NL-08-0533, Transmittal of Analytical Evaluation of Flaws, Calculation No. 0800236.00-301, Rev. 2
| ML081280092 | |
| Person / Time | |
|---|---|
| Site: | Hatch  |
| Issue date: | 05/02/2008 |
| From: | David Jones Southern Nuclear Operating Co |
| To: | Document Control Desk, Office of Nuclear Reactor Regulation |
| References | |
| NL-08-0533 | |
| Download: ML081280092 (41) | |
Text
David H.Jones Southern N!uclear Vice President Operating Company, Inc.
Engineering 40 Inverness Center Parkway Birmingham, Alabama 35242 Tel 205.992.5984 Fax 205.992.0341 May 2, 2008 Energy to Serve Your World' Docket No.: 50-321 NL-08-0533 U. S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, D. C. 20555-0001 Edwin I. Hatch Nuclear Plant - Unit 1 Submittal of Flaw Evaluations to Regulatory Authority Ladies and Gentlemen:
During the recently completed Plant Hatch 1R23 outage, two indications were identified during ultrasonic examination of Residual Heat Removal (RHR) heat exchanger weld 1El 1-2HX-A-1. The examination of the first indication indicated a flaw with a depth of 0.12 inches and a length of 0.75 inches. The examination of the second indication indicated a flaw with a depth of 0.18 inches and a length of 0.80 inches. The indications were found unacceptable per the rules of Table IWC-3410-1 and IWC-3511 of Section XI. ASME Section X1 Code references are to the 2001 Edition with Addenda through 2003.
As allowed by IWC-3122.3, an analytical evaluation of the flaws was performed per the requirements of IWC-3610 and IWB-3610 by Structural Integrity Associates (SIA) for Southern Nuclear Operating Company. The evaluation demonstrated that the two flaws are acceptable for the remaining 27 years of service life. Per IWC-3125, evaluations per IWC-3122.3 shall be submitted to the regulatory authority having jurisdiction at the site. Therefore, a copy of the SIA evaluation is being forwarded to the Nuclear Regulatory Commission.
As required by IWC-2420, if a component with flaws is accepted for continued service in accordance with IWC-3122.3 or IWC-3132.3, the areas containing the flaws or relevant conditions will be reexamined during the next inspection period listed in the schedule of the inspection programs of IWC-2400. If the reexamination required by IWC-2420(b) reveals that the flaws or relevant conditions remain essentially unchanged for the next inspection period, the component examination schedule may revert to the original schedule of successive inspections.
U. S. Nuclear Regulatory Commission NL-08-0533 Page 2 This letter contains no NRC commitments. If you have any questions, please advise.
'~on s/ v Vice Presid nt - Engineering DHJ/PAH/daj
Enclosure:
Analytical Evaluation of Flaws cc: Southern Nuclear Operating Company Mr. J. T. Gasser, Executive Vice President Mr. D. R. Madison, Vice President - Hatch RTYPE: CHA02.004 U. S. Nuclear Regulatory Commission Mr. V. M. McCree, Acting Regional Administrator Mr. R. E. Martin, NRR Project Manager - Hatch Mr. J. A. Hickey, Senior Resident Inspector - Hatch
Edwin 1. Hatch Nuclear Plant - Unit 1 Submittal of Flaw Evaluations to Regulatory Authority Enclosure Analytical Evaluation of Flaws
StructuralIntegrityAssociates, Inc. File No.: 0800236.00-301 CALCULATION PACKAGE Project No.: 0800236.00 PROJECT NAME:
Flaw Evaluation of RHR Heat Exchanger Weld IE I1-2HX-A- 1 CONTRACT NO.:
Blanket P.O. B9246 Release Order 2008-5 CLIENT: PLANT:
Southern Nuclear Operating Co. Hatch Unit I CALCULATION TITLE:
Flaw Evaluation of RHR Heat Exchanger Weld 1El 1-2HX-A-1.
Document Affected Project Manager Preparer(s) &
DoRuments Afted Revision Description Approval Checker(s)
Revision Pages Signature & Date Signatures & Date 0 1-36 Initial Issue Marcos L. Herrera Jagannath Hiremagalur Al 2/21/08 2/21/08 BI Computer Files Stan S. Tang 2/21/08 Chris Lohse(chk) 2/21/08 G.A. Miessi(chk) 2/21/08 1, 4, 8 Incorporate Client Marcos L. Herrera Jagannath Hiremagalur comments 4/10/08 4/10/08 Stan S. Tang 4/10/08 2 1-36, A-1, B-1 Removed Proprietary Footer Marcos L. Herrera Jagannath Hiremagalur 4/16/08 4/1 08 Ton J. Giannuzzi 4/16/08 Page 1 of 36 F0306-O1RO
Table of Contents
1.0 INTRODUCTION
........................................ :................................................ 4 2.0 TECHNICAL APPROACH.............................................................................. 4 3.0 FLAW CHARACTERIZATION........................................................................ 4 4.0 ASSUMPTIONS / DESIGN INPUTS .................................................................. 4 5.0 CALCULATIONS ........................................................................................ 5 6.0 RESULTS OF ANALYSIS.............................................................................. 8
7.0 CONCLUSION
S ........................................................................................ 10
8.0 REFERENCES
.......................................................................................... 10 APPENDIX A ANSYS INPUT AND OUTPUT FILES ................................................ A-i APPENDIX B CRACK GROWTH RELATED COMPUTER INPUT AND OUTPUT FILES .... B-i File No.: 0800236.00-30i Page 2 of 36 Revision: 2 F0306-OI1RO
List of Tables Table 1: External Piping Loads at the Nozzle ........................................................... 11..I Table 2: Scale Factor for Unit Load Case................................................................11..I Table 3: Curve Fit Results of Through Wall Stress Profiles.............................................. 11 List of Figures Figure 1. Residual Heat Removal Heat Exchanger [9] .................................................... 12 Figure 2. Finite Element Model of Inlet Nozzle N-3 of Residual Heat Removal Heat Exchanger .... 13 Figure 3. Boundary Conditions and Loads for Unit Internal Pressure Analysis........................ 14 Figure 4. Boundary Conditions and Loads for Unit Axial Force Analysis.............................. 15 Figure 5. Boundary Conditions and Loads for In-Plane Moment Analysis............................. 16 Figure 6. Application of Heat Transfer Coefficients for the Thermal Transient........................ 17 Figure 7. Application of Bulk Temperature for the Thermal Transient ................................. 18 Figure 8. Application of Structural Boundary Conditions for Thermal Stress Analysis............... 19 Figure 9. Temperature variation of Node 2226 to demonstrate thermal shockup from 70'F to 350OF............................................................................................... 20 Figure 10. Stress Intensity Contour Plot for Unit Internal Pressure Analysis........................... 21 Figure 11. Stress Intensity Contour Plot for Unit Axial Force Analysis ................................ 22 Figure 12. Stress Intensity Contour Plot for Unit Moment Load (In-Plane Moment) Analysis .....23 Figure 13. Stress Intensity Contour Plot for Thermal Shockup Transient (Time = 15.4 seconds) ... 24 Figure 14. Heat Exchanger Weld lEI 1-2HX-A-l, Indication at 12" CCW/Downstreamn............. 25 Figure 15. Heat Exchanger Weld lE Il-2HX-A- 1, Indication at 20 " CCW/Downstream............. 26 Figure 16. Crack Model....................................................................................... 27 Figure 17: Fatigue Crack Growth Curves for Carbon and Low Alloy Ferritic Steels Exposed to Water Environments.............................................................................. 28 Figure 18: Curve fit of Through Wall Stress Profile for Unit Pressure Load Case..................... 29 Figure 19: Curve fit of Through Wall Stress Profile for Unit Axial Load Case........................ 30 Figure 20: Curve fit of Through Wall Stress Profile for Unit Moment.................................. 31 Figure 21: Curve fit of Through Wall Stress Profile for Thermal Transients........................... 32 Figure 22: Curve fit of Through Wall Stress Profile for Residual Stress................................ 33 Figure 23: Applied Stress Intensity Factors................................................................. 34 Figure 24: Allowable Crack Size Results................................................................... 35 Figure 25: Fatigue Crack Growth Results................................................................... 36 File No.: 0800236.00-301 Page 3 of 36 Revision: 2 F0306-OI1RO
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1.0 INTRODUCTION
Two indications were identified during the 2008 in service inspection of the RHR heat exchanger weld 1El 1-2HX-A-1 [1], Figures 14 and 15. These two indications are at the weld between the nozzle and the heat exchanger shell. The first indication, Figure 14 has a depth of 0.12" with a length of 0.75", located 12"0 CCW/downstream. The second indication, Figure 15 has a depth of 0.18" with a length of 0.80", located 20.0" CCW/downstream. The indications were found unacceptable per the rules of ASME Boiler and Pressure Vessel (B&PV) Code,Section XI, IWC-3511, [2].
In this calculation, the indications are evaluated per the guidelines of ASME B&PV Code,Section XI, IWC-3600, which states that the criteria of IWB-3600 may be used. The acceptance criteria of IWB-3600 is based on the applied stress intensity factors (K) and the allowable stress intensity factor based on the fracture toughness, K1c, of the material. Also, a fatigue crack growth is performed to ensure that the indications would not propagate beyond the allowable crack size.
2.0 TECHNICAL APPROACH A finite element model is used to determine the through-wall stress profiles at the weld subjected to the loadings of internal pressure, thermal transient, and external piping loads. These evaluations used design loading inputs provided by Southern Nuclear and are discussed in Section 5.
The fracture mechanics and fatigue crack growth evaluation was performed based on ASME Code,Section XI, Appendix A [2] methodology. The flaw acceptance criteria based on applied stress intensity factor is evaluated based on Paragraph IWB-3612 of Reference 2.
3.0 FLAW CHARACTERIZATION The two indications are at located near the root of the shell-to-nozzle weld, in the base metal on the shell side. The first indication is an inside surface linear indication with a depth of 0.12", a length of 0.75 inches, with a crack aspect ratio a/l = 0.16, located 12" CCW/downstream. The second indication is an inside surface linear indication with a depth of 0.18", a length of 0.80 inches, with a crack aspect ratio a/l = 0.225, located 20" CCW/downstream.
These indications are found to be unacceptable based on the ASME B&PV Code,Section XI, 2001 Edition through 2003 Addenda acceptance criteria [1].
4.0 ASSUMPTIONS / DESIGN INPUTS The following design inputs are used:
(1) Inlet nozzle material: SA-541 Class 1 [8]
(2) Heat exchanger shell material: SA-516, Grade 70 [8]
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(3) Shell thickness, at flaw location: 0.844 inches [8]
(4) Operating pressure: 138 psig [8]
(5) Operating temperature: -350'F [8]
(6) External Piping Loads at Nozzle, Table 1 [4]
The following assumptions are used in the evaluation:
(1) A through-wall bending residual stress is assumed at the weld.
5.0 CALCULATIONS 5.1 Finite Element Models The finite element model is developed using the ANSYS finite element analysis software [7].
The finite element model is a 3-dimensional half (3-D) model (as shown in Figure 2), which is constructed using the 8-node brick element, SOLID185. These elements are converted to thermal solid (SOLID70) elements for the thermal transient analysis to determine the resulting temperature distribution time history. The structural solid elements are then used to calculate the stresses due to the thermal loads, as well as the mechanical loading stresses. Due to the symmetric layout of the nozzle, a 1800 (half-symmetry) section of the nozzle is modeled.
The dimensions used to generate the model are shown in Figure 1 and other dimensions that were unavailable were assumed based on the nozzle dimensions.
5.2 Loading Conditions Three separate mechanical loading analyses (unit pressure, unit axial force, unit in-plane moment),
and a thermal transient stress analysis are performed, as described in the following sections.
5.2.1 Unit InternalPressure A unit internal pressure of 1,000 psi is applied to the interior surfaces of the model. The results from this analysis are then scaled to the operating pressure corresponding to 138 psig [8] for the crack growth analysis. An end-cap load is applied to the free end of the attached inlet nozzle piping in the form of tensile axial pressure, the value is calculated below. Symmetry boundary conditions are applied at the circumferential ends of the heat exchanger shell. The free end of the inlet nozzle piping is coupled in the axial direction (Y-direction). The boundary conditions for the unit pressure analysis are shown in Figure 3.
P rinside 2 1000"9.462 (routside - rinside 10.02 _9.462):8516.19 psi where, File No.: 0800236.00-301 Page 5 of 36 Revision: 2 F0306-O1RO
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Pend-cap = End cap pressure on inlet nozzle piping end (psi)
P = Internal pressure (psi) rinside = Inside radius of inlet nozzle piping (in) routside = Outside radius of inlet nozzle piping (in) 5.2.2 Unit Axial Force An axial force of 500 lbs is applied to the half model (thereby generating 1000 lbs of equivalent loading for the full structure) at the free end of the inlet nozzle piping to simulate axial loads acting on the inlet nozzle. The results from this analysis are then scaled to the actual piping loads seen in Heat Exchanger A. All nodes at the free end of the inlet nozzle piping are coupled in the axial direction (Y-direction). Symmetry boundary conditions are applied to the planes of symmetry and at the circumferential free end of the heat exchanger shell (see Figure 4).
5.2.3 Unit Moment Load Due to the finite element model being axi-symmetric in all planes, it is not necessary to run two separate load cases for the in-plane and out-of-plane moments. The appropriate scaling factor based upon operating piping loads acting on the Heat Exchanger can be computed and incorporated in the mapped stresses obtained from the in-plane moment load case analysis.
An in-plane, unit moment of 1,000 in-lb is applied about the positive global Cartesian (coordinate system 0) Z-axis (for a half model, a 500 in-lb moment is actually applied). The 1,000 in-lbs. is an arbitrary value and moments from other loadings are scaled using this value. The moment is applied to the free end of the attached piping by making use of a pilot node to transfer the loading. The TARGE170 target element type from the ANSYS element library is used to create the pilot node.
The CONTA174 contact element type is used to create a contact surface at the end of the pipe. The pilot node and surface are bonded together, so that the moment applied to the pilot node is transferred to the end of the pipe. The applied moment and boundary conditions are shown in Figure 5.
5.2.4 Thermal Transient Analysis An instantaneous thermal shockup transient from 70'F to 350'F [8] is applied to the internal surface of the inlet nozzle piping and the heat exchanger shell. A heat transfer coefficient of 1000 Btulhr-ft2 -
'F is assumed and applied to the interior surfaces throughout the transient. All exterior surfaces were assumed to be perfectly insulated. Typical thermal boundary conditions are shown in Figures 6 and
- 7. The temperature variation of Node 2226 on the Internal Diameter surface of the nozzle just below the fillet weld is also shown in Figure 9.
The thermal transient is followed by a stress analysis to determine the resulting stresses. The reference temperature for stress-free condition is assumed to be 70'F. Symmetry boundary conditions are applied to the planes of symmetry and at the circumferential free end of the heat exchanger shell. The free end of the inlet nozzle piping is coupled in the axial direction (Y-direction). The boundary conditions for the thermal stress analysis are shown in Figure 8.
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5.3 Fracture Mechanics Evaluation 5.3.1 Crack Model The indications were modeled using an elliptical surface crack in a finite width plate as shown in Figure 16 [5]. Per Article A-3 100 of Reference 2, it can be used for internal and external surface flaws in cylinders for all values of R/t (the ratio of mean radius to thickness). In this evaluation, the model is assumed to be applicable to the spherical shell also. A crack aspect ratio of a/l = 0.2 is selected. It is a reasonable representation of the two indications based on the flaw characterization in Section 3.0.
The stress normal to the plane of the flaw at the flaw location is represented by a polynomial fit through the wall thickness by the following:
2 3 G = Co + CJX +C 2x -C3x (1) where a = stress in psi x = distance from inside surface (in)
CO, C 1 , C 2, C 3 = polynomial coefficients 5.3.2 MaterialFracture Toughness The material fracture toughness for the heat exchanger shell material, SA-516, Grade 70 was estimated based on Article C-8320 of Reference 2. For seamless or wrought ferritic steel pipe and pipe fittings that have a specified minimum yield strength not greater than 40 ksi and welds made in as-welded or postweld heat treated conditions and for temperature > upper-shelf temperature, the Jic is given as 600 in-lb/in 2 .
From Reference 6, the specified minimum yield strength for SA-516 Grade 70 is 38 ksi. Therefore, the material fracture toughness Kjc of SA-516 Grade 70 is estimated as:
Jjc = KIc 2/E (2) where E = Young's modulus With E = 28.Ox106 psi at 3507F and Jjc = 600 in-lb/in 2, the Kjc is calculated to be 127.28 ksi'lin. Per IWB-3612 [2], for normal conditions, a safety factor of ý110 is used to obtain the allowable fracture toughness.
5.3.3 Fatigue Crack Growth Calculation The end of life flaw size due to fatigue crack growth was calculated using the fatigue crack growth curves for carbon and low alloy ferritic steels exposed to water environments, Figure A-4300-2 of Reference 2, reproduced in Figure 17.
5.3.4 Acceptance Criteria File No.: 0800236.00-301 Page 7 of 36 Revision: 2 F0306-01 RO
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Based on applied stress intensity factor per IWB-3612, a flaw exceeding the limits of IWB-3500 is acceptable if the applied stress intensity factor and the flaw size af satisfy the following criteria:
(a) For normal/upset conditions:
Ki < Kla / 4/10 (3) where K, = maximum applied stress intensity for normal and upset condition for the flaw size af KIa = available fracture toughness based on crack arrest for the corresponding crack tip temperature Therefore, the allowable fracture toughness for SA-516 Grade 70 is 127.28 ksiin/4*0 = 40.25 ksix/in. For calculating the allowable crack size, an allowable fracture toughness of 40 ksi',in was used for normal operating condition.
Per Reference 10, the fracture toughness based on crack arrest is the same as the fracture toughness based on crack initiation. The use of crack arrest toughness (Kia) for determining the condition for fracture initiation (K1 c) is conservative since the KIa values are obtained for all static, dynamic and arrest test data. Hence, the 2004 edition of the ASME code incorporated the use of K1c instead of Kia as outlined in the Reference 10 document. That approach was already adopted in Appendix C-7000,Section XI, 2001 edition where K1, calculated from J1, is used for flaw evaluation.
The stress intensity factor and fatigue crack growth calculation were performed using pc-CRACKTM
[5].
6.0 RESULTS OF ANALYSIS 6.1 Stress Analysis Results The hoop and axial stresses are mapped onto a path from Node 4361 to 4286 through the shell thickness and just above the fillet weld (fusion point of Inlet Nozzle with Heat Exchanger Shell).
The mapped stresses are to support crack growth calculations for the peak time step in the analyses (unit axial, unit pressure and thermal transient loads) and output to files which are included with the project computer files (see Appendix A for file listings). Specifically for the unit in-plane moment, the stresses are mapped onto a path from Node 84 to 19 through the shell thickness.
The through-wall mapped stress distributions were curve-fit to a third order polynomial and the coefficients (see Table 3) of the individual powers of the polynomial were further used in the crack growth analysis.
Representative total stress intensity contour plots are provided in Figures 10 through 12 for the mechanical loading analyses, and Figure 13 for the thermal transient.
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6.2 Fracture Mechanics Evaluation Results 6.2.1 Through-wall Applied Stresses The through-wall stress profiles were extracted from the finite element model for the path close to the indication location for the different loading cases and shown in Figures 18 to 21. Some of the through-wall stress profiles are from unit load (i.e. pressure, axial load, bending moment). These would be scaled according to the applied loads for the fracture mechanics evaluation. For the thermal transient, the through-wall stresses are extracted at two different times: the time of maximum tensile stresses at the heat exchanger ID and OD.
In addition, a through-wall bending residual stress was assumed using the code yield strength of 38 ksi, shown in Figure 22.
6.2.2 Applied Stress Intensity Factor Using the elliptical crack model with an aspect ratio a/l = 0.2, the applied stress intensity factors due to each unit load case are presented in Figure 23. The applied K is compressive for all load cases, except pressure and weld residual stress.
6.2.3 Allowable Flaw Size The allowable flaw size was calculated based on the total applied stress intensity factors from each load case. The scale factor used for each unit load case is presented in Table 2. For the axial load case, a positive scale factor is used for conservatism even though the applied axial load is compressive. For moment, a square root of sum of the square of the two bending moments is used since the model is symmetric and one unit moment loading case was analyzed. The thermal stresses corresponding to the time of maximum tensile stress at the shell ID in order to maximize the total stress intensity factor.
The total applied stress intensity factors along with the applied stress intensity factor for each unit load case and the allowable Kjc of 40 ksbiin are presented in Figure 24. It is shown that the allowable flaw size is 0.52 inch.
6.2.4 Fatigue Crack Growth Results For fatigue crack growth calculation, the Kmaxý is defined as the combination of the applied load cases as shown in Table 2. The Kmjn is only due to the residual stress. The thermal stresses corresponding to the time of maximum tensile stress at the shell OD were used as they yield the largest AK. The fatigue crack growth was evaluated for 100 operating cycles with an initial crack size of 0. 18 inches, the deeper of the two indications.
The fatigue crack growth result is presented in Figure 25. For one operating cycle per year, the maximum crack depth is 0. 1803 for 20 years and 0. 1805 for 40 years of remaining operation.
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7.0 CONCLUSION
S Results of the analysis demonstrate that crack growth for the remaining 27 years is minimal and that the flaw is acceptable since the calculated allowable flaw is much larger than the final flaw size.
8.0 REFERENCES
- 1. Southern Nuclear Operating Company Indication Notification No. 108H 11007, 2/16/2008, SI File 0800236.00-204.
- 2. ASME Boiler and Pressure Vessel Code,Section XI, 2001 Edition.
- 3. Not used.
- 4. Design Calculation DCR 82-75, "Hatch 1 Torus Attached Piping", Page 69, August 1982.
- 5. pc-CRACK for Windows, Version 3.1-98348, Structural Integrity Associates, 1998.
- 6. ASME Boiler and Pressure Vessel Code,Section II, Part D 2001 Edition.
- 7. ANSYS/Mechanical, Release 8.1 (w/Service Pack 1), ANSYS Inc., June 2004.
- 8. Southern Nuclear Design Input File, "Hatch RHR Heat Exchanger Nozzle Design Inputs", SI File number 0800236 - 205.
- 10. PVP2005-71718, Proceedings of PVP2005, 2005 ASME Pressure Vessels and Piping Division Conference, "Technical Basis for Revised Flaw Acceptance Criteria under IWB-3610 of ASME Section XI," July 17-21, 2005, Denver, Colorado USA.
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Table 1: External Piping Loads at the Nozzle Load Heat Exchanger A Heat Exchanger B Fx(lb) 4031 2864 Fy(lb) -1532 -686 Fz(lb) 1745 -3726 Mx(ft-lb) 12211 14930 My(ft-lb) 5428 4335 Mz(ft-lb) -18409 14296 Note: y-axis is in the axial direction of the nozzle Table 2: Scale Factor for Unit Load Case Unit Load (for half model) Scale Factor for HX A Pressure (psi) 1000 0.138 Fy(lb) 500 1.532 Mx(in-lb) 500 147 Mz(in-lb) 500 221 Resultant Moment -- 265 Thermal Temperature step change 1 to 350 'F at inside surface Residual Through wall bending 1 with 38 ksi tension at inside surface Table 3: Curve Fit Results of Through Wall Stress Profiles Load Case Co C, C2 C3 Unit Pressure 24955 -1577.29 25167.3 -18247.5 Unit Axial Load 4.5834 0.3400 97.5026 -68.4314 Unit Moment 0.634335 0.05463 18.2977 -12.9226 Thermal 0.454897 -0.004639 5.61673 -3.9728 Thermal2 -30793.4 120851 -130881 50142.5 Residual 38000 -90476 -- --
Note: Thermal and Thermal2 correspond to time of maximum tensile stresses at the heat exchanger ID and OD, respectively.
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1 MAT NUM HTCH =LT NCZLE TO RHR HX SHELL Figure 2. Finite Element Model of Inlet Nozzle N-3 of Residual Heat Removal Heat Exchanger File No.: 0800236.00-301 Page 13 of 36 Revision: 2 F0306-O1RO
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1 MAT NUM U
CP PRES-NM L
-8516 - -6401 - -4287 -2172 1 -57.355
-7459 -5344 -3229 -1115 1000 HTCH TINLET 1ICZZIE 'TO RHR HX SHELL Figure 3. Boundary Conditions and Loads for Unit Internal Pressure Analysis File No.: 0800236.00-301 Page 14 of 36 Revision: 2 F0306-OI RO
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1 MAT NUM U
CIP PRES-CM
-30.291 4-HTCH =NLT NCO= TO RHR HX SELL Figure 4. Boundary Conditions and Loads for Unit Axial Force Analysis File No.: 0800236.00-301 Page 15 of 36 Revision: 2 F0306-O1RO
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1 ELEMETS MAT NUM U
M HTCH INLET NCZZLE TO RHR HK SHELL Figure 5. Boundary Conditions and Loads for In-Plane Moment Analysis File No.: 0800236.00-301 Page 16 of 36 Revision: 2 F0306-O1 RO
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1 MAT NUM CCNV-HCXE
. 001929 HTCH INLET NMZLE TO RHR lX SHELL Figure 6. Application of Heat Transfer Coefficients for the Thermal Transient File No.: 0800236.00-301 Page 17 of 36 Revision: 2 F0306-O1RO
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- 1-MAT NUM CNqV-TBUL 350 HTCH INLET NOKZZLE TO RHR HX SHELL Figure 7. Application of Bulk Temperature for the Thermal Transient File No.: 0800236.00-301 Page 18 of 36 Revision: 2 F0306-O1RO
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1 MAT NUM U
CP ETCH INLET NOZZLE TO RHR HX SHELL Figure 8. Application of Structural Boundary Conditions for Thermal Stress Analysis File No.: 0800236.00-301 Page 19 of 36 Revision: 2 F0306-O1RO
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1 PCST26 TE*P 2 440 400 360 j-320 280 '
VAUJ 240 .
200 1 160 120 '
80 40 , ,,
0 1600 3200 4800 6400 8000 800 2400 4000 5600 7200 TIME HTCH INLET ItZZLE TO RHR HX SHBEL Figure 9. Temperature variation of Node 2226 to demonstrate thermal shockup from 70°F to 350OF File No.: 0800236.00-301 Page 20 of 36 Revision: 2 F0306-O1RO
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1 IDIAL SCOUTIaCT STEP=I SUB =1 TIM-E*1 SINT (AW)
E1MX =12.596 SM4 =2716 SMX =59759 1
2716 15392 28068 40744 53421 9054 21730 34406 47083 59759 HTCH INLET 1NXCEI TO RHR HX SBEL Figure 10. Stress Intensity Contour Plot for Unit Internal Pressure Analysis File No.: 0800236.00-301 Page 21 of 36 Revision: 2 F0306-O1RO
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1 NCKJAL SCEDTIMS STEP-I SUB =1 TIM,=I SINT (AVG)
EMX -.051798 SMl -. 524646 SMX =72.69 SMXB=99.176
.524646 16.561 32.598 48.635 64.671 8.543 24.58 40.616 56.653 72.69 HTCH INLET NUZZLE TO RHR HX SHELL Figure 11. Stress Intensity Contour Plot for Unit Axial Force Analysis File No.: 0800236.00-301 Page 22 of 36 Revision: 2 F0306-01RO
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1 NOKDAL SOLUTION STEP=1 SUB =1 TTME=1 SINT (AVG)
EX =. 179E-04 SMN =.143691 SMX =11.832
.143691 2.741 5.339 7.936 10.533 1.442 4.04 6.637 9.235 11.832 HTCH INIET NOZZLE TO RHR HX SHELL Figure 12. Stress Intensity Contour Plot for Unit Moment Load (In-Plane Moment) Analysis File No.: 0800236.00-301 Page 23 of 36 Revision: 2 F0306-O1RO
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1 1NCDAL SCLUTICM STEP=26 SUB =1 TIIMEI15.4 SINT (AW) 11X =. 03486 SMI =906.427 SMX =29676 SMXB=45466 906.427 7300 13693 20086 26480 4103 10496 16890 23283 29676 HTCH IMLT COZLE TO RHR HX SHELL Figure 13. Stress Intensity Contour Plot for Thermal Shockup Transient (Time = 15.4 seconds)
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Outage No.: H1R23 Report No.: S08HIU080 Summary No.: HI IEII-2HX-A,.
Page No.: 5 of 6 Site: HNP Unit 1 Drawing No.: B-32 Component ID: 1E11.2HX-A-l Oescription: INLET NOZZLE TO RHR HX SHELL Procedure: NMP-ES-024-506 _ Rev.: 1.0 Prepared By: JEFF L DEVERS Level. III Signature: Date: 2/1612008 FLAW CHARACTERIZATION & ACCEPTANCE Code of
Reference:
ASME Section Xl; 2001 edition thru 203 Addenda Flaw Number: 1 Examination Category- C-B 'P*rssure Retalnlng Nozzle Welds In Vessels' Flaw Location: 11.0" CCW I Downstream Code Item Number. C2.21 Flaw Onentation: Circumferential Code Figure Number: IWC-2500.4 (b) Flaw Classiflcation: Surface I Planar Examination Method: Volumetric Flaw Height: 0.12" Acceptance Starndard: IWC-3S1 I Flaw Length: 0.75" Acceptance Table: IWC-3511-1 Thickness @Flaw: 0.844" Flaw 'alr: 14,20%
Allowable:
Nozzle 6.69%
Acceptance: UNACCEPTABLE Indiction LnearIndicationas 1- rspns N/ote, Ufar InterpotalloftAppffed 0.12 Indication # 2-Linear Indication, base response Indication #2- Linear Indication, tip response Figure 14. Heat Exchanger Weld I1El-2H1X-A-1, Indication at 12" CCW/Downstream File No.: 0800236.00-301 Page 25 of 36 Revision: 2 F0306-OI RO
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Outage No.: 141R23 Report No.: SOHIU08O Summary No.; Hi IEII-2HX-A4 Page No.: 6 Of 6 Sito: HNP Unit.: 1 Drawing No.: 8-32 Component ID: IEiI-2HX-A-I
Description:
INLETNOZZLE TO RHR HX SHELL Procedure: NMP-ES-024-506 Rev.: 1.0 Prepared ly: JEFF L. DEVERS Level; I Signature: Data: 2I16W2008 FLAW CHARACTERIZATION & ACCEPTANCE Code of Reference; ASME Section Xl 2001 edition thru 2003 Addenda Flaw Number:
Examination Category: C-8 Presure Retaining Nozzle Welds in Vessels' Flaw Location; 20.0' CCW I Downstream Code Item Number. C2.21 Flaw Orientation: Circumferential Code Figure Number IWC-2500-4 (b) Flaw Clasilfication: Surface I Planar ExameinuationMethod: Volumetrilc Flaw Height 0.1&'
Acceptance Standard: IWC-3511 Flaw Length: 0.8w, Acceptance Table: IWC-3511-1 Thickness @ Flaw: 0,084" Faw 'al: 21.20%
Allowable: 7.83%.
Nozzle Acceptance: UNACCEPTABLE InmdL#4Ind.#3 liaW UnereatIterpokanbon Applied 8-f 8 ___ Shell Indication #3- Linear Indication, base response Indication #4- Linear Indication, tip response Figure 15. Heat Exchanger Weld 1Ell-2HX-A-1, Indication at 20" CCW/Downstream File No.: 0800236.00-301 Page 26 of 36 Revision: 2 F0306-OIRO
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C = Co+C 1X+C2 X2+C3)0 Cu0 C0: surface stress (x=O) a t2 t
lnx A A it Secti on A-A Calculated K is the maximum of K atpoints 1 andd2at each crack depth (a)
Sf'-lTTTPT-" Tf,PUTS:
Ref t: plate thick aess V plate ..thJ cl a..'
ASME Section XI, 95 Ed. a: nnxdmum nrack depth (a,,,.*: 0.8t)
(flaw shape parameter without plastic zone correction factor)
Figure 16. Crack Model File No.: 0800236.00-301 Page 27 of 36 Revision: 2 F0306-OIRO
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Fig. A-4300-2 2001 SECTION XI, DIVISION 1 1o- 3 10-4 10-6 10-7 100 101 102 AK, (ksl V-/*.)
FIG. A-4300-2 REFERENCE FATIGUE CRACK GROWTH CURVES FOR CARBON AND LOW ALLOY FERRITIC STLS EXPOSED TQ WATER ENVIRONMENTS (ksiV in. = 1100 kPaj m) (in.,cycle = 0.025 m/cycle)
Figure 17: Fatigue Crack Growth Curves for Carbon and Low Alloy Ferritic Steels Exposed to Water Environments File No.: 0800236.00-301 Page 28 of 36 Revision: 2 F0306-01 RO
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Curve Fit Stress -- Case: UnitPrs 31000 30000 29000 28000 27000 L input Fit I 26000 25000 24000 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Distance Unit: Stress (psi), Distance (inch from shell inside surface)
Figure 18: Curve fit of Through Wail Stress Proffle for Unit Pressure Load Case File No.: 0800236.00-301 Page 29 of 36 Revision: 2 F0306-OIRO
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Curve Fit Stress -- Case: UnitAxid 35 30 25 g 20 15 Finput Fit I 10 5
0 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Distance Unit: Stress (psi), Distance (inch from shell inside surface)
Figure 19: Curve fit of Through Wall Stress Profile for Unit Axial Load Case File No.: 0800236.00-301 Page 30 of 36 Revision: 2 F0306-O1RO
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Curve Fit Stress -- Case: UnitMnt 7
6 5
i4
- 3 Finput
-'-FitI 2
1 0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Distance Unit: Stress (psi), Distance (inch from shell inside surface)
Figure 20: Curve fit of Through Wail Stress Profile for Unit Moment File No.: 0800236.00-301 Page 31 of 36 Revision: 2 F0306-OIRO
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Curve Fit Stress - Case: Thermal 2.2 2.0 1.8 1.6 1.4 5 1.2 + Input
-FiU 1.0 0.8 0.6 0.4 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 Distance a) Maximum Tensile Stress at Vessel ID Curve Fit Stress - Case: Thermal IUUUU 5000 0
01 02 4 05 06 07 08 09
-5000C 0 I -10000
-15000 + input
-Fit
-20000
-25000
-30000
-35000 Distance b) Maximum Tensile Stress at Vessel OD Unit: Stress (psi), Distance (inch from shell inside surface)
Figure 21: Curve fit of Through Wall Stress Profile for Thermal Transients File No.: 0800236.00-301 Page 32 of 36 Revision: 2 F0306-O1RO
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Curve Fit Stress - Case: Resid 40000 30000 20000 10000 I 0
-10000 0 0 01 02 03 0 06 07 08 9+
Input Fit
-20000
-30000
-40000 Distance Unit: Stress (psi), Distance (inch from shell inside surface)
Figure 22: Curve fit of Through Wall Stress Profile for Residual Stress File No.: 0800236.00-301 Page 33 of 36 Revision: 2 F0306-01RO
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Stress Intensity Factor 50000 45000 40000 35000 30000 - UnitPrs 9 25000 - UnitAxLd 20000 - UnitMnt 15000 - Resid 10000 - Thermal 5000 0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Crack Size Unit: K (psi/in), Crack Size (inch from shell inside surface)
Figure 23: Applied Stress Intensity Factors File No.: 0800236.00-301 Page 34 of 36 Revision: 2 F0306-0I RO
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Critical Crack Size 50000 45000 40000 35000
- UnitPrs U 30000 - UnitAxLd I-25000 - UnitMnt 20000 - Resid 15000 - Thermal 10000 - Total K 5000
- Klc 0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Crack Size Unit: K (psi4 in), Crack Size (inch from shell inside surface)
Figure 24: Allowable Crack Size Results File No.: 0800236.00-301 Page 35 of 36 Revision: 2 F0306-OIRO
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Crack Growth 0.1814 0.1812 0.1810 j.1g 0.1808 U
U 0.1806 0.1804 0.1802 0.1800 0 10 20 30 40 50 60 70 80 90 100 Cycles Unit: Crack Size (inch from shell inside surface)
Figure 25: Fatigue Crack Growth Results File No.: 0800236.00-301 Page 36 of 36 Revision: 2 F0306-0IRO
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APPENDIX A ANSYS INPUT AND OUTPUT FILES HTCH-RHR.INP Base model geometry for inlet nozzle top heat exchanger shell MPropLinear HTCH.INP Material Properties for the finite element model HTCH-RHR-AXIAL.INP Unit axial load analysis HTCH-RHR-PRES.INP Unit internal pressure analysis HTCH-RHR-MOMENT-INPLANE.inp In-plane unit moment analysis HTCH-RHR-TR.INP Thermal transient analysis for shockup HTCH-RHR-STR.INP Transient stress analysis for shockup HTCH-PRES-POST.INP Mapped stress extraction file for Unit Pressure analysis HTCH-AXIAL-POST.INP Mapped stress extraction file for Unit Axial load analysis HTCH-INPLANE-POST.INP Mapped stress extraction file for Unit In-Plane Moment analysis HTCH-STR-POST.INP Mapped stress extraction file for thermal transient stresses HTCH-RHR-*-PATH1.OUT Mapped stress output for ALL stress analyses for paths 1; *= name of transient
= PRES, AXIAL, INPLANE and STR File No.: 0800236.00-301 Page Al of Al Revision: 2 F0306-O1 RO
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APPENDIX B CRACK GROWTH RELATED COMPUTER INPUT AND OUTPUT FILES Filename Description HXA.LFM pc-CRACK input data based for fracture mechanics evaluation HXA.OUT pc-CRACK output file for fracture mechanics evaluation File No.: 0800236.00-301 Page BI of BI Revision: 2 F0306-OIRO