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, UNITED STATES s ~g p, NUCLEAR REGULATORY COMMISSION B <E WASHINGTON, D. C. 20555 #. 1
% / August 19, 1982 L'
% s'o Docket No. 50-289 ,
FACILITY: Three Mile Island, Unit No.1 (TMI-1)
LICENSEE: GPU Nuclear Corporation (3 PUN)
SUBJECT:
SUMMARY
OF MEETING WITH GPUN ON AUGUST 9,1982 CONCERNING GPUN'S STEAM GENERATOR EDDY CURRENT TESTING PROGRAM
" Background ,
As a part of their program to recover the steam generators from intergranular stress corrosien cracking.of the tubes GPUN has been %i
- conducting an extensive eddy current testing (ECT) program to ensure 3 that all defective tubes are identified. The purpose of the o August 9,1982 meeting was to brief the staff on GPUN'.s plans for 3 conducting their ECT inspection program and status of inspection r results to date. A copy of GPUN's presentation is attached'. +
Discussion ..
hg '
GPUN has decided to conduct a 100%, full length ECT program on the steam generators and have been conducting this inspection sinc 6 early July. They have experimented with various ECT probes and have '
concluded that a modified standard differential probe (.540") incorporating a higher fill factor and increased gain settings is able to detect circumferential intergranular cracks in the.TMI 1 tubing, and hence is being used as the production probe. The .540" probe has proved itself far superior for this application than the standard .510" probe commonly used in steam generator ECT. GPUN has performed correlation studies comparing the results of a 4 41 absolute probe with the .540" probe as well as the results of meta 11urigical examination of approximately 18 feet of THI-1 tubing. The results of the correlation studies b&ve shown immediate correlation on 99.4% of the indications using the 4 x 1' absolute and .540" probes. The remaining .6% of the non correlating. indications (17) were under evaluation; at the time of the meeting,14 had been reevaluated and had shown correlation, with the reaining 3 not yet evaluatea. Hence, there is essentially 100%
correlationU Additionally, no defects have been found by metallography below the very top of the tube which were not first identified by ECT.
I lt should be noted that the correlation study was done on tube defects below the roll transition area, oso61g45050125 bJENe4097 PDM
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, . i Preliminary results of the ongoing full ECT have identified additional indications in the tubes, below 16" from the top of tubes (tubes with defects above 16" can be repaired by the explosive expansion technique). ;
c It is presently unknown how many additional tubes will be affected )
- and what the, disposition of these indications will be. j l
Richart Jacobs Proj d Manager Operating Reactors ranth #4 Division of Licens ng
Enclosure:
GPU Presentation cc w/ enclosure:
See next page ,
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MEETING SIN %RY DISTRIBUTION Licensee:
- Copies also sent to those people on service (cc) list for subject plant (s). .,
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ORB #4 Rdg GLaines JStolz Project Manager -RJacobs 1icensing Assistant-R!ngram OELD Heltames, AEOD IE SShove (PWR) or CThayer (BWR), IE Meeting Sumary File-0RBf4 * -
l RFraley, ACRS-10 Program Support Branch.
ORAB, Rm. 542 '
' BGrimes, DEP
$$chwartz, DEP SRamos. EPDB FPagano, EPLB Meeting Participants Fm. NRC:
CMcCracken LFrank SReynolds FYoung t
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AUGUST 9, 1982 TMI - 1 OTSG TASK 4 EDDY CURRENT PRESENTATION TO THE NRC l.
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OTSG Longitudinal Section Elevations (Typ.)
PRIMARY SIDE '
(INSIDE TUBES)
UPPER TUBE 5HEET (UT3) ELEVATION '
FEET AUXILIARY N ,. mi mni i n
- 346* B" FEEDWATER yil l N0ZZLES b- '
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'm 338'5" STEAM OUTLET 3* ' )9 4
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, 333'8" He um i 330'8" MAIN FEEDWATER ll .ql al aldllP
, N0ZZLES (MFW)s 'm
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327'4" ll ing a ruin W "". 324'4" SECONDARY SIDE 321'1" (EXTERNAL TO TUBES) ; d ;gm. ,'- f -
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SUPPORT TUBE
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. REACTOR BLDO. FLOOR 281'0"
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TMI-1 OTSG Upper Tubesheet Detail CTyp.ll o .051" MIN. ? : : .835" REF.
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.825" TURE 0.D. X .034" : 3 --
MINIMUM WALL
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MAX.018 (DIAMETER) i
.835"DIA. HOLE - l
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- 1. E/C Techniques a) Standard Differential-Two interacting coils mounted circumferential; resultant signal response is produced by measuring the differential from the area of discontinuity to clean tubing area.
b) Absolute Technique - '
Single coil wound in a pancake shape normal to SD coil; two sets of four separate (isolation) coils that are assembled in
, tandem to provide an effective eight coil coverage; optimum detection of circumferential oriented discontinuities.
Disadvantage -
Not conducive to broad scale production programs because l it is extremely fra_ gile and wears rapidly; additionally presents numerous electronic recording and analyst l problems associated with having to maintain and read B channel recordings.
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Utilized for OTSG Tubing Examinations
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Multifrequency - s Utilized for all SD examinations; applied 2 base frequencies ,
(400 KHz and 200 KHz) and used an "lD" mix to enhance .
detection of ID defects and minimize affect of ghatter and l tube noise. l l
Saturated Probes - .
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ID mix 1
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FACTORS AFFECTING ECT RESPONSE STANDARD DIFFERENTIAL TO BE USED FOR PRODUCTION RUN INVESTIGATION.
-1. CRACK GEOMETRY
- A) SMALLER ASPECT RATIO (A/L) YIELDS A LOWER AMPLITUDE RESPONSE.
B) DETECTION OF CIRCUMFERENTIAL CRACK IS DEPENDENT UPON CRACK WIDTH, AXIAL BRANCHING AND SPIRALING.
- 2. PROBE DESIGN /CONFIRGUATION A) HIGHER THE FILL FACTOR GREATER THE SENSITIVITY AND REPRODUCEABILITY.
B) 360 COVERAGE.
C). REDUCE PROBE WOBBLE WITH INCREASING FILL FACTOR.
- 3. LIMITATION OF INTERPRETATION A) INDICATIONS YI' ELD LOWER AMPLITUDE RESPONSE.
B) GREATLY AFFECTED BY TUBE TRANSITION AREAS.
- 4. OPERATING PARAMETERS TO BE OPTIMIZED A) FILL FACTOR.
B) FREQUENCY.
C) GAIN.
D)' CHART SPEED.
E) ID' MIXING.
- 5. CONSIDERATION FOR PRODUCTION A) NOISE AND CHATTER.
B) ANALYST PRECISION AND ACCURACY OF COILS.
C) DATA HANDLING.
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FILL FACTOR COMPARISON * ,-
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Differential .187.
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(Tube ID)2 I ll111ll 11lllll I l l l l.l l Illlll1 Illllll Through Wall 20% 40% 60% 80% 100%
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I FILL FACTOR COMPARISON * .
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, Volta 9e Threshold lllllll lllllll lllllll lllllll .lllllll f
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GAIN COMPARISON FOR DETECTION PROBABILITY .
Standard Differential l l1 1 1
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Min. Sensitivity ;
Lab Condition ii
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t ica ti voltage thresliold i lllllll lllllll lllllll
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20% 40%
. 60% 80% 100%
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GAIN COMPARISON FOR DETECTION PROBABILITY -
S tandard llll l l l i l l l' l l l l ll l Differential *3 gy- ,...... W.l...l...l.?. l, ,.l..l %.l.. l l IIl l l.09 l l l M l l l .13
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Min. Sensitivity l .-
Fleid Conditions 1IIIIIl
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t ' REPRO'DUCEABILITY OF RESULTS Standard l I l I I I pifferential .i s7. lllI[llmlll
.ois . l l l o? l l-[m l l- l _n l [ [J3 El ! ! I I I [JIll[u 2 3 4 PULL SAMPLE '\
1 .510 60 GAIN 400 KHZ l I\
2 .540 60 GAIN 400 KHZ l \' 6
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increasing Aspect Ratios a/L Note: Response 0.150 Volts >
Min. Sensitivity Lab Condition ,
i
--- Extrapolated Value From Unknown Zero Voltage Threshold lllllll lllllll lllllll l l l l l l l- l llllll j ,
f Through Wall 20% ,
40% 60% 80% 100%
e #
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STANDARD DIFFERENTIAL .510 50 G AIN *
~
200 MV/DIV VS 100 MV/DIV l11111111111111 I l l i l I I.I I I l l i l 11 I I l i r I g g 1 . j:
.018 .04 .05 .07 .09 .11 .13 .15 .16 .18
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s l N
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lIllIll lllllll lllllll l1llill 1111111
, Through Wall 20% 40% 60% B0% 100%
i .
~
((________._. _ _ _ _ _ _ _ _ _ -- --- -- - - - - - - - - - - - - - - - ^ ~ ^ ^ - ^ ' - - - - - - ~ ~ ~ - ^ ~ ~ ~ ~
OPTIMlZING FREQU'E NCY MIX Standard 1111111 111111I IIIIIII IIIIIll II!llli Differential 123
.187.
540. 45 + RA
~
, 1. SATURATED ID MIX i
i (400 - 200) 800 KHz i 2. ID MIX (ONLY)
(400 - 200) 800 KHz '
i
- 3. 400 KHz Y
a E
- 2 -
O hi -
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., .100. --- -'
o
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. 4 5... . 5.1 - 5 7 V ss N NN I
N9 N Ns 1 N N 2 N H N, 3 ;;
1 RESPONSE 0.300 VOLTS I
~
MIN. SENSITIVITY lllIlll lllllll l l l-l l l l lllllll l llllll Through Wall 20% 40% 60% 80% 100% .
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SIMULATED DEFECTS 0.005" WIDE i
ABS 8x1 (2 RUNS OF 4x1)
, 53 GAIN '
S -
SD .540 60 GAIN 4 -
s J([
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Ta. .
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2 -
4 SN ss*' S 1 -
.st1' O Noise Level U -
n 10 20 30 40 50 60 70 80
~
% Thu Wall '.
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. GAIN COMPARISON FOR DETECTION PROBABILITY ,
Standard llll l l l l l ll ll Ditierential ,...... Qf.l...l...l..4.,l ,.l..l5.l..l ..lN.l.._l.09.I l l l l M l l l 3.
l 100 MV/Div.
,3 gy, . . .
35 l l .1l6 l l l.18 1 2
- 1. .540,45+RA,400KHZ i t
- 2. .510, 35+RA,400K HZ e
b O 'e/O i o
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.100. .20 .24 .27 .31 .34 o 2 2
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Note: Response 0.300 Volts -
l Min. Sensitivity
- Field Conditions lIlllII lllllll lllllll
' lllllll _l iilIi !
Through Wall 20% 40% 60%
..- 80% 100% h L
~ .. .
e
- - - , - - -- - ___ _ - _ _ _ _ _ _ _ _ ___.______________s
_. _. _ _ . _ _ _ _ __ _ _ _. _1-
. FACTORS AFFECTING ECT RESPONSE BE USED FOR DISPOSITIONING PURPOSES ONLY"
- 1. CRACK GEOMETRY A) SMALLER ASPECT RATION (A/L) YEILDS LOWER AMPLITUDE RESPONSE
- 2. PROBE DESIGN / CONFIGURATION
. A) COIL TO COIL VARIANCES, B) AMPLITUDE OF RESPONSE IS INFLUENCED BY DEFECT TO COIL ORIENTA, TION, C) LIMITED FIELD COVERAGE / COIL D) SPRING LOADED - LESS SENSITIVE TO MOTION ,
^
B) AMPLITUDE OF RESPONSE IS NOT RELATED TO SEVERITY OR EXTENT OF DEFECT .
- 4. OPERATING PARAMETERS TO BE OPTIMIZED A) FREQUENCY B) GAIN C) NO. OF COILS
- 5. CONSIDERATIONS FOR PRODUCTION A) NOISE AND CHATTER - MINIMIZED !
B) ANALYST ACCURACY AND PRECISION OF CALLS C) DATA HANDLING D) DURABILITY OF PROBE - NOT SUITED FOR PRODUCTION TECHNIQUE E) DIFFICULTY OF MAINTENANCE AND ANALYZING 8 TAPE RESPONSES
~
, . , _ . _ , _. _ _ , - - _ _ . - - ___.,_-,-___-,,--,.-,__,,1,,..',.,_.,_-,.,.-_,,, , _ , _ _- ^~~ . . _ - - , . _ , _ , ,
4 x 4 UNIT
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s REPRODUCEABILITY OF RESULTS ,..
-Standard llll jll I 1 I
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l l l 07_l l lM_t i ! l 11 l l l.1I l ] l 15
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Increasing Aspect Ratios a/L Nota: Response 0.150 Volts #
Min. Sonsitivity l - Lab Conslition .
l --* Emtrapolated Valise Froni Unknown Zero i
.voete,.Throssiese. 1 l-1 l l 1 l l11111l l11111l l1l[g13 iggigii r
Through Wall 20% 40% SO% SO% 100%
l STANDARD DIFFERENTIAL .510 50 GAIN ,.
j- 200 MV/DIV VS 100 MV/DOW ,
f~ 2.T. . .. ds.'. ' ' A ' ' ' A.' ' ' A ' ' ' A ' ' ' 5 ' ' 'A ' ' ' A ' ' 'A ' ' ' A
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- (NOT DETECTABLE) N
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- s 1111111 1111111- 1111111 1111111 1111111
!' - Through Wall 20% 40% S0% 90% -
100%
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OPTIMlZING FREQUENCY MIX
~
- standard , lllllll lllllll lllllll l.I I I l l l 1Illlll
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Differential '**
d .187.
- l 540. 45 + RA -
'l 1 CATURATED ID MIX-
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- 3. 400 KHz 5 I E
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RESPONSE O.300 VOLTS
,3 .
MIN. SENSITIVITY llllIll illllll1 Illllll llllllI IllIIII i Through Wall 20% 40% -60% 80% 100%
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S8MULATED DEFECTS 0.005" WIDE i
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53 GAIN !
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. GAIN COMPAftISON FOR DETECTION PROSABILITY -
- j Standard gggl[gg gll gggggggggggg Differential .3 g7. D_18 . -
lgl07l l l l
l l l 11l l l g
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- 2. .510,35+RA. 400KHZ ,
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- 1 Note: Response 0.300 Volts Min. Sensitivity Field Condtions lIIIIII IIIllll lllllll lllllll l llllll Through Wat: 20% 40% 60 % 80% 100 %
w . _ _ _ _ _ _ _ _ _ _
FACTORS AFFECTING ECT RESPONSE ABSOLUTE -
"TO BE USED FOR DISPOSITIONING PURPOSES ONLY"
~
- 1. CRACK GEOMETRY A) SMALLER ASPECT RATION (A/L) YEILDS LOWER AMPLITUDE RESPONSE
- 2. PROBE DESIGN / CONFIGURATION A) COIL TO COIL VARIANCES B) AMPLITUDE OF RESPONSE IS INFLUENCED BY DEFECT TO COIL ORIENTATION C) LIMITED FIELD COVERAGE / COIL D) SPRING LOADED - LESS SENSITIVE TO MOTION
- 3. LIMITATIONS OF INTERPRETATION A) PERCENT'THRU WALL DETERMINATIONS ARE NOT RELIABLE B) AMPLITUDE OF RESPONSE IS NOT RELATED TO SEVERITY OR EXTENT OF DEFECT
- 4. OPERATING PARAMETERS TO BE OPTIMIZED A) FREQUENCY B) GAIN C) NO. OF C0lLS ) 1
- 5. CONSIDERATIONS FOR PRODUCTION A) NOISE AND CHATTER - MINIMIZED B) ANALYST ACCURACY AND PRECISION OF CALLS ,
C) DATA HANDLING D) DURABILITY OF PROBE - NOT SUITED FOR PRODUCTION TECHNIOUE E) ' DIFFICULTY OF MAINTENANCE AND ANALYZING 8 TAPE RESPONSES e
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.060" NOTCH X 80% GAIN = 40 :
VERTICAL
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i BACK I
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y;f l
k Field Studies Flaw growth study Analyst correlation Processing data study :
Characterization of absolute vrs. 510 Charac'terization of absolute vrs. 540 !
Characterization of 540 vrs. 510 6
4 e
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i . j 4
yeap .m_< A- + - -. --
y _ . - - . . _ _ -
a Plan -
Check 100 tubes in each generator at different points in time to establish if new defects appear or if existing defects increase a) 102 tube sample from."A" b) 104 tube sample from "B" c) All tubes selected from different areas of generator d) Test employed .510 probe (35 Gain & RA)
Original "A" Generator "B" Generator Retest 12/11/81 12/17/81 1- 1/4/81 12/28/81 2-1/8/82 1/9/82 3- 1/26/82 1/31/82 4- '
2/2/82 4/4/82 i 3/5/82 5- 4/30/82 6- 7/3/82 7/5/82 No substantial increase in number of defects or extent over time period shown -
f) Effect of using .540 probe (high gain) versus .510 above A Generator B Generator Grand Subtotal Subtotal Total %
Agreement 95 93 188 94 No agreement 5 8 13 6
- Below US + 13 0 2 2 1
- Above US + 13 5 6 11 5 l
I
~
, . - ~~ 1 . . _._ .c_. - _ . __ _ __ _ :r : . n_ _ _ _ _ _ _ . , _ _ _ _ _ . _ _ _ _ . _
___,n_,.__..__ . _ _ -
Y , ~ .,
.s PROJECT: DETEPMINE THE PROBABILITY OF ERROR IN THE ANALYSIS OF EDDY CURRENT RESULTS.
PLAN: RE-EVALUATE PRODUCTION RESULTS OF SAMPLE OF 500 TUBES PROCESSED BY 3 CONAM ANALYSTS USING 3 OTHER VENDOR ANALYSTS.
RESULTS:
A. INITIAL AGREEMENT 446 SAMPLES 89.2%
B. AFTER RESOLUTION 492 SAMPLES 98.4%
- 1. OVERCALLS 4 SAMPLES 0.8
. 2. UNDERCALLS 4 SAMPLES 0.8 (INDICATIONS MISSED)
A. USE A SECOND ANALYST TO OVERCHECK STRIP CHART READINGS BY FIRST ANALYST.
B. SCAN REVIEW MAGNETIC-TAPE DISPLAY FOR ENTIRE LENGTH PROBE AND INTERROGATE (EVALUATE) ALL AREAS AS INDICATED BY STRIP-CHART.
C. GPUN/0A MONITOR ANALYSTS ACTIVITIES.
9 e
e 6 $
e e
. . . _ _ -_, .......<-m..-
T ':
1 PROJECT: DETERMINE THE PROBABILITY OF ERRORS IN THE PROCESSING OF h EDDY CURRENT DATA L
ELAN: REVIEW DATA SHEETS AND COMPARE TO COMPUTER PRINTOUT FOR Ali t Tyl[S.WITH LOWEST DEFECT INDICATION LOWER THAN US + 21 .
! (JSU TUBES)
RESULTS: (DATA FOR OTSG 'B' ONLY)
A. AGREEMENT 2f15000 SAMPLESss99.7 %
B. UNDER CALLS 21 SAMPLES at0.14%
C. OVERCALLS ,
5 SAMPLES e 0.03%
D. MISSCALLS 21 SAMPLES 2s0.14%
DIFFERENCE OF 1 INCH + IN LOCATION REPORTED E. TOTAL 47 SAMPLES 2 0.3%
RECOMMENDATION:
- 1. DURING 540 PROBE WITH HIGH GAIN WORK WE WILL REVIEW DATA SHEETS AND COMPARE TO COMPUTER HISTORY FILE FOR ALL TUBES WITH INDICATIONS BELOW FIRST REPAIR PLUS 6"
- 2. MAKE CORRECTIONS NOTED
- 3. DO NOT MAKE ANY ADDITIONAL CHANGES AFFECTING QC CONTROLS ON INPUT e
L *- _ . - --.._. _ _ n . _ . _ . . . _ . . . . _ _ . .__._ _ _ . . _ _ ___ _ .___._.
- t. . .
PLAN:
CHARACTERIZE INDICATIONS SEEN BY 4xl ABSOLUTE BUT NOT SEEN BY 510 TEST POPULATION 3233 NO. OF TUBES WITH CORRELATION 3153 (97.5%)
NO. OF TUBES WITHOUT CORRELATION 80 NO. OF INDICATIONS WITHIN 80 SAMPLE 99 A. CIRCUMFERENTIAL EXTENT - 99 DEFECTS 6 COILS # INDICATIONS CUMULATIVE %
1 90 90 2 7 98 3 2 100 4 0 100
- b. % THRUWALL CALL BY ANALYST
%THRUWALL # INDICATIONS CUMULATIVE %
90-100 23 24 80-90 14 38 70-80 8 45 g.
.Ng 60-70 5 51 50-60 8 59 40-50 20 79 Q 30-40 13 92
- s. 20-30 8 100 L
e
- g. . . . _ _ _ - _ . _ . _ . _ . . . . _ . _ . . . . _ _ . __. _ . . _ . . _ . _ . . _ _,_ . _ _ _ _ _ _ _ _ . _ _
~
.s PLAN: CHARACTERIZE INDICATIONS SEEN.BY ABSOLUTE BUT NOT SEEN BY 540 (HIGH GAIN)
. TEST POPULATION 3233 NO. OF TUBES WITH CORRELATION 3216 99.4%
NO. OF TUBES WITHOUT CORRELATION 17 .
NO. OF INDICATIONS WITHIN DATA SET
- 17 - .
A. CIRCUMFERENTIAL EXTENT 100% OF 17 DEFECTS WERE ONE COIL.
B. AFTER ID MIXING (TO REMOVE CHATTER) THE NUMBER OF TUBES WITH CORRELATION IMPROVED TO 3229.
C. 14 0F 17 DEFECTS ARE RESOLVED AT THIS TIME.
% :THRUWALL CHARACTERIZATION
% THRUWALL # INDICATIONS CUMULATIVE %
90-100 12 85.7 80-90 0 70-80 0 60-70 0 50-60 1 92.8 40-50 0 30-40 0 20-30 0 NO DESICNATION 1 C.1 IHREE TUBES UNRESOLVED ONE TUBE PLUGGED.
TWO TUBES HAVE NOT BEEN EXAMINED WITH SAT. PROBE & ID MIXING.
i a
S
, me.-e-=-,-=r. 4+ . ~ a - -.p. .. ,--.+=*e
---,g.< -*.- --
i-
. s; .
PLAN: CHARACTERIZE INDICATIONS SEEN BY 540 BUT NOT SEEN BY 510 TEST POPULATION - 2771
-NO. OF TUBES WITH CORRELATION 2589 (93)%
NO. OF TUBES WITHOUT CORRELATION *- 182 ( 7)%
NO. OF INDICATIONS FOR
- 288 .
A. . AMPLITUDE OF INDICATION 70t .1 VOLT AND LESS-904 2 VOLTS AND LESS 964' 3 VOLTS AND LESS 98.9% 4 VOLTS AND LESS.
1004 5 VOLTS AND LESS B. 4 THRUWALL CHARACTERIZATION THRUWALL % FREQUENCY CUMULATIVE % REMARKS L
90-100 82 28 68% (V or less 80-90 23 36 65% LV or less 70-80 25 45 804 p or less 60-70 42 59 76%(Vorless g 50-60 46 75.7 65% V or less ,
) 40-50 36 88 l
864{Vorless 30-40 15, 93 60% l:V or.less 20-30 19 47%(Vorless 10-20 0 l l
l l
e l e
e I
e 1 O g,._, .
. e wh een . -- ._em -
m
, ~/*
. . 2) e ASPECT RATIO COMPARISON .
!*r
~ s- .*
METALLOGRAPHY ACTUAL CIRCUMFERENTIAL DEFECTS '.-
E/C SYNTHETIC DEFECTS ORIENTED IN WORST GEOMETRY j 360'-
i
.j,-e c: p. y..
e i
i
. .ga
. . b' .z , ' . .'
- Nota: (1) 1.75" max. t,<
ID circumference )i,,e* I' s\ !.l '
i i
- '^ c. &p- I E
ji i i i ;
- ' I k I { jj l [ Unresolved' boundaries ?' I 300* ijijj s.<
of E/C field of$X . * 5*
iiIj j - 16, . .
iei i e L detectability.%%, .. -. ,w:@4 h
. ' p .;,
. O '
- i i\,i s!, *7rt 5
~
8
' -%v
,Mh. 38~* h ,* c(.a.t N n
}ii ' j :e i
e .
, %. v.yo-r H. . .t .: <
p :. r. /;' x l'
' #.Q y G4,T/4 * ..
c S* .,. . b
-e
, i , . .
y
. . . . n, ' ' . . . ea P.%
- j. .o.
. 'i'g ig i
. 'T 'ry%k.!.-@r/.:. g -
i : '. + y, :
~
'o O
i is*
se 240* .
.<.S .;.r .%;,
.p 2. .,. ,.
e
- ..;... .t ;...
- :. ;..f,ss -, . .y;<4 6
e i i , n O i, :n a ;' O..,. .; r.n *g.r .a s
> l . :.e. w 5 m A..
g &s r;> ,., g w.;[ %; ..y,f3%
4.f.+ *,8 1 i
, C i g
!G. .
! o i : ..j : + - 4]?." . . A.f - ;
jj u. 1.0" 5 l ' ' -
'~ - d,.?.rQ!ijdic'2, Q g % ';%:;4.- . ~ W.. M.$[.
. .L.;' .Y 1;f?
B&W metallography Mi
' ~ ' ~
l 3 ) j .
, ' actual cracks final report t l' ]e 180* .875"I l " . ('.~ )n #$.I]y'.fi '
W!'N.,:w: /,:.Oc;..:!" -
April.1982 '
\ e . .; , , u. - L . . g.: .. -
l li i
! $T . 7:l :; field of : - WRA;.% to
(
g!i 1 ;If. '.r. ,m,'h i ;
Itp ,,;
. ,{,
u .. .
p ....:,,. .
.n i, . w.c.,. s , _ ...
.cs r:y.x o n.,.
. 3 . . .-:- .,, . -. ., %.s
. mMry;. .
a J'? Zi@s, i .
~
o 120' .58" I ,l,?"
l G t il. , ~.: h.& .i iec4 o. -v4F.--
d 3. r . . r.
,*< ._ 3
- c .f a
X s i . ~, . ; ~
c;;. fw~
. gQw *;r: . _x.',:g;
<c e n.w.: n
.v.:.i, c ,
n .. - :ac. ,
ll I 'n -
. ' q,.s:< Q'pt x: . :f ,i' Y '.' i.%QL: 'O. .
L 'A: standard s @$;y$.'auG@ 8
- 60* .30"
~
M@ff?.840's0 said 3.';dd@U ' 4
'. a . W-
- uon
- ; - , , , , , s , ;; -'
- Lab tett.teg30st*.
-e .a :. <h;'/- d 'JU% - * $
.187 ,
nm Q).
U Eddy current test data 7 400001 u .060 Mfield of detectability------------------- // M - 1 i e i e i e i e i b 10 20 30 40 50 60 70 80 90 100 i
% Through Wall s'
d
....__~__.-=-; _ . .
1
~.
q . - - . - - . - . - . - - - . . _
*a ' -
LABORATORY WORK TO EE COMPLETED
- 1. NATURAL IGSCC CRACKS ARE TO BE GROWN (BEST ATTEMPTS) TO FULL PENETRATION AND SMALLEST "L"S POSSIBLE
- 2. BACK OFF FROM TIME ELEMENT AND GROW ADDITIONAL CRACKS AT SMALLER "L" AND THEN SMALLER THRU WALL "A"
- 3. ESTABLISH THRESHOLD OF DETECTABILITY FOR 510,.540 SD, AND ABSOLUTE
- 4. METALLURGICALLY EVALUATE TO CONFIRM "A" AND "L" MEASUREMENTS l
O
. l
.x I e* ,
a .. I.N.. CREASING SEVERITY ------------ -------- .. . .; "A" INCREASES TO MAX. THEN L DECREASES - i
. -o S '+ - . n um ww ~
i a
**- a Oo NOT DETECTABLE DECTECTABLE i
- m ! n
< m e _l o I m ;
' M
)
e 31 m 73 m I' cn
~%g%~'s'%s% z O I
N
- O --I +
- O I urg I . ~
~~
,s s
s
's '
c
~#
a o NOT DETECTABLE DECTECTABLE O z y 71 H
% g n o
g \ - e
%",gs g m m
z ?- m cn t' l -< m i) ,n s mr -< m , 1 > a m
-,/ ,/
- > m z w -i
, Y O DECTECTABLE $
d m
- r E- P
,,s C - - ,
y ' m 7- -s m
,,", -< r
_- m 1 ' " 'd SURFACE ANOMALIES UP TO 110% Tw , 5s in a3 o> T- N r-m T-
.- 2 -4 m W O 1 (n
' N -4 2 -{
I C N - - o
<~ t m
- ~ > rt
/
a
' - \T,(
/
~ . ..-
1 1
' WORK TO BE COMPLETED
- 1. COMPLETE THE 540 HIGH GAIN PRODUCTION WORK AND RECORD ALL INDICATIONS KNOWING WE ARE PROBABLY RECORDING SURFACE AN0MALIES AND OD SIGNALS
- 2. COMPLETE LAB ANALYSIS FOR ESTABLISHING THRESHOLDS
- 3. DISPOSITION THE RESULTS 50 AS TO ACCEPT SURFACE ANOMALIES AND SMALL OD SIGNALS PROVIDING WE DON'T ACCEPT IGSCC 440%)
- 4. ESTABLISH AS SUPPLEMENTARY ISI PROGRAM TO SPECIALLY TREAT ITEMS ACCEPTED IN "D" e
S e 9 e B 9 6 8 g h 6 e t
- e 9
+
c . 3*#@+ e ,8,W w eh<-Adv -t- * .*e.' '*4*,-- J A 9
m_ _ _ . _ _ _ . . _ _ . _ _ _ . . . _
SUMMARY
- 1. ECT QUALIFICATION IS NEARING COMPLETION.
- 2. USING SYNTHETIC DEFECTS WAS ABLE TO ESTABLISH A HIGH GAIN 540 TECHNIQUE THAT IS SENSITIVE ENOUGH TO ASSURE THAT ALL
, NATURAL (IGSCC) INDICATIONS ARE REPORTED.
- 3. NEED TO ESTABLISH AN ENGINEERED BASIS FOR ACCEPTING TUBES WITH NON-RELEVANT INDICATIONS.
- 4. DISPOSITION GENERATOR AND COMPLETE REPAIR. .
- 5. SAFETY ANALYSIS AND REPORTING.
l 8 s e 6 J_ w.A* # ?"Y
r . . ,
~. .
1 AUGUST 9, 1982
+
TMI . OTSG TASK 4 EDDY CURRENT PRESENTATION -
. TO THE ,'
NRC O e 9 9 e
. e e
a 0 0
# e 4
4
-~,ev3.-_-s.,+ . , , .
n _ -_. . _ __ _ _ _ . _ .. _ _ . _ . __ f OTSG Longitudinal Section Elevations (Typ.D PRIMARY SIDE * (IN510E TURES) UPPER ELEVATION TUBE 5HEET (UT5) FEET AUXILIARY .
- 348'8" FEEDWATER , t 'a. ,,
N0ZZLES . . -342'8" (AFW) ,
. h, ,E "* Y!!? ( 339'5"
..l'
- 1,', ll% l . ,
'" 338'5" STEAM OUTLET 3J- * -333'8" i , ,, ,
. l'*' 330'8" M AIN FEEDWATER 1.ql..W MIF N0ZZLES (MFW)s
- '" -327'4" j na nr
-324'4" C
+ !"'. 7
) ,, Mr al SECONDARY SIDE = -321'1" "n 7" k ,
%ja (EXTERNAL TO TUBES) "d f
",, 317'8" "1"';f t*', -314'8"
,- =w , a - -311aga "IW '- -308'5"
/
TUBE
^m- - 305'1" SUPP00.T PLATES - 301'10"
.[ Llio .
LOWER . 't
-- 2 5 8' 8" SECONDARY -
~
LowtR
- i 1, SECONDARY MANWAY HANDHOLE.
- 254'5" LOWER TURE5HEET (LTS)
REACTOR BLOG. FLOOR _=2,g,g,
y _ . -. -- . _ _ . - .
.i TMI-1 OTSG Upper Tubesheet Detail [Typ.?
.til" MIN. ;
- 5
.835" REF.
.351" Mill. l
. 187 -
u ,
, v A* pL
{ f
.835 5/18"
' 1" MIN. EXPANSION
, MIN. ,' . CLADDING N v
. E S
24" 5/16" l h
\ .
\
' N ,'
- ,N7
' .875"i.010" M:
, - .240 TYP.
l [!)i h._,\
,) '
E N l
,l i
l .7578 l 4, R . x\;
, , TYP TUBE PATTERN
.825" TUBE O.D. X .034" : " --
MINIMUM WALL - MIN.OO3 (DIAMETER) MAX.018 (DIAMETER)
.535"DIA. HOLE
~ -
- 1. E/C Techniques a) Standard Differential'-
Two interacting coils mounted circumferential; resultant
' signal response is produced by measuring the differential from the area of discontinuity to clean tubing area, b) Absolute Technique - -
Single coil wound in a pancake shape normal to SD coll; two sets of four separate (isolation) coils that are assembled in tandem to provide an effective eight coil coverage; optimum detection of circumferential oriented discontinuities. Disadvantage - Not conducive to broad scale production programs because it is extremely fragile and wears rapidly; additionally presents numerous electronic recording and analyst problems associated with having to maintain and readg8 channel recordings. O e
, wmm - u
-~s - e a um a
-.- = = = ===
L. .,. t : TMI-1 Eddy Current Probes ; Utilized for OTSG Tubing Examinations e P i II ) O 400 KHZFULL GAIN MIX -200 KHZ
=400 KHZ REDUCED GAIN !
MIX -800 MHZ 4 Differential % i
. ., . -- m, , - , , _
f hk s s w O
. , , w h
n as , i 400 KHZ 4X qu u w g. - r i t. - e e e a of =*E A%gw r q m m m p
.e
- ' s
- 1 ? s .:
G* s # # 4W. us wW%
' 400 KHZ FULL GAIN' '
MIX [200KHZ MIX 800 [400KHZKHZ REDUCED GA 3x3 O l yyyg .m+,se,+ .- --- -e-- - .-~.----.n .. - - . .w.,- -
l
- 1. E/C Techniques Continued Multifrequency - -
Utilized for all SD examinations; applied 2 base frequencies (400 KHz and 200 KHz) and used an "lD" mix to enhance detection of ID defects and minimize affect of chatter and tube noise. Saturated Probes - Improves noise. ID mix e o e - . , _ma--. 1.w w &_a.- -- -. - -
--=
1 _ _ . ,
\ .
Eddy Current Signals Roll Transition Mockup Differential Probe - 4 i NDD No Defect l
.w;.>b *s w E Defeet >hjjig[j$;M$$f M{.,d.$h,Y i 3j.,,e;.<,,
[zy@
; r v. . w100% .W, ThruO.
WaIIh c$ h k.i.S?nwM9e' -94% W*h.180' - NDO or NDD 1 40% Thru Wall l i 900
.lIlN.?
i,.4 .nsa$l{N.lv,5.h b . % ru b.es,h, .$c$+E::d,h, hk;6 '.'.l52' oy . s ;;. g y ~92
.. "W ~ ,p%!g!"qt 3 3p.Ca- "pR.
NDD 1 W.- - ' 4g;iT
- A9 40% Thru Wall 3/16 inch Hole 3?r5%,!!575 YEW66#y%'
'~~
. . . . ..- ' ' ~.. x. :.
. ,,w..*MiMJG
;< - .. wp
. ,.94',,
e :: ., v.,. .".,.~, . 6 6 1 0 0 e e
4x1 Absolute E/C Probe Qualification Data TUBE #3 Colt #1
. DEFECT #5 LOCATED AT i THE CLAD SURFACE (SEAL WELD AREA)
CH p' ' 's@- AgayW'
^
- 4;kM%ety;t e-a g,
'fRufNg,5 ' -'
~
. I .b., - -
~
9,7
. . , ' 1C C0IL #2 *
.
- i'. ~ . . . 1
*NO OEFECT
- 2
; j,, j p%pg g, w;.:we5%%%
j n.g,,, a ,. + - gggjj;f..j,, 4 n.,3 r,g ,, . Y&
!'ff ~ $
' I
.~ .4 Colt #3 '
Ag +pa. p
; 3
*NO DEFECT -
4+ 's :;ggS
-: q ,g g*itp
- COIL #4
*NO DEFECT m
' 4 - .=
- SIGNAL RESPONSE IS NORMAL DEFECT FREE '
RESPONSE AT TUBESHEET/ TUBE EXli 4XI EDDY CURRENT PROBE RESPONSE TO A 40% 10 TUBE WALL DEFECT LOCATED AT THE CLAD SURFACE OF TUBE #3 IN THE SIX (8) TUBE OTSG TUBESHEET MOCKUP m .e., e. - e w -- -*- *- #
T.
. .. s a
s- 8 w a a
~* #), t 8+ g h4 a c 8 d=
1 ,c._______. . __________sg g
"$ .a.
g y ________ _" ......_.,T g*6 e 7 p V u$ 4 5 ,W m U 6 a- - 3~ A m 4 of a g a:e ww J @ e g; . jg w_ _ . .. . _ _ _ _e -7 . . a 4 .g c, zo o :;-
.h.
3 s y e ,4 1 h L e A P '
.O. 8, e -
t
- 2 E m
.to.
g i o g .
.bt.
B .:
> t
.g.
5 s . e Ts 1 g 3; e. _ _ _ _ _... ,w _ _ . . . . . .e s _sy
# ! a' g ea ?) . . . . . . . . . .
_ . . . . .e } } m
,ye., _ n ti gb. .-
d j,*, ?fe-. ~ b _u_----- . y a*ys :-e! g.< g ,py ~s p_
,. . r .70 g:.:- - - - -
a-e ._e....g;8 P y yo.. . .Om . g.. . . . q _ . ..o r _. 3 %g"" .ygo._... ..... c ...: . _ .
;y
.yge.....;...
..a 3.-eir ~ ye f,l 9, ,.
i *e. . _ _.a_ . ~.:.,F .... ..
~2. . _a_ . _ .e -
, a o y- e - .
4e a
*----- ----* -S-N 4 u e .
t;- g n 6
+. ... -~ 3* nSy9 8 n 4e g"I rf 3g c g. T g$ gg
.%W _ _* {g.= :. .. .:. .: .=.=. .: ==.:
~
=
*t-- l _. . . .,g % -e e :
_ O,ps-W9 pe' _1
- I t 4 *
- s. uts o u r.r.r s u r r) r'r,- Y.* 0 , b e s o. .
,5 . I T I e ',
a .'.44 kj$.$ ' 3Noll.vplCNI .L N'B b M O D ACO'3 T.1T*AOMn'"l3V13H - Syn *,lA AMO1YdOSY") e g..mm -e .+=te
. _w. . . . , . . . . . - -
. ': N ,. ~ ,* . o g - .6 .
5 w
.- e W
e , 3 - SQ C *d * ' gsn u y o....... t , s. j $ t.s..... 4 . . . . .
. . . . . ...et- 8 .,
.O 1 yg R
e c,. p5 h. O N 1 I . E 5 - U sk so
.* $~ s*
W fe...... . . . . . . .q '$ C K u$ l
~
T .. b e 9 8
. pe) .
. Q e v -
W e
> M M *1 N. N. D W ..a m
e " .M A g e............ . . . . . . . . . . . .e g g 5 k kg........
- .. . . _ ...e h
-g e
'N - o 3 n j; %$ ... .... S )* M f 8 1
"$gg o.n. . . . . ....o
. . . g, .......g 4 4........ e. . . .1... .. .6.14
. . ., _ _; s. . .,;,.V n . .
_a 1,, e_3 0 -
- - - - - - - - - - - - - -4 !
-3 2 .l .6 - -- -g-g_- .e. . -. .-. --- ....___........,y
,e 9 Se
. . . . .. _g y e- " ,
j d - d 2 I E ~_ f 7 .... . __ y
,a yg go........... ... .
....e ug ,
53o - -
- r. e.
$$ 3 '$j h'y Ns I bye- i gE e-- -- To- ' - - - - -- H 1 - _1 wv L2 ']
E".~ ~~t- b
- - .rOF-Y.8 d: - -9O 6 E 5
.. g I g
~
*si SNOl LVO lq Nt J.N a wk n3 AQC2 9votipun9"tv13W . SynslA Awoavuomv7 "
4
,_ w ---- u .x;n=-,. -
; ;ns.;----- - m- -- n - r--
' -- - - - - --- -- _ _- z - }
-. ,, r I*
f I
. FACTORS AFFECTIM ECT RESPONSE '
l ! STANDARD DIFFERENTIAL To BE USED FOR PRODUCTION RUN INVESTI TION. ; (g-
- l.
CRACK 6E0 METRY A 4 A) SMALLER ASPECT RATIO (A/L),YleLD5 A LOWER AMPLITUDE : Rasem85. l n) DETECTION OF CIRCunctRENTIAL CRACK 18 DEPENDENT UPON CRACK l NIDTH, AX!AL sRANCHING AND SPIRALING. - ! t
- 2. PR0s: Dt814N/CONelReUAT10N
, A) HIGHER THE FILL FACTOR'6REATER THE SEN81TIVITY AND
! REPRODUCEABILITY. 0 a) 360 C0vtRAst. C) REDUCI PROSE WOBBLE WITH INCREASING FILL FACTOR. [ T 3. LIMITATION OF INTERPRETATION . ! A) INDICATIONS Y! ELD LOWER AMPLITUDE RESPON85.
- B) SREATLY APPECTED BY TUBE TRANSITION ARIAS. <
- 4. OPERATINs PARAMETERS 70 at OPTIM!ztD ;
A) FILL FACTOR. ! B) FREQUENCY., I C) .4AIN.
- l D)' CHART SPitD. . . !
f) ID MIXING. ! 5, CONSIDERATION FOR PRODUCTION A) NOISE AND CHATTER. , i B) 8. ANALYST PRECISION [AND ACCURACY OF l C)
~
DATA' HANDLING. . . i
- l
.~
l
. a I
- . ~ . . .. . . . . _ , .- - ..- - - - - - - - -
OTSG TUBING DEFECT MOCKUPS - g,44 . ce d .M" SAMPLE #1 (4) NOTCHit LINGTH 0.840" NOTCMDIPTMe 1.o.cincourtneNTIAL NOTCMas (RAtlAL) Pl# CONT TNAOUSNWALL pneas i.e. 20% 40% 80% 40% f I t 8 t
- l. t I
' h...
i et Mit 1 l 'pt Mim
; sum g, g um SAMPLE #2 (4) NOTCHis LENGTH 0.100" 1.0 cintuutensNTIAL NOTCM NeTCN etPTN . , (RAe All PSRCINT pnem s.e. THROUSNWALL 2 't% 40% '80% 80 %
I j
- j ?
{ l et' mm J l 8 bl*l" '
;i um W L--+ s m,m <
SAMPLE #3 ! (4) NOTCHtt LINGTH 0.107 1.o cincuersalNilAt NOTCH I NOTCMOtPTH. , (nA0lAL) PinCINT TNn0uGNWALL pn0M 1.0. 20% 40% 80 % 80% ~ T I"" I i
,i j i I
t _ e i i 4 9a utets l l 4 8" M'N'
;s min 4 J L-t s"mid I SAMPLE #4 (4) NOTCHil LENGTH 0.000" i.o tontifuntNAL NotCN NetCN 90PTN . '
IA30ALI Pl# CONT TN##USNWA%1 f 30% 40% 80 % 10% 790m l.0. " I __ e r 9 9 < l t e i 6 8 4 4 I ' _ 43 uld l l h!"um4
- r um J L+smm i 1
5 4 _m
.. -. : x: . aj y . p . v i. f i; .':- -
t *, ( - FILL FACTOft COtePAABSOS$* -
~
sw i
,, gy, 11 AIS l I l l lfl l lgl l I :A7 l [ [.99 IIIaggis,1Iyst11gggg
.11 .1 .5 1 .18
.?
1 1 .sio.as + na sce nnz S4% FILL FACTOR - 2 .540. 3s + na ese KHZ '
- 94% FILL FACTOR DETECTA8tE UNDETECTABLE l
3 Y ! j
- 834 .388 18 .14
,j g, .,
17 .29 .24 .27 .31 34 , o e z 3 ' 2 tiC O - as g V- g 4 j, 5 a { .060. .86 .11 .17 .23 2
.28 34 1
39 .45 .51 .57 Incrossing Aspect naties e/L seeee:neaponse 0.150 votes # ' asin. Sensitivity Lam commelen -
- Probe Disj2 -
(Tube fol2 - 1111111 1111111 1111111 11ll111 11lllll l Through Wall 20 % 40% Sc% 30% 100%
vp- - 3 I e f L l Field $tudies Flaw growth study ' , Analyst. correlation Processing data study Characterization of absolute vrs. 510 L Characterization of absolute vrs. 540 L Characterization of 540 vrs. 510 h i O e e p .
~
e
,_am_2_,-.,_ "~ ~
* ~ ~ _ ' _- ~~
~~~*9' ^ # * *- * * ' ' ' ' ' ' * ' '^' ' ~ ~ ~ ~ ~ ^ ' ^ ~ ^ ^ ^ ^'~ ~~
t E l Flaw Growth Study i Plan - l i Check 100 tubes in each generator at different points in time E to establish if new defects appear or if existing defects
- increase a) 102 tube sample from."A" p b) 104 tube' sample from "B" c) All tubes selected from different areas of generator d) Test employed .510 probe (35 Gain & RA)
E Original "A" Generator Retest "B" Generator 12/11/81 12/17/81 1- 1/4/81 12/28/81 1/8/82 } 3 1/9/82 4-
/ 6/82 1/31/82 2/2/82 4/4/82 i 5- 3/5/82 4/30/82 l
7/3/82 7/5/82'
, e) Conclusion -
j No substantial time period shown increase in number of defects or extent over f) Effect of using .540 probe (high gain) versus .510 ab.. re ' A Generator B Generator Grand r = Subtotal Subtotal Total %
- Agreement 95
- No agreement 93 188 94 5 8 13
- Below US + 13 6 0 2 2
- Above US + 13 5 6 1
11 5 L L
Y;-
.{'
e,, . PROJECT: . DETERMINE-THE PROBABILITY. OF ERROR.IN THE ANALYSIS 0F EDDY CURRENT RESULTS.
-PLAN:. RE-EVALUATE PRODUCTION RESULTS OF SAMPLE OF 500 TUBES PROCESSED'BY 3 CONAM ANALYSTS USING 3 OTHER VENDOR ANALYSTS.
REsutTs: A. INITIAL AGREEMENT 446 SAMPLES 89.2% B. AFTER RESOLUTION' 492 SAMPLES 98.4%
- 1. OVERCALLS 4 SAMPLES 0.8
- 2. UNDERCALLS 4 SAMPLES 0.8 (INDICATIONS MISSED)
CORRECTIVE ACTION: A. ~ USE A SECOND ANALYST TO OVERCHECK STRIP CHART READINGS BY
, FIRST ANALYST. Cr3 A LA46 M M TW5 B. SCAN. REVIEW MAGNETIC-TAPE DISPLAY-FOR ENTIRE LENGTH PROBE AND INTERROGATE:(EVALUATE) ALL AREAS AS INDICATED BY STRIP CHART.
C. .GPUN/QA MONITOR ANALYSTS ACTIVITIES. e 4 e 6' o 5 . b '--
P ^~N ._. N.- , j. . PROJECT: ' DETERMINE THE PROBABILITY OF ERRORS IN THE PROCESSING OF EDDY-CURRENT DATA ELAN:: REVIEW DATA SHEETS AND COMPARE TO COMPUTER PRINTOUT FOR ALL TyR[S (3SU TUBESWITH) LOWEST DEFECT INDICATION LOWER THAN US + 21
. RESULTS: (DATA FOR OTSG 'B' ONLY)
A' . AGREEMENT . W 15000 SAMPLESas99.7 % B.. UNDER CALLS 21 SAMPLES as0.14% C. dVERCALLS 5 SAMPLES s0.03% D. MISSCALLS 21 SAMPLES z 0.14% DIFFERENCE OF 1 INCH + IN LOCATION REPORTED E. TOTAL 47 SAMPLES 2f0.3% RECOMMENDATION: ,
. ,, 1. DURING 540 PROBE WITH HIGH GAIN WORK WE WILL REVIEW DATA SHEETS AND COMPARE TO COMPUTER HISTORY FILE FOR ALL TUBES.WITH INDICATIONS BELOW FIRST REPAIR PLUS 6"
- 2. MAKE CORRECTIONS NOTED
- 3. DO NOT MAKE ANY ADDITIONAL C:iANGES AFFECTING- QC CONTROLS ON INPUT e
4
%,ggg rm.mm _ e, - - -mm---,,-
a ., ~ 5 PLAN: CHARACTERIZE INDICATIONS SEEN BY 4xl ABSOLUTE BUT f NOT SEEN BY 510 TEST POPULATION 3233 NO. OF TUBES WITH CORRELATION 3153 (97.5%) NO. OF TUBES WITHOUT CORRELATION 80 NO. OF INDICATIONS WITHIN 80 SAMPLE 99 A. CIRCUMFERENTIAL EXTENT - 99 DEFECTS
# COILS # INDICATIONS CUMULATIVE %
1 90 90 2 7 98 3 2 100 4 0 100 Ib. % THRUWALL CALL BY ANALYST - p M* Me s tuddR '#I'f, ~t i-w u 4., wc( ,
%THRUWALL- # INDICATIONS CUMULATIVE t, M7 e' t- i g(,u(-Q 90-100 23 24 80 14 38 70-80 8 45 60-70 5 51 50-60 8 59 40-50 20 79 30-40 13 ,
92 20-30 . 8 100 . e e 9 e e 4 9-e/F*v MW99149p e r77 s'==e w ,, .. .e.s s- e-p re m ,so.. v- .+,,e-wew ., e-ee ,o- m .,. -- y ,w g ep ,ys , yse r e w ,w ,- e, y- wg e ,-y-ew e , y - --w-*wmm----*'y --
,7 _
;. , - :' 3 PLAN: CHARACTERIZE ~ INDICATIONS SEEN BY ABSOLUTE BUT NOT SEEN
'BY1540
- (HIGH GAIN)
TEST POPULATION 3233 NO. OF TUBES WITH CORRELATION' 3216 99.4% NO. OF-TUBES WITHOUT CORRELATION 17 NO.10F INDICATIONS WITHIN DATA SET
- 17 A. CIRCUMFERENTIAL: EXTENT
;100% OF-17 DEFECTS WERE ONE COIL. -
B. AFTER ID MIXING-(TO REMOVE CHATTER) THE NUMBER OF TUBES WITH
- CORRELATION IMPROVED TO 3229.
C.- 14 0F'17~ DEFECTS ARE RESOLVED AT THIS TIME.
% THRUWALL CHARACTERIZATION
--% -IHRUWALL # INDICATIONS CUMULATIVE %
90-100 12 85.7 80-90 0 70-80 0-60-70 0 50-60 ~1 - 92.8 40-50 0 L30-40 0 20 0 NO DESIGNATION 1 C1. IHREE TUBES UNRESOLVED ONE TUBE-PLUGGED. TWO TUBES HAVE NOT BEEN-EXAMINED WITH SAT. PROBE & ID MIXING. l l
PLAN: CHARACTERIZE INDICATIONS SEEN-BY 540 BUT NOT SEEN BY 510 4 TEST. POPULATION' 2771 NO. .OF TUBES WITH CORRELATION 2589 (93)%
-NO. OF TUBES WITHOUT CORRELATION
- 182 -( 7) %
NO. OF INDICATIONS FOR
- 288 c_ e4.a c. Ma i 2 > & - mc 74 W e~ V #40 'U D td 5 A. AMPLITUDE OF INDICATION 70% 1 VOLT AND LESS 90% 2 VOLTS AND.LESS 96%' 3 VOLTS AND LESS 98.9% 4 VOLTS-AND LESS 100% 5 VOLTS AND LESS B. % THRUWALL CHARACTERIZATION THRUWALL % FREQUENCY CUMULATIVE % Pr1 ARKS 90-100 82 2'8 68% or less 80-90 23 -36 65% IV or less 70-80 25 45 80% IV or'less 60-70 42 59 76% IV or less 50-60 46 75.7 65% IV-or less
. 40-50 36 88 86% IV or less 30-40 15 93 60% IV or less 30 19 47% IV or less 10-20 0 O
a 9 1 mz _ l;
ASPECT RATIO COMPARISOM
,1 .* -
METALLOGRAPHY ACTUALCIRCUMFERENTIAL DEFECTS " j E/C SYNTHETIC DEFECTS ORIENTED IN WORST GEOMETRY
~-,~. -
360'. u ;..i a, m . . . . . % , % s .. ..
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- April,1982
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LABORATORY WORK TO BE COMPLETED
- 1. NATURAL- IGSCC CRACKS ARE TO BE GROWN (BEST ATTEMPTS) TO FULL PENETRATION AND SMALLEST "L"S POSSIBLE
- 2. BACK-OFF FROM TIME ELEMENT AND GROW ADDITIONAL CRACKS AT
;,e w, SMALLER "L" AND THEN SMALLER THRU WALL "A"
- 3. ESTABLISH THRESHOLD OF DETECTABILITY FOR 510, 540 SD, AND ABSOLUTE
- 4. METALLURGICALLY EVALUATE TO CONFIRM "A" AND "L" MEASUREMENTS l
l
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e e e e up,-' ' '^ v - pn-e. t y. 2,. ,w. , , , , , - . , . -,,~,,,,,,,,-,,r,*w- -v - , e- g e - +-- =-e- v-+- - w '-- 'e
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"A" lNCREASES TO MAX. THEN L DECREASES
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DECTECTABLE
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O NOTDET[ECTABLE
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/ . ;. WORK TO BE COMPLETED
- 1. COMPLETE THE 540 HIGH GAIN PRODUCTION WORK AND RECORD ALL INDICATI0tlS KNOWING WE ARE PROBABLY RECORDING SURFACE ANOMALIES AND OD SIGNALS -
Cu k " f/s
- 2. COMPLETE LAB ANALYSIS FOR ESTABLISHING THRESH 0LD'S 3.
DISPOSITION THE RESULTS SO AS TO ACCEPT SURFACE ANOMALIES AND SMALL OD SIGNALS' PROVIDING WE DON'T ACCEPT IGSCC (>40%)
- 4. ESTABLISH AS SUPPLEMENTARY ISI PROGRAM TO SPECIALLY TREAT ITEMS ACCEPTED IN #h"
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SUMMARY
- 1. ECT QUALIFICATION IS NEARING COMPLETION.
- 2. USING SYNTHETIC DEFECTS WAS ABLE TO ESTABLISH A HIGH GAIN 540 TECHNIQUE THAT IS SENSITIVE ENOUGH TO ASSURE THAT ALL NATURAL (IGSCC) INDICATIONS ARE REPORTED.
- 3. NEED.TO ESTABLISH AN ENGINEERED BASIS FOR ACCEPTING TUBES WITH NON-RELEVANT INDICATIONS.
- 4. DISPOSITION GENERATOR AND COMPLETE REPAIR.
- 5. SAFETY ANALYSIS AND REPORT.ING.
e 9 y s .m----
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hi EDDI CURRENT CORRELATIONS - ROUND 1 Ale 2 [ l.0 CATION: 0-1/4" Fmy CURRENT RESULTS BEND IEST RESULTS DIFFEREt(IAL ABSOLl[E ASPECT TIRF LOCATION s .I.M. LOCATION s .I.N. LOCATIONN $_L}k 6TIO k8&7 . 0.03 100% .057
. A-13-63 0.4 95% -0.125 100% .049
.A-112-7 0.125 100% .085
.A-112-9 0.125 100% .049
- A-133-74 0.125 100% .049 B-10-29 NE 0.125 100% .031 A-23-93 0.3 95% 0.25 100% .174 A-88-11 0.25 100% NR-
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'A-71-126 0. 6 ~ 95% 0.25 100% NR A-1168 0.25 100% NR A-16-69 0.3 95% 0.125 100% .043 ky< J" g s1,J NOTES: 1) NE-NOTEXAMINED W , 7 .. v
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2): BLANK SPACE MEANS THAT NO EDDY CURRENT INDICATIONS WERE REPORT
- 3) NR-NOTREPORTED
- 4) BEND TEST RESULTS REFERENCED TO CUT END OF TUBE - A DURING PULLING.
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'-, werlm usu.* NM h-W FTT Mr.rhe*h*"- ' * " -
x- .
- - - . - . = _
EDDY CURENT (EEATIONS - ROUND 15 2 LOCATION: 1/4" - R0u. TRANSITION Fmy CURRENT REsuLTs BEND IEST RESULTS TilRF LOCAT . LOCAT .I.W. LOCATION % I.W. O A-12-62 1.0 75% ND RT NDD-2 RT '95% 1.5 100% .015 A-13-63 RT P0gisisLE 1.7 95% 1.25 100% .034 s UEFECT A-62-8 1.0- 90% 1.0 95% 1.25, 100% .049 RT NDD-1 RT 95% ND A-133-74 0.6 95% 0.56 100% 0.136
- 1.5 PassistE 1.5 NR NR JEFECT B-10-29 1.0 80% E 1.25 100% .034
- B-8-25 RT 65% E ND 1.5 60% E 1.25 100% .035 6
B-11-23 1.0 95% E 1.25 100% .043 1.75 95% E 1.50 100% .174 A-23-93 RT NDD-1 RT 95% ND A-88-11 RT NDD-2 RT DEFECT 1.25 100% .130
-A-112-5 RT NDD-2 RT 95% 1.25 100% .074 A-71-126 RT NDD-1 RT 95% ND A-16-69 <
0.8 95% .69 100% .113 RT NDD-2 RT 95% 1.31 100% .057 WTES: - @ - NO DEFECT FOUND ON BEND TEST RT - IN ROLL TRANSITION AREA .
v-- -
~- --.=-:=-_.-._.-
- . s to-EET/ CURRBiT COE.ATIONS - ROUND 1 a 2 LOCATION: RoLLTRANSITION-10"
, I E"DY CURRENT ResuLTs BEvo iss- RssutTr TUE F3SOLUTg L<rATIONDIFFERENTI6h.d. , I LOCATION i.I.W. LOCATION $ I.W, cdFEC-hTIO A-12. 62. 8.0 .75% 8.7 95% 8.19 1CC .055 A-m-7 2 70% Mutt. 2-5 95 NR 4,
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4.5 9T. u.5 1CG .15 6- 80% 6 903 5.6 1C0'; .073 O.D c-'To O.O iLV,e .LJ 7 90% 7 503 7 '7: ICC .055 A-23-93 2.0 80% 1.8 95% 1.75 100% .093 A-88-11 2 95 2.25 1 Cal .073 A-146-6 9 85% 8.4 90% .8.25 1C0% .045 A-146-8 3 55% 4 90f 4 70% .C43 B-10-29 7.6 95% NE 7.6 1CM .147 l
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, . c, EID( CURRENT CORRELATIONS - R0llND 1 ne 2 LOCATION: 10"-24" Fnny CLRRENT RESULTS EEND IEST RESULTS TilIF L $ E.D.~ lDCAWON % I.W 1 LOCm0N % I.W. O A-11 12- 55% 11.7 90% 11.6 100% . 113 A-146-6 10 55% ,
10.3 95% 10.5 100% . 043 IKATION: 24" - 15m TSP A-1 H 3 27 90% 26.3 95% 26.8 100% . 043 A-133-74 31' 95% 30,7 90% 32- 100% . 147 32 95% 32 90% 33 100% . 147 4 e e 6 O
SLMMRY OF EWY CURRENT CORRELATIONS - Route 1 & 2 - .L*
/
IrelCATIONS fouPO BY EDDY CURRENT. l ... ROFTuBES CRACKS OPENED ON
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LOCATION - 2 TESTS - BOO TEST 0.510" DIFFERENTIAL 4XlABSOLUTE , 0-1/4 12 12 0' 5 1/4 - RT ~12 13- 11 81 BELDWRT-10 - 7 11- 8 102 ; 10 - 24 2 2 2 '2 l; 24-TSP 2 3 3 3 10TESi 1) . 4 wBeS Wim CRACKS IN THIS AREA NOT EXAMINED WIM 4 X 1 ABSOLUTE PROBE.
- 2) I wBE Wim CRACK IN THIS AREA NOT EXAMINED WIM 4 X 1 ABSOLUTE PROBE.
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1 - - . . - - - = = -_ - . 3 SLM%Rf - EIDY CURENT vs. DEFECT CORELATIONS O IN - 0TSG EDDY CURRENT RELIABILITY WAS LOW IN THE TUBE END AN TRANSITION AREA (SINCE THESE TUBES WERE REMOVED, SPECIFIC TECWIQUES 10 INSPECT THIS AREA 1%VE BEEN DEVELOPED.). o BELOW THE ROLL TRANSITION, TE IN-FIELD EDDY CURRENT TECHNIQUES DETECT ACTUAL DEFECTS WITH M RELIABILITY. O NO UNDETECTED DEFECTS HAVE BEEN FOUND BELOW THE ROLL TRANSI DURING THE LABORATORY IWESTIGATION. e e 9 s
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- o -TUBE WITH DEEP' DEFECTS (EC cuALIFICATIO:is).
O BAD TUBE / Good REGION (DEFECT-PATTERNS) O C10CD RJBE/3AD REGION (DEFE~T PATTEPJIS)
. O TuSE WITH tu.TIPLE Deeds (acsiIm) ,
^
- O GOOD I.!SE/ DEEP SAMPLE (EC QUALIFICATICts)
. O'IUBESWITHROLLREGIOnECIraICAnon(ECQuAUF[CAUGTS)
- o Good TusE/ Good AREA e
s 9
- 6 4
4 0 e 6
, 4 6
0 9 9
z r -o n EDY CUREiiT TcST ."ETriOD CORRELATi0i1 O ' 03 JECT!ss - VERIFY REPRODUCIBILITY BETWEEN EX411 NATION METHOD CCRRELATE RESULTS WITH METALL0 GRAPHIC E;W11 NATION. O ECDY CURRENT METriODS USED - 1). IN-SITU .0.510" PR03E, STANDARD DIFFERENTIAL
- 2) IN-SITU - 4 X 1 ABS 0driE FROEE (TCP EMD OF TLGES)
- 3) AT B31 - 0.500" STANDARD DIFFERENTIAL PROSE
- 4) ERI - rEsELOPED 0.540" STANDARD DIFFERENTIALlveFROBE - i' -
j,- t .7 .- O ilFTALL0GRAPHICEXAMINATIONBYSECTICNING AND 3E!DII:G CF SELEC INDICATIONS. i O O O S
l 1 EDIN OJRENT C0 RELATIONS - 3RD ROM TUBES - rt FFn 0.540" FETA 3MPHY llN FlFVATIM DIlttRNI . A _- mMUJit B8W LAB DIFFERHTIAL E91 T REIMRKS A-24-94 0.2 95 -
~
1.3 95 80-100 80-100 100%T.W. I 3.4 95 80-100 80-100 100%T.W. u . 5.2 40-70 40-70 lb CRACK w in w ~ l.DCALIZED S4AIJL PI'TS 12.3 40-70 10-70 lb CRACK ReOVAL IWWiE 12.8 95 l00 t0D ~70%T.W. WITHIN 1/2" 0F CUT EDGE 3 - l-j 15 95 90-10) 90-100 lbT TESTED SCHEDULED FOR REPAIR TESTING ! 34 95 90-100 90-100 j 41 95 E f00 " " tb TESTING SCHEDULED 53.5 ' 95 , f00 f00 " " " " " )
.A-37-29 112 10 40 40 lb CRACK lhNUFACTURINGARTIFACT A-111-13 0.2 - 95 tbT TESTED lb TESTING SCHEDULED
- 3 80 " "
lb BEf0 TEST SCHEDULED ! B-16-22 0.2 ~ 40 CRACKS ll AXIAL CRACKS 1/II" l B-9ft-27 12.5 90-100 90-100 lbT TESTED
~
SCHEDULED FOR CORROSION TEST 13.2 80-100 00-100 l 14 95(HULTIPLE) %-l@ T-IN " " " " " " 238 95 100 10D lb CRACK WITHIN1/4"'OFCUTEDGE- ! B-34-19 0.2 INCOMPLETE - CRACKS 5AXIALCRACKS 1/ll" SIGtML l
w-g ,, 7'N. SlM%R( OF EDDY CURRENT RESULTS
- 1) EDDY CURRENT CALLS OF > 8@ CORRELATE WITH IGSCC.
- 2) EDDY CURRENT CAU.S OF @-7 @ REPRESENT SURFACE ANOMALIES THAN CRACKING.
- 3) No CRACKS FOUND WiERE EDDY CURRENT REPORTS NO INDICATIONS 0
4 9 O O O e t 9 e *
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Nb\; Slit %RY - ETALLURGICAL CORRB.ATIONS O BELOWTHEROLLTRANSITION,EDDYCURRENTINDICATIONSCORRELATE WITH TUBE WALL DEFECTS. O BEND ESTING HAS BEEN DONE ON: ROUND 1 & 2 - 14.1 FT. OUT OF 37.8 FT. REMOVED. ROUND3 - 4.5 FT. OUT OF 124FT. REMOVED. ADDITIONAL 6 FT. OF R0uxD 3 TUBING SCHEDULED. O NO DEFECTS UNDETECTED BY EDDY CURRENT HAVE BEEN DETECTED BY BEND TES
$ 6 5
l , -s- . . - e ,. FILL FACTOR COMPARISON * .",
.- b ctandard l l l l- .l l- l 1 l l : l i Differential .137. .-- S9-l-k g.04 l l l.05 l l l .07 l l l.09 l l l .11 l.13l. g i l l l 15llll16lll18
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1 .510,45 + RA 400 KHZ \
! 84% FILL FACTOR \
1 2 .540,45 + RA 400 KHZ g 94% FILL FACTOR . (
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* .I 68
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.14 .17 .20 .24 .27 .31 .34
., .100. .E --.034 a --~~--l-~~ - ~ ~ - - - ~ ~ ~ - ~ ~ - - - -
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' E e .D6 .11 17 .23 .28 .39 .45 a .060 .34 .51 .57
* (Probe Dia.)2, (Tube ID)2 Increasing Aspect Ration m/L Note: Response 0.150 Volts Min. Sensitivity
--- Entrapolated Value
. From Unknown Zero Voltage Threshold lllllll lllllll lllllll lllllll llllll] -
Through Wall 20% 40% 60% 80% 100%
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- :
.' i:.:; i . a M;. .,^
q) .
. GAIN COMPARISON FOR DETECTION PROBABILITY 1
Standard ~ llll l I 1 I pirierentiat
.1 s7. .--.8.9.l-l-lj .;l-l.*l. -l l l 87 l l l8.! -l l l 11 l l [ A1I l [ l I l l lAl l l l"I
- 1. .540,50+RA. 400KHZ I I
Z. .540,45+RA. 400KHZ I l
- 3. .540. 40+RA. 400KHZ l I
- s. .540, as+RA. 400KHZ J
.010. 35+RA,400KHZ I
5.
~
l lAvg.] ~ I c.' I ..
- D
. .068 .10
.ioo. .g' . 034
=g-
.14 17 .20 .24 .27 31 34 o a z
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o 5 5. \1 11 87 X
._ .23 _ , ,,,8 _ 24 as As .51 .57 -
.E .oso. \ Nsg 's 's s
' g \
i \
\
Ngw N- s g increasing Aspect Ratios a/L Note: Response 0.150 Volts i 2 Min. Sensitivity Lab Condition
--- Extrapolated e.,1ve erom unknown -
iron voltage threshold lllllll [llllll lllllll lllllll lll(([l Through Wall 20% 40% 60% 80% 100% i
~
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. 1 GAIN COMPARISON FOR DETECTION PROBASILITY Standard ?
DNierential ,y g.y* l l l l 04Illll l l l el3 ; l l
, , ,,,= .05 l l l .f17l l l 99 l { l 11[ [ ]."3l .
l I]ll1lllllI8
.15 .16 l l'
- 100 MV/Div. t 2 3 4 5
- 1. .540. 50+RA. 400KHZ t
- 2. .540,45+RA. 400KHZ
*e
- 3. .540,40+RA. 400KHZ . . b -
as g O I 6 * : O. O '
.540. 35+RA. 400KHZ O 8, eO '
- 0. .510. 35+RA. 400KHZ g
oi *$ S
*o F F e
j .034 .068 1O .14 17 g .100. .20 24 .27
.31 .34 o g Z
E o uns k, , .000. .06 .11 17 23 .28 .34 .39 s s , , 45 .51 .57 4 N \ I g N . l s N 1 N j 'N N 1, i l Note: Response 0.300 Volts , . j Min. Senshiwity } Fiend conditions IIIIIII IIIIIII IIIIIII IIIIIII IIIIIII Through wall 20% 40% s0% s0% 100% 1 'k
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