ML20138C840

Metallurgical Investigation of Recorded UT Indications in Steam Generator Stub Barrel to Lower Shell Welds at Byron II Station

ML20138C840
Person / Time
Site:	Byron
Issue date:	07/31/1985
From:	Meyer T, Rao G WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP.
To:
Shared Package
ML20138C830	List: ML20138C824 ML20138C840
References
MT-SMART-726, NUDOCS 8510230061
Download: ML20138C840 (19)

Text

_ _ _ _ _ _ _ _ _ _ _ _

l WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 METALLURGICAL INVESTIGATION OF THE RECORDED UT INDICATIONS IN THE STEAM GENERATOR STUB BARREL

) TO LOWER SHELL WELDS AT BYRON II STATION S

+

Gutti V. Rao

. July 1985 k

s APPROVED ] . (I - )I*'/i Pl T. A. Meyer, Manager Structural Materials and Reliability Technology Work Performed Under Shop Order No. BCNM-1000 s

Westinghouse Electric Corporation Nuclear Energy Systems P.O. Box 355 Pittsburgh, PA 15230 i

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WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 l

i TABLE OF CONTENTS i

Section Title Page I

1 INTRODUCTION 1-1 2 TESTS AND EVALUATIONS 2-1 2 -1 Surface Examinations 2-1 2-2 Metallographic Examinations 2-1 2-3 Fractographic Examinations 2-1 2-4 Chemistry Evaluations 2-2 3 RESULTS AND DISCUSSION 3-1 4 CONCLUSIONS b

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WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 l

SECTION 1 t

INTRODUCTION This report summarizes the findings of the metallurgical investigation of the UT indications recorded in the steam generator stub barrel-to-lower shell circumferential welds of the Commonwealth Edison Company's Byron 2 Nuclear Power Generating Station.

In 1983, a preliminary preservice inspection was performed on four, Byron Unit 2, steam generators and one pressurizer to determine if indications similar to those found in Byron Unit 1 were also present in Byron Unit 2. ]

The examinations were performed in accordance with the 1977 edition of the

~

ASME Code with addenda through the summer of 1977. At the conclusion of the inspection, EBASCO reported there were numerous indications which needed further evaluation. The indications were scattered throughout the various welds in all four steam generators.

During the repair of the Byron Unit 1 steam generators, two full-thickness plugs were removed for detailed metallurgical evaluation of the ultrasonic reflectors.

It was concluded that the discontinuities were caused by the presence of a trapped slag inclusion. (Reference 1) The overall results of the investigation

{ also showed that the ultrasonically-predicted sizes of the indications were signficantly greater than the sizes established by metallurgical examination.

I The current report summarizes the findings of the metallurgical investigation of the UT indications recorded during a preliminary preservice inspection of l the Byron Unit 2 steam generators. The indications,which were located at the f stub barrel-to-lower shell welds of 5/G 2095 and S/G 2097,were removed in the fonn of 2.5" diameter cylindrical plugs (plug 110" cw and plug 107-1/4" cw respectively) and were shipped to Westinghouse facilities for metallurgical evaluation.

I Commonwealth Edison Company's Byron 2 station is a four-loop 1120 MWE plant scheduled for commercial operation in 1985. The steam generator shells were made of A533 Grade B Class 2 material, while the circumferential welds employed submerged arc with SFA5.17 Type EH-14 wire and Modified Flux Linde 0091.

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Reference 1: " Metallurgical Investigation of the Recorded Indications in the Steam Generator Stub Barrel-to-Lower Shell Welds at Byron 1 Station," Gutti V. Rao, Westinghouse Class 3 Report i WCAP-10453, December 1983.

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WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 The metallurgical investigation of the two plugs was conducted by the Structural Materials and Reliability Technology Group of Westinghouse Plant Engineering Division and . included the following ma,ior tasks:

1. Sur%.e examinations by visual and low power light microscopy techniques.

, 2. Development of sectioning methodology of the plugs to obtain maximum infomation on the size, shape and orientation of discontinuities associated with the recorded indications.

3. Metallographic examination of a series of sections through the affected regions of the plugs by light optical microscopy.

4. Fractographic examination of the freshly opened discontinuity regions of the plugs by light optical and scanning electron microscopy techniques.

5. Chemistry evaluation of the deposits and inclusions, if any, present at the discontinuity regions by energy dispersive X-ray analysis.

The overall purpose of the investigation is to establish the size, shape, p orientation and location of the discontinuities or voids associated with the L recorded UT indications and further to establish the cause of their occurrence.

WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 L

SECTION 2 TESTS AND EVALUATIONS 2-1. SURFACE EXAMINATIONS The as-received condition of the two plugs, namely Plug No.110 CCW and Plug No.107-1" CW (designated as Plug 1 and Plug 2, respectively) were carefully examined visually and by low power light microscopy for evidence of surface defects, cracks or other deposits. The examinations were also carried out in the lightly polished condition. The results of {

these surface examinations are illustrated in Figures 2-1 and 2-2. The results are discussed in Section 3.

2-2. METALL0 GRAPHIC EXAMINATIONS Based on the locations established by the recorded UT indications and the results of the surface examinations of the plugs, series of sections through b each of the plugs were taken (dry) to obtain maximum possible information on the cause of reported indications. The sections were taken transverse to the longitudinal direction of the reported indications, and were oriented axial

{ to the plugs and transverse to the steam generator circumferential welds.

4 The sections were examined both in the as-polished and in the polished-and-I etched conditions. The overall purpose of the metallographic examination was to establish the morphology and physical dimensions of the voids or discontinuities associated with the reported indications and further to establish their i relationship to the local microstructure. The results of the met'allographic examination are illustrated in Figures 2-3 through 2-9. The results are . ,

discussed in Section 3 of the report.

2-3. FRACT0 GRAPHIC EXAMINATIONS Dry-cut samples from the plugs containing the voids or discontinuities were opened fresh in the laboratory and were examined for surface morphology by light optical and scanning electron fractography techniques. The examinations were conducted both in the as-opened as well as in the endoxed (oxide removed) condition. The results are illustrated in Figures 2-10 through 2-13. The results are discussed in Section 3.

I 2-1 l

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WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 2-4. CHEMISTRY EVALUATIONS Chemistry analysis of the weld deposit associated with the discontinuities was conducted by wet analys'is to examine its conformance to the specification requirements. The results are listed in Table 1. The chemistry of the deposits present in the discontinuities was examined by energy dispersive x-ray (EDAX) analysis. The results are illustrated in Figures 2-12 and 2-13. The results of the chemistry evaluations are discussed in Section 3.

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l 2-2

WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 4

i SECTION 3 I

RESULTS AND DISCUSSION The results of the surface examination of the as-receivcd plugs are illustrated in figures 2.1 and 2.2. The examinations did not show any evidence of voids or discontinuities on the plug surface. The sectioning procedures employed for plugs 1 and 2 are illustrated in figures 2.3 and 2.4 respectively. The results of the metallographic examination of the discontinuity in plug 1 are illustrated in figures 2.5 and 2.6 while the results of the metallographic examination of the defects in plug 2 are illustrated in figures 2.7 through 2.9.

The results of the fractographic examination by light optical microscopy of the freshly opened discontinuity faces in plugs 1 and 2 are illustrated in figure 2.10. The scanning electron microscopy examination results of the freshly .

opened discontinuity faces are illustrated in figures 2.11 through 2.13. The chemistry evaluation results of the deposits or inclusions associated with the discontinuities conducted by energy dispersive x-ray analysis are illustrated in figures 2.12 and 2.13 The results of the metallographic examinations showed that the recorded indications in plug 110 cce (S/G 2095) were associated with a planar discontinuity in the form of a truncated ellipse. The discontinuity, present in the form of a void, measured 0.27" in length and 0.18" in width at its widest location. The general location of the discontinuity in the plug,as seen from outside into the 0D surface of the steam generator with the plug in place, corresponded 0.585" from the top (12 o' clock) edge and 0.9" from the left (9 o'c'ock) edge of the plug's circular face. The discontinuitywassituatedat0.82"fromtheIDsugfaceofthesteamgenerator with the plane of the discontinuity oriented at 38 to the horizontal plane. The longitudinal direction of the discontinuity was oriented circumferential to the I

steam generator.

The results of the metallographic examinations on plug 107-1/4" cw from S/G 2097 showed that the plug contained planar as well as linear discontinuities. Based on the UT results, the plug was initially sectioned axially through a diameter by a vertical plane (as seen with the plug in place) dividing the plug into two halves.

The left half, designated as Sample A, contained two planar void-like discontinuities each 0.25" long and oriented circumferential to the steam generator. The two discontinuities, located at 0.08" and 0.33" from the ID surface of the steam a generator, measured 0.05" x 0.007" and 0.035" x 0.009" respectively at their widest location. The right half of the plug designated as Sample B. contained two void-like discontinuities approximately 0.278" long each, and were located 0.075" and 0.14" from the ID surface of the steam generator. The discontinuity closer to the ID surface of the steam generator showed branching into a cluster of multiple linear discontinuities running circumferential to the steam generator. The discontinuities were distributed over an area of approximately 0.17" x 0.12" on a vertical section, where the discontinuities were the widest. The widest of the multiple discontinuities measured 0.55" x 0.035" on this section. The second discontinuity in Sample B of plug 107-1/4" cw located at 0.14" from the ID surface was a void-like planar discontinuity which measured 0.03" wide and 0.01" deep and was oriented circumferential i

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WESTINGHOUSE PROPRIETARY CLASS 3 MT-SMART-726 to the steam generator. The metallographic examinations also confirmed the presence of inclusions or particles trapped inside the cavity-like discontinuities and that the discontinuities are primarily located at weld-to-base metal and/or weld-to-weld metal (interbead) interfaces.

The results of the fractographic examinations conducted on freshly opened (dry) discontinuity faces clearly confirmed the presence of trapped inclusions and solidified surfaces. Energy dispersive X-ray analysis confirmed that the trapped inclusions are made up of potassium, calcium, silicon, manganese, titanium and sulfur elements, suggesting that the inclusions most likely correspond to the slag from the welding process.

Based on the overall results of the investigation, it is thus concluded that the recorded UT indications at the Byron Unit 2 steam generator welds are caused by the presence of void-like discontinuities formed by trapped slag particles from the welding process.

A comparison of the UT examination results to the sizing of the discontinuities with the results of the metallurgical investigation suggests that ultrasonic tests over-estimated the discontinuity length by at least 270%.

WESTINGHOUSE PROPRIETARY CLASS 3 MT-SPART-726 l

SECTION 4 CONCLUSIONS Based on the overall results of the investigation, it is concluded that the recorded ultrasonic indications in the Byron 2 steam generator outer shell circumferential welds were caused by the presence of void-like discontinuities near the shell ID surface oriented parallel to the circumferential welds. Based on the results, it is further concluded that the observed discontinuities are located at the weld metal-to-weld metal interface and are caused by the presence of trapped slag inclusions.

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PLUG #1 FRACT A Z=00 PR= S 15SEC 0 INT

V=2048 H=10 KEV 1 30 A0=10 KEV 10

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PHOTO 5, AREA 3 , FE CA SI K TI '

a

.& Ji ? -

< 0.00 KEV XES 10 24 KEV)

Figure 2-13. EDAX Analysis Results From the Area Scan at Location 3 on the Freshly Opened Discontinuity Face in Plug 1. *