ML20206U035

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Forwards Interim Rept on Ultrasonic Exam/Insp of Welds in Cast Stainless Steel Components at Facilities.Further Progress Made in Development of Improved Exam Technique for Cast Stainless Steel Component Welds
ML20206U035
Person / Time
Site: Byron, Braidwood, 05000000
Issue date: 06/25/1986
From: Ainger K
COMMONWEALTH EDISON CO.
To: Harold Denton
Office of Nuclear Reactor Regulation
References
1809K, NUDOCS 8607080291
Download: ML20206U035 (32)
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Text

{{#Wiki_filter:_-_ Commonwealth Edison A-72 West Adams Street, Chicago, Illinois Address Reply to: Post Office Box 767 Chicago, Illinois 60690-0767 June 25, 1986 Mr. Harold R. Denton, Director Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, DC 20555

Subject:

Byron Station Units 1 and 2 4 Braidwood Station Units 1 and 2 Inspection of Cast Stainless Steel Component Welds NRC Docket Nos. 50-454/455 & 456/457

Dear Mr. Denton:

Enclosed is a report titled " Interim Report on Ultrasonic Examination of Welds in Cast Stainless Steel Components at Byron and Braidwood Stations". This report describes further progress made by Commonwealth Edison in the development of an improved examination technique for cast stainless steel component welds. Calibration standards have been machined from a cast stainless steel elbow with attenuation properties comparable to the Byron /Braidwood cast material. Specially designed transducers have been procured which are capable of detecting the calibration holes and notches in the curved calibration blocks. preliminary examinations were performed with the newly developed ultrasonic instrumentation on several cast component welds at Braidwood Unit 2. The results of these trial examinations were successful. Attachment 3 of the enclosed report contains data from these examinations which shows that sound energy sufficiently penetrates the cast material to detect large flaws in the plant piping. Since this improved ultrasonic examination technique produces meaningful results, Commonwealth Edison will use this technique to examine, to the extent possible, the cast side of welds in the reactor coolant system at Byron Unit 2 and Braidwood. i joal Y

o Mr. H. R. Denton June 25, 1986 Please direct any questions regarding this matter to this office. One signed original and fifteen copies of this letter and enclosure are provided for NRC review. Very truly yours, K. A. Ainger Nuclear Licensing Administrator 1m Enclosure cc: Byron Resident Inspector Braidwood Resident Inspector l 1809K l i l

INTERIM REPORT ON ULTRASONIC EXAMINATION OF WELDS 1N 2 CAST STAINLESS STEEL COMPONENTS AT BYRON AND BRAIDWOOD STATIONS

Reference:

Letter from K.A. Ainger to H.R. Denton dated March 12, 1986 i I. Introduction Meaningful ultrasonic examination of cast stainless steel is difficult to perform due to severe attentuation, scattering and re-direction of sound energy-by cast material microstructure. The referenced document provided the history of Commonwealth Edison's efforts to meaningfully examine the cast stainless steel welds at Byron and Braidwood Stations. It described a program, recently undertaken by Commonwealth Edison, to develop an ultrasonic 2 examination technique that detects large flaws in the cast welds. This report describes progress made by Commonwealth Edison in the development of the new examination technique. The information presented here was discussed with the Nuclear Regulatory Commission (NRC) during conference calls held on May 23 and May 29, 1986. I commonwealth Edison is currently writing an ultrasonic procedure that i will detect flaws of sizes 2% through-wall and greater in cast stainless steel welds. Preliminary examinations were performed with the new procedure on the cast sides of several Braidwood Unit 2 welds. Data from these examinations show that sound energy suffici-ently penetrates the cast material to detect large flaws in the plant Piping. Despite some limitations due to component geometry, we believe meaningful examinations can now be made. Commonwealth Edison intends to utilize this state of the art procedure for preservice examinations at Byron Unit 2 and Braidwood as a best effort attempt j to meet the ASME Code Section XI examination requirements for cast i stainless steel welds. l II. Attenuation Properties of Byron and Braidwood Cast Elbows i Static cast fittings and components such as those used at Byron 2 and Braidwood 1 are known to cause high attentuation of ultrasound. Attenuation measurements were made using a 1.0 MHZ L-wave transducer. I and showed variable, but very high attentuation in the cast i components at both sites. The results are presented in Table 1.. Such attenuation properties hinder any attempt to meaningfully examine the cast welds. i i 4 n-. n-..--,,,,,...,,,.,,--..,n, snn..-, ,nn.--.a-, .,,n

. i III. Vogtle Plant Visit In November, 1985, personnel from the Electric Power Research Institute (EPRI) who were involved in preservice examination at the Vogtle plant visited the Byron site. For lack of a proper calibration standard, they were not able to perform a meaningful examination of the cast weldments. However, they did agree that the static cast components at Byron were highly attenuative and believed that examination of Byron would be more difficult than examination of the centrifuga11y cast components at Vogtle. They also recommended that commonwealth Edison should review the work performed at Vogtle before starting a procedure / technique development program. Commonwealth Edison personnel visited the vogtle site on November 25, 1985. The results of attenuation measurements made on the Vogtle calibration block are presented in Table 1. Discussions with Vogtle personnel further emphasized the necessity of a proper calibration standard and equipment for development of a reliable ultrasonic (UT) i technique and procedure. l IV. Calibration Standard ? Cast stainless steel elbows were available at the cancelled Marble Hill plant. Commonwealth Edison personnel visited Marble Hill on January ~1, 1986 and examined nine statically cast elbows, out of j which one 31-inch to 29-inch reducing elbcw was selected as having l comparable attenuation to that of the Byron /Braidwood castings. This elbow had the greatest variation of attenuation and had an area that j had the highest attenuation of all the elbows tested. This elbow was purchased.from Marble Hill for processing into calibration standards. Four calibration standard blocks were machined from this elbow; two from the 29-inch diameter end (2.34 inch thickness) which had lower overall attenuation and two from the 31-inch diameter end (2.83 inch thickness) which had higher attenuation. Both axial and circumferential side drilled holes (S.D.H.) and inner diameter (I.D.) > notches were machined into each block. The S.D.H.'s are 3/16 inch diameter and are located at 1/4,'1/2 and 3/4T locations. The I.D. notches were machined to 10, 25 and 50% through wall depths. The first set of calibration standards (one from the 29 inch end and the other from the 31 inch end) were sent to Krautkramer Branson (KBA) i and the second set was shipped to Harrisonics Labs approximately 3 weeks later. V. Search Units-KBA and Harrisonics Labs were requested to build search units producing optimum results on the 10% and 25% deep I.D. notches. Available EPRI recommendations on the design of the search units were also supplied to the manufacturers. i .... _. -, ~ _. _., _ _ _,. _ _.. _ _ _. _,,, _ -., -, _.,

a f KBA made a set (consisting of one unit for the axial scan and one for the circumferential scan) of search units for each block. Each search unit consists of two 1.0" dia x 1.0 MHZ, Alpha series flat-faced transducers mounted on contoured, removable wedges that produce an approximate 40' to 45*, dual, refracted longitudinal wave' i focused near the block I.D. surface. At the time of this report, 3 j Harrisonics Labs is still working on their optimum search unit design which is apparently very similar to KBA's, but has cylindrically-focused transducers mounted on wedges that produce an approximate i 40', refracted L-wave. VI. UT Results Using KBA supplied search units, tests were conducted on both j calibration blocks using several different UT machines. The UT scopes available were: Nortec 131, Sonic Mark 1, Krautkramer USIP 11 and Panametrics EPOCH 2022. The EPOCH 2002 machine produced the best signal-to-noise ratios (at 0.5 MHZ filter) on the 10% and 25% I.D. notches. The USIP 11 and Mark I were adequate, but not as good as EPOCH 2002. The Nortec 131 was found to be inadequate for angle beam examination. With regard to the search units, several interesting observations were made. The search units optimized for the 29 inch diameter calibration block (lower attenuation) also produced optimum results 1 on the 31 inch diameter calibration block (higher attenuation). The second observation was that despite attenuation differences between the two blocks, approximately the same results were obtained regarding the background noise (10 to 20% screen height at the reference sensitivity) and the signal-to-noise ratio (2 or better) for the I.D. notches. ) The UT results on the calibration block are presented in Attachments 1 & 2 with printouts from the EPOCH 2002. VII. Preliminary Ext'tinations at Braidwood i A plant visit was made on May 2'1, 1986 to Braidwood Unit 2 to perform trial examinations of selected welds. Partial examinations were conducted on 9 welds of loop #1 using the EPOCH 2002.and the KBA transducers. These preliminary examinations showed strong, but intermittent and sometimes continuous signals at the.I.D. These signals, attributed to grain structure and/or I.D. geometry, were similar to the ones obtained from the 10% I.D. notch. However, indications from the 10% notch could be separated from the 25% notch indications because of the % depth location as shown in the EPOCH printouts presented in Attachment 3. i

, VIII. Conclusions Based on this developmental work and the preliminary examination of' some welds on Braidwood Unit 2, a procedure is being written for the Preservice examination of weldments in the cast stainless steel components and fittings at Byron Unit 2 and Braidwood. This. Procedure will be used to examine only the cast side (s) of the reactor coolant system welds. The welds to be examined can be categorized as follows:

l. Forged reactor nozzle safe-end - to - cast elbow welds
2. Steam generator nozzle - to - cast elbow welds
3. Forged pipe - to - cast elbow, pump or valve welds t
4. Cast elbow - to - cast pump or valve welds There are 56 welds of these types in each reactor coolant system at Byron Unit 2 and Braidwood Units 1 and 2.

The procedure will require use of the specific transducers, wedges and equipment as discussed in this report. It will require scanning at sensitivity of noise level around 10-30% full screen height. Equipment and transducer combinations that will give a signal-to-noise ratio of 2 minimum will be specified. I.D. geometry or grain structure signals will be noted and identified. A walkdown of the Braidwood Unit 2 reactor coolant system and a 1 detailed review of the component configurations showed that only a limited examination will be possible at certain locations.- The valve side of.the valve-to-elbow and the pump side of the pump-to-pipe joints may not receive complete examination. These welds will be examined to the extent possible and the extent of coverage will be noted. preservice examinations of the non-cast side of the welds at Byron Unit 2 and Braidwood Unit I have been completed using existing ultrasonic techniques. Ax$al scanning was performed to detect reflectors parallel to the welds. Forty-five (45) degree shear wave transducers were used to examine pipe-to-cast component welds. Forty-five (45) degree refracted longitudinal-wave was utilized on all safe-end - to - cast component welds. Both techniques adequately examined the weld metal and the non-cast component heat-affected zones of these welds. Additionally,'circumferential scans for transverse reflectors were made in both directions along the crown of these welds. Similar ultrasonic examinations will be performed on the non-cast sides of the Braidwood Unit 2 welds when preservice activities begin on that unit. l _.. _ _. - -. _ _ _ _ ~ _ _, _.. _. _

5-1 Examinations utilizing the state of the art ultrasonic procedure will begin on June 20, 1986 at Braidwood Unit 1. These examinations will be performed by commonwealth Edison personnel. The examinations at Byron Unit 2 are scheduled to begin on June 24, 1986 and will be performed by the preservice inspection contractor (Ebasco Services, Inc.). The necessary relief requests related to these examinations should be available for NRC review by September 1, 1986. 1809K i o w ~-*-- -. - - - e,e- -w e,- ..,y_

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