DCL-14-028, Areva Calculation No. 32-9219781-000, Diablo Canyon Unit 2 - Pressurizer Spray Nozzle Weld Overlay Structural Analysis.
Text
Attachments 2 through 7 to the Enclosure contain Proprietary Information
-Withhold Under 10 CFR 2.390 Attachment 13 PG&E Letter DCL-14-028 AREVA Calculation No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non-Proprietary Attachments 2 through 7 to the Enclosure contain Proprietary Information When separated from Attachments 2 through 7, this document is decontrolled.
Controlled Document 0402-01-FOl (Rev. 018, 01/30/2014)
A CALCULATION
SUMMARY
SHEET (CSS)AREVA Document No. 32 -9219781 -000 Safety Related: NYes El No Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Title Proprietary PURPOSE AND
SUMMARY
OF RESULTS: PURPOSE: The purpose of this calculation is to qualify the Diablo Canyon Unit 2 spray nozzle weld overlay design to the requirements specified in Reference
[1]. The analysis was performed using computer program ANSYS version 11.0 and StressRange version 2.0.
SUMMARY
OF RESULTS: The calculation demonstrates that the design of the Pressurizer spray nozzle weld overlay for Diablo Canyon Unit 2 meets the stress and fatigue requirements of the ASME Code (References
[14]).Based on the loads and cycles specified in References
[2] and [4], the conservative fatigue analysis indicates that Pressurizer spray nozzle weld overlay design has the maximum usage factor of [ ] for specified number of cycles per Reference
[2] compared to the ASME Code allowed maximum value of 1.0.This document is the Non-Proprietary document for 32-9049112-003.
Proprietary information is contained within bold square brackets "[ ]".THE DOCUMENT CONTAINS ASSUMPTIONS THAT SHALL BE THE FOLLOWING COMPUTER CODES HAVE BEEN USED IN THIS DOCUMENT:
VERIFIED PRIOR TO USE CODENVERSION/REV CODENERSION/REV ANSYS 11.0 (Rev. 000) i-Yes StressRange 2.0 (Rev. 000) Operating System: Not Known 0 No ANSYS 14.0 (Rev. 002) Operating System: Win 7 Page 1 of 110
.entre4l4 IDGGUMOnt A AREVA 0402-01-FOl (Rev. 018, 01/30/2014)
Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Review Method: [ Design Review (Detailed Check)"' Alternate Calculation Signature Block PIRIA Name and Title and PageslSections (printed or typed) Signature LPILR Date Prepared/RevlewedlApproved Samer H Mahmoud Principal Engineer P -z.- k-I All.Silvester J Noronha E nR Principal Engineer Jv Tim M Wiger A All.Engineering Manger Note: P/R/A designates Preparer (P), Reviewer (R), Approver (A);LP/LR designates Lead Preparer (LP), Lead Reviewer (LR)Project Manager Approval of Customer References (NIA If not applicable)
Name Title (printed or typed) (printed or typed) Signature Date NIA N/A N/A N/A Mentoring Information (not required per 0402-01)Name Title Mentor to: (printed or typed) (printed or typed) (P/R) Signature Date N/A N/A N/A N/A N/A Page la Controlled Document A 0402-01-FOl (Rev. 018, 01/30/2014)
AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Record of Revision Revision Pages/Sections/Paragraphs No. Changed Brief Description
/ Change Authorization 000 All Original Release.000 All Non-Proprietary document for 32-9049112-003
+ I+Page lb Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table of Contents Page SIGNATURE BLOCK ........................................................................................................
A RECORD OF REVISION ....................................................................................................
l B TABLE OF CONTENTS ........................................................................................................
2 LIST OF TABLES ..........................................................................................................................
4 LIST OF FIGURES ........................................................................................................................
7 IPURPOSE ..................................................................................................................................
8 1-1 INTRODUCTION
........................................................................................................
8 1.2 SCOPE ..................................................................................................................................
8 2 ANALYTICAL M ETHODOLOGY
........................................................................................
9 3 KEY ASSUM PTION .................................................................................................................
10 4 DESIGN INPUT ........................................................................................................................
10 4.1 GEOM ETRY ......................................................................................................................
10 5 FINITE ELEM ENT M ODEL ................................................................................................
11 5.1 M ATERIALS ......................................................................................................................
13 5.2 BOUNDARY CONDITION AND LOADS ..................................................................
17 5.2.1 Thermal Boundary.
......................................................................................................
17 5.2.2 Structural Boundary .................................................................................................
17 6 EXTERNAL LOADS ....................
I ...........................................................................................
20 6.1 APPLICABLE LOADS ................................................................................................
20 6.1.1 Nozzle Cross Sections --------.............................................
22 6.1.2 Stress Intensity Due To External Loads Calculation
..............................................
23 7 DESIGN CONDITION
..............................................................................................................
26 8 THERMAL ANALYSIS .................................................
29 9 STRUCTURAL ANALYSIS .................................................................................................
67 10 ASME CODE CRITERIA ...................................................................................................
73 10.1 ASM E Code Primary Stress Intensity (SI) Criteria ......................................................
73 10.2 ASM E Code Primary + Secondary Stress Intensity (SI) Criteria ................................
73 10.2.1 Path Stress Evaluation
...........................................................................................
74 10.2.2 Applicable Stress Intensity Due to External Loads .............................................
76 10.2.3 M aximum Primary + Secondary Stress Intensity Range .......................................
76 10.2.4 Primary + Secondary (P+Q) Stress Intensity Range Qualification (NB 3222.2) ..... 76 Page 2 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table of Contents (continued)
Page 10.2.5 Simplified Elastic-Plastic Analysis (NB-3228.5)
.................................................
78 10.2.6 Fatigue U sage Factor Calculation
..............................................................................
82 11 RESULTS
SUMMARY
/CONSLUSION
............................................................................
91 12 SOFTW ARE VERIFICATION
...........................................................................................
92 13 COM PUTER OUTPUT FILES ...........................................................................................
93 14 RE FERE N C E ...........................................................................................................................
97 APPENDIX A -Stresses used for Fracture Mechanics Analysis ...........................
98 APPENDIX B -Additional Stresses Used For Fracture Mechanics Analysis ..........................
100 Page 3 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary List of Tables Page Table 5-1 Table of M aterials ....................................................................................................
13 Table 5-2 Pressurizer Upper Head Material Properties
............................................................
14 Table 5-3 Spray Nozzle and Nozzle to Head Weld Material Properties
..................................
15 Table 5-4 Safe End M aterial Properties
....................................................................................
15 Table 5-5 Safe End to Nozzle Weld, Buttering Material Properties
.........................................
15 Table 5-6 Thermal Sleeve, Liner, Cladding and Safe End to Pipe Weld Material Properties
...... 16 Table 5-7 Pipe M aterial Properties
...........................................................................................
16 Table 5-8 Weld Overlay Material Properties
............................................................................
16 Table 6-1 External Loads ..............................................................................................................
20 Table 6-2 External Loads Summ ary ........................................................................................
21 Table 6-3 Nozzle Cross Sectional Characteristics
...................................................................
22 Table 6-4 Summary of the Stress Components
-OBE .............................................................
23 Table 6-5 Summary of the Stress Components
-Thermal Expansion
.........
...........
24 Table 6-6 Summary of the Stress Components
-OBE + Thermal Expansion
.............
24 Table 6-7 Stress Intensity Summary -OBE ..............................................................................
24 Table 6-8 Stress Intensity Summary -Thermal Expansion
....................................................
25 Table 6-9 Stress Intensity Summary -OBE + Thermal Expansion
........................................
25 T able 8-1 T ransients
.....................................................................................................................
29 Table 8-2 Summary of Analyzed Transients
...........................................................................
32 Table 8-3 Heat-up Early Spray Transient
................................................................................
33 Table 8-4 Heat-up Late Spray Transient
...................................................................................
34 Table 8-5 Cool-Dovn Early Spray with Temperature Drop of[ I ...................................
35 Table 8-6 Cool-Down Late Spray with Temperature Drop off .....................................
36 Table 8-7 Cool-Down Early Spray with Temperature Drop ot I ..................................
37 Table 8-8 Cool-Down Late Spray wi7th Temperature Drop off .................................
]........
38 Table 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients
............................
39 Table 8-10 Large Step Decrease in Load Transient
.................................................................
39 Table 8-11 Step Load Increase of 10% of Full Power Transient
.............................................
40 Table 8-12 Step Load Decrease of 10% of Full Power Transient
...........................................
41 Page 4 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary List of Tables (continued)
Page Table 8-13 Boron Concentration Equalization Transient
................................................---
.........
42 Table 8-14 Loss of Load Transient
...........................................................................................
42 Table 8-15 Loss of Power Transient
.............................................................................................
43 Table 8-16 Loss of Flow Transient
...........................................................................................
44 Table 8-17 Reactor Trip Transient
..........................................................................................
45 Table 8-18 Inadvertent Auxiliary Spray Transient
...................................................................
46 Table 8-19 Turbine Roll Test Transient
...................................................................................
46 Table 8-20 Nodes of Interest for Evaluation of Temperature Gradients
..................................
48 Table 8-21 Temperature Gradients of Interest ..........................................................................
48 Table 9-1 Time Points of Interest -HU-ES .............................................................................
67 Table 9-2 Time Points of Interest -HU-LS ..................................................................................
68 Table 9-3 Time Points of Interest -CD-E I ............................................
1.........................
68 Table 9-4 Time Points of Interest -CD-LE 1 ..............................
69 Table 9-5 Time Points of Interest -CD-ES[ ] ............................................
].........................
69 Table 9-6 Time Points of Interest -CD-L¶ ] .....................................................................
70 Table 9-7 Time Points of Interest -PLPU ................................................................................
70 Table 9-8 Time Points of Interest -LSL ..................................................................................
70 Table 9-9 Time Points of Interest -SLI ....................................................................................
71 Table 9-10 Time Points of Interest -LOL ................................................................................
71 Table 9-11 Time Points of Interest -SLD ................................................................................
71 Table 9-12 Time Points of Interest -BCE ................................................................................
71 Table 9-13 Time Points of Interest -LOP ................................................................................
71 Table 9-14 Time Points of Interest -LOF ................................................................................
72 Table 9-15 Time Points of Interest -RT ...........................................................................
..... 72 Table 9-16 Time Points of Interest -IA ..................................................................................
72 Table 9-17 Time Points of Interest -TRT ................................................................................
72 Table 10-1 Path Definition
............................................................................................................
74 Table 10-2 Summary of Maximum Primary + Secondary SI Ranges for M + B Stresses ..... 77 Table 10-3 Load Step Combinations for the Locations that Exceed 3Sn Limit ..........
[.............
78 Table 10-4 SI Ranges of Maximum Primary + Secondary Membrane Plus Bending Stress Excluding Thermal Bending Stresses .......................................................................................
79 Page 5 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary List of Tables (continued)
Page Table 10-5 General Membrane Stress for Critical Locations
...................................................
81 Table 10-6 Allowable Ranges of Thermal Stresses .................................................................
81 Table 10-7 Minimum Strength Ratio ......................................................................................
82 Table 10-8 Stress Category and FSRF in Fatigue Evaluation
.................................................
83 Table 10-9 Nozzle Usage Factor .............................................
84 Table 10-10 DM Weld Usage Factor .........................................................
85 Table 10-11 Safe End Usage Factor ........................................................................................
86 Table 10-12 E and Sm at Average Temperature for Table 10-11 Fatigue Evaluation
.............
87 Table 10-13 Safe End to Pipe Weld Usage Factor ..................................................................
88 Table 10-14 Weld Overlay Usage Factor ................................................................................
89 Table 10-15 Pipe U sage Factor ...............................................................................................
90 Table 11-1 Sum m ary of Results ...............................................................................................
91 Table 12-1 ANSYS Verification Files ....................................................................................
92 Table 12-2 StressRange Program v2.0 Verification Files .......................................................
92 Table 13-1 Computer Output and Input Files ........................................
..................................
93 Table A -I Path D escription
.....................................................................................................
98 Table 13-I A dditional Paths in Appendix B ...............................................................................
100 Table B-2 A ppendix B A N SY S files .........................................................................................
105 Page 6 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary List of Figures Page Figure 5-1 Expanded 2-D Axisymmetric Model of the Spray Nozzle with SWOL .................
11 Figure 5-2 Finite Element Model -Mesh ...............................................................................
12 Figure 5-3 Thermal Boundary Conditions
...............................................................................
18 Figure 5-4 Structural Boundary Conditions
............................................................................
19 Figure 6-1 Point of External Loads ..........................................................................................
21 Figure 7-1 Deformed Shape vs. Un-deformed Outline .............................................................
26 Figure 7-2 Stress Intensity Contours at Design Condition
......................................................
27 Figure 7-3 Contact Pressure at Design Condition
....................................................................
28 Figure 8-1 Heat-Up and Cool-Down Early and Late Transients with Spray Actuations
...... 31 Figure 8-2 Location Numbers for Evaluation of Temperature Gradients
.................................
49 Figure 8-3 Heat-Up Early Spray Transient
...............................................................................
50 Figure 8-4 Heat-Up Late Spray Transient
................................................................................
51 Figure 8-5 Cool-Downm Early Spray with Temperature Drop of[ " ....................
52 Figure 8-6 Cool-Down Late Spray with Temperature Drop off I .................
53 Figure 8-7 Cool-Down Early Spray with Temperature Drop of .1 ......................................
54 Figure 8-8 Cool-Down Late Spray with Temperature Drop of. ...................................
55 Figure 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients
.........................
56 Figure 8-10 Large Step Decrease in Load Transient
...............................................................
57 Figure 8-11 Step Load Increase of 10% of Full Power Transient
...........................................
58 Figure 8-12 Step Load Decrease of 10% of Full Power Transient
...........................................
59 Figure 8-13 Boron Concentration Equalization Transient
......................................................
60 Figure 8-14 Loss of Load Transient
..........................................................................................
61 Figure 8-15 Loss of Power Transient
......................................................................................
62 Figure 8-16 Loss of Flow Transient
..........................................................................................
63 Figure 8-17 Reactor Trip Transient
.........................................................................................
64 Figure 8-18 Inadvertent Auxiliary Spray Transient
..................................................................
65 Figure 8-19 Turbine Roll Test Transient
.................................................................................
66 Figure 10-1 Stress Paths through the Spray Nozzle Model ......................................................
75 Figure A-I Paths Defined for Fracture Mechanics Evaluation
.....................................
99 Figure B-1 Additional Paths For Fracture Mechanics
..............................................................
102 Figure B -2 Stress Plots during H U -ES .....................................................................................
103 Figure B-3 Stress Plots during CD -ES[ I ...............................................................................
104 Page 7 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 1 PURPOSE
1.1 INTRODUCTION
Primary water stress corrosion cracking (PWSCC) of Alloy 600/82/182 materials is a well documented phenomenon in the nuclear power industry.
High temperature components, such as those associated with the pressurizer, have risk for PWSCC. Pacific Gas and Electric (PG&E)plans to mitigate the Diablo Canyon Unit 2 pressurizer nozzle Alloy 82/182 dissimilar metal (DM) welds with full structural weld overlays (SWOL) during the spring 2008 2R14 refueling outage for Unit 2. The planned mitigation using SWOL is a preemptive measure to reduce susceptibility of the DM weld and the adjacent pipe to safe end welds to PWSCC.1.2 SCOPE The spray nozzle is located on the top of the pressurizer upper head. The nozzle provides a conduit for spray line sprays. The weld overlay is designed to cover both the Alloy 82/182 DM weld and the austenitic stainless weld between the nozzle safe end and the pipe. Application of weld overlays alters the local stress distribution.
A detailed finite element analysis (FEA) is therefore conducted to investigate stress conditions under various operational transients.
The results are summarized in this report to certify that criteria per ASME Code Section III for Class 1 components (Reference
[14]) are satisfied for the spray nozzle with weld overlays.The analysis is focused on the overlaid region for requirements on both stress distribution and fatigue failure criterion.
The main scope of the analysis includes the spray line piping, the stainless steel weld between the safe end and the piping, the safe end, the DM weld between the safe end and the nozzle, the spray nozzle, SWOL, and the pressurizer upper head. In addition, post-processing of thermal and structural results is performed to provide data for fracture analysis of the spray nozzle (see APPENDIX A).It should be noted that the original nozzle configuration without the Weld Overlay is not analyzed in this calculation.
The application of the SWOL will increase the secondary stress due to thermal gradients and added discontinuities at the SWOL to pipe, and SWOL to nozzle junctures.
The cumulative fatigue usage factors calculated in this document assume the spray nozzle SWOL has been in place since the plant conception.
Therefore, the usage factors calculated will be higher than the actual usage factors based on summing spray nozzle's usage prior to SWOL and usage with the SWOL.Page 8 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 2 ANALYTICAL METHODOLOGY The general methodology of model development and stress analysis consists of 1) Only the minimum SWOL will be modeled and evaluated.
Based on past experience, the stresses due to transients had minor differences between the maximum SWOL and minimum SWOL, and the minimum SWOL stresses due to external loads control over the maximum SWOL. Therefore, it is reasonable to evaluate the minimum SWOL only.2) Building a two-dimensional model of the spray nozzle weld overlay geometry.
The model incorporates the geometry (of the adjacent upper head, spray nozzle, spray nozzle safe end, welds, weld overlay and a part of the pipe welded to the spray nozzle safe end), appropriate materials, and boundary conditions.
The 2-D solid model is converted into a 2-D finite element model. There are two finite element models consisting of thermal and structural elements, respectively, to enable the thermal and structural analysis.3) Applying the design conditions of pressure and temperature (as temperature affects the material properties only) to the structural finite element model and obtaining the deformation and stresses in the model. The deformation field is used to verify the correct behavior of the model and correct modeling of boundary and load conditions.
- 4) Applying the thermal loads resulting from the plant operating transients (in-the form of transient temperatures and corresponding heat transfer coefficients versus time).Evaluating the results of the thermal analysis by examining the magnitude of temperature differences between key locations of the model. The time points of the maximum temperature gradient are those at which the maximum thermal stresses develop.5) Applying the corresponding pressure and thermal loads (nodal temperature) at each time point identified in step 3 and other time points of analytical interest on the structural finite element model and obtaining the stress results.6) Hand calculating the effects due to the nozzle external loads and adding the resulting stresses to the stress results due to the pressure and temperature effect.7) Comparing the results to the ASME Code for acceptability.
- 8) Documenting stresses and temperatures for the fracture mechanics analysis of the spray nozzle weld overlay design.Page 9 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 3 KEY ASSUMPTION There are no major assumptions for this calculation.
Minor assumptions are noted where applicable.
4 DESIGN INPUT 4.1 GEOMETRY Some of the major dimensions (References
[11] and [12]) are: pressurizer upper head inside radius to base metal pressurizer upper head base metal thickness pressurizer upper head cladding thickness spray nozzle ID (to base metal)spray nozzle OD (near head)spray nozzle OD (at nozzle to safe end weld)safe end length (between welds center lines)safe end ID (minimum)pipe ID pipe OD thermal sleeve OD thermal sleeve thickness minimum SWOL configuration:
total SWOL length SWOL thickness at nozzle SWOL thickness at pipe Page 10 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 5 FINITE ELEMENT MODEL The 2D axisymmetric finite element model is built based on the weld overlay minimum design.The model simulates, in two-dimensional space, the spray nozzle, safe end, weld overlay, part of the pipe, thermal sleeve and pressurizer upper head.The finite element analyses in this document are performed using ANSYS 11.0 (Reference
[ 13]).The model was developed in ANSYS WORKBENCH 11.0 and is shown in Figure 5-1. The element type chosen is the structural element PLANE183 (2-D 8-Node Structural Solid). This element is converted to the thermal element type PLANE77 (2-D 8-Node Thermal Solid) for the thermal analysis.
The contact surfaces between the liner and nozzle are modeled by using contact elements TARGE169 (2-D Target Segment) and CONTA172 (2-D 3-Node Surface-to-Surface Contact).The modeled portion of pressurizer head is sufficient for attenuation of the stresses and thermal gradients.
The thermal sleeve is attached by[ ]and it is non-structural weld (Reference
[1] and [12]). Therefore, the thermal sleeve is not included in structual rums.Nevertheless, the thermal sleeve is contained in the thermal runs for temperature distribution.
EnrwWSI-----d-Spray Nozzle Upper HaPip~e SSawe End/Ppe Weld"I Safe End 1-.-.--- Therm l e veW el Figure 5-1 Expanded 2-0 Axisymmetric Model of the Spray Nozzle with SWOL Page 11 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary r---I S* I I I I I* I I* S I* I I I
- I I
- I* I I I I I I I I* I I* B I* I I I I I I I* I I I I I I I* I I I* I I S I
- I I* I I I I I I I* .4 I* I I I* 5 I I* I I I* I I I I I I I I I I I I I I I* I I I* I I I* I* I* I I I* I I I* I I I I I I I I I I I I I* I* I* I* I I I Figure 5-2 Finite Element Model -Mesh Page 12 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 5.1 MATERIALS Reference
[1] and Reference
[2] provide the material designations of various components as listed below. Per reference
[1], the material properties for the structural analysis shall be in accordance with ASME Code 1965 Edition including Addenda through Summer 1966 (Reference
[6]) for existing material and ASMIE Code 2001 Edition including Addenda through 2003 (Reference
[5]) for weld filler material.
Since not all materials and material properties for existing components are provided by Reference
[6], later Addenda or Editions of the ASME Code (Reference
[7], [8] and [9]) were used to determine the remaining material properties.
Table 5-1 Table of Materials Location Material Pressurizer Upper Head Spray Nozzle Nozzle to Pressurizer Weld Safe End Safe End to Nozzle Weld Buttering Weld Liner to Safe End Weld 1 Thermal Sleeve to Safe End Weld Thermal Sleeve Uner Cladding 2 Safe End to Pipe Weld 2 Liner to Cladding Weld 3 Pipe Weld Overlay Reference
[1], par. 4.2.2 specifies material[
]for the "Barrier Layer." This very thin laye4 ] Reference
[11]) is not modeled in detail in this analysis and is covered by the weld overlay filler material.
The effect on the results is negligible.
1 Material for these welds is specified in Reference
[3].2 Reference
[I], par. 4.1.5 and 4.1.7 specify that the claddin material properties should be equivalent tc[ I weld filler material and the existing pipe to safe end weld i u ]istenitic stainless steel. This material is used for welding components with similar chemical composition such 4 -Jnaterial.
Therefore material[ Is considered representative of this weld material.3 The liner to cladding material is specified a as )naterial, and materia[Per [3]. This material has similar chemical composition such Is considered representative of this weld material.Page 13 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary The analysis herein uses the thermal properties
-mean coefficient of thermal expansion (ca), specific heat (C), thermal conductivity (k) and the mechanical properties
-modulus of elasticity (E), Poisson's ratio (p), density (p). The pertinent properties (thermal & structural) for these materials are listed in the following tables. The units of the properties are: Young's Modulus Poisson's Ratio Density E [106 psi]p [unitless]
p [lb/in 3]Coefficient of Thermal Expansion cc [10-6 in/in-°F]Thermal Conductivity k [Btu/hr-in-°F]
Specific Heat C [Btu/lb-PF]
Design Stress Intensity Sm [ksi]Yield Strength Sy [ksi]Tensile Strength Su [ksi](C is a calculated value: C = k/(p
- thermal diffusivity) where thermal diffusivity is taken from the same source as "V)Table 5-2 Pressurizer Upper Head Material Properties I II IReference1
[6]1 typical [10]1 [6] 1 [9] 1 calculated
[8] [8] =8]Page 14 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 5-3 Spray Nozzle and Nozzle to Head Weld Material Properties Temp E p p a k C Sm Sy Su Reference
[6] typical [10] [6] t9] calculated
[7] [1] [7]Table 5-4 Safe End Material Properties TempI E Im Ip Ia Ik I C Sm I Sy I Su I Reference 1 [6] 1 typical I [10] I [6] I [9] I calculated 1 [6] I [6] I [6] I -Table 5-5 Safe End to Nozzle Weld, Buttering, Liner/Safe End Weld and Thermal Sleeve to Safe End Weld Material Properties I Temp I E pI p aI k I C Sm I Sy I Su I--I Reference 1 [6] I typical 1 [10] I [6] I [9] I calculated I M I M I [7] I Page 15 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 5-6 Thermal Sleeve, Liner, Cladding and Safe End to Pipe Weld Material Properties
-Temp E p p a k C Sm Reference
[6] typical [10] [6] 1 [9] calculated
[6] [61 61]Table 5-7 Pipe Material Properties Temp E p p a k n I C Sm I SY I Su-I ReferenceI
[6] Itypical I [10] I [6] I [9] I calculated 1 [6] I [6] I [6]I -1 Table 5-8 Weld Overlay Material Properties rI Temp E p p a k C Sm Sy Su _L- I Reference l [51 I typical I [101 I [5] I [5] I calculated I [5] I [5] I [5] I -Page 16 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 5.2 BOUNDARY CONDITION AND LOADS 5.2.1 Thermal Boundary During operation without spray events, the inside surface of the upper head, the inside bore surfaces of the spray nozzle, pipe, safe end weld, a part of the safe end, and the inside & outside surfaces of the thermal sleeve are in contact with the pressurizer fluid at steam temperature.
During spray events, the inside surfaces of the pipe, safe end weld, a part of the safe end, and thermal sleeve are in contact with the spray fluid at spray temperature.
An appropriate heat transfer coefficient (HTC) and bulk temperature versus time are applied on these surfaces, which are in contact with the pressurizer steam or spray fluid (Figure 5-3).Thermal coupling was applied on the surfaces between the safe end and thermal sleeve in the thermal sleeve weld vicinity and between the liner and nozzle (Figure 5-3).The outside surfaces of the upper head, spray nozzle, pipe and weld overlay are exposed to the ambient temperature in conjunction with a small HTC. Ambient temperature of Is used for all time points in the thermal analysis.
The spray nozzle is assumed to be insulated.
A very small HTC olE Is used.5.2.2 Structural Boundary Pressurizer pressure is applied to all inside surfaces which are in contact with steam or fluid. The exteriors of the pressurizer upper head are not loaded by pressure.
The upper end of the pipe has an end cap pressure p* applied to represent the hydrost end load from the piping c re."~d 2 I Pressure p* is calculated as follows: p* -,. _,d Where p is internal pressure, d is inside diameter of the pipe and D is outside diameter of the pipe.The displacements of the pressurizer upper head in the circumferential direction are set to be zero (see Figure 5-4).Page 17 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 5-3 Thermal Boundary Conditions Page 18 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 5-4 Structural Boundary Conditions Page 19 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 6 EXTERNAL LOADS 6.1 APPLICABLE LOADS Per Reference
[1], the external forces and moments acting on the spray nozzle safe end weld location (Figure 6-1) are listed in Table 6-1. These loads are defined in the local coordinate system with the "'x" axis oriented along the nozzle axis of symmetry in the nozzle to pipe direction per Reference
[3]. The "y" and "z" axes are the horizontal components.
Table 6-1 External Loads The stresses due to OBE and thermal loads are evaluated using hand calculation and they are added to the ANSYS results where appropriate for ASME evaluation in Section 10.Per Reference
[2], the OBE loads hav4[ " ]-ycles[-
--. ]The thermal expansion loads are considered during the maximum temperature variance in the pressurizer, which corresponds to the heatup-cooldown transient.
Much smaller temperature variance occurs during other transients and the loads during these variations are much smaller.Therefore, the thermal expansion is assumed to have same number of cycles as the heatup-cooldown transients fof ]The following Table 6-2 lists the loads used for the SI calculation for the evaluated locations.
The total shear force (Fs) and total bending moment (Mb) by combined as the SRSS method.'Pressure load is not used since it is accounted in stress analysis model.2 The DW, SSE and Pipe Rupture loads are not evaluate in this document, since the document qualifies only Primary plus Secondary stress intensity range (see Section 10.1 ); these loads are listed for information purpose only. Dead weight loads act at all time points of all transients, and therefore do not contribute to the SI Ranges.Page 20 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 6-2 External Loads Summary ITotal ITotal Shear Shear Torsion Bending Bending Shear Bending External Axial Fx Fy Fz Mx My Mz Fs h Mb Load [kips] [kips] [kips] [in-kips]
[in-kips]
[in-kips]
[kips] [in-kips]OBE TH OBE +TH Figure 6-1 Point of External Loads Note: The path's numbering starts from the number "2". The pathline "'Pathl" is not defined.Page 21 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 6.1.1 Nozzle Cross Sections The cross sectional characteristics are calculated for the path locations as shown in Figure 6-1.These paths correspondent with paths defined in Section 10.2.1 for the stress linearization.
The nozzle geometric dimensions are specified in References
[11] and [12] and some dimensions are also taken directly from the FE model.Table 6-3 Nozzle Cross Sectional Characteristics Section Modulus Pathline r [in] R [in] L [in] I [in'] A [in2 S [in)]Sinside Soutlsi Path2 Path3 Path4 Path5 Path6 Path7 Path8r Path9'Path 10 Where: R -outside radius (for the nozzle, WOL or pipe)r -inside radius (for the nozzle, WOL or pipe)L -moment arm I )r(R4 r 4)A=,10R2 ~r2)-moment of inertia-cross-section area at an appropriate location S.=,o =/IR, Sbj, = I/r -section modulus The radii (R, r) are taken at the inside and outside nodes of the paths. Since some of the paths are in slope, the longer moment arm (L) between the safe end weld-root and the further node of the path is conservatively taken into calculation.
For paths Path8, Path9 and PathlO, the stress intensity due to axial bending stress from external shear forces would reduce the stress intensity due to transient loads. Therefore, the moment arms for these locations are conservatively reduced to zero.Page 22 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 6.1.2 Stress Intensity Due To External Loads Calculation The stress components and membrane + bending stress intensities due to external loads and loads combination for inside and outside nodes are calculated based on following formulas and they are listed in Table 6-4 through Table 6-9. The resulting stress intensities will be used along with the transient SI Ranges in the ASME Code Primary plus Secondary Membrane +Bending SI Range qualification in Section 10.2 a.x =FJ/A a- =Mb /S , =Fs L(/. S TT = Ms /(2.- S)axial membrane stress due to an external axial force Fx axial bending stress due to an external moment Mb axial bending stress due to an external shear force Fs shear stress due to an external torsion Mx rVs= Fs 1A shear stress due to an external shear force Fs arx = a. + a + al sum of axial stresses r = Ts + 5T sum of shear stresses a, = ua,' -+4- r 2 membrane + bending stress intensity Table 6-4 Summary of the Stress Components
-OBE Page 23 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 6-5 Summary of the Stress Components
-Thermal Expansion Table 6-6 Summary of the Stress Components
-OBE + Thermal Expansion Shear Inside Outside Pathline oaX[kksi] b [ksiJ obs [ksi] TT [ksi] ob [ksi] Oh, [ksi] TT [ksi]_Path2 Path3 Path4 Path5 Path6 Path7 Path8 Path9 Path 10 Table 6-7 Stress Intensity Summary -OBE Pathfine Inside Outside__-_O'x [ksi] T [ksi] 0 1NT [ksi] 0 x [ksi] r [ksi Or [ksi]Path2 Path3 Path4 Path5 Path6 Path7 Path8 Path9 Path10 Page 24 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 6-8 Stress Intensity Summary -Thermal Expansion Pathine Inside Outside-- 0 x [1ksi] T [ksi] ONT [ksi Ox [ksiJ T [ksel Ow [ksi]Path2 3.923 1.096 4.494 6.193 1.416 6.810 Path3 3.869 1.254 4.611 5.900 1.597 6.709 Path4 3.361 1.254 4.194 5.111 1.597 6.027 Path5 3.551 1.386 4.505 5.451 1.785 6.516 Path6 3.396 1.361 4.352 5.451 1.804 6.537 Path7 3.533 1.511 4.649 5.747 2.034 7.041 Path8 4.967 2.347 6.834 7.094 2.941 9.215 Path9 9.938 4.412 13.290 12.741 5.195 16.440 PathlI 13.190 5.747 17.495 16.213 6.591 20.896 Table 6-9 Stress Intensity Summary -OBE + Thermal Expansion Pathline Inside Outside r" Ox [ksi] T [ksi] Onrr [ksq 0 x [ksij T [ksi] vwwr [ksi]Path2 Path3 Path4 Path5 Path6 Path7 Path8 Path9 Path 10 Page 25 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 7 DESIGN CONDITION It is assumed that the pressurizer assembly was designed to satisfy the ASME Code Criteria at a pressure o[ )3nd temperature of[ ]These design conditions were simulated by setting a unitorm temperature of ]hroughout the model (this temperature is only used to define material properties and not thermal expansion) and a uniform pressure o( ]The pressure loading is described in detail in Section 5.2.2 .The ANSYS computer output is documented in file "min DC.out".Stress analysis of the model under design pressure case served two important purposes.
It provides a basis for verification of the correct behavior of the model as well as boundary conditions.
Attenuation of stress effects at regions distant from the nozzle is also verified.Figure 7-1 shows the deformed shape of the model under the design pressure along with the outline of the un-deformed shape. The stress intensity contours developed in the model under design pressure is shown in Figure 7-2. The contact pressure between the liner and nozzle is shown on Figure 7-3.Figure 7-1 Deformed Shape vs. Un-deformed Outline Page 26 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 7-2 Stress Intensity Contours at Design Condition Page 27 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 7-3 Contact Pressure at Design Condition Page 28 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 8 THERMAL ANALYSIS The operating thermal loads are defined by the thermal transient conditions as contained in Reference
[2] and Reference
[4]. The applicable transient data from references are shown in Table 8-1.Table 8-1 Transients ASME Code Transient Name Cycles Spray Actuation' Condition
_Heat Up Cool Down Unit Loading at 5% of Full Power/Min 0 Unit Unloading at 5% of Z-- Full Power/Min Large Step Decrease in Load With Steam Dump Step Load Increase of 10% of Full Power 0 Step Load Decrease of 10% of Full Power Steady State Fluctuation Boron Concentration Equalization Page 29 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-1 Transients (Continuing)
ASME Code Condition Transient Name Cycles Spray Actuation 0._0)Q, co During the heat-up and cool-down transients, the timing for th{ 1pray actuations at a AT of[ Is arbitrary.
Therefore, the transients are developed as "Early Spray" (ES) and "Late Spray" (LS) to investigate all limiting cases of spray occurrences.
For cool-down transient, there are the additiona[
1pray actuations with AT of )when the pressurizer pressure is below[ jrherefore, the cool-down is developed as early spray and late spray with temperature drop olE 'jo investigate all limiting cases of spray occurrences.
The applicable heat-up and cool-down transients are shown on Figure 8-1.Unit Loading and Unit Unloading transient.
Each transient consists[the composite transient consistf (PLPU) are combined together to form one composite]pray actuations with drop AT ofl )nd therefore]pray actuations.
The spray actuation during Unit Loading/Unloding, Large Step Degrease in Load, Step Load Increase/Decrease of 10% full power and Loss of Load transients starts from the same temperature of[ ]and the same pressure oIf ]with the same temperature rate and sam{[ jecond duration.
Therefore, this spray actuation transient is developed only one time for PLPU and the stresses resulting from this transient bound all spray actuations of rest transients.
The total number of cycles of spray actuations is sum of cycles for PLPU and all bounded transients.
Therefore, the transient PLPU is considered to occuf limes.' Per NB-3226(e), the first[ 1hydrotest cycles need no be considered for the fatigue evaluation.
Page 30 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary According to Reference
[4], there is small temperature fluctuation during the Steady State Fluctuation transient for the spray nozzle. Per Reference
[2], the pressure fluctuation i{These small variations of temperature and pressure create negligible stresses compared to the other transients.
Therefore, the steady state fluctuation transient is not contained in spray nozzle analysis.The leak test comes on at steady state heat-up condition with pressure spikes to[ 2485 momentarily.
Therefore, this transient is modeled by adding a timepoint with pressure o[.- [ ]during heat-up steady state condition.
n~io]I-Figure 8-1 Heat-Up and Cool-Down Early and Late Transients with Spray Actuations Page 31 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-2 Summary of Analyzed Transients Designation Transient Name Design Cycles HU-ES Heat-up Early Spray HU-LS Heat-up Late Spray + Leak Test at CD-ES320 Cool-down Early Spray with tw4 )pray actuations.
CD-LS-320 Cool-down Late Spray with twc[ pray actuations.
CD-ES405 Cool-down Early Spray with 4 land a[ spray actuations.
CD-LS405 Cool-down Late Spray with a AT of 320OF and a AT of 405°F spray actuations PLPU Plant Loading and Plant Unloading LSL Large Step Decrease in Load SLI Step Load Increase SLD Step Load Decrease BCE Boron Concentration Equalization LOL Loss of Load LOP Loss of Power LOF Loss of Flow RT Reactor Trip IA Inadvertent Auxiliary Spray TRT Turbine Roll Test The boundary conditions for thermal analysis are described in detail in Section 5.2.1 .The thermal loading was applied to the finite element model in the form of temperatures and HTC versus time on the appropriate surfaces (see Section 5.2.1 , Figure 5-3). The following transient tables (Table 8-3 through Table 8-19) are based on the data from Reference
[4] and list the pressure, HTC and temperature values for the time points used in the thermal analysis.
Some time-points are omitted from transients that are listed in Reference
[4] to simplify the transient definition.
The differences between original transients and modified transients are negligible, and they have negligible effect to the results.1Number of spray occurrences is described in detail in Table 8-1.2 Leak test witt( ldesign cycles is applied at the end of the heat-up transient at steady state condition.
Therefore, the leak test is considered as internal cycle of the heat-up transient.
3 PLPU transient bounds the spray actuations of the others transients as described in text in this section and it results[ ,])umber of cycles for PLPU.Page 32 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-3 Heat-up Early Spray Transient Page 33 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-4 Heat-up Late Spray Transient Page 34 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-5 Cool-Down Early Spray with Temperature Drop of ]Page 35 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-6 Cool-Down Late Spray with Temperature Drop of I Page 36 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-7 Cool-Down Early Spray with Temperature Drop of ]Page 37 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-8 Cool-Down Late Spray with Temperature Drop o[ ]Page 38 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients ITime TSPR TPR PPZR HTC HC HTC[hr] [0 F] [rF] [psia] Nozzle Annulus Head Table 8-10 Large Step Decrease in Load Transient]Time P I TTPZR IPPZR HTC HTC HTC[hr] TSF] [OF) [psia] Nozzle Annulus Head Page 39 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-11 Step Load Increase of 10% of Full Power Transient Ti[me TSPR [FTPZR siPPZR NzHTC AnHTCl HTC[ hr] [OF] [OF] [psia] Nozzle Annulus Head Page 40 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-12 Step Load Decrease of 10% of Full Power Transient Time PR TPZR PPZR HTC HTC HTC[hr] [0 F] [0 F] [psia] Nozzle Annulus Head Page 41 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-13 Boron Concentration Equalization Transient
'I rTime TSPR[F TPZR [PPZR HNTC HTC HTC[h] [0[OF [psia] Nozzle Annulus Head Table 8-14 Loss of Load Transient I Time TSPR TPZR PPZR HTC HTC HTC[hr] [OF] [psia] Nozzle Annulus Head' The pressure variation of -]md temperature variation o( irom Table 13 of Reference
[4] is neglected-Page 42 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-15 Loss of Power Transient hTire TSPR TPZR pPZR HTC HTC HTC[hr] [OF] [psia] Nozzle Annulus Head Page 43 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-16 Loss of Flow Transient I hlime TSPR TPZR PPZR HTC HTC HTC-[hr] [OF] [OF] [psia] Nozzle Annulus Head Page 44 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-17 Reactor Trip Transient 1 I Time TSPR TPZR PPZR HTC HTC HTC[hr] [°F] [OF] [psia] Nozzle Annulus Head All three reactor trip transients defined in Reference
[4] (Table 23 through Table 25) are identical for the spray nozzle.Page 45 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-18 Inadvertent Auxiliary Spray Transient Time TSPR TPZR PPZR HTC HTC HeTC I [hr] [OF] ["F] [psia] Nozzle Annulus Head7 Table 8-19 Turbine Roll Test Transient rTime TSPR [TPZR PPZR I zHTC AuHTC HTC[hr] [OF] [OF] [psia] Nozzle Annulus Head Page 46 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary The detailed thermal loading due to these transients were applied to the thermal finite element model in the form of fluid and steam temperatures and HTC versus time.The computer input files containing definition of these transients are: HU-ES_tr.inp HU-LStr.inp CD-Ef ,1tr.inp CD-EL -Itr.inp CD-LI ]ltr.inP CD-Lj ]tr.inp PLPUtr.inp BCEtr.inp IAtr.inp LOF_tr.inp LOL-tr.mip LOP tr.inp LSL-tr.inp SLD-tr.inp SLItr.inp RT_tr.inp TRT tr.mip The computer output files for the thermal analyses of the transients are: min HU-ES th.out min HU-LS th.out minCD-El lth.out minCD-El lth.out minCD-L. Ith.out min CD-L4 Ith.out mminPLPU th.out minBCE th.out ainIA th.out mrinLOF th.out min LOL th.out min LOP th.out main LSL th.out min SLD th.out min SLI th.out minnRT th.out min TRT th.out The results of the thermal analyses are evaluated by examining the magnitude of temperature differences between key locations of the model (Figure 8-2). The computer input file"min _dT.mac" contains definitions of the node numbers for temperature (Table 8-20) and temperature gradients calculation (Table 8-21). The time points of the maximum temperature gradients are those at which the maximum thermal stresses develop. The temperature and temperature gradients are plotted in Figure 8-3 through Figure 8-19. These figures are used only to show the trend. Specific data are taken from the computer output files.The computer output files that provide the temperatures at the selected locations are: mn RHU-ES dt.out mm RHU-LS dt.out minCD-F_4 ldt.out mmCD-El Idt.out mmCD-LI ldt.out minPLPU dt.out min BCE dt.out min IA dt.out min LOF dt.out minLOL dt.out min LOP dt.out min LSL dt.out minSLD dt.out min SLI dt.out min RT dt.out mmn TRT-dt.out mmCD-Li ldt.out Page 47 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 8-20 Nodes of Interest for Evaluation of Temperature Gradients Location Node Number Description 2 1660 Pipe 3 262 Weld Overlay 4 1782 Pipe ID 5 1270 Weld Overlay OD at top of the WOL 6 1348 Piping Weld ID at SS weld location 7 1143 Weld Overlay OD near SS weld location 8 1516 Liner to Safe End Weld ID 9 1222 Weld Overlay OD near DM weld 10 7989 Liner ID 11 1289 Weld Overlay OD at bottom of WOL 12 1371 Nozzle/Head Interior Comer (base metal)13 1421 Nozzle/Head Exterior Comer Table 8-21 Temperature Gradients of Interest Gradient Gradient Gradent GradentGradient Description Designation Location 21 2 to 3 Pipe to Weld Overlay 22 4 to 5 Pipe ID to Weld Overlay OD 23 6 to 7 Piping Weld ID to Weld Overlay OD 24 8 to 9 Liner to Safe End Weld ID to Weld Overlay OD 25 10 to 11 Liner ID to Weld Overlay OD 26 12 to 13 Head ID (base metal) to Head OD Page 48 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-2 Location Numbers for Evaluation of Temperature Gradients Page 49 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-3 Heat-Up Early Spray Transient Page 50 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-4 Heat-Up Late Spray Transient Page 51 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-5 Cool-Down Early Spray with Temperature Drop o(I Page 52 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary K Figure 8-6 Cool-Down Late Spray with Temperature Drop o(I Page 53 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-7 Cool-Down Early Spray with Temperature Drop o[I Page 54 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-8 Cool-Down Late Spray with Temperature Drop of I Page 55 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients Page 56 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-10 Large Step Decrease in Load Transient Page 57 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-11 Step Load Increase of 10% of Full Power Transient Page 58 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-12 Step Load Decrease of 10% of Full Power Transient Page 59 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-13 Boron Concentration Equalization Transient Page 60 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-14 Loss of Load Transient Page 61 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-15 Loss of Power Transient Page 62 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-16 Loss of Flow Transient Page 63 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-17 Reactor Trip Transient Page 64 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-18 Inadvertent Auxiliary Spray Transient Page 65 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure 8-19 Turbine Roll Test Transient Page 66 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 9 STRUCTURAL ANALYSIS Stress analyses are performed at the time points listed in Table 9-1 through Table 9-17. The time points include those at which the maximum temperature gradients (maximum thermal stresses)and the maximum and minimum pressures occur, as well as those of analytical interest.
The nodal temperature at the particular time point is read into the structural model directly from the result file of the thermal analysis.
The corresponding pressure is obtained from the transient input macros. The computer output files for the structural analyses are: min HU-ES st.out min HU-LS st.out minCD-F4 lst.out minCD-El[
Jst.out minCD-1_4
]st.out minCD-LI Ist.out nm _PLPU st.out mn _BCE st.out mn _IA st.out mm _LOF st.out mnn LOL st.out mn _LOP st.out min LSL st.out min SLD st.out min SLI st.out min RT st.out mn TRT st.out Table 9-1 Time Points of Interest -HU-ES Page 67 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 9-2 Time Points of Interest -HU-LS Table 9-3 Time Points of Interest -CD-El I Page 68 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 9-4 Time Points of Interest -CD-L4 I Table 9-5 Time Points of Interest -CD-E4 ]Page 69 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 9-6 Time Points of Interest -CD-L-4 I]Table 9-7 Time Points of Interest -PLPU Table 9-8 Time Points of Interest -LSL Page 70 Controlled Document A ARIEVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 9-9 Time Points of Interest -SLI ___Table 9-10 Time Points of Interest -LOL_ Table 9-11 Time Points of Interest -SLO Table 9-12 Time Points of Interest -BCSLD Table 9-13 Time Points of Interest -LOP Page 71 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 9-14 Time Points of Interest -LOF Table 9-15 Time Points of Interest -RT Table 9-16 Time Points of Interest -IA-Table 9-17 Time Points of Interest-TRT Page 72 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 10 ASME CODE CRITERIA The ASME Code stress analysis involves two basic sets of criteria: 1) Assure that failure does not occur due to application of the design loads.2) Assure that failure does not occur due to repetitive loading.In general, the primary stress intensity criteria of the ASME Code (Reference
[14]) assure that the design is adequate for application of design loads.Also, the ASME Code criteria for cumulative fatigue usage factor assure that the design is adequate for repetitive loading.10.1 ASME Code Primary Stress Intensity (SI) Criteria Per NB-3213.8 of Reference
[14], the primary stresses are those normal or shear stresses developed by an imposed loading such as internal pressure and external loadings.
A thermal stress is not classified as a primary stress. The primary stress intensity criteria are specified in: NB-3221 for Design Conditions, NB-3223 for Level B (Upset), NB-3224 for Level C (Emergency), NB-3225 for Level D (Faulted) and NB-3226 for Test Conditions.
The primary stress intensity criteria are. the basic requirements in calculating the weld overlay size, which is under the assumption that a 3600 circumferential flaw has grown completely through the original weld. Loading conditions in each service level have been considered in the weld overlay sizing calculation.
The nozzle to pipe region has been reinforced by the weld overlay since adding materials to the nozzle outside region relieves primary stress burden resulting from internal pressure and external loads. Therefore, the primary stress intensity requirements for the nozzle, welds, safe end and pipe have been satisfied for all service levels without the need for further evaluation.
Other related criteria include the minimum required pressure thickness (NB-3324 of Reference[14]) and reinforcement area (NB-3330 of Reference
[14]), which were addressed in the original nozzle/pressurizer designs. Adding weld overlay will increase the nozzle wall thickness, and therefore, these requirements are satisfied.
10.2 ASME Code Primary + Secondary Stress Intensity (SI) Criteria The analyses of stresses for transient conditions are required to satisfy the requirements for the secondary SI range and repetitive loadings.
The following discussion describes the primary +secondary SI range evaluation and fatigue analysis process employed herein for the design.Overall stress levels are reviewed and assessed to determine which locations require detailed stress/fatigue analysis.
The objective is to assure that: 1) The highly stressed locations affected by implementation of SWOL are evaluated.
- 2) The specified region is quantitatively qualified.
Page 73 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Once specific locations for detailed stress evaluation are established, the related paths lines can be defined with ANSYS. A post-processing is then conducted to convert the component stresses along the selected path lines into the SI categories (i.e., membrane, membrane + bending, total)that correlate to the criteria of the ASME Code (Reference
[14]). For paths that go through two materials partial paths are taken in addition to the free edge to free edge.10.2.1 Path Stress Evaluation The ANSYS Post Processor is used to tabulate the stresses along predetermined paths and classify them in accordance with the ASME Code Criteria (i.e., membrane, membrane plus bending, total and peak stress).The paths are shown in Figure 10-1 and are described in Table 10-1. The stress linearization for all transients is documented in computer file "min_paths.out".
Table 10-1 Path Definition Inside Outside Node No. Node No.Path1 1371 1421 Path2 1433 1372 Path3 5125 3156 Path3A 5125 1248 Path3B 1248 3156 Path4 1484 3249 Path4A 1484 1188 Path4B 1188 3249 Path5 1317 3209 Path5A 1317 1212 Path5B 1212 3209 Path6 1336 1179 Path6A 1336 1209 Path6B 1209 1179 Inside Outside Node No. Node No.Path7 1313 3190 Path7A 1313 1165 Path7B 1165 3190 Path8 3765 1136 Path8A 3765 1140 Path8B 1140 1136 Path9 5948 1270 Path9A 5948 3281 Path9B 3281 1270 Path10 5951 1852 Page 74 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 0 Figure 10-1 Stress Paths through the Spray Nozzle Model Full through thickness paths are taken at the same location as the partial paths (A/B). The partial path name has the letter 'A' or 'B' behind the full path name.Note: The path's numbering starts from the number "'2". The pathline "Pathl" is not defined.Page 75 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 10.2.2 Applicable Stress Intensity Due to External Loads The spray nozzle is exposed to the external loads. The stress intensities applicable for primary +secondary qualification due to these loads were calculated in Section 6. The membrane stress due to internal pressure is not considered here, since this is already included in the ANSYS transient runs.The OBE + Thermal external loads combination produces highest stress intensities at all evaluated locations.
Therefore stress intensities from Table 6-9 has been conservatively added to the maximum transient SI ranges from the ANSYS runs in the following sections.10.2.3 Maximum Primary + Secondary Stress Intensity Range The computer program StressRange version 2.0 (Reference
[15]) is used to calculate membrane+ bending stress intensity range and total stress intensity range based on the method prescribed in paragraph NB-3216.2 of the ASME Code. The computer run containing the results of the stress range calculation for membrane + bending stress for all transient events is"min_paths(M+B).txf'.
A zero stress state (ZSS) is included in this run.The membrane + bending stress intensity range runs are conservatively combined by hand with the stresses due to external loads (calculated in Section 6). The summary of maximum membrane+ bending stress intensity ranges is tabulated in Table 10-2.10.2.4 Primary + Secondary (P+Q) Stress Intensity Range Qualification (NB 3222.2)The maximum membrane + bending stress intensity range, as calculated in the stress range run"'minjpaths(M+B).txf', are conservatively combined with the maximum stress intensities due to external loads from Table 6-9 (as discussed in Section 10.2.2 ). Note, that Table 6-9 lists only SI for the through-wall paths. The SI from outside node of these paths is conservatively used for the partial path -mid-wall locations (outside node of"PathA" and inside node of 'PathB").The sum of the maximum transient SI Range and the stress intensity due to external loads are compared directly to the primary + secondary stress intensities range criteria of the ASME Code.Table 10-2 provides a summary of the maximum stress intensity ranges and allowable limits along with the material and path designation.
Table 10-2 shows that the 3Sm limit is not met at the following locations:
Inside node of paths: Path5, Path7, Path7A, Path8, Path8A, Pathl0 Outside node of paths: Path8, PathlO For the remaining locations, the requirement is met.The load-step combinations for locations which exceed 3Sm limit are shown in Table 10-3.The ASME Code allows that the 3*Sm limit may be exceeded under special condition, one of them being that the Simplified Elastic-Plastic Analysis (NB-3228.5) is used in the fatigue analysis.
See Section 10.2.5 for further qualification.
Page 76 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-2 Summary of Maximum Primary + Secondary SI Ranges for M + B Stresses Transient Stresses + Allowable External Stresses 3Sm limit at 680°FI [ksiJ Material Path SI Range SI Range Outside Outside Inside Node Outside Inside Node Node Inside Node Node r-_ lksil Node [ksi] I_--Path2 80.1 80.1 Path3 80.1 69.9 Path3A 80.1 80.1 Path3B 69.9 69.9 Path4 69.9 69.9 Path4A 69.9 69.9 Path4B 69.9 69.9 Path5 41.1 69.9 Path5A 41.1 41.1 Path5B 69.9 69.9 Path6 41.1 69.9 Path6A 41.1 41.1 Path6B 69.9 69.9 Path7 41.1 69.9 Path7A 41.1 41.1 Path7B 69.9 69.9 Path8 45.6 69.9 Path8A 45.6 45.6 Path8B 69.9 69.9 Path9 49.2 69.9 Path9A 49.2 49.2 Path9B2 69.9 69.9 Path 10 49.2 49.2 1 The Sm values are conservatively taken a[Imaximum transient temperature) 2 The entire through thickness section needs to act together in order for ratcheting to occur. Since partial path"Path9A" is much longer and stiffer than Path9B, the behavior of the section is driven by Path9A. Since Path9A material does not ratchet (3Sm limit is satisfied), it can be deduced that the adjacent material Path9B can not ratchet either. Therefore, Path9B is acceptable without satisfying the 3Sm limit.Page 77 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-3 Load Step Combinations for the Locations that Exceed 3Sm Limit Path Load Step Combination Inside Node Outside Node 119- 301 Path5 CD-Lf .-, .1 Path7 CD-Ej 135-305 N .1 .1 134-305 Path7A CD-El ]-I4 1 134-237 134-237 Path8 CD-Ef I LOt[ 1 CD-Ej I- LOlI 134-305 Path8A CD-Ef .114 .1 134-237 134-236 Path10 CD-E .1- LOl[" 1 CD-E 1-LOlf ]10.2.5 Simplified Elastic-Plastic Analysis (NB-3228.5)
The maximum primary+secondary stress intensity criterion in Section 10.2.4 is not met for the location at specific load step combinations determinate in Section 10.2.4. Therefore, the simplified elastic-plastic analysis for these locations is provided in this section.The primary + secondary stress intensity range may exceed 3 *Sm if the requirements of the simplified elestic-plastic analysis are met. The requirements are: 1) Primary + Secondary SI Range (Excluding thermal bending stresses), NB-3228.5(a)
The range of primary + secondary membrane + bending stress intensity, excluding thermal bending, shall be < 3*Smn The computer program StressRange v2.0 (Reference
[15]) is used to calculate primary plus secondary membrane plus bending stress intensity, excluding the thermal bending stress intensity range. The bending stress due to pressure only is determined by multiplying the bending stress obtain from design linearization file "min _DCpaths.out" with a pressure ratio. The ratio is the pressure at the time point constituting the maximum membrane + bending SI range, divided by the design pressure of 2485 psig at 680'F. The applied temperature effects only physical material properties, therefore the effect of thermal bending is considered to be negligible.
The prorated bending stress is added to the membrane stress and external stress in determining the membrane+ bending SI range excluding thermal bending effect. The run containing the results of the stress range calculation is "minfpaths(M+B-ThBend).t"f'.
Note that the zero stress state (ZSS) is included in this run. Table 10-4 lists the range of primary plus + secondary membrane plus bending stress intensity, excluding thermal bending for locations and load step combinations where the 3Sm limit was exceeded (see Table 10-3).Page 78 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-4 SI Ranges of Maximum Primary + Secondary Membrane Plus Bending Stress Excluding Thermal Bending Stresses Transient Stresses + Allowable Material External Stresses 3Sm limit at 680°F Path SI Range SI Range Outside Outside Inside Node Outside Inside Node Inside Node_ [ksi] Node [ksi_- _ INodeNode Path5 41.1 -Path7 41.1 -Path7A 41.1 -Path8 45.6 69.9 Path8A 45.6 -Path10 49.2 49.2 1 The SI Ranges of maximum primary + secondary membrane plus h nding stress excluding thermal bending stress does not exceed the 3Sm limit at all locations.
The criterion is met.2) Factor Ke (NB-3228.5(b))
The values of Sa used for entering the design fatigue curve is multiplied by the factor KI where K. =1.0+- .-1I n.(m-l) 3S.S, for 3.Sm <S, <3rmeSm, K. =1.0/n m= 1.7 n= 0.3 Sm [ksi]Sn [ksi]forS >_3.m.S, for austenitic stainless steel from Table NB-3228.5 (b)-I (Reference
[14])for austenitic stainless steel from Table NB-3228.5 (b)-1 (Reference
[14])at average temperature of the metal at the critical time points Primary + Secondary membrane plus bending SI Range The Ke factor is calculated for each SI Ranges over the 3Sm limit in the fatigue check as documented in Section 10.2.6.Page 79 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary
- 3) Fatigue Usage Factor (NB-3228.5© and NB-3222.4)
For fatigue usage factor evaluation see Section 10.2.6.4) Thermal Stress Ratchet (NB-3228.5(d) and NB-3222.5)
Thermal Ratchet is considered for the locations at specific load step, where the 3SSm limit was not met (see Section 10.2.4 )Some of these locations are parts of the local geometric discontinuities.
The ASME Code requirements for thermal ratcheting are considered accurately only for cylindrical shells without discontinuities.
On the other hand, the requirements for thermal ratcheting at discontinuities are considered to be "probably overly conservative" (Reference
[ 16], page 207).Maximum Allowable Range of Thermal Stress (NB-3222.5):
Table 10-4 determines the maximum allowable ranges of thermal stresses.NB-3222.5 only requires the SI Range to include thermal SI Ranges. Therefore, the stress analyses due to temperature loads only are performed at all time-points, similar to structural analysis in Section 9, with pressure = 0. The computer output files are: min HU-ES rtch.out mm _PLPU rtch.out min LSL rtch.out min HU-LS rtch.out mm _BCE rtch.out minSLD rtch.out minCD-El 1rtch.out mm _IA rtch.out minSLIrtch.out minCD-Ej[
Irtch.out mm _LOF-rtch.out minRTrtch.out minCD-LI ]_rtch.out mm _LOLrtch.out minTRTrtch.out minCD-LA _rtch.out mn__LOPrtch.out The stress linearization for the transient runs is documented in the file "minpaths rtch.out".
The SI ranges for thermal only are obtained from "minpaths-rtch(M+B).txt".
The general primary membrane stresses "Pmo" due to pressure for load step combinations listed in Table 10-3 are calculated from the general primary membrane stresses at design condition[ ]multiplied by pressure ratios. The pressure ratio for specific load step is given by actual pressure at this load step [psig] divided by design pressure [psig]. The higher "Pm" of two time points is used for determination of the Allowable SI Range. The general primary membrane stresses "PPm" are shown in Table 10-5 and the membrane stresses for all defined paths at design condition are documented in ANSYS output files "minDC paths.out".
Page 80 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-5 General Membrane Stress for Critical Locations Pressure Pressure Pm [ksi] at Pm [ksi]Location Load Step [psia] Ratio 2250 psia P Path5 (inside)Path7 (inside)Path7A (inside)Path8 (inside)Path8 (outside)Path8A (inside)Path10 (inside)Path10 (outside)-3 Table 10-6 Allowable Ranges of Thermal Stresses Where: x = maximum general membrane stress due to pressure ("Pm") divided by the max(Sy, 1.5*Sm).y'=l/x for 0<x<0.5 and y'=4(1-x) for 0_<x_<0.5 Allowable SI Range = y'. max(l.5Sm, Sy)1 Sm and Sy from Section 5.1 are conservatively taken at 6801F.Page 81 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary The maximum SI Ranges of thermal stresses are less than the allowable stresses; therefore the requirement has been met.5) Temperature Limits (NB-3228.5(e))
The maximum temperature of the components is 680'F which does not exceed the maximum allowable temperatures listed in Table NB-3228.5(b)-l, Reference
[14].Therefore, the ASME Code requirement is met.6) Minimum Strength Ratio (NB-3228.5(i))
The material shall have specified minimum yield strength to specified minimum tensile strength ratio of less then 0.80. The Sy and Su values a[ -]are listed in Section 5.1.Table 10-7 Minimum Strength Ratio Location Material Minimum Sy Minimum Su SyISu at 70°F [ksil at 70°F [ksi]Path5 inside, Path7 inside Path7A inside Path8 inside Path8A outside Path 10 inside Path 10 outside Path8 outside All materials above have specified minimum yield strength to specified minimum tensile strength ratio less then 0.80, therefore the ASME Code requirement is met.10.2.6 Fatigue Usage Factor Calculation For consideration of fatigue usage, the Peak Stress Intensity Ranges are calculated.
These values must include the total localized stresses.The fatigue usage factor at a location is usually calculated based on the actual stress intensity range. However, at a geometric or material discontinuity, an unrealistic peak stress may result from the modeling approach, element type and mesh sizes. The total stress obtained from the finite element analysis may not be able to capture the actual stress condition.
To account for the possible modeling inaccuracies, an FSRF is usually applied to the M+B stress intensity range for location experiencing the geometric discontinuity.
The following pages contain the calculation of the cumulative fatigue usage factor for the limiting points. The calculation is performed for all materials (except the head material, since the head is not affected by the WOL). The critical locations are listed in Table 10-8. These locations envelop the remaining paths.* Page 82 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary The stress category used in fatigue evaluation, along with an appropriate FSRF, for each node is listed in Table 10-8. Due to the geometric discontinuities at the outside nodes of Path2, 10 and inside node of Path4A, M+B stress intensities are used with FSRF for fatigue evaluation.
A conservative FSRF of is chosen based on Reference
[17], page 395.Table 10-8 Stress Category and FSRF in Fatigue Evaluation Location Material Stress Category FSRF Path2 outside node SA-508 M+B 2 Path4A inside node Alloy 600 M+B 2 Path7 inside node SA-1 82 Total 1 Path8A inside node SA-213 Total 1 Path9B outside node Alloy 690 Total 1 Path10 outside node SA-376 M+B 2 The load cases of all transients are combined for the maximum SI range. The number of cycles of the appropriate transient is used in the fatigue usage factor calculation.
When combining with other transients, the number of cycles of this transient may be reduced accordingly.
All transient combinations with SI Ranges contributing to the fatigue usage factor are included in the following tables. Fatigue curves in the following calculation are defined in Figures 1-9.2.1 and I-9.2.2 of Reference
[14] for WOL material and Figures N-415(A) and N-415(B) of Reference
[6]and [7] for existing materials as specified in Reference
[1].The Inadvertent Auxiliary Spray transient consists of two cycles (see Figure 8-18); therefore, for the fatigue calculations the transient is splitted into two separate transients "IAl" and "IA2" with the same number of cycles o0[ ]Transient "IAI" is between time-poin[
.]Transient "IA2" is betweei[.. ....The stress intensities due to external loads, as calculated in Section 6.1.2 , are added to the transients SI Ranges where applicable.
As already discussed in Section 10.2.2 , the maximum SI due to external loads are given by the load combination:
OBE+Thermal Loads. Therefore, the stress intensity due to this combination is conservatively added to the maximum SI Ranges for the firsi[ jcycles[ ]cycles is specified for OBE anc[ ]cycles for thermal external loads), unless otherwise noted. The notes below the tables with fatigue usage calculations provide detailed description of the used stresses and cycles of the external loads.The SI Ranges used for the fatigue calculation are documented in the file "minpaths(M+B).txt" for membrane + bending stresses and in the file "minpaths(Total) .txt" for total stresses.Page 83 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-9 Nozzle Usage Factor EVALUATION TITLE: Diablo Canyon, Path2 outside Total Fatigue Usage Factor =The Peak SI Range = 'M+B' x Fatigue Strength Reduction Factor (FSRF) x Ke Factor For Range 1, 'M+B' SI Range = ksi FSRF = Ke =For Range 2. 'MB' SI Range = ksi FSRF = Ke =For Range 3, 'M+B' SI Range = ksl FSRF = Ke =For Range 4, 'M+B' SI Range = kSl FSRF = Ke =For Range 5, 'M+B' SI Range = ksl FSRF = Ke =For Range 6. 'M+B' SI Range = ksi FSRF Ke =For Range 7. 'M+B' SI Range = ksl FSRF Ke =For Range 8. 'M+B' SI Range = ksl FSRF Ke =For Range 9,'M+B' SI Range = ksi FSRF Ke =For Range 10, 'M+B' Si Range = ksi FSRF Ke =For Range 11. 'M+B' SI Range = ksi FSRF Ke =For Ranae 12. 'M+B' SI Ranqe = ksl FSRF Ke =I Usage If] 1.0. Therefore, the--ASME Code requirement is 1The maximum temperature occurring during the plant operation if is conservatively used.]lhe Young's modulus 'Emat' 4 2 Internal cycles SI ol ]due to external loads (OBE+Th) is conservatively added to the highest SI Ranges for the first eight combinations, which consisf "]cycles.Page 84 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-10 DM Weld Usage Factor EVALUATION TITLE: Diablo Canyon, Path4A inside
REFERENCE:
min_paths(M+B).txt TYPE: UTS (ksi)= at T E curve (psi) { ;Emnat (psi) = al I E ratio = EcurvelEmnat RAGE TRANSIENTS REQ'D EKS (Eratio) x ALLOWABLE USAGE WITH RANGE E mat S alt FACTOR NUM,1 ETEE CYCLES IANG Salt CYCLES'N' U Total Fatigue Usage Factor = [I The Peak SI Range = 'M+B' x Fatigue Strength Reduction Factor (FSRF) x Ke Factor For Range 1, 'M+B1 SI Range = ksl FSRF = Ke =For Range 2. 'M+B' SI Range = ksl FSRF = Ke =For Range 3, 'M+B' SI Range = ksl FSRF = Ke =For Range 4. 'M+B' SI Range = ksl FSRF = Ke =For Range 5. 'M+B' SI Range = ksi FSRF = Ke =For Range 6, 'M+B' SI Range = ksl FSRF = Ke =For Range 7. 'M+B' SI Range = ksl FSRF = Ke =For Range 8, 'M+B' SI Range = ksl FSRF = Ke =For Range S. 'M+B' SI Range = ksl FSRF Ke -Usage f y 1.0. Therefore, the ASME Code requirement is met.'The maximum temperature occurring during the plant operation if is conservatively used.I The Young's modulus 'Emat' a[I 2 Internal cycles 3 The external loads do not act during the spray actuations.
4 SI o lue to external loads (OBE+Th) is conservatively added to the highest SI Ranges for the first six axium co iations, which consisf Jcycles.Page 85 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-11 Safe End Usage Factor EVALUATION TITLE: Diablo Canyon, Path7 inside
REFERENCE:
MATERIAL: TYPE: UTS (ksi) =Emat ()sil =min-paths(Total).txt I ,]1 TRANSIENTS RANGE WITH RANGE EXTREMES Total Fatigue Usage Factor = [The Peak SI Range = Total' x Fatigue Strength Reduction Factor (FSRF) x Ke Factor For Range 1, Total SI Range =ksl FSRF Ke=For Range 2, 'Total' SI Range = ksl FSRF Ke =For Range 3, 'Total' SI Range = ksl FSRF Ke =For Range 4. 'Total' SI Range = ksl FSRF Ke =For Range 5. 'Total' SI Range = ksl FSRF Ke =For Range 6. 'Total' SI Range = ksl FSRF Ke =For Range 7, 'Total' SI Range = ksl FSRF KeG =For Range 8. 'Total' SI Range = ksl FSRF Ke 6 =Fo Rng 8 "otl'SIRage=
slFSF__Ke Usage f 1: 1.0. Therefore, the ASME Code requirement is met.' The maximum temperature occurring during the plant operation if .Jrhe Young's modulus 'Emat' a[is conservatively used.2 Internal Cycles 3 The external loads do not act during the spray actuations.
4 The Young's modulus 'Emat' is taken at average metal temperature for this combination (see Table 10-12).SI ot Iue to external loads (OBE+Th) is conservatively added to the highest SI Ranges for the first four combinations, which consist[ Jzycles.6 Sm value for Ke factor calculation is taken at average temperature for this calculation (see Table 10-12).Page 86 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-12 E and Sm at Average Temperature for Table 10-11 Fatigue Evaluation
[IF] Tavg [psi]Page 87 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-13 Safe End to Pipe Weld Usage Factor EVALUATION TITLE: Diablo Canyon, Path8A inside
REFERENCE:
mn paths(Total).txt MATERIAL: TYPE: UTS (ksi)= ] atT E curve (psi) [Emat (psi) =at T E ratio = Ecurve/Emat RANGE WT RANGE REQ'D PEAK SI E mat S alt (Eratlo) x ALLOWABLE FACTOR NU. WTHRANSIN:
USAESGEO L NUM. EXTREMES CYCLES RANGE Salt CYCLES 'N Total Fatigue Usage Factor =The Peak SI Range = 'Total' x Fatigue Strength Reduction Factor (FSRF) x Ke Factor For Range 1. 'Total' SI Range = ksl FSRF= Ke 5 For Range 2, 'Totar Sl Range = ksl FSRF= Ke 5 For Range 3, "Total' SI Range = ksl FSRF= Kees For Range 4, 'Total' SI Range = ksl FSRF= Ke For Range 5. 'Total' Sl Range = ksi FSRF Kes For Range 6, 'Total' Sl Range = ksl FSRF Ke For Range 7, 'Total' SI Range = ksi FSRF Ke]< 1.0. Therefore, the ASME Code requirement is met.Usage I[1 The maximum temperature occurring during the plant operation if, ]The Young's modulus 'Emat' a[is conservatively used.2 Internal cycles 3 The external loads do not act during the spray actuations.
4 SI o[ ]lue to external loads (OBE+Th) is conservatively added for the first four maximum ranges, which consisi }ycles.5 Ke factor using Sm I I I Page 88 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-14 Weld Overlay Usage Factor EVALUATION TITLE: Diablo Canyon, Path9B outside
REFERENCE:
minpaths(Total).txt MATERIAL:
[ ]TYPE: ]UTS (ksi) ] at T { E curve (psi) {Emat si= ) atT E ratio = Ecurve/Emat RANGE TRANSIENTS REQ'D PEAK (Eratlo) x ALLOWABLE USAGE NUM WITH RANGE CYCLES RANGE mat alt tU'EXTREMES 40 years Salt CYCLES IN' F.Total Fatigue Usage Factor =The Peak SI Range = Total' x Fatigue Strength Reduction Factor (FSRF) x Ke Factor For Range 1, "rotal' SI Range = ksl FSRF Ke For Range 2. 'Totae SI Range = ksl FSRF Ke For Range 3, 'Totae SI Range = ksl FSRF Ke For Range 4, 'Total' SI Range = ksl FSRF Ke For Range 5. 'Totae SI Range = ksl FSRF Ke For Range 6, 'Total SI Range = ksl FSRF Ke For Range 7. 'Totar SI Range = ksl FSRF Ke For Range 8, 'Totar SI Range = ksl FSRF Ke For Range 8. "Totar SI Range = ksl FSRF Ke For Range 10, 'Total' SI Range = ksl FSRF[ Ke Usage i[]1 1.0. Therefore, the ASME Code requirement is met.1The maximum temperature occurring during the plant operation if, is conservatively used.]The Young's modulus "Emat' a[I 2 Internal cycles 3 The external loads do not act during the spray actuations.
4 SI of[ itue to external loads (OBE+Th) is conservatively added to the maximum SI Ranges for first six combinations, which consist fron[ I cycles.Page 89 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table 10-15 Pipe Usage Factor EVALUATION TITLE: Diablo Canyon, Path10 outside
REFERENCE:
mirnpaths(M+B T MATERIAL: TYPE: UTS (ksi) atT E curve (psi) ]Emat (psi) at T E ratio = Ecurve/Emat TRANSIENTS USAGE RANGE WITH RANGE REQ'D PEAK S E
- mat S alt (Erat!o) x ALLOWABLE FACTOR NUM. EXTREMES CYCLES RANGE Salt CYCLES 'N U Total Fatigue Usage Factor = L m The Peak SI Range = 'M+B' x Fatigue Strength Reduction Factor (FSRF) x Ke Factor For Range 1. 'M+B' SI Range = ksl FSRF Ke' =For Range 2. 'M+B' SI Range = ksl FSRF KeS =For Range 3. 'M+B' SI Range = ksi FSRF Kes =For Range 4, 'M+B' SI Range = ksl FSRF Ke =For Range 5, 'M+B' SI Range = ksl FSRF Ke =For Range 6. 'M+B' SI Range = ksl FSRF Ke =For Range 7. 'M+B' SI Range = ksl FSRF Ke =For Range 8, 'M+B' SI Range = ksl FSRF Ke =For Range 9. 'M+B' SI Range = ksl FSRF Ke =For Range 10. 'M+B' SI Range = ksl FSRF Ke =For Range 11. 'M+B'SI Range = ksl FSRF Ke =Usage = 0.383 < 1.0. Therefore, the ASME Code requirement is met.1 The maximum temperature occurring during the plant operation i[is conservatively used.2 Internal cycles.I The Young's modulus 'Emat' a[3 The external loads do not act during the spray actuations.
4 sIo[ )ue to external loads (OBE+Th) is conservatively added in f 400 cycles.]5 Ke factor using Sm{ ]Page 90 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 11 RESULTS
SUMMARY
ICONSLUSION Stress analyses of the spray nozzle weld overlay repairs for Diablo Canyon Unit 2 Pressurizer are summarized in this report. Minimum overlay configuration is investigated.
The analyses demonstrate that the weld overlay designs satisfy the stress and fatigue requirements of the ASME Code (Reference
[14]).The summary of the maximum primary+secondary membrane plus bending stress intensity ranges and fatigue usage factor are listed in Table 11-1 for each component.
The cumulative fatigue usage factors at critical locations investigated are less than 1.0, with the highest usage factor beind ]Mhe fatigue evaluation is based on the spray nozzle design transient, and for the specified number of cycles per Reference
[2].In conclusion, the spray nozzle with weld overlay satisfies the ASME Code primary plus secondary stress requirements as well as criteria against the fatigue failure. The primary stress criteria are satisfied as described in Section 10.1.Table 11-1 Summary of Results Max. Sl Range PL+Pb+Q Fatigue Usage Factor Component Material Primary Calculated Limit si Calculated Limit IR [alclate [Limi IR[ksi] [ksi] [ksil [ksi]Nozzle 80.1 1.0 DM Weld 69.9 1.0 Safe End See 41.1 1.0 Safe End to Section 4 Pipe Weld 10.1 45.6 1.0 Pipe 49.2 1.0 Weld 69.9 1.0 Overlay Page 91 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 12 SOFTWARE VERIFICATION The finite element analyses documented in this report were performed using ANSYS vl l.0 software (Reference
[13]). The suitability and accuracy of use of ANSYS v 1.0 was verified by performing the following verification runs.Table 12-1 ANSYS Verification Files File Name Date Element Type VM21 I.OUT 5/31/2007 PLANE183 2-D 8-Node Structural Solid VM1 12.OUT 5/31/2007 PLANE77 2-D 8-Node Thermal Solid VM21 I.OUT 5/31/2007 CONTA172 2-D 3-Node Surface-to-Surface Contact VM211.OUT 5/31/2007 TARGE169 2-D Target Segment The Stress Intensity Range calculations, documented in this report, are performed using Stress Range v2.0 program. The suitability and accuracy of the StressRange v2.0 are verified by comparing the calculated SI ranges listed in the files "SRangeverif(M+B).txt" and"SRangeqverif(Total).txt" with Tables L3 and L4 in Reference
[15].Table 12-2 StressRange Program v2.0 Verification Files File Name Date Description S6/05/2007 StressRange Program verification file for M+B SRangeverif(M+B)txt 7 SI ranges including ZSS SlRangeýverifotal).txt 6/05/2007 StressRange Program verification file for Total Sangv_ (Total)_____
txtI6_05/2007 SI ranges including ZSS Page 92 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 13 COMPUTER OUTPUT FILES Table 13-1 Computer Output and Input Files File Name Date Description mingeo.mac 5/29/2007 Input file to develop geometry of the spray nozzle mingeo.out 5/29/2007 Output file to develop geometry of the spray nozzle min dT.mac 5/18/2007 Input file defining nodes for temperature and thermal gradient evaluation Output file contains path definition for stress component and min_paths.out 5/30/2007 contains the linearized stresses along the paths for all transients Output file for thermal ratchet analysis contains path definition minpathsjrtch.out 5130/2007 for stress component and contains the linearized stresses along the paths for all transients Fatigue Stress Range min.paths(M+B).txt 5/30/2007 SI Ranges (M+B) for combination of all transients minpaths(Total).txt 5/30/2007 SI Ranges (Total) for combination of all transients minjpaths(M+B-ThBend).txt 5/30/2007 SI Ranges (M+B) excluding thermal bending for combination of all transients min~paths rtch(M+B).tt 5/30/2007 SI Ranges (M+B) with pressure = 0 for combination of all transients Design Condition minDC.out 5/29/2007 Output file for stress analysis minDC_paths.out 5/30/2007 Output file contains stress components along the paths Heat-up Transients HU-ES.tr.inp 5/17/2007 Input file contains definition of heat-up early spray transient min_HU-ESth.out 5129/2007 Output file for thermal analysis minHU-ESdt.out 5/29/2007 Output file contains thermal gradients min_HU-ESst.out 5/29/2007 Output file for the stress analysis min_HU-ESrtch.out 5/29/2007 Output file for the thermal ratcheting calculation HU-LS-tr.inp 5/17/2007 Input file contains definition of heat-up late spray transient minHU-LS th.out 5/29/2007 Output file for thermal analysis minHU-LS dt.out 5/29/2007 Output file contains thermal gradients minHU-LS st.out 5/29/2007 Output file for the stress analysis min HU-LS rtch.out 5129/2007 Output file for the thermal ratcheting calculation Cool-down Transients CD-Ea. u'-inp 5/17/2007 Input file contains definition of cool-down early spray transient with drop in a temperature of I min _CD-Ej ,]th.out 5/29/2007 Output file for thermal analysis Page 93 Controlled Document A ARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary min-CD-Ef ldt.out 5/29/2007 Output file contains thermal gradients st.out 5/29/2007 Output file for the stress analysis min CD-El _]rtch.out 5/29/2007 Output file for the thermal ratcheting calculation 5/17/2007 Input file contains definition oj cool-cwn late spray transient CD-L ]tr.inp 5117 with drop in a temperature ol.minCD-El ,th.out 5/29/2007 Output file for thermal analysis minME dt.out 5/29/2007 Output file contains thermal gradients minCD-E st.out 5/29/2007 Output file for the stress analysis minCD-Efl rtch.out 5/29/2007 Output file for the thermal ratcheting calculation 57/2007 Input file contains definition of cool-down early spray transient CD-E tr.inp 5/with drop in a temperature of I min _CD-Etlth.out 5/29/2007 Output file for thermal analysis min CD-E, --ot.out 5129/2007 Output file contains thermal gradients min _CD-E[ ]st.out 5/29/2007 Output file for the stress analysis min _CD-E1 .rtch.out 5/29/2007 Output file for the thermal ratcheting calculation CD-Lj --Itr.inp 5/17/2007 Input file contains definition of cool-down late spray transient with drop in a temperature of. I minCD-L h.out 5/29/2007 Output file for thermal analysis minCD-: __dt.out 5/29/2007 Output file contains thermal gradients minCD-LI-t.out 5/29/2007 Output file for the stress analysis minCD-Lj -jtch.out 5/29/2007 Output file for the thermal ratcheting calculation Plant Loading & Plant Unloading Transient PLPU tr.inp 5/17/2007 Input file contains definition of plant loading and unloading Ptr____np__5/1712007__transient minPLPU th.out 5/29/2007 Output file for thermal analysis minPLPUdt.out 5/29/2007 Output file contains thermal gradients min_PLPU_st.out 5/29/2007 Output file for the stress analysis minPLPU.rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Step Load Decrease Transient SLD tr.inp 5/17/2007 Input file contains definition of 10% step load decrease-ptransient min SLD th.out 5/29/2007 Output file for thermal analysis minSLDdt.out 5/29/2007 Output file contains thermal gradients min _SLDst.out 5/29/2007 Output file for the stress analysis min SLD rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Step Load Increase Transient SLI.r.inp 5/17/2007 Input file contains definition of 10% step load increase transient min SLI th.out 5/29/2007 Output file for thermal analysis min SLI dt.out 5/29/2007 Output file contains thermal gradients minSLIst.out 5/29/2007 Output file for the stress analysis minSLI rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Page 94 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Large Step Load Transient LSL tr.inp 5/17/2007 Input file contains definition of large step load transient minLSLth.out 5/29/2007 Output file for thermal analysis minLSL dt.out 5/29/2007 Output file contains thermal gradients minLSL st.out 5/29/2007 Output file for the stress analysis min LSL rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Boron Concentration Equalization BCEtr.inp 5/17/2007 Input file contains definition of boron concentration equalization transient minBCE th.out 5/29/2007 Output file for thermal analysis minBCE dt.out 5/29/2007 Output file contains thermal gradients minBCE st.out 5129/2007 Output file for the stress analysis min BCE rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Loss of Load LOL tr.inp 5/17/2007 Input file contains definition of loss of load transient minLOL th.out 5/29/2007 Output file for thermal analysis minLOLdt.out 5/29/2007 Output file contains thermal gradients minLOL stout 5129/2007 Output file for the stress analysis minLOL rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Loss of Power LOP tr.inp 5/17/2007 Input file contains definition of loss of power transient min LOP th.out 5/2912007 Output file for thermal analysis min-LOP dt.out 5/29/2007 Output file contains thermal gradients min _LOPst.out 5/29/2007 Output file for the stress analysis min LOP rtch.out .5/29/2007 Output file for the thermal ratcheting calculation Loss of Flow LOF tr.inp 5/17/2007 Input file contains definition of loss of flow transient min LOF th.out 5129/2007 Output file for thermal analysis min LOF dt.out 5/29/2007 Output file contains thermal gradients min LOF st.out 5/29/2007 Output file for the stress analysis min _LOFrtch.out 5/29/2007 Output file for the thermal ratcheting calculation Reactor Trip RTtr.inp 5/17/2007 Input file contains definition of reactor trip transient min RT th.out 5/29/2007 Output file for thermal analysis min RT dt.out 5/29/2007 Output file contains thermal gradients min RT st.out 5/29/2007 Output file for the stress analysis min RT rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Turbine Roll Test TRT.tr.inp 5/17/2007 Input file contains definition of turbine roll test transient minTRTth.out 5/29/2007 Output file for thermal analysis I Page 95 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary minTRT dt.out 5/2912007 Output file contains thermal gradients min TRT st.out 5/29/2007 Output file for the stress analysis min _TRTrtch.out 5129/2007 Output file for the thermal ratcheting calculation Inadvertent Auxiliary Spray Actuation IA tr.inp 5/17/2007 Input file contains definition of inadvertent auxiliary spray actuation transient min IA th.out 5/29/2007 Output file for thermal analysis min IA dt.out 5/29/2007 Output file contains thermal gradients min IA st.out 5/29/2007 Output file for the stress analysis min IA rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Appendix A: Fracture Mechanics Results File Name Date Description minjath fr.mac 5/31/2007 Input file contains path definition for stress component along the paths for all transients Fr PathLocs.out 5/31/2007 Output file contains the path point distances from the inside node HU-ESfrSY HU-ESfrSZ HU-LS ftSY HU-LSftSZ CD-E ]frSY CD-E I fr Sz CD-L ,. SY CD-L r SZ CD-E _ SY CD-E --- Ifr SZ CD-L_ I -SY CD-L iJfr SZ PLPUftSY PLPUfrSZ LSL.frSY LSLfrSZ SLIfrSY SLI_frSZ 5/31/2007 Stress results for fracture mechanics SLD.frSY SLD_frSZ BCE_ fSY BCEfrSZ LOL frSY LOL_frSZ LOPfrSY LOP._fSZ LOF fr SY LOF SZ RT-frSY RT-frSZ IA__frSY IAfSZ TRT fr SY TRT fr SZ HU-ES ft TH SLD TH HU-LS_frTH BCE fti TH CD-E -rTH LOL_frTHJ- TH LOP ft_ TH CD-EL. "r TH LOF ft TH 5/31/2007 Output file contains temperature results for... fracture mechanics CD-Lj hfrTH RT frTH PLPU_frTH IA_frTH LSL fr TH TRT fr TH SLI-ft TH Page 96 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary 14 REFERENCE[1] ARENVA Document OS-9042937-003. "Certified Design Specification for Pressumizer Nozzle Weld Overlays at Pacific Gas and Electric Diablo Canyon Nuclear Power Plant, Unit 2"[2] AREVA Document 3S-9046469-002, "Design Input Transmittal, Non-Proprietary, DIT-A0675765-03-00"[3] AREVA Document 3S-2200488-002, "Design Input Transmittal, Proprietary, DIT -A0675765-04-00, 01 & 03"[4] AREVA Documnent 51-9048271-000, "Diablo Canyon 2 PWOL Design Transients"[5] "ASME Boiler and Pressure Vessel Code",Section II, Part D -Properties, 2001 Edition including Addenda through 2003[6] "ASME Boiler and Pressure Vessel Code",Section III. 1965 Edition including Addenda through Sumnmer 1966[7] "ASME Boiler and Pressure Vessel Code",Section II, 1965 Edition including Addenda through Winter 1967[8] "ASME Boiler and Pressure Vessel Code", Section 111, 1968 Edition including Addenda through Winter 1969[9] "ASME Boiler and Pressure Vessel Code". Section 111, 1971 Edition[10] AREVA Document NPGD-TM-500 rev D. "NPGMAT", NPGD Material Properties Program, User's Manual (03/1985)[11] AREVA Drawing 02-8019233D-001. "Diablo Canyon Pressurizer Spray Nozzle Weld Overly Design Input"[12] AREVA Drawing 02-8018400C-002. "Diablo Canyon Unit 2 Pressurizer Spray Nozzle Existing Configuration"[13] "ANSYS" Finite Element Computer Code, Version 11.0, ANSYS, Inc., Canonsburg.
Pa.[14] "ASME Boiler and Pressure Vessel Code",Section III, Division 1, 2001 Edition including Addenda through 2003[15] AREVA Document 32-5032987-03, "StressRange Program Verification"[16] "Companion Guide to the ASME Boiler & Pressure Vessel Code", Volume 1, ASME Press, New York, 2002[17] John F. Harvey, "Theory and Design of Pressure Vessels", Second Edition, Van Nostran Reinhold.
1991[18] "ANSYS" Finite Element Computer Code, Version 14.0, ANSYS, Inc., Canonsburg, PA[19] AREVA Document 38-9200149-001, "DCPP Unit 2 Pressurizer Nozzle NDE Data" Page 97 Controlled Document A A R EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary APPENDIX A- Stresses used for Fracture Mechanics Analysis A-1 Purpose The purpose of this Appendix is to provide supplemental stress results of the transient analysis for fracture mechanics analysis of the Diablo Canyon Unit 2 spray nozzle weld overlay.A-2 Stress and Temperature Evaluation The ANSYS Post Processor is used to tabulate the stresses and temperatures along the predetermined paths. The paths are shown on Figure A-I and described in Table A-1. Note that all stresses and temperatures are tabulated from the thermal and structural runs output files listed in Section 9.For post preprocessor calculation, the definitions of these paths are contained in computer file"'min_paths_fr.mac".
Table A-1 Path Description Path Name Inside Node No. Outside Node No.FPathl 5349 1246 FPath2 5199 1227 FPath3 5197 1183 FPath4 3765 1143 Stresses along the path line are summarized at twelve points separated by an equal distance from the inside node to the outside node. At each point the axial (longitudinal, Sy) stress and the corresponding temperature of the nozzle are given. The path point distances from the inside node are included in the output file "FrPathLocs.out".
Stress and temperature result files are included in output files with "'frSY", "_frSZ" and"'fr TIH' in their names. They are listed in Section 13.Page 98 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Figure A-1 Paths Defined for Fracture Mechanics Evaluation Page 99 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary APPENDIX B -ADDITIONAL STRESSES USED FOR FRACTURE MECHANICS ANALYSIS B.1 Purpose The purpose of this Appendix is to provide additional stress results of the transient analysis for fracture mechanics analysis of the Diablo Canyon Unit 2 spray nozzle weld overlay. Stress results were evaluated for locations that are in close proximity to the indications found in the Spray Nozzle during 2R17.B.1.1 Stress and Temperature Evaluation The complete finite element analysis as presented in Rev. 000 was conducted using ANSYS version 11.0 on a 32-bit Windows XP machine. Although the ANSYS results from Rev. 000 are available to extract stress and temperature results at additional path lines, ANSYS 14.0 (Reference
[18]) on a 64-bit Windows 7 machine is used for this Appendix and therefore a verification process is performed to ensure all results remain valid under the later version of ANSYS and Windows. Stress and temperature results along the paths defined in Appendix A are first re-produced and then compared with those in Rev. 000. It is verified that all results between two versions of ANSYS (11.0 and 14.0) and Windows (32-bit Windows XP and 64-bit Windows 7) are identical.
Detailed ANSYS outputs are listed in Section B.1.2.The ANSYS post-processing macro used in Appendix A is modified to define different path lines as well as to tabulate the stresses and temperatures along the defined paths in line with the Spray Nozzle NDE indications (see Reference
[19]). The paths are shown on Figure B-1 and with node numbers listed in Table B-1.The definitions of these paths are contained in computer file "minpathsfrAppB.mac".
Table B-1 Additional Paths in Appendix B Path Path N Inside Outside Intermediate Material Selected No. Node No. Node No. Node No.1 FLinel 5104 3271 none Nozzle, WOL 2 FLine2 1265 1257 1194, 1259, 1260 Nozzle, WOL 3 FL2_wol 1265 1257 1194, 1259, 1260 WOL only 4 FL2_noz 1265 1257 1194, 1259, 1260 Nozzle only 5 FLine3 3721 3175 none Safe end, SS weld, WOL 6 FLine4 1145 1141 none SS weld, WOL 7 FL4_wol 1145 1141 none WOL only 8 FL4_wld 1145 1141 none SS weld only Stresses along the path line are summarized at twelve points separated by an equal distance from the inside node to the outside node. At each point the axial (longitudinal, Sy) stress, radial stress (Sx), hoop Page 100 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary stress (Sz), shear stress (Sxy), and the corresponding temperature of the nozzle are given. The path point distances from the inside node are included in the output file "FrPathLocsAppB.out".
Stress (Sx, Sy, Sz and Sxy) and temperature result files are included in output files with_ frSX AppB," " fr SYAppB," " _frSZAppB," " fr Sh AppB" and " fr TH" in their names.They are listed in Section B.1.2.Page 101 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary L Notes: " Only laminar indications are found along pathfines FLine2 and Fline 4."No planar indications were found. Results along pathlines Flainel and Fline3 are provided for Information only in cases they are needed for future evaluations." FLine2 is path line used to sample results for evaluating laminar indication
- FL2_wol usedSWOL materialfor extracting stresses* FL2_noz used nozzle materialfor extracting stresses" FLine4 is path line used to sample results for evaluating laminor indication" FL4_wol used SWOL materialfor extracting stresses" FL4_wld used weld materialfor extracting stresses" Details A and B show the node numbers used for defining the pothlines as discussed in Table B-i Figure B-1 Additional Paths for Fracture Mechanics Page 102 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Typical stress contour plots at high temperature gradients are shown in Figure B-2 for the overlay region during the transient HU-El Ind in Figure B-3 during the transient CD[-Notes: " Only laminar ndications arefound along pothlines FLlne2 and Fline 4." No planar Indications were found. Results along pathlines vertical pathilnes providedfor Information only.Figure B-2 Stress Plots during HU-ES Page 103 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary" Only laminar Indications arefound along pathfines FLIne2 and Fline 4." No planar Indications were found. Results along pathlines vertical pathlines pro vided for Information only.Figure B-3 Stress Plots during CD-ES[Page 104 Controlled Document A AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary B.1.2 Computer Usage and ANSYS Files ANSYS Version 14.0 is used in this Appendix.
It was tested on the computer used for this Appendix (Computer name: SC-MJEHGTA; OS: Windows 7 with 24GB RAM) on October 14, 2013 by the preparer.
The results of the test (as listed in ANSYS output file "VMI 12.out" and "VM21 I.out") are acceptable.
All ANSYS input/output files are collected and listed in Table B-2. ANSYS verification output files are also listed. All files are available in AREVA Inc. ColdStor storage \cold\General-Access\32\32-9000000\32-90491 12-002\official\.
The ColdStor installation date is 10/17/2013 for all files.Table B-2 Appendix B ANSYS files Appendix A regenerated.
Sub-directory:
..¥App-A-benchmark File Name Date and Description Time min_path-frout 10/08/2013 Input file contains path definition in 3:54pm Appendix A FrPathLocs.out 10/08/2013 Output file contains the path point 3:54pm distances from the inside node HU-ES fr SY HU-ES fr SZ HU-LS fr SY HU-LS fr SZ CD-ES[ ] fr SY CD-ES[ ]fr SZ CD-LS[ ] fr-SY CD-LS[ ]frSZ CD-ES J _fr SY CD-ES[ ]fr SZ CD-LS[ ] _fr SY CD-LS[ ]frSZ 10/08/2013 Stress results regenerated as in Appendix PLPU fr SY PLPU fr SZ 3:54pm A LSL fr SY LSL fr SZ SLI fr SY SLI fr SZ SLD frSY SLD-frSZ BCE fr SY BCE fr SZ LOL fr SY LOL fr SZ LOP fr SY LOP fr SZ LOF fr SY LOF frSZ RT fr SY RT fr SZ IA fr SY IAfrSZ TRTfrSY TRT fr SZ HU-ES fr TH SLD frTH IU-LS fr TH BCE fr TH 10/08/2013 Temperature results regenerated as in D-ES3 fr TH LOL-frTH 3:54pm Appendix A CD-ES320 fr TH LOL fr TH Page 105 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary CD-LS[ ] frlTH LOP fr TH CD-ES[ J frTTH LOF fr TH CD-LS [ _frTH RT frTH PLPU fr TH IA frTH LSL fr TH TRT fr TH SLI fr TH Table B-2 Appendix B ANSYS files (conti.)Appendix B results. Sub-directory:
..¥App-B File Name Date Description min 10/17/20 Input file contains path_au1:2p definition in Appendix B 1:21pm 10/17/20 Output file contains the path FrPathLocsAppB.
out 13 point distances from the inside 1:21pm node HU-ESjfr SYAppB HU-ES fr SZAppB HU-ESjfr SXAppB HU-ES fr-ShAppB HU-LSjfr SY_AppB HU-LS frSZAppB HU-LS fr.SXAppB HU-LS fr ShAppB CD-ES [ ] fr-SYAppB CD-ES [ ] frSZAppB CD-ES [ fr-SXAppB CD-ES [ -frShAppB CD-LS [ ] fr-SYAppB CD-LS [ ] fr SZAppB CD-LS [ fr-SXAppB CD-LS ] fr ShAppB CD-ES [ -fr-SYAppB CD-ES [ -fr SZAppB CD-ES [ ] frSXAppB CD-ES [ fr ShAppB 10/17/20 13 Stress results in Appendix B CD-LS [ ] fr-SYAppB CD-LS [ ] fr SZAppB 1:21pm CD-LS [ jr-SXAppB CD-LS [ jrShAppB PLPUfrSYAppB PLPU fr.SZAppB PLPU fr SXAppB PLPUfrShAppB LSL fr SYAppB LSLfrSZAppB LSL fr.SX.AppB LSL fr ShAppB SLI fr SYAppB SLI fr SZAppB SLI fr SXAppB SLI fr ShAppB SLD frSY.AppB SLD fr SZAppB SLD fr SXAppB SLD fr ShAppB BCE-fr.SYAppB BCEfrSZAppB Page 106 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary BCE_frSXAppB BCE frShAppB LOL frSYAppB LOL fr SZAppB LOL fr SXAppB LOL fr ShAppB LOP frSYAppB LOP-frSZAppB LOP fr.SXAppB LOP fr ShAppB LOF fr SYAppB LOF fr SZAppB LOF friSX.AppB LOF frShAppB RT fr SYAppB RT fr SZAppB RT fr.SX.AppB RT fr ShAppB IA fr SYAppB IA fr SZAppB IA frSX_AppB IA fr ShAppB TRT fr SYAppB TRT fr SZAppB TRTIfr SXAppB TRT frShAppB Page 107 Controlled Document A AREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis -Non Proprietary Table B-2 Appendix B ANSYS files (conti.)Appendix B results. Sub-directory:
..¥OApp-B File Name Date Description HU-ES-frTHAppB SLD_frTHAppB HU-LSfr_TH-AppB BCE_fr_TH-AppB CD-ES [ ] frjTHLAppB LOLfr_TH_AppB CD-LS [ fr-THAppB LOP fr THAppB CD-ES [ frjTHAppB LOF fr TH-AppB 10/17/2013 Temperature results in Appendix B C I 1:21pm CD-LS [ _frTHAppB RT-fr-TH-AppB PLPU~frTHAppB IAfr_TH_AppB LSL fr-THAppB TRT-frTHAppB SLI frTHAppB VM112. out 10/14/2013 9:28am VM211. out 10/14/2013 ANSYS verification output files 9:32am Page 108