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#REDIRECT [[DCL-14-028, Areva Calculation No. 32-9219781-000, Diablo Canyon Unit 2 - Pressurizer Spray Nozzle Weld Overlay Structural Analysis.]]
| number = ML14101A251
| issue date = 03/26/2014
| title = Areva Calculation No. 32-9219781-000, Diablo Canyon Unit 2 - Pressurizer Spray Nozzle Weld Overlay Structural Analysis.
| author name = Mahmoud S H
| author affiliation = AREVA NP, Inc
| addressee name =
| addressee affiliation = NRC/NRR
| docket = 05000323
| license number = DPR-082
| contact person =
| case reference number = DCL-14-028
| document report number = 32-9219781-000
| package number = ML14101A245
| document type = Calculation
| page count = 111
}}
 
=Text=
{{#Wiki_filter:Attachments 2 through 7 to the Enclosure contain Proprietary Information
-Withhold Under 10 CFR 2.390Attachment 13PG&E Letter DCL-14-028 AREVA Calculation No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray NozzleWeld Overlay Structural Analysis
-Non-Proprietary Attachments 2 through 7 to the Enclosure contain Proprietary Information When separated from Attachments 2 through 7, this document is decontrolled.
Controlled Document0402-01-FOl (Rev. 018, 01/30/2014)
A CALCULATION SUMMARY SHEET (CSS)AREVADocument No. 32 -9219781 -000 Safety Related:
NYes El NoDiablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-NonTitle Proprietary PURPOSE AND SUMMARY OF RESULTS:PURPOSE:The purpose of this calculation is to qualify the Diablo Canyon Unit 2 spray nozzle weld overlay design to therequirements specified in Reference
[1]. The analysis was performed using computer program ANSYS version11.0 and StressRange version 2.0.SUMMARY OF RESULTS:The calculation demonstrates that the design of the Pressurizer spray nozzle weld overlay for Diablo Canyon Unit2 meets the stress and fatigue requirements of the ASME Code (References
[14]).Based on the loads and cycles specified in References
[2] and [4], the conservative fatigue analysis indicates thatPressurizer spray nozzle weld overlay design has the maximum usage factor of [ ] for specified numberof cycles per Reference
[2] compared to the ASME Code allowed maximum value of 1.0.This document is the Non-Proprietary document for 32-9049112-003.
Proprietary information is contained within bold square brackets
"[ ]".THE DOCUMENT CONTAINSASSUMPTIONS THAT SHALL BETHE FOLLOWING COMPUTER CODES HAVE BEEN USED IN THIS DOCUMENT:
VERIFIED PRIOR TO USECODENVERSION/REV CODENERSION/REV ANSYS 11.0 (Rev. 000) i-YesStressRange 2.0 (Rev. 000) Operating System: Not Known 0 NoANSYS 14.0 (Rev. 002) Operating System: Win 7Page 1 of 110
.entre4l4 IDGGUMOnt AAREVA0402-01-FOl (Rev. 018, 01/30/2014)
Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Review Method: [ Design Review (Detailed Check)"' Alternate Calculation Signature BlockPIRIAName and Title and PageslSections (printed or typed) Signature LPILR Date Prepared/RevlewedlApproved Samer H MahmoudPrincipal Engineer P -z.- k-I All.Silvester J Noronha E nR Principal Engineer JvTim M Wiger A All.Engineering MangerNote: P/R/A designates Preparer (P), Reviewer (R), Approver (A);LP/LR designates Lead Preparer (LP), Lead Reviewer (LR)Project Manager Approval of Customer References (NIA If not applicable)
Name Title(printed or typed) (printed or typed) Signature DateNIA N/A N/A N/AMentoring Information (not required per 0402-01)Name Title Mentor to:(printed or typed) (printed or typed) (P/R) Signature DateN/A N/A N/A N/A N/APage la Controlled DocumentA 0402-01-FOl (Rev. 018, 01/30/2014)
AR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Record of RevisionRevision Pages/Sections/Paragraphs No. Changed Brief Description
/ Change Authorization 000 All Original Release.000 All Non-Proprietary document for 32-9049112-003
+ I+Page lb Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table of ContentsPageSIGNATURE BLOCK ........................................................................................................
ARECORD OF REVISION
....................................................................................................
l BTABLE OF CONTENTS
........................................................................................................
2LIST OF TABLES ..........................................................................................................................
4LIST OF FIGURES ........................................................................................................................
7IPURPOSE
..................................................................................................................................
81-1 INTRODUCTION
........................................................................................................
81.2 SCOPE ..................................................................................................................................
82 ANALYTICAL M ETHODOLOGY
........................................................................................
93 KEY ASSUM PTION .................................................................................................................
104 DESIGN INPUT ........................................................................................................................
104.1 GEOM ETRY ......................................................................................................................
105 FINITE ELEM ENT M ODEL ................................................................................................
115.1 M ATERIALS
......................................................................................................................
135.2 BOUNDARY CONDITION AND LOADS ..................................................................
175.2.1 Thermal Boundary.
......................................................................................................
175.2.2 Structural Boundary
.................................................................................................
176 EXTERNAL LOADS ....................
I ...........................................................................................
206.1 APPLICABLE LOADS ................................................................................................
206.1.1 Nozzle Cross Sections
--------.............................................
226.1.2 Stress Intensity Due To External Loads Calculation
..............................................
237 DESIGN CONDITION
..............................................................................................................
268 THERMAL ANALYSIS
.................................................
299 STRUCTURAL ANALYSIS
.................................................................................................
6710 ASME CODE CRITERIA
...................................................................................................
7310.1 ASM E Code Primary Stress Intensity (SI) Criteria
......................................................
7310.2 ASM E Code Primary + Secondary Stress Intensity (SI) Criteria
................................
7310.2.1 Path Stress Evaluation
...........................................................................................
7410.2.2 Applicable Stress Intensity Due to External Loads .............................................
7610.2.3 M aximum Primary + Secondary Stress Intensity Range .......................................
7610.2.4 Primary + Secondary (P+Q) Stress Intensity Range Qualification (NB 3222.2) ..... 76Page 2 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table of Contents(continued)
Page10.2.5 Simplified Elastic-Plastic Analysis (NB-3228.5)
.................................................
7810.2.6 Fatigue U sage Factor Calculation
..............................................................................
8211 RESULTS SUMMARY/CONSLUSION
............................................................................
9112 SOFTW ARE VERIFICATION
...........................................................................................
9213 COM PUTER OUTPUT FILES ...........................................................................................
9314 RE FERE N C E ...........................................................................................................................
97APPENDIX A -Stresses used for Fracture Mechanics Analysis
...........................
98APPENDIX B -Additional Stresses Used For Fracture Mechanics Analysis
..........................
100Page 3 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary List of TablesPageTable 5-1 Table of M aterials
....................................................................................................
13Table 5-2 Pressurizer Upper Head Material Properties
............................................................
14Table 5-3 Spray Nozzle and Nozzle to Head Weld Material Properties
..................................
15Table 5-4 Safe End M aterial Properties
....................................................................................
15Table 5-5 Safe End to Nozzle Weld, Buttering Material Properties
.........................................
15Table 5-6 Thermal Sleeve, Liner, Cladding and Safe End to Pipe Weld Material Properties
...... 16Table 5-7 Pipe M aterial Properties
...........................................................................................
16Table 5-8 Weld Overlay Material Properties
............................................................................
16Table 6-1 External Loads ..............................................................................................................
20Table 6-2 External Loads Summ ary ........................................................................................
21Table 6-3 Nozzle Cross Sectional Characteristics
...................................................................
22Table 6-4 Summary of the Stress Components
-OBE .............................................................
23Table 6-5 Summary of the Stress Components
-Thermal Expansion
.........
...........
24Table 6-6 Summary of the Stress Components
-OBE + Thermal Expansion
.............
24Table 6-7 Stress Intensity Summary -OBE ..............................................................................
24Table 6-8 Stress Intensity Summary -Thermal Expansion
....................................................
25Table 6-9 Stress Intensity Summary -OBE + Thermal Expansion
........................................
25T able 8-1 T ransients
.....................................................................................................................
29Table 8-2 Summary of Analyzed Transients
...........................................................................
32Table 8-3 Heat-up Early Spray Transient
................................................................................
33Table 8-4 Heat-up Late Spray Transient
...................................................................................
34Table 8-5 Cool-Dovn Early Spray with Temperature Drop of[ I ...................................
35Table 8-6 Cool-Down Late Spray with Temperature Drop off .....................................
36Table 8-7 Cool-Down Early Spray with Temperature Drop ot I ..................................
37Table 8-8 Cool-Down Late Spray wi7th Temperature Drop off .................................
]........
38Table 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients
............................
39Table 8-10 Large Step Decrease in Load Transient
.................................................................
39Table 8-11 Step Load Increase of 10% of Full Power Transient
.............................................
40Table 8-12 Step Load Decrease of 10% of Full Power Transient
...........................................
41Page 4 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis  
-Non Proprietary List of Tables(continued)
PageTable 8-13 Boron Concentration Equalization Transient
................................................---
.........
42Table 8-14 Loss of Load Transient
...........................................................................................
42Table 8-15 Loss of Power Transient
.............................................................................................
43Table 8-16 Loss of Flow Transient
...........................................................................................
44Table 8-17 Reactor Trip Transient
..........................................................................................
45Table 8-18 Inadvertent Auxiliary Spray Transient
...................................................................
46Table 8-19 Turbine Roll Test Transient
...................................................................................
46Table 8-20 Nodes of Interest for Evaluation of Temperature Gradients
..................................
48Table 8-21 Temperature Gradients of Interest
..........................................................................
48Table 9-1 Time Points of Interest
-HU-ES .............................................................................
67Table 9-2 Time Points of Interest
-HU-LS ..................................................................................
68Table 9-3 Time Points of Interest
-CD-E I ............................................
1.........................
68Table 9-4 Time Points of Interest
-CD-LE 1 ..............................
69Table 9-5 Time Points of Interest
-CD-ES[ ] ............................................
].........................
69Table 9-6 Time Points of Interest
-CD-L¶ ] .....................................................................
70Table 9-7 Time Points of Interest
-PLPU ................................................................................
70Table 9-8 Time Points of Interest
-LSL ..................................................................................
70Table 9-9 Time Points of Interest
-SLI ....................................................................................
71Table 9-10 Time Points of Interest
-LOL ................................................................................
71Table 9-11 Time Points of Interest
-SLD ................................................................................
71Table 9-12 Time Points of Interest
-BCE ................................................................................
71Table 9-13 Time Points of Interest
-LOP ................................................................................
71Table 9-14 Time Points of Interest
-LOF ................................................................................
72Table 9-15 Time Points of Interest
-RT ...........................................................................
..... 72Table 9-16 Time Points of Interest
-IA ..................................................................................
72Table 9-17 Time Points of Interest
-TRT ................................................................................
72Table 10-1 Path Definition
............................................................................................................
74Table 10-2 Summary of Maximum Primary + Secondary SI Ranges for M + B Stresses
..... 77Table 10-3 Load Step Combinations for the Locations that Exceed 3Sn Limit ..........
[.............
78Table 10-4 SI Ranges of Maximum Primary + Secondary Membrane Plus Bending StressExcluding Thermal Bending Stresses
.......................................................................................
79Page 5 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary List of Tables(continued)
PageTable 10-5 General Membrane Stress for Critical Locations
...................................................
81Table 10-6 Allowable Ranges of Thermal Stresses
.................................................................
81Table 10-7 Minimum Strength Ratio ......................................................................................
82Table 10-8 Stress Category and FSRF in Fatigue Evaluation
.................................................
83Table 10-9 Nozzle Usage Factor .............................................
84Table 10-10 DM Weld Usage Factor .........................................................
85Table 10-11 Safe End Usage Factor ........................................................................................
86Table 10-12 E and Sm at Average Temperature for Table 10-11 Fatigue Evaluation
.............
87Table 10-13 Safe End to Pipe Weld Usage Factor ..................................................................
88Table 10-14 Weld Overlay Usage Factor ................................................................................
89Table 10-15 Pipe U sage Factor ...............................................................................................
90Table 11-1 Sum m ary of Results ...............................................................................................
91Table 12-1 ANSYS Verification Files ....................................................................................
92Table 12-2 StressRange Program v2.0 Verification Files .......................................................
92Table 13-1 Computer Output and Input Files ........................................
..................................
93Table A -I Path D escription
.....................................................................................................
98Table 13-I A dditional Paths in Appendix B ...............................................................................
100Table B-2 A ppendix B A N SY S files .........................................................................................
105Page 6 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary List of FiguresPageFigure 5-1 Expanded 2-D Axisymmetric Model of the Spray Nozzle with SWOL .................
11Figure 5-2 Finite Element Model -Mesh ...............................................................................
12Figure 5-3 Thermal Boundary Conditions
...............................................................................
18Figure 5-4 Structural Boundary Conditions
............................................................................
19Figure 6-1 Point of External Loads ..........................................................................................
21Figure 7-1 Deformed Shape vs. Un-deformed Outline .............................................................
26Figure 7-2 Stress Intensity Contours at Design Condition
......................................................
27Figure 7-3 Contact Pressure at Design Condition
....................................................................
28Figure 8-1 Heat-Up and Cool-Down Early and Late Transients with Spray Actuations
...... 31Figure 8-2 Location Numbers for Evaluation of Temperature Gradients
.................................
49Figure 8-3 Heat-Up Early Spray Transient
...............................................................................
50Figure 8-4 Heat-Up Late Spray Transient
................................................................................
51Figure 8-5 Cool-Downm Early Spray with Temperature Drop of[ " ....................
52Figure 8-6 Cool-Down Late Spray with Temperature Drop off I .................
53Figure 8-7 Cool-Down Early Spray with Temperature Drop of .1 ......................................
54Figure 8-8 Cool-Down Late Spray with Temperature Drop of. ...................................
55Figure 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients
.........................
56Figure 8-10 Large Step Decrease in Load Transient
...............................................................
57Figure 8-11 Step Load Increase of 10% of Full Power Transient
...........................................
58Figure 8-12 Step Load Decrease of 10% of Full Power Transient
...........................................
59Figure 8-13 Boron Concentration Equalization Transient
......................................................
60Figure 8-14 Loss of Load Transient
..........................................................................................
61Figure 8-15 Loss of Power Transient
......................................................................................
62Figure 8-16 Loss of Flow Transient
..........................................................................................
63Figure 8-17 Reactor Trip Transient
.........................................................................................
64Figure 8-18 Inadvertent Auxiliary Spray Transient
..................................................................
65Figure 8-19 Turbine Roll Test Transient
.................................................................................
66Figure 10-1 Stress Paths through the Spray Nozzle Model ......................................................
75Figure A-I Paths Defined for Fracture Mechanics Evaluation
.....................................
99Figure B-1 Additional Paths For Fracture Mechanics
..............................................................
102Figure B -2 Stress Plots during H U -ES .....................................................................................
103Figure B-3 Stress Plots during CD -ES[ I ...............................................................................
104Page 7 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 1 PURPOSE
 
==1.1 INTRODUCTION==
 
Primary water stress corrosion cracking (PWSCC) of Alloy 600/82/182 materials is a welldocumented phenomenon in the nuclear power industry.
High temperature components, such asthose associated with the pressurizer, have risk for PWSCC. Pacific Gas and Electric (PG&E)plans to mitigate the Diablo Canyon Unit 2 pressurizer nozzle Alloy 82/182 dissimilar metal(DM) welds with full structural weld overlays (SWOL) during the spring 2008 2R14 refueling outage for Unit 2. The planned mitigation using SWOL is a preemptive measure to reducesusceptibility of the DM weld and the adjacent pipe to safe end welds to PWSCC.1.2 SCOPEThe spray nozzle is located on the top of the pressurizer upper head. The nozzle provides aconduit for spray line sprays. The weld overlay is designed to cover both the Alloy 82/182 DMweld and the austenitic stainless weld between the nozzle safe end and the pipe. Application ofweld overlays alters the local stress distribution.
A detailed finite element analysis (FEA) istherefore conducted to investigate stress conditions under various operational transients.
Theresults are summarized in this report to certify that criteria per ASME Code Section III for Class1 components (Reference
[14]) are satisfied for the spray nozzle with weld overlays.
The analysis is focused on the overlaid region for requirements on both stress distribution andfatigue failure criterion.
The main scope of the analysis includes the spray line piping, thestainless steel weld between the safe end and the piping, the safe end, the DM weld between thesafe end and the nozzle, the spray nozzle, SWOL, and the pressurizer upper head. In addition, post-processing of thermal and structural results is performed to provide data for fractureanalysis of the spray nozzle (see APPENDIX A).It should be noted that the original nozzle configuration without the Weld Overlay is notanalyzed in this calculation.
The application of the SWOL will increase the secondary stress dueto thermal gradients and added discontinuities at the SWOL to pipe, and SWOL to nozzlejunctures.
The cumulative fatigue usage factors calculated in this document assume the spraynozzle SWOL has been in place since the plant conception.
Therefore, the usage factorscalculated will be higher than the actual usage factors based on summing spray nozzle's usageprior to SWOL and usage with the SWOL.Page 8 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 2 ANALYTICAL METHODOLOGY The general methodology of model development and stress analysis consists of1) Only the minimum SWOL will be modeled and evaluated.
Based on past experience, thestresses due to transients had minor differences between the maximum SWOL andminimum SWOL, and the minimum SWOL stresses due to external loads control overthe maximum SWOL. Therefore, it is reasonable to evaluate the minimum SWOL only.2) Building a two-dimensional model of the spray nozzle weld overlay geometry.
Themodel incorporates the geometry (of the adjacent upper head, spray nozzle, spray nozzlesafe end, welds, weld overlay and a part of the pipe welded to the spray nozzle safe end),appropriate materials, and boundary conditions.
The 2-D solid model is converted into a2-D finite element model. There are two finite element models consisting of thermal andstructural
: elements, respectively, to enable the thermal and structural analysis.
: 3) Applying the design conditions of pressure and temperature (as temperature affects thematerial properties only) to the structural finite element model and obtaining thedeformation and stresses in the model. The deformation field is used to verify the correctbehavior of the model and correct modeling of boundary and load conditions.
: 4) Applying the thermal loads resulting from the plant operating transients (in-the form oftransient temperatures and corresponding heat transfer coefficients versus time).Evaluating the results of the thermal analysis by examining the magnitude of temperature differences between key locations of the model. The time points of the maximumtemperature gradient are those at which the maximum thermal stresses develop.5) Applying the corresponding pressure and thermal loads (nodal temperature) at each timepoint identified in step 3 and other time points of analytical interest on the structural finite element model and obtaining the stress results.6) Hand calculating the effects due to the nozzle external loads and adding the resulting stresses to the stress results due to the pressure and temperature effect.7) Comparing the results to the ASME Code for acceptability.
: 8) Documenting stresses and temperatures for the fracture mechanics analysis of the spraynozzle weld overlay design.Page 9 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 3 KEY ASSUMPTION There are no major assumptions for this calculation.
Minor assumptions are noted whereapplicable.
4 DESIGN INPUT4.1 GEOMETRYSome of the major dimensions (References
[11] and [12]) are:pressurizer upper head inside radius to base metalpressurizer upper head base metal thickness pressurizer upper head cladding thickness spray nozzle ID (to base metal)spray nozzle OD (near head)spray nozzle OD (at nozzle to safe end weld)safe end length (between welds center lines)safe end ID (minimum) pipe IDpipe ODthermal sleeve ODthermal sleeve thickness minimum SWOL configuration:
total SWOL lengthSWOL thickness at nozzleSWOL thickness at pipePage 10 Controlled DocumentAAREVADocument No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 5 FINITE ELEMENT MODELThe 2D axisymmetric finite element model is built based on the weld overlay minimum design.The model simulates, in two-dimensional space, the spray nozzle, safe end, weld overlay, part ofthe pipe, thermal sleeve and pressurizer upper head.The finite element analyses in this document are performed using ANSYS 11.0 (Reference
[ 13]).The model was developed in ANSYS WORKBENCH 11.0 and is shown in Figure 5-1. Theelement type chosen is the structural element PLANE183 (2-D 8-Node Structural Solid). Thiselement is converted to the thermal element type PLANE77 (2-D 8-Node Thermal Solid) for thethermal analysis.
The contact surfaces between the liner and nozzle are modeled by using contactelements TARGE169 (2-D Target Segment) and CONTA172 (2-D 3-Node Surface-to-Surface Contact).
The modeled portion of pressurizer head is sufficient for attenuation of the stresses and thermalgradients.
The thermal sleeve is attached by[ ]and it is non-structural weld(Reference
[1] and [12]). Therefore, the thermal sleeve is not included in structual rums.Nevertheless, the thermal sleeve is contained in the thermal runs for temperature distribution.
EnrwWSI-----d-Spray NozzleUpper HaPip~eSSawe End/Ppe Weld"I Safe End1-.-.---
Therm l e veW elFigure 5-1 Expanded 2-0 Axisymmetric Model of the Spray Nozzle with SWOLPage 11 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary r---I S* I II I I* I I* S I* I II
* II
* I* I II I II I I* I I* B I* I I II I I I* I I II I I I* I I I* I I SI
* I I* I I II I I I* .4 I* I I I* 5 I I* I I I* I I II I I II II II II I* II I* II I* I* I* II I* II I* II II II II II II I* I* I* I* II IFigure 5-2 Finite Element Model -MeshPage 12 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary
 
===5.1 MATERIALS===
Reference
[1] and Reference
[2] provide the material designations of various components aslisted below. Per reference
[1], the material properties for the structural analysis shall be inaccordance with ASME Code 1965 Edition including Addenda through Summer 1966(Reference
[6]) for existing material and ASMIE Code 2001 Edition including Addenda through2003 (Reference
[5]) for weld filler material.
Since not all materials and material properties forexisting components are provided by Reference
[6], later Addenda or Editions of the ASMECode (Reference
[7], [8] and [9]) were used to determine the remaining material properties.
Table 5-1 Table of Materials Location MaterialPressurizer Upper HeadSpray NozzleNozzle to Pressurizer WeldSafe EndSafe End to Nozzle WeldButtering WeldLiner to Safe End Weld1Thermal Sleeve to Safe End WeldThermal SleeveUnerCladding2Safe End to Pipe Weld2Liner to Cladding Weld3PipeWeld OverlayReference
[1], par. 4.2.2 specifies material[
]for the "Barrier Layer." Thisvery thin laye4 ] Reference
[11]) is not modeled in detail in this analysis and is coveredby the weld overlay filler material.
The effect on the results is negligible.
1 Material for these welds is specified in Reference
[3].2 Reference
[I], par. 4.1.5 and 4.1.7 specify that the claddin material properties should be equivalent tc[ Iweld filler material and the existing pipe to safe end weld i u ]istenitic stainless steel. This material is used forwelding components with similar chemical composition such 4 -Jnaterial.
Therefore material[ Is considered representative of this weld material.
3 The liner to cladding material is specified aas )naterial, and materia[Per [3]. This material has similar chemical composition suchIs considered representative of this weld material.
Page 13 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary The analysis herein uses the thermal properties
-mean coefficient of thermal expansion (ca),specific heat (C), thermal conductivity (k) and the mechanical properties
-modulus ofelasticity (E), Poisson's ratio (p), density (p). The pertinent properties (thermal
& structural) forthese materials are listed in the following tables. The units of the properties are:Young's ModulusPoisson's RatioDensityE [106 psi]p [unitless]
p [lb/in3]Coefficient of Thermal Expansion cc [10-6 in/in-°F]
Thermal Conductivity k [Btu/hr-in-°F]
Specific Heat C [Btu/lb-PF]
Design Stress Intensity Sm [ksi]Yield Strength Sy [ksi]Tensile Strength Su [ksi](C is a calculated value: C = k/(p
* thermal diffusivity) where thermal diffusivity is taken fromthe same source as "V)Table 5-2 Pressurizer Upper Head Material Properties I IIIReference1
[6]1 typical [10]1 [6] 1 [9] 1 calculated
[8] [8] =8]Page 14 Controlled DocumentAAREVADocument No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 5-3 Spray Nozzle and Nozzle to Head Weld Material Properties Temp E p p a k C Sm Sy SuReference
[6] typical [10] [6] t9] calculated
[7] [1] [7]Table 5-4 Safe End Material Properties TempI E Im Ip Ia Ik I C Sm I Sy I SuI Reference 1 [6] 1 typical I [10] I [6] I [9] I calculated 1 [6] I [6] I [6] I -Table 5-5 Safe End to Nozzle Weld, Buttering, Liner/Safe End Weld and Thermal Sleeve toSafe End Weld Material Properties I Temp I E pI p aI k I C Sm I Sy I Su I--I Reference 1 [6] I typical 1 [10] I [6] I [9] I calculated I M I M I [7] IPage 15 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 5-6 Thermal Sleeve, Liner, Cladding and Safe End to Pipe Weld Material Properties
-Temp E p p a k C SmReference
[6] typical [10] [6] 1 [9] calculated
[6] [61 61]Table 5-7 Pipe Material Properties Temp E p p a knIC Sm I SY I Su-I ReferenceI
[6] Itypical I [10] I [6] I [9] I calculated 1 [6] I [6] I [6]I -1Table 5-8 Weld Overlay Material Properties rITemp E p p a k C Sm Sy Su _L- I Reference l [51 I typical I [101 I [5] I [5] I calculated I [5] I [5] I [5] I -Page 16 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 5.2 BOUNDARY CONDITION AND LOADS5.2.1 Thermal BoundaryDuring operation without spray events, the inside surface of the upper head, the inside boresurfaces of the spray nozzle, pipe, safe end weld, a part of the safe end, and the inside & outsidesurfaces of the thermal sleeve are in contact with the pressurizer fluid at steam temperature.
During spray events, the inside surfaces of the pipe, safe end weld, a part of the safe end, andthermal sleeve are in contact with the spray fluid at spray temperature.
An appropriate heattransfer coefficient (HTC) and bulk temperature versus time are applied on these surfaces, whichare in contact with the pressurizer steam or spray fluid (Figure 5-3).Thermal coupling was applied on the surfaces between the safe end and thermal sleeve in thethermal sleeve weld vicinity and between the liner and nozzle (Figure 5-3).The outside surfaces of the upper head, spray nozzle, pipe and weld overlay are exposed to theambient temperature in conjunction with a small HTC. Ambient temperature of Is used forall time points in the thermal analysis.
The spray nozzle is assumed to be insulated.
A very smallHTC olE Is used.5.2.2 Structural BoundaryPressurizer pressure is applied to all inside surfaces which are in contact with steam or fluid. Theexteriors of the pressurizer upper head are not loaded by pressure.
The upper end of the pipe hasan end cap pressure p* applied to represent the hydrost end load from the piping c re."~d2 IPressure p* is calculated as follows:
p* -,. _,dWhere p is internal
: pressure, d is inside diameter of the pipe and D is outside diameter of thepipe.The displacements of the pressurizer upper head in the circumferential direction are set to bezero (see Figure 5-4).Page 17 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 5-3 Thermal Boundary Conditions Page 18 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 5-4 Structural Boundary Conditions Page 19 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 6 EXTERNAL LOADS6.1 APPLICABLE LOADSPer Reference
[1], the external forces and moments acting on the spray nozzle safe end weldlocation (Figure 6-1) are listed in Table 6-1. These loads are defined in the local coordinate system with the "'x" axis oriented along the nozzle axis of symmetry in the nozzle to pipedirection per Reference
[3]. The "y" and "z" axes are the horizontal components.
Table 6-1 External LoadsThe stresses due to OBE and thermal loads are evaluated using hand calculation and they areadded to the ANSYS results where appropriate for ASME evaluation in Section 10.Per Reference
[2], the OBE loads hav4[ " ]-ycles[-
--. ]The thermal expansion loads are considered during the maximum temperature variance in thepressurizer, which corresponds to the heatup-cooldown transient.
Much smaller temperature variance occurs during other transients and the loads during these variations are much smaller.Therefore, the thermal expansion is assumed to have same number of cycles as the heatup-cooldown transients fof ]The following Table 6-2 lists the loads used for the SI calculation for the evaluated locations.
The total shear force (Fs) and total bending moment (Mb) by combined as the SRSS method.'Pressure load is not used since it is accounted in stress analysis model.2 The DW, SSE and Pipe Rupture loads are not evaluate in this document, since the document qualifies only Primaryplus Secondary stress intensity range (see Section 10.1 ); these loads are listed for information purpose only. Deadweight loads act at all time points of all transients, and therefore do not contribute to the SI Ranges.Page 20 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 6-2 External Loads SummaryITotal ITotalShear Shear Torsion Bending Bending Shear BendingExternal Axial Fx Fy Fz Mx My Mz Fs h MbLoad [kips] [kips] [kips] [in-kips]
[in-kips]
[in-kips]
[kips] [in-kips]
OBETHOBE +THFigure 6-1 Point of External LoadsNote: The path's numbering starts from the number "2". The pathline
"'Pathl" is not defined.Page 21 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 6.1.1 Nozzle Cross SectionsThe cross sectional characteristics are calculated for the path locations as shown in Figure 6-1.These paths correspondent with paths defined in Section 10.2.1 for the stress linearization.
Thenozzle geometric dimensions are specified in References
[11] and [12] and some dimensions arealso taken directly from the FE model.Table 6-3 Nozzle Cross Sectional Characteristics Section ModulusPathline r [in] R [in] L [in] I [in'] A [in2 S [in)]Sinside SoutlsiPath2Path3Path4Path5Path6Path7Path8rPath9'Path 10Where: R -outside radius (for the nozzle, WOL or pipe)r -inside radius (for the nozzle, WOL or pipe)L -moment armI )r(R4 r 4)A=,10R2 ~r2)-moment of inertia-cross-section area at an appropriate locationS.=,o =/IR, Sbj, = I/r -section modulusThe radii (R, r) are taken at the inside and outside nodes of the paths. Since some of the paths arein slope, the longer moment arm (L) between the safe end weld-root and the further node of thepath is conservatively taken into calculation.
For paths Path8, Path9 and PathlO, the stress intensity due to axial bending stress from external shear forces wouldreduce the stress intensity due to transient loads. Therefore, the moment arms for these locations are conservatively reduced to zero.Page 22 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 6.1.2 Stress Intensity Due To External Loads Calculation The stress components and membrane
+ bending stress intensities due to external loads and loadscombination for inside and outside nodes are calculated based on following formulas and theyare listed in Table 6-4 through Table 6-9. The resulting stress intensities will be used along withthe transient SI Ranges in the ASME Code Primary plus Secondary Membrane
+Bending SIRange qualification in Section 10.2a.x =FJ/Aa- =Mb /S, =Fs L(/. STT = Ms /(2.- S)axial membrane stress due to an external axial force Fxaxial bending stress due to an external moment Mbaxial bending stress due to an external shear force Fsshear stress due to an external torsion MxrVs= Fs 1A shear stress due to an external shear force Fsarx = a. + a + al sum of axial stressesr = Ts + 5Tsum of shear stressesa, = ua,' -+4- r2  membrane
+ bending stress intensity Table 6-4 Summary of the Stress Components
-OBEPage 23 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 6-5 Summary of the Stress Components
-Thermal Expansion Table 6-6 Summary of the Stress Components
-OBE + Thermal Expansion Shear Inside OutsidePathline oaX[kksi] b [ksiJ obs [ksi] TT [ksi] ob [ksi] Oh, [ksi] TT [ksi]_Path2Path3Path4Path5Path6Path7Path8Path9Path 10Table 6-7 Stress Intensity Summary -OBEPathfine Inside Outside__-_O'x [ksi] T [ksi] 01NT [ksi] 0x [ksi] r [ksi Or [ksi]Path2Path3Path4Path5Path6Path7Path8Path9Path10Page 24 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 6-8 Stress Intensity Summary -Thermal Expansion Pathine Inside Outside-- 0x [1ksi] T [ksi] ONT [ksi Ox [ksiJ T [ksel Ow [ksi]Path2 3.923 1.096 4.494 6.193 1.416 6.810Path3 3.869 1.254 4.611 5.900 1.597 6.709Path4 3.361 1.254 4.194 5.111 1.597 6.027Path5 3.551 1.386 4.505 5.451 1.785 6.516Path6 3.396 1.361 4.352 5.451 1.804 6.537Path7 3.533 1.511 4.649 5.747 2.034 7.041Path8 4.967 2.347 6.834 7.094 2.941 9.215Path9 9.938 4.412 13.290 12.741 5.195 16.440PathlI 13.190 5.747 17.495 16.213 6.591 20.896Table 6-9 Stress Intensity Summary -OBE + Thermal Expansion Pathline Inside Outsider" Ox [ksi] T [ksi] Onrr [ksq 0x [ksij T [ksi] vwwr [ksi]Path2Path3Path4Path5Path6Path7Path8Path9Path 10Page 25 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 7 DESIGN CONDITION It is assumed that the pressurizer assembly was designed to satisfy the ASME Code Criteria at apressure o[ )3nd temperature of[ ]These design conditions were simulated bysetting a unitorm temperature of ]hroughout the model (this temperature is only used todefine material properties and not thermal expansion) and a uniform pressure o( ]Thepressure loading is described in detail in Section 5.2.2 .The ANSYS computer output isdocumented in file "min DC.out".Stress analysis of the model under design pressure case served two important purposes.
Itprovides a basis for verification of the correct behavior of the model as well as boundaryconditions.
Attenuation of stress effects at regions distant from the nozzle is also verified.
Figure 7-1 shows the deformed shape of the model under the design pressure along with theoutline of the un-deformed shape. The stress intensity contours developed in the model underdesign pressure is shown in Figure 7-2. The contact pressure between the liner and nozzle isshown on Figure 7-3.Figure 7-1 Deformed Shape vs. Un-deformed OutlinePage 26 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 7-2 Stress Intensity Contours at Design Condition Page 27 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 7-3 Contact Pressure at Design Condition Page 28 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 8 THERMAL ANALYSISThe operating thermal loads are defined by the thermal transient conditions as contained inReference
[2] and Reference
[4]. The applicable transient data from references are shown inTable 8-1.Table 8-1 Transients ASME Code Transient Name Cycles Spray Actuation' Condition
_Heat UpCool DownUnit Loading at 5% ofFull Power/Min 0 Unit Unloading at 5% ofZ-- Full Power/Min Large Step Decrease inLoad With Steam DumpStep Load Increase of10% of Full Power0 Step Load Decrease of10% of Full PowerSteady State Fluctuation Boron Concentration Equalization Page 29 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-1 Transients (Continuing)
ASME CodeCondition Transient Name Cycles Spray Actuation 0._0)Q,coDuring the heat-up and cool-down transients, the timing for th{ 1pray actuations at a AT of[ Is arbitrary.
Therefore, the transients are developed as "Early Spray" (ES) and "LateSpray" (LS) to investigate all limiting cases of spray occurrences.
For cool-down transient, thereare the additiona[
1pray actuations with AT of )when the pressurizer pressure is below[ jrherefore, the cool-down is developed as early spray and late spray with temperature drop olE 'jo investigate all limiting cases of spray occurrences.
The applicable heat-up and cool-down transients are shown on Figure 8-1.Unit Loading and Unit Unloading transient.
Each transient consists[
the composite transient consistf(PLPU) are combined together to form one composite
]pray actuations with drop AT ofl )nd therefore
]pray actuations.
The spray actuation during Unit Loading/Unloding, Large Step Degrease in Load, Step LoadIncrease/Decrease of 10% full power and Loss of Load transients starts from the sametemperature of[ ]and the same pressure oIf ]with the same temperature rate andsam{[ jecond duration.
Therefore, this spray actuation transient is developed only one time forPLPU and the stresses resulting from this transient bound all spray actuations of rest transients.
The total number of cycles of spray actuations is sum of cycles for PLPU and all boundedtransients.
Therefore, the transient PLPU is considered to occuf limes.' Per NB-3226(e),
the first[ 1hydrotest cycles need no be considered for the fatigue evaluation.
Page 30 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary According to Reference
[4], there is small temperature fluctuation during the Steady StateFluctuation transient for the spray nozzle. Per Reference
[2], the pressure fluctuation i{These small variations of temperature and pressure create negligible stresses compared to theother transients.
Therefore, the steady state fluctuation transient is not contained in spray nozzleanalysis.
The leak test comes on at steady state heat-up condition with pressure spikes to[ 2485momentarily.
Therefore, this transient is modeled by adding a timepoint with pressure o[.- [ ]during heat-up steady state condition.
n~io]I-Figure 8-1 Heat-Up and Cool-Down Early and Late Transients with Spray Actuations Page 31 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-2 Summary of Analyzed Transients Designation Transient Name DesignCyclesHU-ES Heat-up Early SprayHU-LS Heat-up Late Spray + Leak Test atCD-ES320 Cool-down Early Spray with tw4 )pray actuations.
CD-LS-320 Cool-down Late Spray with twc[ pray actuations.
CD-ES405 Cool-down Early Spray with 4 land a[ sprayactuations.
CD-LS405 Cool-down Late Spray with a AT of 320OF and a AT of 405°F spray actuations PLPU Plant Loading and Plant Unloading LSL Large Step Decrease in LoadSLI Step Load IncreaseSLD Step Load DecreaseBCE Boron Concentration Equalization LOL Loss of LoadLOP Loss of PowerLOF Loss of FlowRT Reactor TripIA Inadvertent Auxiliary SprayTRT Turbine Roll TestThe boundary conditions for thermal analysis are described in detail in Section 5.2.1 .Thethermal loading was applied to the finite element model in the form of temperatures and HTCversus time on the appropriate surfaces (see Section 5.2.1 , Figure 5-3). The following transient tables (Table 8-3 through Table 8-19) are based on the data from Reference
[4] and list thepressure, HTC and temperature values for the time points used in the thermal analysis.
Sometime-points are omitted from transients that are listed in Reference
[4] to simplify the transient definition.
The differences between original transients and modified transients are negligible, andthey have negligible effect to the results.1Number of spray occurrences is described in detail in Table 8-1.2 Leak test witt( ldesign cycles is applied at the end of the heat-up transient at steady state condition.
Therefore, the leak test is considered as internal cycle of the heat-up transient.
3 PLPU transient bounds the spray actuations of the others transients as described in text in this section and it results[ ,])umber of cycles for PLPU.Page 32 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-3 Heat-up Early Spray Transient Page 33 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-4 Heat-up Late Spray Transient Page 34 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-5 Cool-Down Early Spray with Temperature Drop of ]Page 35 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-6 Cool-Down Late Spray with Temperature Drop of IPage 36 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-7 Cool-Down Early Spray with Temperature Drop of ]Page 37 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-8 Cool-Down Late Spray with Temperature Drop o[ ]Page 38 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients ITime TSPR TPR PPZR HTC HC HTC[hr] [0F] [rF] [psia] Nozzle Annulus HeadTable 8-10 Large Step Decrease in Load Transient
]Time P I TTPZR IPPZR HTC HTC HTC[hr] TSF] [OF) [psia] Nozzle Annulus HeadPage 39 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-11 Step Load Increase of 10% of Full Power Transient Ti[me TSPR [FTPZR siPPZR NzHTC AnHTCl HTC[ hr] [OF] [OF] [psia] Nozzle Annulus HeadPage 40 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-12 Step Load Decrease of 10% of Full Power Transient Time PR TPZR PPZR HTC HTC HTC[hr] [0F] [0F] [psia] Nozzle Annulus HeadPage 41 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-13 Boron Concentration Equalization Transient
'I rTime TSPR[F TPZR [PPZR HNTC HTC HTC[h] [0[OF [psia] Nozzle Annulus HeadTable 8-14 Loss of Load Transient I Time TSPR TPZR PPZR HTC HTC HTC[hr] [OF] [psia] Nozzle Annulus Head' The pressure variation of -]md temperature variation o( irom Table 13 of Reference
[4] is neglected-Page 42 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-15 Loss of Power Transient hTire TSPR TPZR pPZR HTC HTC HTC[hr] [OF] [psia] Nozzle Annulus HeadPage 43 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-16 Loss of Flow Transient I hlime TSPR TPZR PPZR HTC HTC HTC-[hr] [OF] [OF] [psia] Nozzle Annulus HeadPage 44 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-17 Reactor Trip Transient 1I Time TSPR TPZR PPZR HTC HTC HTC[hr] [°F] [OF] [psia] Nozzle Annulus HeadAll three reactor trip transients defined in Reference
[4] (Table 23 through Table 25) are identical for the spraynozzle.Page 45 Controlled DocumentAAR EVADocument No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-18 Inadvertent Auxiliary Spray Transient Time TSPR TPZR PPZR HTC HTC HeTCI [hr] [OF] ["F] [psia] Nozzle Annulus Head7Table 8-19 Turbine Roll Test Transient rTime TSPR [TPZR PPZR I zHTC AuHTC HTC[hr] [OF] [OF] [psia] Nozzle Annulus HeadPage 46 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary The detailed thermal loading due to these transients were applied to the thermal finite elementmodel in the form of fluid and steam temperatures and HTC versus time.The computer input files containing definition of these transients are:HU-ES_tr.inp HU-LStr.inp CD-Ef ,1tr.inpCD-EL -Itr.inpCD-LI ]ltr.inPCD-Lj ]tr.inpPLPUtr.inp BCEtr.inp IAtr.inpLOF_tr.inp LOL-tr.mip LOP tr.inpLSL-tr.inp SLD-tr.inp SLItr.inp RT_tr.inp TRT tr.mipThe computer output files for the thermal analyses of the transients are:min HU-ES th.outmin HU-LS th.outminCD-El lth.outminCD-El lth.outminCD-L.
Ith.outmin CD-L4 Ith.outmminPLPU th.outminBCE th.outainIA th.outmrinLOF th.outmin LOL th.outmin LOP th.outmain LSL th.outmin SLD th.outmin SLI th.outminnRT th.outmin TRT th.outThe results of the thermal analyses are evaluated by examining the magnitude of temperature differences between key locations of the model (Figure 8-2). The computer input file"min _dT.mac" contains definitions of the node numbers for temperature (Table 8-20) andtemperature gradients calculation (Table 8-21). The time points of the maximum temperature gradients are those at which the maximum thermal stresses develop.
The temperature andtemperature gradients are plotted in Figure 8-3 through Figure 8-19. These figures are used onlyto show the trend. Specific data are taken from the computer output files.The computer output files that provide the temperatures at the selected locations are:mn RHU-ES dt.outmm RHU-LS dt.outminCD-F_4 ldt.outmmCD-El Idt.outmmCD-LI ldt.outminPLPU dt.outmin BCE dt.outmin IA dt.outmin LOF dt.outminLOL dt.outmin LOP dt.outmin LSL dt.outminSLD dt.outmin SLI dt.outmin RT dt.outmmn TRT-dt.out mmCD-Lildt.outPage 47 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 8-20 Nodes of Interest for Evaluation of Temperature Gradients Location Node Number Description 2 1660 Pipe3 262 Weld Overlay4 1782 Pipe ID5 1270 Weld Overlay OD at top of the WOL6 1348 Piping Weld ID at SS weld location7 1143 Weld Overlay OD near SS weld location8 1516 Liner to Safe End Weld ID9 1222 Weld Overlay OD near DM weld10 7989 Liner ID11 1289 Weld Overlay OD at bottom of WOL12 1371 Nozzle/Head Interior Comer (base metal)13 1421 Nozzle/Head Exterior ComerTable 8-21 Temperature Gradients of InterestGradient GradientGradent GradentGradient Description Designation Location21 2 to 3 Pipe to Weld Overlay22 4 to 5 Pipe ID to Weld Overlay OD23 6 to 7 Piping Weld ID to Weld Overlay OD24 8 to 9 Liner to Safe End Weld ID to Weld Overlay OD25 10 to 11 Liner ID to Weld Overlay OD26 12 to 13 Head ID (base metal) to Head ODPage 48 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-2 Location Numbers for Evaluation of Temperature Gradients Page 49 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-3 Heat-Up Early Spray Transient Page 50 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-4 Heat-Up Late Spray Transient Page 51 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-5 Cool-Down Early Spray with Temperature Drop o(IPage 52 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary KFigure 8-6 Cool-Down Late Spray with Temperature Drop o(IPage 53 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-7 Cool-Down Early Spray with Temperature Drop o[IPage 54 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-8 Cool-Down Late Spray with Temperature Drop ofIPage 55 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-9 Unit Loading & Unit Unloading at 5% of Full Power Transients Page 56 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-10 Large Step Decrease in Load Transient Page 57 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-11 Step Load Increase of 10% of Full Power Transient Page 58 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-12 Step Load Decrease of 10% of Full Power Transient Page 59 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-13 Boron Concentration Equalization Transient Page 60 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-14 Loss of Load Transient Page 61 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-15 Loss of Power Transient Page 62 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-16 Loss of Flow Transient Page 63 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-17 Reactor Trip Transient Page 64 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-18 Inadvertent Auxiliary Spray Transient Page 65 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure 8-19 Turbine Roll Test Transient Page 66 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 9 STRUCTURAL ANALYSISStress analyses are performed at the time points listed in Table 9-1 through Table 9-17. The timepoints include those at which the maximum temperature gradients (maximum thermal stresses) and the maximum and minimum pressures occur, as well as those of analytical interest.
Thenodal temperature at the particular time point is read into the structural model directly from theresult file of the thermal analysis.
The corresponding pressure is obtained from the transient input macros. The computer output files for the structural analyses are:min HU-ES st.outmin HU-LS st.outminCD-F4 lst.outminCD-El[
Jst.outminCD-1_4
]st.outminCD-LI Ist.outnm _PLPU st.outmn _BCE st.outmn _IA st.outmm _LOF st.outmnn LOL st.outmn _LOP st.outmin LSL st.outmin SLD st.outmin SLI st.outmin RT st.outmn TRT st.outTable 9-1 Time Points of Interest
-HU-ESPage 67 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 9-2 Time Points of Interest
-HU-LSTable 9-3 Time Points of Interest
-CD-El IPage 68 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 9-4 Time Points of Interest
-CD-L4 ITable 9-5 Time Points of Interest
-CD-E4 ]Page 69 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 9-6 Time Points of Interest
-CD-L-4 I]Table 9-7 Time Points of Interest
-PLPUTable 9-8 Time Points of Interest
-LSLPage 70 Controlled DocumentAARIEVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 9-9 Time Points of Interest
-SLI ___Table 9-10 Time Points of Interest
-LOL_ Table 9-11 Time Points of Interest
-SLOTable 9-12 Time Points of Interest
-BCSLDTable 9-13 Time Points of Interest
-LOPPage 71 Controlled DocumentAAREVADocument No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 9-14 Time Points of Interest
-LOF Table 9-15 Time Points of Interest
-RTTable 9-16 Time Points of Interest
-IA-Table 9-17 Time Points of Interest-TRTPage 72 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 10 ASME CODE CRITERIAThe ASME Code stress analysis involves two basic sets of criteria:
: 1) Assure that failure does not occur due to application of the design loads.2) Assure that failure does not occur due to repetitive loading.In general, the primary stress intensity criteria of the ASME Code (Reference
[14]) assure thatthe design is adequate for application of design loads.Also, the ASME Code criteria for cumulative fatigue usage factor assure that the design isadequate for repetitive loading.10.1 ASME Code Primary Stress Intensity (SI) CriteriaPer NB-3213.8 of Reference
[14], the primary stresses are those normal or shear stressesdeveloped by an imposed loading such as internal pressure and external loadings.
A thermalstress is not classified as a primary stress. The primary stress intensity criteria are specified in:NB-3221 for Design Conditions, NB-3223 for Level B (Upset),
NB-3224 for Level C(Emergency),
NB-3225 for Level D (Faulted) and NB-3226 for Test Conditions.
The primary stress intensity criteria are. the basic requirements in calculating the weld overlaysize, which is under the assumption that a 3600 circumferential flaw has grown completely through the original weld. Loading conditions in each service level have been considered in theweld overlay sizing calculation.
The nozzle to pipe region has been reinforced by the weldoverlay since adding materials to the nozzle outside region relieves primary stress burdenresulting from internal pressure and external loads. Therefore, the primary stress intensity requirements for the nozzle, welds, safe end and pipe have been satisfied for all service levelswithout the need for further evaluation.
Other related criteria include the minimum required pressure thickness (NB-3324 of Reference
[14]) and reinforcement area (NB-3330 of Reference
[14]), which were addressed in the originalnozzle/pressurizer designs.
Adding weld overlay will increase the nozzle wall thickness, andtherefore, these requirements are satisfied.
10.2 ASME Code Primary + Secondary Stress Intensity (SI) CriteriaThe analyses of stresses for transient conditions are required to satisfy the requirements for thesecondary SI range and repetitive loadings.
The following discussion describes the primary +secondary SI range evaluation and fatigue analysis process employed herein for the design.Overall stress levels are reviewed and assessed to determine which locations require detailedstress/fatigue analysis.
The objective is to assure that:1) The highly stressed locations affected by implementation of SWOL are evaluated.
: 2) The specified region is quantitatively qualified.
Page 73 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Once specific locations for detailed stress evaluation are established, the related paths lines canbe defined with ANSYS. A post-processing is then conducted to convert the component stressesalong the selected path lines into the SI categories (i.e., membrane, membrane
+ bending, total)that correlate to the criteria of the ASME Code (Reference
[14]). For paths that go through twomaterials partial paths are taken in addition to the free edge to free edge.10.2.1 Path Stress Evaluation The ANSYS Post Processor is used to tabulate the stresses along predetermined paths andclassify them in accordance with the ASME Code Criteria (i.e., membrane, membrane plusbending, total and peak stress).The paths are shown in Figure 10-1 and are described in Table 10-1. The stress linearization forall transients is documented in computer file "min_paths.out".
Table 10-1 Path Definition Inside OutsideNode No. Node No.Path1 1371 1421Path2 1433 1372Path3 5125 3156Path3A 5125 1248Path3B 1248 3156Path4 1484 3249Path4A 1484 1188Path4B 1188 3249Path5 1317 3209Path5A 1317 1212Path5B 1212 3209Path6 1336 1179Path6A 1336 1209Path6B 1209 1179Inside OutsideNode No. Node No.Path7 1313 3190Path7A 1313 1165Path7B 1165 3190Path8 3765 1136Path8A 3765 1140Path8B 1140 1136Path9 5948 1270Path9A 5948 3281Path9B 3281 1270Path10 5951 1852Page 74 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 0Figure 10-1 Stress Paths through the Spray Nozzle ModelFull through thickness paths are taken at the same location as the partial paths (A/B). The partialpath name has the letter 'A' or 'B' behind the full path name.Note: The path's numbering starts from the number "'2". The pathline "Pathl" is not defined.Page 75 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 10.2.2 Applicable Stress Intensity Due to External LoadsThe spray nozzle is exposed to the external loads. The stress intensities applicable for primary +secondary qualification due to these loads were calculated in Section 6. The membrane stress dueto internal pressure is not considered here, since this is already included in the ANSYS transient runs.The OBE + Thermal external loads combination produces highest stress intensities at allevaluated locations.
Therefore stress intensities from Table 6-9 has been conservatively added tothe maximum transient SI ranges from the ANSYS runs in the following sections.
10.2.3 Maximum Primary + Secondary Stress Intensity RangeThe computer program StressRange version 2.0 (Reference
[15]) is used to calculate membrane+ bending stress intensity range and total stress intensity range based on the method prescribed inparagraph NB-3216.2 of the ASME Code. The computer run containing the results of the stressrange calculation for membrane
+ bending stress for all transient events is"min_paths(M+B).txf'.
A zero stress state (ZSS) is included in this run.The membrane
+ bending stress intensity range runs are conservatively combined by hand withthe stresses due to external loads (calculated in Section 6). The summary of maximum membrane+ bending stress intensity ranges is tabulated in Table 10-2.10.2.4 Primary + Secondary (P+Q) Stress Intensity Range Qualification (NB 3222.2)The maximum membrane
+ bending stress intensity range, as calculated in the stress range run"'minjpaths(M+B).txf',
are conservatively combined with the maximum stress intensities due toexternal loads from Table 6-9 (as discussed in Section 10.2.2 ). Note, that Table 6-9 lists only SIfor the through-wall paths. The SI from outside node of these paths is conservatively used for thepartial path -mid-wall locations (outside node of"PathA" and inside node of 'PathB").
The sum of the maximum transient SI Range and the stress intensity due to external loads arecompared directly to the primary + secondary stress intensities range criteria of the ASME Code.Table 10-2 provides a summary of the maximum stress intensity ranges and allowable limitsalong with the material and path designation.
Table 10-2 shows that the 3Sm limit is not met at the following locations:
Inside node of paths: Path5, Path7, Path7A, Path8, Path8A, Pathl0Outside node of paths: Path8, PathlOFor the remaining locations, the requirement is met.The load-step combinations for locations which exceed 3Sm limit are shown in Table 10-3.The ASME Code allows that the 3*Sm limit may be exceeded under special condition, one ofthem being that the Simplified Elastic-Plastic Analysis (NB-3228.5) is used in the fatigueanalysis.
See Section 10.2.5 for further qualification.
Page 76 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-2 Summary of Maximum Primary + Secondary SI Ranges for M + B StressesTransient Stresses
+ Allowable External Stresses 3Sm limit at 680°FI [ksiJ MaterialPath SI Range SI Range Outside OutsideInside Node Outside Inside Node Node Inside Node Noder-_ lksil Node [ksi] I_--Path2 80.1 80.1Path3 80.1 69.9Path3A 80.1 80.1Path3B 69.9 69.9Path4 69.9 69.9Path4A 69.9 69.9Path4B 69.9 69.9Path5 41.1 69.9Path5A 41.1 41.1Path5B 69.9 69.9Path6 41.1 69.9Path6A 41.1 41.1Path6B 69.9 69.9Path7 41.1 69.9Path7A 41.1 41.1Path7B 69.9 69.9Path8 45.6 69.9Path8A 45.6 45.6Path8B 69.9 69.9Path9 49.2 69.9Path9A 49.2 49.2Path9B2 69.9 69.9Path 10 49.2 49.21 The Sm values are conservatively taken a[Imaximum transient temperature) 2 The entire through thickness section needs to act together in order for ratcheting to occur. Since partial path"Path9A" is much longer and stiffer than Path9B, the behavior of the section is driven by Path9A. Since Path9Amaterial does not ratchet (3Sm limit is satisfied),
it can be deduced that the adjacent material Path9B can not ratcheteither. Therefore, Path9B is acceptable without satisfying the 3Sm limit.Page 77 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-3 Load Step Combinations for the Locations that Exceed 3Sm LimitPath Load Step Combination Inside Node Outside Node119- 301Path5 CD-Lf .-, .1Path7 CD-Ej 135-305N .1 .1134-305Path7A CD-El ]-I4 1134-237 134-237Path8 CD-Ef I LOt[ 1 CD-Ej I- LOlI134-305Path8A CD-Ef .114 .1134-237 134-236Path10 CD-E .1- LOl[" 1 CD-E 1-LOlf ]10.2.5 Simplified Elastic-Plastic Analysis (NB-3228.5)
The maximum primary+secondary stress intensity criterion in Section 10.2.4 is not met for thelocation at specific load step combinations determinate in Section 10.2.4. Therefore, thesimplified elastic-plastic analysis for these locations is provided in this section.The primary + secondary stress intensity range may exceed 3 *Sm if the requirements of thesimplified elestic-plastic analysis are met. The requirements are:1) Primary + Secondary SI Range (Excluding thermal bending stresses),
NB-3228.5(a)
The range of primary + secondary membrane
+ bending stress intensity, excluding thermalbending, shall be < 3*SmnThe computer program StressRange v2.0 (Reference
[15]) is used to calculate primary plussecondary membrane plus bending stress intensity, excluding the thermal bending stress intensity range. The bending stress due to pressure only is determined by multiplying the bending stressobtain from design linearization file "min _DCpaths.out" with a pressure ratio. The ratio is thepressure at the time point constituting the maximum membrane
+ bending SI range, divided bythe design pressure of 2485 psig at 680'F. The applied temperature effects only physical materialproperties, therefore the effect of thermal bending is considered to be negligible.
The proratedbending stress is added to the membrane stress and external stress in determining the membrane+ bending SI range excluding thermal bending effect. The run containing the results of the stressrange calculation is "minfpaths(M+B-ThBend).t"f'.
Note that the zero stress state (ZSS) is included in this run. Table 10-4 lists the range of primaryplus + secondary membrane plus bending stress intensity, excluding thermal bending forlocations and load step combinations where the 3Sm limit was exceeded (see Table 10-3).Page 78 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-4 SI Ranges of Maximum Primary + Secondary Membrane Plus Bending StressExcluding Thermal Bending StressesTransient Stresses
+ Allowable MaterialExternal Stresses 3Sm limit at 680&deg;FPath SI Range SI Range Outside OutsideInside Node Outside Inside Node Inside Node_ [ksi] Node [ksi_- _ INodeNode Path5 41.1 -Path7 41.1 -Path7A 41.1 -Path8 45.6 69.9Path8A 45.6 -Path10 49.2 49.2 1The SI Ranges of maximum primary + secondary membrane plus h nding stress excluding thermal bending stress does not exceed the 3Sm limit at all locations.
The criterion is met.2) Factor Ke (NB-3228.5(b))
The values of Sa used for entering the design fatigue curve is multiplied by the factor KI whereK. =1.0+- .-1In.(m-l) 3S.S,for 3.Sm <S, <3rmeSm,K. =1.0/nm= 1.7n= 0.3Sm [ksi]Sn [ksi]forS >_3.m.S,for austenitic stainless steel from Table NB-3228.5 (b)-I (Reference
[14])for austenitic stainless steel from Table NB-3228.5 (b)-1 (Reference
[14])at average temperature of the metal at the critical time pointsPrimary + Secondary membrane plus bending SI RangeThe Ke factor is calculated for each SI Ranges over the 3Sm limit in the fatigue check asdocumented in Section 10.2.6.Page 79 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary
: 3) Fatigue Usage Factor (NB-3228.5&#xa9; and NB-3222.4)
For fatigue usage factor evaluation see Section 10.2.6.4) Thermal Stress Ratchet (NB-3228.5(d) and NB-3222.5)
Thermal Ratchet is considered for the locations at specific load step, where the 3SSm limit wasnot met (see Section 10.2.4 )Some of these locations are parts of the local geometric discontinuities.
The ASME Coderequirements for thermal ratcheting are considered accurately only for cylindrical shells withoutdiscontinuities.
On the other hand, the requirements for thermal ratcheting at discontinuities areconsidered to be "probably overly conservative" (Reference
[ 16], page 207).Maximum Allowable Range of Thermal Stress (NB-3222.5):
Table 10-4 determines the maximum allowable ranges of thermal stresses.
NB-3222.5 only requires the SI Range to include thermal SI Ranges. Therefore, the stressanalyses due to temperature loads only are performed at all time-points, similar to structural analysis in Section 9, with pressure
= 0. The computer output files are:min HU-ES rtch.out mm _PLPU rtch.out min LSL rtch.outmin HU-LS rtch.out mm _BCE rtch.out minSLD rtch.outminCD-El 1rtch.out mm _IA rtch.out minSLIrtch.out minCD-Ej[
Irtch.out mm _LOF-rtch.out minRTrtch.out minCD-LI
]_rtch.out mm _LOLrtch.out minTRTrtch.out minCD-LA
_rtch.out mn__LOPrtch.out The stress linearization for the transient runs is documented in the file "minpaths rtch.out".
TheSI ranges for thermal only are obtained from "minpaths-rtch(M+B).txt".
The general primary membrane stresses "Pmo" due to pressure for load step combinations listedin Table 10-3 are calculated from the general primary membrane stresses at design condition
[ ]multiplied by pressure ratios. The pressure ratio for specific load step is given byactual pressure at this load step [psig] divided by design pressure
[psig]. The higher "Pm" of twotime points is used for determination of the Allowable SI Range. The general primary membranestresses "PPm" are shown in Table 10-5 and the membrane stresses for all defined paths at designcondition are documented in ANSYS output files "minDC paths.out".
Page 80 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-5 General Membrane Stress for Critical Locations Pressure Pressure Pm [ksi] at Pm [ksi]Location Load Step [psia] Ratio 2250 psia PPath5 (inside)Path7 (inside)Path7A (inside)Path8 (inside)Path8 (outside)
Path8A (inside)Path10 (inside)Path10(outside)
-3Table 10-6 Allowable Ranges of Thermal StressesWhere:x = maximum general membrane stress due to pressure
("Pm") divided by the max(Sy, 1.5*Sm).y'=l/x for 0<x<0.5 and y'=4(1-x) for 0_<x_<0.5 Allowable SI Range = y'. max(l.5Sm, Sy)1 Sm and Sy from Section 5.1 are conservatively taken at 6801F.Page 81 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary The maximum SI Ranges of thermal stresses are less than the allowable stresses; therefore therequirement has been met.5) Temperature Limits (NB-3228.5(e))
The maximum temperature of the components is 680'F which does not exceed the maximumallowable temperatures listed in Table NB-3228.5(b)-l, Reference
[14].Therefore, the ASME Code requirement is met.6) Minimum Strength Ratio (NB-3228.5(i))
The material shall have specified minimum yield strength to specified minimum tensile strengthratio of less then 0.80. The Sy and Su values a[ -]are listed in Section 5.1.Table 10-7 Minimum Strength RatioLocation Material Minimum Sy Minimum Su SyISuat 70&deg;F [ksil at 70&deg;F [ksi]Path5 inside, Path7 insidePath7A insidePath8 insidePath8A outsidePath 10 insidePath 10 outsidePath8 outsideAll materials above have specified minimum yield strength to specified minimum tensilestrength ratio less then 0.80, therefore the ASME Code requirement is met.10.2.6 Fatigue Usage Factor Calculation For consideration of fatigue usage, the Peak Stress Intensity Ranges are calculated.
These valuesmust include the total localized stresses.
The fatigue usage factor at a location is usually calculated based on the actual stress intensity range. However, at a geometric or material discontinuity, an unrealistic peak stress may resultfrom the modeling
: approach, element type and mesh sizes. The total stress obtained from thefinite element analysis may not be able to capture the actual stress condition.
To account for thepossible modeling inaccuracies, an FSRF is usually applied to the M+B stress intensity range forlocation experiencing the geometric discontinuity.
The following pages contain the calculation of the cumulative fatigue usage factor for thelimiting points. The calculation is performed for all materials (except the head material, since thehead is not affected by the WOL). The critical locations are listed in Table 10-8. These locations envelop the remaining paths.* Page 82 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary The stress category used in fatigue evaluation, along with an appropriate FSRF, for each node islisted in Table 10-8. Due to the geometric discontinuities at the outside nodes of Path2, 10 andinside node of Path4A, M+B stress intensities are used with FSRF for fatigue evaluation.
Aconservative FSRF of is chosen based on Reference
[17], page 395.Table 10-8 Stress Category and FSRF in Fatigue Evaluation Location Material Stress Category FSRFPath2 outside node SA-508 M+B 2Path4A inside node Alloy 600 M+B 2Path7 inside node SA-1 82 Total 1Path8A inside node SA-213 Total 1Path9B outside node Alloy 690 Total 1Path10 outside node SA-376 M+B 2The load cases of all transients are combined for the maximum SI range. The number of cyclesof the appropriate transient is used in the fatigue usage factor calculation.
When combining withother transients, the number of cycles of this transient may be reduced accordingly.
All transient combinations with SI Ranges contributing to the fatigue usage factor are included in thefollowing tables. Fatigue curves in the following calculation are defined in Figures 1-9.2.1 and I-9.2.2 of Reference
[14] for WOL material and Figures N-415(A) and N-415(B) of Reference
[6]and [7] for existing materials as specified in Reference
[1].The Inadvertent Auxiliary Spray transient consists of two cycles (see Figure 8-18); therefore, forthe fatigue calculations the transient is splitted into two separate transients "IAl" and "IA2" withthe same number of cycles o0[ ]Transient "IAI" is between time-poin[
.]Transient "IA2" is betweei[.. ....The stress intensities due to external loads, as calculated in Section 6.1.2 , are added to thetransients SI Ranges where applicable.
As already discussed in Section 10.2.2 , the maximum SIdue to external loads are given by the load combination:
OBE+Thermal Loads. Therefore, thestress intensity due to this combination is conservatively added to the maximum SI Ranges forthe firsi[ jcycles[
]cycles is specified for OBE anc[ ]cycles for thermal externalloads), unless otherwise noted. The notes below the tables with fatigue usage calculations provide detailed description of the used stresses and cycles of the external loads.The SI Ranges used for the fatigue calculation are documented in the file "minpaths(M+B).txt" for membrane
+ bending stresses and in the file "minpaths(Total)
.txt" for total stresses.
Page 83 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-9 Nozzle Usage FactorEVALUATION TITLE: Diablo Canyon, Path2 outsideTotal Fatigue Usage Factor =The Peak SI Range = 'M+B' x Fatigue Strength Reduction Factor (FSRF) x Ke FactorFor Range 1, 'M+B' SI Range = ksi FSRF = Ke =For Range 2. 'MB' SI Range = ksi FSRF = Ke =For Range 3, 'M+B' SI Range = ksl FSRF = Ke =For Range 4, 'M+B' SI Range = kSl FSRF = Ke =For Range 5, 'M+B' SI Range = ksl FSRF = Ke =For Range 6. 'M+B' SI Range = ksi FSRF Ke =For Range 7. 'M+B' SI Range = ksl FSRF Ke =For Range 8. 'M+B' SI Range = ksl FSRF Ke =For Range 9,'M+B' SI Range = ksi FSRF Ke =For Range 10, 'M+B' Si Range = ksi FSRF Ke =For Range 11. 'M+B' SI Range = ksi FSRF Ke =For Ranae 12. 'M+B' SI Ranqe = ksl FSRF Ke =IUsage If] 1.0. Therefore, the--ASME Code requirement is1The maximum temperature occurring during the plant operation ifis conservatively used.]lhe Young's modulus 'Emat' 42 Internal cyclesSI ol ]due to external loads (OBE+Th) is conservatively added to the highest SI Ranges for the first eightcombinations, which consisf "]cycles.
Page 84 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-10 DM Weld Usage FactorEVALUATION TITLE: Diablo Canyon, Path4A inside
 
==REFERENCE:==
 
min_paths(M+B).txt TYPE:UTS (ksi)= at T E curve (psi) { ;Emnat (psi) = al I E ratio = EcurvelEmnat RAGE TRANSIENTS REQ'D EKS (Eratio) x ALLOWABLE USAGEWITH RANGE E mat S alt FACTORNUM,1 ETEE CYCLES IANG Salt CYCLES'N' UTotal Fatigue Usage Factor = [IThe Peak SI Range = 'M+B' x Fatigue Strength Reduction Factor (FSRF) x Ke FactorFor Range 1, 'M+B1 SI Range = ksl FSRF = Ke =For Range 2. 'M+B' SI Range = ksl FSRF = Ke =For Range 3, 'M+B' SI Range = ksl FSRF = Ke =For Range 4. 'M+B' SI Range = ksl FSRF = Ke =For Range 5. 'M+B' SI Range = ksi FSRF = Ke =For Range 6, 'M+B' SI Range = ksl FSRF = Ke =For Range 7. 'M+B' SI Range = ksl FSRF = Ke =For Range 8, 'M+B' SI Range = ksl FSRF = Ke =For Range S. 'M+B' SI Range = ksl FSRF Ke -Usage fy 1.0. Therefore, the ASME Code requirement is met.'The maximum temperature occurring during the plant operation ifis conservatively used.I The Young's modulus 'Emat' a[I2 Internal cycles3 The external loads do not act during the spray actuations.
4 SI o lue to external loads (OBE+Th) is conservatively added to the highest SI Ranges for the first sixaxium co iations, which consisf Jcycles.Page 85 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-11 Safe End Usage FactorEVALUATION TITLE: Diablo Canyon, Path7 inside
 
==REFERENCE:==
 
MATERIAL:
TYPE:UTS (ksi) =Emat ()sil =min-paths(Total).txt I ,]1TRANSIENTS RANGE WITH RANGEEXTREMESTotal Fatigue Usage Factor = [The Peak SI Range = Total' x Fatigue Strength Reduction Factor (FSRF) x Ke FactorFor Range 1, Total SI Range =ksl FSRF Ke=For Range 2, 'Total' SI Range = ksl FSRF Ke =For Range 3, 'Total' SI Range = ksl FSRF Ke =For Range 4. 'Total' SI Range = ksl FSRF Ke =For Range 5. 'Total' SI Range = ksl FSRF Ke =For Range 6. 'Total' SI Range = ksl FSRF Ke =For Range 7, 'Total' SI Range = ksl FSRF KeG =For Range 8. 'Total' SI Range = ksl FSRF Ke6 =Fo Rng 8 "otl'SIRage=
slFSF__Ke Usage f 1: 1.0. Therefore, the ASME Code requirement is met.' The maximum temperature occurring during the plant operation if .Jrhe Young's modulus 'Emat' a[is conservatively used.2 Internal Cycles3 The external loads do not act during the spray actuations.
4 The Young's modulus 'Emat' is taken at average metal temperature for this combination (see Table 10-12).SI ot Iue to external loads (OBE+Th) is conservatively added to the highest SI Ranges for the first fourcombinations, which consist[
Jzycles.6 Sm value for Ke factor calculation is taken at average temperature for this calculation (see Table 10-12).Page 86 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-12 E and Sm at Average Temperature for Table 10-11 Fatigue Evaluation
[IF] Tavg [psi]Page 87 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-13 Safe End to Pipe Weld Usage FactorEVALUATION TITLE: Diablo Canyon, Path8A inside
 
==REFERENCE:==
 
mn paths(Total).txt MATERIAL:
TYPE:UTS (ksi)= ] atT E curve (psi) [Emat (psi) =at T E ratio = Ecurve/Emat RANGE WT RANGE REQ'D PEAK SI E mat S alt (Eratlo) x ALLOWABLE FACTORNU. WTHRANSIN:
USAESGEO LNUM. EXTREMES CYCLES RANGE Salt CYCLES 'NTotal Fatigue Usage Factor =The Peak SI Range = 'Total' x Fatigue Strength Reduction Factor (FSRF) x Ke FactorFor Range 1. 'Total' SI Range = ksl FSRF= Ke5For Range 2, 'Totar Sl Range = ksl FSRF= Ke5For Range 3, "Total' SI Range = ksl FSRF= KeesFor Range 4, 'Total' SI Range = ksl FSRF= KeFor Range 5. 'Total' Sl Range = ksi FSRF KesFor Range 6, 'Total' Sl Range = ksl FSRF KeFor Range 7, 'Total' SI Range = ksi FSRF Ke]< 1.0. Therefore, the ASME Code requirement is met.Usage I[1 The maximum temperature occurring during the plant operation if, ]The Young's modulus 'Emat' a[is conservatively used.2 Internal cycles3 The external loads do not act during the spray actuations.
4 SI o[ ]lue to external loads (OBE+Th) is conservatively added for the first four maximum ranges, whichconsisi }ycles.5Ke factor using Sm I IIPage 88 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-14 Weld Overlay Usage FactorEVALUATION TITLE: Diablo Canyon, Path9B outside
 
==REFERENCE:==
 
minpaths(Total).txt MATERIAL:
[ ]TYPE: ]UTS (ksi) ] at T { E curve (psi) {Emat si= ) atT E ratio = Ecurve/Emat RANGE TRANSIENTS REQ'D PEAK (Eratlo) x ALLOWABLE USAGENUM WITH RANGE CYCLES RANGE mat alt tU'EXTREMES 40 years Salt CYCLES IN' F.Total Fatigue Usage Factor =The Peak SI Range = Total' x Fatigue Strength Reduction Factor (FSRF) x Ke FactorFor Range 1, "rotal' SI Range = ksl FSRF KeFor Range 2. 'Totae SI Range = ksl FSRF KeFor Range 3, 'Totae SI Range = ksl FSRF KeFor Range 4, 'Total' SI Range = ksl FSRF KeFor Range 5. 'Totae SI Range = ksl FSRF KeFor Range 6, 'Total SI Range = ksl FSRF KeFor Range 7. 'Totar SI Range = ksl FSRF KeFor Range 8, 'Totar SI Range = ksl FSRF KeFor Range 8. "Totar SI Range = ksl FSRF KeFor Range 10, 'Total' SI Range = ksl FSRF[ KeUsage i[]1 1.0. Therefore, the ASME Code requirement is met.1The maximum temperature occurring during the plant operation if,is conservatively used.]The Young's modulus "Emat' a[I2 Internal cycles3 The external loads do not act during the spray actuations.
4 SI of[ itue to external loads (OBE+Th) is conservatively added to the maximum SI Ranges for first sixcombinations, which consist fron[ I cycles.Page 89 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table 10-15 Pipe Usage FactorEVALUATION TITLE: Diablo Canyon, Path10 outside
 
==REFERENCE:==
 
mirnpaths(M+B TMATERIAL:
TYPE:UTS (ksi) atT E curve (psi) ]Emat (psi) at T E ratio = Ecurve/Emat TRANSIENTS USAGERANGE WITH RANGE REQ'D PEAK S E
* mat S alt (Erat!o) x ALLOWABLE FACTORNUM. EXTREMES CYCLES RANGE Salt CYCLES 'N UTotal Fatigue Usage Factor = LmThe Peak SI Range = 'M+B' x Fatigue Strength Reduction Factor (FSRF) x Ke FactorFor Range 1. 'M+B' SI Range = ksl FSRF Ke' =For Range 2. 'M+B' SI Range = ksl FSRF KeS =For Range 3. 'M+B' SI Range = ksi FSRF Kes =For Range 4, 'M+B' SI Range = ksl FSRF Ke =For Range 5, 'M+B' SI Range = ksl FSRF Ke =For Range 6. 'M+B' SI Range = ksl FSRF Ke =For Range 7. 'M+B' SI Range = ksl FSRF Ke =For Range 8, 'M+B' SI Range = ksl FSRF Ke =For Range 9. 'M+B' SI Range = ksl FSRF Ke =For Range 10. 'M+B' SI Range = ksl FSRF Ke =For Range 11. 'M+B'SI Range = ksl FSRF Ke =Usage = 0.383 < 1.0. Therefore, the ASME Code requirement is met.1 The maximum temperature occurring during the plant operation i[is conservatively used.2 Internal cycles.I The Young's modulus 'Emat' a[3 The external loads do not act during the spray actuations.
4sIo[ )ue to external loads (OBE+Th) is conservatively added in f 400 cycles.]5 Ke factor using Sm{ ]Page 90 Controlled DocumentAAREVADocument No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 11 RESULTS SUMMARYICONSLUSION Stress analyses of the spray nozzle weld overlay repairs for Diablo Canyon Unit 2 Pressurizer aresummarized in this report. Minimum overlay configuration is investigated.
The analysesdemonstrate that the weld overlay designs satisfy the stress and fatigue requirements of theASME Code (Reference
[14]).The summary of the maximum primary+secondary membrane plus bending stress intensity ranges and fatigue usage factor are listed in Table 11-1 for each component.
The cumulative fatigue usage factors at critical locations investigated are less than 1.0, with the highest usagefactor beind ]Mhe fatigue evaluation is based on the spray nozzle design transient, and forthe specified number of cycles per Reference
[2].In conclusion, the spray nozzle with weld overlay satisfies the ASME Code primary plussecondary stress requirements as well as criteria against the fatigue failure.
The primary stresscriteria are satisfied as described in Section 10.1.Table 11-1 Summary of ResultsMax. Sl Range PL+Pb+Q Fatigue Usage FactorComponent Material Primary Calculated Limitsi Calculated Limit IR [alclate
[Limi IR[ksi] [ksi] [ksil [ksi]Nozzle 80.1 1.0DM Weld 69.9 1.0Safe End See 41.1 1.0Safe End to Section 4Pipe Weld 10.1 45.6 1.0Pipe 49.2 1.0Weld 69.9 1.0OverlayPage 91 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 12 SOFTWARE VERIFICATION The finite element analyses documented in this report were performed using ANSYS vl l.0software (Reference
[13]). The suitability and accuracy of use of ANSYS v 1.0 was verified byperforming the following verification runs.Table 12-1 ANSYS Verification FilesFile Name Date Element TypeVM21 I.OUT 5/31/2007 PLANE183 2-D 8-Node Structural SolidVM1 12.OUT 5/31/2007 PLANE77 2-D 8-Node Thermal SolidVM21 I.OUT 5/31/2007 CONTA172 2-D 3-Node Surface-to-Surface ContactVM211.OUT 5/31/2007 TARGE169 2-D Target SegmentThe Stress Intensity Range calculations, documented in this report, are performed using StressRange v2.0 program.
The suitability and accuracy of the StressRange v2.0 are verified bycomparing the calculated SI ranges listed in the files "SRangeverif(M+B).txt" and"SRangeqverif(Total).txt" with Tables L3 and L4 in Reference
[15].Table 12-2 StressRange Program v2.0 Verification FilesFile Name Date Description S6/05/2007 StressRange Program verification file for M+BSRangeverif(M+B)txt 7 SI ranges including ZSSSlRange&#xfd;verifotal).txt 6/05/2007 StressRange Program verification file for TotalSangv_ (Total)_____
txtI6_05/2007 SI ranges including ZSSPage 92 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 13 COMPUTER OUTPUT FILESTable 13-1 Computer Output and Input FilesFile Name Date Description mingeo.mac 5/29/2007 Input file to develop geometry of the spray nozzlemingeo.out 5/29/2007 Output file to develop geometry of the spray nozzlemin dT.mac 5/18/2007 Input file defining nodes for temperature and thermal gradientevaluation Output file contains path definition for stress component andmin_paths.out 5/30/2007 contains the linearized stresses along the paths for alltransients Output file for thermal ratchet analysis contains path definition minpathsjrtch.out 5130/2007 for stress component and contains the linearized stressesalong the paths for all transients Fatigue Stress Rangemin.paths(M+B).txt 5/30/2007 SI Ranges (M+B) for combination of all transients minpaths(Total).txt 5/30/2007 SI Ranges (Total) for combination of all transients minjpaths(M+B-ThBend).txt 5/30/2007 SI Ranges (M+B) excluding thermal bending for combination of all transients min~paths rtch(M+B).tt 5/30/2007 SI Ranges (M+B) with pressure
= 0 for combination of alltransients Design Condition minDC.out 5/29/2007 Output file for stress analysisminDC_paths.out 5/30/2007 Output file contains stress components along the pathsHeat-up Transients HU-ES.tr.inp 5/17/2007 Input file contains definition of heat-up early spray transient min_HU-ESth.out 5129/2007 Output file for thermal analysisminHU-ESdt.out 5/29/2007 Output file contains thermal gradients min_HU-ESst.out 5/29/2007 Output file for the stress analysismin_HU-ESrtch.out 5/29/2007 Output file for the thermal ratcheting calculation HU-LS-tr.inp 5/17/2007 Input file contains definition of heat-up late spray transient minHU-LS th.out 5/29/2007 Output file for thermal analysisminHU-LS dt.out 5/29/2007 Output file contains thermal gradients minHU-LS st.out 5/29/2007 Output file for the stress analysismin HU-LS rtch.out 5129/2007 Output file for the thermal ratcheting calculation Cool-down Transients CD-Ea. u'-inp 5/17/2007 Input file contains definition of cool-down early spray transient with drop in a temperature of Imin _CD-Ej ,]th.out 5/29/2007 Output file for thermal analysisPage 93 Controlled DocumentAARE VA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary min-CD-Ef ldt.out5/29/2007 Output file contains thermal gradients st.out 5/29/2007 Output file for the stress analysismin CD-El _]rtch.out 5/29/2007 Output file for the thermal ratcheting calculation 5/17/2007 Input file contains definition oj cool-cwn late spray transient CD-L ]tr.inp 5117 with drop in a temperature ol.minCD-El
,th.out 5/29/2007 Output file for thermal analysisminME dt.out 5/29/2007 Output file contains thermal gradients minCD-E st.out 5/29/2007 Output file for the stress analysisminCD-Efl rtch.out 5/29/2007 Output file for the thermal ratcheting calculation 57/2007 Input file contains definition of cool-down early spray transient CD-E tr.inp 5/with drop in a temperature of Imin _CD-Etlth.out 5/29/2007 Output file for thermal analysismin CD-E, --ot.out 5129/2007 Output file contains thermal gradients min _CD-E[ ]st.out 5/29/2007 Output file for the stress analysismin _CD-E1 .rtch.out 5/29/2007 Output file for the thermal ratcheting calculation CD-Lj --Itr.inp 5/17/2007 Input file contains definition of cool-down late spray transient with drop in a temperature of. IminCD-L h.out 5/29/2007 Output file for thermal analysisminCD-: __dt.out 5/29/2007 Output file contains thermal gradients minCD-LI-t.out 5/29/2007 Output file for the stress analysisminCD-Lj
-jtch.out 5/29/2007 Output file for the thermal ratcheting calculation Plant Loading & Plant Unloading Transient PLPU tr.inp 5/17/2007 Input file contains definition of plant loading and unloading Ptr____np__5/1712007__transient minPLPU th.out 5/29/2007 Output file for thermal analysisminPLPUdt.out 5/29/2007 Output file contains thermal gradients min_PLPU_st.out 5/29/2007 Output file for the stress analysisminPLPU.rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Step Load Decrease Transient SLD tr.inp 5/17/2007 Input file contains definition of 10% step load decrease-ptransient min SLD th.out 5/29/2007 Output file for thermal analysisminSLDdt.out 5/29/2007 Output file contains thermal gradients min _SLDst.out 5/29/2007 Output file for the stress analysismin SLD rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Step Load Increase Transient SLI.r.inp 5/17/2007 Input file contains definition of 10% step load increasetransient min SLI th.out 5/29/2007 Output file for thermal analysismin SLI dt.out 5/29/2007 Output file contains thermal gradients minSLIst.out 5/29/2007 Output file for the stress analysisminSLI rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Page 94 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Large Step Load Transient LSL tr.inp 5/17/2007 Input file contains definition of large step load transient minLSLth.out 5/29/2007 Output file for thermal analysisminLSL dt.out 5/29/2007 Output file contains thermal gradients minLSL st.out 5/29/2007 Output file for the stress analysismin LSL rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Boron Concentration Equalization BCEtr.inp 5/17/2007 Input file contains definition of boron concentration equalization transient minBCE th.out 5/29/2007 Output file for thermal analysisminBCE dt.out 5/29/2007 Output file contains thermal gradients minBCE st.out 5129/2007 Output file for the stress analysismin BCE rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Loss of LoadLOL tr.inp 5/17/2007 Input file contains definition of loss of load transient minLOL th.out 5/29/2007 Output file for thermal analysisminLOLdt.out 5/29/2007 Output file contains thermal gradients minLOL stout 5129/2007 Output file for the stress analysisminLOL rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Loss of PowerLOP tr.inp 5/17/2007 Input file contains definition of loss of power transient min LOP th.out 5/2912007 Output file for thermal analysismin-LOP dt.out 5/29/2007 Output file contains thermal gradients min _LOPst.out 5/29/2007 Output file for the stress analysismin LOP rtch.out
.5/29/2007 Output file for the thermal ratcheting calculation Loss of FlowLOF tr.inp 5/17/2007 Input file contains definition of loss of flow transient min LOF th.out 5129/2007 Output file for thermal analysismin LOF dt.out 5/29/2007 Output file contains thermal gradients min LOF st.out 5/29/2007 Output file for the stress analysismin _LOFrtch.out 5/29/2007 Output file for the thermal ratcheting calculation Reactor TripRTtr.inp 5/17/2007 Input file contains definition of reactor trip transient min RT th.out 5/29/2007 Output file for thermal analysismin RT dt.out 5/29/2007 Output file contains thermal gradients min RT st.out 5/29/2007 Output file for the stress analysismin RT rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Turbine Roll TestTRT.tr.inp 5/17/2007 Input file contains definition of turbine roll test transient minTRTth.out 5/29/2007 Output file for thermal analysisIPage 95 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary minTRT dt.out 5/2912007 Output file contains thermal gradients min TRT st.out 5/29/2007 Output file for the stress analysismin _TRTrtch.out 5129/2007 Output file for the thermal ratcheting calculation Inadvertent Auxiliary Spray Actuation IA tr.inp 5/17/2007 Input file contains definition of inadvertent auxiliary sprayactuation transient min IA th.out 5/29/2007 Output file for thermal analysismin IA dt.out 5/29/2007 Output file contains thermal gradients min IA st.out 5/29/2007 Output file for the stress analysismin IA rtch.out 5/29/2007 Output file for the thermal ratcheting calculation Appendix A: Fracture Mechanics ResultsFile Name Date Description minjath fr.mac 5/31/2007 Input file contains path definition for stresscomponent along the paths for all transients Fr PathLocs.out 5/31/2007 Output file contains the path point distances fromthe inside nodeHU-ESfrSY HU-ESfrSZ HU-LS ftSY HU-LSftSZ CD-E ]frSY CD-E I fr SzCD-L ,. SY CD-L r SZCD-E _ SY CD-E --- Ifr SZCD-L_ I -SY CD-L iJfr SZPLPUftSY PLPUfrSZLSL.frSY LSLfrSZSLIfrSY SLI_frSZ 5/31/2007 Stress results for fracture mechanics SLD.frSY SLD_frSZBCE_ fSY BCEfrSZLOL frSY LOL_frSZLOPfrSY LOP._fSZLOF fr SY LOF SZRT-frSY RT-frSZIA__frSY IAfSZTRT fr SY TRT fr SZHU-ES ft TH SLD THHU-LS_frTH BCE fti THCD-E -rTH LOL_frTHJ- TH LOP ft_ THCD-EL. "r TH LOF ft TH 5/31/2007 Output file contains temperature results for... fracture mechanics CD-Lj hfrTH RT frTHPLPU_frTH IA_frTHLSL fr TH TRT fr THSLI-ft THPage 96 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary 14 REFERENCE
[1] ARENVA Document OS-9042937-003.
"Certified Design Specification for Pressumizer Nozzle Weld Overlays at Pacific Gas and Electric Diablo Canyon Nuclear Power Plant,Unit 2"[2] AREVA Document 3S-9046469-002, "Design Input Transmittal, Non-Proprietary, DIT-A0675765-03-00"
[3] AREVA Document 3S-2200488-002, "Design Input Transmittal, Proprietary, DIT -A0675765-04-00, 01 & 03"[4] AREVA Documnent 51-9048271-000, "Diablo Canyon 2 PWOL Design Transients"
[5] "ASME Boiler and Pressure Vessel Code", Section II, Part D -Properties, 2001 Editionincluding Addenda through 2003[6] "ASME Boiler and Pressure Vessel Code", Section III. 1965 Edition including Addendathrough Sumnmer 1966[7] "ASME Boiler and Pressure Vessel Code", Section II, 1965 Edition including Addendathrough Winter 1967[8] "ASME Boiler and Pressure Vessel Code", Section 111, 1968 Edition including Addendathrough Winter 1969[9] "ASME Boiler and Pressure Vessel Code". Section 111, 1971 Edition[10] AREVA Document NPGD-TM-500 rev D. "NPGMAT",
NPGD Material Properties
: Program, User's Manual (03/1985)
[11] AREVA Drawing 02-8019233D-001.
"Diablo Canyon Pressurizer Spray Nozzle WeldOverly Design Input"[12] AREVA Drawing 02-8018400C-002.
"Diablo Canyon Unit 2 Pressurizer Spray NozzleExisting Configuration"
[13] "ANSYS" Finite Element Computer Code, Version 11.0, ANSYS, Inc., Canonsburg.
Pa.[14] "ASME Boiler and Pressure Vessel Code", Section III, Division 1, 2001 Edition including Addenda through 2003[15] AREVA Document 32-5032987-03, "StressRange Program Verification"
[16] "Companion Guide to the ASME Boiler & Pressure Vessel Code", Volume 1, ASMEPress, New York, 2002[17] John F. Harvey, "Theory and Design of Pressure Vessels",
Second Edition, Van NostranReinhold.
1991[18] "ANSYS" Finite Element Computer Code, Version 14.0, ANSYS, Inc., Canonsburg, PA[19] AREVA Document 38-9200149-001, "DCPP Unit 2 Pressurizer Nozzle NDE Data"Page 97 Controlled DocumentAA R EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary APPENDIX A- Stresses used for Fracture Mechanics AnalysisA-1 PurposeThe purpose of this Appendix is to provide supplemental stress results of the transient analysisfor fracture mechanics analysis of the Diablo Canyon Unit 2 spray nozzle weld overlay.A-2 Stress and Temperature Evaluation The ANSYS Post Processor is used to tabulate the stresses and temperatures along thepredetermined paths. The paths are shown on Figure A-I and described in Table A-1. Note thatall stresses and temperatures are tabulated from the thermal and structural runs output files listedin Section 9.For post preprocessor calculation, the definitions of these paths are contained in computer file"'min_paths_fr.mac".
Table A-1 Path Description Path Name Inside Node No. Outside Node No.FPathl 5349 1246FPath2 5199 1227FPath3 5197 1183FPath4 3765 1143Stresses along the path line are summarized at twelve points separated by an equal distance fromthe inside node to the outside node. At each point the axial (longitudinal, Sy) stress and thecorresponding temperature of the nozzle are given. The path point distances from the inside nodeare included in the output file "FrPathLocs.out".
Stress and temperature result files are included in output files with "'frSY",
"_frSZ" and"'fr TIH' in their names. They are listed in Section 13.Page 98 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Figure A-1 Paths Defined for Fracture Mechanics Evaluation Page 99 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary APPENDIX B -ADDITIONAL STRESSES USED FOR FRACTURE MECHANICS ANALYSISB.1 PurposeThe purpose of this Appendix is to provide additional stress results of the transient analysis for fracturemechanics analysis of the Diablo Canyon Unit 2 spray nozzle weld overlay.
Stress results wereevaluated for locations that are in close proximity to the indications found in the Spray Nozzle during2R17.B.1.1 Stress and Temperature Evaluation The complete finite element analysis as presented in Rev. 000 was conducted using ANSYS version11.0 on a 32-bit Windows XP machine.
Although the ANSYS results from Rev. 000 are available toextract stress and temperature results at additional path lines, ANSYS 14.0 (Reference
[18]) on a 64-bitWindows 7 machine is used for this Appendix and therefore a verification process is performed toensure all results remain valid under the later version of ANSYS and Windows.
Stress and temperature results along the paths defined in Appendix A are first re-produced and then compared with those inRev. 000. It is verified that all results between two versions of ANSYS (11.0 and 14.0) and Windows(32-bit Windows XP and 64-bit Windows 7) are identical.
Detailed ANSYS outputs are listed in SectionB.1.2.The ANSYS post-processing macro used in Appendix A is modified to define different path lines aswell as to tabulate the stresses and temperatures along the defined paths in line with the Spray NozzleNDE indications (see Reference
[19]). The paths are shown on Figure B-1 and with node numbers listedin Table B-1.The definitions of these paths are contained in computer file "minpathsfrAppB.mac".
Table B-1 Additional Paths in Appendix BPath Path N Inside Outside Intermediate Material SelectedNo. Node No. Node No. Node No.1 FLinel 5104 3271 none Nozzle, WOL2 FLine2 1265 1257 1194, 1259, 1260 Nozzle, WOL3 FL2_wol 1265 1257 1194, 1259, 1260 WOL only4 FL2_noz 1265 1257 1194, 1259, 1260 Nozzle only5 FLine3 3721 3175 none Safe end, SS weld, WOL6 FLine4 1145 1141 none SS weld, WOL7 FL4_wol 1145 1141 none WOL only8 FL4_wld 1145 1141 none SS weld onlyStresses along the path line are summarized at twelve points separated by an equal distance from theinside node to the outside node. At each point the axial (longitudinal, Sy) stress, radial stress (Sx), hoopPage 100 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary stress (Sz), shear stress (Sxy), and the corresponding temperature of the nozzle are given. The path pointdistances from the inside node are included in the output file "FrPathLocsAppB.out".
Stress (Sx, Sy, Sz and Sxy) and temperature result files are included in output files with_ frSX AppB," " fr SYAppB,"
" _frSZAppB,"
" fr Sh AppB" and " fr TH" in their names.They are listed in Section B.1.2.Page 101 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary LNotes:" Only laminar indications are found along pathfines FLine2 and Fline 4."No planar indications were found. Results along pathlines Flainel and Fline3 are provided for Information only in cases they are needed for future evaluations.
" FLine2 is path line used to sample results for evaluating laminar indication
* FL2_wol usedSWOL materialfor extracting stresses* FL2_noz used nozzle materialfor extracting stresses" FLine4 is path line used to sample results for evaluating laminor indication
" FL4_wol used SWOL materialfor extracting stresses" FL4_wld used weld materialfor extracting stresses" Details A and B show the node numbers used for defining the pothlines as discussed in Table B-iFigure B-1 Additional Paths for Fracture Mechanics Page 102 Controlled DocumentAAR EVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Typical stress contour plots at high temperature gradients are shown in Figure B-2 for the overlay region duringthe transient HU-El Ind in Figure B-3 during the transient CD[-Notes:" Only laminar ndications arefound along pothlines FLlne2 and Fline 4." No planar Indications were found. Results along pathlines verticalpathilnes providedfor Information only.Figure B-2 Stress Plots during HU-ESPage 103 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary
" Only laminar Indications arefound along pathfines FLIne2 and Fline 4." No planar Indications were found. Results along pathlines verticalpathlines pro vided for Information only.Figure B-3 Stress Plots during CD-ES[Page 104 Controlled DocumentAAR EVADocument No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary B.1.2 Computer Usage and ANSYS FilesANSYS Version 14.0 is used in this Appendix.
It was tested on the computer used for this Appendix (Computer name: SC-MJEHGTA; OS: Windows 7 with 24GB RAM) on October 14, 2013 by the preparer.
The results of thetest (as listed in ANSYS output file "VMI 12.out" and "VM21 I.out") are acceptable.
All ANSYS input/output files are collected and listed in Table B-2. ANSYS verification output files are alsolisted. All files are available in AREVA Inc. ColdStor storage \cold\General-Access\32\32-9000000\32-90491 12-002\official\.
The ColdStor installation date is 10/17/2013 for all files.Table B-2 Appendix B ANSYS filesAppendix A regenerated.
Sub-directory:
..&#xa5;App-A-benchmark File Name Date and Description Timemin_path-frout 10/08/2013 Input file contains path definition in3:54pm Appendix AFrPathLocs.out 10/08/2013 Output file contains the path point3:54pm distances from the inside nodeHU-ES fr SY HU-ES fr SZHU-LS fr SY HU-LS fr SZCD-ES[ ] fr SY CD-ES[ ]fr SZCD-LS[ ] fr-SY CD-LS[ ]frSZCD-ES J _fr SY CD-ES[ ]fr SZCD-LS[ ] _fr SY CD-LS[ ]frSZ 10/08/2013 Stress results regenerated as in AppendixPLPU fr SY PLPU fr SZ 3:54pm ALSL fr SY LSL fr SZSLI fr SY SLI fr SZSLD frSY SLD-frSZBCE fr SY BCE fr SZLOL fr SY LOL fr SZLOP fr SY LOP fr SZLOF fr SY LOF frSZRT fr SY RT fr SZIA fr SY IAfrSZTRTfrSY TRT fr SZHU-ES fr TH SLD frTHIU-LS fr TH BCE fr TH 10/08/2013 Temperature results regenerated as inD-ES3 fr TH LOL-frTH 3:54pm Appendix ACD-ES320 fr TH LOL fr THPage 105 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary CD-LS[ ] frlTH LOP fr THCD-ES[ J frTTH LOF fr THCD-LS [ _frTH RT frTHPLPU fr TH IA frTHLSL fr TH TRT fr THSLI fr THTable B-2 Appendix B ANSYS files (conti.)Appendix B results.
Sub-directory:
..&#xa5;App-BFile Name Date Description min 10/17/20 Input file contains path_au1:2p definition in Appendix B1:21pm10/17/20 Output file contains the pathFrPathLocsAppB.
out 13 point distances from the inside1:21pm nodeHU-ESjfr SYAppB HU-ES fr SZAppBHU-ESjfr SXAppB HU-ES fr-ShAppB HU-LSjfr SY_AppB HU-LS frSZAppBHU-LS fr.SXAppB HU-LS fr ShAppBCD-ES [ ] fr-SYAppB CD-ES [ ] frSZAppBCD-ES [ fr-SXAppB CD-ES [ -frShAppBCD-LS [ ] fr-SYAppB CD-LS [ ] fr SZAppBCD-LS [ fr-SXAppB CD-LS ] fr ShAppBCD-ES [ -fr-SYAppB CD-ES [ -fr SZAppBCD-ES [ ] frSXAppB CD-ES [ fr ShAppB 10/17/2013 Stress results in Appendix BCD-LS [ ] fr-SYAppB CD-LS [ ] fr SZAppB 1:21pmCD-LS [ jr-SXAppB CD-LS [ jrShAppBPLPUfrSYAppB PLPU fr.SZAppB PLPU fr SXAppB PLPUfrShAppB LSL fr SYAppB LSLfrSZAppB LSL fr.SX.AppB LSL fr ShAppBSLI fr SYAppB SLI fr SZAppBSLI fr SXAppB SLI fr ShAppBSLD frSY.AppB SLD fr SZAppBSLD fr SXAppB SLD fr ShAppBBCE-fr.SYAppB BCEfrSZAppB Page 106 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary BCE_frSXAppB BCE frShAppBLOL frSYAppB LOL fr SZAppBLOL fr SXAppB LOL fr ShAppBLOP frSYAppB LOP-frSZAppB LOP fr.SXAppB LOP fr ShAppBLOF fr SYAppB LOF fr SZAppBLOF friSX.AppB LOF frShAppBRT fr SYAppB RT fr SZAppBRT fr.SX.AppB RT fr ShAppBIA fr SYAppB IA fr SZAppBIA frSX_AppB IA fr ShAppBTRT fr SYAppB TRT fr SZAppBTRTIfr SXAppBTRT frShAppBPage 107 Controlled DocumentAAREVA Document No. 32-9219781-000 Diablo Canyon Unit 2 -Pressurizer Spray Nozzle Weld Overlay Structural Analysis
-Non Proprietary Table B-2 Appendix B ANSYS files (conti.)Appendix B results.
Sub-directory:
..&#xa5;OApp-BFile Name Date Description HU-ES-frTHAppB SLD_frTHAppB HU-LSfr_TH-AppB BCE_fr_TH-AppB CD-ES [ ] frjTHLAppB LOLfr_TH_AppB CD-LS [ fr-THAppB LOP fr THAppBCD-ES [ frjTHAppB LOF fr TH-AppB 10/17/2013 Temperature results in Appendix BC I 1:21pmCD-LS [ _frTHAppB RT-fr-TH-AppB PLPU~frTHAppB IAfr_TH_AppB LSL fr-THAppB TRT-frTHAppB SLI frTHAppBVM112. out 10/14/2013 9:28amVM211. out 10/14/2013 ANSYS verification output files9:32amPage 108}}

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