ML20126G634

Assessment of Ultrasonic Reflectors in Sequoyah Unit 2 Reactor Vessel Nozzle Bores

ML20126G634
Person / Time
Site:	Sequoyah
Issue date:	10/02/1980
From:	Adamonis D, Kishel R, Mager T WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP.
To:
Shared Package
ML073521267	List: ML20126G634
References
NUDOCS 8103270784
Download: ML20126G634 (66)

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ENCLOSURE 3 I

ASSESSMEilT' 0F ULTRASONIC' f

REFLECTOR 5 'lil TIIE SEQUOYAH

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UNIT 11' REACTOR.-

l VESSEL N0ZZLE BORES Y

R. D. Richel '

O. C. Adamonis t

October 2, 1980

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APPROVED:

v T. R. tiagar,Ibnager Meth11urgicci and NCE Anelysis L

Work Perfomed Under shop Order No. UEttM 6000 T

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WESTitiGHOUSE ELECTRIC CORPORATION STRATEGIC CPERATIONS DIVIS10:1 P. O. BOX.855 l

15230 PITTSBURGH, PEllNSYLVANIA

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ASSESSMENT OF ULTRASONIC REFLECTORS IN THE SEQUOYAH UNIT II REACTOR-VESSEL.

N0ZZLE BORES

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INTRODUCTION _

During ultrasonic examinations of the Sequoyah Unit 1 Reflectors in six of the nozzles display all the por the test procedure.

Those in the seventh nozzle ha',e the characteristics of reheat cracking.

small lengths but do not fall into the bands commonly associated with the.

Finally, the last nozzle contains only one reheat cracking phenomenon.

small reflectnr.

A revicw of the clad overlay procedures indicates that all eight SA-508, Class nozzles were clad with one layer of 60 mm strip and stress relieved at 1100*

to reheat Therefore it is concluded that all nozzles are susceptible The cladding procedures preclude theoccurrence of cold cracking.

- 117 5* F.

cracking.

All recorded reflectors have been evaluated per the preserv This report describes the reheat cracking phenomenon, documents the ultrasoni test results, and provides ASME XI analyses of the recorded reflectons.

REHEAT CRACKING VERSUS COLD CRACX1NG - METALLURGICAL CH Reheat cracking, typical of that detected in the Sequoyah Unit II reactor vessel nozzles, was the subject of an exhaustive international res between 1970 and 1974.

The and agreed upon by the metallurgical and welding communitie J

1. 197, dated August 1974. These results were implemented by Regulatory j

Guide 1.43.

Reheat cracking typically occurs in a region of the coarse grained base material structure resulting from a first weld bead which is subsequently reheated to

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a temperature in the range 1000* to 1300*F when a second bead is applied adjacen During the post weld heat treatment, this reheated coarse grained region at the beni o',erlay area undergoes creep at the grain boundaries to the first.

SA-508, Class 2 resulting in small intergranular separations (rcheat cracking).Thus, reheat cracking is material is especially susceptible to this condition.

characterized as multiple cracking, essentially rows of grain boundary separations, located in the base material at the overlap of clad weld beads and restricted in depth to the grain coarsened region of the HAZ beneath the weld bead overlaps.

(References The maximum depth of cracking observed in this zone is 0.100 inch.

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MT-MNA-2339-80 In contrast the cold cracking phenomenon reported by Framatome has been associated with nozzles clad using multiple layer, strip electrode, welding layer but not to subsequent

- processes where preheat was applied to the firstThis phenomenon is thoug layers.

(Reference 4)

Documentation concerning the cladding procedures used by Rotterdam HeavyTo Equipment is provided in Appendix A.

nozzles were clad with a single layer of 60mm strip, deposited by theNozzle submerged a o process.

The clad of the safe end weld preps were clad manuallg with two layers.

nozzles were stress relieved at 1100 - 1175 F for 20 - 23 hours2.662037e-4 days <br />0.00639 hours <br />3.80291e-5 weeks <br />8.7515e-6 months <br />.

g Westinghouse has reviewed the documentation and cladding procedures for the Sequoyah Unit II nozzles and concluded that they preclude the potential for There have been no reportable instances of cold cracking cold cracking.

where only one layer cladding has been deposited with procedures requiring preheat and postheat temperatures equivalent to thuse used for cladding the However, the cladding procedure does have the Sequoyah Unit II nozzles.

potential to result in reheat cracking when used on susceptible material.

DESCRIPTION OF ULTRASONIC TESTING TECHNIQUE The examinations were conducted from the clad nozzle bore surfaces using 70 longitudinal wave, dual element, transmit-receive search units manufactured The time base of the instrument was calibrated on by Krautkramer/RTD/BAM.

Test 2mm diameter side-drilled holes at depths of 3mm, 7mm, and 11mm.

sensitivity was established on the flat bottom of a 2mm diameter hole drilled just below the clad / base metal interface in a representative calibration block.

After the test system was calibrated, instrument sensitivity was increased Scanning was conducted on the clad nozzle bore by 6dB for scanning.

When an indication was surfaces in both circumferential directions.

detected, instrument sensitivity was returned to the primary reference If the' amplitude was equal to or level and the maximum amplitude obtained.

greater than 50% of primary reference, the indication was recorded per the criteria defined in the procedure.

The calibration sensitivity of this examination technique is at least 5 times that required by conventional ASME Section XI examination methods (3/32 side This fact was demonstrated by making a direct comparison between drilled hole).

the instrument gain required to set the amplitude of the 2mm diameter flat bottom reference reflector to 80% of full screen height versus that required to obtain the same signal amplitude from a side drilled hole of the same diameter Calibration on the flat bottom hole required an instrument gain and depth.

setting 14-16dB greater than that for the side drilled hole.

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I Areas were reportable indications were detected with the 70' search h unit.

evaluated with a KBI, Gar.ma Series, 5.0MHz, O', transmit-receive searc Calibration for this examination was established on the diameter flat bottom hole drilled to the clad / base metal interface in c. re longitudinal Any indication detected by the 70 straight beam inspection was resentative calibration block.

wa ve inspection and also detectable by the 0 considered accep A copy of the detailed test procedure is attached as Appendix B.

t The nczzle bore examinations were conducted by qualified ultrasonic from Sonic Systems International, Houston, Texas under the direct Personnel and equipment certification records are on Westinghouse personnel.

f.le.

i It!SPECTION RESULTS 2-1, 2-8, 2-9, 2-17, Characteristics of the reflectors observed in nozzlesUltrasonic test r 2-24, and 2-32 were quite similar.

i vessel nozzle bores revealed distinct patterns of many individual indicat o These bands in parallel rows or bands around the circumference of the nozzles.The nu were separated by 1-1/2" to 2".In five of these six nozzles the quantity of indic In virtually impossible to manually map and record each discrete reflector.

to four.

discrete these cases reflectors were simply marked on the nozzle surface until Representative reflectors from each

, bands could be clearly distinguished.

nozzle were mapped and recorded.

Reficctors in the seventh nozzle, identified as 2-16 had small leng The eighth nozzle, identified as 2-25, contained onl Calibration and raw data sheets along with reflector maps are include Appendix C.

EVALUATION Of TEST RESULTS l

Reflector characteristics in six of the eight Sequoyah Unit 11 reactor ves i

nozzles (2-1, 2-8, 2-9, 2-17, 2-24, 2-32) Indication lengths are typically 3/8" - 1/2",

d by defined for reheat cracking.they appear in distrete bands around the n 1-1/2" to 2", and occur in clusters.In the case of nozzle 2-16 reflectors with one layer, see Appendix A. arc confined to the area clad wit Nozzle.2-25

- cannot be substantiated.

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While the ultrasonic test procedure used for these examinations does provide a reliable measurement of reflector length, current NDE technology does not permit a direct measurement of through-wall dimensions. However, many reheat cracks have been destructively examined in ' earlier investigations (References 1, 2, 3). From these data and from extensive knowledge of the reheat cracking phenomenon a reliable estimate lof the orack through-wall dimensions can be made. These flaws are restricted to the coarse-grained region directly beneath weld bead overlaps and have been found to be less than 0.100" or 1/3 the ultrasonically measured length, whichever is larger, and characterized per IWA-3300, ASME XI,1977 Edition.

Review of IWA-3300 indicated it was not necessary to apply the criteria of IWA-3330 for multiple planar flaws or IWA-3350 for parallel planar flaws during the characterir.ation process. In the first case, distances between adjacent rows of indications were 1-1/2" to 2", much greater than the maximum 2a, for the inlet or outlet nozzles (1/2"); refer to ASME XI, 1977 Edition, Figure IWA-3330-1, Surface Flaw #1.

In the second case, although the primary planes of individual flaws in a band were less than 1/2" apart, they were not displaced axially so as to significantly increase the length l

of the flaw; refer _ to ASME XI,1977 Edition, Figure IWA-3350, Semi-Thus all indications were characterized as Elliptical Surface Flaws.

individual planar surface flaws, IWA-3310, with through-wall dimensions equal to 0.125" or 1/3 their ultrasoniew11y measured length, whichever is larger, for ASME XI preservice acceptance calculations.

The outlet nozzle thickness is 10.8 inches and the inlet nozzle thickness These dimensions were calculated by the method outlined in is 13 8 inches.

Dimensions tnl ""d tn2 Table IWB-3512.1, note 2, where t = tnl + tn2, 2

were obtained from nozzle fabrication drawings.

The longest reflector recorded in any of the outlet nozzles was 0.625 inch.

The through-wall dimension of the reflector is assumed to be 0.208 inch.

For an aspect ratio (a/1) of 0.33, the allowable a/t value is 3 55 as

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compared to an actual a/t of 1.9%, see Figure 1.

The The longest reflector in any of the inlet nozzles was 0.75 inch. For an through-wall dimension in this case is assumed to be 0.25 inch.

aspect ratio (a/1) of 0.33, the allowable a/t value is 3 5% while the actual a/t is 1.8%, see Figure 2.

Thus, it is concluded that the reflectors meet the preservice acceptance criteria of IWB-3512, ASME XI,1977 Edition.

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.i REFERENCES 1.

Mager, T. R. et al,' " Reactor Vessels Wold Cladding - Base Metal Interaction *. Westinghouse Report WCAP 7673-L, April 1979.

2.

Mager, T. R. et al, " Reactor Vessels Weld Cladding - Base Metal Interaction". Westinghouse Report WCAP-7673-L Addendum 1 August 1971.-

u 3

Mager, T. R. et al, " Reactor Vessels Weld Cladding - Base Metal Interaction". Westinghouse Report WCAP 7733 July,1971.

4.

Rao, G. Ve and Albertin, L.

" Metallurgical Investigation of the Offshore Power Company Reactor Vessel. Outlet Nozzle Cracks",

Westinghouse Report WCAP 9704, April 1980.

S.

ASME Boiler and Pressure Vessel Code Section XI: Rules for Inservice Inspection of Nuclear Power Plant Components,1977 Edition, July 1, i

1977, page 68.

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APPENDIX A:

RDM DOCUMENTATION - CLAD OVERLAY PROCEDURES FOR TEll/ CONTRACT 30624/SEQUOYAH 11 O

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SEft"0YA!! UNIT 11 N027LE Cl ADDIllG PROCEDURE _

i Base Material specification grade and type.

1.

The base material of all nozzles in the Sequoyah Unit II reactor vessel is ASTM A-503, Class 2.

2.

Process type, electrode sizes t

Single layer clad using s6bmerged arc, string travel,

't 60 mm X 0.5 mm strip.

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Heat input (amps, volts, speed)

Amp:; = 550 - 650; Volts = 28 - 33; Travel = 9.5 - 12 cm/ min.

4.

Preheat, postheat, interpass temperature 215'F (110 C) i raisepreheattemperatureto400F(205*C).

j Preheat temperature:

Post heat temperature:

and hold for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br />, cool. to ambient.

Interpass temperature:

215 F (110 C) 5.

Post we'id heat treatment Post weld heat treatment 1100*F - 1175 F (595'C - 635 C) for = 21 hours2.430556e-4 days <br />0.00583 hours <br />3.472222e-5 weeks <br />7.9905e-6 months <br /> 6.

Stress relief heat treatment Same as shows in item 5, above.

7, Manufacture

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5 The reactor vessel was manuf actured by Rotterdam Dockyard Company, Rotterdam clad the nozzles.

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. Rotterdam, The Netherlands.

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CROSS-REFEREllCE FOR !!O7ZLE 10 fluiGERS i,

Peport Identification TVA Identification RDM Identification 15 i

2-9 Loop 2 Hot Leg /22.5 2-16 Loop 2 Cold Leg /67 11 12 2-8 Loop 1 Cold Leg /113 16 2-1 Loop i Hot Leg /158' 17 2-25 Loop 4 Hot Leg /202 13 2-32 Loop 4 Cold Leg /247 14 2-24 Loop 3 Ccid Leg /293 18 2-17 Loop 3 Hot Leg /338 9

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For repair in area.2 cce report of deviation V23-624-C26-02D-000

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m n t 1cyn-S t rc r.s relievin-595-G35 C 22 hrs. 3 min.

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• On vesselsido at the nozzleprotrution more ' layers have boon welded (Layer thickness /17 ::::n)

For repair in area 2 see P.eport of deviatien v28 624-C29-at 02D-013.

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595-635 C 22 h,rs. 23 min.

Stress relievin;.

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4 cmarks:

on the vesco.t.nida at the nozzleprotrution more layers havn boon wolded (Layer thickness > 17 c:c).

For repair in area 2'see I;:S report ND 8208-624-C30.02-0M Repair perforr.ed par 3G.04-1 i

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Cladding inside nozzles Ordernumber 30024

=

Type 01' vessel TEN l

outlet Type of nozz.le 1

17

); umber of nozzio:

Concral 1lciding Procedure:

36.02 Rev.:

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2. Ms.

Mter wc1Mng S oalt i n g Lizc* i*ycr Strt'ss re 1 i e v i nt; 595-635 C 2011rs. 34 min.

markt: 2 On the vesselsido at the nozzicprotrution more layers have been welded. (Layer thickness) 17 mm).

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llomarks:, On the vesselside at the no:::leprotrution more layers been welded (Layer thickness,) 17 cm).

• • For repair in ares 2 see Report of deviation V22 62!.-c32.02-D-007.

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' APPENDIX B: ULTRASONIC EXA!11 NATION PROCEDURE 9

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Metallurgical and f1DE Analysis C

,.;1' 244-302S

h. Jute 9,1980 Ultrasonic Test Protudure for Manual Con _taf',

,.pn of

_l_leactor Vessel -hozzle cores for ho-Clac.).

f10 CLEAR TECHt10 LOGY DIVISION 4

,,T...R,.Mager, Manager Metallurgical and tide Analy' sis

" " S E [. F. Enriett

P. L. Ruddle o

r-

.J.cDuran-0

'E. T. Hughes

.. W. A. Siano E. R. Pade R..S. Howard f

R. J. Sero "J. di Stepek'

..L..LuccardiLSpc...

J. A. Vano

~

1," N drcft of our

. Attached for your inf,ormation is a copy.of th i,.i ci crector 4'

' ultrasonic test procttdure. for manual contact v C A r.,i "Ul t rasonic

/vassel nozzle bore.w.The specification superc

r Vr:n: tiezzle

' Test Procedure for' Manual Contcct Examinst.ica 4 is t ' through 0

Bores for Sub-Clad Cracking" by incorporatin...

actual field experience.

In the event it bu t

.:s s:.r; to perform

n. capbiiity is not examinations of nozzles in vessels where res.:

' required, this procedure..is recommendad.

~

I.f you h6ve any questio,ns or ccmments, plcase t.V

-t one cf us.

, dL#

D. C. Adamonis Metallurgical and llDE Analysis

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ULTRAS 0flIC TEST PROCEDURE FOR DETECTI0ft 0F 1

SUB-CLADDitlG CRACKS Ill REACTOR l

VESSEL tt0ZZLE BORES

' t 1.0, SCOP E_

~

This document describes the ultrasonic testing technique an evaluation criteria to establish the existence of cracks 1.1 beneath cladding on reactor vessel nczzle bores.

2.0 MUIPMEllT_

The instrument Pulse-echo ultrasonic equipment shall be used.s l

2.1 A dual-element, transmit-receive, 2.0 MHz, 70* longitudinal wave search unit shall be used for the primary examination.

2.2 This search unit shall be of the type Krautkramer-RTD-BAM SE-70-L2-lS0-F18, or equivalent.

A dual-element, transmit-receive, 2.0 - S.O MHz, miniature 0* longitudinal wave search unit shall be used to aid inTh 2.3 evaluation of reflectors.

type Krautkramer SEB-4-KF-8, or equivalent.

Glycerine or an equivalent shall,be used in sufficient q to maintain continuous coupling of the search unit to the pa 2.4 being examined.

A reference block shall be provided for calibration of the 2.S ultrasonic test system..The contour of the block shall beThe block shall the production part.

representative of the ID of the nozzle bere.contain in Figure 1.

SURFACE FINISH, CLAD THICKilESS, Ai!D PREPARATI0t{

3.0 All examinations will be conducted from the clad 3.1 weld spatter, or any other foreign material t the nozzle bore.

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The defects of concern are located in the heat-affected-zone.

3.2 of the nozzle material, just below the clad / base metal interface, Tc aid in evaluation of reflectors it is icoortant to have as much information as possible concerning the nominal clad thickness.

Divide the nozzle bore into four equal sections to aid in 3.3 Measure the circumference scanning and recordin., of reflectors.

of the nozzle bore at 1.ne sessel and piping ends to establish 0, 90*, 180*, and 270 axes. Mark these the locations of the axes along the entire length of the nozzle bore with an approved, semi-permanent marking pen.

4.0 SWEEP RANGE CALIBRATIO1 examination Establish a linea'r sweep presentation for the 70 4.1 system by adjusting the instrument delay and range controls to set the maximum responses from the side drilled holes whose axes are perpendicular to the clad bead direction such that each screen division represents 2mm of depth.

See Figure 1, reference holes "A", "B", and "C"..

Estahl4sn a,inear sweep presentation for the 0 T-R examination O

4.2 system by adjusting the instrument delay and range controls to set the maximum responses from the side drilled holes whose axes are perpendcular to the clad direction such that each screen division represents 2mm of depth.

See Figure 1, reference holes "A", "B", and "C".

5.0 TEST SENSITIVITY Establish the test sensitivity for the 70" examination system 5.1 by adjusting the instrument gain controls to obtain an 803 of full screen height indication from the flat bottom of the 2wn diameter hole drilled just below the clad / base metal This is interface and parallel to the clad bead direction.

the primary reference level.

See Figure 1, reference hole "D".

Establish the test sensitivity for the O' transmit-receive examina-5.2 tion system by adjusting the instrument gain centrols to obtain an 80% of full screen heignt indication from the flat bottom of the 2 min diameter hole drilled through carbon steel to the clad / base metal interface. This is the primary reference level.

g See Figure 1, reference hole "E".

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0 5.3 Calibration shall be checked at four hour intervals during the examination.

If, during any calibration check it is -determined that the primary reference amplitude has decreesed by 20%'of -

it*, amplitude, all data sheets since tne last calibration check shall'be marked void, a new calibration sheet made, and the voided examination areas reexamined.

If the primary reference amplitude has increased by 20'; of its amplitude, all recorded indications since the last valid calibration check shall be reevaluated with the corrected calibration and their values shall be changed on the data sheets.

6.0.SCAf!f11f1G - 70' EXAMIflATI0t{

3 6.1 Scanning with the 70 search unit shall be nerformed from the clad surface in both circumferential direcions, i.e., parallel to the welding direction.

The entire nozzie bore shall be examined in this fashion. The end f ace of all outlet nozzle projections shall be scanned in two circumferential and two radial directions.

6.2 The scanning speed shall not exceed 6 inches' per second.

6.3. Each scan shall overlap the previous scan by at least 25!! of '

O the search unit width to assure ccmplete edmination coverage.

6.4 Scan using a gain setting of two times the primary reference icvel (+ 6 dB) provided cladding noise does not interfere with interpretation of test results.

In this case scanning sensitivity in tha range + 2 to 1 6 cB is n rmitted.

All indications shall be evaluated at the primary reference level.

7.0 RECORDIf1G 0F REFLECTORS - 70' EXAMIliAT:Tl 6

7.1 Indications eenal to or greater than 50fi of the primary reference level defined in paragraph 5.1 shall be recorded and their locations marked on the nozzle bore for further evaluation with the 0" transmit-receive examination system.

7.2 The specific sequence for data recording is provided below.

7.2.1 Record the maximum amplitude of the reflector, al in cercent of the primary reference level wnen reflector amplitude is less than the primary reference-leni, or b) by number of dB required to reduce the maximum amplitude to the primary reference level when the reflector amplitude is greater than the primary reference level; i.e., "100!; + 6" when reflect r maxinium amplitude is 200; of reference.

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• Vagc 4 :

j Junc 9,.1980

.1 0

7.2.2 Record the search unit location where the maximum amplitude is observed. The search unit location is defined as the midpoint of the. front of the search unit.

Axial location shall be measured frcm the safe-end, circumferential location shall be measured from the nearest-longitudinal axis of the bore; 0*, 90*,

180* or 270*.

7.2.3 Record the scanning direction, clockwise or counter-clockwise as viewed from.the large diameter end of the nozzle (vessel side).

7.2.4 Record the depth of the reflector at the location of snaximum amplitude as read from the instrument sweep.

7.2.5 Record the length of the reflector as determined.by the "12 dB drop" method. Move the search unit to the left of the point of maximum amplitude un.il the reflector amplitude drops to 25% of maximum. Mark this point.

Then move the search unit to the right of the point of maximum amplitude until the reflecter again drops to 25",

of maximum.

The distance between these two points is the reflector length.

7.2.6 Mark the search unit location on the nozzle bore surface O

with an approved, semi-permanent marking pen.

7.2.7 Rotate the search unit 180* and scan the area of interest to establish whether the reflector can be detected when Record scanning in the opposite circumferen-ial direction.

any indication, regardless of amplitude, per paragraphs 7.2.1 through 7.2.5.

8.0 EVALUATIOil 0F REFLECTORS WITH THE 0* TRAftSMIT-RECEIVE EXAMINAT10:1 SYSTEM Only areas where indications are detected with the 70* search B.1 unit shall be scanned with the 0 transmit-receive examination Any indication detected with the 0* transmit-receive

system, i

search unit, regardless of amplitude, shall be recorded.-

Record the maximum amplitude of the reflector, a) in percent 8.1.1 of the primary reference level when reflector amplitude is less than the primary reference level, or b) by number of dB required to reduce the maximum amplitude to the primay reference level when the reflector amplitude is greater than the primary reference level; i.e., "1000 + 6" when i

reflector maximum amplitude is 200', of reference.

0 Record the depth of the reflector at ttm location of 8.2.1 maximum amplitude as read from the instrument sweep.

~ ~ ' ~ ~ ~

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...A Page 5 June 9, 1980

.Q REFLECTOR CHARACTER 17AT10fl 9.0 Reficctors which meet the following criteria are considered 9.1 indicative of inclusions, porosity, or lack of bonding between the cladding and base material. They are, therefore, considered innocuous.

Any indication detected by the 70" examination,

, 9.1.1 regardless of amplitude. at-a depth rithin the weld-deposited. stainless steel ciadding.

Any indication detected by the 70 examination,

9.1.2 regardless of amplitude, also~ detected by the 0 transmit-receive examination at a corresponding location and at a depth within + 2mm of that

~

C predicted by the 70 test.

Reflectors exhibiting characteristics other than those described 9.2 above are considered suspect and will be subject to evaluation -

on an individual basis.

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9.0 REFLECTOR CHARACTERIZAT10t{

9.1 Reflectors which meet the following criteria are considered indicative of inclusions, porosity, or lack of bonding between the cladding and base material. They are, therefore, considered innocuous.

9.1.1 Any indication detected by the'70* examination, regardle s of-amplitude, at a depth within the weld-deposited stainless steel cladding.

9.1.2 Any indication detected by the 70' examination, regardless of amplitude, also detected by the O' transmit-receive examination at a corresponding location and at a depth within + 2mm of that

~

predicted by the 70. test.

9.2 Reflectors exhibiting characteristics other than those described above are considered suspect and will be subject to evaluation on an individual basis.

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All-drilled holes are 2mmt (5/64") with -flat-

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Calibration Block for Examination of Nozzle Bores for Detection of Cracking Beneath the Cladding, Recon:r, ended Design.

. Page /

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Data Sheet !!o.

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