Text

Forwards Exam/Evaluation Results for Weld 1B21N4D-5-2-SWI-2 Performed During Outage 7,per Insp Rept 50-325/89-35
	ML20066C514
Person / Time
Site:	Brunswick
Issue date:	01/07/1991
From:	Vaughn G; CAROLINA POWER & LIGHT CO.
To:	; NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
	NLS-91-001, NLS-91-1, NUDOCS 9101100221
	Download: ML20066C514 (69)
	v • d • e

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i coronne Power a uom company P O Dos 1661 e Rei 6ph, N.c. 27002 SERIAL: NLS 91 001 '

JAN 071991 O L VAUGHN vice ernio nt ww.er seren ooperimoni United States Nuclear Reguintory Commission ATTENTION: Document Control Desk Washington, DC 20555 BRUNSWICK STEAM ELECTRIC PLANT, UNIT NO. 1 DOCKET NO. 50 325 / LICENSE NO. DPR 71 EXAMINATION / EVALUATION RESULTS FOR WELD No. 1821N4D 5 SW1 2 REFUELING OUTAGE 7

Reference:

1.

NRC Inspection Report No, 50 325/89 35, dated December 7, 1989 Centlemen:

Carolina Power & Light Company (CP&L) apprised the NRC Staff of the IGSCC examination / evaluation results of the indication-discovered in the subject feedwater system (WS) vold, via conference call'on Thursday, December 20, 1990 This submittal is a follow up to that conference call, and contains only that information pertinent to the ultrasonic (UT) examinations of the FWS.Inconel and dissimilar metal welds, and the flaw evaluation of the subject weld.

A complete summary of che NUREG 0313, Rev 2 examinations completed, as well as a synopsis of the installation / inspection activities performed,'and mitigative measures taken, as part of the Reactor Coolant Recirculation.and Core Spray System piping replacement will be forthcoming in a subsequent submittal prior to Unit.1-restart.

! contains'(1) a description of the NUREG 0313, Rev 2,LUT examinations performed on the FWS Inconel'and dissimilar metal welds including'the-scope of those examinations, the UT Process used, and the results of.those, inspections.

(2) :a description-of -the inclusion of the. twelve (12) WS Inconel and dissimilar L

metal welds into CP&L's approved.NUREO 0313.Rev-2 Inspection Program, (3).a _

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brief description of the. flaw evaluation performed for veld no. 1B21N4D 5 SW1 2,.-

l (4) a description-of the monitoring of Inconel crack growth rates using CP&L's CAV System, and (5) a conclusion that provides a basis for the. continued l

l operation of BSEP Unit'l-with the Feedwater System.in its present co'nfigurations

is a weld location map for the Feedwater, System: welds addressed by this submittal, 'is a copy of General' Electric Ultrasonic' Examination Report No R 095, for WS Weld No.1B21N4D 5 SW1-2. is a copy of 1

Structural Integrity Flaw Evaluation Report No.. SIR 90 081.

l 9101100221 910207 gDR ADOCK 05000325 WOW A00'

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Document Control Desk NLS 91 001 / page 2 j

Please refer any questions regarding this submittal to Mr. S. D. Floyd at (919)

$46 690),

l Yours very truly, "Y

C. E. Vaughn j

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DBB/cwh (946BNP) i cc: Mr. S. D. Ebneter Mr. N. B. Le i

Mr. R. L. Prevatte-1 J

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1 ENCLOSURE 1 i

BRUNSWICK STEAM ELECTRIC FLANT, UNIT 1 NRC DOCKET 50 325 / LICENSE NO DPR-71 EXAMINATION / EVAUVATION RESULTS FOR WELD NO.1B21N40 5 SWi 2 REFUELING OUTACE 7 i

l (1) ULTRASONIC EXAMINATIONS Scone of Examinations NRC Inspection Report No. 50 325/89 35, section 6.a. (Ref. 1), documented fifteen (15) dissimilar metal and Inconel welds that were potentially susceptible to ICSCC that had not been ultrasonically examined using transducers that produce refracted longitudinal (RL) sound waves.

CP&L committed to examine these welds during refueling outage 7 using the appropriate techniques, thus they were added into the NUREG 0313. Rev 2 inspection scope as ' Category O' welds.

Nine (9) of the fif teen (15) welds documented by the referenced inspection report are Inconel, or Inconel to carbon steel welds in the FUS and are addressed in this submittal.

Of the remaining six (6) welds, two (2) were eliminated as pcrt of the Core Spray safe end/ transition piece replacement, and four (4) are stainless steel to carbon steel dissimilar metal welds and will be addressed in the subsequent submittal as they are not considered to be germane to the examination /cyaluation results of the subject weld, The ISI weld identification numbers of the nine (9) FWS ' Category G' welds which were inspected during refueling outer,e 7 are as follows; IB21N4A 2 FVRN4A45 3 IB21N4B 3 WRN4B135 3 IB21N4C 6 FJRN40225 3 IB21N4B 3 SW1-2 IB21N40 6 SW1-2 1821N40 5 SW1 2 IB21N4B 3 SW2 3 1B21N4C 6 SW2 3 1B21N/,D 5 FWRN4D315 3 (See Enclosure 2 for weld location map)

UT Process The UT examinations of the nine (9) FWS velds identified in this submittal were performed by General Electric (GE) UT personnel who are qualified in accordance with the EPRI/BWROG/NRC requirements, including the latest requalification program.

The examination of these welds incorporated the use of the fully automated CE " SMART UT" System, which uses the " Ultra Image III" computer driven data acquisition system with.the ALARA remote scanning device. Manual examinations were performed as required to supplement the " SMART UT" examinations.

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page 2 of 3 UT Results As previously described in the scope of examinations, nine (9) ' Category G',

FWS, Inconel or Inconel to carbon steel welds were examined.

The results of these examinations are as follows; 1B21N4A 2 FWRN4A45 3 IB21N4B-3 SW1 2 IB21N4B 3 SW2 3 No relevant indications were 1B21N4B-3 FWRN4B135 3 1

detected using 45' shear, and 1821N4C 6 SW1 2 l

45' & 60' RL 1821N40 6 SW2 3 l

transducers.

1B21N4C+6 FWRN4C225 3 l

1B21N4D 5 FWRN40315 3 l

_a 1B21N4D 5 SW1 2 No indications associated with ICSCC were recorded.

However, one (1) non geometric indication was recorded.

(See Enclosure 3 for complete GE report)

NOTE:

The above listed nine (9) welds, along with the remaining four (4) welds noted in the scope of examinations comprised 100% of the BSEP Unit 1, ' Category O' welds, thus-no sample expansion was required.

(2) NUREG 0313. REV 2, INSPECTION PROGRAM i

In accordance with NRC Inspection Report No. 50 325/89 35 (Ref 1), CP&L agreed to evaluate the dissimilar metal welds listed for inclusion in it's approved NUREG 0313 Inspection Program.

CP&L has completed an evaluation of the twelve (12) FWS welds listed in the Inspection Report..0f the welds listed in the Inspection.

Report, nine (9) are addressed in this submittal, while the remaining three (3) were inspected using Rh transducers during BSEP Unit 1 refuel outage 6.

As stated in the " Scope of Examinations", the nine (9) FWS welds which had not been examined using RL transducers were added into the refuel outage'7 inspection schedule as ' Category O' welds.

Based on the examination results of the threeL(3) FWS welds previously inspected during refuel outage 6, and the nine (9) FWS welds inspected during refuel outage 7, CP&L has elected to permanently. include them into the NUREG 0313,. Rev 2, Inspection Program as follows; Weld Number Caterorv Weld Number Categorp 1B21N4A 2 SW1-2 D

lb21N40 6 SW1;2 D

1B21N4A-2 SW2 3 D

1B21N40 6 SW2 3 D

1B21N4A 2 FWN4A45 3 D

1B21N40 6 PWN40225 3 D

1B21N4B 3 SW1 2 D

1B21N4D 5 SW1 2-F 1B21N4B 3 SW2 3 D

1821N4D 5 SW2 3 D

1B21N4B 3 FWN4B135-3 D

1821N4D 5 FWN4D315 3 D

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page 3 of 3 t

(3) FLAW EVALUATION FOR WELD NO, 1B21N4D.5 SW1 2 A flaw evaluation has been completed for the indication recorded in the subject weld by Structural Integrity, Associaten (SIA).

This evaluation was performed in 4

accordance with ASME Code,Section XI, IWB 3640, 1986 Edition, and the requirements of UUREC 0313, Rev 2, and demonstrates that the weld can be returned to service for at least one operating cycle.

In addition to the crack growth analysis, SIA also performed a leak.before break analysis for the recorded flaw l

to demonstrate that in the unlikely event that the flaw would propagate through-j vall, adequate margins exist between the leakage flaw size and the critical flew size (see Enclosure 4 for complete analysis).

i (4) MONITORING OT CRACK CROWTH RATES As discussed in the conference call between the Staff and CP&L on Thursday.

December 20, 1990, CP&L has committed to monitor the crack growth rate of the Inconel 182 material in the BSEP Unit 1 CAV system.

The CAV system crack growth data will be monitored to assure that the crack growth rate assumed in the flaw evaluation (Enclosure 4) remains conservative.

CAV system data will be analyzed on a monthly basis, and Any anomalies in crack growth rates will be evaluated to ensure that the TWS integrity is not compromised, and that the plant can continue to be operated safely, (5) CONCLUSION Carolina Power 6 Light Company has now completed (refuel outages 6 and 7) UT examinations of the twelve (12) FWS weldw using transducers that produce refracted longitudinal sound waves.

One veld (1B21N4D 5 SW1 2) contains a rolevant indication while the remaining welds have bcen found to be free of relevant indications.

The indication recorded in the subject veld has been analyzed by Structural Integrity, Associates, and found to be acceptable by -

cvaluation.

This coupled with CP&L's ability to monitor the actual crack growth rates of Inconel 182 material us1ng the CAV System supports the position that this weld is acceptable to operate for at least one additional refueling cycle.

Therefore, CP&L belicves that Unit 1 can be operated safely until the next refueling outage, presently scheduled for September 1992, without adverse effect to the health and safety of the public,

ENCLOSURE 2 DRUNSWICK STEAM ELECTRIC PLANT, UNIT 1 NRC DOCKET 50-325 / LICENSE NO. DPR-71 EXAMINATION / EVALUATION RESULTS FOR WELD NO.1821N4D-5-SW1-2 REFUELING OUTAGE 7 pg##%

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ULTRASONIC EXAMINATION DATA SHEET GE Nuc/est Energy (M ANU AL' PIPING) SITE: UNIT: 1 REPORT NO. R m< _.S.AuAs wr e g PROJECT NO: _ Li r __to s d l 3 3' CAllBRATION SHEET NO. C - 142. MATERIAL TYPE: O Cs O SS FOTHER.2e/c... PROCEDURE: fgfay[,*,f,pA REY _ A FRR M/A EXAM SURFACE O io F0D SYGTE M: Frr D wa rg R EXAM SURFACE TEMP

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PENETRANT EXAMINATION REPORT SITE: RAud5w/s UNIT: 1 REPORT NO. A-o9f PROJECT NO: nr 96 Ma 7=tr WELD / COMPONENT NO. g2 Nyo-r sur-r Procedure No dE PT /bo Rev. FRR No. x>N - MATERIAL SURFACE CONDITION ITEM gCS AS WELDED 0 CLEANED @ PIPE O FITTING @ WELD ~" SS GROUND -O ROOT T $OTHER 2 AS CAST OTHER O PLATE OTHER -O PARTI AL t.zmasIR.. / LAM MA plygg E C PENETRANT MATERIAL CLEANER PENETRANT DEVELOPER' WIPERS MANUFACTURER />)/j(,,AJAfg /pMMAJA alt.LX ggf/A/2 t/y @ PAPER N ,,,,o m eg 3g,,ny g,u,, pp,3 ygo. gy a ctoin l 90Ho 7X 8')Mol# PiHO 9M agreg wo. o7ggg SURFACE TEMPERATURE: 80 'F THERMOMETER S/N: .2. /A 2 U sunrAce veuptaAvune <60' 40 - 125* > t2 5* / */ gjg [ E PRE-CLEAN METHOD: E SPRAY / WIPE O SWAD/ WIPE DRYING TIME: PENETRANT APPLICATION: 8 BRUSH O SPRAY DWELL TIME: Al[ ifaud A/[ [ 7181A) PENETRANT REMOVAL: 0,';! O,' ENJW"vb DRYING TIME: [ ff>Ir/4 ! DEVELOPER APPLICATION: SPRAY DEVELOPING TIME: POST-CLE ANING: @ SPRAY / WIPE O SWAB / WIPE NOT INDICATION NO. LOCATION / DESCRIPTION ACCEPTABLE ACCEPTABLE R A)O AEcotD ARL K 2dD/LAYlodS E S AJ - U b L / T COM MENTS: g l A' LJ4%sk. f uk/e.o u%s Mc4 X 11neo Examiner Lev el Date Re<iewed Level Date Page Q Q of 2LQ ain a/A Y [/l Jh,_/t-i1va Examiner Level Date / Reviewed Title Date ,,% g,, g.g

ENCLOSURE 4 BRUNSWICK STEAM ELECTRIC PIANT, UNIT 1 NRC DOCKET 50 325 / LICENSE No. DPR 71 i EXM4INATION / EVALUATION RESULTS FOR WELD NO, 1B21N4D 5 SW1 2' REFUELING OUTAGE 7 FLAW EVALUATION FOR VELD NO 1B21N4D-5-SW1 2 STRUCTURAL INTEGRITY REPORT NO. SIR-90-081 i i 5 w

STRUCTURAL INTEGRITY ASSOCIATES,INC. 3150 Almaden Expressway Fossil Plant Operations Suite 226 December 28, 1990 66 South Miller Road Sen Jose, CA 95118 t NGC-90-037 Suite 10 l (408) 978 8200 rAX (408) M8%4 SIR-90-081 Abon, Ohio 44313 (216) 864 8886 TAX:(216) 9694461 Mr. Ashleigh M. Lucas Carolina Power & Light Company 411 Fayetteville Street Raleigh, NC 27602

Subject:

Flaw Evaluation of UT Indication for Feedwater Nozzle Weld 1B21N4D-5-SW1-2 at Brunswick Unit 1

Dear Mr. Lucas:

This letter provides a summary of an evaluation performed by i structural Integrity Associates (SI) to assess the continued operation of the subject feedwater nozzle weld. The 0.38 inch deep by 1 inch long UT indication in this weld is assumed to be an IGSCC flaw for the purpose of this evaluation. In summary, it is found that the weld can be returned to service for at least one fuel cycle, since the indication is predicted to not exceed ASME Code and NRC NUREG-0313, Revision 2 allowable limits in that time. BACKGROUND During in-service inspection of the subject weld during the 1990

outage, a circumferential flaw indication measuring 0.38 inch I

deep and 1.0 inch long was identified by UT with the flaw tip in the Inconel 182 portion of the subject feedwater nozzle weld as shown in Figure 1. A fracture mechanics analysis has been performed te demonstrate that the observed flaw will not grow to an unacceptable size during the next operating fuel cycle. The crack growth law employed in this analysis is based on conservative CAV crack growth data from Brunswick, Unit 1, without the effect of hydrogen water chemistry (HWC). In addition, a leax-before-break evaluation has been performed to demonstrate that in the event that the observed flaw should propagate through-wall, adequate margins exist between the predicted critical flaw and the detectable leakage. leaking flaw sizes to provide a FLAW EVALUATION The flaw evaluation was performed using the -linear elastic fracture mechanics options of the pc-CRACK computer software (1). There are two basic aspects to this evaluation:. crack growth l analysis and allowable flaw size determination. 1

Page 2 December 28, 1990 Mr. A. M. Lucas NGC-90-037/ SIR-90-081 1 1 Crack Growth Analysis Anoroach: ~ It is assumed for this analysis that any crack growth will be due to intergranular stress corrosion cracking (IGSCC). Patigue cracking at this location is considered to be very unlikely since-the weld is protected from any thermal transients by the presence of the thermal sleeve. Furthermore, bypass leakage of cold feedwater into the thermal sleeve annulus, -which has been a problem in other BWR feodwater nozzles, is not a concern here since the thermal sleeve is welded to the safe-end, as shown in-Figure 1. Even in cases where bypass leakage has occurred, cracking has not been found-in the safe-end but only in the thicker nozzle region where high thermal stresses can exist. The important parameters' to be considered in the crack growth analysis are the pertinent stresses, the fracture mechanics crack model and the crack growth law. 3 Stresses: Since the flaw is in the circumferential direction, the axial stresses at the weld will control the crack growth. Torsional stresses are neglected, since they do not tend to open the crack. The stresses at the weld location are due to internal _ pressure; applied piping loads and weld residual stresses. The internal pressure used in this evaluation was conservatively assumed to be the design pressure of 1325 psig. The pressure stress shown in Table 1 was calculated using the relationship: p di2 (do2 - di2) (1) where p = internal pressure di = inside diameter of the pipe do = outside' diameter of the pipe The geometric data.for the pipe is provided in Table 1. The stresses due to piping loads were calculated using loads obtained f om CPE Calculation No. 5A-B21-516, Revision 0 (2). A summary of L'.~.ase stresses is also shown in Table 1. For the IGSCC crack growth evaluation, the sustained stress combination of internal pressure, dead weight and ~ thermal stresses is used, along with weld residual stresses. Since this weld has not been stress-

improved, the residual stresses result from the butt welding during original construction.

USNRC document NUREG-0313, Revision 2 (3) has-provided a butt weld residual stress STRU N INTEGRITY ASSOCWFESINC --

Page 3 December 28, 1990 Mr. A. M. Lucas NGC-90-037/ SIR-90-081 distribution for 12-inch pipe and greater, which is used in this evaluation. This distribution is shown in Figure 2. Crack Growth Model: The outsido diameter of the piping at.the weld location is 13.75 inches with a thickness of 0.84 inch. This results in a thickness-to-inside radius (t/R) ratio of 0.139. A model consisting of a cylinder with t/R 0.1 and a 360* = circumferential crack was chosen from the pc-CRACK library and used in this analysis. This model is very conservative, considering the fact that the actual flaw only extends 1 inch around the circumference. Crack Growth Law: In this evaluation, a power function crack growth law of the form da/dt = CKn (2) was used, where da/dt is the rate of crack growth (inches per hour), K is the applied stress intensity (ksiyTE) and C and n are crack growth constants which are dependent on the material and the environment. In this evaluation, reactor environment CAV crack growth data for Brunswick Unit 1 is used together with industry crack growth data on Inconel 182 to determine the material constants. The material constants for sensitized Type 304 stainless steel, from NUREG-0313, Revision 2, are 3. 59 x 10- 8 and 2.161, respectively. It is assumed in this evaluation the shape of this power law relationship does not change for Inconel

182, i.e., the constant n remains the same value of 2.161.

The value of C is determined using the CAV crack growth data for Brunswick Unit 1 without the-effect of HWC. Crack -growth data for measurements from a CAV specimen for Brunswick, Unit 1 are shown in Figure 3. The data represents all CAV - data for Brunswick, Unit 1 for Inconel 182 for one set of measurements. A duplicate measurement, providing nearly identical results, was also obtained and supports these results. Without the effect of HWC, the crack growth rate is calculated from the CAV computer to 4 be 2.45 x 10-5 in/hr using the conservative data for CAV crack measurement #1 for the 198 data points between 1200 and -14 00 i hours. The average stress intensity factor used to obtain-this crack growth data is 26.15 ksi V R, again computed by the CAV T computer. This crack growth rate of 2.45 x 10- 5 in/hr at K= 26.15 ksi VT5 is seen to be quite consistent with the data of Andresen [4] shown in Figure 4 for sensitized Inconel 600 and 182 in 200 ppb oxygen, water. Knowing the crack growth rate (da/dt), INTEGRITY ASSOCWESINC

i Page 4 December 28, 1990 Mr. A. M. Lucas NGC-90-037/ SIR-90-081 the stress intensity factor and the material constant n, the value of the material constant 'C is ' calculated to be 2.12 x 10-8, Hence the crack growth law used in this evaluation for Inconel 182 is given by: da/dt = 2.12 x 10- 8 2K.161 (3) Crack Growth Results: The IGSCC crack growth for a combination of sustained stresses (Dead weight + Pressure + Thermal) of 7.09 ksi and butt weld residual stress is shown in Figure 5. The crack size of the 0.38 inch deep initial flaw after 1 fuel cycle of operation (18 months or 13,140 hrs.) is calculated to be 0.42 inch. The detailed pc-CRACK compilthtion output is attached as Appendix A.

Again, this is considered to be a conservative prediction of crack growth since a

360' crack model was

assumed, and the UT indication is actually only 1 inch long.

Using the methods of NUREG-0313, Revision 2, the crack length is predicted to grow to only 1.22 inch, corresponding to growth in depth to 0.42 inch. Allowable Flaw Size Determination: The allowable flaw size is determined.using ASME Code, Section'XI IWB-3640 [5). Specifically, Table IWB-3641-5 for circumferential flaws in shielded metal arc and submerged arc welds was used for this evaluation. The methodology of IWB-3640 has been incorporated into the pc-CRACK computer software, and therefore this software was used to perform the evaluation for the Inconel weld. Results of the evaluation are shown in Table 2. The results. indicate that for this relatively short

flaw, the allowable depth-to-thickness ratio is 0.60 The allowable flaw size is therefore 0.504 inch.

As can be seen from Figure 5, the predicted flaw depth of 0.42 inches after 18 months of growth is significantly below the allowable size of 0.504 inch. LEAK-BEFORE-BREAK CONSIDERATIONS In the unlikely event that the observed flaw should propagcite completely through-wall, a leak-before-break (LBB) analysis is performed to determine the margin of safety between the detectable leakage flaw size and the critical through-wall flaw. NUREG-1061 Volume 3 [6] and General Design Criterion 4, for leak-before-break analyses (GDC-4) (7) identify several criteria to be considered in determining the applicability of the leak-before-break approach to piping systems. One of the requirements is that the system should not be susceptible to IGSCC. Strict interpretation of this requirement would make this weld unqualified for a LBB analysis since the Inconel 182 i INTEGRITY ASSOCIATESINC

Page 5 Decouber 28, 19?9 Mr. A. M. Lucas NGC-90-037/ SIR-90-081 material is susceptibio to IGSCC. However, a LBB analysis is presented in this evaluation solely to supplement the crack growth ovaluation presented above. In this caso, the acceptance criterion is that the predicted critical through-wall flaw size (for normal operating plus SSE stresses) must be at least twice the length of that flaw which would result in datectable leakage. Leak Rate Calculat19.D: Leak rates for circumferential through-wall flaws of varying length here computed by using the methods of References 8 and 9. This was done to identify the flaw length required to produce a detectable leak rate, and to assess the sensitivity to flaw size. The c ack opening area (COA) under the influence of steady-state operating stress (combined tension and bending) is computed from Reference 9 as shown in Table 3. Linear clastic methods are used in this case. This calculation is considered quite conservative sinco no correction for the crack tip plastic zone was included. Given the preccding crack opening

areas, tbc corresponding leakage rate is calculated using the methodology provided in Reference 3.

The leakage rate is calculated by multiplying the i crack opening area by a leakage rate constant. A conservative l value for this constant of 125 gpm/ int is provided in Reference 8 l for application to BWR piping. Critical Flaw Si%e Calculatignt In this evaluation the critical flaw size is determined using the J-integral / Tearing Modulus (J/T) Elastic-Plastic Fracture Mechanics (EPFM) analytical techniques. A procedure for using this approach for the assessment of the stability of through wall circumferential flaws in cylindrical geometries such as pipes is i presented in References 10 and 11. This procedure was used for the determination of the critical flaw size using the pc-CRACK computer software. The matcrial properties used in the clastic-plastic fracture i mechanice analyses are shown in Tab 3 e 4. The clastic modulus (E), Code allowable stress (S ), and lower bound yield strength (ao ay ) and ultimate strength (a ) were taken from Section III = u of the ASME Boiler & Pressure Vossel Code for the temperatures of interest (5). The flow stress is computed as an average of vy and a, although this does not influence the stability ana@is u results. Ramborg-Osgood true stress-strain constants a and n for stainless steel were assumed for inconel 182 since the shape of. the stress-strain curvo is expected to be similar to that of INTEGRITY ASSOClKPESINC

- ~- Page 6 December 28, 1990 Mr. A. M. Lucas NGC-90-037/ SIR-90-081 Inconal 182. The stress-strain curve incorporating the ao vy a i values in Table 4 is shown in Figure 6. The EPFM J-Resistance (J-h) curve of J vs. crack extension is shown in Figure 7 for stainless steci flux volds. The power law constants, C and N, representing this curve are given in Table 4. This curve for stainless steci is from Referenco 12 and represents a lower bound for low toughness submerged are welds (SAWS). It is assumed that it is also applicable to Inconel 182 shielded metal arc wolds (SMAWs), as a conservative lower bound. Leak-Before-Break nesults: The detailed critical flaw size computation

output, from pc-CRACK, is given in Appendix B.

Using the conservativo flux weld material J-Resistance curve described

above, critical through-wall circumferential crack lengths wore ccmputed for both pure remote tension and pure bending loading of pipes.

In both the tension and bonding loading, the applied 6 tress of 9.60*/ ksi was used, and the critical crack length results were linearly interpolated to estimato the combined tension-bonding case. The 9.607 ksi total stress is comprised of 4.45 koi pure tension (due to the design pressure of 1325 psi) and 5.157 kci bending (due to 0.143 ksi dead-weight, 2.498 kai thermal, and 2.516 ksi DBE or SSE stresses). The interpolated critical crack length is 14.11 inch, or approximately 35% of the pipe circumference. Table 3 presents leak rate calculations for through-wall circumferential cracks of varying lengths. As described above, the crack opening arca was conservatively calculated using linear elastic methods and taking no credit for the crack tip plasticity. Combined tension and bending loading is considered, with the pressure stress computed from the operating pressure of 1000 psi, and the previously discussed bending stresses due to dead-weight and thermal loads. The crack opening area (COA) in Table 3 is multiplied by 125 gpm/in2 to calculate a conservative leak rate of 23.56 gpm for the crack length of 14.2 inches (approximately the critical length), - and 3.22 gpm for a crack half that length.

Thus, adequate leakage for detection is indicated, and leak-before-break is predicted.

A further salient conclusion is that the predicted critical through-wall crack length of 14.2 inches is well in excess of the 1 inch length of the indication.

SUMMARY

AND COHCLUSIONS A flaw evaluation has been performed for the UT indication (0.38 inch deep by 1 inch long, circumferential) in feedwater nozzle weld 1B21N4D-5-SW1-2 of Brunswick Unit 1 to demonstrate that this

~

INTEGRITY ASSOClKIESIIC

_.__;_.._4.2 _.m., a .a -.m_. ..a_ ._a_ Page 7 December 28, 1990 Mr. A. M. Lucas NGC-90-037/ SIR-90-081 weld can be returned to service as-in for at least one operating cycle. The evaluation was periormed using an Inconel 182 crack growth law derived from reactor coolant CAV crack growth data for Brunswick Unit 1, not taking credit for hydrogen water chemistry. A conservative crack model consisting of a 360* circumferential finw was used for the analysis. The analysis showed that the initial flaw of 0.38 inch depth is predicted to grow to 0.42 inch after 10 months of operation. The allowable flaw size was determined per the requiremc.nts of ASME Code, Section XI IWB-3640 to be 0.504 inch deep. Thus, the flaw indication is acceptablo as-is for at least one more 18-month operating cycle. To supplement the crack growth analysis, a lask-before-break analysis was also performod to demonstrate that in the unlikely event that the existing flaw should propagate through-wall, adequate margins exist between the leakage flaw size (with leakage conservatively computed) and the critical flaw size. Turthermore, the current indication length of 1 inch is well below the predicted critical through-wall crack length of 14.2 inchos, based on clastic-plastic lower bound material toughness. Prepared by: d / h2'8//FSO Date: N. G. Cofie s Dato: / [/' O Reviewed by J. F. Copepnd / Approved by: _. A. ' Giannuzzi F/ /4& C Dato: TO /sn Attachments l [.khbiso'F(5SEP) R. Hanford (Raleigh) cc: T. Gillman"(BSEP) J. M. Brown (Raleigh) l INTEGRITY ASSOCIATES WO

i Page 8 December 28, 1990 i l Mr. A. M. Lucas NGC-90-037/ SIR-90-081 REFERENCES 1. Structural Integrity Associates, "pc-CRACK User's Manual, Version 2.0. 2. CP&L calculation No. SA-B21-516, Rev. O, "Teodwater Loop B Inside Drywell". 3. NUREG-0313, Rev. 2, " Technical Report on Material Selection and Processing Guidelines for BWR Coolant Pressure Boundary Piping, January 1988. 4. Andresen P. L. "Effect of Dissolved

Oxygen, Solution conductivity and Stress Intensity on the Interdendritic Stress Corrosion Cracking of Inconel 182 Weld Metal",

Corrosion 87, Paper No. 84, San Francisco, California, March 9-13, 1987. 5. ASME Boiler Pressure Vessel

Code, Section XI, 1986 Edition.

6. NUREG 1061, Vo),umes 1-5, " Report of ' the U. S. Nuclear Regulatory Commission Piping Review Committee", prepared by the Piping Review Committee, NRC, April 1985. 7. Stello, Jr., V., " Final Broad Scope T.ule to Medify General Design Criterion 4 of Appendix A, 10 CFR Part 50", NRC SECY-87-213, Rulemaking-Issue (Af firmation), Aug. 21, 1987. 8.

Klecker, R.,

Brust, F.,

and Wilkowski, G., "NRC Leak-Before-Break (LBB.NRC) Analysis Method for Circumferentially Through-Wall Cracked Pipes Under Axial Plus Bending Loads", NUREG/CR-4572, BMI-2134, May 1986. l 9. Paris. P.C., 'and Tada, H., "The Application of Fracture Proof Design Methods Using Tearing Instability Theory to Nuclear Piping Postulating Circumferential. Through-Wall Cracks", NUREG/CR-3464, September 1983.' 10.

Kumar, V.,

et. al., " Advances -in Elastic-Plastic Fracture Analysis," EPRI NP-3607, August, 1984. t 11.

Kumar, V.,

et.. al., "An Engineering. Approach for l Elastic-Plastic Fracture Analysis," EPRI NP-1931,

July, 1981.

STRUCTURAL INTEGRITY ASSOCIATES RC I re n-w ,-,,---s-,-.- ,w- ,wn ,w>,

l 'l Page 9 December 28, 1990 Mr. A. M. Lucas NGC-90-037/ SIR-90-081 REFERENCES (concluded) 12. " Evaluation and Discussion of EPRI's High Energy Pipe Rupture Experiments", EPRI Report No. NP-5531, by Structural Integrity Associates and S.

Levy, Inc.,

SI Report No. SIR-86 034, September 1987. i O INTEGRITY ASSOCIATESI_NC

l Table 1 4 4 i .t CPL!Il littlV!Ct.) PllDVAfti Ifif tt. tY N011LI I40 !!!!!!!! (1,0AD8 4 80llit$ P10 CALO. 80, $1811116, !!Y,01 esY .X ,s i VIL630,li!!It6l.IVI! 45l./'

0t!80,101 l

CD(Ill: 13.!! C. f(!I): 0,84 10(!!): !!,01 a P(P!l): Illi f(P): It! boe. So, A(IV't): 34,0ll /g 1(!!'3): 103.811 / y.x gr. Pa t0fAI,.AllAL P PJ P It 1; is (A!!Al.) 16. le ~ 10ttif Iftt38 f!PI (Lil (ll) (Ll} (Pt.LI) (P!48)' (Pf.Lil (LI) (!V.Ll) (II.LB). (IN.LB) ^(Pl!) P _4450 IV 11 .It! .!0 ell) 214 .f11 31 3Hi 1434) 1(II) 113 011 !!01 I!!! (11 !!!!) 3310 11110 3fl 40H0 198085 !!!!!! -!0li HI till 1413 Illi 18813 (111.14131 34f lillt il3114 tillet till fitLIAL1 1111 itil 11 10118 (198. 15111 .lltf '88811 31014 10831 . ((i filtrAtt 2001 l!!! 3.!!(31 4041-1331 1(13.lllit.tllit1 !!(60) 1($1 is. P6. Pb. -f6 trial -8: stained P IV+0l! - IVtHt POVefh '(Pl!} I . (P3!) (P11) (Pl!)- (P!!) 4(50 - Illi c. !Ill-till fil$ [ SIR-90-081' 10 EM i INTEGRITY ASSOCIATESINC

j i Table 2 te i pc CRACR (C) COPYR! TNT 1984,1988 $1RUCTVRAL!NitttlifA$$0CIAltl,INC. $ANJC$t,CA(408)t74!!00 VIR$10N2.0 Date:210s:1990 Tiet: 7:11:26.33 ALL0hAlltTLAW$!!!(VALUA110N$ U$1NG A$RI $tCIION X!, !Wl*3640/50 PROCT 0VRI$ AND CR!!!R!A TDA CIRCVRf tRINTIAL CRACR$ IN $1AINLt$$ $1!!L P1P!NG MA!!RIALll$PIClf!!DA$$N!!L0!0R!iALARCWILD CtfAVLiPROPtRitt$: Ot$ltNSTR!ti 16.95 TLOWstRtst 50.85 BRUNSWlCR Uhlt ! f t 50!!Lt WILD ll!!N40 5 Sul 2 V$lt $UPPill0 RAi! RIAL PROPIRills: 0!$ltN$1Rtt$ 23.30 FLOW $1RI$$ 69.90 P!Pt4!0R!fRT: CVitRO!AR!i!R 13.1500 WAllINICRNI$$ 0.8400 CRACR(!ORITAT: i CRACRCIPfH 0.3800 t CRACRl!Nt1H : 1.0000 th! FLAW!D PIPI !$ A$$URID 10 TA!L DVt 10 UN$1Allt DUCT!Lt itARING (!PTR) THE Alt 0NAllt TLAW $1!! !$ 0!TERMINt0 U$1NG C00t TAltt$ AND OffAVli $Af tif TAC 10R$ FOR NORMAL OPtRATING (!NCL, VP$ti i itST) CON 0!!!0NS FIRIRANIsitt$$(PB) : 4,4500 ($Aflif FACTOR : 2,770) j ltN0!N4$1Rtl$(PD) 2.1980 ($Af tfY TACICR 2.770) (IPAN!!0N$1R!$$(Ps) 2.4980 ($Af tif TACTOR 1.000) tilltM$TRtt$ i 23.3000 (PetPb)/$e 0.2853 ( $fRtl$RA110 0.3240 (Doll NOT INCLUO! $.F.) R 7 ACTOR 1.0000 4 alt 0.4524 1/cireviferen:t 0.0231-ALLOWAllt4/t 0.6000 ?i 1/Cittveltrinct 0.00 0.10 0.20 0.30 0.40 0.50 l Att0 halt! alt 0.6000 0.6000 0.6000 0.6000 0.6000 0.4900 l SIR-90-081 11 gg INTEGRITY ASSOCIATESIIC -~. -.

i j Table 3 i BRUNSWICK UNIT 1 FW N0ZZLE WELD 1B21N4D-6-SW1-2' Leak Rate in Pipes Cire. Thru-wall Cracks (Water Leak) CD 13.75 13.76 13.76 13.76 13.75 13.76 OR 6.876 6.876 6.976 6.876 '6.876 6.876 1 Thk 0.84 0.84 0.84 0.84 0.84 0.84 IR 6.036 6.036 6.036 6.036 6.036 -6.036 R. Nom. 6.466 6.466 -0.466-

6. 4 6 6 =

6.466 6.466 i xcire(2a) 9 12.6 17.6 18 26 36 2a (in) 3.660216 6.060746 7.097643 7.300433 10.13949 14419628 a (in) 1.825108 2.634872 3.648821 3.660216-6.069746 7.097643 a (rad) 0.282743 0.392699 0.649778 0.666486 0.786398 1.099667 1(theth) 0.194696 0.417686 0.961861 1.034626 2.642278 7.366272 pressure 1000 1000 1000 -1000 1000 1000 Tens Str 3369 3369 3369 3369 3369 3369 DW Str 143 143 143 143 143 143 TH Str 2498 2498 2498 2498 2498 2498' Bndg Str 2641 2641 2641 2641-2641 2641 E (psi) 28860000 28860000 28860000 28860000 28850000 28860000 COA (in*2)0.006276 0.011274 0.026768 0.027681 0.066974 0.188447 GPH 0.66 i.41 3.22 3.40' 8.37 23.56 I 1 i l 1 SIR-90-081 -12 m DfTEGIUTY 1 ASSOCIATF.S1FC =.

Table 4 Material Constants Used for Inconel 182 in LBB Evaluation E (ksi) 28,850 S (ksi) 16.994 m v (ksi) 28.35 g(" v)y a 11.56 n 2.88 C 2.673 N 0.3162 J 0.300 IC 5 max F D3 ) 80.0 u i ilow(ksi) 54.175 F l 1 1 1 SIR-90-081 13 STRUCTURAL INTEGRITY ASSOCIATES,INC

I I FEEDWATER NOZZLE DE Fall (N4D) l t Weld 1Il21N4D-5-SWi-2 i 4 j ( e T 238-250' 850-450' , 250" r I I I cs \\ / ncontt N cs cs -I i- --I ) T'/ ac W cs \\V 1( ), /\\ / l i J d I 1315* D R. 1175'DIA. All. DIMS APf110X NTS I l 3 l O Figure 1. ESEP-l'Feedwater Nozzle Detail (N4D) f 14 SIR-90-081/NGC-90-037

Ni-WI 1111 D fil SIDilAl lalill li: 1 li 33 30 4 25 20 - G 15 - 3 O 10 - U d to T ( 5 -- "re O_ ras hl. . % e.,. w-,,:ech-n _,5 O O.2 0:1 0.t i DISI ANCI I HOtt ID. \\/1 o NHC 4TII OHDl:R t

I 3Hn altnl it i

Figure 2. Through-wall Distribution of Axial Residual Stress Versus Wall Fraction for Pipe of 12-inch Size and Greater, Comparing NRC 4th Order Equation [3] with SI 3rd Order Equation h 15 SIR-90-081/UGC-90-037

BSEP UNIT 1 CRRCK GROHTH DRTR: INC-182 .34 ~ CHV CRDCK SET # 1 .33 / r, G .32 I i-- .31 Ed 1 M .30 Of I U I I ' [ Data Used .03 for SCC Law I e s .88 0 1000 2000 3000 4000 5000 6000 i llOURS Figure 3. BSEP-1 CAV Data for Inconel 182, Showing Data Without Hydrogen Water Chemistry, Which Was Used for the SCC Growth Law i Derivation. 16 SIR-90-081/NGC-90-037 'I w

i 4 MPo [m 10 20 30 40 -6 i i i i i i i 10 - = m Sc/5"

DATA AT/WM CCMST. WD

~3 o o.1 10 @ U v5/ m[ m [ wor o 1.0 p /m P9ttIwCTED Opd3 (8tCV th) 10 . BGD CW 30435 ISC/amt Wh 0g ~7 ~ ( 10 7 o.3 _4 E 3 10 v g of o a R o.s k a ~ bo c x x o -B (B"sk)- ' ~ c 10 c a o -5 y 0.1, 3 10 o a g O e o x u <x _g u 10 -6

10

-10 10 10 20-30-40 i STRESS INTENSITY, ksWi5 h Figure 4. Comparison of the Predicted and Observed Crack Growth Rates Versus Strens Intensity for Available i Data on Inconel 600 and 18e Tested at or Near Constant Load in 200 ppb Oxygen, 288'C Water [4). SIR-90-081/NGC-90-037 17 gg INTEGRITY Assoc 1xInIhn

CRACK GROWTH VERSUS TIME ~ I W N(1//ti \\VI;l!) lit;'IN Il1 'i-:aVI-l* O.52 l 0.01 - / O.O - 0.49 - / O.48 - / / [ j O.47 - t 0.40 - 5 / 0.45 - f 'g O.44 3 / 6 0.43 - O.42 - 0.41 - 0.4 - 0.39 - ~c-1 O 20 40 00 (Tsuni:;atus:;) TIME filOllli i1 i Figure 5. Predicted Stress Corrosion Crack Growth, Without Ilydrogen Water Cheraistry c) F 18 sin-90 -oa i/ncc-90-o37

7 3 0 0 9 g l C 9 e G n N o / c 1 n 8 /, , p o 9 I 0 r 0 u f -R e I v S r E uC y V n 3 a R i a U r C t S e o N , j I u N r o I I Ai / T N I RN f i ) I TC N s I N A s Sl l f e y , j l r i a Z t S S 9 1 S e u E r T R / - n o. d T 3 0 o S ogs a O g 4 r , 0 e 0 b j ma i R l 6

0 e

r a o 0 0 0 0 0 O 0 U i f g 7 0 0 4 3 ? u 1 g iF in kto

LOWER BOUND J-RESISTANCE CURVE St AINII :.,. ;li i I ANI) IM'ONI I P 1.9 - '~' 1.0. l.7 - ,/- l.0 -- / 1.5 - 1.4 - /' g ~ 1.3 - l p- _ O U 11 -. Et ta 1 -. Q. q 0.9 -- f 0.8 - h O.7 - 7 0.0 - 0.5 - 0.4 - 0.3 - 02 - 01 -. O-O Of 0.? o, j o,.! CIMCK 1 XII NSION tlN) Figure 7. Lower Bound J-Resistance Curve for Austenitic Stainless Steel and Inconel Flux Welds L1 h 2o SIR-90-081/NGC-90-O37

Appendix A Stress Corrosion Crack Growth Analysis II 1. l SIR-90-081 g INTEGRITY ASSOCIA'IEiINC.

tm pc-CRACK (C) COPYRIGHT 1984, 1968 STRUCTURAL INTEGRITY ASSOCIATES, INC. SAN JOSE, CA (400)978-8200 l VERSION 2.0 Dato: 21-Dec-1990 Tima: 10:34:43.79 STRESS CORROSION CRACK GROWTH ANALYSIS BRUNSWICK UNIT 1 FW NOZZLE WELD 1821N4D-5-SW1-2 INITIAL CRACK SIZE: 0.3800 WALL THICKNESS: 0.d400 MAX CRACK SIZE FOR SCCG: 0.6720 STRESS CORROSION CRACK GROWTH LAW LAW ID C N Kthres K1C INCONEL 2.120E-08 2.1610 1.0000 1000,0000 STRESS COEFFICIENTS CASE ID CO C1 C2 C3 RESIDUAL 30.6313 -266.0472 478.4576 -229.4907 MEMBRN 1.0000 0.0000 0.0000 0.0000 RESIDUALB 1.0000 -2.3810 0.0000 0.0000 Kmax CASE 10 SCALE FACTOR RESIDUAL 1.00 MEMBRN 7.09 TIME PRINT TIME INCREMENT INCREMENT ( 60000.0 73.0 730.0 crack model:CIRCUMFERENTIAL CRACK IN CYLINDER (T/R:0,1) CRACK ---------------STRESS INTENSITY FACTOR---------------- SIZE CASE CASE CASE RESIDUAL MEMBRN RESIDUALD 0.0134 6.513 0.228 0.224 0.0269 8.614 0.324 0.312 0.0403 9.841 0.398 0.376 0.0538 10.572 0.462 0.427 0.0672 10.964 0.519 0.470 0.0806 11.105 0.571 0.507 l 0.0941 11.114 0.623 0.541 l 0.1075 10.986 0.673 0.573 I 0.1210 10.723 0.723 0.601 SIR-90-081 Appendix A

PAGE h p:-CRACK VERSION 2.0 0.1344 10.347 0.770 0.627 0.1478 9.873 0.817 0.650 0.1613 9.313 0.863 0.671 0.1747 8.713 0.910 0.691 0.1882 8.079 0.960 0.712 l 0.2016 7.384 1.010 0.730 l 0.2150 6.634 1.059 0.747 0.2285 5.837 1.109 0.762 0*2419 4.997 1.158 0.776 0.2554 4.175' 1.211 0.790 0.2688 3.488 1.271 0.809 0.2822 2.781 1.332 0.828 0.2957 2.056 1.394 0.844 i 0.3091 1.318 1.457 0.860 1 0.3226 0.572 1.520 0.874 0.3360 -0.179 1.584 0.886 0.3494 -0.929 1.652 0.900 0.3629 -1.683 1.721 0.912 0.3763 -2.440-1.790 0.923 I O.3898 -3.196 1.861 0.933 i 0.4032 -3.949 1.932 0.940 0.4166 -4.696 2.004 0.947 0.4301 -5.512 2.081 0.953 O.4435 -6.355 2.161 0.958 0.4570 ~7.198 2.241 0.961 0.4704 -8.039 2.322 0.963 0.4838 -8.875 2.405 0.962 i 0.4973 -9.703 2.498 0.960 O.5107 -10.282 2.575 0.959 0.5242 -10,586 2.666 0.961 0.5376 -10.843 2.759 0.961 0.5510 -11.053 2.852 0.959 0.5645 -11.211 2.947 0.955 0.5779 -11.317 3.042 0.950 O.5914 -11.572 3.141 0.940 0.6048 -12.398 3.248 0.921 0.6182 -13.197 3.356 0.898 0.6317 -13.966 3.465 0.873 0.6451 -14.701 3.575 0.844 0.6586 -15.399 3.686 0.812 p 0.6720 -16.058 3.799 0.777 l i TIME KMAX DA/DT DA A A/THK 730.0 10.14 3.168E 0.0002 0.3823 0.455 1460.0 10.10 3.138E-06 0.0002 0.3846'O.458-2190.0 10.06 3.109E-06 0.0002 0.3869 0.461 2920.0-10.01 3.080E-06 0.0002 0.3892 0.463 3650.0 9.97 3.052E-06 0.0002 0.3914 0.466 4380.0 9.93 3.025E-06 0.0002 'O.3936 0.469 SIR-90-081 Appendix A. l

p,c-CRACK VERGION 2.0 PAGE 3 5110.0 9.89 2.999E-06 0.0002 0.3958 0.471 5840.0 9.85 2.972E-06 0.0002 0.3980 0.474 6570.0 9.81 2.946E-06 0.0002 0.4001 0.476 7300.0 9.77 2.921E-06 0.0002 0.4023 0.479 8030.0 9.73 2.896E-06 0.0002 0.4044 0.481 8760.0 9.69 2.872E-06 0.0002 0.4065 0.484 9490.0 9.66 2.849E-06 0.0002 0.4066 0.486 10?20.0 9.62 2.826E-06 0.0002 0.4107 0.489 10950.0 9.59 2.803E-06 0.0002 0.4127 0.491 11680.0 9.55 2.780E-06 0.0002 0.4148 0.494 12410.0 9.51 2.75BE-06 0.0002 0.4168 0.496 13140.0 9.47 2.733E-06 0.0002 0.4188 0.499 13870.0 9.43 2.708E-06 0.0002 0.4208 0.501 14600.0 9.39 2.684E-06 0.0002 0.4227 0.503 15330.0 9.36 2.659E-06 0.0002 0.4247 0.506 16060.0 9.32 2.636E-06 0.0002 0.4266 0.500 16790.0 9.28 2.612E-06 0.0002 0.4285 0.510 17520.0 9.24 2.589E-06 0.0002. O.4304 0.512 18250.0 9.20 2.565E-06 0.0002 0.4323 0.515 18980.0 9.16 2.542E-06 0.0002 0.4342 0.517 19710.0 9.12 2.519E-06 0.0002 0.4360 0.519 20440.0 9.09 2.496E-06 0.0002 0.4379 0.521 21170.0 9.05 2.474E-06 0.0002 0.4397 0.523 21900.0 9.01 2.452E-06 0.0002 0.4415 0.526 22630.0 8.97 2.430E-06 0.0002 0.4432 0.528 23360.0 8.94 2.409E-06 0.0002 0.4450 0.530 24090.0 8.90 2.388E 06 0.0002 0.4468 0.532 24820.0 8.87 2.368E-06 0.0002 0.4485 0.534 25550.0 8,83 2.348E-06 0.0002 0.4502 0.536 26280.0 8.80 2.328E-06 0.0002 0.4519 0.538 27010.0 8.76 2.308E-06 0.0002 0.4536 0.540 27740.0 8.73 2.289E-06 0.0002 0.4b53 0.542 20470.0 8.69 2.270E-06 0.0002 0.4570 0.544 29200.0 B.66 2.252E-06 0.0002 0.4586 0.546 29930.0 8.63 2.234E-06 0.0002 0.4602 0.548 30660.0 8.60 2.216E-06 0.0002 0.4619 0.550 31390.0 8.57 2.198E-06 0.0002 0.4635 0.552 32120.0 8.53 2.181E-06 0.0002 0.4651 0.554 32850.0 8.50 2.164E-06 0.0002 0.4667 0.556 33580.0 8.47 2.147E-06 0.0002 0.4682 0.557 34310.0 B.44 2.130E-06 0.0002 0.4698 0.559 35040.0 8.41 2.114E-06 0.0002 0.4713 0.561 - 35770.0 8.38 2.098E-06 0.0002 0.4779 0.563 36500.0 8.35 2.083E-06 0.0002 0.4744 0.565 37230.0 8.33 2.067E-06 0.0002 0.4759 0.567 37960.0 8.30 2.052E-06 0.0001 0.4774 0.568 38690.0 8.27 2.037E-06 0.0001 0.4789 0.570 39420.0 8.24 2.022E-06 0.0001 0.4804 0.572 40150.0 8.21 2.OOBE-06 0.0001 0.4819 0.574 40880.0 8.19 1.993E-06 0.0001 0.4833 0.575 41610.0 8.16 1.979E-06 0.0001 0.4848 0.577 42340.0 8.13 1.966E-06 0.0001 0.4862 0.579 43070.0 8.11 1.953E-06 0.0001 0.4876 0.581 43800.0 8.08 1.940E-06 0.0001 0.4891 0.582 j 1

pc-CRACK VERSION 2.0 PAGE ( 44530.0 8.06 1.927E-06 0.0001 0.4905 0.584 45260.0 8.03 1.914E-06 0.0001 0.4919 0.586 45990.0 8.01 1.901E-06 0.0001 0.4933 0.587 46720.0 7.98 1.888E-06 0.0001 0.4946 0.589 47450.0 7.96 1.876E-06 0.0001 0.4960 0.591 48180.0 7.94 1.864E-06 0.0001 0.4974 0.592 48910.0' 7.94 1.865E-06 0.0001 0.4987 0.594 49640.0 7.94 1.867E-06 0.0001 0.5001 0.595 l 5031Q'.0 7*95 1.869E-06 0.0001 0.5015 0.597 MlW 0 7.95 1.871E-06 0.0001 0.5028 0.599 51830.0 7.96 1.873E-06 0.0001 0.5042 0.600 52560.0 7.96 1.875E-06 0.0001 0.5056 0.602 53290.0 7.96 1.877E-06 0.0001 0.5069 0.604 54020.0 7.97 1.879E-06 0.0001 0.5003 0.605 54750.0 7.97 1.882E-06 0.0001 0.5097 0.607 55480.0 7.98 1.886E-06 0.0001 0.5111 0.608 56210.0 8.02 1.904E-06 0.0001 0.5124 0.610 56940.0 8.05 1.923E-06 0.0001 0.5138 0.612 57670.0 8.09 1.941E-06 0.0001 0.5153 0.613 58400.0 8.12 1.960E-06 0.0001 0.5167 0.615 59130.0 8.16 1.980E-06 0.0001 0.5181 0.617 59860.0 8.20 1.999E-06 0.0001 0.5196 0.619 60000.0 8.21 2.003E-06 0.0001 0.5199 0.619 END OF pc-CRACK i l l l l a SIR-90-081 Appendix A

Appendix B Determination of Critical Through-Wall Flaw Size for Leak-Before-Break Evaluation SIR-90-081 gg INTEGRITY ASSOClKrESINC

tm oc-CRACK (C) COPYRIGHT 1984, 1988 STRUCTURAL INTEGRITY ASSOCIATES, INC. SAN JOSE, CA (408)978-8200 VERSION 2.0 Date: 21-Dec-1990 Timo: 7:54: 2. 1 INSTABILITY EVALUATION BRUNSWICK UNIT 1 FW NOZZLE WELD 1821N4D-5-SW1-2 crack modol:THROUGH WALL CRACK IN CYLINDER UNDER REMOTE TENSION MATERIAL PROPERTIES:- FLOW STRESS (SIGMAf): 54.1750 YIELD STRESS (SIGMAo): 28.3500 YIELD STRAIN (EPSILOHo): 9.827E-04 YOUNG MODULUS: 2.885E+04 POISSON RATIO: 0.3000 RAMBERG-OSGOOD STRESS-STRAIN LAW:- ALPHApl: 11.5600 Npl: 2.8800 GEOMETRIC PROPERTIES:- OUTSIDE DIAMETER: 13.7500 WALL THICKNESS (t): 0.8400 OTHER CONDITIONS:- PLANE STRAIN <1> OR PLANE STRESS <2>= 2 dA: 2.02BE-01 LOADING CONDITIONS:- LOAD: 327.2979 STRESS: 9.6070 i HALF CRACK LENGTH (a): 1.0000 (2a/ circumference): 0.0493 a/t(a/b) F H 0.0000 1.0000 5.7306 0.0625 1.0640 4.3876 0.1250 1.2206 4.2469 0.2500 1.7117 3.5995 0.3750 2.8526 2.5974 0.5000 3.9936 1.5953 SIR-90-081 Appendix B J

l pc-CRACK VERSION 2.0 PAGE MATERIAL J-R CURVE:INCONEL J: 2.6730 * (da)^ 0.3162 Jac: 0.3000 Jmax: 5.0000 INCREMENTATION:- CRACK INCREMENT: 0.2028 NUMBER OF INCREMENTS: 100 INCREMENT CRACK SIZE STRESS: 9.6070 CRACK SIZE Jappl Tappl Tmat dA 1.0000 0.0433 0.5025 61006.2832 0.0000 1.2028 0.0537 0.6153 38865.9221 0.0000 1.4056 0.0664 0.7218 24560.7813 0.0000 1.6084 0.0813 0.8126 15855.6173 0.0000 1.8112 0.0980 0.9154 10569.9355 0.0000 2.0139 0.1169 1.0322 7221.5296 0.0000 2.2167 0.1382 1.1652 5029.1467 0.0000 2.4195 0.1623 1.3385 3555.5334 0.0000 2.6223 0.1899 1.4918 2531.0316 0.0000 2.8251 0.2206 1.6828 1829.0175 0.0000-3.0279 0.2554 1.8999 1333.4600 0.0000 3.2307 0.2946 2.1473 979.2015 0.0000 3.4335 0.3389 2.4297 723.2572 0.0015 3.6363 0.3890 2.7533 536.6920 0.0023 3.8391 0.4458 3.1248 399.6843 0.0035 4.0418 0.5102 3.5526 298.4474 0.0053 4.2446 0.5835 4.0467 223.2630 0.0081 4.4474 0.6670 4.6190 167.1998 0.0124 4.6502 0.7623 5.4011 125.2629 0.0189 4.8530 0.8737 6.6020 93.2597 0.0291 5.0558 1.0099 7.3652 68.1773 0.0460 5.2586 1.1619 8.4181 50.3513 0.0717 5.4614 1.3355 9.6474 37.2547 0.1114 l 5.6642 1.5346 11.0663 27.5878 0.1729 i 5.8670 1.7629 12.7076 20.4390 0.2681 6.0697 2.0250 14.6112 15.1443 0.4156 6.2725 2.3264 16.8251 11.2182 0.6446 BY INTERPOLATION Jerit: 2.0512 Terit: 14.8034 A:rit: 6.0874 Acrit - dA: 5.6545 W: 11.8424 MATERIAL J-R CURVE: INCONEL da Jmat Tmat 0.0020 0.3746 582.1897 SIR-90-081 i Appendix B

....._m. pc-CRACK VERSION 2.0 PAGE S J l 0.0028 0.4172 461.1879 i 0.0040 0.4647 365.3351 t-0.0056 0.5176 289.4042 0.0078 0.5764 229.2547 l 0.0110 0.6420 181.6066 i 0.0154 0.7150 143.8617 I 0.0217 0.7964 113.9616 0.0305 0.8870 90.2759 0.0429 0.9879 71.5131 0.0604 1.1002 56.6499 0.0849 1.2254 44.8758 0.1193 1.3648 35.5489 0.1678 1.5201 28.1604 1 0.2359 1.6930 22.3076 0.3317 1.8856 17.6712 0.4663 2.1000 13.9984 O.6556 2.3389-11.0890 O.9218 2.6050 8.7843 1.2960' 2.9013 6.9586 1.8221 3.2314 5.5123 2.5618 '3.5990 4.3666 3.6018 4.0084 3.4591 5.0640 4.4644 2.7401 7.1199 4.9722 2.1706 END OF pc-CRACK I i 9 A I SIR-90-081 l _... - -....__...,_.. _ _ - _ _ -__., ~., _.,. -... _... ~, -, -.

3 tm pc-CRACK (C) COPYRIGHT 1984, 1988 STRUCTURAL INTEGRITY ASSOCIATES, INC. SAN JOSE, CA (408)978-8200 VERSION 2.0 ) { Date: 21-Dec-1990 ] Time: 8:48:24.42 i INSTABILITY EVALUATION i BRUNSWICK UNIT 1 FW NOZZLE WELD 1821H4D-5-SW1-2 crack model:THROUGH WALL CRACK IN CYLINDER UNDER REMOTE BENDING MATERIAL PROPERTIES:- FLOW STRESS (SIGMAf): 54.1750 YIELD STRESS (SIGMAo): 28.3500 3 YIELD STRAIN (EPSILONo): 9.827E-04 YOUNG MODULUS: 2.885E+04 POISSON RATIO: 0.3000 RAMBERG-OSGOOD STRESS-STRAIN LAW:- ALPHApl: 11.5600 Npl: 2.8800 GEOMETRIC PROPERTIES:- OUTSIDE DIAMETER: 13.7500 j WALL THICKNESS (t): 0.8400 OTHER CONDITIONS:- PLANE STRAIN OR PLANE STRESS <2>= 2 dA: 2.028E-01 l LOADING CONDITIONS:- LOAD: 1060.8260 STRESS: 9.6070 HALF CRACK LENGTH (a): 1.0000. .(2a/ circumference): O.0493

i a/t(a/b)
F H l O.0000 -1.0000-8.3623 l 0.0625 1.0589 6.3423-0.1250 1.1838 5.6635 0.2500 1.5175 4.3380 0.3750 2.1278 3.1355 0.5000 2.7381-1.9330 SIR-90-081 Appendix B 1_-.._.,-.-. c.;. -~._._.._._..;.2_.; .x . a ;,
a.._;. ; ;.,.; _. a c. - _,, _ n a _, _..;
pc-CRbCK VERSION 2.0 h PAGE MATERIAL J-R CURVE:INCONEL J: 2.6730 * (da)^ 0.3162 Jic: 0.3000 i Jmex: 5.0000 INCREMENTATION:- CRACK INCREMENT: 0.2028 NUMBER OF INCREMENTS: 100 J INCREMENT CRACK SIZE STRESS: 9.6070 CRACK SIZE Jappl Tappl Tmat dA 1.0000 0.0284 0.3C82 154515.2647 0.0000 1.2028 0.0347 0.3576 99773.2108 0.0000 1.4056 0.0421 0.3996 65772.1967 0.0000 1.6084 0.0503 0.4337 44675.1280 0.0000 1.8112 0.0593 0.4709 31364.C503 - 0.0000 i 2.0239 0.0690 0.5118 22589.6766 0.0000 2.2167 0.0796 0.5567 16603.1041 0.0000 2.4195 0.0910 0.6262 12403.8482 0.0000 2.6223 0.1040 0.6903 9309.8402 0.0000 2.8251 0.1182 0.7562 7052.9928 0.0000 3.0279 0.1338 0.8289 5394.4662 0.0000 3.2307 0.1509 0.9093 4159.0612 0.0000 3.4335 0.1697 0.9984 3228.1500 0.0000 3.6363 0.1903 1.0973 2519,7001 0.0000. 3.8391 0.2129 1.2073 1975.9330 0.0000 4.0418 0.2378 1.3299 1555.4902 0.0000 4.2446 0.2652 1.4670 1228.3410 0.0000 4.4474 0.2955 1.6204 972.4009 0.0000 4.6502 0.3289 1.8186 771.2436 0.0013 4.8530-0.3665 2.1827 610.5914 0.0019 5.0558 0.4115 2.4870 475.2314-0.0027 5.2586 0.4628 2.7839 368.5931 0.0039 5.4614 0.5202 3.1146 286.2061 0.0056 5.6642 0.5845 3.4885 222.4852 'O.0082 5.8670 0.6564 3.9123 173.0781 . 0.0118 6.0697 0.7372 4.3938 134.6897 - 0.0170 6.2725 0.8278 4.9425 104.8128 0.0245 6.4753 0.9298 5.5693 81.5304. 0.0354-L 6.6781' 1.0447 6.2874 63.3710 0.0512 i- "6.8809 1.1744' 7.1124 49.2004 0.0742 7.0837-1.3211-8.0630 38.1413 0.1077 7.2865 1.4874 9.1616 29.5131 0.1567 7.4893 1.6764 10.4350 22.7861' O.2287 7.6921 1.8917 11.9152 17.5472 0.3351' 7.8949 2.1375-13.6411 13.4732 0.4931 i BY INTERPOLATION Jerit: 2.1304 Tcrit: 13.5911 SIR-90-081 Appendix B +v- 'r--en.- ,---,,--=,n,,e-m.-e-m~ w-~r--- w-- - - - - x, .r-<o,r- ,,w r n-g ~,c.. r ,n.e er n m -se ~e-~r-e,--r+ , -a n w y ev,,vs
) l p'cfdkACK VERSION 2.0 PAGE - 5 Acrit: 7.8890 Acrit - dA: 7.4010 l W: 8.0707 1 MATERIAL J-R CURVE: INCONEL da Jmat Tmat 0.0020 0.3746 582.1897 0.0028 0.4183 458.7269 0.0040 0.4670 361.4464 0.0057 0.5214 284.7959 0.0081 0.5822 224.4003 l 0.0114 0.6500 176.8126 0.0162 0.7257 139.3166 r' O.0229 0.8103 109.7723 O.0325 0.9047 86.4933 i 0.0461 1.0101 68.1510 4 0.0653 1.1278 53.6985 i 0.0925 1.2592 42.3108- -i 0.1311 1.4059 33.3381 0.1857 1.5697 26.2682 ) O.2632 1.7526 20.6976 i 0.3730 1.9568 16.3084 0.5285 2.1848 12.8499 0.7489 2.4394 10.1249 I 1.0612 2.7236 7.9777 1.5037 3.0410 6.2859 i 2.1307 3.3953 4.9529 3.0193 3.7909 3.9026 4.2784 4.2326 3.0750 6.0626 4.7258 2.4229 8.5908 5.0000 1.9091 END OF pc-CRACK' i -i a i i i i i~ L L i 1 . SIR-90-081. Appendix B-L .j 1 .i (- i 5}}

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