ML15147A618

Palisades - Appendix a, Computer File Listing, File No. 1400669.323, Revision 0

ML15147A618
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Site:	Palisades
Issue date:	05/22/2015
From:	Structural Integrity Associates
To:	Document Control Desk, Office of Nuclear Reactor Regulation
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ML15147A613	List: ML15147A616 ML15147A617 ML15147A618 ML15147A619 PNP 2015-037, Appendix a, Computer Files Listing, File No. 1200895.306, Revision 1
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PNP 2015-037 1400669.323, Rev. 0
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jSt uratgrit y Associates, Inc: APPENDIX A COMPUTER FILE LISTING File No.: 1400669.323 Revision:

0 Page A- I of A-2 F0306-01 R2 Cjjsftwciu a furld ft v Associaes, Inc G File Description Palisades CL.DB Base model geometry for crack tip insertion

[3]CL axial.INP Input file to modify base mesh for axial crack tip insertion BCNODES.INP Input file for nodal component definitions FMCLAXL*.INP Geometry input files to create circumferential flaw at specified depth. * = 05, 30, 50, 75, and 95 FMCLAXL*_COORD.INP Input files to determine circumferential crack face element centroid coordinates.

• = 05, 30, 50, 75, and 95 FMCLAXL*_GETSTR.INP Input files to extract circumferential crack face stresses from residual stress analysis.

• = 05, 30, 50, 75, and 95 FMCLAXL*_IMPORT.INP Input files to transfer stresses into circumferential crack face pressure (plus operating pressure on crack face and applied pipe moment). * = 05, 30, 50, 75, and 95 Axial* Nodes.INP Crack tip definition file for axial cracks FMPALISADESCLC#.INP Geometry input files to create circumferential flaw at specified depth. # = 05, 30, 50, 75, and 95 FMPALISADESCLC#_COORD.INP Input files to determine circumferential crack face element centroid coordinates.

1. = 05, 30, 50, 75, and 95 FMPALISADESCLC#_GETSTR.INP Input files to extract circumferential crack face stresses from residual stress analysis.

1. = 05, 30, 50, 75, and 95 FMPALISADESCLC#_IMPORT.INP Input files to transfer stresses into circumferential crack face pressure (plus operating pressure on crack face and applied pipe moment). # = 05, 30, 50, 75, and 95 NodesC#.INP Crack tip definition file for circumferential cracks Extracted circumferential crack face stresses from residual stress-p Sanalysis.

1. 1. = 05, 30, 50, 75, and 95 Extracted axial crack face stresses from residual stress analysis.STR_FieldOperAxl**l1.txt

• 0,ad9**=00, and 90 FM CL AXL** IMPORT K.CSV Formatted K result outputs for axial crack. ** = 00, and 90 FMPALISADESCLC##_IMPORTK.

Formatted K result outputs for circumferential crack.CSV ## = 05, 30, 50, 75, and 95 CircFlaw $$$$.pcf pc-CRACK PWSCC growth input file for circ flaw.$$$$ = 0025 and 01, 0025 = 0.025" and 01 = 0.1" initial flaw size AxialFlaw-0_$$$$.pcf pc-CRACK PWSCC growth input file for axial flaw on 00 plane.$$$$ = 0025 and 01 AxialFlaw 90 $$$$.pcf pc-CRACK PWSCC growth input file for axial flaw on 90' plane.$$$$ = 0025 and 01 CiircFlaw

$$$$.rpt pc-CRACK PWSCC growth output file for circ flaw.C wt$$$$ = 0025 and 01 AxialFlaw 0 $$$$.rpt pc-CRACK PWSCC growth output file for axial flaw on 0' plane.$$$$ = 0025 and 01-90 $$$$.rpt pc-CRACK PWSCC growth output file for axial flaw on 90' plane.AxialFlaw$$$$

= 0025 and 01 File No.: 1400669.323 Revision:

0 Page A-2 of A-2 F0306-01R2 Structural Integrity Associates, Inc.' File No.: 1400669.310 Project No.: 1400669 CALCULATION PACKAGE Quality Program Type: 0 Nuclear El Commercial PROJECT NAME: Palisades Flaw Readiness Program for 1R24 NDE Inspection CONTRACT NO.: 10426669 CLIENT: PLANT: Entergy Nuclear Operations, Inc. Palisades Nuclear Plant CALCULATION TITLE: Finite Element Model for Hot Leg Drain Nozzle Document Affected Project Manager Preparer(s)

&Revision Pages Revision Description Approval Checker(s)

Signature

& Date Signatures

& Date 0 1 -20 Initial Issue Preparer: A-1 -A-2 Computer Files Norman Eng NE 03/09/2015 Minji Fong MF 03/09/2015 Checkers: Charles Fourcade CJF 03/09/2015 Gole Mukhim GSM 03/09/2015 Page 1 of 20 F0306-01 R2 10lra te rry AociMOMs, IMc Table of Contents 1.0 OBJECTIVE

.........................................................................................................

4 2.0 TECHN ICAL APPROACH .....................................................................................

4 3.0 A SSUM PTION S / DESIGN IN PUTS ......................................................................

4 4.0 FIN ITE ELEM ENT M ODEL ....................................................................................

5 4.1 Elem ent Type and M esh ...............................................................................

5 4.2 M aterials ........................................................................................................

5 4.2.1 Creep Properties

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5 4.3 Loads and Boundary Conditions

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6 5.0 CON CLU SION S .....................................................................................................

6

6.0 REFERENCES

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7 APPENDIX A COM PUTER FILES LISTIN G ...............................................................

A-1 File No.: 1400669.310 Revision:

0 Page 2 of 20 F0306-01 R2

~jj~StnwruI Ieftgrl Associates, Inc.List of Tables Table 1: Com ponent M aterials ............................................................................................

8 Table 2: Elastic Properties for SA-516 Grade 70 (< 4" Thick) ..........................................

9 Table 3: Stress-Strain Curves for SA-516 Grade 70 (< 4" Thick) ....................................

10 Table 4: Elastic Properties for ER 308L ..................................................................................

11 Table 5: Stress-Strain Curves for ER308L ........................................................................

12 Table 6: Elastic Properties for Alloy 600 ..........................................................................

13 Table 7: Stress-Strain Curves for Alloy 600 ......................................................................

14 Table 8: Elastic Properties for Alloy 182 ..........................................................................

15 Table 9: Stress-Strain Curves for Alloy 182 ......................................................................

16 T able 10: C reep Properties

.................................................................................................

17 List of Figures Figure 1. Finite Element Model Dimensions

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18 Figure 2. Components Included in the Finite Element Model ..........................................

19 Figure 3. Isometric View of the Finite Element Model ...................................................

20 File No.: 1400669.310 Revision:

0 Page 3 of 20 F0306-01 R2 C antbobrhI Int~r~ify Associates, Inc@1.0 OBJECTIVE The objective of this calculation package is to document the development of a finite element model (FEM) for the reactor hot leg drain nozzle at the Palisades Nuclear Plant, which will be used to perform residual and operational-based fracture mechanics analyses to support a subsequent fracture mechanics evaluation as part of a flaw readiness program.2.0 TECHNICAL APPROACH One three-dimensional (3-D) finite element model is developed using the ANSYS finite element analysis software package [1]. The area of interest is the nozzle-to-pipe weld. The model uses elastic-plastic material properties intended for weld residual stress analysis, and elastic material properties for linear elastic analyses.3.0 ASSUMPTIONS

/ DESIGN INPUTS The dimensions and material types to develop the finite element model are provided in References 2 and 3 and summarized in Figure 1. The material properties are obtained from References 4 and 5. A number of assumptions were made during development of the finite element model, which are listed as follows:* The drain nozzle is modeled as a straight pipe without the nozzle transition since the area of interest is the nozzle-to-hot leg piping weld which is away from the nozzle-to-safe end transition." The axial length of the modeled portion of the hot leg piping is arbitrarily set at 36 inches, which is sufficiently long enough to negate possible end effects in the region of interest.* The ID patch weld is added after removal of the backing ring according to the weld procedure mentioned in the drawing [2]. The same material of the nozzle-to-pipe weld is used for the ID patch weld.File No.: 1400669.310 Revision:

0 Page 4 of 20 F0306-01R2 jSi uI Mfgiy Associates, Inc: 4.0 FINITE ELEMENT MODEL The model includes a local portion of the hot leg pipe and cladding, the drain nozzle, and the nozzle-to-pipe weld, including the ID patch weld, as shown in Figure 2. As shown in the figure, a single 900 quadrant of the drain nozzle penetration is modeled due to geometric symmetry.

The included portion of the hot leg piping measures 36 inches longitudinally and 180 degree circumferentially.

The mesh of the finite element model is shown in Figure 3.4.1 Element Type and Mesh The 8-node solid element (SOLID185) in ANSYS [1] is used for the model. SOLID185 elements support material plasticity which is suitable for residual stress and elastic plastic fracture mechanics (EPFM) analyses.

The model contains adequate mesh refinement within the weld region to predict the residual stresses from welding.4.2 Materials The material designation for the modeled components is listed in Table 1. The temperature dependent nonlinear material property values are provided in a separate calculation package [5], which are based on the 2001 Edition of the ASME Code with Addenda through 2003 [4]. The material properties are listed in Table 2 through Table 9.4.2.1 Creep Properties Since post weld heat treatment (PWHT) will be considered in the subsequent residual stress calculation, creep properties are required.

In general, creep becomes significant at temperatures above 800'F; thus, creep behavior under 800'F will not be considered in this analysis.There are two main categories of creep: primary and secondary.

The primary creep addresses the creep characteristics for a short duration at the early stages of the creep regime, while the secondary creep accounts for the creep behavior for a long duration -usually more than 10,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br />. Based on this definition, the PWIHT falls within the primary creep characteristics.

However, primary creep rates for materials are difficult to obtain, so the conservative secondary creep rates are used since primary creep rate is typically an order of magnitude higher than that for secondary creep.In general, the primary creep rate for the materials is governed by the equation: dce--= Ao'" dt The creep data for the SA-516 Grade 70 hot leg material is based on carbon steel material [6]. The creep data for the Alloy 82/182 and ER308L weld metals are not available, so the creep properties for their base metals are used instead. The creep data for Type 304 (for ER308L) is provided in the same File No.: 1400669.310 Page 5 of 20 Revision:

0 F0306-01R2 V ajlSfnwbr IatMyW Associaes.

IWO~reference document as the carbon steel [6], while the creep data for the Alloy 600 (for Alloy 82/182) is provided in a separate reference document [7]. All the creep strengths, c, are provided at two creep rates[6, 7] for each temperature point.When creep strength is provided at two creep rates at the same temperature point, as listed in Table 10, then A and n can be calculated as follows, where subscripts 1 and 2 refer to the creep data sets 1 and 2: de *=- = Au dt 6 1 Au 1 l 62 =Au,," In El ln(2 Inf~In 4.3 Loads and Boundary Conditions No loads or boundary conditions of any kind are included in the finite element model in this calculation.

Specific loads and boundary conditions, appropriate to the specific analyses, will be applied in the subsequent residual and thermal/mechanical stress calculation packages.

5.0 CONCLUSION

S A finite element model of the hot leg drain nozzle is developed.

The model will be used in subsequent weld residual stress analyses and fracture mechanics analyses.

The necessary ANSYS input file names are listed in Appendix A.File No.: 1400669.310 Revision:

0 Page 6 of 20 F0306-01R2 Vjf funk NOM/ g Associates, 1 nc;

6.0 REFERENCES

1. ANSYS Mechanical APDL and PrepPost, Release 14.5 (w/ Service Pack 1), ANSYS, Inc., September 2012.2. Drawing No. VEN-MI-D, Sheet 108, Rev. 10, "Nozzle Details," SI File No. 1400669.202.

3. Drawing No. VEN-Ml-D, Sheet 106, Rev. 10, "Piping Assembly & Details," SI File No.1400669.202.

4. ASME Boiler and Pressure Vessel Code, Section 11, Part D -Properties, 2001 Edition with Addenda through 2003.5. SI Calculation No. 0800777.307, Rev.5, "Material Properties for Residual Stress Analyses, Including MISO Properties Up To Material Flow Stress." 6. "Steels for Elevated Temperature Service," United States Steel Co., 1949.7. Publication SMC-027, "Inconel Alloy 600," Special Metals Corp., 2004, SI File No.0800777.211.

8. Palisades Design Input Record, "Palisades Alloy 600 Flaw Evaluation DIR 3-4-15 Rev I.pdf," SI File No. 1400669.201.

File No.: 1400669.310 Revision:

0 Page 7 of 20 F0306-01R2 C7j Oltnwbrw lat* rl Associaes.

Inc 6 Table 1: Component Materials Component Material References Hot Leg Piping SA-516 Grade 70 [8]Pipe Cladding ER308L () [3]Drain Nozzle SB-166 (N06600, Alloy 600) (2) [2]Drain Nozzle-to-Pipe Weld Alloy 182 [8]ID Patch Weld Alloy 182 [8]Notes: 1. The material properties are based on equivalent Type 304 base material.2. Alloy SB-166 is assumed to have the same material properties as Alloy 600.File No.: 1400669.310 Revision:

0 Page 8 of 20 F0306-01R2 V nStrurel Integdty Associates, Inc.Table 2: Elastic Properties for SA-516 Grade 70 (5 4" Thick)Temperature Young's Mean Thermal Thermal Specific Heat Modulus Expansion Conductivity (2) Spec f )(°F)(x103 ksi) (Xl10-6 in/in/*F) (Btu/min-in-*F) (B/l-F 70 29.5 6.4 0.0488 0.103 500 27.3 7.3 0.0410 0.128 700 25.5 7.6 0.0369 0.138 1100 18.0 8.2 0.0290 0.171 1500 5.0 8.6 0.0218 0.198 2500 0.1 9.5 0.0014 0.204 2500.1 _ 0.0 _ -Notes: 1. All values per [5].2. Density (p) = 0.283 lb/in 3 [5], assumed temperature independent.

3. Poisson's Ratio (u) = 0.3 [5], assumed temperature independent.

File No.: 1400669.310 Revision:

0 Page 9 of 20 F0306-01 R2 snfu w laefritVy Associates, inc=Table 3: Stress-Strain Curves for SA-516 Grade 70 (5 4" Thick)Temperature Strain Stress (*F) (in/in) (ksi)0.00128814 38.000 0.00187809 42.000 70 0.00257329 46.000 0.00381110 50.000 0.00600383 54.000 0.00113553 31.000 0.00142679 35.875 500 0.00183954 40.750 0.00261139 45.625 0.00415246 50.500 0.00106667 27.200 0.00132412 32.550 700 0.00166876 37.900 0.00228121 43.250 0.00354341 48.600 0.00116667 21.000 0.05116163 22.125 1100 0.05915444 23.250 0.06794123 24.375 0.07755935 25.500 0.00300000 15.000 0.16717493 15.125 1500 0.16992011 15.250 0.17268761 15.375 0.17547742 15.500 0.01000000 1.000 0.10961239 1.125 2500(21 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [5].2. Values at 25001F assumed irbitranily small values for convergence stability.

File No.: 1400669.310 Revision:

0 Page 10 of 20 F0306-O IR2 sISt uabrlIrtgdty ,Associates, Inc: Table 4: Elastic Properties for ER308L Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity ( Specific Heat (2)(°F) ~(Xl03 ksi) (x10-1 in/in/°F) (Btu/min-in-*F) (tuI-F 70 28.3 8.5 0.0119 0.116 500 25.8 9.7 0.0151 0.131 700 24.8 10.0 0.0164 0.135 1100 22.1 10.5 0.0189 0.140 1500 18.1 10.8 0.0213 0.145 2500 0.1 11.5 0.0292 0.159 2500.1 -0.0 --Notes: 1. All values per [5].2. Density (p) = 0.283 lb/in 3 [5], assumed temperature independent.

3. Poisson's Ratio (u) = 0.3 [5], assumed temperature independent.

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0 Page 11 of 20 F0306-01 R2

!jsftntkiru ategdry Assoates, LnO°Table 5: Stress-Strain Curves for ER308L Temperature Strain Stress (TF) (in/in) (ksi)0.00203180 57.500 0.02471351 61.563 70 0.03107296 65.625 0.03861377 69.688 0.04747167 73.750 0.00140089 36.143 0.00714793 40.250 500 0.01065407 44.357 0.01558289 48.464 0.02233857 52.571 0.00132488 32.857 0.00477547 37.125 700 0.00743595 41.393 0.01143777 45.661 0.01727192 49.929 0.00121913 26.943 0.00264833 30.138 1100 0.00404100 33.332 0.00634529 36.527 0.01005286 39.721 0.00117995 21.357 0.05352064 21.563 1500 0.05610492 21.768 0.05878975 21.973 0.06157807 22.179 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [5].2. Values at 2500TF assumed arbitrarily small values for convergence stability.

File No.: 1400669.310 Revision:

0 Page 12 of 20 F0306-01 R2 StoIurId ligray Associates, Inc@Table 6: Elastic Properties for Alloy 600 Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity Specific Heat (2)(OF) (x10 3 ksi) (xl0-6 in/in/°F) (Btu/min-in-*F) (Btu/lb-°F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -0.0 -_Notes: 1. All values per [5].2. Density (p) = 0.300 lb/in 3 [5], assumed temperature independent.

3. Poisson's Ratio (u) = 0.29 [5], assumed temperature independent.

File No.: 1400669.310 Revision:

0 Page 13 of 20 F0306-01 R2 Sb"onIruw grtfy Associates, kc;Table 7: Stress-Strain Curves for Alloy 600 Temperature Strain Stress (*F) (in/in) (ksi)0.00157419 48.800 0.01658847 55.300 70 0.02343324 61.800 0.03212188 68.300 0.04291703 74.800 0.00152069 44.100 0.01539220 50.338 500 0.02210610 56.575 0.03072476 62.813 0.04153277 69.050 0.00152128 42.900 0.01634485 49.000 700 0.02334760 55.100 0.03227153 61.200 0.04338643 67.300 0.00155985 40.400 0.02275193 44.475 1100 0.03004563 48.550 0.03888203 52.625 0.04943592 56.700 0.00092641 21.400 0.08827666 22.475 1500 0.09785101 23.550 0.10796967 24.625 0.11863796 25.700 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [5].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

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0 Page 14 of 20 F0306-01 R2

,SWnoaInlegrlo y Associas, Inc.Table 8: Elastic Properties for Alloy 182 Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity ) Specific Heat (2)(OF) (Xl03 ksi) (x10-1 in/in/°F) (Btu/min-in-*F) (B /l-F 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -0.0 --Notes: 1. All values per [5].2. Density (p) = 0.300 lb/in 3 [5], assumed temperature independent.

3. Poisson's Ratio (u) = 0.29 [5], assumed temperature independent.

File No.: 1400669.310 Revision:

0 Page 15 of 20 F0306-OI R2 V Sbtrounul Iaegrly Associates, Inc Table 9: Stress-Strain Curves for Alloy 182 Temperature Strain Stress (0 F) (in/in) (ksi)0.00179032 55.500 0.03456710 60.113 70 0.04292837 64.725 0.05257245 69.338 0.06359421 73.950 0.00164483 47.700 0.02976152 52.313 500 0.03809895 56.925 0.04790379 61.538 0.05929946 66.150 0.00159574 45.000 0.02849157 49.538 700 0.03680454 54.075 0.04663682 58.613 0.05812078 63.150 0.00159073 41.200 0.03568855 44.488 1100 0.04402702 47.775 0.05360088 5,1.063 0.06449835 54.350 0.00106494 24.600 0.11812735 25.325 1500 0.12540227 26.050 0.13290814 26.775 0.14064577 27.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [5].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.310 Revision:

0 Page 16 of 20 F0306-01 R2 Vjswftrw InrIlte grily Associaes, bIcG Table 10: Creep Properties Material Temperature Creep Strength (ksi) A n (OF) aw (0.0001%/hr) 62 (0.00001%/hr) (ksi/hr)800 19.0 12.4 1.26E-13 5.40 SA-516 Gr. 70 900 9.0 6.7 3.59E-14 7.80 (Based on carbon steel) 1000 3.5 2.8 2.43E-12 10.32 Per [6] 1100 1.4 0.8 2.50E-07 4.11 800 33.4 25.0 7.73E-19 7.95 ER308L 900 24.0 17.6 5.67E- 17 7.42 (Based on Type 304) 1000 17.6 11.5 1.82E-13 5.41 Per[6] 1100 11.5 7.1 8.62E- 12 4.77 Alloy 600 800 40.0 30.0 1.50E-19 8.00 Alloy 182 900 28.0 18.0 2.87E-14 5.21 (Based on 1000 12.5 6.1 3.02E- 10 3.21 Alloy 600)Per [7] 1100 6.8 3.4 1.72E-09 3.32 File No.: 1400669.310 Revision:

0 Page 17 of 20 F0306-01 R2 VaSud" MWaWfY Audat 4 9116" O.D.2 5/16" I.D.36F e From Center Line 10 15116" 1 114" R /7 112°6 3/16" O.D.60° I 1 1 41 518" 114" 49 5/8" I.D. O.D.Figure 1. Finite Element Model Dimensions Note: Dimensions obtained from [2, 3].File No.: 1400669.310 Revision:

0 Page 18 of 20 F0306-01 R2 V an" MokW Ifng ASSOCWuWe, knG ANSYS\ID Patch Weld Figure 2. Components Included in the Finite Element Model File No.: 1400669.310 Revision:

0 Page 19 of 20 F0306-01R2 Cjswaud" iutv AssWOcitS, kn Figure 3. Isometric View of the Finite Element Model (Nozzle weld detail shown in bottom right comer)File No.: 1400669.310 Revision:

0 Page 20 of 20 F0306-01 R2 VjfStatrw It ugrfy Associates, Inc" APPENDIX A COMPUTER FILES LISTING File No.: 1400669.310 Revision:

0 Page A- I of A-2 F0306-01R2 V7SWrO" ftlrI ae ry AssWoae, Wnc File Name Description PalisadesHLDrain.INP Input file to create base model geometry MPropMISO.INP Elastic-plastic Material properties inputs File No.: 1400669.310 Revision:

0 Page A-2 of A-2 F0306-01R2 Structural Integrity Associates, Inc.' File No.: 1400669.320 Project No.: 1400669 CALCULATION PACKAGE Quality Program: 0 Nuclear El Commercial PROJECT NAME: Palisades Flaw Readiness Program for 1 R24 NDE Inspections CONTRACT NO.: 10426669 CLIENT: PLANT: Entergy Nuclear Operations, Inc. Palisades Nuclear Plant CALCULATION TITLE: Finite Element Model Development for the Cold Leg Drain, Spray, and Charging Nozzles Document Affected Project Manager Preparer(s)

&Revision Pages Revision Description Approval Checker(s)

Signature

& Date Signatures

& Date 0 1 -20 Initial Issue Preparer: A-1 -A-2 Computer Files 2P Norman Eng Wilson Wong NE 4/3/15 WW 4/3/15 Checker: Charles Fourcade CJF 4/3/15 Gole Mukhim GSM 4/3/15 Page 1 of 20 F0306-OIRI mfmnrwil Ifegrity Associates, Wn.Table of Contents 1.0 OBJECTIVE

.........................................................................................................

4 2.0 TECHN ICAL APPROACH .....................................................................................

4 3.0 A SSUM PTION S / DESIGN IN PUTS ......................................................................

4 4.0 FIN ITE ELEM EN T M ODEL ....................................................................................

5 4.1 Elem ent Type and M esh ...............................................................................

5 4.2 M aterials ........................................................................................................

5 4.2.1 Creep Properties

...........................................................................................

5 4.3 Loads and Boundary Conditions

.................................................................

6 5.0 CON CLU SION S .....................................................................................................

6 6.0 REFEREN CES ......................................................................................................

7 APPEN DIX A COM PUTER FILES LISTIN G ...............................................................

A -I File No.: 1400669.320 Revision:

0 Page 2 of 20 F0306-01R2 mStWalb g IAirgly AssocWts, Inc" List of Tables Table 1: Com ponent M aterials ............................................................................................

8 Table 2: Elastic Properties for SA-516 Grade 70 (< 4" Thick) ..........................................

9 Table 3: Stress-Strain Curves for SA-516 Grade 70 (< 4" Thick) ....................................

10 Table 4: Elastic Properties for ER 308L ..................................................................................

II Table 5: Stress-Strain Curves for ER308L ........................................................................

12 Table 6: Elastic Properties for Alloy 600 ..........................................................................

13 Table 7: Stress-Strain Curves for Alloy 600 ......................................................................

14 Table 8: Elastic Properties for Alloy 82/182 .....................................................................

15 Table 9: Stress-Strain Curves for Alloy 82/182 ................................................................

16 T able 10: C reep Properties

.................................................................................................

17 List of Figures Figure 1. Finite Element Model Dimensions

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18 Figure 2. Components Included in the Finite Element Model ..........................................

19 Figure 3. Isometric View of the Finite Element Model .....................................................

20 File No.: 1400669.320 Revision:

0 Page 3 of 20 F0306-01R2 j airuIr lAegrify Associates, iWc 1.0 OBJECTIVE The objective of this calculation package is to document the development of a bounding finite element model for the reactor cold leg spray, drain, and charging nozzles at the Palisades Nuclear Plant, which will be used to perform residual and operational-based fracture mechanics analyses to support a subsequent fracture mechanics evaluation as part of a flaw readiness program.2.0 TECHNICAL APPROACH One bounding three-dimensional (3-D) finite element model is developed using the ANSYS finite element analysis software package [1] to represent a group of cold leg nozzles. All three nozzles are of similar size near the forging boss area (within 1/16 inch) [2, 3, and 4]. Therefore, the largest inside diameter (ID) and smallest outside diameter (OD) of the three nozzles is chosen for the bounding model.The spray and drain nozzles have identical nozzle and boss OD dimensions of 4-9/16 inch and 6-3/16 inch, respectively, which are slightly smaller than the charging nozzle OD dimensions of 4-5/8 inch and 6-1/4 inch. For the nozzle ID, the charging nozzle is bored out to 2-5/8 inch in the first 1.5 inch to accommodate a thermal sleeve. For conservatism, it is assumed that the entire nozzle ID is 2-5/8 inch.The area of interest is the nozzle-to-pipe weld. The model uses elastic-plastic material properties intended for weld residual stress analysis, and elastic material properties for linear elastic analyses.3.0 ASSUMPTIONS

/ DESIGN INPUTS The dimensions and material types to develop the finite element model are provided in References 2, 3, and 4 and summarized in Figure 1. The material properties are obtained from References 5 and 6. A number of assumptions were made during development of the finite element model, which are listed as follows:* Since the area of interest is the nozzle to cold leg weld, dimensional differences between nozzles on the attached piping side are considered insignificant." The largest inside diameter (ID) and smallest outside diameter (OD) of the three nozzles will be chosen for the bounding model. This is conservative for pressure and mechanical loads.* The axial length of the modeled portion of the cold leg piping is arbitrarily set at 36 inches, which is sufficiently long to negate possible end effects in the region of interest." The ID patch weld is added after removal of the backing ring according to the weld procedure mentioned in the drawings [2, 3]. The same material of the nozzle-to-pipe weld is used for the ID patch weld.File No.: 1400669.320 Page 4 of 20 Revision:

0 F0306-01R2 Sb"otur latgrfy Associates, IncP 4.0 FINITE ELEMENT MODEL The model includes a local portion of the cold leg pipe and cladding, the nozzle, and the nozzle-to-pipe weld, including the ID patch weld, as shown in Figure 2. As shown in the figure, a single 900 quadrant of the nozzle penetration is modeled due to geometric symmetry.

The included portion of the cold leg piping measures 36 inches longitudinally and 180 degrees circumferentially.

The mesh of the finite element model is shown in Figure 3.4.1 Element Type and Mesh The 8-node solid element (SOLID185) in ANSYS [1] is used tbr the model. SOLIDI85 elements support material plasticity which is suitable for residual stress and elastic plastic fracture mechanics (EPFM) analyses.

The model contains adequate mesh refinement within the weld region to predict the residual stresses from welding.4.2 Materials The material designation for the modeled components is listed in Table 1. The temperature dependent nonlinear material property values are provided in a separate calculation package [6], which are based on the 2001 Edition of the ASME Code with Addenda through 2003 [5]. The material properties are listed in Table 2 through Table 9.4.2.1 Creep Properties Since post weld heat treatment (PWHT) will be considered in the subsequent residual stress calculation, creep properties are required.

In general, creep becomes significant at temperatures above 800'F; thus, creep behavior under 800'F will not be considered in this analysis.There are two main categories of creep: primary and secondary.

The primary creep addresses the creep characteristics for a short duration at the early stages of the creep regime, while the secondary creep accounts for the creep behavior for a long duration -usually more than 10,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br />. Based on this definition, the PWHT falls within the primary creep characteristics.

However, primary creep rates for materials are difficult to obtain, so the conservative secondary creep rates are used since primary creep rate is typically an order of magnitude higher than that for secondary creep.In general, the primary creep rate for the materials is governed by the equation:= A dt The creep data for the SA-516 Grade 70 cold leg material is based on carbon steel material [7]. The creep data for the Alloy 82/182 and ER308L weld metals are not available, so the creep properties for their base metals are used instead. The creep data for Type 304 (for ER308L) is provided in the same reference document as the carbon steel [7], while the creep data for the Alloy 600 (for Alloy 82/182) is provided in a separate reference document [8]. All the creep strengths, u, are provided at two creep rates[7, 8] for each temperature point.File No.: 1400669.320 Page 5 of 20 Revision:

0 F0306-01R2 V SMn r grny Assocates, Ine" When creep strength is provided at two creep rates at the same temperature point, as listed in Table 10, then A and n can be calculated as follows, where subscripts I and 2 refer to the creep data sets I and 2: de = Au"~dt e 1 Acr'1 e, =A o*2 In[] = nlnQ=L In 0In 4.3 Loads and Boundary Conditions No loads or boundary conditions of any kind are included in the finite element model in this calculation.

Specific loads and boundary conditions, appropriate to the specific analyses, will be applied in the subsequent residual and thermal/mechanical stress calculation packages.

5.0 CONCLUSION

S A bounding finite element model for the cold leg spray, drain, and charging nozzles is developed.

The model will be used in subsequent weld residual stress analyses and fracture mechanics analyses.

The necessary ANSYS input file names are listed in Appendix A.File No.: 1400669.320 Revision:

0 Page 6 of 20 F0306-01R2 7s"nu Lategrrfy AssociMs, Inc

6.0 REFERENCES

1. ANSYS Mechanical APDL and PrepPost, Release 14.5 (w/ Service Pack 1), ANSYS, Inc., September 2012.2. Combustion Engineering Drawing E232-675-4, "Nozzle Details," SI File No. 1400669.202.

3. Combustion Engineering Drawing E232-676-7, "Nozzle Details," SI File No. 1400669.202.

4. Combustion Engineering Drawing E232-673-7, "Piping Assembly & Details," SI File No.1400669.202.

5. ASME Boiler and Pressure Vessel Code,Section II, Part D -Properties, 2001 Edition with Addenda through 2003.6. S1 Calculation No. 0800777.307, Rev. 5, "Material Properties for Residual Stress Analyses, Including MISO Properties Up To Material Flow Stress." 7. "Steels for Elevated Temperature Service," United States Steel Co., 1949.8. Publication SMC-027, "Inconel Alloy 600," Special Metals Corp., 2004, SI File 0800777.211.

9. Palisades Design Input Record, "Palisades Alloy 600 Flaw Eval DIR 3-4-15 Rev 1.pdf," SI File No. 1400669.201.

File No.: 1400669.320 Revision:

0 Page 7 of 20 F0306-OIR2 jswnira/ lute r1fy Associates, Inc Table 1: Component Materials Component Material References Cold Leg Piping SA-516 Grade 70 [9]Pipe Cladding ER308L 0) [4]Bounding Nozzle SB- 166 (N06600, Alloy 600)"2) [2, 3]Weld Alloy 182 [9]ID Patch Weld Alloy 182 [9]Notes: 1. The material properties are based on equivalent Type 304 base material.2. Alloy SB-166 is assumed to have the same material properties as Alloy 600.File No.: 1400669.320 Revision:

0 Page 8 of 20 F0306-O0I1R2 Vjstnolgrel lft* rt ASSociaOS.

IRcP Table 2: Elastic Properties for SA-516 Grade 70 (< 4" Thick)Temperature Elastic Mean Thermal Thermal Specific Modulus Expansion Conductivity(2) Heat(2)(OF) (x10 3 ksi) (x10-6 in/in/°F) (Btu/min-in-0 F) (Btu/Ib-°F) 70 29.5 6.4 0.0488 0.103 500 27.3 7.3 0.0410 0.128 700 25.5 7.6 0.0369 0.138 1100 18.0 8.2 0.0290 0.171 1500 5.0 8.6 0.0218 0.198 2500 0.1 9.5 0.0014 0.204 2500.1 -- 0 -- --Notes: 1. All values per [6].2. Density (p) = 0.283 lb/in 3 [6], assumed temperature independent.

3. Poisson's Ratio (v) = 0.3 [6], assumed temperature independent.

File No.: 1400669.320 Revision:

0 Page 9 of 20 F0306-01R2 VjS ucrl lat gdfy Associates, Inc.Table 3: Stress-Strain Curves for SA-516 Grade 70 (! 4" Thick)Temperature Strain Stress (*F) (in/in) (ksi)0.00128814 38.000 0.00187809 42.000 70 0.00257329 46.000 0.00381110 50.000 0.00600383 54.000 0.00113553 31.000 0.00142679 35.875 500 0.00183954 40.750 0.00261139 45.625 0.00415246 50.500 0.00106667 27.200 0.00132412 32.550 700 0.00166876 37.900 0.00228121 43.250 0.00354341 48.600 0.00116667 21.000 0.05116163 22.125 1100 0.05915444 23.250 0.06794123 24.375 0.07755935 25.500 0.00300000 15.000 0.16717493 15.125 1500 0.16992011 15.250 0.17268761 15.375 0.17547742 15.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1.2.All values per [6].Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.320 Revision:

0 Page 10 of 20 F0306-01R2 V siffraf kfrIhtgrfiy Assocates, IncO Table 4: Elastic Properties for ER308L Temperature Elastic Mean Thermal Thermal Specific Modulus Expansion Conductivity(2) HeatG 2)(OF) (Xl03 ksi) (xl0"6 in/in/*F) (Btu/min-in-°F) (Btu/lb-°F) 70 28.3 8.5 0.0119 0.116 500 25.8 9.7 0.0151 0.131 700 24.8 10.0 0.0164 0.135 1100 22.1 10.5 0.0189 0.140 1500 18.1 10.8 0.0212 0.145 2500 0.1 11.5 0.0292 0.159 2500.1 --0 ..Notes: 1. All values per [6].2. Density (p) = 0.283 lb/in 3 [6], assumed temperature independent.

3. Poisson's Ratio (v) = 0.3 [6], assumed temperature independent.

File No.: 1400669.320 Revision:

0 Page 11 of 20 F0306-01R2 VjIs~n fobrfI lfityigI~

Associates, Inc.Table 5: Stress-Strain Curves for ER308L Temperature Strain Stress (OF) (in/in) (ksi)0.00203180 57.500 0.02471351 61.563 70 0.03107296 65.625 0.03861377 69.688 0.04747167 73.750 0.00140089 36.143 0.00714793 40.250 500 0.01065407 44.357 0.01558289 48.464 0.02233857 52.571 0.00132488 32.857 0.00477547 37.125 700 0.00743595 41.393 0.01143777 45.661 0.01727192 49.929 0.00121913 26.943 0.00264833 30.138 1100 0.00404100 33.332 0.00634529 36.527 0.01005286 39.721 0.00117995 21.357 0.05352064 21.563 1500 0.05610492 21.768 0.05878975 21.973 0.06157807 22.179 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1.2.All values per [6].Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.320 Revision:

0 Page 12 of 20 F0306-01 R2 Cjs"ur Inkoiu aegrity Assockiates, Inc.6 Table 6: Elastic Properties for Alloy 600 Temperature Elastic Mean Thermal Thermal Specific Modulus Expansion Conductivity(2) Heat(2)(OF) (x10 3 ksi) (xl0-6 in/in/OF) (Btu/min-in-*F) (Btu/lb-°F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -- 0 -- --Notes: 1. All values per [6].2. Density (p) = 0.300 lb/in 3 [6], assumed temperature independent.

3. Poisson's Ratio (v) = 0.29 [6], assumed temperature independent.

File No.: 1400669.320 Revision:

0 Page 13 of 20 F0306-01 R2

,j W~lundoru IafwdiM ASSOCiatS, Wc Table 7: Stress-Strain Curves for Alloy 600 Temperature Strain Stress (OF) (in/in) (ksi)0.00157419 48.800 0.01658847 55.300 70 0.02343324 61.800 0.03212188 68.300 0.04291703 74.800 0.00152069 44.100 0.01539220 50.338 500 0.02210610 56.575 0.03072476 62.813 0.04153277 69.050 0.00152128 42.900 0.01634485 49.000 700 0.02334760 55.100 0.03227153 61.200 0.04338643 67.300 0.00155985 40.400 0.02275193 44.475 1100 0.03004563 48.550 0.03888203 52.625 0.04943592 56.700 0.00092641 21.400 0.08827666 22.475 1500 0.09785101 23.550 0.10796967 24.625 0.11863796 25.700 0.01000000 1.000 0.10961239 1.125 2500 (2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1.2.All values per [6].Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.320 Revision:

0 Page 14 of 20 F0306-01 R2 IIVIat~fgrfy Associates ftm?Table 8: Elastic Properties for Alloy 82/182 Temperature Elastic Mean Thermal Thermal Specific Modulus Expansion Conductivity (2) Heat (2)(OF) (x10 3 ksi) (xl0-6 in/in/0 F) (Btu/min-in-0 F) (Btu/lb-0 F)70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -0.0 --Notes: 1. All values per [6].2. Density (p) = 0.300 lb/in 3 [6], assumed temperature independent.

3. Poisson's Ratio (v) = 0.29 [6], assumed temperature independent.

File No.: 1400669.320 Revision:

0 Page 15 of 20 F0306-01R2 Ij3Sfruclru Iftegi Associats, kne Table 9: Stress-Strain Curves for Alloy 82/182 Temperature Strain Stress (0 F) (in/in) (ksi)0.00179032 55.500 0.03456710 60.113 70 0.04292837 64.725 0.05257245 69.338 0.06359421 73.950 0.00164483 47.700 0.02976152 52.313 500 0.03809895 56.925 0.04790379 61.538 0.05929946 66.150 0.00159574 45.000 0.02849157 49.538 700 0.03680454 54.075 0.04663682 58.613 0.05812078 63.150 0.00159073 41.200 0.03568855 44.488 1100 0.04402702 47.775 0.05360088 51.063 0.06449835 54.350 0.00106494 24.600 0.11812735 25.325 1500 0.12540227 26.050 0.13290814 26.775 0.14064577 27.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1.2.All values per [6].Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.320 Revision:

0 Page 16 of 20 F0306-0 I R2 IV SlnburaW lMeMrly Associates, In.Table 10: Creep Properties Temperature Creep Strength (ksi) A Material (ep)tr1 G2 A n (OF) (0.0001%/hr)

(0.00001%/hr) (ksilhr)SA-516 Gr. 800 19.0 12.4 1.26E-13 5.40 70 900 9.0 6.7 3.59E-14 7.80 (Based on 1000 3.5 2.8 2.43E-12 10.32 carbonsteel 1100 1.4 0.8 2.50E-07 4.11 per [7])ER308L 800 33.4 25.0 7.73E- 19 7.95 900 24.0 17.6 5.67E- 17 7.42 (Based on Type 304 1000 17.6 11.5 1.82E-13 5.41 per [7]) 1100 11.5 7.1 8.62E-12 4.77 Alloy 600 800 40.0 30.0 1.50E-19 8.00 Alloy 82/182 900 28.0 18.0 2.87E- 14 5.21 (Based on 1000 12.5 6.1 3.02E- 10 3.21 Alloy600 1100 6.8 3.4 1.72E-09 3.32 per [8])File No.: 1400669.320 Revision:

0 Page 17 of 20 F0306-01R2 Vanoeffdkwui M 7 Assodde s, ftN 36" From Center Line 4-2 5/8" I.D.-4 9/16" O.D.6 5/8".6 3/16" O.D.I I I 8\Z 35 11/16"O.D.

29 11/16" I.D. 1/4" Figure 1. Finite Element Model Dimensions Note: Dimensions obtained from [2, 3, and 4].File No.: 1400669.320 Revision:

0 Page 18 of 20 F0306-01R2 Can" MiW*kbudaft Figure 2. Components Included in the Finite Element Model File No.: 1400669.320 Revision:

0 Page 19 of 20 F0306-01R2 Can" MftW hgrY Awsaft ke~Figure 3. Isometric View of the Finite Element Model (Nozzle detail shown in bottom left comer)File No.: 1400669.320 Revision:

0 Page 20 of 20 F0306-01R2 jStmcursw Itegrity Asosaes, Inc;APPENDIX A COMPUTER FILES LISTING File No.: 1400669.320 Revision:

0 Page A- I of A-2 F0306-01R2 jSbvcurlu lMAegrly Associates, Inc" File Name Description PalisadesCL.INP Input file to create base model geometry MPropMiso.INP Elastic plastic material properties inputs MatProp.xls Excel spreadsheet containing calculations of elastic-plastic material properties for residual stress analysis File No.: 1400669.320 Revision:

0 Page A-2 of A-2 F0306-01R2 7!"CStructural Integrity Associates, Inc. File No.: 1400669.312 Project No.: 1400669 CALCULATION PACKAGE Quality Program Type: E Nuclear [L Commercial PROJECT NAME: Palisades Flaw Readiness Program for 1 R24 NDE Inspection CONTRACT NO.: 10426669 CLIENT: PLANT: Entergy Nuclear Operations, Inc. Palisades Nuclear Plant CALCULATION TITLE: Hot Leg Drain Nozzle Weld Residual Stress Analysis Document Affected Project Manager Preparer(s)

&Revision Pages Revision Description Approval Checker(s)

Signature

& Date Signatures

& Date 0 1 -38 Initial Issue Preparer: A-i -A-2 Computer Files Norman Eng NE 5/5/2015 Minji Fong MF 5/5/2015 Checkers: Charles Fourcade CJF 5/5/2015 Gole Mukhim GSM 5/5/2015 Page 1 of 38 F0306-01 R2 latrN e Wgry Associes, Wc?Table of Contents 1.0 OBJECTIVE

.........................................................................................................

5 2.0 TECHN ICAL APPROACH .....................................................................................

5 2.1 M aterial Properties

........................................................................................

5 2.2 Finite Element Model for Weld Residual Stress Analysis ...........................

6 2.3 W elding Sim ulation ......................................................................................

6 2.4 Heat Inputs ....................................................................................................

6 2.5 Creep Properties

.............................................................................................

7 2.6 M echanical Boundary Conditions

.................................................................

7 3.0 A SSUM PTION S ......................................................................................................

7 4.0 W ELD RESIDUAL STRESS AN ALYSIS ...............................................................

8 4.1 Hot Leg Cladding ..........................................................................................

8 4.2 Boss W eld ......................................................................................................

9 4.3 ID Patch W eld ...............................................................................................

9 4.4 Post-weld Heat Treatm ent ............................................................................

9 4.5 Hydrostatic Test ...........................................................................................

10 4.6 Five Norm al Operating Cycles (N OC) ........................................................

10 5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS ....................................

11 5.1 W elding Tem perature Contours .................................................................

11 5.2 PW HT Tem perature Results .........................................................................

11 5.3 Residual Stress Results ...............................................................................

11 6.0 CON CLUSION S .....................................................................................................

12

7.0 REFERENCES

........................................................................................................

12 APPEN DIX A COM PUTER FILES LISTIN G ...............................................................

A-I File No.: 1400669.312 Page 2 of 38 Revision:

0 F0306-01R2 V Ijj~stnwira late ry ASSOGiats, Inc List of Tables Table 1: Table 2: Table 3: Table 4: Table 5: Table 6: Table 7: Table 8: Table 9: Elastic Properties for SA-516 Grade 70 (< 4" Thick) ..........................................

13 Elastic Properties for ER308L .............................................................................

14 Elastic Properties for Alloy 600 ..........................................................................

15 Elastic Properties for Alloy 182 ..........................................................................

16 Stress-Strain Curves for SA-516 Grade 70 (< 4" Thick) .....................................

17 Stress-Strain Curves for ER308L ........................................................................

18 Stress-Strain Curves for Alloy 600 ......................................................................

19 Stress-Strain Curves for Alloy 182 ......................................................................

20 Creep Properties

.................................................................................................

21 File No.: 1400669.312 Revision:

0 Page 3 of 38 F0306-OIR2 0 SMIMi MMt*l Associates, Inc." List of Figures Figure 1. Finite Element Model for Residual Stress Analysis ...........................................

22 Figure 2. Applied Mechanical Boundary Conditions

........................................................

23 Figure 3. Weld Nugget Definitions for the Boss Weld ....................................................

24 Figure 4. Weld Nugget Definitions for the ID Patch Weld ...............................................

25 Figure 5. Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure Loads.. 26 Figure 6. Predicted Fusion Boundary Plot for Cladding ...................................................

27 Figure 7. Predicted Fusion Boundary Plot for Boss Weld ..................................................

28 Figure 8. Predicted Fusion Boundary Plot for ID Patch Weld ..........................................

29 Figure 9. Time vs. Temperature Curve for PWHT ...........................................................

30 Figure 10. Predicted von Mises Residual Stress at 70'F after ID Patch Weld ..................

31 Figure 11. Predicted von Mises Residual Stress at 70'F after PWHT ...............................

32 Figure 12. Paths for Stress Extraction

...............................................................................

33 Figure 13. Residual Stress Comparison at 70'F Before and After PWHT ........................

34 Figure 14. Measured Through-Wall Residual Stresses for PWHT ...................................

35 Figure 15. Predicted von Mises Residual Stress at 70'F after Hydrostatic Test ...............

36 Figure 16. Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle) ....... 37 Figure 17. Predicted Hoop Residual Stress + Operating Conditions (5th NOC Cycle) .........

38 File No.: 1400669.312 Page 4 of 38 Revision:

0 F0306-01R2 CjjSnwbuI atund ftfi ASSOciats, IMcP 1.0 OBJECTIVE The objective of this calculation package is to document the weld residual stress analysis for the hot leg drain nozzle at the Palisades Nuclear Plant (Palisades).

The weld residual stress analysis is based on the latest methodology and process developed by Structural Integrity Associates (SI).2.0 TECHNICAL APPROACH The finite element model is obtained from a previous finite element model (FEM) calculation package[1] and the weld residual stress analysis uses the latest weld residual stress analysis methodology developed by SI, using the ANSYS finite element analysis (FEA) program [3].The residual stress analysis consists of a thermal pass followed by a stress pass, where the temperature distribution time history from the thermal pass is used as temperature input into the stress pass to determine stresses.

Stress results from the weld residual stress analysis are obtained and saved for future use to evaluate flaws which will be performed in a separate calculation package.The finite element model includes all components in the post-nozzle installation stage because new elements cannot be added during an ANSYS analysis run. Since all the weld elements need to be included in the initial model, the element "birth and death" technique in ANSYS is used to initially deactivate the weld elements, with elements corresponding to the active weld segment reactivated at the melting temperature, thus simulating the weld metal deposition.

2.1 Material Properties The weld residual stress analysis performed in this calculation uses the material properties specifically developed in a separate calculation package for weld residual stress analyses [2]. Per the material designation used in the FEM calculation

[1], the following materials are used:* SA-516 Grade 70: " ER308L: " Alloy 182: Hot leg base metal Hot leg cladding (typical weld metal for Type 304)Boss weld and ID patch weld* Alloy 600 (SB-166):

Drain nozzle The material properties are reproduced in Table 1 through Table 8.File No.: 1400669.312 Revision:

0 Page 5 of 38 F0306-01 R2 jsm oral lt hgrlty Associates, Inc.2.2 Finite Element Model for Weld Residual Stress Analysis The finite element model for the analysis was developed in a previous FEM calculation

[1], which was created using the ANSYS finite element analysis software package [3]. The base finite element model for the weld residual stress analysis is meshed with 8-node solid elements (SOLID 185) in ANSYS. This finite element model is shown in Figure 1.2.3 Welding Simulation The FEA for predicting the weld residual stresses is performed as a continuous analysis so that the load history from the cladding is carried over the nozzle-to-pipe weld and ID patch weld. Specifically, the residual stresses and strains at the end of one weld pass are used as initial conditions at the start of the next weld pass.The procedures for this complex multi-step simulation are encoded in ANSYS Parametric Design Language (APDL) macros which utilize elastic-plastic material behavior and elements with large deformation capability to predict the residual stresses due to the various welding processes.

2.4 Heat Inputs The deposition of the weld metal is simulated by imposing a heat generation function on the elements of the FEM representing the active weld, which is applied as a volumetric body heat generation rate. The amount of equivalent heat input energy, Q (in terms of kJ/inch), is determined from the welding parameters.

Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/inch, with an overall heat efficiency of 0.8, is assumed for all the welds. The heat efficiency represents a "composite" value reflecting the concepts of arc efficiency, melting efficiency, etc., and is an optimum value to produce reasonable heat penetration in the analysis.The APDL macros automatically calculate the appropriate time intervals for the thermal pass to ensure that sufficient heat penetration is achieved, the required interpass temperature between weld passes is met, and a reasonable overall temperature distribution within the finite element model is achieved.

The resulting temperature time history is then imported into the stress pass in order to calculate the residual stresses due to the thermal cycling of the weld elements using nonlinear, elastic-plastic load/unload stress reversal relations.

The following summarizes the welding parameters used in the analysis:* Interpass temperature

= 350°F [4]0 Melting temperature

-2500'F (See Section 3.0)* Reference temperature

= 70'F (See Section 3.0)File No.: 1400669.312 Page 6 of 38 Revision:

0 F0306-01R2 stntwbraI l Associates, Inc." Heat input for all welds = 28 kJ/in (See Section 3.0)* Heat efficiency for all welds -0.8 (See Section 3.0)* Inside/Outside heat transfer coefficient 5 Btu/hr-ft 2-"F (See Section 3.0)" Inside/Outside temperature

= 70'F (See Section 3.0)2.5 Creep Properties Strain relaxation due to creep at high temperature is considered in the post-weld heat treatment (PWHT)step of the analysis.

In general, creep becomes significant at temperature above 800'F; thus, creep behavior under 800'F will not be considered in this analysis.

The creep properties listed in Table 9 are determined in the previous FEM calculation

[1].2.6 Mechanical Boundary Conditions The mechanical boundary conditions for the stress analysis are symmetric boundary conditions at the symmetry planes of the model, axial displacement restraint at the end of the nozzle, and axial displacement coupling at the end of the hot leg piping, as shown in Figure 2.3.0 ASSUMPTIONS The following assumptions are used in the analyses:* The hot leg cladding material is assumed to be ER308L, which is a typical weld metal for Type 304 stainless steel cladding.* The metal melting temperature is assumed to be 2500'F, which is the temperature point where the strength of the material is set to near zero [1]." The analysis is performed with a reference temperature of 70 0 F." The exposed surface of the model is subject to a typical ambient air cooling convection film coefficient of 5 Btu/hr-ft 2-OF at a bulk temperature of 70'F. The exposed surfaces are defined as the exterior surfaces of the model, excluding the symmetry planes and the far ends of the modeled piping and nozzle.* Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/in, with an overall heat efficiency of 0.8, is assumed for all of the welds." The focus of this analysis is the residual stresses in the drain nozzle boss weld region, while the interaction between the clad buildup and the hot leg base metal has secondary effects on the region of interest.

Therefore, the clad is assumed to be fully deposited in a single one-layer pass.File No.: 1400669.312 Page 7 of 38 Revision:

0 F0306-01 R2 V ojaturwcb f/sgr/y Associates, Inc?" The boss weld is represented by a 40-bead process, as shown in Figure 3, with each bead represented by a one pass "bead ring" nugget. This approach is a common and acceptable industry practice when information regarding the bead start/stop position and sequencing are unknown.* Similarly, the ID patch weld is represented by a 6-bead process, as shown in Figure 4, with each bead represented by a one pass "bead ring" nugget.* For model simplification, the penetration hole is present during the deposition of the clad material.

This is acceptable since any localized stress with or without the hole would have negligible impact on the final results." For convenience, the modeled ID patch weld has the same geometry as the backing ring for the boss weld.* Additional assumptions on PWHT are discussed in Section 4.4.4.0 WELD RESIDUAL STRESS ANALYSIS The weld residual stress analysis consists of a thermal analysis to determine the temperature distribution followed by a stress analysis to determine the resulting stresses.

The analytical sequence described below is used in the finite element analysis, followed by detailed discussions of the steps in Sections 4.1 through 4.6: 1. Deposit cladding on hot leg pipe inside (ID) surface.2. Install drain nozzle, backing ring, and deposit boss weld.3. Remove backing ring and deposit ID patch weld.4. Post-weld heat treatment, including creep effects based upon experimental data per Table 9.5. Subject the configuration to hydrostatic test.6. Impose five cycles of "shake down" with normal operating temperature and pressure to stabilize the residual stress fluctuations due to stress redistribution caused by normal operating loads.4.1 Hot Leg Cladding The clad material is typically welded onto the inside surface of the hot leg pipe, and the nominal thickness of the clad is thicker than the typical thickness for a single weld layer used in the process.However, the focus of this analysis is on the as-welded residual stresses, while the interaction between the clad buildup and the base material during the many actual weld passes is not of interest.

Therefore, the clad is assumed to be fully deposited in a single pass.File No.: 1400669.312 Page 8 of 38 Revision:

0 F0306-01 R2 jjrIUMn raegIrily AssociMs, Inc" At this step, only the hot leg pipe base metal elements and clad material elements are active; all other components are deactivated during the analysis.

At the end of the cladding application, the entire model is cooled to 70'F before application of the boss weld.4.2 Boss Weld The boss weld connects the drain nozzle boss to the hot leg piping. As shown in Figure 3, the weld is composed of 40 nuggets deposited in 20 weld layers. In the absence of detailed weld fabrication information, a weld sequence is assumed based on standard welding practice at the time of fabrication.

In particular, for every layer, the first nugget is deposited on the hot leg side, the second nugget on the nozzle side.At this step, the drain nozzle elements and backing ring elements are reactivated, and the boss weld nuggets are reactivated sequentially to simulate the welding process. The preheat temperature of the boss weld is 250'F [4]. At the end of the boss weld, the entire model is cooled to 70'F before the application of the ID patch weld.4.3 ID Patch Weld The final weld step is to add the ID patch weld, which replaces the backing ring. As seen in Figure 4, the ID patch weld is composed of 6 nuggets deposited in 2 layers.At this step, the backing ring is first deactivated to allow the residual stresses to redistribute, and the ID patch weld nuggets are reactivated sequentially to simulate the welding process. The preheat temperature of the ID patch weld is 250'F [4]. At the end of the ID patch weld, the entire model is cooled to 70'F before the post-weld heat treatment (PWHT).4.4 Post-weld Heat Treatment PWHT is assumed to be performed as per the following procedure outlined in Article N-532 of the ASME Code,Section III [7] and the welding procedure

[4] for welding on material group P-l: 1. Heat welded piping component to 11 50'F [4] at a heating rate of 400'F per hour divided by the maximum metal thickness (100°F per hour for 4 inch thick hot leg) [7, Article N-532.3 (2)].2. Hold at temperature for approximately 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> (lhr/in of weld thickness)

[7, Table N-532].3. Allow to cool to 600'F at a cooling rate of 500'F per hour divided by the maximum metal thickness (125 0 F per hour for 4 inch thick hot leg) at temperature above 600'F [7, Article N-532.3 (5)].4. Air-cool from 600'F to ambient [7, Article N-532.3 (5)].5. A steady state load step is imposed at the end of the PWHT process.File No.: 1400669.312 Page 9 of 38 Revision:

0 F0306-OIR2 slnfuru, lMaegrlty Associates, Inc1" During the PWHT, creep behavior is activated for time steps with the maximum temperature above 800 0 F. At the end of the PWHT, the entire model is cooled to 70°F before the application of the hydrostatic test.4.5 Hydrostatic Test A hydrostatic test pressure of 3110 psig (3125 psia) and a temperature of 400'F [8, page 9] are applied after the welding. The pressure is applied on the ID surfaces of the hot leg pipe and drain nozzle. End-cap loads, Pend-cap-hi is applied at the free end of the hot leg piping. This is calculated based on the following expression:

Pend-cap-hl r 2 routside-hi

-- rinside-hl where, P = Hydrostatic test pressure (ksi)Pend-cap-hl

= End cap pressure on hot leg pipe end (ksi)rinside-hl

= Inside radius of hot leg pipe (in)routside-hl

= Outside radius of hot leg pipe (in)The applied pressure loads on the model are shown in Figure 5.4.6 Five Normal Operating Cycles (NOC)After the hydrostatic test, the assembled configuration is put into service and subjected to five cycles of shake down to stabilize the as-welded residual stresses.

This step involves ramping the model from zero-load to steady-state conditions at normal operating temperature and pressure then back to steady-state at 70'F and no pressure five times.The applied operating pressure is 2085 psig (2100 psia) and temperature is 583'F [9]. The temperature is assumed to be uniform throughout the components and operating pressure is applied as an internal pressure on the ID surface, with corresponding end cap pressures calculated using the equation in the previous section. The term "P" is replaced by the operating pressure in the expression.

File No.: 1400669.312 Page 10 of 38 Revision:

0 F0306-01 R2 IC SMfirIU laMgrily Associaes, ft!5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS The ANSYS input files and computer output files for the analyses are listed in Appendix A.5.1 Welding Temperature Contours The maximum temperature prediction contours for each weld are created using the macro MapTemp.mac.

This type of contour plot is also called a "fusion boundary" plot because it provides an overview of the maximum temperature on each node throughout the thermal transient for each welding process. The plots are useful in visualizing the melting of weld metal and the extent of heat penetration.

The predicted fusion boundary contours for the cladding, the nozzle-to-pipe weld, and ID patch weld applications are shown in Figure 6, Figure 7, and Figure 8, respectively.

The purple color in the plots represents elements at melting temperature

(>2500'F);

the plots show complete melting of the weld metal for each weld and slight melting of the base metal along the weld interface.

5.2 PWHT Temperature Results Figure 9 plots the inside surface temperature curve for the PWHT process. It shows the linear 100°F/hr heating rate, 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> (240 minutes) hold time at 11 50'F, 125°F/hr cooling rate at temperature above 600'F, and the air cooling to room temperature of 70'F.5.3 Residual Stress Results Figure 10 plots the von Mises residual stresses after welding is complete, but before PWHT. It shows extensive residual stresses of greater than 66.3 ksi in the weld material.

However, as shown in Figure 11, after the PWHT the residual stresses in the weld have relaxed significantly, to below 49.2 ksi, but the residual stresses in the cladding remain essentially unchanged.

To further investigate the effects of the PWHT, before and after PWHT residual stresses are extracted along the two through-wall paths shown in Figure 12. The through-wall residual stresses are compared in Figure 13, and it shows that there is little to no stress reduction in the clad material, while there is significant stress reduction in the pipe base metal.The PWI-HT results from the FEA trend comparably well with the data in EPRI report TR-105697

[10], which contains a comparable through-wall clad residual stress distribution based on experimental measurements, as shown in Figure 14. The experimental measurements were for a low alloy steel vessel with a Type 304 stainless steel clad. The data shows tensile stress through the clad thickness and the base metal near the clad interface, but the stress drops rapidly to compressive values at farther distances from the clad.File No.: 1400669.312 Page II of 38 Revision:

0 F0306-01R2 IV StnmWnl lftgrfty Associa&es, Inc?Figure 15 depicts the predicted von Mises residual stresses after the hydrostatic test. It shows an insignificant reduction in maximum stress when compared to the post-PWHT step: 73.749 ksi (Figure 15) versus 73.750 ksi (Figure 11), while the overall stress contour remains essentially the same.Figure 16 and Figure 17 depict the combined weld residual plus operating radial and hoop stresses at the fifth stabilization NOC cycle, respectively.

The stress results at this step are used in the fracture mechanics evaluations.

6.0 CONCLUSION

S Finite element residual stress analysis has been performed on the hot leg drain nozzle boss weld at Palisades.

Stresses at normal operating conditions combined with residual stresses have been obtained and saved for future use. The stress results will be used in a separate calculation to determine crack growth.

7.0 REFERENCES

1. SI Calculation No. 1400669.3 10, Rev. 0, "Finite Element Model for Hot Leg Drain Nozzle." 2. SI Calculation No. 0800777.307, Rev.5, "Material Properties for Residual Stress Analyses, Including MISO Properties Up To Material Flow Stress." 3. ANSYS Mechanical APDL and PrepPost, Release 14.5 (w/ Service Pack 1), ANSYS, Inc., September 2012.4. Combustion Engineering Welding Procedure No. MA-41, Rev.0, SI File No. 1400669.204.

5. "Steels for Elevated Temperature Service," United States Steel Co., 1949.6. Publication SMC-027, "Inconel Alloy 600," Special Metals Corp., 2004, SI File No.0800777.211.

7. ASME Boiler and Pressure Vessel Code,Section III, 1965 Edition with Addenda through Winter 1966.8. Combustion Engineering Specification No. 0070P-006, Rev.2, "Engineering Specification for Primary Coolant Pipe and Fittings," SI File No. 1300086.203.

9. Palisades Design Input Record, "Palisades Alloy 600 Flaw Eval DIR 3-4-15 Rev 1.pdf," SI File No. 1400669.201.

10. EPRI Report No. TR-105697, "BWR Reactor Pressure Vessel Shell Weld Inspection Recommendations (BWRVIP-05)," September 1995.File No.: 1400669.312 Page 12 of 38 Revision:

0 F0306-01R2 Vj asbuoftInlte grffy Associates, Inc.Table 1: Elastic Properties for SA-516 Grade 70 (5 4" Thick)Temperature Young's Mean Thermal Thermal Specific Heat (2)Modulus Expansion Conductivity (2) (Specif )(0 F) (x10 3 ksi) (xl0-6 in/in/0 F) (Btu/min-in-*F) (Btu/lb-0 F)70 29.5 6.4 0.0488 0.103 500 27.3 7.3 0.0410 0.128 700 25.5 7.6 0.0369 0.138 1100 18.0 8.2 0.0290 0.171 1500 5.0 8.6 0.0218 0.198 2500 0.1 9.5 0.0014 0.204 2500.1 0.0 -Notes: 1. All values per [2].2. Density (p) = 0.283 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.

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0 Page 13 of 38 F0306-01R2 Cj mduckra Iabgftgl ASSOCiats, IncP Table 2: Elastic Properties for ER308L Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity c Specific Heat (2)(OF) (x10 3 ksi) (xl0-6 in/in/IF) (Btu/min-in-0 F) (Btu/lb-0 F)70 28.3 8.5 0.0119 0.116 500 25.8 9.7 0.0151 0.131 700 24.8 10.0 0.0164 0.135 1100 22.1 10.5 0.0189 0.140 1500 18.1 10.8 0.0213 0.145 2500 0.1 11.5 0.0292 0.159 2500.1 -0.0 --Notes: 1. All values per [2].2. Density (p) = 0.283 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.

File No.: 1400669.312 Revision:

0 Page 14 of 38 F0306-01 R2 fStnoiurui lMgrfty Associates, Inc Table 3: Elastic Properties for Alloy 600 Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity 2 Specific Heat (2)(OF) (x10 3 ksi) (X10-6 in/in/IF) (Btu/min-in-*F) (Btu/Ib-°F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -0.0 --Notes: 1. All values per [2].2. Density (p) = 0.300 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.

File No.: 1400669.312 Revision:

0 Page 15 of 38 F0306-01 R2 V Sn MuOMra/at rit1ssociates, Wne Table 4: Elastic Properties for Alloy 182 Temperature Young's Mean Thermal Thermal Tm ru Modulus Expansion Conductivity (2) Specific Heat (2)(0 F) (x10 3 ksi) (xl0- in/in/IF) (Btu/min-in-°F) (Btu/lb-F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -0.0 --Notes: 1. All values per [2].2. Density (p) = 0.300 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.

File No.: 1400669.312 Revision:

0 Page 16 of 38 F0306-01R2 C druI/ lM/Ierfy Associates, Inc Table 5: Stress-Strain Curves for SA-516 Grade 70 (5 4" Thick)Temperature Strain Stress ('F) (in/in) (ksi)0.00128814 38.000 0.00187809 42.000 70 0.00257329 46.000 0.00381110 50.000 0.00600383 54.000 0.00113553 31.000 0.00142679 35.875 500 0.00183954 40.750 0.00261139 45.625 0.00415246 50.500 0.00106667 27.200 0.00132412 32.550 700 0.00166876 37.900 0.00228121 43.250 0.00354341 48.600 0.00116667 21.000 0.05116163 22.125 1100 0.05915444 23.250 0.06794123 24.375 0.07755935 25.500 0.00300000 15.000 0.16717493 15.125 1500 0.16992011 15.250 0.17268761 15.375 0.17547742 15.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

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0 Page 17 of 38 F0306-01 R2 jSaturrI rlatlly Associates, Inc" Table 6: Stress-Strain Curves for ER308L Temperature Strain Stress ('F) (in/in) (ksi)0.00203180 57.500 0.02471351 61.563 70 0.03107296 65.625 0.03861377 69.688 0.04747167 73.750 0.00140089 36.143 0.00714793 40.250 500 0.01065407 44.357 0.01558289 48.464 0.02233857 52.571 0.00132488 32.857 0.00477547 37.125 700 0.00743595 41.393 0.01143777 45.661 0.01727192 49.929 0.00121913 26.943 0.00264833 30.138 1100 0.00404100 33.332 0.00634529 36.527 0.01005286 39.721 0.00117995 21.357 0.05352064 21.563 1500 0.05610492 21.768 0.05878975 21.973 0.06157807 22.179 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.312 Revision:

0 Page 18 of 38 F0306-01 R2 IC ~StncuWO Maefy* Associaes, M'c~Table 7: Stress-Strain Curves for Alloy 600 Temperature Strain Stress ('F) (in/in) (ksi)0.00157419 48.800 0.01658847 55.300 70 0.02343324 61.800 0.03212188 68.300 0.04291703 74.800 0.00152069 44.100 0.01539220 50.338 500 0.02210610 56.575 0.03072476 62.813 0.04153277 69.050 0.00152128 42.900 0.01634485 49.000 700 0.02334760 55.100 0.03227153 61.200 0.04338643 67.300 0.00155985 40.400 0.02275193 44.475 1100 0.03004563 48.550 0.03888203 52.625 0.04943592 56.700 0.00092641 21.400 0.08827666 22.475 1500 0.09785101 23.550 0.10796967 24.625 0.11863796 25.700 0.01000000 1.000 0.10961239 1.125 2500121 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.312 Revision:

0 Page 19 of 38 F0306-01 R2

~jsIC JckNOW Iaigd Associats, Man Table 8: Stress-Strain Curves for Alloy 182 Temperature Strain Stress (0 F) (in/in) (ksi)0.00179032 55.500 0.03456710 60.113 70 0.04292837 64.725 0.05257245 69.338 0.06359421 73.950 0.00164483 47.700 0.02976152 52.313 500 0.03809895 56.925 0.04790379 61.538 0.05929946 66.150 0.00159574 45.000 0.02849157 49.538 700 0.03680454 54.075 0.04663682 58.613 0.05812078 63.150 0.00159073 41.200 0.03568855 44.488 1100 0.04402702 47.775 0.05360088 51.063 0.06449835 54.350 0.00106494 24.600 0.11812735 25.325 1500 0.12540227 26.050 0.13290814 26.775 0.14064577 27.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.312 Revision:

0 Page 20 of 38 F0306-01 R2 IC~SWCAmictI IWW*~t Associats, Monc Table 9: Creep Properties Material Temperature Creep Strength (ksi) A (OF) oyi (0.0001%/hr) 02 (0.00001%/hr) (ksi/hr)800 19.0 12.4 1.26E-13 5.40 SA-516 Gr. 70 900 9.0 6.7 3.59E-14 7.80 (Based on carbon steel) 1000 3.5 2.8 2.43E-12 10.32 Per [5] 1100 1.4 0.8 2.50E-07 4.11 800 33.4 25.0 7.73E-19 7.95 ER308L 900 24.0 17.6 5.67E-17 7.42 (Based on Type 304) 1000 17.6 11.5 1.82E-13 5.41 Per[5] 1100 11.5 7.1 8.62E-12 4.77 Alloy 600 800 40.0 30.0 1.50E-19 8.00 Alloy 182 900 28.0 18.0 2.87E- 14 5.21 (Based on 1000 12.5 6.1 3.02E- 10 3.21 Alloy 600)Per [6] 1100 6.8 3.4 1.72E-09 3.32 File No.: 1400669.312 Revision:

0 Page 21 of 38 F0306-01R2 Van" M*Ify Amcbft kne Figure 1. Finite Element Model for Residual Stress Analysis File No.: 1400669.312 Revision:

0 Page 22 of 38 F0306-O1R2 Van" Mpffy ASXXWK W U Symmetry boundary conditions Axial displacement couples Axial displacement restraint//Figure 2. Applied Mechanical Boundary Conditions File No.: 1400669.312 Revision:

0 Page 23 of 38 F0306-OIR2 I

CSbaw"u laiur* Assadafte kne Figure 3. Weld Nugget Definitions for the Boss Weld File No.: 1400669.312 Revision:

0 Page 24 of 38 F0306-01R2 Cam" MWNY Awack0s, kn@Figure 4. Weld Nugget Definitions for the ID Patch Weld File No.: 1400669.312 Revision:

0 Page 25 of 38 F0306-01R2 Vobwa" IM Ambf W Hot leg end cap pressure Internal pressure-7.38152 -5.05007 -2.71862 -.387175 1.94428-6.2158 -3.88435 -1.5529 .77855 3.11 ksi Hydrostatic test Figure 5. Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure Loads File No.: 1400669.312 Revision:

0 Page 26 of 38 F0306-01R2

~jSVanw hfduuf AwWSscas, W?'rrm SMurrCIV 340 880 1423 1960 70 61 0 I11 S 1 EQfl 2230 340 880 1420 1960 Predicted fusion boundary plot (Purple Tenperature

> Melting)Figure 6. Predicted Fusion Boundary Plot for Cladding (Note: Purple = Temperature

> Melting temperature of 2500'F)2bO0 OF File No.: 1400669.312 Revision:

0 Page 27 of 38 F0306-01R2 Van" bft* Awadaft kne Figure 7. Predicted Fusion Boundary Plot for Boss Weld (Note: Purple = Temperature

> Melting temperature of 2500'F)File No.: 1400669.312 Revision:

0 Page 28 of 38 F0306-01R2 VIatsn"MO Assadates, kn Figure 8. Predicted Fusion Boundary Plot for ID Patch Weld (Note: Purple = Temperature

> Melting temperature of 2500'F)File No.: 1400669.312 Revision:

0 Page 29 of 38 F0306-01 R2

~jsV atur. kiWgr AssacWN~, fte Teirperature (F)1000 1400 1800 2200 2600 1200 1600 2000 2400 Timre (min)3000 2800 Figure 9. Time vs. Temperature Curve for PWHT Note: 1. PWHT temperature history is for a typical ID node on the model.File No.: 1400669.312 Revision:

0 Page 30 of 38 F0306-01R2 Can" N* Aswcft km Figure 10. Predicted von Mises Residual Stress at 70°F after ID Patch Weld File No.: 1400669.312 Revision:

0 Page 31 of 38 F0306-01 R2 108bvft MOMt~ Assadbft Inc6 Figure 11. Predicted von Mises Residual Stress at 70°F after PWHT File No.: 1400669.312 Revision:

0 Page 32 of 38 F0306-01R2 Van" MobW kuu AWdSoits kn Figure 12. Paths for Stress Extraction Notes: 1. In the hot leg coordinates, hoop residual stresses along path P1 and axial residual stresses along path P2 are extracted for comparison of before and after PWHT.2. The before and after PWHT through-wall residual stresses are compared in Figure 13.File No.: 1400669.312 Revision:

0 Page 33 of 38 F0306-01R2

~j~SbvetrWhWrNY 4A FA 80 70 60 50 40 30 20 10 0-10-20-30-40-50f El+ As-Welded (P1)El PWHT (P1)As-Welded (P2)A PWHT (P2)+/-"a: Clad interface--- -- -* I+1 +/-+I I I I+ +I I I I I 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 Normalized Thickness (x/t)Figure 13. Residual Stress Comparison at 70°F Before and After PWHT File No.: 1400669.312 Revision:

0 Page 34 of 38 F0306-01R2 Van" MOM Asxd0s, knG 120 I --A& As-Welded 0 PWHT 100+-Clad Interface 80+4-A 2 C,, 0 C I C., A 60 4 4 A 0 -0 A 40 6 0 0 ()20 +Data from EPRI TR-101989 0 I*A 0 no 0 Thice Cld TUSt Intodece at Depth Shown 0-20+A A NM3I1-40*1 *0 0.: 0.4 0.6 Distance from Clad Surface (inches)0.8 1.0 Figure 14. Measured Through-Wall Residual Stresses for PWHT Notes: 1. Figure is obtained from EPRI report TR-105697

[10].2. Measurements show little to no stress reduction in the cladding after PWHT.3. Measurements show significant stress reduction in the base metal after PWHT.File No.: 1400669.312 Revision:

0 Page 35 of 38 F0306-01R2 VIRWAMWMW*

Aw Int km Figure 15. Predicted von Mises Residual Stress at 70°F after Hydrostatic Test File No.: 1400669.312 Revision:

0 Page 36 of 38 F0306-OIR2 Van" MWAY AmdWVS, MQG Figure 16. Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle)Note: Radial stresses shown in the nozzle axis radial direction.

File No.: 1400669.312 Revision:

0 Page 37 of 38 F0306-01 R2 Vaud"** Adaftkic Figure 17. Predicted Hoop Residual Stress + Operating Conditions (5th NOC Cycle)Note: Hoop stresses shown in the nozzle axis circumferential direction.

File No.: 1400669.312 Revision:

0 Page 38 of 38 F0306-01R2 Vs tnc lfatde y Associs, Icnd APPENDIX A COMPUTER FILES LISTING File No.: 1400669.312 Revision:

0 Page A- I of A-2 F0306-01R2 V mmSflrucbru late d Assaciaes, IncO File Name Description PalisadesHLDrain.INP Input file to create base geometry model [1]MPropMISO.INP Elastic-plastic Material properties inputs [1]Autonugsel.mac Macro that groups elements into nuggets BCNUGGET3D.INP Weld pass and model boundary definition file THERMAL3D.INP Input file to perform the thermal pass of welding simulation THMPWHT.lNP Input file to perform the thermal pass of PWHT STRESS3D.INP Input file to perform the stress pass of welding simulation CBC.INP Input file to apply mechanical boundary conditions THM PWHTnmntr.inp Processed thermal pass load steps for PWHT INSERT3D.INP Input file to perform the stress pass of hydrostatic test WELD#_mntr.inp Processed thermal pass load steps for stress pass # = 1-3*.mac WRS analysis macro files required for analysis THERMAL3D.TXT Parameter input file for thermal pass of welding simulation STRESS3D.TXT Parameter input file for stress pass GenStress.mac Macro to extract PWHT stress results GETPATH.TXT Through-wall stress path definition to extract PWHT stress results File No.: 1400669.312 Revision:

0 Page A-2 of A-2 F0306-01R2

~Structural Integrity Associates, Inc. File No.: 1400669.322 Project No.: 1400669 CALCULATION PACKAGE Quality Program: E Nuclear El Commercial PROJECT NAME: Palisades Flaw Readiness Program for 1 R24 NDE Inspection CONTRACT NO.: 10426669 CLIENT: PLANT: Entergy Nuclear Operations, Inc. Palisades Nuclear Plant CALCULATION TITLE: Cold Leg Bounding Nozzle Weld Residual Stress Analysis Document Affected Project Manager Preparer(s)

&Revision Pages Revision Description Approval Checker(s)

Signature

& Date Signatures

& Date 0 1 -38 Initial Issue Preparer: Computer Files ---YA" Norman Eng Wilson Wong NE 5/5/2015 VWW 5/5/2015 Checkers: Minji Fong MF 5/5/2015 Gole Mukhim GSM 5/5/2015 Page 1 of 38 F0306-OIRI VSt nd/ l rt y AssoDates, Inc.Table of Contents 1.0 OBJECTIVE

.........................................................................................................

5 2.0 TECHN ICAL APPROACH .....................................................................................

5 2.1 M aterial Properties

........................................................................................

5 2.2 Finite Element Model for Weld Residual Stress Analysis ...........................

5 2.3 W elding Sim ulation ......................................................................................

6 2.4 Heat Inputs ....................................................................................................

6 2.5 Creep Properties

.............................................................................................

7 2.6 M echanical Boundary Conditions

.................................................................

7 3.0 A SSUM PTION S ......................................................................................................

7 4.0 W ELD RESIDUAL STRESS AN ALY SIS ...............................................................

8 4.1 Cold leg Cladding ........................................................................................

8 4.2 Boss W eld ......................................................................................................

8 4.3 ID Patch W eld ...............................................................................................

9 4.4 Post-weld Heat Treatm ent ............................................................................

9 4.5 Hydrostatic Test .............................................................................................

9 4.6 Five Norm al Operating Cycles (NOC) ........................................................

10 5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS ....................................

10 5.1 W elding Tem perature Contours .................................................................

10 5.2 PW HT Tem perature Results ........................................................................

10 5.3 Residual Stress Results ...............................................................................

11 6.0 CON CLU SION S .....................................................................................................

11 7.0 REFEREN CES ........................................................................................................

12 APPENDIX A COM PUTER FILES LISTIN G ...............................................................

A -1 File No.: 1400669.322 Page 2 of 38 Revision:

0 F0306-OIRI smnIur lh gridty Associates, IncY List of Tables Table 1: Table 2: Table 3: Table 4: Table 5: Table 6: Table 7: Table 8: Table 9: Elastic Properties for SA-516 Grade 70 (<4" Thick) ..........................................

13 Elastic Properties for ER308L .............................................................................

14 Elastic Properties for Alloy 600 ..........................................................................

15 Elastic Properties for Alloy 82/182 ......................................................................

16 Stress-Strain Curves for SA-516 Grade 70 (<4" Thick) .....................................

17 Stress-Strain Curves for ER308L ........................................................................

18 Stress-Strain Curves for Alloy 600 ......................................................................

19 Stress-Strain Curves for Alloy 82/182 .................................................................

20 Creep Properties

...................................................................................................

21 File No.: 1400669.322 Revision:

0 Page 3 of 38 F0306-01 RI C an ru tgriry ASSMocias Inc.List of Figures Figure 1: Finite Element Model for Residual Stress Analysis ..........................................

22 Figure 2: Applied Mechanical Boundary Conditions

........................................................

23 Figure 3: Weld Nugget Definitions for the Boss Weld .....................................................

24 Figure 4: Weld Nugget Definitions for the ID Patch Weld ...............................................

25 Figure 5: Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure Loads..26 Figure 6: Predicted Fusion Boundary Plot for Cladding ...................................................

27 Figure 7: Predicted Fusion Boundary Plot for Boss Weld ..............................................

28 Figure 8: Predicted Fusion Boundary Plot for ID Patch Weld ..........................................

29 Figure 9: Time vs. Temperature Curve for PWHT ...........................................................

30 Figure 10: Predicted von Mises Residual Stress at 70'F after ID Patch Weld ..................

31 Figure 11: Predicted von Mises Residual Stress at 70'F after PWHT ..............................

32 Figure 12: Paths for Stress Extraction

..............................................................................

33 Figure 13: Residual Stress Comparison at 70'F Before and After PWHT ........................

34 Figure 14: Measured Through-Wall Residual Stresses for PWHT ...................................

35 Figure 15: Predicted von Mises Residual Stress at 70'F after Hydrostatic Test ...............

36 Figure 16: Predicted Radial Residual Stress + Operating Conditions (5 th NOC Cycle) ........ 37 Figure 17: Predicted Hoop Residual Stress + Operating Conditions (5 th NOC Cycle) ..........

38 File No.: 1400669.322 Page 4 of 38 Revision:

0 F0306-OIRI jS"fiuIg Iafyurliy Associates, Inc.1.0 OBJECTIVE The objective of this calculation package is to document the weld residual stress analysis for the bounding cold leg nozzle at the Palisades Nuclear Plant (Palisades).

The bounding nozzle bounds the spray, drain, and charging nozzles discussed in a separate calculation package [1]. The weld residual stress analysis is based on the latest methodology and process developed by Structural Integrity Associates (SI).2.0 TECHNICAL APPROACH The finite element model is obtained from a previous finite element model (FEM) calculation package[1] and the weld residual stress analysis uses the latest weld residual stress analysis methodology developed by SI, using the ANSYS finite element analysis (FEA) program [3].The residual stress analysis consists of a thermal pass followed by a stress pass where the temperature distribution time history from the thermal pass is used as temperature input into the stress pass to determine stresses.

Stress results from the weld residual stress analysis are obtained and saved for future use to evaluate flaws which will be performed in a separate calculation package.The finite element model includes all components in the post-nozzle installation stage because new elements cannot be added during an ANSYS analysis.

Since all the weld elements need to be included in the initial model, the element "birth and death" technique in ANSYS is used to initially deactivate the weld elements, with elements corresponding to the active weld segment reactivated at the melting temperature, thus simulating the weld metal deposition.

2.1 Material Properties The weld residual stress analysis performed in this calculation uses the material properties specifically developed in a separate calculation package for weld residual stress analyses [2]. Per the material designation used in the FEM calculation

[1], the following materials are used:* SA-516 Grade 70: Cold leg base metal* ER308L: Cold leg cladding (typical weld metal for Type 304)0 Alloy 82/182: Boss weld and ID patch weld* Alloy 600 (SB-166):

Nozzle The material properties are reproduced in Table I through Table 8.2.2 Finite Element Model for Weld Residual Stress Analysis The finite element model for the analysis was developed in a previous FEM calculation

[1], which was created using the ANSYS finite element analysis software package [3]. The base finite element model File No.: 1400669.322 Page 5 of 38 Revision:

0 F0306-OIRI S atcuu ra tgrfly Associates, Inc;for the weld residual stress analysis is meshed with 8-node solid elements (SOLID 185) in ANSYS. This finite element model is shown in Figure 1.2.3 Welding Simulation The FEA for predicting the weld residual stresses is performed as a continuous analysis so that the load history from the cladding is carried over to the nozzle-to-pipe weld and the ID patch weld. Specifically, the residual stresses and strains at the end of a weld pass are used as initial conditions at the start of the next weld pass.The procedures for this complex multi-step simulation are encoded in ANSYS Parametric Design Language (APDL) macros which utilize elastic-plastic material behavior and elements with large deformation capability to predict the residual stresses due to the various welding processes.

2.4 Heat Inputs The deposition of the weld metal is simulated by imposing a heat generation function on the elements of the FEM representing the active weld, which is applied as a volumetric body heat generation rate. The amount of equivalent heat input energy, Q (in terms of kJ/inch), is determined from the welding parameters.

Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/inch, with an overall heat efficiency of 0.8, is assumed for all the welds. The heat efficiency represents a "composite" value reflecting the concepts of arc efficiency, melting efficiency, etc., and is an optimum value to produce reasonable heat penetration in the analysis.The APDL macros automatically calculate the appropriate time intervals for the thermal pass to ensure that sufficient heat penetration is achieved, the required interpass temperature between weld passes is met, and a reasonable overall temperature distribution within the finite element model is achieved.

The resulting temperature time history is then imported into the stress pass in order to calculate the residual stresses due to the thermal cycling of the weld elements using nonlinear, elastic-plastic load/unload stress reversal relations.

The following summarizes the welding parameters used in the analysis:* Interpass temperature

= 350'F [4]* Melting temperature

= 2500'F (See Section 3.0)" Reference temperature

= 70'F (See Section 3.0)* Heat input for all welds = 28 kJ/in (See Section 3.0)* Heat efficiency for all welds = 0.8 (See Section 3.0)" Inside/Outside heat transfer coefficient

= 5 Btu/hr-ft 2-'F (See Section 3.0)* Inside/Outside temperature

= 70'F (See Section 3.0)File No.: 1400669.322 Page 6 of 38 Revision:

0 F0306-OIRI Cj§stn urwl I"grfly Associates, Inc.2.5 Creep Properties Strain relaxation due to creep at high temperature is considered in the post-weld heat treatment (PWHT)step of the analysis.

In general, creep becomes significant at temperatures above 800'F; thus, creep behavior under 800'F will not be considered in this analysis.

The creep properties listed in Table 9 are determined in the previous FEM calculation

[1].2.6 Mechanical Boundary Conditions The mechanical boundary conditions for the stress analysis are symmetric boundary conditions at the symmetry planes of the model, axial displacement restraint at the end of the nozzle, and axial displacement coupling at the end of the cold leg piping, as shown in Figure 2.3.0 ASSUMPTIONS The following assumptions are used in the analyses: " The cold leg cladding material is assumed to be ER308L, which is a typical weld metal for Type 304 stainless steel cladding." The metal melting temperature is assumed to be 2500'F, which is the temperature point where the strength of the material is set to near zero [2].* The analysis is performed with a reference temperature of 70'F." The exposed surface of the model is subject to a typical ambient air cooling convection film coefficient of 5 Btu/hr-ft 2-°F at a bulk temperature of 70'F. The exposed surfaces are defined as the exterior surfaces of the model excluding the symmetry planes and the far ends of the modeled piping and nozzle." Since the welding parameters for the welds are not available, a typical heat input of 28 kJ/in, with an overall heat efficiency of 0.8, is assumed for all of the welds." The focus of this analysis is the residual stresses in the nozzle boss weld region, while the interaction between the clad buildup and the cold leg base metal has secondary effects on the region of interest.

Therefore, the clad is assumed to be fully deposited in a single one-layer pass." The boss weld is represented by a 40-bead process, as shown in Figure 3, with each bead represented by a one pass "bead ring" nugget. This approach is a common and acceptable industry practice when information regarding the bead start/stop position and sequencing are unknown.* Similarly, the ID patch weld is represented by a 6-bead process, as shown in Figure 4, with each bead represented by a one pass "bead ring" nugget.* For model simplification, the penetration hole is present during the deposition of the clad material.

This is acceptable since any localized stress with or without the hole would have negligible impact on the final results.File No.: 1400669.322 Page 7 of 38 Revision:

0 F0306-OIRI jsM ralw IfIrIly AssociMs, Inc." For convenience, the modeled ID patch weld has the same geometry as the backing ring for the boss weld.* Additional assumptions on PWHT are discussed in Section 4.4.4.0 WELD RESIDUAL STRESS ANALYSIS The weld residual stress analysis consists of a thermal analysis to determine the temperature distribution followed by a stress analysis to determine the resulting stresses.

The analytical sequence described below is used in the finite element analysis, followed by detailed discussions of the steps in Sections 4.1 through 4.6: 1. Deposit cladding on cold leg pipe inside (ID) surface.2. Install nozzle, backing ring, and deposit boss weld.3. Remove backing ring and deposit ID patch weld.4. Post-weld heat treatment, including creep effects based upon experimental data per Table 9.5. Subject the configuration to a hydrostatic test.6. Impose five cycles of "shake down" with normal operating temperature and pressure to stabilize the residual stress fluctuations due to stress redistribution caused by normal operating loads.4.1 Cold leg Cladding The clad material is typically welded onto the inside surface of the cold leg pipe, and the nominal thickness of the clad is thicker than the typical thickness for a single weld layer used in the process.However, the focus of this analysis is on the as-welded residual stresses, while the interaction between the clad buildup and the base material during the many actual weld passes is not of interest.

Therefore, the clad is assumed to be fully deposited in a single pass.At this step, only the cold leg pipe base metal elements and clad material elements are active; all other components are deactivated during the analysis.

At the end of the cladding application, the entire model is cooled to 70'F before the application of the boss weld.4.2 Boss Weld The boss weld connects the nozzle boss to the cold leg piping. As shown in Figure 3, the weld is composed of 40 nuggets deposited in 20 weld layers. In the absence of detailed weld fabrication information, a weld sequence is assumed based on standard welding practice at the time of fabrication.

In particular, for every layer, the first nugget is deposited on the cold leg side, the second nugget on the nozzle side.File No.: 1400669.322 Page 8 of 38 Revision:

0 F0306-OIRI VSMnwM/W egri Assocates, Inc At this step, the nozzle elements and backing ring elements are reactivated, and the boss weld nuggets are reactivated sequentially to simulate the welding process. The preheat temperature of the boss weld is 250'F [4]. At the end of the boss weld, the entire model is cooled to 70'F before the application of the ID patch weld.4.3 ID Patch Weld The final weld step is to add the ID patch weld, which replaces the backing ring. As seen in Figure 4, the ID patch weld is composed of 6 nuggets deposited in 2 layers.At this step, the backing ring is first deactivated to allow the residual stresses to redistribute, and the ID patch weld nuggets are reactivated sequentially to simulate the welding process. The preheat temperature of the ID patch weld is 250'F [4]. At the end of the ID patch weld, the entire model is cooled to 70'F before the application of the PWHT.4.4 Post-weld Heat Treatment PWHT is assumed to be performed as per the following procedure outlined in Article N-532 of the ASME Code,Section III [7] and the welding procedure

[4] for welding on material group P- 1: 1. Heat welded piping component to 1150°F at a heating rate of 400'F per hour divided by the maximum metal thickness (1330 per hour for 3 inch thick cold leg) [7, Article N-532.3 (2)].2. Hold at temperature for approximately 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> (lhr/in of weld thickness)

[7, Table N-532.3].3. Allow to cool to 600'F at a cooling rate of 500'F per hour divided by the maximum metal thickness (1670 per hour for 3 inch thick cold leg) at temperatures above 600'F [7, Article N-532.3 (5)].4. Air-cool from 600'F to ambient [7, Article N-532.3 (5)].5. A steady state load step is imposed at the end of the PWHT process.During the PWHT, creep behavior is activated for time steps with the maximum temperature above 800'F. At the end of the PWHT, the entire model is cooled 70'F before the application of the hydrostatic test.4.5 Hydrostatic Test A hydrostatic test pressure of 3110 psig (3125 psia) and a temperature of 400°F [8, page 9] are applied after the welding. The pressure is applied on the ID surfaces of the cold leg pipe and nozzle. An end-cap load, Peiid-cap-cl, is applied at the free end of the cold leg piping. This is calculated based on the following expression:

p .r ,i.1J, '12 Pend-cap-c

(. 2 iide 2)File No.: 1400669.322 Page 9 of 38 Revision:

0 F0306-01 RI

§SWnGwbruI I"grffy Assacaes, inc where, P = Hydrostatic test pressure (ksi)Pend-cap-cd

= End cap pressure on cold leg pipe end (ksi)rinsidc_cl

= Inside radius of cold leg pipe (in)routside_ci

= Outside radius of cold leg pipe (in)The applied pressure loads on the model are shown in Figure 5.4.6 Five Normal Operating Cycles (NOC)After the hydrostatic test, the assembled configuration is put into service and subjected to 5 cycles of shake down to stabilize the as-welded residual stresses.

This step involves simultaneously ramping the model from zero-load to steady-state conditions at normal operating temperature and pressure then back to steady-state at 70'F and no pressure five times.The applied operating pressure and temperature is 2085 psig (2100 psia) and 537'F [9]. The temperature is assumed to be uniform throughout the components and operating pressure is applied as an internal pressure on the ID surface, with corresponding end-cap pressure calculated using the equation in the previous section. The term "P" is replaced by the operating pressure in the expression.

5.0 RESULTS OF WELD RESIDUAL STRESS ANALYSIS The ANSYS input files and computer output files for the analyses are listed in Appendix A.5.1 Welding Temperature Contours The maximum temperature prediction contours for each weld are created using macro MapTemp.mac.

This type of contour plot is also called a "fusion boundary" plot because it provides an overview of the maximum temperature on each node throughout the thermal transient for each welding process. The plots are useful in visualizing the melting of weld metal and the extent of heat penetration.

The predicted fusion boundary contours for the cladding, boss weld, and ID patch weld are shown in Figure 6, Figure 7, and Figure 8, respectively.

The purple color in the plots represents elements at melting temperature

(>2500'F);

the plots show complete melting of the weld metal for each weld and slight melting of the base metal along the weld interface.

5.2 PWHT Temperature Results Figure 9 plots the inside surface temperature curve for the PWHT process. It shows the linear 133°F/hour heating rate, three hours (180 minutes) hold time at 1150'F, 167°F/hour cooling rate at temperature above 600'F, and the air cooling to room temperature of 70'F.File No.: 1400669.322 Page 10 of 38 Revision:

0 F0306-01 RI Sticiurui Iuegrlty Associates, IncW 5.3 Residual Stress Results Figure 10 plots the von Mises residual stresses after welding is complete, but before PWHT. It shows extensive residual stresses of greater than 66 ksi in the weld material.

However, as shown in Figure 11, after the PWHT the residual stresses in the weld have relaxed significantly, to below 41 ksi, but the residual stresses in the cladding remain essentially unchanged.

To further investigate the effects of the PWHT, before and after PWHT residual stresses are extracted along the two through-wall paths shown in Figure 12. The through-wall residual stresses are compared in Figure 13, and it shows that there is little to no stress reduction in the clad material, while there is significant stress reduction in the pipe base metal.The PWHT results from the FEA trend comparably well with the data in EPRI report TR-105697

[ 10], which contains a comparable through-wall clad residual stress distribution based on experimental measurements, as shown in Figure 14. The experimental measurements were for a low alloy steel vessel with a Type 304 stainless steel clad. The data shows tensile hoop stress through the clad thickness and the base metal near the clad interface, but the hoop stress drops rapidly to compressive values at farther distances from the clad.Figure 15 depicts the predicted von Mises residual stresses after the hydrostatic test. It shows an insignificant reduction in maximum stress when compared to the post-PWHT step: 73.74 ksi (Figure 15)versus 73.75 ksi (Figure 11), while the overall stress contour remains essentially the same.Figure 16 and Figure 17 depicts the combined weld residual plus operating radial and hoop stresses, respectively, at the fifth stabilization NOC cycle. The stress results at this step are used in the fracture mechanics evaluations.

6.0 CONCLUSION

S Finite element residual stress analysis has been performed on the bounding cold leg nozzle boss weld at Palisades.

Stresses at normal operating conditions combined with residual stresses have been obtained and saved for future use. The stress results will be used in a separate calculation to determine crack growth.File No.: 1400669.322 Page 11 of 38 Revision:

0 F0306-OIRI jISVantraIlat h grfy~ Associates, IncG

7.0 REFERENCES

1. SI Calculation No. 1400669.320, Rev. 0, "Finite Element Model Development for the Cold Leg Drain, Spray, and Charging Nozzles." 2. SI Calculation No. 0800777.307, Rev. 5, "Material Properties for Residual Stress Analyses, Including MISO Properties Up To Material Flow Stress." 3. ANSYS Mechanical APDL and PrepPost, Release 14.5 (w/ Service Pack 1), ANSYS, Inc., September 2012.4. Combustion Engineering Welding Procedure No. MA-41, Rev.0, SI File No. 1400669.204.

5. "Steels for Elevated Temperature Service," United States Steel Co., 1949.6. Publication SMC-027, "Inconel Alloy 600," Special Metals Corp., 2004, SI File 0800777.211.

7. ASME Boiler and Pressure Vessel Code,Section III, 1965 Edition with Addenda through Winter 1966.8. Combustion Engineering Specification No. 0070P-006, Rev. 2, "Engineering Specification for Primary Coolant Pipe and Fittings," SI File No. 1300086.203.

9. Palisades Design Input Record, "Palisades Alloy 600 Flaw Eval DIR 3-4-15 Revl.pdf," SI File No. 1400669.201.

10. EPRI Report No. TR-105697, "BWR Reactor Pressure Vessel Shell Weld Inspection Recommendations (BWRVIP-05)," September 1995.File No.: 1400669.322 Revision:

0 Page 12 of 38 F0306-OIRI oStnwbri ldWf Associaes, Inc Table 1: Elastic Properties for SA-516 Grade 70 (54" Thick)Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity (2) Specific Heat (2)(0 F) (x10 3 ksi) (xlO-6 in/in/0 F) (Btu/min-in-0 F) (Btuib-0 F)70 29.5 6.4 0.0488 0.103 500 27.3 7.3 0.0410 0.128 700 25.5 7.6 0.0369 0.138 1100 18.0 8.2 0.0290 0.171 1500 5.0 8.6 0.0218 0.198 2500 0.1 9.5 0.0014 0.204 2500.1 -0.0 --Notes: 1. All values per [2].2. Density (p) = 0.283 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.

File No.: 1400669.322 Revision:

0 Page 13 of 38 F0306-OIRI jSbvuruI grily Associes, IncW Table 2: Elastic Properties for ER308L Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity(2)

Specific Heat (2)(0 F) (x10 3 ksi) (x10 6 in/in/IF) (Btu/min-in-*F) (Btu/lb-0 F)70 28.3 8.5 0.0119 0.116 500 25.8 9.7 0.0151 0.131 700 24.8 10.0 0.0164 0.135 1100 22.1 10.5 0.0189 0.140 1500 18.1 10.8 0.0213 0.145 2500 0.1 11.5 0.0292 0.159 2500.1 -0.0 --Notes: 1. All values per [2].2. Density (p) = 0.283 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.3 [2], assumed temperature independent.

File No.: 1400669.322 Revision:

0 Page 14 of 38 F0306-01 RI

,Smno rwl NItrgrify Associates, Inc.Table 3: Elastic Properties for Alloy 600 Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity (2) Specific Heat (2)(OF) (x10 3 ksi) (x10-6 in/in/°F) (Btu/min-in-OF) (Btu/lb-°F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -0.0 --Notes: 1. All values per [2].2. Density (p) = 0.300 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.

File No.: 1400669.322 Revision:

0 Page 15 of 38 F0306-01 RI js"OIniorwhts grity Assucates, /nc.Table 4: Elastic Properties for Alloy 82/182 Temperature Young's Mean Thermal Thermal Modulus Expansion Conductivity (2) Specific Heat (2)(°F) (x10 3 ksi) (xl0-6 in/in/IF) (Btu/min-irr-0 F) (Btu/lb-°F) 70 31.0 6.8 0.0119 0.108 500 29.0 7.6 0.0147 0.120 700 28.2 7.9 0.0161 0.125 1100 25.9 8.4 0.0192 0.139 1500 23.1 9.0 0.0222 0.148 2500 0.1 10.0 0.0306 0.177 2500.1 -0.0 --Notes: 1. All values per [2].2. Density (p) = 0.300 lb/in 3 [2], assumed temperature independent.

3. Poisson's Ratio (u) = 0.29 [2], assumed temperature independent.

File No.: 1400669.322 Revision:

0 Page 16 of 38 F0306-OIRI VjtI wfrourul lifgrity Associats, 1nc0 Table 5: Stress-Strain Curves for SA-516 Grade 70 (54" Thick)Temperature Strain Stress (°F) (in/in) (ksi)0.00128814 38.000 0.00187809 42.000 70 0.00257329 46.000 0.00381110 50.000 0.00600383 54.000 0.00113553 31.000 0.00142679 35.875 500 0.00183954 40.750 0.00261139 45.625 0.00415246 50.500 0.00106667 27.200 0.00132412 32.550 700 0.00166876 37.900 0.00228121 43.250 0.00354341 48.600 0.00116667 21.000 0.05116163 22.125 1100 0.05915444 23.250 0.06794123 24.375 0.07755935 25.500 0.00300000 15.000 0.16717493 15.125 1500 0.16992011 15.250 0.17268761 15.375 0.17547742 15.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.322 Revision:

0 Page 17 of 38 F0306-OIRI jj$ wbrui NNW Associates, Inc?Table 6: Stress-Strain Curves for ER308L Temperature Strain Stress ('F) (in/in) (ksi)0.00203180 57.500 0.02471351 61.563 70 0.03107296 65.625 0.03861377 69.688 0.04747167 73.750 0.00140089 36.143 0.00714793 40.250 500 0.01065407 44.357 0.01558289 48.464 0.02233857 52.571 0.00132488 32.857 0.00477547 37.125 700 0.00743595 41.393 0.01143777 45.661 0.01727192 49.929 0.00121913 26.943 0.00264833 30.138 1100 0.00404100 33.332 0.00634529 36.527 0.01005286 39.721 0.00117995 21.357 0.05352064 21.563 1500 0.05610492 21.768 0.05878975 21.973 0.06157807 22.179 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.322 Revision:

0 Page 18 of 38 F0306-OIRI V ~snWakrsI Iiitogriy Associaes.

Inc.Table 7: Stress-Strain Curves for Alloy 600 Temperature Strain Stress ('F) (in/in) (ksi)0.00157419 48.800 0.01658847 55.300 70 0.02343324 61.800 0.03212188 68.300 0.04291703 74.800 0.00152069 44.100 0.01539220 50.338 500 0.02210610 56.575 0.03072476 62.813 0.04153277 69.050 0.00152128 42.900 0.01634485 49.000 700 0.02334760 55.100 0.03227153 61.200 0.04338643 67.300 0.00155985 40.400 0.02275193 44.475 1100 0.03004563 48.550 0.03888203 52.625 0.04943592 56.700 0.00092641 21.400 0.08827666 22.475 1500 0.09785101 23.550 0.10796967 24.625 0.11863796 25.700 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.322 Revision:

0 Page 19 of 38 F0306-OIRI Cjs"19ftni Iaftgdfy~

Assocates, kIcG Table 8: Stress-Strain Curves for Alloy 82/182 Temperature Strain Stress (*F) (in/in) (ksi)0.00179032 55.500 0.03456710 60.113 70 0.04292837 64.725 0.05257245 69.338 0.06359421 73.950 0.00164483 47.700 0.02976152 52.313 500 0.03809895 56.925 0.04790379 61.538 0.05929946 66.150 0.00159574 45.000 0.02849157 49.538 700 0.03680454 54.075 0.04663682 58.613 0.05812078 63.150 0.00159073 41.200 0.03568855 44.488 1100 0.04402702 47.775 0.05360088 51.063 0.06449835 54.350 0.00106494 24.600 0.11812735 25.325 1500 0.12540227 26.050 0.13290814 26.775 0.14064577 27.500 0.01000000 1.000 0.10961239 1.125 2500(2) 0.12781277 1.250 0.14689940 1.375 0.16683167 1.500 Notes: 1. All values per [2].2. Values at 2500'F assumed arbitrarily small values for convergence stability.

File No.: 1400669.322 Revision:

0 Page 20 of 38 F0306-OIRI Ctt 11frud~uh labgte rl Associaes, kIcG Table 9: Creep Properties Material Temperature Creep Strength (ksi) A (OF) a, (0.0001%/hr) 02 (0.00001%/hr) (ksi/hr)800 19.0 12.4 1.26E- 13 5.40 SA-516 Gr. 70 900 9.0 6.7 3.59E-14 7.80 (Based on carbon steel) 1000 3.5 2.8 2.43E-12 10.32 Per [5] 1100 1.4 0.8 2.50E-07 4.11 800 33.4 25.0 7.73E-19 7.95 ER308L 900 24.0 17.6 5.67E-17 7.42 (Based on Type 304) 1000 17.6 11.5 1.82E-13 5.41 PerE[] 1100 11.5 7.1 8.62E-12 4.77 Alloy 600 800 40.0 30.0 1.50E-19 8.00 Alloy 82/182 900 28.0 18.0 2.87E-14 5.21 (Based on 1000 12.5 6.1 3.02E-10 3.21 Alloy 600)Per [6] 1100 6.8 3.4 1.72E-09 3.32 File No.: 1400669.322 Revision:

0 Page 21 of 38 F0306-OIRI

!U~w"MoWuwkb~fv k='Figure 1: Finite Element Model for Residual Stress Analysis File No.: 1400669.322 Revision:

0 Page 22 of 38 F0306-OIRI Van" MW* ASKW8W, WE Axial displacement restraint Axial displacement couples Symmetry boundary conditions Figure 2: Applied Mechanical Boundary Conditions File No.: 1400669.322 Revision:

0 Page 23 of 38 F0306-OIRI C asbew" hfwdfy Assaogs, Inr.t m Figure 3: Weld Nugget Definitions for the Boss Weld File No.: 1400669.322 Revision:

0 Page 24 of 38 F0306-0IRI C an"wetv No*pf Asscates, kncP Figure 4: Weld Nugget Definitions for the ID Patch Weld File No.: 1400669.322 Revision:

0 Page 25 of 38 F0306-OIRI Can" OM AShd% ftm Internal pressure z/Cold leg end cap pressure.... , , k si-6.98787 -4.7439 -2.49993 -.255956 1.98801-5858-3.62191

-1.37794 .866029 3.11 Figure 5: Applied Hydrostatic Test Pressure and Corresponding End Cap Pressure Loads File No.: 1400669.322 Revision:

0 Page 26 of 38 F0306-OIRI

~jSVan" Mudf, Associates, W 7P 1 Predicted pp' 1150a 1420 1690 1960 W(Puploe -Te-perature

> Melting)Figure 6: Predicted Fusion Boundary Plot for Cladding (Note: Purple = Temperature

> Melting Temperature of 2500'F)2230 2500 OF File No.: 1400669.322 Revision:

0 Page 27 of 38 F0306-OIRI Va" b oN Awfl'n'Figure 7: Predicted Fusion Boundary Plot for Boss Weld (Note: Purple = Temperature

> Melting Temperature of 2500 0 F)File No.: 1400669.322 Revision:

0 Page 28 of 38 F0306-OIRI Can" MW~~IVnAwcbf Figure 8: Predicted Fusion Boundary Plot for ID Patch Weld (Note: Purple = Temperature

> Melting Temperature of 2500'F)File No.: 1400669.322 Revision:

0 Page 29 of 38 F0306-OIRI I!VSh m a OW MW*Y Amda& IWO I 1250-1125 1000 875 750 Tenperature (F) 625-500 375 250 125 0 B Hold time I ,V Cooling to 6002F at 1672F/hr p Air cool.........N wf Heating at 133-°F/hr 1000 1250 1500 1750 2000 2250 1125 1375 1625 1875 2125 Time (m n)Figure 9: Time vs. Temperature Curve for PWHT Note: 1. PWHT temperature history is for a typical ID node on the model.File No.: 1400669.322 Revision:

0 Page 30 of 38 F0306-OIRI

~jSVan"hfwwadaft W Figure 10: Predicted von Mises Residual Stress at 70°F after ID Patch Weld File No.: 1400669.322 Revision:

0 Page 31 of 38 F0306-OIRI Van" ~hbgp* saytS Figure 11: Predicted von Mises Residual Stress at 70°F after PWHT File No.: 1400669.322 Revision:

0 Page 32 of 38 F0306-OIRI C OM"ef~w AMP NY Assodaws ba Figure 12: Paths for Stress Extraction Notes: 1. In the cold leg coordinates, hoop residual stresses along path P1 and axial residual stresses along path P2 are extracted for comparison of before and after PWHT.2. The before and after PWHT through-wall residual stresses are compared in Figure 13.File No.: 1400669.322 Revision:

0 Page 33 of 38 F0306-OIRI Vawd"Meffy Akcbft ft 80 70 60 50 40 30 20 10 I-I+ As-Welded (P1)Clad interface 0 PWHT (P1)x As-Welded (P2)A PWHT (P2)x x 0 0++tx+ X i I + I M I7 0 0 Lx: x+ ÷ 0-10-20-30-40-50 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 Normalized Thickness (x/t)0.9 1.0 Figure 13: Residual Stress Comparison at 70'F Before and After PWHT File No.: 1400669.322 Revision:

0 Page 34 of 38 F0306-OIRI Van" hd** Assadoes, Inad 120 120 -Y A& As-Welded 0 PWHT 100 --'-- Clad Interface 80 S.1 ci,*1 S C.)A 60*4 4 40-0 A<-A Onark-)0 0 C 20+Data from EPRI TR-101989 0 I A 0 SThkir Clad Teats, Interfaee at Depth Shown 0-20+A-40 Hil2rl V_ ---- 32 0 0.2 0.4 0.6 0.8 Distance from Clad Surface (inches)1.0 Figure 14: Measured Through-Wall Residual Stresses for PWHT Notes: 1. Figure is obtained from EPRI report TR-105697

[10].2. Measurements show little to no stress reduction in the cladding after PWHT.3. Measurements show significant stress reduction in the base metal after PWHT.Flre No.: 14110669.322 Revision:

0 Page 35 of 38 F0306-OIRI r a n"b MWh b r E Y Figure 15: Predicted von Mises Residual Stress at 70 0 F after Hydrostatic Test File No.: 1400669.322 Revision:

0 Page 36 of 38 F0306-OIR1 S'FIEF1413 Sm -3 TIME-2106 Sx (AWG)PSM 5 sm -43 .7349 Figure 16: Predicted Radial Residual Stress + Operating Conditions (5th NOC Cycle)Note: 1. Radial stresses shown in the nozzle axis radial direction.

File No.: 1400669.322 Revision:

0 Page 37 of 38 F0306-OI RI STFSP-1413 SU -3 TJIW-2106 SY (AW)rM4 1.3462, SM -44.7962 Figure 17: Predicted Hoop Residual Stress + Operating Conditions (5 th NOC Cycle)Note: 1. Hoop stresses shown in the nozzle axis circumferential direction.

File No.: 1400669.322 Revision:

0 Page 38 of 38 F0306-0IRI VS atwrur, Ibgrity Associates, Inc.APPENDIX A COMPUTER FILES LISTING File No.: 1400669.322 Revision:

0 Page A- I of A-2 F0306-OIRI C S"nwIrul laregrlty AssociWes, Inc'File Name Description PalisadesCL.INP Input file to create base geometry model [1]MPropMISO.INP Elastic-plastic Material properties inputs [1]Autonugsel.mac Macro that groups elements into nuggets BCNUGGET3D.INP Weld pass and model boundary definition file THERMAL3D.INP Input file to perform the thermal pass of welding simulation THMPWHT.INP Input file to perform the thermal pass of PWHT STRESS3D.INP Input file to perform the stress pass of welding simulation CBC.INP Input file to apply mechanical boundary conditions THMPWHT mntr.inp Processed thermal pass load steps for PWHT WELD#_mntr.inp Processed thermal pass load steps for stress pass # = 1-3*.mac WRS analysis macro files required for analysis THERMAL3D.TXT Parameter input file for thermal pass of welding simulation STRESS3D.TXT Parameter input file for stress pass GenStress.mac Macro to extract PWHT stress results GETPATH.TXT Through-wall stress path definition to extract PWHT stress results File No.: 1400669.322 Revision:

0 Page A-2 of A-2 F0306-01RI