ML14070A341

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Enclosure 1 - Calculation 1200895.306, Rev. 0, Hot Leg Drain Nozzle Weld Residual Stress Analysis and Circumferential Crack Stress Intensity Factor Determination
ML14070A341
Person / Time
Site: Palisades Entergy icon.png
Issue date: 03/06/2014
From: Ku F
Structural Integrity Associates
To:
Office of Nuclear Reactor Regulation
References
PNP 2014-028 1200895.306, Rev. 0
Download: ML14070A341 (52)
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ENCLOSURE1 Structural Integrity Associates, Inc. Calculation 1200895.306 Hot Leg Drain Nozzle Weld Residual Stress Analysis and Circumferential Crack Stress Intensity Factor Determination Revision 0 51 Pages Follow

ATTACHMENT 9.1 VENDOR DOCUMENT REVIEW STATUS Sheet I of I Af */ttrj ENTERGY NUCLEAR MANAGEMENT MANUAL Enter~yEN-DC-149 VENDOR DOCUMENT REVIEW STATUS I] FOR ACCEPTANCE Li FOR INFORMATION EIIPEC El JAF E9 PLP El PNPS [1 VY El ANO El GGNS El RBS El W3 I- NP Document No.: 1200895.306 1Rev. No.(0 Document

Title:

Hot Leg Drain Nozzle Weld Residual Stress Analysis and Circumferential Crack Stress Intensity Factor Determination EC No.: 49590 Purchase Order No.N/A (NIAfor NP)

STATUS NO:

1. 0 ACCEPTED, WORK MAY PROCEED
2. Li ACCEPTED AS NOTED RESUBMITTAL NOT REQUIRED, WORK MAY PROCEED
3. Li ACCEPTED AS NOTED RESUBMITTAL REQUIRED
4. El NOT ACCEPTED Acceptance does not constitute approval of design details, calculations, analyses, test methods, or materials developed or selected by the supplier and does not relieve the supplier from full compliance with contractual negotiations.

Responsible Engineer Brian Smith I . -3 Print Name J ' - - Date-Engineering Supervisor Dave MacMaster / i. '.. /-

Print Name Signature D~te EN-DC-1 49 REV 8

  • 7tiStructuralIntegrity Associates, Inc.5 File No.: 1200895.306

!C IProject

ý No.: 1400148 CALCULATION PACKAGE Quality Program: ZI Nuclear EJ Commercial PROJECT NAME:

Evaluation of Hot Leg Drain Nozzle CONTRACT NO.:

10404220 CLIENT: PLANT:

Entergy Nuclear Palisades Nuclear Plant CALCULATION TITLE:

Hot Leg Drain Nozzle Weld Residual Stress Analysis and Circumferential Crack Stress Intensity Factor Determination Document Affected Project Manager Preparer(s) &

Revision Pages Revision Description Approval Checker(s)

Signature & Date Signatures & Date 01 - 45 Initial Issue A-i - A-5 Richard Bax RLB 03/06/14 Francis Ku FHK 03/06/14 Charles Fourcade CJF 03/06/14 Page 1 of 45 F0306-OIRI

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Table of Contents 1.0 O B JE C T IV E .................................................................................................................. 5 2.0 TECHNICAL APPROACH .................................................................................... 5 2.1 M aterial Properties ....................................................................................... 5 2.2 Finite Element Model for Weld Residual Stress Analysis ........................... 6 2.3 Finite Element Models with Circumferential Flaws ..................................... 6 2.4 W elding Sim ulation ....................................................................................... 6 2 .5 H eat Inputs ................................................................................................. .. 7 2.6 C reep Properties .......................................................................................... .. 7 2.7 Mechanical Boundary Conditions ............................................................... 8 3.0 A SSU M PT IO N S ........................................................................................................ 8 4.0 WELD RESIDUAL STRESS ANALYSIS ............................................................. 9 4.1 H ot L eg C ladding ......................................................................................... 9 4.2 B oss M ain W eld ......................................................................................... 10 4.3 ID Patch W eld .......................................................................................... . . 10 4.4 Post Weld Heat Treatment ........................................................................... 10 4.5 Hydrostatic T est ......................................................................................... . 11 4.6 Five Normal Operating Cycles (NOC) ........................................................ 11 5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS ..................................... 12 5.1 Welding Temperature Contours ................................................................. 12 5.2 PWHT Temperature Results ...................................................................... 12 5.3 R esidual Stress R esults ................................................................................ 12 6.0 K CALCULATION FOR CIRCUMFERENTIAL CRACKS ................................ 13 6.1 Crack Face Pressure Application ............................................................... 13 6.2 Circumferential Crack Stress Intensity Factor Results ............................... 14 7.0 STRESS EXTRACTION FOR AXIAL CRACKS ................................................ 14 7.1 Hoop Stress Extraction for Axial Crack Growth Evaluation ..................... 14 8.0 C O N C L U SIO N S ..................................................................................................... 15 9.0 RE FE REN C E S ....................................................................................................... 16 APPENDIX A COMPUTER FILES LISTING ............................................................... A-1 File No.: 1200895.306 Page 2 of 45 Revision: 0 F0306-O1 RI

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List of Tables Table 1: Elastic Properties for SA-516 Grade 70 (<4" Thick) ............................................... 17 Table 2: Elastic Properties for ER308L ............................................................................. 17 Table 3: Elastic Properties for Alloy 600 .......................................................................... 18 Table 4: Elastic Properties for Alloy 82/182 ...................................................................... 18 Table 5: Elastic-Plastic Properties for SA-516 Grade 70 (S4" Thick) ............................. 19 Table 6: Elastic-Plastic Properties for ER308L ................................................................. 20 Table 7: Elastic-Plastic Properties for Alloy 600 .............................................................. 21 Table 8: Elastic-Plastic Properties for Alloy 182 .............................................................. 22 T able 9: C reep Properties .................................................................................................. 23 Table 10: Circumferential Crack "K vs. a" Table ........................................................... 24 Table 11: Hoop Stress Table at 0' Azimuth for Axial Crack Growth Evaluation ........... 25 File No.: 1200895.306 Page 3 of 45 Revision: 0 F0306-01 RI

,jj ntumnIa*ur*"Associates. no.° List of Figures Figure 1: Finite Element Model for Residual Stress Analysis ......................................... 26 Figure 2: Finite Element Model for the 0.13" Deep Circumferential Crack .................... 27 Figure 3: Applied M echanical Boundary Conditions ........................................................ 28 Figure 4: Weld Nugget Definitions for the Boss Main Weld ............................................ 29 Figure 5: Weld Nugget Definitions for the ID Patch Weld .............................................. 30 Figure 6: Applied Hydrostatic and Corresponding End Cap Pressure Loads .................. 31 Figure 7: Predicted Fusion Boundary Plot for Cladding ................................................... 32 Figure 8: Predicted Fusion Boundary Plot for Boss Main Weld ....................................... 33 Figure 9: Predicted Fusion Boundary Plot for ID Patch Weld ......................................... 34 Figure 10: Temperature Curve for PW HT ......................................................................... 35 Figure 11: Predicted von Mises Residual Stress after ID Patch Weld at 70'F .................. 36 Figure 12: Predicted von Mises Residual Stress after PWHT at 70'F .............................. 37 Figure 13: Residual Stress Comparison for Before and After PWHT .............................. 38 Figure 14: Measured Through-Wall Residual Stresses for PWHT .................................. 39 Figure 15: Predicted von Mises Residual Stress after Hydrostatic Test at 707F .............. 40 Figure 16: Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle) ........ 41 Figure 17: Predicted Hoop Residual Stresses + Operating Conditions (5th NOC Cycle) ....... 42 Figure 18: Transferred Radial Residual + NOC + Pressure Stresses (3.95" Crack Shown)..43 Figure 19: FEA Calculated Circumferential Crack "K vs. a" at Four Azimuth Locations .... 44 Figure 20: Hoop Stress Extraction Grid for Axial Crack Growth Evaluation ................... 45 File No.: 1200895.306 Page 4 of 45 Revision: 0 F0306-OIRI

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1.0 OBJECTIVE The objective of this calculation package is to document the revised weld residual stress analysis and the resulting circumferential crack stress intensity factor determination for the hot leg drain nozzle at Palisades Nuclear Plant (Palisades).

The revised weld residual stress analysis is based on the latest methodology and process developed by Structural Integrity Associates (SI). The stress intensity factor determination is performed using finite element analysis (FEA) for a full circumferential crack in the nozzle-to-hot leg dissimilar metal weld.

2.0 TECHNICAL APPROACH The finite element model is obtained from a previous project for Palisades [1 ] and the weld residual stress analysis repeats the steps in the previous weld residual analysis [2], but uses the latest weld residual stress analysis methodology and process developed by SI.

The circumferential flaws are modeled in this calculation package and evaluated by finite element analyses. Hoop stress results in the weld region, corresponding to the hot leg, from the weld residual stress analysis are extracted to evaluate axial flaws (i.e. flaws aligned with the hot leg axis), which will be performed in a separate calculation.

The finite element model includes all components in the post-nozzle installation stage because new elements cannot be added during an ANSYS FEA. Since all the weld elements need to be included in the initial model, the element "birth and death" technique in ANSYS is used to initially deactivate the weld elements, with elements corresponding to the active weld segment reactivated at the melting temperature, thus simulating the weld metal deposition.

2.1 Material Properties The revised weld residual stress analysis performed in this calculation uses the material properties specifically developed in a separate calculation package for weld residual stress analyses [3]. Per the material designation used in the previous project [1], the following materials are used:

  • SA-516 Grade 70: Hot leg base metal
  • ER308L: Hot leg cladding (common weld metal for Type 304)
  • Alloy 82/182: Boss main weld and ID patch weld

" Alloy 600 (SB-166): Drain nozzle The material properties for those materials are tabulated in Tables 1 through 8.

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2.2 Finite Element Model for Weld Residual Stress Analysis The finite element model for the analyses was developed in a previous project for Palisades [1], which was created using a legacy version of the ANSYS finite element analysis software package [4]. The finite element model is recreated using that legacy ANSYS version and then transferred into the newer version of ANSYS [5] for the analyses in this calculation to take advantage of the solver and speed enhancements in the newer software release.

The base finite element model for the weld residual stress analysis is meshed with 8-node solid elements (SOLID185) in ANSYS. This finite element model is shown in Figure 1.

2.3 Finite Element Models with Circumferential Flaws The intent of the residual stress analysis is to evaluate the fracture mechanics characteristics of postulated flaws through the nozzle boss weld. The stress intensity factors for a full circumferential flaw in the nozzle boss weld are determined by finite element analysis using deterministic linear elastic fracture mechanics (LEFM) principles. As a result, seven fracture mechanics finite element models are derived to include "collapsed" crack meshing that represent full (3600) circumferential flaws surrounding the nozzle at various depths within the boss weld.

The circumferential cracks align with the interface between the boss weld and the nozzle. The modeled crack depths are: 0.13", 0.57", 1.21, 1.85", 2.49", 3.13", and 3.95".

The modeling of the flaws, or cracks, involves splitting the crack plane and then inserting "collapsed" mesh around the crack tips followed by concentrated mesh refinements that surround the "collapsed" mesh, and are referred to as "crack tip elements". This step is implemented on a source finite element model without the cracks, which is referred to as the "base model", and then the crack tip elements are inserted by an in-house developed ANSYS macro (see Appendix A for file listing).

For the fracture mechanics models, 20-node quadratic solid elements (SOLID95) are used in the crack tip region, while 8-node solid elements (SOLID45) are used everywhere else in the model. The mid-side nodes for the SOLID95 elements around the crack tips are shifted to the "quarter point" locations to properly capture the singularities at the crack tips, consistent with ANSYS recommendations. The finite element model for the 0.13" deep crack, with the crack tip mesh, is shown in Figure 2 as an example; the crack tip mesh for the other crack depths follows the same pattern.

The quarter point mid-side nodes combined with the extra layers of concentrated elements around the crack tips, as shown in Figure 2, provide sufficient mesh refinement to determine the stress intensity factors for the fracture mechanics analyses.

2.4 Welding Simulation The FEA for predicting the weld residual stresses is performed as a continuous analysis so that the load history from the cladding is carried over to the boss main weld and then the ID patch weld. Specifically, the residual stresses and strains at the end of a weld are used as initial conditions for the next weld.

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The procedures for this complex multi-step simulation are encoded in ANSYS Parametric Design Language (APDL) macros which utilize elastic-plastic material behavior and elements with large deformation capability to predict the residual stresses due to the various welding processes.

2.5 Heat Inputs The deposition of the weld metal is simulated by imposing a heat generation function on the elements representing the active weld, which is applied as a volumetric body heat generation rate. The amount of equivalent heat input energy, Q (in terms of kJ/inch), is determined from the welding parameters.

Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/in, with an overall heat efficiency of 0.8, is assumed for all of the welds. The heat efficiency represents a "composite" value reflecting the concepts of arc efficiency, melting efficiency, etc., and is an optimum value to produce reasonable heat penetrations in the analysis.

The APDL macros automatically appropriate cooling time for the thermal pass to ensure that sufficient heat penetration is achieved, the required interpass temperature between weld passes is met, and a reasonable overall temperature distribution within the finite element model is achieved. The resulting temperature time history is then imported into the stress pass in order to calculate the residual stresses due to the thermal cycling of the weld elements using nonlinear, elastic-plastic load/unload stress reversal relations.

The following summarizes the welding parameters used in the analysis:

" Interpass temperature = 350°F

" Melting temperature = 2500°F

  • Ambient temperature = 70°F

" Heat input for all welds = 28 kJ/in

" Heat efficiency for all welds = 0.8

  • Inside/Outside heat transfer coefficient = 5 Btu/hr-ft2 -'F

" Inside/Outside temperature = 70°F 2.6 Creep Properties Strain relaxation due to creep at high temperature is considered in the post weld heat treatment (PWHT) step. In general, creep becomes significant at temperatures above 800°F; thus, creep behavior under 800°F will not be considered in this analysis.

There are two main categories of creep: primary and secondary. The primary creep addresses the creep characteristics for a short duration at the early stages of the creep regime, while the secondary creep accounts for the creep behavior for a long duration - usually more than 10,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br />. Based on this definition, the PWHT falls within the primary creep characteristics. However, primary creep rates for File No.: 1200895.306 Page 7 of 45 Revision: 0 F0306-OIRI

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materials are difficult to obtain, so the conservative secondary creep rates are used since primary creep rate is typically an order of magnitude higher than that for secondary creep.

In general, the primary creep rate for the materials is governed by the equation:

d8 dt The creep data for the SA-516 Grade 70 hot leg material is based on carbon steel material [6]. The creep data for the Alloy 82/182 and ER308L weld metals are not available, so the creep properties for their base metals are used instead. The creep data for Type 304 (for ER308L) is provided in the same reference as the carbon steel [6], while the creep data for the Alloy 600 (for Alloy 82/182) is provided in a separate literature [7]. All the creep strengths, a, are provided at two creep rates [6, 7] for each temperature point.

When creep strength is provided at two creep rates at the same temperature point, as listed in Table 9, then A and n can be calculated as follows, where subscripts 1 and 2 refer to the creep data sets 1 and 2:

de *

-- = c = Ac("

n n In 6* =Ac -, 2 =A a,2 In 6 =nln A i1, 2.7 Mechanical Boundary Conditions For the weld residual stress and all of the LEFM analyses, the mechanical boundary conditions for the stress analysis are symmetric boundary conditions on the symmetry planes of the model, and axial displacement couplings on the ends of the drain nozzle and hot leg piping, as shown in Figure 3.

3.0 ASSUMPTIONS The following assumptions are used in the analyses:

" The hot leg cladding material is assumed to be ER308L, which is a common weld metal for Type 304 stainless steel cladding.

" The modeled circumferential flaws are assumed to align with the boss weld and nozzle interface, which represents a potential crack path of the susceptible material.

  • The welding interpass temperature is assumed to be 350'F, which is a typical parameter.

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" The metal melting temperature is assumed to be 2500'F, which is the temperature point where the strength of the material is set to near zero [3].

" The analysis is performed with an ambient temperature of 70'F.

" The exposed surface of the model is subject to a typical ambient air cooling convection film coefficient of 5 Btu/hr-ft 2 -°F at a bulk temperature of 70'F. The exposed surface is defined as the external surface of the model excluding the symmetry planes and geometric ends.

  • The focus of this analysis is the residual stresses in the drain nozzle boss weld region, while the detailed interactions between the clad buildup and the hot leg base metal is secondary. Therefore, the clad is assumed to be fully deposited in a one-layer single pass process.
  • The boss main weld is represented by an 80-bead process, as shown in Figure 4, with each bead represented by a one pass "bead ring" nugget. This approach is a common and acceptable industry practice when information regarding the bead start/stop position and sequencing are unknown.

" Similarly, the ID patch weld is represented by a 7-bead process, as shown in Figure 5, with each bead represented by a one pass "bead ring" nugget.

  • For modeling simplicity, the penetration hole is present during the deposition of the clad. This is acceptable since any localized stress that would have developed without the hole is relieved when the material is removed from the pipe.
  • For convenience, the modeled ID patch weld shares the same geometry as the backing ring for the main weld.

4.0 WELD RESIDUAL STRESS ANALYSIS The weld residual analysis consists of a thermal analysis to determine the temperature distribution followed by a stress analysis to determine the resulting stresses. The analytical sequence described below is used in the finite element analysis, followed by detailed discussions of the steps:

1. Deposit clad on hot leg pipe inside (ID) surface.
2. Install drain nozzle, backing ring, and deposit boss main weld.
3. Remove backing ring and deposit ID patch weld.
4. Post weld heat treatment.
5. Subject the configuration to hydro test.
6. Impose 5 cycles of "shake down" with normal operating temperature and pressure.

4.1 Hot Leg Cladding The clad material is typically welded onto the inside surface of the hot leg pipe, and the nominal thickness of the clad is thicker than the typical thickness for a single weld layer used in the process.

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However, the focus of this analysis is on the as-welded residual stresses, while the detailed interactions between the clad buildup and the base material during the many actual weld passes is not of interest.

Therefore, the clad is assumed to be fully deposited in a single pass.

At this step, only the hot leg pipe base metal and clad material are active; all other components are deactivated. At the end of the cladding application, the entire model is cooled 70'F before the application of the boss main weld.

4.2 Boss Main Weld The main weld connects the drain nozzle boss to the hot leg piping. As shown in Figure 4, the weld is composed of 80 nuggets deposited in 30 weld layers. In the absence of detailed weld fabrication information, a weld sequence is assumed based on standard welding practice at the time of fabrication.

In particular, for every layer, the first nugget is deposited on the hot leg side, the second nugget on the nozzle side, and the remaining nuggets (if any) are added in the radial direction from hot leg to nozzle.

At this step, the drain nozzle and backing ring are reactivated, and the boss main weld nuggets are reactivated sequentially to simulate the welding process. At the end of the boss main weld, the entire model is cooled 70'F before the application of the ID patch weld.

4.3 ID Patch Weld The final weld step is to add the ID patch weld, which replaces the backing ring. As seen in Figure 5, the ID patch weld is composed of 7 nuggets deposited in 2 layers.

At this step, the backing ring is first deactivated to allow the residual stresses to redistribute, and the ID patch weld nuggets are reactivated sequentially to simulate the welding process. At the end of the ID patch weld, the entire model is cooled 70'F before the application of the PWI-HT.

4.4 Post Weld Heat Treatment An important reason for performing PWHT is to relieve the residual stresses from welding. PWHT is assumed to be performed as per the following procedure outlined in Article 5, paragraph 1-731.3.1 -d of USA Standard B31.7 [8]:

1. Heat welded piping component to 11 25°F at a heating rate of 200'F per hour.
2. Hold at temperature for approximately 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> (I hr/in of weld thickness).
3. Allow to cool to 600'F at a cooling rate of 2007F per hour.
4. Air-cool from 600'F to ambient.
5. A steady state load step is imposed at the end of the PWHT process.

During the PWHT, creep behavior is activated for time steps with the maximum temperature above 800'F. At the end of the PWHT, the entire model is cooled 70'F before the application of the hydrostatic test.

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VjstWbifraI hftgrtfy Assoclat Ws kc 4.5 Hydrostatic Test A hydrostatic test pressure of 3.125 ksi [9, page 9] is applied after the welding. The pressure is applied on the ID surfaces of hot leg pipe and nozzle. End-cap traction loads, Pend-cap-nozzle and Pend-cap-hl, are applied at the free ends of the drain line nozzle and hot leg piping, respectively. These are calculated based on the following expressions:

P*I Pend-cap-nozzle =

2 2 ro,,,side rinside where, P = Hydrostatic test pressure (ksi)

Pend-cap-nozzle = End cap pressure on drain line nozzle end (ksi) rinside = Inside radius of drain line nozzle (in) routside = Outside radius of drain line nozzle (in) and,

  • 2 end-cap-hi I

.oulside_hi - inside hi where, P = Hydrostatic test pressure (ksi)

Pend-cap-hl = End cap pressure on hot leg pipe end (ksi) rinside hi = Inside radius of hot leg pipe (in) routside hi = Outside radius of hot leg pipe (in)

The applied pressure loads on the model are shown in Figure 6.

4.6 Five Normal Operating Cycles (NOC)

After the hydrostatic test, the assembled configuration is put into service and subjected to 5 cycles of shake down to stabilize the as-welded residual stresses. This step involves simultaneously ramping the model from zero-load to steady-state conditions at normal operating temperature and pressure then back to steady-state at 70'F and no pressure five times.

The applied operating pressure is 2.122 ksi and temperature is 593°F [10]. The temperature is assumed to be uniform throughout the components and operating pressure is applied as an internal pressure on the ID surface, with corresponding end cap pressures calculated using the equations in the previous section.

The term "P" is replaced by the operating pressure in the expressions.

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jsktn I latrIItY , O asKL, &MO 5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS The ANSYS input files and computer output files for the analyses are listed in Appendix A.

5.1 Welding Temperature Contours The maximum temperature prediction contours for each weld are created using macro MapTemp.mac.

This type of contour plot is also called a "fusion boundary" plot because it provides an overview of the maximum temperature on each node throughout the thermal transient for each welding process. The plots are useful in visualizing the melting of weld metal and the extent of heat penetration.

The predicted fusion boundary contours for the cladding, main weld, and ID patch weld are shown in Figures 7, 8, and 9, respectively. The purple color in the plots represents elements at melting temperature; the plots show complete melting of the weld metal for each weld and slight melting of the base metal along the weld interface.

5.2 PWHT Temperature Results Figure 10 plots the inside surface temperature curve for the PWHT process. It shows the linear 200°F/hour heating rate, four hours (240 minutes) hold time at 1 125°F, 200°F/hour cooling rate at temperature above 600'F, and the air cooling to room temperature of 70'F.

5.3 Residual Stress Results Figure 11 plots the von Mises residual stresses after welding is complete, but before PWHT. It shows extensive residual stresses of greater than 66 ksi in the weld material. However, as shown in Figure 12, after the PWHT the residual stresses in the weld have relaxed significantly, to below 41 ksi, but the residual stresses in the cladding remain essentially unchanged.

To further investigate the effects of the PWHT, before and after PWHT residual stresses are extracted along the two through-wall paths shown in Figures 11 and 12. The through-wall residual stresses are compared in Figure 13, and it shows that there is little to no stress reduction in the clad material, while there is significant stress reduction in the vessel base metal.

The PWHT results from the FEA trend comparably well with the data in EPRI report TR-105697 [12],

which contains a comparable through-wall clad residual stress distribution based on experimental measurements, as shown in Figure 14. The experimental measurements were for a low alloy steel vessel with a Type 304 stainless steel clad. The data shows tensile hoop stress through the clad thickness and the base metal near the clad interface, but the hoop stress drops rapidly to compressive values at farther distances from the clad.

Figure 15 depicts the predicted von Mises residual stresses after the hydrostatic test. It shows an insignificant reduction in maximum stress when compared to the post-PWHT step: 72.85 ksi (Figure 15) versus 73.75 ksi (Figure 12), while the overall stress contour remains essentially the same.

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Figures 16 and 17 depict the combined weld residual plus operating radial and hoop stresses at the fifth stabilization NOC cycle, respectively. The stress results at this step are used in the fracture mechanics evaluations.

6.0 K CALCULATION FOR CIRCUMFERENTIAL CRACKS The stress intensity factors (Ks) for the circumferential cracks are calculated using the KCALC feature in ANSYS which is based on the LEFM principle. For the LEFM evaluation, only the elastic properties in Tables 1 through 4 are used in the FEA, the stress-strain curves and creep properties in Tables 5 through 9 are not used.

6.1 Crack Face Pressure Application In order to determine the Ks for the circumferential cracks due to residual stresses, the stresses on the boss weld-to-nozzle interface, at the fifth operating condition (at time = 3046 minutes), are extracted from the residual stress analysis and reapplied on the crack face as surface pressure loading.

Representative transferred residual stresses onto the crack face for the deepest circumferential crack of 3.95" are shown in Figure 18.

This approach is based on the load superposition principle [ 11], which is utilized to transfer the stresses from the weld residual stress finite element model onto the fracture mechanics finite element model that contains crack tip elements. The superposition technique is based on the principle that, in the linear elastic regime, stress intensity factors of the same mode, which are due to different loads, are additive (similar to stress components in the same direction).

The superposition method can be summarized with the following sketches [11, page 66]:

P(x) PWx) P(xW (a) (b) (c) (d)

A load p(x) on an uncracked body, Sketch (a), produces a normal stress distribution p(x) on Plane A-B.

The superposition principle is illustrated by Sketches (b), (c), and (d) of the same body with a crack at Plane A-B. The stress intensity factors resulting from these loading cases are such that:

K1(b) = KI(c) + Kj(d)

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Thus, Kl(d) = 0 because the crack is closed, and:

K1 (b) = KI(c)

This means that the stress intensity factor obtained from subjecting the cracked body to a nominal load p(x) is equal to the stress intensity factor resulting from loading the crack faces with the same stress distribution p(x) at the crack location from the uncracked body.

6.2 Circumferential Crack Stress Intensity Factor Results The radial stresses on the weld/nozzle interface, as shown in top of Figure 16, are transferred to the circumferential cracks as crack face pressure per the superposition principle described above.

Figure 18 depicts, as an example, the transferred radial stresses as crack face pressure for the 3.95" crack depth. During the crack face pressure transfer, the operating pressure of 2122 psi [10] is added to the crack face pressure to account for the internal pressure acting on the crack face due to cracking.

Each crack model is analyzed as a steady state stress pass at the operating and reference temperature of 593'F [10] in order to use the material properties at the operating temperature, but without inducing additional thermal stresses.

At the completion of each analysis, the ANSYS KCALC post-processing is performed to extract the Ks at each crack tip node around the nozzle. The K results are summarized in Table 10 for various crack depths "a". The "K vs. a" trend at the 00, 300, 600, and 900 azimuths are then plotted in Figure 19. The results are also included in the Excel spreadsheet listed in Appendix A.

7.0 STRESS EXTRACTION FOR AXIAL CRACKS The axial cracks in the weld region will be evaluated in a separate calculation, designated as SI Calculation No. 1200895.307. That calculation will use the hoop stresses (corresponding to the hot leg) on the model symmetry plane at the 00 azimuth location, which represents the cross section with the most tensile residual stresses, as shown in Figure 17.

7.1 Hoop Stress Extraction for Axial Crack Growth Evaluation The stress extraction location for the axial crack is defined as a rectangular 2.06"x3.75" grid located on the axial cut plane of the hot leg (i.e., at the 00 azimuth), as shown in Figure 20. The hoop stresses at the fifth NOC cycle (with operating loads) are extracted, which are output in terms of Radius, Height, and Stress.

The extracted hoop stresses are tabulated in Table 11 for use in the separate axial crack growth evaluation. The results are also included in the Excel spreadsheet listed in Appendix A.

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8.0 CONCLUSION

S Finite element residual stress and circumferential flaw analyses have been performed on the hot leg drain nozzle boss weld at Palisades:

  • The stress intensity factors for circumferential flaws along the boss/nozzle interface have been determined using finite element analysis at normal operating conditions combined with residual stresses; the stress intensity factor results are presented in Table 10 as a function of flaw depth and azimuth location.
  • Hoop stresses at normal operating conditions combined with residual stresses have been extracted on the hot leg axial cut plane and tabulated in Table 11. The hoop stress results will be used in a separate calculation to determine crack growth for axial cracks in that plane.

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9.0 REFERENCES

1. SI Calculation No. 0801136.311, Rev. 1, "Hot Leg Drain Nozzle Finite Element Model for Welding Residual Stress Estimation."
2. SI Calculation No. 0801136.312, Rev. 1, "Hot Leg Drain Nozzle Residual Stress Analysis."
3. SI Calculation No. 0800777.307, Rev. 5, "Material Properties for Residual Stress Analyses, Including MISO Properties Up To Material Flow Stress."
4. ANSYS, Release 8.1 (w/ Service Pack 1), ANSYS, Inc., June 2004.
5. ANSYS Mechanical APDL and PrepPost, Release 14.5 (w/ Service Pack 1), ANSYS, Inc.,

September 2012.

6. "Pipe and Tubes for Elevated Temperature Service," United States Steel Co., 1949.
7. Publication SMC-027, "Inconel Alloy 600," Special Metals Corp., 2004, S1 File 0800777.211.
8. USA Standard B31.7, Nuclear Power Piping, 1968.
9. Combustion Engineering Specification No. 0070P-006, Rev. 2, "Engineering Specification for Primary Coolant Pipe and Fittings," SI File No. 0801136.206.
10. Palisades Document No. EC-LATER, Revision 0, "Design Input Record," SI File No.

0801136.202.

11. Anderson, T. L., "Fracture Mechanics Fundamentals and Applications", Second Edition, CRC Press, 1995.
12. EPRI Report No. TR-105697, "BWR Reactor Pressure Vessel Shell Weld Inspection Recommendations (BWRVIP-05)," September 1995.

File No.: 1200895.306 Page 16 of 45 Revision: 0 F0306-01 RI

jsiV cww anh Assockilfte WOc rIirsMO Table 1: Elastic Properties for SA-516 Grade 70 (_<4" Thick)

Temperature Elastic Modulus Mean Thermal Thermal Conductivity Specific Heat (OF) (xl03 ksi)3 Expansion (Btu/min-in-'F) (Btu/Ib-'F)

(x10 ~~~(x 0-6 in/in/*F) __ __________

70 29.5 6.4 0.0488 0.103 500 27.3 7.3 0.0410 0.128 700 25.5 7.6 0.0369 0.138 1100 18.0 8.2 0.0290 0.171 1500 5.0 8.6 0.0218 0.198 2500 0.1 9.5 0.0014 0.204 2500.1 N/A 0.0 N/A N/A Density (p) = 0.283 lb/in 3, assumed temperature independent.

Poisson's Ratio (v) = 0.3, assumed temperature independent.

Table 2: Elastic Properties for ER308L Temperature Elastic Modulus Mean Thermal Thermal Conductivity Specific Heat (OF) (x10 3 ksi) (xp0a6 in/in/°F) (Btu/min-in-'F) (Btu/lb-'F) 70 28.3 8.5 0.0119 0.116 500 25.8 9.7 0.0151 0.131 700 24.8 10.0 0.0164 0.135 1100 22.1 10.5 0.0189 0.140 1500 18.1 10.8 0.0212 0.145 2500 0.1 11.5 0.0292 0.159 2500.1 N/A 0.0 N/A N/A Density (p) = 0.283 Ib/in 3, assumed temperature independent.

Poisson's Ratio (v) = 0.3, assumed temperature independent.

Common weld metal for Type 304 File No.: 1200895.306 Page 17 of 45 Revision: 0 F0306-OIRI

lategIlyMO Assocaate fte~

Table 3: Elastic Properties for Alloy 600 Temperature 0 Elastic Modulus Mean Thermal Thermal Conductivity Specific Heat (OF) ( F) (0 3 ksi) ks) Expansion (x10.6 in/in/OF) (Btu/min-in-.F) (Btu/Ilb-F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 N/A 0.0 N/A N/A Density (p) = 0.30 lb/in 3, assumed temperature independent.

Poisson's Ratio (v) = 0.29, assumed temperature independent.

Table 4: Elastic Properties for Alloy 82/182 Temperature Elastic Modulus Mean Thermal Thermal Conductivity Specific Heat (OF) (xl0 3 ksi) usOExpansion (Btu/min-in-°F) (Btu/Ib-°F) 4 0 (xI0 6 inlin/ F) _______

70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 N/A 0.0 N/A N/A Density (p) = 0.30 lb/in 3, assumed temperature independent.

Poisson's Ratio (v) = 0.29, assumed temperature independent.

File No.: 1200895.306 Page 18 of 45 Revision: 0 F0306-OIRI

Vj~bowftrvI Iategf Assads OLtSi' Table 5: Elastic-Plastic Properties for SA-516 Grade 70 (54" Thick)

Temperature Strain Stress (F) (in/in) (ksi) 0.00128814 38.000 0.00187809 42.000 70 0.00257329 46.000 0.00381110 50.000 0.00600383 54.000 0.00113553 31.000 0.00142679 35.875 500 0.00183954 40.750 0.00261139 45.625 0.00415246 50.500 0.00106667 27.200 0.00132412 32.550 700 0.00166876 37.900 0.00228121 43.250 0.00354341 48.600 0.00116667 21.000 0.05116163 22.125 1100 0.05915444 23.250 0.06794123 24.375 0.07755935 25.500 0.00300000 15.000 0.16717493 15.125 1500 0.16992011 15.250 0.17268761 15.375 0.17547742 15.500 0.01000000 1.000 0.10961239 1.125 2500 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 File No.: 1200895.306 Page 19 of 45 Revision: 0 F0306-OIRI

VjSbiMIUrw ifntuVf ASSaGOcAtS Iftu Table 6: Elastic-Plastic Properties for ER308L Temperature Strain Stress

(*F) (in/in) (ksi) 0.00203180 57.500 0.02471351 61.563 70 0.03107296 65.625 0.03861377 69.688 0.04747167 73.750 0.00140089 36.143 0.00714793 40.250 500 0.01065407 44.357 0.01558289 48.464 0.02233857 52.571 0.00132488 32.857 0.00477547 37.125 700 0.00743595 41.393 0.01143777 45.661 0.01727192 49.929 0.00121913 26.943 0.00264833 30.138 1100 0.00404100 33.332 0.00634529 36.527 0.01005286 39.721 0.00117995 21.357 0.05352064 21.563 1500 0.05610492 21.768 0.05878975 21.973 0.06157807 22.179 0.01000000 1.000 0.10961239 1.125 2500 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 File No.: 1200895.306 Page 20 of 45 Revision: 0 F0306-OIRI

VSIjUMckrI LutgrffY ASSOdMAts InCP Table 7: Elastic-Plastic Properties for Alloy 600 Temperature Strain Stress

(°F) (in/in) (ksi) 0.00157419 48.800 0.01658847 55.300 70 0.02343324 61.800 0.03212188 68.300 0.04291703 74.800 0.00152069 44.100 0.01539220 50.338 500 0.02210610 56.575 0.03072476 62.813 0.04153277 69.050 0.00152128 42.900 0.01634485 49.000 700 0.02334760 55.100 0.03227153 61.200 0.04338643 67.300 0.00155985 40.400 0.02275193 44.475 1100 0.03004563 48.550 0.03888203 52.625 0.04943592 56.700 0.00092641 21.400 0.08827666 22.475 1500 0.09785101 23.550 0.10796967 24.625 0.11863796 25.700 0.01000000 1.000 0.10961239 1.125 2500 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 File No.: 1200895.306 Page 21 of 45 Revision: 0 F0306-01 RI

VjsmnwuruI MOMngf ASSoceata~ft6~

Table 8: Elastic-Plastic Properties for Alloy 182 Temperature Strain Stress

('F) (in/in) (ksi) 0.00179032 55.500 0.03456710 60.113 70 0.04292837 64.725 0.05257245 69.338 0.06359421 73.950 0.00164483 47.700 0.02976152 52.313 500 0.03809895 56.925 0.04790379 61.538 0.05929946 66.150 0.00159574 45.000 0.02849157 49.538 700 0.03680454 54.075 0.04663682 58.613 0.05812078 63.150 0.00159073 41.200 0.03568855 44.488 1100 0.04402702 47.775 0.05360088 51.063 0.06449835 54.350 0.00106494 24.600 0.11812735 25.325 1500 0.12540227 26.050 0.13290814 26.775 0.14064577 27.500 0.01000000 1.000 0.10961239 1.125 2500 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 File No.: 1200895.306 Page 22 of 45 Revision: 0 F0306-OIRI

!V1hfu, t*gf Assocites Inc Table 9: Creep Properties Material Temperature Creep Strength (ksi) A (OF) (1 (0.0001%/hr) 0 2 (0.00001%/hr) (ksi/hr) 800 19.0 [6] 12.4 [6] 1.26E-13 5.40 SA-516 Gr. 70 900 9.0 [6] 6.7 [6] 3.59E-14 7.80 (Based on 1000 3.5 [6] 2.8 [6] 2.43E-12 10.32 carbon steel) 1100 1.4 [6] 0.8 [6] 2.50E-07 4.11 800 33.4 [6] 25.0 [6] 7.73E-19 7.95 ER308L 900 24.0 [6] 17.6 [6] 5.67E-17 7.42 (Based on 1000 17.6 [6] 11.5 [6] 1.82E-13 5.41 Type 304) 1100 11.5 [6] 7.1 [6] 8.62E-12 4.78 Alloy 600 800 40.0 [7] 30.0 [7] 1.50E-19 8.00 Alloy 82/182 900 28.0 [7] 18.0 [7] 2.87E-14 5.21 (Based on 1000 12.5 [7] 6.1 [7] 3.02E-10 3.21 Alloy 600) 1100 6.8 [7] 3.4 [7] 1.72E-09 3.32 File No.: 1200895.306 Page 23 of 45 Revision: 0 F0306-OIRI

Table 10: Circumferential Crack "K vs. a" Table 40 105 117 7.685 100 1.

he zimthismatthe axa 98 cTpanle62 ofotherhots

.586 leg (seFiueph c

.17 1).-n .5 0 45 06 07 90 18 937 14.41 50 9.7 96 6.587 113 55 83 .787 19 60 76 .888 26 65 69 ,486 28 70 6.5 61 75 86 35 80 55187 138 85 88 39 90 5.6 52,91 1144 Fil 115.4730 Notes: No.:4 Page924 of4459

1. The 0* azimuth is at the axial cut plane of the hot leg (see Figure 1).
2. The 90' azimuth is at the circumferential cut plane of the hot leg (see Figure 1).

F30-OR File No.: 1200895.306 Page 24 of 45 Revision: 0 F0306-01RI

tjSIn9tfwu, lfrifyAssocats kr.

Table 11: Hoop Stress Table at 00 Azimuth for Axial Crack Growth Evaluation ledlet I. Feb81litres, II edlsaI leigh, I! tree III edle, I leigh 6 tree II lediti, I leigh 8 tree 8 ladle, I I Radius Heiah IStree .Radius eiht treIss lRadius Helahi Stress iRadius Heigh SItres lRadie leiIht iStmes

- I - -Ii U - 4i -- -I - 4 - -F fl - Ii - 4 - -6 U l - i -

0.00 0.00 5.62 0.23 1 0.00 3.69 0.46 1 0.00 4.16 0.60 0.00 1 8.09 0.92 0.00 9.95 1.15 0.00 110.7511 1.38 0.00 112.9811 1.60 0.00 115.1911 1.83 0.00 114.3711 2.06 10.00 9.40 0.00 0.08 5.55 0.23 0.08 4.66 0.46 0.08 5.20 0.69 0.08 8.69 0.92 0.08 10.91 1.15 0.08 12.29 1.38 0.08 12.10 1.60 0.08 14.16 1.83 0.08 13.51 2.06 0.08 9.08 0.00 0.16 6.02 0.23 0.16 5.17 0.46 0.16 0.64 0.69 0.16 9.20 0.92 0.16 12.36 1.15 0.16 13.63 1.38 0.16 10.22 1.60 0.16 11.75 1.83 0.16 14.82 2.06 0.16 9.61 0.00 0.23 6.49 0.23 0.23 5.74 0.46 0.23 6.12 0.69 0.23 9.85 0.92 0.23 13.57 1.15 0.23 14.01 1.38 0.23 9.36 1.60 0.23 5.26 1.83 0.23 6.79 2.06 0.23 2.36 0.00 0.31 7.03 0.23 0.31 6.46 0.46 0.31 7.01 0.69 0.31 10.71 0.92 0.31 14.05 1.15 0.31 14.66 1.38 0.31 10.77 1.60 0.31 -2.45 1.83 0.31 -4.94 2.06 0.31 -5.80 0.00 0.39 7.72 0.23 0.39 7.25 0.46 0.39 8.15 0.69 0.39 11.35 0.92 0.39 14.03 1.15 0.39 1658 1.38 0.39 11.99 1.60 0.39 -0.75 1.83 0.39 -4.51 2.06 0.39 -5.71 0.00 0.47 8.51 0.23 0.47 7.98 0.46 0.47 8.51 0.69 0.47 11.45 0.92 0.47 14.06 1.15 0.47 17.97 1.38 0.47 11.84 1.60 0.47 1.33 1.83 0.47 -3.49 2.06 0.47 -4.75 0.00 0.55 9.26 0.23 0.55 7.92 0.46 0.55 7.52 0.69 0.55 10.99 0.92 0.55 14.11 1.15 0.55 15.81 1.38 0.55 11.78 1.60 0.55 3.59 1.83 0.55 -2.67 2.06 0.55 -3.99 0.00 0.63 9.63 0.23 0.63 6.59 0.46 0.63 5.49 0.69 0.63 10.11 0.92 0.63 14.47 1.15 0.63 14.01 1.38 0.63 11.91 1.60 0.63 5.40 1.83 0.63 -2.08 2.06 0.63 -3.35 0.00 0.70 8.78 0.23 0.70 4.16 0.46 0.70 3.47 0.69 0.70 9.97 0.92 0.70 15.81 1.15 0.70 15.79 1 38 0.70 12.53 1.60 0.70 6.46 1.83 0.70 -1.54 2.06 0.70 -2.80 0.00 0.78 6.56 0.23 0.78 1.16 0.46 0.78 1.65 0.69 0.78 10.04 0.92 0.78 17.40 1.15 0.78 17.53 1 38 0.78 14.17 1.60 0.78 7.64 1.83 0.78 -0.88 2.06 0.78 -2.25 0.00 0.86 3.90 0.23 0.86 -1.72 0.46 0.86 0.26 0.69 0.86 10.29 0.92 0.86 18.76 1.15 0.86 18.03 1.38 0.86 15.45 1.60 0.86 8.63 1.83 0.86 -0.13 2.06 0.86 -1.65 0.00 0.94 1.08 0.23 0.94 -4.07 0.46 0.94 -0.95 0.69 0.94 10.67 0.92 0.94 19.70 1.15 0.94 18.39 1.38 0.94 15.70 1.60 0.94 8.93 1.83 0.94 0.63 2.06 0.94 -1.01 0.00 1.02 -1.69 0.23 1.02 -6.27 0.46 1.02 -1.73 0.69 1.02 11.05 0.92 1.02 20.82 1.15 1.02 18.90 1.38 1.02 14.45 1.60 1.02 11.00 1.83 1.02 1.43 2.06 1.02 -0.34 0.00 1.09 -4.26 0.23 1.09 -8.09 0.46 1.09 -2.85 0.69 1.09 11.26 0.92 1.09 21.88 1.15 1.09 18.56 1.38 1.09 15.88 1.60 1.09 13.74 1.83 1.09 2.29 2.06 1.09 0.35 0.00 1.17 -6.41 0.23 1.17 -9.31 0.46 1.17 -3.76 0.69 1.17 11.19 0.92 1.17 21.65 1.15 1.17 18.35 1.38 1.17 16.53 1.60 1.17 14.75 1.83 1.17 3.14 2.06 1.17 1.01 0.00 1.25 -8.04 0.23 1.25 -10.34 0.46 1.25 -4.85 0.69 1.25 11.18 0.92 1.25 21.77 1.15 1.25 19.00 1.38 1.25 14.65 1.60 1.25 14.46 1.83 1.25 3.91 2.06 1.25 1.69 0.00 1.33 -9.31 0.23 1.33 -11.06 0.46 1.33 -5.23 0.69 1.33 11.36 0.92 1.33 22.00 1.15 1.33 18.10 1.38 1.33 13.97 1.60 1.33 15.05 1 83 1.33 4.58 2.06 1.33 2.41 0.00 141 -10.24 0.23 1.41 -11.79 0.46 1.41 -5.50 0.69 1.41 11.56 0.92 1.41 21.40 1 15 1.41 17.32 1.38 1.41 12.93 1.60 1.41 15.94 1.83 1.41 5.34 2.06 1.41 3.12 0.00 1.48 -10.86 0.23 1.48 -12.07 0.46 1.48 -5.79 0.69 1.48 10.84 0.92 1.48 20.91 1.15 1.48 17.35 1.38 1.48 12.91 1.60 1.48 16.46 1.83 1.48 6.08 2.06 1.48 3.84 0.00 1.56 -11.18 0.23 1.56 -12.35 0.46 1.56 -5.80 0.69 1.56 10.43 0.92 1.56 20.85 1.15 1.56 17.69 1.38 1.56 13.32 1.60 1.56 16.76 1.83 1.56 6.57 2.06 1.56 4.56 0.00 1.64 -11.21 0.23 1.64 -12.38 0.46 1.64 -6.38 0.69 1.64 10.62 0.92 1.64 21 10 1 15 1.64 18.23 1.38 1.64 12.96 1.60 1.64 17.41 1.83 1.64 7.29 2.06 1.64 5.27 0.00 1.72 -11.08 0.23 1.72 -12.14 0.46 1.72 -6.45 0.69 1.72 10.70 0.92 1.72 21.46 1.15 1.72 18.66 1.38 1.72 14.20 1.60 1.72 18.30 1.83 1.72 7.96 2.06 1.72 5.99 0.00 1.80 -10.81 0.23 1.80 -11.86 0.46 1.80 -6.22 0.69 1.80 10.96 0.92 1.80 21.76 1.15 1.80 19.61 1.38 1.80 14.60 1.60 1.80 19.20 1.83 1.80 8.65 2.06 1.80 6.70 0.00 1.88 -10.42 0.23 1.88 -11.48 0.46 1.88 -6.26 0.69 1.88 11.30 0.92 1.88 2240 1 15 1.88 20.66 1.38 1.88 15.54 1.60 1.88 20.13 1.83 1.88 10.32 2.06 1.88 7.42 0.00 1.95 -9.94 0.23 1.95 -11.05 0.46 1.95 -5.92 0.69 1.95 11.93 0.92 1.95 23.17 1.15 1.95 21.83 1.38 1.95 16.85 1.60 1.95 21.07 1.83 1.95 11.32 2.06 1.95 8.14 0.00 2.03 -9.50 0.23 2.03 -10.60 0.46 2.03 -5.60 0.69 2.03 12.75 0.92 2.03 24.05 1 15 2.03 23.25 1.38 2.03 17.65 1.60 2.03 21.70 1.83 2.03 12.95 2.06 2.03 8.84 0.00 2.11 -8.95 0.23 2.11 -10.11 0.46 2.11 -5.12 0.69 2.11 1360 0.92 2.11 25.20 1.15 2.11 24.82 1.38 2.11 19.15 1.60 2.11 22.36 1.83 2.11 14.71 2.06 2.11 9.53 0.00 2.19 -8.36 0.23 2.19 -9.53 0.46 2.19 -4.45 0.69 2.19 14.68 0.92 2.19 26.44 1.15 2.19 26.61 1.38 2.19 20.44 1.60 2.19 2341 1.83 2.19 15.64 2.06 2.19 10.22 0.00 2.27 -7.70 0.23 2.27 -8.87 0.46 2.27 -3.94 0.69 2.27 1580 0.92 2.27 27.94 1.15 2.27 29.42 1.38 2.27 23.79 1.60 2.27 25.07 1.83 2.27 18.24 2.06 2.27 10.96 0.00 2.34 -6.97 0.23 2.34 -8.18 0.46 2.34 -3.26 0.69 2.34 16.90 0.92 2.34 29.53 1.15 2.34 32.47 1.38 2.34 29.09 1.60 2.34 25.60 1.83 2.34 19.32 2.06 2.34 11.73 0.00 2.42 -6.16 0.23 2.42 -7.39 0.46 2.42 -2.49 0.69 2.42 17.78 0.92 2.42 30.57 1.15 2.42 30.17 1.38 2.42 23.94 1.60 2.42 18.19 1.83 2.42 20.36 2.06 2.42 12.61 0.00 2.50 -5.30 0.23 2.50 -6.54 0.46 2.50 -1.87 0.69 2.50 18.47 0.92 2.50 30.00 1.15 2.50 28.49 1.38 2.50 23.99 1.60 2.50 20.82 1.83 2.50 21.46 2.06 2.50 13.80 0.00 2.58 -4.35 0.23 2.58 -5.62 0.46 2.58 -0.98 0.69 2.58 19.16 0.92 2.58 29.53 1.15 2.58 29.19 1.38 2.58 30.19 1.60 2.58 26.15 1.83 2.58 23.15 2.06 2.58 15.46 0.00 2.66 -3.41 0.23 2.66 -4.62 0.46 2.66 -0.19 0.69 2.66 20.35 0.92 2.66 29.88 1.18 2.66 29.78 1.38 2.66 32.03 1.60 2.66 26.87 1.83 2.66 24.98 2.06 2.66 16.86 0.00 2.73 -2.42 0.23 2.73 -3.53 0.46 2.73 0.72 0.69 2.73 20.66 0.92 2.73 30.12 1.15 2.73 30.83 1.38 2.73 33.97 1.60 2.73 29.07 1.83 2.73 25.62 2.06 2.73 18.06 0.00 2.81 -1.31 0.23 2.81 -2.56 0.46 2.81 2.18 0.69 2.81 20.41 0.92 2.81 30.66 1.15 2.81 31.73 1.38 2.81 35.03 1.60 2.81 30.56 1.83 2.81 27.53 2.06 2.81 18.39 0.00 2.89 0.10 0.23 2.89 -1.27 0.46 2.89 2.92 0.69 2.89 20.81 0.92 2.89 31.62 1.15 2.89 33.44 1.38 2.89 35.90 1.60 2.89 31.13 1.03 2.89 28.64 2.08 2.89 19.48 0.00 2.97 1.65 0.23 2.97 0.45 0.46 2.97 3.67 0.69 2.97 21.60 0.92 2.97 32.88 1.15 2.97 35.22 1.38 2.97 36.43 1.60 2.97 32.16 1.83 2.97 30.21 2.06 2.97 20.37 0.00 3.05 3.29 0.23 3.05 2.48 0.46 3.05 4.66 0.69 3.05 22.29 0.92 3.05 33.79 1.15 3.05 36.21 1.38 3.05 37.11 1.60 3.05 32.38 1.83 3.05 31.72 2.06 3.05 21.35 0.00 3.13 4.91 0.23 3.13 4.32 0.46 3.13 5.48 0.69 3.13 23.13 0.92 3.13 34.95 1.15 3.13 37.61 1.38 3.13 37.75 1.60 3.13 33.12 1.83 3.13 32.84 2.06 3.13 22.17 0.00 3.20 6.50 0.23 3.20 5.84 0.46 3.20 7.12 0.69 3.20 24.70 092 3.20 35.98 1.15 3.20 38.37 1.38 3.20 38.19 1.60 3.20 33.85 1.83 3.20 34.18 2.06 3.20 22.94 0.00 3.28 8.02 0.23 3.28 7.44 0.46 3.28 8.69 0.69 3.28 26.13 0.92 3.28 37.40 1.15 3.28 39.41 1.38 3.28 38.48 1.60 3.28 33.98 1.83 3.28 34.76 2.06 3.28 23.63 0.00 3.36 9.49 0.23 3.36 9.05 0.46 3.36 10.50 0.69 3.36 27.75 0.92 3.36 38.72 1.15 3.36 40.46 1.38 3.36 38.66 1.60 3.36 34.26 1.83 3.36 35.23 2.06 3.36 24.25 0.00 3.44 10.90 0.23 3.44 10.62 0.46 3.44 12.68 0.69 3.44 29.41 0.92 3.44 39.69 1.15 3.44 40.71 1.38 3.44 38.28 1.60 3.44 33.99 1.83 3.44 35.34 2.06 3.44 24.78 0.00 3.52 12.23 0.23 3.52 12.19 0.46 3.52 14.20 0.69 3.52 30.68 0.92 3.52 40.84 1.15 3.52 41.43 1.38 3.52 38.40 1.60 3.52 33.42 1.83 3.52 34.71 2.06 3.52 25.30 0.00 3.59 13.46 0.23 3.59 13.66 0.46 3.59 1608 0.69 3.59 31.91 0.92 3.59 41.97 1.15 3.59 42.10 1.38 3.59 39.05 1.60 3.59 33.15 1.83 3.59 34.50 2.06 3.59 26.42 0.00 3.67 14.59 0.23 3.67 14.93 046 3.67 1781 0.69 3.67 32.69 0.82 3.67 43.26 1.15 3.67 42.70 1.38 3.67 40.56 1.60 3.67 33.83 1.83 3.67 3365 2.06 3.67 27.55 0.00 3.75 15.56 0.23 3.75 10.88 046 3.70 18.18 0.08 3.70 33.34 0.92 3.75 44.01 1.10 3.70 4249 1.38 3.75 41.21 1.60 3.75 34.65 1.83 3.75 32.35 2.06 3.70 2742 Note:

1. Stress (ksi) for each Radius (inches) and Height (inches) extracted per the grid shown in Figure 20.

File No.: 1200895.306 Page 25 of 45 Revision: 0 F0306-01R1

Vaud" AdOM ASSOCWK kne Figure 1: Finite Element Model for Residual Stress Analysis Notes:

1. The 0' azimuth is at the axial cut plane of the hot leg.
2. The 900 azimuth is at the circumferential cut plane of the hot leg.

File No.: 1200895.306 Page 26 of 45 Revision: 0 F0306-OIRI

!CUWWW AIM~ AsoWOWK kn Figure 2: Finite Element Model for the 0.13" Deep Circumferential Crack File No.: 1200895.306 Page 27 of 45 Revision: 0 F0306-OIRI

Va"rof kft* Asxd&V% knG Symmetry displacement constraints Axial displacement couples Figure 3: Applied Mechanical Boundary Conditions File No.: 1200895.306 Page 28 of 45 Revision: 0 F0306-O1RI

V ~~~AggrNfrme Figure 4: Weld Nugget Definitions for the Boss Main Weld File No.:n:1200895.306 0

R evisiO

cjasnfiu Iaf#rk ASsaCbfs W.0~

Figure 5: Weld Nugget Definitions for the ID Patch Weld File No.: 1200895.306 Page 30 of 45 Revision: 0 F0306-OIRI

~jsV cuW" Mugr AWsDatuK km ELEM TYPE Um Nozzle end cap pressure 1 PRES Hot leg end cap pressure Internal pressure ksi 7.41713 5.2.73174 389042 1.95365 Figure 6: Applied Hydrostatic and Corresponding End Cap Pressure Loads File No.: 1200895.306 Page 31 of 45 Revision: 0 F0306-OIRI

VO~SW&m&" wIaiwur Mson t N1UAL xCIMICV 70 610 1150 1690 340 880 1420 1960 2230 2500 'F Predicted fusion boundary plot (Purple = Tenperature > Niting)

Figure 7: Predicted Fusion Boundary Plot for Cladding File No.: 1200895.306 Page 32 of 45 Revision: 0 F0306-OIR1

C a~sn"ir kgrqyASaodW4 WO 70 610 1150 1690 2230 Predicted fusion 340 880 = Tenperature 1420 boundary plot. (Purple > Melting) 1960 2500 'F Figure 8: Predicted Fusion Boundary Plot for Boss Main Weld File No.: 1200895.306 Page 33 of 45 Revision: 0 F0306-OIRI

!VfatwwrMW*AMssoWkm Figure 9: Predicted Fusion Boundary Plot for ID Patch Weld File No.: 1200895.306 Page 34 of 45 Revision: 0 F0306-01RI

CS"V"iruIhigrY SKfkn Cooling to 600°F at 200°F/hr Temperature (F) 625 500 Heating 375 at 200°F/hr Air cool 250 125 0 T 2000 2250 2500 2750 3000 3250 2125 2375 Timre 2625 (min) 2875 3125 Figure 10: Temperature Curve for PWHT Note:

1. PWHT temperature history is for an arbitrary ID node on the model.

File No.: 1200895.306 Page 35 of 45 Revision: 0 F0306-O1RI

V&M"M**YS=*ftft Figure 11: Predicted von Mises Residual Stress after ID Patch Weld at 701F Notes:

1. In the hot leg coordinates, hoop residual stresses along path P1 and axial residual stresses along path P2 are extracted for before and after PWHT.
2. The before and after PWHT through-wall residual stresses are compared in Figure 13.

File No.: 1200895.306 Page 36 of 45 Revision: 0 F0306-01 RI

Vsbwforl lugrilMWY Assodaft knc Figure 12: Predicted von Mises Residual Stress after PWHT at 701F Notes:

1. In the hot leg coordinates, hoop residual stresses along path P1 and axial residual stresses along path P2 are extracted for before and after PWHT.
2. The before and after PWHT through-wall residual stresses are compared in Figure 13.

File No.: 1200895.306 Page 37 of 45 Revision: 0 F0306-OIRI

VO~SN" ArW*AKdW4 ft 80 X: + As-Welded (P1) 70 A~: 0 PWHT(P1) 60 4 x As-Welded (P2) 50 x* A PWHT(P2) 40

  • x 30 4- +x 20 IA (A 10 A +
  • 0 0

-10

-20 x +

-30 + x Clad interface +

-40 x

+ *

-50 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Normalized Thickness (x/t)

Figure 13: Residual Stress Comparison for Before and After PWHT File No.: 1200895.306 Page 38 of 45 Revision: 0 F0306-01 RI

CObucmruf ltrNOy ASso~f kics 4÷.

120 A A As-Welded 0 PWHT 100+

,_s--- Clad Interface

<U------ e")

80+

--(I--

Z"(~~m A

60

  • A A 0

A C-40-Q 6

00

()

20-Data from EPRI TR-101989 0 "Th:Wr Clad Tests aO Infltffce at Depth Shown 0 00 Sho 0

-20 A O 1~r

-40 0 0,2 0.4 0.6 0.8 1.0 Distance from Clad Surface (inches)

Figure 14: Measured Through-Wall Residual Stresses for PWHT Notes:

1. Figure is obtained from EPRI report TR-105697 [12].
2. Measurements show little to no stress reduction in the cladding after PWHT.
3. Measurements show significant stress reduction in the base metal after PWHT.

File No.: 1200895.306 Page 39 of 45 Revision: 0 F0306-01 RI

V am"bVOW AM%"~ ASKK~%Ve W Figure 15: Predicted von Mises Residual Stress after Hydrostatic Test at 70°F File No.: 1200895.306 Page 40 of 45 Revision: 0 F0306-OIRI

8 a*

Cftvcftw~bft*a~Amdkftg ksi 4.39

-rain .67 Note: Figure 16: Predicted Radial Residual Stress + Operating Conditions (5 th NOC Cycle)

1. Radial stresses in the nozzle axis.

SFile o, 12 0 9 .06 41 of45 Revisi on.ý0Page 3

F0 06-OIRI

~SVofwro N" W alafturty Iksi

?574 19. 7303 26.2033 32. 6762 39.1492 45. 6221 Figure 17: Predicted Hoop Residual Stresses + Operating Conditions ( 5 th NOC Cycle)

Note:

1. Hoop stresses in the hot leg axis.

File No.: 1200895.306 Page 42 of 45 Revision: 0 F0306-01 RI

Vm"W hdqM Awadift kne Figure 18: Transferred Radial Residual + NOC + Pressure Stresses (3.95" Crack Shown)

File No.: 1200895.306 Page 43 of 45 Revision: 0 F0306-OIRI

C an"wim MOMrf ASSoddMe kM Circumferential Crack FEA "K vs. a" 70 --

  • O - De Deg 60

-30 Deg 50 * -60 Deg U!

. 40 ,0-90 Deg 30 //

20 10 0

0 1 2 3 4 Crack Depth (inch)

Figure 19: FEA Calculated Circumferential Crack "K vs. a" at Four Azimuth Locations File No.: 1200895.306 Page 44 of 45 Revision: 0 F0306-OIRI

SbCa"Aftq* IA rl ubft Figure 20: Hoop Stress Extraction Grid for Axial Crack Growth Evaluation File No.: 1200895.306 Page 45 of 45 Revision: 0 F0306-01R I

1j8mbuobgu Iaturlf Awsca1as. ft6.

APPENDIX A COMPUTER FILES LISTING File No.: 1200895.306 Page A- I of A-5 Revision: 0 F0306-OIRI

V alfffumobftrIlagiffy AssocA, Maueki Geometry Inputs (Geometrylnputs.zip) (1) Description HLDrainMISO.INP Main geometry input file that uses all the files listed below MProp_MISOPALS.INP (2) Revised material property input file Deg90_lines.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP Degl20_lines.INP Sub-Geometry file that is used in the main file - HLDrain_*,INP Degl50_lines.INP Sub-Geometry file that is used in the main file - HLDrain_*,INP Deg180_lines.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP first30vol.INP Sub-Geometry file that is used in the main file - HLDrain_*,INP second30vol.INP Sub-Geometry file that is used in the main file - HLDrain_*,INP third30vol.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP IDpatch volmesh.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP weldmesh.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP lDpatch fix.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP butterlike volmesh.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP cladnexttolDpatch.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP volnextto butterlike.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP boss.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP pipeandclad.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP HLDrainCOMPONENTS1 .INP Sub-Geometry file that is used in the main file - HLDrain_*.INP clearfornewscheme.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP autoweld.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP movetheboss.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP selection.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP newnugidpatch.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP selbutter.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP workontheboss.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP newpipeandcladparts.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP HLDrainCOMPONENTS2.INP Sub-Geometry file that is used in the main file - HLDrain_*.INP File No.: 1200895.306 Page A-2 of A-5 Revision: 0 F0306-0IRI

CjOS OWb frIht*g~j AssacaftS. kfc Notes:

1. All files with the exception of MPropMISO_PALS.INP are obtained from [1]
2. This file contains the updated material properties, as listed in Tables 1 through 8.

File No.: 1200895.306 Page A-3 of A-5 Revision: 0 F0306-OIRI

CjSMU btwoturiltgy AMMSo'aa, Wc.

Residual Stress Files Description (ResidualFiles.zip)

BCNUGGET3D.INP Weld pass and model boundary definition file THERMAL3D.INP Input file to perform the thermal pass of welding simulation THM_PWHT.INP Input file to perform the thermal pass of PWHT STRESS3D.INP Input file to perform the stress pass of welding simulation CBC.INP Input file to apply mechanical boundary conditions and creep properties.

Read in STRESS3D.INP Processed thermal pass load steps for PWHT.

THM_PWHT~mntr.inp Read in STRESS3D.INP INSERT3.INP Input file to perform the stress pass of hydrostatic test and 5 NOC cycles.

Read in STRESS3D.INP WELD#_mntr.inp Processed thermal pass load steps for stress pass. # = 1-3

  • .mac WRS analysis macro files required for analysis THERMAL3D.TXT Parameter input file for thermal pass of welding simulation STRESS3D.TXT Parameter input file for stress pass POSTAXIAL.INP Post-processing input file to extract hoop stress for axial cracks HoopO.csv Formatted hoop stress outputs for axial cracks File No.: 1200895.306 Page A-4 of A-5 Revision: 0 F0306-OIRI

CjStwoIUrw i bigrit Assocats, Inc?

Circ Crack Files Description (CircCrackFiles.zip)

FMSTACK.INP Controller input file LEFM analysis files execution sequence Crack#.lNP Geometry input files to create circ. crack at specified depth. # = 0-6 With 0 = 0.13", 1 = 0.57", 2 = 1.12", 3 = 1.85", 4 = 2.49", 5 = 3.13", 6 = 3.95" Crack nodes#.inp Crack tip node inputs for fracture mechanics model conversion. # = 0-6 Macro to insert crack tip elements to the fracture mechanics model and AnTip80.mac extract K results.

Crack#_COORD.INP Input files to determine crack face element centroid coordinates. # = 0-6 Crack#_COORDl.txt Crack face element centroid coordinate outputs. # = 0-6 Crack#_GETSTR.INP Input files to extract crack face stresses from residual stress analysis. # = 0-6 STRFieldOper#1 .txt Extracted crack face stresses from residual stress analysis. # = 0-6 Crack# IMPORT.INP Input files to transfer stresses into crack face pressure (plus operating pressure on crack face) and solve for solution. # = 0-6 AnTip80_KCALC.INP KCALC post-processing input file Crack#_IMPORTK.CSV Formatted K result outputs. # = 0-6 1200895.306.xlsx Excel spreadsheet containing creep data, PWHT comparison, and K results 1200895.306.ppt PowerPoint slides of selected figures and result plots File No.: 1200895.306 Page A-5 of A-5 Revision: 0 F0306-OIRI

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