ML20203E325
| ML20203E325 | |
| Person / Time | |
|---|---|
| Site: | San Onofre  |
| Issue date: | 06/30/1992 |
| From: | Chiu C, Mostata M, Strom W SOUTHERN CALIFORNIA EDISON CO. |
| To: | |
| Shared Package | |
| ML19317C790 | List:
|
| References | |
| RCE-92-019, RCE-92-19, NUDOCS 9712170019 | |
| Download: ML20203E325 (39) | |
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SONGS 3 PRESSURIZER LEVEL-INSTRUMENT NOZZLE LEAKAGE RCE 92-019 r
9712170019 971212" PDR ADOCK 05000 M1
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June 30,1992 1
MESSRS.: M. P. SHORT L O. CASH
SUBJECT:
Root Cause Evaluation 92-019
- SONGS 3 Pressurizer Level Instrument Nozzle Leakage" RCTS No.: 9206046 This letter transmitts the root cause analysis of the leak found in SONGS 3 pressurizer
- nozzle 407-10B during February 1992. The root cause of the nozzle failure was determined to be primary water stress corrosion cracking (PWSCC) in the INCONEL 600 material, possibly assisted by cold work of the inner surface during fabrication.
The_four yapor space nozzles were replaced using thermally treated INCONEL 690. In addition, great care was taken to minimize cold work during nozzle fabrication. We recommend the following action to make this change at SONGS 2:
Resoonsible Manaaer Action Recuest L O. Cash Replace the SONGS 2 pressurizer vapor space nozzles using thermally t ea cd INCONEL 690. Exercise care to minimize cold work dunng fabrication.
RCTS NO. 9206046 has been established reflecting your need for action regarding the attached evaluation. Please identify the responsible individual and forecast completion date to the ISEG RCTS Coordinator, Maria Corba, by July 31,1992, to facilitate tracking.
If you have additional questions, please call me or M. S. Mostafa (86015).
)
MSMostafa:mc Attachment he C. CHlu /
cc: Harold B. Ray H.- E. Morgan WAV. Strom R. W. Krieger B. Katz CDM' ~
M. A. Herschtha! G. L Johnson, Sr.
4 un-o CLARIFICATION OF PURPOSE This report Is intonded to be a self-critical use of hindsight to identify all problems and the sources of those problems. The root causes identified in this report were discovered and analyzed using allInformation and results available at the time it was written. - All such information was, of course, not available during the timeframe in which relevant actions were taken and decisions were made.
l The purpose of using such a self-critical approach is to provide the most comprehensive analysis possible for identifying ' lessons learned" as a casts for improving future performance. The use of an open, documcated self-critical analysis program is Imperative in the nuclear power Industry and cannot be compromised or confused with a
) management prudency assessment i
They, this report does not attempt to make a balancedjudgement of the prudency or
- easonablerms of any of the actions or decisions that were taken by vendors utlltf , i management, or indMdual personnel based on the information that was known or i available to them at the time.
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SONGS 3 PRESSURIZER LEVEL INSTRUMENT NOZZLE LEAKAGE RCE 92-019 -
AUTHORED BY: vhf J M. S. Mpstafa /
REV EWED BY: 8/!
W. W. Strom, Supervisor Independent Safety Engineering APPROVED BY: 1 1Mf C. Chiu, Manirger Safety Engin;iering s
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-TABLE OF CONTENTS EXECUTIVE S U M M ARY . .. ... ... ............. .... ..... .. .. . .. . . . . .. ..... . ... .... ....... .. ... . ........... .... .... .........
1 INDUCTION................................................................................................................. 2 4
PROCEDURE....................................................................................................................- 2 :
- R ES U LTS AN D DI SCU SSION ............... .......................... ............... ... -.......... ...................... 3 SU M MARY AN D CO N CLU slo N S ........................... ..... . ..... .... ............................................... 5 R nv vn OMMc"ATi^".............................................................................................................. 6 REERMCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . . . . . . .
TABLEI................................................................................................................................ 8 TABLE 11.................................................................................................................................. 9 FIGURES t
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- EXECUTIVE
SUMMARY
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_ During pressurizer _ weld inWi in February 1992 at SONGS 3, rust stains were observed in - i the vicinity of the level instrument nozzle two. 407108. Further inspection of the same nozzle
- indiosted through wall cracking,-in addition to the presence of cracking in two more nozzles; -
- 40710A and 407100. ,
These four nozzles were removed and the remnants from each nozzle were analyzed for material integrtty.- The cracked zone of the three nozzles A, B, and C were destroyed during the removal process.
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The laboratory analysis of these remnants !ndicated the presence of a cold work layer on the inner diameter sh' . face of nozzles B ,n , C a d D I nthe case of nozzle B, a small sub surface crack was found coincident with a cold worked surface area. These three nozzles B, C, and D i had been previously replaced in 1986 and 1967 with similar material (alloy 600) with a yield i strength of 53.5,51.6 and 53.5 Ksi, respectively. ,
Nozzle 'A' was found cracked, but not through. wall, had never been replaced and had a yield s
of 38.5 Kal. This nozzis was found to have intergranular stress corrosion cracking-
, (l ) on the I.D. surface not associated with any cold work zone.
Taking into cor, sideration the industry failure history of alloy 600 in pure water high temperature
- conditions (even with low yield and with thermal treat:nont) as compared to the superior performance of alloy 890 in research laboratories (EPRI and Japan) in simultated PWR and BWR -
conditions, alloy 690 was recommended to replace alloy 600 for nozzle application, Ariditional care was taken during fabrication of the new nozzles to assure absence of a cold work surface layer and minimal I.D. surface irregularities. A sample of each nozzle was microscopically tested and visually inspected as part of the OA acceptance criteria of each
, nozzle.
The same type of repair will be applied to SONGS 2 during the cycle 7 refueling outage.
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INTRODUCTION On February 14,1992, during the cycle 6 refueling outage, rust stains were observed in the -
vicinity of SONGS : Pressurtzer level instrument nozzle No. 40710B during insulation removal for pressurtzer weld lospection . Further penetrant 'nspection of the same nozzle performed or.
February 18,1992 revealed one through wall axial crack indication and another smaller crack hdication estimated to be 0.3' deep. The length of these indications was not measured.
Additional PT inspection of the other three vapor space nozzles No. 40710A,407100, and 407-10D revealed the presence of smaller crack indication in nozzles 40710A and 40710C. The estimated depth of these indications was 0.17*. The length of these crack indications was also not measured.
Leaning nozzls No. 40710B had a yield strength of 53.5 ksi and had been annealed at 1800'F for 30 minutes. Cracked nozzles 40710A and 407100 had a yield strength of 38.5 ksi and 51.6 ksi, respectively. Nozzio 40710C had been annealed at 1625'F e 25'F for 30 minutes then air cooled, while nozzle 40710A was in the mill arocaled condition.
In February 1986, a leak was detected and traced to nozzle No. 407100, and the failure analysis identified the f "v as pure water stress corresion cracking (PWSCC) and attributed it to high yleid strength (Bi t ksi). As a result of the failuru analysis performed at that time all nozzles in the vapor space in Unit 3 with same yield strength (heat #54318) were replaced by a lower ylcid st.ength material of 51.6 ksi (heat #NXO571) and 53.5 ksi theat #94758). Nozzle 40710A had low yield strength cf 38.5 ksi and was not replaced.
The identification numbers c! the four vapor space nozzles mentioned above are per SCE original drawing No. SO23-910 77 0 and CE Drawing No. E 235138. These nozzles were given different identification num>ers throughout the process of NDE and repair, however, for consistency throughout this report the four nozzles will be referred to as nozzles No. A, B, C and D for nozzles 40710A,407108,407100, and 40710D, respectively. Table 1 of this document references the different given I.D. numbers of each nozzle.
ANALYSIS PROCEDURE The indications revealed by PT inspection of leaking nozzle B indicated an approximate crack length of 2' extending from the J-weld along the length of the nozzle. The other cracks on nozzios A and C were also in the vicinity of the J weld.
The removal process of the old nozzles required grindhg at the J weld and grinding of the nozzle to a distance approximately 7/8' (M average) as measured from the I.D. surface of pressunzer vessel. With a crack Indication 2* Iong, a portion of the crack would t>e expected to remain on the remnant part of nozzle 'B', but the cracks on nozzles A and C were expo ~.ed to have been ground out during the removal process.
The removed nozzles wco first cleaned in acetone using an ultrasotiic bath to assure the removal of all chemier.h +,1troduced during the PT process and during the removal process.
Each nozzle was then dya penetrant inspected for any crack indication, with particular care given to the leaky nozzle. This test revealed a false indication on the I.D. surface and did not reveal the remaining portion of the through wall crack on nozzle B. Each nozzle was thers ultrasonically cleaned in acetone for 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> to assure the removal of the penetrant chemicals, in oreparation for addition PT inspection.
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l RCE 92-019 .k m re, teat f
I Further fluorescent PT inspection was performed on each nozzle. This technique is much more sensitive in detecting tight cracks than the regular PT inspection. This technique did not reveal the through wall crack on nozzle B.
As a last attempt in search of the crack on sample B, a helium leak test was performed. This test also did not detect any leakage. Thus, it was concluded that the through-wall indication on nozzle 'B' was not 2' long and was smaller than 7/8' long and was ground out during the removal process.
A transverse cross section of each nozzle at approximately 1/4' away from the ground end of the nozzle was prepared and inspected in the as polished and the as 6tched condition. The purpose of this examination was to find microcracks, identify the I.D. surface condition, and determine the typical microstructure of each nozzle.
The results obtained from the microsection examination suggested further longitudinal cutting of each nozzle in order to examine the machined I.D. sutface condition.
RESULTS AND DISCUSSION Nozzle A The overall appearance of nozzle A afte.r removal is shown in Figure 1. The i.D. of the nozzle which had been ground during removal to a fine thickness measured at 0.045*, exhibited a cracking pattem as illustrated in Figure 2. The fracture surface denoted in Figure 2 was cut opened for SEM examination. The fracture surface was fresh in nature and was not oxidized (see Figure 3), that is to say, this cracking pattern did not develop in service but rather during the removal process. This was further supported by dimple rupture characteristics observed on the fracture surface (see Figure 4).
The microstructural examination of the prepared transverse microsection indicated the presence of Intergranular cracking all around the perimeter on the I.D. surface with an average crack capth of 0.6 mils (0.0006'), as shown in Figure 5. The limited crack growth may be attriouted to the low yield strength of the nozzle material and de absence of weld residual stresses. This microsection was prepared at approximately 2' away from the nozzle / vessel J weld, it is important to mention that 2 crack indications were detected on this nozzle in the vicinity of the J v ald area see Appendix 2 for details.
The microstructural examination of the same microsection also revealed the presence of a banded microstrunce (see Figure 6). Higher magnification and special etching revealed the nature of these bands as high carbide density bands as compared to the matrix. This is illustrated in Figures 7,8, and 9 representing band / matrix interface, the high density carbide band and the matrix, respectively.
The presence of high density carbidos bands may explain the cracking observed on this heat despite its considerable low yield strength (38.5 ksi). The carbon content is cor 3idered an important parameter that elects the susceptibility of Unconel to PWSCC. The higher the carbon content, the more susceptible to PWSCC.
it is possible that the cracks revealed by PT inspection in the vicinity of the J weld may have initiated from a high density carbide area and then propagated under operating conditions.
Since these cracks were ground during the removal process it is difficult to identify exactly the nature of crack initiation, but more likely cracking was due to PWSCC.
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NT 92419 .kme 19,1get Visual examination of the 1.D. surface of the remaining portion of the nonle revealed the presence of surface irregularities created during the fabrication of the nonJe. Typical apr>carance of the machining irregularities is shown in Figure 10, this I.D. surface condition may facilitate crack initiation via cold work.
Nonle B The appearance of the removed nonje is shown in Figure 11. The through wall crack on this nozzle was destroyed during the removal process. The intila! PT inspection reported the presence of an av' lindication that ran approximately 2* from the welded end. Additional testing of the ter aant part of the nozzle (which was cut at approximately 3/4' from the welded and) did not support the initial PT report on the Indication length. This additional lab testing included penetrant inspection, fluorescent penetrant inspection, helium leak tests, and finally a transverse microsection of he nozzle at the cut end.
The microsectional examination, however, revealed the presence of shallow subsurface cracks on the I.D. side and associated with the localized cold worked surface layer created during the fabrication of the nozzle. The appearance of this type of cracking is shown in Figures 12 and
- 13. As illustrated, this crack is not the through wall crack that caused the leak. The presence of these type of cracks combined with the surface imperfections created during the fabrication process (see Figure 14) may provide an explanation of the initial PT false 2' ind! cation results.
The yield strength of this nozzle is 53,000 psi. Introduction of cold work to the surface will further increase the yield strength at the surface. An independent study on mill annealed 600 alloy performed by the writer, showed that the yield strength may increase from 50 Ksl to 80 Ksl as a result of introducing 6% cold work. Thus, the resultant yield strength at the surface probably significantly exceed the CEOG recommended upper limit of yield of 50,000 psi to avoid PWSCC.
The cold work introduced during machining of the nozzle may have accelerated the process of crack initiation. The crack propagation in the examinea microsection, however, was slow due to the fact that this crack was located approximately 1.25* away from the heat affected zone where no residual stress exists. However, a crack of similar origin in the vicinity of the weld, initiated due to I.D. surface cold work, would propagate at a much faster rate.
Nozzle C Figures 15 through 18 represent the nozzle 'C' appearance and microstructure. The penetrant inspection performed by ABD revealed the presence of two small axial crack indications, see Appendix A. The examined section of the nozzle did not contain any cracking upon laboratory penetrant and visual inspection. The microstructure revealed the presence of carbide segregation illustrated in Figures 16 and 17.
The I.D. siirface was irregular and contained an overlapped surface introduced during machining (cee the arrowed location in Figure 18).
Nonle D Figures 19 through 24 represent nozzle *D*, During the removal process, the wall thickness of the tubo near the vessel shell weld was thinned down and apparently cracked. The fracture surface was free of oxidation, i.e., fresh fracture. SEM examinstion of this crack indicated dimple rupture, shown in Figures 20 and 21, typical of overloading ductile conditions, i.e., this 4
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crack developed during the removal process and did not develop in servios.
The I.D. surface microstructure shown in Figure 22 exhibited the presence of a cold work layer <
and an irregular topography with saw tooth appearance. This appearance may have resulted from fast feed during drilling the nozzle bar stock. This I.D. surface irregularity is illustrated in Figures 23 and 24.
SUMMARY
AND CONCLUSIONS The examined portions of the four nozzles removed from SONGS 3 pressurizer, did not contain
- any cracks that were previously revealed by the penetrant inspection. These crack indications were destroyed during the nozzle removal process.
i Visual inspection of the 1.D. surfaces of the four removed nozzles indicated the presence of rough suriace irregularities introduced during machining and fabrication of the nozzles.
Microstructural examination of the nozzle material near the 1.D. surface indicated the presence of a cold worked layer of an average depth of 2 mils (0.002*), introduced during machining, and in the caso of nozzle 'B,' s shallow (0.035' long) crack was coincident with a cold worked zone.
Carbide segregation and banded microstructure was significant in nozzle 'A*. This particular nozzle had the lowest yield .trength of the four nozzles (38.5 ksi) and was the only nozzle that exhibited intergranular cracking at the I.D. surlace in the remaining portion of the nozzle. This cracking has an average depth of 0.6 mils and was mostly due to PWSCC.
Nozzles A and D were cracked during removal, and these cracks were f'resh (no high temperature oxidation) and were ductile in nature (dimple rupture). The through wall cracking of nozzle B in service, was mostly due to PWSCC and perhaps initiated by the cold worked I.D.
surface layer.
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AT 224r0 .kne f9, f992 RECOMMENDATION Intergranular stress corrosion cracking of alloy 600 is known to occur in high temperature pure water conditions. Sev1ral criteria have been developed by the industry as guidelines to minimize IGSCC of inconel 600 alloy. These include lowering the yield strength to below 50 ksi ard lowering the carbon content to below 0.035. Additional thermal treatment has also been recorr. mended. Above and beyond the above mentioned guidelines, additional care to avoid cold working during the fabrication and/or handling is recommended. Better yet, the industry recommends the use of alloy 690 in lieu of 600.
Considering tne low yie!d strength criterion alone as a preventive measure for IGSCC apparently was not suffident as seen in the case of nozzle 'A' which has a 38.5 ksi yield strength and insignificant cold work on i.D. surface, but still IGSCC developed. Cracking in 'A' developed and propagated at a lower rate than in nozzics B & C which have higher yield strengths of 53.5 and 51.6 ksi. In other words, the low yield strength criterion cannot be used alone as a preventive measure for IGSCC.
The other trend in the industry and in research is thermal treatment. Thermal Treatment (TT) of alloy 600 has resulted in an improved resistance to IGSCC. However, a recent study by EPRI for Westinghouse indicates that IGSCC can still develop in thermally treated alloy 600 under simulated reactor coolant environments. EPRI and others are reporting that the new alloy 690 has far superior properties in terms of resistance to IGSCC even in a high cold work condition, l when compared to alloy 600.
As a result of this comparison between alloy 600 and alloy 690, alloy 690 in the thermally treated condition was recommended as a replacement for pressurizer nozzle material. In
' addition, significant measures were taken to assure minimization of cold work during the nozzle fabrication process. This was achieved via allocating a new drill bit for the final machining step, combined with visual and microstructural examination of a sample cut from each nozzle installed.
Drilling versus boring out 'he bar stock was evaluated prior to the fabrication of the replacement nozzles in terms of the amount of cold work and surface irregularities introduced. The results of this comparison showed that drilling introduces ! :ss cold work and less irregularities than l boring out. The reaming process was excluded since industry experience indicates it will cause l cracking in pressurizer nozzles.
The above recommendation to use alloy 690 in the TT conditions with care in fabrication to minimize induced cold work was implemented in the replacement of the four SONGS 3 pressurizer nozzles and later in the temporary repair of two nozzles on SONGS 2.
The reported yield strength of the replacement nozzles was 37.5 ksi with a carbon content of 0.02%. Nozzle samples tested for SCE by an independent laboratory indicated a higher yield strength of 48.6 ksi and a higher carbon content of 0.04% This discrepancy was discovered after the installation of the replacement nozzles. The impact of the difference in yield strength may not be as significant since the testing condition of alloy 690 showed insensitivity to cold working however the impact of higher carbon content may slightly lower the resistivity to IGSCC.
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REFERENCES , l
< oPl! &
- shop, Charlotte, NO October 1991, ' Steam Tests of Alloy 800 and Alloy 800 [
!, t46' ,oal Plugs' by R. J. Jacko and R. E. Gold +
- 2. EPRI NP 3081, May 1983, ' Stress Corrosion Cracking of Alloy 800 and Alloy 800 in All i Volatile Treated Water at Elevated Temperatures'
- 3. EPRI NP 3043, June 1982, ' Stress Corrosion of Alloy 800 and Alloy 890 in Acidic Sullate a
Solutions at Elevated Temperatures'
- 4. EPRI, ' Steam Generator Reference Book' May 1985, Chapter 18 l
- 5. T. Yonezawa, et. al.,1961, 'Effect of Cold Working and Applied Stress on the Stress .
Corrosion Cracking Resistance of Nickel Chromium. iron Alloys'
- 8. ASM, Metals Handbook Ninth Edition, Vol.13, Page 858 I
- 7. INCO Alloys intomational Product Uterature
- 8. Westinghouse letter: ' Evaluation of Westinghouse EPRI Prirr.ary Water Stress Corrosion Cracking Test Data for Elevated Uthium pH Environments', June 1990 .
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ACE 834ft Jwn fe, fear TABLE 2 EABRICATION HISTORY OF UNIT 3 PZR NOZZ.ES
~ Carbon Content- . . '~. .
Nozzle I.D Yield Strength (psi): % Heat No; : Heat Treatment History 40710A 38,500 0.06 NX7630 Mill Annealed 40710B 53.500 0.05 M758 30 min. at 1800*F 407 100 51,000 0.09 NX0571 30 min. at 1825'F 40710D 53.500 0.05 M758 30 min at 1800'F _
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RCE 92419
. lune 19,1992
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- RcE 92 019 Jrn 19,1931 l
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1 APPENDtX A !
ABB PENETRANT INSPECTION REPORT -i a
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i LIQUID PENETRANT EXAMINATlQH PLANT / UNIT 6OM&5 iI 3 Frr NO. 4, 9-COMP / SYSTEM PRZ . Op pdOws TASK NO. QCOD,RM ' PROCEDURE NO.OP 9.4 ~ReV 1R DOCUMENT NOJUDR7,% col REV. J BRAND NAME HEE BATCH NO. DWELL TIME CLEANER:
g$gdc2 Sogbe[
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PENETRANT: >t "
)O % o REMOVER: ts n
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DEVELOPER: n a
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Itstructions: Ccapletely describe ALL ltdications.
- If in the *as*wided" cerdition
- to state.
If ho irdleations wre fotrd + se state.
EXAMINATION WELD / AREA
~
DESCRIPTION / REMARKS MUCE5fdN5d5 G ooeR td c % \e s c d kNb E$
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5A SMA8 SPFF8 7 @$8@ N35ES augw ~. 4 w .y .&
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COMPONENT TEMPERATURE 9D NCR NO. Al/A EXAMINER 1. LEVEL I EXAMINER . DATE O !Sd 2
' LEVEL DATE REVIEWER . LEVEL DATE AUTHORIZED INSPECTION AGENCY ~
DATE 703 LFt (2/9u PAGE f OF k
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'. I APPENDIX B [
i SCE PENETRANT INSPECTION REPORT ;
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[ Southern California Edison Cornpany
, . .. ...,-. .v u e . . .a n a n . n.. . t a n.=
Report No. "l>/- C O /- 9.2.
INSPECTION REPORT Pepe / ot_ 1 Suppher o/m Purchaw Orcer No. #/4 _,
Unit No. 3 Oustity Class / inspection Date 2////92 Tirne /S"/s-Component Description u eear- /n e f,-um a T Work Oroer No._ #/4 no v v }r .P w vY/uo S_31181 MA '221 Section Xl Trsveier No. *)' AF Eouip. Tag / Serial No. 3 *1 12of ME /> f *> Procedure No. .*/ 4 Location Gw fa e'me+ eta t Reference Orswing No. #/4 Contact / Dept..isrey Ctoplon enn / A~m . NCR #lA CAR WlA DCP_.s**l* A7 REPORT
SUMMARY
The yper insframeart .vozzle for ya./ve $.112.0l*+1A 113 wa.s fIcodsd with Dye Pene tea.te at tAe ou.ts/de shell of f/>e pres.r ur lxer . Ins o'de af' th e wo 11 le wa. r Han observed using a. boeoscope , d bro <.d area. of pen e tra.te va.s n o ted 2" bacA pe rom a.pp co x /mrte 17
! t'),e in.r/de edye of Me sde// 4 a t a.pper v % <ta/y the 3 ocloc.k pori ti cn .
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.~efort lg jaf,,3 .saspp Ja'e*d to :
Jerry S+epf assoa / Sh.t raa4 foe ir d o e m t,',,,, ,,, j, ,
Distribution-
~3.*; days 7xf/'A4rAlFod, Sin.7Ec//.
Bill CTanwt Nst. ,
~
5A & #fet/MFA,40 @ Insmcrea By 2'~A >W Date .2l/fl92 Stamp No.
dEdr*1 Approved By / 1h / /d/ Cate [ " / Y
" .. . SE E KING CLARIFICATION, ATTENTION TO DETAIL . . . " SURVEILLANCE" 4. . "WITH" . . , "FORTHRIGHTEESS . . . . " Mr. Howard P.
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Allen's Letter. March M. t 905. -
g$outhera California Edisoa ComZry
. R - noA d-ooa- %
INSPECTION REPORT p,7 g g g Svoolier M!4 Purchase Order No.. N Jnit No. 3 Quality C! ass l Insoection Date Fekm ts. mt ume itso Component Description Os.,r Ldrumed Nenle Work Order No. M/A
_brNAlvc 5311o I mt 2.13 Section XI Traveler No. Mb Eculo. Tag / Serial No. 53 \1onmE087 procesure No. #/d Location b o$ ANN Reference Drawing No. N!"
Contact / Dept.hetru SokeAwn / EN. NCR N/4 CAR M/" DCP M!M REPORT SUMMA 6Y ^
De s((tt lab 4Nak n*2Nt < 05* f N
(4 n, hacstepe, h ideak.n c4 Yo v.%An'i d EA Waskoide Oc ibh c p AA ea i 3g.& Rep <t # 3 N - oo :- et. . N 3iie ..S.
OrtvaNi*^ o k be idh;sdton W er4 '
Incenedu.sive cd c dh M Q habt=ny) en N l43peden, A r.JJ iML wu ,,9.:k %
3o'ct.ck p sh 4 y.at,1 3 Y i n A % J a e e 9 4 % s tett.
01stribution:
Gruf art??AktswH), ETM. M*A.
B/ll 574 tor pSL D.8. .*51M6d// f4,Qt,G4rf instected Bv Y $ l Ca1. YISb2- Stamp No.-
dp @ Approved By / , _ //d/ N Date I ~M*82
. . . $1E KING CLARIFICATION ATTE NTION TO DETAIL . . . " SURVEILLANCE" . . . "WITH" . . "FORTH RtGHTNESS . . . . " Mr. Howerd P.
Ateen's Lettee. M.esh 26. t985.
SMSM4H .SW ofte
norssers Junefe, tsar i
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APPENDIX C MATERIAL CERTS OF REPLACEMENT -
NOZZLES AND ATLAS REPORT >
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CHATTmNooon rtELD sEnvCs g _ _ __l__95.100.. 37.200 t 49' G5J.
8 14'A. 10 7~50' ! N CO.
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87-AT 1923 DE'l to. -23 DEG FI AND AGED AT 1200 DEG. eto. -0 DEO --- - - - -
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ACc0 0ANCE wtTH AsNt-sa-lel EXCEPT COBALT 0.10% MAI LHD WE CERTIFY TilAT IllE MATERIAL filRNI51IED ON ll!!S PURCilASE ORDLR Y lELt: sTsE 40rn 50.000 P81 MAI.
ULTRA 80NIC INSPECTCt IN I IE fEEF E.E06.MEBCURLC0HABIMUOL ;
ACCOE DANCE WITil PARA. HB-2342 AND FROC. CEr-UT-020 ruv 3 WE CERTIFY TilAT NO WEED REPAIR IIAS DEEN PERf0RMED Off IllE 120 e ts. s 's . t tou1D FENETRANT FER FAR A NS-2382 f.ND PROC. 4 3 -P-020 REV Il 123 MAY '89).
(d NAIL [EIb( b!I N I((I_[0fI IIII5 PURCilASE ORDER. -
ABNE 90!s.Et Alio -
y PRE 351BE V :88EL '
CODE BECTIONS 11 8 ! !!'#CLAS8 IItse y EDITI3N ANI ) EEG IIRENENT8 Or 10Cra21 APPLY.
d Q[ h A89HUAMY SYSTEN CER TE(NATNUA y N [- -.
t 50 'h HARE EJM l-314"DIA I 3 FT RIL (ISO FT REQ'D) i _ NUNDER GSC-219--_ _ - - i TOL: *0.08.-0 (OlA I 8 HIPPED /d.I EXPNIATION DATE OF CERTECA1 AOS FT
- /f/6 IFCIIES j-_ . . _ -- ---=s- . - ..< ~~.. =e.- .~....+.
2 10 COPIEB or NILL TEST BEPORTD We cestify that the contents of this scr"'8 a'c t'"'ett an.1 xceivaec. :.ml sic. n.it opre .eions protoemcit I.y us :en.1 eme wisemte.wtors :nc in cemipli.wwe with she er.p4.ca.cmes of rt speciinati..ns tissed in the matreial elesasipsi.e. Ihw winansy .I epe lity gwms.tes 8.= ec.
'g pt: ccment only of any part of this m.stesial =I4ch satwerpient inspccti.m. test m asr sh. -
uanamo aau remo o neou.neut is ..m,,,,,,c,o,,,,,,o,,,,., ""a t'*8"""'acc *i"dc'r"ir.ca.i.ms. Inspecti.. .u a..ccitir.cas ;,ms.. hrmio,s l e.
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C o u tJ14 S T : 0 L a T o tt .E Chit r A rt V '
NOVEMBER 9, 1989 pr r. /Sb- NW '- -
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TE-. S 0 '.2.26 m92 CERTIFIF.D MATERIALS ll!ST REPORT
- ustemer: ABB Cembustion Eneineerine Alloy Inconel 690 (UNS 6690)
.ddress: 1201 Riverfrent Parkway Specification:ASME See II S8-166 (1986) -
lity, State, Zip:Chattancoca, TN 37402 Size: 1-3/4" dia x 15" Qty: 1 !
iL Job No.: 13-07-0001-003A _ Heat No.: n/a ID: J-8732-1 Chemical Analysis (Percent By Weicht):
- Aluminum Nitrogen i
Boron Niobium .
1 Cadmium Phosphorus -
Carbon 0.043 V' Si11 con 0.1P V Chromium 29.96 4 Silver Copper 0.006v Sulfur <0.001 /
Iron 9.17 / Tantalum Lead Tin _.
Magnesium Titanium Manganese 0.20 / Tungsten Molybdenum Vanadium
~
Nickel 60.44 % Zinc' Other: . Cobalt <0.01
- Reviewed by: v//.A r'f8uf Dates ,o - 2 9 - 1/
Physical Precerties: ,
Ultimate Strength, psi 94,000 #
Y3 n d Strength, psi 48,200 Slongation, % 48 /
Hardness, HRB 85.6 Reducticn in Area, % n/r Tested by: ~"177 . tD. Id Date: S- / 4 - t /
Reviewed by: C., ,-* P4u Date: 9' I- F/
Comonts : This allov eets both the chemical and_ mechanical recuirements cf AS:'E Section II SB-166-1996. Material was tested to the seecificatiens and recuirements of the same.
SINGLETON LABORATORIES Kn:xvie. Tennessee pXg,N(sH ,
umn
.dF m
" ATL AS TESTING L ABORATORIES, INC -
di J IM .
A stJescouror Aanm7s, we
- h[ 6929 E.SLAUSON AVE.
- COMMERCE,CA 90040 e (213)722 8810 p
CHEMISTS - METALLURGISTS - ENGINEERS ar IN ACCOUNT WITH SO. CALIFORNIA EDISION 5000 PACIFIC COAST HW.
P.O. BOX 128 SAN CLDiLNTE, CA 926F ATTH: Mostafa DATE W3082 CUSTOMER ORDER NO.
CUSTOMER SHIPPER NO.
LAsORATORY NO. 92-204355 ocurrigo pxg7 wo, Submitted Ast MATE 8tAL Inconal 690 SPECTICATON AS W E 8 HEAT TREATING CO.
WITNESSED BY teECMAmecAL TEST REPORT YIELD STREtsSTN TIN 81Lt $TRENoTH ACTUAL ACTUAL ACTUAL PoONos PER stas ACTUAL POUN0s PER ELONSATIOh MisA LOAD IN Les. 80. ssocN Tl "OUCIO LOAD IN Las. 80.INCN IN 1.4" ga,,, Diassessaces OF msg 1 .357 .1000 4,860 48.600 9,560 95,600 7g,,
2 .357 .71 51.0 .230 59.0
.1000 4,800 48,000 9,430 94,300 3 .355 .0990 5,020 .71 51.0 .225 60.0 50,700 9,580 96,700 .69 49.0 .225 60.0 CRO{ICAL ANALYSIS Atlas (Spectro Carbor l
Atlas (DCP)
Mangar ese 0.046% 0.039*
Phospt orus 0.20 0.20%
Sulfut *o0.01 Silicc n 0.003 0.21 0.19 ChromJum
- 0.00 29.12 TitanJ um Coppet 0.26 0.25 Alumir um 0.06 Iron 0.56 0.55 1 0.00 Nicke] 9.80 Remainder
- Loss than *Perfc tmed at )urkee Tasting, Carbon ty Comboscion MAXtMUM REOUIREMENTS MINIMUM REOUIREMENTS YtELD STRENGTH AT
.2% Offset C.d*: REMARRS: For information only.
3 (F) led. net. tie.
.] to -
me.6. 44. , ,.==t D tl b,.a. .ee. . t u
3UB3CnmED AND SWORN TO BEFORE ME THIS RESPECTFULLY SUBMITTED DAY OF 19 i I
~
NOTARY PUBLIC N Aho tom Tut ecuMTv or Los ANottes, sTAft or cAutomhiA
- %#* % ff 0t##
~
9, AT S TESTING LABORATORIES,INC.
ATLAS TEstiho (Asoutoaits, iNC. susuits This ht*omt As Tnt con,so tNTiAL PROPERTY Cr OUR CUENT PEM0iNC OUR WRiTTth APPROVAL As A MUTUAt PROTscTION TO tlc
. THE PU8 OUR AND ChitNT QURSELVas. . REPRODUCTION RIGHTS ARC RESERVED
Action Request Assignment Report Dato Printed: 11/26/97 08:3 :28
~
initial Root Cause l Action Request #: 970300092- 02
- Assignmesit Type:IRC Resp Org: L2300 Category: 90 CLOSED Priority: 20 Ass % nee BUXTONGS Forecast ") ate:
Reference:
Due Date:
GeneralTabIntormation:
Originator: WATTSOPC L4300 89232 Added: SYSTEM 3/4/97 02.52:24 Updated: BUXTONGS 3/14/07 09;33:49 Problem
Description:
Notification text - Perform an inital root cause assessment per the referenced AR.
DESC- STEAM (1 FT PLUME) EMITTING FROM AREA OF TEMPERATURE ELEMENT 2TE0101. FOUND DURING MODE 4 OPERATIOfJ. PLANT SHUTDOWN REQUIRED TO REPAIR. COMPLLANCE (MCGAWN)
NOTIFIED. NEED INSL*LATION REMOVED TO BETTER IDENTIFY THE NATURE OF THE LEAK. I I
Reference Tab information:
Text TabInformation:
ASSIGNMENT. TEXT PERFORM AN INITIAL ROOT CAUSE ASSESSMENT PER THE GUIDANCE OF SO123-XX-1 Cautlort DO NOT close this IRC unless an associated operability issues have been resolved
...-m The following summarizes the findings of Dr. Mostata on the root cause of this tallure:
The p t nonle was inspected visually using a borosmpe, using UT and Eddy Currert.
Visual inspection revealed the presence of:
- 1) two stain longitudinal mais on the LD. of nozzle, one at 1:00 and the other at 11:00 o' clock positions and located on tre inside end of the nozzle, Le. near the pzr LD. The clock position was given as facin0 the pzr at the nozzle location.
- 2) a crack indcation on the I.D. surface near the pzr I.D., The indicaton is }agged in nature and oriented at an angle with the nozzle axis and losited approximately 0.5* from the nozzle end.
- 3) severe surface roughness and gouges from machining.
Lir Results:
Page 1 of 2
Action Request Assignment Report Date Printed: 11/26/97 08:37:28
~ -~
I[straigN beam LJT kpiled at the nozzio outside-end surface revealed the presencio^ tin in7dicat n beated at 11:00 o'cbck and at approximately 0.6' from the nozzle end ( pzr i.D.). No other indicate were detoded. This supports the visual observations.
- 2) angle beam ( 45deg) was unsuccessful in detecting the 11:00 o' clock indication mentbned above.
Eddy Currere Testwig Resu'ts:
The testing revealed a strong signal near the nozzle inner end ( pzt LD, side), and approximately located at 0.6* from the nozzle inner end. Again this is in support of the visual and UT findings.
Conclusions:
The bcation of the indcation as revealed by the VT,UT, and ECT indicates that the crack la at the proximity of the J-weld HAZ ( 0.6* from the nozzle end). Also the crack went through the nozzle material
( as viewed on the I.D. surface of the nozzle). Crack most likely had inihated at the end of the J-weld in the HAZ ( nozzle side) and propagated through the nozzle wall thickness providing a leak path.
The crack most likely was caused by PWSCC ( from the apparant je90ed appearance) and typical of 1000 alloy ki pure water enviroments.
Mostata, M.S.
3/6/97 Approval Tab information:
Code To Status From By Timestamp Pax l CHO-RESTR FREYDE 37&S7 10:28:13 AR Restraint has changed for assignment: 2 Type: IRC old value was *0.0" CHO RFC FREYDE 3,7&S7 10:28:13 Required for Operab'tity has changed for assignment: 2 Type: IRC old value was T A 90 10 FREYDE 378/97 10:28:07 89634 Notes Tab Information:
I I
- END OF REPORT -
l l
Page 2 of 2
Action Request Assignment Report Date Printed: 11/26/97 08:37:28 initial Root Cause
'C . Action Request #: 970300092 ' AssignmentType:IRC ReepOrg L2300 Category: 90 ~ CLOSED Priority: 20
-- Assignee DUXTONGS Forecast Date:
Reference:
Due Date:
AR Restraint: REO For OPER; General Tab information:
Originator: WATTSOPC L4300 89232 Added: SYSTEM 3/4/97 02:52:24 Updated: BUXTONGS 3/14197 09: 2 49 Prot >lem
Description:
Notsfication text - Perform an initial root cause assessment per the referenced AR.
DESC - STEAM (1 FT PLUME) EMITTING FROM AREA OF TEMPERATURE ELEMENT 2TE0101. FOUND DUR!NG MODE 4 OPERATION. PLANT SHUTDOWN REQUIRED TO REPAIR, COMPLlANCE (MCGAWN)
NOTIFIED. NEED INSUt.ATION REMOVED TO BETTER IDENTIFY THE NATURE OF THE LEAK.
Reference Tab information:
Text Tabinformation:
ASSIGNMENT. TEXT PERFORM AN INITIAL ROOT CAUSE ASSESSMENT PER THE GUIDANCE OF SO123-XX 1 Caution: DO NOT close this IRC unless all associated operability issues have been resolved The followin0 summarizes the findings of Dr. Montafa on the root cause of tNs failure:
The pzt nozzle was inspected visually using a boroscope, using UT and Eddy Current Visual inspection revealed the presence of:
- 1) two stain lon0ltuN' n.to on the LD. of nozzle, one at 1:00 and the other at 11:00 o' clock positions ard ' b*e: ' 1he inside end of the nozzle, Lo, near the pzt I.D. The clock position was given as facire :m the nozzle location.
- 2) a crack indication on the LD. surface near the pzr LD., The indication is ja0ged in nature and oriented at an angle with the nozzle axis and located approxirnately 0.5' from the nozzle end.
- 3) sevee surface roughness and gcuges from machining.
UT Results:
Page 1 of 2
t Acton Request A::'; .. ;..; Report Date Printed: 11/26/97 08:37:28
~
f) straight beam UT appNed d the nozz) outside-end su'rface revM the presorte of an indication .
U beated at 11:00 o' clock and at approximately 0.6' from the nozzle end ( pzt I.D.). No other indication :
were detected. This supports the visual observations.
- 2) argie be m ( 45 des) was unsuccessfulin detecting the 11:00 o' clock Indication mentioned above. -
Eddy Current Testing ResuRs:
The testing revealed a strong algnal near the nozzle inner end ( pzr LD side), and approxknately located at 0.6* from the nozzle inner end. Again this la in support of the visual and UT findings.
Conclusions.
The location of the indication as revealed by the VT,UT, and ECT indicates that the crack is at the proximky of the Fweld HAZ ( 0.6* from the nozzle end). Also the crack went through the nozzle material
( as viewed on the I.D. surface of the nozzle). Crack most likely had initiated at the end of the J-weld in the HAZ ( nonle side) and propagated through the nozzle wall thickness providing a leak path.
Tne crack moet likely was caused by PWSCC ( from the apparant jagged appearance) and typical cf 1600 ahoy in pure water enviroments.
Mostafa, M.S.
3/tV97 ApprovalTab Information:
Code To Status From Bv Timestamp Pax CH4RSSTR . FREYDE- 3/28/97 10-28:13-AR Restraint has changed for assignment: 2 Type: IRC old value was *0.0" CH4RPO FREYDE 3/28/97 1028:13 Required for Operability has changed br assignment: 2 Type: IRC old value was "Y' A 90 10 FREYDE 3/28/97 10 28:07 89634
- Notes Tabinformation:
l= l
- END OF REPORT -
4
- Page 2 of 2 i
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