ML20126D706
| ML20126D706 | |
| Person / Time | |
|---|---|
| Site: | Point Beach  |
| Issue date: | 04/25/1980 |
| From: | Morgan E, Pement F WESTERN NUCLEAR, INC., WESTINGHOUSE ELECTRIC COMPANY, DIV OF CBS CORP. |
| To: | |
| Shared Package | |
| ML20071G838 | List: |
| References | |
| NUDOCS 8005060190 | |
| Download: ML20126D706 (76) | |
Text
.. . . . . . _. _
8005060 6 0
h ATTACHMENT 1 APRIL 25,1980 l l
MICROSCOPIC AND OTHER EXAMINATIONS OF NUCLEAR STEAM GENERATOR TUBING REMOVED i FROM POINT BEACH N0. 1 IN MARCH 1980 F. W. Pement Materials Science Division Westinghouse R & D Center Pittsburgh, PA 15235 E. P. Morgan Nuclear Technology Division Westinghouse Nuclear Energy Systems Pittsburgh, PA 15230 l
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i ABSTRACT Tubes B(26-53), B(30-41), and B(19-37) from the hot leg regions of the l Point Beach 1 steam generators were removed in March 1980 and were examined by ]
EDE and microscopy. General intergranular corrosion was absent above the tube sheet on the tube OD surfaces. Shallow intergranular involvement was absent or was limited to 0.002 in maximum depth on cross sections at or above the top of the tube sheet. Deeper intergranular corrosion within the tube sheet region was oh-served to depths of 40% of the wall thickness on B(19-37), 65% on B(30-41) and 80%
on B(26-53). The results were based on extensive optical metallography and SEM fractography, and they confirm that the corrosion-producing e'nvironment was con-fined to within the tube sheet crevice region.
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SUMMARY
e Three hot leg tubing sections from the "B" nuclear steam generator of Point Beach 1 were examined in detail by optical metallography and scanning election microscope-fractography. Intergranular corrosion was shown to exist within the tube sheet region with maximum depths of 40% on Tube B(19-37), 65% on Tube B(30-41) and 80%
onTubeB(26-53). At the top of the tube sheet and immediately above the tube sheet, general intergranular corrosion tended to be absent or, if present, was microscopic, of the order of one or two grains in depth not exceeding 0.002 in, j The examinations therefore confirm earlier examinations on tubes removed in l October 1979, that the corrosion of the Inconel 600 tubing developed in the I confines of the annulus between the tubes and the tube holes within the tJbe sheet. l Corrosion above the tube sheet was shown in the present examination to be absent or superficial. The presence of 0.002 in. of grain boundary involvement such as observed at the top of the tube sheet in the present examination, is not considered atypical.
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l INTRODUCTION Three tube samples were removed from the "B" nuclear steam generator of Point Beach Unit 1 in March,1980. The samples were hot-leg sections of (1) Row 26 -
Column 53 [B(26-53)], (2) B(30-41), and (3) B(19-37). Tube B(26-53) had a re-ported in-plant eddy current (EC) indication of 86% wall thickness at an elevation of 18 in. above the primary face of the 221/4 - in. - thick tube sheet. Tube B(30-41) had a reported EC indication of 47% at 21 in above the primary face, and Tube B(19-37) had an EC indication of 58% at 22 3/4 in, above the primary face.
The lengths of the cuts made at the Point Beach site and the forces used to extract the tubes from the generator were reported to be as follows:
Cut Length above primary Face of tube sheet Extraction Forces (in.) (1b.)
B(26-53) 70 21,000 Break away 8000-9000 Pulling B(30-41) 65 24,000 Break away 21,000 Pulling B(19-37) 70 22,000 Breakaway 4000-8000 Pulling The tube sections were examined by techniques of nondestructive evaluation (NDE) and by microscopy on selected, inlet-end sections. Both optical metallography ;
and scanning electron microscope (SEM) fractography were used for the microscopic examinations. This report summarizes the results of the NDE and presents the details of the microscopic examinations.
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s NON DESTRUCTIVE EVALUATION (NDE)_
The NDE work was conducted at Westinghouse Forest Hills. All as-received tube sections were photographed, measured, radiographed, and re-tested by eddy current. i Measurements included overall lengths and salient features on the outer diameter (00) surfaces. Figures 1 - 4 are photographs of the inlet-end sections of the as-received tubes. Figures 4A, B and C provide in plant comparison of E.C. signals and E.C. findings in the laboratory. Dimensions appear on drawings in figures associated with the microscopic examinations of the individual tubes and are des-cribed later.
All sections were double-wall radiographed using a Siemens X-ray machine and the following parameters:
Type M Film, Double Pack 200 KV - 5 mA Exposure 60-in. Film-to-Sample Distance 110-sec. Exposure Four rotations (0*, 45 , 90 , and 135*) were used for each tube section. The 0*
mark was made at the plant site on the area of each tube section which faced the divider plate in the steam generator. Reference to the orientation of all tube sections over the entire removed length was based on these 0* marks. The rotations to 45*, 90*, etc. were counterclockwise when the tube was viewed axially in the direction of the internal primary flow. Selected prints of inlet-end areas of Tube B(26-53) are given in Figure 5 and are representative of the observations from radiography in the tube sheet region of all tubes.
( _ ___
o - j MICROSCOPIC EXAMINATIONS _
Tube B(26-53)
The as-received tube lengths, the locations of sections for microscopic exam-inations, and a conspectus of the metallography and fractography appear schsnatically in Figure 6. Two axial cross sections, numbered 1 and 2 in Figure 6, were made through a circumferential, OD " ring" mark which appeared at an elevation on the tube which corresponded with the top of the tube sheet. This ring and adjacent tubing surfaces are shown at 4 rotations in Figure 7.
Sectioning of one of the axial sections at the tubesheet ring is depicted in l Figure 8, together with a photomacrograph of the resultant section and photo-micrographs of the OD edge at an elevation immediately below the ring. Similar photomicrographs at elevations of the ring and immediately above it appear in I
Figure 9. Very shallow grain boundary involvement (< 0.002 in. long) was '
detected below the ring over the entire 0.08 in. axial length shown in Figure 8.
Isolated 0.002 in. max. indications were found in a short zone (0.02 in. long) l above the ring, as shown in Area 3 of Figure 9. Figures 10 and 11 correspond to Figures 8 and 9 for the second axial cross section through the ring at 180* from the preceding section. Photomicrographs show the same shallow (s0.002 in.) grain boundary involvement (Figure 10), except that a deeper, opened network of inter-l granular corrosion 1/2 to 5/8 in. belcw the ring was also present (Figure 11). 1 The remaining four samples for micrographic examination are shown as-cut in Figure 12. Two of these (numbered 3 and 6 in Figure 6) contained fractures that I
occurred on tube removal. These were studied with the SEM to map the depth of intergranular corrosion and tre width of unaffegted metal as evidenced by ductile f l
shear. The other samples were examined metallographically. Sample 4 (of Figure 6) was first bent to open the inte. granular networks to their maximum depth. Sample 5 was a transverse cross section at a region of distortion by the tube pulling. The j results of these examinations appear es SEM fractographs in Figures 13 - 15 for the l I
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higher elevation (Sample 3), optical photomicrographs for the next, lower samples in Figures 16 and 17 (Samples 4 and 5), and as SEM fractographs for the lower fracture (Sample 6) in Figures 18 - 20.
Study of the 24 fractographs (taken every 30 degrees) from the sum of both fractures reveals a shear lip at every point examined, indicating that the inter-granular corrosion was not through wall and confirming that the fractures were the result of pulling the tube apart in the removal operations. The depth of intergranular corrosion as determined by the fractography, varied with circum-ferential location but was usually.50 to 80% through-wall at both elevations.
The bent cross sections shown in Figure 16 contained about 0.010 in, of deformed metal near the inside surface after the intergrunular corrosi.on was opened up.
This value, s20% of the tube wall thickness, was consistent with the fractography with respect to the depth of intergranular corrosion in this area of the tube.
TUBE B(30-41)
This tube contained a ring, located at an elevation which was consistent with the
, top of the tube sheet and through which an axial cross section was prepared and examined metal'1ographically. Above the ring, there was a bright-appearing, relatively deposit-free zone about 2 in. long. Figure 21 locates the ring, the axial cross section, and the bright zone. This figure also contains the as-received length measurements and the locations and orientations of two additional metallographic cross sections from within the tube sheet region. Sectioning of the region con-taining the ring and 4 views of ring at 4 rotations are shown in Figure 22.
The results of the metallography through the tube sheet ring appear in Figures 23 and 24. Very shallow grain boundary involvement to a maximum of 2 grains (0.002 in.)
was detected below the ring (Figure 23), and even more shallow involvement, less than 1 grain deep (<_0.001 in.),was observed at and above the ring (Figure 24). The axial cross section taken 1-1/4 to 2-1/4 in, below the ring and shown in Figures 25 and 26 contained intergranular corrosion to 65% of the wall thickness,
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and the transverse cross section just below this axial section had intergranular corrosion to 55 - 60% of the wall (Figures 27 and 28).
TUBE B(19-37)
A clear visual indication of the top of the tube sheet was not present in the tube sections. Therefore, a special, (oversized) 2-in. long axial cross section was i
prepared to span.an elevation which, from tube dimensions and reconstruction of site dimensions, corresponded to the top of the tube sheet. This section was examined and then ground and polished 0.006 in for a second examination. It was then broken out of its wunt and shortened into 3 sections which were subsequently bent to open up any weakened grain boundaries. The bends were examined with the SEM. These operations, and the location of this and 3 other metallographic sections are summarized, together with the as-received tube section dimensions, in Figure 29. Figure 30 shows 4 views of the zone from which the 2-in.-long micro was cut, and Figure 31 provides higher magnification views of the area, the location of the sample and the resultant section.
The results of the metallographic examination of the special 2-in.-long micro are collected 'in Figures 32 through 36. A maximum depth of 0.0185 in of inter-granular involvement was detected at the mid-elevation of this section (Figures 33 and36). Above this point, two areas studied had only extremely shallow (100008 in.), isolated indications (Figure 34). The cut and bent sections from 3 elevations on this section are shown in Figures 37 and 38. The uppermost bend sample (Figure 37) contained the sha110 west, opened intergranular involvement which, from the scanning electron micrographs, were superficial.
t A number of photomicrographs from 3 additional samples within the tube sheet are collected in Figures 39-42. These show intergranular cormsion of up .to 40%
through the wall (10 020 in, depth).
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l FIGURE 1. Tube B(26-53), Hot leg Inlet Sections, As-Received. Left-to-right =
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M:I, - I _X_ l FIGURE 2. Tube B(26-53), Additional As-Received Section adjoining and above the
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(A higher section of this tube was also received and photographed but is not shown.)
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FIGURE 3. TubeB(30-41),As-receivedInlet-EndSection. X-X denotes match lines in the pair at left, and the + mark locates the tube sheet ring, shown in 2 magnifications and 4 rotations at the right.
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! ow l FIGURE 9. B(26-53), Etched Photomicrographs of Longitudinal Section through Tube Sheet Ring. Area 2 = near ring; Area 3 = above ring. Areas are located in Figure 7. OD is at left; primary flow is upward.
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D %@ D 3"3 h sL y .S. m FIGURE 27. B(30-41), Transverse Cross Section within Tube Sheet, Sample 3 of Figure 21. Photomicrographs are of OD edges at identified i locations. 4
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denotes the polished face. Lower picture is a photomacrograph of the resultant cross section (0D on left) with locations (A-E) of high-magnification photomicrographs (Figures 32-35). Primary flow is upward. (Sample 1 of Figure 29.)
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. a FIGURE 32. B(19-37), Top of Tube Sheet, 2-in.-long Axial Micro. Areas A and B of Figure 31, lower. OD edges are at right; primary flow is upward. Etched with bromine in methanol.
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- topmost sample, A.
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l l FIGURE 42. B(19-37), Transverse Cross Section from within the Tube Sheet. Sample 4 of Figure 29. The higher magnification pictures show OD edges. l I 6.. e fa uns _ _ _ _ _ _ . _ . _ . , . . _ _ . _ , , _ _ . , . ~ . _ . _ , . _ , . .
l l ATTACHMENT 2 RE-EVALUATION OF EDDY Ct!RRENT TAPES FOR TUBES R19C37, R30C41, KidC53, R30C44, R28C38, R32C42, R22C46, AND R30C57 The eddy current tapes from the various inspections of the tubes noted above' have been re-evaluated for signature comparisons. Pictorial presentations arc included as Figures 1 through 8 and a rose detailed discussion of each tube is presented below. Rough estimates of the volume (equivalent diameter) of each of the indications have been compiled in Table I. These calculations were made using the formula D y =VD 7 Vg where D 7 = Equivalent diameter of the indication. Dg = Diameter of the flat-bottom hole in the eddy current standard that has the depth-of-wall penetration closest to that of the indication. V = Peak-to-peak voltage of the indication. 7 Vg = Peak-to-peak voltage displayed by the flat-bottom hole described by D g. Rough estimates of the lengths of the indications have been calculated from high speed strip charts. These are presented individually in Figures 9 through 16 and compiled in Table I. Row 19 Column 37 (Figure 1) This indication is small volume, 1/2" above the tube sheet, and was probably masked during previous on-site evaluations by probe motion (wobble) and the inability of being able to slow down the playback speed. Using slow playback speeds and low-pass filtering techniques, we have been able to track this indication back to l March 1975. The phase angle and amplitude of the indication have-remained approximately the same since that time which is indicative . of no change. Equivalent hole diameter is 0.047 inches and the length <0.15 inches. l l Row 30 Col"rin 41 (Figure 2) Another small volume indication, 1/2" below the top of the tube sheet, which has also been traced back to' March 1975 has remained es,sentially the same. The equivalent hole diameter is 0.080 inches and the length <0.10 inches. l
Row 26 Column 53 (Figure 3)_ This tube indication has become apparent since December 1979 and is typical of tube cracking in the crevice. The equivalent hole diameter is 0.052 inches and the length is <0.58 inches. Row 30 Column 44 (Figure 4) This indication is located at the tube / tube sheet interface and has been masked by the tube sheet entry signal. Use of multiple frequency techniques make the indication quite visible. Progression of this indication cannot be traced other than to note distortion of the tube sheet signal back to December 1975. The equivalent hole diameter is 0.055 inches and the length is <0.68 inches. Row 28 Column 38 (Figure 5) The same as R30C44 above. The equivalent hole diameter is 0.108 inches and the length is <0.20 inches. Row 32 Column 42 (Figure 6) The same as R19C37 above with traceability to March 1975 and remaining essentially the same since then. The equivalent hole diameter is 0.061 inches and the length is <0.29 inches. Row 22 Column 46 (Figure 7) 1 The same as R30C44 above. The equivalent hole diameter is 0.083 inches and the length is <0.29 inches.
)
Row 30 Column 57 (Figure 8) The same as R30C44 above. The equivalent hole diameter is 0.058 inches and the length is <0.53 inches. 1 1 1 il
TABLE I - s VOLTS STD. VOLTS DIA. OF R-C S/G LOCATION % DEPTH P-P P-P - EQUIV. HOLE LENGTH READ FROM 19-37 -B 1/2"1tTTS 58 0.72 , 3.82 0.047 < 0.15 400
- i 30-41 B 1/2"4TTS 47 0.60 3,26 0.080 - , ( 0.10 ,
400
~
26-53 B In Tubesheet 86 1,63 3.68 0.052 (0.58 400 , 30-44 B TTS 83 1,61 3.29 0.055 (0.68 MIX 28-38 B TTS 45 0.94 2.85 0.108 (0.20 MIX 32-42 B 1/2"tTTS 61 1.91 2.94 0.061 (0.29 400 - 22-46 A TTS 55 1.70 2.94 0.083 (0.29 MIX 30-57 A TTS 80 1.60 2.94 0.058 (0.53 MIX j. .w. -%.- -~ . -
l WEP - POINT BEACH NO. 1 S/G B INLET l P.19C37 - 1/2" AB0VE TOP OF TUBESHEET 3/75 - 400 kHz 10/76 = 400 kHz 9 y ;; ' . 2 +. .y : (-T;;_;.. ,.s .. lyj': l ,a. ne ..,;
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WEP - POINT BEACH NO. 1 S/G B INLET R30C41 - 1/2" BELCW TOP OF TUBESHEET 3/75 400 kHz 10/76 - 400 kH:
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WEP - POTNT BEACH NO. 1 S/G B INLET R26C53 - IN TUBE 5HEET 9/78 - 400 kHz 8/79 - 400 kHz i
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t WEP - POINT BEACH NO. 1 S/G B INLET R30C44 = TUBESHEET 12/75 = 400 kHz 9/78 = 400 kHz T. .j
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1 . i WEP - P0lNT BEACH NO. I S/G B INLET R28c38 = TUBESHEET 12/75 - 400 kHz 10/77 = 400 kHz
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s e WEP - PO!NT BEACH NO. 1 S/G B TNLET R32C42 - TUBESHEET 3/75 = 400 kHz 10/76 = 400 kHz
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4 WEP - POINT BEACH NO, 1 S/G A INLET
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WEP - POINT BEACH NO. 1 S/G A INLET R30c57 = TUBESHEET 11/75 = 400 kHz 10/77 = 400 kHz
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ATTACHMENT 3 i l DISCUSSION OF TUBE SHEET SIGNAL MIXING TECHNIQUE In order to establish the feasibility of evaluating the 400 KHZ data near or on the top of the tube sheet by the method of subtracting, the " pseudo-tube sheet signal" from the SIGNAL at the top of the tube sheet, the multi-frequency field data taken on October 1979 on Point Beach Unit 1 steam generators were used. The results obtained by this procedure were then compared to the results obtained from the mix of 400 KHZ and 100 KHZ signals. As a result of this investigation, it is felt that the pseudo-tube sheet subtraction technique produces unreliable results. The most important factor which influences the results is the operator's ability to guess the starting time of the tube sheet signals of the field data versus the starting time of the pseudo-tube sheet signal. The " pseudo-tube sheet" signals used in this work were the most normal looking tube sheet signals in the data. It was found that a slight variation in the time synchronization of the two signals gave a very different final result. Of course, if one knows tha final result beforehand, one can produce that correct answer .y manipulation of the starting time synchronization. The results of such a manipulation are shown on the field data of October 1979 for three tubes.
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