calculation of solution concentration for modified huey test · altran corporatior. date: july 3,...

Altran Corporation Technical Report 02807-TR-001 Revision 0

Appendix A

APPENDIX A

Calculation of Solution Concentration for Modified Huey Test

B- 51


Appendix A

Calculation Sheet

a l r N c a -.t ia. C aw -TP-M -4 By'-v42 Na- _ _ _ _ _ _ D at e, Y ;/ ýQ k z _ _ _ _ _ _ 111,1 6 3 .4 J- e I' z

~ ~ 41f~c.A 2oo - ) A ;VO Z

B- 52

I


Appendix B

APPENDIX B

Bulk Chemical Analysis of Tube Materials Analytical Results

B- 53


Appendix B

07/03/02 14.44 V508 835 6262 MASS MATERIALS It001

A Subsidlwry of THE MMR GROUP, INC

Massachusctts Matciials Reselaich, Inc. P 0. BOX 810 . 1500 CENTURY ORIVE - WEST BOYLSTON, MA 01583 - TEL. 50 6354262 - FAX 508-35-D9025

Altran Corporation OATE: July 3, 2002 451 D Street Boston, MA 02210 PO. NO-* Mlla65

MMR NO.. 0262-26

ATTEN'ION. Tom McKreli MMR ID#: 1

PAGE#: 1 of 1

SAMPLEI IDENTIFICATION: Inconel 600, Sample #02807-IA

CFFEMISTRY (Subcontracted to CT Metallurgical) Element Compositi2o V%)

Carbon .043 Manganese .20 Phosphorus


Appendix B 07103102 14,14 '0508 035 6262 MASS )NATERIALS 1z002

A Subsmd~ary d THE "MMR GnOUP. INC

Massaclhusetts Matusials Rcsearch, Inc. F0 BOX 810 - 1SO0 CENTURY DRIVE * WEST BOYLSTON. MA 01503 * TEL 50-835-262 * FAX 508-3S-9025

Altran Corporatior. DATE: July 3, 2002 451 D Street BOston, MA 02210 P. NO-, M11855

MMR N0- 0262-26 ATTENTION, Ton McKrell

MUR 11# 2

PAGE V 1 of 1

SAMPLE 9DENTfj9ATLON Inconel 600, Sample #C2837-2A

CHEMISTRY (Subcontracted to CT Meta1lurgical) Element Colyosition (S)

Carbon .047 Manganese .20 Phosphorus

.0_8/02 ON 13"39 FAX 1 860 528 1516


Appendix B CMI !0002

CMI A Subsdiary of THE MMR GROUP, INC

ConnEcticut- Metallurgical, Inc. 100 PRESTIGE PARK - EAST HARTFORD. COWN. 06100 - 860-289-7481 * Fax 860-528-1516

LABORATORY REPORT

Massachusetts Materials Research, Ic 1500 Century Drive West Boylston. MA 01583

Atm: Tom Baxter

July 8, 2002

Cust. 4

CMI # 64350

Page I of I

Received: 2 Test Pieces Identified. Ref Quote #WD06288-2, PO #M1 1874 Material: Into. 600. Sample Nos. 02907-5A, 02807-7A Puxpose: Verification Tested to UNS N06600. in accordance vith Purchase Order Requirements:

£bhmimtx

Carbon Manganese Phosphorus Sulfur Silicon Chromium Iron Titanium Alumnum Cobalt Copper Nickel

Dispositon. In Spec

SA

026 .16


Appendix B

A Subsidary of THE MMR GROUP, INC.

Massachusetts Matcvials Rcscarch, ,1nc. P 0 BOX 810 - 1500 CENTURY DRIVE • WEST BOYLSTON, MA 01583 • TEL. 508-835-6262 - FAX 508-835-9025

Altran Corporation 8C Fargo Street Boston, MA 02210

ATTENTION Tom McKrell

SAMPLEIDENTICA 02807-12

CIHEMISTRY Element

Carbon Sulfur

DATE: August 27, 2002

P.O. NO: M11970

MMRNO-: 0278-18

MMR IDN. 1

PAGE #: 1 of 1

Composition (%)

.043

.002

The above testing was conducted in accordance with MMR's Quality Control Manual, Revision 15A, Dated August 31, 2000 and your purchase order requirements.

This material is controlled under the United States Nuclear Regulatory Commission Rules and Regulations, Title 10, Chapter 1, Code of Federal Regulations-Energy, Part #21.

MASSACHUSETTS MATERIALS RESEARCH, INC.

Chief Corporate Chemist

Chemical analysis perlormed by Indictvely Coupled Plasmai'Optcal Emission Spectrometer Cattion sulfur nitrogen. hydrogen I and oxygen performed by Leco Combustion Mecharical and metaillurgscal testing pedormed per MMR Procedures

The results reported above appty o*ly to the test sample(s) provided

We believe the above test to be reliable and coned Inacouracies or errors d Itey occur will be corrected free 01 charte In no event shall Massactluseis Materials FiesearCh Inc be liable for any special. consequeintal or other damages This repot sthat nrot be reproduced except in full without written approval ol WIR

Figure B- 4. Test Report for Seabrook Archive Heat 1456 Sample

B- 57


Appendix B

A Subsidiety of THE MMR GROUP. INC

Massachusetts Materials Rescarlch, Inc. P0. BOX 810 - 1500 CENTURY DRIVE * WEST BOYLSTON, MA 01583 * TEL. 508-836-6252 * FAX 508-835-9025

Altran Corporation DATEZ August 27, 2002 80 Fargo Street Boston, MA 02210 PO NO: M11970

MMRNO: 0278-18 ATTENTION: Tom McKrell

MMR IDE: 2

PAGEI: 1 of 1 SAMPLE IDENTIRZCATION:

02807-13

CHEMI STRY Element Composition (W)

Carbon .022 Sulfur


Appendix B

A Subsidrary of THE MMR GROUP, INC

Massachusetts Maicrials Rcscar.cl, Inc. PO BOX 810 * 1500 CENTURY DRIVE * WEST BOYLSTON, MA 01583 - TEL 508435-6262 - FAX 508-835-9025

Altran Corporation 80 Fargo Street Boston, MA 02210

ATTENTION Tom McKrell

DATE August 27, 2002

PO NO. M11970

MMRNO.: 0278-18

MMR IDS 3

PAGE # i of 1

SAMPLE IENT1FICATIMJ

CHEMISTRY Element

Carbon Sulfur

02807-14

Comoosition (%)

.036


Appendix B

Wfr.ý.t ;,ALS II.4;70

v' "•47S ]. I 31

Figure E- B. CMTR for Heat 1638, Received from Al McIlree of EPRI

B- 60

I I

Altran Corporation STechnical Report 02807-TR-001 Revision 0

Appendix C

APPENDIX C

Two-Step Etch Results

B- 61

I I


Appendix C

Figure C- 1. As Received Sample R5C62-Carbide Etch

Figure C- 2. As Received Sample R5C62-Grain Boundary Etch

B - 62


Appendix C

Figure C- 3. Laboratory Thermally Treated Sample R5C62'- Carbide Etch

Figure C- 4. Boundary Etch

-Laboratory Thermally Treated- Sample R5C62 - Grain

B- 63

'S


Appendix C

Figure C- 5. As Received Sample R9C63-Carbide Etch

Figure C- 6. As Received Sample R9C63-Grain Boundary Etch

B - 64

-J


Appendix C

Figure C- 7. Laboratory Thermally Treated Sample R9C63-Carbide'Etch'

Figure C-, 8. Laboratory ThermallyTreated Sample R9C63-Grain Boundary Etch

B1- 65


Appendix C

Figure C- 9. As Received 96485-Carbide Etch

High Temperature Mill Annealed Sample Heat

Figure C- 10. As Received High Temperature Mill Annealed Sample Heat 96485-Grain Boundary Etch

B- 66

* ;'

t'* -� 1 * 4

'4' 'S.

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's.c * -'-,

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Altran Corporation Technical Repot 02807-TR-001 Revision 0

-Appendix C

Figure C- 11. , Laboratory Solution Treated High Temperature Annealed Sample Heat 96485-Carbide Etch

Mill

4

4 4- 4 *44

*4

'44 4 44 '44

'*4'

4

44

4 Al

44 4

44 44, 4-"

4'' 4� 44,

"V. A

�st t '44' 4'

'V 4' '4

a

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44 44 V ½

4;

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'


Appendix C

Figure C- 13. Laboratory Thermally Treated High Temperature Mill Annealed Sample Heat 96485-Carbide Etch

r-7-7-

Figure C- 14. Laboratory Thermally Treated High Temperature Mill Annealed Sample Heat 96485-Grain Boundary Etch

B- 68

Altran Corporation Technical Rep6'6 02807-TR-001 Revision 0

Appendix C

Figure -C- 15. 'As Received Seabrook Archive Sample TY9402 9993 B9579B-Carbide Etch

Figure C- 16. As Received Seabrook -Archive Sample TY9402 9993 B9579B-Grain Boundary Etch

B- 69


Appendix C

Figure C- 17. Heat 1374 Seabrook Archive, Longitudinal Section-Carbide Etch


Heat 1374 Seabrook Archive, Longitudinal Section-Grain

B - 70

__.

TehiclAltran Corporation Technical Repo't'02807-TR-001 Revision 0

Appendix C

I-~

~# +

Figure C- 19. Heat 1374 Seabrook Archive, Transverse Sebtion 1-Carbide Etch


Heat 1374 Seabrook Archive, Transverse Section _1-Grain

B- 71


Appendix C

Figure C- 21. Heat Etch

1374 Seabrook Archive, Transverse Section 2-Carbide


Heat 1374 Sdeabrook Archive, Transverse Section 2-Grain

B - 72

__j


Appendix C

C-aim

C- 23. 'Heat 1456 Seabrook Archive, Longitudinal' Section-Carbide


.Heat :1456, Seabrook Archive, Longitudinal Section-Grain

B - 73

Figure Etch


A p endix C

N -7W

~~7 7

Figure C- 25. Heat 1456 Seabrook Archive, Transverse Section-Carbide Etch


Heat 1456 Seabrook Archive, Transverse Section-Grain

B - 74

Altran Corporation Technical RepoWO28O7-TR-O91 Revision 0

Appendix C A � AAA

4 .A�; SA�A AAA . AAA,.

Aft if t�" #>** � -J

t ,�. � I A,

� k A� AA�,J,�A f

� -? "� �. .. '�. �

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A A ft ftA t�

AAj�A � - A� �

ftA

� A.ft�

+ �- � 't-� I '�

A �' �AA�#'

ft


Appendix C

Figure C- 29. Etch


Heat 1457 Seabrook Archive, Transverse Section-Carbide

Heat 1457 Seabrook Archive, Transverse Section-Grain

B - 76


Appendix D

APPENDIX D

Residual Stress'Analysis

Prepared by: Thomas Service, Ph.D., P.E. Checked by: Jose Magalhaes, Ph.D.

B- 77


Appendix D RESIDUAL STRESS ANALYSIS

Bending Stress-Diameter Change Relationship

A relationship was given in Reference 17 but no derivation of the relationship was provided and using the relationship on the experimental data from the Seabrook tubes resulted in unrealistic residual stresses. Therefore, the following is a derivation for the deflection of a split ring subject to a point load that can be used to estimate the resulting stress state, Reference 18.

Consider a thin split ring shown in Figure C-i with mean radius, R, thickness, h, and width b subject to a vertical load P at the slit opening. This load results in a bending moment, M, at any location B and is given by the expression:

d M = PR(cos(cL)-cos(e)) (1)

B where ot and 0 are as shown in Figure 1. For a

A small slit (x = 0 and the maximum moment occurs P_ at 0 = 1800 and the corresponding bending stress

C( cy at that location is given by:

P6 P R (1 + cos(a))

D bh2

12PR (2) bh2

Figure D-1. Split Ring

Through the use of Castigliano's theorem and the principle of virtual work the displacement, Y, at the slit opening can be shown to be (Reference 18):

S3tR 2 (T 37rl2PR 3

Eh Ebh3

(3)

where E is the elastic modulus. Similarly, it can be shown that the displacement at the ring diameter, d, is given by Yd:

B- 78


Appendix D

d (7t+4)R 2' 6(7c+4)PR 3 2Eh Ebh 3

(4)

Therefore, given Eq. (4) the maximum bending stress 1800 from the split is given by:

2YdEh (TI + ( 4) R25

where Yd is the diameter displacement after the split is made. Finally, from Eq. (1) the bending stress at 900 from the split is 1/½ that at 1800 from the split giving:

YdEh (7 4) R(6)

Assuming an elastic modulus, E, for Inconel 600 to be 31.1.x106 psi Eq. (6) can be simplified to:

4 .3 5 5 x106Ydh R 2 (7)

This approximates the stress at the location of the applied strain gauges on the split steam generator tubes. The stresses act in the hoop direction and vary with the bending moment around the ring.

Finite Element Analysis Technique

A more realistic assumption of the stress state in a split ring with residual stresses would be to assume a bending moment applied to the split end rather than a vertical applied load. Finite-Element Analysis (FEA)'models were created for both size tubes. The models consisted of ½ /symmetry 2-dimension models. Linear elastic material properties were assumed. A bending moment (a one pound load applied to the ID in the negative vertical direction and to the OD in the positive vertical direction) was applied to the free end of the tube and symmetry displacement conditions were applied to the other end. This results in a outward radial displacement corresponding to an increase in diameter. A moment in the opposite direction will result in a corresponding decrease in diameter. This also results in a uniform bending stress through the wall thickness of the tube. Assuming linear elastic behavior the outward radial displacement can be scaled up

B- 79


Appendix D to equal the measured increase in diameter and the resulting stresses can be scaled in proportion.

Figure C-2 shows the FEA element model and the input files are attached. The nomenclature in the figure refers to the geometry parameters used in the model generation. Figures C-3 and C-4 show the radial displacement plot and the hoop stress plot for the 11/16" diameter tube model.

Figure D-2. FEA Element Model

B- 80

-j

I ANTH

OD

SPLIT TUBE 11/16" DIA


Appendix DANSYS 5.6 SEP 11 2002 16:25:34 NODAL SOLUTION STEP-1 SUB -I TIME-i UY (AVG) PSYS-1 PowerGraphics EFACET-1 AVRES-Mat DMX -. 984E-04 SMN --. 355E-06 SMY -. 844E-04 1' F

-. 355E-06 .906E-05 .185E-04 .279E-04 .373E-04 .467E-04 .561E-04 .656E-04 .750E-04

.844E-04

Figure D-3. Radial Displacement Plot for 11/16" Diameter Tube. ANSYS 5.6 SEP 11 2002 16:26:43 NODAL SOLUTION STEP-I SUB -1 TIME-i SY (AVG) RSYS-I PowerGraphics EFACET-1 AVRES-Mat DMX -. 957E-04 SM -- 143.833 SMX -156.575

-143 833 -11D.454 -77.076

• -43.697 _10.318 23.06 56.439

F-189.817 I•12i.196

C-X 156.575


Figure D-4. Hoop Stress Contour Plot for 11/16" Diameter Tube.

The results of these analyses show that for a unit bending moment applied to the free end of the slit tube there is a radial displacement of 0.844x10 4 inches with an OD hoop stress of 144 psi for the 11/16" diameter tube and a radial displacement

B- 81


L


Appendix D of 0.876x10-' inches with a corresponding OD hoop stress of 115 psi for the 7/8" diameter tube. These results can be used to scale the displacement and resulting OD hoop stresses to the observed diameter changes through the relationships:

S= 1.706x10 6Yd forll/16"

T = 1.313x10 6 Yd

The following are the FEA diameter analyses.

(8)for 7 / 8"

input files used for the 11/16" diameter and 7/8"

1 1/1 6" Diameter Tube

/BATCH /COM,ANSYS RELEASE 5.7 /PREP7 /TITLE, SPLIT TUBE 11/16" DIA ET,1,PLANE42 MPEX,1,31.1E6 MP,NUXY,1,.327

OD=11/16 TH=0.04 K,1,0,0 I

CIRCLE,1,OD/2,,,180 CIRCLE,1,(od/2)-TH,,,180 LSTR,2,5 LSTR,3,6 LSTR,4,7

AL,1,6,3,5 AL,2,7,4,6

MSHKEY,1 ESIZE,0.01 AMESH,1,2 /SOLU ANTYPE,STATIC DL,7,,SYMM DK,7,,,,0,UX FK,2,FY,1 FK,5,FY,-1 SOLVE FINISH /POST1 SET,LAST PLDISP,1 ESEL,U,,,1 ESEL,U.,,2 ESEL,U,,,55

!PLANE42 !INCONEL 600

I DEFINE DIMENSIONS (INCHES)

'DEFINE KEYPOINTS

DEFINE LINES

!DEFINE AREAS

'MESH AREAS

! STATIC ANALYSIS

!SOLVE

B- 82


Appendix DESELU,,,56 ESEL,U,,,109 ESEL,U,,,1 10 ESEL,U,,,163 ESEL,U,,,164 RSYS,1 PLNSOL,S,Y,0,1 ALLSEL PLNSOL,U,Y,0,1 FINISH SAVE /EXIT

7/8" Diameter Tube

/BATCH ICOM,ANSYS RELEASE 5.7 IPREP7 /TITLE, SPLIT TUBE 7/8" DIA ET,1 ,PLANE42 MP,EX,1,31.1E6 MP,NUXY,1,.327

OD=7/8 TH=0.05 K,1,0,0

CIRCLE,1 ,OD12,,,180 CIRCLE,1,(od/2)-TH,,,180 LSTR,2,5 LSTR,3,6 LSTR,4,7 I

AL,1,6,3,5 AL,2,7,4,6

MSHKEY,1 ESIZE,0.01 AMESH,1,2 ISOLU ANTYPE,STATIC DL,7,,SYMM DK,7,,,,0,UX FK,2,FY,1 FK,5,FY,-1 SOLVE FINISH /POST1 SET,LAST PLDISP,1 RSYS,1 PLNSOL,S,Y,0,1 ALLSEL PLNSOL,U,Y,0,1 FINISH SAVE

1PLANE42 !INCONEL 600

! DEFINE DIMENSIONS (INCHES)

DEFINE KEYPOINTS

DEFINE LINES

!DEFINE AREAS

!MESH AREAS

1 STATIC ANALYSIS

! SOLVE

B- 83


Appendix E

APPENDIX E

XPS Analysis of Deposit Collected from Cracked Tube Sample

B- 84

.- a

S C C F- - ( ...... - r -- (*


Appendix E

A.dkmt I~m.hslwAnuCrT.U)1 t&l

IWO& t1fl~l3SStt *191W Wwr~, •WWI 7

A , iwu W ,P 'W.. ...A..AJJ"

Cm 04 zs I -, ==,. . .- 2.. S.......... f ........ • ..... ~... .... ...... ..:................imw" i...••---a,-• ......I

I............. ... .. .-. .-i--.-c $I •,h

II

Figure E- 1. Spectum at Position 1

I I ,B- 85


Appendix E

Momin wwwt A &M 1+1"1

t . i P b,. Ws'w• .. . .... 3.. ~ ~ ~ ~ "XVX OJVu 18W.~~Mk~

2111 41,71

CIB =I%

Mt d lt .

Siet• a .l&7. MOJ .. . .... . .. . .-. •

I 1 -- - - .- . . I1IJ I

I II i I I

.2 -- id..... .. .......

t I( I I I• I" ( f(

; 4 ,

FMt i .. .. ......... . ".\• - • - " - "' / : • • '

Figure E- 2. Spectrum at Position 2 Prior to Sputtering

B- 86

r' '" C U T .. . .... [... r - - ( • ( -- ( -° V- ( - ( - C T - - f- ("


Appendix E

MUM IA"'V mU

wm~~~~~~~~~

~~~~~ uwm ........ T......"

...... .........

,b 4f, O C7

I 75%

I -, - I- II ".,,,-.-,

............

•

I ,I ,

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, 4

4K ~ ~ ~ fl l9 rl m m If

,Figure E- 3. Spectrumn at Position 2 After Sputtering i2 Sec.

B- 87


Appendix E

A.*u~I C.AA)=Id~d~tTAUb "da~w L MAN8 •Im•,. aidltwtm• hmo WU I II V~ 41•lmuIu IIYuw j. lkwlJ~r•4 GMNN Al I VMn3, INAj A. 11 AAm~h ..V

. -..p.. AM& Vd'........ 112 461f cis IM To

I *i• 71I1k ] I Fcb 8A1k)

De M

S... .. ....... . ! I'j

Ak\

I I ...... ..... . . .. . ... . - . . . . I -I 4

A I •l I

b~flq InauyiA

Figure E- 4. Spectrum at Position 2 After Sputtering 30 Sec.

B- 88

L I I i I I ( I I I I I ( I I I

C+ .... r, I - - I-- - I -.. ( - -- ( -r --


Appendix E

t o " I. I - n o ,, V . & - W. S AR AM Ian. l ,A. •, 1Z~.EAa uaI F1 1,WIK• Y

WKWI

| t Py, H.4jn11?Jst I I momaiac4nsws

b 1 I V t . tClEi 2IU I

010 84.%1K ' "• €.I I I

I I 4. I 'I ! ! 1

. .. . ... .... . . . ........ ..

' I _i

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B- 89


Appendix E

fA n j LWfJ S 4i~* U. *

:7=V1ruwfp1g0.6. O"Mms

own tft ape

1P S 04V.

'tCie 3i" q

W203 .3Alb

,1L

md~~~~~~ 'n a n I) Un i

Fiur E- 6..'I t oito

B- 90

L_ ý I f I I I , I I , ( ý I

"m 94m

(� V ( (�i ( .... - ....- ( I--


Appendix E

%o Aft*Ww lowe.Y A**r b4o., i, lm- an.ait o

Figure E- 7. Spectrum for Position 4 Prior to Sputtering

B- 91

( - I- --I • , ( - (• - -- C C- (-- ( - ("-- - r---


Appendix E

Nmt ,%e aum ul3A.OeUtM I

Xneaw" CAVO I ROV u "•a,,Wz iw.,,,I

PI W" I a wu OsDpc$esiram am@ A

go. U4 t4b I

C1 SF3 &&S

aiaps18' 1a•

lilA ISA hO 1W I 410 4� 12


B - 92

C - , i -. ( - f~ -- - F--- I r� r� � r� r �


Appendix E


B- 93


Appendix E

The examination of samples using XPS was performed under contract by Analytical Answers and was witnessed by Altran's Ockert Van Der Schiff. These results are considered to be non safety related, because the vendor was not included on Altran's approved vendor list for Nuclear Grade Services. However, the instrument was calibrated and Analytical Answers maintains a documented calibration program. Since the results of this report do not directly qualify a design basis but rather offer insight to probable root cause, the use of this examination is appropriate.

B- 95


Appendix F

APPENDIX F

GC/MS And EDS Analysis of Tectyl 506G Preservative

B- 96

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Appendix F

File C. Ce\PCdfKM\1 \DATA\50U6GD Operator jh 4cquirnd I 1 Aug 102 6-42 pm using AcqY-ethod CCATING.M in3trument : 5971 - In Sample Niamef Trchryl 506G grease MiSc Info : 50-320 4, L0/!Mmn. 200 purge Vial Number: I

4300000

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S.......... . .. T~me--->. IB• 20.00 25 00 30 00 B5 00

B -100


Appendix F

Fi le C. XIp••I\Ar\•••5•3.

Operator [BSBI]jh Acquired 2 Aug 102 2.22 pm using AcqMetbOd cOATXN5.1

Instrument 5971 - In Saw.ple Vamp, Techtyl S06G grease Misc Info : 50-320 10 l/mln. 300 purge vial Numbber; 1

8500000 2

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I

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TLclooz I L i5•oo0oo I '' ICCOO j iiii I lilkil

B -101


Appendix F

File•: C:\ P H M \ A A S \5 6 3 operator : [BSBI]jh

Acquired 2 AUg 102 Z:22 pWr usinlg AcqMethod cOA7INGJ

Instrument• 5971 - In Sample Nmee: Tech.tyl 506o grease Misc Info : 50-320 0 10/min. 300 pirve Vial Number: I

6000000

50000600 550C0•00 :

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B -102

00

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Appendix F

File C: \HPLMM\t\DtTA\BSB\5 06G3 .D op,:8Laor ; IBSBljjh ACqtuired :2 A~ug 102 2:22 ptr usidng Acql~ethod CodAtITG.M

Instrlument s971 -n saimtpl, tiarne: Techtyl 506U grea0c!

Visc info :50-320 io1/min. 300 purge

Vial Number: 1

243000000

2200000

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B -104


Appendix F OW C7ecu SO 5PCOINV

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B -105

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Appendix G

APPENDIX G

References 1-8 and 15

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Appendix G

Reference 1

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Reference 2

B -109

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Reference 3

B-111


Appendix G

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Appendix G

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B-113

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Reference 5

To be presented later.

B -115


Appendix G

Reference 6

B -116


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B -117


Appendix G

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Reference 7

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Reference 8


B -121


Appendix G

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B -122

, 1

SG-SGDA-02-37,Rev 1 Appendix C

Appendix C

Summary of EC Signature of Degraded Tubes

--

I I 'C

C- I

SG-SGDA-02-37,Rev 1 Appendix C

Summary of EC Signature of Degraded Tubes

1. The low frequency (150 kHz-absolute) EC channel is sensitive to structures adjacent to the tubes, OD flaws and deposits, and to the conductivity of the tube material.

2. The conductivity of the tube material changes when the material is strained, e.g., for bending the u-bends; thus, it can be used to identify relative material condition. This technique was previously utilized to discriminate between thermally treated and non-thermally treated tubing at San Onofre in 1985.

3. The capability of the bobbin to detect a the difference between a strained and stress relieved section can be demonstrated by examining the normal trace for a tube that was thermally treated prior to bending the u-bend compared to a similar trace for a tube that was mill annealed, straightened and polished prior to bending the u-bend (see following figure). For the thermally treated tube (a), the tube is initially stress-free prior to bending the u-bends, and the bending process strains the u-bend region only. The EC signal is clearly offset in the U-bend region. For the Mill Annealed tube, the entire tube is initially strained due to the bending and polishing processes. Bending the u-bend strains the U-bend region, but not in an additive manner. The EC trace for the mill annealed tube (b) does not exhibit the offset in the U-bend region that the thermally treated tube exhibits since the entire length of the tube is strained. The key point is that the EC signal can discriminate between relative levels of strain along the length of a tube.

4. The EC signal (c) for a small radius (< row 11) thermally treated and stress relieved U-bend is essentially flat without exhibiting the u-bend offset. The manufacturing process renders the entire tube essentially stress free. A thermally treated tube is bent into a U-bend, and then the u-bend only is stress relieved after bending. Consequently, the straight legs remain stress free, and the u-bend is made stress free by the stress relief process. Since there is no significant difference in the material condition between the straight legs and the u-bend, the EC signal remains essentially flat from end to end. The beginning and end of the stress relief heated zone is identified by the two bumps at about the 1/3 distance points along the trace.

5. The Seabrook pulled tubes were shown by testing to exhibit significant residual stress along essentially the entire length of the pulled tube section (about 200 inches from the top of the tubesheet).

C- 2

i I

SG-SGDA-02-37,Rev I Appendix C

If it is assumed that a tube with elevated residual stress is bent init0 a u-bend and then'stress relieved as noted aboVe, on•l the u-bend Would be in an essentially stress-'free state. Thus, the condition of this low row tube 'would be opposite of the normal state of a longer row tube, for which the stress state of the material is higher in the u-bend Therefore, it would be expected that the EC signal, which discriminates between relative states of the materiAl, should exhibit the opposite effect of the nornni long row tube. The EC trace for such a short-row if-bend (d) conifirms this ihypothesis. Compare figure (d) with figure (a).

6. All 15 of the degraded Seabrook tubes exhibit the signal characteristic of figure (d). In addition,-4 other tibes in SG-D Withouit degradation also exhibit this characteristic. None of the tubes in any of the other three SGs exhibit this characteristic. None of the tubes in eight other

SGs in two other Model F plants exhibit this characteristic.

C- 3

SG-SGDA-02-37,Rev 1

I

(a) (b) (c) (d)

(a) Normal 150 kHz Eddy Current strip chart for a Row >10 thermally treated tube

(b) Normal 150 kHz Eddy Current strip chart for a Row >10 mill annealed tube

(c) Normal 150 kHz Eddy Current strip chart for a Row

SG-SGDA-02-37,Rev 1 Appendix D

Appendix D

Root Cause Hypotheses

THIS PAGE INTENTIONALLY

BLANK

(&Westinghouse

FPL Energy - Seabrook Sation P.O. Box 300 Seabrook, NH 03874

Attention: Mr. Robert White

Westinghouse Electric Company Nuclear Services Waltz Mill Service Center P.O. BOX 158 Madison, Pennsylvania 15663 USA

Direct tel: 724-722-5082 Direct fax: 724-722-5889

e-mail: lagallhoO~westinghouse corn

Your ref: Our ref: LTR-SGDA-02-361

Date November 6,2002

Subject: Errata for SG-SGDA-02-37, Revision 1; "Seabrook Tube Cracking Root Cause Evaluation Report"

The following is an errata summary for the subject report.

I. On page 22, under Hardness Testing, the reference to tube R5C63 should be R5C62 in two places. 2. On page 23, second paragraph, the reference to R5C63 should be R5C62. 3. On page 23, second paragraph, the sentence "Destructive examination showed a 0.2-inch long by 50% TWD

crack on one ... " should read "Destructive examination showed a 0.139-inch long by 35.6% TWD crack on one

4. On page 40, Table 4.1, the reference to heat no, "NX1460" should be "NX0146".

H.O. Lagally EDRE/SGD&A

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