ML14149A403

Calculation 32-9220625-000, ASME Section III End of Live Analysis of PVNGS3 Rv Bmi Nozzle Repair, (Non-Proprietary), Attachment 4

ML14149A403
Person / Time
Site:	Palo Verde
Issue date:	04/18/2014
From:	Goelz M AREVA
To:	Office of Nuclear Reactor Regulation
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ML14149A349	List: ML14142A029 ML14149A333 ML14149A342 ML14149A402 ML14149A403 ML14149A404
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102-06879-JJC-JHK-DCE 32-9220625-000
Download: ML14149A403 (81)

Text

Enclosure Relief Request 52 Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i)

ATTACHMENT 4 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair

0402-01-FOl (Rev. 018, 01/30/2014)

A CALCULATION

SUMMARY

SHEET (CSS)

ARE VA Document No. 32 - 9220625 - 000 Safety Related: EYes E No Title ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

PURPOSE AND

SUMMARY

OF RESULTS:

AREVA Inc. Proprietary information in the document is indicated by pairs of brackets "[ 1".

Purpose:

The purpose of this analysis is to qualify the Palo Verde Nuclear Generating Station, Unit 3 (PVNGS3) Reactor Vessel Bottom Mounted Instrumentation (BMI) Nozzle Repair to the applicable requirements of ASME Code Section III Subsection NB Class 1 Components, 1998 Edition, through 2000 Addenda [2]. The Code Reconciliation is provided in Reference [3].

Results:

The analysis demonstrates that the PVNGS3 RV BMI Nozzle Repair satisfies the ASME Code [2] primary stress and primary plus secondary stress requirements, as well as the criteria to protect against fatigue failure. The maximum fatigue usage factor is [ for the new nozzle and associated weld and [ ] for the Reactor Vessel lower head at the nozzle opening.

This document is the Non-Proprietary version of 32-9215084-001.

This document contains a total of 80 pages including pages 1-53, Appendix A (4 pages), Appendix B (3 pages), Appendix C (15 pages), and Appendix D (5 pages).

THE DOCUMENT CONTAINS ASSUMPTIONS THAT SHALL BE THE FOLLOWING COMPUTER CODES HAVE BEEN USED IN THIS DOCUMENT: VERIFIED PRIOR TO USE CODENERSION/REV CODENERSION/REV E Yes ANSYS 14.5.7/Windows 7 x64 _ _ _NO Z No Enclosure Attachment 4 Page 1 of 80

A 0402-01-FOI (Rev. 018, 01130/2014)

AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Review Method: Z Design Review (Detailed Check)

[-- Alternate Calculation Signature Block Note: P/R/A designates Preparer (P), Reviewer (R), Approver (A);

LP/LR designates Lead Preparer (LP), Lead Reviewer (LR)

Project Manager Approval of Customer References (N/A if not applicable)

Name Title (printed or typed) (printed or typed) Signature Date Maya Chandrashekhar Project Manager j Mentoring Information (not required per 0402-01)

Enclosure Attachment 4 Page 2

A 0402-01-FOl (Rev. 018, 01/30/2014)

AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV MsiNozzle Repair (Non-Proprietary)

Record of Revision Revision PageslSectionslPa rag raphs No. Changed Brief Description / Change Authorization 000 All. Initial Issue.

Enclosure Attachment 4 Page 3

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table of Contents Page SIG NATURE BLO CK ................................................................................................................................ 2 RECO RD O F REVISIO N .......................................................................................................................... 3 LIST O F TABLES ..................................................................................................................................... 6 LIST O F FIG URES ................................................................................................................................... 7 1.0 PURPO SE AND SCO PE ............................................................................................................... 8 2.0 ANALYTICAL M ETHODOLO GY .............................................................................................. 8 3.0 ASSUM PTIO NS ............................................................................................................................ 9 3.1 Unverified Assumptions ............................................................................................................. 9 3.2 Justified Assumptions ........................................................................................................................ 9 3.3 Modeling Simplifications .......................................................................................................... 9 4.0 DESIG N INPUTS .......................................................................................................................... 9 4 .1 G e o m e try ........................................................................................................................................... 9 4 .2 Ma te ria ls .......................................................................................................................................... 10 4 .3 Loa d s ............................................................................................................................................... 13 4.3.1 Design Condition ........................................................................................................ 13 4.3.2 Operating Transients .................................................................................................. 13 4.3.3 External Loads ........................................................................................................... 20 4.4 Finite Element Model ....................................................................................................................... 21 4.4.1 Boundary Conditions ................................................................................................. 23 5.0 CO M PUTER USAGE .................................................................................................................. 25 5 .1 S o ftwa re .......................................................................................................................................... 25 5 .2 C o m p ute r F ile s ................................................................................................................................ 26 6.0 CALCULATIO NS ......................................................................................................................... 31 6 .1 D e s ig n C on d itio n ............................................................................................................................. 31 6.2 Thermal Analysis ............................................................................................................................. 32 6 .3 Stre ss A n a lys is ................................................................................................................................ 34 6.4 External Nozzle Loads .................................................................................................................... 36 6.4.1 Repair Nozzle .................................................................................................................. 36 6.4.2 Remnant Nozzle ......................................................................................................... 37 7.0 ASM E CO DE CRITERIA ............................................................................................................. 38 7.1 ASME Code Primary Stress Intensity (SI) Criteria ................................................................... 40 7.1.1 Primary Stress Intensity for Design, Level A, B, C, and D Conditions ....................... 40 Enclosure Attachment 4 Page4

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table of Contents (continued)

Page 7.1.2 Primary Stress Intensity for Test Condition per NB-3226 ............................................ 42 7.1.3 Partial Penetration Weld Size ...................................................................................... 43 7.1.4 Pure Shear in the Repair Weld .................................................................................... 44 7.2 Primary plus Secondary Stress Intensity Range ........................................................................ 44 7.3 Fatigue Usage Factor Criteria .................................................................................................... 46 7.4 Consideration of corrosion in the RV Head Low-Alloy Steel ..................................................... 51 8 .0 R E S U LT S .................................................................................................................................... 52 9 .0 R E F E R E N C E S ............................................................................................................................ 53 APPENDIX A: HEAT TRANSFER COEFFICIENT CALCULATION .............................................. A-1 APPENDIX B: REMNANT NOZZLE LOAD CALCULATION ........................................................... B-1 APPENDIX C: TEMPERATURES AND GRADIENTS FROM THERMAL ANALYSIS ................... C-1 APPENDIX D: STRESSES FOR THE REMNANT J-GROOVE WELD FLAW EVALUATIONS ......... D-1 Enclosure Attachment 4 Page 5

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

List of Tables Page Table 4-1: RV Bottom Head Material Properties ............................................................................... 11 Table 4-2: Remnant Nozzle/Weld Material Properties ..................................................................... 12 Table 4-3: Stainless Steel Cladding Material Properties ................................................................... 12 Table 4-4: Repair Nozzle, Weld, and Weld Pad Material Properties ................................................ 13 Table 4-5: Operating Transients ........................................................................................................ 14 Table 4-6: Transient HUlow (Lower Bound Heatup Pressure) .......................................................... 15 Table 4-7: Transient HUup (Upper Bound Heatup Pressure) ............................................................ 15 Table 4-8: Transient CDlow (Lower Bound Cooldown Pressure) .................................................... 16 Table 4-9: Transient CDup (Upper Bound Cooldown Pressure) ....................................................... 16 T a b le 4 -10 : Tra nsie nt P L ....................................................................................................................... 17 T a b le 4 -1 1: T ra nsie nt P U....................................................................................................................... 17 T a ble 4 -12 : T ra nsie nt LS P ..................................................................................................................... 18 T a ble 4 -13 : T ra nsie nt R T ....................................................................................................................... 19 T a ble 4-14 : T ransie nt NV A R .................................................................................................................. 19 Table 4-15: Individual External Loads on Repair Nozzle ................................................................... 20 Table 4-16: Combined External Loads on Repair Nozzle ................................................................. 20 Table 5-1: Computer Files - Analysis and Post Processing .............................................................. 26 Table 5-2: Computer Files - Fracture Mechanics Files ..................................................................... 29 Table 6-1: Nodes of Interest for Evaluation of Temperature Gradients ........................................... 33 Table 6-2: Time Points in Structural Analysis ................................................................................... 35 Table 6-3: Repair Nozzle Section Properties ................................................................................... 36 Table 6-4: Stress Intensity at Nozzle Cross-Section due to External Loads ..................................... 36 Table 7-1: Node Numbers of Defined Path Lines .............................................................................. 39 Table 7-2: P+Q Membrane plus Bending SI Ranges ........................................................................ 45 Table 7-3: FSRF/SCF and Stress Category in Fatigue Evaluation ................................................... 48 Table 7-4: Cumulative Fatigue Usage Factors ................................................................................ 49 Table 7-5: Bottom Head Usage Factor ............................................................................................ 50 Table 7-6: Repair Weld Usage Factor .............................................................................................. 50 Table 7-7: Repair Nozzle Usage Factor ............................................................................................. 51 Table 8-1: Summary of Primary Stress Intensities ............................................................................ 52 Table 8-2: Summary of Primary Stress Intensity for Test Conditions ................................................ 52 Table 8-3: Summary of P+Q SI Ranges and Fatigue Usage Factors ................................................ 52 Table B-i: Peak Seismic Acceleration Post-RSG and Uprate ....................................................... B-3 Table D-1: Step Load Transient Data .................................................................................................. D-3 Enclosure Attachment 4 Page 6

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

List of Figures Page Figure 4-1: Mo d e l G e o m etry .................................................................................................................. 22 Figure 4-2: Meshed FEA Model ...................................................................................................... . . 22 Figure 4-3: Thermal Boundary Conditions ........................................................................................ 23 Figure 4-4: Structural Boundary Conditions ..................................................................................... 24 Figure 6-1: Total Displacement for Design Conditions ..................................................................... 31 Figure 6-2: Stress Intensity for Design Conditions ............................................................................ 32 Figure 6-3: Node Pairs for Evaluation of Temperature Gradient ....................................................... 34 Figure 6-4: Stress Intensity due to White Noise Remnant Nozzle Load ........................................... 37 Figure 7-1: Path Lines on Reactor Vessel Bottom head ................................................................... 38 Figure 7-2: Path Lines for Replacement Nozzle and Repair Weld .................................................. 39 Figure 7-3: Partial Penetration Weld Dimensions ............................................................................ 43 Figure 7-4: Fatigue Locations Investigated for HDPath3 and HDPath4 ........................................... 47 Figure D-1: Pathlines for Post-Processing Hoop Stress Results for FMA ........................................... D-5 Enclosure Attachment 4 Page 7

A AR EVA. Document No. 32-9220625-000 ASME Section III End of.Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 1.0 PURPOSE AND SCOPE As required by the Design Specification [1], the purpose of this analysis, in accordance with ASME Code Section III criteria [2], is to qualify the Reactor Vessel Bottom Mounted Instrumentation (RV BMI) nozzle repair. Results of the analysis are summarized in this report to demonstrate that the repair meets the stress criteria and fatigue requirements of ASME Code Section III, Subsection NB, 1998 edition including Addenda through 2000 [2]. The Code Reconciliation is provided in Reference [3].

The analysis is focused on the elastic structural evaluation and qualification of the half nozzle repair for requirements on both stress distribution and fatigue failure criterion. As a result of the half nozzle repair, the bore surfaces through lower head are exposed to reactor coolant. In accordance with the Design Specification [1],

corrosion of the low alloy steel and its impact on the analysis shall also be addressed. The scope of the analysis includes the Reactor Vessel Bottom Head (RVBH) and the half nozzle repair at BMI Nozzle Penetration #3, including the replacement nozzle, weld pad, and repair J-groove weld. The remnant nozzle no longer serves as the pressure boundary component, and therefore, comparison of the remnant nozzle stresses and attachment weld stresses to ASME Code criteria is not required herein. However, stresses in the remnant nozzle are calculated to provide input to the Section XI Fracture Analysis. AREVA Document 51- 9220420 (latest revision) provides a road map of the AREVA analyses for the Palo Verde BMI Nozzle.

A detailed finite element analysis (FEA) is conducted to investigate the new pressure boundary components as modified by the half nozzle repair.

2.0 ANALYTICAL METHODOLOGY The general methodology of model development and stress analysis consists of:

1) Building a 3-Dimensional model of the instrument nozzle repair. The model incorporates the geometry and material properties for the following components; reactor vessel bottom head, original instrument nozzle remnant, original instrument nozzle attachment weld, part of the replacement instrument nozzle, and replacement nozzle J-groove weld.

2) Applying the design conditions to the structural finite element model to obtain deformation and stresses in the model. The results of the design conditions are used to verify the correct behavior of the model and correct modeling of the structural boundary conditions.

3) Applying the thermal loads due to operational transients in the form of bulk fluid temperatures and heat transfer coefficients versus time. The results of the thermal analysis are examined for the temperature gradients between critical locations within the geometry. The time points corresponding to the maximum/minimum temperature differences are those at which the maximum/minimum thermal stresses develop. The time points corresponding to the maximum/minimum pressure are those at which the maximum/minimum mechanical stresses develop.

4) Applying the corresponding pressure and thermal loads (nodal temperatures) at each time point identified in Step 3 above and other time points of analytical interest on the structural finite element model and obtaining the stress results.

5) Post-processing results generated from the above steps to obtain the appropriate stresses for comparison with the criteria outlined in NB-3200 of Reference [2] for acceptability.

6) Comparing the results to the ASME Code for acceptability (Primary, Primary + Secondary, and Fatigue).

Enclosure Attachment 4 Page 8

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 3.0 ASSUMPTIONS 3.1 Unverified Assumptions There are no unverified assumptions used herein. Modeling simplifications are detailed below.

3.2 Justified Assumptions There are no justified assumptions used herein. Modeling simplifications are detailed below.

3.3 Modeling Simplifications

" The RV bottom head is modeled a sufficient distance away from the BMI penetration in both the radial and circumferential directions to assure that the stress effects have effectively attenuated. The adequacy of these distances is verified by a review of stress results from Design and various operational conditions.

In addition, due to the spacing of the BMI nozzles and the stress attenuation from the relatively small welds, no appreciable overlap of stress fields occurs between adjacent nozzles. Therefore, the modeling of a single nozzle is justified.

• The boat sample excavation is modeled at the uphill side of the remnant nozzle and symmetric about the model symmetry plane which is rotated slightly from the actual orientation as shown on [9]. Modeling the boat sample centered at either the uphill or downhill side of the nozzle allows the execution of a 1800 model including a single boat sample. There is no appreciable difference in the stress distribution at either side due to the small tangent angle at the nozzle.

• Heat Transfer Coefficients (HTC's) are calculated for the internal vessel surfaces based on the stream velocity of [ ] at Nozzle #3 as presented in Figure 12 of[13]. The inside surface of the RVBH is treated in the HTC calculation as a flat isothermal plate with a characteristic length equal to the radial arc length in the model. See Appendix A for detailed calculations.

• Water trapped within the repair and remnant nozzles is stagnant and has negligible interaction with the water at bulk temperature. The major heat transfer mechanism in the nozzle region is the conduction in metal. The heat flow between the stagnant water and the nozzle inside surfaces is insignificant and therefore no heat loads are applied to the inside surfaces of the nozzles or the cut ends of the nozzles within the RVBH bore, resulting in adiabatic thermal boundary conditions at these surfaces.

• The outside surfaces of the nozzles (remnant and repair) are thermally coupled with the inside surface of the RVBH bore, i.e., no thermal resistance is considered between them. This is justified as the gap is sufficiently small and filled with stagnant water.

" Heat Up and Cool Down transients are executed using both an upper bound and lower bound pressure curves. Worst-case combination of these curves will be used in the stress and fatigue assessment.

4.0 DESIGN INPUTS 4.1 Geometry The detailed dimensions of the remnant nozzle and nozzle repair are provided in References [4], [5], [6], [7], [8],

and [9] as well as the original RV Stress Report [18]. Major nominal dimensions are summarized below:

RVBH inside radius to base metal = [ ] [8]

RVBH base metal thickness (min) = [ [8]

Cladding Thickness = [ ] [8]

Enclosure Attachment 4 Page 9

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Buttering Thickness = ]i [7]

BMI Remnant Nozzle OD at Weld = [ ] [4]

BMI Remnant Nozzle ID at Weld = [ ][4]

Remnant J-Groove Weld Thickness = [ ] [6]

BMI Repair Nozzle OD = [ ] [4]

- I ] Nominal Bore ID with max diametral clearance of [ ] per Note 12 of Ref. [4]

BMI Repair Nozzle ID = ] [5]

Weld Pad Thickness = ][4]

Boat Excavation Tool Width = ][9]

Boat Excavation Swept Radius = ] [9]

Boat Excavation Depth into Nozzle = ] [9]

4.2 Materials The material designations are provided in [I] and summarized as follows:

Reactor Vessel Bottom Head (Existing) [ I RVBH Cladding (Existing) - Austenitic Stainless Steel BMI Remnant Nozzle (Existing) [

I Remnant J-groove Weld Buttering (Existing) C Remnant J-groove Weld (Existing) C I BMI Repair Nozzle (Replacement) C Weld Pad and Repair J-groove Weld (Replacement) - [ I Properties for existing materials shall be taken from the original RVBH construction code, Reference [10].

Properties for replacement materials shall be taken from Reference [11]. Note that I ] is representative of the existing weld and buttering materials, while [ ] is representative of the replacement nozzle, repair weld, and weld pad material.

The following tables provide material properties as a function of time for the 4 unique materials within the scope of this analysis.

Young's Modulus E (psi)

Poisson's Ratio v (unitless)

Density p (lbf/in 3)

Mean Coefficient of Thermal Expansion a (1/OF)

Thermal Conductivity k (Btu/s-in-0 F)

Specific Heat C (Btu/lb-OF)

Design Stress Intensity Sm (ksi)

Yield Strength Sy (ksi)

Tensile Strength S. (ksi)

Enclosure Attachment 4 Page 10

A AREV/A Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Thermal conductivity, k, is taken from Table 1-4.0 [10] for existing materials and Table TCD [11] for replacement materials. The thermal conductivity (TC) provided in these tables has units of BTU/hr-ft-°F. The values of thermal conductivity presented in the following tables have been converted to the consistent units of BTU/s-in-°F.

The specific heat, C, is a calculated value based on C =k/(p

• Thermal Diffusivity (TD)). The values presented in the following tables has been calculated as TC/(p*TD) where TC and TD are taken from Tables 1-4.0 [10] and TCD [1 ], for existing and replacement materials, respectively.

Density, p, is calculated as a function of temperature, T, using the following equation:

p(T) = p(70oF)/(1+a(T)*(T-70°F)) 3 Where: p(T) is the density at temperature T, p(70'F) is the density at room temperature, a(T) is the coefficient of thermal expansion at temperature T, and (T-70 0 F) represents the change in temperature from the reference/room temperature.

Density at room temperature for all materials is taken from Table PRD of Reference [ 121.

• UNO = Unless Noted Otherwise.

Table 4-1: RV Bottom Head Material Properties Reactor Vessel Bottom Head: I Temp (F) ot (1/°F) I E (psi) v (- C (BTU/Ib-°F k (BTU/s-in-°F) p (IblinA3) Sm (ksi) Sy (ksi) ISu (ksi) 3: 1l: :1I IEL IL 3 7 71

=C 7: Ei I] E II II "IiI iLLII

I1- I I.II C13IIE t-C =3 I 1 llE1 1

_~ L II]rli L C3 1 C :1 3f I1 C 'R Ref. [91 Table 1-5.0, Table I- Table I- Table I-UNO Coeff. B Table 1-6.0 Typical Calculated Table 1-4.0 Calculated 1.1 2.1 1.1 Enclosure Attachment 4 Page 11

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-2: Remnant Nozzle/Weld Material Properties Remnant Nozzle and Welded Attachme nt 0

Temp(*F) a (1/ F) E (psi) v(-) C(BTU/Ib-°F) k(BTU/s-in-°F)lp(lb/in^3) Sm(ksi) Sy(ksi) Su(ksi)

, 3 E3 E 3 E A] U -Te 3 3[:E 3 * ;: 1 1 3TE 3E 3 " 311C :31E 3 -

3 IIE -I3 abl 3,E b

-li1 Tab3E I-UN Coff B Tabl 1- yal* Calcuae Tabl . Calclated 1.2 2.2 1.

Ta 3Ele4 tiE3 Ste Ca die 3Me 3lE 3PEer

_117TEm :1117 3[ L 1 1EE ( v 3- _E:1 3 1E 31E -i  : E -

Re f . [9] -5.0, Table -Table I- Table I-UNO Coeff. B Table 1-6.0 Typical Calculated Table 1-4.0 Calculated 1.2 2.2 .2 Table 4-3: Stainless Steel Cladding Material Properties Cladding:L-Temip (OF) It a (1°F) [E (psi) [v -)C (BTU/Ib-°F) k (BTU/s-in-OF) p (lb/in^2)

L J IL j II 1 . . .. . .

E713E 1 71 E :1J A1 -

A-A IE Jl J -

.I_111 ]E :1 A

-3 AE]E I

. . [ Jl L1 I Ref" [9] Table 1-5.0, UNO Coeff. B ITable 1-6.0 1Typical ICalculated Table 1-4.0 Calculated Page 12 Enclosure Attachment 4 Enclosure Attachment 4 Page 12

A ARE VA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-4: Repair Nozzle, Weld, and Weld Pad Material Properties Replacement Nozle, Weld Pad, Welded

Attachment:

L JILIL I-Temp(F) _ct (1/F)_ [_E (psi) __y (-)_ CABTU/Ib-OF) k_(BTU/s-in-OF)9_(Ib/in^3_

Ll IL Sm (ksi Sy (ksiSu (ksi L-IL _IIJ IF-JF 1L[F 01 1I

-I11117 II]E r ]IF R. 10 . I ie 311-~Fr li E Ie UNO Table TE-4 Table TM-4 Typical Calculated Table TCD Calculated Table 2B Table Y Table U 4.3 Loads 4.3.1 Design Condition The RVBH Assembly, including BMI nozzles and attachment welds, is designed to meet ASME Code stress criteria for maximum temperature and internal pressure. Per Reference [1], the design temperature and pressure are [ ] and [ ] , respectively.

These design conditions were simulated on the model by applying a uniform temperature of [ ]

(Tunif=Tref, no differential thermal growth) throughout the model and a uniform pressure of [

(conservative) on all surfaces in contact with the primary coolant. These surfaces include the RVBH interior, the original J-groove weld, the head bore, the weld pad bore, the remaining and replacement BMI nozzle inside diameter and the remaining and replacement BMI nozzle outside diameter which is inside the head bore. In addition, the bottom end of the replacement BMI nozzle also has the pressure applied to represent the hydrostatic end cap pressure. See Section 4.3.3 for external nozzle loads.

4.3.2 Operating Transients The ANSYS model is subjected to the Reactor Coolant inlet thermal and pressure conditions versus time. These thermal transient loads are of prime importance in satisfying the fatigue requirements of the ASME Code [2].

All Normal and Upset transients are to be analyzed in detail with the finite element models and are taken from Pages 10-11 of [13] with corresponding curves presented on Pages 37-40 of [13]. The analyzed Normal/Upset transients are described in Table 4-5 below, and digitized temperature/pressure data for each transient are supplied in Table 4-6 through Table 4-14. The Loss of Secondary Pressure (Faulted) is additionally analyzed in detail to provide stress results needed in the fracture mechanics analysis.

Enclosure Attachment 4 Page 13

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-5: Operating Transients Condition Transient Filename Number of Figure in Ref. [13]

Convention Cycles(4)

Heatup, [ HUup or HUlow4 l) [ Fig. 2 Cooldown, [ CDup or CDlowl Fig. 2 Plant Loading, 5% min. PL Fig. 3 Normal Plant Unloading, 5% min. PU Fig. 3 10% Step Load Increase 10% Step Load Decrease NVAR [ ]

Normal Plant Variation ]

Reactor Trip Loss of Reactor Coolant Flow RT [ ] Fig. 4 Upset Loss of Load OBE Faulted Loss of Secondary Pressure LSP Fig. 5 Hydrostatic Test, [

Test ]I Leak Test, [ LEAK [

Notes:

(1). Heatup and Cooldown pressure curves are provided for both upper and lower bound values. All potential permutations will be accounted for and the worst-case results for the primary plus secondary stress intensity range and fatigue usage factors will be presented. Filename conventions are provided for Upper Bound Heatup (HUup), Lower Bound Heatup (HUlow),

Upper Bound Cooldown (CDup), and Lower Bound Cooldown (CDlow).

(2). The Hydrostatic Test is performed at 1.25*Design Pressure per NB-6221 [2]. However, per NB-3226(e) consideration of the first 10 Hydrostatic tests is not required in the fatigue evaluation.

Therefore, stresses produced by the Hydrostatic test are compared to Code Allowable Stresses but not considered in the fatigue evaluation.

(3). The Leak Test will be considered to be performed at the maximum temperature of [

[ ] cycles of Leak Tests are considered in the fatigue usage calculation.

(4). Design Cycles as presented in Reference [ 13 ] for the original 40 year design life remain applicable for the extended 60 year life based on the reasoning and evidence presented in Reference [14] as accepted by the NRC in Reference [15].

Enclosure Attachment 4 Page 14

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-6: Transient HUlow (Lower Bound Heatup Pressure)

RV Inlet RC Pressure Time [s] Temp [psia]

[OF]

[I ] [LIRV nlet RCPesr 11[

Tabl~ Tiesien

[-:Ta Temp (U perBondHatu rsue

[OF]

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A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-8: Transient CDIow (Lower Bound Cooldown Pressure)

RV Inlet RC Pressure Time [s] Temp [psia]

[OF]

Il[ IF]

11411 1 L Time___ [s] Temp ] ______

LI I I, i Table 4-9: Transient CDup (Upper Bound Cooldown Pressure)

RVIletRC Pressure Time [s] Temp [psia]

[°F] __ _ _ _ _

Il 1 [11 [

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A AR EVA Document No. 32-9220625-000 ASME Section.Ill End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-10: Transient PL RV Inlet RC Pressure Time [s] Temp [psia]

Time___ [sF] _ _[psla]

I[ 11 11]

I[ _ ] 1[L.]

Table 4-11: Transient PU Time [s]I Te~m]p [psia]

1[ 11 [l 11[

11I[ ]1[

il L1I[ 1[]

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A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-12: Transient LSP RV Inlet RC Pressure Time [s] Temp [psia]

_________ [OF]_ _ _ _

111 iL l[h -[l]

L [ ) [ )L

[_l [ L LLA lI L fi[i ill[ i i

[l )l ffiL

[I ) il)

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A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 4-13: Transient RT

~RV Inlet RVIletRC Pressure Time [s] Temp [psia]

[pFa

[OF]

[L1 [  !

Table 4-14: Transient NVAR RV Inlet RC Pressure Time [s] Temp [psia]

[OF]

((1111111 L[1 ] [ )

[1L!L[ L W )L[ ) [

Enclosure Attachment 4 Page 19

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 4.3.3 External Loads 4.3.3.1 Repair Nozzle External Loads are defined at the juncture between the nozzle and the outside surface of the RVBH ("Cut A")' on page 46 of the APS Project Specification [16]. These external loads are considered in the nozzle stress calculation. The loads are repeated below for convenience. Stresses due to external load application at remaining cuts along the nozzle are bounded by the evaluation performed herein and the ICI Piping evaluation [17].

Table 4-15: Individual External Loads on Repair Nozzle Loading Condition Shear Tension Bending Moment (Ibs) (lbs) (in-lbs)

Normal Condition hra1 Weight [L - f fili Thermalf[ [ f il Upset Leak Thermal [ ] L 1 i f i OBE (+/-) [ ] [

Emergency Leak Thermal L ] [ ]L J Faulted SSE and Branch Line Pipe Break (BLPB) Combined (:) [ I I IL Loading combinations in Table 4-16 are consistent with the combinations shown on page A-547 of the original Stress Report [ 18], and repeated below for convenience.

Load Combinations Design: Design temperature and pressure + DW (dead weight) + OBE Normal: Normal temperature and pressure + DW + Thermal Upset: 1) Upset temperature and pressure + DW + Leak Thermal ([ J cycles)

2) Upset temperature and pressure + DW + Thermal + OBE ([ ] cycles)

Emergency: Steady state (pressure & temperature) + DW + Leak Thermal Faulted: Faulted pressure and temperature + DW + Thermal + SSE&BLPB Table 4-16: Combined External Loads on Repair Nozzle Pressure Shear Tension Bending Moment Load Combination (psia) (Ibs) (lbs) (in-lbs)

Design I f 11 11i fi Normal 11iif Upset (1)( C ] Cycles) ff ] [ ] m Upset (2) (OBE- - [

cycles)

Emergency [

• JI I ,

Faulted[ [ ] [ ]

(I). [ ] Cycles of Leak loads in combinations with other upset conditions/loading (2). [ ] cycles of OBE loads in combination with other upset conditions/loading.

Enclosure Attachment 4 Page 20

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 4.3.3.2 Remnant Nozzle The external loads presented in Table 4-15 were applied to the original BMI nozzle. Because the original nozzle was cut off inside the RVBH thickness, the loads are not transmitted to the remnant nozzle. However, per the original Reactor Vessel Stress Report [18], the remnant nozzle also experiences loads which are imposed to the section of nozzle inside the vessel, as described on pages A-582 through A-585 of the Stress Report [18]. The following loads remain applicable to the remaining remnant nozzle within the Reactor Vessel:

Fluid Flow Pressure (HF)

Pump Periodic Excitation (PPE)

Seismic Accelerations (OBE,SSE)

Mechanical White Noise Excitation (WN)

The specific loads contained in the Stress Report [18] are the worst case loads for all BMI nozzles. For this evaluation, the remnant nozzle loads will be calculated using the same methodology as the Stress Report [ 18],

with the conditions present specifically for Nozzle #3 when significantly different from the worst-case conditions used in the Stress Report. In addition, Seismic loads will be determined using the same methodology as contained in [18], but will make use of the current response spectra contained in Attachment I of Reference [16) which represent Post-RSG and Power Uprate curves. The magnitude of the remnant nozzle loads are calculated in Appendix B. These remnant nozzle loads will be applied in the Finite Element Model in order to supply accurate cumulative stresses for the ASME Section XI Flaw Evaluation.

4.4 Finite Element Model The 3-D solid model simulates a 1800 section of BMI Nozzle #3 and a portion of the adjacent Reactor Vessel Bottom Head. The model geometry is built with ANSYS Workbench [19] and is shown in Figure 4-1. The model is meshed within the ANSYS Workbench environment. The meshed FEA model is shown in Figure 4-2.

The ANSYS Workbench FEA Model input (nodes, elements, and named components) is documented in the "Geom.dat" computer file. The ANSYS APDL computer file, "Geom.out," documents the geometry creation within the ANSYS APDL environment.

Enclosure Attachment 4 Page 21

A Document No. 32-9220625-000 AR EVA ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Figure 4-1: Model Geometry Figure 4-2: Meshed FEA Model Enclosure Attachment 4 Page 22

A A REVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3.RV BMI Nozzle Repair (Non-Proprietary) 4.4.1 Boundary Conditions 4.4.1.1 Thermal Boundary Conditions Heat transfer coefficients (HTC's) are calculated and applied to the reactor vessel head interior and the outside surfaces of the remnant nozzle located within the vessel head. The calculated HTC's for the head and remnant nozzle are [ ] and [ I , respectively. Calculation details are presented in Appendix A. Bulk fluid temperatures for the surfaces described above are taken as the RV inlet temperature.

In addition, a representative HTC of [ ] is extracted from the APS Insulation Specification

[20] and applied to the vessel outside surfaces including the repair nozzle outside surfaces. Ambient temperature of [ ] is considered as the bulk temperature for the Heatup and Cooldown transients, while an ambient temperature of [ ] is considered for all other operating transients.

As discussed in Section 3.3, no heat loads are applied to the inside diameters of the remnant and repair nozzles or the cut ends located within the RVBH bore, resulting in adiabatic thermal boundary conditions at these surfaces.

Temperatures at the nodes located on the outside surfaces of the repair and remnant nozzle are coupled with corresponding nodes on the head bore, simulating zero thermal resistance present in the annular gap. This is justified as the gap is small ( [ ] ) and filled with stagnant water. All cut-off planes are considered adiabatic (insulated) due to symmetry.

Figure 4-3: Thermal Boundary Conditions Enclosure Attachment 4 Page 23

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 4.4.1.2 Structural Boundary Conditions Symmetric boundary conditions are applied to the 3 faces corresponding to the cut-off sections of the model.

These symmetric boundary conditions allow in-plane displacements (i.e., radial growth) while restricting all out-of-plane displacements.

Contact and target elements are applied to the outside diameter of the repair and replacement nozzles and the bore of the RVBIH to account for possible contact between these surfaces.

Inside surfaces which are in contact with the fluid are loaded with the internal pressure. These surfaces include:

RVBH interior, remnant nozzle OD and top surface within the vessel, remnant nozzle and replacement nozzle ID, remnant nozzle and replacement nozzle OD within the head bore, RVBH bore, and cut ends of remnant and replacement nozzle within the bore. In addition, an end-cap pressure is applied to the external end of the repair nozzle to simulate the hydrostatic pressure which is present in the full system. The exterior of the RVBH and repair nozzle are not loaded by pressure.

Figure 4-4: Structural Boundary Conditions Enclosure Attachment 4 Page 24

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 5.0 COMPUTER USAGE 5.1 Software ANSYS Release 14.5.7 is used in this calculation. Verification tests are listed as follows:

" Computer programs tested: ANSYS Release 14.5.7.

• Verification Tests: VM96 for SOLID87, VM161 for SOLID90, VM211 for CONTA 174 AND TARGEI70, and VM246 for SOLID186 and SOLID 187 elements. Verification output files are identified in the computer listing, using the naming convention of(*)_I and (*)_2, where (*) represents the Test Name and

'l' and '_2' denote the hardware platform tested as identified below.

" Computer hardware used:

Two computers were used for this analysis, with Computer I below used primarily for Analysis runs and Computer 2 below used for Post-Processing runs.

1. DELL Precision T5500 (Service Tag# 1B4PHL1) with the XeonTM CPU 3.33GHz, 24GB RAM; Operating System Microsoft Windows XP Professional x64, Version 2003, Service Pack 2.

2. LENOVO ThinkPad T520 (Computer Name MGOELZ3), Intel(R) Core(TM) i5-2520M CPU @ 2.50 GHz, 8GB RAM; Operating System: Windows 7, Service Pack 1, 64 Bit

" Name of person running the tests: Matthew Goelz.

" Date of tests: 2/18/2014.

Acceptability: Output files of all verification tests are listed in Table 5-1 and have been reviewed and found to be successful.

Page 25 Enclosure Attachment 4 Enc1o~ure Attachment 4 Page 25

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 5.2 Computer Files All computer files generated for this analysis and the Installation Test Files have been uploaded to AREVA ColdStor. Files listed in Table 5-1 have been uploaded to the following directory: "\cold\General-Access\32\32-9000000\32-9215084-000\official".

Table 5-1: Computer Files - Analysis and Post Processing Date Time Size (Bytes) FileName 11/26/2013 8:48 AM 1,143,506 bc st contact.mac 11/20/2013 3:30 PM 268,135 bc_stsymm.mac 12/19/2013 12:28 PM 1,788 CDlowtrTable.mac 1/16/2014 8:01 PM 80,649 CDlowTs.txt 12/19/2013 12:28 PM 1,514 CDup-trTable.mac 1/16/2014 6:31 PM 80,649 CDupTs.txt 12/17/2013 9:38 AM 1,534 defNodePairs.mac 12/17/2013 10:31 AM 496,536 Design.out 1/16/2014 4:35 PM 40,485 Design_HEADSIRs.out 1/17/2014 7:11 AM 41,200 DesignNOZSlRs.out 1/21/2014 1:14 PM 41,410 DesignWELDSIRs.out 2/14/2014 9:36 AM 1,831 ftgStoreData.mac 12/13/2013 11:25 AM 80,783,537 Geom.dat 1/10/2014 3:19 PM 74,182 Geom.out 12/19/2013 12:28 PM 1,820 HUlowtrTable.mac 12/19/2013 5:59 PM 78,989 HUlowTs.txt 12/19/2013 12:24 PM 1,504 HUup trTable.mac 12/19/2013 4:33 PM 78,989 HUupTs.txt 12/19/2013 12:28 PM 3,166 LSP trTable.mac 12/19/2013 11:50 PM 84,301 LSPTs.txt 11/21/2013 7:04 AM 15,700 matDef.mac 2/14/2014 10:08 AM 2,021 NVAR trTable.mac 2/14/2014 10:39 AM 22,217 NVARTs.txt 12/19/2013 12:28 PM 1,492 PL trTable.mac 12/19/2013. 9:19 PM 26,201 PLTs.txt 12/19/2013 12:28 PM 1,502 PU trTable.mac 12/19/2013 9:47 PM 27,861 PUTs.txt 12/19/2013 12:28 PM 1,762 RT trTable.mac 12/19/2013 10:26 PM 35,829 RTTs.txt 2/17/2014 8:12 AM 35,656 SIRIHEADMB.out 2/17/2014 8:12 AM 21,386 SIR1_HEADMB.txt 2/18/2014 8:30 AM 35,674 SIRIHEADTOT.out 2/18/2014 8:30 AM 25,533 SIRIHEADTOT.txt 2/17/2014 9:47 AM 36,716 SIR1_NOZMB.out 2/17/2014 9:47 AM 24,576 SlRINOZMB.txt Page 26 Enclosure Attachment 4 Enclosure Attachment 4 Page 26

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Date Time Size (Bytes) FileName 2/18/2014 10:01 AM 36,726 SIRINOZTOT.out 2/18/2014 10:01 AM 22,981 SIRINOZTOT.txt 2/17/2014 10:36 AM 37,505 SIRIWELDMB.out 2/17/2014 10:36 AM 22,981 SIRIWELDMB.txt 2/18/2014 10:50 AM 37,523 SIRIWELDTOT.out 2/18/2014 10:50 AM 22,343 SIRIWELDTOT.txt 2/17/2014 8:40 AM 35,672 SIR2_HEADMB.out 2/17/2014 8:40 AM 20,748 SIR2_HEAD_MB.txt 2/18/2014 8:57 AM 35,690 SIR2_HEADTOT.out 2/18/2014 8:57 AM 25,533 SIR2_HEADTOT.txt 2/17/2014 9:59 AM 36,732 SIR2_NOZMB.out 2/17/2014 9:59 AM 24,576 SIR2_NOZ_MB.txt 2/18/2014 10:13 AM 36,742 SIR2_NOZTOT.out 2/18/2014 10:13 AM 23,619 SIR2_NOZTOT.txt 2/17/2014 10:49 AM 37,521 SIR2_WELDMB.out 2/17/2014 10:49 AM 22,981 SIR2_WELDMB.txt 2/18/2014 11:04 AM 37,539 SIR2_WELDTOT.out 2/18/2014 11:04 AM 22,981 SIR2_WELDTOT.txt 2/17/2014 9:08 AM 35,664 SIR3_HEADMB.out 2/17/2014 9:08 AM 20,748 SIR3_HEADMB.txt 2/18/2014 9:24 AM 35,682 SIR3_HEADTOT.out 2/18/2014 9:24 AM 25,533 SIR3_HEADTOT.txt 2/17/2014 10:11 AM 36,724 SIR3_NOZMB.out 2/17/2014 10:11 AM 24,576 SIR3_NOZMB.txt 2/18/2014 10:24 AM 36,734 SIR3_NOZTOT.out 2/18/2014 10:24 AM 22,343 SIR3_NOZTOT.txt 2/17/2014 11:02 AM 37,513 SIR3_WELDMB.out 2/17/2014 11:02 AM 22,981 SIR3_WELD_MB.txt 2/18/2014 11:17 AM 37,531 SIR3_WELDTOT.out 2/18/2014 11:17 AM 22,343 SIR3_WELDTOT.txt 2/17/2014 9:35 AM 35,668 SIR4_HEADMB.out 2/17/2014 9:35 AM 21,386 SIR4_HEADMB.txt 2/18/2014 9:50 AM 35,686 SIR4_HEADTOT.out 2/18/2014 9:50 AM 25,533 SIR4_HEADTOT.txt 2/17/2014 10:23 AM 36,728 SIR4_NOZMB.out 2/17/2014 10:23 AM 24,576 SIR4_NOZMB.txt 2/18/2014 10:37 AM 36,738 SIR4_NOZTOT.out 2/18/2014 10:37 AM 22,981 SIR4_NOZTOT.txt 2/17/2014 11:16 AM 37,517 SIR4_WELDMB.out 2/17/2014 11:16 AM 22,981 SIR4_WELDMB.txt Page 27 Attachment 44 Enclosure Attachment Page 27

A Document No. 32-9220625-000 AREVA ASME Section I1l End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Date Time Size (Bytes) FileName 2/18/2014 11:29 AM 37,535 SIR4_WELDTOT.out 2/18/2014 11:29 AM 22,662 SIR4_WELDTOT.txt 1/16/2014 9:55 PM 86,382 TrCDlow st.out 1/16/2014 8:01 PM 2,682,193 TrCDIowth.out 1/16/2014 8:58 PM 86,360 TrCDupst.out 1/16/2014 6:31 PM 2,682,177 TrCDupth.out 1/7/2014 10:49 AM 86,984 Tr_HUlowst.out 12/19/2013 5:59 PM 2,679,892 TrHUlowth.out 1/7/2014 9:17 AM 86,958 TrHUupst.out 12/19/2013 4:33 PM 2,680,726 TrHUupth.out 1/7/2014 9:08 PM 495,341 TrLEAKst.out 1/7/2014 7:01 PM 110,066 TrLSP st.out 12/19/2013 11:50 PM 2,696,211 TrLSP th.out 2/14/2014 2:59 PM 75,453 TrNVarst.out 2/14/2014 10:39 AM 2,579,677 TrNVAR th.out 1/7/2014 2:32 PM 76,157 TrPL st.out 12/19/2013 9:19 PM 2,588,831 TrPL th.out 1/7/2014 3:25 PM 74,507 TrPU st.out 12/19/2013 9:47 PM 2,591,589 TrPU th.out 1/7/2014 4:31 PM 79,357 TrRT st.out 12/19/2013 10:26 PM 2,606,645 Tr RT th.out 2/18/2014 1:02 PM 22,445 vml61_1.out 2/18/2014 1:12 PM 22,445 vml61_2.out 2/18/2014 1:06 PM 256,563 vm2ll1l.out 2/18/2014 1:14 PM 256,563 vm2112.out 2/18/2014 1:02 PM 18,898 vm246_l.out 2/18/2014 1:12 PM 18,898 vm246_2.out 2/18/2014 1:02 PM 24,598 vm96_1.out 2/18/2014 1:12 PM 24,598 vm96_2.out 2/25/14 12:49 PM 32,430 SIR I_H EADTOTcrev.out 2/25/14 12:49 PM 16,824 SIR I_H EADTOTcrev.txt 2/25/14 1:10 PM 32,446 SIR2 HEAD TOT crev.out 2/25/14 1:10 PM 17,143 SI R2_H EADTOTcrev.txt 2/25/14 1:31 PM 32,483 Sl R3_H EADTOTcrev. out 2/25/14 1:31 PM 17,143 SIR3_H EADTOTcrev.txt 2/25/14 1:51 PM 32,422 SIR4_H EADTOTcrev.out 2/25/14 1:51 PM 16,824 Sl R4_H EADTOTcrev.txt 1/16/2014 5:04 PM 591,990 RemNozHF.out 1/16/2014 5:29 PM 593,465 RemNozOBE.out 1/16/2014 6:19 PM 592,005 RemNozPPE.out Enclosure Attachment 4 Page 28

A ARE VA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Date Time Size (Bytes) FileName 1/16/2014 5:53 PM 593,100 RemNozSSE.out 1/16/2014 6:47 PM 591,983 RemNozWN.out Files listed in Table 5-2 have been uploaded to the following directory: "\cold\General-Access\32\32-9000000\32-9215084-000\official\AppDFractureMech".

Table 5-2: Computer Files - Fracture Mechanics Files Date Time Size (Bytes) FileName 1/23/2014 5:55 PM 32,670 CDlow_m b_sum.dat 1/23/2014 5:55 PM 68,763 CDIow path_12.dat 1/24/2014 7:45 AM 32,670 CDupmbsum.dat 1/24/2014 7:45 AM 68,763 CDuppath_12.dat 1/28/2014 9:58 AM 716,281 Design.sav 1/24/2014 1:38 PM 3,334 extractstress.mac 1/28/2014 9:57 AM 3,312 extractstressDES.mac 1/24/2014 2:04 PM 3,316 extractstressLEAK.mac 1/29/2014 9:03 AM 3,507 extract stressNOZ.mac 1/28/2014 9:58 AM 19,678 getdeshoopstress_SectXI.out 1/24/2014 2:16 PM 119,830 get hoopstress_SectXi.out 1/29/2014 2:14 PM 67,314 getNOZ hoop_stress_SectXl.out 2/18/2014 3:15 PM 19,687 getNVAR_hoopstressSectXl.out 2/20/2014 5:40 PM 30,378 get SL hoopstress_SectXI.out 1/23/2014 5:38 PM 32,670 HUlowmbsum.dat 1/23/2014 5:38 PM 68,763 HUlow path_12.dat 1/23/2014 5:29 PM 32,670 HUupmb-sum.dat 1/23/2014 5:29 PM 68,763 HUuppath_12.dat 1/23/2014 6:28 PM 1,815 LEAKmbsum.dat 1/23/2014 6:28 PM 3,942 LEAK path_12.dat 1/23/2014 5:15 PM 2,195 linearize.mac 1/21/2014 8:23 AM 261 Ioc_data.inp 1/23/2014 6:28 PM 59,895 LSP mb sum.dat 1/23/2014 6:28 PM 125,958 LSPpath 12.dat 2/18/2014 10:40 AM 19,965 NVAR mb sum.dat 2/18/2014 10:40 AM 42,072 NVARpath_12.dat 1/23/2014 5:55 PM 214,880 path_resultsCDlow.out 1/24/2014 7:45 AM 214,869 path_resultsCDup.out 1/23/2014 5:38 PM 214,880 path results HUlow.out 1/23/2014 5:29 PM 214,869 pathresultsHUup.out 1/23/2014 6:28 PM 36,573 path results LEAK.out 1/23/2014 6:28 PM 372,182 pathresultsLSP.out Enclosure Attachment 4 Page 29

A AREVA Document No. 32-9220625-000 ASME Section III End of Life.Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 2/18/2014 10:40 AM 140,501 path_resultsNVAR.out 1/23/2014 6:00 PM 151,923 path_resultsPL.out 1/23/2014 6:05 PM 141,435 path_resultsPU.out 1/23/2014 6:12 PM 172,899 path_resultsRT.out 1/23/2014 6:00 PM 21,780 PL mb sum.dat 1/23/2014 6:00 PM 45,885 PL-path_12.dat 1/23/2014 6:05 PM 19,965 PU mb sum.dat 1/23/2014 6:05 PM 42,072 PUpath_12.dat 1/29/2014 2:12 PM 935,086 RemNozHF.sav 1/29/2014 2:13 PM 935,299 RemNozOBE.sav 1/29/2014 2:13 PM 935,086 RemNoz PPE.sav 1/29/2014 2:13 PM 935,299 RemNozSSE.sav 1/29/2014 2:14 PM 935,086 RemNoz WN.sav 1/23/2014 6:12 PM 25,410 RT mb sum.dat 1/23/2014 6:12 PM 53,511 RTpath_12.dat 3/7/2014 2:00 PM 1,547 SLDecCLtrTable.mac 3/7/2014 2:21 PM 19,893 SLDecCLTs.txt 3/11/2014 12:14 PM 1,394 SLIncCLtrTable.mac 3/7/2014 1:38 PM 15,909 SLIncCLTs.txt 1/24/2014 2:10 PM 4,438,661 TrCDlowst.sav 1/24/2014 2:08 PM 4,437,765 Tr_CDupst.sav 1/24/2014 2:07 PM 4,438,917 TrHUlowst.sav 1/24/2014 2:06 PM 4,437,893 TrHUupst.sav 1/24/2014 2:16 PM 716,282 TrLEAKst.sav 1/24/2014 2:14 PM 7,724,180 TrLSPst.sav 2/18/2014 3:15 PM 2,907,966 TrNVARst.sav 1/24/2014 2:10 PM 3,125,439 TrPL st.sav 1/24/2014 2:11 PM 2,906,750 TrPU st.sav 1/24/2014 2:12 PM 3,563,649 TrRT st.sav 3/7/2014 3:40 PM 74,866 Tr_SLDecCL_st.out 3/7/2014 3:47 PM 2,906,252 Tr_SLDecCL_st.sav 3/7/2014 2:21 PM 2,575,588 TrSLDecCL th.out 3/7/2014 3:02 PM 76,482 TrSLIncCLst.out 3/7/2014 3:46 PM 3,124,493 TrSLIncCLst.sav 3/7/2014 1:38 PM 2,568,958 TrSLIncCLth.out Enclosure Attachment 4 Page 30

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 6.0 CALCULATIONS 6.1 Design Condition Design conditions are simulated in the model by applying a uniform temperature and reference temperature of

[ ] throughout the model (no thermal growth) and uniform pressure of [ I on inside surfaces of the model. Note that the temperature is used to evaluate the material properties at the design temperature and no thermal loads are present in the model. In addition, an equivalent end cap pressure, Pcap = P*t2/(Ro2-_R2), is applied on the replacement nozzle cut-off cross-section, where P is the internal pressure, R is the inside radius and Ro is the outside radius of the modeled nozzle cut-off cross-section.

Stress analysis of the model under the design pressure provides a basis for verification of the correct behavior of the model (deformations, spherical head stresses, cylindrical nozzle stresses away from discontinuities), and verifies attenuation of stress effects at regions distant from the nozzle.

The ANSYS outputs for the Design conditions are documented in the file "Design.out."

Figure 6-1 presents the total displacement (with a geometric scaling factor of 40). The stress intensity contours

-developed in the model under the Design Condition case are presented in Figure 6-2.

Figure 6-1: Total Displacement for Design Conditions Enclosure Attachment 4 Page 31

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of. PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Figure 6-2: Stress Intensity for Design Conditions 6.2 Thermal Analysis The thermal analyses apply HTC's and bulk temperatures (with respect to time) to determine the temperature distribution within the model. As stated in Section 4.4.1.1, the bulk fluid temperatures correspond to the RV Inlet temperature and HTC's for the internal vessel and nozzle surfaces are calculated based on fluid conditions present in the vicinity of Nozzle #3. Calculation of these HTC's is presented in Appendix A.

The results of the thermal analyses are evaluated to identify the maximum and minimum temperature gradients between critical locations in the model and the corresponding time points. These temperature gradients generate maximum and minimum thermal stresses, which in turn contribute to the maximum range of stress intensities in the model. The node numbers for the various nodes of interest are listed in Table 6-1. Node pairs used for the evaluation of temperature gradients are shown graphically in Figure 6-3.

The corresponding ANSYS output files are listed in Table 5-1 with the filename convention of"* th.out" for the thermal output file and "* Ts.txt" for the nodal temperature output file. The "*" represents the abbreviation for the specific transient of interest (See Table 4-5). Transient input files follow a similar naming convention of

"*_trTable.mac" and include the temperature and internal pressure as a function of time.

4 Page 32 Attachment 4 Enclosure Attachment Page 32

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 6-1: Nodes of Interest for Evaluation of Temperature Gradients Node Location Designation Node No. Global X,Y,Z Location Description A 1570 Repair Weld B 17680 Replacement Nozzle Wall at Repair Weld C 22867 RVBH at Repair Weld D 46213 [ Replacement Nozzle Wall above Repair Weld E 44055 1 Replacement Nozzle Wall below Repair Weld F 16928 . Replacement Nozzle ID at Crevice G 6211 [ Repair Weld Crevice H 50296 [ RVBH ID I 53750 RVBH mid-thickness J 53743 RVBH OD L 19413 Boat Sample Surface M 19398 Remnant Nozzle ID near Sample N 16412 ] Boat Sample Bottom Surface 0 6367 [ Existing Weld Crevice at Boat Sample P 10030 [ Existing Weld Q 20241 Remnant Nozzle at Existing Weld R 27047 RVBH at Existing Weld S 45084 Remnant Nozzle Wall below Existing Weld T 19494 [ Remnant Nozzle Wall above Existing Weld U 16856 [ Existing Weld Crevice (downhill)

V 19836 C 1 Existing Nozzle ID at Crevice Enclosure Attachment 4 Page 33

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

-a Figure 6-3: Node Pairs for Evaluation of Temperature Gradient The temperatures of selected nodes, as well as the temperature gradients between node pairs as a function of time, are shown in figures listed in Appendix C. These figures are provided to show the trend and for visual aid only.

Specific values and time points are taken directly from the ANSYS nodal temperature output files identified previously.

6.3 Stress Analysis The nodal solution of the thermal analysis is loaded into the structural analysis within ANSYS. Time points selected from the thermal analysis include those with max/min temperature gradients as well as those where the internal pressure changes in linear interpolations. These time points are tabulated below. Internal pressure is added at each time point as the mechanical load.

The corresponding ANSYS output files are listed in Table 5-1 with the filename convention of"* st.out" for the structural output file. The "*" represents the abbreviation for the specific transient of interest (See Table 4-5).

Transient input files (*_trTable.mac) include the internal pressure as a function of time.

Enclosure Attachment 4 Page 34

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 6-2: Time Points in Structural Analysis Time, sec Index lHUup/low CDup/low PL PU RT LSP NVAR LEAK 3 rI1LJLI l 8 [ f3

[ 11 ] fr[

10 4] )fjfi [~ )[~ )[ ) [ )[)~

12 ] [ )) ] [J )11111 ) (( i A) 13f [ [J ) [ [ )[f )) iJ f[)

15 [)[j f I I L ] []-

16 [ )] 101 [ [1)) _ [ ) [ )J ((L ) [)

17 [f1 [)i [1L [L [l W [1 30I I L L f -WlL L 312LIL

[]

1fL-WliL f 20 132LIf1-Wf1--WLILA- [] W] []T] T h[) [ f 21 [) [)J (()T Th [r W [)

14L 22 [j)-fJL 4[)h[LLLL iT]h .. W [)i L

[)-

23 [J)II L Th

[h [) [ )1 L[)

25 L I W 1 fi Th [1W [1--

27 [j _[J [1]1 1 []L []3 29 [j , []l [1 ffL W] fr LL[ []

Enclosure Attachment 4 Page 35

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 6.4 External Nozzle Loads 6.4.1 Repair Nozzle Stresses in the repair nozzle are calculated according to the loads presented in Section 4.3.3.1. The replacement nozzle at the attachment weld vicinity has an ID of [ ] and OD of [ ] , see Section 4.1. The geometric properties of the cross-section are listed in Table 6-3, with D as the outside diameter, d as the inside diameter, I as the area moment of inertia, A as the area of cross-section, and r as the radius of the inside/outside surfaces.

Table 6-3: Repair Nozzle Section Properties D d I A ro r, 4 2 in in in in in in External loads listed in Table 4-15 have been combined consistent with the original RV Stress Report [ 18] as shown in Table 4-16 to calculate the stress intensity (SI) at the inside and outside surfaces of the nozzle. By the following equations, the axial stresses, shear stresses and stress intensities at the inside and outside surfaces are then calculated and tabulated in Table 6-4.

(r)=-FT + rxMB A I (1)

FV r(r) = F-" (2)

A SI::=(72 +41- 2 (3)

Table 6-4: Stress Intensity at Nozzle Cross-Section due to External Loads Tension Shear Bending Load (lbs) (lbs) Moment Inside, ksi Outside ksi Combination (in-lbs)

FT Fv MB U T SI a T SI Design JiI, W UL IL LI Normal l fJLLIL LIL LIL Upset (1) (Leak) (( ]ij(( L [ L L ]

Upset (2) (OBE) j LI L A I I L [ LI L Emergency [11 _,J , A I Faulted i [LL ]

Enclosure Attachment 4 Page 36

A AREVA Document No. 32-9220625-000 ASME .Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 6.4.2 Remnant Nozzle The remnant nozzle loads identified in Section 4.3.3.2 are applied in the FEA model to accurately account for stresses in the existing/remnant J-groove weld. Remnant nozzle loads contained in the original RV Stress Report

[ 18] are bounding for the collection of BMI Nozzles on the lower head. These loads are re-calculated for the conditions specific to Nozzle #3 in Appendix B of this document. In the original RV Stress Report the remnant nozzle is qualified using hand calculations, and therefore both the force and resultant moment (force times half nozzle height) at the welded connection are calculated and used for the evaluation. This resulting bending moment is accounted for in the FEA Model by applying the calculated load at half of the nozzle exposed height.

The loads calculated in Appendix B represent the full resultant load applied to the nozzle. The FEA model takes advantage of symmetry and includes only 1800 of the nozzle/welded connection, and therefore, the loads calculated in Appendix B are divided in half prior to application to the 180' 3-D FEA model. In addition, all horizontal/shear loads are applied in the +/- radial direction as this is judged to be the critical direction due to the presence of the boat sample in weakening the nozzle/weld section properties about this axis.

The remnant nozzle files follow the naming convention of"RemNoz_*.out" where the "*" represents the individual load case considered.

The remnant nozzle and existing J-groove weld no longer serve as the pressure boundary component, and therefore, comparison of the remnant nozzle stresses and attachment weld stresses to ASME Code criteria is not required herein. In addition, it can be observed from Figure 6-4 that the application of the largest remnant nozzle load (white noise) results in negligible stresses in the RVBH and repair nozzle. Therefore, results of these remnant nozzle load analyses are not considered for this analysis. Stresses produced by the remnant nozzle loads are trr nitted for the ASME Section XI Flaw Analysis as documented in Appendix D.

Figure 6-4: Stress Intensity due to White Noise Remnant Nozzle Load Enclosure Attachment 4 Page 37

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 7.0 ASME CODE CRITERIA The ASME Code qualification involves two basic sets of criteria:

1) Assure that failure does not occur due to application of the design loads.

2) Assure that failure does not occur due to repetitive loadings.

In general, the primary stress intensity criteria of the ASME Code [2] assure that the failure does not occur at the application of pressure and mechanical loads for all loading conditions. The ASME Code criteria for cumulative fatigue usage factor assure that the design is adequate for repetitive loadings.

Stress classification path lines at various cross-sections are defined in order to evaluate the primary and primary plus secondary stress intensity ranges, as well as the fatigue usage factors. Figure 7-1 illustrates those paths defined for the reactor vessel bottom head, and Figure 7-2 for paths on the repair nozzle and associated J-groove weld with arrowheads pointing from the inside node to the outside node. The corresponding node numbers for

_each path are listed in Table 7-1.

Figure 7-1: Path Lines on Reactor Vessel Bottom head Page 38 Enclosure Attachment 4 Enclosure Attachment 4 Page 38

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Figure 7-2: Path Lines for Replacement Nozzle and Repair Weld Table 7-1: Node Numbers of Defined Path Lines RVBH Replacement Nozzle Repair Weld Path Node I Node 0 Path Node I Node 0 Path Node I Node 0 HDPathl 50251 53534 NZPathl 16928 6211 WDPathl 30868 4739 HDPath2 383544 53003 NZPath2 17070 6257 WDPath2 6211 4739 HDPath3 22121 26522 NZPath3 19036 6256 WDPath3 6211 6257 HDPath4 24233 39500 NZPath4 17082 6302 WDPath4 40412 4829 HDPath5 373695 51815 NZPath5 44427 43161 WDPath5 6256 4829 HDPath6 29466 26427 NZPath6 17211 16980 WDPath6 6256 6302 Enclosure Attachment 4 Page 39

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 7.1 ASME Code Primary Stress Intensity (SI) Criteria Per NB-3213.8 [2], the primary stresses are those normal or shear stresses developed by an imposed loading such as internal pressure or external loadings. Thermal stresses are not classified as primary stresses. The classification, as well as the limit of any primary stress intensity, is specified in NB-3221 [2] for the Design Condition. The limit of primary stress intensity for Level A (Normal), Level B (Upset), Level C (Emergency), Level D (Faulted) and Testing is specified in NB-3222, NB-3223, NB-3224, NB-3225 and NB-3226 [2], respectively.

The stress intensities (membrane, membrane + bending) along the defined path lines in the Design Condition are documented in ANSYS output files "Design_(*)_SIRs.out,." where (*) may be "HEAD," "NOZ," or "WELD."

The Design Condition pressure bounds that of the Normal, Emergency, and Faulted conditions at all points contained in the associated transient curves. The maximum pressure associated with the Upset Condition is

[ ] (as compared to Design Pressure of [ ] ) during the Reactor Trip/Loss of Flow/Loss of Load Transient. This represents an increase in pressure of [ ] . However, per NB-3223(a)(1), the Upset/Level B Service Limit for primary stresses is 10% greater than the corresponding Stress Limits for the Design Condition. Therefore, neglecting the effects of external nozzle loads which are discussed below, the Upset pressure relative the Upset allowable stress is bounded by the Design pressure relative to the Design allowable stress.

Although the Design Pressure bounds the pressures associated with the Normal, Upset, Emergency, and Faulted conditions as demonstrated above, the external loads applied to the repair nozzle for the Design Condition are exceeded by those associated with each of the listed conditions. Therefore, the bounding external loads are applied to the repair nozzle (Faulted) in combination with the Design Condition case, to determine a singular bounding case. Primary stresses from the Design Condition, in conjunction with Faulted nozzle loads, will be compared to the Design Condition stress limits.

7.1.1 Primary Stress Intensity for Design, Level A, B, C, and D Conditions NB-322 1.1 - General Primar Membrane Stress (P_ < L.0S_m)

The applicable value of general primary membrane stress occurs remote from discontinuities and includes no local effect. For the RVBH, path 'HDPathl' depicts an appropriate location for the RVBH. The general primary membrane stress intensity of'HDPathl' is [ ] , less than Sm = 26.7 ksi at [ ].

For the replacement nozzle, path 'NZPath5' is an appropriate location to evaluation the general primary membrane stress. The membrane stress intensity is [ ] . With the contribution from external loads (see Table 6-4) of [ , the total SI is [ ] less than Sm = 23.3 ksi at I I1-NB-3221.2 - Local Primary Membrane Stress (P, < 1.5Sd The applicable value occurs across any solid section, considering discontinuities but not stress concentrations.

For the RVBH among all paths appropriate for extracting local primary stresses in the head, the highest local membrane stress intensity occurs along path 'HDPath3'. The local primary membrane stress intensity at

'HDPath3' is [ ], less than 1.5S,, =40.05 ksi at [ ].

For the replacement nozzle, the highest local membrane stress intensity occurs along path 'NZPathl'. The local primary membrane stress intensity at 'NZPathl' is [ ] . With the contribution from external loads (see Table 6-4) of [ ],the total SI is [ ], less than 1.5Si 34.95 ksi at [ 1.

Enclosure Attachment 4 Page 40

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

For the repair weld, the highest local membrane stress intensity occurs along path 'WDPath 1'. The local primary membrane stress intensity at 'WDPathl' is [ ] With the contribution from external loads (see Table 6-4) of [ ], the total SI is [ ] less than 1.5Sm = 34.95 ksi at [ ]

NB-3221.3 - Primary Membrane plus Primary Bending Stress (P, + Ptb < 1.5Sm)

For the RVBH, the maximum membrane plus bending stresses intensity occurs at the inside node of path

'HDPath4',. and is equal to I ] , less than 1.5Sm = 40.05 ksi at [ ]. Note that HDPath3 and HDPath4 are located in close proximity to the head bore, and consequently the linearized stresses include the effects of the stress concentration at the bore (SCF of 2 for a hole in a plate subjected to biaxial stress). Inclusion of the stress concentration is not required by Code, but is conservatively included here. By comparison, the membrane plus bending stresses along HDPaths 1, 2, 5, and 6 (away from the bore) are all less than [ ]

For the replacement nozzle, the highest membrane plus bending stress intensity occurs at the outside node of path

'NZPath3' and is equal to I ] . Conservatively considering the contribution from external loads (see Table 6-4) of [ , the total SI is [ ], less than 1.5Sm = 34.95 ksi at I I.

For the repair weld, the highest membrane plus bending stress intensity occurs at the inside node of path

'WDPath 1' and is equal to 20.64 ksi. Conservatively considering the contribution from external loads (see Table 6-4) of [ ], the total SI is [ ], less than 1.5Sm = 34.95 ksi at [ ].

As stated previously, the maximum pressures which are experienced during the Emergency and Faulted Conditions are less than the design pressure. In addition, the [ ] increase in maximum pressure for the Upset Condition is covered by the 10% increase in stress limits as specified in NB-3223 [2]. In addition, stress intensities presented above for the half-nozzle repair components (replacement nozzle and repair weld) conservatively include the additional stress intensity due to Faulted nozzle loads, while comparing to Design Condition stress limits.

Enclosure Attachment 4 Page 41

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 7.1.2 Primary Stress Intensity for Test Condition per NB-3226 As noted in Table 4-5, there are two Test Conditions. These transients result in a maximum pressure 1.25*Design Pressure, or [ I occurring within a temperature ranging from [ ] . Therefore, the pressure-induced primary stresses are greater than the design condition. The stresses due to the Test Condition are calculated by ratio of the design condition based on the pressure and elastic modulus. In order to bound the temperature range given, the cold modulus (Ej)is taken at [ ] to maximize the factor below, while the yield stress is taken at [ ] to minimize the allowable stress. The allowable stress for 'membrane plus bending' is conservatively taken as 1.35Sy, rather than (2.15 Sy - 1.2Pm) as allowed by NB-3226(c) for 0.67Sm <

Pm < 0.9Sy.

For the RVBH: _

For the Repair Nozzle/Weld:I Design Stress

[ksi]

Test Stress

[ksi]

]

Test Allowable Stress

@400*F [ksi]

General Membrane 0.9Sy = 25.7 Membrane plus Bending [J ] 1.35Sy =38.6 Enclosure Attachment 4 Page 42

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 7.1.3 Partial Penetration Weld Size The repair configuration includes a partial penetration welded connection - Replacement Nozzle to Weld Pad.

The required geometry of this weld is specified in paragraph 3352.4(d) [2] and Figure 4244(d)-i [2].

The nominal thickness of the penetrating part (nozzle) is:

tn=(D- d)/2=[]

The required and actual weld dimensions are listed below. Actual dimensions are taken from Reference [4] and presented in Figure 7-3 for convenience. All required dimensions are met.

Depth of weld attachment along the nozzle is 1 V2 t.

Depth of J-groove Weld is 3/4 tn Required 1.75 in < Actual Required 0.87 in < Actual

[

[

j Fillet Weld Leg dimension is 3/4 tn Required 0.87 in < Actual Required 0.25 in < Actual I

Thickness of the weld in the perpendicular direction t

• Calculated based on triangular geometry asI I

Figure 7-3: Partial Penetration Weld Dimensions Analyses contained within this document show that all Code stress requirements are met for the BMI Nozzle Repair, and therefore, formal evaluation of the required reinforcement at the opening is not required as allowed by Item NB-3331(c) [2].

Enclosure Attachment 4 Page 43

A AR EVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 7.1.4 Pure Shear in the Repair Weld Per NB-3227.2 [2], pure shear stress in the weld due to axial loading, FA, and pressure, P, shown in Table 4-16 shall be limited to 0.6Sm. The shear area is calculated as:

As = 27rat Where: t= [ ] minimum required weld throat a= [ ] nozzle outside radius The maximum shear stress is calculated as:

2 FA + P~ra max - As Where: FA = [ ] maximum axial force at nozzle/shell interface - Faulted Loads P [ ] maximum pressure experienced during all transients - Upset Pressure

[ )

The maximum pure shear stress in the repair weld remains below 0 .6Sm (13.98 ksi), and therefore, the pure shear stress criterion is met for the repair welds. The considered loading is bounding for the Normal, Upset, Emergency, and Faulted conditions.

7.2 Primary plus Secondary Stress Intensity Range The evaluation of stresses for transient conditions is required to satisfy the criteria for the primary plus secondary (P+Q) SI range and repetitive loadings. The following discussion describes the primary + secondary SI range evaluation and fatigue analysis process employed herein for the repair design.

Overall stress levels are reviewed and assessed to determine which locations require detailed stress/fatigue analysis. The objective is to assure that:

1) The most severely stressed locations affected by the implementation of the repair are evaluated.

2) The specified region is quantitatively qualified.

Once the specific locations for detailed stress evaluation are established, the ANSYS path lines are defined as shown in Figure 7-1 and Figure 7-2. A post-processing routine is conducted to convert the component stresses along the selected path lines into the SI categories (i.e., membrane, membrane + bending, total) and determine SI ranges between extreme transient time points, as well as perform fatigue calculations.

There are two sets of Heatup (HUup and HUlow) and Cooldown (CDup and CDlow) pressure transients, each representing an upper and lower bound pressure curve for the respective transient. Note that the transient inlet temperature is represented by a single curve for the Heatup and a single curve for the Cooldown. The four permutations of the Heatup and Cooldown curves are all evaluated to determine which combination results in the Enclosure Attachment 4 Page 44

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV. BMI Nozzle Repair (Non-Proprietary) highest stress intensity range and cumulative fatigue usage factor (CFUF) as reported on the following pages.

The filename convention is provided below, where "_MB" for M+B SI and "-TOT" for Total SI.

Combination RVBH Repair Weld Replacement Nozzle HUup - CDup SIRIHEAD_MB.out/txt SIRIWELDMB.out/txt SIRINOZMB.out/txt SIRI HEAD TOT.out/txt SIRI WELD TOT.out/txt SIRI NOZ TOT.out/txt HUlow - CDIow SIR2 HEADMB.outltxt SIR2 WELD MB.out/txt SIR2 NOZ MB.out/txt SIR2 HEAD TOT.out/txt SIR2 WELD TOT.out/txt SIR2 NOZ TOT.out/txt HUup - CDlow SIR3_HEAD_MB.out/txt SIR3_WELDMB.out/txt SIR3_NOZMB.out/txt SIR3 HEAD TOT.out/txt SIR3 WELD TOT.out/txt SIR3 NOZ TOT.out/txt HUlow - CDup SIR4_HEADMB.out/txt SIR4_WELDMB.out/txt SIR4_NOZMB.out/txt SIR4 HEAD TOT.out/txt SIR4 WELD TOT.out/txt SIR4 NOZ TOT.out/txt The maximum P+Q membrane plus bending SI ranges for each component are summarized in Table 7-2.

Table 7-2: P+Q Membrane plus Bending SI Ranges SI range, ksi SI range"', ksi SI range 2 ', ksi Inside Outside Inside Outside Inside Outside HDPath 1 ] WDPath 1I[ ] NZPath 1 j- ]

HDPath2 [ ] (( WDPath2 [ ] J NZPath2 [

HDPath3 [ [ WDPath3 [ ][ [ NZPath3 1 .L[..

HDPath4 [ [ WDPath4 [ NZPath4 [ ] .L.[.]

HDPath5 [ ] WDPath5 [ j J NZPath5 [ l i HDPath6 L 80] 1 WDPath6 [ .1 1 NZPath6 [ ]i [ .

Head 3S= 80.1 ksi@ Repair weld 3Sm 69.9 ksi@ Nozzle 3Sm = 69.9 ksi@

Notes:

1. SI Ranges at all weld path locations (inside and outside path nodes) include the SI contribution at the OD of the nozzle of I ] due to Upset Conditions (See Table 6-4).

2. SI Ranges at the inside nodes of the Nozzle Paths include the SI contribution at the ID of the nozzle of

[ ] due to Upset Conditions, and SI Ranges at the outside nodes of the Nozzle Paths include the SI contribution at the OD of the nozzle of I ] due to Upset Conditions (See Table 6-4).

Enclosure Attachment 4 Page 45

A Document No. 32-9220625-000 ARE VA ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 7.3 Fatigue Usage Factor Criteria For consideration of the cumulative fatigue usage, the Peak Stress Intensity Ranges are calculated. These values must include the 'total' localized stresses. A conservative maximum Fatigue Strength Reduction Factor (FSRF) of [ ] is used at all locations unless further investigation is required.

The geometry of the original and the repaired design results in a crevice-like configuration between the BMI nozzle OD and the penetration bore diameter which terminates at the repair weld. Therefore, the linearized

'membrane + bending' stress intensity range at the weld location is multiplied by a FSRF of [ J as required by NB-3352.4(d) [2] to represent the Peak Stress Intensity Range at the crevice. A FSRF of [ ] is conservatively used for all fatigue locations chosen in the repair weld and replacement nozzle, rather than only the locations at the crevice.

The geometry of the repair weld pad can produce peak stresses at the outside nodes of Head Paths 2 and 5 (Figure 7-1). Therefore, an FSRF of [ ] is used at these two specific fatigue locations to account for the additional peak stress due to the geometric discontinuity caused by the presence of the weld pad. In addition, corrosion in the RVBH penetration bore could result in irregular contours which will increase the peak stresses. The model used for analysis may not depict all of the potential peak stresses for the fatigue analysis. Therefore, to account for the potential effect of these considerations, all remaining fatigue locations in the head are conservatively multiplied by an FSRF of [ ] , although a smaller FSRF could reasonably be applied to some of the locations. Note that the resulting values are confirmed to be greater than the 'total' stress intensities calculated directly from the model.

Head Paths HDPath3 and HDPath4 are both defined 1-2 elements away from the bore inside surface to evaluate the local P+Q M+B stress intensity ranges. In order to calculate the fatigue usage factors for the head on the nearby surface locations at the junction between the head and the original J-groove weld buttering (see Figure 7-4 nodes "3a" and "4a") or between the head and the repair weld pad (see Figure 7-4 nodes "3b" and "4b"), an FSRF of [ ] is applied to the M+B SI ranges obtained from these two path lines. Locations "3a", "3W', "4a" and "4b are located at the free surface of the head bore, at the interface of the head and remnant/repair weld. At the ID of the RVBH the buttering provides a separation between locations "3a"/"4a" and the crevice tip, while at the OD of the RVBH the weld pad provides a separation between locations "3b"/"4b"and the crevice tip. Therefore, none of these 4 points are located at a crevice tip. Use of the linearized stresses along HDPath3 and HDPath4 with an FSRF of [ I results in higher fatigue usage factors as compared to the usage factors obtained directly by the "Total" stresses at these four surface locations ("3a", "3b", "4a" and "4b). Therefore results from the M+B stresses of the two path lines with an FSRF of [ I are kept herein. These 'Total' Stress results at the penetration bore surface locations are contained in the computer files titled 'SIRHEADTOTcrev.out/txt'.

The relative locations of the crevice tip, 'Total' stress point at the penetration bore, and path end nodes for HDPath3 and HDPath 4 are shown in Figure 7-4.

Page 46 Attachment 4 Enclosure Attachment 4 Page 46

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Figure 7-4: Fatigue Locations Investigated for HDPath3 and HDPath4 Page 47 Enclosure Attachment 4 Enclosure Attachment 4 Page 47

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 7-3: FSRF/SCF and Stress Category in Fatigue Evaluation Path Inside Node Outside Node FSRF SCF Stress FSRF SCF Stress HDPathlI [ ] [ M+B [ ] [ ] M+B HDPath2 [ ] [ ] M+B [ ] [ ] M+B HDPath3 [ ] [ I M+B [ ] [ ] M+B HDPath4 [ ] [ ] M+B [ 1 [ I M+B HDPath5 [ ] [ ] M+B [ ] [ ] M+B HDPath6 [ ] [ ] M+B [ ] C ] M+B WDPathl [ ] C ] M+B C I [ J M+B WDPath2 [ ] C I M+B [ ] [ I M+B WDPath3 [ ] C ] M+B [ ] C ] M+B WDPath4 [ ] [ ] M+B [ ] C ] M+B WDPath5 [ ] C I M+B [ ] C I M+B WDPath6 [ ] [ I M+B [ ] [ ] M+B NZPathlI [ C ] M+B [ ] C ] M+B NZPath2 [ I C I M+B [ ] C ] M+B NZPath3 [ ] C I M+B [ ] [ I M+B NZPath4 [ ] C ] M+B [ ] C I M+B NZPath5 [ ] [ ] M+B [ I C I M+B NZPath6 [ I C I M+B C I C I M+B Page 48 Enclosure Attachment 4 Enclosure Attachment 4 Page 48

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

The ANSYS fatigue module is used to calculate the total stress intensity ranges based on the method prescribed in paragraph NB-3216.2 of the ASME Code at each node of selected path lines for all transients. The ANSYS output files are listed in Section 6.2 with filenames " MB.out" for using the M+B stresses in conjunction with the FSRF's tabulated above, and " TOT.out" for comparing the Total stresses in the fatigue usage calculation. The CFUF's summarized in Table 7-4 do not include contributions of external loads in order to determine the controlling CFUF for each component. Once the controlling CFUF is determined, the external loads on the nozzle and repair weld are accounted for in the detailed calculations presented in Tables 7-6 and 7-7. External nozzle loads have a negligible effect on the CFUF for the RVBH.

Table 7-4: Cumulative Fatigue Usage Factors CFIJF CFUF CFUF Path Path Path Inside Outside Inside Outside Inside Outside HDPath 1 I [1[ ] WDPathI1 j [ L[ J] NZPath I] [ [ ]

HDPath2 L [ WDPath2 [ ] [ 1 NZPath2 ] L[ ]

HDPath3 j[ j j WDPath3 L ((L 1 NZPath3 (( ] L[ ]

HDPath4 jJ [ ] WDPath4 [ ]l I ] NZPath4

[ ] [ NZPath5 9HDPath5 1[ ](( ] WDPath5 HD;ah6 ((

[ý 1 1 I ,I IDah I , NZPath6 (1). See detailed calculation in Table 7-5.

(2). See detailed calculation in Table 7-6. Detailed calculation accounts for external nozzle loads.

(3). See detailed calculation in Table 7-7. Detailed calculation accounts for external nozzle loads.

Detailed calculations are presented in Tables 7-5, 7-6, and 7-7 for the RV bottom head, repair weld, and replacement nozzle, respectively. In these tables, the following conventions apply:

• 'Req'd Cycles' represents the full number of cycles for the 60 year life of the plant (see Table 4-5).

" 'M+B SI Range' represents the extreme M+B SI Range between two load steps, including the SI range due to external nozzle loads where applicable.

o The contribution of the external nozzle loads is accounted for by directly adding the maximum SI at the OD of the nozzle due to Upset conditions ( [ ] ) to the first [ ]

cycles of the controlling S1 Range as shown in Table 6-4 to account for [ ] cycles of OBE loading and [ ] cycles of leak thermal loading.

• 'Peak SI Range'= [M+B SI Range]*Ke*FSRF*SCF

" 'Sa' = ([Peak SI Range]*E_ratio)/2, where Eratio = E_curve/Ematerial and E£material is conservatively taken at the Design Temperature of [ ] for all cases.

• ASME Fatigue Curves are taken from Appendix I of [2].

o Figure 1-9.1 is used for the RVBH

" Figures 1-9.2.1 and 1-9.2.2 are used for the Replacement Nozzle and Repair Weld Enclosure Attachment 4 Page 49

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 7-5: Bottom Head Usage Factor Material = [ ]

Location = HDPath5 Outside Node ANSY output SIRIHEADMB.out/txt FSRF[=

SCF =[

E ratio fi No Transient Req'd M+B SI e Peak SI S., ksi Allowable UF Extreme Cycles range, ksi range, ksi "N"

,1 Uup - HUup L 2 CDup - RI fL1 1L f iL f1 I 3CDup - NVAR 4j [ ]L LI [ L.L. L 4NVAR-NVAR J I [IIi I fr L I 5 PL -LEAK Jfi J LIiLI iL I 7

6 PU-PU PL -PU 11 ((

1 L ] 11 11 [FF] LI

[ ] [ ] [

CFUF =

Table 7-6: Repair Weld Usage Factor Material = I Location = WDPath 1 Inside Node ANSY output = SIR3_WELD_MB.out/txt FSRF=[ J SCF=

E-ratio = I I Transient Req'd M+B SI Peak SI Allowable No Extreme Cles yces range, ksi Ke range, ksi Sa, ksi N" UF I {Uup - CDIow LI L L L 2 1HFuup - CDlow LiL LI11 I LL L 3 RT-RT [ L[ Li I [ l LI il 4 NVAR- NVAR J ] L II +/- 1 1 5 PU-LEAK fi ff[ LIII L1 l L 111 6 PL-PU I ] [ ][ L1 1 7 PL-PL [ f1 LI LA ] 111111 CFUF=

1. Contains SI contribution due to [ I cycles of OBE loading and [ ] cycles of Leak Thermal loading on the repair nozzle, see Section 6.4.1.

Page 50 Enclosure Attachment 4 4 Page 50

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary)

Table 7-7: Repair Nozzle Usage Factor Material= [I Location = NZPath3 Outside Node ANSY output = SIR3_NOZMB.out/txt FSRF =[

SCF =

E-ratio =j No Transient Req'd M+B SI Peak SI Allowable Extreme Cycles range, Ke range Sa, ksi "N"UF ksi ksi "N" IHUup - CDlow0) . . I L L L L 2 HUup-CDIow [ ] [ ] [I[ ] (( 1 3RT -RT frL II 1LIEiL 4- NVAR -NVARfj fJL L1I iL L I 5 PL-PU [ LJ LI ][ U 1 1 1 1 1 CFUF= [

1. Contains SI contribution due to [ ] cycle*s of OBE loading and [ I cycles of Leak Thermal loading on the repair nozzle, see Section 6.4.1.

7.4 Consideration of corrosion in the RV Head Low-Alloy Steel The design configuration of the BMI nozzle repair results in a small area of the RVBH base material (SA-533 Grade B) at the penetration bore being exposed to continuous contact with the Reactor Coolant water. The chemistry of the Reactor Coolant combined with the properties of the RV Head material result in corrosion of the wetted surface.

The corrosion rate is determined to be [ ] per year [21]. At this rate, the total surface (radial) corrosion in the penetration bore for 40 years would be [I (note that 40 years conservatively bounds the remaining life of the plant). This small amount of corrosion volume lost will not have a significant impact on the analysis. The increase in the penetration bore radius will tend to shift the peak stress field slightly outward to the new surface but will not cause an increase in the magnitude of the stress. Therefore, the slightly larger bore diameter does not impact the stresses or fatigue usage factors for the assembly. In addition, the fatigue effect due to potentially irregular bore contours has been included in the fatigue analysis in Section 7.3 by applying an FSRF of [ ] to all fatigue locations in the RVBH.

In conclusion, the corrosion of the exposed low-alloy material has negligible impact on the response of the BMI nozzle repair and is acceptable.

Enclosure Attachment 4 Page 51

A AREVA Document No. 32-9220625-000 ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair (Non-Proprietary) 8.0 RESULTS Stress analysis of the Palo Verde BMI nozzle repair demonstrates that.the nozzle modification satisfies the requirements of the ASME Code [2].

The primary stress criteria are satisfied as summarized in Table 8-1 and Table 8-2. Note that the primary stress intensities identified below are a result of Design Conditions in conjunction with Faulted nozzle loads as applicable, along with Design Condition allowable stress. See Section 7.1.1 for further discussion.

Table 8-1: Summary of Primary Stress Intensities Pm, ksi PL, ksi PL-Pb, ksi Component Material Calculated Allowable Calculated Allowable Calculated Allowable Bottom Head m l LL im I Repl. Nozzle [I [ l i Repair Weld 11 ] [ ] ilL [ Ill ml [ ]

Table 8-2: Summary of Primary Stress Intensity for Test Conditions Component Material Pm, ksi PL+Pb. ksi ComponentMaterial _Calculated Allowable Calculated Allowable Bottom Head [ ] [ ] [ ] l] l Repl. Nozzle/ [

Repair Weld The summary of the maximum primary + secondary membrane plus bending stress intensity ranges and cumulative fatigue usage factors are listed in Table 8-3. The cumulative fatigue usage factors at critical locations are less than 1.0 for the number of design cycles specified in reference [13] and repeated in Section 4.3.2.

Table 8-3: Summary of P+Q SI Ranges and Fatigue Usage Factors Component Material Max P+Q M+B Range, ksi Fatigue Usage Factor Calculated Allowable Calculated Allowable Location Bottom Head J 1 80.1 [ 1.0 HDPath5 Outside Repl. Nozzle 69.9 1.0 NZPath3 Outside Repair Weld [ [ 69.9 J J 1.0 WDPathl Inside In conclusion, the PV BMI nozzle repair satisfies the ASME Code primary plus secondary stress requirements as well as criteria against the fatigue failure as set forth in the ASME Code [2].

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9.0 REFERENCES

References identified with an (*) are maintained within Palo Verde Nuclear Generating Station Records System and are not retrievable from AREVA Records Management. These are acceptable references per AREVA Administrative Procedure 0402-01, Attachment 8. See page 2 for Project Manager Approval of customer references.

1. AREVA Document 08-9212780-001, "Design Specification: Palo Verde Unit 3 Reactor Vessel Bottom Mounted Instrument Nozzle Modification."

2. ASME B&PV Code,Section III, "Rules for Construction of Nuclear Facility Components," Division 1, Subsection NB, 1998 Edition, including Addenda through 2000.

3. AREVA Document 51-9213335-001, "ASME Section XI Reconciliation for Palo Verde Unit 3 Reactor Vessel Bottom Mounted Instrument Nozzle Modification"

4. AREVA Document 02-9212754E-001, "Palo Verde Unit 3 Bottom Mounted Instrument Nozzle Repair (Penetration 3)."

5. AREVA Document 02-9212760C-000, "Palo Verde Unit 3 Bottom Mounted Instrument Replacement Nozzle (Penetration 3)."

6. *APS Document N001-0301-00527, Revision 0, "Lower Vessel Final Assembly, Arizona Public Service III 182.25" ID PWR."

7. *APS Document N001-0301-00530, Revision 0, "Bottom Head Penetrations, Arizona Public Service III 182.25" ID PWR."

8. *APS Document NOO1-0301-00054, Revision 2, "General Arrangement., Arizona Public Service III 182.25" ID PWR."

9. *APS Document NOO1-0301-00633, Revision 0, "Boat Sample Extraction General Layout - 25 Degree Angle."

10. ASME B&PV Code,Section III, "Nuclear Power Plant Components," Division 1, 1971 Edition including Addenda through Winter 1973.

11. ASME B&PV Code,Section II, Part D, Materials, "Properties," 1998 Edition, including Addenda through 2000.

12. ASME B&PV Code,Section II, Part D, Materials, "Properties," 2010 Edition, including 201 la Addenda.

13. *APS Specification NOO1-0301-00006, Revision 6, "General Specification for Reactor Vessel Assembly."

14. NRC ADAMS Accession No. ML083510627, "Palo Verde Nuclear Generating Station (PVNGS) Units 1, 2 and 3I License Renewal Application."

15. NRC ADAMS Accession No. ML110800473, "Renewed Operating License Number NPF-74."

16. *APS Specification MN742-A00 179, Revision 4, "Project Specification for a Reactor Vessel Assembly for Arizona Nuclear Power Project Units 1, 2, and 3."

17. AREVA Document 32-9213294-001, "In-Core Piping Stress Analysis of Socket-Welded Connections."

18. *APS Report NOO1-0301-00214, Revision 7, "Reactor Vessel, Unit 3, Analytical Report, V-CE-30869, 30AU84."

19. ANSYS and ANSYS Workbench, Release 14.5.7, ANSYS Inc., Canonsburg, Pa.

20. *APS Specification 13-MN-0163, Revision 01, "Containment Thermal Reflective Insulation."

21. AREVA Document 51-9213061-001, "Corrosion Evaluation for Palo Verde Unit 3 Reactor Vessel Bottom Mounted Instrument Nozzle Modification."

22. Hodge, B. K., "Analysis and Design of Energy Systems," Prentice Hall 1985.

23. Incropera et. al., "Fundamentals of Heat and Mass Transfer," 61h Edition, Wiley 2007.

24. *APS Document N001-0101-00060, Revision 4. "Compilation NSSS Resp on Design Bases Dynamic Events VCE7014."

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APPENDIX A: HEAT TRANSFER COEFFICIENT CALCULATION Enclosure Attachment 4 Page A-1

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A.1 Inputs Properties of Saturated Water at [ ] are taken from Reference [22]. The temperature of [ ] is representative of the average temperature of the RV inlet water during all transients considered.

Density ]

Specific Heat ]

Viscosity Thermal Conductivity Prandtl Number [ ]

The fluid stream velocity in the vicinity of the BMI I Nozzle #3 is [ I according to Reference [13].

I I A.2 HTC for Reactor Vessel Spherical Bottom Head Heat Transfer equations are taken from Reference [23].

The spherical head is considered as a flat iso-thermal plate.

Rex =-

Reynold's Number Critical/Transition Reynolds Number for a Flat Plate Determine the Critical Distance, xc, at which flow becomes turbulent.

Therefore, the flow is turbulent after a very short distance and can be simplified as being turbulent from the start..

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Consider the Characteristic Length of the "Plate" to be equal to the arc length of the vessel ID in the FEA model.

Vessel ID Modeled Arc in the FEA Model 2 Characteristic Length I

Reynold's Number for Lc I

Fully Turbulent average Nussle Number

- See page 412 of [23]

hbar"Lc I

Average Nusselt Number Definition NUbar -

k Determine the Heat Transfer hL bar := k'NuL bar Coefficient (HTC) per the NU definition LC -

7 I]

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A.3 HTC for External Surface of Remnant Nozzle Inside Vessel The remnant nozzle is modeled as a simple cylinder in external cross-flow.

Maximum Outside Diameter of Nozzle E Upstream Fluid Velocity E I-

- I Reynold's Number i

Average Nusselt Number per Equation 7.54, page 427 [23].

Applicable to all values of ReD Determine the Heat Transfer k hd bar := .NUD bar Coefficient (HTC) per the Nu definition Dnoz E I

]

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APPENDIX B: REMNANT NOZZLE LOAD CALCULATION Page B-i Enclosure Attachment 4 Enclosure Attachment 4 Page B-1

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B.1 Purpose As stated in Sections 4.3.3.2 and 6.4.2 there are external loads which are applied to the portion of the remnant nozzle which extends into the RVBH. These external loads are due to hydraulic flow, seismic excitation, pump periodic excitation, and white noise. Loads were calculated on pages A-582 through A-585 in the original RV Stress Report [ 18] for the bounding BMI Nozzle Location. In some cases the loads calculated in the RV Stress Report are overly conservative for application to BMI Nozzle #3. Loads are calculated in this Appendix for application to the FEA Model. As discussed in Section 6.4.2, the loads are applied to the nozzle at half of its exposed height. Therefore, the moment at the welded attachment is accounted for implicitly through the eccentric force and does not need to be entered directly. In addition, the FEA model takes advantage of symmetry and only includes 1800 of the nozzle and weld. Therefore, the loads calculated below are divided by 2 for application in the FEA model.

B.2 Hydraulic Flow Loads The bounding load calculated on page A-582 of the RV Stress Report is [ ] pounds. This load is the result of using the maximum drag force of [ ] with the corresponding projected area of [ ] . Nozzle

1. 3 has a slightly larger projected area but a much lesser drag force. The hydraulic flow load at Nozzle #3 is re-calculated below.

FHYD = Amplification Factor * (Exposed Height

• Diameter)

• Drag Force

-- [ ]

Where: the Amplification Factor is taken from page A-514 and is equal to the ratio of the water density at

[ ]to the water density at [ ] , the Exposed Height is taken from page A-526, the Maximum Diameter is taken from page A-507, and Drag Force is taken from page A-514 of the Stress Report [18]. The amplification factor and drag force can also be found on Figure 12, Sheet 2 of 2, of Reference [13].

B.3 Seismic Loads The bounding seismic loads are calculated on page A-583 and 584 of the RV Stress Report. This load is the result of using the largest participation factor (PF based on frequency separation) and nozzle mass. Accounting for the specific frequency and mass of Nozzle #3 does not provide an appreciable difference from the bounding values used in the Stress Report. Therefore, the PF of [ ] and weight/mass of [ ] pounds will be used herein.

However, the loads calculated in the Stress Report use response spectra (page A-516) which are outdated. The appropriate curves are presented in Attachment 1, Figure 1.1, of Reference [ 16] for post-RSG and power uprate.

The peak accelerations presented in these curves are tabulated below ( [ ] damping).

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Table B-I: Peak Seismic Acceleration Post-RSG and Uprate Direction OBE [g] SSE [g]

Seismic loads are calculated using the same methodology as used on page A-584 of [18].

FXOBE ]

FYOBE FZOBE FXSSE FYssE ]

FZSSE The axial load (A) in the nozzle is equal to the vertical load, FY. The resultant shear load (V) in the nozzle is equal to the Square Root of the Sum of the Squares (SRSS) of the FX and FZ Loads.

FAOBE = FYOBE =I FVOBE =SRSS(FXOBE, FZOBE) = ]

FASSE = FYSSE

]

FVsSE =SRSS(FXSSE, FZsSE) =

]

B.4 Pump Periodic Excitation The design input used to calculate the pump periodic excitation load on page A-584 [18] remains applicable, and the calculated load is representative of the load at Nozzle #3 and is therefore used as-is. Pump Periodic Excitation (PPE) loads are specified to occur in two perpendicular horizontal directions (X and Z) and thus the maximum shear force is equal to the SRSS of the two components. This results in a load which is [ ] times the single component load shown below. Stresses due to PPE loading shall be multiplied by [ ] to account for this.

FPPE = I I B.5 White Noise The design input used to calculate the white noise load on page A-585 [18] remains applicable, and the calculated load is conservative for the load at Nozzle #3 and is therefore used as-is. White Noise loads are specified to occur in two perpendicular horizontal directions (X and Z) and thus the maximum shear force is equal to the SRSS of the two components. This results in a load which is [ ] times the single component load shown below.

Stresses due to White Noise shall be multiplied by [ ] to account for this.

FWjN= I[

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APPENDIX C: TEMPERATURES AND GRADIENTS FROM THERMAL ANALYSIS The following temperatures and temperature gradients between points of interest are used to determine critical time points for thermal stresses. The temperature distribution at the critical time points is used as an input to the structural analysis along with the pressure at that time. Plots below are produced from data contained within the nodal temperature thermal output files named "* Ts.txt" The "*" represents the abbreviation for the specific transient of interest. See Section 6.2 for additional discussion.

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CA.1 Heat Up Transient m

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C.5 Reactor TriplLoss of Flow/Loss of Load Transient Enclosure Attachment 4 Page C- 10

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C.7 Normal Plant Variation Transient 7

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APPENDIX D: STRESSES FOR THE REMNANT J-GROOVE WELD FLAW EVALUATIONS Page 0-1 Attachment 4 Enclosure Attachment 4 Page D-1

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D.1 Purpose The purpose of this appendix is to provide supplemental stress results from the transient analyses and remnant nozzle load analyses for Fracture Mechanics Analysis (FMA) of the original J-groove weld. One such analysis evaluates postulated flaws in the J-groove weld, butter, and RVBH. For this analysis, data is supplied at each node on the plane of symmetry, to be mapped to an FEA model. A second analysis is performed to evaluate flaws in the existing/remnant nozzle. For this analysis, data is supplied along pre-defined path lines. Further details are provided below, and computer files used and produced are listed in Table 5-2.

In addition, more representative pressure and temperature transient curves for the Normal Variations/Step Load transient were executed and post-processed for use in the FMA which evaluates the flaw through the RVBH.

The conservative Normal Variation transient (NVAR) detailed in Section 4.3.2 and Table 4-14 was used for the Section III analysis as well as the FMA concerned with the remnant nozzle.

D.2 Methodology D.2.1 Executing Step Load Transient for Fracture Mechanics Analysis As noted previously, the Step Load/Normal Variation transient curves used for transmitting hoop stress results for the FMA are different than that which is used in the main body of the report. Transient curves are taken from Figures 3-B and 4-B of [24], corresponding to the Step Load Increase and Step Load Decrease, respectively. This data takes the place of the NVAR transient used for the Section III evaluation in the main body of the calculation.

These replacement transients are executed with files 'TrSLIncCLth.out', 'TrSLDecCLth.out',

'TrSLIncCLst.out', and 'TrSLDecCLst.out' in conjunction with 'SLIncCLtrTable.mac' and

'SLDecCLtrTable.mac' as listed in Table 5-2. See Sections 4.3.2 and 6.2 for additional details regarding transient analysis. The digitization of the transient curves and structural time points of interest are provided below. Structural time points are chosen at times when the pressure changes abruptly and/or maximum temperature gradients exist in the model as observed in the text files 'SLIncCLTs.txt' and 'SLDecCLTs.txt.'

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Table D-1: Step Load Transient Data Step Load Increase Step Load Decrease RV Inlet RC tStructural e PrnRC ssr Time RV Inlet RC Structural Temp Pressure Points Temp Pressure Time Time Is] Time [s]

[psia] [iS]nt [psia] Points

[*F] [F]

L[ 11[ 11[ 1IL

[l ) I 1]

s

((L1 £[11 ((h1

[L1 [lL [1 I[ ]

[1 [I [r I I[ r I r1 [ I [ 1 ffiL~LL Th LL..LL LLTh11 ffiL. Lli ~Lr Ill - L1 LL Th Eli ll~llL ff1 liffi ffiL D.2.2 Post-Processing for Analysis of Remnant Weld, Butter, and RVBH As stated previously, this data set is supplied for each node lying in the symmetry plane (z = 0). This data may be used to map results to a fracture mechanics finite element model for detailed analysis. Node locations on the symmetry plane and the corresponding hoop stresses are extracted and saved in the "(*).sav" files (see Table 5-2) as ANSYS array parameters. [

J  ; this ensures that stresses can be mapped to and from the correct body (nozzle or RVBH) in areas where the gap between the two is small. This data is supplied for every transient time-step and remnant nozzle load direction. In addition, the Load Step index, time.,

applied nozzle load (if applicable) and Reactor Vessel Inlet temperature and pressure are provided at each time-step.

The required data is gathered and saved using the files 'get.hoop_stress SectXI.out' and 'extractstress.mac' identified in Table 5-2. The resulting files follow the naming convention of 'Tr (*)_st.sav' and

'RemNoz_(*).sav' where (*) represents the transient of interest or the remnant nozzle load case, respectively.

Each of the '.sav' files includes parameters containing all nodal coordinates and corresponding hoop stresses, as well as time, temperature, and pressure data at each time-step.

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D.2.3 Post-Processing for Analysis of Flaws in the Remnant Nozzle The second set of data is supplied at pre-defined path-lines to be used in a separate FMA. The data included in the second set includes linearized hoop stresses at each of the 23 paths shown in Figure D-1, for each time-step of the analyzed transients and remnant nozzle load case. Paths start at an elevation of [ ] (path P1) and each successive path is incremented by [ ] ; these path locations are defined by the ANSYS input file 'loc data.inp'. The direction of all paths is from the nozzle OD to the nozzle ID. In addition to the linearized stresses, hoop stresses are provided at approximately 100 locations through the thickness of Path P12.

The required data is gathered and saved using the files 'pathresults (*).out', 'linearize.mac', and 'loc_data.inp' identified in Table 5-2. The resulting files follow the naming convention of '(*) mb sum.dat' and

'(*)_path_12.dat' for the linearized stresses and through-thickness hoop stresses, respectively. As denoted previously, (*) represents either the transient of interest or the remnant nozzle load case.

The '(*).mbsum.dat' files contain membrane and membrane plus bending hoop stress results which are calculated by the ANSYS macro file 'linearize.mac'. The membrane stress is calculated using numerical integration as follows:

6_ f!:;2 t

t/2 of w-al t/2e 6 +hoop,i A Xhoop-i1

++ X where t is the wall thickness, x is the path coordinate, ahoopiSi=n-1 the hoop stress, n is the number of point on the path.,

ahoopB and Ax is the distance between adjacent points on the path. The bending component of stress is calculated

=X similarly using 6 't/2 6 iZnl hoopji+ '7hoopi+l(.Xi +Xi+i Xl"+-Xn.A Uhoop,B = T2 f ahoop (x -- xc) dx = (xn- xJ)2 2 2 2 A

_-t/2 n=

where xc is the path coordinate of the wall midpoint.

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Figure D-1: Pathlines for Post-Processing Hoop Stress Results for FMA

[

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