ML18059A545

Pressurizer PORV Nozzle Safe End Crack Evaluation Using PICEP-4

ML18059A545
Person / Time
Site:	Palisades
Issue date:	11/23/1993
From:	Pistolese B ABB COMBUSTION ENGINEERING NUCLEAR FUEL (FORMERLY, ASEA BROWN BOVERI, INC.
To:
Shared Package
ML18059A543	List: ML18059A542 ML18059A545 ML18059A546
References
P-ME-C-011, P-ME-C-011-R00, P-ME-C-11, P-ME-C-11-R, NUDOCS 9312080131
Download: ML18059A545 (32)

Text

{{#Wiki_filter:* ATTACHMENT 2 Consumers Power Company Palisades Plant Docket 50-255 REPLY TO NRC REQUEST FOR INFORMATION REGARDING THE PRESSURIZER SAFE END CRACK CRITICAL FLAW SIZE AND MARGIN TO FAILURE ANALYSIS !931208013-1 931130. PDR ADOCK 05000255 S PDR P-ME-C-011, "Palisades Pressurizer PORV Nozzle Safe End Crack Evaluation using PICEP-4," November 23, 1993 November 30, 1993 31 Pages

~ ~ ~ jl II- ,., 19 ASEA BROWN BOVERI Contract Calculation _l_/~_ Pages Appendix _/_o __ Pages Microfiche ___ _ Calculation Number P - ME - C - 011 Revision

• 0 0 Palisades Pressurizer P.O.R.V.

Nozzle Safe End Crack Evaluation Title---------------------------------------~ using PICEP-4 Author ___ B_._P_i_*_s_t_o_l_e_s_e_~/'--f--=~~~__:_/!...~~=-~_:::_-=--=------- 7 Calculation contains safety related design information: Yes _x_ Distribution VERIFICATION STATUS: COMPLETE The design Information contained in this document has been verified to be correct by means of ~esign Review. Name SrAA- ~~" 'N "'~'ti Signature ...\\..M - c.4.n~e Date~ Ir.dependent ReWaw8r 6 ~ B. Lubin Date 19 Nov 1993 No __ Summary

Purpose:

To support responses to ~.R c. request for additional information regarding Palisades pressurizer PORV safe end crack Method and Results of Review: THc 1'1E7Hoo Or OEf 16-N /f,ff V/£1,V WAS USC/) lo V'!f>l~Y fHIS C.AlrCt.Jt..ATlaN. THE,f'E5Vi-{_f' 1urc SA-flJ'F'4c:rolfY Fo~ TH£ /)()f?f'ciSc.SrAr£1,) A-4oVE. Form ii 0013320 (Rev. 7/90) ABB Combustion Engineering Nuclear Power

No. Date 0 . ~ f-/v/c-C,_- Oii 0 Cal-culation Number Rev. Page Number RECORD OF REVISIONS Sections Involved Prepared By Approvals ALL

8. PIS7oLESc

COMBUSTIOll~EllGlllEERlllG TABLE OF CONTENTS I. Purpose II.

Background

III. Scope IV. Method of Analysis

1.

Overview

2.

Details of Analysis

a.

dimensions for circular sections ? 11c c 011 Calculation Number 3 Page Number

b.

definition of PORV nozzle safe end crack length

c.

def'n. of mechanical properties for Inconel-600

d.

stress-strain correlation using RO equation

e.

definition of loadings, PORV nozzle safe end Spray nozzle Surge Nozzle

f.

Limit-Moment for PORV safe end based on observed crack

g.

PICEP analyses--general parameters for input files

3.

Explanation of Specific Assumptions & procedures

a.

Concerning the Inconel-600 Flow Stress

b.

Concerning the Ramberg-Osgood fit to the Inconel-600 stress-strain curve

c.

Concering flow from critical-length cracks whose half-angle exceeds Ninety Degrees V. Summary of Results VI. References 4 4 4 5 6 7 8 8 10 13 15 16 16 17 18 19 Figure 1 Figure 2 600 F Stress-strain curve at Low Strains 20 Comparison of Ramberg-Osgood stress-strain fit over 21 full strain range Appendix A -- Picep Results summarized PORV nozzle safe end, flow & determine L-critical, N. PORV nozzle safe end, determine L-critical, Faulted PORV nozzle safe end, flow at N.Op L-critical Spray nozzle, determine L-critical, N.Op Spray nozzle, determine L-critical, Faulted Spray nozzle, flow at N.Op L-critical Surge nozzle, determine L-critical, N.Op. Surge nozzle, determine L-critical, Faulted Surge nozzle, flow at N.Op L-critical Op. A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 A-10 Oo Rev.

COMBUSTIOll~EllGlllEERlllG f O/I Calculation Number Page Number I. Purpose The purpose of this calculation is to provide technical justification for responses to "Request for Additional Information on Palisades Plant Regarding the Report on the Pressurizer Safe End Crack (TAC NO. M87760)", questions 10 and 11. II. Background (per Reference 1) The Palisades pressurizer power-operated relief valve (PORV) nozzle safe end experienced a steam leak during startup on September 16, 1993. The Safe-end was fabricated from Inconel-600. The crack was observed to be circumferential, through-wall, oriented perpendicular to the pipe axis, having a length of 2.5 inches measured (Ref. 10) along the PORV inner radius. The leak was initially detected through an increase in the containment sump level which indicated an additional 0.2 gallons-per-minute (gpm) of equivalent water. III. Scope This analysis considers the PORV line, Spray Line, and Surge Line of the Palisades Pressurizer. The critical length of a circumferential crack is determined for each line, under either normal operation (NOp) or Faulted loads. Leakage rates are then determined for critical-length cracks under NOp loads. The "collapse load" moment, which is based on Inconel 600 flow stress, is also determined for the PORV line based on the actual geometry. All references to critical crack lengths in the Spray and Surge lines are strictly hypothetical and for the sake of analytical treatment only. 0 Rev.

COMBUSTIOll~EllGlllEERlllG P 11C ~ 011 Calculation Number Page Number IV.1.Method of Analysis -- OVERVIEW

1.

Dimensions for circular sections are established.

2.

The length of the PORV safe end crack is established at mid-radius, based on scaling an ID measurement from Ref. 10

3.

The elastic-plastic behavior of Inconel 600 is characterized using a Ramberg-Osgood (RO) fit, based on a stress-strain curve at 600 degrees F. ~conservative yield stress based on the RO fit, along with the 600 F minimum UTS from ASME Section III, when averaged, determine the "flow stress" which is used to calculate collapse loads.

4.

NOp and Faulted forces and moments are determined for each of the three nozzles.

s.

The PICEP program (Ref. 2) is utilized to (a) predict the flow from the cracked PORV nozzle safe end (b) predict critical crack lengths for all three nozzles under NOp and Faulted loadings (c) predict hypothetical flow (gpm) from each nozzle based on its own critical crack & thermodynamic conditions (Ref. 6), under NOp loading.

6.

Calculate collapse load based on material flow stress and observed cracks for the PORV nozzle safe end based on method given in NUREG 1061 (Ref. 3).

7.

Determine Safety factors for the cracked PORV.nozzle safe end based on flow rates, crack length, and load: (a) compare flow from critical crack size (from Sc above) to actual ,detected flow (b) compare critical crack length (from Sb above) to actual crack length (c) compare collapse load moment (from 6 above) to Faulted condition moment. 0 Rev.

COMBUSTIOll~EllGlllEERlllG p /VIE ~ Oii Calculation Number Page Number Iv.a.DETAILS OF ANALYSIS a... Dimensions for Circular Sections: I. PORV Safe End: Do 4.632 inch t 0.504 inch Di Do - 2t = 3.624 inch Rm (Do + Di) /4 2.064 c 2 ;r Rm 12.968 2.. Ast (Do - Di ) 7r /4 6.54 sq. inch Afl ').. Di 1f' /4 10.315 sq. inch II. Spray Nozzle: Do 4.5 inch t 0.438 inch Di Do - 2t = 3.624 inch Rm (Do + Di)/4 2.031 c 2 rr Rm 12.761 Ast (Do ,.. - Di:a.),,. /4 5.59 sq. inch Afl Di :i.. 1f' I 4

10. 315 sq. inch III. Pressurizer Surge Nozzle:

Do 12.75 inch t 1.125 inch Di Do - 2t = 10.50 inch Rm (Do + Di)/4 5.8125 c 2 ;TRm 36.521 ~ Ast (Do - Di ) 7i/4

41. 09 sq. inch Afl Di,_ 71'/4 86.6 sq. inch inch inch inch inch Outer Diameter; Ref. 4 wall thickness; "

Inner Diameter Mean Radius Mean Circumference Steel area (axial cross sect.) Flow area (interior) Outer Diameter; Refs. 7--9 wall thickness; 11 Inner Diameter Mean Radius Mean Circumference Steel area (axial cross sect.) Flow area (interior) Outer Diameter; Refs. 7--9 wall thickness; 11 Inner Diameter inch Mean Radius inch Mean Circumference Steel area (axial cross sect.) Flow area (interior) 0 Rev.

COMBUSTION~ENGINEERING f 11e-c. 011 0 Calculation Number Rev. 7 Page Number 1Y ;l. Details of analysis, cont'd

b.

Definition of PORV nozzle safe end crack length Per Reference 10, the PORV safe end crack was measured as 2.5 inches along the ID. PICEP input requires that crack lengths be defined at mid-radius. The input crack length is determined by scaling according to the radius ratio. L 2.5 inches x (2.064/1.812) 2.848 inches at mid-radius

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COMBUSTION~EllGlllEERlllG ? /VI,: c. ot I Calculation Number IS-Page Number Method of Analysis, cont'd PICEP analyses--general parameters for input files:

1) Solution for through-wall, circumferential cracks

2) Combined tension-plus-bending solution with plastic zone correction

3) English units, e.g. inch-pounds

4) E, Yield Stress, Flow stress as given in "Properties Definition" for Inconel-600 characterization

5) Ramberg-Osgood fit to stress-strain curve as given in "Properties Definition" specifying alpha=0.734 and exponent n=6.256.

6) Elliptical crack area cross-section for flow calculation.

7) Axial load due to internal pressure only

8) Surface roughness 0.0002 inches for a corrosion-type crack

9) Twelve 45 degree turns through thickness for flow calculation, applies to the PORV safe end.

Ten turns for the Spray nozzle only. Twenty-seven turns for the Surge nozzle only.

10) Entrance loss coefficient -- 0.61.

11) Exit area = entrance area Notes:

(8) to (11) are as recommended in PICEP-4 manual. 0 Rev.

COMBUSTION~ENGINEERING f /'1£ C. O/I Calculation Number 16 Page Number IV. Method of Analysis, cont'd

3.

Explanation of Specific assumptions & procedures

a.

Concerning the Inconel-600 Flow Stress:

b.

Figure 1 provides stress-strain behavior for Inconel-600 at 600 Degrees F through strains of about 1 percent. Plainly the material exhibits a pronounced yield at around 50 Ksi. To establish a value of "flow stress", which is the average of Yield and Ultimate stresses, a conservative approach was used. The value of Yield Stress which was adopted was 45 Ksi, which is more conservative than the 50 Ksi yield indicated in Fig. 1. The value of Ultimate Tensile Stress which was adopted was 80 Ksi, which is more conservative than the actual value (109.4 Ksi) furnished through Reference 10. The average of 45.0 and 80.0 Ksi is 62.5 Ksi flow stress, which is used in this calculation (to calculate "collapse load" Limit-moments) and also furnished to the PICEP program. It is noted that Collapse-load is proportional to flow stress in Reference 3. The collapse load, based on a flow stress other than 62.5 Ksi, can be determined by linear scaling. Concerning the Ramberg-Osgood fit to the Inconel-600 stress-strain curve: The Ramberg-Osgood correlation approximates the stress-strain behavior of relatively ductile materials through three parameters

1) Sigma-0

<5""0 which is generally the same as Yield stress;

2) n the exponent which characterizes the work-hardening "slo~e" (stress-vs-strain in the fully plastic region).

A high value of n indicates a relatively shallow slope, i.e. there is a great increase of plastic strain associated with a relatively small increase in stress. For practical purposes, n should lie between 2 and 10; a value which exceeds 10 indicates extreme non-linear behavior;

3) Alpha oC the constant which characterizes the transition region between fully-elastic and fully-plastic behavior.

(Lower alpha characterizes a more abrupt transition.) Since the Yield Stress can be reasonably established by other means, the Ramberg-Osgood fit requires that two stress-strain pairs be chosen as points where the fit is exact, thereby establishing n & alpha. The RO fit is otherwise an approximation with inherent inaccuracies, and cannot be made to continuously fit an actual stress-strain 0 Rev.

COMBUSTIOll~EllGlllEERlllG f' ME c. 011 IV 3 b. Calculation Number /7 Page Number Method of analysis; specific rocedure & assum tions, cont'd. curve. The inaccuracies are more evident when a (relatively) less ductile material is fit by RO. In this analysis, the effect of the RO fit is on the Crack-Opening-Displacement predicted by PICEP, which is in turn the basis for predicting flow rates. FOR A CONSERVATIVE ANALYSIS INVOLVING PREDICTIONS OF FLOW, it is important that strains NOT be over-predicted as the onset of plasticity is approached. For this analysis, the engineering judgement was to fit the RO correlation exactly at the UTS and max. elongation (from Ref.

10) and also at 0.4 percent strain, where a recognizable work-hardening slope begins.

The full-range comparison (RO fit versus actual) is shown in Figure 2; the overshoot of stresses at somewhat higher stresses/strains is a consequence of insisting on a fit as the 0.4 percent strain is approached. (The possibility of an RO fit using two points on the work-hardening portion of Figure 1 had been considered and subsequently declined; the calculated exponent n exceeded 20, and the engineering judgement was that this was not acceptable). Provided that the (50 Ksi, 0.4 percent strain) point in Figure 1 is an exact-fit point, this analysis is relatively insensitive to modest changes in the RO parameters n & alpha. The resulting n=6.256 and alpha=0.734 agrees reasonably with RO fits involving (relatively) high strength, low ductility steels.

c.

Concerning flow from critical-length cracks whose half-angle exceeds Ninety Degrees: PICEP results show that the effects of crack half-angle, theta on predicted flow is non-linear, as expected. As theta approaches ninety degrees, this effect becomes more pronounced. For example, results for the PORV nozzle predicted a 56 percent increase in flow (15.44 vs 9.79 gpm) corresponding to a 12 percent increase (100.3 vs 88.9 degrees) in angle (&hence crack length) under the same Normal Operation moment of 27150 inch-pounds. As crack half-angle is increased beyond Ninety Degrees, PICEP continues to give usable results but only over a limited additional range. There then comes a point where PICEP can no longer provide a meaningful result. Where flow is calculated from a critical length crack whose half-angle exceeds Ninety-Degrees, in some cases it is necessary to reduce the crack length somewhat in order to remain in the range of meaningful PICEP results. This procedure, when invoked out of necessity, produces a conservative prediction of flow rate, and is thus considered acceptable. Any redefinition of critica crac engt summary s ee. 0 Rev.

? i1E c.. Of/ 0 f-

g*

V.

SUMMARY

OF RESULTS

1.

Margin-to-failure for the cracked PORV nozzle safe end: Limit-moment based on observed crack---------319,886 inch-lbs RSS Moment Applied under Faulted Cond.------- 58,276 inch-lbs ratio of Limit-Moment to Faulted Cond.-------- 5.5

2.

Critical through-wall (circumferential) crack lengths: PORV nozzle safe end, Normal Operation------- PORV nozzle safe end, Faulted Condition------ Spray line, Normal Operation------------------- Spray line, Faulted Condition------------------ Surge line, Normal Operation------------------- Surge line, Faulted Condition------------------ 7.53 inches 6.81 inches 6.7 inches 5.2 inches 22.1 inches 18.6 inches

3.

Leakage rates associated with Critical through-wall flaws based on Normal Operation, and under Normal Operation conditions: PORV nozzle safe end--------------------------- 12.4 gal/min Spray nozzle----------------------------------- 77.3 gal/min Surge nozzle---------------------------------- 110.1 gal/min Values quoted are gallons-per-minute of 200 F water, equivalent.

4.

Comparison of results with factors of safety on load, crack size and leakage from draft NRC SRP 3.6.3: PORV nozzle safe end, leakage from Critical through-wall flaw (12.4 gpm), divided by detected leakage (0.2 gpm) is a safety factor of 62. This compares favorably with the SRP 3.6.3 safety factor of 10 on leakage rate. PORV nozzle safe end, Critical through-wall flaw length (6.81 inch) under Faulted Condition, divided by actual flaw (2.848 inch) is a safety factor of 2.39. This compares favorably with the SRP 3.6.3 safety factor of 2.00 on crack length PORV nozzle safe end, Collapse limit-moment (319,886 inch-pounds) based on observed flaw, divided by Faulted condition moment (58,276 inch-pounds), is a safety factor of 5.5. This compares favorably with the SRP 3.6.3 safety factor of 1.4 on load.

p ME c... O/I 0 REFERENCES

1.

Consumers Power Co., Docket 50-255, "Pressurizer Safe End Crack Engineering Analysis & Root Cause Evaluation", 07 OCT 1993.

2.

Electric Power Research Institute, PICEP: Pipe Crack Evaluation Program Revision 4, 18 DEC 1992.

3.

NUREG 1061, A2.0 "Description of Analytical Methodology", 1984.

4.

Consumers Power Co., "Section of the PORV Nozzle on Pressurizer T-72, Original Design", fax transm. 11:31 05 OCT 1993.

5.

Consumers Power Co., "Pressurizer Nozzle Loads", S. Ramalingam to P. Hammer, fax transm. 13:09 21 OCT 1993.

6.

Consumers Power Co., "Thermodynamic Conditions", S. Ramalingam to P. Hammer, fax transm. 13:56 25 OCT 1993.

7.

Consumers Power Company, Palisades Plant Piping and Instrument Diagram, Primary coolant System, Dwg M-201, Rev 31.

8.

Consumers Power Company, Palisades Plant, Piping Class Sheet, Dwg 5935-M-260, sheet l/CC, Rev. 17.

9.

Crane, Flow of Fluids, p. B-17, 1969.

10.

Consumers Power Co., James Wong, to ABB-CE, B. Lubin, "PORV line Crack Profile" fax. trasnm. 12:46 19 NOV 1993.

11.

EPRI Report NP-2957, "Fatigue Performance of Ni-Cr-Fe Alloy 600 under Typical PWR Steam Generator Conditions", March 1993

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APPENDIX A PICEP-4 ANALYSIS RESULTS SUMMARIZED f /1E c o// A - J .; C>)

Result from Picep Analysis of PORV nozzle safe end under N.Op PROGRAM INPUT: Applied Moment 27150 inch-lbs Crack Length at mid-radius 2.848 inches

• Thermodynamic conditions 2100 psia Saturated 642 degrees F steam quality 100%

80% 60% PROGRAM OUTPUT: Calculated Critical crack length ..... corresponding half-angle 7.53 104.5 Calculated Crack opening Calculated Flow Flow at 80% dry Flow at 60% dry fL/D equivalent 0.00223 0.261 0.283 0.311 37.8 porv501 porv502 porv503 . ~.L o II 1"0) A-2 Steam (dry) (dry) (dry) inches at mid-radius degrees inches gpm equiv. water

~- Result from Picep Arialysis of PORV nozzle saf~ end under Faulted condition (for determining L-critical) Applied Moment Crack Length at mid-radius Thermodynamic conditions 58276 inch-lbs (input) 2.848 inches (input) 2100 psia Saturated Steam 642 degrees F steam quality 100% (dry) O// A-3 Calculated Critical crack length ..... corresponding half-angle 6.81 94.5 inches at mid-radius degrees porv'511 0

Result from Picep Analysis of PORV nozzle safe end under Normal Operation loading; flow at L-critical from N. Op. cond. PROGRAM INPUT: Applied Moment Crack Length at mid-radius Thermodynamic conditions PROGRAM OUTPUT: Calculated Crack opening Calculated Flow fL/D equivalent 27150 inch-lbs 7.53 inches (exceeds 90 degrees) 2100 psia Saturated Steam 642 degrees F steam quality 100% (dry) 80% (dry) 60% (dry) 0.0245 inches 12.44 gpm equiv. water

• 13.47
  • 14.82 10.4 porv521x
• porv521y
  • porv521z Of/

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f A -.s-Result from Picep Analysis of Spray Nozzle -- Normal Operation Determine L-critical Applied Moment 41555 inch-lbs (input) Crack Length at mid-radius n/a (dummy 1.0 inch input) Thermodynamic conditions 2100 psia Subcooled Water at 549 degrees F Calculated Critical crack length ..... corresponding crack half-angle 6.702 94.5 pspn2207 inches degrees Of I

Result from Picep Analysis of Spray Nozzle -- Faulted Condition Determine L-~ritical Applied Moment Crack Length at mid-radius Thermodynamic conditions Calculated L-critical 114714 inch-lbs (input) 1.0 (dummy input) 2100 psia Subcooled Water at 549 degrees F 5.18 inches ..... corresponding_crack half-angle 73.1 degrees pspn22f7 o II

p Result from Picep Analysis of Spray Nozzle -- Normal Operation Loads Determine flow at L-critical from Normal Op. PROGRAM INPUT: Applied Moment 41555 inch-lbs Crack Length at mid-radius 6.702

• 6.3 inches (exceeds 11 (reset to Thermodynamic conditions 2100 psia Subcooled Water at 549 degrees F*

PROGRAM OUTPUT: Calculated Crack opening (.... subcooling = 95 degr.) 0.0427 inches

• 0.0314 inches

/'1 c A-7 90 degr.) 90 degr.) Calculated Flow 77.3

• 51.7 gpm equiv. water gpm II fL/D (Ninety-degree result, for information:

7.2

• 7.9 pspn4203
• pspn2203 o If

f ME C. A - g-Result from Picep Analysis of Surge Nozzle -- Normal Operation Determine L-critical Applied Moment Crack Length at mid-radius Thermodynamic conditions N45 57085 inch-lbs (input) n/a (dummy 1.0 inch input) 2100 psia Saturated Water at 642 degrees F 27 0// Calculated Critical crack length 22.09 inches at mid-radius ..... corresponding crack half-angle 108.9 degrees psgn33n4

A-1 Result from Picep Analysis of Surge Nozzle -- Faulted Condition Determine L-critical Applied Moment Crack Length at mid-radius Thermodynamic conditions N45 961568 inch-lbs (input) n/a (dummy 1.0 inch input) 2100 psia Saturated Water at 642 degrees F 27 o// Calculated Critical crack length 18.60 inches at mid-radius ..... corresponding crack half-angle 91.7 degrees psgn33f4

p -/'1E"- C-ol/ A-JO Result from Picep Analysis of Surge nozzle under Normal Operation loading; flow at L-critical from N. Op. cond. Applied Moment 57085 inch-lbs (input) Crack Length at mid-radius 20.0 inches (exceeds 9 0 deg) (approx. 90 degr) Thermodynamic conditions N45 Calculated Crack opening Calculated Flow fL/D equivalent

• 18.2 inches 2100 psia Saturated Water at 642 degrees F 27 0.0507 inches
• 0.0426 inches 110.1
• 82.3 19.4
• 18.4 gpm equiv. water II Note, PICEP prog~am limitations prevented analysis of the 22.09 inch critical crack length as this is well in excess of ninety degrees crack half-angle.

The crack length was redefined to 20 inches to obtain a meaningful result. Results for a crack length corresponding to a half-angle of ninety degrees are also furnished for information. See IV-3 of this calc. psgn43nl (For information

• psgn33nl)}}