ML14149A404

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Calculation 32-9222043-000, Bmi Nozzle Crack Growth Analysis, (Non-Proprietary), Attachment 5
ML14149A404
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Issue date: 04/18/2014
From: Riordan T
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Enclosure Relief Request 52 Proposed Alternative in Accordance with 10 CFR 50.55a(a)(3)(i)

ATTACHMENT 5 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis

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

A CALCULATION

SUMMARY

SHEET (CSS)

ARE VA Document No. 32 9222043 - 000 Safety Related: RYes El No Title Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

PURPOSE AND

SUMMARY

OF RESULTS:

The purpose of this calculation is to perform a conservative crack growth analysis to demonstrate that radial axial flaws in the BMI nozzle No. 3 will not grow large enough to reach both ends of the nozzle, before the plant license expiration in 2047. Both primary water stress corrosion cracking (PWSCC) and fatigue crack growth (FCG) mechanisms will be considered.

Based on NDE, an initial surface crack with depth, a=-,[ and length, 2c= [ ] was postulated.

This crack will grow to be through wall in [ ] years at which time it will have a length, 2c= [ L In an additional [ ] years, the crack length will grow to 2c= [ ] , at which time it will grow to the end of the bottom portion of the nozzle, which is confined below the j-groove weld and the reactor vessel bore and as such will not become a loose part.

In the remaining [ ] years until plant license expiration in 2047 the crack grows up the nozzle to a total length of approximately a= [ ]; this leaves a remaining un-cracked ligament of approximately [ ] inches at the top of the nozzle so the generation of loose parts is unlikely.

This is the Non-Proprietary version of 32-9217241-002.

AREVA Inc. proprietary information in the document is indicated by pairs of brackets "[ ]".

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 EIIYes None 0 No Enclosure Attachment 5 Page 1 of 38

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

Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Review Method: j[ Design Review (Detailed Check)

[D 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 (NIA if not applicable)

Name Title (printed or typed) (printed or typed) Sgnature Date/

Maya Chandrashekhar Project Managerg' Mentoring Information (not required per 0402-01)

Name Title Mentor to:

(printed or typed) (printed or typed) (P/R) Signature Date N/A Enclosure Attachment S Page 2

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

AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Record of Revision Revision PageslSections/Paragraphs No. Changed Brief Description I Change Authorization 000 All Initial Release 1I_ _ _ _ _ _ I _ ____ ___

4 4 i i 4 +

t .4.

4 +

.4.

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A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Table of Contents Page SIGNATURE BLOCK ................................................................................................................................ 2 RECORD OF REVISION .......................................................................................................................... 3 LIST OF TABLES ..................................................................................................................................... 5 LIST OF FIG URES ................................................................................................................................... 6

1.0 INTRODUCTION

........................................................................................................................... 7 2.0 ANALYTICAL M ETHODOLOGY .............................................................................................. 7 3.0 ASSUM PTIONS .......................................................................................................................... 10 4.0 ANALYSIS INPUTS ..................................................................................................................... 11 4.1 Geometry and Material .................................................................................................................... 11 4.2 Bounding Initial Flaw Size ......................................................................................................... 11 4.3 Loading Data and Stresses ...................................................................................................... 12 5.0 CALCULATIONS ......................................................................................................................... 13 5.1 Path Lines for Stresses ................................................................................................................... 13 5.2 Growth of Initial Surface Crack ................................................................................................. 13 5.3 Growth of Through Wall Crack .................................................................................................. 15 5.4 Growth of Single Edge Notched Plate Crack ............................................................................ 19 5 .5 S ta b ility C h e c k ................................................................................................................................. 26 6.0 SUM MARY OF RESULTS .......................................................................................................... 27

7.0 REFERENCES

............................................................................................................................ 28 APPENDIX A : BOUNDING AXIAL FLAW IN NOZZLE ................................................................ A-1 APPENDIX B : CO M PUTER FILES ................................................................................................. B-1 Enclosure Attachment 5 Page4

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

List of Tables Page Table 5-1: Crack Growth Calculation for Longitudinal Surface Flaw ................................................ 14 Table 5-2: Crack Growth Calculation for Longitudinal Through Wall Flaw ...................................... 15 Table 5-3: Crack Growth Calculation for Single Edge Notched Plate .............................................. 20 Table A-i: UT Data for Flaw Indications I Through 4 .......................................................................... A-3 Table A-2: UT Data for Flaw Indications 5 Through 10 ........................................................................ A-4 Table A-3: Calculation of Nozzle Cutout .............................................................................................. A-5 Table B-I: List of Revision 000 Computer Files ................................................................................... B-2 Table B-2: List of Revision 001 Computer Files ................................................................................... B-5 Enclosure Attachment 5 Page 5

A ARIEVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

List of Figures Page Figure 5-1: Path Lines for Stresses .................................................................................................. 13 Figure 6-1: Sketch of Flaw Growth Progression .............................................................................. 27 Figure A-i: Reference Positions for UT Inspection Data ..................................................................... A-2 Enclosure Attachment 5 Page 6

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

1.0 INTRODUCTION

Non-destructive examination (NDE) of bottom mounted instrumentation (BMI) nozzle 3 at Palo Verde Unit 3 indicated the presence often predominantly axial cracks in the outer portion of the nozzle at the partial penetration weld to the vessel head. Although a half-nozzle repair performed on nozzle 3 moved the primary pressure boundary from the original J-groove partial penetration weld at the inner surface of the vessel to a new J-groove partial penetration weld at an outer surface weld pad, there remains a concern that cracks in the nozzle may propagate over the remaining life of the plant to the extent that loose parts are formed. AREVA Document 51-9220420 (latest revision) provides a road map of the AREVA analyses for the Palo Verde BMI Nozzle.

The purpose of this calculation is to perform a conservative crack growth analysis to demonstrate that radial axial flaws in the BMI nozzle No. 3 will not grow large enough to reach both ends of the nozzle, before the plant license expiration in 2047. Both primary water stress corrosion cracking (PWSCC) and fatigue crack growth (FCG) mechanisms will be considered.

2.0 ANALYTICAL METHODOLOGY

1. Based on NDE data, postulate a single bounding surface crack in the longitudinal (axial) direction, [

in depth by [ ] in length, on the outside of the nozzle near the uphill side of the original J-groove weld.

See Appendix A for discussion of the NDE data and determination of the bounding axial flaw size. Assume the crack is centered at the location of maximum operating plus weld residual stress.

2. The stress intensity factor, K,, for the surface crack is calculated using the solution from Section C.5.l 1 (Equation C. 192) of API-579-1 [1]. This is the solution for a cylinder, with a surface crack, in the longitudinal direction, an elliptical shape, and a through-wall fourth order polynomial stress distribution (API-579-1 Solution KCSCLE2). This solution is valid for crack depths up to 80% of the wall thickness.

Equation C. 192 of API-579-1 is:

K, = [Q.{o( + p,}I+ Glo-1 +G ty )2

+ Gty * ~r 1K 4

)4]r'(

Note that the influence coefficients, G,, vary with elliptical angle p, with 9=0 at the surface and 9=7r/2 at the deepest point of the crack.

3. The stress intensity factor, K,, for the through wall crack is calculated using the solution from Section C.5.1 (Equation C.156) of API-579-1. This is the solution for a long cylinder, with a through wall longitudinal crack and through-wall membrane and bending stress distributions (API Solution KCTCL).

Equation C. 156 of API-579-1 is:

K, = [{tm + pI Go + ab (Go -2G,)]1;P As noted, the above solution is for a long cylinder; as the crack grows towards the end of the nozzle boundary effects can become important. To account for boundary effects correction factors are applied. The correction factor utilized is based on a polynomial fit to the data in Table 2.1 of Reference [2]. The resulting correction factor is where 2c is the crack length and [ ] inches is the effective width of the plate (twice the distance from the crack centerline to the bottom of the nozzle).

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A ARIEVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

4. If the through wall crack grows to 2c= [ ] the crack has essentially grown through the bottom of the remnant nozzle. At this point the stress intensity factor solution utilized is that for a single edge crack plate.

From Reference [2] the solution is K,= avira (a)b where o is the applied stress, a is the crack width, 2b is the plate width, andf(a/b) is a correction factor given in Table 2.2 of Reference [2]. Conservatively, the applied stress utilized is the sum of the membrane stress, bending stress, and crack face pressure. The polynomial fit to the tabulated correction factor data is given below.

f (2) = 2.0492 (1)2 - 0.4245 (1) + 1.1995

5. Stresses are obtained from References [3] and [4]. Hoop stresses are obtained at a set of through-wall pathlines closely spaced in the longitudinal direction.
a. For the surface crack, the stress intensity solution requires that stresses be fit with a fourth-order (K) -( (K-polynomial:

0-(X) =Oo+ a,(K:) +°' +0-2 t +c3t

+ ++a7

++r 4 For this purpose a single conservative pathline (within the region of the surface crack) is chosen and stresses are fit by least squares.

b. For the through wall crack, the stress intensity solution requires membrane stress which is assumed constant. In reality, the membrane stress (through wall average hoop stress) varies over the width of the crack (axial location on the nozzle). The membrane and bending (through wall hoop) stress will be evaluated at a number of different axial positions on the nozzle. For evaluating crack growth rate, the average membrane and bending stress within the current crack length will be used.
c. For the single edge notch plate the stress utilized will also be the average of the stresses over the current crack length.
6. Calculate the flaw growth versus time as follows:
a. The surface crack starts with the length to depth ratio (aspect ratio) for the bounding crack defined in step
1. Growth in depth and length will be separately calculated for each time step by calculating the applied K1 at the surface and at the deepest part of the crack.
b. The surface flaw is grown until it propagates to [ ] % of the thickness of the nozzle; Then the flaw is transformed into a through-wall axial crack with a length and depth increased by a factor of [

J times the corresponding values at the time when [ ] depth is reached. Through wall crack growth is then calculated.

c. Once the through wall crack reaches 2c= [ J the single edge notched plate solution is utilized for the remainder of the analysis.
d. SCC crack growth rates are calculated using equation (4) of ASME Code Case N-694-1 [5] (developed in MRP-55, Reference [6]), and the stress intensity factors are calculated as above. ASME Code Case N-694-1 is noted as being conditionally acceptable in Regulatory Guide 1.147 Reference [7], subject to the following conditions:
1. The maximum instantaneous through-thickness stress distribution along the crack front and in the crack-length path must be used to calculate the crack driving force.

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A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

2. The stress intensity factor expression of Raju and Newman is only applicable to cylindrical products having a ratio of wall thickness to inside radius between 0.1 and 0.25.

Condition I is satisfied since the maximum stress distributions are used to calculate Kz. Condition 2 is not applicable since the Raju Newman solution provided in the code case is not used here.

Equation (4) of ASME Code Case N-694-1 is as follows, when K1 is greater than K,,

S=exp [ "g-\717f)] a(KI - Kth)pl Qg(I where

= crack growth rate at temperature T in m/s Qg = thermal activation energy for crack growth

= l30kJ/mole R = universal gas constant

= 8.314 x 10-3 kJ/mole K T = absolute operating temperature at location of crack, K Trf = absolute reference temperature used to normalize data

= 598.15K a = crack growth rate coefficient 2.67 x 10-12 at 325"C for 6 in units of m/s and K 1 in units of MPa K1 = crack tip stress intensity factor, MPa %m KtA = crack tip stress intensity factor threshold for SCC

= 9 MPa vm = 8.19 ksiqin fl = exponent

= 1.16 When K1 is less than or equal to K,1 , ci = 0.

The resulting crack growth rate is 4 = 7.0852 x 10-13 (K1 - 9 MPav/I') n6m/s

e. The fatigue crack growth rate for each transient is calculated using equation (3) from N-694-1, and stress intensity factor ranges are calculated for each transient. Note that in equation (3) from N-694- 1, the rise time is fixed to be 30 seconds. Equation (3) of ASME Code Case N-694-1 is as follows:

da da = CSRS,.VA(n dN The fatigue crack growth behavior of Alloy 600 materials is affected by temperature, R ratio (K,1jKmj),

and environment. Reference fatigue crack growth rates for PWR water environments are given by:

C = 4.835 x 10-14 + 1.622 x .10- 6 T- 1.490 x l0-I 7T + 4.355 x 10-21" SR = [1 - 0.82R]- 2' SEe =I+ A R where:

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A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

A =4.4 x 10-7 m = 0.33 n=4.1 T = degrees C AK = range of stress intensity factor MPa vm R KmjK,,.,

TR = rise time, set at 30 sec da/dN = m/cycle

f. For each time step, the crack growth due to SCC and due to fatigue from each transient is calculated and the total growth is accumulated.
7. The through wall crack growth will be calculated at each time interval until the crack reaches the bottom end of the remnant nozzle at a crack length of approximately 2c= [ ] in. Note that cracking through the bottom of the nozzle below the weld does not create a loose parts concern since the material is captured in the recess in the head. After the crack tip reaches the bottom of the nozzle, the single edge notched plate crack will then be propagated until plant license expiration.
8. Additionally, a stability check in accordance with C-5410 of ASME Section XI (Reference [8]) to determine the allowable length of the axial flaw. The calculation will conservatively assume that there is only pressure on the ID of the nozzle such that a tensile hoop stress is generated.

3.0 ASSUMPTIONS No unverified or unjustified assumptions are used in this calculation.

Assumptions include the following justified simplifications:

1. To bound crack growth rates, the initial bounding flaw is assumed to be centered near the location of maximum weld residual plus normal operating stress. This location is approximately [ ] inches from the end of the nozzle.
2. As discussed in Appendix A, the bounding initial flaw size is justified based on NDE data.

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A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

3. The stress intensity factor solutions from API-579-1 are functions of influence coefficients that are given in tabular form for ratios of wall thickness to inner radius, t,, / R, < 1.0. For the remnant nozzle this ratio is:

t4/RI = [ ]. Since the thicker nozzle provides more constraint against crack opening, it is conservative to use influence coefficients calculated for t4/Ri = 1.0 for the present flaw growth evaluations.

4. Growth rates of the through wall crack are greater on the outside wall than at the inside wall. The larger of the two rates is used to calculate through wall crack growth, which overestimates the actual crack growth along the nozzle.
5. Faulted loads (SSE and Loss of Secondary Pressure, LSP) are not applicable to this evaluation since they do not contribute to growth of cracks under PWSCC or fatigue crack growth under cyclic loading conditions.
6. The loads due to OBE, Hydraulic Flow, White Noise, Pump Periodic Excitation and Vortex Shedding result in bending moments and corresponding axial stresses in the nozzle, that are negligibly small, and would not contribute to growth of the existing radial axial flaws in the nozzle due to fatigue or PWSCC.
7. The Hydrostatic test is not included in fatigue evaluations, since the [ ] cycles will result in negligible crack growth in comparison to PWSCC crack growth. Also, excluding the immediate vicinity of the J-Groove weld the hoop stress along the nozzle length due to a hydrostatic test is a compressive hoop stress equal in magnitude to the applied pressure, which results in Gm+pcp 0 (i.e., no driving force for crack growth).

4.0 ANALYSIS INPUTS 4.1 Geometry and Material Dimensions used in the flaw growth analysis are:

Outside Diameter of BMI Nozzle: [ ] inches, Reference [9].

Inside diameter of BMI Nozzle: [ ] inches, Reference [9].

The remnant BMI Nozzle is ASME SB-166, Alloy 600 material, Reference [12].

4.2 Bounding Initial Flaw Size See Appendix A.

Page 11 Enclosure Attachment 5 Enclosure Attachment 5 Page 11

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary) 4.3 Loading Data and Stresses Applicable design transients, cycles and external loads are specified in References [10] and [ 11].

Filename Number of Figure in Condition Transient Convention Cycles Reference [11]

Heatup, [ I HUup/HUIow [ ] Fig. 2 Cooldown, [ ] CDup/CDlow 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 [ j Fig. 4 Upset Loss of Load OBE [ J Faulted Loss of Secondary Pressure LSP [ ] Fig. 5 Hydrostatic Test, [ ] °F -

I ]

Test Leak Test, [ ] psia, LEAK

_][ ]oE [ ]oF OF LEAK [ ]

Other external loads include [11 ]:

  • Hydraulic Flow

" White Noise

  • Pump Periodic Excitation
  • Vortex Shedding The normal operating inlet water temperature is [ ] [11].

The operating pressure is [ ] [12].

Weld residual stresses, normal operating stresses and stresses for all design transients and due to all external loads are taken from References [3] and [4].

Page 12 Enclosure Attachment 5 Enclosure Attachment 5 Page 12

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary) 5.0 CALCULATIONS Detailed calculations are contained in Mathcad and Excel files attached with this calculation (See Appendix B).

5.1 Path Lines for Stresses Stresses for the crack growth analysis were evaluated on the path lines shown in Figure 5-1.

Figure 5-1: Path Lines for Stresses 5.2 Growth of Initial Surface Crack Details of the calculation of crack growth for the longitudinal surface flaw are contained in the Mathcad files named "Surface crack__growth.xmcd", "Polynomial.xmcd", "APITable13.xmcd","Interpolate3d.xmcd",

"KCSCLE2.xmcd", "Influence coeff outside-surfacecrack.xmcd", and "Fatigue CrackGrowth.xmcd".

Surface crack growth is calculated using hoop stresses from the pathline labeled P12 in Figure 5-1. Weld residual stresses and weld residual plus operating stresses are input to Mathcad using the files "WRSPathl2.csv" and "WRS OPPath12.csv".Transient stresses as input to matrices using the Mathcad file "TransientsP12.xmcd.

A summary of results from the calculation of crack growth for the longitudinal surface flaw is given in Table 5-1.

At approximately [ I months or [ ] years, the crack depth, a, will grow to [ ] of the wall thickness. At that time, the crack length, 2c is approximately [ ] inches. The flaw is then assumed to be transformed into a though-wall axial crack with a length and depth increased by a factor of I ] times Enclosure Attachment 5 Page 13

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary) the corresponding values at the time when [ ] depth is reached. Thus the initial length for through wall crack growth is 2c = [ I x[ I] = ] inches.

Table 5-1: Crack Growth Calculation for Longitudinal Surface Flaw Growth of crack depth,a Growth of crack length, 2c Time, t SCC FCG SCC FCG (month) a (in) a/tw K, da/dt da/dt 2c (in) K, dc/dt dc/dt (ksi*in^0.5) (in/yr) (in/yr) (ksi*inAO.5)1 (in/yr) (in/yr)

Enclosure Attachment 5 Page 14

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary) 5.3 Growth of Through Wall Crack Details of the calculation of crack growth for the longitudinal surface flaw are contained in the Mathcad files named "Throughcrackgrowth-BC.xmcd", "APITable_6_and 7.xmcd", and "FatigueCrackGrowth.xmcd".

Weld residual stresses and weld residual plus operating stress as a function of crack length are calculated in the Mathcad files "WRSMB.xmcd", and "WRSOP_MB.xmcd". Transient stresses as a function of crack length arec calculated in Mathcad files "Transients_MB.xmcd. The trapezoidal rule was used to average hoop membrane and bending stress over the length of the through wall crack.

A summary of results from the calculation of crack growth for the longitudinal through wall flaw is given in Table 5-2. The results show that in [ I months or [ ] years, the crack length will grow to 2c= [

at which time the crack tip will be located near the bottom end of the remnant nozzle.

Table 5-2: Crack Growth Calculation for Longitudinal Through Wall Flaw SCC I FCG K, K,at outside dc/dt dc/dt at inside wall wall (in/yr) (in/yr)

(ksi*inAo.5) (ksi*inAO.5)

W Enclosure Attachment 5 Page 15

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

SCC Enclosure Attachment 5 Page 16

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

I scc [ FCG I Page 17 Attachment 5 Enclosure Attachment 5 Page 17

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

SCC FCG Grm COb K, K,at outside dc/dt dc/dt Time, t 2c (in) (ksi) (ksi) at inside wall wall (in/yr) (in/yr)

(month)

(ksi*inAO.5) (ksi*inAO.5)

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A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary) 5.4 Growth of Single Edge Notched Plate Crack Once the crack reaches the bottom of the nozzle (2c= [ ]) the crack growth is calculated based on a single edge cracked plate stress intensity factor solution. Since the results of the previous section indicate that fatigue crack growth is small compared to PWSCC, fatigue crack growth is not evaluated. The welding residual stress (WRS) plus operating stress results are supplied up to path P23 in Reference [3]. Review of the results indicates that by path P23 the residual stresses have decayed and thus the stresses will be constant and equal to those at path P23 above that point.

Based on the dimensions from the references noted the length of the remnant nozzle is calculated to be

[ ] as shown below.

Height from RVBH CL to bottom of nozzle ] (Reference [9])

Radial distance from vessel CL to nozzle OD ] (Reference [13])

RVBH outside radius (Reference [ 14])

Height from RVBH CL to RVBH OD at nozzle ]

OD Length of nozzle below vessel I

Length of nozzle removed in RVBH bore (Reference [9]), Step 5 I

Length of nozzle removed Length of original nozzle (Reference [9])

Length of remnant nozzle The stress intensity solution for the single edge notched plate uses a plate width of 2b = [ I.

At the time the crack growth to the bottom of the nozzle a total of [ I months have elapsed. To reach plant license expiration in 2047 the single edge notched plate crack growth is calculated for an additional

[ I months ([ ] years) in Table 5-3. After [ ] months the crack grows to a= [ ], which results in a remaining un-cracked ligament of approximately [ ] inches at the top of the remnant nozzle. The calculation is performed in the spreadsheet "Nozzle_CG.xlsm ". An example of the calculation of K, performed in the spreadsheet is shown below for the first time step.

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A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Table 5-3: Crack Growth Calculation for Single Edge Notched Plate Month I a (in) I Or.(ksi)I ob (ksi) I K,(MPaVm) I i(in/year) da (in)

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A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Month a (in) I om (ksi) Gb (ksi) K,(MPfm/) I i(in/year) da (in)

Enclosure Attachment 5 rage 4 1

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Month a (in) I a (ksi) Ob (ksi) K,(MPa/m) I &(in/year) I da (in)

Enclosure Attachment 5 M a

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Month a (in) om(ksi) m Ob (ksi) K,(MPlam) a (in/year) da (in)

Enclosure Attachment 5 D,.cavu

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Month a (in) cOm (ksi) Ob (ksi) K,(MPaVm) i (in/year) I da (in)

L Enclosure Attachment 5 0 ^^A avc 4

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Attachment 5 Page 25 Enclosure Attachment 5 Page 25

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary) 5.5 Stability Check Per article C-5410 of Reference [8], the allowable length of an axial flaw is given by 5 i(jO.5 w =1.58(R lal mt) f

-s where:

of = flow stress =(y + S.) = (27.9 ksi + 80 ksi) = 53.95 ksi, Alloy 600 at 600°F (Reference [15])

Rm = Mean radius = []

t = wall thickness On-t= I Inserting the values above results in lallow = [ ]

Since the nozzle tapers over the length the calculation is also performed based on the dimensions of the thinnest section (OD = [ ] , ID = [ ], Reference [16]).

Rm = Mean radius=[]

t = wall thickness =[ J PRmF Oh - - =.

]

Inserting the values above results in allow =[ ]

The final allowable length is then calculated using a weighted average of the thin section and the thick section considering the thin section to be [ ] (DIM "B", Reference [16], rounded up) and the thick section to make up the remainder. alo=[

Since lallow = [ I is greater than the final flaw size of [ ] this criterion is satisfied.

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A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary) 6.0

SUMMARY

OF RESULTS Based on NDE, an initial surface crack with depth, a= [ J, and length, 2c= [ J was postulated. This crack will grow to be through wall in [ ] years at which time it will have a length, 2c= [ I.

In an additional [ ] years, the crack length will grow to 2c= [ ], at which time it will grow through the bottom portion of the nozzle.

In the remaining [ ] years until plant license expiration in 2047 the crack grows up the nozzle to a total length of approximately a= [ ]. This leaves a remaining un-cracked ligament of approximately [ ]

inches at the top of the nozzle so the generation of loose parts is unlikely.

Figure 6-1 shows a sketch of the progression of the crack growth.

Figure 6-1: Sketch of Flaw Growth Progression Enclosure Attachment 5 Page 27

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7.0 REFERENCES

References identified with an (*) are maintained within the Palo Verde 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. API 579-1/ASME FFS-1 2007, "Fitness-For-Service", Second Edition, June 5, 2007.
2. S.T. Rolfe and J.M. Barsom, "Fracture and Fatigue Control in Structures - Applications of Fracture Mechanics", Prentice-Hall, Englewood Cliffs, New Jersey, 1977
3. AREVA Document Number 32-9215089-001, "Weld Residual Stress Analysis for PVNGS3 RV BMI Nozzle Repair," Proprietary.
4. AREVA Document Number 32-9215084-001, "ASME Section III End of Life Analysis of PVNGS3 RV BMI Nozzle Repair," Proprietary.
5. ASME Code Case N-694-1 "Evaluation Procedure and Acceptance Criteria for PWR Reactor Vessel Head Penetration Nozzles,"Section XI, Divisions 1, Approved February 20, 2004.
6. MaterialsReliabilityProgram (MRP) Crack Growth Ratesfor EvaluatingPrimary Water Stress CorrosionCracking (PWSCC) of Thick-Wall Alloy 600 Materials(MRP-55) Revision 1, EPRI, Palo Alto, CA: 2002. 1006695.
7. Regulatory Guide 1.147, Revision 16, "Inservice Inspection Code Case Acceptability, ASME Section XI, Division 1", October 2010.
8. ASME Boiler and Pressure Vessel Code,Section XI, "Rules for Inservice Inspection of Nuclear Power Plant Components", 2001 Edition including Addenda through 2003.
9. AREVA Drawing 02-9212754E-001, "Palo Verde Unit 3, Bottom Mounted Instrument Nozzle Repair (Penetration 3)".
10. *Report N001-0301-00214, Revision 7, "Reactor Vessel, Unit 3, Analytical Report, V-CE-30869, 30AU84.
11.
  • Specification NOO1-0301-00006, Revision 6, "General Specification for Reactor Vessel Assembly."
12. AREVA Document Number 08-9212780-001,"Palo Verde Unit 3 Reactor Vessel Bottom Mounted Instrument Nozzle Modification," Proprietary.
13. *PVNGS Document NOO1-0301-00530, Revision 0, "Bottom Head Penetrations - Arizona Public Service III, 182.25 ID PWR".
14. *PVNGS Document N001-0301-00054, Revision 2, "General Arrangement Arizona Public Service III 182.25 ID Reactor Vessel".
15. ASME Boiler and Pressure Vessel Code,Section III, "Nuclear Power Plant Components", Division 1, 1971 Edition including Addenda through Winter 1973.
16. *PVNGS Document N001-0603-00208, Revision 3, "Bottom Head Instrument Tubes".

Enclosure Attachment 5 Page 28

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

APPENDIX A: BOUNDING AXIAL FLAW IN NOZZLE A.1 Purpose Non-destructive examination (NDE) of the Palo Verde Unit 3 bottom mounted instrumentation (BMI) nozzle #3 by ultrasonic inspection (UT) revealed ten flaw indications in the nozzle in the vicinity of the partial penetration J-groove weld that attaches the nozzle to the reactor vessel bottom head. The purpose of this appendix is to define a bounding axial flaw for use in a flaw growth analysis that examines the potential for the flaw to grow to the ends of the nozzle during the remaining life of the plant and possibly create a loose part.

A.2 Definition of Flaw Indications and Calculation of Nozzle Cutout The NDE inspection report [1] describes ten part-through wall flaw indications in BMI nozzle #3 located on the outside surface of the nozzle near the J-groove weld. Flaw indications I through 4 are oriented primarily in the axial direction (with respect to the nozzle) while flaw indications 5 through 10 are slightly skewed. It is postulated that over time the "axial" flaws (indications 1 through 4) and the skewed flaws (indications 5 through 10) will increase in depth and length until they link up, at which time the skewed flaws will be considered to have arrested. It is further postulated that the axial flaws will continue to grow along the length of the nozzle until they either arrest or reach the ends of the nozzle. [

]

Table A- 1 and Table A-2 are taken from the UT inspection report [1]. Table A- 1 presents the inspection data for flaw indications 1 through 4 and Table A-2 provides similar data for flaw indications 5 through 10. Each flaw indication is defined by linear (LI/L2) and angular (d1 /2) positions of its two end points, relative to horizontal and vertical datum lines. The vertical position of the weld at the location of the flaw indication is defined by the linear dimensions L3 and L4. The reference positions for these parameters are explained below, with the aid of Figure A-1.

Distance is measured in inches.

Angular position is measured in degrees.

Horizontal datum: [ ]

Azimuthal datum: [ ]

C I The UT data in Table A-I and Table A-2 are rearranged and processed in Table A-3 to determine bounding flaw characteristics. The bounding axial flaw is defined to be [ ] deep and [ ] long, extending from

[ ] to [ ] below the horizontal datum.

A.3 References

1. *Palo Verde Unit 3 U3R17, Reactor Vessel Bottom Mounted Instrumentation ID Examinations, Wesdyne Report WDI-PJF- 1312161-FSR-001, Rev. 0, October 2013.

Enclosure Attachment 5 Page A-1

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Figure A-I: Reference Positions for UT Inspection Data Enclosure Attachment 5 Page A-2

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Table A-I: UT Data for Flaw Indications I Through 4 Enclosure Attachment 5 Page A-3

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Table A-2: UT Data for Flaw Indications 5 Through 10 Enclosure Attachment 5 Page A-4

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Table A-3: Calculation of Nozzle Cutout Page A-5 Enclosure Attachment 55 Enclosure Attachment Page A-5

A AREVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

APPENDIX B: COMPUTER FILES Computer files used in this analysis have been stored in the ColdStor directory:

"IcoldýGeneral-Accessl32132-9000000132-9217241-O001official" All files, listed in Table B-I, were uploaded to ColdStor on 24 Feb 2014.

Computer files used in revision 001 of this analysis are stored in the ColdStor directory:

"\coldlGeneral-Accessl32132-9000000132-9217241-0011offcial" The revision 001 computer files are listed in Table B-2. The following files from revision 000 (Table B-I) are superseded by the indicated files from revision 001 (Table B-2):

Rev. 000 File (Table B-1) Rev. 001 File (Table B-2)

APITable 6_and_7.xmcd APITable_6_and_7.xmcd Throughcrackgrowth.xmcd Throughcrackgrowth-BC.xmcd ThroughCrackGrowthSCCFCG.txt ThroughCrackGrowthSCCFCG.txt Page B-i Enclosure Attachment 5 Enclosure Attachment 5 Page B-1

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Table B-I: List of Revision 000 Computer Files CheckSumn Permissions User Size Month Day Year Time TFilename

\cold\General-Access\32\32-9000000\32-9217241-000\official 0 drwxdc Masnyder 0 Feb 17 2014 9:46:08 FatigueCrack Growth 0 drwxdc Masnyder 0 Feb 21 2014 13:37:02 Outside-Surface Crack SIF 0 drwxdc Masnyder 0 Feb 21 2014 13:44:06 Through Wall Crack SIF 0 drwxdc Masnyder 0 Feb 21 2014 14:37:46 Transient-stresses 0 drwxdc Masnyder 0 Jan 30 2014 9:25:51 WRS OP stresses

./FatigueCrackGrowth:

32173 -rw-dc ] Masnyder ] 75405 I Feb 1 17 1 2014 1 9:46:08 ] Fatigue_Crack_Growth.xmcd:1

./OutsideSurfaceCrackSIF:

26967 -rw-dc Masnyder 354816 Jan 20 2014 14:04:23 API_579-1lTables.xls:1 49679 -rw-dc Masnyder 906247 Jan 19 2014 22:34:28 APITablel3.xmcd:1 21094 -rw-dc Masnyder 23792 Feb 21 2014 13:36:59 CrackGrowthSCCFCG.txt:l 46601 -rw-dc Masnyder 265511 Jan 19 2014 22:35:17 Influencecoeffoutsidesurfacecrack.xmcd:1 13138 -rw-dc Masnyder 156663 Feb 17 2014 11:22:36 Interpolate3d.xmcd:l 53723 -rw-dc Masnyder 46293 Jan 19 2014 22:37:52 KCSCLE2.xmcd:1 16789 -rw-dc masnyder 34224 Jan 19 2014 10:04:43 Polynomial.xmcd:l 56179 -rw-dc masnyder 2793267 Feb 21 2014 13:36:45 Surface crackgrowth.xmcd:l 30509 -rw-dc masnyder 1797 Jan 22 2014 15:26:31 WRS OP Pathl2.csv:l 32071 -rw-dc masnyder 18144 Jan 22 2014 15:26:13 WRS OP Pathl2.xlsx:l 40680 -rw-dc masnyder 1780 Jan 25 2014 19:41:47 WRSPathl2.csv:l 23961 -rw-dc masnyder 13619 Jan 25 2014 19:41:13 WRS Path12.xlsx:l 3047 -rw-dc masnyder 53811 Jan 18 2014 18:37:36 c_13.csv:l

./ThroughWall.CrackSIF:

43129 -rw-dc masnyder 401399 Feb 17 2014 12:27:19 APIlTable_6_and_7.xmcd:l 31505 -rw-dc masnyder 122484 Feb 21 2014 13:38:06 ThroughCrackGrowthSCCFCG.txt:1 50605 -rw-dc masnyder 3132947 Feb 21 2014 13:44:02 Through_crackgrowth.xmcd:l 62564 -rn--dc masnyder 1541 Jan 20 2014 J 14:04:52 c_6.csv:l Enclosure Attachment 5 Page B-2

A.

AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

CheckSum Permissions User Size Month Day Year Time Filename 12859 -rw-dc masnyder 1557 Jan 20 2014 14:05:51 c_7.csv:l

./Transientstresses:

60992 -rw-dc masnyder 32670 Jan 23 2014 17:55:04 CDlow mb sum.dat:l 62349 -rw-dc masnyder 68763 Jan 23 2014 17:55:04 CDlowpath 12.dat:1 9602 -rw-dc masnyder 32670 Jan 24 2014 7:45:08 CDupmb sum.dat:l 58779 -rw-dc masnyder 68763 Jan 24 2014 7:45:08 CDuppath_12.dat:l 27397 -rw-dc masnyder 32670 Jan 23 2014 17:38:20 HUlow mb sum.dat:1 39873 -rw-dc masnyder 68763 Jan 23 2014 17:38:20 HUlow path_12.dat:1 26577 -rw-dc masnyder 32670 Jan 23 2014 17:29:42 HUupmb sum.dat:l 58736 -rw-dc masnyder 68763 Jan 23 2014 17:29:42 HUuppath_12.dat:l 38729 -rw-dc masnyder 1815 Jan 23 2014 18:28:56 LEAK mb sum.dat:1 40359 -rw-dc masnyder 3942 Jan 23 2014 18:28:56 LEAK path_12.dat:1 4531 -rw-dc masnyder 59895 Jan 23 2014 18:28:06 LSP mb sum.dat:l 17201 -rw-dc masnyder 125958 Jan 23 2014 18:28:06 LSPpath_12.dat:1 62683 -rw-dc masnyder 19965 Feb 18 2014 11:40:21 NVAR mb sum.dat:l 3076 -rw-dc masnyder 42072 Feb 18 2014 11:40:21 NVARpath_12.dat:l 17058 -rw-dc masnyder 2509 Jan 24 2014 14:37:50 P12_x t.csv:1 52454 -rw-dc masnyder 21780 Jan 23 2014 18:00:44 PL mb sum.dat:1 8543 -rw-dc masnyder 45885 Jan 23 2014 18:00:44 PL path_12.dat:l 50182 -rw-dc masnyder 19965 Jan 23 2014 18:05:58 PU mb sum.dat:l 43941 -rw-dc masnyder 42072 Jan 23 2014 18:05:58 PUpath_12.dat:l 45487 -rw-dc masnyder 25410 Jan 23 2014 18:12:36 RT mb sum.dat:l 31684 -rw-dc masnyder 53511 Jan 23 2014 18:12:36 RT path_12.dat:l 65034 -rw-dc masnyder 292 Feb 21 2014 10:58:52 Transient events.csv:1 31021 -rw-dc masnyder 24285 Feb 20 2014 15:47:42 TransientsBending.csv:l 50929 -rw-dc masnyder 324817 Feb 21 2014 10:59:48 Transients MB.xlsm:l 10696 -rw-dc masnyder 1434290 Feb 21 2014 11:01:20 Transients MB.xmcd:l 3137 -rw-dc masnyder 27655 Feb 20 2014 15:47:06 TransientsMembrane.csv:l 37330 -rw-dc masnyder 103608 Feb 20 2014 14:15:49 TransientsP12.csv:1 Enclosure Attachment 5 Page B-3

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

CheckSum Permissions User Size Month Day Year Time Filename 30899 -rw-dc masnyder 613391 Feb 21 2014 10:58:32 TransientsP12.xlsm:1 1553 -rw-dc masnyder 703975 Feb 21 2014 11:00:30 Transients_P12.xmcd:1

./WRSOP stresses:

0 drwxdc masnyder 0 Jan 30 2014 9:24:32 FracturePPNozzleLoads 64441 -rw-dc masnyder 265411 Jan 28 2014 21:43:36 WRS MB.xmcd:l 11001 -rw-dc masnyder 272075 Jan 28 2014 21:43:28 WRS OP MB.xmcd:l 35403 -rw-dc masnyder 1779 Jan 21 2014 11:40:21 WRS OP mb sum.dat:l 16740 -rw-dc masnyder 1156517 Jan 21 2014 11:46:44 WRS OP pathresults.pdf:l 54429 -rw-dc masnyder 87023 Jan 21 2014 11:40:21 WRS OP paths.dat:l 33323 -rw-dc masnyder 1779 Jan 21 2014 11:40:39 WRS mb sum.dat:l 23762 -rw-dc masnyder 1148814 Jan 21 2014 11:48:02 WRSpath_results.pdf:1 52190 -rw-dc masnyder 87023 Jan 21 2014 11:40:39 WRSpaths.dat:l

./WRS OP stresses/FracturePPNozzleLoads:

47281 -rw-dc masnyder 3668 Jan 29 2014 12:26:28 RemNoz HF mb sum.dat:l 26278 -rw-dc masnyder 7793 Jan 29 2014 12:26:28 RemNoz HF path_12.dat:l 49126 -rw-dc masnyder 3668 Jan 29 2014 12:29:58 RemNozOBE_mb_sum.dat:1 43572 -rw-dc masnyder 7793 Jan 29 2014 12:29:58 RemNozOBEpath_12.dat:l 62457 -rw-dc masnyder 3668 Jan 29 2014 12:28:42 RemNoz PPE mb sum.dat:1 11288 -rw-dc masnyder 7793 Jan 29 2014 12:28:42 RemNozPPEpath 12.dat:l 7071 -rw-dc masnyder 3668 Jan 29 2014 12:31:14 RemNoz SSE mb sum.dat:l 8843 -rw-dc masnyder 7793 Jan 29 2014 12:31:14 RemNozSSE path_12.dat:1 9840 -rw-dc masnyder 3668 Jan 29 2014 12:32:26 RemNoz WN mb sum.dat:l 26387 -rw-dc masnyder 7793 Jan 29 2014 12:32:26 RemNozWNpath_12.dat:1 Page BA Enclosure Attachment 5 Enclosure Attachment 5 Page B-4

A AR EVA Document No. 32-9222043-000 Palo Verde Unit 3 - BMI Nozzle Crack Growth Analysis (Non-Proprietary)

Table B-2: List of Revision 001 Computer Files CheckSum Permissions User Size month Day Year I Time Filename

\cold\General-Access\32\32-9000000\32-9217241-001\official 0 drwxdc triordan 0 Mar 24 2014 9:48:06 SENPCrack 0 drwxdc triordan 0 Mar 24 2014 9:47:10 ThroughWall Crack SIF

./SENPCrack:

49914 -rw-dc triordan 286588 Mar 1 27 12014 8:38:45 NozzleCG.xlsm

./ThroughWallCrackSlF:

48879 -rw-dc triordan 401905 Mar 20 2014 16:20:39 API Table 6 and 7.xmcd 53027 -rw-dc triordan 120971 Mar 23 2014 15:14:58 ThroughCrackGrowth SCC FCG.txt 47255 -rw-dc triordan 3115328 Mar 23 2014 15:28:40 Throughcrackgrowth-BC.xmcd Enclosure Attachment 5 Page B-5

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

ATTACHMENT 6 Natural Frequency and Structural Integrity Analysis Natural Frequency and Structural Integrity Analysis for PVNGS Unit 3 RV BMI Nozzle Repair

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