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Rev 0 to Nine Mile Point Unit 1 CRD Return Nozzle Fatigue Evaluation.
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P>1MPRASSOCIATESINC.ENGINEERSMPR-1485Revision0April1994NineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluationPreyaredforNiagaraMohawkPowerCoryoration301PlainfieldRoadSyracuse,NY132129407010168940M3PDR.ADOCK05000220P'DR 0

Pi9MPRASSOCIATESINC.EN&INEERSNineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluationMPR-1485Revision0April1994PrincipalContributorsE.B.BirdJ.E.NestellR.S.PaulA.B.RussellPreparedforNiagaraMohawkPowerCorporation301PlainfieldRoadSyracuse,NY13212J.GawlerNMPCEngineer320KINGSTREETALEXANDRIA.VA22314-3238703-519-0200FAX:703.519-0224

Pa1MPRASSOCIATESINC.ENGINEE0SCONTENTSSection1INTRODUCTION1.1Background2SUMMARY3DISCUSSION3.1DesignandOperation3.2LoadCycleDefinition3.3StructuralAnalysis3.4FatigueEvaluation3.5FractureMechanics-CrackGrowthRate3.6ExperienceSurvey4REFERENCES5APPENDICES~Pae2-13-13-1.3-13-23-33-43-54-15-1APPENDIXAAPPENDIXBAPPENDIXCAPPENDIXDAPPENDIXEAPPENDIXFAPPENDIXGAPPENDIXHAPPENDIXICalculationofCRDRNozzleThermalandPressureCyclesCRDRNozzleFiniteElementModel,GeometryCRDRNozzleFiniteElementModel,MaterialPropertiesCalculationofHeatTransferCoefGcientsCRDRNozzleFiniteElementModel,BoundaryConditionsandResultsLowCycleFatigueUsageCrackGrowthRateComputerProgramVerificationCrackGrowthRateAnalysisCasesImplementationPlanA-1B-1C-1D-1E-1F-1G-1H-1

PA1MPRASS0CIATESINC.ENGINEERSLISTOFFIGURESF~Fiore3-13-23-33-43-53-6~DetcritiooCRDRNozzleDimensionsFiniteElementModelFiniteElementModelDetailsCalculatedTemperatureDistributionCalculatedStressIntensityDistributionFatigueCrackGrowth

Pa1MPRASSOCIATESINC.ENG'INEERSSection1INTRODUCTIONThepurposeofthisreportistodocumentafatigueevaluationoftheControlRodDriveReturn(CRDR)nozzleintheNineMilePointUnit1reactorvessel.Thenozzleisafourinchvesselpenetrationthatacceptslowtemperaturewaterfromthecontrolroddrivesystem.Theobjectivesoftheevaluationweretoestimate:1)thelong-termsusceptibilityoftheCRDRnozzletothermalfatiguecracking,and2)thecrackgrowthrateofapotentialflawintheCRDRnozzleovertheremaininglifeoftheplant.ThisevaluationwasundertakentosupportNiagaraMohawkPowerCorporation(NMPC)effortstoperformanultrasonicinspectionoftheCRDRnozzleinsteadofthedyepenetrantinspectionspecifiebyNUREG-0619.ThefatigueevaluationoftheCRDRnozzleconsideredthenumberofpressureandtemperaturecyclesthenozzlehasexperiencedtodateaswellasanestimateofthenumberoffuturecycles.Finiteelementstressanalysesofthenozzlewereperformedtodeterminethestressdistributioninthenozzleduetothepressureandtemperaturecycles.Stressanalysisresultswerethenusedtocalculatenozzlefatigueusageandcrackgrowthrates.1.1BACKGROUNDInthe1970's,anumberofBWRsdetectedsigniTicantcrackingoffeedwaterandCRDRnozzles.ThecracksintheCRDRnozzleswerecausedbythermalfatigueresultingfromchangesincoldCRDRflowatthenozzles,TheNRCissuedNUREG-0619,"BWRFeedwaterNozzleandControlRodDriveReturnLineNozzleCracking,"(Reference1)thatidentifiedinterimandlong-termrecommendationsregardingthisissue,includinginspectionrequirements.ForNineMilePointUnit1,theinspectionrequirementsincludeperformingadyepenetrant(PT)examinationoftheCRDRnozzleinternalsurfaceduringtheupcoming1995ref'uelingoutage.NMPCplanstoperformanultrasonic(UT)inspectionoftheCRDRnozzleinsteadofthedyepenetrantexaminationbasedonthefollowing:1.AutomatedUTinspectionsystemsarenowavailableforperformingaccurateinspectionsfromoutsidethevessel.UTinspectionsystemsatthetimeNUREG-0619wasissueddidnotprovidesufficientdetectionorflawsizingcapabilities.2.TheCRDRnozzlethermalsleevedesign(weldedinplace)makesthenozzlelesssusceptibletothermalfatiguecrackingthantheoriginaldesignsatotherBWRs.Infact,nodamagetotheCRDRnozzlewasfoundduringthe1977in-vesselPTexaminationorinanysubsequentexamination.1-1

3.DetailedanalyticmodelingoftheCRDRnozzleshowsthatsmallsurfaceflawswillnotgrowtounacceptablevalueswithinspecifiedoperatingperiods.ThisreportaddressesItem3abovefortheCRDRnozzle.Inaddition,thisreportdocumentstheresultsofasurveyofBWRsregardingCRDRnozzleinspectionhistoryandexperience.TheimplementationplanforthistaskisprovidedinAppendixI.1-2

P&qMPRASSOCIATESINC.ENGINEERSSection2SUMMARYThreepressureandtemperaturecycleswereidentifiedfortheCRDRnozzle:startup/shutdown,reactorscram,andhydrostatictest.ThesecyclearedefinedfortheCRDRnozzleasfollows:Startup/Shutdown-areactorvesselheatup/cooldownbetweenpoweroperationandshutdownorstandbyconditionswheretheshutdownisachievedmanuallybyplantoperators.ReactorScram-astartup/shutdowncyclewheretheshutdownisachievedbyareactorscram.~HydrostaticTest-reactorvesselpressurizationanddepressurizationtoidentifyleakspriortopowerascension.Thenumberofcyclesexperiencedtodate,thenumberofcyclesexperiencedsincethe1977PTinspectionandtheprojectednumberofcyclesinthefuturearelistedbelow.Startup/ShutdownReactorScramHydrostaticTestNumberofCyclestoDate9610018NumberofCyclesSince1977PTInspection38279ProjectedNumberofCyclesperYear5ThereactorscramtransientisthelimitingcycleforCRDRnozzlestresses,Finiteelementmodelingofthethermaltransientshowsthatthepeakstressintensityinthebasemetaloccursattheendofthetransientintheboreofthenozzlejustabovetheblendregion.Thepeakstressintensityduetopressureandtemperaturewascalculatedtobe110ksi.FatigueanalysesshowthatfatigueusagefortheCRDRnozzleisverylow(approximately0.003peroperatingyear).Forthecalculatedstressandthenumberofcyclesexperiencedtodate,afatiguecrackwouldnotbepredictedtoinitiateinthe2-1

CRDRnozzleatthepresenttime.Consideringthecalculatedstressandthenumberofcyclesexpectedinthef'uture,afatiguecrackisnotpredictedwithinthelifeoftheplant.Fracturemechanicscalculationsshowthatapostulated1/4inchflawlocatedinthehigheststressedregionofthenozzlewouldnotgrowtoanunacceptablesizewithinthelifeoftheplant.Thepostulated1/4inchQawiscalculatedtogrowtoadepthofonly0.4inchesin40years.A0.4inchflawdoesnotexceedtheallowableQawsizefortheanalyzedsectionofthenozzlewhichisapproximately0.5inchesbasedoncriteriagiveninSectionXIoftheASMECode.TheallowableQawsizeprovidessigniTicantmargintoensurethenozzledoesnotfailbybrittlef'racture.2-2

PAIMPRASSOCIATESINC.EN&INEERSSection3DISCUSSION3.1DESIGNANDOPERATIONTheNMP-1ControlRodDriveReturn(CRDR)nozzleisa4-inchreactorvesselpenetrationlocatedatthesameelevationasthefeedwaternozzle.Figure3-1isasectionviewofthenozzlewhichshowsselecteddimensions.TheCRDRnozzleisequippedwithathermalsleevewhichisweldedtotheCRDRnozzleatthesleeveinletandextendsintothereactordowncomerwithacircularplateattheend.ThisdesignisintendedtoprotecttheboreofthenozzleandthevesselwalladjacenttothenozzlefromtherelativelycoldCRDRflow.TheControlRodDrive(CRD)Systemprovideswaterfromthecondensatestoragetankatatemperatureofabout70'Ftothecontrolroddrivemechanismstocoolthecontrolroddrives,torepositionrods,andtoscramtherods.Undertypicalplantconditions,thesystemoperatesatalltimeswhenfuelisinthevessel.Duringnormaloperation,flowfromtheCRDpumpsismaintainedrelativelyconstantwithaportionoftheflowrecirculatedtothecondensatestoragetank,about30-47gpmoftheflowusedforcontrolroddrivemechanismcooling,andabout17-35gpm(theremainingflow)returnedtothevesselviatheCRDRnozzle.Someaccidentsequencesinvolvingloss-of-offsitepowermayresultinsystemshutdownforashortperiodoftime,Theseaccidentsequencesarenotconsideredforthisanalysis.TheflowratedoesnotchangeasaresultofrepositioningacontrolrodsincetheflowdivertedtomovetherodiscompensatedbythewaterdisplacedbytheroddrivewhichisroutedtotheCRDRline.AreactorscramresultsinaCRDRnozzleflowtransient.Duringascram,theCRDRaccumulatorsdischargetodrivethecontrolrodsintothecore.ThisresultsinanincreaseinCRDRnozzleflowto65gpm.Whenaccumulatorpressuredropsbelowreactorpressure,CRDRflowrategoestozeroastheaccumulatorsarerecharged.Aftertheaccumulatorshavebeenrecharged,CRDRflowratereturnstothenominal17to35gpm.3.2LOADCYCLEDEFINITIONTable3-1liststhepressureandtemperaturecycleswhichwereconsideredinthestructuralevaluation.Thenumberofcycleswasdeterminedfromplantdataregardingthenumberofplantstartups/shutdownsandscrams.Thecyclesaredefinedasfollows:3-1 0

~Startup/Shutdown-areactorvesselheatup/cooldownbetweenpoweroperationandshutdownorstandbyconditionswheretheshutdownisachievedmanuallybyplantoperators.~ReactorScram-astartup/shutdowncyclewheretheshutdownisachievedbyareactorscram.~HydrostaticTest-reactorvesselpressurizationanddepressurizationtoidentifyleakspriortopowerascension.Thenumberofannualcyclesexpectedinthefutureisconservativelyestimatedtobe50%morethantheaverageannualnumberofcyclesthatoccurredoverthepast10years.AcalculationofoperatingcyclesispresentedinAppendix'A.33STRUCTURALANALYSISStressanalyseswereperformedtodeterminethestressesforthefatigueandcrackgrowthrateanalysesdescribedinSection3.4and3.5below.Transientthermalanalyseswereperformedtocalculatethetemperaturedistributioninthenozzleasafunctionoftimeforthereactorscramtransient.Steadystatestressesduetopressureandtemperaturewerecalculatedatspecifiedtimeintervalsthroughoutthetransient.Thesectionsbelowdescribethefiniteelementmodel,materialproperties,boundaryconditions,andresults.33.1FiniteElementModelTheANSYScomputerprogramwasusedtodevelopafiniteelementmodeloftheCRDRnozzle.ThemodelincludestheCRDRnozzleitselfandasufficientlengthofthereactorvesselshellandattachedCRDRpipingtoeliminateinteractionbetweentheCRDRnozzleandthestructuralboundaryconditionsappliedtotheedgesofthevesselshellandattachedpiping.Thethree-dimensionalnozzle-to-cylinderintersectionwasmodeledwithatwo-dimensionalaxisymmetricmodelofanozzleinasphere.Theequivalentsphericalradiuswaschosentobe3.2timestheradiusofthereactorvesselcylindertoinsurethatthemaximumhoopstressandstressintensitycalculatedbytheaxisymmetricmodelwouldbecomparabletothoseintheactualthree-dimensionalintersection.AppendixBdocumentsthefiniteelementmodel.ThefiniteelementmeshoftheCRDRnozzleisshowninFigures3-2and3-3.33.2MaterialProertiesThemodeloftheCRDRnozzleiscomposedofthreeregionswithdifferentmaterialproperties.ThereactorvesselwallisSA302GradeBlowalloysteel.TheCRDRnozzleisanSA336lowalloysteelforgingwithASMECodeCase1236-1fornickeladdition.ThecladisassumedtobeType308stainlesssteel.3-2

Temperaturedependentmaterialpropertieswereusedinthethermal'a'ndstressanalysesoftheCRDRnozzle.AppendixCdocumentsthematerialpropertiesusedintheanalyses.399ThermalBoundaConditionsThermalboundaryconditionsforthereactorscramtransientarediscussedindetailinAppendicesDandEandsummarizedbelow.Thelastportionofthereactorscramtransientwasmodeled.Initially,theCRDRnozzleisatauniformtemperatureof525'FcorrespondingtozeroflowthroughtheCRDRnozzleastheaccumulatorsarerecharged.Atthestartofthetransient,theCRDRflowrateisstepchangedtoit'snominalvalueof35gpmwithafluidtemperatureof70'F.HeattransfercoefficientsandbulkfluidtemperaturesareappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Allothersurfacesareassumedtobeadiabatic(insulated).AppendixDisacalculationoftheheattransfercoefficientinth'eCRDRnozzlebore.TheoverallheattransfercoefficientbetweentheCRDRfluidandthenozzleborewhichincludestheeffectsofthethermalsleeveandwaterannuluswascalculatedtobe100BTU/hr-ft~-'F.Thisincludestheeffectsofthefluidfilmontheinsidesurfaceofthethermalsleeve,conductionthroughthethermalsleeve,andnaturalconvectionthroughthestagnantfluidlayerbetweenthethermalsleeveandthenozzlebore.Aheattransfercoefficientof1000BTU/hr-ft2-'Fwasusedbetweenthebulkdowncomerfluidtemperatureandthevesselwall.39.4StructuralBoundaConditionsThestructuralboundaryconditionsforthestressanalysisincludeappliedpressuresanddisplacements(AppendixE).Apressureof1250psigwasappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Anegativepressurewasappliedtothesafeendtosimulatetheaxialloadintheattachedpiping.Attheendofthereactorvesselwall,symmetryboundaryconditionsareappliedtopermitradialdisplacementandtoprohibitrotation.Atthesafeend,couplesareusedtoallowtranslationofthesafeendbuttoprohibitrotation.39.5ResultsThepeakstressintensityinthebasemetaloccursattheendofthescramtransient.Figure3-4showsthecalculatedtemperaturedistributionattheendofthetransient.Figure3-5showsthecalculatedstressintensitydistributionattheendofthetransient.Thepeakstress(110ksi)inthebasemetaloccursintheboreoftheCRDRnozzleatthebasemetaltocladdinginterface,justabovetheblendintothevesselwall.Theprincipalcomponentofthestressintensityishoopstress.3-3

3.4FATIGUEEVALUATIONAfatigueevaluationoftheCRDRnozzlewasperformedbasedontheloadcyclesdefinedinSection3.2andtheresultsofthefiniteelementstressanalysisdiscussedinSection3.3.Nozzlefatigueusageforcurrentplantoperationconditionswasevaluatedonapercyclebasis.AsdiscussedinSection3.2,theCRDRnozzleissubjecttostartup/shutdowncyclesandstartup/scramcycles.Fatigueusagewascalculatedforbothofthesecycles.Thenozzlealsoundergoeshydrostatictesting;however,thiscycleisboundedbythepressure-temperatureconditionsduringastartup/shutdowncycle.Fatigueusageiscalculatedby:u=gnNwhere:u=fatigueusagen=numberofcycleswhichoccurN=numberofallowablecyclesbasedonthecyclicstressesAfatigueusageof1.0indicatesthatthereisapotentialforfatiguecrackinitiationinthenozzle.TheallowablecyclesaredeterminedfromtheASMECodeDesignFatigueCurveforCarbon,LowAlloyandHighTensileSteels(Reference2,FigureI-9.1).Thiscurveprovidesaconservativenumberofallowablecyclesforagivenalternatingstressrange(safetyfactorshavealreadybeenapplied).Therefore,useofthiscurvefortheusageevaluationprovidesaconservativeestimateoffatigueusageforthenozzle.Calculationoffatigueusageforstartup/shutdownandstartup/scramcyclesaredocumentedinAppendixF.Thecalculationisperformedusingthepeakstressintensityrangeonthebasemetalinsidesurfaceofthenozzleforeachofthecycles.Thefatigueusageforthenozzlewascalculatedtobe1.963x10~perstartup/shutdowncycleand3.848x10perstartup/scramcycle.Basedonrecentplantoperatinghistory,thereareapproximatelyfivestartup/shutdowncycles,onehydrostatictestandfourstartup/scramcyclesperyear,whichcorrespondstoanannualfatigueusageof0.003.3.5FRACTUREMECHANICS-CRACKGROWTHRATECrackgrowthofanassumedpre-existingfiawinthenozzleduetothepressureandthermalcyclesdefinedinSection3.2isanalyzedusingthePariscrackgrowthrateequation:=C(AK)dN3-4

\where:crackgrowthrate(inches/cycle)daGnstressintensityfactorrange(ksiPin)C,m=constants(dependentonmaterial,environment,andloading)CandmaretakenfromtheASMEcrackgrowthcurveforsurfaceQawsinawaterreactorenvironment(Reference2,FigureA-4300-1).Thestressintensityfactorrangeisthemaximumchangeinstressintensityfactorduringthegivencycle.Stressintensityfactorisafunctionofstressandcracksize.AsdescribedinSection3.3,stresseswereanalyzedbyQniteelementanalysis,UsingtheQniteelementmodelresults,asectionthoughthenozzlewall,passingthroughthepeaksurfacestressesontheinsideandoutsidesurfacesofthenozzle,wasdetermined.Thissectionislocatedintheblendregionofthenozzleneartothetransitiontotheboreregion.AthirdorderpolynomialwasQittothestressesthroughthesectionasafunctionofdepththroughthenozzle.StressintensityfactorsweredeterminedbythemethodsofReference3.Stressintensityfactorsarecalculatedasaf'unctionofcracksizeandthepolynomialcoefficientsfromthecubicstressdistribution.AcomputerprogramthatcalculatescrackgrowthbasedonthemethoddescribedabovewasdevelopedtoanalyzeassumedQawsinthenozzle.TheprogramdescriptionandveriQcationaredocumentedinAppendixG.InputsandresultsofthecrackgrowthanalysisareprovidedinAppendixH.Theresultsofthecrackgrowthanalysis,assuminganinitialQawsizeof0.25inches,areshowninFigure3-6.AsshowninFigure3-6,theassumed0.25inchinitialQawwillgrowtoapproximately0.40inchesin40yearsofoperation.TheresultsindicateaverysmallcrackgrowthrateforacrackintheCRDRnozzle.Inaddition,the0.40inchfinalQawsizeislessthantheallowableQawsizeof0.5inches.TheallowableflawsizefortheanalyzedsectionofthenozzlewasdeterminedfromcriteriagiveninSectionXIoftheASMECode[Ref.2].DeterminationoftheallowableQawsizeisdocumentedinAppendixH.Anallowableflawsizeof0,5inchesprovidessigniQcantmargintoensurethenozzlewillnotfailbybrittlefracture.Theappliedstressintensityfactorfora0.5inchflawunderthemostseverestressconditionsinthenozzleisapproximately81ksiIin.ThenozzleisnotpredictedtofailbybrittlefractureuntiltheappliedstressintensityfactorexceedsthecriticalstressintensityfactorfortheCRDRnozzlematerial.Atnormaloperatingtemperaturesthecriticalstressintensityfactorisapproximately200ksiIin,whichismorethantwicetheappliedstressintensityfactorofthe0.5inchallowableflaw.3-5

3.6EXPERIENCESURVEYAsurveywasperformedtodeterminetheexperiencesofotherutilitieswithregardtoCRDRnozzlecracking.NUREG-0619responsestotheNRCfromutilitiesoperatingBWRplantswerereviewedtodeterminehowtheCRDRnozzlecrackingissuewasresolvedateachoftheplants.Inaddition,severalutilitieswerecontactedtodeterminemoredetailedinformationaboutinspectionpracticesfortheCRDRnozzle.Theresultsaresurnrnarizedbelow.ReviewofutilityresponsestotheNRCindicatedthatalmostalloperatingBWRscutandcappedtheCRDRreturnline,eitherwithorwithoutflowrerouted'toanothersystem.PlantswithacappedCRDRnozzlearenotrequiredbyNUREG-0619toperforminspectionsofthenozzle(besidesafinalPTinspectionrequiredpriortocappingthenozzle).However,someplantswereoperatedforextendedperiodsoftimewiththeCRDreturnlinevalvedout,whichNUREG-0619considerstobeatemporarysolution.Inaddition,oneplant,OysterCreekNuclearGeneratingStation,hascontinuedtooperatewithCRDreturnlineflowthroughtheCRDRnozzle.OysterCreekistheonlyotherplantbesidesNMPUnit1permittedtooperatewiththeCRDRnozzleinservice,Severalplants,includingOysterCreek,werecontactedtodetermineinformationaboutinspectiontechniquesandresultsofnozzleinspections.Twooftheplantscontacted,DuaneArnoldEnergyCenterandQuad-CitiesStation,foundcracksintheCRDRnozzleduringrecentinspections(pastGiveyears).AtDuaneArnold,theCRDreturnlinewasvalvedoutandcappedwithablindflangein1982.DuringavisualinspectionoftheCRDRnozzlein1990,evidenceofcrackingwasfoundandafullPTexaminationwasperformed.Acrackapproximately3incheslongand0.25inchesdeep,justpenetratingintothebasemetalofthenozzle,wasfoundandgroundout.Thenozzleprobablyhadathermalsleeveinstalledpriortobeingcapped;however,thetypeofthermalsleeveisunknown.Theplantperformsavisualinspectionofthenozzleeveryoutage,butdoesnotperformanyultrasonicinspections.QuadCitiesoperatedwiththeCRDreturnlineinavalved-outconflgurationuntil1989whencrackingwasfoundintheCRDRnozzle.Duringthisperiodofoperation,theCRDreturnlinewasvisuallyinspectedeveryoutage.Asaresultofthecracking,theCRDreturnlinewascutandcappedin1989.Sincethattimenoinspectionsofthenozzlehavebeenperformed.Inbothofthesecases,crackingwasfoundafterasigniflcantperiodofoperationwiththeCRDRnozzleisolatedfromCRDRflow.Mostlikely,crackinginitiatedpriortoisolationoftheCRDRflow,butwasnotidentifleduntillaterinspections,OysterCreekistheonlyotherplant(besidesNileMilePointUnit1)allowedbyNUREG-0619tooperatewithflowtotheCRDRnozzle.SimilartoNMPUnit1,OysterCreekappliedforanexemptionoftheNUREG-0619requirementsfortheCRDRnozzle,includingthescheduledPTexamination.Basedonautomatedultrasonic~~~~(UT)examinationsoftheCRDRnozzle,whichdidnotidentifyanyindications,OysterreekwasgivenanexemptionfromthenozzlePTexaminationuntilthenextrefuelingoutage.QualiflcationoftheUTsystemwasperformedusingamock-upoftheCRDRnozzle.EventhoughtheUTsystemwasdesignedspecificallyforthenozzlegeometry,3-6

Itherewereseveralproblemsencounteredduringsetupofthesystem.MountingthesystemtooklongerthantypicalUTsystemsduetospaceconstraintsaroundthenozzle.Inaddition,removalofthemirrorinsulationaroundthenozzleareawasexpensiveandtimeconsuming.Aftertheinspection,anewtypeofremovableinsulationwasinstalledtoprovideeasieraccessforfutureinstallations.3-7 0

Table3-1CRDRNozzlePressureandTemperatureCyclesDescription1NormalStartup/Shutdown2ReactorScram3InitialHydro4RefuelingHydro510yearISIHydroReactorVesselPressure(psi)01030-0103012500187500>>1030-0011330DowncomerFluidTemperature('F)70-525-70250250250CRDRNozzleFluidTemperature('F)7070<<525<<70707070NumberofCyclestoDate9615NumberofCyclesExpectedperYear5.03.90.01.00.1

23e~')ASSCQ.SKQIgCULCLI'QTLRe~It$0JiVc48>~~~mt'TTIcuenor.~~tgncuovr.lup~tITb~+prre<v+'.i)aeisa)~'Mi7(Sb~T.IL)Z1VOVreeaaRCr.)4~~q~'-iTYTT,SYSIEIIgETUTPTTuCJLEKSQ'YFigure3-1.CRDRNozzleDimensions

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i0 ANSYS5.0APR4199416:33:47PLOTNO.1NODALSOLUTIONSTEP=2SUB=21TIME=3601TEMPTEPC=9.434SMN=88.846SMX=523.56288.846100200300400500600Figure3-4.CalculatedTemperatureDistribution

4hrentawQ~7Qp:PANSYS5.0MAR31199410:40:18PLOTNO.1NODALSOLUTIONSTEP=14SUB=1TIME=3600SINT(AVG)DMX=1.462SMN=3533SMNB=2569SMX=96413SMXB=1050083533138532417334493448135513365453757738609396413'+~~Figure3-5.CalculatedStressIntensityDistribution

0.440.420.400.38~0.36~0.34(~p0.32.0.3000.280.260.240.220.20050IIIIIIIITIIIII100150200250300350400Cycles(10cyclesperyear}Figure3-6.FatigueCrackGrowth

PD1MPRASSOCIATESINC.EN&INEEITSSection4REFERENCES1.NUREG-0619,"BWRFeedwaterNozzleandControlRodDriveReturnLineNozzleCracking,November1980.2.ASMEBoilerandPressureVesselCode,1980EditionwithAddenda.3.Buchalet,'C.B.,andBamford,'.W.H.,"StressIntensityFactorSolutionsforContinuousSurfaceFlawsinReactorPressureVessel,"ASTM-STP-590,1975.4-1 I'

rpMPRENGINEERSSection5APPENDICESA.CalculationofCRDRNozzleThermalandPressureCyclesB.CRDRNozzleFiniteElementModel,GeometryC.CRDRNozzleFiniteElementModel,MaterialPropertiesD.CalculationofHeatTransferCoefficientsE.CRDRNozzleFiniteElementModel,BoundaryConditionsandResultsF.LowCycleFatigueUsageG.CrackGrowthRateComputerProgramVerificationH.CrackGrowthRateAnalysisCasesI.ImplementationPlan5-1

FA1MPRSSOCIATESINC.ENGINEERSAppendixACALCULATIONOFCRDRNOZZLETHERMALANDPRESSURECYCLES

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NINEMILEPOINTUNITNON-CFIITICALHYDROTEST14001200O'I000800614eoOK4003600O200NCN-CRITICALOPERATIONMINllvLMTEMPI=TLREFORBOLTLP100F100130050100'150200250800850REACTORVESSELBELTLINEDOWNCOMERNATERTEMPERATURE(F)(reactorvesselbelt!incdowncomerwatertemperatureismeasuredatrecirculationloopsuction)FIGURE3.2.2.eMINIMUMSELTLINEDOWNCOMERWATERTEMPERATUREFORPRESSURIZATIONDURINGIN-SERVICEHYDROSTATICTFSTINGAND'LEAKTESTING(REACTORNOT.CRITICAL)FORUPTO18EFFECTIVEFULLPOWERYEARSOFOPERATIONAmendmentIio.pn,p,pnl27

PDIMPRASSOCIATESINC.ENGINEERSAppendixBCRDRNOZZLEFINITEELEMENTMODELGEOMETRY

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WMPQMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.ops-z~-685-ol'7S'CheckedByPagePurposeThepurposeofthiscalculationistodocumentthegeometricinputdataforafiniteelementanalysisoftheNiagaraMohawkPowerCorporation,NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransientthermal/stressanalysissimulatingareactorscramwasperformed.References1and2arecalculationswhichdocumentthefiniteelementmodelmaterialpropertiesandboundaryconditions/results.TheANSYScomputerprogram(Reference3)wasusedtocalculatethetransienttemperaturedistributioninanaxisymmetricmodelofthenozzle.Theprogramwasthenusedtocalculatestressprofilesduetopressureandduetothecalculatedtemperaturedistribution.Theresultsofthisanalysis,intheformofstressdistributionsthroughthebore/blendsectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluationoftheCRDreturnnozzle.DiscussionFigure1isadrawingoftheCRDreturnnozzlewhichshowspertinentdimensions(Reference4).Thedimensionsusedintheanalysisareasfollows:VesselRadiusRVVesselThicknessTVCladThicknessCLADAngularExtentANG1106.7*3.2inches7.125inches.2188inches8degreesOtherdimensionsfromFigure1areasfollows:NozzleBoreNozzleODSafeEndODVesselCutOutR1R2R3R42.061inches4.813inches2A69inches5.563inches8.688inches4.125inches1.344inchesSafeEndH1SafeEndH2SafeEndH3Theradialdimensionsforthenozzlebore,R1,andthevessel,RV,aretothebasemetal-claddinginterface.Thesedimensionsshouldbereducedbythethicknessof

OlxlMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.4785-g~)t-Q,S-OICheckedByP~74uPagethecladding(7/32").Thisdiscrepancybetweenthefiniteelementmodelandthedrawingdimensionsshouldhaveanegligibleaffectonthecalculatedstresses.Figures2and3showtheaxisymmetricfiniteelementmodelofthenozzle.The'xisymrnetricmodelusesaradius3.2timestheactualradiusofthereactorvessel.Thisistoinsurethemaximumhoopstressandstressintensityfromthemodelwillbecomparabletothoseintheactualthree-dimensionalintersection(Reference5).Theangularextentofthefiniteelementmodelaffectsthenumberofelementsinthemodelandconsequentlythecomputerrunningtimeforthemodel.Theangularextentassumedintheseanalysesis8degrees.Thisextentwasselectedbyperformingpressureonlyloadcaseswithmodelsofvaryingextentandevaluatingthestressesatthevesselcutline.Thepressureanalysesshowedthat8degreesissufficientlyfarfromtheCRDreturnnozzlesuchthatthestressdistributionatthevesselcutlineisuniform.Reference6istheANSYSoutputfilewhichshowsthePREP7echooftheinputdata.ReferencesMPRCalculation085-229-EBB-02,"CRDRNozzleFiniteElementModelMaterialProperties",Revision0.2.MPRCalculation085-229-EBB-03,"CRDRNozzleFiniteElementModelBoundaryConditionsandResults",Revision0.3.ANSYScomputerprogramversion5.0.4CombustionEngineeringReportCENC1142,"AnalyticalReportForNiagaraMohawkReactorVessel",drawingnumber231-567-7.5.J.B.TruittandP.P.Raju,ASME-78-PVP-6,"Three-DimensionalVersusAxisymmetricFiniteElementAnalysisofaCylindricalVesselInletNozzleSubjecttoInternalPressure,AComparativeStudy"6.7.MPRCalculation"Geometry",tasknumber85-31"LowFlowFeedwaterControlSystem",2/28/83.ANSYSoutputfileNOZZLE.OUT,87,853bytesdated4-04-943:45:28pm.

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pfPath:C:)NOZZLEFile:GEOM.INP1,511.a..3-24-941:30:36pm/PREP7/TITLE,NMPUnit1CRDReturnNozzlePageg~!ReactorVesselModifiedRadius!ReactorVesselWallThicknessRV=(106.+23/32)*3.2TV=7.125ANG1=82ANG2=90CLAD=7/32R1=4.122/2R2=(9+5/8)/2R3=(4+15/16)/2R4=(11+1/8)/2H1=8+ll/16H2=4+1/8H3=1+11/32tm~4~~44gtcilcrc~!MaterialPropertyMacroMATLCSYS,1PCIRC~RVgRV+TVgANGlgANG2CSYS,ORECTNGIOgRlgRV2gRV+TVASBA,1,2RECTNGiRliR2IRV+TV/2iRV+TV+HlH2RECTNG~RlgR3gRV+TV+HlH2gRV+TV+HlH3RECTNGgRlgR3~RV+TV+HlH3IRV+TV+HlP'<0'A'wclia//g"JimrnJ/oe~rn~py~g/,~Pvrr/gu~4W4~~<<ckXcl~Qj~J/~2(/XAcIC~j'//jZ,7AJI/isa"ysPPl=KP(R3,RV+TV+Hl-H2,0)P2KP(R2IRV+TV+HlH2IO)P3=KP(R3,RV+TV+Hl-H3,0)A,P1,P2,P3AADD,ALLYF=SQRT((RV+TV)**2-R2**2)RADIUSgR2JYFgO/1~5YF=SQRT(RV**2-R2**2)RADIUSgR2gYFgOgl~25RADIUS/R2IRV+TV+HlH2JO/1~0RADIUS/R3gRV+TV+HlH3gOI1~0LSELgS~LOCgXgR1LCOMB,ALLCSYS,1LSELgSgLOCgXgRV2IRV+2Clirm~z~J'"4v/C~S/c~/~l~lr/~p"r/v~~MPRASSOC!ATFS,i!i,'g.CalculationNo.os-42$'-Kdd-ofPfoparedByChcc'(c<Jf"yBow~

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~&qMPRASSOCIATESINCENGINEERSAppendixCCRDRNOZZLEFINITEElEMENTMODELMATERIALPROPERTIES

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PRIMP'PRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.+g-gag-$3/f-0ZPreparedByCheckedByPageg~PuroeeThepurposeofthiscalculationistodocumentthematerialpropertiesusedinafiniteelementanalysisoftheNiagaraMohawkPowerCorporation,NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.TheANSYScomputerprogramwasusedtocalculatethetransienttemperaturedistributioninthenozzle.Inaddition,theprogramwasusedtocalculatestressprofilesduetopressureandduetothecalculatedtemperaturedistribution.Thematerialpropertiesrequiredintheanalysesare:ElasticModulusCoefficientofThermalExpansionThermalConductivitySpecificHeatPoisson'sRatioDensityDiscussionFigure1showsaschematicoftheCRDRnozzleoutline.Thenozzlemodeliscomposedofthreeregionswithdistinctmaterialproperties.~Region1isthereactorvesselwall.ThevesselwallmaterialisSA302GradeB(Mn-1/2Mo),Reference1.~Region2istheCRDRnozzle.ThenozzlematerialisSA336withASMECodeCase1236-1,Reference1.EquivalentmaterialisSA508Class2(3/4Ni-1/2Mo-1/3Cr-V)asdiscussedbelow.~Region3istheClad,assumedtobetype308StainlessSteel.StainlessSteelType304,18Cr-8Nimaterialpropertiesareaclosematchandareusedinthisanalysis.Previousfiniteelementanalysesofthefeedwaternozzleused1980ASMECodematerialproperties(Reference2).Inthatcalculation,acomparisonofmaterialchemicalcompositionbetweentheoriginal1964specificationandthe1980Codewasmade.Thecomparisonshowedthatforthevesselwall1980ASMECodematerialpropertieswereequivalent.Thecalculationalsoshowedthattheequivalentmaterial

lxHMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.de-d45'+44-ozCheckedByS~mt~~PageypropertyforthenozzlewasSA508Class2(3/4Ni-1/2Mo-1/3Cr-V).ThesamematerialpropertiesusedinthepreviouscalculationforthefeedwaternozzleandvesselwallareusedinthisanalysisfortheCRDReturnnozzleandvesselwallrespectively.ResultsTemperaturedependentmaterialpropertiesarelistedinTables1through3forthereactorvesselwall,CRDReturnnozzleandcladdingrespectively.AttachmentAisalistingoftheANSYSmacroMATL.MACwhichisthecomputerprograminputdataformaterialproperties.(Theinputdataalsolistsheattransfercoefficients.)Forallthreematerials,adensityof489Ib/ftandPoisson'sRatioof0.3wereused(Reference3).Thereferencetemperatureforthecoefficientofthermalexpansion(REFTinfileMATL.MAC)is70'Fforthenozzleandvesselwall.Forthecladdingmaterial,theaveragetemperaturebetweenthedowncomerandnozzlefluidtemperaturesatfullpowerconditionswasusedforthereferencetemperaturetoapproximatetheresidualstressstateinthecladding.Specificheatwascalculatedfromthermaldiffusivitybythefollowingformula:Cp=K/(Rho*TD)Where:CpKRhoTDSpecificHeat(btu/Ib-'F)ThermalConductivity(btu/hr-ft-'F)Density(Ib/ft)ThermalDiffusivity(ft/hr)ReferencesCombustionEngineeringReportCENC1142,"AnalyticalReportForNiagaraMohawkReactorVessel",pageA-78.2.MPRCalculation"MaterialProperties",tasknumber85-31"LowFeed-waterFlowControl",2/28/93.3.StandardHandbookForMechanicalEngineers,SeventhEdition,pages5-6and6-7.

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wiiMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.gg~+g$'-prZ8-azPreparedByw<W./CheckedByPagegTable1,MaterialProperties-SA302GradeBCarbonMolybdenum(Mn-1/2Mo)":"~sg!i%~:.,:,ii~iq'~~c,"..'...i:,.',.);..."'(10apepsi)~'.<<x.;.,::.::Exp'a'rision',"',';:~'l:,:::,:,:;:I,:';,Cor'iductiyity',";,!k::';.'-.:".::;::.;':.::::.:',::(ee'a'r'i.::,iafii'e)'.m.':~'::"::.'::I<(Btulhi;-:,':ft';,,F)'4'::,:;.,pe'ciho'::.;',';:(Btb1lb';.,F).jI7010015020025030035040045050055060029.2029.0428.7728.5028.2528.0027.7027.4027.2027.0026.7026.407.027.067.167.257.347.437.507.587.637.707.777.8323.323.624.124.424.624.724.724.624.424.223.923.5.1047.1070.1110.1142~1173.1203.1235.1264.1286.1313.1343.1361

~i MPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.Od~-g2g-E.g/P-o2-PreparedByCheckedByPdb/R~~Pagep.Table2MaterialProperties-SA336withCodeCase1236-1EquivalenttoSA508Class2(3/4¹i1/2Mo-1/3Cr-V)70100150200250300350400450500550600Mo'du!.'Us~of'.:,":Ela'sticity",:;:E:;'::,'~"..=;;(10:::;:;psi):::;:"':29.7029.5429.2729.0028.7528.5028.2027.9027.7027.5027.2026.90.":.:::Co'etficie'nt<of~~'.:,."'I';:I:'::::.j'(me'an'j~yaIue}<~",,-::,'.:,i';:::;:I::(1;0;.:,.',;.~!n/iril,;,F)km,:.,6.416.506.576.676.776.876.987.077.157.257.347.42'IG'ondiictiyity'.:k,I,l'j<:(Btu/hr',-:,,',ft-."':,F(}':,-';:I:.-;,23.623.723.924.024.023.923.723.623.323.122.722.4K,"m,'(Bi'u/ib;-";,,F}',;",'",:~1063.1084.~1118.1149.1180.1204.1224.1254.1274.1305.1326.1351ModulusofElasticityvaluesarefor1/2-2CrChromeMolybdenum.

~r>1MPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.dA-gg5'-8/-oz-PreparedByCheckedByPo'in.~Page8Table3MaterialProperties-StainlessSteelType308Type304PropertiesUsted(18Cr-8Ni),;:!Tem'jeratu'r'e">r:.>M,odulus:,.",,of;:;:.;.::,:I>Ela'sticjtj-::>E,::'::.,'.<<'(<1Q~;>,psl)i&py>..,"'::;;;.:,:,::,"',;.'.(incan~;yafii'e)>>-",-:.',':,'::,.':,:?(Btu'jar,;-'.:ft'-,,',.F)';:;,,,':Ni>>'"<a,-',>,'..:<,ISÃ'SpTl7010015020025030035040045050055060028.3028.14,27.8727.6027.3027.0026.7526.5026.1525.8025.5525.308.168.558.678.798.909.009.109.199.289.379.459.538.68.79.09.39.69.810.110.410.610.911.3~1165.1170.1195.1219.1243.1253.1275.1289.1298.1311.1320.1328

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eASSOCIATESINC.ENGINEERSAppendixDCALCULATIONOFHEATTRANSFERCOEFFICIENTS

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ASSOCIATESINC.ENGINEERSAppendixECRDRNOZZLEFINITEELEMENTMODELBOUNDARYCONDITIONSANDRESULTS

lLimpRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CALCULATIONTITLEPAGEClient~~~~gp/~/g+//L/gW/Qg/0/rv/~~///Page1ofgqProjectg~/~~~~opygmyrT/QTaskNo.0Z~Titlego~~p~pYAnted/77@AS~i>ZF~ur-I~CalculationNo.~-P29-Ct~d-o3Preparer/Dateaz.8.'/Z-Z/-5'yChecker/Dateg<g.'7~Reviewer/DateRev.No.

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t>IMPRCalculationNo.dd~-cVW-ggg-oJPreparedByMPRAssociates,Inc.320KingStreetAlexandria,VA22314Page~PurposeThepurposeofthiscalculationistodocumenttheboundaryconditionsandresultsofafiniteelementanalysisoftheNiagaraMohawkPowerCorporation,NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransientthermal/stressanalysissimulatingareactorscramwasperformed.References1and2arecalculationswhichdocumentthefiniteelementmodelgeometryandmaterialproperties.TheANSYScomputerprogram(Reference3)wasusedtocalculatethetransienttemperaturedistributioninanaxisymmetricmodelofthenozzle.Theprogramwasthenusedtocalculatestressprofilesduetopressureandduetothecalculatedtemperaturedistribution.Theresultsofthisanalysis,intheformofstressdistributionsthroughthebore/blendsectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluationoftheCRDreturnnozzle.DiscussionTheCRDsystemprovideswaterfromthecondensatestoragetankatatemperatureofabout70'Ftothecontrolroddrivemechanismstocoolthecontrolroddrives,torepositionrodsandtoscramtherods.Thesystemoperatesatalltimesthatfuelisinthevessel.ExcessfiowfromtheCRDpumpsisroutedtothereactorvesselviatheCRDreturnnozzle.Consequently,flowthroughtheCRDreturnnozzleistypical.NominalCRDreturnflowrateis17to35gpm.Theflowratedoesnotchangeasaresultofrepositioningacontrolrodsincetheflowdivertedtomovetherodiscompensatedbythewaterdisplacedbytherod.AreactorscramresultsinaCRDreturnnozzleflowtransient(Reference4).Duringascram,theCRDaccumulatorsdischargetodrivethecontrolrodsintothecore.thisresultsinanincreaseinCRDreturnflowto65gpm.Whenaccumulatorpressuredropsbelowreactorpressure,CRDflowrategoestozeroastheaccumulatorsarerecharged.Aftertheaccumulatorshavebeenrecharged,CRDflowratereturnstothenominal17to35gpm.Thelastportionofthereactorscramtransientissimulatedinthiscalculation.Attimezerothenozzleisatauniformtemperatureof525'FcorrespondingtozeroflowthroughtheCRDreturnnozzleastheaccumulatorsarerecharged.At1secondintothetransient,theCRDreturnflowrateisstepchangedtothenominalflowrateof35

l41MPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.os%->z1wed-o7PreparedByCheckedBygR~Page~gpmwithafluidtemperatureof70'F.Apressureof1250psigisappliedtotheinsidesurfaceofthereactorvesselwallandtheinsideofCRDreturnnozzlethroughoutthetransient(nominalreactorpressureis1030psig,scrampressureis1250psig).Detailsofthethermalandstructuralboundaryconditionsarediscussedbelow.ThermalBoundaConditionsforthereactorscramtransientareshownonFigure1anddiscussedbelow.AttimezerotheCRDreturnnozzleandreactorvesselwallareatauniformtemperatureof525'Fcorrespondingtothebulkdowncomerfluidtemperature.Theoverallheattransfercoefficientbetweenthedowncomerfluidandthevesselwallisassumedtobe1000Btu/(hr-ft-'F).Thisisthevalueusedinprioranalysesforthefeedwaternozzle.At1secondintothetransient,thebulkfluidtemperatureintheCRDreturnnozzleisstepchangedto70'F.TheoverallheattransfercoefficientbetweentheCRDreturnfluidandthenozzlewallis100Btu/(hr-ft-'F).Theheattransfercoefficientinthenozzleincludestheeffectsofthefluidfilmontheinsidediameterofthethermalsleeve,conductionthroughthethermalsleeve,andnaturalconvectionthroughthestagnantlayerbetweenthethermalsleeveandthenozzlebore.Reference5isacalculationoftheoverallheattransfercoefficientbetweentheCRDreturnfluidandthenozzleinsidesurface.Theoutsideofthevesselwall,theoutsideofthenozzleandtheradialcutlinesthroughthevesselwallandsafeendaremodeledasadiabatic(noheatflowacrossthesurface).StructuralBoundaConditionsincludeappliedpressureanddisplacementconstraints.Figure2showstheappliedpressurealongtheinsidesurfaceofthereactorvesselwallandtheinsidesurfaceoftheCRDreturnnozzle.Theappliedpressureonthesesurfacesis1250psig.Apressureisalsoappliedtothesafeendtorepresenttheaxialloadintheattachedpiping,Thevalueofthepressureappliedtothesafeendiscalculatedasfollows(dimensionsarefromReference1):AintFlAlPend=Where:pi*R12Pint"Aintpi*(R3-R1)=FI/AI13.34in16681.Ibf5.803in2875.psi 0

RMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.oN-d4f-F4ss'-oZPreparedBy7K~PageAintR1PintFlAIR3Pend=Insideareaofsafeend(in)Safeendinsidediameter=2.061inchesInternalpressure=1250psigLongitudinalforce(Ibf)CrosssectionalareaofsafeendSafeendoutsidediameter=2A69inchesPressureappliedtothesafeend(psi)Figure3showsthedisplacementboundaryconditionsappliedtotheendofthereactorvesselwall.Symmetryboundaryconditionsareappliedtopermitradialdisplacementalongthecutlinebuttoprohibitrotationofthecutline.Figure4showsthedisplacementboundaryconditionsappliedtothesafeend.Couplesareusedtoallowtranslationofthesafeendcutlinebuttoprohibitrotationofthecutline.ResultsThepeakstressintensityoccursattheendofthetransientwhensteadystateconditionshavebeenreached.Figure5showsthetimehistoryofstressintensityatseveralnodesinthebore/blendregion.Thestressesshowninthetimehistoryareatthecladdingtobasemetalinterface.Figure6showsthecalculatedtemperaturedistributionattheendofthetransient.Thepeakstressintensityinthebasemetalforthetransientoccursatnode806intheboreblendregionofthenozzleatthebasemetaltocladdinginterface(AttachmentA).Thepeakstressintensityatnode806duetotemperatureandpressureis110ksi.Thestressintensityduetopressurealoneatnode806is65ksi.Theprincipalcomponentofthestressintensityisthehoopstress.ColorcodedcontourplotsofstressdistributionareshowninFigures7through10forpressureonlyloading(timezeroofthetransient).Figures11through14showstressdistributionsattheendofthereactorscramtransientforpressureandtemperatureloading.Fourplotsareshownforeachloading:Stressintensity,ASMEcodeorTrescastressintensity,Hoopstress,theZcomponentofstressfortheaxisymmetricmodel,~Xcomponentstress,interpretedasasecondhoopstressforthe e0 lLiMpRCalculationNo.ogJ-g2g-flag-cgPreparedByZ.N.N~clMPRAssociates,Inc.320KingStreetAlexandria,VA22314Pagesphericalmodelofthevesselwall,Ycomponentstress,interpretedasaxialstressinthenozzleregion.Figures15and16showthelocationsofnodes806and14.Node806isthepointofmaximumstressintensityattheinterfacebetweenthecladdingandthebasemetal.Node14isthepointofmaximumstressintensityontheoutsidesurfaceofthenozzle/vesselintersection.Astraightline(path)isdrawnfromnode806tonode14andthestressintensityvaluesareinterpolatedontothepath(Figure11showstheinterpolationpath).Figures17and18showstressintensityalongthispathforthepressureonlycaseandthepressureandtemperaturecase.AttachmentBisatabularlistingofthestressversuspathlengthvaluesforFigures17and18.AttachmentsCandDprovidetheANSYSinputdataforthethermalandstresspassesoftheanalysis.Reference6isthehardcopyoutputfilefortheboththethermalandstresspasses.References1.MPRCalculation085-229-EBB-01,"CRDRNozzleFiniteElementModelGeometry".2.MPRCalculation085-229-EBB-02,"CRDRNozzleFiniteElementModelMaterialProperties",Revision0.3.ANSYScomputerprogramversion5.0.MPRCalculation085-230-ABR-01,"NineMilePointUnit1,ControlRodDriveReturnNozzleThermalandPressureCycles",Revision1.5.MPRCalculation085-230-ABR-02,"OverallHeatTransferCoefficientForCRDRNozzleatNMP-1",Revision0.6.ANSYSoutputfileNOZZLE.OUT,87,853bytesdated4-04-943:45:28pm.

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ANSYS5.0(x10442)105SZ-80610090SZ-803SZ-806SZ-805SZ80785800757065060S50040080012001600200024002800320036004000440048005200Time(Sec)ReactorScramTransient+/&u/Z~

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4+zc:t$a.~ANSYS5.0APR4199416:33:31PLOTNO.7NODALSOLUTIONSTEP=14,'UB=1TIME=3600SX(AVG)RSYS=ODMX=1.46SMN=-5953SMNB=-23928SMX=65837SMXB=70794-595320231000017977259533393041907498835786065837ReactorScram,XComponentStress

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(x104I'2)110102ANSYS5.0APR4199418:06:26PLOTNO.2POST1STEP=14SUB=1TIME=3600PATHPLOTNOD1=806NOD2=14957.962887.1+816.23C745.37CZV=1DIST=0.75ZF=0.5YF=0.5ZF=0.5CENTROIDHIDDEN674.51C603.65532.79461.93391.07101.0832.1653.2484.3315.4140.5411.6242.7073.79Position,IDtoOD4.872ReactorScramTransient-g/6.use/8

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0()vac-Qgc.~Q~RC-K.BXC;'hisprogramcalculatescrackgrowthIn~nozzleduetopressureand'hermalcyclesDECLARESUSCrackgrowth(At,Nsbl,PII,P2I,Sdist1,T11,TrII,Sdlst2,T21,Tr21)DECLAREfUNC'I!OHKlt(Al¹,L)DECLAREfUNCTIDHdadxt(dK,R)DIHNSub(5,5),hain(5,5),Peax(5,5),Strdistsn(5,5),Strdistex(5,5),Tlein(5,5),Tieax(5,5),12min(5,5),T2eax(5,5)DIHNsubcyc(5),Repcyc(5),BO(5),Sl(5),82(5),83(5),RefStr(5)CQHHOHSNAREDPlCLS~OpenInputandoutputfliesinputfileS~COrp(ANDSOPENinputflleSFORINPUTAStlflan~LEN(RTRINS(lnputfileS))outflleS~LEFIS(RIRINS(lnputflleS),flan-4)+".OUT"OPENoutfileSFOROUtPUTAS¹2'eadinputfileINPUTtl,Aot,NflnalINPUTt1,Rmin,CIRmlnt,C2Rmint,ml,e2INPUT¹I,Reax,C1Reaxt,C2RmaxtINPUTtieFl,f2,F3,F4INPUItl,NstrdlstfoRI~0TONstrdistINPUI'l,80(l),81(l),82(1),83(l),Refgtr(l)NEXTIINPUT<<I,NcyctypefORI~1TONcyctypeINpUTtl,Repcyc(1),Nsctrcyc(l)fORJaITONsubcyc(l)INPUTtl,NSub(l,J)~Pein(l,J),Peax(l,J),Strdistsn(I~J)~TImin(I,J),T2min(l~J),Strdistex(l~J),TIeax(I,J),T2eax(l,J)NEXTJNEXTI'onstantsPi~3.I81592CalculatecrackgrowthNtot~0At~AotPRINTt2,USING"ttODOUNTILNtot>>NfinalFORI~1TONcyctype<<.ttN'tot;AtFORK~'ITORepcyc(l)Ntot~Hiot+1fORJ~ITONsubcyc(l)CALLCrackgrowth(AS,NSub(I,J),hain(l,J),Peax(l,J),Strdlstcn(l,J),Tlmln(l,J),T2eln(l,J),Strdlstex(l,J),Tieax(l,J),T2eax(I,J))NEXTJPRINT<<2,USING"ttOt.ttO"INtot;AtNEXTKNEXTILOOPEND0QLo1Oc0Rp0V'0I)xO~Qto-cC)coCoCDtolOCr)o

CCF(Dd(P-ACE,E,ME.(('~>SUBCrsckGrorrth(A¹,Nsb,Pl,P2,Sdlstl,'ll,Trl,Sdist2,12,Tr2)~ThissubroutinecalculatescrackgrorrthgiventheInitialcracklength,'hememberofcyclesandthemlnfaaraandmsxfaaaapressuresand-'ecperatures.dtl=Trl-Tl=dt2~tr2-12KlPliKIN(AN,0)+dtleKIN(AN,Sdlstl)L2aI2~Kit(AN,0)+dt2eKIN(AN,Sdlst2)IFKleK2THENKmin~KlKmsx~K2ELSEKein8K2KmsxKlENDIFdKiKesx-KminR~Kmin/Kesxdst~dscgrf(d(,R)eNab~Af+ds¹FUNCTIONdscgrf(cB:,R)'alculatedscBIgivendKsndRSHAREDhain,Clhainf,C2Relnf,el,e2SHAREDRmsx,CIRmsxt,C2RmsxtIfhain~RmsxTHENClf~ClhalnfC2N~C2ibalntELSESELECTCASERCASEIS<<ReinClf~CIRmlntC2N~C2Rmlnf-CASEIS>>RmsxClt~CIRmaxfC2N~C2ResxfCASEELSEClt~Cllbalnt+(CIResxt-CIReinf)a((R-Rmln)/(Rmsx-hain))C2N~C2lbalnt+(C2Resxt-C2Reint)e((R-hain)/(Rmsx-Rein))ENDSELECTENOIFIFClt~C2NTHEMdscgrt~ClfedKmlELSEcB:tran~(C2N/Clf)(1/(ml-m2))SELEC'tCASEcXCASEISedxtrsndsdxf~CltadKallCASEIS>adKtrsndsdMNC2NadKENDSELECTEHDIFENDFUXC'tlOHFUNCTIONKit(Alt,L)'alculateStressIntensityfactor'ivencrack'LengthsndstressdistributlonSHAREDFl,f2,f3,F4,80(),81(),82(),83(),Refstr()Klf((PleAIN).5)a(Fla80(L)+F?*81(L)a2aAlf/Pl+f3e82(L)eAlf2/2+F4~83(L)a4eAlt3/3/Pl)/Refgtr(L)EHDFUNCTIONPqoQo>IO~0U(DoQ(I)O.~Cr)QxOgIDDK(o-CQCDo.0)o(ZIO'(D~cDcDQw(oQ(r)4o

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FPMPRFN&INEEASAppendixHCRACKGROWTHRATEANALYSISCASES

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tÃMPRENGINEERSAppendixIIMPLEMENTATIONPLAN

WMPRASSOCIATESINC.ENGINEERSImplementationPlanforStructuralAnalysisofNMP-0CRDRNozzleSpecificationNo.MPR-085-223-01Revision0February1994Preparedby:Reviewedby:EdwardBird(MPREngineer)I1.:,('..'~/;,JaesNestell(MPREnginedr)~~/~S~YDateDate'pprovedby:PhillipKasik(MPREngineer)lS-5'-DateApprovedby:.QP.IK(JQ.L'Qr-AcJneGawler(NMPCCognizantEngineer)c~l;-qIDate320KING51REETAI,EXANDRIA,VA22314-323703-51'.0200FAX70351r7.0224

r~lMPRASSOCIATESINC.ENGINEERSCONTENTSSectionBACKGROUNDPURPOSETECHNICALAPPROACHExperienceSurveyThermalLoadDefinitionStructuralAnalysisFractureMechanics/FatigueEvaluationINFORMATIONSOURCES~Pae10"11-

eASSOCIATESINC.EN&INEEASBACKGROUNDNUREG-0619requiresNMPCtoperformanin-vesselPTexamononeofthefourfeed-waternozzlesandthecontrolroddrivereturn(CRDR)nozzleduringthenextrefuelingoutageatNineMilePointUnit1.Thisexamisexpectedtoresultinhighworkerexposure,potentialoutagedelaysandassociatedhighcostswithoutcomparableincreasesinsafety.Asaresult,NMPCplanstorequestanexemptionfromthisrequirement,basedonthefollowing:AutomatedUTinspectionsystemsarenowavailableforperformingaccurateinspectionsfromoutsideofthevessel.Modificationshavebeenmadetothefeedwaternozzles,spargersandfiowcontrolsystemtoeliminateorlessenthefeedwaternozzlecrackingproblemsthatoccurredinthe1970s.~NodamagewasfoundontheCRDRnozzleduringthein-vesselexamin1977orduringvisualexaminationsthereafter.~DetailedmodelingandanalyseshavebeendonetoshowthatsmallQawswillnotgrowtounacceptablevalueswithinspecifiedoperatingperiodsforthefeedwaternozzles.PURPOSEThepurposeofthistaskistoevaluatethelong-termsusceptibilityoftheCRDRnozzletothermalfatiguecracking,determinecrackgrowthratesandcriticalcracksizes.NMPCwillusetheresultsofthistasktosupporttheirexemptionrequestandtoevaluatetheseverityofanyindicationfoundduringtheautomatedUTinspectionplannedforthe1995refuelingoutage.TECHNICALAPPROACHAfourstepapproachwillbeusedtoaccomplishthistask:~ExperienceSurvey~ThermalLoadDefinition~StructuralAnalysis~FractureMechanicslFatigueEvaluation

Eachofthesestepsisdescribedbelow.TheresultsofallfourstepswillbedocumentedinasingleMPRreport.Thisworkwillbeperformedinaccordancewith10CFR50,AppendixB,usingthelatestapprovedversionofMPR'sQAManual.ExerienceSurveAtelephonesurveyofapplicableBWRswillbeperformedtodeterminetheirexami-nationhistory/frequencyandcrackingexperiencefortheCRDRnozzle.SurveyinformationwillbecollectedforweldedthermalsleevedesignssimilartoNMP-1andothernon-weldeddesigns.Thetelephonesurveywillincludequestionsaboutexami-nationtechniquesandtools.Thisinformationisexpectedtobeusefulinevaluatingthesensitivityofthecrackingproblemtothermalsleevedesign.ThermalLoadDefinitionTheNMP1operatingflowcharacteristicsandlogrecordsoftheCRDsystemwillbereviewedtodetermineflowvariationsandresultingtemperaturevariationsfortheCRDRnozzleduringdifferentCRDoperatingconditions,e.g,,duringmovementofthecontrolrodsandscrams,andduringdifferentplantoperatingconditions,e.g.,startup,shutdown,andstandby.Themagnitudeandfrequencyofthermalandpressurechangeswillbeusedasinputtothestructuralmodelandtocalculatecrackgrowthratesandfatigueusage.StructuralAnalsisTheANSYScomputerprogramwillbeusedtodevelopatwo-dimensionalaxisymmetricfiniteelementmodeloftheCRDRnozzle.ThemodelwillincludeasectionofthereactorvesselwalladjacenttotheCRDRnozzle.TheextentofthissectionwillbelongenoughtoeliminateinteractionbetweentheboundaryconditionsappliedtothevesselwallandtheCRDRnozzle.Theradiusofthereactorvesselwallsectionwillbemodeledat3.2timestheactualradius.Thiswillinsurethatthemaximumhoopstressandstressintensitycalculatedbytheaxisymmetricmodelwillbecomparabletothoseintheactualthree-dimensionalintersection.Thermalboundaryconditions,includingheattransfercoefficients,willbecalculatedfortheloadcycledefinedabove.Theresultsofthepreviouslyperformedfeedwaternozzleanalysiswillbefactoredintothiscalculation.Thetemperaturedistributionwithintheaozzlewillbecalculatedasafunctionoftimefortheseboundaryconditions.Through-wallstressesthatresultfrompressureandtemperaturewillbecalculatedatseveralsnap-shotsintimetoestablishthetimeofpeakstress.Through-wallstresseswillbeusedinthefracturemechanics/fatigueevaluationbelow.TheoriginalstructuralevaluationfortheCRDRnozzledocumentedinReference3isanareareinforcementcalculation.Becausestresseswerenotexplicitlycalculated,adirectcomparisontostressesobtainedfromthisanalysisisnotpossible.

FractureMechanicsatiueEvaluationsFatigueusageandcrackgrowthrateswillbecalculatedforthestresscyclesdeterminedinthestructuralanalysis.Smallsurfaceflawsofvarioussizeswillbepostulatedtoexistonthevesselwallandnozzleboreregions.Crackgrowthratesduetolowfrequencypressureandthermalcycleswillbecalculatedtodeterminehowquicklytheseinitialsmallflawscouldgrowtounacceptablesizes.AfatigueusageevaluationfortheCRDRnozzleswasnotperformedfortheoriginalstructuralevaluation(Reference3)ontheupdatedvesselusagereport(Reference4).Acomparisontothecurrentanalysisisnotpossible.INFORMATIONSOURCESInformationsourcesfortheCRDRnozzlestructuralanalysisinclude:CombustionEngineeringDrawingNo.231-567,Revision7,"NozzleDetails-Vessel."2.ASMECodeforMaterialProperties.3.CombustionEngineeringReportCENC1142,"AnalyticalReportforNiagaraMohawkReactorVessel."4.MPRReport629,"Re-evaluationofReactorVesselFatigueAnalysisforRevisedOperatingCycles,NineMilePointNuclearGeneratingStationUnitNo.1,"August13,1979.-3-

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