PNNL-17698 Prepared for the U.S. Department of Energy Under Contract DE-AC05-76RL01830 Technical Letter Report Assessment of Ultrasonic Phased Array Testing for Cast Austenitic Stainless Steel Pressurizer Surge Line Piping Welds and Thick Section Primary System Cast Piping Welds JCN N6398, Task 2A AA Diaz KM Denslow AD Cinson M Morra SL Crawford MS Prowant SE Cumblidge MT Anderson July 2008 PNNL-17698 Technical Letter Report Assessment of Ultrasonic Phased Array Testing for Cast Austenitic Stainless Steel Pressurizer Surge Line Piping Welds and Thick Section Primary System Cast Piping Welds JCN N6398, Task 2A AA Diaz KM Denslow AD Cinson M Morra SL Crawford MS Prowant SE Cumblidge MT Anderson July 2008 Prepared for the U.S. Nuclear Regulatory Commission under the U.S. Department of Energy Contract DE-AC05-76RL01830 Pacific Northwest National Laboratory Richland, Washington 99352 Executive Summary Research is being conducted for the U.S. Nuclear Regulatory Commission (NRC) at the Pacific Northwest National Laboratory (PNNL) to assess the effectiveness and reliability of advanced nondestructive examination (NDE) methods for the inspection of light water reactor (LWR) components. The scope of this research encompasses primary system pressure boundary materials including cast austenitic stainless steels (CASS), dissimilar metal welds (DMWs), piping with corrosion-resistant cladding, weld overlays, and far-side examinations of austenitic piping welds. A primary objective of this work is to evaluate various NDE methods to assess their ability to detect, localize, and size cracks in coarse-grained steel components. This interim technical letter report (TLR) provides a synopsis of recent investigations at PNNL aimed at evaluating the capabilities of phased-array (PA) ultrasonic testing (UT) methods as applied to the inspection of CASS welds in nuclear reactor piping. A description of progress, recent developments and interim results are provided. The ongoing work presented in this report encompasses: • The use of phased-array ultrasonic methods and advanced probe designs to enhance detection and characterization of circumferentially oriented flaws in CASS piping specimens, and • Preliminary investigation of delta-techniques for flaw-depth sizing using tip-diffracted energy from thermal fatigue cracks in CASS components. While previous work primarily focused on thicker primary loop piping components with outer diameters (OD) ranging from 28 to 36 inches (71.12 to 91.44 cm), a variety of thinner cast piping welds exist in pressurized water reactors (PWRs) and an optimum frequency has yet to be established to examine these thin CASS components. While the sample specimens used in this study may not represent worst-case field conditions with regard to microstructures, weld root conditions, counterbore facets, surface roughness/geometry, etc., the sample specimens provide a range of grain structure conditions and are representative of components found in plants. The work reported here is focused toward evaluating UT inspection capabilities in CASS pressurizer surge line piping welds as well as continuing to assess improved PA probe designs on primary loop, CASS piping. PNNL was tasked with acquisition and procurement of materials, fabrication of flawed specimens, modeling and procurement of specialized phased-array probes, and conducting data acquisition and analysis on these specimens. The macrostructure of vintage pressurizer (PZR) surge line piping to determine grain size, shape, and orientation was performed in FY-2007. The material comprising these components include both centrifugally cast (pipe segments) and statically cast (elbows), with dimensions of approximately 12- to 14-inch (30.5 to 35.5 cm) OD and 1.3-inch (33-mm) wall thickness. This thickness is representative of typical PZR surge lines and various safe-ends in Combustion Engineering-designed plants. The ongoing activities reported here included PA-UT examinations on implanted/fabricated thermal fatigue cracks to evaluate detection, localization, and sizing performance as a function of frequency. In conjunction with these activities, PNNL employed custom- designed, low-frequency PA probes for continued evaluation of inspection performance on thicker-section CASS pipe segments, such as the Westinghouse Owner’s Group practice set of specimens. iii The work consisted of design and sound field modeling for various PA probes and probe configurations, development of specific PA focal laws, and use of a new data acquisition system for implementing examinations, including: • Low-frequency PA-UT examination of CASS PZR surge-line components – As a function of inspection frequency (1.5 MHz and 800 kHz) • Low-frequency PA-UT examination of thick-section, primary loop CASS piping components – New data acquired at 800 kHz, with an optimized PA system • Initial evaluation of the PA-delta technique for detecting tip-diffracted energy in CASS – Contrasting data from examinations in wrought stainless parent material with electrical discharge machining (EDM) notches at 10%, 20%, 30%, and 40% through-wall depth versus thermal fatigue crack tips in the CASS PZR surge-line specimen. Low-frequency phased-array and delta-technique data were acquired on specimens in the 12–14 inch (305–356 mm) diameter range using a manual-encoded scanner while data acquired on the larger diameter pipe sections (32 inch [813 mm]) were acquired with a flat track scanner. Data acquisition was accomplished using a prototype, low frequency DYNARAY® system for the 800-kHz probe that accommodates a maximum of 128 channels and runs beta-version Ultravision® 3.0B1 software. Its low- frequency pulsing will drive probes in the 0.2–20 MHz range. The 1.5-MHz data were acquired with a standard Tomoscan® III system, which has 32 channels in transmission and up to 64 channels in the receive mode, and runs Ultravision® 1.1Q5 software. This system was designed to drive probes in the 1–25 MHz range. For the delta-technique, the setup included configuring two 800-kHz phased array probes in an arrangement similar to that of a time-of-flight diffraction (TOFD) method, where transmit and receive transducers are oriented opposite and facing each other, with some separation distance. Results show that the thermal fatigue cracks in the PZR surge line specimen were detected from both the centrifugally cast stainless steel (CCSS) and the statically cast stainless steel (SCSS) sides of the weld at 800 kHz and at 1.5 MHz. Length sizing was better from the SCSS side, with a factor of two less error in the 800-kHz data and only slightly less error in the 1.5-MHz data as compared to the CCSS side. The crack depth sizing was similar from either the CCSS or the SCSS side at both frequencies with an approximate 3-mm error. Signal-to-noise values were in the 6.8 to 23 dB range showing generally good detection of both the crack corner signal and top of flaw signal. The 800-kHz probe with a wavelength in the material of approximately 7 mm (0.28 inch) performed well in comparison to the 1.5-MHz probe, which has a wavelength of 4 mm (0.16 inch). A very limited frequency analysis showed that the 800-kHz probe was actually operating at 730–780 kHz in the material due to microstructural “filtering” effects, and the 1.5-MHz probe was effectively operating at 1–1.2 MHz. With both probes approaching a similar frequency range of operation in this thinner material and for these four flaws, it is not surprising that the signal-to-noise ratio (SNR) and depth sizing results were similar. Length sizing differences were attributed to variations in the effective focal spot size of each phased-array beam. It should be noted that the microstructures for both the elbow and pipe sections of the PZR surge- line were comprised of finer grained microstructures where the average grain diameters were typically smaller than the wavelength of the ultrasonic energy used to inspect this specimen. The PZR surge-line specimen evaluated here represents only one type of microstructure, and additional work using the 800-kHz PA probe will be needed to more effectively assess detection and sizing capabilities for PZR iv surge-line components where the average grain diameters are much larger and where material homogeneity and grain anisotropy will provide more significant inspection challenges. The limited data comparison from the three WOG specimens evaluated here shows that the 800-kHz probe has the potential for inspecting some of the thicker section coarse-grained materials where attenuation and scattering allow for suitable penetration and resolution. However, it is anticipated that a lower frequency (500 kHz) will be required for many of the dimensionally larger microstructures exhibited (as an example) by the more challenging WOG practice set of specimens that were not evaluated here. The 800-kHz probe was pulsed at its optimum frequency, an 825-nanosecond pulse in this instance. In both the MPE-6 and OPE-5 specimens the center frequency of the flaw signal was greater on the SCSS side than the CCSS side showing that this CCSS material attenuates and scatters more than the SCSS material and also contributes to frequency “filtering” effects. The signal frequency dropped from 810 to 780 kHz in the MPE-6 specimen and from 780 to 680 kHz in the OPE-5 specimen. Again, these are preliminary findings are based on limited data. With regard to acquiring baseline data and evaluating the delta-technique for capturing tip-diffracted energy from crack tips in CASS, the 40%, 30%, and 20% through-wall EDM notches were detected and depth sized with a root mean square error (RMSE) of 2.29 mm (0.091 inch) and length sized with a RMSE of 7.62 mm (0.30 inch) in the wrought stainless steel specimens. The 10% through-wall EDM notch was not detected using the delta technique. This is attributed to the size of the wavelength relative to the size of the notch. Flaws 1, 2, and 4 on the PZR surge-line specimen were detected and depth sized with an RMSE of 3.44 mm (0.116 inch) and length sized with an RMSE of 24.0 mm (0.812 inch). Flaw 3 was not scanned using the delta-technique. The flaw sizing tended to be slightly larger than the true state. This “resolution” issue is attributed to the blooming effect that occurs from an incident sound field where the large 7.5-mm wavelength in the material relative to the flaw size results in a distortion of the scattered energy where the resultant image has an exaggerated size, and hence oversized dimension. The tip-diffraction signals observed from the EDM notches have low to moderate signal-to-noise ratios that range from 1.62 (4.2 dB) to 3.70 (11.4 dB). The certainty in reporting tip-diffraction signals comes from the significant backwall signal dropout that accompanies these low-amplitude responses, which range from 3.26 (10.3 dB) to 8.23 (18.3 dB). If the backwall dropout were not evident in the overall images, it would be more challenging to identify and discriminate the tip-diffracted energy from coherent energy scattered from the grain boundaries. As anticipated, the larger the EDM notch (in through-wall depth) the larger the SNR of the tip-diffracted signal for the case of the wrought stainless steel (WSS) coupons. The, tip-diffracted signals observed from the thermal fatigue cracks in the pressurizer surge line were similar to their EDM counterparts, with the exception of Flaw #2, with signal- to-noise ratios ranging from 2.6 (8.3 dB) to 12 (21.6 dB). The detection and localization of crack tip- diffracted signals is again only made possible from observing a significant backwall signal loss that accompanies these signals, which range from 7.98 (18.0 dB) to 12.0 (21.6 dB). The frequency and focusing/steering of the phased-array probes used in these delta-technique examinations were not designed to accommodate very thin sample materials. Nevertheless, the results obtained in this study demonstrate that there is potential for improving the delta technique by employing optimally designed probes and suitably chosen inspection frequencies. The degree of success, however, is contingent upon the appropriate phased-array probe designs, the amount of background scatter from the microstructure, and the ability to capture the backwall signal dropout as a fiduciary for locating/detecting v the areas where tip-diffracted energy should be seen. With suitable probes designed for thin materials and more evaluation of appropriate focal laws, the delta-technique approach may prove useful for crack depth determination. vi Acronyms and Abbreviations ASME American Society of Mechanical Engineers BMI bottom-mounted instrumentation BWR boiling water reactor CASS cast austenitic stainless steel CRDM control rod drive mechanism CCSS centrifugally cast stainless steel DMW dissimilar metal weld EDM electrical discharge machining EPRI Electric Power Research Institute ET eddy current testing ID inner diameter ISI inservice inspection LWR light water reactor NDE nondestructive examination NRC U.S. Nuclear Regulatory Commission OD outer diameter PA phased array PA-UT phased array ultrasonic testing PNNL Pacific Northwest National Laboratory PZR pressurizer PWR pressurized water reactor RMSE root mean square error RPV reactor pressure vessel SAFT synthetic aperture focusing technique SCSS statically cast stainless steel SG steam generator SNR signal-to-noise ratio TLR technical letter report TOFD time-of-flight diffraction TRL transmit-receive longitudinal UT ultrasonic testing WOG Westinghouse Owner’s Group WSS wrought stainless steel vii