ML20235N316
| ML20235N316 | |
| Person / Time | |
|---|---|
| Site: | Calvert Cliffs  |
| Issue date: | 02/28/1987 |
| From: | Goland L, Maison J SOUTHWEST RESEARCH INSTITUTE |
| To: | |
| Shared Package | |
| ML20235N256 | List: |
| References | |
| 17-4772-861, NUDOCS 8710060475 | |
| Download: ML20235N316 (30) | |
Text
,
SOUTHWEST RESEARCH INSTITUTE r Post Office Drawer 28510, 6220 Culebra Road San Antonio, Texas 78284 STRESS ANALYSIS OF THIN PIPE REGION IN NO.12 STEAM GENERATOR MAIN STEAM LINE LEB-01-1005-05L By L. J. Goland, P.E.
J. R. Maison, Ph.D., P.E.
1
)
FINAL REPORT 17-4772-861 l
)
For Baltimore Gas and Electric Charles Center P. O. Box 1475 Baltimore, Maryland 21203 February 1987 j C
Reviewed By: Approved:
a -a"
/
P. K. Nair, Ph.D., P.E. Edward M. Briggs, Director Department of Structural i and Mechanical Systems
!DR DOC 50 17-P PDR j i
l
TABLE OF CONTENTS P.!!jte k List of Figures 11 CHAPTER 1. INTRODUCTION 1 1.1 Ba'ckground Information 1 1.2 Pipe System Design Parameters 1 1.3 Thinned Pipe Section Parameters 3 CHAPTER 2. ANSI /ASME B31.1 CODE REQUIREMENTS 4 2.1 Allowable Stress Level 4 2.2 Minimum Required Wall Thickness 4 -
CHAPTER 3. FINITE ELEMENT ANALYSIS 6 3.1 Finite Element Model 6 3.2 Boundary Conditions and Loads 10 3.3 Stress Levels in Thin Pipe Region 13 CHAPTER 4. DISCUSSION OF RESULTS 20 4.1 Theoretical Hoop Membrane Stresses 20 in Pipe 4.2 Hoop Stress Obtained From Analysis 21
(
4.3 Elbow Under Internal Pressure 21 CHAPTER 5.
SUMMARY
24 REFERENCES 26 r.
1
W C LIST OF FIGURES Page FIGURE 1. Location of Thin Pipe Region 2 FIGURE 2. Side View of Finite Element Model 7 i_
L . FIGURE 3. Isometric. View of Finite' Element Model 8-
~ FIGURE 4. Bottom View of Finite Element Model 9
- FIGURE 5. Cross Section of Thinned Pipe and Transition 11.
Region-FIGURE 6. Loads and Boundary Conditions 12 FIGURE 7. Hoop Stress in Thin Pipe Region-(Outside 14 Surface) -
FIGURE.8. Hoop Stress in Thin Pipe Region (Middle 15 Surface)
~
l FIGURE 9. Hoop Stress in Thin Pipe Region (Botton 16 Surface)
FIGURE 10. Longitudinal Stress in Thin Pipe Region 17 (Outside Surface)
FIGURE 11. Longitudinal Stress in Thin Pipe Region 18 a.
(Middle Surface)
FIGURE 12. Longitudinal Stress in Thin Pipe Region -19 (Bottom Surface)
FIGURE 13. Torus /90 Deg Elbow 22 L
l i
1 11 b
l l
f CHAPTER 1. INTRODUCTION 1.1 . Background Information C During a voluntary inspection of piping components within Unit 1 of.the-Calvert Cliffs Nuclear Power Plant,.a section of thin pipe was discovered'(1). This thin region occurs in the No. 12 Steam Generator .
Main Steam Line (EB-01-1005-05) at the intersection between the- second elbow downstream from the flow restrictor and horizontal pipe run as shown schematically in Figure 1. The reduced wall thickness is thought to be the result of grinding during fit-up and construction rather than from' erosion or corrosion. Wall thickness measurements were made using ultrasonic methods. A review of the readings indicates that the 9 thinnest wall section is less than that allowed by the ANSI /ASME B31.1 Power Piping Code (2), referred to as the Code in the remainder of this report. Since the thin wall area is localized at the intersection with I a 90* elbow section,'a finite element analysis was performed in order to predict the behavior and stress levels within the subject area.
1.2 Pipe System Design Parameters The piping system components in question are made from ASTM A-155 KCF70 Grade 1 material. The design temperature and pressure are 4 580*F' and.1000 psig, respectively. The pipe outside diameter is 34.0 inches.
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3 1.3 Thinned Pipe Section Parameters The thinned pipe section occurs in a horizontal straight pipe adjacent to the intersection with a 90' elbow component. The thin band is approximately 1/2 inch wide and 24 inches long (1). The band starts U
at approximately 172' from Top-Dead-Center (TDC) of the pipe and extends to about 253*. This is indicated in Figure 1. No other indication of the shape of the region is given in any reference presented to Southwest !
Research Institute (SwRI).
The wall thickness readings (3) in the thin area vary and are as low as 0.86 inches. The wall thickness for the pipe excluding the -
thin pipe region ranged from 1.00 in. to 1.12 in. A review of the readings indicate that most thicknesses fall between 1.06 in, and 1.10 in., thus, an average wall thickness of 1.08 in. is. assumed. The wall 2
thickness readings for the elbow range from 1.06 in, to 1.28 in. A review of these readings indicate that most of the thicknesses range j from 1.08 in. to 1.26 in. A conservative assumption of using a wall thickness of 1.08 in, for the elbow section is made. l l
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I CHAPTER 2. ANSI /ASME B31.1 C'0DE REQUIREMENTS 2.1 Allowable Stress Level The pipe material used in the steam line is ASTM A-155 KCF70 Grade 1. The design temperature for the system is 580'F. From Table A-1 of the Code, the smaximum allowable stress in the material due to
-internal pressure is 17,500 psi. This stress level is based on primary i
membrane behavior of the pipe. (
i The thinned pipe section , can be ~ classified as a structural discontinuity. The Code does not specifically address allowable discontinuity stress levels. -However, the ASME Boiler and Pressure Vessel Code (B&PV),Section VIII, . Division 1, Paragraph UG-23 (7) recognizes that high localized discontinuity stresses may exist in a structure. This code limits the combined maximum primary membrane plus bending stress level to 1} times tne maximum allowable stress value.
Applying this criterion to the subject material,.the allowable membrane plus bending stress would be 26,250 psi.
2.2 Minimum Required Wall Thickness Paragraph 104.1.2 of the Code presents the equation which dictates the minimum wall thickness for a straight pipe under internal pressure. The minimum required wall thickness is:
' D min 2(SE y) + A (2.1) i' l
5 where t min
= minimum required wall thickness, in.,
P = internal design pressure, psig, Do = outside diameter of pipe, in.,
SE = maximum allowable stress in the material assuming a joint efficiency of E = 1.0, psi, y = coeff.1,cient from Table 104.1.2(A) of the Code, and A = additional thickness to provide for corrosion and/or erosion, assumed to be zero as discussed in Reference 1.
Using the parameters previously discussed, the minimum required wall thickness is:
( 00 psO W .0 in.)
min -- 2[17,500 psi + (1000 psi) (0.4)]
t t
min
= 0.950 in.
This required wall thickness is greater than the minimum local wall thickness measurements of 0.86 in. recorded during the inspection.
1 i
-_ _- _ - i
. 6 I
g CHAPTER 3. FINITE ELEMENT ANALYSIS -
3.1 Finite Element Model g In order to predict the stress levels in the thin pipe region, which is ' localized and adjacent. to an elbow, a finite element analysis ,
was performed. The finite element program ANSYS (4) was used for this canalysis. The components modelled were the' complete 90' elbow, the thin pipe region,' and a segment of the . horizontal straight pipe. Side and j isometric views of the model are presented in Figures 2 and 3, respec- ,
i tively. Figure 4 is a view from underneath the pipe indicating the -
smaller element mesh used to model the thin pipe region.
The entire 90* elbow was modelled as well as 4 ft of the horizontal pipe. The pipe elbow ' is a long l radius elbow whose bend radius along the centerline is 51.0 in. These dimensions are presented on Figure 2. The outside diameter of the pipe and . elbow is 34.0 in.
The wall thickness of.the regular straight pipe and elbow, as discussed
\
in Section 1.3, was taken to be 1.08 in, minus the expected tolerance (1) of the ultrasonic measurements 0(1 005 in), resulting in a 1.075 in.
thickness. Likewise, the wall thickness of the thin region was assumed to be the minimum recorded thickness of 0.86 in. minus the ultrasonic measurements tolerance, resulting in a 0.855 in, wall thickness. These \
g thicknesses result in conservative stress predictions.
Quadrilateral shell . . elements (type STIF63 elements in ANSYS) were used to model the structure. These elements have membrane and ,
bending stiffnesses and can have either a constant or tapered FIGURE <
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L thickness. The normal pipe, elbow, and thin pipe regions were modelled-p using constant thickness elements. Tapered thickness elements were used to provida the transition between the normal and thin areas. The tapered segments and thin pipe run were assumed to be 0.25 in. in length in the pipe longitudinal direction. This assumption resulted in a
~ 0.75 in, wide thin egion. It is not known from the provided 9
information whether or not the reported width of the thin wall section of 0.5 in. includes some transition between the thin and normal thickness walls. Since the finite element model includes transition elements, the use of a 0.75 in, wide thin region bounds the reported .
width of the thin region. These dimensions and modelling techniques are shown in Figure 5.
t 3.2 Boundary Conditions and Leads Two different types of loadings were imposed on the model in order to determine the primary stresses in the area of concern. These loads were an internal pressure of 1000 psig and forces and moments corresponding to deadweights acting simultaneously on the structure.
From deadweight loadings presented in References 3 and 5, the forces and moments at the ends of the model were determined using statics. The model was assumed fixed at the end of the elbow and the calculated deadweight loads were applied at the end of the straight pipe section.
These boundary conditions and loads are presented in Figure 6.
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13 3.3 Stress Levels in Thin Pipe Region-Of concern are the stress levels within the thin pipe region.
For this presentation, this area is taken to be the act'ual thin pipe whose thickness is 0.855 in, and the surrounding tapered regions to the normal thickness pipe.- The elements which comprise this area in the model were isolated from the rest of the structure and stress contour plots .for the hoop and longitudinal stresses were obtained. These stress contours were obtained for the top (outside of pipe), middle, and bottom (inside of pipe) surfaces of the elements. The middle surface stresses are the local primary membrane stress level and the top and .
bottom : surface stresses indicate the level . cf local primary bending stresses.
The stress contour plots of the hoop stresses in the thin pipe region on the outside, middle, and inside surfaces are presented in Figures 7, 8, and 9, respectively. These plots indicate that the 1
maximum hoop membrane stress, which is the middle surface stress, is 15,874 psi. The maximum bending plus membrane hoop stresses on the outside and inside surfaces are 14,158 psi and 19,615 psi, respectively, not necessarily at the same location on the pipe.
4 The stress contour plots of the longitudinal stresses in the thin pipe region on the outside, middle, and inside surfaces are presented in Figures 10, 11 and 12, respectively. These plots indicate that the maximum longitudinal membrane stress, which is the middle surface stress, is 8,673 psi. Tne maximum bending plus membrane longitudinal stresses on the outside and inside surfaces are 7,421 psi and 11,374 psi, respectively, not necessarily at the same location on the pipe.
G T N O I
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-20 CHAPTER 4. DISCUSSION OF RESULTS 4.1 Theoretical Hoop Membrane Stresses In Pipe The theoretical hoop membrane stress in the pipe is given by the following equation:
I w
H t
- )
where H
= hoop stress, psi P = internal pressure, psig, R = radius to midsurface, in., and t = thickness of pipe, in.
For the normal pipe, the midsurface radius is taken to be the outside radius (17.0 in.) minus one-half of the wall thickness (1.075 in.),
which includes the reduction of 0.005 in, for the ultrasonic measurement I
tolerance. The midsurface radius R is 16.463 in. For an internal pressure of 1000 psig and a wall thickness of 1.075 in., the theoretical i '
hoop membrane stress is 15,314 psi. Using the same procedure, considering a pipe whose wall thickness is 0.855 in. as is the case for the thin pipe region, the theoretical hoop membrane stress is 19,383 -
F
! ps1.
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29 4.2 Hoop Stress Obtained From Analysis As indicated previously, the maximum hoop stress at the middle surface of the thin pipe region is 15,874 psi as shown in Figure 8.
This stress level occurs near an end transition which is a discontinuity region. This figure indicates that away from the end transitions, the hoop stress is 14,400 psi as indicated by stress contour level D. This hoop membrane stress level is lower than either of the theoretical
)
i levels calculated previously for the normal and thin pipes. These
]
results appear to contradict one another inasmuch as it might be expected that the actual hoop stress level in the thin pipe region would -
)
be somewhere in between the two levels calculated previously. However, the reason that the finite element predicted stress levels lower than 1 the theoretical stress levels is due to the fact that the 90* elbow affects the behavior of the structure in the region of the thin pipe ,
i section. This effect is now discussed.
(
4.3 Elbow Under Internal Pressure I The 90' elbow is a segment of a torus vessel as shown in Figure
- 13. The hoop stress in a torus under internal pressure (6) varies from a maximum at the crotch, point A in the figure, to a minimum at the outside of the torus, point B in the figure. At the centerline of the g torus, points C in the figure, the hoop stress is the same as that for a cylinder and given in equation 4.1.
As indicated in Figure 1, the thin pipe region occurs on the outside of the elbow, or torus. It is in this region that the hoop j
22 i
1 90 DEG ELBOW -
p _
R C, .
~ t
- A B
e + e l J k . e i
C l
t FIGURE 13. TORUS /90 DEG ELBOW s
l l
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L _________l______ _ _ _ _ _ _ !
23
, stress is a minimum. The magnitude of the hoop stress in this region,
! point B in Figure 13, is given as:
U Pr 2R + r p HTO 2t R +r l
where ,.
C = hoop stress in torus on outside, psi
- HTO P = internal pressure, psig, r = mean radius of torus cross section, in.,
R = centerline bend radius of torus, in., and -
T = thickness of vessel' wall, in.
,, For the long radius elbow, the centerline bend radius R is 51.0 in. The mean radius r of the vessel is 16.463 in, assuming an outside radius of 17.0 in, and a wall thickness t of 1.075 in. Then, for an f
internal pressure of 1000 psig, the hoop stress on the outside of the torus is 13,446 psi. This magnitude is less than the nominal hoop stress in the cylinder which is 15,314 psi. Since the thin section is adjacent to this region of the torus, it is affected by the torus' behavior resulting in lower hoop stresses than those for an equivalent cylinder. The predicted hoop stress of 14,400 psi in the thin region is g,. between that in the torus, 13,446 psi, and that for the nominal cylin-der, 15,314 psi to 19,383 psi.
24 i
L CHAPTER 5
SUMMARY
A thin pipe section was discovered at the intersection between the second elbow from the flow restrictor and horizontal pipe run within the No. 12 Steam Generator Main Steam Line (EB-01-1005-05) in Unit 1 of the Calvert Cliffs Nuclear Power Plant. The thin region is a circumferential band approximately 24 in. long by 1/2 in, wide. The minimum wall thickness measured in this region was 0.86 in. This is less than the minimum required wall thickness of 0.950 in. in accordance with the ANSI /ASME B31.1 Power Piping Code.
In order to predict the actual primary membrane stress levels within the thin region, a finite element analysis was performed. The components modelled were the 90* elbow with a wall thickness of 1.075 in., the pipe region with the reduced wall thickness of 0.855 in., and a length of horizontal pipe with a wall thickness of 1.075 in. Internal pressure of 1000 psig and dead weight loads were imposed on the model in order to predict the primary membrane stresses. The results of the analysis were obtained in the form of hoop and longitudinal stress contour plots at the outside, middle, and inside surfaces of the thin pipe area. The middle surface stress components correspond to the local primary membrane stresses while the outside and inside surface stresses correspond to the local primary membrane plus bending stresses.
The results of the finite element analysis indicate that the maximum primary hoop membrane stress is 15,874 psi. This stress level is affected by the thin region's close proximity to the 90* elbow, or
25 torus vessel, which helps reduce the hoop stress level. This preJicted hoop stress level of 15,874 psi is below the Code allowable stress level of 17,500 psi. The predicted maximum membrane plus bending stress level is 19,615 psi. This stress level is below the ASME B&PV Code allowable membrane plus bending stress level of 26,250 psi.
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' REFERENCES
- 1. Thornton, A. R. (Baltimore Gas and Electric), Letter to Mr. Ashok C.
Thadani (U.S. Nuclear. Regulatory Commission), dated December 16,.
1986.
Subject:
Calvert Cliffs Nuclear Power Plant, Unit.No. 1, Docket No. 50-317, Request for Approval of Main Steam Piping i
Evaluation . per ASME Section XI, IWB-3600 and Relief from 1 IWB-3610(b).- (Letter telecopied from Mr. Bernie Rudell, BG&E, to Dr. Prasad K. Nair, SwRI.)
- 2. American Society of Mechanical Engineers. Power Piping, ANSI /ASME-B31.1 - - 1980 Edition. New York, American Society of Mechanical Engineers, 1980.
~3. Telecopied information from Mr. Bernie Rudell, Baltimore Gas and Electric, to Dr. Prasad K. Nair, Southwest Research Institute, dated December 12, 1986.
Subject:
Ultrasonic wall thickness measurements for ID No. EB-01-1005-05.
l
- 4. DeSalvo, G. J. and J. A. Swanson. ANSYS Engineering Analysis System
-User's Manual, Revision 4.1. Houston, Pennsylvania: Swanson Analysis Systems, Inc., 1983 Edition.
- 5. Telecopied information from Mr. W. Holston, Baltimore Gas and electric, to Mr. L. J. Goland, Southwest Research Institute, dated December 15, 1986.
Subject:
Forces and' moments on data points of elbow and pipe sections.
- 6. Harvey, ' John F. Theory and Design of Modern Pressure Vessels, 2nd Edition. New York: Van Nostrand Reinhold Company, 1974.
- 7. American Society of Mechanical Engineers. ASME Boiler and Pressure Vessel Code,Section VIII. Division 1, 1983 Edition. New York, American Society of Mechanical Engineers, 1983