ML20116J825
| ML20116J825 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 08/31/1974 |
| From: | Michael Lee GILBERT/COMMONWEALTH, INC. (FORMERLY GILBERT ASSOCIAT |
| To: | |
| Shared Package | |
| ML20116J740 | List: |
| References | |
| NUDOCS 9608140094 | |
| Download: ML20116J825 (200) | |
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} FLORIDA POWER CORPORATION l CRYSTAL RIVER NU, CLEAR POWER PLANT UNIT NO. 3 !
- i s-l MAIN STEAM SAFETY AND RELIEF a
3 VALVE SYSTEM STRESS ANALYSIS REPORT 1
SUMMARY
i 1 l i i i i i
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l ! AUGUST 1974 i 1 1
- MOO-ZUNG LEE
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' I PIPING ENGINEERING DEPARTMENT GILBERT ASSDCIATES, INC.
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- 1. l INTRODUCTION At least two cases of safety valve installation failures have been reported in recent years. In both cases the failures were attributed to the moments l 1
generated by reaction forces of the stesa discharged from the valves at the ! testing stages of the new nuclear power plants, d ! In view of these incidents, a review of the main steam safety and relief I ! i valve installations in Crystal River Unit 3 was undertaken. The discharge stack orientation was modified to correct the unf avorable condition. The
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- following sections represent a condensed presentation of the analysis per- ;
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- 2.
- GENERAL LAYOUT AND CONSTRUCTION The main steam piping system of Crystal River Nuclear Power Plant Unit #3 consists of four 24" lines connecting two steam generators to the turbine.
Each of these four lines has four spring loaded safety valves located in the Intermediate Building. Fourteen of these valves are of 6" inlet, 10" outlet and two are of 6" inlet, 8" outlet, and all are supplied by Dresser. The safety valves are mounted on 24" schedule 60 (0.986" vall thicknees) headers using Bonney Forge sweepolets. The outlets of the valves are inclined so that the bending moments on the branch connections created by the steam discharge flow reaction forces are minimized. The safety valve outlet el-bows are connected to the discharge stacks by Flexonic Joints which are esentially closed type flexible bellows connectors. () There are also two power operated atmospheric relief valves installed on two lines, one from each steam generator. The main steam pipes are made of ASTM A106 Gr. B, the discharge stacks are of ASTM A53 Gr. B. Sweepolets, weldolets, flanges and elbows are made of ASTM A105 Gr. II. STRESS COMBINATIONS AND ALLOWABLE STRESS CRITERIA Stresses in the main steam pipes, safety and relief valve inlet branches and outlet pipes are analyzed for sustained loads, occasional loads and thermal expansion loads. Sustained loads include the effects of pressure and dead weight. Occasional loads include seismic responses and the loads created by valve discharge flow reaction forces. Design loads due to seismic i responses are taken as twice of those excited by operational basis earth-quake (OBE). Dynamic effect of safety valve discharge reaction loads are I considered by using dynsmic load factor. The load combinations and allowable ; I l
- 3. ;
stresses are based on Power Piping Code USAS B31.1.0 Par. 104.8 1973 Addenda. VALVE DISCHARGE REACTION FORCES. 1 Maximum discharge flow capacities of the safety valves are taken as 111% ! 1 of the rated capacities given by the valve manufacturer. The order of l i these figures are checked by independent calculation based on the steam con-- j
, i ditions and the orifice sizes of the valves using Napier's formula. Steam l t
flow conditions are established and the maximum reaction forces are calcu- ! i laced for overall isentropic nozzle efficiencies of the safety valves ranging l from 25 to 50%. These reaction forces include the pressure and the momentum . effects of the tiow. The results are in close agreement with the data given f by Dresser. (Ref. Consolidated Safety Valves Reactions Forces for steam i f Services March 1973). It must be noted that Safety Valve Reaction Forces availabla from manufacturers prior co 1973 were 30% to 50% lower than those l I stated today. The flow reaction forces of the power operated relief valves are calculated ! i by assuming that the maximum flow rate may reach 120% of the rated flow rate. ! The effects of the back pressure in the Flexonic joints are estimated and ! e added to the discharge flow reaction forces in calculating the stresses due to valve operation. Detailed flow analysis for the stacks performed later l showed that the estimated back pressure effects are conservative. l l DYNAMIC LOAD FACTOR fi The effects of safety valve discha.de reaction on the piping is dynamic in l neture. The dynamic load factor (DLF) is defined as the ratio of the stress caused by a dynamic load to the stress caused by the same quantity of load applied statically. DLF depends on the nature of the forcing function and
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the dynamic characteristics of the piping system. O Most of the safety valves pop open to 70% of their lifts in 40 mili-seconds I followed by gradual increase in opening. In this analysis the time characteristies of the safety valve reaction force is assumed to be a ramp function rising j from zero to maximum in 40 mili-seconds and remains constant thereafter. The fundamental natural periods of the main steam pipes are calculated by ! simplified analysis. The lower bound of this natural period and the forcing function as assumed above establishes the conservative value of DLF. Although the safety valves on the same line are set to pop at different pressures, it is assumed that all the valves on the same line may open simultaneously and the worst combination of the effect on the header is con- . sidered. O v STRESS INTENSIFICATION FACTORS Two methods are employed in calculating stress intensification factors for the branch connections. For safety valve branch connections where sweepolets are used, Bonney Forges' formula for stress intensification is employed. Qtef. Stress Intensification Factors and Stress Indixes for Bonney Forge Sweepolets Jan, ,1971.) For the relief valve branches, connected to the header by weldolets, method given by ASME Boiler and Pressure Vessel Code Sec. III Winter 72 Addenda NC-3673.2 (b) and Table NB-3683.2-1 are used. DISCHARGE STACKS AND FLEXONIC JOINTS , Steam flow conditions in the discharge stacks and the back pressure in the bellows of the Flexonic joints are calculated by employing the conservation d equations of mass, momentum and energy assuming adiabatic process. Pressure
5. in the bellows of the Flexonic joints for the 6" x 10" safety valves was found to be slightly higher than the design pressure. However, con-sidering the conservative assumptions made in the analysis and the bursting pressure and other data provided by the manufacturer, it is our- judgement that the joints can be used without compromising the safety. The effects of flow reaction loads on the stack supports and the stacks themselves were reviewed and necessary modifications in support design were made to meet the stress criteria.
SUMMARY
OF DATA AND RESULTS
- 1. Discharge Flow Rates Safety Valves 6R10 rated 845,759 lbs./hr.
max. 940,000 lbs./hr. Safety Valves 6Q8 rated 579,000 lbs./hr. C-) max. 645,000 lbs./hr. Relief valves 6" rated 418,500 lbs./hr.
- 2. Discharge Reaction Forces Safety Valves 6R10 23.5 Kips Safety Valves 6Q8 15.3 Kips
- Relief Valves 13.5 Kips
- 3. Dynamic Load Factors Main Steam Pipe, calculated 1.22 used 1.5 Discharge Stack, calculated 1.21 used 1.3
- 4. Stress intensification Factors Sweepolet main pipe 1.5 branch 1.0 Weldolet main pipe 1.5 branch 1.84 4
! 6.
- 1
- 5. Maximum stresses and Codes Allowable Stresses.
A. Msin Steam Pipe at Safety Valve installation f i k stresses due to sustained loads Allowable j Line CR-3 7,583 psi 15,000 psi l Line CR-4 7,449 psi 15,000 psi Line CR-5 7,632 psi 15,000 psi ! Line CR-6 7,615 psi 15,000 psi s ! Max stresses due to sustained + occasional loads Allowable Line CR-3 14,871 psi 18,000 psi
- Line CR-4 17,701 psi 18,000 psi !
- Line CR-5 13,739 psi 18,000 psi r
- Line CR-6 15,382 psi 18,000 psi l i Max stresses due to thermal load Allowable s
l Line CR-3 3,417 psi 22,500 psi , Line CR-4 13,815 psi 22,500 psi ! Line CR-5 13.498 psi 22,500 psi i Line CR-6 13,620 psi 22,500 psi j B. Safety Valve Inlet Connections- ! Max stresses due to sustained loads Allowable i k i Line CR-3 2,773 psi 17,500 psi Line CR-4 2,773 psi 17,500 psi ; ) Line CR-5 2,908 psi 17,500 psi j l Line CR-6 2,660 psi 17,500 psi
- Max stresses due to sustained + occasional loads Allowable
! Line CR-3 15,098 psi 21,000 psi l Line CR-4 14,432 psi 21,000 psi j Line CR-5 17,121 psi 21,000 psi [ Line CR-6 15,813 psi 21,000 psi l Thermal loads on the safety valve branches are so small that d the stress calculations are not meaningful. j C. Stress in safety valve outlet elbow i
- Max. stress 12,000 psi i
- Allowable 21,000 psi j D. Relief Valve Branch Connection I
- j. Max stresses due to sustained load Allowable Run Pipe 7,234 psi 15,000 psi Branch 7,730 psi- 15,000 psi
7. Max stresses dua to sustained + occasional Allowable O'N load Run Pipe- 9,254 poi 18,000 psi Branch 14,350 psi 18,000 psi 1 Thermal stress Allowable l Run Pipe 9,770 poi 22,500 psi I Branch 5,620 psi 22,500 psi ; E. Discharge Stacks i t Max. stress Allowable 14" stack 16,840 psi 18,000 psi , 12" stack 14,770 psi 18,000 psi
- 6. Flexonic Bellows Back Pressure j Calculated Pressure 14" stack 51~54 psig ;
12" stack 31 pois Designed Pressure 50 psig Bursting Process 150-200 psig , I O
8. t l l CONCLUSION. This analysis of the Main Steam Safety Valve System, with the modifica-tion of the discharge angle at the outlet of the safety valves and with the addition of supports HSH 219, 220, 221, 222, 244, 245, concludes that the design is satisfactory based on USAS B31.1.0 stress criteria. l 1 e 0 e
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i FLORIDA POWER CORPORATION CRYSTAL RIVER NUCLEAR POWER PLAHT UNIT NO. 3 MAIN STEAM SAFETY AND RELIEF VALVE SYSTEM STRESS ANALYSIS REPORT l 1 O . I i AUGUST 1974 MOO-ZUNG LEE PIPING ENGINEERING DEPARTMENT l GILBERT ASSOCIATES, INC. j O l _ - _ _ .)
TABLE OF CONTENTS' Section Safety Valves Page Introduction i Valve Specification and Set Pressure 5 Optimal Exit Angles 7 Discharge Capacities 10 Discharge Reaction Forces 12 Steam Condition in Safety Valve Outlet 16 Force on Flexonic Shroud 22 Dynamic Load Factors 24 Stress Intensification Factors for Sweepolets 28 Sectional Modulus 33 Allowable stresses 34 Stress due to Internal Pressure 35 Loads on Safety Valve Connection for Computer Input 38 Stresses in Line CR-3 42 Stresses in Line CR-4 50 l Stresses in Line CR-5 59
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Stresses in Line CR-6 66 Stresses in Outlet Elbow 73 Main Steam Header Supports 75 Atmospheric Relief Valves Discharge Reaction Force 88 Stress Intensification Factor of Weldolet 95 Stresses in the Header 104 Stres.;as in the Branch 108 O References 110
TABLE OF CONTENTS CONTINUED Appendix A - Flexonic Joint Backpressure Page Assumptions and Key Equations A-201 Results A-239 References A-240 Appendix B - Discharge Stack Bending stresses due to flow B -301 Dynamic Load Factor B-309 , Offset Angles B-311 , Support Loads on Lower Guides & Pipe Stresses B-312 l Structure Loads for Line through Pen. #107 B-330 Deflection of Support B-332 Effect of Support Beam on DLF B-337 , i Structure Load on Other lines B -339 l Transient Load B-342 Pipe Stresses at Roof Anchor B-344 References B-345 i l O !
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