.
L l
l l
- a. s
/ ,
g
~ .
.w %.
, w; e-
.. ..-. . . s
. y.
.
- p.
.. . ~.
- .r;n.s ,
g o.' / ...**.
. %. 1
.s
- i. -.
s .
j.f: ., s. , .*(Thl... . ,:.h' .
- fd'l, . N ;~c. q..' .. %A - -
,s .
/'... . s, - .s.-.m
.,,,6 .
,. , s- ,5 .8
~ ~.
,' ,e .
l
- c. .-* . , ,
t-
.,., y. .
..+, a.. . .
. %.-s. 7
. .'..l%.:....,.n..v. l. J.: )
.r
. .).~ ~f.8..Y. T ::,y _. p .., :: . . .
\ ...,. -
u.
- <; ,- ., p' , ' -
N .:. a . .
1 ;.,-y6c . . . .
, %r ..
g-Nital Etch 5 .
a ., .
- /
./
s . ,. /
..-N ,
g
[ .
(
.F N i.
s -
. 4 . _ _ ~ .
. v. -
I -
N < .. ,
! . r-
- i>. r
.r. T . . ~
<.. t r.
{ .
s . .
Orthophosphoric Etch.
Figure 6. Microstructures of Tube L29R84 (Transverse View, Neg.
- 68020, 68021,.500X).
t l
/.
{ .
\
i -
I
) - 4 i .
.=._
(a) As-Polished (Neg. #68022, 200X)
...)
i
~
, .s ( ,')* '
w.'
's ,
=
q.
. ./ r
/
J- .,
.. r ;
i e'
%( ,
. # 's .
t
{ ,.
s .
i (b) Higher Magnification View of a Crack Shown in l
Figure 7a (Nital Etch, Neg. #68017, 500X) ;
Figure 7.
Transverse View of Cracks at the End of the Major Crack, Mount 17B.
i
I'* -
/ - -
.i **
s.
, s .
t ~
- /.
I .
- /
7 .
7 (c) Tip of One of the Figure 7a Cracks (Nital Etch, Neg. #68018, 1000X) 4 i i
I
~ . . . . .. ; ,. '
_: . ' = ; .:' , ' * *
~-
q .
(. y. . _.. . ~
'[:> ..
3 K,
.N
.. . .~
(d) Area Shown in Figure 7a After Etching with Glyceregla to Determine if Intergranular Attack Had Occurred.
(Neg. #68059, 200X)
Figure 7.
Transverse View of Cracks at the End of the Major Crack, Mount 17B (continued) .
1 I
4 1 l
l
\ l l
4 i
j i
I 4 .
f L
=-
r i l
.i
.'f . . . ,. Y : '
, ; . \;,. ?;; ~
R i
,N e
l'l ,
, < ;v'f ( , ?'I' Y ,'_.,
. . . . -M t
..g4.- ,
44,s . '9-
.. g .g
~ 14 - m' 1
t 1
Figure 8.
A Section Electron of the Major Microscope Crack After Descaling for Scanning Examination.
(Neg. #6802f, 10X)
j . .
1 i
i
}
i 1
i l
l l
~
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l 1
,~ .
t a ..
! ' ~ ,Y 6.fi f'$.%*Sj; f..ep' -
..s g.f.?'.p'$hth ;
.u ;tn .v:::-p ;
l
.e-.s.~
j .-
- }
, .:. n.n; .u. s l
1
! i 1 i
'l 1
i i 1 '
l 3
i e I i
i Figure 9.
Low Power Scanning Electron Micrograph of the Fracture Surface.
, (Neg. #68039, 10X) 4 i
, i i I
. i 1
- I I
l I
i ,
i e
i i
r i
Figure 10. Scanning Electron Micrograph Showing Appearance of the Fracture Surface from 0.0. to I.O.
l (Neg. #68045, 70X) l t
. . - _ _ _ . _ _ . . _ _ _ . .________-__1_-
i l
-a : ?
% \ -
T h f~h' \ #
M, gi k ,*
.Q: .
? m c
3 b '
. ' 't 1
-i .Fe. ,w/bc w ~x e .
... Q c.,
, s s-
' L. ) .
m ,y~r -
g .' <r D
'f
\ f- ..!';
Q N
. b3 St 3'/ E j: q , \l j."! A 5 M ;
(('m > -[j' i
(.['
f . J.
n%
M '
( f f ,
-r -
f yffs Q c 'l*
4 ;c wps,~1ep ~f-
.a r )y ..x ,
w ,.
ai. o
- , ~ s.
~ ^ '
f _
, k t
Figure 11. Montage of Scanning Electron Micrographs :
Showing the' Appearance of the Crack Surface of the Major Crack.
i r
i i
i s
I I %
'\
l l
[ : - *g Tw l l y P- .. . . , c ;V c , *
.4 ?
,I y A: %4 5 g%es:_
s 1. 'c.' '
I"4 '
' g. c s-c-: xe - -
- . t '- '
.r f -
gg- '
, _ f(_. 7 o y p r :. ~ - , .
s...
y (,-
- 3. -
, _ '-.}g ,'gfd,
. * *%&': w' ;
!r k' ' ? .. 55 ') . 5 .'
g
% ' ;_- j l 3 ' .
.',s .: s, qs x -)/ g; ?q; .
t
'1bp:[ ' .~. . .
Figure 12. Scanning Electron Micrograph Showing a Ductile Tear Ridge Extending from 0.D. to I.D. Surface. ,
(Neg. #68034, 60X)
- -w-**----w-e y- -em, e , -w w wen._ .--m-.__._m_ . . ,
l l
\
\
e-
, . M' ,, .
l Figure 13. Scanning Electron Micrograpos Showing Part of the Ductile Tear Ridge Shown in Figure 12.
(Neg. #68033, 200X)
)
v 4, $
t k.,, '
s rs v s .
' u , ( %[, -
- s j
'f
'73 ,\ . ?,
s
. s ,~
s t s- b
) fe ,- 4
- iT c 3 A ,- -
.s I th ..
1
+ 1, s. , -+t. .a..
. x _ _, ~ y f' l* *_ 'd
_g-g i .- .
G ) - '
_) xsg l
, ,f . ,
' 'q ' kQiy
.w
, e.- .
ws ' -y' , .
~
1
! Figure 14. A Ductile Tear Area Surrounded on Both Sides by Areas of Intergranular Cracking, Including Some Secondary Cracking.
(Neg. #68043, 150X) l l
I I
l l
. :::: i l
l
\
-s . ,_ , p. .
1 ct N
, ,(
7 q g *,
. r, g l
~g u(
- ;~
A .. .-
5 4
m yp , .. y h ,
[ j
.b
&g
' ^ 3 \
, s L c,s - .; -,
> c g
- q. \. m >
7 p.
s l
/ J!F
. (3 gA c '
Q. X&,
(
c.: t L
=_g
?! .
. I cp , 'r
- ', , * .T
- . ~*
bj_}f m r
/. ' )
y- - -
- e. ,.~ -
i i
Figure 15. High Magnification View of an Area of the Major Crack Surface Showing Intergranular Nature of the Crack. .
(Neg. #68046, 500X) l '
l' :
- i
\, . .- 1 i
l l
l i
i i .
i l
.~:-g .
.. .w n ..
.+
~
T' y$
" ) yl5, '
' .b
, i, _?
'- c
,..k'.t ;
J).y.;t
$ j,. . .
7 '
af _ ' 4 ,i
.y .
$,fQ)* t'- k,f' .
p- !. ',' l
~. .
fe ,\ '
e.)
l
- s. tv ,
' , k ', f.
~h * . / ), 'g , j
. , / .' ',
' I
' ft: . / c4 , . , c I
/f' g
- s I;' * '..' ,
.. r e .
l l
I Figure 16. Scanning Electron Micrograph of Another Area of the Major Crack Showing Intergranular Cracking from 0.0. to I.D.
Surfaces.
(Neg. #68049, 70X)
~) I I
4 l
i l
/
l 1
s l
i
), (a) (Neg. #68031, As-Polished, 50X)
I
} ;
s.,.
t i
i I
(b) (Neg. #68029, As-Polished, 200X)
I i
Figure 17. Transverse View of Individual Cracks in the Smaller Area of Cracking. !
l .
= 4 w :::E .
i i -
I ee i
l _
- \ l
! (c) Higher Magnification View of the Deposit Crack in i
Figure 17a.
i (Neg. #68028, As-Polished, 500X)
T i
l 1
.s o . l /
t l ,
4 4 l
3 -
! 6
. . / .
2.- .c JN . ,
.j- ..
t I s i e 1 ,
} .
i
! -l l
l (b) High Magnification View of the Small Crack in i Figure 17a.
(Neg. #68030, As-Polished, 500X) l Figure 17. Transverse View of Individual Cracks in the Smaller Area of Cracking (continued).
- (
f
1
(
- l s 1 1 s * * )
t
.s._ . g :- .
- e. ,
n.1 ' : i
{
_fhh? s 1
i - :. .- '
j E. .. .
' #s. :: . .
4:E:... -
\
-94.p '
lRf&: .~ Q 1
=-:
1
! (c) Overall View j
(Neg. #68036, 60X) i I
< x . ...:. # '
i .-i;::2 'y '
.uc
[:'} [.Ek,". - '
k J 3 2;
.s .
l
- A s~-
j (~ ,j ,. .,. 4 .
l
,s: '
i
.. ' ' .- r
,. . s' t , ,-y I . .[
i e;. -
~. .
\
?/-
) .y ,Th, .- , , -
j {
.- .? ~ 5 l
i '
(; W .
i (b) Close-Up of Area Indicated (Neg. #68037, 100X) 1
' Figure 18. Scanning Electron Micrographs of the Spe'cimen Shown in '
j Figure 18.
1
t 9
~
g' ~> {
w l _
y& ,-
_sy ;
m
's
- . 1 i
e '
- x _r-
[Y N ~
4 l
. s.
d .
29-Mau-1984 11: 46:36 -WARfiING- .
Vert.
Preset = 200 secs 500 counts Disp = 1 Elapsed =
.: . : :.. 200 secs i
i001-008:
l fuI1.;lar e a.
Ic e :. Uiti tire
- "n':-
.n
- .:: 1.,
. . . . s ,.-
. 1, :. .
\
- J/v 4
- : ,:.. .). . .. .,,
_ ,.;;.i ' %~ .vn.w .
Range.
4- 0.000 20.460 kev 20.220 -) l i Inte9ral 0 =
39730 '
Figure 19. Scanning Electron Micrograph of Crack Tips and EDS Analysis Results from the Area Shown.
(Neg. #67771, 260X)
FW"M'*QWNWPM-- ._,wwww-
_. ,;, . _, .w. . .
,. ..;, q,%.
4.- n
~-
i
%. . l:-.
~n
@ z..i,. ,.
.?.
- 1.. g i
} Yby *.$. WE- ,
~
T!!d.; . .. . .*
%~
-+ '
.,, ,4 l
b.v U. ~!
\ .
~
- a.
(
.#*v',=,., :. .
l 2.
t l
29-11a u -1984 12:33:21 -WARitING-i Preset. Off vert. 500 counts Disp = 1 Elapsed.
- 3
- . 200 secs
. : s; -
f
, jh! ~001-009- '
i
- .. . idot 1 I
.i: -
- !3
- 7 : . .. .
<. c r i
- 7 ;if e: .'< n n l
- i . w==
!.4;!
ils a !
. .. ; i . . i. . .
p.
- s : -
t i.b,$r'*h.*.**; '_,,* * . i l, ' '
7 ..
p*y l O;!' ,
'&! .M*=vwmys
(- 0.000 _. -_
Range. ;
20.460 Lev
[, 20.220 ->
Integral 2 55 0 l__., 1 Figure 20. Scanning Electron Micrograph of Crack Tips and EDS Analysis Results from the Area Shown.
(Neg. #67772, 1500X)
-- --=--w- ---
wew-ee m=== ww_ _ _ ----%9"--'*--
l
+
.r t*
i l
Wi l -:.r.
\
\
i s:
t l
29-May-1984 00:02: 44 LN Sensor -
l l
Preset = 100 secs Vert = 2000 counts Disp. 1 Elapsed =
l
- =.: 100 secs
- .i! _
l l ?005-003'i
'. d o t . 1
, :fiei l.
,I
!9
~
- } cr
.i' +
ng.
D
- yf - [ e* . ,__- **
' (-
i 0.000 Range = 20.460 Lev 20.220 -)
Integral 0 -
41665 !
l
'1 i
Figure 21. Scanning Electron Micrograph of Crack Tips and EDS Analysis Results from the Area Shown.
(Neg. #67769, 1000X) i I
I w e---ww m v m .--ew-rm
29-May-1984 00:11:07 LN, Sensor
- Preset. 100 secs Vert = 1000 counts Disp. 1 Elapsed. 100 secs 001-003l dot!2:
i:n ;
Tii
'. h. '
j :ic e.i !?.Cu:
jfe!
- ! : [*S:
llt i i !!.mi! ;:: .!!c u i
- *E '
- .:::.a ::
. ::,e.:: . : . .' : : , t::. ..
- . s
- N %' $$ (* .b , , , _. _ _ _
(- 0.000 Range = 20.460 kev 20.220 -)
Integral 0 =
26125 28-M49-1984 23: 46: 43 -WARNING-Preset = Off Vert- 500 counts Disp = 1 El psed. 120 ses;
(
i!001-002*?
- n { ~
!!aii
- s::
l
- Cr.
! :e~
Es a .Ca : fe
,,N- ;g ; . E . 5,. . . .
l l .. J
!!* /.%,va * ,.,i
' '*:... .'c
,. ' " *. ~ Q : ' ~ _ -- --
i 4- 0.000 Range = 20.460 kev
_n 20.220 -)
Integral 2 =
0 Figure 21. Scanning Electron Micrograph of Crack Tips and EDS Analysis Results from the Area Shown (continued).
4
=
"~ anyc_. < w m ,ee . , - ' . ~ :o, e -
.a rpy .,
l_ ..
1
-st,-, , , 9 1 '
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105189 Figure 22. Scanning Electron Micrograph of a Crack Tip and EDS Analysis Results from the Area 3hown.
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