TMI-11-078, Response to Request for Additional Information - Submittal of Relief Request RR-10-02 Concerning the Weld Overlay of the Pressurizer Spray Nozzle to Safe-End and Safe-End to Elbow Dissimilar Metal Welds
| ML111160137 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 04/25/2011 |
| From: | David Helker Exelon Nuclear, Exelon Generation Co |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| Shared Package | |
| ML111160149 | List: |
| References | |
| RR-10-02, TMI-11-078 1000320.310, Rev 0 | |
| Download: ML111160137 (27) | |
Text
PROPRIETARY INFORMATION - WITHHOLD UNDER 10 CFR 2.390 10 CFR 50.55a TMI-11-078 April 25, 2011 U.S. Nuclear Regulatory Commission Attn: Document Control Desk Washington, DC 20555-0001 Three Mile Island Nuclear Station, Unit 1 Renewed Facility Operating License No. DPR-50 NRC Docket No. 50-289
Subject:
Response to Request for Additional Information - Submittal of Relief Request RR-10-02 Concerning the Weld Overlay of the Pressurizer Spray Nozzle to Safe-End and Safe-End to Elbow Dissimilar Metal Welds
References:
1)
Letter from P. B. Cowan (Exelon Generation Company, LLC) to U.S. Nuclear Regulatory Commission, "Submittal of Relief Request RR-10-02 Concerning the Weld Overlay of the Pressurizer Spray Nozzle to Safe-End and Safe-End to Elbow Dissimilar Metal Welds," dated September 30,2010 2)
Letter from P. Bamford (U.S. Nuclear Regulatory Commission) to M. J.
Pacilio, "Three Mile Island Nuclear Station, Unit 1 - Request for Additional Information Regarding Relief Request RR-10-02, Weld Overlay of the Pressurizer Spray Nozzle to Safe-End and Safe-End to Elbow Dissimilar Metal Welds (TAC NO. ME4795)," dated February 28,2011 3)
Letter from D. P. Helker (Exelon Generation Company, LLC) to U.S. Nuclear Regulatory Commission, "Response to Request for Additional Information -
Submittal of Relief Request RR-10-02 Concerning the Weld Overlay of the Pressurizer Spray Nozzle to Safe-End and Safe-End to Elbow Dissimilar Metal Welds," dated March 9, 2011 4)
Letter from D. P. Helker (Exelon Generation Company, LLC) to U.S. Nuclear Regulatory Commission, "Response to Request for Additional Information -
Submittal of Relief Request RR-10-02 Concerning the Weld Overlay of the Pressurizer Spray Nozzle to Safe-End and Safe-End to Elbow Dissimilar Metal Welds," dated April 6, 2011 In the Reference 1 letter, Exelon Generation Company, LLC (Exelon) requested relief to perform a weld overlay of pressurizer spray nozzle to safe-end and safe-end to elbow dissimilar metal welds at Three Mile Island Nuclear Station (TMI), Unit 1. In the Reference 2 letter, the U.S.
Nuclear Regulatory Commission requested additional information. References 3 and 4 provided a response to this request. transmitted herewith contains Proprietary Information.
When separated from attachments, this document is decontrolled.
Response to Request for Additional Information Relief Request RR~10~02 Concerning the Weld Overlay of Dissimilar Metal Welds April 25, 2011 Page 2 Based on further discussions with the U.S. Nuclear Regulatory Commission, Attachment 1 contains copies of Calculation NO.1 000320.31 0, Revision 0 with updated proprietary markings. contains information proprietary to AREVA NP Inc. (AREVA) and Structural Integrity Associates (SI), Inc. AREVA and Sl request that Calculation No. 1000320.310, Revision 0 be withheld from public disclosure in accordance with 10 CFR 2.390(b)(4). contains a non~proprietary version of Calculation No. 1000320.310, Revision O.
Affidavits supporting AREVA and SI's request are contained in Attachment 3.
There are no regulatory commitments contained in this submittal.
If you have any questions concerning this letter, please contact Tom Loomis at (61 0) 765~551 O.
Respectfully, David P. Helker Manager ~ Licensing & Regulatory Affairs Exelon Generation Company, LLC Attachments: 1)
Calculation No. 1000320.310, "Pressurizer Spray Nozzle Weld Overlay Sizing Calculation," Revision 0 (Proprietary Version) 2)
Calculation NO.1 000320.31 0, "Pressurizer Spray Nozzle Weld Overlay Sizing Calculation," Revision 0 (Non~Proprietary Version) 3)
Affidavits cc: Regional Administrator, Region I, USNRC USNRC Senior Resident Inspector, TMI USNRC Project Manager, [TMI] USNRC
ATTACHMENT 2 Non-Proprietary Version Calculation No. 1000320.310, "Pressurizer Spray Nozzle Weld Overlay Sizing Calculation,"
Revision 0
""t"'It'!tIJ'::Jlllllfmnrv Associates, Inc.1/Jl CALCULATION PACKAGE PROJECT NAME:
TMI Pressurizer Spray Nozzle WOL CONTRACT NO.:
59091 1000320.310 Project No.: 1000320 Quality Program:
Nuclear 0 Commercial CLIENT:
Welding Services Inc. (WSI)
PI.ANT:
Three Mile Island Nuclear Generating Station, Unit I CAl.CULATION TITLE:
Pressurizer Spray Nozzle Weld Overlay Sizing Calculation Document R.evision o
Affected Pages I - 18 Revi~ion Description Initial Issue Project Manager Approval Si nature & Date R. L. Bax RLB 03/11111 Preparer(s) &
Checker(s)
Si atures & Date tJ~t cQak.~
N. Sadeghi NS 03/10111 A. Alleshwaram AA 03/10/11 Page I of 18 fH,(b01RI
SlnJclLIfJJllnlf;!Ontv Associates, Inc.
Table of Contents 1.0 2.0 3.0 4.0 5.0 6.0 6.1 6.2 6.3 6.4 7.0
8.0 INTRODUCTION
3 DESCRIPTION OF CONFrGURAnON AND REPAIR PROCESS 3
I\\Sl\\.1E (X)[)E C:RITERIA J
U)ADS AND DESIGN INPUTS 7
WELD OVERLAY THICKNESS SIZING 10 WELD OVERLAY LENGTH REQUIREMENTS................
12 Structural ReinforcemenL 12 Preservice EXl1rninalion 14 Area Limitation on Nozzle 14 Maxinluln ()verlay Sizing 15 DISCUSSIONS AND CONCLUSIONS 15 I~EFERENCES 17 List of Tables Table I' Safety Factors for Sizing - Cirwmferential Flaw 5
Table 2: Specified Forces and Moments at the Safe End-tn-Elbow Weld Location 8
Table 3: Forces and Moments at Weld Locations 9
Table 4: Dimensions !()r Overlay Sizing 10
'Table 5: Calculated Stresses 11 Table 6: Allowable Stresses and Calculated Stress to Allowable Stress Ratios 12 Table 7: Minimum Required Overlay Length 14 Table 8: Minimum Required Overlay I)imensions 15 List of' Figures Figure I. Locations E.xamined for FSWOL Sizing 10 Figure 2: Full Structural Weld Overlay Geometry, Minimum Dimensions (Selle/natie I<cpresentation) 16 File No.' IO00320.Jl0 Revision: 0 Page 2 of 18
1.0 INTRODlJCflON A weld repair is for the nominal diameter spray nozzle-tn-safe end dissimilar metal weld (DMW I) and the end-to-elbow dissimilar metal weld (DMW2) at Three Mile Island Nuclear Generating Unit I (TMI-I). This calculation documents the required structural sizing calculations a full structural weld overlay (FSWOL) repair these welds, based on plant-specific geometry and loadings, and the design requirements of ASME Code,Section XI, Code Cases N-504-3 [4] and N-638-1 [51 (Note: A relief rC<luest will be prepared to allow the use of these two Code Cases).
2.0 DESCRIPTION
OF CONFIGURATION AND REPAIR PROCESS The pressurizer spray nozzle is SA-508 Class I carbon steel_ the safe end is SB-166_ and the auached spray line elbow is SA-403 WP316 stainless st~ 16). The DMWs, which join the pressurizer spray nozzle to the end and the safe end to the elbow, arc assumed to be fabricated using Alloy 82/182 weld metal. This assumption is based on the Alloy 600 visual examination records for these welds.
The FSWOL repair will be performed using primary water stress corrosion cracking (PWSCC) resistant Alloy 52M material deposited around the circumference of the configuration. 'rhe overlay material will be deposited using the machine mngsten arc welding (GTAW) process. For the Alloy 52M weld overlay filler metal, the selected material is SB-166, Rod & Bar [3" corresponding to Alloy 690 (58Ni-29Cr-9Fe).
3.0 ASME CODE CRITI~Rli\\
The applicable ASME Code of repair and replacement for TMI-I is the 2004 Edition of ASME Code,Section XI [I] per Reference 6. The basis for FSW()L sizing is the ASME Code,Section XI, Code Case N-504-3 [4Jand the ASME Code,Section XI, Division I. Class I III rules for allowable fluw sizes in austenitic and ferritk piping (lWH-3640). The ASME Code,Section XI, Code Case N-504-3 [41, and the temper bead welding approach documented in Code Case N-638-1 [5], are used herein and are applied to dissimilar metal welds using nickel,1Iloy filler, Alloy 52M. To determine the overlay thickness, Code Case N-504-3 refers to the requirements of ASME Code, Section XL IWB-3640. IWB-3640 of the 2004 edition of the Code refers to Appendix C, which conwins the specific methodology for meeting the allowable flaw The overlays are to be applied using the errAW process, which is a non-flux process, Therefore, for circumferential Haws, the source equations in Reference I, Appendix Section C-5J20 (limit load criteria) are lhe controlling allowable flaw size equations for combined hJadillg (membmne plus bending) and membrane-only loading, These equations (\\re valid for Ilaw depth-to-thickness mtios for naw lenu:ths faill!irH! from 0 to H)Olfl' the circumference us defined in I~eference I,
- ';/
,=,<
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Section Appendix For purposes of designing the overlay, a circumferential l1aw is assumed to be 100% through the original wall thickness for the elllire circumference of the item being overlaid.
overlay is by the source equations in Section,,~.-,,_,~.v [II.
The allowable bending stress under combined membrane pius bending loads is given by the equation:
Reference I. C-5321,
- where,
/3=
If 2
a I
The allowable membrane stress is given by the equation:
Reference I, C-5322,
- where, cp =arc.:Sin!o.s( Il)Sin 81-L
\\. I J
and
~)c (1'"
SI;~fI
,'iF" a
SI d m
()
{i allowable bending stress for acircumferentiaHy l1awcd pipe bending stress at incipient plastic collapse safety factor for mClllbnme stress based on Service Level as shown in Table I II, C-262 I 1 safety factor for bending stress based on Service Level as shown in Table I [I, C-262 I I llaw depth total wall thickness lincludes overlay thickness, in this case}
allowable membrane stress for a circmnferelltially flawed pipe membrane stress at incipient plastic collapse half flaw angle II, Figure C-431O-1 J, IS()" or 1f for a IOO/it full circlimfen.:ntial flaw angle to neutral axis of flawed pipe in radians File No.. 1000320..310 Revision: 0 Page 4 of 18
.'\\trut:JJ!!:ft Integrity Associates, (1/"
=
.)1/
unintensil1ed primary membrane stress at the llaw location flow stress :=
+S/I)12 [ I. C-8200(a)}
specit1ed value for material yield taken at ev,duation (operating) temperature from Ref(~renlce 3 specified value for materialultimme taken at the evaluation (operating) temperature Rert~rel1l:e.~
Safety factors are provided in Appendix C of Section XI for evaluation of flaws in austenitic stainless steel piping. The safety factors used for the weld overlay sizing are shown in Table I and are taken from C-2621 [II.
Table I: Safety Factors for Sizing - Circumferential Flaw Service Membrdne Stress Rending Stress Level Safety Factor, SPlit Safety Factor, SP/1 r----A 2.7 2.3 B
2.4 2.0 C
1.8 1.6 D
1.3 1.4 The overlay thickness must be established so that the flaw assumption herein meets the allowable tlaw depth-to-thickness ratio requirement of t.he source equations [I, C-5320). for the thickness of the weld-overlaid item. considering combined primary membrane-plus-bending stresses,md membrane-only st.resses, per the source equations defined previously, Since the weld overlay is an austenitic material and applied with a non-flux welding process, which has high fracture toughness, the limit load failure mode is applil.:able [I, Figure C-42 I0-1 for non-flux welds},md hence, limit load evaluation techniques are used here.
The non-overlaid piping stresses for lise in the equations are usually obtained from the applicable stress reports for the items to be overlaid. However, in this calculation, they are calculated b'lsed on forces and moments at the welds using equations from C-2500 of St~l:tion XI, Appendix C as described below.
Primary membrane stress (0;/1) is given by:
0;"
- pD/(4t). where:
p
=
operating pressure for the Service Level being ccmsidered D
outside diameter of the component including the overlay f
thickness, consistent with the location at which the outside diameter is taken including the overlay (note Ihat the inside diameter (II) cladding is not counted
[(Jwlud wall thickness)
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Primary bending stress (0/,) is by:
D
=:;
d M"
I outside diameter of the component including the overlay inside diameter, consistent with the point at which the outside diameter is taken that the ID cladding is not counted in the inside diameter) resultant moment for the appropriate primary load combination for each Service Level (square root of the sum of the squares (SRSS) of three moment components in X, Y, and Z directions) moment of inertia, (lC!64) (D4 - it)
The contribution of axial and shear forces to piping stress (other than force couples contributing to moments) is not included based on C-25OO of Section XI, Appendix C [I].
The followin load combinations are used for the full structural weld overla Service Level A (Normal):
Service Level B (Upset):
Service Level C (Emergency):
Service Level D (Faulted):
Pressure (P) + Deadweight (OW)
P + DW + Operational Basis Earthquake (OBE)
P + DW + Safe Shutdown Earthquake (SSE)
P+ DW +SSE Service Levels A, B, C, and D in the ASME Code [I] are altematively referred as Normal, Upset, Emergency, and Faulted conditions, respectively, in this evaluation. Per ASME Code,Section XI C-53 I I for the Combined Loading case. test conditions shall be included with the Service Level B Load Combination. However, the hydrostatic pressure test is not applicable to the weld overlay repair and is not included in the FSWOL design.
The weld overlay sizing is an iterative process, in which the allowable stresses are calculated and then compared to the stresses in the overlaid component. If the stresses in the component are larger than the allowable stresses in the component then the overlay thickness is increased. and the process is repealed until it converges to an overlay thickness which meets the allowable stresses.
The thickness of the weld overlay is determined through an iterative process. The thickness of the overlay (toi) is assumed resulting in a total thickness of Up + lull where '" is the original pipe thickness.
The applied flaw size-ttHhiekness ratio based on a FSWOL (flawed through the original pipe wall thickness, Iv) is l,lll" + f"/). The allowable stresses are then determined from lhe source equations (see the heginning of Section 3J>>. If this allowable stress value is greater than the calculated stress for the overlaid component, the overlay thickness ((iii) is reduced. On the other hand, if the aIlO\\\\'able stress value is than the calculated stress for the overlaid component, the overlay thickness (1,,1) is increased.
The pnx:css is repeated until the assumed overlay thickness n.'sults in a stress ratio of the calculated File No.: 1000320.310 Revision: 0 Paue 6 of 18 ec
SlrucLurallnlegrity Associates, Inc!
stress to the aIrowable stress that is equal or less than 1.0. As the maximum allowed value for alt is 0.75 (I. C~5-'20],10, is initially set as 1,)3. If the overlay thit.:kness of 1,13 meets the allowable stresses for pure membrane and combined membrane pillS bending stresses. then no more iterations are perfonned. If the allowable stresses arl: not met, then the overlay thickness is increased until the ratio of the computed stress to the allowable stress is less than or equal 10 1.0.
In this process, the allowable stresses and adjusted stresses due to overlay thickness iterations are calculated for all applicable Service Levels (A. B. C, and D) and compared. The service level with lhe maximum ratio of the calculated stress to the allowable Slr~SS will control the overlay thickness.
The axial length and end slope of the FSWOL are sized to be sufficient to provide for load redistribution (considering both axial force due to pressure and bending loads) from the overlaid component to the weld overlay and back. such that applicable stress limits of the ASME Code. Section Ill, NB-1200 (2]
are satisfied. Shear stress calculations are performed to assure that the weld overlay length meets these requirements.
4.0 LOADS AND DESIGN INPUTS In order to determine the loads at the nozz e~to-sa e en we.* t e orees an moments must e transformed such that the revised coordinate system is aligned with the nozzle axis. After the transformation performed in the spreadsheet TMl.xlsx, the loads are in a local coordinate system with local-y axial to the nozzle. See Table 2 for the transformed results.
Tables 2 and J do not include forces and moment" due to thermal expansion of the piping attached to the nozzle. For designing FSWOLs, only primary loads are considered and the secondary loads, such as thennal expansion, need not be included in the design calculations. For the transformed result. all forces Dnd moments are taken on an absolute basis. That is, in Table 2 (Post-Transfommtion), all forces and moments are taken as positive.
The loads shown in Table 2 are assumed lo be applied at the safe end-to-elbow weld. These moments are adjusted for the nOlzle-to-safe end weld to account for the eo.;ccntricity between the shear forces (trallsfonned Fv dnd F:J at the safe end-to-e1bow weld and the nozzle-to-safe end weld centcrlines.
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Table 2: Specitied Forces and Moments at the Safe End-to-Elbow Weld Location Pre-Transt'ormution F,
llh Dead Weight
.J Fl,
F:
M, (Ih:)
r1h:-.)
(in-Ihs)
- 1
_52 IOlJ.n
_1~64 1
lin-Ihs) 1 On-Ih )
6192 Post-Transformation P,
Po, F:
M, M,.
"'(
(Ihs)
(Ibs) lIhs)
(in*lbs)
(in-Ihs)
(in-Ihs)
D~ad Weight
,i 14 IJ 252 1222 7X1 OBE 422 629 493 10932 20102 1.';723 SSE 844 1257 986 2JX64 40201
.\\1446 Notes:
I)
Transformed forces and muments are listed on an absolute baSIS.
2) f v is oriented in the altial direction of the nOllle.
Fil~ No.: 1000320..110 Revision: 0 Page Xof 1S
SlfIJI.:LW"lJJ Inlplu,rhi Associates, Table 3: Forces and Moments at Weld Locations 425 643 506 I
14,976 21.324 19,691 I 32,661 425 643 506 ILl84 21,324 16,504 I 847 U71 998 29.604 41 A25 I
38.580 63,881 847 I 1 I
998 22,116 41.425 32,221 56,954 56,954 32.227 41,425 116 1.0932 20102 I
21864 4{)203 3
252 1,222 781 1,472 998 1.271 847 1,503 63,881 7776 S03 18888 38580 vVeld (DMWl)lllW Forces and M.
Mz I MRSS Fx F,.,
F::.
..........., '(in.lbs)
(in*lbs)
(lbs)
(Ibs)
(lbs) 1222 I
SO:!
I 3
14 13 4"
629 493 k....
844 1257 986 3
14 13 41A25 29.611-t 998 1.171 Forces and Moments, Nozzle*f(...Safe End..
Fz
,\\'lx
,,,'v!
r"__,_" __,_,,+-,=,,,,"_,+..~,=c::."--t-",,,(J;;;;;b.;;;.s',-j -+,-(,-"in;;;..=lb!l.+ (in.ih..I !
13 341' 493 20102 I*"""
+
,..... t
_*",,*,**,*1..*..,******,,*
=
..j-.._",...
~..-
i 257 986 29251 40203 3
14 13 347 1.222 847 Notes:
I 21 Tn.:
end moments account for the of 7S' the ccmerlincs of DMW I and DMW2.
Forces at the nOlllc..to-safe end weld arc assumed equIvalent to the forces allhe safe cnd-to..elbow weld.
--_..._._-='."'--.--.-----------------------_.
File No.; 1000320,310 Revision; 0 18
Struclurallnlegrity Associates, Inc.1t 5.0 WELD OVERLAY THICKNE...~S SIZING The normal operating pressure [6], dimension and overlay thickness are shown in Table 4. At the nozzle side of the DMW I, Location I R includes the thickn~ss of the lIllzzle plus the thickness of the If) dadding, while Lorution IA considers only the thickness of the nozzle (excluding the thickness of the 10 cladding) (see Figure I). An initial alt value of 0.75 (the limiting value as stated in C-S.U2 of Appendix C of Section XI rI1) was the initial input to the iteration. The assumed 360° flaw results in a flaw length to circumfcrenl'e ratio of 1.0. Figure I shows the locations for FSWOL sizing.
EI,BOW 4
SAFE END lAiIB PRESSURIZER SPRAY NOZZLE Figure 1: Locations Examined for FSWOL Sizing Table 4: Dimensions for Overlay Sizing Location IA l.ocatiQn IB Location 2 Ltx:ation j Location 4 tna ""I. in Uti, in Nozzle Side ofDMWI w/oClad 2155
.U.515 NOllIe Side ofUMWI wi Clad 2155 40.667 Sate End Side of UMWI 2155 40.667 Safe End Side of UMW2 2155 IlU21 16.506
('i)
Normal operating prt'Ssure of 2155 psig 161 is t1~'d.
The final calculated membrane stresses (0;,,) and hending stresses (Oi,l at each service level for the pipe +
overlay configuration are shown ill Tahle 5. This table also shows the ratio of the memhrane stress (0;,,)
File No.: 1000320.310 Revision: 0 Page 10 of 18
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to the now stress (Of) at the selected locmions. The material properties are evaluated at the normal nnl>rlll!nu temperature F (6) using Section II, Part D of the ASME Code [31.
Table 5: Calculated Stresses Level 80,000 53,750 0.0564 A
1M B
2765 2259
~:c_.__._+E~B~12J~~L~_25'~40~8_+__44_18 D
5408 4418 80,000 5.1.750 0.0564 104 2259 4418 4418 53,750 0.0833 195 3874 7558 7558 8247 8247 Table 6 shows the allowable stresses as determined from the source equations discussed in Section 3.0, Tbe membrane and bending stresses from Table 5 are compared to the allowable stresses as shown by the ratios in Table 6. The limiting CHses for the membrane and bending stresses are shown in bold. In the limit load Hnalyses, the now stress of the Alloy 52M weld overlay material is used. consistent with the assumption of a full 36()O flaw through the original pipe wall for the design of the full structural weld overlay.
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Tl1ble 6: Allowable Stresses and Calculated Stress to Allowable Stress Itatios Location fA Location 18 Location 2 Location J Location 4 Service Level NOlzle Side of Nozzle Side of Safe End Sate End Elbow DMW I DMW I Side of Side of Side ()f win Clad wi Clad DMWI DMW2 DMW2 I-~-.~_.-~.~~--~w._---~_.t--~--~-~._._--+.._._....._..._.-.----f------ -.---- ~-----.~
IJ in radians 0.4494 0.4866 04866 0.4327 0.4230 crt!" psi 18619 20002 20002 18025 17660 Level A Level B I LevelC Level D Level A LevelB Level C Level D Normal Sc, psi 5613 6789 6789 5019 4698 Upset S., psi 70 I0 8233 8233 640 I 6069 Sc, psi
_..:;9~88=5__~.
11155 11155 9276 8934 Faulted S" psi 12389 I
13588 13588 11842 11522 Normal crtiS(
0.0227 0.0153 0.0153 0.0389 0.0454
--j----'-....;.....--'---+----'-'---+----f---'-.........;--'--;
Upset otiSc 0.2743 0.274.3 0605 I 0.6965 Emergency crtiSc
,5471 0.3961 0.396J 0.8148 0.9231 Faulted cr,,ISc 04365 0.3251 0.3251 0.6382 0.7158 13571 13438 13438 I
13776 13833 Level A Normal S" psi 5026 4977 4977 5102 5123__
Level B Upset S" psi 5655 5599 5599 5740 5764
__-CC__t-
...c.L.~..;;.;;.L..:;c*_*__ *+***--..:;.**=c;:...*~--**r*********-:.;.- -_
+_.._~~..:;.:.:..:;_.-+-----:..'--.:......- +_
_';;'.;";;;"';'_-1 Level C Ernenl,ency St, psi 7540 7465 7465 7653 7685 Level [)
Faulted St, psi 10440 10337 10337 10597 10641 I-_Le::::;.:::.:v...;:.e.:..;1A-:.-+__.:..N;.::o:..;.n:.:;na:;.l.:.:.cr,!I!:.i.::;;JS,i.--_-+-_..:::0.::;.7..;:::8..:.;41:..._+-_...:0:.:.;:.6:.:;O:.;:.89:..._-+_..::O.:.:.60~8:::9:............ 0.8773 0.9240 Level B Upset OlliS 0.6970 (1541.3 (15413 0.7798 0,8213 Level C El1Ier~ency o,,,IS, 0.5227 0.4059 OA059 0.5849 0.6160
~
Faulted alliS, (U775 0.2932 O.29c::32=-._~..L_:..:;.:;O._4.:..;22.:..;4_--L_Q~44__9 __
Notes:
<I" Bending stress III incipient plastic collapst! [l, C*5320]
S,.
Allowable bending slrt's!> 1.1. C>5320J S,
=:
Allowable mcmbnme stress II, ('-5320J Membrane siress at indpielll plastk t:Olllll)SC fI, C 53201 (All terms defined in Seclion 3'(>>
6.0 WEIjD OVERLAY L~:N(n'H REQIHREMENTS The weld overlay length must consider three requirements: (I) length required for structural reinforcement, (21 length required for preservice examination access of the overlaid weld, and 0) limitation on the area of the Ilozzle surface that can be overlaid.
6.1 Structural Reinf'orcement Structural reinforcement requirements are expected to be satisfied if the weld overlay length is O.75fRi on citbcr side of the susceptible weld being overlaid [41, where R is outside radius of the item and t is the File No.. 1000320.310 Revision: 0 Page 12 of 18
StructtJl'8t InregfJ'ly Associates, nominal thickness of the item at the applicable side of the overlay, However, to assure ASME Code,Section III, NB-3200 [2J stress calculations are instead performed to determine minimum required structural length, The length the overlay is for axial due to transfer of axial load and moment from overlaid item to overlay.
NB-3227.2 [2J limits pure shear due to Design Loading or any Level locldings except Service Level D to O.6SI1l
- Pm
"",,-u,,'p Level D (Paulted) conditions, the stress intensity limit is the lesser of 2.481/1 and O.7Su [2, NB-3225 and Appendix Fl, equivalent to the lesser of 1.251m and 0.35SI/ for shear stress, since stress intensity is equal to twice the shear stress. These values are shown in Table 7 for the spray nozzle, attached elbow, weld overlay materials.
Shear stress around the circumference at the overlay-base material interface due to axial force and moment loading equals:
- where, P
M
=
=:
outside radius of overlaid item at crack length of overlay at outside surface of overlaid item on one side of crack shear area, 2:nR"L TCRo pressure resultant moment from piping interface loads at crack Solving for L and equating rwith the allowable shear stress (Sa/hili') yields:
L:::: rpR,j2 + M/( :nRlll)lI,S~llIm", where,
=: O.6Sm (Service Levels A, B, and C)
=: Lesser of 1.2Sn,.md 035811 (Service Level D)
The evaluation for required length is documented in Table 7 for the pressurizer spray nozzle and elbow.
The overhly weld metal is also evaluated as it may control if the base metal has a higher value of Sill or Su. The greater value of the required overlay length will be taken. The material properties are evaluated at the normal operating temperature of 650 uF [61 using Section If, Part D of the ASME Oldc [31.
Since the overlay ends on the pressurizer spray nozzle at one end and the elbow at the other end, and extends over the safe end. the surface shear transfer imo the base metal occurs onto the nozzle and elbow only. In this configuration, the requirements for shear lengths at intermediate locations (safe end) are not relevant and would have no influence on the required overlay. Therefore, they are not included herein.
The required overlay length is calculated at Locations I and 4 along the nozzle and elbow configuration (both sides of lhe DMW I and DMW2). The evalUal.ion results are presented in Table 7. The design File No." 1000320.310 Revision: 0 Page 13 of IS
SlrLJcllJrallm~ellrjilV Associates, Inc.'
drawing implements a contlguration that meets all the designed FSWOL thickness and length requirements. The lengths shown in Table 7 ensure adequate shear stress transfer along lhe of the weld overlay.
Level C is the most limiting of all cases. This is sufficient 10 the imposed loads and maintain stresses (shear) within the appropriate ASME Code allowable limits (2).
Table 7: Minimum Required Overlay Length Location INIB IAX:<uion INIB Nozzle Side of Nozzle Side of DMWI DMWI 2.563 SA*508 Class I 6.2 Preservice Examination Location 4 Elbow Side of DMW2 2.25 Location 4 EI!l<lW Side of DMW2 2.25 SA*403 WP316 Weld overlay access for preservke examination requires that the overlay length and pnlfile be such that the overlaid weld and any adjacent welds can be inspected using the required NDE techniques. This requirement could cause the overlay length to be longer than required for structural reinforcement. The specific overlay length required for preservice examination is determined based on the examination techniques and proximity of adjacent welds 10 be inspected.
6.3 Area Limitation on Nozzle The total weld overlay surface arl:'H is limited 10500 inl (Ihis valul:' will be specified in the relief request) on the nozzle (t~arb()n steel base material) when using ambient temperature temper bead welding to apply the overlay. Using an outside diameter of 5.125", the maximum length is limitt'(/ to 5()()/(rtD,,) =31.0" 60 Ihe carbon steel nozzle materiaL 'rile required overlay length on the nOllh~ will be less than this limit (see Table 7).
File Revision: 0 Page 14 I (j HJ(,.1l! R!
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6.4 Maximum Overlay Sizing 111i5 calculation the minimum thickness and length for structurnl requirements, Additional and lengt.h may he added to address inspectability and growth concerns. In addition, a maximum overlay (typically an additional 0,25") and a maximum overlay length will he detennined. TIle determination of the maximum length is based on implementation and is intended to be large enough so as to not unnecessarily constrain the overlay process. These dimensions will be indicated on a subsequent design drawing to create a "box" within whk::h the overlay is analyzed. In the subsequent analyses, the finite clement models use the geometry (minimum or maximum) th'lt will produce conservative results.
1.0 DISCUSSIONS AND CONCIJtJSIONS Table 8 and Figure 2 summarize the minimum required overlay dimensions. This calculation documents the development of a weld overlay design for the 4" nomimtl diameter pressurizer spray nozzle-to-safe end dissimilar metal weld and the safe end-to-elbow dissimilar metal weld at 'I'MI-I. The design meets the requirements of the ASME Code.Section XI, Code Case N-504-3 [4} and ASME Code, Scct.ion XI, Appendix C [11 for a full structural weld overlay.
The weld overlay sizing presented in Tnble 8 is based upon the primary loadings documented in Section 4,0 and using the criteria from the ASME Code,Section XI, AppendiX C. The overlay thicknesses and lengths listed in Table 8 meet ASME Code stress criteria.
Table 8: Minimum Required Overlay Dimensions I.oeation Thickness, il1.
M...tl.
File No: 1000320*.110 Revision: 0 Nozzle Side of DMWI Safe find Side of DMW I Sate End Side of DMW2 Elbow Side of DMW2 tAIlH 2
0,1910.25 015 014 0.55 NA NA 0,61 Page 15 of 18
Stfl'lC/llrallntl!lTritv Associates, Inc.1t:
PRESSURIZER SPRAY NOZZLE 0.25" 0.15" 0.14" ELB()W Figure 2: Full Structural Weld Overlay Geometry, Minimum Dimensions (Schematic Representation)
File No.. 1000320,310 Revision: 0 Page 16 of 18
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8.0 REFERENCES
I.
ASME Boiler and Pressure Vessel Code.Section XI. Rules for Inservice Inspection of Nuclear Power Plant Components. 2004 Edition.
2.
ASME Boiler and Pressure Vessel Code.Section III, Rules for Construction of Nuckar Facility Components. 2004 Edition.
1.
ASME Boikr and Pressure Vessel Code.Section II. Part D. Marerial Properties. 2004
- Edition, 4.
ASME Boiler and Pressure Vessel Code. Code Case N-504-3. "Alternative Rules for Repair of Classes 1.2. and 1 Austenitic Stainless Sted Piping.Section XI. Division I,"
5.
ASME Boiler and Pressure Vessel Code. Code Case N-638-1. "Similar and Dissimilar Metal Welding Using Amhient Temperature Machine GTAW Temper Bead Technique.
Section XI. Division I."
6.
Email from William McSorley (Exelon) to Nornlan Eng (SI). dated March 02. 2011.
Suhject "Staws of pzr Spray SWOL Analysis." includes altached tile "GDeBoo Review on 10.314,315 & 316.doc", SI File No. 1000320.212.
File No.:
1000320_110 Revision: ()
Page 17 of -18
S/ruclUlallli'learJlv Associates, Inc.
Company, Technical No. 410. "Flow of Fluids through Valves, Fittings. and Pipe." 1976.
- 16. GPU Nuclear Drawing No. 10-21 Sheet 2 of6, Rev. I, "LPSIIDecay Heat Removal, Piping Analysis," Sf File No. 1000320.204.
File No.: IO00320..UO Revision: 0 Page 18 of 18
ATTACHMENT 3 Affidavits
AFFIDAVIT COMMONWEALTH OF VIRGINIA
)
)
ss.
CITY OF LYNCHBURG
)
1.
My name is Gayle F. Elliott. I am Manager, Product Licensing, for AREVA NP Inc. (AREVA NP) and as such I am authorized to execute this Affidavit.
2.
I am familiar with the criteria applied by AREVA NP to determine whether certain AREVA NP information is proprietary. I am familiar with the policies established by AREVA NP to ensure the proper application of these criteria.
3.
I am familiar with the AREVA NP information contained in the Structural Integrity Associates, Inc. Calculation Package, NO.1 000320.31 0, Revision 0, entitled "Pressurizer Spray Nozzle Weld Overlay Sizing Calculation," dated March of 2011 and referred to herein as "Document." Information contained in this Document has been classified by AREVA NP as proprietary in accordance with the policies established by AREVA NP for the control and protection of proprietary and confidential information.
4.
This Document contains information of a proprietary and confidential nature and is of the type customarily held in confidence by AREVA NP and not made available to the public. Based on my experience, I am aware that other companies regard information of the kind contained in this Document as proprietary and confidential.
5.
This Document has been made available to the U.S. Nuclear Regulatory Commission in confidence with the request that the information contained in this Document be withheld from public disclosure. The request for withholding of proprietary information is
made in accordance with 10 CFR 2.390.
The information for which withholding from disclosure is requested qualifies under 10 CFR 2.390(a}(4} "Trade secrets and commercial or financial information."
6.
The following criteria are customarily applied by AREVA NP to determine whether information should be classified as proprietary:
(a)
The information reveals details of AREVA NP's research and development plans and programs or their results.
(b)
Use of the information by a competitor would permit the competitor to significantly reduce its expenditures, in time or resources, to design, produce, or market a similar product or service.
(c)
The information includes test data or analytical techniques concerning a process, methodology, or component, the application of which results in a competitive advantage for AREVA NP.
(d)
The information reveals certain distinguishing aspects of a process, methodology, or component, the exclusive use of which provides a competitive advantage for AREVA NP in product optimization or marketability.
(e)
The information is vital to a competitive advantage held by AREVA NP, would be helpful to competitors to AREVA NP, and would likely cause substantial harm to the competitive position of AREVA NP.
The information in the Document is considered proprietary for the reasons set forth in paragraphs 6(b) and 6(c} above.
7.
In accordance with AREVA NP's policies governing the protection and control of information, proprietary information contained in this Document have been made available, on a limited basis, to others outside AREVA NP only as required and under suitable agreement providing for nondisclosure and limited use of the information.
,2011.
8.
AREVA NP policy requires that proprietary information be kept in a secured file or area and distributed on a need-to-know basis.
9.
The foregoing statements are true and correct to the best of my knowledge, information, and belief.
SUBSCRIBED before me this -'--'--__
daYOf~
Kathleen Ann Bennett NOTARY PUBLIC, COMMONWEALTH OF VIRGINIA MY COMMISSION EXPIRES: 8/31/11 Reg. # 110864 KAfHLIEN ANN 8ENNm Notary Public Commonw.alth of virginia 110864 My Commission Expires Aug 31, 2011
~
""'tr"r<'"r?JIllnn~II"'V Associates, Inc.@
5215 Hellyer Ave.
Suite 210 San Jose. CA 95138*1025 Phone: 408*978-8200 Fax:
408*978*8964 WWW$truclinl.com April 15.2011 AFFIDAVIT I, Marcos Legaspi Herrera, state as follows:
(I)
I am a Vice President of Structural Integrity Associates, Inc. (SI) and have been delegated the function of reviewing the information described in paragraph (2) which is sought to be withheld, and have been authorized to apply for its withholding.
(2)
The information sought to be withheld is contained in SI Calculation 1000320.310, Rev. 0, "Pressurizer Spray Nozzle Weld Overlay Sizing Calculation." This calculation is to be treated as SI proprietary information, because it contains significant information that is deemed proprietary and confidential to AREVA NP. AREVA NP design input information was provided to SI in strictest confidence so that we could generate the aforementioned calculation on behalf of Sl's client, Exelon Nuclear Company, LLC (Exelon).
Paragraph.1 of this Affidavit provides the basis for the proprietary determination.
(3)
SI is making this application for withholding of proprietary information 011 the basis that such information was provided to SI under the protection of a Proprietary/Confidentiality and Nondisclosure Agreement between SI and AREVA NP. In a separate Affidavit requesting withholding of such proprietary information prepared by AREVA NP, AREVA NP relies upon the exemption of disclosure set forth in NRC Regulation 10 CFR 2.390(a)(4) pertaining to "trade secrets and commercial or financial information obtained from a person and privileged or confidential" (Exemption 4). As delineated in AREVA NP's Affidavit, the material for which exemption from disclosure is herein sought is considered proprietary for the following reasons (taken directly from Items 6(b) and 6(c) of AREVA NP's Affidavit):
a)
Use of the infonnation by a competitor would permit the competitor to significantly reduce its expenditures, in time or resources, to design, produce, or market a similar product or service; and
SI Art1davit for Calculation 1000320.310, Rev. 0 April 15,2011 Page 2 of2 b) The information includes test data or analyticallechniques concerning a process, methodology, or component, the application of which results in a competitive advantage for AREVA NP.
Public disclosure of the information sought to be withheld is likely to cause substantial harm to AREVA NP with which SI has established a Proprietary/Confidentiality and Nondisclosure Agreement.
I declare under penalty of pe~iury that the above infonnation and request are true, correct, and complete to the best of my knowledge, information, and belief.
Executed at San Jose, California on this 15th day of April, 2011.
Vice President Nuclear Plant Services State of California County 0 f
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C. METZGER Commission II 1866327 I
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Notary Public* Calitornia
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i Santa Clara County
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- Ml :oT"l: [x~r:s see 27. 201;1 Plate Nowry S(*"l antI/or Slamp,\\hole Subscribed and sworn to (or affirmed) before me on this \\Silaay of -l1b-l-_~(....l.'.J-\\
, 20lL, Date
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Monti' Year by proved to Inc on the basis of satist~lctoryevidence to be the person who appeared before me (.) (\\tJ (and (2) _~
"'am,' or Signer proved to me on the basis (If satisfactory evidence to be the person who appeared before me.)
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