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{{#Wiki_filter:ENCLOSURE 3 Analytical Evaluation of Steam Generator B Upper Shell to Transition Cone Weld Indications 27 pages follow structuralntegrity CALCULATION FileNo.: PBCH-14Q-303 Associates, Inc. PACKAGE Project No.: PBCH-14Q PROJECT NAME: Point Beach Unit 1 Flaw Evaluation Fall 2005 Contract No.: P305817 CLIENT: Nuclear Management Company, LLC lPLANT: Point Beach Nuclear Plant CALCULATION TITLE: Steam Generator A Flaw Evaluation Project Mgr. Preparer(s)  
{{#Wiki_filter:ENCLOSURE 3 Analytical Evaluation of Steam Generator B Upper Shell to Transition Cone Weld Indications 27 pages follow
&Document Affected Pages Revision Description Approval Checker(s)
 
Revision Signature  
structuralntegrity     CALCULATION                   FileNo.: PBCH-14Q-303 Associates, Inc.             PACKAGE                   Project No.: PBCH-14Q PROJECT NAME: Point Beach Unit 1 Flaw Evaluation Fall 2005 Contract No.: P305817 CLIENT: Nuclear Management Company, LLC lPLANT: Point Beach Nuclear Plant CALCULATION TITLE: Steam Generator A Flaw Evaluation Project Mgr. Preparer(s) &
& Signatures  
Document     Affected Pages   Revision Description       Approval         Checker(s)
&Date Date 0 1-7 Initial Issue H. L. Gustin H. L. Gustin Appendices 10/28/05 10/28/05 A,B, C S. S. Tang 10/28/05 1 5 Modified Reference 5, H. L. Gustin H. L. Gustin Appendix C added e-mail reference 11/28/05 11/17/05 to Appendix C 11/2-80 J. E. Smith 11/28/05 Page 1 SI Form F2001R2a 1 INTRODUCTION The 2005 inservice inspection of steam generator A at Point Beach Nuclear Plant Unit 1 identified several indications in the transition cone to upper shell weld region of the steam generator.
Revision                                                   Signature &     Signatures &
The indications were assessed per the flaw proximity rules of ASME Boiler and Pressure Vessel Code Section XI, IWA-3300[1]. Following assessment of flaw proximity, indication dimensions were compared to the flaw acceptance standards of Section XI, IWC-3510 [1] by the plant [4]. One indication did not meet the flaw acceptance standards of Section A, IWC-35 10 [1]. It is therefore necessary to conduct a flaw evaluation per Section XI, IWB-3600 (since IWC-3600 is in preparation) for this flaw. This calculation evaluates the flaw per the guidelines of Section XI, IWB-36 10, which include acceptance criteria based on linear elastic fracture mechanics and consideration of potential flaw growth. This calculation does not apply to other flaws which may be identified, without further evaluation.
Date             Date 0               1-7             Initial Issue         H. L. Gustin       H. L. Gustin Appendices                                   10/28/05         10/28/05 A,B, C S. S. Tang 10/28/05 1               5       Modified Reference 5,         H. L. Gustin     H. L. Gustin Appendix C   added e-mail reference         11/28/05         11/17/05 to Appendix C                 11/2-80 J. E. Smith 11/28/05 Page 1 SI Form F2001R2a
Conservative assumptions have been used in this evaluation to demonstrate flaw acceptability per IWB-3610.
 
This calculation has been design reviewed in accordance with the requirements of the Structural Integrity Associates Quality Assurance Program.2 TECHNICAL APPROACH Fracture mechanics methods consistent with the requirements of ASME Section XI have been applied in this flaw evaluation.
1 INTRODUCTION The 2005 inservice inspection of steam generator A at Point Beach Nuclear Plant Unit 1 identified several indications in the transition cone to upper shell weld region of the steam generator. The indications were assessed per the flaw proximity rules of ASME Boiler and Pressure Vessel Code Section XI, IWA-3300
The acceptance criterion is that the applied stress intensity factor due to the observed flaw, with consideration of flaw growth over the remaining life of the plant, remains below the material toughness, including applicable margins from Section XI. The flaw acceptance criteria, based on applied stress intensity factor, was determined based on Paragraph IWB-3612 of ASME Section XI [1]. The material toughness for the carbon/low alloy steel steam generator shell material at operating temperature is taken to be 200 ksi-4inch, consistent with Figure A-4200-1 from ASME Section XI Appendix A for K 1 c.A safety factor of 4110 is applied, as required by IWB-3610.
[1]. Following assessment of flaw proximity, indication dimensions were compared to the flaw acceptance standards of Section XI, IWC-3510 [1] by the plant [4]. One indication did not meet the flaw acceptance standards of Section A, IWC-35 10 [1]. It is therefore necessary to conduct a flaw evaluation per Section XI, IWB-3600 (since IWC-3600 is in preparation) for this flaw. This calculation evaluates the flaw per the guidelines of Section XI, IWB-36 10, which include acceptance criteria based on linear elastic fracture mechanics and consideration of potential flaw growth. This calculation does not apply to other flaws which may be identified, without further evaluation. Conservative assumptions have been used in this evaluation to demonstrate flaw acceptability per IWB-3610. This calculation has been design reviewed in accordance with the requirements of the Structural Integrity Associates Quality Assurance Program.
This gives an allowable stress intensity factor of 200/h10 = 63.25 ksi-4inch.
2 TECHNICAL APPROACH Fracture mechanics methods consistent with the requirements of ASME Section XI have been applied in this flaw evaluation. The acceptance criterion is that the applied stress intensity factor due to the observed flaw, with consideration of flaw growth over the remaining life of the plant, remains below the material toughness, including applicable margins from Section XI. The flaw acceptance criteria, based on applied stress intensity factor, was determined based on Paragraph IWB-3612 of ASME Section XI [1]. The material toughness for the carbon/low alloy steel steam generator shell material at operating temperature is taken to be 200 ksi-4inch, consistent with Figure A-4200-1 from ASME Section XI Appendix A for K1 c.
The fracture mechanics analysis was performed for the unacceptable flaw.3 FLAW CHARACTERIZATION A total of 24 flaw indications were observed.
A safety factor of 4110 is applied, as required by IWB-3610. This gives an allowable stress intensity factor of 200/h10 = 63.25 ksi-4inch.
These flaws were compared to the flaw proximity rules of IWA-3300.
The fracture mechanics analysis was performed for the unacceptable flaw.
Table 1 (which is based on data in [4]) lists all 24 flaw dimensions and their locations, and summarizes the results of the proximity rule assessment.
3 FLAW CHARACTERIZATION A total of 24 flaw indications were observed. These flaws were compared to the flaw proximity rules of IWA-3300. Table 1 (which is based on data in [4]) lists all 24 flaw dimensions and their locations, and summarizes the results of the proximity rule assessment. None of the 24 indications had to be combined by the proximity rules. Plant personnel assessed all flaws to the IWC-3510 acceptance standards, and determined that only one flaw (number 19 in Table 1) required further evaluation. This flaw has length
None of the 24 indications had to be combined by the proximity rules. Plant personnel assessed all flaws to the IWC-3510 acceptance standards, and determined that only one flaw (number 19 in Table 1) required further evaluation.
= 1.75 inch, and depth = 0.22 inch. It is located 1.03 inches below the outside surface.
This flaw has length= 1.75 inch, and depth = 0.22 inch. It is located 1.03 inches below the outside surface.The observed unacceptable flaw is entirely subsurface and not exposed to any fluid chemistry.
The observed unacceptable flaw is entirely subsurface and not exposed to any fluid chemistry.
Structural Integrity File No.: PBCH-14Q-303 Revision:
Structural Integrity           File No.: PBCH-14Q-303                                     Revision: I Associates, Ind.                                                                                 Page 2
I Associates, Ind. Page 2 4 DESIGN INPUTS The as-measured wall thickness is 3.68 inches in the transition cone region (from plant UT reports [4]).The transition cone material is SA-533 Grade A, Class 2 [6] with specified yield stress = 70 ksi. The Upper Shell material has a yield stress of less than 50 ksi.From [5], the combined membrane, bending and secondary stress (PL+PB+Q) at the affected weld location is 64.7 ksi.Welding residual stresses at the flaw location are negligible since the vessel is a thick walled shell that has been stress relieved.
 
Residual stresses are steady state secondary stresses.5 ASSUMPTIONS
4 DESIGN INPUTS The as-measured wall thickness is 3.68 inches in the transition cone region (from plant UT reports [4]).
The transition cone material is SA-533 Grade A, Class 2 [6] with specified yield stress = 70 ksi. The Upper Shell material has a yield stress of less than 50 ksi.
From [5], the combined membrane, bending and secondary stress (PL+PB+Q) at the affected weld location is 64.7 ksi.
Welding residual stresses at the flaw location are negligible since the vessel is a thick walled shell that has been stress relieved. Residual stresses are steady state secondary stresses.
5   ASSUMPTIONS
: 1. To be conservative, the limiting stress value reported in Section 4.0 is used, and treated as an applied membrane stress. This is conservative because membrane stresses are more severe than bending stresses at equal magnitude.
: 1. To be conservative, the limiting stress value reported in Section 4.0 is used, and treated as an applied membrane stress. This is conservative because membrane stresses are more severe than bending stresses at equal magnitude.
: 2. The service life is assumed to be 60 years.3. The material toughness K 1 , is taken as 200 ksi- Iinch, from Section XI Appendix A [1].6 CALCULATIONS 6.1 Fracture mechanics evaluation Linear elastic fracture mechanics and fatigue flaw growth evaluations of the flaw were performed.
: 2. The service life is assumed to be 60 years.
The flaw was modeled as a subsurface semi-elliptical flaw in an infinite plate subjected to membrane and bending stress as illustrated in Figure 1. This is a common fracture mechanics model applied to subsurface flaws in thick shells. Figure 1 refers to the 1986 Edition of ASME Section XI. This is the Edition to which the SI fracture mechanics program pc-CRACK [3] was developed.
: 3. The material toughness K1 , is taken as 200 ksi- Iinch, from Section XI Appendix A [1].
However, the flaw definition in that figure remains the same in subsequent Editions of the Code, including the committed Edition and Addenda for Point Beach [1]. For this subsurface flaw model, the flaw depth is defined as 2a. Therefore, the flaw depth, a, is half of the measured flaw depth as reported in the UT reports.For the indication the flaw parameters were calculated as follows: Depth [4] 2a = 0.22 inch Length [4] 1 = 1.75 inches Aspect ratio: a/l = 0.063 a/t = 2.99%Eccentricity ratio: 2e/t = 0.38 ,Structural integrity File No.: PBCH-14Q-303 Revision:
6   CALCULATIONS 6.1     Fracture mechanics evaluation Linear elastic fracture mechanics and fatigue flaw growth evaluations of the flaw were performed. The flaw was modeled as a subsurface semi-elliptical flaw in an infinite plate subjected to membrane and bending stress as illustrated in Figure 1. This is a common fracture mechanics model applied to subsurface flaws in thick shells. Figure 1 refers to the 1986 Edition of ASME Section XI. This is the Edition to which the SI fracture mechanics program pc-CRACK [3] was developed. However, the flaw definition in that figure remains the same in subsequent Editions of the Code, including the committed Edition and Addenda for Point Beach [1]. For this subsurface flaw model, the flaw depth is defined as 2a. Therefore, the flaw depth, a, is half of the measured flaw depth as reported in the UT reports.
1 Associates, Inc. Page 3 The applied stress intensity factors for the indication above were calculated using pc-CRACK, [3]. The aspect ratio of 0.1 was used in the evaluation for the indication (limit of the model). The applied stress intensity factor Kappiied at the limiting location on the flaw face was compared to an allowable value of Kid4l 0, where KIC is the material toughness (assumed to be 200 ksi-'Iinch for the steam generator shell material at the service temperatures, from Section XI, Appendix A, Figure A-4200-1), and the factor of l 110 represents the factor of safety that is imposed by ASME Section XI, IWB-3610 for Normal and Upset conditions.
For the indication the flaw parameters were calculated as follows:
The allowable K is therefore 63.25 ksi-qinch.
Depth [4]             2a = 0.22 inch Length [4]             1= 1.75 inches Aspect ratio:           a/l = 0.063 a/t = 2.99%
As long as the applied stress intensity factor remains below the allowable value for the flaw size, the flaw remains acceptable by Section XI criteria.pc-CRACK output for the fracture mechanics analysis is contained in Appendix A.6.2 End of Life Fatigue Flaw Growth Calculation Since the indication is subsurface and therefore not wetted, the end of life flaw size due to fatigue growth was calculated using the fatigue growth curves for carbon and low alloy ferritic steels exposed to air environments, Figure A-4300-1 of Appendix A of Section XI [1]. The flaw was conservatively assumed to experience cyclic stresses corresponding to a stress range from 0 to 64.7 ksi [5]. This is conservative because the latter value corresponds to the sum of the highest reported membrane plus bending plus secondary (PL+PB+Q) stress..Fatigue growth results are contained in Appendix B.7 RESULTS OF ANALYSIS The fracture mechanics analysis shows that flaw 19 is acceptable per the criteria of ASME Section XI, IWB-3612.
Eccentricity ratio:   2e/t = 0.38
The calculated maximum stress intensity factor for the observed flaw is 40 ksi-qinch, as compared to the allowable value of 63.25 ksi-qinch, which includes required safety margins ('110) as noted in Section 2 of this calculation.
    ,Structural integrity           File No.: PBCH-14Q-303                                       Revision:   1 Associates, Inc.                                                                                   Page 3
 
The applied stress intensity factors for the indication above were calculated using pc-CRACK, [3]. The aspect ratio of 0.1 was used in the evaluation for the indication (limit of the model). The applied stress intensity factor Kappiied at the limiting location on the flaw face was compared to an allowable value of Kid4l 0, where KIC is the material toughness (assumed to be 200 ksi-'Iinch for the steam generator shell material at the service temperatures, from Section XI, Appendix A, Figure A-4200-1), and the factor of l110 represents the factor of safety that is imposed by ASME Section XI, IWB-3610 for Normal and Upset conditions. The allowable K is therefore 63.25 ksi-qinch. As long as the applied stress intensity factor remains below the allowable value for the flaw size, the flaw remains acceptable by Section XI criteria.
pc-CRACK output for the fracture mechanics analysis is contained in Appendix A.
6.2     End of Life Fatigue Flaw Growth Calculation Since the indication is subsurface and therefore not wetted, the end of life flaw size due to fatigue growth was calculated using the fatigue growth curves for carbon and low alloy ferritic steels exposed to air environments, Figure A-4300-1 of Appendix A of Section XI [1]. The flaw was conservatively assumed to experience cyclic stresses corresponding to a stress range from 0 to 64.7 ksi [5]. This is conservative because the latter value corresponds to the sum of the highest reported membrane plus bending plus secondary (PL+PB+Q) stress..
Fatigue growth results are contained in Appendix B.
7 RESULTS OF ANALYSIS The fracture mechanics analysis shows that flaw 19 is acceptable per the criteria of ASME Section XI, IWB-3612. The calculated maximum stress intensity factor for the observed flaw is 40 ksi-qinch, as compared to the allowable value of 63.25 ksi-qinch, which includes required safety margins ('110) as noted in Section 2 of this calculation.
The fatigue growth calculation demonstrates that over more than 4800 cycles from 0 to 64.7 ksi, the resulting flaw growth of the flaw remains below the allowable flaw size. Most transients experienced by the component are much less severe than this transient, and would lead to negligible growth. Therefore, growth of the flaw to an unacceptable size over the remaining life of the plant is not predicted.
The fatigue growth calculation demonstrates that over more than 4800 cycles from 0 to 64.7 ksi, the resulting flaw growth of the flaw remains below the allowable flaw size. Most transients experienced by the component are much less severe than this transient, and would lead to negligible growth. Therefore, growth of the flaw to an unacceptable size over the remaining life of the plant is not predicted.
The flaw analyzed in this calculation is more severe than are any of the flaws in this weld that were accepted under the Acceptance Standards of IWC-3510.
The flaw analyzed in this calculation is more severe than are any of the flaws in this weld that were accepted under the Acceptance Standards of IWC-3510. Therefore, although fracture mechanics evaluation of such acceptable flaws is not required, the fracture mechanics analysis in this calculation could conservatively be applied to such flaws, if necessary.
Therefore, although fracture mechanics evaluation of such acceptable flaws is not required, the fracture mechanics analysis in this calculation could conservatively be applied to such flaws, if necessary.
structuralintegrity              File No.: PBCH-14Q-303                                   Revision: 1 Associates, Inc.                                                                                 Page 4
structural integrity File No.: PBCH-14Q-303 Revision:
 
1 Associates, Inc. Page 4 8 DEGRADATION MECHANISMS The observed flaws are subsurface flaws that are remote from any surface (either the wetted inside surface or the air outside surface).
8 DEGRADATION MECHANISMS The observed flaws are subsurface flaws that are remote from any surface (either the wetted inside surface or the air outside surface). Such a flaw is therefore not a result of chemistry-driven mechanisms such as stress corrosion cracking or corrosion. These factors lead to the conclusion that the observed flaws are in fact artifacts of original fabrication, and not due to an active degradation mechanism. The evaluation of the hypothetical flaw growth by a fatigue mechanism is therefore conservative.
Such a flaw is therefore not a result of chemistry-driven mechanisms such as stress corrosion cracking or corrosion.
9   CONCLUSIONS AND DISCUSSIONS Based on the results of the evaluation presented in this calculation package, the indications found during the inservice inspection of the steam generator A transition cone weld are acceptable and meet the requirement of ASME Code, Section XI, IWB-3610 [1].
These factors lead to the conclusion that the observed flaws are in fact artifacts of original fabrication, and not due to an active degradation mechanism.
The total of all indication areas is about 5.06 in2 . The area of the steam generator weld is about 1928 in2, assuming a circumference of 524 inches [4], and a wall thickness of 3.68 inches. The transverse area reduction is less than 0.26% of the original area. This area reduction will have no significant affect on the hoop stress in the weld. Thus, the steam generator stress analysis based on ASME Boiler and Pressure Vessel Code Section III is not affected. Therefore, the requirement of IWB-3610 (d) (2) is satisfied.
The evaluation of the hypothetical flaw growth by a fatigue mechanism is therefore conservative.
9 CONCLUSIONS AND DISCUSSIONS Based on the results of the evaluation presented in this calculation package, the indications found during the inservice inspection of the steam generator A transition cone weld are acceptable and meet the requirement of ASME Code, Section XI, IWB-3610 [1].The total of all indication areas is about 5.06 in 2.The area of the steam generator weld is about 1928 in 2 , assuming a circumference of 524 inches [4], and a wall thickness of 3.68 inches. The transverse area reduction is less than 0.26% of the original area. This area reduction will have no significant affect on the hoop stress in the weld. Thus, the steam generator stress analysis based on ASME Boiler and Pressure Vessel Code Section III is not affected.
Therefore, the requirement of IWB-3610 (d) (2) is satisfied.
10 REFERENCES
10 REFERENCES
: 1. ASME Boiler and Pressure Vessel Code, Section XI, 1998 Edition with Addenda through 2000.2. Steam Generator Design Summary, E-mail from Brian Kemp (NMC) to Hal Gustin (SI), dated 10/19/05 SI File: PBCH-14Q-220
: 1. ASME Boiler and Pressure Vessel Code, Section XI, 1998 Edition with Addenda through 2000.
: 3. pc-CRACK for Windows, Version 3.1-98348, Structural Integrity Associates, 1998.4. Point Beach Ultrasonic Examination Reports, SI File: PBCH-14Q-222
: 2. Steam Generator Design Summary, E-mail from Brian Kemp (NMC) to Hal Gustin (SI), dated 10/19/05 SI File: PBCH-14Q-220
: 5. E-mail from Brian Kemp (NMC) to Hal Gustin (SI) dated 10/22/05, supplemented by e-mail from Brian Kemp (NMC) to Hal Gustin (SI) dated 11/10/05.
: 3. pc-CRACK for Windows, Version 3.1-98348, Structural Integrity Associates, 1998.
SI File: PBCH-14Q-220
: 4. Point Beach Ultrasonic Examination Reports, SI File: PBCH-14Q-222
: 6. Telecon, Russell Turner (NMC) to Hal Gustin (SI) 10/25/05 SI File: PBCH-14Q-220 Structural Integrity File No.: PBCH-14Q-303 Revision:
: 5. E-mail from Brian Kemp (NMC) to Hal Gustin (SI) dated 10/22/05, supplemented by e-mail from Brian Kemp (NMC) to Hal Gustin (SI) dated 11/10/05. SI File: PBCH-14Q-220
1^ St0 0MAAr uc^ tu ra Inte r t __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _Assocates, Inc. PageI5 CY 3 ~Ca+C 1 X* Calclated K isma5rnm ofK atpointsl l 2.* Moh del assumes that the centerof the crack ispasitionedatxVt/2 C 1  b=C + C @)f(emrane stress)= f-c ,) (?bending stress)A:.L A-I;ecd=oA-A REQUIRED INPUTS: t:; :wall thwriness:
: 6. Telecon, Russell Turner (NMC) to Hal Gustin (SI) 10/25/05 SI File: PBCH-14Q-220 Structural Integrity             File No.: PBCH-14Q-303                                     Revision: 1
a' nmamnum crackdepth (aq 3  .nhn[(f.95
^       St0 0MAAr uc^ tura Inte r t Assocates, Inc.                                                                                  PageI5
:X,- 2e/tt/2 0.325tJ)iyj rn mat lfyiEd&stres s a/:t ci ck aspei t ratiao (0. 1 S5 a/ .5 0.5)2 e/: eccentficity rati o (O :5 2ett 0<.6)I Figure 1: ASME B&PV Code Section XI Subsurface Crack Model Ed'Strucitral Integrity File No.: PBCH-14Q-303 Revision:
__   _ _ _   _ _ _   _   _ _   _ _ _   _ _ _   _ _ _   _  _   _
1>Associates, Inc. Page 6 Explanation of Tes tilized for the Resolution of Indications Slw:: NO. 1754004 x tuince &thibm r14 o iV"MfMsurf.=:o0 I: Ib upw ti Of: flaw Page o of 1 S DW- O D a<eft 11E"w wsd xu awr lo the "W tip of( be faw Thtuwan1 Ou or 4) -Flw h sFa e 4 : L=tth (1) Fbaw lenph Thieknes:68 hhe s Lmax: Raw d mreww kecallo "Waaiwd iniftchts co1w fmr veis Zer.Y_ (&AXM)AS&
 
a Y U 9 flaw fddasmGrfacYj(Y>
3 CY ~Ca+C 1 X
l0.then Y= 1l N -X S 2.: 1 Y a : AJ _ bk,?I 45 -37.25 389.50 1.7 :176 008 0U1S 1.25 100 0.06 2.61% 2.04% YES 2 45 61. 62.50 26 12 005 010 1.0 LO 0.03 239% 1t36% YES 3 4 103100 101375 246 1.08 07 014 0WS 1.00 : 0.09 .73% 1.U% E 4 i 45 109.50 110.0 3.16 40 0.06 : 0.12 I00 1 0 0.06 2.61% 1.63% YES 5 45 109.50 110.50 2.66 0.7 af0 0.15 tOO 1.00s 0.0 2.671% 204% YES 6 45 255.2 256.50 2.671 0.8 0.0 0.16 1.25 1.0 0.06 2.61% 2.17% YES 7 45 7 27 219 0.76 0.06 0 13 3.25 1.0 002 239% 1.77% YES 8 4 1278.0D 279.8w 2.45 1.06 ~0.09 0.17 .8 100 0.05 2.48% 2.31% YE 9 45 2910 2925 1.1 27 0.10 01 a9 1.00 10 0.0 28% 2.55% YES 1O 45 10O0 0 6 0.9 .1 2.75 1.00 0.0 2.43%. 231%, YS 11 45 3100 311.25 2.98 0.66 : A0 A14 1.25 10 0.06 2.61% 1.90% YES 121 45 124.25 125.2,5.1 1.81 0.08 0.16 1.00I 1.00 I0.08 2.73%1 2.17% YES 13. 45 1335.5( 33600 19 2.40 040 0A9 0.50 1 .0 0.I9 3.71l 2.58% YES 14 45 1341.38 34312 2.04 1.53 0g04 009 1,88 100 0.02 2.39% 1.22% YES 15 45 157.75 3602 2.04 1,5 0.04 0.09 250 I.00 002 2.39% 122% YPS 16 45 170.25 71.00 2. 1.21 0. 0U4 0.08 7 .0.05 % 1.OK Y WS 17 45 437.75 438.7 283 0.4 .1 02 1.00 1.00 0.11 2.98 2.5% YES is; 60 472.25 473.75 1.76 :176 0.08 016 I 0 14.0, 0.0 173% 2-17% Ms 19 45 499.K 4199.75 1.03 2431 0.11 :0.22 1.75 1.00 0.06 2.61% 2.99% NO 21 A45 4997 54.00 24 41.06 009 0617 4.25 LOO 0.02 239% .31% I ES 22: 4: A 050 5w0o6.50 1.03: 2. .0 .0M3 '243% L36% YES 23 45 317,00 5 18.00 11 244 ;0.0 0.12 1,00 1.0 0i.06 2.61O M1.63% YES 74 45 23 25 09 2.77 0.06 A0.1 O1.00 1-:006 2.61%. 11.63% YES Note: luKiktlo 20 & 21 are *1 sant ddea ltio *rvOr&d*Oitwo  
* Calclated K isma5rnm ofK atpointsl           l2.
&eetveam Reloluimn Prfore4o Ely:; i Re"utkRm 3ek ie-d By.26O0 :-2005 WELD NUMER: SG-A-4 APPENDIX A pc-CRACK OUTPUT FILES: ALLOWABLE FLAW DETERMINATION Struefintgtrity File No.: PBCH-14Q-303 I Revision:
* Moh del assumesthat the centerof the crack ispasitionedatxVt/2 A:                          A
1 as Associates, Inc.:
    .L                      -I                                                      ;ecd=oA-A C1            b
303SSF tm pc-CRACK for windows version 3 .1-98348 (c) copyright  
                                          =C       + C @)f(emrane stress)
'84 -'98 structural Integrity Associates, Inc.3315 Almaden Expressway, Suite 24 San Jose, CA 95118-1557 voice: 408-978-8200 Fax: 408-978-8964 E-mail: pccrackcstructint.com Linear Elastic Fracture Mechanics Date: Thu Oct 27 13:49:16 2005 Input Data and Results File: 303SSF.LFM Title: PBCH-14Q:
                                        =   f-c ,) (?bending stress)
Steam Generator A Flaw Evaluation Load cases: stress Coefficients Case ID Co Cl C2 C3 Type PL+PB+Q 64.7 0 0 0 coeff------Through wal wall case Depth PL+PB+Q 1 stresses for Load Cases With stress coeff-------
REQUIRED INPUTS:
0.0000 0.0400 0.0800 0.1200 0.1600 0.2000 0.2400 0.2800 0.3200 0.3600 0.4000 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 Crack Model: Elliptical subsurface cracked Plate under Membrane & Bending stresses  
t:; :wall thwriness:
a' nmamnum crackdepth (aq3 .*nhn[(f.95 :X,-   2e/tt/2 0.325tJ) iyj     rn matlfyiEd&stres s I                          a/:t ci ck aspei t ratiao (0.1 S5   a/ 0.5)
                                                                            .5 2 e/: eccentficity ratio (O:5 2ett         0<.6)
Figure 1: ASME B&PV Code Section XI Subsurface Crack Model Ed'Strucitral Integrity   File No.: PBCH-14Q-303                                         Revision: 1
>Associates,   Inc.                                                                           Page 6
 
Explanation of Tes tilized for the Resolution ofIndications Slw:: NO. 1754004 x       tuince &thibm             o r14 iV"MfMsurf.=:o0 I: Ib upw         Of: flaw ti                                Page oof 1 S D a<eft O      DW-11E"wwsd      xu awr         lo "W tip of(be faw the Thtuwan1 Ou or 4)- Flw 4 h sFa           e                       :
L=tth (1) Fbaw lenph Thieknes                                     :68 hhes Lmax: Raw d         mreww kecallo "Waaiwd iniftchts co1w               fmr veis       Zer.
Y_ (&AXM)AS&   a         U 9Y          flaw         fddasmGrfacYj(Y>           l0.then Y= 1l N           -                       X     S                 2.:     1         Y                 a:             AJ   _bk,?
I     45     -37.25 389.50       1.7   :176       008     0U1S     1.25     100       0.06   2.61% 2.04%         YES 2     45       61.     62.50   26       12       005     010     1.0       LO         0.03   239% 1t36%         YES 3     4       103100 101375 246           1.08       07     014     0WS       1.00         :
0.09       .73% 1.U%         E 4 i   45     109.50 110.0 3.16             40     0.06   :0.12     I00       1     0 0.06     2.61% 1.63%         YES 5     45     109.50 110.50 2.66         0.7       af0     0.15     tOO       1.00s0.0           2.671% 204%         YES 6     45     255.2 256.50 2.671         0.8       0.0     0.16     1.25     1.0       0.06   2.61% 2.17%         YES 7     45       7       27       219     0.76     0.06     0 13     3.25     1.0       002     239% 1.77%         YES 8     4 1278.0D 279.8w 2.45               1.06   ~0.09     0.17       .8     100       0.05   2.48% 2.31%         YE 9     45     2910 2925         1.1     27       0.10   a9 01       1.00     10         0.0     28%     2.55%     YES 1O     45     10O0       0           6           0.9       .1     2.75 1.00           0.0     2.43%. 231%,       YS 11     45     3100 311.25 2.98           0.66     : A0     A14     1.25     10         0.06   2.61%   1.90%     YES 121     45     124.25 125.2,5.1           1.81     0.08   0.16     1.00I 1.00 I0.08             2.73%1 2.17%       YES
: 13. 45     1335.5(   33600 19         2.40     040     0A9     0.50     1 .0       0.I9   3.71l 2.58%         YES 14     45 1341.38 34312         2.04     1.53     0g04     009     1,88     100       0.02   2.39%   1.22%     YES 15     45     157.75 3602       2.04     1,5       0.04   0.09     250       I.00       002     2.39%   122%       YPS 16     45     170.25     71.00 2.         1.21     0.0U4 0.08         7     .           0.05         % 1.OK       WS Y
17     45     437.75 438.7       283     0.4         .1     02       1.00     1.00       0.11   2.98     2.5%       YES is;     60     472.25 473.75       1.76   :176     0.08     016   I     0     14.0,     0.0     173% 2-17%           Ms 19     45     499.K 4199.75 1.03         2431 0.11         :0.22     1.75     1.00     0.06     2.61%   2.99%     NO 21 A45     4997     54.00 24 41.06                           009     0617     4.25     LOO       0.02     239% .31%   I       ES 22:   A4:       050     5w0o6.50 1.03:   2.                                     .0       .0M3   '243% L36%         YES 23       45     317,00 5       18.00 11     244     ;0.0     0.12     1,00     1.0       0i.06 M1.63%2.61O              YES 74     45       23       25     09       2.77     0.06   A0.1           O1.001-:006             2.61%. 11.63%     YES Note: luKiktlo       20 & 21 are *1 sant ddea ltio                   *rvOr&d*Oitwo&eetveam Reloluimn Prfore4o Ely:;                                               i Re"utkRm                 By.                                3ek                   ie-d 26O0 :-2005 WELD NUMER: SG-A-4
 
APPENDIX A pc-CRACK OUTPUT FILES: ALLOWABLE FLAW DETERMINATION Struefintgtrity   File No.: PBCH-14Q-303           I   Revision: 1 as Associates, Inc.:
 
303SSF tm pc-CRACK     for windows version 3 .1-98348 (c) copyright '84 - '98 structural Integrity Associates, Inc.
3315 Almaden Expressway, Suite 24 San Jose, CA 95118-1557 voice:   408-978-8200 Fax:     408-978-8964 E-mail: pccrackcstructint.com Linear Elastic Fracture Mechanics Date: Thu Oct 27 13:49:16 2005 Input Data and Results File: 303SSF.LFM Title: PBCH-14Q: Steam Generator A Flaw Evaluation Load cases:
stress Coefficients Case ID                         Co               Cl         C2       C3   Type PL+PB+Q                     64.7                 0           0       0   coeff
        ------ Through wal 1 stresses for Load Cases With stress coeff-------
wall          case Depth      PL+PB+Q 0.0000         64.7 0.0400         64.7 0.0800         64.7 0.1200         64.7 0.1600         64.7 0.2000         64.7 0.2400         64.7 0.2800          64.7 0.3200          64.7 0.3600          64.7 0.4000          64.7 Crack Model: Elliptical subsurface cracked Plate under Membrane & Bending stresses


==Reference:==
==Reference:==
ASME Boiler and Pressure vessel code, section XI, '86 Ed.
WARNING: The stress i ntensity factor (K) is the maxi mum of K at point 1 and K at point 2 as identi fi ed in Section XI.
Crack Parameters:
wall thickness:          3. 6800 Max. crack depth:      0. 4000 crack aspect ratio:                0.1000 Eccentricity ratio:                0.3800 Material yield strength:        70.0000 Co = Sigma(membrane)  + Sigma(bending)
Cl = -2*sigma(bending)/thickness
            -------------------- Stress Intensity Factor--------------------
Page 1
303SSF Crack        case Size    PL+PB+Q 0.0080      10.6409 0.0160      15.0576 0.0240      18.4528 0.0320      21.3202 0.0400      23.8511 0.0480      26.1433 0.0560      28.2549 0.0640      30.2239 0.0720      32.0765 0.0800      33.8319 0.0880      35. 5045 0.0960      37.1054 0.1040      38.6437 0.1120      40.1264 0.1200      41.5596 0.1280      42.9482 0.1360      44.2965 0.1440      45.6079 0.1520      46.8856 0.1600      48.1323 0.1680      49.3503 0.1760      50.5417 0.1840      51.7084 0.1920      52.8519 0.2000      53.9738 0.2080      55.0754 0.2160      56.1579 0.2240      57.2223 0.2320      58.2697 0.2400      59.3009 0.2480      60.3169 0.2560      61.3183 0.2640      62.3058 0.2720      63.2802 0.2800      64.2898 0.2880      65.3371 0.2960      66.3756 0.3040      67.4057 0.3120      68.4277 0.3200      69.4422 0.3280      70.4493 0.3360      71.4495 0.3440      72.4431 0.3520      73.4302 0.3600      74.4114 0.3680      75.3866 0.3760      76.3563 0.3840      77.3207 0.3920      78.2799 0.4000      79.2342 Material fracture toughness:
Material ID: SG Plate Depth        K1C 0.0000    63.2500 Page 2


ASME Boiler and Pressure vessel code, section XI, '86 Ed.WARNING: The stress i ntensity factor (K) is the maxi mum of K at point 1 and K at point 2 as identi fi ed in Section XI.Crack Parameters:
303SSF 1.0000    63.2500 3.0000    63.2500 4.0000    63.2500 Load combination for cri tical crack size:
wall thickness:
Load Case      scale Factor PL+PB+Q               1.00 00 Crac k      Total Si ze          K        K1C 0.00UT    10.6409        63.25 0.016    15.0576        63.25 0.024    18.4528        63.25 0.032    21.3202        63.25 0.04    23.8511      63.25 0.048    26.1433        63.25 0.0 56    28.2549        63.25 0.064    30.2239        63.25 0.072      32.0765      63.25 0.08    33.8319      63.25 0.088      35. 5045      63.25 0.096      37.1054      63.25 0.104      38.6437      63.25 0.112    40.1264        63.25 0.12    41.5596        63.25 0.128    42.9482        63.25 0.136    44.2965       63.25 0.144    45.6079        63.25 0.152    46.8856        63.25 0.16    48.1323        63.25 0.168    49.3503        63.25 0.176      50. 5417      63.25 0.184      51.7084      63.25 0.192      52.8519      63.25 0.2    53.9738      63.25 0.208      55.0754      63.25 0.216      56.1579      63.25 0.224     57.2223      63.25 0.2 32     58.2697      63.25 0.24    59.3009      63.25 0.248      60.3169      63.25 0.2 56   61.3183        63.25 0.264    62.3058       63.25 0.272      63.2802      63.25 0.28    64.2898        63.25 0.288    65.3371        63.25 0.296    66.3756        63.25 0.304      67.4057      63.25 0.312    68.4277        63.25 0.32    69.4422        63.25 0.328      70.4493      63.25 0.336      71.4495      63.25 0.344      72.4431      63.25 0.3 52    73.4302      63.25 0.36    74.4114      63.25 0.368      75. 3866      63.25 0.376      76.3563      63.25 0.384    77.3207      63.25 0.3 92    78.2799      63.25 0.4    79.2342      63.25 Page 3
: 3. 6800 Max. crack depth: 0. 4000 crack aspect ratio: 0.1000 Eccentricity ratio: 0.3800 Material yield strength:
 
70.0000 Co = Sigma(membrane)
303SSF Critical crack size = 0.2716 End of PC-C RACK Output Page 4
+ Sigma(bending)
 
Cl = -2*sigma(bending)/thickness
Ii APPENDIX B pc-CRACK OUTPUT FILE: FATIGUE CRACK GROWTH iStructural Integrity File No.: PBCH-14Q-303           I Revision: 1 V> Associates, Inc.
--------------------
 
Stress Intensity Factor--------------------
303FCG2 tm pc-CRACK     for windows version 3 .1-98348 (C) copyright '84 - '98 Structural Integrity Associates, Inc.
Page 1 303SSF Crack case Size PL+PB+Q 0.0080 0.0160 0.0240 0.0320 0.0400 0.0480 0.0560 0.0640 0.0720 0.0800 0.0880 0.0960 0.1040 0.1120 0.1200 0.1280 0.1360 0.1440 0.1520 0.1600 0.1680 0.1760 0.1840 0.1920 0.2000 0.2080 0.2160 0.2240 0.2320 0.2400 0.2480 0.2560 0.2640 0.2720 0.2800 0.2880 0.2960 0.3040 0.3120 0.3200 0.3280 0.3360 0.3440 0.3520 0.3600 0.3680 0.3760 0.3840 0.3920 0.4000 10.6409 15.0576 18.4528 21.3202 23.8511 26.1433 28.2549 30.2239 32.0765 33.8319 35. 5045 37.1054 38.6437 40.1264 41.5596 42.9482 44.2965 45.6079 46.8856 48.1323 49.3503 50.5417 51.7084 52.8519 53.9738 55.0754 56.1579 57.2223 58.2697 59.3009 60.3169 61.3183 62.3058 63.2802 64.2898 65.3371 66.3756 67.4057 68.4277 69.4422 70.4493 71.4495 72.4431 73.4302 74.4114 75.3866 76.3563 77.3207 78.2799 79.2342 Material fracture toughness:
3315 Almaden Expressway, Suite 24 San lose, CA 95118-1557 voice: 408 -978-8200 Fax:     408-978-8964 E-mail: pccrack@structint.com Linear Elastic Fracture Mechanics Date: Thu Oct 27 13:51:18 2005 Input Data and Results File: 303FCG2.LFM Title: PBCH-14Q: steam Generator A Flaw Evaluation Load cases:
Material ID: SG Plate Depth K1C 0.0000 63.2500 Page 2 303SSF 1.0000 3.0000 4.0000 63.2500 63.2500 63.2500 Load combination for cri tical crack size: Load Case scale Factor PL+PB+Q Crac k Si ze 0.00UT 0.016 0.024 0.032 0.04 0.048 0.0 56 0.064 0.072 0.08 0.088 0.096 0.104 0.112 0.12 0.128 0.136 0.144 0.152 0.16 0.168 0.176 0.184 0.192 0.2 0.208 0.216 0.224 0.2 32 0.24 0.248 0.2 56 0.264 0.272 0.28 0.288 0.296 0.304 0.312 0.32 0.328 0.336 0.344 0.3 52 0.36 0.368 0.376 0.384 0.3 92 0.4 1.00 00 Total K 10.6409 15.0576 18.4528 21.3202 23.8511 26.1433 28.2549 30.2239 32.0765 33.8319 35. 5045 37.1054 38.6437 40.1264 41.5596 42.9482 44.2965 45.6079 46.8856 48.1323 49.3503 50. 5417 51.7084 52.8519 53.9738 55.0754 56.1579 57.2223 58.2697 59.3009 60.3169 61.3183 62.3058 63.2802 64.2898 65.3371 66.3756 67.4057 68.4277 69.4422 70.4493 71.4495 72.4431 73.4302 74.4114 75. 3866 76.3563 77.3207 78.2799 79.2342 K1C 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 63.25 Page 3 303SSF Critical crack size =0.2716 End of PC-C RACK Output Page 4 I i APPENDIX B pc-CRACK OUTPUT FILE: FATIGUE CRACK GROWTH iStructural Integrity File No.: PBCH-14Q-303 I Revision:
stress coefficients case ID                         Co             C1           C2     C3   Type PL+PB+Q                     64.7                 0           0       0   Coeff
1 V> Associates, Inc.
        ------ Through wal 1 stresses for Load cases with stress coeff-------
303FCG2 tm pc-CRACK for windows version 3 .1-98348 (C) copyright  
wall          Case Depth      PL+PB+Q 0.0000           64.7 0.0400           64.7 0.0800           64.7 0.1200           64.7 0.1600           64.7 0.2000           64.7 0.2400          64.7 0.2800          64.7 0.3200          64.7 0.3600          64.7 0.4000          64.7 crack Model: Elliptical subsurface cracked Plate under Membrane & Bending Stresses
'84 -'98 Structural Integrity Associates, Inc.3315 Almaden Expressway, Suite 24 San lose, CA 95118-1557 voice: 408 -978-8200 Fax: 408-978-8964 E-mail: pccrack@structint.com Linear Elastic Fracture Mechanics Date: Thu Oct 27 13:51:18 2005 Input Data and Results File: 303FCG2.LFM Title: PBCH-14Q:
steam Generator A Flaw Evaluation Load cases: stress coefficients case ID Co C1 C2 C3 Type PL+PB+Q 64.7 0 0 0 Coeff------Through wal wall Case Depth PL+PB+Q 1 stresses for Load cases with stress coeff-------
0.0000 0.0400 0.0800 0.1200 0.1600 0.2000 0.2400 0.2800 0.3200 0.3600 0.4000 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 64.7 crack Model: Elliptical subsurface cracked Plate under Membrane & Bending Stresses  


==Reference:==
==Reference:==
ASME Boiler and Pressure vessel code, section XI, '86 Ed.
WARNING: The stress i ntensity factor (K) is the maxi mum of K at point 1 and K at point 2 as identified in Section XI.
crack Parameters:
wall thickness:          3. 6800 Max. crack depth:        0.4000 crack aspect ratio:                0.1000 Eccentricity ratio:                0.3800 Material yield strength:          70.0000 Co = sigma(membrane) + sigma(bending)
Cl = -2 sigma(bending)/thickness
            --------------------Stress Intensity Factor--------------------
Page 1


ASME Boiler and Pressure vessel code, section XI, '86 Ed.WARNING: The stress i ntensity factor (K) is the maxi mum of K at point 1 and K at point 2 as identified in Section XI.crack Parameters:
303FCG2 crack           Case size     PL+PB+Q 0.0080       10.6409 0.0160       15.0576 0.0240       18.4528 0.0320       21.3202 0.0400       23.8511 0.0480       26.1433 0.05 60       28.2549 0.0640       30.2239 0.0720       32.0765 0.0800       33.8319 0.0880       35.5045 0.0960       37.1054 0.1040       38.6437 0.1120       40.1264 0.1200       41.5596 0.1280       42.9482 0.1360       44.2965 0.1440         45.6079 0.1520         46.8856 0.1600         48.1323 0.1680         49.3503 0.1760         50.5417 0.1840         51.7084 0.1920         52.8519 0.2000         53.9738 0.2080         55.0754 0.2160         56.1579 0.2240         57.2223 0.2320         58.2697 0.2400         59.3009 0.2480         60.3169 0.25 60       61.3183 0.2640         62.3058 0.2720         63. 2802 0.2800         64.2898 0.2880         65.3371 0.2960         66.3756 0.3040         67.4057 0.3120         68.4277 0.3200         69.4422 0.3280         70.4493 0.3360         71.4495 0.3440         72.4431 0.35 20       73.4302 0.3600         74.4114 0.3680         75.3866 0.3760         76.3563 0.3840         77.3207 0.3920         78.2799 0.4000         79.2342 crack Growth Laws:
wall thickness:
Law ID:     SG subsurface Model:   ASME section XI - ferritic steel in air environment da/dN = C
: 3. 6800 Max. crack depth: 0.4000 crack aspect ratio: 0.1000 Eccentricity ratio: 0.3800 Material yield strength:
70.0000 Co = sigma(membrane)
+ sigma(bending)
Cl = -2 sigma(bending)/thickness
--------------------
Stress Intensity Factor--------------------
Page 1 303FCG2 crack Case size PL+PB+Q 0.0080 0.0160 0.0240 0.0320 0.0400 0.0480 0.05 60 0.0640 0.0720 0.0800 0.0880 0.0960 0.1040 0.1120 0.1200 0.1280 0.1360 0.1440 0.1520 0.1600 0.1680 0.1760 0.1840 0.1920 0.2000 0.2080 0.2160 0.2240 0.2320 0.2400 0.2480 0.25 60 0.2640 0.2720 0.2800 0.2880 0.2960 0.3040 0.3120 0.3200 0.3280 0.3360 0.3440 0.35 20 0.3600 0.3680 0.3760 0.3840 0.3920 0.4000 10.6409 15.0576 18.4528 21.3202 23.8511 26.1433 28.2549 30.2239 32.0765 33.8319 35.5045 37.1054 38.6437 40.1264 41.5596 42.9482 44.2965 45.6079 46.8856 48.1323 49.3503 50.5417 51.7084 52.8519 53.9738 55.0754 56.1579 57.2223 58.2697 59.3009 60.3169 61.3183 62.3058 63. 2802 64.2898 65.3371 66.3756 67.4057 68.4277 69.4422 70.4493 71.4495 72.4431 73.4302 74.4114 75.3866 76.3563 77.3207 78.2799 79.2342 crack Growth Laws: Law ID: SG subsurface Model: ASME section XI -ferritic steel in air environment da/dN = C
* S
* S
* dKA3.07 where Page 2 I S = 25.72 * (2.R = O for R'= R for dK = Kmax -Kmin R = Kmin / Kmax 303FCG2 88 -R')A(-3.07)
* dKA3.07 where Page 2
R < 0 R >= 0 where: C = 1.99OOe-010 is for the currently selected units of: force: kip length: inch Material Fracture Toughness KIc: Material ID: SG Plate Depth KIC 0.0000 1.0000 3.0000 4.0000 63.2500 63.2500 63.2500 63.2500 Initial crack size=Max. crack size=Number of blocks=Print increment of block 0.1100 0.4000 1-= 1 Calc. Print crk. Grw.incre. incre. Law cycles/Ti me Mat.K1C Subblock fcg3O3 10000 100 100 SG subsurface SG Plate Kmax Kmin Subblock case ID scale Factor case ID scale Factor fcg3O3 P L+PB+Q 1.00 00 PL+P B+Q 0.0000 crack growth results: Total Cycles/Ti me a/thk Subblock cycles/Time DaDn Kmin DeltaK R /DaDt K max Da a Block: 100 200 300 400 500 600 700 800 900 1 100 200 300 400 500 600 700 800 900 3.98e+ 001 4.Ole+ 001 4.04e+ 001 4.07e+ 001 4.10e+ 001 4.13e+ 001 4.16e+ 001 4.19e+ 001 4.23e+ 001 0.OOe+000 0.OOe+000 0. OOe+000 0.OOe+000 0.OOe+000 0. OOe+000 0. 00e+000 0 .OOe+000 0.OOe+000 3. 98e+001 0.00 4. Ole+001 0.00 4. 04e+001 0.00 4. 07e+001 0.00 4. 10e+001 0.00 4. 13e+001 0.00 4. 16e+001 0.00 4. 19e+001 0.00 4. 23e+001 0.00 Page 3 1. 62e-005 1. 66e-005 1. 69e-005 1. 73e-005 1. 77e-005 1. 82e-005 1. 86e-005 1. 91e-005 1. 95e-005 1.62e-00 3 1.66e-00 3 1. 69e-00 3 1. 73e-00 3 1.77e-00 3 1.82e-00 3 1.86e-00 3 1.91e-00 3 1.95e-00 3 0.1116 0.1133 0.115 0.1167 0.1185 0.1203 0.1222 0.1241 0.126 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900 5000 4.26e+ 001 4.30e+ 001 4.33e+ 001 4.37e+ 001 4.40e+ 001 4.44e+ 001 4.48e+ 001 4.51e+ 001 4.55e+ 001 4.59e+ 001 4.63e+ 001 4.67e+ 001 4. 72e+ 001 4.76e+ 001 4.80e+ 001 4.85e+ 001 4.89e+ 001 4.94e+ 001 4.98e+ 001 5.03e+ 001 5.08e+ 001 5.13e+ 001 5.18e+ 001 5.24e+ 001 5.29e+ 001 5.34e+ 001 5.40e+ 001 5.46e+ 001 5.52e+ 001 S. 58e+ 001 5.64e+ 001 5.70e+ 001 5.76e+ 001 5.83e+ 001 S. 90e+ 001 5.97e+ 001 6.04e+ 001 6.lle+ 001 6.19e+ 001 6.26e+ 001 6.35e+ 001 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0 .OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0.00e+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0.OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0.OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 0. OOe+000 303 FCG2 4. 26e+001 4. 30e+001 4. 33e+001 4. 37e+001 4. 40e+001 4. 44e+001 4. 48e+001 4. 51e+001 4. 55e+001 4. 59e+001 4. 63e+001 4. 67e+001 4. 72e+001 4. 76e+001 4. 80e+001 4. 85e+001 4. 89e+001 4. 94e+001 4. 98e+001 5. 03e+001 5. 08e+001 5. 13e+001 5. 18e+001 5.24e+001 5. 29e+001 5. 34e+001 5. 40e+001 5. 46e+001 5. 52e+001 5. 58e+001 5. 64e+001 5. 70e+001 5. 76e+001 5. 83e+001 5. 90e+001 5. 97e+001 6. 04e+001 6. lle+001 6. 19e+001 6. 26e+001 6. 35e+001 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 2. OOe-005 2. 05e-005 2. lOe-005 2. 16e-005 2. 21e-005 2. 27e-005 2. 33e-005 2. 39e-005 2. 45e-005 2. 52e-005 2. 59e-005 2. 66e-005 2. 73e-005 2. 81e-005 2. 89e-005 2. 97e-005 3. 06e-005 3. 15e-005 3. 24e-005 3. 34e-005 3. 44e-005 3. 54e-005 3. 65e-005 3. 77e-005 3. 89e-005 4. Ole-005 4. 14e-005 4. 28e-005 4. 42e-005 4. 57e-005 4. 73e-005 4. 89e-005 5. 06e-005 5. 24e-005 5. 43e-005 5. 63e-005 5. 84e-005 6. 06e-005 6. 29e-005 6. 54e-005 6. 80e-005 2.OOe-00 3 2.05e-00 3 2.lOe-00 3 2.16e-00 3 2.21e-00 3 2.27e-00 3 2.33e-003 2.39e-003 2.45e-00 3 2.52e-003 2.59e-003 2.66e-00 3 2.73e-00 3 2.81e-00 3 2.89e-00 3 2.97e-00 3 3.06e-00 3 3.15e-003 3.24e-00 3 3.34e-00 3 3.44e-00 3 3.54e-00 3 3.65e-00 3 3.77e-00 3 3.89e-00 3 4.Ole-00 3 4.14e-00 3 4.28e-00 3 4.42e-00 3 4.57e-00 3 4.73e-00 3 4.89e-00 3 5.06e-00 3 5.24e-00 3 5.43e-00 3 5.63e-00 3 5.84e-00 3 6.06e-00 3 6.29e-00 3 6. 54e-00 3 6.80e-00 3 0.128 0.03 0.1301 0.04 0.1322 0.04 0.1343 0.04 0.1365 0.04 0.1388 0.04 0.1411 0.04 0.1435 0.04 0.146 0.04 0.1485 0.04 0.1511 0.04 0.1537 0.04 0.1565 0.04 0.1593 0.04 0.1622 0.04 0.1651 0.04 0.1682 0.05 0.1713 0.05 0.1746 0.05 0.1779 0.05 0.1814 0.05 0.1849 0.05 0.1886 0.05 0.1923 0.05 0.1962 0.05 0.2002 0.05 0.2044 0.06 0.2086 0.06 0.2131 0.06 0.2176 0.06 0.2224 0.06 0.2273 0.06 0.2323 0.06 0.2376 0.06 0.243 0.07 0.2486 0.07 0.2545 0.07 0.2605 0.07 0.2668 0.07 0.2734 0.07 0.2801 0.08 End of pC-CRACK Output Page 4 APPENDIX C DESIGN INPUT MEMOS (E-MAIL) FROM NMC File No.: PBCH-14Q-303 Revision:
 
1 V ~Assocatesl; 0Ilnc.
I 303FCG2 S = 25.72 * (2. 88 - R')A(-3.07)
Hal L. Gustin From: Sent: To:
R=O         for R < 0 R'= R       for R >= 0 dK = Kmax - Kmin R = Kmin / Kmax where:
C=   1.99OOe-010 is for the currently selected units of:
force: kip length: inch Material Fracture Toughness KIc:
Material ID: SG Plate Depth             KIC 0.0000       63.2500 1.0000       63.2500 3.0000       63.2500 4.0000       63.2500 Initial crack size=           0.1100 Max. crack size=               0.4000 Number of blocks=                     1 Print increment of block     -=       1 cycles        Calc. Print   crk. Grw.       Mat.
Subblock            /Ti me        incre. incre. Law             K1C fcg3O3             10000         100     100     SG subsurface   SG Plate Kmax                           Kmin Subblock                   case ID scale Factor             case ID scale Factor fcg3O3                     P L+PB+Q       1.00 00         PL+P B+Q     0.0000 crack growth results:
Total     Subblock Cycles cycles                                                      DaDn
    /Ti me   /Time           K max        Kmin     DeltaK   R     /DaDt       Da     a a/thk Block:         1 100        100 3.98e+ 001 0.OOe+000 3. 98e+001     0.00 1. 62e-005 1.62e-00 3 0.1116 0.03 200        200 4.Ole+ 001 0.OOe+000 4. Ole+001     0.00 1. 66e-005 1.66e-00 3 0.1133 0.03 300        300 4.04e+ 001 0.OOe+000 4. 04e+001    0.00 1. 69e-005 1.69e-00 3  0.115 0.03 400        400 4.07e+ 001 0.OOe+000 4. 07e+001    0.00 1. 73e-005 1.73e-00 3 0.1167 0.03 500        500 4.10e+ 001 0.OOe+000 4. 10e+001     0.00 1. 77e-005 1.77e-00 3 0.1185 0.03 600        600 4.13e+ 001 0.OOe+000 4. 13e+001     0.00 1. 82e-005 1.82e-00 3 0.1203 0.03 700        700 4.16e+ 001 0.00e+000 4. 16e+001    0.00 1. 86e-005 1.86e-00 3 0.1222 0.03 800        800 4.19e+ 001 0 .OOe+000 4. 19e+001 0.00 1. 91e-005 1.91e-00   3 0.1241 0.03 900        900 4.23e+ 001 0.OOe+000 4. 23e+001 0.00 1. 95e-005 1.95e-00     3 0.126 0.03 Page 3
 
303 FCG2 1000 1000 4.26e+ 001  0.OOe+000  4. 26e+001 0.00 2. OOe-005 2.OOe-00 3   0.128 0.03 1100 1100 4.30e+ 001  0.OOe+000  4. 30e+001 0.00 2. 05e-005 2.05e-00 3 0.1301 0.04 1200 1200 4.33e+ 001  0.OOe+000  4. 33e+001 0.00 2. lOe-005 2.lOe-00 3  0.1322 0.04 1300 1300 4.37e+ 001  0.OOe+000  4. 37e+001 0.00 2. 16e-005 2.16e-00 3  0.1343 0.04 1400 1400 4.40e+ 001  0.OOe+000  4. 40e+001 0.00 2. 21e-005 2.21e-00 3  0.1365 0.04 1500 1500 4.44e+ 001 0.OOe+000  4. 44e+001 0.00 2. 27e-005 2.27e-00 3  0.1388 0.04 1600 1600 4.48e+ 001 0.OOe+000  4. 48e+001 0.00 2. 33e-005 2.33e-003  0.1411 0.04 1700 1700 4.51e+ 001 0.OOe+000  4. 51e+001 0.00 2. 39e-005 2.39e-003  0.1435 0.04 1800 1800 4.55e+ 001 0.OOe+000  4. 55e+001 0.00 2. 45e-005 2.45e-00 3  0.146 0.04 1900 1900 4.59e+ 001 0.OOe+000  4. 59e+001 0.00 2. 52e-005 2.52e-003  0.1485 0.04 2000 2000 4.63e+ 001 0.OOe+000  4. 63e+001 0.00 2. 59e-005 2.59e-003  0.1511 0.04 2100 2100 4.67e+ 001 0.OOe+000  4. 67e+001 0.00 2. 66e-005 2.66e-00 3  0.1537 0.04 2200 2200 4. 72e+ 001 0 .OOe+000 4. 72e+001 0.00 2. 73e-005 2.73e-00 3  0.1565 0.04 2300 2300 4.76e+ 001  0.OOe+000 4. 76e+001 0.00 2. 81e-005 2.81e-00 3  0.1593 0.04 2400 2400 4.80e+ 001  0.OOe+000 4. 80e+001 0.00 2. 89e-005 2.89e-00 3  0.1622 0.04 2500 2500 4.85e+ 001  0.OOe+000 4. 85e+001 0.00 2. 97e-005 2.97e-00 3  0.1651 0.04 2600 2600 4.89e+ 001  0.OOe+000 4. 89e+001 0.00 3. 06e-005 3.06e-00 3  0.1682 0.05 2700 2700 4.94e+ 001  0.OOe+000 4. 94e+001 0.00 3. 15e-005 3.15e-003  0.1713 0.05 2800 2800 4.98e+ 001  0.00e+000 4. 98e+001 0.00 3. 24e-005 3.24e-00 3  0.1746 0.05 2900 2900 5.03e+ 001  0.OOe+000 5. 03e+001 0.00 3. 34e-005 3.34e-00 3  0.1779 0.05 3000 3000 5.08e+ 001 0.OOe+000  5. 08e+001 0.00 3. 44e-005 3.44e-00 3  0.1814 0.05 3100 3100 5.13e+ 001 0.OOe+000  5. 13e+001 0.00 3. 54e-005 3.54e-00 3  0.1849 0.05 3200 3200 5.18e+ 001 0.OOe+000  5. 18e+001 0.00 3. 65e-005 3.65e-00 3  0.1886 0.05 3300 3300 5.24e+ 001 0.OOe+000  5.24e+001 0.00 3. 77e-005 3.77e-00 3  0.1923 0.05 3400 3400 5.29e+ 001 0.OOe+000  5. 29e+001 0.00 3. 89e-005 3.89e-00 3  0.1962 0.05 3500 3500 5.34e+ 001 0.OOe+000  5. 34e+001 0.00 4. Ole-005 4.Ole-00 3  0.2002 0.05 3600 3600 5.40e+ 001 0.OOe+000  5. 40e+001 0.00 4. 14e-005 4.14e-00 3  0.2044 0.06 3700 3700 5.46e+ 001  0.OOe+000  5. 46e+001 0.00 4. 28e-005 4.28e-00 3  0.2086 0.06 3800 3800 5.52e+ 001  0.OOe+000  5. 52e+001 0.00 4. 42e-005 4.42e-00 3  0.2131 0.06 3900 3900 S.58e+ 001  0.OOe+000  5. 58e+001 0.00 4. 57e-005 4.57e-00 3  0.2176 0.06 4000 4000 5.64e+ 001  0.OOe+000  5. 64e+001 0.00 4. 73e-005 4.73e-00 3  0.2224 0.06 4100 4100 5.70e+ 001  0.OOe+000  5. 70e+001 0.00 4. 89e-005 4.89e-00 3  0.2273 0.06 4200 4200 5.76e+ 001  0.OOe+000  5. 76e+001 0.00 5. 06e-005 5.06e-00 3  0.2323 0.06 4300 4300 5.83e+ 001  0.OOe+000  5. 83e+001 0.00 5. 24e-005 5.24e-00 3  0.2376 0.06 4400 4400 S.90e+ 001  0.OOe+000  5. 90e+001 0.00 5. 43e-005 5.43e-00 3   0.243 0.07 4500 4500 5.97e+ 001  0.OOe+000  5. 97e+001 0.00 5. 63e-005 5.63e-00 3 0.2486 0.07 4600 4600 6.04e+ 001  0.OOe+000  6. 04e+001 0.00 5. 84e-005 5.84e-00 3  0.2545 0.07 4700 4700 6.lle+ 001  0.OOe+000  6. lle+001 0.00 6. 06e-005 6.06e-00 3  0.2605 0.07 4800 4800 6.19e+ 001  0.OOe+000  6. 19e+001 0.00 6. 29e-005 6.29e-00 3  0.2668 0.07 4900 4900 6.26e+ 001  0.OOe+000  6. 26e+001 0.00 6. 54e-005 6. 54e-00 3 0.2734 0.07 5000 5000 6.35e+ 001  0.OOe+000  6. 35e+001 0.00 6. 80e-005 6.80e-00 3 0.2801 0.08 End of pC-CRACK Output Page 4
 
APPENDIX C DESIGN INPUT MEMOS (E-MAIL) FROM NMC File No.: PBCH-14Q-303        Revision: 1 V ~Assocatesl; 0Ilnc.
 
Hal L. Gustin From:                Kemp, Brian [Brian.Kemp~nmcco.com]
Sent:                Saturday, October 22, 2005 11:08 AM To:                 Kemp, Brian; Hal L. Gustin


==Subject:==
==Subject:==
Kemp, Brian [Brian.Kemp~nmcco.com]
Additional PBNP Design Input
Saturday, October 22, 2005 11:08 AM Kemp, Brian; Hal L. Gustin Additional PBNP Design Input Hal, The following information should be used as a design input for the UlR29 SG structural evaluation that SIA is performing.
: Hal, The following information should be used as a design input for the UlR29 SG structural evaluation that SIA is performing.
This information is an exerpt from the Westinghouse Report titled "PBNP Power Uprate Project NSSS Engineering Report Volume 1." The PBNP Unit 1 Steam Generators (Westinghouse Model 44F) calculated stress for normal and abnormal conditions (PL+PB+Q) in the flaw region (upper shell to upper head weld) is 64.7 ksi.Brian Kemp 1 Page 1 of 1 Hal L. Gustin From: Kemp, Brian [Brian.Kemp~nmcco.com]
This information is an exerpt from the Westinghouse Report titled "PBNP Power Uprate Project NSSS Engineering Report Volume 1."
Sent: Thursday, November 10, 2005 9:21 AM To: Hal L. Gustin Cc: Turner, Russell Attachments:
The PBNP Unit 1 Steam Generators (Westinghouse Model 44F) calculated stress for normal and abnormal conditions (PL+PB+Q) in the flaw region (upper shell to upper head weld) is 64.7 ksi.
design paramters rl.doc Hal, As described in my email to you (dated October 22, 2005), the calculated stress for normal and abnormal conditions (PL+PB+Q) that should be used in the SIA analysis for the PBNP-1 SG flaw region (upper shell to upper head weld) is 64.7 ksi. This value was selected because it represented the highest stress values in the Model 44F SG transition cone region and is clearly referenced in the text of the Westinghouse SG Analysis .This is a conservative value that is appropriate to use for the SIA analysis of upper shell to transition cone weld.Additionally, the file that I forwarded to you October 19, 2005 titled "design parameters.doc" has a *.pdf to *.doc conversion error in it's note 1. The correct note should read "Parameters reflect Model A47 replacement steam generators but also bound operation with Model 44F in Unit 1." The note is corrected and the revised file is attached to this email.Please call with questions.
Brian Kemp 1
Brian Kemp[1]"PBNP Power Uprate Project NSSS Engineering Report Volume 1." Brian Kemp NMC Fleet Lead -Materials 715-426-6960 (office)612-202-9286 (cell)"PBNP Power Uprate Project NSSS Engineering Report Volume 1." 11/17/2005 Hal L. Gustin From: Kemp, Brian [Brian.Kempenmcco.com]
 
Sent: Wednesday, October 19, 2005 9:30 AM To: Hal L. Gustin  
Page 1 of 1 Hal L. Gustin From:       Kemp, Brian [Brian.Kemp~nmcco.com]
Sent:       Thursday, November 10, 2005 9:21 AM To:         Hal L. Gustin Cc:         Turner, Russell Attachments: design paramters rl.doc Hal, As described in my email to you (dated October 22, 2005), the calculated stress for normal and abnormal conditions (PL+PB+Q) that should be used in the SIA analysis for the PBNP-1 SG flaw region (upper shell to upper head weld) is 64.7 ksi. This value was selected because it represented the highest stress values in the Model 44F SG transition cone region and is clearly referenced in the text of the Westinghouse SG Analysis . This is a conservative value that is appropriate to use for the SIA analysis of upper shell to transition cone weld.
Additionally, the file that I forwarded to you October 19, 2005 titled "design parameters.doc" has a *.pdf to *.doc conversion error in it's note 1. The correct note should read "Parameters reflect Model A47 replacement steam generators but also bound operation with Model 44F in Unit 1." The note is corrected and the revised file is attached to this email.
Please call with questions.
Brian Kemp
[1]
    "PBNP Power Uprate Project NSSS Engineering Report Volume 1."
Brian Kemp NMC Fleet Lead - Materials 715-426-6960 (office) 612-202-9286 (cell)
  "PBNP Power Uprate Project NSSS Engineering Report Volume 1."
11/17/2005
 
Hal L. Gustin From:                             Kemp, Brian [Brian.Kempenmcco.com]
Sent:                             Wednesday, October 19, 2005 9:30 AM To:                               Hal L. Gustin


==Subject:==
==Subject:==
PBNP design input Attachments:
PBNP design input Attachments:                     design paramters.doc; load cycles.doc; Pzr Fatigue Usage.doc; SG Design Information.doc; Transition Cone Region Figure.doc; Transition Cone Region Figure -Thicknesses.doc design       load cydes.doc (68   Pzr Fatigue         SG Design       Transition Cone   Transition Cone aramters.doc (70 KE         KB)       Usage.doc (43 KB) iformation.doc (37 . Region Figure.... Region Figure...
design paramters.doc; load cycles.doc; Pzr Fatigue Usage.doc; SG Design Information.doc; Transition Cone Region Figure.doc; Transition Cone Region Figure -Thicknesses.doc design load cydes.doc (68 Pzr Fatigue SG Design Transition Cone Transition Cone aramters.doc (70 KE KB) Usage.doc (43 KB) iformation.doc (37 .Region Figure....
Hal, The attached information should be used as design inputs for the U1R29 SG & PZR structural evaluations that SIA is performing.
Region Figure...Hal, The attached information should be used as design inputs for the U1R29 SG & PZR structural evaluations that SIA is performing.
This information is non-proprietary exerpts from the Westinghouse Report titled "PBNP Power Uprate Project NSSS Engineering Report Volume 1."
This information is non-proprietary exerpts from the Westinghouse Report titled "PBNP Power Uprate Project NSSS Engineering Report Volume 1." Please call with questions.
Please call with questions.
Brian Kemp I I I.I~#1I 1.2-2 (weld)*- 3_- 4.5 6 (weld)7 Transition Cone Region PBNP Unit 1 Model 44F And A47 Steam Generator Loading Cycles Number of Load Cycles lDescription of Loading 44F Design A47 Design 60-Year Conditions Spec. (Ref. 1) Spec. (Ref. 2) Sect. 3.1 Transients Heatup/Cooldown 200 200 200 Hot Standby at No Power Feedwater Cycling at HSB 25,000 10,000 25,000 Loading/Unloading  
Brian Kemp I
@5% PWR/min 14,500 18,300 18,300 Steady-state at Full Load ----10% Step-Load Increase 2,000 2,000 2,000 10% Step-Load Decrease 2,000 2,000 2,000 Large Step-Load Decrease 200 200 200 (50% Step-Load Decrease) l Reactor Trip 400 400 400 Loss of Load 80 80 80 Partial Loss of Flow 80 80 80 Loss of Power (Power Blackout) 40 40 40 Inadvertent Auxiliary Spray 10 10 Primary Hydrotest  
 
@ 3106 psig 1 5 5 Primary Pressure Test @ 2485 psig 50 120 94 (100) 100 Secondary Hydrotest  
I I
@ 1356 psig 1 10 10 Secondary Pressure Test @ 1085 psig 50 10 50 Prim-to-Sec Leak Tests 5 27 (30) 30 Sec-to-Prim Leak Tests 5 120 128 (130) 130 PBNP Power Uprate Project (Bounding 10.5% Core Power Uprate)NSSS Design Parameters"'1 2 Used for Systems, Components  
1
& Accident Analyses Case 1 Case 2 Case 3 Case 4 Low T.v Low T.g, High T.g High T 5 v 3 Parameter 0% SGTP 10% SGTP 0% SGTP 10% SGTP Steam Generator Steam Pressure (psia) 662(34) 637(3'4) 764(4) 737(3"4)Steam Temperature (0 F) 496.8(3) 492.7(3) 512.9 508.8(3)Steam Flow, Total (106 lb.Ihr) 7.37 7.37 7.39() 7.39(5)Feedwater Temperature (0 F) 442.9 442.9 442.9 442.9 Tube Plugging(%)
                      .2-2     (weld)
0 10 0 10 Notes: 1. Parameters reflect Model A47 replacement steam generators but also bound operation with Model 44F in Unit 1 2. Systems and components analyses have been performed using the parameters identified in Table 1-1.3. Steam pressure/temperature must be greater than 745.7 psia/510.0 0 F due to the steam generator design pressure differential requirements.
    .I                *-   3
: 4. Steam pressure at the outlet of the steam generator nozzle.5. A maximum moisture carry over of 0.10% was assumed; however, this value cannot be warranted at this high power level and low steam pressure.
_- 4
The maximum moisture carry over for the Model 44F steam generators is 0.25% and the maximum steam flow associated with this value is 7.40x10 6 lb/hr.
                      .5 6 (weld)
Structural The critical steam generator components that were evaluated for structural adequacy are: Primary side: Primary chamber, tubesheet, primary nozzles, primary manway, divider plate, and tube-to-tubesheet weld. The primary side of the replacement steam generators was evaluated as a whole through a review of the uprating transients that affect the primary side of the steam generator, i.e., RCS transients.
  ~#1I 7
Secondary side: Upper shell, transition cone, lower shell, junction of tubesheet and stub barrel, main and auxiliary feedwater and spray nozzles, secondary manway opening and bolts, inspection ports, and minor shell taps.These components were evaluated for the effects of the uprate on the steady-state and transient conditions for the normal and upset loads in the design specifications, References 1 (Model 44F) and Reference 2 (Model A47). The test, emergency, and faulted loading conditions are unaffected by the uprate. The structural acceptance criteria for both steam generator models are given in the 1965 Edition through Summer 1966 Addenda of the ASME B&PV, Section III, Reference
Transition Cone Region
: 3. Details of the actual acceptance criteria employed in the structural evaluation of both the 44F and A47 are given in Section 4 of Volume 1 of Reference 4.Secondary Shell -Model 44F Summary stress results for the secondary shell transition cone are given in Table 7-44 of Reference 5 for current power rating. These results, shown in Table 5.6-9, remain bounding for the uprated conditions since a reduction in secondary pressure will reduce the stresses in the shell. Citical sections in the transition cone region are depicted in Figure 5.6-3. The results in Table 5.6-9 show that all stress limits are satisfied.
 
For fatigue, Section BB, shown in Figure 5.6-1, is the overall governing location for the secondary shell and has been considered above in the evaluation for the channel head, the tubesheet and the tubesheet to shell junctions.
PBNP Unit 1 Model 44F And A47 Steam Generator Loading Cycles Number of Load Cycles             l Description of Loading         44F Design     A47 Design               60-Year Conditions             Spec. (Ref. 1) Spec. (Ref. 2) Sect. 3.1 Transients Heatup/Cooldown                           200           200                   200 Hot Standby at No Power Feedwater Cycling at HSB                 25,000         10,000                 25,000 Loading/Unloading @5% PWR/min             14,500       18,300                 18,300 Steady-state at Full Load                   -             -                     --
The structural evaluation of the relocated PBNP Unit 1 level taps in the secondary shell is discussed below.Upper Shell Remnant -Model 44F The upper shell (along with its manway) and the steam outlet nozzle are remnant components from the original 44 Series steam generator.
10% Step-Load Increase                   2,000         2,000                 2,000 10% Step-Load Decrease                   2,000         2,000                 2,000 Large Step-Load Decrease                   200           200                   200 (50% Step-Load Decrease)                                                                 l Reactor Trip                               400           400                   400 Loss of Load                               80             80                     80 Partial Loss of Flow                       80             80                     80 Loss of Power (Power Blackout)             40           40                     40 Inadvertent Auxiliary Spray                               10                     10 Primary Hydrotest @ 3106 psig                 1           5                     5 Primary Pressure Test @ 2485 psig           50           120       94 (100)     100 Secondary Hydrotest @ 1356 psig             1             10                     10 Secondary Pressure Test @ 1085 psig         50             10                     50 Prim-to-Sec Leak Tests                       5                       27 (30)     30 Sec-to-Prim Leak Tests                       5           120       128 (130)   130
The remnant components were evaluated for continued use in Model 44F replacement steam generators in Section 7.20 of Reference 5.Figure 5.6-5 shows the locations in the upper shell remnant evaluated in Reference
 
: 5. Section DD in Figure 5.6-5 refers to the manway pad. The feedwater nozzle is evaluated above as a separate item. As discussed previously, the power uprate results in reduced secondary (steam) pressures and temperatures.
PBNP Power Uprate Project (Bounding 10.5% Core Power Uprate)
Therefore, the specified loads, considered in Reference 5, bound the structural evaluation.
NSSS Design Parameters"'1     2 Used for Systems, Components & Accident Analyses Case 1           Case 2             Case 3             Case 4 Low T.v         Low T.g,           High T.g           High T5v3 Parameter                     0% SGTP         10% SGTP             0% SGTP           10% SGTP Steam Generator Steam Pressure (psia)                     662(34)           637(3'4)             764(4)           737(3"4)
The calculated fatigue usage factor for 40 years is less than 1.0 at the limiting location, Section BB in Figure 5.6-5. Since the maximum usage in the remnant based on 40 years is very low, extension to 60 years and ASME Code compliance within the usage limit of one are obvious.
Steam Temperature     (0 F)               496.8(3)         492.7(3)             512.9           508.8(3)
Body No.1 2,3 4 5 6-8 9 10-15 16, 17 18 Meridional length, in.8.43 5.15 1.00 7.24 7.29 7.24 6.38 Thickness in.3.50 3.50 3.62 -2.50 3.62 3.62 3.62 2.62 2.62 CUT BODY 1I 2 4 3 4 5 f-'4 6 5 6 7 8 8.10 9 12 t 13 C a/10/11 12 13 14 114 15 16 1 7 16 1 7 D18 Transition Cone Region -Model 44F}}
Steam Flow, Total (106 lb.Ihr)               7.37             7.37               7.39()             7.39(5)
Feedwater Temperature       (0F)           442.9           442.9               442.9             442.9 Tube Plugging(%)                               0               10                   0                 10 Notes:
: 1. Parameters reflect Model A47 replacement steam generators but also bound operation with Model 44F in Unit 1
: 2. Systems and components analyses have been performed using the parameters identified in Table 1-1.
: 3. Steam pressure/temperature must be greater than 745.7 psia/510.00 F due to the steam generator design pressure differential requirements.
: 4. Steam pressure at the outlet of the steam generator nozzle.
: 5. A maximum moisture carry over of 0.10% was assumed; however, this value cannot be warranted at this high power level and low steam pressure. The maximum moisture carry over for the Model 44F steam generators is 0.25% and the maximum steam flow associated with this value is 7.40x10 6 lb/hr.
 
Structural The critical steam generator components that were evaluated for structural adequacy are:
Primary side:     Primary chamber, tubesheet, primary nozzles, primary manway, divider plate, and tube-to-tubesheet weld. The primary side of the replacement steam generators was evaluated as a whole through a review of the uprating transients that affect the primary side of the steam generator, i.e., RCS transients.
Secondary side:     Upper shell, transition cone, lower shell, junction of tubesheet and stub barrel, main and auxiliary feedwater and spray nozzles, secondary manway opening and bolts, inspection ports, and minor shell taps.
These components were evaluated for the effects of the uprate on the steady-state and transient conditions for the normal and upset loads in the design specifications, References 1 (Model 44F) and Reference 2 (Model A47). The test, emergency, and faulted loading conditions are unaffected by the uprate. The structural acceptance criteria for both steam generator models are given in the 1965 Edition through Summer 1966 Addenda of the ASME B&PV, Section III, Reference 3. Details of the actual acceptance criteria employed in the structural evaluation of both the 44F and A47 are given in Section 4 of Volume 1 of Reference 4.
Secondary Shell - Model 44F Summary stress results for the secondary shell transition cone are given in Table 7-44 of Reference 5 for current power rating. These results, shown in Table 5.6-9, remain bounding for the uprated conditions since a reduction in secondary pressure will reduce the stresses in the shell. Citical sections in the transition cone region are depicted in Figure 5.6-3. The results in Table 5.6-9 show that all stress limits are satisfied. For fatigue, Section BB, shown in Figure 5.6-1, is the overall governing location for the secondary shell and has been considered above in the evaluation for the channel head, the tubesheet and the tubesheet to shell junctions. The structural evaluation of the relocated PBNP Unit 1 level taps in the secondary shell is discussed below.
Upper Shell Remnant - Model 44F The upper shell (along with its manway) and the steam outlet nozzle are remnant components from the original 44 Series steam generator. The remnant components were evaluated for continued use in Model 44F replacement steam generators in Section 7.20 of Reference 5.
Figure 5.6-5 shows the locations in the upper shell remnant evaluated in Reference 5. Section DD in Figure 5.6-5 refers to the manway pad. The feedwater nozzle is evaluated above as a separate item. As discussed previously, the power uprate results in reduced secondary (steam) pressures and temperatures. Therefore, the specified loads, considered in Reference 5, bound the structural evaluation. The calculated fatigue usage factor for 40 years
 
is less than 1.0 at the limiting location, Section BB in Figure 5.6-5. Since the maximum usage in the remnant based on 40 years is very low, extension to 60 years and ASME Code compliance within the usage limit of one are obvious.
 
Body     Meridional            Thickness                  CUT        BODY No. length, in.                in.
1I 1                                 3.50 2,3           8.43                3.50 2
4             5.15                3.62    -
5             1.00               2.50 6-8            7.24               3.62 43 9              7.29              3.62                     4      '4 5 f-     5 10-15          7.24              3.62                 6 16, 17                                                7            6 6.38              2.62 8
18                                2.62                           8
                                              .10             9 a/10 12 t          /11 13 C            12 13 14 114 15 16           16 17 17 D18 Transition Cone Region - Model 44F}}

Revision as of 23:34, 23 November 2019

Calculation PBCH-14Q-303, Rev 1, Steam Generator a Flaw Evaluation.
ML053620350
Person / Time
Site: Point Beach NextEra Energy icon.png
Issue date: 11/28/2005
From: Gustin H, James Smith
Structural Integrity Associates
To:
Office of Nuclear Reactor Regulation
References
P305817 PBCH-14Q-303, Rev 1
Download: ML053620350 (28)
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Text

ENCLOSURE 3 Analytical Evaluation of Steam Generator B Upper Shell to Transition Cone Weld Indications 27 pages follow

structuralntegrity CALCULATION FileNo.: PBCH-14Q-303 Associates, Inc. PACKAGE Project No.: PBCH-14Q PROJECT NAME: Point Beach Unit 1 Flaw Evaluation Fall 2005 Contract No.: P305817 CLIENT: Nuclear Management Company, LLC lPLANT: Point Beach Nuclear Plant CALCULATION TITLE: Steam Generator A Flaw Evaluation Project Mgr. Preparer(s) &

Document Affected Pages Revision Description Approval Checker(s)

Revision Signature & Signatures &

Date Date 0 1-7 Initial Issue H. L. Gustin H. L. Gustin Appendices 10/28/05 10/28/05 A,B, C S. S. Tang 10/28/05 1 5 Modified Reference 5, H. L. Gustin H. L. Gustin Appendix C added e-mail reference 11/28/05 11/17/05 to Appendix C 11/2-80 J. E. Smith 11/28/05 Page 1 SI Form F2001R2a

1 INTRODUCTION The 2005 inservice inspection of steam generator A at Point Beach Nuclear Plant Unit 1 identified several indications in the transition cone to upper shell weld region of the steam generator. The indications were assessed per the flaw proximity rules of ASME Boiler and Pressure Vessel Code Section XI, IWA-3300

[1]. Following assessment of flaw proximity, indication dimensions were compared to the flaw acceptance standards of Section XI, IWC-3510 [1] by the plant [4]. One indication did not meet the flaw acceptance standards of Section A, IWC-35 10 [1]. It is therefore necessary to conduct a flaw evaluation per Section XI, IWB-3600 (since IWC-3600 is in preparation) for this flaw. This calculation evaluates the flaw per the guidelines of Section XI, IWB-36 10, which include acceptance criteria based on linear elastic fracture mechanics and consideration of potential flaw growth. This calculation does not apply to other flaws which may be identified, without further evaluation. Conservative assumptions have been used in this evaluation to demonstrate flaw acceptability per IWB-3610. This calculation has been design reviewed in accordance with the requirements of the Structural Integrity Associates Quality Assurance Program.

2 TECHNICAL APPROACH Fracture mechanics methods consistent with the requirements of ASME Section XI have been applied in this flaw evaluation. The acceptance criterion is that the applied stress intensity factor due to the observed flaw, with consideration of flaw growth over the remaining life of the plant, remains below the material toughness, including applicable margins from Section XI. The flaw acceptance criteria, based on applied stress intensity factor, was determined based on Paragraph IWB-3612 of ASME Section XI [1]. The material toughness for the carbon/low alloy steel steam generator shell material at operating temperature is taken to be 200 ksi-4inch, consistent with Figure A-4200-1 from ASME Section XI Appendix A for K1 c.

A safety factor of 4110 is applied, as required by IWB-3610. This gives an allowable stress intensity factor of 200/h10 = 63.25 ksi-4inch.

The fracture mechanics analysis was performed for the unacceptable flaw.

3 FLAW CHARACTERIZATION A total of 24 flaw indications were observed. These flaws were compared to the flaw proximity rules of IWA-3300. Table 1 (which is based on data in [4]) lists all 24 flaw dimensions and their locations, and summarizes the results of the proximity rule assessment. None of the 24 indications had to be combined by the proximity rules. Plant personnel assessed all flaws to the IWC-3510 acceptance standards, and determined that only one flaw (number 19 in Table 1) required further evaluation. This flaw has length

= 1.75 inch, and depth = 0.22 inch. It is located 1.03 inches below the outside surface.

The observed unacceptable flaw is entirely subsurface and not exposed to any fluid chemistry.

Structural Integrity File No.: PBCH-14Q-303 Revision: I Associates, Ind. Page 2

4 DESIGN INPUTS The as-measured wall thickness is 3.68 inches in the transition cone region (from plant UT reports [4]).

The transition cone material is SA-533 Grade A, Class 2 [6] with specified yield stress = 70 ksi. The Upper Shell material has a yield stress of less than 50 ksi.

From [5], the combined membrane, bending and secondary stress (PL+PB+Q) at the affected weld location is 64.7 ksi.

Welding residual stresses at the flaw location are negligible since the vessel is a thick walled shell that has been stress relieved. Residual stresses are steady state secondary stresses.

5 ASSUMPTIONS

1. To be conservative, the limiting stress value reported in Section 4.0 is used, and treated as an applied membrane stress. This is conservative because membrane stresses are more severe than bending stresses at equal magnitude.
2. The service life is assumed to be 60 years.
3. The material toughness K1 , is taken as 200 ksi- Iinch, from Section XI Appendix A [1].

6 CALCULATIONS 6.1 Fracture mechanics evaluation Linear elastic fracture mechanics and fatigue flaw growth evaluations of the flaw were performed. The flaw was modeled as a subsurface semi-elliptical flaw in an infinite plate subjected to membrane and bending stress as illustrated in Figure 1. This is a common fracture mechanics model applied to subsurface flaws in thick shells. Figure 1 refers to the 1986 Edition of ASME Section XI. This is the Edition to which the SI fracture mechanics program pc-CRACK [3] was developed. However, the flaw definition in that figure remains the same in subsequent Editions of the Code, including the committed Edition and Addenda for Point Beach [1]. For this subsurface flaw model, the flaw depth is defined as 2a. Therefore, the flaw depth, a, is half of the measured flaw depth as reported in the UT reports.

For the indication the flaw parameters were calculated as follows:

Depth [4] 2a = 0.22 inch Length [4] 1= 1.75 inches Aspect ratio: a/l = 0.063 a/t = 2.99%

Eccentricity ratio: 2e/t = 0.38

,Structural integrity File No.: PBCH-14Q-303 Revision: 1 Associates, Inc. Page 3

The applied stress intensity factors for the indication above were calculated using pc-CRACK, [3]. The aspect ratio of 0.1 was used in the evaluation for the indication (limit of the model). The applied stress intensity factor Kappiied at the limiting location on the flaw face was compared to an allowable value of Kid4l 0, where KIC is the material toughness (assumed to be 200 ksi-'Iinch for the steam generator shell material at the service temperatures, from Section XI, Appendix A, Figure A-4200-1), and the factor of l110 represents the factor of safety that is imposed by ASME Section XI, IWB-3610 for Normal and Upset conditions. The allowable K is therefore 63.25 ksi-qinch. As long as the applied stress intensity factor remains below the allowable value for the flaw size, the flaw remains acceptable by Section XI criteria.

pc-CRACK output for the fracture mechanics analysis is contained in Appendix A.

6.2 End of Life Fatigue Flaw Growth Calculation Since the indication is subsurface and therefore not wetted, the end of life flaw size due to fatigue growth was calculated using the fatigue growth curves for carbon and low alloy ferritic steels exposed to air environments, Figure A-4300-1 of Appendix A of Section XI [1]. The flaw was conservatively assumed to experience cyclic stresses corresponding to a stress range from 0 to 64.7 ksi [5]. This is conservative because the latter value corresponds to the sum of the highest reported membrane plus bending plus secondary (PL+PB+Q) stress..

Fatigue growth results are contained in Appendix B.

7 RESULTS OF ANALYSIS The fracture mechanics analysis shows that flaw 19 is acceptable per the criteria of ASME Section XI, IWB-3612. The calculated maximum stress intensity factor for the observed flaw is 40 ksi-qinch, as compared to the allowable value of 63.25 ksi-qinch, which includes required safety margins ('110) as noted in Section 2 of this calculation.

The fatigue growth calculation demonstrates that over more than 4800 cycles from 0 to 64.7 ksi, the resulting flaw growth of the flaw remains below the allowable flaw size. Most transients experienced by the component are much less severe than this transient, and would lead to negligible growth. Therefore, growth of the flaw to an unacceptable size over the remaining life of the plant is not predicted.

The flaw analyzed in this calculation is more severe than are any of the flaws in this weld that were accepted under the Acceptance Standards of IWC-3510. Therefore, although fracture mechanics evaluation of such acceptable flaws is not required, the fracture mechanics analysis in this calculation could conservatively be applied to such flaws, if necessary.

structuralintegrity File No.: PBCH-14Q-303 Revision: 1 Associates, Inc. Page 4

8 DEGRADATION MECHANISMS The observed flaws are subsurface flaws that are remote from any surface (either the wetted inside surface or the air outside surface). Such a flaw is therefore not a result of chemistry-driven mechanisms such as stress corrosion cracking or corrosion. These factors lead to the conclusion that the observed flaws are in fact artifacts of original fabrication, and not due to an active degradation mechanism. The evaluation of the hypothetical flaw growth by a fatigue mechanism is therefore conservative.

9 CONCLUSIONS AND DISCUSSIONS Based on the results of the evaluation presented in this calculation package, the indications found during the inservice inspection of the steam generator A transition cone weld are acceptable and meet the requirement of ASME Code,Section XI, IWB-3610 [1].

The total of all indication areas is about 5.06 in2 . The area of the steam generator weld is about 1928 in2, assuming a circumference of 524 inches [4], and a wall thickness of 3.68 inches. The transverse area reduction is less than 0.26% of the original area. This area reduction will have no significant affect on the hoop stress in the weld. Thus, the steam generator stress analysis based on ASME Boiler and Pressure Vessel Code Section III is not affected. Therefore, the requirement of IWB-3610 (d) (2) is satisfied.

10 REFERENCES

1. ASME Boiler and Pressure Vessel Code,Section XI, 1998 Edition with Addenda through 2000.
2. Steam Generator Design Summary, E-mail from Brian Kemp (NMC) to Hal Gustin (SI), dated 10/19/05 SI File: PBCH-14Q-220
3. pc-CRACK for Windows, Version 3.1-98348, Structural Integrity Associates, 1998.
4. Point Beach Ultrasonic Examination Reports, SI File: PBCH-14Q-222
5. E-mail from Brian Kemp (NMC) to Hal Gustin (SI) dated 10/22/05, supplemented by e-mail from Brian Kemp (NMC) to Hal Gustin (SI) dated 11/10/05. SI File: PBCH-14Q-220
6. Telecon, Russell Turner (NMC) to Hal Gustin (SI) 10/25/05 SI File: PBCH-14Q-220 Structural Integrity File No.: PBCH-14Q-303 Revision: 1

^ St0 0MAAr uc^ tura Inte r t Assocates, Inc. PageI5

__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

3 CY ~Ca+C 1 X

  • Calclated K isma5rnm ofK atpointsl l2.
  • Moh del assumesthat the centerof the crack ispasitionedatxVt/2 A: A

.L -I ;ecd=oA-A C1 b

=C + C @)f(emrane stress)

= f-c ,) (?bending stress)

REQUIRED INPUTS:

t:; :wall thwriness:

a' nmamnum crackdepth (aq3 .*nhn[(f.95 :X,- 2e/tt/2 0.325tJ) iyj rn matlfyiEd&stres s I a/:t ci ck aspei t ratiao (0.1 S5 a/ 0.5)

.5 2 e/: eccentficity ratio (O:5 2ett 0<.6)

Figure 1: ASME B&PV Code Section XI Subsurface Crack Model Ed'Strucitral Integrity File No.: PBCH-14Q-303 Revision: 1

>Associates, Inc. Page 6

Explanation of Tes tilized for the Resolution ofIndications Slw:: NO. 1754004 x tuince &thibm o r14 iV"MfMsurf.=:o0 I: Ib upw Of: flaw ti Page oof 1 S D a<eft O DW-11E"wwsd xu awr lo "W tip of(be faw the Thtuwan1 Ou or 4)- Flw 4 h sFa e  :

L=tth (1) Fbaw lenph Thieknes :68 hhes Lmax: Raw d mreww kecallo "Waaiwd iniftchts co1w fmr veis Zer.

Y_ (&AXM)AS& a U 9Y flaw fddasmGrfacYj(Y> l0.then Y= 1l N - X S 2.: 1 Y a: AJ _bk,?

I 45 -37.25 389.50 1.7 :176 008 0U1S 1.25 100 0.06 2.61% 2.04% YES 2 45 61. 62.50 26 12 005 010 1.0 LO 0.03 239% 1t36% YES 3 4 103100 101375 246 1.08 07 014 0WS 1.00  :

0.09 .73% 1.U% E 4 i 45 109.50 110.0 3.16 40 0.06 :0.12 I00 1 0 0.06 2.61% 1.63% YES 5 45 109.50 110.50 2.66 0.7 af0 0.15 tOO 1.00s0.0 2.671% 204% YES 6 45 255.2 256.50 2.671 0.8 0.0 0.16 1.25 1.0 0.06 2.61% 2.17% YES 7 45 7 27 219 0.76 0.06 0 13 3.25 1.0 002 239% 1.77% YES 8 4 1278.0D 279.8w 2.45 1.06 ~0.09 0.17 .8 100 0.05 2.48% 2.31% YE 9 45 2910 2925 1.1 27 0.10 a9 01 1.00 10 0.0 28% 2.55% YES 1O 45 10O0 0 6 0.9 .1 2.75 1.00 0.0 2.43%. 231%, YS 11 45 3100 311.25 2.98 0.66  : A0 A14 1.25 10 0.06 2.61% 1.90% YES 121 45 124.25 125.2,5.1 1.81 0.08 0.16 1.00I 1.00 I0.08 2.73%1 2.17% YES

13. 45 1335.5( 33600 19 2.40 040 0A9 0.50 1 .0 0.I9 3.71l 2.58% YES 14 45 1341.38 34312 2.04 1.53 0g04 009 1,88 100 0.02 2.39% 1.22% YES 15 45 157.75 3602 2.04 1,5 0.04 0.09 250 I.00 002 2.39% 122% YPS 16 45 170.25 71.00 2. 1.21 0.0U4 0.08 7 . 0.05  % 1.OK WS Y

17 45 437.75 438.7 283 0.4 .1 02 1.00 1.00 0.11 2.98 2.5% YES is; 60 472.25 473.75 1.76 :176 0.08 016 I 0 14.0, 0.0 173% 2-17% Ms 19 45 499.K 4199.75 1.03 2431 0.11 :0.22 1.75 1.00 0.06 2.61% 2.99% NO 21 A45 4997 54.00 24 41.06 009 0617 4.25 LOO 0.02 239% .31% I ES 22: A4: 050 5w0o6.50 1.03: 2. .0 .0M3 '243% L36% YES 23 45 317,00 5 18.00 11 244 ;0.0 0.12 1,00 1.0 0i.06 M1.63%2.61O YES 74 45 23 25 09 2.77 0.06 A0.1 O1.001-:006 2.61%. 11.63% YES Note: luKiktlo 20 & 21 are *1 sant ddea ltio *rvOr&d*Oitwo&eetveam Reloluimn Prfore4o Ely:; i Re"utkRm By. 3ek ie-d 26O0 :-2005 WELD NUMER: SG-A-4

APPENDIX A pc-CRACK OUTPUT FILES: ALLOWABLE FLAW DETERMINATION Struefintgtrity File No.: PBCH-14Q-303 I Revision: 1 as Associates, Inc.:

303SSF tm pc-CRACK for windows version 3 .1-98348 (c) copyright '84 - '98 structural Integrity Associates, Inc.

3315 Almaden Expressway, Suite 24 San Jose, CA 95118-1557 voice: 408-978-8200 Fax: 408-978-8964 E-mail: pccrackcstructint.com Linear Elastic Fracture Mechanics Date: Thu Oct 27 13:49:16 2005 Input Data and Results File: 303SSF.LFM Title: PBCH-14Q: Steam Generator A Flaw Evaluation Load cases:

stress Coefficients Case ID Co Cl C2 C3 Type PL+PB+Q 64.7 0 0 0 coeff

Through wal 1 stresses for Load Cases With stress coeff-------

wall case Depth PL+PB+Q 0.0000 64.7 0.0400 64.7 0.0800 64.7 0.1200 64.7 0.1600 64.7 0.2000 64.7 0.2400 64.7 0.2800 64.7 0.3200 64.7 0.3600 64.7 0.4000 64.7 Crack Model: Elliptical subsurface cracked Plate under Membrane & Bending stresses

Reference:

ASME Boiler and Pressure vessel code, section XI, '86 Ed.

WARNING: The stress i ntensity factor (K) is the maxi mum of K at point 1 and K at point 2 as identi fi ed in Section XI.

Crack Parameters:

wall thickness: 3. 6800 Max. crack depth: 0. 4000 crack aspect ratio: 0.1000 Eccentricity ratio: 0.3800 Material yield strength: 70.0000 Co = Sigma(membrane) + Sigma(bending)

Cl = -2*sigma(bending)/thickness

Stress Intensity Factor--------------------

Page 1

303SSF Crack case Size PL+PB+Q 0.0080 10.6409 0.0160 15.0576 0.0240 18.4528 0.0320 21.3202 0.0400 23.8511 0.0480 26.1433 0.0560 28.2549 0.0640 30.2239 0.0720 32.0765 0.0800 33.8319 0.0880 35. 5045 0.0960 37.1054 0.1040 38.6437 0.1120 40.1264 0.1200 41.5596 0.1280 42.9482 0.1360 44.2965 0.1440 45.6079 0.1520 46.8856 0.1600 48.1323 0.1680 49.3503 0.1760 50.5417 0.1840 51.7084 0.1920 52.8519 0.2000 53.9738 0.2080 55.0754 0.2160 56.1579 0.2240 57.2223 0.2320 58.2697 0.2400 59.3009 0.2480 60.3169 0.2560 61.3183 0.2640 62.3058 0.2720 63.2802 0.2800 64.2898 0.2880 65.3371 0.2960 66.3756 0.3040 67.4057 0.3120 68.4277 0.3200 69.4422 0.3280 70.4493 0.3360 71.4495 0.3440 72.4431 0.3520 73.4302 0.3600 74.4114 0.3680 75.3866 0.3760 76.3563 0.3840 77.3207 0.3920 78.2799 0.4000 79.2342 Material fracture toughness:

Material ID: SG Plate Depth K1C 0.0000 63.2500 Page 2

303SSF 1.0000 63.2500 3.0000 63.2500 4.0000 63.2500 Load combination for cri tical crack size:

Load Case scale Factor PL+PB+Q 1.00 00 Crac k Total Si ze K K1C 0.00UT 10.6409 63.25 0.016 15.0576 63.25 0.024 18.4528 63.25 0.032 21.3202 63.25 0.04 23.8511 63.25 0.048 26.1433 63.25 0.0 56 28.2549 63.25 0.064 30.2239 63.25 0.072 32.0765 63.25 0.08 33.8319 63.25 0.088 35. 5045 63.25 0.096 37.1054 63.25 0.104 38.6437 63.25 0.112 40.1264 63.25 0.12 41.5596 63.25 0.128 42.9482 63.25 0.136 44.2965 63.25 0.144 45.6079 63.25 0.152 46.8856 63.25 0.16 48.1323 63.25 0.168 49.3503 63.25 0.176 50. 5417 63.25 0.184 51.7084 63.25 0.192 52.8519 63.25 0.2 53.9738 63.25 0.208 55.0754 63.25 0.216 56.1579 63.25 0.224 57.2223 63.25 0.2 32 58.2697 63.25 0.24 59.3009 63.25 0.248 60.3169 63.25 0.2 56 61.3183 63.25 0.264 62.3058 63.25 0.272 63.2802 63.25 0.28 64.2898 63.25 0.288 65.3371 63.25 0.296 66.3756 63.25 0.304 67.4057 63.25 0.312 68.4277 63.25 0.32 69.4422 63.25 0.328 70.4493 63.25 0.336 71.4495 63.25 0.344 72.4431 63.25 0.3 52 73.4302 63.25 0.36 74.4114 63.25 0.368 75. 3866 63.25 0.376 76.3563 63.25 0.384 77.3207 63.25 0.3 92 78.2799 63.25 0.4 79.2342 63.25 Page 3

303SSF Critical crack size = 0.2716 End of PC-C RACK Output Page 4

Ii APPENDIX B pc-CRACK OUTPUT FILE: FATIGUE CRACK GROWTH iStructural Integrity File No.: PBCH-14Q-303 I Revision: 1 V> Associates, Inc.

303FCG2 tm pc-CRACK for windows version 3 .1-98348 (C) copyright '84 - '98 Structural Integrity Associates, Inc.

3315 Almaden Expressway, Suite 24 San lose, CA 95118-1557 voice: 408 -978-8200 Fax: 408-978-8964 E-mail: pccrack@structint.com Linear Elastic Fracture Mechanics Date: Thu Oct 27 13:51:18 2005 Input Data and Results File: 303FCG2.LFM Title: PBCH-14Q: steam Generator A Flaw Evaluation Load cases:

stress coefficients case ID Co C1 C2 C3 Type PL+PB+Q 64.7 0 0 0 Coeff

Through wal 1 stresses for Load cases with stress coeff-------

wall Case Depth PL+PB+Q 0.0000 64.7 0.0400 64.7 0.0800 64.7 0.1200 64.7 0.1600 64.7 0.2000 64.7 0.2400 64.7 0.2800 64.7 0.3200 64.7 0.3600 64.7 0.4000 64.7 crack Model: Elliptical subsurface cracked Plate under Membrane & Bending Stresses

Reference:

ASME Boiler and Pressure vessel code, section XI, '86 Ed.

WARNING: The stress i ntensity factor (K) is the maxi mum of K at point 1 and K at point 2 as identified in Section XI.

crack Parameters:

wall thickness: 3. 6800 Max. crack depth: 0.4000 crack aspect ratio: 0.1000 Eccentricity ratio: 0.3800 Material yield strength: 70.0000 Co = sigma(membrane) + sigma(bending)

Cl = -2 sigma(bending)/thickness

Stress Intensity Factor--------------------

Page 1

303FCG2 crack Case size PL+PB+Q 0.0080 10.6409 0.0160 15.0576 0.0240 18.4528 0.0320 21.3202 0.0400 23.8511 0.0480 26.1433 0.05 60 28.2549 0.0640 30.2239 0.0720 32.0765 0.0800 33.8319 0.0880 35.5045 0.0960 37.1054 0.1040 38.6437 0.1120 40.1264 0.1200 41.5596 0.1280 42.9482 0.1360 44.2965 0.1440 45.6079 0.1520 46.8856 0.1600 48.1323 0.1680 49.3503 0.1760 50.5417 0.1840 51.7084 0.1920 52.8519 0.2000 53.9738 0.2080 55.0754 0.2160 56.1579 0.2240 57.2223 0.2320 58.2697 0.2400 59.3009 0.2480 60.3169 0.25 60 61.3183 0.2640 62.3058 0.2720 63. 2802 0.2800 64.2898 0.2880 65.3371 0.2960 66.3756 0.3040 67.4057 0.3120 68.4277 0.3200 69.4422 0.3280 70.4493 0.3360 71.4495 0.3440 72.4431 0.35 20 73.4302 0.3600 74.4114 0.3680 75.3866 0.3760 76.3563 0.3840 77.3207 0.3920 78.2799 0.4000 79.2342 crack Growth Laws:

Law ID: SG subsurface Model: ASME section XI - ferritic steel in air environment da/dN = C

  • S
  • dKA3.07 where Page 2

I 303FCG2 S = 25.72 * (2. 88 - R')A(-3.07)

R=O for R < 0 R'= R for R >= 0 dK = Kmax - Kmin R = Kmin / Kmax where:

C= 1.99OOe-010 is for the currently selected units of:

force: kip length: inch Material Fracture Toughness KIc:

Material ID: SG Plate Depth KIC 0.0000 63.2500 1.0000 63.2500 3.0000 63.2500 4.0000 63.2500 Initial crack size= 0.1100 Max. crack size= 0.4000 Number of blocks= 1 Print increment of block -= 1 cycles Calc. Print crk. Grw. Mat.

Subblock /Ti me incre. incre. Law K1C fcg3O3 10000 100 100 SG subsurface SG Plate Kmax Kmin Subblock case ID scale Factor case ID scale Factor fcg3O3 P L+PB+Q 1.00 00 PL+P B+Q 0.0000 crack growth results:

Total Subblock Cycles cycles DaDn

/Ti me /Time K max Kmin DeltaK R /DaDt Da a a/thk Block: 1 100 100 3.98e+ 001 0.OOe+000 3. 98e+001 0.00 1. 62e-005 1.62e-00 3 0.1116 0.03 200 200 4.Ole+ 001 0.OOe+000 4. Ole+001 0.00 1. 66e-005 1.66e-00 3 0.1133 0.03 300 300 4.04e+ 001 0.OOe+000 4. 04e+001 0.00 1. 69e-005 1.69e-00 3 0.115 0.03 400 400 4.07e+ 001 0.OOe+000 4. 07e+001 0.00 1. 73e-005 1.73e-00 3 0.1167 0.03 500 500 4.10e+ 001 0.OOe+000 4. 10e+001 0.00 1. 77e-005 1.77e-00 3 0.1185 0.03 600 600 4.13e+ 001 0.OOe+000 4. 13e+001 0.00 1. 82e-005 1.82e-00 3 0.1203 0.03 700 700 4.16e+ 001 0.00e+000 4. 16e+001 0.00 1. 86e-005 1.86e-00 3 0.1222 0.03 800 800 4.19e+ 001 0 .OOe+000 4. 19e+001 0.00 1. 91e-005 1.91e-00 3 0.1241 0.03 900 900 4.23e+ 001 0.OOe+000 4. 23e+001 0.00 1. 95e-005 1.95e-00 3 0.126 0.03 Page 3

303 FCG2 1000 1000 4.26e+ 001 0.OOe+000 4. 26e+001 0.00 2. OOe-005 2.OOe-00 3 0.128 0.03 1100 1100 4.30e+ 001 0.OOe+000 4. 30e+001 0.00 2. 05e-005 2.05e-00 3 0.1301 0.04 1200 1200 4.33e+ 001 0.OOe+000 4. 33e+001 0.00 2. lOe-005 2.lOe-00 3 0.1322 0.04 1300 1300 4.37e+ 001 0.OOe+000 4. 37e+001 0.00 2. 16e-005 2.16e-00 3 0.1343 0.04 1400 1400 4.40e+ 001 0.OOe+000 4. 40e+001 0.00 2. 21e-005 2.21e-00 3 0.1365 0.04 1500 1500 4.44e+ 001 0.OOe+000 4. 44e+001 0.00 2. 27e-005 2.27e-00 3 0.1388 0.04 1600 1600 4.48e+ 001 0.OOe+000 4. 48e+001 0.00 2. 33e-005 2.33e-003 0.1411 0.04 1700 1700 4.51e+ 001 0.OOe+000 4. 51e+001 0.00 2. 39e-005 2.39e-003 0.1435 0.04 1800 1800 4.55e+ 001 0.OOe+000 4. 55e+001 0.00 2. 45e-005 2.45e-00 3 0.146 0.04 1900 1900 4.59e+ 001 0.OOe+000 4. 59e+001 0.00 2. 52e-005 2.52e-003 0.1485 0.04 2000 2000 4.63e+ 001 0.OOe+000 4. 63e+001 0.00 2. 59e-005 2.59e-003 0.1511 0.04 2100 2100 4.67e+ 001 0.OOe+000 4. 67e+001 0.00 2. 66e-005 2.66e-00 3 0.1537 0.04 2200 2200 4. 72e+ 001 0 .OOe+000 4. 72e+001 0.00 2. 73e-005 2.73e-00 3 0.1565 0.04 2300 2300 4.76e+ 001 0.OOe+000 4. 76e+001 0.00 2. 81e-005 2.81e-00 3 0.1593 0.04 2400 2400 4.80e+ 001 0.OOe+000 4. 80e+001 0.00 2. 89e-005 2.89e-00 3 0.1622 0.04 2500 2500 4.85e+ 001 0.OOe+000 4. 85e+001 0.00 2. 97e-005 2.97e-00 3 0.1651 0.04 2600 2600 4.89e+ 001 0.OOe+000 4. 89e+001 0.00 3. 06e-005 3.06e-00 3 0.1682 0.05 2700 2700 4.94e+ 001 0.OOe+000 4. 94e+001 0.00 3. 15e-005 3.15e-003 0.1713 0.05 2800 2800 4.98e+ 001 0.00e+000 4. 98e+001 0.00 3. 24e-005 3.24e-00 3 0.1746 0.05 2900 2900 5.03e+ 001 0.OOe+000 5. 03e+001 0.00 3. 34e-005 3.34e-00 3 0.1779 0.05 3000 3000 5.08e+ 001 0.OOe+000 5. 08e+001 0.00 3. 44e-005 3.44e-00 3 0.1814 0.05 3100 3100 5.13e+ 001 0.OOe+000 5. 13e+001 0.00 3. 54e-005 3.54e-00 3 0.1849 0.05 3200 3200 5.18e+ 001 0.OOe+000 5. 18e+001 0.00 3. 65e-005 3.65e-00 3 0.1886 0.05 3300 3300 5.24e+ 001 0.OOe+000 5.24e+001 0.00 3. 77e-005 3.77e-00 3 0.1923 0.05 3400 3400 5.29e+ 001 0.OOe+000 5. 29e+001 0.00 3. 89e-005 3.89e-00 3 0.1962 0.05 3500 3500 5.34e+ 001 0.OOe+000 5. 34e+001 0.00 4. Ole-005 4.Ole-00 3 0.2002 0.05 3600 3600 5.40e+ 001 0.OOe+000 5. 40e+001 0.00 4. 14e-005 4.14e-00 3 0.2044 0.06 3700 3700 5.46e+ 001 0.OOe+000 5. 46e+001 0.00 4. 28e-005 4.28e-00 3 0.2086 0.06 3800 3800 5.52e+ 001 0.OOe+000 5. 52e+001 0.00 4. 42e-005 4.42e-00 3 0.2131 0.06 3900 3900 S.58e+ 001 0.OOe+000 5. 58e+001 0.00 4. 57e-005 4.57e-00 3 0.2176 0.06 4000 4000 5.64e+ 001 0.OOe+000 5. 64e+001 0.00 4. 73e-005 4.73e-00 3 0.2224 0.06 4100 4100 5.70e+ 001 0.OOe+000 5. 70e+001 0.00 4. 89e-005 4.89e-00 3 0.2273 0.06 4200 4200 5.76e+ 001 0.OOe+000 5. 76e+001 0.00 5. 06e-005 5.06e-00 3 0.2323 0.06 4300 4300 5.83e+ 001 0.OOe+000 5. 83e+001 0.00 5. 24e-005 5.24e-00 3 0.2376 0.06 4400 4400 S.90e+ 001 0.OOe+000 5. 90e+001 0.00 5. 43e-005 5.43e-00 3 0.243 0.07 4500 4500 5.97e+ 001 0.OOe+000 5. 97e+001 0.00 5. 63e-005 5.63e-00 3 0.2486 0.07 4600 4600 6.04e+ 001 0.OOe+000 6. 04e+001 0.00 5. 84e-005 5.84e-00 3 0.2545 0.07 4700 4700 6.lle+ 001 0.OOe+000 6. lle+001 0.00 6. 06e-005 6.06e-00 3 0.2605 0.07 4800 4800 6.19e+ 001 0.OOe+000 6. 19e+001 0.00 6. 29e-005 6.29e-00 3 0.2668 0.07 4900 4900 6.26e+ 001 0.OOe+000 6. 26e+001 0.00 6. 54e-005 6. 54e-00 3 0.2734 0.07 5000 5000 6.35e+ 001 0.OOe+000 6. 35e+001 0.00 6. 80e-005 6.80e-00 3 0.2801 0.08 End of pC-CRACK Output Page 4

APPENDIX C DESIGN INPUT MEMOS (E-MAIL) FROM NMC File No.: PBCH-14Q-303 Revision: 1 V ~Assocatesl; 0Ilnc.

Hal L. Gustin From: Kemp, Brian [Brian.Kemp~nmcco.com]

Sent: Saturday, October 22, 2005 11:08 AM To: Kemp, Brian; Hal L. Gustin

Subject:

Additional PBNP Design Input

Hal, The following information should be used as a design input for the UlR29 SG structural evaluation that SIA is performing.

This information is an exerpt from the Westinghouse Report titled "PBNP Power Uprate Project NSSS Engineering Report Volume 1."

The PBNP Unit 1 Steam Generators (Westinghouse Model 44F) calculated stress for normal and abnormal conditions (PL+PB+Q) in the flaw region (upper shell to upper head weld) is 64.7 ksi.

Brian Kemp 1

Page 1 of 1 Hal L. Gustin From: Kemp, Brian [Brian.Kemp~nmcco.com]

Sent: Thursday, November 10, 2005 9:21 AM To: Hal L. Gustin Cc: Turner, Russell Attachments: design paramters rl.doc Hal, As described in my email to you (dated October 22, 2005), the calculated stress for normal and abnormal conditions (PL+PB+Q) that should be used in the SIA analysis for the PBNP-1 SG flaw region (upper shell to upper head weld) is 64.7 ksi. This value was selected because it represented the highest stress values in the Model 44F SG transition cone region and is clearly referenced in the text of the Westinghouse SG Analysis . This is a conservative value that is appropriate to use for the SIA analysis of upper shell to transition cone weld.

Additionally, the file that I forwarded to you October 19, 2005 titled "design parameters.doc" has a *.pdf to *.doc conversion error in it's note 1. The correct note should read "Parameters reflect Model A47 replacement steam generators but also bound operation with Model 44F in Unit 1." The note is corrected and the revised file is attached to this email.

Please call with questions.

Brian Kemp

[1]

"PBNP Power Uprate Project NSSS Engineering Report Volume 1."

Brian Kemp NMC Fleet Lead - Materials 715-426-6960 (office) 612-202-9286 (cell)

"PBNP Power Uprate Project NSSS Engineering Report Volume 1."

11/17/2005

Hal L. Gustin From: Kemp, Brian [Brian.Kempenmcco.com]

Sent: Wednesday, October 19, 2005 9:30 AM To: Hal L. Gustin

Subject:

PBNP design input Attachments: design paramters.doc; load cycles.doc; Pzr Fatigue Usage.doc; SG Design Information.doc; Transition Cone Region Figure.doc; Transition Cone Region Figure -Thicknesses.doc design load cydes.doc (68 Pzr Fatigue SG Design Transition Cone Transition Cone aramters.doc (70 KE KB) Usage.doc (43 KB) iformation.doc (37 . Region Figure.... Region Figure...

Hal, The attached information should be used as design inputs for the U1R29 SG & PZR structural evaluations that SIA is performing.

This information is non-proprietary exerpts from the Westinghouse Report titled "PBNP Power Uprate Project NSSS Engineering Report Volume 1."

Please call with questions.

Brian Kemp I

I I

1

.2-2 (weld)

.I *- 3

_- 4

.5 6 (weld)

~#1I 7

Transition Cone Region

PBNP Unit 1 Model 44F And A47 Steam Generator Loading Cycles Number of Load Cycles l Description of Loading 44F Design A47 Design 60-Year Conditions Spec. (Ref. 1) Spec. (Ref. 2) Sect. 3.1 Transients Heatup/Cooldown 200 200 200 Hot Standby at No Power Feedwater Cycling at HSB 25,000 10,000 25,000 Loading/Unloading @5% PWR/min 14,500 18,300 18,300 Steady-state at Full Load - - --

10% Step-Load Increase 2,000 2,000 2,000 10% Step-Load Decrease 2,000 2,000 2,000 Large Step-Load Decrease 200 200 200 (50% Step-Load Decrease) l Reactor Trip 400 400 400 Loss of Load 80 80 80 Partial Loss of Flow 80 80 80 Loss of Power (Power Blackout) 40 40 40 Inadvertent Auxiliary Spray 10 10 Primary Hydrotest @ 3106 psig 1 5 5 Primary Pressure Test @ 2485 psig 50 120 94 (100) 100 Secondary Hydrotest @ 1356 psig 1 10 10 Secondary Pressure Test @ 1085 psig 50 10 50 Prim-to-Sec Leak Tests 5 27 (30) 30 Sec-to-Prim Leak Tests 5 120 128 (130) 130

PBNP Power Uprate Project (Bounding 10.5% Core Power Uprate)

NSSS Design Parameters"'1 2 Used for Systems, Components & Accident Analyses Case 1 Case 2 Case 3 Case 4 Low T.v Low T.g, High T.g High T5v3 Parameter 0% SGTP 10% SGTP 0% SGTP 10% SGTP Steam Generator Steam Pressure (psia) 662(34) 637(3'4) 764(4) 737(3"4)

Steam Temperature (0 F) 496.8(3) 492.7(3) 512.9 508.8(3)

Steam Flow, Total (106 lb.Ihr) 7.37 7.37 7.39() 7.39(5)

Feedwater Temperature (0F) 442.9 442.9 442.9 442.9 Tube Plugging(%) 0 10 0 10 Notes:

1. Parameters reflect Model A47 replacement steam generators but also bound operation with Model 44F in Unit 1
2. Systems and components analyses have been performed using the parameters identified in Table 1-1.
3. Steam pressure/temperature must be greater than 745.7 psia/510.00 F due to the steam generator design pressure differential requirements.
4. Steam pressure at the outlet of the steam generator nozzle.
5. A maximum moisture carry over of 0.10% was assumed; however, this value cannot be warranted at this high power level and low steam pressure. The maximum moisture carry over for the Model 44F steam generators is 0.25% and the maximum steam flow associated with this value is 7.40x10 6 lb/hr.

Structural The critical steam generator components that were evaluated for structural adequacy are:

Primary side: Primary chamber, tubesheet, primary nozzles, primary manway, divider plate, and tube-to-tubesheet weld. The primary side of the replacement steam generators was evaluated as a whole through a review of the uprating transients that affect the primary side of the steam generator, i.e., RCS transients.

Secondary side: Upper shell, transition cone, lower shell, junction of tubesheet and stub barrel, main and auxiliary feedwater and spray nozzles, secondary manway opening and bolts, inspection ports, and minor shell taps.

These components were evaluated for the effects of the uprate on the steady-state and transient conditions for the normal and upset loads in the design specifications, References 1 (Model 44F) and Reference 2 (Model A47). The test, emergency, and faulted loading conditions are unaffected by the uprate. The structural acceptance criteria for both steam generator models are given in the 1965 Edition through Summer 1966 Addenda of the ASME B&PV,Section III, Reference 3. Details of the actual acceptance criteria employed in the structural evaluation of both the 44F and A47 are given in Section 4 of Volume 1 of Reference 4.

Secondary Shell - Model 44F Summary stress results for the secondary shell transition cone are given in Table 7-44 of Reference 5 for current power rating. These results, shown in Table 5.6-9, remain bounding for the uprated conditions since a reduction in secondary pressure will reduce the stresses in the shell. Citical sections in the transition cone region are depicted in Figure 5.6-3. The results in Table 5.6-9 show that all stress limits are satisfied. For fatigue, Section BB, shown in Figure 5.6-1, is the overall governing location for the secondary shell and has been considered above in the evaluation for the channel head, the tubesheet and the tubesheet to shell junctions. The structural evaluation of the relocated PBNP Unit 1 level taps in the secondary shell is discussed below.

Upper Shell Remnant - Model 44F The upper shell (along with its manway) and the steam outlet nozzle are remnant components from the original 44 Series steam generator. The remnant components were evaluated for continued use in Model 44F replacement steam generators in Section 7.20 of Reference 5.

Figure 5.6-5 shows the locations in the upper shell remnant evaluated in Reference 5. Section DD in Figure 5.6-5 refers to the manway pad. The feedwater nozzle is evaluated above as a separate item. As discussed previously, the power uprate results in reduced secondary (steam) pressures and temperatures. Therefore, the specified loads, considered in Reference 5, bound the structural evaluation. The calculated fatigue usage factor for 40 years

is less than 1.0 at the limiting location, Section BB in Figure 5.6-5. Since the maximum usage in the remnant based on 40 years is very low, extension to 60 years and ASME Code compliance within the usage limit of one are obvious.

Body Meridional Thickness CUT BODY No. length, in. in.

1I 1 3.50 2,3 8.43 3.50 2

4 5.15 3.62 -

5 1.00 2.50 6-8 7.24 3.62 43 9 7.29 3.62 4 '4 5 f- 5 10-15 7.24 3.62 6 16, 17 7 6 6.38 2.62 8

18 2.62 8

.10 9 a/10 12 t /11 13 C 12 13 14 114 15 16 16 17 17 D18 Transition Cone Region - Model 44F

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