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Steve McCracken
Senior Project Manager
Welding and Repair Technology Center
Electric Power Research Institute (EPRI)
1300 West WT Harris Blvd
Charlotte, NC 28262
USA
Abstract
It is well recognized and understood that
welding and fabrication techniques can
have an adverse affect as it relates to a
materials ability to withstand certain corrosion
mechanisms such as Stress Corrosion
Cracking (SCC). While construction Codes
such as ASME provide minimum requirements
for design and fabrication, environmentally
assisted degradation modes are not
addressed. EPRI has developed a tool recently
that provides members with guidance when
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Keywords
Stress Corrosion Cracking (SCC)
Electric Power Research Institute (EPRI)
welding
fabrication
influence
environment
microstructure
residual stress
mitigation
prevention
critical factors
surface stress
degradation
optimization
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Introduction
Stress Corrosion Cracking (SCC) is a
failure process that occurs because of the
simultaneous presence of tensile stress, an
environment, and a susceptible material. (See
Figure 1) Although manifest mostly in metals,
it can also occur in other engineering solids,
such as ceramics and polymers. Removal of or
changes in any one of these three factors will
often eliminate or reduce susceptibility to SCC
and therefore are obvious ways of controlling
SCC in practice, as is discussed later.
Stress Corrosion Cracking is a subcritical
crack growth phenomenon involving crack
initiation at selected sites, crack propagation,
and overload final fracture of the remaining
section. Failure by SCC is frequently
encountered in seemingly mild chemical
environments at tensile stresses well below the
yield strength of the metal. The failures often
take the form of fine cracks that penetrate
deeply into the metal, with little or no evidence
of corrosion on the nearby surface or distortion
of the surrounding structure. Therefore during
casual inspection no macroscopic evidence of
impending failure is seen.
Stress Corrosion Cracking continues to be a
cause of significant service failures. It is very
likely that for every alloy there is an environment
that will cause SCC, but, fortunately, most of
the ones of industrial significance are known
and avoidable. Changes in one or more of the
three necessary factors material, stress, and
environment can prevent or mitigate SCC,
either in design or after a problem has occurred
in the field. Material selection and specification
is the first line of defense. Lowering of the
applied stresses and elimination of residual
stresses can go a long way toward eliminating
problems too. Sometimes minor changes or
additions to the environment can help. Finally,
proper design and operation to avoid such things
as splash zones and wet/dry concentration also
are important. Stress-corrosion cracking is a
dangerous and severe degradation mechanism,
but with proper understanding and care,
failures can be avoided [1] .
Stress Corrosion Cracking, as it related to
metals utilized in the nuclear power industry,
has been an ongoing problem in both the
Boiling Water Reactor (BWR) and Pressurized
Water Reactor (PWR) fleet. Again, SCC is the
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A Growing Demand
Pressures to meet the growing demand for
reliable, around-the-clock electricity and to
reduce greenhouse gas emissions have revived
interest in nuclear power in the United States.
Several United States utilities are actively
planning to build advanced nuclear power
plants, and these plants could come on line by
decade end.
A key reason for the renewed interest in
construction of new nuclear plants is the existing
nuclear fleets strong record of safe and reliable
operation. In 2008, for example, United States
nuclear power plants achieved an average 91%
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assisted relaxation, welding conditions (such as
weld heat input, degree of constraint, welding
speed, part misalignment), or stress relief heat
treatment. Small changes in the residual stress
pattern can have a marked effect on the locus
of the crack depth/ time relationship.
Weld repair is also known to be of significance
(witness the implication of the role of weld
repairs on the incidence of IGSCC of nickel alloy
weldments in PWR primary piping systems).
Quantification of these factors will have a
marked effect on the accuracy of the prediction
of cracking under specific conjoint conditions
of material and environment. Finally, in this
category of residual stress analytical needs,
there is the question of predicting the adverse
effect of surface cold work in accelerating crack
behavior in the region up to 100 m below the
surface; such an effect has been known for
decades spanning the effect of surface grinding
on the IGSCC of BWR piping in the 1970s to
more recent examples in BWR core components.
Preliminary analysis indicates that such effects
may be predicted quantitatively merely by taking
into account the change in the residual stress
profile; in a proactive mitigation program, such
analyses should be reexamined to account for
other known changes, such as microstructural
changes (e.g., martensite formation) and
increases in yield stress due to bulk cold work,
which are known to independently alter the
cracking susceptibility [6] .
To ensure the reliability and longevity of
future nuclear plants, the Electric Power
Research Institute (EPRI) has worked with
utilities and equipment manufacturers to
develop welding and fabrication best practice
guidelines for new nuclear plant construction.
Such guidelines will equip the welding
community and utility engineers with practical
tools for identifying and implementing the most
efficient, timely, and cost-effective methods to
reduce the risk of degradation mechanisms
such as Stress Corrosion Cracking.
As an independent, nonprofit research
and development organization, EPRI does not
attempt to advocate or dictate any particular
process for reducing the risks inherent in
welding and fabrication practices. Rather, the
Welding and Fabrication Best Practices project
aims to provide multiple ways of achieving risk
reduction goals, so users can choose among
several options and select the most practical
or cost-effective approach in a given situation
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The project involved the following key steps:
Evaluate welding and fabrication practices in
operating plants to identify lessons learned
Identify the relative susceptibility of critical
welds in new nuclear plant designs to
known degradation mechanisms
Develop a systematic process that identifies
the key factors influencing the susceptibility of
high-risk welds to degradation mechanisms
Provide recommendations for reducing
the propensity of welds to degradation
mechanisms.
The 104 nuclear generating units now operating
in the United States offer a wealth of information
about welding and fabrication practices,
materials failure, and component degradation.
The lessons learned from the existing nuclear
fleet can help the industry identify practices
that contribute to failures, and apply improved
practices to increase the reliability and extend
the life of new nuclear plants.
In 2008, as a first step in the best practices
project, EPRI assembled a team of welding
and fabrication experts to survey welding and
fabrication practices in nuclear plants and in
other industries. The survey team reviewed
and documented practices that contributed,
or could contribute, to the premature failure of
critical components.
The researchers confirmed that most
material failures in operating plants occur in
or near welds. Root cause evaluations showed
that many of these failures resulted from less
than optimum welding, fabrication, or surfaceconditioning practices.
For example, residual stresses induced by
welding and uncontrolled grinding on reactor
coolant piping are known contributors to
Stress Corrosion Cracking. Weld repairs
in particular can induce high weld residual
stresses that increase susceptibility to
cracking mechanisms. However, optimized
welding and fabrication processes along with
properly controlled repair practices can reduce
susceptibility to known cracking mechanisms.
Operating experience from the current fleet
of nuclear power plants can be analyzed to
identify and manage materials performance
issues for advanced light water reactor designs
currently being considered for new nuclear
power plants. In many cases, evaluation of
operating plant issues and implementation of
mitigation or management technologies can
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Cold Work
Reduced toughness
Fabrication processes.
Restraint conditions and configurations.
Available mitigation technologies.
These influence tables can be used to quickly
identify where welding and fabrication effects
can be significant and what kinds of process
controls or mitigation techniques may be
applied.
These influence tables provide an upperlevel view of the relative influence of welding
and fabrication techniques on materials
degradation. Supporting these influence tables
are technical discussions and reference listings.
Influence tables are used to illustrate
the relative influence of welding and
fabrication factors on applicable degradation
mechanisms. Again, these tables have been
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for the four identified; sensitization, residual
stress, cold work, and reduced toughness.
This document is built around a set of
assumptions regarding welding and fabrication
processes and how these processes influence
materials degradation. While this project
is focused on advanced BWR and PWR
designs, the process is based on establishing
fundamental relationships between welding
and fabrication process and degradation
modes. As a result, the concepts used by this
process could be applied to other applications,
such as evaluation of repair processes for
operating reactor plants. The following key
assumptions provide the framework for this
critical factors document:
The project focuses on areas where
welding and fabrication factors can
influence the initiation of degradation
mechanisms. Therefore, the results address
only those degradation mechanisms
which are influenced by welding and
fabrication processes. The EPRI project
team determined that only SCC, Fatigue,
and IASCC are significantly influenced by
welding and fabrication processes. Other
degradation mechanisms were considered
by the project team, but determined not to
be significantly influenced by welding and
fabrication processes.
Degradation phenomena can be related to
underlying contributing conditions. These
degradation contributors are deleterious
material conditions that are promoted
or caused by a welding or fabrication
process and which increase a materials
susceptibility to a known degradation
mechanism. For example, cold work is
considered to be a substantial contributor
to SCC of stainless steel materials in the
BWR environment. The EPRI project team
identified four key degradation contributors;
sensitization, residual stresses, cold work,
and reduced toughness. Table 1 defines
these contributors.
Degradation phenomena can be related
to
underlying
initiating/accelerating
conditions. These degradation initiators/
accelerators are deleterious material
conditions that promote initiation or
which increase susceptibility to a known
degradation mechanism. For example,
crevice corrosion or surface connected weld
flaws are likely sites for (and can promote)
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Definition / Applicability
Crevice Corrosion
Micro Fissures
Welding Flaws
(surface connected)
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Figure 2. Example critical factor influence table cell, Figure 2-2 from the report.
Figure 3. Example influence table, low carbon stainless steel base metal HAZ fabrication influence for a BWR environment, Table 3.1-2 from the report.
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Figure 4. Example influence table, low carbon stainless steel base metal HAZ welding influence, Table 3.1-1 from the report.
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Conclusion
EPRI issued a document which provides a
tool to assist ANT members in developing,
reviewing, and implementing requirements for
fabrication and installation of new nuclear plant
components from a materials degradation
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Acknowledgments
The author would like to acknowledge the
support of the Advanced Nuclear Technology
(ANT) department within EPRI for the
development of Welding and Fabrication Critical
Factors for New Nuclear Power Plants, 1019209,
including J. Hamel and L. Midmore. The
principle investigators who were responsible for
preparation of the document: S. McCracken and
E. Willis, Welding and Repair Technology Center
(WRTC) of EPRI. And the EPRI contractors who
prepared, supported, and coordinated efforts to
create the document, including: W. Lunceford,
T. DeWees and D. Beal (Alliance Engineering);
D. Sandusky (XGEN Engineering), A. Giannuzzi
and R. Hermann (Hermann and Associates).
References
1. ASM Handbook Volume 11, Failure
Analysis and Prevention, ASM
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International, 2002.
2. Russell H. Jones, Stress Corrosion
Cracking, Materials Performance and
Evaluation.
3. Materials Handbook for Nuclear Plant
Pressure Boundary Applications
(2010), EPRI, Palo Alto, CA, 2010.
1022344.
4. Jeremy E. Scheel, Douglas J. Hornbach
and N. Jayaraman PhD, Preventing
Stress Corrosion Cracking of Nuclear
Weldments via Low Plasticity
Burnishing, Lambda Technologies.
5. Steve McCracken, Eric Willis and
Jeffery Hamel, Welding for New
Nuclear Power Plants: Building on
Experience, AWS Welding Journal,
May 2009.
6. NUREG/CR-6923, BLNNUREG-77111-2006, United States
Nuclear Regulatory Commission.
7. Welding and Fabrication Critical Factors
for New Nuclear Power Plants. EPRI,
Palo Alto, CA, 2009. 1019209.
n
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