Technical Basis for Weld Overlay Repair to Address Thermal Fatigue Cracking in Class 1, 2, and 3 Nuclear Reactor Piping
Authors: Marlette Stephen , McCracken Steven L. , Segletes David 
Published: November 2019

Since 1982 the nuclear industry has employed weld overlay repairs to address intergranular stress corrosion cracking (IGSCC) in boiling water reactors (BWR) and primary water stress corrosion cracking (PWSCC) in pressurized water reactors (PWR). The American Society of Mechanical Engineers (ASME) has created several documents to provide rules and guidelines for weld overlay repair of nuclear components that have experienced stress corrosion cracking (SCC). These documents include ASME Code Case N-504-4 and ASME Section XI, Nonmandatory Appendix Q which specifically address weld overlay repair of stainless steel components.

Recently, stainless steel components that have experienced thermal fatigue cracking at the inner diameter surfaces have been repaired with weld overlays using the methodology of Case N-504-4 and Appendix Q. This repair technique is appropriate to address thermal fatigue cracking because it provides structural reinforcement to the affected location and places the inside diameter (ID) surface into compression preventing, or significantly reducing, further flaw growth. However, the rules of Case N-504-4 and Appendix Q were not specifically written to address thermal fatigue cracking as the primary cause and may not adequately address design, analysis and examination requirements when thermal fatigue is the active mechanism because it is very different in nature than SCC. For example, SCC is driven by a combination of steady state operating stresses, residual stresses from welding and fabrication processes, and temperature, whereas thermal fatigue is driven by thermal stress cycles resulting from fluid thermal cycling or stratification. The source of the thermal events that result in cracking may not be as well understood or predicable as SCC degradation. Therefore, alternative rules are needed for repair of piping damaged by thermal fatigue.

This paper provides a technical basis for weld overlay repair of components that have experienced thermal fatigue cracking. It addresses design, analysis and examination requirements considering the nature of thermal fatigue in nuclear piping systems. The basis begins with the industry accepted rules of Case N-504-4 and Appendix Q and discusses the appropriate modifications needed to address thermal fatigue cracking. These modifications include removing restrictions such as the delta ferrite limit that is only applicable to address SCC, and enhancements to the examination requirements to ensure that the repaired location is adequately monitored throughout the remaining service life of the plant. The purpose of this paper is to outline the basis for a new ASME Code Case that will contain the appropriate rules for weld overlay repair of Class 1, 2 and 3 stainless steel piping degraded by thermal fatigue cracking. The new Case is currently in draft form and the requirements and specific details are still evolving. Thus, it is envisioned that this technical basis will be revised to include updates and revisions to the Case.