L-MT-08-091, Calculation 0801040.301, Steam Dryer Outer Hood Submodel Analysis.

Calculation 0801040.301, Steam Dryer Outer Hood Submodel Analysis.

ML083510666
Person / Time
Site:	Monticello
Issue date:	10/31/2008
From:	Kok S, Qin M Structural Integrity Associates
To:	Northern States Power Co, Office of Nuclear Reactor Regulation, Xcel Energy
References
L-MT-08-091, Project No.: 0801040, TAC MD9990 0801040.301
Download: ML083510666 (32)

Text

V StructuralIntegrity Associates, Inc. File No.: 0801040.301 CALCULATION PACKAGE Project No.: 0801040 Quality Program: Z Nuclear E] Commercial PROJECT NAME:

Monticello Steam Dryer Submodel Analysis CONTRACT NO.:

08-510 CLIENT: PLANT:

Continuum Dynamics, Inc. Monticello Nuclear Generating Plant CALCULATION TITLE:

Steam Dryer Outer Hood Submodel Analysis Project Manager Preparer(s) &

Document Affected Revision Description Approval Checker(s)

Revision Pages Signature & Date Signatures & Date 0 1-30 Initial Issue A-i - A-2 Karen K. Fujikawa 10/31/08 Minghao Qin 10/31/08 Soo Bee Kok 10/31/08

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Table of Contents 1.0 IN TRO D UCTION ................................................................................................... 4 2.0 METHODOLOGY AND ASSUMPTIONS ............................................................... 6 3.0 M A TERIA L PROPERTIES ....................................................................................... 7 4.0 CO V ER PLATE ANA LY SIS ..................................................................................... 7 4.1 Key D im ensions .................................................................................................. 7 4.2 Boundary Conditions and A pplied Load ............................................................ 9 4.3 Shell Finite Elem ent M odel .............................................................................. 11 4.4 Solid Finite Elem ent M odel .............................................................................. 12 4.5 Solid M odel Stress Paths .................................................................................. 14 4.6 Shell M odel Results ......................................................................................... 15 4.7 Solid M odel Results ......................................................................................... 16 4.8 Stress Com parison ........................................................................................... 18 5.0 OU TER H O O D ANA LY SIS ..................................................................................... 19 5.1 K ey D imensions ................................................................................................ 19 5.2 Boundary Conditions and Applied Load .......................................................... 19 5.3 Shell Finite Elem ent M odel .............................................................................. 21 5.4 Solid Finite Elem ent M odel .............................................................................. 22 5.5 Solid M odel Stress Paths .................................................................................. 24 5.6 Shell M odel Results ......................................................................................... 26 5.7 Solid M odel Results .......................................................................................... 27 5.8 Stress Com parison ........................................................................................... 29 6.0 CON CLU SION S ...................................................................................................... 30 7.0 REFEREN CES ............................................................................................................... 30 A PPEND IX A CO M PUTER FILES ................................................................................ A -i File No.: 0801040.301 Page 2 of 30 Revision: 0 F0306-01'

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List of Tables Table 4-1: Cover Plate Submodel Key Dimensions ............................................................ 8 Table 4-2: Cover Plate Stress Profile Comparison ........................................................... 10 Table 4-3: Cover Plate Solid Model Maximum Stress Intensity ....................................... 17 Table 4-4: Cover Plate Solid Model / Shell Model Stress Ratio .................. 18 Table 5-1: Outer Hood Stress Profile Comparison ........................................................... 20 Table 5-2: Outer Hood Solid Model Maximum Stress Intensity ...................................... 28 Table 5-3: Outer Hood Solid Model / Shell Model Stress Ratio ....................................... 29 List of Figures Figure 1-1: Hot Spots Locations ........................................................................................... 5 Figure 4-1: Cover Plate Model Boundary Conditions and Applied Load ........................... 9 Figure 4-2: CDI Shell Model and Shell Submodel at the Cover Plate .............................. 10 Figure 4-3: Cover Plate Shell Submodel Finite Element Model Mesh .................................. 11 Figure 4-4: Cover Plate Solid Finite Element Model Mesh (Isometric View) .................. 12 Figure 4-5: Cover Plate Solid Finite Element Model Mesh (Side View) .......................... 13 Figure 4-6: Cover Plate Solid Model Stress Paths ............................................................ 14 Figure 4-7: Cover Plate Shell Model Stress Intensity at High Stress Location ................. 15 Figure 4-8: Cover Plate Solid Model Stress Intensity at High Stress Region ................... 16 Figure 5-1: Outer Hood Model Boundary Conditions and Applied Load ........................ 19 Figure 5-2: CDI Shell Model and Shell Submodel at the Outer Hood ............................. 20 Figure 5-3: Outer Hood Shell Finite Element Model Mesh ............................................. 21 Figure 5-4: Outer Hood Solid Finite Element Model Mesh ............................................. 22 Figure 5-5: Outer Hood Solid Finite Element Model Mesh (Weld Region) ..................... 23 Figure 5-6: Outer Hood Solid Finite Element Stress Paths (End View) .......................... 24 Figure 5-7: Outer Hood Solid Finite Element Stress Paths (Side View) ........................... 25 Figure 5-8: Outer Hood Shell Finite Element Pm + Pb Stress Intensity ............................ 26 Figure 5-9: Outer Hood Solid Finite Element Stress Intensity at the Bottom of the Gusset (Inside W eld R egion) ........................................................................................ 27 File No.: 0801040.301 Page 3 of 30 Revision: 0 A. *~JptA~flflkJ Jn..UfhhkaII.sIz F0306-O1

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1.0 INTRODUCTION

Background

The Monticello steam dryer has been analyzed using a shell finite element model, which does not specifically model the weld. The results show that there are localized high stresses at some of the welded connections. Based on past experience, it has been established that if the connections are modeled using solid elements to represent the weld, the weld can better distribute the stresses in the region of high stress concentration. Coupled with the use of stress linearization approach, the maximum stress intensity computed using the solid model (with the weld modeled) generally gives a better prediction of stresses compared with shell elements in the region of the high stress concentration.

Obiective This calculation documents the comparison of the stress intensity computed using a shell finite element model and a solid finite element model with linearization stress paths in the region of interest. In the shell finite element model, the details of the connecting welds are not modeled, while the welds are modeled in detail in the solid finite element model. In order to make a direct comparison between the shell and the solid finite element models, these models must have the same dimensions, same material properties, and subjected to the same boundary conditions and loading.

Two steam dryer components are being analyzed in this calculation:

1. The cover plate, which is welded to the outer hood (Hot Spot 1 of Figure 1-1).

2. The outer hood, which is welded to the gusset (Hot Spot 2 of Figure 1-1).

Stress profiles from the full model analysis (Reference 3) are provided for each of the two components. Appropriate loading conditions that closely match the original stress profiles will be used. This ensures that the loading that causes the localized high stress is captured.

The finite element analyses in this calculation are performed using ANSYS Version 11.0 (References 5 and 6).

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Figure 1-1: Hot Spots Locations File No.: 0801040.301 Page 5 of 30 Revision: 0 F0306-O01

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2.0 METHODOLOGY AND ASSUMPTIONS Cover Plate The full model analysis shows that the maximum stress is essentially bending stress (Pb) with little membrane stresses (Pm). When the linearized stresses are obtained for the different locations in the solid model, both the membrane stress (Pm) and the membrane plus bending stress (Pm + Pb) are computed.

The evaluation only compares the membrane plus bending stress (Pm + Pb) of the solid model with the membrane plus bending stress (Pm + Pb) of the shell model. The computed stress ratio will be used to adjust the stresses in the full model.

The stress profile for the full model shows that the highest stress is localized at the node that is the intersection at the outer hood and the cover plate at horizontal and slope sections. A unit load of 38.9 lb is applied to 28 outer hood nodes located about 7 inches above the cover plate.

Outer Hood The full model analysis shows that the maximum stress is essentially bending stress (Pb) for the outer hood, and membrane stresses (Pm) for the connected gusset. When the linearized stresses are obtained for the different locations in the solid model, both the membrane stress (Pm) and the membrane plus bending stress (Pm + Pb) are computed.

The evaluation only compares the membrane plus bending stress (Pm + Pb) of the solid model with the membrane plus bending stress (Pm + Pb) of the shell model. The computed stress ratio will be used to adjust the stresses in the full model.

The stress profile for the full model shows that the highest stress is localized at the node located at the bottom of the outer hood and gusset connection. A load of 9,397.3 lb is applied to top plate and 28.9 lb is applied at the bottom end of the support brace.

Key Assumptions

1. A submodel is used for comparing the maximum stress intensity between the full shell and the shell submodel. In the submodels, appropriate boundary conditions are assumed.

2. The weld material is assumed to be the same as the base metal material.

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3.0 MATERIAL PROPERTIES The material properties used are as follows:

Modulus of Elasticity 25.55E6 psi (Reference 4)

Poisson's Ratio = 0.30 (Reference 4) 4.0 COVER PLATE ANALYSIS The cover plate submodel consists of six key parts: the cover plate, the outer hood, the end panel, the top plate, the gusset, and the support brace. For the solid submodel, the weld is also included.

4.1 Key Dimensions The key dimensions of the submodel are as follows:

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Table 4-1: Cover Plate Submodel Key Dimensions Component Thickness / Size Modeled Dimensions (2)

Cover Plate 1/4" -14" (depth) x -54 (width)

Outer Hood 1/2" -54" (width) x -62" (height)

Side Hood 1/2" -29" (width) x -62" (height)

Top Plate 1/2" 18.5" (depth) x -75" (width)

Gusset 1/2" 5" (width) x 7" (height)

Support Brace 3/8" 2" x 2" x -54" (length)

Cover Plate Weld (1) 1/4" One sided fillet weld Top Plate Weld () 1/2" / 3/16" Both sided fillet weld Gusset Weld (1 1/4" Both sided fillet weld Support Brace Weld (1) 5/16" Both sided fillet weld Notes: (1) The fillet weld is modeled in the solid submodel.

(2) The dimensions are taken from the drawings (Reference 1).

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4.2 Boundary Conditions and Applied Load The boundary conditions and applied load are identified in Figure 4-1.

1 ELEMENTS OCT 27 2009 RLM Edge C 20:50:10 F

Edge

-Edge B Edges E 38.9 lb at each node Mt Ed*G' d F 4*,x Monticello, Steeam* D~ryrE Figure 4-1: Cover Plate Model Boundary Conditions and Applied Load Boundary Conditions Edges A, B, C, D, H: Plane of symmetry.

Edges C, E, F: Restrained in Z translation.

Edge G: Restrained in all three directions.

Applied Load Load: 38.9 lb is applied at outer hood 28 nodes, located at about 7 inches above the cover plate.

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The comparison of the stress profiles between the submodel and the full model is provided in Table 4-2 and Figure 4-2.

Table 4-2: Cover Plate Stress Profile Comparison CDI Shell Model Shell Submodel Node SI (psi) (1) Node SI (psi) 139068 2,415 172329 2,965 139053 3,178 172339 3,164 139052 4,590 168677 4,590 139051 3,374 168787 3,361 139077 2,791 168777 3,218 Note: 1. These values are taken from References 3 and 2.

CDI Shell Model Shell Submodel Figure 4-2: CDI Shell Model and Shell Submodel at the Cover Plate File No.: 0801040.301 Page 10 of 30 Revision: 0 F0306-01

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4.3 Shell Finite Element Model The shell finite element model is modeled using SHELL63 elements. A regular mesh size of 0.25" is used for the entire model. The entire model consists of approximately 97,000 nodes and 96,000 shell elements. The finite element mesh is shown in Figure 4-3.

RE.AL Figure 4-3: Cover Plate Shell Submodel Finite Element Model Mesh File No.: 0801040.301 Page 11 of 30 Revision: 0

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1ural 4.4 Solid Finite Element Model The solid finite element model is modeled using SOLID45 elements. A regular mesh size of 0.25" is used throughout the model, except in the transition regions. Six layers of element are modeled across the plate thickness, therefore, providing adequate discretization through the plate thickness to capture the stress variations across the thickness. The entire model consists of approximately 888,000 nodes and 759,000 solid elements. The finite element mesh is shown in Figure 4-4 and Figure 4-5.

Figure 4-4: Cover Plate Solid Finite Element Model Mesh (Isometric View)

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Figure 4-5: Cover Plate Solid Finite Element Model Mesh (Side View)

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4.5 Solid Model Stress Paths Linearization stress paths are taken from the weld root to the component surface in the vicinity of the high stress region. In addition, linearization stress paths are also taken from the weld toe to the opposite surface of the connected parts. The stress paths used for the Cover Plate solid model are shown in Figure 4-6.

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4.6 Shell Model Results The stress intensity plot for the shell model is provided in Figure 4-7.

Figure 4-7: Cover Plate Shell Model Stress Intensity at High Stress Location Summary The maximum Pm + Pb stress intensity is 4,590 psi.

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4.7 Solid Model Results The stress intensity plot for the solid model is provided in Figure 4-8.

Figure 4-8: Cover Plate Solid Model Stress Intensity at High Stress Region File No.: 0801040.301 Page 16 of 30 Revision: 0 001-1 1 F0306-O1

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Maximum Stress Intensity The stress intensity is computed for the different stress paths. There are multiple locations for each of the paths, and the largest magnitude is identified as the maximum stress intensity for that path.

The maximum stress intensity for the different paths are summarized in Table 4-3.

Table 4-3: Cover Plate Solid Model Maximum Stress Intensity Pm+Pb Path # psi)

(psi) 1 2,259 2 4,158 3 4,447 4 1,492 5 1,438 6 3,615 File No.: 0801040.301 Page 17 of 30 Revision: 0 t~tnn.ppny V ~ a ~,pa n..-saa J .Lnt~. .....t.,..

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4.8 Stress Comparison The stress comparison between the shell and the solid finite element models is summarized in Table 4-4.

Table 4-4: Cover Plate Solid Model / Shell Model Stress Ratio Solid Shell Stress (psi) (psi) Ratio 1 2,259 0.49 2 4,158 0.91 3 4,447 0.97 4,590 4 1,492 0.33 5 1,438 0.31 6 3,615 0.79 Maximum = 0.97 Summary The maximum stress ratio for the solid model stress intensity / shell model stress intensity is 0.97.

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Nmdwrl Iegr/iy Asocat, In SV 5.0 OUTER HOOD ANALYSIS The outer hood submodel is the same as cover plate submodel that is described in Section 4.0.

5.1 Key Dimensions The key dimensions of the submodel are provide in Table 4-1.

5.2 Boundary Conditions and Applied Load The boundary conditions and applied load are identified in Figure 5-1.

1 ELEMENTS OCT 27 2008 22:24:23 RERL NUN F

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Boundary Conditions Edges A B, C, E: Plane of symmetry.

Edges F, G: Restrained in Z translation.

Applied Load

1. Apply a total load of 28.9 lb in the X direction at Edge H nodes.

2. A load of 9,397.3 lb is applied in the X direction along Edge D, at a node that corresponds to the gusset location in the Y direction.

The comparison of the stress profiles between the submodel and the full model is provided in Table 5-1 and Figure 5-2.

Table 5-1: Outer Hood Stress Profile Comparison CDI Shell Model Shell Submodel Node SI (psi)(') Node SI (psi) 140301 4,303 20005 5,769 140300 952 67206 3,622 140307 642 67202 3,561 140306 530 67198 3,768 Note: 1. These values are taken from Reference 3.

CDI Shell Model Sub-Shell Model Figure 5-2: CDI Shell Model and Shell Submodel at the Outer Hood File No.: 0801040.301 Page 20 of 30 Revision: 0 F0306-01I

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5.3 Shell Finite Element Model The shell finite element model is modeled using SHELL63 elements. A regular mesh size of 0.25" is used for the entire model. The entire model consists of approximately 99,000 nodes and 98,000 shell elements. The finite element mesh is shown in Figure 5-3.

Figure 5-3: Outer Hood Shell Finite Element Model Mesh File No.: 0801040.301 Page 21 of 30 Revision: 0

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5.4 Solid Finite Element Model The solid finite element model is modeled using SOLID45 elements. A regular mesh size of 0.25" is used throughout the model, except in the transition regions. Six layers of element are modeled across the plate thickness, therefore, providing adequate discretization through the plate thickness to capture the plate bending behavior. The entire model consists of approximately 902,000 nodes and 772,000 solid elements. The finite element mesh is shown in Figure 5-4 and Figure 5-5.

Figure 5-4: Outer Hood Solid Finite Element Model Mesh File No.: 0801040.301 Page 22 of 30 Revision: 0 F0306-01*

V trdueurl utgily Associates, Inc, Figure 5-5: Outer Hood Solid Finite Element Model Mesh (Weld Region)

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5.5 Solid Model Stress Paths Linearization stress paths are taken from the weld root to the component surface in the vicinity of the high stress region. In addition, linearization stress paths are also taken from the weld toe to the opposite surface of the connected parts. The stress paths used for the outer hood solid model are shown in Figure 5-6 and Figure 5-7.

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-11 Z x F-Figure 5-6: Outer Hood Solid Finite Element Stress Paths (End View)

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k IV nMwtw, Intogri, Assocat, Inc 5.6 Shell Model Results The stress intensity plot for the shell model at the bottom of the Outer Hood, which is the location of interest, is provided in Figure 5-8.

Figure 5-8: Outer Hood Shell Finite Element P. + Pb Stress Intensity Summary The maximum membrane plus bending stress (Pm + Pb) stress intensity at the bottom of the gusset is 5,769 psi.

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Figure 5-9: Outer Hood Solid Finite Element Stress Intensity at the Bottom of the Gusset (Inside Weld Region)

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Maximum Stress Intensity The stress intensity is computed for the different stress paths. There are multiple locations for each of the paths, and the largest magnitude is identified as the maximum stress intensity for that path.

The maximum stress intensity for the different paths is summarized in Table 5-2.

Table 5-2: Outer Hood Solid Model Maximum Stress Intensity Pm + Pb Path # Pi)

(psi) 1 1,665 2 933 3 1,096 4 1,313 5 835 6 1,017 7 1,443 8 882 9 966 10 966 11 878 12 1,665 13 1,129 14 1,395 15 773 16 985 File No.: 0801040.301 Page 28 of 30 Revision: 0 t-tphIpnhp, V tpfltfl.~n .B~ A ~~jJn *t~tpi,, ~

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5.8 Stress Comparison The stress comparison between the shell and the solid finite element models is summarized in Table 5-3.

Table 5-3: Outer Hood Solid Model / Shell Model Stress Ratio Solid Shell Stress (psi) (psi) Ratio 1 1,665 0.39 2 933 0.22 3 1,096 0.25 4 1,313 0.31 5 835 0.19 6 1,017 0.24 7 1,443 0.34 8 882 4,303 0.21 9 966 0.22 10 966 0.22 11 878 0.20 12 1,665 0.39 13 1,129 0.26 14 1,395 0.32 15 773 0.18 16 985 0.23 Maximum 0.39 Summary The maximum stress ratio for the solid model stress intensity / shell model stress intensity is 0.39.

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6.0 CONCLUSION

S The stress intensity comparison shows that the stress intensities computed using the stress linearization approach for the solid elements (with the weld modeled) are lower than the stress intensities computed using the shell elements (without the weld modeled).

Cover plate The solid model / shell model stress ratio for the cover plate is 0.97. This ratio is applicable to the cover plate shell stress intensity at the welded connection between the cover plate and the outer hood.

Outer hood The solid model / shell model stress ratio for the outer hood is 0.39. This ratio is applicable to the outer hood shell stress intensity at the bottom of the welded connection between the outer hood and the gusset.

7.0 REFERENCES

1. Monticello Steam Dryer Drawings, SI File No. 0801040.202:

a. General Electric Drawing, 729E913, "Steam Dryer."

b. Steams-Roger Drawing, 21775, Rev. 2, Sheet 3, "Final Field Assembly."

c. Steams-Roger Drawing, 21775, Rev. 4, Sheet 4, "Final Assembly."

d. Stearns-Roger Drawing, 21775, Rev. 1, Sheet 6, "Shop Assembly Details."

2. Email with attachments from Alexander Boschitsch (CDI) to Soo Bee Kok (SI) on 10/21/08 at 3:53 am, "Re Additional Nodal Stress Needed," SI File No. 0801040.20 1P.

3. Email with attachment from Alexander Boschitsch (CDI) to Karen Fujikawa (SI) on 10/10/08 at 10:46 am, "Monticello Hot Spots," SI File No. 0801040.201P.

4. Email with attachment from Pavel Danilov (CDI) to Karen Fujikawa (SI) on 10/10/2008 at 10:34 am, "IBackup File - Folder Share - Monticello FEM," SI File No. 0801040.203.

5. ANSYS Mechanical, Release 11.0 (w/ Service Pack 1), ANSYS, Inc., August 2007.

6. SI calculation No. 0801040.303, Revision 0, "Project Specific Software Verification and Validation of ANSYS Release 11.0 (w/Service Pack 1)."

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APPENDIX A COMPUTER FILES File No.: 0801040.301 Page A- I of A-2 Revision: 0 a j,.a,.ah a....

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Filename Description SteamDryerShell-Top.inp Cover Plate Shell Model Geometry input.

tl 1.inp Cover Plate Shell Model Analysis input.

tl 1.oo Cover Plate Shell Model load output.

SteamDryerSolid-BOTTOM.inp Cover Plate Solid Model Geometry input.

t22.inp Cover Plate Solid Model Analysis input.

Pathbot.dat Cover Plate Path Definition file.

PPpath2.mac Post Process File for Extracting Stresses for Cover Plate.

t22.o Cover Plate Solid Model Stress output.

t22pp.xls Cover Plate Result Summary Spreadsheet.

Shelltop.inp Outer Hood Shell Model Geometry input.

t77.inp Outer Hood Shell Model Analysis input.

SteamDryerSolid-TOP.inp Outer Hood Solid Model Geometry input.

t44.inp Outer Hood Solid Model Analysis input.

Pathtop.dat Outer Hood Path Definition file.

t44.o Outer Hood Solid Model Stress output.

t44pp.xls Outer Hood Result Summary Spreadsheet.

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