ML051360100
| ML051360100 | |
| Person / Time | |
|---|---|
| Site: | Dresden, Quad Cities  |
| Issue date: | 04/30/2005 |
| From: | Hayes M, Schrag M, Slack D General Electric Co |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| DRF 0000-0039-5306, Class I, GE-NE-0000-0034-4803-02 | |
| Download: ML051360100 (42) | |
Text
ENCLOSURE 2 ATTACHMENT 2 "Replacement Steam Dryer Reactor Vessel Bracket Stress Report for Quad Cities 1, 2, and Dresden 2,3," GE-NE-0000-0034-4803-02, Non-Proprietary, dated April 2005
GE Nuclear Energy GE-NE-0000-0034-4803-02 DRF 0000-0039-5306 Class I April, 2005 Project Task Report Replacement Steam Dryer Reactor Vessel Bracket Stress Report for Quad Cities 1,2 and Dresden 2,3 Principal Contributor:
Michelle Hayes Principal Verifier:
Darrel Slack Approver:
Michael Schrag
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION NON PROPRIETARY NOTICE This is a non proprietary version of the document GE-NE-0000-0034-4803-02P, which has the proprietary information removed. Portions of the document that have been removed are indicated by an open and closed bracket as shown here (( )).
IMPORTANT NOTICE REGARDING THE CONTENTS OF THIS REPORT Please Read Carefully The only undertakings of the General Electric Company (GENE) with respect to the information in this document are contained in the contract between EXELON and GENE, and nothing contained in this document shall be construed as changing the contract. The use of this information by anyone other than EXELON or for any purpose other than that for which it is intended, is not authorized; and with respect to any unauthorized use, GENE makes no representation or warranty, express or implied, and assumes no liability as to the completeness, accuracy, or usefulness of the information contained in this document, or that its use may not infringe upon privately owned rights.
2 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION CERTIFICATION I, the undersigned, being a Registered Professional Engineer competent in the applicable field of design and using the certified Design Specification and the drawings identified below as a basis for design, do hereby certify that to the best of my knowledge and belief the Design Report is complete and accurate and complies with the design requirements of the ASME Boiler and Pressure Vessel Code,Section III, Division NB, 1998 Edition with Addenda up to and including 2000.
SUPPORTING DOCUMENTS Document Number Revision Type of Document Title Number 26A6432 0 Certified Design RPV Steam Dryer Bracket Design Specification Specification 26A5587 0 Certified Design Reactor Vessel - Power Uprate, Specification Quad Cities 1 & 2 26A5588 0 Certified Design Reactor Vessel - Power Uprate, Specification Dresden 2 & 3 GENE-0034-4803 0 Certified Design Replacement Steam Dryer Reactor Report Vessel Support Bracket Stress Report for Quad Cities 1 & 2 and Dresden 2 & 3.
885D660 Sh 1, 6 Specification Control Reactor Vessel - Dresden 2 & 3 Sh 2, 10 Drawing Sh3,4
____ ____ __ Sh 4,8 885D910 6 Specification Control Vessel Loading - Dresden 2 & 3 Drawing 886D485 Sh 1, 4 Specification Control Reactor Vessel - Quad Cities I & 2 Sh 2, 9 Drawing Sh3,3 Sh4,4 Sh 5, 1 Sh 6, 1 Sh 7,8 117C1438 1 Specification Control Steam Dryer Guide Drawing VPF-1248-162 10 Specification Control Vessel Sub Assy- Dresdeit2 Vendor Document VPF-2252-120 4 Specification Control Vessel Sub Assy- Dresden 3
__ _ Vendor Document RPV Bracket Stress Repoit 33 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION Document Number Revision Type of Document Title Number VPF-1744-127 7 Specification Control Vessel Sub Assy - Quad Cities 1&2 Vendor Document VPF-2252-132 3 Specification Control Vessel Attachment Details -
Vendor Document Dresden 3 VPF-1 744-140 7 Specification Control Vessel Attachment Details - Quad Vendor Document Cities 1&2 VPF-1248-174 5 Specification Control List of Materials -Dresden 2 Vendor Document VPF-2252-148 3 Specification Control List of Materials - Dresden 3 Vendor Document VPF-1744-147 6 Specification Control List of Materials - Quad Cities 1&2 Vendor Document Certified by: -/41A -I1 &//M Date: 5/2/2005 Registered Professional Engineer State: Ohio P.E. Number: 56495 RPV Bracket Stress Report 4 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION Table of Contents 1 Introduction ............................... 7 2 Summary ............................................................................................................................. 7 3 Assumptions .............................. 13 4 Material Properties .............................. 13 5 Structural Acceptance Criteria .............................. 14 6 Load Combinations .............................. 15 6.1 Support Bracket Load Combinations .............................. 15 6.2 Support Bracket Load Cases .............................. 16 6.3 Guide Rod Bracket Load Cases .............................. 16 7 Structural Evaluation ................................ 16 7.1 Dimensions ....................................... . 16 7.2 Support Bracket Loads ........................................ 18 7.3 Primary Membrane and Bending Stresses ....................................... 22 7.3.1 RPV Primary Stress Calculations ....................................... 22 7.3.2 Bracket Bearing Stress Calculations ....................................... 22 7.3.3 Bracket Shear and Primary Bending Calculations ....................................... 24 7.4 RPV Local Primary Membrane and Bending Stresses . ...............................26 7.4.1 Analysis Model ....................................... 26 7.4.2 Boundary Conditions ....................................... 26 7.4.3 Analysis Results ....................................... 29 7.5 Support Bracket Fatigue ................. 29 7.5.1 Low Cycle Fatigue ................. 29 7.5.2 High Cycle Fatigue ................. 36 7.6 Guide Rod Bracket Primary Membrane Stress .............................. 38 7.7 Design Margins .............................. 39 8 References ........ 40 RPV Bracket Stress Re pail 55 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION List of Tables Table 2-1 Minimum Design Margins .................................................... 9 Table 4-1 Material Properties .................................................... 13 Table 5-1 Stress Limits ..................................................... 14 Table 6-1 Load Combinations .................................................... 15 Table 6-2 Guide Rod Bracket Loads .................................................... 16 Table 7-1. Support Bracket Loads for Individual Load Cases ................................... 20 Table 7-2. Support Bracket Loads for Load Combinations ..................................... 21 Table 7-3 RPV Primary Membrane Stress Intensity .................................................... 22 Table 7-4 Support Bracket Bearing Stress in ksi ..................................................... 24 Table 7-5 Support Bracket Shear and Primary Bending Stress in ksi .......................................... 25 Table 7-6 RPV Linearized Stress Intensity.................................................... 29 Table 7-7 FIV Primary Membrane plus Primary Bending Stress ................................................. 36 List of Figures Figure 2-1 Dryer Mounting Block - Uninstalled ..................................................... 10 Figure 2-2 Dryer Mounting Block - Installed in RPV ..................................................... 11 Figure 2-3 Finite Element Model.................................................... 12 Figure 7-1 Support Bracket / Dryer Interface Dimensions ................................................... 17 Figure 7-2. Finite Element Model of Dryer .................................................... 19 Figure 7-3 Boundary Conditions .................................................... 27 Figure 7-4 Finite Element Load Application ..................................................... 28 Figure 7-5 Stress Intensity for Load Combination Design 1.I.............................................. 30 Figure 7-6 Stress Intensity for Load Combination D1A .................................................... 31 Figure 7-7 Local Stress Linearization in Load Combination Design 1............................... 32 Figure 7-8 4(Rt) Stress Linearization in Design I .................................................... 33 Figure 7-9 Linearized Stress Intensity for Load Combination Design 1............................ 34 Figure 7-10 Bracket Stress Intensity ................................................... 35 Figure 7-11 FIV Alternating Stress Intensity ............................................. 37 RPV Bracket Stress Repwt 66 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 1 Introduction This report demonstrates that the installation of the replacement steam dryers in the Dresden 2
& 3 and Quad Cities 1 & 2 reactors will not affect the structural integrity of the Reactor Pressure Vessel (RPV) [Reference I].
The RPV / dryer support bracket and RPV / dryer guide rod bracket interfaces were analyzed per the RPV Steam Dryer Brackets Design Specification [Reference 2]. Analysis results demonstrate that RPV stresses will remain within the ASME Code Section III stress limits
[Reference 9].
2 Summary StructuralDesign Features The dryer assembly, located above the shroud head and steam separators, consists of dryer units arranged in parallel rows called banks, which are attached to the dryer support ring.
The dryer assembly includes four mounting blocks (Figure 2-1) where the dryer interfaces with the four brackets (also referred to as lugs) welded to the inside of the RPV. The dryer mounting blocks sit on each bracket, which provides a downward vertical load path. A spacer is attached to each mounting block to provide a lateral load path and the latch mechanism attached to the mounting block during installation provides dryer hold down for upward loads (Figure 2-2). During installation, the jack bolt on the top of each mounting block is torqued in order to insure contact between the dryer and each support bracket.
The RPV assembly contains two dryer guide rods, which are located 1800 apart. Each guide rod is supported by an upper and lower bracket, which are welded to the RPV. The guide rods are used to orient the dryer during assembly. Once the dryer is installed, the guide rod brackets do not interface with the dryer until the dryer is removed.
Analvsis Analyses were performed for the support bracket and guide rod bracket loads as described by the design specification [Reference 2]. General primary membrane stresses for the RPV and bearing stresses for the bracket were calculated using closed form equations with the support reaction loads from finite element analyses of the entire dryer. Primary bending stress in the bracket was calculated using force equilibrium and ANSYS finite element analyses. Local primary membrane and bending stresses in the RPV were calculated using the ANSYS finite element model shown in Figure 2-3 which includes the dryer support bracket and adjoining segments of the RPV vessel. Local peak stresses in the weld were calculated using an ANSYS finite element model.
RPV Bracket Stress Report 7 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION Desi2n Afarrins Calculated maximum stresses representing the RPV primary membrane, local primary membrane + bending, and bracket primary shear, primary bending, bearing and FIV alternating stresses are compared with the associated ASME Code Section III stress limits.
As shown in Table 2-1, all stress limits are satisfied.
RPV Bracket Stress Report 8 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION Table 2-1 Minimum Design Margins lStress l Stress l Design Component l Category Stress limit (ksi) l Margin Support Brackets Limiting Design Reactor pressure vessel Pm Sm Pi 1.5 Sm PI+Pb 1.5 Sm Support bracket Shear stress 0.6 Sm PI+Pb 1.5 Sm Bearing stress SY Bolt Bearing Stress 1.5 S, Limiting Normal Operation Reactor pressure vessel Pm Sm P, 1.5 Sm, P1+Pb 1.5 Sm Support bracket Shear stress 0.6 Sm PJ+Pb 1.5 Sm Bearing stress SY Bolt Bearing Stress 1.5 S, Limiting Upset Conditfions Reactor pressure vessel Pm Sm Pi 1.5 Sm PI+Pb 1.5 Sm Support bracket Shear stress 0.6 Sm PI+Pb 1.5 Sm Bearing stress Sy Bolt Bearng Stress 1.5 Sx Limiting Faulted Condition Reactorpressurevessel Pm 0.7 Su P, 1.05 Su PI+Pb 1.05 Su Support bracket Shear stress 0.42 Su PF+Pb 3.6 Sm FJV Support Bracket Stress Amplitude 16.5 ksi Guide Rod Brackets Installation Condition Reactor pressure vessel Pm S Pi 1.5 Sm P&Pb 1.5 Sm Support bracket Shear stress 0.6 Sm PI+Pb 1.5 Sm Bearing stress S, ]
Notes: Design margin = (stress limit / calculated stress) - I Pm = General primaly membrane stress intensity Sm Stress intensity P = Local primar) membrane stress intensity Sy = Yield stress Pb = Primar) bending stress intensity S. = Tensile stress 9 RPV BracketStress Report
GE-NE-0000-0034-4803-02 .
NON PROPRIETARY VERSION A
Dryer Support Ring A
I Dryer Skirt Dryer Mounting Block q Interface with RPV Support Bracket e
Spacer Dryer Mounting Block .
A FJack Bolt U
I Figure 2-1 Dryer Mounting Block - Uninstalled 10 RPV Bracket Stress Report Cal
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION Figure 2-2 Dryer Mounting Block - Installed in RPV 11 RPV Bracket Stress Report 11 RPV Bracket Stress Report C(:f
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION RPV Vessel Segment Figure 2-3 Finite Element Model 12 RPV Bracket Stress Report C~~p M
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 3 Assumptions The load combination identified as "Design 2, Installation Service Level," evaluates the loads that occur during the installation of the dryer. For this load combination, the weight of the dryer, lifting device and crane hook is transferred to two support brackets. This is conservative, as three points are required to statically support the dryer. Once installed, three points will define the plane of the dryer, so for all load cases, the dryer weight is evenly divided between three brackets. The remaining bracket will not support any dryer weight, but it will carry the jack bolt preload. Installation includes tightening all jack bolts to a specified maximum preload, which forces the jack bolt to make contact with the top of the support bracket. ((
)) All operational loads, excluding the weight, will be distributed among the four brackets.
4 Material Properties The support brackets and guide rod brackets are made of SA182, Class F304 austenitic stainless steel, and are welded to the RPV shell segments, which are SA302 Grade B steel plate [References 5,6]. Table 4-1 shows the material properties from the Dresden and Quad Cities Codes of Construction [References 7, 8,] for the design stress intensity, yield strength and elastic modulus. The tensile strength was obtained from the 1998 ASME Code
[Reference 9] because this property was not included in the Codes of Construction, except as a Minimum Value. The Su Minimum Values from the Codes of ConstructionfReferences 5,6]
match the Su at 1000 F from 1998 ASME Code[Reference 9].
Table 4-1 Material Properties Installation Operating Design Temperature l 120 0F l 5470 F l 5750 F RPV Shell Segment, SA302 Grade B Sm, Design Stress intensity, ksi 26.7 26.7 26.7 S,, Yield strength, ksi 49.4 42.6 42.3 S,, Tensile strength, ksi 80.0 80.0 80.0 E, Elastic modulus, E6 psi 29.7 27.7 27.6 Support Brackets, SA182 Grade F304 Sm., Design Stress intensity, ksi 20.0 16.0 15.8 Sy, Yicld strcngth, ksi 29.1 17.8 17.5 S,, Tensile strength, ksi 74.2 63.4 63.4 E, Elastic modulus, E6 psi 27.3 25.7 25.6 RPV Bracket Stwss Repofl 13 13 RPV Bracket Stress Repott
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 5 Structural Acceptance Criteria The RPV / support bracket and RPV/ guide rod bracket interfaces were analyzed using design rules and stress limits [Section NB, Reference 9] and the appropriate properties from Table 4-1. The limits for the bolt bearing stress are based on a non-free edge condition because of the design configuration; should the bolt bearing stress result in a vertical displacement of the dryer, the load and strain will be redistributed to the mounting block, resulting in a limited small displacement under the bearing bolt. The bearing stress under the total footprint of the mounting block is limited to the free edge stress limit. The stress limits are summarized in Table 5-1.
Table 5-1 Stress Limits Stress Value (ksi) at Temperature Service Condition Stress category Limit 1200 F l 5470 F l 5750 F Design, Normal and Upset Conditions Reactor Vessel Pm Sm 26.7 26.7 26.7 P, I.5Sm 40.1 40.1 40.1 PI + Pb 1.5Sm 40.1 40.1 40.1 Support Bracket Shear stress 0.6Sm 12.0 9.6 9.5 PI + Pb 1.5Sin 30.0 24.0 23.7 Bearing stress SY 29.1 17.8 17.5 Bolt Bearing 1.5 Sy 43.7 26.7 26.3 Stress FaultedConditions Reactor Vessel Pm 0.7S, 56.0 P, 1.5(.7SU) 84.0 PI + Pb 1.5(.7Su) 84.0 Support Bracket Shear stress 0.42 S, 26.6 PI + Pb 1.5(2.4Sm) 57.6 Pm: General primary membrane stress intensity Sm: Dcsign Stress intensity PI: Local primary membrane stress intensity Sy: Yield strength Pb: Primary bending stress intensity Su: Tensile strength Bearing Stress: Free edge condition Bolt Bearing Stress: Non Free edge condition 14 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 6 Load Combinations 6.1 Support Bracket Load Combinations The RPV/support bracket interface was analyzed using the load combinations [References 2 and 3] except as follows:
- The support bracket loads for TSV2 are significantly less than TSVI, so Combination B I (DW + Pn + DPn + TSVI + FIVn) will encompass Combination B2 (DW + Pn + DPn + TSV2).
Pn + DPn + [SSE 2+ACI 2 ]j5 4 FlVn ) will encompass Combination D2A (DW +
DPn + AC2 : FIVn)
The combinations shown in Table 6-1 control the support bracket design.
Table 6-1 Load Combinations Combination Service Identifier Condition Load combination Design 1 Design DW + Pd + DPn + OBE Design 2 Design Dryer Installation Weight A Normal DW + Pn + DPn 4 FIVn BI Upset DW + Pn + DPn + TSVI + FIVn B3 Upset DW + Pn + DPu + FIVu B4 Upset DW + Pn + DPn + OBE + FIVn DIA Faulted DW + Pn + DPn + [SSE 2+ACII 2]- FlVn DIB Faulted DW +/- [SSE2 + DPf12].5 D2B Faulted DW + DPf2 Legend.
ACI Acoustic load due to Main Steam Line Break outside containment, at the Rated Power and Core Flow (HI-Power) Condition DW Dead Weight DPn Differential Static Pressure Load During Normal Operation Dpu Differential Static Pressure Load During Upset Operation DPfI Differential Pressure Load in the Faulted condition, due to Main Steam Line Break outside containment at the Rated Power and Core Flow condition DPf2 Differential Pressure Load in the Faulted condition, due to Main Steam Line Break outside containment at the Low Power/High Core Flow condition FIVn Flow Induced Vibration Load during Normal Operation RPV Bracket Stress Report 15 is RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION FIVu Flow Induced Vibration Load during Upset Operation Pd RPV Design Internal Pressure Pn RPV Operating Internal Pressure OBE Operating Basis Earthquake SSE Safe Shutdown Earthquake TSVI The initial acoustic component of the turbine stop valve closure load 6.2 Support Bracket Load Cases This analysis uses the load definitions from [References 3,4]. These documents define all loading conditions except Dead Weight The Dead Weight of the dryer is (( )) This analysis conservatively uses ((
)) except for the bracket shear and bending stress calculations, which used the referenced dryer weight.
The Dryer Installation Weight adds the combined weights of the lifting device and reactor building crane hook [ (( )) Reference 2] to the dryer weight.
Steam mass and bouyancy effects are ignored.
Internal Pressure The RPV Design Internal Pressure is 1250 psig [Reference 2] and the RPV Operating Internal Pressure is 1005 psig [Section 4.4.1.a of Reference 10].
6.3 Guide Rod Bracket Load Cases The loads shown in Table 6-2 are the original guide rod bracket loads [Reference 12] scaled by the ratio of installation weight/original dryer weight. The original dryer weight is ((
)) [Reference 11].
Table 6-2 Guide Rod Bracket Loads (Kips)
Load l Upper Bracket Lower Bracket Vertical ((
Horizontal ))
7 Structural Evaluation 7.1 Dimensions The dimensions used in this analysis are shown in Figure 7-1. The support bracket dimensions are from the design specification [Reference 2] and the mounting block component RPV Bracket Stress Repon 16 16 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION dimensions are from the replacement dryer drawings [Reference 17], except for the two marked with an asterisk. These dimensions reflect discrepant conditions (smaller than expected overlap between mounting block and bracket, jack bolt located closer than expected to edge of bracket) found during manufacturing of the Quad Cities 2 dryer.
1]
Figure 7-1 Support Bracket I Dryer Interface Dimensions RPV Bracket Stress Report 17 17 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 7.2 Support Bracket Loads Individual Load Cases A finite element model 0 of the entire dryer was used to generate the support bracket loads for all load cases except FIV and RPV internal pressure. This dryer model has a weight of ((
11 and a center of gravity of(( Ilabove the center of the support bracket. This is conservative compared to the actual measured weight of (( 11 The support reactions at each mount location were extracted for each load case and the following processing was performed:
- Dead Weipht: The model is constrained at all four mount locations, so the vertical reaction force is the weight/4. This analysis assumes the weight is carried by only three of the support brackets, so the vertical reaction force at each mounting location is manually set to weight/3. No changes are made to the radial or tangential reaction forces.
Each of the fourjack bolts will have a maximum torque of f[f 1
[Reference 17] The thread diameter is (( )), and the friction coefficient consistent with thejack bolt lubricant is (( )), so the maximum axial load from the jack bolt is (( )) The bolt preload is applied to the mounting block that does not carry any dryer weight.
- TSVI: The Reaction Forces from TSVI pressure loads are reduced by a factor of
(( )), which is consistent with more refined analyses.
- OBE and SSE: The reaction forces for these cases are a root sum square combination of the following individual runs: NS Zero Period Acceleration (ZPA) static, EW ZPA static, Vertical ZPA static, NS response spectrum and EW response spectrum. The ZPA cases are included because the response spectrum was only evaluated to 33 Hz.
The normal FIV loads came from time history analyses using a finite element model similar to the one described above, except that super-elements were used to represent the vane banks and the skirt. The results of the Scale Model Test nominal, +10%, -10% and In Plant nominal, +10%, -10% profiles, run with 1% structural damping, were reviewed in order to identify the limiting profile, which was In Plant -10%. This time history was rerun with 2%
structural damping, to be consistent with the nature of the dryer, which is a welded steel structure, partially submerged in water, and containing vane bank inserts that allow for sliding and contact. The maximum absolute value for each reaction force at each mount location from the In Plant -10%, 2% structural damping time history was used to represent the FIV normal loads. The FIV upset loads are 1.5 x the FIV normal loads [Reference 4].
RPV Bracket Stress Report 18 18 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION Figure 7-2. Finite Element Model of Dryer 19 RPV Bracket Stress Report 19 RPV Bracket Stress Report
GE-NE-OOO-00344803-02 NON PROPRIETARY VERSION The resulting radial, tangential and axial components of the forces are shown in Table 7-1 for each mounting location.
Table 7-1. Support Bracket Loads for Individual Load Cases Reaction Force in pounds Mount #1 Mount #2 Mount #3 Mount #4 Dead Weight FR FT FZ DPn FR FT FZ DPu FR FT FZ ACI FR FT FZ TSVI FR FT FZ DPf1 FR FT FZ DPf2 FR FT FZ OBE SRSS FR FT FZ SSE SRSS FR FT FZ FIV NORMAL FR FT FZ FIV UPSET FR FT FZ ]
Notes: FR is the radial component of force FT is the tangential component of force FZ is the axial component of force, vwhere a negative force acts downward on the bracket RPV Bracket Sti'oss Report 20 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION Load Combinations The individual load cases were combined as described in Table 6-1, and the results are shown in Table 7-2.
Table 7-2. Support Bracket Loads for Load Combinations Reaction Force in pounds Mount #1 Mount #2 Mount #3 Mount#4 Design I FR FT FZ Design 2 FR FT FZ A FR FT FZ BI FR FT FZ B3 FR FT FZ B4 FR FT FZ DIA FR FT FZ DIB FR FT FZ D2B FR FT FZ Notes: FR is the radial component of force FT is the tangential component of force FZ is the axial component of force, where a negative force acts downward on the bracket Load combinations B2 and DIA [Reference 3] are not included as described in Section 6.1 21 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 7.3 Primary Membrane and Bending Stresses 7.3.1 RPV Primary Stress Calculations The RPV primary stress intensity due to RPV internal pressure is (hoop stress-axial stress),
which is defined by the following equation Pm,RPV = PR/t+P/2 where P is the RPV internal pressure, Section 6.2 R is the RPV inner radius, 125.5 in t is the RPV thickness of 6.125" The results are shown in Table 7-3.
Table 7-3 RPV Primary Membrane Stress Intensity Service Condition RPV Internal Pressure, psig Pm, ksi Design 1250 1[
Operating 1005 1]
Notes: Operating includes normal, upset and faulted conditions The bracket loads are local, as discussed in Section 7.4.3, so they do not contribute to the primary stress intensity of the RPV.
7.3.2 Bracket Bearing Stress Calculations BearingSurface
((
))
22 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION Bearial' Stress The bearing stress acting on the different portions of the bracket are Bearing Stress, Top = FZmax downward/ A X hio-Bearing Stress, Side = FT/AL Bearing Stress, Bottom = FZ w,l,,,dfA ;up The loads in Table 7-2 include a downward axial load of Dead Weight/3. The jack bolt preload is applied to all four jack bolts. For the three mounts sharing the Dead Weight, it is conservatively not subtracted. For the remaining bolt, the load acting on the jack bolt will not include the Dead W'eight/3 component, but it will include the jack bolt preload [page 18],
so it is found from FZbolt = FZmax downward - Dead Weight/3 + Jack Bolt Preload
= FZmax downward (( ]
The jack bolt bearing stress is Bearing Stress, Jack Bolt = (FZmaxdownward-(( )) Ag bolt The results of the bracket bearing stress calculations are shown in Table 7-4. Bearing stresses are not calculated for faulted conditions, because it is not required [Reference 9].
RPV Bracket Stress Repair 23 RPV Bracket Stress Report
GE-NE-OO-0034-4803-02 NON PROPRIETARY VERSION Table 7-4 Support Bracket Bearing Stress in ksi Lug # Top Side Jack Bolt Bottom Design 1 1 2
3 4
Design 2 1,2 A I 2
3 4
Bi 1 2
3 4
B3 2
3 4
B4 1 2
3 4
Note: Load combinations B2 [Rcference 3] is not included as described in Section 6.1 7.3.3 Bracket Shear and Primary Bending Calculations The primary shear and primary bending stresses in the bracket are evaluated using the Dead Weight of the Quad Cities 2 Dryer, (( )) compared to Table 7-1 and Table 7-2, which used the Dead Weight of the finite element model, (( )) The results are shown in Table 7-5.
24 RPV Bracket Stwss Report RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION Table 7-5 Support Bracket Shear and Primary Bending Stress SHEAR BENDING Shear Allowable Stress Ratio Combined Allowable Stress Ratio stress Bending lug ksi ksi i h i Design 1 1 2
3 4
Design 2 1 A 1 2
3 4
Bi 1 2
3 B3 1 2
3 4
B4 1 2
3 4
4 MiA 2
3 DIB 1 2
3 D2B 1 2
3 Notes: Stress Ratio is Calculated Stress/Allowable Stress Load combinations B2 and DIA [Rcefcrcnce 3] arc not included as dcscribcd in Scction 6.1 25 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION 7.4 RPV Local Primary Membrane and Bending Stresses Per Paragraph NB-3213.10 [Reference 9], a stress region is considered local if the distance over which the primary membrane stress intensity exceeds 1.1 Sm does not extend in the meridional direction more than 1.0 x 4(Rt), where R is the midsurface radius of the vessel and t is the thickness of the vessel. Analyses were performed using ANSYS Code [Reference 13]
to show that the primary membrane stresses from the bracket loads are within the local stress region and to predict the maximum local stresses.
7.4.1 Analysis Model The analysis model (Figure 2-3) is composed of solid elements (ANSYS SOLID45) and includes the support bracket and surrounding shell region. The RPV shell in the model spans a total of 800, which is the smallest distance between adjacent support brackets. The height is a total of 130".
7.4.2 Boundary Conditions Symmetry boundary conditions (no displacement out of the symmetry plane) were applied on the vertical boundaries of the analysis model. Vertical support was assumed at the lower edge of the model. The axial (Blow off) pressure load (-10.0*P) was applied to the shell top surface Boundary conditions are shown in Figure 7-3. Analysis was performed for each of the nine Load Combinations using loads from Table 7-2 and internal pressures from Section 6.2.
For each Load Combination, the maximum value of FR, FT, FZ from any of the four mounts is conservatively applied to one mount. The RPV pressure load was applied as a surface load at the inner radius of the RPV shell and inner surface of the support bracket.. The tangential and vertical bracket loads were applied as pressure loads on the side and top surfaces respectively. The top surface is selected because all vertical loads from Table 7-2 act downward. The radial loads are evenly distributed at the nodes located at the top bearing surface. Examples of the load applications are included in Figure 7-4 26 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION A
Figure 7-3 Boundary Conditions 27 RPV Bracket Stress Re pail RPV Bracket Stress Report m - -
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION Figure 7-4 Finite Element Load Application 28 28 RPV Bracket Sttss Report RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPREETARY VERSION 7.4.3 Analysis Results Figure 7-5 and Figure 7-6 show the stress distribution in the RPV shell for the two limiting load combinations, Design 1 and DI A.
The primary membrane or primary membrane plus bending stress intensities were extracted for each load case by linearizing the stresses within ANSYS. Stresses were linearized across the RPV thickness in the radial direction at the location of maximum stress in the RPV elements (Figure 7-7, Figure 7-9) in order to extract the local primary membrane and primary membrane plus bending stresses. Stresses were linearized across the RPV thickness at the axial location of the maximum stress at an meridinal distance equal to 4(Rt) =SQRT( ((
)) in order to extract the primary membrane stress (Figure 7-8, Figure 7-9) and demonstrate that the bracket loads are local. The results are shown in Table 7-6, where it is seen that the primary membrane stresses at '/(Rt), are within 1.1 Sm = ((
))ksi. Therefore the bracket loads are a local effect and will be evaluated as local primary membrane and local primary membrane plus bending stresses for the RPV Table 7-6 RPV Linearized Stress Intensity At location of maximum S.I. At 4(Rt)
PI., ksi l P,.+Pb, ksi Pi, ksi Design I Design 2 A
BI B2 B4 DIA D2A DIB 11 Note: Load combinations B2 and DIA [Reference 31 are not included as described in Section 6.1 7.5 Support Bracket Fatigue 7.5.1 Low Cycle Fatigue The bracket stresses shown in Figure 7-10 can be used to demonstrate acceptable fatigue usage. The contribution of the OBE load is evaluated by comparing Load Combination A (no OBE) to Load Combination B (with OBE). Stresses at select nodes were extracted to determine the maximum stress difference between these two analyses, which gives an alternating stress of (( )). The Stainless Steel Fatigue curve [Fig. N415(B) of Reference 7 and 8] predicts approximately (( )) for a stress amplitude of ((
)) Thus, the fatigue usage for 5 OBE events, with 10 cycles per events (50 OBE cycles) will be (( 1]
RPV Bracket Stwss Report 29 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION
((
1]
Figure 7-5 Stress Intensity for Load Combination Design 1.
RPV Bracket Stress Repoit 30 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION 1]
Figure 7-6 Stress Intensity for Load Combination DIA RPV Bracket Sttss Report 31 31 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 11 Figure 7-7 Local Stress Linearization in Load Combination Design I RPV Bracket Struss Report 32 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION
((
11 Figure 7-8 4(Rt) Stress Linearization in Design 1 RPV Bracket Stress Report 33 RPV Bracket Stress Report
GE-NE-OOOO-0034-4803-02 NON PROPRIETARY VERSION 1]
Figure 7-9 Linearized Stress Intensity for Load Combination Design 1 34 RPV Bracket Stress Report 34 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION 11 Figure 7-10 Bracket Stress Intensity 35 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION 7.5.2 High Cycle Fatigue The forces used in FIV fatigue evaluation came from the limiting time history, In Plant -10%,
run with 2% structural damping. The time steps defining the minimum and maximum stresses from the time history file were used to determine the force range. This differs from the FIVn loads reported in Table 7-1, which used the entire time history to define the extreme value of each force. The alternating Force (F,a) is found from Force Range/2, and shown in Table 7-7 for the limiting lug location.
The Primary Membrane Stress at the weld is Pm = FR,a/ A where A= Bracket width XBracket height (( ]
There are no secondary stresses acting on the weld, so Pm+Pb+Q =Pm + Pb,t + Pb,v This value is calculated in Table 7-7 FIV Primary Membrane plus Primary Bending Stress Force Range FR (( lb FT lb FZ lb Stress Range Pm ksi Pb,t ksi Pb,v ksi Pm+Pb+Q ksi Alternating Force FRa lb FT,a lb FZ,1 )) lb Because Pm+Pb+Q )) the fatigue threshold from Curve B of Figure I-9-2-2
[Reference 9] can be used. From this curve, (( ))the corresponding alternating stress is (( 1 These loads were applied to a finite element model similar to the one previously used except that the weld is explicitly modeled. The resulting peak stress intensity is (( )) as shown in Figure 7-11.
RPV Bracket Stress Repoti 36 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION
((
1]
Figure 7-11 FIV Alternating Stress Intensity 37 RPV Bracket Stress Report RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 7.6 Guide Rod Bracket Primary Membrane Stress As noted in Reference 12, the Vertical and Horizontal loads are not applied concurrently, so each row in Table 6-2 represents a different design case. The load occurs during assembly, so there is no RPV internal pressure and the associated temperature is 1200 F.
The upper and lower guide rod brackets have the same design except that the upper bracket is longer than the lower bracket. Both are (( )) at the base and the guide for the rod has an (( )) chamfers on each edge[ 15, 16].
Verfical Load. The vertical load is only applied to the upper bracket, which is ((
1))
LateralLoad. The same lateral load is applied to both brackets, so the limiting case is the lower bracket, which is (( )) The rod diameter is (( )) [Reference 14 ], so the bearing stress will be limited by the Vertical Load case.
38 RPV Bracket Stress Report
GE-NE-0000-00344803-02 NON PROPRIETARY VERSION 7.7 Design Margins RPV primary membrane stress intensity is from Table 7-3 , the support bracket bearing stress intensities is from Table 74, support bracket primary shear and bending stresses are from Table 7-5, RPV local primary membrane stress intensities and primary membrane + bending stress intensities are shown in Table 7-6. The FIV peak stress is from Figure 7-11.
RPV general primary membrane stress intensity and guide rod bracket shear and bearing stress intensities are calculated in Section 7.6.
These stress intensities are compared with the applicable stress limits in Table 2-1. The comparison shows that all ASME Code limits are satisfied.
RPV Bracket Stress Report 39 39 RPV Bracket Stress Report
GE-NE-0000-0034-4803-02 NON PROPRIETARY VERSION 8 References 1 885D660, Reactor Vessel - Dresdeni 2, 3.
886D485, Reactor Vessel - Quad Cities 1, 2.
2 26A6432, Rev. 1, RPV Steam Dryer Brackets Design Specification.
3 26A6266, Rev. 3, Steam Dryer Design Specification.
4 26A6266AB, Rev. 2, Steam Dryer Design Specification Data Sheet 5 VPF-1248-174, List of Materials - Dresden 2 VPF-2252-148, List of Materials - Dresden 3 VPF- 1744-147, List of Materials - Quad Cities 1&2 6 B&W Summary Stress Reports for Dresden 2 (7/70), Dresden 3 (8/0o), and Quad Cities 1&2 (10/70).
7 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code,Section III, 1965 Edition with addenda through Summer of 1965 (Code of Construction for the Dresden Unit 3, Quad Cities Units 1 and2 reactorvessels).
8 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section HI, 1963 Edition with addenda through Summer of 1964 (Code of Construcltion for the Dresden Unit 2 reactorvessel).
9 American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code,Section III, 1998 Edition, Division 1, Subsection NB, Class I Components with addenda through 2000.
10 26A5587, Reactor Vessel - Power Uprate (Dresden 2,3).
26A5588, Reactor Vessel - Power Uprate (Quad Cities 1,2).
11 GE-NE-B13-02098-00-07, Rev. 0, "Dresden and Quad Cities Steam Dryer Modifications for Extended Power Uprate, RPV/Steam Dryer Interface Loads Stress Analysis", 7/01.
12 885D910, Vessel Loading - Dresden 2,3, 885D485-7,Reactor Vessel- Quad Cities J&2, 13 ANSYS Release 8.1, ANSYS, Incorporated, 2004.
14 117C1438, Steam Dryer Guide RPV Bracket Stzss Repofl 40 RPV Bracket Stress Report
GE-NE-MOOO-0034-4803-02 NON PROPRIETARY VERSION 15 VPF-1248-162, Vessel Sub Assy- Dresden 2 VPF-2252-120, Vessel Sub Assy- Dresden 3 VPF-1 744-127, Vessel Sub Assy - Quad Cities 1&2 16 VPF-2252-132, Vessel Attachment Details- Dresden 3 VPF-1744-140, Vessel Attachment Details - Quad Cities 1&2 17 GE Replacement Dryer Drawings:
105E3886, Rev. 0, Steam Dryer 234C6947, Rev. 0, Mounting Block, Outer 234C7155, Rev. 0, Jack Bolt 234C7009, Rev. 0, Arm, Latch 234C6945, Rev. 0, Ring and Skirt Assembly 234C7153, Rev. 0, Steam Dryer RPV Bracket Sfress Repoti 41 41 RPV Bracket Stress Report