View source for L-09-268, Calculation, 0800777.309, Rev. 0, Sensitivity Study of Temperbead Surface Area Limitations for Large Bore Weld Overlay Repairs Over Ferritic Materials (from 500 to 1,000 Square Inches).

{{Adams
| number = ML093360332
| issue date = 11/02/2009
| title = Calculation, 0800777.309, Rev. 0, Sensitivity Study of Temperbead Surface Area Limitations for Large Bore Weld Overlay Repairs Over Ferritic Materials (from 500 to 1,000 Square Inches).
| author name = Jenson C, Ku F
| author affiliation = FirstEnergy Nuclear Operating Co, Structural Integrity Associates, Inc
| addressee name = 
| addressee affiliation = NRC/NRR
| docket = 05000346
| license number = NPF-003
| contact person = 
| case reference number = L-09-268, TAC ME0477, TAC ME0478
| document report number = 0800777.309, Rev. 0
| document type = Calculation
| page count = 29
| project = TAC:ME0477, TAC:ME0478
| stage = Other
}}

=Text=
{{#Wiki_filter:V StructuralIntegrity Associates, Inc.                      File No.: 0800777.309 CALCULATION PACKAGE                               Project No.: 0800777 Quality Program: M Nuclear   El Commercial PROJECT NAME:
Generic Weld Overlay Analyses/Methods CONTRACT NO.:
NA CLIENT:                                             PLANT:
Internal Development                                NA CALCULATION TITLE:
Sensitivity Study of Temperbead Surface Area Limitations for Large Bore Weld Overlay Repairs Over Ferritic Materials (from 500 to 1,000 Square Inches)
Document         Affected                                   Project Manager             Preparer(s) &
Revision         Pages          Revision Description           Approval                 Checker(s)
Signature & Date         Signatures & Date 0            1 - 23              Initial Issue A A-2 Computer Files Craig E. Jenson Richard L. Bax           [CEJ] 11/02/09
[RLB] 11/02/09 Francis H. Ku
[FHK] 11/02/09 Page 1 of 23 F0306-01RO

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Table of Contents 1.0     OB JE C TIV E .........................................................................................................                 4 2.0     WELD OVERLAY AREA SIZE COMPARISON .................................................                                                     4 2.1        Configuration Summary ...............................................................................                            4 3.0     ASSUMPTIONS / DESIGN INPUTS ......................................................................                                      5 4.0     M ETH OD OLO G Y ...................................................................................................                    5 4.1        W eld B ead Sim ulation ..................................................................................                       5 4.2        W elding Sim ulation ......................................................................................                      6 4.2.1  FEA Residual Stress Methods......................................................................                                6 5.0     RESIDUAL STRESS COMPONENTS AND RADIAL DISPLACEMENTS ......                                                                              6

==6.0     CONCLUSION==
S AND DISCUSSIONS .................................................................                                           8 7.0     RE FERE N CE S ........................................................................................................                 9 APPENDIX A INPUT AND OUTPUT FILES ...............................................................                                             A-1 List of Tables Table 1: Inside Surface Residual Axial Stress, Post Weld Overlay Repair .........................                                               7 Table 2: Inside Surface Residual Hoop Stress, Post Weld Overlay Repair .........................                                                7 Table 3: Inside Surface Residual Radial Displacement, Post Weld Overlay Rep air ....................................................................................................................... 7 File No.: 0800777.309                                                                                                                                 Page 2 of 23 Revision: 0 F0306-O1

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List of Figures Figure 1. Weld Overlay Repair Configuration Schematic .................................................                          10 Figure 2. Finite Element Model Example (500 Square Inch) .................................................                       11 Figure 3. Nugget Area Plot for 500 Square Inch Size Weld Overlay Repair (30 1 Nuggets) .................................................................................................  . . 12 Figure 4. Nugget Area Plot for 750 Square Inch Size Weld Overlay Repair (422 Nuggets) ................................................................................................... 13 Figure 5. Nugget Area Plot for 1000 Square Inch Size Weld Overlay Repair (524 Nuggets) ................................................................................................... 14 Figure 6. Post Weld Overlay Axial Stress at 707F for 500 Square Inch ...........................                                 15 Figure 7. Post Weld Overlay Hoop Stress at 70'F for 500 Square Inch ...........................                                  16 Figure 8. Post Weld Overlay Axial Stress at 707F for 750 Square Inch ...........................                                 17 Figure 9. Post Weld Overlay Hoop Stress at 70'F for 750 Square Inch ...........................                                  18 Figure 10. Post Weld Overlay Axial Stress at 707F for 1000 Square Inch ........................ 19 Figure 11. Post Weld Overlay Hoop Stress at 707F for 1000 Square Inch ...................... 20 Figure 12: ID Surface Axial Residual Stress ......................................................................               21 Figure 13: ID Surface Hoop Residual Stress ......................................................................                22 Figure 14: ID Surface Radial Residual Displacement ......................................................                        23 File No.: 0800777.309                                                                                                                  Page 3 of 23 Revision: 0 F0306-01I

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1.0          OBJECTIVE The objective of this document is to perform a series of finite element based residual stress evaluations to support increasing the area of temper bead weld overlay repairs over ferritic materials. This increase in temper bead area is necessary to support weld overlay repairs of large bore piping components in the pressurized water reactors (PWR).
The temper bead area for an overlay repair of a ferritic component is currently limited to 500 square inches, which was qualified in a prior EPRI program [1]. Therefore, a comparison will be performed between the currently allowed 500 square inch repair and enlarged 750 and 1000 square inches repairs to ascertain the impact of the enlarged overlays on large bore ferritic piping components.
Three separate analyses (one for each repair size) will be performed. These analyses will serve as sensitivity studies for justifying the increase of the temper bead weld overlay repair area of large bore ferritic piping components up to a repair area of 1000 square inches. The analyses will provide the weld residual stress condition on the inside surface at the centerline of the dissimilar metal weld (DMW), that area susceptible to PWSCC, and on the inside surface at the toe of the overlay on the ferritic side of the overlay and on the stainless steel side of the overlay for the three different temper bead weld overlay areas evaluated, as well as the radial displacements associated with the weld overlay repair applications on the inside surface of the components beneath the overlay. These analyses are relevant only to nozzles, pipes and similar cylindrical component welds. It should be noted that the stainless steel pipe is not susceptible to PWSCC so the residual stress and shrinkage information associated with the stainless steel component is only provided for completeness.
These analyses are not intended to support any increase in the size of vessel shell cavity repairs, which was also previously evaluated in Reference 1. Nor are these evaluations intended to specifically address residual stress and its impact on Primary Water Stress Corrosion Cracking (PWSCC).
2.0         WELD OVERLAY AREA SIZE COMPARISON The same residual stress analysis methods are applied to the 500, 750 and 1000 square inch weld overlay repairs. The three configurations are identical, except for the axial length of the weld overlay repair, which is increased to achieve the desired coverage area over the ferritic component. The finite element model meshing characteristics are also essentially identical for all three configurations.
2.1         Configuration Summary The configuration for this study is based on a large bore stainless steel to ferritic steel dissimilar metal weld (DMW) configuration. The base inside diameter is 28 inches and the base stainless wall thickness is 3.25 inches. The axial DMW length at the outside surface, including the ferritic steel weld butter, is 3.75 inches. The weld repair area parameter is determined by the base ferritic component outside diameter and the axial length measured from the edge of the butter.
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3.0        ASSUMPTIONS / DESIGN INPUTS The configuration and geometry for a representative large bore weld overlay repair is shown in Figure 1.
The base configuration consists of is a SA-351 Grade CF8M stainless steel pipe welded to a SA-516 Grade 70 carbon steel pipe, which is clad with 304L stainless material. The total configuration therefore comprised of the stainless pipe, the Alloy 82/182 DMW, the Alloy 82/182 butter on the carbon steel pipe, the carbon steel pipe (with stainless cladding) and the weld overlay repair, which is comprised of Alloy 52M, with a stainless steel buffer layer over the cast stainless pipe. The weld overlay repair covers the DMW and extends in both directions. The area measurement of the weld overlay is one side only and is measured from the edge of the butter to the end of the weld overlay repair on the carbon steel pipe side, as that is the side requiring a temper bead weld overlay repair. The overlay thickness roughly conforms to 1/3 of the thickness of the DMW (overlay thickness over the DMW is 1.083 inches and the thickness of the susceptible material is if 3.18 inches) and is not the result of a specific sizing evaluation.
The dimensions and materials are typical for PWR large bore pipes used on the cold leg and hot leg sides of the reactor coolant system. An example of the finite element model, for the 500 in2 weld overlay repair case is shown in Figure 2.
Material properties used for the residual analysis are temperature dependent and use the Multilinear Isotropic Hardening formulation as defined in the ANSYS software. The material properties are documented in Reference [2].
4.0        METHODOLOGY The residual stresses due to welding are controlled by various welding parameters, thermal transients due to application of the welding process, temperature dependent material properties, and elastic-plastic stress reversals. The analytical technique uses finite element analysis to simulate the multi-pass weld overlay processes. A residual stress evaluation process was previously developed in an internal SI project. Details of the process and its comparison to actual test data are provided in Reference 3. The same process will be used herein.
4.1        Weld Bead Simulation In order to reduce computational time, individual weld beads or passes are lumped together into weld nuggets. This methodology is based on the approach presented in References 4, 5, 6 and 7.
The number of equivalent bead passes is estimated by dividing each nugget area by the area of an individual bead. The resulting number of equivalent bead passes per nugget is used as a multiplier to the heat generation rate. The welding direction is defined to be from the ferritic pipe to the stainless. A plot of nuggets for the weld overlays are shown in Figures 3, 4 and 5.
All three weld overlay repairs are performed using 10 layers, each of which is approximately 0.1 inches thick. The number of nuggets increases for each configuration due to the added length of the overlay.
Therefore, the 500 in 2 repair has 301 nuggets, the 750 in 2 repair has 422 nuggets and the 1000 in 2 repair has 524 nuggets.
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4.2         Welding Simulation The welding simulation is basically a two step process within the ANSYS finite element software package [8]. In the first step, time dependent thermal loads are applied and temperature gradients are solved for many points in time for the welding process. This sequence of temperature history is then used in the stress analysis step to calculate residual stresses resulting from the welding process.
The stainless buffer layer is applied first, after which it is cooled to an ambient temperature of 707F. The remainder of the weld overlay repair simulation is then performed. After the weld overlay is completed, the entire structure is again allowed to cool to a uniform ambient temperature of 70'F. The final result is the predicted state of stress with path dependent effects based on representative thermal and mechanical load history.
Note that no simulation of the DMW welding process was considered. This evaluation is only intended to compare the effects of the enlarged overlay on the ferritic component and not consider the overlay residual stress, and its effects on PWSCC or other cracking concerns.
4.2.1       FEA Residual Stress Methods Axisymmetric PLANE55 elements are used in the thermal analysis, while axisymmetric PLANE182 elements are used in the stress analysis. The weld bead depositions are simulated using the element "birth and death" feature in ANSYS. The element "birth and death" feature in ANSYS allows for the deactivation (death) and reactivation (birth) of the elements' stiffness contribution when necessary. It is used such that elements that have no contribution to a particular phase of the weld simulation process are deactivated (via EKILL commnand) because they have not been deposited. The deactivated elements have near-zero conductivity and stiffness contribution to the structure. When those elements are required in a later phase, they are then reactivated (via EALIVE command). The analyses consist of a thermal pass to determine the temperature distribution due to the welding process, and an elastic-plastic stress pass to calculate the residual stresses through the thermal history. Appropriate weld heat efficiency along with sufficient cooling time are utilized in the thermal pass to ensure that the temperature between weld layer nuggets meets the required interpass temperature of 350OF for a temper bead weld overlay repair [9] as well as obtain acceptable overall temperature distribution within the finite element model (i.e., peak temperature, sufficient resolution of results, etc.).
During all welding processes, a convection heat transfer coefficient of 5.0 Btu/hr-ftl2 -F at 70OF bulk ambient temperature is applied to simulate an air backed condition at the inside and outside surfaces of the structure.
5.0         RESIDUAL STRESS COMPONENTS AND RADIAL DISPLACEMENTS The resulting axial and hoop residual stresses, following the completion of the overlay and cooling to 707F ambient, for each of the configurations is shown in Figure 6 through 11. Figures 12 and 13 are ID surface stress plots for the axial and hoop directions, for each configuration, as a function of distance File No.: 0800777.309                                                                                  Page 6 of 23 Revision: 0 F0306-01I

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from the DMW centerline, respectively. Finally, Figure 14 shows the resulting inside surface radial displacement, for each configuration, as a function of distance from the DMW centerline, respectively.
Tables 1 through 3 tabulate the inside surface residual axial stress, the inside surface residual hoop stress, and the inside surface residual radial displacements at the centerline of the DMW, at the toe of the overlay over the ferritic component and at the toe of the overlay over the stainless component.
Table 1: Inside Surface Residual Axial Stress, Post Weld Overlay Repair Residual Axial Stress, psi Inside Surface At Toe                                             Inside Surface At Toe of Overlay Over            A       nsideS        face             of Overlay Over Ferritic ComponentO)           At Centerline of DMW                Stainless Component 500                          -22,915                        22,146                            -17,448 750                          -26,232                         12,409                           -18,212 1000                          -27,059                          6,061                           -18,553 Note: 1. The results for the ferritic component are taken at the ID of the ferritic material and not the stainless cladding.
Table 2: Inside Surface Residual Hoop Stress, Post Weld Overlay Repair Residual Hoop Stress, psi Inside Surface At Toe                                             Inside Surface At Toe of Overlay Over                  InsideS         face             of Overlay Over Ferritic ComponentO)           At Centerline of DMW                Stainless Component 500                          -33,022                       -40,201                            -30,718 750                          -31,426                       -47,590                            -29,561 1000                          -30,100                       -51,627                            -29,534 Note: 1. The results for the ferritic component are taken at the ID of the ferritic material and not the stainless cladding.
Table 3: Inside Surface Residual Radial Displacement, Post Weld Overlay Repair Residual Radial Displacement, inches Inside Surface At Toe                                             Inside Surface At Toe of Overlay Over                   InsideS face                    of Overlay Over Ferritic Component('           At Centerline of DMW                Stainless Component 500                           -0.013                         -0.031                            -0.013 750                           -0.011                         -0.034                            -0.012 1000                           -0.011                         -0.035                            -0.012 Note: 1. The results for the ferritic component are taken at the ID of the ferritic material and not the stainless cladding.
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==6.0         CONCLUSION==
S AND DISCUSSIONS As expected, the results provided in Tables 1 and 2 and Figures 6 through 13 show that for each incremental increase in weld overlay size there is a reduction in tensile stress on the inside surface in the region of the DMW in both the axial and hoop directions. The same trend is observed for inside surface locations at the axial locations of the WOL toes. However, the hoop stress shows a slightly different trend than the axial stress. The hoop stress on inside surface at the axial location of the WOL toe on the ferritic side shows increasing compressive stress with increasing WOL area. The hoop stress on the inside surface at the axial location of the WOL toes on the stainless side shows approximately the same compressive stress for all three WOL areas. Again, it is noted that the stainless steel information is provided herein for completeness, as stainless steel is not susceptible to PWSCC in the PWR environment.
As expected, the residual radial displacement does increase with weld overlay area increase. However, Table 3 and Figure 14 indicate that the displacements change is minimal; 0.031 inches at the DMW centerline for the 500 in2 configuration to 0.034 inches for the 1000 in 2 configuration. The variation in residual radial displacement is even less at the toes of the overlay, with the 750 in2 configuration having essentially identical displacement as the 1000 in2 configuration.
Once again, these analyses are not intended to support any increase in the size of vessel shell cavity repairs, which was also previously evaluated in Reference 1. Nor are these evaluations intended to specifically address residual stress and its impact on Primary Water Stress Corrosion Cracking (PWSCC). While the indicated results may imply a inadequate residual stress in the region of the DMW, the overlay configurations were not specifically intended to meet that requirement, only to compare the impact of increased overlay temper bead area on the ferritic component. In the case of an actual repair design, the overlay configuration will be designed to generate desired residual stresses.
In conclusion, the residual stress and radial variations that result between the 500 in 2, 750 in2 and 1000 in2 configurations conformed to expectations and produced no unexpected or unacceptable results that would preclude the use of temper bead weld overlays up to and beyond 1000 in2 . In fact, the residual stress results illustrate that at the DMW, on the inside surface of the component, the axial and hoop residual stresses are improved as the weld overlay area is increased over the ferritic component.
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==7.0       REFERENCES==
: 1. RRAC Code Justification for the Removal of the 100 Square Inch Temper Bead Weld Repair Limitation, EPRI Report 1011898, Technical Update November 2005.
: 2. SI Calculation No. 0800777.307, Revision 1, "Material Properties for Residual Stress Analyses, Including MISO Properties Up To Material Engineering Ultimate Tensile Strength."
: 3. SI Calculation No. 0800777.303, Revision 0, "Residual Stress Methodology Development and Benchmarking of a Large Diameter Pipe Weld Overlay."
: 4. P. Dong, "Residual Stress Analysis of a Multi-Pass Girth Weld: 3-D Special Shell Versus Axisymmetric Models," Journal of Pressure Vessel Technology, Vol. 123, May 2001.
: 5. Rybicki, E. F., et al., "Residual Stresses at Girth-Butt Welds in Pipes and Pressure Vessels," U.S.
Nuclear Regulatory Commission Report NUIREG-0376, R5, November 1977.
: 6. Rybicki, E. F., and Stonesifer, R. B., "Computation of Residual Stresses Due to Multipass Welds in Piping Systems," Journal of Pressure Vessel Technology, Vol. 101, May 1979.
: 7. Materials Reliability Program: Technical Basis for Preemptive Weld Overlays for Alloy 82/182 Butt Welds in PWRs (MRP-169), EPRI, Palo Alto, CA, and Structural Integrity Associates, Inc.,
San Jose, CA: 2005. 1012843.
: 8. ANSYS/Mechanical, Release 11.0 (w/Service Pack 1), ANSYS Inc., August 2007.
: 9. ASME Boiler and Pressure Vessel Code, Code Case N-740-2, Full Structural Dissimilar Metal Weld Overlay for Repair or Mitigation of Class 1, 2, and 3 Items, Section XI, Division 1.
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0.963" OVC!) y         A4"           ,/'-30&L  Bufe Layer 3.25"   SA-35S4 Grade CFM                                           29-   SA-516 G*o  70 AftBlloy                                     0.31"  SA-204 304L DMW/f                                        Clad     Cladding 28.10" I.D.                               28.16" I.D.       28.00" I.D.
3:1=
T1150                             /     l_,,1    a S    I       I 4:1 ToWr                          -~:'~c 0.91M
* I I      I M4-M -- 0.67"f Figure 1. Weld Overlay Repair Configuration Schematic Overlay Shape is for 500 SquareIn Configuration File No.: 0800777.309                                                                           Page 10 of 23 Revision: 0 F0306-0Y1

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Figure 2. Finite Element Model Example (500 Square Inch)
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Figure 3. Nugget Area Plot for 500 Square Inch Size Weld Overlay Repair (301 Nuggets)
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S-  ____
i Figure 4. Nugget Area Plot for 750 Square Inch Size Weld Overlay Repair (422 Nuggets)
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Figure 5. Nugget Area Plot for 1000 Square Inch Size Weld Overlay Repair (524 Nuggets)
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             -66515          -35050         -3586            27878            59343
                     -50783          -19318          12146            43610          75075 Residual stress analysis Figure 6. Post Weld Overlay Axial Stress at 701F for 500 Square Inch File No.: 0800777.309                                                                     Page 15 of 23 Revision: 0 F0306-01

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NODAL SOLUTION STEP=6537 SUB =2 TIME=1751 SZ         (AVG)
RSYS=0 DMX =.033942 SMN =-67428 SMX =113795
              -67428               -27156       13115         53387           93659
                          -47292          -7020       33251            73523          113795 Residual    stress     analysis Figure 7. Post Weld Overlay Hoop Stress at 701F for 500 Square Inch File No.: 0800777.309                                                                      Page 16 of 23 Revision: 0 F0306-01

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NODAL SOLUTION STEP=9140 SUB =2 TIME=2307 BY        (AVG)
RSYS=O DMX =.036383 SMN =-58641 SMX =79139
            /
              -58641           -28024          2594             33212           63830
                       -43332          -12715          17903             48521          79139 Residual stress analysis Figure 8. Post Weld Overlay Axial Stress at 701F for 750 Square Inch File No.: 0800777.309                                                                      Page 17 of 23 Revision: 0 F0306-01

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NODAL SOLUTION STEP=9140 SUB =2 TIME=2307 Sz        (AVG)
RSYS=O DMX =.036383 SMN =-64995 SMX =114581
              -64995           -25089          14817           54723           94628
                       -45042          -5136          34770             74675          114581 Residual stress analysis Figure 9. Post Weld Overlay Hoop Stress at 701F for 750 Square Inch File No.: 0800777.309                                                                    Page 18 of 23 Revision: 0 F0306-01

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             -53289          -23750          5789              35329            64868
                      -38520         -8980            20559             50098          79638 Residual stress analysis Figure 10. Post Weld Overlay Axial Stress at 701F for 1000 Square Inch File No.: 0800777.309                                                                   Page 19 of 23 Revision: 0 F0306-01

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NODAL SOLUTION STEP=11352 SUB =2 TIME=2754 SZ         (AVG)
RSYS=0 DMX =.03631 SMN =-64027 SMX =114460
              -64027           -24363         15301            54964            94628
                        -44195        -4531           35132             74796          114460 Residual stress analysis Figure 11. Post Weld Overlay Hoop Stress at 701F for 1000 Square Inch File No.: 0800777.309                                                                   Page 20 of 23 Revision: 0 F0306-O1

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ID Surface Axial Residual Stress 40000                                         -     - I!.
Ferritic                    DMW                       Stainless Pipe                        Weld                       Pipe 30000 20000                                            ---
C*                                                                                       4s00 Square Inch 0                                                    "o                        -   750 Square Inch
                                                                           ,41-0i-               1000 Square Inch
         -10000
         -20000                            .-..........                . .    .
         -30000
         -40000 Distance from DMW Centerline (Inches)
Figure 12: ID Surface Axial Residual Stress The resultsfor the ferritic component are taken at the ID of the ferriticmaterialand not the stainless cladding.
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ID Surface Hoop Residual Stress 40000 Ferritic                   DMW                  Stainless Pipe                      Weld                   Pipe 30000 iUUUU 10000 0
                    -                 -10          -5                   51                20
                                                                                             -*-50OOSquare Inch CA-10000        \9*\___
ooj-750                                                                                   Square Inch U%) 200                                                                                      1000 Square Inch
          -20000             --             ____       __-        ___              -
          -30000
          -40000
         -50000                                  -   _      -
         -O0000 Distance from DMW Centerline (inches)
Figure 13: ID Surface Hoop Residual Stress The resultsfor the ferritic component are taken at the ID of the ferriticmaterialand not the stainless cladding.
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IDSurface Radial Residual Displacement 0 .1                                                                                - -----
Ferritic                 DMW                     Stainless Pipe                  Weld                      Pipe 0.08 0.06 0.04 1Z (V
0.02 C
aj 0 S-#--SO0                                                                               001__     0 Square Inch u                                                                                                      - 750 Square Inch CL  -0.0 2      .     .. ....                                                                            10 0 0 Sq ua re In c h
          -0.04
          -0.06
          -0.08
            -0.1                                             - - -----                              --
                  -20   -15            -10         -5       0          5         10         15            20 Distance from DMW Centerline (inches)
Figure 14: ID Surface Radial Residual Displacement The resultsfor the ferritic component are taken at the ID of the ferritic materialand not the stainless cladding.
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APPENDIX A INPUT AND OUTPUT FILES File No.: 0800777.3 09 Page A- I of A-2 Revision: 0 F0306-OIRO

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Input File                                              Description/Comment WOLEPRI_500_64.INP                     2D axisymmetric model for 500 in 2 temper bead weld overlay repair WOLEPRI_750_64.INP                     2D axisymmetric model for 750 in2 temper bead weld overlay repair WOLEPRI_1000_64.INP                   2D axisymmetric model for 1000 in 2 temper bead weld overlay repair MProp EngrMISO.lliP                    Material Property data of E, alpha, conductivity, specific heat, and stress strain curves [2]
NODE-??-2                              ID surface nodal coordinate outputs, Cladding Removed Where ?? = 500, 750, 1000 STRESS.-??-2                      ID surface  stress outputs for post-WOL at 70'F, Cladding Removed Where ?? = 500, 750, 1000 DISP-??-2                ID surface radial displacement outputs for post-WOL at 70'F, Cladding Removed Where ?? = 500, 750, 1000 RESULTS-TEST.XLS                                   Excel spreadsheet containing all output data The following files are generic in that they appear for each of the three weld overlay configurations. Thus three sets of similarly named files are generated and stored separately.
BCNUGGET2D.INP                              Weld nuggets defmition and boundary conditions file PICK2D.1NP                  Writes boundary conditions and nugget definitions into BCNUGGET2D.INP file THERMAL2D.INP                                     Thermal pass for simulating weld processes STRESS2D.INP                                      Stress pass for simulating weld processes WELDImntr.INP                     Contains LDREAD commands for buffer layer portion of the stress pass WELD2_nmtr.INP                   Contains LDREAD commands for weld overlay portion of the stress pass POSTID.INP                                  Post-processing file to extract ID surface stresses Output File                                              Description/Comment' IDNLIST.OUT                                          ID surface nodal coordinate outputs IDWELD1.OUT                               ID surface stress outputs for post-ID weld repair at 70'F IDWELD2.OUT                                  ID surface stress outputs for post butt weld at 70&deg;F IDT70.OUT                                    ID surface stress outputs for post-WOL at 70'F File No.: 0800777.309                                                                                            Page A-2 of A-2 Revision: 0 F0306-01RO

8                                   5 8542                                                             2 NOTES: SEE SHEET 2.
PUMP DISCHARGE                                 CROSS SECTION INCLUDING NO7LIE                                    PRESSURE TAP SEE DRAWING                 D 0800368.520 SHEET 1 OF 4 SPRAY NOZZLE SEE DRAWING 0800368.520 SHEET 3 OF 4 (ZONE C-5)
STATION B c
(EXCLUDES BUFFER LAYER)
                         .84" (MIN) 1.09" (MAX)            Ai    GENERAL REVISION PARTS LIST             MATERIAL STATION C &#xfd;>&#xfd;                                                                                           WELD         STAINLESS STEEL
: 2. SAFE END        A-376, TYPE316 TABLE1
: 3. WELD OVERLAY          ALLOY52M 0 28.00"                                      WELD OVERLAY THICKNESS @ STATION C A-516, GRADE 70
: 4.       ELBOW 2.90"                                    MLNOVERLAY        MAXOVERLAY LOCATIONON ELBOW       THICKNESS         THICKNESS                     5. CLADDING       STAINLESS STEEL INTRADOS              .87"               1.12"                                                 ER308L       B
: 6. BUFFER LAYER SIDEHILL             .87"               1.12"
: 7. DM WELD          ALLOY82/182
            >STATION A                        EXTRADOS        j      .95"               1.20"
: 8. PRESSURE TAP       A-336 CL.F8M
            &#xfd;&#xfd;".84" (MIN)
: 9.       WELD          STAINLESS STEEL 1.09" (MAX)                                                                                       10.      BUTTER          ALLOY82/182 (EXCLUDES                                                                                                  PUMP BUFFER LAYER)                                                                                        It     DISCHARGE        A-351 GR CFBM NOZZLE
: 12. SPRAY NOZZLE          A-182 F316
: 13. BRIDGE BEAD(S)         ALLOY 82 w
Associates, Inc. IPLANT: DAVIS-BESSE NUCLEAR POWER STATION, UNIT1 DRAWN F. HSUBY:
01/29/09 F. HSU FENGINEER C. FOURCADE 01/29/09 C. FOURCADE ffREVIEWED J. AXLINEBY:ITAPPROVED N. ENG BY:
01/29/09 1 01/29/09 J. AXLINE         N. ENG PROJECT NO.
DRAWING NO.
SIZE: B REVISION:
FILE NO.
0800368.00 0800368.520 0800368.520 ISCALE: NONE A
06/17/09         06/17/09       06/17/09        06/17/09 NUCLEAR SAFETY         SHEET:
RELATED YesI M     NofM          0F4 85                                  5

8                        7                                                                         4 NOTES:
: 1. COMPONENT SURFACE IS TO BE EXAMINED BY LIQUID PENETRANT METHOD AND THE WELD OVERLAY AREA SHALL BE UT INSPECTED PRIOR TO WELDING INACCORDANCE WITH DAVIS-BESSE RELIEF REQUEST AND DETERMINED TO BE ACCEPTABLE PRIOR TO OVERLAY APPLICATION. THE SURFACE TO BE EXAMINED SHALL EXTEND BEYOND THE SURFACE TO BE OVERLAYED BY /2". INTHE EVENT THAT THE ORIGINAL COMPONENT SURFACE IS FOUND UNACCEPTABLE, THE SURFACE SHALL BE PREPARED/REPAIRED INACCORDANCE WITH THE OWNERS ASME SECTION XI PROGRAM AND RELIEF REQUEST AND REEXAMINED. ANY DEPOSITED WELD LAYER(S) REQUIRED FOR COMPONENT SURFACE REPAIR SHALL NOT BE CREDITED TOWARD MEETING THE REQUIRED MINIMUM THICKNESS, NOR COUNT AGAINST THE MAXIMUM (MAXIMUM OVERLAY THICKNESS OF ALL LAYERS (INCLUDING ANY REPAIR LAYERS) SHALL BE 1.35").                                                                                             D
: 2. WELD FILLER METAL SHALL BE ASME, SECTION II,SFA-5.14, ERNiCrFe-7A (ALLOY 52M), CERTIFIED TO SECTION IIISUBSECTION NB.
: 3. THE THICKNESS SHOWN ON THE DRAWING IS THE THICKNESS BEYOND ANY SURFACE PREPARATION REQUIRED BY NOTE I ABOVE. THE OVERLAY THICKNESS SHOWN IN THE DRAWING ASSUMES NO DILUTION LAYER. IFA DILUTION LAYER IS REQUIRED, THE DILUTION LAYER THICKNESS SHALL NOT BE CREDITED TOWARDS THE REQUIRED STRUCTURAL MINIMUM, NOR COUNT AGAINST THE ALLOWED MAXIMUM.
: 4. TWO LAYERS OF OVERLAY ARE THE MINIMUM REQUIRED. APPLY AS MANY LAYERS AS REQUIRED TO ACHIEVE THE DESIGN OVERLAY THICKNESS.
: 5. THE TEMPERBEAD TECHNIQUE DESCRIBED IN THE DAVIS-BESSE RELIEF REQUEST SHALL BE USED TO ELIMINATE THE NEED FOR PWHT OF THE CARBON STEEL ELBOW, THE NUMBER AND PLACEMENT 2
OF LAYERS SHALL COMPLY WITH THE RELIEF REQUEST. THIS METHOD SHALL BE LIMITED TO LESS THAN 600 IN COVERAGE ON THE CARBON STEEL ELBOW.
: 6. DESIGN STRUCTURAL THICKNESS INCLUDES NO ALLOWANCE FOR SURFACE CONDITIONING TO FACILITATE UT INSPECTION OF THE COMPLETED OVERLAY. THE SURFACE OF THE OVERLAY SHALL BE MECHANICALLY FINISHED AND HAVE A FINISH OF 250 RMS OR SMOOTHER. IN ADDITION THE SURFACE SHALL BE FLAT WITH NO OUT OF FLATNESS GREATER THAN 1/32" WITHIN ANY 1" DISTANCE.
: 7. DIMENSIONS APPLY TO ALL AZIMUTHS UNLESS OTHERWISE NOTED.
: 8. CALCULATION INFORMATION: THE NECESSARY OVERLAY LENGTH FOR STRUCTURAL PURPOSES, FROM THE WELD FUSION LINE, IS 4.01" ON THE SAFE END (EXCEPT AS NOTED) AND 3.46" ON THE ELBOW SIDE. THE LAYER LENGTH SHOWN ON THE DRAWING AS THE MINIMUM (E.G. 3.46" AT THE ELBOW) IS REQUIRED DUE TO UT EXAMINATION CONSTRAINTS.
: 9. AXIAL SHRINKAGE MEASUREMENTS SHALL BE MEASURED AT FOUR AZIMUTHS AROUND THE PIPE WITH A MEASUREMENT RESOLUTION OF +/-0.02".
: 10. OVERLAY IS TO BE APPLIED WITH EITHER AIR-BACKING OR WATER-BACKING, OR A TRANSITION BETWEEN THE TWO, FOR ANY OR ALL LAYERS.
THE DIMENSION SHALL BE MEASURED AND RECORDED.                                                                                                                                                              C NOT USED.
ASTAINLESS STEEL BUFFER LAYER (ITEM 6) SHALL BE INSTALLED. BUFFER LAYER TO CONSIST OF ASINGLE LAYER AND SHALL COVER THE STAINLESS STEEL SAFE END, WITHOUT CONTACTING THE DM WELD. THE BUFFER LAYER SHALL BE PLACED AS CLOSE AS PRACTICAL TO THE DM WELD FUSION LINE, BUT SHALL NOT TOUCH THE DM WELD. BUFFER LAYER SHALL NOT COUNT TOWARD MEETING THE REQUIRED MINIMUM OVERLAY THICKNESS, NOR COUNT AGAINST THE MAXIMUM. WELD FILLER METAL SHALL BE ASME, SECTION II SFA-5.9 ER3O8L, CERTIFIED TO SECTION III,SUBSECTION NB. NOMINAL BUFFER LAYER THICKNESS IS 0.08". THE BUFFER LAYER SHALL BE CONNECTED TO THE DM WELD, COVERING THE NOMINAL GAP SHOWN, USING ONE TO FIVE BRIDGE BEADS (ITEM 13) CONSISTING OF WELD FILLER METAL SFA-5.14, ERNiCr (ALLOY 82), CERTIFIED TO SECTION III,SUBSECTION NB. IF REQUIRED, ONE OR MORE LAYERS OF THIS ALLOY 82 WELD METAL SHALL BE USED TO SEAL UNACCEPTABLE INDICATIONS IN THE BRIDGE BEAD AREA TO BE WELDED, WITH OR WITHOUT EXCAVATION. THE THICKNESS OF THE BRIDGE BEADS OR THE REPAIR, IF REQUIRED, SHALL NOT COUNT TOWARD MEETING THE REQUIRED MINIMUM OVERLAY THICKNESS, BUT SHALL BE COUNTED AGAINST THE MAXIMUM.
: 4. DUE TO THE VARYING INTERSECTION ANGLE OF THE OVERLAY WITH THE ELBOW, THE OVERLAY SHALL HAVE THE THICKNESS LIMITS AT THE STATION C LOCATION AS SHOWN IN TABLE 1.
THE MINIMUM THICKNESS LISTED IS NECESSARY DUE TO BOTH STRUCTURAL AND INSPECTABILITY REQUIREMENTS.
I    APPLIES ONLY AT EXTRADOS.
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: 6. FINAL SURFACE FINISH OF END SLOPE OF WELD OVERLAY SHALL MEET THE SURFACE FINISH REQUIREMENTS FOR VISUAL AND LIQUID PENETRANT EXAMINATION. NO GRINDING IS REQUIRED. THE AGGREGATE SLOPE SHALL HAVE AN INCLUDED ANGLE OF 135. OR GREATER.
FINAL SURFACE FINISH OF END SLOPE OF OVERLAY AT SIDEHILL OF PRESSURE TAP SHALL MEET THE SURFACE FINISH REQUIREMENTS FOR VISUAL AND LIQUID PENETRANT EXAMINATION. NO GRINDING IS REQUIRED.
: 8. FINAL SURFACE FINISH OF END SLOPE OF OVERLAY AT SIDEHILL OF SPRAY NOZZLE SHALL MEET THE SURFACE FINISH REQUIREMENTS FOR VISUAL AND LIQUID PENETRANT EXAMINATION. NO GRINDING IS REQUIRED.
Structural Integriy             WELD OVERLAY DESIGN Associates, Inc. 1       PLANT: DAVIS-BESSENUCLEAR POWER STATION, UNIT 1 PROJECT NO.        0800368.00  A DRAWING NO.        0800368.520
                                                                                                                                       /0V9DAW0Y: /09NE~ 01-W090.
0         F. HSU    C.FOURCADE J. AXLINE          N.ENG     SIZE: B I FILENO. 0800368.520
                                                                                                                              +/-    F.HSU     C.FOURCADE J. AXLINE         N.ENG      REVISION: 1   ISCALE: NONE
_____{06/17/09     06/17/09     06/17/09     06/17/09 NUCLEAR SAFETY       SHEET:
RELATED Yes[!]   NoE         20F4 4                         3                            2 7                        6                       5                         4                         3                            2 S                                                                        5

8                                                                           4 B                                 7                    6        5           4                3                          2 PUMP DISCHARGE                            CROSS SECTION INCLUDING NOZZLE                               PRESSURE TAP SEE DRAWING A  7-                     0800368.520 SHEET I OF 4 (ZONEA-7)
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SAFEEND                  /
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DETAIL J C
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SECTION A-A           *Slructural integrity TTLE:RCP  WELD OVERLAY DESIGN DISCHARGE NOZZLE   OPTIMIZED (OWOL)
Associates, Inc. PLANT: DAVIS-BESSE NUCLEAR POWER STATION, UNIT I PROJECT  NO.       0800368.00 A
REV;  DRAWNBY:    ENGINEER:TREVIEWED  BY: APPROVED   BY:
DRAWINGNO.         0800368.520 0      F.IHSU 0I/29/09 C. FOURCADE J. AXLINE 01/29/09     01/29/09 T    N. ENG 01/29/09        SIZE: B I FILENO. 0800368.520 1     F. HSU    C. FOURCADE J. AXLINE I     NENG           REVISION:1 ISCALE: NONE 06/17/09    0/157/09    006/17/09    08/17/09 NUCLEAR  SAFETY    SHEET:
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8             7             6         5      4                                                        2 D
C EXTENT OF OVERLAY ONTO SPRAY NOZZLE BOSS CURVATURE 0.00" (NOM) (MAX OVERLAY) 0.40" (NOM) (MIN OVERLAY)
B SPRAY NOZZLE (9
VIEW B-B          StrUl~tlral   ralU integrfit GIn111grit*        TITLE:RCPv DISCHARGE NOZZLE OPtIE0 WELD OVERLAY DESIGN (WL             SStrcU Associates, Inc.               PLANT:DAVIS-BESSE    NUCLEARPOWERSTATION,    UNITI PROJECT NO.         0800368.00  A REV:      DRAWNBY:           ENGINEER: REVIEWED    BY: APPROVED   BY:
DRAWING NO.         0800368.520 0             F.HSU       C.FOURCADE     J.AXLINE         N. ENG 01/29/09          01/29/09    01/29/09        01/29/09      SIZE: B I FILENO. 0800368.520 F. HSU      C. FOURCADE    J. AXLINE        N. ENG      REVISION: 1    I SCALE: NONE
                                                -         06/17/09          06/17/09     06/17/09       06/17/09 NUCLEAR SAFETY       SHEET:
RELATED Yes ff    Noj         40F4
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