ML20246K361
| ML20246K361 | |
| Person / Time | |
|---|---|
| Site: | Brunswick  |
| Issue date: | 04/25/1989 |
| From: | Copeland J, Gustin H, Pitcairn D STRUCTURAL INTEGRITY ASSOCIATES, INC. |
| To: | |
| Shared Package | |
| ML20246K342 | List: |
| References | |
| SIR-89-003, SIR-89-003-R00, SIR-89-3, SIR-89-3-R, NUDOCS 8905180039 | |
| Download: ML20246K361 (90) | |
Text
_ _ _ _ _ _ _ _
_v Report No. SIR-89-003-Revision: O Project:
CPL-02Q April 24, 1989 VOLUME 2 Weld overlay Repairs of Recirculation Inlet and Core Spray Nozzle-to-Safe End Welds and Recirculation Inlet Nozzle Thermal Sleeve Attachment Welds Brunswick Steam Electric Plant Unit 1 Prepared for:
Carolina Power & Light company Prepared by:
Structural Integrity Associates 4 [2f !PT Prepared by:
e hM8 Date:
D. R.
Pitcairn4 Date:
4 L5 81 H.'
L.
Gustin Af2Sfb9 Date:
~. Gerbe'r D.
A ArcABS Date:
4/2 5/89 R.
B.
Storiesifer V 3
Y Date:
j J.
F.
C gland Date:
2h 9
A. ( T/. Giannuzzi
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8905180039 890503 M
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e' REVISION CONTROL SHEET SECTION PARAGRAPH DATE REVISION REEUKS l'0 - 8.0 All 4/25/89 0
Initial Issue
& Appendix A
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SIR-89-003, Vol. 2 ii ASSOCIATESINC
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t TABLE OF CONTENTS Section Pace EXECUTIVE
SUMMARY
.. vii
1.0 INTRODUCTION
.1 2.0 NOZZLE-TO-SAFE END WELD EXAMINATIONS 5
2.1 Apparent Growth of Flaw Indications in Two Welds 5
2.2 Machining to Provide Better Post-Overlay UT 5
2.3 Evaluation 6
3.0 THERMAL SLEEVE ATTACHMENT WELD OVERLAYS 11 3.1 New UT Findings With Refracted Longitudinal Wave Transducers.
11 3.2 Overlay Design Basis 11 I
3.3 Residual Stress Evaluation 16 4.0 WELD OVERLAY EXAMINATIONS 49 4.1 Preservice Ultrasonic Examination of Weld overlay Repairs Applied During Current Outage.
49 4.2 Inservice Examination of Existing Weld Overlay Repairs 51 4.3 Conclusions.
53 l
l 5.0 RECONCILIATION OF DESIGN AND AS-BUILT WELD OVERLAY DIMENSIONS 57 I
5.1 Weld Overlay Dimensions 57 5.2 Comparison of As-built and Design Dimensions 57 I
6.0 EVALUATION OF WELD OVERLAY SHRINKAGE-INDUCED I
STRESSES 61 6.1 Introduction 61 6.2 Analysis 62 6.3 Acceptance Criteria.
63
7.0 CONCLUSION
S 69
8.0 REFERENCES
71 I
APPENDIX A I
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e LIST OF TABLES Table face 1-1 UT Flaw Characterization 4
3-1 Recirculation Inlet Nozzle Thermal Sleeve Attachment Weld Location - Summary of UT Indications.
26 3-2 Recirculation Inlet Thermal Sleeve Attachment Weld Location Axial Primary Stresses for Weld Overlay Repair Design at Brunswick, Unit 1 27 3-3 Allowable Flaw Size Using Source Equations for Circumferential Crack 28 3-4 Structural Reinforcement Sizing Evaluation -
TS/SE Weld, Riser D 29 3-5 Structural Reinforcement Sizing Evaluation TS/SE Weld, Riser J 30 3-6 Structural Reinforcement Sizing Evaluation TS/SE Weld, Riser C 31 4-1 Review of Ultrasonic (UT) Examination Results Weld Overlay Repairs Applied During 1988-1989 Brunswick Steam Electric Plant Unit 1 54 4-2 Inservice Ultrasonic (UT) Examination Results a
Previously Applied Weld Overlay Repairs j)
Brunswick Steam Electric Plant Unit 1 56 5-1 As-built Weld Overlay Data Nozzle-to-Safe End Welds 59 5-2 As-built Weld Overlay Data Thermal Sleeve Attachment Welds 60 6-1 As-built Weld Shrinkage Nozzle-to-Safe End Welds.
63 1
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6-2 As-built Weld Shrinkage Thermal Sleeve Attachment I
Welds 64
[
6-3 Weld Overlay Induced Shrinkages on Overlays l
Applied Prior to 1988 65 SIR-89-003, Vol. 2 iv 6
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LIST OF FIGURES Ficure Pace 2-1 Overlay Thickness Dimensions in Machined Area for Recirculation Inlet Nozzle D
.8 2-2 Overlay Thickness Dimensions in Machined Area for Recirculation Inlet Nozzle H 9
2-3 Comparison of Axial and Hoop Stresses at Section U Before and After Machining to Facilitate Post-repair UT 10 I
3-1 Thermal Sleeve Attachment Weld Overlay Extension 32 3-2 Thermal Sleeve Attachment Weld Overlay 33 3-3 Recirculation System Inlet Nozzle-to-Safe End Geometry Used for Welding Residual Stress Analyses.
34 3-4 overlay Repair Configurations, Materials, Finite Element Grid, and Definition of Sections Used for Through-Thickness Stress Plots 35 3-5 Weld Segments and Overlay Welding Sequence Used for I
the WELD 3 Simulation of the Temperbead and Extended Temperbead Overlay Configurations 36 3-6 Weld Segments and Overlay Welding Sequence Used for I
the WELD 3 Simulation of the Thermal Sleeve Weld Overlay Configuration.
37 I
3-7 Butt Weld Induced Residual Stresses from a Last Pass (LP) Weld Simulation 38 I
Residual Stresses After Repair of an Assumed Weld 3-8 Defect at the Butt Weld / Butter Interface With Repair Welding Done from Inside the Safe End 39 I
3-9 Residual Stresses After Completion of the Thermal Sleeve Attachment Weld Simulation.
40 I
3-10 Residual Stresses at the Start of the Structural Weld Overlay (Temperbead Weld Layers Complete) 41 3-11 Residual Stresses After 170 mils of Structural I
Weld overlay 42 3-12 Residual Stresses After 340 mils of Structural Weld Overlay (Minimum Thickness Overlay Complete).
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e LIST OF FIGURES Ficure Eage 3-13 Residual Stresses After Completion of the Thermal Sleeve Weld Overlay Extension.
44 I
3-14 Summary of the Residual Stress History at Section U for the Temperbead overlay and Extended Temperbead Overlay Configurations 45 3-15 Summary of the Residual Stress History at Section T I
for the Temperbead Overlay and Extended Temperbead Overlay Configurations 46 3-16 Residual Stresses After Overlay Completion for the Thermal Sleeve Weld Overlay Configuration.
47 3-17 Summary of the Residual Stress History at Section T for the Thermal Sleeve Weld Overlay Configuration.
48 6-1 Finite Element Model of BSEP-1 Recirculation System for Weld Overlay Shrinkage Analysis 68 I
I l I SIR-89-003, Vol. 2 vii STRUCTUIULL Rev. O M
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EXECUTIVE
SUMMARY
An extensive ultrasonic (UT) examination program during the Fall / Winter 1988-1989 Brunswick Steam Electric Plant Unit 1
3 (BSEP-1) refueling outage revealed the presence of flaw indications in seven of the ten 12-inch recirculation inlet nozzle-to-safe-end weldments, and in both of the core spray nozzle-to-safe end weldments.
Volume 1
of this report demonstrated that the flawed pipe analysis and weld overlay repair design in support of these UT flaw indications meets the requirements of Generic Letter 88-01, [1], NUREG-0313, Revision 2 I
(2] and agreements between the U.S.
Nuclear Regulatory Commission and Carolina Power & Light.
During the post-overlay ultrasonic testing (UT) examination of the nine nozzle-to-safe end welds, UT flaw indications were discovered in all ten 12-inch recirculation inlet nozzle thermal sleeve attachment weld areas.
This volume provides:
I 1.
The flaw characterization of the thermal sleeve attachment welds and the design basis of the overlay repair welds applied to these locations.
I
- 2. A reconciliation of the as-built dimensions, examination results and shrinkage effects resulting from application of the nozzle-to-safe end and thermal sleeve attachment weld overlay repairs.
I I
SIR-89-003, Vol. 2 viii STRUCTURRI.
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1 t-1.O INTRODUCTION Ultrasonic (UT) examinations of nozzle-to-safe end welds potentially susceptible to intergranular stress corrosion (IGSCC) in the recirculation and core spray system were performed during the Fall / Winter 1988-1989 BSEP-1 outage.
As a result of these examinations, flaw indications were identified in several nozzle-to-safe end welds in the recirculation and core spray systems.
The details of the flaws and the evaluations and repair designs are contained in References 3 and 4.
The flaws evaluated are shown for reference in Table 1-1.
Weld overlay repairs were designed for all of the flawed welds.
Volume 1 of this report [1] provided the design bases, stress data and the detailed dimensions for the weld overlay repairs which were applied to the recirculation and core spray nozzle-to-safe end welds.
During the post-overlay UT examinations of the seven (7) recirculation inlet nozzle-to-safe end weld overlay
- repairs, previously undiscovered flaws were reported in the thermal sleeve attachment weld area of those nozzles.
Further examination revealed similar flaws in the three (3) remaining recirculation inlet nozzle thermal sleeve attachment weld areas.
Weld overlay repairs were designed and installed for the ten (10) thermal sleeve attachment welds.
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Volume 2 provides:
i the data and analytical results which reconcile the as-built weld overlay dimensions and as-measured axial shrinkage with l
the nozzle-to-safe end weld overlay designs [1].
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the UT examination results, flaw characterization and design
- bases, stress data and detailed dimensions for the weld overlay repairs performed on the thermal sleeve attachment I
weld flaws discovered during the post-weld overlay UT examination of the recirculation inlet nozzle-to-safe end weld overlays.
the data and analytical results which reconcile the as-built weld overlay dimensions and as-measured axial shrinkage with the thermal sleeve attachment weld overlay designs.
This volume is organized into several sections as follows:
I Section 2
of this volume describes the nozzle-to-safe end post-overlay examinations and the investigation of the apparent growth of two flaws and provides the analytical results justifying the acceptability of the weld overlays.
Section 3 of this volume provides the results of the thermal sleeve attachment weld UT findings, the weld overlay design bases, design overlay dimensions and the residual stress analysis results.
Section 4
of this volume provides the results of the nondestructive examinations (NDE) of the weld overlay repairs, including both the preservice examination of those applied this outage and the inservice inspection of the previously applied weld overlay repairs.
Section 5
of this volume demonstrates that the as-built I
dimensions of the nozzle-to-safe end weld overlay repairs meet or exceed the minimum design requirements provided in Reference 1,
I and that the thermal sleeve weld overlay repairs meet the designs provided in Section 3.
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1 Section 6 of this volume provides the results of stress analyses.
I of the recirculation and core - spray systems which evaluate the effects on these systems ' of the as-measured weld overlay axial shrinkages.
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TABLE 1-1 l
UT Flaw Characterization l
Weld Number Flaw Recirculation Inlet Characterization Nozzle-to-Safe End I
12AR-A6 2 axial flaws, 50% maximum depth 1
12AR-B6 2 axial flaws, 45% maximum depth 12AR-C6 4 axial flaws, 37% maximum depth 1
12AR-D6 6 axial flaws, 82% maximum depth 12AR-E6 10 axial flaws, 65% maximum depth 12BR-G6 4 axial flaws, 52% maximum depth 12BR-H6 11 axial flaws, 71% maximum depth Core Spray Inlet Nozzle-to-Safe End Core Spray NSA 1 axial, 30% maximum depth Core Spray NSB 1 circumferential, 2.3"x60% max. depth l
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2.0 NOZZLE-TO-SAFE END WELD EXAMINATIONS I
J This section provides a description of the post-overlay UT examination results and the resolution of the apparent growth of original flaw indications in two (2) of the recirculation inlet nozzle-to-safe end welds.
2.1 Apparent Growth of Flaw Indications in Two Welds Post-overlay UT examinations revealed little or no growth in the pre-overlay UT indications following the application of the weld overlays on recirculation inlet nozzles A, B,
C, E and G and both core spray nozzles.
Several new UT indications were reported following the overlay applications.
These indications were characterized.as lack of bond / lack of fusion and were evaluated as acceptable per ASME Section XI Subsection IWB-3500 [5].
Post-overlay UT examinations initially showed the apparent growth of pre-overlay indications in recirculation inlet nozzles D and H.
These indications appeared to extend from the Inconel material into the low alloy steel nozzle in both nozzles, but did not extend.into the overlay material.
Further UT examination of these apparent indications concluded that they did not extend into the low alloy steel, as discussed below.
2.2 Machining to Provide Better Post-Overlay UT The UT examination was performed with a Refracted Longitudinal (RL) wave transducer from the surface of the weld overlay.
The l
indication end point was not confirmed for either nozzles D or H 1
when the UT transducer was at the furthest extent of the flat surface on the nozzle side of the overlay.
Due to this uncertainty in the extent of the flaws in the two nozzles, the overlay material on the nozzle side was machined down to provide an enhanced inspection surface to the nozzle edge of the overlay (see Figures 2-1 and 2-2).
After this operation, the extent of SIR-89-003, Vol. 2 5
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s the-apparent flaw was determined.
Following machining, a minimum of 0.16 inches and 0.15 inches of overlay material remained on nozzles D and H, respectively.
This minimum thickness was not in the' area of the flaws.
A second UT examination team evaluated the region under the machined area in the D nozzle and found no flaws in the low alloy steel material.
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2.3 Evaluation The nozzle-to-safe end weld overlays for recirculation inlet nozzles D and H were re-evaluated following the post-overlay inspections discussed above.
These weld overlays were evaluated to be acceptable as-is for the following reasons:
The thickness of temperbead material left on the two nozzles after machining (0.16 inches for nozzle D and 0.15 inches for nozzle H) provides an effective leakage barrier overlay.
The total full thickness overlay width was reduced from approximately 5.5 inches to approximately 4.5 inches through the machining process.
Because the required design width of overlay material is 4.4 inches, the remaining width of full thickness overlay material is adequate for full structural load transfer.
l l
The residual stress benefits of the overlay were reduced somewhat by the machining, but remain highly favorable.
Prior to the machining, the residual stress was approximately -30 ksi on the inside surface of the nozzle.
After machining, the residual stress is approximately -20 ksi on the inside surface. A discussion of the model and analysis of residual stress follows.
1 The post-overlay residual stress state for the nine (9) nozzle-to-safe end weld overlays is discussed in Volume 1 [1].
1 This section describes the r.ange in residual stress for SIR-89-003, Vol. 2 6
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recirculation nozzles D and H as a
result of the overlay machining operation.
The WELD 3 [6] computer code used for this evaluation is described in detail in Section 4 of Volume 1 [1].
The simulation of the material removal was accomplished using the finite element mesh and post-overlay residual stress state from the analyses presented in Volume 1
[1].
The material was simulated as being removed in two steps. The first step removed the outermost layer of overlay finite elements in the machined region (see dashed outline in Figure 3-3) and the second step removed the second layer of elements.
The thickness of the material that was removed from the model was 0.34 inches or about 73% of the total modeled overlay thickness.
This percentage of removed overlay thickness is comparable to that which was removed I
from the actual overlay, although absolute thicknesses tended to be smaller in the model due to as-built thicknesses being greater than design minimum thicknesses.
Figure 2-3 shows the effect of the material removal on the axial and hoop stress distributions at Section U.
Since the removed material was initially under a state of axial and hoop tension, the compressive stresses in the remaining material tended to be reduced (i.e.,
made less compressive).
The change in stresses was 10 ksi or less, except for the axial stresses near the outer surface.
The larger change there was due to the proximity of the end of the overlay after the machining.
Since the stresses were quite favorable before the material removal, this change due to machining does not represent a significant reduction in the overall overlay weld stress improvement.
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t Figure 2-1 Brunswick Steam Electric Plant-Unit 1 Overlay Thickn'ess Dimensions in Machined Area for Recirculation Inlet Nozzle D TAE THICKE5 EEADIM65 AT Tal6.
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k 3.O THERMAL SLEEVE ATTACHMENT WELD OVERLAYS i
This section describes the post-overlay UT examination findings in the thermal sleeve attachment weld area, the design basis and detailed design dimensions of the weld overlays applied and the residual stress evaluation of the nozzles.
3.1 New UT Findings with Refracted Longitudinal (RL) Wave Transducers During the performance of the post-overlay UT examinations of the nozzle-to-safe end weld overlays with the RL Wave UT transducers, IGSCC-type flaw indications were discovered in all ten (10) thermal sleeve attachment weldments in the 12-inch recirculation inlet nozzles.
No indications had been found in this location during the previous UT examinations.
These indications were evaluated and are tabulated on Table 3-1.
3.2 Overlay Design Basis This subsection of the report describes the design of weld overlay repairs for ten (10) recirculation inlet nozzle thermal sleeve attachment welds.
The analyses include the determination of loads and stresses, and the sizing of weld overlay repair thicknesses and width (length in the axial direction of the safe end).
These overlays serve three purposes:
1.
Cracks in the nozzle tend to arrest as the result of residual stresses on the inside portion of the safe end wall containing the flaw indication locations.
These favorable residual stresses are introduced by the weld overlay application.
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2.
Continued IGSCC crack growth tends to be mitigated at the nozzle-to-overlay junction through the use of overlay material that is IGSCC resistant.
This effect exists for that porta.cn of overlay material whose chemistry is not
~
diluted by the base material chemistry.
3.
Structural reinforcement is provided by adding material to the outside diameter of the safe ends.
For the seven (7) recirculation inlet nozzles for which a
nozzle-to-safe end and weld overlay was applied during this outage, the overlay was designed as an extension to the safe end side of the existing weld overlays (see Figure 3-1).
For the remaining three (3) recirculation inlet nozzles, the overlay was I
designed te blend into the taper of the safe end (see Figure 3-2).
By keeping the welding process as remote as possible from the adjacent nozzle-to-safe end welds, these designs ensured that the thermal sleeve attachment weld overlays did not negatively influence the nozzle-to-safe end butt welds.
3.2.1 Stresses The piping stress analysis for the recirculation system at BSEP-1 I
was performed by General Electric (GE) [7].
This stress report includes an appendix which serves as the GE interface for the reactor vessel and includes calculated forces and moments on the reactor vessel nozzles.
These nozzle forces and moments were used to compute axial dead-weight and seismic (OBE) stresses with the following equation:
I
+M
)!
lFx{ + (My z
a=
3 where:
F
= Axial force I
x M,M
= Bending moments y
z E
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e A
= Nozzle-to-safe end cross-sectional area Z
= Nozzle-to-safe end section modulus Using the above equation, OBE stresses were computed for the x, y and z global coordinate directions, and the maximum stress in either the x or z direction was added to the stress in the y direction absolutely, to obtain the OBE stress in the same manner I
as in the stress report
[7].
The effects of stress concentrations (e.g.,
stress indices or stress intensification factors) are not included in these stresses, in accordance with NUREG-0313, Revision 2 [2].
Axial pressure stress for the recirculation inlet thermal sleeve attachment welds was calculated for a pressure of 1325 psig [7],
using the design outside diameter of 13.0 inches, the design inside diameter of 12.75 inches and the following equation:
p (ID)2 v= (OD) 2 - (ID) 2 where:
p
= Pressure (1325 psig)
ID = Inner diameter (12.75 inches)
OD = Outer diameter (15.0 inches)
Primary membrane (P ) and bending (P ) stresses, where P, is the m
b prescare stress and P is the dead-weight plus OBE stress, are b
shown for the ten recirculation inlet thermal sleeve attachment welds which were repaired on Table 3-2.
It can be seen that P,=
3450 psi for all welds, based on the above calculation.
The l
maximum value of P is for Nozzle C, where the sum of dead-weight 3
and OBE stresses gives P3 = 2250 psi.
3.2.2 Weld Overlay Repair Thickness 1
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f The thickness for the weld overlays was determined in accordance with ASME,Section XI, Paragraph IWB-3640
[5]
as the design criterion.
This design assumes a through-wall circumferential1y oriented flaw extending 360 degrees around the component.
The net section collapse source equations in ASME,Section XI, Appendix C,
[5]
were used to determine the allowable a/t ratio.
In accordance with IWB-3642, a safety margin of 3.0 on load was used for normal and upset conditions in the Appendix C -[5] source equations.
This safety factor of 3.0 is conservative, compared to the value of 2.77 used in Appendix C of ASME Section XI
[5]
and in NUREG-0313, Kevision 2 [2].
This method produced allowable a/t ratios in excess of 0.75, even if no credit for additional overlay repair thickness were taken, (see Table 3-3 for riser C),
due to the very low primary stresses (see Table 3-2).
Where I
credit is taken for overlay repair thickness, the allowable a/t is increased slightly above those in Table 3-3, as shown in the overlay design calculations of Tables 3-4, 3-5, and 3-6.
The safety factor of 3.0 is included implicitly in the values of bending stress shown in the above tables.
The ten (10) thermal sleeve attachment welds were placed into three groups for the purpose of determining the overlay thickness, as follows:
- 1. Nozzle C - Ties into the existing overlay and envelopes the design requirements of nozzles A, B,
E, G and H.
- 2. Nozzle J For application at those locations that do not have an existing overlay.
This calculation envelopes nozzles F and K, also.
l
- 3. Nozzle D - Ties into the existing overlay.
SIR-89-003, Vol. 2 14 Rev. O IGSOCIATESINC
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l The design process iteratively determines the minimum required additional thickness to satisfy the above criteria.
This process l
has been automated in the Structural Integrity Associates
]
l computer program pc-CRACK [8].
The stress and wall thickness dimensions used in the analysis are shown in the overlay repair thickness computations of Tables 3-4, 3-5 and 3-6 for the bounding thermal sleeve attachment weld overlays.
The overlay material is Inconel 82, with an allowable stress intensity (S,)
of 23,300 psi at 562*F, taken as the same as that for Alloy 600 in Appendix I of ASME Section III [9].
An overlay repair was designed for each thermal sleeve attachment weld location.
The conservative assumption of a
360*
circumferential flaw eliminates any potential concern about the reliability of the ultrasonic examination to size flaws.
In addition, concerns about the toughness of the original butt weld material are not applicable, since no credit is taken in the design process for the load carrying capability of the remaining component wall ligament.
Overlay thickness calculations are shown in Tables 3-4, 3-5, and 3-6.
Use of the appropriate bounding P and P values results in m
b conservative overlay repair design thicknesses of 0.17 inch for recirculation inlet nozzles A, B,
C, E, G and H and 0.15 inch for I
nozzles D, F, J and K.
j 3.2.3 Weld Overlay Repair Length In keeping with standard weld overlay repair design practice, the minimum width (iength along the pipe axis) was calculated to provide full overlay thickness for a length of 0.75% on both sides of the centerline of the original weldment, where R is the outer radius and t is the thickness, both of the unrepaired component.
For the recirculation inlet nozzle-to-safe end welds, where R = 7.5 inches and t 1.125 inch, 0.75% = 2.2 inches.
=
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_7
- e i
O The half-length of the overlay on the piping' side (2.2 inches),
finishes on the safe end taper section, and is relatively remote from any adjacent butt welds.
The " half-length" of the overlay on the nozzle side is blended into the pre-existing overlay (where present) or the safe end taper, and is kept off the flat (horizontal) section of the safe end adjacent to the safe
)
end-to-nozzle weld, so as not to induce unfavorable residual stresses on that weld.
The overlay design drawings for these welds are shown in Appendix A.
3.3 Residual Stress Evaluation Volume 1 [1] of this report concentrated on residual stresses in the vicinity of the nozzle-to-safe end weld, since that was the site of the original UT indications.
Subsequent UT indicated some circumferential IGSCC initiating at the crevice created by the thermal sleeve attachment welds.
This section describes the determination of residual stresses at the nozzle-to-safe end and thermal sleeve-to-safe end weld joints.
While the residual stresses of primary interest were those existing after the weld overlay repairs, the analyses also calculated residual stresses for the pre-overlay configuration to have realistic initial residual stress states for the overlay welding simulations.
The geometry of the subject nozzle-to-safe end weld joints and key dimensions used in constructing the WELD 3 [6] finite element model are given in Figure 3-3.
The geometry shown in this figure is based on drawings for the recirculation inlet nozzle safe ends. 'The overlay geometry shown in this figure largely reflects minimum overlay design dimensions.
Where differences exist, the modeled dimensions were sclected to more closely represent anticipated as-built dimensions.
SIR-89-003, Vol. 2 16 Rev. O ASSOCIATESINC
l.
t The following subsections describe residual stress analyses completed since the compilation of Volume 1 [1] of this report.
Because much of the modeling reported in Volume 1 [1] has been necessarily duplicated and thus superseded by the new analyses, a comprehensive set of residual stress results are presented in this section.
Background information and details on the weld modeling methodology, thermal and stress
- models, boundary conditions, assumed material properties, and welding parameters were discussed in Section 4 of Volume 1
[1].
Because that discussion remains applicable to the newer analyses, it is not repeated here.
3.3.1 Models and Assumptions Three basic repair configurations are considered in the residual stress analyses.
The first configuration is the original temperbead structural weld overlay applied over the nozzle-to-safe end weld (the configuration considered exclusively by the work reported in Volume 1 [1]).
The second configuration is the same as the first except that the overlay is extended (with reduced thickness) past the thermal sleeve attachment weld position.
This configuration is called the Extended overlay in the following discussion and is labeled as such in Figure 3-4.
The third configuration has an overlay covering only the thermal sleeve weld portion of the safe end and thus is called the I
Thermal Sleeve Weld overlay configuration (see Figure 3-4).
The axisymmetric finite element grid used in the WELD 3
[6]
simulations is shown at the bottom of Figure 3-4.
The grid is composed of 672, 4-noded, isoparametric elements.
It contains 756 nodes and was used for all analyses reported in this section.
The sections labeled U,
I, S,
T, and E in Figure 3-4, are cross-sections for which through-thickness stress plots are provided.
Secticn U is the cross-section at which UT indicated axially oriented flaws in most of the nozzle-to-safe end welds.
Section I is taken through the Inconel butter, which is the SIR-89-003, Vol. 2 17 Rev. 0 ASSOCI/UES,INC.
l l
location of a circumferentially oriented flaw in one of the core spray welds.
Section S is taken through the heat affected zone (HAZ) on the safe end side of the butt weld.
Section T is a cross-section starting at the crevice created by the thermal l
sleeve attachment weld, for which circumferential1y oriented flaws were found in several of the safe ends.
Section E was z
included to document the stresses under the extended / thermal f
I sleeve portion of the overlay beyond the thermal sleeve weld.
Figures 3-5 and 3-6 show overlay weld regions of the finite element grid for the extended overlay and the thermal sleeve weld overlay configurations.
The numbers within the finite elements indicate the WELD 3 [6] model weld segments to which the elements belong.
The weld segments are alwayc " deposited" in numerical sequence in the analysis.
Therefore, these figures document the modeled weld sequences.
Segments 1 through 6 each represent a layer of weld passes in the butt weld.
For the extended overlay configuration, segments 7 through 12 represent the temperbead weld, segments 13 through 17 bring the non-temperbead portion of the overlay up to the level of the temperbead layers, and segments 18 through 34 represent the structural overlay weld layers.
Segments 35 through 38 represent the overlay extension for the thermal sleeve weld. For the thermal sleeve weld overlay configuration, segments 7
through 11 represent the overlay materit.l.
The WEU)3 [6] stress analysis models the sequential deposition of weld material by assigning those elements which represent currently nonexistent material a temperature above the " stress free" temperature.
Elements above the stress free temperature have an insignificant stiffness and are assumed (i.e.,
forced) to have zero stress and strain and thus do not affect the stresses or displacements in the material which does exist.
Welding simulations for all three overlay configurations started with simulation of the nozzle-to-safe end butt weld.
The next SIR-89-003, Vol. 2 18 Rev. O ASSOCIATESINC
e I-0 step was to simulate a repair to the inside diameter surface of the Inconel butter at the nozzle-to-safe end weld joint.
This butt weld and repair sequence produced highly tensile residual stresses at the joint, thus being consistent with the observed cracking and providing a realistic initial residual stress state I
for the subsequent overlay welding simulations.
The last step in the simulation before overlay weld modeling was to simulate the residual stresses due to the thermal sleeve attachment weld.
Analysis of this joint predicted highly tensile residual axial and hoop stresses at the thermal sleeve attachment weld crevice, thus being consistent with the UT results which indicated circumferential flaws initiating from this crevice.
3.3.2 Welding Analysis Results This subsection presents and discusses the stresses from the numerical welding simulations.
The weld modeling considers each of the three weld overlay repair configurations described above.
Since the extended overlay is just an addition to the original temperbead structural overlay, there are really only two welding sequences to be considered (Figures 3-5 and 3-6).
Since both sequences had the butt weld, inside diameter repair weld, and thermal sleeve attachment welds in common, simulation of these pre-overlay welds needed to be done only once.
The residual stress results are presented in chronological order.
The original temperbead overlay configuration is presented first, followed by the results for the extended overlay and the thermal sleeve weld overlay.
Since the various materials in the vicinity of this joint have different coefficients of thermal expansion, stress plots are generally given at a temperature of 550 F,
unless the results are for an intermediate stage of overlay completion.
Results of these analyses, shown in Figures 3-7 through 3-17, are discussed below.
{
l l
l SIR-89-003, Vol. 2 19 Rev. O E
I ASSOCIATESINC J
k 3.3.2.1 Butt Weld As described above, the first step in the simulation was to model the butt weld.
Previous experience has shown that modeling only the last pass of a butt weld often produces residual stresses qualitatively similar to those from modeling each weld layer.
Since the subsequent inside diameter repair simulation would significantly alter the butt weld residual strecs state anyway, the butt weld simulation used this computational shortcut.
Figure 3-7 shows the through thickness, butt weld induced, stress distributions at the various sections defined in Figure 3-4.
It is seen that the predicted hoop stresses at the inner surface of the joint are compressive (or nearly so) for all the sections.
At Section U the inner surface hoop stresses are strongly compressive.
While the inner surface axial stresses are tensile I
at Sections I and S, they become strongly compressive at a small distance into the wall.
At Section U, the inner surface axial stresses are compressive at the inner surface and remain compressive over the inner half wall thickness.
It can be seen from Figure 3-7 that the largely compressive butt weld induced residual stresses at the inside diameter are not consistent with the axially oriented cracking that was found near Section U.
I 3.3.2.2 Inside Diameter Inconel Butter Repair A weld repair at the edge of the counterbore, referred to as a repair to the Inconel butter, was simulated starting with the butt weld residual stress state.
The results of the repair simulation are given in Figure 3-8.
The repair produced significant axial tensile stress at the inside diameter surface and resulted in the hoop stresses at Sections I and S being highly tensile at all points through the wall.
While the hoop stresses at Section U were slightly less severe than those at i
l SIR-89-003, Vol. 2 20 Rev. O ASSOCIATES,INC
h i
Section I, these calculated post-repair tensile hoop stresses are largely consistent with the observed axial cracking at this joint.
I 3.3.2.3 Thermal Sleeve Attachment Weld l
The thermal sleeve attachment weld stresses were simulated in I
this study using a nonstandard approach to weld modeling.
There l
were three reasons for this.
First, a-previous simulation [10]
had already been done for the joint using the more rigorous standard methods.
Second, a simulation of just the last layer of weld passes using the sta-dard methods was found to produce residual stresses which were significantly different from those computed in the previous simulation.
Finally, as a result of already knowing the form of the residual stress distributions at the thermal sleeve due to the previous analysis, it was more cost-effective to create the residual stresses via a single heating and cooling cycle using a trial and error approach than to perform the simulation again using the more rigorous standard approach.
The axial and hoop stress distributions at Section T resulting from this nonstandard approach were found to be within 10 to 15 ksi of those obtained using the more rigorous modeling approach of Reference 10 and thus were judged to be satisfactory.
Figure 3-9 shows the axial and hoop stresses at the various sections after all fabrication weld simulations were completed i
and the model was heated to 550*F.
It can be seen that as a 1
I result of the inside diameter butter repair and the thermal sleeve attachment weld, the axial and hoop stress distributions l
at all of the sections were tensile at the inner surface.
The sections at which cracking has been found all have significantly tensile axial and hoop stresses at the inner surface, and the t
hoop stresses at Sections S and I are tensile at all points through the wall thickness.
MM SIR-89-003, Vol. 2 21 g
Rev. O g
l 4
1 I
3.3.2.4 Nozzle-to-Safe End Temperbead Weld Overlay The simulation of the minimum design thickness nozzle-to-safe end temperbead weld overlay configuration involved the deposition of three weld layers over the uniform thickness portion of the overlay.
While the actual number of weld layers was more than I
the modeled number, experience has shown that as long as the layer thicknesses are not grossly misrepresented, the stress results are rather insensitive to the number of layers used to attain a given thickness.
The present simulation of this overlay configuration differed from that reported in Volume 1 [1] in three respects.
First, the new refined grid was used.
Since this grid was different only in the thermal sleeve crevice region, this difference only affected results in the thermal sleeve attachment weld region.
Another difference from the previous analysis was the reversal in direction for depositing the temperbead weld layers.
In the original simulation, the temperbead welding started at the nozzle end and worked towards the butt weld.
The actual welding progressed in the opposite direction and, therefore, this was reflected in the new analysis.
The other difference was that the new analysis included the thermal sleeve attachment weld residual stresses.
The reversal in welding direction and the inclusion of the thermal sleeve attachment weld stresses caused a slight (about 10 ksi) improvement in the inside diameter residual stresses at Sections U,
I, and S relative to the original analysis.
Results at Section T were of course quite different due to the thermal sleeve attachment weld modeling.
Figure 3-10 shows the residual stress distributions at the start of the structural overlay layers.
For this
- figure, the temperbead welding is complete, and the overlay at sections beyond the temperbead layers has been built up to the level of the temperbead portion.
It is seen that a significant residual stress improvement is already evident at this stage of overlay a
SIR-89-003, Vol. 2 22 Rev. O ASSOCIATES,INC.
l
t completion.
Hoop stresses at sections for which axial cracks have been found are now compressive at the inner surface.
The axial stresses are also significantly improved, although the magnitude of the compressive stress tends to decrease as the.
' inner surface is approached.
Figure 3-11 shows the residual stresses after 170 mils of the structural overlay layers are complete.
Allowing 125 mils for the temperbead layers, this corresponds to a total thickness of 295 mils.
The largest difference between the residual stresses at this stage of completion and thoce at the start of the structural layers is in the hoop stress at the inner surface.
The inside diameter hoop stress at Sections U and I has been further reduced (i.e.,
made more compressive) by about 15 ksi.
While there is still significant compressive axial stress over much of the inner half wall thickness, the increase in wall thickness has resulted in a slightly more tensile inner surface axial stress at Section U than at the start of the structural overlay welding.
Figure 3-12 shows the residual stresses after completion of the minimum thickness overlay.
While the intermediate results of Figures 3-10 and 3-11 were plotted at 70*F, this final plot is for an operating temperature level of 550*F.
By plotting results at 550* F, the results include any effects of differential thermal expansion due to the various materials of the safe end.
It can be seen that the inner surface hoop stress at Section U is f
further improved to a level of -45 ksi.
The increased thickness effect on the inside diameter axial stress was offset by the effects of heating to 550*F so that the final inside diameter axial stress at Sections U, I,
and S are between 0 and -10 ksi.
It can be seen that this overlay configuration has resulted in a significant stress improvement at the thermal sleeve crevice Section T.
While the axial and hoop stresses at the crevice are predicted to be compressive after the overlay welding, the SIR-89-003, Vol. 2 23 Rev. O ASSOCIATESINC
6 4
e original high tensile stresses at this section have not been totally overcome by the overlay residual stress improvement.
3.3.2.5 Thermal Sleeve Weld Overlay Extension Figure 3-13 shows the residual stresses for the extended temperbead overlay configuration.
Comparing this figure with Figure 3-12, it can be seen that the largest change in stresses due to this overlay extension are at Sections T and E.
At Section T, the axial and hoop stresses are more compressive after the extension by about 15 ksi.
The overlay extension has a minimal effect at Sections U, I,
and S with changes being on the order of 5 ksi.
While the post overlay extension axial stresses at Section E are highly tensile at the inner surface, there is a zone of significant compressive axial and hoop stress near mid-wall.
3.3.2.6 Temperbead Overlay and Extended Overlay Stress Summary Figures 3-14 and 3-15 summarize the residual stress histories at Sections U and T for the temperbead overlay and the extended overlay configurations.
From these
- figures, the change in residual stress resulting from each step in the fabrication and weld overlay repair sequence can be readily seen.
All plots are for a temperature of 550* F.
3.3.2.7 Thermal Sleeve Weld Overlay l
l Figures 3-16.and 3-17 show the residual stresses for the thermal sleeve weld overlay configuration.
This is the configuration for which no temperbead overlay preceded the application of the thermal sleeve weld overlay.
The simulation of this overlay started from the residual stress state resulting from the butt weld, inside diameter butter repair and thermal sleeve attachment I
weld (Figure 3-9).
Figure 3-16 shows the axial and hoop stresses at the various sections after completion of the overlay.
SIR-89-003, Vol. 2 24 Rev. O N
ASSOCIATESINC
____-_ _ _ _ a
e.
Since the sleeve weld overlay had little effect on Sections U, I,
and S,
it is seen that the residual stresses at these sections remain largely unimproved.
Of course if the inside diameter butter repair had not been included in the pre-overlay welding simulation, the stresses at these sections would be largely favorable.
The overlay does result in a significant improvement in the stresses at the thermal sleeve crevice Section T.
Figure 3-17 summarizes the residual stress history at Section T for the thermal sleeve weld overlay configuration.
Comparing the final stresses from this figure with those for Section T on Figure 3-15 shows that axial stress improvement with just the thermal sleeve weld overlay tends to be slightly less than for the temperbead overlay plus extension.
The tendency for higher compression at the crevice with the temperbead overlay is believed to be the result of bending at Section T induced by radial contraction of the temperbead overlay.
i i
(
l l
l SIR-89-003, Vol. 2 25 STRUCTURRI.
Rev. 0 M
ASSOCIATESINC
- o 4
Table 3-1 Recirculation Inlet Nozzle Thermal Sleeve Attachment Weld Location Summary of UT Indications Nozzle Flaw Indications A
12 Circumferentials, 70% Max. Depth, 2.9" Max. Length B
7 Circumferentials, 68% Max. Depth, 1.7" Max. Length C
29 Circumferentials, 23% Max. Depth, 2.5" Max. Length D
1 Circumferential, 56% Max. Depth, 360*
11 Axials, 64% Max. Depth,
.5" Max. Length E
8 Circumferentials, 56% Max. Depth, 360*
5 Axials, 42% Max. Depth, 3" Max. Length F
1 Circumferential, 61% Max. Depth, 360*
G 12 Circumferentials, 56% Max. Depth, 5.9" Max. Length 4 Axials, 47% Max. Depth,
.36" Max Length H
17 Circumferentials, 70% Max. Depth, 1.2" Max. Length 6 Axials, 58% Max. Depth,
.25" Max. Length J
1 Circumferential, 59% Max. Depth, 360*
1 Circumferential, 33% Max ~ Depth, 6.8" Max. Length 46 Axials, 65% Max. Depth,
.6" Max. Length K
1 Circumferential, 56% Max. Depth, 360*
2 Circumferentials, 12% Max. Depth, 20.5" Max. Length 32 Axials, 61% Max. Depth,
.55" Max. Length SIR-89-003, Vol. 2 26
~
N ASSOCIATESINC
s Table 3-2 Recirculation Inlet Thermal Sleeve Attachment Weld Location Axial Primary Stresses for Weld Overlay Repair Design at Brunswick, Unit 1 P,_
P3 Weld Pressure Dead-Weight
' Seismic (OBE)
Deadweight +
No.
Stress Stress Stress Seismic Stress (psi)
(psi)
(psi)
(psi)
A 3450 99 713 812 B
3450 271 1194 1465 C
3450 672.
1578 2250 D
3450 207 870 1077 E
3450 834 507 1341
- F 3450 228 544 772 l
G 3450 454 865 1319 H
3450 710 1411 2121 J
3450 535 878 1413 K
3450 97 662 759 l
l l
l l
l
)
l l
SIR-89-003, Vol. 2 27
[
Rev. O N
ASSOCIA'ITSINC
Table 3-3 l
tm
]
pc-CRACK l
-l-(C) COPYRIGHT 1984, 1987 l
STRUCTURAL INTEGRITY ASSOCIATES, INC.
l SAN JOSE, CA (408)978-8200 VERSION 1.2 ALLOWABLE FLAW SIZE EVALUATION LLOWABLE FLAW SIZE USING SOURCE EQUATIONS FOR CIRCUMFERENTIAL CRACK hPL-02Q,TS/SEWELD,WELDOVERLAY(REM.LIG. CREDIT)
WALL THICKNESS:
1.1250 MBRANE STRESS: 3450.0000 1
ENDING STRESS =13653.0000 STRESS RATIO:
0.7340 I^FLOWSTRESS=69900.0000
" "^" "'****=
L/ CIRCUM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 ALLOWABLE A/T 1.0000 1.0000 1.0000 1.0000 1.0000 0.9971 0.9170 0.8740 0.80 0.90 1.00 ALLOWABLE A/T 0.8564 0.8525 0.8525 END OF pc-CRACK I
I I
I I
i I
I I
SIR-89-003, Vol. 2 28 ASSOCIATESINC Rev. o J
- t Table 3-4 9
9 tm pc-CRACK (C) COPYRIGHT 1984, 1987 STRUCTURAL INTEGRITY ASSOCIATES, INC.
SAN JOSE, CA (408)S78-8200 VERSION 1.2 STRUCTURAL REINFORCEMENT SIZING EVALUATION
@RUCTURAL REINFORCEMENT SIZING USING SOURCE EQUATIONS FOR CIRCUMFERENTIAL CRACK iPL-02Q, TS/SE WELD, RISER D, STANDARD OVERLAY, SOURCE EQ., SF=3 7ALL THICKNESS:
1.1250 (EMBRANE STRESS: 3450.0000 BENDING STRESS: 10134.0000 BTRESS RATIO =
0.5830 LLLOMABLE STRESS =23300.0000 PLOW STRESS =69900.0000 L/ CIRCUM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 FINAL A/T 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 0.9541 0.9150 REINFORCEMENT THICK.
0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0541 0.1045 0.80 0.90 1.00 FINAL A/T-0.8975 0.8916 0.8916 REINFORCEMENT THICK.
0.1285 0.1368 0.1368 END OF pc-CRACK r
l l
t SIR-89-003 Vol. 2 29 g
i I
Rev. O ggg
Table 3-5 a
tm pc-CRACK STRUCTURAL INTEGRITY ASSOCIATES. INC.
(C) COPYRIGHT 1984, 1987 SAN JOSE, CA (408)978-8200 VERSION 1.2 STRUCTURAL REINFORCEMENT SIZING EVALUATION ISTRUCTURAL REINFORCEMENT SIZING USING SOURCE EQUATIONS FOR CIRCUMFERENTIAL CRACK.
I CPL-02Q, TS/SE WELD, RISER J, STANDARD OVERLAY, SOURCE EQ., SF=3 IWALL THICKNESS:
1.1250 MEMBRANE STRESS: 3450.0000 IEENDINGSTRESS:
11139.0000 STRESS RATIO:
0.6261 ALLOWABLE STRESS =23300.0000 IFLOW STRESS =69900.0000 L/ CIRCUM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 FINAL A/T 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 0.9463 0.9072 l
REINFORCEMENT THICK.
0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0639 0.1150 0.80 0.90 1.00 IFINAL A/T 0.8916 0.8857 0.8857 REINFORCEMENT THICK.
0.1368 0.1451 0.1451 END OF pc-CRACK I
I I
I I
I 30 EN SIR-89-003, Vol 2 I
ev.
g
Table 3-6 f
j tm pc-CRACK l
(C) COPYRIGHT 1984, 1987 STRUCTURAL INTEGRITY ASSOCIATES, INC.
SAN JOSE, CA (408)978-8200 VERSION 1.2 STRUCTURAL REINFORCEMENT SIZING EVALUATION TRUCTURAL REINFORCEMENT SIZING USING SOURCE EQUATIONS FOR CIRCUMFERENTIAL CRACK
@L-02Q, TS/SE WELD, RISER C, STANDARD OVERLAY, SOURCE EQ..SF=3 BLL THICKNESS:
1.1250 RMERANE STRESS = 3450.0000 HNDING STRESS: 13653.0000 BTRESS RATIO:
0.7340 sLLOWABLE STRESS =23300.0000 PLOW STRESS =69900.0000 L/ CIRCUM 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 FINAL A/T 1.0000 1.0000 1.0000 1.0000 1.0000 0.9971 0.9287 0.8916 UCINFORCEMENT THICK.
0.0000 0.0000 0.0000 0.0000 0.0000 0.0033 0.0864 0.1368 i
0.80 0.90 1.00 FINAL A/T 0.8760 0.8721 0.8721 REINFORCEMENT THICK.
0.1593 0.1650 0.1650 END OF pc-CRACK l
l I
i SIR-89-003, Vol. 2 31 M
7 Rev. 0 ggggg
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Overlay Repair Configurations, Materials, Finite Element Grid, and Definition of Sections Used for Through Thickness Stress Plots STRU N
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4.O WELD OVERLAY EXAMINATIONS This section presents a summary and discussion of the results I~
from the preservice UT examination of weld overlay repairs I
applied during the Brunswick Steam Electric Plant Unit 1
Fall / Winter. 1988-1989 outage and the inservice ultrasonic (UT) examinations of existing weld overlay repairs Volume 1
of this report
[1],
along with other information submitted by Carolina Power & Light to the NRC [4], provided a detailed discussion of the UT examination
- program, the examination results and the disposition of all flawed weldments.
4.1 Preservice Ultrasonic Examination of Weld Overlay Repairs Applied During Current Outage As a result of UT examinations performed in accordance with NUREG-0313, Revision 2 [2], weld overlay repairs were applied to:
e seven (7) 12-inch recirculation inlet nozzle-to-safe o
two (2) core spray nozzle-to-safe end welds and e
ten (10) recirculation inlet safe ends exterior to the thermal sleeve attachment region.
Preservice UT examinations in accordance with techniques and procedures developed by the EPRI NDE Center were performed by Carolina Power Light's examination contractor (General Electric) for all of the nozzle-to-safe end weld overlays.
The results of these ex'iminations are summarized in Table 4-1.
Flaw indications evaldoted in the low alloy steel (nozzle) base material / cladding / dilution zone of two of the nozzle-to-safe end examinations prompted extensive additional UT examination by General
Rev. 0 ASSOCIATESINC
1 j
Universal Testing (Kraftwerke Union).
These examinations and their results have been extensively discussed with the NRC and are discussed in Section 2 of this volume.
Ultrasonic indications evaluated as axial and lack of fusion m
and/or lack of bond were reported within the weld overlay j
material in a number of these examinations.
Based on these observations, analyses b accordance with Section XI of the ASME Boiler and Pressure Vessel Code (5] were performed.
All of the I
weld overlays were shown to be acceptable for service based on these analyses, except for one lack of bond indication on the overlay repair of the nozzle-to-safe end weld on the A-riser.
This indication was the result of combining three indications in accordance with IWB-3360 [5] to give a resulting laminar area of 2
7.65 in, which is marginally over the current Section XI (1988 2
Addenda) allowable of 7.5 in.
This small deviation is considered analytically justified because the overlay serves simply as a " leak barrier / stress improvement" repair to two (2) axial flaws (50% of wall) in this weld.
4.2 Inservice Examination of Existing Weld Overlay Repairs In accordance with Carolina Power & Light's response to Generic Letter 88-01 [1] and NUREG-0313, Revision 2 [2], eighteen (18) existing weld overlay repairs were UT examined during the Brun.= Wick Steam Electric Plant Unit 1
Fall / Winter 1988-1989 outage.
The results of the examinations of fifteen (15) of these weld overlays showed no indications in the weld overlay and no change in any flaw indications in the base metal under the weld overlay.
The flaw indications reported in the UT examination of the remaining three (3) existing weld overlays are summarized in Table 4-2 and are discussed in detail in the following paragraphs.
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4 1B32-RR-12"-BR-J2 A manual examination of this weld overlay was performed during the current 1988-1989 outage.
The data was evaluated as two (2) circumferential IGSCC-like indications one of which penetrated the weld overlay material and one of which did not.
No axial indications were reported.
Upon further
- review, it was determined by GE that the ultrasonic signals were due to signals from counterbore and a redirection of the RL wave due to the weld overlay surface.
An automated scan was then performed using the GE " Smart" system.
The results from this examination were evaluated as two (2) circumferential and three (3) axial indications.
Of the circumferential indications observed during the current examination, one is consistent with the indication evaluated as from the counterbore in the manual examination.
The other indication is in a region where several axial flaws were reported in the pre-overlay ultrasonic examination.
Two (2) of the three (3) axial indications observed in the current examination are consistent with the data reported from the last refueling outage.
The third axial indication is consistent in location and spacing with the axial flaws reported in the pre-overlay examination.
While all three (3) axial indications are in the " upper 25%" of the original base metal wall thickness, the " deepest" of these axial indications is at the base metal /first weld overlay layer interface.
Inspection results demonstrate that the indications have not l
penetrated the weld overlay material or the " discarded" first layer.
In tne " worst" case, an axial indication is located at the interface between the original base material and the SIR-89-003, Vol. 2 51 STItUCTUIMI.
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" discarded" low delta ferrite weld overlay layer.
In all cases, the indications are outside of the effective weld overlay
)
thickness by at least 0.1 inch and the required full structural 1
or standard design thickness by 0.27 inch.
1 The two (2)
- short, circumferential indications, which were previously unobserved, are located well within the base material.
As-with the axial indications, these two indications are also consistent with the 1988 manual examination and the pre-overlay evaluation of counterbore geometry.
It is likely that " flaws" existed in the weld or weld heat affected zone and ultrasonic inspections and were discovered during this outage as a result of improvements in technique, equipment and training.
The evaluation of the ultrasonic examination data from weld 1B32-RR-12"-BR-J2 demonstrates that there are no flaw indications which penetrate the effective weld overlay thickness or the
" discarded" first layer of the weld overlay.
This weld overlay exceeds the thickness requirements of a standard designed weld overlay of NUREG-0313, Revision 2 [2].
Indications have been observed during the current outage which are consistent with the pre-overlay ultrasonic examination and prior examination of this weld overlay.
It is, therefore, concluded that the indications-cbserved in the current examination of this weld overlay are technically not significant to the continued service of this repair.
This weld overlay repair will be re-examined at the next refueling outage to further demonstrate the conclusions contained in this evaluation.
1B32-RR-12"-BR-J3 An axially oriented IGSCC flaw indication within the upper 25% of the base metal (remaining ligament of 0.59 inch) was evaluated.
An area of interbead lack of fusion (1 inch long) was also SIR-89-003, Vol. 2 52 STRUCTURAI.
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c evaluated in the weld overlay material significantly removed b
(15 inches) from the axial flaw.
This weld overlay is acceptable for continued service.
1B32-RR-12"-BR-K4 1
No flaw indications associated with IGSCC were evaluated in this UT examination of this weldment.
Three areas of interbead lack of fusion which had previously been observed were evaluated in the weld overlay material.
No change in the indications were reported.
This weld overlay is acceptable for continued service.
4.3 Conclusions A total of twenty-seven (27) new and existing weld overlay repairs were ultrasonically examined during the Fall / Winter 1988-1989 Brunswick Steam Electric Plant Unit 1 refueling outage.
Lack of fusion / bonding was evaluated in a number of the nine (9) new nozzle-to-safe end weld overlay repairs applied during the outage.
All of these weld overlay repairs are acceptable for service.
Flaw indications were also evaluated in three (3) of the eighteen (18) previously applied weld overlay repairs which were UT examined during this outage.
Each of these observations was evaluated and these weld overlay repairs are alsc acceptable for continued service, l
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Table 4-1 q
{
Review of Ultrasonic (UT) Examination Results
{
Weld Overlay Repairs Applied During 1988-1989 j
l Brunswick Steam Electric Plant j
Unit 1 k
i' Recirculation Inlet (12-inch) Nozzle-to-Safe End Wcld Number UT Results 1B32-RR-12"-AR-A6 1 axial in base metal Lack of fusion in WOR (1 indication)
Lack of bond at WOR / Base metal interface (11 areas) 1B32-RR-12"-AR-B6 2 axials in base metal Lack of fusion in WOR (6 indications) 1B32-RR-12"-AR-C6 1 axial in base metal Lack of fusion in WOR (5 indications)
Lack of bond at WOR / Base metal interface (3 areas) 1B32-RR-12"-AR-D6 6 axials in base metal Lack of fusion in WOR (41 indications)
Lack of bond at WOR / Base metal interface (1 area) i 1B32-RR-12"-AR-E6 7 axials in base metal Lack of fusion in WOR (19 indications) i 1B32-RR-12"-BR-G6 2 axials in base metal j
Lack of fusion in WOR (5 indications) l 1B32-RR-12"-BR-H6 8 axials in base metal l
Lack of fusion in WOR (13 indications)
Lack of bond at WOR / Base metal interface (15 areas) l l
l l
l SIR-89-003, Vol. 2 54 S11HICT13RAL 1
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Table 4-1 (concluded)
Core Spray (10 inch) Nozzle-to-Safe End Weld Number UT Results 1B11-N5A-RPV-FWRNA16 Lack of f'Ision in WOR (12 indications) 1511*N5B-RPV-FWRNB16 2 circumferentials in base metal Lack of fusion in WOR (10 indications)
Lack of bond at WOR / Base metal interface (3 areas)
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A j.
~.,
- 4 l-4-
1 Table 4-2 Inservice Ultrasonic (UT) Examination Results i"
Previously Applied Weld Overlay Repairs.
Brunswick Steam Electric Plant Unit 1 l
Weld Number UT Results 1B32-RR-12"-BR-J2 2 circs & 3-axials - See discussion (2 axials extend into WOR) 1B32-RR-12"'BR-J3 No IGSCC in WOR Axial flaw in upper 25% of base metal Small area of lack of fusion in WOR 1B32-RR-12"-BR-K4 Small " contamination crack" in WOR SIR-89-003, Vol. 2 56 M
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5.0 RECONCILIATION OF DESIGN AND AS-BUILT WELD OVERLAY DIMENSIONS Nineteen (19) new weld overlay repairs were applied during the Fall / Winter 1988-1989 BSEP-1 refueling outage, as follows:
12-inch Recirculation Inlet Nozzles
- Seven (7) repairs to the nozzle-to-safe end butt welds
- Ten (10) repairs to the thermal sleeve attachment welda 10-inch Core Spray Nozzles
- Two (2) repairs to the nozzle-to-safe end butt welds 5.1 Weld Overlay Dimensions
- The - design bases, analyses and design dimensions of the weld overlay repairs which were applied to the recirculation inlet and core spray nozzle-to-safe end butt welds during the Fall / Winter 1988-1989 refueling outage were reported in Volume 1 [1].
The design bases, analyses and design dimensions of the weld overlay repairs which were applied to the recirculation inlet thermal j
sleeve attachment welds during the Fall / Winter 1988-1989 refueling outage are described in Section 3 of this volume.
5.2 Comparison of As-built and Design Dimensions The design and ar-built, nozzle-to-safe end weld overlay repair dimensions are summarized in Table 5-1.
In all cases, the as-built thickness of the weld overlay repairs meet or exceed the design dimensions and are acceptable, as explained below.
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As described in Section 2,
a portion of the nozzle-to-safe end weld overlays on recirculation inlet nozzles D
and H were i
machined to enhance UT examination.
The as-built thickness remaining is less than the design thickness of a full structural overlay.
- However, the thickness is sufficient to act as a leakage barrier weld overlay in that area (only axial flaws were identified in the affected area).
In addition, the width of the remaining full thickness overlay is sufficient for full structural load transfer and is believed to be sufficient for the performance of UT examinations.
These two weld overlays would require additional welding only if required to successfully perform UT examinations at a later date.
In Section 4 of Volume 1 (1], pre-and post-overlay crack growth calculations were reported for the nozzle-to-safe end welds.
In these calculations, a minimum design thickness of 0.465 inches was assumed.
As shown on Table 5-1, all as-built overlay thickness measurements exceeded the 0.465 minimum thickness.
For nozzles A,
B, C,and G the as-built width of the overlay repairs exceeded the design dimensions.
For nozzle E,
the as-built width dimension was slightly less than the design dimension,
- however, the as-built width of this nozzle is sufficient for full structural load transfer.
The as-built width dimension of nozzles D and H are very close to design as discussed previously in this subsection.
The design and as-built thermal sleeve attachment weld overlay repair dimensions are summarized in Table 5-2.
In all cases, the as-built thickness of the weld overlay repairs exceeded the design dimension and are acceptable.
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4.
4 I
Table 5-1 Brunswick Steam Electric Plant - Unit 1 Fall / Winter 1988-1989 Outage As-built Weld Overlay Data Nozzle-to-Safe End We3ds Weld Thickness Width Number Desion(1)
As-built Desion(3)
As-built 12" Recirculation Inlet Nozzles 1B32-RR-12"-AR-A6 0.34 0.598 5.4 5.734 1B32-RR-12"-AR-B6 0.34 0.679 5.4 5.631 1B32-RR-12"-AR-C6 0.34 0.679 5.4 5.663 1B32-RR-12"-AR-D6 0.34 0.700(2) 5.4 5.398 1B32-RR-12"-AR-E6 0.34 0.789 5.4 5.177 1B32-RR-12"-AR-G6 0.34 0.580 5.4 5.814 1B32-RR-12"-AR-H6 0.34 0.606(2) 5.4 5.114 10" Core Sorav Inlet Nozzles 1B11-N5A-RPV-FWRNB16 0.32 0.649 5.4 5.538 1B11-NSB-RPV-FWRNB16 0.32 0.610 5.4 6.076 Notes:
(1)
The design thickness shown is the required structural reinforcement thickness for the weld overlay.
The allowance of 0.125 inches for the non-structural temperbead weld overlay layers must be added to the design thickness for comparison with the as-built thickness.
(2)
A portion of these weld overlays was machined off to provide an enhanced surface for post-overlay UT (see Section 2).
The average as-built thickness dimension for weld D6 is 0.19 inches and for weld H6 is 0.24 inches.
(3)
The required design width for structural reinforcement is 4.4 inches.
The design width Ehown on this table is provided for inspection purposes.
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Table 5-2 l
l Brunswick Steam Electric Plant - Unit 1 Fall / Winter 1988-1989 Outage i
As-built Weld Overlay Data j
Thermal Sleeve Attachment Welds l
i Nozzle Thickness i
Number Desian As-built j
l A
0.17 0.245
(
B 0.17 0.180
{
C 0.17 0.250 j
D 0.15 0.170 E
0.17 0.190 F
0.15 0.173 G
0.17 0.338 H
0.17 0.215 J
0.15 0.193 K
0.15 0.155 l
l 1
l l
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6.0 EVALUATION OF WELD OVERLAY SHRINKAGE-INDUCED STRESSES 1
6.1 Introduction As the weld metal applied during a weld overlay repair solidifies and cools, the weld overlay shrinks radially and axially.
The axial shrinkage effectively shortens the length of the run of piping in which the repair is situated.
This shrinkage produces both axial and bending stresses at other locations in the piping system.
Although this stress is a secondary steady state stress of a type not usually addressed by the Code of construction, it can have a predicted effect on the growth of flaws at the stressed locations.
In addition, stresses of this type may have some effect on initiation of flaws in unflawed locations.
Consequently, it is necessary to evaluate the effects of weld overlay shrinkage-induced stresses on the repaired system as a whole.
l 6.2 Analysis In order to evaluate these stresses, a finite element model of the recirculation system from the outlet nozzles to the inlet nozzles was developed.
The geometry of the model was taken from Reference 7.
The resulting model is illustrated in Figure 6-1.
The model was constructed using the commercially available program SUPERSAP [11].
A bounding value of weld overlay shrinkages of 0.1 inch for weld l
overlays applied during the 1988-1989 outage was used in the l
analysis.
Subsequent review of as-built data confirmed that the i
shrinkage was conservatively modeled in all cases.
Tables 6-1
]
and 6-2 list the shrinkages measured during this outage.
In
- addition, shrinkage values for those overlays which were previously applied to the recirculation system were also incorporated into the finite element model of the recirculation SIR-89-003, Vol. 2 61 ST1tt)CT15 TAI.
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9 9
1 system.
These prior shrinkages from Reference 12 are shown in Table 6-3.
A static stress analysis of the repaired recirculation system was performed.
. Weld overlay shrinkage was simulated by imposing a pseudo-thermal contraction at each overlay repaired element, with the imposed pseudo-temperature determined from the measured or assumed shrinkage.
The recirculation system model was conservatively assumed to be rigidly anchored at the nozzles..
The bounding stresses calculated by this analysis are summarized in Tables 6-4 and 6-5.
Table 6-4 includes the results for the unrepaired recirculation system nozzle-to-safe end welds (3
total) and for the one location known to contain a flaw indication which is not weld overlay repaired (weld 28-A-8).
The shrinkage stress at this
- location, as shown in Table 6-4, is negligible (560 psi).
Therefore, the previous analysis [12] is not invalidated by the as-built weld overlay shrinkage stresses.
Table 6-5 includes weld overlay shrinkage stress results-for the five highest stressed unrepaired ISI weld locations in the recirculation
- system, all of which occur in the 12-inch recirculation risers.
6.3 Acceptance Criteria There are no criteria available for the acceptance of weld overlay shrinkage stresses.
The conclusion, based upon the comparison with shrinkage-induced stresses at other plants, is that the shrinkage stresses produced by the weld overlay repairs applied previously and during 1988 do not lead to an unacceptably high stress state in the recirculation or core spray system.
The flaw analysis for the one flawed and unrepaired location is not invalidated by these results.
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{
+
i Table 6-1 Brunswick Steam Electric Plant - Unit 1 Fall / Winter 1988-1989 Outage As-built Weld Shrinkage Nozzle-to-Safe End. Welds Weld Number Shrinkace (in.)
,L2" Recirculation Inlet Nozzles 1B32-RR-12"-AR-A6 0.105 1B32-RR-12"-AR-B6 N/R 1B32-RR-12"-AR-C6 N/R 1B32-RR-12"-AR-D6 0.058 1
1B32-RR-12"-AR-E6 0.020 j
1B32-RR-12"-BR-G6 N/R 1B32-RR-12"-BR-H6 0.021 N/R = not reportable (too small to be measured) o SIR-89-003, Vol. 2 63 M
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Table 6-2 As-built Weld Shrinkage Thermal Sleeve Attachment Welds Nozzle Number Shrinkace (in.)
i A
N/R l
B 0.029 C
0.056 D
0.009 E
0.027 F
0.030 G
0.071 H
0.066 i
J 0.019 K
0.004 1
N/R = Not Reported I
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.m m _,-
. _, _, _ _ _ = _
- 7g u
Table 6-3
)
1 Weld' overlay Induced ShrinkagesLon d
overlays Applied Prior to 1988 j
Weld Shrinkage Number (in.I 12-AR-A2 0.378' 12-AR-A3-O.272 12-AR-A4 0.205 12-AR-B2 0.352 12-AR-B3 0.269 12-AR-B4 0.234 12-AR-C2 0.242 12-AR-C3 0.223 12-AR-D2 0.483 12-AR-D3 0.204 12-AR-D4 0.206 12-AR-E2 0.483 12-AR-E3 0.322 12-BR-F2 0.264 12-BR-F4-0.182-12-BR-G2 0.310 12-BR-G3 0.220 12-BR-G4 0.114 12-BR-H2 0.166 12-BR-H3 0.275 12-BR-H4 0.085 12-BR-J2 0.244 12-BR-J3 0.311 12-BR-K2 0.306 12-BR-K3 0.304 12-BR-K4 0.532
.p 22-AM-3 0.050 28-A-4 0.057
'28-A-14 0.195 28-B-4 0.112 28-B-8 0.429 SIR-89-003, Vol. 2 65 Rev. 0 M
ASSOCIATES &JC
=___:_-____---______--
.sc 4
Table 6-4 l.
Weld Overlay Shrinkage-Induced Stress at Unrepaired. Flaw Evaluation Location (1~ total) and at Unrepaired Inlet Nozzle-to-Safe End Welds (3 total)
Weld Number
. Stress (ksi) 28-A-8 0.560 12-BR-F6 12.24 12-BR-J6 2.216 12-BR-K6 2.299 e
1 2
SIR-89-003, Vol. 2 66 M
Rev. 0 9
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7.0 CONCLUSION
S Volume 1 of this report
[1]
discussed the flaw indications 6
evaluated during the extensive UT examination program during the Winter 1989/1989 BSEP-1 outage, as well as the flawed pipe
- analysis, weld overlay repair design basis and weld overlay repair design dimensions.
This volume:
e provides the design basis and detailed design for the thermal sleeve attachment weld overlays applied during this
- outage, compares the as-built dimensions to these design dimensions, e
e evaluates the NDE and inspection results from the examination of the weld overlays applied this refueling outage, as well as the inservice inspection results of the weld overlay repairs which were applied in prior refueling outages, and e
evaluates the effects of the axial shrinkage which results from weld overlay application on the affected piping systems.
The conclusions from the dimensional data and evaluations follow.
- 1. The as-built weld overlay repair thicknesses and widths are acceptable, in accordance with NUREG-0313, Revision 2 [2].
- 2. The preservice UT examination results for the weld overlay repairs applied during this refueling outage justify acceptability for operation.
j l:
1 i
a SIR-89-003, Vol. 2 69 STRUCTUIIAI.
Rev. O M
i ASSOCIATESINC
7_
l s
c l
l l
l
- 3. The inservice UT examination results of the weld overlay I
repairs applied in prior refueling outages justify acceptability for continued service.
i
- 4. Results of the analyses of the effects of the weld overlay induced axial shrinkages are acceptable.
The shrinkage stresses at the highest stressed locations in
.the recirculation and core spray systems are typical for such repairs.
The snrinkage stress at the 28-inch recirculation system weld 28-A8 (containing an unrepaired flaw indication) is minimal.
i SIR-89-003, Vol. 2 70 S11tUC11JRAL
{
Rev. 0 g
ASSOCIATESINC
a
.c
8.0 REFERENCES
1.
U.
S.
Nuclear Regulatory Commission Generic Letter 88-01, i
"NRC Position on IGSCC in BWR Austenitic Stainless Steel Piping, January 25, 1988.
)
2.
U.
S. Nuclear Regulatory Commission NUREG-0313, Revision 2,
" Technical Report on Material Selection and processing Guidelines for BWR Coolant Pressure Boundary Piping",
January, 1988.
3.
Structural Integrity Associates, Inc. Report SIR-89-003, Vol.
1, Revision 0,
" Weld Overlay Repairs of Recirculation Inlet and Core Spray Nozzle-to-Safe End Welds, Brunswick Steam Electric Plant, Unit 1, January 23, 1989 4.
Carolina Power & Light (Mr. Leonard I.
Loflin) letter to U.
S.
Nuclear Regulatory Commission, dated December 28, 1988,
" Brunswick Steam Electric Plant Unit 1, Evaluation and Mitigation Measures for Reactor Recirculation and Core Spray Inlet Nozzle-to-Safe End Weldments".
5.
ASME Boiler and Pressure Vessel Code,Section XI, " Rules for Inservice Inspection of Nuclear Power Plant Components,"
1983 Edition with Addenda through Winter 1985.
6.
Stonesifer, R.
B.,
" WELD 3 Computer Code Verification Manual," April, 1988.
7.
Design Report - Recirculation Piping, Brunswick 1 and 2, General Electric Company, Spec. No. 23A5485, Revision 0, October 1, 1985.
8.
pc-CRACK, Version 1.2, Structural Integrity Associates, May, 1987.
9.
ASME Boiler and Pressure Vessel Code,Section III, " Rules for Construction of Nuclear Power Plant Components," 1986 Edition with latest Addenda.
10.
" Residual Stress Analysis of Thermal Sleeve to Safe End Welds: Brunswick Steam Electric Plant Units 1 and 2",
prepared for Carolina Power and Light Co. by Nuclear Technology, Inc., April, 1979.
11.
Algor Interactive Systems, Inc., " Software User Guide for Supersap," 1987.
12.
Nutech Engineers, " Design Report for Recirculation System Weld Overlay Repairs at Brunswick Steam Electric Plant Unit 1", XCP-40-102, Revision 2, May, 1987.
SIR-89-003, Vol. 2 71 ST'RIJCT'tIRAL Rev. 0 M
ASSCCIATESINC
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_._-_____,,,____,y, s
' I 5
APPENDIX A 6DrrEGMTY ASSOCIATESINC
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^ STRUCTURAL l
INTEGRITY Page 3 of 4 es DfTE,GIITY anerv a g g v f --
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1 NOTES 1.
Weld Overlay Design Thickness is 0.34' Af ter First Three Temper Layers
- 2. Weld Layers To Be Applied in Accordance With CP&L Approved Contractor Welding Procedures Drawing No.: CPL-020-001, Rev 0 STRUCTURAL INTEGRITY Page 4 of 4 ASSOCI AT E S, I N C.
STRUCTURAI.
l INTEGMTY Assoc'mESINc l
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I (See Attached Drawing) i WELD OVERLAY REPAIR DETAILS
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l DA~I DESCRIPTION:
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Drawing No.: E3EP1-NSA, Rev 0
^ STRUCTURAL INTEGRITY Page 3 of 4
, AS$CCI ATES, INC.
STRUCTURAL INTN8FFY v ASSOCIA tSINC A-7
4 4
NOTES
- 1. Weld Overlay Design Thickness is 0.32' Af ter First Three Temper Layers
- 2. Weld Layers To Be Applied in Accordance With CP&L Approved Contractor Welding Procedures STRU TURAL Drawing No.: BSEP1-NS A, Rev 0 NTEGRITy
' ASSOCI ATES, INC.
Page 4 of 4 STRUCTURAL l
INTMrFY w Abbociani;NC
___ A & ____.
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WELD OVERLAY RE? AIR DETAILS rLAW jDE5IGN DIMENSIONS, COMMEN_i:
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PREPARE 3 SY:
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MY f 2-2,7 9-Core Spray No: le-to-Safe End Weld Overlay Repair CHE:xE3 ST:
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^ STRUCTURAL CPL-020, Page 3 of 4 AS SOCI AT e s,Y INTEGRIT
, IN C.
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2.
4 p.
l-n NOTES 1.
Weld Overlay Design Thickness is 0.32" Af ter First Three Temper Layers 2.
Weld Layers To Be Applied in Accordance With CP&L Approved Contractor Welding Procedures O STRUCTURAL
/
Drawing No.: BSEP1-N58, Rev 1 INTEGRITY CPL-020, Page 4 of 4
' ASSOCI ATES, INC.
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