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{{#Wiki_filter:P>1MPRASSOCIATESINC.ENGINEERSMPR-1485Revision0April1994NineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluationPreyaredforNiagaraMohawkPowerCoryoration301PlainfieldRoadSyracuse,NY132129407010168940M3PDR.ADOCK05000220P'DR 0
{{#Wiki_filter:P>1MPRASSOCIATES INC.ENGINEERS MPR-1485Revision0April1994NineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluation PreyaredforNiagaraMohawkPowerCoryoration 301Plainfield RoadSyracuse, NY132129407010168 940M3PDR.ADOCK05000220P'DR 0
Pi9MPRASSOCIATESINC.EN&INEERSNineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluationMPR-1485Revision0April1994PrincipalContributorsE.B.BirdJ.E.NestellR.S.PaulA.B.RussellPreparedforNiagaraMohawkPowerCorporation301PlainfieldRoadSyracuse,NY13212J.GawlerNMPCEngineer320KINGSTREETALEXANDRIA.VA22314-3238703-519-0200FAX:703.519-0224  
Pi9MPRASSOCIATES INC.EN&INEERSNineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluation MPR-1485Revision0April1994Principal Contributors E.B.BirdJ.E.NestellR.S.PaulA.B.RussellPreparedforNiagaraMohawkPowerCorporation 301Plainfield RoadSyracuse, NY13212J.GawlerNMPCEngineer320KINGSTREETALEXANDRIA.
VA22314-3238 703-519-0200 FAX: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
Pa1MPRASSOCIATES INC.ENGINEE0SCONTENTSSection1INTRODUCTION


PA1MPRASS0CIATESINC.ENGINEERSLISTOFFIGURESF~Fiore3-13-23-33-43-53-6~DetcritiooCRDRNozzleDimensionsFiniteElementModelFiniteElementModelDetailsCalculatedTemperatureDistributionCalculatedStressIntensityDistributionFatigueCrackGrowth
===1.1Background===
2SUMMARY3DISCUSSION 3.1DesignandOperation 3.2LoadCycleDefinition 3.3Structural Analysis3.4FatigueEvaluation 3.5FractureMechanics
-CrackGrowthRate3.6Experience Survey4REFERENCES 5APPENDICES
~Pae2-13-13-1.3-13-23-33-43-54-15-1APPENDIXAAPPENDIXBAPPENDIXCAPPENDIXDAPPENDIXEAPPENDIXFAPPENDIXGAPPENDIXHAPPENDIXICalculation ofCRDRNozzleThermalandPressureCyclesCRDRNozzleFiniteElementModel,GeometryCRDRNozzleFiniteElementModel,MaterialProperties Calculation ofHeatTransferCoefGcients CRDRNozzleFiniteElementModel,BoundaryConditions andResultsLowCycleFatigueUsageCrackGrowthRateComputerProgramVerification CrackGrowthRateAnalysisCasesImplementation PlanA-1B-1C-1D-1E-1F-1G-1H-1


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
PA1MPRASS0CIATESINC.ENGINEERS LISTOFFIGURESF~Fiore3-13-23-33-43-53-6~DetcritiooCRDRNozzleDimensions FiniteElementModelFiniteElementModelDetailsCalculated Temperature Distribution Calculated StressIntensity Distribution FatigueCrackGrowth


3.DetailedanalyticmodelingoftheCRDRnozzleshowsthatsmallsurfaceflawswillnotgrowtounacceptablevalueswithinspecifiedoperatingperiods.ThisreportaddressesItem3abovefortheCRDRnozzle.Inaddition,thisreportdocumentstheresultsofasurveyofBWRsregardingCRDRnozzleinspectionhistoryandexperience.TheimplementationplanforthistaskisprovidedinAppendixI.1-2  
Pa1MPRASSOCIATES INC.ENG'INEERS Section1INTRODUCTION Thepurposeofthisreportistodocumentafatigueevaluation oftheControlRodDriveReturn(CRDR)nozzleintheNineMilePointUnit1reactorvessel.Thenozzleisafourinchvesselpenetration thatacceptslowtemperature waterfromthecontrolroddrivesystem.Theobjectives oftheevaluation weretoestimate:
1)thelong-term susceptibility oftheCRDRnozzletothermalfatiguecracking, and2)thecrackgrowthrateofapotential flawintheCRDRnozzleovertheremaining lifeoftheplant.Thisevaluation wasundertaken tosupportNiagaraMohawkPowerCorporation (NMPC)effortstoperformanultrasonic inspection oftheCRDRnozzleinsteadofthedyepenetrant inspection specifiebyNUREG-0619.
Thefatigueevaluation oftheCRDRnozzleconsidered thenumberofpressureandtemperature cyclesthenozzlehasexperienced todateaswellasanestimateofthenumberoffuturecycles.Finiteelementstressanalysesofthenozzlewereperformed todetermine thestressdistribution inthenozzleduetothepressureandtemperature cycles.Stressanalysisresultswerethenusedtocalculate nozzlefatigueusageandcrackgrowthrates.1.1BACKGROUND Inthe1970's,anumberofBWRsdetectedsigniTicant crackingoffeedwater andCRDRnozzles.ThecracksintheCRDRnozzleswerecausedbythermalfatigueresulting fromchangesincoldCRDRflowatthenozzles,TheNRCissuedNUREG-0619, "BWRFeedwater NozzleandControlRodDriveReturnLineNozzleCracking,"
(Reference 1)thatidentified interimandlong-term recommendations regarding thisissue,including inspection requirements.
ForNineMilePointUnit1,theinspection requirements includeperforming adyepenetrant (PT)examination oftheCRDRnozzleinternalsurfaceduringtheupcoming1995ref'ueling outage.NMPCplanstoperformanultrasonic (UT)inspection oftheCRDRnozzleinsteadofthedyepenetrant examination basedonthefollowing:
1.Automated UTinspection systemsarenowavailable forperforming accurateinspections fromoutsidethevessel.UTinspection systemsatthetimeNUREG-0619wasissueddidnotprovidesufficient detection orflawsizingcapabilities.
2.TheCRDRnozzlethermalsleevedesign(weldedinplace)makesthenozzlelesssusceptible tothermalfatiguecrackingthantheoriginaldesignsatotherBWRs.Infact,nodamagetotheCRDRnozzlewasfoundduringthe1977in-vessel PTexamination orinanysubsequent examination.
1-1


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
3.DetailedanalyticmodelingoftheCRDRnozzleshowsthatsmallsurfaceflawswillnotgrowtounacceptable valueswithinspecified operating periods.Thisreportaddresses Item3abovefortheCRDRnozzle.Inaddition, thisreportdocuments theresultsofasurveyofBWRsregarding CRDRnozzleinspection historyandexperience.
Theimplementation planforthistaskisprovidedinAppendixI.1-2


CRDRnozzleatthepresenttime.Consideringthecalculatedstressandthenumberofcyclesexpectedinthef'uture,afatiguecrackisnotpredictedwithinthelifeoftheplant.Fracturemechanicscalculationsshowthatapostulated1/4inchflawlocatedinthehigheststressedregionofthenozzlewouldnotgrowtoanunacceptablesizewithinthelifeoftheplant.Thepostulated1/4inchQawiscalculatedtogrowtoadepthofonly0.4inchesin40years.A0.4inchflawdoesnotexceedtheallowableQawsizefortheanalyzedsectionofthenozzlewhichisapproximately0.5inchesbasedoncriteriagiveninSectionXIoftheASMECode.TheallowableQawsizeprovidessigniTicantmargintoensurethenozzledoesnotfailbybrittlef'racture.2-2
P&qMPRASSOCIATES INC.ENGINEERS Section2SUMMARYThreepressureandtemperature cycleswereidentified fortheCRDRnozzle:startup/shutdown, reactorscram,andhydrostatic test.ThesecyclearedefinedfortheCRDRnozzleasfollows:Startup/Shutdown
-areactorvesselheatup/cooldown betweenpoweroperation andshutdownorstandbyconditions wheretheshutdownisachievedmanuallybyplantoperators.
ReactorScram-astartup/shutdown cyclewheretheshutdownisachievedbyareactorscram.~Hydrostatic Test-reactorvesselpressurization anddepressurization toidentifyleakspriortopowerascension.
Thenumberofcyclesexperienced todate,thenumberofcyclesexperienced sincethe1977PTinspection andtheprojected numberofcyclesinthefuturearelistedbelow.Startup/Shutdown ReactorScramHydrostatic TestNumberofCyclestoDate9610018NumberofCyclesSince1977PTInspection 38279Projected NumberofCyclesperYear5Thereactorscramtransient isthelimitingcycleforCRDRnozzlestresses, Finiteelementmodelingofthethermaltransient showsthatthepeakstressintensity inthebasemetaloccursattheendofthetransient intheboreofthenozzlejustabovetheblendregion.Thepeakstressintensity duetopressureandtemperature wascalculated tobe110ksi.FatigueanalysesshowthatfatigueusagefortheCRDRnozzleisverylow(approximately


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
==0.0 03peroperating==
~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
year).Forthecalculated stressandthenumberofcyclesexperienced todate,afatiguecrackwouldnotbepredicted toinitiateinthe2-1  


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
CRDRnozzleatthepresenttime.Considering thecalculated stressandthenumberofcyclesexpectedinthef'uture,afatiguecrackisnotpredicted withinthelifeoftheplant.Fracturemechanics calculations showthatapostulated 1/4inchflawlocatedinthehigheststressedregionofthenozzlewouldnotgrowtoanunacceptable sizewithinthelifeoftheplant.Thepostulated 1/4inchQawiscalculated togrowtoadepthofonly0.4inchesin40years.A0.4inchflawdoesnotexceedtheallowable Qawsizefortheanalyzedsectionofthenozzlewhichisapproximately 0.5inchesbasedoncriteriagiveninSectionXIoftheASMECode.Theallowable QawsizeprovidessigniTicant margintoensurethenozzledoesnotfailbybrittlef'racture.
2-2


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
PAIMPRASSOCIATES INC.EN&INEERSSection3DISCUSSION 3.1DESIGNANDOPERATION TheNMP-1ControlRodDriveReturn(CRDR)nozzleisa4-inchreactorvesselpenetration locatedatthesameelevation asthefeedwater nozzle.Figure3-1isasectionviewofthenozzlewhichshowsselecteddimensions.
TheCRDRnozzleisequippedwithathermalsleevewhichisweldedtotheCRDRnozzleatthesleeveinletandextendsintothereactordowncomer withacircularplateattheend.Thisdesignisintendedtoprotecttheboreofthenozzleandthevesselwalladjacenttothenozzlefromtherelatively coldCRDRflow.TheControlRodDrive(CRD)Systemprovideswaterfromthecondensate storagetankatatemperature ofabout70'Ftothecontrolroddrivemechanisms tocoolthecontrolroddrives,toreposition rods,andtoscramtherods.Undertypicalplantconditions, thesystemoperatesatalltimeswhenfuelisinthevessel.Duringnormaloperation, flowfromtheCRDpumpsismaintained relatively constantwithaportionoftheflowrecirculated tothecondensate storagetank,about30-47gpmoftheflowusedforcontrolroddrivemechanism cooling,andabout17-35gpm(theremaining flow)returnedtothevesselviatheCRDRnozzle.Someaccidentsequences involving loss-of-offsite powermayresultinsystemshutdownforashortperiodoftime,Theseaccidentsequences arenotconsidered forthisanalysis.
Theflowratedoesnotchangeasaresultofrepositioning acontrolrodsincetheflowdivertedtomovetherodiscompensated bythewaterdisplaced bytheroddrivewhichisroutedtotheCRDRline.AreactorscramresultsinaCRDRnozzleflowtransient.
Duringascram,theCRDRaccumulators discharge todrivethecontrolrodsintothecore.ThisresultsinanincreaseinCRDRnozzleflowto65gpm.Whenaccumulator pressuredropsbelowreactorpressure, CRDRflowrategoestozeroastheaccumulators arerecharged.
Aftertheaccumulators havebeenrecharged, CRDRflowratereturnstothenominal17to35gpm.3.2LOADCYCLEDEFINITION Table3-1liststhepressureandtemperature cycleswhichwereconsidered inthestructural evaluation.
Thenumberofcycleswasdetermined fromplantdataregarding thenumberofplantstartups/shutdowns andscrams.Thecyclesaredefinedasfollows:3-1 0
~Startup/Shutdown
-areactorvesselheatup/cooldown betweenpoweroperation andshutdownorstandbyconditions wheretheshutdownisachievedmanuallybyplantoperators.
~ReactorScram-astartup/shutdown cyclewheretheshutdownisachievedbyareactorscram.~Hydrostatic Test-reactorvesselpressurization anddepressurization toidentifyleakspriortopowerascension.
Thenumberofannualcyclesexpectedinthefutureisconservatively estimated tobe50%morethantheaverageannualnumberofcyclesthatoccurredoverthepast10years.Acalculation ofoperating cyclesispresented inAppendix'A.
33STRUCTURAL ANALYSISStressanalyseswereperformed todetermine thestressesforthefatigueandcrackgrowthrateanalysesdescribed inSection3.4and3.5below.Transient thermalanalyseswereperformed tocalculate thetemperature distribution inthenozzleasafunctionoftimeforthereactorscramtransient.
Steadystatestressesduetopressureandtemperature werecalculated atspecified timeintervals throughout thetransient.
Thesectionsbelowdescribethefiniteelementmodel,materialproperties, boundaryconditions, andresults.33.1FiniteElementModelTheANSYScomputerprogramwasusedtodevelopafiniteelementmodeloftheCRDRnozzle.ThemodelincludestheCRDRnozzleitselfandasufficient lengthofthereactorvesselshellandattachedCRDRpipingtoeliminate interaction betweentheCRDRnozzleandthestructural boundaryconditions appliedtotheedgesofthevesselshellandattachedpiping.Thethree-dimensional nozzle-to-cylinder intersection wasmodeledwithatwo-dimensional axisymmetric modelofanozzleinasphere.Theequivalent spherical radiuswaschosentobe3.2timestheradiusofthereactorvesselcylindertoinsurethatthemaximumhoopstressandstressintensity calculated bytheaxisymmetric modelwouldbecomparable tothoseintheactualthree-dimensional intersection.
AppendixBdocuments thefiniteelementmodel.ThefiniteelementmeshoftheCRDRnozzleisshowninFigures3-2and3-3.33.2MaterialProertiesThemodeloftheCRDRnozzleiscomposedofthreeregionswithdifferent materialproperties.
ThereactorvesselwallisSA302GradeBlowalloysteel.TheCRDRnozzleisanSA336lowalloysteelforgingwithASMECodeCase1236-1fornickeladdition.
ThecladisassumedtobeType308stainless steel.3-2


\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
Temperature dependent materialproperties wereusedinthethermal'a'nd stressanalysesoftheCRDRnozzle.AppendixCdocuments thematerialproperties usedintheanalyses.
399ThermalBoundaConditions Thermalboundaryconditions forthereactorscramtransient arediscussed indetailinAppendices DandEandsummarized below.Thelastportionofthereactorscramtransient wasmodeled.Initially, theCRDRnozzleisatauniformtemperature of525'Fcorresponding tozeroflowthroughtheCRDRnozzleastheaccumulators arerecharged.
Atthestartofthetransient, theCRDRflowrateisstepchangedtoit'snominalvalueof35gpmwithafluidtemperature of70'F.Heattransfercoefficients andbulkfluidtemperatures areappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Allothersurfacesareassumedtobeadiabatic (insulated).
AppendixDisacalculation oftheheattransfercoefficient inth'eCRDRnozzlebore.Theoverallheattransfercoefficient betweentheCRDRfluidandthenozzleborewhichincludestheeffectsofthethermalsleeveandwaterannuluswascalculated tobe100BTU/hr-ft~-'F.
Thisincludestheeffectsofthefluidfilmontheinsidesurfaceofthethermalsleeve,conduction throughthethermalsleeve,andnaturalconvection throughthestagnantfluidlayerbetweenthethermalsleeveandthenozzlebore.Aheattransfercoefficient of1000BTU/hr-ft2-'F wasusedbetweenthebulkdowncomer fluidtemperature andthevesselwall.39.4Structural BoundaConditions Thestructural boundaryconditions forthestressanalysisincludeappliedpressures anddisplacements (Appendix E).Apressureof1250psigwasappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Anegativepressurewasappliedtothesafeendtosimulatetheaxialloadintheattachedpiping.Attheendofthereactorvesselwall,symmetryboundaryconditions areappliedtopermitradialdisplacement andtoprohibitrotation.
Atthesafeend,couplesareusedtoallowtranslation ofthesafeendbuttoprohibitrotation.
39.5ResultsThepeakstressintensity inthebasemetaloccursattheendofthescramtransient.
Figure3-4showsthecalculated temperature distribution attheendofthetransient.
Figure3-5showsthecalculated stressintensity distribution attheendofthetransient.
Thepeakstress(110ksi)inthebasemetaloccursintheboreoftheCRDRnozzleatthebasemetaltocladdinginterface, justabovetheblendintothevesselwall.Theprincipal component ofthestressintensity ishoopstress.3-3


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
3.4FATIGUEEVALUATION Afatigueevaluation oftheCRDRnozzlewasperformed basedontheloadcyclesdefinedinSection3.2andtheresultsofthefiniteelementstressanalysisdiscussed inSection3.3.Nozzlefatigueusageforcurrentplantoperation conditions wasevaluated onapercyclebasis.Asdiscussed inSection3.2,theCRDRnozzleissubjecttostartup/shutdown cyclesandstartup/scram cycles.Fatigueusagewascalculated forbothofthesecycles.Thenozzlealsoundergoes hydrostatic testing;however,thiscycleisboundedbythepressure-temperature conditions duringastartup/shutdown cycle.Fatigueusageiscalculated by:u=gnNwhere:u=fatigueusagen=numberofcycleswhichoccurN=numberofallowable cyclesbasedonthecyclicstressesAfatigueusageof1.0indicates thatthereisapotential forfatiguecrackinitiation inthenozzle.Theallowable cyclesaredetermined fromtheASMECodeDesignFatigueCurveforCarbon,LowAlloyandHighTensileSteels(Reference 2,FigureI-9.1).Thiscurveprovidesaconservative numberofallowable cyclesforagivenalternating stressrange(safetyfactorshavealreadybeenapplied).
Therefore, useofthiscurvefortheusageevaluation providesaconservative estimateoffatigueusageforthenozzle.Calculation offatigueusageforstartup/shutdown andstartup/scram cyclesaredocumented inAppendixF.Thecalculation isperformed usingthepeakstressintensity rangeonthebasemetalinsidesurfaceofthenozzleforeachofthecycles.Thefatigueusageforthenozzlewascalculated tobe1.963x10~perstartup/shutdown cycleand3.848x10perstartup/scram cycle.Basedonrecentplantoperating history,thereareapproximately fivestartup/shutdown cycles,onehydrostatic testandfourstartup/scram cyclesperyear,whichcorresponds toanannualfatigueusageof0.003.3.5FRACTUREMECHANICS
-CRACKGROWTHRATECrackgrowthofanassumedpre-existing fiawinthenozzleduetothepressureandthermalcyclesdefinedinSection3.2isanalyzedusingthePariscrackgrowthrateequation:
=C(AK)dN3-4


Itherewereseveralproblemsencounteredduringsetupofthesystem.MountingthesystemtooklongerthantypicalUTsystemsduetospaceconstraintsaroundthenozzle.Inaddition,removalofthemirrorinsulationaroundthenozzleareawasexpensiveandtimeconsuming.Aftertheinspection,anewtypeofremovableinsulationwasinstalledtoprovideeasieraccessforfutureinstallations.3-7 0
\where:crackgrowthrate(inches/cycle) daGnstressintensity factorrange(ksiPin)C,m=constants (dependent onmaterial, environment, andloading)CandmaretakenfromtheASMEcrackgrowthcurveforsurfaceQawsinawaterreactorenvironment (Reference 2,FigureA-4300-1).
Table3-1CRDRNozzlePressureandTemperatureCyclesDescription1NormalStartup/Shutdown2ReactorScram3InitialHydro4RefuelingHydro510yearISIHydroReactorVesselPressure(psi)01030-0103012500187500>>1030-0011330DowncomerFluidTemperature('F)70-525-70250250250CRDRNozzleFluidTemperature('F)7070<<525<<70707070NumberofCyclestoDate9615NumberofCyclesExpectedperYear5.03.90.01.00.1  
Thestressintensity factorrangeisthemaximumchangeinstressintensity factorduringthegivencycle.Stressintensity factorisafunctionofstressandcracksize.Asdescribed inSection3.3,stresseswereanalyzedbyQniteelementanalysis, UsingtheQniteelementmodelresults,asectionthoughthenozzlewall,passingthroughthepeaksurfacestressesontheinsideandoutsidesurfacesofthenozzle,wasdetermined.
Thissectionislocatedintheblendregionofthenozzleneartothetransition totheboreregion.Athirdorderpolynomial wasQittothestressesthroughthesectionasafunctionofdepththroughthenozzle.Stressintensity factorsweredetermined bythemethodsofReference 3.Stressintensity factorsarecalculated asaf'unction ofcracksizeandthepolynomial coefficients fromthecubicstressdistribution.
Acomputerprogramthatcalculates crackgrowthbasedonthemethoddescribed abovewasdeveloped toanalyzeassumedQawsinthenozzle.Theprogramdescription andveriQcation aredocumented inAppendixG.InputsandresultsofthecrackgrowthanalysisareprovidedinAppendixH.Theresultsofthecrackgrowthanalysis, assuminganinitialQawsizeof0.25inches,areshowninFigure3-6.AsshowninFigure3-6,theassumed0.25inchinitialQawwillgrowtoapproximately 0.40inchesin40yearsofoperation.
TheresultsindicateaverysmallcrackgrowthrateforacrackintheCRDRnozzle.Inaddition, the0.40inchfinalQawsizeislessthantheallowable Qawsizeof0.5inches.Theallowable flawsizefortheanalyzedsectionofthenozzlewasdetermined fromcriteriagiveninSectionXIoftheASMECode[Ref.2].Determination oftheallowable Qawsizeisdocumented inAppendixH.Anallowable flawsizeof0,5inchesprovidessigniQcant margintoensurethenozzlewillnotfailbybrittlefracture.
Theappliedstressintensity factorfora0.5inchflawunderthemostseverestressconditions inthenozzleisapproximately 81ksiIin.Thenozzleisnotpredicted tofailbybrittlefractureuntiltheappliedstressintensity factorexceedsthecriticalstressintensity factorfortheCRDRnozzlematerial.
Atnormaloperating temperatures thecriticalstressintensity factorisapproximately 200ksiIin,whichismorethantwicetheappliedstressintensity factorofthe0.5inchallowable flaw.3-5
 
3.6EXPERIENCE SURVEYAsurveywasperformed todetermine theexperiences ofotherutilities withregardtoCRDRnozzlecracking.
NUREG-0619 responses totheNRCfromutilities operating BWRplantswerereviewedtodetermine howtheCRDRnozzlecrackingissuewasresolvedateachoftheplants.Inaddition, severalutilities werecontacted todetermine moredetailedinformation aboutinspection practices fortheCRDRnozzle.Theresultsaresurnrnarized below.Reviewofutilityresponses totheNRCindicated thatalmostalloperating BWRscutandcappedtheCRDRreturnline,eitherwithorwithoutflowrerouted'to anothersystem.PlantswithacappedCRDRnozzlearenotrequiredbyNUREG-0619 toperforminspections ofthenozzle(besidesafinalPTinspection requiredpriortocappingthenozzle).However,someplantswereoperatedforextendedperiodsoftimewiththeCRDreturnlinevalvedout,whichNUREG-0619 considers tobeatemporary solution.
Inaddition, oneplant,OysterCreekNuclearGenerating Station,hascontinued tooperatewithCRDreturnlineflowthroughtheCRDRnozzle.OysterCreekistheonlyotherplantbesidesNMPUnit1permitted tooperatewiththeCRDRnozzleinservice,Severalplants,including OysterCreek,werecontacted todetermine information aboutinspection techniques andresultsofnozzleinspections.
Twooftheplantscontacted, DuaneArnoldEnergyCenterandQuad-Cities Station,foundcracksintheCRDRnozzleduringrecentinspections (pastGiveyears).AtDuaneArnold,theCRDreturnlinewasvalvedoutandcappedwithablindflangein1982.Duringavisualinspection oftheCRDRnozzlein1990,evidenceofcrackingwasfoundandafullPTexamination wasperformed.
Acrackapproximately 3incheslongand0.25inchesdeep,justpenetrating intothebasemetalofthenozzle,wasfoundandgroundout.Thenozzleprobablyhadathermalsleeveinstalled priortobeingcapped;however,thetypeofthermalsleeveisunknown.Theplantperformsavisualinspection ofthenozzleeveryoutage,butdoesnotperformanyultrasonic inspections.
QuadCitiesoperatedwiththeCRDreturnlineinavalved-out conflguration until1989whencrackingwasfoundintheCRDRnozzle.Duringthisperiodofoperation, theCRDreturnlinewasvisuallyinspected everyoutage.Asaresultofthecracking, theCRDreturnlinewascutandcappedin1989.Sincethattimenoinspections ofthenozzlehavebeenperformed.
Inbothofthesecases,crackingwasfoundafterasigniflcant periodofoperation withtheCRDRnozzleisolatedfromCRDRflow.Mostlikely,crackinginitiated priortoisolation oftheCRDRflow,butwasnotidentifled untillaterinspections, OysterCreekistheonlyotherplant(besidesNileMilePointUnit1)allowedbyNUREG-0619 tooperatewithflowtotheCRDRnozzle.SimilartoNMPUnit1,OysterCreekappliedforanexemption oftheNUREG-0619 requirements fortheCRDRnozzle,including thescheduled PTexamination.
Basedonautomated ultrasonic
~~~~(UT)examinations oftheCRDRnozzle,whichdidnotidentifyanyindications, Oysterreekwasgivenanexemption fromthenozzlePTexamination untilthenextrefueling outage.Qualiflcation oftheUTsystemwasperformed usingamock-upoftheCRDRnozzle.EventhoughtheUTsystemwasdesignedspecifically forthenozzlegeometry, 3-6
 
Itherewereseveralproblemsencountered duringsetupofthesystem.MountingthesystemtooklongerthantypicalUTsystemsduetospaceconstraints aroundthenozzle.Inaddition, removalofthemirrorinsulation aroundthenozzleareawasexpensive andtimeconsuming.
Aftertheinspection, anewtypeofremovable insulation wasinstalled toprovideeasieraccessforfutureinstallations.
3-7 0
Table3-1CRDRNozzlePressureandTemperature CyclesDescription 1NormalStartup/Shutdown 2ReactorScram3InitialHydro4Refueling Hydro510yearISIHydroReactorVesselPressure(psi)01030-0103012500187500>>1030-0011330Downcomer FluidTemperature
('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  
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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Illlllllll~ls>ylllllll>gt~pllllllllllIIII~)l<)p~gy))l)~)(lpga/jilla'~'>If(l>~l//jgod,'hagi~/jfbi)]4~~%Iaaaammmmmmmmmaa~)~lykyggggRR%%%~%%%g%%%WaOrsnaammmmmmmmmmmm%~~~+~~~~~~~~~~~~~~~~~~
Illlllllll~ls>
i0 ANSYS5.0APR4199416:33:47PLOTNO.1NODALSOLUTIONSTEP=2SUB=21TIME=3601TEMPTEPC=9.434SMN=88.846SMX=523.56288.846100200300400500600Figure3-4.CalculatedTemperatureDistribution
ylllllll>gt~p llllllllll IIII~)l<)p~gy))l)~)(lpga/j illa'~'>If(l>~l//j god,'hagi~/j fbi)]4~~%Iaaaammmmmmmmmaa
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%~~~+~~~~~~~~~~~~~~~~~~
i0 ANSYS5.0APR4199416:33:47PLOTNO.1NODALSOLUTIONSTEP=2SUB=21TIME=3601 TEMPTEPC=9.434 SMN=88.846SMX=523.56288.846100200300400500600Figure3-4.Calculated Temperature Distribution


4hrentawQ~7Qp:PANSYS5.0MAR31199410:40:18PLOTNO.1NODALSOLUTIONSTEP=14SUB=1TIME=3600SINT(AVG)DMX=1.462SMN=3533SMNB=2569SMX=96413SMXB=1050083533138532417334493448135513365453757738609396413'+~~Figure3-5.CalculatedStressIntensityDistribution
4hrentawQ~7Qp:PANSYS5.0MAR31199410:40:18PLOTNO.1NODALSOLUTIONSTEP=14SUB=1TIME=3600 SINT(AVG)DMX=1.462SMN=3533SMNB=2569 SMX=96413SMXB=105008 3533138532417334493448135513365453757738609396413'+~~Figure3-5.Calculated StressIntensity Distribution


0.440.420.400.38~0.36~0.34(~p0.32.0.3000.280.260.240.220.20050IIIIIIIITIIIII100150200250300350400Cycles(10cyclesperyear}Figure3-6.FatigueCrackGrowth  
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'
PD1MPRASSOCIATES INC.EN&INEEITS Section4REFERENCES 1.NUREG-0619, "BWRFeedwater NozzleandControlRodDriveReturnLineNozzleCracking, November1980.2.ASMEBoilerandPressureVesselCode,1980EditionwithAddenda.3.Buchalet,'C.B.,
rpMPRENGINEERSSection5APPENDICESA.CalculationofCRDRNozzleThermalandPressureCyclesB.CRDRNozzleFiniteElementModel,GeometryC.CRDRNozzleFiniteElementModel,MaterialPropertiesD.CalculationofHeatTransferCoefficientsE.CRDRNozzleFiniteElementModel,BoundaryConditionsandResultsF.LowCycleFatigueUsageG.CrackGrowthRateComputerProgramVerificationH.CrackGrowthRateAnalysisCasesI.ImplementationPlan5-1  
andBamford,'.W.H.,
"StressIntensity FactorSolutions forContinuous SurfaceFlawsinReactorPressureVessel,"ASTM-STP-590, 1975.4-1 I'
rpMPRENGINEERS Section5APPENDICES A.Calculation ofCRDRNozzleThermalandPressureCyclesB.CRDRNozzleFiniteElementModel,GeometryC.CRDRNozzleFiniteElementModel,MaterialProperties D.Calculation ofHeatTransferCoefficients E.CRDRNozzleFiniteElementModel,BoundaryConditions andResultsF.LowCycleFatigueUsageG.CrackGrowthRateComputerProgramVerification H.CrackGrowthRateAnalysisCasesI.Implementation Plan5-1  


FA1MPRSSOCIATESINC.ENGINEERSAppendixACALCULATIONOFCRDRNOZZLETHERMALANDPRESSURECYCLES
FA1MPRSSOCIATES INC.ENGINEERS AppendixACALCULATION OFCRDRNOZZLETHERMALANDPRESSURECYCLES


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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  
NINEMILEPOINTUNITNON-CFIITICAL HYDROTEST 14001200O'I000800614eoOK4003600O200NCN-CRITICAL OPERATION MINllvLMTEMPI=TLREFORBOLTLP100F100130050100'150200250800850REACTORVESSELBELTLINEDOWNCOMER NATERTEMPERATURE (F)(reactorvesselbelt!incdowncomer watertemperature ismeasuredatrecirculation loopsuction)FIGURE3.2.2.eMINIMUMSELTLINEDOWNCOMER WATERTEMPERATURE FORPRESSURIZATION DURINGIN-SERVICE HYDROSTATIC TFSTINGAND'LEAKTESTING(REACTORNOT.CRITICAL)
FORUPTO18EFFECTIVE FULLPOWERYEARSOFOPERATION Amendment Iio.pn,p,pnl27  


PDIMPRASSOCIATESINC.ENGINEERSAppendixBCRDRNOZZLEFINITEELEMENTMODELGEOMETRY
PDIMPRASSOCIATES INC.ENGINEERS AppendixBCRDRNOZZLEFINITEELEMENTMODELGEOMETRY


ylLIMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CALCULATIONTITLEPAGEClientNr4~g~oh'5-wW~rn/P~/ggjOr~IMWI7Page1ofI3Projectg~>~mneozan.E-J'WFsSTaskNo.dew-22.fTitle~<ODEC~%MdI/r-/'alculationNo.~g~-+gal-dZ8-0/Preparer/DateChecker/DateReviewer/DateRev.No.  
ylLIMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULATION TITLEPAGEClientNr4~g~oh'5-wW~rn/P~/ggjOr~IMWI7Page1ofI3Projectg~>~mneozan.E-J'WFsSTaskNo.dew-22.fTitle~<ODEC~%MdI/r-/'alculation No.~g~-+gal-dZ8-0/Preparer/Date Checker/Date Reviewer/Date Rev.No.  


lx)MPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314RECORDOFREVISIONSCalculationNo.Old-2zf-~jPQ-aIRevision<T.~CheckedByP~fib',;DescriptionPage
lx)MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314RECORDOFREVISIONS Calculation No.Old-2zf-~jPQ-aI Revision<T.~CheckedByP~fib',;Description Page


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
WMPQMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.ops-z~-685-ol'7S'CheckedByPagePurposeThepurposeofthiscalculation istodocumentthegeometric inputdataforafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransient thermal/stress analysissimulating areactorscramwasperformed.
References 1and2arecalculations whichdocumentthefiniteelementmodelmaterialproperties andboundaryconditions/
results.TheANSYScomputerprogram(Reference 3)wasusedtocalculate thetransient temperature distribution inanaxisymmetric modelofthenozzle.Theprogramwasthenusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.
Theresultsofthisanalysis, intheformofstressdistributions throughthebore/blend sectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluation oftheCRDreturnnozzle.Discussion Figure1isadrawingoftheCRDreturnnozzlewhichshowspertinent dimensions (Reference 4).Thedimensions usedintheanalysisareasfollows:VesselRadiusRVVesselThickness TVCladThickness CLADAngularExtentANG1106.7*3.2inches7.125inches.2188inches8degreesOtherdimensions fromFigure1areasfollows:NozzleBoreNozzleODSafeEndODVesselCutOutR1R2R3R42.061inches4.813inches2A69inches5.563inches8.688inches4.125inches1.344inchesSafeEndH1SafeEndH2SafeEndH3Theradialdimensions forthenozzlebore,R1,andthevessel,RV,aretothebasemetal-cladding interface.
Thesedimensions shouldbereducedbythethickness of


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.  
OlxlMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.4785-g~)t-Q,S-OICheckedByP~74uPagethecladding(7/32").Thisdiscrepancy betweenthefiniteelementmodelandthedrawingdimensions shouldhaveanegligible affectonthecalculated stresses.
Figures2and3showtheaxisymmetric finiteelementmodelofthenozzle.The'xisymrnetric modelusesaradius3.2timestheactualradiusofthereactorvessel.Thisistoinsurethemaximumhoopstressandstressintensity fromthemodelwillbecomparable tothoseintheactualthree-dimensional intersection (Reference 5).Theangularextentofthefiniteelementmodelaffectsthenumberofelementsinthemodelandconsequently thecomputerrunningtimeforthemodel.Theangularextentassumedintheseanalysesis8degrees.Thisextentwasselectedbyperforming pressureonlyloadcaseswithmodelsofvaryingextentandevaluating thestressesatthevesselcutline.Thepressureanalysesshowedthat8degreesissufficiently farfromtheCRDreturnnozzlesuchthatthestressdistribution atthevesselcutlineisuniform.Reference 6istheANSYSoutputfilewhichshowsthePREP7echooftheinputdata.References MPRCalculation 085-229-EBB-02, "CRDRNozzleFiniteElementModelMaterialProperties",
Revision0.2.MPRCalculation 085-229-EBB-03, "CRDRNozzleFiniteElementModelBoundaryConditions andResults",
Revision0.3.ANSYScomputerprogramversion5.0.4Combustion Engineering ReportCENC1142,"Analytical ReportForNiagaraMohawkReactorVessel",drawingnumber231-567-7.
5.J.B.TruittandP.P.Raju,ASME-78-PVP-6, "Three-Dimensional VersusAxisymmetric FiniteElementAnalysisofaCylindrical VesselInletNozzleSubjecttoInternalPressure, AComparative Study"6.7.MPRCalculation "Geometry",
tasknumber85-31"LowFlowFeedwater ControlSystem",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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~~'v4wi~~~~s.~4.ii~.~~,~Path:C:)NOZZLEFile:MSH.MACLSELgR~LOCgYgANG1CSYS,OLESIZEgALLggg12gl/4!LESIZE~ALL,,~12~2LSLALSELgRJLOCgXgR4LESIZEgALLJfg12f4!LESIZE~ALLggg12~2ALLSELLESIZEg11~gg20I!MeshAreasI1,019.a..3-24-941:39:32pmPagelQET,l,PLANE55KEYOPT~1~3g1TYPE,1ESHAPE,2ESIZE,3/4MAT,1AMESH,2ESIZE,1/2MAT,2AMESH,6MAT,3AMESH,3,5,1MAT,2AMESH,1*l=Axisymmetric>~~RAs8oclA768;,Ca(CulatianNO.Oez-WV-e4g~plsdQyCr~ecredgy~&Iact."4fPage  
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~&qMPRASSOCIATESINCENGINEERSAppendixCCRDRNOZZLEFINITEElEMENTMODELMATERIALPROPERTIES
~&qMPRASSOCIATES INCENGINEERS AppendixCCRDRNOZZLEFINITEElEMENTMODELMATERIALPROPERTIES


taiMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CALCULATIONTITLEPAGEClient~gfJQ<EQ~op/~/C/g//V/MMI//Project4EBAMn/o+RcE-J'rPEssgwdc-Pea'age1ofmTaskNo.gF-P4gTitle/&#xc3;oPEWTiEiCalculationNo.y8<-gal'-pZ/j-o2Preparer/DateChecker/DateReviewer/DateRev.No.Pe~a~c44yj/p(/  
taiMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULATION TITLEPAGEClient~gfJQ<EQ~op/~/C/g//V/MMI//Project4EBAMn/o+RcE-J'rPEssgwdc-Pea'age 1ofmTaskNo.gF-P4gTitle/&#xc3;oPEWTiEiCalculation No.y8<-gal'-pZ/j-o 2Preparer/Date Checker/Date Reviewer/Date Rev.No.Pe~a~c44yj/p(/  


RMPRMPRAssociates,Inc.320.KingStreetAlexandria,VA22314RECORDOFREVISIONSCalculationNo.-o4f-JJ$-fart'rt-oZRevisionPrepare/ByQ/5.CheckedBy$0@DescriptionPagegOW/6r~+C.AJob  
RMPRMPRAssociates, Inc.320.KingStreetAlexandria, VA22314RECORDOFREVISIONS Calculation No.-o4f-JJ$-fart'rt-oZRevisionPrepare/ByQ/5.CheckedBy$0@Description PagegOW/6r~+C.AJob  


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
PRIMP'PRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.+g-gag-$3/f-0ZPreparedByCheckedByPageg~PuroeeThepurposeofthiscalculation istodocumentthematerialproperties usedinafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.TheANSYScomputerprogramwasusedtocalculate thetransient temperature distribution inthenozzle.Inaddition, theprogramwasusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.
Thematerialproperties requiredintheanalysesare:ElasticModulusCoefficient ofThermalExpansion ThermalConductivity SpecificHeatPoisson's RatioDensityDiscussion Figure1showsaschematic oftheCRDRnozzleoutline.Thenozzlemodeliscomposedofthreeregionswithdistinctmaterialproperties.
~Region1isthereactorvesselwall.ThevesselwallmaterialisSA302GradeB(Mn-1/2Mo),
Reference 1.~Region2istheCRDRnozzle.ThenozzlematerialisSA336withASMECodeCase1236-1,Reference 1.Equivalent materialisSA508Class2(3/4Ni-1/2Mo-1/3Cr-V) asdiscussed below.~Region3istheClad,assumedtobetype308Stainless Steel.Stainless SteelType304,18Cr-8Nimaterialproperties areaclosematchandareusedinthisanalysis.
Previousfiniteelementanalysesofthefeedwater nozzleused1980ASMECodematerialproperties (Reference 2).Inthatcalculation, acomparison ofmaterialchemicalcomposition betweentheoriginal1964specification andthe1980Codewasmade.Thecomparison showedthatforthevesselwall1980ASMECodematerialproperties wereequivalent.
Thecalculation alsoshowedthattheequivalent material


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.  
lxHMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.de-d45'+44-ozCheckedByS~mt~~PageypropertyforthenozzlewasSA508Class2(3/4Ni-1/2Mo-1/3Cr-V).
Thesamematerialproperties usedinthepreviouscalculation forthefeedwater nozzleandvesselwallareusedinthisanalysisfortheCRDReturnnozzleandvesselwallrespectively.
ResultsTemperature dependent materialproperties arelistedinTables1through3forthereactorvesselwall,CRDReturnnozzleandcladdingrespectively.
Attachment AisalistingoftheANSYSmacroMATL.MACwhichisthecomputerprograminputdataformaterialproperties.
(Theinputdataalsolistsheattransfercoefficients.)
Forallthreematerials, adensityof489Ib/ftandPoisson's Ratioof0.3wereused(Reference 3).Thereference temperature forthecoefficient ofthermalexpansion (REFTinfileMATL.MAC) is70'Fforthenozzleandvesselwall.Forthecladdingmaterial, theaveragetemperature betweenthedowncomer andnozzlefluidtemperatures atfullpowerconditions wasusedforthereference temperature toapproximate theresidualstressstateinthecladding.
Specificheatwascalculated fromthermaldiffusivity bythefollowing formula:Cp=K/(Rho*TD)
Where:CpKRhoTDSpecificHeat(btu/Ib-'F)
ThermalConductivity (btu/hr-ft-'F)
Density(Ib/ft)ThermalDiffusivity (ft/hr)References Combustion Engineering ReportCENC1142,"Analytical ReportForNiagaraMohawkReactorVessel",pageA-78.2.MPRCalculation "Material Properties",
tasknumber85-31"LowFeed-waterFlowControl",
2/28/93.3.StandardHandbookForMechanical Engineers, SeventhEdition,pages5-6and6-7.  


K1MPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.CtP~-V25'-Z45-oZPreparedBy~a.w../CheckedByP0~:~4'~PageC>lA0  
K1MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.CtP~-V25'-Z45-oZPreparedBy~a.w../CheckedByP0~:~4'~PageC>lA0  


wiiMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.gg~+g$'-prZ8-azPreparedByw<W./CheckedByPagegTable1,MaterialProperties-SA302GradeBCarbonMolybdenum(Mn-1/2Mo)":"~sg!i%~:.,:,ii~iq'~~c'',"..'...i:,.',.);..."'(10apepsi)~'.<<x.;.,::.::Exp'a'rision',"',';:~'l:,:::,:,:;:I,:';,Cor'iductiyity',";,!k::';.'-.:".::;::.;':.::::.:',::(ee'a'r'i.::,iafii'e)'.m.':~'::"::.'::I<(Btulhi;-:,':ft';,'',F)'4'::,:;.,pe'ciho'::.;',';:(Btb1lb';.'',F).''jI7010015020025030035040045050055060029.2029.0428.7728.5028.2528.0027.7027.4027.2027.0026.7026.407.027.067.167.257.347.437.507.587.637.707.777.8323.323.624.124.424.624.724.724.624.424.223.923.5.1047.1070.1110.1142~1173.1203.1235.1264.1286.1313.1343.1361  
wiiMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.gg~+g$'-prZ8-azPreparedByw<W./CheckedByPagegTable1,MaterialProperties
~i MPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.Od~-g2g-E.g/P-o2-PreparedByCheckedByPdb/R~~Pagep.Table2MaterialProperties-SA336withCodeCase1236-1EquivalenttoSA508Class2(3/4&#xb9;i1/2Mo-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.  
-SA302GradeBCarbonMolybdenum (Mn-1/2Mo)
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~i MPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.Od~-g2g-E.g/P-o2-PreparedByCheckedByPdb/R~~Pagep.Table2MaterialProperties
-SA336withCodeCase1236-1Equivalent toSA508Class2(3/4&#xb9;i1/2Mo-1/3Cr-V) 70100150200250300350400450500550600Mo'du!.'Us~of
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~1063.1084.~1118.1149.1180.1204.1224.1254.1274.1305.1326.1351ModulusofElasticity valuesarefor1/2-2CrChromeMolybdenum.  


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~r>1MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.dA-gg5'-8/-oz-PreparedByCheckedByPo'in.~Page8Table3MaterialProperties
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Path:C:)NOZZLEFile:MATL.MAC2,346.a..4-01-9412:10:32pmPageg9G=386.4F=3600*12MPTEMP/1/70/100/150/200/250/300MPTEMP/7i350/400/450/500i550/600!&#xb9;1-VesselWallMaterial-SA302GrB-Carbon-molybdenumMPDATA/EX/1/1/2920E6/29~04E6i2877E6/2850E6/28~25E6/28OOE6MPDATA/EX/1/7/27~70E6i27~40E6/27~20E6/27~OOE6/26~70E6/26~40E6MPDATA/KXX/1/1/233/F/23~6/F/24~1/F/24~4/F/24~6/F/24~7/FMPDATA/KXX/1/7/247/F/24~6/F/24~4/F/24~2/F/23~9/F/23~5/FMPDATA/ALPX/1/1/7~02E6/7~06E6/7~16E6/7~25E6/7~34E6/7~43E6MPDATA/ALPX/1i7/750E6/7~58E6/7~63E6/770E6/7~77E6/7~83E6MPDATA,C,1,1,.1047*G,.1070*G,.1110*G,.1142*G,.1173*G,.1203*GMPDATA/C/1/7/1235*G/1264*G/~1286*G/~1313*G/.1343*G/1361*GMP/DENS/1/489/1728/GMP/NUXY/1/0~3MP/REFT/1i70!&#xb9;2-CRDRNozzleMaterial-SA336!&#xb9;3-CladMaterial-308StainlessSteelMPDATA/EX/3/1/28~30E6/2814E6/27~87E6/2760E6/27~30E6/27~OOE6MPDATA/EX/3i7/26~75E6/26~50E6/26~15E6/25~80E6/25~55E6/25~30E6MPDATA/KXX/3/1/8~6/F/8~7/F/9~0/Fi93/F/9~6/F/9~8/FMPDATA/KXX/3/7/10~1/F/10~4/F/10~6/F/10~9/F/11~1/F/11~3/FMPDATA/ALPX/3/1/8~16E6/8~55E6/8~67E6/8~79E6/8~90E6/9~OOE6MPDATA/ALPX/3/7/9~10E6/9~19E6/9~28E6/9~37E6/9~45E6/9~53E6MPDATA,C,3,1,.1165*G,.1170*G,.1195*G,.1219*G,.1243*G,1253*GMPDATA,C,3,7,.1275*G,.1289*G,.1298*G,.1311*G/.1320*G,.1328*GMP/DENS/3/489/1728/GMP/NUXY/3/0~3MP/REFT/3i(70+525)/2MPRASSOCIATES,INC.CalcutatfonNo.+~~~~~~+PreparedBy+CheckedByPageMPDATA/EX/2/1/29~70E6/29~54E6/29~27E6/29~OOE6/28~75E6/28~50E6MPDATA/EX/2/7/28~20E6/27~90E6/27~70E6/27~50E6/27~20E6/26~90E6MPDATA/KXX/2/1/23~6/F/23~7/F/23~9/F/24~0/F/24~0/F/23~9/FMPDATA/KXX/2/7/23~7/F/23~6/F/23~3/F/23~1/F/22~7/F/224/FMPDATA/ALPX/2/1/6~41E6/6~50E6/6~57E6/6~67E6/6~77E6/6~87E6MPDATA/ALPX/2/7/6~98E6/7~07E6/7~15E6/725E6/7~34E6/7~42E6MPDATA/C/2/1i1063*G/1084*G/~1118*G/~1149*G/~1180*G/~1204*GMPDATA,C,2,7,.1224*G,.1254*G,.1274*G,.1305*G,.1326*G,1351*GMP/DENS/2i489/1728/GMP/NUXY/2/0~3MPiREFT/2i70  
Path:C:)NOZZLE File:MATL.MAC2,346.a..4-01-9412:10:32pmPageg9G=386.4F=3600*12 MPTEMP/1/70/100/150/200/250/300 MPTEMP/7i350/400/450/500i550/600!&#xb9;1-VesselWallMaterial-SA302GrB-Carbon-molybdenum MPDATA/EX/1/1/2920E6/29~04E6i2877E6/2850E6/28~25E6/28OOE6MPDATA/EX/1/7/27~70E6i27~40E6/27~20E6/27~OOE6/26~70E6/26~40E6MPDATA/KXX/1/1/233/F/23~6/F/24~1/F/24~4/F/24~6/F/24~7/FMPDATA/KXX/1/7/247/F/24~6/F/24~4/F/24~2/F/23~9/F/23~5/FMPDATA/ALPX/
1/1/7~02E6/7~06E6/7~16E6/7~25E6/7~34E6/7~43E6MPDATA/ALPX/
1i7/750E6/7~58E6/7~63E6/770E6/7~77E6/7~83E6MPDATA,C,1,1,.1047*G,.1070*G,.1110*G,.1142*G,.1173*G,.1203*GMPDATA/C/1/7/1235*G/1264*G/~1286*G/~1313*G/.1343*G/1361*GMP/DENS/1/489/1728/GMP/NUXY/1/0~3MP/REFT/1i70!&#xb9;2-CRDRNozzleMaterial-SA336!&#xb9;3-CladMaterial-308Stainless SteelMPDATA/EX/3/
1/28~30E6/2814E6/27~87E6/2760E6/27~30E6/27~OOE6MPDATA/EX/3i7/26~75E6/26~50E6/26~15E6/25~80E6/25~55E6/25~30E6MPDATA/KXX/3/1/8~6/F/8~7/F/9~0/Fi93/F/9~6/F/9~8/FMPDATA/KXX/
3/7/10~1/F/10~4/F/10~6/F/10~9/F/11~1/F/11~3/FMPDATA/ALPX/3/
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9~10E6/9~19E6/9~28E6/9~37E6/9~45E6/9~53E6MPDATA,C,3,1,.1165*G,.1170*G,.1195*G,.1219*G,.1243*G,1253*GMPDATA,C,3,7,.1275*G,.1289*G,.1298*G,.1311*G/.1320*G,.1328*GMP/DENS/3/489/1728/GMP/NUXY/3/0~3MP/REFT/3i(70+525)/2MPRASSOCIATES, INC.Calcutatfon No.+~~~~~~+PreparedBy+CheckedByPageMPDATA/EX/2/1/29~70E6/29~54E6/29~27E6/29~OOE6/28~75E6/28~50E6MPDATA/EX/2/7/28~20E6/27~90E6/27~70E6/27~50E6/27~20E6/26~90E6MPDATA/KXX/2/1/23~6/F/23~7/F/23~9/F/24~0/F/24~0/F/23~9/FMPDATA/KXX/2/7/23~7/F/23~6/F/23~3/F/23~1/F/22~7/F/224/FMPDATA/ALPX/2/
1/6~41E6/6~50E6/6~57E6/6~67E6/6~77E6/6~87E6MPDATA/ALPX/
2/7/6~98E6/7~07E6/7~15E6/725E6/7~34E6/7~42E6MPDATA/C/2/1i1063*G/1084*G/~1118*G/~1149*G/~1180*G/~1204*GMPDATA,C,2,7,.1224*G,.1254*G,.1274*G,.1305*G,.1326*G,1351*GMP/DENS/2i489/1728/GMP/NUXY/2/0~3MPiREFT/2i70  


~'w-~4ii~~.vowsPath:C:(NOZZLEFile:MATL.MAC2,346.a..4-01-9412:10:32pmPagegr'0g4-HeatTransferCoefficient-CRDRNozzleIDHT=144*3600MPDATAiHF~4i1~100/HTi100/HT~100/HTI100/HTi100/HTi100/HTMPDATAiHFi4i7I100/HTi100/HTi100/HTi100/HTI100/HTi100/HT!g5-HeatTransferCoefficient-VesselAnnulusHT=144*3600MP,HF,5,1000'HTMPRASSOC)ATES,fNC.CatculattonNo.~~~++~PreparedByCheckedBgPagelO,r  
~'w-~4ii~~.vowsPath:C:(NOZZLE File:MATL.MAC2,346.a..4-01-9412:10:32pmPagegr'0g4-HeatTransferCoefficient
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-VesselAnnulusHT=144*3600 MP,HF,5,1000'HTMPRASSOC)ATES, fNC.Catculatton No.~~~++~PreparedByCheckedBgPagelO,r  


eASSOCIATESINC.ENGINEERSAppendixDCALCULATIONOFHEATTRANSFERCOEFFICIENTS
eASSOCIATES INC.ENGINEERS AppendixDCALCULATION OFHEATTRANSFERCOEFFICIENTS


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WMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314RECORDOFREVISIONSCalculationNoPreparedByDP5-23o-ggg-dzeggRevisionCheckedByDescriptionPage~GPtbl~1ttissuG  
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ASSOCIATESINC.ENGINEERSAppendixECRDRNOZZLEFINITEELEMENTMODELBOUNDARYCONDITIONSANDRESULTS
ASSOCIATES INC.ENGINEERS AppendixECRDRNOZZLEFINITEELEMENTMODELBOUNDARYCONDITIONS ANDRESULTS


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.  
lLimpRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULATION TITLEPAGEClient~~~~gp/~/g+//L/gW/Qg/0/rv/~~///Page1ofgqProjectg~/~~~~opygmyrT/QTaskNo.0Z~Titlego~~p~pYAnted/77@AS~i>ZF~ur-I~Calculation No.~-P29-Ct~d-o3 Preparer/Date az.8.'/Z-Z/-5'yChecker/Date g<g.'7~Reviewer/Date Rev.No.  


txrMPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo..080=PP9-Fd'rs-y3RevisionRECORDOFREVISIONSPreparedByDescriptionPage0+1+pv<rrO'JvP  
txrMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No..080=PP9-Fd'rs-y3RevisionRECORDOFREVISIONS PreparedByDescription Page0+1+pv<rrO'JvP  


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  
t>IMPRCalculation No.dd~-cVW-ggg-oJPreparedByMPRAssociates, Inc.320KingStreetAlexandria, VA22314Page~PurposeThepurposeofthiscalculation istodocumenttheboundaryconditions andresultsofafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransient thermal/stress analysissimulating areactorscramwasperformed.
References 1and2arecalculations whichdocumentthefiniteelementmodelgeometryandmaterialproperties.
TheANSYScomputerprogram(Reference 3)wasusedtocalculate thetransient temperature distribution inanaxisymmetric modelofthenozzle.Theprogramwasthenusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.
Theresultsofthisanalysis, intheformofstressdistributions throughthebore/blend sectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluation oftheCRDreturnnozzle.Discussion TheCRDsystemprovideswaterfromthecondensate storagetankatatemperature ofabout70'Ftothecontrolroddrivemechanisms tocoolthecontrolroddrives,toreposition rodsandtoscramtherods.Thesystemoperatesatalltimesthatfuelisinthevessel.ExcessfiowfromtheCRDpumpsisroutedtothereactorvesselviatheCRDreturnnozzle.Consequently, flowthroughtheCRDreturnnozzleistypical.NominalCRDreturnflowrateis17to35gpm.Theflowratedoesnotchangeasaresultofrepositioning acontrolrodsincetheflowdivertedtomovetherodiscompensated bythewaterdisplaced bytherod.AreactorscramresultsinaCRDreturnnozzleflowtransient (Reference 4).Duringascram,theCRDaccumulators discharge todrivethecontrolrodsintothecore.thisresultsinanincreaseinCRDreturnflowto65gpm.Whenaccumulator pressuredropsbelowreactorpressure, CRDflowrategoestozeroastheaccumulators arerecharged.
Aftertheaccumulators havebeenrecharged, CRDflowratereturnstothenominal17to35gpm.Thelastportionofthereactorscramtransient issimulated inthiscalculation.
Attimezerothenozzleisatauniformtemperature of525'Fcorresponding tozeroflowthroughtheCRDreturnnozzleastheaccumulators arerecharged.
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
l41MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.os%->z1wed-o7PreparedByCheckedBygR~Page~gpmwithafluidtemperature of70'F.Apressureof1250psigisappliedtotheinsidesurfaceofthereactorvesselwallandtheinsideofCRDreturnnozzlethroughout thetransient (nominalreactorpressureis1030psig,scrampressureis1250psig).Detailsofthethermalandstructural boundaryconditions arediscussed below.ThermalBoundaConditions forthereactorscramtransient areshownonFigure1anddiscussed below.AttimezerotheCRDreturnnozzleandreactorvesselwallareatauniformtemperature of525'Fcorresponding tothebulkdowncomer fluidtemperature.
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.  
Theoverallheattransfercoefficient betweenthedowncomer fluidandthevesselwallisassumedtobe1000Btu/(hr-ft
-'F).Thisisthevalueusedinprioranalysesforthefeedwater nozzle.At1secondintothetransient, thebulkfluidtemperature intheCRDreturnnozzleisstepchangedto70'F.Theoverallheattransfercoefficient betweentheCRDreturnfluidandthenozzlewallis100Btu/(hr-ft-
'F).Theheattransfercoefficient inthenozzleincludestheeffectsofthefluidfilmontheinsidediameterofthethermalsleeve,conduction throughthethermalsleeve,andnaturalconvection throughthestagnantlayerbetweenthethermalsleeveandthenozzlebore.Reference 5isacalculation oftheoverallheattransfercoefficient betweentheCRDreturnfluidandthenozzleinsidesurface.Theoutsideofthevesselwall,theoutsideofthenozzleandtheradialcutlinesthroughthevesselwallandsafeendaremodeledasadiabatic (noheatflowacrossthesurface).
Structural BoundaConditions includeappliedpressureanddisplacement constraints.
Figure2showstheappliedpressurealongtheinsidesurfaceofthereactorvesselwallandtheinsidesurfaceoftheCRDreturnnozzle.Theappliedpressureonthesesurfacesis1250psig.Apressureisalsoappliedtothesafeendtorepresent theaxialloadintheattachedpiping,Thevalueofthepressureappliedtothesafeendiscalculated asfollows(dimensions arefromReference 1):AintFlAlPend=Where:pi*R12Pint"Aint pi*(R3-R1)=FI/AI13.34in16681.Ibf5.803in2875.psi 0
RMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.oN-d4f-F4ss'-oZPreparedBy7K~PageAintR1PintFlAIR3Pend=Insideareaofsafeend(in)Safeendinsidediameter=2.061inchesInternalpressure=1250psigLongitudinal force(Ibf)Crosssectional areaofsafeendSafeendoutsidediameter=2A69inchesPressureappliedtothesafeend(psi)Figure3showsthedisplacement boundaryconditions appliedtotheendofthereactorvesselwall.Symmetryboundaryconditions areappliedtopermitradialdisplacement alongthecutlinebuttoprohibitrotationofthecutline.Figure4showsthedisplacement boundaryconditions appliedtothesafeend.Couplesareusedtoallowtranslation ofthesafeendcutlinebuttoprohibitrotationofthecutline.ResultsThepeakstressintensity occursattheendofthetransient whensteadystateconditions havebeenreached.Figure5showsthetimehistoryofstressintensity atseveralnodesinthebore/blend region.Thestressesshowninthetimehistoryareatthecladdingtobasemetalinterface.
Figure6showsthecalculated temperature distribution attheendofthetransient.
Thepeakstressintensity inthebasemetalforthetransient occursatnode806intheboreblendregionofthenozzleatthebasemetaltocladdinginterface (Attachment A).Thepeakstressintensity atnode806duetotemperature andpressureis110ksi.Thestressintensity duetopressurealoneatnode806is65ksi.Theprincipal component ofthestressintensity isthehoopstress.Colorcodedcontourplotsofstressdistribution areshowninFigures7through10forpressureonlyloading(timezeroofthetransient).
Figures11through14showstressdistributions attheendofthereactorscramtransient forpressureandtemperature loading.Fourplotsareshownforeachloading:Stressintensity, ASMEcodeorTrescastressintensity, Hoopstress,theZcomponent ofstressfortheaxisymmetric model,~Xcomponent stress,interpreted asasecondhoopstressforthe e0 lLiMpRCalculation No.ogJ-g2g-flag-cgPreparedByZ.N.N~clMPRAssociates, Inc.320KingStreetAlexandria, VA22314Pagespherical modelofthevesselwall,Ycomponent stress,interpreted asaxialstressinthenozzleregion.Figures15and16showthelocations ofnodes806and14.Node806isthepointofmaximumstressintensity attheinterface betweenthecladdingandthebasemetal.Node14isthepointofmaximumstressintensity ontheoutsidesurfaceofthenozzle/vessel intersection.
Astraightline(path)isdrawnfromnode806tonode14andthestressintensity valuesareinterpolated ontothepath(Figure11showstheinterpolation path).Figures17and18showstressintensity alongthispathforthepressureonlycaseandthepressureandtemperature case.Attachment BisatabularlistingofthestressversuspathlengthvaluesforFigures17and18.Attachments CandDprovidetheANSYSinputdataforthethermalandstresspassesoftheanalysis.
Reference 6isthehardcopyoutputfilefortheboththethermalandstresspasses.References 1.MPRCalculation 085-229-EBB-01, "CRDRNozzleFiniteElementModelGeometry".
2.MPRCalculation 085-229-EBB-02, "CRDRNozzleFiniteElementModelMaterialProperties",
Revision0.3.ANSYScomputerprogramversion5.0.MPRCalculation 085-230-ABR-01, "NineMilePointUnit1,ControlRodDriveReturnNozzleThermalandPressureCycles",Revision1.5.MPRCalculation 085-230-ABR-02, "OverallHeatTransferCoefficient ForCRDRNozzleatNMP-1",Revision0.6.ANSYSoutputfileNOZZLE.OUT, 87,853bytesdated4-04-943:45:28pm.  


ANSYS5.0APR7199412:00:41PLOTNO.2NODESTYPENUMCONVZV=1DIST=25.552XF=25.29YF=347.745~g-0I=pg=/EgoHeatTransferBoundaryConditions  
ANSYS5.0APR7199412:00:41PLOTNO.2NODESTYPENUMCONVZV=1DIST=25.552 XF=25.29YF=347.745~g-0I=pg=/EgoHeatTransferBoundaryConditions  


ANSYS5.0APR7199411:59:26PLOTNO.1NODESTYPENUMPRESP8P<PZgcyylrccf~gag-g<~+~JJu~ZV=1DIST=25.552XF=25.29YF=347.745~~QJIQ4/pl]eel+~JCMPressureBoundaryConditionsr/'Cut6  
ANSYS5.0APR7199411:59:26PLOTNO.1NODESTYPENUMPRESP8P<PZgcyylrccf~gag-g<~+~JJu~ZV=1DIST=25.552 XF=25.29YF=347.745~~QJIQ4/pl]eel+~JCMPressureBoundaryConditions r/'Cut6  


ANSYS5'APR7199412:03:24PLOTNO.3NODESTYPENUMUZV=1DIST=25.552XF=25.29YF=347.745+r'I'/IIIIIIIIIIiIIII~~~~IiiiiiiStructuralBoundaryConditions-RadialSymmetry,~/QU/Z&  
ANSYS5'APR7199412:03:24PLOTNO.3NODESTYPENUMUZV=1DIST=25.552 XF=25.29YF=347.745+r'I'/III IIIIIIIiIIII~~~~IiiiiiiStructural BoundaryConditions
-RadialSymmetry,~/QU/Z&  


ANSYS5'APR7199412:05:05PLOTNO.4NODESTYPENUMCP/OAc.+a!1~ZV=1DIST=25.552ZF=25.29YF=347.745A"~1';~,~~~~~~~~//IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIStructuralBoundaryConditions-NoRotationatSafeEndg-((-ugC  
ANSYS5'APR7199412:05:05PLOTNO.4NODESTYPENUMCP/OAc.+a!1~ZV=1DIST=25.552 ZF=25.29YF=347.745A"~1';~,~~~~~~~~//IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIStructural BoundaryConditions
-NoRotationatSafeEndg-((-ugC  


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


ANSYS5.0APR4199416:33:47PLOTNO.1NODALSOLUTIONSTEP=2SUB=21TIME=3601TEMPTEPC=9.434SMN=88.846SMX=523.56288.846100200300400500600ReactorScram,TemperatureProfile+/5-u4C-.  
ANSYS5.0APR4199416:33:47PLOTNO.1NODALSOLUTIONSTEP=2SUB=21TIME=3601 TEMPTEPC=9.434 SMN=88.846SMX=523.56288.846100200300400500600ReactorScram,Temperature Profile+/5-u4C-.  


~gtt"'~SiSQSySfS)9ANSYS5.0APR4199416:32:56PLOTNO.1NODALSOLUTIONSTEP=1SUB=1TIME=1SINT(AVG)DMX=1.501SMN=1421SMNB=920.904SMZ=66400SMKB=72225142186411586123081303003752044740519605918066400PressureOnly,StressIntensityP/6u4E'  
~gtt"'~SiSQSySfS)9ANSYS5.0APR4199416:32:56PLOTNO.1NODALSOLUTIONSTEP=1SUB=1TIME=1SINT(AVG)DMX=1.501SMN=1421SMNB=920.904 SMZ=66400SMKB=72225 142186411586123081303003752044740519605918066400PressureOnly,StressIntensity P/6u4E'  


ANSYS5.0APR4199416:33:00PLOTNO.2NODALSOLUTIONSTEP=1SUB=1TIME=1SZ(AVG)RSYS=ODMX=1.501SMN=-22178SMNB=-30892SMX=63262SMXB=68966-22178-12685-31926302157952528834782442755376963262PressureOnly,HoopStressErbv~g8  
ANSYS5.0APR4199416:33:00PLOTNO.2NODALSOLUTIONSTEP=1SUB=1TIME=1SZ(AVG)RSYS=ODMX=1.501SMN=-22178SMNB=-30892 SMX=63262SMXB=68966
-22178-12685-31926302157952528834782442755376963262PressureOnly,HoopStressErbv~g8  


S$.E..eCANSYS5.0APR4199416:33:03PLOTNO.3NODALSOLUTIONSTEP=1SUB=1TIME=1SX(AVG)RSYS=ODMX=1.501SMN=-3074SMNB=-13025SMZ=42194SMZB=46227-30741956698612015170452207527104321343716442194PressureOnly,XComponentStressP/'bu/ZC  
S$.E..eCANSYS5.0APR4199416:33:03PLOTNO.3NODALSOLUTIONSTEP=1SUB=1TIME=1SX(AVG)RSYS=ODMX=1.501SMN=-3074SMNB=-13025 SMZ=42194SMZB=46227
-30741956698612015170452207527104321343716442194PressureOnly,XComponent StressP/'bu/ZC  


ANSYS5.0APR4199416:33:06PLOTNO.4NODALSOLUTIONSTEP=1SUB=1TIME=1SY(AVG)RSYS=ODMX=1.501SMN=-23031SMNB=-32313SMX=4943SMXB=9878-23031-19923-16815-13706-10598-7490-4382-127318354943PressureOnly,YComponentStress.g/gu/Z&/0  
ANSYS5.0APR4199416:33:06PLOTNO.4NODALSOLUTIONSTEP=1SUB=1TIME=1SY(AVG)RSYS=ODMX=1.501SMN=-23031SMNB=-32313 SMX=4943SMXB=9878
-23031-19923-16815-13706-10598-7490-4382-127318354943PressureOnly,YComponent Stress.g/gu/Z&/0  


~~q~</'oc-877onf/~(ANSYS5.0APR4199416:33:25PLOTNO.5NODALSOLUTIONSTEP=14SUB=1TIME=3600SINT(AVG)DMX=1.46SMN=3550SMNB=2589SMX=95834SMXB=10440635501380424057343114456554819650727532685580~95834X~sSW~oWReactorScram,StressIntensityy4-&,c.//  
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(x10I01)652612ANSYS5.0APR4199418:06:06PLOTNO.1POST1STEP=1SUB=1TIME=1PATHPLOTNOD1=806NOD2=14CO5735331C453CZV=1DIST=0.75XF=0.5YF=0.5ZF=0.5CENTROIDHIDDEN41337333329325370.5411.0831~6242.1653.2482.7073.794.3314.8725.414Posi4ion,ID4oODPressureOnlyBiduel7  
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Thiscouldinvalidate errorestimation.
SUMMARYOFVARIABLESINTMAX=65283.MIN=25366.DISPLAYALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=0CUMULATIVE DISPLAYNUMBER1WRITTENTOFILEXPATH.PLT DISPLAYTITLE=PressureOnlyPRINTALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=01-RASTERMODE.*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION50*****MPRASSOCIATES VERSIONPC386/486180607APR04g1994CPFORSUPPORTCALLPHONE703/519-0200 FAXPressureOnly22.460*****PATHVARIABLESUMMARY*****S0.00000E+00 0.112780.225570.338350.451140.563920.676700.789490902271.01511.12781.24061.35341.46621.57901.69181.80451.91732.03012.14292.25572.36852.48132.59402.7068NT6528356417.55542.54202.52785.51498.50264.49109.48019.46971.46001.45053.44170.43285.42462.41670.40901.40178.39460.38800.38185.37550.36926.36478.35974.I~oCs  


Path:C:)NOZZLEFile:XPATH.OUT13,436.a..4-04-946:06:28pmXageSQ82.81962.93243.04523.15803.27073.38353.49633.60913.72193.83473.94744.06024.17304.28584.39864.51144.624235466.34944.34360.33722.32732.31830'0986.30218.29503'883128199.27566.2693826171'5366.27591.29301.*****ANSYS-ENGINEERINGANALYSISSYSTEMREVISION5.0*****MPRASSOCIATESVERSIONPC386/486180607APR04~1994CPFORSUPPORTCALLPHONE703/519-0200FAXPressureOnly22.510,*****PATHVARIABLESUMMARY*****S4.73694.84974.96255.07535.18815.30095.4136SINT31204.33304.35360.36726.38077.39423.40778.USELASTSUBSTEPONRESULTFILEFORLOADCASE0SETCOMMANDGOTLOADSTEP=14SUBSTEP=1CUMULATIVEITERATION=14TIME/FREQUENCY=3600.0TITLE=ReactorScramTransientGRAPHPLOTKEY=1XAXISLABEL=Position,IDtoODYAXISLABEL=StressIntensity(psi)  
Path:C:)NOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmXageSQ82.81962.93243.04523.15803.27073.38353.49633.60913.72193.83473.94744.06024.17304.28584.39864.51144.624235466.34944.34360.33722.32732.31830'0986.30218.29503'883128199.27566.2693826171'5366.27591.29301.*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSIONPC386/486180607APR04~1994CPFORSUPPORTCALLPHONE703/519-0200 FAXPressureOnly22.510,*****PATHVARIABLESUMMARY*****S4.73694.84974.96255.07535.18815.30095.4136SINT31204.33304.35360.36726.38077.39423.40778.USELASTSUBSTEPONRESULTFILEFORLOADCASE0SETCOMMANDGOTLOADSTEP=14SUBSTEP=1CUMULATIVE ITERATION=
14TIME/FREQUENCY=
3600.0TITLE=ReactorScramTransient GRAPHPLOTKEY=1XAXISLABEL=Position, IDtoODYAXISLABEL=StressIntensity (psi)  


Path:C:iNOZZLEFile:XPATH.OUT13,436.a..4-04-946:06:28pmDEFINEAPATHFORSUBSEQUENTCALCULATIONSTHROUGHNODES:80614Page6a<Z***NOTE***CP=32.130TIME=18:06:17Previousinterpolatedpathdatahasbeenerased.ReissuePDEFcommandtointerpolatedesireddata.DEFINEPATHINPATHCOORDINATESYSTEM0DIRECTIONMAXMINX6.28552.2798Y348.57344.93Z0.00000E+000.00000E+00TOTALPATHLENGTH=5.4136DEFINEPATHVARIABLESINTASTHENODALDATAITEM=SCOMP=INTROTATEDINTOCOORDINATESYSTEM0ANDMOVEDTOTHEPATHNUMBEROFPATHVARIABLESDEFINEDIS5***WARNING***CP=37.950Theselectedelementsetcontainsmixedmaterials.Thiscouldinvalidateerrorestimation.TIME=1806:22SUMMARYOFVARIABLESINTMAX=0.10997E+06MIN=39107.CUMULATIVEDISPLAYNUMBER2WRITTENTOFILEXPATH.PLTDISPLAYTITLE=ReactorScramTransientRASTERMODE.PRINTALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=01*****ANSYS-ENGINEERINGANALYSISSYSTEMREVISION5.0*****MPRASSOCIATESVERSION=PC386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200FAXReactorScramTransient41.680*****PATHVARIABLESUMMARY*****S0.00000E+000.112780.225570.338350.451140.563920.67670SINT0.10997E+06911)rru~i88915.86153.83317.80781.78373.  
Path:C:iNOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmDEFINEAPATHFORSUBSEQUENT CALCULATIONS THROUGHNODES:80614Page6a<Z***NOTE***CP=32.130TIME=18:06:17Previousinterpolated pathdatahasbeenerased.ReissuePDEFcommandtointerpolate desireddata.DEFINEPATHINPATHCOORDINATE SYSTEM0DIRECTION MAXMINX6.28552.2798Y348.57344.93Z0.00000E+00 0.00000E+00 TOTALPATHLENGTH=5.4136DEFINEPATHVARIABLESINTASTHENODALDATAITEM=SCOMP=INTROTATEDINTOCOORDINATE SYSTEM0ANDMOVEDTOTHEPATHNUMBEROFPATHVARIABLES DEFINEDIS5***WARNING***CP=37.950Theselectedelementsetcontainsmixedmaterials.
Thiscouldinvalidate errorestimation.
TIME=1806:22SUMMARYOFVARIABLESINTMAX=0.10997E+06 MIN=39107.CUMULATIVE DISPLAYNUMBER2WRITTENTOFILEXPATH.PLT DISPLAYTITLE=ReactorScramTransient RASTERMODE.PRINTALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=01*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSION=PC 386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200 FAXReactorScramTransient 41.680*****PATHVARIABLESUMMARY*****S0.00000E+00 0.112780.225570.338350.451140.563920.67670SINT0.10997E+06 911)rru~i88915.86153.83317.80781.78373.  


Patn:File:0.789490.902271.01511.12781.24061.35341'6621.57901.69181.80451.91732.03012.14292.25572.36852.48132.59402'0682.81962.93243.04523.15803.27073.38353.49633.60913.72193.83473.9474406024.17304.28584.39864.51144.6242C:KNOZZLEXPATH.OUT13,436.a..4-04-946:06:28pm76148.74078.72106.70305.68564.66937.65312.63805.62374.60995.59673.58388.57214.56098.54950.53857.53067.52158.51230.50269.49216.48061.46233.44546.43265.42541.41859.41175.40518.39815.39107.39160.41883.44307.46492.Page7Pg8*****ANSYS-ENGINEERINGANALYSISSYSTEMREVISION5.0*****MPRASSOCIATESVERSION=PC386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200FAXReactorScramTransient41.740*****PATHVARIABLESUMMARY*****S4.73694.84974.9625507535.1881SINT49026'1915.54876.'57081.59280.  
Patn:File:0.789490.902271.01511.12781.24061.35341'6621.57901.69181.80451.91732.03012.14292.25572.36852.48132.59402'0682.81962.93243.04523.15803.27073.38353.49633.60913.72193.83473.9474406024.17304.28584.39864.51144.6242C:KNOZZLE XPATH.OUT13,436.a..4-04-946:06:28pm76148.74078.72106.70305.68564.66937.65312.63805.62374.60995.59673.58388.57214.56098.54950.53857.53067.52158.51230.50269.49216.48061.46233.44546.43265.42541.41859.41175.40518.39815.39107.39160.41883.44307.46492.Page7Pg8*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSION=PC 386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200 FAXReactorScramTransient 41.740*****PATHVARIABLESUMMARY*****S4.73694.84974.9625507535.1881SINT49026'1915.54876.'57081.59280.  


Path:C:(NOZZLEFile:XPATH.OUT13,436.a..4-04-946:06:28pmPage8~+85.30095.413661484.63709.*****ENDOFINPUTENCOUNTERED*****NUMBEROFWARNINGMESSAGESENCOUNTERED=NUMBEROFERRORMESSAGESENCOUNTERED=*****PROBLEMTERMINATEDBYINDICATEDERROR(S)ORBYENDOFINPUTDATA*****ANSYSRUNCOMPLETEDREV.5.0CPTIME(sec)ELAPSEDTIME(sec)47.00047.000PC386/486TIME=18:06:26DATE=04/04/94  
Path:C:(NOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmPage8~+85.30095.413661484.63709.*****ENDOFINPUTENCOUNTERED
*****NUMBEROFWARNINGMESSAGESENCOUNTERED=
NUMBEROFERRORMESSAGESENCOUNTERED=
*****PROBLEMTERMINATED BYINDICATED ERROR(S)ORBYENDOFINPUTDATA*****ANSYSRUNCOMPLETED REV.5.0CPTIME(sec)ELAPSEDTIME(sec)47.00047.000PC386/486TIME=18:06:26DATE=04/04/94  


4774<P~Fr~iC'ath:C:(NOZZLEFile:BCT.INP/SOLUTIONOUTRESgALLgALLANTYPE,TRANSKBC,1TREF,70THOT=525TCOLD=70570.a..3-28-945:13:42pm!1=StepChange,0=RampPage1p//TUNIF,THOTLSELISJLOCgXgRlSFLgALLgCONVg4ggTHOTCMSELISgLIDLSELgU~LOC/XgR1SFLgALLgCONVI5IgTHOTALLSELNSUBST,1TIME,1SOLVESAVELSEL~SgLOCIXgR1SFLDELEgALLfCONVSFLgALL~CONVI4I~TCOLDALLSELUTOTS,ONELTIM,1,1TIME,3601SOLVESAVEFINISH!CRDRID!NumberofSub-Load-Steps!CRDRID!AutomaticTime-SteppingON~0mAmmC~a~WIN'.CalculaUon80.~PreparactDyCheckedByC'-)Page  
4774<P~Fr~i C'ath:C:(NOZZLE File:BCT.INP/SOLUTION OUTRESgALLgALL ANTYPE,TRANS KBC,1TREF,70THOT=525TCOLD=70570.a..3-28-945:13:42pm!1=StepChange,0=RampPage1p//TUNIF,THOT LSELISJLOCgXgRlSFLgALLgCONVg4ggTHOTCMSELISgLIDLSELgU~LOC/XgR1SFLgALLgCONVI5IgTHOTALLSELNSUBST,1TIME,1SOLVESAVELSEL~SgLOCIXgR1SFLDELEgALLfCONVSFLgALL~CONVI4I~TCOLDALLSELUTOTS,ONELTIM,1,1 TIME,3601 SOLVESAVEFINISH!CRDRID!NumberofSub-Load-Steps
!CRDRID!Automatic Time-Stepping ON~0mAmmC~a~WIN'.CalculaUon 80.~Preparact DyCheckedByC'-)Page  


Path:C:)NOZZLEFile:STRESS.INP/PREP7ETCHG767.a..3-29-9412:17:26pm4TrHrumgnli7)Page1g/CSYS,1LSELISILOCgYgANGlDL,ALL,,SYMMCSYS,OLSEL,ALL!Symmetryat,CutNSELIS~LOCgYIRV+TV+H1~05gRV+TV+H1+05CP~1~UYgALLTREF,70PINT=1250CMSELgS/LIDSFLgALLfPRESIPINTPI=ACOS(-1)FLONG=PINT*PI*R1**2ALONG=PI*(R3**2-R1**2)PLONG=FLONG/ALONGLSELgSgLOCgYIRV+TV+H1~05gRV+TV+H1+05SFLgALLIPRESIPLONGFINISH!LongitudinalForce!EndPressure/SOLUTIONANTYPEISTATICNSUBST,1ALLSEL*NumberofSub-Load-Steps*DIM,SNAP,ARRAY,14SNAP(1)1I10I20I40I60J801100'00SNAP(9)600I1200I1800g2400g3000g3600NT=14*DO,N,1,NTT=SNAP(N)TIME,TLDREADgTEMPgIgTIgNOZZLEgRTHSOLVE*ENDDOSAVEFINISHMpRASSOCIATES,INC..CalculationNo.PreparedByCheckedByPage  
Path:C:)NOZZLE File:STRESS.INP/PREP7ETCHG767.a..3-29-9412:17:26pm4TrHrumgnli7)Page1g/CSYS,1LSELISILOCgYgANGlDL,ALL,,SYMM CSYS,OLSEL,ALL!Symmetryat,CutNSELIS~LOCgYIRV+TV+H1~05gRV+TV+H1+05CP~1~UYgALLTREF,70PINT=1250 CMSELgS/LIDSFLgALLfPRESIPINTPI=ACOS(-1)
FLONG=PINT*PI*R1**2 ALONG=PI*(R3**2-R1**2)
PLONG=FLONG/ALONG LSELgSgLOCgYIRV+TV+H1
~05gRV+TV+H1+
05SFLgALLIPRESI PLONGFINISH!Longitudinal Force!EndPressure/SOLUTION ANTYPEISTATICNSUBST,1ALLSEL*NumberofSub-Load-Steps
*DIM,SNAP, ARRAY,14SNAP(1)1I10I20I40I60J801100'00SNAP(9)600I1200I1800g2400g3000g3600NT=14*DO,N,1,NT T=SNAP(N)TIME,TLDREADgTEMPgIgTIgNOZZLEgRTHSOLVE*ENDDOSAVEFINISHMpRASSOCIATES, INC..Calculation No.PreparedByCheckedByPage  


PD~MPRASSOCIATESINC.EN&INEERSAppendixFLO%CYCLEFATIGUEUSAGE  
PD~MPRASSOCIATES INC.EN&INEERSAppendixFLO%CYCLEFATIGUEUSAGE  


PLIMpRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CALCULAT!ONTITLEPAGEClienthJIRGR<R4(ol8>ICPUBA.Co'R~DNRTidlJPage1ofProjectQg,gg~~Q<agQ>~4.7~4'~C~c~lc.~>]TaskNo.o&s=)50gp.gwk,~~L.,'nza~4L,~P~lqF'4j<vwq~CalculationNo.ugly530psp3Preparer/DateChecker/Datepiq6(Reviewer/DateAPL~~~](~i~asRev.No.  
PLIMpRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULAT!ON TITLEPAGEClienthJIRGR<R4(ol8>ICPUBA.Co'R~DNRTidlJ Page1ofProjectQg,gg~~Q<agQ>~4.7~4'~C~c~lc.~>]TaskNo.o&s=)50gp.gwk,~~L.,'nza~4L,~P~lqF'4j<vwq~Calculation No.ugly530psp3Preparer/Date Checker/Date piq6(Reviewer/Date APL~~~](~i~asRev.No.  


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t>~MPRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.og<-~so-PsP9'2S'~CheckedByPagePvCpo&F  
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PA1MPRASSOCIATESINC.ENGINEERSAppendixGCRACKGROWTHRATECOMPUTERPROGRAMVERIFICATION
PA1MPRASSOCIATES INC.ENGINEERS AppendixGCRACKGROWTHRATECOMPUTERPROGRAMVERIFICATION


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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(Al&#xb9;,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"OPENoutfileSFOROUtPUTAS&#xb9;2'eadinputfileINPUTtl,Aot,NflnalINPUTt1,Rmin,CIRmlnt,C2Rmint,ml,e2INPUT&#xb9;I,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  
0()vac-Qgc.~Q~RC-K.BXC;'hisprogramcalculates crackgrowthIn~nozzleduetopressureand'hermalcyclesDECLARESUSCrackgrowth (At,Nsbl,PII,P2I,Sdist1,T11,TrII,Sdlst2,T21,Tr21)DECLAREfUNC'I!OH Klt(Al&#xb9;,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(ANDS OPENinputflleS FORINPUTAStlflan~LEN(RTRINS(lnputfileS))
outflleS~LEFIS(RIRINS(lnputflleS),
flan-4)+".OUT"OPENoutfileSFOROUtPUTAS&#xb9;2'eadinputfileINPUTtl,Aot,NflnalINPUTt1,Rmin,CIRmlnt,C2Rmint,ml,e2INPUT&#xb9;I,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'onstants Pi~3.I81592Calculate crackgrowthNtot~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(A&#xb9;,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+ds&#xb9;FUNCTIONdscgrf(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  
CCF(Dd(P-ACE,E,ME.(('~>SUBCrsckGrorrth (A&#xb9;,Nsb,Pl,P2,Sdlstl,'ll,Trl,Sdist2,12,Tr2)~Thissubroutine calculates crackgrorrthgiventheInitialcracklength,'hememberofcyclesandthemlnfaaraandmsxfaaaapressures and-'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+ds&#xb9;FUNCTIONdscgrf(cB:,R)'alculate dscBIgivendKsndRSHAREDhain,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'tlOH FUNCTIONKit(Alt,L)'alculate StressIntensity factor'iven crack'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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lLIMpRMPRAssociates,Inc.320KingStreetAlexandria,VA22314CalculationNo.OSS'-Z~-t2SPIPreparedByCheckedByPager2PInputVariableDefinitionsforMCRACK.EXE:Ao-NfinalRminC1RminC2Rmfnm1lll2RmaxC1RmaxC2RmaxF1F2F3FIoNstrdistBO(-)'B1(-)B2(-)B3(-)RefStr(-)McyctypeRepcyc(-)Nsubcyc(-)Nsub(-,-)Pmin(-~-)Pmax(-e-)Strdistnn(-T1min(-,-)T2min(-,-)strdistmx(-71max(-,-)72max(-e-)1'nitialCrackLength(inches)TotalNwberofCyclestoAnalyzeHinfmmRfactorcorrespondingtocrackgrowthconstantsFirstParisCrackGrowthLawCoefficientforRminSecondParisCrackGrowthLawCoefficientforRminFirstParisCrackGrowthLawExponentforRminandRmaxSecondParisCrackGrowthLawExponentforRminandRmaxHaxigunRfactorcorrespondingtocrackgrowthconstantsFirstParisCrackGrowthLawCoefficientforRmaxSecondParisCrackGrowthLawCoefficientforRmaxStressIntensityHagnificationFactorStressIntensityHagnificationFactorStressIntensityHagnificationFactorStressIntensityHagnificationFactorNumberofThermalStressDistributions(Note1)StressDistributionCoefficientStressDistributionCoefficientStressDistributionCoefficientStressDistributionCoefficientReferencePressureorTemperatureChangeforStressDistribution(PrefordTref)NsmterofDifferentTypesofCycles(Note2)NumberofCycleRepetitions(Mote2)NumberofDifferentTypesofSubcyclesforaGivenCycle(Note2)NumberofCyclesforaGivenSubcyclePressureatHinisxIaStressStateDuringCycle(psi)PressureatHaxfaunStressStateDuringCycle(psi)ThermalStressDistributionNumberforHinirmmTemperaturesFirstNozzleTegperatureatHinimmStressStateDuringCycle('F)(Note3)SecondNozzleTemperatureatHiniaunStressStateDuringCycle('F)(Note3)ThermalStressDistributionNunberforHaxiaunTemperaturesFirstNozzleTemperatureatHaxiguaStressStateDuringCycle('F)(Note3)SecondNozzleTemperatureatHaxinxmStressStateDuringCycle('F)(Note3)Aroe'roohio.mlira+As~lJ:~cLip&.AlebrIlgIIVIr0(aeerie$horro~a(erre~%)resenes4eessAstlo~4ieuo,a.merc~r.ka~a)iwnmoP5',Pp.en)$'psoF'ela',~<lec~l1e~rp]o8gigere~]gyp'l'uboolclcss4e~decrsnsr's+oic"ppresrurcnd/uu%~premc-.erlc(c.ricevr'riel"gs.,Ii"nrroloei.oC'~refo.equioyelbo.t'cliaa$~oIPa~o.(-')oJrMerel/inietypciAVhcnor/pele.-Wc.4)er~J~gessAsarLJ~serec4cae4eri~'J51.~+~taI'eAAe~onc~,Ll,~hem~,
MI~ai~~~$Pile.C<<w4a<<.Aqagr<yrna'tC' pi(8%NB>h,~.ql,~~CA."~A~eJe~g<~.Ke.(D14WlQf~laCLI&CAQhl&CO(~i4IplUse.5'e<ed%-44~cl~l4~Wv~~ia44lJ-.,:4s,.<.khi.4l<<<<av~di~$~Qe<~a$E4eHnI<IFigetEl<4~<ewerDlo4'$4<IAc)<I<<Q<lP'aCovAvYla, khalyahoo..I44.I~(wdala.Ape<<d~Vl~e.~-lsos.g;s4h.H~p.dflic.II&l<Yb+IAj'<Ja,svsc(<$pl<l/e)II/&LI 0
0' Ao,NfinalRmin,C1Rmin,C2Rmin,m1,m2Rmax,C1Rmax,C2RmaxF1,F2,F3,F4Nstrdist80(0),81(0),82(0),83(0),RefStr(0)80(1),81(1),82(1),83(1),RefStr(1)0'08Z080(Nstrdist),81(Nstrdist),82(Nstrdist),83(Nstrdist),RefStr(Hstrdist)NcyctypeRepcyc(1),Nsubcyc(1)Nsub(1,1),Pmin(1,1),Pmax(1,'1),Strdistan(1,1),T1min(1,1),T2min(1,1),Strdistmx(1,1),T1max(1,1),T2max(1,1)Nsub(1,Nsubcyc(1)),Pmin(1,Ksubcyc(1)),Pmax(1,Hsubcyc(1)),Strdistan(1,Nsubcyc(1)),...,T2max(1,Nsubcyc(1))Repcyc(2),Nsubcyc(2)Nsub(2,1),Pmin(2,1),Pmax(2,1),Strdistan(2,1),Tlmin(2,1),T2min(2,1),Strdistmx(2,1),T1max(2,1),T2max(2,1)(0lu(0CLHsub(2,Nsubcyc(2)),Pmin(2,Nsubcyc(2)),Pmax(2,Ksubcyc(2)),Strdistaa(2,Nsubcyc(2)),...,T2max(2,Nsubcyc(2))Repcyc(Hcyctype),Xsubcyc(Hcyctype)Nsub(Kcyctype,1),Pmin(Ncyctype,1),Pmax(Hcyctype,1),Strdistam(Kcyctype,1),...,T2max(Kcyctype,1)Nsub(Kcyctype,Nsubcyc(Ncyctype)),Pmin(Kcyctype,Nsubcyc(Ncyctype)),...,T2max(Ncyctype,Nsubcyc(Kcyctype))gyveQ.l~g$7(+~40fJckjIcg.(=~QCp~g~~$~~~~i~~(~~~~~~I~i(pJ~g~,pi~i)  
lLIMpRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.OSS'-Z~-t2SPIPreparedByCheckedByPager2PInputVariableDefinitions forMCRACK.EXE:
Ao-NfinalRminC1RminC2Rmfnm1lll2RmaxC1RmaxC2RmaxF1F2F3FIoNstrdistBO(-)'B1(-)B2(-)B3(-)RefStr(-)
McyctypeRepcyc(-)
Nsubcyc(-)
Nsub(-,-)
Pmin(-~-)Pmax(-e-)
Strdistnn(-
T1min(-,-)
T2min(-,-)
strdistmx(-
71max(-,-)
72max(-e-)
1'nitialCrackLength(inches)TotalNwberofCyclestoAnalyzeHinfmmRfactorcorresponding tocrackgrowthconstants FirstParisCrackGrowthLawCoefficient forRminSecondParisCrackGrowthLawCoefficient forRminFirstParisCrackGrowthLawExponentforRminandRmaxSecondParisCrackGrowthLawExponentforRminandRmaxHaxigunRfactorcorresponding tocrackgrowthconstants FirstParisCrackGrowthLawCoefficient forRmaxSecondParisCrackGrowthLawCoefficient forRmaxStressIntensity Hagnification FactorStressIntensity Hagnification FactorStressIntensity Hagnification FactorStressIntensity Hagnification FactorNumberofThermalStressDistributions (Note1)StressDistribution Coefficient StressDistribution Coefficient StressDistribution Coefficient StressDistribution Coefficient Reference PressureorTemperature ChangeforStressDistribution (PrefordTref)NsmterofDifferent TypesofCycles(Note2)NumberofCycleRepetitions (Mote2)NumberofDifferent TypesofSubcycles foraGivenCycle(Note2)NumberofCyclesforaGivenSubcyclePressureatHinisxIaStressStateDuringCycle(psi)PressureatHaxfaunStressStateDuringCycle(psi)ThermalStressDistribution NumberforHinirmmTemperatures FirstNozzleTegperature atHinimmStressStateDuringCycle('F)(Note3)SecondNozzleTemperature atHiniaunStressStateDuringCycle('F)(Note3)ThermalStressDistribution NunberforHaxiaunTemperatures FirstNozzleTemperature atHaxiguaStressStateDuringCycle('F)(Note3)SecondNozzleTemperature atHaxinxmStressStateDuringCycle('F)(Note3)Aroe'roohio.mlira+As~lJ:~cLip&.AlebrIlgIIVIr0(aeerie$horro~a(erre~%)resenes4eessAstlo~4ieuo, a.merc~r.ka~a)iwnmoP5',Pp.en)$'psoF'ela',~<lec~l1e~rp]o8gigere~]gyp'l'uboolclcs s4e~decrsnsr's+
oic"ppresrurcnd/uu%~premc-.erlc(c.ricevr'riel"gs.,Ii"nrroloei.oC'~refo.equioyelbo.t'cliaa$~oIPa~o.(-')oJrMerel/inietypciAVhcnor/pele.-Wc.4)er~J~gessAsarLJ~serec4cae4eri~'J 51.~+~taI'eAAe~onc~,
Ll,~hem~,
0' Ao,NfinalRmin,C1Rmin,C2Rmin,m1,m2Rmax,C1Rmax,C2RmaxF1,F2,F3,F4Nstrdist80(0),81(0),82(0),83(0),RefStr(0) 80(1),81(1),82(1),83(1),RefStr(1) 0'08Z080(Nstrdist),
81(Nstrdist),
82(Nstrdist),
83(Nstrdist),
RefStr(Hstrdist)
NcyctypeRepcyc(1),
Nsubcyc(1)
Nsub(1,1),Pmin(1,1),Pmax(1,'1),
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FPMPRFN&INEEASAppendixHCRACKGROWTHRATEANALYSISCASES
FPMPRFN&INEEAS AppendixHCRACKGROWTHRATEANALYSISCASES


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115.0110.0CRDRNozzleStressDistributionLoadCase1Oo+icCfoDI105.0~~100.0~95090.0C85.080.075.01IIIIIIIIIII70.065.II00.100.200.300.40DepthThroughIJI0.500.600.700.800.901.00NozzleWall(inches)~ActualStress~CurveFitStress>CDQfO~xO~QD-CIICo(~g'IlQ~tylOGlo  
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70.0gt&URE5CRDRNozzleStressDistributionLoadCase2IIIOQop65.060.0e55.0C~50.0(045.0IIrIII'LILIIIIII'ILLILLIIIII'LIIILIILIIt~'ILLIILIIII'3QCLO40II.ooo.to0.200.30OAO0.500.600.70.0.800.901.00DepthThroughNozzleWall(inches)~ActualStress~CurveFitStress>Cog6UxN~f~a-tCtIQCoo(~g'o6lO~CeIQcoo  
70.0gt&URE5CRDRNozzleStressDistribution LoadCase2IIIOQop65.060.0e55.0C~50.0(045.0IIrIII'LILIIIIII'ILLILLIIIII'LIIILIILIIt~'ILLIILIIII'3QCLO40II.ooo.to0.200.30OAO0.500.600.70.0.800.901.00DepthThroughNozzleWall(inches)~ActualStress~CurveFitStress>Cog6UxN~f~a-tCtIQCoo(~g'o6lO~CeIQcoo  


t&#xc3;MPRENGINEERSAppendixIIMPLEMENTATIONPLAN
t&#xc3;MPRENGINEERS AppendixIIMPLEMENTATION PLAN


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  
WMPRASSOCIATESINC.ENGINEERSImplementation PlanforStructural AnalysisofNMP-0CRDRNozzleSpecification No.MPR-085-223-01 Revision0February1994Preparedby:Reviewedby:EdwardBird(MPREngineer)
I1.:,('..'~/;,
JaesNestell(MPREnginedr)
~~/~S~YDateDate'pprovedby:PhillipKasik(MPREngineer) lS-5'-DateApprovedby:.QP.IK(JQ.L'Qr-AcJneGawler(NMPCCognizant Engineer) c~l;-qIDate320KING51REETAI,EXANDRIA, VA22314-323 703-51'.0200 FAX70351r7.0224  


r~lMPRASSOCIATESINC.ENGINEERSCONTENTSSectionBACKGROUNDPURPOSETECHNICALAPPROACHExperienceSurveyThermalLoadDefinitionStructuralAnalysisFractureMechanics/FatigueEvaluationINFORMATIONSOURCES~Pae10"11-  
r~lMPRASSOCIATES INC.ENGINEERS CONTENTSSectionBACKGROUND PURPOSETECHNICAL APPROACHExperience SurveyThermalLoadDefinition Structural AnalysisFractureMechanics/Fatigue Evaluation INFORMATION SOURCES~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
eASSOCIATES INC.EN&INEEAS BACKGROUND NUREG-0619 requiresNMPCtoperformanin-vessel PTexamononeofthefourfeed-waternozzlesandthecontrolroddrivereturn(CRDR)nozzleduringthenextrefueling outageatNineMilePointUnit1.Thisexamisexpectedtoresultinhighworkerexposure, potential outagedelaysandassociated highcostswithoutcomparable increases insafety.Asaresult,NMPCplanstorequestanexemption fromthisrequirement, basedonthefollowing:
Automated UTinspection systemsarenowavailable forperforming accurateinspections fromoutsideofthevessel.Modifications havebeenmadetothefeedwater nozzles,spargersandfiowcontrolsystemtoeliminate orlessenthefeedwater nozzlecrackingproblemsthatoccurredinthe1970s.~NodamagewasfoundontheCRDRnozzleduringthein-vessel examin1977orduringvisualexaminations thereafter.
~DetailedmodelingandanalyseshavebeendonetoshowthatsmallQawswillnotgrowtounacceptable valueswithinspecified operating periodsforthefeedwater nozzles.PURPOSEThepurposeofthistaskistoevaluatethelong-term susceptibility oftheCRDRnozzletothermalfatiguecracking, determine crackgrowthratesandcriticalcracksizes.NMPCwillusetheresultsofthistasktosupporttheirexemption requestandtoevaluatetheseverityofanyindication foundduringtheautomated UTinspection plannedforthe1995refueling outage.TECHNICAL APPROACHAfourstepapproachwillbeusedtoaccomplish thistask:~Experience Survey~ThermalLoadDefinition
~Structural Analysis~FractureMechanicslFatigue Evaluation


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.  
Eachofthesestepsisdescribed below.Theresultsofallfourstepswillbedocumented inasingleMPRreport.Thisworkwillbeperformed inaccordance with10CFR50,AppendixB,usingthelatestapprovedversionofMPR'sQAManual.ExerienceSurveAtelephone surveyofapplicable BWRswillbeperformed todetermine theirexami-nationhistory/frequency andcrackingexperience fortheCRDRnozzle.Surveyinformation willbecollected forweldedthermalsleevedesignssimilartoNMP-1andothernon-welded designs.Thetelephone surveywillincludequestions aboutexami-nationtechniques andtools.Thisinformation isexpectedtobeusefulinevaluating thesensitivity ofthecrackingproblemtothermalsleevedesign.ThermalLoadDefinition TheNMP1operating flowcharacteristics andlogrecordsoftheCRDsystemwillbereviewedtodetermine flowvariations andresulting temperature variations fortheCRDRnozzleduringdifferent CRDoperating conditions, e.g,,duringmovementofthecontrolrodsandscrams,andduringdifferent plantoperating conditions, e.g.,startup,shutdown, andstandby.Themagnitude andfrequency ofthermalandpressurechangeswillbeusedasinputtothestructural modelandtocalculate crackgrowthratesandfatigueusage.Structural AnalsisTheANSYScomputerprogramwillbeusedtodevelopatwo-dimensional axisymmetric finiteelementmodeloftheCRDRnozzle.ThemodelwillincludeasectionofthereactorvesselwalladjacenttotheCRDRnozzle.Theextentofthissectionwillbelongenoughtoeliminate interaction betweentheboundaryconditions appliedtothevesselwallandtheCRDRnozzle.Theradiusofthereactorvesselwallsectionwillbemodeledat3.2timestheactualradius.Thiswillinsurethatthemaximumhoopstressandstressintensity calculated bytheaxisymmetric modelwillbecomparable tothoseintheactualthree-dimensional intersection.
Thermalboundaryconditions, including heattransfercoefficients, willbecalculated fortheloadcycledefinedabove.Theresultsofthepreviously performed feedwater nozzleanalysiswillbefactoredintothiscalculation.
Thetemperature distribution withintheaozzlewillbecalculated asafunctionoftimefortheseboundaryconditions.
Through-wallstressesthatresultfrompressureandtemperature willbecalculated atseveralsnap-shotsintimetoestablish thetimeofpeakstress.Through-wall stresseswillbeusedinthefracturemechanics/fatigue evaluation below.Theoriginalstructural evaluation fortheCRDRnozzledocumented inReference 3isanareareinforcement calculation.
Becausestresseswerenotexplicitly calculated, adirectcomparison tostressesobtainedfromthisanalysisisnotpossible.  


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-}}
FractureMechanics atiueEvaluations Fatigueusageandcrackgrowthrateswillbecalculated forthestresscyclesdetermined inthestructural analysis.
Smallsurfaceflawsofvarioussizeswillbepostulated toexistonthevesselwallandnozzleboreregions.Crackgrowthratesduetolowfrequency pressureandthermalcycleswillbecalculated todetermine howquicklytheseinitialsmallflawscouldgrowtounacceptable sizes.Afatigueusageevaluation fortheCRDRnozzleswasnotperformed fortheoriginalstructural evaluation (Reference 3)ontheupdatedvesselusagereport(Reference 4).Acomparison tothecurrentanalysisisnotpossible.
INFORMATION SOURCESInformation sourcesfortheCRDRnozzlestructural analysisinclude:Combustion Engineering DrawingNo.231-567,Revision7,"NozzleDetails-Vessel."2.ASMECodeforMaterialProperties.
3.Combustion Engineering ReportCENC1142,"Analytical ReportforNiagaraMohawkReactorVessel."4.MPRReport629,"Re-evaluation ofReactorVesselFatigueAnalysisforRevisedOperating Cycles,NineMilePointNuclearGenerating StationUnitNo.1,"August13,1979.-3-}}

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P>1MPRASSOCIATES INC.ENGINEERS MPR-1485Revision0April1994NineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluation PreyaredforNiagaraMohawkPowerCoryoration 301Plainfield RoadSyracuse, NY132129407010168 940M3PDR.ADOCK05000220P'DR 0

Pi9MPRASSOCIATES INC.EN&INEERSNineMilePointUnit1ControlRodDriveReturnNozzleFatigueEvaluation MPR-1485Revision0April1994Principal Contributors E.B.BirdJ.E.NestellR.S.PaulA.B.RussellPreparedforNiagaraMohawkPowerCorporation 301Plainfield RoadSyracuse, NY13212J.GawlerNMPCEngineer320KINGSTREETALEXANDRIA.

VA22314-3238 703-519-0200 FAX:703.519-0224

Pa1MPRASSOCIATES INC.ENGINEE0SCONTENTSSection1INTRODUCTION

1.1Background

2SUMMARY3DISCUSSION 3.1DesignandOperation 3.2LoadCycleDefinition 3.3Structural Analysis3.4FatigueEvaluation 3.5FractureMechanics

-CrackGrowthRate3.6Experience Survey4REFERENCES 5APPENDICES

~Pae2-13-13-1.3-13-23-33-43-54-15-1APPENDIXAAPPENDIXBAPPENDIXCAPPENDIXDAPPENDIXEAPPENDIXFAPPENDIXGAPPENDIXHAPPENDIXICalculation ofCRDRNozzleThermalandPressureCyclesCRDRNozzleFiniteElementModel,GeometryCRDRNozzleFiniteElementModel,MaterialProperties Calculation ofHeatTransferCoefGcients CRDRNozzleFiniteElementModel,BoundaryConditions andResultsLowCycleFatigueUsageCrackGrowthRateComputerProgramVerification CrackGrowthRateAnalysisCasesImplementation PlanA-1B-1C-1D-1E-1F-1G-1H-1

PA1MPRASS0CIATESINC.ENGINEERS LISTOFFIGURESF~Fiore3-13-23-33-43-53-6~DetcritiooCRDRNozzleDimensions FiniteElementModelFiniteElementModelDetailsCalculated Temperature Distribution Calculated StressIntensity Distribution FatigueCrackGrowth

Pa1MPRASSOCIATES INC.ENG'INEERS Section1INTRODUCTION Thepurposeofthisreportistodocumentafatigueevaluation oftheControlRodDriveReturn(CRDR)nozzleintheNineMilePointUnit1reactorvessel.Thenozzleisafourinchvesselpenetration thatacceptslowtemperature waterfromthecontrolroddrivesystem.Theobjectives oftheevaluation weretoestimate:

1)thelong-term susceptibility oftheCRDRnozzletothermalfatiguecracking, and2)thecrackgrowthrateofapotential flawintheCRDRnozzleovertheremaining lifeoftheplant.Thisevaluation wasundertaken tosupportNiagaraMohawkPowerCorporation (NMPC)effortstoperformanultrasonic inspection oftheCRDRnozzleinsteadofthedyepenetrant inspection specifiebyNUREG-0619.

Thefatigueevaluation oftheCRDRnozzleconsidered thenumberofpressureandtemperature cyclesthenozzlehasexperienced todateaswellasanestimateofthenumberoffuturecycles.Finiteelementstressanalysesofthenozzlewereperformed todetermine thestressdistribution inthenozzleduetothepressureandtemperature cycles.Stressanalysisresultswerethenusedtocalculate nozzlefatigueusageandcrackgrowthrates.1.1BACKGROUND Inthe1970's,anumberofBWRsdetectedsigniTicant crackingoffeedwater andCRDRnozzles.ThecracksintheCRDRnozzleswerecausedbythermalfatigueresulting fromchangesincoldCRDRflowatthenozzles,TheNRCissuedNUREG-0619, "BWRFeedwater NozzleandControlRodDriveReturnLineNozzleCracking,"

(Reference 1)thatidentified interimandlong-term recommendations regarding thisissue,including inspection requirements.

ForNineMilePointUnit1,theinspection requirements includeperforming adyepenetrant (PT)examination oftheCRDRnozzleinternalsurfaceduringtheupcoming1995ref'ueling outage.NMPCplanstoperformanultrasonic (UT)inspection oftheCRDRnozzleinsteadofthedyepenetrant examination basedonthefollowing:

1.Automated UTinspection systemsarenowavailable forperforming accurateinspections fromoutsidethevessel.UTinspection systemsatthetimeNUREG-0619wasissueddidnotprovidesufficient detection orflawsizingcapabilities.

2.TheCRDRnozzlethermalsleevedesign(weldedinplace)makesthenozzlelesssusceptible tothermalfatiguecrackingthantheoriginaldesignsatotherBWRs.Infact,nodamagetotheCRDRnozzlewasfoundduringthe1977in-vessel PTexamination orinanysubsequent examination.

1-1

3.DetailedanalyticmodelingoftheCRDRnozzleshowsthatsmallsurfaceflawswillnotgrowtounacceptable valueswithinspecified operating periods.Thisreportaddresses Item3abovefortheCRDRnozzle.Inaddition, thisreportdocuments theresultsofasurveyofBWRsregarding CRDRnozzleinspection historyandexperience.

Theimplementation planforthistaskisprovidedinAppendixI.1-2

P&qMPRASSOCIATES INC.ENGINEERS Section2SUMMARYThreepressureandtemperature cycleswereidentified fortheCRDRnozzle:startup/shutdown, reactorscram,andhydrostatic test.ThesecyclearedefinedfortheCRDRnozzleasfollows:Startup/Shutdown

-areactorvesselheatup/cooldown betweenpoweroperation andshutdownorstandbyconditions wheretheshutdownisachievedmanuallybyplantoperators.

ReactorScram-astartup/shutdown cyclewheretheshutdownisachievedbyareactorscram.~Hydrostatic Test-reactorvesselpressurization anddepressurization toidentifyleakspriortopowerascension.

Thenumberofcyclesexperienced todate,thenumberofcyclesexperienced sincethe1977PTinspection andtheprojected numberofcyclesinthefuturearelistedbelow.Startup/Shutdown ReactorScramHydrostatic TestNumberofCyclestoDate9610018NumberofCyclesSince1977PTInspection 38279Projected NumberofCyclesperYear5Thereactorscramtransient isthelimitingcycleforCRDRnozzlestresses, Finiteelementmodelingofthethermaltransient showsthatthepeakstressintensity inthebasemetaloccursattheendofthetransient intheboreofthenozzlejustabovetheblendregion.Thepeakstressintensity duetopressureandtemperature wascalculated tobe110ksi.FatigueanalysesshowthatfatigueusagefortheCRDRnozzleisverylow(approximately

0.0 03peroperating

year).Forthecalculated stressandthenumberofcyclesexperienced todate,afatiguecrackwouldnotbepredicted toinitiateinthe2-1

CRDRnozzleatthepresenttime.Considering thecalculated stressandthenumberofcyclesexpectedinthef'uture,afatiguecrackisnotpredicted withinthelifeoftheplant.Fracturemechanics calculations showthatapostulated 1/4inchflawlocatedinthehigheststressedregionofthenozzlewouldnotgrowtoanunacceptable sizewithinthelifeoftheplant.Thepostulated 1/4inchQawiscalculated togrowtoadepthofonly0.4inchesin40years.A0.4inchflawdoesnotexceedtheallowable Qawsizefortheanalyzedsectionofthenozzlewhichisapproximately 0.5inchesbasedoncriteriagiveninSectionXIoftheASMECode.Theallowable QawsizeprovidessigniTicant margintoensurethenozzledoesnotfailbybrittlef'racture.

2-2

PAIMPRASSOCIATES INC.EN&INEERSSection3DISCUSSION 3.1DESIGNANDOPERATION TheNMP-1ControlRodDriveReturn(CRDR)nozzleisa4-inchreactorvesselpenetration locatedatthesameelevation asthefeedwater nozzle.Figure3-1isasectionviewofthenozzlewhichshowsselecteddimensions.

TheCRDRnozzleisequippedwithathermalsleevewhichisweldedtotheCRDRnozzleatthesleeveinletandextendsintothereactordowncomer withacircularplateattheend.Thisdesignisintendedtoprotecttheboreofthenozzleandthevesselwalladjacenttothenozzlefromtherelatively coldCRDRflow.TheControlRodDrive(CRD)Systemprovideswaterfromthecondensate storagetankatatemperature ofabout70'Ftothecontrolroddrivemechanisms tocoolthecontrolroddrives,toreposition rods,andtoscramtherods.Undertypicalplantconditions, thesystemoperatesatalltimeswhenfuelisinthevessel.Duringnormaloperation, flowfromtheCRDpumpsismaintained relatively constantwithaportionoftheflowrecirculated tothecondensate storagetank,about30-47gpmoftheflowusedforcontrolroddrivemechanism cooling,andabout17-35gpm(theremaining flow)returnedtothevesselviatheCRDRnozzle.Someaccidentsequences involving loss-of-offsite powermayresultinsystemshutdownforashortperiodoftime,Theseaccidentsequences arenotconsidered forthisanalysis.

Theflowratedoesnotchangeasaresultofrepositioning acontrolrodsincetheflowdivertedtomovetherodiscompensated bythewaterdisplaced bytheroddrivewhichisroutedtotheCRDRline.AreactorscramresultsinaCRDRnozzleflowtransient.

Duringascram,theCRDRaccumulators discharge todrivethecontrolrodsintothecore.ThisresultsinanincreaseinCRDRnozzleflowto65gpm.Whenaccumulator pressuredropsbelowreactorpressure, CRDRflowrategoestozeroastheaccumulators arerecharged.

Aftertheaccumulators havebeenrecharged, CRDRflowratereturnstothenominal17to35gpm.3.2LOADCYCLEDEFINITION Table3-1liststhepressureandtemperature cycleswhichwereconsidered inthestructural evaluation.

Thenumberofcycleswasdetermined fromplantdataregarding thenumberofplantstartups/shutdowns andscrams.Thecyclesaredefinedasfollows:3-1 0

~Startup/Shutdown

-areactorvesselheatup/cooldown betweenpoweroperation andshutdownorstandbyconditions wheretheshutdownisachievedmanuallybyplantoperators.

~ReactorScram-astartup/shutdown cyclewheretheshutdownisachievedbyareactorscram.~Hydrostatic Test-reactorvesselpressurization anddepressurization toidentifyleakspriortopowerascension.

Thenumberofannualcyclesexpectedinthefutureisconservatively estimated tobe50%morethantheaverageannualnumberofcyclesthatoccurredoverthepast10years.Acalculation ofoperating cyclesispresented inAppendix'A.

33STRUCTURAL ANALYSISStressanalyseswereperformed todetermine thestressesforthefatigueandcrackgrowthrateanalysesdescribed inSection3.4and3.5below.Transient thermalanalyseswereperformed tocalculate thetemperature distribution inthenozzleasafunctionoftimeforthereactorscramtransient.

Steadystatestressesduetopressureandtemperature werecalculated atspecified timeintervals throughout thetransient.

Thesectionsbelowdescribethefiniteelementmodel,materialproperties, boundaryconditions, andresults.33.1FiniteElementModelTheANSYScomputerprogramwasusedtodevelopafiniteelementmodeloftheCRDRnozzle.ThemodelincludestheCRDRnozzleitselfandasufficient lengthofthereactorvesselshellandattachedCRDRpipingtoeliminate interaction betweentheCRDRnozzleandthestructural boundaryconditions appliedtotheedgesofthevesselshellandattachedpiping.Thethree-dimensional nozzle-to-cylinder intersection wasmodeledwithatwo-dimensional axisymmetric modelofanozzleinasphere.Theequivalent spherical radiuswaschosentobe3.2timestheradiusofthereactorvesselcylindertoinsurethatthemaximumhoopstressandstressintensity calculated bytheaxisymmetric modelwouldbecomparable tothoseintheactualthree-dimensional intersection.

AppendixBdocuments thefiniteelementmodel.ThefiniteelementmeshoftheCRDRnozzleisshowninFigures3-2and3-3.33.2MaterialProertiesThemodeloftheCRDRnozzleiscomposedofthreeregionswithdifferent materialproperties.

ThereactorvesselwallisSA302GradeBlowalloysteel.TheCRDRnozzleisanSA336lowalloysteelforgingwithASMECodeCase1236-1fornickeladdition.

ThecladisassumedtobeType308stainless steel.3-2

Temperature dependent materialproperties wereusedinthethermal'a'nd stressanalysesoftheCRDRnozzle.AppendixCdocuments thematerialproperties usedintheanalyses.

399ThermalBoundaConditions Thermalboundaryconditions forthereactorscramtransient arediscussed indetailinAppendices DandEandsummarized below.Thelastportionofthereactorscramtransient wasmodeled.Initially, theCRDRnozzleisatauniformtemperature of525'Fcorresponding tozeroflowthroughtheCRDRnozzleastheaccumulators arerecharged.

Atthestartofthetransient, theCRDRflowrateisstepchangedtoit'snominalvalueof35gpmwithafluidtemperature of70'F.Heattransfercoefficients andbulkfluidtemperatures areappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Allothersurfacesareassumedtobeadiabatic (insulated).

AppendixDisacalculation oftheheattransfercoefficient inth'eCRDRnozzlebore.Theoverallheattransfercoefficient betweentheCRDRfluidandthenozzleborewhichincludestheeffectsofthethermalsleeveandwaterannuluswascalculated tobe100BTU/hr-ft~-'F.

Thisincludestheeffectsofthefluidfilmontheinsidesurfaceofthethermalsleeve,conduction throughthethermalsleeve,andnaturalconvection throughthestagnantfluidlayerbetweenthethermalsleeveandthenozzlebore.Aheattransfercoefficient of1000BTU/hr-ft2-'F wasusedbetweenthebulkdowncomer fluidtemperature andthevesselwall.39.4Structural BoundaConditions Thestructural boundaryconditions forthestressanalysisincludeappliedpressures anddisplacements (Appendix E).Apressureof1250psigwasappliedtotheinsidesurfaceofthereactorvesselwallandtheboreoftheCRDRnozzle.Anegativepressurewasappliedtothesafeendtosimulatetheaxialloadintheattachedpiping.Attheendofthereactorvesselwall,symmetryboundaryconditions areappliedtopermitradialdisplacement andtoprohibitrotation.

Atthesafeend,couplesareusedtoallowtranslation ofthesafeendbuttoprohibitrotation.

39.5ResultsThepeakstressintensity inthebasemetaloccursattheendofthescramtransient.

Figure3-4showsthecalculated temperature distribution attheendofthetransient.

Figure3-5showsthecalculated stressintensity distribution attheendofthetransient.

Thepeakstress(110ksi)inthebasemetaloccursintheboreoftheCRDRnozzleatthebasemetaltocladdinginterface, justabovetheblendintothevesselwall.Theprincipal component ofthestressintensity ishoopstress.3-3

3.4FATIGUEEVALUATION Afatigueevaluation oftheCRDRnozzlewasperformed basedontheloadcyclesdefinedinSection3.2andtheresultsofthefiniteelementstressanalysisdiscussed inSection3.3.Nozzlefatigueusageforcurrentplantoperation conditions wasevaluated onapercyclebasis.Asdiscussed inSection3.2,theCRDRnozzleissubjecttostartup/shutdown cyclesandstartup/scram cycles.Fatigueusagewascalculated forbothofthesecycles.Thenozzlealsoundergoes hydrostatic testing;however,thiscycleisboundedbythepressure-temperature conditions duringastartup/shutdown cycle.Fatigueusageiscalculated by:u=gnNwhere:u=fatigueusagen=numberofcycleswhichoccurN=numberofallowable cyclesbasedonthecyclicstressesAfatigueusageof1.0indicates thatthereisapotential forfatiguecrackinitiation inthenozzle.Theallowable cyclesaredetermined fromtheASMECodeDesignFatigueCurveforCarbon,LowAlloyandHighTensileSteels(Reference 2,FigureI-9.1).Thiscurveprovidesaconservative numberofallowable cyclesforagivenalternating stressrange(safetyfactorshavealreadybeenapplied).

Therefore, useofthiscurvefortheusageevaluation providesaconservative estimateoffatigueusageforthenozzle.Calculation offatigueusageforstartup/shutdown andstartup/scram cyclesaredocumented inAppendixF.Thecalculation isperformed usingthepeakstressintensity rangeonthebasemetalinsidesurfaceofthenozzleforeachofthecycles.Thefatigueusageforthenozzlewascalculated tobe1.963x10~perstartup/shutdown cycleand3.848x10perstartup/scram cycle.Basedonrecentplantoperating history,thereareapproximately fivestartup/shutdown cycles,onehydrostatic testandfourstartup/scram cyclesperyear,whichcorresponds toanannualfatigueusageof0.003.3.5FRACTUREMECHANICS

-CRACKGROWTHRATECrackgrowthofanassumedpre-existing fiawinthenozzleduetothepressureandthermalcyclesdefinedinSection3.2isanalyzedusingthePariscrackgrowthrateequation:

=C(AK)dN3-4

\where:crackgrowthrate(inches/cycle) daGnstressintensity factorrange(ksiPin)C,m=constants (dependent onmaterial, environment, andloading)CandmaretakenfromtheASMEcrackgrowthcurveforsurfaceQawsinawaterreactorenvironment (Reference 2,FigureA-4300-1).

Thestressintensity factorrangeisthemaximumchangeinstressintensity factorduringthegivencycle.Stressintensity factorisafunctionofstressandcracksize.Asdescribed inSection3.3,stresseswereanalyzedbyQniteelementanalysis, UsingtheQniteelementmodelresults,asectionthoughthenozzlewall,passingthroughthepeaksurfacestressesontheinsideandoutsidesurfacesofthenozzle,wasdetermined.

Thissectionislocatedintheblendregionofthenozzleneartothetransition totheboreregion.Athirdorderpolynomial wasQittothestressesthroughthesectionasafunctionofdepththroughthenozzle.Stressintensity factorsweredetermined bythemethodsofReference 3.Stressintensity factorsarecalculated asaf'unction ofcracksizeandthepolynomial coefficients fromthecubicstressdistribution.

Acomputerprogramthatcalculates crackgrowthbasedonthemethoddescribed abovewasdeveloped toanalyzeassumedQawsinthenozzle.Theprogramdescription andveriQcation aredocumented inAppendixG.InputsandresultsofthecrackgrowthanalysisareprovidedinAppendixH.Theresultsofthecrackgrowthanalysis, assuminganinitialQawsizeof0.25inches,areshowninFigure3-6.AsshowninFigure3-6,theassumed0.25inchinitialQawwillgrowtoapproximately 0.40inchesin40yearsofoperation.

TheresultsindicateaverysmallcrackgrowthrateforacrackintheCRDRnozzle.Inaddition, the0.40inchfinalQawsizeislessthantheallowable Qawsizeof0.5inches.Theallowable flawsizefortheanalyzedsectionofthenozzlewasdetermined fromcriteriagiveninSectionXIoftheASMECode[Ref.2].Determination oftheallowable Qawsizeisdocumented inAppendixH.Anallowable flawsizeof0,5inchesprovidessigniQcant margintoensurethenozzlewillnotfailbybrittlefracture.

Theappliedstressintensity factorfora0.5inchflawunderthemostseverestressconditions inthenozzleisapproximately 81ksiIin.Thenozzleisnotpredicted tofailbybrittlefractureuntiltheappliedstressintensity factorexceedsthecriticalstressintensity factorfortheCRDRnozzlematerial.

Atnormaloperating temperatures thecriticalstressintensity factorisapproximately 200ksiIin,whichismorethantwicetheappliedstressintensity factorofthe0.5inchallowable flaw.3-5

3.6EXPERIENCE SURVEYAsurveywasperformed todetermine theexperiences ofotherutilities withregardtoCRDRnozzlecracking.

NUREG-0619 responses totheNRCfromutilities operating BWRplantswerereviewedtodetermine howtheCRDRnozzlecrackingissuewasresolvedateachoftheplants.Inaddition, severalutilities werecontacted todetermine moredetailedinformation aboutinspection practices fortheCRDRnozzle.Theresultsaresurnrnarized below.Reviewofutilityresponses totheNRCindicated thatalmostalloperating BWRscutandcappedtheCRDRreturnline,eitherwithorwithoutflowrerouted'to anothersystem.PlantswithacappedCRDRnozzlearenotrequiredbyNUREG-0619 toperforminspections ofthenozzle(besidesafinalPTinspection requiredpriortocappingthenozzle).However,someplantswereoperatedforextendedperiodsoftimewiththeCRDreturnlinevalvedout,whichNUREG-0619 considers tobeatemporary solution.

Inaddition, oneplant,OysterCreekNuclearGenerating Station,hascontinued tooperatewithCRDreturnlineflowthroughtheCRDRnozzle.OysterCreekistheonlyotherplantbesidesNMPUnit1permitted tooperatewiththeCRDRnozzleinservice,Severalplants,including OysterCreek,werecontacted todetermine information aboutinspection techniques andresultsofnozzleinspections.

Twooftheplantscontacted, DuaneArnoldEnergyCenterandQuad-Cities Station,foundcracksintheCRDRnozzleduringrecentinspections (pastGiveyears).AtDuaneArnold,theCRDreturnlinewasvalvedoutandcappedwithablindflangein1982.Duringavisualinspection oftheCRDRnozzlein1990,evidenceofcrackingwasfoundandafullPTexamination wasperformed.

Acrackapproximately 3incheslongand0.25inchesdeep,justpenetrating intothebasemetalofthenozzle,wasfoundandgroundout.Thenozzleprobablyhadathermalsleeveinstalled priortobeingcapped;however,thetypeofthermalsleeveisunknown.Theplantperformsavisualinspection ofthenozzleeveryoutage,butdoesnotperformanyultrasonic inspections.

QuadCitiesoperatedwiththeCRDreturnlineinavalved-out conflguration until1989whencrackingwasfoundintheCRDRnozzle.Duringthisperiodofoperation, theCRDreturnlinewasvisuallyinspected everyoutage.Asaresultofthecracking, theCRDreturnlinewascutandcappedin1989.Sincethattimenoinspections ofthenozzlehavebeenperformed.

Inbothofthesecases,crackingwasfoundafterasigniflcant periodofoperation withtheCRDRnozzleisolatedfromCRDRflow.Mostlikely,crackinginitiated priortoisolation oftheCRDRflow,butwasnotidentifled untillaterinspections, OysterCreekistheonlyotherplant(besidesNileMilePointUnit1)allowedbyNUREG-0619 tooperatewithflowtotheCRDRnozzle.SimilartoNMPUnit1,OysterCreekappliedforanexemption oftheNUREG-0619 requirements fortheCRDRnozzle,including thescheduled PTexamination.

Basedonautomated ultrasonic

~~~~(UT)examinations oftheCRDRnozzle,whichdidnotidentifyanyindications, Oysterreekwasgivenanexemption fromthenozzlePTexamination untilthenextrefueling outage.Qualiflcation oftheUTsystemwasperformed usingamock-upoftheCRDRnozzle.EventhoughtheUTsystemwasdesignedspecifically forthenozzlegeometry, 3-6

Itherewereseveralproblemsencountered duringsetupofthesystem.MountingthesystemtooklongerthantypicalUTsystemsduetospaceconstraints aroundthenozzle.Inaddition, removalofthemirrorinsulation aroundthenozzleareawasexpensive andtimeconsuming.

Aftertheinspection, anewtypeofremovable insulation wasinstalled toprovideeasieraccessforfutureinstallations.

3-7 0

Table3-1CRDRNozzlePressureandTemperature CyclesDescription 1NormalStartup/Shutdown 2ReactorScram3InitialHydro4Refueling Hydro510yearISIHydroReactorVesselPressure(psi)01030-0103012500187500>>1030-0011330Downcomer FluidTemperature

('F)70-525-70250250250CRDRNozzleFluidTemperature

('F)7070<<525<<70707070NumberofCyclestoDate9615NumberofCyclesExpectedperYear5.03.90.01.00.1

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

PD1MPRASSOCIATES INC.EN&INEEITS Section4REFERENCES 1.NUREG-0619, "BWRFeedwater NozzleandControlRodDriveReturnLineNozzleCracking, November1980.2.ASMEBoilerandPressureVesselCode,1980EditionwithAddenda.3.Buchalet,'C.B.,

andBamford,'.W.H.,

"StressIntensity FactorSolutions forContinuous SurfaceFlawsinReactorPressureVessel,"ASTM-STP-590, 1975.4-1 I'

rpMPRENGINEERS Section5APPENDICES A.Calculation ofCRDRNozzleThermalandPressureCyclesB.CRDRNozzleFiniteElementModel,GeometryC.CRDRNozzleFiniteElementModel,MaterialProperties D.Calculation ofHeatTransferCoefficients E.CRDRNozzleFiniteElementModel,BoundaryConditions andResultsF.LowCycleFatigueUsageG.CrackGrowthRateComputerProgramVerification H.CrackGrowthRateAnalysisCasesI.Implementation Plan5-1

FA1MPRSSOCIATES INC.ENGINEERS AppendixACALCULATION OFCRDRNOZZLETHERMALANDPRESSURECYCLES

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PDIMPRASSOCIATES INC.ENGINEERS AppendixBCRDRNOZZLEFINITEELEMENTMODELGEOMETRY

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WMPQMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.ops-z~-685-ol'7S'CheckedByPagePurposeThepurposeofthiscalculation istodocumentthegeometric inputdataforafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransient thermal/stress analysissimulating areactorscramwasperformed.

References 1and2arecalculations whichdocumentthefiniteelementmodelmaterialproperties andboundaryconditions/

results.TheANSYScomputerprogram(Reference 3)wasusedtocalculate thetransient temperature distribution inanaxisymmetric modelofthenozzle.Theprogramwasthenusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.

Theresultsofthisanalysis, intheformofstressdistributions throughthebore/blend sectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluation oftheCRDreturnnozzle.Discussion Figure1isadrawingoftheCRDreturnnozzlewhichshowspertinent dimensions (Reference 4).Thedimensions usedintheanalysisareasfollows:VesselRadiusRVVesselThickness TVCladThickness CLADAngularExtentANG1106.7*3.2inches7.125inches.2188inches8degreesOtherdimensions fromFigure1areasfollows:NozzleBoreNozzleODSafeEndODVesselCutOutR1R2R3R42.061inches4.813inches2A69inches5.563inches8.688inches4.125inches1.344inchesSafeEndH1SafeEndH2SafeEndH3Theradialdimensions forthenozzlebore,R1,andthevessel,RV,aretothebasemetal-cladding interface.

Thesedimensions shouldbereducedbythethickness of

OlxlMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.4785-g~)t-Q,S-OICheckedByP~74uPagethecladding(7/32").Thisdiscrepancy betweenthefiniteelementmodelandthedrawingdimensions shouldhaveanegligible affectonthecalculated stresses.

Figures2and3showtheaxisymmetric finiteelementmodelofthenozzle.The'xisymrnetric modelusesaradius3.2timestheactualradiusofthereactorvessel.Thisistoinsurethemaximumhoopstressandstressintensity fromthemodelwillbecomparable tothoseintheactualthree-dimensional intersection (Reference 5).Theangularextentofthefiniteelementmodelaffectsthenumberofelementsinthemodelandconsequently thecomputerrunningtimeforthemodel.Theangularextentassumedintheseanalysesis8degrees.Thisextentwasselectedbyperforming pressureonlyloadcaseswithmodelsofvaryingextentandevaluating thestressesatthevesselcutline.Thepressureanalysesshowedthat8degreesissufficiently farfromtheCRDreturnnozzlesuchthatthestressdistribution atthevesselcutlineisuniform.Reference 6istheANSYSoutputfilewhichshowsthePREP7echooftheinputdata.References MPRCalculation 085-229-EBB-02, "CRDRNozzleFiniteElementModelMaterialProperties",

Revision0.2.MPRCalculation 085-229-EBB-03, "CRDRNozzleFiniteElementModelBoundaryConditions andResults",

Revision0.3.ANSYScomputerprogramversion5.0.4Combustion Engineering ReportCENC1142,"Analytical ReportForNiagaraMohawkReactorVessel",drawingnumber231-567-7.

5.J.B.TruittandP.P.Raju,ASME-78-PVP-6, "Three-Dimensional VersusAxisymmetric FiniteElementAnalysisofaCylindrical VesselInletNozzleSubjecttoInternalPressure, AComparative Study"6.7.MPRCalculation "Geometry",

tasknumber85-31"LowFlowFeedwater ControlSystem",2/28/83.ANSYSoutputfileNOZZLE.OUT, 87,853bytesdated4-04-943:45:28pm.

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taiMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULATION TITLEPAGEClient~gfJQ<EQ~op/~/C/g//V/MMI//Project4EBAMn/o+RcE-J'rPEssgwdc-Pea'age 1ofmTaskNo.gF-P4gTitle/ÃoPEWTiEiCalculation No.y8<-gal'-pZ/j-o 2Preparer/Date Checker/Date Reviewer/Date Rev.No.Pe~a~c44yj/p(/

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PRIMP'PRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.+g-gag-$3/f-0ZPreparedByCheckedByPageg~PuroeeThepurposeofthiscalculation istodocumentthematerialproperties usedinafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.TheANSYScomputerprogramwasusedtocalculate thetransient temperature distribution inthenozzle.Inaddition, theprogramwasusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.

Thematerialproperties requiredintheanalysesare:ElasticModulusCoefficient ofThermalExpansion ThermalConductivity SpecificHeatPoisson's RatioDensityDiscussion Figure1showsaschematic oftheCRDRnozzleoutline.Thenozzlemodeliscomposedofthreeregionswithdistinctmaterialproperties.

~Region1isthereactorvesselwall.ThevesselwallmaterialisSA302GradeB(Mn-1/2Mo),

Reference 1.~Region2istheCRDRnozzle.ThenozzlematerialisSA336withASMECodeCase1236-1,Reference 1.Equivalent materialisSA508Class2(3/4Ni-1/2Mo-1/3Cr-V) asdiscussed below.~Region3istheClad,assumedtobetype308Stainless Steel.Stainless SteelType304,18Cr-8Nimaterialproperties areaclosematchandareusedinthisanalysis.

Previousfiniteelementanalysesofthefeedwater nozzleused1980ASMECodematerialproperties (Reference 2).Inthatcalculation, acomparison ofmaterialchemicalcomposition betweentheoriginal1964specification andthe1980Codewasmade.Thecomparison showedthatforthevesselwall1980ASMECodematerialproperties wereequivalent.

Thecalculation alsoshowedthattheequivalent material

lxHMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.de-d45'+44-ozCheckedByS~mt~~PageypropertyforthenozzlewasSA508Class2(3/4Ni-1/2Mo-1/3Cr-V).

Thesamematerialproperties usedinthepreviouscalculation forthefeedwater nozzleandvesselwallareusedinthisanalysisfortheCRDReturnnozzleandvesselwallrespectively.

ResultsTemperature dependent materialproperties arelistedinTables1through3forthereactorvesselwall,CRDReturnnozzleandcladdingrespectively.

Attachment AisalistingoftheANSYSmacroMATL.MACwhichisthecomputerprograminputdataformaterialproperties.

(Theinputdataalsolistsheattransfercoefficients.)

Forallthreematerials, adensityof489Ib/ftandPoisson's Ratioof0.3wereused(Reference 3).Thereference temperature forthecoefficient ofthermalexpansion (REFTinfileMATL.MAC) is70'Fforthenozzleandvesselwall.Forthecladdingmaterial, theaveragetemperature betweenthedowncomer andnozzlefluidtemperatures atfullpowerconditions wasusedforthereference temperature toapproximate theresidualstressstateinthecladding.

Specificheatwascalculated fromthermaldiffusivity bythefollowing formula:Cp=K/(Rho*TD)

Where:CpKRhoTDSpecificHeat(btu/Ib-'F)

ThermalConductivity (btu/hr-ft-'F)

Density(Ib/ft)ThermalDiffusivity (ft/hr)References Combustion Engineering ReportCENC1142,"Analytical ReportForNiagaraMohawkReactorVessel",pageA-78.2.MPRCalculation "Material Properties",

tasknumber85-31"LowFeed-waterFlowControl",

2/28/93.3.StandardHandbookForMechanical Engineers, SeventhEdition,pages5-6and6-7.

K1MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.CtP~-V25'-Z45-oZPreparedBy~a.w../CheckedByP0~:~4'~PageC>lA0

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-SA302GradeBCarbonMolybdenum (Mn-1/2Mo)

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-SA336withCodeCase1236-1Equivalent toSA508Class2(3/4¹i1/2Mo-1/3Cr-V) 70100150200250300350400450500550600Mo'du!.'Us~of

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~1063.1084.~1118.1149.1180.1204.1224.1254.1274.1305.1326.1351ModulusofElasticity valuesarefor1/2-2CrChromeMolybdenum.

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-Stainless SteelType308Type304Properties Usted(18Cr-8Ni)

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ASSOCIATES INC.ENGINEERS AppendixECRDRNOZZLEFINITEELEMENTMODELBOUNDARYCONDITIONS ANDRESULTS

lLimpRMPRAssociates, Inc.320KingStreetAlexandria, VA22314CALCULATION TITLEPAGEClient~~~~gp/~/g+//L/gW/Qg/0/rv/~~///Page1ofgqProjectg~/~~~~opygmyrT/QTaskNo.0Z~Titlego~~p~pYAnted/77@AS~i>ZF~ur-I~Calculation No.~-P29-Ct~d-o3 Preparer/Date az.8.'/Z-Z/-5'yChecker/Date g<g.'7~Reviewer/Date Rev.No.

txrMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No..080=PP9-Fd'rs-y3RevisionRECORDOFREVISIONS PreparedByDescription Page0+1+pv<rrO'JvP

t>IMPRCalculation No.dd~-cVW-ggg-oJPreparedByMPRAssociates, Inc.320KingStreetAlexandria, VA22314Page~PurposeThepurposeofthiscalculation istodocumenttheboundaryconditions andresultsofafiniteelementanalysisoftheNiagaraMohawkPowerCorporation, NineMilePointUnit1(NMP-1)ControlRodDrive(CRD)ReturnNozzle.Atransient thermal/stress analysissimulating areactorscramwasperformed.

References 1and2arecalculations whichdocumentthefiniteelementmodelgeometryandmaterialproperties.

TheANSYScomputerprogram(Reference 3)wasusedtocalculate thetransient temperature distribution inanaxisymmetric modelofthenozzle.Theprogramwasthenusedtocalculate stressprofilesduetopressureandduetothecalculated temperature distribution.

Theresultsofthisanalysis, intheformofstressdistributions throughthebore/blend sectionofthenozzle,willbeusedinafatigueandcrackgrowthevaluation oftheCRDreturnnozzle.Discussion TheCRDsystemprovideswaterfromthecondensate storagetankatatemperature ofabout70'Ftothecontrolroddrivemechanisms tocoolthecontrolroddrives,toreposition rodsandtoscramtherods.Thesystemoperatesatalltimesthatfuelisinthevessel.ExcessfiowfromtheCRDpumpsisroutedtothereactorvesselviatheCRDreturnnozzle.Consequently, flowthroughtheCRDreturnnozzleistypical.NominalCRDreturnflowrateis17to35gpm.Theflowratedoesnotchangeasaresultofrepositioning acontrolrodsincetheflowdivertedtomovetherodiscompensated bythewaterdisplaced bytherod.AreactorscramresultsinaCRDreturnnozzleflowtransient (Reference 4).Duringascram,theCRDaccumulators discharge todrivethecontrolrodsintothecore.thisresultsinanincreaseinCRDreturnflowto65gpm.Whenaccumulator pressuredropsbelowreactorpressure, CRDflowrategoestozeroastheaccumulators arerecharged.

Aftertheaccumulators havebeenrecharged, CRDflowratereturnstothenominal17to35gpm.Thelastportionofthereactorscramtransient issimulated inthiscalculation.

Attimezerothenozzleisatauniformtemperature of525'Fcorresponding tozeroflowthroughtheCRDreturnnozzleastheaccumulators arerecharged.

At1secondintothetransient, theCRDreturnflowrateisstepchangedtothenominalflowrateof35

l41MPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.os%->z1wed-o7PreparedByCheckedBygR~Page~gpmwithafluidtemperature of70'F.Apressureof1250psigisappliedtotheinsidesurfaceofthereactorvesselwallandtheinsideofCRDreturnnozzlethroughout thetransient (nominalreactorpressureis1030psig,scrampressureis1250psig).Detailsofthethermalandstructural boundaryconditions arediscussed below.ThermalBoundaConditions forthereactorscramtransient areshownonFigure1anddiscussed below.AttimezerotheCRDreturnnozzleandreactorvesselwallareatauniformtemperature of525'Fcorresponding tothebulkdowncomer fluidtemperature.

Theoverallheattransfercoefficient betweenthedowncomer fluidandthevesselwallisassumedtobe1000Btu/(hr-ft

-'F).Thisisthevalueusedinprioranalysesforthefeedwater nozzle.At1secondintothetransient, thebulkfluidtemperature intheCRDreturnnozzleisstepchangedto70'F.Theoverallheattransfercoefficient betweentheCRDreturnfluidandthenozzlewallis100Btu/(hr-ft-

'F).Theheattransfercoefficient inthenozzleincludestheeffectsofthefluidfilmontheinsidediameterofthethermalsleeve,conduction throughthethermalsleeve,andnaturalconvection throughthestagnantlayerbetweenthethermalsleeveandthenozzlebore.Reference 5isacalculation oftheoverallheattransfercoefficient betweentheCRDreturnfluidandthenozzleinsidesurface.Theoutsideofthevesselwall,theoutsideofthenozzleandtheradialcutlinesthroughthevesselwallandsafeendaremodeledasadiabatic (noheatflowacrossthesurface).

Structural BoundaConditions includeappliedpressureanddisplacement constraints.

Figure2showstheappliedpressurealongtheinsidesurfaceofthereactorvesselwallandtheinsidesurfaceoftheCRDreturnnozzle.Theappliedpressureonthesesurfacesis1250psig.Apressureisalsoappliedtothesafeendtorepresent theaxialloadintheattachedpiping,Thevalueofthepressureappliedtothesafeendiscalculated asfollows(dimensions arefromReference 1):AintFlAlPend=Where:pi*R12Pint"Aint pi*(R3-R1)=FI/AI13.34in16681.Ibf5.803in2875.psi 0

RMPRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.oN-d4f-F4ss'-oZPreparedBy7K~PageAintR1PintFlAIR3Pend=Insideareaofsafeend(in)Safeendinsidediameter=2.061inchesInternalpressure=1250psigLongitudinal force(Ibf)Crosssectional areaofsafeendSafeendoutsidediameter=2A69inchesPressureappliedtothesafeend(psi)Figure3showsthedisplacement boundaryconditions appliedtotheendofthereactorvesselwall.Symmetryboundaryconditions areappliedtopermitradialdisplacement alongthecutlinebuttoprohibitrotationofthecutline.Figure4showsthedisplacement boundaryconditions appliedtothesafeend.Couplesareusedtoallowtranslation ofthesafeendcutlinebuttoprohibitrotationofthecutline.ResultsThepeakstressintensity occursattheendofthetransient whensteadystateconditions havebeenreached.Figure5showsthetimehistoryofstressintensity atseveralnodesinthebore/blend region.Thestressesshowninthetimehistoryareatthecladdingtobasemetalinterface.

Figure6showsthecalculated temperature distribution attheendofthetransient.

Thepeakstressintensity inthebasemetalforthetransient occursatnode806intheboreblendregionofthenozzleatthebasemetaltocladdinginterface (Attachment A).Thepeakstressintensity atnode806duetotemperature andpressureis110ksi.Thestressintensity duetopressurealoneatnode806is65ksi.Theprincipal component ofthestressintensity isthehoopstress.Colorcodedcontourplotsofstressdistribution areshowninFigures7through10forpressureonlyloading(timezeroofthetransient).

Figures11through14showstressdistributions attheendofthereactorscramtransient forpressureandtemperature loading.Fourplotsareshownforeachloading:Stressintensity, ASMEcodeorTrescastressintensity, Hoopstress,theZcomponent ofstressfortheaxisymmetric model,~Xcomponent stress,interpreted asasecondhoopstressforthe e0 lLiMpRCalculation No.ogJ-g2g-flag-cgPreparedByZ.N.N~clMPRAssociates, Inc.320KingStreetAlexandria, VA22314Pagespherical modelofthevesselwall,Ycomponent stress,interpreted asaxialstressinthenozzleregion.Figures15and16showthelocations ofnodes806and14.Node806isthepointofmaximumstressintensity attheinterface betweenthecladdingandthebasemetal.Node14isthepointofmaximumstressintensity ontheoutsidesurfaceofthenozzle/vessel intersection.

Astraightline(path)isdrawnfromnode806tonode14andthestressintensity valuesareinterpolated ontothepath(Figure11showstheinterpolation path).Figures17and18showstressintensity alongthispathforthepressureonlycaseandthepressureandtemperature case.Attachment BisatabularlistingofthestressversuspathlengthvaluesforFigures17and18.Attachments CandDprovidetheANSYSinputdataforthethermalandstresspassesoftheanalysis.

Reference 6isthehardcopyoutputfilefortheboththethermalandstresspasses.References 1.MPRCalculation 085-229-EBB-01, "CRDRNozzleFiniteElementModelGeometry".

2.MPRCalculation 085-229-EBB-02, "CRDRNozzleFiniteElementModelMaterialProperties",

Revision0.3.ANSYScomputerprogramversion5.0.MPRCalculation 085-230-ABR-01, "NineMilePointUnit1,ControlRodDriveReturnNozzleThermalandPressureCycles",Revision1.5.MPRCalculation 085-230-ABR-02, "OverallHeatTransferCoefficient ForCRDRNozzleatNMP-1",Revision0.6.ANSYSoutputfileNOZZLE.OUT, 87,853bytesdated4-04-943:45:28pm.

ANSYS5.0APR7199412:00:41PLOTNO.2NODESTYPENUMCONVZV=1DIST=25.552 XF=25.29YF=347.745~g-0I=pg=/EgoHeatTransferBoundaryConditions

ANSYS5.0APR7199411:59:26PLOTNO.1NODESTYPENUMPRESP8P<PZgcyylrccf~gag-g<~+~JJu~ZV=1DIST=25.552 XF=25.29YF=347.745~~QJIQ4/pl]eel+~JCMPressureBoundaryConditions r/'Cut6

ANSYS5'APR7199412:03:24PLOTNO.3NODESTYPENUMUZV=1DIST=25.552 XF=25.29YF=347.745+r'I'/III IIIIIIIiIIII~~~~IiiiiiiStructural BoundaryConditions

-RadialSymmetry,~/QU/Z&

ANSYS5'APR7199412:05:05PLOTNO.4NODESTYPENUMCP/OAc.+a!1~ZV=1DIST=25.552 ZF=25.29YF=347.745A"~1';~,~~~~~~~~//IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIStructural BoundaryConditions

-NoRotationatSafeEndg-((-ugC

ANSYS5.0(x10442)105SZ-80610090SZ-803SZ-806SZ-805SZ80785800757065060S50040080012001600200024002800320036004000440048005200Time(Sec)ReactorScramTransient

+/&u/Z~

ANSYS5.0APR4199416:33:47PLOTNO.1NODALSOLUTIONSTEP=2SUB=21TIME=3601 TEMPTEPC=9.434 SMN=88.846SMX=523.56288.846100200300400500600ReactorScram,Temperature Profile+/5-u4C-.

~gtt"'~SiSQSySfS)9ANSYS5.0APR4199416:32:56PLOTNO.1NODALSOLUTIONSTEP=1SUB=1TIME=1SINT(AVG)DMX=1.501SMN=1421SMNB=920.904 SMZ=66400SMKB=72225 142186411586123081303003752044740519605918066400PressureOnly,StressIntensity P/6u4E'

ANSYS5.0APR4199416:33:00PLOTNO.2NODALSOLUTIONSTEP=1SUB=1TIME=1SZ(AVG)RSYS=ODMX=1.501SMN=-22178SMNB=-30892 SMX=63262SMXB=68966

-22178-12685-31926302157952528834782442755376963262PressureOnly,HoopStressErbv~g8

S$.E..eCANSYS5.0APR4199416:33:03PLOTNO.3NODALSOLUTIONSTEP=1SUB=1TIME=1SX(AVG)RSYS=ODMX=1.501SMN=-3074SMNB=-13025 SMZ=42194SMZB=46227

-30741956698612015170452207527104321343716442194PressureOnly,XComponent StressP/'bu/ZC

ANSYS5.0APR4199416:33:06PLOTNO.4NODALSOLUTIONSTEP=1SUB=1TIME=1SY(AVG)RSYS=ODMX=1.501SMN=-23031SMNB=-32313 SMX=4943SMXB=9878

-23031-19923-16815-13706-10598-7490-4382-127318354943PressureOnly,YComponent Stress.g/gu/Z&/0

~~q~</'oc-877onf/~(ANSYS5.0APR4199416:33:25PLOTNO.5NODALSOLUTIONSTEP=14SUB=1TIME=3600 SINT(AVG)DMX=1.46SMN=3550SMNB=2589 SMX=95834SMXB=104406 35501380424057343114456554819650727532685580~95834X~sSW~oWReactorScram,StressIntensity y4-&,c.//

ANSYS5.0APR4199416:33:28PLOTNO.6NODALSOLUTIONSTEP=14SUB=1TIME=3600 SZ(AVG)RSYS=OmX=1.46SMN=-44957SMNB=-61709 Sm=98365SMXB=106937

-44957-29032-131082817187423466650591665168244098365ReactorScram,HoopStress.+J+u/C~

4+zc:t$a.~ANSYS5.0APR4199416:33:31PLOTNO.7NODALSOLUTIONSTEP=14,'UB

=1TIME=3600 SX(AVG)RSYS=ODMX=1.46SMN=-5953SMNB=-23928 SMX=65837SMXB=70794

-595320231000017977259533393041907498835786065837ReactorScram,XComponent Stress

ANSYS5.0APR4199416.33.35PLOTNO.8NODALSOLUTIONSTEP=14SUB=1TIME=3600 SY(AVG)RSYS=ODMX=1.46SMN=-45246SMNB=-61830 SMX=18196SMXB=20255

-45246-38197-31148-24099-17050-10001-295240981114718196ReactorScram,YComponent Stress~g~d.v/Z0/'/

82283183383l835$36$37838839$l0$41$42843$44845$46$47$48849ANSYS5.0APR7199412:23:22PLOTNO.1NODESNODENUMZV=1*DIST=1.386

  • XF=5.994*YF=348.819141214014821139213811371136$1352134113321323131213013NodeNumbers-OD253164275+/&v/z.C/J

$03l323l300$04l322l301$05l321l302$65$64$63948920$92947919946945ANSYS5.0APR7199412:27:42PLOTNO.2NODESNODENUMZV=1*DIST=2.621

  • XF=2.975*YF=344.095$62917$06l3$89l303$61916944943$07$88l319l304915$60942$08$87l318914l305941$59$86l317l306$58913.7861316l283$57$85$84.789l315l286$56NodeNumbers-ID.788l314l285.78713131284+/pv/CC/4

(x10I01)652612ANSYS5.0APR4199418:06:06PLOTNO.1POST1STEP=1SUB=1TIME=1PATHPLOTNOD1=806NOD2=14CO5735331C453CZV=1DIST=0.75 XF=0.5YF=0.5ZF=0.5CENTROIDHIDDEN41337333329325370.5411.0831~6242.1653.2482.7073.794.3314.8725.414Posi4ion,ID4oODPressureOnlyBiduel7

(x104I'2)110102ANSYS5.0APR4199418:06:26PLOTNO.2POST1STEP=14SUB=1TIME=3600 PATHPLOTNOD1=806NOD2=14957.962887.1+816.23C745.37CZV=1DIST=0.75 ZF=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

Path:C:(NOZZLE File:PRINC.OUT3,779.a..4-19-9411:26:26amPage12PRINTSNODALSOLUTIONPERNODE*****POST1NODALSTRESSLISTING*****LOADSTEP=14TIME=3600.0SUBSTEP=LOAD1CASE=0NODE786788789804805806807808809856857858859860861862863864884885886887888889890891913914915916917918919942943944945S181146~56018.67399.94075.96912.98365.98266.96331.91893.57385.68590.79143.85484.88636.89736.89338.87672.84840.59084.68866.76618.80398.82186.82524.81716.79890.68225.73604.75714.76516.76268.75133.73179.70289.71275.71356.70657.S2109116038'6629.014592.14833.14961.14952.14815.14731.14104.14550.16890.19029.19955.20410.20538.20432.20125.20609.20742.21866.23376.24231.24660.24790.24681.25290.25862.26976.27659.27992.28080.27924.29135.29919.30402.30633.S3-319~20-6398.43727~288.1971399.52531.23189.83144.33307.7-5699.0-2822.1-785.25836.861416.91333.5696.85-258.09-1283.0-4961.7-3016.3-1252.0-159.6398.306-166.38-798.84-1622.9-2831.9-1587.6-1036.3-1036.6-1413.2-2032.6-2739.3-1999.6-1828.9-2021.0-2474.8SINT81465'2416'1126.93987.95513.95834.95076.93187.88585.63084.71412.79929.84647.87219'8402.88641.87930.86123.64045.71882.77870.80557'2087.82690.82515.81512.71057.75192.76750.77553.77682.77165.75918.72289.73104.73377.73132.SEQV76471.57221.66555.87640.89555.90263.89775.87934.83462.55880.64505.72720.77176.79586.80576.80574.79627.77664.55839.63433.69267.71746.73073.73493.73158.72056.61981.65904.67271.67915.67933.67362.66151.62804.63492.63689.63429.*****POST1NODALSTRESSLISTING*****LOADSTEP=14TIME=3600.0SUBSTEP=LOAD1CASE=0

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          • ENTERHELP,ERRORFORANEXPLANATION OFANSYSERRORESTIMATION
                    • ENDOFINPUTENCOUNTERED
          • EXITTHEANSYSPOST1DATABASEPROCESSOR

Path:C:hNOZZLE Fi.le:XPATH.OUT13,436.a..4-04-946:06:28pmArecsi~idwT' Page1QdWELCOMETOTHEANSYSPROGRAM

          • ANSYSCOMMANDLINEARGUMENTS
          • MEMORYREQUESTED (MB)=64.0*****INPUTFROMCONFIG.ANS FILEKEYWORDINPUTVALUEVALUEUSEDNUMVPAG512512SIZVPAG1228812288EXTFILE00*****ANSYSDYNAMICMEMORYALLOCATION
          • WORKSPACEREQUESTED 1677721664.000MBCOMMANDLINEMINIMUMWORKSPACEREQUIRED681574426.000MBMINIMUMWORKSPACERECOMMENDED

=879964833.568MBWORKSPACEOBTAINED1677721464.000MBBYTESPERWORD4*****NOTICE*****THISISTHEANSYSGENERALPURPOSEFINITEELEMENTCOMPUTERPROGRAM.NEITHERSWANSONANALYSISSYSTEMS,INC.NORTHEDISTRIBUTOR SUPPLYING THISPROGRAMASSUMEANYRESPONSIBILITY FORTHEVALIDITYi ACCURACY'R APPLICABILITY OFANYRESULTSOBTAINEDFROMTHEANSYSSYSTEM.USERSMUSTVERIFYTHEIROWNRESULTS.ANSYS(R)COPYRIGHT (C)1971i1978i1982i1983i1985i1987'989i1992BYSWANSONANALYSISSYSTEMS,INC.ASANUNPUBLISHED WORK.PROPRIETARYDATAUNAUTHORI ZEDUSEiDISTRIBUTIONiORDUPLICATIONISPROHIBITED.

ALLRIGHTSRESERVED.

SWANSONANALYSISSYSTEMS,INC.

ISENDEAVORING TOMAKETHEANSYSPROGRAMASCOMPLETEiACCURATEiANDEASYTOUSEASPOSSIBLE.

SUGGESTIONS ANDCOMMENTSAREWELCOMEDANYERRORSENCOUNTERED INEXTHERTHEDOCUMENTATION ORTHERESULTSSHOULDBEIMMEDIATELY BROUGHTTOOURATTENTION

Path:C:)NOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmPage2><~ENTER/SHOW,deviceTOSETTHEGRAPHICSDISPLAYTOdevice(e.g.

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5.0FORSUPPORTCALLPHONE703/519-0200 CURRENTJOBNAME=file 18:05:44APR04,1994CP=FAX0.000BEGIN:12345678910111213141516171819202122232425/FILNAM,NOZZLE RESUME/POST1/SHOWgXPATHgPLTFILETSNOZZLE'ST SET,1/TITLE,PressureOnly/GRID,1/AXLAB,X,Position, IDtoOD/AXLAB,Y,Stress Intensity (psi)LPATHg806g14PDEFgSINTERSgINTPLPATH,SINT PRPATH,SINT SET,LAST/TITLE,ReactorScramTransient

/GRID,1/AXLAB,X,Position, IDtoOD/AXLAB,Y,Stress Intensity (psi)LPATH~806g14 PDEFgSINTgSgINT PLPATH,SINT PRPATH,SINT CURRENTJOBNAMEREDEFINED ASNOZZLERESUMEANSYSDATAFROMFILENAME=NOZZLE.db

      • ANSYSGLOBALSTATUS***TITLE=NMPUnit1CRDReturnNozzleANALYSISTYPE=STATIC(STEADY-STATE)

NUMBEROFELEMENTTYPES=11358ELEMENTSCURRENTLY SELECTED.

MAXELEMENTNUMBER1470NODESCURRENTLY SELECTED.

MAXNODENUMBER25KEYPOINTS CURRENTLY SELECTED.

MAXKEYPOINTNUMBER31LINESCURRENTLY SELECTED.

MAXLINENUMBER6AREASCURRENTLY SELECTED.

MAXAREANUMBER1COMPONENTS CURRENTLY DEFINED1358147025316

Path:C:)NOZZLE File:XPATH.OUT13,436.a..MAXIMUMLINEARPROPERTYNUMBERACTIVECOORDINATE SYSTEMMAXIMUMCOUPLEDD.O.F.SETNUMBERNUMBEROFSPECIFIED CONSTRAINTS NUMBEROFSPECIFIED SURFACELOADSINITIALJOBNAME=fileCURRENTJOBNAME=NOZZLE14-04-946:06:28pm50(CARTESIAN) 115208Page3Qgd*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSIONPC386/486180548APR04i1994CPFORSUPPORTCALLPHONE703/519-0200 FAXNMPUnit1CRDReturnNozzle3.790*****ANSYSRESULTSINTERPRETATION (POST1)*****/SHOWSWITCHPLOTSTOFILEXPATH.PLT RASTERMODE.DATAFILECHANGEDTOFILE=NOZZLE.RST USELOADSTEP1SUBSTEP0FORLOADCASE0SETCOMMANDGOTLOADSTEP=TIME/FREQUENCY=

1.0000TITLE='ressure Only1SUBSTEP=1CUMULATIVE ITERATION=

GRAPHPLOTKEY=1XAXISLABEL=Position, IDtoODYAXISLABEL=StressIntensity (psi)DEFINEAPATHFORSUBSEQUENT CALCULATIONS THROUGHNODES:80614DEFINEPATHINPATHCOORDINATE SYSTEM0DIRECTION MAXMINX6.28552.2798Y348.5734493Z0.00000E+00 0.00000E+00 TOTALPATHLENGTH=5.4136DEFINEPATHVARIABLESINTASTHENODALDATAITEM=SCOMP=INTROTATEDINTOCOORDINATE SYSTEM0ANDMOVEDTOTHEPATHNUMBEROFPATHVARIABLES DEFINEDIS5

Path:C:)NOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmPage4ogcP***WARNING***CP=18.730TIME=18:06:03Theselectedelementsetcontainsmixedmaterials.

Thiscouldinvalidate errorestimation.

SUMMARYOFVARIABLESINTMAX=65283.MIN=25366.DISPLAYALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=0CUMULATIVE DISPLAYNUMBER1WRITTENTOFILEXPATH.PLT DISPLAYTITLE=PressureOnlyPRINTALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=01-RASTERMODE.*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION50*****MPRASSOCIATES VERSIONPC386/486180607APR04g1994CPFORSUPPORTCALLPHONE703/519-0200 FAXPressureOnly22.460*****PATHVARIABLESUMMARY*****S0.00000E+00 0.112780.225570.338350.451140.563920.676700.789490902271.01511.12781.24061.35341.46621.57901.69181.80451.91732.03012.14292.25572.36852.48132.59402.7068NT6528356417.55542.54202.52785.51498.50264.49109.48019.46971.46001.45053.44170.43285.42462.41670.40901.40178.39460.38800.38185.37550.36926.36478.35974.I~oCs

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14TIME/FREQUENCY=

3600.0TITLE=ReactorScramTransient GRAPHPLOTKEY=1XAXISLABEL=Position, IDtoODYAXISLABEL=StressIntensity (psi)

Path:C:iNOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmDEFINEAPATHFORSUBSEQUENT CALCULATIONS THROUGHNODES:80614Page6a<Z***NOTE***CP=32.130TIME=18:06:17Previousinterpolated pathdatahasbeenerased.ReissuePDEFcommandtointerpolate desireddata.DEFINEPATHINPATHCOORDINATE SYSTEM0DIRECTION MAXMINX6.28552.2798Y348.57344.93Z0.00000E+00 0.00000E+00 TOTALPATHLENGTH=5.4136DEFINEPATHVARIABLESINTASTHENODALDATAITEM=SCOMP=INTROTATEDINTOCOORDINATE SYSTEM0ANDMOVEDTOTHEPATHNUMBEROFPATHVARIABLES DEFINEDIS5***WARNING***CP=37.950Theselectedelementsetcontainsmixedmaterials.

Thiscouldinvalidate errorestimation.

TIME=1806:22SUMMARYOFVARIABLESINTMAX=0.10997E+06 MIN=39107.CUMULATIVE DISPLAYNUMBER2WRITTENTOFILEXPATH.PLT DISPLAYTITLE=ReactorScramTransient RASTERMODE.PRINTALONGPATHDEFINEDBYLPATHCOMMAND.DSYS=01*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSION=PC 386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200 FAXReactorScramTransient 41.680*****PATHVARIABLESUMMARY*****S0.00000E+00 0.112780.225570.338350.451140.563920.67670SINT0.10997E+06 911)rru~i88915.86153.83317.80781.78373.

Patn:File:0.789490.902271.01511.12781.24061.35341'6621.57901.69181.80451.91732.03012.14292.25572.36852.48132.59402'0682.81962.93243.04523.15803.27073.38353.49633.60913.72193.83473.9474406024.17304.28584.39864.51144.6242C:KNOZZLE XPATH.OUT13,436.a..4-04-946:06:28pm76148.74078.72106.70305.68564.66937.65312.63805.62374.60995.59673.58388.57214.56098.54950.53857.53067.52158.51230.50269.49216.48061.46233.44546.43265.42541.41859.41175.40518.39815.39107.39160.41883.44307.46492.Page7Pg8*****ANSYS-ENGINEERING ANALYSISSYSTEMREVISION5.0*****MPRASSOCIATES VERSION=PC 386/48618:06:26APR04,1994CP=FORSUPPORTCALLPHONE703/519-0200 FAXReactorScramTransient 41.740*****PATHVARIABLESUMMARY*****S4.73694.84974.9625507535.1881SINT49026'1915.54876.'57081.59280.

Path:C:(NOZZLE File:XPATH.OUT13,436.a..4-04-946:06:28pmPage8~+85.30095.413661484.63709.*****ENDOFINPUTENCOUNTERED

          • NUMBEROFWARNINGMESSAGESENCOUNTERED=

NUMBEROFERRORMESSAGESENCOUNTERED=

          • PROBLEMTERMINATED BYINDICATED ERROR(S)ORBYENDOFINPUTDATA*****ANSYSRUNCOMPLETED REV.5.0CPTIME(sec)ELAPSEDTIME(sec)47.00047.000PC386/486TIME=18:06:26DATE=04/04/94

4774<P~Fr~i C'ath:C:(NOZZLE File:BCT.INP/SOLUTION OUTRESgALLgALL ANTYPE,TRANS KBC,1TREF,70THOT=525TCOLD=70570.a..3-28-945:13:42pm!1=StepChange,0=RampPage1p//TUNIF,THOT LSELISJLOCgXgRlSFLgALLgCONVg4ggTHOTCMSELISgLIDLSELgU~LOC/XgR1SFLgALLgCONVI5IgTHOTALLSELNSUBST,1TIME,1SOLVESAVELSEL~SgLOCIXgR1SFLDELEgALLfCONVSFLgALL~CONVI4I~TCOLDALLSELUTOTS,ONELTIM,1,1 TIME,3601 SOLVESAVEFINISH!CRDRID!NumberofSub-Load-Steps

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0()vac-Qgc.~Q~RC-K.BXC;'hisprogramcalculates crackgrowthIn~nozzleduetopressureand'hermalcyclesDECLARESUSCrackgrowth (At,Nsbl,PII,P2I,Sdist1,T11,TrII,Sdlst2,T21,Tr21)DECLAREfUNC'I!OH Klt(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(ANDS OPENinputflleS FORINPUTAStlflan~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'onstants Pi~3.I81592Calculate crackgrowthNtot~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)~Thissubroutine calculates crackgrorrthgiventheInitialcracklength,'hememberofcyclesandthemlnfaaraandmsxfaaaapressures and-'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)'alculate dscBIgivendKsndRSHAREDhain,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'tlOH FUNCTIONKit(Alt,L)'alculate StressIntensity factor'iven crack'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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lLIMpRMPRAssociates, Inc.320KingStreetAlexandria, VA22314Calculation No.OSS'-Z~-t2SPIPreparedByCheckedByPager2PInputVariableDefinitions forMCRACK.EXE:

Ao-NfinalRminC1RminC2Rmfnm1lll2RmaxC1RmaxC2RmaxF1F2F3FIoNstrdistBO(-)'B1(-)B2(-)B3(-)RefStr(-)

McyctypeRepcyc(-)

Nsubcyc(-)

Nsub(-,-)

Pmin(-~-)Pmax(-e-)

Strdistnn(-

T1min(-,-)

T2min(-,-)

strdistmx(-

71max(-,-)

72max(-e-)

1'nitialCrackLength(inches)TotalNwberofCyclestoAnalyzeHinfmmRfactorcorresponding tocrackgrowthconstants FirstParisCrackGrowthLawCoefficient forRminSecondParisCrackGrowthLawCoefficient forRminFirstParisCrackGrowthLawExponentforRminandRmaxSecondParisCrackGrowthLawExponentforRminandRmaxHaxigunRfactorcorresponding tocrackgrowthconstants FirstParisCrackGrowthLawCoefficient forRmaxSecondParisCrackGrowthLawCoefficient forRmaxStressIntensity Hagnification FactorStressIntensity Hagnification FactorStressIntensity Hagnification FactorStressIntensity Hagnification FactorNumberofThermalStressDistributions (Note1)StressDistribution Coefficient StressDistribution Coefficient StressDistribution Coefficient StressDistribution Coefficient Reference PressureorTemperature ChangeforStressDistribution (PrefordTref)NsmterofDifferent TypesofCycles(Note2)NumberofCycleRepetitions (Mote2)NumberofDifferent TypesofSubcycles foraGivenCycle(Note2)NumberofCyclesforaGivenSubcyclePressureatHinisxIaStressStateDuringCycle(psi)PressureatHaxfaunStressStateDuringCycle(psi)ThermalStressDistribution NumberforHinirmmTemperatures FirstNozzleTegperature atHinimmStressStateDuringCycle('F)(Note3)SecondNozzleTemperature atHiniaunStressStateDuringCycle('F)(Note3)ThermalStressDistribution NunberforHaxiaunTemperatures FirstNozzleTemperature atHaxiguaStressStateDuringCycle('F)(Note3)SecondNozzleTemperature atHaxinxmStressStateDuringCycle('F)(Note3)Aroe'roohio.mlira+As~lJ:~cLip&.AlebrIlgIIVIr0(aeerie$horro~a(erre~%)resenes4eessAstlo~4ieuo, a.merc~r.ka~a)iwnmoP5',Pp.en)$'psoF'ela',~<lec~l1e~rp]o8gigere~]gyp'l'uboolclcs s4e~decrsnsr's+

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0' Ao,NfinalRmin,C1Rmin,C2Rmin,m1,m2Rmax,C1Rmax,C2RmaxF1,F2,F3,F4Nstrdist80(0),81(0),82(0),83(0),RefStr(0) 80(1),81(1),82(1),83(1),RefStr(1) 0'08Z080(Nstrdist),

81(Nstrdist),

82(Nstrdist),

83(Nstrdist),

RefStr(Hstrdist)

NcyctypeRepcyc(1),

Nsubcyc(1)

Nsub(1,1),Pmin(1,1),Pmax(1,'1),

Strdistan(1, 1),T1min(1,1),T2min(1,1),Strdistmx(1, 1),T1max(1,1),T2max(1,1)Nsub(1,Nsubcyc(1)),

Pmin(1,Ksubcyc(1)),

Pmax(1,Hsubcyc(1)),

Strdistan(1, Nsubcyc(1)),...,

T2max(1,Nsubcyc(1))

Repcyc(2),

Nsubcyc(2)

Nsub(2,1),Pmin(2,1),Pmax(2,1),Strdistan(2, 1),Tlmin(2,1),T2min(2,1),Strdistmx(2, 1),T1max(2,1),T2max(2,1)(0lu(0CLHsub(2,Nsubcyc(2)),

Pmin(2,Nsubcyc(2)),

Pmax(2,Ksubcyc(2)),

Strdistaa(2, Nsubcyc(2)),...,

T2max(2,Nsubcyc(2))

Repcyc(Hcyctype),

Xsubcyc(H cyctype)Nsub(Kcyctype, 1),Pmin(Ncyctype, 1),Pmax(Hcyctype, 1),Strdistam(Kcyctype, 1),...,T2max(Kcyctype, 1)Nsub(Kcyctype, Nsubcyc(Ncyctype)

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tÃMPRENGINEERS AppendixIIMPLEMENTATION PLAN

WMPRASSOCIATESINC.ENGINEERSImplementation PlanforStructural AnalysisofNMP-0CRDRNozzleSpecification No.MPR-085-223-01 Revision0February1994Preparedby:Reviewedby:EdwardBird(MPREngineer)

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JaesNestell(MPREnginedr)

~~/~S~YDateDate'pprovedby:PhillipKasik(MPREngineer) lS-5'-DateApprovedby:.QP.IK(JQ.L'Qr-AcJneGawler(NMPCCognizant Engineer) c~l;-qIDate320KING51REETAI,EXANDRIA, VA22314-323 703-51'.0200 FAX70351r7.0224

r~lMPRASSOCIATES INC.ENGINEERS CONTENTSSectionBACKGROUND PURPOSETECHNICAL APPROACHExperience SurveyThermalLoadDefinition Structural AnalysisFractureMechanics/Fatigue Evaluation INFORMATION SOURCES~Pae10"11-

eASSOCIATES INC.EN&INEEAS BACKGROUND NUREG-0619 requiresNMPCtoperformanin-vessel PTexamononeofthefourfeed-waternozzlesandthecontrolroddrivereturn(CRDR)nozzleduringthenextrefueling outageatNineMilePointUnit1.Thisexamisexpectedtoresultinhighworkerexposure, potential outagedelaysandassociated highcostswithoutcomparable increases insafety.Asaresult,NMPCplanstorequestanexemption fromthisrequirement, basedonthefollowing:

Automated UTinspection systemsarenowavailable forperforming accurateinspections fromoutsideofthevessel.Modifications havebeenmadetothefeedwater nozzles,spargersandfiowcontrolsystemtoeliminate orlessenthefeedwater nozzlecrackingproblemsthatoccurredinthe1970s.~NodamagewasfoundontheCRDRnozzleduringthein-vessel examin1977orduringvisualexaminations thereafter.

~DetailedmodelingandanalyseshavebeendonetoshowthatsmallQawswillnotgrowtounacceptable valueswithinspecified operating periodsforthefeedwater nozzles.PURPOSEThepurposeofthistaskistoevaluatethelong-term susceptibility oftheCRDRnozzletothermalfatiguecracking, determine crackgrowthratesandcriticalcracksizes.NMPCwillusetheresultsofthistasktosupporttheirexemption requestandtoevaluatetheseverityofanyindication foundduringtheautomated UTinspection plannedforthe1995refueling outage.TECHNICAL APPROACHAfourstepapproachwillbeusedtoaccomplish thistask:~Experience Survey~ThermalLoadDefinition

~Structural Analysis~FractureMechanicslFatigue Evaluation

Eachofthesestepsisdescribed below.Theresultsofallfourstepswillbedocumented inasingleMPRreport.Thisworkwillbeperformed inaccordance with10CFR50,AppendixB,usingthelatestapprovedversionofMPR'sQAManual.ExerienceSurveAtelephone surveyofapplicable BWRswillbeperformed todetermine theirexami-nationhistory/frequency andcrackingexperience fortheCRDRnozzle.Surveyinformation willbecollected forweldedthermalsleevedesignssimilartoNMP-1andothernon-welded designs.Thetelephone surveywillincludequestions aboutexami-nationtechniques andtools.Thisinformation isexpectedtobeusefulinevaluating thesensitivity ofthecrackingproblemtothermalsleevedesign.ThermalLoadDefinition TheNMP1operating flowcharacteristics andlogrecordsoftheCRDsystemwillbereviewedtodetermine flowvariations andresulting temperature variations fortheCRDRnozzleduringdifferent CRDoperating conditions, e.g,,duringmovementofthecontrolrodsandscrams,andduringdifferent plantoperating conditions, e.g.,startup,shutdown, andstandby.Themagnitude andfrequency ofthermalandpressurechangeswillbeusedasinputtothestructural modelandtocalculate crackgrowthratesandfatigueusage.Structural AnalsisTheANSYScomputerprogramwillbeusedtodevelopatwo-dimensional axisymmetric finiteelementmodeloftheCRDRnozzle.ThemodelwillincludeasectionofthereactorvesselwalladjacenttotheCRDRnozzle.Theextentofthissectionwillbelongenoughtoeliminate interaction betweentheboundaryconditions appliedtothevesselwallandtheCRDRnozzle.Theradiusofthereactorvesselwallsectionwillbemodeledat3.2timestheactualradius.Thiswillinsurethatthemaximumhoopstressandstressintensity calculated bytheaxisymmetric modelwillbecomparable tothoseintheactualthree-dimensional intersection.

Thermalboundaryconditions, including heattransfercoefficients, willbecalculated fortheloadcycledefinedabove.Theresultsofthepreviously performed feedwater nozzleanalysiswillbefactoredintothiscalculation.

Thetemperature distribution withintheaozzlewillbecalculated asafunctionoftimefortheseboundaryconditions.

Through-wallstressesthatresultfrompressureandtemperature willbecalculated atseveralsnap-shotsintimetoestablish thetimeofpeakstress.Through-wall stresseswillbeusedinthefracturemechanics/fatigue evaluation below.Theoriginalstructural evaluation fortheCRDRnozzledocumented inReference 3isanareareinforcement calculation.

Becausestresseswerenotexplicitly calculated, adirectcomparison tostressesobtainedfromthisanalysisisnotpossible.

FractureMechanics atiueEvaluations Fatigueusageandcrackgrowthrateswillbecalculated forthestresscyclesdetermined inthestructural analysis.

Smallsurfaceflawsofvarioussizeswillbepostulated toexistonthevesselwallandnozzleboreregions.Crackgrowthratesduetolowfrequency pressureandthermalcycleswillbecalculated todetermine howquicklytheseinitialsmallflawscouldgrowtounacceptable sizes.Afatigueusageevaluation fortheCRDRnozzleswasnotperformed fortheoriginalstructural evaluation (Reference 3)ontheupdatedvesselusagereport(Reference 4).Acomparison tothecurrentanalysisisnotpossible.

INFORMATION SOURCESInformation sourcesfortheCRDRnozzlestructural analysisinclude:Combustion Engineering DrawingNo.231-567,Revision7,"NozzleDetails-Vessel."2.ASMECodeforMaterialProperties.

3.Combustion Engineering ReportCENC1142,"Analytical ReportforNiagaraMohawkReactorVessel."4.MPRReport629,"Re-evaluation ofReactorVesselFatigueAnalysisforRevisedOperating Cycles,NineMilePointNuclearGenerating StationUnitNo.1,"August13,1979.-3-

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