NL-07-120, Response to Request for Additional Information Regarding Relief Request 3-43 for Temporary Repair to Service Water Pipe
| ML072890132 | |
| Person / Time | |
|---|---|
| Site: | Indian Point  |
| Issue date: | 10/03/2007 |
| From: | Robert Walpole Entergy Nuclear Northeast |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| NL-07-120 | |
| Download: ML072890132 (45) | |
Text
Entergy Nuclear Northeast Indian Point Energy Center 450 Broadway, GSB Buchanan, NY 10511-0249 Robert Walpole Licensing Manager Tel (914) 734-6710 October 3, 2007 Re: Indian Point Unit 3 Docket 50-286 NL-07-120 U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, DC 20555-0001
SUBJECT:
Response to Request for Additional Information Regarding Relief Request 3-43 for Temporary Repair to Service Water Pipe
Reference:
- 1. Entergy letter NL-07-118 dated September 27, 2007 regarding Relief Request 3-43 for Temporary Repair to Service Water Pipe
Dear Sir or Madam:
Entergy Nuclear Operations, Inc (Entergy) requested relief (Reference 1) in accordance with 10 CFR 50.55a(a)(3)(i) for a temporary non-code repair to an ASME Code Class 3 piping elbow in the Indian Point 3 (IP3) Service Water System. During a conference call with NRC staff on October 1, 2007, Entergy agreed to provide additional information regarding this request as summarized in Attachment 1. Based on this additional information, Entergy is providing Revision 1 of the Relief Request 3-43 in Attachment 2. Other information being provided to support NRC review of this Relief Request is:
" Attachment 3, Flaw Evaluation based on ASME Code Case N-513-1
" Attachment 4, Ultrasonic Test results for current flaw and historical data
" Attachment 5, Structural calculation for proposed repair There are no new commitments being made in this submittal. If you have any questions or require additional information, please contact Mr. Robert Walpole, Manager, Licensing at (914) 734-6710.
Robert alpol e Licensing Manager Indian Point Energy Center
NL-07-120 Docket 50-286 Page 2 of 2 cc: Mr. John P. Boska, Senior Project Manager, NRC NRR DORL Mr. Samuel J. Collins, Regional Administrator, NRC Region 1 NRC Resident Inspector, IP3 Mr. Paul D. Tonko, President NYSERDA Mr. Paul Eddy, New York State Dept. of Public Service
ATTACHMENT 1 TO NL-07-120 REPLY TO REQUEST FOR ADDITIONAL INFORMATION REGARDING INDIAN POINT 3 RELIEF REQUEST 3-43 FOR TEMPORARY NON-CODE REPAIR TO SERVICE WATER PIPING ENTERGY NUCLEAR OPERATIONS, INC INDIAN POINT NUCLEAR GENERATING UNIT NO. 3 DOCKET NO. 50-286
NL-07-120 Attachment 1 Page 1 of 2
SUMMARY
OF ADDITIONAL INFORMATION The following summarizes the additional information being provided in this transmittal regarding IP3 Relief Request 3-43, based on a conference call with NRC staff on October 1, 2007. The revised relief request is provided in Attachment 2. The contents of Attachments 3, 4, and 5 are as described in the following summary.
A. Flaw Characterization and Evaluation
- The flaw evaluation performed per ASME Code Case N-513-1 is provided in Attachment 3.
- Two ultrasonic examination test (UT) reports for the affected area are provided in Attachment 4. One is for the recent examination performed in September 2007 for the current flaw and one is for the examination performed in March 2007 for a repair performed prior to startup from the last refueling outage (3R14). A UT examination in 3R13 was not required and therefore no report for that timeframe is available. Radiography of the area prior to 3R13 identified an area of concern on the opposite side of the pipe which was investigated and repaired in March 2005. The Relief Request has been revised to include these previous inspections and repairs.
" The typical unprotected metal corrosion rate for service water crevice corrosion observed at Indian point is 0.024 inches per two year cycle (0.012 inches per year). This is based on the wear rates observed and calculated for the evaluation of previous service water piping degradations.
B. Repair Design and Installation
" Additional description of the proposed repair has been added to the revised Relief Request, including dimensions and weld detail provided in Figure A. The reinforcing plate will be fabricated to match the contour of the repair area to the extent practical and the perimeter gap will be maintained within the limits of the procedure for this type of weld.
" The design calculation, including the applied stress allowables and safety factors, is provided in Attachment 5.
" The welding of the reinforcing plate will be in accordance with applicable requirements of ASME Section XI, with qualified welders using a welding procedure qualified per ASME Section IX.
C. Repair Examination and Inservice Monitoring
- The relief request has been revised to provide additional information regarding the NDE to be performed as part of the repair, for inservice monitoring, and for extent-of-condition augmented inspections.
NL-07-120 Attachment 1 Page 2 of 2
" During the repair, Entergy will perform surface examinations prior to starting the welding, after the root pass weld, and after the final pass weld.
- Inservice examinations will use straight line UT. Initial baseline exam after repair installation will be followed by monthly exam for the first quarter, and then quarterly for the balance of the Relief Request duration, unless maintaining a more frequent exam is warranted based on UT results.
" Selection of the 5 locations for augmented inspections will be per ASME Code Case N-513-1.
" NPO visual check walkdowns will be performed at a frequency of at least once per day.
ATTACHMENT 2 TO NL-07-120 INDIAN POINT 3 RELIEF REQUEST 3-43, REVISION 1 REGARDING TEMPORARY NON-CODE REPAIR TO SERVICE WATER PIPING (Supersedes Revision 0 from Entergy letter NL-07-118 dated September 27, 2007)
ENTERGY NUCLEAR OPERATIONS, INC INDIAN POINT NUCLEAR GENERATING UNIT NO. 3 DOCKET NO. 50-286
NL-07-120 Attachment 2 INDIAN POINT UNIT 3 RELIEF REQUEST 3-43, REVISION 1 PAGE 1 OF 6 Proposed Alternative in accordance with 10 CFR 50.55a (a)(3)(i)
Alternative Provides Acceptable Level of Quality and Safety A. ASME Code Component Affected 18" Service Water supply line number 408 to the Containment Fan Cooler Units (FCU). This line is one of two lines which supplies Hudson River water to the FCUs which are used to remove containment heat during normal plant operation and following a design basis accident.
B. Applicable Code Edition and Addenda The applicable Code of Record for the current 10 year inservice inspection interval is the ASME Section Xl Code, 1989 Edition with no Addenda. However, for Repair and Replacement activities, Entergy has requested and the NRC has approved (Reference 1) the use of subsection IWA-4000 of the ASME Section Xl, 2001 Edition through the 2003 Addenda.
The affected portion of the service water piping was designed and constructed in accordance with the requirements of the USAS B31.1.0, 1967 Edition of the Power Piping Code.
C. Applicable Code Requirement IWA-4422.1 requires that defects be removed or reduced to an acceptable size prior to implementing a repair or replacement in accordance with the requirements of IWA-4000. Since the current through-wall defects are beyond the acceptance criteria of IWD-3000 and removal is not practical without system depressurization, the proposed repair method would not be consistent with IWA-4422.1.
D. Reason for Request On September 18, 2007 a Nuclear Plant Operator conducting a routine plant walkdown noted minor leakage of approximately 5 drops per minute in one of the two cement-lined 18" diameter, 0.375" nominal thickness service water supply lines for the containment fan cooler units. As a result of this leak a volumetric examination of the surrounding area was performed and the results were evaluated (IP-CALC-07-00083) against the requirements of ASME Code Case N-513-1. Although this evaluation confirmed that the affected piping remains within the requirements of Code Case N-513-1, the calculated corrosion rate does not support continued structural integrity through the remainder of the current operating cycle.
A weld repair/replacement fully compliant with the requirements of IWA-4000 is not practical.
The affected piping section would need to be removed from service which would result in 3 FCUs inoperable. Indian Point 3 Technical Specification 3.6.6 does not have a Condition Statement for that configuration.
NL-07-120 Attachment 2 INDIAN POINT UNIT 3 RELIEF REQUEST 3-43, REVISION 1 PAGE 2 OF 6 Entergy has evaluated alternative options for repairing this degraded area including weld overlay using ASME Code Case N-661 or an approach using a welded reinforcing plate. The weld overlay based on Code Case N-661 does not have a high probability of success due to the risk of "burn-through" in small areas where the remaining pipe thickness is insufficient to deposit weld metal. To protect against "burn-through" as shown in EPRI testing, a modified approach for weld overlay may be possible by placing a small intermediate plate over the localized area subject to "burn-through" and then the weld overlay could be applied over that plate. Both the reinforcing plate option and the overlay-with-intermediate-plate option could be designed to adequately restore the required structural margin for the remainder of the current operating cycle. The welded reinforcing plate is the preferred option because less welding will result in lower residual shrinkage stresses. Therefore the balance of the discussion provided in this relief request is directed at describing the welded reinforcing plate approach.
E. Proposed Alternative and Basis for Use As discussed above, IWA-4422.1 requires that a defect be removed prior to implementing an IWA-4000 repair. However, this is not practical for the reason described in Section D regarding Technical Specification 3.6.6 for the FCUs. The preferred alternative proposed under this relief request would install a reinforcing plate over the degraded area to allow the attachment welding (Figure A) to be located in an area with minimal degradation therefore ensuring a structurally sound load path while minimizing the risk of "burn-through" and increased leakage.
The design will also ensure that the configuration of the repair will allow continued monitoring of the region by volumetric examination to ensure that future degradation will not adversely impact the structural capability of the repaired section.
- 1. Materials and Installation The material of the component to be repaired is concrete lined Carbon Steel, A-234, Grade WPB. The proposed reinforcing material to be installed is ASTM A-234, Grade WPB/A-106 or equivalent carbon steel material with an ASME Code stress allowable of 15,000 psi. The welding process to be used in this repair is SMAW with a Carbon Steel, 7018 weld wire. The reinforcing material would either be plate stock rolled to fit the contour of the affected repair area or a section from pipe will be used to fit the contour.
The gap between the repair area and the reinforcing material will be controlled by procedure.
The welding will be performed per the requirements of ASME Section Xl using qualified welders and the weld procedure will be qualified in accordance with ASME Section IX.
The weld procedure specifies 50 OF pre-heat for welds less than 33/44 inch thickness and no post weld heat treatment required for P-1 materials less than 3/4 inch thick.
- 2. Design Parameters The welded plate/weld repair option will be designed and installed consistent with the original USAS B31.1.0, 1967 Edition of the Power Piping Code requirements for a reinforcing plate (paragraph 104.3). A structural evaluation (IP-CALC-07-00209) has
NL-07-120 Attachment 2 INDIAN POINT UNIT 3 RELIEF REQUEST 3-43, REVISION 1 PAGE 3 OF 6 been performed to ensure that the resulting stresses in the piping, the plate and the attaching welds do not exceed the allowable stresses of the USAS B31.1.0 Code, 1967 Edition. The repair material will be carbon steel or pipe equivalent to the existing pipe material with allowable stress of S = 15,000 psi. The Code Case N-513-1 evaluation used the required factors of safety of 2.77 for the normal / upset condition and 1.39 for the emergency / faulted condition.
For purposes of this repair design and monitoring, Entergy will assume that the cement lining is no longer present in the area of the planned repair so that the corrosion rate for unprotected carbon steel will be applied.
- 3. Non Destructive Examinations The area to be repaired has been characterized by performing straight beam UT mapping (Report IP3-UT-07-1 10) of the region to bound the degraded area and to ensure that the welds for repair are located in areas of sound base metal. At least 1/2 inch of the weld for attaching the reinforcing plate to the elbow will be performed in an area of average wall thickness exceeding 0.18 inches to ensure a structurally sound load path around the perimeter of the repair area.
NDE of this area was also performed in March 2007 (Report IP3-UT-07-049) when a through-wall flaw was discovered during startup from refueling outage 3R14. Plant conditions at that time allowed for a weld repair consistent with ASME IWA-4422.1, so that a relief request was not needed. Four areas with thickness readings less than 0.110 inches were excavated and weld repaired in accordance with the requirements of ASME Section XI. Corrective action at that time also included developing plans for replacing this elbow at the next refueling outage (3R15, Spring 2009).
The pipe wall was repaired to a minimum wall thickness needed to support operation until the next refueling outage, based on nominal corrosion rate assumptions. The typical unprotected metal corrosion rate for service water crevice corrosion observed at Indian point is 0.024 inches per two year cycle (0.012 inches per year). This is based on the wear rates observed and calculated for the evaluation of previous service water piping degradations. However, corrosion rates could be higher in localized areas.
The location of the March 2007 repair with respect to the current area of interest is adjacent to grid location H6 asshown on the UT map in IP3-UT-07-1 10. A final assessment of why a new through-wall leak developed near the area of the prior repair has not been completed at this time. Further characterization of the degradation in this elbow will be accomplished when the component is replaced.
Prior to shutdown for 3R1 3 (March 2005) radiography of this elbow as part of the Generic Letter 89-13 Corrosion Monitoring Program identified an area of interest on the opposite side of the elbow from the current flaw. Localized UT performed during 3R13 identified a 0.25-inch diameter area in the weld with a thickness less than 0.135 inches.
An ASME Section XI repair was implemented prior to startup from that outage. There is no historical UT data resulting from the March 2005 repair for the current area of interest.
NL-07-120 Attachment 2 INDIAN POINT UNIT 3 RELIEF REQUEST 3-43, REVISION 1 PAGE 4 OF 6 NDE inspections for the extent-of-condition review will also be performed as stated in section E.5. NDE related to the repair and inservice monitoring is discussed in Section E.4.
- 4. Repair Monitoring During installation of the reinforcing plate, welds will be examined, consistent with the requirements described in Code Case N-661. This includes performing a surface examination of the area to be welded, a surface examination (dye penetrant or magnetic particle) after the first weld pass and a final surface examination of the completed weld.
Inservice monitoring of the repair will be accomplished by applying a 1-inch by 1-inch grid over the area which will cover the reinforcing plate and the flat portion of the attaching weld (refer to Figure A). The intersection points in the grid will be inspected using straight beam UT. An initial baseline UT will be performed after installing the repair. Subsequent UTs will then be performed to verify that the structural requirements of the original construction code are maintained through the remainder of the current operating cycle. The UTs will be performed monthly for the first quarter and if no unexpected degradation is identified, UTs will then be performed quarterly for the balance of the duration of this relief request.
Also, routine walkdowns will be performed by Nuclear Plant Operators at least daily.
This piping is not insulated and is accessible for visual inspection.
- 5. Degradation mechanism Based on the location of the defect and based on the UT inspections of the degraded area, Entergy concludes that this was likely caused by degradation of the protective concrete lining directly under the degraded area which allowed brackish water from the Hudson River to contact the unprotected carbon steel piping resulting in localized corrosion. The degradation of the concrete lining was likely caused by the high flow velocities and turbulence from the valve located just upstream of the degraded area.
Further evaluation of the degradation mechanism will be performed during the next outage as stated in Section F, when the elbow can be removed and replaced.
Entergy will perform augmented inspections, as required by Code Case N-513-1, for the extent-of-condition evaluation. The inspections will be at 5 locations selected as most susceptible to the degradation mechanism suspected at this time. Parameters to be considered for selection of the augmented inspection locations will include system operating conditions, proximity of upstream valves, and years of service.
- 6. Applicable Loads The repair will be designed to accommodate all appropriate deadweight, pressure, and seismic loads. Since the system is a moderate energy system which operates at a low temperature, differential thermal expansion between the repair plate and the repaired component is not a concern.
NL-07-120 Attachment 2 INDIAN POINT UNIT 3 RELIEF REQUEST 3-43, REVISION 1 PAGE 5 OF 6 F. Duration of Proposed Alternative The duration of the temporary repair is limited until the next scheduled outage exceeding 30 days, but no later than the next refueling outage currently scheduled for the Spring of 2009.
G. References
- 1. NRC Safety Evaluation dated April 24, 2007 for Relief Request 3-42 (ML070880358).
NL-07-120 Attachment 2 INDIAN POINT UNIT 3 RELIEF REQUEST 3-43, REVISION 1 PAGE 6 OF 6 FIGURE A TL e-e-
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NUCLEAR QUALTY RELATED EN-DC-1 26 REV. 0
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Title:
Evaluation OF Through Wall Flaw at leak downstream of SWN-38 System(s): SWS (9 Review Org (Department): Civil I Structural Design Engineering (10) Safety Class: (11) Component/Equipment/Structure Type/Number:
Z Safety / Quality Related SWN-38 0l Augmented Quality Program Line 408 L-1 Non-Safety Related (12) Document Type: CALC (13) Keywords (Description/Topical Codes):
REVIEWS (14) Name/Signature/Date (15) Name/*Signature/Date (16) Name/Siaratua /Da e Kai Lo 9-19-07..- c PAL W ,ALLA IR.Drake - -
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[LI Comments Attached Comments Attached ATTACHMENT 9.3 CALCULATION REFERENCE SHEET Sheet 1 of 3 NIMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
CALCULATION CALCULATION NO: IP-CALC-07-00083, REV. 0 REFERENCE SHEET Page 2 of 12 I. EC Markups Incorporated: NONE 1,
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II. Relationships: Sht Rev Input Output Impact Tracking Doc Doc Y/N No.
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REFERENCES:
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IV. SOFTWARE USED: NONE
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Version/Release: Disk/CD No.
V. DISK/CDS INCLUDED: NONE
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VI. OTHER CHANGES: NONE NMM EN-DC- 126, FIO Attachment 9.2 Calculation Cover Page
NUCLEAR OUAUTY RELATED EN-DC-126 REV. 0
- itergy* MANAGEMENT....
MANUAL REFERENCE USE PAGE 27 OF 32 Engineering Calculation Process Page 3 of 12 Revision Record of Revision Initial issue of Calculation IP-CALC-07-00083 0
NMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
LIST OF EFFECTIVE PAGES Page 4 of 12 Calculation Number: IP-CALC-07-00083 Revision Number: 0 PAGE REV. PAGE RE V. PAGE REV.
All 0 NMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
TABLE OF CONTENTS PAGE 5 OF 12 Toplc Page No.
I Calculation Cover Page ............................................................... 1 2 Calculation Reference Sheet .................................................................. 2 3 Record of Revisions ......................................................... . . 3 4 List of Effective Pages ............................................... .............. 4 5 Table of Contents ................................................................ 5 6 Calculation Section ................................................................ 6 6.1 Background ...................................................... 6 6.2 Purpose ................................................... 6 6.3 Method of Analysis ......................................................... 6 6.4 Assumptions ............................................................... 6 6.5 Design Input ................................................................. 6 6.6 References .......................................... 6 6.7 Calculation . ....
.................................... 7 6.8 Results/Conclusions .................................................................. 12 NMM EN-OC-126, RO Attachment 9.2 Calculation Cover Page
6.0 Calculation Section Page 6 of 12 6.1 Background Two through wall leaks were found on an elbow downstream of SWN-38. This line is for the Service Water supply line. This weld was weld repaired at end of 3R14.
6.2 Purpose The leak is at downstream of SWN-38 and is ISI class 3, seismic class I. It is necessary to evaluate the structural integrity of the through wall leak for operability and extent of weld repair.
6.3 Method of analysis
- 1. Based on the reference, "Companion Guide to the ASME BPVC", page 555, the SIF at an elbow is maximum at the 45 degrees location. Since the leak and thinned area is approximately 3" from the elbow weld, an SIF of 1.0 for a straight pipe is used, i.e. 0.75i = 1.0.
- 2. Instead of using an uniform thinning approach to determine the minimum required wall thickness t'min, the exact method was used by using average UT readings at locations of leakage and wall thinning.
- 3. Determine the minimum required wall thickness to satisfy the 1967 B31.1 code limit.
- 4. ASME CC-N513 is used to determine the acceptable flaw length for normal/upset and emergency/faulted loading condition.
6.4 Assumption
- 1. The wall thickness of locations beyond the 1"x1" grids (Al through K6) are assumed to be the same as the average wall thickness of section 1,2 & 3 for the 2" grids at the weld section UT.
- 2. The wall thickness used for the CC N-513 evaluation is an average value of the thickness around the thinned area.
6.5 Design Input
- 1. This leak location is the same as inspection ID PAB-90 in 3R13.
- 2. IP3 Pipe specification MS-TS-027
- 3. Flow diagram 9321-F-27223
- 4. Drawing 9321-F-53533
- 5. 1P3 Line List
- 6. IP-CALC-07-00083 Rev. 0
- 7. UT Report IP3-UT-07-1 10 6.6 Reference
- 1. ENN-CS-S-008, "Pipe Wall Thinning Structural Evaluation"
- 2. EN-DC-185, 'Through-Wall Leaks in ASME X1 Class 3 Moderate Energy Piping Systems"
- 4. ASME B & PV Nuclear Code Case N-513, Rev. 1.
- 5. USAS B31.1, Power Piping Code, 1967.
- 6. "Companion Guide to the ASME BPVC", volume 1 NMM EN-DC-126, R0 Attachment 9.2 Calculation Cover Page
Calculation No: IP-CALC-07-00083 Rev. 0 Page 7 of I?-
6.7 Calculation Forpipe stress correspondingto 0. 751 = 1.0 P = design pressure = 150 psi D = outside diameter = 18 in t= pipe wall thickness = 0.375 in for std size pipe 0.75i SIF at pipe section = 1.00 0.75i' = SIF used in stress run = .75"3.5 = 2.625 at 45 degrees portion of elbow [Ref. 6]
f'nor = normal stress from stress run t3 from PAB-90 inpsection point p20IPsi, f'dw-obe = DW+OBE stress from stress run =[5490 psi f'd+dbe = DW+DBE stress from stress run = [psi 6680 Based on 0.751 = 1.0 fp = longitudinal stress due to pressure = PD/(4t) 1800 psi f'dw = dead weight stress w/out pressure f',,, - fp = 1320 psi fd, = dead weight stress = f'd(i/i') = 503 psi fnor = normal stress fp + fd, = 2303 psi f'd,ý,bo = obe pipe stress w/out pressure = f'dw,,b, - fp = 2370 psi lote = obe pipe stress = f'ob,(i/i') = 903 psi fups = DW+OBE stress = fp + fore = 2703 psi f'dbe = dbe pipe stress w/out pressure = f'dwdbe - fp = 4880 psi fdbe = dbe pipe stress = f'dbe(i/i') = 1859 psi fomg = DW+DBE stress = fp + fdbe = 3659 psi
of;=
6.7 Calculation Determine Minimum Wall for Operability based on Axial Stress Calculation for Actual Thinned Section
- 1. Actual Section Modulus Calculation: (See Ref. 2.7)
(Boxed values are input.)
DO: Pipe OD, (in) is1 R 0 : Pipe outside radius, = D/2, (in) 9~
tnom: Pipe nominal wall thickness, (in) 0.375 Y' Total service years up to latest inspection, (yr) W0 Y Service years between latest inspection and next inspection, (yr) 1 1.
N Total no. of thickness measurements (equal grid) in circumferential direction 20 AO = 2r/N, angle of each grid, (rad) (where ;t = 3.142) 0.314 Section 4 UT reading was used:
n (trma.)n (tol)n .. R, IYcv 8n A~n Amn B6 BI,. ln lvn.
(in.) (in.) (rad) (in2 ) (in2 ) (in3) (in3) (in4) (in4) (in4) 1 0.229 0.221 8.78 0.00 12,1 0.62 70.9 0.0 48.8 0.0 0.0 2 0.152 0.140 8.86 0.31 12.3 0.39 69.3 22.5 28.3 3.0 9.2 note 1 3 0.090 0.074 8.93 0.63 12.5 0.21 60.2 43.8 11.0 5.8 8.0 4 0.186 0.175 8.82 0.94 12,2 0.49 42.3 58.2 13.5 25.5 18.5 5 0.255 0.248 8.75 1.26 12.0 0.69 21.7 66.8 5.2 49.4 16.0 note 2 6 0.255 0.248 8.75 1.57 12.0 0.69 0.0 70.2 0.0 54.6 0.0 7 0.255 0.248 8.75 1.88 12.0 0.69 -21.7 66.8 5.2 49.4 -16.0 8 0.255 0.248 8.75 2.20 12.0 0.69 -41.3 56.8 18.9 35.7 -26.0 9 0.255 0.248 8.75 2.51 12.0 0.69 -56.8 41.3 35.7 18.9 -26.0 10 0.255 0.248 8.75 2.83 12.0 0.69 -66.8 21.7 49.4 5.2 -16.0 11 0.255 0.248 8.75 3.14 12.0 0.69 -70.2 0.0 54.6 0.0 0.0 12 0.255 0.248 8.75 3.46 12.0 0.69 -66.8 -21.7 49.4 5.2 16.0 13 0.255 0.248 8.75 3.77 12.0 0.69 -56.8 -41.3 35.7 18.9 26.0 14 0.255 0.248 8.75 4.08 12.0 0.69 3 -56.8 18.9 35.7 26.0 15 0.255 0.248 8.75 4.40 12.0 0.69 -21.7 -66.8 5.2 49.4 16.0 16 0.255 0.248 8.75 4.71 12.0 0.69 0.0 -70.2 0.0 54.6 0.0 17 0.255 0.248 8.75 5.03 12.0 0.69 21.7 -66.8 5.2 49.4 -16.0 18 0.255 0.248 8.75 5.34 12.0 0.69 41.3 -56.8 18.9 35.7 -26.0 19 0.255 0.248 8.75 5.65 12.0 0.69 56.8 -41.3 35.7 18.9 -26.0 20 0.255 0.248 8.75 5.97 12.0 0.69 66.8 -21.7 49.4 5.2 -16.0 Min. 0.09 0.074 A, A., Bp six . I IY aver 0,23683 241.7 12.8 7.7 4.8 488.8 520.3 -32.2 Where n : IDof measurement grid (tm.eas).: Min. thickness measured in nth grid (tp)n : Min. predicted thickness of nth grid at next inspection, = (tmeas)n - Y[. l(tnom - (tmeas)n )Y']
Ri : inside thinned radius = R, - (tfa)n of nth grid On : Circumferential angle clockwise of nth grid (from vertical axis of pipe section)
Arnn = (R02 "Rtn2)'(AO)/2, Ain = Rin'"(AO)!2 B" = RF,3 "COS(8))(AO)/3, Six, = R,2 3"sin(,,)*(AO)/4 I. = (Ro 4-Rin 4) sin 2(0n)'(*AO)/4, 1, = (R, 4-R 4 2 I.n = (R0 -R=n')*coS (O)*(AO)/4, Ri)-sin(On) 1 cos(On)'(AO)/4, Am = Y-1nn= Am,,,similar for A,, B%,B1, I,, 11,and I, (The origin of x-y coordinates is at the center of pipe section.)
Gravity center of pressure area : Yp = B2 A1 ; X0 =B3j/A, ; (in) 0.032 0.020 Gravity center of metal area : X, = -A/Am*Xp ; Y, = -A/AmY*.; (in) -0.373 -0.600 Moment inertias at G.C. of metal area : I, = 1, -Am'X' 2 , Iy.= 1y- A,,Ym3 , & . = Ixy "A.*Xm'Ym (;n) 487.0 515.7 -35.09 Actual thinned Section: , {I.+l,.[(l,.l,)2 + , /2, R,,= R, + (Xm+Ym3 )oS, Zm,, =lmiU~ra, 463.4 9.71 47.7 Nominal section: Incm, Ra, Z,,, ( for t..,= 0.375 in.); (in3 , in, in2 ) 806.6 9.00 89.6 Uniformly thinned section: I, R0, Z ( for (tmeas)min 0.074 in.); (in3, in, in3 ) 168.1 9.00 18.7 IP-CALC-07-00083 mark up.xls
- 2. Axial Stress for Actual Thinned Section Page 2 of 2 P : Design pressure, (psi)
SP = P'AAr, /1000, (ksi) 2.83 8 = (X, 2+Ym*'), Eccentricity of thinned section, (in) 0.71 M, = ptcRo2)'P&1000, Bending moment due to eccentricity of pressure force, (k-in) 27.0 Operating Condition Normal Upset Emer S :Code axial stress, (ksi) Ref. Inspection ID. PAB-90 in3R13 3.12 i 5.49 6 6.68 M, = (S - P-Dd/4tnon-/1000)'Zfom Bending moment due code loadings, (k-in) 118 331 437 M'= Mb + M,,: Total bending moment for thinned section, (k-in) 145 358 464 S' = S, + M'/Z,1 n : Actual stress due to thinning, (ksl) 5.88 10.33 12.56 new (0.75x sif) : use 1.0 1.00 1.00 1.00 original (0.75xsif) used in stress calc 2.625 2.625 2.625
[(new 0.75xslf) / (old 0.75xsif)](S') : Stress adjusted for new sit from wall thinning 2.2 3.9 4.8 S. : Allowable stress, (ksi) 15.0 I1 Acceptable if Saii0 > S' Yes Yes Yes Note: Due to accessibility, the wall thickness beyond the 10' region is an average of all the 2" grid UT readings Note 1: trnin = PD/[2(Sh+ .4P)] = 0.090 inch for hoop stress Note 2: average wall thicknes = 0.255 IP-CALC-07-00083 mark up. xls
IP-CALC-07-00083 Rev. 0 Page ID of 12 ID No. Through wall leak and flaw at A. Pipe Parameters Do = Pipe OD (in) 18 t = Pipe wall thickness (in) (.179+. 18,5+.231+. 156+. 131+. 159+. 149)17.231)/7 = o.170 1,om = nominal pipe wall thickness (in) 0.375 P' = Operational Pressure (psi) 70 P = Design Pressure (psi) 150 T = Design Temperature ("F) 160 R = pipe mean radius (in) = (Do - 1)/2 8.915 E = elastic modulus at T (ksi) 27800 JI, = material toughness (lb/in) 45 K1 ý = material critical stress intensity factor =Jj,*E/1000)0 - (ksi(in)°5 ) 35.37 B. Evaluation of Axial Flaw c = M/2 = Half axial flaw length (in) try "c' to make Kle- K,> 0.0 1.31 1,23 1.07 1.00 Fýl+,4A-2+B,f +Cg. +DW +-f_
1.58 1 52 Where A= 0.0724 B= 0.6486 C= -0.2327 D= 0.03B2 E= -0.0023 Operating Conditions Nor/Ups Eme/Fau P' = Pressure (psi) use P' for Nor/Ups & P for Eme/Fau condition 70 150 a, = P"'R/t/1000 = Hoop Stress (ksi) 3.67 7.87 SF : Safety Factor 3.00 1.50 0
Kjc -K, = KI, - (SF)-(P'R/t)-U7c-c) 'F > 0.0 0.0 0.0 Flaw length (2c) = 2.63 2.46 C. Evaluation of Circumferential Flaw c : Half circumferential flaw length tr yc" to make K,, - Ki > 0.0 1.46 1.98 a = chrR 0.052 0.071 r R/t 52.4 52.4 i= 0 1 2 3 3
Am= Am0 + Am,'r + AM2 "r + Ama'r A,- -2.0292 1.6776 -0.0799 0.0018 120.1 120.1 2 3 B,= B,0 + B,, 1 r + BM2"r + Bm 3 "r Bm. 7.0999 -4 .4239 0.2104 -0.0046 -314.1 -314.1 2 3 Cm= Co + Cm, r + Cm2 ?r + Cmr3 "r Cm 7.7966 5 .1668 -0.2458 0.0054 383.1 383.1 3
Ab= At0 + AbI *r + Ab2*r2 + Abt3r Aq -3.2654 1 .5278 -0.0727 0.0016 107.8 107.8 2 3 Bb= Bbo + St6,*r + B 2 r ++ B 3 r B, 11.363 -3 .9141 0.1862 -0.0041 -273.0 -273.0 2 3 0 Cb=Cw +Cblr -C,-*2'r +C,'r Cb -3.1861 3 .8476 -0.1830 0.0040 276.4 276.4 Operating Conditions Nor/Ups Eme/Fau 3 2 5 3 5 Fmo= I+ A,-a' 5+Bm' +Cm*a 2.25 2.88 5 25 5 Ft)= 1+ Ab*& +BE'*X+CbCt'. 2.12 2,69 P,= P'0/4tr,, : Axial stress due to design pressure (ksi) 1.80 1,80 S = P, + P.: Piping Axial Stress S...3.661 Pb=S- P, 0.90 1.86 SF: Safety Factor 2.77 1.39 Ki4 = 35.4 35.4 Kjc - K, = Kc - (SF)'(tc)f's (Pm'Fn +Po'Fb) > 0.0 0.0 0.0 Raw length (2'c) = 2.92 3.97
1/ ~ '2 The acceptable circumferential flaw length for normal/upset loading condition is 2.9", less than the combined (1" + 0.5" + 1.875") = 3.375", the flaw must be repaired and can not delayed until 3R15.
Since the acceptable circumferential flaw length for emergency/upset loading condition is 3.9", greater than the 3.375" flaw, the flaw is structural acceptable and operable for the past and present. The wall thinning area and the leak need to be repaired by weld overlay.
Provide minimum weld overlay from 1.5" beyond section 1 to 1.5" beyond section K in the circumferential direction and 1.5" beyond section 1 to 1.5" beyond section 6 in the axial direction.
The minimum overlay area is 9" axial by 14" circumferential.
After weld overlay, the SIF needs to be 2.1 for even a straight pipe. Since the pipe stress is low, the new stress after using the SIF mutiplier of 2.1 will still be below code limit.
UkT17\
Y J3
~K~A 2~'16 c~7~Th413I 4 ~
/~A~ /2 ~ Ii 6,8 Conclusion The acceptable circumferential flaw length for normal/upset loading condition is 2.9", less than the combined (1" + 0.5" + 1.875") = 3.375", the flaw must be repaired and can not delayed until 3R15. Since the acceptable circumferential flaw length for emergency/upset loading condition is 3.9", greater than the 3.375" flaw, the flaw is structural acceptable and operable for the past and present. The wall thinning area and the leak need to be repaired by weld overlay.
NMM EN-DC-126, R0 Attachment 9.2 Calculation Cover Page
ATTACHMENT 9.4 OPERABILITY EVALUATIONIFUNCTIONALITY FORM Sheet 1 of 1
[ Operability/Functionality Evaluation
- 1. Condition Report NoJOperability Evaluation No.CR-IP3-2007-03630 r Page 1 of 1
- 2. Summary of Operability Evaluation:
A thru wall leak was observed on the base metal of the elbow just above the weld of the 18" diameter SW FCU supply line downstream of SWN-38 on line #408.
The leak is a downstream of SWN-38 on a ISI class 3, Seismic class I line. The flaw was measured and characterized by UT Report IP3-UT-07-110 as three flaws (two leaking). The flaws were evaluated one flaw
.75" circumferential by 1.75" axial and another combined flaw of 3.375" circumferentially by 1.75" axial. These flaws were evaluated by using the ASME Code Case N-513 and acceptable at this time since they are less than the allowable flaw length of 3.97" circumferential and 2.46" axial. ( See attached calculation).
The flaws are acceptable but will not last until the next outage.
The pipe needs to be repalred as soon as possible, Within the month, so an proper repair can be made and to prevent the flaw from growing beyond the acceptable length.
- 3. Basis for Operability Evaluation attached. [ IP-CALC-07-00083 mark up attached.
- 4. Are there any other affected SSCs? [I No [ Yes Service Water supply header to the FCUs
- 5. Recommendation: [ Operable; E] Operable - COMP; [I Inoperable El Functional; E- Non-functional
- 6. Identify any Limitations, Long Term Actions and/or Compensatory Measures to maintain Operability: C] N/A 0 Yes (List WO, CA, tracking no., etc.) The pipe Is operable at this time in accordance with ASME Code Case N-513 "Evaluation Criteria for Temporary Acceptance of Flaws in Class 3 Piping". The pipe needs to be repaired as soon as possible, within the month, so an effective repair can be made and to prevent the flaw from growing beyond the acceptable length. ECR#2532 (EC 00003047).
50.59 Process Completed for Compensatory Actions Required to Maintain Operabillty',C" Yesl- N/AZJ N/A Approvals: .' P,/4., I/1-Prepared By (Name/Date): . (' "_ )
Additional Reviews (Assign thru CA Process) By (Name/Date): /0)v L *. , M A No. /
Additional Reviews (Assign thru CA Process) By (Name/Date) CA No.
Engineering Manager Approval By (Complete only if not entered in PCRS) (Print/Sign/Date) 1" Z4. CA.y Shift Manager (Complete only if not entered in PCRS) (Print/Sign/Date)
OE Closed: Date: Shift Manager:
Send a copy of the Operability Evaluation to the System Engineer for use in the System Health Report.
(Attach additional pages as necessary)
ATTACHMENT 4 TO NL-07-120 REPLY TO REQUEST FOR ADDITIONAL INFORMATION REGARDING INDIAN POINT 3 RELIEF REQUEST 3-43 Ultrasonic Test Results for Area of Interest Downstream of SWN-38 IP3-UT-07-1 10, September 2007 IP3-UT-07-049, March 2007 ENTERGY NUCLEAR OPERATIONS, INC INDIAN POINT NUCLEAR GENERATING UNIT NO. 3 DOCKET NO. 50-286
'i..' ~ UT Erosion/Corr' ý`on Examination Enter" Site/Unit: IP3 / 3 Procedure: ENN-NDE-9.05 Outage No.: N/A Summary No.: 18" Line # 408 Procedure Rev.: 1 Report No.: IP3-UT-07-110 Workscope: BOP Work Order No.: 00123409-02 Page: 1 of 5 Code: ANSI B31.1 1967 Ed. Thru 1969 Add. Cat./Item: N/A Location: PAB / Minim Containment Drawing No.: 9321 -F-27223
Description:
Characterize thru wall pipe leak System ID: Service Water Component ID: 18" Line # 408 DIS of valve SWN-38 Size/Length: 18" Sch STD Thickness/Diameter: 0.375" Limitations: Partially painted Component File No.: SWN-38 Start Time: 0800 Finish Time: 1630 Calibration Information Partitioning Information Component Information Calibration Thickness (In) Calibration Times / Initials Component Begin/Col/Row Ending/Col/Row Component Geometry: 90 Deg. Elbow
.040" .500" Start: 0945 REA M. UPST Ext. N/A Outside Diameter: 18" Grid Size: 1" X 2"
.100" N/A Verify: 1025 REA Main UPST. N/A Max. Thickness: .369" Min. Thickness: .077"
.200" N/A Verify: 1120 REA Main Al AC3 Nominal Thickness: .375" Tmin.: .090"
.300" N/A Verify: 1410 REA Main DNST. Al K6 Mi. Thickness Location: Micro grid 14
.400" N/A Final: 1445 REA M. DNST Ext. N/A M . i e L a nl g d Branch BrnhNAMax.N/A Thickness Location: Weld grid 01 Branch Ext. N/A Instrument: Transducer: Reference/Simulator Block: Temp. Tool:
Manufacturer: Panametrics Manufacturer: Panametrics Serial No.: A23867 Manufacturer: Control Co., Inc Model: 37DL+ Serial No.: 1003013 Type: C/S .04"-.5" Serial No.: QS-78 Serial No.: 031110106 Size: .312 Freq.: 5 MHZ Ref/Simulator Block Temp.: 91.2 °F Couplant:
Gain: 60 Model: D7906 Type: Ultragel Range: 1.0" # of Elements: Dual Material/Component Temp.: 85.6 IF Batch No.: 05325 Comments/Obstructions: Thru coat mode used for micro & weld grids. D798 probe (S/N 532905) use for area sizing data. 'z Results: Accept [§7 Reject _vj Info E] Tmin = .090" per IP-CACL-07-00083. -z_ a -a---7 - ,
Examiner Level III-PDI nature Date Reviewe Signature Date Allen II, Robert E. 6919/2007 " 7 Examiner Level N/A I nature Date e Review Jn f-S- r*+Dte N/A !Id&L Alvuej1 Other Level N/A Signature Date A I Review Si~naturE Date N/A __/_G_
Supplemenrat Report Report No.: ,P3-UT-07-110 Entergy Page: 2 of 5 Summary No.: 18" Line #,408 :
1.
Examiner: Allen II, Robert E. Level: III-PDI Examiner: N/A Level: N/A Date Other: N/A Level: N/A Comments: Sketch of weld & micro grid layouts. Weld grid locations U3, V3, W3, X3 and Y3 correspond with micro grid locations B6, D6, F6, H6, and J6 and are only shown in th micro grid data printouts.
Sketch or Photo:
~LC~-O C~Zs~
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AY, lC tlZA-Z.
t i
Lo Uj iýý W9 Lo &C SW 11ý -35 (-ocA-rwý
Win37DLPlur-"ata Grid 18" Line #408 D/S of .A-38-Weld Grid File Name: SWN-38 Survey Date 91912007 File Type: 2D Grid Minimum thickness: i.162" @ 02 File
Description:
E/C Maximum thickness: @ Q1Q.369" Location Note .P3-UT-07-1 IP3 Report No.: 10 Inspector ID: '~ Page 3of 6 RobertAllen -
Obstructions: F1-H3, nee scaffold to reach U3-Y3, -locati.ro,-
ns o
..n mic_.
c-ro .gri*
-d . Reviwer...".A.0.. ..
Color Legend
- I--
=3 F 0.328 o-0.421 o
Ud i022 3n28 Under Range F-oo Page 1 Report Date: 911912007
Win37DLPluf-'ata Grid 18" Line #408 D/S of SWN- - - Micro Grid on elbow File Name: SWN-38M Survey Date: 911912007 File Type: :2D Grid Minimum thickness: i.077" 14 File Description : E/C Maximum thickness: A28" K1 Location Note: IP3 Report No.: IP2-UT-07-1 10 Inspector ID -Page 4015 Robert Alle n Obstructions: *A2-C2, valve hand wheel Reviwer,
-Color Legend Over Rarnge
[_
FO.421 i0.328-0.421
- 0o328 0-.o262 Fo .328 Fo .262 F 112 1-000-0 I Under Range Page 1 Report Date: 91 912007
Supplem~ental Report Report No.: IP3-UT-07-110
£u/erg~y Page: 5 of 5 Summary No.: 18" Line # 408 Examiner: Allen II, Robert E. Level: III-PDI Reviewer: , Date:
Examiner: N/A
'I Level: N/A Site Review . , Xl P6 lag , _ Date:
Other: N/A Level: N/A ANII Review: L-i Date: "_ "
Comments: Scan of the elbow micro grid showing the areas that are less than .109" thick. These areas are around both through wall leaks and the grid locations H4 and 14. Leak #1 is contained in grid B3-B4-C3-C4, and leak #2 is contained in grid F4-FS-G4-G5.
UT Erosion/Coi sion Examination Enterg Site/Unit: IPEC / 3 Procedure: ENN-NDE-9.05 Outage No.: N/A Summary No.: N/A Procedure Rev.: 0 Report No.: IP3-UT-07-049 Workscope: BOP Work Order No.: IP3-07-17850 Page: 1 of 3 Code: ANSI B31.1, 1967 Ed. thru 1969 Add. Cat./Item: N/A Location: 32' PAB SW Chase Drawing No.: 9321F27223
Description:
Pipe and weld down stream of SWN-38 System ID: Service Water Component ID: SWN-38 Size/Length: 18" Sch Std. Thickness/Diameter: .375" Limitations: Painted surface Component File No.: N/A Start Time: 0830 Finish Time: 1045 Calibration Information Partitioning Information Component Information Calibration Thickness (In) Calibration Times / Initials Component Begin/Col/Row Ending/Col/Row Component Geometry: Pipe & weld
.040" N/A Start: 0830 RDH M. UPST Ext. N/A N/A Outside Diameter: 18' Grid Size: 1"
.100" NWA Verity: 0920 RDH Main UPST. N/A N/A Max. Thickness: .340" Min. Thickness: .033"
.200" N/A Verity: N/A N/A Main N/A N/A Nominal Thickness: .375" Tmin.: .110
.300" N/A Verify: N/A N/A Main DNST. N/A N/A M. Thickness Location: H6
.400" N/A Final: 1045 RDH M. DNST Ext. N/A N/A Branch rac N/AAWA N/A Max. Thickness Location: A4 Branch Ext. N/A N/A Instrument: Transducer: Reference/Simulator Block: Temp. Tool:
Manufacturer: Panametrics Manufacturer: Panametrics Serial No.: 99-7437 Manufacturer: Control Co., Inc Model: 37DL+ Serial No.: 576062 Type: Cf/S .04"-.5" Serial No.: 0S-75 Serial No.: 031110106 Size: .312' Freq.: 5 MHZ Couplant:
Gain: 59db Model: D7906 RefJSimulator Block Temp.: 71.7 OF Type: Ultragel Range: 2" # of Elements: Dual Material/Component Temp.: 46 OF Batch No.: 05325 Comments/Obstructions: The grid range was from Al to K6. No readings were taken at Al, A2, A6, B1, K1, K2 or K6.
Results: Accept I Reject ý41 Info 1.1 Gage operated In thru-coat mode.
Examiner Level IlL ,Signature Date Rev ewer Signature Date Herrmann, Robert D. 3/27/2007 Examiner Level Signature Date SitRe~eview- Signature Date Other Level Signature Date ANII Rev ew Signature Date A-.
r0r OFA IP4TEAkT tI oA-4 oZ2A 8 8
.7-7~ 0A 0. ki o -
-1 1-4 F-ID.-1 1 'o1-Z 1 -4 0.II ,104 A~~ 0~ 1~es O' S 01 *,a' 0a1 ,3
rA cI'JVc ST 51'415 ViEw A' f~~ A41S' MgrcL.SC 600'O K
347 2
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ATTACHMENT 5 TO NL-07-120 REPLY TO REQUEST FOR ADDITIONAL INFORMATION REGARDING INDIAN POINT 3 RELIEF REQUEST 3-43 Entergy Calculation IP-CALC-07-00209, Revision 0 Design Reinforcement Plate for Through Wall Leak Repair D/S SWN-38 ENTERGY NUCLEAR OPERATIONS, INC INDIAN POINT NUCLEAR GENERATING UNIT NO. 3 DOCKET NO. 50-286
NUCLEAR OUALIT RELATED EN-DC-126 REV. 0 Enteoi., MANAGEMENT MANUAL REFERENCE USE PAGE 27 OF 32 Engineering Calculation Process E ANO-1 E ANO-2 M GGNS 561P-2 [ IP-3 LIJAF [E]PNPS [] RBS El VY El W3 CALCULATION (1)EC # 3/ 76, (2) Page 1 of 8 COVER PAGE (3)Design Basis Caic. El YES O NO (4) E CALCULATION - EC Markup Calculation No: IP-CALC-07-00209 I6) Revision: 0
Title:
Design Reinforcement Plate for Through Wall Leak Repair DIS SWN-38 (8 System(s): SWS (9) Review Org (Department): Civil / Structural Design Engineering (10) Safety Class: (11) Component/Equipment/Structure Type/Number:
Z Safety / Quality Related SWN-38 FI- Augmented Quality Program F-1 Non-Safety Related (12) Document Type: CALC (13) Keywords (Description/Topical Codes):
REVIEWS (14) Name/Signatu e/Date (15)Name/Signý ýate (16) Name/Signatpre/D~te Kai Lo 9-25-07 P, Bowe 9-26-07 -R. Drake 9-26071' Responsible Engineer Z Design Verifier Supervisor/Approval fit4z, F- Reviewer LI Comments Attached M- Comments Attached NMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
ATTACHMENT 9.3 CALCULATION REFERENCE SHEET CALCULATION CALCULATION NO: IP-CALC-07-00209, REV. 0 REFERENCE SHEET Page 2 of 8 I. EC Markups Incorporated: NONE 1,
2.
3.
4.
- 5. __
II. Relationships: Sht Rev Input Output Impact Tracking Doc Doc Y/N No.
- 1. 00
- 2. 0 0 __
- 3. _ 0 0 _
- 4. _ 0 0 _
- 5. 0 0 _ _
iii. CROSS
REFERENCES:
1.
2.
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5.
IV. SOFTWARE USED: NONE
Title:
Version/Release: Disk/CD No.
V. DISK/CDS INCLUDED: NONE
Title:
Version/Release Disk/CD No.
VI. OTHER CHANGES: NONE NMM EN-DC-126. RO Attachment 9.2 Calculation Cover Page
Page 3 of 8 Rnevision:-.. Record of-Revision~
Initial issue of Calculation IP-CALC-07-00209.
0 NMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
LIST OF EFFECTIVE PAGES Page 4 of 8 Calculation Number: IP-CALC-07-00209 Revision Number: 0 PAGE REV. PAGE RE' V. PAGE REV.
All 0 NMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
TABLE OF CONTENTS PAGE 5 OF 8 T211! Page No.
1 Calculation Cover Page .............................................. ......... 1 2 Calculation Reference Sheet .................................................................. 2 3 Record of Revisions ................................................................ 3 4 List of Effective Pages ................................................................ 4 5 Table of Contents ............................................................... 5 6 Calculation Section .................................................................. 6 6.1 Background .................................................... 6 6.2 Purpose .... .......................... .................. 6 6.3 Method of Analysis ......................................................... 6 6.4 Assumptions ................................................................ 6 6.5 Design Input ............................................ 6 6.6 References ....................................................... 6 6.7 Calculation ........................................................ 7 6.8 Results/Conclusions ............................................................... 8 NMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
6.0 Calculation Section Page 6 of 8
6.1 Background
Two through wall leaks and a below minimum wall thickness area were found down-stream of the valve SWN-36 at the region next to the weld toe on Line 408.
6.2 Purpose A temporary repair is needed to repair the elbow at two leaks and below minimum wall thickness area. Itis necessary to design a plate and weld it over the leaked/thinned area.
6.3 Method of analysis
- 1. Based on a four side simple support regular plate with a uniform design pressure of 150 psi acting on it, determine plate thickness required to stay below the allowable stress for the plate material.
- 2. Based on item 1, reaction at the simple supported edge can be obtained for the weld stress.
- 3. Determine the transverse shear to be carried by the weld (in the longitudinal direction) in order for the elbow and curved plate to act as one integral piece to resist flexural bending.
- 4. Determine the torsion shear taken by weld along the circumferential direction.
- 5. SRSS the weld stresses to obtain the resultant weld stress and determine the fillet size to ensure the weld stress is below the allowable weld stress.
- 6. Evaluate the pipe stress of a section of uniform wall thickness of 0.2 (minimum pipe thickness outside of the reinforced plate) for design loadings.
6.4 Assumption
- 1. Allowable stress of 15000 psi is based on either a curved section of a 20" elbow of A53 Gr. B seamless material, or A106 Gr B or C, or a rolled plate from A442, A515 or A516 Gr. 60 material.
- 2. Three times the larger reaction from the two adjacent pipe supports is used to design for the transverse shear carried by the weld for the reinforcement plate.
6.5 Design Input
- 1. IP3 Pipe specification TS-MS-027
- 2. Drawing 9321-F-53533
- 3. USAS B31.1, Power Piping Code, 1967.
- 4. Pipe support calculation for SWN-R-524-R & SWN-H&R-525-U 6.6 Reference
- 1. IP3 Pipe specification TS-MS-027
- 2. Drawing 9321-F-53533
- 3. "Formula of Stress and Strain", Roark and Young, 5t edition
- 4. USAS B31.1, Power Piping Code, 1967.
- 5. Pipe support calculation for SWN-R-524-R & SWN-H&R-525-U NMM EN-DC-126, RO Attachment 9.2 Calculation Cover Page
6.7 Calculation Determine reinforcement plate thickness and fillet weld size Pipe thickness beyond the reinforcement plate is greater than 0.25".
new reinforcement plate t = plate thickness = 0.5 in a = plate length in the circumferential direction = 10 in, line from A to J plus 1.5" on each side b = plate length in the axial direction = 7 in, from line 1 to 6 plus 1.5" from line 1 q = design pressure of piping = 150 psi w = filet weld size = 0.5 in Use plate material A442, A515, or A516 Gr. 60, Sh = 15000 psi (or cut from a pipe elbow)
Design plate for uniform pressure:
Assume 4 sides simple support [Ref 3, table 26, case la]
a/b= 1.429 0.463 7= 0.48 (Y= plate normal stress = P3qb 2/t2=
13612 p,si< S = 15000 psi max R = ,qb = 504 lb per inch fw, = weld stress for pressure = R/(0.707w) = 1426 p*si Design plate for bending:
Plate and exist pipe must act together as a composite, integral section with the weld taking the transverse shear.
f = transverse shear at weld = VAy/(In)
For a continuous beam, the resisting shear will be smaller than the reaction at the support To design for shear, consider the adjacent support reaction.
Reaction at adjacent support SWN-R-524-R = 2411 lb [Ref. 5]
Design for 3 times the reaction, V = shear = 7233 lb Determine the distance from the c.g. of new plate to pipe cenetrline for new plate:
t = nominal thickness of new plate = 0.5 in R = mean radius to plate = 9.25 in L, = length of new plate = 10.0 in
. ., (36o0 30.97 degrees o( radiaiiz) = 0.5405 tR = 0.0541 A = area = ctt(2R-t) = 4.86 in2 [Ref 3, table 1, case 19]
V ,, =
0.680 in
/P -f ,F e y = distance from c.g. of segment to pipe center = R - Yia = 8.570 in D = outside diameter = 18 in For moment of inertia calculation, use t = 0.200 in d =inside diameter =D - 2t= 17.600 in I = moment of inertia of the pipe = 0.0491[D' - d4] = 443.1 in4 n = number of welds to carry the transverse shear = 2 f = transverse shear at weld = VAy/(In) = 340 #/in note: in the longitudinal of the pipe fw2 f/(.707w) = 963 psi Design weld for torsional shear T = torsion at pipe, conservatively use 437248 in-lb, see 0.75i(Ma + Mb) for value (S e e6CQOvi)
R outside radius = D/2 = 9.0 in R= inside radius = (R-t) = 8.80 in
= 2TR/[n(R 4-Ri 4 )] = 4442 psi f,3 = T(t/w)1(.707) = 2513 psi fw = {f.,2 + fw2 2 +fw 32 10". = 3045 psi e = efficiency factor for weld = 0.8 Allowable weld stress is governed by base metal = eSh = 12000 psi > f, = 3045 psi, o.k.
Verify the repaired condition meeet original design loading requirement.
For original pipe stress analysis P - design pressure = 150 psi D = outside diameter = 18 in t'= nominal pipe wall thickness = 0.375 in S'= section modulus = 89.60 in3 0.75i' = SIF used in stress run =.75*3.5 = 2.625 at 45 degrees portion of elbow f'nor = normal stress from stress run =[ 312 psi, from PAB-90 inpsection point fdw~obe = DW+OBE stress from stress run Psi p5490 f'dwdbe = DW+DBE stress from stress run = 660 Psi fl = PD/(4t') = 1800 psi f'dw = dead weight stress w/out pressure = f'nor - f'p = 1320 psi 0.75iMa = moment due to DW loading = fdwS' = 118272 in-lb Based on wall thinning pipe wall, t = 0.20 in S based on t= 61 in3 PD/(4t) + 0.75iMa/S = 5314 psi < S= 15000 psi f'dwobe = obe pipe stress w/out pressure = f'dw-be - fp 3690 psi 0.75i(Ma+Mb) = moment due to DW+OBE loading =f'doS 330624 in-lb PD0(4t) + 0.75i(Ma+Mb)/S 8795 psi < 1.2 Sh = 18000 psi f'dbe = dbe pipe stress w/out pressure = f'dw~db - fp 4880 psi 0.75i(Ma+Mb) = moment due to DW+DBE loading = f'd+dbeS' = 437248 in-lb PD/(4t) + 0.75i(Ma+Mb)/S = 10543 psi < 1.8 Sh = 27000 psi 6.8 Conclusion The new reinforcement plate stress, new fillet weld, and pipe section with reinforcement plate are structurally adequate per 831.1 code and criteria.
,*fr. (j )0. /a P Z MLE 26 Formulasfor flat plates with straight boundaries and constant thickness
- ATIOt3:The notation for Table 24 applies with the following nmodifications: a and b refer t? plate dimensions, and when used as subscripts for stress, A refer to the stresses in directions parallel to the sides a and b, respectively. o is a bending stress which is positive when tensile on the bottom and npressive on the top if Iadings are considered vertically downward. R is the reaction force nornal to the plate sitrface exerted b\ the boundary support the edge of the plate (poutnds per inch). rt, is the equivalent radius of contact fitr a load concentrated on a very small area and is given hy 7'
+ t2 - 0.6751 if r, < 0.51 and r, = r if I > 0.51
- at.ettu,lr sCasn., lading F r.,t..as R3d Wlt.ulatedIspecifiv ihae.i shap,. and nipap-ts Uo Re.tangular platvc;all rdge, dAg t . li~erm over q,,, entire MR MaA, 1 (=- and -axI -
simply 5uaprttL*C plat D3 (Ai center ,of 1,n, sideq M-a R = yqb a/6 1.0 1.2 1.4 1,6 1.8 2,0 t.0 4.0 5.0 00 Ss i0.2874 0.37(2 0.4530 0.5172 0.5368 0.6102 0.7134 017410 0,7476 0.7500 0.0444 0.0770 0.0500 0.1017 0Is061 0.1110 tOs,335 0,1400 0.1417 0.1421 0.120 0.455 0.47 0.40t
. n.499 0,50. 0.505 0.502 0.501 0.500 (Rdf. 2t for x 0.3)
Ib. U nifism oner siall (At rentcel Max tai +~n[ ) t 2 aWiw ("wte Mini- -a I.1 n). 1.2 1.4 1.6 LS5 2.01 10(.435 0.6,50 0.78!1 t.3;75 0.927 0.95,4 L.OW0 10.12617 0.14781 0.I6-21 1.1715 0t.t530 0.1,905 0.Ib51 (Her. 21 f- t a
P 0
I(. L~u~tt OtIemml (S Ciel ' .la, Ct =t (, ,,ere t11= Flb,.
.. =l nn = 1.4b a = 2b 11.2 0,4 1). 0.r1 1.0U 1 0.2 01 0.11 1.2 1.4 01.4 0.S 1.2 1.6 2,0 I.82 1.3f 1.12 0,010 0.76 2.0 1.55 1.12 0.84 0.75 1.64 1.21) 0.47 (1.73 0.64 0.641i17 1.31 1.03 0.84 0.6S 0.57 0,2 IX2 1.21' 1.0. 0.9 0.76 0.63 1.7, 1.43 1.23 0.95 0,74 0.55 1.32 1.07 0.,4 0.72 0,62 0.52 1:1.. 1.1 I W.00 0.80 0,62 1.0," 0.818 0.74 0.60 0.50 f-.4 1 .3Itq 0.53 0.47, 1.04 0.991 0.76 0.04 0.54 0.44 0.6 .1 0.910 0.72 0,60 0.52 0.431 1.10 0.91 0.82 0.68 01.76 0.62 01.31 0.42 0.:136 0.90 0.76 0.0s (.57 V.4:0 0.40 0117 0. 76 0,10 0.54 U.44 0UPS 11,33 7 ((.1 11.(i 0.53 1 0.45 0.1K U.30 1.0 !0.76, 0.(fi.. 0.52 1)42 0.35 0.301 0.7 0 62 0.57 0.47 01.3 (tVe f-M hat, of Re4. R:, k= i 1)
,hs
,.. ... .. t....
Idt. [',,iform~d l l, titJl rt[12]4 0,71, al mhtgth "" MR,* Itd m*?* .1'-53 2..l( 2.5 :.0 3.5 4.0 0.314 0 11 0,41 0,47 0.44 0.6 (.l76*
OA( fl.17-S' 1i.W~ 0*S*
.09 1
((022 0.0(43 f........ cta.i A Rf 8i: 0JL.)
INmnv~s Ra -n. ad
- nat'1 o ari.i 2.11 o.1
.1.5 4.0 16 ,.2( (I.7 0.33 0:17 3.78I 0.11
inertia ah- 1~A.~ 2"' ".7 TABL.E I Properties of sections (Cpnt.)
H' R 2'in, Ar'.eaaid dstaiic, ir.nt Fern i~ -icc.
Cttiiiil idw tremitits in n 2
I -f .'d circl Nglm (iL i. 4 /? (,X iii n Cin 4
case is)ii J - ~itnI-cos a)]
2 Rf 2itta 1 ------- ~ i 2
a~n 20ii~
cosilI in oi=~I , -I 4 k I - 0 9 i + i 21 1, R a 030lt I0. 0 Rnf )t4i I~~~ 9. *+/- Siinen 41).
ui Iiisid ,t4 -0Oi~n
___ 2 y
ca
- 19. Sievientfh(lliii 6i,,le fAnti; If .4 w( 2lR -1) ll R "t I N*-- :.4 n/.iii + ~
2 ýi 'J 11i A
-l i . J RI +~2
.,~~tiI, If ;t qs Id 5
I in III t .
6-- 21-a Ii ,4 i+ i45ii4-
- 20. K~iflli .- n Oe.1n irith .1 i.4 cI'l I in- + x SO.3tiuiici) t Ii'I n II vTILn,~i 770P14 ]sini [-
I If. i uwf:
if ,/2 i, odd;.
.1
'12