ML082250675
ML082250675 | |
Person / Time | |
---|---|
Site: | Palo Verde |
Issue date: | 07/11/2008 |
From: | Mims D APS, Arizona Public Service Co |
To: | Document Control Desk, Office of Nuclear Reactor Regulation |
References | |
102-05869-DCM/RJR | |
Download: ML082250675 (59) | |
Text
Dwight C. Mims Mail Station 7605 Palo Verde Nuclear Vice President Tel. 623-393-5403 P.O. Box 52034 Generating Station Regulatory Affairs and Plant Improvement Fax 623-393-6077 Phoenix, Arizona 85072-2034 102-05869-DCM/RJR July 11, 2008 ATTN: Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555-0001
Dear Sirs:
SUBJECT:
Palo Verde Nuclear Generating Station (PVNGS)
Units 1, 2, and 3 Docket Nos. STN 50-528, 50-529, and 50-530 American Society of Mechanical Engineers (ASME) Code,Section XI, Request for Approval of an Alternative Repair Method - Relief Request No. 39 Pursuant to 10 CFR 50.55a(a)(3)(i), Arizona Public Service Company (APS) requests NRC approval of Relief Request 39, which proposes an alternative repair method to the ASME Code requirements of Section Xl. Specifically, APS is proposing the alternatives discussed in the enclosure to this letter to the flaw characterization requirements of IWC-3420 and IWA-3300.
APS requests approval of this relief request within one year from the date of this letter.
If you have any questions about this change, please contact Russell A. Stroud, Licensing Section Leader at (623) 393-5111.
Sincerely, DCM/RAS/RJR/gat Enclosure cc: E. E. Collins Jr. NRC Region IVRegional Administrator M. T. Markley NRC NRR Project Manager R. I. Treadway NRC Senior Resident Inspector A40 a
Enclosure Relief Request 39 Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i) " Structural Integrity Associates, Inc. Calculation 0800802.303, Thermal and Mechanical Stress Analysis of Safety Injection Tank Vent Relief Nozzle Repair Structural Integrity Associates, Inc. Calculation 0800802.306, Flaw Tolerance Evaluation of Safety Injection Tank Nozzle Penetration
Enclosure Relief Request No. 39 Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i)
Background
There are four Safety Injection Tanks (SIT) in each unit which contain borated water and are pressurized with nitrogen. They discharge their contents to the Reactor Coolant System (RCS) following depressurization as a result of a Loss-of-Coolant Accident (LOCA). Each tank is piped into a cold leg of the RCS via a safety injection nozzle located on the RCS piping near the reactor vessel inlet. The tank vent nozzle is on the upper head of the tank in the nitrogen blanket. Each tank is approximately 41 ft.
high and 9 ft. in diameter. The operating level is maintained at approximately 32 ft. to 34 ft. The upper alarm limit is set at approximately 35 ft. Technical Specifications require the boron concentration be in the range of 2300 ppm to 4400 ppm; and that the nitrogen cover pressure be maintained from 600 pounds per square inch, gauge (psig) to 625 psig. The SIT operates at a temperature range of 600 Fahrenheit (F) to 1400 F.
On Thursday June 5, 2008, Palo Verde Nuclear Generating Station (PVNGS) declared the Unit 1 SIT 1A inoperable when a small leak was identified at the annulus between the tank and the vent line during the performance of a leak test.
Ultrasonic (UT) examination of the carbon steel material of the vessel around the nozzle attachment weld (Alloy 82/182) showed no flaws. It appeared that the leak was due to flaw(s) in the 82/182 weld material. The nozzle repair consisted of making a new J-weld to attach the nozzle at the outer surface of the vessel. The original J-weld on the inner surface was left in place. The design of the new configuration complies with the construction Code. The weld was completed and examined visually and nondestructively in full compliance with the requirements of ASME Sections III and XI.
After the repair was completed, an Operability Determination (OD) of SIT 1A was completed and the SIT was determined to be operable with an action to submit a relief request in a timely manner after completion of the OD.
ASME Code Components Affected ASME Item number: C2.20
==
Description:==
Safety Injection Tank (SIT) Nozzles Code Class: 2 Applicable Code Editions and Addenda Third 10-year Inservice Inspection Interval Code for PVNGS for Units 1,2, and 3:
American Society of Mechanical Engineers (ASME) Code,Section XI, 2001 Edition, 2003 Addenda Page 1
Enclosure
Applicable Code Requirement
IWC-3420, Characterization, states that each detected flaw or group of flaws shall be characterized by the rules of IWA-3300 to establish the dimensions of the flaw(s). These dimensions shall be used in conjunction with the acceptance standards of IWC-3500.
IWA-3300, Flaw Characterization, states that flaws detected by inservice examinations shall be sized by the bounding rectangle or square for the purpose of description and dimensioning.
Reason for Request
Unit 1 SIT 1A was indicating a gradual lowering trend in nitrogen pressure. During the investigation of potential leak paths, a leakage source was identified at the 2 inch vent line nozzle annulus (see Figure 1) where leak testing (snoop method) indicated a two bubble per second leak.
Manway N2 Inlet Vent 28'!
41 Approx Figure 1 Page 2
Enclosure APS repaired the leak by moving the pressure boundary from the inside of the SIT to the outside by making a partial penetration nozzle attachment weld as shown in Figure 2, This resulted in leaving the flaw in the original weld in place.
Removal of the flaw would require access to the nozzle weld on the interior of the SIT.
This would require scaffolding both outside and inside the SIT. The limited size of the manway and the distance from the manway to the repaired nozzle presented significant personnel safety concerns such as, confined space entry due to the small size of the manway and personnel fall protection due to the 40 foot distance from the weld to the tank bottom (see Figure 1). Additionally, the difficulty in controlling entry of foreign material from grinding and welding into the SIT was considered. The requirements of ASME Section IWC-3420 and IWA-3300 require that a flaw or group of flaws be characterized to establish -the dimensions of the flaw(s) and that these dimensions be used in conjunction with. the acceptance standards of IWC-3500, Acceptance Standards. Characterization by UT is not possible due to the geometry of the partial penetration weld.
Due to the personnel safety concerns and the inability to characterize the flaw, APS developed an alternative that postulated a worst-case flaw in the original weld, evaluated its acceptance using IWB-3600, Analytical Evaluation of Flaws, and determined that the defective J-weld could be left in place. The postulated flaw is an axial crack in the Alloy 82/182 weld metal. This postulated crack represents the worst-case for the most-likely weld discontinuities such as porosity and slag inclusions that caused the leak. This material, as well as the base material, are not susceptible to stress corrosion cracking at 1400 F in a nitrogen environment. In addition, no operating experience concerning incidents of stress corrosion cracking of Alloy 600/182/82 in an air or nitrogen environment at ambient temperature was found.
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Enclosure Proposed Alternative and Basis For Relief Pursuant to 10 CFR 50.55a(a)(3)(i), APS is proposing an alternative to the required flaw characterization of IWC-3420 and IWA-3300. APS is not proposing any alternative to the required successive examinations (IWB/IWC-2420, Successive Inspections).
This Relief Request seeks approval to allow the analyzed flaw to remain in-place for the remainder of the expected plant life for Unit 1 and to allow the application of this alternative to any similar repairs on the remaining safety injection tanks in Unit 1 as well as Units 2 and 3.
Proposed Alternative In lieu of fully characterizing/sizing the existing flaw, APS has assumed a worst-case flaw and performed the following:
- a Thermal and Mechanical Stress Analysis of the repair (Attachment 1), and
- a Flaw Tolerance Evaluation (Attachment 2) to ensure that the postulated, worst-case flaw, meets the acceptance criteria of the ASME Code.
The Flaw Tolerance evaluation resulted in a postulated final flaw of 0.352 inch (original depth of the partial penetration weld plus projected growth due to fatigue) in the carbon steel material of the vessel. This postulated flaw was analyzed in accordance with IWB-3600 and shown to be acceptable to the IWB-3612, Acceptance Criteria Based on Applied Stress Intensity Factor. The flaw evaluation demonstrates that the flaw will remain within acceptable Section Xl limits for the expected 40-year plant life (remaining plant operating license plus 20-year life extension).
Basis for Relief When moving the pressure boundary of a tank attached nozzle from the inside to the outside of the tank, the flaw must be characterized and shown not to impact the integrity of the tank or new weld. In lieu of fully characterizing/sizing the existing flaw, APS postulated a worst-case flaw and performed the analysis delineated above.
The analysis demonstrates that any flaw in the nozzle or attachment weld will not propagate such that the structural integrity of the new weld or the tank boundary is affected. Therefore, the proposed alternative provides an acceptable level of quality and safety as required by 10 CFR 50.55a(a)(3)(i).
Duration of Proposed Alternative APS requests that this relief be granted for this repair to PVNGS Unit 1 and be applicable to any subsequent similar repairs to Units 1, 2, or 3 SITs and that the relief remain in effect for the remainder of the expected plant life. The current operating licenses are scheduled to expire on June 1, 2025, April 24, 2026 and November 25, Page 4
Enclosure 2027, for Units 1,2, and 3 respectively. On May 15, 2008, APS filed its advance notice of intent to pursue operating license renewal, Agency Document Access and Management System (ADAMS) ML081420365.
Commitments There are no commitments made in this request.
Conclusion 10 CFR 50.55a(a)(3) states:
"Proposed alternatives to the requirements of paragraphs (c), (d), (e), (f), (g), and (h) of this section or portions thereof may be used when authorized by the Director of the Office of Nuclear Reactor Regulation. The applicant shall demonstrate that:
(i) The proposed alternatives would provide an acceptable level of quality and safety, or (ii) Compliance with the specified requirements of this section would result in hardship or unusual difficulty without a compensating increase in the level of quality and safety."
The proposed alternative discussed in this relief request provides an acceptable level of quality and safety. Therefore, APS requests that the proposed alternative be authorized pursuant to 10 CFR 50.55a(a)(3)(i).
Precedents
- 1. Palo Verde Relief Request 31 Revision 1, Safety Evaluation dated September 12, 2006, (TAC NOS. MC9159, MC9160, AND MC9161) Agencywide Documents Access and Management System (ADAMS) Accession Number: ML062300333.
In lieu of fully characterizing/sizing the potentially existing flaws, APS assumed worst-case flaws in the Alloy 600 base and weld material and used the methodology presented in NRC-approved Westinghouse Topical Report (TR) WCAP-15973-P, Revision 01, "Low-Alloy Steel Component Corrosion Analysis Supporting Alloy 600/690 Nozzle Repair Program," to support the request. APS reviewed the bases and arguments presented in the TR and determined that the TR bases and arguments can be applied to the previously repaired Unit 1, 2, and 3 hot-leg small-bore nozzles and demonstrated compliance with ASME Section XI criteria for the remaining plant operating license plus 20-year life extension.
The difference between Relief Request 31, Revision 1 and Relief Request 39 is the environment. Relief Request 31, Revision 1 had to account for a higher operating temperature and exposure to borated water.
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Enclosure
- 2. Palo Verde Relief Request 29 Safety Evaluation dated November 11, 2004, (TAC NOS. MC3606, MC3607, AND MC3608) ADAMS Accession Number:
Relief Request 29 provided relief from certain flaw evaluation requirements and from the successive examination of the remnant pressurizer heater sleeves left in-place after performing a half-sleeve mid-wall weld repair in Units 1 and 3. The flaw evaluation supporting this request utilized both Linear Elastic Fracture Mechanics (LEFM) and Elastic Plastic Fracture Mechanics (EPFM), and demonstrated compliance with ASME Section XI criteria for the remaining plant operating license plus 20-year life extension.
The difference between Relief Request 29 and Relief Request 39 is the environment of the analysis. Relief Request 29 had to account for a higher operating temperature and exposure to borated water.
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Attachment 1 Structural Integrity Associates, Inc. Calculation 0800802.303, Thermal and Mechanical Stress Analysis of Safety Injection Tank Vent Relief Nozzle Repair
C StructuralIntegrityAssociates, Inc. File No.: 0800802.303 CALCULATION PACKAGE Project No.: 0800802 [ Q - Non-Q PROJECT NAME: ASME Code Evaluation of Safety Injection Tank Nozzle Repair CONTRACT NO.: Master Agreement No. 500299013 CLIET:
rizoa Pbli SericeCo.PLANT: Palo Verde Nuclear Generating Station, Unit I CALCULATION TITLE: Thermal and Mechanical Stress Analyses of Safety Injection Tank Nozzle Repair Document Affected Project Manager Preparer(s) &
Revision Pages Revision Description Approval Checker(s)
Signature & Date Signatures & Date 0 1-16 Original Issue A1-A2 Computer Files G.A. Miessi P. Jing GAM 07/03/08 PJ 07/03/08 F.H. Ku FHK 07/03/08 A. Chintapalli AC 07/03/08 Page 1 of 16 F0306-O1RO
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Table of Contents 1.0 IN TR O DU CTIO N .............................................................................................................. 3 2.0 D E SIG N INPU T S......................................................................................................................... 3 3.0 M E T HO D O L O GY ......................................... I.............................................................................. 3 4 .0 AN AL Y SIS ...................................... ........................................................................................... 3 5.0 R E SU LTS ..................................................................................................................................... 5 6 .0 CON CLU SIO N ............................................................................................ ................................. 5 7 .0 REFERE N CE S .............................................................................................................................. 6 APPENDIX A - ANSYS INPUT AND OUTPUT FILES ....... ...... . ......................... Al List of Figures Figure 1: Finite Element Model of the Safety Injection Tank Vent Relief Nozzle ............. 7 Figure 2: Path Definitions for Stress Results Extraction ................................................................. 8 Figure 3: Applied Boundary Conditions .......................................................................................... 9 Figure 4: Applied Internal and End Cap Pressure ............. .................................... 10 Figure 5: Applied Force Load in the X-Direction ............................................................................... 11 Figure 6: Applied Moment Load About Z-Axis .................................................................................. 12 Figure 7: Total Stress Intensity Results for Internal Pressure Load, Half-Sectional View ............ 13 Figure 8: Total Stress Intensity Results for FX Load, Half-Sectional View ................ .. 14 Figure 9: Total Stress Intensity Results for MZ Load, Half-Sectional View ................................. 15 Figure 10: Total Stress Intensity Results for Thermal Load, Half-Sectional View ....................... 16 File No.: 0800802.303 Page 2 of 16 Revision: 0 F0306-OIRO
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1.0 INTRODUCTION
The purpose of this calculation is to perform stress analyses on the vent relief nozzle of the Safety Injection Tank (SIT) 1A at Palo Verde Nuclear Generating Station, Unit 1, due to thermal and unit mechanical loads.
Stress paths are extracted throughout the finite element model the location of the original weld and the stress results are stored in computer files for subsequent ASME Code evaluations.
2.0 DESIGN INPUTS 2.1 Finite Element Model The finite element model is developed in a previous calculation package [1] using the ANSYS finite element software package [2]. The finite element model is constructed using 3-D structural solid (SOLID45) elements and includes a portion of the SI Tank shell, the vent relief nozzle, the original J-groove weld, and the weld repair, as shown in Figure 1.
2.2 Material Properties The material properties are included in the finite element model developed in Reference 1.
3.0 METHODOLOGY The unit mechanical loading includes unit internal pressure (P = 1,000 psi), unit nozzle force loading (Fx = Fy = Fz = 1,000 lbs) in X, Y, and Z directions, and unit nozzle moment loading (Mx - My Mz =1,000 in-lbs) about X, Y, and Z axes.
In support of future ASME Code evaluations, eight (Paths 1-8) linearized through-wall stress paths are defined for the stress and fatigue evaluations, and one through-wall hoop stress path is defined for the crack growth evaluation (Path 9). The path definitions are shown in Figure 2.
Note that for Paths 1 through 7, four sub-paths are defined (downhill, +90 deg., uphill, -90 deg.
azimuths); for Paths 8 and 9, only two sub-paths are defined (downhill and uphill azimuths).
4.0 ANALYSIS Seven separate mechanical loading analyses and one thermal loading analysis are performed as described in the following sections. Symmetric boundary conditions are applied on the symmetry planes of the SI Tank, as shown in Figure 3.
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4.1 Mechanical Loading Analyses Unit internal pressure, unit force loadings, and unit moment loadings are performed. The mechanical loads are analyzed at a uniform body temperature of 70' and reference temperature of 70'F.
4.1.1 Unit InternalPressure A unit internal pressure of 1,000 psi is applied on the interior surfaces of the model, as well as on the annulus region of the nozzle penetration, assuming the original J-groove weld is flawed and hence causing leakage. An induced end-cap load is applied to the top free end of the nozzle in the form of a tensile axial pressure, and the value is calculated below. The applied pressure load is shown in Figure 4.
P, rinside Penp 1000. (1.203)2 1803 psi renc2 2 22 =103ps (routside - rinside 1.5 -1.2032 where, Pend-cap = End cap pressure on nozzle end (psi)
P = Applied internal pressure (psi) rinside = Inside radius of nozzle top end (in) routside = Outside radius of nozzle top end (in) 4.1.2 Unit Forces in X, Y, and Z Directions A unit force of 1,000 lbs in each of the three directions is applied on the top free end of the nozzle to simulate mechanical force loads acting on the nozzle. The force load is applied at the center location of the nozzle top end via the rigid Pilot Node feature in ANSYS [2] through CONTA174 and TARGE170 elements. Sample illustration for the FX application is shown in Figure 5.
4.1.3 Unit Moment about X, Y, and ZAxes A unit moment of 1,000 in-lbs in each of the three orthogonal axes is applied on the free end of the nozzle to simulate mechanical piping moment loads acting on the nozzle. The force load is applied at the center location of the nozzle top end via the rigid Pilot Node feature in ANSYS [2] through CONTA174 and TARGE170 elements. Sample illustration for the MX application is shown in Figure 6.
4.2 Thermal Analysis A steady state body temperature of 200"F design temperature [3] is applied on the entire model, with a reference temperature of 70'F.
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5.0 RESULTS Representative total stress intensity contour plots are shown in Figures 7 through 9 for the mechanical loading analyses, and Figure 10 for thermal loading analysis. Note that since the analyses are linear elastic, localized stress concentration can occur at the crevice of the welds as observed in Figure 7.
6.0 CONCLUSION
Unit mechanical load and thermal stress analyses are performed on the Safety Injection Tank Vent Relief Nozzle. Linearized and mapped stress results are extracted from the analyses for Paths 1 through 9 in support of the subsequent ASME Code evaluations.
The associated computer files for the analyses and stress results are listed in Appendix A.
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7.0 REFERENCES
- 1. SI Calculation 0800802.302, Rev. 0, "Finite Element Model Development of Safety Injection Tank Vent Relief Nozzle Repair."
- 2. ANSYS/Mechanical, Release 8.1 (w/Service Pack 1), ANSYS Inc., June 2004.
- 3. APS Supplier Number Sdoc N001-11.02-41-1, Bechtel Power Corp. File No. 8836.10-01, Rev. 8, "Analysis of a System 80 Safety Injection Tank," SI File No. 0800802.201.
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FELE=NS MA~T NUK Palo-Verde-Saftety-Injection-Tank-Nozzle-R(
Figure 1: Finite Element Model of the Safety Injection Tank Vent Relief Nozzle File No.: 0800802.303 Page 7 of 16 Revision: 0 F0306-O1RO
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Figure 2: Path Definitions for Stress Results Extraction File No.: 0800802.303 Page 8 of 16 Revision: 0 F0306-O1RO
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MAT NU U
Palo-Verde-Saftety- Inject ion-Tank-Nozzle-Repair Figure 3: Applied Boundary Conditions File No.: 0800802.303 Page 9 of 16 Revision: 0 F0306-OIRO
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PPES
-183 -180 -55.06 65.75
-1803_14911180-6.
1491 -557. 068 868.481 -245.654 688.586
- 65. 759377.173 1000 Palo-Verde-Saftety-Inj ect i N Figure 4: Applied Internal and End Cap Pressure File No.: 0800802.303 Page 10 of 16 Revision: 0 F0306-O1RO
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MAT NUM F
Palo-Verde-Saftety-Injection-Tank-Nozzle-Repair Figure 5: Applied Force Load in the X-Direction File No.: 0800802.303 Page 11 of 16 Revision: 0 F0306-O1RO
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MAT NUJM H
Palo-Verde-Saftety-Injection-Tank-Nozzle-Repair Figure 6: Applied Moment Load About Z-Axis File No.: 0800802.303 Page 12 of 16 Revision: 0 F0306-O1 RO
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NCDAL* SOLJT ICN STEP=-1 SUB =1 TIME=7 SINT (AVG)
DMX =. 17537 SMN =441.735 SMX =226326 SMXB=341188 441.735 50638 100835 151031 201228 25540 75737 125933 176130 22632E Palo-Verde-Saftety-Inject ion-Tank-Nozzle-geair Figure 7: Total Stress Intensity Results for Internal Pressure Load, Half-Sectional View File No.: 0800802.303 Page 13 of 16 Revision: 0 F0306-OIRO
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1.
NQJAL SOLUTIQM STEP-1 Mo SUB =1 TTME4--
SINT (AVG)
DMX =342E-03 SHMI=.001037 SMX =3072 SKOX-3831 F
.001037 682.687 1365 2048 2731 341.344 1024 1707 2389 3072 Palo-Verde-SaftetyTInjection-Tank-Nozzle-ReI Figure 8: Total Stress Intensity Results for FX Load, Half-Sectional View File No.: 0800802.303 Page 14 of 16 Revision: 0 F0306-O1RO
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NCDAL SOLXJTICQ STEP=-1 SUB =1 TTM-=6 S=h] (AVG)
DMX =. 262E-03 S1N =.271E-03 SMX =2456 M
.271EL03 545.844 1092 1638 2183 272.922 818.765 1365 1910 2456 Palo-Verde-Saftety-Inject ion-Tank-Nozzle-ReI Figure 9: Total Stress Intensity Results for MZ Load, Half-Sectional View File No.: 0800802.303 Page 15 of 16 Revision: 0 F0306-O1RO
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NCDAL SOLUTICM MN STEP=-1 SUB =1 TTME--8 SINT (AVG)
DMX =.091991 SI-N =1. 031 SMX =11355 SMXB=16562
- 1. 031 2524 5047 7570 10093 1263 3786 6309 8832 11355 Palo-Verde-Saftety-Injection-Tank-Nozzle-ReI air Figure 10: Total Stress Intensity Results for Thermal Load, Half-Sectional View File No.: 0800802.303 Page 16 of 16 Revision: 0 F0306-O1RO
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APPENDIX A ANSYS INPUT AND OUTPUT FILES File No.: 0800802.303 Page Al of A2 Revision: 0 F0306-OIRO
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STACK.INP Controller input file to submit the following files GEOM3D.INP Finite element model input file (from [2])
Pressure.INP Unit internal pressure input file FX.INP Force in X direction FY.INP Force in Y direction FZANP Force in Z direction MX.INP Moment about X-axis MY.INP Moment about Y-axis MZ.INP Moment about Z-axis THERMAL.INP Thermal load POSTPATH.INP Post-processing input file to extract path stresses
- _LINOUT Linearized stress output files for paths 1 through 8 (* = load case name)
- MAPOUT Mapped hoop stress output files path 9 (* = load case name)
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Attachment 2 Structural Integrity Associates, Inc. Calculation 0800802.306 Flaw Tolerance Evaluation of Safety Injection Tank Nozzle Penetration
StructuralIntegrity Associates, Inc. File No.: 0800802.306 CALCULATION PACKAGE Project No.: 0800802 Z Q E Non-Q PROJECT NAME: ASME Code Evaluation of Safety Injection Tank Nozzle Repair CONTRACT NO.: Master Agreement No. 500299013 CLIENT: Arizona Public Service Co. PLANT: Palo Verde Nuclear Generating Station, Unit I CALCULATION TITLE: Flaw Tolerance Evaluation of Safety Injection Tank Nozzle Penetration Project Manager Preparer(s) &
Document Affected Revision Description' Approval Checker(s)
Revision Pages Signature & Date Signatures & Date 0 1 -20 Original Issue Al Computer Files G. A. Miessi G. A. Miessi GAM 07/10/08 GAM 07/10/08 S. S. Tang SST 07/10/08 Page 1 of 20 F0306-O1RO
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Table of Contents 1.0 IN TR OD U CTIO N ............................................................................................................... 3 2.0 TECHN ICA L APPRO A CH ..................................................................................................... 3 3.0 D E SIG N IN PU T ........................................................................................................................... 3 4 .0 A S SUM P TIO N S ............................................... ;........................................................................... 9 5.0 STRESS INTENSITY FACTORS ......................................................................................... 9 6.0 ALLOWABLE FLAW SIZE ............................................................................................... 13 7.0 FATIGUE CRACK GROWTH ANALYSIS ........................................................................ 15 8.0 CON CLU SIO N S ................................... ..................................................................... 19 9 .0 R E F E REN CE S ........................................................................................................................... 20 APPENDIX A ANSYS POST-PROCESSING OUTPUT FILES LIST ...................... Al APPENDIX B PC-CRACK OUTPUT FILES ............................................................................. B1 List of Tables Table 1: Maximum Hoop Stresses (psi) ......................................................................................... 6 Table 2: Stress Intensity Factors (psi-4 in) ..................................................................................... 10 T able 3 : E v ent C y cles ....................................................................................................................... 15 Table 4: Crack Grow th Results ...................................................................................................... 17 List of Figures Figure 1: SIT Vent Relief Nozzle Penetration Through-Wall Stress Paths ...................................... 7 Figure 2: Maximum Hoop Stress Distribution from SIT Nozzle Comer ........................ 8 Figure 3: Simulated 3-D Nozzle Comer Crack Model ................................................................... 11 Figure 4: Safety Injection Tank Nozzle Penetration Stress Intensity Factors ............................... 12 Figure 5: Crack Growth of Postulated Flaws in SIT Shell ................................ 18 File No.: 0800802.306 Page 2 of 20 Revision: 0 F0306-OIRO
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1.0 INTRODUCTION
A leak was discovered at a vent relief nozzle of the safety injection tank (SIT) IA at Palo Verde Unit
- 1. The vent relief nozzle is attached to the SIT shell by a partial penetration J-Groove weld at its inside surface. A repair which consists of a J-Groove weld and a cover fillet weld at the outside surface of the SIT shell is designed to address the leakage. The repair design effectively moves the pressure boundary of the safety injection vessel from its ID surface to its OD surface.
The objective of this calculation is to perform a fracture mechanics analyses to ensure that a postulated nozzle corner crack in the SIT vessel shell meet the acceptance criteria of ASME Code,Section XI [ 1].
2.0 TECHNICAL APPROACH The fracture mechanics evaluation consists of the following tasks:
Determine the bounding through-wall stress distributions based on the finite element stress analysis results documented in Reference 2.
- Determine the stress intensity factors for a postulated flaw in the existing partial penetration weld at the SIT inside surface.
Perform a flaw evaluation based on the guidelines of ASME B&PV Code,Section XI [1] to calculate the allowable flaw size for the vent relief nozzle.
- Perform a fatigue crack growth analysis to compute end-of-evaluation period flaw sizes to compare to the allowable flaw sizes computed above.
3.0 DESIGN INPUT 3.1 Design and Operating Conditions The design and operating conditions obtained from Reference 3 are as follows:
Design Conditions:
- Design pressure, internal = 700 psi
- Design pressure, external - 100 psi.
- Design temperature = 200°F File No.: 0800802.306 Page 3 of 20 Revision: 0 F0306-OIRO
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Operating Conditions:
- Operating pressure, internal = 610 psi
- Operating pressure, external = 5 psi
- Operating temperature = 140°F 3.2 Pipe Dimensions The SIT vent relief nozzle penetration dimensions are obtained from Reference 3. The principal dimensions are:
- SIT Vessel Shell Minimum Thickness: 1.87"
- SIT Vessel Cladding Thickness: 1/8" 0 Nozzle Outside Diameter: 2.5" e Nozzle Inside Diameter: 1.939" 3.3 Material Properties The material of the different components of nozzle penetration is specified in Reference 3 as follows:
- SIT Vessel Shell: SA-516 Grade 70
- Vent Relief Nozzle: Alloy 600
- SIT Vessel Shell Cladding: Stainless Steel 3.4 Applied Stresses The applied stresses are obtained from Reference 2 which contains stress results from detailed three-dimensional finite element analyses of the SIT vent relief nozzle repair design. The stress analyses performed with the ANSYS finite element analysis program [4] included internal pressure, attached piping loads and the steady-state thermal condition.
Since the postulated flaw is the entire cross-section of the existing J-Groove weld which is oriented axially with respect to the nozzle axis, the results of the Reference 2 stress analyses are post-processed to obtain the bounding through-wall hoop stress distribution at the nozzle penetration for each of the applied mechanical and thermal loads. The through-wall normal stress distributions at Path 9 at the uphill and downhill locations, as shown in Figure 1, are extracted from the finite element analysis of Reference 2. Then, the through-wall normal stress distributions are obtained by File No.: 0800802.306 Page 4 of 20 Revision: 0 F0306-01RO
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applying the appropriate scale factors presented in Reference 12 for the normal operating internal pressure, mechanical and thermal loads to the results from the unit load analyses of Reference 2.
The resulting maximum through-wall hoop stress distributions at Path 9 are listed in Table 1 and presented in Figure 2.
The ANSYS post-processing files containing the hoop stress distributions are listed in Appendix A.
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Table 1: Maximum Hoop Stresses (psi)
Distance from Nozzle PRESSURE THERMAL FX FY FZ MX MY' MZ Corner (in) 0 23238.2 -2673.2 -184.8 279.9 0.0 0.0 0.0 63.7 0.12801 21670.4 -2448.8 -148.3 226.9 0.0 0.0 0.0 47.9 0.25601 22855.3 -1904.4 -117.1 186.6 0.0 0.0 0.0 38.2 0.38402 22437.4 67.9 -85.6 145.5 0.0 0.0 0.0 28.5 0.51203 21146.5 216.1 -65.2 109.3 0.0 0.0 0.0 20.6 0.64003 20625.2 329.0 -48.3 78.5 0.0 0.0 0.0 15.3 0.76804 20379.5 418'8 -32.7 51.0 0.0 0.0 0.0 11.1 0.89605 20302.8 488.8 -17.7 26.0 0.0 0.0 0.0 7.6 1.0241 20316.4 544.1 -3.3 3.3 0.0 0.0 0.0 4.7 1.1521 20350.2 593.3 10.9 -18.5 0.0 0.0 0.0 1.9 1.2801 20382.7 633.7 25.1 -38.4 0.0 0.0 0.0 -1.3 1.4081 20439.9 672.9 39.4 -58.2 0.0 0.0 0.0 -4.2 1.5361 20666.1 697.2 53.2 -76.0 0.0 0.0 0.0 -6.3 1.6641 20924.2 712.8 66.3 -92.7 0.0 0.0 0.0 -8.4 1.7921 21197.8 724.5 79.3 -109.2 0.0 0.0 0.0 -10.6 1.9201 21498.8 733.6 91.8 -125.1 0.0 0.0 0.0 -12.8 2.0481 21707.4 738.2 100.9 -138.9 0.0 0.0 0.0 -14.7 2.1761 21922.6 741.7 110.6 -153.1 0.0 0.0 0.0 -16.7 2.3041 22112.4 743.5 119.5 -166.9 0.0 0.0 0.0 -18.8 2.4321 22284.0 744.5 127.9 -180.1 0.0 0.0 0.0 -20.8 2.5601 22453.0 744.3 136.1 -193.1 0.0 0.0 0.0 -22.9 File No.: 0800802.306 Page 6 of 20 Revision: 0 F0306-0IRO
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Figure 1: SIT Vent Relief NozzlePenetration Through-Wall Stress Paths Note: Paths 1 through 8 are used for the Section III design analysis only.
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Hoop Stress 25000.0 20000.0 15000.0 10000.0 CL 5000.0 0.0
-5000.0 Distance from Nozzle Corner (in.)
Figure 2: Maximum Hoop Stress Distribution from SIT Nozzle Comer File No.: 0800802.306 Page 8 of 20 Revision: 0 F0306-OIRO
StructuralIntegrityAssociates, Inc, 4.0 ASSUMPTIONS
- 1. It is assumed that a nozzle comer flaw exists in the original J-Groove weld that attaches the vent relief nozzle to the SIT shell at its inside surface. Therefore, analyses performed herein assume an assumed initial flaw size equal to the size of the existing J-Groove weld.
- 2. The postulated nozzle comer crack is assumed to grow congruently in the SIT shell, keeping its same shape and a constant aspect ratio.
- 3. The total number of specified full pressure cycles transients which correspond to a 40-year plant life (20-year remaining life plus 20-year life extension) will be used in this evaluation for crack growth purposes.
5.0 STRESS INTENSITY FACTORS The base material of the SIT shell has been UT inspected and found to be free of defects [5]. Thus, for the fracture mechanics evaluation, it is assumed that the remnant J-Groove weld at the inside surface of the SIT is completely flawed. Consequently, an initial nozzle corner flaw encompassing the full cross-section of the J-groove weld is postulated. The flaw is axially oriented with respect the SIT vent relief nozzle. The appropriate crack model used for this evaluation is a comer crack model, Simulated 3-D Nozzle Crack, from the pc-CRACK TM [6] library which is illustrated in Figure 3.
The stress intensity factors for the postulated nozzle comer crack are computed with pc-CRACK TM for starting for various flaw sizes. The calculated stress intensity factor distributions are listed in Table 2 and plotted in Figure 4.
The pc-CRACKTM output file is listed in Appendix B.
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Table 2: Stress Intensity Factors (psi-4 in)
Crack Depth Pressure Thermal Nozzle Loads Total 0.040 5807.4 -681.2 38.6 5164.8 0.120 9965.0 -1066.2 63.2 8962.0 0.200 12751.7 -1239.5 77.0 11589.3 0.280 14963.2 -1315.7 86.0 13733.4 0.360 16835.2 -1333.1 91.9 15594.0 0.400 17680.3 -1326.1 94.0 16448.1 0.480 19232.6 -1289.4 96.9 18040.1 0.520 19951.7 -1262.1 97.8 18787.4 0.600 21298.0 -1705.8 98.7 19691.0 0.640 21931.9 -1155.1 98.8 20875.7 0.720 23134.4 -1069.6 98.4 22163.2 0.800 24263.5 -977.7 97.3 23383.0 0.840 24804.6 -930.4 96.5 23970.7 0.920 25846.8 -834.4 94.5 25106.9 1.000 26842.9 -738.5 92.1 26196.5 1.040 27326.0 -691.1 90.8 26725.7 1.120 28266.2 -598.2 87.9 27755.8 1.200 29176.3 -509.0 84.7 28752.0 1.280 30060.9 -424.1 81.4 29718.2 1.320 30494.8 -383.5 79.6 30190.9 1.400 31347.9 -306.2 76.0 31117.7 1.440 31767.9 -269.5 74.1 31572.5 1.480 32183.9 -234.2 72.2 32021.9 1.520 32596.3 -200.3 70.3 32466.3 1.560 33005.3 -167.7 68.4 32906.0 1.600 33411.2 -136.5 66.4 33341.2 1.640 33814.2 -106.5 64.4 33772.1 1.680 34214.6 -77.8 62.4 34199.2 1.720 34612.5 -50.4 60.4 34622.5 1.760 35008.1 -24.1 58.4 35042.4 1.800 35401.5 1.2 56.3 35459.0 1.840 35793.0 25.4 54.3 35872.6
.1.880 36182.7 48.6 52.2 36283.5 1.920 36570.7 71.0 50.1 36691.8 1.960 36957.0 92.7 47.9 37097.6 2.000 37341.9 113.7 45.8 37501.4 File No.: 0800802.306 Page 10 of 20 Revision: 0 F0306-0I RO
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Figure 3: Simulated 3-D Nozzle Comer Crack Model File No.: 0800802.306 Page 11 of 20 Revision: 0 F0306-O1RO
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Stress Intensity Factors 40000.0 ......
35000.0" ____ __
KIlallowable D***m-30000.0 7 - - - - --
25000.0 _ _ _ _ _-.~.
/ "
LI 15000.0 20000.0____ .. - - ..-- . -....... . -........
15000.0 - . ...
-0D- Pres su re 50000.0 ' . "*-" NozLoads *
- , ... 1..1000 1 1 100 100 200 Crack Depth (in)
Figure 4: Safety Injection Tank Nozzle Penetration Stress Intensity Factors File No.: 0800802.306 Page 12 of 20 Revision: 0 F0306-OIRO
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6.0 ALLOWABLE FLAW SIZE 6.1 Fracture Toughness Material test data for the SA-516 Grade 70 material of the SIT shell are provided in Reference 7. The CMTR show that the SIT material exhibits a minimum Charpy V-Notch (CVN) impact energy of 86 fIt-lb at 60'F. The maximum reported CVN value was 118 ft-lb.
The CVN value of the material can be used to estimate K1,. Rolfe and Barsom [8] include several relationships between K1, and CVN for materials in the toughness transition temperature region. One of the relationship is:
K1c2iE = A(CVN) where, E is the elastic modulus and A is a constant ranging from about 4 to 5.
Using the expression above with E = 29.1 x 106 psi at 150'F [9], A = 4 to 5 and CVN = 86 ft-lb, the fracture toughness, K1 c, for the SIT shell material is calculated to vary from a minimum value of 100.0 to 118.8 ksi'Iin at the 60'F test temperature. The actual fracture toughness of the SIT at its normal operating temperature of 140'F will bemuch higher. Thus, the use of the modulus of elasticity at the operating temperature rather than at the design temperature is justified.
6.2 Critical and Allowable Flaw Sizes The stress intensity factors calculated in Section 5 are used to determine the critical flaw size for the SIT shell at the vent relief nozzle penetration. The critical flaw size is determined by comparing the calculated stress intensity factors to the SIT lower bound material toughness. As shown in Figure 4, the calculated total stress intensity factor is less than the fracture toughness for flaw sizes up to the full thickness of the SIT shell.
The flaw acceptance criteria of IWC-3610 of Section XI of the ASME Code [1] are applicable for this evaluation. IWC-3610 stipulates that the criteria of IWB-3610 may be applied. Hence, the flaw acceptance criteria based on applied stress intensity factor of IWB-3612 are used to calculate the allowable flaw size. For normal and upset conditions, IWB-3612 requires a safety factor of 'l 0 on the material toughness to obtain the allowable fracture toughness, such that:
K1 _ KI&a/410 where, File No.: 0800802.306 Page 13 of 20 Revision: 0 F0306-O1RO
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K, = maximum applied stress intensity factor KIa = available fracture toughness based on crack arrest for the corresponding crack tip temperature Reference 10 documents the technical basis for the use of the available fracture toughness based on fracture initiation, KI, instead of Kla in the evaluation of flaws in vessels. In fact, the 2007 edition of Section XI of the ASME Code has incorporated that change in the flaw acceptance criteria.
Using the lower bound SIT shell material toughness calculated above (KI, = 100 ksilin), the allowable flaw size is determined as the flaw size which corresponds to a stress intensity factor equal to Ki, =
100/*410 = 31.6 ksi4in. As shown in Table 2 and Figure 4, the allowable flaw size is equal to 1.44 inches.
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7.0 FATIGUE CRACK GROWTH ANALYSIS 7.1 Fatigue Crack Growth Cycles The applicable cyclic loadings specified in the design specification of the safety injection tank [ 11] are the full pressure cycles, hydrostatic tests and blowdown tests. The number of design cycles over a 40-year period (20-year remaining life plus 20-year life extension) is listed in Table 3 along with the corresponding internal pressure level for each event.
Table 3: Event Cycles I
Event Cycles Pressure (psi)
Pressure Transients 500 650 E Hydrostatic Test Blowdown Test 20 10 883 max.
650 7.2 Fatigue Crack Growth Rate The postulated flaw in the original attachment weld can potentially grow due to cyclic fatigue loading in the SIT shell. The methodology of Section XI, Appendix A of the ASME Code [1] was used to perform the fatigue crack growth analysis. The fatigue crack growth rate (da/dN) for the ferritic steel SIT material is a function of the range of applied stress intensity factor (AKI) that can be expressed in the form of a Paris law. The ASME Code,Section XI reference fatigue crack growth curves for low alloy steels in air environments are used for the evaluation of the SIT shell. The curves are given as:
da where, a = flaw depth (in.)
N - number of stress cycles AK1 = stress intensity factor range (ksi'lin)
R = Kmin/Kmax n 3.07 Co = 1.99 x 101° S with, For 0<_R< 1.0 S = 25.72(2.88-R) -3.07 and AKI = Kmin - Kmax File No.: 0800802.306 Page 15 of 20 Revision: 0 F0306-OIRO
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For R < 0 and Kmax - Kmin > 1.12 or 1%f S = I and AKI = Krnin - Kmax For -2 < R< 0 and Kmax- Kmin< 1.12 afia S = 1 and AKI = Kmax For R < -2 and Kmax - Kmin < 1. 12 O"§i ra S = 1 and AKI = (1-R)Kmax/3 where, a- = material flow stress = I(u + uii) ory, = material yield strength at,,, = material ultimate tensile strength 7.3 End of Plant Life Fatigue Crack Growth Analysis The fatigue crack growth analyses are performed with the fracture mechanics software program pc-CRACKTM [6] using the stress intensity factors calculated in Section 5 for a postulated corner crack and the 40-year (20-year remaining life.lus 20-year life extension) design life cycles in Table 3. The use of pc-CRACK is appropriate since the R ratio is zero in this evaluation. Based on the assumption of a nozzle comer flaw encompassing the entire cross-section of the existing weld, the initial flaw depth is taken as the depth of the remnant J-Groove weld at the SIT inside surface, i.e., ai =
0.351" [3].
In the fatigue crack growth analysis, appropriate scale factors based on the internal pressure levels in Table 3 are used to determine the stress intensity factors due to the full pressure cycles as well as the hydrostatic and blowdown tests. For output purposes, the cycles are grouped in 40 sub-blocks, each sub-block representing a year of plant operation. Since there is less than 1 occurrence per year for the tests, the analysis is performed conservatively using 1 occurrence per year for both of the hydrostatic and blowdown test.
The results of the fatigue crack growth evaluation are presented in Table 4 and illustrated in Figure 5. It is shown that the postulated flaw grows by only 1 mil to a final depth of 0.352 inches after 40 years of plant operation (20-year remaining life plus 20-year life extension).
The pc-CRACK TM output files for the crack growth analyses are presented in Appendix B.
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Table 4: Crack Growth Results Total Kmax Kmin DeltaK Da a Cycles (ksi-inl 2) (ksi-in 1 2) (ksi-in"12) R Da/Dn (in) (in) 13 1L54E+04 0.OOE+00 1.54E+04 0 8.78E-07 8.78E-07 0.351 30 1.66E+04 0.00E+00 1.66E+04 0 1.11E-06 1.11E-06 0.351 60 1.66E+04 0.OOE+00 1.66E+04 0 1.11E-06 1.11E-06 0.3511 90 1.66E+04 0.OOE+00 1.66E+04 0 1.11E-06 1.11E-06 0.3511 120 1.66E+04 0.00E+00 1.66E+04 0 1.12E-06 1.12E-06 0.3511 150 1.66E+04 O.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3512 180 1.66E+04 O.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3512 210 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3512 240 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3512 270 1.66E+04 O.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3513 300 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3513 330 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3513 360 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3514 390 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3514 420 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3514 450 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3515 480 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3515 510 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3515 540 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3516 570 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3516 600 1.66E+04 0.OOE+00 1.66E+04 0 1.12E-06 1.12E-06 0.3516 File No.: 0800802.306 Page 17 of 20 Revision: 0 F0306-O1RO
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Fatigue Crack Growth 0.3517 0.3516 .............
0.3515 0.3514 0.3513 ...........
0.3512 0.3511 0.351 0.3509 0 100 200 300 400 500 600 700 Number of Cycles i.............................
Figlure 5: Crack Growth of Postulated Flaws in SIT Shell File No.: 0800802.306 Page 18 of 20 Revision: 0 F0306-OI RO
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8.0 CONCLUSION
S Fracture mechanics analyses have been performed to assess the impact of leaving a flaw in the original J-Groove weld after repair of the vent relief nozzle of Palo Verde, Unit 1, Safety Injection Tank 1A. Based on the results of the evaluation presented herein, the postulated nozzle corner flaw is acceptable and meets the requirements of ASME Code,Section XI, IWC-3610 [1]. The allowable flaw size for the SIT shell at the vent relief penetration is 1.44 inches and the critical flaw size is larger than the thickness of the SIT.
A fatigue crack growth analysis was performed to determine the potential for crack propagation into the SIT shell. The postulated initial flaw of 0.351" depth grows only by 1 mil for the 40-year design plant life (20-year remaining life plus 20-year life extension).
The final crack size at the end of SIT service life is 0.352 inches, which is much less than the calculated allowable flaw size of 1.44 inches. The applied stress intensity factor at the end of service life is also less than the allowable fracture toughness.
The results of the fracture mechanics evaluation presented herein, which are based on more detailed analyses, supersede those documented in Reference 13.
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9.0 REFERENCES
- 1. ASME Boiler and Pressure Vessel Code,Section XI, 2001 Edition with Addenda through 2003.
- 2. Structural Integrity Calculation 0800802.303, Rev. 0, "Thermal and Mechanical Stress Analyses of Safety Injection Tank Vent Nozzle Relief"
- 3. Bechtel Corporation Report TR-76-61," Analysis of a System 80 Safety Injection Tank, Main Report," Revision 08, Prepared by NUS Corporation, April 1981, APS Sdoc #NOOl-1 1.02-41-1, SI File No. 0800802.201.
- 4. ANSYS/Mechanical, Release 8.1 (w/ Service Pack 1), ANSYS, Inc., June 2004.
- 5. Palo Verde Nuclear Generating Station, Ultrasonic Examination Report, Report No.08-513, June 7, 2008, SI File No. 0800802.205.
- 6. pc-CRACK TM for Windows, Version 3.1-98348, Structural Integrity Associates, 1998.
- 8. S. T. Rolfe and J. M. Barsom, Fracture and Fatigue Control in Structures, 2 nd Edition, Prentice-Hall, NJ, 1987
- 9. ASME Boiler and Pressure Vessel Code,Section II, Part D, 2001 Edition with Addenda through 2003.
- 10. R. Cipolla and K. Wichman, "Technical Basis for Revised Flaw Acceptance Criteria Under IWB-3610 of ASME Code Section XI," PVP2005-71718, July 2005.
- 11. APS Supplier Number Sdoc N001-11.02-5-6, Combustion Engineering, Inc.,
"Standard Specification for Safety Injection Tanks for System 80 Standard Design,"
Specification No. SYS80-PE-601, Rev. 3, January 1978. File No. 0800802.204.
- 12. Structural Integrity Calculation 0800802.305, Rev. 0, "ASME Code Evaluation of Safety Injection Tank Vent Relief Nozzle Repair."
- 13. Structural Integrity Calculation 0800802.301, Rev. 0, "Safety Injection Tank Nozzle Repair Design Analysis."
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APPENDIX A ANSYS Post-Processing Output Files List Filename Description PRESSURE MAP.OUT Through-Wall Stress Distribution due to Pressure THERMAL MAPOUT Through-Wall Stress Distribution due to Thermal Load FX MAP.OUT Through-Wall Stress Distribution due to X-Direction Force FY MAP.OUT Through-Wall Stress Distribution due to Y-Direction Force FZ MAP.OUT Through-Wall Stress Distribution due to Z-Direction Force MX MAP.OUT Through-Wall Stress Distribution due to X-Direction Moment MY MAP.OUT Through-Wall Stress Distribution due to Y-Direction Moment MZ MAP.OUT Through-Wall Stress Distribution due to Z-Direction Moment File No.: 0800802.306 Page Al of Al Revision: 0 F0306-O0 RO
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APPENDIX B pc-CRACK TM Output files Filename Description Pages SITNOZL.OUT Fatigue Crack Growth Analysis B2 - B10 File No.: 0800802.306 PageB1 of B10 Revision: 0 F0306-OIRO
StructuralIntegrityAssociates, Inc.
tm pc-CRACK for Windows Version 3.1-98348 (C) Copyright '84 - '98 Structural Integrity Associates, Inc.
3315 Almaden Expressway, Suite 24 San Jose, CA 95118-1557 Voice: 408-978-8200 Fax: 408-978-8964 E-mail: pccrack@structint.com Linear Elastic Fracture Mechanics Date: Fri Jul 04 11:30:38 2008 Input Data and Results File: SITNOZL.LFM
Title:
PV Safety Injection Tank Vent Relief Nozzle Repair Load Cases:
Case ID: Pressure --- Stress Distribution Depth Stress 0.0000 23238.1992 0.1280 21670.4004 0.2560 22855.3008 0.3840 22437.4004 0.5120 21146.5000 0.6400 20625.1992 0.7680 20379.5000 0.8960 20302.8008 1.0240 20316.4004 1.1520 20350.1992 1.2800 20382.6992 1.4080 20439.9004 1.5360 20666.0996 1.6640 20924.1992 1.7920 21197.8008 1.9200 21498.8008 2.0480 21707.4004 2.1760 21922.5996 2.3040 22112.4004 2.4320 22284.0000 2.5600 22453.0000 Case ID: NozLoads --- Stress Distribution Depth Stress File No.: 0800802.306 Page B2 of B10 Revision: 0 F0306-OIRO
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0.0000 158 .800.0 0.1280 126.5000 0.2560 107.8000 0.3840 88.4000 0.5120 64.7000 0.6400 45.5000 0.7680 29.3000 0.8960 15. 9000 1.0240 4.6000 1.1520 -5.7000 1.2800 -14. 6000 1.4080 -23.0000 1.5360 -29.1000 1.6640 -34.8000 1.7920 -40.4000
- 1. 9200 -46.0000 2.0480 -52.6000 2.1760 -59.2000 2.3040 -66.2000 2.4320 -73.1000 2.5600 -79.8000 Case ID: Thermal --- Stress Distribution Depth Stress 0.0000 -2673.1599 0.1280 -2448.8101 0.2560 -1904.4200 0.3840 67.8538 0.5120 216.0760 0.6400 328.9650 0.7680 418.8240 0.8960 488.8170 1.0241 544.1030 1.1521 593.2710 1.2801 633.7030 1.4081 672. 9380 1.5361 697 .2210 1.6641 712.8100 1.7921 724 .5000 1.9201 733. 6000 2.0481 738.2200 2.1761 741.6500 2.3041 743.5400 2.4321 744.4500 2.5601 744.3100 Stress Coefficients Case ID CO Cl C2 C3 Type Pressure 23317.9 -5951.27 3603.48 -543.2 StressDist NozLoads 158.829 -230.887 96.0423 -16.5247 StressDist Thermal -2860 7243.89 -4579.15 910.24 StressDist File No.: 0800802.306 Page B3 of B10 Revision: 0 F0306-O1 RO
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Crack Model: Simulated 3-D Nozzle Corner Crack WARNING: The stress intensity factor (K) is calculated at the deepest point only.
May be non-conservative in some cases.
Crack Parameters:
Max. crack size: 2.0000
Stress Intensity Factor----------------------
Crack Case Case Case Size Pressure NozLoads Thermal 0.0400 5807.38 38.643 -681.237 0.0800 8174 53.1178 -916.188 0.1200 9965 63.2208 -1066.2 0.1600 11455.1 70.9288 -1168.8 0.2000 12751.7 77.0352 -1239.48 0.2400 13910 81.9612 -1286.68 0.2800 14963.2 85.9657 -1315.72 0.3200 15933.2 89.2233 -1330.28 0.3600 16835.2 91.8595 -1333.06 0.4000 17680.3 93.9687 -1326.13 0.4400 18477.2 95.6244 -1311.13 0.4800 19232.6 96.8855 -1289.4 0.5200 19951.7 97.8003 -1262.06 0.5600 20638.9 98.4092 -1230.04 0.6000 21298 98.7461 -1194.14 0.6400 21931.9 98.8404 -1155.05 0.6800 22543.3 98.7172 -1113.37 0.7200 23134.4 98.3988 -1069.63 0.7600 23707.3 97.9046 -1024.28 0.8000 24263.5 97.2518 -977.748 0.8400 24804.6 96.4558 -930.381 0.8800 25332 95.5302 -882.501 0.9200 25846.8 94.4874 -834.392 0.9600 26350.1 93.3385 -786.306 1.0000 26842.9 92.0935 -738.464 1.0400 27326 90.7615 -691.063 1.0800 27800.2 89.3505 -644.273 1.1200 28266.2 87.8682 -598.246 1.1600 28724.8 86.3211 -553.111 1.2000 29176.3 84.7155 -508.981 1.2400 29621.6 83.0568 -465.948 1.2800 30060.9 81.35 -424.093 1.3200 30494.8 79.5997 -383.478 113600 30923.7 77.81 -344.153 1.4000 31347.9 75.9845 -306.154 1.4400 31767.9 74.12 65 -269.504 1.4800 32183.9 72.239 -234.215 File No.: 0800802.306 Page B4 of BI1 Revision: 0 F0306-O1 RO
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1.5200 32596.3 70.3244 -200.288 1.5600 33005.3 68.3851 -167.713 1.6000 33411.2 66.4231 -136.469 1.6400 33814.2 64.44 -106.526
- 1. 6800 34214.6 62.4373 -77.8455 1.7200 34612.5 60.4162 -50.3779 1.7600 35008.1 58.3776 -24.0666 1.8000 35401.5 56.3222 1.15363 1.8400 35793 54.2505 25.3563 1.8800 36182.7 52.1628 48.6224 1 .9200 36570.7 50.0592 71.0405 1.9600 36957 47.9396 92.7064 2.0000 37341.9 45.8037 113.723 Crack Growth Laws:
Law ID: Carbon Steel in Air Model: ASME Section XI - fEerritic steel in air environment da/dN = C
- S
- dK^3.07 where 25.72 * (2.88 - R')'^(-3.07) 0 for R < 0 R for R >= 0 Kmax - Kmin Kmin / Kmax where:
C = 1,2270e-019 is for the currently selected units of:
force: lb length: inch Material Fracture Toughness KIc:
Material ID: SA-516 Gr 70 Depth KIc 0.0000 100000.0000 2.6000 '100000.0000 Initial crack size= 0.3510 Max. crack size= 2.0000 Number of blocks= 40 Print increment of blocý 1 Cycles Calc. Print Crk. Grw. Mat.
Subblock /Time incre. incre. Law Klc File No.: 0800802.306 Page B5 of BI1 Revision: 0 F0306-O1 RO
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Full Pressure 13 1 13 Carbon Steel in SA-516 Gr 70 Hydrostatic 1 1 1 Carbon Steel in SA-516 Gr 70 Blowdown 1 1 1 Carbon Steel in SA-516 Gr 70 Kmax Kmin Subblock Case ID Scale Factor Case ID Scale Factor Full Pressure Pressure 1.0000 Thermal 1.0000 NozLoads 1.0000 Hydrostatic Pressure 1.3600 Blowdown Pressure 1.0000 Crack growth results:
Total Subblock Cycles Cycles DaDn
/Time /Time Kmax Kmin DeltaK R /DaDt Da a a/thk Block: 1 13 13 1 .54e+004 0.00e+000 1.54e+004 0.00 8.78e-007 8.78e-007 0.351 0.00 14 1 2. 26e+004 0.00e+000 2 .26e+004 0.00 2.86e-006 2. 86e-006 0.351 0.00 15 1 1 .66e+004 0 . 00e+000 1. 66e+004 0.00 1.lle-006 1.lle-006 0.351 0.00 I
Block: 2 28 13 1.54e+004 0 . 00e+000 1 . 54e+004 0.00 8.79e-007 8.79e-007 0.351 0.00 29 1 2. 26e+004 0.00e+000 2 .26e+004 0.00 2.86e-006 2.86e-006 0.351 0.00 30 1 1. 66e+004 0 . 00e+000 1. 66e+004 0.00 1.lle-006 1.lie-006 0.351 0.00 Block: 3 43 13 1 . 54e+004 0 . 00e+000 1 . 54e+004 0.00 8. 79e-007 8.79e-007 0.351 0.00 44 1 2 .26e+004 0.00e+000 2 .26e+004 0.00 2. 87e-006 2.87e-006 0.351 0.00 45 1 1. 66e+004 0.00e+000 1. 66e+004 0.00 1.lie-006 1. lle-006 0.351 0.00 Block: 4 58 13 1.54e+004 0 . 00e+000 1.54e+004 0.00 8.79e-007 8.79e-007 0.3511 0.00 59 1 2. 26e+004 0.00e+000 2. 26e+004 0.00 2. 87e-006 2. 87e-006 0.3511 0.00 60 1 1. 66e+004 0 . 00e+000 1. 66e+004 0.00 1.lie-006 1.lle-006 0.3511 0.00 Block: 5 73 13 1 . 54e+004 0.00e+000 1.54e+004 0.00 8.79e-007 8.79e-007 0.3511 0.00 74 1 2 .26e+004 0 . 00e+000 2.26e+004 0.00 2. 87e-006 2. 87e-006 0.3511 0.00 75 1 1 . 66e+004 0.00e+000 1.66e+004 0.00 1.lle-006 1. lle-006 0.3511 0.00 Block: 6 88 13 1 . 54e+004 0 . 00e+000 1.54e+004 0.00 8.79e-007 8 .79e-007 0.3511 0.00 89 1 2 .26e+004 0 . 00e+000 2 .26e+004 0.00 2.87e-006 2. 87e-006 0.3511 0.00 90 1 1. 66e+004 0.00e+000 1. 66e+004 0.00 1.lie-006 1. lle-006 0.3511 0.00 Block: 7 File No.: 0800802.306 Page B6 of BlO Revision: 0 F0306-OIRO
StructuralIntegrity Associates, Inc.
103 13 1. 54e+004 0 .00e+000 1 .54e+004 0.00 8.79e-007 8.79e-007 0.3511 0.00 104 1 2.26e+004 0 .00e+000 2 .26e+004 0.00 2.87e-006 2. 87e-006 0.3511 0.00 105 1 1. 66e+004 0 .00e+000 1. 66e+004 0.00 1.12e-006 1. 12e-006 0.3511 0.00 Block: 8 118 13 1 . 54e+004 0 .00e+000 1.54e+004 0.00 8 .79e-007 8.79e-007 0.3511 0.00 119 1 2.26e+004 0 .00e+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3511 0.00 120 1 1 . 66e+004 0.OOe+000 1. 66e+004 0.00 1. 12e-006 1. 12e-006 0.3511 0.00 Block: 9 133 13 1 . 54e+004 0.OOe+000 1.54e+004 0.00 8.79e-007 8.79e-007 0.3511 0.00 134 1 2. 26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3511 0.00 135 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1. 12e-006 1.12e-006 0.3511 0.00 Block: 10 148 13 1 . 54e+004 0.OOe+000 1.54e+004 0.00 8.79e-007 8.79e-007 0.3511 0.00 149 1 2. 26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3512 0.00 150 1 1. 66e+004 0. OOe+000 1. 66e+004 0.00 1. 12e-006 1. 12e-006 0.3512 0.00 Block: 11 163 13 1.54e+004 0.OOe+000 1.54e+004 0.00 8.79e-007 8. 79e-007 0.3512 0.00 164 1 2 .26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3512 0.00 165 1 1 . 66e+004 0 . OOe+000 1. 66e+004 0.00 1. 12e-006 1. 12e-006 0.3512 0.00 Block: 12 178 13 1 . 54e+004 0 . OOe+000 1 . 54e+004 0.00 8.79e-007 8.79e-007 0.3512 0.00 179 1 2. 26e+004 0.OOe+000 2 .26e+004 0.00 2.87e-006 2.87e-006 0.3512 0.00 180 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1.12e-006 1. 12e-006' 0.3512 0.00 Block: 13 193 13 1 . 54e+004 0 . OOe+000 1 . 54e+004 0.00 8.79e-007 8.79e-007 0.3512 0.00 194 1 2 .26e+004 0 . OOe+000 2. 26e+004 0.00 2.87e-006 2.87e-006 0.3512 0.00 195 1 1. 66e+004 0.OOe+000 1 . 66e+004 0.00 1.12e-006 1.12e-006 0.3512 0.00 Block: 14 208 13 1 . 54e+004 0 . OOe+000 1 . 54e+004 0.00 8 .79e-007 8.79e-007 0.3512 0.00 209 1 2 .26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3512 0.00 210 1 1. 66e+004 0.OOe+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3512 0.00 Block: 15 223 13 1 . 54e+004 0 . OOe+000 1.54e+004 0.00 8.79e-007 8.79e-007 0.3512 0.00 224 1 2 .26e+004 0.OOe+000 2. 26e+004 0.00 2. 87e-006 2. 87e-006 0.3512 0.00 225 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1.12e-006 1. 12e-006 0.3512 0.00 Block: 16 238 13 1 . 54e+004 0 . OOe+000 1 . 54e+004 0.00 8.79e-007 8.79e-007 0.3512 0.00 239 1 2 .26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2.87e-006 0.3512 0.00 240 1 1 . 66e+004 0.OOe+000 1. 66e+004 0.00 1. 12e-006 1. 12e-006 0.3512 0.00 Block: 17 253 13 1 . 54e+004 0 . OOe+000 1.54e+004 0.00 8.79e-007 8.79e-007 0.3513 0.00 254 1 2. 26e+004 0 . OOe+000 2 .26e+004 0.00 2.87e-006 2.87e-006 0.3513 0.00 255 1 1. 66e+004 0.OOe+000 1. 66e+004 0.00 1 . 12e-006 1.12e-006 0.3513 0.00 File No.: 0800802.306 Page B7 of B1O Revision: 0 F0306-O1 RO
Z StructuralIntegrityAssociates, Inc.
Block: 18 268 13 1 .54e+004 0 . 00e+000 1.54e+004 0.00 8. 79e-007 8.79e-007 0.3513 0.00 269 1 2 .26e+004 0.00e+000 2 .26e+004 0.00 2.87e-006 2.87e-006 0.3513 0.00 270 1 1. 66e+004 0.00e+000 1. 66e+004 0.00 1. 12e-006 1.12e-006 0.3513 0.00 Block: 19 283 13 1. 54e+004 0.00e+000 1.54e+004 0.00 8.80e-007 8.80e-007 0.3513 0.00 284 1 2. 26e+004 0. 00e+000 2. 26e+004 0.00 2.87e-006 2. 87e-006 0.3513 0.00 285 1 1 .66e+004 0 . 00e+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3513 0.00 Block: 20 298 13 1 54e+004 0. OOe+000 1.54e+004 0.00 8. 80e-007 8.80e-007 0.3513 0.00 299 1 2. 26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3513 0.00 300 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1. 12e-006 1.12e-006 0.3513 0.00 Block: 21 313 13 1 .54e+004 0 . OOe+000 1 . 54e+004 0.00 8 . 80e-007 8.80e-007 0.3513 0.00 314 1 2. 26e+004 0 . OOe+000 2 .26e+004 0.00 2.87e-006 2. 87e-006 0.3513 0.00 315 1 1. 66e+004 0 . OOe+0.00 1. 66e+004 0.00 1. 12e-006 1. 12e-006 0.3513 0.00 Block: 22 328 13 1 .54e+004 0 . OOe+00.0 1 . 54e+004 0.00 8 . 80e-007 8.80e-007 0.3513 0.00 329 1 2. 26e+004 0.OOe+000 2 .26e+004 0.00 2.87e-006 2. 87e-006 0.3513 0.00 330 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3513 0.00 Block: 23 343 13 1 .54e+004 0 . Oe+O00 1 . 54e+004 0.00 8 . 80e-007 8.80e-007 0.3513 0.00 344 1 2. 26e+004 0.OOe+000 2 .26e+004 0.00 2.87e-006 2. 87e-006 0.3514 0.00 345 1 1. 66e+004 0.OOe+000 1. 66e+004 0.00 1.12e-006 1. 12e-006 0.3514 0.00 Block: 24 358 13 1.54e+004 0.OOe+000 1.54e+004 0.00 8. 80e-007 8 . 80e-007 0.3514 0.00 359 1 2. 26e+004 0.OOe+000 2. 26e+004 0.00 2.87e-006 2.87e-006 0.3514 0.00 360 1 1 . 66e+004 0 . OOe+000 1 . 66e+004 0.00 1.12e-006 1.12e-006 0.3514 0.00 Block: 25 373 13 1 . 54e+004 0.00e+000 1.54e+004 0.00 8.80e-007 8.80e-007 0.3514 0.00 374 1 2 .26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3514 0.00 375 1 1. 66e+004 0. OOe+000 1. 66e+004 0.00 1.12e-006 1. 12e-006 0.3514 0.00 Block: 26 388 13 1.54e+004 0 . OOe+000 1 . 54e+004 0.00 8.80e-007 8 . 80e-007 0.3514 0.00 389 1 2. 26e+004 0.OOe+000 2. 26e+004 0.00 2. 87e-006 2.87e-006 0.3514 0.00.
390 1 1 . 66e+004 0 . OOe+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3514 0.00 Block: 27 403 13 1 . 54e+004 0. OOe+000 1.54e+004 0.00 8. 80e-007 8.80e-007 0.3514 0.00 404 1 2. 26e+004 0 . 00e+000 2. 26e+004 0.00 2.87e-006 2.87e-006 0.3514 0.00 405 1 1. 66e+004 0. OOe+000 1. 66e+004 0.00 1. 12e-006 1. 12e-006 0.3514 0.00 Block: 28 418 13 1. 54e+004 0.OOe+000 1.54e+004 0.00 8.80e-007 8.80e-007 0.3514 0.00 419 1 2. 26e+004 0. 00e+000 2. 26e+004 0.00 2. 87e-006 2 87e-006 0.3514 0.00 420 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1. 12e-006 1.12e-006 0.3514 0.00 File No.: 0800802.306 Page B8 of B10 Revision: 0 F0306-O1 RO
I 2 StructuralIntegrity Associates, Inc.
Block: 29 433 13 1.54e+004 0. 00e+000 1. 54e+004 0.00 8. 80e-007 8. 80e-007 0.3514 0.00 434 1 2. 26e+004 0.00e+000 2 .26e+004 0.00 2.87e-006 2.87e-006 0.3514 0.00 435 1 1. 66e+004 0 . 00e+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3514 0.00 Block: 30 448 13 1 . 54e+004 0.00e+000 1.54e+004 0.00 8.80e-007 8 . 80e-007 0.3515 0.00 449 1 2. 26e+004 0 . 00e+000 2. 26e+004 0.00 2. 87e-006 2.87e-006 0.3515 0.00 450 1 1. 66e+004 0.00e+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3515 0.00 Block: 31 463 13 1 . 54e+004 0.00e+000 1 . 54e+004 0.00 8.80e-007 8 . 80e-007 0.3515 0.00 464 1 2 .26e+004 0 . OOe+000 2. 26e+004 0.00 2. 87e-006 2. 87e-006 0.3515 0.00 465 1 1. 66e+004 0 OOe+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3515 0.00 Block: 32 478 13 1 . 54e+004 0.OOe+000 1. 54e+004 0.00 8. 80e-007 8. 80e-007 0.3515 0.00 479 1 2. 26e+004 0. OOe+000 2. 26e+004 0.00 2.87e-006 2.87e-006 0.3515 0.00 480 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3515 0.00 Block: 33 493 13 1 . 54e+004 0.OOe+000 1.54e+004 0.00 8.80e-007 8.80e-007 0.3515 0.00
.494 1 2 .26e+004 0 . OOe+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3515 0.00 495 1 1. 66e+004 0 . OOe+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3515 0.00 Block: 34 508 13 1. 54e+004 0.OOe+000 1 . 54e+004 0.00 8.80e-007 8.80e-007 0.3515 0.00 509 1 2. 26e+004 0. 00e+000 2. 26e+004 0.00 2. 87e-006 2. 87e-006 0.3515 0.00 510 1 1. 66e+004 0 . 00e+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3515 0.00 Block: 35 523 13 1 . 54e+004 0 . 00e+000 1.54e+004 0.00 8.8le-007 8.81e-007 0.3515 0.00 524 1 2.26e+004 0 . 00e+000 2 .26e+004 0.00 2. 87e-006 2. 87e-006 0.3515 0.00 525 1 1. 66e+004 0.00e+000 1. 66e+004 0.00 1. 12e-006 1. 12e-006 0.3515 0.00 Block: 36 538 13 1 . 54e+004 0 . 00e+000 1.54e+004 0.00 8 . 81e-007 8. 81e-007 0.3516 0.00 539 1 2 .26e+004 0.00e+000 2 .26e+004 0.00 2.87e-006 2. 87e-006 0.3516 0.00 540 1 1. 66e+004 0 . 00e+000 1. 66e+004 0.00 1.12e-006 1.12e-006 0.3516 0.00 Block: 37 553 13 1.54e+004 0.OOe+000 1.54e+004 0.00 8.81e-007 8.81e-007 0.3516 0.00 554 1 2. 26e+004 0.00e+000 2. 26e+004 0.00 2.87e-006 2. 87e-006 0.3516 0.00 555 1 1 . 66e+004 0 . 00e+000 1. 66e+004 0.00 1.12e-006 1. 12e-006 0.3516 0.00 Block: 38 568 13 1 . 54e+004 0 . 00e+000 1.54e+004 0.00 8.81e-007 8.81e-007 0.3516 0.00 569 1 2. 26e+004 0.00e+000 2 .26e+004 0.00 2.87e-006 2.87e-006 0.3516 0.00 570 1 1. 66e+004 0. 00e+000 1 . 66e+004 0.00 1.12e-006 1.12e-006 0.3516 0.00 Block: 39 583 13 1.54e+004 0.00e+000 1.54e+004 0.00 8.81e-007 8.81e-007 0.3516 0.00 584 1 2.26e+004 0.00e+000 2.26e+004 0.00 2.87e-006 2.87e-006 0.3516 0.00 File No.: 0800802.306 Page B9 of B10 Revision: 0 F0306-O1RO
$StructuralIntegrity Associates, Inc.
585 1 1.66e+004 0.00e+000 1.66e+004 0.00 1.12e-006 1.12e-006 0.3516 0.00 Block: 40 598 13 1.54e+004 0.00e+000 1.54e+004 0.00 8.81e-007 8.81e-007 0.3516 0.00 599 1 2.26e+004 0.00e+000 2.26e+004 0.00 2.87e-006 2.87e-006 0.3516 0.00 600 1 1.66e+004 0.00e+000 1.66e+004 0.00 1.12e-006 1.12e-006 0.3516 0.00 End of pc-CRACK Output File No.: 0800802.306 Page B10 of B10 Revision: 0 F0306-O1RO