ML061090479

M-DSC-360, Rev. 0 - Evaluation of Half-Nozzle Repair for Pressurizer and Steam Generator Inst. Nozzles Under Long-Term Service Conditions

ML061090479
Person / Time
Site:	San Onofre
Issue date:	03/16/2006
From:	Rainsberry J Southern California Edison Co
To:	Kalyanam N NRC/NRR/ADRO/DORL/LPLIV
Kalynanam N, NRR/DORL/LP4, 415-1480
References
TAC MD9484, TAC MD9488 M-DSC-360
Download: ML061090479 (103)

Text

I N. Kaly Kalyanam - Re: Fwd: SONGS Unit 2: Relief Request IS1-3-17 Pressurizer instrument line repair TAC MC9434 and 94Oge 1 V.

From: <rainsbjl songs.sce.com>

To: "N. Kaly Kalyanam" <NXK~nrc.gov>

Date: 3/16/06 3:43PM

Subject:

Re: Fwd: SONGS Unit 2: Relief Request ISI-3-17 Pressurizer instrument line repa r TAC MC9434 and 9488 1.

They are being boxed now. You may wish to try to intercept them in your mail room (or whereever Fed Ex delivers). We usually hear from Fed Ex that the delivers are made to your offices around 9 or 10 in the morning your time.

I CALCuL-ANTI tr N Wi)Sc3 6 o.

I:HEX scL_6 SNorJG 5 Wi "N. Kaly Kalyanam" jALUA-TIc>N 6

<NXK~nrc.gov> To

<rainsbjl @songs.sce.com> PA i R 9: F P- F ->

PU -AQGc 03/16/2006 08:32 cc AM Subject 5t r No-T\O2-2.U:LC-Fwd: SONGS Unit 2: Relief Request ISI-3-17 Pressurizer instrument ON 9&P, Losi Ge&th 2T line repair TAC MC9434 and 9488

~54-2~t CCI 3C-&r-F L 0 / 36kp-XA Ae 4" 0 3 S-o-Jack, Can you provide the documents John Tsao has identified in the attached email?

Thanks Kaly

---

Message from "John Tsao" <JCT~nrc.gov> on Thu, 16 Mar 2006 09:55:01

-0500 To: "N. Kaly Kalyanam" <NXK.OWGWPOO2.HQGWDO01 @nrc.gov>

cc: "Kimberly Gruss" <KAG1.twf4-po.TWFN-DO @nrc.gov>

Subjec SONGS Unit 2: Relief Request ISI-3-17 Pressurizer instrument line t: repair TAC MC9434 and 9488 Kaly,

N. Kaly Kalyanam - Re: Fwd: SONGS Unit 2: Relief Request ISI-3-17 Pressurizer instrument line repair TAC MC9434 and 940age2 RE: SONGS Unit 2: Relief Request ISI-3-17 Pressurizer instrument line repair TAC MC9434 and MC9488 I would like the licensee to mail us a copy of the following reports:

1). M-DSC-414, Rev. 0, "SONGS Unit 2 & 3 Pressurizer Lower Level and Thermcwell Nozzles J-Weld Fracture Mechanics Evaluation."

2). M-D'SC-41 1, Revision 0, "SONGS Unit 2 and 3 Pressurizer Lower Level Nozzle 'Nelding and Transient Analysis."

3). M-C'SC-360, Revision 0, "Evaluation of Half Nozzle Repair for PZR and SG INST. Nozzles under Long-Term Service Conditions -SONGS 2 and 3."

I am wondering if the licensee can simply forward a copy of the reports without ormal submittal. I will take a look at the reports. If I think the reports need to be on the docket (i.e., if I use the information in my SE) we can put the reports on the docket later. This is to expedite the review process due to the short fuse of the SE.

Also I would like SONGS to fedex the reports to us due to the short fuse of the SE.

The purpose of reviewing the reports is to confirm what SONGS said in its relief request is acceptable. Also, SONGS relief request contains no numerical values and is sketchy in flaw evaluations.

CALCULATION TITLE PAGE ICCN NOJCCN NO.

PRELIM. PAGE O_

CCN CONVERSIO'J:

Calc. No._M-DSC-360 DCP/FIDCN/FCN No. & Rev. CCN NO. CCN___

Subject Ev~aluation of Half-Nozzle Repair for PZR and SG Inst. Nozzles Under Lona-Term Service Sheet 1 of t j Systen Number/PriaryStallonSystemDesignator 1201 f BBB SONGSUnit 2&3 Q-Cbass I Tech. Spec.Affecting? *No 0 YES, Section No. NIA Equipment Tag No.

Site Programs/Procedure Impact? NO 0 YES, AR No. _

CON'rROLLED PROGRAM/DATABASE NAM E(S) VERSION/RELEASE Y0.(S)

COF4PUTER E PROGRAM PROGRAM/ lg ALSO, LISTED BELOW DATABASE 0 DATABASE BIGIF 1.n ACCORDING TO 50123-XXIV4.1 RECORDS OF ISSUES REV. TOTAL PREPARED APPROVED DISC. DESCRIPTION_ LAST SHT. (Print name/sign/date) lSIgnature/date)

LASSH- - n Initial Issue -- O . eLS c(Jpoa,9 F1 f )) Otler

° 1Di , A 527/r 1 -lls

_R l Cl Other * .. Othe r

-I C> V- n07 0RJGAJZ,1~,q/ r.

&'4k/, FLS other IRE ' 6cki.0 Other Othcr ORIG. FLS Other IRE Other Othe r ORIG. FLS Other IRE Other Othcr Space for RPE Stamp, Identify use of an alternate calc., and notes as applicable.

Note: This calculation provides the long-term Justification/Evaluation report on the modified PZR and SG Instrument Nozzle performed by Aptech Engineering Services for Songs 2&3.

RECEVED CDM SEP 161998 SITE FILE COPY This calc. w3s prepared for the Identified DCPlFCN. DCPIFCN completion and turnover acceptance to be verified by receipt of a memorandum diecting DCN Conversion. Upon receipt, this cac. represents the as-built condition. Memo date by Site File Copy M-DSC-3 60

CALCULATION CROSS-INDEX

• i, IICCN 1RLI NOJ CC f'1 Uno I .I r _I_

Calculation No. M-DSC-360 Sheet No. JPCN CONVERSION:

GZ. of ICCN NO. CCN-1 1 1* B I

INPUTS OUTPUTS Does the out-Calc. rev. These Interfacing calculations and/or put Interace number and Results and concluslons of the subject responsible documents provide input to the subject calculation are used In these Interfacing cald Identity output Interface FLS Initials calculation and If revised may require calculations andlor documents. document cealldocument CCN, DCN, revision of the subject calculation. require TCNJRev., FMOCN, or and date tracling number.

revision?

Caie I Document No. Rev. No. Cale/ Docurnent No. YESINO 0 M-DSC-279 M-DSC-279 0 Yes ICCN # C-1 I M-DSC-351

, PU_ M-DSC-354

' s/,?;>

= ' : - t,2* =. .

T.VETFOMFORASCEDO GeNM424 02.MDF Velr 02.00.01 5120198i LJNYITLED) avl -1.0000 Pinted: 07127198

-SCC 'O. 5 CALCULATION COVER SHEET 0M_ .

Calculation No.: AES-C-3247-1 Client: Southern California Edison Co t

Title:

Evaluation of Half-Nozzle Repair for Project No.: AES 97123247-1Q Pressurizer and Steam Generator Instrumentation Nozzles Under Long-Term Service APTECH Office: Sunnyvale Conditions - SONGS 2 and 3 Sheet No. 1 of 69 a Uncontrolled N Controlled Document Control No.: 1-2

Purpose:

This calculation documents the evaluation performed to assess the long-term service of the Alloy 690 half-nozzle repair, as designed for use in the pressurizer and steam generator. The evaluation is based on a fracture mechanics analysis of the repair geometry conservatively postulating flaws to exist in the low alloy steel base metal. Both fatigue crack growth and borated water corrosion are evaluated in this calculation.

Assumptions: The analysis assumptions are described in Section 3.

Results: The results of this calculation are summarized in Section 2. The evaluation period covered by this calculation is a 40-year service life, considering all loads from the original design. The postulated degradation for corrosion and fatigue for the evaluation period will be acceptable to the safety margin:; of ASME Section XI under IWB-3600.

Prepared Checked Verified Approved Revision By By By By Revision Description No. Date Date. Date Date 0 'CL 1t- a11 tic- ____ Initial Release

_ _ _ _ _ _ _ Al a? 3 3S~/ +/-ij?

HiAPT4S!!

ENGINEERING SERVICES. I CLAN45 REM. 8196 M-DSC-3 60

H1+iAPTECH -;

ENGINEERING AEVCID INC. -5 Made by: Date: Client:

Calculation AES-C-3247-1 _o.: SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair forPressurizer -4 F-_ 9t- 5 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern service Conditions -SONGS 2 and 3 0 1-2 2 of 69 TABLE OF CONTENTS

1.0 INTRODUCTION

4 2.0

SUMMARY

11 2.1 Scope and Objectives 11 2.2 Nozzle Stub Flaw Evaluation 11 2.3 B3orated Water Corrosion Evaluation 12 2.4 Allowable Flaw Depths 13 3.0 ANALYSIS ASSUMPTIONS 14 4.0 METHODOLOGY 16 4.1 ]Evaluation of Nozzle Stub Flaw 16 4.1.1 Technical Approach 16 4.1.2 Flaw Acceptance Criteria 17 4.1.3 Calculation of End-of-Life Flaw Size (af) 18 4.1.4 Calculation of Minimum Critical Flaw Size (ad)for 19 Normal/Upset Conditions 4.1.5 Calculation of Minimum Initiating Flaw Size (a;) for 20 Accident Conditions 4.1.6 Calculation of Stress Intensity Factor 21 4.2 ]Evaluation of Borated Water Corrosion 21 4.2.1 Technical Approach 21 4.2.2 Corrosion Acceptance ,Criteria 23 4.2.3 Definition of Nozzle Stresses 23 4.2.4 Determination of Critical Bending Stress 24 4.2.5 Corrosion/Fatigue Growth Analysis 25 5.0 DESIGN INPUT 30 5.1 Nozzle and Shell Geometry 30 5.2 Design and Operating Conditions 31 5.2.1 Pressurizer 31 5.2.2 Steam Generator 32 5.2.3 Bounding Transient Conditions 32 5.3 Mechanical Loads 33 CQAE17 1EiV 8196 M-DSC-3 60

EEAPTIECX3 ENGINEERING SEaY S~ INC.

Made by: Date; Client:

Calculation No.: AES-C-3247-1 A Z__ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer '-n-m..-hawk 'X AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Controa No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 3 of 69 5.4 Material Properties 34 5.4.1 Mechanical Strength 34 5.4.2 Fracture Toughness 35 5.4.3 Fatigue Crack Growth Rate 35 5.4.4 Corrosion Rates 36

6.0 REFERENCES

46 7.0 NOMENCLATURE 48 8.0 CALCULATIONS 51 8.1 Evaluation of Postulated Flaws in the Penetration Hole 51 8.1.1 Flaw Model 51 8.1.2 Penetration Stresses 51 8.1.3 Allowable Flaw Depth Evaluation 52 8.1.4 Fatigue Evaluation 53 8.2 Evaluation of Postulated Borated Water Corrosion 54 8.2.1 Allowable Corrosion Depth 54 8.2.1.1 Technical Approach 54 8.2.1.2 Maximum Limit on Depth 55 8.2.1.3 Calculated Results 56 8.2.2 Fatigue Analysis 57 8.22.1 Gap Region 58 8.2.2.2 Crevice Region 59 8.3 Allowable Flaw Depth Limits for Inspection 61 8.3.1 Nozzle Stub Weld Region 61 8.3.2 Corrosion Degradation of Hole Penetrations 62 APPENDIX A -

SUMMARY

OF HOLE PENETRATION A-1 of HOOP STRESSES A-8 APPENDIX B - COMPUTER OUTPUT FROM BIGIF B-1 of B-9 APPENDIX C - ALLOWABLE DEPTHS FOR POSTULATED C-1 of CORROSION DEGRADATION C-3 QAE17 REV 8/96 M-DSC-360

EC&FS DEPARTMENT CALCULATION SHEETTccNNolPRELIm. ccN NO.

NO.

Jj PG OF CON CONVERSION:

Project or DCP/FCN SONGS 2&3 Calc No. M-DSC-360 CCN NO. CCN -

Subject

, , See Title Sheet S~heet st 4 5ht of SCE2842B REV. 0 8I91 (

REFERENCE:

$0123-XXJV-7.i6]

M-DSC-3 60

IWAPTICH ENGNt(EER1IG SERVIIES. INC, M-D- fs ~ 4 II,.

Made b,: Date: Client:

Calculation No.: AES-C-3247-1 5//./9 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer ' 7t 8 ro W ce6 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 4 of 69

1.0 INTRODUCTION

The pressurizer and steam generators at San Onofre Nuclear Generating Station, Units 2 and 3 (SONGS 2 and 3) are provided with small diameter instrumentation nozzles. The original nozzles are 3/4 inch and 1 inch nominal pipe size (NPS) fabricated from Inconel 600. These nozzles penetrate the head/shell and are attached at the inside surface by a J-groove weld.

A replacement nozzle design, called a half-nozzle design and fabricated from Inconel 690, has been developed by Southern California Edison Company (SCE). The replacement nozzle is of similar configuration to the original design except that the attachment weld is located on the outside diameter (OD) of the head/shell, rather than on the inside diameter (ID).

The compliance of the half-nozzle repair design to American Society of Mechanical Engineers (ASME)Section III (Ref. 1) has been satisfied by explicit code calculations (Refs. 2 through 4).

The stress allowable limits were satisfied for all design requirements of the original design specification, including normal operating, upset, faulted, and test conditions. The nozzle fatigue exemption requirements of NB-3222.4(d) were also satisfied.

The new half-nozzle design will replace the existing Inconel 600 nozzles in the event that repairs to the original nozzles become necessary. The original nozzle configurations are shown in Figures 1-1 and 1-2 (Refs. 3 and 4). As previously mentioned, the original nozzle is attached 1.o the head/she]l by a J-groove weld at the ID. The replacement design for the pressurizer bottom head is illustrated in Figure 1-3 (Ref 4). Similarly, the replacement designs for the pressurizer shell and the steam generator primary head nozzles are shown in Figures 1-4 and 1-5 (Refs. 2 and 3). The new design is installed by first cutting and removing an outer segment of the existing nozzle, laying down a base pad of Inconel 690 on the OD by welding, and installing the new Inconel 690 nozzle by a 3-groove attachment weld with a reinforcing fillet to the base pad. The inner segment or stub and J-groove weld of the original nozzle is left in place.

The purpose of this calculation is to evaluate the long-term acceptance of the half-nozzle configuration, specifically the possibility of flaws remaining in the inner nozzle stub and the possible corrosion of the low allow steel head/shell material, which is now exposed to primary (borated), water. The overall objectives are to evaluate postulated flaws in the nozzle stub to assess the potential of flaw propagation during plant operation and to determine the extent of borated water corrosion (BWC) within the annulus between the nozzle and head/shell penetration. Ix; performing this evaluation, the postulated flaws and corrosion degradation are conservatively assessed -ascracks oriented in the worst possible manner, as discussed herein.

'QAE17 RHV 8/96 M-DSC-3 60

EMIPTNOHS 0

&44NEERING SWICUS.M.

• 9-DSC- 36 0 Sll. x<

Made by: Date: Client:

Calculation Nwo.: AES-C-3247.1 _ _ e 96 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer t -3 cf (> AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 [-2 S of 69 The evaluated conditions addressed in this evaluation are pressure, mechanical loads, and design basis transients. The design cycles for a 40 year design life are imposed to justify long-term acceptance. The flaw evaluation procedures and acceptance criteria of ASME Section XI, Appendices A and H, are used as guidance in completing.the calculations (Ref. 5).

Mechanical Nozzle Seal Assemblies (MNSA) were installed on SONGS Unit 2 pressurizer and steam generator E089 during Cycle 9 mid-cycle outage. Each MNSA installation requires drilling four bolt holes in the vessel wall to attach the MNSA. An .

evaluation of the effect of the MNSA holes on the stresses in the nozzle is included in Appendix D of this calculation.

QAE17 REV 8196

• , -S.

M-DSC-3 60

ENGINEERING SERVICES. INC.

IA-05C-- 3&c Made b Dale: ,lient:

Calculation No.: AES-C-3247-1 C_/8/98 SCE Checked by: Dale: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -- T -T- t i SAES 97123247-IQ and Steamri Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Shect No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 6 of 69 Upper RTD Hread 7,Nozzle Bottom

, Head.

Nozzle

• (4!- ,. - .1 O rIWA 0EW__4>

- 1. ~1.0-'

r~r Figure 1 Illustration Showing the Original Nozzle Configurations for the Pressurizer.

QAE17

.REV8/96 M-DSC-3 60

EDNGNEERING SER1VIEES. IN'.

1A-fX6- 160 5A-- 10 Made by: Ditec Client:

Calculation No.: AES-C-3247-1 AfZ... ______9__7_ SCE Checked by: Date: Project No.;

Title:

Evaluation of Half-Nozzle Repair for Pressurizer _j 9 p -_ AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 7 of 69 Figure 1 Illustration Showing the Original Nozzle Configuration for the Steam Generator Primary Head.

QAE17 REV 8196 M-DSC-3 60

ENGINEER1NG SERMlCES, IN=

5i4. II Madc bv: Date: / Client:

Calculation No.: AES-C-;247-1 S/9 c / SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -y41-r_ n Pv 9 g AES 97123247-1(Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern Service Conditions - SONGS 2 and 3 0 1-2 8 of 69 PZR LCOWER LEVEL INSERT ASSY (41116 SH. 2)

R 1/16" GAP

. 158 MIN.

_. .PZRBOTTOM GR. BSA-533 HEAD CL E=0.1;5- (MIN TRHOAT) J /

E Ei l 1 3/8

-L INCONEL WELD BUILD-UP

-1.050"E.015" O.D.

t, x 0.614 Figure 1-3 Illustration Showing the Replacement Nozzle Design for the Pressurizer Botitom Head.

QAE17 REV 8196 M-DSC-3 60

ENGINEERING SERVICES. INC.

M f)5c , ,6 C> 5,4. I1?

Made by: Date: Clent:

Calculation No.: AES-C-3247-l _______ __SA_ SCE Checked by: Datc: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer Ax3 f-t4 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 9 of 69 Figure 1 Illustration Showing the Replacement Nozzle Design for the 1-Inch RTD Nozzle in the Pressurizer.

QAE17

REV 8196 M-DSC-3 60

ENGINEERING SfOLES. INC M-0sC- 360 54' 15 Made by: Date: Client:

Calculatima No.: AES-C-3247-1 16669 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 71 r _y

_ 2) AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Rcvision No.: Document Control No.: Sheet No.:

Long-Tern Service Conditions - SONGS 2 and 3 0 1-2 10 of 69 Figure 1 Illustration Showing the Replacement Nozzle Design for the Steam Generator Primary Head.

QAEI17 l.MV8/96 M-DSC-3 60

APTEICE ENGINEERING SERVICEtS. IN.

Made by: Date: Client:

Calculation No.: AES-C-3247-1 Mad SCE Cli Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer S k-t-m- - " c? f AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 I l of 69 2.0

SUMMARY

2.1 Scope and Objectives A fracture mechanics-based evaluation has been performed to justify the long-term acceptance of the half-rtozzle design for repair of existing Inconel 600 instrumentation nozzles in the pressurizer and steam generator. The long-term service of the half-nozzle design is subject to two postulated degradation mechanisms: (1) the existence of axial cracks in the remaining nozzle stub at the original J-groove attachment weld and (2) BWC of the low alloy steel head, which is now in contact with primary water. The flaw evaluation rules and acceptance criteria of ASME Section XI were employed to establish the allowable service life for the replacement design.

2.2 Nozzle Stub Flaw Evaluation The cracks postulated to remain in the original nozzle stub were conservatively evaluated. Tha highest computed stresses for the nozzles were used to envelop the service conditions for all instrumentation nozzles subject to repair. A large 1-inch depth corner crack, penetrating into the low alloy steel head/shell was conservatively assumed to bound the size of any remaining in the Inconel 600 material. The postulated flaw is illustrated in Figures 4-1 and 8-1. Fracture mechanics and fatigue crack growth analyses following the procedures of ASME Section XI, Appendix A, were completed to determine the allowable flaw depths and service life. The calculations for this evaluation are given in Section 8.1.

The allowable flaw depth is computed to be 2.59 inches. The acceptance criterion is based on maintaining a minimum safety factor of f10 on load for normal and upset loading conditions and 12 on load for emergency and faulted conditions, whichever is limiting. For the completed evaluation, the limiting service condition is the hydrotest for which the smallest allowable flaw depth is calculated (i.e., a,,, = 2.59 inches). The maximum flaw growth for the postulated initial flaw (a0 = 1 inch) for a 40-year design life is computed to be 0.37 inch. Therefore, the final crack depth is calculated to be 1.37 inches < a,,w = 2.59 inches and is therefore acceptable for a 40 year design life. Based on this evaluation, any flaws remaining in the nozzle stub will be acceptable to the safety margin requirements of ASME Section XI under IWB-3600.

QAE17 REV 8196 M-DSC-360

MHAPTIM-C MNINEERING SERVI(ES. M~.

IN VY!.-,pS 6- 3 60 6 15' Made by: Date: Client:

Calculation No.: AES-C-3247-1 . 8/fFe SCE Checked by: Date: Project No.:

Title:

Evalu3tion of Half-Nozzle Repair for Pressurizer -AH-t Tr. e-.' -- 'Y IF e AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Terr Service Conditions - SONGS 2 and 3 0 I-2 12 of 69 2.3 Borated Water Corrosion Evaluation The potential BWC of the low alloy steel head/shell material was conservatively evaluated. Local corrosion was modeled as a circumferential planar groove within the hole penetration. The postulated corrosion damage is shown in Figure 4-2. The integrity of the nozzle attachment was determined as a function of location of BWC within the hole, and depth and length of the corrosion groove. A limit load-based evaluation (including fatigue crack growth) was completed following the general approach of ASME Section XI, Appendix H, for flaws in ferritic piping. The allowable corrosion depths and lengths were established based on maintaining a minimum saftty factor of :2.77 for normal and upset service conditions and 1.39 for accident conditions.

The allowable corrosion depths were computed at two hole penetration locations: (1) at the gap region between the new nozzle and the remaining nozzle stub and (2) in the crevice region at -he nozzle-to-pad weld. The allowable corrosion depths for a 360° circumferential groove are summarized below:

Allowable Corrosion Size Location Depth Length Gap Region > 0.50 inch 3600 Crevice Region 0.42 inch 360° The computed corrosion growth rates and maximum flaw growth by fatigue (FCG) for a 40-year design life are as follows:

Flaw Depths (inches)

Location BWC FCG Total Gap Region 0.144 0.0007 0.15 Crevice Region 0.064 0.002 0.07 QAE17 REV 8/96 M-DSC-360

ENGLWERING SERVAKES. INC.

WM-Q$C. 5C- 5 o Made by Date: Client:

Calculation No.: AES-C-3247-I / Date: 91ClSCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 0S B y __________ 5_ AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tert Service Conditions - SONGS 2 and 3 0 1-2 13 of 69 The total corrosion depths (including fatigue), after 40 years of service, are computed to be less than the allowable corrosion depths. Therefore, the safety margin requirements of ASME Section XI will be satisfied for the half-nozzle attachment weld design.

2.4 Allowable Flaw Depths The allowable flaw depths for nozzle stub flaws and BWC degradations for use as inspection standards are developed in Section 8.3. The computed results are given in Figures 8-3 and 8-4.

'QAE17 REWV8/96 M-DSC-360

ENGWNEE1NG SERVIO ES. INC, S-3eS o .t4 I1 Madc by: Date: _/ 1 s Client:

Calculation No.: AES-C-3247-1 1/L- __ SCE Checked by: Date: Project No.:

Title:

EvaluationofHalf-NozzleRepairforPressurizer

• a 43 Fobey p, 9c AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 14 of 69 3.0 ANALYSIS ASSUMPTIONS The following general assumptions regarding methods and analysis parameters are made in this evaluation:

1. Flaw evaluation procedure given under IWB-3610 and Appendix A of ASME Section XI are generally applicable.

2. Weld residual stresses and the effects of vessel cladding are neglected. ('ACla da e>IM$

COKe MPT SCOAT PK&40s-

3. The hoop stresses at the inside surface of the shell due to external pipe loads applied at the modified pad-weld attachment (outside surface of the head) are assumed to be negligible.

4. Acceptance criteria for normal/upset and accident conditions are considered in the evaluation.

5. Maximum stress conditions for the pressurizer bottom head are assumed, which bounds all instrumentation nozzles covered by this calculation.

6. Maximum envelop of applied mechanical nozzle loads is assumed to bound external loads for all nozzles covered by this calculation.

7. Weld indications are assumed to be crack-like. The crack model is assumed to completely penetrate the J-groove weld and enter the low alloy steel shell.

8. Minimum strength properties for Inconel 690 material are assumed. Since these properties bound the strength properties for the low alloy steel material, they are conservatively used in the limit load evaluation.

9. Crack growth rate for reactor water for an R > 0.65 is conservatively assumed.

10. Conservative estimates of BWC rates from Ref. 7 are considered in the evaluation of general corrosion.

11. Irradiation embrittlement of the pressurizer and steam generator is negligible since these components are remote from the reactor pressure vessel (RPV) beltline.

QAE17 REV 8196 M-DSC-360

ENGINEERING SERVIF S.s M. LA. I?

16ade by: Datc: Client:

Calculation No.: AES-C-3247-1 1)6.. 5/-9/?41 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer I-i--r. o f-f 4-Y 5 Z AES 97123247-1 Q and Steam 3enerator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern Service Conditions - SONGS 2 and 3 0 I-2 15 of 69

12. The design specification for the pressurizer specifies 200 cycles for the operating basis earthquake event (OBE). For the fatigue evaluation, one OBE cycle is conservatively assumed to cause 40 stress cycles at the nozzle attachment. This assumption is consistent with nozzle design calculations (Ref. 2).

In general, use of the above assumptions will result in a conservative analysis of the flaw for normal operating conditions. Conservative means any condition that will result in a smaller calculated critical flaw size or in accelerated crack growth rates under normal operation.

The flaw evaluation was completed using the 1992 Edition of ASME Section XI as guidance. The current approved Code for SONGS is the 1989 Edition of ASME Section XI. However, the flaw evaluation methods and criteria are very similar in both the 1989 and 1992 codes. The 1992 Edition is; used herein because the equations and information are more complete and direct in application to the problem being evaluated. For these reasons, the 1992 Edition is technically equivalent to the 1989 Edition and can be used as guidance in the assessment of half-nozzle repair.

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MAtSPTrECH1, ENGINEERING SERVICES. U5CI 1'-9$c-^3co s14I Made by: Date: Client:

Calculation No.: AES-C-3247-1 _ _ _ _ _ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer Wen Af c Ad3 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Temi Service Conditions - SONGS 2 and 3 0 1-2 16 of 69 4.0 METHODOLOGY 4.1 Evaluation of the Nozzle Stub Flaw 4.1.1 Technical Approach The evaluation procedures of ASME Section XI, Appendix A, are used to analyze the postulated flaw geometries. The flaw is evaluated as a sharp crack and normal to the maximum principal stress direction (hoop direction) of the head/shell. The flaws are postulated as axially oriented cracks originating in the nozzle stub, as shown in Figure 4-1. It is conservatively assumed that the flaws will, grow radially through the J-groove and into the low alloy steel head/shell material. The initial flaw assumed in the evaluation is a large quarter circular crack that resides in the low alloy steel. 'This assumption conservatively ignores any crack growth life through the J-groove material.

The evaluation procedure is described in Article A-5000 of Section XI, Appendix A. Both theoretical solutions and numerical methods are used to evaluate the flaw, given the flaw size and geometry data, material properties, and the transient stresses and temperatures at the penetration location. These methods are used to calculate the following Section XI flaw parameters:

a, -The maximum size to which the detected flaw is calculated to grow in a specified time period

a. -The minimum critical size of the flaw under normal/upset operating conditions a; -The minimum critical size of the flaw under emergency/faulted accident conditions Stress results from design calculations are used to define boundary stress distributions at the :[D corner of the shell penetrations. The BIGIF (Ref. 6) computer program is used in the stress intensity factor and FCG analyses. The accuracy of the BIGIF program has been verified for both fracture mnd FCG analyses.

QAE17 REv8s96 M-DSC-3 60

OlPTEDH7 INC.

ENGINEERING SEW1ssESM 14-lpC-3( 4A.'2 Made by: Date: Client:

Calculation No.: AES-C-3247-l ._____ 5_/__/9_ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair forPressurizer -A Ah q? 9 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 17 of 69 4.1.2 Flaw Acceptance Criteria Flaws are acceptable if the critical flaw parameters satisfy the criteria of LWB-3611. These flaw size acceptance criteria are:

af < 0.1 a, (4-1) af <O.5ai (4-2) where af, a,, and ai are defined in Section 4.1. Equation 4-1 is the requirement for normal conditions and Eq. 4-2 governs the emergency/faulted conditions.

Alternatively, if the applied stress intensity factor and the flaw size, af, satisfy the following IWB-3612 criteria af <aa... (4-3) where a,,,. is the minimum value of "a" determined from the following equations:

KI (a) <Kla /igS, (normal/upset) (4-4a)

K, (a) <K 10c i2, (emergency/faulted) (4-4b) then the flaw is acceptable based on load. For Eq. 4-4a, KI is the maximum applied stress intensity factor under normal conditions, and Kia is the available fracture toughness based on crack arrest for the corresponding crack tip temperature. For Eq. 4-4b, K1 is the maximum stress intensity factor under emergency and faulted conditions, and KI, is the available fracture toughness based on fracture initiation for the corresponding crack tip temperature.

2AE17 RUV8196 M-DSC-360

RSAPTIECSI ENGINEERMl SERVIES. INCNG s-?4 L Made by: Date: Client:

Calculation No.: AES-C-3247-1 bya/- SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer - 7. r I cS AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 18 of 69 Satisfying either the flaw size criteria or the applied load criteria and checking that the appropriate primary Stress limits are satisfied will demonstrate acceptance of the flaw to ASME Section XI for the design conditions. It is expected that the acceptance criteria for normal conditions will govern the allowable flaw size because of the higher required safety margins imposed by ASME Section PI.

4.1.3 Calculation of End-of-Life Flaw Size (at)

The expected end-of-life flaw size (as) is computed by a cumulative FCG analysis for normal operating conditions for the remainder of the expected service life of the component, according to Article A-5200 of Section XI, Appendix A. Normal conditions include all transients expected to occur dwuing testing and normal operation. Included in normal operation are upset conditions that are anticipated to occur frequently enough as to warrant their consideration during design.

The FCG rate (da/dN) of the shell material is characterized by the following relation:

da/dN = CoAK (4-5) where da,'dN is the crack growth rate (i.e., inches per cycle of loading), CO and n are material constants, and AK, is the range in stress intensity factor for the load cycle (AK, = K~, - K.,,,,). The BIGIF computer program performs the FCG analysis by integrating Eq. 4-5. The number of applied load cycles, N, for the design transients is calculated from N = f da (4-6)

DO da/dN where ao is the starting crack depth and at is the final crack depth.

QAE17 REV 8/96 M-DSC-360

MERPTS. I --

G ENGINEERING SERVK.ES. INQ 75 0 -- f Made by: Date: Client:

I Calculation No.: AES-C-3247-1 5 9 98 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 5 f 0 1-f q cp AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 19 of 69 4.1.4 Calculation of Minimum Critical Flaw Size (a,) for Normal/Upset Conditions The procedure to compute the minimum critical flaw size for normal operation (a:) as specified by Article A-5200 of Section XI, Appendix A is outlined below:

1. Determine the maximum end-of-life irradiation level at the flaw location (embrittlernent of the pressurizer or steam generator shell due to neutron radiation is assumed to bt:

negligible, i.e., A RTNDT = 0).

2. Using fracture toughness data, determine the crack-arrest fracture toughness (Ka) as a function of temperature.

3. Calculate stress intensity factors, K,, for various geometrically similar crack depths of the assumed flaw.

4. Compare the calculated stress intensity factors to the material fracture toughness (K,1) for the appropriate temperature to determine a, for the transient.

5. Proceed to the next transient.

The calculated values for the stress intensity factor as a function of crack depth, K,(a), are utilized in the determination of a, from K1 (ae) = Kla (T, RTNDT) (4-7) where T is temperature at the crack tip and RTNDT is the nil ductility temperature for the shell material. Equation 4-7, therefore, represents the intersection of the toughness distribution and the applied K. field. The smallest value of a, determined by the above procedure after all transients have been considered is the minimum critical flaw size for normal operation. This minimum value of a. is checked against the flaw acceptability criteria of IWB-3600 (see Section 4.1.2).

QAE17 REV 8/96 M-DSC-360

APTEDIIH ENGIWEERING SERVICES, INC.

Made by: Date: Client:

Calculation No.: AES-C-3247-1 _ _ _/_9_ 9 SCE Checked by: Date: Project No.:

Title:

Evaluition of Half-Nozzle Repair for Pressurizer B y 3 ec.?9, AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 20 of 69 4.1.5 Calculation of Minimum Initiating Flaw Size (a;) for Accident Conditions The procedure to compute the minimum initiating flaw size (aL) for emergency/faulted conditions as specified by Article A-5200 of Section XI, Appendix A, is outlined below:

1. Determine the maximum end-of-life irradiation level at the flaw location (embrittlerment of the pressurizer or steam generator shell due to neutron radiation is assumed to be negligible, i.e., A RTND = 0).

2. Using fracture toughness data, determine the initiation fracture toughness (K) as a function of temperature.

3. Calculate stress intensity factors, KI, for various geometrically similar crack depths of the assumed flaw.

4. Compare the calculated stress intensity factors to the material fracture toughness (K, 1 )

for the appropriate temperature to determine ai for the transient.

5. Proceed to the next transient.

The calculated values for the stress intensity factor as a function of crack depth, KE(a), are utilzed in the determination of a, from KI (a;) = KIC (T, RTNDT) (4-8) where T is the temperature at the crack tip and RTNDT is the nil ductility temperature for the shell material. Equation 4-8, therefore, represents the intersection of the toughness distribution and the applied K, field. The smallest value of ai determined by the above procedure after all accident conditions have been considered is the minimum initiating flaw size for emergency/faulted conditions. This minimum value of a, is checked against the flaw acceptability criteria of IWB-3600) (see Section 4.1.2);

QAE17 REV 8196 M-DSC-3 60

APTCHIe ENGINEERING SERVIGMs. INC. M, C 36- r s '-f-Made, by Dae: Client:

Calculation No.: AES-C-3247-1 _ /8/9' SCE Checked by: Datc: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer o7-T _ !5 H ry AES 97123247-1 Q and Steam G3enerator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 21 of 69 4.1.6 Calculation of Stress Intensity Factor The stress intensity factor is defined as K1 = aF (4-9) where a is the applied stress, F is a function which accounts for flaw geometry and loading mode, "a " is the crack depth, and Q is the flaw shape parameter. Details of the calculation of K1 are provided later.

4.2 Evaluation of Borated Water Corrosion 4.2.1 Technical Approach The evaluation procedures of Section XI, Appendix H are used to analyze the postulated corrosion damage. The postulated damage from BWC is illustrated in Figure 4-2. The degradation is postulated as the loss of metal in the annulus between the nozzle and shell penetration. The integrity of the weld attachment would be challenged if significant metal loss occurred l.o cause the nozzle to pull out under pressure plus mechanical nozzle loads.

The BWC rate increases with increasing flow velocity (Ref. 7). It is expected that water in the annulus will be stagnant except at the 1/16-inch gap between the half-nozzle and the original nozzle stub. At this location, circumferential flow (swirling) is postulated. The resulting corrosion is assumed to be localized, as illustrated in Figure 4-2. In addition, BWC just under the pad is postulated.. This corrosion degradation, although at a slower rate, would be acting at a location where the metal reinforcement for the fillet weld is the smallest.

The integrity of the nozzle-to-pad weld is assessed by modeling the axial load-carrying section by an equivalent cylinder, as illustrated in Figure 4-3. The inner radius is defined as r,, outer radius as r2, and the thickness as "w." The thickness, "w", is defined as the distance from the corrosion QkE17 REM' 8196 M-DSC-3 60

MMAPTCH ENGINEERING SERVIES. tIC.

Madejy: Date: / Client:

Calculation No.: AES-C-3247-1 8/9-

/5/ '5 ft8 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer Ah o 1 cle AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 l-2 22 of 69 region to the toe of the fillet weld and, therefore, represents the minimum structural connection distance. From the geometry of Figure 4-3, a = tan [t-- -l tp + e r, = (dh/2)/sina w = [(tP + e)2 + t2] 1 2 r2 = r, +w The flaw penetration in the equivalent cylinder is the projected length (a) of the corrosion along the minimum section (w), as illustrated in Figure 4-3. The corrosion depth is defined as "d." To characterize a skewed flaw per ASME Section XI, the evaluated flaw depth is the perpendicular projection of the skewed flaw to the plane of interest. In this evaluation, the projected length is conservatively doubled to account for the irregularities and roughness of the corrosion groove, as shown in Figure 4-3. This projected length assumes that the triangular area between the area of corrosion and the minimum section does not carry any load. This triangular area is an isosceles triangle with an apex angle equal to 2o: (factor of two on projected length). Therefore, the projected depth, a, is conservatively defined as:

a = 2d sinca (4-10)

The cross-sectional area of the equivalent cylinder is the conical surface area given by:

A, = nr[dh +Jew (4-11)

QAE17 REV 8196 M-DSC-360

PfHAPTEICH.

ENGINEERING SERtVYt ES. INC.

A4 2 '

Made by: Date: Client:

Calculation No.: AES-C-3247-1 /s/81 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer A d fle,,y H 5L AES 97123247-1 Q and Steam '3enerator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 23 of 69 The section modulus of the equivalent cylinder is conservatively defined as the normal cross-section across the fillet weld leg:

Z = 4 [(dh/2 +)4-(dh/2)4]/(dh/2 + A) (4-12)

The values of area and section modulus define the magnitude of applied stress to be carried by the equivaler t cylinder.

4.2.2 Corrosion Acceptance Criteria The BWC of the low alloy steel shell is acceptable provided that the safety margins of Appendix H are satisfied. These safety margins of factors (SF) are 2.77 on load for normal/upset loading conditions and 1.39 on load for emergency and faulted conditions. For the applied bending (crb) and membrane (q.) stresses acting on the nozzle, the acceptance of BWC is established from the following relationship consistent with Article H-5320 (Ref. 5):

Cb +m 2 SF (4-13)

Cm + ab where cy' is the critical bending stress at incipient failure, a. is the applied membrane stress, ( is the applied bending stress, and SF is the appropriate safety factor.

4.2.3 Definition of Nozzle Stresses The membrane and bending stresses acting on the nozzle attachment are determined from the:

pressure and mechanical loads. The membrane stress is conservatively estimated from the absolute summation of forces Um = FA /A (4-14)

QAE17 REV 8196 M-DSC-360

IPT!.-HCH ENGINEERING SERVICES. I.

4li. 21 Made by: Date: Client:

Calculation No.: AES-C-3247-1 , -40 "AR SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -}--r . 9 E AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 24 of 69 FA = n (dh/2) 2 PD +Fa +Fb +FC The bending stress is computed from applied moments according to Cyb = MB/Z (4-15)

MB = M2 +M2 +M2 ]1 1 2 4.2.4 Determination of Critical Bending Stress The allowable flaw depth due to corrosion is determined from the limit load criteria of Article 1-5000. It is assumed that the low alloy steel head/shell material will be ductile under all service conditions, as supported by the upper shelf toughness material behavior determined in Section 5.4.2. For the pipe flaw geometry of Figure 4-4, the relationship between plastic failure, applied stresses, and flaw geometry is given by (Ref. 5):

b = f((2sinp - (a/w)sinO] (4-16) 0,= (st/2) [1- (alw) (0/h))- (a /Of )] (4-17)

For (I + 0) c ic. When (I + 0) > n, the above equations become:

6-b = [2-- (a/w)]sinP (4-18)

D =)[I-(afw)-(am/,,

2 (a/w) f )] (4-19)

QAE17 REV 8/96 M-DSC-360

ENGINEERING SERVICES. INC. M- S(d- V6o 5d. C g Made by Date: Z t ient:

Calculation. No.: AES-C-3247-1 ae:/6/98 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 5 3 e Ah- AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 25 of 69 In the above equations, "a" is the depth of the corrosion flaw, 0 is the half-flaw angle around the penetration, and crf is the flow stress equal to (Sy + S.)I2. The angle, P,is the angle position of the neutral axis, as shown in Figure 4-4.

4.2.5 Corrosion/Fatigue Growth Analysis The depth of the corrosion is established from the estimated growth rate for a 40 year service life.

Estimated growth rates for stagnant and high flow rate conditions are discussed later in Section 5.4.4. Flaw growth due to FCG is also included and combined by the simple linear cumulative damage rule. An initial crack depth equal to the corrosion flaw depth is assumed in a FCG analysis. Forty years of cyclic service loads, including seismic, is applied in the fatigue evaluaticin. The calculation of final flaw size from FCG follows the approach discussed in Section 4.1.3.

QAE17 REV 8196 M-DSC-3 60

NOEMIPTEDIC Mt{INEERlING SEFMICES. INC.

Made by: Date Client:

Calculation No.: AES-C-3247-1 5 / 0 / _ _ _ SCE Checked by: Date: Project No.:

Title:

Evaluztion of Half-Nozzle Repair for Pressurizer -ATd-r- g3 e-C AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 26 of 69 Nozzle Weld Nozzle

// Pad Head or Nozzle- _> Shell Stub Corner Crack Nozzle Crack Original J-Groove Weld Figure 4 Postulated Flaw in Nozzle Stub Weld Region.

REV 8/96 M-DSC-3 60

U4NGIEERING SAKCES. itt.

M- 6SC-S90 5;f. so Made by: Date: Clicnt:

Calculation No.: AES-C-3247-1 _SCE s__/_

Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 14 1 " ?2Z AES 97123247-IQ and Stearm Generator Instumentation Nozzles Under Revision No.: Document Control No.: Shect No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 27 of 6)

Figure 4 Postulated BWC in Nozzle Repair Region.

QAE17 REV 8196 M-DSC-3 60

lmPE-C-H7 ENGINEERING SERVICES. INC.

MA-5c-- S4o e,- 51 Made y: Date: Clicnt:

Calculation No.: AES-C-3247-1 5/08 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer S t-c.-c- 0 M & '- t ce) AES 97123247-Q and Steamt Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions. - SONGS 2 and 3 0 1-2 28 of 69 t

e Figure 4 Equivalent Cylinder Model for Nozzle Loading.

QAE17 Q1AV17 MY &1/96 M-DSC-3 60

M1APT9;W ENGINEERING SERVICES. INC.

fA- VS6--60 Made by: Date: / Clicnt:

Calculation No.: AES-C-3247-1 5 SCE Checked by: Data: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -l41 23 rA.-y- ci S AES 97123247-1Q and Steair. Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 29 of 69 1% I w Nieutral axis Figure 4 Net Section Plastic Failure Model.

QAE17 RIW 8196 M-DSC-3 60

ENGINEERING SERVI-ES. INC.

M- DSC-a10 4$.- S.3 Mad:eby: Date: SCient:

Calculation No.: AES-C-3247-1 Mad lqe SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 14-t-Z t , q s AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Documcnt Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 . 1-2 30 of 69 5.0 DESIGN INPUT 5.1 Nozzle and Shell Geometry The instrumentation nozzles used in the pressurizer and steam generators for pressure and level sensors are 3/4-inch Schedule 160 pipe size. There is one temperature instrumentation nozzle in the pressurizer that is 1-inch Schedule 160. The nozzles penetrate either the spherical head or cylindrical shell portions of the components. A schematic illustration of the nozzle geometry is given in Figure 5-1. A summary of the important dimensions for the different nozzles is given in Table 5-1.

The geometry information in Table 5-1 was used to select a repair nozzle configuration that is conservative/bounding of all nozzles. The nozzle geometry that was selected was the pressurizer bottom head for the following reasons:

1. Largest local R /t value for the hole penetration

2. Smallest pad thickness

3. Small pad diameter The above: attributes would cause the pressurizer bottom head nozzle to produce the highest stress of all the 3/4-inch nozzles. The 1-inch nozzle has a much thicker and larger pad and a smaller local R, /t value for the penetration. However, the 1-inch nozzle penetrates the cylindrical shell and would have a higher nominal hoop stress in the circumferential direction. The elevated hoop

-stress is estimated below:

se (1-inch) p R1 /t 7.33 1.17 CFO (3/4-inch) p R1 /2t (12.50)/2 Therefore:, the nominal hoop stress in the shell at the 1-inch nozzle location is approximately 20%

higher than at the pressurizer bottom head nozzle. This hoop stress increase will be taken into account in this evaluation, with a multiplication factor on pressure loading.

QAE17 RE' 8196 M-DSC-3 60

HiNHRJPTILSIN ENGINEERUNG SEYVVES. INC.

toI/ QiC -360 Sl*t- 54 Made by, Date: Client:

Calculation No.: AES-C-3247-l C19/?9 8 Cl SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -y ?t 3 AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 31 of 69 5.2 Design and Operating Conditions 5.2.1 Pressurizer The design data for the pressurizer from Ref. 4 are as follows:

Design pressure = 2500 psia Design temperature = 7000F Operating pressure = 2250 psia Operating temperature = 6530F Hydrotest pressure = 1.25 PD = 3125 psia (3110 psig)

Thermal transients are given in Table 5-2 (Ref. 4). Five thermal cases were conservatively assumed in Ref. 4 that envelop the thermal transients. These cases are:

1. Isothermal steady-state load of 6530F

2. Heatup/cooldown at a rate of 200'F per hour

3. Cooldown with flow stratification (Figure 5-2)

4. Temperature step change of +/-20'F for plant load changes

5. Temperature change of -400 F and -20'F then +600 F for loss of flow conditions (Figure 5-3)

All normal/upset transients are less severe than loss of flow condition or cooldown transient with flow stratification.

QAE17 REV 8/96 M-DSC-360

ENGiNEERING SERVICES. INC 4col, *5 Made by: Date: / Client:

Calculation No.: AES-C-3247-1 TI 8/i9

/ SCE Checked by: Date: Project No.:

Title Evalu ition of Half-Nozzle Repair for Pressurizer 1'-. -Ii4 J " AES 97123247.1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 32 of 69 5.2.2 Steam Generator The design data for the primary side of steam generators from Ref. 3 are as follows:

Design pressure = 2500 psia Design temperature = 6500F Operating pressure = 2250 psia Operating temperature = 553 0F (cold leg), 611'F (hot leg)

Hydrotest pressure = 1.25 PD = 3125 psia (3110 psig)

Thermal transients are given in Table 5-3 (Ref. 3). Four thermal cases were conservatively assumed in Ref. 3 that envelop the thermal transients. These are:

1. Isothermal steady-state load of 553TF

2. Heatup/cooldown at a rate of 100 per hour

3. Temperature step change of +/-100 F for plant load changes

4. Temperature change of +100F and -30F for loss of flow conditions (Figure 5-4)

All nornal/upset transients are less severe than loss of flow condition.

5.2.3 Bounding Transient Conditions From a comparison of the transient conditions in Tables 5-2 and 5-3, and the temperature transient responses (Figures 5-2 through 5-4), the pressurizer bottom head nozzle has the most limiting operating and upset conditions. Therefore, the stress results from the pressurizer bottom head nozzle will be used to evaluate all component instrumentation nozzles.

QAE17 RIV 8/96 M-DSC--3 60

HAP1IJF ENGINEERING SERVICES. INC.

Made by Date: I Client:

Calculation No.: AES-C-3247-1 DatCE Checked by: Date: Project No.:

Title:

EvaluationofHalf-NozzleRepairforPressurizer -i .,- 6 r t 2 i3 AES 97123247-lQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Teny. Service Conditions - SONGS 2 and 3 0 1-2 33 of 69 5.3 Mechanical Loads The medianical loads due to dead weight (DW), operating basis earthquake (OBE), and design basis earthquake (DBE) are different. A maximum envelop of the reported mechanical loads is conservatively used to bound all nozzle locations. These maximum values are summarized be: ow:

MAXIMUM NOZZLE EXTERNAL LOADS FOR 3/4-INCH PIPING F Fb F. Ma Mb M:

Loading (lb (lb) (lb) (in-lbs) (in-lbs) (in-lbs)

Dead weight (DW) 25 19 0 0 0 240 Thermal (THERM) 0 104 0 0 0 1176 Seismic (OBE) 76 55 35 816 420 360 Seismic (DBE) 152 110 70 1632 840 720 Notes:

F. - Axial to the nozzle (outward positive)

Fb = Lateral to the nozzle Fe = Lateral to the nozzle Ma: Mb, Me = Moments associated with a, b, and c axes The above loads were extracted from Table 8.1 (Sheets 33 and 116) of Ref. 2, Table 5-2 of Ref. 3, and Table 5-2 of Ref. 4.

QAE17 REV 8/96 M-DSC-360

MAPT5CH ENGINEERING SERVIOES. INC.

MA- 5 c -6 o 4AI 51 Made b Date: Client:

Calculation No.: AES-C-3247-1 s 8/f8 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 43 i , AES 97123247-IQ and Steam Generator Instumentation Nozzles Under Revision No.: Documeni Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 34 of 69 5.4 Material Properties 5.4.1 Mechanical Strength The materials that comprise the heads, shell, and replacement instrument nozzle (Refs. 2 through 4) are as follows:

Head and Shell: SA-533, Grade B, Class 1 Cladding: Stainless steel Instrumentation Nozzle: Inconel SB-166, Grade 690 Pad: Inconel 690 In the analysis, the cladding is conservatively ignored. The mechanical strength properties at the highest design temperature are summarized below (Ref. 4):

MECHANICAL STRENGTH AT 700F I Inconel 690 SA-533B-1 S.m (ksi) 23.3 26.7 Sy (ksi) 27.6 40.6 S. (ksi) 85.0 80.0 Also, Sy for Inconel 690 at 100 0F is 35 ksi.

(QAE17 RV 896 M-DSC-360

MAPPTECW ENGINEERING SERVICES. INC. 16o -s A Made by: Date: / Cient:

Calculation No.: AES-C-3247-1 /9&- S 8/98 SCE Checked by: Date: Project No.:

Title:

EvalulationofHalf-NozzleRepairforPressurizer b y t-.-7ro y ? 6 AES 97123247-IQ

. and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 35 of 69 5.4.2 Fracture Toughness Definition of fracture toughness at the flaw location as a function of temperature was obtained from Article A-4000 of Appendix A to Section XI (Ref. 5).Section XI defines lower-bound behavior for KIa and K,, for SA-533B-1, SA-503-2, and SA-508-3 steels and associated welds, as shown in Figure 5-5. The equational formats of these reference curves are given below:

Kla = 26.8 + 12.445 exp [0.0145 (T - RTNDT)] (5-1)

K10 = 33.2 + 20.734 exp [0.02 (T - RTNDT)] (5-2) where T isthe metal temperature in 'F, RTNDT is the reference nil ductility temperature in 'F, and Ka and K10 are fracture toughness in ksi in"1. The toughness parameter, Kit, is based on the Icwer bound of static initiation critical K1 , values measured from specimens tested at several temperatures. Similarly, K1. is based on the lower bound of crack-arrest toughness data. It is assumed that the transition behavior of SA-533B-1 will be such that the normal operation of the pressurizer will be on the upper shelf during times when maximum pressure stresses are imposed.

The pressure-temperature (P-T) operation of the reactor coolant system (RCS) will be controlled by the P-T limit curves for the RPV and, therefore, maximum operating stresses will not be experienced by the pressurizer or steam generator at low temperatures. This assumption is justified on the fact that RTNDT of SA-533B-1 will be less than +20'F, which is the mean plus two standard deviations bound reported in Ref. 8. An RTNDT = +20EF will cause the onset of upper shelf conditions at T - 120'F for initiation toughness. For this condition, the upper shelf toughness is 200 ksi in', as reflected in Figure 5-5, and is based on data evaluations in Ref. 9.

5.4.3 Fatigue Crack Growth Rate The reference curve for crack growth rate (da/dN) in a reactor water environment is given in Figure A-4300-2 of ASME Section XI, Appendix A, and is shown in Figure 5-6 for two R-ratio regimes. The crack growth behavior for the highest R-ratio range (0.65

• R s 1.0) is conservatively used in this evaluation. The equation for crack growth is:

da/dN = 1.20 x 10-" AK5-95 AK

• 12.04 ksi in3/2 (5-3)

QAE17 REV 8196 M-DSC-3 60

H+t7HAPTECHI-eN1tNEERMNG SEI MS.INC.

' 4 - 5e Made by: Date: Clicnt:

Calculation lNo.: AES-C-3247-l1 eS _ 5/b 9 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressuxizer Sy HA - CS AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 36 of 69 da/dN = 2.53 x 10-7 AKW95 AK 12.04 ksi in"12 (5-4)

These crack growth rates are used as input to the FCG analysis.

5.4.4 Corrosion Rates It is postulated that BWC will occur within the penetrations of repaired nozzles. The nozzle penetrations will be under deaerated conditions at high temperatures during normal operation. In shutdown conditions, the water is conservatively taken to be under aerated conditions at low temperatures, as assumed in Ref. 7. Corrosion rates are also greater for high flow rates than for stagnant conditions. It is assumed that the pressurizer nozzles in the water space will experience stagnant conditions, whereas the pressurizer nozzles in the steam space and the steam generator nozzles will experience nonstagnant conditions. For these conditions, the following metal losses were conservatively estimated (Ref. 7):

Pressurizer upper head: 0.0036 in/yr Pressurizer shell and bottom: 0.0017 in/yr Steam Generator bottom head: 0.0036 in/yr The highest estimated corrosion rate of 0.0036 inches/year (nonstagnant) will be used in the evaluation for the gap region between the new nozzle and the original nozzle stub. This corrosion rate corresponds to a 0.144 inch increase in the penetration hole radius in 40 years of service. In the crevice region at the nozzle-to-pad attachment, the stagnant corrosion rate (0.0017 inches/year) will be used. This corrosion rate corresponds to a 0.068 inch increase in penetration hole radius in 40 years of service.

QAE17 REV 8/96 M-DSC-3 60

APTECIN ENGINEERINC3 SERVICES. INCA M_ 0,5 6- -3("D 5 if. q-cS Made W. Date: Client:

Calculation No.: AES-C-3247-1 I_________ _ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair forPressurizer 7 3 h u> ,S AES 97123247-1I and Steamn Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 37 of 69 Table 5-1

SUMMARY

OF INSTRUMENTATION NOZZLES/GEOMETRIES (Refs. 2 through 4, and 15)

INSTRUMENTATION NOZZLES Steam Pressurizer Nozzles Generator l _Nozzles Description Tap/Level Level Tap Tap Loca:ion Upper head Bottom head Shell Bottom head Number 4 2 1 4 Size (NPS) 3/4-inch 3/4-inch 1-inch 3/4-inch Schedule 160 160 160 160 Nozzle, ro (in) 0.525 0.525 0.6575 0.5095 ri (in) 0.307 0.307 0.4075 0.3125

t. (in) 0.218 0.218 0.250 0.197 Shell, R. (in) 52.375 52.313 53.000 86.125 RI (in) 48.500 48.438 48.125 78.750 l (in) t 3.875 3.875 4.875 7.375 dh (in) 1.072 1.072 1.325 1.029 Weld pad, dp (in) 4.55 3.80 6.00 3.77 tp (in) 0.50 0.4375 1.6875 0.4375 Nozzle insert depth, xd min (in) 11/16 11/16 7/8 11/16 Ratio, r, / t. 1.408 1.408 1.630 1.586 Ratio, R, / t, 12.52 12.50 9.87* 10.68 Note: " The local R, It values at the 1-inch nozzle, taking into account the larger pad reinforcement thickness is 7.33.

QAE17 REV 8/96 M-DSC-3 60

DI . . . .

ENGINEERING SEFVICES. WNC.

Calculation No.: AES-C-3247-1

Title:

Evaluation of Half-Nozzle Repair for Pressurizer and Stearm Generator Instrumentation Nozzles Under Long-Teim Service Conditions - SONGS 2 and 3 tD tp dh12 Figure 5 Illustration of the Repair Nozzle Geometry.

QAE17 xEV 8196 M-DSC-3 60

ENGINEERING SER/ICES, IN-.

591. 4.L Made by: Date: Client:

Calculation No.: AES-C-3247-l ,&Z. SCE Checked by: Date: Project No.:

Title:

Eva.uationofHalf-NozzleRepairforPressurizer r f , o AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Shect No.:

Long-Terzt Service Conditions - SONGS 2 and 3 0 1-2 41 of 65 COOLDOWN WITH STRATIFICATION 700

'-'600 1--

E6 500

~40 a) 400 t 300 C3 200 Q 100 0-Q 0 20 40 60 80 100 120 140 160 180 200 Transient time, t (Min]

Figure 5 Transient Condition - Cooldown Stratification Transient (Ref. 4).

QAE17 lEV 8/96 M-DSC-3 60

MgP-rECH ENGINEERING SEAtVICES. ING.

M-V56C-3e6o 5H 472 MadeCy Date: Client:

Calculation No.: AES-C-3247-1 S8 98 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair forPressurizer -re-ss-riz S AES 97123247- Q and Steam Generator Instrumentation Nozzles Under Revision No.- Document Control No.: Sheet No.:

Long-Term Service Conditions- SONGS 2 and 3 . 0 1-2 42 of 69 REACTOR TRIP/LOSS OF FLOW

"'j 20 i

E-0 a)

H-L

. & -40 CL-0 ri4 a)

-80

-0 500 1000 1500 2000 2500 L-)

Transient time, t (Sec]

Figure 5 Temperature Change in Pressurizer Bottom Head During Loss of Flow Transient (Ref. 4).

QAF 17 FEV 8196 M-DSC-3 60

. .ll. .l . .

ENGINEERING Sl3lICES. INC.

NA-195C 3t.Q s5i. 44 Made bF Date: Cient:

Calculation No.: AES-C-3247-1 /5 /8/ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair forPressurizer Vr=3 M'-y V c!a AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 . 0 1-2 43 of 59 I I REACTOR TRIP/LOSS OF FLOW

< 40 I I I I I' I 4 I I I I aS6

30 a 20 w 10 c- -

0 c0 -lo

,, -20 0

7s -30 I I I I I I I I I I I I I I a -40 I 200 400 600 800 1000 1200 1400 1600 0

C-)

Transient time, t [Sec]

Figure .5-4 - Temperature Change in the Steam Generator Primary Head During Loss of Flow Transient (Ref. 3).

QAE17 REV 8/96 M-DSC-3 60

r....

ENGINEERING SERUMCES. W^.

U,'0A 6C- 3660 5I4 . 4-<

Made by: Daie. Client:

Calculation No.: AES-C-3247-1 . 8//98 l SC Checked by Date: Project No.:

Title:

Eva!.uation of Half-Nozzle Repair for Pressurizer --

g-~y c? , - AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern Service Conditions - SONGS 2 and 3 . 0 1-2 44 of 69 220 200

/- -I---

180 160 V,

.W140 t 120 _

1-a K1,

.I C

100 1-_

0- 80 I'-

6 V 60 U-40 20 I

0 I I

I I E

I f I t E I 1-I -

I iI II 'I

• i II I t ____

-80 -40 0 AD 80 120 160 200 (r- lrrND],, f Figure 5 Lower Bound Fracture Toughness from Tests of SA-533B-1, SA-508-2, and SA-508-3 Steel (Figure A-4200-1 from ASME Section XI, Appendix A, in Ref. 5).

QAE17

.REV 8196 M-DSC-3 60

ENGINEERING SERVICES. INC.

5I; M -

Madc'by Date: Client:

Calculation No.: AES-C-3247-1 ___________ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer j-1-f . P3 T ^j" ' AES 97123247- 1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 45 of 69 7

107 L_

IOo lot 102

~ -bkt rkin.)

Figure 5 Reference Fatigue Crack Growth Curves for Carbon and Low Alloy Ferritic Steels Exposed to Water Environments (Figure A-4300-2 from~ASME Section XI, Appendix A, in Ref. 5).

QAE17 REV 8196 M-DSC-3 60

MERPTI CI E2GINEERING SERVII=, INC.M DS a5 M-1) . 6  : q,4 ..

Made by Date: Client:

Calculation No.: AES-C-3247-1 16.c §SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -st-rr." c?' AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 46 of 69

6.0 REFERENCES

1. AME Boilerand PressureVessel Code,Section III, "Rules for Construction of Nuclear Power Plant Components," 1971 Edition, 1971 Summer Addenda.

2. Calculation Number M-DSC-260, "Pressurizer Instrumentation Nozzle Evaluation -

SONGS 2," Southern California Edison Company (March 28, 1992).

3. Calculation AES-C-3098-1, Revision 1,"Steam Generator Primary Head Instrumentation Nozzle Evaluation - SONGS Units 2 and 3," Aptech Engineering Services, Inc.,

A.TTACH Project AES 97063098-1Q (March 25, 1998).

4. Calculation AES-C-3213-1, Revision 1, "Pressurizer Bottom Head Instrumentation Nozzle Evaluation - SONGS Units 2 and 3," Aptech Engineering Services, Inc.,

APTECH Project AES 97103213-1Q (March 30, 1998).

5. ASME Boilerand PressureVessel Code,Section XI, "Rules for Inservice Inspection of Nuclear Power Plant Components," 1992 Edition.

6 Cipolla, R C., P. M. Besuner, and D. C. Peters, "BIGIF - Fracture Mechanics Code for Structures," Manual 2, User's Guide, EPRI NP-838 (August 1978).

7. Document 51-1235153, "Corrosion Evaluation for Base Metal Exposure Within RCS Nozzles," B&W Nuclear Technologies (February 27, 1995), p. 9 (ECD-3).

8. NIJREG-0577, "Potential for Low Fracture Toughness and Lamellar Tearing on PWR Steam. Generator and Reactor Coolant Pump Supports," Appendix C (October 1979).

9. "Flaw Evaluation Procedures - Background and Application of ASME Section XI Appendix A," EPRI NP-719-SR, Electric Power Research Institute (August 1973).

10. Drawing S023-915-13-8, Rev. 3, "High Pressure Head Details and Assembly - San Ortofre 3 Steam Generator," (November 7, 1976) (ECD-3 from APTECH Project AES 97063098-1Q).

11. Drawing S023-919-2-8, Rev. 6, "Pressurizer Outline for San Onofre 2," (October 15, 1976)

(ECD-8 from APTECH Project ABS 97103213-1Q).

QAE17 REV 8196 M-DSC-360

HTAPTIECH

.ENGINEER~ING SERVFI ES. INC. H 4 Calculation No.: AES-C-3247-1 Made bv:

M a~rC Checked by.

IDate:

Dte Date:

1 0 1/

Cl,ient:

SCE Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer B y -- 2 tB-y- I lae AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 47 of 69

12. D.rawing S023-919-13-1, Rev. 2, "Bottom Head Welding and Machining for San Onofr.5 2,"

(November 7, 1973) (ECD-10 from APTECH Project AES 97103213-1Q).

13. "Analytical Report for Southern California Edison, San Onofre Unit 3, Pressurizer,"

CENC-1296 (September 1977) (APTECH Project 97103213-1Q, ECD-5).

14. "Analytical Report for Southern California Edison, San Onofre Unit 3, Steam Generat:ors,"

CENC-1298 (September 1977) (APTECH Project 97063098-1Q, ECD-6).

15. Drawing S023-919-79-0, "Pressurizer General Arrangement for San Onofre 3," Revision 3, (October 20, 1976) (APTECH Project 97103213-1Q, ECD-11).

16. Zahoor, A., "Ductile Fracture Handbook," Volume 2, Chapter 4, EPRI NP-6301-D, Electric Power Research Institute (October 1990).

17. "General Specification for a Pressurizer Assembly," Specification No. 00000-PE-130, Revision 3, Combustion Engineering, (October 25, 1972) (APTECH Project AES 97103213-1Q, ECD-2)

QAE17 REV 8196 M-DSC-3 60

ENGINEER3NG SERVICES. INC.

M- P5 C- 360 m1H. 4q, Made by: Datc: Client:

Calculation No.: AES-C-3247-1 M/a& ate:/8 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 1_____ C_ e R E AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 48 of 69 7.0 NOMENCLATURE a = Flaw depth, inch Cal,,o = Allowable flaw depth, inch ac = Minimum critical crack size for normal/upset conditions, inch a, = Final flaw depth, inch ai = Minimum critical crack size for accident conditions, inch

a. = Initial flaw depth, inch CO = Material constant in the reference fatigue crack growth equation d = Depth of corrosion groove, inch dh = Diameter of hole penetration, inch dP -Diameter of pad, inch Do = Outer diameter, inch e = Distance to the corrosion groove within the hole penetration from the OD surface, inch F = Flaw correction factor F = Force, lb FA = Axial force, lb FL = Lateral force, lb Fa Fl.,, Fe = Forces in the a, b, c directions, lb F., F., F. = Forces in the x, y, z directions, lb K = Stress intensity factor, ksi in' K1 = Mode I stress intensity factor, ksi int2 Kia = Fracture toughness for crack arrest, ksi in'2

= Static fracture toughness for initiation, ksi int2 Arc.

= Maximum value of K in stress cycle, ksi in'2 Kmin = Minimum value of K in stress cycle, ksi in"2 AK = Range in stress intensity factor (K, , - K..,,), ksi in"n

= Leg length of the fillet weld, inch OAE17 REV8196 M-DSC-3 60

EEPTEIE.

ENGINEEPSJNG BSMAES, INa kA- 9s5C-3 51 - 60 Made k: Date: Client:

Calculation No.: AES-C-3247-1 fSZ9- SCE Checked by: Date: Project No.:

Title. Evaluation of Half-Nozzle Repair for Pressurizer A t 1-c__ T V--y qj AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern. Service Conditions - SONGS 2 and 3 0 1-2 49 of 69 MB = Bending moment, in-lb MT = Torsion, in-lb Ma, Mb, Ml = Moments in the a, b, c directions, in-lb MY.'MY, MZ = Moments in the x, y, z directions, in-lb n = Exponent in the reference fatigue crack growth equation N = Number of cycles P = Pressure, psi PD = Design pressure, psi Pma. = Maximum pressure in transient, psi PWin = Minimum pressure in transient, psi AP = Pressure fluctuation, psi Q = Flaw shape parameter r = Radial distance, inch rO = Outer radius of nozzle, inch ri = Inner radius of nozzle, inch R = Mean radius, inch R = R-ratio (K in/ Ka)

R0 = Outer radius of head or shell, inch R1 = Inner radius of head or shell,. inch Sm = Allowable stress intensity, psi Su = Ultimate strength, psi Sy = Yield strength, psi t = Wall thickness, inch T = Temperature, IF AT = Temperature difference, 0F

= Pad thickness, inch th = Head or shell thickness, inch tt = Fillet weld throat thickness, inch QAE17 RE:V8196 M-DSC-3 60

HHAPTKI G 14 *-

ENGINEERINGSERVICES. I.-.

Made by: Date: Client:

Calculation No.: AES-C-3247-1 16-e 6SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer - 1 -, W t __ 97123247-1

__!:AES Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 50 of 69 w = Thickness, inch a = Geometric angle, radians P = Angle to neutral axis for bending, radians a,, = Applied membrane stress, psi ab Applied bending stress, psi acb = Critical bending stress, psi of = Material flow stress, psi o = Circumferential half-crack angle, radians o = Angle coordinate, radians QAE17 REV 8/96 M-DSC-3 60

HAPTIfCHIV M-P56 2;6 o - 57 ENGINEERING SERVIOES. MC. X Calculation No.: AES-C-3247-1 Mad by Checked by.

Date:

Date:

s7/9/7

!XGC } aient:

C SCE Project No.:

Title:

Evalution of Half-Nozzle Repair for Pressurizer A x 0 pi k-? ? b AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 51 of 69 8.0 CALCULATIONS 8.1 Evaluation of Postulated Flaws in the Penetration Hole 8.1.1 Flaw Model To evaluate the integrity of the half-nozzle repair geometry, it is postulated that an axial flaw(s) remains ia the nozzle stub at the original J-groove weld. It is further assumed that the postulated flaw has extended through the nozzle/weldment and penetrated into the low alloy steel base metal.

An illustration of the flaw model representing the postulated flaw geometry is shown in Figure 8-1.

This represents the worst flaw orientation and size that could develop by stress corrosion cracking.

The initial flaw is conservatively assumed to be located at the corner of the hole and semicircular in shape of depth "a." The initial flaw depth is assumed to be 1-inch (i.e., a. = 1.0 inch). For this depth, the flaw tip will be in low alloy steel since the nominal J-groove prep is approximately 7/8-inch (Ref. 10). A review of drawing details (Refs. 10 through 12) indicates that the size of the J-groove ,weld could range from 0.5 inch to 1.25 inches, depending on the angle of hole penetration with a curved head. Hence, it will be reasonable and conservative to assume a 1-inch deep flaw as an initial flaw depth for the evaluation.

8.1.2 Penetration Stresses The hoop stresses for the hole penetration were obtained from the finite element analysis contained in Ref. 4. These stress summaries are given in Appendix A. The loading conditions and corresponding stress results for the pressurizer bottom head nozzle penetration are bounding due to the more severe thermal transients in the pressurizer bottom head region. The following lo ad cases front Ref. 4 were used to bound the maximum stresses and stress ranges at the postulated flaw locations for all nozzles:

1. Internal Pressure (P = 2485 psig)

2. Isothermal (T= 653-F)

3. Heatup Ramp (2000 F/hr)

QAE17 REV 8196 M-DSC-3 60

HGIHAPT1 SRVICSlH ENGINEERING SERVIC:ES. INC.

,;~1 55s!

Made. b-.- ate: Client:

Calculation No.: AES-C-3247-1 Dcate: ClSCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer _d yft & AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 52 of 69

4. Cooldown with Stratification (Figure 5-2)

5. Plant load/unload (AT = +/- 200 F)

6. Reactor trip - loss of flow (Figure 5-3)

Appendb: A contains the stresses for each individual load case.

The stress combination for the fatigue stress ranges for the five transient conditions were developed from the load cases. The five plant transient conditions (Ref. 17) are listed below:

Pressure (psig)

Plant Condition N AT N/Month

1. Startup/Shutdown 500 2235 0 200F/hr 1.042

2. Plant Load Change 106 2485 2385 +200 F 2084

3. Reactor Trip 480 2535 1685 -600 F 1.0

4. Leak Test 200 2235 435 100 0 F/hr 0.417

5. H.ydro Test 10 3110 0 0 0.021 The stress summary for orna and %min for each transient is given in Appendix A. These stresses are used as input to the BIGIF computer program.

8.1.3 Allowable Flaw Depth Evaluation The evaluation of allowable flaw depth requires the solution of KY, and KY, or K1, in accordance with Eqs. 4-7 and 4-8. For determining the allowable flaw depth, the fracture toughness acceptance criteria require that K, < Kja 1/1 = 200/4i0 = 63.2 ksi in"' (8-1)

QAE17 REV 8196 M-DSC-3 60

MGAPTIN.

ENINEERING SERMICES. INC. M-56 US < O D. -50 Made b Date: Client:

Calculation No.: AES-C-3247-1 _ _ ___ 5/9/?b SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repairfor Pressurizer Sly " 1 9 g AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern Service Conditions - SONGS 2 and 3 0 1-2 53 of 69 for normal, upset, and test conditions, and K1 < KI, / -= 200/li = 141 ksi inm2 (8-2) for emergency and faulted conditions. Since seismic loading will have a negligible effect on stress at the flaw location, the limiting criteria for defining allowable flaw depth is Eq. 8-1.

The solution for KIfor the five plant transient conditions defined in Section 8.1.2 was determined with the ]3IGIF computer program. The semicircular corner crack flaw model (IFI = 303 moiel in Ref. 6) was used. A listing of the input file for BIGIF is given in Table 8-1 and the solution output is given in Appendix B. The highest K1 is computed for the hydro test condition. The -worst normal operating condition is the startup/shutdown transient, assuming that cooldown with fluid stratification occurs with every cycle. A plot of K1 versus flaw depth is given in Figure 8-2. The smallest allowable flaw depth is computed to be 2.59 inches (hydro test) or approximately 67% of the wall thickness.

8.1.4 Fatigue Evaluation An FCG analysis was performed to determine the final crack depth (a,) after 40 years of service.

The following conservative analysis assumptions were used:

1. Initial flaw depth equal to 1-inch is assumed to exist at the start of service for the repair.

2. The reference FCG curve with the highest R-ratio behavior is assumed.

The 40 year service cycles were divided into one-month block loading, as given in Section 8.1.'.

Therefore, 480 blocks equals 40 years of operation. The BIGIF input file is given in Table 8-1 and the fatigue life results are given in Appendix B. The final flaw depth when N = 480 is calculated to be 1.37 inches.

Therefore, af = 1.37 inches < aal,,w = 2.59 inches. Any flaws remaining in the nozzle stub will be acceptable to the ASME Section XI flaw evaluation rules.

QAE17 RIXV8/96 M-DSC-360

. .i. i . .

ENGINEEF(ING SERVIQES, INQ (A M-S-3 60 5 4 , 575 Madelky: Date: Client:

Calculation No. AES-C-3247-1 ________ 5/'89/ SCE Checked by: Dale: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer b t-y- I 1-t A-y jf c AES 97123247-lQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 54 of 69 8.2 Evaluation of Postulated Borated Water Corrosion The degradation due to possible BWC at the penetration bore surface was conservatively evaluated. It is postulated that the corrosion will be localized at the circumferential gap between the new nozzle and the old nozzle stub, and in the crevice under the nozzle-to-pad weld. This degradation is schematically shown in Figure 4-2 The potential failure mode for this damage mechanism will be nozzle blow out due to pressure and applied mechanical loads. The amount of metal loss that can be safely tolerated is determined for both limit load and fatigue failure modes that could initiate from the corrosion groove.

8.2.1 Allowable Corrosion Depth 8.2.1.1 Technical Approach The allowable corrosion depth in the region of the nozzle-to-pad attachment weld was computed from the equivalent cylinder model shown in Figure 4-4 and the limit load equations of Section 4.2.4. In the evaluation of the attachment weld integrity with BWC, the localized corrosion is projected to the minimum section and is conservatively modeled as a loss in load carrying area. A spreadsheet analysis was performed to solve the equations for allowable depths for a given circumferential length of corrosion damage. In this analysis, the following assumptions were made:

1. The design pressure was used for all transient pressure loads (P = 2485 psig).

2. The flow stress was computed for Alloy 690 material, which is less than the low alloy steel flow stress:

C(f = (SY +Su)/2

= (27.6 + 85)/2 = 56.3ksi

3. The seismic loads for OBE were used in conjunction with upset conditions. Seismic loads for DBE were used for accident conditions.

QAE17 REV 8196 M-DSC-3 60

WAPTiCHa ENGINEERIN3 SEVI(:ES. INC.

I'A- psC-360O MaCDate: Client:

Calculation No.: AES-C-3247-1 /__ 5/SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair forPressurizer S JT t tr S AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 55 of 69

4. Safety margins for normal/upset conditions will be limiting.

8.2.1.2 Maximum Limit on Depth It should be noted that the evaluation of BWC addresses only the integrity of the weld attachment of the nozzle. Loss of metal reinforcement around the hole penetration and the resulting impact to stress :requirements for pressure loading are not explicitly evaluated. To limit the depth of grooving based on limits on metal reinforcement, the rules of NB-3330 are applied.

It is initially proposed that an upper limit for corrosion depth be set at 0.5 inch and constant through the thickness. This corresponds to a corroded area equal to the wall thickness "t". This metal loss would be compensated by an excess metal reinforcement area at each penetration. For the 3/4-inch nozzles, the excess reinforcement areas are as follows:

Reinforcement / Metal Areas (in2) I Furnished Removed Excess Corroded Area Area I Area Limit I Ref.

V'ZR Upper Head 12.16 2.76 9.40 3.875 13, p. A43l PZR Bottom Head 12.09 2.94 9.15 3.875 13, p. A47 l SG Bottom Head 51.55 4.04 47.5 7.375 J14, p. A33 In all cases, the upper limit on corroded area is less than the excess area available for compensation.

For the 1-inch RTD nozzle, the excess reinforcement area from the original calculations is 2.2.4 in2 (Ref. 13, p. A32). This would allow the 0.5 inch depth limit to be valid for a part-thickness length of 2.24 inches or (2.24 / 4.815)t = 0.46t. However, the RTD nozzle is an isolated nozzle away from other penetrations. Applying the exemption rules of NB-3332.1, additional reinforcement is not required for a single penetration, provided that the hole diameter is less than 0.2 (Rt)19 per NB-3332.1(a). The minimum hole diameter satisfying this limit for the pressurizer shell is 0.2(Rt)" 2 = 0.2[0.5(53.0+48.125)(4.875)]112 = 3.14 inches QAE17 REV 8196 M-DSC-3 60

ENGIEERING SERM:ES. INC.5 51.d 5-7 lMade by: Date: SCient:

CMaculation Node /DbES-C-3247-1 y - SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer E- _ TCS I cbyS AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision NoD Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 56 of 69 Therefore, the maximum increase in radius of the existing RTD penetration is (3.14 - 1.325) / 2

= 0.91 inch. This value exceeds the maximum corrosion depth limit set at 0.5 inch.

The requirements of NB-3332.1(b) and (c) were also confirmed to be satisfied. Since there are no other penetrations near the RTD, NB-3332.1(b) is satisfied. The nearest discontinuity to the RTD is the lower head-to-shell weld. The distance to this region cannot be less than 2.5 (Rt)" if PL at the head-to-shell is greater than 1.1 Sm,:

2.5(Rt)1 1 2 = 2.5[0.5(53.0 + 48.125)(4.875) ]112 = 39.3 inches The distance to the head-to-shell tangent line is 107.31 - 78.06 - 1.325 /2 = 28.59 inches (Ref. 15).

A review of the stress summary results (Ref. 13, p. 10) indicates that the primary membrane stress at this location is 20.3 ksi, which is less than 1.1 SM = 1.1 (26.7) = 29.4 ksi. Therefore, NB-3332. 1(c) at this location is satisfied.

The next closest discontinuity region is the head-to-skirt attachment. The distance to this location is conservatively estimated from Ref. 15 to be 28.59 + R1 0, where 0 is the angle from the tangent line to the top of the support skirt shoulder. The angle 0 V20° from Ref. 15; hence, 28.59 + 48.4375(20/360) (2c) = 45.5 inches This distance exceeds the NBR3332.1(c) requirement of 2.5 (Rt)'S = 39.3 inches. Therefore, the RTD penetration satisfies the reinforcement exemption rules.

8.2.1.3 Calculated Results The spreadsheet evaluation is contained in Appendix C to this calculation. For the weld repair geometry, t -Minimum

= pad thickness = 0.4375 inch t, = Minimum weld throat = 0.13 inch

,2AE17 REV 8196 M-DSC-360

MRPTICH ENGINEERING SERVIC ES. INC. .s _

. . 56  %' _,;H -

Made b Date: Sient:

l Calculation No.: AES-C-3247-1 SCE Cli9 Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer t- 4ly BY? Sc AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 57 of 69 V = Minimum fillet leg length = 0.13 12 = 0.184 inch For the location at the axial gap between the original nozzle stub and the new nozzle, e = 11/16 inch = 0.6875 inch. The predicted corrosion depth at this location is 0.144 inch (Section :5.4.4). For a continuous 360° corrosion groove, the allowable depth exceeds 0.5 inch, from Table C-1. Therefore, the expected corrosion at the gap location wil be acceptable with regard to the integrity margins for the nozzle attachment weld.

At the crevice location, the predicted corrosion depth is 0.068 inch (Section 5.4.4). For a continuous 360° corrosion groove, the allowable depth is approximately 0.28 inch, from Table C-2.

Therefore, the expected corrosion at the crevice location will be acceptable with regard to the integrity margins for the nozzle attachment weld.

8.2.2 Fatigue Analysis An FCG evaluation is performed to determine that no significant flaw growth due to cyclic stresses will extend from any corrosion grooving. The FCG equation (Eq. 4-6) is approximated by the following relationship Aa = (Aa/AN)N (8-3) where AaIAN - da/dN given by Eqs. 5-3 and 5-4, and N is the total number of cycles. The following conservative assumptions are made:

1. Pressure, thermal, dead weight, and mechanical (seismic) loads are assumed to cycle together under OBE conditions. Therefore, N = 200 events times 40 cycles per event equals 8,000 total cycles in a 40-year service life.

2. The membrane and bending stresses are combined to give a uniform stress to be applied across the nozzle section.

3. The stress intensity factor for a continuous 3600 flaw will be used to define AK in the crack growth rate equation.

42AE17 REV8196 M-DSC-3 60

HWAPTWCH ENGWMEERN SACES. INC.

r'A-Q5C--160 51/21.

Made by: Date: Client:

Calculation No.: AES-C-3247-1 _____ 76/98 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer and Steam Generator Instrumentation Nozzles Under Long-Term Service Conditions - SONGS 2 and 3 J - T Revision No.:

0 0E no? g AES 97123247-IQ Document Control No.: Sheet No.:

1-2 58 of 69

4. The ratio of rjfw is conservatively assumed to be 10 (thin-wall cylinder).

8.2.2.1 Gap Region For uniform axial stress, the stress intensity factor solution for a continuous 3600 circumferential crack is given by (Ref. 16):

K = aF(ra)112 where d = 0.144 inch w = 1.14inches(TableC-1) oa = 0.16212 radians (TableC-1) a = 2d sin a = 2(0.144) sin (.16212)

= 0.0465 inch a/w = 0.0465/1.14 = 0.041 Al = [0.125(r 1/w) - 0.25]35 0

= [0.125(10) - 0.25]-25 = 1.0 F = 1.1 + A1 [1.948(a/w)'5 + 0.3342(a/w) 4 2 ]

= 1.1 + (1)[1.948 (0.041)1.5 +0.3342(0.041)42]

= 1.116 Aa = am,+b =0.568+9.84=10.41ksi(TableC-1) 0AE17 REV 8/96 M-DSC-3 60

MAPTIECHIV ENGINEE RING SERICES.

M fiA- 5C5-360 Made by: Date: Cl/ient:

Calculation No.: AES-C-3247-1 5 / <  !  ?/ _98G SCE

.Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer A d -r--r0..Ax CZ 2 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 59 of 69 Therefoie, AK is computed as AK = AOF(ira)" 2

= 10.41(1.116)[7T(0.0465)]1/2 = 44ksiin12 The crack growth rate from Eq. 5-3 is computed as da/dN = 1.20 x 10S- (4.44)-.95

= 8.53 x 10i8 inches/cycle The change in crack size (extension in depth of a corrosion groove) is ha = 8.53 x 104 (8000) = 0.00068inch Te value: of Aa = 0.0007 inch is not a significant increase in flaw depth due to fatigue and will not cause the predicted corrosion depths to exceed the allowable depths previously computed.

Therefore, the final estimated flaw depths due to the combined degradation of BWC and FCG will be acceptable to the safety margins of ASME Section X.

8.2.2.2 Crevice Region For the crevice region:

d = 0.068 inch w = 0.4746 inch (Table C - 2)

QAE17 REV 8196 M-DSC-3 60

1APTlCH ENGINEERING SERVICES. INC

%A -Ys- ;o Made by: Datc. Cient:

Calculation No.: AES-C-3247-1 /_ _ _ 5/8/98 SCE Checked by. Date: Project No.:

Title:

Evalu;3tion of Half-Nozzle Repair for Pressurizer 7tt-r-- V fc..y Ci e AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 60 of 69 a = 0.39811 radians (Table C-2) a = 2dsina = 2(0.068)sin(0.39811)

= 0.0527 inch a/w = 0.0527/0.4746 = 0.111 A1 = 1.0 F = 1.1 + A1 [1.948(a/w) 1 5 + 0.3342(a/w) 4 2 ]

= 1.1 + (1)[1.948 (0.111)1 5 + 0.3342 (0.111)4.2]

= 1.172 au = am+ab (TableC-2)

= 1.37 + 9.84 = 11.21 ksi Therefore, AK is computed as:

AK = ^ F(7a) 2

= 1121(1.172) [i (0.0527)]12

= 5.35 ksi in112 QAE17 RV8/96 M-DSC-3 60

APTiCH ENGINEERING SERIM ES. INC.

LA-IT' W_-

%A Ace ~ IA .

l tq, Z-Made b Date: Cient:

Calculation No.: AES-C-3247-1 _ A/8

_ _ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -4t - V - e E AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Rcvision No.: Document Control No.: Sheet No.:

Long-Term. Service Conditions - SONGS 2 and 3 0 1-2 61 of 69 The crack growth rate from Eq. 5-3 is computed as:

da/dN = 1.20 x 10-1 (5.35)5.95

= 2.59 x 10-7 inches/cycle The change in crack size (extension in depth of a corrosion groove) is Aa = 2.59 x 10-7 (8000) = 0.0021 inch The value of Aa = 0.002 inch is not a significant increase in flaw depth due to FCG and will not cause the predicted corrosion depths to exceed the allowable depths previously computed.

Therefore, the final estimated flaw depths due to the combined degradation of BWC and FCG will be acceptable to the safety margins of ASME Section XM.

8.3 Allowable Flaw Depth Limits for Inspection 8.3.1 Nozzle Stub Weld Region The allowable flaw depth for use as an inspection standard for flaw acceptance was computed from the previous results, given in Section 8.1. The allowable flaw depth at end-of-life is

.aOw = 2.59 inches. Conservatively subtracting from a.,,, the crack growth computed for 40-year service duty will give the allowable flaw depth for continued service to end-of-life. This value is obtained from the fatigue results in Appendix B, as determined below:

N = 1850 cycles a = 2.59 inches N = 1850-480 = 1370cycles a = 2.14inches Q2AE17 REV 8096 M-DSC-3 60

ENGINEERING SERVICES. I - PS C 3 a0 Made by: Date: eCient:

Calculation No.: AES-C-3247-1 6/980 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 1 t *, (i % AES 97123247-]Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern Service Conditions - SONGS 2 and 3 0 1-2 62 of 69 Therefore, a = 2.14 inches is the maximum allowable flaw depth for acceptance, given a 40-year service life.

The allowable flaw limits for inspection are summarized in Figure 8-3. Two flaw locations are shown. Location A is for an axial flaw contained within the nozzle. For this case, a through-thickness flaw is acceptable because it does not impact the structural integrity of the nozzle repair or the head/shell (flaw at Location B is bounding for all nozzle flaws penetrating into the head/shell). Location B isfor a flaw propagating into the original J-groove weld. For this flaw location, the allowable flaw depth is 2.14 inches, as computed above.

8.3.2 Corrosion Degradation of Hole Penetrations The allowvable corrosion sizes (depth and length) for use in in-service inspection for BWC were determined from the calculations given in Section 8.2 and Appendix C. The allowable corrosion depths at end-of-service are summarized in Tables C-1 and C-2. In establishing the allowable inspection standards, FCG was determined to be insignificant. In addition, the upper cut-off limit of 0.50 inch for local corrosion depth was imposed to restrict the maximum size of corrosion, as previously established.

The resulting acceptance values are given in Figure 84 as a function of axial position (e) and circumferential angle (0). Intermediate values for axial position between e = 0 and e = 0.6 inch were conservatively determined by linear interpretation.

QAE17 RPJ 8196 M-DSC-3 60

ENGINEERING SERVICES. INC.

A1~

M_05 $fh 6&

Made by: Date: Client:

Calculation :Nio.: AES-C-3247-1 / . S/ 8 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -t 3 nA a AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 63 of 69 Table 8-1 BIGIF INPUT FILE FOR NOZZLE HOLE PENETRATION FLAW PZR INSTRUMENT NOZZLE CORNER FLMW EVALUATION - SONGS UNIT 2 & 3 1 05 303 1 0 2 1 3 0 20 1.00 3.875 80.0 0.65 3 1.000 1.20 E-11 12.04 3.23 E-05 100. 2.01 E-03 STARTUP/SHUTD OWN 1.042 1.0 0 5 0 0 5 3 0.0 0.0 53.83 0.0 1.478 415.71 0.0 3.875 220.12 0.0576 0.0 417.74 0.0576 1.478 410.16 0.0576 3.875 3.6.58 0.4983 0.0 I 13.20 0.4983 1.478 226.44 0.4983 3.875 2.4.47 1.0407 0.0 229.40 1.0407 1.478 222.29 1.0407 3.875 2.2.65 4.12 0.0 227.08 4.12 1.478 2.9.19 4.12 3.875 2.3.87 0.0 3 0 0 0 0 0 PLANT LOAD/UNLOAD 2084.

1.0 0 5 0 O 5 3 0.0 0.0 3 8.62 0.0 1.478 338.16 0.0 3.675 2 9.31 0.0576 0.0 334.29 0.0576 1.478 3.3.83 0.0576 3.875 2 7.68 0.4983 0.0 2 3.93 0.4983 1.478 2 3.57 0.4983 3.875 2 3.01 1.0407 0.0 2 1.06 1.0407 1.478 2 0.70 1.0407 3.875 2 1.09 4.12 0.0 1 9.30 4.12 1.478 1 8.76 4.12 3.875 1 8.06 1.0 1 5 0 0 5 3 0.0 0.0 3 2.62 0.0 1.478 3 4.18 0.0 3.875 2 9.65 QAE17 REV 8/96 M-DSC-3 60

ENGINEEBJNG SERVK ES. INC Ml Q$C- 1o $H14. 6c6 Made by: Date: aient:

Calculation No.: AES-C-3247-1 AZ. 9 811 98 SCE Checked by: Date: Project No.:

{

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 1q rn 0, - ° AES 97123247-IQ and Steamn Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1 -2 64 of 69 0.0576 0.0 28.98 0.0576 1.478 30.45 0.0576 3.875 27.97 0.4983 0.0 20.27 0.4983 1.478 21.85 0.4983 3.875 23.30 1.0407 0.0 17.72 1.0407 1.478 19.57 1.0407 3.875 21.42 4.12 0.0 15.95 4.12 1.478 17.97 4.12 3.875 18.22 REACTOR TRIP 1.0 1.0 0 S 0 0 5 3 0.0 0.0 51.30 0.0 1.478 46.94 0.0 3.875 30.56 0.0576 0.0 45.45 0.0576 1.478 41.22 0.0576 3.875 28.84 0.4983 0.0 31.6D 0.4983 1.478 27.20 0.4983 3.875 23.88 1.0407 0.0 28.13 1.0407 1.478 23.22 1.0407 3.875 21.85 4.12 0.0 26.29 4.12 1.478 20.91 4.12 3.875 19.44 1.0 2 5 0 0 5 3 0.0 0.0 24.29 0.0 1.478 26.37 0.0 3.875 24.96 0.0576 0.0 21.59 0.0576 1.478 23.49 0.0576 3.875 23.70 0.4983 0.0 15.10 0.4983 1.478 16.87 0.4983 3.875 20.00 1.0407 0.0 13.23 1.0407 1.478 15.11 1.0407 3.875 18.46 4.12 0.0 12.07 4.12 1.478 14.02 4.12 3.875 14.94 PLANT LEAK TES2 0.417 1.0 , 0 5 0 0 5 3 0.0 0.0 42.64 0.0 1.478 39.84 0.0 3.875 25.58 0.0576 0.0 37.85 0.0576 1.478 35.23 0.0576 3.875 23.86 QAE17 REY 816 M-DSC-360

ERGPTEWHI ENGINEERING SERVI1:ES, INC.

M-1)5c-360G $4.- &&

Made by; Date: Client:

Calculation No.: AES-C-3247-l 4Zle- .16/f6 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer '7-g-rTr V t-& - C? - AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 65 of 69 0.4983 0.0 26.38 0.4983 1.4 78 24.20 0.4983 3.8 75 19.25 1.0407 0.0 23.22 1.0407 1.4'78 21.06 1.0407 3.8' 75 17.51 4.12 0.0 21.12 4.12 1.4' 78 18.86 4.12 3.8' 75 17.03 1.0 2 5 0 0 5 3 0.0 0.0 3.410 0.0 1.4' 78 5.759 0.0 3.8' 75 9.638 0.0576 0.0 3.042 0.0576 1.4' 78 5.185 0.0576 3.8'75 9.426 0.4983 0.0 2.154 0.4983 1.4' 78 3.955 0.4983. 3.8'75 8.476 1.0407 0.0 1.896 1.0407 1.4' 78 3.673 1.0407 3.8'75 7.910 4.12 0.0 1.939 4.12 1.4' i8 3.559 4.12 3.8. 75 4.553 HYDROTEST 0.021 1.0 0 5 0 0 5 3 0.0 0.0 57.33 0.0 1.4' 78 52.67 0.0 3. 8 75 31.29 0.0576 0.0 50.90 0.0576 1.4'7Is 46.70 0.0576 3.6': 75 28.37 0.4983 0.0 35.49 0.4983 1.41 F8 32.60 0.4983 3.8'i15 21.47 1.0407 0.0 30.99 1.0407 1.47Fe 28.70 1.0407 3. 8 F5 19.41 4.12 0.0 27.03 4.12 1.47A re 26.04 4.12 3.87r5 24.65 0.0 3 0 0 0 0 0 FISIS QAE17 WYV 8/96 M-DSC-3 60

ENGINEERING SERVICES. INC.

. _ ____r KA - D - -

3&0 cu.

. IV r--7 IC I Made by: Date: Client:

Calculation No.: AES-C-3247-1 /_____ s- Y6 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -1.d-r-T '  : ' AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions-SONGS 2 and3 -- 0 1-2 66 of 6' II -a 4

--r t,

a Figure 8 Hole Penetration Flaw Model.

QAE17 FEV816 M-DSC-3 60

E'GINEERUNO SERVICES. IN;

&X-195 (I- "6O Made by. Date: Client:

Calculation No.: AES-C-3247-1 _____ S/I 908 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer by - ey Jf i AES 97123247-KC) and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Terrn Service Conditions - SONGS 2 and 3 . 0 1-2 67 of 69 100 90 80

. 0 Lr-60 L.:

50 C,,

L-) 40

'U, at, 30 U-,

20 10 0

0.0 0.5 1.0 1.5 2.0 2.5 3.0 Crack Depth, a (inches)

Figure 8 Stress Intensity Factor Versus Flaw Depth for Comner Flaw.

QAE17 REV 8196 M-DSC-3 60

aHP1ECH [

ENONEERING SERAIC:S IN(O.

0,. g7

.-- Made by Datc: / Clicnt:

Calculation No.: AES-C-3247-1 D ae 8/AS SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer p t , 9nS AES 97123247-lQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 68 of 6S-Location Description Allowable Size (inch)

A Axial Nozzle Flaw a=t B Base Metal Flaw (at Corner) a = 2.14 Figure 8-3 - Inspection Acceptance Standards for Nozzle Flaws in Stub J-Groove Regio;m.

QAE17 R1EV8/96 M-DSC-3 60

MAPTIECH7 ENGINERING SERVIES. INC.

I . - (ct., IJ " 7(7 Made by: Date: Client:

Calculation No.: AES-C-3247-1 Dale: SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer O A ,- -T,.- AES 97123247-I Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Ternt Service Conditions - SONGS 2 and 3 0 1-2 69 of 69 Allowable BWC Depth, d (inch) e Circumferential Extent (inch) 20% l 40% 60% 80% l 100%

0.0 0.50 0.50 0.44 0.42 0.42 0.2 0.50 0.50 0.46 0.44 0.44 0.4 0.50 0.50 0.48 0.47 0.47

>0.6 0.50 0.50 0.50 0.50 0.50 Figure 8-4 - Inspection Acceptance Standards for BWC Flaws.

QAE17 RIWV 8196 M-DSC-360

E APTIN DS ENGINEERING SERVI MS. WNC

" - QS C-'4,& 58 -7 Made b Date: Client:

Calculation No.: AS-C-3247-1 - Da/te:/. lSCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer f4. -j- . g' t ' ? 6 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 A-1 of A-9 Appendix A

SUMMARY

OF HOLE PENETRATION HOOP STRESSES CAE17 REI/ 8196 M-DSC-3 60

IEIRPTSN MI~NEERING SERVI::ES, INC-M- V no . SH - -t Made by: Date:' Client:

Calculation No.: AES-C-3247-1 _____ S_______ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer  ; - ¢-YW 3 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern. Service Conditions - SONGS 2 and 3 0 1-2 A-2 of A.9 Appendix A

SUMMARY

OF HOLE PENETRATION HOOP STRESSES A.1 ANALYSIS GEOMETRY The stress results from the finite element analysis of the pressurizer bottom head (Ref. 4) were used to define the hoop stresses for the evaluation of a postulated flaw in the hole penetration.

The finite element model geometry is shown in Figure A-1. The node numbers shown in Figure A-1 were used to define the stress input points for BIGIF (Ref. 6). The hoop stress values for the selected nodes are summarized in Table A-1.

The r -0 coordinate points for the inside surface nodes were used to define a rectangular grid in x - y coordinates for input to BIGIF. Node 454 is located at the corner and is assigned the x - y coordinate of (0, 0). The three y coordinates for the grid are defined from the radial positions of Nodes 454,482, and 298 relative to Node 454. The five x coordinates are defined from the arc:

distances between the nodes along the inside surface where x = R, AO:

Node o (degreeso AO (radians) x (inches) 454 89.36597 ... 0 453 89.29781 1.1896 x 10' 0.0576 560 88.77654 1.0287x 10-i 0.4983 555 88.13498 2.1485 x 10-' 1.0407 951 84.49266 8.5055 x 103 4.1200 CIAE1 7 REV 8196 M-DSC-3 60

m P1pECHI ENGINEERING SERV:CE&. INC.

tM-P*54- $ Go 5 4. 7h Made by: Date: Client:

Calculation No.: ASS-C-3247-1 ________9____ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer ASK-- rT.. V A-V ? AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: SheetNo.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 A-3 of A-9 A.2 STRESS COMBINATIONS The stress values for maximum and minimum values for each plant transient were determined from appropriate combinations of stresses from the individual loading cases of Table A-1. The following scaling factors were used:

Iso-T l Ramp Cooldown Step Trip Trip I Plant Transient Stress P T=6530 F 2000 Fihr w/strat AT=200 F = (t=20tl1)_

Startup/Shutdown ax 0.90 0.0 0.0 1.0 0.0 0.0 0.0 aria 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Load/Unload max 0.90 1.0 0.0 0.0 0.0 0.0 0.0 a 0.859 1.0 0.0 0.0 1.0 0.0 0.0 Reactor Trip C,= 1.02 0.0 0.0 0.0 0.0 1.0 0.0 o, 0.678 0.0 0.0 0.0 0.0 0.0 1.0 Leak Test 0.90 0.613 -0.5 0.0 0.0 0.0 0.0

°m,.,0.175 0.613 +0.5 0.0 0.0 0.0 0.0 Hydr est ax 1.25 0.0 0.0 0.0 0.0 0.0 0.0

° 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Table A-2 provides the stress values for a,,. and Oa,, and ha for each transient condition. As noted in Table A-1, the pressure stress was increased by 20% over and above the values listed in Column I of Table A-1 to account for elevated hoop stress in the cylindrical shell portion of the pressurizer where the 1-inch temperature nozzle is located. Also the pressure acting on the crack face was added to the pressure stress term. As an example, the hoop stress for operating pressure for use in BIGIF is (1.2) (0.9) times the stress values in Column 1 of Table A-1 plus the operating pressure of 2235 psi:

ae = (1.2) (0-9) [PJoadCe] + 2235 CAE1I7 REV 8196 M-DSC-3 60

APTECHI ENGiNEERING SERVICIES. INC.

M4-0[ -3(60 .5 Wt Mad by: Date:Cle S Calculation No.: AES-C-3247-1 Ma8/ Date SCE Cli Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizcr q ,i-f.y_ 's - AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 A4 of A-x This formula was consistently applied to all pressure stress terms contributing to Omnaj and am.n.

Thermal stress cases were combined with pressure to obtain the absolute maximum stress range possible for the transient.

QAE17 REVf 8196 M-DSC-3 60

I1iECHI eMG\NEERING SERV'ICES. INC.

M - D5 c- -69 -5A -715 Made Date: aCient:

Calculation. No.: AES-C-3247-1 MC S E8/

Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -trz S t Fro AES 97123247-lQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tenn Service Conditions - SONGS 2 and 3 0 1-2 A-5 of ik-9 TABLE A-1 STRESS LOAD CASES FOR NOZZLE PENETRATION Plant Load Heatup Cooldown Change Reactor Reactor Pressure Isothermal 200FtHr w/Strat AT-2OF Trip Trip 2485 psig T=653F t=3600s t=6264s t=60s t=50s t=2000s NODE (psi) (psi) (psi) (psi) (psi) (psi) 454 36150 -2636 -6007 125B0 -4150 4516 -6806 482 33040 265 -3558 7811 -2285 3962 -2201 289/550". 18790 6790 2194 -2397 1350 5021 7983 453 31860 -2336 -5310 11120 -3663 3914 -6022 481 29060 228 -2988 6560 -1878 3110 -1840 28M549" 16840 7268 2004 -1830 1208 5687 8310 560 21590 -1610 -3660 76t3I -2512 2634 -4149 644 19660F 113 -1359 29821 -667 594 -815 32818481 12240 7567 1669 -972 978 6358 8352 555 18590 -12401 -33681 7100 -2338 2841 -3579 639 17060 501 -7531 16471 -204 -197 -454 323i843 10870 7127 1652 -1118 953 6004 7931 951 15950 -147 -3512 76321 -2481 4230 -2593 1231 15290 27 -208 4561 411 -342 -107 1951 1A3601 328 _ 1801 -3860 947 -677 1569

'Pressure stresses will be mu[ ilied b 'Factor' to account for inc rease in hoop stress for cylindrical shell. Factor 1.21 I (Also, crack face pressure was added to pressure stress) _ _

"Next node below outer node was used to define stress when sharp gradient at pad/shell interface affected the value at outer node. _ i

__ I _ I

_ __ I _ I __ __

__ __ __ __ I __ __ __

QAE17 REV 8196 M-DSC-360

EN ENPTI N SC.r ENGINEERING SERVltES. INQ

&A-05Cv3(o6 $A. 7&

Made by: Date: Client:

Calculation :No.: AES-C-3247-1 S/_8/__ _ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer - -j . 'a 4tl,6 ( AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 A-6 of A-9 TARLF A-2 STRFS_

SUMMARY

_PSfl FOR N0ZLE PNETRATION

1) STARTUPiSHUTDOWN (w STRATIFICATION)

X Y SIG MAX SIG-MIN DEL.SIG 0 0 53831 0 53831 0 1.478 45705 0 45705 0 3.875 2D118 0 20118 0.0576 0 47741 0 47741 0.0576 1.478 40159 0 40159

_0.0576 3.875 18580 0 18580 0.4983 0 33200 0 33200 0.4983 1.478 26438 0 26436 0.4983 3.875 14473 0 14473 1.0407 0 29399 0 29399 1.0407 1.478 22294 0 22294 1.0407 3.875 12849 0 12849 4.12 0 270B1 0 27081 4.12 1.478 19193 0 191931 4.12 3.875 13873 0 13873

2) PLANT LOADINGIUNLOADING .

X Y SIG MAX SIGMIN DELSIG O O 38616 32619 5996 0 1.478 38159 34179 3980 _

0 3.875 29305 29647 -343 0.0576 0 34285 28983 5302 0.0576 1.4781 33827 30445 3381 0.0576 3.8751 27678 27973 -295 0.4983 0 23927 20272 3655 0.4983 1.478 23567 21850 1716 0.4983 3.875 23012 23299 -287 1.0407 0 21059 17723 3336 1.0407 1.478 20697 19570 1128 1.0407 3.875 21094 21422 -328 4.12 0 19302 15851 3351 4.12 1.478 18764 17967 797 4.12 3.875 18061 18215 -154

- - _ ._I QAE17 REV 8196 M-DSC-360

EgfiAPT S EtNGINEM:RNG SER>IIES. tWO sA - 056 -q7420 -- 4, -7 7 Madc bv: Date: Client:

Calculation No.: AES-C-3247-1 / Da e:// SCE Checked by: Date: Project No.:

Title:

Evaliation of Half-Nozzle Repair for Pressurizer 1-t. jce- y q-3 AES 97123247-1q and Steam Generator Instrumentation Nozzles Under . Revision No.: Document Control No.: Sheet No.:

Long-Ternt Service Conditions - SONGS 2 and 3 0 1-2 A-7 of A-9 TABLE A-2 STRESS

SUMMARY

(PSI) FOR NOZZLE PENETRATION (Contd)

3) REACTOR TRIP X Y SIGMAX SIGMIN DELSIG

_ 0 51304 24294 27010 o 1.478 46943 26368 20575 0 3.875 30558 24957 5601 0.0576 0 45450 21587 23863 0.0576 1.478 41219 23491 17728 0.0576 3.875 28837 23697 51391 0.4983 0 31598 15103 164951 0.4983 1.4781 27196 16S67 -1032 0.4983 3.875 23877 19996 38801

. 1.0407 0 25133 13232 149011 1.0407 1.478 23222 15112 8109 l

_ 1.0407 3.875 21845 18461 33851 4.12 0 26290] 12070 142201 4.12 1.478 209101 14019 6891 l 4.12 3.875 194371 14938 44986

4) PLANT LEAK TEST X Y SIGMAX SIGMIN DELSIG _

o o 42640 3410 30229 0 1.478 39836 5759 34077 0 3.875 25577 9538 15939 0.0576 0 37845 3042 34803 _

0.0576 1.478 35232 5185 30047 0.0576 3.875 23860 9426 144341 0.4983 0 26380 2154 24226 0.4953 1.478 24202 3955 20248 0.4983 3.875 19246 8476 10770 1.0407 0 23223 1896 21327 _

1.0407 1.478 21055 3673 17382 1.0407 3.875 17506 7910 9596 _

4.121 0 21115 1939 19176l 4.12 1.478 18858 3559 15298l 4.12 3.875 17034 4553 12481 1 C!AE17 REW 8196 M-DSC-3 60

MAPTIfCH ENGINEERING SERVIES. INC.

r L4A -r4- 3 6t ~4,. i1A

_.Madeb: Da[e. Client:

Calculation No.: AES-C-3247-1 5/8/_9 ____________ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer .0 41 _ 9 AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 A-8 of A-9 TABLE A-2 STRESS

SUMMARY

(PSI) FOR NOZZLE PENETRATION (Contd)

5) HYDRO TEST X Y SIGMAX SIGMIN DEL SIG

° 0 57331 0 57331

. 0 1.478 52656 0 52666 O

_ 3.875 31291 0 31291

. 0.0576 0 50896 0 50896 0.0576 1.478 46696 0 466961 0.0576 3.875 28366 0 283661 0.4983 0 35491 01 354911 0.4983 1.478 32596 0 325961 0.4933 3.875 21466 0 21466 1.0407 0 30991 0 30991 1.0407 1.478 28696 0 28696 1.0407 3.875 19411 0 194111 4.12 :___0 27031 01 270311 4.12 1.478 26041 0 260411

_ 4.12 3.875 24646 0l 246461 I I_ _ __ _ _

CQAE17 REV 8/96 M-DSC-360

MAPTUCH7 ENGINEERING SERYIES. INC.

A- 15C6- 1360  ; it.

Made b y Date: Cl/ient:

Calculation No.: AES-C-3247-1 Date:Ci8e8 sc Checked by. Date: Project No.:

Title:

EvaluationofHalf-NozzleRepairforPressurizer - .. - tIA-y W?to AES 97123247-IQ and Stearn Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 A-9 of A-9 Figure A Finite Element Model and Node Positions for Stresses.

CAE17 RMt 8196 M-DSC-360

fiNGEITt33IS ENGINEERING SEI'MCS INC.

I-V19C- 360 5A-Madc by: Date: Client Calculation No.: AES-C-3247-1 /CCL. A09 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer V "004-ffs AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 B-1 of B-5s Appendix B COMPUTER OUTPUT FROM BIGIF CIAE17 REV 8/96 M-DSC-3 60

EIAPTE R ENGINEERING SERVCES. INC.

M-9056- 3'o 5N-. gi Mad b Date: Client:

Calculation No.: AES-C-3247-1 C_8__ SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer '7 1 IES B3 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Terra Service Conditions - SONGS 2 and 3 0 1-2 B-2 of B-9 PZR INSTRUMKNT NOZZLE CORNER rLAW xVALA.TiOH - SONGSUNIT 2 £3 01(:Xr: SOUNDARYINTEGRAL EQUATION IBM PC VERSION REV. 0 - SEPSZIZR 23, iNSS GENERATED INFLUENCE FUNCTIONS rOR USE IN rRACSURE sMCHANICS PROBLEMS ANALYSIS SELECTION (IFAT) 1 TATIGUE ANALYSIS CRACK GECOKTRY HODEL INDEX NN.IER (Irx) 303 SURrACX 1/4 CIRCULAR CRACK VAAIADXX 7TRCOWSS SPECIFICATION (NT) 0 CONSTANT BODYT5ICKNESS CRACX GROR(T$RATE 3ULE (IDADSN) 2 INPUT TA5LN DA/DW, DELTA-K DATA TNTECRATION INCRz)ENT SCNEtE MM) 3 REFINED SINGLE OR HUCS INTEGRATION $CNEHMS(INCL) o 31100LE fNCREMENTS USED T5 DOBLE CRACICSIZE (NDOU)

VS£R SPECIFIED NDVB - 20 GEOMETRYAND :4ATERIAL PZR INSTRIEHNT NOZZLE CORNER LA EVALUATION - SONCS UNIT 2 1 3 CRACK G201TH INPUT NUtSER OF DMI:ES Or 1RerDO - I INITIAL A-VALUES rOR EACH DEGREE or FREEDOM CRACIC LENGTH AISt) - 1.0000 GEOMETRY FACTORS G(1) 3.0750 DOD WIDSTH C (2) .00000 0(3) .00000 C(4) .00000 a(S) .00000 0(6) .00000 X-COORD. TO CRACK CENTER CXCX G(7) .00000 Y-COORD. TO CRACK CENSER CYC) 0(S) .00000 CRACK ORIENTATION ANGLE (PHI, DEGREES)

DA/DN OPTION SELECTED: 2 XIC - 50.000 TRACTSUE TOUGHNESS THERE ARK $ITS or INPVT DATA FOR I P.-RATIOS R-RATXO - .SS000 3 POINTS INPUT DELTA-X AON 1.0000 1.20000£-11 12.040 3.23000E-05 100.00 2.01000E-03 QAE17 REX' 8196 M-DSC-3 60

SEAPTCCHKI ENGINEERIN3 SERVPEES. INC. M-3 G.oeO) 7'9 r.

Made by.

I w v-Date-

__ - -s Client:

Calculation No.: AES-C-3247-1 M d / De SCE Checded by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer - f -- 0/ 7'- S3 AES 97123247-1 Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Ternm Service Conditions - SONGS 2 and 3 0 I-2 B-3 of B-9 LOAD SRANS18NhSt s 7TAM4SrH1(S) IN rROBLIAH PlR 11ST211T NOZSLL CORHER FLAW EVALSOAIN - 8ONS MINY 2 e hiXR or CYCLS PER DLOCK PUEIR SPECIFIER AOGD XPSRD tLD KAMC IWO NPX NPY I 5TARTV/S3OOWOA 1.0420 1 1.0000 0 5 0 0 a 3 SIVARMAEr STR£SS TABLE X Y SIQOAIX,YI

.000O0 .00coo 53.030

.00000 1.4780 4S.710

.00000 3.1750 20.120 5.760001-02 .00000 47.740 5.7600OZ-02 1.47S0 40.160 3.76000E-02 3.0750 19.590

.40930 .00000 33.200

.49930 1.4780 26.440

.49830 3.87S0 14.470 1.0407 .00000 29.400 1.0407 1.4700 22.2P0 1.0407 3.87S0 12.O50 4.1200 .00000 27.080 4.1200 1.4780 19.190 4.1200 3.9730 13.070 SS£ DABA Fl.OIT SE51NAB FlEW KJ2 DEC" P"D COP.CELY 2 .00000 3 0 0 0 0 0 2 FLUNT Zo0AOD/VNLOAD 2084.0 1 1.0000 0 5 0 0 S 3 BIVARLAT STRXESS TABLE X Y SI4XAIX.T)

.00000 .00000 30.620

.00000 1.4700 30.160

.00000 3.9750 29.310 5.76000r-02 .00900 34.200 S.76000E-02 1.4700 33.830 S.76000t-02 .3.0750 27.690

.49630 .00000 23.§30

.19s30 1.4700 23.570

.49S30 3.9750 23.010 1.0407 .00000 2L.060 1.0407 1.4700 2D.700 1.0407 3.8750 2L.090 4.1200 .00000 19.300 4.1200 1.4700 l1.760 4.1200 3.0750 18.060 SRE OATS FOR THE STRrs FILD H SEEN READ CORRECTLY 2 1.0000 1 S 0 0 5 3 RIVARIA7E 1SY9SS TABLt

.00000 .00000 32.620

.00000 1.47E0 34.1S0

.00000 3.8750 29.6s0 S.74000r-02 .00000 *6.060 5.760001-02 2.4780 30.450 5.760001-02 3.E7s0 27.970

.40930 .00000 20.270

.48930 1.4780 21.Eso

.49930 3.s750 23.300 1.0407 .00000 17.720 1.0407 1.4790 19.570 1.0407 3.S750 21.420 4.1200 .00000 15.950 4.1200 L.A7M0 17.070 4.1200 3.9750 20.220 THE DATA FOR THE SSRXS FIEL IAS OZl RAD CONARRCTY QAE17 RE' 8/96 M-DSC-3 60

ENGINEERING SERMVC ES. ING. fJ-056- 3 0o 4- 9B

-l .I _ - - '-* S 11 - U Made by Date: Client:

Calculation Ngo.: AES-C-3247-1 ec 6'/9'8 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 1 "OHY ? -, AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 B-4 of B-9 3 REACTOR TRIP 1.0000 1 1.0000 0 6 0 0 S 3 SIVARAIATZ S37SS TADLE X 1 SIGHNIXY)

.00000 .00000 51.300

.00000 1.4780 46.940

.00000 3.0750 30.560 6.76DOOE-02 .000O0 43.450 5.76DOO-02 1.4780 41.220 5.76$oDo-02 3.8750 28.640

.49830 .000 0 St.600

.49830 1.4780 27.200

.49830 3.8730 23.380 1.0407 .00000 28.130 1.0407 1.4730 23.220 1.0407 3.8750 21.850 4.2200 .00000 24.290 4.1200 1.4780 20.920 4.1200 3.8750 19.440 THE DATA F010 TSE STRESS FIELD SAS NEE READ CORRECTLY 2 1.000O 2 5 0 0 5 3 USVARLUAE STRESS TABLE X I SSCK(X,2Y

.00000 .00090 24.290

.00000 2.4760 26.370

.00000 3.s750 24.960 5.76000E-02 .00000 21.590 5.760001-02 1.4780 23.400 3.760001-02 3.0750 23.700

.49330 .00000 15.100

.49830 1.4700 16.670

.49830 3.0750 20.000 1.0407 .00000 13.230 1.0407 1.4780 15.110 1.0407 3.8750 10.460 4.1200 .00000 12.070 4.1200 1.4700 14.020 4.1200 3.6750 14.940 TES DASA FO;. TaE sr55ss ruELD mS 1tre READ cowEcTLY 4 PLANT XA TEST .41700 1 1.0000 0 5 0 0 s 3 RIVAPEATX STRESS TABLE X r SGNAMXIT)

.00000 .00000 62.640

.00000 1.4760 39.640

.00000 3.8750 25.580 5.740001-02 .00000 37.SO S.740001-02 1.4780 35.230 5.76000E-02 3.8750 23.060

.49830 .00000 26.380

.49830 1.4780 24.200

.49630 3.8750 19.250 1.0407 .00000 23.220 1.0407 1.47e0 21.060 1.0407 3.07SO 17.510 4.1200 .00000 21.120 4..200 1.4700 16.860 4.1200 3.8750 17.030 THE VATA SOR THESTRESS MELD HAS BEEN READ CORPECTLY 2 1.0000 2 S 0 0 5 3 CAE17 REV 8196 M-DSC-3 60

ENGINEERING SERVICES. INC.

~M Q0 1C -34O Made by: Date: Client:

Calculation No.: AES-C-3247-1 ______5_/Y/ , SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 7-?-rt-- 1 " -'Y TS AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Terra Service Conditions - SONGS 2 and 3 0 1-2 B-5 of B139 BIVARTArE 87RESS TA1LC X Y SIG(AXI) 00000 .00000 3 4100 000o00 i.4700 5.7590

.00000 3.6750 9.63e0 5.7600e-0:: .00000 3.0420 5.76000c-0o: 1.4720 5.190 S.760009-O:: 3.8750 I.4260

.49830 .00000 2.1540

.4930 1.4700 3.9550

.49e30 3.8750 9.4760 1.0407 .00000 0.8960 1.0407 1.47S0 3.6730 1.0407 3.8730 7.9100 4.1200 .00000 1.9390 4.1200 1.4780 3.5390 4.1200 3.8730 4.3330 r3r DATA VCR SHE SYR=15 FIELD aAH BZEN READ CORRECTLY I ZIDROTIST 2.100001-02 1 1.0000 0 3 0 0 5 3 BIVJAATIS SSRESS 1DLE x Y 61014A(X,

.00000 .00000 57.330

.00000 1. 780 32.670

.00000 3.87S0 31.290 5.76000E-02 .00000 so.900 5.76000E-02 1.4780 46.700 5.76OO0E-02 3.0750 28.370

.49830 .00000 35.490

.49830 1.4780 32.600

.49830 3.0750 21.470 1.0407 .00000 30.990 1.0407 1.4780 20.700 1.0407 3.8750 19.420 4.1200 .00000 27.030 4.1200 1.4700 26.040 4.1200 3.8750 24.650 TRE DA-7AFOR THE STRESS FIELD RAS SESN READ CORRECSLY 2 .00000 3 0 0 0 0 0 DTAITLED 01T72 5SFO ALL LOAD 171SIrrT1SJ AND CRACK DECREEtS1 OF 18EEDOH

..... O......

SNfl:OTxcN .P-R xrrD - PFR 2027RDNW NOZZLE COR8R FLAW IVALVA.TXON - ON= VXT? 2 S 3 7RW3091NT 0or 7aANSIErT EOREE OF CYCLES DA/DH DA/DX CRACK 0F110R F 0EEDO /JDOCK KIQ mIn K4A2 DCL-K R-RXT 411R CYCLE) 191R BLOCK) SIZE 1 1 1.042 44.03 .00 22.03 44.05 .000 4.051E-0 7.08SE-04 1.00 .0000 2 1 2084. 33.65 29.24 31.44 4.41 .89 8.1l4961E-0 3 1 1.000 42.97 20.90 31.93 22.07 .486 1.053sE-04 4 1 .4170 36.31 32.46 34.40 3.83 .894 3.3522E-08 5 1 2.1000E-02 48.71 .00 24.36 48.71 .600 4.9396E-04 1 1 1.042 44.36 .00 22.19 44.38 .000 4.1177E-04 7.1951-04 1.04 2 1 2084. 33.90 29.S6 31.77 4.42 .870 8.261SE-08 3 1 1.000 43.33 21.00 32.16 22.32 .485 1.0774Z-04 4 1 .4170 36.64 32.74 34.69 3.90 .893 3.9676E-08 5 2 2.1000Z-02 49.15 .00 24.sa 49.1S .000 S.0260E-04 1 1 1.042 44.70 .00 22.35 44.70 .000 4.1769E-04 7.304E-04 1.07 99.75 2 1 2084. 34.32 29.90 32.11 4.42 .071 8.3S94E-08 3 1 1.000 43.69 21.10 32.40 22.38 .483 1.1022E-04 4 1 .4170 36.98 33.00 34.99 3.98 .e92 4.440&E-08 5 1 2.1000Z-02 49.60 .00 24.80 46.60 .000 5.1161z-04 QAE17 REV 8196 M-DSC-3 60

E4MAPT11K.NKRW ENGINEMfNGa SERVIES. INC.

A - 95"'

Made by: Date: Caient:

Calculation No.: AES-C-3247-1 _O__ -, -S2-/968 l SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer r'IL.- V s.,i c 'IO AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 1-2 B-6 of B-9 1 1 1.042 45.08 .0o 22.53 45.09 .000 4.2456t-04 7.436E-04 1.11 151.0 2 1 2084. 34.70 30.27 32.48 4.44 .872 8.5049t-o0 3 1 1.000 44.10 22.23 32.67 22.00 .481 1.1301Z-04 4 1 .4170 37.35 33.29 35.32 4.06 .881 5.0069s-08 5 1 2.1000E-02 50.10 .00 25.05 50.10 .000 5.2177Z-04 1 1.042 45.44 .00 22.72 45.44 .000 4.3134t-04 7.562E-04 1.15 203.2 1

2 1 20B4. 35.09 30.44 32.e6 4.45 .873 8.62361t-0 3 1 1.000 44.51 22.34 32.93 23.17 .479 1.1586X-04 1 .4170 37.73 33.58 35.66 4.14 .890 3.6522r-08 a

5 1 2.1000E-02 80.60 .00 28.30 50.60 .000 3.32021-04 1 1.042 48.81 .00 22.91 48.81 .000 4.381SX-04 7.685z-04 1.19 256.3 1

2 1 2084. 3S.48 31.02 33.25 4.46 .874 8.7179r-00 3 1 1.000 44.92 21.45 33.19 23.47 .478 1.1881Z-04 4 1 .4170 38.11 33.88 35.99 4.23 .889 6.39251-08 S 1 2.10000-02 S1.11 .00 25.55 51.11 .000 5.4244t-04 1 1 1.042 46.16 .00 2S.0* 46.14 .000 4.4473Z-04 7.796E-04 1.23 310.S 2 1 2084. 35.86 31.40 33.63 4.46 .876 8.7711t-08 1 1.000 45.32 21.59 33.44 23.77 .476 1.21802-04 3

4 1 .4170 38.48 34.16 36.32 4.32 .688 7.23402-08 5 1 2.100DE-02 51.61 .00 25.80 51.61 .000 3.5250r-o 1 1.042 46.51 .00 23.26 46.S1 .000 4.513SE-04 7.9062-04 1.27 343.8 1

2 1 2084. 36.25 31.79 34.02 4.46 .877 s.s024r-0c 3 1 1.000 45.73 21.65 33.69 24.00 .473 1.2492t-04 1 .4170 39.66 34.45 36.6S 4.41 .88g 8.20S71-08 4

s 1 2.10002-02 52.11 .00 26.06 52.11 .000 S.43481-04 23.43 46.85 .000 4.57781-04 8.0032-04 1.32 422.3 I 1 1.042 46.85 .00 2 1 2094. 36.44 32.18 34.41 4.46 .870 8.75631-08 1 1.000 46.12 21.73 33.92 24.39 .471 1.28071-04 3

' 1 .4170 39.23 34.72 36.97 4.51 .885 S.3134t-08 1 2.10001-02 52.61 .00 26.30 52.61 .000 1.74001-04 s

23.59 47.1* .000 4.64011-04 8.0900-04 1.37 480.2 1 1 1.042 47.18 .00 2 1 2084. 37.03 32.57 34.90 4.46 .880 8.7291t-08 3 1 1.000 48.30 21.00 34.15 24.70 .4c9 1.3130E-04 4 1 .4170 39.59 34.90 37.29 4.60 .SB4 1.0s941-07 5 1 2.1000E-02 £3.10 .00 26.35 53.10 .000 3.s457r-04

.00 23.73 47.51 .000 4.70412-04 6.178E-04 1.41 539.4 1 1 1.042 47.51 1 2094. 37.43 32.98 35.21 4.45 .881 9.6S31M-08 2

3 1 1.000 46.89 21.86 34.38 25.03 .466 1.34701-04 4 1 .4170 39.$7 35.27 37.62 4.71 .982 1.2067E-07 1 2.1000I-02 33.62 .00 26.81 53.62 .000 S.6s600-04 5

23.92 47.04 .000 4.7682E-04 8.259E-04 1.46 600.1 1 1 1.042 47.84 .00

.9*3 8.5433E-0o 2 1 2084. 37.84 33.40 35.62 4.44 1.392S5-04 3 1 1.000 47.29 21.93 34.61 23.36 .4*4 4 1 .4170 40.38 35.5S 37.9S 4.81 .881 1.37912-07 5 1 2.12000-02 £4.13 .00 27.07 54.13 .000 6.0690Z-04 24.12 40.24 .000 4.84s5r-04 B.374E-04 1.52 462.1 1 1 1.042 48.24 .00 2 1 2084. 30.31 33.88 36.10 4.44 .B04 9.49451-08 3 1 1.000 47.76 22.02 34.09 25.74 .461 1.42292-04 1 .4170 40.80 35.87 38.34 4.63 .879 1.5917Z-07 4

S 1 2.10000-02 54.73 .00 27.37 54.73 .000 6.200SX-04 48.64 .000 4.92SE9-04 8.491E-04 1.57 725.5 1 1 1.042 48.64 .00 24.32 2 1 2084. 38.80 34.37 36.59 4.43 .686 0.44030-40 1 1.000 40.25 22.11 35.18 26.14 .458 1.4657Z-04 3

4 1 .4170 41.26 36.21 38.74 5.05 .978 1.8467E-007 2.1000Z-02 35.35 .00 27.67 ss.3s .000 6.3373C-04 a 1 49.03 .000 5.0034-904 6.5990-04 1.62 790.3 1 1 1.042 49.03 .00 24.52 39.29 34.87 37.0e 4.42 .007 8.3438E-08 2 1 2084.

3 L L.000 40.73 22.29 35.46 26.54 .455 1.S097r-04 1 .4170 41.72 36.53 39.13 5.19 .876 2.149lE-07 4

5 1 2.1000E-02 55.9s .00 27.98 55.95 .000 6.47310-04 49.40 .000 5.07740-04 e.6s4c-04 1.68 956.6 1 1 1.042 48.40 .00 24.70 2 1 2084. 39.78 35.37 37.57 4.41 .889 O.1ss1E-08 1.5547E-04 1 1.000 49.20 22.24 35.73 26.94 .452 3

1 .4170 42.16 36.84 36.50 5.32 .874 2.50751-07 4

5 1 2.1000t-02 56.54 .00 28.27 56.54 .900 6.6070t-04

.00 24.8e 49.75 .000 5.24761-04 8.777r-04 1.74 924.4 1 1 1.042 49.75 2 1 2084. 40.26 35.87 36.06 4.39 .891 8.0127r-op 2.000 49.46 22.32 35.99 27.34 .449 1.6008E-08 3 1 4 1 .4170 42.60 37.14 39.87 5.46 .S72 2.9341Z-07 1 2.10000-02 57.12 .00 28.56 37.12 .000 6.7384E-04 5

QAE17 RE.V 8196 M-DSC-3 60

I.... i- _ -

ENGINEERING SERVICES. IN M-V$L--%o s A- F Made by: Date: Client:

Calculation No.,: AES-C-3247-1 /8/98 8 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer y- gAt Yi ' 5 AES 97123247-IQ and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term. Service Conditions - SONGS 2 and 3 0 I-2 B-7 of B-9) 2 1 1.042 50.09 .00 25.05 50.09 .000 S.2162E-04 8.6551-04 1.80 894.1 2 1 2084. 40.75 36.37 3e.56 4.37 .893 7.79641E-0 3 1 1.000 50.12 22.37 36.24 27.76 .446 L.646E-04 4 1 .4170 43.04 37.42 40.23 5.61 .070 3.4450E-07 5 1 2.1000E-02 57.69 .O0 28.84 57.69 .o00 6.66991-04 1 1 1.042 50.44 .00 25.22 50.44 .000 5.28721-04 e.3er-o04 1.87 1066.

2 1 2084. 41.26 34.90 39.09 4.3s .894 7.58621-0e 3 1 1.000 50.62 22.42 36.51 26.19 .443 1.69931-04 4 1 .4170 43.49 37.72 40.60 5.77 .867 4.06551-07 5 1 2.1000}-02 58.27 .00 29.23 59.27 .000 7.0092Z-04 1 1 1.042 30.77 .00 25.38 50.77 .000 5.3S43E-04 9.012E-04 1.93 1139.

2 1 2084. 41.76 37.43 39.60 4.33 .896 7.3398Z-08 3 1 1.000 51.09 22.45 36.77 2e.63 .440 l.7123E-04 4 1 .4170 43.93 38.00 40.96 5.94 .6s5 4.81091-07 5 1 2.1000E-02 58.84 .00 29.42 56.84 .000 7.13988-04 1 1 1.042 31.07 .00 25.54 51.07 .000 5.4173E-04 S.0751-04 2.00 1214.

2 1 2084. 42.27 37.97 40.12 4.30 .896 7.0565C-08 3 1 1.000 51.56 22.48 37.02 29.09 .426 1.8047E-04 4 1 .4170 44.37 50.26 41.32 6.11 .862 5.70640-07 5 1 2.10000-02 59.36 .00 29.69 59.39 .000 7.27060-04 1 1 1.042 51.36 .00 25.68 51.36 .000 5.4759E-04 9.229E-04 2.07 1292.

2 1 2084. 42.77 36.51 40.64 4.27 .900 6.7414E-08 3 1 1.000 52.02 22.49 37.25 29.53 .432 1.85950-04 4 1 .4170 44.70 36.50 41.65 6.29 .e60 6.7848E-07 5 1 2.1000E-02 59.92 .00 29.96 59.92 .000 7.3982c-04 1 1 1.042 51.61 .00 25.61 51.61 .000 S.52981-04 9.173E-04 2.14 1371.

2 1 2064. 43.27 39.04 412.6 4.23 .902 6.40120-08 3 1 1.000 52.47 22.40 37.46 29.89 .429 1.91596-04 4 1 .4170 45.21 3e.73 42.87 6.46 .957 8.0870E-07 s 1 2.1000E-02 60.43 .00 30.21 60.43 .000 7.5220C-04 51.85 .00 25.92 51.85 .000 5.5771b-01 9.20D2-04 2.22 1 1 1.042 2 1 2064. 43.77 89.56 41.68 4.19 .904 6.03501-08 3 1 1.000 52.92 22.47 37.70 30.44 .425 1.97375-04 4 1 .4170 45.41 56.94 42.26 6.66 .654 8.4C001-07 s 1 2.0001-02 60.92 .00 30.46 60.92 .000 7.64161-04 1 1.042 52.11 .00 26.05 52.11 .000 s.46331Z-04 9.262E-04 2.30 1538.

3 2 1 2084. 44.31 40.16 42.23 4.15 .906 5.7008K-09 5 1 1.000 53.40 22.47 37.94 30.93 .421 2.03601-04 4 1 .4170 16.05 39.17 42.61 6.68 .851 1.16001-06 5 1 2.1000E-02 61.44 .00 30.72 61.44 .000 7.77001-04 1 1 1.042 52.34 .00 26.17 52.34 .000 5.6631t-04 9.309e-04 2.38 1626.

2 1 20B4. 44.04 40.74 42.79 4.10 .908 5.349S1E-0 2 1 1.000 53.00 22.45 36.17 31.43 .417 2.10045-04 4 a .4170 46.46 39.30 42.93 7.10 .647 1.39571-O0 5 1 2.10001-02 61.95 .00 30.96 61.95 .000 7.69611-04 1 1 1.042 52.55 .00 26.28 52.55 .000 5.72811-04 9.350E-04 2.46 1716.

2 1 2084. 45.30 41.32 43.35 4.06 .911 4.96500-0 3 1 1.000 54.35 22.42 38.39 3L.93 .413 2.1666E-04 4 1 .4270 44.89 39.57 43.23 7.33 .a44 1.60251-06 5 L 2.10001-02 62.44 .00 31.22 62.44 .000 8.01761-04 1  % 1.042 52.77 .00 26.39 52.77 .000 5.77491-04 9.400E-04 2.55 1808.

2 L 20e4. 45.94 41.93 43.93 4.O0 .913 4.6349E-08 3 1 1.000 54.86 22.40 13.63 32.46 .406 2.23721-04 A 1 .4270 47.33 39.76 43.55 7.57 .840 2.0366E-06 s L 2.10002-02 62.8 .00 321.47 62.94 .000 8.14421-04 1 1 1.042 53.05 .00 26.53 53.05 .000 5.83490-04 9.4635-04 2.64 1903.

2 1 2084. 46.06 42.60 44.56 3.96 .915 4.333B1-08 3 1 1.000 55.44 22.40 38.92 33.04 .404 2.31551-04

• 1 .4170 47.83 40.00 43.92 7.82 .836 2.48371-06 5 1 2.1000E-02 63.52 .00 31.76 63.52 .000 8.2909E-04 1 1 1.042 S3.31 .00 26.65 53.51 .000 5.6597Z-04 9.S62E-04 2.73 2001.

2 1 2064. 47.19 43.26 45.23 3.91 .P17 4.0186Z-08 3 1 1.090 S6.02 22.38 35.20 53.63 .400 2.3§731-04 4 1 .4170 48.32 40.23 44.27 8.o0 .833 3.03261-06 5 1 2.10000-02 64.08 .00 32.04 64.09 .000 6.4346Z-04 CIAE17 REV 5M96 M-DSC-3 60

MMAPTIECHl CES, INC.

ENGINEERING SERVW

. M psc-36c0 54 - 237 Made by: Date! Client:

Calculation No.: AES-C-3247-1 ___9 __ SCE Checked by: Date: Project No.:

Title:

EvaluationofHalf-NozzleRepair for Pressurizer 1-I-j-c. . r7oyQq 5 AES 97123247-1C and Steatr Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Term Service Conditions - SONGS 2 and 3 0 I-2 B-8 of B-9 I 1 1.042 53.54 .00 26.77 53.54 .000 5.9394E-04 9.636E-04 2.83 2102.

2 1 2084. 47.82 43.96 45.89 3.84 .919 3.69600-08 3 1 1.000 56.60 22.36 39.48 34.23 .395 2.4*150-04

• 1 .410 48.80 40.43 44.62 8.37 .825 3.7070Z:06 5 1 2.000E-02 64.63 .00 32.31 64.63 .000 S.5752C-04 1 1 1.042 53.74  ; 00 26.87 53.74 .000 6.9934E-04 9.708E-04 2.93 2205.

2 1 2084. 48.4$ 44.4S 46.56 3.00 .922 3.36*90-08 3 1 1.000 57.17 22.33 39.75 34.84 .391 2.5697E-04 4 1 .4170 49.28 40.62 44.96 * .64 .024 4.5335E-06 5 1 2.1000E-02 65.15 .00 32.56 65.15 .000 8.71212-04 1 1 1.042 53.92 .00 26.96 53.92 .000 6.0220t-04 9.776E-04 3.03 2311.

2 1 2084. 49.09 45.35 47.22 3.73 .924 3.0409Z-09 3 1 1.000 57.74 22.27 40.01 35.46 .366 2.63SOO-04 4 1 .4170 49.74 40.79 45.27 8.96 .820 S.5527E-06 5 1 2.20000-02 65.56 .00 32.82 65.66 .000 6.e4550-04 1 1 1.042 54.11 .00 27.06 34.11 .000 6.0643E-04 9.862E-04 3.14 2420.

2 1 2084. 49.76 46.09 47.92 3.67 .926 2.74DCE -08 3 1 1.000 58.35 22.23 40.29 36.12 .381 2.7552E-04 4 1 .4170 50.24 40.97 45.60 9.27 .915 6.8149E-06 5 1 2.1000E -02 66.20 .00 33.10 66.20 .000 8.98000-04 1 1 1.042 54.30 .00 27.15 54.30 .000 6.10490-04 9.955t-04 3.25 2531.

2 1 2084. 50.44 46.84 48.64 3.60 .929 2.4518E-00 3 1 1.000 58.57 22.3e 40.58 36.79 .37d 2.0564E-04 4 1 .4170 50.74 41.14 45.94 9.60 .811 8.37200-06 5 1 2.1000E-02 66.75 .00 33.37 64.7S .000 9.1333C-04 1 1 1.042 54.45 .00 27.23 64.45 .000 6.1392G -04 1.005t-03 3.36 2646.

2 1 2084. 51.13 47.60 49.37 3.53 .931 2.1669Z-08 3 1 1.000 59.59 22.11 40.85 37.40 .371 2.S612E-04 4 1 .4170 51.23 41.30 46.27 8.93 .S06 1.02050-05 5 1 2.1000E-02 67.28 .00 33.64 67.28 .000 S.27575-04 1 1 1.042 64.69 .00 27.29 S4.S8 .000 6.1668E-04 1.014t-03 3.48 2763.

2 1 2084. 51.82 48.37 50.10 3.45 .933 1.9S02E-08 3 1 1.000 60.21 22.03 41.12 38.17 .366 3.0697r-04 4 1 .4170 51.72 41.44 46.58 10.28 .S01 1.26331-05 5 1 2.1000E-02 67.80 .00 33.90 67.80 .000 S.4148E-04 1 1 1.042 54.69 .00 27.34 64.68 .000 6.18200-04 1.023Z-03 3.61 2884.

2 1 2084. 52.51 49.15 50.83 3.36 .936 1.62780-00 3 1 1.000 60.82 21.94 41.30 38.88 .361 3.1810e-04 4 1 .4170 S2.20 41.56 46.88 10.64 .796 1.59080-05 5 I 2.1000E-02 69.29 .00 34.15 68.29 .000 9.5506E-04 1 1 1.042 54.74 .00 27.37 54.74 .000 6.20200-04 1.033t-03 3.73 3008.

2 1 2084. 53.21 49.84 51.57 3.27 .939 1.38012E-08 3 1 1.000 61.43 21.82 41.42 39.60 .355 3.29800-04 4 1 .4170 52.67 41.65 47.16 11.02 .7S1 1.9023Z-05 5 1 2.10000-02 68.78 .00 34.39 66.78 .000 9.6932E-04 1 1 1.042 54.77 .00 27.38 54.77 .000 6.2085E-04 1.043E-03 3.86 3134.

2 1 2084. S3.90 50.73 52.32 3.17 .941 1.1511E-08 3 1 1.000 62.03 21.64 41.86 40.34 .350 3.41800-04 4 1 .4170 33.13 41.73 47.43 11.40 .785 2.3317E-05 5 1 2.1000E-02 69.25 .00 34.62 69.25 .000 9.8121E-04 NOTE: CrACX 6SZEor 10ST or WILL EXCEED ODY ROTS, 0(11, ONNtrXS S0E0ATON. PROCESSING SER1oTED.

RZFXID IBREAKUP P.zr IRIMEWT NOzzLE CORNER MAMEVALUAXION - SONGSUNIT 2 3 FATIGMU CRACK GROWTH ANALYSIS Z 24ANY CRACKD2HENS4OX(S) MAXIMUM STiESS ONTENSITYFACTOR(S( TOTAL CRACK 02OWTH NO2R OF CYCLES 0'P. BLOCKS TO FaA WORSTnnriT LOAD TRANSSENT RXTE(S) GROWCRACK FROM2 ANITSE SIZE A(i) BYM 2DAwN1 2 X1 DADM1 1.000 48.713 7. 0852-04 .00D0 1.035 49.152 7 .354-04 49.39 1.072 4 9.597 7 .3043E-04 99.75 1.110 50.100 7.4362£-OS 151.0 1.149 50.601 7.36230-04 203.2 1.189 S1.107 7.64642-04 256.3 1.231 31.605 7.7964E-04 310.5 1.275 52.112 7.9057E-04 335.8 1.320 32.610 8.0028E-04 422.3 1.366 53.104 0.0903r-04 480.2 1.414 53.1316 8.1776E-04 639.4 1.464 34 .134 8.2593E-04 600.1 QAE17 REV 8196 M-DSC-360

IAPTNOCHT ENGINEEFUNO SERM:ES. NC.

M f) 5,C - -34o Madc b* Date: Client:

Calculation :No.: AES-C-3247-1 _ _sxe/m SCE Checked by. Dale: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -pi-r-.- E 5 3 AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Terrm Service Conditions - SONGS 2 and 3 0 1-2 B-9 of B-9 I3.16 S4.732 e.3737E-04 662.1 1.569 55.346 0. S913E-04 725.5 1 .625 SS.953 0.59B9E-04 790.3 2 .682 56.543 * .6g820-04 B56.6 2.741 57.116 F .77t2E-04 924.4 1.803 57.685 S0.85406-04 994.1 3 .*66 SB.26S B0.03836-04 1066.

I.932 50.B35 s9.01206.-04 1139.

2 000 59.305 S .0752E-0< 1214.

2.071 09.917 s.129r-04 1292.

2.144 60.429 S.1732E-04 1371.

2.219 60.920 9.20BBE-04 1404.

2.297 61.444 9.261BE-04 1538.

2.370 61. S51 9.3076E-04 1626.

2.462 62.437 1716.

2.549 62.941 9.20E01-04 100.

2.639 63.S19 9. 603JE-04 1903.

2.732 64.0el 9.36106-04 2001.

2.828 64.626 9.C362E-04 2102.

2.9928 65.153 9.70756-04 2205.

3.031 65.662 9.7764E-04 2311.

3.138 66.202 9.S625E-04 2420.

2.249 66.74P S 9553E-04 2531.

3.344 67.280 1.0047E-03 2646.

3.482 67 .79S 1.01406-03 2763.

3.605 60.295 1.0234E-03 2804.

3.732 6B.779 1.03316-03 3008.

3.864 69 .247 1.0431E-03 3L234.

QAE17 REV 8196 M-DSC-3 60

ENGINEIERING SERVICMS ING-t-DA C-D66 Gfl- t;q Made by: Date: / Client:

Calculation No.: AES-C-3247-1 S '/98/v SCE Checked by: Date: ProjectNo.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer -riry 279 94 AES 97123247-1Q and Steam Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Termi Service Conditions - SONGS 2 and 3 0 1-2 C-1 of C-3 Appendix C ALLOWABLE DEPTHS FOR POSTULATED CORROSION DEGRADATION OAE17 REV 8196 M-DSC-3 60

PgAPTECH-ENGINEERING SEYV.CES INC i<@  % sit* 115 Made t:

Calculation No.: AES-C-3247-1 A11 SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozze Repair for Pressurizer o"ff I-r- 9 - r I AES 97123247-10 and Steam. Generator Instrumentation Nozzles Under Revision No.: I Document Control No.: Sheet No.:

Long-Terma Service Conditions - SONGS 2 and 3 O 1 1-2 C-2 of C-3 TABLE C-1 LIMIT LOAD ANALYSIS OF BWC - PZR & SG NOZZLES Gap Realon (e-0.6875")

Geometry Material Properties - Loan ng tp (in) 0.4376 Sy (ksl) 27.6 P (psig) 2485 e (in) 0.6875 Su (ksi) 85.0 F (Ibs) 2242.9 L (in) 0.184 Sf (ksi) 56.3 Fa (Ibs) 101 dh/2 (in) 0.536 SF 2.77 Fb(lbs) 178 Alpha 0.16212 Pce_ (Ibs) 35 r1 (in) 3.3207 l Ma (in-lbs) 816 2(n) 4.4607 Mb (In-lbs) 420 w (in) 1.1399 _M (in-Ibs) 1776 A (inA2) 4.4981 FA (lbs) 2556.9 Z (inA3) 0.2031 MB (in-lbs) 1999.1 rItw 2.913 SM (ksi) 0.568

. . SB (ksi) 9.842 Theta d a

Beta Theta +

Beta fi SBc SBc+SM Theta/Pi (rads) (in) (in) alw (rads) (rads) (ksi) SB+SM 0.050 0.15708 21.800 7.0371 6.173 1.07008 1.22715 28.270 2.77 0.100 0.31416 10.991 3.548 3.113 1.06602 1.38018 28.270 277 0.150 0.47124 7.430 2.398 2.104 1.05920 1.53043 28.270 2.77 0.200 0.62832 5.631 1.834 1.609 1.04952 167783 28.270 2.77 0.250 0.785401 4.659 1.504 1.319 1.03685l 1.82225 28.270 277 0.300 0.94248 4.001 1.292l 1.133 1.021051 1.96352 28.270 2.77 0.350 1.09956 3.552 1.147 1.008 1.00191 2.10147 28.270 2.77 0.400 1.25664 3.235 1.044j 0.916 0.97924 2.23587 28.270 2.77 0.450 1.41372 3.008 0.971 0.852 0.95280 2.36652 28.270 2.77 0.500 1.57080 2.844 0.918 0.805 0.92240 2.49320 28.270 2.77 0.550 1.72788 z727 0.880 0.772 0.88782 2.61570 28.270 Z77 0.600 1.88496 2.645 0.854 0.749 0.848s4 2.73389 28.270 2.77 0.650 2.04204 2.591 0.837 0.734 0.805671 2.84771 28.270 2.77 0.700 2.19911 2.559 0.826 0.725 0.758071 2.95718 28.270 277 0.750 2.35619 2.544 0.821 0.720 0.70632 3.06252 2B.270 2.77 0.800 2.51327 2.540 0.8201 0.719 0.66355 3.17683 28.270 2.77 0.850 2.67035 2.540 0.8201 0.719 0.66355 3.33391 28.270 2.77 0.900 2.82743 2,540 0.820 0.719 0.66355 3.49099 28.270 2.77 0.9501 2.98451 2.540 0.820 0.719 0.66355 3.64807 28.270 2.77 1.0001 3.14159 2.540 0.820 0.7191 0.66355 3.80515 28.270 2.77 QAE17 REV 8196 M-DSC-3 60

unAPTt>

MNGINEERING SERVICES. IN.

LA-O_*Z-' e) C4. CH Made by: Date: Client:

Calculation No.: AES-C-3247-1 __ /& _SCE Checked by: Date: Project No.:

Title:

Evaluation of Half-Nozzle Repair for Pressurizer 7,-r-c. E3 t ' 8 AES 97123247-10 and Stean Generator Instrumentation Nozzles Under Revision No.: Document Control No.: Sheet No.:

Long-Tern Service Conditions - SONGS 2 and 3 0 1-2 C-3 of C-3 Table C-2 LIMIT LOAD ANALYSIS OF BWC - PZR & SG NOZZLES Crevice Location (e0o)

Geometry Material Properties Load ing tp (in) 0.4375 Sy (ksi) 27.6 P (Psig) 2485 e (in) 0 Su (ksi) 85.0 F (Ibs) 2242.9 L (in) 0.184 Sf (ksi) 56.3 Fa (Ibs) 101 dhl2 (In) 0.536l SF 2.771 fb (Ibsj 178 Alpha 0.39811 r Fc (Ibs) 35 _

r1(in) 1.3826 T __ Ma (in-lbs) 816 r2 (in) 1.8572 _ Mb (in-lbs) 420 il w (in) 0.4746 Mc (in-lbs) 1776 A (inA2) 1.8728 _ FA (lbs) 2556.9 Z (inr'3) 0.2031 MB (in-lbs) 1999.1 _

_ _ _SM (ksi) 1.365f

_ = SB(ksi) 9.8421

_ _ _Theta + lI _

_T_ lheta d a Beta Beta Sac SBc+SM ThetalPi (rads) (in) a (rads) (rads) (ksi) SB+SM 0.050 0.15708 3.619 2.806 5.912 1.06841 1.22549 29.680 2.77 0.100 0.31416 ¶.824 1.415 2.981 1.06452 1.37868 29.680 2.77 0.150 0.47124 1.233 0.956 2.015 1.05800 1.52924 29.68C 2.77 0.200 0.62832 0.943 0.731 1.541 1.04873] 1.67705 29.680 2.77 0.250 0.7S540 0.773 0.600 1.263 1.03661 1.82201 29.680 2.77 0.300 0.94248 0.684 0.515 1.085 1.02147 1.98395 29.680 2.7 0.350 1.09956 0.590 0.457 0.963 1.00314 2.102701 29.60 2.77 0.400 1.25664 0.537 0.416 0.877 0.98141 2.23804 29.680 2.77 0.450 1.41372 0.499 0.387 0.816 0.95605 2.36977 29.680 2.77 0.500 1.57080 0.472 0.366 0.771 0.92686 2.49765 29.680 2.77 0.550 1.72788 0.453 0.351 0.740 0.89363 2.62150l 29.680 2.77 0.600 1.88496 0.439 0.341 0.718 0.85621 2741177 29.680 2.77 0.650 2.04204 0.431 0.334 0.703 0.81453 2.856571 29.680 2.77 0.700 2.19911 0.425 0.330 0.695 0.76861 296773 29.680 2.77 0.750 2.35619 0.423 0.328 0.691 0.71863 3.07482 29.680 2.77 0.800 2.51327 0.423 0.328 0.690 0.6S454 3.19781 29.680 2.77 0.850 2.67035 0.423 0.3281 0.690 0.68454 3.354891 29.680 2.77 0.900 2.82743 0.423 0.32Bl 0.690 0.68454 3.51197 29.680 2.77 0.950 2.98451 0.423 0.3281 0.690 0.68454 3.669051 29.680 2.7 1.000 3.14159 0.423 0.328 1 0.690 0.68454 3.82613 29.680 2.77 QAE17 REV 8196 M-DSC-3 60

EC&FS DEPARTMENT ECUFS DEPARTMENT CALCULATION SHEETICCNNOJ 1PRELIM. CCN NO. h-OF CCN CONVERSION:

Project or DCP.(FCN SONGS 2&3 CadIc No. . M-DSC-360 CCN NO. CCN -

!::1Ihinl;

%JUUJCjML

'"4l.

K.

Rht.

- t ----

.chnat 1-O1001 t 9 _/U>,

R OI INATOR I DATE I IRE I DATE ll REV I ORIGINATOR I DATE iRE I DATE C

-NabilM.Ei-Aly 07/24198 Jun Gaor I 07/24198 I _ -J

_ I I_

= 4 Appendix D EVALUATION OF THE EFFECT OF THE MNSA HOLES ON THE NOZZLE STRESSES SCE 26-420 rEV. 0 6194

IREFERENCE:

60123-XXIV-7.151 M-DSC-360

EC&FS DEPARTMENT CALCULATION SHEETICCN NOJ1 PRELIM. CCN NO. ] PAGE -OF_

CCN CONVERSION:

Project or DCP.FCN SONGS 2&3 CaIc No. M-DSC-360 CCN NO. CCN -

Subject See Title Sheet Sheet . of _

l ORIGINTOR l DATE TREV I DATE REV l ONATOR DATE IRE DATE l I 1 WEWIMA HNl 07/24198 Jun Gaor 107/24/98 l I l l I _ -

I PIJRPOSEIBACKGROUND The purpose of this Appendix is to evaluate the effect of the bolt holes of the Mechanical Nozzle Seal Assemblies (MNSA) on the stress concentration at the nozzle hole, and consequently on the flaw evaluation performed in the base calculation. The MNSAs were installed on SONGS Unit 2 pressurizer and steam generator E089 to address the problem of Instrument nozzle leaks during Units 2 & 3 Cycle 9 mid-cycle outages in 1998. In Unit 3 pressurizer, holes were drilled without installing a MNSA.

Each MNSA Installation requires drilling four bolt holes in the vicinity of the nozzle (pressurizer RTD nozzle), and an additional two shoulder screw holes (steam generator PDT and pressurizer level nozzle), as shown in Figures 1.1 through 1.4. These figures depict different MNSA installations for a steam generator PDT, a pressurizer level instrument nozzle and a pressurizer RTD nozzle.

The MNSA is installed externally, and relies on a grafoil seal arrangement, for the gap between the nozzle and the outside surface of the vessel, to prevent leaks. Each MNSA is attached to the outside surface of the vessel by means of bolts, as shown in Figures1.1 through 1.4. The nozzle through-wall hole and the bolt holes act as stress raisers in the vessel. The bolt holes are drilled, close to the nozzle, on a bolt circle diameter of 3.812", for the pressurizer RTD MNSA, and 6" and 6.5" for the pressurizer level MNSA and the steam generator PDT MNSA. It follows that the center-to-center distance between the nozzle and the bolt holes varies between 1.906" to 3.25".

Accordingly, there is a potential for interaction between the regions of stress concentration of the nozzle and the bolt holes.

In the event a decision is made to replace the MNSA installations in the future, the half-nozzle design will be used to replace them (a typical half-nozzle design is described in detail in the base calculation). The new nozzles will be welded to the outside surface of the vessel, and threaded plugs will be installed in the bolt holes. Reference 1, Appendix G, provides a quantitative evaluation of the interaction between the nozzle and the MINSA bolt holes, for the hot leg MNSAs, in order to assess its effect on the hot leg stresses when they are replaced by the permanent half nozzle design. Results of this evaluation will be used in this appendix to assess the effect of the MNSA bolt holes on the flaw analysis performed in the base calculation to evaluate the long-term SCE 26-426 REV. 0 8194IREFERENCE :0123-)VIV-7.15]

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EC&FS DEPARTMENT CALCULATION SHEETICCNNO. .

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.-I-Cai NailI.EI-Akily I07124/98 IJun Gaor I07(24198 IIII acceptance of the half nozzle design since the flaw evaluation was made prior to the MNSA installation.

2 RlESULTSICONCLUSIONS The interaction between the MNSA bolt holes and the nozzle hole was evaluated in Section El of this appendix. It was concluded that the effect of the bolt holes.on the stresses at the nozzle connection is insignificant. The postulated flaws, in the flaw evaluation in the base calculation, are located at the nozzle area where the presence of the MNSA bolt holes does not impact the stresses and allowable flaw size. It is, therefore, concluded that the flaw evaluation is valid, and is not impacted by the MNSA bolt holes.

3 AS'SUMPTIONS See Reference 6.1, Appendix G.

4 DEESIGN INPUT See Reference 1,Appendix G.

5. METHODOLOGY See Reference 1, Appendix G.

6 REFERENCES 6.1 Calculation No. M-DSC-279, Revision O,"Hot and Cold Leg Instrument Nozzle Modification."

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EC&FS DEPARTMENT EC&FS DEPARTMENT CALCULATION SH EETeccNNoJ NO.

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Seep Title Sheet - -:Sheet 5.i of RNATORI DATE I IRE I DATE ll REV l ORIGINATOR I DATE IRE DATE

_ __ _ _ !72 Nab . EI- y 07/24198 Jun Gaor 107/24198 = 1 = CZ° II, 6.2 Drawing No. S023-411-57-20, Revision 1,"Steam Generator PDT Mechanical Nozzle Seal Assembly."

6.3 Drawing No. S023-411-57-21, Revision 1,"Steam Generator PDT Mechanical Nozzle Seal Assembly."

6.4 Drawing No. S023-411-57-4, Revision 1,"Bottom Pressurizer Mechanical Nozzle Seal Assembly."

6.5 Drawing No. S023-411-57-33, Revision 0,"Bottom Pressurizer Mechanical Nozzle Seal Assembly & Details.'

6.6 Drawing No. S023-411-57-34, Revision 0,"Bottom Pressurizer Mechanical Nozzle Seal Assembly & Details.'

6.7 Drawing No. S023-411-57-5, Revision 1,"Side Pressurizer RTD Mechanical Nozzle Seal Assembly."

7 NOMENCLATURE k -stress concentration factor MNSA =Mechanical Nozzle Seal Assembly 8 CALCULATIONS During Cycle 9 mid-cycle outage, MNSAs were installed on the PDT instrument nozzle in steam generator primary head, bottom pressurizer head level instrument nozzle and pressurizer RTD nozzle. As described in Section 1 of this appendix, each MNSA is attached to the outside surface of the vessel by means of bolts. Figures 1.1 through 1.4 show the details of the MNSAs installed on the primary head of the steam generator and the pressurizer based on References 6.2 through 6.7. The nozzle through-wall hole and he 1"-Inch maximum depth bolt holes act as stress raisers in the hot leg. The A_

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EC&FS DEPARTMENT CALCULATION SHEETICCNNoN 1 O.

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SubJect See Title Sheet . . Sheet /Do cf REV l RiMNATOR DATE IRE DATE ll REV ORIGINATOR DATE IRE DATE EI-Akily A1A. 07124I98 Jun Gaor 107124198 ll l_

bolt holes are drilled in close proximity to the nozzle, on a bolt circle diameter from 3.812" to 6.5", i.e., the center-to-center distance between the nozzle and the bolt holes varies between 1.906" to 3.25". In addition, 1%/E" deep holes, for the shoulder screws in the steam generator and pressurizer bottom head MNSAs, are located on a 6" bolt circle. Accordingly, there is a potential for interaction between the regions of stress concentration of the nozzle and the bolt holes.

The MN'SA installations may be replaced by the permanent half-nozzle design in the future. In the event that the MNSAs are replaced, threaded plugs will be installed in the bolt holes as part of replacing the MNSA installations with the half-nozzle design. The interaction between the nozzle and the MNSA bolt holes was evaluated, using the finite element method, for the MNSAs installed on the RCS hot leg (Reference 1,Appendix G). In that evaluation, the hot leg wall was modeled with a nozzle hole only, with a nozzle hole and four bolt holes on the nominal bolt circle diameter, and with a nozzle hole and four bolt holes on 150% nominal bolt circle diameter. Loading included biaxial tension to model internal pressure. Stress on the surface of the nozzle hole, and the stress concentration factor, k, were calculated to assess the interaction between the nozzle hole and the bolt holes. Based on the analysis results, it was concluded that the increase in the value of k due to the presence of the bolt holes is insignificant; therefore, does not affect the nozzle stresses. The results of this analysis will be used to assess the acceptability of the MNSA holes in the steam generator and pressurizer in the evaluation below.

A (1) The pressurizer RTD bolt holes are located on a 3.812" bolt circle diameter, i.e.,

the same as the hot leg MNSA installations. On the other hand, the major differences between the steam generator and pressurizer bottom head MNSA, and the RCS.hot leg MNSA are:

a) The bolt circle diameter on the steam generator MNSA is larger than the bolt circle diameter on the RCS hot leg (6.5" and 6" versus 3.8"). The larger separation between the bolt holes and the nozzle hole will result in a smaller interaction between the different holes, i.e., smaller effect on the nozzle stress concentration factor.

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EC&FS DEPARTMENT CALCULATION SHEETgccNN NotNO..

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b) The steam generator and pressurizer wall thickness is larger than the hot leg wall thickness (73/%" and 47/%" versus 33/4"). The larger wall thickness will not result in increasing the value of k since the depth of the bolt holes relative to the wall thickness is smaller in the steam generator, and the pressurizer, than the hot leg, which would decrease the effect of these holes on the stresses.

(2) Slight differences exist between the RCS hot leg instrument diameters and wall thicknesses, and the steam generator and pressurizer instrument nozzles (the difference in outside diameter is 3% only). This difference is considered insignificant.

Based on the above considerations, it is concluded that the effect of the MNSA bolt holes on the stresses in the nozzle connection is insignificant.

.1 SCE 26A426 REV. 0 6I9 I IREFERENcEs 90123.XXV-7,15]

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