HNP-16-095, Relief Request l3R-16, Reactor Vessel Closure Head Nozzle Repair Technique, Inservice Inspection Program, Third Ten-Year Interval, Non-Proprietary Version of Calculation

Relief Request l3R-16, Reactor Vessel Closure Head Nozzle Repair Technique, Inservice Inspection Program, Third Ten-Year Interval, Non-Proprietary Version of Calculation

ML16295A159
Person / Time
Site:	Harris
Issue date:	10/21/2016
From:	Waldrep B Duke Energy Progress
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
HNP-16-095
Download: ML16295A159 (118)

Text

Benjamin C. Waldrep

~~ DUKE Vice President Harris Nuclear Plant

~ ENERGY. 5413 Shearon Harris Road New Hill, NC 27562-9300 919.362.2502 10 CFR 50.55a October 21, 2016 Serial: HNP-16-095 ATIN: Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555-0001 Shearon Harris Nuclear Power Plant, Unit 1 Docket No. 50-400/Renewed License No. NPF-63

Subject:

Relief Request l3R-16, Reactor Vessel Closure Head Nozzle Repair Technique, lnservice Inspection Program, Third Ten-Year Interval, Non-Proprietary Version of Calculation Ladies and Gentlemen:

Duke Energy Progress, LLC (Duke Energy), requested NRC approval of relief request 13R-16 for the Shearon Harris Nuclear Power Plant, Unit 1 (HNP) inservice inspection program in a letter dated October 19, 2016 (Agencywide Documents Access and Management System (ADAMS) Accession Nos. ML16294A218 and ML16294A219). The October 19, 2016, letter contained the relief request and the proprietary version of the AREVA Inc. calculation to support this request. The purpose of this letter is to provide the non-proprietary version of the calculation provided in the October 19, 2016, letter.

This letter does not contain any regulatory commitments.

Please refer any questions regarding this submittal to John Caves, HNP Regulatory Affairs Manager, at (919) 362-2406.

Sincerely,

~a~n*~~

Enclosure:

Calculation 32-9215680-002, Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non-Proprietary) cc: Mr. M. Riches, NRC Resident Inspector, HNP Ms. M. Barillas, NRC Project Manager, HNP NRC Regional Administrator, Region II

Benjamin C. Waldrep Vice President Harris Nuclear Plant 5413 Shearon Harris Road New Hill, NC 27562-9300 919.362.2502 10 CFR 50.55a October 21, 2016 Serial: HNP-16-095 ATTN: Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555-0001 Shearon Harris Nuclear Power Plant, Unit 1 Docket No. 50-400/Renewed License No. NPF-63

Subject:

Relief Request I3R-16, Reactor Vessel Closure Head Nozzle Repair Technique, Inservice Inspection Program, Third Ten-Year Interval, Non-Proprietary Version of Calculation Ladies and Gentlemen:

Duke Energy Progress, LLC (Duke Energy), requested NRC approval of relief request I3R-16 for the Shearon Harris Nuclear Power Plant, Unit 1 (HNP) inservice inspection program in a letter dated October 19, 2016 (Agencywide Documents Access and Management System (ADAMS) Accession Nos. ML16294A218 and ML16294A219). The October 19, 2016, letter contained the relief request and the proprietary version of the AREVA Inc. calculation to support this request. The purpose of this letter is to provide the non-proprietary version of the calculation provided in the October 19, 2016, letter.

This letter does not contain any regulatory commitments.

Please refer any questions regarding this submittal to John Caves, HNP Regulatory Affairs Manager, at (919) 362-2406.

Sincerely, Benjamin C. Waldrep

Enclosure:

Calculation 32-9215680-002, Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non-Proprietary) cc: Mr. M. Riches, NRC Resident Inspector, HNP Ms. M. Barillas, NRC Project Manager, HNP NRC Regional Administrator, Region II

U.S. Nuclear Regulatory Commission Relief Request I3R-16 HNP-16-095 Enclosure HNP-16-095 Shearon Harris Nuclear Power Plant, Unit 1 Docket No. 50-400/Renewed License No. NPF-63 Relief Request I3R-16, Reactor Vessel Closure Head Nozzle Repair Technique, Inservice Inspection Program, Third Ten-Year Interval, Non-Proprietary Version of Calculation Enclosure Calculation 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non-Proprietary)

Controlled Document 0402-01-F01 (Rev. 019, 6/25/2015)

CALCULATION

SUMMARY

SHEET (CSS)

Document No. 32 - 9215680 - 002 Safety Related: Yes No Title Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

PURPOSE AND

SUMMARY

OF RESULTS:

AREVA NP Proprietary information in the document are indicated by pairs of brackets [ ] . The proprietary version of this document is in AREVA document 32- 9176350-003.

Purpose The purpose of the present fracture mechanics analysis is to determine the suitability of leaving degraded J-groove weld and butter material in the Shearon Harris Unit 1 reactor vessel head following the repair of either a Control Rod Drive Mechanism (CRDM) nozzle or Core Exit Thermocouple (CET) nozzle by the ID temper bead (IDTB) weld procedure. It is postulated that a small flaw in the head would combine with a large stress corrosion crack in the weld and butter to form a radial corner flaw that would propagate into the low alloy steel head by fatigue crack growth under cyclic loading conditions.

The purpose of Rev 001 is to revise the primary stress limit analysis performed in Section 6.5 (updated analysis in Appendix C) by performing a detailed primary stress limit analysis considering each of the CRDM repairs performed on Shearon Harris Unit 1s RVCH. Also, the objective is to determine the RVCH service life considering all the repaired CRDM configurations that have been performed to date as of the Spring (April) 2015 Outage.

The purpose of Rev 002 is to add a brief evaluation for nozzle repair at penetrations 30, 40 and 51 in the absence of original J-groove weld sizes and head thickness at these locations for additional 5 years operation.

Summary of Results Based on a combination of linear elastic and elastic-plastic fracture mechanics analysis of a postulated remaining flaw in the original Alloy 182 J-groove weld and butter material, a Shearon Harris Unit 1 CRDM or CET nozzle is considered to be acceptable for 30 years of operation following an IDTB weld repair based on EPFM analysis consideration only. The controlling loading condition is a large loss of coolant accident, for which it was shown that with safety factors of 3 on primary loads and 1.5 on secondary loads that the applied J-integral (2.359 kips/in) was still less than the J-integral of the low alloy steel head material (2.474 kips/in) at a crack extension of 0.1 inch.

Rev 001: Based on the evaluation presented in Appendix C, the RVCH repairs are acceptable for an additional 12 years beyond the Spring (April) 2015 outage (or 15 years from the time of installation).

Rev 002: Rev 001 conclusion for the nine repaired nozzles remains valid. Nozzle repairs at penetrations 30, 40 and 51 are acceptable for additional 5 years beyond the repair (Fall 2016 outage) based on the assumptions listed in Sub-Sections 3.1 and 3.2, and the analysis presented in Section C.7 of Appendix C. The limiting service life of all nozzle repairs is 5 years from the Fall 2016 outage.

If the computer software used herein is not the latest version per the EASI list, THE DOCUMENT CONTAINS AP 0402-01 requires that justification be provided. ASSUMPTIONS THAT SHALL BE VERIFIED PRIOR TO USE THE FOLLOWING COMPUTER CODES HAVE BEEN USED IN THIS DOCUMENT:

CODE/VERSION/REV CODE/VERSION/REV YES ANSYS 12.1 (Rev 000)

NO Page 1 of 115

Controlled Document Controlled Document 0402-01-F01 (Rev. 019, 6/25/2015)

Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Record of Revision Revision Pages/Sections/Paragraphs No. Changed Brief Description / Change Authorization 000 All Original release. The corresponding proprietary version is in AREVA document 32- 9176350-001.

001 All Updated with the latest form (0402-01-F01 Rev. 018).

CSS page Added purpose and summary of Rev 001.

Section 6.5 Text deleted and replaced with statement referencing Appendix C for Limit Load Analysis.

Section 7.0 Added statements to address the service life of the RVCH considering all the CRDM repaired configurations to-date as of April 2015.

Appendix C Added the updated Limit Load Analysis to address each of the repaired CRDM configurations to-date as of April 2015.

002 All Updated with the latest form (0402-01-F01 Rev. 019).

CSS page Added purpose and summary of Rev 002.

Throughout Changed terminology from limit load analysis to primary stress limit analysis since limit load analysis is only one of the possible methods for satisfying primary stress limits.

Pages 2-3 Updated for Rev 002.

Section 3.1 Revised to include two unverified assumptions.

Section 3.2 Added clarification to second paragraph.

Added a justified assumption (last paragraph).

Section 6.5 Updated service life discussion based on Appendix C revision.

Section 7.1 Deleted discussion of service life due to primary stress limit, which was redundant with discussion in Section 7.2 Section 7.2 Updated service life discussion based on Appendix C revision.

Section 8.0 Updated Reference 1 to latest revision.

Section C.2 Revised second paragraph and inserted a table.

Sections C.4, C.6 Corrected table titles for Tables C9 and C10.

Section C.7 Added to address the three nozzle repairs (#30, #40 and #51).

Section C.8 Updated from C.7; added References C14 to C16; updated revision for References C2 and C12.

Page 3

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table of Contents Page SIGNATURE BLOCK ................................................................................................................................ 2 RECORD OF REVISION .......................................................................................................................... 3 LIST OF TABLES ..................................................................................................................................... 6 LIST OF FIGURES ................................................................................................................................... 7

1.0 INTRODUCTION

........................................................................................................................... 8 2.0 ANALYTICAL METHODOLOGY ................................................................................................. 10 2.1 Stress Intensity Factor Solution ..................................................................................................... 12 2.1.1 Finite Element Crack Models ........................................................................................... 12 2.1.2 Stress Mapping ................................................................................................................ 12 2.1.3 Crack Growth Considerations .......................................................................................... 15 2.1.4 Plastic Zone Correction ................................................................................................... 15 2.2 Linear Elastic Fracture Mechanics ................................................................................................. 16 2.3 Elastic-Plastic Fracture Mechanics ................................................................................................ 17 2.3.1 Screening Criteria ............................................................................................................ 17 2.3.2 Primary Stress Limit Analysis .......................................................................................... 17 2.3.3 Flaw Stability and Crack Driving Force ............................................................................ 18 3.0 ASSUMPTIONS .......................................................................................................................... 20 3.1 Unverified Assumptions.................................................................................................................. 20 3.2 Justified Assumptions..................................................................................................................... 20 3.3 Modeling Simplifications ................................................................................................................. 20 4.0 DESIGN INPUTS ........................................................................................................................ 21 4.1 Materials ......................................................................................................................................... 21 4.1.1 Mechanical and Thermal Properties ................................................................................ 21 4.1.2 Toughness Properties ...................................................................................................... 23 4.1.3 Fracture Toughness ......................................................................................................... 23 4.1.4 J-integral Resistance Curve............................................................................................. 23 4.1.5 Fatigue Crack Growth Rate ............................................................................................. 25 4.2 Basic Geometry .............................................................................................................................. 26 4.3 Operating Transients ...................................................................................................................... 26 4.4 Applied Stresses ............................................................................................................................ 28 4.4.1 Residual Stresses ............................................................................................................ 28 4.4.2 Operating Stresses .......................................................................................................... 28 5.0 COMPUTER USAGE .................................................................................................................. 29 Page 4

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table of Contents (continued)

Page 5.1 Hardware/Software......................................................................................................................... 29 5.2 Installation/Validation Test ............................................................................................................. 29 5.3 Computer Files ............................................................................................................................... 31 6.0 CALCULATIONS ......................................................................................................................... 35 6.1 Initial Flaw Size .............................................................................................................................. 35 6.2 Fatigue Crack Growth .................................................................................................................... 35 6.3 LEFM Flaw Evaluations.................................................................................................................. 39 6.3.1 Normal and Upset Conditions .......................................................................................... 39 6.3.2 Faulted Conditions ........................................................................................................... 40 6.4 EPFM Flaw Evaluations ................................................................................................................. 41 6.4.1 Operating Conditions ....................................................................................................... 41 6.4.2 Low Temperature Conditions........................................................................................... 43 6.4.3 Faulted Conditions ........................................................................................................... 45 6.5 Primary Stress Limit Analysis ......................................................................................................... 47 7.0

SUMMARY

OF RESULTS AND CONCLUSIONS....................................................................... 48 7.1 Summary of Results ....................................................................................................................... 48 7.2 Conclusion ...................................................................................................................................... 49

8.0 REFERENCES

............................................................................................................................ 49 APPENDIX A : DETAILED FLAW EVALUATIONS FOR UPHILL SIDE ............................................................. 51 APPENDIX B : DETAILED FLAW EVALUATIONS FOR DOWNHILL SIDE....................................................... 69 APPENDIX C : CALCULATION OF AVAILABLE YEARS OF SERVICE BASED ON AVAILABLE REINFORCEMENT AREA DUE TO CRACK GROWTH............................................................ 89 Page 5

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

List of Tables Page Table 1-1: Safety Factors for Flaw Acceptance ....................................................................................... 9 Table 4-1: Material Properties for Head ................................................................................................. 21 Table 4-2: Material Properties for Weld Metal ....................................................................................... 22 Table 4-3: Material Properties for Cladding ........................................................................................... 22 Table 4-4: Bounding Transients for Normal and Upset Conditions........................................................ 27 Table 4-5: Emergency and Faulted Condition Transients...................................................................... 27 Table 5-1: Test Case Results ................................................................................................................ 30 Table 6-1: LEFM Fracture Toughness Margins for Uphill Side .............................................................. 37 Table 6-2: LEFM Fracture Toughness Margins for Downhill Side ......................................................... 38 Page 6

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

List of Figures Page Figure 1-1: ID Temper Bead Weld Repair ............................................................................................... 8 Figure 2-1: Postulated Radial Flaw on Uphill Side................................................................................. 11 Figure 2-2: Postulated Radial Flaw on Downhill Side ............................................................................ 11 Figure 2-3: Finite Element Crack Model - Uphill Side ........................................................................... 13 Figure 2-4: Finite Element Crack Model - Downhill Side....................................................................... 14 Figure 4-1: Correlation of Coefficient, C, of Power Law with Charpy V-Notch Upper Shelf Energy ...... 24 Figure 4-2: Correlation of Exponent, m, of Power Law with Coefficient, C, and Flow Stress, o ........... 24 Page 7

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

1.0 INTRODUCTION

Due to the susceptibility of Alloy 600 partial penetration nozzles to primary water stress corrosion cracking (PWSCC), the Progress Energy plans to inspect the Control Rod Drive Mechanism (CRDM) and Core Exit Thermocouple (CET) nozzles in the Shearon Harris Unit 1 reactor vessel head. In the event that a repair is necessary, an ID temper bead weld repair procedure has been developed wherein the lower portion of the nozzle is removed by a boring procedure and the remaining portion is welded to the low alloy steel reactor vessel head above the original Alloy 82/182 J-groove attachment weld. The repair concept is illustrated in Figure 1-1, both with and without an overlap between the original J-groove weld and the new IDTB weld. The IDTB repair is more fully described by the design drawing [1]

and the technical requirements document [2]. Since a potential flaw in the J-groove weld cannot be sized by currently available non-destructive examination techniques, it is assumed that the as-left condition of the remaining J-groove weld includes degraded or cracked weld material extending through the entire J-groove weld and Alloy 82/182 butter material.

(a) With Weld Overlap (b) With Overlap Removed Figure 1-1: ID Temper Bead Weld Repair Page 8

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Since it is known from the residual stress analysis of the Shearon Harris reactor vessel head outermost nozzle penetration [3] that the hoop stress in the J-groove weld is greater than the axial stress at the same location, the preferential direction for cracking would be axial, or radial relative to the nozzle. It is postulated that a radial crack in the Alloy 82/182 weld metal would propagate by PWSCC, through the weld and butter, to the interface with the low alloy steel head material, where it is fully expected that such a crack would then blunt, or arrest, as discussed in Reference [4]. Since the vertical distance along the bored surface between the inside corner of the remnant J-groove weld and the point where the butter meets the head is more than two inches, a crack extending from the corner of the weld to the low alloy steel head would be very deep. Although primary water stress corrosion cracking would not extend into the head, it is further postulated that a small fatigue initiated flaw forms in the low alloy steel head and combines with the stress corrosion crack in the weld to form a large radial corner flaw that would propagate into the head by fatigue crack growth under cyclic loading conditions. Linear-elastic (LEFM) and elastic-plastic (EPFM) fracture mechanics procedures are utilized to evaluate this worst case flaw in the original J-groove weld and butter.

Key features of the fracture mechanics analysis are:

• This analysis applies specifically to the CRDM nozzle penetrations in the Shearon Harris Unit 1 reactor vessel closure head. A J-integral resistance curve is developed based on the Charpy V-notch upper-shelf energy for the Shearon Harris Unit 1 head plate material.

• Flaw growth is calculated for a 30 year period of operation, corresponding to 20 18-month fuel cycles.

• Final flaw acceptance is based on the available fracture toughness and ductile tearing resistance of the RVCH material considering the safety factors listed in Table 1-1.

• Since the same design is used at Shearon Harris Unit 1 for both the CRDM and CET nozzles and the CET nozzles are located within the same outermost penetration circle as the CRDM nozzles, the analysis performed herein for the CRDM nozzles is also applicable to the CET nozzles.

Table 1-1: Safety Factors for Flaw Acceptance Linear-Elastic Fracture Mechanics Operating Condition Evaluation Method Fracture Toughness / KI Normal/Upset KIa fracture toughness 10 = 3.16 Emergency/Faulted KIc fracture toughness 2 = 1.41 Elastic-Plastic Fracture Mechanics Operating Condition Evaluation Method Primary Secondary Normal/Upset J/T based flaw stability 3.0 1.5 Normal/Upset J0.1 limited flaw extension 1.5 1.0 Emergency/Faulted J/T based flaw stability 1.5 1.0 Emergency/Faulted J0.1 limited flaw extension 1.5 1.0 Page 9

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 2.0 ANALYTICAL METHODOLOGY A radial flaw at the inside corner of non-radial head penetration is evaluated based on a combination of linear elastic fracture mechanics (LEFM) and elastic-plastic fracture mechanics (EPFM), as outlined below.

1. Postulate radial flaws in the J-groove weld, extending from the inside corner of the penetration to the interface between the butter and head, as shown in Figure 2-1 and Figure 2-2 for the uphill and downhill sides of the penetration, respectively. Initial flaw size, ao, is arbitrarily characterized by the vertical distance along the uphill side penetration bore, from the inside surface of the cladding to the weld-to-butter/head interface, as shown Figure 2-1. For the constant depth J-groove design used for the Shearon Harris head, this same flaw depth is also used for the downhill side flaw evaluations.

2. Develop finite element models of the reactor vessel head in the vicinity of the outermost nozzle penetration, with crack tip elements along the interface between the Alloy 82/182 butter and the low alloy steel base metal. These models will be used to obtain stress intensity factors at various positions along the crack front for linearly superimposed residual and operating stresses.

3. Develop a mapping procedure to transfer stresses from an uncracked finite element stress model to the crack face of each crack model. This will enable stress intensity factors to be calculated for arbitrary stress distributions over the crack face utilizing the principle of superposition.

4. Calculate fatigue crack growth, in one year increments, for cyclic loading conditions using operational stresses from pressure and thermal loads. Since the stresses used in the fatigue crack growth analysis are the combined residual plus operating stresses, the effect of the residual stresses on fatigue crack growth is captured by the R ratio, or Kmin/Kmax. Starting from the stress intensity factor calculated by the finite element crack model for the initial flaw size, stress intensity factors are updated for each increment of crack growth by the square root of the flaw size.

5. Utilize the screening criteria of ASME Code Section XI, Appendix C to determine the failure mode and appropriate method of analysis (LEFM, EPFM, or limit load) for flaws in ferritic materials, considering the applied stress, temperature, and material toughness. For LEFM flaw evaluations, compare the stress intensity factor at the final flaw size to the available fracture toughness, with appropriate safety factors, as discussed in Section 2.2. When the material is more ductile and EPFM is the appropriate analysis method, evaluate flaw stability and crack driving force as described in Section 2.3. A primary stress limit analysis would be performed to satisfy the primary stress limits of the ASME Code, as described in Section 2.3.2.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure 2-1: Postulated Radial Flaw on Uphill Side Figure 2-2: Postulated Radial Flaw on Downhill Side Page 11

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 2.1 Stress Intensity Factor Solution Stress intensity factors for corner flaws at a non-radial nozzle penetration are best determined by finite element analysis using three-dimensional models with crack tip elements along the crack front.

Although loads can be applied to finite element crack models like any other structural model, the crack models were developed to serve as a flaw evaluation tool that could accept stresses from separate stress analyses. This strategy makes it possible, for example, to obtain pressure and thermal stresses from an independent thermal/structural analysis and then transfer these stresses to a crack model for flaw evaluations. Using the principle of superposition common to fracture mechanics analysis, the only stresses that need be considered for these flaw evaluations are the stresses on the crack face. A mapping procedure is developed to transfer stresses from a separate stress analysis to the crack face of the crack model.

2.1.1 Finite Element Crack Models Three-dimensional finite element models are developed for the reactor vessel head in the vicinity of the outermost nozzle penetration, by modeling a portion of the head, cladding, and butter with the ANSYS finite element computer program [5]. Since stresses increase with penetration angle, it is conservative to base the finite element models on the outermost nozzle penetration.

A three-dimensional finite element model is first constructed to represent an unflawed non-radial nozzle penetration in the reactor vessel head using the ANSYS SOLID186 20-node structural element.

Elements along the crack front are then replaced by a sub-model of crack tip elements along the interface between the Alloy 82/182 butter and the low alloy steel base metal. These elements consist of 20-node isoparametric elements that are collapsed to form a wedge with the appropriate mid-side nodes shifted to quarter-point locations to simulate the singularity at the crack tip. The final crack models are shown in Figure 2-3 and Figure 2-4 for the uphill and downhill sides of the nozzle, respectively.

Stress intensity factors will be obtained using the ANSYS CINT contour integral procedure at 17 positions along each crack front, as indicated in Figure 2-3 and Figure 2-4 for the two crack models.

Position 1 is located on the cladding surface, Position 3 at the cladding/base metal interface, Position 11 at the kink in the crack profile, and Position 17 is at the bored surface in the head.

2.1.2 Stress Mapping Stresses from the finite element stress model are mapped onto the crack faces of the uphill and downhill finite element crack models (Figure 2-3 and Figure 2-4). An ANSYS scripting language instruction (macro) has been developed to query the residual and operating stress models for nodal locations associated with each crack face node of the crack model. The nodal stress from the stress model is then transferred to the corresponding node on the crack model.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure 2-3: Finite Element Crack Model - Uphill Side Page 13

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure 2-4: Finite Element Crack Model - Downhill Side Page 14

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 2.1.3 Crack Growth Considerations The fundamental expression for the crack tip stress intensity factor is K I = a Since each crack model is developed for a single flaw size, stress intensity factors are updated at each increment of crack growth by the square root of the flaw size; i.e.,

ai +1 K I ( a i +1 ) = K I (a i ) ,

ai where a = flaw size i = increment of crack growth.

Since the stress intensity factor is directly proportional to the magnitude of the stress and both residual and operating stresses decrease in the direction of crack growth, this procedure produces conservative estimates of stress intensity factor as the crack extends into the head and stresses diminish over the expanding crack face.

2.1.4 Plastic Zone Correction The Irwin plasticity correction is used to account for a moderate amount of yielding at the crack tip. For plane strain conditions, this correction is 2

1 K I (a) ry = , [ Ref. 6, Eqn. (2.63) ]

6 y where K I ( a ) = stress intensity factor based on the actual crack size, a y = material yield strength.

A stress intensity factor, K I (a e ) , is then calculated for an effective crack size, a e = a + ry ,

based on the same scaling technique utilized for crack growth; i.e, ae K I (a e ) = K I (a) .

a Page 15

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 2.2 Linear Elastic Fracture MechanicsSection XI, Article IWB-3612 [11] requires that the applied stress intensity factor, KI, at the final flaw size be less than the available fracture toughness at the crack tip temperature, with appropriate safety factors, as outlined below.

Normal Conditions: K I < K Ia / 10 where KIa is the fracture toughness based on crack arrest.

Faulted Conditions: K I < K Ic / 2 where KIc is the fracture toughness based on crack initiation.

Section XI, Article IWB-3613 [11] provides alternate fracture toughness requirements for shell regions near structural discontinuities, such as nozzle penetrations, when the pressure does not exceed 20% of the design pressure and the temperature is not less than RTNDT + 60 °F. Within these operational limits a lower safety factor may be used to evaluate fracture toughness margin. For the Shearon Harris Unit 1 reactor vessel head, the design pressure is [ ] psig [13] and the fracture toughness reference temperature is [ ] [9]. Thus for pressures at or below [ ] psig and crack tip temperatures at or above [ ] the acceptance criterion for applied stress intensity factor is as follows:

At pressures [ ] psig and temperatures [ ]

K I < K Ia / 2 Page 16

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 2.3 Elastic-Plastic Fracture Mechanics Elastic-plastic fracture mechanics (EPFM) will be used as alterative acceptance criteria when the flaw related failure mechanism is unstable ductile tearing. This type of failure falls between rapid, non-ductile crack extension and plastic collapse. Linear elastic fracture mechanics (LEFM) would be used to assess the potential for non-ductile failure, whereas primary stress limit analysis would be used to check for plastic collapse.

2.3.1 Screening Criteria Screening criteria for determining failure modes in ferritic materials may be found in Appendix C of Section XI. Although Appendix C, Article C-4221 [11] contains specific rules for evaluating flaws in Class 1 ferritic piping, its screening criteria may be adapted to other ferritic components, such as the reactor vessel head, as follows:

Let, Kr = KIapp / KIc Sr = max / f Then the appropriate method of analysis is determined by the following limits:

LEFM Regime: Kr / Sr 1.8 EPFM Regime: 1.8 > Kr / Sr 0.2 Limit Load Regime: 0.2 > Kr / Sr 2.3.2 Primary Stress Limit Analysis While in most instances the screening criteria identify EPFM as the appropriate method of analysis, there are cases where low stress intensity factors (Kr) relative to the applied stress (Sr) places the analysis in the limit load regime. Such cases are analyzed through consideration of the primary stress limits of ASME Code Section III as embodied in the equation in Article NB-3324 [7] for the minimum required thickness (tmin) of the spherical closure head, PRo t min = ,

2Sm where P = design pressure, [ ] psig [13]

Ro = outside radius, [ ] [1]

Sm = design stress intensity, 26.7 ksi [12]

A conservative primary stress limit analysis would be to limit the remaining net-section of the head after removal of the final volume of weld material (after fatigue crack growth) to the minimum required design thickness, tmin. This is equivalent to removing a uniform depth of material along the inner surface of the vessel to encompass the final flaw and comparing the remaining thickness to t min = 3.74 in.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 2.3.3 Flaw Stability and Crack Driving Force Elastic-plastic fracture mechanics analysis will be performed using a J-integral/tearing modulus (J-T) diagram to evaluate flaw stability under ductile tearing, where J is either the applied (Japp) or the material (Jmat) J-integral, and T is the tearing modulus, defined as (E/f2)(dJ/da). The crack driving force, as measured by Japp, is also checked against the J-R curve at a crack extension of 0.1 inch (J0.1).

Consistent with industry practice for the evaluation of flaws in partial penetration welds used to attach nozzles to vessels, different safety factors will be utilized for primary and secondary loads. Flaw stability assessments for normal and upset conditions will consider a safety factor of 3 on the stress intensity factor due to primary (pressure) stresses and a safety factor of 1.5 for secondary (residual plus thermal) stresses. The crack driving force will be calculated using safety factors of 1.5 and 1 for primary and secondary stresses, respectively. For EPFM analysis of faulted conditions, safety factors of 1.5 and 1 will be used for flaw stability assessments and 1.5 and 1 for evaluations of crack driving force.

The general methodology for performing an EPFM analyses is outlined below.

Let E = E/(1-2)

Final flaw depth = a Total applied KI = KIapp KI due to pressure (primary) = KIp KI due to residual plus thermal (secondary) = KIs = KIapp - KIp Safety factor on primary loads = SFp Safety factor on secondary loads = SFs For small scale yielding at the crack tip, a plastic zone correction is used to calculate an effective flaw depth based on ae = a + [1/(6)] [ (KIp + KIs) / y ]2, which is used to update the stress intensity factors based on ae K 'Ip = K Ip a

ae and K'Is = K Is .

a The applied J-integral is then calculated using the relationship Japp = (SFp*KIp + SFs*KIs)2/E.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

The final parameter needed to construct the J-T diagram is the tearing modulus. The applied tearing modulus, Tapp, is calculated by numerical differentiation for small increments of crack size (da) about the final crack size (a), according to E Japp (a + da) Japp (a da)

Tapp = .

2f 2(da)

Using the power law expression for the J-R curve, JR = C(a)m ,

the material tearing modulus, Tmat, can be expressed as Tmat = (E/f2)Cm(a)m-1.

Constructing the J-T diagram, J

Unstable Region Tapp Tmat Applied Instability Point Material Stable Region Tapp < Tmat T

flaw stability is demonstrated at an applied J-integral when the applied tearing modulus is less than the material tearing modulus. Alternately, the applied J-integral is less than the J-integral at the point of instability.

To complete the EPFM analysis, it must be shown that the applied J-integral is less than J0.1, demonstrating that the crack driving force falls below the J-R curve at a crack extension of 0.1 inch.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 3.0 ASSUMPTIONS This section discusses assumptions and modeling simplifications applicable to the present analysis.

3.1 Unverified Assumptions This analysis contains the following two assumptions used in Appendix C for Nozzles 30, 40 and 51 that must be verified before structural integrity of the ASME Code Class 1 Reactor Vessel is assured.

1) The RV head wall thickness at any of the three penetrations (30, 40 and 51) is assumed to be no less than [ ] inches.

2) The J-groove weld size (in terms of cross-sectional area) of penetration 37 is assumed for penetrations 30 and 40; the J-groove weld size of penetration 49 is assumed for penetration 51.

3.2 Justified Assumptions The austenitic cladding is assumed to be adequately represented by 18Cr-8Ni (Type 304) stainless steel material.

In the body of the document, the size of the J-groove weld prep and the thickness of the buttering are based on nominal dimensions. This is considered to be standard practice in stress analysis and fracture mechanics analysis. It is conservatively assumed that the postulated flaw extends through the entire J-groove weld and butter.

In Appendix C, the crack growth areas at the three penetrations 30, 40 and 51 are estimated by the crack growth areas at Nozzles 14 and 37 (Figures C8 to C10). A review of Figures C8 to C10 indicates that closer the nozzle to the head center higher the crack growth area results. Therefore the crack growth area of Nozzle 14 for 15 years operation is taken as the bounding case for the three nozzles. A linear crack grown is assumed in the 15 years which is conservative, as the crack grown area in earlier years is less than that in later years.

3.3 Modeling Simplifications The finite element computer models used to generate residual stresses do not include the ID temper bead repair weld. This is deemed to be an appropriate modeling simplification since compressive stresses induced in the material adjacent to the repair weld would lower stresses on the uphill side of the J-groove weld (in close proximity to the repair weld) and have negligible effect on the downhill side of the J-groove weld (far removed from the repair weld).

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 4.0 DESIGN INPUTS This section provides basic input data needed to perform a fatigue crack growth analysis and a flaw evaluation of the final flaw size.

4.1 Materials 4.1.1 Mechanical and Thermal Properties Table 4-1, Table 4-2, and Table 4-3 list the temperature dependent values of modulus of elasticity (E),

Poissons ratio (), and coefficient of thermal expansion () properties used in the finite element crack models. These properties are obtained from the ASME Code,Section II [8], except for Poissons ratio, where 0.3 is a typical value used in structural analysis. The flow stress in Table 4-1 is the average of the yield and ultimate strengths.

Component Material Head SA-533, Grade B Class 1 [Ref. 2, Par. 6.1.1]

Cladding use Type 304 stainless steel (SA-240)

J-groove weld filler Equivalent to Alloy 600, SB-167 [Ref. 2, Par. 6.1.5]

J-groove weld butter use Alloy 600, SB-167 Table 4-1: Material Properties for Head Component Head Material SA-533 Grade B Class 1 (Mn-1/2Mo-1/2Ni)

Temperature E (106 psi) (10-6 in./in./oF) y (ksi) u (ksi) f (ksi) 70 29.20 0.3 7.0 50.0 80.0 65.0 100 29.04 0.3 7.1 50.0 80.0 65.0 150 28.77 0.3 7.2 48.1 80.0 64.1 200 28.50 0.3 7.3 47.0 80.0 63.5 250 28.25 0.3 7.3 46.2 80.0 63.1 300 28.00 0.3 7.4 45.5 80.0 62.8 350 27.70 0.3 7.5 44.9 80.0 62.4 400 27.40 0.3 7.6 44.2 80.0 62.1 450 27.20 0.3 7.6 43.7 80.0 61.9 500 27.00 0.3 7.7 43.2 80.0 61.6 550 26.70 0.3 7.8 42.7 80.0 61.3 600 26.40 0.3 7.8 42.1 80.0 61.1 650 25.85 0.3 7.9 41.5 80.0 60.8 700 25.30 0.3 7.9 40.7 80.0 60.4 Page 21

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table 4-2: Material Properties for Weld Metal Component Weld Butter and Weld Filler Material Use Alloy 600, SB-167 (72Ni-15Cr-8Fe) - UNS N06600 Temperature E (106 psi) (10-6 in./in./oF) 70 31.00 0.3 6.8 100 30.82 0.3 6.9 150 30.51 0.3 7.0 200 30.20 0.3 7.1 250 30.00 0.3 7.2 300 29.80 0.3 7.3 350 29.65 0.3 7.4 400 29.50 0.3 7.5 450 29.25 0.3 7.6 500 29.00 0.3 7.6 550 28.85 0.3 7.7 600 28.70 0.3 7.8 650 28.45 0.3 7.8 700 28.20 0.3 7.9 Table 4-3: Material Properties for Cladding Component Cladding Material Use Type 304 Stainless Steel (18Cr-8Ni) 6 Temperature E (10 psi) (10-6 in./in./oF) 70 28.30 0.3 8.5 100 28.14 0.3 8.6 150 27.87 0.3 8.8 200 27.60 0.3 8.9 250 27.30 0.3 9.1 300 27.00 0.3 9.2 350 26.75 0.3 9.3 400 26.50 0.3 9.5 450 26.15 0.3 9.6 500 25.80 0.3 9.7 550 25.55 0.3 9.8 600 25.30 0.3 9.8 650 25.05 0.3 9.9 700 24.80 0.3 10.0 Page 22

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 4.1.2 Toughness Properties The reference temperature for nil-ductility transition for the SA-533 Grade B Class 1 plate material in the dome portion of the Shearon Harris reactor vessel closure head is reported as RTNDT = [ ] [9]

and the Charpy upper-shelf energy is [ ] [9] in the transverse (weak) direction. Based on the welding procedure qualification record [10] for the ID temperature bead weld, a temperature of +5 °F should be added to the RTNDT of the base material to account for embrittlement in the heat affected zone, so that the effective RTNDT is [ ] for flaw evaluations in the head.

4.1.3 Fracture Toughness From Article A-4200 of Section XI [11], the lower bound KIa fracture toughness for crack arrest can be expressed as KIa = 26.8 + 12.445 exp [ 0.0145 (T - RTNDT) ],

where T is the crack tip temperature, RTNDT is the reference nil-ductility temperature of the material, KIa is in units of ksiin, and T and RTNDT are in units of °F. In the present flaw evaluations, KIa is limited to a maximum value of 200 ksiin (upper-shelf fracture toughness). Using the above equation with an RTNDT of [ ] KIa equals 200 ksiin at a crack tip temperature of [ ].

A higher measure of fracture toughness is provided by the KIc fracture toughness for crack initiation, approximated in Article A-4200 of Section XI [11] by KIc = 33.2 + 20.734 exp [ 0.02 (T - RTNDT) ].

4.1.4 J-integral Resistance Curve The J-integral resistance (J-R) curve, needed for the EPFM method of analysis, is obtained from the following power law expression for nuclear reactor pressure vessel steels, JR = C(a)m, where the coefficient, C, and exponent, m, depend on the Charpy V-notch upper-shelf energy, CVN, and the flow stress, o or f, as shown in Figure 4-1 and Figure 4-2.

Using the above referenced Charpy V-notch upper-shelf energy correlation for the J-integral resistance curve with a Charpy V-notch upper-shelf energy of [ ] the coefficients of the power law equation over a wide range of temperatures are:

C= [ ]

m= [ ]

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure 4-1: Correlation of Coefficient, C, of Power Law with Charpy V-Notch Upper Shelf Energy Figure 4-2: Correlation of Exponent, m, of Power Law with Coefficient, C, and Flow Stress, o Page 24

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 4.1.5 Fatigue Crack Growth Rate Flaw growth due to cyclic loading is calculated using the fatigue crack growth rate model from Article A-4300 of Section XI [11],

da

= C o ( K I )n ,

dN where KI is the stress intensity factor range in ksiin and da/dN is in inches/cycle. The crack growth rates for a surface flaw will be used for the evaluation of the corner crack since it is assumed that the degraded condition of the J-groove weld and butter exposes the low alloy steel head material to the primary water environment.

The following equations from Section XI [11] are used to model fatigue crack growth.

KI = KImax - KImin R = KImin / KImax 0 R 0.25: KI < 17.74, n = 5.95 Co = 1.02 x 10-12 x S S = 1.0 KI 17.74, n = 1.95 Co = 1.01 x 10-7 x S S = 1.0 0.25 R 0.65: KI < 17.74 [ (3.75R + 0.06) / (26.9R - 5.725) ]0.25, n = 5.95 Co = 1.02 x 10-12 x S S = 26.9R - 5.725 KI 17.74 [ (3.75R + 0.06) / (26.9R - 5.725) ]0.25, n = 1.95 Co = 1.01 x 10-7 x S S = 3.75R + 0.06 0.65 R < 1.0: KI < 12.04, n = 5.95 Co = 1.02 x 10-12 x S S = 11.76 KI 12.04, n = 1.95 Co = 1.01 x 10-7 x S S = 2.5 Page 25

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 4.2 Basic Geometry The reactor vessel head and CRDM nozzle penetration are described by the following key dimensions:

Spherical radius to base metal = [ ] in. [9]

Head thickness = [ ] in. [9]

Cladding thickness = [ ] in. [9]

Butter thickness = [ ] in. [9]

Penetration bore = [ ] in. [9]

Horizontal radius to outermost penetration = [ ] in. [9]

Penetration angle at outermost nozzle = [ ] deg. (derived*)

• (sin-1(horizontal radius/spherical radius))

4.3 Operating Transients Based on bounding transients developed for the companion ASME Code Section III fatigue stress analysis [12], fatigue crack growth will be calculated for the normal and upset condition transients listed in Table 4-4. Since crack growth will be calculated in one-year increments, the number of cycles is obtained by dividing the forty-year design life cycles by 40. While not physically meaningful, a fractional yearly cycle count is computationally acceptable since it is merely used to determine an increment of crack growth from a calculated value of da/dN.

Table 4-5 lists the emergency and faulted condition transients applicable to Shearon Harris reactor vessel components [13]. From a review of the pressure and temperature time-history definitions for these transients, it is clear that the large LOCA and large steam line break transients would bound the remaining transients for emergency and faulted condition flaw evaluations.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table 4-4: Bounding Transients for Normal and Upset Conditions Table 4-5: Emergency and Faulted Condition Transients

• Bounding transients to be considered in emergency and faulted condition flaw evaluations Page 27

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 4.4 Applied Stresses Two sources of applied stress are considered for the present flaw evaluations, residual stresses from welding and stresses that occur during plant operation.

4.4.1 Residual Stresses Residual stresses are obtained from a three-dimensional elastic-plastic finite element stress analysis [3]

that simulates fabrication of the outermost nozzle to head partial penetration weld and the effect of subsequent hydrostatic tests and operating cycles on stresses in the welded joint. It is widely accepted that stresses at the outermost CRDM nozzle location conservatively bound stresses at all other nozzle locations exhibiting a smaller penetration angle (the angle between the nozzle and inside surface of the head on the downhill side of the penetration). Stresses are transferred from the finite element residual stress model in the form of nodal arrays contained in ANSYS parameter save files.

4.4.2 Operating Stresses Operating stresses are obtained from the three-dimensional finite element stress analysis [12] used to qualify the nozzle repair to ASME Code Section III requirements. Hoop stresses from the Section III analysis are conservatively superimposed on the residual stresses to represent the crack face opening stresses during operation. Stresses are transferred from the finite element operating stress model in the form of nodal arrays contained in ANSYS parameter save files. Pressure is added to the operating stresses to account for the additional loading on the crack face due to pressure.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 5.0 COMPUTER USAGE This section describes computer resources, software testing, and stored computer files.

5.1 Hardware/Software 5.2 Installation/Validation Test Page 29

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table 5-1: Test Case Results Verification Problem VM256 Fracture Mechanics Analysis of a Crack in a Plate File: vm256.vrt

---

VM256 RESULTS COMPARISON ----------------------------------------

l TARGET l ANSYS l RATIO USING PLANE 183 ELEMENT (2-D ANALYSIS)

KI 1.0249 1.0038 0.979 USING SOLID 185 ELEMENT (3-D ANALYSIS)

KI 1.0249 1.0383 1.013 USING SOLID 186 ELEMENT - SURFACE CRACK (3-D ANALYSIS)

KI 1.4000 1.4132 1.009 Page 30

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 5.3 Computer Files The computer files listed below are stored in the AREVA ColdStor repository in the directory

\cold\41304\32-9176350-000\official.

ANSYS Models ColdStor ColdStor File Name Description Storage Storage Checksum Date Time

[

[ ] 04-15-12 09:01:06 22856

]

[

[ ] 04-15-12 09:00:56 18509

]

ANSYS Macros ColdStor ColdStor File Name Description Storage Storage Checksum Date Time

[ ] [ ] 04-15-12 09:01:22 15845

[ ] [ ] 04-15-12 09:01:21 11056 ANSYS Input Files ColdStor ColdStor File Name Description Storage Storage Checksum Date Time

[

[ ] 04-15-12 09:01:42 32454

]

[

[ ] 04-15-12 09:01:41 08793

]

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

ANSYS Result Files for Uphill Stress Intensity Factors File Name ColdStor ColdStor Loading Condition Storage Storage Checksum Date Time 04-15-12 09:04:35 22371 04-15-12 09:04:07 16344 04-15-12 09:04:03 19578 04-15-12 09:04:10 45340 04-15-12 09:04:10 36382 04-15-12 09:04:09 50736 04-15-12 09:04:08 46959 04-15-12 09:04:09 35163 04-15-12 09:04:07 46631 04-15-12 09:04:04 15882 04-15-12 09:04:05 54622 04-15-12 09:04:08 25345 04-15-12 09:04:04 17221 04-15-12 09:04:03 01071 04-15-12 09:04:06 55706 04-15-12 09:04:05 62230 04-15-12 09:04:06 06099 Page 32

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

ANSYS Result Files for Downhill Stress Intensity Factors Loading Condition ColdStor ColdStor File Name Storage Storage Checksum Date Time 04-15-12 09:04:34 59428 04-15-12 09:03:13 59492 04-15-12 09:03:10 49475 04-15-12 09:03:16 50217 04-15-12 09:03:17 37165 04-15-12 09:03:16 34304 04-15-12 09:03:15 19734 04-15-12 09:03:16 29947 04-15-12 09:03:14 23156 04-15-12 09:03:11 35585 04-15-12 09:03:12 60112 04-15-12 09:03:15 42106 04-15-12 09:03:11 65275 04-15-12 09:03:10 04872 04-15-12 09:03:13 36168 04-15-12 09:03:12 09825 04-15-12 09:03:13 31095 Page 33

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Excel Spreadsheets Description ColdStor ColdStor File Name Storage Storage Checksum Date Time 04-15-12 09:06:58 58102 04-15-12 09:06:57 00505 04-15-12 09:06:57 38955 04-15-12 09:06:57 63694 04-15-12 09:06:56 21575 04-15-12 09:06:56 25218 ANSYS Test Cases ColdStor ColdStor File Name Description Storage Storage Checksum Date Time

[

[ ] 04-15-12 09:07:25 49343

]

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 6.0 CALCULATIONS Propagation of a postulated initial flaw in the J-groove weld and butter is calculated to determine the final flaw size after 30 years of service. Flaw evaluations are then performed to assess the acceptability of the final flaw size.

6.1 Initial Flaw Size It is both difficult and unnecessary to prescribe initial flaw sizes for the non-classical flaw shapes comprising the postulated uphill and downhill flaws in the J-groove weld and butter. Since the explicit finite element crack models described in Section 2.1.1 were developed to realistically capture the basic geometry of the J-shaped flaws, any characteristic dimension of the flaws may be used to track flaw growth during cyclic fatigue. The constant depth J-groove design suggests that a common value can be utilized to describe the initial depth of the uphill and downhill flaws. Accordingly, the vertical distance along the uphill side penetration bore, from the inside surface of the cladding to the weld-to-butter/head interface, is used to define the initial flaw size, ao (as shown Figure 2-1). From the uphill crack model, the initial flaw size value is determined to be 2.1482.

As discussed in Section 2.1.3, crack tip stress intensity factors are calculated directly from the finite element crack models for the initial flaw size and then updated based on incremental crack growth according to ai +1 K I ( a i +1 ) = K I (a i ) ,

ai so that after the first increment of crack growth, a1 K I ( a i ) = K I (a 0 ) .

a0 6.2 Fatigue Crack Growth Although it is believed that a PWSCC flaw would be confined to the J-groove weld and butter, it is postulated that a fatigue flaw would initiate in the low alloy steel head, combine with the PWSCC flaw, and propagate farther into the head under cyclic loads. Fatigue crack growth is calculated from finite element based stress intensity factors using residual and operational stresses from References [3] and

[12], respectively. The actual flaw growth calculations are presented in Appendix A for the uphill flaw and Appendix B for the downhill flaw, along with a comparison of the final stress intensity factor for each transient with the fracture toughness requirements of Section XI. Table 6-1 and Table 6-2 summarize the flaw growth analyses for the uphill and downhill sides of the flaw, respectively. These tables serve several purposes; they present the final flaw size at the end the design life, they compare stress intensity factors at the final flaw size with LEFM acceptance criteria, and they serve as a means of screening for the worst case loading conditions and stress intensity factors for subsequent EPFM analysis.

Crack growth is calculated in one-year increments for each of the analyzed transients, while uniformly distributing the growth over the service life by linking the yearly crack growth between the crack growth tables in Appendix A for the uphill flaw and the tables in Appendix B for the downhill flaw.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Stress intensity factors are provided in the crack growth tables for all locations along the postulated crack fronts, including the cladding. It is apparent from the tables in Appendix A that on the uphill side of the penetration, the highest stress intensity factors in the low alloy steel head occur near the cladding surface (Position 3) for residual stresses and near the penetration bore (Position 16) for operating stresses. It is noted that due to residual tensile strain in the cladding material, cladding stresses and the associated stress intensity factors may be higher than those in the adjacent head material. However, stress intensity factors within the stainless steel cladding portion of the crack front need not be considered in the evaluation of the potential for non-ductile failure of the low alloy steel head. Fatigue crack growth analysis performed for both Position 3 and 16 showed that the operating stresses controlled, producing higher final stress intensity factors at Position 16. Thus Position 16 on the uphill side will be used to calculate fatigue crack growth and evaluate the final stress intensity factors for each transient considering flaw acceptance standards for the low alloy steel head material. The downhill side crack growth tables in Appendix B, use Position 7 to calculate crack growth and evaluate fracture toughness margins since the highest stress intensity factors occur either at or near this crack front position for both the residual and operating stresses.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table 6-1: LEFM Fracture Toughness Margins for Uphill Side Period of Operation: Time = 30 years Flaw Size: a=

Loading Conditions Temperature Pressure Fracture Toughness, KIc 200.0 200.0 98.0 200.0 200.0 200.0 63.5 200.0 200.0 200.0 200.0 200.0 200.0 63.5 200.0 ksiin Fracture Toughness, KIa 200.0 85.5 55.2 200.0 200.0 200.0 43.2 200.0 200.0 200.0 200.0 200.0 200.0 43.2 200.0 ksiin Position 16 KI(a) 73.546 50.736 31.531 78.325 79.225 94.843 64.199 82.085 72.962 109.077 73.540 96.413 89.569 233.116 190.113 ksiin ae 3.1971 3.0955 3.0602 3.2163 3.2219 3.2883 3.1266 3.2381 3.1944 3.3708 3.1972 3.2988 3.2369 4.1923 3.9097 in.

KI(ae) 75.434 51.204 31.640 80.576 81.573 98.653 65.117 84.729 74.802 114.874 75.428 100.448 92.437 273.795 215.630 ksiin Margin = KIc / KI(ae) n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 0.23 0.93 Margin = KIa / KI(ae) 2.65 1.67 1.75 2.48 2.45 2.03 0.66 2.36 2.67 1.74 2.65 1.99 2.16 n/a n/a Required Margin 3.16 1.41 1.41 3.16 3.16 3.16 1.41 3.16 3.16 3.16 3.16 3.16 3.16 1.41 1.41 Acceptable by LEFM? No Yes Yes No No No No No No No No No No No No where: ae = a + 1/(6) [KI(a)/Sy] 2 KI(ae) = KI(a)*(ae/a)

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table 6-2: LEFM Fracture Toughness Margins for Downhill Side Period of Operation: Time = 30 years Flaw Size: a=

Loading Conditions Temperature Pressure Fracture Toughness, KIc 200.0 200.0 98.0 200.0 200.0 200.0 63.5 200.0 200.0 200.0 200.0 200.0 200.0 63.5 200.0 ksiin Fracture Toughness, KIa 200.0 85.5 55.2 200.0 200.0 200.0 43.2 200.0 200.0 200.0 200.0 200.0 200.0 43.2 200.0 ksiin Position 7 KI(a) 56.220 22.499 17.076 58.314 58.716 65.540 55.130 59.913 55.969 72.039 56.216 66.756 65.585 77.409 63.626 ksiin ae 2.3201 2.2388 2.2339 2.3259 2.3279 2.3467 2.2923 2.3337 2.3191 2.3724 2.3201 2.3515 2.3338 2.3549 2.3255 in.

KI(ae) 57.373 22.555 17.099 59.585 60.021 67.267 55.923 61.322 57.105 74.341 57.369 68.584 67.127 79.587 65.007 ksiin Margin = KIc / KI(ae) n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 0.80 3.08 Margin = KIa / KI(ae) 3.49 3.79 3.23 3.36 3.33 2.97 0.77 3.26 3.50 2.69 3.49 2.92 2.98 n/a n/a Required Margin 3.16 1.41 1.41 3.16 3.16 3.16 1.41 3.16 3.16 3.16 3.16 3.16 3.16 1.41 1.41 Acceptable by LEFM? Yes Yes Yes Yes Yes No No Yes Yes No Yes No No No Yes where: ae = a + 1/(6) [KI(a)/Sy] 2 KI(ae) = KI(a)*(ae/a)

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 6.3 LEFM Flaw Evaluations Results of the linear-elastic fracture mechanics flaw evaluations are summarized below for the final flaw size after 30 years of crack growth.

6.3.1 Normal and Upset Conditions Listed below are the controlling LEFM fracture toughness margins from the fatigue crack growth tables.

Uphill Side Downhill Side Flaw Sizes Initial flaw size, ai = 2.148 in. 2.148 in.

Final flaw size, af = [ ] in. [ ] in.

Flaw growth, a = [ ] in. [ ] in.

Operating Conditions Reactor Trip Reactor Trip Temperature, T= [ ] o F [ ] o F

Fracture toughness, KIa = 200.0 ksiin 200.0 ksiin Final stress intensity factor, KI(af) = 109.1 ksiin 72.04 ksiin Effective flaw size, ae = 3.371 in. 2.372 in.

Effective stress intensity factor, KI(ae) = 114.9 ksiin 74.34 ksiin Fracture toughness margin (> 3.16), KIa/KI(ae) = 1.74 2.69 Low Temperature Conditions Refueling Refueling Temperature, T= [ ] o F [ ] o F

Fracture toughness, KIa = 43.2 ksiin 43.2 ksiin Final stress intensity factor, KI(af) = 64.20 ksiin 55.13 ksiin Effective flaw size, ae = 3.127 in. 2.292 in.

Effective stress intensity factor, KI(ae) = 65.12 ksiin 55.92 ksiin Fracture toughness margin (> 1.41), KIa/KI(ae) = 0.66 0.77 Since the above fracture toughness margins for the controlling normal and upset conditions are less than the Code required minimums, EPFM flaw evaluations will be performed in Section 6.4 to account for the ductile behavior of the low alloy steel under stable crack propagation.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 6.3.2 Faulted Conditions The bounding faulted condition stress intensity factors are evaluated below for the final flaw size after 30 years of crack growth.

Uphill Side Downhill Side Flaw Sizes Final flaw size, af = [ ] in. [ ] in.

Large Loss of Coolant Accident Temperature, T= [ ] o F [ ] o F

Fracture toughness, KIc = 63.5 ksiin 63.5 ksiin Final stress intensity factor, KI(af) = 233.1 ksiin 77.41 ksiin Effective flaw size, ae = 4.192 in. 2.355 in.

Effective stress intensity factor, KI(ae) = 273.8 ksiin 79.59 ksiin Fracture toughness margin (> 1.41), KIc/KI(ae) = 0.23 0.80 Large Steam Line Break Temperature, T= [ ] o F [ ] o F

Fracture toughness, KIc = 200.0 ksiin 200.0 ksiin Final stress intensity factor, KI(af) = 190.1 ksiin 63.63 ksiin Effective flaw size, ae = 3.910 in. 2.326 in.

Effective stress intensity factor, KI(ae) = 215.6 ksiin 65.01 ksiin Fracture toughness margin (> 1.41), KIc/KI(ae) = 0.93 3.08 Since some of the above fracture toughness margins for the controlling faulted conditions are less than the Code required minimums, EPFM flaw evaluations will be performed in Section 6.4 to account for the ductile behavior of the low alloy steel under stable crack propagation.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 6.4 EPFM Flaw Evaluations The EPFM analysis is used to evaluate the limiting loading conditions that fail the LEFM-based Code margins. In this context, EPFM is meant to include either classical elastic-plastic fracture mechanics or primary stress limit analysis, as applicable.

6.4.1 Operating Conditions Uphill Side Downhill Side Controlling Conditions Reactor Trip Reactor Trip Flaw size at 30 years of service, a= [ ] in. [ ] in.

Effective flaw size, ae = 3.371 in. 2.373 in.

SCREENING PROCEDURE T= [ ] o F [ ] o F

E = 27200 ksi 27200 ksi

= 0.3 0.3 E = E/(1-2) = 29890 ksi 29890 ksi y = 43.6 ksi 43.6 ksi u = 80.0 ksi 80.0 ksi f = 61.8 ksi 61.8 ksi Crack initiation toughness, KIc = 200.0 ksiin 200.0 ksiin Total applied KI, KI(ae) = 114.9 ksiin 74.34 ksiin Kr = KI(ae) / KIc = 0.574 0.372 From finite element analysis, the maximum crack face stresses due to residual stress, pressure, and thermal gradients are max = 68.3 ksi 70.9 ksi Sr = max / f = 1.105 1.147 Screening ratio, Kr / Sr = 0.520 0.324 (1.8 > Kr / Sr 0.2) (1.8 > Kr / Sr 0.2)

Analysis regime: EPFM EPFM Page 41

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

EPFM ANALYSIS Uphill Side Downhill Side Controlling Conditions Reactor Trip Reactor Trip KI primary, KIp(a) = 190.8 ksiin 86.02 ksiin KI secondary (residual plus thermal), KIs(a) = 68.19 ksiin 65.05 ksiin Total KI, KI(a) = 259.0 ksiin 151.1 ksiin Effective flaw size, ae = 4.912 in. 2.865 in.

Total KI, KI(ae) = 329.3 ksiin 171.3 ksiin Table A-14 (uphill side) and Table B-14 (downhill side) develop all the data necessary to construct J-T diagrams for the controlling operating conditions. The J-T diagrams are presented in Figures A-1 and B-1 for the uphill and downhill sides, respectively.

Uphill Side:

It can be seen from Table A-14 that for an applied J-integral of 3.628 kips/in, corresponding to safety factors of 3 and 1.5, the applied tearing modulus, 8.502, is less than the material tearing modulus, 50.70, indicating flaw stability. Alternately, the applied J-integral is less than the J-integral, 8.181 kips/in, at the point of instability. For safety factors of 1.5 and 1, the applied J-integral of 0.785 kips/in is less than the J0.1 value of 2.473 kips/in, demonstrating that the crack driving force falls below the J-R curve at a crack extension of 0.1 inch.

Downhill Side:

Table B-14 shows that for an applied J-integral of 0.982 kips/in, corresponding to safety factors of 3 and 1.5, the applied tearing modulus, 3.139, is less than the material tearing modulus, 242.0, indicating flaw stability. The applied J-integral is also less than the J-integral, 7.102 kips/in, at the point of instability.

For safety factors of 1.5 and 1, the applied J-integral of 0.273 kips/in is less than the J0.1 value of 2.473 kips/in, demonstrating that the crack driving force falls below the J-R curve at a crack extension of 0.1 inch.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 6.4.2 Low Temperature Conditions Uphill Side Downhill Side Controlling Conditions Refueling Refueling Flaw size at 30 years of service, a= [ ] in. [ ] in.

Effective flaw size, ae = 3.127 in. 2.292 in.

SCREENING PROCEDURE T= [ ] o F [ ] o F

E = 29200 ksi 29200 ksi

= 0.3 0.3 2

E = E/(1- ) = 32080 ksi 32080 ksi y = 50.0 ksi 50.0 ksi u = 80.0 ksi 80.0 ksi f = 65.0 ksi 65.0 ksi Crack initiation toughness, KIc = 63.5 ksiin 63.5 ksiin Total applied KI, KI(ae) = 65.12 ksiin 55.92 ksiin Kr = KI(ae) / KIc = 1.025 0.880 From finite element analysis, the maximum crack face stresses due to residual stress, pressure, and thermal gradients are max = 59.1 ksi 49.5 ksi Sr = max / f = 0.909 0.762 Screening ratio, Kr / Sr = 1.127 1.156 (1.8 > Kr / Sr 0.2) (1.8 > Kr / Sr 0.2)

Analysis regime: EPFM EPFM Page 43

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

EPFM ANALYSIS Uphill Side Downhill Side Controlling Conditions Refueling Refueling KI primary, KIp(a) = 0.0 ksiin 0.0 ksiin KI secondary (residual plus thermal), KIs(a) = 96.30 ksiin 82.70 ksiin Total KI, KI(a) = 96.30 ksiin 82.70 ksiin Effective flaw size, ae = 3.236 in. 2.373 in.

Total KI, KI(ae) = 99.37 ksiin 85.35 ksiin Table A-15 (uphill side) and Table B-15 (downhill side) develop all the data necessary to construct J-T diagrams for the controlling operating conditions. The J-T diagrams are presented in Figures A-2 and B-2 for the uphill and downhill sides, respectively.

Uphill Side:

It can be seen from Table A-15 that for an applied J-integral of 0.308 kips/in, corresponding to safety factors of 3 and 1.5, the applied tearing modulus, 0.700, is less than the material tearing modulus, 942.9, indicating flaw stability. Alternately, the applied J-integral is less than the J-integral, 8.179 kips/in, at the point of instability. For safety factors of 1.5 and 1, the applied J-integral of 0.132 kips/in is less than the J0.1 value of 2.474 kips/in, demonstrating that the crack driving force falls below the J-R curve at a crack extension of 0.1 inch.

Downhill Side:

Table B-15 shows that for an applied J-integral of 0.227 kips/in, corresponding to safety factors of 3 and 1.5, the applied tearing modulus, 0.704, is less than the material tearing modulus, 1357, indicating flaw stability. The applied J-integral is also less than the J-integral, 7.101 kips/in, at the point of instability.

For safety factors of 1.5 and 1, the applied J-integral of 0.097 kips/in is less than the J0.1 value of 2.474 kips/in, demonstrating that the crack driving force falls below the J-R curve at a crack extension of 0.1 inch.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 6.4.3 Faulted Conditions Uphill Side Downhill Side Controlling Conditions LLOCA LLOCA Flaw size at 30 years of service, a= [ ] in. [ ] in.

Effective flaw size, ae = 4.192 in. 2.355 in.

SCREENING PROCEDURE T= [ ] o F [ ] o F

E = 29200 ksi 29200 ksi

= 0.3 0.3 2

E = E/(1- ) = 32080 ksi 32080 ksi y = 50.0 ksi 50.0 ksi u = 80.0 ksi 80.0 ksi f = 65.0 ksi 65.0 ksi Crack initiation toughness, KIc = 63.5 ksiin 63.5 ksiin Total applied KI, KI(ae) = 273.8 ksiin 79.59 ksiin Kr = KI(ae) / KIc = 4.310 1.253 From finite element analysis, the maximum crack face stresses due to residual stress, pressure, and thermal gradients are max = 198.3 ksi 163.2 ksi Sr = max / f = 3.051 2.511 Screening ratio, Kr / Sr = 1.413 0.499 (1.8 > Kr / Sr 0.2) (1.8 > Kr / Sr 0.2)

Analysis regime: EPFM EPFM Page 45

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

EPFM ANALYSIS Uphill Side Downhill Side Controlling Conditions LLOCA LLOCA KI primary, KIp(a) = 2.596 ksiin 1.170 ksiin KI secondary (residual plus thermal), KIs(a) = 231.4 ksiin 76.63 ksiin Total KI, KI(a) = 234.0 ksiin 77.80 ksiin Effective flaw size, ae = 4.201 in. 2.356 in.

Total KI, KI(ae) = 275.1 ksiin 80.01 ksiin Table A-16 (uphill side) and Table B-16 (downhill side) develop all the data necessary to construct J-T diagrams for the controlling operating conditions. The J-T diagrams are presented in Figures A-3 and B-3 for the uphill and downhill sides, respectively.

Uphill Side:

It can be seen from Table A-16 that for an applied J-integral of 2.359 kips/in, corresponding to safety factors of 1.5 and 1, the applied tearing modulus, 5.364, is less than the material tearing modulus, 82.38, indicating flaw stability. Alternately, the applied J-integral is less than the J-integral, 8.179 kips/in, at the point of instability. For safety factors of 1.5 and 1, the applied J-integral of 2.359 kips/in is less than the J0.1 value of 2.474 kips/in, demonstrating that the crack driving force falls below the J-R curve at a crack extension of 0.1 inch.

Downhill Side:

Table B-16 shows that for an applied J-integral of 0.200 kips/in, corresponding to safety factors of 1.5 and 1, the applied tearing modulus, 0.619, is less than the material tearing modulus, 1584, indicating flaw stability. The applied J-integral is also less than the J-integral, 7.101 kips/in, at the point of instability. For safety factors of 1.5 and 1, the applied J-integral of 0.200 kips/in is less than the J0.1 value of 2.474 kips/in, demonstrating that the crack driving force falls below the J-R curve at a crack extension of 0.1 inch.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 6.5 Primary Stress Limit Analysis The primary stress limit analysis (also referred to as primary stress limits of NB-3000) that addresses all the Shearon Harris repaired configurations as of the Fall 2016 outage are addressed in Appendix C. Based on this primary stress limit analysis, it is concluded that amongst the twelve repairs performed to-date as of October 2016, Nozzles 30, 40, and 51 yield the most limiting life of 5 years since the repairs were performed in October 2016.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) 7.0

SUMMARY

OF RESULTS AND CONCLUSIONS Linear-elastic and elastic-plastic fracture mechanics has been used to evaluate a postulated radial flaw in the J-groove weld and butter of an outermost CRDM nozzle reactor vessel head penetration. It was determined that an acceptable flaw size would be present after 30 years of fatigue crack growth, based on EPFM analysis consideration only, as summarized below.

7.1 Summary of Results Uphill Side Downhill Side Flaw Sizes Initial flaw size, ai = 2.148 in. 2.148 in.

Final flaw size after 30 years, af = [ ] in. [ ] in.

Flaw growth, a = [ ] in. [ ] in.

Operating Conditions Reactor Trip Reactor Trip Temperature, T= [ ] o F [ ] o F

Material tearing modulus, Tmat = 50.70 242.0 Material J-integral at 0.1 crack extension, J0.1 = 2.473 kips/in. 2.473 kips/in.

Safety factors (primary/secondary), SF = 3 / 1.5 3 / 1.5 Applied tearing modulus (< Tmat) Tapp = 8.502 3.139 Safety factors (primary/secondary), SF = 1.5 / 1 1.5 / 1 Applied J-integral (< J0.1) Japp = 0.785 kips/in 0.273 kips/in Low Temperature Conditions Refueling Refueling Temperature, T= [ ] o F [ ] o F

Material tearing modulus, Tmat = 942.9 1357 Material J-integral at 0.1 crack extension, J0.1 = 2.474 kips/in. 2.474 kips/in.

Safety factors (primary/secondary), SF = 3 / 1.5 3 / 1.5 Applied tearing modulus (< Tmat) Tapp = 0.700 0.704 Safety factors (primary/secondary), SF = 1.5 / 1 1.5 / 1 Applied J-integral (< J0.1) Japp = 0.132 kips/in 0.097 kips/in Page 48

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Summary of Results (Contd)

Faulted Conditions LLOCA LLOCA Temperature, T= [ ] o F [ ] o F

Material tearing modulus, Tmat = 82.38 1584 Material J-integral at 0.1 crack extension, J0.1 = 2.474 kips/in. 2.474 kips/in.

Safety factors (primary/secondary), SF = 1.5 / 1 1.5 / 1 Applied tearing modulus (< Tmat) Tapp = 5.364 0.619 Safety factors (primary/secondary), SF = 1.5 / 1 1.5 / 1 Applied J-integral (< J0.1) Japp = 2.359 kips/in 0.200 kips/in 7.2 Conclusion Based on a combination of linear elastic and elastic-plastic fracture mechanics analysis of a postulated remaining flaw in the original Alloy 182 J-groove weld and butter material, the Shearon Harris Unit 1 CRDM and CET nozzles are considered to be acceptable for at least 30 years of operation following an IDTB weld repair. However, based on primary stress limit analysis, considering all the CRDM repaired configurations as of October 2016, the overall service life of the Shearon Harris Unit 1 RVCH is 5 years from the performance of the October 2016 repairs, as determined in Appendix C of the document.

8.0 REFERENCES

1. AREVA Drawing 02-9175500E-007, Shearon Harris CRDM ID Temper Bead Weld Repair

2. AREVA Document 08-9172870-003, Shearon Harris RVCH CRDM and CET Nozzle Penetration Modification

3. AREVA Document 32-9176344-000, Shearon Harris Unit 1 IDTB CRDM/CET Nozzle Weld Residual Stress Analysis - Proprietary Document

4. AREVA Document 51-5012047-00, Stress Corrosion Cracking of Low Alloy Steel

5. ANSYS Finite Element Computer Code, Version 12.1, ANSYS Inc., Canonsburg, PA.

6. T.L. Anderson, Fracture Mechanics: Fundamentals and Applications, CRC Press, 1991.

7. ASME Boiler and Pressure Vessel Code,Section III, Rules for Construction of Nuclear Facility Components, Division 1, Subsection NB, Class 1 Components, 2001 Edition with Addenda through 2003.

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

8. ASME Boiler and Pressure Vessel Code,Section II, Materials, 2001 Edition with Addenda through 2003.

9. AREVA Document 38-2200979-000, Shearon Harris - Proprietary Document Transmittal 1

10. AREVA Document 55-PQ7183-005, Procedure Qualification Record PQ7183-005

11. ASME Boiler and Pressure Vessel Code,Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components, 2001 Edition with Addenda through 2003.

12. AREVA Document 32-9175220-003, Shearon Harris Unit 1 Contingency CRDM IDTB Weld Repair Analysis

13. AREVA Document 38-2201004-000, Shearon Harris - Proprietary Document Transmittal 4 Page 50

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

APPENDIX A: DETAILED FLAW EVALUATIONS FOR UPHILL SIDE This appendix presents the fatigue crack growth tables and the elastic-plastic fracture mechanics flaw evaluations for the uphill side of the CRDM penetration.

Table A-1: Stress Intensification Factors for Uphill Side - Welding Residual Stress Condition WRS Temperature 70.0 F Pressure n/a psig Sy 50.0 ksi KIc 98.0 ksiin KIa 55.2 ksiin Crack Front KI Position (ksiin) 1 45.118 2 41.056 3 38.435 4 31.191 5 27.747 6 24.365 7 20.513 8 14.773 9 18.055 10 9.772 11 -2.101 12 7.352 13 14.344 14 18.763 15 22.133 16 26.509 17 17.849 Page 51

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-2: Fatigue Crack Growth for Uphill Side - Heatup/Cooldown STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* HU1 HU2 CD SD Transient

Description:

200 cycles over 40 years Temperature 557.0 349.0 120.0 70.0 F Pressure 2317 467 467 0 psig N = 5.0 cycles/year Sy 42.6 44.9 49.2 50.0 ksi KIc 200.0 200.0 200.0 98.0 ksiin Position 16 KIa 200.0 200.0 85.5 55.2 ksiin Operating HU1 HU2 CD SD Crack Front Stress Intensity Factor, KI Time Cycle a KI(a) KI(a) KI a KI(a) KI(a)

Position (ksiin) (ksiin) (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.) (ksiin) (ksiin) 1 18.527 -18.920 13.250 0.000 0 0.0 61.833 13.247 48.586 42.656 26.509 2 18.826 -17.438 12.738 0.000 1 5.0 61.857 13.252 48.604 42.672 26.519 3 19.351 -15.934 12.257 0.000 2 10.0 62.217 13.329 48.888 42.921 26.674 4 18.420 -13.078 10.820 0.000 3 15.0 62.579 13.407 49.172 43.171 26.829 5 18.505 -11.272 10.097 0.000 4 20.0 62.943 13.485 49.458 43.422 26.985 6 18.197 -9.462 9.289 0.000 5 25.0 63.309 13.563 49.746 43.674 27.142 7 16.954 -7.589 8.195 0.000 6 30.0 63.678 13.642 50.035 43.929 27.300 8 12.946 -5.678 6.169 0.000 7 35.0 64.048 13.722 50.326 44.184 27.459 9 16.968 -5.646 7.508 0.000 8 40.0 64.420 13.801 50.619 44.441 27.618 10 8.787 -3.529 4.085 0.000 9 45.0 64.795 13.881 50.913 44.699 27.779 11 -3.688 -1.066 -0.898 0.000 10 50.0 65.171 13.962 51.209 44.959 27.940 12 7.147 -2.712 3.264 0.000 11 55.0 65.550 14.043 51.506 45.220 28.102 13 14.991 -4.996 6.623 0.000 12 60.0 65.930 14.125 51.805 45.483 28.266 14 20.357 -7.186 9.121 0.000 13 65.0 66.313 14.207 52.106 45.747 28.430 15 25.782 -9.743 11.777 0.000 14 70.0 66.698 14.289 52.409 46.012 28.595 16 35.324 -13.262 16.147 0.000 15 75.0 67.085 14.372 52.713 46.279 28.761 17 23.491 -9.495 10.995 0.000 16 80.0 67.474 14.455 53.018 46.547 28.927 17 85.0 67.865 14.539 53.326 46.817 29.095

• Condition Description 18 90.0 68.258 14.624 53.635 47.089 29.264 HU1 Time step 6 at 7.67 hr. (Heatup) - Maximum KI 19 95.0 68.654 14.708 53.946 47.362 29.433 HU2 Time step 3 at 2.29 hr. (Heatup) - Minimum KI 20 100.0 69.052 14.794 54.258 47.636 29.604 CD Time step 15 at 14.37 hr. - Maximum KI at Low Temperature 21 105.0 69.452 14.879 54.572 47.912 29.775 SD Shutdown at Ambient Conditions 22 110.0 69.854 14.965 54.888 48.189 29.948 23 115.0 70.258 15.052 55.206 48.468 30.121 24 120.0 70.665 15.139 55.526 48.749 30.295 25 125.0 71.073 15.227 55.847 49.031 30.471 26 130.0 71.484 15.315 56.170 49.314 30.647 27 135.0 71.898 15.403 56.494 49.599 30.824 28 140.0 72.313 15.492 56.821 49.886 31.002 29 145.0 72.731 15.582 57.149 50.174 31.181 30 150.0 73.151 15.672 57.479 50.464 31.361 Page 52

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-3: Fatigue Crack Growth for Uphill Side - Unit Loading/Unloading STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* UL UU Transient

Description:

18300 cycles over 40 years Temperature 533.8 574.3 F Pressure 2265 2209 psig N = 457.5 cycles/year Sy 42.9 42.4 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating UL UU Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 23.007 10.659 0 0.0 65.851 53.629 12.222 2 23.018 11.371 1 457.5 65.891 53.662 12.229 3 23.249 12.295 2 915.0 66.275 53.974 12.301 4 21.710 12.334 3 1372.5 66.661 54.288 12.372 5 21.430 12.954 4 1830.0 67.049 54.604 12.444 6 20.760 13.214 5 2287.5 67.439 54.922 12.517 7 19.115 12.658 6 2745.0 67.831 55.241 12.589 8 14.550 9.722 7 3202.5 68.225 55.563 12.663 9 18.795 13.197 8 3660.0 68.622 55.886 12.736 10 9.829 6.679 9 4117.5 69.021 56.210 12.810 11 -3.731 -3.452 10 4575.0 69.422 56.537 12.885 12 7.964 5.477 11 5032.5 69.825 56.865 12.960 13 16.596 11.668 12 5490.0 70.230 57.196 13.035 14 22.593 15.748 13 5947.5 70.638 57.528 13.110 15 28.716 19.782 14 6405.0 71.048 57.861 13.187 16 39.342 27.120 15 6862.5 71.460 58.197 13.263 17 26.287 17.846 16 7320.0 71.875 58.535 13.340 17 7777.5 72.291 58.874 13.417

• Condition Description 18 8235.0 72.710 59.215 13.495 UL Time step 12 at 0.29 hr. - Maximum KI 19 8692.5 73.132 59.559 13.573 UU Time step 11 at 0.29 hr. - Minimum KI 20 9150.0 73.555 59.904 13.652 21 9607.5 73.981 60.250 13.731 22 10065.0 74.410 60.599 13.811 23 10522.5 74.841 60.950 13.890 24 10980.0 75.274 61.303 13.971 25 11437.5 75.709 61.657 14.052 26 11895.0 76.147 62.014 14.133 27 12352.5 76.587 62.372 14.215 28 12810.0 77.030 62.733 14.297 29 13267.5 77.475 63.095 14.379 30 13725.0 77.922 63.460 14.462 Page 53

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-4: Fatigue Crack Growth for Uphill Side - Step Load Increase/Decrease STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* SLI SLD Transient

Description:

4000 cycles over 40 years Temperature 551.4 570.8 F Pressure 2367 2246 psig N = 100.0 cycles/year Sy 42.7 42.5 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating SLI SLD Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 22.974 11.043 0 0.0 66.608 54.168 12.440 2 23.070 11.733 1 100.0 66.884 54.393 12.492 3 23.434 12.620 2 200.0 67.274 54.709 12.564 4 21.981 12.614 3 300.0 67.665 55.028 12.637 5 21.803 13.209 4 400.0 68.059 55.348 12.711 6 21.191 13.451 5 500.0 68.455 55.670 12.785 7 19.546 12.878 6 600.0 68.853 55.994 12.859 8 14.887 9.896 7 700.0 69.253 56.319 12.934 9 19.268 13.414 8 800.0 69.656 56.647 13.009 10 10.061 6.796 9 900.0 70.061 56.976 13.085 11 -3.874 -3.486 10 1000.0 70.468 57.307 13.161 12 8.146 5.579 11 1100.0 70.877 57.640 13.237 13 16.990 11.874 12 1200.0 71.288 57.974 13.314 14 23.108 16.034 13 1300.0 71.702 58.311 13.391 15 29.318 20.161 14 1400.0 72.118 58.649 13.469 16 40.099 27.659 15 1500.0 72.536 58.989 13.547 17 26.771 18.203 16 1600.0 72.957 59.331 13.626 17 1700.0 73.380 59.675 13.705

• Condition Description 18 1800.0 73.805 60.021 13.784 SLI Time step 10 at 0.05 hr. - Maximum KI 19 1900.0 74.233 60.369 13.864 SLD Time step 10 at 0.042 hr. - Minimum KI 20 2000.0 74.663 60.718 13.944 21 2100.0 75.095 61.070 14.025 22 2200.0 75.530 61.424 14.106 23 2300.0 75.967 61.779 14.188 24 2400.0 76.406 62.136 14.270 25 2500.0 76.848 62.496 14.353 26 2600.0 77.293 62.857 14.436 27 2700.0 77.739 63.221 14.519 28 2800.0 78.189 63.586 14.603 29 2900.0 78.640 63.953 14.687 30 3000.0 79.095 64.323 14.772 Page 54

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-5: Fatigue Crack Growth for Uphill Side - Turbine Roll Test STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* TRT1 TRT2 Transient

Description:

80 cycles over 40 years Temperature 443.4 557.4 F Pressure 1692 2317 psig N = 2.0 cycles/year Sy 43.8 42.6 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating TRT1 TRT2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 40.587 7.354 0 0.0 79.738 50.447 29.291 2 39.304 8.260 1 2.0 80.133 50.697 29.436 3 38.158 9.378 2 4.0 80.599 50.992 29.607 4 34.061 9.845 3 6.0 81.069 51.289 29.780 5 32.161 10.713 4 8.0 81.540 51.587 29.953 6 29.935 11.230 5 10.0 82.015 51.887 30.127 7 26.687 10.973 6 12.0 82.492 52.189 30.303 8 20.115 8.468 7 14.0 82.971 52.493 30.479 9 24.921 11.756 8 16.0 83.453 52.798 30.656 10 13.413 5.859 9 18.0 83.938 53.104 30.834 11 -3.551 -3.409 10 20.0 84.426 53.413 31.013 12 10.752 4.835 11 22.0 84.916 53.723 31.193 13 21.987 10.400 12 24.0 85.409 54.035 31.374 14 30.173 13.981 13 26.0 85.905 54.348 31.556 15 38.799 17.463 14 28.0 86.403 54.664 31.739 16 53.229 23.938 15 30.0 86.904 54.981 31.923 17 36.060 15.642 16 32.0 87.408 55.300 32.109 17 34.0 87.915 55.620 32.295

• Condition Description 18 36.0 88.424 55.943 32.482 TRT1 Time step 5 at 0.278 hr. - Maximum KI 19 38.0 88.937 56.267 32.670 TRT2 Time step 8 at 1.418 hr. - Minimum KI 20 40.0 89.452 56.593 32.859 21 42.0 89.970 56.920 33.050 22 44.0 90.491 57.250 33.241 23 46.0 91.014 57.581 33.433 24 48.0 91.541 57.914 33.627 25 50.0 92.070 58.249 33.821 26 52.0 92.603 58.586 34.017 27 54.0 93.138 58.924 34.213 28 56.0 93.676 59.265 34.411 29 58.0 94.217 59.607 34.610 30 60.0 94.761 59.952 34.810 Page 55

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-6: Fatigue Crack Growth for Uphill Side - Refueling STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* RF1 RF2 Transient

Description:

80 cycles over 40 years Temperature 32.0 140.0 F Pressure 0 0 psig N = 2.0 cycles/year Sy 50.0 48.5 ksi KIc 63.5 200.0 ksiin Position 16 KIa 43.2 105.3 ksiin Operating RF1 RF2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 27.949 -4.885 0 0.0 53.975 22.705 31.270 2 26.345 -4.536 1 2.0 54.247 22.819 31.427 3 24.683 -4.194 2 4.0 54.563 22.952 31.610 4 21.095 -3.491 3 6.0 54.880 23.086 31.794 5 18.978 -3.063 4 8.0 55.200 23.220 31.979 6 16.815 -2.617 5 10.0 55.521 23.355 32.165 7 14.330 -2.135 6 12.0 55.844 23.491 32.353 8 10.707 -1.614 7 14.0 56.168 23.628 32.541 9 12.277 -1.643 8 16.0 56.495 23.765 32.730 10 6.961 -1.007 9 18.0 56.823 23.903 32.920 11 -0.430 -0.243 10 20.0 57.153 24.042 33.111 12 5.491 -0.781 11 22.0 57.485 24.181 33.303 13 10.857 -1.457 12 24.0 57.819 24.322 33.497 14 15.170 -2.084 13 26.0 58.154 24.463 33.691 15 19.962 -2.802 14 28.0 58.492 24.605 33.887 16 27.466 -3.804 15 30.0 58.831 24.748 34.083 17 19.022 -2.699 16 32.0 59.172 24.891 34.281 17 34.0 59.515 25.035 34.480

• Condition Description 18 36.0 59.860 25.180 34.679 RF1 Time step 7 at 0.171 hr. - Maximum KI 19 38.0 60.207 25.326 34.880 RF2 Time step 1 at 0.0001 hr. - Minimum KI 20 40.0 60.555 25.473 35.082 21 42.0 60.906 25.621 35.285 22 44.0 61.259 25.769 35.490 23 46.0 61.613 25.918 35.695 24 48.0 61.969 26.068 35.902 25 50.0 62.328 26.219 36.109 26 52.0 62.688 26.370 36.318 27 54.0 63.051 26.523 36.528 28 56.0 63.415 26.676 36.739 29 58.0 63.781 26.830 36.951 30 60.0 64.150 26.985 37.165 Page 56

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-7: Fatigue Crack Growth for Uphill Side - Loss of Load STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* LL1 LL2 Transient

Description:

210 cycles over 40 years Temperature 575.8 588.8 F Pressure 2710 1844 psig N = 5.25 cycles/year Sy 42.4 42.2 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating LL1 LL2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 23.554 -4.474 0 0.0 69.012 37.236 31.776 2 23.806 -3.022 1 5.3 69.364 37.426 31.938 3 24.444 -1.387 2 10.5 69.768 37.644 32.124 4 23.114 0.461 3 15.8 70.174 37.863 32.311 5 23.111 2.069 4 21.0 70.582 38.083 32.499 6 22.576 3.396 5 26.3 70.993 38.305 32.688 7 20.873 4.163 6 31.5 71.406 38.527 32.878 8 15.923 3.330 7 36.8 71.821 38.751 33.069 9 20.646 5.710 8 42.0 72.238 38.977 33.261 10 10.754 2.498 9 47.3 72.658 39.203 33.455 11 -4.216 -2.966 10 52.5 73.080 39.431 33.649 12 8.702 2.160 11 57.8 73.504 39.660 33.844 13 18.163 5.054 12 63.0 73.931 39.890 34.041 14 24.668 6.566 13 68.3 74.360 40.122 34.238 15 31.190 7.815 14 73.5 74.792 40.354 34.437 16 42.503 10.727 15 78.8 75.225 40.588 34.637 17 28.370 6.584 16 84.0 75.662 40.824 34.838 17 89.3 76.100 41.060 35.040

• Condition Description 18 94.5 76.541 41.298 35.243 LL1 Time step 2 at 0.003 hr. - Maximum KI 19 99.8 76.985 41.538 35.447 LL2 Time step 12 at 0.033 hr. - Minimum KI 20 105.0 77.430 41.778 35.652 21 110.3 77.879 42.020 35.859 22 115.5 78.330 42.263 36.066 23 120.8 78.783 42.508 36.275 24 126.0 79.239 42.754 36.485 25 131.3 79.697 43.001 36.696 26 136.5 80.158 43.250 36.908 27 141.8 80.621 43.500 37.121 28 147.0 81.087 43.751 37.336 29 152.3 81.555 44.004 37.551 30 157.5 82.026 44.258 37.768 Page 57

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-8: Fatigue Crack Growth for Uphill Side - Loss of Power STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* LP1 LP2 Transient

Description:

100 cycles over 40 years Temperature 553.8 600.5 F Pressure 2295 2464 psig N = 2.5 cycles/year Sy 42.7 42.1 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating LP1 LP2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 18.177 2.404 0 0.0 61.342 46.871 14.471 2 18.484 3.685 1 2.5 61.668 47.120 14.548 3 19.014 5.180 2 5.0 62.027 47.395 14.633 4 18.116 6.387 3 7.5 62.388 47.671 14.718 5 18.212 7.727 4 10.0 62.751 47.948 14.803 6 17.922 8.703 5 12.5 63.116 48.227 14.890 7 16.708 8.918 6 15.0 63.483 48.507 14.976 8 12.759 6.975 7 17.5 63.852 48.789 15.063 9 16.740 10.142 8 20.0 64.224 49.073 15.151 10 8.663 4.906 9 22.5 64.597 49.358 15.239 11 -3.661 -3.498 10 25.0 64.972 49.645 15.327 12 7.047 4.105 11 27.5 65.349 49.933 15.416 13 14.789 9.001 12 30.0 65.729 50.223 15.506 14 20.078 12.011 13 32.5 66.110 50.514 15.596 15 25.423 14.846 14 35.0 66.494 50.807 15.686 16 34.833 20.362 15 37.5 66.879 51.102 15.777 17 23.159 13.095 16 40.0 67.267 51.398 15.869 17 42.5 67.657 51.696 15.961

• Condition Description 18 45.0 68.049 51.996 16.053 LP1 Time step 2 at 0.003 hr. - Maximum KI 19 47.5 68.443 52.297 16.146 LP2 Time step 11 at 0.053 hr. - Minimum KI 20 50.0 68.840 52.600 16.240 21 52.5 69.238 52.905 16.334 22 55.0 69.639 53.211 16.428 23 57.5 70.042 53.519 16.523 24 60.0 70.447 53.828 16.619 25 62.5 70.855 54.140 16.715 26 65.0 71.264 54.453 16.812 27 67.5 71.676 54.767 16.909 28 70.0 72.090 55.084 17.007 29 72.5 72.507 55.402 17.105 30 75.0 72.926 55.722 17.204 Page 58

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-9: Fatigue Crack Growth for Uphill Side - Reactor Trip STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* RT1 RT2 Transient

Description:

250 cycles over 40 years Temperature 457.4 537.4 F Pressure 2205 1803 psig N = 6.25 cycles/year Sy 43.6 42.8 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating RT1 RT2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 50.109 15.130 0 0.0 91.705 55.567 36.138 2 48.502 15.368 1 6.3 92.195 55.864 36.331 3 47.097 15.728 2 12.5 92.732 56.189 36.543 4 42.010 14.966 3 18.8 93.272 56.516 36.755 5 39.651 14.995 4 25.0 93.814 56.845 36.969 6 36.864 14.741 5 31.3 94.360 57.176 37.184 7 32.808 13.760 6 37.5 94.909 57.508 37.401 8 24.760 10.481 7 43.8 95.461 57.843 37.618 9 30.517 13.823 8 50.0 96.016 58.179 37.837 10 16.474 7.136 9 56.3 96.573 58.517 38.056 11 -4.144 -3.110 10 62.5 97.134 58.857 38.278 12 13.197 5.817 11 68.8 97.698 59.199 38.500 13 26.924 12.241 12 75.0 98.266 59.542 38.723 14 36.980 16.629 13 81.3 98.836 59.888 38.948 15 47.575 21.108 14 87.5 99.409 60.235 39.174 16 65.196 29.058 15 93.8 99.986 60.585 39.401 17 44.202 19.322 16 100.0 100.566 60.936 39.630 17 106.3 101.149 61.289 39.859

• Condition Description 18 112.5 101.735 61.644 40.090 RT1 Time step 13 at 0.171 hr. - Maximum KI 19 118.8 102.324 62.001 40.323 RT2 Time step 8 at 0.025 hr. - Minimum KI 20 125.0 102.917 62.361 40.556 21 131.3 103.513 62.722 40.791 22 137.5 104.112 63.085 41.027 23 143.8 104.714 63.450 41.265 24 150.0 105.320 63.817 41.503 25 156.3 105.929 64.186 41.743 26 162.5 106.542 64.557 41.985 27 168.8 107.157 64.930 42.227 28 175.0 107.777 65.305 42.471 29 181.3 108.399 65.683 42.717 30 187.5 109.025 66.062 42.963 Page 59

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-10: Fatigue Crack Growth for Uphill Side - Inadvertent Depressurization STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* ID1 ID2 Transient

Description:

100 cycles over 40 years Temperature 557.4 556.6 F Pressure 2317 1161 psig N = 2.5 cycles/year Sy 42.6 42.6 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating ID1 ID2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 18.517 -4.170 0 0.0 61.828 33.923 27.905 2 18.817 -3.034 1 2.5 62.182 34.117 28.065 3 19.343 -1.801 2 5.0 62.544 34.316 28.228 4 18.414 -0.310 3 7.5 62.908 34.515 28.392 5 18.500 0.933 4 10.0 63.274 34.716 28.558 6 18.193 1.996 5 12.5 63.642 34.918 28.724 7 16.951 2.674 6 15.0 64.012 35.121 28.891 8 12.944 2.112 7 17.5 64.384 35.325 29.059 9 16.966 3.967 8 20.0 64.758 35.531 29.228 10 8.786 1.655 9 22.5 65.135 35.737 29.397 11 -3.689 -2.383 10 25.0 65.513 35.945 29.568 12 7.146 1.450 11 27.5 65.893 36.154 29.740 13 14.989 3.509 12 30.0 66.276 36.363 29.912 14 20.354 4.514 13 32.5 66.660 36.574 30.086 15 25.779 5.327 14 35.0 67.047 36.787 30.261 16 35.319 7.414 15 37.5 67.436 37.000 30.436 17 23.488 4.490 16 40.0 67.827 37.215 30.613 17 42.5 68.220 37.430 30.790

• Condition Description 18 45.0 68.616 37.647 30.968 ID1 Time step 1 at 0.0001 hr. - Maximum KI 19 47.5 69.013 37.865 31.148 ID2 Time step 9 at 0.022 hr. - Minimum KI 20 50.0 69.413 38.085 31.328 21 52.5 69.815 38.305 31.510 22 55.0 70.219 38.527 31.692 23 57.5 70.625 38.750 31.875 24 60.0 71.034 38.974 32.060 25 62.5 71.445 39.199 32.245 26 65.0 71.858 39.426 32.432 27 67.5 72.273 39.654 32.619 28 70.0 72.691 39.883 32.808 29 72.5 73.110 40.113 32.997 30 75.0 73.533 40.345 33.188 Page 60

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-11: Fatigue Crack Growth for Uphill Side - Excessive Feedwater Flow STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* EFF1 EFF2 Transient

Description:

40 cycles over 40 years Temperature 462.4 557.4 F Pressure 1977 2317 psig N = 1.0 cycles/year Sy 43.6 42.6 ksi KIc 200.0 200.0 ksiin Position 16 KIa 200.0 200.0 ksiin Operating EFF1 EFF2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 40.206 18.517 0 0.0 81.058 61.828 19.230 2 39.093 18.817 1 1.0 81.529 62.187 19.342 3 38.174 19.343 2 2.0 82.003 62.549 19.454 4 34.281 18.414 3 3.0 82.480 62.913 19.567 5 32.584 18.500 4 4.0 82.960 63.279 19.681 6 30.503 18.193 5 5.0 83.443 63.647 19.796 7 27.311 16.951 6 6.0 83.928 64.017 19.911 8 20.626 12.944 7 7.0 84.416 64.389 20.027 9 25.683 16.966 8 8.0 84.907 64.764 20.143 10 13.771 8.786 9 9.0 85.400 65.140 20.260 11 -3.839 -3.689 10 10.0 85.896 65.518 20.378 12 11.051 7.146 11 11.0 86.395 65.899 20.496 13 22.647 14.989 12 12.0 86.896 66.281 20.615 14 31.036 20.354 13 13.0 87.401 66.666 20.735 15 39.815 25.779 14 14.0 87.908 67.053 20.855 16 54.549 35.319 15 15.0 88.418 67.442 20.976 17 36.881 23.488 16 16.0 88.930 67.833 21.098 17 17.0 89.446 68.226 21.220

• Condition Description 18 18.0 89.964 68.621 21.343 EFF1 Time step 30 at 0.167 hr. - Maximum KI 19 19.0 90.485 69.019 21.466 EFF2 Time step 1 at 0.0001 hr. - Minimum KI 20 20.0 91.009 69.418 21.591 21 21.0 91.536 69.820 21.716 22 22.0 92.066 70.225 21.842 23 23.0 92.599 70.631 21.968 24 24.0 93.134 71.039 22.095 25 25.0 93.673 71.450 22.223 26 26.0 94.215 71.863 22.351 27 27.0 94.759 72.279 22.480 28 28.0 95.307 72.696 22.610 29 29.0 95.857 73.116 22.741 30 30.0 96.411 73.539 22.872 Page 61

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-12: Fatigue Crack Growth for Uphill Side - Leak Test STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* LT1 LT2 Transient

Description:

280 cycles over 40 years Temperature 238.0 82.0 F Pressure 2351 602 psig N = 7.0 cycles/year Sy 46.4 50.0 ksi KIc 200.0 115.6 ksiin Position 16 KIa 200.0 60.6 ksiin Operating LT1 LT2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 36.203 7.924 0 0.0 75.304 37.270 38.034 2 35.188 7.716 1 7.0 75.743 37.487 38.255 3 34.376 7.578 2 14.0 76.184 37.705 38.478 4 30.852 6.820 3 21.0 76.627 37.925 38.702 5 29.318 6.511 4 28.0 77.073 38.145 38.927 6 27.425 6.103 5 35.0 77.521 38.367 39.154 7 24.524 5.455 6 42.0 77.972 38.590 39.381 8 18.585 4.155 7 49.0 78.425 38.815 39.610 9 22.970 5.093 8 56.0 78.881 39.040 39.841 10 12.351 2.750 9 63.0 79.339 39.267 40.072 11 -3.258 -0.668 10 70.0 79.800 39.495 40.305 12 9.923 2.208 11 77.0 80.263 39.725 40.539 13 20.272 4.493 12 84.0 80.729 39.955 40.774 14 27.806 6.166 13 91.0 81.198 40.187 41.011 15 35.677 7.901 14 98.0 81.669 40.420 41.249 16 48.795 10.761 15 105.0 82.143 40.655 41.488 17 33.019 7.282 16 112.0 82.619 40.890 41.729 17 119.0 83.098 41.127 41.970

• Condition Description 18 126.0 83.579 41.366 42.214 LT1 Time step 6 at 3.92 hr. - Maximum KI 19 133.0 84.064 41.605 42.458 LT2 Time step 2 at 0.12 hr. - Minimum KI 20 140.0 84.550 41.846 42.704 21 147.0 85.040 42.089 42.951 22 154.0 85.532 42.332 43.200 23 161.0 86.027 42.577 43.450 24 168.0 86.525 42.823 43.701 25 175.0 87.025 43.071 43.954 26 182.0 87.528 43.320 44.208 27 189.0 88.034 43.571 44.464 28 196.0 88.543 43.822 44.721 29 203.0 89.054 44.075 44.979 30 210.0 89.569 44.330 45.239 Page 62

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-13: Stress Intensification Factors for Uphill Side - Faulted Conditions STRESS INTENSITY FACTORS TOTAL STRESS INTENSITY FACTORS FOR OPERATING CONDITIONS WITH RESIDUAL STRESS Condition* LLOCA LSLB Temperature 32.0 204.3 F Pressure 60 1331 psig ao = 2.1482 in.

Sy 50.0 46.9 ksi KIc 63.5 200.0 ksiin KIa 43.2 200.0 ksiin Condition* LLOCA LSLB Crack Front KI Crack Front KI Position (ksiin) (ksiin) Position (ksiin) (ksiin) 1 172.666 125.310 1 217.784 170.428 2 162.695 118.971 2 203.751 160.027 3 152.220 112.724 3 190.655 151.159 4 129.976 97.510 4 161.167 128.701 5 116.733 89.073 5 144.480 116.820 6 103.336 80.161 6 127.701 104.526 7 88.075 69.285 7 108.588 89.798 8 65.634 51.855 8 80.407 66.628 9 75.591 61.179 9 93.646 79.234 10 42.758 34.017 10 52.530 43.789 11 -3.101 -4.606 11 -5.202 -6.707 12 33.734 26.937 12 41.086 34.289 13 66.840 53.893 13 81.184 68.237 14 93.354 74.686 14 112.117 93.449 15 122.911 97.237 15 145.044 119.370 16 169.481 133.327 16 195.990 159.836 17 117.360 91.670 17 135.209 109.519

• Condition Description LLOCA Time step 15 at 0.03889 hr. (140 sec.) - Maximum KI LSLB Time step 10 at 0.09889 hr. (356 sec.) - Maximum KI Page 63

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-14: EPFM Evaluations for Uphill Side - Reactor Trip EPFM Equations: Jmat = C(a)m C=

Tmat = (E/f 2)*Cm(a)m-1 m=

Japp = [KI'(ae)] 2/E' Tapp = (E/f 2)*(dJapp/da)

Ductile Crack Growth Stability Criterion: Tapp < Tmat At instability: Tapp = Tmat Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp Tapp Stable?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) 1.00 1.00 63.614 45.463 109.077 3.3712 114.881 0.442 1.035 Yes 2.00 1.00 127.227 45.463 172.690 3.8714 194.907 1.271 2.978 Yes 3.00 1.50 190.841 68.194 259.035 4.9117 329.307 3.628 8.502 Yes 4.00 1.00 254.455 45.463 299.918 5.5495 405.277 5.495 12.877 Yes 6.00 1.00 381.682 45.463 427.145 8.1310 698.669 16.331 38.270 No Iterate on safety factor until Tapp = Tmat to determine Jinstability :

Jinstability Tapp Tmat 3.1437 3.1437 199.980 142.920 342.900 6.3206 494.503 8.181 19.171 19.171 at Jmat = 3.628 kips/in, Tmat = 50.698 Applied J-Integral Criterion: Japp < J0.1 where, J0.1 = Jmat at a = 0.1 in.

Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp J0.1 OK?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) (kips/in) 1.50 1.00 95.421 45.463 140.883 3.5931 153.185 0.785 2.473 Yes Page 64

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure A-1: J-T Diagram for Uphill Side - Reactor Trip 10 9

Instablility Point 8

7 J-T Material 6

J-Integral (kips/in) 5 J-T Applied 4

SF = 3 & 1.5 3

2 1

0 0 5 10 15 20 25 30 35 40 45 50 Tearing Modulus Page 65

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-15: EPFM Evaluations for Uphill Side - Refueling EPFM Equations: Jmat = C(a)m C=

Tmat = (E/f 2)*Cm(a)m-1 m=

Japp = [KI'(ae)] 2/E' Tapp = (E/f 2)*(dJapp/da)

Ductile Crack Growth Stability Criterion: Tapp < Tmat At instability: Tapp = Tmat Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp Tapp Stable?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) 1.00 1.00 0.000 64.199 64.199 3.1266 65.117 0.132 0.301 Yes 3.00 1.50 0.000 96.299 96.299 3.2359 99.368 0.308 0.700 Yes 10.00 3.00 0.000 192.598 192.598 3.8263 216.106 1.456 3.311 Yes 10.00 4.00 0.000 256.798 256.798 4.4385 310.338 3.002 6.827 Yes 10.00 7.00 0.000 449.396 449.396 7.3248 697.672 15.173 34.504 No Iterate on safety factor until Tapp = Tmat to determine Jinstability :

Jinstability Tapp Tmat 5.7241 5.7241 0.000 367.482 367.482 5.9048 512.230 8.179 18.599 18.599 at Jmat = 0.308 kips/in, Tmat = 942.947 Applied J-Integral Criterion: Japp < J0.1 where, J0.1 = Jmat at a = 0.1 in.

Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp J0.1 OK?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) (kips/in) 1.50 1.00 0.000 64.199 64.199 3.1266 65.117 0.132 2.474 Yes Page 66

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure A-2: J-T Diagram for Uphill Side - Refueling 10 9

Instablility Point 8

7 J-T Material 6

J-T Applied J-Integral (kips/in) 5 4

3 2

1 SF = 3 & 1.5 0

0 5 10 15 20 25 30 35 40 45 50 Tearing Modulus Page 67

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table A-16: EPFM Evaluations for Uphill Side - LLOCA EPFM Equations: Jmat = C(a)m C=

Tmat = (E/f 2)*Cm(a)m-1 m=

Japp = [KI'(ae)] 2/E' Tapp = (E/f 2)*(dJapp/da)

Ductile Crack Growth Stability Criterion: Tapp < Tmat At instability: Tapp = Tmat Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp Tapp Stable?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) 1.00 1.00 1.731 231.385 233.116 4.1923 273.795 2.337 5.314 Yes 1.50 1.00 2.596 231.385 233.982 4.2009 275.092 2.359 5.364 Yes 20.00 1.00 34.620 231.385 266.005 4.5407 325.143 3.295 7.494 Yes 50.00 1.00 86.549 231.385 317.934 5.1842 415.242 5.375 12.223 Yes 100.00 1.00 173.098 231.385 404.484 6.5110 592.037 10.926 24.847 No Iterate on safety factor until Tapp = Tmat to determine Jinstability :

Jinstability Tapp Tmat 1.5764 1.5764 2.729 364.753 367.482 5.9048 512.230 8.179 18.599 18.599 at Jmat = 2.359 kips/in, Tmat = 82.380 Applied J-Integral Criterion: Japp < J0.1 where, J0.1 = Jmat at a = 0.1 in.

Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp J0.1 OK?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) (kips/in) 1.50 1.00 2.596 231.385 233.982 4.2009 275.092 2.359 2.474 Yes Page 68

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure A-3: J-T Diagram for Uphill Side - LLOCA 10 9

Instablility Point 8

7 J-T Applied J-T Material 6

J-Integral (kips/in) 5 4

3 2 SF = 1.5 & 1 1

0 0 5 10 15 20 25 30 35 40 45 50 Tearing Modulus APPENDIX B: DETAILED FLAW EVALUATIONS FOR DOWNHILL SIDE Page 69

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

This appendix presents the fatigue crack growth tables and the elastic-plastic fracture mechanics flaw evaluations for the downhill side of the CRDM penetration.

Table B-1: Stress Intensification Factors for Downhill Side - Welding Residual Stress Condition WRS Temperature 70.0 F Pressure n/a psig Sy 50.0 ksi KIc 98.0 ksiin KIa 55.2 ksiin Crack Front KI Position (ksiin) 1 -1.701 2 13.932 3 15.717 4 27.178 5 33.890 6 37.604 7 40.501 8 40.098 9 37.638 10 33.447 11 24.673 12 27.528 13 26.926 14 24.389 15 21.701 16 16.768 17 5.776 Page 70

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-2: Fatigue Crack Growth for Downhill Side - Heatup/Cooldown STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* HU1 HU2 CD SD Transient

Description:

200 cycles over 40 years Temperature 557.0 349.0 120.0 70.0 F Pressure 2317 467 467 0 psig N = 5.0 cycles/year Sy 42.6 44.9 49.2 50.0 ksi KIc 200.0 200.0 200.0 98.0 ksiin Position 7 KIa 200.0 200.0 85.5 55.2 ksiin Operating HU1 HU2 CD SD Crack Front Stress Intensity Factor, KI Time Cycle a KI(a) KI(a) KI a KI(a) KI(a)

Position (ksiin) (ksiin) (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.) (ksiin) (ksiin) 1 0.943 1.525 -0.207 0.000 0 0.0 55.207 31.286 23.921 22.094 16.768 2 2.680 -5.311 2.591 0.000 1 5.0 55.214 31.290 23.924 22.097 16.770 3 3.692 -5.535 2.956 0.000 2 10.0 55.247 31.309 23.938 22.110 16.780 4 7.332 -8.637 5.117 0.000 3 15.0 55.280 31.327 23.953 22.123 16.790 5 10.761 -9.272 6.370 0.000 4 20.0 55.313 31.346 23.967 22.137 16.800 6 12.898 -9.294 6.973 0.000 5 25.0 55.347 31.365 23.982 22.150 16.810 7 14.706 -9.215 7.386 0.000 6 30.0 55.380 31.384 23.996 22.163 16.821 8 15.467 -8.853 7.381 0.000 7 35.0 55.414 31.403 24.011 22.177 16.831 9 15.906 -8.287 7.265 0.000 8 40.0 55.447 31.422 24.025 22.190 16.841 10 15.601 -7.685 6.943 0.000 9 45.0 55.481 31.441 24.040 22.204 16.851 11 12.347 -6.288 5.571 0.000 10 50.0 55.514 31.460 24.054 22.217 16.861 12 14.585 -7.340 6.566 0.000 11 55.0 55.548 31.479 24.069 22.230 16.872 13 15.201 -7.848 6.962 0.000 12 60.0 55.582 31.498 24.083 22.244 16.882 14 14.925 -7.826 6.945 0.000 13 65.0 55.615 31.517 24.098 22.257 16.892 15 14.388 -7.578 6.747 0.000 14 70.0 55.649 31.536 24.112 22.271 16.902 16 11.322 -5.983 5.326 0.000 15 75.0 55.683 31.556 24.127 22.284 16.912 17 2.718 -1.762 1.368 0.000 16 80.0 55.716 31.575 24.142 22.298 16.923 17 85.0 55.750 31.594 24.156 22.311 16.933

• Condition Description 18 90.0 55.784 31.613 24.171 22.325 16.943 HU1 Time step 6 at 7.67 hr. (Heatup) - Maximum KI 19 95.0 55.818 31.632 24.186 22.338 16.954 HU2 Time step 3 at 2.29 hr. (Heatup) - Minimum KI 20 100.0 55.852 31.651 24.200 22.352 16.964 CD Time step 15 at 14.37 hr. - Maximum KI at Low Temperature 21 105.0 55.886 31.671 24.215 22.366 16.974 SD Shutdown at Ambient Conditions 22 110.0 55.920 31.690 24.230 22.379 16.984 23 115.0 55.953 31.709 24.244 22.393 16.995 24 120.0 55.988 31.728 24.259 22.406 17.005 25 125.0 56.022 31.748 24.274 22.420 17.015 26 130.0 56.056 31.767 24.289 22.434 17.026 27 135.0 56.090 31.786 24.303 22.447 17.036 28 140.0 56.124 31.806 24.318 22.461 17.046 29 145.0 56.158 31.825 24.333 22.475 17.057 30 150.0 56.192 31.844 24.348 22.488 17.067 Page 71

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-3: Fatigue Crack Growth for Downhill Side - Unit Loading/Unloading STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* UL UU Transient

Description:

18300 cycles over 40 years Temperature 533.8 574.3 F Pressure 2265 2209 psig N = 457.5 cycles/year Sy 42.9 42.4 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating UL UU Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 0.746 1.229 0 0.0 57.263 50.968 6.295 2 3.671 0.911 1 457.5 57.277 50.980 6.297 3 4.755 1.748 2 915.0 57.311 51.011 6.300 4 9.072 4.086 3 1372.5 57.346 51.042 6.304 5 12.751 6.918 4 1830.0 57.381 51.073 6.308 6 14.950 8.813 5 2287.5 57.415 51.104 6.312 7 16.762 10.467 6 2745.0 57.450 51.134 6.316 8 17.430 11.286 7 3202.5 57.485 51.165 6.319 9 17.756 11.855 8 3660.0 57.519 51.196 6.323 10 17.317 11.772 9 4117.5 57.554 51.227 6.327 11 13.737 9.268 10 4575.0 57.589 51.258 6.331 12 16.213 10.975 11 5032.5 57.624 51.289 6.335 13 16.951 11.372 12 5490.0 57.659 51.320 6.339 14 16.691 11.113 13 5947.5 57.694 51.351 6.342 15 16.112 10.692 14 6405.0 57.729 51.382 6.346 16 12.687 8.404 15 6862.5 57.764 51.414 6.350 17 3.091 1.937 16 7320.0 57.799 51.445 6.354 17 7777.5 57.834 51.476 6.358

• Condition Description 18 8235.0 57.869 51.507 6.362 UL Time step 12 at 0.29 hr. - Maximum KI 19 8692.5 57.904 51.538 6.365 UU Time step 11 at 0.29 hr. - Minimum KI 20 9150.0 57.939 51.570 6.369 21 9607.5 57.974 51.601 6.373 22 10065.0 58.009 51.632 6.377 23 10522.5 58.045 51.664 6.381 24 10980.0 58.080 51.695 6.385 25 11437.5 58.115 51.726 6.389 26 11895.0 58.151 51.758 6.393 27 12352.5 58.186 51.789 6.396 28 12810.0 58.221 51.821 6.400 29 13267.5 58.257 51.853 6.404 30 13725.0 58.292 51.884 6.408 Page 72

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-4: Fatigue Crack Growth for Downhill Side - Step Load Increase/Decrease STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* SLI SLD Transient

Description:

4000 cycles over 40 years Temperature 546.7 577.3 F Pressure 2300 2290 psig N = 100.0 cycles/year Sy 42.7 42.4 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating SLI SLD Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 0.772 1.285 0 0.0 57.658 51.114 6.544 2 3.722 0.748 1 100.0 57.676 51.130 6.546 3 4.835 1.591 2 200.0 57.711 51.161 6.550 4 9.238 3.871 3 300.0 57.746 51.192 6.554 5 13.010 6.778 4 400.0 57.781 51.223 6.558 6 15.276 8.792 5 500.0 57.816 51.254 6.562 7 17.157 10.613 6 600.0 57.851 51.285 6.566 8 17.864 11.582 7 700.0 57.885 51.316 6.570 9 18.206 12.260 8 800.0 57.920 51.347 6.574 10 17.751 12.215 9 900.0 57.955 51.378 6.578 11 14.072 9.584 10 1000.0 57.991 51.409 6.582 12 16.598 11.333 11 1100.0 58.026 51.440 6.586 13 17.336 11.683 12 1200.0 58.061 51.471 6.590 14 17.050 11.350 13 1300.0 58.096 51.502 6.594 15 16.440 10.878 14 1400.0 58.131 51.533 6.598 16 12.943 8.536 15 1500.0 58.166 51.565 6.602 17 3.170 1.973 16 1600.0 58.202 51.596 6.606 17 1700.0 58.237 51.627 6.610

• Condition Description 18 1800.0 58.272 51.659 6.614 SLI Time step 9 at 0.041 hr. - Maximum KI 19 1900.0 58.308 51.690 6.618 SLD Time step 9 at 0.028 hr. - Minimum KI 20 2000.0 58.343 51.721 6.622 21 2100.0 58.378 51.753 6.626 22 2200.0 58.414 51.784 6.630 23 2300.0 58.449 51.816 6.634 24 2400.0 58.485 51.847 6.638 25 2500.0 58.521 51.879 6.642 26 2600.0 58.556 51.910 6.646 27 2700.0 58.592 51.942 6.650 28 2800.0 58.627 51.973 6.654 29 2900.0 58.663 52.005 6.658 30 3000.0 58.699 52.037 6.662 Page 73

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-5: Fatigue Crack Growth for Downhill Side - Turbine Roll Test STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* TRT1 TRT2 Transient

Description:

80 cycles over 40 years Temperature 443.4 557.4 F Pressure 1692 2317 psig N = 2.0 cycles/year Sy 43.8 42.6 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating TRT1 TRT2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 -0.097 1.296 0 0.0 64.359 49.628 14.731 2 7.596 0.314 1 2.0 64.381 49.645 14.736 3 8.926 1.073 2 4.0 64.419 49.675 14.745 4 15.799 2.965 3 6.0 64.458 49.705 14.754 5 20.199 5.609 4 8.0 64.497 49.735 14.763 6 22.374 7.456 5 10.0 64.536 49.765 14.772 7 23.858 9.127 6 12.0 64.575 49.795 14.780 8 23.895 10.028 7 14.0 64.614 49.825 14.789 9 23.591 10.686 8 16.0 64.653 49.855 14.798 10 22.575 10.691 9 18.0 64.692 49.885 14.807 11 18.078 8.372 10 20.0 64.732 49.915 14.816 12 21.311 9.916 11 22.0 64.771 49.945 14.825 13 22.588 10.205 12 24.0 64.810 49.976 14.834 14 22.546 9.905 13 26.0 64.849 50.006 14.843 15 21.928 9.491 14 28.0 64.888 50.036 14.852 16 17.326 7.446 15 30.0 64.928 50.067 14.861 17 4.367 1.684 16 32.0 64.967 50.097 14.870 17 34.0 65.007 50.127 14.879

• Condition Description 18 36.0 65.046 50.158 14.888 TRT1 Time step 5 at 0.278 hr. - Maximum KI 19 38.0 65.085 50.188 14.897 TRT2 Time step 8 at 1.418 hr. - Minimum KI 20 40.0 65.125 50.219 14.906 21 42.0 65.165 50.249 14.915 22 44.0 65.204 50.280 14.924 23 46.0 65.244 50.310 14.934 24 48.0 65.283 50.341 14.943 25 50.0 65.323 50.371 14.952 26 52.0 65.363 50.402 14.961 27 54.0 65.403 50.433 14.970 28 56.0 65.443 50.464 14.979 29 58.0 65.482 50.494 14.988 30 60.0 65.522 50.525 14.997 Page 74

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-6: Fatigue Crack Growth for Downhill Side - Refueling STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* RF1 RF2 Transient

Description:

80 cycles over 40 years Temperature 32.0 140.0 F Pressure 0 0 psig N = 2.0 cycles/year Sy 50.0 48.5 ksi KIc 63.5 200.0 ksiin Position 7 KIa 43.2 105.3 ksiin Operating RF1 RF2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 -1.034 0.410 0 0.0 54.137 37.685 16.452 2 6.136 -1.478 1 2.0 54.156 37.698 16.458 3 6.728 -1.554 2 4.0 54.189 37.721 16.468 4 11.118 -2.447 3 6.0 54.222 37.744 16.478 5 12.933 -2.684 4 8.0 54.254 37.767 16.488 6 13.508 -2.754 5 10.0 54.287 37.790 16.498 7 13.636 -2.816 6 12.0 54.320 37.812 16.508 8 13.111 -2.783 7 14.0 54.353 37.835 16.518 9 12.453 -2.669 8 16.0 54.386 37.858 16.528 10 11.656 -2.515 9 18.0 54.419 37.881 16.538 11 9.511 -2.035 10 20.0 54.452 37.904 16.548 12 11.218 -2.375 11 22.0 54.485 37.927 16.558 13 12.125 -2.502 12 24.0 54.517 37.950 16.568 14 12.312 -2.456 13 26.0 54.551 37.973 16.578 15 12.086 -2.355 14 28.0 54.584 37.996 16.588 16 9.579 -1.852 15 30.0 54.617 38.019 16.598 17 2.556 -0.538 16 32.0 54.650 38.042 16.608 17 34.0 54.683 38.065 16.618

• Condition Description 18 36.0 54.716 38.088 16.628 RF1 Time step 7 at 0.171 hr. - Maximum KI 19 38.0 54.749 38.111 16.638 RF2 Time step 1 at 0.0001 hr. - Minimum KI 20 40.0 54.783 38.134 16.648 21 42.0 54.816 38.158 16.658 22 44.0 54.849 38.181 16.668 23 46.0 54.882 38.204 16.679 24 48.0 54.916 38.227 16.689 25 50.0 54.949 38.250 16.699 26 52.0 54.983 38.274 16.709 27 54.0 55.016 38.297 16.719 28 56.0 55.050 38.320 16.729 29 58.0 55.083 38.344 16.740 30 60.0 55.117 38.367 16.750 Page 75

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-7: Fatigue Crack Growth for Downhill Side - Loss of Load STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* LL1 LL2 Transient

Description:

210 cycles over 40 years Temperature 575.8 588.8 F Pressure 2710 1844 psig N = 5.25 cycles/year Sy 42.4 42.2 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating LL1 LL2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 0.950 1.766 0 0.0 58.834 42.239 16.595 2 3.481 -2.663 1 5.3 58.857 42.255 16.601 3 4.682 -2.204 2 10.5 58.892 42.281 16.611 4 9.183 -2.532 3 15.8 58.928 42.306 16.621 5 13.346 -0.958 4 21.0 58.963 42.332 16.631 6 15.991 0.418 5 26.3 58.999 42.357 16.642 7 18.333 1.738 6 31.5 59.035 42.383 16.652 8 19.392 2.668 7 36.8 59.070 42.409 16.662 9 19.973 3.496 8 42.0 59.106 42.434 16.672 10 19.585 3.858 9 47.3 59.142 42.460 16.682 11 15.468 2.902 10 52.5 59.177 42.486 16.692 12 18.216 3.502 11 57.8 59.213 42.511 16.702 13 18.870 3.448 12 63.0 59.249 42.537 16.712 14 18.370 3.223 13 68.3 59.285 42.563 16.722 15 17.573 3.041 14 73.5 59.321 42.589 16.732 16 13.802 2.360 15 78.8 59.357 42.614 16.742 17 3.440 0.326 16 84.0 59.393 42.640 16.753 17 89.3 59.429 42.666 16.763

• Condition Description 18 94.5 59.465 42.692 16.773 LL1 Time step 2 at 0.003 hr. - Maximum KI 19 99.8 59.501 42.718 16.783 LL2 Time step 12 at 0.033 hr. - Minimum KI 20 105.0 59.537 42.744 16.793 21 110.3 59.573 42.770 16.804 22 115.5 59.610 42.796 16.814 23 120.8 59.646 42.822 16.824 24 126.0 59.682 42.848 16.834 25 131.3 59.718 42.874 16.844 26 136.5 59.755 42.900 16.855 27 141.8 59.791 42.926 16.865 28 147.0 59.828 42.952 16.875 29 152.3 59.864 42.978 16.886 30 157.5 59.900 43.005 16.896 Page 76

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-8: Fatigue Crack Growth for Downhill Side - Loss of Power STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* LP1 LP2 Transient

Description:

100 cycles over 40 years Temperature 553.8 600.5 F Pressure 2295 2464 psig N = 2.5 cycles/year Sy 42.7 42.1 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating LP1 LP2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 0.946 1.583 0 0.0 54.961 47.394 7.567 2 2.604 -0.933 1 2.5 54.986 47.416 7.570 3 3.602 -0.235 2 5.0 55.019 47.444 7.575 4 7.174 0.851 3 7.5 55.053 47.473 7.580 5 10.560 3.271 4 10.0 55.086 47.502 7.584 6 12.672 5.130 5 12.5 55.119 47.530 7.589 7 14.460 6.893 6 15.0 55.152 47.559 7.593 8 15.213 7.988 7 17.5 55.186 47.588 7.598 9 15.652 8.849 8 20.0 55.219 47.617 7.603 10 15.355 9.056 9 22.5 55.253 47.645 7.607 11 12.150 7.048 10 25.0 55.286 47.674 7.612 12 14.353 8.381 11 27.5 55.319 47.703 7.616 13 14.958 8.536 12 30.0 55.353 47.732 7.621 14 14.686 8.199 13 32.5 55.386 47.761 7.626 15 14.157 7.823 14 35.0 55.420 47.790 7.630 16 11.141 6.120 15 37.5 55.454 47.819 7.635 17 2.671 1.294 16 40.0 55.487 47.848 7.639 17 42.5 55.521 47.877 7.644

• Condition Description 18 45.0 55.555 47.906 7.649 LP1 Time step 2 at 0.003 hr. - Maximum KI 19 47.5 55.588 47.935 7.653 LP2 Time step 11 at 0.053 hr. - Minimum KI 20 50.0 55.622 47.964 7.658 21 52.5 55.656 47.993 7.663 22 55.0 55.690 48.022 7.667 23 57.5 55.723 48.052 7.672 24 60.0 55.757 48.081 7.677 25 62.5 55.791 48.110 7.681 26 65.0 55.825 48.139 7.686 27 67.5 55.859 48.169 7.691 28 70.0 55.893 48.198 7.695 29 72.5 55.927 48.227 7.700 30 75.0 55.961 48.257 7.705 Page 77

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-9: Fatigue Crack Growth for Downhill Side - Reactor Trip STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* RT1 RT2 Transient

Description:

250 cycles over 40 years Temperature 457.4 537.4 F Pressure 2205 1803 psig N = 6.25 cycles/year Sy 43.6 42.8 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating RT1 RT2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 -0.344 0.927 0 0.0 70.741 52.016 18.725 2 9.813 2.017 1 6.3 70.774 52.040 18.734 3 11.437 2.874 2 12.5 70.816 52.071 18.745 4 20.106 5.810 3 18.8 70.859 52.103 18.756 5 25.541 8.607 4 25.0 70.902 52.134 18.768 6 28.273 10.252 5 31.3 70.945 52.166 18.779 7 30.240 11.515 6 37.5 70.987 52.197 18.790 8 30.411 11.924 7 43.8 71.030 52.229 18.802 9 30.082 12.163 8 50.0 71.073 52.260 18.813 10 28.819 11.886 9 56.3 71.116 52.292 18.824 11 23.051 9.451 10 62.5 71.159 52.324 18.836 12 27.143 11.204 11 68.8 71.202 52.355 18.847 13 28.677 11.791 12 75.0 71.246 52.387 18.859 14 28.509 11.714 13 81.3 71.289 52.419 18.870 15 27.648 11.387 14 87.5 71.332 52.450 18.881 16 21.824 8.989 15 93.8 71.375 52.482 18.893 17 5.557 2.099 16 100.0 71.418 52.514 18.904 17 106.3 71.462 52.546 18.916

• Condition Description 18 112.5 71.505 52.578 18.927 RT1 Time step 13 at 0.171 hr. - Maximum KI 19 118.8 71.548 52.610 18.939 RT2 Time step 8 at 0.025 hr. - Minimum KI 20 125.0 71.592 52.642 18.950 21 131.3 71.635 52.674 18.962 22 137.5 71.679 52.706 18.973 23 143.8 71.722 52.738 18.985 24 150.0 71.766 52.770 18.996 25 156.3 71.810 52.802 19.008 26 162.5 71.853 52.834 19.019 27 168.8 71.897 52.866 19.031 28 175.0 71.941 52.898 19.043 29 181.3 71.985 52.931 19.054 30 187.5 72.029 52.963 19.066 Page 78

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-10: Fatigue Crack Growth for Downhill Side - Inadvertent Depressurization STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* ID1 ID2 Transient

Description:

100 cycles over 40 years Temperature 557.4 556.6 F Pressure 2317 1161 psig N = 2.5 cycles/year Sy 42.6 42.6 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating ID1 ID2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 0.944 1.606 0 0.0 55.203 40.508 14.695 2 2.677 -2.583 1 2.5 55.235 40.531 14.703 3 3.690 -2.226 2 5.0 55.268 40.556 14.712 4 7.328 -2.753 3 7.5 55.301 40.580 14.721 5 10.757 -1.643 4 10.0 55.335 40.605 14.730 6 12.894 -0.738 5 12.5 55.368 40.629 14.739 7 14.702 0.007 6 15.0 55.402 40.654 14.748 8 15.463 0.486 7 17.5 55.435 40.678 14.757 9 15.902 1.001 8 20.0 55.468 40.703 14.766 10 15.598 1.266 9 22.5 55.502 40.727 14.775 11 12.345 0.914 10 25.0 55.536 40.752 14.784 12 14.583 1.172 11 27.5 55.569 40.777 14.792 13 15.199 1.177 12 30.0 55.603 40.801 14.801 14 14.922 1.172 13 32.5 55.637 40.826 14.810 15 14.385 1.175 14 35.0 55.670 40.851 14.819 16 11.320 0.928 15 37.5 55.704 40.876 14.828 17 2.717 -0.029 16 40.0 55.738 40.900 14.837 17 42.5 55.772 40.925 14.846

• Condition Description 18 45.0 55.805 40.950 14.855 ID1 Time step 1 at 0.0001 hr. - Maximum KI 19 47.5 55.839 40.975 14.864 ID2 Time step 9 at 0.022 hr. - Minimum KI 20 50.0 55.873 41.000 14.873 21 52.5 55.907 41.025 14.882 22 55.0 55.941 41.050 14.891 23 57.5 55.975 41.075 14.901 24 60.0 56.009 41.100 14.910 25 62.5 56.043 41.125 14.919 26 65.0 56.077 41.150 14.928 27 67.5 56.111 41.175 14.937 28 70.0 56.146 41.200 14.946 29 72.5 56.180 41.225 14.955 30 75.0 56.214 41.250 14.964 Page 79

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-11: Fatigue Crack Growth for Downhill Side - Excessive Feedwater Flow STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* EFF1 EFF2 Transient

Description:

40 cycles over 40 years Temperature 448.6 557.4 F Pressure 1809 2317 psig N = 1.0 cycles/year Sy 43.7 42.6 ksi KIc 200.0 200.0 ksiin Position 7 KIa 200.0 200.0 ksiin Operating EFF1 EFF2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 -0.519 0.944 0 0.0 65.553 55.203 10.350 2 9.452 2.677 1 1.0 65.592 55.236 10.356 3 10.871 3.690 2 2.0 65.632 55.269 10.362 4 18.778 7.328 3 3.0 65.672 55.303 10.369 5 23.040 10.757 4 4.0 65.711 55.336 10.375 6 24.576 12.894 5 5.0 65.751 55.370 10.381 7 25.052 14.702 6 6.0 65.791 55.403 10.388 8 24.101 15.463 7 7.0 65.830 55.437 10.394 9 23.123 15.902 8 8.0 65.870 55.470 10.400 10 21.900 15.598 9 9.0 65.910 55.504 10.406 11 17.871 12.345 10 10.0 65.950 55.537 10.413 12 21.256 14.583 11 11.0 65.990 55.571 10.419 13 23.048 15.199 12 12.0 66.030 55.604 10.425 14 23.529 14.922 13 13.0 66.070 55.638 10.432 15 23.259 14.385 14 14.0 66.110 55.672 10.438 16 18.487 11.320 15 15.0 66.150 55.706 10.444 17 4.524 2.717 16 16.0 66.190 55.739 10.451 17 17.0 66.230 55.773 10.457

• Condition Description 18 18.0 66.270 55.807 10.463 EFF1 Time step 4 at 0.013 hr. - Maximum KI 19 19.0 66.310 55.841 10.470 EFF2 Time step 1 at 0.0001 hr. - Minimum KI 20 20.0 66.351 55.875 10.476 21 21.0 66.391 55.909 10.482 22 22.0 66.431 55.943 10.489 23 23.0 66.472 55.977 10.495 24 24.0 66.512 56.011 10.501 25 25.0 66.553 56.045 10.508 26 26.0 66.593 56.079 10.514 27 27.0 66.634 56.113 10.521 28 28.0 66.674 56.147 10.527 29 29.0 66.715 56.181 10.533 30 30.0 66.756 56.216 10.540 Page 80

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-12: Fatigue Crack Growth for Downhill Side - Leak Test STRESS INTENSITY FACTORS FATIGUE CRACK GROWTH Condition* LT1 LT2 Transient

Description:

280 cycles over 40 years Temperature 238.0 82.0 F Pressure 2351 602 psig N = 7.0 cycles/year Sy 46.4 50.0 ksi KIc 200.0 115.6 ksiin Position 7 KIa 200.0 60.6 ksiin Operating LT1 LT2 Crack Front KI Time Cycle a KI(a) KI(a) KI a Position (ksiin) (ksiin) (end of yr.) (in.) (ksiin) (ksiin) (ksiin) (in.)

1 -0.484 -0.180 0 0.0 64.403 46.197 18.206 2 7.656 1.843 1 7.0 64.442 46.225 18.217 3 8.820 2.100 2 14.0 64.481 46.253 18.228 4 15.468 3.646 3 21.0 64.520 46.281 18.239 5 19.687 4.609 4 28.0 64.559 46.309 18.250 6 21.987 5.170 5 35.0 64.598 46.337 18.261 7 23.902 5.696 6 42.0 64.637 46.365 18.272 8 24.423 5.902 7 49.0 64.676 46.393 18.283 9 24.437 5.952 8 56.0 64.715 46.421 18.294 10 23.571 5.765 9 63.0 64.754 46.449 18.305 11 18.741 4.566 10 70.0 64.793 46.477 18.316 12 22.027 5.351 11 77.0 64.832 46.505 18.327 13 23.041 5.545 12 84.0 64.872 46.533 18.338 14 22.643 5.386 13 91.0 64.911 46.561 18.350 15 21.785 5.139 14 98.0 64.950 46.589 18.361 16 17.137 4.030 15 105.0 64.990 46.618 18.372 17 4.398 1.055 16 112.0 65.029 46.646 18.383 17 119.0 65.068 46.674 18.394

• Condition Description 18 126.0 65.108 46.703 18.405 LT1 Time step 6 at 3.92 hr. - Maximum KI 19 133.0 65.147 46.731 18.416 LT2 Time step 2 at 0.12 hr. - Minimum KI 20 140.0 65.187 46.759 18.428 21 147.0 65.227 46.788 18.439 22 154.0 65.266 46.816 18.450 23 161.0 65.306 46.845 18.461 24 168.0 65.346 46.873 18.472 25 175.0 65.385 46.902 18.484 26 182.0 65.425 46.930 18.495 27 189.0 65.465 46.959 18.506 28 196.0 65.505 46.987 18.517 29 203.0 65.545 47.016 18.529 30 210.0 65.585 47.045 18.540 Page 81

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-13: Stress Intensification Factors for Downhill Side - Faulted Conditions STRESS INTENSITY FACTORS TOTAL STRESS INTENSITY FACTORS FOR OPERATING CONDITIONS WITH RESIDUAL STRESS Condition* LLOCA LSLB Temperature 32.0 207.8 F Pressure 60 1316 psig ao = 2.1482 in.

Sy 50.0 46.9 ksi KIc 63.5 200.0 ksiin KIa 43.2 200.0 ksiin Condition* LLOCA LSLB Crack Front KI Crack Front KI Position (ksiin) (ksiin) Position (ksiin) (ksiin) 1 -6.103 -3.533 1 -7.804 -5.234 2 38.630 26.671 2 52.562 40.603 3 42.411 29.689 3 58.128 45.406 4 70.343 50.026 4 97.521 77.204 5 81.924 59.828 5 115.814 93.718 6 85.195 63.651 6 122.799 101.255 7 85.364 65.558 7 125.865 106.059 8 81.305 64.020 8 121.403 104.118 9 76.653 61.644 9 114.291 99.282 10 71.333 58.060 10 104.780 91.507 11 58.183 46.864 11 82.856 71.537 12 68.598 55.118 12 96.126 82.646 13 74.395 58.941 13 101.321 85.867 14 75.853 59.256 14 100.242 83.645 15 74.663 57.792 15 96.364 79.493 16 59.246 45.712 16 76.014 62.480 17 15.675 12.059 17 21.451 17.835

• Condition Description LLOCA Time step 15 at 0.03889 hr. (140 sec.) - Maximum KI LSLB Time step 9 at 0.09222 hr. (332 sec.) - Maximum KI Page 82

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-14: EPFM Evaluations for Downhill Side - Reactor Trip EPFM Equations: Jmat = C(a)m C=

Tmat = (E/f 2)*Cm(a)m-1 m=

Japp = [KI'(ae)] 2/E' Tapp = (E/f 2)*(dJapp/da)

Ductile Crack Growth Stability Criterion: Tapp < Tmat At instability: Tapp = Tmat Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp Tapp Stable?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) 1.00 1.00 28.672 43.367 72.039 2.3726 74.344 0.185 0.591 Yes 2.00 1.00 57.345 43.367 100.711 2.5108 106.918 0.382 1.223 Yes 3.00 1.50 86.017 65.050 151.067 2.8646 171.305 0.982 3.139 Yes 8.00 1.00 229.378 43.367 272.745 4.3038 379.096 4.808 15.371 Yes 15.00 1.00 430.084 43.367 473.451 8.4835 923.906 28.558 91.296 No Iterate on safety factor until Tapp = Tmat to determine Jinstability :

Jinstability Tapp Tmat 4.3064 4.3064 123.476 186.756 310.232 4.9137 460.742 7.102 22.705 22.705 at Jmat = 0.982 kips/in, Tmat = 242.047 Applied J-Integral Criterion: Japp < J0.1 where, J0.1 = Jmat at a = 0.1 in.

Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp J0.1 OK?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) (kips/in) 1.50 1.00 43.008 43.367 86.375 2.4360 90.321 0.273 2.473 Yes Page 83

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure B-1: J-T Diagram for Downhill Side - Reactor Trip 10 9

8 Instablility Point 7

J-T Material 6

J-Integral (kips/in)

J-T Applied 5

4 3

2 1

SF = 3 & 1.5 0

0 5 10 15 20 25 30 35 40 45 50 Tearing Modulus Page 84

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-15: EPFM Evaluations for Downhill Side - Refueling EPFM Equations: Jmat = C(a)m C=

Tmat = (E/f 2)*Cm(a)m-1 m=

Japp = [KI'(ae)] 2/E' Tapp = (E/f 2)*(dJapp/da)

Ductile Crack Growth Stability Criterion: Tapp < Tmat At instability: Tapp = Tmat Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp Tapp Stable?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) 1.00 1.00 0.000 55.130 55.130 2.2923 55.923 0.097 0.302 Yes 3.00 1.50 0.000 82.695 82.695 2.3729 85.346 0.227 0.704 Yes 10.00 3.00 0.000 165.391 165.391 2.8082 185.692 1.075 3.335 Yes 10.00 4.00 0.000 220.521 220.521 3.2597 266.751 2.218 6.881 Yes 10.00 7.00 0.000 385.912 385.912 5.3881 600.168 11.228 34.834 No Iterate on safety factor until Tapp = Tmat to determine Jinstability :

Jinstability Tapp Tmat 6.0382 6.0382 0.000 332.889 332.889 4.5793 477.273 7.101 22.029 22.029 at Jmat = 0.227 kips/in, Tmat = 1357.163 Applied J-Integral Criterion: Japp < J0.1 where, J0.1 = Jmat at a = 0.1 in.

Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp J0.1 OK?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) (kips/in) 1.50 1.00 0.000 55.130 55.130 2.2923 55.923 0.097 2.474 Yes Page 85

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure B-2: J-T Diagram for Downhill Side - Refueling 10 9

8 Instablility Point 7

J-T Material 6

J-T Applied J-Integral (kips/in) 5 4

3 2

1 SF = 3 & 1.5 0

0 5 10 15 20 25 30 35 40 45 50 Tearing Modulus Page 86

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Table B-16: EPFM Evaluations for Downhill Side - LLOCA EPFM Equations: Jmat = C(a)m C=

Tmat = (E/f 2)*Cm(a)m-1 m=

Japp = [KI'(ae)] 2/E' Tapp = (E/f 2)*(dJapp/da)

Ductile Crack Growth Stability Criterion: Tapp < Tmat At instability: Tapp = Tmat Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp Tapp Stable?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) 1.00 1.00 0.780 76.629 77.409 2.3549 79.587 0.197 0.613 Yes 1.50 1.00 1.170 76.629 77.799 2.3562 80.010 0.200 0.619 Yes 200.00 1.00 156.040 76.629 232.668 3.3765 286.443 2.558 7.935 Yes 300.00 1.00 234.059 76.629 310.688 4.2761 430.443 5.776 17.918 Yes 400.00 1.00 312.079 76.629 388.708 5.4341 607.088 11.489 35.642 No Iterate on safety factor until Tapp = Tmat to determine Jinstability :

Jinstability Tapp Tmat 4.3004 4.3004 3.355 329.534 332.889 4.5793 477.273 7.101 22.029 22.029 at Jmat = 0.200 kips/in, Tmat = 1584.010 Applied J-Integral Criterion: Japp < J0.1 where, J0.1 = Jmat at a = 0.1 in.

Safety Factors KI*p KI*s KI*(a) ae KI'(ae) Japp J0.1 OK?

Primary Secondary (ksiin) (ksiin) (ksiin) (in.) (ksiin) (kips/in) (kips/in) 1.50 1.00 1.170 76.629 77.799 2.3562 80.010 0.200 2.474 Yes Page 87

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Figure B-3: J-T Diagram for Downhill Side - LLOCA 10 9

8 Instablility Point 7

J-T Material 6

J-Integral (kips/in) 5 J-T Applied 4

3 2

1 SF = 1.5 & 1 0

0 5 10 15 20 25 30 35 40 45 50 Tearing Modulus Page 88

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

APPENDIX C: CALCULATION OF AVAILABLE YEARS OF SERVICE BASED ON AVAILABLE REINFORCEMENT AREA DUE TO CRACK GROWTH C.1 Purpose The purpose of this appendix is to demonstrate that the as-repaired RVCH continues to satisfy the primary stress limits of NB-3000, considering postulated flaws emanating from the original J-groove weld. This is accomplished by comparing the available reinforcement areas in the vicinity of the repaired nozzles with the areas removed from consideration of carrying primary load, in accordance with NB-3330. The acceptable life for crack growth is determined, and the limiting case is reported.

C.2 Analytical Methodology The approach of calculating available years of service is based on determining the available area of reinforcement as required per NB-3330 Reference [C1]. The repair results in removal of the structural material. In addition for repaired nozzles, as left Alloy 600 region of the original J-groove weld is not considered as structural material as it contains flaws.

Finally, additional area due to postulated crack growth into the carbon steel of the head is also discounted from the available structural area.

Analyzed nozzles are those already repaired and in operation as well as those being repaired. Nozzles previously repaired and in operation are: # 5, #14, #17, #18, #23, #37,

1. 38, #49 and #63 (Reference [C11]). Nozzles being repaired in the 2016 outage are #30,

1. 40 and #51 (References [C14] to [C16]). The dates for these repairs are listed as follows:

Nozzle Repair Date 5 May 2012 14 May 2015 17 May 2012 18 May 2015 23 May 2015 30 Current Oct-2016 Outage 37 Nov 2013 38 May 2012 40 Current Oct-2016 Outage 49 May 2013 51 Current Oct-2016 Outage 63 May 2012 Note that for the previously repaired nozzles the detailed evaluations are contained in Sub-Sections C.3.6, C.4 to C.6, while for the current (2016) nozzle repairs the detailed evaluations are provided in Sub-Section C.7.

The calculation of the available years of service is performed in MS Excel spread sheet Harris_Sizing_Tables.xlsx.

There are two approaches which are used in this calculation. Both of them follow the guidelines of NB-3330 Reference [C1]. These approaches are described below:

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Approach 1 is the more conservative approach and evaluates each repaired nozzle on an individual basis by imposing a limit of reinforcement equal to half the distance to the nearest nozzle. This is roughly equivalent to assuming that the repaired nozzle is surrounded by other nozzles that have been repaired. This approach is described below:

1) Calculation of structural area removed due to nozzle bore, repair and corrosion

2) Structural area of flawed J-groove weld is determined and considered as area removed

3) Calculation of limits of reinforcement for determination of area of reinforcement

4) Calculation of available head area of reinforcement

5) Calculation of reinforcement area of portion of the IDTB weld

6) Determination of structural area lost due to postulated crack growth in Alloy 600 and into the carbon steel of the head

7) Calculation of available area of reinforcement by adding all areas of reinforcement and subtracting areas lost due to bore and crack growth

8) Available years of service is determined as an iterative process by calculating loss of structural area due to corrosion and postulated crack growth until area of reinforcement is exhausted.

Approach 2 removes some of the conservatism of Approach 1 and was used to examine the bounding case as determined by Approach 1. This approach analyzes the ligament between adjacent nozzles, where one nozzle is in the repaired condition and one nozzle is unrepaired. This approach is appropriate for use as long as there are no repaired nozzles in neighboring penetrations. This approach is described below:

1) Calculation of structural area removed due to nozzle bore, repair and corrosion

2) Structural area of flawed J-groove weld (i.e. repaired nozzle) is determined and considered as area removed; the structural area of the unflawed J-groove weld (i.e.

unrepaired nozzle) is determined and discounted based upon the material strength ratio

3) Calculation of limits of reinforcement for determination of area of reinforcement

4) Calculation of available head area of reinforcement

5) Calculation of reinforcement area of portion of the IDTB weld for the repaired nozzle only

6) Determination of structural area lost due to postulated crack growth in Alloy 600 and into the carbon steel of the head for the repaired nozzle location

7) Calculation of available area of reinforcement by adding all areas of reinforcement and subtracting areas lost due to bore, crack growth, and a portion of the unflawed J-groove area as determined by material strength ratio Page 90

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

8) Available years of service is determined as an iterative process by calculating loss of structural area due to corrosion and postulated crack growth until area of reinforcement is exhausted.

C.2.1 Conservatisms

• Crack growth is considered to be linear over the course of 30 years. This slightly overestimates flaw growth in the early years.

• The crack growth area at the IDTB weld anomaly was conservatively taken as

[ ] . This crack is specified to have a maximum flaw radius of [ ],

2 which would produce a smaller area when calculated (maximum flaw depth x / 4)

[C6].

• For the IDTB Weld, the area is calculated assuming machining to remove IDTB overlap onto the original weld (Detail D, Ref. [C2], conservatively, doubled to account for the larger side of the weld in Approach 1.

• This method does not account for load distribution from weak ligament to stronger/larger structural area, compared to detailed limit load analysis.

• For Nozzle 23 Overbore, the diameter of the overbore is considered for the entire length of the opening. For all other repaired openings, the diameter is conservatively considered to be [ ] . This accounts for the counterbore from the outer surface of the head.

• In Section C.4, using Approach 2, the downhill J-groove weld for Nozzle 7 is conservatively considered to be 1.15 times larger than the value of the downhill J-groove weld for Nozzle 14 Minimum. This is conservative because J-groove weld areas should increase as the nozzle moves further from the head center and Nozzle 14 Minimum is further from center than Nozzle 7.

• Approach 2 uses the minimum design thickness for the head at the unrepaired nozzle.

C.3 Calculation of Available Reinforcement Areas using Approach 1 The following approach is used for calculation of the available reinforcement area.

C.3.1 Tentative Thickness Calculation The tentative thickness of the Reactor Vessel Closure Head (RVCH) is determined by the approach specified in NB-3324 of the ASME Boiler and Pressure Vessel Code Reference

[C1]. As stated in the article, except in local areas, the wall thickness of a vessel shall never be less than that obtained from the formula in NB-3324.2 for spherical shells.

Formula NB-3324.2 (Spherical Shells):

PR (Equation 1) t=

2S m P Page 91

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Where:

t = Tentative thickness of shell or head, in.

P = Design Pressure, psi R = Inside radius of shell or head, in.

Sm = Design stress intensity values, psi C.3.1.1 Closure Head (Spherical Head)

[ ] Reference [C3]

[ ] Reference [C2]

Temperature, design [ ] Reference [C3]

Sm = 26,700 psi at the design temperature for SA-533 Grade B Class 1, Reference [C1]

Substituting these values into Equation (1) yields the tentative thickness (tt) of the RVCH to be:

C.3.2 Calculation of Structural area removed due to nozzle bore The following table shows the calculation of area lost due to nozzle bore used in MS Excel spread sheet Harris_Sizing_Tables.xlsx. Figure C1 shows used parameters.

Table C1: Area Removed from Selected Nozzles Parameter Reference Nozzle Plane Coordinate x, in. [ ] [C10]

Nozzle Plane Coordinate y, in. [ ] [C10]

(1)

Opening Diameter, do, in.

[ [C5][C4][C13]

]

Plane Distance of center of nozzle, C,

= + [C10]

in.

Inside radius of the head, Ri, in. [ ] [C2]

Tentative thickness of RVCH, tt, in. [ ] Calculated Tentative outside radius of head, Rt, in. [ ] Calculated Vertical Distance to inside radius, Hi,

= Calculated in.

Vertical Distance to outer tentative

= Calculated thickness, Ht, in.

Depth of opening, to, in. [ ] Calculated Opening area removed Armv, in 2

[ ] Calculated Page 92

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

Note(s):

(1) The corrosion rate is considered to [ ] , reference [C4]. This is multiplied by 2 to account for corrosion on both sides of the diameter.

C.3.3 Minimum Reinforcement Area The following calculations for the minimum required reinforcement are based on the approach listed in ASME Boiler and Pressure Code, Reference [C1].

Per NB-3334, the boundaries of the cross-sectional area in any plane normal to the vessel wall and passing through the center of the opening and within which metal shall be located in order to have value as reinforcement are designated as the limits of reinforcement for that plane.

First, metal will be identified that may be considered for reinforcement:

NB-3335 (b) and (e) of the ASME code require that the reinforcing metal be continuous with vessel wall metal or joined to it by full penetration weld. Since the nozzles are joined by partial penetration welds, the nozzle wall metal is not considered for reinforcement.

NB-3335 (c) states that weld metal which is fully continuous with the vessel wall may be considered for reinforcement. The IDTB weld satisfies this criterion and can contribute towards reinforcement; the j-groove weld and buttering do not satisfy this criterion under cracked conditions and therefore will not be considered as contributing towards reinforcement. NB-3335 (d) of the ASME Code requires that the mean coefficient of thermal expansion of the reinforcing metal (including weld metal) be within 15% of the value of the vessel wall material.

Second, the limits of reinforcement will be calculated:

NB-3334 establishes the limits of reinforcement area along and normal to the vessel surface. Since the nozzle wall metal is not considered for reinforcement, only the limit along the surface of the head mean radius (Lw) is relevant for this calculation. For the limit of reinforcement measured along the mid-surface of the nominal vessel wall thickness, NB-3334.1 requires:

a) One hundred percent of the required reinforcement shall be within a distance on each side of the axis of the opening equal to the greater of the following:

1) The diameter of finished opening in the corroded condition, Lw1

2) The sum of the radius of the finished opening in the corroded condition, the thickness of the nozzle wall, and the thickness of the vessel wall, Lw2 b) Two-thirds of the required reinforcement shall be within a distance on each side of the axis of the opening equal to the greater of the following:

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

1) + . , where R is the mean radius of the shell or head, t is the nominal vessel wall thickness, and r is the radius of the finished opening in the corroded condition

2) The radius of the finished opening in the corroded condition plus two-thirds the sum of the thicknesses of the vessel wall and the nozzle wall Furthermore, the ASME Code prohibits the same reinforcing material from being applied to more than one opening and requires that one half of the reinforcing material lie on each side of the opening.

These conditions restrict Lw to one-half of the distance between similar adjacent penetrations less the radius of the opening. Axis-to-axis distances between adjacent nozzles are considered rather than distances along the curved surface of the RVCH mean radius.

The following table shows the calculation of limits of reinforcement used in MS Excel spread sheet Harris_Sizing_Tables.xlsx. Figure C1 shows used parameters.

Table C2: Limits of Reinforcement for Selected Openings Parameter References Diameter do, in. (upper) Specific for each nozzle [C5][C13]

Radius, r, in. (upper) r = do/2 Calculated RVCH wall thickness, t, in. Specific for each nozzle [C5][C4]

Nozzle wall thickness, tn, in. No credit taken -

Inside radius of RVCH, Ri, in. [ ] [C2]

Mean radius of RVCH, Rm, in. = + 2 Calculated Distance to NB-3334.1 (a)(1) Lw1 = 2r Calculated accommodate 100% NB-3334.1 (a)(2) Lw2 = r+t+tn Calculated reinforcement > of Lw & Lw Calculated 1 2 Distance to NB-3334.1 (b)(1) + 0.5 Calculated accommodate 2( + )

2/3 NB-3334.1 (b)(2) + 3 Calculated reinforcement > of (b)(1) & (b)(2) Calculated Grid distance for nozzles, in. [ ] [C10]

Center line distance between this opening and the nearest CRDM [ ] [C10]

opening, in.

Max. length available for (see note below) Calculated reinforcement, Lr, in.

The following considerations were taken in Table C2:

• Since the nozzle wall is not fully continuous with the head, the metal cannot be counted as contributing to the area of reinforcement per NB-3335. Therefore, the nozzle wall thickness is considered to be zero (tn = 0 in.).

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• The reinforcement limit (Lr) for the CRDM nozzle is calculated by one half of the centerline distance between the two nearest consecutive openings

( [ ] ).

C.3.4 Required Area of Reinforcement NB-3332.2 indicates that reinforcement is required for the RVCH with the tentative thickness calculated in C.3.1 By NB-3332.2, the total cross-sectional area of reinforcement, A, shall not be less than:

=

Where d = finished diameter of a circular opening (or chord of an elliptical opening) in the corroded condition, F = a correction factor which compensates for the variation in pressure stresses on different planes with respect to the axis of a vessel (correlates to F

= 1.00 with a 0.00° angle of the plane with the longitudinal axis), and tr (in this case) is the minimum required thickness in the absence of the opening. The body of this calculation will refer to do as the diameter of the circular opening and tr as the depth of reinforcement. Not less than half the required material shall be on each side of the center line. Figure C1 diagrams the reinforcement area above the tentative thickness.

Figure C1: Reinforcement Area Diagram Page 95

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Figure C2: Overview of Approach 1 Page 96

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The following table shows calculation of IDTB weld reinforcement area used in MS Excel spread sheet Harris_Sizing_Tables.xlsx.

Table C3: IDTB Weld Reinforcement Parameter Reference Outside Diameter at IDTB Weld, dwo in. [C2]

[ ]

Inside Diameter at IDTB Weld, dwi in. [C2]

[ ]

Width of IDTB Weld, w in. [ ] Calculated Min. Ligament Thickness, tlig in. [C2]

[ ]

Area of IDTB Weld Anamoly, Aanamoly in2 [ ] Section C.2.1 Area of IDTB Weld for Reinforcement, [ Calculated AIDTB in2

]

Note 1: [ ] The mean coefficient of thermal expansion at [ ] of the reinforcing metal of the IDTB weld ( [ ]

per Reference [C3]) is within of 15% of the mean coefficient of thermal expansion at 650 F of the head material. The ASME requirement is satisfied. Values are taken from the ASME code, Reference [C12].

Note 2: Reduction coefficient of [ ] for the IDTB weld area of reinforcement used in Table C3 is calculated as SmIDTB /Smvessel = [ ] . Values are taken from the ASME code, Reference [C1].

Note 3: Nozzle 23 Over Bore conservatively uses the smaller geometry for the standard IDTB welds.

The following table shows the calculation of head reinforcement area used in MS Excel spread sheet Harris_Sizing_Tables.xlsx. Figure C1 shows used parameters.

Table C4: Actual Reinforcement Margin Parameter Opening Diameter, do, in. [ ]

Reinforcement limit, Lr, in. [ ]

Outer RVCH surface radius, Ro, in. [ ]

Plane Distance of center of nozzle

= +

C, in.

Vertical Distance to outer tentative

=

thickness, Ht, in.

Vertical Distance to outer RVCH

=

surface, H, in.

Depth of reinforcement, tr, in. [ ]

Head reinforcement area, Ah, in.2 [ ] =2 ( 2)

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C.3.5 Calculation of area lost due to crack growth The entire area of Alloy 600 is considered removed due to presence of flaws for repaired nozzles. In addition, area lost due to postulated crack growth into the carbon steel is considered. Area removed of the Alloy 600 is taken from Reference [C5]. These drawings give as-built areas of the uphill and downhill J-groove welds for each nozzle of interest. Those numbers are tabulated below in Table C5.

Table C5: Alloy 600 weld area lost J-Groove Weld Area Uphill Downhill Min Max Min Max Nozzle Condition Condition Condition Condition In2 In2 In2 In2 5

14 17 18 23 23 OB 37 38 49 63 Area lost due to postulated crack growth is determined using a CAD feature of the Workbench program. The weld profiles of the uphill and downhill side taken from Reference [C5] are used and offset by the postulated crack growth. The area of the cracked carbon steel section is taken from the ANSYS Workbench program. The crack growth on the uphill side is [ ] for [ ] years of service and the downhill crack growth is [ ] inches for [ ] years of service taken from Section 6.3.1. Conservatively, crack growth per year is calculated as [ ] for the uphill side and [ ] for the downhill side. This growth is conservative for service that is less than 30 years since the crack propagates with slower rate at the beginning of the repair service.

In addition, the reinforcement area lost due to crack growth at the weld anomaly in the IDTB weld is also accounted for and reduced based upon a ratio of material strength.

Min and Max Conditions refer to minimum and maximum head thickness configurations.

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QA Note: The crack growth areas have been checked with approximate hand calculations to verify the Workbench computer program results, based on the weld profiles give in Ref. [C5].

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C.3.6 Calculation of available area of reinforcement The total remaining reinforcement area is calculated by adding Ah (see Table C4), area of reinforcement available in the carbon steel head portion, to area of reinforcement due to portion of the IDTB weld (AIDTB - see Table C3) and subtracting areas lost due to nozzle bore (Armv - see Table C1), Alloy 600 J-groove weld area (see Table C5), and crack growth at the weld anomaly point. This is calculated in MS Excel spread sheet Harris_Sizing_Tables.xlsx without corrosion and without J-groove crack growth, initially to identify limiting nozzles (i.e. for screening purposes).

Table C6: Initial Calculation of Reinforcement Area Remaining Total Area of Total Area Removed, in2 Total Remaining Reinforcement, in2 Reinforcement, in2 Nozzle 5 Minimum (Special Case - See (Special Case - See (Special Case - See Section C.4) Section C.4) Section C.4)

Nozzle 14 Minimum Nozzle 14 Maximum Nozzle 17 Minimum Nozzle 18 Minimum Nozzle 18 Maximum Nozzle 23 Minimum OB Nozzle 23 Minimum Nozzle 37 Minimum Nozzle 37 Maximum Nozzle 38 Minimum Nozzle 38 Maximum Nozzle 49 Minimum Nozzle 49 Maximum Nozzle 63 Minimum Based on Table C6, Nozzle 14 Minimum and Nozzle 37 Minimum are identified as potential limiting cases. Since neither of these nozzles have an adjacent nozzle in the repaired configuration, they will be analyzed using Approach 2.

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Since Nozzle 17 Minimum and 18 Minimum are adjacent and each nozzle is in the repaired configuration, these nozzles are analyzed using Approach 1 considering corrosion and crack growth for [ ] years. The J-groove weld crack growth areas are documented in Figures C3 - C6.

Figure C3: Nozzle 17 Minimum Uphill J-groove Weld Crack Growth Area for 30 Years Page 101

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Figure C4: Nozzle 17 Minimum Downhill J-groove Weld Crack Growth Area for 30 Years Page 102

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Figure C5: Nozzle 18 Minimum Uphill J-groove Weld Crack Growth Area for 30 Years Page 103

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Figure C6: Nozzle 18 Minimum Downhill J-groove Weld Crack Growth Area for 30 Years Page 104

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary)

The calculation for Nozzle 17 Minimum and 18 Minimum is documented in MS Excel spread sheet Harris_Sizing_Tables.xlsx and the results are represented below in Table C7 for [ ] years of operation.

Table C7: Nozzle 17 Minimum and 18 Minimum Results for 30 Years of Operation Total Area of Total Area Removed, in2 Total Remaining Reinforcement, in2 Reinforcement, in2 Nozzle 17 Minimum Nozzle 18 Minimum As shown above in Table C7, the area of reinforcement exceeds the area removed for the limiting case (Nozzle 17 Minimum) and therefore since Nozzle 17 was repaired in May 2012, this nozzle is acceptable for an additional [ ] years beyond this date to May [ ].

C.4 Calculation of Remaining Years of Service using Approach 2 The purpose of this section is to remove some of the conservatisms presented in Section C.3 for the reinforcement calculation when a repaired nozzle is not adjacent to another repaired nozzle. Section C.3 looked at each nozzle individually without considering additional reinforcement that could be gained from neighboring nozzles. This approach is overly conservative when no neighboring nozzles have been repaired.

To remove some conservatism, a second approach was taken to calculate the available reinforcement area and area removed for a repaired nozzle neighboring an unrepaired nozzle. This approach will utilize an iterative process to determine when reinforcement area is exhausted. The limiting condition will occur on the uphill side of the repaired nozzle as a result of the significantly greater crack growth rate on the uphill J-groove weld side. Nozzle 14 Minimum was chosen as the limiting case based upon information from Table C6, and by comparing the growth in the J-Groove uphill weld between Nozzle 14 Minimum and Nozzle 37 Minimum. Since Nozzle 14 Minimum has a greater growth in the area of the uphill weld ( [ ] in2 - see Figure C8) as opposed to Nozzle 37 Minimum ( [ ] in2 - see Figure C10), Nozzle 14 Minimum is still the bounding location. For this analysis, Nozzle 14 Minimum is paired with its uphill neighbor Nozzle 7.

Nozzle 5 Minimum will also be evaluated since this nozzle has close proximity to the vent pipe.

The area removed was calculated by determining the area below the tentative thickness between each nozzles respective axis and the outside of the nozzle wall in the corroded condition. The J-groove weld area with crack propagation area (shown in Figure C8) was removed for the uphill weld at Nozzle 14 Minimum. In addition, the J-groove weld area was discounted for Nozzle 7 downhill based upon the material strength in comparison with the RVCH, as specified in NB-3330 [C1]. The downhill J-groove weld for Nozzle 7 was conservatively considered to be [ ] times larger than the value of the downhill J-groove weld for Nozzle 14 Minimum (Figure C9). This is conservative Page 105

Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) because J-groove weld areas should increase as the nozzle moves further from the center and Nozzle 14 Minimum is further from center than Nozzle 7.

Figure C7: Overview of Approach 2 The length for the area of reinforcement was calculated by determining the distance between the two nozzles and subtracting the radius of each nozzle. This value was multiplied by the average thickness between the tentative thickness and the outer radius of the RVCH measured at each location. Since the as-built thickness was not available for Nozzle 7, the design minimum thickness was conservatively used ( [ ] in [C2]).

In addition to this reinforcement area, the IDTB weld on the uphill side was credited for reinforcement on Nozzle 14 Minimum. The IDTB weld was discounted for material strength and the weld anomaly, as described in Note 2 of Table C3.

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Figure C8: Nozzle 14 Minimum Uphill J-groove Weld Crack Growth Area for 15 Years Page 107

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Figure C9: Nozzle 14 Minimum Downhill J-groove Weld Crack Growth Area for 15 Years Page 108

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Figure C10: Nozzle 37 Minimum Uphill J-groove Weld Crack Growth Area for 15 Years Page 109

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The available years of service are calculated using an iterative process utilizing Approach 2. Area lost due to crack growth into the carbon steel is calculated for each year of service. The maximum number of years is determined at the point when the available reinforcement area is exhausted.

The calculation for Nozzle 14 Minimum and Nozzle 7 is documented in MS Excel spread sheet Harris_Sizing_Tables.xlsx and the results are represented below in Table C8 for 15 years of operation.

Table C8: Nozzle 14 Minimum and Nozzle 7 Results for 15 Years of Operation Ligament between Nozzle 14 Min / Nozzle 7 Total Area of Reinforcement, in2 Total Area Removed, in2 Reinforcement Remaining, in2 A special case exists for Nozzle 5, and therefore the lifetime of Nozzle 5 will be verified separately below. Nozzle 5 does not border any repaired nozzles, but it lies within a closer proximity to an opening than the other cases as a result of the placement of the vent line. The Nozzle 5 Minimum case was modeled using Approach 2 in which the ligament between Nozzle 5 Minimum and the vent line was examined. The Nozzle 5 Uphill weld was used for this analysis, because the crack growth on the uphill weld produces a larger area which requires reinforcement. For conservatism, the minimum design thickness was used for the vent line and a [ ] in2 weld was conservatively used for the vent line J-groove weld. This J-groove weld area is conservative because it is larger than the J-groove weld areas on Nozzle 5 Minimum and the vent line does not require as large of a J-groove weld as the CRDM nozzles [C10]. In addition, corrosion was applied to the penetration diameter of the vent line to calculate area removed, despite the knowledge that this area would be protected by the vent line pipe. The calculation for Nozzle 5 Minimum and the vent line is documented in MS Excel spread sheet Harris_Sizing_Tables.xlsx and the results are represented below in Table C9 for 15 years of operation. This calculation uses the crack growth area for the uphill J-groove weld after 15 years for Nozzle 5 Minimum as shown in Figure C11.

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Figure C11: Nozzle 5 Minimum Uphill J-groove Weld Crack Growth Area for 15 Years Page 111

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Table C9: Nozzle 5 Minimum and Vent Pipe Results for 15 Years of Operation Ligament between Nozzle 5 Min / Vent Pipe Total Area of Reinforcement, in2 [ ]

Total Area Removed, in2 [ ]

Reinforcement Remaining, in2 [ ]

Based upon the results represented in Table C9, it can still be concluded that Nozzle 14 Minimum is the bounding case for 15 years of operation.

C.5 Results/Conclusion After analyzing all the critical nozzle locations, Nozzle 14 was identified as the limiting condition. Table C8 displays that Nozzle 14 is acceptable for 15 years of service from the date of the repair. Since this value is bounding for the other nozzles, this conclusion is applicable to all other cases. By this conclusion, and since the earliest repairs were performed in May 2012, the RVCH nozzles are acceptable for 12 years of additional operation, from April 2015.

C.6 Computer File(s)

Table C10: COLDStor - Official Computer Files

\cold\General-Access\32\32-9000000\32-9176350-002\

Date Time Size File Name 4/29/15 14:47:22(EST) 36172 Bytes Harris_Sizing_Tables.xlsx This computer file inputs dimensions from References [C2], [C4], [C5], [C6], and [C10].

C.7 Additional Evaluation at Penetrations #30, #40 and #51 for 5 years operation During the recent outage inspection according to References [C14], [C15] and [C16],

additional nozzle repair is needed for nozzles 30, 40 and 51. However, no original J-groove weld dimensions nor RV head thickness at the three nozzle penetrations are available for a complete evaluation at the time this revision is prepared. The results presented in the Sections C.1 to C.6 for the nine repaired nozzles are then used as the basis to justify a 5-year operation for the three nozzle repairs.

RV head thickness at the nozzle:

As shown in previous sections, the head thickness is the most critical parameter in the evaluation. The following analysis is based on the assumption that the RV head wall thickness (t in Table C2) is no less than [ ] inches, i.e.,

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Controlled Document Document No. 32-9215680-002 Shearon Harris Unit 1 CRDM/CET Nozzle As-Left J-groove Weld Analysis (Non Proprietary) t[ ] in.

J-groove weld size:

Table C6 indicates that the total remaining reinforcement area for a particular nozzle of the minimum condition is always less than that of the maximum condition. Therefore the J- groove weld size of the minimum condition is considered herein. Furthermore, the geometric symmetry of the nozzle penetrations indicates that the J- groove weld size of Nozzle 37 may be assumed for Nozzle 40, and that of Nozzle 49 for Nozzle 51; J-groove weld size of Nozzle 37 may be assumed for Nozzle 30.

Crack growth area:

Since no detailed J-groove weld dimensions are available, crack growth areas at the three nozzle penetrations are estimated by the crack growth areas at Nozzles 14 and 37 (Figures C8 to C10). A review of Figures C8 to C10 indicates that closer the nozzle to the head center higher the crack growth area results (in contrast to that away from the center the J-groove weld size is larger). Therefore the crack growth area of Nozzle 14 for 15 years operation is taken as the bounding case for the three nozzles. A linear crack grown is assumed in the 15 years which is conservative, as the crack growth area in earlier years is less than that in later years. The crack growth area of 5 years is estimated as follows in Table C11:

Table C11: Estimate of Crack Growth area at Penetrations 30, 40 and 51 for 5 Years of Operation Crack growth area (in2) Area in in2 Eq.

Crack growth area of Nozzle 14 (15 years), upper hill Crack growth area of Nozzle 14 (15 years), down hill Total crack growth area of 15 years Crack growth area of 5 years Nozzle 30 is adjacent to Nozzle 38, and Nozzle 51 is adjacent to Nozzle 63. Approach 1 mentioned in Section C.2 is used. The calculation procedure is the same as in Section C.3.6 for Nozzles 17 and 18.

MS Excel spread sheet Harris_Sizing_Tables.xlsx from Rev. 002 is used in the calculation, and the results are presented in Table C12.

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Table C12: Results of Nozzle Repair at Penetrations 30, 40 and 51 for 5 Years of Operation Penetration area (in2) 30 40 51 Eq.

Head reinforcement area IDTB weld reinforcement area Total area of reinforcement J-groove weld area before crack growth J-groove weld area after crack growth Area removed due to opening and corrosion Total area removed Total area remaining Computer File:

Updated MS Excel spread sheet of the same file name is uploaded to the COLDStor at

\cold\General-Access\32\32-9000000\32-9176350-003\:

Table C13: COLDStor - Official Computer File of Rev. 003 Date Time Size File Name 10/17/2016 1:35 PM (CT) 43026 Bytes Harris_Sizing_Tables.xlsx Page 114

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C.8 Appendix References References identified with an (*) are maintained within Duke Energy Records System and are not retrievable from AREVA Records Management. These are acceptable references per AREVA Administrative Procedure 0402-01, Attachment 8. See page 2 for Project Manager Approval of customer references C1 ASME Boiler and Pressure Vessel Code,Section III, Rules for Construction of Nuclear Facility Components, 2001 Edition with Addenda through 2003.

C2 AREVA Drawing 02-9175500E-007, Shearon Harris CRDM ID Temper Bead Weld Repair C3 AREVA Document 08-9172870-003, Design Specification for Shearon Harris RVCH CRDM and CET Nozzle Penetration Modification C4 AREVA Document 51-9176114-002, Corrosion Evaluation of Shearon Harris RV Head Penetration IDTB Weld Repair.

C5 AREVA Drawing 02-9239552B-001, Shearon Harris RVCH Repaired Penetration J-Groove Details C6 AREVA Document 32-9176345-002, Shearon Harris Unit 1 RVCH CRDM/CET Nozzle IDTB Repair Weld Anomaly C7 Reference Removed C8 Reference Removed C9 ANSYS/Workbench Finite Element Computer Code, Version 15.0, ANSYS Inc. Canonsburg, P.A.

C10 AREVA Document 38-2200979-000, Shearon Harris - Proprietary Document LTR-MRCDA-12-8 C11 AREVA Document 50-9176411-005, Shearon Harris CRDM Nozzle IDTB Weld Repair Traveler C12 ASME Boiler and Pressure Vessel Code,Section II, Rules for Construction of Nuclear Facility Components, 2001 Edition with Addenda through 2003.

C13 CR 2015-3494 C14 *Duke Energy NCR #02070424 C15 *Duke Energy NCR #02070179 C16 *Duke Energy NCR #02070259 Page 115