ML19332D666

Nonproprietary Rev 2 to Indian Point Unit 2 Steam Generator Girth Weld/Feedwater Nozzles Rept Spring,1989 Outage.

ML19332D666
Person / Time
Site:	Indian Point
Issue date:	10/31/1989
From:	WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP.
To:
Shared Package
ML100331159	List: ML100331158 ML19332D661 ML19332D666
References
WCAP-12294, WCAP-12294-R02, WCAP-12294-R2, NUDOCS 8912050098
Download: ML19332D666 (287)

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-WESTINGl @' ' ASS'3 g[ [0 WCAP-12294'.

REVISION 2 >1 i

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INDIAN POINT UNIT-2 1

STEAM GENERATOR GIRTH WELD /

FEEDWATER N0ZZLES REPORT SPRING, 1989 OUTAGE CONSOLIDATED EDISON OF NEW YORK OCTOBER)1989 i

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l WORK PERFORMED UNDER SHOP ORDER IEJP 4745 l-l

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l WESTINGHOUSE ELECTRIC CORPORATION ENERGY SYSTEMS BUSINESS UNIT P.O. BOX 355

c. PITTSBURGH, PA 15230-0355 9275M:1E-060589

i.

TABLE OF CONTENTS  !

Page

1.0 INTRODUCTION

. 1.1-1

.. 1.1 Summary of Inspection Results 1.1-2 1.2 Overall Action Plan 1.,2-1 2.0- STEAM GENERATOR GIRTH WELD DETAILS 2.1-1 1

2.1 Industry Experience 2.1-l' 2.2 Metallurgical Examinations 2.2-1 2.3 Indian Point 2 Experience 2.3-1 2.4 Feedwater Thermal Hydraulics 2.4-1 2.5 Fatigue Usage Evaluations 2.5-1 L 2.6 Downcomer Plate History 2.6-1  :

L l' 2.7 Fracture Mechanics Evaluations 2.7-1 2.8 Stress Relief Process 2.8-1 L* 3.0 STEAM GENERATOR FEEDWATER N0ZZLE DETAILS 3.1-1 u

3.1 Inspection Results 3.1-1 3.2 Industry Experience 3.2-1 3.3 Root Cause Discussion 3.3-1 3.4 Stress and Fatigue Evaluations 3.4-1 3.5 Fracture Mechanics Evaluations 3.5-1 A APPENDIX A A-1 i

6793R/499R890605:50 i

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Follcwing is a- revision to' HCAP-12294 Revision 2. Changes to the text are identified by a vertical double bar along the margin of the changed page. l l

.-e 1.0' INTRODUCTION This report presents the recent inspections performed on the Indian Point Unit 2 steam generators, the inspection results and the follow-up actions taken to minimize the potential of recurrence of linear indications in the girth welds and feedwater nozzles.

Initially, examinations were conducted during this outage on the stehm generator.(SG) girth weld (transition cone upper girth weld) and feedwater nozzle area in SG 22. Linear indications were detected and as a result examinations were increased to include all four SG's.

All indications were ground out and weld repairs with post weld heat treatment were accomplished on SG 22.

x The probable mechanism of the occu'trence of the cracks has been established as

.- corrosion fatigue caused by a combined action of thermal cycling, oxygen in

the auxiliary feedwater and copper from the feedwater system.

l .:

L To 'ninimize the cause for the fatigue corrosion mechanism, the downcomer resistance plates were removed. Additionally, the controls of the feedwater low flow valves have been modified and consideration is being given to a

, nitrogen gas cover in the condensate storage tank or deaeration.

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9275M:1E-101289 1.1-1

v. : ,og J1.F Summary of Inspection Results

,f ..

-During'the current refueling outage, visual (VT) and magnetic particle (MT) examinations were conducted initially on 1/3 of the inside circumference of the SG 22 girth weld. .These examinations were conducted as part of the ,

l ongoing steam generator girth weld examination program as identified previously1!n.a Con Edison letter to the NRC dated December 11, 1987. Linear )

indications were detected during this examination. Subsequently 100% of the

. inside circumferences of the girth welds in all four steam generators were  !

inspected. Linear indications were also detected in these additional ]

examinations. Details regarding the as-found indications, the grindout -l h geometry and planned weld repairs and post weld heat-treatment are discussed in subsequent sections of this report. l l

During this outage, a VT examination was also conducted on the SG 22.feedwater j nozzis-inside radius section in accordance with Inservice Inspection Program I l relief request:25, previously approved by the NRC in a letter dated December j 24, 1987. . The visual examinations detected several linear indications within I L

.the nozzle inner radius section in the bottom 120* segment of the nozzle. ,

L, Visual and liquid penetrant tests were subsequently performed on the nozzles j of all four steam generators. SG 22 and 23 nozzles contained similar .

-indications whereas none were detected in SG 21 and 24. During the course of 1

performing liquid penetrant tests on the nozzles, linear indications were also  ;

L detected in support bracket welds directly below the nozzle inside radius section on SG 22 and 23. No such indications ~were detected in SG 21 and 24.  !

I

-As=a result of detecting the linear indications in the nozzle inner radius L

h section an expanded inspection program was initiated to determine the overall l

condition of the feedwater nozzles. This program included radiography of all four nozzle to feedwater inlet piping welds, ultrasonic examinations of all four. nozzle bores, and a borescopic examinations of segments of the SG 22 and 23 thermal sleeve inside diameter surface and outside diameter surface and the nozzle bore inside diameter surface. The indications on the SG 22 and 23 ,

nozzle inner radius have been removed by grinding and the indications on the SG 22 and 23 support bracket welds have been removed and repair welded. . ,

1.1-2 6793R/499R890526:50

+

sn -

o L. Details of the as-found indications ~on the nozzle ~ inner radius sections and .

the support brackets,-the expanded inspection program, the.grindout geometry g, 'and support plate repairs are discussed in subsequent sections of this report.

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9275M;1E-060589 '

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1.21 0vera11' Action Plan-LAs'a' result ofLthe inspection and analysis performed, an overall action plan i has been implemented to address the postulated mechanisms and min %ize the )

m potential of recurrence of the indications. The plan includes the following j

steps:

q ., .

1. Removal of all indications (cracks) J

2. Repair welding a) Girth weld in SG 22 to an equivalent maximum grindout depth'of 3/4 in, b) Support brack'et attachment areas-in SG 22 and 23 f 3. Removal-of downcomer flow resistance plates (DFRP) l

4. Modification'of main feedwater flow bypass regulator valves

5. Operational controls c, 6. -In-service inspection /mid-cycle outage 1

m 1.2.1 Removal of All Indications '

All indications were removed by grinding and the surface was examined by MT techniques to assure that no linear indications remain. The primary method used' dry powder with an AC yoke. In addition, several ground out areas were cooled locally and MT tested with dry powder and DC magnetization. No '

indications were detected.

1.2.2 Repair Welding Analysis'showed that a girth weld grindout of approximately 1 inch depth is -

I suitable for. continued operation. Steam generators 21, 23 and 24 meet the above criterion without additional repair. Steam generator 22 had a larger 1.2-1 9275M:1E-060589 L_____-

a 1

number.of indications and a higher crack growth rate.during the previous j cycle. .Thus=to provide a greater margin for SG 22, all grindout areas were rewelded to leave a maximum grindout of less than 3/4 in. A subsequent post weld heat treatment (PWHT) at 1125 + 25'F.will be performed. Table 1.2-1 shows'the grindout areas to be welded. An RT examination will be made of the repair. areas. After PWHT, MT examination will be made of 100% of the girth' i

-weld-inner circumference.

The support bracket welds with indications w e 2 stored to original design configuration. In SG 22 a shielded metal are welding.(SMAW) process with E-7018 filler metal was used. The PWHT for the girth weld repair was used for heat treating these repairs. Both vertical welds on both support brackets showed indications with the deepest area to 0.36 in.

The grindout repairs to the support bracket in SG 23 were in the attachment welds. A half bead technique with E9018M filler was used. The vertical welds on both support brackets showed indications to a maximum depth of 0.36 in. ,

1.2.3 Downcomer Flow Resistance Plate The plates were removed to prevent the damming action which might concentrate .

the colder water in the area of the girth weld during the injection of

. auxiliary feedwater.

1.2.4 Main Feedwater Bypass Flow Regulator Valve Modification L This modification installs a timer that can delay closure of the main feedwater flow bypass flow regulator valves following a reactor trip

l. coincident with low Tave (5,541*F) signal. This modification in conjunction 1

p with operation of the bypass flow regulator valves in the open position, L provides hot. main feedwater flow to the steam generators following a trip.

This will enhance maintaining the steam generator girth welds and the ,

feedwater nozzle in relatively warm water when the auxiliary feedwater enters

~ '

the~ steam generator nozzle and feedwater ring of the steam generator, which could minimize potential thermal shock to the girth welds and feedwater nozzle.

l u 1.2-2 1

9275M.1E-060589

v

~The main feedwater r3gulator valves ~will still close on the reactor. trip / low: , }

Tave signal._ Both the main and bypass regulator valves will still be closed i by the independent circuitries of Safety Injection and High Steam Generator-Water Level.- The timer will be set to zero until the optimum setting is determined < Implementation of the modification is under evaluation.

L1.2.5 ' Operational contrel ,

.v 1.2.5.1' Feedwater Chemistry All: plant INPO chemistry parameters, as identified in the Chemistry ,

Performance Index are on the average 2/3 less than.the corresponding industry

~

guideline values and show a downward trend. Figure 1.2-1 shows this.

At the same time, chemistry appears to play an adverse role in two abnormal plant operating modes. For reactor trips and plant operation in the hot ,

standby mode, relatively cold, oxygenated auxiliary feedwater'is pumped into the steam generators. The results of the metallurgical evaluation indicate j that the oxygen contained in this water, acting catalytically in the presence of copper, causes pitting in the' steam generator _ girth weld area. Pits in the

.- range of 20 to 25 mils diameter correlate strongly as nucleation sites for the cracks observed. <

Continuing _ improvements have been made to both the water treatment facility ,

and'to' condensate and feedwater components to ensure the water quality coeld meet the requirements of the SG chemistry limits. These include the change out of the material in external feedwater heaters to remove copper sources and the addition of prefilters to further reduce the chloride content in makeup-water., Oxygen concentrations have also been reduced over the past several years through a rigorous program of monitoring for and eliminating of air in-leakage. As a result, 0 in2 feedwater is being maintained generally at less than 5 ppb. However, during periods of operation when the auxiliary boiler feedwater pumps supply water to the SGs, no current method exists for assuring the 02 in the feedwater is maintained below 50 ppb. A potential correction to this problem would be the installati~en of a nitrogen cover gas blanket on the condensate storage tank or deaeration to mitigate this effect.

This modification is currently being evaluated.

1,2-3 9275M:1E-o60589

7 I,

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7 As'part.of: an overalllimprovemers program, consideration is being given to

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retubing the. Indian Point 2 condensers with Titanium. ,

o 1.E.5.2 Leakage Detection -

% Multiple detection methods are located within containment for monitoring' system leakage. The methods are primarily directed to detection of. leakage from the Reactor-Coolant System and their operability and out-of-service times are controlled by the requirements of the Technical Specification. (Section 3.1.F. " Reactor Coolant System Leakage and Leakage into the-Containment Free-Volume"). The reactor cannot be brought above cold shutdown unless the following leakage detection and removal systems are operable:

(1) Two containment sump pum;,s (2) Two containment sump level. monitors (3) A containment sump discharge line flow monitoring system (4) Two recirculation sump level monitors -

(5) Two reactor cavity level monitors (6) Two of-the following three systems (a) A containment atmosphere gaseous radioactivity monitoring system (b) A :ontainment atmosphere particulate radioactivity monitoring }

system (c) The containment fan cooler condensate flow monitoring system.

The above leakage detection methods represent a comprehensive monitoring system.which is capable of datecting leakage from different systems. Those detection methods, dependent upon sensing airborne radioactivity levels, are limited in their application to Reactor Coolant System Leakage. However, those which monitor water accumulation or flow would detect process equipment pressure boundary leakage including significant secondary side steam generator leakage. Of the various methods, the radioactivity monitors are the most sensitive and detect the lowest amount of leakage. Exc.ept for beginning of life, the absence of radioactivity indication would indicate that leakage is '

from a source other than the Reactor Coolant System. Thus all of the monitoring systems are of value in detection of a breach in the pressure boundary of a steam generator.

1.2-4 9275M:1E-060589

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The Technical Specifications establish limits for total leakage into the containment from all sources. If the limits cannot be met, the source of

.. leakage must be reduced to allowable limits or the plant be brought to cold shutdown within the prescribed time periods. Relative to the steam a generau.rs,the.pertinentlimitis10GPW(total).

'1 Of the various monitoring schemes, the containment fan cooler condensete flow monitoring system measures the moisture condensed from the containment I atmosphere by the cooling coils of the main air recirculation units. Steam generator leakage could r6sult in an increase in containment humidity, i Condensate flows from approximately 1 gpm to 15 gpm per detector can be I l

measured. Condensate flows less than 1 gpm may be determined by periodic l observation of water accumulation in the standpipes of the condensate collection system. Measuring flows greater than 15 gpm with this system is also possible. By procedure, containment fan cooler unit condensate flow c monitoring is performed once every four hours. -An additional method of monitoring water buildup in the containment atmosphere is possible via changes in-the dew point of the containment atmosphere. The change in water content

. of the containment atmosphere is also possible via this route.

Monitoring of the containment sump level monitor actuation, containment sump

! pump flow, recirculation sump level monitor actuation or recirculation sump level monitor actuation provide a more direct means of quantifying leakage into the containment. The containment and recirculation sump inventories are monitored once a shift; their related pumps are demonstrated to be operable on a monthly basis.

Operation procedures currently require containment entry at 5 gpm (refer to 2.7.1) to identify the cource of leakage should a leakage detection system annunciate. Additionally, routine containment entry is required once a month for inspection purposes.

. Any alarm annunciation would be followed by a timely containment inspection of the source of leakage.

^

l I

l 1.2-5

! B275M:1E-060589

l 1.2.6 -Inservice Inspections /Mid-Cycle Outage The following' inservice inspections are planned to be conducted for the SG ,

girth welds and feedwater nozzles following the current plant outage.

During a special plant shutdown which will occur approximately at mid-cycle, VT and NT inspections of 1/3 of the inner circumference of the S.G. 22 and 23 girth welds will be conducted. This will include areas of representative ]

repairs, previously ground out areas, and non ground areas. If relevant I linear indications are detected, the examination will be extended to 100% of the SG 22 and 23 girth welds and 1/3 of SG 21 and 24. If relevant linear I indications a found in SG 21 and 24 the examinations will extend to 100% of l

.these welds.

Simultaneously inspection of the feedwater nozzle areas is planned. A VT and MT (or PT) will be conducted on the nozzle inner radius section in the lower 180* segment and on the welds of the support brackets on SG 22 and 23. If  ;

l indications are found, the examinations will be expanded to the SG 21 and 24 nozzles and/or brackets, as applicable. ,

If an unplanned outage of sufficient duration occurs within a few months prior ,

to the planned mid-cycle outage, the above examinations may be performed at that time in lieu of conducting the inspections later at the planned mid-cycle outage.

The above examinations VT and MT (or PT) on girth weld and feedwater nozzle areas will also be repeated during the next refueling outage.

Subsequent to grinding out/ repair welding the girth welds during this outage, ultrasonic baseline mapping and future inservice volumetric testing of the i girth welds will not be accomplished as specified in ASME Section XI. l Ultrasonic examinations during 1987 following girth weld grindout indicate that the complex grindout geometries preclude meaningful ultrasonic examinations. In liee of volumetric examinations, visual and MT examinations of the interior circumference of the girth weld will be substituted for future ,

Section XI exams.

1.2-6 9275M:1E-060589

=______:______________________--___-___-_______-__

1 Indian Point #2 a.

INPO Chemletry Performance Index (CPI) y Perforunamee lades (CPI) llhesmistr'

.s l

'* econsists of five seeendary-side water quality parametere I

• Condentate System - Disso6ved Oxygen (10 ppb) - 1 3 '

• Steem Generator Bloosewn - I '"

L'. Chlorise (20 ppb) g 5

i -- Sutfots (20 ppb) '

0.71

Sodium (20 ph) '

O.35 i

Cetion Conducivity (0.8 uS/om)

- MPO uediori

' eused se e report cord to trock statson performance over -

<0.25)

e to o w.e ,y. .- e ,,

e end ,, ,,

• lmplemented by INPO effective Januory 1988  %',

j Condenoote Dissolved Ozygen  ;

se 50

' es -

a -

[

[

t0 9 INP0/EPRt 32 * ' ~ ~ ""*'

em - EM4 (10 ppb) se a es en e' es e7 as e,

Steam Generator Slowdown Cotion Conductivity Stoom Generator Bloedown Sulfote

'* INP0/EPRI i

-' GutDEUNE a

10.1 (20 @ 2.81 0.29

~

f (0.8 uS/cm)

e. en s, 8 ,, ,, ,,

es=me res=s essee punis Steam Generator Blowdown Chloride steem Generotor Blowdown Sedum 100 INP0/EPRI ,, ,

12.2 se l 12 'e u CUCEUNE '

~

m {so - >

{, 86 ,

i- 4g a - i ,

g se i 5.8 ee -

e ,

INP0/EPRI

! j, g,g - GUIDEUNE

. 30 -

(20 ppb) ij .,

4

• e. . ei . Figure 1.2-1 o-, L , , , , , ,, ,

e - =.*-==

1.2-7

, 1 TABLE 1,2-1 l 4

l

. AREAS IN SG 22 DEEPER THAN 3/4 IN.'TO BE REPAIR WELDED

. '.1 l

Vertical Distance Zone Length Width Start from Zone Line from Reference i

' No. (in.)- (in.) (in.) Line In.

6 5 1 1/2 17 7 1/2 4 1 1/2 24* 8 5 2 38* 7 1/4 7 5 3 9 8-6 3 26*- 7 1/4

8. 8 3/4- 4 3 1/2* 8 6 3 20* 7 9 11 3 1 7 3/4 5 3 6 8 11 10 5 9 7 0 Approximate

(-

l-1.

l l-l l 1.2-8 l

6793R/499R890526:50

2.0 -STEAM GENERATOR GIRTH WELD DETAILS t

., 2.1 Industry Experience

.. Following the Indian Point 3 girth weld shell leak, several utilities performed NDE inspections in the girth weld region of their steam generators.

A total of five plants reported linear indications on the inner circumference -

of the girth welds. The plants are Indian Point Units 2 and [

)9, plant A, [ 19 , plant C and [ ]9, plant D 2, and [ ]9, plant B. In all five plants, the indications were removed' by grinding. Previously, only one of the five [ 3 9 . plant A required weld repair.. Subsequent reinspections at three plants have revealed no indications at two: [ 39 plant D and [ )9, plant A and ene shallow indication [ 19 , plant C which was removed by light grinding (less than 0.020 inches in depth). The inspection techniques used, the number of steam generators inspected, and other pertinent data are summarized in Tables 2.1-1, 2.1-2, 2.1-3 and 2.1-4. A general outline of the girth weld region is shown in Figures 2.1-1 and 2.1-2.

Few plants with downcomer flow resistance plates installed have performed MT l- examinations similar to Indian Point 2. Only [ 39 , plant C and l [ 39 , plant D had downcomer flow resistance plates in place prior ,

to the first MT inspections. (The plates were removed in order to perform the l

inspections and were not reinstalled.).

Additionally, the only remaining plants with Westinghouse Series 51 steam generators which presently have their downcomer flow resistance plates in

-place are [ )9, plant E, [ )9, plant F, [

)9, plant G and [ )9, plant H. There are no domestic Westinghouse Series 44 steam generators which presently have downcomer flow l-resistance plates installed.

l 2.1-1 i l 9275M:1E-060589

t

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pIillajii-s_ ,I, g 1 '. GENERAL OUTLINE OF n nn,..n...ana"d8 WESTINGH0USE MODEL d4 -

n ,t. 2.1-1 STEAM GENERATOR 2.1-2

___m._-____-_--._-*-----*w- - ---w- .i g  :-m 4.. - y*.- A

Q,C-pSHELLI.D.

t = .

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. ia-,

Figure 2.1-2 ,

2.1-3

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v. e- -g S y,:

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= c st :I:= a  : a a a a y

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Table 2.1-1 2.1-4

, ' +- ..

'i INITIAL STEAM GENERATOR GIRTH WELD INSPECTIONS PIANTS WITH NO REPORTED INDICATIONS INSPECfleN DATA S. S.

NO9EL TEARS sensessessessessesseessessee NMEN RESm.fS .

NO. . SERWICE seesessessese.ees 'l PLANT seese esseems seeeeees eseesseesses _

g 83 2f94 1991 Si i 58 27

)

l 44 15 9182 Rt I SS - Pits q w # 13 fire 2 Isot ALL Se S 44

~ s O

l 19152 INSPECTER 1 SS.

• " St 4 METMOS WINCIIOWN m'

9 2154 1981 WT l SS SI 5 2184 lett WT I 58 51 12 19/02 lost WT K L SS'S SI il 12 19152 WT 24' TS 49* EL 58

Si ,

12 19182 Ut 24*-TO 48' ALL 58 4

St

• DOWNCOMER OUT IN 1975 1

i

n .

~

g GIRTH WELD REPAIR HISTORY . .

1982. [ [ kMODEL 44) REPORTED SHELL LE IN S/G #32. UT/NT EXAMINATION C0NFIRMED ADDITIONAL INDICATIONS. REPAIRED BY '

GRINDING / WELDING.

~

L 1983 ' ' kMODEL 33) UT/NT INSPECTION L

SHOWED PITTING / LINEAR INDICATIONS.

ALL LINEAR INDICATIONS REMOVED BY GRINDING.

. .9

• 1985

_ (MODEL 51F) UT/NT INSPECTION .

r SHOWED PITTING / LINEAR INDICATIONS.

ALL LINEAR INDICATIONS REMOVED BY GRINDING.

1986 [ '(MODEL 51F) UT/NT INSPECTION SHOWED PITTING / LINEAR INDICATIONS.

ALL LINEAR INDICATIONS REMOVED BY GRINDING.

Table 2.1-3 2.1-6

)

4 GIRTH WELD NO. 6 INDUSTRY INSPECTION-

SUMMARY

- 1 e FOLLOWING[ [GIRTN_WELDINDICATIONS,ANUMBER OF UTILITIES PERFORHED INSPECTIONS 0F GIRTN WELD I N0. 6.  !

FIVE N0 DEL 51 S/Gs WERE 100% INSPECTED BY UT.  !

L e NO UNACCEPTABLE INDICATIONS FOUND. 1 I ONE S/G.EXNIBITED INDICATIONS JUDGED TO BE GE0NETRY. i SIX H0 DEL 51 S/Gs WERE PARTIALLY EXAMINED (APPR0XINATELY 8 FT.) BY UT.

L. '

l e N0 UNACCEPTABLE INDICATIONS FOUND, ISOLATED INDICATIONS FOUND WHICN WERE JUDGED TO BE GEONETRY.

FOUR H0 DEL 44 S/Gs WERE 100% UT AND SIX WERE 100% NT.

e H0 UNACCEPTABLE INDICATIONS FOUND.

1 i ..

l Table 2.1-4 l 2.1-7

l '[f' GIRTH WELD h'0. 6 IhDUSTRY IhSPECTION1JnARY "'

(CONTINUED) '

L e

FOLLOWING THE REPAIR.0F INDICATIONS AT'IP I ~

AND} l'SUBSEQUENTUT/MTINSPECTIONS NAVE BEEN PERFORMED:

[ - FOUND (BY MT) ONE $NALLOW INDICATION WHICH WAS REMOVED BY LIGHT  !

GRINDING (<0,02"); INSPECTION WAS EXPANDED >

l BUT NO FURTHER INDICATIONS FOUND.

-) JS TWO RE-INSPECTIONS (BY MT) -

L WITH NO REPORTED-INDICATIONS.

- ', ~

- THREE RE-INSPECTIONS (BY HT) WITH NO REPORTED (ID) INDICATIONS.

• L e WITH THE ISSUANCE OF INFORMATION NOTICE IN 85'-86, 0THER UTILITIES HAVE PERFORHED PARTIAL INSPECTION. (EITHER VISUAL, NT OR.UT) 0F THE GIRTH WELD N0. 6 WITHOUT REPORTED INDICATIONS.

l l

- i Table 2.1-4 (Cont.)

1

[ 2.1-8 r

'2.2 Metallurgical Examination 1

Fo1~1owing the detecticu of indications in the girth welds, surface replicas were taken from the affected regions for preliminary site evaluation purposes. Boat samples were taken from the girth weld areas containing the indications for the purpose' of conducting metallurgical investigations (Tables 2.2-1 to 2.2-3).

The boat sample from Steam Generator 24 contained a portion of a long crack initiated from the original 10 surface and was identified as " boat 1". The sample from Steam Generator 22 contained a 1/2 in. long crack initiating from a surface ground during the previous refueling outage and was designated as

" boat 2".

Theevaluationincluded(Table 2.2-4):

o Surface examination of the as-received boats by light optical and scanning electron microscopy techniques.

o Meta 11ographic examination of the boat sections containing the major

. cracked' regions o Fractographic examinations of the freshly opened and Endexed cracks by light optical and scanning electron microscopy techniques

~

o High resolution transmission electron microscopy examination of replicas from the fracture face for evidence of fatigue-striations o Hardness traverse measurement of the material microstructure containing the cracked regions o Chemistry evaluation of the crack deposits l

l ..

The results of the surface examination of the as received boat-samples showed oxide deposits and extensive surface pitting where the cracking was initiated. The surface pitting and the oxide deposits seen in boat 2 was l

2.2-1 9275M;1E-060589

1 i 5

- significantly less severe than in boat 1. The cracking in boat 1 extended over the entire length of the boat while the cracking in boat 2 extended approximately over,the middle third of the boat length. The surface examina-tions also showed the presence of a small crack on the bottom cut face of the -

boat 1 suggesting that' the cracking extended as deep as the thickness of the boat. The results of the surface examinations are illustrated in Figures '

2.2-1 and 2.2-2. ,

The results c,f the metallographic examinations (illustrated in Figures 2.2-3 to 2.2-10) showed evidence of multiple crack initiation sites originating from the surface pitting. The maximum size of the pits where cracking was initiated corresponded to approximately 25 mils. The cracking was initiated at the knee of tha weld metal to base metal interface, where stress

[ concentration due to geometric discontinuity is likely to be present. The l cracks were extensively covered with oxide deposits all the way up to the crack tip regions. The cracking measured approximately 0.20 in, and 0.09 in.

deep at their deepest locations in boats 1 and 2, respectively. The cracking

l. was relatively straight and transgranular and disregarded the local microstructure of the material. No evidence of branching was seen in the-cracks. For the most part, the heat affected zone microstructure where -

cracking was situated corresponded to quenched and tempered martensite-bainite

1. aggregate. A hardness traverse measurements through the these regions showed a peak hardness level of 38 Rockwell "C" number suggesting that adequate l' toughness existed in the material. Boat 1 also revealed the presence of a tight secondary crack, below the main crack. Close examination of the crack

_ however confirmed that the crack contained oxide deposits and hence is an extension of the main crack, perhaps connected at a different location along the crack length.

Fractographic examination of the freshly opened cracks by scanning electron microscopy (Figures 2.2-13 through 2.2-15) showed evidence of oxide deposits covering the entire fracture face. Energy dispersive X-ray analysis of the crack deposits confirmed the presence of copper, sulfur and zine at the crack mouth regions where pitting was seen (Figures 2.2-16 through 2.2-18). The -

remainder of the crack however is free from any aggressive elements. Light optical fractographic examination of the freshly opened and Endexed fracture 2.2-2 9275Mn E-060589

I faces.showed clear evidence of crack initiation sites corresponding to pits on the boat surface with typical thumb nail patterns (Figures 2.2-11 and

. 2.2-12). Evidence of numerous beach marks were seen at the crack-tip regions 1 suggesting that changes in-the load and/or environment occurred'during the life of the crack. Scanning electron fractographic examination of the Endoxed crack's confirmed the presence of finely spaced crack arrest lines and corroded

• = base metal.

Replica transmission electron microscopy examination of the crack tip regions ,

showed some areas resembling the appearance of fatigue striations on the freshly opened and Endoxed faces of the subsurface crack seen in boat #1

-(Figures 2.2-19 and 2.2-20). The formation of the oxides in the crack probably censumed much of the evidence of fine fatigue striations.

The presence of heavy oxide deposits, pitting and multiple crack initiation sites seen at the surface suggest that crack initiation may have occurred by surface pitting. Since the boat sample from SG 22 was taken from a surface ground during the previous outage, the surface pitting seen in boat #2 must

-. have been introduced during the last operating cycle. The generally straight nature af the cracks with no evidence of branching, suggests that.the crack '

progression may have occurred under the influence of loads axial to the steam-generator. The presence of numerous crack arrest lines on the fracture face suggests that cracking may have occurred under the influence of intermittant or cyclic loads. The presence of heavy oxide deposits and corrosive attack seen on the entire fracture face confirms the strong role of corrosion in enhancing the crack growth process.

Baced on the overall results of the evaluations, it is concluded (Table 2.2-5) that cracking in the steam generator girth weld and nozzle area most likely occurred by corrosion fatigue mechanism. The presence of corrosive elements and stress concentration at the knee of the weld joint contributed to pitting and crack initiation.

L ..

l

-~:

2.2-3 9275M:1E-060589

. t s

n k,

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Figure 2.2-1 As-received surface appearance of the Boat I sample from Steam j

Generator 24 girth weld , 111ustrating the surface pitting and

• a cracking seen on the 10 surface.

a h

i b

P l i i t

g

s. .; . . . . .,

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'I t i- i Y > * "MkUQ,Lji;&&{:${.f[h- *l} L fpgf f,453 fgi) (sxF 1 Figure 2.2-2 As-received surface appearance of the Boat 2 sample from Steam Generator 22 girth weld, illustrating the surface pitting and  : cracking seen on the 10 surface.  ;

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! C-1 14x ! A-2 14x Figure 2.2-4 Metallographic examination results illustrating the cracking morphology and microstructure seen in Boat 1. l 1 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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BOAT -1 SECTION A-2 50x figure 2.2-5 Metall.) graphic examination results illustrating the pitting and oxide deposits at the crack initiation in Boat 1. 2.2-8

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METALLURGICAL EXAMINATION ' 0F BOAT SAMPLES- ' t OBJECTIVES: o TO ESTABLISH THE CAUSE AND MECHANISM OF CRACKING e o TO DEVELOP INFORMATION THAT WOULD BE HELPFUL IN FORMING CORRECTIVE ACTIONS l 1 Table 2.2-1 1 1 2.2-24 1:

t CRACK DEPTH OF POLISHED BOAT SAMPLES k

        - SG-24 BOAT #1           INCHES                 MM    COMMENTS A-1           0.0714                1.81      '

A-2 0.0714 1.81 > B-2 0.0536 1.36 B-2 0.0536 1.36 SECONDARY CRACK C-1 0.196 4.99 WENT TO END OF BOAT SAMPLE. POSSIBLY FARTHER. SG-22 BOAT #2 , C-1 0.0875 2.22 FIRST POLISH l C-1 0.065 1,55 SECOND POLISH L .. . Table 2.2-2 2 2.2-25

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                                                         .i SAMPLES e  BOAT 1  SG #24      VIRGIN ID SURFACE-0  BOAT 2  SG #22      PREVIOUSLY CROUND-0UT SURFACE Table 2.2-3 2.2-26

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1 i 4 MAJOR TASKS  : f f 0 SURFACE EXAMINATIONS 0 METALLOGRAPHlc EXAt$1NAT10NS > 0 FRACT0 GRAPHIC EXAMINATIONS ' LIGHT OPTICAL

• SCANNING ELECTRON 0 HIGH RESOLUTION TRANSMISSION ELECTRON MICROSCOPY ,

EXAMINATION OF REPLICAS O CHEMISTRY EVALUA110N OF CRACK DEPOSITS 0 HARDNESS TRAVERSE MEASUREMENTS 1 Table 2.2-4 2 2.2-27

CONCLUSIONS ... ; O CRACKING IN THE STEAM GENERATOR GIRTH WELDS WAS CAUSED BY CORROSION FATIGUE MECHANISM 0 SURFACE PITTING AND STRESS CONCENTRATION AT THE KNEE OF THE WELD JOINT CONTRIBUTED TO CRACK INITIATION i Table ?.2-5 2.2-28

t 2.3 Indian Point 2 Experience (1989) MT examination was performed on the girth weld inside circum.ference surface on all four steam generators. The process was performed in accordance with -% Westinghouse Nondestructive Examinatic- Procedure NDE-310, Rev. O. This procedure is for examination of ferromagnetic materials and weldments at less than 600 degrees F utilizing dry powder magnetic particle examination techniques, Yoke Method. This procedure is prepared based on requirements in the ASME Boiler and Pressure Vessel Code, Section III and V. Examination results indicated that the extent of the indications found varied between steam generators, with No. 22 exhibiting the highest number of recordable indications (49) and No. 21 the least (5). The following table summarizes the number of indications found per steam generator. Steam Number of Generators Indications ., 21 5 22 49 23 15 24 6 A detailed renair procedure was prepared for removal of the all surface indications by grinding. To assist in record keeping of each indication, the girth weld region was divided into 12 zones per Figure 2.3-1. A baseline MT examination was performed to document the total number of indications, locating each indication horizontally within each zone and vertically relative to the weld centerline. The repair process for removal of the indications involved controlled grinding to a specific depth (typically, 0.25 inches), followed by a VT or MT

.. inspection. This process was continued until the surface indication was removed. Once the indication was verified as MT clear, the adjacent metal was
?   then blonded to a 2:1 taper (minimum) down to the base of the excavation.

2.3-1 9275M.1E-060589

This surface contouring was performed to assure conformance with analyzed geometry for reducing stress concentrations at all ground locations. After all contouring was completed, all ground surfaces were given a final HT inspection to assure the MT clear condition. Table 2.3-1 lists the locations and sizes of the indications found and removed. ,, Tables 2.3-2, 2.3-3, 2.3-4,'2.3-5 and 2.3-6 provide a comparison between the 1989 experience 'to that of the 1987 experience of the number of indications per zone and the maximum depth of metal removed to clear the indications. For all four steam generators, the data reveals that the number of indications in 1989(76 total) were significantly less than those revealed in 1987 (291 total). Twenty-five zones had no indications (by MT inspection) in 1989 whereas only 6 zones had no indications in 1987. Also compared on a zone by , zone basis (1989 to 1987) were the maximum depths of grinding required to remove an indication. Of 48 total zones (all four steam generators), only 12 zones required deeper depth of grinding to remove indictions in 1989 when compared to the original depth of grinds from 1987. The maximum depth of . grind for 1989, 1.42 inches, occurred in Zone 7 of steam generator No. 22. The average depth of grinding (all four steam generators) for 1989 was 0.24 inches versus an average of 0.35 inch depth for 1987 per Table 2.3-7. Table 2.3-8 provides a summary of the number of indications, maximum depth of grind, , l and average depth of grind of the 1989 data relative to the 1987 data. Figure 2.3-2 depicts the depth of final grindout in terms of the frequency of occurrence of various depths for each steam generator. In terms of final depth, the figure shows that 22 is unique when compared to the other steam generators since the eight deepest grindouts ocurred in 22. 1 Figure 2.3-3 depicts the depth of indication growth during one fuel cycle in l terms of the frequency of occurrence of various depths for each steam generator. In terms of maximum growth rate, the figure shows that SG 22 is again unique when compared to the other steam generator since the eleven largest crack growth rates occurred only in SG 22. .. l 1 2.3-2 , 9275M;1E-060589

                                                                                           )

l l Figures 2.3-4, 2.3-5, 2.3-6, and 2.3-7 provide a comparison of location of the j indications (for both 1989 and 1987) relative to the feedwater nozzle, l

 ,      feedring and J-nozzle orientation. No conclusive correlation was noted between indications and distribution of J-nozzles, hot or cold leg location,                                              J or orientation of the feedring sections as per Tables 2.3-9 and 2.3-10.

[- 39 A review of the material properties and fabrication history of the steam generator girth welds was made. Chemical analysis and mechanical properties are summarized in Table 2.3-11 and 2.3-12, respectively, all values were within acceptable limits. Girth Weld No. 6 for the Indian Point Unit 2 steam generators was fabricated by field welding the inside surface and then back gouging or grinding and welding from the outside. Figure 2.3-26 is a general schematic showing the EV steps for the upper shell/ cone section of the steam generators. The weld records indicated that the welds were deposited using E8018 filler

  ,    and post weld heat treated using qualified procedures that satisfied the requirements of the ASME III 1965/S 1966 code of construction. Per Section III requirements, the alignment at the edges of the shell shall be such that the maximum offset does not exceed 29/64 in. On-site fit-up was used to obtain *best minimum offset condition". Records available do not indicate results of the maximum allowable offset, however, no nonconformances were uncovered.                                           It was common practice to jack the upper shell, up to one inch in diameter, in order to meet the offset guidelines. The stresses resulting from jacking or cold spreading were relieved during subsequent post weld heat treatment of the closure joint. All offsets were required to be flared in a 3:1 taper over the width of the finished weld, and if necessary, additional weid metal was added beyond what would otherwise be the edge of the weld.

The heat treat records for weld #6 were reviewed and found to meet procedure

  .. requirements.                                            Weld procedures in place at the time of the field weld required I       a minimum preheat of 225'F and a maximum interpass temperature of 500'F. The ID of the closure weld was completed, followed by chipping and grinding to remove any unfused root section of weld from the 00. The OD weld was then 2.3-3 9275M;1E-060s89

4 made. The post weld stress relief was performed per Section III require- , ments. The maximum rate of heating was as specified in the procedure,  : 100'F/hr. The soak temperature and time was determined by the minimum temperature attained by any one of the thermo:ouples on the weld when the . maximum temperature attained was 1150'F. The minimum hold time / temperature limits were as follows: Min Temp When Max Temp Hold Time 1100'F 1150*F 3 1/2 hrs 1050*F 1150*F 7 hrs 2000'F 1100'F 10 1/2 hrs - Table 2.3-13 summarizes the heat treat requirements and records for the various steam generators at Indian. Point 2. As can be seen by the data, all limits were satisfied. Additionally, an earlier review of the closure weld records indicated that there were no nonconformances noted for either NDE inspections or weld repairs. Code required NDE was performed, but documentation is not currently available to determine whether the MT was perforned before or after post weld , heat treatment. , e

                                                                             .4 2.3-4 9275M;1E-060589

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                           $        11                 8 4 1/2 1 8                                                           -_

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                                  !4                                                      1- 1 1/2 1 M2 i M4 1 002 i 1 30                i t 11                1 30 i 1/2 1 171 1 339 l h6 I 1 73/4 1 2 1/2' 1 391 1 411                    l'.      020 t i6                 1 34 1/2 1 9 I 7.

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               '4 41 4 I i 1/2 ! 7t/2                                     11 I2                                                                  1 4 71 1 534 1 045 I 1 22 3/4 I I                           I3 13                                                                   1 290 1 334 I e44 i

_ 1 33 1/2 i e I in I oss i 157 1 102 i l4 8 1 40 1 7 11 S/15/91 1 M4 1 380 1 014 Table 2.3-1 (Cont.) 2.3-32

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• EN IMICAi!ON 18 N!TH IN 1/4' 0F OLD IMICATION 88
• TOUND SURING CONTOURIE S/15/11 Table 2.3-1 (Cont.)

2.3-35 '

1 >

             ,3 19M Off! AGE 41RTH EL8 leltatths N 24                                 i 1              I     Em OF IND. FISM l       i              BEPTW           l i              l                     i       i                              !
                     ' 20E I . IR I 18ME IIERll. KF +1 10 181 Mile !- Fille l WBNIN 1 W. I W. I LINE I                          ILENSTN l            l       l         l l              l    la. I    te. I 1a. I alls I alls I alls !

I i i i I I I I 3 11 1 35 1. I I 3/4 1 218 1 264 1 666 I 4 11 1211/2 I I I21 1 - 064 0 1 255 1 331 I i i l i 1 0 1283 Il !  ! j 9999 l 6 11 l' 1 15 1/2 1 51/2 1 1/2 1 151 1 328 1 177 I I2 8 1 27 3/4 1 51/4 14 1 097 1 211 1 114 I s. i 7 11 I i1 1 6 11 1 195 1 256 1 461 I 1 t 11 I 32 8 7 17 1 007 1 1 58 1 071 3 . i ,. ETE$s - E ;MICATIMS - 20NL;I 1,2,5,8,10, 412 ] \- 1

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                                                                                                                    ]

I ? INDIAN POINT UNIT 2 l

                                                                                                                  .l lI p

SUMMARY

-OF NUMBER OF INDICATIONS PER ZONE AND MAX OVERALL DEPTH, STEAM GENERATOR 21 l:. V \ 1989 1987 . l # OF MAX. # 0F MAX. ZDE 1E DEPTH IND. DEPTH 1 2 .57 -4 .56 2 NONE N/A 4 .40 1 3 NOME .N/A - 4 .37 I j 4 -NONE N/A NONE N/A ) j' 5 NONE N/A NONE N/A

                                                                                                                    )
      ,        6               NONE-             N/A                NONE                       N/A                1

7. NONE- N/A 2 .28 l 8 NONE N/A 4 .36 9 NONE N/A 4 .32 )

10 NONE N/A 7 .36  ! 11 HONE N/A NONE N/A l 12 3 .54 9 .50 TOTALS -5 38 Table 2.3-2 l 2.3-37

                                                                                      ..              .w.---, ,

s T INDIAN POINT UNIT 2 1 q

SUMMARY

OF NUMBER OF INDICATIONS PER' ZONE- , *J AND MAX OVERAli. DEPTH, STEAM GENERATOR 22 l

          ;-                                                                                                                      .: \

l 1989' 1987-

                                           # 0F.           HAX.                                # OF'         HAX.

ZDE Ilill DEPTH IND. DEPTH 1 1 4 .63 9 - 49 2- 2 .54 11 .68 I 3 NONE N/A 6 .56 l

                  -4                        3              .51                                   10             .88                   1
                                                                                                                                   ,1 L                   5                        7-             .78                                    5          1.00                        '

6 4 .58 10 .76 , 1

                 -7                         6             1.42                                    9          1.07                       !

8 10- 1.38 12 .89  !

                  .9                        5              .58                                   11         1.01-                     l  1 10                          .4              .71                                   12            .51                     1 11                           4            1.24                                     3            .85                      t 12                         NONE             N/A                                    3            .49 1

. TOTALS 49 101 L- , L l

                                                                                                                                      .l l
                                                                                                                                 .4 Table 2.3-3 l                                                                                                                                   Y!

l 2.3-38 l .

                    . . . .    ~ - _ _            _  ~ ~ _                          .
            .                                                                                       .i

[ INDIAN POINT UNIT 2 1

SUMMARY

0F NUMBER OF INDICATIONS PER ZONE '

    . . .          AND MAX OVERALL DEPTH, STEAM GENERATOR 23 y                                                                                                  .

l 1989 1987 o i 0F MAX. # 0F HAX.  ! ZdE IEL DEPTH IND. DJfIll , 1 6 .76 4 1.01 2 NONE N/A 11- .33 l 3 1- .20 13 .65-4 NONE N/A 10 .49 5 1 .09 8 .38 6 NONE N/A 3 .34

    .            7     1               .11.                                     4        .42 l-                8     2               .36                                      3        .16 9     4'              .79                                20             .65-10    NONE               N/A                                      7        .58 11    NONE               N/A                                     8         .29 12    NONE               N/A                               11              .57

TOTALS 15 102 l

Table 2.3-4 l: (: l 2.3-39

6 1;. 4' INDIAN. POINT UNIT 2 ..

SUMMARY

OF NUMBER OF INDICATIONS PER ZONE AND MAX OVERALL DEPTH, STEAM GENERATOR 24

                                                                                             /i 1989                               1987
                       # OF-            MAX.                 # 0F             MAX, g         ZDE           IND.             DEPTH                IND.             DEPTH 1            NONE             N/A                       14            .48 2            NONE             N/A                        1            .27 3             1               .28                        3           .13
                                                                                             ~

4- 1 .28 NONE N/A L 5 NONE N/A 4 .42 ' 6 2 .33 6 .57 L 7 1 .26 8 .36 L 8 N/A NONE 1 .51 9 1 .16 NONE N/A 10 NONE N/A 2 .33

11. NONE N/A 2 .07

      '12              NONE             N/A-                    10             .40              .

LTOTALS 6 50 L Table 2.3-5 2.3-40

d IhDIAN POINT UNIT 2-

   ,                    FIh!AL FAX. DEPTH OF GRIND s            (C0KBIVATIONOF1987AND1989DATAL                                   '

S/G21 S/G M _ S/G 23 S/G 24  ! M 1989 198Z 1989 198Z 1989 M M M  : 1 .57 .56 .63 .49 .76 1.01 .48 .48 2 .40 .40 .54 .68 .33 .33 .27 .27 3 .37 .37 .56 .56 .2 .65 .28 .u  ! 4 WA .51 .88 .49 .49 .28 .00 l 5 WA .73 1.00 .09 .38 .42 .42 6 WA .58 .76 .34 .34 .33 .57 l 7 .28 .28 1.42 1.07 .11 .42 .26 .36  ! 8 .36 .36 1.38 .89 .36 .16 .51 .51 l l- 9 .32 .32 .58- 1.01 .79 .65 .16 .00 10 .36 .36 .71 .51 .58 .58 .33 .33 l 11 N/A 1.24 .85 .29 .29 .07 .07 12 .54 .50 .49 .49 .57 .57 .40 .40 I Table 2.3-6 2.3-41 c

x j. w .. INDIAN POINT UNIT 2 - L AVERAGE DEPTH OF GRINDING . .. - S/G 21 im 22 SM 23 S/G 24 M M M 1919 M 1989 M M M 1 .30' .49 .25 .31 .28 .80 WA .38 L 2 WA .38 .06 .46 WA .5 WA .25 3~ WA .32 WA .45 .15 .31 .07 .12 4 WA WA .31 .30 WA .27 .35 WA 5 WA WA .23 .85 .10 .31 WA .5 6 WA WA .06 .56 WA .24 .15 .37

             -7       WA            .20       .41              .64       .02       .25          .06                .24 8      WA            .21       .33              .58       .26       .15         WA                 .51 9      WA            .27      .13               .66       .08       .26          .07               WA                       !

10 WA .D .B .41 WA .41 . WA .30 11 WA WA .43 .63 WA -.19 WA .04 '

12 .15 .5 WA .37 WA .41 WA .25 ,

AVERAGE: .21 .5 .26 .51 .19 .31 .17 .30 , DURAll AVERAI(All 4 S/Gs) = .24 1 l Table 2.3-7 i ' l 2.3-42 l l l

W, 7, . . ,

            .(l '     ,

t I'^ b GIRTH WELD INDICATION

SUMMARY

n , Li i

                                             $G21      SG22-          SG23    $G24 1987                                                       r i OF                                                       L INDICATIONS.    .38~       101            102     50
                          - MAX. DEPTH

• 0.56' 3.07'- 1.01" 0.57' a.

                          - AVG. DEPTH       0.29'     O.49'         O.31"    0.29 "

1989'

                           # 0F l}

INDICATIONS '5 49 15 7 MAX. DEPTH

• 0.30' O.95* 0.33' O.34 "

L AVG.' DEPTH 0.21' O.26' O.16 " 0.14 " t DEPTH OF GRIND REQUIRED TO REMOVE INDICATION 1 l Table 2.3-8 2.3-43 l L

l .' . .g , l_ 5 t l: - n f ?.

SUMMARY

OF MT INDICATIONS # o . PER. HOT LEG / COLD LEG DISTRIBUTION HOT LEG COLD LEG 1989 1989 1987 1982 l S/G 21 NONE 13 5 25 S/G 22 17- 47 32 54 S/G 23- -8 49 7 53 4. S/G 24! .4 21 2 29 . . o N0 APPARENT CORRELATION I i l 1 i Table 2.3-9 2.3-44 l l l l l

y . p l

SUMMARY

0F MT INDICATIONS PER ZONES ZONES t/s 12 1 2 3 4 s 6 7 a e 10 11 _ _ . 21-(1987) 9 4 4 4 0 0 0 2 4- 4 7 0' (1989) 3 2 0 0 0 0 0 0 0 0 0 0 l-L p2 (1987) 3 9 11 6 10 5 10 9 12 11 12 3 l-(1989) 4 2 0 3 7 4 6 10 5 4 4 23'(1987) 11 d' 11 13 10 8 3 4 3 20 7 8 (1989) 0 6 0 1 0 1 0 1 2 4 0 0 24 (1987)- 10 14 1 2 0 4 6 8 1 0 2 2 - (1989) 0 0 0 1 1 0 2 1 0 1 0 0 AL: (1987) 33 31 27 25 20 17 19- 23 20 35 28 13 (1989) 3 12 2 2 4 8 6 8 12 10 4 4 FWN RISER THR WGH RISER THROUGH RISER (1987)- 64- 52 37- 42 55 41 L. l (1989) 15 4 12 14 22 8 l e N0 APPARENT CORRELATION Table 2.3-10 j_ 2.3-45

t

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                                               ..      ..-                                                      .         s            ,                                                    .p.               i, :
                                                                                                                                                                                                                      .*t,,
                                                                                                                                                                                                       -2 j

9* MitfulNICAL McPERitts ANO 10NG851t55 OF ' Sittts A03CtWT to SittM Wtte MO. 6 IN THE . IN91A4 PolWT IWilf 2 SitAM GENERATOR $ , (Freur Felwicetten Dete) - TItt0 ftR5ftt [tlMGAfttM (Att0lg. l MAfttlpt NEAT SLA8 'StatNGTH STRtWGill 13-2 in M S$*. . ERMN5ft1R - l SttIAL Fiftg51 _ Mits - a SPECIFICAfl0N LOCAfl0E NUMRft M _{R5il. (RSil 1

                                                           , sun 8ga
                                                           $/G 821                                                                                                         19/78/79 Stell 85612              1               68.0      99.5/99.9      39                                          '-

16A5780-1 A302 Gr. B 85012 2 68.2. 89/99.9 27 79/97/60 - - Ldens A0042 2 72.1 95.0/97.9 39 - 01/74/77 - Cene A0042 4 75.4 97.5/95.5 2s 55/se/se - SM 8M 195/97/91 - A302 Gr. 8 Stell A0126 3 79.5 94.5/95.5 28 1645780-2 A0126 4 64.7 88.1/94.4 3e 79/98/64 - teens Cll08 - 2 64.9 88.5/99.1 ~ 31 35/98/97 -

                                                    .e Cone l

A0042 4 15.4 37.5/95.5 M 55/64/E8 - I

                        ,o                        {         3/8 #23 L                         to A302 Gr. 8         Stell A0877              2                66.0      85.3/97.3      39     77/88/97                               -

1 to 1645780-3 AOR12 3 61.9 83.7/83.7 39 79/83/83 - -i N w Ldens L 29 91/95/78 -

                                                  "                                               Cone  C1108               1               70.3      93.1/98.9 84973              5               64.7      91.5/98.8      26     08/123/95-                             -

85010 1 69.9 92.9/92.5 28 93/73/113 -

                                                            $/8.#74                                                                                                   M     89/92/95                               -

A302 er. B Shell VM 4 12.9 93.4/93.9 16A5780-4 EMM 2 '71.1 93.9/97.5 28 05/74/79 - Ldens t i 73.2 94.9/97.5 27 8F/gB/89 - tone C1488 4 95387 1 79.9 90.5/89.5 29 04/94/88 .! I 3

• Test Teaperatore = 10*F

                                                                                                                                                                                                                                               , t 9116M:49/019589-19 J
                                                                                                                                                                                                                                               'I

                                                                                           ]
        ~

ASMELBOILER AND PRESSURE VESSEL PWHTJREQUIREMENTS L MANDATORY ANDLNON-MANDATORY-REQUIREMENTS IN' j SECTION:NB-4620 BPVC.(1968) REQUIRED A-MINIMUM HEAT

              . TREATMENT BAND 0F 2T EITHER SIDE OF THE l

.. WELD AT 1100 DEGREES F FOR ONE HOUR / INCH l LOWER TEMPERATURE.FOR LONGER PERIODS

                    , ACCEPTABLE-BPVC- (1974) REQUIRED A MINIMUM CONTROLLED                           '-

BAND OF T OR 2 INCHES WHICHEVER. IS LESS, EITHER SIDE OF WIDEST WELD WIDTH:BE HEAT

             -TREATED BETWEEN1100/1250 DEGREES F TIME AT' TEMPERATURE-2 HRS PLUS 15 MINUTES FOR EACH ADDITIONAL INCH OVER 2 INCH s                          LOWER TEMPERATURE FOR LONGER TIME ACCEPTABLE                                              

Table 2.3-13 2.3-48 w s

                           --              -      -    ~         -     ~ -- - - - - - - - - - - -
   >2                                                                                             3 y         

i q q-t[

• ' P-3; GRADES'USED HAVE: PROPERTIES DEVELOPED

. ~, DURING TEMPERING HEAT TREATMENTS AT TEMPERATURES-IN THE RANGE OF 1200/1250 DEGREES F N0LPWHT PERFORMED AT OR NEAR THIS RANGE '

WESTINGHOUSE SPECIFICATION FOR LOCAL PWHT y l0FLS/GCLOSUREWELDREQUIREASOAK  ! TEMPERATURE OF 1125. DEGREES- 25 DEGREES F

   .             LFOR'A PERIOD OF.4 HOURS HEA' TING / COOLING RATE A?OVE 800 DEGREES f SHALL BE'100 DEGREES-F/HR.

LOWER TEMPERATURE FOR LONGER PERIODS'0F

                       .TIMETARE PERMITTED 1050 DEGREES F MIN. FOR 12 HRS 1000' DEGREES F MIN FOR 18 HRS.

[ Table 2.3-13 (Cont.) 2.3-49

t l PWHT (MFG FACILITY OR FIELD) FOLLOWED ABOVE SPECIFICATION USING PORTABLE EQUIPMENT .' e l= FACTORYPWHTPERFORMEDINPORTABUE

                     " CALM SHELL" FURNACE, VESSEL IN A
                  ' HORIZONTAL POSITION REVIEW OF A TOTAL OF 44 CLOSURE WELD HEAT TREAT CHARTS (INCLUDE- 19 FIELo PWHT) DURING 1969 - 1978 19 BETWEEN 1000 DEGREES - 1030 DEGREES F 1   BETWEEN 1000 DEGREES-- 1050 DEGREES F L          -

8 BETWEEN 1050 DEGREES - 1100 DEGREES F 16 BETWEEN 1050 DEGREES - 1085 DEGREES F l

         - PWHT OF CLOSURE WELDS AFTER 1978 WERE

! CONTROLLED IN THE 1100/1150 DEGREES F RANGE Table 2.3-13 (Cont.) 1 2.3-50

s . MATERIAL OF CONSTRUCTION- -

                                                                                                           )

u FOR CONE /SHELL' AREA FOR IPP STEAM GENERATORS 1 NATERIAL: A-302 GRADE B WELD PRACTICE: MANUAL STICK WELD HETAL: ASTM - A-233 TYPE 8018 PREHEAT: 2250F-MINIMUN , l L INTERPASS: 5000F MAXIMUN PWHT: SOAK TEMPERATURE (AND HENCE SOAK TIME) HINIMUM TEMPERATURE ATTAINED BY ANY ONE THERM 0 COUPLE WHEN MAXIMUM ' TEMPERATURE IS 11500F. MIN. TEMP, WiiEJLEAX. TEMP. HOLD TIME 11000F 11500F 3-1/2 HRS. 10500F- 11500F 7 HRS. , 10000F 11000F 10-1/2 HRS. Table 2.3-13 (Cont.) 2.3-51 l.

m , t 3 REHEAT TEMPERATURE

SUMMARY

FOR GIRTH WELD N0,_6 -

            -IN THE INDIAN P0 INT 2 STEAM GENERATORS                        .
                                                                                                                -l liENERATOR         PREHEAT                                 COMENTS 21              2500F - 3500F            N0 UNUSUAL TEMPERATURE SWINGS                                      l l
      ;22              2750F - 3750F            N0 UNUSUAL TEMPERATURE SWINGS-l 23              2500F - 3500F            N0 UNUSUAL TEMPERATURE SWINGS
                                                                                                           ,l -
      - 24             2500F - 3500F            N0 UNUSUAL TEMPERATURE SWINGS                                    1 l

1 i-I i l Table 2.3-13 (Cont.) l 2.3-52 e

                                                          .. c  ..                                                                  .    .. .     .                                                                                                   ..

4 POST WELD HEAT TREAT _ TIME AND TEN ERATURE ~ FOR GIRTH WELD NO. 6 IN THE IIBIAN P0 INT UNIT _2._ STEAM GENERATORS PI5fT EINNALElfT'9 L11258F ~s- 258F TDE AT TBtPERATURE

                                                                                                                                                                                                                                                       ~

S/G (DATE FMIT) .( p u a IN Iss.) 6A5780-1 7 Mts. 9 1950 4 - 1150er 3,g 5/7/69) ' (3 M S. 35 NIN NES 911258Fi258F) e i Y g; 6A5780-4/18/69 12 Mts. 919258F - Il50eF 4.25 j i (4 Mts.15 RIWS. 91125'F i 258F ' ,  : q 6A5780- 7 MS. 30 NIWS. 91950*F - Il50*F 3.75 ~i ' ~ 4/25/69 * ~! (3 m s. 45 RINS. 9 It25'F i 258F) 6A5780-4 12 MS. 91000eF - 1150eF 4.15 ' 4/12/69) (4 Mts. 19 nius. 9 1125*F 25*F) j Table 2.3-13 (Cont.) I

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!        2.4' Feedwater Thermal Hydraulics                                                 i 1
  .      This section provides the basis for the' thermal hydraulic boundary conditions used to perform the stress and fatigue analyses for the girth weld region         l (Table 2.4-1). It begins with a presentatien-of the enveloping transient conditions established previously in WCAP-11730, completed for the Fall 1987     1 l

Outage when girth weld indications were first detected. The current evaluations are consistent with the 1987 evaluation. Two conditions, reactor trip (RT) and feedwater cycling (FWC)1 , are identified as the most limiting conditions since they cause significant temperature changes to the girth weld region. The auxiliary feedwater flow that is associated with each of these conditions is described in text and graphically illustrated in the figures. The flow of auxiliary feedwater in the generator, and specifically the impingement of the flow on the girth weld, is shown to be directly related to the position of the downcomer flow

        . resistance plate (DCRP). The flow path, degree of mixing, and temperature of the water as it strikes the shell are best estimate thermal hydraulic
   ,      calculations. It is recognized that there is some uncertainty associated with this description as neither direct measurements nor test data are available.
         .In addition, another associated loading mechanism is postulated, i.e., thermal striping, in a later section that-could significantly contribute to fatigae usage..

The section concludes with the recognition that water level control and water temperature control would have a direct influence on girth weld fatigue. Table 2.4-2 presents the umbrella transient events used for the design basis evaluation of fatigue usage. It is the same casis as used previously in WCAP-11730 for the 0.75' inch and 1.0 inch groove models and is the basis for the evaluation of two new models with 0.5 inch and 1.25 inch grooves. All conditions involve stress changes due to pressure while two of the events,

  ... reactor trip and feedwater cycling also cause stress changes due to temperature changes at the girth weld.

1 Feedwater cycling is the title given to auxiliary feedwater injection at zero power, hot standby conditions, to control water level. 2.4-1 9275M;1E-060589

i l Recognizing that cracking recurred in just one fuel cycle, a review of Indian- ) Point'2 operating conditions since startup was made to compare the last fuel cycle history of-events to the prior years. This comparison is provided in j Table.2.4-3 which shows that the last fuel cycle was equivalent to or less *'l severe than the averages for prior years. It also shows that reactor trip and hot standby (feedwater cycling) are the most significant events, excluding *l heatup and cooldown which are less; severe conditions. l The thermal hydraulic boundary conditions for reactor trip and feedwater l cycling used in the prior evaluations (WCAP-11730) and in the analysis of the i 1 two new models are described in Table 2.4-4. Following that is a schematic  ! illustration (Figure 2.4-1) of the upper part of the steam generator (shown ] without the DCRP). Figure 2,4-2 is a copy of a portion of the steam generator assembly drawing showing the DCRP located adjacent to the girth weld. A bounding condition is assumed for the purpose of analysis to occur during 1 'the reactor trip, 'The water level is assumed to drop well below the girth , weld region. This permits the auxiliary feedwater that automatically is injected within a short time [ l Ja,c Figure 2.4-2 shows the current position of the DCRP within 1 or 2 inches of the girth weld centerline. l Figure 2.4-4 shows how [ i Ja,c Figure 2.4-5 shows [ Ja,c This last sketch  ! ' illustrates the boundary condition analyzed for the reactor trip transient. This condition may not normally occur in the sense that the water level may I not be that low when auxiliary feedwater enters the generator. [ ] Ja,c In that - case, the conditions analyzed should be very similar, l l During feedwater cycling, the water level is approximately 7.0 inches above " l the feedwater ring and a best estimate calculation indicates [ 1 l 2.4-2 9275M;1E-060589 )

1 Ja,c Again, it is possible'that the feedwater  ;

'Ja,c if that is the case, the design basis L.. analysis would under predict the fatigue usage.

For stretch conditions, the expected water level during normal operation and during reactor trip and at hot standby is slightly lower than in the non-stretch (current) condition. The bounding condition assumed for analysis is not affected by this difference. If the actual conditions experienced at the girth weld are different than the assumed analysis conditions, the water level difference with stretch is judged to be small enough to have no efffect on the girth weld. The importance of the cold water thermal hydraulics to the boundary conditions used in the fatigue evaluation has been illustrated. Any internal or system modification that would result in avoiding [ Ja,c at the girth weld would be beneficial as would any change that

   ,    would lessen the temperature difference between the hot and cold fluids (Table 2,4-5).

l l l ( i l l 2.4-3 9275M:1E-360589

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