Improved criteria for the repair of fabrication flaws

Section III of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code for nuclear power plant components requires radiographic examinations (RT) of welds and requires repairs for RT indications that exceed code acceptable sizes. This paper describes research that has generated data on welding flaws, which indicated that the largest flaws occur in repaired welds. The fabrication flaws were detected in material removed from cancelled nuclear power plants using high sensitivity Nondestructive Examination (NDE) and validated by complementary NDE and destructive testing. Evidence suggests that repairs are often for small and benign RT indications at locations buried within the vessel or pipe wall. Probabilistic fracture mechanics calculations are described in this paper to predict the increases in vessel failure probabilities caused by the repair-induced flaws. Calculations address failures of embrittled vessel welds for pressurized thermal shock (PTS) transients. In this case small flaws, which are relatively common, can cause brittle fracture, such that the rarely encountered repair flaws of large sizes gave only modestly increased failure probabilities. The paper recommends the use of more discriminating ultrasonic examinations in place of RT examinations along with repair criteria based on a fitness-for-purpose approach that minimize the number of unjustified repairs. (author)