ML15190A268

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1400669.312, Rev. 0, Hot Leg Drain Nozzle Weld Residual Stress Analysis
ML15190A268
Person / Time
Site: Palisades Entergy icon.png
Issue date: 05/05/2015
From: Fong M
Structural Integrity Associates
To:
Office of Nuclear Reactor Regulation
Shared Package
ML15190A274 List:
References
10426669, 1400669 1400669.312, Rev. 0
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  • -j'*jStructural Integrity Associates, Incl File No.: 1400669.312 V s Project No.: 1400669 CALCULATION PACKAGE Quality Program Type: Z Nuclear [] Commercial PROJECT NAME:

Palisades Flaw Readiness Program for 1R24 NDE Inspection CONTRACT NO.:

10426669 CLIENT: PLANT:

Entergy Nuclear Operations, Inc. Palisades Nuclear Plant CALCULATION TITLE:

Hot Leg Drain Nozzle Weld Residual Stress Analysis Document Affected Project Manager Preparer(s) &

Revision Pages Revision Description Approval Checker(s)

Signature & Date Signatures & Date 0 1 - 38 Initial Issue Preparer:

A A-2 Computer Files Norman Eng NE 5/5/2015 Minji Fong MF 5/5/2015 Checkers:

Charles Fourcade CJF 5/5/2015 Gole Mukhim GSM 5/5/2015 Page 1 of 38 F0306-01R2

j an ni hglfn yAssociates, Inc.

Table of Contents 1.0 OBJECTIVE .................................................................................................................. 5 2.0 TECHNICAL APPROA CH ...................................................................................... 5 2.1 M aterial Properties ......................................................................................... 5 2.2 Finite Element Model for Weld Residual Stress Analysis ........................... 6 2.3 W elding Sim ulation ...................................................................................... 6 2.4 H eat Inputs .................................................................................................... 6 2.5 Creep Properties ........................................................................................... 7 2.6 M echanical Boundary Conditions ............................................................... 7 3.0 A SSUM PTION S...................................................................................................... 7 4.0 WELD RESIDUAL STRESS AN ALY SIS ............................................................. 8 4.1 Hot Leg Cladding ........................................................................................ 8 4.2 Boss Weld .................................................................................................... 9 4.3 ID Patch W eld ................................................................................................ 9 4.4 Post-weld Heat Treatm ent ............................................................................ 9 4.5 Hydrostatic Test ........................................................................................... 10 4.6 Five N orm al Operating Cycles (N OC) ........................................................ 10 5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS .................................... 11 5.1 Welding Tem perature Contours ................................................................. 11 5.2 PWH T Tem perature Results ...................................................................... 11 5.3 Residual Stress Results ............................................................................... 11 6.0 CON CLU SION S ................................................................................................... 12 7.0 REFEREN CES ........................................................................................................ 12 APPEN DIX A COM PUTER FILES LISTIN G ............................................................... A -1 File No.: 1400669.312 Page 2 of 38 Revision: 0 F0306-01R2

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List of Tables Table 1: Elastic Properties for SA-516 Grade 70 (5 4" Thick) .......................................... 13 Table 2: Elastic Properties for ER308L ............................................................................. 14 Table 3: Elastic Properties for Alloy 600 ................................................................................ 15 Table 4: Elastic Properties for Alloy 182 .......................................................................... 16 Table 5: Stress-Strain Curves for SA-516 Grade 70 (< 4" Thick) .................. 17 Table 6: Stress-Strain Curves for ER308L ........................................................................ 18 Table 7: Stress-Strain Curves for Alloy 600 ....................................................................... 19 Table 8: Stress-Strain Curves for Alloy 182 ...................................................................... 20 Table 9: Creep Properties ................................................................................................. 21 File No.: 1400669.312 Page 3 of 38 Revision: 0 F0306-01R2

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List of Figures Figure 1. Finite Element Model for Residual Stress Analysis ........................................... 22 Figure 2. Applied Mechanical Boundary Conditions ........................................................ 23 Figure 3. Weld Nugget Definitions for the Boss Weld ..................................................... 24 Figure 4. Weld Nugget Definitions for the ID Patch Weld ............................................... 25 Figure 5. Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure Loads ..26 Figure 6. Predicted Fusion Boundary Plot for Cladding ................................................... 27 Figure 7. Predicted Fusion Boundary Plot for Boss Weld .................................................. 28 Figure 8. Predicted Fusion Boundary Plot for ID Patch Weld .......................................... 29 Figure 9. Time vs. Temperature Curve for PWHT ........................................................... 30 Figure 10. Predicted von Mises Residual Stress at 70'F after ID Patch Weld .................. 31 Figure 11. Predicted von Mises Residual Stress at 70'F after PWHT .............................. 32 Figure 12. Paths for Stress Extraction ............................................................................... 33 Figure 13. Residual Stress Comparison at 70'F Before and After PWHT ........................ 34 Figure 14. Measured Through-Wall Residual Stresses for PWHT ................................... 35 Figure 15. Predicted von Mises Residual Stress at 70'F after Hydrostatic Test ............... 36 Figure 16. Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle) ....... 37 Figure 17. Predicted Hoop Residual Stress + Operating Conditions (5th NOC Cycle) ......... 38 File No.: 1400669.312 Page 4 of 38 Revision: 0 F0306-01R2

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1.0 OBJECTIVE The objective of this calculation package is to document the weld residual stress analysis for the hot leg drain nozzle at the Palisades Nuclear Plant (Palisades). The weld residual stress analysis is based on the latest methodology and process developed by Structural Integrity Associates (SI).

2.0 TECHNICAL APPROACH The finite element model is obtained from a previous finite element model (FEM) calculation package

[1] and the weld residual stress analysis uses the latest weld residual stress analysis methodology developed by SI, using the ANSYS finite element analysis (FEA) program [3].

The residual stress analysis consists of a thermal pass followed by a stress pass, where the temperature distribution time history from the thermal pass is used as temperature input into the stress pass to determine stresses. Stress results from the weld residual stress analysis are obtained and saved for future use to evaluate flaws which will be performed in a separate calculation package.

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

2.1 Material Properties The weld residual stress analysis performed in this calculation uses the material properties specifically developed in a separate calculation package for weld residual stress analyses [2]. Per the material designation used in the FEM calculation [1], the following materials are used:

" SA-516 Grade 70: Hot leg base metal

" ER308L: Hot leg cladding (typical weld metal for Type 304)

" Alloy 182: Boss weld and ID patch weld 0 Alloy 600 (SB-166): Drain nozzle The material properties are reproduced in Table 1 through Table 8.

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Cj Msiwiw lae grityAssoCkiats, Wl 2.2 Finite Element Model for Weld Residual Stress Analysis The finite element model for the analysis was developed in a previous FEM calculation [1], which was created using the ANSYS finite element analysis software package [3]. The base finite element model for the weld residual stress analysis is meshed with 8-node solid elements (SOLID 185) in ANSYS. This finite element model is shown in Figure 1.

2.3 Welding Simulation The FEA for predicting the weld residual stresses is performed as a continuous analysis so that the load history from the cladding is carried over the nozzle-to-pipe weld and ID patch weld. Specifically, the residual stresses and strains at the end of one weld pass are used as initial conditions at the start of the next weld pass.

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

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

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

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

The following summarizes the welding parameters used in the analysis:

" Interpass temperature = 350°F [4]

" Melting temperature = 2500'F (See Section 3.0)

  • Reference temperature = 70'F (See Section 3.0)

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V obn fri/Irs gr/flr Assoceis, Inc.

0 Heat input for all welds = 28 kJ/in (See Section 3.0) 0 Heat efficiency for all welds = 0.8 (See Section 3.0) a Inside/Outside heat transfer coefficient 5 Btu/hr-ft2-°F (See Section 3.0) 0 Inside/Outside temperature = 70'F (See Section 3.0) 2.5 Creep Properties Strain relaxation due to creep at high temperature is considered in the post-weld heat treatment (PWHT) step of the analysis. In general, creep becomes significant at temperature above 800'F; thus, creep behavior under 800'F will not be considered in this analysis. The creep properties listed in Table 9 are detennined in the previous FEM calculation [1].

2.6 Mechanical Boundary Conditions The mechanical boundary conditions for the stress analysis are symmetric boundary conditions at the symmetry planes of the model, axial displacement restraint at the end of the nozzle, and axial displacement coupling at the end of the hot leg piping, as shown in Figure 2.

3.0 ASSUMPTIONS The following assumptions are used in the analyses:

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

  • The metal melting temperature is assumed to be 2500'F, which is the temperature point where the strength of the material is set to near zero [1].

" The analysis is performed with a reference temperature of 70'F.

" The exposed surface of the model is subject to a typical ambient air cooling convection film coefficient of 5 Btu/hr-ft2 -°F at a bulk temperature of 70'F. The exposed surfaces are defined as the exterior surfaces of the model, excluding the symmetry planes and the far ends of the modeled piping and nozzle.

" Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/in, with an overall heat efficiency of 0.8, is assumed for all of the welds.

" The focus of this analysis is the residual stresses in the drain nozzle boss weld region, while the interaction between the clad buildup and the hot leg base metal has secondary effects on the region of interest. Therefore, the clad is assumed to be fully deposited in a single one-layer pass.

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" The boss weld is represented by a 40-bead process, as shown in Figure 3, with each bead represented by a one pass "bead ring" nugget. This approach is a common and acceptable industry practice when information regarding the bead start/stop position and sequencing are unknown.

" Similarly, the ID patch weld is represented by a 6-bead process, as shown in Figure 4, with each bead represented by a one pass "bead ring" nugget.

  • For model simplification, the penetration hole is present during the deposition of the clad material. This is acceptable since any localized stress with or without the hole would have negligible impact on the final results.
  • For convenience, the modeled ID patch weld has the same geometry as the backing ring for the boss weld.

" Additional assumptions on PWHT are discussed in Section 4.4.

4.0 WELD RESIDUAL STRESS ANALYSIS The weld residual stress analysis consists of a thermal analysis to determine the temperature distribution followed by a stress analysis to determine the resulting stresses. The analytical sequence described below is used in the finite element analysis, followed by detailed discussions of the steps in Sections 4.1 through 4.6:

1. Deposit cladding on hot leg pipe inside (ID) surface.
2. Install drain nozzle, backing ring, and deposit boss weld.
3. Remove backing ring and deposit ID patch weld.
4. Post-weld heat treatment, including creep effects based upon experimental data per Table 9.
5. Subject the configuration to hydrostatic test.
6. Impose five cycles of "shake down" with normal operating temperature and pressure to stabilize the residual stress fluctuations due to stress redistribution caused by normal operating loads.

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

However, the focus of this analysis is on the as-welded residual stresses, while the interaction between the clad buildup and the base material during the many actual weld passes is not of interest. Therefore, the clad is assumed to be fully deposited in a single pass.

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

4.2 Boss Weld The boss weld connects the drain nozzle boss to the hot leg piping. As shown in Figure 3, the weld is composed of 40 nuggets deposited in 20 weld layers. In the absence of detailed weld fabrication information, a weld sequence is assumed based on standard welding practice at the time of fabrication.

In particular, for every layer, the first nugget is deposited on the hot leg side, the second nugget on the nozzle side.

At this step, the drain nozzle elements and backing ring elements are reactivated, and the boss weld nuggets are reactivated sequentially to simulate the welding process. The preheat temperature of the boss weld is 250'F [4]. At the end of the boss weld, the entire model is cooled to 70'F before the application of the ID patch weld.

4.3 ID Patch Weld The final weld step is to add the ID patch weld, which replaces the backing ring. As seen in Figure 4, the ID patch weld is composed of 6 nuggets deposited in 2 layers.

At this step, the backing ring is first deactivated to allow the residual stresses to redistribute, and the ID patch weld nuggets are reactivated sequentially to simulate the welding process. The preheat temperature of the ID patch weld is 250'F [4]. At the end of the ID patch weld, the entire model is cooled to 70'F before the post-weld heat treatment (PWHT).

4.4 Post-weld Heat Treatment PWHT is assumed to be performed as per the following procedure outlined in Article N-532 of the ASME Code,Section III [7] and the welding procedure [4] for welding on material group P-i:

1. Heat welded piping component to 11 50'F [4] at a heating rate of 400'F per hour divided by the maximum metal thickness (100'F per hour for 4 inch thick hot leg) [7, Article N-532.3 (2)].
2. Hold at temperature for approximately 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> (lhr/in of weld thickness) [7, Table N-532].
3. Allow to cool to 600'F at a cooling rate of 500'F per hour divided by the maximum metal thickness (125°F per hour for 4 inch thick hot leg) at temperature above 600'F [7, Article N-532.3 (5)].
4. Air-cool from 600'F to ambient [7, Article N-532.3 (5)].
5. A steady state load step is imposed at the end of the PWHT process.

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

4.5 Hydrostatic Test A hydrostatic test pressure of 3110 psig (3125 psia) and a temperature of 400'F [8, page 9] are applied after the welding. The pressure is applied on the ID surfaces of the hot leg pipe and drain nozzle. End-cap loads, Pend-cap-hl is applied at the free end of the hot leg piping. This is calculated based on the following expression:

P x Finside-hi 2

Pend-cap-hl " 2 routside-hl - rinside-h1 where, P = Hydrostatic test pressure (ksi)

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

The applied pressure loads on the model are shown in Figure 5.

4.6 Five Normal Operating Cycles (NOC)

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

The applied operating pressure is 2085 psig (2100 psia) and temperature is 583°F [9]. The temperature is assumed to be uniform throughout the components and operating pressure is applied as an internal pressure on the ID surface, with corresponding end cap pressures calculated using the equation in the previous section. The term "P" is replaced by the operating pressure in the expression.

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5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS The ANSYS input files and computer output files for the analyses are listed in Appendix A.

5.1 Welding Temperature Contours The maximum temperature prediction contours for each weld are created using the macro MapTemp.mac. This type of contour plot is also called a "fusion boundary" plot because it provides an overview of the maximum temperature on each node throughout the thermal transient for each welding process. The plots are useful in visualizing the melting of weld metal and the extent of heat penetration.

The predicted fusion boundary contours for the cladding, the nozzle-to-pipe weld, and ID patch weld applications are shown in Figure 6, Figure 7, and Figure 8, respectively. The purple color in the plots represents elements at melting temperature (>2500'F); the plots show complete melting of the weld metal for each weld and slight melting of the base metal along the weld interface.

5.2 PWHT Temperature Results Figure 9 plots the inside surface temperature curve for the PWHT process. It shows the linear 100F/hr heating rate, 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> (240 minutes) hold time at 1150°F, 125°F/hr cooling rate at temperature above 600'F, and the air cooling to room temperature of 70'F.

5.3 Residual Stress Results Figure 10 plots the von Mises residual stresses after welding is complete, but before PWHT. It shows extensive residual stresses of greater than 66.3 ksi in the weld material. However, as shown in Figure 11, after the PWHT the residual stresses in the weld have relaxed significantly, to below 49.2 ksi, but the residual stresses in the cladding remain essentially unchanged.

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

The PWIJT results from the FEA trend comparably well with the data in EPRI report TR-105697 [10],

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

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Figure 15 depicts the predicted von Mises residual stresses after the hydrostatic test. It shows an insignificant reduction in maximum stress when compared to the post-PWHT step: 73.749 ksi (Figure

15) versus 73.750 ksi (Figure 11), while the overall stress contour remains essentially the same.

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

6.0 CONCLUSION

S Finite element residual stress analysis has been performed on the hot leg drain nozzle boss weld at Palisades. Stresses at normal operating conditions combined with residual stresses have been obtained and saved for future use. The stress results will be used in a separate calculation to determine crack growth.

7.0 REFERENCES

1. SI Calculation No. 1400669.310, Rev. 0, "Finite Element Model for Hot Leg Drain Nozzle."
2. SI Calculation No. 0800777.307, Rev.5, "Material Properties for Residual Stress Analyses, Including MISO Properties Up To Material Flow Stress."
3. ANSYS Mechanical APDL and PrepPost, Release 14.5 (w/ Service Pack 1), ANSYS, Inc.,

September 2012.

4. Combustion Engineering Welding Procedure No. MA-41, Rev.0, SI File No. 1400669.204.
5. "Steels for Elevated Temperature Service," United States Steel Co., 1949.
6. Publication SMC-027, "Inconel Alloy 600," Special Metals Corp., 2004, SI File No.

0800777.211.

7. ASME Boiler and Pressure Vessel Code,Section III, 1965 Edition with Addenda through Winter 1966.
8. Combustion Engineering Specification No. 0070P-006, Rev.2, "Engineering S1pecification for Primary Coolant Pipe and Fittings," SI File No. 1300086.203.
9. Palisades Design Input Record, "Palisades Alloy 600 Flaw Eval DIR 3-4-15 Revl.pdf," SI File No. 1400669.201.
10. EPRI Report No. TR-105697, "BWR Reactor Pressure Vessel Shell Weld Inspection Recommendations (BWRVIP-05)," September 1995.

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VjIsbwhtrhI,hglnfyAssacials, Incs Table 1: Elastic Properties for SA-516 Grade 70 (5 4" Thick)

Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity (2) Specific Heat (2)

(0 F) 3 (x10 ksi) (x10- 6 in/in/0 F) (Btu/min-in-°F) (Btu/lb'°F) 70 29.5 6.4 0.0488 0.103 500 27.3 7.3 0.0410 0.128 700 25.5 7.6 0.0369 0.138 1100 18.0 8.2 0.0290 0.171 1500 5.0 8.6 0.0218 0.198 2500 0.1 9.5 0.0014 0.204 2500.1 - 0.0 - -

Notes:

1. All values per [2].
2. Density (p) = 0.283 lb/in 3 [2], assumed temperature independent.
3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.

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Table 2: Elastic Properties for ER308L Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity (2) Specific Heat (2)

(0 F) 3 (x10 ksi) (xl0-6 in/in/lF) (Btu/min-in-°F) 0 (Btu/lb- F) 70 28.3 8.5 0.0119 0.116 500 25.8 9.7 0.0151 0.131 700 24.8 10.0 0.0164 0.135 1100 22.1 10.5 0.0189 0.140 1500 18.1 10.8 0.0213 0.145 2500 0.1 11.5 0.0292 0.159 2500.1 - 0.0 - -

Notes:

1. All values per [2].
2. Density (p) = 0.283 lb/in 3 [2], assumed temperature independent.
3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.

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Table 3: Elastic Properties for Alloy 600 Temperature Young's Mean Thermal Thermal (0 F) Modulus (x10 3 ksi) Expansion (x10-6 in/in/0 F) Conductivity (2)

(Btu/min-in-*F) SpecificHeat(2)

(Btu/lb-'F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 - 0.0 - -

Notes:

1. All values per [2].
2. Density (p) = 0.300 lb/in3 [2], assumed temperature independent.
3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.

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6ssociats. Inc.

Vjstnwbra91I tughTir A Table 4: Elastic Properties for Alloy 182 Temperature Young's Mean Thermal Thermal

( 0 F)

Modulus Expansion Conductivity (2) Specific Heat (2)

(xl03 ksi) (xl0-6 in/in/0 F) (Btu/min-in-°F) 0 (Btu/lb- F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -_ 1:____0.0 - -

Notes:

1. All values per [2].
2. Density (p) = 0.300 lb/in 3 [2], assumed temperature independent.
3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.

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Table 5: Stress-Strain Curves for SA-516 Grade 70 (5 4" Thick)

Temperature Strain Stress

('F) (in/in) (ksi) 0.00128814 38.000 0.00187809 42.000 70 0.00257329 46.000 0.00381110 50.000 0.00600383 54.000 0.00113553 31.000 0.00142679 35.875 500 0.00183954 40.750 0.00261139 45.625 0.00415246 50.500 0.00106667 27.200 0.00132412 32.550 700 0.00166876 37.900 0.00228121 43.250 0.00354341 48.600 0.00116667 21.000 0.05116163 22.125 1100 0.05915444 23.250 0.06794123 24.375 0.07755935 25.500 0.00300000 15.000 0.16717493 15.125 1500 0.16992011 15.250 0.17268761 15.375 0.17547742 15.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes:

1. All values per [2].
2. Values at 2500'F assumed arbitrarily small values for convergence stability.

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Table 6: Stress-Strain Curves for ER308L Temperature Strain Stress

('F) (in/in) (ksi) 0.00203180 57.500 0.02471351 61.563 70 0.03107296 65.625 0.03861377 69.688 0.04747167 73.750 0.00140089 36.143 0.00714793 40.250 500 0.01065407 44.357 0.01558289 48.464 0.02233857 52.571 0.00132488 32.857 0.00477547 37.125 700 0.00743595 41.393 0.01143777 45.661 0.01727192 49.929 0.00121913 26.943 0.00264833 30.138 1100 0.00404100 33.332 0.00634529 36.527 0.01005286 39.721 0.00117995 21.357 0.05352064 21.563 1500 0.05610492 21.768 0.05878975 21.973 0.06157807 22.179 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes:

1. All values per [2].
2. Values at 2500'F assumed arbitrarily small values for convergence stability.

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Table 7: Stress-Strain Curves for Alloy 600 Temperature Strain Stress

('F) (in/in) (ksi) 0.00157419 48.800 0.01658847 55.300 70 0.02343324 61.800 0.03212188 68.300 0.04291703 74.800 0.00152069 44.100 0.01539220 50.338 500 0.02210610 56.575 0.03072476 62.813 0.04153277 69.050 0.00152128 42.900 0.01634485 49.000 700 0.02334760 55.100 0.03227153 61.200 0.04338643 67.300 0.00155985 40.400 0.02275193 44.475 1100 0.03004563 48.550 0.03888203 52.625 0.04943592 56.700 0.00092641 21.400 0.08827666 22.475 1500 0.09785101 23.550 0.10796967 24.625 0.11863796 25.700 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes:

1. All values per [2].
2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.312 Page 19 of 38 Revision: 0 F0306-01R2

V ~SM&,Ifri~rIht, y Associaes, IncG Table 8: Stress-Strain Curves for Alloy 182 Temperature Strain Stress

('F) (in/in) (ksi) 0.00179032 55.500 0.03456710 60.113 70 0.04292837 64.725 0.05257245 69.338 0.06359421 73.950 0.00164483 47.700 0.02976152 52.313 500 0.03809895 56.925 0.04790379 61.538 0.05929946 66.150 0.00159574 45.000 0.02849157 49.538 700 0.03680454 54.075 0.04663682 58.613 0.05812078 63.150 0.00159073 41.200 0.03568855 44.488 1100 0.04402702 47.775 0.05360088 51.063 0.06449835 54.350 0.00106494 24.600 0.11812735 25.325 1500 0.12540227 26.050 0.13290814 26.775 0.14064577 27.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375

__ __ __ 0.16683167 1.500 Notes:

1. All values per [2].
2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.312 Page 20 of 38 Revision: 0 F0306-01R2

VjS&InAUMi IntgrfiyAssocates. InO' Table 9: Creep Properties Material Temperature Creep Strength (ksi) A (OF) al (0.0001%/hr) 02 (0.00001%/hr) (ksi/hr)

SA-516 Gr. 70 800 19.0 12.4 1.26E-13 5.40 900 9.0 6.7 3.59E-14 7.80 (Based on carbon steel) 1000 3.5 2.8 2.43 E- 12 10.32 Per[5] 1100 1.4 0.8 2.50E-07 4.11 ER308L 800 33.4 25.0 7.73E-19 _____

7.95 900 24.0 17.6 5.67E- 17 7.42 (Based on Type 304) 1000 17.6 11.5 1.82E-13 5.41 Per[5] 1100 11.5 7.1 8.62E-12 4.77 Alloy 600 800 40.0 30.0 1.50E-19 8.00 Alloy 182 900 28.0 18.0 2.87E-14 5.21 (Based on 1000 12.5 6.1 3.02E- 10 3.21 Alloy 600)

Per [6] 1100 6.8 3.4 1.72E-09 3.32 File No.: 1400669.312 Page 21 of 38 Revision: 0 F0306-01R2

~SbwbnI Iabgnfy Associafs, ~

Figure 1. Finite Element Model for Residual Stress Analysis File No.: 1400669.312 Page 22 of 38 Revision: 0 F0306-01R2

Van" bft* ASSOWN, him's ELEMENT'S Axial displacement couples Symmetry boundary conditions Axial displacement restraint

/

/

Figure 2. Applied Mechanical Boundary Conditions File No.: 1400669.312 Page 23 of 38 Revision: 0 F0306-01R2

COW" bft* AMOGWOS, fte Figure 3. Weld Nugget Definitions for the Boss Weld File No.: 1400669.312 Page 24 of 38 Revision: 0 F0306-01R2

&Vean"ahuIqIy Associaes1 IncG Figure 4. Weld Nugget Definitions for the ID Patch Weld File No.: 1400669.312 Page 25 of 38 Revision: 0 F0306-O1R2

V on"~wuu IAfuge Associates, IncG TYPE NU Hot leg end cap pressure Internal pressure

-7.38152 -5.05007 -2.71862 -. 387175 1.94428 Hydrostatic test -6.2158 -3.88435 -1.5529 .77855 3.11 ksi Figure 5. Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure Loads File No.: 1400669.312 Page 26 of 38 Revision: 0 F0306-01R2

SVan"w lWAbry Assocafts, W 17- 1 70 340 610 880 1150 1420 1690 2230 1960 2500 OF Predicted fusion boundary plot (Purple - Temperature > Melting)

Figure 6. Predicted Fusion Boundary Plot for Cladding (Note: Purple = Temperature > Melting temperature of 2500'F)

File No.: 1400669.312 Page 27 of 38 Revision: 0 F0306-01R2

Van" NWNY Awdeft, knO Figure 7. Predicted Fusion Boundary Plot for Boss Weld (Note: Purple = Temperature > Melting temperature of 2500'F)

File No.: 1400669.312 Page 28 of 38 Revision: 0 F0306-01R2

Cjjouiww Iaqg*l Associats, /nc Figure 8. Predicted Fusion Boundary Plot for ID Patch Weld (Note: Purple = Temperature > Melting temperature of 2500'F)

File No.: 1400669.312 Page 29 of 38 Revision: 0 F0306-01R2

wbvwV klft ASSiate, k,.

1250 1125 1000 875 750 Terrperature (F) 6251 500 375-250 125 0

1000 1400 1800 2200 2600 3000 1200 1600 2000 2400 2800 Time (min)

Figure 9. Time vs. Temperature Curve for PWHT Note:

1. PWHT temperature history is for a typical ID node on the model.

File No.: 1400669.312 Page 30 of 38 Revision: 0 F0306-01 R2

VON" MWW As=Aft Inc.0 Figure 10. Predicted von Mises Residual Stress at 70°F after ID Patch Weld File No.: 1400669.312 Page 31 of 38 Revision: 0 F0306-01R2

Can" &A" Assadates,hY.0 Figure 11. Predicted von Mises Residual Stress at 70°F after PWHT File No.: 1400669.312 Page 32 of 38 Revision: 0 F0306-01R2

W itstViiaW& hgfysociates, Ince Figure 12. Paths for Stress Extraction Notes:

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

File No.: 1400669.312 Page 33 of 38 Revision: 0 F0306-01R2

CAW" MM* Awadates, Inalm 80

]: + As-Welded (P1) 70 El PWHT (PI) 60

  • As-Welded (P2) 50 A PWHT (P2) 40

+

30 IA

+

20 ---

In U'

S..

4.'

10 0

-10 Clad interface

-20

-30

++ - ---- -- - ------------- -----

-40 ++

-50 I . I . I . I . I . I 0.6 0.7 0.8 0.9 1 I C).0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Normalized Thickness (x/t)

Figure 13. Residual Stress Comparison at 70°F Before and After PWHT File No.: 1400669.312 Page 34 of 38 Revision: 0 F0306-01R2

Cjsban"u hbp*ft'sociats,him@

120 A a A-Welded OPWHT 100 +

~- Clad Interface 80 +

A LD 60' 7at 0-0 A 40 0 0 0 I )*

20t Data from EPRI TR-1 01 989 0 -I

  • Thi*wC4ud Test, no Inuufue at Depth 0

0 0

-20 +

A

-40 4 4 I I I 0 02 0.4 0.6 0.8 1.3 Distance from Clad Surface (inches)

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

1. Figure is obtained from EPRI report TR-105697 [10].
2. Measurements show little to no stress reduction in the cladding after PWHT.
3. Measurements show significant stress reduction in the base metal after PWHT.

File No.: 1400669.312 Page 35 of 38 Revision: 0 F0306-01R2

Cj~suan" Ibfwgd Assocatps, Inr.G Figure 15. Predicted von Mises Residual Stress at 70°F after Hydrostatic Test File No.: 1400669.312 Page 36 of 38 Revision: 0 F0306-01 R2

can&*etuw MWfwgly Assocates, Wc Figure 16. Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle)

Note: Radial stresses shown in the nozzle axis radial direction.

File No.: 1400669.312 Page 37 of 38 Revision: 0 F0306-01R2

VOW&W AdW* AwacWes, Inc.'s Figure 17. Predicted Hoop Residual Stress + Operating Conditions (5th NOC Cycle)

Note: Hoop stresses shown in the nozzle axis circumferential direction.

File No.: 1400669.312 Page 38 of 38 Revision: 0 F0306-01R2

CAN" Moo* AWsc&M,tes APPENDIX A COMPUTER FILES LISTING File No.: 1400669.312 Page A- I of A-2 Revision: 0 F0306-01R2

C aj~n"i hiidfy ASSOciates, Wnc File Name Description PalisadesHLDrain.INP Input file to create base geometry model [1]

MPropMISO.INP Elastic-plastic Material properties inputs [1]

Autonugsel.mac Macro that groups elements into nuggets BCNUGGET3D.INP Weld pass and model boundary definition file THERMAL3D.INP Input file to perform the thermal pass of welding simulation THMPWHT.INP Input file to perform the thermal pass of PWHT STRESS3D.INP Input file to perform the stress pass of welding simulation CBC.INP Input file to apply mechanical boundary conditions THMPWHT-mntr.inp Processed thermal pass load steps for PWHT INSERT3D.INP Input file to perform the stress pass of hydrostatic test WELD#_mntr.inp Processed thermal pass load steps for stress pass # = 1-3

  • .mac WRS analysis macro files required for analysis THERMAL3D.TXT Parameter input file for thermal pass of welding simulation STRESS3D.TXT Parameter input file for stress pass GenStress.mac Macro to extract PWHT stress results GETPATH.TXT Through-wall stress path definition to extract PWHT stress results File No.: 1400669.312 Page A-2 of A-2 Revision: 0 F0306-01R2
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