ML20204H214
| ML20204H214 | |
| Person / Time | |
|---|---|
| Site: | Waterford, San Onofre  |
| Issue date: | 02/10/1998 |
| From: | Falvo G, Tursi J ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY |
| To: | |
| Shared Package | |
| ML20204H122 | List: |
| References | |
| S2-NOME-CALC, S2-NOME-CALC-00, S2-NOME-CALC-0085-R0, S2-NOME-CALC-85-R, NUDOCS 9903290032 | |
| Download: ML20204H214 (57) | |
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Design Analysis In-Process Approvals Tdle: Seismic Quahfication of the Steam Ceor PDT, Hot Leg PDT. and Hot Im S==!iw MNSA Hardware De==* Number: 62-NOME-CALC-0085 Revision Number. 00
- 1. Ammig=====* es "n - " ""y - Managanaw asaps the folkmng adsvuhals to this Degn Analyas. Dese nadshals ase quah8ed to perfonn the amaned task tw vinue strammt and -
Printed Nanne Ma=p Appnwal(Inidais) cephantrMs) J.G.Twai c .,uA
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Manner SName IP Ws) G.E. Falvo nyJ
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- 1. De obpzam ad method (s) have been revwmed and app:.ed.
1% Revumer'sinmals: d. . u,, ai d-- to a,,s i ,_ c nameme nodenanonsorwh e appaned anniyncat urh=9= 0 Denanons or ="% to approved anniyixat a-h 9- are appn=ed. M===r==~* W W b
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- 3. Appewat dsigm8 mat changs in the mode denmpen program use:
S neue are no =rnde=nt changes in the mode of apphanon d enmpen programs. C Cognuant Program Manager concurs with the appixahdity doompmer programs for this use: PmgramMannerinmals ' 4. Demp inpas are appropnme and namahie io their saunas:- Inder=waan Renemer'simoals: - .
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- 5. De Venfkanon Plan is apprwed.
Managememinitials - #/) J 4 ABB_ Combustion Engineering Nuclear Operations 9903290032 990323 PDR ADOCK 05000382 P PDR u
4 VesiGcation Plan
Title:
Seismic Qualine= don of Steam Generator PDT, Hot Leg PDT. and Hot Leg Sas-#14E MNSA H.idware Document Number. S2-NOME-CALC-0085 Revision Number: 00 jaggggggg- Desenbe the method (s) of vs.'fient== to be employed. i.e., Dgaga Review. Alternata Analyms, Quah8 canon Tesung, a mad ===*== of these or an ahoranteve. 'I)e Design Analysis Verdimema shaliar is to bc used for all Desaga Analyses. Other classents to comeder in fonautaung the pian are: methods for cheddag ralad=*==r commenson of results with ihmiar analvess, etc. i i Daudon of Verine=+ ion Method: '
- 1. Verification of Design Analysis by Design Review (per OP 3.4 of the Qualitt Procedures Manual).
- 2. Verification that an appropriate enethodology is selected and correctly implemented
- 3. Review that the assumptes, resuhs, conclusions, report format, ... etc. are made in accordance with Design Analysis Verification checklist.
- 4. Verify all design input is appropriately and correctly obtained from traceable sources. ,
- 5. Review numencal calculations for accuracy.
i l Venficauon Plan p,M by: Approved by: we, ,. , C FAuolA 1f$ r k ?/N /d G betaR ,5 & a-- - w - _ - - w n-1: i
4 Design Analysis Verification Checklist (Page 1 of 4) lastructines: 'llte ladependent Reviewer is to ra==plaea this charirlier for each analysis and it is into the cr==pis**d anasysis. If a anajor topic area (generally unnG.4 bold face type such as Us Software) in act applicable, then N/A (not appbcable) next to the topic anay be checked and the check bon itemis under it may be IcA blank. Where there is no check box under N/A for a amnbered item generally inappsopnate. If N/A is checked in such a situauon, * -- : the basis at the end of this checklist in the Cm sectica.
Title:
Seismic Qii E" =k i of Steam Generator PDT, Hot r og PDT, aisf1Iot lag Sr.#--- MNSA Hardware Daemm=mt Nasaber: S2-NOME 4ALC-0085 Revision Number: 00 m.,.. N, in% lNIN. _ m. . a
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- 1. Are the results/ conclusions correct and appropriate for their intended use?
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- 2. Are millhnitations and contingencies on the results/ conclusions documented?
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1. Haue Cagussa Ensimann, W Reviewma and Wesesru, if appleashia, bem ammesad and appuoved by saammesmas?
- 2. Ifene ese umhgis Caguese Eagmasm, has eksir essps been desumuscad?
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- 3. Iftse ese muhele P Reviewsm, has their asspe base desummesd?
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- 4. Iftese smallbeunduple hae Approvera, has their enspe base dessumused?
O I 5. If om W Reviseur is the supervaar, has samharusass as am W Rawower home demamassed?
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- 1. Is the enemme appheshis isr this smalysis?
2. Q Ifone ese myseessa ekseen in the made of asemme uns, has the Peepam Adamments) base emmashed and have they the appsevehassaien etthe Design Analysm In Pressus Appsevels isnn? O O For assuers which has nas home tendstad modar QF 3.13:
- 1. Is the sunpasar sype, proyees name and sevenus edessdenesem desumanad?
2. O i Is the damsmessnessm essman ist the W Reviseur to esasur thus the sehsere is apprepnses for tbs assiyeis? 3. Is die was summest for the W Asviseur to esser thss the nuntes are servess? 4. O Ifte desumsmarsen 4 inserparated by refeusse, is there auswanas that the seaware acmaally named is idsmaanal to thes in abs ndeness? [ 5. Ifspseedshassa have home met is the desummassanom @ ist the W Reviewer to esasur shot she sende are sanea7 [ I pp 12 Jam
Design Analysis Verification Checklist Doceanent No. S2-NOME-CALC-0085, Rev. 00 (Page 2 of 4) Design Sija5fCessemas:d , ' ' o - "'
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2. [ Mas the meses why the emaiyms is hang performed er mined home damsmsmed? M 3. Has to apphashaley and hasaded uns afes sumuhe huss desumussed?
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Am the amahmaal todagens (massh) dummehad is naimsut dmail to judge their apprepnaammem? 2. QI Ham ammheisel enkmges maaperuand by nimense to gumns aanhasa, had plant aanham er m sysis amaham hem paammiy tended? [ 3. Fw estasshans er spesumus tem pmesudy appewed anniyment asshmess erc-1 F_._Aanhas Psusadam(gr 3.19): Q Q" a, Ase esyammmmandandjueSed? h, Hase tsy has appmed by u Q @ g- heahas es Desi Anahum idensen Appenh Ame? 4. O Ifaspansend sess ved amelyommi em6magias er Espasareg Analyas Presasses are used, is their weejusaded and appmed 3. O Q' Dess the dets afismas ofseinemsed approved pressimum er Espasarms Analyas Presasses 7 predias esir use in this _-_% i m.s e a.e 4 , , . . . , Y b3s8"*3m"2: ~elDesigE ImpIBisE! M4 " W g3 'Nti
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- 2. Aso the design impues sensely salassed and massable es their masus?
3. Q Ase sudsummes as disent as pasmhis to the engmal suums er domsmans esmaamma -"----" erinpues? -
- 4. b es sudmasse asesmen apprepnsesty sysmas to the infanmesa utsland?
7 5. Q 6. Ase the bases ist animass ofall damien impass desusammed? k es vendesmem means afdssigs impias erammuusi tan sussemers appreyness and desumasad? h 7. G O k the verdenham means ofdesigs impass tenemsmed tems ABB CENS apprepnans and desusammad? 8. O 6 k the uns of mnemmer sammeund asunus ass as Tes spam, UFIAlta, sac. asshanand, and dans the aussnaamse sponly assadeus jewel, sownsen number, sas.7 y * . ' !q a!Si - - t ; '0 ,o r
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_ _ . _ ~ _ .. _ . _ _ _ . _ . _ _ _ _ _ f v 1 Design Analysis Verification Checklist l-( Docusnest No. S2-NOME-CALC-0085, Rev. 00 t ] (Page 3 of 4) s i Bassi +1/M,-.aleesh,
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t 1. , m aR neds ensansed in er nismmond in the RamuheCammlus am semen? j l 2. [ Ase au lisenshems em the sudslemmelussens and esir - win this senesen? f 3. 7 Ase au amongsames as eks roses that musst be einered linead in the RassheCemsiussam session and om aW and i Assuuspammsisso? _ [ j 4. Is apresens apinestoasum . mm.is .e th. e.s. sam,e that these esemesames ubish ase the sumamour's napsmediday to clear will be inskadad in t4 i S. Has a ammsperams afthe seses wth thess of a psevious syuis er ammilar smalyuss basm made and agansamt deSmenses espissand? I j Other G d i " ' h , ' ~ ' W ,' *'
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- 3. Ase hemd animalaessus earsus and appugneesty dansmissed?
d C 4. O Is e assimshis empener emeye and impa imsamesdr In at semputer andemess mand idended by name and savaise sdamesGenessa? O [
- 6. Ase au messasshe envelopen edunded wieb IF Jealysm number and ammber afshases?
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- 2. Ase au pegu idemand widi the dammen member, instudes revesen musher?
[ 3.' De au pages base a amispas pass member? [ 4. Hase all shamess hema aushausessmed by the initials and does ofhoek she Cayusant Eaganer eW Reviewer and, if segmeed,by Hammemmem:1 Far e ensamma as a ammpissed anniyass: 1. g Whes presmani have ahnsens and addeses hues idemand by asshammums audi as venisal liman, ses.?
- 2. Whee peusmani have doissions base ideanded by smashmanmus sush as striks sues, ses.?
- 3. Have endianasses of shanom in previous rovasses home samoved?
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- 4. Has a Rasani of Revemas a pass heum added er revised, and dass it ensain the ensamt of the revissen?
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- 5. Dras the shedhamnum af the sevassa hashade these en the absenbusen of the previous revinen?
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A BR M DW ASEA BROWN BOVERI Contract: SONGS 2 & 3 MNSA chibdon: 39 Pages Appendix: 0 Pages Pages Micmfiche: 0 C*ih6m Number: S2-NOME-CALC-0085 Revision: 00
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Title:
J. Seismic Oualification of Steam Generator PDT. Hot leg PDT, and Hot 12g Sampling MNSA H.Jware Author: N Date: 8/7 J.G. Tursi, ogmzant gineer '/ Approval: J.TAdcGarry, Project M_ er Date: 0 7 l Approval: d/f//h w w Date: 7//o/W J.M. Burger, Supe'rvisor, Reactor Vessel Systems ! 'Ihis calculation contains safety related design information: YES O NO @ VERIFICATION STATUS: COMPLETE n.4 i, int ==.u= ei.- 6 6 IWWiWf. v.ui.4 a 6. by wo i, Nas :C/s40n t. FA tav Sip. ass: 4( D.k: d-/d- 7 T Rmew.- / '/ Distnbution: NOME File (9481-1934), Bev Bova (9485-1903) Summary
Purpose:
'1he purpose of this calculation is to compare the calculated values for overturmng moment for the Steam Genemtor PDT, Hot Leg PDT, and Hot Leg Sampling MNSA to those of the previously seismically tested Bottom Pressurizer MNSA to qualify the three new designs by comparison. Method and Results of Review: 4,~1 petvnw. vn pw c~$ ?,e -L Qk m@' M~ p M hC U C Qn t:LfS M vv1H c e-s^~ f nni i A4 a s Fou o 7p be accew j\L% .i c cd7A ble.
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Record of Revisions No. Date Pages Involved Prepared By Approvec' By 00 All, OriginalIssue J.G. Tursi J.T. McGarry J.M. Burger
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_ s .-.a-- .-..a-u .- .s-s 2--.- . . . . n as---- ...~.a.n,-. . - -> _w,,a.u (. - . 1 l Ak EDED 7%E9E9 ASEA BROWN BOVERI S2-NOME-CALC-0085 00 Calculation Number Rev. I Page 3 of 39 Page Number l Table of Contents ,+- Section Title Page 1.0 Scope 4 2.0 Method 4 3.0 References 4 4.0 C=Imilation of Bottom Pressurizer (BP) MNSA 6 Overturning Moment 5.0 Calculation of Steam Generator PDT (SG) MNSA 13 Overturnmg Moment 6.0 Calculatin of Hot Leg PDT (HLP) MNSA Overturning 20 Momem 7.0 rila'idon of Hot Leg Sampling (HLS) MNSA 24 Overturning Moment 8.0 Comparison Between BP MNSA and SG MNSA 27 9.0 Comparison between BP MNSA and HLP MNSA 28 10.0 Comparison between BP MNSA and HLS MNSA M 11.0 Conclusion $1 List of Figures No. Title Page 1 Bottom Pressurizer Mechanical Nozzle Seal Assembly 32 2 Steam Generator PDT Mechanical Nozzle Seal Assembly 33 3 Hot Leg PDT Mechanical Nozzle Seal Assembly 34 4 Hot Leg Sampling Mechanical Nozzle Seal Assembly 35 List of Tables No. Title Page Bottom Pressurizer MNSA Weight 1 36 2 Steam Generator MNSA Weight 37 3 Hot leg PDT MNSA Weight 38 4 Hot I2g Sampling Weight 39 ABB Combustion Engineering Nuclear Power
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l pg 3 p ASEA BROWN BOVERI I S2-NOME-CALC-0085 00 Calculation Number Rev. Page 4 of 39 Page Number 1 1.0 Scope
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'Ihe scope of this al~1*i= is to a1~1* the overtuming moments in the Bottom Pmssurizar MNSA, the Steam Genesator PIyr MNSA, the Hot Ieg PDT MNSA, and the Hot Lag Sampling MNSA, r from a 1 G seismic loading applied to each dengn. 'Ihe abi1*M values for the Bottom Presanizer
! MNSA will be cur. .p 4 to the three new design's values. Under seismic conditions, the increase in loading acts to offset the preload in the Hex Head Bolts, whic would result in no sealing or anti <jection capability. By showmg that the overtummg moment of the Bottom Pmssurizer MNSA, subjected to the seismic load, is equal or greater than either the ca .iig moment values of the Steam Generator PDT, Hot Ieg PDT, or Hot Iag 9maling MNSA, we can conclude that seismically testing the three new MNSA assemblies is urrmy lwane the loadings in the three new designs will be less than the loadings the Bottom Pressurizer MNSA was subjected to d gnalinadaa testing (Reference 3.1) 2.0 Method
'Ihe method used to al~1* the overtuming moments is hand calculations, utilizing the p-T= of whaaial design. Once a1~I*M, a direct co...p.dson of the overturning moments will be made for the Bottom Pr=n'4- and Steam Gerw.iur PDT MNSA's since there geometry is very similar and the bolt circles for the Hex Head Bolts are identical.
Further calculations will be performed to &kinaire the force acting to offset the Preload in the four Hex Head Bolts, created by the overtuming moments, for the Bottom Pressunzer, Hot Img PDT, and Hot leg Sampling MNSA's. The unloading forte values for the Bottom Pressurizer MNSA will be compared to ' both the Hot leg PDT MNSA and Hot leg Sampling MNSA values, since there geometry and bolt circles are different. 3.0 References 3.1 ABB Report No. TR-PENG 033, Rev. 00, " Test Report, Seismic Qualification of the San Onofre Units 2 & 3 MNSA Clamps for Pressuruer Instrument Nozzles and RTD Hot leg Nozzles". 3.2 ABB Report No. S-PENG-DR 005, Rev. 00, " Design Report, Addendum to CENC-1365 and CENC-15M Analytical Reports for Southem California Edison San Onofre Units 2 & 3 Piping". ABB Combustion Engineering Nuclear Power
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_ ___ . _. _ . . . _ _ . . . _ . . _ . . _ _ . . _ . . . _ . . . _m _ . _ _ _ . . i l A DED l' M EDED ASEA BROWN BOVERI i S2-NOME-CALC-0085 00 Calculation Humber Rev. Page 5 of 3? Page Huntar 3.3 ABB CENO Drawing No. E MNSA-228-001, Rev. 02, "Bottomlessunzer Mechanical Nozzle : Seal Assembly". 1 3.4 ABB CENO Drawing No. E-MNSA-228-014, Rev. 02, " Steam Generem PDT Mechamcal Nozzle Seal Assembly". 3.5 ABB CENO Drawing No. E-MNSA-228 015, Rev. 01, " Hot Leg PDT MNSA". 3.6 ABB CENO Drawing No. E-MNSA-228416, Rev. 03, " Hot leg Sampling MNSA". , 3.7 ABB CENO Drawing No. E-MNSA-228-004, Rev. 05, " Mechanical Nozzle Seal Assembly Details". 3.8 ABB CENO Drawing No. E-MNSA-228-013, Rev. 04, "Meh2 nim Nozzle Seal Assembly Details". I 1 1 l l ABB Combustion Engineering Nuclear Power
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TABLEl' - q i Bottom Pressurizer MNSA (E-MNSA-228-001-1, Assembly) Weight ' i Nanne Detail Part No. Volense (ca.in.) Density Ob/ca.in.) ' Weishe/~--:e (hs) C- ^:1 Total Wai-ht (Ibs) Imwer Flange E-MNSA-228-004-1 87.057 0.283 24.64 1 24.64 Seal Retainer -004-2 2.614 0.283 0.74 1 0.74 Compression Collar
-004-3 2.899 0.283 0.82 ;
1 0.82 Usi Flange (Bottom t
-004-29 25.100 0.283 7.10 I 7.10 Upper Flange (Top) -004-5 24.593 0.283 6.% I 6.%
Top Plete -004-6 12.826 0.283 3.63 1 3.63 Hex Bok (Short) -004-25 0.773 0.283 0.22 2 0.44 ; Hex Bok (Iang) -004-24 1.266 0.233 0.36 2 0.72 Tie Rod -004-15 1.381 0.283 0.39 4 1.56 Hex Nut -004-27 0.081 0.283 0.02 12 0.27 1/2" Retainer Washer -004-22 0.093 0.283 0.03 4 0.11 3/8" Retainer Washer -004-21 0.066 0.283 0.02 12 0.22 Total: 47.2I
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Notes:
- 1. Weight of Grafoil Seal is negligible.
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S2-NOME-CALC-0085 Rev.00 Page 36 of 39
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TABLE 2 - Steam Generator MNSA (E-MNSA-228-014-1, Assembly) Weight Name Detail Part No. Volume (cu.in.) Dmeity Ob/cu.in.) Weight /Plece (Ibs) QuantglEWeight Obs) Lower Flange E-MNSA-228-013-2 35.655 0.283 10.09 1 10.09 Seal Retainer -013-3 1.138 0.283 0.32 1 [ 0.32 Compmssion Collar -013-4 2.042 0.283 0.58 1 0.58 Upper Flange (Bottom i
-013-10 25.007 0.283 7.08 1 7.08 Upper Flange (Top) -013-11 24.561 0.283 6.95 1 6.95 i Top Plate -083-6 12.670 0.283 3.59 1 3.59 Hex Bolt (Short) -013-9 0.663 0.283 0.19 2 0.38 Hex Bolt (long) -013-8 0.799 0.283 0.23 2 0.45 Tie Rod -013-1 1.463 0.283 0.41 4 1.66 Hex Nut -004-27 0.081 0.283 0.02 12 0.27 1/2" Retainer Washer -004-22 0.093 0.283 0.03 4 3.I1 3/8" Retainer Washer -004-21 0.066 0.283 0.02 12 0.22 Total: 31.69 Notes:
- 1. Weight of Grafoil Seal is negligible. !
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t i i i I S2-NOME-CALC-0085 Rev.00 Page 37 of 39
TABLE 3 - Hot Lea PDT MNSA (E-MNSA-228-015-1, Assembly) Weight " I I. Name Detail Part No. Volume (ca.in.) Density (b/ce.in.) WeiehuPlece (ts)I Quantity Total W@ (Ibs) Iower Flange E-MNSA-228-013-13 9.477 0.283 2.68 2.68 Seal Retainer 1 [
-004-32 0.628 0.283 0.18 1 0.18 Compression Collar -013-16 1.865 0.283 0.53 1 0.53 !
Upper Flange (Bottom) -013-12 12.925 0.283 3.66 1 3.66 } Upper Flange (Top) -013-14 14.973 0.283 4.24 1 4.24 I Top Plate -013-06 12.670 0.283 3.59- 1 3.59 : Hex Bok -013-21 0.701 0.283 0.20 4 0.79 l Tie Rod -013-18 1.767 0.283 0.50 4 2.00 Hex Nut -004-27 0.081 0.283 0.02 12 0.27 Retiiner Plate -013-20 0.054 0.283 0.02 4 0.06 3/8" Retainer Washer -004-21 0.066 0.283 0.02 8 0.15 t i Total: 18.15 Notes:
- 1. Weight of Grafoil Seal is negligible.
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t L i i } S2-NOME-CALC-0085 Rev.00 Page 38 of 39 !
TABLE 4 - Hot Leg Sampling MNSA (E-MNSA-228-016-1, Assembly) Weight ' i + Name Detail Part No. Vohnne (ca.in.) Density (Ib/ca.in.) W@t/ Place (ts) Quantity Total Weight (Ibs) l lower Flange E-MNSA-228-013-13 9.477 0.283 2.68 I 2.68 Seal Retainer -004-32 0.628 0.283 0. I 8 I 0.I8 Compression Collar -013-17 1.735 0.283 0.49 1 0.49 Upper Flange (Bottom) -013-12 12.925 0.283 3.66 1 3.66 Upper Flange (Top) -013-14 14.973 0.283 4.24 1 4.24 ! Top Plate -013-15 17.430 0.283 4.93 I 4.93 1 Hex Bolt -013-21 0.701 0.283 0.20 4 0.79 Tie Rod -013-19 0.884 0.283 0.25 4 1.00 i Hex Nut -004-27 0.081 0.283 0.02 12 0.27 - Retainer Plate -013-20 0.054 0.283 0.02 4 0.06 3/8" Retainer Washer -004-21 0.066 0.283 0.02 8 0.15 , Total: 18.46 i Notes:
- 1. Weight of Grafoil Seal is negligible.
- 2. Seismic effect of the weight of Clamp (Detail -013-22), Hex El Bolts (Detail -016-15), and 1/2" Retainer Washers (Detail -004-22) is addmssed in the Design Repont, Ref. 3.2 !
I. ! l S2-NOME-CALC-0085 Rev.00 Page 39 of 39 i
A B ED Mpp March 18,1999 NOME-99-C-0123 Mr. Bruce N. Proctor Entergy Operations, Inc. Waterford Steam Electric Station Unit 3 P.O. Box B Killona, LA 70066 l
SUBJECT:
Mechanical Nozzle Seal Assemblies (MNSA) Entergy Contract No. NWC00385 Volumes and Surface Area
Dear Mr. Proctor:
Paragraph 4.4.9 of the Technical and Quality Requirements of the subject contract requests volume and surface areas of the steel parts of the MNSAs. The requested information is as follows: MNSA Surface Area-sa in Volume- cu in RTD Nozzle MNSA 135 42 PDT Nozzle MNSA 174 63 Sampling Nozzle MNS A 286 89 Total 595 194 l If there are any questions please call me at (860) 285-2030. Sincerely, ?
fhh,ffs vlohn T. McG rry '
Project Manager i xc: G. Bundick I l i l ABB Combustion Engineering Nuclear Operations Cornbustion Engineenng Inc PO Box 500 Teiephone (8601688-1911 2000 Day Hit Road Fax (860) 285-9521 Windsor, CT 06095-0500 Teieu 99297 COMBEN WSOR
5 March 18,1999 NOME-99-C-0124 (REVISION 2) March 22,1999 Mr. Bruce N. Proctor Entergy Operations, Inc. Waterford Steam Electric Station Unit 3 P.O. Box B Killona LA 70066
SUBJECT:
Mechanical Nozzle Seal Assemblies Entergy Contract No.NWC00385 Corrosion Issues
Dear Mr. Proctor:
The attached discussion addresses corrosion issues associated with the MNSAs. Included is a section that discusses fatigue crack growth in carbon steel. This was one of the topics ABB was asked to address. If there are any questions please call the author, John Hall at (860)285-4762 or me at (860)285-2030. Sincerely, John T. Mc Project Manage n xc: G. Bundick ABB Combustion Engineering Nuclear Operations Combustion Engineenng. Inc. PO Box 500 Telephone (860) f48-1911 2000 Day Hill Road Fax (860) 285-9521 Windsor. CT 06095-0500 Tetex 99297 COMBEN WSOR
Attachment to NOME 99-C-0124 i Revision 2 o Corrosion Issues Associated with the Inse.n=*ien of Mech ==ical Na=I Seal Assemblies (MNSAs) on 1,.m. Hot Ier Nozzles at Waterford-3 The purpose of this discussion is to summarize the available industry and ABB CENP information j on various corrosion related issues associated with the use of mechanical nozzle seal assemblies ; such as the ones currently being installed at Waterford-3. Backaround Entergy Operations is installing mechanical nozzle seal assemblies (MNSAs) on three Alloy 600 hot leg nozzles (two RTD and one sampling) at Waterford-3. Visual inspection of these nozzles during the current refueling outage indicated that they were leaking, as were two pressurizer , instrumentation nozzles. l Leaking or cracked small diameter Alloy 600 nozzles are not unique to Waterford-3. All Combustion Engineering (CE) supplied PWRs have numerous Alloy 600 nozzles in the pressurizers (instrumentation nozzles and heater sleeves), hot and cold leg piping (RTD and sampling nozzles), reactor vessel heads (CEDM, ICI and vent line nozzles) and steam generators (instrument nozzles). Most of these were procured as hot-worked and annealed bar stock to the requirements of ASME SB-166. They were machined and welded to the ID of the components with partial penetration welds. Reference 1 describes the fabrication sequence and material properties for all Alloy 600 nozzles in CE supplied PWRs. Commencing about 1986, primary water stress corrosion cracking (PWSCC) began to occur in Alloy 600 nozzles in CE supplied units. The first failures were in pressurizer instnimentation
~
nozzles, which was to be expected since PWSCC is temperature dependent and temperatures in the pressurizers are higher (653 F) than elsewhere in the primary system. More recently, cracks have occurred in the hot leg nozzles in several CE supplied units including Palo Verde-2, SONGS-2 and 3, and St Lucie-2. Reference 2 summarizes Alloy 600 nozzle cracking experience through about 1995 and there have been several additional occurrences since, including Waterford-3 during the current outage. Most leaking o. cracked Alloy 600 nozzles have been repaired by replacing them with Alloy 690 (more corrosion resistant) nozzles. The Waterford-3 pressurizer nozzles were replaced in this way. Another repair technique is the mechanical nozzle seal assembly (MNSA) which eliminates leakage by mechanically sealing without removing the nozzles. This technique will be used for the three leaking Waterford-3 hot leg nozzles.
- With the MNSA approach, the defective nodes are left in place. As a result, borated water from the primary system will fill the crevice between the nozzle and carbon steel piping. Carbon and low alloy steel used in PWR primary systems are clad with stainless steel to isolate these materials from the primary coolant and minimize corrosion and corrosion product release to the primary coolant. Nozzle hole ID surfaces are not clad because in the as-built condition they are not exposed to primary coolant. Under cettain conditions, accelerated corrosion of carbon and low i
1
. . - . . - . - - . . . - . . - . ~ .~ - - - - - . . . . . - - . - - - - - - . - . . - -
Attachment to NOME 99-C-0124 Revision 2
^ alloy steels will occur if they are exposed to primary coolant and, even under normal operating conditions, some corrosion will occur. Although this corrosion is expected to be minor, there is frequently concern that it could be significant relative to long term service of the repaired nozzle.
, A second MNSA concern related to propagation of cracks in the Alloy 600 nozzles through the weld metal and into the carbon steel. If this occurs, continued propagation of the cracks through the carbon steel by a stress corrosion mechanism or a fatigue mechanism from cyclic loads during
-service may result.
In addition, questions have been raised about potential corrosion specific to the MNSA. These questions have been in three areas: boric acid corrosion of the pipe OD surface if the MNSA develops a leak; galvanic corrosion of the carbon steel as a result of the presence of a grafoil seal, Alloy 600 nozzle, stainless steel MNSA parts, carbon steel and an aqueous environment; and stress corrosion cracking of the stainless steel fasteners that attach the MNSA to the pipe and apply the loads that seal the leaks. The balance of this letter addresses the various corrosion issues described above. Boric Acid Corrosion ofNozzle Holes 4 If a repaired nozzle has a through-wall crack, the crevice between the nozzle and pipe will fill with aerated borated water when the RCS is re-filled. If the MNSA device itself does not leak, the j crevice environment will be a stagnant solution that cannot be replenished except perhaps at ! shutdown when the RCS is drained Thus, the level of boric acid will not exceed that of the i pnmary coolant at the beginning of a cycle. Although the crevice solution is initially aerated, corrosion of the carbon steel, and to a lesser extent the Alloy 600, will consume the dissolved oxygen, thereby establishing a deaerated condition for most of an operating cycle. During shutdown, the crevice solution may become aerated again. .f The corrosion ofcarbon and low alloy steels in aerated and deaerated borated water at ambient,
- intermediate and elevated temperatures has been studied in laboratory tests and there have been a 4
number ofinstances in operating plants where areas of unciad carbon or low alloy steels have been exposed to the primary coolant for significant numbers ofyears. These data have been used by ABB CENP to develop a corrosion rate that can be used to estimate the amount of corrosion that will occur in crevice regions (Reference 3). The analysis assumed that a plant would operate for 88 percent o?the time, be in a shutdown condition for 10 percent of the time and be in a start-up condition for 2 percent of the time. Corrosion rates for carbon and low alloy steels in borated i water are highest at low temperature aerated conditions and intermediate temperature aerated i conditions (start-up). Because of the characteristics of boric acid and the deaerated condition, corrosion at operating conditions is minimal The laboratory data also indicated that the corrosion will be uniform, significant pitting will not occur, there will not be a galvanic effect and 4 there is not a potential for hydrogen embrittlement of the carbon or low alloy steel. Using the available data, ABB CENP has estimated an overall corrosion rate for these materials in primary coolant of 1.51 mils per year (0.00151 in/yr). j 2 4 v< - .
- - - . , . . -- ,+ a , ,- ..v - -
I Attachment to NOME 99-C-0124 l Revision 2 A specific analysis to determine how much carbon steel could be corroded in the crevice region , has not been conducted for the MNSA appi; cation. Analysis for weld repairs in pressurizers and ' piping for weld repairs indicate that the bore holes could be enlarged by several tenths of an inch , and still meet ASME code requirements. Assuming this to be the case for a MNSA repair as well, the crevice corrosion lifetime of the MNSA should exceed the remaining plant lifetime, i including a 20 year lifetime extension. Welded nozzle repairs have also been used for leaking Alloy 600 nozzles. Some of these result in the crevice region being filled with borated water or steam. The repair with the longest service , time is at ANO-1 where a repaired pressurizer vapor space nozzle has been in sersice since 1991. l After approximately 8 years of service, there has not been any detectable degradation of the low , alloy steel based on periodic UT inspection. l A similar repair was made to a SONGS-3 leaking hot leg nozzle in 1993. After 4 years, the l repaired nozzle was removed for inspection which indicated only minor pitting corrosion (depths l I of pits were 0.005 to 0.008 in.) of the carbon steel on the ID of the nozzle hole. St Lucie -2 has ! had three similar repairs of pressurizer water space nozzles in service since 1994, without l indications of corrosion problems. ) 1 l Other plants have operated for prolonged periods with areas of unclad carbon or low alloy steels exposed to primary coolant. The longest of these was at Yankee Rowe which had sections of the reactor vessel unciad from 1%5 until end oflife without any apparent degradation. Palo Verde-1 has always operated with a small section of a carbon steel pump body without cladding. Since 1994, another CE plant has had a pressurizer heater hole exposed to primary coolant and has operated for approximately 5 years without any indication of problems. In summary, available laboratory corrosion data and service experience indicate that any l corrosion of the carbon steel in the hot leg Alloy 600 nozzle holes will be minor and will not l affect the lifetime of the MNSA repair. l 3
Attachment to NOME 99-C-0124 Revision 2 Stress Corrosion Cracking of Carbon Steel Pipe With the MNSA repair, the Alloy 600 nozzle, which has a through-wall crack, will remain in-place. The residual stresses from the original partial-penetration welds will also remain. CEOG, EPRI and other industry studies (Reference 4) indicate that residual stresses from the welding process are the major driving force for SCC initiation and propagation in Alloy 600 nozzles. Cracks in the nozzle and weld metal may continue to grow because of these residual stresses through the weld and weld butter to the carbon steel pipe. Propagating the cracks through the nozzle and weld metals will relieve most of these residual stresses but not before the cracks reach the carbon steel pipe. Stresses in the pipe may be sufficient to propagate the cracks by a stress corrosion cracking or fatigue mechanism. An extensive body ofliterature data exists on the SCC of carbon and low alloy steels in water environments, including those typical ofPWRs and BWRs (Reference 5). These data indicate that the key factor affecting SCC initiation and growth in these materials is the oxidizing potential (primarily dissolved oxygen content) of the environment. Dissolved oxygen significantly affects the electrochemical potential (corrosion potential) of the materials. In a typical PWR, dissolved oxygen levels in the primary coolant are less than 10 ppb. At temperatures of about 600*F, the corrosion potential of carbon steels in a PWR environment is about -600 mV versus the standard hydrogen electrode, as a result of the hydrogen overpressure in PWR primary systems. Numerous laboratory corrosion tests of carbon and low alloy steels indicate that there is a critical corrosion potential of approximately -200 mV below which crack' initiation and propagation will not occur. This corresponds to a dissolved oxygen level of approximately 100 ppb which is about an order of magnitude higher than in a PWR. At 200 ppb oxygen (with a sufficiently high stress level and sulfur content in the steel), these steels readily , crack. The laboratory data are supported by Seid experience (i.e., there have not been any documented instances of SCC of carbon steels in PWR primary system components but there have been occurrences in BWRs where oxygen levels are on the order of 200 ppb). In summary, the extensive collection oflaboratory data indicates that, at normal operating conditions, propagation of cracks from the Alloy 600 nozzles and weld metals into the carbon steel pipe material by a stress corrosion mechanism will not occur because of the low corrosion potential resulting from the PWR environment. Fatinue Crack Growth into the Carbon Steel A Section XI flaw evaluation has not been conducted for the Waterford-3 hot leg nozzles. However, this case is similar to the situation for SCC in that a crack could propagate through the nozzle and weld metals to the carbon steel and then be propagated by a fatigue mechanism as a result of cyclic loads caused by plant operations. 4 ABB CENP has conducted an approximation type calculation (Reference 6) for another plant as
- part of an engineenng evaluation of the longevity of a half-nozzle repair. This evaluation assumed 4
__ _ _ _ _ _ . _ _ _ _ _ _ - . __ _ _ _ - _ ~ _ _ _ _ _ . _ _ . . . . _ _ _ . _ _ _ _ l 1 Attachment to NOME 99-C 0124 Revision 2 , that part of the Alloy 600 nozzle and the J-groove partial penetration weld between the nozzle and the carbon steel pipe remained in place. Further, the evaluation assumed that a stress corrosion crack had propagated through the nozzle, weld metal and weld butter to the carbon steel. The crack was assumed to have the geometry of the weld prep; i.e., it was a quarter circle crack with a depth of 0.75 inch. The resulting K ifor this crack geometry and size and normal plant conditions (design pressure of 2500 psi was used) was 37.6 KSI int /2 The amount of fatigue crack growth for 500 heat-up and shutdown cycles was then calculated using the relationship provided by Figure A-4300-1 from the 1974 ASME Code. The calculation indicated a total of 0.14 inch of growth of the assumed flaw, which was considered relatively minor. Given l the similarity in operating conditions and pipe geometry, a similar value for crack growth would I be probable for the Waterford-3 piping. I A section XI evaluation of a similar crack in an instrumentation nozzle in the Waterford-3 pressurizer has been performed . Although the crack size and stress conditions are different, the calculated crack growth over the remaining plant lifetime for the pressurizer indicates that only minor crack growth could occur over the next several cycles in a cracked pipe nozzle. As indicated in the discussions of boric acid corrosion of the nozzle holes and stress corrosion cracking of the carbon steel pipe, there are a number of cases where cracked nozzles have been left in service. At ANO-1, the section of a pressurizer nozzle contaimng a crack has been in service since 1991. At San Onofre-3, a similarly cracked nozzle in the hot leg piping has been in service since 1993 and several additional similarly cracked nozzles have been in service for lesser times. At St Lucie-2 and at Calvert Cliffs-1, three repaired pressurizer nozzles and three repaired heater sleeves, with cracks left in-place, have been in service for 1 to 5 years. Considering the service experience from the significant number of nozzles with known cracks currently in-service and the fatigue crack growth calculations for the Waterford-3 pressurizer and the hot leg cracked nozzles at another plant, ABB CENP is confident that fatigue crack growth in the Waterford-3 hot leg nozzles will be minor. Accordingly, ABB CENP recommends that no further evaluations be conducted for these nozzles for the next cycle of operations. If Entergy Operations decides to leave the MNSA devices in-place for additional cycles or elects to repair with a half-nozzle technique, a more rigorous evaluation should be conducted that will demonstrate that fatigue crack growth into the carbon steel pipe over the plant lifetime, including a 20-year life extension, will not be signi6 cant. Boric Acid Corrosion of the Pine OD Surface j If the MNSA also leaks, a mixture of borated water and steam will escape the nozzle and may j impinge on the A-286 bolts, and 304 stainless steel parts. A buildup of boric acid deposits will make such a leak evident during the boric acid walk-down inspections required by GL 88-05. Thus, any significant leakage should exist for only one fuel cycle.
Attachment to NOME 99-C-0124 Revision 2 The tests described in Reference 7 included impingment of a borated water-steam mixture onto corrosion resistant materials similar to A-286. After 2500 hours there was no observable corrosion confirmmg the corrosion resistance of these type materials. However, low alloy steels exposed to borated water under conditions promoting the development of wet boric acid deposits, slurries or concentrated solutions will experience signi6 cant corrosion (References 7 and 8). The available laboratory data did not adequately represent the geometry of a cracked nozzle in a low alloy steel shell which prompted the Combustion Engineering Owners Group (CEOG) to fund a test program to evaluate low alloy steel corrosion resulting from leakage through a stress corrosion crack near the J-groove weld in a nozzle. The test included blocks of SA 533 Grade B steel heated to 600-650 F, water from a high temperature test loop with nominal primary side chemical conditions and leakage from laboratory induced stress corrosion cracks in Alloy 600 tubes welded into the blocks. Post-test examinations indicated high (up to 2.15 inches per year) corrosion rates in localized areas, overall metal loss rates that were relatively low (1.07 cubic ini:h/ year or less), and that the maximum metal loss occurred where the leakage left the annulus with most of the ID surfaces of Ne low alloy steel having no corrosion (Reference 9). The above results were then used to develop andjustify inspection recommendations. The approach was to calculate the maximum amount (volume) of material that could be removed at pressurizer heater or nozzle holes without violating the ASME Code shell reinforcement requirements. Two adjacent holes were assumed to suffer corrosion damage such that the remaining undamaged ligament was at a minimum. The resulting volume of material was divided by the maximum observed corrosion rate to determine the time required to violate the reinforcement requirements. This conservative value was then reduced by an additional 50% to provide additional conservatism. For the most limiting nozzle con 6guration in a CEOG plant, the time required was 7.5 years of operation and for the most limiting heater sleeve configuration, the time was 3.2 years or 1175 days. This type analysis has not been completed for RCS piping nozzles but the pressurizer results should approximate the conditions for the piping application. In smary, boric acid corrosion of the materials ofconstruction for the MNSA and the OD surfas have been addressed by CEOG sponsored and other testing and analysis. With the inspections currently required, a leaking MNSA should be detected before significant corrosion of the piping occurs. Galvanic Corrosion l Galvanic corrosion occurs because of the difference in electrochemical potential (ECP) between the different parts of a cell (in this case, the MNSA materials, Grafoil seal, Alloy 600 nozz!c and carbon steel of the piping) in a conductive solution (electrolyte). The part with the highest ECP (least noble) will corrode preferentially. Specific tests to evaluate galvanic corrosion of the MNSA cell have not been conducted but it is obvious that the carbon steel will be the most l limiting member of this cell and will corrode preferentially. ! 6
l Attachmect to NOME 99-C-0124 Revision 2 The major concern centers on the corrosion occurring in the carbon steel in contact with the I grafoil seal. This particular combination is used in other applications where the low alloy (or carbon steel) is frequently inspected (for example, steam generator secondary side manway and had hole applications) and there is no history of corrosion problems in these applications. The MNSA application is similar and for these reasons significant galvanic corrosion is not expected. Tests in simulated reactor coolant (Reference 9) with low alloy steel coupled to a more noble corrosion resistant alloy (Type 304 stainless steel) did not show a significant galvanic effect. These results provide additional confidence that galvanic corrosion will not be a concern. ) It should be noted that the Grafoil used in the MNSA is Grade GTJ which has been treated with ammonium phosphate to inhibit corrosion. The corrosion protection provided by this inhibitor is comparable to sacrificial inhibitors such as zine or aluminum. Union Carbide ran a seven-month corrosion test with Grafoil Grade GTJ placed against Grade 420 stainless steel, which is vulnerable to corrosion, in deionized water. A second sample using uninhibited Grafoil was also l tested under the same conditions. For the sample with the GTJ Grafoil, there was minimal visible I pitting with a maximum pit depth of.0007 inches. For the sample with the uninhibited Grafoil there was considerable pitting with a maximum pit depth of.0053 inches. While the carbon steel I in piping may have a somewhat higher ECP than the 420 stainless steel, it is apparent that the GTJ
)
Grafoil significantly reduces the galvani: corrosion process. It should also be noted that, in the l absence ofleakage past the Grafoil seal, the annulus will become stagnant and will not allow l replenishment of the boric acid or oxygen. Stress Corrosion Crackinn of the MNSA Fasteners The bolts attaching the MNSA to the piping are SA453 grade 660 (A-286), a precipitation hardening austenitic iron-nickel-chromium alloy. The alloy was developed for high temperature applications requiring good corrosion resistance and high strength. In PWR applications, A-286 is typically used where corrosion resistance similar to that of types 304 and 316 stainless steel is required along with higher strength and fatigue resistance. A-286 has been used for reactor vessel internals bolts, CRDM parts, reactor coolant pump shafts and fasteners and for external bolting applications. In many applications, A-286 has performed satisfactorily but there have been some stress corrosion cracking failures of fasteners immersed in primary coolant. These failures have resulted in concerns about potential SCC failures of all A-286 applications. Stress corrosion cracking requires the simultaneous presence of three elements: j 1 a) a susceptible material condition b) an aggressive environment c) a tensile stress above some threshold level. A-286 has been proven in the laboratory and in field service, to be susceptible to SCC in a PWR environment when highly stressed (References 1.1 and 12). The Reference 11 investigation indicated that bolts that were hot headed had increased susceptibility to SCC. Most of the A-286 field failures have occurred in hot headed ' as. The bolts for the MNSA application were ; 4 7 1
Attachment to NOME 90-C-0124 Revision 2 machined from heat treated bar stock and are expected to be less susceptible than hot headed bolts to SCC. Pnmary cociant is sufEcient to cause SCC in highly stressed A-286. The MNSA bolts are external to the reactor coolant system pressure boundary and not exposed under normal conditions to reactor coolant. Under these conditions, A-286 bolts have been in service for more than 10 years in high stress level application without any riported failures. If the MNSA develops a leak, the bolts may be sprayed with a mixture of borated water and steam. Since the bolts are hot, conditions for wetting and drying will exist and thus the accumulation ofwet deposition or a slurry of boric acid on the bolts may occur. Laboratory tests (Reference 13) have indicated that A-286 is resistant to SCC at 482'F in highly concentrated (40%) boric acid solutions. Since leakage is a condition that will require repair and, that condition will be obvious by the buildup of boric acid deposits, the bolts are not expected to remain in service for more than one fuel cycle (24 months) before the leaking MNSA will be repaired. In summary, testing in PWR environments and concentrated boric acid solutions and service experience indicate that A-286 bolts in the MNSA application will operate indefinitely without SCC failures under normal conditions. If the MNSA device leaks, the bolts may be exposed to borated water or steam under conditions in which deposits or slurries will develop. At stress levels present in the MNSA application, these bolts will operate satisfactorily for more than one fW cycle but the leaking MNSA will be discovered and repaired as part of the GL 88-05 walkdown inspections, limiting the service life for these conditions to a cycle or less. Summary In summary, there are not any potential corrosion problems associated with the application of the mechanical nozzle seal assemblies to hot leg piping at Waterford-3. The available data indicate that corrosion of the nozzle hole will be acceptable over the expected lifetime. Cracks present in the nozzle or weld metal will not propagate by a stress corrosion crraking mechanism 1 into the carbon steel pipe from such cracks. Boric acid corrosion of the pipe OD surface will be l detected by required inspections before it becomes significant. There will not be significant galvanic corrosion associated with the use of a Grafoil seal nor will the other MNSA materials be affected if a leak should develop in a MNSA. Significant plant experience with repairs in which cracked nozzles have been left in-service and crack growth calculations for the Waterford-3 pressurizer nozzles and the hot leg pipes at another plant indicate that fatigue crack growth into the carbon steel pipe should not be a problem. Accordingly, ABB CENP recommends that additional evaluations of the hot leg nozzles not be conducted for the next cycle of operations. If the MNSA devices continue in-service for additional cycles or if a half-nozzle repair is considered, a more rigorous evaluation should be completed to demont,trate acceptability for remaining plant life. i i J t 8
Attachment to NOME 99-C 0124 Revision 2 l-
References:
- 1. "Information Package, Inconel 600 Primary Pressure Boundary Penetrations CEOG Task 634", CE-NPSD-649, January 1991.
- 2. R. Scott Boggs, Mark W. Joseph and John F. Hall, " Experience with Detection and Disposition of PWSCC Flaws in PWR Pressurizer and Reactor Coolant System Loop Alloy 600 Penetrations",1996 ASME Pressure Vessels and Piping Conference, July 21-26,1996.
- 3. Unpublished ABB Combustion Engineering Data,1998.
- 4. J. F. Hall, J. P. Molkenthin ad P. S. Prevey, "XRD Residual Stress Measurements on Alloy 600 Pressurizer Heater Cleeve Mockups", Proceedinas of the Sixth International Symoosium on Environmental Decadation of Materials in Nuclaar Power Systems-Water Reactors. TMS, pp 855-862.
- 5. J. F. Hall and B. W. Woodman, "An Assessment of the Potentir' for Stress Corrosion Cracking of Light Water reactor Pressure Vessels", TR-MCC-201, March 1992.
- 6. Unpublished ABB Combustion Engineering Data,1998.
7 J.F. Hall, " Corrosion of Low Alloy Steel Fastener Materials Exposed to Borated Water", Proceedinns of the Third International Svmoosium on Environmental Dearadation of Enninaarina Materials in Nnclaar Power Systems - Water Raar* ors. NACE,1988, pp 711-722.
- 8. J. F. Hall, R.S. Frisk, A. S. O'Neill, R. S. Pathania, and W. B. Neff, " Boric Acid Corrosion of Carbon and Low Alloy Steels", Proceedinns of the Fourth Internatienal Symoosium on Environmental Degradation of Ennineerina Materials in Nuclear Power Systems-Water Reactors. NACE,1990,pp 9-38 to 9-50. I
- 9. " Corrosion and Corrosion / Erosion Testing of Pressurizer Shell Material Exposed to Borated Water", CE-NPSD-648-P, April 1991.
- 10. " Absorption of Corrosion Hydrogen by A302B Steel at 70' to 500*F",
WCAP-7099, December 1,1%7. I1 G. O. Hayner, " Babcock and Wilcox Experience with Alloy A-286 Reactor Vessel Internal Bolting" Proceedinas: 1986 Workshoo on AdvancaA Hinh Strenath Materials Paner 5. EPRI NP-6363, May 1989. 9
Anachment to NOME 99-C-0124 Revisi:n 2
- 12. D. E. Powell and J. F. Hall," Stress Cerrosion Cracking of A-286 Stainless Steel in High Temperature Water", Imoroved Technoloav for Critical Bolting Applications.MPC-Vol 26.
pp15-22,1986.
- 13. J. Gorman, " Materials Handbook for Nuclear Plant Pressure Boundaay Applications", EPRI TR-199668-S1, December 1997 (draft)
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