ML20033F566

Design Rept for Recirculation Sys Repair & Flaw Evaluation Performed During Fall 1989 Refueling Outage at Brunswick Steam Electric Plant Unit 2

ML20033F566
Person / Time
Site:	Brunswick
Issue date:	03/01/1990
From:	Giannuzzi A, Gustin H, Riccardella P STRUCTURAL INTEGRITY ASSOCIATES, INC.
To:
Shared Package
ML20033F565	List: ML20033F564 ML20033F566
References
SIR-90-016, SIR-90-16, NUDOCS 9003220057
Download: ML20033F566 (33)

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i Report No.: SIR-90-016. Rev. No. O Project No.: CPL-09Q March, 1990 i I 1 l 1 1 Design Report For 'l Recirculation System Repair and Flaw Evaluation Performed During Fall, 1989 Refueling Outage at , Brunswick Steam Electric Plant i Unit 2 Prepared for: Carolina Power & Light Company q I Prepared by Structural Integrity Associates San Jose, California a~ (, . Prepared by: Date: 3 ' l' T C H. L. Gustin 3"I-fd Prepared'by:- M Date: -IL. A. Gi n (z / / c Reviewed and / Approved by: /f,[)/ /) Date: 3/I 90 F. ~C. Riccardell C l 5 1 l l

4 i. I TABLE OF CONTENTS Section Pacre -{

1.0 INTRODUCTION

1-1 2.0 DESIGN CRITERIA. 2-1 i

3.0 ANALYSIS.

3-1 3.1 Flaw Characterization. 3-1 3.2 Weld overlay Design Calculations 3-1 3.3 Flaw Growth Evaluation For Continued Service Justification.. 3-3 3.4 Weld overlay Shrinkage Stress Analysis 3-4

4.0 CONCLUSION

S 4-1

5.0 REFERENCES

5-1 APPENDIX A - Repair Design Calculatiotis for Weld 28-B10 APPENDIX B - Flaw Growth Analysis for Weld 22-AM-1 t l k SIR-90-016, Rev. O i I'.D M n DfTEGBITY ASSOCIATESIlO

e 4 LIST OF TABLES Table 2-1 Stress Components for Flaw-Growth Analysis 2-2 ' Stress Components for Weld Overlay Design 3-1 Observed Flaws In Welds During 1989-1990 Outage 3-2 1989 Weld Overlay Repair Design and As-Built Dimensions i 3-3 Measured Weld overlay Shrinkages LI 3-4 Weld overlay Shrinkage Induced Stresses at Unrepaired Flawed Welds h .I I-4 i + t' SIR-90-016, Rev. O 11 ^ ASSOCIATESINC n a ,w--

I LIST OF FIGURES l Ficure j 3-1 Finite Element Model of Recirculation System for Use In i Determination of Weld overlay Shrinkage Induced Stresses i 1 4 I L ..] T . I SIR-90-016, Rev. O iii DfTEGRITY I, m yc

5

1. 0 - INTRODUCTION Carolina Power & Light's (CP&L's) Brunswick Steam Electric Plant Unit 2 (BSEP-2) performed augmented ' ultrasonic examinations as

.part of.its inservice inspection program of austenitic stainless steel welds in the recirculation and related systems during the-Fall 1989 refueling outage. During this inspection, indications believed to be due to Intergranular Stress Corrosion Cracking (IGSCC) were identified in the heat affected zones of two welds I. in the recirculation system. One of the welds, weld 22-AM-1, a 22-inch diameter recirculation header cross-tie valve to. pup piece weld, contained one circumferential1y orientied IGSCC-like defect. The other weld, weld 28-B10, a 28-inch diameter pipe to pump suction elbow

weld, contained 8

axial IGSCC-like indications. The flaws in weld 28-B10 were repaired by application of a weld overlay meeting the " standard" weld overlay' criteria of NUREG-0313, Revision 2 (Reference 1). The fit y in weld 22-AM-1, was of a limited circumferential extent and dep h. Thus a flaw evaluation was performed for this weld in accordance with the Reference 1 requirements to justify the weld for continued operation without a repair. The as-built - dimensions of the weld overlay repair applied to weld 28-B10, during the Fall, 1989 outage were reviewed and found to meet or exceed the design minimum dimensional requirements for the repair. An evaluation of the effects of the weld overlay induced shrinkage on the existing recirculation piping system, including the replaced recirculation riser piping and safe ends was also performed. Significant stresses do not result from the 1989 Weld overlay repair. This report documents the design analysis and evaluation j activities conducted on the flawed welds by Structural Integrity l. Associates (SI) for CP&L and summarizes the current state of the recirculation piping at BSEP-2. Section 2 defines the design l SIR-90-016, Rev. 0 1-1 ASSOCIATESINC 1:

- - - =.... - t i criteria employed on the affected locations. Section 3 discusses the analysis and weld overlay repair design for the new repair i (weld. 28-B10) and the crack growth analysis for the flawed weld 'i (22-AM1) for which repair was not required. The analysis of weld overlay induced shrinkage stress is also discussed in Section 3. I t a h t s .f 2 I l 1 1 1 l I 1 ] ~ l SIR-90-016, Rev. 0 1-2 M M 1 ISSOCMPESHC L

.f -2.0 DESIGN CRITERIA The requirements for design of weld overlay repairs are defined in NUREG-0313, Revision 2 (Reference 1). Flaws are evaluated and the analytical basis for the repairs are in accordance with the requirements of ASME Section XI, IWB-3641 (Reference 2) as 7 specified in.NUREG-0313. Weld overlay repairs are considered to be acceptable long term repairs to IGSCC flawed locations if they ~ meet a conservative set of design assumptions which qualify them as " standard" weld overlays, in accordance with NUREG-0313, Rev. 2. The two principal design requirements to qualify a. weld overlay as a " standard" weld overlay and therefore IGSCC Category E are: 1. The' design basis flaw for the repair is a circumferentially oriented flaw which extends 360* around the component, and is through the original component wall. This conservative assumption eliminates concerns about the reliability of the ultrasonic inspection which initially identified the flaw. 'I - In addition, concerns about the toughness of the original butt weld material are not applicable, since no credit is E: taken in the design process for the load carrying capability of the remaining component wall ligament. 2. Following the repair, the surface finish of.the repair must l be sufficiently smooth to allow ultrasonic examination through the overlay material and into a portion of the original wall. The purpose of this examination is, in part, . g-B to demonstrate that the repair thickness does not degrade "~ with time due to continued flaw propagation. In addition to the requirements of Reference 1, the requirements of the CP&L Design Basis Document DBD-85-20, Revision 6 (Reference 3) apply to the design of weld overlay repairs at BSEP-2. This document defines the applicable Codes and SIR-90-016, Rev. 0 2-1 ernuerunn. -a DrTEGRrFY ]- ASSOCWESINC

i regulatory basis'for the repairs, and also specifies inspection ] requirements for in-process and completed repairs. The applied stresses used in the design for the flaw evaluation and the weld overlay repair were taken from Reference 4 and are summarized,in Tables 2-l' ' and. 2-2. As required by ASME Section XI, IWB-3640 (Roference 2), pressure, ' deadweight, and seismic components were ' considered in the design of the weld overlay ] repair for weld 28-B10. Thermal and other secondary stress 1 components are not required to be addressed, since the toughness i of the original butt' weld material is not' a concern for a 1 f L standard weld overlay, and since no credit is taken for remaining ligament in the original component wall. The stresses used for the crack growth evaluation of weld 22-AM-1 include pressure, deadweight and thermal stresses as well as weld overlay induced shrinkage stresses. I 1 3 SIR-90-016, Rev. 0 2-2 'E. M -E ASSOCIATESINC

Table 2-1 l-1 Stress Components for Flaw Growth Analysis ) Weld' Number Pressure Stresq' Deadweicht Thermal Total (Psi) (psi) (psi) (psi) i 22-AM-1 5502 622 1302 7426. l 1 r j Table 2-2 Stress Components for Weld Overlay Design . Weld Number Pressure Stress Deadweicht + Seismic Total (Psi) (psi) (psi) 28-B10 6750 1281. 8031

g SIR-90-016, Rev. 0 2-3 6

DETEGRFFY m ac y , ~~ c- -.., n s

M 3.0 ANALYSIS i As previously noted, flaws were identified in.two locations in the recirculation system during the 1989-1990 inspection program at BSEp-2. One location was the 22-inch ring header cross-tie valve ~ to pup' piece weld, 22-AM-1. The second location was'the 28-inch pipe to pump suction elbow weld, 28-B10. A standard weld i overlay ' repair, as defined in Section 2 of this report, was designed and applied to the weld 28-B10 location. A flaw growth l evaluation providing justification for continued operation in- ~ accordance with the Reference 1 requirements was performed for weld 22-AM-1. This section describes the design and analysis performed for these two welds, as well as the shrinkage analysis performed for the recirculation system. 3.1 Flaw Characterization i Table 3-1 summarizes the flaw character.4 rations for the two locations addressed by this report (References 5 and 6). For I veld 28-B10, the existence of 8 axial flaw indications exceeds the number' allowed by Reference 1 for continued operation without a repair.- For weld 22-AM-1, the single circumferential flaw met the Reference 1 conditions such that a crack growth evaluation is permitted to justify continued operation without a repair. 3.2 Weld overlav Desian calculations For design of the~ repair, the flaws in weld 28-B10 were assumed to be=circumferentially oriented, to extend 360* around the pipe, and to be through the original - component wall thickness. Comparison of the observed flaws listed in Table 3-1 to that assumed for this design demonstrates that this assumption is very conservative. SIR-90-016, Rev. 0 3-1 I. ASSOCUWESINC

-] The weld overlay design thickness was determined using-the u Structural-Integrity Associates . computer . program pc-CRACK. (Reference 7), which automates;the calculation of ASME.' Section XI, IWB-3640 margins and allowable flaw depths. The. primary stresses listed in ' Table 2-2 were used as input to the, repair thickness calculations. The computer output for this calculation .is. included for reference in Appendix A of this report. In accordance with Reference 1, ' the outside surface of the weld heat affected zone' of the pipe and elbow were surface examined and determined to be free of defects. The initial layer of deposited weld metal contained a ferrite level of greater than 7.5 FN, such that IGSCC credit can be-taken for the initial weld layer.. I The minimum full thickness weld overlay length L was determined from: i. ~ L =-1.5 * @t where:' L R is the pipe outside radius, and l t is the pipe wall thickness 1 l l The design' thickness and length for the weld overlay for weld o 28-B10 are presented in Table 3-2; the as-built dimensions for this overlay repair are also included in Table 3-2 for comparison. Tne as-built dimensions exceed the design minimum l dimensions following surface finish improvement. Consequently, the as-built weld overlay repair for veld 28-B10 is acceptable as s a standard weld overlay in accordance with Reference 1. l l" SIR-90-016, Rev. 0 3-2 m IEFEGRFFY E ASSOCIATEINC i

3 + ) .r 3.3 I Flaw Growth Evaluation For Continued Service JustificatiorJ ~ 1-A' crack growth evaluation. was performed in' accordance with the-Reference 1 requirements for weld'22-AM-1, the cross-tie' valve to pup piece weld in the recirculation system ring header at BSEP-2. 'The conclusion of the evaluation was that the. observed flaw, as . described in Table 3-1, will not grow to a depth corresponding to. the-allowable' flaw size permitted by Section XI,' Table.IWD-3641-5 . (Reference. 2) in1less than 24 months, even under a conservative set of assumptions which include estimated weld ~ overlay shrinkage stresses which'are-expected'to-bound the stresses anticipated at .this location due to system weld overlay application. The input shrinkage. stress was assumed to be that which resulted from system-wide weld overlay appl.ication prior to pipe replacement in. 1 1989. These stresses have. been reduced by the removal and replacement of the 12" risers in.1989, but were used here as a worst case bounding shrinkage stress case. Without consideration s 'of' shrinkage stresses, the remaining ecceptable service life of weld 22-AM-1 is greater than 56 months. Both sets of. flaw grouth calculations (with the previous riser veld overlay shrinkage stresses and without these shrinkage stresses)~ were performed using the SI computer program pc-CRACK (Reference'.7)- and the residual stress correlations ' and _ flaw growth methodology of Reference 1. Applied stresses-were taken from tha Reference-4 stress report. The initial flaw characterization was taken from Reference 5 as presented in Table 3-1. o. R .The results of this evaluation are presented in Appendix A. The calculations show that the flaw remains below the Section XI allowable for a minimum of 24

months, even including the shrinkage stresses due to the old weld overlay repairs-on the

[ risers. The remaining service life is greater than 56 months when the riser shrinkage stresses are not included. [ SIR-90-016, Rev. 0 3-3 a em a w

~ i These - results confirm, that the system may -be operated conservativelyfor the: next fuel / operating cycle with weld 322-AM-l'in its.present unrepaired condition. This weld should be W reinspected and're-evaluated-during-the next refueling outage in I accordance with Reference 1 requirements. 3.4. Weld O'verlav Shrinkaae Stress Analysis j .i Weld overlay shrinkage, which helps produce.the very favorable i s .rr:sidual stress benefits of the weld overlay, also produces - secondary _ stresses at other locations in _ the repaired system. These stresses may affect the potential for' crack growth at unrepaired locations, and consequently the ' effects of weld overlay induced-shrinkage must be assessed in the acceptance e evaluation for these repairs. The measured shrinkage values-resulting from the. application of the ~ single repair applied f during the present outage, together with those observed during previous repair activities (Reference 8), are listed in Table /i 3-3. Note that the Table 3-3 weld overlays include - only those repairs on the 22 inch and 28 inch diameter welds. The riser - replacement _perf ormed during this outage removed all of the 12 H inch diameter overlay repairs e I-In order. to a s s ers s the ef fects of weld overlay shrinkage on -unrepaired locations in the recirculation

system, a

finite i element analysis of the entire system was performed using the ALGOR ' SUPERSAP computer program (Reference 9). The finite i element model is shown in Figure 3-1. Weld overlay shrinkage was [ ~ simulated in the analysis by imposing a fictitious thermal Jeontraction ~ between the locations representing the ends of the h repairs in the model. The analysis included not only the li measured shrinkage resulting from the single weld overlay applied to weld 28-310 during the current outage, but alsc the effects of '~ the remaining previously applied weld overlays on the 22-inch or 28-inch portions of. the recirculation system (9 previous weld overlays as illustrated in Table 3-3). i SIR-90-015, Rev. 0 3"4 6 o lg ASSCXWESINC .s

j 1 The. shrinkage stress results for the three flawed and unrepaired' locations in the recirculation system are summarized in Table J 3-4. Weld. overlay' shrinkage induced stress is a secondary, stress,. which must-be addressed. in - evaluation of - flaws ' accepted without repairs, but are'not. included in design of standard weld'- 1 overlays, as - discussed in NUREG-0313 (Reference 1). Note that .the flaws in two of the three flawed and unrepaired welds are axial, and not affected by shrinkage stresses. 3 The shrinkage stress to the circumferential flaw in weld 22-AM-1 has. been bounded in the flaw analysis-in 'Section 3.3. -The. ( results indicate that the stresses predicted to result from th e aggregate-weld overlay shrinkage in the recirculation system are small enough that effects on unflawed locations will be l insignificant. I b M (:m. l } 1; l.' ^ . ~ - SIR-90-016, Rev. 0 35 g n mm 1,n

.~ , l->;. L] t ,d ;) Table 3-1 1 observed-Flaws In Welds During'1989-1990 Outage. ' Weld Number Flaw Characterization 1 22-AM-1 Circumferential: 2.4" long, 16% through wall, pipe side ?E 28-B10 -Axial: 8 flaws:.0.55" maximum- !5 length, 20% maximum through-wall, elbow side i Table 3-2 f 1989 Weld overlay Repair Design and As-Built Dimensions Design .As-Built . Weld Number Lenath' Thickness Lenath Thickness (in) (in) 28-B10 6.20 0.440 6.367 0.573 I y

,jp

= SIR-90-016, Rev. 0 3-6 137 M 3;; ASSOCIAIESINC BL

je t 1 Table 3-3 Measured. Weld: Overlay Shrinkage Weld Number Total Shrinke.ce 22AM 0.193 22BM-1 0.235 28A-4 0.117 28A-C 0.066 28A-13 0.048 28B-3 0.132 28B-4 0.076 J ^ 28B 0.083 i 28B-10 0.0705 28B-11 0.085 i Table 3-4 . Weld ~ Overlay Shrinkage Induced Stresses at Unrepaired, Flawed. Welds l:: Weld Number Flaw Orientation Stress g (psi) / 22-AM-1 Circumferential 320 i-28-Al Axial-613-l;. l 28-B1 Axial 226- = l; I I '.1 t y . SIR-90-016, Rev. 0 3-7 ~

3 ASSOCIATESINC 1

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~ h / i m y [ g: [ [ D / g s I ,y J ll N -/' / g: r / g J %/ Ny I / j I I ( I 'E Figure 3-1. Finite Element Model of Recirculation System for Use in ' E.'- Determination of Weld Overlay Shrinkage Induced Stresses ,a. 30 a 3-8 smewan.

E INTEGENT s-ASSOCIATESINC

e 1 E 4. 0; CONCLUSIONS l0 L' During.the Fall,- ~1989, refueling -outage, _two new flaws.were detected in large diameter recirculation system plying components at' Brunswick Steam Electric Plant Unit'2. One weld,;containing 8 h axial'

flaws, received a

standard' weld overlay repair in accordance with1 Reference 1 criteria. The second

weld, containing a single, shallow-circumferential crack, was analyzed to be suitable for continued service without: repair in accordance-with the requirements of Reference 1.

Analysis of the effects of weld overlay shrinkage indaced [3 stresses was performed, and the resulting stress on the three unrepaired locations in the recirculation system was observed: to be acceptably low. The values were conservatively bounded by the prior shrinkage _ analyses, wherein the weld overlay repaired riser- . welds were still in the system. q -The recirculation system at BSEP2 currently contains 10 locations which have been repaired by the weld - overlay technique. There remain two~ 28-inch flawed and.unrepaired nozzle to safe end weldments and one 22-inch flawed and unrepaired cross-tie valve to pup piece.weldment. These three welds and other locations'in this system have - been treated by the Induction Heatings Stress Improvement (IHSI). technique or the Mechanical Stress Improvement Process (MSIP) and the plant is currently operating with Hydrogen. Water-Chemistry (HWC) to mitigate the potential for-further IGSCC. Consequently continued operation - with these flaws in .their present condition is justified. t SIR-90-016, Rev. 0 4-1 DITEGRITY o mg

5.0 REFERENCES

1. NUREG-0313, " Technical Report on Material Selection and Processing Guidelines for BWR Coolant Pressure Boundary. Piping", Final Report, Revision 2, U.S. Nuclear Regulatory I Commission, January, 1988. 2. American Society of Mechanical Engineers Boiler & Pressure I Vessel Code, Section XI, 1983 Edition with Addenda through Winter 1985. 3 '. CP&L Design Basis Document DBD-85-20, "BSEP Units'1&2 Weld I Overlays", Revision 6,' October 12, 1989. 4 '. General Electric Company Report, " Brunswick Units 1 & 2-Recirculation Piping Analysis", Report 23AS485, Revision 0, October 1, 1985. -- l 5. GE Nuclear Energy Indication Resolution Sheet R-070, L5 Examination of BSEP-2 Recirculation System Weld 2B32-RR-22-AM-1, Revision 0, October 16, 1989. 6. GE Nuclear Energy Indice. tion Resolution Sheet R-053 Examination of BSEP-2 Recirculation System Weld 2B32-RR-28B-10,.levision 0, October 11, 1989. 7. Structural Integrity Associates, pc-CRACK program, Version 2.0, August, 1989. Structural Integrity Associates Report, " Design Report For 8.- Recirculation System Repairs Performed During Spring 1988 Refueling Outage at Brunswick Steam Electric Plant Unit, 2", ' I -. SIR-88-010, March, 1988. 9. ALGOR SUPERSAP Computer

Program, Version 9.000, ALGOR Interactive Systems, Inc.

I LI

I I

I SIR-90-016, Rev. 0 5-1 I

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.o 4 D ] t s 5 91 .l - ll 3 APPENDIX A'

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'3,..} Y <s -5S Repair Design Calculations for Weld 28-B10: 97m M' .a. I i l 1. L~ g 6-v 1, (- i, SIR-90-016, Rev. O i ~ - w ~' - 3

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8a FLOW l ' = 45* :ilN j IYP l [ l exsxxxxs%xxsz%xzsz b///.mmscsw//w//.scssw!,w.m, T i \\ f 'I I EL30W - PIPE 1 I! cWELD L. WELD DVERLAY o L m-REPAIR DETAILS L3 FLAW DE5IGN OIMENSIONSl COMMENic WELD NUMBER-C9.ARACTERIZATION t. l A l 8 l- ~ o L 2B32-RR-28-B10 8 Axials, Max 0.44" 3.1" 3.1 " - Standard Design Depth 20% Basis Per NUREG-0313, Revision 2 PREPARED SY: DATE DESCRIPTION, ((m j,/26/g9 Reactor Recirculation Loop B: 28" Pipe to Pump Suction Elbow Weld Chr xgs y, gat-l ;. 10/26/f4 aca soi-a'.Ast / ustii REV. L l-CPL-09Q Brunswick Steam Elec'tric 0 Plant, Unit 2 gg lJ M Ja.E sai

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E M E H4C c.HT CPL-090-301 CPL-790-001 1 2

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~ ;.;. ,j e + tm pc-CRACK' (C) COFYRIGHT 1984,'1988 V STRUCT0F<AL, INTEGRITY ASSOCI ATES, INC. .t ".i SAN JOSE, CA (403)378-8200 VERSION 2.0 l Dat.e:'26-Oct-1989 [ Time: 11:12:22.33. j STRUCTURAL' REINFORCEMENT SIZING EVALUATION -i It f8 STRUCTURAL REINFORCEMENT SIZING FO'- CIFCUMF. CRACK WROUGHT / CAST STAINLESSq g - t l L . CPL-094, BRUNSWICF.-UNIT-2, ISI s.25310 ? ? -- WALL THICKNESS: 1.2000 MEMBRANE STRESS ' 6.7500-s BENDING STRESS: l'.2810 . STRESS RATIO:. O.4738 ALLOWAELE. STRESS:- 16.9500 i ^ FLOW. STRESS: 50.8500 L El L/ CIRCUM J-0.00 0.10 0.20 0.30 0.40 0.50 . FINAL A/T 0.7500.0.7500 0.7500 0.7500 0.7500 0.7393 } \\. REINFORCEMENT THICK. 0.4000 0.4000 0.4000 0.4000 0.4000 0.4232 y. t END OF pc-CRACK d ' t k 4 J O o? +

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i 5 a APPENDIX B ,ie s I I-Flaw Growth Analysis-fa'? , Weld-22-AM-1 g i i l l g i s k l l t - SIR-90-016,-Rev. O B-0 4 l

L.. s: ~' 1 3 Ob d' tm oc-CRACK I (C)- COPYRIGHT 1984, 1985 [ STRUCTURAL INTEGRITY ASSOCIATE 5, INC. SAN JOSE,.CA-(405)c78-8200 VERSION 12.0 Date: 5-Jan-1990 . Time: 12: -1:23.81 STRESS CORROSION CRACK GROWTH ANALYSIS j ~! CPLO9: WELD.22 AM-1 INITIAL CRACK SIZE = 0.1800 WALL THICKNESS = 1.1250 f MAX CRACK SIZE FOR SCCG= 0.9000 . STRESS CORRCSION CRACK GROWTH LAW LAW ID C N K t h r e,r. K1C ? i NRR 3.590E-OS 2.1610 0.0000 200.0000 Lg STRESS CCEFFICIENTE P E3 CASE-ID CO C1 C2 CO RESID22 30.2573 -1=0.8645 254.1497 -86.52:1 RPPLIED 10.,0000 0.0000 0.0000 0.0000 lg

5 Kms.M CASE ID SCALS FACTOR

--RESID22 1.00 + APPLIED O.70 TIME PRINT 1 TIME INCREMENT INCREMENT .100000.O 1000.O 1000.O a ' crack medel:CIRCUMFERENTIAL CRACK.IN CYLINDER (T/R=0.1) ' CRACK ---------------ETRESS INTENSITY FACTOh------ ---- SIZE CASE CASE RESID22 APPLIED 0.0190 7.452 2.638 0.0360 9.963 3.747 i .O.0540-11.279 4.610 J 0.0720-12.127 5.347 0.0900 12.589 6.004 IL O.1080 12.763 6.eGe 0.1260 12.787 '7.206 3 0.1440 12.652 7.794 L O.'1620 12.364 S.361 10.1800 11.944 S.914 ? B-1

'] g:: 3 +> 'n '.s e s s (.' < VERSION-2.O l, - p::-CRACK I ' 'm. O~1990 11.410-9.~ 454 0.2160-10.790 9.984- .O.2340 .10.102 1*- '!!5 0.2520 9.083 11.110 e O.2700 S.592 '11.685 0.2880 7.738> 10.258 ~ O. 3060 ~ 6.5,29 .12.931 B O.3240 -5.S67. 10.405 ,x .O.3420-4.925 14.010 O.3600 14.137-14.711. -s 1.. o.mego 4 e.,. 4,9 - t O.3960. 2.AS6 16.136 0.4140 1.e'4 16.860 l 0.4320 0.76o 17.591 1 O.4500- -0.103 10.331 i O.4690 -0.972 19.118 .0.4860 -1.849 19.915 O.5040 -2,700 20.720 ...,e ~.e., O.S-.,O. _v.;1. ' t 0.5400' -4.492 22.359 L , 0..=., c e.,0 _ e... s e 4.e., e, . ~ . O.5760-

.317

-24.084 g JO.5940 -7.300. 25.004 i O.6120 -S.294 25.9~5 a .O.6000 -9.'065 26.876 -O.e4SO -10.240-27.829 '11.207' 22.791 -0.6660 s, iT nv -0.6940 -11.591 29.300 7 'O.7020 -12.2e2 -30.S58-0.7200 -12.530 31.928 0.7380- -12.241. 33.010 0'7560 -13.044 34.104 [; .0.7740- -13.IS4 35.209 'I l 0.7920 ' -13;4o2-36.353 t -O.9100 -14.452 37.588 D ~ 0.9460 -16.2=o 40.098 0.8280 -15,380 OS.836 [ L 0.5640 -17.116 41=.37A 0.8820 -17.917 42.663 0.9000 -1S.=63 43.9e4 a 1 1 ;-. l TIME KMAX DA/DT DA A A/THK l' 1. 1000.0. 18.45 1.oS4E-05 O.01@5 O.1?95 O.177 ) L' i-2000.0 18.29 1.o18E-05 0.01o2 0.2187 0.194 3000.'O 1E.03 1.S5SE-05 0.0186 0.2-~5 0.211 L 4000.0 17.74 1.7o4E-05 O.017o 0.2553 0.227 5000.0-17.43 1.727E-05 O.0173 O.2725 0,242 i 6000.O _17.06 1.650E-05 O.0165 O.2890 0.257 7000.0 16.66 1.5e7E-05 0.0157 0.0047~0.271-B-2

9. : l a

4

pc-CRACK NERSION 2.0' 5000,0 16.27 21.481E-05 0.0148 0.01*5 0.294-9000.0' 15.79 1.;95E-05 0.0140 0.0005 0.296 . I '. 10000.0-15.00 1.320E-05 0.01 2 0.0467 0.008 11000.0 '15.05 1.2s4E-05 0.0126 0.059~ C.01o 12000.0 14.So 1.22*E-05. 0.0120 0.~716 0.000 ,K _ 1~000.0 14.63 1.19;E-05' O.0110 0.0S05 0.'041 14000.0 14.09 1.15EE-05 0.0116 0.CoS1 0.051 1 15000.0' 14.29 1.12;E-05 0.0110 0.406; 0.261 1e000.0 14.0E 1.089E-05 0.010o 0.4170 0.071 17000.0 1~.So 1.057E-05 0.0106 0.4279 0.090 ~ 13000.0 10.:: 1.025E-05 'O.0100 C.4050 0.059 1C000.0 !!.50 9.*49E-06 0.00cc

0. 4'ASC'* V ; !98 20000.0 10.02 9.65EE-06 0.0097 C.457s/0.407 21000.0 10.15 9.405E-06 c.0094

0.1671 0.415-22000.0 10.00

.1s9E-06 0.0092 0.4762:O.42; 22000.'O 12.55 S.941E-0c 0.0099 0.4'E52 3.4 1 24000.0 12.70 S.721E-06 0.0057 c.4?;9 0.c;7 25000.0 12.5: 5.5.2E-Oe 0.0085 0.5024 0.447 26000.0 12.42 8.~10E-Oc 0.005; C.5107 O.454 27000.0 12.2@ 5.119E-Oe 0.0051 c.5198 0.461 Co000.0 12.' 1 : 7.o;5E-Oi O.0079-0.52:3 0.4c3 29000.0 12.0; 7.761E-0: 0.0078 0.5345 0.475 00000.0 11.:2 7.CCSE-06 0.007s .-0.5421 0.482 01000.0 11,&O 7.407E-06 0.0074 0.5496 0.48S 32000.0 11.ec '.299E-Oc 0,007; 0.5568 c.4o5 '{ 5 . 000.0 11_.53 7.145E-Oc 0.0071 0.Sc40 0.501- ~4000.0 11.c7 6.c90E-06 0.0070 C.5710 C.50s 2 35000.0 11.05 .S;7E-Oc 0.0063 0.5772 0.514 Oc000.0 11.22

.627E-06 0.00e7 0.5845 0.520

!7000.0 11.12

.509E-Oc C.0065 O.5:10 C.525 08000.0 11.00.

e.;o6E-Oe O.00e4 0.5:74 0.531 l '09000.0

10. 0 c.250E-06 0.00c; 0.6007 0.507 40000.0 10.79 s.129E-06 0.0061 0.6092 0.542 41000.0-10 e9 6.000E-06 0.0060 C.6158 0.547 I'

42000.0-10,59 5.SS;E-06 0.005o 0.6217 0.55; 40000.0 10.49 5.769E-06 0.0052 0.6275 0.558 44000.O 10,40 5.c57E-06 0.0057 u 6;;1 C.56; 45000.0 10.01 5.551E-Oc 0.00Fe 0.cOS7 U.568 4:000.0 10.22 5.451E-Oc 0.0055 0.c44 0.57; 1 4~C00.0 10.1; 5.054E-Os 0.0054 0.:4: 5 0.577 j u8000.O 10.05 5.Os0E-Oc 0.0050 0. 548 0,552 s 4o000.0 ?.98 5.17;E-06 0.0052 -0.e599 0.557 50000.0 9.80 ' 08cE-Oc 0.0051 0,6650 0.So1 51000.0 9.52 5.00eE-06 0.0050 0.6700'O.596 I! 52000.O o.S2 5.000E-06 0.0050 0.e750 0.600 5~000.O 9.Se 5.019E-Os O.0050 C.6500 C.e04 54000.0 9.55 5.005E-06 0.0050 0,eE51 C.SOo .I-- 55000.0 9.99 5.075E-Oe 0.0051 0.6CO2 0.61; 56000.0 1c.00 5.201E-06 0.0052 C.4954 0 ilS $7000.0 10.12 ~.000E-06 0.005; U.7007 0.62; I 5S000.0 10.24 5.44 E-Oe 0.0055 0.7062 0.628 59000.0

10. "l7 5.62SE-06 0.0056 0.7118 0.5;;

60000.0

10. 5

5. 79'i E-06 0.0058 0.7176 0.609 61000.0

10. 7 5.97EE-06 0.0060

?.7206 0.64; B-3 1

e. s p=-CRACK VERSION 2.o 7 62000.0 .10.93 6.132E-06' O.0062 0.7297:0.649

60000.Os 11.01 6.40eE-Oc 0.0064

'O.7361 0.654 64000.0 11.20 6.e47E-06 0.0066 0.7422 0.6eo 65000.0 11.41 6.903E-06 0.0069 0.7497.O.666 4 -66000.0= 11.64 7.227E-06 0.0072 0.7569 0.673 I.' 67000.0 11.89 7.557E-06 0.0076-0.7645 O.680 63000.O. 12.17 7.947E-06 0.0079 0.7724 0.687 I 69000.0 12.46 E.36SE-06 0.0084 0.7805 O.694 70000.O 12.72 9.74SE-06' O.0097 C.7896 0.702 71000.0 .12.o7 9.130E-06 0.00c1 0.7987 0.710 72000.0 13.02 9.205E-06 'O.0092 0.3079 0.718 73000.0 12.99 c.159E-06 0.0092 0.S171 0.726 '74000.0 12.95 9.139E-06 0.0091 0.SL.2 0.734 75000.0 12.97-9.127E-06. O.0091 0.8353 0.743 7e000.0- '12.93 9.145E-06 0.0091 0.8445 0.751 77000.0

13. C.O 9.170E-06 0.0092 0.953e O. 75c/

78000.0 13.04-9.229E-06 0.0092 0.862c 0.767 1 i 7o000.O 11.08 c.2o5E-06 0.0093 0.8722 0.775 { 80000.0 13.15 9.400E-06 0.0094 0.8516 0.784 91000.'O -13.22 9.514E-06 0.0095 O.5911 3.7o2 E2000.0' 13,33 9.67sE-06 0.0097 0.900S 0. Sol CRACM. SI:'E EXCEEDED 0.o000 AT TIME S.200E+04 [ '- END OF p::-CRACM 1 l \\- i l-l l' g l l I:' l l l l' ~ B-4 1 1 - i

I' oc-CRACK: tm' i ,, " ~ f(C) COPYRIGHT 1984,: 1988 STRUCTURAL 1 INTEGRITY. ASSOCIATES. INC. I (408)978-8200 . SAN _ JOSE, CA VERSION ' 2 '. 0: ~ ALLOWABLE-FLAW SIZE EVALUATIONS' -USING ASME~SECTION XI --IWB-3640/50- PROCEDURES AND CRITERIA- ~ FOR_CIRCUMFERENTIAL. CRACKS IN-STAINLESS STEEL-PIPING -c ' MATERIAL:IS SPECIFIED'AS SUBMERGED ARC WELD) e DEFAULT PROPERTIES: [ DESIGN STRESS 16.95 sg' ' FLOW STRESS 50.85 .i-b CPL-09Q: WELD 22-AM1 m THE. EVALUATION ASSUMES DEFAULT MATERIAL PROPERTIES PIPE GEOMETRY: OUTER-DIAMETER : 22.0000 It ~ CRACK GEOMETRY: WALL THICKNESS : 11.1250 CRACK! DEPTH 0.1800 L CRACK LENGTH 2.4000 THE' FLAWED PIPE IS' ASSUMED TO FAIL DUE TO UNSTABLE DUCTILE' TEARING (EPFM) J. THE ALLOWABLE: FLAW SIZE IS DETERMINED USING CODELTABLES AND! DEFAULT SAFETY FACTORS FOR NORMAL OPERATING (INCL. UPSET &' TEST) CONDITIONS-c MEMBRANE STRESS (Pm)- 5.5020 (SAFETY FACTOR : 2.770)- .BEHDING STRESS (Pb) 1.3810 (SAFETY FACTOR = 2.770) 1.000) -g', EXPANSION 1 STRESS (Pe) 1.3020 (SAFETY FACTOR 15; DESIGN-STRESS 16.9500 = 0.4061 (Pm + Pb)/Sm , gf -STRESS RATIO 0.4685 (DOES NOT INCLUDE S.F.') fg M FACTOR 1.0800 = 0.1600 L; 'a/t 0.0347 1/ circumference 0.6000 ALLOWABLE a/t [ 1/ circumference J i 0.00 0.10 0.20 0.30 0.40 0.50 ALLOWABLE a/t 0.6000 0.6000 0.6000 0.6000 0.6000 0.4900 !I;' B-5 o 1

i, b E-m tm y J =. pc-CRACK $o

./ 'Y' (C); COPYRIGHT-1994, 1988 t ',

7]/ STRUCTURAL' INTEGRITY' ASSOCIATES ~ INC. g, SAN JOSE, CA. (408) 978-82OO. "4' e VERSION"2.O' Dates? 5-Jan-1990 Time:M 12: 59 : 25. 541 o STRESS CORROSION' CRACK GROWTH ANALYS15 1

• g INITIAL CRACK SIZE =

0.1800 WALL THICKNEES= 1.1250 i . MAX CRACK-SIZE FOR-SCCG=- 0.9000 STREEE CORROSION CRA2K SROWTH LAW 'LAWLID C .N Kthras K1C 9 i LNRR~ 3.590E-OS- ,2.1:10 0.0000 200.0000' l STRESS COE.:ICIENTS -CASE ID .C0 C1 C2-C; 'lL 'RESIDOC 30.2570 -193.Sc45 254.1497 -86.8261 Im. . APPLIED 10.0000. 0.0000 O.0000 O.0000 igJ kman 'gl CASE ID SCALE CA2 TOR RESID22 1.00 sa- -APPLIED ~ 1.10- 'g4 TIME PRINT -TIME 1NCREMENT INCREMENT 100000.O~ 1000.0 1000.0- ' crack model: CIRCUMFERENTI Al. CRACK IN CYLINDER (T/R=0.1:= i CRACK ---------------STRESS INTENSITY FACTOR---------------- {gl SIZE CASE CASE p3 RESID22 APPLIED YE!- 0 0130 7 452 2 609 k g.: 0.03c0 9.860 0.747 0.0540 11.278 4.610 'O.0720 12.127 5.347 0.0900 12.5&9 6.004 0.1080 12.7e; 6.506 O.1260 12.7S7 7.206 'lL O.1440 12.652 7.794 Wi O.1620 12.364 S.5c1 0.1900 11.944 S.914 B-6 m ( * .Sh- .i 3 4

4 f-pc-CR'ACK; VERSION: 2.' O , PAGE:

O.1980 11=.412 9.454 0.0160 10.750

.9.984 j I 'O.2340. '10.102-10.505 0.2500 '9.353-11.110-l O.2700 S.592-11.685 I 0.2880-7.708-12.258 L0.0060' '6.929 12.801 i 'O.3240' 5.967 10.40" 0.0420' 4.925- '14.010 0.3600 4.137 14.711 .O.0780: 0.002 -15.400 LO.0960 2.486. 16.106 i 10.4140 1L64 16.860 0.4020 0.769 17.591 i 0.4500l -0.103 13.331 .? 1 O.4680' -0.972 19.118 .s 0.4860: -1.849'- 19.915 I' O.5040 -2.750 ,00.720-O.5220. -0.610-21.505- + 0.5400; -4.490-22.359 0.5580 -5.365 23.192 g LO. 576Ci -6.017 24.084 ? 10.5940 -7.000~ 05.004 d .O.6100 -S.264 25.905 i ( 0.6300 -9.265 '06.876 ~0.o480- -10.240 .27.928 ~ 29.791 0.6660- -11'.007 .0.6800- ~-11.891 '29.800 so.7020 1-12'.262 30.559 A

0. 720Cr 2-12;550 31.929 l

l 0'7380 -12.'941-03.010 0.7560. ' -10.044 34.104~ 0.7740' .-13.184 05.209 0.7920 -1'O.492, 36.353 I, ~ O.9100- -14.450 37.588 0.8280 -15.390 .38.836 i 0.8460 -le.26c 40.099 O.8640 -17.11: 41.374 O.8820 -17.o17 42.6o3 [ O.9000 -18.see 43.964 E: TIME

KMAX DA/DT DA A

A/THK '1000.0 21.75 0.78SE-05 0.0279 0.2079 0.185 12000.0. H21'.79 2.79EE-05 0.0290 0.0359 0.210 1 3000.0 01.69 2.769E-05 0.0077 0.2656 0.004 4000.0 21.50 0.720E-05 0.0272 0.0908 0.258 5000.0 01.18 2.603E-05 0.0263 0.3171 0.082 t 6000.0 20.'74 0.516E-05 0.0050 0.3422 0.004 z7000.0 20.34 O.411E-05 0.0041 0.06e4 0.026 t B-7 't .1 "k. ~ o

I' 1 I> .pc-CRACK. VERSION'2.0 I 8000.0 20.01 0.404E-05. 0.0240 0.0904'O.347 9000.0~ 20;25. 2.039E-05 0.0239 0.4143 0.068 10000.0-20.18 2.071E-05 .O.0237 O.4380 0.089 11000.0 20.10. 2.051E-05 0.0235 0.4615 0.410 L 12000.0 '20.06 2.041E-05 0.0234 0.4349 0.401 10000.0 20.06 2.040E-05 0.0204 0.5053 0.452 14000.0-20.07 2.343E 0.0204 0.5017 0.473 15000.0 20.09 2.249E-05 0.0235 0.5552 0.494 16000.0-20.14 2.Co1E-05 0.0206 0.5789 0.515 17000.0 20.13-2.072E-05 0.0207-0.6026 0.53 1'8000.0 20.22 2.0SOE-05 0.0238 0.62e4 0.557 19000.0 20.29 0.3??E-05 0.0240 0.6504 0.579 I. 20000.0 20.35 2.42;E-05 .O.0242 0.6746 0.600 21000.0 20.67 2.497E-05 0.0250 0.6996 0.62 '402000.0 01.58 2.740E-05 0.0274 0.7070'O.646 23000.0 22.90' O.117E-05 0.0312 0.7582 0.e74 124000.0 .24.60 0.i38E-05 U.00e4 0.7946 0.70c- = 05000.0 26.55 '4.291E-05 0.0409 0.8075 0.744- -26000.0-27.c0 4.6c7E 0.0467 0.' 8E 41. 0. 7 56. 27000.0 29.09 5.22SE-05 0.0523 0.9364 0.SO2 -CRACK SI:E EXCEEDED O.9000 AT TIME. 2.700E+04 END OF pc-CRACK LI: k LI g g- ,k l

4: . -g _ .. tm. 4 b C . oc-CRACK : (C)l COPYRIGHT 1984, 1988 e ~ INC.

1. I STRUCTURAL INTEGRITY: ASSOCIATES, SAN" JOSE,,CA (408)978-8200 VERSION-2.0

'l ALLOWABLE FLAW, SIZE EVALUATIONS-. 7 USING'ASME SECTIONLXI,-IWB-3640/50 PROCEDURES AND CRITERIA FOR CIRCUMFERENTIAL CRACKS'IN STAINLESS STEEL PIPING-i MATERIAL IS SPECIFIED AS SUBMERGED' ARC-WELD = --DEFAULT' PROPERTIES: sh' -! DESIGN = STRESS ' 16.95 FLOW > STRESS 50.85 ] i LCPL'-090i WELD'22-AM1. 'THE EVALUATION ASSUMES DEFAULT MATERIAL PROPERTIES-PIPii MEOMETRY: [' OUTER DIAMETER : 22.0000: 'E' WALL THICKNESS;: 1.1250-J g CRACK GEOMETRY: CRACK DEPTH' 0.1800 1 CRACK-LENGTH 2.4000 THE-FLA'ED PIPE:IS ASSUMED-.TO-FAIL DUE-TO UNSTABLE DUCTILE TEARING (EPFM).L W l; [ l THE' ALLOWABLE FLAW-SIZE.IS' DETERMINED USING CODE TABLES L. AND-DEFAULT SAFETY--FACTORS'FOR NORMAL OPERATING'(INCL. bPSET&nT -CONDITIONS } f5.5020 (SAFETY' FACTOR = 2.770). MEMBRANE.' STRESS-(Pm) =* = 1.3810.(SAFETY FACTOR : 2.770) BENDING STRESS (Pb) 4.'9020 (SAFETY FACTOR :. 1'.000) EXPANSION STRESS (Pe) - DESIGN' STRESS 16.9500 i l-- l L(Pm + Pb)/Sm O.4061 0.5513 (DOES NOT INCLUDE S.F.)- l i STRESS RATIO II M FACTOR = '1.0800 0.1600 a/t' <l/ circumference 0.0347 0.6000 . ALLOWABLE'a/t 1/ circumference 0.00 0.10 0.20 0.30 0.40 0.50 g ' ALLOWABLE.a/t 0.6000 0.6000 0.6000 0.6000 0.6000 0.4900 B-9 I u -1 I, } 7 .c. ~ --L :. t --}}