ML20115A417

Evaluation of Isolation Condenser Cracks at Oyster Creek Unit 1

ML20115A417
Person / Time
Site:	Oyster Creek
Issue date:	01/11/1985
From:	Czajkowski C BROOKHAVEN NATIONAL LABORATORY
To:	Danni Smith NRC
Shared Package
ML20115A421	List: ML20115A417
References
CON-FIN-A-3763 NUDOCS 8501170121
Download: ML20115A417 (52)

Text

Enclosure

( t BROOKliAVEN NAllONAL LABORATORY ASSOCIATED UNIVERSITIES, INC.

Upton. Long Is!and. New York .11073 (516) 282-Deportment o' Nue eor Energy FTS 666g420

- January 11, 1985 Mr. D. Smith U. S. Nuclear Regulatory Commission -

Mail Stop P-328 Washington, DC 20555

Dear Dave:

Enclosed please find a letter report entitled, " Evaluation of the Isolation Condenser Cracks at Oyster Creek Unit No. 1." _

This work was accomplished under FIN A-3763.

If there are any questions regarding this evaluation, please call me at the above number.

Sinc,erel ,

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• zw h CJC:ob Carl J. zaj gw Materia s TecTrnology Division ec: J. R. Weeks W. Y. Kato B. Koo O

At h ll70121 h

.t 1.0 Introduction On March 22, 1984, the Oyster Creek Unit fl facility developed a Icak in the condensate piping near weld NE-2-12 of isolation condenser NE01-A, during hydrostatic testing of the system. The reactor was in shutdown mode at the time of the incident.

Prior to the incident, the shell side of both isolation condensers (NE01-A, B) was hydrolayzed and coated to prevent corrosion. The integrity of

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the condenser tubing was verified after the coating by hydrostatic testing.

The test was performed by pressurizing the system after the steam and conden-sate piping were isolated for that particular condenser and then checking for leaks. The hydrostatic test showed no leaks on isolation condenser NE01-B.

The incident was documented on May 1, 1984 by issuance of Licensing Event' Report (LER) No. 50-219/84-005.

In order to determine the extent of cracking in the system, ultrasonic measurements were performed on the isolation condenser piping welds by both General Public Utilities (GPU) and its contractor; The Virginia Corporation of Richmond (VCR), with the following results: 27 welds were affected exhibiting approximately 50 ultrasonic testing (UT) indications.

The leakage of the condensate piping and the ultrasonic indications of extensive cracking in the isolation condenser piping system was of concern to the U.S. Nuclear Regulatory Commission (U.S. NRC) because this system (specifi-cally the condensate side) was considered to be nominally cool and operating below 200*F. This temperature is" the lower limit below which ICSCC would not i occur under nuclear power plant operating conditions.

A meeting was held at the Oyster Creek station in ndd-May 1984 between utility (GPU) representatives, U.S. NRC representatives and Brookhaven National l

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Laboratory (BNL) personnel in order to determine the size and types of pipe samples which would be needed in order to analyze the cracking phenomenon. At this eeeting, it was decided that General Electric (GE) would analyze the 1 caking portion of weld NE-2-12, indication 200 (condensing side) and BNL would receive the lower portion of NE-2-12, indication 201 and a sample of pipe NE-1-15 (steam side) indications 200 and 201.

Additional information [1] obtained during this visit regarding the isolation condensers follows:

a) Stagnation of the lines on the tubeside of the isolation condensers can occur during both power operation or shutdown.

b) The condensers were not drained prior to this outage nor had they ever been previously drained.

c) The temperature of the pipe near weld NE-2-12 (with no leakage through the condensate return isolation valves) is considered to have been ambient. Later evidence disclosed that these lines had seen temperatures significantly above ambient during earlier operations.

d) The condensers had been used extensively from 1969-1979-condenser "A" approximately 33 times and condenser "B" 36 times.

e) From November 1979 to present, neither "A" nor "B" condenser were used or initiated. This period covered 10 separate SCRAM events.

f) The base material was AISI 316 stainless steel.

A description of the condenser system was later provided [2] by GPU personnel.-

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"The emergency condenser system is a standby, high pressure system for renoval of fission product decay heat after reactor isolation scran when the main turbine condenser is not available as a heat sink. During reactor isola-tion the refluxing-type emergency condenser will control the pressure rise, and thus limit the loss of reactor water, and avoid overheating of the reactor fuel, which could occur through opening the reactor vessel pres'sure-relief valves. l l

l The system is operable and ready for service at all times during power l operation of the reactor.

The emergency condenser system operates by natural circulation, with steam flowing from the reactor pressure vessel through the tubes of heat exchangers, and with the condensate returning by gravity to the reactor pressure vessel, forming a closed-loop system.

The emergency condenser system consists of two loops, each with one con-denser shell containing two tube bundles. When a loop is in operation, both tube bundles are in service. Normally, both loops are placed into operation simultaneously, and either loop can be activated or shut down separately. Each loop has separate steam and condensate return valves, separate shell steam vents, and separate instrumentation and control."

This incident of pipe leakage was of concern to the US NRC because the failure implied IGSCC below 200*F at a BWR. A failure analysis. was initiated by the US NRC under contract at Brookhaven National Laboratory. The failure analysis was to consist of:

1) Visual Inspections / Photography,

2) Optical Microscopy / Meta 11ography,

3) ASTM A-262 Practice A evaluation,

4) Ferrite readings of the weld metal,

5) Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS).

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4 This re por t is a failure analysis of selected failed pipe sections based upon ultrasonic examinations performed by GPU and its contrcctor.

2.0 Visual Inspections / Photography The first specimen received at BNL was a half section of 8" Schedule 80 AISI 316 pipe which was identified as containing welds NE-2-12 and NE-2-12A.

These welds were separated by a 6" long spacer pipe (" pup piece"). There were no visible cracks or indications on the outside surface of this specimen (Figure 1). The area containing the UT indication #200 'was bracketed in paint stick on the outside surface of the specimen.

Visual examination of the inside surface of this specimen disclosed no cracks (Figure 2), h oweve r, there was a significant area of weld convexity visible on weld NE-2-12. This convexity displayed considerable cross sectional variations by the weld root which could pose interpretation problems during ultrasonic evaluations. This specimen was sectioned dry and cut perpeadicular to the two welds NE-2-12 and NE-2-12A. Four (approximately 0.375 inch) sections were made through the painted area. Visual examination of the cross sections revealed no evidence of heat aff ected -zone (HAZ) cracking. There was one area of apparent lack of fusion visible in the cross sections which will be discussed in the optical microscopy section of the report. In ' the event that the indication had been missarked on the pipe, four additional parallel cuts were made adjacent to the painted area moving circunferentially

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about the pipe in t .ie direction of the seam weld. These specimens were ap-proximately 0.500 inch in width. Visual examination of these specimens re-vealed no evidence of HAZ cracking. Although some areas of oxide were noted on the inside surface of the pipe, in general, the pipe was relatively clean.

The second specimen received and examined was a piece of 12 inch diameter Schedule 80 AISI 316 stainless steel pipe containing steam side weld NE-I-6]

(Figure 3). The pipe had a heavy oxide scale present on the inside surface.

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' 1 This scale was Ifghtly brushed with a nylon brush. A faint indication of a crnck in the weld HAZ was revealed. This specimen was sectioned dry with four equal cuts perpendicular to weld NE-1-61 for both indicaticos 200and 201 (Figure 4).

An additional pipe section containing weld NE-1-15 (steam side) was then received from CE. This pipe also had a heavy oxide scale evident on the inside surface and was sectioned through indication 200 and 201 in a similar manner to NE-1-61 (Figure 4a).

3.0 Optical Microscopy /Metallography At least one cut section removed from each crack indication was ground down and polished to a one quarter micron finish, electrochemically etched lightly in a 10% oxalic acid solution and then examined by optical microscopy.

Figure 5 is a cross-sectional view of a crack found in the weld wetal of weld NE-1-61. (indication #200). The crack's measured depth was approximately 0.220" (5.59 mm). This crack was entirely in the weld with no evidence of it starting in the base metal or HAZ. The weld crack was interdendritic and approximated the path of the deposited metal.

The next indication examined was #201 on pipe NE-1-61 (Figure 6). This crack initiated at the base metal / weld metal fusion line and followed the weld contour for approximately 0.130" (3.25 mm) before changing direction and entering the weld. The total measured length of this crack was 0.154" (3.9 mm). The crack was completely intergranular while following the weld and interdendritic (Figure 10) when it entered the weld. Closer examination of the crack (Figure 7) shows that the intergranular portion of the crack enters the weld metal slightly (1/2-1 grain deep) prior to the change of direction into the weld.

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During the evaluation of indication f201 of weld NE-1-61 a second crack was observed (Figure 8). This crack was approximately 0.364" (9.25 mm) distant (on the same side of the weld) from the crack previously examined as Figure 6.'

The crack was entirely intergranular (Figure 9) in nature and was restricted entirely to the base metal /HAZ of the pipe. This crack measured approximately 0.260" (6.6 mm).

The purely intergranular nature of the HAZ crack in indication #200 of weld NE-1-15 is shown in Figure 11. This crack initiated in the weld HAZ and

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finally terminated at the weld / base metal fusion line (Figure 15) with no indication of the crack having entered the weld. This crack ceasured 0.218" (5.54 mm) in depth.

Two cross sections were examined on indication #201 of weld NE-1-15 (Figures 12 and 13). The faces depicted on the two photomicre ;raphs are ap-proximately 0.375" apart showing that the weld crack runs at least that dis-tance. The crack initiated (1-2 grains away from the deposited weld metal) in the.HAZ. The crack ran parallel to the weld metal, keeping this distance from the weld for approximately 0.220" (5.58 mm) before entering and propagating into the weld metal. The measured crack depth ranged between .420" (10.67 mm) and 430" (10.92 m=) on the two cross sections. Further examination of this crack revealed another discontinuity in the weld. metal of NE-1-15 approximately

.150" (3.81 mm) across the weld from the crack (Figure 14). This discontinuity was very straight in appearance and looked like an area of lack of fusion in the weld metal. Its depth was approximately 0.020" (051 mm).

Figure 16 is a higher magnification photomicrograph of the crack in NE-1-15 indication b201 which shows that while the main crack ran parallel to the weld, some crack branches propagated into the weld (1/2-1 grain deep).

The only defect found during the examination of indication #200 of NE-2-12 is shown in Figure 17. The crtek oas approximately 0.20" (0.51 mm) in depth and was associated with the base metal / weld metal fusion line. The 6

discontinuity would be characterized as lack of fusion. There was a signifi-c a r.: a ount of convexity associated with t'his weld which was discerned earlier during the visual exacination of the pipe section.

4.0 ASTM A-262 Practice A Evaluation i

Intergranular corrosion is commonly defined as a local attack on the grain boundaries of a metal by a corrosive media.

In stainless steels, susceptibility to intergranu1Ar corrosion is enhanced by the sensitization process. Sensitization can be described as the formation of chromium carbide precipitates in the grain boundaries of an austenitic stainless steel and the resultant depletion of Cr, brought about by heating the steel in the temperature range 500-800*C [3, 4].

This teeperature range is achieved readily during the welding process where the normal temperature of welding exceeds 1600*C during fusion welding.

'Therefore, the welded base material could receive a sensitizing heat treatment in the critical range (500-800*C) at some point outward from the weld fusion line which would be maintained long enough to precipitate Cr carbide at the l grain boundaries. This is not to say that the welding process alone will induce a sensitization effect on the base material, as the degree of material sensitization is a cumulation of the material's prior thecmal and mechanical treatments, weld cycle history, (# passes, heat input, etc.) material chem-

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i istry, thickness and thermal conductivity, and time at temperature in the sen- '

sitization range.

In order , to measure a materials' degree of sensitization, the American Society for Testing and Materials (ASTM) has published Standard A-262,

" Standard Recommended Practices for Detecting Susceptibility to Intergranular Attack in Stainless Steels." This standard includes a rapid screening test as 4

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part of its content; Practice A - Oxalic Acid Etch Test for classification of etch structures of stainless steels. This practice is described in A-262 as:

"1.3 The oxalic acid etch test is a rapid method of identifying, by simple etching, those specimens of certain stainless steel grades which are essen-tially free of susceptibility to intergranular attack associated with Cr car-bide precipitates. These specimens udll have low corrosion rates in certain corrosion tests and therefore can be elimina t ed (screened) from testing as

" acceptable.""

For purposes of this investigation, the polished specimens were etched with a current density of IA/cm2 for 1.5 min. in a 10% oxalic acid + demin-eralized water solution. The cathode used for the etching was a piece of 304 stainless steel while the polished specimen was used as the anode. The welded cross sections were then examined on a metallograph.

The results of the etching are shown in Figures 18-23. In all cases, the structure observed had at least one grain completely ditched which would have classified the structure as sensitized. Figure 22 is an area in athe center of the 6" log " pup piece" associated with weld NE-2-12 indication /200 shows that the 6" long piece itself was sensitized.

s 5.0 Ferrite Readings of the Weld Metal l Since welds NE-1-15 (indication #201) and NE-1-61 (indication #200 and

1. 201) had cracks either initiating in or propagating into the weld; ferrite measurements were performed on the welded samples. The requirement for ferrite control and content in austenitic stainless steel welds has been documented in at least two Regulatory Guides [5, 6] and is considered a first order defense against microfissuring and SCC prevention in the deposited weld metal. Addi-tionally [7] at least one literature reference considers the role of delta-(

ferrite quite important in reducing the susceptibility of austenitic materials to intergranular cracking.

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The instrument used to nake the ferrite readings on the specimens was a Ferritescope. The ferritescope operation (according to i ts manufacturer)

"...is based on a magneto-induction principle, whereby the relative permea-bility of the specimen (which bears a known relationship to its ferrite content) is measured.

When the probe is placed on the material to be tested, a closed magnetic circuit is formed and excited by a low-frequency magneto-motive force. The resultant field induces a voltage in a pick-up coil (located in the probe), the magnitude of which is a measure of the relative perme' ability and hence the ferrite content of pick-up coil is amplified in a meter unit and the resultant amplitude indicated on a meter which is calibrated in either % Fe or WRC ferrite figures.

The configuration of the alternating field in the material is governed primarily by the construction of the probe, this being designed so as to minimize any field attentuation due to eddy currents and thus eliminate the effect of material conductivity from the measurement..."

The instrument was recalibrated after each specimen was set in order to assure accurate readings. Measurements were taken on both sides of the weld crown parallel to the pipe's outside surface, as well as one measurement per-pendicular to the pipes outside surface. These measurements were performed on the polished and etched specimen cross sections in order to obtain representa-tive readings of the "as deposited" metal. The results of this testing are shown in Table #1. There was a wide variance of ferrite content between welds with the lowest readings found associated with NE-1-61 (indication #201).

This weld had its cracks located solely in the weld metal deposit.

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TABLE 1 Ferrite Readings of Oyster Creek Pipe 11 elds l

Pe]d No. Indication ~ Ferrite %

NE-2-12 #200_(two sets of readings) 5.4/5.0 5.5/4.4 3.4/3.6 NE-2-12A 5.9 4.7 4.8 NE-1-61 #200 (two sets of readings) 2.6/1.6 1.4/2.5 1.8/2.0 NE-1-61 #201 (two sets of readings) 1.4/1.6 1.3/1.4 1.4/1.4 NE-1-15 #200 11.0 10.5 6.75 NE-1-15 #201 (two sets of readings) 9.3/7.9 6.7/9.4 5.1/5.6 4

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6.0 SEM/EDS A total of five fracture f aces were examined by SEM/EDS for determination of fracture code and possible detection of detrimental contaminants. The first specimen examined was f rom indication #201 of weld NE-2-12. This specimen was sent to BNL by CE when it became apparent that indication #200 did not yield an intergranular crack for evaluation. The crack was opened for evaluation by dry cutting a counternotch below the crack, immersing the cpecimen in liquid nitro-gen and then imposing a bending moment to the notch in order to open the

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crack. This technique was typical of that performed on the other fracture faces.

The fracture face of indication #201 of NE-2-12 is shown in Figure 24.

The fracture face was predominantly intergranular with no visible indication of fatigue interaction. A total of six EDS scans were taken on the fracture sur-face (Figures 25-30). The approximate locations of the scans are depicted on Figure 24. All of the scans showed peaks of chromium (Cr), iron (Fe) and nickel (Ni) ..which would be characteristic of a 300 series stainless steel.

Molybdenum (Mo) appeared on one scan (Figure 25a) which is an alloying addition to the stainless steel. There were traces of silicon (Si) on five of the six scans and sulfur (S) indications on four of the scans with a relatively high peak appearing in area #6 (Figure 30s). The fracture face was covered by a light powd er-like oxide (Figure 28 is typical) which is similar to that found in relatively low operating temperature environments.

The next fracture face examined was a section of indication #200 of weld NE-1-15 (Figure 31). The fracture was predominantly intergranular. Repre-sentative EDS scans were taken on the fracture face in the approximate area of the circles on the photograph. The areas scanned (Figures 32-34) were covered by a thick crystalline adherent oxide film. This type of oxide is the type one 11

t would expect of higher temperature service. The three areas examined all exhibited characteristic Cr, Fe and Ni peaks with only area 3 (Figure 34 and 34a) having an oxide which exhibited a S peak.

The third fracture examined was associated with indication #201 of weld NE-1-15 (Figure 35). This f racture was intergranular and also was covered by a tightly adherent crystalline oxide. Four EDS scans were performed on the fracture surface (Figures 36-39). Three of these scans (Figures 36, 38, 39) detected sulfur while two of the scans showed silicon present (Figures 37, 39) and one scan (Figure 36) had traces of magnesium and cal'cium in evidence. l Indication #200 of NE-1-61 was the next specimen evaluated. The crack was entirely in the weld metal and did not have any intergranular characteristics when viewed at low magnification (Figure 40). Higher magnification examination (FiFures 41-43) revealed that the fracture face was covered by a crystalline adherent oxide very sicllar to that observed on the other steam side indica-tions. Two of the three scans (Figures 41a and 42a) had silicon traces associ-ated with thee, while the #2 area scan had a trace of titanium present. These trace amounts were in addition to the Cr, Fe and Ni present in all scans.

After EDS examination, the specimen received a deoxidizing treatment in order to remove the oxide adhering to the fracture face. This procedure is described below. A working solution of Endox-214 is prepared by adding 8 l ounces of Endox-214 powder to 1000 ml of cold water and stirring until it is completely dissolved. A small amount of Photoflow is added to the solution to aid the wetting of the specimen and eliminate some of the featuring during the electrochemical cleaning step. A glass beaker with 500 ml of the Endox-214 solution is placed in an ultrasonic cleaner. The specimen is made the cathode, and a platinum wire loop is the anode. A current density of approximately 250 mA/cm2 is applied for 15 seconds. Remove the specimen from the electrolyte e

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1 and ultrasonically wash it in a detergent solution consisting of A]conox and Photoflow for one minute, then rinse fn clean water, dip in methanol and dry in hot ai r. The above procedure conprises one cycle. It may be necessary to repeat the above cycle several times before removing all the corrosion products. It is not possible to predetermine the exact number of cleaning cycles for any given specimen, since it depends upon the severity of the oxidation, roughness of surface, and the physical size of the sample. Observe the specimen optically after each cycle so that the process can be discontinued after the oxide or the corrosion product is removed and the specimen surface looks clean. After the speciraen is thoroughly dry, examine it imediately or store in a desiccator. The resultant fracture face (after the treatment) is shown in Figure 44. The cracking is interdendritic in nature very similar to interdendritic hot cracks found in weld deposits.

The last fracture examined was from indication #201 of weld NE-1-61.

This fracture was predominantly intergranular (Figure 45). The fracture had a significantly smaller amount of oxide covering the surface. The oxide which was present appeared to be of a lesser thickness than the other steam side specimens examined. Four EDS scans were performed on this fracture (Figures46-49a). The scans of areas 1 and 3 had only Cr, Fe and Ni peaks associated with them, while areas 2 and 4 both had a copper (Cu) peak in evidence. The area 2 scen additionally had Al and Si in the scan and the area 4 scan had a trace of selfur present.

The deoxidizing treatment was also given to indications #200 and #201 of NE-1-15 and #201 of NE-1-61. Figures 50-52 are SEM photos of the deoxidized fractures. It is clear that they are intergranular in nature.

7.b Discussion In order for intergranular stress corrosion cracking (IGSCC) to occur, three key conditions must be present. These three conditions are:

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a) a susceptible microstructure b) a corrosive environment c) tensile stress (applied or residual).

In the case of austenitic stainless steels, the susceptible microstructure is termed " sensitized." This condition (as previously described) is easily obtained during the welding process of these steels.

The second condition needed to cause ICSCC is a corrosive environment. In light water reactors (LWRs), the corrosive species re'sponsible for the most instances of IGSCC has been oxygen. These instances have been well documented

[6, 9] and will not be discussed in this report. Although normally indicted for higher temperature IGSCC of the austenitic steels, low temperature cracking has been observed. This paper [10] recorded laboratory produced IGSCC in sen-sitized 304 stainless steel at temperatures as low as 50*C (with some cracking at room temperature) with oxygen levels of 2 ppm present. This level of oxygen can be obtained quite easily in stagnant lines as the oxygen content of air saturated water can be 5-8 ppm 02 depending upon temperature. .

Sulfur and its various compounds have been 1nvolved in IGSCC of Type 304 stainless steel [11, 12]. IGSCC of Type 304 has occurred at ambient tempera-tures (during constant extension rate tests) with as low a concentration as 10-5M Na2 S02 3 [13]. Although, thiosulfate contamination is discounted (for these failures), the deleterious effects of even minute amounts of sulfur com-pounds on sensitized stainless steel cannot be underestimated.

The third condition required to induce IGSCC is tensile stress. For this instance of cracking, the stresses were probably the residual tensile stresses induced by welding. Various instances have been cited [14] of residual ten-sile stresses in Type 304 stainless steel heat affected zones of higher than 40 ksi. The direction and amount of tensile stresses developed in piping seem to be closely related to the pipe's diameter. Chrenko [15] has postulated that 14

the inner cross sections of smaller diameter pipes provide a less efficient heat sink and a more flexible surface during welding. The heat t ransf erred by welding is then distributed over a larger area with an increased weld shrinkage area resulting in larger axial stresses.

The welding process itself has a most significant effect on the sensitiza-tion process and the subsequent susceptibility of stainless steels to IGSCC.

k'ork by Solomon [16] showed that for .05 to .08 w/o C, 304 stainless steel that the critical cooling rate for sensitization is about 5-10*C/S and that for 0.35 in plate thickness and a 30,000 V in-I heat input a cooling rate of 10*C Sec-I can be obtained which would be in the sensitizing range of the material. The measured carbon content of the 8** pipe by CE [17] was 0.046% and the 12** pipe was 0.060% which accounts for the sensitized structures observed.

As previously mentioned, the resistance of an austenitic stainless steel to IGSCC increases with an increase in ferrite content of the material. Ad-ditionally a ferrite level of at least 3FN will effectively eliminate hot cracking (fissuring) in E316 and E316L weld metal [18]. In either instance, a critical minicum of ferrite must be present in order to assure a sound, trouble free weld.

8.0 Conclusions

1. The cracking associated with condensing side weld NE-2-12 indication #201

( was intergranular. The crack associated with the steam supply side weld NE-1-15 indication #200 was also entirely intergranular. Intergranular cracking was the failure mode of a second crack associated with NE-1-61, indication #201. The fracture faces and photomicrographs of the above referenced cracks were typical of IGSCC previously seen on Ek'Rs.

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2. The crack identified as weld NE-1-15 indication #201 initiated in the HAZ of the weld and progressed intergranularly into the weld metal. A similar type crack was identified on NE-1-01 indication f201. Delta ferrite' measurements were quite low on NE-1-61 indication #201 (less than 1.5%

average). Although delta ferrite readings were quite good on NE-1-15 indication #201 (7.3% average) the readings did show a range of ferrite content 5%-9.4 % through the weld cross section, implying non-uniform distribution in the. weld.

3. An interdendritic crack entirely in the weld metal'was identified in weld NE-1-61 indication #200. The weld deposit for this weld had an average of only 2% delta ferrite (in 6 readings). This low level of ferrite would make this weld susceptible to IGSCC.

4 ASTM A262 Practice A technique showed that the heat affected zones in the base material of all the welds examined were sensitized,

5. EDS examination of indication #201 of NE-2-12 did show the presence of some sulfur. This does establish the possibility that contamination may

, have contributed to the cracking.- This is not conclusive, however, as no definitive corredent was identified.

6. The heasy oxide coating on some of the cracks did indicate that they had been exposed to the environment for a long period of time. The relatively l

l clean fracture on NE-1-61 indication #201 does suggest that this crack may have been of later origin than the heavily oxidized cracks.

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7. A cc: pari son of crack depths measured ultrasonically (by GPU and its centractor VCR) versus crack depths measured photomicroscopically show a The most striking (see Table 2).

marked dif ference in some of the values difference is that displayed by N E-2-12 indication #200-measured .020" 480"/.375 when measured oltra-

.(by destructive examination) versus senically.

This does tend to dilute confidence in these techniques.

TABLE 2 ,,,

Measured Crack Depth vs. Ultrasonic Measurement CPU VCR Measured Depth L' eld Indication Measured Measured No.

480" .375" 200 . 020" NE-2-12

- .250" 200 . 218" .155" NE-1-15 .420/.430"  :.508" 201

"# .560" .150" 200~

. 220" .220" NE-1-61 .260" (.154")

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D 9.0 -References

1. GPU Memorandum dated April 17, 1984 from Abramovici to Giacobbe.

2. Telex D. 'Covill to C. Czajkowski 10/84

3. Pande, C. S., Suenaga, M., Vyas, B., Isaacs, H. S., and Hailing, D. F.,

Scripta Metallurgica, Vol. 11, 1977, pg. 681.

4 Cowan, R. L. and Tedmon, C. S., Jr., Advances in Corrosion Science and Technology,-Vol. 3, 1973, pg. 293.

Regulatory Guide 1.44, May 1973.

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5.

16 . Regulatory Guide .31, Rev. 3, April 1978.

7. Devine, T. M., J. Electrochem. Soc. , Vol.126, March 1979, pg. 374-385.

8. NUREG-0531, US NRC, February 1979.

9. NUREG-75/067, US NRC Pipe Crack Study Group, October 1975.

10. Andresen, P. L., Ford,- P., Proceedings: Seminar on Countermeasures for Pipe Cracking in BWR's, EPRI, Vol. 1, Workshop Report, May 1980, Paper No. 7. ,

11. Newman, R. C., Sieradzki, K., Corrosion Science, Vol. 23, No. 4, pp. 363-378.

12. Newman, R. C., Sieradzki, K., Isaacs, H. S., Met. Trans A, Vol. 13A, November 1982.

13. Sieradzki, K. , Isaacs, H. S. , Newman, R. C. , Paper No. 224, NACE 1983.

14. Fox, M., Proceedings: Seminar on Countermeasures for Pipe Cracking in BWR's, EPRI, Vol. 1, Workshop Report, May 1980, Paper No 1.

' 15. Chrenko, M., Proceedings: Seminar on Countermeasures for Pipe Cracking in BWR's, EPRI, Vol. 2, Workshop Report, May 1980, Paper No. 21.

16. Solomon, H. D.', Proceedings: Seminar on Countermeasures for Pipe Cracking b in BWR's, EPRI, Vol. 2, Workshop Report, May 1980, Paper No. 24.

, 17. Could, G. C., Memo Report CI-1108, GE Turbine Technology Laboratory, June 20, 1984.

18. Welding Handbook, Vol. 4, Seventh Edition.

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c- -.4. l u i , I . I i 0 l - l Figure 4a Layout of indications f200 and 201 on weld NE-1-15. (Not to scale). 22 PIPE INSIDE SURFACE 'F -f' 14 . .  ;;*.fac..;47.~;;,: .T -.,f, ,- . o . < T A ' *1. - m,2..-- %/.. r.'~.!. p,. = . ' ' ' ' a . c- . . . j, " 'i ' . ' fI. ' . . j .f. , ~~ , i - '[i WELD . :' )-h'.,, Y ( . ]k *"""'hr 61 1 ek found in weld indica ion (200 mear METAL , . ' f(.U:9 -;.i.l;. . '- , . ' k. . . D. .~. "'*d ""

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L' I... . e -m y _w- .... _ .u : . ., L _ . t ,. l t ~... .. . . - . . [ . l ' s "' Figure 8 Photomicrograph of the second crack found ' ~ - 0.364" away from the crack in Figure 6. . -l {, ._ ~~ This crack appeared to be entirely inter- ~ ! F '8t granular in nature and entirely in the 1 -n ' /' '. . . c % f. base material /HAZ. (Measured crack M- . depth =.260").

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' i 'J ( , , (m' *9 . 1200X b \ BASE METAL . . , . 200X Figure 15 Iligh magnification photo showing Figure 16 liigher magnification photo of the crack terminating at weld #201 of NE-1-15 showing a 1/2 fusion line on #200 of NE-1-15. to I grain penetration into O the weld metal. .e'd ~ ~G3- ,@ j 4 ,.,, . ~ . ., {( ,. . ,e .. .,. ... < , h, , p Nt '.' A. ' f ,. '? ?f;,  : 'A y_ q .uye,eg gQ ~ $ q, :. s..a w M < g y<~ y. s< _.; t AL L2 $* $1'b"f'w,R,,.g - 4? p,4 N?lh 'g %-.f * ' ,. g.f .n['b'Q . e ? - - Nf Figure 17 MN Photomicrograph of crack (.020" C ) Sox depth) an indication #200 of NE-2-12. 6 r- )lc ; .h .r>- v -., , ,-. c, f r:- s f y', %yd r,-- - , . y r.. e , s , f \.1 , .y m(ie..'.1" u (.'r> 1 f.r-.g.- y 1 't .). .. ..\a b, . ,~).. -- N.W k.k .ip. .W ' q % .' ~jy* . . J , ,('. .Qr 7 ." % -.7,;. f :_ N,q_ 'Z: ~ \ q1 o; - V -)MOA h, : a _ -l' - W: s- k . ..:. QQ~ t., 1 . . , - - - ,Q. s ,. . .. g x. lf d . '/ ** - , . t' . o *--1' /. *

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1. 200, weld NE-1-15 after ASTM #201, weld NE-1-15 after ASTM A262 Practice A. A262 Practice A.

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1. 200, weld NE-1-61 after ASTM

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1. 201, weld NE-1-15 after ASTM center of 6" long " pup piece" A262 Practice A. (NE-2-12, #200) after ASTM A262 w Practice A.

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1. 201 of NE-2-12.

w C. pu . 7 t . - _ , e ,. y - ( .r 9. ) , v . . %,a;M,,. .g* ..yr . r? T. . y ;f ,,. 9 n. p. p ,.e..q.. s . c,- ,..r. - .. . r . y o g -;' 'q %,,. ? . .! . . R.~k. ,,./.# , ~wW:n r w, V-s . :, ,N' ffi.h. . w - .,:1 k.,A..k.h\k;. f{', ..lf:& G l.\,' dT..d. L ~ a.! . j. -Q -r ,. s r.::gb,r, .f w '. - r p i. $.f. . a.<,> e. - - - e .!,1. .?ql{I'!l. f.w. 'i.'f}{;f.

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1. 201 of NE-2-12.

m . M f t , . /1 ; L,. . fJ .g 7. % . J --- - m v- ~

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v. J

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1. 201 of NE-2-12.

() N a= 6 ' .

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1. 201 of NE-2-12. Note the powder-like oxide.

, O '*5 0. .$.*.~'.\.Y.~, , T, - .@. 1 U,,' - f.U -;.?. : '9MM.  :.Mf. &.5y. iL, r .r,..a ,- ,:q ' f;.) , . (a a, Ns.s. ,= s . . .. J., fe.:y<* ; )a )#;.4 .. . s s. , r s.j .-.../,/ -' , ' . 4 . .s . 4 .. . . . ,; -I* 4 < ,* ' { = 'g t ,t ,.*,'p .*/ . /7; y . ,(g g .;,'l. /. .- .  :: , 1 P f. f' hf.. ,.,L . . -l , , 's? l , Y ) @. , N, . N'.%.. . ,' -.4 ,, . ..v .. . * .k.h* . ...', .:..., .'!(.. i.k<s.g@J a '. ,L*.:

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li ,, , , - v r .-( ,.. .s. . . ,.. t .. ,.1< .n.v . E: 4.. ) . . , .'. .. L v v . < hsD ^ N'.15 ; .,$pdg;k.. . I' D ' . . ' ' - u w_ d ,d M." _- . t '- f./ ,, .g @ Glasop Q G, $;i tfa' to i e o. c . 1. > . e .a.r.y*.'*c f - .,- '. . I ./ ..T. ,4 i . . e. . u . , , - - ^^ "" l .r-4,Wo " . f. - ' ' .. 3'//Yl3650X " - ~ - ~ Figure 29a EDS scan of Area 5 for contaminants. Figure 29 SEtt photo of Area 5 of indication

1. 201 of NE-2-12.

i.a co p;.. . i p < m. -- -%r- - - q, ;s g.sy - ~ Ni.  % '.. .~.s. 3.: ! , (' ? [* 's' e- - /.4*S,,,.'*;V. ,;,r..) 7 ,,.! ' h' .,J ,, ',s

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Figure 30 SEM photo of Area 6 of indication Figure 30a EDS' analysis of Area 6 for constituents.

1. 201 of NE-2-12.

4 m ' /.,. ), } ,r' , - . 1 . . . - ~ . . .. , s; - I . . .q e . l,.= - . , , .s , \. \ . .,.i , ,. s .g-3 . 1 .. , . . . { im m 3*' ' .- r' -s .:'I4$ . p (t.

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+ j. . . . ~ ... _s . p..-. . . ,.!c y ..a in. ; .,: . e 'y=-.g. . r  :. . . ... .- . . ,b. . . >, s.. n r .r.... c ... . . .. ,. . - t. ,. _-. .,e ,v . + . ...n..... w, y.. -. .:.. ,.. w.) , . . . c. . g . 20X .. i 7, s ,. t ,t . ,. 3. . . .l. ..v.. . . .. . - ', s v. ..- ,, +. 4 . w. ' r 32% x:- _ !- \ . 9m y 4 _a : l Figure 31 The intergranular cracking is readily evident on this fractograph l of indication #200 of NE-1-15. The circled areas are approviente t locations of the EDS scans. i l l 39 ,g.o ,,

3. w ---- ,..g., r.- -- -

i .g e P. 2 ;, ., - g j Ig ';} .. - *f # -t a

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= +. t q< n ,e,s . c . ,- m., n, . , ) s ~ .-. _-_._ mg. %. t . ., ,- , q;.' ,?. . v, ' 1 ; , 1'% ' .Y .' - g~s ~

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.( * / . b,; . f .$, . 2400X ~ ~ " - - - ~ ~ " - - Figure 32 High magnification fractograph of Area 1 Figure 32a EDS scan of Area 1 for constituents. 3 of indication #200 of NE-2-15. o . .p.v $,- 5 - g., . . , , w -;m..y , 1 . .. , a .

s. . .. . - . ... , r >

INN,.c .,.c. ,N'# Q. ,,p;/ .V,- g,Cpe,m. .d2tN [n..24.M j','y[b.@E, ys.hyh,5, yM.,..,- 4, n  !. y. - ' .s 7. . f .. A. .a., . hh;

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8 ?lG .'.[ .:. .'.:]f':?;1'in . - ' +,' 0.'.'h '& .*,, f. '. f y z , ' 'G: .' tp g..t.;e(..,,(.qj+'j,,;,p...,. .., .i,. . - . . , :.. . : . . 9, . ., .*,, .. s ,. p. 9, - s .. .. / s..j 7g s .'- - ^ . . '1 .. , b' *.it g rd .,1: . .se.1 * . ,", # , ~'. 7w. -h .7.. S.. 2. ' ' l ., .; ,.,',.- -8 o l' =7 * -. .n? ., A,3;. m.. . .. .i.g *3 f ;.. '.j. g, .%,3; ',:, iy@: . . .- f . ) t, . ,,..* I .j' L @ @. -  : i

• c.,; y, b;,. :. .: .% u... Z,;s. u - w m uu-r w v. ..e w s +

' }. *,# O  ?.I)pc . , f,$'ff- Uf* ' 7i *yr's:. Y. w.9,s . ;: ,c,f. 3 . a . . * ~.:*lcf.[ ' @ @ O OO OUO L* *N 9 . t -. * 't * . i *. , . y 8- ' .: i.s.* rg, - .- L - -- .. ... . a . Mi.w.g"f.2. . . .e .J Wm< fc u .IL .h. .-  %,,800X Figure 33 SEM photo of Arca 2 of indication. Figure 33a EDS scan of Area 2 for constituents.

1. 200 of NE-2-15.

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1. 201 of NE-1-15.

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1. 201 of NE-t-15.

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1. 201 of NE-1-15.

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1. 200 of NE-1-61.

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1. 200 of NE-1-61.

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1. 201 of NE-1-61.

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1. 201 of NE-1-61.

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1. 201 of NE-1-61.

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~ r3E-1-15 after deoxidizing treatment. NE-1-15 after deoxidizing treatm<nt. .y-- I . ,j . 4

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