ML20151Y725
| ML20151Y725 | |
| Person / Time | |
|---|---|
| Site: | Farley  |
| Issue date: | 04/28/1988 |
| From: | Mcdonald R ALABAMA POWER CO. |
| To: | NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM) |
| Shared Package | |
| ML20151Y729 | List: |
| References | |
| NUDOCS 8805050091 | |
| Download: ML20151Y725 (49) | |
Text
{{#Wiki_filter:___ - _. 4 At*bama Power Company C00 North 18th Street Post office Box 2641 Dirmingham, Alabama 352914400 Telephone 205 250-1835 , R. P. Mc Donald Senior Vic1 Pres 4 dent Alabama POWCT tre s<xthren ekctic splevn Docket No. 50-348 10CTR50.55a(g) ; April 28, 1988 U. S. Nuclear Regulatory Comission Attention: Document Control Desk " Washington, D. C. 20555 Gentlemen: Joseph M. Farley Nuclear Plant - U"'t 1 i Initial Reports on the Evaluation of Indications from the Reactor vessel Inservice Inspectio.. During the Unit 1 eighth refueling outage, an inservice ultrasonic examination was performed on the reactor vessel welds and flange ligaments in accordance with the ASME Code, Section XI. %e scope of work for the first Ten-Year Interval included examination of the longitudinal and circumferential shell welds, inlet nozzle-to-shell welds, flange-to-shell weld and the inlet nozzle safe-end welds under the 1974 Edition through the Sumer 1975 Addenda of Section XI. For the Second Ten Year Interval, the scope included the outlet nozzle-to-shell welds, outlet nozzle safe-end ! welds, flange-to-shell weld and the flange ligaments under the 1983 Edition F ough the Summer 1983 Addenda of Section XI. he entire examination i 4 completed on April 24, 1988 ; 1 Examination results concluded that four indications were in excess of the l
- Section XI acceptance criteria based on conventional ultrasonic examination data. To provide enhanced characterization and sizing of these indications, the UDRPS (Ultrasonic Data Recording and Processing System) was utilized. Following evaluation of UDRPS data, two indications remained i in excess of the Code acceptance criteria. 'Ivo other indications were f found to be located in the vessel cladding which is outside of the Code '
required examination volume; therefore, no further evaluation is required by the Code. A fif th indication thich was found during a previous . inservice examination was found to be acceptable by both conventional i ultrasonic and UDRPS sizing evaluations. l h i ap 8905050091 880428 pl ') PDR ADOCK 05000348 Q DCD
U. S. Nuclear Regulatory Comission April 28, 1988 Page 2 n e two indications in excess of the Code acceptance criteria and the indication found during a previous inservice examination are located in the Loop B outlet nozzle-to-shell weld (Wold No. 21). All three indications lie along the fusion 31ne between the outlet nozzle base material and the weld and are considered rubsurface. Wese indications are volumetric in nature and probably resulted from slag inclusions which occurred during the fabrication process. Detailed discussions of these indications and related evaluations are provided in Enclosure 1. We two remaining indications are located in the lower shell longitudinal weld at 133' (Weld No. 6). With conventional ultrasonic examination, both indications appeared to be located in the base material near the inside vessel surface just below the clad-to-base metal interface and were sized in excess of the Code acceptance criteria. Since near surface ultrasenic examination techniques include inherent indication positioning errors near the surface of the metal, UDRPS was used to further define the exact location of the indications. Using the ultrasonic signal enhancement capabilities of UDRPS, further evaluation concluded that both indications are actually located in the cladding material and not in the base material. Wese indications are also volumetric in nature and appear to be inclusions from the original cladding process. Both indications were located outside of the Code required examination volume; therefore, no further Code evaluation is required. Detailed discussions of these indications and related evaluations are provided in Enclosure 2. Enclosures 1 and 2 provide the ultrasonic examination data, UDRPS data, preservice and inservice examination results, summaries of radiographic and ultrasonic examinations performed on the areas of interest during fabrication and discussions of the characterization of indications from conventional ultrasonic and UDRPS examination data. In addition, Enclosure 1 includes discussions of low temperature overpressurization transients, reexamination plans, radiation damage assessments, stress corrosion concerns and fracture mechanics ev&luations relative to the outlet nozzle-to-shell weld indications. Enclosure 3 is a Handbook on Flaw Evaluation which was developed for both the Units 1 and 2 reactor vessels by Westinghouse. Wis document provides the fracture mechanics analysis applicable to the outlet nozzle-to-shell weld and the supporting bases. hese bases include material fracture mechanics properties, stress intensity factors, operating transients in the design bases, fatigue evaluation and crack growth analysis which were analyzed in agreement with Section XI. We initial reports provided in Enclosures 1, 2 and 3 are based on informtion provided to Alabama Power Company by Westinghouse wttich will be developed further before undergoing final approval. he final report will be submitted to the NRC by May 6, 1988. A detailed probabilistic risk assessment of the low temperature overpressurization transient will be provided in the final report. i
U. S. Nuclear Regulatory Comission April 28, 1988 Page 3 Based on the Section XI, IWB-3500 flaw evaluation criteria for the five indications discussed herein, two nozzle-to-shell weld indications exceed the criteria, one nozzle-to-shell weld indication is acceptable and two longitudinal weld indications are outside the Code required examination volume and do not require further evaluation. For the two nozzle-to-shell weld indications which are unacceptable under IWB-3500, a fracture mechanics analysis was performed as sumarized in Enclosures 1 and 3 which concluded that both indications are acceptable based on the criteria of Section XI, IWB-3600. Pursuant to the requirements of Section XI, IWB-3125(b), Alabama Power Company herewith submits the evaluation analyses documenting the acceptability of these two indications. Alabama Power Company furthermore requests that the NRC approve the acceptable disposition of these two indications based on this evaluation analysis as required by Section XI, IWB-3610(b). It is respectfully requested that this approval be granted no later than May 12, 1988 as this is the date tentatively scheduled for initial criticality following the current refueling outage. Approval by this date will prevent extension of the outage beyond the current schedule. Pursuant to 10CFR170.21, the required application fee of $150.00 is enclosed. If there are any questions, please edvise. Respectfully submitted, ALABAMA PONER COMPANY (Y..b. f " R. P. Mcdonald RPM / SIB:cs1-D8.2 Enclosures cc: Mr. L. B. Long Dr. J. N. Grace Mr. E. A. Reeves Mr. C. E. Fox Mr. W. H. Bradford f$
ENCLOSURE 1 INITIAL
SUMMARY
REPORT G! INDICATIONS 3A, 4A AND 22A OF WELD NO. 21 1.0 Weld Location 2.0 Conventional Ultrasonic Examinations 3.0 Supplemental Ultrasonic Examinations Using UDRPS 4.0 Characterization of Indications 5.0 Use of the Dynacon UDRPS for Evaluation of Data 6.0 Review of Fabrication Radiographs 7.0 Review of Post-Hydrostatic Test Ultrasonic Examination Report 8.0 Preservice and Inservice Examination Results 9.0 Reexamination Schedule 10.0 Fracture Mechanics Evaluation 11.0 Low Ternperature overpressurization Trantbnt Consideration 12.0 Irradiation Damage In the Nozzle Region 13.0 Stress Corrosion Cracking Susceptibility
~ , . . - - - - - - -
1.0 Weld Location Weld No. 21 is the Loop B, Hot Leg (outlet) nozzle-to-shell weld which is located as shown in the elevation and plan views of Figures 1-A and 1-B, respectively. 2.0 Conventional Ultrasonic Examinations Results of the conventional ultrasonic examinations of indications 3A, 4A and 22A are sumarized in Table 1-A. Locations of these indications relative to Weld No. 21 are shown in Figures 1-C, 1-D and 1-E, respectively. 3.0 Supplemental Ultrasonic Examinations Using UDRPS In order to obtain better information regarding the nature and size of the ultrasonic indications found to be unacceptable to the ASME Code, Section XI acceptance tables, it was decided to utilize the Dynacon Ultrasonic Data Recording and Processing System (UDRPS) with the conventional inservice inspection transducers. he UDRPS system has the capability of recording, storing, processing and imaging ultrasonic test data. This capability allows for more flexibility in evaluation of the data. Indications 3A, 4A and 22A were found using the Westinghouse 40-month array plate. The transducer which detected these indications is a 2.25 MHz, 1-1/2" diameter, O'L unit (TR6). For the UDRPS examination this unit was also used. h ree scans were done on each indication. h e first scan established the amplitude from the indication at 80% of full screen height (FSH). The remaining two scans increased the gains by 10 dB nnd 16 dB. %ese higher sensitivity scans were performed to distinguish secondary response which could determine the nature of the indications. %e lower sensitivity scan was performed to enable a -6 dB drop sizing methodology to be applied. Results of the UDRPS examinations of indications 3A, 4A and 22A are summarized in Table 1-A. 3.1 Nozzle-to-Shell Weld No. 21, Indication No. 3A his indication was detected with transducer TR6 during the conventional ISI. This transducer's beam is directed from the l nozzle bore down to the weld at an angle of 0*. The results of these examinations can best be seen in Figures 1-F through 1-H. A brief explanation of these figures is provided below. Figure 1-F (Transducer TR6 - Low Sensitivity Scan) This image is of the scan line which showed the maximum response from indication 3A. As a means of understanding the geometry of the scan, estimated positions of the shell, weld and nozzle have been shown. he scans were established such that a response from the nozzle OD could be observed in order to determine the relative position of the indication. Using -6 dB drop sizing
(i.e., points where the amplitude drops to half the maximum value), the 2a dimension of indication 3A is determined to 1.2". Indication 3A appears to be at or near the weld / nozzle forging fusion line and embedded within the weld. We minimum distance from the half maximum extremity point of indication 3A to the intersection of the weld taper and the nozzle OD is 4.5 inches. Figure 1-G (Transducer TR Low Sensitivity Scan) he series of images shown on this figure display the linear extent of indication 3A without any amplitude drop type sizing. Using -6 dB drop amplitude sizing, indication 3A can be seen ranging from 123.6 to 126.1 degrees or 6 increments. Each increment was 0.5 degrees; therefore, the indication extends approximately 3 degrees. Assuming a 51" diameter from the nozzle centerline to the weld fusion line, this establishes a conversion factor of 0.445"/ degree. Werefore, indication 3A, by -6 dB drop sizing, measures 1.34" in length. Figure 1-H (Transducer TR6 - High Sensitivity Scan, +10 dB) This image shows a saturated response from indication 3A as well as a weak trailing secondary response approximately 3 microseconds behind the primary indication 3A response. Trailing secondary responses are evidence of rounded volumetric reflectors.
%erefore, using UDRPS and -6 dB drop sizing, indication 3A is an embedded, subsurface reflector, and it is most probably a volumetric weld flaw having a 2a dimension of 1.20" and a length of 1.34".
3.2 Nozzle-to-Shell Weld No. 21, Indication No. 4A h is indication was detected with transducer TR6 during the conventional ISI. % is transducer's beam is directed from the nozzle bore down to the weld at an angle of 0 degrees. We results of these examinations can best be seen in Figures 1-I through 1-K. A brief explanation of these figures is provided below. Figure 1-I (Transducer TR6 - Low Sensitivity Scan) This image is of the scan line which showed the maximum response from indication 4A. Estimated positions of the shell, weld and nozzle are shown for clarity. Indication 4A appears to be at or near the weld / nozzle forging fusion line and embedded within the weld. Using -6 dB drop sizing, the 2a dimension of indication 4A is determined to be 1.14". he minimum distance from the half maximum extremity point of indication 4A to the intersection of the weld taper and the nozzle OD is 5.1".
. . . _ . ~ -~ .
Figure 1-J (Transducer TR6 - Low Sensitivity Scan) We series of images shown on this figure display the linear extent of indication 4A without any amplitude drop type sizing. Using -6 dB drop amplitude sizing, indication 4A can be seen ranging from 236.5 to 238.5 degrees or 5 increments. Each
. increment was 0.5 degrees; therefore, the indication extends approximately 2.5 degrees. Werefore, indication 4A, by -6 dB drop sizing, measures 1.11" in length.
Figure 1-K (Transducer TR6 - High Sensitivity Scan, +10 dB) This image shows a saturated response from indication 4A as well as a weak trailing secondary response approximately 3.5 microseconds behind the primary indication 4A response. Trailing secondary responses are evidence of rounded volumetric reflectors. Therefore, using UDRPS and -6 dB drop sizing, indication 4A is an embedded, subsurface reflector, and it is most probably a < volumetric weld flaw having a 2a dimension of 1.14" and a length of 1.11". 3.3 Nozzle-to-Shell Weld No. 21, Indication No. 22A his indication was detected with transducer TR6 during the conventional ISI. This transducer's beam is directed from the nozzle bore down to the weld at an angle of 0 degrees. The results of these examinations can best be seen in Figures 1-L through 1-N. A brief explanation of ther.e figures is provided below.' , Figure 1-L (Transducer TR6 - Low Sensitivity Scan) his image is of the scan line which showed the maximum 2a dimension of indication 4A at half maximum amplitude points. Estimated positions of the shell, weld and nozzle are shown for clarity. Indication 22A is two reflectors approximately 0.6" apart located at or near the weld / nozzle forging fusion line and embedded within the weld. Using -6 dB drop sizing and ASME Code 1983 Edition with 1983 Winter Addenda section XI proximity rules, the 2a dimension of indication 22A is determined to be 1.58". The minimum distance from the half maximum extremity poir.t of indication 22A to the intersection of the weld taper and the nozzle OD is 5.5". Figure 1-M (Transducer TR6 - Low Sensitivity Scan) he series of images shown on this figure display the linear extent of indication 22A without any amplitude drop type sizing. Using -6 dB drop amplitude sizing, indication 22A can ba seen
- ranging from 102.0 to 102.5 degrees, from 99.0 to 101.0 degrees and at 97.5 degrees. Using ASME Code proximity rules, indication 22A extents from 97.5 degrees to 102.5 degrees or 11 increments. Each increment was 0.5 degrees; therefore, the
indication extends approximately 5.5 degrees. Therefore, indication 22A, by -6 dB drop sizing, measures 2.45" in length. Figure 1-N (Transducer TR6 - High Sensitivity Scan, +10 dB) his image shows a saturated response from indication 22A, as well as a weak trailing secondary response approximately 3 to 3.5 microseconds, being the primary indication 22A response. Trailing secondary responses are evidence of rounded volumetric reflectors. herefore, using UDRPS and -6 dB drop cizing with the ASME Code, 1983 Edition with 1983 Winter Addenda, Section XI proximity rules, indication 22A is comprised of two embedded, subsurface reflectors and these reflectors are most probably volumetric weld flaws having a 2a dimension of 1.58" and a length of 2.45". 4.0 Characterization of Indications Characterization is defined as "the determination of whether a valid indication originates from a volumetric or planar type defect". Generally, the use of supplemental straight beam techniques provides for the verification of a volumetric type flaw (i.e., slag, porosity, etc.) since a relatively strong reflection should occur from both. Planar flaws, however, should reflect little or no energy to a straight beam transducer. Another supplemental characterization technigpe is based on satellite pulse observation technique (SPCTT) principles . SPOT relies on the observation of a doublet signal emanating from a volumetric defect. This doublet consists of a strong specularly reflected signal, followed by a weak, synchronous satellite pulse response. This satellite pulse is created by a portion of the sound beam propagating around the circumference of a rounded type of reflector and being reradiated back to the receiver transducer. Synchronous means that, when the specularly reflected signal peaks, the associated satellite pulse signal should also peak with the satellite pulse lagging in arrival time. Therefore, these two peaks should occur in the same A-scan. On a system such as UDRPS, two relatively close parallel images, one behind the other, would be indicative of synchronous signals and, therefore, a volumetric type of defect. For planar flaws, SPOT also relies on the observation of a doublet signal but these signals are asynchronous in nature. In this case the satellite responses are created by a portion of the sound beam being reradiated from a planar flaw extremity back to the receiver transducer. Since the extremities of planar flaws are separated in position, the peaks of each extremity would not occur in the same A-scan. On a system such as UDRPS, two parallel images shifted in position would be indicative of asynchronous signals and, therefore, a planar type of defect. 1
- Gruber, G. J., G. J. Hendrix, and W. R. Schick, "Characterization of Flaws in Piping Welds Using Satellite Pulses", Materials Evaluation, Volume 42, April 1984, pp. 426-432.
4 5 For the supplemental examinations of indications 3A, 4A and 22A of the nozzle-to-shell Weld No. 21 using UDRPS, synchronous satellite signals were observed in the images suggesting volumetric type reflectors. 5.0 Use of the Dynacon Ultrasonic Data Recording and Processing System (UDRPS) for Evaluation of Data
%e UDRPS system allows for more extensive recording of data, better-visualization of examination data through the use of color-coded images, more flexible manipulation of data, more consistent examination quality, and archival retrieval of past examinations for comparison purposes. In terms of amplitude-drop' sizing methcdologies, the UDRPS system has the same fallacies as conventional ultrasonic examination methodologies (-6 dB drop, 50%
DAC). For small flaws it will still provide estimated sizes more consistent with the beam size of the transducer rather than the size of the flaw (for beam sizes greater than the size of the flaw). For the indications in the nozzle-to-shell welds, a sizing methodology known as -6 dB amplitude drop or half maximum technique was applied. his methodology was applied because overall (on a defect matrix consisting of volumetric and planar type flaws) it has been shown to provide the more accurate results when compared to i other amplitude-based tephniques such as 50% DAC, 20% DAC, and 20% DAC with beam correction ne best use of the UDRPS data is the ability to observe secondary responses and their relation to the primary signals from the indications. his aids in the characterization of the reflectors as well as providing more accurate sizing information. i 6.0 Review of Fabrication Radiographs , l Construction radicgraphs of the Farley Nuclear Plant Unit 1 Reactor Vessel outlet nozzle-to-upper shell Weld No. 21 (CE No. 1-897E) were , reviewed in an effort to establish whether or not a correlation ! exists between 1988 ultrasonic data and results from the 1971 construction radiograph examinations, t he radiograpic technique for vessel nozzle-to-shell exams specified l the use of Kodak "AA" film in a double loaded cassette with a high I energy x-ray source located on the outside vessel diameter. In the nozzle-to-shell technique, the incident beam was angled from normal to include as much of the nozzle to shell weld volume as was practical.
* - Willetts, A. J. , F. V. Amirato, and E. K. Kietzman, J. A. Jones Applied Research Company /EPRI NDE Center, Accuracy of Ultrasonic ;
Flaw Sizing Techniques for Reactor Pressure Vessels, Draft Interim Report, EPRI RP 1570-2, March 2, 1988. e i I
e-An attempt was made to verify numerous ultrasonic indications by radiographic review. No relevant flaw-type images were noticeable on the construction radiographs for Weld No. 21. 7.0 Review of Post-Hydrostatic Test Ultrasonic Examination Report In 1973, the Farley Nuclear Plant Unit 1 reactor vessel was examined by manual ultrasonic examination techniques for acceptance to Section III Paragraph N-625, 1968 Edition, including Addenda up to and including Sumer 1970. Results from Weld No. 21 (CE No. 1-897E) were reviewed in an effort to establish whether or not a correlation exists between 1988 remote inservice ultrasonic data and manual contact examinations. For Weld No. 21, no recordable indications were found during the 1973 examination, which was conducted using 0', 45' and 60' transducers. 8.0 Preservice and Inservice Examination Results A comparison of the conventional ultrasonic examination data results from preservice and inservice examinations is provided in Table 1-B. 9.0 Reexamination Schedule Pursuant to the requirements of Section XI, IWB-3122.4(b) and IWB-2420(b), Weld No. 21 will be reexamined during the next three inspection periods as defined in IWB-2412, beginning with Interval 2, Period 2. If these reexaminations reveal that the flaw indications remain essentially unchanged for these three inspection periods, the examination schedule will revert to the original schedule of successive inspections as permitted by IWB-2420(c). l 10.0 Fracture Mechanics Evaluation the three indications (3A, 4A, 22A) found in weld No. 21 have baen l evaluated by fracture mechanics analysis using the document i MT-SME-186: Background and Technical Basis for the Handbook on Flaw l Evaluation for the Joseph M. Farley Nuclear Plant Units 1 and 2 l Reactor Vessel Beltline and Nozzle-to-Shell Welds, dated April 1988. This evaluation is provided in Figure 1-0 using the data in Table 1-C. All the indications identified by both the conventional ISI data and the UDRPS data are acceptable by fracture mechanics analysis. 11.0 LTOP Transient Consideration The goal of this task is to estimate the probability of a low temperature overpressurization (LTOP) transient which occurred at Turkey Point several years ago, and use this information to categorize the transient as normal, upset, emergency or faulted. The flaw evaluation will then consider the transient using the appropriate safety margins.
A detailed probabilistic risk assessment is being performed for the Farley Plants, and will be included in the final report to be submitted May 6, 1988. In the interim, an estimate of the probability of this L10P event has been made based on earlier work for several other plants. Event tree analysis has been used to define the various scenarios which could lead to the overpressure event. %ese event trees are plant specific in nature, but the cases treated thus far have had very similar results. Based on these earlier analyses, it may be concluded that the frequency of a significant L10P event is very low for the Farley Nuclear Plant units. A best estimate frequency for this event is 3E-05 pet calendar year. According to the event categorization rules of ANS and the NRC Regulatory Guide 1.48, this probability clearly classifies the event as a faulted condition. Even if the probability were higher by two orders of magnitude, the event would still be an emergency condition, and subject to the same safety margins for the flaw evaluation. This event was not a governing transient for the flaw evaluation because the small 14CA, large LOCA, and large steam line break were all found to be more severe. %erefore, the LIOP event was not the event which determined the allowable flaw size in the flaw evaluation. 12.0 Irradiation Damage in the Nozzle Region The level of irradiation damage at the outlet nozzle-to-shell weld of the Farley Nuclear Plant Unit I reactor vessel is three orders of magnitude lower than at the core midplane. %e end of life fluence for the vessel inner surface was calculated based on operation at l 2,652 Mwr for 32 EFPY and assumed that exposure for all cycles after j 7 is at the same rate as that calculated for Cycle 7. The end of ' life fast neutron fluence at the vessel inner surface is 3.88E19 I N/SqCm based on the measurements of the most recent surveillance capsule. Reducing this fluence appropriately for the outlet nozzle-to-vessel weld, the applicable fluence is 3.88E16 N/SqCm at the lowest point of the weld. The indication closest to this location is designated 3A, at 120 degrees from the top of the nozzle, and 4A at 238 degrees from the nozzle top. Wese locations are approximately 10 inches above the lowermost point of the nozzle-to-shell weld, and this additional height results in a further reduction in fluence of a factor of 10. herefore, the fluence applicable to the indications of interest here is 3.88E15 at the vessel inner surface. This value would be further reduced by the l fact that the indications are embedded. Clearly at these fluences I irradiation damage is negligible. The fluence values used herein were taken from the most recent surveillance capsule test report, WCAP 11563, Revision 1 dated September, 1987.
13.0 Stress Corrosion Cracking Susceptibility In evaluating flaws, all mechanisms of suberitical crack growth must be evaluated to ensure that proper safety margins are maintained during service. Stress corrosion cracking has been observed to occur in stainless steel in operating BWR piping systems; the discussion presented here is the technical basis for not considering this mechanism in the present analysis. For all Westinghouse plants, there is no history of cracking failure in the reactor coolant system loop. For stress corrosion cracking (SCC) to occur in piping, the following three conditions must exist simultaneously: high tensile stresses, a susceptible material, and a corrosive environment. Since some residual stresses and some degree of material susceptibility exist in any stainless steel piping, the potential for stress corrosion is minimized by proper selection of materials immune to SCC as well as preventing the occurrence of a corrosive environment. In the reactor vessel, stress relief ensures that the residual stresses are low. The material specifications consider compatibility with the system's operating environment (both internal and external) as well as other materials in the system, applicable ASME Code rules, fracture toughness, welding, fabrication and processing. The environments known to increase the susceptibility of austenitic stainless steel to stress corrosion are oxygen, fluorides, chlorides, hydroxides, hydrogen peroxide and reduced forms of sulfur (e.g., sulfides, sulfites and thionates). Strict cleaning standards prior to operation and careful control of water chemistry during plant operation are used to prevent the occurrence of a corrosive environment. Prior to being put into service, the piping is cleaned internally and externally. During flushes and preoperational testing, water chenistry is controlled in accordance with written specifications. External cleaning for Class 1 stainless steel piping includes swipe tests to monitor and control chloride and fluoride levels. For preoperational flushes, influent water chemistry is controlled. Requirements on chlorides, fluorides, conductivity and pH are included in the acceptance criteria for the piping. During plant operation, the reactor coolant system (RCS) water chemistry is monitored and maintained within very specific limits. Contaminant concentrations are kept below the thresholds known to be conducive to stress corrosion cracking with the major water chemistry control standards being included in the plant operating procedures as a condition for plant operation. For example, during normal power operation, oxygen concentration in the RCS is expected to be less than 0.005 ppm by controlling charging flow chemistry and maintaining hydrogen in the reactor coolant at specified concentrations. Halogen concentrations are also stringently controlled by maintaining concentrations of chlorides and fluorides within the specified limits. This is assured by controlling charging flow chemistry and specifying proper wetted surface materials, i
TABLE 1-A CONVENTIONAL AND UDRPS ULTRASONIC EXAMINATION DATA FROM 1988 INSERVICE EXAMINATION Indication No. 3A 4A 22A Exam. Angle O'L O'L O'L Radius from Vessel 83.5" 82.75" 79.0" Centerline Nozzle Azimuth (UDRPS) 124.1' 237.5* 100.5' Depth from ID Surface 10.88" 10.79" 10.15" Depth from OD Surface 4.5" 5.1" 5.5" Method (Tr UDRPS (Tr UDRPS ITF UDRPS Length "1" 0.74" 1.34" 0.50" 1.11" 0.64" 2.45" t ru-Wall Dimension "2a" 1.32" 1.20" 0.98" 1.14" 1.44" 1.58" Nominal Wicknes: "t" 9.0" 9.0" 3.0" 9.0" 9.0" 9.0" Surface or Subsurface Sub. Sub. Sub. Sub. Sub. Sub. Aspect Ratio "a/1" 0.5 0.44 0.5 0.5 0.5 0.32 a/t 7.3% 6.7% 5.44% 6.3% 8.0% 8.8% 1 i l l l L
TABLE 1-B-COMPARISON OF CONVENTIONAL ULTRASONIC EXAMINATION DATA FROM PRESERVICE AND INSERVICE EXAMINATIONS Indication No. 3A 4A 22A Year 1977 1984 1988 1977 1984 1988 1977 1984 1988 Exam. Angle O'L O'L 0*L O'L O'L O'L O'L 0*L 0*L Radius from Vessel - 83.0 83.5 - 82.75 82.75 - - 79.0 Centerline (inches) Depth from ID - 10.77 10.88 - 10.77 10.79 - - 10.15 Surface (inches) Length "1" (inches) - 0.39 0.74 - 0.70 0.50 - - 0.64 h ru-wall Dimension - 0.88 1.32 - 1.21 0.98 - - 1,44 "2a" (inches) Nominal h ickness - 9.12 9.0 - 9.12 9.0 - - 9.0 "t" (inches) Surface or - Sub. Sub. - Sub. Sub. - - Sub. Subsurface , Aspect Ratio - 1.12 0.5 - 0.85 0.5 - - 0.5 "a/1" a/t - 4.8% 7.3% - 6.6% 5.44% - - 8.0% % DAC - 69% 100% - 100% 65% - - 100% 1
1 TABLE 1-C INDICATION ANALYSIS INFORMATION INDICATION NO. a a/t S* Sigma t Sigma /t COMMENTS 3A .66" 7.3% 1.4" 2.1" 9.0" .23 Conventional trr 4A .49" 5.4% 2.1" 2.6" 9.0" .29 Conventional trr 22A .72" 8.0% 3.5" 4.2" 9.0" .47 conventional trr 3A .6" 6.7% 1.4" 2.0" 9.0" .22 UDRPS 4A .57" 6.3% 2.1" 2.7" 9.0" .30 UDRPS 22A .79" 8.8% 3.5" 4.3" 9.0" .48 UDRPS .
- S was taken from scaled "CAMP" plots from closest extremity of indication to u ld taper.
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v ENCICSURE 2 INITIAL
SUMMARY
REPORT ON INDICATIONS 1 AND 8 OF WELD NO. 6 1.0 Weld Location 2.0 conventional Ultrasonic Examinations 3.0 Supplemental Ultrasonic Examinations Using UDRPS 4.0 Characterization of Indications 5.0 Use of the Dynacon UDRPS for Evaluation of Data 6.0 Review of Fabrication Radiographs 7.0 Review of Post-Hydrostatic 'lest Ultrasonic Examination Report 8.0 Preservice and Inservice Examination Results l
l.0 Weld Location Wold No. 6 is a lower shell longitudinal seam which is located at 133' as showr, in the elevation and plan views of Figures 2-A and 2-B respectively. 2.0 Conventional Ultrasonic Examinations t Results of the conventional ultrasonic examinations of indications 1 and 8 are summarized in Table 2-A. Locations of these indications relative to Weld No. 6 are shown in rigures 2-C and 2-D respectively. 3.0 Supplemental Ultrasonic Examinations Using UDRPS In order to obtain better information regarding the nature and size of these ultrasonic indications, it was decided to utilize the Dynacon Ultrasonic Data Recording and Processing System (UDRPS) with the conventional inservice inspection transducers. We UDRPS system has the capability of recording, storing, processing and imaging ultrasonic test data. his capability allows for more flexibility in evaluating the data. Indications 1 and 8 were both found using the Westinghouse 10-year near surface array plate. %e transducers on this plate consist of 2.25 MHz, transmit-receive, focused transducers aligned to provide an incident angle of approximately 12.2' or an approximate 60' refracted longitudinal wave in the material to be examined. For the UDRPS examination these units were also adjusted to provide an incident angle of approximately 10.2* or an approximate 45' refracted longitudinal wave in the material to be examined. Results of the UDRPS examinations of indications 1 and 8 are sur:rnarized in Table 2-A. 3.1 Longitudinal Weld Seam No. 6, Indication No. 1 This indication was detected with transducer AD4 during the conventional ISI, his transducer's beam is directed along the axial direction of the reactor vessel with the beam propagating toward the top of the vessel. his indication was examined using UDRPS with transducer AD4 configured in the normal 60*L arrangement and a supplemental 45'L arrangement, and with transducer AD3 (complimuntary axial direction transducer with the beam propagating toward the bottuu of the vessel) configured in the same manner. We results of these examinations can best be seen in Figures 2-E and 2-F. A brief explanation of these figures is provided below. Figure 2-E (Transducer AD4 - 60'L Scan) In the image of the data there appears to be a band of higher amplitude signals. his band of signals in nd the indication 1 response (identified on the figure) and r? caused by the interfaces associated with the stainletr W.el cladding, one
interface is between the water and the cladding and the other is between the cladding and the base metal of the shell, he indication response is clearly within these two interfaces. Associated with the peak response from the indication (magenta in color) is a trailing secondary response (green in color). his is evidence that the indication is a volumetric reflector embedded in the stainless steel cladding. Figure 2-r (Transducer AD4 - 45'L Scan) Aow.n, in this image a band of higher amplitude signals is evident, his band is bounded by the clad interfaces as discussed above for rigure 2-E. Again, the indication 1 is within these bounds. h e data from transducer AD3 was reviewed but proved to be not very useful in evaluating this indication due to poor detection results. Therefore, indication 1 of weld 6 is interpreted to be a volumetric-type flaw in the stainless steel cladding. This indication is not within the required examination volume and is not subject to ASME Code, Section XI siring. 3.2 Longitudinal Weld Seam No. 6, Indication No. 8 h is indication was detected with transducer AD2 during the conventional ISI. This transducer's beam is directed in the clockwise direction when viewed from the top of the reactor vessel. his indication was examined using UDRPS with transducer AD2 configured in the normal 60*L arrangement and a supplemental 45'L arrangement, and with transducer AD2 rotated 180' (beam in counterclockwise direction) configured as a 60*L and a 45'L. W e results of these examinations can be seen in Figures 2-G through 2-K. A brief explanation of these figures is provided below. Figure 2-G (Transducer AD2 - 60'L Scan) he stainless steel cladding can be seen in the image by the band of higher amplitude signals. We bounds to this band of signals are the cladding interfaces with the water and the carbon steel. Indication No. 8 is within these bounds. A trailing secondary response is seen which is indicative of a volumetric type reflector. Figure 2-H (Transducer AD2 - 60*L Scan) h is figure shows the linear extent of Indication No. 8 at higher gain settings. This indication is highly reflective from 256.9 to 257.31 inches below the vessel flange and from 256.5 to 256.6 inches below the vessel flange. Werefore, it has an approximate length of 0.41 inch and 0.1 inch with a separation in between of approximately 0.3 inch.
rigure 2-I (Transducer AD2 - 60'L Scan) his figure is the same as Figure 2-G. I' clearly distinguishes the indication maximum response and its associated trailing secondary o6 satellite response. his trailing response is indicative of a volumetric and rounded type of reflector, rigure 2-J (Transducer AD2 - 45'L Scan) Again, a band of high amplitude signals clearly define the extent of the stainless steel cladding. Within these bounds a response from Indication No. 8 is observed. Figure 2-K (Transddcer AD2 Rotated 180' - 60*L Scan) As with the previous figures, a band of high amplitude signals clearly defines the extent of the stainless steel cladding. As before the Indication No. 8 response is within these bounds. Also, although not ider.tified in the figure, there appears to be a trailing secondary response. Examination data using a pulse-echo, 0.5" x 1.0", 5 MHz, O'L transducer and the transducer AD2 rotated to provide a O' incident angle was taken and reviewed, but the results were inconclusive. Therefore, Indication No. 8 of Weld No. 6 is interpreted to be a volumetric type flaw in the stainless steel cladding. Wis indication is not within the required examination volume and is not subject to ASME Code, Section XI sizing. 4.0 Characterization of Indications Characterization is defined as "the determination of whether a valid indication originates from a volumetric or planar type defect". Generally, the use of supplemental straight beam techniques provides for the verification of a volumetric type flaw (i.e., slag, porosity, etc.) since a relatively strong reflection should occur from both. Planar flaws, however, should reflect little or no energy to a straight beam transducer. Another supplemental characterization techniq}ie is based on satellite pulse observation technique (SPOT) principles . Spor relies on the observation of a doublet signal emanating from a volumetric defect. This doublet consists of a strong specularly reflected signal, follo e 'ay a weak, synchronous satellite pulse response. his satellite pulse is created by a portion of the sound beam propsgating around the circumference of a rounded type of reflector and being reradiated back to the receiver transducer. Synchronous means that, yhen the specularly reflected signal peaks, the associated satellite
- Gruber, G. J., G. J. Hendrix, and W. R. Schick, "Characterization ; of Flaws in Piping Welds Using Satellite Pulses", Materials Evaluation, Volume 42, April 1984, pp. 426-432.
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pulse signal should also peak with the satellite pulse lagging in arrival time. Werefore, these two peaks should occur in the same A-scan. On a system such as UDRPS, two relatively close parallel images, one behind the other, would be indicative of synchronous signals and, therefore, a volumetric type of defect. For planar flaws, SPOT also relies on the observation of a doublet signal but these signals are asynchronous in nature. In this case the satellite responses are created by a portion of the sound beam being reradiated from a planar flaw extremity back to the receiver transducer. Since the extremities of planar flaws are separated in position, the peaks of each extremity would not occur in the same A-scan. On a system such as UDRPS, two parallel images shifted in position would be indicative of asynchronous signals and, therefore, a planar type of defect. For the supplemental examinations of indications 1 and 8 of the longitudinal weld seam 6 using UDRPS, synchronous satellite signals were observed in the images suggesting volumetric type reflectors. 5.0 Use of the Dynacon Ultrasonic Data Recording and Processing System (UDRPS) for Evaluation of Data The UDRPS system allows for more extensive recording of data, better visualization of examination data through the use of color-coded images, more flexible manipulation of data, more consistent examination quality, and archival retrieval of past examinations for comparison purposes. In terms of amplitude-drop sizing methodologies, the UDRPS system has the same fallacies as conventional ultrasonic examination methodologies (-6 da drop, 50% DAC). For small flaws it will still provide estimated sizes more consistent with the beam size of the transducer rather than the size of the flaw (for beam sizes greater than the size of the flaw). For the indications in the nozzle-to-shell welds, a sizing methodology known as -6 dB amplitude drop or half maximum technique was applied. This methodology was applied because overall (on a defect matrix consisting of volumetric and planar type flaws) it has been shown to provide the more accurate results when compared to other amplitude-based tephniques such as 50% DAC, 20% DAC, and 20% DAC with beam correction h e best use of the UDRPS data is the ability to observe secondary responses and their relation to the primary signals from the indications, his aids in the characterization of the reflectors as well as providing more accurate sizing information.
- Willetts, A. J., F. V. Ammirato, and E. K. Kietzman, J. A. Jones
, Applied Research Company /EPRI NDE Center, Accuracy of Ultrasonic Flaw Sizing Techniques for Reactor Pressure Vessels, Draft Interim Report, EPRI RP 1570-2, March 2, 1988. 1
- __ - ___ __ - - - _ _ . ._ - _ _ , - - - _ _ _ ~ _ . _ . . .--
6.0 Review of Fabrication Radiographs Construction radiographs of the Farley Nuclear Plant Unit i reactor vessel longitudinal weld 6 (CE No. 20-894A) were reviewed in an effort to establish whether or not a correlation exists between 1988 ultrasonic data and results from the 1971 construction radiographic examinations. h e radiographic technique for vessel shell exams specified the use of Kodak "AA" film in a double loaded cassette with a high energy X-ray source located on the outside vessel diameter. Results for Indication No. 8 A distinct 3/16" near surface defect is noticeably 2" to the left of the No. 8 marker on shot 8-9, at the edge of the weld prep. This RT indication is in the vicinity of indication 8, which is interpreted by ultrasonic data as being a cladding defect. A more definite correlation cannot be expected on this particular flaw because the lower shell course longitudinal weld radiography was performed prior to final vessel assembly, and ultrasonic data is referenced from as-built weld locations in the assembled vessel. Weld for Indication No. 1 Indication 1 is actually located at the intersection of weld 6 and weld 8; therefore, the weld 8 (CE No. 12-894) radiographs were reviewed. From available records, the radiographic numbering system for weld 8 was referenced as starting from the inter'ection of weld 6 and weld 8, making the 50-1 radiographs and the 1-2 radiographs applicable to the area of interest. In both the 50-1 and 1-2 sets, a small 3/32" rounded indication is noticeable in the area relating to indication 1. Although depth cannot be determined conclusively from radiography, the location of the flaw corresponds well with t7r results and the correlation can be considered reasonable. 7.0 Review of Post-Hydrostatic Test Ultrasonic Examination Report In 1973, the Farley Nuclear Plant Unit I reactor vessel was examined by manual ultrasonic examination techniques for acceptance to Section III Paragraph N-625, 1968 Edition with addenda up to and including Summer 1970. 1 Results from weld 6 (CE No. 20-894A) were reviewed in an effort to establish whether or not a correlation exists between 1988 remote inservice ultrasonic data and manual contact examinations. The review results in no correlation being established between the i two data sets.
For Weld 6, ultrasonic data plots show a number of lower-amplitude indications noted for the record having metal paths of 2" and greater. Examinations were conducted from the o.D. and I.D., with no recordable indications reported at the I.D near surface. 8.0 Preservice and Inservice Examination Results I Both indications were detected using a near surface examination technique which was not utilized during preservice inspection. Despite this difference in technique, no recordable indications were noted in the preservice examination which could be correlated wi d the indications found in 1988.
t TABLE 2-A : CONVDTIIONAL AND UDRPS UL'Il% SONIC EXAMINATICH EATA TROM 1988 INSERVICE EXAMINATION Indication No. 1 8 Examination Angle 45'L Nominal 45'L Nominal 60'L Nominal 60'L Nominal Angle from Vessel O' 135.84* 136.66' Depth from riange (UT) 332.82" 256.73" Method Ur* UDRPS** UT* UDRPS** Depth from ID Surface .34" N/A .25" N/A , I Length "1" .24" N/A .36" N/A t ru-Wall Dimension "2a" .43" N/A .48" N/A , Nominal h ickness "t" 7.95" 7.95" i.95" 7.95" Surface or Subsurface Sur. Sur. Sur. Sur. Aspect Ratio "a/l" .5 N/A .5 N/A l a/t 5.4% N/A 6.03% N/A
- 60'L Nominal
** 60'L and 45'L Nominal 1
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